Home

2005 Yamaha Kodiak YFM 450 Service Manual

Contents

1. 9 15 80302 ELECTRIC STARTING SYSTEM ELEC TROUBLESHOOTING IF THE STARTER MOTOR FAILS TO OPERATE Procedure Check 1 Fuse main ignition 6 Engine stop switch 2 Battery 7 Start switch 3 Starter motor 8 Wiring connection the entire starting 4 Starter relay system 5 Main switch NOTE _ e Hemove the following part s before Pocket tester troubleshooting 0 03112 90890 03112 1 Seat 2 Fuel tank side panels 3 Fuel tank 4 Air cleaner case 5 Front carrier 6 Front fender panel Use the following special tool s for troubleshooting EB802011 1 Fuse main ignition Refer to CHECKING THE SWITCH 1 CONTINUITY Replace the fuse NO CONTINUITY EB802012 2 Batt ee INCORRECT e Check the battery condition Refer to CHECKING THE BATTERY in 1 3 Open circuit voltage e Clean the battery terminals e Recharge or replace the battery iL CORRECT ELECTRIC STARTING SYSTEM ELEC 3 Starter motor A WARNING e A wire that is used as a jumper lead must have the equivalent capacity or more as that of the battery lead otherwise the jumper lead may burn e This check is likely to produce sparks so be sure that no flammable gas or fluid is the vicinity e Connect the battery positive terminal 1 and starter motor cable 2 using a jumper l
2. 10 5 SHOCK ABSORBER MALFUNCTION 10 6 MALFUNCTION MER 10 6 UNSTABLE HANDLING 10 6 UNSTABLE HANDLING detinent rate opaca 10 6 LIGHTING SYSTEM cie et epu meta atte 10 6 AEADEIGHT DARK NER EROR LUE 10 6 sS Scie Et 10 6 TRBL EE 4 STARTING FAILURE HARD STARTING SHTG e TROUBLESHOOTING NOTE The following troubleshooting does not cover all the possible causes of trouble It should be helpful however as a guide to troubleshooting Refer to the relative procedure in this manual for checking adjusting and replacing of parts STARTING FAILURE HARD STARTING FUEL SYSTEM Fuel tank e Empty e Clogged fuel filter e Clogged fuel strainer e Clogged fuel breather hose e Deteriorated or contaminated fuel Fuel cock e Clogged fuel hose ELECTRICAL SYSTEM Spark plug e Improper plug gap e Worn electrodes e Wire between terminals broken e Improper heat range e Faulty spark plug cap Ignition coil e Broken or shorted primary secondary e Faulty spark plug lead e Broken body CDI system e Faulty CDI unit e Faulty pickup coil e Faulty charging rotor rotation direction coil e Broken woodruff key Carburetor e Deteriorated or contaminated fuel e Clogged pilot jet e Clogged pilot
3. 9 6 CHECKING THE CONDITION OF THE BULB SOCKETS 9 8 IGNITION SYSTEM hien PER tfc 9 9 CIRCUIT DIAGRAM 9 9 TROUBLESHOOTING 9 10 ELECTRIC STARTING SYSTEM 9 15 CIRCUIT DIAGRAM esos atte 9 15 TROUBLESHOOTING 9 16 STARTER MOTOR encase celum Cera tie dci 9 19 CHECKING THE STARTER MOTOR 4 41 12 9 20 ASSEMBLING THE STARTER 9 21 CHARGING SYSTEM 9 22 CIRCUIT DIAGRAM edendi 9 22 TROUBLESHOOTING 9 23 LIGHTING SYSTEM 4 1 2 010 2 2 020 2020 1024 0005 9 25 CIRCUIT DIAGRAM dentes 9 25 TROUBLE oO 9 26 CHECKING THE LIGHTING SYSTEM 9 28 SIGNAL SYSTEM 9 30 CIRCUIT DIAGRAM 9 30 TROUBEESHOOTING oos eto ene 9 32 CHECKING THE SIGNAL SYSTEM 9 34 COOLING SYSTEM 9 38 CIRCUIT DIAGRAM alcatel tet 9 38 TROUBLESHOOTING dated tx dec 9 39 2WD AWD SELECTING SYSTEM 2 2 02 22 20 074700207407 4 9 43 CIRCUIT DIAGBAM 9 43 TROUBLESHOOTING 9 44 ELECTRICAL COMPONENTS 800000 ELECTRI
4. 1 10 SPECIAL TOOLS iuter b trenes 1 11 MACHINE IDENTIFICATION 926 GENERAL INFORMATION MACHINE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the left side of the frame MODEL LABEL The model label is affixed to the frame This information will be needed to order spare parts FEATURES 076 FEATURES LIQUID COOLING ENGINE Compact liquid cooled 45 inclined engine A liquid cooling system has been incorporated for stable power and engine endurance 1 Radiator 2 Thermo switch 3 Fan motor PARK POSITION When the drive select lever is shifted into the park position a stopper lever is engaged into the stopper gear preventing the drive select lever and transmission from moving When the drive select lever is at the L or R positions the stopper lever end 1 is moved away from the stopper gear 2 by the return spring 3 When the drive select lever is in the P position the lever cam 2 at the side of the shift cam 5 lifts the stopper lever end 6 and the stopper lever end locks the drive axle 7 When the stopper lever end is not synchronized a torsion spring retains the rotation force of the shift cam 5 until it is synchronized FRONT DIFFERENTIAL CD Adapter 2 Drive clutch 3 Differential side
5. 8 48 REMOVING THE SWINGARM 8 50 CHECKING THE REAR SHOCK ABSORBER 8 50 CHECKING THE SWINGARIM iiir ipta ruens te Rue bp 8 51 CHECKING THE RUBBER BOOT 8 51 INSTALLING THE RUBBER BOOT itus om dap 8 51 INSTALLING THE REAR AXLE HOUSING 2 0 eee 8 52 FRONT AND REAR WHEELS CHAS 36 CHASSIS FRONT AND REAR WHEELS FRONT WHEELS 150 Nm 15 0 m kg 110 ft Ib 30 Nm 3 0 m kg 22 ft Ib 64 Nm 6 4 m Kg 46 ft Ib Job Removing front wheel Remove the parts in the order below Place the machine on a level surface A WARNING Securely support the machine so there is no danger of it falling over Front wheel Refer to INSTALLING THE WHEEL Wheel Refer to INSTALLING THE WHEEL Cotter pin HUB Axle nut Brake caliper assembly NOTE nm Do not squeeze the brake lever when the brake caliper is off of the brake disc as the brake pads will be forced shut Wheel hub Brake disc For installation reverse the removal procedure FRONT AND REAR WHEELS CHAS 36 REAR WHEELS 150 Nm 15 0 kg 110 ft Ib 150 Nm 15 0 m kg 110 ft Ib 30 Nm 3 0 m kg 22 ft Ib w _ 0 5 Ny 12 NN PE eS 3 55 Nm 5 5 m kg 40 ft Ib Job Removing the rear wheel Remove the parts in the order below Place the machine on a l
6. 0000 2 4 13 CAMSHAFT ROCKER ARMS AND VALVES 4 16 REMOVING THE CAMSHAFT AND ROCKER ARM 4 18 REMOVING THE VALVE AND VALVE SPRING 4 18 CHECKING THE CAMSHAFT emnes 4 19 CHECKING THE ROCKER ARM AND CAMSHAFT 4 19 CHECKING THE VALVE AND VALVE SPRING 4 21 INSTALLING THE VALVE AND VALVE SPRING 4 25 INSTALLING THE CAMSHAFT AND ROCKER ARM 4 26 CYLINDER AND PISTON ELE E Leo tacet etos 4 27 REMOVING THE PISTON 0 10 2 4 6 4 28 CHECKING THE TIMING CHAIN GUIDE 200 4 28 CHECKING THE CYLINDER AND PISTON 4 28 CHECKING THE PISTON RING 4 30 CHECKING THE PISTON PIN eru i tue pu cm 4 31 INSTALEING THE PISTON ee 4 32 INSTALLING THE CYLINDER gene ns 4 33 RECOIL STARTER AND 4 34 REMOVING THE MAGNETO 4 37 DISASSEMBLING THE RECOIL STARTER 4 37 CHECKING THE CDI MAGNETO 0 1
7. PERIODIC MAINTENANCE LUBRICATION ang Q INITIAL ROUTINE Whichever km 320 1 200 2 400 2 400 4 800 comes first mile 200 750 1 500 1 500 3 000 a 29 75 150 1 Front and rear Check operation suspension Correct if necessary Check operation Replace if damaged g sy e Check toe in Adjust if necessary Drive shaft universal T A Lubricate joint Front axle boots cop Replace if damaged Fittings and Check all chassis fittings and fasteners fasteners Correct if necessary Itis recommended that these items be serviced by a Yamaha dealer Lithium soap based grease NOTE e Recommended brake fluid DOT 4 e Brake fluid replacement 1 When disassembling the master cylinder or caliper replace the brake fluid Normally check the brake fluid level and add fluid as required 2 On the inner parts of the master cylinder and caliper replace the oil seals every two years 3 Replace the brake hoses every four years or if cracked or damaged WARNING Indicates a potential hazard that could result serious injury or death 4o SEAT CARRIERS FENDERS AND FUEL TANK ADJ SEAT CARRIERS FENDERS AND FUEL TANK SEAT AND SIDE PANELS Job name Pariname Removing the seat and side panels Remove the parts in the order below c NOTE o oOo Pull up the seat lock lever then pull up on the rear of the seat Fuel tank side panel le
8. ehe 7 20 DISASSEMBLING THE FINAL DRIVE GEAR 7 20 REPLACING THE FINAL DRIVE ROLLER BEARING 7 21 POSITIONING THE FINAL DRIVE PINION GEAR AND FING GEAR ER ERE E ME 7 22 CHECKING THE REAR AXB 7 26 CHECKING THE DRIVESHAFT 7 27 CHECKING THE FINAL DRIVE GEAR 7 27 MEASUREMENT AND ADJUSTING THE FINAL GEAR LASH 7 28 ASSEMBLING THE FINAL DRIVE GEAR 2 2 22 7 30 INSTALLING THE FINAL DRIVE GEAR 7 30 vl TROUBLESHOOTING DRIV DRIVE TRAIN TROUBLESHOOTING The following conditions may indicate damaged shaft drive components 1 A pronounced hesitation or jerky movement during acceleration deceleration or sustained speed This must not be confused with engine surging or transmission characteristics 2 rolling rumble noticeable at low speed a high pitched whine a clunk from a shaft drive component or area 3 A locked up condition of the shaft drive train mechanism no power transmitted from the engine to the front and or rear wheel NOTE Possible Causes A Bearing damage B Improper gear lash C Gear tooth damage D Broken drive shaft E Broken gear teeth Seizure due to lack of lubrication G Small foreign objects lodged between the moving parts Areas A B and C above may be extremely difficult to diagnose The symptoms are quite subtle and difficu
9. Replace the meter assembly SIGNAL SYSTEM ELEC NO CONTINUITY Replace the neutral switch NO CONTINUITY EE Replace the high range switch NO CONTINUITY Replace the low range switch NO CONTINUITY Replace the reverse switch NO CONTINUITY Replace the four wheel drive switch SIGNAL SYSTEM ELEC 3 If the coolant temperature warning light does not come on e Check that the light comes on when the main switch is set to ON e Check that the light comes on when the coolant temperature is 120 3 C 248 5 4 F or higher and that the light remains on when the coolant temperature drops to 113 C 235 4 F 1 Thermo switch 1 e Remove the thermo switch 1 from the cylinder head e Connect the pocket tester Q x 1 to the thermo switch 1 1 e Immerse the thermo switch 1 in coolant 2 e Check the thermo switch 1 for continuity While heating the coolant use a thermometer 3 to record the temperatures Test Coolant temperature Continuit step Thermo switch 1 y Less than 120 3 248 5 4 F More than 120 3 C EN 5E More than 113 C EN D Less than 113 C 235 4 F Test steps 1 amp 2 Heating phase Test steps 3 amp 4 Cooling phase The thermo switch 1 circuit is open and the coolant temperature warning light is off 4 The thermo switch 1 circuit is closed and t
10. small amount of metal particles in the oil is normal 3 Check e Oil leakage kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Checking steps eClean the entire machine thoroughly then dry it eApply a leak localizing compound or dry powder spray to the shaft drive Road test the machine for the distance necessary to locate the leak Leakage Check the component housing gasket and or seal for damage Damage Replace the component NOTE 2 LL e An apparent oil leak on a new or nearly new machine may be the result of a rust preventative coating or excessive seal lubrication e Always clean the machine and recheck the suspected location of an apparent leakage kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Yd TROUBLESHOOTING DRIV Troubleshooting chart When basic condition and b exist check the following points Elevate and spin both wheels Feel for is Replace the wheel bearing wheel bearing damage Refer to STEERING SYSTEM and REAR SHOCK ABSORBER AND SWINGARM in CHAPTER 8 NO Check the wheel nuts and hub nuts for Ne Torque to specification tightness Refer to FRONT AND REAR WHEELS _ in CHAPTER 8 YES Constant velocity joint bearings and differential gear bearings are probably not damaged Repeat the test or remove the individual components Check the constant velocity join
11. two C size batteries to the gear motor terminals 1 as shown illustration pinion gear Check that the pinion gear 2 turns counterclockwise Check that the pinion gear 2 turns clockwise NOTE Be sure not to disassemble the gear motor or remove the pinion gear kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk ASSEMBLING THE FRONT CONSTANT VELOCITY JOINT 1 Apply e Molybdenum disulfide grease into the ball joint assembly NOTE _ Molybdenum disulfide grease is included in the repair kit 2 Install e Dust boots 1 e Dust boot bands 2 3 kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Installation steps e Apply molybdenum disulfide grease into the dust boots Molybdenum disulfide grease 40 g 1 4 oz per dust boot e Install the dust boots e Install the dust boot bands e The new boot bands may differ from the Original ones e The dust boots should be fastened with the dust boot bands 3 at the grooves in the joint shaft kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk 7 11 FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR DRIV 3 Check e Free play thrust movement Excessive play Replace the joint assembly ASSEMBLING THE DIFFERENTIAL GEAR 1 Measure e Gear lash Refer to MEASURING AND ADJUSTING THE DIFFERENTIAL GEAR LASH 2 Install e Gear motor kkkkkkkkkkkk
12. Tighten the bolts stages using crisscross pattern 8 5 Apply e 4 stroke engine oil to the crank pin bearing and oil delivery hole 6 Check e Crankshaft and transmission operation Unsmooth operation Repair INSTALLING THE SHIFT LEVER 1 Install e Shift lever 2 assembly 1 e Shift lever 1 2 NOTE When installing the shift lever 1 align the punch mark 8 on the shift lever 1 with the punch marks on the shift lever 2 CRANKCASE ENG oD INSTALLING THE OIL PUMP DRIVE GEAR 1 Install e otraight key e Oil pump drive gear e Lock washer e Oil pump drive gear nut 2 Tighten e Oil pump drive gear nut 50 Nm 5 0 kg 36 ft Ib Tightening steps e Temporary install the clutch carrier assembly D e Hold the clutch carrier assembly with a clutch holding tool 2 and tighten the oil pump drive gear nut Clutch holding tool P N YM 91042 90890 04086 lt Remove the clutch carrier assembly kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk 3 Bend the lock washer tab 8 CRANKSHAFT AND OIL PUMP ENG CRANKSHAFT AND OIL PUMP Removing the crankshaft and oil Remove the parts in the order below pump Crankcase separation Refer to CRANKCASE Washer circlip Oil pump assembly gasket Balancer Refer to REMOVING THE Crankshaft seal CRANKSHAFT INSTALLING THE Crankshaft CRANKSHAFT AND BALANCER For installation reve
13. PRIMARY AND SECONDARY SHEAVES ENG 10 Nm 1 0 m kg 7 2 ft Ib 10 Nm 1 0 m kg 7 2 ft Ib Job name 8 Primary fixed sheave 1 Refer to REMOVING INSTALLING THE 9 Secondary sheave assembly 1 Fr PRIMARY AND SECONDARY SHEAVES For installation reverse the removal procedure PRIMARY AND SECONDARY SHEAVES ENG PRIMARY SLIDING SHEAVE 3 Nm 0 3 m kg 2 2 ft Ib Job nameiPart Disassembling the primary sliding sheave Primary pulley sheave cap Primary pulley slider Spacer Primary pulley cam Primary pulley weight Collar Oil seal Primary sliding sheave O ring Remove the parts in the order below Refer to ASSEMBLING THE PRIMARY SHEAVE C 69 9 NO 00 do nx For assembly reverse the disassembly procedure PRIMARY AND SECONDARY SHEAVES ENG SECONDARY SHEAVE Job name Part name Remarks Disassembling the secondary Remove the parts in the order below sheave Nut Spring seat Compression spring Spring seat Guide pin Secondary sliding sheave O ring Secondary fixed sheave Oil seal Oil seal Refer to DISASSEMBLING ASSEMBLING THE SECONDARY SHEAVE C 9 qmod Ld For assembly reverse the disassembly procedure 7 PRIMARY AND SECONDARY SHEAVES ENG REMOVING THE PRIMARY AND SECOND
14. FRONT AND REAR BRAKES CHAS 36 e Brake fluid delivery passage brake caliper body Blockage Blow out with compressed air WARNING Replace the caliper piston seal and dust seal whenever the brake caliper is disassembled Front Rear ASSEMBLING THE FRONT AND REAR BRAKE CALIPER WARNING e All internal brake components should be cleaned and lubricated with new brake fluid only before installation Recommended brake fluid DOT 4 e Replace the caliper piston seal whenever a brake caliper is disassembled 1 Install e Caliper piston seal e Dust seal 0 2 Install e Brake caliper piston 1 INSTALLING THE FRONT BRAKE CALIPER 1 Install e Brake caliper assembly e Brake caliper mounting bolt 1 X 130 Nm 3 0 m kg 22 ft Ib e Brake hose 2 e Copper washers 3 e Union bolt W Vy NS 24 FRONT AND REAR BRAKES CHAS 36 When installing the brake hose on the brake caliper make sure that the brake pipe touches the projection on the brake caliper WARNING Proper brake hose routing is essential to insure safe motorcycle operation Refer to CABLE ROUTING in CHAPTER 2 2 Fill e Brake reservoir Recommended brake fluid DOT 4 Brake fluid may damage painted surfaces or plastic parts Always clean up spilled brake fluid immediately WARNING e Use only the designated quality brake fluid other brake fluids may deteriorate the rub
15. Out of specification Replace the brake pad as a Set Brake pad wear limit 1 mm 0 04 2 Install e Brake pads e Brake pad spring NOTE Always install new brake pads brake pad shims insulator and brake pad spring as a set kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Installation steps Connect a suitable hose 1 tightly to the brake caliper bleed screw Put the other end of this hose into an open container Loosen the brake caliper bleed screw and using a finger push the caliper piston into the brake caliper Tighten the brake caliper bleed screw Brake caliper bleed screw 6 Nm 0 6 m kg 4 3 Ib e install new brake pads new insulator new pad shims and a new brake pad spring e Install the holding bolts and brake caliper Brake pad holding bolt 18 Nm 1 8 m kg 13 Ib Brake caliper mounting bolt 30 Nm 3 0 kg 22 Ib kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk 8 10 FRONT AND REAR BRAKES CHAS 36 3 Check e Brake fluid level Refer to CHECKING THE BRAKE FLUID LEVEL in CHAPTER 3 4 Check e Brake lever or brake pedal operation Soft or spongy feeling Bleed the rear brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in CHAPTER 3 FRONT AND REAR BRAKES CHAS 36 FRONT BRAKE MASTER CYLINDER 7 Nm 0 7 kg 5 1 ft Ib 27 Nm 2 7 kg 19 ft Ib Job
16. CHECKING THE CDI MAGNETO 1 Check e otator assembly e Pickup coil Damage Replace RECOIL STARTER AND MAGNETO ENG CHECKING THE STARTER CLUTCH 1 Check e Starter one way clutch 1 Cracks damage Replace e Bolts 2 starter clutch Loose Replace with a new one and clinch the end of the bolt NOTE aaam The arrow mark on the starter clutch must face inward away from the rotor Bolts starter clutch 30 Nm 3 0 kg 22 Ib LOCTITE kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Checking steps the starter wheel gear to the starter clutch and hold the starter clutch eWhen turning the starter wheel gear counterclockwise A the starter clutch and the wheel gear should be engaged If not the starter clutch is faulty Replace it eWhen turning the starter wheel gear clockwise B the starter wheel gear should turn freely If not the starter clutch is faulty Replace it kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk 2 Check e Gear teeth starter idle 1 e Gear teeth starter wheel 2 Burrs chips roughness wear Replace 3 Check e Starter wheel gear contacting surface Damage pitting wear Replace RECOIL STARTER AND A C MAGNETO ENG CHECKING THE STARTER PULLEY 1 Check e otarter pulley Cracks pitting Deburr or replace CHECKING THE RECOIL STARTER 1 Check e Rope 1 e Sheave drum e
17. Refer to CHECKING THE SIGNAL SYSTEM SIGNAL SYsTEM ELEC 1 Bulb and bulb socket NO CONTINUITY e Check the bulb and bulb socket for continuity i iL CONTINUITY Replace the bulb and or bulb socket NO CONTINUITY 2 Brake light switches CHECKING THE SIGNAL SYSTEM 1 If the brake light fails to come Refer to CHECKING THE SWITCH iL CONTINUITY Replace the brake light switch 3 Voltage e Connect the pocket tester DC 20 V to the bulb socket connector Tester lead gt Yellow terminal 1 Tester lead gt Black terminal 2 OUT OF SPECIFICATION e the main switch to ON e Pull in the brake lever or push down on the es brake pedal e Check the voltage 12 V of the Yellow TEM connector The wiring circuit from the main switch to the bulb socket connector is faulty repair it 5 4 i SPECIFICATION This circuit is not faulty 806024 2 1 the indicator lights fails to come 1 Neutral switch Refer to CHECKING THE SWITCH CONTINUITY 2 High range switch Refer to CHECKING THE SWITCH CONTINUITY 3 Low range switch Refer to CHECKING THE SWITCH 4 Reverse switch Refer to CHECKING THE SWITCH CONTINUITY 5 Four wheel drive switch Refer to CHECKING THE SWITCH
18. 0 23 L 0 20 Imp qt 0 24 US qt Total amount 0 28 L 0 25 Imp qt 0 30 US qt Recommended oil SAE 80 API GL 4 Hypoid gear oil NOTE 2 If gear oil is filled to the brim of the oil filler hole oil may start leaking from the differential gear case breather hose Therefore check the quantity of the oil not its level ake care not to allow foreign material to enter the differential gear case 7 Install e Oil filler bolt 23 Nm 2 3 m kg 17 ft Ib CHECKING THE CONSTANT VELOCITY JOINT DUST BOOT 1 Check e Dust boots 1 Damage Replace Refer to FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR in CHAPTER 7 CHECKING THE STEERING SYSTEM CHK ADJUSTING THE TOE IN ADJ Q CHECKING THE STEERING SYSTEM 1 Place the machine on a level surface 2 Check Steering assembly bushings Move the handlebar up and down and or back and forth Excessive play Replace the steering stem bushings 3 Check e lie rod ends Turn the handlebar to the left and or right until it stops completely then move the handlebar from the left to the right slightly Tie rod end has any vertical play Replace the tie rod end s 4 Raise the front end of the machine so that there is no weight on the front wheels 5 Check e Ball joints and or wheel bearings Move the wheels laterally back and forth Excessive free play Replace the front arms upper and lower and or wheel bearings
19. Adjust Throttle lever free play 3 5 mm 0 12 0 20 in 2 Remove e Seat e Fuel tank side panel right Refer to SEAT CARRIERS FENDERS AND FUEL TANK 3 Adjust e Throttle lever free play kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Adjustment steps First step Pull back the adjuster cover 1 Loosen the locknut on the carburetor side e Turn the adjuster 9 in or out until the correct free play is obtained Free play is increased Free play is decreased Tighten the locknut 2 e Push in the adjuster cover 1 NOTE LL If the free play cannot be adjusted here adjust it at the throttle lever side of the cable ADJUSTING THE THROTTLE LEVER FREE PLAY CHK ADJUSTING THE SPEED LIMITER ADJ Q Second step Pull back the adjuster cover 4 Loosen the locknut 5 e Turn the adjuster 6 in or out until the correct free play is obtained Free play is increased Free play is decreased e Tighten the locknut 5 e Push in the adjuster cover 4 A WARNING After adjusting the free play turn the handlebar to the right and left to make sure that the engine idling speed does not increase kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk 4 Install e Fuel tank side panel right e Seat Refer to SEAT CARRIERS FENDERS AND FUEL TANK ADJUSTING THE SPEED LIMITER The speed limiter keeps the carburetor throttle from becoming fully open
20. D Battery 2 Positive battery lead 3 Tail brake light lead 4 CDI unit 6 Negative battery lead f S 21 NNIES P i d E AN IPS PR VARANA m CABLE ROUTING SPEC y lt CABLE ROUTING SPEC y CD Final drive gear case breather hose 2 Rear brake hose 3 Air filter case check hose 4o CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS 3 1 PERIODIC MAINTENANCE LUBRICATION 3 1 SEAT CARRIERS FENDERS AND FUEL TANK 3 3 SEAT AND SIDE PANELS suisse sioe Eei 3 3 FRONT CARRIER FRONT BUMPER AND FRONT FENDER 3 4 REAR CARRIER AND REAR FENDER 3 6 FUELTANK eee 3 8 FOOTREST BOARDS srangenge aes 3 9 ENGINE 3 10 ADJUSTING THE VALVE CLEARANCE _ 3 10 ADJUSTING THE IDLING SPEED doo ntn rte PR PER S ER up 3 13 ADJUSTING THE THROTTLE LEVER FREE PLAY 3 14 ADJUSTING THE 3 16 ADJUSTING THE STARTER CABLE
21. Lubricate the O ring of the new oil filter cartridge with a thin coat of engine oil Make sure that the O ring 3 is positioned correctly in the groove of the oil filter cartridge lighten the new oil filter cartridge to eee specification with an oil filter wrench Oil filter cartridge 17 Nm 1 7 me kg 12 ft Ib kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk 8 Install e Oil strainer e Compression spring e Oil strainer cover 1 32 Nm 3 2 kg 23 Ib Engine oil drain 2 9 1 Refer to CHECKING THE ENGINE OIL LEVEL Oil quantity Periodic oil change 2 3 L 2 0 Imp qt 2 4 US qt With oil filter replacement 2 4 L 2 1 Imp qt 2 5 US qt Total amount 2 6 L 2 3 Imp qt 2 7 US qt 10 Install e Engine oil filler plug 11 Warm up the engine for a few minutes then stop the engine 12 Check e Engine for engine oil leaks e Cil level e Refer to CHECKING THE ENGINE OIL LEVEL CHANGING THE ENGINE OIL CHK CLEANING THE AIR FILTER ADJ Q 13 Check Engine oil pressure kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk e Slightly loosen the oil gallery bolt 1 eStart the engine and keep it idling until engine oil starts to seep from the oil gallery bolt If no engine oil comes out after one minute turn the engine off so that it will not seize e Check the engine oil passages the oil filter car
22. NE g MIDDLE GEAR ENG 5 Remove Front drive shaft coupling Bearing retainer 1 Bearing NOTE Attach the ring nut wrench 2 Ring nut wrench 38404 90890 01430 has left handed threads loosen the retainer turn it clockwise 6 Remove e Middle drive shaft 1 with bearing CHECKING THE PINION GEAR 1 Check e Damper cam surfaces Wear scratches Replace damper cam and driven pinion gear as a Set 2 Check e Damper spring Damage cracks Replace 3 Check e Gear teeth drive pinion gear 1 e Gear teeth driven pinion gear Pitting galling wear Replace MIDDLE GEAR ENG 4 Check e O ring Damage Replace e Bearings Pitting damage Replace 5 Check e U joint movement Roughness Replace U joint SELECTING THE MIDDLE DRIVE AND DRIVEN GEAR SHIM When the drive and driven gear bearing housing assembly and or crankcase replaced be sure to adjust the gear shim 1 1 Select e Middle drive gear shim 1 e Middle driven gear shim 2 kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Selection steps e Position middle drive and driven gear by using shims 1 and 2 with their respective thickness calculated from information marked on crankcase bearing housing and drive gear end D Shim thickness A 2 Shim thickness B elo find shim thickness A use following formula Where a numeral usu
23. SF SE SD etc YAMALUBE 4 20W40 or SAE 20W40 YAMALUBE 4 10W30 or SAE 10W30 SAE 5W30 20 10 07 109 20 4 Start the engine and let it warm up for several minutes 5 Stop the engine and check the oil level again NOTE 2222 Wait a few minutes until the oil settles before checking the oil level WARNING Never remove the dipstick just after high speed operation because the heated oil could spurt out Wait until the oil cools down before removing the dipstick 6 Install e Engine side panel CHANGING THE ENGINE OIL eme CHANGING THE ENGINE OIL 1 Start the engine and let it warm up for several minutes 2 Stop the engine and place an oil pan under the engine 3 Remove e Seat e Fuel tank side panel left e Engine side cover Refer to SEAT CARRIERS FENDERS AND FUEL TANK 4 Remove e Engine oil filler plug dipstick 5 Remove e Engine oil drain bolt 1 Drain the engine oil e Oil strainer cover 2 e Compression spring 3 e Oil strainer 24 6 Clean e Oil strainer 7 f the oil filter cartridge is also to be replaced perform the following procedure kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Replacement steps e Remove the oil filter cartridge 1 with an oil filter wrench 2 filter wrench Z P N YU 38411 90890 01426 CHANGING THE ENGINE OIL
24. 0 6 0 7 mm 0 024 0 028 in CORRECT Repair or replace the spark plug For CDN 4 gnition spark e Disconnect the spark plug cap from the spark plug e Connect the dynamic spark tester 1 as shown 2 Spark plug cap 3 Spark plug e Turn the main switch to e Check the ignition spark gap e Crank the engine by pushing the starter MEETS SPECIFICATION switch and increase the spark gap until a misfiring occurs Minimum spark gap 6 0 mm 0 24 in The ignition system is not faulty For Europe and Oceania 4 gnition spark e Disconnect the spark plug cap from the spark plug e Connect the ignition checker 1 as shown 2 Spark plug cap e Turn the main switch to ON e Check the ignition spark gap 3 e Crank the engine by pushing the starter switch and increase the spark gap until a misfiring occurs OUT OF SPECIFICATION The ignition system is not faulty OR NO SPARK ee E 22 5 Spark plug cap resistance Remove the spark plug cap Connect the pocket tester Q x 1k to the spark plug cap IGNITION ELEC e Check that the spark plug cap has the specified resistance OUT OF SPECIFICATION 1 Spark plug cap resistance ri 10 at 20 C 68 F D MEETS SPECIFICATION Replace the spark plug cap 6 Ignition coil resistance e Disconnect the ignition coil connector from the wire harness e Connect the pocket t
25. 12 30 kg 23 58 27 11 Ib at 1 32 Outer 235 4 251 1 at 36 6 mm 24 00 25 60 kg 52 91 56 45 Ib at 1 44 in e CAMSHAFT ROCKER ARMS AND VALVES ENG 12 Measure e Spring tit Out of specification Replace Spring tilt limit Inner 2 5 1 6 mm 0 06 in Outer 2 5 1 6 mm 0 06 in 302 028 INSTALLING THE VALVE AND VALVE SPRING 1 Apply Molybdenum disulfide oil onto the valve stem and valve stem seal 2 Install e Valve spring seats e Valve stem seals e Valves e Valve springs inner and outer e Valve spring retainers NOTE LLL Install the valve springs with the larger pitch 8 facing upwards D Smaller pitch 3 Install e Valve cotters NOTE Install the valve cotters while compressing the valve spring with the valve spring compressor 1 Valve spring compressor P N YM 04019 90890 04019 gt 4 secure the valve cotters onto the valve stem lightly tap the valve tip with a piece of wood Hitting the valve tip with excessive force could damage the valve e CAMSHAFT ROCKER ARMS AND VALVES ENG INSTALLING THE CAMSHAFT AND ROCKER ARM 1 Apply Engine oil onto the rocker arm shafts 2 Install e Rocker arms 1 e Rocker arm shafts intake and exhaust NOTE 6 _ Use a slide hammer bolt 3 to install the rocker arm shaft 3 Install e Camshaft 1 NOTE Install the camshaft pin hole 8 f
26. CRANKSHAFT AND OIL PUMP Refer to TRANSMISSION Refer to MIDDLE GEAR For installation reverse the removal procedure CRANKCASE ENG OD REMOVING THE OIL PUMP DRIVE GEAR 1 Straighten e Lock washer tab 2 Remove e Oil pump drive gear nut kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Removal steps Temporary install the clutch carrier assembly 1 Hold the clutch carrier assembly with a clutch holding tool and loosen the oil pump drive gear nut Clutch holding tool P N YM 91042 90890 04086 2 Remove the clutch carrier assembly kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk SEPARATING THE CRANKCASE 1 Separate Left crankcase kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Separation steps Remove the crankcase bolts NOTE WW e Loosen each bolt 1 4 of a turn at a time and after all the bolts are loosened remove them Loosen the bolts in stages using crisscross pattern Left crankcase Right crankcase CRANKCASE ENG Remove the left crankcase e Use a soft hammer to tap on one side of the crankcase Tap only on reinforced portions of the crankcase Do not tap on the crankcase mating surfaces Work slowly and carefully Make sure that the crankcase halves separate evenly e Remove the dowel pins kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk CHECKING THE TIMING CHAIN AND GUIDE 1 Check e T
27. Recommended oil SAE 80 API GL 4 Hypoid gear ake care not to allow foreign material to enter the final gear case 8 Check e Oil level Refer to CHECKING THE FINAL GEAR OIL LEVEL 9 Install e Oil filler bolt 23 Nm 2 3 kg 17 ft Ib e Final gear case protector 16 Nm 1 6 m kg 11 ft Ib CHECKING THE DIFFERENTIAL GEAR OIL CHANGING THE DIFFERENTIAL GEAR OIL ADJ Q CHECKING THE DIFFERENTIAL GEAR OIL 1 Place the machine on a level surface 2 Remove e Oil filler bolt 3 Check e Oil level Oil level should be up to the brim of hole Oil level low Add oil to proper level Recommended oil SAE 80 API GL 4 Hypoid gear oil Oil quantity periodic oil change 0 23 L 0 20 Imp qt 0 24 US qt Take care not allow foreign material to enter the gear case 4 nstall e Oil filler bolt 23 Nm 2 3 kg 17 ft Ib CHANGING THE DIFFERENTIAL GEAR OIL 1 Place the machine on a level surface 2 Place a receptacle under the differential gear case 3 Remove e Oil filler bolt e Drain plug 1 CHANGING THE DIFFERENTIAL GEAR OIL CHECKING CHK THE CONSTANT VELOCITY JOINT DUST BOOT ADJ Q 4 Drain Differential gear oil 5 Install e Drain plug 3 amp 10 Nm 1 0 m kg 7 2 ft Ib NOTE Check the gasket drain plug If it is damaged replace it with new one 6 Fill e Differential gear case Periodic oil change
28. YAMAHA YFM45FAR YFM450FAR SERVICE MANUAL YFM45FAR YFM450FAR SERVICE MANUAL 2002 by Yamaha Motor Co Ltd First edition March 2002 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited 001000 This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics It is not possible to include all the knowledge of a mechanic in one manual so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha machine has a basic understanding of the mechanical ideas and the procedures of machine repair Repairs attempted by anyone without this knowledge are likely to render the machine unsafe and unfit for use Yamaha Motor Company Ltd is continually striving to improve all 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 Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED WARNING Failure to follow WARNING instructions could result in severe injury or death to the m
29. lead gt Red terminal 1 Tester end er eens terminaron d lead White Blue terminal 2 OUT OF SPECIFICATION Rotor rotation direction sensing g coil resistance 0 A 0 105 Q at 20 C 68 F MEETS SPECIFICATION IGNITION SYSTEM ELEC 11 Wiring connection POOR CONNECTION e Check the connections of the entire ignition system Refer to CIRCUIT DIAGRAM CORRECT Properly connect the ignition system Replace the CDI unit ELECTRIC STARTING SYSTEM ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM EB803000 yms yams dois 6 asnj uous 69 110 JOJOW 1 9 e oJ SOURIS D Se oe urew 9 e 2 ey Mh l I 1 47 fen UUn IDE lt gt pas EE Na 8 09 09 Ald 10v 18 ge Er prs bry a Tung NN 1 AvH5 Aveo WE E 1 09 I for 649 wa a our Mes V UEC tees eet uis Vr uetus 18 el wa E mum n i CE v L CE Rm SSHNHVH SSANYVH SSHNHVH SS3NHVH
30. 0 01 mm 0 0004 in 40 52 mm 1 5953 in 32 08 mm 1 2630 in 40 52 mm 1 5953 in 32 08 mm 1 2630 in 0 03 mm 0 0012 in MAINTENANCE SPECIFICATIONS SPEC y Item Cam chain Cam chain type No of links Cam chain adjustment method Rocker arm rocker arm shaft Bearing inside diameter Shaft outside diameter Arm to shaft clearance Valve valve seat valve guide Valve clearance cold IN Valve dimensions Head Diameter Face Width head diameter IN EX B face width IN EX C seat width IN EX D margin thickness IN EX stem outside diameter IN EX Guide inside diameter IN EX Stem to guide clearance IN EX DID SCR 0409 SDH 116 Automatic 12 000 12 018 mm 0 4724 0 4731 in 11 981 11 991 mm 0 4717 0 4721 in 0 009 0 037 mm 0 0004 0 0015 in 0 06 0 10 mm 0 0024 0 0039 0 16 0 20 mm 0 0063 0 0079 in Seat Width 39 9 40 1 mm 1 5708 1 5787 in 33 9 34 1 mm 1 3346 1 3425 in 2 26 mm 0 0890 in 2 26 mm 0 0890 in 1 2 1 4mm 0 0472 0 0551 in 1 2 1 4 mm 0 0472 0 0551 in 1 0 1 4 mm 0 0394 0 0551 in 0 8 1 2 mm 0 0315 0 0472 in 6 975 6 990 mm 0 2746 0 2752 in 6 955 6 970 mm 0 2738 0 2744 in 7 000 7 012 mm 0 2756 0 2761 in 7 000 7 012 mm 0 2756 0 2761 in 0 010 0 037 mm 0 0004 0 0015 in 0 030 0 057 mm 0 0012 0 0022 in 2 5
31. 1 Battery terminal Yellow Black terminal 2 NO CONTINUITY Tester lead gt Blue Red terminal Tester lead Gray terminal e Check the four wheel drive relay 3 for continuity Replace the four wheel drive relay 3 CONTINUITY 7 On command four wheel drive switch and INCORRECT differential gear lock switch Refer to Refer to CHECKING THE SWITCH THE SWITCH Replace the on command four wheel drive C CORRECT switch and differential gear lock switch 2WD AWD SELECTING SYSTEM ELEC 8 Gear motor e Disconnect the gear motor coupler e Remove the gear motor from the differential gear case Refer to FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR in CHAPTER 7 e Connect two C size batteries to the gear motor terminals 1 as shown illustrations A Check that the pinion gear 2 turns counterclockwise Check that the pinion gear 2 turns clockwise e Make sure that the drive gear shift fork sliding gear operates correctly NOTE When installing the differential gear case in the gear motor refer to FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR in CHAPTER 7 INCORRECT CORRECT Replace the gear motor EB803028 9 Wiring connection e Check the connections of the entire 2WD POOR CONNECTION 4WD selecting system Refer to CIRCUIT DIAGRAM CORRECT Properly connect the 2WD 4WD selecting system Rep
32. 3 17 CHECKING THE SPARK PLUG 3 19 CHECKING THE IGNITION TIMING eene 3 20 MEASURING THE COMPRESSION PRESSURE 3 21 CHECKING THE ENGINE OIL LEVEL esses 3 23 CHANGING THE ENGINE OIL a 3 24 CLEANING TEAR 3 26 CHECKING THE COOLANT LEVEL ox 3 29 CHANGING THE COOLANT 3 30 CHEGNING THE V BEBL detis Raid 3 33 CLEANING THE SPARK ARRESTER op ura mena a ox phas s 3 34 3 36 ADJUSTING THE BEAR BRAKE rein ep 3 36 CHECKING THE BRAKE FLUID LEVEL 3 38 CHECKING THE FRONT BRAKE PAD 3 39 CHECKING THE REAR BRAKE 3 39 CHECKING THE BRAKE LIO SE 3 40 BLEEDING THE HYDRAULIC BRAKE SYSTEM 3 41 ADJUSTING THE SELECT LEVER CONTROL CABLE c 3 42 ADJUSTING THE REAR BRAKE LIGHT SWITCH 3 43 CHECKING THE FINAL GEAR OIL LEVEL 3 44 CHANGING THE FINAL GEAR 00420 000 3 45 CHECKING THE DIFFERENTIAL GEAR 3 46 CHANGING THE DIFFERENTIAL GEAR 3 46 CHEC
33. 32 ft Ib 7 Nm 0 7 m kg 5 1 ft Ib 45 Nm 4 5 m kg 32 ft Ib 30 Nm 3 0 m kg 22 ft Ib 30 Nm 3 0 m kg 22 ft Ib Job name Removing the front arms and front Remove the parts in the order below shock absorber Engine skid plate Refer to SEAT CARRIERS FENDERS Front fender AND FUEL TANK in CHAPTER 3 Front wheel brake disc Refer to FRONT AND REAR WHEELS Air duct Brake disc guard Protector FRONT ARMS AND FRONT SHOCK ABSORBER CHAS 36 45 Nm 4 5 m kg 32 ft Ib 8 5 X M 25 Ks By D ST ps ym 7 ey 1 45 Nm 4 5 m kg 32 ft Ib 7 Nm 0 7 m kg 5 1 ft Ib 45 Nm 4 5 m kg 32 ft Ib 30 Nm 3 0 m kg 22 ft Ib 30 Nm 3 0 m kg 22 ft Ib Job name Part name Bolt nut Refer to REMOVING THE FRONT Front lower arm bushing ARMS and INSTALLING THE FRONT Nut bolt ARMS AND FRONT SHOCK Front shock absorber ABSORBER Bolt nut Front upper arm bushing Circlip Ball joint For installation reverse the removal procedure FRONT ARMS AND FRONT SHOCK ABSORBER CHAS 36 REMOVING THE FRONT ARMS 1 Check e Front arm free play kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Checking steps e Check the front arm side play A by moving it from side to side If side play is noticeable check the bushings e Check the front arm vertical movement B by moving it up and down If the
34. 4 37 CHECKING THE STARTER CLUTCH 4 38 CHECKING THE STARTER 4 39 CHECKING THE RECOIL STARTER 4 39 ASSEMBLING THE RECOIL STARTER 4 39 INSTALLING THE A C MAGNETO eene 4 40 8 PRIMARY AND SECONDARY SHEAVES 4 42 PRIMARY SLIDING SHEAVE enin dE 4 44 SECONDARY SHEAVE prone 4 45 REMOVING THE PRIMARY AND SECONDARY SHEAVES 4 46 DISASSEMBLING THE SECONDARY SHEAVE 4 46 CHECKING THE PRIMARY SHEAVE 4 47 CHECKING THE SECONDARY SHEAVE 4 47 ASSEMBLING THE PRIMARY SHEAVE 4 48 ASSEMBLING THE SECONDARY SHEAVE 4 48 INSTALLING THE PRIMARY AND SECONDARY SHEAVES 4 50 epe 4 51 REMOVING THE CET Ci leone oan AR 4 53 CGEHEGNING TTE a Tos 4 53 INSTALLING THE CLUTGOEI iint i an eh ra irat rt exe rta 4 54 c E E a Y 4 56 STARTER MOTOR TIMING CHAIN AND OIL FILTER 4 56 eundem 4 58 GRANKCASE BEARING iiie A UNUM 4 59 REMOVING THE OIL PUM
35. ADJUSTING THE TOE IN 1 Place the machine on a level surface 2 Measure e Out of specification Adjust Toe in 0 10 mm 0 0 39 in with tire touching the ground kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Measurement steps NOTE nmm Before measuring the toe in make sure that the tire pressure is correct e Mark both front tire tread centers e Face the handlebar straight ahead ADJUSTING THE e Measure the width A between the marks Rotate the front tires 180 until the marks are exactly opposite one another e Measure the width B between the marks Calculate the toe in using the formula given below Toe in ef toe in is incorrect adjust it 3 Adjust e Oe in WARNING Be sure that both tie rods turned the same amount If not the machine will drift right or left even though the handlebar is positioned straight This may lead to mishandling and an accident e After setting the toe in to specification run the machine slowly for some distance with both hands lightly holding the handlebar and check that the handlebar responds correctly If not turn either the right or left tie rod within the toe in specification kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Adjustment steps e Mark both tie rods ends This reference point will be needed during adjustment e Loosen
36. Ib e Engine mount bolt rear upper nut 7 56 Nm 5 6 kg 40 ft Ib e Engine mount bolt rear lower nut 6 Nm 5 6 kg 40 Ib CYLINDER HEAD ENG CYLINDER HEAD 4 11 Nm 1 1 m kg 8 0 ft Ib 23 Nm 2 3 m kg 17 ft Ib 33 Nm 3 3 m kg 24 ft Ib 40 Nm 4 0 m kg 29 ft Ib 18 Nm 1 8 m kg 13 ft Ib 42 Nm 4 2 m kg 30 ft Ib 60 Nm 6 0 m kg 43 ft Ib 10 Nm 1 0 m kg 7 2 ft Ib Job name Part name Remarks Removing the cylinder head Remove the parts in the order below Fuel tank rubber cover Refer to SEAT CARRIERS FENDERS Front fender air filter case AND FUEL TANK in CHAPTER 3 Air duct assembly 1 Exhaust pipe muffler Carburetor assembly Refer to CARBURETOR in CHAPTER 6 Recoil starter timing plug Refer to ADJUSTING THE VALVE CLEARANCE in CHAPTER 3 Thermostat Refer to THERMOSTAT in CHAPTER 5 Spark plug lead Spark plug Engine mount bolt upper nut Engine bracket upper f Refer to ENGINE REMOVAL CYLINDER HEAD ENG 11 Nm 1 1 m kg 8 0 ft Ib 23 Nm 2 3 m kg 17 ft Ib 33 Nm 3 3 m kg 24 ft Ib 2 40 Nm 4 0 m kg 29 ft Ib 18 Nm 1 8 m kg 13 ft Ib 42 Nm 4 2 m kg 30 ft Ib 60 Nm 6 0 m kg 43 ft Ib 10 Nm 1 0 m kg 7 2 ft Ib Job name Part name Remarks 5 1 Cylinder head breather hose Camshaft sprocket cover O ring 1 1 Ta
37. Ib NOTE 2L The upper handlebar holder should be installed with the punched mark 1 forward 2 First tighten the bolts 3 on the front side of the handlebar holder and then tighten the bolts on the rear side INSTALLING THE REAR BRAKE LEVER 1 Install e Handlebar switch 1 e Rear brake lever e Lever bracket 2 NOTE Install the lever bracket as shown 8 80 mm 3 1 in STEERING SYSTEM CHAS 36 INSTALLING THE MASTER CYLINDER ASSEMBLY 1 Install e Throttle lever assembly e Master cylinder assembly Nm 0 7 me kg 5 1 ft Ib NOTE 2777 The UP mark on the master cylinder bracket should face up STEERING SYSTEM CHAS 56 STEERING STEM 23 Nm 2 3 m kg 17 ft Ib hse 130 Nm 13 0 m kg 94 ft Ib 30 Nm 3 0m kg 22 ft Ib Job name Part name Remarks Removing the steering stem Remove the parts in the order below Handlebar Refer to HANDLEBAR Seat Refer to SEAT CARRIERS FENDERS Front fender AND FUEL TANK in CHAPTER 1 Lock washer Refer to INSTALLING THE CABLE 2 Cable guide GUIDE 3 Steering stem bushing 4 Collar 5 Oil seal 6 Tie rod end nut 7 Tie rod Disconnect 8 Steering stem nut 9 Pitman arm 10 Steering stem STEERING SYSTEM CHAS 56 23 Nm 2 3 m kg 17 ft Ib hse 130 Nm 13 0 m kg 94 ft Ib 30 Nm 3 0m kg 22 ft Ib Job name Part name Remarks 1 11 Oil seal 12 Bearing retainer 1 Refer to REMOV
38. OO CABLE ROUTING SPEC y CABLE ROUTING 1 Rear brake switch lead 9 Main switch lead 2 Starter cable Fan motor breather hose 3 Rear brake cable 1 Differential gear case breather hose 2 Front brake hose 2 Sub wire harness to gear motor 5 On command four wheel drive switch and 43 On command four wheel drive switch differential gear lock switch differential gear lock switch lead 6 Throttle cable 7 Handlebar switch Handlebar switch lead CABLE ROUTING SPEC y Fasten the on command four wheel drive switch and differential gear lock switch lead behind the handlebar with a plastic band Fasten the starter cable handlebar switch lead and rear brake switch lead behind the handlebar with a plastic band Fasten the handlebar switch lead and rear brake switch lead behind the handlebar with a plastic band 1 Sub wire harness 2 Headlight lead 3 Auxiliary DC jack lead 4 Four wheel drive relay 3 5 Fan motor breather hose 6 Differential gear case breather hose 7 Coolant reservoir breather hose Meter assembly coupler CABLE ROUTING SPEC y CABLE ROUTING SPEC y 1 Starter cable Insert the fuel tank breather hose into the hole of 2 Cylinder head breather hose the handlebar cover 3 Fuel hose Fasten the sub wire harness differential gear 4 Carburetor drain hose case breather hose coolant reservoir hose 5 Coolant reservoir breather hose coolant reservoir breather h
39. Rear brake lever free play 0 5 2 mm 0 02 0 08 in Tighten the locknut handlebar e Adjust the select lever control cable Refer to ADJUSTING THE SELECT LEVER CONTROL CABLE AND SHIFT ROD Install the rear brake master cylinder cover WARNING After this adjustment is performed lift the 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 noticed perform the above steps again kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk 4o CHECKING THE BRAKE FLUID LEVEL ADJ CHECKING THE BRAKE FLUID LEVEL 1 Place the machine on a level surface NOTE When checking the brake fluid level make sure that the top of the brake fluid reservoir top is horizontal 2 Remove rear brake e Front carrier e Front fender panel Refer to SEAT CARRIERS FENDERS AND FUEL TANK 3 Check e Brake fluid level Fluid level is under LOWER level line 1 gt Fill up Recommended brake fluid DOT 4 Front brake Rear brake Brake fluid may erode painted surfaces or plastic parts Always clean up spilled fluid immediately WARNING e Use only the designed quality brake fluid otherwise the rubber seals may deteriorate causing leakage and poor brake performance e Refill with the same type of brake fluid mixing fluids may result in a harmful chemical r
40. a punch kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk MIDDLE GEAR ENG 2 Remove e Nut 1 e Washer e Universal joint yoke NOTE Use the universal joint holder 2 to hold the universal joint yoke 8 RL Universal joint holder P N YM 04062 90890 04062 3 Remove e Bearing housing assembly 1 kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Removal steps e Clean the outside of the middle driven shaft ePlace the middle driven shaft onto a hydraulic press e Never directly press the shaft end with a hydraulic press this will result in damage to the shaft thread e Install the suitable socket 2 on the shaft end to protect the thread from damage e Press the shaft end and remove the bearing housing JOGOS IG TOSI GIGI IO TEI TO TAI TA TOI II IIH 4 Remove e Bearing retainer e Bearing kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Removal steps Attach the folded rag 1 Secure the bearing housing edge in the vise e Attach the bearing retainer wrench 2 Vz Bearing retainer wrench 2 04128 90890 04128 The middle driven shaft bearing retainer has left handed threads To loosen the retainer turn it clockwise Remove the bearing retainer and bearing kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk 4 80 TN
41. e the valve is removed or replaced always replace the oil seal 6 Eliminate e Carbon deposits from the valve face and valve seat 7 Check e Valve seats Pitting wear Reface the valve seat 8 Measure e Valve seat width Out of specification Reface the valve seat Valve seat width Intake 1 2 1 4 mm 0 0472 0 0551 in lt Limit gt 1 6 mm 0 0630 in Exhaust 1 2 1 4 mm 0 0472 0 0551 in lt Limit gt 1 6 mm 0 0630 in e CAMSHAFT ROCKER ARMS AND VALVES ENG kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Measurement steps e Apply Mechanic s blueing dye to the valve face Install the valve into the cylinder head e Press the valve through the valve guide onto the valve seat to make a clear pattern eMeasure the valve seat width Where the valve seat and valve face made contact blueing will have been removed elf the valve seat is too wide too narrow the seat is not centered the valve seat must be refaced kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk 9 Lap Valve face Valve seat NOTE o lt lt lt After refacing the valve seat or replacing the valve and valve guide the valve seat and valve face should be lapped kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Lapping steps Apply a coarse lapping compound to the valve face Do not let the compound enter the gap be
42. e Clutch dog 2 4 e Spring long 5 e Shift fork L 6 NOTE nmm Install the shift fork with the mark facing towards the right side of the crankcase and the shift fork with the L mark facing towards the left side of the crankcase Be sure that the shift fork guide pin is properly seated in the shift drum groove Q pein Y yi PRAAN gy 4 Anne CO AA IND 4 74 TRANSMISSION ENG 2 Check Shift operation Unsmooth operation Repair NOTE Oil each gear and bearing thoroughly Before assembling the crankcase be sure that the transmission is in neutral and that the gears turn freely 8 MIDDLE GEAR ENG 8 MIDDLE GEAR MIDDLE DRIVE SHAFT 130 Nm 13 0 m kg 94 ft Ib Removing the middle drive shaft Remove the parts in the order below Crankcase separation Refer to CRANKCASE Transmission Refer to TRANSMISSION Bearing housing assembly Nut Refer to REMOVING INSTALLING THE Middle drive pinion gear MIDDLE DRIVE SHAFT shim Refer to SELECTING THE MIDDLE DRIVE AND DRIVEN GEAR SHIM Middle drive shaft Bearing retainer For installation reverse the removal procedure MIDDLE GEAR ENG 8 MIDDLE DRIVEN SHAFT 97 Nm 9 7 kg 70 ft Ib 25 Nm 2 5 m kg 18 ft Ib Job Removing middle driven shaft Remove the parts in the order below Crankcase separation Refe
43. e Cylinder and piston walls Vertical scratches Rebore or replace the cylinder and the piston e Cylinder water jacket Mineral deposits rust Eliminate CYLINDER AND PISTON ENG 2 Measure Piston to cylinder clearance e kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Measurement steps 1st step eMeasure the cylinder bore C with the cylinder bore gauge NOTE ____esese Measure cylinder bore C by taking side to side and front to back measurements of the cylinder Then find the average of the measurements c 84 500 84 510 mm Cylinder bore C 3 3268 3 3272 in 55 0 05 mm Max taper T 0 0016 in 0 01 mm Out of round 0 0004 in maximum of D De T z maximum of 0 or D maximum of Ds or De R maximum of D or 05 minimum of D D or De elf out of specification replace the cylinder and the piston and piston rings as a set 2nd step eMeasure piston skirt diameter P with a micrometer 8 5 0 mm 0 20 in from the piston bottom edge oS Piston skirt diameter P 84 445 84 460 mm Standard 3 3246 3 3252 e f out of specification replace the piston and piston rings as a set CYLINDER AND PISTON ENG OD 3rd step Find the piston to cylinder clearance with the following formula Piston to cylinder clearance Cylinder bore Piston skirt diameter P Piston to
44. 01083 Weight P N 90890 01084 ye REMOVING THE VALVE AND VALVE SPRING 1 Check e Valve sealing Leakage at the valve seat Check the valve face valve seat and valve seat width Refer to CHECKING THE VALVE AND VALVE SPRING kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Checking steps e Pour a clean solvent 1 into the intake and exhaust ports e Check that the valve seals properly There should be no leakage at the valve seat 2 kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk 8 CAMSHAFT ROCKER ARMS AND VALVES ENG 2 Remove Valve cotters Attach a valve spring compressor 1 between the valve spring retainer and the cylinder head to remove the valve cotters Valve spring compressor P N YM 04019 90890 04019 CHECKING THE CAMSHAFT 1 Check e Cam lobes Pitting scratches blue discoloration gt Replace 2 Measure e Cam lobes length and Out of specification Replace Camshaft lobe limit Intake 40 52 mm 1 595 b 32 08 mm 1 263 in Exhaust 8 40 52 mm 1 595 in b 32 08 mm 1 263 CHECKING THE ROCKER ARM AND CAMSHAFT 1 Check e Camshaft lobe contact surface 1 e Valve adjusters 2 Blue discoloration pitting scratches Replace 8 CAMSHAFT ROCKER ARMS AND VALVES ENG 2 Check e Rocker arms e Rocker arm shafts Damage wear Replace kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk
45. 1 Check e Carburetor body e Float chamber Cracks damage Replace e Fuel passage Contamination Clean as indicated e Carburetor body Contamination Clean kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Cleaning steps e Wash the carburetor in a petroleum based solvent Do not use any caustic carburetor cleaning solution Blow out all of the passages and jets with compressed air kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk 2 Check e Float 1 e Float tang 2 Damage Replace 3 Check e Valve seat 1 e Needle valve 2 e O ring 3 Contamination wear damage Replace as a set NOTE 2 Always replace the needle valve and valve Seat as a set 4 Check e Piston valve 1 Scratches wear damage Replace e Rubber diaphragm 2 Tears Replace CARBURETOR CARB gl 5 Check e Vacuum chamber cover 1 e Spring 2 Cracks damage Replace 6 Check e Diaphragm coasting enricher 1 e Spring 2 e Cover 3 Tears diaphragm damage Replace 7 Check e Jet needle 1 e Main jet 2 e Needle jet 3 e Pilot air jet 4 e Pilot jet 5 e Pilot screw 6 e Starter jet 7 e otarter plunger Bends wear damage Replace e Blockage Blow out the jets with compressed air 8 e Free movement piston valve Sticks Replace the piston valve guide and the piston valve Insert the piston valve into the carburetor body
46. 14 A at 3 000 r min 0 41 0 61 Q at 20 C 68 F White White Semi conductor short circuit 14 1 14 9 V SH640E 11 SHINDENGEN 14 A 200 V Constantmesh type Sues SM 13 MITSUBA Hunc 0 8 kW one 0 025 0 035 at 20 C 68 F MAINTENANCE SPECIFICATIONS SPEC y ltem Brush overall length Spring force Commutator diameter Mica undercut Starter relay Model manufacturer Amperage rating Coil winding resistance Four wheel drive relay 1 Model manufacturer Coil winding resistance Four wheel drive relay 2 Model manufacturer Coil winding resistance Four wheel drive relay 3 Model manufacturer Coil winding resistance Electric fan Running rpm Thermostat switch Thermostat switch 1 Model manufacturer Thermostat switch 2 Model manufacturer Circuit breaker Type Amperage for individual circuit Main fuse Headlight fuse Ignition fuse Auxiliary DC jack fuse Four wheel drive fuse Signaling system fuse Back up fuse odometer Reserve Reserve Reserve Reserve Standard Limit 12 5 mm 0 49 in 7 65 10 01 N 780 1 020 g 27 54 36 03 oz 28 mm 1 10 in 0 7 mm 0 03 MS5F 561 JIDECO 180A 4 18 4 62 Q at 20 C 68 F 5DM OMRON 94 5 115 5 at 20 C 68 F 5DM OMRON 94 5 115 5 at 20 C 68 F 29U MATSUSHITA 72 88 at 20 C 68 F 3 500 r min 5KM DENSO 5ND NIPPON THERMOSTAT HOW USE THE CONVERSION TABLE GENERAL TORQUE SPECIFICA
47. 47 Front brake light switch Rear brake light switch Tail brake light Horn switch 6 Horn For Europe and Oceania SIGNAL SYSTEM ELEC IF THE BRAKE LIGHT AND OR INDICATOR LIGHT FAILS TO COME ON EB80601 TROUBLESHOOTING IF THE HORN FAILS TO SOUND Procedure Check 1 Fuse main backup ignition signaling system 2 Battery 3 Main switch 4 Wiring connections the entire signal system NOTE e Hemove the following part s before Pocket tester troubleshooting P N YU 03112 90890 03112 1 Seat 2 Fuel tank 3JAir filter case 4 Front carrier 5 Front fender panel Use the following special tool s for troubleshooting EB802011 1 Fuse main backup ignition signaling system Refer to CHECKING THE SWITCH NO CONTINUITY CONTINUITY Replace the fuse INCORRECT e Check the battery condition Refer to CHECKING THE BATTERY in CHAPTER 3 Clean the battery terminals 12 8 V or more at 20 C 68 F e Recharge or replace the battery iL CORRECT EB802012 2 Battery SIGNAL SYSTEM ELEC 3 Main switch INCORRECT Refer to CHECKING THE SWITCH CORRECT Replace the main switch EB806011 im POOR CONNECTION 4 Wiring connections e Check the connections of the entire signal 1 system Refer to CIRCUIT DIAGRAM Properly connect the signal system CORRECT Check the condition of each of the signal system s circuits
48. 5ND4 For Oceania Dimensions Overall length Overall width Overall height 1 984 mm 78 1 in 1 085 mm 42 7 in 1 120 mm 44 1 in 827 mm 32 6 1 233 mm 48 5 in Minimum ground clearance 245 mm 9 7 in Minimum turning radius 3 000 mm 118 1 in Basic weight With oil and full fuel tank 267 kg 589 Ib Engine Engine type Liquid cooled 4 stroke SOHC Cylinder arrangement Forward inclined single cylinder Displacement 421 cm Bore x stroke 84 5 x 75 0 mm 3 33 x 2 95 in Compression ratio 10 1 Standard compression pressure at sea level 1 270 kPa 12 7 kg cm 181 psi at 700 r min otarting system Electric and recoil starter Oil type or grade Engine oil For CDN 0 10 30 50 n 90 i API service SE SF SG type or higher Seat height Wheelbase ey EE ERE YAMALUBE 4 20W40 or SAE 20W40 NM a eee YAMALUBE 4 10W30 or SAE 10W30 SAE 5W30 20 10 0 10 20 30 For Europe Oceania Temp 10W 40 15W 40 20W 40 b Final gear oil SAE 80API GL 4 Hypoid Gear Differential gear oil SAE 80API GL 4 Hypoid Gear GENERAL SPECIFICATIONS SPEC y ltem Standard Oil capacity Engine oil Periodic oil change 2 3 L 2 0 Imp qt 2 4 US qt With oil filter replacement 2 4 L 2 1 Imp qt 2 5 US qt Total amount 2 6 L 2 3 Imp qt 2 7 US qt Final gear case oil Periodic oil change 0 23 L 0 20 Imp
49. AND REAR BRAKES in CHAPTER 8 NOTE Hold the machine in an upright position and apply the front or rear brake 3 Check e Brake hose clamp Loosen gt Tighten 4 Install e Right footrest board Refer to FOOTREST BOARDS e Front fender e Front carrier e Seat Refer to SEAT CARRIERS FENDERS AND FUEL TANK 4o BLEEDING THE HYDRAULIC BRAKE SYSTEM ADJ BLEEDING THE HYDRAULIC BRAKE SYSTEM WARNING Bleed the brake system if e The system has been disassembled e A brake hose or brake pipe have been loosened or removed e The brake fluid has been very low e The brake operation has been faulty A loss of braking performance may occur if the brake system is not properly bled 1 Bleed e Brake system NON 7 kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Air bleeding steps a Add the proper brake fluid to the reservoir b Install the diaphragm Be careful not to spill any fluid or allow the reservoir to overflow c Connect the clear plastic hose 1 tightly to the caliper bleed screw 2 Front Rear d Place the other end of the hose into a container e Slowly apply the brake lever or pedal several times f Pull the lever in or push down on the pedal and hold it g Loosen the bleed screw and allow the lever or pedal to travel towards its limit h Tighten the bleed screw when the lever or pedal limit has be
50. Drive pawl 3 Wear damage Replace e Coil spring 4 e Pawl spring 5 e Spring Fatigue Replace ASSEMBLING THE RECOIL STARTER 1 Install Sheave drum 1 e Rope 2 e Pawl spring 3 e Drive pawl 4 NOTE 2L Wind the rope 4 1 2 turns clockwise around the sheave drum Then insert the rope into the drum slit 8 RECOIL STARTER AND A C MAGNETO ENG 2 Install e Starter spring 1 e Sheave drum assembly 2 NOTE e Mesh the spring hook 3 with the case slit then wind the spring clockwise into the case from the larger to smaller diameter e Mesh the sheave drum hook 4 with the spring hook 5 3 Install e Spring 1 e Friction plate 2 e Nut NOTE Insert the spring hooks into the pawl side holes 4 Turn the sheave drum 3 turn clockwise to give preload to the spring 5 Install e Starter handle 1 e 2 NOTE 2L e Pass the rope through the case hole and make a knot 3 on the rope so that the rope is not pulled into the case e Untie the knot 3 after making a knot 4 above the handle INSTALLING THE A C MAGNETO 1 Apply e Sealant Quick Gasket 1 into the slit Sealant Quick Gasket P N ACC 11001 05 01 Yamaha bond No 1215 P N 90890 85505 8 RECOIL STARTER AND A C MAGNETO ENG 2 Install e Woodruff key e Rotor NOTE e Before installing the rotor clean the outside of the crankshaft and the
51. E This tool is needed when removing or installing the middle driven pinion gear bearing retainer Pinion gear fix clamp 90890 04129 YM 04129 This tool is used to hold the shift cam Ignition checker 90890 06754 This instrument is necessary for checking the ignition system components Dynamic spark tester YM 34487 This instrument is necessary for checking the ignition system components Yamaha bond No 1215 Bond Sealant Quick Gasket 90890 85505 Sealant ACC 11001 05 01 This sealant bond is used crankcase mating surfaces etc 2 SPECIFICATIONS GENERAL SPECIFICATIONS 5 tun uias 2 1 MAINTENANCE SPECIFICATIONS 2 4 clle 2 4 VP e TR 2 14 ELECTRIORLB toute bis e su dO REN I MI a M OE 2 18 HOW TO USE THE CONVERSION TABLE 2 20 GENERAL TORQUE SPECIFICATIONS 2 20 LUBRICATION POINTS AND LUBRICANT TYPES 2 21 ENGINE A 2 21 COOLANT FLOW DIAGRAMS 2 22 OIL FLOW DIAGRAMS retro ame RO 2 24 GABLE ROUTING acca 2 27 GENERAL SPECIFICATIONS SPEC y SPECIFICATIONS GENERAL SPECIFICATIONS Model code 5ND2 For CDN 5ND3 For Europe
52. Lubricate the nut with molybdenum disulfide oil e Use a clutch holding tool 2 to hold the clutch carrier assembly Clutch holding tool P N YM 91042 90890 04086 ye 2 Lock the threads with a drift punch 3 Install e One way clutch bearing NOTE The one way clutch bearing should be installed in the clutch carrier assembly with the arrow mark facing toward the clutch housing 8 ENG 4 Install e Dowel pins e Gasket e Clutch housing assembly 10 Nm 1 0 kg 7 2 ft Ib D __ _ e lighten the bolts in stages using a crisscross pattern e After tightening the bolts check that the clutch housing assembly to counterclockwise rotates smoothly 8 CRANKCASE ENG CRANKCASE STARTER MOTOR TIMING CHAIN AND OIL FILTER 18 Nm 1 8 m kg 13 ft Ib 10 Nm 1 0 m kg 7 2 ft Ib 20 Nm 2 0 m kg 14 ft Ib 18 Nm 1 8 m kg 13 ft Ib Job Removing the starter motor timing Remove the parts in the order below chain and oil filter Engine assembly Refer to ENGINE REMOVAL Cylinder head Refer to CYLINDER HEAD Cylinder and piston Refer to CYLINDER AND PISTON Recoil starter and rotor Refer to RECOIL STARTER AND A C MAGNETO Primary and secondary sheaves Refer to PRIMARY AND SECONDARY SHEAVES Clutch carrier assembly Refer to CLUTCH Oil pump drive gear straight key
53. Never use gasoline or low flash point solvents as they may cause a fire or explosion eSqueeze the excess solvent out of the element and let it dry could damage the foam material e Apply engine oil to the element e Squeeze out the excess NOTE _ The element should be wet but not dripping kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk 6 Install e Air filter element e Air filler case cover NOTE 2 To prevent air leaks make sure that the sealing surface of the element matches the sealing surface of the case e Seat Refer to SEAT CARRIERS FENDERS AND FUEL TANK CHECKING THE COOLANT LEVEL CHECKING THE COOLANT LEVEL 1 Place the machine on a level surface 2 Remove e Seat e Fuel tank side panel left 3 Check e Coolant level The coolant level should be between the minimum level mark and maximum level mark b Below the minimum level mark Add the recommended coolant to the proper level e Adding water instead of coolant lowers the antifreeze content of the coolant If water is used instead of coolant check and if necessary correct the antifreeze concentration of the coolant e Use only distilled water However soft water may be used if distilled water is not available 4 Start the engine warm it up for several minutes and then turn it off 5 Check e Coolant level NOTE _ Before checking the coolant level wait a few minutes u
54. Refer to REMOVING INSTALLING THE OIL PUMP DRIVE GEAR Oil pump driven gear Timing chain guide Timing chain Starter motor O ring CRANKCASE ENG 8 18 Nm 1 8 m kg 13 ft Ib 10 Nm 1 0 m kg 7 2 ft Ib 20 Nm 2 0 m kg 14 ft Ib 18 Nm 1 8 m kg 13 ft Ib Job 6 1 Oil filter cartridge Speed sensor Shift cam stopper Low range switch High range switch Neutral switch switch Oil filler cap Bearing cover gasket Oil delivery pipe Oil strainer cover O ring Compression spring Oil strainer For installation reverse the removal procedure CRANKCASE ENG 8 CRANKCASE 10 Nm 1 0 m kg 7 2 ft Ib 14 Nm 1 4 m kg 10 ft Ib 10 Nm 1 0 m kg 7 2 ft Ib Job name Part name Remarks Separating the crankcase Remove the parts in the order below Shift lever cover gasket Shift lever 1 O ring Shift lever 2 assembly Crankcase left Dowel pin Crankcase right Refer to INSTALLING THE SHIFT LEVER Refer to SEPARATING ASSEMBLING THE CRANKCASE For installation reverse the removal procedure CRANKCASE BEARING CRANKCASE ENG 10 Nm 1 0 m kg 7 2 ft Ib Job name Part name Removing the crankcase bearing Crankshaft and oil pump Transmission Middle drive driven shaft Oil seal Bearing retainer Bearing 11 Nm 1 1 m kg 8 0 ft Ib Remarks Remove the parts in the order below Refer to
55. SYSTEM orate neha late Sosa Ges td 8 30 HANDLEBAR coUe Suede ele 8 30 REMOVING THE REAR BRAKE SWITCH 8 31 CHECKING THE HANDLEBAR usta aad aes 8 31 INSTALLING THE HANDLEBAR mE E Pt bi drum pens 8 31 INSTALLING THE REAR BRAKE LEVER 8 31 INSTALLING THE MASTER CYLINDER ASSEMBLY 8 32 STEERING STEM E p 8 33 REMOVING THE BEARING RETAINER _ 8 35 CHECKING THE STEERING STEM sese 8 35 INSTALLING THE BEARING RETAINER 8 35 INSTALLING THE CABLE GUIDE 5 Res eR 8 35 TIE ROD AND STEERING KNUCKLE 2 02 8 36 REMOVING THE STEERING KNUCKLE eee 8 38 CHECKING THE TE ROD 8 38 CHECKING THE STEERING KNUCKLE 8 38 INSTALLING THE TIE ROD Retina 8 41 FRONT ARMS AND FRONT SHOCK ABSORBER 8 42 REMOVING THE FRONT ARMS 8 44 CHECKING THE FRONT ARM 8 44 CHECKING THE FRONT SHOCK ABSORBER 8 46 INSTALLING THE FRONT ARMS AND FRONT SHOCK ABSORBER 8 47 REAR SHOCK ABSORBER AND SWINGARM
56. air passage e Sucked in air e Deformed float e Worn needle valve e Improperly sealed valve seat e Improperly adjusted fuel level e Improperly set pilot jet e Clogged starter jet e otarter plunger malfunction Air filter e Clogged air filter element Switches and wiring e Faulty main switch e Faulty engine stop switch e Broken or shorted wiring e Faulty neutral switch e Faulty reverse switch e Faulty low range switch e Faulty high range switch e Faulty start switch e Faulty rear brake switch Starter motor e Faulty starter motor e Faulty starter relay e Faulty starter clutch 10 1 STARTING FAILURE HARD STARTING POOR IDLE HBL PERFORMANCE POOR MEDIUM AND HIGH SPEED PERFORMANCE SHTG COMPRESSION SYSTEM Cylinder and cylinder head e Loose spark plug e Loose cylinder head or cylinder e Broken cylinder head gasket e Broken cylinder gasket e Worn damaged or seized cylinder Piston and piston rings e Improperly installed piston ring e Worn fatigued or broken piston ring e Seized piston ring e Seized or damaged piston POOR IDLE SPEED PERFORMANCE POOR IDLE SPEED PERFORMANCE Carburetor e Improperly returned starter plunger e Loose pilot jet e Clogged pilot jet e Clogged pilot air jet e Improperly adjusted idle speed Throttle stop screw e Improper throttle cable play e Flooded carburetor Valve camshaft and crankshaft e Improperly sealed valve e Improperly contacted
57. and check for free movement 9 Check e Free movement throttle valve Sticks Replace 6 5 CARBURETOR CARB gl ASSEMBLING THE CARBURETOR Before reassembling wash all of the parts in clean petroleum based solvent 1 Install e Pilot screw 1 Pilot screw setting 2 1 2 2 Measure e Float height 8 Out of specification Adjust Float height F H 13 mm 0 51 in kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Measurement and adjustment steps Hold the carburetor an upside down position Measure the distance from the mating surface of the float chamber gasket removed to the top of the float NOTE The float arm should be resting on the needle valve but not compressing it elf the float height is not within the specification check the valve seat and needle valve e f either is worn replace them both elf both are fine adjust the float height by bending the float tang 1 on the float e Recheck the float height kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk CARBURETOR CARB gl ADJUSTING THE FUEL LEVEL 1 Measure e Fuel level Out of specification Adjust Fuel level 4 0 5 0 mm 0 16 0 20 in Above the float chamber mating surface kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Measurement and adjustment steps Place the machine on a level surface Connect the fuel level gauge 1 to the drain pipe
58. between the valve stem tips and their respective rocker arm adjusting screws e f there is no clearance rotate the crankshaft counterclockwise one turn e Measure the valve clearance using a feeler gauge 3 kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk 4o ADJUSTING THE VALVE CLEARANCE ADJ 8 Adjust e Valve clearance Adjustment steps Loosen locknut 1 e Insert a feeler gauge 2 between the adjuster end and the valve end eTum the adjuster 3 clockwise counterclockwise with the valve adjusting tool until the proper clearance is obtained 2 Tappet adjusting tool A P N YM 08035 90890 01311 Hold the adjuster to prevent it from moving and then tighten the locknut Locknut 25 20 Nm 2 0 kg 14 ft e Measure the valve clearance elf the clearance is incorrect repeat the above steps until the proper clearance is obtained kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk 9 Install e All removed parts Install all removed parts in the reverse order their disassembly Note the following points 10 Install e Recoil starter 41 e Spark plug e covers 10 Nm 1 0 kg 7 2 Ib NOTE 2 Install the tappet covers with the ridge facing up 3 12 ADJUSTING THE VALVE CLEARANCE ADJUSTING THE IDLING SPEED ADJ Q 11 Install e Fuel tank e Front fender e Front carrie
59. cylinder clearance 0 040 0 065 mm 0 0016 0 0026 in lt Limit gt 0 150 mm 0 0059 in ef out of specification rebore or replace the cylinder and replace the piston and piston rings as a set kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk CHECKING THE PISTON RING 1 Measure e Ring side clearance Use a feeler gauge Out of specification Replace the piston and rings as a set D NOTE LLL Clean carbon from the piston ring grooves and rings before measuring the side clearance Side clearance Top 0 03 0 07 mm 0 12 mm ring 0 0012 0 0028 in 0 0047 0 02 0 06 mm 0 12 mm 0 0008 0 0024 in 0 0047 in 2 Position e Piston ring in cylinder NOTE 277 Insert a ring into the cylinder and push it approximately 40 mm 1 6 in into the cylinder Push the ring with the piston crown so that the ring will be at a right angle to the cylinder bore 8 40 mm 1 6 in 307 027 CYLINDER AND PISTON ENG 3 Measure e Ring end gap Out of specification Replace NOTE _ You cannot measure the end on the expander spacer of the oil control ring If the oil control ring rails show excessive gap replace all three rings End 220000 Endgap 00 21 0 20 0 40 0 65 ring 0 0079 0 0157 in 0 0256 in 0 40 0 60 mm 0 95 mm 0 0157 0 0236 in 0 0374 in 0 2 0 7 mm 0 0079 0 0276
60. em vao 01 IM M 993 ambu Ulsi vV zy ue YOUMS ouueu 10JOW JeXeoJq osnj yms L y a M a M as l Ava A A bee 18 Grove 4 eG ee ae 1 1 1 1 1g 1g i i 18 ur Big or farg E lofo usna m 09 eee prm 126 peer 0 en ee p ea Oo I lt lt SSHNHVH 6 SSHNHVH SSANYVH FRANEA UM 3uIM ans v18 anfwa unas 9 38 COOLING SYSTEM ELEC TROUBLESHOOTING Procedure Check 1 Fuse main 6 Thermo switch 2 2 Battery 7 Wiring connection 3 Main switch the entire cooling system 4 Fan motor 5 Circuit breaker fan motor NOTE e Remove the following part s before Pocket tester troubleshooting 2 P N YU 03112 90890 03112 1 Seat 2 Front carrier 3 Front fender Use the following special tool s for
61. harness e Connect the pocket tester Q x 1 and the battery 12 V to the four wheel drive relay 1 terminals Tester lead gt Brown Black terminal 1 Tester lead Black terminal 2 Battery terminal Brown Red terminal 3 Battery terminal Blue Green terminal Tester lead gt NO CONTINUITY Brown Black terminal 1 Tester lead Brown Red terminal e Check the four wheel drive relay 1 for continuity Replace the four wheel drive relay 1 5 Four wheel drive relay 2 e Remove the four wheel drive relay 2 from the wire harness e Connect the pocket tester O x 1 and the battery 12 V to the four wheel drive relay 2 terminals Tester lead gt Black Yellow terminal 1 Tester lead Black terminal 2 Battery terminal Brown Red terminal 3 Battery terminal Blue Red terminal Tester lead gt NO CONTINUITY Black Yellow terminal 1 Tester lead Brown Red terminal Replace the four wheel drive relay 2 CONTINUITY 2WD AWD SELECTING SYSTEM ELEC 6 Four wheel drive relay 3 e Remove the four wheel drive relay 3 from the wire harness e Connect the pocket tester O x 1 and the battery 12 V to the four wheel drive relay 3 terminals Tester lead gt Brown Red terminal 1 Tester lead gt Yellow Black terminal 2 Battery terminal gt Brown Red terminal
62. hose routing is essential to insure safe machine operation Refer to CABLE ROUTING in CHAPTER 2 FRONT AND REAR BRAKES CHAS 36 2 Fill e Brake fluid reservoir Recommended brake fluid DOT 4 Brake fluid may damage painted surfaces or plastic parts Always clean up spilled brake fluid immediately WARNING e Use only the designated quality brake fluid other brake fluids may deteriorate the rubber seals causing leakage and poor brake performance e Refill with the same type of brake fluid mixing brake fluids may result in a harmful chemical reaction and lead to poor brake performance e Be careful that water does not enter the brake master cylinder when refilling Water will significantly lower the boiling point of the brake fluid and may result in vapor lock 3 Air bleed e Brake system Hefer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in CHAPTER 3 4 Check e Brake fluid level Brake fluid level is under the LOWER level line Fill up Refer to CHECKING THE BRAKE FLUID LEVEL in CHAPTER 3 FRONT AND REAR BRAKES CHAS 36 FRONT BRAKE CALIPER 18 Nm 1 8 m kg 13 ft Ib 30 Nm 3 0 m kg 22 ft Ib 27 Nm 2 7 m kg 19 ft Ib Job Removing front brake caliper Remove the parts in the order below Brake fluid Drain Front wheel Refer to FRONT AND REAR WHEELS Union bolt Copper washer Brake hose Disconnect Refer to INSTALLING Cap
63. its open circuit Voltmeter voltage 12 8 V gt Charging is complete 12 0 12 7 V Recharging is required Under 12 0 V Replace the battery Constant amperage chargers are not suitable for charging MF batteries Leave the battery unused for more than 30 minutes before measuring its open circuit voltage NO This type of battery charger cannot charge an MF battery A variable voltage charger is recommended Charger CHECKING THE FUSE ADJ 5 Check e Battery terminals Dirty Clean with a wire brush Poor connection Correct NOTE After cleaning the terminals apply a light coat of grease 6 Install e Battery 7 Connect e Battery leads First connect the positive lead 1 then connect the negative lead 8 Install e Battery lead cover e Battery holding bracket e Seat Refer to SEAT CARRIERS FENDERS AND FUEL TANK CHECKING THE FUSE Always turn off the main switch when checking or replacing a fuse Otherwise a short circuit may occur 1 Remove e Seat Refer to SEAT CARRIERS FENDERS AND FUEL TANK 2 Check e Fuses kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Checking steps e Connect the pocket tester to the fuse and check it for continuity CHECKING THE FUSE Set the tester to the Q x 1 position Pocket test
64. lead and A C magneto lead with a plastic band Fasten the wire harness starter motor lead with a plastic band D Fasten the low range switch lead high range switch lead neutral switch lead reverse switch lead speed sensor lead A C magneto lead rectifier regulator lead and negative battery lead with a plastic band 0 KT i 4 Eu LI O 4 D Tm E A 4 25 7 XS SA E EX ELE BRE 62227474 2 I v AK JE ERO o ee TS S CABLE ROUTING SPEC y D Throttle cable Fasten the radiator inlet hose and spark plug 2 Radiator inlet hose lead with a plastic band 3 Spark plug lead 2 Main switch 5 Wire harness 6 Rear brake light switch lead 7 Rear brake fluid reservoir hose Select lever control cable 9 Rear brake cable Hear brake hose 10 SEEN 7 7122 P ain D VEL 777717 2 9 1 c CABLE ROUTING SPEC y 1 Front brake hose 2 Float chamber air vent hose 3 Throttle cable 4 Wire harness 5 Final drive gear case breather hose 6 Starter cable 7 Rear brake cable en Co 1 ee _ ES EP LO lt 5 TIR T uw 622 ea E Q r awe ll COSE IA DIS cL ak do bnl 2 34
65. length 12 5 mm 0 49 in lt Wear limit gt 5 mm 0 20 in 18210402 6 Measure e Brush spring force Fatigue out of specification Replace the brush holder set Brush spring force 7 65 10 01 Nm 780 1 020 g 27 54 36 03 oz 7 Check e O rings Wear damage Replace ASSEMBLING THE STARTER MOTOR 1 Install e Brush holder set 1 NOTE 2 LLL Align the projection 8 on the brush seat 1 with the slot b on the yoke 2 Install e Yoke e Brackets NOTE _ Align the match marks on the yoke with the match marks on the brackets lt 0 CHARGING SYSTEM ME S Leere CHARGING SYSTEM CIRCUIT DIAGRAM 9 EB804000 L wa a fara E AvH5 gog L Yow pns prin V 1 2 Rectifier regulator CD A C magneto 5 Battery 6 Main fuse a une Es O gt I gt See ae SS SSHNHVH SSHNHVH SSHNHVH SYIM 8Ns SSOMEVHIOHIM mm unas GS un 9 22 EB80401 CHARGING SYSTEM ELEC TROUBLESHOOTING IF THE BATTERY IS NOT CHARGED Procedure Check 1 Fuse main 4 Charging coil resistance 2 B
66. lower d 2nd ring end 3 Install e Piston 1 e Piston e Piston pin clips 3 NOTE e Apply engine oil onto the piston pin piston ring and piston e Be sure that the arrow mark 8 on the piston points to the exhaust side of the engine e Before installing the piston pin clip cover the crankcase with a clean rag to prevent the piston pin clip from falling into the crankcase CYLINDER AND PISTON ENG 4 Lubricate e Piston e Piston rings e Cylinder NOTE Apply a liberal coating of engine oil e INSTALLING THE CYLINDER 1 Install e Cylinder NOTE Install the cylinder with one hand while compressing the piston rings with the other hand damper during installation e Pass the timing chain through the timing chain cavity RECOIL STARTER AND MAGNETO ENG RECOIL STARTER AND A C MAGNETO 10 Nm 1 0 m kg 7 2 ft Ib Job nameiPart Removing the CDI magneto Remove the parts in the order below Engine oil Drain Refer to CHANGING THE ENGINE OIL in CHAPTER 3 Seat and side panels Refer to SEAT AND SIDE PANELS in CHAPTER 3 L eft footrest board Refer to FOOTREST BOARDS in CHAPTER 3 Recoil starter assembly A C magneto coupler Disconnect Starter pulley Crankcase cover left gasket Dowel pin Lead holder Refer to REMOVING INSTALLING THE MAGNETO 10 Nm 1 0 m kg 7 2 ft Ib Job name 7 1 Pic
67. name Removing the front brake master Remove the parts in the order below cylinder Brake fluid Drain On command four wheel drive switch Refer to HANDLEBAR and differential gear lock switch Brake fluid reservoir cap Brake fluid reservoir diaphragm Brake lever Union bolt Copper washer Brake hose Front brake light switch Brake master cylinder bracket Brake master cylinder Refer to INSTALLING THE FRONT BRAKE MASTER CYLINDER ODO gt a S For installation reverse the removal procedure FRONT AND REAR BRAKES CHAS 56 Job name Disassembling the front brake Remove the parts in the order below master cylinder Brake master cylinder kit Refer to ASSEMBLING THE FRONT Brake master cylinder 1 BRAKE MASTER CYLINDER For assembly reverse the disassembly procedure FRONT AND REAR BRAKES CHAS REAR BRAKE MASTER CYLINDER 30 Nm 3 0 m kg 22 ft Ib 23 Nm 2 3 m kg 17 ft Ib 7 Nm 0 7 m kg 5 1 ft Ib Job Removing rear brake master Remove the parts in the order below cylinder Front fender Refer to SEAT CARRIERS FENDERS AND FUEL TANK in CHAPTER 3 Brake fluid Drain Brake fluid reservoir cap Brake fluid reservoir diaphragm holder Brake fluid reservoir diaphragm Brake fluid reservoir Brake master cylinder cover Brake fluid reservoir hose Union bolt
68. qt 0 24 US qt Total amount 0 25 L 0 22 Imp at 0 26 US at Differential gear case oil Periodic oil change 0 23 L 0 20 Imp qt 0 24 US qt Total amount 0 28 L 0 25 Imp qt 0 30 US qt Radiator capacity including all routes 1 32 L 1 16 Imp qt 1 40 US qt Fuel Type Unleaded fuel Fuel tank capacity 15 L 3 3 Imp gal 3 9 US gal Fuel reserve amount 4 5 L 0 99 Imp gal 1 19 US gal Carburetor Type quantity BSR33 1 Manufacturer MIKUNI Spark plug Type manufacturer DRSEA NGK Spark plug gap 0 6 0 7 mm 0 024 0 028 in Transmission Primary reduction system V belt Secondary reduction system Spur gear Secondary reduction ratio 39 24 x 24 18 x 33 9 7 944 Transmission type V belt automatic Operation Left hand operation Single speed automatic 2 55 0 75 1 Sub transmission ratio 45 16 2 813 38 23 1 652 Heverse gear 29 17 1 706 Chassis Frame type oteel tube frame Caster angle 4 Camber angle 1 Kingpin angle 11 Kingpin offset 5 mm 0 2 in Trail 21 mm 0 83 in Tread STD 850 mm 33 46 in 825 mm 32 48 in Toe in 10 mm 0 0 39 in GENERAL SPECIFICATIONS SPEC y Item Tire Type Size Manufacturer Type Tire pressure cold tire Maximum load Off road riding front rear Load in total weight of rider accessories Brake Front brake type operation type operation Hear brake Suspension Front suspension Hear suspension Shock absorber Front shock absorber Rear shock a
69. reservoir diaphragm 2 Cracks damage Replace 2 FRONT AND REAR BRAKES CHAS EB7020 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER A WARNING e All internal brake components should be cleaned and lubricated with new brake fluid only before installation Recommended brake fluid DOT 4 e Whenever master cylinder 15 Pei replace the piston seals and dust seals EB702060 ASSEMBLING THE REAR BRAKE MASTER CYLINDER WARNING e All internal brake components should be cleaned and lubricated with new brake fluid only before installation Recommended brake fluid DOT 4 e Whenever a master cylinder is disassembled replace the piston seals and dust seals 1 Install e Brake master cylinder kit e Nut 1 e Joint 2 NOTE Turn the adjusting bolt 3 until the clearance is within the specified limits when install the joint 2 Clearance 4 6 mm 0 16 0 24 in 2 FRONT AND REAR BRAKES CHAS INSTALLING THE FRONT BRAKE MASTER CYLINDER 1 Install e Brake master cylinder 1 e Brake master cylinder bracket 2 7 Nm 0 7 me kg 5 1 ft 16 NOTE The UP mark on the brake master cylinder bracket 2 should face up 2 Install e Copper washers e Brake hose e Union bolt 27 Nm 2 7 m kg 19 ft Ib e Tighten the union while holding the brake hose as shown e Turn the handlebar to the left and to the right to check that the
70. several times to obtain an average figure e During this test the other front wheel will turn in the opposite direction Front wheel starting torque differential gear preload New unit 17 25 Nm 1 7 2 5 m kg 12 18 ft Ib Minimum 10 Nm 1 0 m kg 7 2 ft Ib 4 Out of specification Replace the differential gear assembly 5 Within specification Install the new cotter pin and wheel cap gt REAR AXLE FINAL DRIVE GEAR AND DRIVE SHAFT DRIV REAR AXLE FINAL DRIVE GEAR AND DRIVE SHAFT 63 Nm 6 3 m kg 45 ft Ib Job Removing the rear axle final drive Remove the parts in the order below gear assembly and drive shaft Final gear oil Drain Rear wheel hubs brake disc Refer to FRONT AND REAR WHEELS in CHAPTER 8 1 O ring 2 Rear axle dust cover 3 Trailer hitch bracket ae INSTALLING THE 4 Final drive gear case breather hose Disconnect REAR AXLE 5 Final drive gear 6 Drive shaft For installation reverse the removal procedure REAR AXLE FINAL DRIVE GEAR AND DRIVE SHAFT DRIV 23 Nm 2 3 m kg 17 ft Ib 23 Nm 2 3 m kg 17 ft Ib Disassembling the final drive gear Remove the parts in the order below Bolt NOTE Bolt Working in a crisscross pattern loosen each bolt 1 4 of a turn After all the bolts are loosened remove them Bearing housing Oil seal bearing Ring gear stopper Ring gear s
71. the body 3 FRONT ARMS AND FRONT SHOCK ABSORBER CHAS 36 e Attach the assembled ball joint remover installer new ball joint 47 and installer attachment 7 to the front lower arm 2 NOTE Do not tap or damage the top of the ball joint e Hold the body 3 in place while turning in the long bolt to install the new ball joint 1 into the front lower arm 2 e Remove the ball joint remover installer e Apply lithium soap base grease to the new ball joint 4 e Install new rubber boot and new circlip NOTE Always use a new ball joint set kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk CHECKING THE FRONT SHOCK ABSORBER 1 Check e Shock absorber rod Bends damage gt Replace the shock absorber assembly e Shock absorber assembly Oil leaks Replace the shock absorber assembly e Spring Fatigue Replace the shock absorber assembly Move the spring up and down FRONT ARMS AND FRONT SHOCK ABSORBER CHAS 36 INSTALLING THE FRONT ARMS AND FRONT SHOCK ABSORBER 1 Install e Front arms e Front shock absorber kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Installation steps Install the front upper arm 1 and front lower arm NOTE L C O e Lubricate the bolts 3 with lithium soap based grease e Be sure to position the bolts 3 so that the bolt head faces outward e Temporarily tighten the nuts 4 e Install the front shock ab
72. the copper washer 9 Drain e Coolant 10 Check e Copper washer 1 D Coolant drain bolt Damage Replace 11 Install e Coolant drain bolt water pump 10 Nm 1 0 m kg 7 2 ft Ib e Coolant drain bolt cylinder 10 Nm 1 0 m kg 7 2 ft Ib 12 Fill e Cooling system EN with the specified amount of recommended coolant Recommended antifreeze High quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines Mixing ratio 1 1 antifreeze water Quantity Total amount 1 32 L 1 16 Imp qt 1 40 US qt Coolant reservoir capacity 0 39 L 0 34 Imp qt 0 41 US qt Handling notes for coolant Coolant is potentially harmful and should be handled with special care WARNING elf coolant splashes eyes thoroughly wash them with water and consult a doctor elf coolant splashes on your clothes quickly wash it away with water and then with soap and water e If coolant is swallowed induce vomiting and get immediate medical attention CHANGING THE COOLANT e Adding water instead of coolant lowers the antifreeze content of the coolant If water is used instead of coolant check and if necessary correct the antifreeze concentration of the coolant e Use only distilled water However soft water may be used if distilled water is not available e If coolant comes into contact with painted surfaces immediate
73. the locknuts tie rod end 1 of both 1 tie rods e same number of turns should be given ps xi EL c CN EC e gt to both the right and left tie rods until the SENE 27 D LE 6 specified toe in is obtained This is to keep ecco the length of the rods the same Tighten the rod end locknuts of both tie rods Locknut rod end 25 40 Nm 4 0 kg 29 ft Ib NOTE ALL Adjust the rod ends so that A and B are equal kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk ADJUSTING THE FRONT SHOCK ABSORBER ADJUSTING THE REAR CHK SHOCK ABSORBER CHECKING THE TIRE ADJ ADJUSTING THE FRONT SHOCK ABSORBER WARNING Always adjust both front shock absorber spring preload to the same setting Uneven adjustment can cause poor handling and loss of stability 1 Adjust e Spring preload Turn the adjuster 1 to increase or decrease the spring preload Standard position 2 Minimum Soft position 1 Maximum Hard position 5 ADJUSTING THE REAR SHOCK ABSORBER 1 Adjust e Spring preload Turn the adjuster 1 to increase or decrease the spring preload NOTE The spring preload of the rear shock absorber can be adjusted to suit the rider s preference weight and the riding conditions Standard position 2 Minimum Soft position 1 Maximum Hard position 5 CHECKING THE TIRE W
74. the starter pulley Rotor holding tool P N YU 01235 90890 01235 5 Check e Camshaft sprocket e Rotor T mark Out of alignment Adjust CAMSHAFT ROCKER ARMS AND VALVES CAMSHAFT ROCKER ARMS AND VALVES Removing the camshaft rocker arms and valves Intake manifold O ring Thermo switch Oil check bolt Lock washer bearing retainer Camshaft Rocker arm shaft O ring Rocker arm Locknut valve adjuster Valve cotter Valve spring retainer Valve spring outer Refer to REMOVING INSTALLING THE CAMSHAFT AND ROCKER ARM DOF WN Refer to REMOVING INSTALLING THE VALVE AND VALVE SPRING 8 Nm 0 8 m kg 5 8 ft Ib Job 12 2 Valve spring inner 13 Valve intake 14 Valve exhaust 15 stem seal 16 spring seat Refer to REMOVING INSTALLING THE VALVE AND VALVE SPRING For installation reverse the removal procedure CAMSHAFT ROCKER ARMS AND VALVES ENG REMOVING THE CAMSHAFT AND ROCKER ARM 1 Remove e Camshaft 1 NOTE Screw in a M10 bolt 2 into the thread hole on the camshaft and pull out the camshaft 2 Remove e Rocker arm shafts intake and exhaust 1 e Rocker arms 2 NOTE SS Use a slide hammer 3 to remove the rocker arm shafts Slide hammer set P N YU 01083 A Slide hammer bolt M6 P N 90890
75. vertical movement is tight or rough or if there is binding check the bushings kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Dr W 2 NS 2 Hemove e Front arms CHECKING THE FRONT ARM 1 Check e Front arms Bends damage Replace 2 Check e Bushings Wear damage Replace 3 Check e Ball joint Damage pitting Replace the ball joint Free play Replace the ball joint Turns roughly Replace the ball joint FRONT ARMS AND FRONT SHOCK ABSORBER CHAS kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Replacement steps e Clean the outside of the front lower arm Remove the circlip 1 and rubber boot 2 Use the ball joint remover and installer set 2 Ball joint remover installer set e P N YM 01474 90890 01474 Ball joint remover installer attachment set P N YM 01477 YM 01474 50890 01474 YM 01474 90890 01474 01477 01477 Installer attachment 01477 Installer spacer YM 01477 9 Installer guide einstall the body 3 long bolt 2 remover washer 5 and remover spacer 6 onto ball joint NOTE Remover washer 5 must be aligned with the projection on the head of the ball joint Hold the body 3 place while turning the long bolt 4 to remove the ball joint 9 from the front lower arm e Remove the ball joint remover installer einstall the long bolt 49 installer spacer and installer guide 9 onto
76. 004 0 0010 in Balancer Balancer drive method Gear Automatic centrifugal clutch Clutch shoe thickness 1 5 mm 0 06 in Clutch in revolution 1 960 2 240 r min Clutch stall revolution 3 300 3 900 r min MAINTENANCE SPECIFICATIONS SPECIFICATIONS SPEC g 0 06 mm 0 0024 in Item Transmission Main axle deflection limit Drive axle deflection limit 0 06 mm 0 0024 in Shifter Shifter type Shift cam and guide bar Air fiter cil grade Carburetor Il D mark Main jet Main air jet Jet needle Needle jet Pilot air jet Pilot air jet Pilot outlet Pilot jet Bypass 1 Bypass 2 Bypass 3 Pilot screw turns out Valve seat size Starter jet Starter jet Throttle valve size Float height Fuel level Engine idle speed Intake vacuum Oil pump Oil filter type Oil pump type Tip clearance A or B Side clearance Bypass valve setting pressure Oil pressure hot Pressure check location 5ND1 00 3131 3 50 5EP13 55 3 80 1 3 0 95 17 5 0 8 0 8 0 8 2 1 2 2 0 70 0 9 90 13 mm 0 51 in 4 0 5 0 mm 0 16 0 20 in 1 450 1 550 r min 32 kPa 240 mmHg 9 45 inHg Foam Trochoid 0 15 mm 0 006 in 0 20 mm 0 008 in 0 04 0 09 mm 0 002 0 004 in 78 118 kPa 0 78 1 18 kg cm 11 3 17 11 psi 7 kPa 0 07 kg cm 1 02 psi at 1 500 r min Cylinder head Cooling system Radiator core Width Height Thickness MAINTENANCE SP
77. 3uIM gns SS3NHVH 3ulM ans EB80201 TROUBLESHOOTING IGNITION SYSTEM ELEC IF THE IGNITION SYSTEM FAILS TO OPERATE NO SPARK OR INTERMITTENT SPARK Procedure Check 1 Fuse main ignition 7 Engine stop switch 2 Battery 8 Main switch 3 Spark plug 9 Pickup coil resistance 4 gnition spark 5 Spark plug cap resistance 6 Ignition coil resistance 10 Charging rotor rotation direction detection coil resistance 11 Wiring connection the entire ignition system Dynamic spark tester e the following part s before 2 P N YM 34487 troubleshooting Ignition checker 1 Seat P N 90890 06754 2 Fuel tank side panels Pocket tester 3 Front carrier P N YU 03112 90890 03112 4 Front fender e Use the following special tool s for troubleshooting EB802011 1 Fuse main ignition NO CONTINUITY Refer to CHECKING THE SWITCH 1 CONTINUITY Replace the fuse INCORRECT e Check the battery condition Refer to CHECKING THE BATTERY in 1 CHAPTER 3 Open circuit voltage e Clean the battery terminals 12 8 V or more at 20 C 68 F e Recharge or replace the battery Standard spark plug DR8EA NGK EB802012 2 Battery CORRECT e Check the spark plug condition e Check the spark plug type e Check the spark plug gap 3 Spark plug Refer to CHECKING THE SPARK PLUG in CHAPTER 3 IGNITION SYSTEM ELEC INCORRECT Spark plug gap
78. 5 0 25 mm 0 0020 0 0098 in NOTE Measure the gear lash at four positions Rotate the shaft 90 each time FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR DRIV Adjusting differential gear lash 1 Remove e Shim s left e Differential gear assembly 2 e Shim s right 3 2 Adjust e Gear lash kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Adjustment steps Select the suitable shims using the following chart Reduce shim Increase shim Too large gear lash 96 9 thickness elf it is necessary to increase by more than 0 05 mm 0 002 in Reduce right shim thickness by 0 1 mm 0 004 in for every 0 1 mm 0 004 in of left shim increase elf it is necessary to reduce by more than 0 1 mm 0 004 in Increase right shim thickness by 0 1 mm 0 004 in for every 0 1 mm of left shim decreased aS Ring gear shim left and right Thickness mm Right only kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR DRIV CHECKING THE DIFFERENTIAL GEAR OPERATION 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 _ e Repeat this step
79. AKE LIGHT SWITCH CHK CHECKING THE FINAL GEAR OIL LEVEL ADJ Q 2 Adjust Rear brake light switch operation timing kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkxkk e Hold the main body 1 of the rear brake light switch so that it does not rotate and turn the adjusting nut 2 in direction or until the rear brake light comes on at the proper time Direction Brake light comes on sooner Direction 6 dicm light comes on kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkxkk CHECKING THE FINAL GEAR OIL LEVEL 1 Place the machine on a level place 2 Remove e Oil filler bolt 3 Check e Oil level Oil level should be up to the brim of the hole Oil level low Add oil to the proper level Recommended oil SAE 80 API GL 4 Hypoid gear oil Take care not allow foreign material to enter the final gear case 4 nstall e Oil filler bolt CHANGING THE FINAL GEAR OIL CHANGING THE FINAL GEAR OIL 1 Place the machine on a level surface 2 Remove e Final gear case protector 1 3 Place a receptacle under the final gear case 4 Remove e Oil filler bolt e Drain plug 1 5 Drain e Final gear oil 6 Install e Drain plug 23 Nm 2 3 kg 17 ft Ib NOTE Check the gasket drain plug If it is damaged replace it with a new one 7 Fill e Final gear case Periodic oil change 0 23 L 0 20 Imp qt 0 24 US qt Total amount 0 25 L 0 22 Imp qt 0 26 US qt
80. AR WIRING DIAGRAM A BLACK BLACK SUB WIRE HH BS EEE psg E BLACK BLACK BLACK 1 4 En qua LE 1 O Br EL eu iam 5 par A A Y S PME Y 9 az GRAY BLACK BLACK au BLACK BLACK 1 DARK GRAY L eH E E Y 1 1 eD W Re White Brown p Qu Yellow c Green B R Black Red m Blue B Y Black Yellow o Orange Br B Brown Black NET Pink Brown Blue Br R Brown Red Sb Sky blue Green Blue Gy Gray Green Red D A C magneto 2 Rectifier regulator 3 Main switch 4 Backup fuse 5 Battery 6 Main fuse Starter relay Starter motor 9 Reverse switch CDI unit 4 Rear brake switch 42 Ignition coil 3 Spark plug Speed sensor 5 Thermo switch 1 Meter assembly 7 Multi function meter Differential gear lock indicator light Coolant temperature warning light 09 Reverse indicator light Neutral indicator light 9 Park indicator light 03 High range indicator light 623 Low range
81. ARNING This model is equipped with low pressure tires It is important that they be inflated correctly and maintained at the proper pressures eme e TIRE CHARACTERISTICS 1 Tire characteristics influence the handling of ATV s The tires listed below have been approved by Yamaha Motor Co Ltd for this model If other tire combinations are used they can adversely affect your machine s handling characteristics are therefore recommended Type Rear CHENG SHIN 25 x 10 12 M912Y e TIRE PRESSURE 1 Recommended tire pressure Front 25 kPa 0 25 kg cm 3 6 psi Rear 25 kPa 0 25 kg cm 3 6 psi 2 Tire pressure below the minimum specification could cause the tire to dislodge from the rim under severe riding conditions The following are minimums Front 22 kPa 0 22 kg cm 3 2 psi Rear 22 kPa 0 22 kg cm 3 2 psi 3 Use no more than Front 250 kPa 2 5 kg cm 36 psi Rear 250 kPa 2 5 kg cm 36 psi when seating the tire beads Higher pressures may cause the tire to burst Inflate the tires slowly and carefully Fast inflation could cause the tire to burst e MAXIMUM LOADING LIMIT 1 Vehicle load limit total weight of cargo rider and accessories and tongue weight 210 kg 463 Ib 2 Front carrier 40 kg 88 Ib 3 Rear carrier 80 kg 176 Ib 4 Storage box 2 0 kg 4 4 Ib 5 Trailer hitch Pulling load total weight of trail
82. ARY SHEAVES 1 Loosen Nut secondary sheave 1 Nut primary sheave NOTE _ Use the sheave holder 3 to hold the primary sheave e First loosen the nut Secondary sheave then loosen the nut primary sheave 1 Sheave holder P N YU 01880 90890 01701 DISASSEMBLING THE SECONDARY SHEAVE 1 Remove e Nut kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Removing steps Attach the sheave fixed block 2 locknut wrench 3 and sheave spring compressor 4 to the secondary sheave assembly V Sheave fixed block 2 04135 90890 04135 Locknut wrench P N 90890 01348 Sheave spring compressor P N YM 04134 90890 04134 Place the sheave fixed block in a vise and secure it Tighten the sheave spring compressor nut and compress the spring Loosen the nut 1 with the locknut wrench 3 Remove the nut Remove the sheave spring compressor and locknut wrench kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk 8 PRIMARY AND SECONDARY SHEAVES ENG CHECKING THE PRIMARY SHEAVE 8 1 e Weight outside diameter Out of specification Replace the weight Weight outside diameter 30 mm 1 18 in Limit 29 5 mm 1 16 in 2 Check e Primary pulley slider e Primary sliding sheave splines Wear cracks damage Replace e Spacer e Primary pulley cam Cracks damage R
83. CAL ELECTRICAL COMPONENTS D Main switch Four wheel drive Reverse switch 2 Fan 2 Front brake light relay 2 5 Neutral switch 3 Headlight switch 9 Four wheel drive High range switch 4 Circuit breaker fan 3 Rear brake switch relay 1 7 Low range switch 5 Four wheel drive relay 3 4 Thermo switch 1 Main fuse Speed sensor 6 Ignition coil 5 Battery 1 Starter relay Rear brake light switch 6 Tail brake light 42 CDI unit 09 Gear motor 7 Fuse box 3 Rectifier regulator 0 Thermo switch 2 CHECKING THE SWITCH ELEC CHECKING THE SWITCH CHECKING THE SWITCH Use a pocket tester to check the terminals for continuity If the continuity is faulty at any point replace the switch Pocket tester P N YU 03112 90890 03112 NOTE c ll e oet the pocket tester to 0 before starting the test e he pocket tester should be set to the Q x 1 range when testing the switch for continuity e Turn the switch on and off a few times when checking it CHECKING A SWITCH SHOWN IN THE MANUAL The terminal connections for switches main switch handlebar switch engine stop switch light switch etc are shown in a chart similar to the one on the left This chart shows the switch positions in the column and the switch lead colors in the top row For each switch position OQ indicates the terminals with continuity The example chart shows that There is continuity betwee
84. Check e Shift cam grooves Scratches wear damage Replace TRANSMISSION ENG CHECKING THE TRANSMISSION 1 Measure e Axle runout Use a centering device and a dial gauge Out of specification Replace the bent axle Runout limit drive axle 0 06 mm 0 0024 in 2 Check e Gear teeth Blue discoloration pitting wear Replace e Mated dogs Rounded edges cracks missing portions gt Replace 319 001 3 Check e Gear movement Unsmooth Repeat steps 1 and 2 or replace the defective parts 4 Check e Circlip Bends looseness damage Replace CHECKING THE SECONDARY SHAFT AND DRIVEN SPROCKET 1 Check e Gear teeth Blue discoloration pitting wear Replace 2 Check e Gear movement Unsmooth Repeat steps 1 or replace the defective parts 3 Check e Circlip e Bends looseness damage Replace TRANSMISSION ENG CHECKING THE CHAIN 1 Check Chain Cracks shift Replace the chain secondary shaft and driven sprocket as a set 7 CHECKING THE STOPPER LEVER AND STOPPER WHEEL 1 Check e Stopper lever pawl 1 Bends damage wear Replace the stopper lever and stopper wheel as a set e Stopper wheel Damage wear Replace the stopper wheel and stopper lever as a set e Shaft 3 Bends damage wear Replace INSTALLING THE TRANSMISSION 1 Install e Shift cam e Washer e Spring short e Shift fork 1 e Drive axle assembly 2 e Guide bar 9
85. Check the open circuit remove it from the motorcycle voltage charging has to be done with the battery mounted on the motorcycle be sure to Ambient disconnect the wire at the negative t t ae terminal e Never remove the sealing caps of an MF battery e Make sure that the charging clips are in full contact with the terminal and that they are not shorted together A corroded clip 100 75 50 302520 Charging condition of the battery on the charger may cause the battery to generate heat in the contact area A weak clip spring may cause sparks e Before removing the clips from the battery terminals be sure to turn off the charger s power switch e The open circuit voltage variation for the MF battery after charging is shown below As shown in the figure the open circuit voltage stabilizes about 30 minutes after charging has been completed Therefore wait 30 minutes after charging is completed before measuring the open circuit voltage Charging method using a variable voltage charger NOTE Leave the battery unused for Measure the open circuit more than 30 minutes before Charger voltage prior to charging measuring its open circuit voltage Ammeter LS NOTE Set the charging voltage to 16 17 V If the charging voltage is lower charging will be insufficient if it is higher the battery will be over charged Connect a charger and amme
86. Copper washer Brake hose Refer to INSTALLING THE REAR BRAKE MASTER CYLINDER cl FRONT AND REAR BRAKES CHAS 30 Nm 3 0 m kg 22 ft Ib 23 Nm 2 3 m kg 17 ft Ib 7 Nm 0 7 m kg 5 1 ft Ib Job 1 Brake cable Disconnect Bracket Brake master cylinder Hose joint Brake pedal Select lever control cable Rear brake light switch Bracket Bracket Brake master cylinder bracket Disconnect ll For installation reverse the removal procedure FRONT AND REAR BRAKES CHAS 56 Job Disassembling the rear brake Remove the parts in the order below master cylinder Brake master cylinder kit Refer to ASSEMBLING THE REAR Brake master cylinder 1 BRAKE MASTER CYLINDER For assembly reverse the disassembly procedure FRONT AND REAR BRAKES CHAS 36 CHECKING THE MASTER CYLINDER 1 Check e Brake master cylinder 1 Wear scratches Replace the brake master cylinder assembly e Brake master cylinder body Cracks damage Replace e Brake fluid delivery passage brake master cylinder body Blockage Blow out with compressed air Front Rear 2 Check e Front brake master cylinder reservoir 1 e Front brake master cylinder reservoir diaphragm 2 Cracks damage Replace 3 Check e Rear brake fluid reservoir 1 e Rear brake fluid
87. EAR WHEELS Tie rod Brake disc guard Brake hose holder bolt Protector Nut Nut O ring Steering knuckle Refer to INSTALLING THE TIE ROD CON DOA LA ee Refer to REMOVING THE STEERING KNUCKLE STEERING SYSTEM CHAS 56 30 Nm 3 0 m kg 22 ft Ib a i ADU 30 Nm 3 0 m kg 22 ft Ib 30 Nm 3 0 m kg 22 ft Ib 30 Nm 3 0 m kg 22 ft Ib 7 Nm 0 7 kg 5 1 ft Ib 9 Cil seal Oil seal Bearing Spacer Circlip Rubber boot Ball joint y For installation reverse the removal procedure STEERING SYSTEM CHAS 36 REMOVING THE STEERING KNUCKLE 1 Remove e Steering knuckle 1 NOTE Use a general puller to separate the ball joint 2 and steering knuckle 1 or front lower arm 3 CHECKING THE TIE ROD 1 Check e Tie rod free play and movement Free play Replace the tie rod end Turns roughly Replace the tie rod end 2 Check e rod e Bends damage Replace CHECKING THE STEERING KNUCKLE 1 Check e oteering knuckle Damage pitting Replace 2 Check e Ball joint Damage pitting Replace the ball joint Free play Replace the ball joint Turns roughly Replace the ball joint kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Replacement steps Clean the outside of the steering knuckle Remove the steering knuckle oi
88. ECIFICATIONS SPEC Radiator cap opening pressure Radiator capacity Coolant reservoir Capacity From low to full Water pump Type Reduction ratio Thermostat level Valve opening temperature Valve full open temperature Valve lift full open Shaft drive Middle gear backlash Final gear backlash Differential gear backlash Lubrication chart Pressure feed Splashed scavenge Oil Filter 300 mm 11 8 in 208 mm 8 19 in 26 mm 1 02 in 93 7 122 6 kPa 0 937 1 226 kg cm 13 32 17 43 psi 0 70 L 0 62 Imp at 0 74 US qt 0 39 L 0 34 Imp qt 0 41 US qt 0 15 L 0 13 Imp 0 16 US qt Single suction centrifugal pump 38 32 1 188 63 5 66 5 C 146 3 151 7 F 80 C 176 F mm 0 12 in 0 1 0 3 mm 0 004 0 012 in 0 1 0 2 mm 0 004 0 008 in 0 05 0 25 mm 0 0020 0 0098 in Cam Shaft Valve 4 Transmission Timing Chain Area MAINTENANCE SPECIFICATIONS SPEC y Cylinder head tightening sequence MAINTENANCE SPECIFICATIONS SPEC y Tightening torques Part to be tightened AME Tightening torque _ Tightening torque _ Remarks name size ft lb Cylinder head oil passage Union bolt Cylinder head exhaust pipe Stud bolt Cylinder head Bolt Bolt Camshaft sprocket cover baffle Bolt plate Camshaft bearing retainer Bolt Spark plug Coolant drain bolt cylinder Bolt otarter clutch Bolt Camshaft sprocket Bolt Timing chain tensioner
89. ENG NOTE nmm Fasten a safety wire to the timing chain to prevent it from falling into the crankcase e When removing the camshaft sprocket it is not necessary to separate the timing chain e 5 Remove e Cylinder head NOTE e Loosen the 6 mm bolts first e Working in a crisscross pattern loosen each 10 mm bolt 1 4 of a turn After all the bolts are loosened remove them CHECKING THE TAPPET COVER 1 1 e covers 1 e O rings 2 Cracks damage Replace CHECKING THE TIMING CHAIN TENSIONER 1 Check e One way cam operation tensioner Unsmooth operation Replace CHECKING THE CAMSHAFT SPROCKET 1 Check e Camshaft sprocket Wear damage Replace the camshaft sprocket and timing chain as a set 1 4 of a tooth D Correct CD Timing chain 2 Sprocket CYLINDER HEAD ENG CHECKING THE CYLINDER HEAD 1 Eliminate e Carbon deposits from the combustion chambers Use a rounded scraper NOTE _ Do not use a sharp instrument to avoid damaging or scratching e Spark plug threads e Valve seats 2 Check e Cylinder head Scratches damage Replace e Cylinder head water jacket Mineral deposits rust Eliminate 8 3 Measure e Cylinder head warpage Out of specification Cylinder head warpage Less than 0 03 mm 0 0012 in kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Measurement and resurfaci
90. Fuel level gauge P N YM 01312 A 90890 01312 Loosen the drain screw 3 Hold the gauge vertically next to the float chamber line e Measure the fuel level 8 with the gauge elf the fuel level is incorrect adjust the fuel level e Remove the carburetor e Check the valve seat and needle valve e If either is worn replace them both elf both are fine adjust the float level by bending the float tang 5 slightly e Install the carburetor e Recheck the fuel level kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk CHAPTER 7 DRIVE TRAIN TROUBLESHOOTING 2 hs ee a eee 7 1 FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR 7 4 REMOVING THE UNIVERSAL JOINT 7 9 REMOVING THE RING GEAR 2 0 1 1 01 1 1 1 144 7 9 CHECKING THE CONSTANT VELOCITY JOINT 7 10 CHECKING THE DIFFERENTIAL GEAR 2 2 7 7 10 CHECKING THE GEAR MOTOR 7 11 ASSEMBLING THE FRONT CONSTANT VELOCITY JOINT 7 11 ASSEMBLING THE DIFFERENTIAL GEAR 7 12 INSTALLING THE UNIVERSAL JOINT 7 13 MEASURING AND ADJUSTING THE DIFFERENTIAL GEAR LASH 4 5 detta be ache 7 14 CHECKING THE DIFFERENTIAL GEAR OPERATION 7 16 REAR AXLE FINAL DRIVE GEAR AND DRIVE SHAFT 7 17 REMOVING THE REAR AXLE 5 5
91. HECKING THE WHEEL 1 Check e Wheels 1 Damage bends Replace NOTE 27 Always balance the wheel when a tire or wheel has been changed or replaced WARNING e Never attempt even small repairs to the wheel e Ride conservatively after installing a tire to allow it to seat itself properly on the rim CHECKING AND LUBRICATING THE CABLE A WARNING A damaged cable sheath may cause corrosion and interfere with the cable movement An unsafe condition may result so replace a damaged cable as soon as possible 1 Check Cable sheath Damage Replace 2 Check Cable operation Unsmooth operation Lubricate or replace Recommended lubricant Yamaha chain and cable lube or Engine oil NOTE _ Hold the cable end up and apply several drops of lubricant to the cable 3 Apply e Lithium soap based grease onto end of the cable CHK 4o LUBRICATING THE LEVERS PEDAL ETC ADJ LUBRICATING THE LEVERS PEDAL ETC 1 Lubricate the pivoting parts Recommended lubricant Yamaha chain and cable lube or Engine oil ELECTRICAL CHECKING THE BATTERY NOTE Since the battery is a sealed type battery it is not possible to measure the specific gravity of the electrolyte in order to check the charge state of the battery Therefore the charge of the battery has to be checked by measuring the voltage
92. IAL ROUTINE Whichever km 320 1 200 2 400 2 400 4 800 comes first PES ae m 500 500 a 000 p Check valve clearance Valves Adjust if necessary Check coolant leakage Cooling system Repair if necessary Replace coolant every 24 months Check condition Spark plug Adjust gap and clean Replace if necessary Clean Every 20 40 hours Air filter element Replace if necessary More often in wet or dusty areas Check and adjust idle speed starter operation Carburetor Adjust if necessary Crankcase breather Check breather hose for cracks or damage system Replace if necessary Check for leakage Exhaust system e Tighten if necessary Replace gasket s if necessary Check fuel hose for cracks or damage Replace if necessary Engine oil Replace Warm engine before draining Engine oil filter cartridge Engine strainer Engine strainer strainer e Clean Final gear oil e level oil leakage Differential gear oil Differential gear oil oil Replace every 12 months Front brake Check operation fluid leakage See NOTE page 3 2 Correct if necessary Bess Brake Check operation fluid leakage See NOTE page 3 2 Correct if necessary Check operation Check balance damage runout Repair if necessary Wheel bearing Check bearing assemblies for looseness damage Replace if damaged
93. ING INSTALLING THE BEARING RETAINER 13 Bearing 1 14 Oil seal 1 For installation reverse the removal procedure STEERING SYSTEM CHAS 36 REMOVING THE BEARING RETAINER 1 Remove e Bearing retainer steering stem Damper rod holder P N YM 01327 90890 01327 1 e Steering stem Bends Replace WARNING Do not attempt to straighten a bent stem this may dangerously weaken the stem 2 Check e Oil seals 1 e Steering stem bushings 2 Wear damage Replace INSTALLING THE BEARING RETAINER 1 Install e Bearing retainer steering stem 140 Nm 4 0 m 29 ft Ib lt Damper rod holder Y P N YM 01327 90890 01327 INSTALLING THE CABLE GUIDE 1 Install e Cable guide e Lock washer 2 Bend the lock washer tab along a flat side of the bolt NOTE nmm Pass the cables and hoses through the cable guide Refer to CABLE ROUTING in CHAPTER 2 STEERING SYSTEM CHAS 56 TIE ROD AND STEERING KNUCKLE 30 Nm 3 0 m kg 22 ft Ib BA I Qn zi 30 Nm 3 0 m kg 22 ft Ib 30 Nm 3 0 m kg 22 ft Ib 30 Nm 3 0 m kg 22 ft Ib 7 Nm 0 7 kg 5 1 ft Ib Removing the tie rod and steering Remove the parts in the order below knuckle Front fender Refer to SEAT CARRIERS FENDERS AND FUEL TANK in CHAPTER Front wheel brake disc Refer to FRONT AND R
94. Install e Universal joint kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Installation steps Install the opposite yoke into the U joint Apply wheel bearing grease to the bearings e Install the bearing 1 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 e Press each bearing into the U joint using suitable socket NOTE 2 The bearing must be inserted far enough into the U joint so that the circlip can be installed e Install the circlips 2 into the groove of each bearing kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR DRIV MEASURING AND ADJUSTING THE DIFFERENTIAL GEAR LASH Measuring the differential gear lash 1 Secure the gear case in a vise or another supporting device 2 Remove e Drain plug e Gasket 3 Install e A bolt of the specified size 1 into the drain plug hole Finger danen the bolt until it holds the ring gear Otherwise the ring gear will be damaged 4 Attach e Gear lash measurement tool 1 e Dial gauge 2 Gear lash measurement tool P N YM 01467 90890 01467 Measuring point is 21 mm 0 83 5 Measure e Gear lash Gently rotate the gear coupling from engagement to engagement Differential gear lash 0 0
95. Install the crankshaft seals in the correct place and in the correct direction 3 Install e Balancer 1 NOTE W Align the punch marks 8 on the drive and driven gear TRANSMISSION ENG 8 TRANSMISSION 10 Nm 1 0 m kg 7 2 ft Ib Job name Part name Remarks Removing the transmission Remove the parts in the order below Crankcase separation Refer to CRANKCASE Driven sprocket Chain Clutch dog 2 Shift fork L Spring Low wheel gear Secondary shaft Middle driven gear Drive axle assembly Guide bar gt gt ll O TRANSMISSION ENG 10 Nm 1 0 m kg 7 2 ft Ib Job name Part name Remarks Shift fork Spring Shift cam Stopper wheel Clutch dog 1 High wheel gear Middle drive gear Stopper lever Spacer O ring For installation reverse the removal procedure TRANSMISSION ENG CHECKING THE SHIFT FORK 1 Check e Shift fork cam follower 1 Shift fork pawl Scoring bends wear damage Replace e 2 Check e Guide bar Roll the guide bar on a flat surface Bends Replace WARNING Do not attempt to straighten bent guide bar 3 Check e Shift fork movement on the guide bar Unsmooth operation Replace the shift fork and the guide bar 319 011 4 Check e Spring Cracks damage Replace CHECKING THE SHIFT CAM 1
96. KING THE CONSTANT VELOCITY JOINT DUST BOOT 3 47 CHECKING THE STEERING SYSTEM 3 48 ADJUSTING THE ERU BLU tod 3 48 ADJUSTING THE FRONT SHOCK ABSORBER 3 50 ADJUSTING THE REAR SHOCK ABSORBER 3 50 CHIE CINUING THE 3 50 CHECKING THE 3 53 CHECKING AND LUBRICATING THE CABLE 3 53 LUBRICATING THE LEVERS PEDAL ETC 3 54 ME 3 55 CHECKING THE BATTER Rete uut S ceu IR Bei Su 3 55 Salze CN iube D a 3 60 ADJUSTING THE HEADLIGHT BEAM 3 62 CHANGING THE HEADLIGHT BULB 3 62 INTRODUCTION CHK 4o PERIODIC MAINTENANCE LUBRICATION ADJ Qi EB300000 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments These preventive maintenance procedures if followed will ensure more reliable vehicle operation and a longer service life The need for costly overhaul work will be greatly reduced This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale All service technicians should be familiar with this entire chapter PERIODIC MAINTENANCE LUBRICATION INIT
97. LLING THE WHEEL HUB imt ER IRE n 8 4 INSTALLING THE 8 4 FRONT AND REAR BRAKES 8 6 FRONT BRAKE PADS Uie 8 6 REAR BRAKE PADS 6 8 7 REPLACING THE FRONT BRAKE PAD 8 8 REPLACING THE REAR BRAKE 8 10 FRONT BRAKE MASTER CYLINDER 8 12 REAR BRAKE MASTER CYLINDER 8 14 CHECKING THE MASTER CYLINDER 8 17 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER 8 18 ASSEMBLING THE REAR BRAKE MASTER CYLINDER 8 18 INSTALLING THE FRONT BRAKE MASTER CYLINDER 8 19 INSTALLING THE REAR BRAKE MASTER CYLINDER 8 20 FRONT BRAKE 8 22 REAR BRAKE CALIPER VEMM xu 8 24 DISASSEMBLING THE FRONT AND REAR BRAKE CALIPER 8 26 CHECKING THE FRONT AND REAR BRAKE CALIPER 8 26 ASSEMBLING THE FRONT AND REAR BRAKE CALIPER 8 27 INSTALLING THE FRONT BRAKE CALIPER 8 27 INSTALLING THE REAR BRAKE CALIPER 8 29 STEERING
98. Limit 12 078 mm 0 4755 in 11 951 mm 0 4705 in 0 080 mm 0 0031 in 1 D Margin Thickness 1 6 mm 0 0630 in 1 6 mm 0 0630 in 6 950 mm 0 2736 in 6 915 mm 0 2722 in 7 030 mm 0 2768 in 7 030 mm 0 2768 in 0 080 mm 0 0031 0 100 0 0039 MAINTENANCE SPECIFICATIONS SPEC y Item Standard Limit 0 01 mm 0 0004 in Stem runout limit Valve seat width 1 2 1 4 mm 0 0472 0 0551 in 1 2 1 4 mm 0 0472 0 0551 in Valve spring Inner spring Free length 39 9 mm 1 57 in 37 9 mm 1 49 in 3 9 mm 1 49 in 39 9 mm 1 57 in Set length valve closed 33 6 mm 1 32 in 33 6 mm 1 32 in Compressed pressure installed 104 9 120 6 N 10 70 12 30 kg 23 58 27 11 Ib 104 9 120 6 N 10 70 12 30 kg 23 58 27 11 Ib 2 5 1 6 mm 2 5 0 06 in 2 5 1 6 mm 2 5 0 06 in Tilt limit 3 Direction of winding top view Counterclockwise Counterclockwise Outer spring Free length 43 27 mm 1 70 in 41 27 mm 1 62 in 41 27 mm 1 62 in 43 27 mm 1 70 in Set length valve closed 36 6 mm 1 44 in 36 6 mm 1 44 in Compressed pressure installed 235 4 251 1 24 00 25 60 kg 52 91 56 45 Ib 235 4 251 1 24 00 25 60 kg 52 91 56 45 Ib MAINTENANCE SPECIFICATIONS SPEC y Item Tilt limit X Direction of winding top view Piston Piston to cylinder clearance Piston size D Measuring point H Pist
99. NOTE Be sure not to disassemble the gear motor or remove the pinion gear Refer to REMOVING INSTALLING THE UNIVERSAL JOINT 3 cl c FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR DRIV 13 Nm 1 3 kg 9 4 ft Ib 10 Nm 1 0 kg 7 2 ft Ib Ny 25 Nm 2 5 kg 18 ft Ib Job name Part name Remarks Differential gear assembly Shim right Circlip bearing Drive pinion gear Differential gear case For assembly reverse the disassembly procedure FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR DRIV REMOVING THE UNIVERSAL JOINT 1 Remove e Universal joint kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Removal steps Remove the circlips 1 Place the U joint in a press e With a suitable diameter pipe 2 beneath the yoke 3 press the bearing 4 into the pipe as shown NOTE nmm It may be necessary to lightly tap the yoke with a punch e Repeat the steps for the opposite bearing e Remove the yoke NOTE IL S S S it may be necessary to lightly tap the yoke with a punch A V O 2 Remove e Universal joint yoke Use a universal joint holder 1 Universal joint holder 04062 90890 04062 REMOVING THE RING GEAR 1 Remove e Ring gear 1 NOTE _ The ri
100. NSTALLING THE TRANSMISSION 4 74 7 NIDDEE GEAR e 4 76 MIDDLE DRIVE SHAFT arum M 4 76 MIDDLE DRIVEN SHAFT 4 77 REMOVING THE MIDDLE DRIVE SHAFT 4 79 REMOVING THE MIDDLE DRIVEN SHAFT 4 79 CHECKING THE GEAR 4 81 SELECTING THE MIDDLE DRIVE AND DRIVEN GEAR SHIM 4 82 INSTALLING THE MIDDLE DRIVEN SHAFT 4 85 INSTALLING THE MIDDLE DRIVE SHAFT 4 87 MEASURING THE MIDDLE GEAR BACKLASH 4 87 8 ENGINE REMOVAL ENG ENGINE ENGINE REMOVAL AIR DUCTS MUFFLER AND EXHAUST PIPE 20 Nm 2 0 m kg 14 ft Ib 14 Nm 1 4 m kg 10 ft Ib Job Removing air ducts muffler and Remove the parts in the order below exhaust pipe Engine oil Drain Refer to CHANGING THE ENGINE OIL in CHAPTER 3 Front and rear fender footrest boards Refer to SEAT CARRIERS FENDERS Fuel tank rubber cover AND FUEL TANK in CHAPTER 3 Coolant Drain Refer to CHANGING THE COOLANT in CHAPTER 3 Carburetor assembly Refer to CARBURETOR in CHAPTER 6 Air duct assembly 1 Muffler Exhaust pipe stay 1 Exhaust pipe gasket Air duct assembly 2 20 Nm 2 0 m kg 14 ft Ib 14 Nm 1 4 m kg 10 ft Ib Job 1 Final drive gear case breather hose Cy
101. P DRIVE GEAR 4 60 SEPARATING THE CRANKCASE eene 4 60 CHECKING THE TIMING CHAIN AND GUIDE 4 61 CHECKING THE OIL STRAINER AND OIL DELIVERY PIPE 4 61 CHECKING THE CRANKCASE erae 4 62 CHECKING THE BEARINGS 4 pH beue 4 62 ASSEMBLING THE CRANKCASE eene 4 62 INSTALLING T TIE SHIFT DEVE EQ pu EUR a bus 4 63 INSTALLING THE OIL PUMP DRIVE GEAR 4 64 CRANKSHAFT AND OIL PUMP 4 65 assiettes turam ecu Mets 4 66 REMOVING THE CRANKSHAFT 4 67 CHECKING TRE OILPUMP tens 4 67 CHECKING THE CRANKSHAFT teens pn 4 68 INSTALLING THE CRANKSHAFT AND BALANCER 4 69 4 70 CHECKING THE OFIFT FORK haan dea 4 72 CHECKING THE SEE 4 72 CHECKING THE TRANSMISSION 04021 4 73 CHECKING THE SECONDARY SHAFT AND DRIVEN SPROCKET 4 73 CHECKING THE CHAIN acit nn ER RI E ER E Stade 4 74 CHECKING THE STOPPER LEVER AND STOPPER WHEEL 4 74 I
102. R 8 Disconnect wheel drive switch and differential gear lock switch coupler Differential gear case breather hose Disconnect FRONT CONSTANT VELOCITY JOINTS AND Yd DIFFERENTIAL GEAR DRIV P 2 zl W DA gt acs o BE gt 55 Nm 5 5 m kg 40 ft Ib Job name Differential gear Drive shaft Compression spring For installation reverse the removal procedure FRONT CONSTANT VELOCITY JOINTS AND Yd DIFFERENTIAL GEAR DRIV Job name Disassembling the constant velocity Remove the parts in the order below joint Circlip Boot band Boot band Dust boot Circlip Double off set joint Snap ring Ball bearing Joint shaft assembly Refer to ASSEMBLING THE FRONT CONSTANT VELOCITY JOINT 9 C 9 For assembly reverse the disassembly procedure FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR DRIV 10 Nm 1 0 kg 7 2 ft Ib 13 Nm 1 3 kg 9 4 ft Ib Ny 25 Nm 2 5 kg 18 ft Ib Job Disassembling the differential gear Remove the parts in the order below 6 Gear motor O ring Circlip Bearing Universal joint Universal joint yoke O ring Stopper bolt shaft Shift fork sliding gear Shift fork Differential gear case cover Drive clutch Shim left
103. RETOR ee eee 6 1 CHECKING THE CARBURETOR 04 100 6 4 ASSEMBLING THE CARBURETOR 0114222000000 00 000000 6 6 ADJUSTING THE FUEL LEVEL CARBURETOR CARB gl CARBURETION CARBURETOR Remarks Removing the carburetor Remove the parts in the order below Seat fuel tank side panels fuel tank Refer to SEAT CARRIERS FENDERS rubber cover AND FUEL TANK in CHAPTER 3 Drain hose Starter cable starter plunger Vacuum chamber breather hose Carburetor assembly Throttle valve cover Throttle cable end Throttle cable NOTE W After removing the carburetor assembly remove the throttle cable For installation reverse the removal procedure CARBURETOR CARB gl Job name Part name Remarks Disassembling the carburetor Remove the parts in the order below Float chamber air vent hose Throttle stop screw Vacuum chamber cover Spring Jet needle holder Spring Jet needle set Piston valve Coasting enricher Float chamber Drain screw Float ll Refer to ASSEMBLING THE CARBURETOR QOO GO O0OC 000600090 Needle valve set CARBURETOR CARB gl Pilot jet Pilot screw set Refer to DISASSEMBLING ASSEMBLING THE CARBURETOR Main jet Needle jet Starter jet Pilot air jet 0000 oO For assembly reverse the disassembly procedure CARBURETOR CARB gl CHECKING THE CARBURETOR
104. RONT AND REAR BRAKES CHAS 36 REAR BRAKE PADS 30 Nm 3 0 m kg 22 ft Ib Job name Part name Remarks Removing the rear brake pads Remove the parts in the order below Rear wheel left Refer to FRONT AND REAR WHEELS Brake caliper mounting bolt Brake pad holding bolt Refer to REPLACING THE REAR Brake pad insulator pad shim 2 2 2 BRAKE PAD Pad spring For installation reverse the removal procedure FRONT AND REAR BRAKES CHAS 36 2222 8 Disc brake components rarely require disassembly DO NOT e disassemble components unless absolutely necessary e use solvents on internal brake components use spent brake fluid for cleaning use only clean brake fluid allow brake fluid to come in contact with the eyes as this may cause eye injury Splash brake fluid onto painted surfaces or plastic parts as this may cause damage disconnect any hydraulic connection as this would require the entire brake system to be disassembled drained cleaned properly filled and bled after reassembly REPLACING THE FRONT BRAKE PAD NOTE It is not necessary to disassemble the brake caliper and brake hose to replace the brake pads 1 Measure e Brake pad wear limit 2 Out of specification Replace the brake pad as a set Brake pad wear limit 1 mm 0 04 in 2 Install e Brake pads e Brake pad spring NOTE Al
105. TAT 5 6 WATER PUMP itte n dete nite renee eee eee 5 7 DISASSEMBLING THE WATER PUMP 5 9 CHECKING THE WATER PUMP 5 9 ASSEMBLING THE WATER PUMP 5 10 RADIATOR coo COOLING SYSTEM RADIATOR 28 Nm 2 8 m kg 20 ft Ib 7 Nm 0 7 m kg 5 1 ft Ib Job name Part name Removing the radiator Remove the parts in the order below Seat and fuel tank side panels Refer to SEAT AND SIDE PANELS in CHAPTER 3 Front carrier front bumper and front Refer to FRONT CARRIER FRONT fender BUMPER AND FRONT FENDER in CHAPTER 3 Left footrest board Refer to FOOTREST BOARDS in CHAPTER 3 Coolant Drain Refer to CHANGING THE COOLANT in CHAPTER 3 Radiator fan coupler Disconnect Thermo switch coupler Disconnect Coolant reservoir hose Disconnect Radiator fan breather hose 1 i O H e lt 28 Nm 2 8 m kg 20 ft Ib 7 Nm 0 7 m kg 5 1 ft Ib Disconnect Radiator inlet hose 2 x as gt c QO c 5 d Disconnect Radiator outlet hose Hadiator Radiator fan Thermo switch For installation reverse the removal procedure 14110401 14110202 RADIATOR coo CHECKING THE RADIATOR 1 Check e Radiator fin
106. TIONS SPEC EB201000 HOW TO USE THE CONVERSION TABLE All specification data in this manual are listed in Sl and METRIC UNITS Use this table to convert METRIC unit data to IMPERIAL unit data Ex METRIC MULTIPLIER IMPERIAL mm x 0 03937 in 2mm x 0 03937 0 08 in CONVERSION TABLE METRIC TO IMPERIAL Multiplier Imperial unit 2 205 See mm ms _ Distance cc cm oz IMP liq Volume Ca cc cm cu in pacity It liter qt IMP liq It liter gal IMP liq kg mm kon 55 997 Ib in 14 2234 psi Ib in 9 5 32 Fahrenheit F Centigrade C GENERAL TORQUE SPECIFICATIONS This chart specifies torque for standard fasteners with standard 1 5 pitch threads Torque specifications for special components or assemblies are provided for each chapter of this manual To avoid warpage tighten multi fastener assemblies in a crisscross fashion in progressive stages until the specified torque is reached Unless otherwise specified torque specifications require clean dry threads Components should be at room temperature A Distance between flats B Outside thread diameter General e a ib nut us LUBRICATION POINTS AND LUBRICANT TYPES SPEC LUBRICATION POINTS AND LUBRICANT TYPES ENGINE Lubrication points Oil seal lips all O ring all Bearings all Crank pin Connecting rod bearing C
107. TS The wiring circuit from the main switch to the 1 SPECIFICATION bulb socket connector is faulty repair it This circuit is not faulty SIGNAL SYSTEM 8 M V 8 M V 10v18 17 Y 9 un 9 g 49 ova 1 L aA waja NC RET i ere EE 6i0v18 ce 1 I 1 4 1 EST 8 giu ory Tg EUIS Peaca a LLLA ON 5 0k DE SIGNAL SYSTEM CIRCUIT DIAGRAM EB806000 Y SSANYVH SSANYVH SSANYVH 3ulM ans 9 30 SIGNAL SYSTEM 3 Main switch 4 Backup fuse 5 Battery 6 Main fuse 9 Reverse switch CDI unit Speed sensor 5 Thermo switch 1 7 Multi function meter Differential gear lock indicator light Coolant temperature warning light 09 Reverse indicator light 2 Neutral indicator light 02 Park indicator light 03 High range indicator light 62 Low range indicator light 05 Low range switch 69 High range switch 07 Neutral switch 82 On command four wheel drive switch and differential gear lock switch 63 Gear motor Ignition fuse Signaling system fuse
108. Tester lead White terminal 1 Tester lead gt White terminal OUT OF SPECIFICATION e Measure the stator coil resistance 1 Charging coil resistance 0 41 0 61 at 20 C 68 F Replace the pickup coil stator assembly MEETS SPECIFICATION EB804015 5 Wiring connections e Check the connections of the entire POOR CONNECTION charging system Refer to CIRCUIT DIAGRAM CORRECT Properly connect the charging system Replace the rectifier regulator LIGHTING SYSTEM ELEC LIGHTING SYSTEM CIRCUIT DIAGRAM EB805000 1 69 1 69 1 9 YOUMS Gey Woe an fas fr 7 vV 0 telesi v 7 IM M 18 en DXT L v ula A ur Big or Big s AE 1 all Wa SSE SSHNHVH pne luas SS3NHVH 6 SSHNHVH LIF SS3NHVH SSHNHVH 3HIM ans 2 0 1 AvHOoIHVO em ova oova Gov
109. achine operator a bystander or a person inspecting or repairing the machine A CAUTION indicates special precautions that must be taken to avoid damage to the machine NOTE A NOTE provides key information to make procedures easier or clearer 002000 HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual consists of chapters for the main categories of subjects See Illustrated symbols 1st title This is the title of the chapter with its symbol in the upper right corner of each page 2nd title This title indicates the section of the chapter and only appears on the first page of each section It is located in the upper left corner of the page 3rd 3 This title indicates a sub section that is followed by step by step procedures accompanied by corresponding illustrations EXPLODED DIAGRAMS To help identify parts and clarify procedure steps there are exploded diagrams at the start of each removal and disassembly section 1 easy to see exploded diagram 4 is provided for removal and disassembly jobs 2 Numbers 5 are given in the order of the jobs in the exploded diagram A number that is enclosed by circle indicates a disassembly step 3 An explanation of jobs and notes is presented in an easy to read way by the use of symbol marks 6 The meanings of the symbol marks are given on the next page 4 A job instruction chart 7 accompanies the exploded diagram providing the order of jobs na
110. acing up 8 CYLINDER AND PISTON ENG CYLINDER AND PISTON 4 10 Nm 1 0 m kg 7 2 ft Ib 10 Nm 1 0 m kg 7 2 BN Job name Part name Remarks Removing the cylinder and piston Remove the parts in the order below Cylinder head Refer to CYLINDER HEAD Water pump outlet hose pipe Refer to WATER PUMP in CHAPTER 5 Coolant inlet joint Timing chain guide exhaust Cylinder O ring Cylinder gasket Dowel pin O ring Piston pin clip Piston pin Piston Piston ring set Refer to INSTALLING THE CYLINDER Refer to REMOVING INSTALLING THE PISTON OMAN OAH N For installation reverse the removal procedure CYLINDER AND PISTON ENG REMOVING THE PISTON 1 Remove e Piston pin clips 1 e Piston pin e Piston 3 8 NOTE nmm Before removing piston pin deburr the clip groove and pin hole area If the piston groove is deburred and the piston pin is still difficult to remove use the piston pin puller 4 22222722707222 3 CAUTION Am Do not use a hammer to drive the piston pin out 2 Remove e Piston rings NOTE LL opread the end gaps apart while at the same time lifting the piston ring over the top of the piston crown CHECKING THE TIMING CHAIN GUIDE 1 Check e Exhaust side timing chain guide Wear damage Replace CHECKING THE CYLINDER AND PISTON 1 Check
111. ally a decimal number on the bearing housing is either added to or subtracted from 10 5 D drive pinion gear to driven pinion gear center distance considered constant 55 numeral usually a decimal number on the right crankcase specifies a thickness of 66 MIDDLE GEAR ENG Example 1 If the bearing housing is marked 04 m 8 is 10 54 2 D is 55 3 If the crankcase right is marked 66 03 RS C is 66 03 4 Therefore the shim thickness is 0 47 mm A 66 03 10 54 55 0 49 5 Round off hundredths digit and select appropriate shim s In the example above the calculated shim thickness is 0 49 mm The chart instructs you however to round off 9 to 10 8 9 10 Shims are supplied in the following thickness A Middle drive pinion gear shim Thickness mm find shim thickness B use the following formula Middle driven pinion gear shim thickness D 0 05 MIDDLE GEAR ENG oD Where 0 a numeral usually a decimal number on the bearing housing is either added to or subtracted from 76 a numeral usually a decimal number on the middle driven pinion gear is either added to or subtracted from 59 a numeral usually a decimal number on the middle driven pinion gear is either added to or subtracted from 79 5 numeral usually decimal number on th
112. amaged radiator fin e Damaged or faulty water pump e Thermostat stays closed e Clogged or damaged oil cooler e Damaged hose e Improperly connected hose e Damaged pipe e Improperly connected pipe Brake e Brake drag 10 5 TRBL EN SHOCK ABSORBER MALFUNCTION UNSTABLE TRBL HANDLING LIGHTING SYSTEM ISHTG SHOCK ABSORBER MALFUNCTION MALFUNCTION e Bent or damaged damper rod e Damaged oil seal lip e Fatigued shock absorber spring UNSTABLE HANDLING UNSTABLE HANDLING Handlebar e Improperly installed or bent Steering e Incorrect toe in e Bent steering stem e Improperly installed steering stem e Damaged bearing or bearing race e Bent tie rods e Deformed steering knuckles Tires e Uneven tire pressures on both sides e Incorrect tire pressure e Uneven tire wear LIGHTING SYSTEM HEADLIGHT DARK e Improper bulb e oo many electric accessories e Hard charging broken charging coil and or faulty rectifier regulator e Incorrect connection e Improperly grounded e Poor contacts main or light switch e Bulb life expired Wheels e Deformed wheel e Loose bearing e Bent or loose wheel axle e Excessive wheel runout Frame e Bent e Damaged frame BULB BURNT OUT e Improper bulb e Faulty battery e Faulty rectifier regulator e Improperly grounded e Faulty main and or light switch e Bulb life expired 10 6 YAMAHA YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN YFM45FAR YFM450F
113. amshaft sprocket Crankshaft Piston surface piston rings Piston pin Baffer boss Valve stem valve stem end Rocker arm shaft Rocker arm Camshaft lobe journal Cylinder head bolt Oil pump shaft rotor housing Oil filter O ring Starter idle gear shaft Transmission gear wheel pinion Axle main drive Shift fork guide bar Shift cam shift shaft shift cam stopper ball Shift lever select lever shift guide Shift cam lever Stopper lever Clutch housing One way bearing Drive chain sprocket Driven cam Front drive shaft collar Crankcase mating surfaces Stater lead grommet left side crankcase 2 21 Lubricant type LLLA AAM LL hada Sealant Quick Gasket Yamaha Bond No 1215 Sealant Quick Gasket Yamaha Bond No 1215 COOLANT FLOW DIAGRAMS SPEC y COOLANT FLOW DIAGRAMS 1 Radiator 2 Thermo switch 3 Fan motor To coolant reservoir COOLANT FLOW DIAGRAMS SPEC y 1 Radiator 2 Thermostat To coolant reservoir 2 23 OIL FLOW DIAGRAMS SPEC y OIL FLOW DIAGRAMS 57 N m wu NIS 52 ev ml s NC all CU e T 1 We 4 pem x nir CI i m H L i ne Ale ALY OIL FLOW DIAGRAMS SPEC y D filter OIL FLOW DIAGRAMS SPEC y
114. at the battery terminals CHARGING METHOD e This is a sealed type battery Never remove the sealing caps If the sealing caps have been removed the balance will not be maintained and battery performance will deteriorate e Charging time charging current and charging voltage for the MF battery are different from those of general type batteries The MF battery should be charged as explained in CHARGING METHOD If the battery is overcharged the electrolyte level will drop considerably Therefore take special care when charging the battery WARNING Battery electrolyte is dangerous it contains sulfuric acid which is poisonous and highly caustic Always follow these preventive measures e Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury e Wear protective eye gear when handling or working near batteries Antidote EXTERNAL e SKIN Wash with water e EYES Flush with water for 15 minutes and get immediate medical attention Antidote INTERNAL e Drink large quantities of water or milk followed with milk of magnesia beaten egg or vegetable oil Get immediate medical attention Batteries generate explosive hydrogen gas Always follow these preventive measures e Charge batteries in a well ventilated area e Keep batteries away from fire sparks or open flames e g welding equipment lighted cigare
115. attery 5 Wiring connections 3 Charging voltage the entire charging system NOTE e Remove the following part s before Inductive tachometer troubleshooting P N YU 8036 A Engine tachometer 90890 03113 2 Fuel tank side panels Pocket tester Use the following special tool s for P N YU 03112 90890 03112 troubleshooting EB802011 Refer to CHECKING THE SWITCH CONTINUITY Replace the fuse INCORRECT e Clean the battery terminals e Recharge or replace the battery EB802012 2 Battery e Check the battery condition Refer to CHECKING THE BATTERY in CHAPTER 3 Open circuit voltage 12 8 V or more at 20 C 68 F CORRECT EB80401 1 3 Charging voltage e Connect the engine tachometer to the spark plug lead 71 e Connect the pocket tester DC 20 V to the battery Tester lead gt Battery terminal Tester lead gt Battery terminal CHARGING system ELEC ij Charging voltage MEETS SPECIFICATION ri 14 V at 3 000 r min l NOTE ye oo The charging circuit is not faulty OUT OF SPECIFICATION e Start the engine and accelerate to about 3 000 r min EB804012 4 Charging coil resistance e Disconnect the AC magneto coupler from the wire harness e Connect the pocket tester Q x 1 to the charging coils Tester lead White terminal 1 Tester lead White terminal 2
116. ber seals causing leakage and poor brake performance e Refill with the same type of brake fluid mixing brake fluids may result in a harmful chemical reaction and lead to poor brake performance e Be careful that water does not enter the master cylinder when refilling Water will significantly lower the boiling point of the brake fluid and may result in vapor lock 3 Air bleed e Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in CHAPTER 3 4 Check e Brake fluid level Brake fluid level is under the LOWER level line Fill up Hefer to CHECKING THE BRAKE FLUID LEVEL in CHAPTER 3 FRONT AND REAR BRAKES CHAS 36 INSTALLING THE REAR BRAKE CALIPER 1 Install e Brake caliper assembly e Brake caliper mounting bolt 1 30 Nm 3 0 kg 22 Ib e Brake hose 2 e Copper washers 3 e Union bolt G 2 Fill e Brake reservoir Recommended brake fluid DOT 4 Brake fluid may damage painted surfaces or plastic parts Always clean up spilled brake fluid immediately WARNING e Use only the designated quality brake fluid other brake fluids may deteriorate the rubber seals causing leakage and poor brake performance e Refill with the same type of brake fluid mixing brake fluids may result in a harmful chemical reaction and lead to poor brake performance e Be careful that water does not enter the master cylinder when refilling Water will significantly lower the boil
117. brake hose does not touch other parts throttle cable wire harness leads etc Correct if necessary WARNING Proper brake hose routing is essential to insure safe machine operation Refer to CABLE ROUTING in CHAPTER 2 3 Fill e Brake fluid reservoir Recommended brake fluid DOT 4 Brake fluid may damage painted surfaces or plastic parts Always clean up spilled brake fluid immediately WARNING e Use only the designated quality brake fluid other brake fluids may deteriorate the rubber seals causing leakage and poor brake performance e Refill with the same type of brake fluid mixing brake fluids may result in a harmful chemical reaction and lead to poor brake performance FRONT AND REAR BRAKES CHAS 36 e Be careful that water does not enter the brake master cylinder when refilling Water will significantly lower the boiling point of the brake fluid and may result in vapor lock 4 Air bleed e Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in CHAPTER 3 5 Check e Brake fluid level Brake fluid level is under the LOWER level line Fill up Hefer to CHECKING THE BRAKE FLUID LEVEL in CHAPTER 3 INSTALLING THE REAR BRAKE MASTER CYLINDER 1 Install e Copper washers 1 e Brake hose 2 e Union bolt 3 30 Nm 3 0 kg 22 ft Ib brake master cylinder make sure the brake pipe touches the projection 8 as shown WARNING Proper brake
118. bsorber Wheel travel Front wheel travel Rear wheel travel Electrical Ignition system Generator system Battery type Battery capacity Headlight type Bulb wattage x quantity Headlight Brake tail light Indicator lights Neutral Reverse Coolant temperature Park position High gear Low gear Diff lock Standard Tubeless AT25 x 8 12 AT25 x 10 12 CHENG SHIN CHENG SHIN M911Y 912 210 kg 463 22 28 kPa 0 22 0 28 3 2 4 0 psi 22 28 kPa 0 22 0 28 3 2 4 0 psi Dual disc brake Right hand operation Single disc brake Left hand and right foot operation Double wishbone Swingarm monocross Coil spring oil damper Coil spring oil damper 160 mm 6 30 in 180 mm 7 09 in D C C D I A C magneto YTX20L BS 12V 18 Ah Krypton bulb 12 V W 30 W x2 12 V 21 W 5 LED x 1 LED x 1 LED x 1 LED x 1 LED x 1 LED x 1 LED x 1 MAINTENANCE SPECIFICATIONS SPEC y MAINTENANCE SPECIFICATIONS ENGINE Item Cylinder head Warp limit Cylinder Bore size Taper limit Out of round limit Camshaft Drive method Cam dimensions Exhaust Camshaft runout limit 84 500 84 510 mm 3 3268 3 3272 in Chain drive Left 40 62 40 72 mm 1 5992 1 6031 in 32 18 32 28 mm 1 2669 1 2709 in 40 62 40 72 mm 1 5992 1 6031 in 32 18 32 28 mm 1 2669 1 2709 in 0 03 mm 0 0012 in 84 600 mm 3 3307 in 0 05 mm 0 0016 in
119. cap Bolt Timing chain tensioner Bolt Timing chain guide intake Bolt Valve adjusting screw Nut Radiator Bolt Oil pump assembly Screw Oil pump Screw strainer cover Plug Oil drain bolt Bolt Oil pump drive gear Nut Oil delivery pipe Union bolt Oil filter bolt Union bolt Oil filter cartridge Intake manifold Bolt Muffler and exhaust pipe Bolt Exhaust pipe Nut Muffler Bolt Exhaust pipe stay Bolt Crankcase cover Screw Oil seal retainer Screw Drive belt case cover Bolt Crankcase oil passage plug Plug Bearing retainer right crankcase Screw Plug right crankcase Bolt Bearing retainer left crankcase Bolt Crankcase cover left Bolt Recoil starter Bolt Starter one way clutch Bolt Clutch carrier assembly Nut Middle drive shaft bearing retainer Torx screw gt OFA 22 gt Naaa a AH HH A HAH gt MAINTENANCE SPECIFICATIONS SPEC y Part to be tightened mo m Remarks Middle driven shaft drive pinion gear Middle drive shaft bearing housing Middle driven gear bearing retainer Left hand threads Yoke middle driven gear Middle driven gear bearing housing Middle driven shaft bearing retainer Left hand threads Shift arm Shift rod Primary sheave assembly oecondary sheave assembly Secondary sheave spring retainer Shift lever 2 Shift control cable Select lever unit Shift cam ball holding bolt CDI unit Neu
120. ceives See sectional view 4 Shaft CHECKING CONNECTIONS Ed 926 CHECKING OF CONNECTIONS Check the connectors for stains rust moisture etc 1 Disconnect e Connector 2 Check e Connector Moisture Dry each terminal with an air blower Stains rust gt Connect and disconnect the terminals several times 3 Check e Connector leads Looseness Bend up the pin and connect the terminals 4 Connect e Connector terminals NOTE The two terminals click together 5 Check e Continuity using a pocket tester NOTE 3 e If there is no continuity clean the terminals e When checking the wire harness be sure to perform steps 1 to 3 e AS a quick remedy use a contact revitalizer available at most part stores e Check the connector with a pocket tester as shown SPECIAL TOOLS Ed 926 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune up and assembly Use only the appropriate special tools this will help prevent damage caused by the use of inappropriate tools or improvised techniques Special tools may differ by shape and part number from country to country In such a case two types are provided When placing an order refer to the list provided below to avoid any mistakes For US and CDN P N YM YU YS YK ACC Except for US and CDN P N 90890 Bolt Slide hammer bolt M6 weight set 90890 01083 Weight 90890 01084 Set These tools are used t
121. d if gear replacement is necessary WARNING Always use new bearings and races gt REAR AXLE FINAL DRIVE GEAR AND DRIVE SHAFT DRIV REPLACING THE FINAL DRIVE ROLLER BEARING 1 Remove e Roller bearing ring gear Use a suitable press tool and an appropriate support for the main housing e Oil seal 3 2 Remove e Roller bearing final drive pinion gear 1 kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Removal steps the main housing only to 150 C 302 F Remove the roller bearing outer race with an appropriately shaped punch 2 e Remove the inner race from the final drive pinion gear NOTE The removal of the final drive pinion gear roller bearing is difficult and seldom necessary kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk 3 Install e Roller bearing final drive pinion gear kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Installation steps Heat the main housing only to 150 C 302 F Install the roller bearing outer race using the proper adapter the inner race onto the drive pinion gear 4 Install e Oil seal e Roller bearing 2 Use a suitable press tool and a press to install the above components into the main housing gt REAR AXLE FINAL DRIVE GEAR AND DRIVE SHAFT DRIV POSITIONING THE FINAL DRIVE PINION GEAR AND RING GEAR When the final drive pinion gear ring gear final gear case and or rin
122. e rear brake 1 Check e Rear brake lever free play Out of specification Adjust Rear brake lever free play 0 5 2 mm 0 02 0 08 in 2 Check e Rear brake pedal height 8 Out of specification Adjust Rear brake pedal height 70 80 mm 2 76 3 15 in 1 Brake pedal 2 Footrest 1021222222722 3 Adjust e Rear brake lever free play e Rear brake pedal height Adjustment steps Loosen the locknut handlebar 1 and fully screw in the brake lever cable adjuster handlebar 0 Remove the rear brake master cylinder cover 3 ADJUSTING THE REAR BRAKE Loosen the locknut 4 eTurn the adjusting until the brake pedal height is within the specified limits Brake pedal height 70 80 mm 2 76 3 15 in Tighten the locknut 4 NOTE _ _ When adjusting the brake pedal height make sure the locknut to adjusting bolt clearance does not exceed 6 mm 0 24 in Loosen the locknut 6 Pull up the brake outer cable and turn the brake cable adjusting nut until the clearance is within the specified limits Clearance b Less than 1 mm 0 04 in NOTE nmm Make sure the 8 is all the way to the right of the link plate hole Hold the adjusting nut and tighten the locknut 6 elum the brake lever cable adjuster handlebar until the rear brake lever free play is within the specified limits
123. e gy Removing the water pump Remove the parts in the order below Seat fuel tank side panel left and Refer to SEAT AND SIDE PANELS in engine side cover CHAPTER 3 Left footrest board Refer to FOOTREST BOARDS in CHAPTER 3 Coolant Drain Refer to CHANGING THE COOLANT in CHAPTER 3 Water pump outlet hose Water pump outlet pipe O ring Radiator outlet hose Water pump breather hose Water pump assembly O ring For installation reverse the removal procedure WATER PUMP coo Job name Part name Disassembling the water pump Remove the parts in the order below Water pump housing cover Gasket Circlip Impeller Rubber damper holder Rubber damper Water pump seal Oil seal Bearing Water pump housing 009 For assembly reverse the disassembly procedure WATER PUMP coo DISASSEMBLING THE WATER PUMP 1 Remove e Rubber damper holder 1 e Rubber damper 2 from the impeller with a thin flathead screwdriver NOTE Do not scratch the impeller shaft 2 Water pump seal 1 NOTE out the water pump seal from inside of the water pump housing 2 Water pump housing 323 010 3 Remove e Oil seal e Bearing NOTE Tap out the bearing and oil seal from the outside of the water pump housing 3 Water pump housing CHECKING THE WATER PUMP 1 Check e Water pump housing c
124. e left crankcase specifies a thickness of 95 8 Example 1 If the bearing housing is marked 03 sea d is 76 03 2 If the driven pinion gear is marked 02 mm is 59 02 3 If the driven pinion gear is marked 10 D is 79 40 4 If the crankcase left is marked 95 79 95 79 5 Therefore the shim thickness is 0 57 mm B 76 03 59 02 79 40 95 79 0 05 57 6 Round off hundredths digit and select appropriate shim s In the example above the calculated shim thickness is 0 57 mm The chart instructs you however to round off 7 to 5 MIDDLE GEAR ENG Shims are supplied in the following thickness oS Middle drive pinion gear shim 0 10 0 40 0 15 0 50 0 20 0 60 0 30 g Thickness mm kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk INSTALLING THE MIDDLE DRIVEN SHAFT 1 Install e Bearing retainer 4 1 80 Nm 8 0 kg 58 ft Ib NOTE Attach the ring nut wrench 2 Ring nut wrench P N YM 38404 90890 01430 2 The middle driven shaft bearing retainer has left handed threads To tighten the retainer turn it counterclockwise 2 Install e Bearing retainer J kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Installation steps Attach the folded rag Secure the bearing housing edge in the vise e Attach the bearing retainer wrench 3 Bearing retainer w
125. eS iG V lofo usna 09 SSANYVH 9 25 EB80501 LIGHTING SYSTEM ELEC TROUBLESHOOTING IF THE HEADLIGHT AND OR TAILLIGHT FAIL TO COME ON Procedure Check 1 Fuse main headlight 4 Light switch 2 Battery 5 Wiring connections 3 Main switch the entire lighting system NOTE e Remove the following part s before Pocket tester 1 Seat 2 Front carrier 3 Front fender panel e Use the following special tool s for troubleshooting EB802011 1 Fuse main headlight Refer to CHECKING THE SWITCH 1 NO CONTINUITY CONTINUITY Replace the fuse INCORRECT EB802012 2 Battery e Check the battery condition Refer to CHECKING THE BATTERY in CHAPTER 3 e Clean the battery terminals 12 8 V or more at 20 C 68 F e Recharge or replace the battery CORRECT Open circuit voltage LIGHTING SYSTEM ELEC 3 Main switch INCORRECT Refer to CHECKING THE SWITCH 1 Replace the main switch INCORRECT 4 Light switch Refer to CHECKING THE SWITCH 1 CORRECT Light switch is faulty replace the handlebar switch left EB805013 5 Wiring connection POOR CONNECTION system Refer to WIRING DIAGRAM e Check the connections of the entire lighting CORRECT Properly c
126. eaction and lead to poor performance e 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 a vapor lock 4 Install rear brake e Front fender panel e Front carrier Refer to SEAT CARRIERS FENDERS AND FUEL TANK CHECKING THE FRONT BRAKE PAD CHK CHECKING THE REAR BRAKE PAD ADJ Q CHECKING THE FRONT BRAKE PAD 1 Remove e Front wheels 2 Check e Brake pad 8 Wear indicators groove 1 almost touch the brake disc Replace the brake pads as a set Refer to FRONT AND REAR BRAKES in CHAPTER 8 Brake pad wear limit 1 mm 0 04 in 3 Operate the brake lever 4 nstall e Front wheels CHECKING THE REAR BRAKE PAD 1 Remove e Rear wheel left 2 Check e Brake pad Wear indicator groove 1 almost disappeared Replace the brake pads as a set Refer to FRONT AND REAR BRAKES in CHAPTER 8 Brake pad wear limit 1 mm 0 04 in 3 Operate the brake lever or brake pedal 4 Install e Rear wheel left CHECKING THE BRAKE HOSE CHECKING THE BRAKE HOSE 1 Remove e Seat e Front carrier e Front fender Refer to SEAT CARRIERS FENDERS AND FUEL TANK e Right footrest board Refer to FOOTREST BOARDS 2 Check e Front brake hoses 1 e Rear brake hoses 2 Cracks wear damage Replace Fluid leakage Replace the hose Refer to FRONT
127. ead 3 e Check the operation of the starter motor DOES NOT TURN Repair or replace the starter motor e Remove the starter relay from the wire harness e Connect the pocket tester Q x 1 and the battery 12 V to the starter relay terminals Battery terminal gt Blue White terminal 1 Battery terminal Blue Black terminal 2 NO CONTINUITY Tester lead gt Red terminal 3 1 Tester lead Black terminal 4 e Check the starter relay for continuity Replace the starter relay CONTINUITY ELECTRIC STARTING SYSTEM ELEC 5 Main switch INCORRECT Refer to CHECKING THE SWITCH 1 a CORRECT Replace the main switch 6 Engine stop switch INCORRECT Refer to CHECKING THE SWITCH 1 iL CORRECT Replace the handlebar switch left 7 Start switch INCORRECT Refer to CHECKING THE SWITCH iL Replace the handlebar switch left EB803028 8 Wiring connection e Check the connections of the entire starting POOR CONNECTION system Refer to CIRCUIT DIAGRAM Properly connect the starting system ELECTRIC STARTING SYSTEM ELEC STARTER MOTOR 10 Nm 1 0 m kg 7 2 ft Ib 5 Nm 0 5 m kg 3 6 ft Ib V EXE aN Poh SS 552 9 n TS K 3 SS CY SS Job name Part name Remarks Removing the starter motor Remove the parts in the order below Starter motor lead Starter motor O ring Disassembling the starter motor Remove the parts in t
128. ear carrier Battery holding bracket Battery lead cover Battery lead Battery Starter relay ground lead Tail brake light connector CHK 4o SEAT CARRIERS FENDERS AND FUEL TANK ADJ REAR CARRIER AND REAR FENDER ay Remove the parts in the order below Refer to SEAT AND SIDE PANELS Refer to FUEL TANK Disconnect then disconnect the positive lead Disconnect Disconnect 4o SEAT CARRIERS FENDERS AND FUEL TANK ADJ Job name Part name CDI unit Wire harness Rear fender For installation reverse the removal procedure 4o SEAT CARRIERS FENDERS AND FUEL TANK ADJ FUEL TANK Removing the fuel tank Remove the parts in the order below Seat and fuel tank side panels Refer to SEAT AND SIDE PANELS Fuel tank cover Refer to FRONT CARRIER FRONT BUMPER AND FRONT FENDER Fuel hose NOTE Before disconnecting the fuel hose turn the fuel cock to OFF Fuel cock lever Fuel tank NOTE _ When installing the fuel tank pass the fuel tank breather hose through the hole of the handlebar protector Float chamber air vent hose Plastic band Rubber cover For installation reverse the removal procedure FOOTREST BOARDS FOOTREST BOARDS 7 Nm 0 7 m kg 5 1 ft Ib Remarks Removing the footrest boards Remove the parts in the order below Fuel tank side panels Refer to SEAT AND SIDE PANELS 1 Left footrest board 2 Right footrest b
129. eave bolts SPECIAL TOOLS Izd 926 ose Tootnameftowfouse _ Compression gauge Compression gauge 90890 03081 Adapter YU 33223 Adapter 90890 04082 These tools are needed to measure YU 33223 3 engine compression Pocket tester 90890 03112 YU 03112 This instrument is needed for checking the electrical system Engine tachometer 90890 03113 This tool is needed for observing engine rpm Inductive tachometer YU 8036 A This tool is needed for observing engine rpm Timing light 90890 03141 YM 33277 A This tool is necessary for checking ignition timing Valve spring compressor 90890 04019 YM 04019 This tool is needed to remove and install the valve assemblies Middle driven shaft Middle driven shaft bearing driver bearing driver 90890 04058 Mechanical seal installer YM 04058 1 Mechanicalseal install 5990258 6 These tools are used to install the 33221 water pump seal Bearing retainer wrench This tool is needed when removing or installing the final drive shaft bearing retainer Universal joint holder 90890 04062 YM 04062 This tool is needed when removing or installing the universal joint yoke nut SPECIAL TOOLS Ed Tool No Tool name How to use Illustration Clutch holding tool Ere 2 This tool is needed to hold the clutch carrier when removing or installing the carrier nut Bearing retainer wrench
130. ed even when the throttle lever is applied to the maximum position Screwing in the adjuster stops the engine speed from increasing 1 Check e Speed limiter length Out of specification Adjust Speed limiter length 12 mm 0 47 in ADJUSTING THE SPEED LIMITER ADJUSTING THE STARTER CABLE ADJ Q 2 Adjust Speed limiter length kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Speed limiter length adjustment steps Loosen the locknut 1 eTurn the adjuster in or out until the specified speed limiter length is obtained Turnina i Speed limiter length is urning in decreased Turning out Speed limiter length is increased e Tighten the locknut WARNING Particularly for a beginner rider the speed limiter should be screwed in completely Screw it out little by little as their riding technique improves Never remove the speed limiter for a beginning rider e For proper throttle lever operation do not turn out the adjuster more than 12 mm 0 47 in Also always adjust the throttle lever free play to 3 5 mm 0 12 0 20 in kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk ADJUSTING THE STARTER CABLE 1 Remove Seat Fuel tank side panel left Refer to SEAT CARRIERS FENDERS AND FUEL TANK ADJUSTING THE STARTER CABLE 2 Adjust kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Adjustment steps Disconnect the starter cable 1
131. en reached then release the lever or pedal i Repeat steps e to h until all the air bubbles have disappeared from the fluid j Tighten the bleed screw Bleed screw 25 6 Nm 0 6 me kg 4 3 ft Ib NOTE If bleeding is difficult it may be necessary to let the brake fluid settle for a few hours Repeat the bleeding procedure when the tiny bubbles in the system have disappeared 3 41 BLEEDING THE HYDRAULIC BRAKE SYSTEM ADJUSTING THE SELECT LEVER CONTROL CABLE AND SHIFT ROD ADJ k Add brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL A WARNING Check the operation of the brake after bleeding the brake system kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk ADJUSTING THE SELECT LEVER CONTROL CABLE AND SHIFT ROD D NEUTRAL 2 HIGH 3 LOW REVERSE 5 PARK 6 Control cable 7 Select lever shift rod WARNING Before moving the select lever bring the machine to a complete stop and return the throttle lever to its closed position Otherwise the transmission be damaged 1 Adjust e Rear brake pedal free play Refer to ADJUSTING THE REAR BRAKE 2 Adjust e Select lever control cable e Select lever shift rod kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Adjustment steps Control cable Make sure the select lever is in NEUTRAL e Adjust the control cable so there is zero free play in the cable When the adjus
132. eplace 3 Check e Primary sliding sheave e Primary fixed sheave Cracks damage Replace CHECKING THE SECONDARY SHEAVE 1 Check e Secondary fixed sheave smooth operation e Secondary sliding sheave smooth operation Scratches damage Replace as a set 2 Check e Torque cam groove 1 Wear damage Replace 3 Check e Guide Wear damage Replace 4 Check e Secondary sheave spring Damage Replace 5 Measure e Secondary sheave spring free length Out of specification Replace the secondary sheave spring Free length 121 4 mm 4 78 in lt Limit gt 115 33 mm 4 54 in e PRIMARY AND SECONDARY SHEAVES ENG ASSEMBLING THE PRIMARY SHEAVE 1 Clean Primary sliding sheave face 1 Primary fixed sheave face e Collar 3 e Weight 4 Primary pulley cam face NOTE Remove any excess grease 2 Install e Weight 1 NOTE W e Apply Yamaha Grizzly grease 120 g to the whole outer surface of the weight and install e Apply Yamaha Grizzly grease to the inner surface of the collar e Apply Yamaha Grizzly grease to the inner surface of the primary sliding sheave 3 Install e opacer e Slider 1 e Primary pulley cam 2 e Primary sliding sheave cap 8 Nm 0 3 m kg 2 2 ft Ib ASSEMBLING THE SECONDARY SHEAVE 1 Apply e BEL RAY assembly lube to the secondary sliding sheave 1 inner surface and oil seals e BEL RAY assembly lube to
133. er P N YU 03112 90890 03112 f the tester indicates oo replace the fuse n 3 Replace e Blown fuse 18030103 kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Replacement steps Turn off the ignition Install a new fuse of the proper amperage e Turn on switches to verify operation of the related electrical devices elf the fuse immediately blows again check the electrical circuit kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Current rating Quantity Terminal Auxiliary DC jack 4WD Four wheel drive Signaling system fuse Backup fuse odometer Reeve 394 r Reserve Reserve Reserve A WARNING Never use a fuse with a rating other than that specified Never use other materials in place of a fuse An improper fuse may cause extensive damage to the electrical system a malfunction of the lighting and ignition systems and could possibly cause a fire 3 61 CHECKING THE FUSE ADJUSTING THE HEADLIGHT CHK BEAM CHANGING THE HEADLIGHT BULB ADJ Q 4 nstall e Seat Refer to SEAT CARRIERS FENDERS AND FUEL TANK ADJUSTING THE HEADLIGHT BEAM 1 Adjust e Headlight beam vertically Turn the adjuster 1 in or out Headlight beam raised Headlight beam lowered CHANGING THE HEADLIGHT BULB 1 e Cover 1 2 Remove e Bulb holder 1 e Bulb NOTE Turn the bulb holder counterclockwi
134. er and cargo 500 kg 1 102 Ib Tongue weight vertical weight on trailer hitch point 15 kg 33 Ib Be extra careful of the machine balance and stability when towing a trailer CHECKING THE TIRE 1 Measure LOY e lire pressure cold tire pressure Out of specification Adjust MC NOTE 5 e e The low pressure tire gauge 1 is included j as standard equipment P e If dust or the like is stuck to this gauge it will N not provide the correct readings Therefore N take two measurements of the tire s pressure and use the second reading Cold tire pressure 25 kPa 25 kPa Standard 0 25 kg cm 0 25 kg cm 3 6 psi 3 6 psi 22 kPa 22 kPa 0 22 kg cm 0 22 kg cm 3 2 psi 3 2 psi 28 kPa 28 kPa 0 28 kg cm 0 28 kg cm 4 0 psi 4 0 psi WARNING Uneven or improper tire pressure adversely affect the handling of this machine and may cause loss of control e Maintain proper tire pressures e Set tire pressures when the tires are cold e Tire pressures must be equal in both front tires and equal in both rear tires 2 Check e Tire surfaces Wear damage Replace Tire wear limit Front and rear 3 0 mm 0 12 in WARNING It is dangerous to ride with a worn out tire When tire wear is out of specification replace the tire immediately CHECKING THE WHEEL CHK CHECKING AND LUBRICATING THE CABLE ADJ Q C
135. es the direction show in the illustration 2 Tighten e Nut primary sheave 1 e Nut secondary sheave 2 100 Nm 10 0 kg 72 ft Ib NOTE L 3 e Use the sheave holder 3 to hold the primary sheave e First tighten the nut primary sheave 1 then tighten the nut secondary sheave 2 Sheave holder P N YU 01880 90890 01701 ye CLUTCH Removing the clutch Primary and secondary sheaves Cover Clutch housing assembly Gasket dowel pin One way clutch bearing Nut Clutch carrier assembly Remove the parts in the order below Refer to PRIMARY AND SECONDARY SHEAVES Refer to REMOVING INSTALLING THE CLUTCH For installation reverse the removal procedure ENG Job nameiPart Disassembling the clutch housing Hemove the parts in the order below Oil seal Circlip Bearing housing Circlip Bearing Circlip Bearing Clutch housing 9 For assembly reverse the disassembly procedure ENG REMOVING THE CLUTCH 1 Remove e Clutch housing assembly e Gasket e Dowel pins NOTE o llAL 1 Working in crisscross pattern loosen each bolt 1 4 of a turn Remove them after all of them are loosened 8 2 Straighten e Punched portion of the nut 1 3 Remove e Nut NOTE _ Use a clutch holdi
136. ester Q x 1 to the ignition coil Tester lead gt Orange lead terminal Tester lead Ignition coil base e Check that the primary coil has the specified resistance 11 Primary coil resistance 0 18 0 28 at 20 68 F e Connect the pocket tester O x 1k to the ignition coil Tester lead gt Orange lead terminal Tester lead Spark plug lead e Check that the secondary coil has the specified resistance Secondary coil resistance 6 32 9 48 at 20 C 68 F OUT OF SPECIFICATION BOTH MEET 1 SPECIFICATION Replace the ignition coil INCORRECT Refer to CHECKING THE SWITCH Replace the handlebar switch left 7 Engine stop switch IGNITION SYSTEM ELEC INCORRECT Refer to CHECKING THE SWITCH di CORRECT Replace the main switch 9 Pickup coil resistance Disconnect the AC magneto coupler from the wire harness e Connect the pocket tester Q x 100 to the pickup coil terminal Tester lead White Red terminal Tester lead White Green terminal 2 OUT OF SPECIFICATION Pickup coil resistance 459 561 at 20 C 68 F White Red White Green Replace the pickup coil stator assembly MEETS SPECIFICATION e Disconnect the AC magneto coupler from the wire harness e Connect the pocket tester Q 100 to the charging rotor rotation direction detection coil terminal Tester
137. et is aligned with the match mark on the cylinder head 8 Force the camshaft clockwise counterclockwise to remove timing chain slack a screwdriver into the timing chain tensioner hole and push the timing chain guide inward While pushing the timing chain guide be sure that the camshaft sprocket I mark is aligned with the cylinder head match mark 2 the marks are aligned tighten the camshaft sprocket bolt If the marks are not aligned change the meshing position of the camshaft sprocket and timing chain kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk 3 Install e Timing chain tensioner kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Installation steps e Remove the tensioner cap bolt 1 washer and spring 3 Release the timing chain tensioner one way 4 and push the tensioner rod 5 all the way in Install the tensioner 6 with a new gasket into the cylinder BN Bolts timing chain tensioner 25 11 Nm 1 7 kg 8 0 ft Ib A WARNING Always use a new gasket Install the spring washer and cap bolt Cap bolt timing chain tensioner 23 Nm 2 3 kg 17 ft Ib kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk CYLINDER HEAD ENG 4 Tighten e Camshaft sprocket bolt 1 60 Nm 6 0 kg 43 ft Ib NOTE Use the rotor holding tool 2 to hold
138. evel surface WARNING Securely support the machine so there is no danger of it falling over Refer to INSTALLING THE WHEEL Refer to INSTALLING THE WHEEL HUB Rear wheel Wheel cap Cotter pin Axle nut Wheel hub Brake caliper mounting bolt Brake disc bracket Brake disc Brake disc guard a m nm rn For installation reverse the removal procedure FRONT AND REAR WHEELS CHAS 36 CHECKING THE WHEEL 1 Check e Wheel 2 Measure e Wheel runout Over the specified limit Replace the wheel or check the wheel bearing play 1 Wheel runout limit Radial 2 2 0 mm 0 08 in Lateral 3 2 0 mm 0 08 in 3 Check e Wheel balance Out of balance Adjust A WARNING After replacing the tire ride conservatively to allow the tire to be properly seated in the rim Failure to do so may cause an accident resulting in machine damage and possible operator injury CHECKING THE WHEEL HUB 1 Check e Wheel hub 1 Cracks damage Replace e Splines wheel hub 2 Wear damage Replace 12040301 FRONT AND REAR WHEELS CHAS 36 CHECKING THE BRAKE DISC 1 Check e Brake disc Galling damage Replace 2 Measure e Brake disc deflection Out of specification Check the wheel runout If wheel runout is within the limits replace the brake disc Brake disc maximum deflection 0 15 mm 0 006 in e Brake disc
139. foreign objects lodged between the 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 and check them 10 3 FAULTY GEAR SHIFTING TRBL FAULTY CLUTCH PERFORMANCE SHTG e FAULTY GEAR SHIFTING HARD SHIFTING Refer to CLUTCH SLIPPING DRAGGING CLUTCH DRAGGING SHIFT LEVER DOES NOT MOVE Shift shaft Transmission e Bent shift shaft e Seized transmission gear Shift cam shift fork e Jammed impurities e Groove jammed with impurities e Incorrectly assembled transmission e Seized shift fork Shift guide e Bent shift fork guide bar e Broken shift guide JUMPS OUT OF GEAR Shift shaft Shift cam e Improperly adjusted shift lever position e Improper thrust play e Worn shift shaft lever e Worn shift cam groove e Improperly returned stopper lever Transmission Shift fork e Worn gear dog e Worn shift fork FAULTY CLUTCH PERFORMANCE ENGINE OPERATES BUT MACHINE WILL NOT MOVE V belt Transmission e Bent damaged or worn V belt e Damaged transmission gears e V belt slips Primary pulley cam and primary pulley slider e Damaged or worn primary pulley cam e Damaged or worn primary pulley slider CLUTCH SLIPPING Clutch spring Primary sliding sheave e Damaged loose or worn clutch shoe spring e Seized primary
140. from the carburetor body NOTE Do not remove the starter plunger 2 from the starter cable Measure the starter plunger stroke distance of the starter lever fully close to fully open position If the distance is out of specification adjust it as described below Starter plunger stroke distance 15 mm 0 59 in Fully closed position Fully open position Pull back the boot Loosen the locknut 5 e Turn the adjuster 6 in or out until the correct free play is obtained Turning in Free play increased Turning out Free play decreased e Tighten the locknut 5 e Push in the boot 4 e Connect the starter cable to the carburetor WARNING After adjusting the cable turn the handlebar to right and left and make sure that the engine idling speed does not increase kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk 3 Install e Fuel tank side panel left e Seat Refer to SEAT CARRIERS FENDERS AND FUEL TANK CHECKING THE SPARK PLUG CHECKING THE SPARK PLUG 1 Remove e Seat e Fuel tank side panel right Refer to SEAT CARRIERS FENDERS AND FUEL TANK 2 Remove e Spark plug 3 Check e Spark plug type Incorrect Replace Standard spark plug DRSEA NGK 4 Check e Electrode 1 Wear damage Replace e Insulator 2 Abnormal color Replace Normal color is a medium to light tan color 5 Clea
141. ft Fuel tank side panel right Engine side panel Engine side cover For installation reverse the removal procedure 4o SEAT CARRIERS FENDERS AND FUEL TANK ADJ FRONT CARRIER FRONT BUMPER AND FRONT FENDER 33 Nm 3 3 m kg 24 ft Ib 3 ANG 7 Nm 0 7 m kg 5 1 ft Ib 33 Nm 3 3 m kg 24 ft Ib Job nameiPart Removing the front carrier front Remove the parts in the order below bumper and front fender Seat and fuel tank side panels Refer to SEAT AND SIDE PANELS Front carrier Front fender panel Engine skid plate Front bumper cover Front bumper Headlight coupler Front grill Main switch coupler Handlebar cover Fuel tank cover Disconnect Disconnect LL O 4o SEAT CARRIERS FENDERS AND FUEL TANK ADJ 33 Nm 3 3 m kg 24 ft Ib Wire Cc OQ EM ANG 7 Nm 0 7 m kg 5 1 ft Ib 33 Nm 3 3 m kg 24 ft Ib XbramePainame Gy Meter assembly coupler Disconnect Four wheel drive relay 3 coupler Disconnect Auxiliary DC jack connector Disconnect Coolant reservoir breather hose Fan motor breather hose Differential gear case breather hose Front fender For installation reverse the removal procedure Job name Part name Removing the rear carrier and rear fender Seat and fuel tank side panels Fuel tank R
142. fuse 09 Four wheel drive relay 1 Four wheel drive relay 2 8 Four wheel drive relay 3 82 On command four wheel drive switch and differential gear lock switch 63 Gear motor 80302 2WD AWD SELECTING SYSTEM ELEC TROUBLESHOOTING IF THE GEAR MOTOR FAILS TO OPERATE Procedure Check 1 Fuse main four wheel drive 7 four wheel drive switch and 2 Battery differential gear lock switch 3 Main switch 8 Gear motor 4 Four wheel drive relay 1 9 Wiring connections 5 Four wheel drive relay 2 the entire 2WD 4WD selecting system 6 Four wheel drive relay 3 NOTE e Remove following part s before Pocket tester troubleshooting 1 Seat 2 Front carrier 3 Front fender eUse the following special tool s for troubleshooting P N YU 03112 90890 03112 EB802011 1 Fuse main four wheel drive NO CONTINUITY Refer to CHECKING THE SWITCH CONTINUITY Replace the fuse INCORRECT e Check the battery condition Refer to CHECKING THE BATTERY in CHAPTER 3 e Clean the battery terminals EB802012 2 Battery Open circuit voltage 12 8 V or more at 20 C 68 F CORRECT INCORRECT 3 Main switch e Recharge or replace the battery Refer to CHECKING THE SWITCH CORRECT Replace the main switch 2WD AWD SELECTING SYSTEM ELEC 4 Four wheel drive relay 1 e Remove the four wheel drive relay 1 from the wire
143. g gear bearing housing are replaced be sure to adjust the positions of the final drive pinion gear and ring gear using the shim s Final drive pinion gear shim selection 1 Select e Final drive pinion gear shim s 1 kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Selection steps elo find the final drive pinion gear shim thickness A use the following formula Final drive pinion gear shim thickness O a numeral usually a decimal number on the final drive pinion gear either added to or subtracted from 84 D a numeral usually a decimal number on the final gear case either added to or subtracted from 83 Example 1 If 01 is stamped on the final drive pinion gear 84 0 01 84 01 2 If 50 is stamped on final gear case D 83 0 50 83 50 3 Therefore A is 0 51 84 01 83 50 0 51 4 Round off the hundredth digit and select the appropriate shim s In the example above the calculated number is 0 51 The chart instructs you to round off 1 to O at the hundredth place Thus the shim thickness is 0 50 mm gt REAR AXLE FINAL DRIVE GEAR AND DRIVE SHAFT DRIV Shims are supplied the following thicknesses oS Final drive pinion gear shim 0 15 0 30 0 40 Thickness mm 0 45 0 50 060 kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Ring gear shim selection 1 Select e Ring gear shim s 1 kk
144. gear left 4 Differential pinion gear 5 Ring gear 6 Differential side gear right FEATURES 626 7 Drive pinion gear Gear motor To front wheel From the middle gear FEATURES 076 2WD Power is transmitted as follows middle gear front drive shaft drive pinion gear gt ring gear gt differential pinion gear 24 In the 2WD mode the left differential side gear 3 and the drive clutch are not engaged therefore the left side gear runs idle and does not transmit power to the left front constant velocity joint 1 4 FEATURES 926 4WD When the 4WD mode is selected the gear motor is operated and the drive clutch moves to the right and engages with the left differential side gear 3 Accordingly power is transmitted as follows ring gear differential pinion gear 4 left differential side gear drive clutch adapter D left front constant velocity joint Meanwhile power from the differential pinion gear 4 is transmitted to the right front constant velocity joint via the right differential side gear 6 The ring gear 5 and the drive clutch 2 are not engaged at this time Therefore the rotational difference that occurs between the right and left wheels while the handlebar is being turned is absorbed by the difference in the rotational speeds of the ring gear 5 and the left differential side gear 3 ic FEATURES 076 AWD Diff Loc
145. he 113 C 120 3 coolant temperature warning light is come 235 4 F 248 5 4 WARNING Handle the thermo switch 1 with special care Never subject it to a strong shock or allow it to be dropped Should it be dropped it must be replaced BAD CONDITION Thermo switch 1 1 8 Nm 0 8 m kg 5 8 ft Ib Three bond sealock 10 Replace the thermo switch 1 GOOD CONDITION Replace the meter assembly SIGNAL SYSTEM ELEC 1 Horn switch INCORRECT Refer to CHECKING THE SWITCH i SORATTE Replace horn switch e Connect the pocket tester DC 20 V to the horn connector at the horn terminal Tester lead Pink lead 1 Tester lead gt Frame ground 4 Horn does not sound for Europe and Oceania 2 Voltage e Push the horn switch e Check for voltage 12 V on the Pink lead at the horn terminal MEETS The wiring circuit from the main switch to the 1 SPECIFICATION bulb socket connector is faulty repair it e Disconnect the black lead at the horn terminal e Connect a jumper lead 1 to the horn terminal and ground the jumper lead e Turn the main switch to ON e Push the horn switch HORN IS SOUNDED Horn is good HORN IS NOT SOUNDED Adjust or replace horn 37 COOLING SYsTEM JELEC COOLING SYSTEM CIRCUIT DIAGRAM AN ES fries Grey Woe fas fro v vV EET Eel x m
146. he order below Bracket 1 Washer kit Bracket 2 bushing Shims Brush holder set Armature coil Yoke Refer to ASSEMBLING THE STARTER For assembly reverse the disassembly procedure ELECTRIC STARTING SYSTEM ELEC CHECKING THE STARTER MOTOR 1 Check e Commutator Dirty Clean it with 600 grit sandpaper 2 Measure e Commutator diameter Out of specification Replace the starter motor Outside diameter 28 mm 1 10 in Wear limit 27 mm 1 06 in 3 Measure e Mica undercut Out of specification Scrape the mica using a hacksaw blade Mica undercut 0 7 mm 0 03 in NOTE Scrape the mica to the proper measurement using a hacksaw blade which has been grounded to fit the commutator 4 Check e Armature coil insulation continuity Defects Replace the starter motor kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Checking steps e Connect the pocket tester for the continuity check 1 and insulation check Measure the armature resistances Armature coil resistance Continuity check 1 0 025 0 035 at 20 C 68 F Insulation check 0 More than 1 MQ at 20 C 68 F elf the resistance is incorrect replace the starter motor kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk ELECTRIC STARTING SYSTEM ELEC 5 Measure e Brush length each Out of specification Replace the brush holder set Brush
147. he recoil starter Recoil starter bolt 10 Nm 1 0 m kg 7 2 ft Ib LOCTITE kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk CHECKING THE IGNITION CHK MEASURING THE COMPRESSION PRESSURE ADJ Q 4 Detach e Timing light e Inductive tachometer or engine tachometer 5 Install e Seat e Fuel tank side panel right Refer to SEAT CARRIERS FENDERS AND FUEL TANK MEASURING THE COMPRESSION PRESSURE NO TES L L L Insufficient compression pressure will result in a loss of performance 1 Check e Valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEARANCE 2 Start the engine and let it warm up for several minutes 3 Stop the engine 4 Remove e Seat e Fuel tank side panel right Refer to SEAT CARRIERS FENDERS AND FUEL TANK 5 Remove e Spark plug 6 Attach e Adapter e Compression gauge 1 Compression gauge gt P N YU 33223 90890 03081 Adapter P N YU 33223 3 90890 04082 4o MEASURING THE COMPRESSION PRESSURE ADJ 7 Measure e Compression pressure Above the maximum pressure Check the cylinder head valve surfaces and piston crown for carbon deposits Below the minimum pressure Squirt a few drops of oil into the affected cylinder and measure again e Refer to the table below Compression pressure with oil introduced into cylinder Higher than
148. ication Replace the crankshaft Crank width 62 95 63 00 mm 2 4783 2 4803 in e Side clearance Out of specification Replace the crankshaft Big end side clearance 0 25 0 75 mm 0 0098 0 0295 in lt Limit gt 1 00 mm 0 0394 in e Runout Out of specification Replace the crankshaft Runout limit C1 0 03 mm 0 0012 in C2 0 03 mm 0 0012 in kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Crankshaft reassembling point The crankshaft 1 and the crank passages must be properly interconnected with a tolerance of less than 1 mm 0 04 in kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk The buffer boss and woodruff key should be replaced when removed from the crankshaft e CRANKSHAFT AND OIL PUMP ENG INSTALLING THE CRANKSHAFT AND BALANCER 1 Install e Crankshaft Crankshaft installer set 1 3 P N YU 90050 Buffer boss installer set 2 P N 90890 04088 Adapter 11 3 P N YM 33279 Spacer crankshaft 4 P N YM 90070 A 90890 04060 NOTE Hold the connecting rod at the Top Dead Center T D C with one hand while turning the nut of the installing tool with the other Operate the installing tool until the crankshaft bottoms against the bearing Apply engine oil to each bearing to protect the crankshaft against scratches and to make installation easier 2 Install e Crankshaft seal NOTE _
149. ightening the bolts 1 will push the secondary sliding sheave away causing the gap between the secondary fixed and sliding sheaves to widen Remove the V belt 1 from the primary sheave and secondary sheave e Install the V belt NOTE 22222 Install the V belt so that its arrow faces the direction shown in the illustration e Remove the bolts kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk CLEANING THE SPARK ARRESTER 1 Clean e Spark arrester kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Cleaning steps WARNING e Select a well ventilated area free of combustible materials e Always let the exhaust system cool before performing this operation e Do not start the engine when removing the tailpipe from the muffler CLEANING THE SPARK ARRESTER e Remove the bolt 1 e Remove the tailpipe 2 by pulling it out of the muffler the tailpipe lightly with a soft face hammer or suitable tool then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe and the inner contact surfaces of the muffler the tailpipe into the muffler and align the bolt holes e Insert the bolt 1 and tighten it kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk ADJUSTING THE REAR BRAKE CHASSIS ADJUSTING THE REAR BRAKE WARNING Always adjust both the brake pedal and the rear brake lever whenever adjusting th
150. iming chain Cracks stiff Replace the timing chain and camshaft sprocket as a set 2 Check e Intake side timing chain guide Wear damage Replace 343 007 CHECKING THE OIL STRAINER AND OIL DELIVERY PIPE 1 Check e Oil strainer 1 2 Check e Oil delivery pipe Cracks damage Replace Clogged Blow out with compressed air CRANKCASE ENG CHECKING THE CRANKCASE 1 Thoroughly wash the case halves in a mild solvent 2 Clean all the gasket mating surfaces and crankcase mating surfaces thoroughly 3 Check e Crankcase Cracks damage Replace e Oil delivery passages Clogged Blow out with compressed air CHECKING THE BEARINGS 1 Check e Bearing Clean and lubricate then rotate the inner race with a finger Roughness Replace OD ASSEMBLING THE CRANKCASE 1 e Sealant Quick Gasket 1 to the mating surfaces of both case halves 4 j Sealant Quick Gasket 2 11001 05 01 Yamaha bond 1215 90890 85505 2 Install e Dowel pin 3 Fit the left crankcase onto the right case Tap lightly on the case with a soft hammer efor installing torquing the crankcase holding bolts be sure to check whether the transmission is functioning properly by manually rotating the shift cam in both directions 4 62 CRANKCASE ENG 4 Tighten Crankcase bolts follow the proper tightening sequence Right crankcase Left crankcase
151. in CHECKING THE PISTON PIN 1 Check e Piston pin Blue discoloration grooves Replace then check the lubrication system 2 Measure e Piston pin to piston clearance kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Measurement steps Measure the piston pin outside diameter If out of specification replace the piston pin Outside diameter piston pin 19 991 20 000 mm 0 7870 0 7874 in lt Limit gt 19 971 mm 0 7863 in Piston pin bore inside diameter 20 004 20 015 mm 0 7876 0 7880 in lt Limit gt 20 045 mm 0 7892 in 307 018 e Calculate the piston pin to piston clearance with the following formula Piston pin to piston clearance z Bore size piston pin Outside diameter piston CYLINDER AND PISTON ENG e f out of specification replace the piston 8 Piston pin to piston clearance 0 004 0 024 mm 0 00016 0 00094 in Limit 0 074 mm 0 0029 in kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk INSTALLING THE PISTON 1 Install e Piston rings onto the piston NOTE e Be sure to install the piston rings so that the manufacturers marks or numbers located on the upper side of the rings e Lubricate the piston and piston rings liberally with engine oil 2 Position e Top ring e 2nd ring e Oil ring Offset the piston ring end gaps as shown Top ring end D ring end upper C ring end
152. inal gear case and bearing housing Final gear case and bearing housing Battery holding bracket Footrest board and footrest bracket Yoke drive pinion gear Trailer hitch bracket Front brake pad holding bolt Rear brake pad holding bolt Rear brake master cylinder bracket Brake outer cable bracket Brake master cylinder cover Front brake caliper retaining bolt Air duct front MAINTENANCE SPECIFICATIONS SPEC ELECTRICAL Voltage Ignition system Ignition timing B T D C Magneto model manufacturer Pickup coil resistance color Rotor rotation direction sensing coil resistance color C D I unit model manufacturer Ignition coil Model manufacturer Minimum spark gap Primary winding resistance Secondary winding resistance Spark plug cap Type Resistance Charging system Type Model manufacturer Nominal output Charging coil resistance color Rectifier regulator Regulator type No load regulated voltage DC Model manufacturer Capacity Withstand voltage Electric starter system Type Starter motor Model manufacturer Output Armature coil resistance 10 1 500 r min F4T46471 MITSUBISHI 459 561 at 20 C 68 F White Red White Green 0 085 0 105 Q at 20 C 68 F Red White Blue F8T38678 MITSUBISHI 2JN MORIYAMA 6 mm 0 24 in 0 18 0 28 Q at 20 C 68 F 6 32 9 48 kQ at 20 C 68 F Resin type 10 kQ A C magneto generator FATA64 MITSUBISHI 14 V
153. indicator light 05 Low range switch 06 High range switch 07 Neutral switch Four wheel drive fuse 9 Four wheel drive relay 1 Four wheel drive relay 2 8 Four wheel drive relay 3 82 On command four wheel drive switch and differential gear lock switch 83 Gear motor 64 Auxiliary DC jack fuse 85 Auxiliary DC jack Ignition fuse 67 Headlight fuse Handlebar switch left Light switch Engine stop switch Start switch 42 Headlight Circuit breaker fan motor 02 Thermo switch 2 45 Fan motor Signaling system fuse 47 Front brake light switch Rear brake light switch Tail brake light Horn switch 6 Horn For Europe and Oceania Green White R W Red White Green Yellow R Y Red Yellow Blue Black WJB White Black Blue Green W G White Green Blue Red W L White Blue Blue White WIR White Red Blue Yellow Dace Yellow Black Red Black Red Green
154. ing gear stopper gt REAR AXLE FINAL DRIVE GEAR AND DRIVE SHAFT DRIV Ring gear stopper clearance adjustment 1 Remove e Ring gear 1 e Ring gear stopper 2 e Shim s 2 Bearing housing Left hand threads 2 Select e Suitable shim s em 0 0 10 0 15 0 20 Thickness mm 0 30 0 40 0 50 3 Install e Shim s e Ring gear stopper left hand threads X 9 Nm 0 9 kg 6 5 Ib e Ring gear NOTE 2 ALL Use LOCTITE on the ring gear stopper 4 Measure e Ring gear stopper clearance Out of specification Repeat adjustment steps Ring gear stopper clearance 0 30 0 60 mm 0 012 0 024 in CHECKING THE REAR AXLE 1 Check e Rear axle runout Out of specification Replace WARNING Do not attempt to straighten a bent axle Rear axle runout limit 1 5 mm 0 06 in REAR AXLE FINAL DRIVE GEAR AND DRIVE SHAFT DRIV CHECKING THE DRIVE SHAFT 1 Check e Drive shaft splines Wear damage Replace CHECKING THE FINAL DRIVE GEAR 1 Check e Final gear case 1 e Bearing housing ring gear 2 Cracks damage Replace NOTE LLL When the final gear case and or the ring gear bearing housing are replaced be sure to adjust the shim of the final drive pinion gear and or ring gear 2 Check e Gear teeth Pitting galling wear Replace the drive pinion gear and ring gear as a set e Oil seals e O rings Damage Replace 3 Check e Bear
155. ing point of the brake fluid and may result in vapor lock 3 Air bleed e Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in CHAPTER 3 4 Check e Brake fluid level Brake fluid level is under the LOWER level line Fill up Hefer to CHECKING THE BRAKE FLUID LEVEL in CHAPTER 3 STEERING SYSTEM CHAS 56 STEERING SYSTEM HANDLEBAR 23 Nm 2 3 m kg 17 ft Ib Removing the handlebar Handlebar cover Band On command four wheel drive switch and differential gear lock switch Refer to INSTALLING THE MASTER 4 Master cylinder assembly bracket CYLINDER ASSEMBLY 5 Throttle lever assembly bracket 6 Rear brake switch Refer to REMOVING THE REAR BRAKE SWITCH 7 Rear brake lever bracket Refer to INSTALLING THE REAR 8 Handlebar switch BRAKE LEVER 9 Handlebar grip 10 Handlebar holder Refer to INSTALLING THE 11 Handlebar HANDLEBAR For installation reverse the removal procedure STEERING SYSTEM CHAS 36 REMOVING THE REAR BRAKE SWITCH 1 Hemove e Rear brake switch 1 NOTE Push the fastener when removing the rear brake switch out of the rear brake lever holder CHECKING THE HANDLEBAR 1 Check e Handlebar Bends cracks damage Replace WARNING Do not attempt to straighten a bent handlebar as this may dangerously weaken the handlebar INSTALLING THE HANDLEBAR 1 Install e Handlebar e Handlebar holders 123 Nm 2 3 m kg 17 ft
156. ings Damage Replace NOTE _ e Reusing roller bearings is acceptable but Yamaha recommends installing new ones Do not reuse the oil seal e When the final drive pinion gear and or ring gear are replaced be sure to adjust the shim of the final drive pinion gear and or ring gear gt REAR AXLE FINAL DRIVE GEAR AND DRIVE SHAFT DRIV MEASUREMENT AND ADJUSTING THE FINAL GEAR LASH Final gear lash measurement 1 Secure the gear case in a vise or another supporting device 2 Remove e Drain plug e Gasket 3 Install e A bolt of the specified size 1 into the drain plug hole Finger danen the bolt until it holds the ring gear Otherwise the ring gear will be damaged 4 Attach e Gear lash measurement tool 1 e Dial gauge 2 Gear lash measurement tool P N YM 01475 90890 01475 Measuring point is 31 46 mm 1 24 in 5 Measure e Gear lash Gently rotate the gear coupling from engagement to engagement Final gear lash 0 1 0 2 mm 0 004 0 008 in NOTE LL Measure the gear lash at four positions Rotate the shaft 90 each time REAR AXLE FINAL DRIVE GEAR AND DRIVE SHAFT DRIV Final gear lash adjustment 1 Remove e Bearing housing 1 e Ring gear shim s 2 e Ring gear 3 e Thrust washer 4 2 Adjust e Gear lash kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Adjustment steps eSelect a suitable shim s and
157. inside of the rotor e After installing the rotor check that the rotor rotates smoothly If not reinstall the key and rotor 3 Install e Dowel pins e Gasket e Crankcase cover left 10 Nm 1 0 m kg 7 2 Ib NOTE __ When installing the crankcase cover left use a long rod to hold the rotor in position from the outside This will make assembly easier Be careful not to damage the oil seal e lighten the bolts in stages using a crisscross pattern 4 Install e Starter pulley 1 x50 Nm 5 0 m kg 36 ft Ib NOTE 2 LL Use a rotor holding tool 2 to hold the starter pulley Rotor holding tool P N YU 01235 90890 01235 vz NOTE _ Before installing the starter pulley do not forget to install the O ring PRIMARY AND SECONDARY SHEAVES ENG PRIMARY AND SECONDARY SHEAVES 10 Nm 1 0 m kg 7 2 ft Ib 9 10 Nm 1 0 m kg 7 2 ft Ib Job amp Removing the primary secondary sheave Front fender Rear fender Right footrest board Exhaust pipe bracket Drive belt cover Rubber gasket Bearing housing Dowel pin Primary sliding sheave assembly V belt Remove the parts in the order below Refer to SEAT CARRIERS FENDERS AND FUEL TANK in CHAPTER Refer to REMOVING INSTALLING THE PRIMARY AND SECONDARY SHEAVES
158. k When the 4WD Diff Lock mode is selected the gear motor moves the drive clutch 2 further to the right which causes the ring gear 5 and the drive clutch 2 to engage As a result power is transmitted directly from the ring gear 5 to the drive clutch 2 then to the left front constant velocity joint via the adapter 1 Meanwhile because the ring gear 5 and the drive clutch 2 are engaged the ring gear 5 the drive clutch 2 and the right differential side gear 6 become locked coaxially Thus power is transmitted as follows differential pinion gear 4 right differential pinion gear right front constant velocity joint When the ATV is in the 4WD Diff Lock mode the right and left wheels rotate constantly at the same speed which affects the maneuverability of the ATV e g making it difficult to steer Therefore the maximum traveling speed is limited to 35 km h 22 mph 1 6 FEATURES 976 In addition the 4WD Diff Lock mode can be engaged only when the is stopped Even if an attempt is made to select this mode when the ATV is traveling it will only result in a standby condition i e when the differential lock select switch and the differential gear are not matched 1 When the ATV is traveling Even if the 4WD Diff Lock mode is selected the gear motor will stand by instead of operating Therefore the ATV can be driven in the normal 4WD mode When this occurs the differential gear loc
159. k Checking steps Check the two contact areas on the rocker arms for signs of abnormal wear 1 Rocker arm shaft hole 2 Camshaft lobe contact surface Excessive wear Replace Check the surface of the rocker arm shafts Blue discoloration pitting scratches Replace check lubrication e Measure the inside diameter 8 of the rocker arm holes Out of specification Replace Rocker arm inside diameter 12 000 12 018 mm 0 4724 0 4731 in eMeasure the outside diameter b of the rocker arm shafts Out of specification Replace Rocker arm outside diameter 11 981 11 991 mm 0 4717 0 4721 in eCalculate the clearance by subtracting the rocker arm shaft outside diameter from the rocker arm inside diameter Clearance greater than 0 08 mm 0 003 in Replace the defective part s Rocker arm to shaft standard clearance 0 009 0 037 mm 0 0004 0 0015 in kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk 8 CAMSHAFT ROCKER ARMS AND VALVES ENG CHECKING THE VALVE AND VALVE SPRING 1 Measure Stem to guide clearance Stem to guide clearance valve guide inside diameter 8 valve stem diameter b Out of specification Replace the valve guide Clearance stem to guide Intake 0 010 0 037 mm 0 0004 0 0015 in Limit 0 080 mm 0 0031 in Exhaust 0 030 0 057 mm 0 0012 0 0022 in lt Limit gt 0 100 mm 0 0039 in 2 Re
160. k Thrust washer selection 1 Measure select e Ring gear thrust clearance kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Measurement steps Place four pieces of Plastigauge between the originally fitted thrust washer and the ring gear e Install the ring gear assembly and tighten the bolts to specification 2 8 Bolts bearing housing 23 Nm 2 3 kg 17 Ib M10 Bolts bearing housing 40 Nm 4 0 kg 29 ft Ib NOTE Do not turn the drive pinion gear and ring gear when measuring the clearance with Plastigauge gt REAR AXLE FINAL DRIVE GEAR AND DRIVE SHAFT DRIV Remove the ring gear assembly e Measure the thrust clearance Calculate the width of the flattened Plastigauge Ring gear thrust clearance 0 1 0 2 mm 0 004 0 008 in elf out of specification select the correct washer Thrust washer selection steps Select a suitable thrust washer using the following chart Thrust washer Thickness mm Repeat the measurement steps until the ring gear thrust clearance is within the specified limits kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Ring gear stopper shim selection 1 Measure Ring gear stopper clearance D Use a feeler gauge 1 Out of specification Adjust Ring gear stopper clearance D 0 30 0 60 mm 0 012 0 024 in 2 Ring gear 3 R
161. k indicator light 4 in the speedometer unit will flash to alert the driver that the control is on standby When the ATV is stopped the control transfers to the condition described in 2 2 When the ATV is stopped The gear motor operates to connect the drive clutch to the differential case thus resulting in the differential lock condition When this occurs the differential gear lock indicator light i in the speedometer unit changes to a constant illumination Until the drive clutch and the differential case mesh together i e the splines are unmeshed the engine misfires to control the engine speed During this time the differential gear lock indicator light in the speedometer unit continues to flash IMPORTANT INFORMATION Ed 976 PREPARATION FOR REMOVAL PROCEDURES 1 Remove all dirt mud dust and foreign material before removal and disassembly 2 Use proper tools and cleaning equipment Refer to the SPECIAL TOOLS section 3 When disassembling the machine always keep mated parts together This includes gears cylinder piston and other parts that have been mated through normal wear Mated parts must always be reused or replaced as an assembly 4 During machine disassembly clean all parts and place them in trays in the order of disassembly This will speed up assembly and allow for the correct installation of all parts 5 Keep all parts away from any source
162. ket Brake caliper piston Refer to DISASSEMBLING Dust seal ASSEMBLING THE FRONT AND REAR Caliper piston seal BRAKE CALIPER Bleed screw 9 9 For assembly reverse the disassembly procedure FRONT AND REAR BRAKES CHAS 36 DISASSEMBLING THE FRONT AND REAR BRAKE CALIPER 1 Remove e Brake caliper piston e Dust seal 1 e Caliper piston seal 2 kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Removal steps Blow compressed air into the hose joint opening to force out the caliper piston from the brake caliper body WARNING e Never try to pry out the caliper piston e Cover the caliper piston with a rag Be careful not to get injured when the piston is expelled from the master cylinder e Remove the caliper piston seals kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk EB702040 CHECKING THE FRONT AND REAR BRAKE CALIPER Recommended brake component replacement schedule Piston seal dust seal Every two years Replace when Brake fluid brakes are disassembled WARNING All internal brake components should be cleaned in new brake fluid only Do not use solvents as they will cause seals to swell and distort 1 Check e Brake caliper piston 1 Scratches rust wear the brake caliper assembly e Brake caliper cylinder 2 Wear scratches Replace the brake caliper assembly e Brake caliper body 3 Cracks damage Replace
163. kkkkkkkkkk INSTALLING THE MIDDLE DRIVE SHAFT 1 Tighten e Nut middle drive pinion gear NOTE WW Secure the middle drive shaft in the vise with a clean rag 2 Lock the threads with a drift punch MEASURING THE MIDDLE GEAR BACKLASH 1 Measure e Gear lash Middle gear lash 0 1 0 3 mm 0 004 0 012 in kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Measurement steps Temporarily install the right crankcase e Wrap a rag 2 around a screwdriver 3 and then insert it into the installation hole 1 of the left crankcase speed sensor to hold the middle driven gear MIDDLE GEAR ENG OB e Attach the gear lash measurement tool 3 dial gauge 4 2 Gear lash measurement tool P N YM 01467 90890 01467 8 12 mm 0 32 in eMeasure the gear lash while rotating the middle driven shaft back and forth NOTE _ Measure the gear lash at 4 positions Rotate the middle driven gear 90 each time elf the gear lash is incorrect adjust the gear lash by middle driven pinion gear shims and or middle drive pinion gear shim s kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk 5 COOLING SYSTEM RADIATOR ec UE 5 1 CHECKING THE RADIATOR 5 3 INS TALEING THE RADIATOR 5 4 THERMOSTAT 5 5 CHECKING THE THERMOSTAT qui Ra a IU 5 6 INSTALLING THE THERMOS
164. kkkkkkkkkkkkkkkkkkkkkk Checking steps eCheck the tightening torque of the nuts Swingarm Nut swingarm 25 82 Nm 8 2 kg 59 Ib e Check the swingarm side play by moving it from side to side If side play is noticeable check the bushing and frame pivot eCheck the swingarm vertical movement by moving it up and down If vertical movement is tight or rough or if there is binding check the bushing and frame pivot 2 Remove e Nuts e Bolts e Swingarm CHECKING THE REAR SHOCK ABSORBER 1 Check e Shock absorber Oil leaks Replace the shock absorber assembly e Shock absorber rod Bends damage gt Replace the shock absorber assembly e opring Fatigue Replace the shock absorber assembly Move the spring up and down REAR SHOCK ABSORBER AND SWINGARM CHAS 36 CHECKING THE SWINGARM 1 Check e Swingarm 1 e Rear axle housing 2 Bends cracks damage Replace 2 Check e Bushings 1 Wear damage Replace CHECKING THE RUBBER BOOT 1 Check e Rubber boot 1 Damage Replace INSTALLING THE RUBBER BOOT 1 e Adhesive for rubber to the engine 1 2 Install e Rubber boot 2 NOTE LL Be sure to position the rubber boot so that the tang 3 faces towards the left REAR SHOCK ABSORBER AND SWINGARM CHAS 36 INSTALLING THE REAR AXLE HOUSING 1 Install e Rear axle housing e Final gear case assembly e Rear axle with dust seal kkkkkkkkkkkkkk
165. kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Installation steps Install the drive shaft Refer to REAR AXLE FINAL DRIVE GEAR AND DRIVE SHAFT in CHAPTER 7 Apply sealant Quick Gasket to the mating surfaces of the swingarm and the final gear case Temporarily install the rear axle housing 1 and final gear case assembly 2 on the swingarm bolts and nuts 3 5 should be temporarily tightened Install the rear axle with dust seal from the left side of the machine Refer to REAR AXLE FINAL DRIVE GEAR AND DRIVE SHAFT in CHAPTER 7 Tighten the bolts and nuts in the specified order 8 Nut 4 2 Bolt x4 5 Bolt nut x4 63 Nm 6 3 m kg 45 Ib Bolt 2 63 Nm 6 3 kg 45 Ib Nut 63 Nm 6 3 m kg 45 Ib kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk 9 ELECTRICAL ELECTRICAL COMPONENTS 2 41 1 20102020040041040 00 0000 9 1 CHECKING THE SWITCH 22 12 40 012020200020022000 660 1 9 2 CHECKING THE SWITCH 9 2 CHECKING SWITCH SHOWN THE MANUAL 9 2 CHECKING THE SWITCH CONTINUITY 9 4 CHECKING THE BULBS AND BULB SOCKETS 9 6 TYPES OF BULBS api kc M 9 6 CHECKING THE CONDITION OF THE BULBS
166. kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Installation steps Slide the shift fork sliding gear 1 which is installed to the differential gear to the left to put it into the 2WD mode Connect two C size batteries to the gear motor terminal 2 to operate the pinion gear 3 and operate it until the paint mark 4 on the gear is aligned with the paint mark 5 on the gear motor case Do not use a 12 V battery to operate the pinion gear 8 mm bolts into the gear motor and use them as a guide to set the motor on the differential gear assembly 8 so that the shift fork sliding gear 9 does not move is moved the position of the differential gear and the indicator light display may differ and the 2WD or differential lock mode may not be activated e Remove the 8 mm bolts and then install the motor with the gear motor bolts Bolts gear motor 2 13 Nm 1 3 me kg 9 4 ft Ib kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR DRIV 3 Install e Universal joint yoke e O ring e Washer et q Use a universal joint holder 1 02 1 Universal joint holder P N YM 04062 90890 04062 4 Check e Differential gear operation Unsmooth operation Replace the differential gear assembly Insert the double off set joint into the differential gear and turn the gear back and forth INSTALLING THE UNIVERSAL JOINT 1
167. kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Selection steps To find the ring gear shim thickness B use the following formula Ring gear shim thickness D a numeral usually a decimal number on the final gear case either added to or subtracted from 45 d a numeral usually a decimal number on the outside of the ring gear bearing housing and added to 1 a numeral usually a decimal number on the inside of the ring gear either added to or subtracted from 35 00 D bearing thickness considered constant Bearing thickness f 11 00 mm Example 1 If 53 is stamped on the final gear case 45 0 53 45 53 2 If 05 is stamped on the ring gear bearing housing 1 0 05 1 05 If 05 is stamped on the ring gear 35 0 05 34 95 D 11 00 gt REAR AXLE FINAL DRIVE GEAR AND DRIVE SHAFT DRIV 5 Therefore shim thickness B is 0 63 45 53 1 05 34 95 11 00 46 58 45 95 0 63 6 Round off the hundredth digit and select the appropriate shim s In the example above the calculated number is 0 63 The chart instructs you to round off 3 to 5 at the hundredth place Thus the shim thickness is 0 65 mm 8 9 10 Shims are supplied the following thicknesses oS Ring gear shim 0 25 0 30 0 35 0 40 0 45 0 50 Thickness mm kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk
168. kup coil Stator assembly Rotor Starter wheel gear Woodruff key Washer Starter idle gear shaft Washer bearing Starter idle gear Refer to REMOVING INSTALLING THE A C MAGNETO N AL For installation reverse the removal procedure ZY RECOIL STARTER AND A C MAGNETO oD Job name Disassembling the recoil starter Remove the parts in the order below Cap Starter handle Friction plate Pawl spring Drive pawl Spring Sheave drum Rope Coil spring Refer to DISASSEMBLING ASSEMBLING THE RECOIL STARTER 6 9 For assembly reverse the disassembly procedure RECOIL STARTER AND A C MAGNETO ENG REMOVING THE A C MAGNETO 1 e Starter pulley 1 NOTE Use the rotor holding tool 2 to hold the starter pulley Rotor holding tool P N YU 01235 90890 01235 ye 2 Remove e Crankcase cover left e Gasket e Dowel pins NOTE Working in a crisscross pattern loosen each bolt 1 4 of a turn Remove them after all of them are loosened 3 Remove e Rotor 1 NOTE Use the flywheel puller 2 Flywheel puller P N YM 01404 90890 01404 DISASSEMBLING THE RECOIL STARTER 1 Remove 1 e Starter handle 2 NOTE W Before untying the knot 3 above the starter handle make a knot 2 in the rope so that the rope is not pulled into the case
169. l 12x6 0AT Steel Panel wheel 12x7 5AT Steel 0 04 in 1mm 0 04 in 2mm 0 08 in 2 0 08 MAINTENANCE SPECIFICATIONS SPEC y Item Front disc brake Type Disc outside diameter x thickness Pad thickness Pad thickness Master cylinder inside diameter Caliper cylinder inside diameter Brake fluid type Rear disc brake Type Disc outside diameter x thickness Pad thickness Pad thickness Master cylinder inside diameter Caliper cylinder inside diameter Brake fluid type Brake lever and brake pedal Brake lever free play pivot Brake pedal position Throttle lever free play inner outer inner outer Dual 200 0 3 5 mm 7 87 0 14 in 4 5 0 18 1mm 0 04 in 4 5 mm 0 18 in 1mm 0 04 in 14 mm 0 55 in 32 mm 1 26 in DOT 4 pu Single 220 0 x 3 5 mm 8 66 0 14 in 5 6 mm 0 22 in 5 6 mm 0 22 in 14 mm 0 55 in 32 03 mm 1 26 in DOT 4 mm 0 in 0 5 2 mm 0 02 0 08 in 70 80 mm 2 76 3 15 in 3 5 mm 0 12 0 20 in MAINTENANCE SPECIFICATIONS SPEC y Tightening torques Tightening torque torque Part to be tightened Thread size Remarks i T Engine bracket front upper and frame Engine bracket front lower and frame Engine bracket front upper and engine Engine bracket front lower and engine Engine and frame Frame and bearing retainer steering stem holder bearing Select lever as
170. l seal Remove the circlip 1 and rubber boot 2 Use the ball joint remover and installer set STEERING SYSTEM CHAS 36 Ci Ball joint remover installer set 01474 90890 01474 joint remover installer attachment set P N YM 01477 YM 01474 Body 90890 01474 01474 90890 01474 01477 01477 1477 01477 01477 YM 01477 einstall the body 3 short bolt remover washer 6 and remover spacer 7 onto ball joint NOTE e Remover washer 6 must be aligned with the projection on the head of the ball joint e Surface 8 of the remover spacer 7 must be aligned with surface of the steering knuckle e Hold the body 3 in place while turning in the short bolt to remove the ball joint 4 from the steering knuckle e Remove the ball joint remover installer einstall the long bolt 4 installer spacer and installer guide do onto the body 3 STEERING SYSTEM CHAS 36 e Attach the assembled ball joint remover installer new ball joint 2 and installer attachment 8 to the steering knuckle 3 NOTE nmm Do not tap or damage the top of the ball joint e Hold the body 3 in place while turning in the long bolt to install the new ball joint 2 into the steering knuckle 43 e Remove the ball joint remover installer e Apply lithium soap base grease to the new ball joint 42 e Install ne
171. lace the CDI unit TRBL SHTG CHAPTER 10 TROUBLESHOOTING STARTING FAILURE HARD STARTING 10 1 FUEL SYSTEM ereire Tm 10 1 ELEGTRIGAL SYSTEM societies uxor 10 1 COMPRESSION SYSTEM 45 A 10 2 POOR IDLE SPEED PERFORMANCE 10 2 POOR IDLE SPEED PERFORMANCE 10 2 POOR MEDIUM AND HIGH SPEED PERFORMANCE 10 2 POOR MEDIUM AND HIGH SPEED PERFORMANCE 10 2 FAULTY DRIVE TRAIN eian eniten a ECL Eo beet be eo edet 10 3 FAULTY GEAR SHIFTING 10 4 E 10 4 LEVER DOES NOT MOVE itt atm 10 4 JUMPS OUT OF a 10 4 FAULTY CLUTCH PERFORMANCE 10 4 ENGINE OPERATES BUT MACHINE WILL NOT MOVE 10 4 CEUTCOCRH SEIFPING a a 10 4 POOR STARTING PERFORMANCE 10 4 POOR SPEED PEREORMANG LE oasis E 10 5 OVERHEATING sires 2 sews 10 5 OVERHEATING 10 5 FAULIY BRAKE ste UA 10 5
172. lfide grease Illustrated symbols 65 to in the exploded diagrams indicate where to apply a locking agent and when to install a new part 00 Apply the locking agent LOCTITE 6 Replace TABLE CONTENTS GENERAL INFORMATION h SPECIFICATIONS o U m PERIODIC CHECKS AND Q ADJUSTMENTS ADs 3 ENGINE s COOLING SYSTEM 41 CARBURETION CAR t i T DRIVE TRAIN 2 lt m CHASSIS ELECTRICAL TROUBLESHOOTING o Or SHT 1 GENERAL INFORMATION MACHINE IDENTIFICA TION scsntiteienindeeGnhin ei qr tu adu eR 1 1 VEHICLE IDENTIFICATION NUMBER 1 1 yu B NIE S1 arna 1 1 FEATURE tt nnde een eee M NE 1 2 COOLING ENGINE emet deu tq n 1 2 Mtr 1 2 FRONTDIEFERENTIALE det 1 3 IMPORTANT INFORMATION 2 1 8 PREPARATION FOR REMOVAL PROCEDURES 1 8 RERLACEMENT PARTO Dou le IRE dU 1 8 GASKETS OIL SEALS AND O RINGS 1 8 LOCK WASHERS PLATES AND COTTER PINS 1 9 BEARINGS AND OIE SEAES atquc eR Eri oasis Pedum 1 9 Hi E 1 9 CHECKING OF CONNECTIONS
173. linder head breather hose Vacuum chamber breather hose Air filter case For installation reverse the removal procedure ENGINE REMOVAL ENG SELECT LEVER UNIT AND COOLANT RESERVOIR 14 Nm 1 4 m kg 10 ft Ib 23 Nm 2 3 m kg 17 ft Ib Job nameiPart Removing the select lever unit and Hemove the parts in the order below coolant reservoir Shift arm Select lever shift rod Select lever unit Coolant reservoir breather hose Coolant reservoir hose Coolant reservoir For installation reverse the removal procedure ENGINE REMOVAL ENG 8 HOSES AND LEADS Job name Part name Remarks Removing the hoses and leads Remove the parts in the order below Water pump inlet hose Refer to WATER PUMP in CHAPTER 5 Cylinder head breather hose Spark plug lead Thermo switch 1 lead Starter motor lead A C magneto lead coupler Speed sensor lead coupler Reverse switch lead Green White Neutral switch lead Sky blue High range switch Blue White Low range switch White Red Engine ground lead gt eek O For installation reverse the removal procedure ENGINE MOUNTING BOLTS COON DOOR WD 133 Nm 3 3 m kg 24 ft Ib Removing the engine mounting bolts Rear wheels Swingarm Engine mounting bolt rear lower nut Engine mounting bolt rear upper nut Engine bracket bolt front lower Engine mounting bolt font lower Engine bracket fron
174. lt to distinguish from normal machine operating noise If there is reason to believe these components are damaged remove the components and check them 1 Check e Unusual noises kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk The following noises may indicate a mechanical defect a A rolling rumble noise during coasting acceleration or deceleration The noise increases with front and or rear wheel speed but it does not increase with higher engine or transmission speeds Diagnosis Possible wheel bearing damage b A whining noise that varies with acceleration and deceleration Diagnosis Possible incorrect reassembly too little gear lash gt TROUBLESHOOTING DRIV Too little gear lash is extremely destructive to the gear teeth If a test ride following reassembly indicates this condition stop riding immediately to minimize gear damage C A slight thunk evident at low speed operation This noise must be distinguished from normal machine operation Diagnosis Possible broken gear teeth WARNING Stop riding immediately if broken gear teeth are suspected This condition could result in the shaft drive assembly locking up causing loss of control of the machine and possible injury to the rider kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk 2 Check Drained oil Drained oil shows large amounts of metal particles Check the bearing for seizure NOTE __
175. ly wash them with water e Do not mix different types of antifreeze 13 Install e Radiator cap 14 F ill e Coolant reservoir with the recommended coolant to maximum level mark 15 Install e Coolant reservoir cap 16 Start the engine warm it up for several minutes and then turn it off 17 Check e Coolant level Refer to CHECKING THE COOLANT LEVEL NOTE _ Before checking the coolant level wait a few minutes until the coolant has settled 18 Install e Left footrest board Refer to FOOTREST BOARDS e Front fender e Engine skid plate e Front carrier e Engine side cover e Fuel tank side panel left e Seat Refer to SEAT CARRIERS FENDERS AND FUEL TANK CHECKING THE V BELT CHECKING THE V BELT 1 Remove e Right footrest board e Crankcase cover right Refer to PRIMARY AND SECONDARY SHEAVES in CHAPTER 4 2 Check e V belt 1 Cracks wear scaling chipping Replace Oil grease Check primary sheave and secondary sheave 3 Measure e V belt width 2 Out of specification Replace V belt width 30 7 mm 1 21 in lt Limit gt 27 6 mm 10 9 in CHECKING THE V BELT CLEANING THE SPARK ARRESTER ADJ Q 1 0 mm 0 04 4 uM V belt NN 0 24 in e 45 mm 1 77 in Replacing steps einstall the bolts 1 90101 06016 into the secondary fixed sheave hold NOTE T
176. mes of parts notes in jobs etc 5 For jobs requiring more information the step by step format supplements 8 are given in addition to the exploded diagram and the job instruction chart 22 Xp 3 E ENG up CLUTCH REMOVING THE CLUTCH 1 Remove NS e Clutch housing assembly e Gasket e Dowel pins NOTE LL Working in crisscross pattern loosen each bolt 1 4 of a turn Remove them after all of them Ky NN ES x are loosened 5 e 2 Straighten 8 Q te lt I 3 cT A e Punched portion of the nut 3 Remove e Nut D NOTE 22 Use a clutch holding tool to hold the clutch carrier assembly Clutch holding tool P N YM 91042 90890 04086 gt CHECKING THE CLUTCH 6 V 1 Check e Clutch housing CD Heat damage wear damage Replace One way clutch bearing Chating wear damage Replace 10 Nm 1 0 m kg 7 2 ft Ib NOTE e Replace the one way clutch assembly and clutch housing as a set e The one way clutch bearing must be installed with the arrow mark side facing up Job name Part name j Remarks Removing the clutch Remove the parts in the order below Primary and secondary sheaves Refer to PRIMARY AND SECONDARY SHEAVES Checking steps e Install the one way clutch bearing and clutch carrier assembly to the clutch housing and Cover Clutch housing assembl
177. n red and brown blue and between red and brown when the switch is set to ON CHECKING THE SWITCH ELEC CHECKING THE SWITCH ELEC CHECKING THE SWITCH CONTINUITY Refer to CHECKING THE SWITCH and check for continuity between lead terminals Poor connection no continuity Correct or replace The coupler locations are circled 9 JRWRB B ots BLACK LB Br BLACK GRAY XT eee 4 eee eee ee ees el BLACK mi X A BLACK uide P __ 4 E d M 5 p SUP Br e 4 d 4 dg Ed a ae 018 i BT HT Hi E p Lo EQ CHECKING THE SWITCH CD Light switch 2 Engine stop switch 3 Start switch 4 On command four wheel drive switch and differential gear lock switch 5 Main switch 6 Rear brake light switch 7 Front brake light switch Rear brake switch 9 Horn switch for Europe and Oceania Reverse switch 17 Neutral switch 2 High range switch 3 Low range switch Fuse CHECKING THE BULBS AND BULB SOCKETS ELEC 18410603 18410604 EB8010 CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage wear proper connections and also for continui
178. n the spark plug with a spark plug cleaner or wire brush 18040201 6 Measure e Plug gap Use a wire gauge or feeler gauge Out of specification gt Regap Spark plug gap 0 6 0 7 mm 0 024 0 028 in 7 Tighten ae e Spark plug NOTE Before installing a spark plug clean the gasket surface and plug surface 8 Install e Fuel tank side panel right e Seat Refer to SEAT CARRIERS FENDERS AND FUEL TANK CHECKING THE IGNITION TIMING CHECKING THE IGNITION TIMING NOTE _ Engine idling speed and throttle cable free play should be adjusted properly before checking the ignition timing 1 Remove e Seat e Fuel tank side panel right Refer to SEAT CARRIERS FENDERS AND FUEL TANK 2 Attach e Inductive tachometer or engine tachometer e Timing light to spark plug lead Inductive tachometer P N YU 8036 A Engine tachometer P N 90890 03113 Timing light P N YM 33277 A 90890 03141 3 Check e Ignition timing kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Checking steps eWarm up the engine and keep it at the specified speed Engine speed ey 1 450 1 550 r min Remove the recoil starter 1 Remove the timing plug 2 e Visually check the stationary pointer 3 to verify it is within the required firing range 4 indicated on the flywheel Incorrect firing range Check the pulser coil assembly e Install the timing plug e Install t
179. ng gear and the differential gear cover should be fastened together not disassemble the differential gear assembly The differential gears are assembled into a proper unit at the factory by means of specialized equipment Do not attempt to disassemble this unit Disassembly will result in the malfunction of the unit FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR DRIV CHECKING THE CONSTANT VELOCITY JOINT 1 Check e Double off set joint spline e Ball joint spline e Shaft spline Wear damage Replace 2 Check e Dust boots Cracks damage Replace 3 Check e Balls and ball races e Inner surface of double off set joint Pitting wear damage Replace CHECKING THE DIFFERENTIAL GEAR 1 Check e Gear teeth Pitting galling wear Replace drive pinion gear and ring gear as a set e Bearing Pitting damage Replace e Oil seal e O ring Damage Replace 2 Check e Drive shaft splines e Universal joints e Front drive gear splines Wear damage Replace e Spring Fatigue Replace Move the spring up and down 3 Check e Front drive shaft Bends Replace WARNING Do not attempt to straighten bent shaft this may dangerously weaken the shaft FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR DRIV 1 e Gear motor kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Checking steps
180. ng steps ePlace a straightedge and a feeler gauge across the cylinder head e Use a feeler gauge to measure the warpage elf the warpage is out of specification resurface the cylinder head Place a 400 600 grit wet sandpaper on the surface plate and resurface the head using a figure eight sanding pattern NOTE W 7777 To ensure an even surface rotate the cylinder head several times kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk CYLINDER HEAD ENG INSTALLING THE CYLINDER HEAD 1 Install e Cylinder head e Bolt M10 Bolt M6 NOTE e Lubricate the washer with engine oil e Tighten the bolts M10 in two stages and a crisscross pattern e 2 Install e Camshaft sprocket kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Installing steps Rotate the camshaft to align the camshaft 1 with the cylinder head match mark Turn the crankshaft counterclockwise with wrench Align the mark 3 on the rotor with the stationary pointer on the crankcase cover When the mark is aligned with the stationary pointer the piston is at the Top Dead Center T D C Do not turn the crankshaft during the camshaft sprocket installation ePlace the timing chain onto the camshaft sprocket einstal the camshaft sprocket onto the camshaft and finger tighten the sprocket bolt CYLINDER HEAD ENG NOTE Be sure the mark on the camshaft sprock
181. ng tool 2 to hold the clutch carrier assembly Clutch holding tool P N YM 91042 90890 04086 vz CHECKING THE CLUTCH 1 Check e Clutch housing 1 Heat damage wear damage Replace e One way clutch bearing 2 Chafing wear damage Replace NOTE e Replace the one way clutch assembly and clutch housing as a set e The one way clutch bearing 2 must be installed with the arrow mark side facing up kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Checking steps Install the one way clutch bearing and clutch carrier assembly to the clutch housing and hold the clutch carrier assembly eWhen turning the clutch carrier assembly clockwise A the clutch carrier assembly should turn freely If not the one way clutch assembly is faulty Replace it eWhen turning the clutch carrier assembly counterclockwise the clutch housing and clutch carrier assembly should be engaged If not the one way clutch assembly is faulty Replace it kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk 4 53 8 ENG 2 Check e Clutch shoe Heat damage Replace 3 Measure e Clutch shoe thickness Out of specification Replace Clutch shoe thickness 1 5 mm 0 06 in Clutch shoe wear limit 1 0 mm 0 04 in INSTALLING THE CLUTCH 1 Install e Collar e Clutch carrier assembly e Nut NOTE L e
182. ntil the coolant has settled 6 Install e Fuel tank side panel left e Seat Refer to SEAT CARRIERS FENDERS AND FUEL TANK CHANGING THE COOLANT CHANGING THE COOLANT 1 Remove e Seat e Fuel tank side panel left e Engine side cover e Front carrier e Engine skid plate e Front fender Refer to SEAT CARRIERS FENDERS AND FUEL TANK e Left footrest board Refer to FOOTREST BOARDS 2 Remove e Plastic band 1 e Coolant reservoir bolts e Coolant reservoir 3 3 Disconnect e Coolant reservoir breather hose 4 Drain e Coolant from the coolant reservoir 5 Connect e Coolant reservoir breather hose 6 Install e Coolant reservoir bolts e Plastic band 7 e Radiator 1 WARNING hot radiator is under pressure Therefore do not remove the radiator cap when the engine is hot Scalding hot fluid and steam may be blown out which could cause serious injury When the engine has cooled open the radiator cap as follows Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap counterclockwise toward the detent to allow any residual pressure to escape When the hissing sound has stopped turn the radiator cap counterclockwise while pressing down on it and then remove it CHANGING THE COOLANT 8 Remove e Coolant drain bolt cylinder 1 along with the copper washer e Coolant drain bolt water pump along with
183. o CHANGING THE COOLANT in CHAPTER 3 Radiator inlet hose Thermostat cover Thermostat For installation reverse the removal procedure THERMOSTAT coo CHECKING THE THERMOSTAT 1 Check e Thermostat 1 Does not open at 63 5 66 5 C 146 3 151 7 F Replace kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Checking steps e Suspend the thermostat in a container filled with water e Slowly heat the water Place a thermometer in the water eWhile stirring the water observe the thermostat thermometers indicated temperature kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk D Thermostat 2 Thermometer 3 Water 2 Container Fully closed Fully open NOTES If the accuracy of the thermostat is in doubt replace it A faulty thermostat could cause serious overheating or overcooling 2 Check e Thermostat cover 176 F Cracks damage Replace Temperature 14250201 INSTALLING THE THERMOSTAT 1 Install e hermostat 1 e Thermostat cover NOTE Install the thermostat with its breather hole toward the projection b 2 Fill e Cooling system with the specified amount of the recommended coolant Refer to CHANGING THE COOLANT in CHAPTER 3 3 Check e Cooling system Leak Repair or replace any faulty part WATER PUMP coo WATER PUMP 10 Nm 1 0 m kg 7 2 ft Ib Job name Part nam
184. o remove the YU 01083 A rocker arm shaft Crankcase separating tool 90890 01135 YU 01135 A This tool is used to separate the crankcase Valve guide remover 7 0 mm 90890 01225 YM 01225 A This tool is needed to remove and install the valve guide Valve guide installer 7 0 mm 90890 0401 7 YM 04017 This tool is needed to install the valve guide Valve guide reamer 7 0 mm 90890 01227 YM 01227 This tool is needed to rebore the new valve guide Rotor holding tool This tool is needed to hold the starter 2 pulley when removing installing the starter pulley bolt or camshaft sprocket bolts Buffer boss installer set 90890 04088 Crankshaft installer bolt Bolt 90890 01275 These tools are used to install the crankshaft SPECIAL TOOLS Ed Crankshaft installer set YU 90050 Adapter YM 33279 Spacer 90890 04060 YM 90070 A 90890 01304 YU 01304 90890 01311 YU 08035 90890 01312 YM 01312 A 90890 01325 YU 24460 01 90890 01352 YU 33984 90890 01348 90890 04134 YM 04134 These tools are used to install the crankshaft Adapter 11 Spacer crankshaft These tools are used to install the crankshaft Piston pin puller set This tool is used to remove the piston pin Tappet adjusting tool 8 mm This tool is necessary for adjusting the valve clearance Fuel level gauge This gauge is used to measure the fuel level in the float chamber Radia
185. oard 1 3 Footrest bracket For installation reverse the removal procedure 4o ADJUSTING THE VALVE CLEARANCE ADJ ENGINE ADJUSTING THE VALVE CLEARANCE NOTE e he valve clearance must be adjusted when the engine is cool to the touch e Adjust the valve clearance when the piston is at the Top Dead Center T D C on the compression stroke 1 Remove e Seat e Front carrier e Front fender e Fuel tank Refer to SEAT CARRIERS FENDERS AND FUEL TANK 2 Remove Tappet cover intake 1 e cover exhaust 2 3 Disconnect e Spark plug 3 4 Remove e 5 plug 5 Remove e Recoil starter 1 6 Remove e Timing plug 1 4o ADJUSTING THE VALVE CLEARANCE ADJ 7 Check e Valve clearance Out of specification Adjust Valve clearance cold Intake 0 06 0 10 mm 0 0024 0 0039 in Exhaust 0 16 0 20 mm 0 0063 0 0079 in kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Checking steps e Turn the crankshaft counterclockwise with a wrench Align the mark on the rotor with the stationary pointer on the crankcase cover When the T mark is aligned with the stationary pointer the piston is at the Top Dead Center T D C NOTE e When the piston is at the Top Dead Center T D C on the compression stroke there Should be clearance
186. of fire EB101010 REPLACEMENT PARTS 1 Use only genuine Yamaha parts for all replacements Use and grease recommended by Yamaha for all lubrication jobs Other brands may be similar in function and appearance but inferior in quality EB101020 GASKETS OIL SEALS AND O RINGS 1 Replace all gaskets seals and O rings when overhauling the engine All gasket surfaces oil seal lips and O rings must be cleaned 2 Properly oil all mating parts and bearings during reassembly Apply grease to the seal lips IMPORTANT INFORMATION Fd 976 101030 LOCK WASHERS PLATES AND COTTER PINS 1 Replace all lock washers plates G and cotter pins after removal Bend lock tabs along the bolt or nut flats after the bolt or nut has been tightened to specification EB101040 BEARINGS AND OIL SEALS 1 Install bearings and oil seals so that the manufacturer s marks or numbers are visible When installing oil seals apply a light coating of lightweight lithium base grease to the seal lips Oil bearings liberally when installing if appropriate 1 Oil seal not use compressed air to spin the bearings dry This will damage the bearing surfaces D Bearing EB101050 CIRCLIPS 1 Check circlips carefully before reassembly Always replace piston pin clips after one use Replace distorted circlips When installing a circlip make sure that the sharp edged corner 2 is positioned opposite the thrust 3 it re
187. on off set Offset direction Piston pin bore inside diameter Piston pin outside diameter Piston rings Top ring Type Dimensions B x T End gap installed Side clearance installed Clockwise Clockwise 0 040 0 065 mm 0 0016 0 0026 in 84 445 84 460 mm 3 3246 3 3252 in 5 mm 0 20 in 0 5 mm 0 0200 in Intake side 20 004 20 015 mm 0 7876 0 7880 in 19 991 20 000 mm 0 7870 0 7874 in Barrel 1 0 x 3 1 mm 0 03937 x 0 1220 in 0 20 0 40 mm 0 0079 0 0157 in 0 03 0 07 mm 0 0012 0 0028 in Limit 2 5 1 6 mm 2 5 0 06 in 2 5 1 6 mm 2 5 0 06 in 0 150 mm 0 0059 in 20 045 mm 0 7892 in 19 971 mm 0 7863 in 0 65 mm 0 0256 in 0 12 mm 0 0047 in MAINTENANCE SPECIFICATIONS SPEC y 2nd ring Type Dimensions B x T End gap installed Side clearance Taper 1 0 x 3 6 mm 0 0394 x 0 1417 in 0 40 0 60 mm 0 0157 0 0236 in 0 02 0 06 mm 0 0008 0 0024 in 0 95 mm 0 0374 in 0 12 mm 0 0047 in Oil ring m Dimensions B x T 2 0 x 2 8 mm 0 0787 x 0 1102 in End gap installed 0 2 0 7 mm 0 0079 0 0276 in Crankshaft Crank width A 62 95 63 00 mm 2 4783 2 4803 in Runout limit C1 0 03 0 0012 2 0 03 0 0012 Big end side clearance 0 25 0 75 mm 1 00 mm 0 0098 0 0295 in 0 0394 in Big end radial clearance E 0 010 0 025 mm 0 0
188. onnect the lighting system Check the condition of each of the lighting system s circuits Refer to CHECKING THE LIGHTING SYSTEM LIGHTING SYSTEM ELEC NO CONTINUITY Replace the bulb and or bulb socket EB805020 CHECKING THE LIGHTING SYSTEM 1 If the headlights fail to come on 2 Voltage e Connect the pocket tester DC 20 V to the headlight couplers Tester lead gt Green terminal 1 or Yellow terminal 2 Tester lead Black terminal 3 When the light switch is on When the light switch is on OUT OF SPECIFICATION e Turn the main switch to ON e Turn the light switch to Z0 or O 2 e Check the voltage 12 V of the Green and Yellow leads on the bulb socket connector MEETS SPECIFICATION This circuit is not faulty The wiring circuit from the main switch to the bulb socket connector is faulty repair it LIGHTING SYSTEM ELEC NO CONTINUITY EB805021 2 1 the taillight fails to come on 1 Bulb and bulb socket e Check the bulb and bulb socket for continuity CONTINUITY e Connect the pocket tester 20 V to the bulb socket coupler L Tester lead Blue lead Y Tester lead Black lead 2 B Replace the bulb and or bulb socket 2 Voltage e Turn the light switch to ZO or O e Check the voltage 12 V of the Blue lead on the bulb socket connector MEE
189. ose thermo switch 6 Radiator outlet hose lead 2 and fan motor breather hose with a plastic 7 Coolant reservoir hose band Sub wire harness 9 Differential gear case breather hose Thermo switch 2 Z anan gt 20 c eee Lad Ser Nan f 55 x 1 CABLE ROUTING SPEC y CD Cylinder head breather hose 2 Fuel hose 2 Final drive gear case breather hose 3 Low range switch 3 Wire harness High range switch 4 Starter motor lead 5 Neutral switch lead 6 Negative battery lead Reverse switch lead Air filter case check hose 7 Rectifier regulator 7 Water pump breather hose Radiator outlet hose 9 Starter cable Float chamber air vent hose 1 Cylinder head breather hose S Up S dd d Ma Z Za 4 p 2 8 mm 0 08 0 03 in e 29 6 9 2 15 2 y 5 0 gt 2 4 KS A lt A Y A 52 MIO FD AO J Qu Im A ASA M oS es DE aT 8 CABLE ROUTING v Fasten the wire harness with a plastic band Fasten the starter motor lead wire harness negative battery lead final gear case breather hose rectifier regulator lead low range switch lead high range switch lead neutral switch lead reverse switch lead speed sensor
190. over 1 e Water pump housing 2 e Impeller 3 e Rubber damper 4 e Rubber damper holder 5 Cracks damage wear Replace 2 Check e Water pump outlet pipe Cracks damage wear Replace s WATER Pump COOL 3 Measure e Impeller shaft tilt Out of specification Replace Max impeller shaft tilt 0 15 mm 0 006 in D Straightedge 2 Impeller 14150203 ASSEMBLING THE WATER PUMP 1 Install e Oil seal 1 into the water pump housing 2 NOTE Bam Install the oil seal with a socket 3 that 0 33 matches its outside diameter 2 Install e Water pump seal 1 into the water pump housing 2 NOTE 2 LL Before installing the water pump seal 1 apply tap water or coolant onto its outer surface Never lubricate the water pump seal surface with oil or grease NOTES Install the water pump seal with the special tools gt Mechanical seal installer 5 P N YM 33221 90890 04078 Middle driven shaft bearing driver P N YM 04058 1 90890 04058 Push down WATER PUMP coo 3 Install e Rubber damper 1 e Rubber damper holder 2 NOTE Before installing the rubber damper apply tap water or coolant onto its outer surface 14150204 ake sure that the rubber damper and rubber damper holder are flush with the impeller 6 CARBURETION CARBU
191. place e Valve guide kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Replacement steps NOTE LL To ease guide removal installation and to maintain correct fit heat the cylinder head to 100 C 212 F in an oven Remove the valve guide using a valve guide remover 1 the new valve guide using a valve guide remover 1 and valve guide installer 2 installing the valve guide bore the valve guide using a valve guide reamer 3 to obtain proper stem to guide clearance Valve guide remover 7 0 mm P N YM 01225 A 90890 01225 Valve guide installer 7 0 P N YM 04017 90890 04017 Valve guide reamer 7 0 mm P N YM 01227 90890 01227 ye lt _____ After replacing the valve guide reface the valve Seat kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk 302 013 4 21 8 CAMSHAFT ROCKER ARMS AND VALVES ENG 3 Check Valve face Pitting wear Grind the face e Valve stem end Mushroom shape or diameter larger than the body of the stem Replace 4 Measure e Margin thickness Out of specification Replace Margin thickness Intake 1 0 1 4 mm 0 0394 0 0551 in Exhaust 0 8 1 2 mm 0 0315 0 0472 in 5 Measure e Runout valve stem Out of specification Replace Runout limit 0 01 mm 0 0004 in LL Sl _ e When installing a new valve always replace the guide
192. ppet cover O ring 2 2 Thermo switch 1 lead Timing chain tensioner cap bolt Timing chain tensioner gasket Camshaft sprocket Cylinder head Cylinder head gasket Dowel pin O ring Disconnect Refer to REMOVING INSTALLING THE CYLINDER HEAD n For installation reverse the removal procedure CYLINDER HEAD ENG REMOVING THE CYLINDER HEAD 1 Align e T mark with stationary pointer 8 kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Checking steps e Turn the crankshaft counterclockwise with wrench Align the T mark 1 on the rotor with the stationary pointer 2 on the crankcase cover When the mark is aligned with the stationary pointer the piston is at the Top Dead Center T D C NOTE l e When the piston is at the Top Dead Center T D C on the compression stroke there should be clearance between the valve stem tips and their respective rocker arm adjusting SCrews e If there is no clearance rotate the crankshaft counterclockwise one turn kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk 2 Loosen e Camshaft sprocket bolt 1 NOTE Use the rotor holding tool 2 to hold the starter pulley Rotor holding tool P N YU 01235 90890 01235 lt gt 3 Loosen e Timing chain tensioner cap bolt 4 Remove e Timing chain tensioner e Camshaft sprocket CYLINDER HEAD
193. r e Seat Refer to SEAT CARRIERS FENDERS AND FUEL TANK ADJUSTING THE IDLING SPEED 1 Start the engine and let it warm up for several minutes 2 Remove e Seat e Fuel tank side panels Refer to SEAT CARRIERS FENDERS AND FUEL TANK 3 Attach e Inductive tachometer or engine tachometer to the spark plug lead Inductive tachometer P N YU 8036 A Engine tachometer P N 90890 03113 4 Check e Engine idling speed Out of specification Adjust Engine idling speed bed 1 450 1 550 r min ADJUSTING THE IDLING SPEED CHK ADJUSTING THE THROTTLE LEVER FREE PLAY ADJ Q 5 Adjust Engine idling speed kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Adjustment steps e Turn the throttle stop screw 1 in or out until the specified idling speed is obtained Idling speed becomes higher Idling speed becomes lower 6 Detach Inductive or engine tachometer 7 Adjust Throttle lever free play Refer to ADJUSTING THE THROTTLE LEVER FREE PLAY Throttle lever free play 3 5 mm 0 12 0 20 in 8 Install e Fuel tank side panels e Seat Refer to SEAT CARRIERS FENDERS AND FUEL TANK ADJUSTING THE THROTTLE LEVER FREE PLAY NOTE W Engine idling speed should be adjusted properly before adjusting the throttle lever free play 4 ADJUSTING THE THROTTLE LEVER FREE PLAY ADJ 1 Check e Throttle lever free play 3 Out of specification
194. r to CRANKCASE Circlip Bearing Universal joint Universal joint yoke Bearing housing O ring Shim Refer to SELECTING THE MIDDLE DRIVE AND DRIVEN GEAR SHIM Middle drive pinion gear Refer to REMOVING INSTALLING THE Bearing retainer MIDDLE DRIVEN SHAFT Damper cam Spring Gear coupling Refer to REMOVING INSTALLING THE MIDDLE DRIVEN SHAFT MIDDLE GEAR ENG 8 97 Nm 9 7 kg 70 ft Ib 25 Nm 2 5 m kg 18 ft Ib Job 12 1 Bearing retainer 13 Middle driven shaft For installation reverse the removal procedure MIDDLE GEAR ENG oD REMOVING THE MIDDLE DRIVE SHAFT 1 Straighten e Punched portion of the nut middle drive pinion gear 2 Loosen e Nut middle drive pinion gear 1 NOTE EE Secure the middle drive shaft in the vise with clean rag 3 Remove e Nut middle drive pinion gear e Middle drive pinion gear e Shim s REMOVING THE MIDDLE DRIVEN SHAFT 1 Remove e Universal joint kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Removal steps e Remove the circlips 1 e Place the U joint in a press e With a suitable diameter pipe 2 beneath the yoke 3 press the bearing into the pipe as shown NOTE LL It may be necessary to lightly tap the yoke with a punch e Repeat the steps for the opposite bearing e Remove the yoke NOTE It may be necessary to lightly tap the yoke with
195. rench P N YM 04128 90890 04128 Ko MIDDLE GEAR ENG Tighten the bearing retainer e The middle driven shaft bearing retainer has left handed threads To tighten the retainer turn it counterclockwise Bearing retainer 2 110 Nm 11 0 m kg 80 Ib IG TOSI IG IE IO TE III TI TA TOI I k 3 Install e Shims 1 e Bearing housing NOTE _ Install the shims so that the tabs are positioned as shown in the illustration 4 Install e Universal joint yoke rear side e Washer C A NOTE Use the universal joint holder 2 to hold the yoke Universal joint holder P N YM 04062 90890 04062 5 Install e Universal joint kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Installation steps Install the opposite yoke into the U joint Apply wheel bearing grease to the bearings MIDDLE GEAR ENG e Install the bearing 1 onto the yoke e 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 e Press each bearing into the U joint using suitable socket NOTE nmm The bearing must be inserted far enough into the U joint so that the circlip can be installed e Install the circlips into the groove of each bearing kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk
196. retaining bolt Loosen THE FRONT BRAKE Brake pad holding bolt Loosen CALIPER Brake caliper mounting bolt Brake caliper assembly For installation reverse the removal procedure FRONT AND REAR BRAKES CHAS 36 6 Nm 0 6 m kg 4 3 ft Ib 22 Nm 2 2 m kg 16 ft Ib Job Disassembling the front brake Remove the parts in the order below caliper Brake pad holding bolt Brake pad pad shim Pad spring Retaining bolt Caliper bracket Brake caliper piston Refer to DISASSEMBLING Dust seal ASSEMBLING THE FRONT AND REAR Caliper piston seal BRAKE CALIPER Bleed screw 6 For assembly reverse the disassembly procedure FRONT AND REAR BRAKES CHAS 56 REAR BRAKE CALIPER 18 Nm 1 8 m kg 13 ft Ib 30 Nm 3 0 m kg 22 ft Ib Job Removing the rear brake caliper Remove the parts in the order below Brake fluid Drain Rear wheel Refer to FRONT AND REAR WHEELS Union bolt Copper washer Refer to INSTALLING Brake hose Disconnect THE REAR BRAKE Brake pad holding bolt Loosen CALIPER Brake caliper mounting bolt Brake caliper assembly For installation reverse the removal procedure FRONT AND REAR BRAKES CHAS 36 6 Nm 0 6 m kg 4 3 ft Ib Job name Part name Remarks Disassembling the rear brake caliper Brake pad holding bolt Brake pad insulator pad shim Pad spring Caliper brac
197. rse the removal procedure 8 CRANKSHAFT AND OIL PUMP ENG OIL PUMP 7 Nm 0 7 m kg 5 1 ft Ib Job nameiPart Disassembling the oil pump Remove the parts in the order below Rotor cover Pin Shaft Pin Inner rotor Outer rotor Oil pump housing For assembly reverse the disassembly procedure CRANKSHAFT AND OIL PUMP CRANKSHAFT AND OIL PUMP ENG 17 REMOVING THE CRANI THE CRANKSHAFT 1 Remove e Crankshaft seal 1 NOTE 7777 222 Mark a note of the position of each crankshaft seal so that they can be installed in the correct place and in the correct direction 2 Remove e Crankshaft Use a crankcase separating tool 1 Ko Crankcase separating tool P N YU 01135 A 90890 01135 CHECKING THE OIL PUMP 1 Check e Oil pump driven gear e Oil pump housing Rotor cover Cracks wear damage Replace 2 Measure e Tip clearance 8 between the inner rotor 1 and the outer rotor 2 e Side clearance b between the outer rotor 2 and the pump housing 3 Out of specification Replace the oil pump Tip clearance 3 0 15 mm 0 006 in Limit 0 20 mm 0 008 Side clearance 0 04 0 09 mm 0 002 0 004 in e CRANKSHAFT AND OIL PUMP ENG 3 Check e Oil pump operation Unsmooth Repeat steps 1 and 2 or replace the defective parts CHECKING THE CRANKSHAFT 1 Measure e Crank width Out of specif
198. s Obstruction Clean Apply compressed air to the rear of the radiator Damage Repair or replace NOTE _ Straighten any flattened fins with a thin flat head screwdriver 2 Check e Radiator hoses Cracks damage Replace 3 Measure e Radiator cap opening pressure Below the specified pressure Replace the radiator cap Radiator cap opening pressure 93 7 122 6 kPa 0 937 1 226 kg cm 13 32 17 43 psi kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Measurement steps Install the radiator cap tester 1 and adapter 2 onto the radiator cap 3 Radiator cap tester gt P N YU 24460 01 90890 01325 Adapter P N YU 33984 90890 01352 Apply the specified pressure for ten seconds and make sure that there is no drop in pressure 4 Check e Radiator fan Damage Replace Malfunction Check and repair Refer to COOLING SYSTEM in CHAPTER 9 RADIATOR coo INSTALLING THE RADIATOR 1 Fill e Cooling system with the specified amount of recommended coolant Refer to CHANGING THE COOLANT in CHAPTER 3 2 Check e Cooling system Leaks Repair or replace any faulty part THERMOSTAT coo THERMOSTAT 10 Nm 1 0 m kg 7 2 ft Ib Job name Part name Removing the thermostat Remove the parts in the order below Seat and fuel tank side panel right Refer to SEAT AND SIDE PANELS in CHAPTER 3 Coolant Drain Refer t
199. se and remove the defective bulb WARNING Keep flammable products your hands away from the bulb while it is on since it will be hot Do not touch the bulb until it cools down 3 62 CHANGING THE HEADLIGHT BULB 3 Install e Bulb secure the new bulb with the headlight unit Avoid touching the glass part of the bulb Keep it free from oil otherwise the transparency of the glass life of the bulb and luminous flux will be adversely affected If oil gets on the bulb thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 4 Install e Bulb holder e Cover CHAPTER 4 ENGINE ENGINE REMOVAL ich vent ettet o ei eee 4 1 AIR DUCTS MUFFLER AND EXHAUST PIPE _ 4 1 SELECT LEVER UNIT AND COOLANT RESERVOIR 4 3 HOSES AND LEADS ee 4 4 ENGINE MOUNTING BOLTS 1 2 2 0 1 0 4 5 INSTALLING THE ENGINE nit a 4 7 CYLINDER HEAD 4 8 REMOVING THE CYLINDER HEAD 4 10 CHECKING THE TAPPET GOV ER nentes rettet eris Ga teens 4 11 CHECKING THE TIMING CHAIN TENSIONER 2 4 11 CHECKING THE CAMSHAFT SPROCKET 4 11 CHECKING THE CYLINDER HEAD 4 12 INSTALLING THE CYLINDER HEAD
200. sembly and frame Swingarm Rear shock absorber and frame Final gear case and swingarm Final gear case and rear axle housing Swingarm and rear axle housing Differential gear case and frame Front arm and frame Front shock absorber and frame Front shock absorber and upper front arm Steering stem pitman arm and frame Steering stem holder and frame 17 Use lock washer Steering stem and handlebar holder Pitman arm and tie rod end Tie rod and locknut Steering knuckle and upper front arm Steering knuckle and lower front arm Steering knuckle and tie rod Fuel tank and fuel cock Front wheel and wheel hub Front axle and wheel hub Steering knuckle and brake caliper Front brake disc and wheel hub Rear wheel and rear wheel hub Rear axle and nut Rear axle housing and rear brake caliper Rear brake disc and brake disc bracket Front brake pipe nut Front brake hose union bolt Rear brake hose union bolt Bleed screw Master cylinder and handlebar Footrest and frame MAINTENANCE SPECIFICATIONS SPEC y 4 TUN Tightening torque E art to be tightene read size emarks 39 3 3 24 Front bumper and frame Front carrier and frame Front carrier and front bumper Hear carrier and frame Differential gear case filler bolt Differential gear case drain bolt Differential gear case and bearing housing Gear motor Final gear case oil filler bolt Final gear case oil drain bolt Bearing retainer drive pinion gear F
201. sliding sheave Clutch shoe e Damaged or worn clutch shoe POOR STARTING PERFORMANCE V belt Clutch shoe e V belt slips e Bent damaged or worn clutch shoe e Oil or grease on the V belt Primary sliding sheave e Faulty operation e Worn pin groove e Worn pin 10 4 FAULTY CLUTCH PERFORMANCE OVERHEATING FAULTY BRAKE POOR SPEED PERFORMANCE V belt e Oil or grease on the V belt Primary pulley weight e Faulty operation e Worn primary pulley weight Primary fixed sheave e Worn primary fixed sheave OVERHEATING OVERHEATING Ignition system e Improper spark plug gap e Improper spark plug heat range e Faulty CDI unit Fuel system e Improper carburetor main jet improper setting e Improper fuel level e Clogged air filter element Compression system e Heavy carbon build up Engine oil e Improper oil level e Improper oil viscosity e Inferior oil quality FAULTY BRAKE POOR BRAKING EFFECT e Worn brake pads e Worn disc e Air in brake fluid e Leaking brake fluid e Faulty master cylinder kit cup e Faulty caliper kit seal e Loose union bolt e Broken brake hose and pipe e Oily or greasy disc brake pads e Improper brake fluid level Primary sliding sheave e Worn primary sliding sheave Secondary fixed sheave e Worn secondary fixed sheave Secondary sliding sheave e Worn secondary sliding sheave Cooling system e Low coolant level e Damaged or leaking radiator e Faulty radiator cap e Bent or d
202. sorber 5 Nut 6 25 45 Nm 4 5 kg 32 Ib e Install the ball joints Nut 7 24 30 Nm 3 0 m kg 22 Ib Install the new pins Tighten the nuts 4 NOTE _ _ Before tightening the nuts 2 adjust the length to 310 mm 12 2 in Nut 4 2 45 Nm 4 5 kg 32 ft Ib kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk REAR SHOCK ABSORBER AND SWINGARM CHAS 56 REAR SHOCK ABSORBER AND SWINGARM 82 Nm 8 2 kg 59 ft Ib Remarks Removing the rear shock absorber Remove the parts in the order below and swingarm Rear wheel hubs brake disc Refer to FRONT AND REAR WHEELS Rear brake caliper brake hose Refer to FRONT AND REAR BRAKES Final drive gear assembly Refer to REAR AXLE FINAL DRIVE GEAR AND DRIVE SHAFT in CHAPTER 7 Clip washer pin Nut bolt Rear shock absorber Collar Trailer hitch bracket Final drive gear case breather hose Metal clamp REAR SHOCK ABSORBER AND SWINGARM CHAS 56 82 Nm 8 2 m kg 59 ft Ib Job 8 1 Hefer to INSTALLING THE REAR AXLE Rear axle housing HOUSING 9 Nut bolt 2 2 Refer to REMOVING THE 10 Swingarm bushing 1 2 H SWINGARM 11 Spring rubber boot 1 1 For installation reverse the removal procedure REAR SHOCK ABSORBER AND SWINGARM CHAS 36 REMOVING THE SWINGARM 1 Check e owingarm free play kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk
203. t REAR AXLE FINAL DRIVE GEAR AND DRIVE SHAFT DRIV 3 Apply e Sealant Quick Gasket to the mating surfaces of the swingarm and the final drive gear case 2 Sealant Quick gasket 2 11001 05 01 Yamaha bond 1215 P N 90890 85505 4 Install e Final drive gear e Nuts C gt 63 Nm 6 3 m kg 45 Ib e Bolts C 2163 Nm 6 3 kg 45 Ib 5 Install e Dust cover e Rear axle kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Installation steps Install the dust cover 1 onto the rear axle NOTE Adjust the length to 210 1 mm 8 3 when install the dust cover Install the rear axle with dust cover 2 Install the rear brake disc and rear wheel hub left Temporarily tighten the left axle nut 3 NOTE ___ Z LVS After tightening the rear axle nut 3 the position of the dust cover 1 will slightly move to protect the oil seal of the final gear case kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk 8 CHASSIS FRONT AND REAR WHEELS 8 1 FRONT WHEELS e 8 1 REAR WHEE 8 2 CHECKING THE WHEE G 8 3 CHECKING THE WHEEL HUB 8 3 CHEOKING THE BRAKE DISO sirrinin a 8 4 INSTA
204. t Feel for ne bearing damage YES Check the rear brake adjustment NO Adjust per instructions gt Refer to ADJUSTING THE REAR BRAKE in CHAPTER 3 YES Check the rear axle Feel for bearing ne Rear axle bearings and rear drive shaft damage bearings are probably not damaged Repeat the test or remove the individual components YES Remove the rear axle Check for axle YES Replace the rear axle bearing bearing damage gt Refer to REAR AXLE FINAL DRIVE GEAR AND DRIVE 5 NO Remove the drive shaft components FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR a 4 B 24 aN 22 7 Wt S J AV M 21 ii US NY 15 A 55 Nm 5 5 m kg 40 ft Ib Job name Removing the front constant velocity joint and differential gear Engine skid plate front Front fender Differential gear oil Steering knuckle Front arms lower Brake master cylinder cover Constant velocity joint Gear motor coupler on command four Remove the parts in the order below Refer to SEAT CARRIERS FENDERS AND FUEL TANK in CHAPTER 3 Drain Refer to STEERING SYSTEM in CHAPTER 8 Refer to FRONT ARMS AND FRONT SHOCK ABSORBER in CHAPTER 8 Refer to FRONT AND REAR BRAKES in CHAPTE
205. t for continuity If any of the readings indicate no continuity replace the bulb socket kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk IGNITION SYSTEM IGNITION SYSTEM CIRCUIT DIAGRAM EB802000 yams 05 0 uoniuD 69 eds uoniuD 2 YOUMS 1eeu D 140 09 osnj d 4 4 9 ras 1 D 9n TP uo un 9 15 9 un 1 e MeV x E GENES i bu GI i519 4 Mov 14 Hz jung 1 pod Ej i Sea Seal ES AvH5 NEJ a a 69 l 42 09 09 1 D Av Y I l 1 9N za cites 4 al Qo nene M las hio Wa Wa Wad Wad e Ea NE ESISTENTE PP tae ES i OSRE 0 CIS Ulsi Oo I 4 4 SSHNHVH SSHNHVH SSHNHVH SS3NHVH 3ul ans SS3NHVH 3ulM ans SS3NUVH
206. t lower Engine bracket bolt front upper Engine mounting bolt front upper nut Engine bracket front upper ENGINE REMOVAL ENG Remove the parts in the order below Refer to FRONT AND REAR WHEELS in CHAPTER 8 Refer to REAR SHOCK ABSORBER AND SWINGARM in CHAPTER 8 Install all of the bolts nuts and then tighten them full torque specifications Refer to INSTALLING THE ENGINE ENGINE REMOVAL ENG 33 Nm 3 3 m kg 24 ft Ib Job 1 I Engine assembly NOTE Remove the engine assembly from the left side of the machine For installation reverse the removal procedure ENGINE REMOVAL ENG INSTALLING THE ENGINE 8 1 Install e Engine bracket front upper 1 3 6 e Engine mount bolt front upper nut 2 ss e Engine bracket bolt front upper 3 NEL Tel e Engine bracket front lower 4 e Engine mount bolt front lower 5 e Engine bracket bolt front lower 6 es e Engine mount bolt rear upper nut 7 Engine mount rear lower nut gt 7 y Do not fal tighten the bolts and nut not fully tighten the bolts a uts 6 NN i 6 J 2 Tighten N OEE SCIT e Engine mount bolt front upper nut o e Engine bracket bolt front upper 3 33 Nm 3 3 m kg 24 Ib e Engine mount bolt front lower 5 e Engine bracket bolt front lower 6 33 Nm 3 3 m kg 24 ft
207. ter to the battery and start charging Is the amperage higher than the standard charging NO amperage written on the battery Adjust the charging voltage to 20 25 V Monitor the amperage for 3 5 minutes Is the standard charging amperage exceeded Adjust the voltage to obtain the standard charging amperage lf the amperage does exceed the standard charging amperage after 5 minutes replace the battery Set the timer to the charging time determined by the open circuit voltage Refer to CHECKING THE BATTERY If the required charging time exceeds 5 hours it is advisable to check the charging amperage after 5 hours If there is any change in the amperage readjust the voltage to obtain the standard charging amperage Leave the battery unused for more than 30 minutes before measuring its open circuit voltage 12 8 V gt Charging is complete 12 0 12 7 V Recharging is required Under 12 0 V Replace the battery CHECKING THE BATTERY Charging method using a constant voltage charger Measure the open circuit voltage prior to charging Connect a charger and ammeter to the battery and start charging Is the amperage higher YES than the standard charging amperage written on the battery Charge the battery until the charging voltage reaches 15 V NOTE Set the charging time to a maximum of 20 hours Leave the battery unused for more than 30 minutes before measuring
208. than 86 3 C 186 8 5 4 F More than 80 3 C 176 5 4 F NM Less than 80 3 C 176 5 4 F Test steps 1 amp 2 Heating phase Test steps 3 amp 4 Cooling phase The thermo switch 2 circuit is open and the radiator fan is off The thermo switch 2 circuit is closed and the radiator fan is on WARNING Handle the thermo switch 2 with special care Never subject it to a strong shock or BAD CONDITION allow it to be dropped Should it be dropped it must be replaced Thermo switch 2 Replace the thermo switch 2 176 5 4 28 Nm 2 8 kg 20 ft Ib Three bond sealock 10 GOOD CONDITION COOLING system 7 Wiring connection e Check the connections of the entire starting 1 system Refer to CIRCUIT DIAGRAM Properly connect the cooling system CORRECT This circuit is not faulty 2WD 4WD SELECTING SYSTEM 2WD 4WD SELECTING SYSTEM CIRCUIT DIAGRAM SUB WIRE SUB WIRE WIRE HARNESS WIREHARNESS ih nwESS2 BLACK BLACK CN R wel CN wel G l a TE Er WR GRAY GRAY C jer GRAY 9 43 W BXA WB B R d 4 07 43 m 1 n ED 3 Main switch 6 Battery 6 Main fuse CDI unit Four wheel drive
209. the bearings oil seals and inner surface of the secondary fixed sheave 2 Install e Guide pin 1 8 PRIMARY AND SECONDARY SHEAVES ENG 3 Apply e BEL RAY assembly lube to the guide pin sliding groove D and O ring BM 4 Install e opring seat e Compression spring e opring seat e Nut kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Installing steps Attach the sheave fixed block locknut wrench and sheave spring compressor to the secondary sheave assembly Sheave fixed block P N YM 04135 90890 04135 Locknut wrench P N 90890 01348 Sheave spring compressor P N YM 04134 90890 04134 ye ePlace the sheave fixed block in a vise and secure it e Tighten the sheave spring compressor nut 1 and compress the spring einstall the nut and tighten it to the specified torque using the locknut wrench Nut 25 90 Nm 9 0 kg 65 Ib Remove the sheave spring compressor locknut wrench and sheave fixed block kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk 2 PRIMARY AND SECONDARY SHEAVES oD 1 0 mm 0 04 in INSTALLING THE PRIMARY AND 6 mm SECONDARY SHEAVES Gin 024 in 1 Install 45 mm 1 77 in e Secondary sheave assembly e V belt e Primary sheave assembly NOTE e Tightening the bolts 1 will push the secondary sliding sheave away causing the gap between the secondary fixed and sliding sheaves to widen e Install the V belt so that its arrow fac
210. thickness 8 Out of specification Replace Brake disc minimum thickness 3 mm 0 12 in INSTALLING THE WHEEL HUB 1 Install e Axle nut 1150 Nm 15 0 kg 110 ft Ib e Cotter pin 1 NOTE W 77 77 22 Do not loosen the axle nut after torquing it If the axle nut groove is not aligned with the cotter pin hole align the groove with the hole by tightening the axle nut INSTALLING THE WHEEL 1 Install e Wheel NOTE LO The arrow mark 1 on the tire must point in the direction of rotation of the wheel e FRONT AND REAR WHEELS CHAS 36 E SN 2 Install e Nuts wheel 1 WARNING Tapered wheel nuts 1 are used for both the front and rear wheels Install each nut with its tapered side towards the wheel 3 Tighten e Nuts front wheel 64 Nm 6 4 m kg 46 ft Ib e Nuts rear wheel 55 Nm 5 5 m kg 40 ft Ib NOTE 2 7 Tighten the nuts in stages and in a crisscross pattern FRONT AND REAR BRAKES CHAS 56 FRONT AND REAR BRAKES FRONT BRAKE PADS 30 Nm 3 0 m kg 22 ft Ib 18 Nm 1 8 m kg 13 ft Ib Job name Removing front brake pads Remove the parts in the order below Front wheel Refer to FRONT AND REAR WHEELS Brake caliper mounting bolt Brake pad holding bolt Refer to REPLACING THE FRONT Brake pad pad shim BRAKE Pad spring For installation reverse the removal procedure F
211. thrust washer s using the following chart Increase shim Too large gear lash ge g thickness ef increased by more than 0 2 mm 0 008 in Reduce the thrust washer thickness by 0 2 0 008in for every 0 2 0 008 of ring gear shim increase ef reduced by more than 0 2 mm 0 008 Increase the thrust washer thickness by 0 2mm 0 008 in for every 0 2 0 008 in that the ring gear shim is decreased A Ring gear shim 0 25 0 30 0 35 Thickness mm 0 10 045 050 oS Thrust washer Thickness mm kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk gt REAR AXLE FINAL DRIVE GEAR AND DRIVE SHAFT DRIV ASSEMBLING THE FINAL DRIVE GEAR 1 Install e Drive pinion gear with shim s and bearing proper shim size as calculated e Bearing retainer drive pinion gear 1 100 Nm 10 0 m kg 72 ft Ib Use a bearing retainer wrench 2 e Always use a new bearing e The final drive shaft bearing retainer has left hand threads Turn the retainer counterclockwise to tighten it d Bearing retainer wrench P N YM 04050 90890 04050 2 Adjust e Final gear lash Refer to MEASUREMENT AND ADJUSTING THE FINAL GEAR LASH INSTALLING THE FINAL DRIVE GEAR 1 Lubricate e Drive shaft e Coupling gear e O ring e Oil seal e Bearing D Lithium soap based grease 2 Install e Drive shaft 1 to the universal joint g
212. tment is correct slack in the return spring 1 will be taken up NOTE WW In some cases it will be necessary to further adjust the cable with the locknuts arrangement that holds the cable to its mount ADJUSTING THE SELECT LEVER CONTROL CABLE AND SHIFT ROD CHK ADJUSTING THE REAR BRAKE LIGHT SWITCH ADJ When the brake begins to work 20 30 mm 0 8 1 2 in verify that the select lever can be shifted to REVERSE from NEUTRAL to PARK from REVERSE and to NEUTRAL from REVERSE Before the brake begins to work 0 20 mm 0 0 8 in verify that the select lever cannot be shifted to REVERSE from NEUTRAL to REVERSE from PARK and to NEUTRAL from REVERSE eCheck that locknuts 2 tightened correctly elf the operation of the select lever is incorrect adjust the select lever control cable 3 with the adjuster 4 Select lever shift rod Make sure the select lever is in NEUTRAL Loosen both locknuts 1 Adjust the shift rod length for smooth and correct shifting Tighten the locknuts 1 kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk ADJUSTING THE REAR BRAKE LIGHT SWITCH The rear brake light switch is operated by movement of the brake pedal The rear brake light switch is properly adjusted when the brake light comes on just before the braking effect starts 1 Check e Brake light operation timing Incorrect Adjust ADJUSTING THE REAR BR
213. topper shim Oil seal bearing Ring gear shim Ring gear Thrust washer REAR AXLE FINAL DRIVE GEAR AND DRIVE SHAFT DRIV pe 23 Nm 2 3 m kg 17 ft Ib 23 Nm 2 3 m kg 17 ft Ib y 2 09 9 D Bearing retainer O ring Oil seal Final drive pinion gear Refer to DISASSEMBLING ASSEMBLING THE FINAL DRIVE Collar GEAR Bearing Final drive pinion gear shim Final drive gear case O ring Bearing oil seal Refer to REPLACING THE FINAL Bearing DRIVE ROLLER BEARING For assembly reverse the disassembly procedure REAR AXLE FINAL DRIVE GEAR AND DRIVE SHAFT DRIV REMOVING THE REAR AXLE 1 Remove e Rear axle 1 with dust seal e O ring e Never directly tap the axle end with a hammer since this will result in damage to the axle thread and spline e Attach a suitable socket 2 on the axle end and tap it with a soft hammer Pull out the rear axle to the right DISASSEMBLING THE FINAL DRIVE GEAR 1 Remove e Bearing retainer final drive pinion gear NOTE Use a bearing retainer wrench 1 Vo Bearing retainer wrench P N YM 04050 90890 04050 The final drive shaft bearing retainer has left handed threads To loosen the retainer turn it clockwise 2 Remove e Final drive pinion gear assembly With a soft hammer lightly tap on the final drive pinion gear end Removal of the final drive pinion gear should only be performe
214. tor cap tester This tool is used to check the cooling system Adapter This tool is used to check the cooling system Locknut wrench This tool is needed when removing or installing the secondary sheave spring Sheave spring compressor This tool is needed when removing or installing the secondary sheave spring SPECIAL TOOLS Ed Tool name How to use 90890 04135 YM 04135 90890 01404 YM 01404 90890 01327 YM 01327 90890 01426 YU 3844 1 90890 01430 YM 38404 90890 01467 YM 01467 90890 01475 YM 01475 90890 01474 YM 01474 YM 01477 90890 01 701 YU 01880 Sheave fixed block This tool is needed when removing or installing the secondary sheave spring Flywheel puller These tools are needed to remove the rotor Damper rod holder 30 mm This tool is needed to loosen and tighten the steering stem bearing retainer filter wrench This tool is needed to loosen or tighten the oil filter cartridge Ring nut wrench This tool is needed to removing and installing the middle driven shaft bearing retainer Gear lash measurement tool This tool is used to measure the gear lash Ball joint remover installer set This tool is used to remove install the ball joint Ball joint remover installer attachment set This tool is used to remove and install the ball joint Sheave holder This tool is needed to hold the primary sheave when removing or installing the sh
215. tral switch Reverse switch Stator assembly Pickup coil Ignition coil Thermo switch cylinder head Speed sensor Thermo switch radiator Tappet covers Coolant drain bolt water pump Coolant inlet joint Bearing housing Primary pulley sheave cap Clutch housing assembly Clutch housing assembly cover Starter motor Shift lever cover Crankcase right Stopper lever Yoke middle driven shaft Thermostat cover Water pump outlet pipe Water pump assembly Low range switch High range switch lt OO 0 OF B Na NM WH SS S NY MAINTENANCE SPECIFICATIONS SPEC CHASSIS Steering system Steering bearing type Front suspension Shock absorber travel Fork spring free length Spring fitting length Spring rate Stroke Optional spring Rear suspension Shock absorber travel Spring free length Spring fitting length Spring rate Stroke Optional spring Swingarm Free play limit Front wheel Type Rim size Rim material Rim runout limit radial lateral Rear wheel Type Rim size Rim material Rim runout limit radial lateral Standard Ball and race bearing 99 mm 3 90 in 265 mm 10 43 in 215 8 mm 8 50 in 15 N mm 1 53 kg mm 85 68 Ib in 0 99 mm 0 3 90 in No 126 mm 4 96 in 317 mm 12 48 in 283 mm 11 14 in 30 4 N mm 3 10 kg mm 173 60 Ib in 126 mm 0 4 96 in No Panel whee
216. tridge and the oil pump for damage or leakage Refer to CRANKCASE in CHAPTER 4 e Start the engine after solving the problem s and check the engine oil pressure again Tighten the oil gallery bolt to specification Oil gallery bolt 7 Nm 0 7 me kg 5 1 ft Ib 14 Install e Engine side cover e Fuel tank side panel left e Seat Refer to SEAT CARRIERS FENDERS AND FUEL TANK CLEANING THE AIR FILTER c There is a check hose 1 at the bottom of the air filler case If dust and or water collects in this hose clean the air filter element and air filler case CLEANING THE AIR FILTER 1 Remove e Seat 2 Remove e Air filter case cover 1 3 Remove e Air filter element assembly 1 e Air filter element cap e Air filter element 2 Air filter element cap 3 Air filter element element removed This will allow unfiltered air to enter causing rapid wear and possible engine damage Additionally operation without the filter element will affect carburetor tuning with subsequent poor performance and possible engine overheating 4 Check e Air filter element Damaged Replace CLEANING THE AIR FILTER 5 Clean e Air filter element kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Cleaning steps e Wash the element gently but thoroughly in solvent WARNING iod Use a cleaning solvent which is designed to clean parts only
217. troubleshooting EB802011 NO CONTINUITY 1 Fuse main Refer to CHECKING THE SWITCH 1 CONTINUITY Replace the fuse INCORRECT e Check the battery condition Refer to CHECKING THE BATTERY in CHAPTER 3 e Clean the battery terminals EB802012 2 Battery Open circuit voltage 12 8 V or more at 20 C 68 F CORRECT Refer to CHECKING THE SWITCH i CORRECT Replace the main switch e Recharge or replace the battery COOLING system 4 Fan motor e Disconnect the fan motor coupler e Connect the battery 12 V as shown Battery lead Blue terminal 1 Battery lead gt Black terminal 2 DOES NOT TURN Replace the fan motor 5 Circuit breaker fan motor e Remove the circuit breaker from the wire harness e Connect the pocket tester Q x 1 to the circuit breaker OUT OF SPECIFICATION Circuit breaker resistance Zero at 20 68 F Replace the circuit breaker MEETS SPECIFICATION COOLING SYSTEM ELEC 6 Thermo switch 2 e Remove the thermo switch 2 from the radiator e Connect the pocket tester Q x 10 to the thermo switch 2 1 e Immerse the thermo switch 2 in coolant 2 e Check the thermo switch 2 for continuity While heating the coolant use a thermometer 9 to record the temperatures step Less than 86 3 186 8 5 4 F More
218. ttes etc eDO NOT SMOKE when charging or handling batteries KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN 1 Remove e Seat e Battery holding bracket e Battery lead cover Refer to SEAT CARRIERS FENDERS AND FUEL TANK 2 Disconnect e Battery leads disconnect the positive lead 2 3 Remove e Battery 4 Check e Battery condition kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Battery condition checking steps eConnect a digital voltmeter to the battery terminals Tester lead battery terminal Tester lead battery terminal NOTE LL The charge state of an MF battery can be checked by measuring the open circuit voltage i e the voltage when the positive terminal is disconnected Relationship between the open circuit voltage and the charging time at 20 C Open circuit voltage 12 8 V or higher Check condition of the battery using following charts radi time hours Example Open circuit voltage 12 0 V e Charging time 6 5 hours e Charge condition of the battery 20 30 e Charging method for MF batteries Charging time Open circuit voltage v elf it is impossible to set the standard charging current be careful not to overcharge a e When charging the battery be sure to Time minutes
219. tween the valve stem and the guide e Apply molybdenum disulfide oil to the valve stem Install the valve into the cylinder head e Turn the valve until the valve face and valve seat are evenly polished then clean off all of the compound NOTE vy For best lapping results lightly tap the valve seat while rotating the valve back and forth between your hands 302 024 4 23 8 CAMSHAFT ROCKER ARMS AND VALVES ENG Apply a fine lapping compound to the valve face and repeat the above steps NOTE _ After every lapping operation be sure to clean off all of the compound from the valve face and valve seat e Apply Mechanic s blueing dye Dykem to the valve face e Install the valve into the cylinder head e Press the valve through the valve guide and onto the valve seat to make a clear pattern e Measure the valve seat width again If the valve seat width is out of specification reface and relap the valve seat kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk 10 Measure e Valve spring free length Out of specification Replace Free length valve spring Inner 39 9 mm 1 57 in lt Limit gt 37 9 mm 1 49 Outer 43 27 mm 1 70 in lt Limit gt 41 27 mm 1 62 in 11 Measure e Compressed spring force Out of specification Replace Installed length Compressed spring force Inner 104 9 120 6 N at 33 6 mm 10 70
220. ty between the terminals Damage wear Repair or replace the bulb bulb socket or both Improperly connected Properly connect Incorrect continuity reading Repair or replace the bulb bulb socket or both TYPES OF BULBS The bulbs used on this machine are shown in the illustration on the left e Bulbs and B are used for headlights and usually use a bulb holder which must be detached before removing the bulb The majority of these bulbs can be removed from their respective socket by turning them counterclockwise e Bulb O is used for turn signal and brake tail lights and can be removed from the socket by pushing turning the bulb counterclockwise e Bulbs and are used for meter and indicator lights and can be removed from their respective socket by carefully pulling them out CHECKING THE CONDITION OF THE BULBS The following procedure applies to all of the bulbs 1 Remove e Bulb 18410602 CHECKING THE BULBS AND BULB SOCKETS ELEC Since the headlight bulb gets extremely hot keep flammable products and your hands away from the bulb until it has cooled down e Be sure to hold the socket firmly when removing the bulb Never pull the lead otherwise it may be pulled out of the terminal in the coupler e Avoid touching the glass part of the headlight bulb to keep it free from oil otherwise the transparency of the glass the life of the bulb and the luminous flux will be adversel
221. valve and valve seat e Improper valve timing e Broken valve spring e Seized camshaft e Seized crankshaft Electrical system e Faulty spark plug e Faulty CDI unit e Faulty pickup coil e Faulty charging rotor rotation direction coil e Faulty ignition coil Valve train e Improperly adjusted valve clearance Air filter e Clogged air filter element POOR MEDIUM AND HIGH SPEED PERFORMANCE POOR MEDIUM AND HIGH SPEED PERFORMANCE Refer to STARTING FAILURE HARD STARTING and POOR IDLE SPEED PERFORMANCE VALVE TRAIN Carburetor e Improper jet needle clip position e Improperly adjusted fuel level e Clogged or loose main jet e Deteriorated or contaminated fuel Air filter e Clogged air filter element 10 2 4 FAULTY DRIVE TRAIN GHTG e FAULTY DRIVE TRAIN The following conditions may indicate damaged shaft drive components 1 A pronounced hesitation or jerky movement A Bearing damage during acceleration deceleration or sustained speed This must not be confused with B Improper gear lash engine surging Or transmission characteristics C Gear tooth damage 2 A rolling rumble noticeable at low speed a high pitched whine a clunk from a shaft D Broken drive shaft drive component or area locked up condition of the shaft drive E Broken gear teeth mechanism no power transmitted from the engine to the front and or rear wheels F Seizure due to lack of lubrication G Small
222. w rubber boot and new circlip NOTE Always use a new ball joint set e Install a steering knuckle oil seal kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk 3 Check Front wheel bearings Bearings allow play in the wheel hubs or the wheel turns roughly Replace e Oil seals Damage Replace kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Replacement steps e Clean the outside of the steering knuckle e Remove the oil seals 1 e Drive out the bearings 2 WARNING Eye protection is recommended when using striking tools e Remove the spacer 3 lithium base grease to the bearings and oil seals e Install the spacer to the steering knuckle STEERING SYSTEM CHAS 36 e Install the new bearings NOTE Install the outside bearing first bearing Contact should be made only with the outer race e Install a new oil seal NOTE 27 When installing the oil seals the seal side of the oil seal faces out kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk INSTALLING THE TIE ROD 1 Install e Tie rods left and right NOTE 2L The tie rod which must be installed on the out side has grooves 1 2 Adjust e Refer to ADJUSTING THE CHAPTER 3 FRONT ARMS AND FRONT SHOCK ABSORBER CHAS 36 FRONT ARMS AND FRONT SHOCK ABSORBER 45 Nm 4 5 m kg 32 ft Ib 9 9 Bu 15 E 45 Nm 4 5 m kg
223. ways install new brake pads brake pad shim and brake pad spring as a set FRONT AND REAR BRAKES CHAS 36 kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Installation steps Connect a suitable hose 1 tightly to the brake caliper bleed screw Put the other end of this hose into an open container Loosen the brake caliper bleed screw and using a finger push the caliper piston into the brake caliper Tighten the brake caliper bleed screw Brake caliper bleed screw 6 Nm 0 6 m kg 4 3 Ib einstall new brake pads new pad shims 3 and a new brake pad spring e Install the retaining bolts and brake caliper NOTE cl The arrow mark 8 on the pad shim must point in the direction of the disc rotation Brake pad holding bolt 18 Nm 1 8 m kg 13 Ib Brake caliper mounting bolt 30 Nm 3 0 kg 22 Ib kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk 3 Check Brake fluid level Refer to CHECKING THE BRAKE FLUID LEVEL in CHAPTER 3 4 Check Brake lever operation Soft or spongy feeling Bleed the front brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in CHAPTER 3 FRONT AND REAR BRAKES CHAS 36 REPLACING THE REAR BRAKE PAD NOTE _ It is not necessary to disassemble the brake caliper and brake hose to replace the brake pads 1 Measure e Brake pad wear limit
224. without oil Worn or damaged pistons Defective ring s valves cylinder head gasket or piston is possible Same as without oil Compression pressure at sea level Standard 1 270 kPa 12 7 kg cm2 181 psi Minimum 1 105 kPa 11 1 kg cm 158 psi Maximum 1 422 kPa 14 2 2 202 psi kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Measurement steps eCrank over the engine with the electric starter be sure the battery is fully charged with the throttle wide open until the compression reading on gauge stabilizes WARNING When cranking the engine ground the spark plug lead to prevent sparking kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk 8 Install e Spark plug 9 Hemove e Fuel tank side panel right e Seat Refer to SEAT CARRIERS FENDERS AND FUEL TANK CHECKING THE ENGINE OIL LEVEL CHECKING THE ENGINE OIL LEVEL 1 Place the machine on a level surface 2 Remove e Engine side panel Refer to SEAT CARRIERS FENDERS AND FUEL TANK 3 Check e Engine oil level Oil level should be between the maximum level mark 1 and minimum level mark 2 Oil level low Add oil to the proper level NOTE _ Do not screw the dipstick 3 in when checking the oil level Recommended oil Follow the left chart NOTE 10 309 50 709 90 110 F Recommended oil classification Service SE SF type or equivalent e g SF SE CC
225. y hold the clutch carrier assembly Gasket dowel pin Refer to REMOVING INSTALLING THE eWhen turning the clutch assembly clockwise A the clutch carrir assembly should turn freely If not the one way clutch assembly is faulty Replace it eWhen turning the clutch carrir assembly One way clutch bearing CLUTCH Nut Clutch carrier assembly For installation reverse the removal procedure counterclockwise B the clutch housing and clutch carrir assembly should be engaged If not the one way clutch assembly is faulty Replace it TRBL SHTG ILLUSTRATED SYMBOLS Illustrated symbols 1 to 49 are printed on the top right of each page and indicate the subject of each chapter D General information 2 Specifications 3 Periodic checks and adjustments 2 Engine 5 Cooling system 6 Carburetion 7 Drive train Chassis 9 Electrical Troubleshooting Illustrated symbols 7 to 09 are used to identify the specifications appearing in the text 1 Can be serviced with engine mounted 42 Filling fluid 43 Lubricant Special tool 5 Torque Wear limit clearance 7 Engine speed Q V A Illustrated symbols to 4 in the exploded diagrams indicate the types of lubricants and lubrication points Apply engine oil 09 Apply gear oil 2 Apply molybdenum disulfide oil 02 Apply wheel bearing grease 3 Apply lithium soap based grease 63 Apply molybdenum disu
226. y affected If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 2 Check e Bulb for continuity with the pocket tester No continuity Replace Pocket tester P N YU 03112 90890 03112 NOTE ll VV Before checking for continuity set the pocket tester to 0 and to the Q x 1 range kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk a Connect the tester positive probe to terminal D and the tester negative probe to terminal 2 and check the continuity b Connect the tester positive probe to terminal D and the tester negative probe to terminal 3 and check the continuity c lf either of the readings indicate no continuity replace the bulb kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk CHECKING THE BULBS AND BULB SOCKETS ELEC CHECKING THE CONDITION OF THE BULB SOCKETS The following procedure applies to all of the bulb sockets 1 Check e Bulb socket for continuity with the pocket tester No continuity Replace Pocket tester P N YU 03112 90890 03112 NOTE 2 Check each bulb socket for continuity in the same manner as described in the bulb section however note the following kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk a lnstall a good bulb into the bulb socket b Connect the pocket tester probes to the respective leads of the bulb socket c Check the bulb socke

Download Pdf Manuals

Related Search

Related Contents

The Rental Show Rules and Regulations  B E T R I E B S A N L E I T U N G - wittfan.de    SELMATER User Manual  Aqua Paint Marker  A13-OLinuXino and A13-OLinuXino-WIFI  Control Keyboard - Lupus Electronics  ja-110a_manual  4 Class Communications Brochure - Mid  Descargar Reglamento Victoria  

Copyright © All rights reserved. Failed to retrieve file