Yamaha 5TE-F8197-10 manual

LIT-11616-16-02 5TE-F8197-10 YFM400FAR SERVICE MANUAL[...]

YFM400FAR SERVICE MANUAL © 2002 by Yamaha Motor Corporation, U.S.A. First Edition, April 2002 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. LIT-11616-16-02[...]

EB001000 NOTICE This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not po ssible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to pe rform maintenance and repairs on Yamaha machine has a basic understanding o f the [...]

EB002000 HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual consists of chapters for the main ca tegories of subjects. (See “Illustrat ed symbols”) 1st title 1 : This is the title of the chapter with its symbol in the upper right corner of each page. 2nd title 2 : This title indicates the section of the chapter a nd only appears on the firs[...]

EB003000 ILLUSTRATED SYMBOLS Illustrated symbols 1 to 0 are pr inted on the top right of each page and indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic checks and ad justments 4 Engine 5 Cooling system 6 Carburetion 7 Drive train 8 Chassis 9 Electrical 0 Troubleshooting Illustrated symbols A to H are used to i[...]

TABLE OF CONTENTS GENERAL INFORMATION GEN INFO 1 SPECIFICATIONS SPEC 2 PERIODIC CHECKS AND ADJUSTMENTS CHK ADJ 3 ENGINE ENG 4 COOLING SYSTEM COOL 5 CARBURETION CARB 6 DRIVE TRAIN DRIV 7 CHASSIS CHAS 8 ELECTRICAL ELEC 9 TROUBLESHOOTING TRBL SHTG 10 – +[...]

CONTENTS CHAPTER 1. GENERAL INFORMATION MACHINE IDENTIFICATION ............................................. ........................... 1-1 VEHICLE IDENTIFICATION NUMBER ................................................. 1-1 MODEL LABEL ...................................................................................... 1-1 IMPORTANT INFORMATION [...]

CHAPTER 3. PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION ........... .......................................... ...................................... 3-1 PERIODIC MAINTENANCE/LUBRICATION ................................................ 3-1 SEAT, CARRIERS, FENDERS AND FUEL TANK ....................................... 3-3 SEAT AND SIDE PANELS .......[...]

CHECKING THE CONSTANT VELOCITY JOINT DUST BOOTS ...... 3-46 CHECKING THE STEERING SYSTEM .............................................. 3-47 ADJUSTING THE TOE-IN ..................................................... .............. 3-47 ADJUSTING THE FRONT SHOCK ABSORBERS ............... .............. 3-49 ADJUSTING THE REAR SHOCK ABSORBER ........[...]

CYLINDER AND PISTON .................. ..................................................... .... 4-27 REMOVING THE PISTON ......... ........................................... .............. 4-28 CHECKING THE TIMING CHAIN GUIDE .................. ......................... 4-28 CHECKING THE CYLINDER AND PISTON ......................... ............[...]

CRANKSHAFT AND OIL PUMP ....................................... ......................... 4-65 OIL PUMP ... .......................................... .............................................. 4-66 REMOVING THE CRANKSHAFT ......... .......................................... .... 4-67 CHECKING THE OIL PUMP ................. ....................[...]

CHAPTER 6. CARBURETION CARBURETOR ............. .......................................... ...................................... 6-1 DISASSEMBLING THE CARBURETOR ............................................... 6-4 CHECKING THE CARBURETOR ......................................................... 6-4 ASSEMBLING THE CARBURETOR .......................[...]

CHAPTER 8. CHASSIS FRONT AND REAR WHEELS ........................................... ........................... 8-1 FRONT WHEELS ............................................................................ ...... 8-1 REAR WHEELS ............... .......................................... ........................... 8-2 CHECKING THE WHEELS .........[...]

FRONT ARMS AND FRONT SHOCK ABSORBERS .................. .............. 8-40 REMOVING THE FRONT ARMS ........................................................ 8-42 CHECKING THE FRONT ARMS ......................................................... 8-42 CHECKING THE FRONT SHOCK ABSORBER ............................. .... 8-44 INSTALLING THE FRONT ARMS A[...]

LIGHTING SYSTEM ...................................... .............................................. 9-25 CIRCUIT DIAGRAM ........................................................................ .... 9-25 TROUBLESHOOTING ............................................... ......................... 9-26 CHECKING THE LIGHTING SYSTEM ....................[...]

OVERHEATING ...................................................... .................................... 10-5 OVERHEATING .................................... .......................................... .... 10-5 FAULTY BRAKE ................................................................ ......................... 10-5 POOR BRAKING EFFECT ..........[...]

1 - 1 GEN INFO MACHINE IDENTIFICATION 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 1 is affixed to the frame. This information will be needed to order spare parts.[...]

1 - 2 GEN INFO EB101000 IMPORTANT INFORMATION 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, pis[...]

1 - 3 GEN INFO EB101030 LOCK WASHERS/PLATES AND COTTER PINS 1.Replace all lock washers/plates 1 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 numbe rs are vis[...]

1 - 4 GEN INFO CHECKING OF CONNECTIONS EB801000 CHECKING OF CONNECTIONS Check the connectors for stains, rust, moisture, etc. 1.Disconnect: ● Connector 2.Check: ● Connector Moisture → Dry each t erminal with an air blower. Stains/rust → Connect and disconnect the terminals several times. 3.Check: ● Connector leads Looseness → Bend up th[...]

GEN INFO 1 - 5 SPECIAL TOOLS EB102001 SPECIAL TOOLS The following special tools are necessary for complete an d accurate tune-up and assembly. Use only the appropriate special tools; this will help preven t damage caused by the use of inappropriate tools or improvised techniques. Sp ecial tools may differ by shape and part number from country to co[...]

GEN INFO 1 - 6 SPECIAL TOOLS YU-90050 Crankshaft installer set These tools are used to install the crankshaft. Adapter YM-33279 Spacer 90890-04060 YM-90070- A Adapter #11 Spacer (crankshaft) These tools are used to install the crankshaft. 90890-01304 YU-01304 Piston pin puller set This tool is used to remove the piston pin. 90890-01311 YU-08035 Tap[...]

GEN INFO 1 - 7 SPECIAL TOOLS 90890-04135 YM-04135 Sheave fixed block This tool is needed when removing or installing the secondary sheave spring. 90890-01404 YM-01404 Flywheel puller These tools are needed to remo ve the rotor. 90890-01327 YM-01327 Damper rod holder (30 mm) This tool is needed to loosen and tighten the steering stem bearing retaine[...]

GEN INFO 1 - 8 SPECIAL TOOLS Compression gauge 90890-03081 YU-33223 Adapter 90890-04082 YU-33223- 3 Compression gauge Adapter These tools are needed to mea sure engine compression. 90890-03112 YU-03112-C Pocket tester This instrument is needed for checking the electrical system. 90890-03113 Engine tachometer This tool is needed for observing engine[...]

GEN INFO 1 - 9 SPECIAL TOOLS 90890-04086 YM-91042 Clutch holding tool This tool is needed to hold the clutch carrier when removing or installing the carrier nut. 90890-04128 YM-04128 Bearing retainer wrench This tool is needed when removing or installing the middle driven pinion gear bearing retainers. 90890-04129 YM-04129 Pinion gear fix clamp Thi[...]

2 - 1 SPEC SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Model code: 5TE1, 5TE5 Dimensions: Overall length 1,984 mm (78.1 in) Overall width 1,085 mm (42.7 in) Overall height 1,120 mm (44.1 in) Seat height 827 mm (32.6 in) Wheelbase 1,233 mm (48.5 in) Minimum ground clearance 245 mm (9.7 in) Minimum turning radius 3,000 mm (118.1 in) Basic wei[...]

2 - 2 SPEC Differential gear case oil Periodic oil change 0.35 L (0.31 Imp qt, 0.37 US qt) Total amount 0.40 L (0.35 Imp qt, 0.42 US qt) Radiator capacity (including all routes) 1.32 L (1.16 Imp qt, 1.40 US qt) Air filter: Wet type element 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[...]

2 - 3 SPEC Tire pressure (cold tire): Maximum load* 210 kg (463 lb) Off-road riding front 22 ~ 28 kPa (0.22 ~ 0.28 kg/cm 2 , 3.2 ~ 4 .0 psi) rear 22 ~ 28 kPa (0.22 ~ 0.28 kg/cm 2 , 3.2 ~ 4 .0 psi) *Load in total weight of rider acce ssories Brakes: Front brake type Dual disc brake operation Right hand operation Rear brake type Drum brake operation [...]

2 - 4 SPEC MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Cylinder head: Warp limit ---- 0.03 mm (0.0012 in) Cylinder: Bore size 84.500 ~ 84.510 mm (3.3268 ~ 3.3272 in) 84.600 mm (3.3307 in) Taper limit ---- 0.05 mm (0.0016 in) Out of round limit ---- 0.01 mm (0.0004 in) Camshaft: Drive method Chain drive (left) ---- Cam dimensio ns Intake ?[...]

2 - 5 SPEC Cam chain: Cam chain type/No. of links DID SCR-0409 SDH/116 ---- Cam chain adjustment method Automatic ---- Rocker arm/rocker arm shaft: Bearing inside diameter 12.000 ~ 12.018 mm (0.4724 ~ 0.4731 in) 12.078 mm (0.4755 in) Shaft outside diamete r 11.981 ~ 11.991 mm (0.4717 ~ 0.4721 in) 11.951 mm (0.4705 in) Arm-to-shaft clearance 0.009 ~[...]

2 - 6 SPEC Stem runout limit ---- 0.01 mm (0.0004 in) Valve seat width IN 1.2 ~ 1.4 mm (0.0472 ~ 0.0551 in) ---- EX 1.2 ~ 1.4 mm (0.0472 ~ 0.0551 in) ---- Valve spring: Inner spring Free length IN 39.9 mm (1.57 in) 37.9 mm (1.49 in) EX 39.9 mm (1.57 in) 37.9 mm (1.49 in) Set length (valve closed) IN 33.6 mm (1.32 in) ---- EX 33.6 mm (1.32 in) ---- [...]

2 - 7 SPEC Tilt limit IN 2 . 5 ° /1.6 mm (2.5 ° /0.06 in) EX 2 . 5 ° /1.6 mm (2.5 ° /0.06 in) Direction of winding (top view) IN Clockwise ---- EX Clockwise ---- Piston: Piston to cylinder clearance 0. 040 ~ 0.065 mm (0.0016 ~ 0.0026 in) 0.150 mm (0.0059 in) Piston size “ D ” 84.445 ~ 84.460 mm (3.3246 ~ 3.3252 in) ---- Measuring point “ [...]

2 - 8 SPEC 2nd ring Type Taper ---- Dimensions (B × T) 1.2 × 3.6 mm (0.04724 × 0.1417 in) ---- End gap (installed) 0.40 ~ 0.60 mm (0.0157 ~ 0.0236 in) 0.95 mm (0.0374 in) Side clearance 0.03 ~ 0.07 mm (0.0012 ~ 0.0028 in) 0.13 mm (0.0051 in) Oil ring Dimensions (B × T) 2.8 × 2.8 mm (0.1102 × 0.1102 in) ---- End gap (installed) 0.2 ~ 0.7 mm (0[...]

2 - 9 SPEC Transmission: Main axle deflection limit ---- 0.06 mm (0.0024 in) Drive axle deflection limit ---- 0.06 mm (0.0024 in) Shifter: Shifter type Shift cam and guide bar ---- Air filter oil grade: Engine oil ---- Carburetor: I. D. mark 5TE1 00 ---- Main jet (M.J) #132.5 ---- Main air jet (M.A.J) #50 ---- Jet needle (J.N) 5EP13-55-3 ---- Needl[...]

2 - 10 SPEC Cooling system: Radiator core Width 300 mm (11.8 in) ---- Height 208 mm (8.19 in) ---- Thickness 26 mm (1.02 in) ---- Radiator cap opening pressure 93.7 ~ 122.6 kPa (0.937 ~ 1.226 kg/c m 2 , 13.32 ~ 17.43 psi) ---- Radiator capacity 0.70 L (0.62 Imp qt, 0.74 US qt) ---- Coolant reservoir Capacity 0.39 L (0.34 Imp qt, 0.41 US qt) ---- Fr[...]

2 - 11 SPEC Cylinder head tightening sequence: Item Standard Limit MAINTENANCE SPECIFICATIONS[...]

2 - 12 SPEC Tightening torques Part to be tightened Part name Thread size Q ’ ty Tightening torque Remarks Nm m · kg ft · lb Cylinder head oil passage Union bolt M6 1 7 0.7 5.1 Cylinder head (exhaust pipe) Stud bol t M8 2 15 1 .5 11 Cylinder head Bolt M10 4 40 4.0 29 Bolt M6 2 10 1.0 7.2 Camshaft sprocket cover baffle plate Bolt M6 2 10 1.0 7.2[...]

2 - 13 SPEC Middle driven shaft drive pinion gear Nut M22 1 130 1 3 94 Stake Middle drive shaft bearing ho using Bolt M8 6 32 3.2 23 Middle driven gear bearing retainer Nut M65 1 110 11 80 LT Left-hand threads Yoke (middle driven gear) Nut M14 1 97 9.7 70 LT Middle driven gear bearing housing Bolt M8 4 25 2.5 18 Middle driven sh aft bearing retaine[...]

2 - 14 SPEC CHASSIS Item Standard Limit Steering system: Steering bearing type Ball and race bearing ---- Front suspension: Shock absorber travel 99 mm (3.90 in) ---- Fork spring free length 265 mm (10.43 in) ---- Spring fitting length 215.8 mm (8.50 in) ---- Spring rate (K1) 15 N/mm ( 1.53 k g/mm , 85. 68 lb /in) ---- Stroke (K1) 0 ~ 99 mm (0 ~ 3.[...]

2 - 15 SPEC Front disc brake: Type Dual ---- Disc outside diameter × thickness 200.0 × 3.5 mm (7.87 ~ 0.14 in) ---- Pad thickness inner 4.5 mm (0.18 in) 1 mm (0.04 in) Pad thickness outer 4.5 mm (0.18 in) 1 mm (0.04 in) Master cylinder inside diameter 14 mm (0.55 in) ---- Caliper cylinder inside diameter 32 mm (1.26 in) ---- Brake fluid type DOT [...]

2 - 16 SPEC Tightening torques Part to be tightened Thread size Tightening torque Remarks Nm m · kg ft · lb Engine bracket (front-upper) and frame M8 33 3.3 24 Engine bracket (front-lower) and fra me M8 33 3.3 24 Engine bracket (front-upper) and engine M10 42 4.2 30 Engine bracket (front-lowe r) and engine M10 4 2 4.2 30 Engine and frame M10 5 6 [...]

2 - 17 SPEC Front bumper and frame M8 33 3.3 24 Front carrier and frame M8 33 3.3 24 Front carrier and front bumper M8 33 3.3 24 Rear carrier and frame M8 33 3.3 24 Differential gear case filler bolt M14 23 2.3 17 Differential gear case drain bolt M10 10 1.0 7 Differential gear case and bearing housing M8 25 2.5 18 Gear motor M8 13 1.3 9.4 Final ge[...]

2 - 18 SPEC ELECTRICAL Item Standard Limit Voltage: 12 V ---- Ignition system: Ignition timing (B.T.D.C.) 10 ° / 1,500 r/min ---- C.D.I.: Magneto model/manufacturer F4T46472/MITSUBISHI ---- Pickup coil resistance/color 459 ~ 561 Ω at 20 ° C (68 ° F)/ White/Red – White/Green ---- Rotor rotation direction sensing coil resistance/color 0.085 ~ [...]

2 - 19 SPEC Brush overall length 12.5 mm (0.49 in) 5 mm (0.20 in) Spring force 7.65 ~ 10.01 N (780 ~ 1,020 g, 27.54 ~ 36.03 oz) ---- Commutator diameter 28 mm (1.10 in) 27 mm (1.06 in) Mica undercut 0.7 mm (0.03 in) ---- Starter relay Model/manufacturer MS5F-561/JIDECO ---- Amperage rating 180 A ---- Coil winding resistance 4.18 ~ 4.62 Ω at 20 °[...]

2 - 20 SPEC EB201000 HOW TO USE THE CONVERSION TABLE All specification data in this manual are listed in SI and METRIC UNITS. Use this table to convert METRIC unit data to IMPERIAL unit data. Ex. CONVERSION TABLE EB202001 GENERAL TORQUE SPECIFICATIONS This chart specifies torque for standard fasteners with standard I.S.O. pitch threads. Torque spec[...]

2 - 21 SPEC LUBRICATION POINTS AND LUBRICANT TYPES ENGINE Lubrication points Lubricant type Oil seal lip (all) LS O-ring (all) LS Bearing (all) E Crank pin E Connecting rod (bearing) E Camshaft sprocket M Crankshaft E Piston surface/piston rings E Piston pin E Buffer boss E Valve stem/valve stem end M Rocker arm shaft E Rocker arm M Camshaft lobe/j[...]

2 - 22 SPEC COOLANT FLOW DIAGRAMS 1 Radiator 2 Thermo switch (radiator) 3 Fan motor È To coolan t reservoir COOLANT FLOW DIAGRAMS[...]

2 - 23 SPEC 1 Radiator 2 Thermostat È To coolan t reservoir COOLANT FLOW DIAGRAMS[...]

2 - 24 SPEC OIL FLOW DIAGRAMS 1 Camshaft 2 Crankshaft 3 Drive axle OIL FLOW DIAGRAMS[...]

2 - 25 SPEC 1 Oil filter OIL FLOW DIAGRAMS[...]

2 - 26 SPEC 1 Oil pump 2 Oil strainer OIL FLOW DIAGRAMS[...]

2 - 27 SPEC CABLE ROUTING 1 Rear brake switch lead 2 Starter cable 3 Rear brake cable 4 Front brake ho se 5 On-command four-wheel drive swit ch 6 Throttle cable 7 Handlebar switch 8 Handlebar switch lead 9 Main switch lead 0 Fan motor breat her hose A Differential gear case br eather hose B Sub-wire harness (to g ear motor) C On-command four-wh eel[...]

2 - 28 SPEC È Fasten the on-com mand four-wheel drive switch lead behind the ha ndlebar with a plastic ba nd. É Fasten the starter cable, handlebar switch le ad and rear b rake switch lead behind the handlebar with a plastic band. Ê Fasten the handleba r switch lead and rear brake switch lea d behind the handlebar with a plastic band. CABLE ROUT[...]

2 - 29 SPEC 1 Sub-wire harness 2 Headlight lead 3 Auxiliary DC jack lead 4 Meter assemb ly coupler 5 Differential gear case breather hose 6 Coolant reservo ir breather hose 7 Fan motor brea ther hose CABLE ROUTING[...]

2 - 30 SPEC 1 Starter cable 2 Cylinder hea d breather h ose 3 Fuel hose 4 Carburetor drain hose 5 Rear brake lever cable 6 Coolant reservo ir breather hose 7 Radiator outlet hose 8 Coolant reserv oir hose 9 Sub-wire harn ess 0 Differential gear case breather hose A Thermo switch (radiator) B Speedometer cable È Insert the fuel ta nk breather hos e[...]

2 - 31 SPEC 1 Cylinder hea d breather h ose 2 Final drive gear case brea ther hose 3 Rear brake breather hose 4 Wire harness 5 Starter moto r lead 6 Negative batte ry lead 7 Rear brake lever cable 8 Air filt er case c heck ho se 9 Water pump brea ther hose 0 Radiator outlet hose A Starter cable B Float chamber air vent hose C Cylinder head breather[...]

2 - 32 SPEC È Fasten the wire harness with a plastic ban d. É Fasten the start er motor lead, wire harness, negat ive battery lea d, final drive g ear case breather hose, rear brake breather hose, rectifier/re gulator lead, g ear position switch lead and A.C. magn eto lead with a plastic band. Ê Fasten the wire harness, start er motor lead with [...]

2 - 33 SPEC 1 Throttle cable 2 Radiator inlet hose 3 Spark plug lead 4 Main switch 5 Wire harness 6 Rear brake light switch lead 7 Select lever control cable 8 Rear brake pedal cable È Fasten the radiat or inlet hose and spark plu g lead with a plastic band. CABLE ROUTING[...]

2 - 34 SPEC 1 Front brake ho se 2 Float chamb er air vent hose 3 Throttle cable 4 Wire harness 5 Final drive gear case brea ther hose 6 Rear brake breather hose 7 Starter cable 8 Rear brake lever cable CABLE ROUTING[...]

2 - 35 SPEC 1 Battery 2 Negative batte ry lead 3 Tail/brake light lead 4 CDI unit 5 Positive battery lead CABLE ROUTING[...]

2 - 36 SPEC 1 Rear brake pedal cable 2 Final drive gear case brea ther hose 3 Rear brake breather hose 4 Rear brake lever cable 5 Air filt er case c heck ho se CABLE ROUTING[...]

3 - 1 CHK ADJ INTRODUCTION/ PERIODIC MAINTENANCE/LUBRICATION EB300000 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information ne cessary to perform recommended checks and ad justments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and a longer service life. The need for [...]

3 - 2 CHK ADJ PERIODIC MAINTENANCE/LUBRICATION * It is recommended that these items be service d by a Yamaha dealer. N OTE: ● Recommended brake fluid: DOT 4 ● 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[...]

3 - 3 CHK ADJ SEAT, CARRIERS, FENDERS AND FUEL TANK SEAT, CARRIERS, FENDERS AND FUEL TANK SEAT AND SIDE PANELS Order Job n ame/Part name Q ’ ty Remarks Removing the seat and side panel s Remove the parts in the order below. 1S e a t 1 N OTE: Pull up the seat lock lever, then pull up on the rear of the seat. 2 Fuel tank side panel (left) 1 3 Fuel [...]

3 - 4 CHK ADJ SEAT, CARRIERS, FENDERS AND FUEL TANK FRONT CARRIER, FRONT BUMPER AND FRONT FENDER Order Job n ame/Part name Q ’ ty Remarks Removing the front carrier, front bumper and front fender Remove the parts in the order below. Seat and fuel tank side panels Refer to “ SEAT AND SIDE PANELS ” . 1 F ront carrier 1 2 Front fender panel 1 3 [...]

3 - 5 CHK ADJ SEAT, CARRIERS, FENDERS AND FUEL TANK Order Job n ame/Part name Q ’ ty Remarks 11 Auxiliary DC jack connector 2 Disconnect. 12 Meter assembly coupler 3 Disconnect. 13 Speedometer cable 1 Disconnect. 14 Coolant reservoir breather hose 1 15 Fan motor breather hose 1 16 Differential gear case breather hose 1 17 Front fender 1 For insta[...]

3 - 6 CHK ADJ SEAT, CARRIERS, FENDERS AND FUEL TANK REAR CARRIER AND RE AR FENDER Order Job n ame/Part name Q ’ ty Remarks Removing the rear carrier and rear fender Remove the parts in the order below. Seat and fuel tank side panels Refer to “ SEAT AND SIDE PANELS ” . Fuel tank Refer to “ FUEL TA NK ” . 1 R ear carrier 1 2 B attery holdin[...]

3 - 7 CHK ADJ SEAT, CARRIERS, FENDERS AND FUEL TANK Order Job n ame/Part name Q ’ ty Remarks 8 C .D.I. unit 1 9 Wire harness 1 10 Rear fender 1 For installation, reverse the removal procedure.[...]

3 - 8 CHK ADJ SEAT, CARRIERS, FENDERS AND FUEL TANK FUEL TANK Order Job n ame/Part name Q ’ ty Remarks 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 ” . 1 Fuel hose 1 N OTE: Before discon[...]

3 - 9 CHK ADJ FOOTREST BOARDS FOOTREST BOARDS Order Job n ame/Part name Q ’ ty Remarks Removing the footrest boards Remove the parts in the order below. Fuel tank side panels Refer to “ SEAT AND SIDE PANELS ” . 1 Left footrest board 1 2 R ight footrest board 1 3 Footrest bracket 4 For installation, reverse the removal procedure.[...]

3 - 10 CHK ADJ ADJUSTING THE VALVE CLEARANCE ENGINE ADJUSTING THE VALV E CLEARANCE N OTE: ● The valve clearance must be adjusted when the engine is cool to the touch. ● Adjust the valve clearance when the piston is at the Top Dead Center (T.D.C.) on the compression stroke . 1.Remove: ● Seat ● Front carrier ● Front fender ● Fuel tank Ref[...]

3 - 11 CHK ADJ ADJUSTING THE VALVE CLEARANCE 7.Check: ● Valve clearance Out of specification → Adjust. ********************* ********************** ********** Checking steps: ● Turn the crankshaft counterclockwise with a wrench. ● Align the “ T ” mark 1 on the rotor with the stationary pointer 2 on the crankcas e cover. When the “ T ?[...]

3 - 12 CHK ADJ ADJUSTING THE VALVE CLEARANCE 8.Adjust: ● Valve clearance ********************* ********************** ********** Adjustment steps: ● Loosen the locknut 1 . ● Insert a feeler gauge 2 between the a djuster end and the valve end. ● Turn the adjuster 3 clo ckwise or counterclockwise with the valve adjusting tool 4 until the prop[...]

3 - 13 CHK ADJ ADJUSTING THE VALVE CLEARANCE/ ADJUSTING THE IDLING SPEED 11.Install: ● Fuel tank ● Front fender ● Front carrier ● 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: ● Seat ● Fuel tank side panels Refer to “ SEAT, [...]

3 - 14 CHK ADJ ADJUSTING THE IDLING SPEED/ ADJUSTING THE THROTTLE LEVER FREE PLAY 5.Adjust: ● Engine idling speed ********************* ********************** ********** Adjustment steps: ● Turn the throttle stop screw 1 in or out until the specified idling speed is obtained . ********************* ********************** ********** 6.Detach: ?[...]

3 - 15 CHK ADJ ADJUSTING THE THROTTLE LEVER FREE PLAY 1.Check: ● Throttle lever free play a Out of specification → Adjust. Throttle lever free play: 3 ~ 5 mm (0.12 ~ 0.20 in) 2.Remove: ● Seat ● Fuel tank side panel (right) Refer to “ SEAT, CARRIERS, FENDERS AND FUEL TANK ” . 3.Adjust: ● Throttle lever free play ********************* *[...]

3 - 16 CHK ADJ ADJUSTING THE THROTTLE LEVER FREE PLAY/ ADJUSTING THE SPEED LIMITER Second step: ● Pull back the adjuster cover 4 . ● Loosen the locknut 5 . ● Turn the adjuster 6 in or out until the corre ct free play is obtained. ● Tighten the locknut 5 . ● Push in the adjuster cover 4 . W ARNING After adjusting the free play, turn the ha[...]

3 - 17 CHK ADJ ADJUSTING THE SPEED LIMITER/ ADJUSTING THE STARTER CABLE 2.Adjust: ● Speed limiter length ********************* ********************** ********** Speed limiter length adjustment steps: ● Loosen the locknut 1 . ● Turn the adjuster 2 in or out until the specified speed limiter length is obta ined. ● Tighten the locknut. W ARNIN[...]

3 - 18 CHK ADJ ADJUSTING THE STARTER CABLE 2.Adjust: ********************* ********************** ********** Adjustment steps: ● Disconnect the starter cable 1 from the carburetor body. N OTE: Do not remove the starter p lunger 2 from the starter cable. ● Measure the starter plunger stro ke distance a of the starter lever 3 fully close to fully[...]

3 - 19 CHK ADJ CHECKING THE SPARK PLUG CHECKING THE SPARK PLUG 1.Remove: ● Seat ● Fuel tank side panel (right) Refer to “ SEAT, CARRIERS, FENDERS AND FUEL TANK ” . 2.Remove: ● Spark plug 3.Check: ● Spark plug type Incorrect → Replace. Standard spark plug: DR8EA/NGK 4.Check: ● Electrode 1 Wear/damage → Replace. ● Insulator 2 Abno[...]

3 - 20 CHK ADJ CHECKING THE IGNITION TIMING CHECKING THE IGNITION TIMING N OTE: Engine idling speed and throttle cable free play should be adjusted properly before che cking the ignition timing. 1.Remove: ● Seat ● Fuel tank side panel (right) Refer to “ SEAT, CARRIERS, FENDERS AND FUEL TANK ” . 2.Attach: ● Inductive self-powered tachomete[...]

3 - 21 CHK ADJ 4.Detach: ● Timing light ● Inductive self-powered tachometer or engine tachometer 5.Install: ● Seat ● Fuel tank side panel (right) Refer to “ SEAT, CARRIERS, FENDERS AND FUEL TANK ” . MEASURING THE COMPRESSION PRESSURE N OTE: Insufficient compression pressure will result in a loss of performance. 1.Check: ● Valve cleara[...]

3 - 22 CHK ADJ MEASURING THE COMPRESSION PRESSURE 7.Measure: ● 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. ● Refer to the table below. ********************* *****[...]

3 - 23 CHK ADJ CHECKING THE ENGINE OIL LEVEL CHECKING THE ENGINE OIL LEVEL 1.Place the machine on a level surface. 2.Remove: ● Engine side panel Refer to “ SEAT, CARRIERS, FENDERS AND FUEL TANK ” . 3.Check: ● Engine oil level Oil level should be between the maximu m level mark 1 and minimu m level mark 2 . Oil level low → Add oil to the p[...]

3 - 24 CHK ADJ CHANGING THE ENGINE OIL 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: ● Seat ● Fuel tank side panel (left) ● Engine side cover Refer to “ SEAT, CARRIERS, FENDERS AND FUEL TANK ” . 4.Remove: ● Engine oil filler plug (dip[...]

3 - 25 CHK ADJ ● Lubricate the O-ring 3 of th e new oil filter cartridge with a thin coat of eng ine oil. CAUTION: Make sure that the O-rin g 3 is positioned correctly in the groove of the oil filter cartridge. ● Tighten the new oil filter cartridge to specification with an oil filter wrench. ********************* ********************** *******[...]

3 - 26 CHK ADJ CHANGING THE ENGINE OIL/ CLEANING THE AIR FILTER 13.Check: ● Engine oil pressure ********************* ********************** ********** ● Slightly loosen the oil gallery bolt 1 . ● Start the engine and keep it idling until engine oil starts to seep from the oil gallery bolt. If no engine oil come s out after one minute, turn t[...]

3 - 27 CHK ADJ CLEANING THE AIR FILTER 1.Remove: ● Seat Refer to “ SEAT, CARRIERS, FENDERS AND FUEL TANK ” . 2.Remove: ● Air filter case cover 1 3.Remove: ● Air filter element asse mbly 1 ● Air filter element cap ● Air filter element 2 Air filter el ement cap 3 Air filter eleme nt CAUTION: Never operate the engine with the air filter [...]

3 - 28 CHK ADJ CLEANING THE AIR FILTER 5.Clean: ● Air filter element ********************* ********************** ********** Cleaning steps: ● Wash the element gently, but thoroughly in solvent. W ARNING Use a cleaning solvent which is designed to clean parts only. Nev er use gasoline or low flash point solvents as they may ca use a fire or exp[...]

3 - 29 CHK ADJ CHECKING THE COOLANT LEVEL CHECKING THE COOLANT LEVEL 1.Place the machine on a level surface. 2.Remove: ● Seat ● Fuel tank side panel (left) Refer to “ SEAT, CARRIERS, FENDERS AND FUEL TANK ” . 3.Check: ● Coolant level The coolant level should be between the minimum level mark a and maximum level mark b . Below the minimum [...]

3 - 30 CHK ADJ CHANGING THE COOLANT CHANGING THE COOLANT 1.Remove: ● Seat ● Fuel tank side panel (left) ● Engine side cover ● Front carrier ● Engine skid plate ● Front fender Refer to “ SEAT, CARRIERS, FENDERS AND FUEL TANK ” . ● Left footrest board Refer to “ FOOTREST BOARDS ” . 2.Remove: ● Plastic band 1 ● Coolant reserv[...]

3 - 31 CHK ADJ CHANGING THE COOLANT 8.Remove: ● Coolant drain bolt (cylinder) 1 (along with the copper washer) ● Coolant drain bolt (water pump) 2 (along with the copper washer) 9.Drain: ● Coolant 10.Check: ● Copper washer 1 ● Coolant drain bolt 2 Damage → Replace. 11.Install: ● Coolant drain bolt (water pump) ● Coolant drain bolt ([...]

3 - 32 CHK ADJ CHANGING THE COOLANT CAUTION: ● Adding water instead of coo lant lowers the antifreeze content of the coolant. If water is used instead of coolant, check, and if necessary, correct the antifree ze concentration of the coolant. ● Use only distilled water. However, soft water may be used if distilled water is not available. ● If [...]

3 - 33 CHK ADJ CHECKING THE COOLANT TEMPERATURE WARNING LIGHT/CHECKING THE V-BELT CHECKING THE COOLANT TEMPERATURE WARNING LIGHT 1 Coolant tempera ture warning ligh t Turn the main switch “ ON ” and the engine stop switch to “” . Coolant temper ature warning light ch ecking method Coolant temp erature warn ing light does not come on. Push s[...]

3 - 34 CHK ADJ CHECKING THE V-BELT 4.Replace: ● V-belt ********************* ********************** ********** Replacing steps: ● Install the bolts 1 (90101-06016) into the secondary fixe d sheave hold. N OTE: Tightening the bolts 1 will push th e secondary sliding sheave away, causing the gap between the secondary fixed and sliding shea ves to[...]

3 - 35 CHK ADJ CLEANING THE SPARK ARRESTER CLEANING THE SPARK ARRESTER 1.Clean: ● Spark arrester ********************* ********************** ********** Cleaning steps: W ARNING ● Select a well-ventilated area free of combustible materials. ● Always let the exhaust system cool before performing this operation. ● Do not start the engine when[...]

3 - 36 CHK ADJ ADJUSTING THE REAR BRAKE CHASSIS ADJUSTING THE REAR BRAKE W ARNING Always adjust both the brake pedal and the rear brake lever whenever adjusting the rear brake. 1.Check: ● Rear brake pedal free play a ● Rear brake lever free play b Out of specification → Adjust. Rear brake pedal free play: 20 ~ 30 mm (0.80 ~ 1.18 in) Rear brak[...]

3 - 37 CHK ADJ ADJUSTING THE REAR BRAKE ● Turn the brake lever cable adjusting nut (drum) 3 clockwise until the gap a is within the specified limits. Gap a : 0 ~ 1 mm (0.00 ~ 0.04 in) ● Checking the rear brake pedal free play to see whether or not it is within the specified limits. If not, perform the above steps again. ● Turn the brake lever[...]

3 - 38 CHK ADJ CHECKING THE FRONT BRAKE FLUID LEVEL 1.Place the machine on a level surface. N OTE: When checking the front brake fluid level, make sure that the top of the master cylinder top is horizontal. 2.Check: ● Brake fluid level Fluid level is under “ LOWER ” level line 1 → Fill up. CAUTION: Brake fluid may erode painted surfa ces or[...]

3 - 39 CHK ADJ CHECKING THE FRONT BRAKE PADS/ CHECKING THE REAR BRAKE SHOES CHECKING THE FRONT BRAKE PADS 1.Remove: ● Front wheel 2.Check: ● Brake pads Wear indicator groove 1 almo st touch the brake disc → Replace the brake pads as a set. Refer to “ FRONT BRAKE ” in CHAPTER 8. 3.Operate the brake lever. 4.Install: ● Front wheel Brake p[...]

3 - 40 CHK ADJ CHECKING THE BRAKE HOSES CHECKING THE BRAKE HOSES 1.Remove: ● Seat ● Front carrier ● Front fender Refer to “ SEAT, CARRIERS, FENDERS AND FUEL TANK ” . 2.Check: N OTE: Hold the machine in an upright p osition and apply the parking brake. ● Front brake hoses 1 Cracks/wear/damage → Re place. Fluid leakage → Replace any d[...]

3 - 41 CHK ADJ BLEEDING THE HYDRAULIC BRAKE SYSTEM BLEEDING THE HYDRAULIC BRAKE SYSTEM W ARNING Bleed the brake system if: ● The system has been disassembl ed. ● A brake hose or brake p ipe have been loosened or removed. ● The brake fluid has been very l ow. ● The brake operation has been faulty. A loss of braking performance ma y occur if [...]

3 - 42 CHK ADJ BLEEDING THE HYDRAULIC BRAKE SYSTEM/ ADJUSTING THE SELECT LEVER CONTROL CABLE AND SHIFT ROD W ARNING Check the operation of the brake after bleeding the brake system. ********************* ********************** ********** ADJUSTING THE SELE CT LEVER CONTROL CABLE AND SHIFT ROD 1 NEUTRAL 2 FORWARD 3 REVERSE 4 Control cable 5 Select l[...]

3 - 43 CHK ADJ ADJUSTING THE SELECT LEVER CON TROL CABLE AND SHIFT ROD/ ADJUSTING THE REAR BRAKE LIGHT SWITCH ● When the brake begins to work “ a = 20 ~ 30 mm (0.8 ~ 1.2 in) ” , verify that the select lever can be shifted to REVERSE from NEUTRAL, to NEUTRAL from REVERSE. ● Before the brake begins to work “ a = 0 ~ 20 mm (0 ~ 0.8 in) ” ,[...]

3 - 44 CHK ADJ ADJUSTING THE REAR BRAKE LIGHT SWITCH/ CHECKING THE FINAL GEAR OIL LEVEL 2.Adjust: ● Rear brake light switch operation timing *********************************************** ● 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 a or b until the rear brake light [...]

3 - 45 CHK ADJ CHANGING THE FINAL GEAR OIL CHANGING THE FINAL GEAR OIL 1.Place the machine on a level surface. 2.Remove: ● Final gear case protector 1 3.Place a receptacle under the final gear case. 4.Remove: ● Oil filler bolt ● Drain plug 1 5.Drain: ● Final gear oil 6.Install: ● Drain plug N OTE: Check the drain plug gasket. If it is dam[...]

3 - 46 CHK ADJ CHANGING THE DIFFERENTIAL GEAR OIL/CHECKING THE CONSTANT VELOCITY JOINT DUST BOOTS CHANGING THE DIFFERENTIAL GEAR OIL 1.Place the machine on a level surface. 2.Place a receptacle under the differential gear case. 3.Remove: ● Oil filler bolt ● Drain plug 1 4.Drain: ● Differential gear oil 5.Install: ● Drain plug N OTE: Check t[...]

3 - 47 CHK ADJ 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 ste m bearing. 3.Check: ● Tie-rod ends Turn the handlebar to the left and/or right until it stops completely, then move the handl[...]

3 - 48 CHK ADJ ● Measure the width È between the marks. ● Rotate the front tires 180 ° until the marks are exactly opposite one another. ● Measure the width É between the marks. ● Calculate the toe-in using the formula given below. ● If the toe-in is incorrect, adjust it. ********************* ********************** ********** 3.Adjust[...]

3 - 49 CHK ADJ ADJUSTING THE FRONT SHOCK ABSORBERS/ADJUSTING THE REAR SHOCK ABSORBER/CHECKING THE TIRES ADJUSTING THE FRONT SHOCK ABSORBERS W ARNING Always adjust both front shock absorber spring preload to the same setting. Uneven adjustment can cause poor handling and loss of stability. 1.Adjust: ● Spring preload Turn the adjuster 1 to increase[...]

3 - 50 CHK ADJ CHECKING THE TIRES ● TIRE CHARACTERISTICS 1)Tire characteristics influence the handling of ATVs. 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 hand ling characteristics and are therefore not recommended. ● TIRE PR[...]

3 - 51 CHK ADJ CHECKING THE TIRES 1.Measure: ● Tire pressure (cold tire pressure) Out of specification → Adjust. N OTE: ● The low-pressure tire gauge 1 is inclu ded as standard equipment. ● If dust or the like is stuck to this gauge, it will not provide the correct readings. There fore, take two measurements of the tire ’ s pressure and u[...]

3 - 52 CHK ADJ CHECKING THE WHEELS/ CHECKING AND LUBRICATING THE CABLES CHECKING THE WHEELS 1.Check: ● Wheel 1 Damage/bends → Replace. N OTE: Always balance the wheel when a tire or wheel has been changed or replaced. W ARNING ● Never attempt even small repairs to the wheel. ● Ride conservatively after installing a tire to allow it to seat [...]

3 - 53 CHK ADJ LUBRICATING THE LEVERS, PEDAL, ETC. LUBRICATING THE LEVERS, PEDA L, ETC. 1.Lubricate the pivoting parts. Recommended lubricant: Lithium soap base grease[...]

3 - 54 CHK ADJ CHECKING THE BATTERY EB305000 ELECTRICAL CHECKING THE BATTERY N OTE: Since the MF battery is a sealed-t ype battery, it is not possible to measure the specific gravity of the electrolyte in order to check the charge state of the battery. Ther efore, the charge of the battery has to be checked by measuring the voltage at the battery t[...]

3 - 55 CHK ADJ Batteries generate explosive hy drogen gas. Always follow these preventive measures: ● Charge batteries in a well-ventilated area. ● Keep batteries away from fire, sparks or open flames (e.g., welding equipment, lighted cigarettes, etc. ) ● DO NOT SMOKE when charging or handling batteries. KEEP BATTERIES AND ELECTROLYTE OUT OF [...]

3 - 56 CHK ADJ CHECKING THE BATTERY ● Check the condition of the battery using the following charts. Example: ● Open-circuit voltage = 12.0 V ● Charging time = 6.5 hours ● Charge condition of the battery = 2 0 ~ 30% ● Charging method for MF batteries CAUTION: ● If it is impossible to set the standard charging current, be careful not to [...]

3 - 57 CHK ADJ CHECKING THE BATTERY Charging method using a variable voltage ch arger Measure the open -circuit voltage prior to chargin g. Connect a char ger and ammeter to the batt ery and start charging . Is the amperage hig her than the standa rd charging amperage wr itten on the battery? NO YES Charger Ammeter Adjust the voltage to obtain the [...]

3 - 58 CHK ADJ CHECKING THE BATTERY Charging method using a constant voltage charger Measure the open-circuit voltage prior to chargi ng. Connect a char ger and ammeter to the batter y and start charging. NO YES Is the amperage hi gher than the stand ard charging amperage writt en on the battery? Charge the battery until th e charging voltage reach[...]

3 - 59 CHK ADJ CHECKING THE BATTERY/ CHECKING THE FUSES 5.Check: ● Battery terminals Dirty → Clean with a wire brush. N OTE: After cleaning the terminals, apply a light coat of grease. 6.Install: ● Battery 7.Connect: ● Battery leads CAUTION: First, connect the positive lead 1 , then connect the negative lead 2 . 8.Install: ● Battery lead [...]

3 - 60 CHK ADJ CHECKING THE FUSES N OTE: Set the tester to the “ Ω × 1 ” position. ● If the tester indicates ∞ , replace the fuse. ********************* ********************** ********** Pocket tester: P/N. YU-03112-C, 90890-03112 3.Replace: ● Blown fuse(s) ********************* ********************** ********** Replacement steps: ● [...]

3 - 61 CHK ADJ CHECKING THE FUSES/ADJUSTING THE HEADLIGHT BEAMS/CHANGING THE HEADLIGHT BULB W ARNING 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 o f the lighting and ignition systems and could possibly ca u[...]

3 - 62 CHK ADJ CHANGING THE HEADLIGHT BULB 2.Remove: ● Bulb holder 1 ● Bulb N OTE: Turn the bulb holder counterclockwise and remove the defective bulb. W ARNING Keep flammable products and y our hands away from the bulb while it is on, since it will be hot. Do not touch the bulb until it cools down. 3.Install: ● Bulb Secure the new bulb with [...]

4 - 1 ENG ENGINE REMOVAL ENGINE ENGINE REMOVAL AIR DUCTS, MUFFLER AND EXHAUST PIPE Order Job n ame/Part name Q’ty Remarks Removing the air ducts, muffler and exhaust pipe Remove the parts in the order below. Engine oil Drain. Refer to “CHANGING THE ENGINE OIL” in CHAPTER 3. Front and rear fender/footrest boards Refer to “SEAT, CARRIERS, FEN[...]

4 - 2 ENG ENGINE REMOVAL Order Job name/Part name Q ’ ty Remarks 6 Final drive gear case breather hose 1 7 Rear brake breather hose 1 8 Cylinder head breather hose 1 9 Vacuum chamber breather hose 1 10 Air filter case 1 For installation, reverse the removal procedure.[...]

4 - 3 ENG ENGINE REMOVAL SELECT LEVER UNIT AND COOLANT RESERVOIR Order Job name/Part name Q ’ ty Remarks Removing the select lever unit and coolant reservoir Remove the parts in the order below. 1 Select lever shift rod 1 2 Select lever unit 1 3 Coolant reservoir breather hose 1 4 Coolant reservoir hose 1 5 Coolant reservoir 1 For installation, r[...]

4 - 4 ENG ENGINE REMOVAL HOSES AND LEADS Order Job name/Part name Q ’ ty Remarks Removing the hoses and leads Remove the parts in the order below. Water pump inlet hose Ref e r to “ WATER PUMP ” in CHAPTER 5. 1 Cylinder head breather hose 1 2 Spark plug lead 1 Disconnect. 3 Thermo switch (cylinder head) lead 1 4 Starter motor lead 1 5 A.C. ma[...]

4 - 5 ENG ENGINE REMOVAL ENGINE MOUNTING BOLTS Order Job name/Part name Q ’ ty Remarks Removing the engine mounting bolts Remove the parts in the order below. Rear wheels Refer to “ FRONT AND REAR WHEELS ” in CHAPTER 8. Swingarm Refer to “ REAR SHOCK ABSORBER AND SWINGARM ” in CH APTER 8. 1 Engine mounting bolt (rear-lower)/nut 1/1 2 Engi[...]

4 - 6 ENG ENGINE REMOVAL Order Job name/Part name Q ’ ty Remarks 9 Engine assembly 1 N OTE: Remove the engine assembly from the left side of the machine. For installation, reverse the removal procedure.[...]

4 - 7 ENG INSTALLING THE ENGINE 1.Install: ● Engine bracket (front upper) 1 ● Engine mounting bolt (front upper)/nut 2 ● Engine bracket bolt (front upper) 3 ● Engine bracket (front lower) 4 ● Engine mounting bolt (front lower) 5 ● Engine bracket bolt (front lower) 6 ● Engine mounting bolt (rear upper)/nut 7 ● Engine mounting bolt (r[...]

4 - 8 ENG CYLINDER HEAD CYLINDER HEAD Order Job name/Part name Q ’ ty Remarks Removing the cylinder head Remove the parts in the ord er below. Fuel tank/rubber cover Refer to “ SEAT, CARRIERS, FENDERS AND FUEL TANK ” in CHAPTER 3. Front fender/air filter case Air duct assembly 1 Refer to “ ENGINE REMOVAL ” . Exhaust pipe/muffler Carbureto[...]

4 - 9 ENG CYLINDER HEAD Order Job name/Part name Q ’ ty Remarks 5 Cylinder head breather hose 1 6 Camshaft sprocket cover/O-ring 1/1 7 Tappet cover/O-ring 2/2 8 Thermo switch (cylinder head) lead 1 Disconnect. 9 Timing chain tensioner cap bolt 1 Refer to “ REMOVING/INSTALLING THE CYLINDER HEAD ” . 10 Timing chain tensioner/gasket 1/1 11 Camsh[...]

4 - 10 ENG CYLINDER HEAD REMOVING THE CYLINDER HEAD 1.Align: ● “ T ” mark (with stationary pointer) ********************* ********************** ********** Checking steps: ● Turn the crankshaft counterclockwise with a wrench. ● Align the “ T ” mark 1 on the rotor with the stationary pointer 2 on the crankcase cover. When the “ T ”[...]

4 - 11 ENG CYLINDER HEAD N OTE: ● Fasten a safety wire to t he timing chain to prevent it from falling int o the crankcase. ● When removing the camshaft sprocket, it is not necessary to separate the timin g chain. 5.Remove: ● Cylinder head N OTE: ● Loosen the 6 mm bolts first. ● Working in a crisscross patte rn, loosen each 10 mm bolt 1/4[...]

4 - 12 ENG CYLINDER HEAD CHECKING THE CYLINDER HEAD 1.Eliminate: ● Carbon deposits (from the combustion chambers) Use a rounded scraper. N OTE: Do not use a sharp instrume nt to avoid damaging or scratching: ● Spark plug threads ● Valve seats 2.Check: ● Cylinder head Scratches/da mage → Replace. ● Cylinder head water jacket Mineral depo[...]

4 - 13 ENG CYLINDER HEAD INSTALLING THE CYLINDER HEAD 1.Install: ● Cylinder head ● Bolts (M10) ● Bolts (M6) N OTE: ● Lubricate the washer with engine oil. ● Tighten the bolts (M10) in two stages a nd a crisscross pattern. T R . . 40 Nm (4.0 m • kg, 29 ft • lb) T R . . 10 Nm (1.0 m • kg, 7.2 ft • lb) 2.Install: ● Camshaft sprocke[...]

4 - 14 ENG CYLINDER HEAD N OTE: Be sure the “ I ” mark 5 on the camshaft sprocket is aligned with the match mark 2 on the cylinder head. ● Force the camshaft clockwise and counterclockwise to remove timing chain slack. ● Insert a screwdriver into the timing chain tensioner hole and push the timing chain guide inward. ● While pushing the t[...]

4 - 15 ENG CYLINDER HEAD 4.Tighten: ● Camshaft sprocket bolt 1 N OTE: Use the rotor holding tool 2 to hold the starter pulley. 5.Check: ● Camshaft sprocket “ I ” mark ● Rotor “ T ” mark Out of alignment → Adjust. Rotor holding tool: P/N. YU-01235, 90890-01235 T R . . 60 Nm (6.0 m • kg, 43 ft • lb)[...]

4 - 16 ENG CAMSHAFT, ROCKER ARMS AND VALVES CAMSHAFT, ROCKER ARMS AND VALVES Order Job name/Part name Q ’ ty Remarks Removing the camshaft, rocker arms and valves Remove the parts in the order below. 1 Intake manifold/O-ring 1/1 2 Thermo switch (cylinder head) 1 3 Oil check bolt 1 4 Lock washer/bearing retainer 1/1 5 Camshaft 1 Refer to “ REMOV[...]

4 - 17 ENG CAMSHAFT, ROCKER ARMS AND VALVES Order Job name/Part name Q ’ ty Remarks 12 Valve spring (inner) 2 Refer to “ REMOVING/INSTALLING THE VALVES AND VALVE SPRINGS ” . 13 Valve (intake) 1 14 Valve (exhaust) 1 15 Valve stem seal 2 16 Valve spring seat 2 For installation, reverse the removal procedure.[...]

4 - 18 ENG CAMSHAFT, ROCKER ARMS AND VALVES REMOVING THE CAMSHAFT AND ROCKER ARMS 1.Remove: ● Camshaft 1 N OTE: Screw in a M10 bolt 2 into the thread hole on the camshaft, and pull out the camshaft. 2.Remove: ● Rocker arm shafts (intake and exhaust) 1 ● Rocker arms 2 N OTE: Use a slide hammer 3 to remove the rocker arm shafts. Slide hammer se[...]

4 - 19 ENG CAMSHAFT, ROCKER ARMS AND VALVES 2.Remove: ● Valve cotters N OTE: Attach a valve spring compressor 1 between the valve spring retainer and the cylinder head to remove the valve cotters. CHECKING THE CAMSHAFT 1.Check: ● Cam lobes Pitting/scratches/blue discoloration → Replace. 2.Measure: ● Cam lobes length a and b . Out of specifi[...]

4 - 20 ENG CAMSHAFT, ROCKER ARMS AND VALVES 2.Check: ● Rocker arms ● Rocker arm shafts Damage/wear → Replace. ********************* ********************** ********** Checking steps: ● Check the two contact areas o n the rocker arms for signs of abnormal wear. 1) Rocker arm shaft hole 2) Camshaft lobe contact surface Excessive wear → Repla[...]

4 - 21 ENG CAMSHAFT, ROCKER ARMS AND VALVES CHECKING THE VALVES AND VALVE SPRINGS 1.Measure: ● Stem-to-guide clearance Out of specification → Replace the valve guide. Stem-to-guide clearance = valve guide inside diameter a – valve stem diameter b Clearance (stem to guide): Intake: 0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in) <Limit>: 0.080 mm [...]

4 - 22 ENG CAMSHAFT, ROCKER ARMS AND VALVES 3.Check: ● Valve face Pitting/wear → Grind the face. ● Valve stem end Mushroom shape or diameter larger than the body of the stem → Replace. 4.Measure: ● Margin thickness a Out of specification → Replace. Margin th ickn ess: Intake: 1.0 ~ 1.4 mm (0.0394 ~ 0.05 51 in) Exhaust: 0.8 ~ 1.2 mm (0.0[...]

4 - 23 ENG CAMSHAFT, ROCKER ARMS AND VALVES ********************* ********************** ********** Measurement steps: ● Apply Mechanic ’ s blueing dye (Dykem) b to the valve face. ● Install the valve into the cylinder he ad. ● Press the valve through the valve guide and onto the valve seat to make a clear pattern. ● Measure the valve sea[...]

4 - 24 ENG CAMSHAFT, ROCKER ARMS AND VALVES ● Apply a fine lapping compound to the valve face and repeat the above ste ps. N OTE: After every lapping operation , be sure to clean off all of the compound from the valve face and valve se at. ● Apply Mechanic ’ s blueing dye (Dykem) to the valve face. ● Install the valve into the cylinder he a[...]

4 - 25 ENG CAMSHAFT, ROCKER ARMS AND VALVES 12.Measure: ● Spring tilt a Out of specification → Replace. Spring tilt limit: Inner: 2.5 ° /1.6 mm (0.06 in) Outer: 2.5 ° /1.6 mm (0.06 in) INSTALLING THE VALVES AND VALVE SPRINGS 1.Apply: ● Molybdenum disulfide oil (onto the valve stem and valve stem seal) 2.Install: ● Valve spring seat ● Va[...]

4 - 26 ENG CAMSHAFT, ROCKER ARMS AND VALVES INSTALLING THE CAMSHAFT AND ROCKER ARMS 1.Apply: ● Engine oil (onto the rocker arm shafts) 2.Install: ● Rocker arms 1 ● Rocker arm shafts (intake and exhaust) 2 N OTE: Use a slide hammer bolt 3 to install the rocker arm shafts. 3.Install: ● Camshaft 1 N OTE: Install the camshaft pin hole a facing [...]

4 - 27 ENG CYLINDER AND PISTON CYLINDER AND PISTON Order Job name/Part name Q ’ ty Remarks Removing the cylinder and piston Remove the parts in the order below. Cylinder head Refer to “ CYLINDER HEAD ” . Water pump outlet hose/pipe Ref er to “ WATER PUMP ” in CHAPTER 5. 1 Coolant inlet joint 1 2 Timing chain guide (exhaust) 1 3 Cylinder/O[...]

4 - 28 ENG CYLINDER AND PISTON REMOVING THE PISTON 1.Remove: ● Piston pin clips 1 ● Piston pin 2 ● Piston 3 N OTE: Before removing piston pin, deburr the clip groove and pin hole area. If the piston pin groove is deburred and the piston pin is still difficult to remove, use the piston p in puller 4 . CAUTION: Do not use a hammer to drive the [...]

4 - 29 ENG CYLINDER AND PISTON 2.Measure: ● Piston-to-cylinder clearance ********************* ********************** ********** Measurement steps: 1st step: ● Measure the cylinder bore “ C ” with the cylinder bore gauge. N OTE: Measure cylinder bore “ C ” by taking side-to- side and front-to-back measurements of the cylinder. Then, fin[...]

4 - 30 ENG CYLINDER AND PISTON 3rd step: ● Find the piston-to-cylinder clearance with the following formula. ● If out of specification, rebore or replace the cylinder, and replace the piston and piston rings as a set. ********************* ********************** ********** Piston-to-cylinder clearance = Cylinder bore “ C ” – Piston skirt [...]

4 - 31 ENG CYLINDER AND PISTON 3.Measure: ● Ring end gap Out of specification → Replace. N OTE: You cannot measure the end gap on the expander spacer of the oil control ring. If the oil control ring rails show excessive gap, replace all three rings. End gap Standard Limit Top ring 0.20 ~ 0.40 mm (0.0079 ~ 0.0157 in) 0.65 mm (0.0256 in) 2nd ring[...]

4 - 32 ENG CYLINDER AND PISTON ● If out of specification, replace the piston. ********************* ********************** ********** Piston pin-to-piston clearance: 0.004 ~ 0.024 mm (0.00016 ~ 0.00094 in) <Limit>: 0.074 mm (0.0029 in) INSTALLING THE PISTON 1.Install: ● Piston rings (onto the piston) N OTE: ● Be sure to install the pist[...]

4 - 33 ENG CYLINDER AND PISTON 4.Lubricate: ● Piston ● Piston rings ● Cylinder N OTE: Apply a liberal coating of engine oil. INSTALLING THE CYLINDER 1.Install: ● Cylinder N OTE: Install the cylinder with one hand while compressing the piston rings wit h the other hand. CAUTION: ● Be careful not to damage the timing chain damper during ins[...]

4 - 34 ENG RECOIL STARTER AND A.C. MAGNETO RECOIL STARTER AND A.C. MAGNETO Order Job name/Part name Q ’ ty Remarks Removing the A.C. 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. Left footrest board Refe[...]

4 - 35 ENG RECOIL STARTER AND A.C. MAGNETO Order Job name/Part name Q ’ ty Remarks 7 Pickup coil 1 8 Stator assembly 1 9 Rotor 1 Refer to “ REMOVING/INSTALLING THE A.C. MAGNETO ” . 10 Starter wheel gear 1 11 Woodruff key 1 12 Washer 1 13 Starter idle gear shaft 1 14 Washer/bearing 1/1 15 Starter idle gear 1 For installation, reverse the remov[...]

4 - 36 ENG RECOIL STARTER AND A.C. MAGNETO Order Job name/Part name Q ’ ty Remarks Disassembling the recoil starter Remove the parts in the order below. 1 Cap 1 Refer to “ DISASSEMBLING/ ASSEMBLING THE RECOIL STARTER ” . 2 Starter handle 1 3 Friction plate 1 4 Pawl spring 1 5 Drive pawl 1 6 Spring 1 7 Sheave drum 1 8 Rope 1 9 Coil spring 1 Fo[...]

4 - 37 ENG RECOIL STARTER AND A.C. MAGNETO REMOVING THE A.C. MAGNETO 1.Remove: ● Starter pulley 1 N OTE: Use the rotor holding tool 2 to hold the starter pulley. 2.Remove: ● Crankcase cover (left) ● Gasket ● Dowel pins N OTE: Working in a crisscross pattern, loosen each bolt 1/4 of a turn. Remove them a fter all of them are loosened. Rotor [...]

4 - 38 ENG RECOIL STARTER AND A.C. MAGNETO CHECKING THE STARTER CLUTCH 1.Check: ● Starter one-way clutch 1 Cracks/damage → Replace. ● Bolts 2 (starter clutch) Loose → Replace with a new one, and clinch the end of the bolt. N OTE: The arrow mark o n the starter cl utch must face inward, away from the rotor. ********************* ************[...]

4 - 39 ENG RECOIL STARTER AND A.C. MAGNETO CHECKING THE STARTER PULLEY 1.Check: ● Starter pulley Cracks/pitting → Deburr or replace. CHECKING THE RECOIL STARTER 1.Check: ● Rope 1 ● Sheave drum 2 ● Drive pawl 3 Wear/damage → Replace. ● Coil spring 4 ● Pawl spring 5 ● Spring 6 Fatigue → Replace. ASSEMBLING THE RECOIL STARTER 1.Ins[...]

4 - 40 ENG RECOIL STARTER AND A.C. MAGNETO 2.Install: ● Starter spring 1 ● Sheave drum assembly 2 N OTE: ● Mesh the spring hook 3 with the case slit, then wind the spring clockwise into the case from the larger to smaller diameter. ● Mesh the sheave drum hook 4 with the spring hook 5 . 3.Install: ● Spring 1 ● Friction plate 2 ● Nut N [...]

4 - 41 ENG RECOIL STARTER AND A.C. MAGNETO 2.Install: ● Woodruff key ● Rotor N OTE: ● Before installing the rotor, clean the outside of the crankshaft and the inside of the rotor. ● After installing the rotor, check that the rotor rotates smoothly. If not, reinstall the key and rotor. 3.Install: ● Dowel pins ● Gasket ● Crankcase cover[...]

4 - 42 ENG PRIMARY AND SECOND ARY SHEAVES PRIMARY AND SECONDARY SHEAVES Order Job name/Part name Q ’ ty Remarks Removing the primary and secondary sheaves Remove the parts in the order below. Front fender Refer to “ SEAT, CARRIERS, FENDERS AND FUEL TANK ” in CHAPTER 3. Rear fender Right footrest board Refer to “ FOOTREST BOARDS ” in CHAPT[...]

4 - 43 ENG PRIMARY AND SECOND ARY SHEAVES Order Job name/Part name Q ’ ty Remarks 8 Primary fixed sheave 1 Refer to “ REMOVING/INSTALLING THE PRIMARY AND SECONDARY SHEAVES ” . 9 Secondary sheave assembly 1 For installation, reverse the removal procedure.[...]

4 - 44 ENG PRIMARY AND SECOND ARY SHEAVES PRIMARY SLIDING SHEAVE Order Job name/Part name Q ’ ty Remarks Disassembling the primary sliding sheave Remove the parts in the order below. 1 Primary sliding sheave cap 1 Refer to “ ASSEMBLING THE PRIMARY SHEAVE ” . 2 Primary pulley slider 4 3 Spacer 4 4 Primary pulley cam 1 5 Primary pulley weight 8[...]

4 - 45 ENG PRIMARY AND SECOND ARY SHEAVES SECONDARY SHEAVE Order Job name/Part name Q ’ ty Remarks Disassembling the secondary sheave Remove the parts in the order below. 1 Nut 1 Refer to “ DISASSEMBLING/ ASSEMBLING THE SECONDARY SHEAVE ” . 2 Spring seat 1 3 Compression spring 1 4 Spring seat 1 5 Guide pin 4 6 Secondary sliding sheave 1 7 O-r[...]

4 - 46 ENG PRIMARY AND SECOND ARY SHEAVES REMOVING THE PRIMARY AND SECONDARY SHEAVES 1.Loosen: ● Nut (secondary sheave) 1 ● Nut (primary sheave) 2 N OTE: ● Use the sheave holder 3 to hold the primary sheave. ● First, loosen the nut (secondary sheave) 2 , then loosen the nut (primary sheave) 1 . Sheave h older: P/N. YS-01880-A, 90890-01701 D[...]

4 - 47 ENG PRIMARY AND SECOND ARY SHEAVES CHECKING THE PRIMARY SHEAVE 1.Check: ● Weight outside diameter a Out of specification → Replace the we ight. W eight outside diameter: 30 mm (1.18 in) <Limit>: 29.5 mm (1.16 in) 2.Check: ● Primary pulley sliders ● Primary sliding sheave splines Wear/cracks/damage → Replace. ● Spacers ● P[...]

4 - 48 ENG PRIMARY AND SECOND ARY SHEAVES ASSEMBLING THE PRIMARY SHEAVE 1.Clean: ● Primary sliding sheave face 1 ● Primary fixed sheave face 2 ● Collar 3 ● Weights 4 ● Primary pulley cam face N OTE: Remove any excess grease. 2.Install: ● Weights 1 N OTE: ● Apply Yamaha Grizzly grease (120 g) to the whole outer surface of the weights a[...]

4 - 49 ENG PRIMARY AND SECOND ARY SHEAVES 3.Apply: ● BEL-RAY assembly lube ® (to all guide pin sliding groo ves 1 , and O-rings 2 ) New 4.Install: ● Spring seat ● Compression spring ● Spring seat ● Nut ********************* ********************** ********** Installing steps: ● Attach the sheave fixed block, locknut wrench and sheave sp[...]

4 - 50 ENG PRIMARY AND SECOND ARY SHEAVES INSTALLING THE PRIMARY AND SECONDARY SHEAVES 1.Install: ● Secondary sheave assembly ● V-belt ● Primary sheave ass embly N OTE: ● Tightening the bolts 1 will push the secondary sliding sheave away, causing the gap between the secondary fixed and slid ing sheaves to widen. ● Install the V-belt so th[...]

4 - 51 ENG CLUTCH CLUTCH Order Job name/Part name Q ’ ty Remarks Removing the clutch Remove the parts in the order below. Primary and secondary sheaves Refer to “ PRIMARY AND SECONDAR Y SHEAVES ” . 1 Cover 1 2 Clutch housing assembly 1 Refer to “ REMOVING/INSTALLING THE CLUTCH ” . 3 Gasket/dowel pin 1 / 2 4 One-way clutch bearing 1 5N u t[...]

4 - 52 ENG CLUTCH Order Job name/Part name Q ’ ty Remarks Disassembling the clutch housing Remove the parts in the orde r below. 1 Oil seal 1 2 Circlip 1 3 Bearing housing 1 4 Circlip 1 5 Bearing 1 6 Circlip 1 7 Bearing 1 8 Clutch housing 1 For assembly, revers e the disassembly procedure.[...]

4 - 53 ENG CLUTCH REMOVING THE CLUTCH 1.Remove: ● Clutch housing assembly ● Gasket ● Dowel pins N OTE: Working in crisscross pattern, loosen each bolt 1/4 of a turn. Remove them after all of them are loosened. 2.Straighten: ● Punched portion of the nut 1 . 3.Remove: ● Nut 1 N OTE: Use a clutch holding tool 2 to hold the clutch carrier ass[...]

4 - 54 ENG CLUTCH 2.Check: ● Clutch shoe Heat damage → Replace. 3.Measure: ● Clutch shoe thickness Out of specification → Replace. Clutch shoe thic kness: 1.5 mm (0.06 in) Clutch shoe wea r limit a : 1.0 mm (0.04 in) INSTALLING THE CLUTCH 1.Install: ● Clutch carrier assembly ● Nut 1 N OTE: ● Lubricate the nut with molybdenum disulfide[...]

4 - 55 ENG CLUTCH 4.Install: ● Dowel pins ● Gasket ● Clutch housing assembly N OTE: ● Tighten the bolts in stages, u sing a crisscross pattern. ● After tightening the bolts, ch eck that the clutch housing assembly to counterclockwise rotates smoothly. New T R . . 10 Nm (1.0 m • kg, 7.2 ft • lb)[...]

4 - 56 ENG CRANKCASE CRANKCASE STARTER MOTOR, TIMING CHAIN AND OIL FILTER Order Job name/Part name Q ’ ty Remarks Removing the starter motor, timing chain and oil filter Remove the parts in the order below. Engine assembly Refer to “ ENGINE REMOVAL ” . Cylinder head Refer to “ CYLINDER HEAD ” . Cylinder and piston Refer to “ CYLINDER AN[...]

4 - 57 ENG CRANKCASE Order Job name/Part name Q ’ ty Remarks 6 Oil filter cartridge 1 7 Speed sensor 1 8 Shift cam stopper 1 9 Neutral switch 1 10 Reverse switch 1 11 Oil filler cap 1 12 Gear unit 1 13 Bearing cover/gasket 1/1 14 Oil delivery pipe 1 15 Oil strainer cover/O-ring 1/1 16 Compression spring 1 17 Oil strainer 1 For installation, rever[...]

4 - 58 ENG CRANKCASE CRANKCASE Order Job name/Part name Q ’ ty Remarks Separating the crankcase Remove the parts in the ord er below. 1 Engine side cover bracket 1 Refer to “ INSTALLING THE SHIFT LEVER ” . 2 Shift lever assembly 1 3 Crankcase (left) 1 Refer to “ SEPARATING/ASSEMBLING THE CRANKCASE ” . 4 Dowel pin 2 5 Crankcase (right) 1 F[...]

4 - 59 ENG CRANKCASE CRANKCASE BEARINGS Order Job name/Part name Q ’ ty Remarks Removing the crankcase bearings Remove the parts in the order below. Crankshaft and oil pump Refer to “ CRANKSHAFT AN D OIL PUMP ” . Transmission Refer to “ TRANSM ISSION ” . Middle drive/driven shaft Refer to “ MIDDLE GEAR ” . 1 Oil seal 2 2 Bearing retai[...]

4 - 60 ENG CRANKCASE REMOVING THE OIL PUMP DRIVE GEAR 1.Straighten: ● Lock washe r tab 2.Remove: ● Oil pump drive gear nut ********************* ********************** ********** Removal steps: ● Temporarily install the clutch carrier assembly 1 . ● Hold the clutch carrier assembly with a clutch holding tool 2 and loosen the oil pump drive [...]

4 - 61 ENG CRANKCASE ● Remove the left crankcase. CAUTION: 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. W ork slowly and carefully. Make sure that the crank case halves separate evenly. ● Remove the dowel pins. ********************* ********[...]

4 - 62 ENG CRANKCASE 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: ● Crankcase Cracks/damage → Replace. ● Oil delivery passages Clogged → Blow out with compressed air. CHECKING THE BEARINGS 1.Check: ● Bearings Clean and [...]

4 - 63 ENG CRANKCASE 4.Tighten: ● Crankcase bolts (follow the proper tig htening sequence) È Right crankcase É Left crankcase N OTE: Tighten the bolts in stages, using a crisscross pattern. È É T R . . 10 Nm (1.0 m • kg, 7.2 ft • lb) 5.Apply: ● 4-stroke engine oil (to the crank pin, bearin gs and oil delivery hole) 6.Check: ● Cranksha[...]

4 - 64 ENG CRANKCASE INSTALLING THE OIL PUMP DRIVE GEAR 1.Install: ● Straight key ● Oil pump drive gear ● Lock washe r ● Oil pump drive gear nut New 2.Tighten: ● Oil pump drive gear nut ********************* ********************** ********** Tightening steps: ● Temporary install the clutch carrier assembly 1 . ● Hold the clutch carrie[...]

4 - 65 ENG CRANKSHAFT AND OIL PUMP CRANKSHAFT AND OIL PUMP Order Job name/Part name Q ’ ty Remarks Removing the crankshaft and oil pump Remove the parts in the order below. Crankcase separation Refer to “ CRANKCASE ” . 1 Washer/circlip 1/1 2 Oil pump assembl y/gasket 1/1 3 Balancer 1 Refer to “ REMOVING THE CRANKSHAFT/INSTALLING THE CRANKSH[...]

4 - 66 ENG CRANKSHAFT AND OIL PUMP OIL PUMP Order Job name/Part name Q ’ ty Remarks Disassembling the oil pump Remove the parts in the order below. 1 Rotor cover 1 2 Pin 2 3 Shaft 1 4 Pin 1 5 Inner rotor 1 6 Outer rotor 1 7 Oil pump housing 1 For assembly, revers e the disassembly procedure.[...]

4 - 67 ENG CRANKSHAFT AND OIL PUMP REMOVING THE CRANKSHAFT 1.Remove: ● Crankshaft seal 1 N OTE: Mark a note of th e position of each crankshaft seal so that they can be installed in the correct place and in the correct direction. 2.Remove: ● Crankshaft Use a crankcase separating tool 1 . Crankcase separating tool: P/N. YU-01135-A, 90890-01135 C[...]

4 - 68 ENG CRANKSHAFT AND OIL PUMP 3.Check: ● Oil pump operation Unsmooth → Repeat steps #1 and #2 or replace the defective parts. CHECKING THE CRANKSHAFT 1.Measure: ● Crank width A Out of specification → Replace the crankshaft. ● Side clearance D Out of specification → Replace the crankshaft. ● Runout C Out of specification → Repla[...]

4 - 69 ENG CRANKSHAFT AND OIL PUMP INSTALLING THE CRANKSHAFT AND BALANCER 1.Install: ● Crankshaft N OTE: 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. CAUTION: Apply engine oil to each [...]

4 - 70 ENG TRANSMISSION TRANSMISSION Order Job name/Part name Q ’ ty Remarks Removing the transmission Remove the parts in the order below. Crankcase separation Refer to “ CRANKCASE ” . 1 Driven sprocket 1 2 Chain 1 3 Guid e bar 1 4 Shift fork 1 5 Clutch dog 1 6 Low wheel gear 1 7 Secondary shaft 1 8 Middle driven gear 1 9 Drive axle assembly[...]

4 - 71 ENG TRANSMISSION Order Job name/Part name Q ’ ty Remarks 10 Shift cam 1 11 Middle drive gear 1 12 Spacer/O-ring 1/1 For installation, reverse the removal procedure.[...]

4 - 72 ENG TRANSMISSION CHECKING THE SHIFT FORKS 1.Check: ● Shift fork cam follower 1 ● Shift fork pawls 2 Scoring/bends/wear/damage → Replace. 2.Check: ● Guide bar Roll the guide bar on a flat surface . Bends → Replace. W ARNING Do not attempt to straighten a bent guide bar. 3.Check: ● Shift fork movement (on the guide bar) Unsmooth op[...]

4 - 73 ENG TRANSMISSION 2.Check: ● Gear teeth Blue discoloration/pitting/wear → Replace. ● Mated dogs Rounded edges/cracks/missing portions → Replace. 3.Check: ● Gear movement Unsmooth → Repeat steps #1 and #2 or replace the defective parts. 4.Check: ● Circlips Bends/looseness/damage → Replace. CHECKING THE SECONDARY SHAFT AND DRIVE[...]

4 - 74 ENG TRANSMISSION INSTALLING THE TRANSMISSION 1.Install: ● Shift cam 1 ● Drive axle assembly 2 ● Clutch dog 3 ● Shift fork 4 ● Guide bar 5 N OTE: Install 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. 2.Check: ?[...]

4 - 75 ENG MIDDLE GEAR MIDDLE GEAR MIDDLE DRIVE SHAFT Order Job name/Part name Q ’ ty Remarks Removing the middle drive shaft Remove the parts in th e order below. Crankcase separation Refer to “ CRANKCASE ” . Transmission Refer to “ TRANSM ISSION ” . 1 Bearing housing assembly 1 2N u t 1 Refer to “ REMOVING/INSTALLING THE MIDDLE DRIVE [...]

4 - 76 ENG MIDDLE GEAR MIDDLE DRIVEN SHAFT Order Job name/Part name Q ’ ty Remarks Removing the middle driven shaft Remove the parts in the order below. Crankcase separation Refer to “ CRANKCASE ” . 1 Circlip 2 Refer to “ REMOVING/INSTALLING THE MIDDLE DRIVEN SHAFT ” . 2 Bearing 2 3 Universal joint 1 4 Universal joint yoke 1 5 Bearing hou[...]

4 - 77 ENG MIDDLE GEAR Order Job name/Part name Q ’ ty Remarks 12 Front drive shaft coupling 1 13 Bearing retainer 1 14 Middle driven shaft 1 For installation, reverse the removal procedure.[...]

4 - 78 ENG MIDDLE GEAR REMOVING THE MIDDLE DRIVE SHAFT 1.Straighten: ● Punched portion of the nut (mid dle drive pinion gear) 2.Loosen: ● Nut (middle drive pinion ge ar) 1 N OTE: Secure the middle drive shaft in the vise with a clean rag. 3.Remove: ● Nut (middle drive pinion ge ar) ● Middle drive pinion gear ● Shim(s) REMOVING THE MIDDLE [...]

4 - 79 ENG MIDDLE GEAR 2.Remove: ● Nut 1 ● Washer ● Universal joint yoke N OTE: Use the universal joint holder 2 to hold the universal joint yoke. 3.Remove: ● Bearing housing assembly 1 ********************* ********************** ********** Removal steps: ● Clean the outside of the middle driven shaft. ● Place the middle driven shaft o[...]

4 - 80 ENG MIDDLE GEAR 5.Remove: ● Front drive shaft coupling ● Bearing retainer 1 ● Bearing N OTE: Attach the ring nut wrench 2 . CAUTION: The middle driven shaft bearing retaine r has left-handed threads. To loosen the bearing retainer, turn it clockwise. Ring nut wrench: P/N. YM-38404, 90890-01430 6.Remove: ● Middle driven shaft 1 (with [...]

4 - 81 ENG MIDDLE GEAR 4.Check: ● O-ring Damage → Replace. ● Bearings Pitting/damage → Replace. 5.Check: ● U-joint movement Roughness → Replace U-joint. SELECTING THE MIDDLE DRIVE AND DRIVEN GEAR SHIMS When the drive and driven gear, bearing housing assembly and/or crankcase are replaced, be sure to adjust the gear shims. 1.Select: ● [...]

4 - 82 ENG MIDDLE GEAR Example: 1) If the bearing housing is marked “ +04 ” , ..... a is 10.54. 2) b is 55 3) If the crankcase (right) is marked “ 66.03 ” , ..... 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 [...]

4 - 83 ENG MIDDLE GEAR Where: d = a numeral (usually a decimal number) on the bearing housing is either added to or subtracted from “ 76 ” . e = a numeral (usually a decimal number) on the middle driven pinion gear is either added to or subtracted from “ 59 ” . f = a numeral (usually a decimal number) on the middle driven pinion gear is eit[...]

4 - 84 ENG MIDDLE GEAR Shims are supplied in the following thickness. ********************* ********************** ********** Middle drive pinion gear shim Thic kness (mm) 0.10 0.40 0.15 0.50 0.20 0.60 0.30 INSTALLING THE MIDDLE DRIVEN SHAFT 1.Install: ● Bearing retainer 1 N OTE: Attach the ring nut wrench 2 . CAUTION: The middle driven shaft bea[...]

4 - 85 ENG MIDDLE GEAR ● Tighten the bearing retainer. CAUTION: The middle driven shaft bearing retaine r has left-handed threads. To tighten the bearing retainer, turn it counterclockwi se. ********************* ********************** ********** 3.Install: ● Shims 1 ● Bearing housing N OTE: Install the shims so that the tabs are positioned a[...]

4 - 86 ENG MIDDLE GEAR ● Install each bearings 1 ont o the yoke. CAUTION: Check each bearing. T he needles can easily fall out of their races . Slide the yoke back and forth on the bearings; the yoke will not go all the way onto a bearing if a needle is out of place. ● Press each bearing into the U-joint using a suitable socket. N OTE: The bear[...]

4 - 87 ENG MIDDLE GEAR ● Attach the gear lash measureme nt tool 3 and dial gauge 4 . a Measuring point is 8.12 mm (0. 32 in) ● Measure the gear lash while rotating the middle driven shaft back and forth. N OTE: Measure the gear lash at 4 positions. Rotate the middle dri ven gear 90 ° each time. ● If the gear lash is incorrect, adjust the gea[...]

5 - 1 COOL RADIATOR COOLING SYSTEM RADIATOR Order Job n ame/Part name Q ’ ty Remarks 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 fr ont fender Refer to “ FRONT CARRIER, FRONT BUMPER AND FRONT FENDER ” in CHAPTER 3.[...]

5 - 2 COOL RADIATOR Order Job n ame/Part name Q ’ ty Remarks 5 R adiator inlet hose 1 Disconnect. 6 R adiator outlet hose 1 Disconnect. 7R a d i a t o r 1 8 R adiator fan 1 9 Thermo switch (radiator) 1 For installation, reverse the removal procedure. 5[...]

5 - 3 COOL RADIATOR CHECKING THE RADIATOR 1.Check: ● Radiator fins Obstruction → Clean. Apply compressed air to the rear of the radiator. Damage → Repair or repla ce the radiator. N OTE: Straighten any flattened fins with a thin, flat- head screwdriver. 2.Check: ● Radiator hoses Cracks/damage → Replace. 3.Measure: ● Radiator cap opening[...]

5 - 4 COOL RADIATOR INSTALLING THE RADIATOR 1.Fill: ● Cooling system (with the specified amount of the recommended coolant) Refer to “ CHANGING THE COOLANT ” in CHAPTER 3. 2.Check: ● Cooling system Leaks → Repair or replace any faulty part.[...]

5 - 5 COOL THERMOSTAT THERMOSTAT Order Job n ame/Part name Q ’ ty Remarks Removing the thermostat Re move the parts in the order below. Seat and fuel tank side panel (rig ht) Refer to “ SEAT AND SIDE PANELS ” in CHAPTER 3. Coolant Drain. Refer to “ CHANGING THE COOLANT ” in CHAPTER 3. 1 R adiator inlet hose 1 2 Thermostat cover 1 3 Thermo[...]

5 - 6 COOL THERMOSTAT CHECKING THE THERMOSTAT 1.Check: ● Thermostat 1 Does not open at 63.5 ~ 66.5 ° C (146.3 ~ 151.7 ° F) → Replace. ********************* ********************** ********** Checking steps: ● Suspend the thermostat in a container filled with water. ● Slowly heat the water. ● Place a thermometer in the water. ● While st[...]

5 - 7 COOL WATER PUMP WATER PUMP Order Job n ame/Part name Q ’ ty Remarks Removing the water pump Remove the parts in the order below. Seat, fuel tank side panel (left) and engine side cover Refer to “ SEAT AND SIDE PANELS ” in CHAPTER 3. Left footrest board R efer to “ FOOTREST BOARDS ” in CHAPTER 3. Coolant Drain. Refer to “ CHANGING [...]

5 - 8 COOL WATER PUMP Order Job n ame/Part name Q ’ ty Remarks Disassembling the water pump Remove the parts in the order below. 1 Water pump housing cover 1 2 Gasket 1 3 Circlip 1 4 Impeller 1 5 Rubber damper hold er 1 6 Rubber damper 1 7 Water pump seal 1 8 Oil seal 1 9 Bearing 1 0 Water pump housing 1 For assembly, reverse the disassembly proc[...]

5 - 9 COOL WATER PUMP DISASSEMBLING THE WATER PUMP 1.Remove: ● Rubber damper holder 1 ● Rubber damper 2 (from the impeller, with a thin, flathead screwdriver) N OTE: Do not scratch the impeller shaft. 2.Remove: ● Water pump seal 1 N OTE: Tap out the water pump seal from the inside of the water pump housing. 2 Water pump housing 3.Remove: ● [...]

5 - 10 COOL WATER PUMP 3.Measure: ● Impeller shaft tilt Out of specification → Replace. 1 Straightedge 2 Impeller Max. impeller shaft tilt: 0.15 mm (0.006 in) ASSEMBLING THE WATER PUMP 1.Install: ● Oil seal 1 (into the water pump housin g 2 ) N OTE: Install the oil seal with a socket 3 that matches its outside diameter. New 2.Install: ● Wat[...]

5 - 11 COOL WATER PUMP 3.Install: ● Rubber damper 1 ● Rubber damper holder 2 N OTE: Before installing the rubber damper, apply tap water or coolant onto its outer surface. CAUTION: Make sure that the rubber damper and rubber damper holder are flush with the impeller. New New[...]

6 - 1 CARB CARBURETOR CARBURETION CARBURETOR Order Job n ame/Part name Q ’ ty Remarks Removing the carburetor Remove the parts in the order below. Seat/fuel tank side panels/fuel tank/ rubber cover Refer to “ SEAT, CARRIERS, FENDERS AND FUEL TANK ” in CHAPTER 3. 1D r a i n h o s e 1 2 S tarter cable/starter plunger 1 / 1 3 V acuum chamber bre[...]

6 - 2 CARB CARBURETOR Order Job n ame/Part name Q ’ ty Remarks Disassembling the carburetor Remove the parts in the order below. 1 Float chamber air vent hose 1 2 Throttle stop screw 1 3 Vacuum chamber cover 1 4 Spring 1 5 Jet needle holder 1 6 Spring 1 7 Jet needle set 1 8 Piston valve 1 9 Coasting enricher 1 0 Float chamber 1 A Drain screw 1 B [...]

6 - 3 CARB CARBURETOR Order Job n ame/Part name Q ’ ty Remarks D Pilot jet 1 N OTE: Before disassembling the carbureto r, make sure to note the number of times the pilot screw is turned out fro m the seated position to its set posit ion. E Main jet 1 F Needle jet 1 G Starter jet 1 H Pilot air jet 1 For assembly, reverse the disassembly procedure.[...]

6 - 4 CARB CARBURETOR DISASSEMBLING THE CARBURETOR N OTE: Before disassembling the carburetor, make sure to note the number of times the pilot screw is turned out from the seated position to its set position. CHECKING THE CARBURETOR 1.Check: ● Carburetor body ● Float chamber Cracks/damage → Replace. ● Fuel pas sage Contamination → Clean a[...]

6 - 5 CARB CARBURETOR 4.Check: ● Piston valve 1 Scratches/wear/damage → Replace . ● Rubber diaphragm 2 Tears → Replace. 5.Check: ● Vacuum chamber cover 1 ● Spring 2 Cracks/damage → Replace. 6.Check: ● Diaphragm (coasting enricher) 1 ● Spring 2 ● Cover 3 Tears (diaphragm) /damage → Replace. 7.Check: ● Jet needle 1 ● Main je[...]

6 - 6 CARB CARBURETOR 8.Check: ● Free movement (piston valve) Sticks → Replace the piston valve guide and the piston valve. Insert the piston valve into the carburetor body, and check for free moveme nt. 9.Check: ● Free movement (throttle valve) Sticks → Replace. ASSEMBLING THE CARBURETOR CAUTION: Before reassembling, wash all of the parts [...]

6 - 7 CARB CARBURETOR ● If either is worn, replace them both. ● If both are fine, adjust the float height by bending the float tang 1 on the flo at. ● Recheck the float height. ********************* ********************** ********** ADJUSTING THE FUEL LEVEL 1.Measure: ● Fuel level a Out of specification → Adjust. ********************* ***[...]

7 - 1 DRIV TROUBLESHOOTING DRIVE TRAIN TROUBLESHOOTING The following conditions may indicate damaged sh aft drive components: N OTE: 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 damage[...]

7 - 2 DRIV TROUBLESHOOTING CAUTION: Too little gear lash is extremely destructive to the gear teeth. If a test ride fol lowing reassembly indi cates this cond ition, stop riding immediately to minimize gear da mage. c.A slight “ thunk ” evident at low speed operation. This noise must be distinguished from normal machine operation. Diagnosis: Po[...]

7 - 3 DRIV TROUBLESHOOTING Troubleshooting chart When basic condition “ a ” and “ b ” exist, check the following points: Elevate and spin both whee ls. Feel for wheel bearing damage. YES Replace the wheel bearings. (Refer to “ STEERING SYSTEM ” and “ REAR SHOCK ABSORBER AND SWINGARM ” in CHAPTER 8.) NO Check the wheel nuts and hub n[...]

7 - 4 DRIV FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR Order Job n ame/Part name Q ’ ty Remarks Removing the front constant velocity joints and differential gear Remove the parts in the order below. Engine skid plate (front) Front fender Refer to “ SEAT, CARRIERS, FENDERS AND FUEL TA[...]

7 - 5 DRIV FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR Order Job n ame/Part name Q ’ ty Remarks 4 D ifferential gear 1 5 D rive shaft 1 6 C ompression spring 1 7 C oupling gear 1 For installation, reverse the removal procedure.[...]

7 - 6 DRIV FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR Order Job n ame/Part name Q ’ ty Remarks Disassembling the constant velocity joints Remove the parts in the order below. 1 Circlip 1 2 Boot band 2 Refer to “ ASSEMBLING THE FRONT CONSTANT VELOCITY JOINTS ” . 3 Boot band 2 4 Dust boot 2 5 Circlip 1 6 Double off-set joint 1 7 Circl[...]

7 - 7 DRIV FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR Order Job n ame/Part name Q ’ ty Remarks Differential gear Remove the parts in the order below. 1 Gear motor/O-ring 1/1 2 Four-wheel drive switch 1 3 Dust seal 1 4 Circlip 1 5 Coupling gear/bearing/circlip 1/1/1 6 Stopper bolt/shaft 1 /1 7 Shift fork sliding gear 1 8 Shift fork 1 9 2[...]

7 - 8 DRIV FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR Order Job n ame/Part name Q ’ ty Remarks C Shim (right) D Circlip/bearing 1/1 E Drive pinion gear 1 F Differential gear case 1 For assembly, reverse the disassembly procedure.[...]

7 - 9 DRIV REMOVING THE DIFFERENTIAL GEAR ASSEMBLY 1.Remove: ● Differential gear assembly 1 N OTE: The ring gear and the differential gear cover should be fastened together. Do not disassemble the differential gear assembly. CAUTION: The differential gears are assembled in to a proper unit at the factory by means of specialized equipment. Do not [...]

7 - 10 DRIV FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR CHECKING THE DIFFERENTIAL GEAR 1.Check: ● Gear teeth Pitting/galling/wear → Replace drive pinion gear and differential gear assembly a s a set. ● Bearing Pitting/damage → Replace. ● Oil seal ● O-ring Damage → Replace. 2.Check: ● Drive shaft splines ● Universal joints[...]

7 - 11 DRIV FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR ● Install the dust boots. ● Install the dust boot bands. N OTE: ● The new boot bands may differ from the original ones. ● The dust boots should be fastened with the dust boot bands 3 at the grooves in the joint shaft. ********************* ********************** ********** 3.C[...]

7 - 12 DRIV FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR 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: ● Drain plug ● Gasket 3.Install: ● A bolt of the specified size 1 (into the drain plug hole ) CAUTION: Finger tighten [...]

7 - 13 DRIV FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR Adjusting differential gear lash 1.Remove: ● Shim(s) (left) 1 ● Differential gear assembly 2 ● Shim(s) (right) 3 2.Adjust: ● Gear lash ********************* ********************** ********** Adjustment steps: ● Select the suitable shims using the followi ng chart. ● If it [...]

7 - 14 DRIV CHECKING THE DIFFERENTIAL GEAR OPERATION 1.Block the rear wheels, and elevate the front wheels by placing a suitable stand unde r 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 preloa d) with the torque wrench. N OTE: ● Repea[...]

7 - 15 DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT Order Job n ame/Part name Q ’ ty Remarks Removing the rear axle, final driv e gear assembly and drive shaft Remove the parts in the order below. Final gear oil Drain. Refer to “ CHANGING THE FINAL GEAR OIL ” in CHAPTER 3. Rear wheel hubs Refer to[...]

7 - 16 DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT Order Job n ame/Part name Q ’ ty Remarks Disassembling the final drive gear Remove the parts in the order below. 1 Bolt 2 2 Bolt 6 3 Bearing housing 1 4 Oil seal/bearing 1/1 5 Ring gear stopper 1 6 Ring gear stopper shim 7 Oil seal/bearing 1/ 1 8 Ring gear shim 9 Ring gear 1 0 Thrust washer 1[...]

7 - 17 DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT Order Job n ame/Part name Q ’ ty Remarks A Bearing retainer/O-ring 1/1 Refer to “ DISASSEMBLING/ ASSEMBLING THE FINAL DRIVE GEAR ” . B Oil seal 1 C Final drive pinion gear 1 D Collar 1 E Bearing 1 F Final drive pinion gear shim G Final drive gear case/O-ring 1/1 H Bearing/oil seal 1/1 Ref[...]

7 - 18 DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT REMOVING THE REAR AXLE 1.Remove: ● Rear axle 1 (with dust seal) ● O-ring CAUTION: ● Never directly tap the axle end with a hammer, since this will result in damage to the axle thread and spline. ● Attach a suitable socket 2 on the axle end and tap it with a soft hammer. Pull out the rea[...]

7 - 19 DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT REPLACING THE FINAL DRIVE ROLLER BEARINGS 1.Remove: ● Roller bearing (ring gear) 1 Use a suitable press tool 2 and an appropriate support for the main housing. ● Oil seal 3 2.Remove: ● Roller bearing (final drive pinion gear) 1 ********************* ********************** ********** Remov[...]

7 - 20 DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT POSITIONING THE FINAL DRIVE PINION GEAR AND RING GEAR When the final drive pinion gear, ring g ear, final gear case and/or ring gear bearing housing are replaced, be sure to adjust the positions of the final d rive pinion gear and ring gear using shim(s). Final drive pinion gear shim selec tion[...]

7 - 21 DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT Shims are supplied in the following thicknesses. ********************* ********************** ********** Final drive pinion gear shim Thickness (mm) 0.15 0.30 0.40 0.45 0.50 0.60 Ring gear shim selection 1.Select: ● Ring gear shim(s) ********************* ********************** ********** Sel[...]

7 - 22 DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT 5) Therefore, shim thickness “ B ” is 0.63. “ B ” = 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 hund[...]

7 - 23 DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT ● Remove the ring gear assembly. ● Measure the thrust clearance. Calculate the width of the flattened Plastigauge ® 1 . ● If out of specificat ion, select the correct washer. Ring gear thrust clearance: 0.1 ~ 0.2 mm (0.004 ~ 0.008 in) Thrust washer selection steps: ● Select a suitable [...]

7 - 24 DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT Ring gear stopper clearance ad justment 1.Remove: ● Ring gear 1 ● Ring gear stopper 2 ● Shim(s) 3 4 Bearing housing È Left-hand t hreads 2.Select: ● Suitable shim(s) Shim Thickness (mm) 0.10 0.15 0.20 0.30 0.40 0.50 3.Install: ● Shim(s) ● Ring gear stopper (left-hand threads) ● R[...]

7 - 25 DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT CHECKING THE DRIVE SHAFT 1.Check: ● Drive shaft (splines) Wear/damage → Replace. CHECKING THE FINAL DRIVE GEAR 1.Check: ● Final gear case 1 ● Bearing housing (ring gear) 2 Cracks/damage → Replace. N OTE: When the final gear case and/or the ring gear bearing housing are replaced, be su[...]

7 - 26 DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT 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: ● Drain plug ● Gasket 3.Install: ● A bolt of the specified size 1 (into the drain plug hole ) CAUTION: Finger tighten the bolt until it holds [...]

7 - 27 DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT Final gear lash adjustment 1.Remove: ● Bearing housing 1 ● Ring gear shim(s) 2 ● Ring gear 3 ● Thrust washer 4 2.Adjust: ● Gear lash ********************* ********************** ********** Adjustment steps: ● Select suitable shim(s) and thrust washer(s) using the following chart. ?[...]

7 - 28 DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT ASSEMBLING THE FINAL DRIVE GEAR 1.Install: ● Drive pinion gear (with shim(s) and bearing) (proper shim size as calculated) ● Bearing retainer (drive pinion gear) 1 Use a bearing retainer wrench 2 . CAUTION: ● Always use a new bearing. ● The final drive shaft bearing retaine r has left-h[...]

7 - 29 DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT 3.Apply: ● Sealant (Quick Gasket ® ) (to the mating surfaces of the swingarm and the final drive gear case) Sealant (Quick gasket ® ): P/N. ACC-11001-05-01 Yamaha bond No.1215: P/N. 90890-85505 4.Install: ● Final drive gear ● Nuts ● Bolts LT T R . . 63 Nm (6.3 m • kg, 45 ft • lb) [...]

8 - 1 CHAS FRONT AND REAR WHEELS CHASSIS FRONT AND REAR WHEELS FRONT WHEELS Order Job n ame/Part name Q’ty Remarks Removing the front wheels Remove the parts in the order below. Place the machine on a level surface. W ARNING Securely support the machine so there is no danger of it falling over. 1 Front wheel 1 Refer to “INSTALLING THE WHEELS”[...]

8 - 2 CHAS FRONT AND REAR WHEELS REAR WHEELS Order Job n ame/Part name Q ’ ty Remarks Removing the rear wheels Remove the parts in the order below. Place the machine on a level surface. W ARNING Securely support the machine so there is no danger of it falling over. 1 Wheel cap 2 2 R ear wheel 2 Refer to “ INSTALLING THE WHEELS ” . 3 C otter p[...]

8 - 3 CHAS FRONT AND REAR WHEELS CHECKING THE WHEELS 1.Check: ● Wheel 2.Measure: ● Wheel runou t Over the specified limit → Replace the whe el or check the wheel bearing plays 1 . 3.Check: ● Wheel balance Out of balance → Adjust. Wheel runout limit: Radial 2 : 2.0 mm (0.08 in) Lateral 3 : 2.0 mm (0.08 in) W ARNING After replacing the tire[...]

8 - 4 CHAS FRONT AND REAR WHEELS CHECKING THE BRAKE DISCS 1.Check: ● Brake disc Galling /damage → Replace. 2.Measure: ● Brake disc deflection Out of specification → Check the wheel runout. If wheel runout is within the limits, replace the brake disc. ● Brake disc thickness a Out of specification → Replace. Brake disc maximum deflection:[...]

8 - 5 CHAS FRONT AND REAR WHEELS 2.Install: ● Nuts (wheel) 1 W ARNING Tapered wheel nuts 1 are use d for both the front and rear wheels. Install each nut with its tapered side towards the wheel. 3.Tighten: ● Nuts (front wheels) ● Nuts (rear wheels) N OTE: Tighten the nuts in stages and in a crisscross pattern. T R . . 64 Nm (6.4 m • kg, 46 [...]

8 - 6 CHAS FRONT BRAKE FRONT BRAKE FRONT BRAKE PADS Order Job n ame/Part name Q ’ ty Remarks Removing the front brake pads Remove the parts in the order below. Front wheel Refer to “ FRONT AND REAR WHEELS ” . 1 B rake caliper mounting bolt 2 Refer to “ REPLACING THE FRONT BRAKE PADS ” . 2 B rake pad holding bolt 2 3 B rake pad/pad shim 2/[...]

8 - 7 CHAS FRONT BRAKE CAUTION: Disc brake components rarely require disassembly. DO NOT: ● disassemble components unl ess absolutely necessary; ● 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; ?[...]

8 - 8 CHAS FRONT BRAKE ********************* ********************** ********** Installation steps: ● Connect a suitable hose 1 tightly to the brake caliper bleed screw 2 . Put the other end of this hose into an open cont ainer. ● Loosen the brake caliper bleed screw a nd, using a finger, push the ca liper piston into the brake caliper. ● Tigh[...]

8 - 9 CHAS FRONT BRAKE FRONT BRAKE MASTER CYLINDER Order Job n ame/Part name Q ’ ty Remarks Removing the front brake master cylinder Remove the parts in the order below. Brake fluid Drain. 1 B rake fluid reservoir cap 1 2 B rake fluid reservoir diaphragm 1 3 B rake lever 1 4 Union bolt 1 Refer to “ INSTALLING THE FRONT BRAKE MASTER CYLINDER ”[...]

8 - 10 CHAS FRONT BRAKE Order Job n ame/Part name Q ’ ty Remarks Disassembling the front brake master cylinder Remove the parts in the order below. 1 Brake master cylinder kit 1 Refer to “ ASSEMBLING THE FRONT BRAKE MASTER CYLINDER ” . 2 Brake master cylinder 1 For assembly, reverse the disassembly procedure.[...]

8 - 11 CHAS FRONT BRAKE CHECKING THE MASTER CYLINDER 1.Check: ● Brake master cylinder 1 Wear/scratches → Replace the brake master cylinder assembly. ● Brake master cylinder body Cracks/damage → Replace. ● Brake fluid delivery passage (brake master cylin der body) Blockage → Blow out with compressed air. 2.Check: ● Front brake master c[...]

8 - 12 CHAS FRONT BRAKE INSTALLING THE FRONT BRAKE MASTER CYLINDER 1.Install: ● Brake master cylinder 1 ● Brake master cylinder bracket 2 N OTE: The “ UP ” mark on the brake master cylinder bracket 2 should face up. T R . . 7 Nm (0.7 m • kg, 5.1 ft • lb) 2.Install: ● Copper washers ● Brake hose ● Union bolt N OTE: ● Tighten the [...]

8 - 13 CHAS FRONT BRAKE ● Be careful that water does not enter the brake master cylinder when refilling. Water will significantl y lower the boiling point of the brake fluid and may result in vapor lock. 4.Air bleed: ● Brake system Refer to “ BLEEDING THE HYDRAULIC BRAKE SYSTEM ” in CHAPTER 3. 5.Check: ● Brake fluid level Brake fluid leve[...]

8 - 14 CHAS FRONT BRAKE FRONT BRAKE CALIPER Order Job n ame/Part name Q ’ ty Remarks Removing the front brake calipers Remove the parts in the order below. Brake fluid Drain. Front wheel Refer to “ FRONT AND REAR WHEELS ” . 1 Union bolt 1 Refer to “ INSTALLING THE FRONT BRAKE CALIPERS ” . 2 C opper washer 2 3 B rake hose 1 Disconnect. 4 C[...]

8 - 15 CHAS FRONT BRAKE Order Job n ame/Part name Q ’ ty Remarks Disassembling the front brake calipers Remove the parts in the order below. 1 Brake pad holding bolt 2 2 Brake pad/pad shim 2/1 3 Pad spring 1 4 Retaining bolt 1 5 Caliper bracket 1 6 Brake caliper piston 1 Refer to “ DISASSEMBLING/ ASSEMBLING THE FRONT BRAKE CALIPERS ” . 7 Dust[...]

8 - 16 CHAS FRONT BRAKE DISASSEMBLING THE FRONT BRAKE CALIPERS 1.Remove: ● Brake caliper piston ● Dust seal 1 ● Caliper piston seal 2 ********************* ********************** ********** Removal steps: ● Blow compress ed air into the hose joint opening to force out the caliper piston from the brake caliper body. W ARNING ● Never try to[...]

8 - 17 CHAS FRONT BRAKE ● Brake fluid delivery passage (brake caliper body) Blockage → Blow out with compressed air. W ARNING Replace the caliper piston seal and dust seal whenever the brake caliper is disassembled. ASSEMBLING THE FRONT BRAKE CALIPERS W ARNING ● All internal brake components should be cleaned and lubricated with new brake flu[...]

8 - 18 CHAS FRONT BRAKE CAUTION: When installing the brake hose on the brake caliper, make sure that the brake pipe touches the projection a on the brake caliper. W ARNING Proper brake hose routing is essential to insure safe motorcycle operation. Refer to “ CABLE ROUTING ” in CHAPTER 2. 2.Fill: ● Brake reservoir CAUTION: Brake fluid may dama[...]

8 - 19 CHAS REAR BRAKE REAR BRAKE Order Job n ame/Part name Q ’ ty Remarks Removing the rear brake lever Remove the parts in the order below. 1 R ear brake switch 1 2 R ear brake lever cable 1 3 R ear brake lever holder bracket 1 4 R ear brake lever holder 1 5 R ear brake lever 1 For installation, reverse the removal procedure.[...]

8 - 20 CHAS REAR BRAKE Order Job n ame/Part name Q ’ ty Remarks Removing the rear brake pedal Remove the parts in the order below. 1 R ear brake light switch cover 1 2 R ear brake pedal cable 1 3 B rake pedal 1 4 S elect lever control cable 1 5 R ear brake light switch 1 6B r a c k e t 1 For installation, reverse the removal procedure.[...]

8 - 21 CHAS REAR BRAKE Order Job n ame/Part name Q ’ ty Remarks Removing the rear brake drum Remove the parts in the order below. Rear wheel (left) Refer to “ FRONT AND REAR WHEELS ” 1 B rake drum cove r 1 2 D ust seal 1 3B r a k e d r u m 1 4 A djusting nut 2 5P i n 2 6S p r i n g 2 7 R ear brake lever cable 1 8 R ear brake pedal cable 1 9 B[...]

8 - 22 CHAS Order Job n ame/Part name Q ’ ty Remarks 11 Brake camshaft lever 1 12 Brake shoe wear indicator 1 13 Brake camshaft 1 14 O-ring 2 15 Dust seal 1 16 Brake shoe plate 1 For installation, reverse the removal procedure. REAR BRAKE[...]

8 - 23 CHAS REAR BRAKE REMOVING THE REAR BRAKE 1.Remove: ● Rear wheel (left) ● Rear wheel hub (left) Refer to “ FRONT AND REAR WHEELS ” . 2.Remove: ● Brake drum cover 1 3.Remove: ● Brake drum 1 4.Remove: ● Adjusting nuts 1 ● Pins 2 ● Springs 3 5.Disconnect: ● Rear brake lever cable 4 ● Rear brake pedal cable 5 6.Remove: ● Br[...]

8 - 24 CHAS REAR BRAKE 7.Remove: ● Spring 1 ● Brake camshaft lever 2 ● Brake shoe wear indicator 3 ● Brake camshaft 4 CHECKING THE REAR BRAKE 1.Check: ● Brake drum 1 Cracks/damage → Replace. ● Splines (wheel drum) 2 Wear/damage → Replace. 2.Check: ● Brake shoe plate 1 ● Pivot pin 2 ● Brake camshaft 3 Bends/cracks/damage → Re[...]

8 - 25 CHAS REAR BRAKE 5.Measure: ● Brake shoe lining thickness a Out of specification → Replace. 1 Measuring points N OTE: Replace the brake shoes as a set if either is worn to the wear limit. Brake shoe lining thickness limit: 2.0 mm (0.08 in) 6.Measure: ● Brake drum inside diameter a Out of specification → Replace. Brake drum inside diam[...]

8 - 26 CHAS REAR BRAKE CAUTION: During installation, lightly grea se the brake camshaft and the pivot pin. Wipe off the excess grease. 2.Install: ● Brake shoe wear indicator 1 N OTE: When installing the wear indicator pointer, fit the projection into a brake camshaft groove and align the pointer with the rig ht end of the wear indicator scale 2 .[...]

8 - 27 CHAS REAR BRAKE 6.Check: ● Brake camshaft operation Unsmooth operation → Repair. 7.Lubricate: ● Dust seal 1 Lithium-soap base grease 8.Connect: ● Rear brake lever cable 1 ● Rear brake pedal cable 2 9.Install: ● Springs 3 ● Pins 4 ● Adjusting nuts 5 ● Brake drum ● Brake drum cover 10.Install: ● Rear wheel hub (left) ● [...]

8 - 28 CHAS STEERING SYSTEM STEERING SYSTEM HANDLEBAR Order Job n ame/Part name Q ’ ty Remarks Removing the handlebar Remove the parts in the order below. 1 H andlebar cover 1 2B a n d 4 3 O n-command four-wheel drive switch 1 Refer to “ INSTALLING THE MASTER CYLINDER ASSEMBLY ” . 4 M aster cylinder assembly/bracket 1/1 5 Throttle lever assem[...]

8 - 29 CHAS STEERING SYSTEM REMOVING THE REAR BRAKE SWITCH 1.Remove: ● Rear brake switch 1 N OTE: Push the fastener when removing the rear brake switch out of the rear brake leve r holder. CHECKING THE HANDLEBAR 1.Check: ● Handlebar Bends/cracks/damage → Replace. W ARNING Do not attempt to straighten a bent handlebar as this may dangerously w[...]

8 - 30 CHAS STEERING SYSTEM INSTALLING THE MASTER CYLINDER ASSEMBLY 1.Install: ● Throttle lever assembly ● Master cylinder assembly N OTE: The “ UP ” mark on the master cylinder bracket should face up. T R . . 7 Nm (0.7 m • kg, 5.1 ft • lb)[...]

8 - 31 CHAS STEERING SYSTEM STEERING STEM Order Job n ame/Part name Q ’ ty Remarks Removing the steering stem Remove the parts in the order below. Handlebar Refer to “ HANDLEBAR ” . Seat Refer to “ SEAT, CARRIERS, FENDERS AND FUEL TANK ” in CHAPTER 3. Front fender 1 Lock washer 1 Refer to “ INSTALLING THE CABLE GUIDE ” . 2 Cable gu id[...]

8 - 32 CHAS STEERING SYSTEM Order Job n ame/Part name Q ’ ty Remarks 11 Oil seal 1 12 Bearing retainer 1 Refer to “ REMOVING/INSTALLING THE BEARING RETAINER ” . 13 Beari ng 1 14 Oil seal 1 For installation, reverse the removal procedure.[...]

8 - 33 CHAS STEERING SYSTEM REMOVING THE BEARING RETAINER 1.Remove: ● Bearing retainer (steering stem) Damper rod holder (30 mm): P/N. YM-01327, 90890-01327 CHECKING THE STEERING STEM 1.Check: ● Steering stem Bends → Replace. W ARNING Do not attempt to straighten a bent stem; this may dangerously weaken the stem. 2.Check: ● Oil seals 1 ● [...]

8 - 34 CHAS STEERING SYSTEM TIE RODS AND STEERING KNUCKLES Order Job n ame/Part name Q ’ ty Remarks Removing the tie rods and steering knuckles Remove the parts in the order below. Front fender Refer to “ SEAT, CARRIERS, FENDERS AND FUEL TANK ” in CHAPTER 3. Front wheel/brake disc Refer to “ FRONT AND REAR WHEELS ” . 1 Tie rod 1 Refer to [...]

8 - 35 CHAS STEERING SYSTEM Order Job n ame/Part name Q ’ ty Remarks 9O i l s e a l 1 10 Oil seal 1 11 Beari ng 2 12 Spacer 1 13 Circlip 1 14 Rubber boot 1 15 Ball joint 1 For installation, reverse the removal procedure.[...]

8 - 36 CHAS STEERING SYSTEM REMOVING THE STEERING KNUCKLES 1.Remove: ● Steering knuckle 1 N OTE: Use a general puller to sepa rate the ball join ts 2 from the steering knuckle 1 or the front lower arm 3 . CHECKING THE TIE RODS 1.Check: ● Tie rod free play and movement Free play → Replace the tie rod end. Turns roughly → Replace the tie rod [...]

8 - 37 CHAS STEERING SYSTEM ● Install the body 3 , short bolt 5 , remover washer 6 and remove r spacer 7 onto ball joint. N OTE: ● Remover washer 6 must be aligned with the projection on the head of the ba ll joint. ● Surface a of the remover spacer 7 must be aligned with surface b of the steering knuckle. ● Hold the body 3 in pla ce while [...]

8 - 38 CHAS ● Attach the assembled ball joint remover/ installer, new ball joint B and installer attachment 8 to the steering knuckle C . N OTE: Do not tap or damage the top of th e ball joint. ● Hold the body 3 in pla ce while turning in the long bolt 4 to install th e new ball joint B into the steering knuckle C . ● Remove the ball joint re[...]

8 - 39 CHAS ● Install the new bearings. N OTE: Install the outside bearing first. CAUTION: Do not strike the center race or balls of the bearing. Contact should be mad e only with the outer race. ● Install the new oil seals. N OTE: When installing the oil seals, the “ seal sid e ” of the oil seal faces out. ********************* ***********[...]

8 - 40 CHAS FRONT ARMS AND FRONT SHOCK ABSORBERS FRONT ARMS AND FRONT SHOCK ABSORBERS Order Job n ame/Part name Q ’ ty Remarks Removing the front arms and front shock absorbers Remove the parts in the order below. Engine skid plate Refer to “ SEAT, CARRIERS, FENDERS AND FUEL TANK ” in CHAPTER 3. Front fender Front wheel/brake disc Ref er to ?[...]

8 - 41 CHAS FRONT ARMS AND FRONT SHOCK ABSORBERS Order Job n ame/Part name Q ’ ty Remarks 4N u t 1 Refer to “ REMOVING THE FRONT ARMS ” and “ INSTALLING THE FRONT ARMS AND FRONT SH OCK ABSORBER ” . 5N u t 1 6 Bolt/nut 2/2 7 Front lower arm/bushing 1/2 8 Nut/bolt 2/2 9 Front shock absorber 1 10 Bolt/nut 2/2 11 Front upper arm/bushing 1/2 1[...]

8 - 42 CHAS FRONT ARMS AND FRONT SHOCK ABSORBERS REMOVING THE FRONT ARMS 1.Check: ● Front arm free play ********************* ********************** ********** Checking steps: ● Check the front arm side play È by moving it from side to side. If side play is noticeable, check the bushings. ● Check the front arm vertical movement É by moving [...]

8 - 43 CHAS ********************* ********************** ********** Replacement steps: ● Clean the outside of the front lower a rm. ● Remove the circlip 1 and rubber boot 2 . Use the ball joint remover and installer set. ● Install the body 3 , long bolt 4 , remover washer 5 and remove r spacer 6 onto ball joint. N OTE: Remover washer 5 must b[...]

8 - 44 CHAS FRONT ARMS AND FRONT SHOCK ABSORBERS ● Attach the assembled ball joint remover/ installer, new ball joint A and installer attachment 7 to the front lower arm B . N OTE: Do not tap or damage the top of th e ball joint. ● Hold the body 3 in pla ce while turning in the long bolt 4 to install th e new ball joint A into the front lower a[...]

8 - 45 CHAS FRONT ARMS AND FRONT SHOCK ABSORBERS INSTALLING THE FRONT ARMS AND FRONT SHOCK ABSORBER 1.Install: ● Front arms ● Front shock absor ber ********************* ********************** ********** Installation steps: ● Install the front upper arm 1 and front lower arm 2 . N OTE: ● Lubricate the bolts 3 with lithium-soap- based grease[...]

8 - 46 CHAS REAR SHOCK ABSORBER AND SWINGARM REAR SHOCK ABSORBER AND SWINGARM Order Job n ame/Part name Q ’ ty Remarks Removing the rear shock absorber and swingarm Remove the parts in the order below. Rear wheel hubs Refe r to “ FRONT AND REAR WH EELS ” . Rear brake drum Refe r to “ REAR BRAKE ” . Rear brake lever cable/rear brake pedal [...]

8 - 47 CHAS REAR SHOCK ABSORBER AND SWINGARM Order Job n ame/Part name Q ’ ty Remarks 8 R ear axle housing 1 Refer to “ INSTALLING THE REAR AXLE HOUSING ” . 9 N ut/bolt 2/2 Refer to “ REMOVING THE SWINGARM ” . 10 Swingarm/bushing 1/2 11 Spring/rubber boot 1/1 For installation, reverse the removal procedure.[...]

8 - 48 CHAS REAR SHOCK ABSORBER AND SWINGARM REMOVING THE SWINGARM 1.Check: ● Swingarm free play ********************* ********************** ********** Checking steps: ● Check the tightening torque of the nu ts (swingarm). ● Check the swingarm side play È by moving it from side to side. If side play is noticeable, check the bushings and fra[...]

8 - 49 CHAS REAR SHOCK ABSORBER AND SWINGARM CHECKING THE SWINGARM 1.Check: ● Swingarm 1 ● Rear axle housing 2 Bends/cracks/damage → Replace. 2.Check: ● Bushings 1 Wear/damage → Replace. CHECKING THE RUBBER BOOT 1.Check: ● Rubber boot 1 Damage → Replace. INSTALLING THE RUBBER BOOT 1.Apply: ● Adhesive (for rubber) (to the engine 1 ) [...]

8 - 50 CHAS REAR SHOCK ABSORBER AND SWINGARM INSTALLING THE REAR AXLE HOUSING 1.Install: ● Rear axle housing ● Final gear case asse mbly ● Rear axle (with dust seal) ********************* ********************** ********** Installation steps: ● Install the drive shaft. Refer to “ REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT ” in CHAPTER 7.[...]

9 - 1 –+ ELEC ELECTRICAL COMPONENTS EB800000 ELECTRICAL ELECTRICAL COMPONENTS 1 Main switch 2 Front brake ligh t switch 3 Rear brake switch 4 Thermo switch (cylinder head) 5 Battery 6 Tail/brake light 7 Fuse box 8 Main fuse 9 Starter re lay 0 CDI un it A Rectifier/regulator B Reverse switch C Neutral switch D Speed sensor E Rear brake light switc[...]

9 - 2 – + ELEC CHECKING THE SWITCHES CHECKING THE SWITCHES CHECKING A SWITCH Use a pocket tester to che ck the terminals for continuity. If the continuity is faulty at any point, replace the switch. N OTE: ● Set the pocket tester to “0” before starting the test. ● The pocket tester should be set to the “ Ω × 1” range when testing t[...]

9 - 3 – + ELEC CHECKING THE SWITCHES[...]

9 - 4 – + ELEC CHECKING THE SWITCHES CHECKING THE SWITCH CONTINUITY Refer to “ CHECKING THE SWITCHES ” and check for continuity between lead termin als. Poor connection, no continuity → Correct or replace. * The coupler locatio ns are circled. L B Y G Br L / B (BLACK) 1 4 5 A 6 23 R / BR / W PUSH Br L Y G B R / W Br L / RL / G B L / B R / B[...]

9 - 5 – + ELEC CHECKING THE SWITCHES 1 Light switch 2 Engine stop switch 3 Start switch 4 On-command four-wheel drive swit ch 5 Main switch 6 Rear brake light switch 7 Front brake ligh t switch 8 Rear brake switch 9 Neutral switch 0 Reverse switch A Fuses[...]

9 - 6 – + ELEC CHECKING THE BULBS AND BULB SOCKETS EB801020 CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage or wear, proper connections, and also for continuity between the terminals. Damage/wear → Repair or replace the bu lb, bulb socket or both. Improperly connected → Properly connect. Incorrect continuity rea[...]

9 - 7 – + ELEC CHECKING THE BULBS AND BULB SOCKETS W ARNING Since the headlight bulbs gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. CAUTION: ● Be sure to hold the socket firmly when removing the bulb. Never pull the l ead, otherwise it may be pulled out of the terminal in the coupler. ?[...]

9 - 8 – + ELEC CHECKING THE CONDITION OF THE BULB SOCKETS The following procedure applies to all of the bulb sockets. 1.Check: ● Bulb socket (for continuity) (with the pocket tester) No continuity → Replace. N OTE: Check each bulb socke t for continuity in the same manner as described in the bulb section; however, note the following. ********[...]

9 - 9 – + ELEC IGNITION SYSTEM EB802000 IGNITION SYSTEM CIRCUIT DIAGRAM Br / L R / Y P L / B W / L W / L L / B N R W / G W / LW / R W / G R W / RW / G W WW W WW 1 W / G W / R W / G R W W W W W W 2 B R Br / L Br / L Br R R Br 3 V Q (BLACK) BR WWW R L / WL / B B B G / W G / W G / W B B R R R R R B B L / W 7 5 4 6 O R B O O O B / Y 0 9 W / R W / G L[...]

9 - 10 – + ELEC IGNITION SYSTEM EB802010 TROUBLESHOOTING Procedure Check: 1.Fuse (main, ignition) 2.Battery 3.Spark plug 4.Ignition spark gap 5.Spark plug cap resistance 6.Ignition coil resistance IF THE IGNITION SYSTEM FAILS TO OPERATE (NO SPARK OR INTERMITTENT SPA RK): 7.Engine stop switch 8.Main switch 9.Pickup coil resistance 10.Charging/roto[...]

9 - 11 – + ELEC IGNITION SYSTEM CORRECT Spark plug gap: 0.6 ~ 0.7 mm (0.024 ~ 0. 028 in) INCORRECT Repair or replace the spark plug. OUT OF SPECIFICATION OR NO SPARK 4.Ignition spark gap ● Disconnect the spark plug cap from the spark plug. ● Connect the dynamic spark tester 1 as shown. 2 Spark plug cap 3 Spark plug ● Turn the main switch to[...]

9 - 12 – + ELEC IGNITION SYSTEM C0NTINUITY 6.Ignition coil resistance ● Disconnect the ignition coil connector from the wire harness. ● Connect the pocket test er ( Ω × 1) to the ignition coil. Tester (+) lead → Orange lead terminal Tester ( – ) lead → Ignition coil base ● Check that the primary coil has the specified resistance. P[...]

9 - 13 – + ELEC IGNITION SYSTEM C0NTINUITY CORRECT 8.Main switch Refer to “ CHECKING THE SWITCHES ” . * INCORRECT Replace the main switch. 9.Pickup coil resistance ● Disconnect the AC magneto coupler from the wire harness. ● Connect the pocket tester ( Ω × 1 00) to the pickup coil terminals. Tester (+) lead → White/Red terminal 1 Tes[...]

9 - 14 – + ELEC IGNITION SYSTEM C0NTINUITY CORRECT 11.Wiring connections ● Check the connections of t he entire ignition system. Refer to “ CIRCUIT DIAGRAM ” . Replace the CDI unit. * POOR CONNECTION Properly connect the ignition system.[...]

9 - 15 – + ELEC ELECTRIC STARTING SYSTEM EB803000 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM Br / L R / Y P L / B W / L W / L L / B N R W / G W / LW / R W / G R W / RW / G W WW W WW 1 W / G W / R W / G R W W W W W W 2 B R Br / L Br / L Br R R Br 3 V Q (BLACK) BR WWW R L / WL / B B B G / W G / W G / W B B R R R R R B B L / W 7 5 4 6 O R B O O O B / [...]

9 - 16 – + ELEC ELECTRIC STARTING SYSTEM EB803020 TROUBLESHOOTING Procedure Check: 1.Fuse (main, ignition) 2.Battery 3.Starter motor 4.Starter relay 5.Main switch 6.Engine stop switch 7.Start switch IF THE STARTER MOTOR FAILS TO OPERATE: 8. Wiring connections (the entire starting system) N OTE: ● Remove the following part(s) before troubleshoot[...]

9 - 17 – + ELEC ELECTRIC STARTING SYSTEM C0NTINUITY TURNS 3.Starter motor ● Connect the battery posit ive terminal 1 and starter motor cable 2 using a jumper lead 3 . ● Check the operation of the sta rter motor. * * W ARNING ● A wire that is used as a jumper lead must have the equivalent capacity or more as that of the battery lead, otherwi[...]

9 - 18 – + ELEC ELECTRIC STARTING SYSTEM C0NTINUITY CORRECT 5.Main switch Refer to “ CHECKING THE SWITCHES ” . * INCORRECT Replace the main switch. CORRECT 6.Engine stop switch Refer to “ CHECKING THE SWITCHES ” . INCORRECT Replace the handlebar switch (le ft). CORRECT 7.Start switch Refer to “ CHECKING THE SWITCHES ” . INCORRECT Repl[...]

9 - 19 – + ELEC ELECTRIC STARTING SYSTEM STARTER MOTOR Order Job n ame/Part name Q ’ ty Remarks Removing the starter motor Remove the parts in the order below. 1 S tarter motor lead 1 2 Starter motor/O-ring 1/1 Disassembling the starter motor Remove the parts in the order below. 1 Bracket 1 1 Refer to “ ASSEMBLING THE STARTER MOTOR ” . 2 Wa[...]

9 - 20 – + ELEC ELECTRIC STARTING SYSTEM CHECKING THE STARTER MOTOR 1.Check: ● Commutator Dirty → Clean it with #600 grit sandpaper. 2.Measure: ● Commutator diameter a Out of specification → Replace the starter motor. 3.Measure: ● Mica undercut b Out of specification → Scrape the mica using a hacksaw blade. N OTE: Scrape the mica to t[...]

9 - 21 – + ELEC ELECTRIC STARTING SYSTEM 5.Measure: ● Brush length a (each) Out of specification → Replace the brush holder set. Brush length: 12.5 mm (0.49 in) <Wear limit:> 5 mm (0.20 in) 6.Measure: ● Brush spring force Fatigue/out of specification → Replace the brush holder set. Brush spring force: 7.65 ~ 10.01 Nm (780 ~ 1,020 g,[...]

9 - 22 – + ELEC CHARGING SYSTEM EB804000 CHARGING SYSTEM CIRCUIT DIAGRAM Br / L R / Y P L / B W / L W / L L / B N R W / G W / LW / R W / G R W / RW / G W WW W WW 1 W / G W / R W / G R W W W W W W 2 B R Br / L Br / L Br R R Br 3 V Q (BLACK) BR WWW R L / WL / B B B G / W G / W G / W B B R R R R R B B L / W 7 5 4 6 O R B O O O B / Y 0 9 W / R W / G [...]

9 - 23 – + ELEC CHARGING SYSTEM EB804010 TROUBLESHOOTING Procedure Check: 1.Fuse (main) 2.Battery 3.Charging voltage IF THE BATTERY IS NOT CHARGED: 4.Charging coil resistance 5.Wiring connections (the entire charging system) N OTE: ● Remove the following part(s) before troubleshooting: 1)Seat 2)Fuel tank side panels ● Use the following specia[...]

9 - 24 – + ELEC CHARGING SYSTEM OUT OF SPECIFICATION ● Start the engine and accelerate to abo ut 5,000 r/min. Charging voltage: 14 V at 5,000 r/min N OTE: Use a fully charged battery. MEETS SPECIFICATION The charging circuit is not faulty. EB804012 MEETS SPECIFICATION 4.Charging coil resistance ● Disconnect the AC magneto coupler from the wir[...]

9 - 25 – + ELEC LIGHTING SYSTEM EB805000 LIGHTING SYSTEM CIRCUIT DIAGRAM Br / L R / Y P L / B W / L W / L L / B N R W / G W / LW / R W / G R W / RW / G W WW W WW 1 W / G W / R W / G R W W W W W W 2 B R Br / L Br / L Br R R Br 3 V Q (BLACK) BR WWW R L / WL / B B B G / W G / W G / W B B R R R R R B B L / W 7 5 4 6 O R B O O O B / Y 0 9 W / R W / G [...]

9 - 26 – + ELEC LIGHTING SYSTEM EB805010 TROUBLESHOOTING Procedure Check: 1.Fuses (main, headlight) 2.Battery 3.Main switch IF THE HEADLIGHT AND/OR TAILLIGHT FAIL TO COME ON: 4.Light switch 5.Wiring connections (the entire lighting system) N OTE: ● Remove the following part(s) before troubleshooting: 1)Seat 2)Front carrier 3)Front fender panel [...]

9 - 27 – + ELEC LIGHTING SYSTEM C0NTINUITY CORRECT 3.Main switch Refer to “ CHECKING THE SWITCHES ” . * INCORRECT Replace the main switch. CORRECT 4.Light switch Refer to “ CHECKING THE SWITCHES ” . INCORRECT Light switch is faulty, replace the handlebar switch (left). EB805013 CORRECT 5.Wiring connections ● Check the connections of t h[...]

9 - 28 – + ELEC LIGHTING SYSTEM EB805020 CHECKING THE LIGHTING SYSTEM 1.If the headlights fail to come on: CONTINUITY 1.Bulb and bulb so cket ● Check the bulb and bulb socket for continuity. NO CONTINUITY Replace the bulb and/or bulb socke t. 2.Voltage ● Connect the pocket tester (DC 20 V) to the headlight couplers. Tester (+) lead → Green [...]

9 - 29 – + ELEC LIGHTING SYSTEM EB805021 2.If the taillight fails to come on: CONTINUITY 1.Bulb and bulb so cket ● Check the bulb and bulb socket for continuity. NO CONTINUITY Replace the bulb and/or bulb socke t. 2.Voltage ● Connect the pocket tester (20 V) to the bulb socket coupler. Tester (+) lead → Blue lead 1 Tester ( – ) lead → B[...]

9 - 30 – + ELEC LIGHTING SYSTEM EB805021 3.If the speedometer light fails to come on: CONTINUITY 1.Bulb and bulb so cket ● Check the bulb and bulb socket for continuity. NO CONTINUITY Replace the bulb and/or bulb socke t. 2.Voltage ● Connect the pocket tester (20 V) to the bulb socket coupler. Tester (+) lead → Blue terminal 1 Tester ( – [...]

9 - 31 – + ELEC LIGHTING SYSTEM[...]

9 - 32 – + ELEC SIGNAL SYSTEM EB806000 SIGNAL SYSTEM CIRCUIT DIAGRAM Br / L R / Y P L / B W / L W / L L / B N R W / G W / LW / R W / G R W / RW / G W WW W WW 1 W / G W / R W / G R W W W W W W 2 B R Br / L Br / L Br R R Br 3 V Q (BLACK) BR WWW R L / WL / B B B G / W G / W G / W B B R R R R R B B L / W 7 5 4 6 O R B O O O B / Y 0 9 W / R W / G L / [...]

9 - 33 – + ELEC SIGNAL SYSTEM 3 Main switch 4 Battery 5 Main fuse 8 CDI unit A Reverse switch B Neutral switch F Coolant temper ature warning lig ht G Four-wheel drive indicato r light H Thermo switch (cylinder head) I Four-wheel drive fu se K Gear moto r N Diode O Ignition fuse S Engine stop switch T Start switch V Signaling system fuse W Front [...]

9 - 34 – + ELEC SIGNAL SYSTEM EB806010 TROUBLESHOOTING Procedure Check: 1.Fuses (main, four-wheel drive , ignition, signaling system) 2.Battery 3.Main switch 4.Wiring connections (the entire signal system) IF THE BRAKE LIGHT AND/OR AN INDICATOR LIGHT FAILS TO COME ON: N OTE: ● Remove the following part(s) before troubleshooting: 1)Seat 2)Fuel t[...]

9 - 35 – + ELEC SIGNAL SYSTEM C0NTINUITY CORRECT 3.Main switch Refer to “ CHECKING THE SWITCHES ” . * INCORRECT Replace the main switch. EB806011 CORRECT 4.Wiring connections ● Check the connections of the entire signal system. Refer to “ CIRCUIT DIAGRAM ” . Check the condition of each of t he signal system ’ s circuits. Refer to “ [...]

9 - 36 – + ELEC SIGNAL SYSTEM CHECKING THE SIGNAL SYSTEM 1.If the brake light fails to come on: CONTINUITY 1.Bulb and bulb so cket ● Check the bulb and bulb socket for continuity. NO CONTINUITY Replace the bulb and/or bulb socke t. CONTINUITY 2.Brake light switches Refer to “ CHECKING THE SWITCHES ” . NO CONTINUITY Replace the brake light s[...]

9 - 37 – + ELEC SIGNAL SYSTEM EB806024 2.If the neutral indicator light fails to come on: CONTINUITY 1. Bulb and bulb socket ● Check the bulb and bulb socket for continuity. NO CONTINUITY Replace the bulb and/or bulb socke t. CONTINUITY 2.Neutral switch Refer to “ CHECKING THE SWITCHES ” . NO CONTINUITY Replace the neutral switch. 3.Voltage[...]

9 - 38 – + ELEC SIGNAL SYSTEM 3.If the reverse indicator light fails to come on: CONTINUITY 1. Bulb and bulb socket ● Check the bulb and bulb socket for continuity. NO CONTINUITY Replace the bulb and/or bulb socke t. CONTINUITY 2.Reverse swi tch Refer to “ CHECKING THE SWITCHES ” . NO CONTINUITY Replace the reverse switch. 3.Voltage ● Con[...]

9 - 39 – + ELEC SIGNAL SYSTEM 4.If the coolant temperature warning light does not come on: ● Check that the light comes on when the main switch is set to “ ON ” . ● Check that the light comes on when the coolant temperature is 120 ± 3 ° C (24 8 ± 5.4 ° F) or higher and that the light remains on when th e coolant temperature drops to 1[...]

9 - 40 – + ELEC SIGNAL SYSTEM C0NTINUITY GOOD CONDITION W ARNING Handle the thermo switch (cylinder head) with special care. Never subject it to a strong shock or allow it to be dropped. Should it be dropped, it must be replaced. T R . . Thermo switch (cylinder head): 8 Nm (0.8 m • kg, 5.8 ft • lb) Three bond sealock ® #10 * BAD CONDITION Re[...]

9 - 41 – + ELEC SIGNAL SYSTEM C0NTINUITY CORRECT 4.Diode ● Remove the diode from the couple r. ● Connect the pocket test er ( Ω × 1) to the diode terminals as shown. ● Check the diode for continuity a s follows. Tester (+) lead → Blue/Black terminal 1 Tester ( – ) lead → White/Blue terminal 2 Continuity Tester (+) lead → White/Bl[...]

9 - 42 – + ELEC SIGNAL SYSTEM 5.If the four-wheel drive indicator light fails to come on: CONTINUITY 1.Bulb and bulb so cket ● Check the bulb and bulb socket for continuity. NO CONTINUITY Replace the bulb and/or bulb socke t. 2.Voltage ● Connect the pocket tester (DC 20 V) to the bulb socket lead. Tester (+) lead → Brown/Red terminal 1 Test[...]

9 - 43 – + ELEC COOLING SYSTEM COOLING SYSTEM CIRCUIT DIAGRAM Br / L R / Y P L / B W / L W / L L / B N R W / G W / LW / R W / G R W / RW / G W WW W WW 1 W / G W / R W / G R W W W W W W 2 B R Br / L Br / L Br R R Br 3 V Q (BLACK) BR WWW R L / WL / B B B G / W G / W G / W B B R R R R R B B L / W 7 5 4 6 O R B O O O B / Y 0 9 W / R W / G L / W G / L[...]

9 - 44 – + ELEC COOLING SYSTEM TROUBLESHOOTING Procedure Check: 1.Fuse (main) 2.Battery 3.Main switch 4.Fan motor 5.Circuit breaker (fan motor) IF THE FAN MOTOR DOES NOT MOVE: 6.Thermo switch (radiator) 7.Wiring connections (the entire cooling system) N OTE: ● Remove the following part(s) before troubleshooting. 1)Seat 2)Front carrier 3)Front f[...]

9 - 45 – + ELEC COOLING SYSTEM C0NTINUITY TURNS 4.Fan motor ● Disconnect the fan motor coupler. ● Connect the battery (12 V) as shown. Battery (+) lead → Blue terminal 1 Battery ( – ) lead → Black terminal 2 ● Check the operation of the fan motor. * DOES NOT TURN Replace the fan motor. MEETS SPECIFICATION 5.Circuit breaker (fan motor)[...]

9 - 46 – + ELEC COOLING SYSTEM C0NTINUITY GOOD CONDITION 6.Thermo switch (radiator) ● Remove the thermo switch (radiator) from the radiator. ● Connect the pocket tester ( Ω × 10) to the thermo switch (radiator) 1 . ● Immerse the thermo switch (radiator) in coolant 2 . ● Check the thermo switch (radiator) for continuity. While heating t[...]

9 - 47 – + ELEC COOLING SYSTEM C0NTINUITY EB803028 CORRECT 7.Wiring connections ● Check the connections of the entire starting system. Refer to “ CIRCUIT DIAGRAM ” . This circuit is not faulty. * POOR CONNECTION Properly connect the cooling system.[...]

9 - 48 – + ELEC 2WD/4WD SELECTING SYSTEM 2WD/4WD SELECTING SYSTEM CIRCUIT DIAGRAM Br / L R / Y P L / B W / L W / L L / B N R W / G W / LW / R W / G R W / RW / G W WW W WW 1 W / G W / R W / G R W W W W W W 2 B R Br / L Br / L Br R R Br 3 V Q (BLACK) BR WWW R L / WL / B B B G / W G / W G / W B B R R R R R B B L / W 7 5 4 6 O R B O O O B / Y 0 9 W /[...]

9 - 49 – + ELEC 2WD/4WD SELECTING SYSTEM EB803020 TROUBLESHOOTING Procedure Check: 1.Fuses (main, four-wheel drive ) 2.Battery 3.Main switch IF THE GEAR MOTOR FAILS TO OPERATE: 4.On-command four-wheel drive switch 5.Gear motor 6.Wiring connections (the entire 2WD/4WD selecting system) N OTE: ● Remove the following part(s) before troubleshooting[...]

9 - 50 – + ELEC 2WD/4WD SELECTING SYSTEM C0NTINUITY CORRECT 4.On-command four-wheel drive switch Refer to “ CHECKING THE SWITCHES ” . * INCORRECT Replace the on-command four-wheel d rive switch. CORRECT 5.Gear motor ● Check that the shift fork sliding gear is in the 2WD position. ● Disconnect the gear motor coupler. ● Remove the gear mo[...]

9 - 51 – + ELEC 2WD/4WD SELECTING SYSTEM EB803028 CORRECT 6.Wiring connections ● Check the connections of the entire 2WD/ 4WD selecting system. Refer to “ CIRCUIT DIAGRAM ” . Replace the CDI unit. POOR CONNECTION Properly connect the 2W D/4WD selecting system.[...]

10 - 1 TRBL SHTG STARTING FAILURE/HARD STARTING TROUBLESHOOTING N OTE: The following troubleshooting does no t cover all the possible causes of trouble. It shou ld be helpful, however, as a guide to troubleshootin g. Refer to the relative procedure in this manual for checking, adjusting and replacing of parts. STARTING FAILURE/HARD STARTING FUEL SY[...]

10 - 2 TRBL SHTG STARTING FAILURE/HARD STARTING/POOR IDLE SPEED PERFORMANCE/POOR MEDIUM AND HIGH-SPEED PERFORMANCE COMPRESSION SYSTEM Cylinder and cylinder head ● Loose spark plug ● Loose cylinder head or cylinder ● Broken cylinder head gasket ● Broken cylinder gasket ● Worn, damaged or seized cylin der Piston and piston rings ● Imprope[...]

10 - 3 TRBL SHTG FAULTY DRIVE TRAIN FAULTY DRIVE TRAIN The following conditions may indicate damaged sh aft drive components: N OTE: 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 damage[...]

10 - 4 TRBL SHTG F A UL TY GEAR SHIFTING/ FAULTY CLUTCH PERFORMANCE FAULTY GEAR SHIFTING HARD SHIFTING Refer to “ CLUTCH SLIPPING/DRAGGING-CLUTCH DRAGGING ” . SHIFT LEVER DOES NOT MOVE Shift shaft ● Bent shift shaft Shift cam, shift fork ● Groove jammed with impurities ● Seized shift fork ● Bent shift fork guide bar Transmission ● Sei[...]

10 - 5 TRBL SHTG FAULTY CLUTCH PERFORMANCE/ OVERHEATING/FAULTY BRAKE POOR SPEED PERFORMANCE V-belt ● Oil or grease on the V-belt Primary pulley weight ● Faulty operation ● Worn primary pulley weight Primary fixed sheave ● Worn primary fixed sheave Primary sliding sheave ● Worn primary sliding sheave Secondary fixed sheave ● Worn seconda[...]

10 - 6 TRBL SHTG SHOCK ABSORBER MALFUNCTION MALFUNCTION ● Bent or damaged damper rod ● Damaged oil seal lip ● Fatigued shock absorber spring SHOCK ABSORBER MALFUNCTION/UNSTABLE HANDLING/LIGHTING SYSTEM UNSTABLE HANDLING UNSTABLE HANDLIN G Handlebar ● Improperly installed or bent Steering ● Incorrect toe-in ● Bent steering stem ● Impro[...]

YFM400FAR WIRING DIAGRAM Br / L R / Y P L / B W / L W / L L / B N R W / G W / LW / R W / G R W / RW / G W WW W WW 1 W / G W / R W / G R W W W W W W 2 B R Br / L Br / L Br R R Br 3 V Q (BLACK) BR WWW R L / WL / B B B G / W G / W G / W B B R R R R R B B L / W 7 5 4 6 O R B O O O B / Y 0 9 W / R W / G L / W G / L B / W B / W B / W G / W R / B Sb G / L[...]

Y AMAHA MO T OR CO . , L TD . 2500 SHINGAI IW A T A SHIZUOKA JAP AN PRINTED IN U.S.A.[...]