Yamaha 5KM2-AE1 Manuals

Manuals and User Guides for Yamaha 5KM2-AE1. We have 1 Yamaha 5KM2-AE1 manual available for free PDF download: Service Manual

Yamaha 5KM2-AE1 Service Manual

Yamaha 5KM2-AE1 Service Manual (431 pages)

Brand: Yamaha | Category: Offroad Vehicle | Size: 21.61 MB

Table of Contents

Table of Contents

7
- Carburetion
  6
- Chassis
  6
- Cooling System
  6
- Drive Train
  6
- Electrical
  6
- Engine
  6
- Periodic Checks and Adjustments
  6
- Troubleshooting
  6
  - Table of Contents
    7
- General Information
  12
- Machine Identification
  12
- Model Label
  12
- Vehicle Identification Number
  12
- Features
  13
- Front Differential
  13
- Transmission
  20
- Gaskets, Oil Seals and O-Rings
  21
- Important Information
  21
- Preparation for Removal Procedures
  21
- Replacement Parts
  21
- Bearings and Oil Seals
  22
- Circlips
  22
- Lock Washers/Plates and Cotter Pins
  22
- Checking of Connections
  23
- Special Tools
  24
- Spec
  30
2 Spec

31
- Chapter 2. Specifications
  33
- General Specifications
  33
- Engine
  36
- Maintenance Specifications
  36
- Chassis
  46
- Electrical
  50
- General Torque Specifications
  52
- How to Use the Conversion Table
  52
- Engine
  53
- Lubrication Points and Lubricant Types
  53
- Coolant Flow Diagrams
  54
- Oil Flow Diagrams
  56
- Cable Routing
  59
- Chk Adj
  73
Chapter 3. Periodic Inspections and Adjustments

74
- Introduction
  76
- Periodic Inspections and Adjustments
  76
- Periodic Maintenance/Lubrication Intervals
  76
- Seat and Side Panels
  78
- Seat, Carriers, Fenders and Fuel Tank
  78
- Front Carrier, Front Bumper and Front Grill
  79
- Handlebar Cover, Fuel Tank Cover and Front Fender
  80
- Rear Carrier and Rear Fender
  82
- Engine Skid Plate (Center) and Engine Skid Plate (Rear)
  84
- Fuel Tank
  85
- Footrest Boards
  87
- Adjusting the Valve Clearance
  88
- Engine
  88
- Adjusting the Timing Chain
  91
- Adjusting the Idling Speed
  92
- Adjusting the Throttle Lever Free Play
  92
- Adjusting the Speed Limiter
  94
- Adjusting the Starter Cable
  96
- Checking the Spark Plug
  96
- Checking the Ignition Timing
  97
- Measuring the Compression Pressure
  99
- Checking the Engine Oil Level
  101
- Changing the Engine Oil
  102
- Cleaning the Air Filter
  105
- Checking the Coolant Level
  106
- Changing the Coolant
  107
- Checking the V-Belt
  111
- Cleaning the Spark Arrester
  112
- Adjusting the Rear Brake
  114
- Chassis
  114
- Checking the Brake Fluid Level
  116
- Checking the Front Brake Pad
  118
- Checking the Rear Brake Pad
  118
- Bleeding the Hydraulic Brake System
  119
- Checking the Brake Hose
  119
- Adjusting the Select Lever Control Cable and Shift Rod
  121
- Adjusting the Rear Brake Light Switch
  122
- Changing the Final Gear Oil
  123
- Checking the Final Gear Oil Level
  123
- Checking the Differential Gear Oil
  124
- Changing the Differential Gear Oil
  125
- Checking the Constant Velocity Joint Dust Boot
  126
- Checking the Steering System
  126
- Adjusting the Toe-In
  127
- Adjusting the Front Shock Absorber
  128
- Adjusting the Rear Shock Absorber
  129
- Checking the Tire
  129
- Checking the Wheel
  131
- Checking and Lubricating the Cable
  132
- Lubricating the Levers, Pedal, Etc
  132
- Checking the Battery
  133
- Electrical
  133
- Checking the Fuse
  139
- Adjusting the Headlight Beam
  140
- Changing the Headlight Bulb
  141
- Eng
  142
Chapter 4. Engine

143
- Air Ducts, Muffler and Exhaust Pipe
  147
- Engine Removal
  147
- Select Lever Unit and Coolant Reservoir
  149
- Hoses and Leads
  150
- Engine Mounting Bolts
  151
- Installing the Engine
  153
- Cylinder Head Cover
  154
- Checking the Cylinder Head Cover
  156
- Removing the Cylinder Head Cover
  156
- Checking the Tappet Cover
  157
- Installing the Cylinder Head Cover
  157
- Rocker Arms
  158
- Checking the Rocker Arm
  160
- Removing the Rocker Arm
  160
- Installing the Rocker Arm
  161
- Camshaft and Cylinder Head
  162
- Removing the Camshaft and Cylinder Head
  164
- Checking the Camshaft
  165
- Checking the Camshaft Sprocket
  165
- Checking the Decompression System
  165
- Checking the Cylinder Head
  166
- Checking the Timing Chain Guide
  166
- Checking the Timing Chain Tensioner
  166
- Installing the Camshaft and Cylinder Head
  167
- Valves and Valve Springs
  170
- Removing the Valve and Valve Spring
  171
- Checking the Valve and Valve Spring
  172
- Installing the Valve and Valve Spring
  176
- Cylinder and Piston
  178
- Checking the Cylinder and Piston
  179
- Removing the Piston
  179
- Checking the Piston Ring
  181
- Checking the Piston Pin
  182
- Installing the Piston
  182
- Installing the Cylinder
  183
- Recoil Starter and Ac Magneto
  184
- Checking the Ac Magneto
  187
- Disassembling the Recoil Starter
  187
- Removing the Ac Magneto
  187
- Checking the Starter Clutch
  188
- Assembleing the Recoil Starter
  189
- Checking the Recoil Starter
  189
- Checking the Starter Pulley
  189
- Installing the Ac Magneto
  190
- Balancer Gears and Oil Pump Gears
  193
- Checking the Oil Pump Drive
  194
- Removing the Balancer Drive Gear and Balancer Driven Gear
  194
- Removing the Balancer Drive Gear and Buffer Boss
  194
- Checking the Balancer Drive
  195
- Installing the Balancer Drive Gear and Balancer Driven Gear
  195
- Primary and Secondary Sheaves
  197
- Primary Sheave
  199
- Secondary Sheave
  200
- Disassembling the Secondary Sheave
  201
- Removing the Primary and Secondary Sheaves
  201
- Checking the Secondary Sheave
  202
- Cheking the Primary Sheave
  202
- Assembling the Primary Sheave
  203
- Assembling the Secondary Sheave
  203
- Installing the Primary and Secondary Sheaves
  205
- Clutch
  206
- Checking the Clutch
  208
- Removing the Clutch
  208
- Installing the Clutch
  209
- Crankcase
  211
- Starter Motor, Timing Chain and Oil Filter
  211
- Crankcase
  212
- Crankcase Bearing
  214
- Checking the Oil Delivery Pipe
  215
- Checking the Timing Chain and Guide
  215
- Separating the Crankcase
  215
- Assembling the Crankcase
  216
- Checking the Bearings
  216
- Checking the Crankcase
  216
- Installating the Shift Lever
  217
- Crankshaft and Oil Pump
  218
- Oil Pump
  219
- Checking the Oil Pump
  220
- Removing the Crankshaft
  220
- Assembling the Oil Pump
  221
- Checking the Oil Strainer
  221
- Checking the Relief Valve
  221
- Checking the Crankshaft
  222
- Installing the Crankshaft and Balancer
  223
- Transmission
  224
- Checking the Shift Fork
  227
- Removing the Transmission
  227
- Checking the Drive Axle
  228
- Checking the High Wheel Gear and Middle Drive Gear
  228
- Checking the Shift Cam
  228
- Checking the Chain
  229
- Checking the Secondary Shaft and Driven Sprocket
  229
- Checking the Stopper Lever and Stopper Wheel
  229
- Assembling the Shift Fork Assembly
  230
- Middle Drive Shaft
  231
- Middle Gear
  231
- Middle Driven Shaft
  232
- Removing the Middle Drive Shaft
  234
- Removing the Middle Driven Shaft
  234
- Checking the Pinion Gear
  237
- Middle Drive and Driven Gear Shim Selection
  237
- Installing the Middle Driven Shaft
  240
- Installing the Middle Drive Shaft
  242
- Measuring the Middle Gear Backlash
  243
- Cool
  245
5 Cool

246
- Chapter 5. Cooling System
  248
- Radiator
  248
- Checking the Radiator
  250
- Installing the Radiator
  251
- Thermostat
  252
- Checking the Thermostat
  253
- Installing the Thermostat
  253
- Water Pump
  254
- Checking the Water Pump
  256
- Disassembling the Water Pump
  256
- Assembling the Water Pump
  257
- Carb
  260
6 Carb

261
- Carburetor
  263
- Chapter 6. Carburetion
  263
- Checking the Carburetor
  266
- Assembling the Carburetor
  268
- Adjusting the Fuel Level
  269
- Driv
  271
7 Driv

272
8 Chas

307
- Chapter 8. Chassis
  309
- Front Wheels
  309
- Front Wheels and Brake Discs
  309
- Checking the Front Wheel
  311
- Checking the Front Wheel Hub
  311
- Checking the Front Brake Disc
  312
- Installing the Front Wheel
  312
- Installing the Front Wheel Hub
  312
- Rear Wheels
  314
- Rear Wheels and Brake Disc
  314
- Rear Brake Disc
  315
- Checking the Rear Brake Disc
  316
- Checking the Rear Wheel
  316
- Checking the Rear Wheel Hub
  316
- Installing the Rear Wheel
  317
- Installing the Rear Wheel Hub
  317
- Front and Rear Brakes
  318
- Front Brake Pads
  318
- Rear Brake Pads
  319
- Replacing the Front Brake Pad
  320
- Replacing the Rear Brake Pad
  322
- Front Brake Master Cylinder
  324
- Rear Brake Master Cylinder
  326
- Checking the Master Cylinder
  329
- Assembling the Front Brake Master Cylinder
  330
- Assembling the Rear Brake Master Cylinder
  330
- Installing the Front Brake Master Cylinder
  331
- Installing the Rear Brake Master Cylinder
  332
- Front Brake Caliper
  334
- Rear Brake Caliper
  336
- Disassembling the Brake Caliper
  338
- Disassembling the Rear Brake Caliper
  338
- Checking the Front and Rear Brake Caliper
  339
- Assembling the Front Brake Caliper
  340
- Installing the Front Brake Caliper
  340
- Assembling the Rear Brake Caliper
  342
- Installing the Rear Brake Caliper
  343
- Handlebar
  344
- Checking the Handlebar
  345
- Installing the Handlebar
  345
- Installing the Rear Brake Lever
  345
- Removing the Rear Brake Switch
  345
- Installing the Master Cylinder Assembly
  346
- Steering Stem
  347
- Checking the Steering Stem
  349
- Installing the Bearing Retainer
  349
- Installing the Steering Stem
  349
- Removing the Bearing Retainer
  349
- Installing the Cable Guide
  350
- Tie Rod and Steering Knuckle
  351
- Checking the Steering Knuckle
  352
- Checking the Tie Rod
  352
- Removing the Steering Knuckle
  352
- Checking the Ball Joint
  353
- Checking the Tie Rod
  353
- Front Arms and Front Shock Absorber
  354
- Checking the Front Arm
  356
- Checking the Front Shock Absorber
  356
- Removing the Front Arms
  356
- Installing the Front Arms and Front Shock Absorber
  357
- Rear Knuckle and Stabilizer
  358
- Checking the Rear Knuckle
  359
- Checking the Stabilizer
  359
- Rear Arms and Rear Shock Absorber
  360
- Checking the Rear Arm
  361
- Checking the Rear Arms and Rear Shock Absorber
  361
- Checking the Rear Shock Absorber
  361
- Elec
  363
9 Elec

364
- Chapter 9. Electrical
  366
- Electrical Components
  366
- Checking a Switch Shown in the Manual
  367
- Checking the Switch
  367
- Checking the Switch Continuity
  368
- Checking the Bulbs and Bulb Sockets
  370
- Checking the Condition of the Bulbs
  370
- Types of Bulbs
  370
- Checking the Condition of the Bulb Sockets
  372
- Circuit Diagram
  373
- Ignition System
  373
- Troubleshooting
  374
- Circuit Diagram
  379
- Electric Starting System
  379
- Starting Circuit Operation
  380
- Troubleshooting
  381
- Starter Motor
  385
- Checking the Starter Motor
  386
- Assembling the Starter Motor
  387
- Charging System
  388
- Circuit Diagram
  388
- Troubleshooting
  389
- Circuit Diagram
  391
- Lighting System
  391
- Troubleshooting
  392
- Checking the Lighting System
  394
- Circuit Diagram
  396
- Signal System
  396
- Troubleshooting
  398
- Checking the Signal System
  400
- Circuit Diagram
  411
- Cooling System
  411
- Trbl Shtg
  422
Trbl Shtg

423
- Troubleshooting
  423
- Electrical System
  425
- Fuel System
  425
- Starting Failure/Hard Starting
  425
- Compression System
  426
- Poor Idle Speed Performance
  426
- Poor Medium and High-Speed Performance
  426
- Faulty Drive Train
  427
- Clutch Slipping
  428
- Engine Operates but Machine will Not Move
  428
- Faulty Clutch Performance
  428
- Faulty Gear Shifting
  428
- Hard Shifting
  428
- Jumps out of Gear
  428
- Poor Starting Performance
  428
- Shift Lever Does Not Move
  428
- Faulty Brake
  429
- Overheating
  429
- Poor Braking Effect
  429
- Poor Speed Performance
  429
- Bulb Burnt out
  430
- Headlight Dark
  430
- Lighting System
  430
- Malfunction
  430
- Shock Absorber Malfunction
  430
- Unstable Handling
  430

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