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5YF2-AE1
Yamaha 5YF2-AE1 Manuals
Manuals and User Guides for Yamaha 5YF2-AE1. We have
1
Yamaha 5YF2-AE1 manual available for free PDF download: Service Manual
Yamaha 5YF2-AE1 Service Manual (262 pages)
Brand:
Yamaha
| Category:
Offroad Vehicle
| Size: 9.47 MB
Table of Contents
Table of Contents
7
Periodic Checks and Adjustments
6
Engine
6
Carburetor
6
Drive Train
6
Chassis
6
Electrical
6
Troubleshooting
6
Table of Contents
7
Gen Info
9
General Information
12
Machine Identification
12
Vehicle Identification Number
12
Model Label
12
Important Information
13
Preparation for Removal and Disassembly
13
Replacement Parts
13
Gaskets, Oil Seals and O-Rings
13
Lock Washers/Plates and Cotter Pins
14
Bearings and Oil Seals
14
Circlips
14
Checking the Connections
15
Special Tools
16
Spec
20
Spec
21
General Specifications
23
Specifications
23
Engine Specifications
27
Chassis Specifications
34
Electrical Specifications
35
Engine Tightening Torques
37
Tightening Torques
37
Chassis Tightening Torques
38
General Tightening Torque Specifications
40
How to Use the Conversion Table
40
Engine
41
Lubrication Points and Lubricant Types
41
Oil Flow Diagrams
43
Cable Routing
45
Chk Adj
53
Chapter 3 Periodic Checks and Adjustments
54
Introduction
56
Periodic Checks and Adjustments
56
Periodic Maintenance/Lubrication
56
Seat and Front Panel
57
Seat, Fenders and Fuel Tank
57
Front Fender
58
Rear Fender and Footrest Boards
59
Fuel Tank
61
Adjusting the Timing Chain Tensioner
62
Engine
62
Adjusting the Valve Clearance
63
Adjusting the Engine Idling Speed
65
Adjusting the Throttle Lever Free Play
66
Adjusting the Speed Limiter
67
Checking the Spark Plug
68
Checking the Ignition Timing
69
Measuring the Compression Pressure
70
Checking the Engine Oil Level
72
Changing the Engine Oil
74
Cleaning the Air Filter Element
75
Adjusting the Front Brake
77
Chassis
77
Checking the Front and Rear Brake Shoes
77
Adjusting the Rear Brake
78
Changing the Final Gear Oil
79
Checking the Final Gear Oil Level
79
Checking the Swingarm Dust Boot
80
Checking the Steering System
81
Adjusting the Toe-In
82
Checking the Front and Rear Shock Absorbers
83
Checking the Tires
84
Checking the Wheels
86
Checking and Lubricating the Cables
87
Lubricating the Levers, Steering Shaft and Steering Knuckles
87
Checking and Charging the Battery
88
Electrical System
88
Checking the Fuse
92
Eng
94
Chapter 4 Engine
95
Engine
97
Exhaust Pipe/Muffler, Breather Hose and Leads
97
Engine Mounting Bolts
98
Installing the Engine
100
Removing the Engine
100
Cylinder Head
101
Removing the Cylinder Head
103
Checking the Camshaft Sprocket
104
Checking the Tappet Covers and Camshaft Sprocket Cover
104
Checking the Timing Chain Guides
104
Checking the Timing Chain Tensioner Assembly
104
Checking the Cylinder Head
105
Installing the Cylinder Head
106
Camshaft, Rocker Arms and Valves
108
Removing the Rocker Arms and Camshaft
110
Removing the Valves and Valve Springs
110
Checking the Camshaft
111
Checking the Rocker Arms and Rocker Arm Shafts
111
Checking the Valves and Valve Springs
113
Installing the Valves and Valve Springs
117
Installing the Camshaft and Rocker Arms
118
Cylinder and Piston
119
Checking the Cylinder and Piston
120
Removing the Piston
120
Checking the Piston Rings
122
Checking the Piston Pin
123
Installing the Piston
124
Installing the Cylinder
125
C.D.I. Magneto
126
Checking the Pickup Coil/Stator Assembly
127
Removing the C.D.I. Magneto Rotor
127
Installing the C.D.I. Magneto Rotor
128
Installing the Shift Lever
128
Clutch
129
Checking the Friction Plates
131
Removing the Clutch
131
Removing the Primary Drive Gear
131
Checking the Clutch Housing
132
Checking the Clutch Plates
132
Checking the Clutch Springs
132
Checking the Clutch Balls
133
Checking the Clutch Boss
133
Checking the Pressure Plate
133
Checking the Primary Drive Gears
133
Installing the Clutch
134
Installing the Primary Drive Gear
134
Starter Clutch and Oil Pump
138
Checking the Starter Clutch
140
Checking the Oil Pump
141
Shift Shaft
143
Checking the Shift Shaft
144
Checking the Stopper Lever
144
Installing the Shift Shaft
144
Installing the Stopper Lever
144
Crankcase
145
Crankcase Bearings
146
Checking the Timing Chain
147
Separating the Crankcase
147
Checking the Bearings and Oil Seals
148
Checking the Crankcase
148
Installing the Bearings
148
Assembling the Crankcase
149
Crankshaft
150
Checking the Crankshaft
151
Installing the Crankshaft
151
Transmission
152
Checking the Shift Fork
153
Removing the Transmission
153
Checking the Shift Drum
154
Checking the Transmission
154
Installing the Transmission
155
Middle Gear
156
Removing the Middle Driven Shaft
157
Checking the Pinion Gears
158
Selecting Middle Driven Gear Shims
159
Installing the Middle Driven Shaft
160
Measuring the Middle Gear Backlash
162
Carb
163
Driv
172
Driv
173
Drive Train
175
Troubleshooting
175
Checking Noises
176
Troubleshooting Chart
178
Rear Axle/Final Drive Assembly and Drive Shaft
179
Rear Axle/Final Drive Assembly
181
Removing the Nuts
182
Removing the Rear Axle/Final Drive Assembly
182
Disassembling the Final Gear Case
183
Disassembling the Rear Axle Housing
183
Checking the Drive Shaft
184
Checking the Rear Axle
184
Checking the Rear Axle Housing and Final Drive Assembly
184
Assembling the Final Gear Case
185
Assembling the Rear Axle Housing
185
Installing the Rear Axle/Final Drive Assembly
186
Installing the Nuts
187
Chas
189
Chas
190
Front and Rear Wheels
192
Front Wheels
192
Rear Wheels
193
Checking the Front Wheel Hubs
194
Checking the Wheels
194
Checking the Rear Wheel Hubs
195
Installing the Wheel Hubs
195
Installing the Wheels
196
Front and Rear Brakes
197
Front Brake
197
Rear Brake
198
Checking the Brake Shoe Plates
200
Checking the Brake Shoes
200
Removing the Brakes
200
Checking the Brake Drums
201
Installing the Front Brakes
202
Installing the Rear Brake
203
Handlebar
205
Steering System
205
Checking the Handlebar
207
Removing the Handlebar Grips
207
Removing the Rear Brake Switch
207
Installing the Handlebar
208
Installing the Handlebar Grips
208
Installing the Front Brake Lever Assembly
209
Installing the Rear Brake Lever
209
Steering Stem
210
Checking the Steering Stem
211
Installing the Lock Washer
211
Installing the Steering Stem
211
Removing the Steering Stem
211
Tie-Rods and Steering Knuckles
212
Checking the Steering Knuckles
213
Checking the Tie-Rods
213
Removing the Tie-Rods
213
Installing the Tie-Rods
214
Front Shock Absorber Assemblies and Front Swingarm
215
Checking the Front Shock Absorber Assemblies
216
Checking the Front Swingarm
216
Removing the Front Swingarm
216
Rear Shock Absorber and Rear Swingarm
217
Checking the Rear Shock Absorber
218
Removing the Rear Swingarm
218
Checking the Dust Boot
219
Checking the Rear Swingarm
219
Installing the Lock Washer
219
Elec
220
Elec
221
Electrical Components
223
Checking Switch Continuity
224
Checking the Switches
225
Checking the Bulbs and Bulb Sockets
226
Checking the Condition of the Bulbs
226
Types of Bulbs
226
Checking the Condition of the Bulb Sockets
228
Circuit Diagram
229
Ignition System
229
Troubleshooting
230
Circuit Diagram
235
Electric Starting System
235
Starting Circuit Operation
236
Troubleshooting
237
Starter Motor
241
Checking the Starter Motor
242
Assembling the Starter Motor
243
Charging System
244
Circuit Diagram
244
Troubleshooting
245
Circuit Diagram
247
Signal System
247
Troubleshooting
248
Checking the Signaling System
249
Trbl Shtg
251
Trbl Shtg
252
Electrical System
254
Fuel System
254
Starting Failure/Hard Starting
254
Troubleshooting
254
Compression System
255
Poor Idle Speed Performance
255
Poor Medium and High-Speed Performance
255
Faulty Drive Train
256
Clutch Dragging
257
Clutch Slipping
257
Clutch Slipping/Dragging
257
Faulty Gear Shifting
257
Hard Shifting
257
Jumps out Gear
257
Overheating
257
Shift Lever Does Not Move
257
Faulty Brake
258
Malfunction
258
Poor Braking Effect
258
Shock Absorber Malfunction
258
Unstable Handling
258
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