Yamaha 2012 Grizzly 300 Service Manual
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Yamaha 2012 Grizzly 300 Service Manual

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GRIZZLY 300
2012
Service Manual
LIT-11616-25-16

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Summary of Contents for Yamaha 2012 Grizzly 300

  • Page 1 GRIZZLY 300 2012 Service Manual LIT-11616-25-16...
  • Page 2 YFM30GB SERVICE MANUAL ©2011 by Yamaha Motor Corporation, U.S.A. First edition, September 2011 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-11616-25-16...

  • Page 3: Important Information

    IMPORTANT This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man- ual, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha machine has a basic understanding of the mechanical ideas and the procedures of machine repair.
  • Page 4 HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual consists of chapters for the main categories of subjects. (See “symbols”) 1st title : This is the title of the chapter with its symbol in the upper right corner of each page. 2nd title : This title indicates the section of the chapter and only appears on the first page of each section.

  • Page 5: General Information

    SYMBOLS The following symbols are not relevant to every SPEC machine. INFO Symbols indicate the subject of each chapter. General information Specifications Periodic and adjustments checks Engine Cooling system Carburetor COOL CARB Drive train Chassis Electrical Troubleshooting CHAS DRIV Symbols indicate the following TRBL Serviceable with engine mounted...

  • Page 7: Table Of Contents

    TABLE OF CONTENTS GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC CHECKS ADJUSTMENTS ENGINE COOLING SYSTEM COOL CARBURETOR CARB DRIVE TRAIN DRIV CHASSIS CHAS – ELECTRICAL ELEC TROUBLESHOOTING TRBL SHTG...

  • Page 8: General Information

    CHAPTER 1 GENERAL INFORMATION MACHINE IDENTIFICATION ........1-1 VEHICLE IDENTIFICATION NUMBER.

  • Page 9: Specifications

    CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS ........2 ENGINE SPECIFICATIONS.

  • Page 10: Periodic Checks And Adjustments

    CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION ......... . . 3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM .
  • Page 11 CHANGING THE TRANSFER GEAR OIL ....3-42 CHANGING THE FINAL DRIVE GEAR OIL ....3-43 CHECKING THE REAR AXLE BOOT .
  • Page 12 CHAPTER 4 ENGINE ENGINE REMOVAL ......... 4 -1 AIR DUCTS, A.I.C.V., MUFFLER AND EXHAUST PIPE .
  • Page 13 BELT DRIVE ..........4-32 CRANKCASE COVER .

  • Page 14: Cooling System

    CHAPTER 5 COOLING SYSTEM RADIATOR ..........5-1 CHECKING THE RADIATOR .

  • Page 15: Chassis

    CHAPTER 8 CHASSIS FRONT AND REAR WHEELS ........8-1 FRONT WHEELS .
  • Page 16 CHECKING THE STEERING STEM ......8-36 INSTALLING THE STEERING STEM ......8-37 INSTALLING THE LOCK WASHER .

  • Page 17: Electrical

    CHAPTER 9 ELECTRICAL ELECTRICAL COMPONENTS ....... . . CHECKING SWITCH CONTINUITY .

  • Page 18: Troubleshooting

    CHAPTER 10 TROUBLESHOOTING STARTING FAILURE/HARD STARTING ......10-1 FUEL SYSTEM ......... . 10-1 ELECTRICAL SYSTEM .

  • Page 19: Gen Info

    MACHINE IDENTIFICATION INFO GENERAL INFORMATION MACHINE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER The vehicle identification number is stamped into the front side of the frame. MODEL LABEL The model label is affixed to the air filter case cover. This information will be needed to order spare parts.

  • Page 20: Important Information

    5. Keep all parts away from any source of fire. REPLACEMENT PARTS 1. Use only genuine Yamaha parts for all replacements. Use oil and grease recom- mended by Yamaha for all lubrication jobs.

  • Page 21: Bearings And Oil Seals

    IMPORTANT INFORMATION INFO BEARINGS AND OIL SEALS Install bearings and oil seals so that the manu- facturer’s marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if appro- priate.

  • Page 22: Checking The Connections

    IMPORTANT INFORMATION INFO CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: • lead • coupler • connector 2. Check: • lead • coupler • connector Moisture Dry with an air blower. → Rust /stains Connect and disconnect →...

  • Page 23: Special Tools

    SPECIAL TOOLS INFO SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools; this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools may differ by shape and part number from country to country.
  • Page 24 SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Crankshaft installer pot Crankshaft installer bolt 90890-01274 Bolt 90890-01275 These tools are used to install the crankshaft. Crankshaft installer set YU-90050 These tools are used to install the crankshaft. Spacer 90890-01288 90890-04164 YM-04164 These tools are used to install the crankshaft.
  • Page 25 SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Compression gauge set 90890-03081 Adapter YU-33223 Adapter 90890-04082 This tool is needed to measure the engine YU-33223-3 compression. Engine tachometer 90890-03113 YU-8036-B This tool is needed for observing engine rpm. Pocket tester Analog pocket tester 90890-03112 YU-03112-C...
  • Page 26 SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Fuel level gauge 90890-01312 YM-01312-A This gauge is used to measure the fuel level in the float chamber. Radiator cap tester 90890-01325 YU-24460-01 This tool is used to check the cooling system. Adapter 90890-01325 YU-24460-01...

  • Page 27: General Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Model code 1SC1 Dimensions Overall length 1895 mm (74.6 in) Overall width 1069 mm (42.1 in) Overall height 1124 mm (44.3 in) Seat height 794 mm (31.3 in) Wheelbase 1199 mm (47.2 in) Minimum ground clearance 137 mm (5.4 in) Minimum turning radius...
  • Page 28 SPEC GENERAL SPECIFICATIONS Item Standard Final gear oil Total amount 0.15 L (0.16 US qt, 0.13 Imp.qt) Radiator capacity (including all routes) 0.94 L (0.99 US qt, 0.83 Imp.qt) Air filter Wet type element Fuel Type Unleaded gasoline only Fuel tank capacity 10.7 L (2.35 lmp gal, 2.83 US gal) Fuel reserve amount 3.0 L (0.66 Imp gal, 0.79 US gal)
  • Page 29 SPEC GENERAL SPECIFICATIONS Item Standard Tire pressure (cold tire) Maximum load* 155.0 kg (342 lb) Off-road riding front 27 ~ 30 kPa (0.27 ~ 0.30 kgf/cm , 4.0 ~ 4.4 psi) rear 22 ~ 25 kPa (0.22 ~ 0.25 kgf/cm , 3.2 ~ 3.6 psi) *Load in total weight of rider and accessories Brake Front brake...

  • Page 30: Spec

    SPEC ENGINE SPECIFICATIONS EBS01002 ENGINE SPECIFICATIONS Cylinder head 20.30 ~ 21.30 cm (1.24 ~ 1.30 cu.in) ---- ---- (0.0020 in) Cylinder 74.995 ~ 75.015 mm (2.9526 ~ 2.9533 in) 75.100 mm (2.9567 in) Camshaft Camshaft lobe dimensions Intake “A” 34.780 ~ 34.980 mm (1.3693 ~ 1.3701 in) 34.680 mm (1.4484 in) “B”...
  • Page 31 SPEC ENGINE SPECIFICATIONS Valve, valve seat, valve guide ---- Valve clearance (cold) 0.08 ~ 0.12 mm (0.0031 ~ 0.0047 in) 0.13 ~ 0.17 mm (0.0051 ~ 0.0067 in) ---- Valve dimensions Head Diameter Face Width Seat Width Margin Thickness ---- “A”...
  • Page 32 SPEC ENGINE SPECIFICATIONS Valve spring Inner spring 38.70 mm (1.52 in) 35.20 mm (1.38 in) 38.70 mm (1.52 in) 35.20 mm (1.38 in) Installed length 31.80 mm (1.25 in) ---- 31.80 mm (1.25 in) ---- Spring rate K1 7.15 N/mm (0.73 kg/mm, 40.84 lb/in) ---- 9.54 N/mm (0.97 kg/mm, 54.38 lb/in) ----...
  • Page 33 SPEC ENGINE SPECIFICATIONS Tilt limit ° 5 ---- (2.5°/0.063 in) ° 5 ---- (2.5°/0.063 in) Direction of winding ---- ---- Piston Piston to cylinder clearance 0.010 ~ 0.040 mm (0.0004 ~ 0.0016 in) 0.10 mm (0.004 in) “ ” 74.975 ~ 74.985 mm (2.9518 ~ 2.9522 in) ---- ---- 0.50 mm (0.0197 in)
  • Page 34 SPEC ENGINE SPECIFICATIONS Piston rings Top ring ---- Dimensions (B × T) 1.00 × 2.61 mm (0.039 × 0.103 in) ---- End gap (installed) 0.15 ~ 0.30 mm (0.006 ~ 0.012 in) 0.50 mm (0.020 in) 0.015 ~ 0.050 mm (0.0005 ~ 0.0019 in) 0.09 mm (0.0035 in) 2nd ring...
  • Page 35 SPEC ENGINE SPECIFICATIONS Balancer ---- Transmission Main axle runout limit ---- (0.0024 in) Drive axle runout limit ---- (0.0024 in) ---- Main axle assembly width 102.2 ~ 102.4 mm (4.02 ~ 4.03 in) Shifter t f i t f i ---- Max.
  • Page 36 SPEC ENGINE SPECIFICATIONS Carburetor ---- 1SC1 00 ---- #138 ---- NPPC ---- ø3.8 ---- . J . ---- ø 0.8x3 ---- ---- o l i ---- . P . ø ø ---- ---- ---- Oil filter type ---- Oil pump ---- Inner-rotor-to-outer-rotor-tip cleara (0.0078 in)

  • Page 37: Chassis Specifications

    SPEC CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS Item Standard Limit Front suspension Shock absorber travel 75.0 mm (2.95 in) ---- Fork spring free length 281.0 mm (11.06 in) (K ) 1.8 kg/mm (K ) 3.0 kg/mm Rear suspension Shock absorber travel 100.0mm (3.94 in) ---- Spring free length 295.0 mm (11.61 in)
  • Page 38 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Rear disc brake Type Single cylinder ---- Disc outside diameter × thickness 220.0 mm × 4.0 mm 3.00 mm (8.66 in × 0.16 in) (0.12 in) Brake disk maximum deflection 0.15 mm (0.006 in) Pad thickness inner 4.8 mm (0.19 in) 1.00 mm...

  • Page 39: Electrical Specifications

    SPEC ELECTRICAL SPECIFICATIONS EBS01004 ELECTRICAL SPECIFICATIONS Item Standard Limit Voltage 12 V ---- Ignition system Ignition timing (B.T.D.C.) 10.0°/1,700 r/min ---- Advanced timing (B.T.D.C.) 27°/4,000 r/min ---- Advancer type Electrical (digital) ---- C.D.I. Magneto model/manufacturer 31120-RFS-0000/SHIHLIN ---- Ω Pickup coil resistance/color 96 ~ 144 at 20 °C (68 °F)/ ----...
  • Page 40 SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit Electric starter system Type Constant mesh ---- Starter motor Model/manufacturer 31200-RFS-0000/SHIHLIN ---- Output 0.60 kW ---- Ω Armature coil resistance 0.018 ~ 0.028 at 20 °C (68 °F) ---- Brush overall length 12.7 mm (0.50 in) 8.2 mm (0.32 in) Spring force...

  • Page 41: Tightening Torques

    SPEC TIGHTENING TORQUES EBS01005 TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Tightening torque Part Thread Part to be tightened Q’ty Remarks name size m•kg ft•lb Reed valve comp. Bolt Air pipe Bolt Cylinder head cover Bolt Cylinder head 27.4 Cylinder head side cover Bolt Camshaft sprocket washer Bolt...
  • Page 42 SPEC TIGHTENING TORQUES Tightening torque Part Thread Part to be tightened Q’ty Remarks name size m•kg ft•lb Starter motor Bolt Oil pump Bolt Crankcase L and R Bolt Crankcase L Bolt Change switch Bolt Air clean case Bolt Muffler Bolt 18.1 Exhaust pipe 18.1...

  • Page 43: Chassis Tightening Torques

    SPEC TIGHTENING TORQUES CHASSIS TIGHTENING TORQUES Tightening torque Part to be tightened Thread size Remarks m•kg ft•lb Engine bracket (front) and frame 43.4 Engine bracket (front) and engine 43.4 Engine and frame 43.4 Select lever assembly and frame 18.1 Shift tie-rod and select lever assembly 18.1 Shift tie-rod and engine 18.1...
  • Page 44 SPEC TIGHTENING TORQUES Tightening torque Part to be tightened Thread size Remarks m•kg ft•lb brake hose union bolt 20.3 Bleed screw Rear brake master cylinder and 18.1 brake pedal bracket Brake pedal bracket and frame 18.1 Brake master cylinder cup and frame Fuel tank and fuel cock 11.6 Fuel tank and frame...

  • Page 45: How To Use The Conversion Table

    HOW TO USE THE CONVERSION TABLE/ SPEC GENERAL TIGHTENING TORQUE SPECIFICATIONS EBS00022 EBS00023 HOW TO USE THE CONVERSION GENERAL TIGHTENING TORQUE TABLE SPECIFICATIONS All specification data in this manual are listed This chart specifies tightening torques for in SI and METRIC UNITS. standard fasteners with a standard ISO thread Use this table to convert METRIC unit data to pitch.

  • Page 46: Lubrication Points And Lubricant Types

    SPEC LUBRICATION POINTS AND LUBRICANT TYPES EBS00024 LUBRICATION POINTS AND LUBRICANT TYPES ENGINE Oil seal lips O-rings Bearings Cylinder head bolts (bearing surface of bolts) Cylinder head bolts (thread part) Cylinder body surface Crankshaft journals Connecting rod small end and big end Piston pin Piston surface Boss periphery...
  • Page 47 SPEC LUBRICATION POINTS AND LUBRICANT TYPES Sealant ® (Three Bond No.1215 Crankcase mating surfaces Yamaha bond No.1215 Sealant ® (Three Bond No.1215 AC magneto lead grommet (AC magneto cover) Yamaha bond No.1215 2-21...

  • Page 48: Coolant Flow Diagrams

    SPEC COOLANT FLOW DIAGRAMS COOLANT FLOW DIAGRAMS Fan motor Radiator Thermostat 2-22...
  • Page 49 SPEC COOLANT FLOW DIAGRAMS Fan motor Radiator Thermo switch Thermostat 2-23...

  • Page 50: Oil Flow Diagrams

    SPEC OIL FLOW DIAGRAMS OIL FLOW DIAGRAMS Press-In Lubrication Cam Shaft Spray Lubrication Spray Lubrication Con-Rod Oil Route Oil Route Oil Pump Press-In Lubrication Oil Strainer Valve Rocker Arm 2-24...

  • Page 51: Cable Routing

    SPEC CABLE ROUTING CABLE ROUTING Fuel tank breather hose Handlebar switch lead Parking brake cable Choke cable Front brake hose Throttle cable Rear brake cable Front brake switch lead Insert the fuel tank breather hose into the hole in the handlebar cover. Fasten the front brake switch lead and front brake hose with plastic bands.
  • Page 52 SPEC CABLE ROUTING Headlight couplers Positive battery lead Coolant reservoir breather hose Thermo switch coupler Start relay Reserve rubber tube Handlebar switch couplers Starter motor lead A.I.C.V. inlet tube Shift controller Fuse boxes C.V.T. inlet tube CDI unit Head relay Coolant temperature warning light Negative battery lead Indicator light terminals...
  • Page 53 SPEC CABLE ROUTING Fasten the coolant reservoir breather hose and reserve rubber tube with a plastic band, then route the coolant reservoir breather hose through the front fender. Route the A.I.C.V. inlet tube and C.V.T. inlet tube through the hole in the front fender. Fasten the negative battery lead with plastic bands.
  • Page 54 SPEC CABLE ROUTING Front brake hose Throttle cable Negative battery lead Fan motor coupler Rear brake cable Taillight lead coupler Heater control switch coupler Select lever control cable Parking brake cable Generator & wire harness coupler Carburetor air vent hose Rear brake hose Rectifier/regulator &...
  • Page 55 SPEC CABLE ROUTING Route the radiator outlet hose and coolant reservoir breather hose through the guides on the frame. Fasten the generator lead and heater control switch lead on the wire harness with plastic bands. Fasten the generator lead and wire harness with plastic bands. Fasten the front brake switch lead and change switch lead with plastic bands.
  • Page 56 SPEC CABLE ROUTING Front brake hose Choke cable Negative battery lead Rectifier/regulator Rear brake hose A.I.C.V. rubber tube Thermo switch coupler Transfer gear case breather hose A.I.C.V. outlet tube Ignition coil Fuel tube A.I.C.V. inlet tube A.I.C.V. connecting tube Parking brake cable Carburetor air vent hose Route the choke cable and parking brake cable through the guides on the frame.
  • Page 57 SPEC CABLE ROUTING Fixed the negative battery lead on engine by a bolt of the starter motor. Fasten the parking brake cable with plastic bands. Route the rear brake hose through the guide on the swingarm. Fasten the rear brake hose and parking brake cable with plastic bands Route the parking brake cable through the guide on the swingarm.
  • Page 58 SPEC CABLE ROUTING Front brake hose Horn switch terminals Generator & rectifier/regulator coupler Rectifier/regulator Wire harness Ignition coil Generator & wire harness coupler Rectifier/regulator & wire harness coupler Fan motor coupler Rear brake cable Heater control switch coupler Route the Front brake hose through the guides on the frame and upper front arms. Insert the couplers on the bracket of the front fender holder.

  • Page 59: Periodic Checks And

    However, keep in mind that if the ATV isn’t used for a long period of time, the month main- tenance intervals should be followed. • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.

  • Page 60: Chk Adj

    GENERAL MAINTENANCE AND LUBRICATION CHART GENERAL MAINTENANCE AND LUBRICATION CHART INITIAL EVERY month Whichever CHECK OR MAINTENANCE ITEM comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Every 20–40 hours (more often in wet or Air filter element •...
  • Page 61 GENERAL MAINTENANCE AND LUBRICATION CHART INITIAL EVERY month Whichever CHECK OR MAINTENANCE ITEM comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Check operation and correct if necessary. Throttle lever hous- • Check throttle cable free play and adjust if neces- √...

  • Page 62: Seat, Fenders And Fuel Tank

    SEAT, FENDERS AND FUEL TANK EBS00033 SEAT, FENDERS AND FUEL TANK SEAT, SIDE COVERS AND FOOTREST BOARDS 9 Nm (0.9 m kg, 6.5 ft • • (X6) (X6) (X4) (X4) (X6) (X6) 9 Nm (0.9 m kg, 6.5 ft • •...

  • Page 63: Front Carrier, Front Bumper And Front Fender

    SEAT, FENDERS AND FUEL TANK FRONT CARRIER, FRONT BUMPER AND FRONT FENDER 9 Nm (0.9 m kg, 6.5 ft • • (X2) 25 Nm (2.5 m kg, 18.1 ft • • (X2) (X2) 9 Nm (0.9 m kg, 6.5 ft •...

  • Page 64: Rear Fender And Air Fillter Case

    SEAT, FENDERS AND FUEL TANK REAR FENDER AND AIR FILLTER CASE 25 Nm (2.5 m kg, 18.1 ft • • (X2) (X2) (X2) (X3) (X4) 9 Nm (0.9 m kg, 6.5 ft • • 9 Nm (0.9 m kg, 6.5 ft •...
  • Page 65 SEAT, FENDERS AND FUEL TANK REAR FENDER AND AIR FILLTER CASE 25 Nm (2.5 m kg, 18.1 ft • • (X2) (X2) (X2) (X3) (X4) 9 Nm (0.9 m kg, 6.5 ft • • 9 Nm (0.9 m kg, 6.5 ft •...

  • Page 66: Fuel Tank

    SEAT, FENDERS AND FUEL TANK FUEL TANK 13 Nm (1.3 m•kg, 9.4 ft•Ib) 13 Nm (1.3 m•kg, 9.4 ft•Ib) Order Job/Part Q’ty Remarks Removing the fuel tank Remove the parts in the order listed. f / t S “ TANK”. Fuel tank cap Remove the fuel tank shield and install fuel tank cap.

  • Page 67: Engine

    ADJUSTING THE VALVE CLEARANCE ENGINE ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. • Valve clearance adjustment should be made on a cold engine, at room temperature. • When the valve clearance is to be measured or adjusted, the piston must be at the Top Dead Center (TDC) on the compression stroke.
  • Page 68 ADJUSTING THE VALVE CLEARANCE a. Turn camshaft bolt in clockwise direction. • Do not turn the bolt in Counterclockwise direction to prevent from camshaft bolt looseness. b. Align the “ I ” mark on the camshaft sprocket with the stationary pointer on the cylinder head.

  • Page 69: Adjusting The Engine Idling Speed

    ADJUSTING THE VALVE CLEARANCE/ ADJUSTING THE ENGINE IDLING SPEED d. Hold the adjusting screw to prevent it from moving and tighten the locknut to specifica- tion. Locknut: 9 Nm (0.9 m • kg, 6.5 ft • lb) e. Measure the valve clearance again. f.

  • Page 70: Adjusting The Throttle Lever Free Play

    ADJUSTING THE ENGINE IDLING SPEED/ ADJUSTING THE THROTTLE LEVER FREE PLAY 4. Measure: • engine idling speed Out of specification Adjust. → Engine idling speed 1,600 ~ 1,800 r/min 5. Adjust: • engine idling speed a. Turn the throttle stop screw in direction until the specified idling speed is obtained.
  • Page 71 ADJUSTING THE THROTTLE LEVER FREE PLAY 2. Remove: • seat • right side cover Refer to “SEAT AND FENDERS”. 3. Adjust: • throttle lever free play First step: a. Remove the throttle cover b. Loosen the locknut on the carburetor side.

  • Page 72: Adjusting The Speed Limiter

    ADJUSTING THE SPEED LIMITER ADJUSTING THE SPEED LIMITER The speed limiter keeps the carburetor throttle from becoming fully-opened even when the throttle lever is applied to the maximum posi- tion. Screwing in the adjusting screw stops the engine speed from increasing. 1.

  • Page 73: Checking The Spark Plug

    CHECKING THE SPARK PLUG CHECKING THE SPARK PLUG 1. Remove: • seat • left side cover Refer to “SEAT AND FENDERS”. 2. Disconnect: • spark plug cap 3. Remove: • spark plug 4. Check: • spark plug type Incorrect → Change. Standard spark plug NGK/CR8E 5.

  • Page 74: Checking The Ignition Timing

    CHECKING THE IGNITION TIMING CHECKING THE IGNITION TIMING Engine idling speed and throttle cable free play should be adjusted properly before checking the ignition timing. 1. Attach: • digital tachometer Digital tachometer 90890-06760, YU-39951-B • timing light (to spark plug lead) Timing light 90890-03141 Inductive clamp timing light...

  • Page 75: Measuring The Compression Pressure

    MEASURING THE COMPRESSION PRESSURE MEASURING THE COMPRESSION PRESSURE The following procedure applies to the cylinder. Insufficient compression pressure will result in a loss of performance. 1. Remove: • seat • left side cover and right side cover Refer to “SEAT AND FENDERS”. 2.
  • Page 76 MEASURING THE COMPRESSION PRESSURE 7. Measure: • Compression pressure Out of specification → Refer to steps (c) and (d). Compression pressure (standard) 1,200 kPa/720 r/min (12.2 kgf/cm , 174 psi/720 r/min) Compression pressure (maximum) 1,400 kPa/720 r/min (14.3 kgf/cm , 203 psi /720 r/min) Compression pressure (minimum) 1000 kPa/720 r/min (10.2 kgf/cm...

  • Page 77: Checking The Engine Oil Level

    MEASURING THE COMPRESSION PRESSURE/ CHECKING THE ENGINE OIL LEVEL 8. Install: • Spark plug Spark plug 12.0 Nm (1.20 m·kgf, 8.9 ft · lbf) 9. Connect: • Spark plug cap 10. Install: • left side cover and right side cover •...

  • Page 78: Changing The Engine Oil

    CHECKING THE ENGINE OIL LEVEL/ CHANGING THE ENGINE OIL NOTICE • Do not add any chemical additives. Engine oil also lubricates the clutch and additives could cause clutch slippage. • Do not allow foreign material to enter the crankcase. 5. Start the engine, warm it up for several min- utes, and then turn it off.
  • Page 79 CHANGING THE ENGINE OIL 9. Fill: • crankcase (with the specified amount of the recom- mended engine oil) Quantity Periodic oil change 1.20 L (1.27 US qt, 1.06 Imp.qt) 10.Install: • dipstick 11.Start the engine, warm it up for several min- utes, and then turn it off.

  • Page 80: Cleaning The Air Filter Element

    CLEANING THE AIR FILTER ELEMENT CLEANING THE AIR FILTER ELEMENT There is a check hose at the bottom of the air filter case. If dust and/or water collects in this hose, clean the air filter element and air fil- ter case. 1.
  • Page 81 NOTICE Do not twist or wring out the element. This could damage the foam material. c. Apply Yamaha foam air filter oil or other quality foam air filter oil. d. Squeeze out the excess oil. The element should be wet but not dripping.

  • Page 82: Cleaning The Spark Arrester

    CLEANING THE SPARK ARRESTER 9. Install: • air filter case cover 10. Install: • seat Refer to “SEAT, FENDERS AND FUEL TANK”. CLEANING THE SPARK ARRESTER 1. Clean: • Spark arrester WARNING • Select a well-ventilated area free of com- bustible materials.

  • Page 83: Checking The Coolant Level

    CHECKING THE COOLANT LEVEL/ CHANGING THE COOLANT CHECKING THE COOLANT LEVEL Place the machine on a level surface. Check: • Coolant level The coolant level should be between the minimum level mark and maximum level mark Below the minimum level mark → Add the recommended coolant to the proper level.
  • Page 84 CHANGING THE COOLANT Remove: • radiator cap WARNING A hot radiator is under pressure. Therefore, do not remove the radiator cap when the engine is hot. Scalding hot fluid and steam may be blown out, which could cause seri- ous injury. When the engine has cooled, open the radiator cap as follows: Place a thick rag or a towel over the radia- tor cap and slowly turn the radiator cap...
  • Page 85 CHANGING THE COOLANT 10.Fill: • cooling system (with the specified amount of the recom- mended coolant) Recommended antifreeze High-quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines Mixing ratio 1:1 (antifreeze:water) Quantity Total amount 0.94L (0.83 lmp qt, 0.99 US qt) Coolant reservoir capacity 0.25 L (0.22 lmp qt, 0.26 US qt)

  • Page 86: Check The Coolant Temperature Indicator Light

    CHANGING THE COOLANT/ CHECK THE COOLANT TEMPERATURE INDICATOR LIGHT 12.Fill: • coolant reservoir (with the recommended coolant to the maximum level mark 13.Install: • coolant reservoir cap 14.Start the engine, warm it up for ten minutes, and then rev the engine five times. 15.Pour the recommended coolant into the radi- ator until it is full.
  • Page 87 Push start switch with transmission in “neutral”. Coolant temperature Coolant temperature indicator indicator light comes light does not come on. on momentarily. Ask a Yamaha dealer to Coolant temperature inspect the electrical circuit. and electrical circuit are OK. Go ahead with riding. 3-29...

  • Page 88: Chassis

    CHECKING THE FRONT BRAKE/ ADJUSTING THE REAR BRAKE LEVER CHASSIS CHECKING THE FRONT BRAKE 1. Measure: • brake lever free play Out of specification → Bleed the front brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM”. Brake lever free play (at the end of the brake lever) 0 mm (0 in) ADJUSTING THE...
  • Page 89 ADJUSTING THE REAR BRAKE LEVER 3. Adjust: • rear brake lever free play First step: a. Loosen the locknut b. Turn the adjuster in or out until the specified rear brake lever free play is obtained. Direction Free play is increased. Direction Free play is decreased.

  • Page 90: Adjusting The Rear Pedal Position

    ADJUSTING THE REAR PEDAL POSITION ADJUSTING THE REAR PEDAL POSITION 1. Measure: • rear brake pedal height Out of specification → Adjust. Rear brake pedal height 47.0–57.0 mm (1.85–2.24 in) 2. Remove: • seat • right side cover • right footboard Refer to “SEAT, SIDE COVERS AND FOOTREST BOARDS”.

  • Page 91: Adjusting The Parking Brake

    ADJUSTING THE PARKING BRAKE ADJUSTING THE PARKING BRAKE 1. Check: • parking brake cable end length Out of specification → Adjust. Parking brake cable end length 52–56 mm (2.05–2.20 in) 2. Adjust: • parking brake cable end length a. Loosen the locknut and adjusting bolt b.

  • Page 92: Checking The Brake Fluid Level

    CHECKING THE BRAKE FLUID LEVE CHECKING THE BRAKE FLUID LEVEL 1. Place the machine on a level surface. When checking the brake fluid level, make sure that the top of the brake master cylinder reser- voir or brake fluid reservoir is horizontal. 2.

  • Page 93: Checking The Front Brake Pads

    CHECKING THE FRONT BRAKE PADS/ CHECKING THE REAR BRAKE PADS CHECKING THE FRONT BRAKE PADS 1. Remove: • front wheels Refer to “FRONT AND REAR WHEELS” in chapter 6. 2. Check: • brake pads Wear indicators almost touch the brake disc →...

  • Page 94: Adjusting The Rear Brake Light Switch

    ADJUSTING THE REAR BRAKE LIGHT SWITCH ADJUSTING THE REAR BRAKE LIGHT SWITCH • The rear brake light switch is operated by movement of the brake pedal. • The rear brake light switch is properly adjusted when the brake light comes on just before the braking effect starts.

  • Page 95: Checking The Brake Hoses

    CHECKING THE BRAKE HOSES CHECKING THE BRAKE HOSES 1. Remove: • seat • front fender Refer to “SEAT, FENDERS AND FUEL TANK”. 2. Check: • front brake hoses • rear brake hose Cracks/wear/damage → Replace. 3. Check: • brake hose clamps Loosen →...

  • Page 96: Bleeding The Hydraulic Brake System

    BLEEDING THE HYDRAULIC BRAKE SYSTEM BLEEDING THE HYDRAULIC BRAKE SYSTEM WARNING Bleed the hydraulic brake system when- ever: • the system is disassembled. • a brake hose is loosened, disconnected or replaced. • the brake fluid level is very low. •...

  • Page 97: Adjustment The Select Lever Control Cable And Shift Rod

    BLEEDING THE HYDRAULIC BRAKE SYSTEM/ADJUSTMENT THE SELECT LEVER CONTROL CABLE AND SHIFT ROD h. Tighten the bleed screw and then release the brake lever or brake pedal. i. Repeat steps (e) to (h) until all of the air bubbles have disappeared from the brake fluid in the plastic hose.
  • Page 98 ADJUSTMENT THESELECT LEVER CONTROL CABLE AND SHIFT ROD 3. Adjust: • select lever control cable • select lever shift rod Select lever control cable and select lever shift rod adjustment steps: Control cable: a. Make sure the select lever is in NEUTRAL. b.
  • Page 99 ADJUSTMENT THESELECT LEVER CONTROL CABLE AND SHIFT ROD Select lever shift rod: g. Make sure the select lever is in NEUTRAL. h. Loosen both locknuts i. Adjust the shift rod length for smooth and correct shifting. j. Tighten the locknuts 3-41...

  • Page 100: Changing The Transfer Gear Oil

    CHANGING THE TRANSFER GEAR OIL CHANGING THE TRANSFER GEAR OIL 1. Place the machine on a level surface. 2. Place a receptacle under the transfer gear case. 3. Remove: • right footboard • right side cover • seat 4. Remove: •...

  • Page 101: Changing The Final Drive Gear Oil

    CHANGING THE FINAL DRIVE GEAR OIL CHANGING THE FINAL DRIVE GEAR OIL 1. Place the machine on a level surface. 2. Place a receptacle under the final gear case. 3. Remove: • final drive gear filling bolt • final drive gear oil drain bolt 4.

  • Page 102: Checking The Rear Axle Boot

    CHECKING THE REAR AXLE BOOT / CHECKING THE STEERING SYSTEM CHECKING THE REAR AXLE BOOT Check • dust boots Damage → Replace. Refer to “DIFFERENTIAL GEAR AND CON- STANT VELOCITY JOINT” in CHAPTER 6. CHECKING THE STEERING SYSTEM 1. Place the machine on a level surface. 2.

  • Page 103: Adjusting The Toe-In

    ADJUSTING THE TOE-IN ADJUSTING THE TOE-IN 1. Place the machine on a level surface. 2. Measure: • toe-in Out of specification → Adjust. Toe-in 15 mm (0.59 in) Before measuring the toe-in, make sure that the tire pressure is correct. a.

  • Page 104: Checking The Front And Rear Shock Absorbers

    ADJUSTING THE TOE-IN/CHECKING THE FRONT AND REAR SHOCK ABSORBERS a. Mark both tie-rods ends. This reference point will be needed during adjustment. b. Loosen the locknuts (tie-rod end) of both tie-rods. c. The same number of turns should be given to both the right and left tie-rods until the specified toe-in is obtained.

  • Page 105: Adjusting The Rear Shock Absorber

    ADJUSTING THE REAR SHOCK ABSORBER ADJUSTMENT THE REAR SHOCK ABSORBER Adjust: • Spring preload Turn the adjuster to increase or decrease the spring preload. The spring preload of the rear shock absorber can be adjusted to suit the rider’s preference, weight, and the riding conditions.

  • Page 106: Checking The Tires

    • TIRE CHARACTERISTICS 1) Tire characteristics influence the han- dling of ATVs. The tires listed below have been approved by Yamaha Motor Co., Ltd. for this model. If other tire com- binations are used, they can adversely affect your machine’s handling charac- teristics and are therefore not recom- mended.
  • Page 107 CHECKING THE TIRES 1. Measure: • tire pressure Out of specification → Adjust. • The low-pressure tire gauge is included as standard equipment. • If dust or the like is stuck to this gauge, it will not provide the correct readings. Therefore, take two measurements of the tire’s pressure and use the second reading.

  • Page 108: Checking The Wheels

    Damage → Replace. 2. Check: • cable operation Unsmooth operation → Lubricate or replace. Recommended lubricant Yamaha chain and cable lube or engine oil Hold the cable end up and apply several drops of lubricant to the cable. 3. Apply: •...

  • Page 109: Lubricating The Levers And Pedals

    LUBRICATING THE LEVERS AND PEDALS LUBRICATING THE LEVERS AND PEDALS Lubricate the pivoting point and metal-to-metal moving parts of the levers and pedal. Recommended lubricants Brake lever Silicone grease Clutch lever and brake pedal Lithium-soap-based grease 3-51...

  • Page 110: Electrical System

    CHECKING AND CHARGING THE BATTERY ELECTRICAL SYSTEM CHECKING AND CHARGING THE BATTERY WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: • Wear protective eye gear when handling or working near batteries.
  • Page 111 CHECKING AND CHARGING THE BATTERY Since VRLA (Valve Regulated Lead Acid) batteries are sealed, it is not possible to check the charge state of the battery by measuring the specific gravity of the electrolyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals.
  • Page 112 CHECKING AND CHARGING THE BATTERY Example c. Open-circuit voltage = 12.0 V d. Charging time = 6.5 hours e. Charge of the battery = 20 ~ 30% 5. Charge: Charging Ambient temperature 20°C (68°F) • battery (refer to the appropriate charging method illustration) WARNING Do not quick charge a battery.
  • Page 113 CHECKING AND CHARGING THE BATTERY • As shown in the following illustration, the open-circuit voltage of an VRLA (Valve Regulated Lead Acid) battery stabilizes about 30 minutes after charging has been completed. Therefore, wait 30 minutes after charging is completed before measuring the open-circuit voltage.
  • Page 114 CHECKING AND CHARGING THE BATTERY Charging method using a variable-current (voltage) charger Charger Ammeter Measure the open-circuit Leave the battery unused for voltage prior to charging. more than 30 minutes before measuring its open-circuit voltage. Connect a charger and ammeter to the battery Set the charging voltage to 16 ~ 17 V.
  • Page 115 CHECKING AND CHARGING THE BATTERY Charging method using a constant voltage charger Measure the open-circuit Leave the battery unused for more voltage prior to charging. than 30 minutes before measuring its open-circuit voltage. Connect a charger and ammeter to the battery and start charging.
  • Page 116 CHECKING AND CHARGING THE BATTERY 6. Install: • battery 7. Connect: • battery leads (to the battery terminals) NOTICE First, connect the positive battery lead and then the negative battery lead 8. Check: • battery terminals Dirt → Clean with a wire brush. Loose connection →...

  • Page 117: Checking The Fuses

    CHECKING THE FUSES CHECKING THE FUSES The following procedure applies to all of the fuses. NOTICE To avoid a short circuit, always set the main switch to “OFF” when checking or replac- ing a fuse. 1. Remove: • seat Refer to “SEAT, FENDERS AND FUEL TANK”.

  • Page 118: Adjusting The Headlight Beam

    CHECKING THE FUSES/ ADJUSTING THE HEADLIGHT BEAM Amperage Items Q’ty rating Main fuse 30.0 A Fan fuse 10.0 A Ignition fuse 10.0 A Headlight fuse 10.0 A Signaling system 10.0 A fuse WARNING Never use a fuse with an amperage rating other than that specified.

  • Page 119: Replacing A Headlight Bulb

    REPLACING A HEADLIGHT BULB REPLACING A HEADLIGHT BULB 1. Remove: • Front carrier • Front fender panel Refer to “FRONT CARRIER, FRONT BUMPER AND FRONT FENDER”. 2. Disconnect: • headlight lead coupler 3. Remove: • cover 4. Remove: • headlight bulb holder cover 5.
  • Page 120 REPLACING A HEADLIGHT BULB 6. Remove: • Headlight bulb holder • bulb Push the headlight bulb holder inward, pull it out- ward and remove the defective bulb. WARNING Keep flammable products and your hands away from the bulb while it is on. since it will be hot.
  • Page 121 ENGINE REMOVAL ENGINE ENGINE REMOVAL AIR DUCTS, A.I.C.V., MUFFLER AND EXHAUST PIPE 25 Nm (2.5 m•kg, 18.1 ft•Ib) 6 Nm (0.6 m•kg, 4.3 ft•Ib) 8 Nm (0.8 m•kg, 5.8 ft•Ib) 6 Nm (0.6 m•kg, 4.3 ft•Ib) 25 Nm (2.5 m•kg, 18.1 ft•Ib) 25 Nm (2.5 m•kg, 18.1 ft•Ib) Order Job/Parts to remove...
  • Page 122 ENGINE REMOVAL ENGINE ENGINE REMOVAL SELECT LEVER SHIFT ROD, CABLES, LEAD AND HOSES 6 Nm (0.6 m•kg, 4.3 ft•Ib) 25 Nm (2.5 m•kg, 18.1 ft•Ib) Order Job/Parts to remove Q’ty Remarks Removing the elect lever shift rod, Remove the parts in the order listed. cables, lead and hoses.
  • Page 123 ENGINE REMOVAL ENGINE ENGINE MOUNTING BOLTS 60 Nm (6 m•kg, 43.4 ft•Ib) 60 Nm (6 m•kg, 43.4 ft•Ib) 60 Nm (6 m•kg, 43.4 ft•Ib) Order Job/Parts to remove Q’ty Remarks Removing the engine mounting Remove the parts in the order listed. bolts Engine mounting bolt (front) Engine bracket (L/R)
  • Page 124 ENGINE REMOVAL INSTALLING THE ENGINE 1. Install: • Engine mounting bolt (rear lower side) • Engine mounting bolt (rear upper side) • Engine brackets (front side) • Engine mounting bolt (front side) • The direction of the bolt insertion is made from the right side of the body.

  • Page 125: Cylinder Head

    CYLINDER HEAD EBS00218 CYLINDER HEAD 12 Nm (1.2 m kg, 8.7 ft • • 38 Nm (3.8 m kg, 27.4 ft • • 12 Nm (1.2 m kg, 8.7 ft • • 11 Nm (1.1 m kg, 8.0 ft • •...
  • Page 126 CYLINDER HEAD REMOVING THE CYLINDER HEAD 1.Remove: pipe • (x4) reed pipe assy. • • cylinder head cover • head cover gasket • spark plug • therm unit (x4) • breather assy. bolt stopper plate • Working in a crisscross pattern, loosen e- ach nut 1/4 of a turn.
  • Page 127 CYLINDER HEAD CKING THE CYLINDER HEAD COVER ASSY. 1. Check: • cylinder head cover assy. • o-rings → Cracks/damage Replace. EBS00230 CHECKING THE CYLINDER HEAD 1. Eliminate: • combustion chamber carbon deposits (with a rounded scraper) Do not use a sharp instrument to avoid damag- ing or scratching: •...

  • Page 128: Pipe

    CYLINDER HEAD INSTALLING THE CYLINDER HEAD 1.Install: • timing chain tensioner (x4) cylinder head gasket • holding nut/ sealing washer • sprocket • breather plate • • bolt stopper plate (x4) breather assy. • therm unit • spark plug • head cover gasket •...
  • Page 129 CYLINDER HEAD c. Measure the valve clearance with a thick- ness gauge Out of specification → Adjust. Thickness gauge 90890-03079 Narrow gauge set YM-34483 3. Adjust: • valve clearance a. Loosen the locknut b. Insert a thickness gauge between the adjuster end and the valve end.

  • Page 130: Eng

    ROCKER ARMS AND CAMSHAFT ROCKER ARMS AND CAMSHAFT 9 Nm (0.9 m kg, 6.5 ft • • 12 Nm (1.2 m kg, 8.7 ft • • Order Job/Part Q’ty Remarks Removing the camshaft and rocker Remove the parts in the order listed. arms Cylinder head Refer to “CYLINDER HEAD”.
  • Page 131 ROCKER ARMS AND CAMSHAFT REMOVING THE ROCKER ARMS AND CAMSHAFT 1. Loosen: • bolt 2. Remove: • plate • intake rocker arm shaft • exhaust rocker arm shaft • intake rocker arm • exhaust rocker arm Remove the rocker are shafts with a hammer bolt and weight.
  • Page 132 ROCKER ARMS AND CAMSHAFT EAS00206 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS The following procedure applies to all of the rocker arms and rocker arm shafts. 1. Check: rocker arm • • Valve clearance adjusting screws Damage/wear Replace. 2. Check: rocker arm shaft •...
  • Page 133 ROCKER ARMS AND CAMSHAFT EAS00205 CHECKING THE CAMSHAFT 1. Check: camshaft bushings • Damage/wear Replace. 2. Check: camshaft lobes • Blue discoloration/pitting/scratches Replace the camshaft. 3. Measure: camshaft lobe dimensions a and • Out of specification Replace the cam- shaft. Camshaft lobe dimension limit Intake a a a a a 34.880 mm (1.3732 in)
  • Page 134 ROCKER ARMS AND CAMSHAFT INSTALLING THE CAMSHAFT AND ROCKER ARMS 1. Lubricate: camshaft • Recommended lubricant Camshaft Molybdenum disulfide oil Camshaft bearing Engine oil 2. Lubricate: rocker arm shafts • Recommended lubricant Molybdenum disulfide oil Install: • camshaft comp. • a.
  • Page 135 VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS Order Job/Part Q’ty Remarks Removing the valves and valve Remove the parts in the order listed. springs Cylinder head Refer to “CYLINDER HEAD”. Refer to “REMOVING THE ROCKER Rocker arm and rocker arm shaft ARMS AND CAMSHAFT”...
  • Page 136 VALVES AND VALVE SPRINGS EBS00238 REMOVING THE VALVES AND VALVE SPRINGS 1. Check: • valve sealing Leakage at the valve seat → Check the valve face, valve seat and valve seat width. Refer to “CHECKING THE VALVES AND VALVE SPRINGS”. a.
  • Page 137 VALVES AND VALVE SPRINGS EBS00240 CHECKING THE VALVES AND VALVE SPRINGS 1. Measure: • stem-to-guide clearance Stem-to-guide clearance = valve guide inside diameter – valve stem diameter → Out of specification Replace the cylinder head ass'y. Stem-to-guide clearance Intake 0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in) <Limit>: 0.08 mm (0.0031 in) Exhaust...
  • Page 138 VALVES AND VALVE SPRINGS 4. Measure: • runout (valve stem) → Out of specification Replace. Runout limit 0.01 mm (0.0004 in) • When installing a new valve always replace the guide. • If the valve is removed or replaced always replace the oil seal.
  • Page 139 VALVES AND VALVE SPRINGS 8. Lap: • valve face • valve seat After refacing the valve seat or replacing the valve and valve guide, the valve seat and valve face should be lapped. a. Apply a coarse lapping compound to the valve face.
  • Page 140 VALVES AND VALVE SPRINGS 9.Measure: • valve spring free length → Out of specification Replace. Valve spring free length Inner spring 38.700 mm (1.5236 in) <limit>: 35.200 mm (1.3858 in) Outer spring 40.400 mm (1.5906 in) <limit>: 36.900 mm (1.4528 in) 10.Measure: •...
  • Page 141 VALVES AND VALVE SPRINGS 3. Install: • valve cotters Install the valve cotters while compressing the valve spring with the valve spring compressor and attachment Valve spring compressor P/N. YM-04019, 90890-04019 Valve spring compressor attach- ment P/N. YM-01253-1, 90890-01243 4. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a piece of wood.
  • Page 142 CYLINDER AND PISTON CYLINDER AND PISTON EBS00245 CYLINDER AND PISTON Order Job/Part Q’ty Remarks Removing the cylinder and piston Remove the parts in the order listed. Cylinder head Refer to “CYLINDER HEAD”. Cylinder Refer to “INSTALLING THE CYLINDER”. Cylinder gasket Dowel pin Piston pin clip Piston pin...
  • Page 143 CYLINDER AND PISTON EBS00247 REMOVING THE PISTON 1. Remove: • piston pin clips • piston pin • piston • Before removing the piston pin clip, cover the crankcase opening with a clean rag to prevent the piston pin clip from falling into the crankcase. •...
  • Page 144 CYLINDER AND PISTON 74.995~75.015 mm Cylinder bore “C” (2.9526~2.9533 in) Taper limit “T” 0.05 mm (0.002 in) Out-of-round “R” 0.01 mm (0.0004 in) “C” = maximum of D “T” = maximum of D or D – maximum of D or D “R”...
  • Page 145 CYLINDER AND PISTON EBS00250 CHECKING THE PISTON RINGS 1. Measure: • piston ring side clearance → Out of specification Replace the piston and piston rings as a set. Before measuring the piston ring side clear- ance, eliminate any carbon deposits from the piston ring grooves and piston rings.
  • Page 146 CYLINDER AND PISTON EBS00251 CHECKING THE PISTON PIN 1. Check: • piston pin → Blue discoloration/grooves Replace the piston pin and then check the lubrication system. 2. Measure: • piston pin outside diameter → Out of specification Replace the piston pin.
  • Page 147 CYLINDER AND PISTON EBS00252 INSTALLING THE PISTON 1. Install: • piston rings (onto the piston) • Be sure to install the piston rings so that the manufacturer’s marks numbers located on the upper side of the rings. • Lubricate the piston and piston rings liberally with engine oil.
  • Page 148 CYLINDER AND PISTON EBS00253 INSTALLING THE CYLINDER 1. Install: • cylinder Install the cylinder with one hand while com- pressing the piston rings with the other hand. N O T I C E • Be careful not to damage the timing chain damper during installation.
  • Page 149 C.D.I. MAGNETO C.D.I. MAGNETO 12 Nm (1.2 m kg, 8.7 ft • • 55 Nm (5.5 m kg, 40 ft • • Order Job/Part Q’ty Remarks Removing the C.D.I. magneto Disassemble the parts in the order listed. Stator coil assembly Refer to “INSTALLING STATOR COIL ASSEMBLY “.
  • Page 150 C.D.I. MAGNETO EBS00259 REMOVING THE C.D.I. MAGNETO ROTOR 1. Remove: plate washer bolt 2. Remove: C.D.I. magneto rotor (with flywheel puller Flywheel puller 90890-01404 (YM-01404) EBS00262 CHECKING THE PICKUP COIL/STATOR ASSEMBLY 1. Check: • pickup coil/stator assembly → Damage Replace. 4-30...
  • Page 151 C.D.I. MAGNETO INSTALLING THE PICKUP COIL AND STATOR ASSEMBLY Install tator assembly Install ickup coil Tighten the bolts to secure the stator assembly cable EBS00268 INSTALLING THE C.D.I. MAGNETO ROTOR 1. Install: C.D.I. magneto rotor Clean the tapered portion of the crankshaft and the magneto rotor hub.

  • Page 152: Belt Drive

    BELT DRIVE EAS00316 BELT DRIVE CRANKCASE COVER 12 Nm (1.2 m kg, 8.7 ft • • (x4) 12 Nm (1.2 m kg, 8.7 ft • • (x9) 12 Nm (1.2 m kg, 8.7 ft • • Order Job/Part Q’ty Remarks Removing the belt drive Remove the parts in the order listed.

  • Page 153: V-Belt, Clutch, Primary And Secondary Sheave

    BELT DRIVE V-BELT, CLUTCH, PRIMARY AND SECONDARY SHEAVE 55Nm (5.5m．kg, 39.8ft．lb) • • Order Job/Part Q’ty Remarks Removing the V-belt, clutch, primary Remove the parts in the order listed. and secondary sheave Primary sheave nut / Plate washer Primary fixed sheave Refer to “...

  • Page 154: Disassembling The Secondary Sheave

    BELT DRIVE DISASSEMBLING THE SECONDARY SHEAVE 95Nm (9.5m．kg, 68.7ft．lb) • • Order Job/Part Q’ty Remarks Disassembling the secondary Disassemble the parts in the order listed. sheave Clutch carrier assembly Spring seat -1 Refer to “ REMOVING THE SECONDARY SHEAVE AND V-BELT “. Compression spring Spring seat - 2 Guide pin...
  • Page 155 BELT DRIVE DISASSEMBLING THE SECONDARY SHEAVE 95Nm (9.5m．kg, 68.7ft．lb) • • Order Job/Part Q’ty Remarks Guide roller Secondary sliding sheave O-ring Oil seal Secondary fixed sheave For assembly, reverse the disassembly procedure. 4-35...

  • Page 156: Removing The Primary Sheave

    BELT DRIVE EAS00317 REMOVING THE PRIMARY SHEAVE 1. Remove: primary sheave nut • plate washer • primary fixed sheave • collar • primary sliding sheave • While holding the clutch housing with the rotor holding tool , loosen the secondary sheave nut.

  • Page 157: Disassembling The Secondary Sheave

    BELT DRIVE 3. Remove: secondary sheave assembly • • V-belt Remove the V-belt and clutch assembly from the primary sheave side. EAS00319 DISASSEMBLINGTHE SECONDARY SHEAVE 1. Remove: clutch carrier nut • Install the clutch spring holder and clutch spring holder arm onto the secondary sheave as shown.

  • Page 158: Checking The V-Belt

    BELT DRIVE EAS00320 CHECKING THE V-BELT 1. Check: V-belt • Cracks/damage/wear Replace. Grease/oil Clean the primary and sec- ondary sheave. 2. Measure: V-belt width • Out of specification Replace. V-belt width <Limit>: 22.500 mm (0.8858 in) CHECKING THE PRIMARY SHEAVE 1.

  • Page 159: Checking The Slider

    BELT DRIVE CHECKING THE SLIDER Check: slider Damage/wear Replace EAS00322 CHECKING THE SECONDARY SHEAVE 1. Check: secondary fixed sheave • secondary sliding sheave • Cracks/damage/wear Replace the sec- ondary fixed and sliding sheaves as a set. 2. Check: torque cam groove •...

  • Page 160: Assembling The Primary Sheave

    BELT DRIVE 5. Measure: Clutch housing internal diameter • Out of specification Replace. Clutch housing internal diameter 144.850~145.150 mm (5.7028~ 5.7146 in) <Limit>: 145.450 mm (5.7264 in) EAS00323 ASSEMBLING THE PRIMARY SHEAVE 1. Clean: primary sliding sheave • primary fixed sheave •...

  • Page 161: Assembling The Secondary Sheave

    BELT DRIVE EAS00324 ASSEMBLING THE SECONDARY SHEAVE 1. Lubricate: secondary fixed sheave’s inner surface • secondary sliding sheave’s inner surface • torque cam groove • oil seals • bearings • (with the recommended lubricant) Recommended lubricant BEL-RAY assembly lube 2. Install: secondary sliding sheave •...

  • Page 162: Installing The Belt Drive

    BELT DRIVE 5. Install: secondary sheave • spring • clutch carrier • Attach the clutch spring holder and clutch spring holder arm onto the secondary sheave as shown. Then, compress the spring, and tighten the clutch carrier nut Clutch spring holder 90890-01337(YM-33285) Clutch spring holder arm 90890-01464(YM-33285-6)
  • Page 163 BELT DRIVE 2. Install: clutch carrier nut • 90 Nm (9.0 m • kg, 65.1 ft • lb) While holding the clutch carrier with the rotor holding tool , tighten the clutch carrier nut with the locknut wrench Rotor holding tool 90890-01235 Locknut wrench 90890-01348 (YM-01348)

  • Page 164: Starter Clutch

    STARTER CLUTCH STARTER CLUTCH 12 Nm (1.2 m kg, 8.7 ft • • 55 Nm (5.5 m kg, 39.8 ft • • Order Job/Part Q’ty Remarks Removing the starter clutch Disassemble the parts in the order listed. Shaft Idle gear Washer Bolt Rotor assembly...

  • Page 165: Removing The Starter Clutch

    STARTER CLUTCH REMOVING THE STARTER CLUTCH 1. Remove: starter clutch bolts • Hold the AC magneto rotor with the sheave • holder while removing the starter clutch bolts. Do not allow the shave holder to touch the pro- • jection on the AC magneto rotor. Sheave holder 90890-01701 Primary clutch holder...

  • Page 166: Installing The Starter Clutch

    STARTER CLUTCH INSTALLING THE STARTER CLUTCH 1. Install: starter clutch bolts • Starter clutch bolt 30 Nm (3.0 m kg, 22 ft lb) • • LOCTITE While holding the AC magneto rotor with the • sheave holder , tighten the starter clutch bolts.

  • Page 167: Oil Pump

    OIL PUMP EBS00315 OIL PUMP 1.5 Nm (0.15 m kg, 1.1 ft • • Order Job/Part Q’ty Remarks Disassembling the oil pump Remove the parts in the order listed. C.D.I. magneto Refer to “ C.D.I. MAGNETO “ Circlip Oil pump driven sprocket Screw Oil pump housing Dowel pin...

  • Page 168: Checking The Oil Pump

    OIL PUMP EAS00364 CHECKING THE OIL PUMP 1. Check: oil pump driven gear • Cracks/damage/wear Replace the de- fective part(s). 2. Measure: inner-rotor-to-outer-rotor-tip clearance • outer-rotor-to-oil-pump-housing clear- ance oil-pump-housing-to-inner-rotor-and- • outer-rotor clearance • Out of specification Replace the oil pump. Inner rotor Outer rotor Oil pump housing...

  • Page 169: Installing The Oil Pump

    OIL PUMP 3. Check: oil pump operation • Rough movement Repeat steps (1) and (2) or replace the defective part(s). EAS00376 INSTALLING THE OIL PUMP 1. Install: oil pump assembly • oil pump screws • 1.5 Nm (0.15 m • kg, 1.1 ft • lb) N O T I C E After tightening the bolts, make sure the oil pump turns smoothly.

  • Page 170: Crankcase And Crankshaft

    CRANKCASE AND CRANKSHAFT EBS00319 CRANKCASE AND CRANKSHAFT 10Nm (1.0m．kg, 7.2ft．lb) • • 10Nm (1.0m．kg, 7.2ft．lb) • • 12Nm (1.2m．kg, 8.7ft．lb) • • 12Nm (1.2m．kg, 8.7ft．lb) • • (x9) 10Nm (1.0m．kg, 7.2ft．lb) • • Order Job/Part Q’ty Remarks Removing the crankshaft assembly Remove the parts in the order listed.

  • Page 171: Removing The Crankshaft Assembly

    CRANKCASE AND CRANKSHAFT EAS00389 REMOVING THE CRANKSHAFT ASSEMBLY 1. Remove: timing chain • • Before removing the crankshaft assembly, remove the timing chain from the crankshaft sprocket. • The crankshaft assembly cannot be re- moved if the timing chain is attached onto the crankshaft sprocket.

  • Page 172: Checking The Timing Chain And Timing Chain Guides

    CRANKCASE AND CRANKSHAFT EAS00207 CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDES 1. Check: • timing chain Damage/stiffness Replace the timing chain. 2. Check: • timing chain guide Damage/wear Replace the timing chain guide. EAS00394 CHECKING THE CRANKSHAFT AND CON- NECTING ROD 1.
  • Page 173 CRANKCASE AND CRANKSHAFT 3. Measure: • crankshaft width Out of specification Replace the crank- shaft. Crankshaft width 56.00 ~ 56.05 mm (2.205 ~ 2.207 in) 4. Check: • crankshaft sprocket Damage/wear Replace the crankshaft. • bearing Cracks/damage/wear Replace the crankshaft. •...
  • Page 174 CRANKCASE AND CRANKSHAFT 2. Install: crankshaft • Install the crankshaft assembly with the crank- shaft installer pot , crankshaft installer bolt , adapter (M14) , spacer (crankshaft in- staller) and spacer Crankshaft installer pot 90890-01274 Installing pot YU-90058 Crankshaft installer bolt 90890-01275 Bolt YU-90060...

  • Page 175: Assembling The Crankcase

    CRANKCASE AND CRANKSHAFT EAS00418 ASSEMBLING THE CRANKCASE 1. Thoroughly clean all the gasket mating sur- faces and crankcase mating surfaces. 2. Install: • crankcase gasket (onto the crankcase mating surfaces) 3. Install: • crankshaft • timing chain 4. Tighten: • crankcase 10 Nm (1.0 m •...

  • Page 176: Transmission

    TRANSMISSION EAS00419 TRANSMISSION 12 Nm (1.2 m kg, 8.7 ft • • 28 Nm (2.8 m kg, 20.3 ft • • (x4) (x2) 40 Nm (4.0 m kg, 28.9 ft • • 28 Nm (2.8 m kg, 20.3 ft • •...
  • Page 177 TRANSMISSION EAS00419 TRANSMISSION 12 Nm (1.2 m kg, 8.7 ft • • 28 Nm (2.8 m kg, 20.3 ft • • (x4) (x2) 40 Nm (4.0 m kg, 28.9 ft • • 28 Nm (2.8 m kg, 20.3 ft • •...

  • Page 178: Removing The Transfer Case Assy

    TRANSMISSION REMOVING THE TRANSFER CASE ASSY 1. Remove: bolt-1 • bolt-2 • • transfer case-1 o-ring • (x4) (x2) 2. Remove: bolt • • transfer case-2 • gasket • cap bolt • bearing-2 • thrust shim • washer (x4) spring •...

  • Page 179: Installingthe Transfer Case Assy

    TRANSMISSION 2. Check: • driven pinion Blue discoloration/pitting/wear Replace the defective gear(s). 3. Check: • driven pinion engagement (each pinion gear to its respective wheel gear) Incorrect Reassemble the transmission axle assemblies. 4. Check: • driven pinion movement Rough movement Replace the defec- tive part(s).

  • Page 180: Adjusting The Bearing-2 Shim

    TRANSMISSION ADJUSTING THE BEARING-2 SHIM 1. Measure: • Washer-to-bore bottom clearance = bore bottom-to case back clearance b = washer-to-case back clearance 2. Calculate: • Number of shims (with the following formula) Washer-to-bore bottom clearance c 0.1(shim thickness) = number of shims required (truncated) 3.
  • Page 181 TRANSMISSION 2. Calculate: • Number of shims (with the following formula) Driven pinion-to-bearing clearance 0.1(shim thickness) = number of shims required (truncated) 3. Install: • Required quantity of shims 4-61...
  • Page 182 TRANSMISSION 28 Nm (2.8 m kg, 20.2 ft • • (x9) Order Job/Part Q’ty Remarks Removing the transmission cover Remove the parts in the order listed. Transmission oil Drain. Crankcase cover Refer to “BELT DRIVE “. Belt drive Refer to “V-BELT, CLUTCH, PRIMARY Secondary sheave AND SECONDARY SHEAVE “.
  • Page 183 TRANSMISSION Order Job/Part Q’ty Remarks Removing the shift cam and shift Remove the parts in the order listed. shaft Shift fork guide bar Spring-1 Shift fork-1 Spring-2 Shift fork-2 Shift cam assembly Shift shaft assembly For installation, reverse the removal pro- cedure.

  • Page 184: Checking The Shift Forks

    TRANSMISSION CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks. 1. Check: • Shift fork movement (along the shift fork guide bar) Rough movement → Replace the shift forks and shift fork guide bar as a set. Shift forks 1 and 2 Springs 1 and 2 Shift fork guide bar...

  • Page 185: Removing The Transmission

    TRANSMISSION 22 23 9 10 14 15 Order Job/Part Q’ty Remarks Removing the transmission Remove the parts in the order listed. Pinion shim Circlip-1 Bearing-1 Low wheel gear Middle shaft Bearing-2 Bearing-3 Gear hold washer-1 Low pinion gear Collar-1 Gear hold washer-2 Dog clutch-1 Circlip-2 Thrush washer...
  • Page 186 TRANSMISSION 22 23 9 10 14 15 Order Job/Part Q’ty Remarks Circlip-3 Drive axle Dog clutch-2 Gear hold washer-4 1st wheel gear Collar-3 Gear hold washer-5 Bearing-4 Bearing-5 Idle axle Reverse wheel gear-2 Bearing-6 Counter axle Bearing-7 Oil seal For installation, reverse the removal pro- cedure.

  • Page 187: Checking The Transmission

    TRANSMISSION EAS00425 CHECKING THE TRANSMISSION 1. Measure: • counter axle runout (with a centering device and dial gauge ) Out of specification Replace the main axle. Counter axle runout limit 0.08 mm (0.0031 in) 2. Measure: • middle shaft runout (with a centering device and dial gauge ) Out of specification Replace the drive...

  • Page 188: Check

    TRANSMISSION 5. Check: • transmission gears Blue discoloration/pitting/wear Replace the defective gear(s). 6. Check: • transmission gear engagement (each pinion gear to its respective wheel gear) Incorrect Reassemble the transmission axle assemblies. 7. Check: • transmission gear movement Rough movement Replace the defec- tive part(s).

  • Page 189: Install

    TRANSMISSION = pitch point-to-back clearance (specified as 43.4 mm or 1.709 in) = coupling surface-to-bearing clearance Calculate the coupling surface-to-bearing clearance by subtracting crown-to-bearing clearance from crown-to-coupling sur- face clearance Coupling surface-to-bearing clearance can be derived from the mission case (as illustrated). 3.
  • Page 190 TRANSMISSION Thickness gauge 90890-03079 Narrow gauge set YM-34483 3. Select: • Suitable wahser (using the following table) SPEC. COLOR GREEN 2.1 ± 0.01 1SC-E7529-00 BROWN 2.2 ± 0.01 1SC-E7529-10 YELLOW 2.3 ± 0.01 1SC-E7529-20 BLUE 2.4 ± 0.01 1SC-E7529-30 2.5 ± 0.01 1SC-E7529-40 Each size has its corresponding color.
  • Page 191 COOL RADIATOR COOLING SYSTEM RADIATOR 28 Nm (2.8 m kg, 20.3 ft • • 13 Nm (1.3 m kg, 9.4 ft • • Order Job/Part Q’ty Remarks Removing the radiator Remove the parts in the order listed. Seat/fuel tank cover/side covers Refer to “SEAT, FENDERS AND FUEL /front fender TANK”...
  • Page 192 COOL RADIATOR EBS00127 CHECKING THE RADIATOR 1. Check: • radiator fins Obstruction → Clean. Apply compressed air to the rear of the radi- ator. Damage → Repair or replace. Straighten any flattened fins with a thin, flat- head screwdriver. 2. Check: •...
  • Page 193 COOL RADIATOR EBS00128 INSTALLING THE RADIATOR 1. Fill: • cooling system (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT” in chapter 3. 2. Check: • cooling system Leaks → Repair or replace any faulty part.

  • Page 194: Nm (1.2 M Kg, 8.7 Ft Ib)

    COOL THERMOSTAT THERMOSTAT 12 Nm (1.2 m kg, 8.7 ft • • Order Job/Part Q’ty Remarks Thermostat removal Remove the parts in the order below. Coolant Drain. Refer to “CHANGING THE COOLANT” in CHAPTER 3. Radiator inlet hose Thermostat cover Thermostat For installation, reverse the removal procedure.

  • Page 195: Install

    COOL THERMOSTAT CHECKING THE THERMOSTAT 1.Check: • Thermostat Does not open at 63.5 ~ 65.5 ˚C (146.3 ~ 149.9 ˚F) → Replace. Checking steps: • Suspend the thermostat in a container filled with water. • Slowly heat the water. • Place a thermometer in the water. •...

  • Page 196: Gasket

    COOL WATER PUMP WATER PUMP (x9) 12 Nm (1.2 m kg, 8.7 ft • • Order Job/Part Q’ty Remarks Water pump removal Remove the parts in the order below. Seat, right side cover, right footboard Refer to “SEAT, SIDE COVERS AND FOOTREST BOARDS”...
  • Page 197 COOL WATER PUMP 12 Nm (1.2 m kg, 8.7 ft • • 12 Nm (1.2 m kg, 8.7 ft • • Order Job/Part Q’ty Remarks Water pump disassembly Remove the parts in the order below. Water pump housing cover Gasket Circlip Water pump impeller Washer...
  • Page 198 COOL WATER PUMP REMOVING THE WATER PUMP 1.Remove: • Water pump housing • Gasket • Water pump impeller (remove the impeller with a pump impeller.) The impeller is provided with left turn thread. • Washer • Circlip • Water pump shaft Do not scratch the impeller shaft.
  • Page 199 COOL WATER PUMP CHECKING THE WATER PUMP 1.Check: • Water pump housing cover • Water pump impeller • Water pump shaft • Water pump housing Cracks/damage/wear → Replace. 2.Check: • Water pump seal • Oil seal Cracks/damage/wear → Replace. • Bearing Rough movement →...

  • Page 200: Cool

    COOL WATER PUMP 3.Install: • Oil seal (into the water pump housing • Water pump oil seal driver • Before installing the oil seal, apply tap water or coolant onto its outer surface. 4.Install: • Water pump seal (into the water pump housing •...

  • Page 201: Carb

    CARB CARBURETOR CARBURETOR Order Job/Part Q’ty Remarks Carburetor removal Remove the parts in the order below. Seat/side covers/fuel tank cover/ Refer to “SEAT, FENDERS AND FUEL fuel tank TANK” in CHAPTER 3. Drain hose Starter cable/starter plunger Carburetor assembly Throttle valve cover Throttle cable After removing the carburetor assembly, remove the throttle cable.
  • Page 202 CARB CARBURETOR CARBURETOR Order Job/Part Q’ty Remarks Carburetor disassembly Disassemble the parts in the order below. Air vent hose Throttle stop screw Vacuum chamber cover Spring Jet needle holder Jet needle set Piston valve Coasting enricher Float chamber Drain screw Float Refer to “CARBURETOR ASSEMBLY”.
  • Page 203 CARB Order Job/Part Q’ty Remarks Pilot jet Air adjusting screw Refer to “DISASSEMBLY THE CAR- Main jet BURETOR” AND “ASSEMBLY Needle jet THE CARBURETOR”. Starter jet For assembly, reverse the disassembly procedure.
  • Page 204 CARB CARBURETOR EBS00146 DISASSEMBLING THE CARBURETOR 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. EAS00485 CHECKING THE CARBURETOR 1. Check: • carburetor body •...
  • Page 205 CARB CARBURETOR 4. Check: • piston valve Damage/scratches/wear Replace. • piston valve diaphragm Cracks/tears Replace. 5. Check: • vacuum chamber cover • piston valve spring Cracks/damage Replace. Check: • diaphragm (coasting enricher) • spring • cover • o-ring Cracks/damage/wear Replace. Check: •...
  • Page 206 CARB CARBURETOR Check: • fuel hoses Cracks/damage/wear Replace. Obstruction Clean. Blow out the hoses with compressed air. Check: • piston valve movement Insert the piston valve into the carburetor body and move it up and down. Tightness Replace the piston valve. Check: •...
  • Page 207 CARB CARBURETOR EBS00150 ASSEMBLING THE CARBURETOR Before assembling the carburetor, make sure to turn out the pilot air screw the same number of times, as noted before disassembly, from the seated position to the set position. NOTICE Before assembling the carburetor, wash •...
  • Page 208 CARB CARBURETOR INSTALLING THE CARBURETOR 1. Install: • carburetor Align the projection on the carburetor with the slot in the carburetor joint. 2. Install: • throttle cable • throttle cable cover 3. Adjust: • engine idling speed Engine idling speed 1,600 ~ 1,800r/min Refer to “ADJUSTING THE ENGINE IDLING SPEED”...
  • Page 209 CARB CARBURETOR EBS00154 MEASURING AND ADJUSTING THE FUEL LEVEL 1. Measure: • fuel level Out of specification → Adjust. Fuel level (above the float chamber mating surface) 5.0 mm (0.20 in) a. Stand the machine on a level surface. b. Install the fuel level gauge onto the fuel drain pipe Fuel level gauge...

  • Page 210: Driv

    DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT Order Job/Part Q’ty Remarks Remove the parts in the order below. Rear axle, final drive gear assembly and drive shaft removal Final gear oil Drain. Rear wheel hubs/brake disc Refer to “FRONT AND REAR WHEELS”...
  • Page 211 DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT 25 Nm (2.5 m kg, 18.1 ft 15 Nm (1.5 m kg, 10.8 ft • • • • 30 Nm (3.0 m kg, 21.7 ft • • 20 Nm (2.0 m kg, 14.5 ft •...
  • Page 212 DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT 25 Nm (2.5 m kg, 18.1 ft 15 Nm (1.5 m kg, 10.8 ft • • • • 30 Nm (3.0 m kg, 21.7 ft •...
  • Page 213 DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT REMOVING THE REAR AXLE 1.Remove: • Rear axle (with dust seal) • O-ring NOTICE • Never directly tap the axle end with a hammer, since this will result in damage to the axle thread and spline. •...
  • Page 214 DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT REMOVING THE FINAL DRIVE ROLLER BEARING 1.Remove: • Oil seal • Roller bearing (ring gear) Use a suitable press tool and an appro- priate support for the main housing. 2.Remove: • Roller bearing (final drive pinion gear) Removal steps: •...
  • Page 215 DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT INSTALLING THE REAR AXLE 1.Check: • Rear axle runout Out of specification → Replace. WARNING Do not attempt to straighten a bent axle. Rear axle runout limit: 1.5 mm (0.06 in) INSTALLING THE DRIVE SHAFT 1.Check: •...
  • Page 216 REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT 3.Check: • Bearings Damage → Replace. • Reusing roller bearings is acceptable, but Yamaha recommends installing ones. Do not reuse the oil seal. • When the final drive pinion gear and/or ring gear are replaced, be sure to adjust the shim of the final drive pinion gear and/ or ring gear.
  • Page 217 DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT INSTALLING THE FINAL DRIVE GEAR 1.Lubricate: • Drive shaft • Coupling gear • O-ring • Oil seal • Bearing Lithium-soap base grease 2.Install: • Drive shaft (to the universal joint) 3.Install: • Final drive gear •...
  • Page 218 DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT 3.Remove: Final drive gear case filling bolt • • O-ring 4.Install: • Dial indicator (on the ring gear through the filling hole) 5.Measure: • Backlash Install the dial indicator onto the tip of the ring gear .
  • Page 219 DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT Name Size Ring gear shim (L) Ring gear shim (R) Avg. 0.15~0.28 mm 1.5 mm 1.5 mm 1.55 mm 1.45 mm Avg. 0.25 mm ＞ Avg. 0.15 mm 1.45 mm 1.55 mm ＜...
  • Page 220 CHAS FRONT AND REAR WHEELS CHASSIS FRONT AND REAR WHEELS FRONT WHEELS 40 Nm (4.0 m kg, 28.9 ft • • (x4) 135 Nm (13.5 m kg, 97.6 ft • • 45 Nm (4.5 m kg, 32.5 ft • • 28 Nm (2.8 m kg, 20.3 ft •...
  • Page 221 CHAS FRONT AND REAR WHEELS 40 Nm (4.0 m kg, 28.9 ft • • (x4) 135 Nm (13.5 m kg, 97.6 ft • • 45 Nm (4.5 m kg, 32.5 ft • • 28 Nm (2.8 m kg, 20.3 ft •...
  • Page 222 CHAS FRONT AND REAR WHEELS REAR WHEELS 55 Nm (5.5 m kg, 40.0 ft • • (x4) 55 Nm (5.5 m kg, 40.0 ft • • 170 Nm (17.0 m kg, 123.0 ft • • 40 Nm (4.0 m kg, 28.9 ft •...
  • Page 223 CHAS FRONT AND REAR WHEELS REAR WHEELS 55 Nm (5.5 m kg, 40.0 ft • • (x4) 55 Nm (5.5 m kg, 40.0 ft • • 170 Nm (17.0 m kg, 123.0 ft • • 40 Nm (4.0 m kg, 28.9 ft •...
  • Page 224 CHAS FRONT AND REAR WHEELS CHECKING THE WHEELS The following procedure applies to both of the front and rear wheels. 1. Check: • wheel 2. Measure: • wheel runout → Over the specified limit Replace the wheel or check the wheel bearing play Wheel runout limit Radial : 2.0 mm (0.08 in)
  • Page 225 CHAS FRONT AND REAR WHEELS 2. Check: • wheel bearings → Wheel hub play/ wheel turns roughly Replace. a. Clean wheel hub exterior. b. Drive bearing out by pushing spacer aside and tapping around perimeter of bearing inner race. Use soft metal drift punch and hammer.
  • Page 226 CHAS FRONT AND REAR WHEELS INSTALLING THE BRAKE DISCS 1. Install: • brake discs Install the brake disc with its spot-faced side facing the bolt heads. Front Rear INSTALLING THE REAR BRAKE DISC ON THE REAR AXLE 1. Install: • rear brake disc •...
  • Page 227 CHAS FRONT AND REAR WHEELS INSTALLING THE FRONT WHEEL HUB BEARINGS 1. Install: • bearings Face the oil seal side of the bearing inward. INSTALLING THE WHEEL HUBS The following procedure applies to both of the front and rear wheel hubs. 1.
  • Page 228 CHAS FRONT AND REAR BRAKES FRONT AND REAR BRAKES FRONT BRAKE CALIPER 30 Nm (3.0 m kg, 21.7 ft 28 Nm (2.8 m kg, 20.3 ft • • • • Order Job/Part Q’ty Remarks Removing the front brake caliper Remove the parts in the order listed. Brake fluid Drain.
  • Page 229 CHAS FRONT AND REAR BRAKES Order Job/Part Q’ty Remarks Removing the front brake pads Remove the parts in the order listed. Brake pad Brake pad spring For installation, reverse the removal procedure. 8-10...
  • Page 230 CHAS FRONT AND REAR BRAKES REAR BRAKE CALIPER 30 Nm (3.0 m kg, 21.7 ft • • 28 Nm (2.8 m kg, 20.3 ft • • Order Job/Part Q’ty Remarks Removing the rear brake caliper Remove the parts in the order listed. Brake fluid Drain.
  • Page 231 CHAS FRONT AND REAR BRAKES 8 Nm (0.8 m kg, 6.5 ft • • 25 Nm (2.5 m kg, 18.1 ft • • Order Job/Part Q’ty Remarks Remove the parts in the order listed. Disassembling the rear brake cali- Adjusting bolt Brake pad Brake pad spring Caliper bracket...
  • Page 232 CHAS FRONT AND REAR BRAKES REMOVING THE PARKING BRAKE CABLE 1. Loosen: • nut • adjusting bolt 2. Disconnect: • parking brake cable (from parking brake lever) 3. Disconnect: • parking brake cable (from rear brake) CHECKING THE BRAKE CALIPER Recommended brake component replacement schedule Brake pads...
  • Page 233 CHAS FRONT AND REAR BRAKES 2. Check: • parking brake arm to parking brake bracket distance → Out of specification Adjust. Parking brake arm to parking brake bracket distance 63.0 mm (2.48 in) B Rear brake caliper INSTALLING THE BRAKE CALIPER 1.
  • Page 234 CHAS FRONT AND REAR BRAKES WARNING • Use only the designated quality brake fluid: other brake fluids may deteriorate the rubber seals, causing leakage and poor brake performance. • Refill with the same type of brake fluid: mixing brake fluids may result in a harm- ful chemical reaction and lead to poor brake performance.
  • Page 235 CHAS FRONT AND REAR BRAKES REPLACING THE FRONT BRAKE PADS It is not necessary to disassemble the brake caliper and brake hose to replace the brake pads. 1. Remove: • brake pads wear limit Brake pad wear limit 1.0 mm (0.04 in) Replace the brake pads as a set if either is found to be worn to the wear limit.
  • Page 236 CHAS FRONT AND REAR BRAKES REPLACING THE REAR BRAKE PADS It is not necessary to disassemble the brake caliper and brake hose to replace the brake pads. 1. Remove: • brake pads wear limit Brake pad wear limit 1.0 mm (0.04 in) Replace the brake pads as a set if either is found to be worn to the wear limit.
  • Page 237 CHAS FRONT AND REAR BRAKES FRONT BRAKE MASTER CYLINDER 13 Nm (1.3 m kg, 9.4 ft • • 6 Nm (0.6 m kg, 4.3 ft • • 28 Nm (2.8 m kg, 20.3 ft • • Order Job/Part Q’ty Remarks Removing the front brake master Remove the parts in the order listed.
  • Page 238 CHAS FRONT AND REAR BRAKES Order Job/Part Q’ty Remarks Disassembling the front brake Remove the parts in the order listed. master cylinder Brake master cylinder kit For assembly, reverse the disassembly procedure. 8-19...

  • Page 239: Chas

    CHAS FRONT AND REAR BRAKES REAR BRAKE MASTER CYLINDER Order Job/Part Q’ty Remarks Remove the parts in the order listed. Removing the rear brake master cylinder Rihgt foot portector Refer to “SEAT, FENDERS AND FUEL TANK” in chapter 3. Brake fluid Drain.
  • Page 240 CHAS FRONT AND REAR BRAKES Order Job/Part Q’ty Remarks Union bolt Refer to “INSTALLING Copper washer Disconnect. THE REAR BRAKE Brake hose MASTER CYLINDER”. Brake master cylinder Control cable Rear brake light switch/spring 1/1/1 Brake master cylinder arm/spring Brake pedal Master cylinder holder Axle fixed For installation, reverse the removal...
  • Page 241 CHAS FRONT AND REAR BRAKES 17 Nm (1.7 m kg, 12.3 ft • • Order Job/Part Q’ty Remarks Disassembling the rear brake Remove the parts in the order listed. master cylinder Brake master cylinder kit For assembly, reverse the disassembly procedure.
  • Page 242 CHAS FRONT AND REAR BRAKES EBS00413 CHECKING THE MASTER CYLINDERS 1. Check: • brake master cylinder Wear/scratches → Replace the brake mas- ter cylinder assembly. • brake master cylinder body Cracks/damage → Replace. • brake fluid delivery passage (brake master cylinder body) Blockage →...
  • Page 243 CHAS FRONT AND REAR BRAKES ASSEMBLING THE FRONT BRAKE MASTER CYLINDER WARNING • All internal brake components should be cleaned and lubricated with new brake fluid only before installation. Recommended brake fluid DOT 4 • Whenever a master cylinder is disassem- bled, replace the piston seals and dust seals.
  • Page 244 CHAS FRONT AND REAR BRAKES INSTALLING THE FRONT BRAKE MASTER CYLINDER 1. Install: • brake master cylinder • parking brake lever Brake master cylinder holder bolt 13 Nm (1.3 m•kg, 9.4 ft•lb) • The parking brake lever installing, please refer to “INSTALLING THE PARKING BRAKE LEVER”.
  • Page 245 CHAS FRONT AND REAR BRAKES 3. Fill: • brake fluid reservoir Recommended brake fluid DOT 4 NOTICE Brake fluid may damage painted surfaces or plastic parts. Always clean up spilled brake fluid immediately. WARNING • Use only the designated quality brake fluid: other brake fluids may deteriorate the rubber seals, causing leakage and poor brake performance.
  • Page 246 CHAS FRONT AND REAR BRAKES INSTALLING THE REAR BRAKE MASTER CYLINDER 1. Install: • copper washers • brake hose • union bolt Union bolt 28 Nm (2.8 m•kg, 20.3 ft•lb) NOTICE When installing the brake hose onto the brake master cylinder, make sure the brake pipe touches the projection shown.
  • Page 247 CHAS FRONT AND REAR BRAKES WARNING • Use only the designated quality brake fluid: other brake fluids may deteriorate the rubber seals, causing leakage and poor brake performance. • Refill with the same type of brake fluid: mixing brake fluids may result in a harm- ful chemical reaction and lead to poor brake performance.
  • Page 248 CHAS STEERING SYSTEM STEERING SYSTEM HANDLEBAR 13 Nm (1.3 m kg, 9.4 ft • • 25 Nm (2.5 m kg, 18.1 ft • • 13 Nm (1.3 m kg, 9.4 ft • • 8 Nm (0.8 m kg, 5.8 ft •...
  • Page 249 CHAS STEERING SYSTEM 13 Nm (1.3 m kg, 9.4 ft • • 25 Nm (2.5 m kg, 18.1 ft • • 13 Nm (1.3 m kg, 9.4 ft • • 8 Nm (0.8 m kg, 5.8 ft • • Order Job/Part Q’ty Remarks...
  • Page 250 CHAS STEERING SYSTEM REMOVING THE HANDLEBAR GRIPS 1. Remove: • handlebar grips Blow compressed air between the handlebar and handlebar grip, and gradually push the grip off the handlebar. REMOVING THE REAR BRAKE SWITCH 1. Remove: • rear brake switch Push the fastener when removing the rear brake switch out of the rear brake lever holder.
  • Page 251 CHAS STEERING SYSTEM INSTALLING THE HANDLEBAR 1. Install: • handlebar • upper handlebar holders 25 Nm (2.5 m · kg, 18.1 ft · lb) • Install the handlebar, please align the punch mark and the gap at handlebar holder • The upper handlebar holders should be installed with the flange forward NOTICE...
  • Page 252 CHAS STEERING SYSTEM INSTALLING THE REAR BRAKE LEVER 1. Install: • handlebar switch • rear brake lever • Installing the rear brake lever, make sure the handlebar switch , handlebar grip , and rear brake lever are in the positions shown in the illustration.
  • Page 253 CHAS STEERING SYSTEM INSTALLING THE PARKING BRAKE LEVER 1. Install: • parking brake lever • parking brake cable • damper • parking brake lever plate • Brake master cylinder Align the holder plate on the handlebar with the align position of the parking brake lever.
  • Page 254 CHAS STEERING SYSTEM EBS00454 STEERING STEM 25 Nm (2.5 m kg, 18.1 ft • • 35 Nm (3.5 m kg, 25.3 ft 55 Nm (5.5 m kg, 39.8 ft • • • • Order Job/Part Q’ty Remarks Removing the steering stem Remove the parts in the order listed.
  • Page 255 CHAS STEERING SYSTEM REMOVING THE STEERING STEM 1. Remove: • steering stem When loosening each tie-rod end nut , hold the tie-rod ball joint with a 14-mm wrench CHECKING THE STEERING STEM 1. Check: • steering stem Bends Replace. → WARNING Do not attempt to straighten a bent stem;...
  • Page 256 CHAS STEERING SYSTEM INSTALLING THE STEERING STEM 1. Tighten: • steering stem nut 1 55 Nm (5.5 m·kg, 39.8 ft·lb) • tie-rod end nut 2 35 Nm (3.5 m·kg, 25.3 ft·lb) When tightening each tie-rod end nut 2, hold the tie-rod ball joint with a 14-mm wrench 3. INSTALLING THE LOCK WASHER 1.
  • Page 257 CHAS STEERING SYSTEM TIE-RODS AND STEERING KNUCKLES 35 Nm (3.5 m • kg, 25.3 ft • Ib) 13 Nm (1.3 m • kg, 9.4 ft • Ib) 35 Nm (3.5 m • kg, 25.3 ft • Ib) 35 Nm (3.5 m • kg, 25.3 ft • Ib) 45 Nm (4.5 m •...
  • Page 258 CHAS STEERING SYSTEM REMOVING THE TIE-RODS The following procedure applies to both of the tie-rods. 1. Remove: • tie-rod When removing the tie-rod, hold each tie-rod ball joint with a 14-mm wrench and then loosen the tie-rod end nut. REMOVING THE STEERING KNUCKLES The following procedure applies to both of the steering knuckles.
  • Page 259 CHAS STEERING SYSTEM CHECKING THE TIE-RODS The following procedure applies to both of the tie-rods. 1. Check: • tie-rod free play and movement Free play → Replace the tie-rod end. Turns roughly → Replace the tie-rod end. 2. Check: • tie-rod Bends/damage →...

  • Page 260: Front Arms And Front Shock Absorber

    FRONT ARMS AND FRONT SHOCK ABSORBER CHAS ASSEMBLIES FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES 35 Nm (3.5 m • kg, 25.3 ft • Ib) 35 Nm (3.5 m • kg, 25.3 ft • Ib) 7 7 7 35 Nm (3.5 m • kg, 25.3 ft • Ib) 35 Nm (3.5 m •...
  • Page 261 FRONT ARMS AND FRONT SHOCK ABSORBER CHAS ASSEMBLIES REMOVING THE FRONT ARMS 1. Check: • front arm free play a. Check the front arm side play by moving it from side to side. If side play is noticeable, check the bush- ings.
  • Page 262 FRONT ARMS AND FRONT SHOCK ABSORBER CHAS ASSEMBLIES EBS00472 CHECKING THE BALL JOINTS The following procedure applies to both of the front arm ball joints. 1. Check: • ball joint Damage/pitting → Replace the front arm. Free play → Replace the front arm. Turns roughly →...
  • Page 263 REAR SHOCK ABSORBER AND SWINGARM CHAS REAR SHOCK ABSORBER AND SWINGARM 38 Nm (3.8 m • kg, 27.5 ft • Ib) 75 Nm (7.5 m • kg, 54.2 ft • Ib) 38 Nm (3.8 m • kg, 27.5 ft • Ib) 75 Nm (7.5 m •...
  • Page 264 REAR SHOCK ABSORBER AND SWINGARM CHAS 38 Nm (3.8 m • kg, 27.5 ft • Ib) 75 Nm (7.5 m • kg, 54.2 ft • Ib) 38 Nm (3.8 m • kg, 27.5 ft • Ib) 75 Nm (7.5 m • kg, 54.2 ft • Ib) 8 Nm (0.8 m •...

  • Page 265: Rear Shock Absorber

    REAR SHOCK ABSORBER AND SWINGARM CHAS REMOVING THE REAR SHOCK ABSORBER 1. Remove: • rear shock absorber lower bolt • rear shock absorber upper bolt While removing the rear shock absorber lower bolt, hold the swingarm so that it does not drop down.

  • Page 266: Plug

    REAR SHOCK ABSORBER AND SWINGARM REAR SHOCK ABSORBER AND SWINGARM CHAS c. Check the swingarm vertical movement by moving it up and down. If vertical movement is tight or rough, or if there is binding, check the spacer, bearings and frame pivot. 2.

  • Page 267: Rubber Boot

    REAR SHOCK ABSORBER AND SWINGARM CHAS CHECKING THE RUBBER BOOT 1. Check: • Rubber boot Damage Replace. → INSTALLING THE RUBBER BOOT 1. Apply: • Adhesive (for rubber) (to the swingarm 2. Install: • Rubber boot Be sure to position the rubber boot so that the ellipsoid towards the swingarm.

  • Page 268: Elec

    ELEC – ELECTRICAL COMPONENTS EBS00500 ELECTRICAL ELECTRICAL COMPONENTS Indicator light Indicator light Headlight Headlight relay Circuit breaker (fan) Main switch Diode Gear position switch Thermo unit Rear brake switch Starter relay Ignition coil Front brake switch C.D.I. unit Thermo switch Handlebar switch (left) Fuse box Fan motor...
  • Page 269 ELEC – CHECKING THE SWITCHES EBS01028 CHECKING SWITCH CONTINUITY Check each switch for continuity with the pocket tester. If the continuity reading is incor- rect, check the wiring connections and if nec- essary, replace the switch. NOTICE Never insert the tester probes into the cou- pler terminal slots .
  • Page 270 ELEC – CHECKING THE SWITCHES EBS01029 CHECKING THE SWITCHES Check each switch for damage or wear, proper connections, and also for continuity between the terminals. Refer to “CHECKING SWITCH CONTINUITY”. → Damage/wear Repair or replace. → Improperly connected Properly connect. →...
  • Page 271 ELEC – CHECKING THE BULBS AND BULB SOCKETS EBS01030 CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage or wear, proper connections, and also for con- tinuity between the terminals. → Damage/wear Repair or replace the bulb,bulb socket or both.
  • Page 272 ELEC – CHECKING THE BULBS AND BULB SOCKETS 2. Check: • bulb (for continuity) (with the pocket tester) No continuity → Replace. Pocket tester P/N. YU-03112-C, 90890-03112 Before checking for continuity, set the pocket tester to “0” and to the “Ω × 1” range. a.
  • Page 273 ELEC – IGNITION SYSTEM EBS00503 IGNITION SYSTEM CIRCUIT DIAGRAM...
  • Page 274 ELEC – IGNITION SYSTEM EBS01045 EBS01032 TROUBLESHOOTING 1. Spark plug The ignition system fails to operate (no • Check the condition of the spark plug. spark or intermittent spark). • Check the spark plug type. • Measure the spark plug gap. Check: Refer to “CHECKING THE SPARK PLUG”...
  • Page 275 ELEC – IGNITION SYSTEM EBS01034 EBS01036 2. Ignition spark gap 3. Spark plug cap resistance • Disconnect the spark plug cap from the • Remove the spark plug cap from the spark spark plug. plug lead. • Connect the pocket tester (“ Ω × 1k” range) •...
  • Page 276 ELEC – IGNITION SYSTEM EBS01038 EBS01041 4. Ignition coil resistance 5. Main switch • Disconnect the ignition coil connectors • Check the main switch for continuity. from theignitioncoil terminals. Refer to “CHECKING THE SWITCHES”. • Connect the pocket tester (Ω×1) to the •...
  • Page 277 ELEC – IGNITION SYSTEM EBS01040 7. Pickup coil resistance • Disconnect the C.D.I. magneto coupler from the wire harness. • Connect the pocket tester (Ω× 100) to the pickup coil terminal as shown. → Positive tester probe blue terminal → Negative tester probe green terminal •...
  • Page 278 ELEC – ELECTRIC STARTING SYSTEM EBS00506 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM 9-11...
  • Page 279 ELEC – ELECTRIC STARTING SYSTEM EBS00507 STARTING CIRCUIT OPERATION The starting circuit on this model consists of the starter motor, starter relay, engine stop switch, rear brake switch, Shift gear control unit, neutral switch. If the main switch is on and the engine stop switch is in the RUN position, the starter motor can be operated only if: •...
  • Page 280 ELEC – ELECTRIC STARTING SYSTEM EBS01050 EBS01044 TROUBLESHOOTING 2. Battery The starter motor fails to turn. • Check the condition of the battery. Refer to “CHECKING AND CHARGING Check: THE BATTERY” in chapter 3. 1. main fuse 2. battery Minimum open-circuit voltage 3.
  • Page 281 ELEC – ELECTRIC STARTING SYSTEM EBS01054 EBS01046 4. Starter relay 6. Rear brake switch • Disconnect the starter relay coupler from • Check the rear brake switch for continuity. the coupler. Refer to “CHECKING THE SWITCHES”. • Connect the pocket tester ( Ω× 1) and bat- •...

  • Page 282: Starter Motor

    ELEC – ELECTRIC STARTING SYSTEM EBS01061 STARTER MOTOR 9 Nm (0.9 m kg, 6.5 ft • • Order Job/Part Q’ty Remarks Removing the starter motor Remove the parts in the order listed. Exhaust pipe Refer to “ ENGINE REMOVAL ” in chapter 4.
  • Page 283 ELEC – CHARGING SYSTEM EBS00516 CHARGING SYSTEM CIRCUIT DIAGRAM 9-16...

  • Page 284: Charging System

    ELEC – CHARGING SYSTEM EBS01065 EBS01043 TROUBLESHOOTING 1. Main fuse The battery is not being charged. • Check the main fuse for continuity. Refer to “CHECKING THE FUSE” in chap- Check: ter 3. 1. main fuse • Is the main fuse OK? 2.
  • Page 285 ELEC – CHARGING SYSTEM EBS01066 EBS01100 3. Charging voltage 4. Charging coil resistance • Connect the engine tachometer to the • Disconnect the C.D.I. magneto coupler spark plug lead. from the wire harness. • Connect the pocket tester (DC 20 V) to the •...
  • Page 286 ELEC – LIGHTING SYSTEM EBS00518 LIGHTING SYSTEM CIRCUIT DIAGRAM 9-19...
  • Page 287 ELEC – LIGHTING SYSTEM EBS01067 EBS01100 TROUBLESHOOTING 2. Charging coil resistance Any of the following fail to light: headl- • Disconnect the C.D.I. magneto coupler ight, tail/brake light. from the wire harness. • Connect the pocket tester (Ω×1) to the charging coils.
  • Page 288 ELEC – LIGHTING SYSTEM EBS01069 2. Voltage 3. Wiring • Connect the pocket tester (AC 20 V) to the • Check the entire lighting system’s wiring. headlight couplers as shown. Refer to “CIRCUIT DIAGRAM”. • Is the lighting system’s wiring properly con- When the light switch is set to “LO”...
  • Page 289 ELEC – LIGHTING SYSTEM 2. The tail/brake light fails to come on. 1. Tail/brake light bulb and bulb socket • Check the tail/brake light bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS”. • Are the tail/brake light bulb and socket OK? Replace the tail/brake light bulb, socket or both.
  • Page 290 ELEC – SIGNAL SYSTEM EB806000 SIGNAL SYSTEM CIRCUIT DIAGRAM 9-23...
  • Page 291 ELEC – SIGNAL SYSTEM EB806010 EBS01044 TROUBLESHOOTING 2. Battery Any of the following fail to light: indica- • Check the condition of the battery. tor light, brake light. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: Minimum open-circuit voltage 1.
  • Page 292 ELEC – SIGNAL SYSTEM EBS01075 CHECKING THE SIGNALING SYSTEM • Set the main switch to “ON”. EBS01076 • Pull in the brake levers. 1. The tail/brake light fails to come on. • M ea su re t he v o l t ag e ( DC 12 V) of 1.
  • Page 293 ELEC – SIGNAL SYSTEM 2. Gear position switch 3. Voltage • Check the gear position switch for continuity. • Connect the pocket tester (AC 20 V) to the Refer to “CHECKING THE SWITCHES”. neutral light coupler as shown. • Is the gear position switch OK? Positive tester probe →...

  • Page 294: Signal System

    ELEC – SIGNAL SYSTEM EBS01076 2.Thermo unit 4. The coolant temperature warning light does not come on when the start switch is pushed • Remove the thermo unit from the cylinder head. (Ω × • Connect the pocket tester 1) to the 1.
  • Page 295 ELEC – SIGNAL SYSTEM 3. Voltage • Connect the pocket tester (AC 20 V) to the indicator light connector (wire harness side) as shown. Positive tester probe → gray Negative tester probe → green • Set the main switch to “ON”. •...
  • Page 296 ELEC – COOLING SYSTEM EBS00532 COOLING SYSTEM CIRCUIT DIAGRAM 9-29...
  • Page 297 ELEC – COOLING SYSTEM EBS01085 EBS01044 TROUBLESHOOTING 2. Battery The radiator fan motor fails to turn. • Check the condition of the battery. Refer to “CHECKING AND CHARGING Check: THE BATTERY” in chapter 3. 1. fuse Minimum open-circuit voltage 2. battery 12.0 V or more at 20°C (68°F) 3.
  • Page 298 ELEC – COOLING SYSTEM EBS01086 EBS01088 4. Radiator fan motor 6. Thermo switch • Disconnect the radiator fan motor coupler • Remove the thermo switch from the radi- from the wire harness. ator. Connect the battery (DC 12 V) as shown. •...
  • Page 299 ELEC – COOLING SYSTEM WARNING • Handle the thermo switch with special care. • Never subject the thermo switch to strong shocks. If the thermo switch is dropped, replace it. Thermo switch 28 Nm (2.8 m · kg, 20 ft · lb) The thermo switch circuit is open and the radia- tor fan is off.

  • Page 300: Trbl Shtg

    TRBL STARTING FAILURE/HARD STARTING SHTG EBS00537 TROUBLESHOOTING The following troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to troubleshooting. Refer to the relative procedure in this manual for check, adjustment and replacement of parts. STARTING FAILURE/HARD STARTING FUEL SYSTEM ELECTRICAL SYSTEM...

  • Page 301: Poor Idle Speed Performance

    TRBL STARTING FAILURE/HARD STARTING/POOR IDLE SPEED SHTG PERFORMANCE/POOR MEDIUM AND HIGH-SPEED PERFORMANCE COMPRESSION SYSTEM Cylinder and cylinder head Piston and piston rings • Loose spark plug • Improperly installed piston ring • Loose cylinder head or cylinder • Worn, fatigued or broken piston ring •...
  • Page 302 FAULTY GEAR SHIFTING/CLUTCH SLIPPING/ TRBL DRAGGING/OVERHEATING SHTG EBS00541 FAULTY GEAR SHIFTING HARD SHIFTING Refer to “CLUTCH DRAGGING”. SHIFT PEDAL DOES NOT MOVE Transmission Shift shaft Seized transmission gear • • Bent shift shaft Jammed impurities • Shift drum and shift forks Incorrectly assembled transmission •...

  • Page 303: Faulty Brake

    OVERHEATING/FAULTY BRAKE/ TRBL SHOCK ABSORBER MALFUNCTION SHTG EBS00547 OVERHEATING OVERHEATING Ignition system Engine oil • Improper spark plug gap • Improper oil level • Improper spark plug heat range • Improper oil viscosity • Faulty C.D.I. unit • Inferior oil quality Fuel system Brake •...
  • Page 304 UNSTABLE HANDLING/ TRBL LIGHTING SYSTEM SHTG EBS00552 UNSTABLE HANDLING UNSTABLE HANDLING Handlebar Wheels • Improperly installed or bent • Deformed wheel Steering • Loose bearing • Bent or loose wheel axle • Incorrect toe-in • Excessive wheel runout • Bent steering stem Frame •...
  • Page 305 PRINTED IN U.S.A.
  • Page 306 YFM30GB WIRING DIAGRAM Main switch C.D.I. magneto Rectifier/Regulator Battery Main fuse Ignition fuse Signal fuse Head fuse Battery (+) lead Battery (-) lead Wire lead Starter relay Starter motor C.D.I. unit Ignition coil Start switch W/BW/G Dimmer switch Engine stop switch Shift gear control unit Headlight relay Br/Y...

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