Page 1 YFM400FWA 2000 5GH3-AE1 SERVICE MANUAL...
Page 2 YFM400FWA(M) 2000 SERVICE MANUAL © 1999 by Yamaha Motor Co., Ltd. First Edition, July 1999 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
Page 3: Specifications
EB001000 NOTICE This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform mainte- nance 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
EB002000 HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual consists of chapters for the main categories of subjects. (See “Illustrated sym- bols”) 1st title 1 : This is the title of the chapter with its symbol in the upper right corner of each page.
Page 5 EB003000 ILLUSTRATED SYMBOLS Illustrated symbols 1 to 0 are printed on SPEC the top right of each page and indicate the INFO subject of each chapter. 1 General information INSP 2 Specifications 3 Periodic inspections and adjustments 4 Engine 5 Cooling system 6 Carburetion COOL CARB...
Page 6: Table Of Contents
TABLE OF CONTENTS GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC INSPECTION AND INSP ADJUSTMENTS ENGINE COOLING SYSTEM COOL CARBURETION CARB DRIVE TRAIN DRIV CHASSIS CHAS – ELECTRICAL ELEC TROUBLESHOOTING TRBL SHTG...
Page 7 INFO...
Page 8 INFO CHAPTER 1. GENERAL INFORMATION MACHINE IDENTIFICATION .................1-1 VEHICLE IDENTIFICATION NUMBER ..........1-1 MODEL LABEL ..................1-1 FEATURES ....................1-2 LIQUID COOLING ENGINE ..............1-2 PARK POSITION ...................1-2 IMPORTANT INFORMATION ...............1-3 PREPARATION FOR REMOVAL PROCEDURES .........1-3 REPLACEMENT PARTS ................1-3 GASKETS, OIL SEALS AND O-RINGS ..........1-3 LOCK WASHERS/PLATES AND COTTER PINS ........1-4 BEARINGS AND OIL SEALS ..............1-4 CIRCLIPS ....................1-4...
Page 9 INFO...
Page 10: Chapter 1. General Information
MACHINE IDENTIFICATION INFO GENERAL INFORMATION MACHINE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the left side of the frame. MODEL LABEL The model label 1 is affixed to the frame. This information will be needed to order spare parts.
Page 11: Features
FEATURES INFO FEATURES LIQUID COOLING ENGINE Compact liquid cooled 45˚ inclined engine. A liquid cooling system has been incorpo- rated for stable power and engine endur- ance. 1 Radiator 2 Thermo switch 3 Fan motor PARK POSITION When the drive select lever is shifted into the park position, a stopper lever is engaged into the stopper gear preventing the drive select lever and transmission from...
Page 12: Important Information
5.Keep all parts away from any source of fire. EB101010 REPLACEMENT PARTS 1.Use only genuine Yamaha parts for all replacements. Use oil and grease recom- mended by Yamaha for all lubrication jobs. Other brands may be similar in func- tion and appearance, but inferior in qual- ity.
Page 13: Lock Washers/Plates And Cotter Pins
IMPORTANT INFORMATION INFO EB101030 LOCK WASHERS/PLATES AND COTTER PINS 1.Replace all lock washers/plates 1 and cot- ter pins after removal. Bend lock tabs along the bolt or nut flats after the bolt or nut has been tightened to specification. EB101040 BEARINGS AND OIL SEALS 1.Install bearings and oil seals so that the manufacturer’s marks or numbers are vis-...
Page 14: Checking Of Connections
CHECKING OF CONNECTIONS INFO EB801000 CHECKING OF CONNECTIONS Check the connectors for stains, rust, mois- ture, etc. 1.Disconnect: Connector 2.Check: Connector Moisture → Dry each terminal with an air blower. Stains/rust → Connect and disconnect the terminals several times. 3.Check: Connector leads Looseness →...
Page 15: Special Tools
SPECIAL TOOLS INFO EB102001 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 16 SPECIAL TOOLS INFO Tool No. Tool name/How to use Illustration Buffer boss installer set Crankshaft installer bolt 90890-04088 Bolt These tools are used to install the 90890-01275 crankshaft. Crankshaft installer set YU-90050 These tools are used to install the crankshaft. Adapter (#11) Adapter Spacer (crankshaft installer)
Page 17 SPECIAL TOOLS INFO Tool No. Tool name/How to use Illustration Sheave spring compressor 90890-04134 This tool is needed when removing or YM-04134 installing the secondary sheave spring. Sheave fixed block 90890-04135 This tool is needed when removing or YM-04135 installing the secondary sheave spring.
Page 18 SPECIAL TOOLS INFO Tool No. Tool name/How to use Illustration Pocket tester 90890-03112 YU-03112 This instrument is needed for checking the electrical system. Engine tachometer 90890-03113 This tool is needed for observing engine rpm. Inductive tachometer YU-8036-A This tool is needed for observing engine rpm.
Page 19 This instrument is necessary for check- ing the ignition system components. Dynamic spark tester YM-34487 This instrument is necessary for check- ing the ignition system components. Yamaha bond No. 1215 ® Bond Sealant (Quick Gasket 90890-85505 Sealant This sealant (bond) is used on crank- ACC-11001-05-01 case mating surfaces, etc.
Page 20 SPEC...
Page 21: Specifications
SPEC CHAPTER 2. SPECIFICATIONS GENERAL SPECIFICATIONS.................2-1 MAINTENANCE SPECIFICATIONS...............2-5 ENGINE ....................2-5 CHASSIS ....................2-15 ELECTRICAL ..................2-19 HOW TO USE THE CONVERSION TABLE ..........2-21 GENERAL TORQUE SPECIFICATIONS ............2-21 LUBRICATION POINTS AND LUBRICANT TYPES ........2-22 ENGINE ....................2-22 COOLANT FLOW DIAGRAMS ..............2-23 OIL FLOW DIAGRAMS ................2-25 CABLE ROUTING ..................2-28...
Page 22 SPEC...
Page 23: General Specifications
SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Model code: 5GH3 : (For CDN) 5GH4 : (For GB, F, CH) 5GH5 : (For Oceania) Dimensions: Overall length 1,965 mm (77.36 in) Overall width 1,070 mm (42.13 in) Overall height 1,120 mm (44.09 in) Seat height 820 mm (32.28 in) Wheelbase...
Page 24 SPEC GENERAL SPECIFICATIONS Item Standard Differential gear case oil Periodic oil change 0.35 L (0.31 lmp qt, 0.37 US qt) Total amount 0.40 L (0.35 lmp qt, 0.42 US qt) Radiator capacity (including all routes) 1.1 L (0.97 lmp qt, 1.16 US qt) Air ﬁlter: Wet type element Fuel:...
Page 25 SPEC GENERAL SPECIFICATIONS Item Standard Manufacturer front DUNLOP (For CDN, GB, F, CH) CHENG SHIN (For Oceania) rear DUNLOP (For CDN, GB, F, CH) CHENG SHIN (For Oceania) Type front KT123 (For CDN, GB, F, CH) C828 (For Oceania) rear KT127 (For CDN, GB, F, CH) C828 (For Oceania) 2 - 3...
Page 26 SPEC GENERAL SPECIFICATIONS Item Standard Tire pressure (cold tire): Maximum load* 210 kg (463 lb) Off-road riding front 22 ~ 28 kPa (0.22 ~ 0.28 kg/cm , 3.2 ~ 4.0 psi) rear 22 ~ 28 kPa (0.22 ~ 0.28 kg/cm , 3.2 ~ 4.0 psi) *Load in total weight of rider accessories Brake:...
Page 27: Engine
SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Cylinder head: Warp limit ---- 0.03 mm (0.0012 in) Cylinder: Bore size 84.500 ~ 84.510 mm 84.600 mm (3.3268 ~ 3.3272 in) (3.3307 in) Taper limit ---- 0.05 mm (0.0016 in) Out of round limit ---- 0.01 mm...
Page 28 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Cam chain: Cam chain type/No. of links 92RH2015/116 ---- Cam chain adjustment method Automatic ---- Rocker arm/rocker arm shaft: Shaft outside diameter 11.981 ~ 11.991 mm 11.951 mm (0.4717 ~ 0.4721 in) (0.4705 in) Arm-to-shaft clearance 0.009 ~ 0.037 mm 0.08 mm...
Page 29 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Stem runout limit ---- 0.01 mm (0.0004 in) Valve seat width 1.2 ~ 1.4 mm ---- (0.0472 ~ 0.0551 in) 1.2 ~ 1.4 mm ---- (0.0472 ~ 0.0551 in) Valve spring: Inner spring Free length 39.9 mm (1.57 in) 37.9 mm (1.49 in)
Page 30 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Compressed pressure (installed) 235.4 ~ 251.1 N (24.00 ~ ---- 25.60 kg, 52.92 ~ 56.45 lb) 235.4 ~ 251.1 N (24.00 ~ ---- 25.60 kg, 52.92 ~ 56.45 lb) Tilt limit 2.5˚/1.6 mm (2.5˚/0.06 in) 2.5˚/1.6 mm (2.5˚/0.06 in) Direction of winding...
Page 31 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit 2nd ring Type Taper ---- Dimensions (B × T) 1.2 × 3.6 mm ---- (0.0472 × 0.1417 in) End gap (installed) 0.4 ~ 0.6 mm 0.95 mm (0.0157 ~ 0.0236 in) (0.0374 in) Side clearance 0.03 ~ 0.07 mm 0.13 mm (0.0012 ~ 0.0028 in)
Page 32 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Transmission: Main axle deﬂection limit ---- 0.06 mm (0.0024 in) Drive axle deﬂection limit ---- 0.06 mm (0.0024 in) Shifter: Shifter type Cam drum and guide bar ---- Air ﬁlter oil grade: Engine oil ---- Carburetor: I.
Page 33 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Radiator cap opening pressure 93.3 ~ 122.7 kPa (0.933 ~ ---- 1.227 kg/cm , 13.53 ~ 17.79 psi) Radiator capacity 0.55 L (0.48 Imp qt, 0.58 US qt) ---- Coolant reservoir Capacity 0.25 L (0.22 Imp qt, 0.26 US qt) ---- From low to full level 0.15 L (0.13 Imp qt, 0.16 US qt)
Page 34 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Cylinder head tightening sequence: 2 - 12...
Page 35 SPEC MAINTENANCE SPECIFICATIONS Tightening torques Tightening torque Part Thread Part to be tightened Q’ty Remarks name size m·kg ft·lb Cylinder head oil passage Union bolt Cylinder head (exhaust pipe) Stud bolt Cylinder head Bolt Bolt Camshaft sprocket cover baffle Bolt plate Camshaft bearing retainer Bolt...
Page 36 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part Thread Part to be tightened Q’ty Remarks name size m·kg ft·lb Crankcase cover (left) Bolt Recoil starter Bolt Starter one-way clutch Bolt Clutch carrier assembly 100 Stake Middle drive shaft bearing Torx retainer screw Middle driven shaft drive pinion Stake gear...
Page 37: Chassis
SPEC MAINTENANCE SPECIFICATIONS CHASSIS Item Standard Limit Steering system: Steering bearing type Bushings (top) ---- Ball bearing (bottom) Front suspension: Shock absorber travel 106 mm (4.17 in) ---- Fork spring free length 317.5 mm (12.50 in) ---- Spring ﬁtting length 256.5 mm (10.09 in) ---- Spring rate...
Page 38 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Front disc brake: Type Dual ---- Disc outside diameter × thickness 180.0 × 3.5 mm (7.09 ~ 0.14 in) ---- Pad thickness inner 4.5 mm (0.18 in) 1 mm (0.04 in) Pad thickness outer 4.5 mm (0.18 in) 1 mm (0.04 in)
Page 39 SPEC MAINTENANCE SPECIFICATIONS Tightening torques Tightening torque Part to be tightened Thread size Remarks m·kg ft·lb Engine bracket (front-upper) and frame Engine bracket (front-lower) and frame Engine bracket (front-upper) and engine Engine bracket (front-lower) and engine Engine and frame Frame and bearing retainer (steering stem holder bearing) Select lever assembly and frame Pivot shaft and frame...
Page 40 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Remarks m·kg ft·lb Front bumper and frame Front carrier and frame Front carrier and front bumper Rear carrier and frame Differential gear case filler bolt Differential gear case drain bolt Ring gear Differential gear case and bearing housing Gear motor...
Page 41: Electrical
Rotor ratation direction sensing coil resis- ---- tance/color Red – White/Blue C.D.I. unit model/manufacturer F8T36472/MITSUBISHI ---- Ignition coil: Model/manufacturer 2JN/YAMAHA ---- Minimum spark gap 6 mm (0.24 in) ---- 0.18 ~ 0.28 Ω at 20 ˚C (68 ˚F) Primary winding resistance ---- Secondary winding resistance 6.32 ~ 9.48 kΩ...
Page 42 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Starter relay Model/manufacturer MS5F-561/JIDECO ---- Amperage rating 180 A ---- 4.18 ~ 4.62 Ω at 20 ˚C (68 ˚F) Coil winding resistance ---- Horn: Type Plane type ---- Quantity ---- Model/manufacturer MF-12/NIKKO ---- Maximum amperage 1.5 A ---- Performance...
Page 43: How To Use The Conversion Table
HOW TO USE THE CONVERSION TABLE/ SPEC GENERAL TORQUE SPECIFICATIONS EB201000 EB202001 HOW TO USE THE CONVERSION GENERAL TORQUE TABLE SPECIFICATIONS All specification data in this manual are This chart specifies torque for standard fas- listed in SI and METRIC UNITS. teners with standard I.S.O.
Page 44: Lubrication Points And Lubricant Types
Stopper lever Clutch housing One-way bearing Drive chain/sprocket Driven cam Front drive shaft collar ® Sealant (Quick Gasket Crankcase mating surfaces Yamaha Bond No.1215 ® Stater lead grommet Sealant (Quick Gasket (left side crankcase) Yamaha Bond No.1215 2 - 22...
Page 45: Coolant Flow Diagrams
SPEC COOLANT FLOW DIAGRAMS COOLANT FLOW DIAGRAMS 1 Radiator 2 Thermo switch 3 Fan motor 2 - 23...
Page 46 SPEC COOLANT FLOW DIAGRAMS 1 Radiator 2 Thermostat 2 - 24...
Page 47: Oil Flow Diagrams
SPEC OIL FLOW DIAGRAMS OIL FLOW DIAGRAMS 1 Camshaft 2 Crankshaft 3 Drive axle 2 - 25...
Page 48 SPEC OIL FLOW DIAGRAMS 1 Oil filter 2 - 26...
Page 49 SPEC OIL FLOW DIAGRAMS 1 Oil pump 2 Oil strainer 2 - 27...
Page 50: Cable Routing
SPEC CABLE ROUTING CABLE ROUTING 1 Rear brake switch 0 Coolant reservoir breather hose 2 Rear brake cable A Sub-wire harness 1 (to fan motor coupler) 3 Front brake hose B Sub-wire harness 1 (to gear motor and four- 4 On command four-wheel drive switch wheel drive switch) 5 Throttle cable C Differential gear case breather hose...
Page 51 SPEC CABLE ROUTING 1 Headlight coupler A Differential gear case breather hose 2 Terminal B Indicator light coupler 3 Terminal coupler C Main switch coupler 4 Engine temperature warning light D Ignition coil lead 5 Four-wheel drive indicator light E Ignition coil 6 Neutral indicator light F Circuit braker 7 Parking indicator light...
Page 52 SPEC CABLE ROUTING 1 Thermo switch 0 Speed sensor 2 Fuel tank breather hose A CDI magneto lead 3 Starter motor lead B Final drive gear case breather hose 4 Negative battery lead C Rectifier/regulator 5 Speed sensor D Sub-wire harness 1 6 Carburetor drain hose E Coolant reservoir breather hose 7 Wire harness...
Page 53 SPEC CABLE ROUTING Å To hole on the front fender. ı Insert the fuel tank into the hole in the handlebar cover. Ç Fasten the CDI magneto lead and starter motor lead with a plastic band. Î To hole on the rear fender. ‰...
Page 54 SPEC CABLE ROUTING 1 Cylinder head breather hose 2 Spark plug lead 3 Rear brake cable 4 Select lever control cable 5 Rear brake reservoir hose 6 Rear brake hose 2 - 32...
Page 55 SPEC CABLE ROUTING 1 Diode 1 A Negative battery lead 2 Diode 2 B Final drive gear case breather hose 3 Positive battery lead C Cylinder head breather hose 4 Taillight lead D Starter cable 5 Starter relay E Rear brake cable 6 CDI unit F Wire harness 7 Main fuse...
Page 56 SPEC 2 - 34...
Page 57: Insp Adj
INSP...
Page 58 INSP CHAPTER 3. PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION ...................3-1 PERIODIC MAINTENANCE/LUBRICATION INTERVALS ......3-1 SEAT, CARRIERS, FENDERS AND FUEL TANK .........3-3 SEAT AND SIDE PANELS ..............3-3 FRONT CARRIER, FRONT BUMPER AND FRONT FENDER ....3-4 REAR CARRIER AND REAR FENDER ..........3-6 FUEL TANK ...................3-8 FOOTREST BOARDS ..................3-9 ENGINE .......................3-10 VALVE CLEARANCE ADJUSTMENT ..........3-10...
Page 59 INSP DIFFERENTIAL GEAR OIL REPLACEMENT ........3-45 CONSTANT VELOCITY JOINT DUST BOOT INSPECTION ....3-46 STEERING SYSTEM INSPECTION ............3-46 TOE-IN ADJUSTMENT ...............3-47 FRONT SHOCK ABSORBER ADJUSTMENT ........3-49 REAR SHOCK ABSORBER ADJUSTMENT ........3-49 TIRE INSPECTION ................3-49 WHEEL INSPECTION ................3-52 CABLE INSPECTION AND LUBRICATION ........3-52 LEVERS, PEDAL, ETC.
Page 60: Chapter 3. Periodic Inspections And Adjustments
• Check operation. Front axle boots* • Replace if damaged. Fittings and fasten- • Check all chassis fittings and fasteners. ers* • Correct if necessary. * It is recommended that these items be serviced by a Yamaha dealer. 3 - 1...
Page 61 INSP PERIODIC MAINTENANCE/LUBRICATION INTERVALS NOTE: Recommended brake fluid: DOT 4 Brake fluid replacement: 1.When disassembling the master cylinder or caliper cylinder, replace the brake fluid. Nor- mally check the brake fluid level and add fluid as required. 2.On the inner parts of the master cylinder and caliper cylinder, replace the oil seals every two years.
Page 62: Seat, Carriers, Fenders And Fuel Tank
INSP SEAT, CARRIERS, FENDERS AND FUEL TANK SEAT, CARRIERS, FENDERS AND FUEL TANK SEAT AND SIDE PANELS Order Job name/Part name Q’ty Remarks Seat and side panels removal Remove the parts in the order below. Seat NOTE: Pull up the seat lock lever, then pull up on the rear of the seat.
Page 63: Front Carrier, Front Bumper And Front Fender
INSP SEAT, CARRIERS, FENDERS AND FUEL TANK FRONT CARRIER, FRONT BUMPER AND FRONT FENDER Order Job name/Part name Q’ty Remarks Front carrier, front bumper and front Remove the parts in the order below. fender removal Seat and fuel tank side panels Refer to “SEAT AND SIDE PANELS”.
Page 64 INSP SEAT, CARRIERS, FENDERS AND FUEL TANK Order Job name/Part name Q’ty Remarks Indicator light coupler Disconnect. Sub-wire harness 1 coupler Disconnect. Main switch coupler Disconnect. Auxiliary DC jack coupler Disconnect. Speedometer light coupler Disconnect. Speedometer cable Disconnect. Coolant reservoir breather hose Fan motor breather hose Differential gear case breather hose Front fender...
Page 65: Rear Carrier And Rear Fender
INSP SEAT, CARRIERS, FENDERS AND FUEL TANK REAR CARRIER AND REAR FENDER Order Job name/Part name Q’ty Remarks Rear carrier and rear fender removal Remove the parts in the order below. Seat and fuel tank side panels Refer to “SEAT AND SIDE PANELS”. Fuel tank Refer to “FUEL TANK”.
Page 66 INSP SEAT, CARRIERS, FENDERS AND FUEL TANK Order Job name/Part name Q’ty Remarks Final drive gear case breather hose Cylinder head breather hose Clamp screw Loosen. Air filter case Plastic band Rear fender For installation, reverse the removal procedure. 3 - 7...
Page 67: Fuel Tank
INSP SEAT, CARRIERS, FENDERS AND FUEL TANK FUEL TANK Order Job name/Part name Q’ty Remarks Fuel tank removal Remove the parts in the order below. Seat and side panels Refer to “SEAT AND SIDE PANELS”. Fuel tank cover Refer to “FRONT CARRIER, FRONT BUMPER AND FRONT FENDER”.
Page 68: Footrest Boards
INSP FOOTREST BOARDS FOOTREST BOARDS Order Job name/Part name Q’ty Remarks Footrest boards removal Remove the parts in the order below. Fuel tank side panels Refer to “SEAT AND SIDE PANELS”. Footrest Left footrest board Right footrest board Left footrest bracket Right footrest bracket For installation, reverse the removal procedure.
Page 69: Engine
INSP VALVE CLEARANCE ADJUSTMENT ENGINE VALVE CLEARANCE ADJUSTMENT NOTE: The valve clearance must be adjusted when the engine is cool to the touch. Adjust the valve clearance when the pis- ton is at the Top Dead Center (T.D.C.) on the compression stroke. 1.Remove: Seat Front carrier...
Page 70 INSP VALVE CLEARANCE ADJUSTMENT 6.Remove: Timing plug 1 7.Check: Valve clearance Out of specification → Adjust. Valve clearance (cold): Intake: 0.06 ~ 0.10 mm (0.0024 ~ 0.0039 in) Exhaust: 0.16 ~ 0.20 mm (0.0063 ~ 0.0079 in) ********************************* Checking steps: Turn the crankshaft counterclockwise with a wrench.
Page 71 INSP VALVE CLEARANCE ADJUSTMENT 8.Adjust: Valve clearance ********************************* Adjustment steps: Loosen the locknut 1. Insert a feeler gauge 2 between the adjuster end and the valve end. Turn the adjuster 3 clockwise or counter- clockwise with the valve adjusting tool 4 until the proper clearance is obtained.
Page 72: Timing Chain Adjustment
VALVE CLEARANCE ADJUSTMENT/TIMING CHAIN INSP ADJUSTMENT/IDLING SPEED ADJUSTMENT 11.Install: Fuel tank Front fender Front carrier Seat Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”. TIMING CHAIN ADJUSTMENT Adjustment free. IDLING SPEED ADJUSTMENT 1.Start the engine and let it warm up for several minutes.
Page 73: Idling Speed Adjustment
IDLING SPEED ADJUSTMENT/ INSP THROTTLE LEVER FREE PLAY ADJUSTMENT 5.Adjust: Engine idling speed ********************************* Adjustment steps: Turn the throttle stop screw 1 in or out until specified idling speed obtained. Idling speed becomes Turning in higher. Idling speed becomes Turning out lower.
Page 74 INSP THROTTLE LEVER FREE PLAY ADJUSTMENT 1.Check: Throttle lever free play a Out of specification → Adjust. Throttle lever free play: 3 ~ 5 mm (0.12 ~ 0.20 in) 2.Remove: Seat Fuel tank side panel (right) Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”.
Page 75: Speed Limiter Adjustment
THROTTLE LEVER FREE PLAY ADJUSTMENT/ INSP SPEED LIMITER ADJUSTMENT Tighten the locknut 5. Push in the adjuster cover 4. WARNING After adjusting the free play, turn the handle- bar to the right and left to make sure that the engine idling speed does not increase. ********************************* 4.Install: Fuel tank side panel (right)
Page 76: Starter Lever Free Play Adjustment
SPEED LIMITER ADJUSTMENT/ INSP STARTER LEVER FREE PLAY ADJUSTMENT Speed limiter length is Turning in decreased. Speed limiter length is Turning out increased. Tighten the locknut. WARNING Particularly for a beginner rider, the speed limiter should be screwed in completely. Screw it out little by little as their riding technique improves.
Page 77: Spark Plug Inspection
STARTER LEVER FREE PLAY ADJUSTMENT/ INSP SPARK PLUG INSPECTION Turning in Free play increased. Turning out Free play decreased. Tighten the locknut 2. Push in the adjuster cover 1. WARNING After adjusting the free play, turn the han- dlebar to right and left, and make sure that the engine idling speed does not increase.
Page 78: Ignition Timing Check
SPARK PLUG INSPECTION/ INSP IGNITION TIMING CHECK 6.Measure: Plug gap a Use a wire gauge or feeler gauge. Out of specification → Regap. Spark plug gap: 0.6 ~ 0.7 mm (0.024 ~ 0.028 in) 7.Tighten: Spark plug 18 Nm (1.8 m • kg, 13 ft • lb) NOTE: Before installing a spark plug, clean the gasket surface and plug surface.
Page 79: Compression Pressure Measurement
IGNITION TIMING CHECK/ INSP COMPRESSION PRESSURE MEASUREMENT 3.Check: Ignition timing ********************************* Checking steps: Warm up the engine and keep it at the specified speed. Engine speed: 1,450 ~ 1,550 r/min Remove the recoil starter 1. Remove the timing plug 2. Visually check the stationary pointer 3 to verify it is within the required firing range 4 indicated on the flywheel.
Page 80 INSP COMPRESSION PRESSURE MEASUREMENT 1.Check: Valve clearance Out of specification → Adjust. Refer to “VALVE CLEARANCE ADJUST- MENT”. 2.Start the engine and let it warm up for several minutes. 3.Stop the engine. 4.Remove: Seat Fuel tank side panel (right) Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”.
Page 81: Engine Oil Level Inspection
COMPRESSION PRESSURE MEASUREMENT/ INSP ENGINE OIL LEVEL INSPECTION Compression pressure (at sea level): Standard: 1,400 kPa (14 kg/cm , 203 psi) Minimum: 1,218 kPa (12.2 kg/cm , 177 psi) Maximum: 1,568 kPa (15.7 kg/cm , 227 psi) ********************************* Measurement steps: Crank over the engine with the electric starter (be sure the battery is fully charged) with the throttle wide-open until...
Page 82: Engine Oil Replacement
ENGINE OIL LEVEL INSPECTION/ INSP ENGINE OIL REPLACEMENT NOTE: Recommended oil classification: 0° 10° 30° 50° 70° 90° 110°F API Service “SE”, “SF” type or equivalent YAMALUBE 4 (20W40) or SAE 20W40 (e.g. “SF–SE–CC”, “SF–SE–SD” etc.) YAMALUBE 4 (10W30) or SAE 10W30 SAE 5W30 CAUTION: Do not allow foreign material to enter the...
Page 83 INSP ENGINE OIL REPLACEMENT 4.Remove: Engine oil filler plug (dipstick) 1 Engine oil drain bolt 2 Drain the crankcase of its oil. 5.If the oil filter cartridge is also to be replaced, perform the following proce- dure. ********************************* Replacement steps: Remove the oil filter cartridge 1 with an oil filter wrench 2.
Page 84 INSP ENGINE OIL REPLACEMENT 7.Fill: Crankcase Refer to “ENGINE OIL LEVEL INSPEC- TION”. Oil quantity: Periodic oil change: 2.3 L (2.0 Imp qt, 2.4 US qt) With oil filter replacement: 2.4 L (2.1 Imp qt, 2.5 US qt) Total amount: 2.6 L (2.3 Imp qt, 2.7 US qt) 8.Install: Engine oil filler plug...
Page 85: Air Filter Cleaning
INSP AIR FILTER CLEANING AIR FILTER CLEANING NOTE: There is a check hose 1 at the bottom of the air filter case. If dust and/or water col- lects in this hose, clean the air filter element and air filter case. 1.Remove: Seat Fuel tank cover...
Page 86 INSP AIR FILTER CLEANING 6.Clean: Air filter element ********************************* Cleaning steps: Wash the element gently, but thoroughly in solvent. WARNING Use a cleaning solvent which is designed to clean parts only. Never use gasoline or low flash point solvents as they may cause a fire or explosion.
Page 87: Coolant Level Inspection
INSP COOLANT LEVEL INSPECTION COOLANT LEVEL INSPECTION 1.Place the machine on a level surface. 2.Remove: Seat Fuel tank side panel (left) 3.Inspect: Coolant level The coolant level should be between the minimum level mark a and maximum level mark b. Below the minimum level mark →...
Page 88: Coolant Replacement
INSP COOLANT REPLACEMENT COOLANT REPLACEMENT 1.Remove: Seat Fuel tank side panel (left) Engine side cover Front carrier Front fender Refer to “SEAT, CARPIERS, FENDERS AND FUEL TANK”. Left footrest board Refer to “FOOTREST BOARDS”. 2.Remove: Engine skid plate (rear) 1 3.Remove: Plastic band 1 Coolant reservoir bolts 2...
Page 89 INSP COOLANT REPLACEMENT 8.Remove: Radiator cap 1 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 90 INSP COOLANT REPLACEMENT 13.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 1.1 L (0.97 lmp qt, 1.16 US qt) Coolant reservoir capacity 0.25 L (0.22 lmp qt, 0.26 US qt)
Page 91 INSP COOLANT REPLACEMENT 15.Fill: Coolant reservoir (with the recommended coolant to the maximum level mark a) 16.Install: Coolant reservoir cap 17.Start the engine, warm it up for several minutes, and then turn it off. 18.Inspect: Coolant level Refer to “CHECKING THE COOLANT LEVEL”.
Page 92: Coolant Temperature Indicator Light Check
COOLANT TEMPERATURE INDICATOR LIGHT CHECK/ INSP V-BELT INSPECTION COOLANT TEMPERATURE INDICATOR LIGHT CHECK 1 Coolant temperature indicator light V-BELT INSPECTION 1.Remove: Right footrest board Crankcase cover (right) Refer to “PRIMARY AND SECONDARY SHEAVES” in CHAPTER 4. 2.Inspect: V-belt 1 Cracks/wear/scaling/chipping → Replace. Oil/grease →...
Page 93 INSP V-BELT INSPECTION 4.Replace: V-belt ********************************* Replacing steps: Install the bolts 1 (90101-06016) into the secondary fixed sheave hold. NOTE: Tightening the bolts 1 will push the sec- ondary sliding sheave away, causing the gap between the secondary fixed and slid- ing sheaves to widen.
Page 94: Chassis
FRONT BRAKE ADJUSTMENT/ INSP REAR BRAKE ADJUSTMENT CHASSIS FRONT BRAKE ADJUSTMENT 1.Check: Brake lever free play a Out of specification → Bleed the front brake system. Refer to “AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)”. Free play: 0 mm (0 in) (at brake lever end) REAR BRAKE ADJUSTMENT WARNING Always adjust both the brake pedal and the...
Page 95 INSP REAR BRAKE ADJUSTMENT 3.Check: Rear brake pedal height a Out of specification → Adjust. Rear brake pedal height: 53 ~ 60 mm (2.09 ~ 2.36 in) 4.Adjust: Rear brake lever free play Rear brake pedal height ********************************* Adjustment steps: Loosen the locknut (handlebar) 1 and fully screw in the brake lever cable adjuster (handlebar) 2 until the clearance...
Page 96 INSP REAR BRAKE ADJUSTMENT Loosen the locknut 6. Pull up the brake outer cable and turn the brake cable adjusting (nut) 7 until the clearance c is within the specified limits. Clearance c: 1 mm (0.04 in) NOTE: Make sure the pin 8 is all the way to the right of the link plate hole.
Page 97: Brake Fluid Level Inspection
INSP BRAKE FLUID LEVEL INSPECTION BRAKE FLUID LEVEL INSPECTION 1.Place the machine on a level surface. NOTE: When inspecting the brake fluid level, make sure that the top of the brake fluid reservoir top is horizontal. 2.Remove: (rear brake) Front carrier Front fender panel Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”.
Page 98: Front Brake Pad Inspection
FRONT BRAKE PAD INSPECTION/REAR BRAKE PAD INSP INSPECTION/BRAKE HOSE INSPECTION FRONT BRAKE PAD INSPECTION 1.Remove: Front wheels 2.Inspect: Brake pad Wear indicators 1 almost touch the brake disc → Replace the brake pads as a set. Refer to “FRONT AND REAR BRAKES” in CHAPTER 8.
Page 99: Brake Hose Inspection
BRAKE HOSE INSPECTION/ INSP AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) 2.Inspect: Front brake hoses 1 Rear brake hoses 2 Cracks/wear/damage → Replace. 3.Check: Brake hose clamp Loosen → Tighten. 4.Hold the machine in an upright position and apply the front or rear brake. 5.Check: Brake hoses Active the brake lever several times.
Page 100 INSP AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) b. Install the diaphragm. Be careful not to Å spill any fluid or allow the reservoir to overflow. c. Connect the clear plastic hose 1 tightly to the caliper bleed screw 2. Å Front ı...
Page 101: Select Lever Control Cable And Shift Rod Adjustment
SELECT LEVER CONTROL CABLE AND INSP SHIFT ROD ADJUSTMENT SELECT LEVER CONTROL CABLE AND SHIFT ROD ADJUSTMENT 1 NEUTRAL 2 HIGH 3 LOW 4 REVERSE 5 PARK 6 Control cable 7 Select lever shift rod WARNING Before moving the select lever, bring the machine to a complete stop and return the throttle lever to its closed position.
Page 102: Final Gear Oil Level Inspection
SELECT LEVER CONTROL CABLE AND SHIFT ROD INSP ADJUSTMENT/FINAL GEAR OIL LEVEL INSPECTION Check that locknuts 2 are tightened cor- rectly. If the operation of the select lever is incor- rect, adjust the select lever control cable 3 with the adjuster 4. Select lever shift rod: Make sure the select lever is in NEUTRAL.
Page 103: Final Gear Replacement
INSP FINAL GEAR REPLACEMENT FINAL GEAR REPLACEMENT 1.Place the machine on a level surface. 2.Remove: Final gear case protector 1 3.Place a receptacle under the final gear case. 4.Remove: Oil filler bolt Drain plug 1 5.Drain: Final gear oil 6.Install: Drain plug 23 Nm (2.3 m •...
Page 104: Differential Gear Oil Inspection
DIFFERENTIAL GEAR OIL INSPECTION/ INSP DIFFERENTIAL GEAR OIL REPLACEMENT DIFFERENTIAL GEAR OIL INSPECTION 1.Place the machine on a level surface. 2.Remove: Oil filter bolt Oil drain plug 1 3.Drain: Differential gear oil 4.Install: Oil drain plug 10 Nm (1.0 m • kg, 7 ft • lb) 5.Fill: Differential gear oil Recommended oil:...
Page 105: Constant Velocity Joint Dust Boot Inspection
DIFFERENTIAL GEAR OIL REPLACEMENT/ INSP CONSTANT VELOCITY JOINT DUST BOOT INSPECTION/ STEERING SYSTEM INSPECTION 4.Drain: Differential gear oil 5.Install: Drain plug 10 Nm (1.0 m • kg, 7 ft • lb) NOTE: Check the gasket (drain plug). If it is dam- aged, replace it with new one.
Page 106: Steering System Inspection
STEERING SYSTEM INSPECTION/ INSP TOE-IN ADJUSTMENT 3.Check: Tie-rod ends Turn the handlebar to the left and/or right until it stops completely, then move the handlebar from the left to the right slightly. Tie-rod end has any vertical play → Replace the tie-rod end(s). 4.Raise the front end of the machine so that there is no weight on the front wheels.
Page 107 INSP TOE-IN ADJUSTMENT Face the handlebar straight ahead. Measure the width Å between the marks. Rotate the front tires 180˚ until the marks are exactly opposite one another. Measure the width ı between the marks. Calculate the toe-in using the formula given below.
Page 108: Front Shock Absorber Adjustment
FRONT SHOCK ABSORBER ADJUSTMENT/REAR INSP SHOCK ABSORBER ADJUSTMENT/TIRE INSPECTION FRONT SHOCK ABSORBER ADJUSTMENT WARNING Always adjust both front shock absorber spring preload to the same setting. Uneven adjustment can cause poor handling and loss of stability. 1.Adjust: Spring preload Turn the adjuster 1 to increase or decrease the spring preload.
Page 109 INSP TIRE INSPECTION 1)Tire characteristics influence the handling of ATV’s. The tires listed below have been approved by Yamaha Motor Co., Ltd. for this model. If other tire combina- tions are used, they can adversely affect your machine’s handling characteristics and are therefore not recommended.
Page 110 INSP TIRE INSPECTION Pulling load (total weight of trailer and cargo): 500 kg (1,102 lb) Tongue weight (vertical weight on trailer hitch point): 15 kg (33 lb) Be extra careful of the machine balance and stability when towing a trailer. 1.Measure: Tire pressure (cold tire pressure) Out of specification →...
Page 111: Wheel Inspection
Damage → Replace. 2.Check: Cable operation Unsmooth operation → Lubricate or replace. Recommended lubricant: Yamaha chain and cable lube or Engine oil NOTE: Hold the cable end up and apply several drops of lubricant to the cable. 3.Apply: Lithium soap base grease...
Page 112: Levers, Pedal, Etc. Lubrication
INSP LEVERS, PEDAL, ETC. LUBRICATION LEVERS, PEDAL, ETC. LUBRICATION 1.Lubricate the pivoting parts. Recommended lubricant: Yamaha chain and cable lube or Engine oil 3 - 53...
Page 113: Electrical
INSP BATTERY INSPECTION EB305000 ELECTRICAL BATTERY INSPECTION NOTE: Since the MF battery is a sealed type bat- tery, it is not possible to measure the spe- cific gravity of the electrolyte in order to check the charge state of the battery. There- fore the charge of the battery has to be checked by measuring the voltage at the battery terminals.
Page 114 INSP BATTERY INSPECTION Batteries generate explosive hydrogen gas. Always follow these preventive measures: Charge batteries in a well-ventilated area. Keep batteries away from fire, sparks or open flames (e.g., welding equipment, lighted cigarettes, etc.). DO NOT SMOKE when charging or han- dling batteries.
Page 115 INSP BATTERY INSPECTION Check the condition of the battery using the following charts. Example: Open-circuit voltage = 12.0 V Charging time = 6.5 hours Charge condition of the battery = 20 ~ 30% Charging method for MF batteries CAUTION: If it is impossible to set the standard charging current, be careful not to over- charge.
Page 116 INSP BATTERY INSPECTION Charging method using a variable voltage charger 3 - 57...
Page 117 INSP BATTERY INSPECTION Charging method using a constant voltage charger 3 - 58...
Page 118 INSP BATTERY INSPECTION/FUSE INSPECTION 5.Inspect: Battery terminals Dirty → Clean with a wire brush. Poor connection → Correct. NOTE: After cleaning the terminals, apply a light coat of grease. 6.Install: Battery 7.Connect: Battery leads CAUTION: First, connect the positive lead 1, then connect the negative lead 2.
Page 119: Fuse Inspection
INSP FUSE INSPECTION NOTE: Set the tester to the “Ω × 1” position. Pocket tester: P/N. YU-03112, 90890-03112 If the tester indicates o, replace the fuse. ********************************* 3.Replace: Blown fuse ********************************* Replacement steps: Turn off the ignition. Install a new fuse of the proper amperage. Turn on switches to verify operation of the related electrical devices.
Page 120: Headlight Beam Adjustment
HEADLIGHT BEAM ADJUSTMENT/ INSP HEADLIGHT BULB REPLACEMENT HEADLIGHT BEAM ADJUSTMENT 1.Adjust: Headlight beam (vertically) Turn the adjuster 1 in or out. Turning in Headlight beam raised. Turning out Headlight beam lowered. HEADLIGHT BULB REPLACEMENT 1.Remove: Front carrier Front fender panel Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”.
Page 121 INSP HEADLIGHT BULB REPLACEMENT 5.Install: Bulb Secure the new bulb with the headlight unit. CAUTION: Avoid touching the glass part of the bulb. Keep it free from oil; otherwise, the trans- parency of the glass, life of the bulb, and luminous flux will be adversely affected.
Page 123 CHAPTER 4. ENGINE ENGINE REMOVAL ..................4-1 AIR DUCTS, MUFFLER AND EXHAUST PIPE ........4-1 SELECT LEVER UNIT AND COOLANT RESERVOIR ......4-2 HOSES AND LEADS ................4-3 ENGINE MOUNTING BOLTS ...............4-4 ENGINE INSTALLATION ..............4-6 CYLINDER HEAD ..................4-7 CYLINDER HEAD REMOVAL ..............4-9 TAPPET COVER INSPECTION ............4-10 TIMING CHAIN TENSIONER INSPECTION ........4-10 CAMSHAFT SPROCKET INSPECTION ..........4-10 CYLINDER HEAD INSPECTION ............4-11...
Page 124 PRIMARY AND SECONDARY SHEAVES ..........4-42 PRIMARY SHEAVE ................4-44 SECONDARY SHEAVE ...............4-45 PRIMARY AND SECONDARY SHEAVES REMOVAL ......4-46 SECONDARY SHEAVE DISASSEMBLY ..........4-46 PRIMARY SHEAVE INSPECTION ............4-47 SECONDARY SHEAVE INSPECTION ..........4-47 PRIMARY SHEAVE ASSEMBLY ............4-48 SECONDARY SHEAVE ASSEMBLY ..........4-48 PRIMARY AND SECONDARY SHEAVES INSTALLATION ....4-50 CLUTCH .......................4-51 CLUTCH REMOVAL ................4-53 CLUTCH INSPECTION ................4-53...
Page 125 MIDDLE GEAR ....................4-75 MIDDLE DRIVE SHAFT ...............4-75 MIDDLE DRIVEN SHAFT ..............4-76 MIDDLE DRIVE SHAFT REMOVAL ............4-78 MIDDLE DRIVEN SHAFT REMOVAL ..........4-78 INSPECTION ..................4-80 MIDDLE DRIVE AND DRIVEN GEAR SHIM SELECTION ....4-81 MIDDLE DRIVEN SHAFT INSTALLATION .........4-84 MIDDLE DRIVE SHAFT INSTALLATION ..........4-86 GEAR LASH MEASUREMENT ............4-86...
Page 127: Chapter 4. Engine
ENGINE REMOVAL ENGINE ENGINE REMOVAL AIR DUCTS, MUFFLER AND EXHAUST PIPE Order Job name/Part name Q’ty Remarks Air ducts, muffler and exhaust pipe Remove the parts in the order below. removal Engine oil Refer to “ENGINE OIL REPLACEMENT” in CHAPTER 3. Front and rear fender/footrest Refer to “SEAT, CARRIERS, FENDERS boards...
Page 128: Select Lever Unit And Coolant Reservoir
ENGINE REMOVAL SELECT LEVER UNIT AND COOLANT RESERVOIR Order Job name/Part name Q’ty Remarks Select lever unit and coolant Remove the parts in the order below. reservoir removal Shift arm Select lever shift rod Select lever unit Coolant reservoir breather hose Coolant reservoir hose Coolant reservoir For installation, reverse the removal...
Page 129: Hoses And Leads
ENGINE REMOVAL HOSES AND LEADS Order Job name/Part name Q’ty Remarks Hoses and leads removal Remove the parts in the order below. Water pump inlet hose Refer to “WATER PUMP” in CHAPTER 5. Cylinder head breather hose Spark plug lead Thermo switch lead Starter motor lead CDI magneto lead coupler...
Page 130: Engine Mounting Bolts
ENGINE REMOVAL ENGINE MOUNTING BOLTS Order Job name/Part name Q’ty Remarks Engine mounting bolt removal Remove the parts in the order below. Rear wheels Refer to “FRONT AND REAR WHEELS” in CHAPTER 8. Swingarm Refer to “REAR SHOCK ABSORBER AND SWINGARM” in CHAPTER 8. Engine mounting bolt (rear-lower)/ Engine mounting bolt (rear-upper)/ CAUTION:...
Page 131 ENGINE REMOVAL Order Job name/Part name Q’ty Remarks Engine assembly NOTE: Remove the engine assembly from the left side of the machine. For installation, reverse the removal procedure. 4 - 5...
Page 132: Engine Installation
ENGINE REMOVAL ENGINE INSTALLATION 1.Install: Engine bracket (front upper) 1 Engine mount bolt (front upper)/nut 2 Engine bracket bolt (front upper) 3 Engine bracket (front lower) 4 Engine mount bolt (front lower) 5 Engine bracket bolt (front lower) 6 Engine mount bolt (rear upper)/nut 7 Engine mount bolt (rear lower)/nut 8 NOTE: Do not fully tighten the bolts and nuts.
Page 133: Cylinder Head
CYLINDER HEAD CYLINDER HEAD Order Job name/Part name Q’ty Remarks Cylinder head removal Remove the parts in the order below. Fuel tank/rubber cover Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK” in CHAPTER 3. Front fender/air filter case Air duct assembly 1 Refer to “ENGINE REMOVAL”.
Page 134 CYLINDER HEAD Order Job name/Part name Q’ty Remarks Cylinder head breather hose Camshaft sprocket cover/O-ring Tappet cover/O-ring Thermo switch lead Disconnect. Timing chain tensioner cap bolt Timing chain tensioner/gasket Refer to “CYLINDER HEAD REMOVAL/ INSTALLATION”. Camshaft sprocket Cylinder head Cylinder head gasket Dowel pin O-ring For installation, reverse the removal...
Page 135: Cylinder Head Removal
CYLINDER HEAD CYLINDER HEAD REMOVAL 1.Align: “T” mark (with stationary pointer) ********************************* Checking steps: Turn the crankshaft counterclockwise with a wrench. Align the “T” mark 1 on the rotor with the stationary pointer 2 on the crankcase cover. When the “T” mark is aligned with the stationary pointer, the piston is at the Top Dead Center (T.D.C.).
Page 136: Tappet Cover Inspection
CYLINDER HEAD NOTE: Fasten a safety wire to the timing chain to prevent it from falling into the crankcase. When removing the camshaft sprocket, it is not necessary to separate the timing chain. 5.Remove: Cylinder head NOTE: Loosen the 6 mm bolts first. Working in a crisscross pattern, loosen each 10 mm bolt 1/4 of a turn.
Page 137: Cylinder Head Inspection
CYLINDER HEAD CYLINDER HEAD INSPECTION 1.Eliminate: Carbon deposits (from the combustion chambers) Use a rounded scraper. NOTE: Do not use a sharp instrument to avoid damaging or scratching: Spark plug threads Valve seats 2.Inspect: Cylinder head Scratches/damage → Replace. Cylinder head water jacket Mineral deposits/rust →...
Page 138: Cylinder Head Installation
CYLINDER HEAD CYLINDER HEAD INSTALLATION 1.Install: Cylinder head Bolt (M10) 40 Nm (4.0 m • kg, 29 ft • lb) Bolt (M6) 10 Nm (1.0 m • kg, 7.2 ft • lb) NOTE: Lubricate the washer with engine oil. Tighten the bolts (M10) in two stages and a crisscross pattern.
Page 139 CYLINDER HEAD NOTE: Be sure the punch mark 5 on the camshaft sprocket is aligned with the match mark 2 on the cylinder head. Force the camshaft clockwise and coun- terclockwise to remove timing chain slack. Insert a screwdriver into the timing chain tensioner hole and push the timing chain guide inward.
Page 140 CYLINDER HEAD 4.Tighten: Camshaft sprocket bolt 1 60 Nm (6.0 m • kg, 43 ft • lb) NOTE: Use the rotor holder 2 to hold the starter pulley. Rotor holder: P/N. YU-01235, 90890-01235 5.Check: Camshaft sprocket punch mark Rotor “T” mark Out of alignment →...
Page 141: Camshaft, Rocker Arms And Valves
CAMSHAFT, ROCKER ARMS AND VALVES CAMSHAFT, ROCKER ARMS AND VALVES Order Job name/Part name Q’ty Remarks Camshaft, rocker arms and valves Remove the parts in the order below. removal Intake manifold/O-ring Thermo switch Oil check bolt Lock washer/bearing retainer Camshaft Refer to “CAMSHAFT AND ROCKER Rocker arm shaft/O-ring ARM REMOVAL/INSTALLATION”.
Page 142 CAMSHAFT, ROCKER ARMS AND VALVES Order Job name/Part name Q’ty Remarks Valve spring (inner) Valve (intake) Refer to “VALVE AND VALVE SPRING Valve (exhaust) REMOVAL/INSTALLATION”. Valve stem seal Valve spring seat For installation, reverse the removal procedure. 4 - 16...
Page 143: Camshaft And Rocker Arm Removal
CAMSHAFT, ROCKER ARMS AND VALVES CAMSHAFT AND ROCKER ARM REMOVAL 1.Remove: Camshaft 1 NOTE: Screw in a M10 bolt 2 into the thread hole on the camshaft, and pull out the camshaft. 2.Remove: Rocker arm shafts (intake and exhaust) 1 Rocker arms 2 NOTE: Use a slide hammer 3 to remove the rocker...
Page 144: Camshaft Inspection
CAMSHAFT, ROCKER ARMS AND VALVES 2.Remove: Valve cotters NOTE: Attach a valve spring compressor 1 between the valve spring retainer and the cylinder head to remove the valve cotters. Valve spring compressor: P/N. YM-04019, 90890-04019 CAMSHAFT INSPECTION 1.Inspect: Cam lobes Pitting/scratches/blue discoloration →...
Page 145: Valve And Valve Spring Inspection
CAMSHAFT, ROCKER ARMS AND VALVES Inspect the surface of the rocker arm shafts. Blue discoloration/pitting/scratches → Replace/check lubrication. Measure the inside diameter a of the rocker arm holes. Out of specification → Replace. Rocker arm inside diameter: 12.000 ~ 12.018 mm (0.4724 ~ 0.4731 in) Measure the outside diameter b of the rocker arm shafts.
Page 146 CAMSHAFT, ROCKER ARMS AND VALVES 2.Replace: Valve guide ********************************* Replacement steps: NOTE: To ease guide removal, installation and to maintain correct fit, heat the cylinder head to 100 ˚C (212 ˚F) in an oven. Remove the valve guide using a valve guide remover 1.
Page 147 CAMSHAFT, ROCKER ARMS AND VALVES 5.Measure: Runout (valve stem) Out of specification → Replace. Runout limit: 0.01 mm (0.0004 in) NOTE: When installing a new valve always replace the guide. If the valve is removed or replaced always replace the oil seal. 6.Eliminate: Carbon deposits (from the valve face and valve seat)
Page 148 CAMSHAFT, ROCKER ARMS AND VALVES 9.Lap: Valve face Valve seat NOTE: After refacing the valve seat or replacing the valve and valve guide, the valve seat and valve face should be lapped. ********************************* Lapping steps: Apply a coarse lapping compound to the valve face.
Page 149 CAMSHAFT, ROCKER ARMS AND VALVES 10.Measure: Valve spring free length a Out of specification → Replace. Free length (valve spring): Inner: 39.9 mm (1.57 in) <Limit>: 37.9 mm (1.49 in) Outer: 43.27 mm (1.71 in) <Limit>: 41.27 mm (1.62 in) 11.Measure: Compressed spring force a Out of specification →...
Page 150: Valve And Valve Spring Installation
CAMSHAFT, ROCKER ARMS AND VALVES VALVE AND VALVE SPRING INSTALLATION 1.Apply: Molybdenum disulfide oil (onto the valve stem and valve stem seal) 2.Install: Valve spring seats Valve stem seals Valves Valve springs (inner and outer) Valve spring retainers NOTE: Install the valve springs with the larger pitch a facing upwards.
Page 151: Camshaft And Rocker Arm Installation
CAMSHAFT, ROCKER ARMS AND VALVES CAMSHAFT AND ROCKER ARM INSTALLATION 1.Apply: Engine oil (onto the rocker arm shafts) 2.Install: Rocker arms 1 Rocker arm shafts (intake and exhaust) 2 NOTE: Use a slide hammer bolt 3 to install the rocker arm shaft. 3.Install: Camshaft 1 NOTE:...
Page 152: Cylinder And Piston
CYLINDER AND PISTON CYLINDER AND PISTON Order Job name/Part name Q’ty Remarks Cylinder and piston removal Remove the parts in the order below. Cylinder head Refer to “CYLINDER HEAD”. Water pump outlet hose/pipe Refer to “WATER PUMP” in CHAPTER 5. Cooling water inlet joint Timing chain guide (exhaust) Cylinder/O-ring...
Page 153: Piston Removal
CYLINDER AND PISTON PISTON REMOVAL 1.Remove: Piston pin clips 1 Piston pin 2 Piston 3 NOTE: Before removing piston pin, deburr the clip groove and pin hole area. If the piston pin groove is deburred and the piston pin is still difficult to remove, use the piston pin puller Piston pin puller: P/N.
Page 154 CYLINDER AND PISTON 2.Measure: Piston-to-cylinder clearance ********************************* Measurement steps: 1st step: Measure the cylinder bore “C” with the cylinder bore gauge. NOTE: Measure cylinder bore “C” by taking side- to-side and front-to-back measurements of the cylinder. Then, find the average of the measurements.
Page 155: Piston Ring Inspection
CYLINDER AND PISTON 3rd step: Find the piston-to-cylinder clearance with the following formula. Piston-to-cylinder clearance = Cylinder bore “C” – Piston skirt diameter “P” Piston-to-cylinder clearance: 0.040 ~ 0.065 mm (0.0016 ~ 0.0026 in) <Limit>: 0.15 mm (0.0059 in) If out of specification, rebore or replace the cylinder, and replace the piston and piston rings as a set.
Page 156: Piston Pin Inspection
CYLINDER AND PISTON 3.Measure: Ring end gap Out of specification → Replace. NOTE: You cannot measure the end gap on the expander spacer of the oil control ring. If the oil control ring rails show excessive gap, replace all three rings. End gap Standard Limit...
Page 157: Piston Installation
CYLINDER AND PISTON If out of specification, replace the piston. Piston pin-to-piston clearance: 0.004 ~ 0.022 mm (0.00016 ~ 0.00087 in) <Limit>: 0.07 mm (0.003 in) ********************************* PISTON INSTALLATION 1.Install: Piston rings (onto the piston) NOTE: Be sure to install the piston rings so that the manufacturer’s marks or numbers are located on the upper side of the rings.
Page 158: Cylinder Installation
CYLINDER AND PISTON 4.Lubricate: Piston Piston rings Cylinder NOTE: Apply a liberal coating of engine oil. CYLINDER INSTALLATION 1.Install: Cylinder NOTE: Install the cylinder with one hand while compressing the piston rings with the other hand. CAUTION: Be careful not to damage the timing chain damper during installation.
Page 159: Recoil Starter And Cdi Magneto
RECOIL STARTER AND CDI MAGNETO RECOIL STARTER AND CDI MAGNETO Order Job name/Part name Q’ty Remarks CDI magneto removal Remove the parts in the order below. Engine oil Drain. Refer to “ENGINE OIL REPLACEMENT” in CHAPTER 3. Seat and side panels Refer to “SEAT AND SIDE PANELS”...
Page 160 RECOIL STARTER AND CDI MAGNETO Order Job name/Part name Q’ty Remarks Pickup coil Stator assembly CDI rotor Refer to “CDI MAGNETO REMOVAL/ Starter wheel gear INSTALLATION”. Woodruff key Bearing/washer Starter idle gear shaft Washer/bearing Starter idle gear For installation, reverse the removal procedure.
Page 161 RECOIL STARTER AND CDI MAGNETO Order Job name/Part name Q’ty Remarks Recoil starter disassembly Disassemble the parts in the order below. Starter handle Friction plate Pawl spring Refer to “RECOIL STARTER DISAS- Drive pawl SEMBLY/ASSEMBLY”. Spring Sheave drum Rope Coil spring For assembly, reverse the disassembly procedure.
Page 162: Recoil Starter Disassembly
RECOIL STARTER AND CDI MAGNETO CDI MAGNETO REMOVAL 1.Remove: Starter pulley 1 NOTE: Use the rotor holder 2 to hold the starter pulley. Rotor holder: P/N. YU-01235, 90890-01235 2.Remove: Crankcase cover (left) Gasket Dowel pins NOTE: Working in a crisscross pattern, loosen each bolt 1/4 of a turn.
Page 163: Starter Clutch Inspection
RECOIL STARTER AND CDI MAGNETO STARTER CLUTCH INSPECTION 1.Inspect: Starter one-way clutch 1 Cracks/damage → Replace. Bolts 2 (starter clutch) Loose → Replace with a new one, and clinch the end of the bolt. NOTE: The arrow mark on the starter clutch must face inward, away from the CDI rotor.
Page 164: Starter Pulley Inspection
RECOIL STARTER AND CDI MAGNETO STARTER PULLEY INSPECTION 1.Inspect: Starter pulley Cracks/pitting → Deburr or replace. RECOIL STARTER INSPECTION 1.Inspect: Rope 1 Sheave drum 2 Drive pawl 3 Wear/damage → Replace. Coil spring 4 Pawl spring 5 Spring 6 Fatigue → Replace. RECOIL STARTER ASSEMBLY 1.Install: Sheave drum 1...
Page 165: Cdi Magneto Installation
Untie the knot 3 after making a knot 4 above the handle. CDI MAGNETO INSTALLATION 1.Apply: ® Sealant (Quick Gasket (into the slit) ® Sealant (Quick Gasket P/N. ACC-11001-05-01 ® Yamaha bond No. 1215 P/N. 90890-85505 4 - 39...
Page 166 RECOIL STARTER AND CDI MAGNETO 2.Install: Woodruff key CDI rotor NOTE: Before installing the rotor, clean the out- side of the crankshaft and the inside of the rotor. After installing the rotor, check that the rotor rotates smoothly. If not, reinstall the key and rotor.
Page 167 RECOIL STARTER AND CDI MAGNETO 5.Install: Select lever unit Select lever shift rod NOTE: Before installing the select lever shift rod, make sure that the select lever and shift cam is in the NEUTRAL position. 6.Adjust: Select lever shift rod Refer “SELECT LEVER...
Page 168: Primary And Secondary Sheaves
PRIMARY AND SECONDARY SHEAVES PRIMARY AND SECONDARY SHEAVES Order Job name/Part name Q’ty Remarks Primary and secondary sheave Remove the parts in the order below. removal Front fender Refer to “SEAT, CARRIERS, FENDERS Rear fender AND FUEL TANK” in CHAPTER 3. Right footrest boards Exhaust pipe stay 1 Exhaust pipe stay 2...
Page 169 PRIMARY AND SECONDARY SHEAVES Order Job name/Part name Q’ty Remarks Primary fixed sheave Refer to “PRIMARY AND SECONDARY SHEAVES REMOVAL/INSTALLATION”. Secondary sheave assembly For installation, reverse the removal procedure. 4 - 43...
Page 170: Primary Sheave
PRIMARY AND SECONDARY SHEAVES PRIMARY SHEAVE Order Job name/Part name Q’ty Remarks Primary sheave disassembly Disassemble the parts in the order below. Primary pulley sheave cap Primary pulley slider Spacer Primary pulley cam Refer to “PRIMARY SHEAVE ASSEM- Primary pulley weight BLY”.
Page 171: Secondary Sheave
PRIMARY AND SECONDARY SHEAVES SECONDARY SHEAVE Order Job name/Part name Q’ty Remarks Secondary sheave disassembly Disassemble the parts in the order below. Spring seat Compression spring Spring seat Refer to “SECONDARY SHEAVE DIS- ASSEMBLY/ASSEMBLY”. Guide pin Secondary sliding sheave O-ring Secondary fixed sheave Oil seal Oil seal...
Page 172: Primary And Secondary Sheaves Removal
PRIMARY AND SECONDARY SHEAVES PRIMARY AND SECONDARY SHEAVES REMOVAL 1.Loosen: Nut (secondary sheave) 1 Nut (primary sheave) 2 NOTE: Use the sheave holder 3 to hold the pri- mary sheave. First, loosen the nut (secondary sheave) 2, then loosen the nut (primary sheave) 1. Sheave holder: P/N.
Page 173: Primary Sheave Inspection
PRIMARY AND SECONDARY SHEAVES PRIMARY SHEAVE INSPECTION 1.Inspect: Weight outside diameter a Out of specification → Replace the weight. Weight outside diameter: 30 mm (1.18 in) <Limit>: 29.5 mm (1.16 in) 2.Inspect: Primary puller slider Primary sliding sheave splines Wear/cracks/damage → Replace. Spacer Primary puller cam Cracks/damage →...
Page 174: Primary Sheave Assembly
PRIMARY AND SECONDARY SHEAVES PRIMARY SHEAVE ASSEMBLY 1.Clean: Primary sliding sheave face 1 Primary fixed sheave face 2 Collar 3 Weight 4 Primary sliding sheave cam face 2.Install: Weight 1 NOTE: Apply Shell SSG-2656-2 grease (120 g) to the whole outer surface of the weight and install.
Page 175 PRIMARY AND SECONDARY SHEAVES 3.Apply: ® BEL-RAY assembly lube (to the guide pin sliding groove 1, and o- ring 2 4.Install: Spring seat Compression spring Spring seat ********************************* Installing steps: Attach the sheave fixed block, locknut wrench and sheave spring compressor to the secondary sheave assembly.
Page 176: Primary And Secondary Sheaves Installation
PRIMARY AND SECONDARY SHEAVES PRIMARY AND SECONDARY SHEAVES INSTALLATION 1.Install: Secondary sheave assembly V-belt Primary sheave assembly NOTE: Tightening the bolts 1 will push the sec- ondary sliding sheave away, causing the gap between the secondary fixed and slid- ing sheaves to widen. Install the V-belt so that its arrow faces the direction show in the illustration.
Page 177: Clutch
CLUTCH CLUTCH Order Job name/Part name Q’ty Remarks Clutch removal Remove the parts in the order below. Primary and secondary sheaves Refer to “PRIMARY AND SECONDARY SHEAVES”. Cover Clutch housing assembly Gasket/dowel pin Refer to “CLUTCH REMOVAL/INSTAL- LATION”. One-way clutch bearing Clutch carrier assembly For installation, reverse the removal procedure.
Page 178 CLUTCH Order Job name/Part name Q’ty Remarks Clutch housing disassembly Disassemble the parts in the order below. Oil seal Circlip Bearing housing Circlip Bearing Circlip Bearing Clutch housing For assembly, reverse the disassembly procedure. 4 - 52...
Page 179: Clutch Removal
CLUTCH CLUTCH REMOVAL 1.Remove: Clutch housing assembly Gasket Dowel pins NOTE: Working in crisscross pattern, loosen each bolt 1/4 of a turn. Remove them after all of them are loosened. 2.Straighten: Punched portion of the nut 1. 3.Remove: Nut 1 NOTE: Use a clutch holding tool 2 to hold the clutch carrier assembly.
Page 180: Clutch Installation
CLUTCH 2.Inspect: Clutch shoe Heat damage → Replace. 3.Measure: Clutch shoe thickness Out of specification → Replace. Clutch shoe thickness: 1.5 mm (0.06 in) Clutch shoe wear limit a: 1.0 mm (0.04 in) CLUTCH INSTALLATION 1.Install: Collar Clutch carrier assembly Nut 1 140 Nm (14.0 m •...
Page 181 CLUTCH 4.Install: Dowel pins Gasket Clutch housing assembly 10 Nm (1.0 m • kg, 7.2 ft • lb) NOTE: Tighten the bolts in stages, using a criss- cross pattern. After tightening the bolts, check that the clutch housing assembly to counterclock- wise rotates smoothly.
Page 182: Crankcase
CRANKCASE CRANKCASE STARTER MOTOR, TIMING CHAIN AND OIL FILTER Order Job name/Part name Q’ty Remarks Starter motor, timing chain and oil Remove the parts in the order below. filter removal Engine assembly Refer to “ENGINE REMOVAL”. Cylinder head Refer to “CYLINDER HEAD”. Cylinder and piston Refer to “CYLINDER AND PISTON”.
Page 183: Crankcase
CRANKCASE Order Job name/Part name Q’ty Remarks Oil filter Speed sensor Shift cam stopper Neutral switch Park switch Reverse switch Oil filler cap Bearing cover/gasket Oil delivery pipe Drain plug/O-ring Compression spring Oil strainer For installation, reverse the removal procedure. 4 - 57...
Page 184 CRANKCASE CRANKCASE Order Job name/Part name Q’ty Remarks Crankcase separation Remove the parts in the order below. Shift lever cover/gasket Refer to “SHIFT LEVER INSTALLA- Shift lever 1/O-ring TION”. Shift lever 2 assembly Crankcase (left) Refer to “CRANKCASE SEPARATION/ Dowel pin ASSEMBLY”.
Page 185: Crankcase Bearing
CRANKCASE CRANKCASE BEARING Order Job name/Part name Q’ty Remarks Crankcase bearing removal Remove the parts in the order below. Crankshaft and oil pump Refer to “CRANKSHAFT AND OIL PUMP”. Transmission Refer to “TRANSMISSION”. Middle drive/driven shaft Refer to “MIDDLE GEAR”. Oil seal Bearing retainer Bearing...
Page 186: Oil Pump Drive Gear Removal
CRANKCASE OIL PUMP DRIVE GEAR REMOVAL 1.Straighten: Lock washer tab 2.Remove: Oil pump drive gear nut ********************************* Removal steps: Temporaly install clutch carrier assembly 1. Hold the clutch carrier assembly with a clutch holding tool 2 and loosen the oil pump drive gear nut.
Page 187: Timing Chain And Guide Inspection
CRANKCASE Remove the left crankcase. CAUTION: Use a soft hammer to tap on one side of the crankcase. Tap only on reinforced por- tions of the crankcase. Do not tap on the crankcase mating surfaces. Work slowly and carefully. Make sure that the crankcase halves separate evenly.
Page 188: Crankcase Inspection
(to the mating surfaces of both case halves) ® Sealant (Quick Gasket P/N. ACC-11001-05-01 Yamaha bond No. 1215: P/N. 90890-85505 2.Install: Dowel pin 2 3.Fit the left crankcase onto the right case. Tap lightly on the case with a soft hammer.
Page 189: Shift Lever Installation
CRANKCASE 4.Tighten: Å Crankcase bolts (follow the proper tightening sequence) 10 Nm (1.0 m • kg, 7.2 ft • lb) Å Right crankcase ı Left crankcase NOTE: Tighten the bolts in stages, using a criss- cross pattern. ı 5.Apply: 4-stroke engine oil (to the crank pin, bearing and oil delivery hole) 6.Check:...
Page 190: Oil Pump Drive Gear Installation
CRANKCASE OIL PUMP DRIVE GEAR INSTALLATION 1.Install: Straight key Oil pump drive gear Lock washer Oil pump drive gear nut 2.Tighten: Oil pump drive gear nut 50 Nm (5.0 m • kg, 36 ft • lb) ********************************* Tightening steps: Temporary install clutch carrier...
Page 191: Crankshaft And Oil Pump
CRANKSHAFT AND OIL PUMP CRANKSHAFT AND OIL PUMP Order Job name/Part name Q’ty Remarks Crankshaft and oil pump removal Remove the parts in the order below. Crankcase separation Refer to “CRANKCASE”. Washer/circlip Oil pump assembly/gasket Balancer Refer to “CRANKSHAFT REMOVAL/ Crankshaft seal CRANKSHAFT AND BALANCER INSTALLATION”.
Page 192: Oil Pump
CRANKSHAFT AND OIL PUMP OIL PUMP Order Job name/Part name Q’ty Remarks Oil pump disassembly Disassemble the parts in the order below. Rotor cover Shaft Inner rotor Outer rotor Oil pump housing For assembly, reverse the disassembly procedure. 4 - 66...
Page 193: Crankshaft Removal
CRANKSHAFT AND OIL PUMP CRANKSHAFT REMOVAL 1.Remove: Crakshaft seal 1 NOTE: Mark a note of the pasition of each crank- shaft seal so that they can be installed in the correct place and in the correct direc- tion. 2.Remove: Crankshaft Use a crankcase separating tool 1.
Page 194: Crankshaft Inspection
CRANKSHAFT AND OIL PUMP 3.Check: Oil pump operation Unsmooth → Repeat steps #1 and #2 or replace the defective parts. CRANKSHAFT INSPECTION 1.Measure: Crank width A Out of specification → Replace the crank- shaft. Crank width: 62.95 ~ 63.00 mm (2.478 ~ 2.480 in) Side clearance D Out of specification →...
Page 195: Crankshaft And Balancer Installation
CRANKSHAFT AND OIL PUMP CRANKSHAFT AND BALANCER INSTALLATION 1.Install: Crankshaft Crankshaft installer set 1: P/N. YU-90050 Buffer boss installer set 2: P/N. 90890-04088 Adapter #11 3: P/N. YM-33279 Crank pot spacer 4: P/N. YM-90070-A, 90890-04060 NOTE: Hold the connecting rod at the Top Dead Center (T.D.C.) with one hand while turning the nut of the installing tool with the other.
Page 196: Transmission
TRANSMISSION TRANSMISSION Order Job name/Part name Q’ty Remarks Transmission removal Remove the parts in the order below. Crankcase separation Refer to “CRANKCASE”. Driven sprocket Drive sprocket Chain Clutch dog 2 Shift fork “L” Spring Low wheel gear Secondary shaft Middle driven gear Drive axle assembly Guide bar 4 - 70...
Page 197 TRANSMISSION Order Job name/Part name Q’ty Remarks Shift fork “R” Spring Shift cam Stopper wheel Clutch dog 1 High wheel gear Stopper lever Spacer/O-ring For installation, reverse the removal procedure. 4 - 71...
Page 198: Shift Fork Inspection
TRANSMISSION SHIFT FORK INSPECTION 1.Inspect: Shift fork cam follower 1 Shift fork pawl 2 Scoring/bends/wear/damage → Replace. 2.Inspect: Guide bar Roll the guide bar on a flat surface. Bends → Replace. WARNING Do not attempt to straighten a bent guide bar.
Page 199: Transmission Inspection
TRANSMISSION TRANSMISSION INSPECTION 1.Measure: Axle runout Use a centering device and a dial gauge. Out of specification → Replace the bent axle. Runout limit (drive axle): 0.03 mm (0.001 in) 2.Inspect: Gear teeth Blue discoloration/pitting/wear → Replace. Mated dogs Rounded edges/cracks/missing portions →...
Page 200 TRANSMISSION 2.Check: Shift operation Unsmooth operation → Repair. NOTE: Oil each gear and bearing thoroughly. Before assembling the crankcase, be sure that the transmission is in neutral and that the gears turn freely. 4 - 74...
Page 201: Middle Gear
MIDDLE GEAR MIDDLE GEAR MIDDLE DRIVE SHAFT Order Job name/Part name Q’ty Remarks Middle drive shaft removal Remove the parts in the order below. Crankcase separation Refer to “CRANKCASE”. Transmission Refer to “TRANSMISSION”. Bearing housing assembly Refer to “MIDDLE DRIVE SHAFT REMOVAL/INSTALLATION”.
Page 202: Middle Driven Shaft
MIDDLE GEAR MIDDLE DRIVEN SHAFT Order Job name/Part name Q’ty Remarks Middle driven shaft assembly Remove the parts in the order below. Crankcase separation Refer to “CRANKCASE”. Circlip Bearing Refer to “MIDDLE DRIVEN SHAFT Universal joint REMOVAL/INSTALLATION”. Universal joint yoke Bearing housing/O-ring Shim Refer to “MIDDLE DRIVE AND DRIVEN...
Page 203 MIDDLE GEAR Order Job name/Part name Q’ty Remarks Front drive shaft coupling Bearing retainer Middle driven shaft For installation, reverse the removal procedure. 4 - 77...
Page 204: Middle Drive Shaft Removal
MIDDLE GEAR MIDDLE DRIVE SHAFT REMOVAL 1.Straighten: Punched portion of the nut (middle drive pinion gear) 2.Loosen: Nut (middle drive pinion gear) 1 NOTE: Secure the middle drive shaft in the vise with a clean rag. 3.Remove: Nut (middle drive pinion gear) Middle drive pinion gear Shim(s) MIDDLE DRIVEN SHAFT REMOVAL...
Page 205 MIDDLE GEAR 2.Remove: Nut 1 Washer Universal joint yoke NOTE: Use the universal joint holder 2 to hold the universal joint yoke. Universal joint holder: P/N. YM-04062, 90890-04062 3.Remove: Bearing housing assembly 1 ********************************* Bearing housing removal steps: Clean the outside of the middle driven shaft.
Page 206: Inspection
MIDDLE GEAR 5.Remove: Front drive shaft coupling Bearing retainer 1 Bearing 2 NOTE: Attach the ring nut wrench 3. Ring nut wrench: P/N. YM-38404, 90890-01430 CAUTION: The middle driven shaft bearing retainer has left-handed threads. To loosen the retainer turn it clockwise. 6.Remove: Middle drive shaft 1 (with bearing)
Page 207: Middle Drive And Driven Gear Shim Selection
MIDDLE GEAR 4.Inspect: O-ring Damage → Replace. Bearings Pitting/damage → Replace. 5.Check: U-joint movement Roughness → Replace U-joint. MIDDLE DRIVE AND DRIVEN GEAR SHIM SELECTION When the drive and driven gear, bearing housing assembly and/or crankcase replaced, be sure to adjust the gear shim 1. 1.Select: Middle drive gear shim 1 Middle driven gear shim 2...
Page 208 MIDDLE GEAR Example: 1) If the bearing housing is marked “+04”, ..a is 10.54, 2) b is 55 3) If the crankcase (right) is marked “66.03”, ..c is 66.03. 4) Therefore, the shim thickness is 0.47 mm. A = 66.03 – 10.54 – 55 = 0.49 5) Round off hundredths digit and select appropriate shim(s).
Page 209 MIDDLE GEAR Where: d = a numeral (usually a decimal num- ber) on the bearing housing is either added to or subtracted from “76”. e = a numeral (usually a decimal num- ber) on the middle driven pinion gear is either added to or subtracted from “59”.
Page 210: Middle Driven Shaft Installation
MIDDLE GEAR Shims are supplied in the following thick- ness. Middle drive pinion gear shim 0.10 0.40 0.15 0.50 Thickness (mm) 0.20 0.60 0.30 ********************************* MIDDLE DRIVEN SHAFT INSTALLATION 1.Install: Bearing retainer 1 80 Nm (8.0 m • kg, 58 ft • lb) NOTE: Attach the ring nut wrench 2.
Page 211 MIDDLE GEAR Tighten the bearing retainer. CAUTION: The middle driven shaft bearing retainer has left-handed threads. To tighten the retainer turn it counterclockwise. Bearing retainer: 110 Nm (11.0 m • kg, 80 ft • lb) ********************************* 3.Install: Shims 1 Bearing housing NOTE: Install the shims so that the tabs are posi- tioned as shown in the illustration.
Page 212: Middle Drive Shaft Installation
MIDDLE GEAR Install the bearing 1 onto the yoke. CAUTION: Check each bearing. The needles can easily fall out of their races. Slide the yoke back and forth on the bearings; the yoke will not go all the way onto a bearing if a needle is out of place.
Page 213 MIDDLE GEAR Attach the gear lash measurement tool 2 and dial gauge 3. Gear lash measurement tool: P/N. YM-01467, 90890-01467 a 46 mm (1.8 in) Measure the gear lash while rotating the middle driven shaft back and forth. NOTE: Measure the gear lash at 4 positions. Rotate the middle driven gear 90˚...
Page 214 4 - 88...
Page 215 COOL...
Page 216 COOL CHAPTER 5. COOLING SYSTEM RADIATOR .....................5-1 RADIATOR INSPECTION ..............5-3 RADIATOR INSTALLATION ..............5-4 THERMOSTAT ....................5-5 THERMOSTAT INSPECTION ...............5-6 THERMOSTAT INSTALLATION ............5-6 WATER PUMP ....................5-7 WATER PUMP DISASSEMBLY ............5-9 WATER PUMP INSPECTION ..............5-9 WATER PUMP ASSEMBLY ..............5-10...
Page 217 COOL...
Page 218: Chapter 5. Cooling System
COOL RADIATOR COOLING SYSTEM RADIATOR Order Job name/Part name Q’ty Remarks Radiator removal Remove the parts in the order below. Seat and side panels Refer to “SEAT AND SIDE PANELS” in CHAPTER 3. Front carrier, front bumper and front Refer to “FRONT CARRIER, FRONT fender BUMPER AND FRONT FENDER”...
Page 219: Radiator
COOL RADIATOR Order Job name/Part name Q’ty Remarks Radiator inlet hose Disconnect. Radiator outlet hose Disconnect. Radiator Radiator fan Thermo switch For installation, reverse the removal procedure. 5 - 2...
Page 220: Radiator Inspection
COOL RADIATOR RADIATOR INSPECTION 1.Inspect: Radiator fins Obstruction → Clean. Apply compressed air to the rear of the radiator. Damage → Repair or replace. NOTE: Straighten any flattened fins with a thin, flat-head screwdriver. 2.Inspect: Radiator hoses Cracks/damage → Replace. 3.Measure: Radiator cap opening pressure Below the specified pressure →...
Page 221: Radiator Installation
COOL RADIATOR RADIATOR INSTALLATION 1.Fill: Cooling system (with the specified amount of the recom- mended coolant) Refer to “COOLANT REPLACEMENT” in CHAPTER 3. 2.Check: Cooling system Leaks → Repair or replace any faulty part. 5 - 4...
Page 222: Thermostat
COOL THERMOSTAT THERMOSTAT Order Job name/Part name Q’ty Remarks Thermostat removal Remove the parts in the order below. Seat and fuel tank side panel (right) Refer to “SEAT AND SIDE PANELS” in CHAPTER 3. Coolant Drain. Refer to “COOLANT REPLACEMENT” in CHAPTER 3.
Page 223: Thermostat Inspection
COOL THERMOSTAT THERMOSTAT INSPECTION 1.Check: Thermostat 1 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. While stirring the water, observe the ther- mostat and thermometer’s indicated tem- perature.
Page 224: Water Pump
COOL WATER PUMP WATER PUMP Order Job name/Part name Q’ty Remarks Water pump removal Remove the parts in the order below. Seat, fuel tank side panel (left) and Refer to “SEAT AND SIDE PANELS” in engine side cover CHAPTER 3. Left footrest board Refer to “FOOTREST BOARDS”...
Page 225: Water Pump Disassembly
COOL WATER PUMP Order Job name/Part name Q’ty Remarks Water pump disassembly Remove the parts in the order below. Water pump housing cover Gasket Circlip Impeller Rubber damper holder Rubber damper Water pump seal Oil seal Bearing Water pump housing For assembly, reverse the disassembly procedure.
Page 226: Water Pump Inspection
COOL WATER PUMP WATER PUMP DISASSEMBLY 1.Remove: Rubber damper holder 1 Rubber damper 2 (from the impeller, with a thin, flathead screwdriver) NOTE: Do not scratch the impeller shaft. 2.Remove: Water pump seal 1 NOTE: Tap out the water pump seal from the inside of the water pump housing.
Page 227: Water Pump Assembly
COOL WATER PUMP WATER PUMP ASSEMBLY 1.Install: Oil seal 1 (into the water pump housing 2) NOTE: Before installing the oil seal, apply tap water or coolant onto its outer surface. Install the oil seal with a socket 3 that matches its outside diameter.
Page 228 COOL WATER PUMP 4.Measure: Impeller shaft tilt Out of specification → Repeat steps (3) and (4). CAUTION: Make sure that the rubber damper and rub- ber damper holder are flush with the impel- ler. Max. impeller shaft tilt: 0.15 mm (0.006 in) 1 Straightedge 2 Impeller 5 - 11...
Page 229 COOL 5 - 12...
Page 230 CARB...
Page 231 CARB CHAPTER 6. CARBURETION CARBURETOR ....................6-1 CARBURETOR INSPECTION ..............6-4 CARBURETOR ASSEMBLY ..............6-6 FUEL LEVEL ADJUSTMENT ..............6-7...
Page 232 CARB...
Page 233: Chapter 6. Carburetion
CARB CARBURETOR CARBURETION CARBURETOR Order Job name/Part name Q’ty Remarks Carburetor removal Remove the parts in the order below. Seat/fuel tank side panels/fuel tank/ Refer to “SEAT, CARRIERS, FENDERS rubber cover AND FUEL TANK” in CHAPTER 3. Drain hose Starter cable/starter plunger Air vent hose Carburetor assembly Throttle valve cover...
Page 234 CARB CARBURETOR Order Job name/Part name 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 Spring Jet needle set Piston valve Coasting enricher Float chamber Drain screw Float Refer to “CARBURETOR ASSEMBLY”.
Page 235 CARB CARBURETOR Order Job name/Part name Q’ty Remarks Pilot jet Pilot screw set Refer to “CARBURETOR ASSEMBLY”. Main jet Needle jet Refer to “CARBURETOR DISASSEM- BLY/ASSEMBLY”. Starter jet Pilot air jet For assembly, reverse the disassembly procedure. 6 - 3...
Page 236: Carburetor Inspection
CARB CARBURETOR CARBURETOR INSPECTION 1.Inspect: Carburetor body Float chamber Cracks/damage → Replace. Fuel passage Contamination → Clean as indicated. Fuel chamber body Contamination → Clean. ********************************* Cleaning steps: Wash the carburetor in a petroleum based solvent. (Do not use any caustic carburetor clean- ing solution.) Blow out all of the passages and jets with compressed air.
Page 237 CARB CARBURETOR 5.Inspect: Vacuum chamber cover 1 Spring 2 Cracks/damage → Replace. 6.Inspect: Diaphragm (coasting enricher) 1 Spring 2 Cover 3 Tears (diaphragm)/damage → Replace. 7.Inspect: Jet needle 1 Main jet 2 Needle jet 3 Pilot air jet 4 Pilot jet 5 Pilot screw 6 Starter jet 7 Starter plunger 8...
Page 238: Carburetor Assembly
CARB CARBURETOR CARBURETOR ASSEMBLY CAUTION: Before reassembling, wash all of the parts in a clean petroleum based solvent. 1.Install: Pilot screw 1 Pilot screw: 2-1/2 turns out 2.Measure: Float height a Out of specification → Adjust. Float height (F.H.): 13 mm (0.51 in) ********************************* Measurement and adjustment steps: Hold the carburetor in an upside down...
Page 239: Fuel Level Adjustment
CARB CARBURETOR FUEL LEVEL ADJUSTMENT 1.Measure: Fuel level a Out of specification → Adjust. Fuel level: 2.0 ~ 3.0 mm (0.08 ~ 0.12 in) Above the float chamber mat- ing surface ********************************* Fuel level measurement and adjustment steps: Place the machine on a level surface. Connect the fuel level gauge 1 to the drain pipe 2.
Page 240 CARB 6 - 8...
Page 241 DRIVE...
Page 242 DRIV CHAPTER 7. DRIVE TRAIN TROUBLESHOOTING ...................7-1 CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR ....7-4 RING GEAR REMOVAL ................7-9 CONSTANT VELOCITY JOINT INSPECTION ........7-9 DIFFERENTIAL GEAR INSPECTION ............7-9 CONSTANT VELOCITY JOINT ASSEMBLY ........7-10 DIFFERENTIAL GEAR ASSEMBLY ............7-11 DIFFERENTIAL GEAR LASH MEASUREMENT AND ADJUSTMENT ................7-11 DIFFERENTIAL GEAR OPERATION CHECK ........7-13 REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT ......7-14...
Page 243 DRIV...
Page 244: Chapter 7. Drive Train
DRIV TROUBLESHOOTING DRIVE TRAIN TROUBLESHOOTING The following conditions may indicate damaged shaft drive components: Symptoms Possible Causes 1.A pronounced hesitation or “jerky” move- A.Bearing damage. ment during acceleration, deceleration, or B.Improper gear lash. sustained speed. (This must not be con- fused with engine surging or transmission C.Gear tooth damage.
Page 245 DRIV TROUBLESHOOTING CAUTION: Too little gear lash is extremely destructive to the gear teeth. If a test ride following reas- sembly indicates this condition, stop riding immediately to minimize gear damage. c.A slight “thunk” evident at low speed operation. This noise must be distin- guished from normal machine operation.
Page 246 DRIV TROUBLESHOOTING Troubleshooting Chart When basic condition “a” and “b” exist, check the following points: Elevate and spin both wheels. Feel for Replace the wheel bearing. wheel bearing damage. (Refer to “STEERING SYSTEM” and “REAR SHOCK ABSORBER AND SWINGARM” in CHAPTER 8.) Check the wheel nuts and hub nuts for Torque to specification.
Page 247: Constant Velocity Joints And Differential Gear
DRIV CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR Order Job name/Part name Q’ty Remarks Constant velocity joint and differen- Remove the parts in the order below. tial gear removal Engine skid plate (front) Refer to “SEAT, CARRIERS, FENDERS Front fender AND FUEL TANK”...
Page 248 DRIV CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR Order Job name/Part name Q’ty Remarks Differential gear Drive shaft Compression spring Coupling gear For installation, reverse the removal procedure. 7 - 5...
Page 249 DRIV CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR Order Job name/Part name Q’ty Remarks Constant velocity joint disassembly Disassemble the parts in the order below. Circlip Boot band Boot band Dust boot Circlip Refer to “CONSTANT VELOCITY JOINT ASSEMBLY”. Double off-set joint Snap ring Ball bearing Joint shaft assembly...
Page 250 DRIV CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR Order Job name/Part name Q’ty Remarks Defferential gear disassembly Disassembly the parts in the order below. Gear motor/O-ring Four-wheel drive switch Dust seal Circlip Coupling gear/bearing/circlip 1/1/1 Stopper bolt/shaft Shift fork sliding gear Shift fork 2WD/4WD shift sleeve Differential gear case cover...
Page 251 DRIV CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR Order Job name/Part name Q’ty Remarks Shim (right) Circlip/bearing Drive pinion gear Differential gear case For assembly, reverse the disassembly procedure. 7 - 8...
Page 252: Ring Gear Removal
DRIV CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR RING GEAR REMOVAL 1.Remove: Ring gear 1 NOTE: The ring gear and the differential gear cover should be fastened together. Do not disas- semble the differential gear. CAUTION: The differential gears are assembled into a proper unit at the factory by means of spe- cialized equipment.
Page 253: Constant Velocity Joint Assembly
DRIV CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR 2.Inspect: Drive shaft splines Universal joints Front drive gear splines Wear/damage → Replace. Spring Fatigue → Replace. Move the spring up and down. 3.Inspect: Front drive shaft Bends → Replace. WARNING Do not attempt to straighten a bent shaft; this may dangerously weaken the shaft.
Page 254: Differential Gear Assembly
DRIV CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR 3.Check: Free play (thrust movement) Excessive play → Replace the joint assem- bly. DIFFERENTIAL GEAR ASSEMBLY 1.Measure: Gear lash Refer to “DIFFERENTIAL GEAR LASH MEASUREMENT AND ADJUSTMENT”. 2.Install: Gear motor Refer to “FEATURES” in CHAPTER 1. 3.Check: Differential gear operation Unsmooth operation →...
Page 255 DRIV CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR 4.Attach: Gear lash measurement tool 1 Dial gauge 2 Gear lash measurement tool: P/N. YM-01475, 90890-01475 a Measuring point is 30 mm (1.18 in) 5.Measure: Gear lash Gently rotate the gear coupling from engagement to engagement Differential gear lash: 0.08 ~ 0.39 mm (0.003 ~ 0.015 in)
Page 256: Differential Gear Operation Check
DRIV CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR Ring gear shim (left and right) Thickness (mm) DIFFERENTIAL GEAR OPERATION CHECK 1.Block the rear wheels, and elevate the front wheels by placing a suitable stand under the frame. 2.Remove the wheel cap and cotter pin from the axle nut (right or left).
Page 257 DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT Order Job name/Part name Q’ty Remarks Rear axle, final drive gear assembly Remove the parts in the order below. and drive shaft removal Final gear oil Drain.
Page 258 DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT Order Job name/Part name Q’ty Remarks Final drive gear disassembly Disassemble the parts in the order below. Bolt NOTE: Bolt Working in a crisscross pattern, loosen each bolt 1/4 of a turn. After all the bolts are loosened, remove them.
Page 259 DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT Order Job name/Part name Q’ty Remarks Bearing retainer/O-ring Oil seal Final drive pinion gear Refer to “FINAL DRIVE GEAR DISAS- SEMBLY/ASSEMBLY”. Collar Bearing Final drive pinion gear shim Final drive gear case/O-ring Bearing/oil seal Refer to “FINAL DRIVE ROLLER BEAR- ING REMOVAL AND REASSEMBLY”.
Page 260: Rear Axle/Final Drive Gear And Drive Shaft
DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT REAR AXLE REMOVAL 1.Remove: Rear axle 1 (with dust seal) O-ring CAUTION: Never directly tap the axle end with a hammer, since this will result in damage to the axle thread and spline. Attach a suitable socket 2 on the axle end and tap it with a soft hammer.
Page 261: Final Drive Roller Bearing Removal And Reassembly
DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT FINAL DRIVE ROLLER BEARING REMOVAL AND REASSEMBLY 1.Remove: Roller bearing (ring gear) 1 Use a suitable press tool 2 and an appro- priate support for the main housing. Oil seal 3 2.Remove: Roller bearing (final drive pinion gear) 1 ********************************* Removal steps:...
Page 262: Final Drive Pinion Gear And Ring Gear Positioning
DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT FINAL DRIVE PINION GEAR AND RING GEAR POSITIONING When the final drive pinion gear, ring gear, final gear case and/or ring gear bearing housing are replaced, be sure to adjust the positions of the final drive pinion gear and ring gear using the shim(s).
Page 263 DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT Shims are supplied in the following thick- nesses. Final drive pinion gear shim 0.15 0.30 0.40 Thickness (mm) 0.45 0.50 0.60 ********************************* Ring gear shim selection 1.Select: Ring gear shim(s) 1 ********************************* Shim selection steps: To find the ring gear shim thickness “B”, use the following formula.
Page 264 DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT 5) Therefore, shim thickness “B” is 0.63. “B”= 45.53 + 1.05 – (34.95 + 11.00) = 46.58 – 45.95 = 0.63 6) Round off the hundredth digit and select the appropriate shim(s). In the example above, the calculated number is 0.63.
Page 265 DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT Remove the ring gear assembly. Measure the thrust clearance. Calculate ® the width of the flattened Plastigauge Ring gear thrust clearance: 0.1 ~ 0.2 mm (0.004 ~ 0.008 in) If out of specification, select the correct washer.
Page 266: Rear Axle Inspection
DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT Ring gear stopper clearance adjustment 1.Remove: Ring gear 1 Ring gear stopper 2 Shim(s) 3 4 Bearing housing Å Left-hand threads 2.Select: Suitable shim(s) Shim 0.10 0.15 0.20 Thickness (mm) 0.30 0.40 0.50 3.Install: Shim(s)
Page 267: Drive Shaft Inspection
Damage → Replace. 3.Inspect: Bearings Damage → Replace. NOTE: 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 268: Final Gear Lash Measurement And Adjustment
DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT FINAL GEAR LASH MEASUREMENT AND ADJUSTMENT Final gear lash measurement 1.Secure the gear case in a vise or another supporting device. 2.Remove: Drain plug Gasket 3.Install: A bolt of the specified size 1 (into the drain plug hole) CAUTION: Finger tighten the bolt until it holds the...
Page 269 DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT Final gear lash adjustment 1.Remove: Bearing housing 1 Ring gear shim(s) 2 Ring gear 3 Thrust washer 4 2.Adjust: Gear lash ********************************* Adjustment steps: Select a suitable shim(s) and thrust washer(s) using the following chart. Too little gear lash Reduce shim thickness.
Page 270: Final Drive Gear Assembly
DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT FINAL DRIVE GEAR ASSEMBLY 1.Install: Drive pinion gear (with shim(s) and bear- ing) (proper shim size as calculated) Bearing retainer (drive pinion gear) 1 100 Nm (10.0 m • kg, 72 ft • lb) Use a bearing retainer wrench 2.
Page 271 (to the mating surfaces of the swingarm and the final drive gear case) ® Sealant (Quick gasket P/N. ACC-11001-05-01 ® Yamaha bond No.1215 P/N. 90890-85505 4.Install: Final drive gear Nuts 57 Nm (5.7 m • kg, 41 ft • lb) Bolts 63 Nm (6.3 m •...
Page 272: Chas
CHAS...
Page 273 CHAS CHAPTER 8. CHASSIS FRONT AND REAR WHEELS ...............8-1 FRONT WHEELS ...................8-1 REAR WHEELS ..................8-2 WHEEL INSPECTION ................8-3 WHEEL HUB INSPECTION ..............8-3 BRAKE DISC INSPECTION ..............8-4 WHEEL HUB/BRAKE DRUM INSTALLATION ........8-4 WHEEL INSTALLATION ...............8-4 FRONT AND REAR BRAKES ................8-6 FRONT BRAKE PADS ................8-6 REAR BRAKE PADS ................8-7 FRONT BRAKE PAD REPLACEMENT ..........8-8 REAR BRAKE PAD REPLACEMENT ...........8-10...
Page 274 CHAS STEERING KNUCKLE INSPECTION ..........8-38 BALL JOINT INSPECTION ..............8-39 TIE ROD INSTALLATION ..............8-39 FRONT ARMS AND FRONT SHOCK ABSORBER ........8-40 FRONT ARMS REMOVAL ..............8-42 FRONT ARM INSPECTION ..............8-42 FRONT SHOCK ABSORBER INSPECTION ........8-42 FRONT ARMS AND FRONT SHOCK ABSORBER INSTALLATION ........8-43 REAR SHOCK ABSORBER AND SWINGARM ..........8-44 SWINGARM REMOVAL ..............8-45 REAR SHOCK ABSORBER INSPECTION ...........8-45...
Page 275: Chapter 8. Chassis
CHAS FRONT AND REAR WHEELS CHASSIS FRONT AND REAR WHEELS FRONT WHEELS Order Job name/Part name Q’ty Remarks Front wheel removal Remove the parts in the order below. Place the machine on a level surface. WARNING Securely support the machine so there is no danger of it falling over.
Page 276: Rear Wheels
CHAS FRONT AND REAR WHEELS REAR WHEELS Order Job name/Part name Q’ty Remarks Rear wheel removal Remove the parts in the order below. Place the machine on a level surface. WARNING Securely support the machine so there is no danger of it falling over. Rear wheel Refer to “WHEEL INSTALLATION”.
Page 277: Wheel Inspection
CHAS FRONT AND REAR WHEELS WHEEL INSPECTION 1.Inspect: Wheel 2.Measure: Wheel runout Over the specified limit → Replace the wheel or check the wheel bearing play 1. Wheel runout limit: Radial 2: 2.0 mm (0.08 in) Lateral 3: 2.0 mm (0.08 in) 3.Check: Wheel balance Out of balance →...
Page 278: Brake Disc Inspection
CHAS FRONT AND REAR WHEELS BRAKE DISC INSPECTION 1.Inspect: Brake disc Galling/damage → Replace. 2.Measure: Brake disc deflection Out of specification → Inspect the wheel runout. If wheel runout is within the limits, replace the brake disc. Brake disc maximum deflection: 0.15 mm (0.006 in) Brake disc thickness a Out of specification →...
Page 279 CHAS FRONT AND REAR WHEELS 2.Tighten: Nuts (wheel) 1 WARNING Tapered wheel nuts 1 are used for both the front and rear wheels. Install each nut with its tapered side towards the wheel. 8 - 5...
Page 280: Front And Rear Brakes
CHAS FRONT AND REAR BRAKES FRONT AND REAR BRAKES FRONT BRAKE PADS Order Job name/Part name Q’ty Remarks Front brake pads removal Remove the parts in the order below. Front wheel Refer to “FRONT AND REAR WHEELS”. Brake caliper mounting bolt Brake pad holding bolt Refer to “FRONT BRAKE PAD REPLACEMENT”.
Page 281: Rear Brake Pads
CHAS FRONT AND REAR BRAKES REAR BRAKE PADS Order Job name/Part name Q’ty Remarks Rear brake pads removal Remove the parts in the order below. Rear wheel (left) Refer to “FRONT AND REAR WHEELS”. Brake caliper mounting bolt Brake pad holding bolt Refer to “REAR BRAKE PAD REPLACEMENT”.
Page 282: Front Brake Pad Replacement
CHAS FRONT AND REAR BRAKES CAUTION: Disc brake components rarely require dis- assembly. DO NOT: disassemble components unless abso- lutely necessary; use solvents on internal brake compo- nents; use spent brake fluid for cleaning; (use only clean brake fluid) allow brake fluid to come in contact with the eyes, as this may cause eye injury;...
Page 283 CHAS FRONT AND REAR BRAKES ********************************* Installation steps: Connect a suitable hose 1 tightly to the brake caliper bleed screw 2. Put the other end of this hose into an open container. Loosen the brake caliper bleed screw and, using a finger, push the caliper piston into the brake caliper.
Page 284: Rear Brake Pad Replacement
CHAS FRONT AND REAR BRAKES REAR BRAKE PAD REPLACEMENT NOTE: It is not necessary to disassemble the brake caliper and brake hose to replace the brake pads. 1.Measure: Brake pad wear limit a Out of specification → Replace the brake pad as a set.
Page 285 CHAS FRONT AND REAR BRAKES 3.Inspect: Brake fluid level Refer to “BRAKE FLUID LEVEL INSPEC- TION” in CHAPTER 3. 4.Check: Brake lever or brake pedal operation Soft or spongy feeling → Bleed the rear brake system. Refer to “AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)”...
Page 286: Front Brake Master Cylinder
CHAS FRONT AND REAR BRAKES FRONT BRAKE MASTER CYLINDER Order Job name/Part name Q’ty Remarks Front brake master cylinder removal Remove the parts in the order below. Brake fluid Drain. Brake fluid reservoir cap Brake fluid reservoir diaphragm holder Brake fluid reservoir diaphragm Brake lever Union bolt Copper washer...
Page 287 CHAS FRONT AND REAR BRAKES Order Job name/Part name Q’ty Remarks Front brake master cylinder disas- Disassemble the parts in the order sembly below. Dust boot Refer to “FRONT BRAKE MASTER Circlip CYLINDER ASSEMBLY”. Brake master cylinder kit For assembly, reverse the disassembly procedure.
Page 288: Rear Brake Master Cylinder
CHAS FRONT AND REAR BRAKES REAR BRAKE MASTER CYLINDER Order Job name/Part name Q’ty Remarks Rear brake master cylinder removal Remove the parts in the order below. Front fender panel Refer to “SEAT, CARRIERS, FINDERS AND FUEL TANK” in CHAPTER 3. Brake fluid Drain.
Page 289 CHAS FRONT AND REAR BRAKES Order Job name/Part name Q’ty Remarks Union bolt Copper washer Refer to “REAR BRAKE MASTER CYL- INDER INSTALLATION”. Brake hose Brake master cylinder For installation, reverse the removal procedure. 8 - 15...
Page 290 CHAS FRONT AND REAR BRAKES Order Job name/Part name Q’ty Remarks Front brake master cylinder disas- Disassemble the parts in the order sembly below. Brake master cylinder kit Refer to “REAR BRAKE MASTER CYL- INDER ASSEMBLY”. Brake master cylinder For assembly, reverse the disassembly procedure.
Page 291: Master Cylinder Inspection
CHAS FRONT AND REAR BRAKES MASTER CYLINDER INSPECTION Å 1.Inspect: Brake master cylinder 1 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 → Blow out with compressed air.
Page 292: Front Brake Master Cylinder Assembly
CHAS FRONT AND REAR BRAKES EB702060 FRONT BRAKE MASTER CYLINDER ASSEMBLY 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 293: Front Brake Master Cylinder Installation
CHAS FRONT AND REAR BRAKES FRONT BRAKE MASTER CYLINDER INSTALLATION 1.Install: Brake master cylinder 1 7 Nm (0.7 m • kg, 5.1 ft • lb) NOTE: The “UP” mark on the brake master cylin- der bracket should face up. 2.Install: Copper washers Brake hose Union bolt...
Page 294: Rear Brake Master Cylinder Installation
CHAS FRONT AND REAR BRAKES Be careful that water does not enter the brake master cylinder when refilling. Water will significantly lower the boiling point of the brake fluid and may result in vapor lock. 4.Air bleed: Brake system Refer to “AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)”...
Page 295 CHAS FRONT AND REAR BRAKES 2.Fill: Brake fluid reservoir Recommended brake fluid: DOT 4 CAUTION: 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 296: Front Brake Caliper
CHAS FRONT AND REAR BRAKES FRONT BRAKE CALIPER Order Job name/Part name Q’ty Remarks Front brake caliper removal Remove the parts in the order below. Brake fluid Drain. Front wheel Refer to “FRONT AND REAR WHEELS”. Union bolt Copper washer Brake hose Disconnect.
Page 297 CHAS FRONT AND REAR BRAKES Order Job name/Part name Q’ty Remarks Front brake caliper disassembly Disassemble the parts in the order below. Brake pad holding bolt Brake pad/pad shim Pad spring Retaining bolt Caliper bracket Brake caliper piston Refer to “FRONT AND REAR BRAKE Dust seal CALIPER DISASSEMBLY/ASSEM- BLY”.
Page 298: Rear Brake Caliper
CHAS FRONT AND REAR BRAKES REAR BRAKE CALIPER Order Job name/Part name Q’ty Remarks Rear brake caliper removal Remove the parts in the order below. Brake fluid Drain. Rear wheel Refer to “FRONT AND REAR WHEELS”. Union bolt Copper washer Refer to “REAR BRAKE Brake hose Disconnect.
Page 299 CHAS FRONT AND REAR BRAKES Order Job name/Part name Q’ty Remarks Rear brake caliper disassembly Disassemble the parts in the order below. Brake pad holding bolt Brake pad/insulator/pad shim 2/2/2 Pad spring Caliper bracket Brake caliper piston Refer to “FRONT AND REAR BRAKE Dust seal CALIPER DISASSEMBLY/ASSEM- BLY”.
Page 300: Front And Rear Brake Caliper Disassembly
CHAS FRONT AND REAR BRAKES FRONT AND REAR BRAKE CALIPER DISASSEMBLY 1.Remove: Brake caliper piston Dust seal 1 Caliper piston seal 2 ********************************* Removal steps: Blow compressed air into the hose joint opening to force out the caliper piston from the brake caliper body. WARNING Never try to pry out the caliper piston.
Page 301: Front And Rear Brake Caliper Assembly
CHAS FRONT AND REAR BRAKES Brake fluid delivery passage (brake caliper ı body) Blockage → Blow out with compressed air. WARNING Replace the caliper piston seal and dust seal whenever the brake caliper is disas- sembled. Å Front ı Rear FRONT AND REAR BRAKE CALIPER ASSEMBLY WARNING...
Page 302 CHAS FRONT AND REAR BRAKES CAUTION: When installing the brake hose on the brake caliper, make sure that the brake pipe touches the projection a on the brake caliper. WARNING Proper brake hose routing is essential to insure safe motorcycle operation. Refer to “CABLE ROUTING”.
Page 303: Rear Brake Caliper Installation
CHAS FRONT AND REAR BRAKES REAR BRAKE CALIPER INSTALLATION 1.Install: Brake caliper assembly Brake caliper mounting bolt 1 30 Nm (3.0 m • kg, 22 ft • lb) Brake hose 2 Copper washers 3 Union bolt 4 30 Nm (3.0 m • kg, 22 ft • lb) 2.Fill: Brake reservoir Recommended brake fluid:...
Page 304: Steering System
CHAS STEERING SYSTEM STEERING SYSTEM HANDLEBAR Order Job name/Part name Q’ty Remarks Handlebar removal Remove the parts in the order below. Handlebar cover Band Master cylinder assembly/bracket Refer to “MASTER CYLINDER On command four-wheel drive switch ASSEMBLY INSTALLATION”. Throttle lever assembly/bracket Rear brake switch Refer to “REAR BRAKE SWITCH REMOVAL”.
Page 305 CHAS STEERING SYSTEM Order Job name/Part name Q’ty Remarks Handlebar holder Refer to “HANDLEBAR INSTALLA- TION”. Handlebar Refer to “HANDLEBAR INSTALLA- TION”. For installation, reverse the removal procedure. 8 - 31...
Page 306: Rear Brake Switch Removal
CHAS STEERING SYSTEM REAR BRAKE SWITCH REMOVAL 1.Remove: Rear brake switch 1 NOTE: Push the fastener when removing the rear brake switch out of the rear brake lever holder. HANDLEBAR INSPECTION 1.Inspect: Handlebar Bends/cracks/damage → Replace. WARNING Do not attempt to straighten a bent han- dlebar as this may dangerously weaken the handlebar.
Page 307: Master Cylinder Assembly Installation
CHAS STEERING SYSTEM MASTER CYLINDER ASSEMBLY INSTALLATION 1.Install: Throttle lever assembly Master cylinder assembly 7 Nm (0.7 m • kg, 5.1 ft • lb) NOTE: The “UP” mark on the master cylinder bracket should face up. 8 - 33...
Page 308: Steering Stem
CHAS STEERING SYSTEM STEERING STEM Order Job name/Part name Q’ty Remarks Steering removal Remove the parts in the order below. Handlebar Refer to “HANDLEBAR”. Seat Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK” in CHAPTER 3. Front fender Lock washer Refer to “CABLE GUIDE INSTALLA- Cable guide TION”.
Page 309 CHAS STEERING SYSTEM Order Job name/Part name Q’ty Remarks Oil seal Bearing retainer Refer to “BEARING RETAINER REMOVAL/INSTALLATION”. Bearing Oil seal For installation, reverse the removal procedure. 8 - 35...
Page 310: Bearing Retainer Removal
CHAS STEERING SYSTEM BEARING RETAINER REMOVAL 1.Remove: Bearing retainer (steering stem) Damper rod holder: P/N. YM-01327, 90890-01327 STEERING STEM INSPECTION 1.Inspect: Steering stem Bends → Replace. WARNING Do not attempt to straighten a bent stem; this may dangerously weaken the stem. 2.Inspect: Oil seals 1 Steering stem bushings 2...
Page 311: Tie Rod And Steering Knuckle
CHAS STEERING SYSTEM TIE ROD AND STEERING KNUCKLE Order Job name/Part name Q’ty Remarks Tie rod and steering knuckle removal Remove the parts in the order below. Front fender Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK” in CHAPTER 3. Front wheel/brake disc Refer to “FRONT AND REAR WHEELS”.
Page 312: Steering Knuckle Removal
CHAS STEERING SYSTEM STEERING KNUCKLE REMOVAL 1.Remove: Steering knuckle 1 NOTE: Use a general puller to separate the ball joint 2 and steering knuckle. TIE ROD INSPECTION 1.Check: Tie rod free play and movement Free play → Replace the tie rod end. Turns roughly →...
Page 313: Ball Joint Inspection
CHAS STEERING SYSTEM Install the new bearings. NOTE: Install the outside bearing first. CAUTION: Do not strike the center race or balls of the bearing. Contact should be made only with the outer race. Install a new oil seal. NOTE: When installing the oil seals, the “seal side”...
Page 314: Front Arms And Front Shock Absorber
CHAS FRONT ARMS AND FRONT SHOCK ABSORBER FRONT ARMS AND FRONT SHOCK ABSORBER Order Job name/Part name Q’ty Remarks Front arms and front shock absorber Remove the parts in the order below. removal Engine skid plate (front) Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”...
Page 315 CHAS FRONT ARMS AND FRONT SHOCK ABSORBER Order Job name/Part name Q’ty Remarks Bolt Bolt/nut Refer to “FRONT ARMS REMOVAL” Front arm (lower)/bushing and “FRONT ARMS AND FRONT Nut/bolt SHOCK ABSORBER INSTALLATION”. Front shock absorber/collar Bolt/nut Front arm (upper)/bushing For installation, reverse the removal procedure.
Page 316: Front Arms Removal
CHAS FRONT ARMS AND FRONT SHOCK ABSORBER FRONT ARMS REMOVAL 1.Check: Front arm free play ********************************* Checking steps: Check the front arm side play Å by mov- ing it from side to side. If side play is noticeable, check the bush- ings.
Page 317 CHAS FRONT ARMS AND FRONT SHOCK ABSORBER FRONT ARMS AND FRONT SHOCK ABSORBER INSTALLATION 1.Install: Front arms Front shock absorber ********************************* Installation steps: Install the front arm (upper) 1 and front arm (lower) 2. NOTE: Lubricate the bolts 3 with lithium soap base grease.
Page 318: Rear Shock Absorber And Swingarm
CHAS REAR SHOCK ABSORBER AND SWINGARM REAR SHOCK ABSORBER AND SWINGARM Order Job name/Part name Q’ty Remarks Rear shock absorber and swingarm Remove the parts in the order below. removal Rear wheel hubs/brake disc Refer to “FRONT AND REAR WHEELS”. Final drive gear assembly Refer to “REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT”...
Page 319: Swingarm Removal
CHAS REAR SHOCK ABSORBER AND SWINGARM SWINGARM REMOVAL 1.Inspect: Swingarm free play ********************************* Inspection steps: Check the tightening torque of the nuts (swingarm). Nut (swingarm): 59 Nm (5.9 m • kg, 43 ft • lb) Check the swingarm side play Å by mov- ing it from side to side.
Page 320: Swingarm Inspection
CHAS REAR SHOCK ABSORBER AND SWINGARM SWINGARM INSPECTION 1.Inspect: Swingarm Bends/cracks/damage → Replace. 2.Inspect: Bushings 1 Wear/damage → Replace. RUBBER BOOT INSPECTION 1.Inspect: Rubber boot 1 Damage → Replace. RUBBER BOOT INSTALLATION 1.Apply: Adhesive (for rubber) (to the engine 1) 2.Install: Rubber boot 2 NOTE:...
Page 321: Elec
– ELEC...
Page 322 – ELEC CHAPTER 9. ELECTRICAL ELECTRICAL COMPONENTS ...............9-1 SWITCH INSPECTION ..................9-2 SWITCH INSPECTION ................9-2 INSPECTING A SWITCH SHOWN IN THE MANUAL ......9-2 SWITCH CONTINUITY INSPECTION ...........9-3 IGNITION SYSTEM ..................9-5 CIRCUIT DIAGRAM ................9-5 TROUBLESHOOTING ................9-6 ELECTRIC STARTING SYSTEM ..............9-11 CIRCUIT DIAGRAM ................9-11 STARTING CIRCUIT OPERATION ............9-12 TROUBLESHOOTING .................9-13 STARTER MOTOR ................9-17...
Page 323 – ELEC...
Page 324: Chapter 9. Electrical
– ELEC ELECTRICAL COMPONENTS EB800000 ELECTRICAL ELECTRICAL COMPONENTS 1 Indicator light 9 Main fuse G Park switch O Fan 2 Main switch 0 Starter relay H Speed sensor P Headlight 3 On command four- A CDI unit I Reverse switch Q Circuit breaker (fan) wheel drive switch B Starting circuit...
Page 325: Switch Inspection
– ELEC SWITCH INSPECTION SWITCH INSPECTION SWITCH INSPECTION Use a pocket tester to check the terminals for continuity. If the continuity is faulty at any point, replace the switch. Pocket tester: P/N. YU-03112, 90890-03112 NOTE: Set the pocket tester to “0” before starting the test.
Page 326: Switch Continuity Inspection
– ELEC SWITCH INSPECTION SWITCH CONTINUITY INSPECTION Refer to “SWITCH INSPECTION” and check for continuity between lead terminals. Poor connection, no continuity → Correct or replace. The coupler locations are circled. 9 - 3...
Page 327 – ELEC SWITCH INSPECTION 1 Lights switch 2 Engine stop switch 3 Starter switch 4 Main switch 5 On command four-wheel drive switch 6 Rear brake switch 7 Four-wheel drive switch 8 Reverse switch 9 Park switch 0 Neutral switch A Fuse B Horn switch (For GB, F, CH, Oceania) 9 - 4...
Page 328: Ignition System
– ELEC IGNITION SYSTEM EB802000 IGNITION SYSTEM CIRCUIT DIAGRAM 9 - 5...
Page 329: Troubleshooting
– ELEC IGNITION SYSTEM EB802010 TROUBLESHOOTING IF THE IGNITION SYSTEM FAILS TO OPERATE (NO SPARK OR INTERMITTENT SPARK): Procedure Check: 1.Fuse (main, ignition) 7.Engine stop switch 2.Battery 8.Main switch 3.Spark plugs 9.Pickup coil resistance 4.Ignition spark gap 10.Charging/rotor rotation direction detec- 5.Spark plug cap resistance tion coil resistance 6.Ignition coil resistance...
Page 330 – ELEC IGNITION SYSTEM INCORRECT Spark plug gap: 0.6 ~ 0.7 mm (0.02 ~ 0.03 in) CORRECT Repair or replace the spark plug. For CDN 4.Ignition spark gap Disconnect the spark plug cap from the spark plug. Connect the dynamic spark tester 1 as shown.
Page 331 – ELEC IGNITION SYSTEM 5.Spark plug cap resistance Remove the spark plug cap. Connect the pocket tester (Ω × 1k) to the spark plug cap. OUT OF SPECIFICATION Check that the spark plug cap has the specified resistance. Spark plug cap resistance: Replace the spark plug cap.
Page 332 – ELEC IGNITION SYSTEM OUT OF SPECIFICATION Check that the secondary coil has the specified resistance. Secondary coil resistance: 6.32 ~ 9.48 kΩ at 20 ˚C (68 ˚F) Replace the ignition coil. BOTH MEET SPECIFICATION INCORRECT 7.Engine stop switch Refer to “SWITCH INSPECTION”. CORRECT Replace the handlebar switch (left).
Page 333 – ELEC IGNITION SYSTEM C0NTINUITY 10.Charging/rotor rotation direction detec- tion coil resistance Disconnect the CDI magneto coupler from the wire harness. Connect the pocket tester (Ω × 100) to the charging/rotor rotation direction detection coil terminal. Tester (+) lead → Red terminal 1 Tester (–) lead →...
Page 334: Electric Starting System
– ELEC ELECTRIC STARTING SYSTEM EB803000 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM 9 - 11...
Page 335: Starting Circuit Operation
– ELEC ELECTRIC STARTING SYSTEM STARTING CIRCUIT OPERATION The starting circuit on this model consists of the starter motor, starter relay, starting circuit cut-off relay, rear brake switch, park switch CDI unit and 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: The transmission is in neutral (the neu-...
Page 336: Troubleshooting
– ELEC ELECTRIC STARTING SYSTEM EB803020 TROUBLESHOOTING IF THE STARTER MOTOR FAILS TO OPERATE: Procedure Check: 8.Neutral switch 1.Fuse (main, ignition) 9.Rear brake switch 2.Battery 10.Park switch 3.Starter motor 11.Start switch 4.Starting circuit cut-off relay 12.Diode 5.Starter relay 13.Wiring connection 6.Main switch (the entire starting system) 7.Engine stop switch...
Page 337 – ELEC ELECTRIC STARTING SYSTEM C0NTINUITY WARNING 3.Starter motor A wire that is used as a jumper lead must Connect the battery positive terminal 1 have the equivalent capacity or more as and starter motor cable 2 using a that of the battery lead, otherwise the jumper lead 3 jumper lead may burn.
Page 338 – ELEC ELECTRIC STARTING SYSTEM C0NTINUITY 5.Starter relay Remove the starter relay from the wire harness. Connect the pocket tester (Ω × 1) and the battery (12 V) to the starter relay termi- nals. Battery (+) terminal → Blue/White terminal 1 Battery (–) terminal →...
Page 339 – ELEC ELECTRIC STARTING SYSTEM C0NTINUITY INCORRECT 10.Park switch Refer to “SWITCH INSPECTION”. CORRECT Replace the park switch. INCORRECT 11.Start switch Refer to “SWITCH INSPECTION”. CORRECT Replace the handlebar switch (left). 12.Diode Remove the diode from the coupler. Connect the pocket tester (Ω × 1) to the diode terminals as shown.
Page 340 – ELEC ELECTRIC STARTING SYSTEM STARTER MOTOR Order Job name/Part name Q’ty Remarks Starter motor removal Remove the parts in the order below. Starter motor lead Starter motor/O-ring For installation, reverse the removal procedure. Starter motor disassembly Disassemble the parts in the order below.
Page 341: Starter Motor Inspection
– ELEC ELECTRIC STARTING SYSTEM STARTER MOTOR INSPECTION 1.Inspect: Commutator Dirty → Clean it with #600 grit sandpaper. 2.Measure: Commutator diameter a Out of specification → Replace the starter motor. Outside diameter: 28 mm (1.10 in) <Wear limit>: 27 mm (1.06 in) 3.Measure: Mica undercut b Out of specification →...
Page 342: Starter Motor Assembly
– ELEC ELECTRIC STARTING SYSTEM 5.Measure: Brush length a (each) Out of specification → Replace the brush. Brush length: 12.5 mm (0.49 in) <Wear limit>: 5 mm (0.20 in) 6.Measure: Brush spring force Fatigue/out of specification → Replace as a set. Brush spring force: 7.65 ~ 10.01 Nm (780 ~ 1,020 g, 27.5 ~ 36.0 oz)
Page 343: Charging System
– ELEC CHARGING SYSTEM EB804000 CHARGING SYSTEM CIRCUIT DIAGRAM Br/W W (BLACK) (BLACK) (BLUE) WIRE HARNESS SUB-WIRE HARNESS 2 WIRE HARNESS IGNITION COIL LEAD WIRE HARNESS S W/G R R W/G W/R W/L W/L W/R L/W L/B (BLACK) (BLACK) Y/B L/W R/W R/W B B/W B/W B...
Page 344: Troubleshooting
– ELEC CHARGING SYSTEM EB804010 TROUBLESHOOTING IF THE BATTERY IS NOT CHARGED: Procedure Check: 1.Fuse (main) 4.Charging coil resistance 2.Battery 5.Wiring connections 3.Charging voltage (the entire charging system) NOTE: Inductive tachometer: Remove the following part(s) before trou- P/N. YU-8036-A bleshooting: Engine tachometer: 1)Seat P/N.
Page 345 – ELEC CHARGING SYSTEM Start the engine and accelerate to about 3,000 r/min. MEETS SPECIFICATION Charging voltage: 14 V at 1,000 r/min NOTE: Use a fully charged battery. The charging circuit is not faulty. OUT OF SPECIFICATION EB804012 4.Charging coil resistance Disconnect the CDI magneto coupler from the wire harness.
Page 346: Lighting System
– ELEC LIGHTING SYSTEM EB805000 LIGHTING SYSTEM CIRCUIT DIAGRAM (BLACK) (BLACK) WIRE HARNESS SUB-WIRE HARNESS 2 WIRE HARNESS IGNITION COIL LEAD W/G R R W/G W/R W/L W/L W/R L/W L/B (BLACK) (BLACK) Y/B L/W R/W R/W B B/W B/W B Br/L R Br/L Br/L...
Page 347: Troubleshooting
– ELEC LIGHTING SYSTEM EB805010 TROUBLESHOOTING IF THE HEADLIGHT, TAILLIGHT AND/OR METER LIGHT FAIL TO COME ON: Procedure Check: 4.Lights switch 1.Fuse (main) 5.Wiring connections 2.Battery (the entire lighting system) 3.Main switch NOTE: Pocket tester: Remove the following part(s) before trou- P/N.
Page 348 – ELEC LIGHTING SYSTEM C0NTINUITY INCORRECT 3.Main switch Refer to “SWITCH INSPECTION”. CORRECT Replace the main switch. INCORRECT 4.Lights switch Refer to “SWITCH INSPECTION”. Lights switch is faulty, replace the handle- CORRECT bar switch (left). EB805013 5.Wiring connection POOR CONNECTION Check the connections of the entire light- ing system.
Page 349: Lighting System Check
– ELEC LIGHTING SYSTEM EB805020 LIGHTING SYSTEM CHECK 1.If the headlights fail to come on: NO CONTINUITY 1.Bulb and bulb socket Check the bulb and bulb socket for conti- nuity. Replace the bulb and/or bulb socket. CONTINUITY 2.Voltage Connect the pocket tester (DC 20 V) to the headlight couplers.
Page 350 – ELEC LIGHTING SYSTEM EB805021 2.If the tailight fails to come on: NO CONTINUITY 1.Bulb and bulb socket Check the bulb and bulb socket for conti- nuity. Replace the bulb and/or bulb socket. CONTINUITY 2.Voltage Connect the pocket tester (20 V) to the bulb socket coupler.
Page 351 – ELEC LIGHTING SYSTEM 3.If the speedometer light (option) fails to come on: NO CONTINUITY 1.Bulb and bulb socket Check the bulb and bulb socket for conti- nuity. Replace the bulb and/or bulb socket. CONTINUITY 2.Voltage Connect the pocket tester (20 V) to the bulb socket coupler.
Page 352: Signal System
– ELEC SIGNAL SYSTEM EB806000 SIGNAL SYSTEM CIRCUIT DIAGRAM 9 - 29...
Page 353: Troubleshooting
– ELEC SIGNAL SYSTEM EB806010 TROUBLESHOOTING IF THE INDICATOR LIGHT FAILS TO COME ON: Procedure Check: 1.Fuse (main, ignition, signal, four-wheel drive) 2.Battery 3.Main switch 4.Wiring connections (the entire signal system) NOTE: Pocket tester: Remove the following part(s) before trou- P/N.
Page 354 – ELEC SIGNAL SYSTEM C0NTINUITY INCORRECT 3.Main switch Refer to “SWITCH INSPECTION”. CORRECT Replace the main switch. EB806011 POOR CONNECTION 4.Wiring connections Check the connections of the entire sig- nal system. Refer to “CIRCUIT DIAGRAM”. Properly connect the signal system. CORRECT Check the condition of each of the signal system’s circuits.
Page 355: Signal System Check
– ELEC SIGNAL SYSTEM SIGNAL SYSTEM CHECK 1.Horn does not sound. INCORRECT 1.“HORN” switch. Refer to “SWITCH INSPECTION”. CORRECT Replace the horn switch. 2.Voltage Connect the pocket tester (DC 20 V) to the horn lead. Tester (+) lead → Pink lead 1 Tester (–) lead →...
Page 356 – ELEC SIGNAL SYSTEM 4.Voltage Connect the pocket tester (DC 20 V) to the horn at the “Black” terminal. Tester (+) lead → Black lead 1 Tester (–) lead → Frame ground OUT OF SPECIFICATION Turn the main switch to “ON”. Push the “HORN”...
Page 357 – ELEC SIGNAL SYSTEM EB806024 2.If the neutral indicator light fails to come NO CONTINUITY 1.Bulb and bulb socket Check the bulb and bulb socket for conti- nuity. Replace the bulb and/or bulb socket. CONTINUITY NO CONTINUITY 2.Neutral switch Refer to “SWITCH INSPECTION”. CONTINUITY Replace the neutral switch.
Page 358 – ELEC SIGNAL SYSTEM 3.If the reverse indicator light fails to come NO CONTINUITY 1.Bulb and bulb socket Check the bulb and bulb socket for conti- nuity. Replace the bulb and/or bulb socket. CONTINUITY NO CONTINUITY 2.Reverse switch Refer to “SWITCH INSPECTION”. CONTINUITY Replace the reverse switch.
Page 359 – ELEC SIGNAL SYSTEM OUT OF SPECIFICATION Turn the main switch to “ON”. Check the voltage (12 V). MEETS The wiring circuit from the main switch to SPECIFICATION the bulb socket connector is faulty, repair This circuit is not faulty. 4.If the park indicator light fails to come on: 1.Bulb and bulb socket NO CONTINUITY...
Page 360 – ELEC SIGNAL SYSTEM 5.If the coolant temperature indicator light does not come on when the start switch is pushed on, or if the coolant temperature indicator light does not come on when the temperature is high (more than 107 ~ 113 ˚C (224.6 ~ 235.4 ˚F)): NO CONTINUITY 1.Bulb and bulb socket Check the bulb and bulb socket for conti-...
Page 361 – ELEC SIGNAL SYSTEM C0NTINUITY 3.Voltage Connect the pocket tester (DC 20V) to the bulb socket connector. Tester (+) lead → Red/White lead 1 Tester (–) lead → Frame ground OUT OF SPECIFICATION Turn the main switch to “ON”. Check the voltage (12 V). MEETS SPECIFICATION The wiring circuit from the main switch to...
Page 362 – ELEC SIGNAL SYSTEM C0NTINUITY INCORRECT 5.Start switch Refer to “SWITCH INSPECTION”. CORRECT Replace the handlebar switch (left). This circuit is not faulty. 6.If the four-wheel drive indicator light fails to come on: NO CONTINUITY 1.Bulb and bulb socket Check the bulb and bulb socket for conti- nuity.
Page 363: Cooling System
– ELEC COOLING SYSTEM COOLING SYSTEM CIRCUIT DIAGRAM 9 - 40...
Page 364: Troubleshooting
– ELEC COOLING SYSTEM TROUBLESHOOTING IF THE FAN MOTOR DOES NOT MOVE: Procedure Check: 1.Fuse (main) 6.Thermo switch 2.Battery 7.Wiring connection 3.Main switch (the entire cooling system) 4.Fan motor 5.Circuit breaker (fan motor) NOTE: Pocket tester: Remove the following part(s) before trou- P/N.
Page 365 – ELEC COOLING SYSTEM C0NTINUITY 4.Fan motor Disconnect the fan motor coupler. Connect the battery (12 V) as shown. Battery (+) lead → Blue terminal 1 Battery (–) lead → Black terminal 2 DOES NOT TURN Replace the fan motor. Check the operation of the fan motor.
Page 366 – ELEC COOLING SYSTEM C0NTINUITY 6.Thermo switch Remove the thermo switch from the radiator. Connect the pocket tester (Ω × 10) to the thermo switch 1. Immerse the thermo switch in coolant Check the thermo switch for continuity. While heating the coolant use a ther- mometer 3 to record the temperatures.
Page 367 – ELEC COOLING SYSTEM C0NTINUITY EB803028 POOR CONNECTION 7.Wiring connection Check the connections of the entire start- ing system. Refer to “CIRCUIT DIAGRAM”. Properly connect the cooling system. CORRECT This circuit is not faulty. 9 - 44...
Page 368: 2Wd/4Wd Selecting System
– ELEC 2WD/4WD SELECTING SYSTEM 2WD/4WD SELECTING SYSTEM CIRCUIT DIAGRAM 3 Main switch 4 Battery 5 Main fuse T Four-wheel drive fuse U On command four-wheel drive switch V Gear motor 9 - 45...
Page 369 – ELEC 2WD/4WD SELECTING SYSTEM EB803020 TROUBLESHOOTING IF THE FOUR-WHEEL DRIVE INDICATOR LIGHT FAILS TO COME ON: Procedure Check: 1.Fuse (main, four-wheel drive) 5.Gear motor 2.Battery 6.Wiring connections 3.Main switch (the entire 2WD/4WD selecting system) 4.On command four-wheel drive switch NOTE: Pocket tester: Remove the following part(s) before trou-...
Page 370 – ELEC 2WD/4WD SELECTING SYSTEM C0NTINUITY INCORRECT 4.On command four-wheel drive switch Refer to “SWITCH INSPECTION”. CORRECT Replace the on command four-wheel drive select switch. 5.Gear motor Check that the shift fork sliding gear is in the 2WD position. Disconnect the gear motor coupler. Remove the gear motor from the differ- ential gear case.
Page 371 – ELEC 9 - 48...
Page 372: Trbl Shtg
TRBL SHTG...
Page 373: Troubleshooting Trbl
TRBL SHTG CHAPTER 10. TROUBLESHOOTING STARTING FAILURE/HARD STARTING ............10-1 FUEL SYSTEM ..................10-1 ELECTRICAL SYSTEM ................10-1 COMPRESSION SYSTEM ..............10-2 POOR IDLE SPEED PERFORMANCE ............10-2 POOR IDLE SPEED PERFORMANCE ..........10-2 POOR MEDIUM AND HIGH-SPEED PERFORMANCE ......10-2 POOR MEDIUM AND HIGH-SPEED PERFORMANCE .......10-2 FAULTY DRIVE TRAIN ................10-3 FAULTY GEAR SHIFTING ................10-4 HARD SHIFTING .................10-4...
Page 374 TRBL SHTG UNSTABLE HANDLING ................10-6 UNSTABLE HANDLING ..............10-6 LIGHTING SYSTEM ..................10-6 HEADLIGHT DARK ................10-6 BULB BURNT OUT ................10-6...
Page 375: Troubleshooting
TRBL STARTING FAILURE/HARD STARTING SHTG TROUBLESHOOTING NOTE: The following troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to troubleshooting. Refer to the relative procedure in this man- ual for inspection, adjustment and replacement of parts. STARTING FAILURE/HARD STARTING FUEL SYSTEM Fuel tank...
Page 376 TRBL STARTING FAILURE/HARD STARTING/POOR IDLE SPEED PERFORMANCE/POOR MEDIUM AND HIGH-SPEED PERFORMANCE SHTG COMPRESSION SYSTEM Cylinder and cylinder head Valve, camshaft and crankshaft Loose spark plug Improperly sealed valve Loose cylinder head or cylinder Improperly contacted valve and valve seat Broken cylinder head gasket Improper valve timing Worn, damaged or seized cylinder Broken valve spring...
Page 377 TRBL FAULTY DRIVE TRAIN SHTG FAULTY DRIVE TRAIN The following conditions may indicate damaged shaft drive components: Symptoms Possible Causes 1.A pronounced hesitation or “jerky” move- A.Bearing damage. ment during acceleration, deceleration, or sustained speed. (This must not be con- B.Improper gear lash.
Page 378 FAULTY GEAR SHIFTING/ TRBL FAULTY CLUTCH PERFORMANCE SHTG FAULTY GEAR SHIFTING HARD SHIFTING Refer to “CLUTCH SLIPPING/DRAGGING-CLUTCH DRAGGING”. SHIFT LEVER DOES NOT MOVE Shift cam, shift fork Transmission Groove jammed with impurities Seized transmission gear Seized shift fork Jammed impurities Bent shift fork guide bar Incorrectly assembled transmission Shift guide...
Page 379 FAULTY CLUTCH PERFORMANCE/OVERHEATING/ TRBL OVER COOLING/FAULTY BRAKE SHTG POOR SPEED PERFORMANCE V-belt Primary sliding sheave Oil or grease on the V-belt Worn primary sliding sheave Primary pulley weight Secondary fixed sheave Faulty operation Worn secondary fixed sheave Worn primary pulley weight Secondary sliding sheave Primary fixed sheave Worn secondary sliding sheave...
Page 380 SHOCK ABSORBER MALFUNCTION/ TRBL UNSTABLE HANDLING/LIGHTING SYSTEM SHTG SHOCK ABSORBER MALFUNCTION MALFUNCTION Bent or damaged damper rod Damaged oil seal lip Fatigued shock absorber spring UNSTABLE HANDLING UNSTABLE HANDLING Handlebar Wheels Improperly installed or bent Deformed wheel Steering Loose bearing Incorrect toe-in Bent or loose wheel axle Bent steering stem...
Page 381 YFM400FWA(M) WIRING DIAGRAM CDI magneto Rectifier/regulator Main switch Battery Main fuse Starter relay Br/W W Br/W W/G W/L Y/B G/Y Starter motor W/R R R/W B/W (BLACK) (BLACK) (BLACK) (BLACK) (BLUE) (BLUE) Starting circuit cut-off relay WIRE HARNESS SUB-WIRE HARNESS 2 WIRE HARNESS IGNITION COIL LEAD WIRE HARNESS SUB-WIRE HARNESS 1 Ignition fuse...

Yamaha YFM400FWA 2000 5GH3-AE1 Service Manual

Table of Contents

2 Spec

Periodic Inspections and Adjustments Chapter 3.

Chapter 4. Engine

5 Cool

Carb Chapter 6. Carburetion

7 Drive

Chapter 8. Chassis

Chapter 9. Electrical

Quick Links

Chapters

Troubleshooting

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Summary of Contents for Yamaha YFM400FWA 2000 5GH3-AE1