Yamaha 5KM2-AE1 Service Manual
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Yamaha 5KM2-AE1 Service Manual

Yamaha 5KM2-AE1 Service Manual

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2002
YFM660F
P
(
)
5KM2-AE1
SERVICEMANUAL

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Summary of Contents for Yamaha 5KM2-AE1

  • Page 1 2002 YFM660F 5KM2-AE1 SERVICEMANUAL...
  • Page 3 YFM660F(P) 2002 SERVICE MANUAL © 2001 by Yamaha Motor Co., Ltd. First edition, May 2001 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
  • Page 4 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 maintenance and repairs on Yamaha machine has a basic understanding of the mechanical ideas and the procedures of machine repair.
  • Page 5 EB002000 HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”) 1st title 1: This is the title of the chapter with its symbol in the upper right corner of each page. 2nd title 2: This title indicates the section of the chapter and only appears on the first page of each section.

  • Page 6: Periodic Checks And Adjustments

    EB003000 ILLUSTRATED SYMBOLS Illustrated symbols 1 to 0 are printed on the SPEC INFO top right of each page and indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Cooling system 6 Carburetion 7 Drive train COOL...

  • Page 7: Table Of Contents

    TABLE OF CONTENTS GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC CHECKS AND ADJUSTMENTS ENGINE COOLING SYSTEM COOL CARBURETION CARB DRIVE TRAIN DRIV CHASSIS CHAS – ELECTRICAL ELEC TROUBLESHOOTING TRBL SHTG...
  • Page 9 INFO...
  • Page 10 INFO CHAPTER 1. GENERAL INFORMATION MACHINE IDENTIFICATION ................ 1-1 VEHICLE IDENTIFICATION NUMBER ..........1-1 MODEL LABEL ..................1-1 FEATURES ....................1-2 FRONT DIFFERENTIAL ............... 1-2 TRANSMISSION ................... 1-9 IMPORTANT INFORMATION ..............1-10 PREPARATION FOR REMOVAL PROCEDURES ......1-10 REPLACEMENT PARTS ..............1-10 GASKETS, OIL SEALS AND O-RINGS ..........
  • Page 11 INFO...

  • Page 12: 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 13: Features

    FEATURES INFO FEATURES FRONT DIFFERENTIAL 1 Adapter 7 Drive pinion gear 2 Drive clutch 8 Gear motor 3 Differential side gear (left) 4 Differential pinion gear È To front wheel 5 Ring gear É From the middle gear 6 Differential side gear (right) 1 - 2...
  • Page 14 FEATURES INFO Power is transmitted as follows: middle gear → front drive shaft → drive pinion gear 7 → ring gear 5 → differential pinion gear 4. In the 2WD mode, the left differential side gear 3 and the drive clutch 2 are not engaged, therefore, the left side gear runs idle and does not transmit power to the left front constant velocity joint.
  • Page 15 FEATURES INFO When the 4WD mode is selected, the gear motor is operated, and the drive clutch 2 moves to the right and engages with the left differential side gear 3. Accordingly, power is transmitted as follows: ring gear 5 → differential pinion gear 4 → left differential side gear 3 → drive clutch 2 → adapter 1 →...
  • Page 16 FEATURES INFO 4WD (Diff-Lock) When the 4WD (Diff-Lock) mode is selected, the gear motor moves the drive clutch 2 further to the right, which causes the ring gear 5 and the drive clutch 2 to engage. As a result, power is transmit- ted directly from the ring gear 5 to the drive clutch 2, then to the left front constant velocity joint via the adapter 1.
  • Page 17 FEATURES INFO In addition, the 4WD (Diff-Lock) mode can be engaged only when the ATV is stopped. Even if an attempt is made to select this mode when the ATV is traveling, it will only result in a standby condi- tion (i.e., when the differential lock select switch and the differential gear are not matched).
  • Page 18 FEATURES INFO Shift mechanism A new shift mechanism with a parking position has been added to the YFM660F. 1.Shift cam 2.Shift fork guide bar 3.Drive axle 4.Stopper lever shaft 1 - 7...
  • Page 19 FEATURES INFO Parking (1) L (Low), H (High), N (Neutral), and R (Reverse) positions The end of the stopper lever is held by the return spring 1. Then, the stopper lever tab is sepa- rated from the drive axle stopper to free the drive axle. (2) P (Park) position When the drive select lever is shifted to the “P”...

  • Page 20: Transmission

    FEATURES INFO TRANSMISSION To create a compact, 3-axle transmission, a chain drive has been adopted for the reverse transmis- sion. 1 Secondary shaft 2 Drive axle 3 Middle drive shaft 4 Low wheel gear 5 Chain 1 Secondary shaft 2 Drive axle L (Low) or H (High) mode When the transmission is in either the low or high mode, the drive axle is driven via the sec-...

  • Page 21: 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 function and appearance, but inferior in quality.

  • Page 22: Lock Washers/Plates And Cotter Pins

    IMPORTANT INFORMATION INFO EB101030 LOCK WASHERS/PLATES AND COTTER PINS 1.Replace all lock washers/plates 1 and cotter pins after removal. Bend lock tabs along the bolt or nut flats after the bolt or nut has been tightened to specification. EB101040 BEARINGS AND OIL SEALS 1.Install bearings and oil seals so that the manufacturer’s marks or numbers are visible.

  • Page 23: 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 24: 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 25 SPECIAL TOOLS INFO Tool No. Tool name/How to use Illustration Piston pin puller 90890-01304 YU-01304 This tool is used to remove the piston pin. Tappet adjusting tool (3 mm) 90890-01311 YU-08035 This tool is necessary for adjusting the valve clearance. Fuel level gauge 90890-01312 YM-01312-A...
  • Page 26 SPECIAL TOOLS INFO Tool No. Tool name/How to use Illustration Ring nut wrench 90890-01430 This tool is needed to removing and YM-38404 installing the middle driven shaft bearing retainer. Gear lash measurement tool 90890-01467 YM-01467 This tool is used to measure the gear lash.
  • Page 27 SPECIAL TOOLS INFO Tool No. Tool name/How to use Illustration Adapter Adapter 90890-04059 Spacer (crankshaft installer) YM-90069 Spacer These tools are used to install the crank- 90890-04081 YM-91044 shaft. Universal joint holder 90890-04062 YM-04062 This tool is needed when removing or installing the universal joint yoke nut.
  • Page 28 INFO Tool No. Tool name/How to use Illustration Ignition checker 90890-06754 This instrument is necessary for checking the ignition system components. Yamaha bond No. 1215 ® Bond Sealant (Quick Gasket 90890-85505 Sealant This sealant (bond) is used on crankcase ACC-11001-05-01 mating surfaces, etc.

  • Page 30: Spec

    SPEC...
  • Page 31 SPEC CHAPTER 2. SPECIFICATIONS GENERAL SPECIFICATIONS ..............2-1 MAINTENANCE SPECIFICATIONS ............2-4 ENGINE ....................2-4 CHASSIS ..................... 2-14 ELECTRICAL ..................2-18 HOW TO USE THE CONVERSION TABLE ..........2-20 GENERAL TORQUE SPECIFICATIONS ........... 2-20 LUBRICATION POINTS AND LUBRICANT TYPES ......... 2-21 ENGINE ....................
  • Page 32 SPEC...

  • Page 33: Chapter 2. Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Model code: 5KM2 : (for CDN) 5KM3 : (for Europe) 5KM4 : (for Oceania) Dimensions: Overall length 2,085 mm (82.1 in) Overall width 1,150 mm (45.3 in) Overall height 1,210 mm (47.6 in) Seat height 880 mm (34.6 in) Wheelbase...
  • Page 34 SPEC GENERAL SPECIFICATIONS Item Standard Oil capacity: Engine oil Periodic oil change 1.9 L (1.7 lmp qt, 2.0 US qt) With oil filter replacement 2.0 L (1.8 lmp qt, 2.1 US qt) Total amount 2.2 L (1.9 lmp qt, 2.3 US qt) Final gear case oil Periodic oil change 0.25 L (0.22 lmp qt, 0.26 US qt)
  • Page 35 SPEC GENERAL SPECIFICATIONS Item Standard Tire: Type Tubeless AT25 × 8–12 Size front AT25 × 10–12 rear Manufacturer front DUNLOP: (for CDN, Europe) CHENG SHIN: (for Oceania) rear DUNLOP: (for CDN, Europe) CHENG SHIN: (for Oceania) Type front KT131: (for CDN, Europe) C828-4P: (for Oceania) rear KT135: (for CDN, Europe)

  • Page 36: Maintenance Specifications

    SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Cylinder head: Warp limit ---- 0.03 mm (0.0012 in) Cylinder: Bore size 100.005 ~ 100.055 mm 100.1 mm (3.9372 ~ 3.9392 in) (3.94 in) Measuring point 50 mm (1.97 in) ---- Camshaft: Drive method Chain drive (Left)
  • Page 37 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Cam chain: Cam chain type/No. of links 92RH2010J/126M ---- Cam chain adjustment method Automatic ---- Rocker arm/rocker arm shaft: Bearing inside diameter 12.000 ~ 12.018 mm ---- (0.4724 ~ 0.4731 in) Shaft outside diameter 11.976 ~ 11.991 mm ---- (0.4715 ~ 0.4721 in)
  • Page 38 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Stem runout limit ---- 0.01 mm (0.0004 in) Valve seat width 0.9 ~ 1.1 mm ---- (0.0354 ~ 0.0433 in) 0.9 ~ 1.1 mm ---- (0.0354 ~ 0.0433 in) Valve spring: Inner spring Free length 32.63 mm (1.28 in) 31.0 mm (1.22 in)
  • Page 39 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Piston: Piston to cylinder clearance 0.05 ~ 0.07 mm 0.15 mm (0.0020 ~ 0.0028 in) (0.0059 in) Piston size “D” 99.945 ~ 99.995 mm ---- (3.9348 ~ 3.9368 in) Measuring point “H” 2.5 mm (0.10 in) ---- Piston off-set 1.0 mm (0.0394 in)
  • Page 40 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit 2nd ring Type Taper ---- Dimensions (B × T) 1.2 × 4.0 mm ---- (0.0472 × 0.1575 in) End gap (installed) 0.30 ~ 0.45 mm 0.80 mm (0.0118 ~ 0.0177 in) (0.0315 in) Side clearance 0.03 ~ 0.07 mm 0.13 mm (0.0012 ~ 0.0028 in)
  • Page 41 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 Shift cam and guide bar ---- Air filter oil grade: Engine oil ---- Carburetor: I.
  • Page 42 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Cooling system: Radiator core Width 360 mm (14.17 in) ---- Height 219 mm (8.62 in) ---- Thickness 27 mm (1.06 in) ---- Radiator cap opening pressure 93.3 ~ 122.7 kPa (0.933 ~ ---- 1.227 kg/cm , 13.53 ~ 17.79 psi) Radiator capacity 0.78 L (0.69 Imp qt, 0.82 US qt)
  • Page 43 SPEC MAINTENANCE SPECIFICATIONS Item Standard Cylinder head tightening sequence: 2 - 11...
  • Page 44 SPEC MAINTENANCE SPECIFICATIONS Tightening torques Tightening torque Part Thread Part to be tightened Q’ty Remarks name size m·kg ft·lb Cylinder head (exhaust pipe) Stad bolt Bolt Cylinder head Bolt Bolt Spark plug — Cylinder head cover Bolt Camshaft end cap Bolt Oil check bolt Union bolt...
  • Page 45 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part Thread Part to be tightened Q’ty Remarks name size m·kg ft·lb Primary sheave assembly 12.0 Secondary sheave assembly 10.0 Secondary sheave spring retainer Clutch carrier assembly 16.0 Balancer driven gear 11.0 Middle driven shaft bearing retainer Screw Middle driven shaft drive pinion 14.5...

  • Page 46: Chassis

    SPEC MAINTENANCE SPECIFICATIONS CHASSIS Item Standard Limit Steering system: Steering bearing type Ball and race bearing ---- Front suspension: Shock absorber travel 86 mm (3.39 in) ---- Fork spring free length 295 mm (11.61 in): (for CDN) ---- 305.5 mm (12.03 in): (for Europe, ---- Oceania) Spring fitting length...
  • Page 47 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Front disc brake: Type Dual ---- Disc outside diameter × thickness 220.0 × 3.5 mm (8.66 × 0.14 in) ---- Pad thickness inner 4.2 mm (0.17 in) 1 mm (0.04 in) Pad thickness outer 4.2 mm (0.17 in) 1 mm (0.04 in)
  • Page 48 SPEC MAINTENANCE SPECIFICATIONS Tightening torques Tightening torque Part to be tightened Thread size Remarks m·kg ft·lb Engine bracket and engine Engine bracket and rubber damper (front) Engine bracket and rubber damper (front) Engine and rubber damper (rear) Engine and rubber damper (rear) Rubber damper and frame Front wheel and front wheel hub Front wheel hub and constant velocity joint...
  • Page 49 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Remarks m·kg ft·lb Rear knuckle and rear frame (upper) Rear knuckle and rear frame (lower) Rear shock absorber and frame Rear shock absorber and rear arm (lower) Rear arm (upper) and frame Rear arm (lower) and frame Differential gear case and frame Differential gear case filler bolt...

  • Page 50: 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 51 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: Horn type Plane ---- Model (manufacturer) × quantity MF-12 (NIKKO) × 1 ---- Max.

  • Page 52: 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 listed This chart specifies torque for standard fasten- in SI and METRIC UNITS. ers with standard I.S.O.

  • Page 53: Lubrication Points And Lubricant Types

    Shift lever (select lever)/shift guide Shift cam lever Stopper lever Clutch carrier assembly One-way bearing Drive chain/sprocket  Sealant (Quick Gasket Crankcase mating surfaces Yamaha Bond No.1215  Stater lead grommet Sealant (Quick Gasket (left side crankcase) Yamaha Bond No.1215 2 - 21...

  • Page 54: Coolant Flow Diagrams

    SPEC COOLANT FLOW DIAGRAMS COOLANT FLOW DIAGRAMS 1 Radiator 2 Radiator cap 3 Thermo switch 4 Radiator inlet hose 5 Thermostat assembly breather hose 6 Water pump outlet pipe 7 Water pump outlet hose 8 Radiator outlet hose B - B 2 - 22...
  • Page 55 SPEC COOLANT FLOW DIAGRAMS 1 Thermostat 2 Radiator inlet hose 3 Radiator 4 Radiator outlet hose 2 - 23...

  • Page 56: Oil Flow Diagrams

    SPEC OIL FLOW DIAGRAMS OIL FLOW DIAGRAMS 1 Camshaft 2 Oil delively pipe 2 3 Oil delively piep 3 4 Crankshaft 2 - 24...
  • Page 57 SPEC OIL FLOW DIAGRAMS 1 Oil delively pipe 1 2 Oil delively pipe 2 3 Oil delively pipe 3 4 Oil pump 5 Oil strainer 2 - 25...
  • Page 58 SPEC OIL FLOW DIAGRAMS 1 Oil filter 2 Oil delively pipe 2 3 Oil delively pipe 1 4 Drive axle 5 Relief valve 6 Oil pump 7 Oil strainer 2 - 26...

  • Page 59: Cable Routing

    SPEC CABLE ROUTING CABLE ROUTING 1 Rear brake light switch 0 Rear brake light switch lead 2 Rear brake cable A Fan motor lead 3 Starter cable B Sub-wire harness (to gear motor) 4 Front brake hose C Differential gear case breather hose 5 Throttle cable 6 Horn switch È...
  • Page 60 SPEC CABLE ROUTING É Fasten the handlebar switch lead and rear brake Ì Pass the brake hose through the hose guide. Í Fasten the on-command four-wheel drive switch light switch lead with a plastic band. Ê Fasten the thermo switch 2 lead, fan motor lead, and differential gear lock switch lead, front brake coolant reservoir breather hose, coolant reser- light switch lead, handlebar switch lead, and rear...
  • Page 61 SPEC CABLE ROUTING 1 Park brake light switch È To the front brake light switch, on-command four- 2 On-command four-wheel drive switch and differ- wheel drive switch and differential gear lock switch, ential gear lock switch lead handlebar switch, and rear brake light switch. 3 Headlight lead É...
  • Page 62 SPEC CABLE ROUTING Ì Pass the fan motor breather hose through the guide on the front fender. Í Pass the headlight lead through the guide on the front fender. É È Ê Í Ë Ì 2 - 30...
  • Page 63 SPEC CABLE ROUTING 1 Coolant reservoir hose È Connect the ignition coil coupler under the front 2 Fan motor lead fender. 3 Ignition coil coupler É Pass the starter cable through the cable guide at 4 Starter cable the front of plastic cover. 5 Fuel tank breather hose Ê...
  • Page 64 SPEC CABLE ROUTING Í Slacken the coolant reservoir hose, and then Ð Fasten the gear motor lead and differential gear case insert it between the frame and the water pump breather hose with a plastic band. Be sure not to inlet.
  • Page 65 SPEC CABLE ROUTING 1 Fuel sender lead B Starter cable 2 Differential gear case breather hose C Fuel hose 3 Vacuum chamber breather hose D Thermo switch 1 lead 4 Starter motor lead E Reverse switch lead 5 Wireharness F AC magneto coupler 6 Gear position switch lead G Gear position switch coupler 7 Final drive gear case breather hose...
  • Page 66 SPEC CABLE ROUTING È Fasten the final drive gear case breather hose, speed sensor lead, ground lead, gear position switch lead, AC magneto lead, wire harness, and reverse indicator light lead with a plastic locking tie. Be careful not to pinch the breather hose.
  • Page 67 SPEC CABLE ROUTING Ï Pass the vacuum chamber breather hose through the plastic cover hole. Ð Insert a clamp into the third hole from the top of the rectifier/regulator bracket, and then clamp the final drive gear case breather hose with the clamp. È...
  • Page 68 SPEC CABLE ROUTING 1 Gear position switch B Rear brake hose 2 Reverse switch 3 Crankcase breather hose È Pass the rear brake cable and throttle cable 4 Select lever control cable through the cable guide. 5 Rear brake cable É...
  • Page 69 SPEC CABLE ROUTING Ê Clamp the spark plug lead and radiator inlet hose with a plastic clamp. Ë When installing the ignition coil, face the spark lead to the right side of the frame. Ì To the rear fender hole Í...
  • Page 70 SPEC CABLE ROUTING 1 Negative battery lead È Pass the tail/brake light lead through the lead 2 Tail/brake light lead guide. 3 Fuse box É Position the wire harness tape at the end of the 4 Four-wheel drive relay 3 rear fender guide.
  • Page 71 SPEC CABLE ROUTING 1 Front brake hose È Pass the thermo sensor 1 lead through the lead 2 Throttle cable guide. 3 Thermo switch 1 lead É Pass the crankcase breather hose through the 4 Crankcase breather hose hose guide. 5 Fuel sender lead Ê...
  • Page 72 SPEC CABLE ROUTING Î Fasten the speed sensor coupler, thermo switch 1 lead, reverse switch lead, ground lead, gear position switch lead, and AC magneto couplers with a band. Í A - A Ì Ë Î È É C - C Ê...
  • Page 74 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 GRILL ....3-4 HANDLEBAR COVER, FUEL TANK COVER AND FRONT FENDER . 3-5 REAR CARRIER AND REAR FENDER ..........
  • Page 75 CHASSIS ....................3-39 ADJUSTING THE REAR BRAKE ............3-39 CHECKING THE BRAKE FLUID LEVEL ..........3-41 CHECKING THE FRONT BRAKE PAD ..........3-43 CHECKING THE REAR BRAKE PAD ..........3-43 CHECKING THE BRAKE HOSE ............3-43 BLEEDING THE HYDRAULIC BRAKE SYSTEM ....... 3-44 ADJUSTING THE SELECT LEVER CONTROL CABLE AND SHIFT ROD ................

  • Page 76: Periodic Inspections And Adjustments

    INTRODUCTION/PERIODIC MAINTENANCE/ LUBRICATION INTERVALS EB300000 PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjust- ments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and a longer service life. The need for costly overhaul work will be greatly reduced. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale.
  • Page 77 • Check for cracks or damage. 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. ** Lithium-soap-based grease NOTE: Recommended brake fluid: DOT 4 Brake fluid replacement: 1.When disassembling the master cylinder or caliper, replace the brake fluid.

  • Page 78: Seat, Carriers, Fenders And Fuel Tank

    SEAT, CARRIERS, FENDERS AND FUEL TANK SEAT, CARRIERS, FENDERS AND FUEL TANK SEAT AND SIDE PANELS Order Job name/Part name Q’ty Remarks Removing the seat and side panels 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 79: Front Carrier, Front Bumper And Front Grill

    SEAT, CARRIERS, FENDERS AND FUEL TANK FRONT CARRIER, FRONT BUMPER AND FRONT GRILL 33 Nm (3.3 m kg, 24 ft • • 33 Nm (3.3 m kg, 24 ft • • 9 Nm (0.9 m kg, 6.5 ft • • Order Job name/Part name Q’ty...

  • Page 80: Handlebar Cover, Fuel Tank Cover And Front Fender

    SEAT, CARRIERS, FENDERS AND FUEL TANK HANDLEBAR COVER, FUEL TANK COVER AND FRONT FENDER 12 10 Order Job name/Part name Q’ty Remarks Removing the handlebar cover, fuel Remove the parts in the order below. tank cover and front fender Seat and fuel tank side panels Refer to “SEAT AND SIDE PANELS”.
  • Page 81 SEAT, CARRIERS, FENDERS AND FUEL TANK 12 10 Order Job name/Part name Q’ty Remarks Rear brake switch coupler Disconnect. Front brake light switch coupler Disconnect. Rear brake light switch coupler Disconnect. Main switch coupler Disconnect. Auxiliary DC jack coupler Disconnect. Fan motor breather hose Differential gear case breather hose Coolant reservoir breather hose...

  • Page 82: Rear Carrier And Rear Fender

    SEAT, CARRIERS, FENDERS AND FUEL TANK REAR CARRIER AND REAR FENDER 7 Nm (0.7 m kg, 5.1 ft • • Order Job name/Part name Q’ty Remarks Removing the rear carrier and rear Remove the parts in the order below. fender Seat and fuel tank side panels Refer to “SEAT AND SIDE PANELS”.
  • Page 83 SEAT, CARRIERS, FENDERS AND FUEL TANK 7 Nm (0.7 m kg, 5.1 ft • • Order Job name/Part name Q’ty Remarks Battery Starter relay ground lead Disconnect. Taillight connector Disconnect. Crankcase breather hose Clamp screw Loosen. Air filter case Rear fender For installation, reverse the removal procedure.

  • Page 84: Engine Skid Plate (Center) And Engine Skid Plate (Rear)

    SEAT, CARRIERS, FENDERS AND FUEL TANK ENGINE SKID PLATE (CENTER) AND ENGINE SKID PLATE (REAR) 9 Nm (0.9 m kg, 6.5 ft • • Order Job name/Part name Q’ty Remarks Removing the engine skid plate Remove the parts in the order below. (center) and engine skid plate (rear) Engine skid plate (center) Engine skid plate (rear)

  • Page 85: Fuel Tank

    SEAT, CARRIERS, FENDERS AND FUEL TANK FUEL TANK Order Job name/Part name Q’ty Remarks Removing the fuel tank Remove the parts in the order below. Seat and side panels Refer to “SEAT AND SIDE PANELS”. Fuel tank cover Refer to “HANDLEBAR COVER, FUEL TANK COVER AND FRONT FENDER”.
  • Page 86 SEAT, CARRIERS, FENDERS AND FUEL TANK Order Job name/Part name Q’ty Remarks Clamp Vacuum chamber breather hose Differential gear case breather hose Crankcase breather hose Plastic band Bushing Plastic cover For installation, reverse the removal procedure. 3 - 11...

  • Page 87: Footrest Boards

    FOOTREST BOARDS FOOTREST BOARDS 9 Nm (0.9 m kg, 6.5 ft • • (12) (12) 33 Nm (3.3 m kg, 24 ft • • Order Job name/Part name Q’ty Remarks Removing the footrest boards Remove the parts in the order below. Fuel tank side panels Refer to “SEAT AND SIDE PANELS”.

  • Page 88: Engine

    ADJUSTING THE VALVE CLEARANCE ENGINE ADJUSTING THE VALVE CLEARANCE NOTE: The valve clearance must be adjusted when the engine is cool to the touch. Adjust the valve clearance when the piston is at the Top Dead Center (T.D.C.) on the com- pression stroke.
  • Page 89 ADJUSTING THE VALVE CLEARANCE 6.Remove: Timing plug 1 7.Check: Valve clearance Out of specification → Adjust. Valve clearance (cold): Intake: 0.10 ~ 0.15 mm (0.0039 ~ 0.0059 in) Exhaust: 0.15 ~ 0.20 mm (0.0059 ~ 0.0079 in) ***************************************************** Checking steps: Turn the crankshaft counterclockwise with a wrench.
  • Page 90 ADJUSTING THE VALVE CLEARANCE 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 tappet adjusting tool 4 until the proper clearance is obtained.

  • Page 91: Adjusting The Timing Chain

    ADJUSTING THE VALVE CLEARANCE/ADJUSTING THE TIMING CHAIN/ ADJUSTING THE IDLING SPEED 11.Install: Engine side cover Fuel tank Front fender Front carrier Seat Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”. ADJUSTING THE TIMING CHAIN Adjustment free. ADJUSTING THE IDLING SPEED 1.Start the engine and let it warm up for sev- eral minutes.

  • Page 92: Adjusting The Idling Speed

    ADJUSTING THE IDLING SPEED/ ADJUSTING THE THROTTLE LEVER FREE PLAY 5.Adjust: Engine idling speed ***************************************************** Adjustment steps: Turn the throttle stop screw 1 in or out until the specified idling speed is obtained. Idling speed becomes Turning in higher. Idling speed becomes Turning out lower.
  • Page 93 ADJUSTING THE THROTTLE LEVER FREE PLAY 1.Check: Throttle lever free play a Out of specification → Adjust. Throttle lever free play: 3 ~ 5 mm (0.12 ~ 0.20 in) 2.Remove: Seat Fuel tank side panel (right) Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”.

  • Page 94: Adjusting The Speed Limiter

    ADJUSTING THE THROTTLE LEVER FREE PLAY/ ADJUSTING THE SPEED LIMITER Second step: Pull back the adjuster cover 4. Loosen the locknut 5. Turn the adjuster 6 in or out until the correct free play is obtained. Turning in Free play is increased. Turning out Free play is decreased.
  • Page 95 ADJUSTING THE SPEED LIMITER 2.Adjust: Speed limiter length ***************************************************** Adjustment steps: Loosen the locknut 1. Turn the adjuster 2 in or out until the speci- fied speed limiter length is obtained. Speed limiter length is Turning in decreased. Speed limiter length is Turning out increased.

  • Page 96: Adjusting The Starter Cable

    ADJUSTING THE STARTER CABLE/ CHECKING THE SPARK PLUG ADJUSTING THE STARTER CABLE 1.Remove: Seat Fuel tank side panel (left) 2.Adjust: ***************************************************** Adjustment steps: Disconnect the starter cable 1 from the car- buretor body. NOTE: Do not remove the starter plunger 2 from the starter cable.

  • Page 97: Checking The Ignition Timing

    CHECKING THE SPARK PLUG/ CHECKING THE IGNITION TIMING CHECKING THE SPARK PLUG 1.Remove: Spark plug 2.Check: Spark plug type Incorrect → Replace. Standard spark plug: DPR8EA-9/NGK 3.Check: Electrode 1 Wear/damage → Replace. Insulator 2 Abnormal color → Replace. Normal color is a medium-to-light tan color. 4.Clean the spark plug with a spark plug cleaner or wire brush.
  • Page 98 CHECKING THE IGNITION TIMING CHECKING THE IGNITION TIMING NOTE: Engine idling speed and throttle cable free play should be adjusted properly before checking the ignition timing. 1.Remove: Seat Fuel tank side panel (left) Engine side cover Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”.

  • Page 99: Measuring The Compression Pressure

    CHECKING THE IGNITION TIMING/ MEASURING THE COMPRESSION PRESSURE 4.Detach: Timing light Tachometer 5.Install: Engine side cover Fuel tank side panel (left) Seat Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”. MEASURING THE COMPRESSION PRESSURE NOTE: Insufficient compression pressure will result in a loss of performance.
  • Page 100 MEASURING THE COMPRESSION PRESSURE 6.Measure: Compression pressure Above the maximum pressure: Inspect the cylinder head, valve surfaces, and piston crown for carbon deposits. Below the minimum pressure: Squirt a few drops of oil into the affected cyl- inder and measure again. Refer to the table below.

  • Page 101: Checking The Engine Oil Level

    CHECKING THE ENGINE OIL LEVEL CHECKING THE ENGINE OIL LEVEL 1.Place the machine on a level surface. 2.Remove: Engine side panel Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”. 3.Check: Engine oil level Oil level should be between the maximum 1 and minimum 2 marks.

  • Page 102: Changing The Engine Oil

    CHANGING THE ENGINE OIL CHANGING THE ENGINE OIL 1.Start the engine and let it warm up for sev- eral minutes. 2.Stop the engine and place an oil pan under the engine. 3.Remove: Seat Fuel tank side panel (left) Engine side cover Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”.
  • Page 103 CHANGING THE ENGINE OIL 6.Install: Engine oil drain bolt 1 30 Nm (3.0 m • kg, 22 ft • lb) 7.Fill: Crankcase (with sufficient oil to reach the specified level) Refer to “CHECKING THE ENGINE OIL LEVEL”. Oil quantity: Periodic oil change: 1.9 L (1.7 Imp qt, 2.0 US qt) With oil filter replacement: 2.0 L (1.8 Imp qt, 2.1 US qt)
  • Page 104 CHANGING THE ENGINE OIL Start the engine after solving the problem(-s) and check the engine oil pressure again. Tighten the oil gallery bolt to specification. Oil gallery bolt: 7 Nm (0.7 m • kg, 5.1 ft • lb) ***************************************************** 12.Install: Engine side cover Fuel tank side panel (left) Seat...

  • Page 105: Cleaning The Air Filter

    CLEANING THE AIR FILTER 3.Remove: Air filter element assembly 1 Air filter element cap Air filter element NOTE: When removing the air filter element, rotate the air filter element cap 1/4 of a turn and remove the element. 2 Air filter element cap 3 Air filter element CAUTION: Never operate the engine with the air filter...

  • Page 106: Checking The Coolant Level

    CLEANING THE AIR FILTER/ CHECKING THE COOLANT LEVEL Squeeze the excess solvent out of the ele- ment and let it dry. CAUTION: Do not twist or wring out the element. This could damage the foam material. Apply engine oil to the element. Squeeze out the excess oil.

  • Page 107: Changing The Coolant

    CHECKING THE COOLANT LEVEL/ CHANGING THE COOLANT 3.Check: Coolant level The coolant level should be between the minimum level mark a and maximum level mark b. Below the minimum level mark → Add the recommended coolant to the proper level. CAUTION: Adding water instead of coolant lowers the antifreeze content of the coolant.
  • Page 108 CHANGING THE COOLANT 2.Remove: Plastic band 1 Coolant reservoir bolts 2 Coolant reservoir cap 3 3.Disconnect: Coolant reservoir breather hose 4 4.Drain: Coolant (from the coolant reservoir) 5.Connect: Coolant reservoir breather hose 6.Install: Coolant reservoir bolts Plastic band 7.Remove: Radiator cap 1 WARNING A hot radiator is under pressure.
  • Page 109 CHANGING THE COOLANT 10.Check: Copper washer 1 Coolant drain bolt 2 Damage → Replace. 11.Install: Coolant drain bolt (water pump) 10 Nm (1.0 m • kg, 7.2 ft • lb) 12.Fill: Cooling system (with the specified amount of the recom- mended coolant) Recommended antifreeze High-quality...
  • Page 110 CHANGING THE COOLANT CAUTION: Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant, check, and if necessary, correct the antifreeze concentration of the coolant. Use only distilled water. However, soft water may be used if distilled water is not available.

  • Page 111: Checking The V-Belt

    CHECKING THE V-BELT CHECKING THE V-BELT 1.Remove: Right footrest board Crankcase cover (right) Refer to “PRIMARY AND SECONDARY SHEAVES” in CHAPTER 4. 2.Check: V-belt 1 Cracks/wear/scaling/chipping → Replace. Oil/grease → Check primary sheave and secondary sheave. 3.Measure: V-belt width 2 Out of specification →...

  • Page 112: Cleaning The Spark Arrester

    CHECKING THE V-BELT/ CLEANING THE SPARK ARRESTER 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 secondary sliding sheave away, causing the gap between the secondary fixed and sliding sheaves to widen.
  • Page 113 CLEANING THE SPARK ARRESTER Tap the tailpipe lightly with a soft-face ham- mer or suitable tool, then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe and the inner contact surfaces of the muffler. Insert the tailpipe 2 into the muffler and align the bolt holes.

  • Page 114: Chassis

    ADJUSTING THE REAR BRAKE CHASSIS ADJUSTING THE REAR BRAKE WARNING Always adjust both the brake pedal and the rear brake lever whenever adjusting the rear brake. 1.Check: Rear brake lever free play b Out of specification → Adjust. Rear brake lever free play: 0.5 ~ 2 mm (0.02 ~ 0.08 in) 2.Check: Rear brake pedal height a...
  • Page 115 ADJUSTING THE REAR BRAKE Loosen the locknut 4. Turn the adjusting bolt 5 until the brake pedal height is within the specified limits. Rear brake pedal height: 45 mm (1.77 in) Tighten the locknut 4. NOTE: When adjusting the brake pedal height make sure the locknut-to-adjusting bolt clearance b does not exceed 2 mm (0.08 in).

  • Page 116: Checking The Brake Fluid Level

    ADJUSTING THE REAR BRAKE/ CHECKING THE BRAKE FLUID LEVEL Adjust the select lever control cable. Refer to “ADJUSTING THE SELECT LEVER CONTROL CABLE AND SHIFT ROD”. Install the rear brake master cylinder cover. WARNING After this adjustment is performed, lift the front and rear wheels off the ground by placing a block under the engine, and spin the rear wheels to ensure there is no brake...
  • Page 117 CHECKING THE BRAKE FLUID LEVEL WARNING Use only the designed quality brake fluid: otherwise, the rubber seals may deterio- rate, causing leakage and poor brake per- formance. Refill with the same type of brake fluid; mixing fluids may result in a harmful chemical reaction and lead to poor perfor- mance.

  • Page 118: Checking The Front Brake Pad

    CHECKING THE FRONT BRAKE PAD/CHECKING THE REAR BRAKE PAD/CHECKING THE BRAKE HOSE CHECKING THE FRONT BRAKE PAD 1.Remove: Front wheels 2.Check: 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 119: Checking The Brake Hose

    CHECKING THE BRAKE HOSE/ BLEEDING THE HYDRAULIC BRAKE SYSTEM 2.Check: Front brake hoses 1 Rear brake hoses 2 Cracks/wear/damage → Replace. Fluid leakage → Replace the hose. Refer to “FRONT AND REAR BRAKES” in CHAPTER 8. NOTE: Hold the machine in an upright position and apply the front or rear brake.
  • Page 120 BLEEDING THE HYDRAULIC BRAKE SYSTEM 1.Bleed: È Brake system ***************************************************** Air bleeding steps: a. Add the proper brake fluid to the reservoir. b. Install the diaphragm. Be careful not to spill any fluid or allow the reservoir to overflow. c. Connect the clear plastic hose 1 tightly to the caliper bleed screw 2.

  • Page 121: Adjusting The Select Lever Control Cable And Shift Rod

    ADJUSTING THE SELECT LEVER CONTROL CABLE AND SHIFT ROD ADJUSTING THE SELECT LEVER CONTROL CABLE AND SHIFT ROD 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 122: Adjusting The Rear Brake Light Switch

    ADJUSTING THE SELECT LEVER CONTROL CABLE AND SHIFT ROD/ ADJUSTING THE REAR BRAKE LIGHT SWITCH 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.

  • Page 123: Checking The Final Gear Oil Level

    CHECKING THE FINAL GEAR OIL LEVEL/ CHANGING THE FINAL GEAR OIL CHECKING THE FINAL GEAR OIL LEVEL 1.Place the machine on a level place. 2.Loosen: Oil check bolt 1 NOTE: Loosen the slightly. Do not remove the bolt, otherwise the gear oil may come out.

  • Page 124: Checking The Differential Gear Oil

    CHANGING THE FINAL GEAR OIL/ CHECKING THE DIFFERENTIAL GEAR OIL 6.Fill: Final gear case Periodic oil change: 0.28 L (0.25 Imp qt, 0.30 US qt) Total amount: 0.33 L (0.29 Imp qt, 0.35 US qt) Recommended oil: SAE 80 API “GL-4” Hypoid gear CAUTION: Take care not to allow foreign material to enter the final gear case.

  • Page 125: Changing The Differential Gear Oil

    CHANGING THE DIFFERENTIAL GEAR OIL CHANGING THE DIFFERENTIAL GEAR OIL 1.Place the machine on a level surface. 2.Place a receptacle under the differential gear case. 3.Remove: Oil filler bolt Drain plug 1 4.Drain: Differential gear oil 5.Install: Drain plug 10 Nm (1.0 m • kg, 7.2 ft • lb) NOTE: Check the gasket (drain plug).

  • Page 126: Checking The Constant Velocity Joint Dust Boot

    CHECKING THE CONSTANT VELOCITY JOINT DUST BOOT/CHECKING THE STEERING SYSTEM/ADJUSTING THE TOE-IN CHECKING THE CONSTANT VELOCITY JOINT DUST BOOT 1.Check: Dust boots 1 Damage → Replace. Refer to “FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR” in CHAPTER 7. CHECKING THE STEERING SYSTEM 1.Place the machine on a level surface.

  • Page 127: Adjusting The Toe-In

    ADJUSTING THE TOE-IN ***************************************************** Measurement steps: NOTE: Before measuring the toe-in, make sure that the tire pressure is correct. Mark both front tire tread centers. Face the handlebar straight ahead. Measure the width È between the marks. Rotate the front tires 180° until the marks are exactly opposite one another.

  • Page 128: Adjusting The Front Shock Absorber

    ADJUSTING THE TOE-IN/ ADJUSTING THE FRONT SHOCK ABSORBER ***************************************************** Adjustment steps: Mark both tie-rods ends. This reference point will be needed during adjustment. Loosen the locknuts (tie-rod end) 1 of both tie-rods. The same number of turns should be given to both the right and left tie-rods 2 until the specified toe-in is obtained.

  • Page 129: Adjusting The Rear Shock Absorber

    TIRE CHARACTERISTICS 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 combinations are used, they can adversely affect your machine’s handling characteristics and are therefore not recommended.
  • Page 130 CHECKING THE TIRE TIRE PRESSURE 1)Recommended tire pressure Front 35 kPa (0.35 kg/cm , 5.0 psi) Rear 30 kPa (0.30 kg/cm , 4.3 psi) 2)Tire pressure below the minimum specifi- cation could cause the tire to dislodge from the rim under severe riding condi- tions.

  • Page 131: Checking The Wheel

    CHECKING THE TIRE/CHECKING THE WHEEL Cold tire Front Rear pressure 35 kPa 30 kPa Standard (0.35 kg/cm (0.30 kg/cm 5.0 psi) 4.3 psi) 32 kPa 27 kPa Minimum (0.32 kg/cm (0.27 kg/cm 4.6 psi) 3.9 psi) 38 kPa 33 kPa Maximum (0.38 kg/cm (0.33 kg/cm...

  • Page 132: Checking And Lubricating The Cable

    Cable sheath 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:...

  • Page 133: Electrical

    CHECKING THE BATTERY EB305000 ELECTRICAL CHECKING THE BATTERY NOTE: Since the MF battery is a sealed type battery, it is not possible to measure the specific gravity of the electrolyte in order to check the charge state of the battery. Therefore the charge of the battery has to be checked by measuring the voltage at the battery terminals.
  • Page 134 CHECKING THE BATTERY 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 135 CHECKING THE BATTERY Check the condition of the battery using the Relationship between the open-circuit voltage and the charging time at 20 °C 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 Charging time (hours) CAUTION:...
  • Page 136 CHECKING THE BATTERY Charging method using a variable voltage charger NOTE: Leave the battery unused for more than 30 minutes before Measure the open-circuit measuring its open-circuit voltage. voltage prior to charging. Charger Ammeter NOTE: Set the charging voltage to Connect a charger and 16 ~ 17 V.
  • Page 137 CHECKING THE BATTERY Charging method using a constant voltage charger NOTE: Leave the battery unused for Measure the open-circuit more than 30 minutes before voltage prior to charging. measuring its open-circuit voltage. Connect a charger and ammeter to the battery and start charging.
  • Page 138 CHECKING THE BATTERY/CHECKING THE FUSE 5.Check: 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 139: Checking The Fuse

    CHECKING THE FUSE 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 140: Adjusting The Headlight Beam

    CHECKING THE FUSE/ADJUSTING THE HEADLIGHT BEAM/ CHANGING THE HEADLIGHT BULB 4.Install: Seat Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”. ADJUSTING THE HEADLIGHT BEAM 1.Adjust: Headlight beam (vertically) Turn the adjuster 1 in or out. Turning in Headlight beam raised. Turning out Headlight beam lowered.

  • Page 141: Changing The Headlight Bulb

    CHANGING THE HEADLIGHT BULB 4.Remove: Cover 1 Bulb holder 2 Bulb NOTE: Turn the bulb holder counterclockwise and remove the defective bulb. WARNING Keep flammable products and your hands away from the bulb while it is on, since it will be hot. Do not touch the bulb until it cools down.
  • Page 143 CHAPTER 4. ENGINE ENGINE REMOVAL ..................4-1 AIR DUCTS, MUFFLER AND EXHAUST PIPE ........4-1 SELECT LEVER UNIT AND COOLANT RESERVOIR ......4-3 HOSES AND LEADS ................4-4 ENGINE MOUNTING BOLTS ..............4-5 INSTALLING THE ENGINE ..............4-7 CYLINDER HEAD COVER ................4-8 REMOVING THE CYLINDER HEAD COVER ........
  • Page 144 RECOIL STARTER AND AC MAGNETO ........... 4-38 REMOVING THE AC MAGNETO ............4-41 DISASSEMBLING THE RECOIL STARTER ........4-41 CHECKING THE AC MAGNETO ............4-41 CHECKING THE STARTER CLUTCH ..........4-42 CHECKING THE STARTER PULLEY ..........4-43 CHECKING THE RECOIL STARTER ..........4-43 ASSEMBLEING THE RECOIL STARTER ...........
  • Page 145 CRANKSHAFT AND OIL PUMP ..............4-72 OIL PUMP .................... 4-73 REMOVING THE CRANKSHAFT ............4-74 CHECKING THE OIL PUMP ............... 4-74 CHECKING THE RELIEF VALVE ............4-75 CHECKING THE OIL STRAINER ............4-75 ASSEMBLING THE OIL PUMP ............4-75 CHECKING THE CRANKSHAFT ............4-76 INSTALLING THE CRANKSHAFT AND BALANCER ......

  • Page 147: Chapter 4. Engine

    ENGINE REMOVAL ENGINE ENGINE REMOVAL AIR DUCTS, MUFFLER AND EXHAUST PIPE Order Job name/Part name Q’ty Remarks Removing the air ducts, muffler and Remove the parts in the order below. exhaust pipe Engine oil Drain. Refer to “CHANGING THE ENGINE OIL” in CHAPTER 3.
  • Page 148 ENGINE REMOVAL Order Job name/Part name Q’ty Remarks Air duct assembly 3 For installation, reverse the removal procedure. 4 - 2...

  • Page 149: Select Lever Unit And Coolant Reservoir

    ENGINE REMOVAL SELECT LEVER UNIT AND COOLANT RESERVOIR Order Job name/Part name Q’ty Remarks Removing the select lever unit and Remove the parts in the order below. coolant reservoir Coolant Drain. Refer to “CHANGING THE COOLANT” in CHAPTER 3. Shift arm Select lever shift rod Select lever unit Coolant reservoir breather hose...

  • Page 150: Hoses And Leads

    ENGINE REMOVAL HOSES AND LEADS Order Job name/Part name Q’ty Remarks Removing the hoses and leads Remove the parts in the order below. Radiator inlet hose Refer to “THERMOSTAT” in CHAPTER 5. Water pump assembly Refer to “WATER PUMP” in CHAPTER 5. Spark plug lead Crankcase breather hose Thermo switch lead...

  • Page 151: Engine Mounting Bolts

    ENGINE REMOVAL ENGINE MOUNTING BOLTS Order Job name/Part name Q’ty Remarks Removing the engine mounting bolt Remove the parts in the order below. Engine skid plate (front) Refer to “SEAT, CARRIERS, FENDERS Engine skid plate (center) AND FUEL TANK” in CHAPTER 3. Engine skid plate (rear) Rear wheels Refer to “REAR WHEELS AND BRAKE...
  • Page 152 ENGINE REMOVAL Order Job name/Part name Q’ty Remarks Rubber damper nut (front) NOTE: Engine mounting bolt (rear-upper) Remove the engine assembly from the Engine mounting bolt (rear-lower)/nut left side of the machine. Engine assembly Rubber damper nut (rear) CAUTION: Rubber damper (rear) Install all of the bolts/nuts and then Rubber damper (front) tighten them to full torque specifica-...

  • Page 153: Installing The Engine

    ENGINE REMOVAL INSTALLING THE ENGINE 1.Install: Engine mounting bolt (front) 1 Rubber damper (front) 2 Rubber damper nut (rear) 3 Engine assembly 4 Engine mounting bolt (rear lower)/nut 5 Engine mounting bolt (rear upper) 6 Rubber damper nut (front) 7 NOTE: Do not fully tighten the bolts and nuts.

  • Page 154: Cylinder Head Cover

    CYLINDER HEAD COVER CYLINDER HEAD COVER Order Job name/Part name Q’ty Remarks Removing the cylinder head cover Remove the parts in the order below. Seat/front fender Refer to “SEAT, CARRIERS, FEND- ERS AND FUEL TANK” in CHAPTER 3. Fuel tank/plastic cover Recoil starter/timing plug Refer to “ADJUSTING THE VALVE CLEARANCE”...
  • Page 155 CYLINDER HEAD COVER Order Job name/Part name Q’ty Remarks Cylinder head cover Refer to “REMOVING/INSTALLING THE CYLINDER HEAD COVER”. Dowel pin For installation, reverse the removal procedure. 4 - 9...

  • Page 156: Removing The Cylinder Head Cover

    CYLINDER HEAD COVER REMOVING THE CYLINDER HEAD COVER 1.Align: “I” mark (with stationary pointer) ***************************************************** Checking steps: Turn the crankshaft counterclockwise with a wrench. Align the “I” mark 1 on the rotor with the sta- tionary pointer 2 on the crankcase cover. When the “I”...

  • Page 157: Checking The Tappet Cover

    (to the mating surfaces of the cylinder head and cylinder head cover)  ) 1: Sealant (Quick Gasket P/N. ACC-11001-05-01 Yamaha bond No. 1215: P/N. 90890-85505 2.Install: Cylinder head cover Washers 1 Bolts 10 Nm (1.0 m • kg, 7.2 ft • lb)

  • Page 158: Rocker Arms

    ROCKER ARMS ROCKER ARMS Order Job name/Part name Q’ty Remarks Removing the rocker arm Remove the parts in the order below. Cylinder head cover Refer to “CYLINDER HEAD COVER”. Plug/O-ring Bolt Rocker arm shaft 2 Rocker arm 3 Rocker arm shaft 3/O-ring Refer to “REMOVING/INSTALLING THE Rocker arm 4 ROCKER ARM”.
  • Page 159 ROCKER ARMS Order Job name/Part name Q’ty Remarks Spring Locknut Valve adjuster For installation, reverse the removal procedure. 4 - 13...

  • Page 160: Removing The Rocker Arm

    ROCKER ARMS REMOVING THE ROCKER ARM 1.Remove: Rocker arm shafts 1 Rocker arms 2 NOTE: Use a slide hammer bolt 3 and weight 4 to remove the rocker arm shafts. Slide hammer set: P/N. YU-01083-A Slide hammer bolt (M6): P/N. 90890-01083 Weight: P/N.

  • Page 161: Installing The Rocker Arm

    ROCKER ARMS Measure the outside diameter b of the rocker arm shafts. Out of specification → Replace. Rocker arm shaft outside diameter: 11.976 ~ 11.991 mm (0.4715 ~ 0.4721 in) Calculate the clearance by subtracting the rocker arm shaft outside diameter from the rocker arm inside diameter.

  • Page 162: Camshaft And Cylinder Head

    CAMSHAFT AND CYLINDER HEAD CAMSHAFT AND CYLINDER HEAD Order Job name/Part name Q’ty Remarks Removing the camshaft and cylin- Remove the parts in the order below. der head Seat/front fender Refer to “SEAT, FENDERS AND FUEL TANK” in CHAPTER 3. Fuel tank/plastic covers Carburetors Refer to “CARBURETOR”...
  • Page 163 CAMSHAFT AND CYLINDER HEAD Order Job name/Part name Q’ty Remarks Camshaft Thermo switch Cylinder head Cylinder head gasket Dowel pin Carburetor joint For installation, reverse the removal procedure. 4 - 17...

  • Page 164: Removing The Camshaft And Cylinder Head

    CAMSHAFT AND CYLINDER HEAD REMOVING THE CAMSHAFT AND CYLINDER HEAD 1.Loosen: Camshaft sprocket bolts 1 2.Loosen: Timing chain tensioner cap bolt 3.Remove: Timing chain tensioner Timing chain guide (exhaust) Decompressor cam guide plates Camshaft sprocket Camshaft NOTE: Fasten a safety wire to the timing chain to prevent it from falling into the crankcase.

  • Page 165: Checking The Camshaft

    CAMSHAFT AND CYLINDER HEAD CHECKING THE CAMSHAFT 1.Check: Cam lobes Pitting/scratches/blue discoloration → Replace. 2.Measure: Cam lobes length a and b. Out of specification → Replace. Camshaft lobe limit: Intake: a 35.59 mm (1.4012 in) b 29.96 mm (1.1795 in) Exhaust: a 36.40 mm (1.4331 in) b 30.01 mm (1.1815 in)

  • Page 166: Checking The Timing Chain Guide

    CAMSHAFT AND CYLINDER HEAD CHECKING THE TIMING CHAIN GUIDE 1.Check: Exhaust side timing chain guide Wear/damage → Replace. CHECKING THE TIMING CHAIN TENSIONER 1.Check: Timing chain tensioner Cracks/damage/rough movement → Replace. ***************************************************** a.Lightly press the timing chain tensioner rod into the timing chain tensioner housing by hand.

  • Page 167: Installing The Camshaft And Cylinder Head

    CAMSHAFT AND CYLINDER HEAD 3.Measure: Cylinder head warpage Out of specification → Resurface. Cylinder head warpage: Less than 0.05 mm (0.002 in) ***************************************************** Measurement and resurfacing steps: Place a straightedge and a feeler gauge across the cylinder head. Use a feeler gauge to measure the warpage. If the warpage is out of specification, resur- face the cylinder head.
  • Page 168 CAMSHAFT AND CYLINDER HEAD 2.Install: Camshaft Camshaft sprocket ***************************************************** Installation steps: Turn the crankshaft counterclockwise with a wrench. Align the “I” mark 1 on the rotor with the sta- tionary pointer 2 on the crankcase cover. When the “I” mark is aligned with the station- ary pointer, the piston is at the Top Dead Center (T.D.C.).
  • Page 169 CAMSHAFT AND CYLINDER HEAD Install the decompressor cam guide plates 9 and camshaft sprocket bolts 0. Camshaft sprocket bolt: 20 Nm (2.0 m • kg, 14 ft • lb) NOTE: Insert a screwdriver into the timing chain ten- sioner hole and push the timing chain guide inward.

  • Page 170: Valves And Valve Springs

    VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS Order Job name/Part name Q’ty Remarks Removing the valve and valve Remove the parts in the order below. spring Cylinder head Refer to “CAMSHAFT AND CYLINDER HEAD”. Valve cotter Valve spring retainer Intake valve spring Exhaust valve spring Refer to “REMOVING/INSTALLING THE...

  • Page 171: Removing The Valve And Valve Spring

    VALVES AND VALVE SPRINGS REMOVING THE VALVE AND VALVE SPRING 1.Check: Valve sealing Leakage at the valve seat → Inspect the valve face, valve seat and valve seat width. Refer to “CHECKING THE VALVE AND VALVE SPRING”. ***************************************************** Checking steps: Pour a clean solvent 1 into the intake and exhaust ports.

  • Page 172: Checking The Valve And Valve Spring

    VALVES AND VALVE SPRINGS CHECKING THE VALVE AND VALVE SPRING 1.Measure: Stem-to-guide clearance Stem-to-guide clearance = valve guide inside diameter a – valve stem diameter b Out of specification → Replace the valve guide. Clearance (stem to guide): Intake: 0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in) <Limit>: 0.08 mm (0.0031 in) Exhaust:...
  • Page 173 VALVES AND VALVE SPRINGS 3.Check: Valve face Pitting/wear → Grind the face. Valve stem end Mushroom shape or diameter larger than the body of the stem → Replace. 4.Measure: Margin thickness a Out of specification → Replace. Margin thickness: Intake: 0.85 ~ 1.15 mm (0.0335 ~ 0.0452 in) Exhaust:...
  • Page 174 VALVES AND VALVE SPRINGS 8.Measure: Valve seat width a Out of specification → Reface the valve seat. Valve seat width: Intake: 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) <Limit>: 1.6 mm (0.0630 in) Exhaust: 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) <Limit>: 1.6 mm (0.0630 in) ***************************************************** Measurement steps:...
  • Page 175 VALVES AND VALVE SPRINGS Install the valve into the cylinder head. Turn the valve until the valve face and valve seat are evenly polished, then clean off all of the compound. NOTE: For best lapping results, lightly tap the valve seat while rotating the valve back and forth between your hands.

  • Page 176: Installing The Valve And Valve Spring

    VALVES AND VALVE SPRINGS 11.Measure: Compressed spring force a Out of specification → Replace. b Installed length Compressed spring force: Intake: 100.0 ~ 115.7 N at 27.5 mm (10.20 ~ 11.80 kg, 22.48 ~ 26.01 lb at 1.08 in) Exhaust: 120.6 ~ 138.3 N at 31.0 mm (12.30 ~ 14.10 kg, 27.11 ~ 31.09 lb at 1.22 in)
  • Page 177 VALVES AND VALVE SPRINGS 3.Install: Valve cotters NOTE: Install the valve cotters while compressing the valve spring with the valve spring compressor 1 and valve spring compressor attachment Valve spring compressor: P/N. YM-04019, 90890-04019 Valve spring compressor attachment: P/N. 90890-01243 4.To secure the valve cotters onto the valve stem, lightly tap the valve tip with a piece of wood.

  • Page 178: Cylinder And Piston

    CYLINDER AND PISTON CYLINDER AND PISTON Order Job name/Part name Q’ty Remarks Removing the cylinder and piston Remove the parts in the order below. Water pump outlet hose Refer to “WATER PUMP” in CHAPTER 5. Cylinder head Refer to “CAMSHAFT AND CYLINDER HEAD”.

  • Page 179: Removing The Piston

    CYLINDER AND PISTON REMOVING THE PISTON 1.Remove: Piston pin clips 1 Piston pin 2 Piston 3 NOTE: Put identification marks on each piston head for reference during reinstallation. Before removing each 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 4.
  • Page 180 CYLINDER AND PISTON NOTE: Measure cylinder bore “C” in parallel to and at right angles to the cylinder matching surface. Then, find the average of the measurements. Standard Wear limit 100.005 ~ Cylinder 100.100 mm 100.055 mm bore “C” (3.9404 in) (3.9372 ~ 3.9392 in) If out of specification, rebore or replace the cylinder, and replace the piston and piston...

  • Page 181: Checking The Piston Ring

    CYLINDER AND PISTON CHECKING THE PISTON RING 1.Measure: Ring side clearance Use a feeler gauge. Out of specification → Replace the piston and rings as a set. NOTE: Clean carbon from the piston ring grooves and rings before measuring the side clearance. Side clearance Standard Limit...

  • Page 182: Checking The Piston Pin

    CYLINDER AND PISTON CHECKING THE PISTON PIN 1.Check: Piston pin Blue discoloration/grooves → Replace, then inspect the lubrication system. 2.Measure: Piston pin-to-piston clearance ***************************************************** Measurement steps: Measure the piston pin outside diameter a. If out of specification, replace the piston pin. Outside diameter (piston pin): 21.991 ~ 22.000 mm (0.8658 ~ 0.8661 in)

  • Page 183: Installing The Cylinder

    CYLINDER AND PISTON 2.Position: Top ring 2nd ring Oil ring Offset the piston ring end gaps as shown. a Top ring end b Oil ring end (lower) c Oil ring end (upper) d 2nd ring end 3.Install: Piston 1 Piston pin 2 Piston pin clips 3 NOTE: Apply engine oil onto the piston pin, piston...

  • Page 184: Recoil Starter And Ac Magneto

    RECOIL STARTER AND AC MAGNETO RECOIL STARTER AND AC MAGNETO Order Job name/Part name Q’ty Remarks Removing the AC magneto Remove the parts in the order below. Engine oil Drain. Refer to “CHANGING THE ENGINE OIL” in CHAPTER 3. Coolant Drain.
  • Page 185 RECOIL STARTER AND AC MAGNETO Order Job name/Part name Q’ty Remarks Starter pulley Refer to “REMOVING/INSTALLING THE Crankcase cover (left)/gasket AC MAGNETO”. Dowel pin Lead holder Pickup coil Starter assembly CDI rotor Refer to “REMOVING/INSTALLING THE Woodruff key AC MAGNETO”. Starter wheel gear Washer Starter idle gear shaft...
  • Page 186 RECOIL STARTER AND AC MAGNETO Order Job name/Part name Q’ty Remarks Disassembling the recoil starter Remove the parts in the order below. Starter handle Friction plate Pawl spring Refer to “DISASSEMBLING/ASSEM- Drive pawl BLING THE RECOIL STARTER”. Spring Sheave drum Rope Coil spring For assembly, reverse the disassembly...

  • Page 187: Removing The Ac Magneto

    RECOIL STARTER AND AC MAGNETO REMOVING THE AC MAGNETO 1.Remove: Starter pulley 1 NOTE: Use the rotor holding tool 2 to hold the starter pulley. Rotor holding tool: 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 188: Checking The Starter Clutch

    RECOIL STARTER AND AC MAGNETO CHECKING THE STARTER CLUTCH 1.Check: Starter one-way clutch 1 Cracks/damage → Replace. Bolts 2 (starter clutch) Loose → Replace with a new one, and clinch the end of the bolt. NOTE: The arrow mark on the starter clutch must face inward, away from the CDI rotor.

  • Page 189: Checking The Starter Pulley

    RECOIL STARTER AND AC MAGNETO CHECKING THE STARTER PULLEY 1.Check: Starter pulley Cracks/pitting → Deburr or replace. CHECKING THE RECOIL STARTER 1.Check: Rope 1 Sheave drum 2 Drive pawl 3 Wear/damage → Replace. Coil spring 4 Pawl spring 5 Spring 6 Fatigue →...

  • Page 190: Installing The Ac Magneto

    Untie the knot 3 after making a knot 4 above the handle. INSTALLING THE AC MAGNETO 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 - 44...
  • Page 191 RECOIL STARTER AND AC MAGNETO 2.Install: Woodruff key CDI rotor NOTE: Before installing the rotor, clean the outside of the crankshaft and the inside of the rotor. After installing the rotor, check that the rotor rotates smoothly. If not, reinstall the key and rotor.
  • Page 192 RECOIL STARTER AND AC 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 to “ADJUSTING THE SELECT LEVER CONTROL CABLE AND SHIFT ROD”...

  • Page 193: Balancer Gears And Oil Pump Gears

    BALANCER GEARS AND OIL PUMP GEARS BALANCER GEARS AND OIL PUMP GEARS Order Job name/Part name Q’ty Remarks Removing the balancer gears and oil Remove the parts in the order below. pump gears Starter wheel gear Refer to “RECOIL STARTER AND AC MAGNETO”.

  • Page 194: Removing The Balancer Drive Gear And Balancer Driven Gear

    BALANCER GEARS AND OIL PUMP GEARS REMOVING THE BALANCER DRIVE GEAR AND BALANCER DRIVEN GEAR 1.Straighten the lock washer tabs. 2.Loosen: Balancer driven gear nut 1 NOTE: Place an aluminum plate 2 between the teeth of the balancer drive gear 3 and balancer driven gear 4.

  • Page 195: Checking The Balancer Drive

    BALANCER GEARS AND OIL PUMP GEARS CHECKING THE BALANCER DRIVE 1.Check: Balancer drive gear 1 Balancer driven gear 2 Damage/wear → Replace the balancer drive gear and balancer driven gear as a set. Excessive noise during operation → Replace the balancer drive gear and balancer driven gear as a set.
  • Page 196 BALANCER GEARS AND OIL PUMP GEARS 3.Install: Lock washer Balancer driven gear nut 1 140 Nm (14.0 m • kg, 100 ft • lb) NOTE: Place an aluminum plate 2 between the teeth of the balancer drive gear 3 and bal- ancer driven gear 4.

  • Page 197: Primary And Secondary Sheaves

    PRIMARY AND SECONDARY SHEAVES PRIMARY AND SECONDARY SHEAVES 10 Nm (1.0 m kg, 7.2 ft • • 100 Nm (10.0 m kg, 72 ft • • 120 Nm (12.0 m kg, 85 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 198 PRIMARY AND SECONDARY SHEAVES 10 Nm (1.0 m kg, 7.2 ft • • 100 Nm (10.0 m kg, 72 ft • • 120 Nm (12.0 m kg, 85 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft •...

  • Page 199: Primary Sheave

    PRIMARY AND SECONDARY SHEAVES PRIMARY SHEAVE Order Job name/Part name Q’ty Remarks Disassembling the primary sheave Remove the parts in the order below. Primary pulley sheave cap Primary pulley slider Spacer Primary pulley cam Refer to “ASSEMBLING THE PRIMARY Primary pulley weight SHEAVE”.

  • Page 200: Secondary Sheave

    PRIMARY AND SECONDARY SHEAVES SECONDARY SHEAVE Order Job name/Part name Q’ty Remarks Disassembly the secondary sheave Remove the parts in the order below. Spring seat Compression spring Spring seat Refer to “DISASSEMBLING/ASSEM- BLING SECONDARY SHEAVE”. Guide pin Secondary sliding sheave O-ring Secondary fixed sheave Oil seal...

  • Page 201: Removing The Primary And Secondary Sheaves

    PRIMARY AND SECONDARY SHEAVES REMOVING THE PRIMARY AND SECONDARY SHEAVES 1.Loosen: Nut (secondary sheave) 1 Nut (primary sheave) 2 NOTE: Use the sheave holder 3 to hold the primary sheave. First, loosen the nut (secondary sheave) 2, then loosen the nut (primary sheave) 1. Sheave holder: P/N.

  • Page 202: Cheking The Primary Sheave

    PRIMARY AND SECONDARY SHEAVES CHEKING THE PRIMARY SHEAVE 1.Check: 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.Check: Primary puller slider Primary sliding sheave splines Wear/cracks/damage →...

  • Page 203: Assembling The Primary Sheave

    Remove any excess grease. 2.Install: Weight 1 NOTE: Apply Yamaha Grizzly grease (90 g) to the whole outer surface of the weight and install. Apply Yamaha Grizzly grease to the inner surface of the collar. Apply Yamaha Grizzly grease to the inner surface of the primary sliding sheave.
  • Page 204 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 205: Installing The Primary And Secondary Sheaves

    PRIMARY AND SECONDARY SHEAVES INSTALLING THE PRIMARY AND SECONDARY SHEAVES 1.Install: Secondary sheave assembly V-belt Primary sheave assembly NOTE: Tightening the bolts 1 will push the second- ary sliding sheave away, causing the gap between the secondary fixed and sliding sheaves to widen.

  • Page 206: Clutch

    CLUTCH CLUTCH Order Job name/Part name Q’ty Remarks Removing the clutch Remove the parts in the order below. Primary and secondary sheaves Refer to “PRIMARY AND SECONDARY SHEAVES”. Clutch housing assembly Gasket/dowel pin Refer to “REMOVING AND INSTALL- ING THE CLUTCH”. One-way clutch bearing Clutch carrier assembly For installation, reverse the removal...
  • Page 207 CLUTCH Order Job name/Part name Q’ty Remarks Disassembling the clutch housing Remove the parts in the order below. Oil seal Circlip Bearing housing Circlip Bearing Circlip Bearing Clutch housing For assembly, reverse the disassembly procedure. 4 - 61...

  • Page 208: Removing The Clutch

    CLUTCH REMOVING THE CLUTCH 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 209: Installing The Clutch

    CLUTCH 2.Check: 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) INSTALLING THE CLUTCH 1.Install: Collar Clutch carrier assembly Nut 1 160 Nm (16.0 m •...
  • Page 210 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 counterclockwise rotates smoothly.

  • Page 211: Crankcase

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

  • Page 212: Crankcase

    CRANKCASE Order Job name/Part name Q’ty Remarks Oil filter Speed sensor Shift cam stopper Gear position switch Reverse switch Oil filler cap Oil delivery pipe Drain plug For installation, reverse the removal procedure. 4 - 66...
  • Page 213 CRANKCASE CRANKCASE 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 14 Nm (1.4 m kg, 10 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job name/Part name Q’ty Remarks Separating the crankcase...

  • Page 214: Crankcase Bearing

    CRANKCASE CRANKCASE BEARING 10 Nm (1.0 m kg, 7.2 ft • • Order Job name/Part name Q’ty Remarks Removing the crankcase bearing Remove the parts in the order below. Crankshaft and oil pump Refer to “CRANKSHAFT AND OIL PUMP”. Transmission Refer to “TRANSMISSION”.

  • Page 215: Separating The Crankcase

    CRANKCASE SEPARATING THE CRANKCASE È 1.Separate: Left crankcase Right crankcase ***************************************************** Separation steps: Remove the crankcase bolts. NOTE: Loosen each bolt 1/4 of a turn at a time and after all the bolts are loosened, remove É them. Loosen the bolts in stages, using a criss- cross pattern.

  • Page 216: Checking The Crankcase

    Sealant (Quick Gasket (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 217: Installating The Shift Lever

    CRANKCASE 4.Tighten: È Crankcase bolts (follow the proper tightening sequence) 10 Nm (1.0 m • kg, 7.2 ft • lb) È Right crankcase É Left crankcase NOTE: Tighten the bolts in stages, using a crisscross pattern. É 5.Apply: 4-stroke engine oil (to the crank pin, bearing and oil delivery hole) 6.Check:...

  • Page 218: Crankshaft And Oil Pump

    CRANKSHAFT AND OIL PUMP CRANKSHAFT AND OIL PUMP Order Job name/Part name Q’ty Remarks Removing the crankshaft and oil Remove the parts in the order below. pump Crankcase separation Refer to “CRANKCASE”. Oil strainer/O-ring Oil pump assembly/gasket Balancer Refer to “REMOVING THE CRANK- Plate SHAFT/INSTALLING THE CRANK- SHAFT AND BALANCER”.

  • Page 219: Oil Pump

    CRANKSHAFT AND OIL PUMP OIL PUMP Order Job name/Part name Q’ty Remarks Disassembling the oil pump Remove the parts in the order below. Rotor cover Shaft Inner rotor Outer rotor Oil pump housing For assembly, reverse the disassembly procedure. 4 - 73...

  • Page 220: Removing The Crankshaft

    CRANKSHAFT AND OIL PUMP REMOVING THE CRANKSHAFT 1.Remove: Crankshaft Use a crankcase separating tool 1. Crankcase separating tool: P/N. YU-01135-A, 90890-01135 CHECKING THE OIL PUMP 1.Check: Rotor housings Rotor cover Cracks/wear/damage → Replace. 2.Measure: Tip clearance a (between the inner rotor 1 and the outer rotor 2) Side clearance b (between the outer rotor 2 and the pump...

  • Page 221: Checking The Relief Valve

    CRANKSHAFT AND OIL PUMP CHECKING THE RELIEF VALVE 1.Check: Relief valve body 1 Relief valve 2 Spring 3 O-ring 4 Damage/wear → Replace the defective parts(s). CHECKING THE OIL STRAINER 1.Check: Oil strainer 1 O-ring 2 Damage → Replace. Contaminants → Clean with engine oil. ASSEMBLING THE OIL PUMP 1.Install: Inner rotor...

  • Page 222: Checking The Crankshaft

    CRANKSHAFT AND OIL PUMP CHECKING THE CRANKSHAFT 1.Measure: Crank width A Out of specification → Replace the crank- shaft. Crank width: 74.95 ~ 75.00 mm (2.9508 ~ 2.9528 in) Side clearance D Out of specification → Replace the crank- shaft. Big end side clearance: 0.35 ~ 0.65mm (0.0138 ~ 0.0256 in)

  • Page 223: Installing The Crankshaft And Balancer

    CRANKSHAFT AND OIL PUMP INSTALLING THE CRANKSHAFT AND BALANCER 1.Install: Crankshaft Crankshaft installer pot 1: P/N. 90890-01274 Crankshaft installer bolt 2: P/N. 90890-01275 Crankshaft installer set 3: P/N. YU-90050 Adapter 4: P/N. YM-90069, 90890-04059 Spacer (crankshaft installer) 5: P/N. YM-91044, 90890-04081 Spacer 6: P/N.

  • Page 224: Transmission

    TRANSMISSION TRANSMISSION Order Job name/Part name Q’ty Remarks Removing the transmission Remove the parts in the order below. Crankcase separation Refer to “CRANKCASE”. Middle driven gear Refer to “MIDDLE GEAR”. Low wheel gear Shift cam Shift fork assembly Short spring White painting.
  • Page 225 TRANSMISSION Order Job name/Part name Q’ty Remarks Chain Shaft Stopper lever Spring Stopper cam For installation, reverse the removal procedure. 4 - 79...
  • Page 226 TRANSMISSION Order Job name/Part name Q’ty Remarks Disassembling the drive axle Remove the parts in the order below. assembly Clutch dog High wheel gear Middle drive gear Stopper wheel Driven sprocket Drive axle For assembly, reverse the disassembly procedure. 4 - 80...

  • Page 227: Removing The Transmission

    TRANSMISSION REMOVING THE TRANSMISSION 1.Remove: Sift cam 1 Sift fork assembly 2 ***************************************************** Removing steps: Pull out the guide bar from the left crank- case. Push down on the drive shaft, and then slide the shift fork assembly to remove the shift fork cam followers.

  • Page 228: Checking The Shift Cam

    TRANSMISSION 3.Check: Shift fork movement (on the guide bar) Unsmooth operation → Replace the shift fork and the guide bar. 4.Check: Spring Cracks/damage → Replace. CHECKING THE SHIFT CAM 1.Check: Shift cam grooves Scratches/wear/damage → Replace. CHECKING THE DRIVE AXLE 1.Measure: Axle runout Use a centering device and a dial gauge.

  • Page 229: Checking The Secondary Shaft And Driven Sprocket

    TRANSMISSION 2.Check: Gear movement Unsmooth → Repeat steps #1 or replace the defective parts. 3.Check: Circlip Bends/looseness/damage → Replace. CHECKING THE SECONDARY SHAFT AND DRIVEN SPROCKET 1.Check Gear teeth Blue discoloration/pitting/wear → Replace. 2.Check: Gear movement Unsmooth → Repeat steps #1 or replace the defective parts.

  • Page 230: Assembling The Shift Fork Assembly

    TRANSMISSION ASSEMBLING THE SHIFT FORK ASSEMBLY 1.Install: Guide bar 1 Shift fork 2 2 Long spring 3 Shift fork 1 4 Short spring 5 INSTALLING THE TRANSMISSION 1.Install: Stopper lever Shaft 1 Chain 2 Drive axle assembly 3 Secondary shaft 4 Shift fork assembly 5 Shift cam 6 Low wheel gear...

  • Page 231: Middle Gear

    MIDDLE GEAR MIDDLE GEAR MIDDLE DRIVE SHAFT Order Job name/Part name Q’ty Remarks Removing the middle drive shaft Remove the parts in the order below. Crankcase separation Refer to “CRANKCASE”. Bearing housing Middle driven gear Refer to “REMOVING/INSTALLING THE MIDDLE DRIVE SHAFT”. Middle drive pinion gear Shim Refer to “MIDDLE DRIVE AND DRIVEN...

  • Page 232: Middle Driven Shaft

    MIDDLE GEAR MIDDLE DRIVEN SHAFT Order Job name/Part name Q’ty Remarks Disassembling the middle driven Remove the parts in the order below. shaft Crankcase separation Refer to “CRANKCASE”. Circlip Bearing Universal joint Refer to “INSTALLING/REMOVING THE MIDDLE DRIVEN SHAFT”. Universal joint yoke Coupling gear Bearing housing/O-ring Shim...
  • Page 233 MIDDLE GEAR Order Job name/Part name Q’ty Remarks Bearing retainer Middle driven shaft For installation, reverse the removal procedure. 4 - 87...

  • Page 234: Removing The Middle Drive Shaft

    MIDDLE GEAR REMOVING THE MIDDLE DRIVE SHAFT 1.Straighten: Punched portion of the nut (middle drive pin- ion 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) REMOVING THE MIDDLE DRIVEN SHAFT...
  • Page 235 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 3.Remove: Nut 1 Washer Coupling gear 2 NOTE: Use the coupling gear/middle shaft tool 3 to hold the coupling gear.
  • Page 236 MIDDLE GEAR 5.Remove: Bearing retainer Bearing ***************************************************** Removal steps: Attach the folded rag 1. Secure the bearing housing edge in the vise. Attach the bearing retainer wrench 2. Bearing retainer wrench: P/N. YM-04128, 90890-04128 CAUTION: The middle driven shaft bearing retainer has left-handed threads.

  • Page 237: Checking The Pinion Gear

    MIDDLE GEAR CHECKING THE PINION GEAR 1.Check Gear teeth (drive pinion gear) 1 Gear teeth (driven pinion gear) 2 Pitting/galling/wear → Replace. 2.Check O-ring Damage → Replace. Bearings Pitting/damage → Replace. 3.Check: U-joint movement Roughness → Replace U-joint. MIDDLE DRIVE AND DRIVEN GEAR SHIM SELECTION When the drive and driven gear, bearing hous- ing assembly and/or crankcase replaced, be...
  • Page 238 MIDDLE GEAR Where: a = a numeral (usually a decimal number) on the bearing housing is either added to or subtracted from “7.5”. b = 17.0 c = 55.0 d = a numeral (usually a decimal number) on the right crankcase specifies a thickness of “64.98”.
  • Page 239 MIDDLE GEAR To find shim thickness “B” use the following formula: Middle driven pinion gear shim thick- ness: “B” = e – f + g – h + i – 0.05 Where: e = a numeral (usually a decimal number) on the bearing housing is either added to or subtracted from “76”.

  • Page 240: Installing The Middle Driven Shaft

    MIDDLE GEAR 6) Round off hundredths digit and select appropriate shim(s). In the example above, the calculated shim thickness is 0.64 mm. The chart instructs you, however, to round off 4 to 5. Hundredths Round value 0, 1, 2 3, 4, 5, 6, 7 8, 9 Shims are supplied in the following thickness.
  • Page 241 MIDDLE GEAR 2.Install: Bearing retainer 1 ***************************************************** Installation steps: Attach the folded rag 2. Secure the bearing housing edge in the vise. Attach the bearing retainer wrench 3. Bearing retainer wrench: P/N. YM-04128, 90890-04128 Tighten the bearing retainer. CAUTION: The middle driven shaft bearing retainer has left-handed threads.

  • Page 242: Installing The Middle Drive Shaft

    MIDDLE GEAR 5.Install: Universal joint ***************************************************** Installation steps: Install the opposite yoke into the U-joint. Apply wheel bearing grease to the bearings. Install the bearing 1 onto the yoke. CAUTION: Check each bearing. The needles can eas- ily fall out of their races. Slide the yoke back and forth on the bearings;...

  • Page 243: Measuring The Middle Gear Backlash

    MIDDLE GEAR MEASURING THE MIDDLE GEAR BACKLASH 1.Measure: Gear lash Middle gear lash: 0.1 ~ 0.3 mm (0.004 ~ 0.012 in) ***************************************************** Measurement steps: Temporary install the right crankcase. Wrap a rag 2 around a screwdriver 3, and then insert it into the installation hole 1 of the left crankcase speed sensor to hold the middle driven gear.

  • Page 245: Cool

    COOL...
  • Page 246 COOL CHAPTER 5. COOLING SYSTEM RADIATOR ....................5-1 CHECKING THE RADIATOR ..............5-3 INSTALLING THE RADIATOR .............. 5-4 THERMOSTAT ..................... 5-5 CHECKING THE THERMOSTAT ............5-6 INSTALLING THE THERMOSTAT ............5-6 WATER PUMP ....................5-7 DISASSEMBLING THE WATER PUMP ..........5-9 CHECKING THE WATER PUMP ............
  • Page 247 COOL...

  • Page 248: Chapter 5. Cooling System

    COOL RADIATOR COOLING SYSTEM RADIATOR 7 Nm (0.7 m kg, 5.1 ft • • 28 Nm (2.8 m kg, 20 ft • • Order Job name/Part name Q’ty Remarks Removing the radiator Remove the parts in the order below. Seat and side panels Refer to “SEAT AND SIDE PANELS”...
  • Page 249 COOL RADIATOR 7 Nm (0.7 m kg, 5.1 ft • • 28 Nm (2.8 m kg, 20 ft • • 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.

  • Page 250: Checking The Radiator

    COOL RADIATOR CHECKING THE RADIATOR 1.Check: Radiator fins Obstruction → Clean. Apply compressed air to the rear of the radia- tor. Damage → Repair or replace. NOTE: Straighten any flattened fins with a thin, flat- head screwdriver. 2.Check: Radiator hoses Cracks/damage →...

  • Page 251: Installing The Radiator

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

  • Page 252: Thermostat

    COOL THERMOSTAT THERMOSTAT 10 Nm (1.0 m kg, 7.2 ft • • Order Job name/Part name Q’ty Remarks Removing the thermostat Remove the parts in the order below. Seat and fuel tank side panel (right) Refer to “SEAT AND SIDE PANELS” in CHAPTER 3.

  • Page 253: Checking The Thermostat

    COOL THERMOSTAT CHECKING THE THERMOSTAT 1.Check: Thermostat 1 Does not open at 50 ~ 54 °C (122 ~ 158 °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 thermo- stat and thermometer’s indicated tempera- ture.

  • Page 254: Water Pump

    COOL WATER PUMP WATER PUMP 10 Nm (1.0 m kg, 7.2 ft • • Order Job name/Part name Q’ty Remarks Removing the water pump 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.
  • Page 255 COOL WATER PUMP Order Job name/Part name Q’ty Remarks Disassembling the water pump 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 256: Disassembling The Water Pump

    COOL WATER PUMP DISASSEMBLING THE WATER PUMP 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 257: Assembling The Water Pump

    COOL WATER PUMP ASSEMBLING THE WATER PUMP 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 258 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 260: Carb

    CARB...
  • Page 261 CARB CHAPTER 6. CARBURETION CARBURETOR ..................... 6-1 CHECKING THE CARBURETOR ............6-4 ASSEMBLING THE CARBURETOR ............. 6-6 ADJUSTING THE FUEL LEVEL ............6-7...
  • Page 262 CARB...

  • Page 263: Chapter 6. Carburetion

    CARB CARBURETOR CARBURETION CARBURETOR Order Job name/Part name Q’ty Remarks Removing the carburetor Remove the parts in the order below. Seat/fuel tank side panels/fuel tank Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK” in CHAPTER 3. Exhaust pipe protector Refer to “ENGINE REMOVAL” in CHAP- TER 3.
  • Page 264 CARB CARBURETOR Order Job name/Part name Q’ty Remarks Disassembling the carburetor Remove the parts in the order below. Throttle stop screw Vacuum chamber cover Spring Jet needle holder Spring Jet needle set Piston valve Coasting enricher diaphragm Pilot air jet Drain screw Float chamber Float...
  • Page 265 CARB CARBURETOR Order Job name/Part name Q’ty Remarks Pilot screw set Refer to “ASSEMBLING THE CARBURE- TOR”. Main jet Needle jet Refer to “ASSEMBLING THE CARBURE- TOR”. Pilot jet Starter jet For assembly, reverse the disassembly procedure. 6 - 3...

  • Page 266: Checking The Carburetor

    CARB CARBURETOR CHECKING THE CARBURETOR 1.Check: 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 cleaning solution.) Blow out all of the passages and jets with compressed air.
  • Page 267 CARB CARBURETOR 4.Check: Piston valve 1 Scratches/wear/damage → Replace. Rubber diaphragm 2 Tears → Replace. 5.Check: Vacuum chamber cover 1 Spring 2 Cracks/damage → Replace. 6.Check: Diaphragm (coasting enricher) 1 Spring 2 Cover 3 Tears (diaphragm) /damage → Replace. 7.Check: Jet needle 1 Main jet 2 Needle jet 3...

  • Page 268: Assembling The Carburetor

    CARB CARBURETOR 8.Check: Free movement (piston valve) Sticks → Replace the piston valve guide and the piston valve. Insert the piston valve into the carburetor body, and check for free movement. 9.Check: Free movement (throttle valve) Sticks → Replace. ASSEMBLING THE CARBURETOR CAUTION: Before assembling, wash all of the parts in a clean petroleum based solvent.

  • Page 269: Adjusting The Fuel Level

    CARB CARBURETOR If either is worn, replace them both. If both are fine, adjust the float height by bending the float tang 1 on the float. Recheck the float height. ***************************************************** ADJUSTING THE FUEL LEVEL 1.Measure: Fuel level a Out of specification → Adjust. Fuel level: 4.5 mm (0.18 in) Above the float chamber mating...

  • Page 271: Driv

    DRIV...
  • Page 272 DRIV CHAPTER 7. DRIVE TRAIN TROUBLESHOOTING .................. 7-1 FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR ..............7-4 DISASSEMBLING THE UNIVERSAL JOINT ........7-9 REMOVING THE RING GEAR ............7-10 CHECKING THE CONSTANT VELOCITY JOINT ......7-10 CHECKING THE DIFFERENTIAL GEAR ........... 7-10 CHECKING THE GEAR MOTOR ............
  • Page 273 DRIV...

  • Page 274: 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” movement A.Bearing damage. during acceleration, deceleration, or sustained B. Improper gear lash. speed. (This must not be confused with engine surging or transmission characteris- C.Gear tooth damage.
  • Page 275 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 opera- tion. This noise must be distinguished from normal machine operation.
  • Page 276 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 KNUCKLE AND STABILIZER” in CHAPTER 8.) Check the wheel nuts and hub nuts for Torque to specification.

  • Page 277: Front Constant Velocity Joints And Differential Gear

    FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR 55 Nm (5.5 m kg, 40 ft • • Order Job name/Part name Q’ty Remarks Removing the front constant veloc- Remove the parts in the order below. ity joint and differential gear Engine skid plate (front) Refer to “SEAT, CARRIERS, FENDERS...
  • Page 278 FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR 55 Nm (5.5 m kg, 40 ft • • Order Job name/Part name Q’ty Remarks Differential gear Drive shaft Compression spring For installation, reverse the removal procedure. 7 - 5...
  • Page 279 FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR Order Job name/Part name Q’ty Remarks Disassembling the constant velocity Remove the parts in the order below. joint Circlip Boot band Boot band Dust boot Circlip Refer to “ASSEMBLING THE FRONT CONSTANT VELOCITY JOINT” Double off-set joint Snap ring Ball bearing...
  • Page 280 FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR Order Job name/Part name Q’ty Remarks Disassembling the differential gear Remove the parts in the order below. Gear motor/O-ring NOTE: Be sure not to disassemble gear motor and remove the pinion gear. Circlip Refer to “DISASSEMBLING AND Bearing...
  • Page 281 FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR Order Job name/Part name Q’ty Remarks Differential gear assembly Shim (right) Circlip/bearing Drive pinion gear Differential gear case For assembly, reverse the disassembly procedure. 7 - 8...

  • Page 282: Disassembling The Universal Joint

    FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR DISASSEMBLING THE UNIVERSAL JOINT 1.Remove: Universal joint ***************************************************** Removal steps: Remove the circlips 1. Place the U-joint in a press. With a suitable diameter pipe 2 beneath the yoke 3, press the bearing 4 into the pipe as shown.

  • Page 283: Removing The Ring Gear

    FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR REMOVING THE RING GEAR 1.Remove: Ring gear 1 NOTE: The ring gear and the differential gear cover should be fastened together. Do not disassem- ble the differential gear. CAUTION: The differential gears are assembled into a proper unit at the factory by means of spe- cialized equipment.

  • Page 284: Checking The Gear Motor

    FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR 2.Check: Drive shaft splines Universal joints Front drive gear splines Wear/damage → Replace. Spring Fatigue → Replace. Move the spring up and down. 3.Check: Front drive shaft Bends → Replace. WARNING Do not attempt to straighten a bent shaft; this may dangerously weaken the shaft.

  • Page 285: Assembling The Differential Gear

    FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR 2.Install: Dust boots 1 Boot bands 2, 3 ***************************************************** Installation steps: Apply molybdenum disulfide grease into the dust boots. Molybdenum disulfide grease: 40 g (1.4 oz) per dust boot Install the dust boots. Install the dust boot bands.
  • Page 286 FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR ***************************************************** Installation steps: Slide the shift fork sliding gear 1, which is installed to the differential gear, to the left to put it into the 2WD mode. Connect two C size batteries to the gear motor terminal 2 to operate the pinion gear 3, and operate it until the paint mark 4 on the gear is aligned with the paint mark 5 on...

  • Page 287: Installing The Universal Joint

    FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR 4.Check: Differential gear operation Unsmooth operation → Replace the differen- tial gear assembly. Insert the double off-set joint into the differ- ential gear, and turn the gear back and forth. INSTALLING THE UNIVERSAL JOINT 1.Install: Universal joint *****************************************************...

  • Page 288: Measuring And Adjusting The Differential Gear Lash

    FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR MEASURING AND ADJUSTING THE DIFFERENTIAL GEAR LASH Measuring the differential gear lash 1.Secure the gear case in a vise or another supporting device. 2.Remove: Drain plug Gasket 3.Install: A bolt of the specified size 1 (into the drain plug hole) CAUTION: Finger tighten the bolt until it holds the ring...
  • Page 289 FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR Adjusting differential gear lash 1.Remove: Shim(s) (left) 1 Differential gear assembly 2 Shim(s) (right) 3 2.Adjust: Gear lash ***************************************************** Adjustment steps: Select the suitable shims using the following chart. Reduce shim thick- Too little gear lash ness.

  • Page 290: Checking The Differential Gear Operation

    FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR CHECKING THE DIFFERENTIAL GEAR OPERATION 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). 3.Measure the starting torque of the front wheel (i.e., differential gear preload) with the torque wrench.

  • Page 291: Rear Constant Velocity Joint/Final Drive Gear And Drive Shaft

    REAR CONSTANT VELOCITY JOINT/FINAL DRIVE GEAR DRIV AND DRIVE SHAFT REAR CONSTANT VELOCITY JOINT/FINAL DRIVE GEAR AND DRIVE SHAFT 55 Nm (5.5 m kg, 40 ft • • Order Job name/Part name Q’ty Remarks Removing the rear constant velocity Remove the parts in the order below. joint, final drive gear assembly and drive shaft Final gear oil...
  • Page 292 REAR CONSTANT VELOCITY JOINT/FINAL DRIVE GEAR DRIV AND DRIVE SHAFT Order Job name/Part name Q’ty Remarks Disassembling the rear constant Remove the parts in the order below. velocity joint Dust cover Circlip Boot band Boot band Dust boot Circlip Refer to “CONSTANT VELOCITY JOINT ASSEMBLY”.
  • Page 293 REAR CONSTANT VELOCITY JOINT/FINAL DRIVE GEAR DRIV AND DRIVE SHAFT Order Job name/Part name Q’ty Remarks Disassembling the final drive gear Remove the parts in the order below. Rear brake disc Refer to “REAR WHEELS AND BRAKE DISC” in CHAPTER 8. Boss Ring gear stopper shim Ring gear stopper...
  • Page 294 REAR CONSTANT VELOCITY JOINT/FINAL DRIVE GEAR DRIV AND DRIVE SHAFT Order Job name/Part name Q’ty Remarks Thrust washer Final drive pinion gear shim O-ring Oil seal Inner race Refer to “ASSEMBLING THE FINAL Final drive pinion gear DRIVE GEAR”. Bearing retainer Bearing Pinion gear bearing housing Final drive gear case...

  • Page 295: Assembling The Rear Constant Velocity Joint

    REAR CONSTANT VELOCITY JOINT/FINAL DRIVE GEAR DRIV AND DRIVE SHAFT ASSEMBLING THE REAR CONSTANT VELOCITY JOINT 1.Apply: Lithium-soap base grease (into the ball joint assembly) 2.Install: Dust boots 1 Boot bands 2, 3 ***************************************************** Installation steps: Apply lithium-soap base grease into the dust boots.

  • Page 296: Removing And Disassembling The Final Drive Roller Bearing

    REAR CONSTANT VELOCITY JOINT/FINAL DRIVE GEAR DRIV AND DRIVE SHAFT REMOVING AND DISASSEMBLING THE FINAL DRIVE ROLLER BEARING 1.Remove: Roller bearing (ring gear) 1 Use a suitable press tool 2 and an appropri- ate support for the main housing. 2.Remove: Roller bearing (final drive pinion gear) 1 ***************************************************** Removal steps:...

  • Page 297: Positioning The Final Drive Pinion Gear And Ring Gear

    REAR CONSTANT VELOCITY JOINT/FINAL DRIVE GEAR DRIV AND DRIVE SHAFT POSITIONING THE FINAL DRIVE PINION GEAR AND RING GEAR When the final drive pinion gear, ring gear, final gear case and/or ring gear bearing hous- ing are replaced, be sure to adjust the posi- tions of the final drive pinion gear and ring gear using the shim(s).
  • Page 298 REAR CONSTANT VELOCITY JOINT/FINAL DRIVE GEAR DRIV AND DRIVE SHAFT 6) Round off the hundredth digit and select the appropriate shim(s). In the example above, the calculated number is 0.97. The chart instructs you to round off 7 to 5 at the hundredth place.
  • Page 299 REAR CONSTANT VELOCITY JOINT/FINAL DRIVE GEAR DRIV AND DRIVE SHAFT h =bearing thickness (considered constant) Bearing thickness h: 14.00 mm Example: 1) If “98” is stamped on the final drive gear case, e = 50 + 0.98 = 50.98 2) If “55” is stamped on the ring gear bear- ing housing, f = 1 + 0.55 = 1.55...
  • Page 300 REAR CONSTANT VELOCITY JOINT/FINAL DRIVE GEAR DRIV AND DRIVE SHAFT Thrust washer selection 1.Measure/select: Ring gear thrust clearance “C” ***************************************************** Measurement steps: ® Place four pieces of Plastigauge between the originally fitted thrust washer and the ring gear. Install the ring gear assembly and tighten the bolts to specification.
  • Page 301 REAR CONSTANT VELOCITY JOINT/FINAL DRIVE GEAR DRIV AND DRIVE SHAFT Adjusting the ring gear stopper 1.Measure: Ring gear stopper clearance “D” Use a feeler gauge 1. Out of specification → Adjust. Ring gear stopper clearance “D”: 0.30 ~ 0.60 mm (0.012 ~ 0.024 in) 2 Ring gear 3 Ring gear stopper 2.Remove:...

  • Page 302: Checking The Drive Shaft

    Bearings Damage → Replace. NOTE: Reusing roller bearings is acceptable, but Yamaha recommends installing new 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 303: Measurement And Adjusting The Final Gear Lash

    REAR CONSTANT VELOCITY JOINT/FINAL DRIVE GEAR DRIV AND DRIVE SHAFT MEASUREMENT AND ADJUSTING THE FINAL GEAR LASH Final gear lash measurement 1.Secure the gear case in a vise or another supporting device. 2.Remove: Drain plug Gasket 3.Install: A bolt of the specified size 1 (into the drain plug hole) CAUTION: Finger tighten the bolt until it holds the ring...
  • Page 304 REAR CONSTANT VELOCITY JOINT/FINAL DRIVE GEAR DRIV AND DRIVE SHAFT Final gear lash adjustment 1.Remove: Bearing housing 1 Ring gear shim(s) 2 Ring gear 3 Thrust washer 4 2.Adjust: Gear lash ***************************************************** Adjustment steps: Select suitable shim(s) thrust washer(s) using the following chart. Reduce shim thick- Too little gear lash ness.

  • Page 305: Assembling The Final Drive Gear

    INSTALLING THE FINAL DRIVE GEAR 1.Lubricate: Drive shaft Coupling gear O-ring Oil seal Bearing Recommended lubricant: Yamaha Grizzly grease 2.Install: Drive shaft Coupling gear 3.Install: Final drive gear Nuts 55 Nm (5.5 m • kg, 40 ft • lb) 7 - 32...

  • Page 306: Chas

    CHAS...
  • Page 307 CHAS CHAPTER 8. CHASSIS FRONT WHEELS AND BRAKE DISCS ............8-1 FRONT WHEELS .................. 8-1 CHECKING THE FRONT WHEEL ............8-3 CHECKING THE FRONT WHEEL HUB ..........8-3 CHECKING THE FRONT BRAKE DISC ..........8-4 INSTALLING THE FRONT WHEEL HUB ..........8-4 INSTALLING THE FRONT WHEEL ............
  • Page 308 CHAS STEERING SYSTEM .................. 8-36 HANDLEBAR ..................8-36 REMOVING THE REAR BRAKE SWITCH ......... 8-37 CHECKING THE HANDLEBAR ............8-37 INSTALLING THE HANDLEBAR ............8-37 INSTALLING THE REAR BRAKE LEVER .......... 8-37 INSTALLING THE MASTER CYLINDER ASSEMBLY ......8-38 STEERING STEM ................8-39 REMOVING THE BEARING RETAINER ..........

  • Page 309: Chapter 8. Chassis

    CHAS FRONT WHEELS AND BRAKE DISCS CHASSIS FRONT WHEELS AND BRAKE DISCS FRONT WHEELS 30 Nm (3.0 m kg, 22 ft • • 200 Nm (20.0 m kg, 145 ft • • 30 Nm (3.0 m kg, 22 ft • •...
  • Page 310 CHAS FRONT WHEELS AND BRAKE DISCS 30 Nm (3.0 m kg, 22 ft • • 200 Nm (20.0 m kg, 145 ft • • 30 Nm (3.0 m kg, 22 ft • • 55 Nm (5.5 m kg, 40 ft •...

  • Page 311: Checking The Front Wheel

    CHAS FRONT WHEELS AND BRAKE DISCS CHECKING THE FRONT WHEEL 1.Check: 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 312: Checking The Front Brake Disc

    CHAS FRONT WHEELS AND BRAKE DISCS CHECKING THE FRONT BRAKE DISC 1.Check: Brake disc Galling/damage → Replace. 2.Measure: Brake disc deflection Out of specification → Check the wheel runout. If wheel runout is within the limits, replace the brake disc. Brake disc maximum deflection: 0.15 mm (0.006 in) Brake disc thickness a...
  • Page 313 CHAS FRONT WHEELS AND BRAKE DISCS 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 314: Rear Wheels And Brake Disc

    CHAS REAR WHEELS AND BRAKE DISC REAR WHEELS AND BRAKE DISC REAR WHEELS 200 Nm (20.0 m kg, 145 ft • • 55 Nm (5.5 m kg, 40 ft • • Order Job name/Part name Q’ty Remarks Removing the rear wheel Remove the parts in the order below.

  • Page 315: Rear Brake Disc

    CHAS REAR WHEELS AND BRAKE DISC REAR BRAKE DISC 10 Nm (1.0 m kg, 7.2 ft • • Order Job name/Part name Q’ty Remarks Disassembling the rear brake disc Remove the parts in the order below. Brake caliper assembly Refer to “REAR BRAKE CALIPER”. Final drive gear Refer to “FINAL DRIVE GEAR AND DRIVE SHAFT”...

  • Page 316: Checking The Rear Wheel

    CHAS REAR WHEELS AND BRAKE DISC CHECKING THE REAR WHEEL 1.Check: Wheel Refer to “CHECKING THE FRONT WHEEL”. 2.Measure: Wheel runout Refer to “CHECKING THE FRONT WHEEL”. Over the specified limit → Replace. Wheel runout limit: Radial: 2.0 mm (0.08 in) Lateral: 2.0 mm (0.08 in) 3.Check: Wheel balance...

  • Page 317: Installing The Rear Wheel Hub

    CHAS REAR WHEELS AND BRAKE DISC INSTALLING THE REAR WHEEL HUB 1.Install: Cotter pin Refer to “INSTALLING THE FRONT WHEEL HUB”. 2.Adjust: Rear brake lever and pedal free play Refer to “ADJUSTING THE REAR BRAKE LEVER AND PEDAL” in CHAPTER 3. INSTALLING THE REAR WHEEL 1.Install: Wheel...

  • Page 318: Front And Rear Brakes

    CHAS FRONT AND REAR BRAKES FRONT AND REAR BRAKES FRONT BRAKE PADS Order Job name/Part name Q’ty Remarks Removing the front brake pads Remove the parts in the order below. Front wheel Refer to “FRONT WHEELS”. Brake caliper mounting bolt Brake pad holding bolt Refer to “REPLACING THE FRONT BRAKE PAD”.

  • Page 319: Rear Brake Pads

    CHAS FRONT AND REAR BRAKES REAR BRAKE PADS 18 Nm (1.8 m kg, 13 ft • • Order Job name/Part name Q’ty Remarks Removing the rear brake pads Remove the parts in the order below. Rear wheel (left) Refer to “REAR WHEELS AND BRAKE DISC”.

  • Page 320: Replacing The Front Brake Pad

    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 321 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 322: Replacing The Rear Brake Pad

    CHAS FRONT AND REAR BRAKES REPLACING THE REAR BRAKE PAD 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 323 CHAS FRONT AND REAR BRAKES 3.Check: Brake fluid level Refer to “CHECKING THE BRAKE FLUID LEVEL INSPECTION” in CHAPTER 3. 4.Check: Brake lever or brake pedal operation Soft or spongy feeling → Bleed the rear brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM”...

  • Page 324: Front Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES FRONT BRAKE MASTER CYLINDER Order Job name/Part name Q’ty Remarks Removing the front brake master Remove the parts in the order below. cylinder Brake fluid Drain. On command four-wheel drive switch Refer to “HANDLEBAR”. Brake fluid reservoir cap Brake fluid reservoir diaphragm Brake lever Union bolt...
  • Page 325 CHAS FRONT AND REAR BRAKES Order Job name/Part name Q’ty Remarks Disassembling the front brake mas- Remove the parts in the order below. ter cylinder Dust boot Refer to “ADJUSTING THE FRONT Circlip BRAKE MASTER CYLINDER”. Brake master cylinder kit For assembly, reverse the disassembly procedure.

  • Page 326: Rear Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES REAR BRAKE MASTER CYLINDER U PP E 30 Nm (3.0 m kg, 22 ft • • 23 Nm (2.3 m kg, 17 ft • • Order Job name/Part name Q’ty Remarks Removing the rear brake master cyl- Remove the parts in the order below.
  • Page 327 CHAS FRONT AND REAR BRAKES U PP E 30 Nm (3.0 m kg, 22 ft • • 23 Nm (2.3 m kg, 17 ft • • Order Job name/Part name Q’ty Remarks Union bolt Copper washer Brake hose Refer to “INSTALLING THE REAR BRAKE MASTER CYLINDER”.
  • Page 328 CHAS FRONT AND REAR BRAKES Order Job name/Part name Q’ty Remarks Disassembling the rear brake mas- Remove the parts in the order below. ter cylinder Brake master cylinder kit Refer to “ASSEMBLING THE REAR BRAKE MASTER CYLINDER”. Brake master cylinder For assembly, reverse the disassembly procedure.

  • Page 329: Checking The Master Cylinder

    CHAS FRONT AND REAR BRAKES CHECKING THE MASTER CYLINDER È 1.Check: Brake master cylinder 1 Wear/scratches → Replace the brake master cylinder assembly. Brake master cylinder body Cracks/damage → Replace. Brake fluid delivery passage (brake master cylinder body) Blockage → Blow out with compressed air. È...

  • Page 330: Assembling The Front Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EB702060 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER WARNING All internal brake components should be cleaned and lubricated with new brake fluid only before installation. Recommended brake fluid: DOT 4 Whenever a master cylinder is disassem- bled, replace the piston seals and dust seals.

  • Page 331: Installing The Front Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES INSTALLING THE FRONT BRAKE MASTER CYLINDER 1.Install: Brake master cylinder 1 7 Nm (0.7 m • kg, 5.1 ft • lb) NOTE: The “UP” mark on the brake master cylinder bracket should face up. 2.Install: Copper washers Brake hose Union bolt...

  • Page 332: Installing The Rear Brake Master Cylinder

    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 “BLEEDING THE HYDRAULIC BRAKE SYSTEM”...
  • Page 333 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 334: Front Brake Caliper

    CHAS FRONT AND REAR BRAKES FRONT BRAKE CALIPER Order Job name/Part name Q’ty Remarks Removing the front brake caliper Remove the parts in the order below. Brake fluid Drain. Front wheel Refer to “FRONT WHEELS”. Union bolt Copper washer Brake hose Disconnect.
  • Page 335 CHAS FRONT AND REAR BRAKES Order Job name/Part name Q’ty Remarks Disassembling the front brake cali- Remove 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 “DISASSEMBLING THE Dust seal FRONT BRAKE CALIPER/ASSEM- BLING THE FRONT BRAKE CALIPER”.

  • Page 336: Rear Brake Caliper

    CHAS FRONT AND REAR BRAKES REAR BRAKE CALIPER 30 Nm (3.0 m kg, 22 ft • • 30 Nm (3.0 m kg, 22 ft 40 Nm (4.0 m kg, 29 ft • • • • Order Job name/Part name Q’ty Remarks Removing the rear brake caliper Remove the parts in the order below.
  • Page 337 CHAS FRONT AND REAR BRAKES Order Job name/Part name Q’ty Remarks Disassembling the rear brake caliper Remove the parts in the order below. Brake pad holding bolt plug Brake pad holding bolt Pad spring Brake pad/insulator/pad shim 2/2/2 Brake caliper piston Refer to “DISASSEMBLING THE REAR Dust seal BRAKE CALIPER/ASSEMBLING THE...

  • Page 338: Disassembling The Brake Caliper

    CHAS FRONT AND REAR BRAKES DISASSEMBLING THE BRAKE CALIPER 1.Remove: Brake caliper piston Dust seal 1 Caliper piston seal 2 ***************************************************** Removal steps: Blow compressed air into the hose joint opening a to force out the caliper piston from the brake caliper body. WARNING Never try to pry out the caliper piston.

  • Page 339: Checking The Front And Rear Brake Caliper

    CHAS FRONT AND REAR BRAKES EB702040 CHECKING THE FRONT AND REAR BRAKE CALIPER Recommended brake component replace- ment schedule: Brake pads As required Piston seal, dust seal Every two years Brake hoses Every two years Replace when Brake fluid braked are disas- sembled.

  • Page 340: Assembling The Front Brake Caliper

    CHAS FRONT AND REAR BRAKES ASSEMBLING THE FRONT BRAKE CALIPER WARNING All internal brake components should be cleaned and lubricated with new brake fluid only before installation. Recommended brake fluid: DOT 4 Replace the caliper piston seal whenever a brake caliper is disassembled. 1.Install: Caliper piston seal 1 Dust seal 2...
  • Page 341 CHAS FRONT AND REAR BRAKES WARNING Proper brake hose routing is essential to insure safe motorcycle operation. Refer to “CABLE ROUTING”. 2.Fill: Brake reservoir Recommended brake fluid: DOT 4 CAUTION: Brake fluid may damage painted surfaces or plastic parts. Always clean up spilled brake fluid immediately.

  • Page 342: Assembling The Rear Brake Caliper

    CHAS FRONT AND REAR BRAKES ASSEMBLING THE REAR BRAKE CALIPER WARNING All internal brake components should be cleaned and lubricated with new brake fluid only before installation. Recommended brake fluid: DOT 4 Replace the caliper piston seal whenever a brake caliper is disassembled. 1.Install: Caliper piston seal 1 Dust seal 2...

  • Page 343: Installing The Rear Brake Caliper

    CHAS FRONT AND REAR BRAKES INSTALLING THE REAR BRAKE CALIPER 1.Install: Brake caliper assembly Brake caliper mounting bolt 30 Nm (3.0 m • kg, 22 ft • lb) Brake hose Copper washers Union bolt 30 Nm (3.0 m • kg, 22 ft • lb) 2.Fill: Brake reservoir Recommended brake fluid:...

  • Page 344: Handlebar

    CHAS STEERING SYSTEM STEERING SYSTEM HANDLEBAR 20 Nm (2.0 m kg, 14 ft • • Order Job name/Part name Q’ty Remarks Removing the handlebar Remove the parts in the order below. Handlebar cover Band On-command four-wheel drive switch and differential gear lock switch Refer to “INSTALLING THE MASTER Master cylinder assembly/bracket CYLINDER ASSEMBLY”.

  • Page 345: Removing The Rear Brake Switch

    CHAS STEERING SYSTEM REMOVING THE REAR BRAKE SWITCH 1.Remove: Rear brake switch 1 NOTE: Push the fastener when removing the rear brake switch out of the rear brake lever holder. CHECKING THE HANDLEBAR 1.Inspect: Handlebar Bends/cracks/damage → Replace. WARNING Do not attempt to straighten a bent handle- bar as this may dangerously weaken the handlebar.

  • Page 346: Installing The Master Cylinder Assembly

    CHAS STEERING SYSTEM INSTALLING THE MASTER CYLINDER ASSEMBLY 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 - 38...

  • Page 347: Steering Stem

    CHAS STEERING SYSTEM STEERING STEM 23 Nm (2.3 m kg, 17 ft • • 65 Nm (6.5 m kg, 47 ft • • 180 Nm (18.0 m kg, 130 ft • • 25 Nm (2.5 m kg, 18 ft • •...
  • Page 348 CHAS STEERING SYSTEM 23 Nm (2.3 m kg, 17 ft • • 65 Nm (6.5 m kg, 47 ft • • 180 Nm (18.0 m kg, 130 ft • • 25 Nm (2.5 m kg, 18 ft • • Order Job name/Part name Q’ty Remarks...

  • Page 349: Removing The Bearing Retainer

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

  • Page 350: Installing The Cable Guide

    CHAS STEERING SYSTEM INSTALLING THE CABLE GUIDE 1.Install Cable guide Lock washer 23 Nm (2.3 m • kg, 17 ft • lb) 2.Bend the lock washer tab along a flat side of the bolt. NOTE: Pass the cables and hoses through the cable guide.

  • Page 351: Tie Rod And Steering Knuckle

    CHAS STEERING SYSTEM TIE ROD AND STEERING KNUCKLE 25 Nm (2.5 m kg, 18 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 25 Nm (2.5 m kg, 18 ft • • 48 Nm (4.8 m kg, 35 ft •...

  • Page 352: Removing The Steering Knuckle

    CHAS STEERING SYSTEM REMOVING THE STEERING KNUCKLE 1.Remove: Steering knuckle 1 NOTE: Use a general puller to separate the ball joint 2 and steering knuckle. CHECKING THE TIE ROD 1.Check: Tie rod free play and movement Free play → Replace the tie rod end. Turns roughly →...

  • Page 353: Checking The Ball Joint

    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 354: Front Arms And Front Shock Absorber

    CHAS FRONT ARMS AND FRONT SHOCK ABSORBER FRONT ARMS AND FRONT SHOCK ABSORBER 45 Nm (4.5 m kg, 32 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 45 Nm (4.5 m kg, 32 ft • • 25 Nm (2.5 m kg, 18 ft •...
  • Page 355 CHAS FRONT ARMS AND FRONT SHOCK ABSORBER 45 Nm (4.5 m kg, 32 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 45 Nm (4.5 m kg, 32 ft • • 25 Nm (2.5 m kg, 18 ft •...

  • Page 356: Removing The Front Arms

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

  • Page 357: Installing The Front Arms And Front Shock Absorber

    CHAS FRONT ARMS AND FRONT SHOCK ABSORBER INSTALLING THE FRONT ARMS AND FRONT SHOCK ABSORBER 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 358: Rear Knuckle And Stabilizer

    CHAS REAR KNUCKLE AND STABILIZER REAR KNUCKLE AND STABILIZER 30 Nm (3.0 m kg, 22 ft • • 48 Nm (4.8 m kg, 35 ft • • 45 Nm (4.5 m kg, 32 ft • • 48 Nm (4.8 m kg, 35 ft •...

  • Page 359: Checking The Rear Knuckle

    CHAS REAR KNUCKLE AND STABILIZER CHECKING THE REAR KNUCKLE 1.Check: Rear knuckle Damage/pitting → Replace. 2.Check: Rear wheel bearings Bearings allow play in the wheel hubs or the wheel turns roughly → Replace. Oil seals Damage → Replace. ***************************************************** Replacement steps: Clean the outside of the rear knuckle.

  • Page 360: Rear Arms And Rear Shock Absorber

    CHAS REAR ARMS AND REAR SHOCK ABSORBER REAR ARMS AND REAR SHOCK ABSORBER 45 Nm (4.5 m kg, 32 ft • • 45 Nm (4.5 m kg, 32 ft • • 45 Nm (4.5 m kg, 32 ft • • 45 Nm (4.5 m kg, 32 ft •...

  • Page 361: Checking The Rear Arm

    CHAS REAR ARMS AND REAR SHOCK ABSORBER CHECKING THE REAR ARM 1.Check: Rear arms 1 Bends/damage → Replace. 2.Check: Bushings 2 Wear/damage → Replace. CHECKING THE REAR SHOCK ABSORBER 1.Check: Shock absorber rod → Bends/damage Replace shock absorber assembly. Shock absorber assembly Oil leaks →...
  • Page 362 CHAS REAR ARMS AND REAR SHOCK ABSORBER Install the rear shock absorber 5. Nut 6: 45 Nm (4.5 m • kg, 32 ft • lb) Install the rear knuckle. Nut 7: 45 Nm (4.5 m • kg, 32 ft • lb) Tighten the nuts 4.

  • Page 363: Elec

    – ELEC...
  • Page 364 – ELEC CHAPTER 9. ELECTRICAL ELECTRICAL COMPONENTS ..............9-1 CHECKING THE SWITCH ................9-2 CHECKING THE SWITCH ..............9-2 CHECKING A SWITCH SHOWN IN THE MANUAL ......9-2 CHECKING THE SWITCH CONTINUITY ..........9-3 CHECKING THE BULBS AND BULB SOCKETS ........9-5 TYPES OF BULBS ................
  • Page 365 – ELEC 2WD/4WD SELECTING SYSTEM .............. 9-51 CIRCUIT DIAGRAM ................9-51 TROUBLESHOOTING ................ 9-52...

  • Page 366: Chapter 9. Electrical

    – ELEC ELECTRICAL COMPONENTS EB800000 ELECTRICAL ELECTRICAL COMPONENTS 1 Main switch 8 Circuit breaker (fan) C CDI unit K Rear brake light switch 2 Diode 9 Fuse box D Starter relay L Thermo switch 2 3 Thermo switch 1 0 Four-wheel drive E Main fuse M Fan 4 Front brake light...

  • Page 367: Checking The Switch

    – ELEC CHECKING THE SWITCH CHECKING THE SWITCH CHECKING THE SWITCH 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 368: Checking The Switch Continuity

    – ELEC CHECKING THE SWITCH CHECKING THE SWITCH CONTINUITY Refer to “CHECKING THE SWITCH” and check for continuity between lead terminals. Poor connection, no continuity → Correct or replace. The coupler locations are circled. Br L Y G R/B R/W PUSH (BLACK) L/B L/G...
  • Page 369 – ELEC CHECKING THE SWITCH 1 Light switch 2 Engine stop switch 3 Start switch 4 On-command four-wheel drive switch and differential gear lock switch 5 Main switch 6 Rear brake light switch 7 Front brake light switch 8 Rear brake switch 9 Horn switch (for Europe and Oceania) 0 Gear position switch A Reverse switch...

  • Page 370: Checking The Bulbs And Bulb Sockets

    – ELEC CHECKING THE BULBS AND BULB SOCKETS EB801020 CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage or wear, proper connections, and also for con- tinuity between the terminals. Damage/wear → Repair or replace the bulb, bulb socket or both.
  • Page 371 – ELEC CHECKING THE BULBS AND BULB SOCKETS WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. CAUTION: Be sure to hold the socket firmly when removing the bulb.

  • Page 372: Checking The Condition Of The Bulb Sockets

    – ELEC CHECKING THE BULBS AND BULB SOCKETS CHECKING THE CONDITION OF THE BULB SOCKETS The following procedure applies to all of the bulb sockets. 1.Check: Bulb socket (for continuity) (with the pocket tester) No continuity → Replace. Pocket tester: P/N.

  • Page 373: Ignition System

    – ELEC IGNITION SYSTEM EB802000 IGNITION SYSTEM CIRCUIT DIAGRAM 9 - 8...

  • Page 374: 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 plug 9.Pickup coil resistance 4.Ignition spark gap 10.Charging/rotor rotation direction detection 5.Spark plug cap resistance coil resistance 6.Ignition coil resistance...
  • Page 375 – ELEC IGNITION SYSTEM INCORRECT Spark plug gap: 0.8 ~ 0.9 mm (0.03 ~ 0.04 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 376 – 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 377 – ELEC IGNITION SYSTEM Connect the pocket tester (Ω × 1k) to the ignition coil. Tester (+) lead → Orange lead terminal Tester (–) lead → Spark plug lead Check that the secondary coil has the specified resistance. Secondary coil resistance: OUT OF SPECIFICATION 6.32 ~ 9.48 kΩ...
  • Page 378 – ELEC IGNITION SYSTEM C0NTINUITY 10.Charging/rotor rotation direction detec- tion coil resistance Disconnect the AC 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 379: Electric Starting System

    – ELEC ELECTRIC STARTING SYSTEM EB803000 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM 9 - 14...

  • Page 380: Starting Circuit Operation

    – ELEC ELECTRIC STARTING SYSTEM STARTING CIRCUIT OPERATION The starting circuit on this model consists of the starter motor, starter relay, rear brake switch, rear brake switch CDI unit and gear position 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 neutral...

  • Page 381: Troubleshooting

    – ELEC ELECTRIC STARTING SYSTEM EB803020 TROUBLESHOOTING IF THE STARTER MOTOR FAILS TO OPERATE: Procedure Check: 8.Rear brake switch 1.Fuse (main, ignition) 9.Start switch 2.Battery 10.Diode 3.Starter motor 11.Wiring connection (the entire starting sys- 4.Starter relay tem) 5.Main switch 6.Engine stop switch 7.Gear position switch NOTE: Pocket tester:...
  • Page 382 – 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 jumper that of the battery lead, otherwise the lead 3 jumper lead may burn.
  • Page 383 – ELEC ELECTRIC STARTING SYSTEM C0NTINUITY INCORRECT 5.Main switch Refer to “CHECKING THE SWITCH”. CORRECT Replace the main switch. INCORRECT 6.Engine stop switch Refer to “CHECKING THE SWITCH”. CORRECT Replace the handlebar switch (right). INCORRECT 7.Gear position switch Refer to “CHECKING THE SWITCH”. CORRECT Replace the gear position switch.
  • Page 384 – ELEC ELECTRIC STARTING SYSTEM C0NTINUITY INCORRECT 9.Start switch Refer to “CHECKING THE SWITCH”. CORRECT Replace the handlebar switch (left). 10.Diode Remove the diode from the coupler. Connect the pocket tester (Ω × 1) to the diode terminals as shown. Check the diode for continuity as follows.

  • Page 385: Starter Motor

    – ELEC ELECTRIC STARTING SYSTEM STARTER MOTOR Order Job name/Part name Q’ty Remarks Removing the starter motor Remove the parts in the order below. Starter motor lead Starter motor/O-ring Disassembling the starter motor Remove the parts in the order below. Bracket 1 Washer kit Bracket 2...

  • Page 386: Checking The Starter Motor

    – ELEC ELECTRIC STARTING SYSTEM CHECKING THE STARTER MOTOR 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 387: Assembling The Starter Motor

    – 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.

  • Page 388: Charging System

    – ELEC CHARGING SYSTEM EB804000 CHARGING SYSTEM CIRCUIT DIAGRAM 1 AC magneto 2 Rectifier/regulator 5 Battery 6 Main fuse 9 - 23...

  • Page 389: 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 trouble- P/N. YU-8036-A shooting: Engine tachometer: 1)Seat P/N.
  • Page 390 – 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 AC magneto coupler from the wire harness.

  • Page 391: Lighting System

    – ELEC LIGHTING SYSTEM EB805000 LIGHTING SYSTEM CIRCUIT DIAGRAM 3 Main switch 5 Battery 6 Main fuse ` Headlight fuse b Light switch e Headlight i Brake/tail light 9 - 26...

  • Page 392: Troubleshooting

    – ELEC LIGHTING SYSTEM EB805010 TROUBLESHOOTING IF THE HEADLIGHT AND/OR TAILLIGHT FAIL TO COME ON: Procedure Check: 4.Light switch 1.Fuse (main, headlight) 5.Wiring connections 2.Battery (the entire lighting system) 3.Main switch NOTE: Pocket tester: Remove the following part(s) before trouble- P/N.
  • Page 393 – ELEC LIGHTING SYSTEM C0NTINUITY INCORRECT 3.Main switch Refer to “CHECKING THE SWITCH”. CORRECT Replace the main switch. INCORRECT 4.Light switch Refer to “CHECKING THE SWITCH”. Light switch is faulty, replace the handlebar CORRECT switch (left). EB805013 5.Wiring connection POOR CONNECTION Check the connections of the entire lighting system.

  • Page 394: Checking The Lighting System

    – ELEC LIGHTING SYSTEM EB805020 CHECKING THE LIGHTING SYSTEM 1.If the headlights fail to come on: NO CONTINUITY 1.Bulb and bulb socket Check the bulb and bulb socket for continu- ity. Replace the bulb and/or bulb socket. CONTINUITY 2.Voltage Connect the pocket tester (DC 20 V) to the headlight couplers.
  • Page 395 – ELEC LIGHTING SYSTEM EB805021 2.If the taillight fails to come on: NO CONTINUITY 1.Bulb and bulb socket Check the bulb and bulb socket for continu- ity. Replace the bulb and/or bulb socket. CONTINUITY 2.Voltage Connect the pocket tester (20 V) to the bulb socket coupler.

  • Page 396: Signal System

    – ELEC SIGNAL SYSTEM EB806000 SIGNAL SYSTEM CIRCUIT DIAGRAM 9 - 31...
  • Page 397 – ELEC SIGNAL SYSTEM 3 Main switch 5 Battery 6 Main fuse 9 Reverse switch 0 CDI unit F Multi-function meter G Differential gear lock indicator light H Coolant temperature indicator light I Reverse indicator light J Neutral indicator light K Park indicator light L High-range indicator light M Low-range indicator light...

  • Page 398: Troubleshooting

    – ELEC SIGNAL SYSTEM EB806010 TROUBLESHOOTING IF THE BRAKE LIGHT AND/OR INDICATOR LIGHT FAILS TO COME ON: IF THE HORN FAILS TO SOUND: Procedure Check: 1.Fuse (main, ignition, signaling system) 2.Battery 3.Main switch 4.Wiring connections (the entire signal system) NOTE: Pocket tester: Remove the following part(s) before trouble- P/N.
  • Page 399 – ELEC SIGNAL SYSTEM C0NTINUITY INCORRECT 3.Main switch Refer to “CHECKING THE SWITCH”. CORRECT Replace the main switch. EB806011 POOR CONNECTION 4.Wiring connections Check the connections of the entire signal system. Refer to “CIRCUIT DIAGRAM”. Properly connect the signal system. CORRECT Check the condition of each of the signal sys- tem’s circuits.

  • Page 400: Checking The Signal System

    – ELEC SIGNAL SYSTEM CHECKING THE SIGNAL SYSTEM 1.If the brake light fails to come on: 1.Bulb and bulb socket NO CONTINUITY Check the bulb and bulb socket for continu- ity. CONTINUITY Replace the bulb and/or bulb socket. NO CONTINUITY 2.Brake light switches Refer to “CHECKING THE SWITCH”.
  • Page 401 – ELEC SIGNAL SYSTEM EB806024 2.If the neutral indicator light fails to come on: 1.Neutral indicator light LED NO CONTINUITY Check the LED of the neutral indicator light. CONTINUITY Replace the meter assembly. NO CONTINUITY 2.Gear position switch Refer to “CHECKING THE SWITCH”. CONTINUITY Replace the gear position switch.
  • Page 402 – ELEC SIGNAL SYSTEM 3.If the park indicator light fails to come on: 1.Park indicator light LED NO CONTINUITY Check the LED of the park indicator light. CONTINUITY Replace the meter assembly. NO CONTINUITY 2.Gear position switch Refer to “CHECKING THE SWITCH”. CONTINUITY Replace the gear position switch.
  • Page 403 – ELEC SIGNAL SYSTEM 4.If the high-range indicator light fails to come 1.High-range indicator light LED NO CONTINUITY Check the LED of the high-range indicator light. CONTINUITY Replace the meter assembly. NO CONTINUITY 2.Gear position switch Refer to “CHECKING THE SWITCH”. CONTINUITY Replace the gear position switch.
  • Page 404 – ELEC SIGNAL SYSTEM 5.If the low-range indicator light fails to come 1.Low-range indicator light LED NO CONTINUITY Check the LED of the low-range indicator light. CONTINUITY Replace the meter assembly. NO CONTINUITY 2.Gear position switch Refer to “CHECKING THE SWITCH”. CONTINUITY Replace the gear position switch.
  • Page 405 – ELEC SIGNAL SYSTEM 6.If the reverse indicator light fails to come on: 1.Reverse indicator light LED NO CONTINUITY Check the LED of the reverse indicator light. CONTINUITY Replace the meter assembly. NO CONTINUITY 2.Reverse switch Refer to “CHECKING THE SWITCH”. CONTINUITY Replace the reverse switch.
  • Page 406 – ELEC SIGNAL SYSTEM 7.If the coolant temperature indicator light does not come on when the main switch to “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.Coolant temperature indicator light LED Check the LED of the coolant indicator...
  • Page 407 – ELEC SIGNAL SYSTEM C0NTINUITY 3.Voltage Connect the pocket tester (DC 20 V) to the bulb socket connector. Tester (+) lead → White/Blue terminal 1 Tester (–) lead → Frame ground OUT OF SPECIFICATION Turn the main switch to “ON”. Check the voltage (12 V).
  • Page 408 – ELEC SIGNAL SYSTEM 8.If the differential gear lock indicator light LED fails to come on: 1.Differential gear lock indicator light NO CONTINUITY Check the LED of the differential gear lock indicator light. CONTINUITY Replace the meter assembly. NO CONTINUITY 2.Four-wheel drive switch Refer to “CHECKING THE SWITCH”.
  • Page 409 – ELEC SIGNAL SYSTEM 9.Horn does not sound. (for Europe and Oce- ania) INCORRECT 1.Horn switch Refer to “CHECKING THE SWITCH”. CORRECT Replace horn switch. 2.Voltage Connect the pocket tester (DC 20 V) to the horn connector at the horn terminal. Tester (+) lead →...
  • Page 410 – ELEC SIGNAL SYSTEM 4.Voltage Connect the pocket tester (DC 20 V) to the horn connector at the horn terminal. Tester (+) lead → Black lead 1 Tester (–) lead → Frame ground OUT OF SPECIFICATION Turn the main switch to “ON”. Push the horn switch.

  • Page 411: Cooling System

    – ELEC COOLING SYSTEM COOLING SYSTEM CIRCUIT DIAGRAM 9 - 46...
  • Page 412 – ELEC COOLING SYSTEM TROUBLESHOOTING IF THE FAN MOTOR DOES NOT MOVE: Procedure Check: 1.Fuse (main) 6.Thermo switch 2 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 trouble- P/N.
  • Page 413 – 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 414 – ELEC COOLING SYSTEM C0NTINUITY 6.Thermo switch 2 Remove the thermo switch 2 from the radiator. Connect the pocket tester (Ω × 10) to the thermo switch 2 1. Immerse the thermo switch 2 in coolant 2. Check the thermo switch 2 for continuity. While heating the coolant use a thermome- ter 3 to record the temperatures.
  • Page 415 – ELEC COOLING SYSTEM C0NTINUITY EB803028 POOR CONNECTION 7.Wiring connection Check the connections of the entire starting system. Refer to “CIRCUIT DIAGRAM”. Properly connect the cooling system. CORRECT This circuit is not faulty. 9 - 50...
  • Page 416 – ELEC 2WD/4WD SELECTING SYSTEM 2WD/4WD SELECTING SYSTEM CIRCUIT DIAGRAM 3 Main switch 5 Battery 6 Main fuse 0 CDI unit U Four-wheel drive fuse V Four-wheel drive relay 1 W Four-wheel drive relay 2 X Four-wheel drive relay 3 Y On-command four-wheel drive switch and differential gear lock switch Z Gear motor...
  • Page 417 – ELEC 2WD/4WD SELECTING SYSTEM EB803020 TROUBLESHOOTING IF THE FOUR-WHEEL DRIVE INDICATOR FAILS TO COME ON: Procedure Check: 1.Fuse (main, four-wheel drive) 7.On-command four-wheel drive switch and 2.Battery differential gear lock switch 3.Main switch 8.Gear motor 4.Four-wheel drive relay 1 9.Wiring connections 5.Four-wheel drive relay 2 (the entire 2WD/4WD selecting system)
  • Page 418 – ELEC 2WD/4WD SELECTING SYSTEM C0NTINUITY 4.Four-wheel drive relay 1 Remove the four-wheel drive relay 1 from the wire harness. Connect the pocket tester (Ω × 1) and the battery (12 V) to the four-wheel drive relay 1 terminals. Tester (+) lead → Brown/Black terminal 1 Tester (–) lead →...
  • Page 419 – ELEC 2WD/4WD SELECTING SYSTEM C0NTINUITY 6.Four-wheel drive relay 3 Remove the four-wheel drive relay 3 from the wire harness. Connect the pocket tester (Ω × 1) and the battery (12 V) to the four-wheel drive relay 3 terminals. Tester (+) lead → Brown/Red terminal 1 Tester (–) lead →...
  • Page 420 – ELEC 2WD/4WD SELECTING SYSTEM C0NTINUITY È 8.Gear motor Disconnect the gear motor coupler. Remove the gear motor from the differen- tial gear case. Refer to “FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR” in CHAPTER 7. Connect two C size batteries to the gear motor terminals 1 (as shown illustrations).

  • Page 422: Trbl Shtg

    TRBL SHTG...

  • Page 423: Troubleshooting

    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 .....
  • Page 424 TRBL SHTG...

  • Page 425: Starting Failure/Hard Starting

    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 manual for inspection, adjustment and replacement of parts. STARTING FAILURE/HARD STARTING FUEL SYSTEM Fuel tank...

  • Page 426: Compression System

    TRBL STARTING FAILURE/HARD STARTING/POOR IDLE SPEED SHTG PERFORMANCE/POOR MEDIUM AND HIGH-SPEED PERFORMANCE 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 Broken cylinder gasket Broken valve spring...

  • Page 427: Faulty Drive Train

    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” movement A.Bearing damage. during acceleration, deceleration, or sustained speed. (This must not be confused with B.Improper gear lash.

  • Page 428: Faulty Gear Shifting

    TRBL FAULTY GEAR SHIFTING/ FAULTY CLUTCH PERFORMANCE SHTG FAULTY GEAR SHIFTING HARD SHIFTING Refer to “CLUTCH SLIPPING/DRAGGING-CLUTCH DRAGGING”. SHIFT LEVER DOES NOT MOVE Shift shaft Transmission Bent shift shaft Seized transmission gear Shift cam, shift fork Jammed impurities Groove jammed with impurities Incorrectly assembled transmission Seized shift fork Shift guide...

  • Page 429: Poor Speed Performance

    TRBL FAULTY CLUTCH PERFORMANCE/ OVERHEATING/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 430: Shock Absorber Malfunction

    TRBL SHOCK ABSORBER MALFUNCTION/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 Excessive wheel runout...
  • Page 431 YFM660F(P) 2002 WIRING DIAGRAM 1 AC magneto 2 Rectifier/regulator 3 Main switch R/B Br/B Br/B (GRAY) (GRAY) R/B L/W G/W W/B 4 Backup fuse B/Y R WIRE HARNESS SUB-WIRE HARNESS WIRE HARNESS SUB-WIRE HARNESS WIRE HARNESS IGNITION COIL LEAD 5 Battery (BLACK) (BLACK) (BLACK)

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Yfm660f(p) 2002

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