Yamaha 5YF2-AE1 Offroad Vehicle Manuals

Yamaha 5YF2-AE1 Offroad Vehicle Manuals

Manuals and User Guides for Yamaha 5YF2-AE1 Offroad Vehicle. We have 1 Yamaha 5YF2-AE1 Offroad Vehicle manual available for free PDF download: Service Manual

Yamaha 5YF2-AE1 Service Manual

Yamaha 5YF2-AE1 Service Manual (262 pages)

Brand: Yamaha | Category: Offroad Vehicle | Size: 9 MB

Table of Contents

Table of Contents

7
- Periodic Checks and Adjustments
  6
- Engine
  6
- Carburetor
  6
- Drive Train
  6
- Chassis
  6
- Electrical
  6
- Troubleshooting
  6
  - Table of Contents
    7
- Gen Info
  9
- General Information
  12
- Machine Identification
  12
- Vehicle Identification Number
  12
- Model Label
  12
- Important Information
  13
- Preparation for Removal and Disassembly
  13
- Replacement Parts
  13
- Gaskets, Oil Seals and O-Rings
  13
- Lock Washers/Plates and Cotter Pins
  14
- Bearings and Oil Seals
  14
- Circlips
  14
- Checking the Connections
  15
- Special Tools
  16
- Spec
  20
Spec

21
- General Specifications
  23
- Specifications
  23
- Engine Specifications
  27
- Chassis Specifications
  34
- Electrical Specifications
  35
- Engine Tightening Torques
  37
- Tightening Torques
  37
- Chassis Tightening Torques
  38
- General Tightening Torque Specifications
  40
- How to Use the Conversion Table
  40
- Engine
  41
- Lubrication Points and Lubricant Types
  41
- Oil Flow Diagrams
  43
- Cable Routing
  45
- Chk Adj
  53
Chapter 3 Periodic Checks and Adjustments

54
- Introduction
  56
- Periodic Checks and Adjustments
  56
- Periodic Maintenance/Lubrication
  56
- Seat and Front Panel
  57
- Seat, Fenders and Fuel Tank
  57
- Front Fender
  58
- Rear Fender and Footrest Boards
  59
- Fuel Tank
  61
- Adjusting the Timing Chain Tensioner
  62
- Engine
  62
- Adjusting the Valve Clearance
  63
- Adjusting the Engine Idling Speed
  65
- Adjusting the Throttle Lever Free Play
  66
- Adjusting the Speed Limiter
  67
- Checking the Spark Plug
  68
- Checking the Ignition Timing
  69
- Measuring the Compression Pressure
  70
- Checking the Engine Oil Level
  72
- Changing the Engine Oil
  74
- Cleaning the Air Filter Element
  75
- Adjusting the Front Brake
  77
- Chassis
  77
- Checking the Front and Rear Brake Shoes
  77
- Adjusting the Rear Brake
  78
- Changing the Final Gear Oil
  79
- Checking the Final Gear Oil Level
  79
- Checking the Swingarm Dust Boot
  80
- Checking the Steering System
  81
- Adjusting the Toe-In
  82
- Checking the Front and Rear Shock Absorbers
  83
- Checking the Tires
  84
- Checking the Wheels
  86
- Checking and Lubricating the Cables
  87
- Lubricating the Levers, Steering Shaft and Steering Knuckles
  87
- Checking and Charging the Battery
  88
- Electrical System
  88
- Checking the Fuse
  92
- Eng
  94
Chapter 4 Engine

95
- Engine
  97
- Exhaust Pipe/Muffler, Breather Hose and Leads
  97
- Engine Mounting Bolts
  98
- Installing the Engine
  100
- Removing the Engine
  100
- Cylinder Head
  101
- Removing the Cylinder Head
  103
- Checking the Camshaft Sprocket
  104
- Checking the Tappet Covers and Camshaft Sprocket Cover
  104
- Checking the Timing Chain Guides
  104
- Checking the Timing Chain Tensioner Assembly
  104
- Checking the Cylinder Head
  105
- Installing the Cylinder Head
  106
- Camshaft, Rocker Arms and Valves
  108
- Removing the Rocker Arms and Camshaft
  110
- Removing the Valves and Valve Springs
  110
- Checking the Camshaft
  111
- Checking the Rocker Arms and Rocker Arm Shafts
  111
- Checking the Valves and Valve Springs
  113
- Installing the Valves and Valve Springs
  117
- Installing the Camshaft and Rocker Arms
  118
- Cylinder and Piston
  119
- Checking the Cylinder and Piston
  120
- Removing the Piston
  120
- Checking the Piston Rings
  122
- Checking the Piston Pin
  123
- Installing the Piston
  124
- Installing the Cylinder
  125
- C.D.I. Magneto
  126
- Checking the Pickup Coil/Stator Assembly
  127
- Removing the C.D.I. Magneto Rotor
  127
- Installing the C.D.I. Magneto Rotor
  128
- Installing the Shift Lever
  128
- Clutch
  129
- Checking the Friction Plates
  131
- Removing the Clutch
  131
- Removing the Primary Drive Gear
  131
- Checking the Clutch Housing
  132
- Checking the Clutch Plates
  132
- Checking the Clutch Springs
  132
- Checking the Clutch Balls
  133
- Checking the Clutch Boss
  133
- Checking the Pressure Plate
  133
- Checking the Primary Drive Gears
  133
- Installing the Clutch
  134
- Installing the Primary Drive Gear
  134
- Starter Clutch and Oil Pump
  138
- Checking the Starter Clutch
  140
- Checking the Oil Pump
  141
- Shift Shaft
  143
- Checking the Shift Shaft
  144
- Checking the Stopper Lever
  144
- Installing the Shift Shaft
  144
- Installing the Stopper Lever
  144
- Crankcase
  145
- Crankcase Bearings
  146
- Checking the Timing Chain
  147
- Separating the Crankcase
  147
- Checking the Bearings and Oil Seals
  148
- Checking the Crankcase
  148
- Installing the Bearings
  148
- Assembling the Crankcase
  149
- Crankshaft
  150
- Checking the Crankshaft
  151
- Installing the Crankshaft
  151
- Transmission
  152
- Checking the Shift Fork
  153
- Removing the Transmission
  153
- Checking the Shift Drum
  154
- Checking the Transmission
  154
- Installing the Transmission
  155
- Middle Gear
  156
- Removing the Middle Driven Shaft
  157
- Checking the Pinion Gears
  158
- Selecting Middle Driven Gear Shims
  159
- Installing the Middle Driven Shaft
  160
- Measuring the Middle Gear Backlash
  162
- Carb
  163
- Driv
  172
Driv

173
- Drive Train
  175
- Troubleshooting
  175
- Checking Noises
  176
- Troubleshooting Chart
  178
- Rear Axle/Final Drive Assembly and Drive Shaft
  179
- Rear Axle/Final Drive Assembly
  181
- Removing the Nuts
  182
- Removing the Rear Axle/Final Drive Assembly
  182
- Disassembling the Final Gear Case
  183
- Disassembling the Rear Axle Housing
  183
- Checking the Drive Shaft
  184
- Checking the Rear Axle
  184
- Checking the Rear Axle Housing and Final Drive Assembly
  184
- Assembling the Final Gear Case
  185
- Assembling the Rear Axle Housing
  185
- Installing the Rear Axle/Final Drive Assembly
  186
- Installing the Nuts
  187
- Chas
  189
Chas

190
- Front and Rear Wheels
  192
- Front Wheels
  192
- Rear Wheels
  193
- Checking the Front Wheel Hubs
  194
- Checking the Wheels
  194
- Checking the Rear Wheel Hubs
  195
- Installing the Wheel Hubs
  195
- Installing the Wheels
  196
- Front and Rear Brakes
  197
- Front Brake
  197
- Rear Brake
  198
- Checking the Brake Shoe Plates
  200
- Checking the Brake Shoes
  200
- Removing the Brakes
  200
- Checking the Brake Drums
  201
- Installing the Front Brakes
  202
- Installing the Rear Brake
  203
- Handlebar
  205
- Steering System
  205
- Checking the Handlebar
  207
- Removing the Handlebar Grips
  207
- Removing the Rear Brake Switch
  207
- Installing the Handlebar
  208
- Installing the Handlebar Grips
  208
- Installing the Front Brake Lever Assembly
  209
- Installing the Rear Brake Lever
  209
- Steering Stem
  210
- Checking the Steering Stem
  211
- Installing the Lock Washer
  211
- Installing the Steering Stem
  211
- Removing the Steering Stem
  211
- Tie-Rods and Steering Knuckles
  212
- Checking the Steering Knuckles
  213
- Checking the Tie-Rods
  213
- Removing the Tie-Rods
  213
- Installing the Tie-Rods
  214
- Front Shock Absorber Assemblies and Front Swingarm
  215
- Checking the Front Shock Absorber Assemblies
  216
- Checking the Front Swingarm
  216
- Removing the Front Swingarm
  216
- Rear Shock Absorber and Rear Swingarm
  217
- Checking the Rear Shock Absorber
  218
- Removing the Rear Swingarm
  218
- Checking the Dust Boot
  219
- Checking the Rear Swingarm
  219
- Installing the Lock Washer
  219
- Elec
  220
Elec

221
- Electrical Components
  223
- Checking Switch Continuity
  224
- Checking the Switches
  225
- Checking the Bulbs and Bulb Sockets
  226
- Checking the Condition of the Bulbs
  226
- Types of Bulbs
  226
- Checking the Condition of the Bulb Sockets
  228
- Circuit Diagram
  229
- Ignition System
  229
- Troubleshooting
  230
- Circuit Diagram
  235
- Electric Starting System
  235
- Starting Circuit Operation
  236
- Troubleshooting
  237
- Starter Motor
  241
- Checking the Starter Motor
  242
- Assembling the Starter Motor
  243
- Charging System
  244
- Circuit Diagram
  244
- Troubleshooting
  245
- Circuit Diagram
  247
- Signal System
  247
- Troubleshooting
  248
- Checking the Signaling System
  249
- Trbl Shtg
  251
Trbl Shtg

252
- Electrical System
  254
- Fuel System
  254
- Starting Failure/Hard Starting
  254
- Troubleshooting
  254
- Compression System
  255
- Poor Idle Speed Performance
  255
- Poor Medium and High-Speed Performance
  255
- Faulty Drive Train
  256
- Clutch Dragging
  257
- Clutch Slipping
  257
- Clutch Slipping/Dragging
  257
- Faulty Gear Shifting
  257
- Hard Shifting
  257
- Jumps out Gear
  257
- Overheating
  257
- Shift Lever Does Not Move
  257
- Faulty Brake
  258
- Malfunction
  258
- Poor Braking Effect
  258
- Shock Absorber Malfunction
  258
- Unstable Handling
  258

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