YFM450FAR SERVICE MANUAL LIT-11616-16-01 5ND-F8197-10 Not For Resale www.SmallEngineDiscount.
YFM450FAR SERVICE MANUAL ©2002 by Yamaha Motor Corporation, U.S.A. First Edition, March 2002 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. LIT-11616-16-01 Not For Resale www.SmallEngineDiscount.
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. Repairs attempted by anyone without this knowledge are likely to render the machine unsafe and unfit for use.
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. It is located in the upper left corner of the page.
1 EB003000 2 GEN INFO ILLUSTRATED SYMBOLS Illustrated symbols 1 to 0 are printed on the top right of each page and indicate the subject of each chapter. SPEC 3 4 CHK ADJ 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Cooling system 6 Carburetion 7 Drive train 8 Chassis 9 Electrical 0 Troubleshooting ENG 5 6 COOL CARB 7 8 CHAS DRIV 9 0 – ELEC TRBL SHTG + A Illustrated symbols A to H are used to identify the specifications appearing in the text.
TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS ENGINE COOLING SYSTEM CARBURETION DRIVE TRAIN CHASSIS GEN INFO 1 SPEC 2 CHK ADJ 3 ENG 4 COOL 5 CARB 6 DRIV 7 CHAS 8 – ELECTRICAL TROUBLESHOOTING Not For Resale www.SmallEngineDiscount.
CONTENTS CHAPTER 1. GENERAL INFORMATION MACHINE IDENTIFICATION ........................................................................ 1-1 VEHICLE IDENTIFICATION NUMBER ................................................. 1-1 MODEL LABEL ...................................................................................... 1-1 FEATURES ................................................................................................... 1-2 LIQUID COOLING ENGINE ..................................................
COOLANT FLOW DIAGRAMS ................................................................... 2-22 OIL FLOW DIAGRAMS .............................................................................. 2-24 CABLE ROUTING ....................................................................................... 2-27 CHAPTER 3. PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION ........................................................................................... 3-1 PERIODIC MAINTENANCE/LUBRICATION ......................
CHASSIS .................................................................................................... 3-36 ADJUSTING THE REAR BRAKE ........................................................ 3-36 CHECKING THE BRAKE FLUID LEVEL ............................................. 3-38 CHECKING THE FRONT BRAKE PAD .............................................. 3-39 CHECKING THE REAR BRAKE PAD ................................................. 3-39 CHECKING THE BRAKE HOSE .........................................
CAMSHAFT, ROCKER ARMS AND VALVES ........................................... 4-16 REMOVING THE CAMSHAFT AND ROCKER ARM .......................... 4-18 REMOVING THE VALVE AND VALVE SPRING ................................ 4-18 CHECKING THE CAMSHAFT ............................................................. 4-19 CHECKING THE ROCKER ARM AND CAMSHAFT ........................... 4-19 CHECKING THE VALVE AND VALVE SPRING ................................. 4-21 INSTALLING THE VALVE AND VALVE SPRING ...............
CRANKCASE .............................................................................................. 4-56 STARTER MOTOR, TIMING CHAIN AND OIL FILTER ...................... 4-56 CRANKCASE ...................................................................................... 4-58 CRANKCASE BEARING ..................................................................... 4-59 REMOVING THE OIL PUMP DRIVE GEAR ....................................... 4-60 SEPARATING THE CRANKCASE .................................
CHAPTER 5. COOLING SYSTEM RADIATOR .................................................................................................... 5-1 CHECKING THE RADIATOR ................................................................ 5-3 INSTALLING THE RADIATOR .............................................................. 5-4 THERMOSTAT .............................................................................................. 5-5 CHECKING THE THERMOSTAT ........................................................
REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT ........................... 7-17 REMOVING THE REAR AXLE ............................................................ 7-20 DISASSEMBLING THE FINAL DRIVE GEAR ..................................... 7-20 REPLACING THE FINAL DRIVE ROLLER BEARING ........................ 7-21 POSITIONING THE FINAL DRIVE PINION GEAR AND RING GEAR ............................................................................ 7-22 CHECKING THE REAR AXLE .......................................
STEERING SYSTEM .................................................................................. 8-30 HANDLEBAR ....................................................................................... 8-30 REMOVING THE REAR BRAKE SWITCH ......................................... 8-31 CHECKING THE HANDLEBAR .......................................................... 8-31 INSTALLING THE HANDLEBAR ........................................................ 8-31 INSTALLING THE REAR BRAKE LEVER .....................
CHECKING THE BULBS AND BULB SOCKETS ........................................ 9-6 TYPES OF BULBS ................................................................................ 9-6 CHECKING THE CONDITION OF THE BULBS ................................... 9-6 CHECKING THE CONDITION OF THE BULB SOCKETS ................... 9-8 IGNITION SYSTEM ....................................................................................... 9-9 CIRCUIT DIAGRAM ................................................................
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 ......................................................
MACHINE IDENTIFICATION GEN INFO GENERAL INFORMATION MACHINE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 stamped into the left side of the frame. is MODEL LABEL The model label 1 is affixed to the frame. This information will be needed to order spare parts. Not For Resale 1-1 www.SmallEngineDiscount.
FEATURES GEN INFO FEATURES LIQUID COOLING ENGINE Compact liquid cooled 45° inclined engine. A liquid cooling system has been incorporated for stable power and engine endurance. 1 Radiator 2 Thermo switch 3 Fan motor PARK POSITION When the drive select lever is shifted into the park position, a stopper lever is engaged into the stopper gear preventing the drive select lever and transmission from moving.
FEATURES GEN INFO FRONT DIFFERENTIAL 1 Adapter 2 Drive clutch 3 Differential side gear (left) 4 Differential pinion gear 5 Ring gear 6 Differential side gear (right) 7 Drive pinion gear 8 Gear motor È To front wheel É From the middle gear Not For Resale 1-3 www.SmallEngineDiscount.
FEATURES GEN INFO 2WD 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. Not For Resale 1-4 www.SmallEngineDiscount.
FEATURES GEN INFO 4WD 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 → left front constant velocity joint.
FEATURES GEN 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 transmitted directly from the ring gear 5 to the drive clutch 2, then to the left front constant velocity joint via the adapter 1.
FEATURES GEN 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 condition (i.e., when the differential lock select switch and the differential gear are not matched). (1) When the ATV is traveling Even if the 4WD (Diff-Lock) mode is selected, the gear motor will stand by, instead of operating. Therefore, the ATV can be driven in the normal 4WD mode.
IMPORTANT INFORMATION GEN INFO EB101000 IMPORTANT INFORMATION PREPARATION FOR REMOVAL PROCEDURES 1.Remove all dirt, mud, dust and foreign material before removal and disassembly. 2.Use proper tools and cleaning equipment. Refer to the “SPECIAL TOOLS” section. 3.When disassembling the machine, always keep mated parts together. This includes gears, cylinder, piston and other parts that have been “mated” through normal wear. Mated parts must always be reused or replaced as an assembly. 4.
IMPORTANT INFORMATION GEN 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. When installing oil seals, apply a light coating of lightweight lithium base grease to the seal lips.
CHECKING OF CONNECTIONS GEN INFO EB801000 CHECKING OF CONNECTIONS Check the connectors moisture, etc. for stains, rust, 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 → Bend up the pin 1 and connect the terminals. 4.Connect: ● Connector terminals NOTE: The two terminals “click” together. 5.
SPECIAL TOOLS GEN 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. In such a case, two types are provided. When placing an order, refer to the list provided below to avoid any mistakes. For US and CDN P/N.
SPECIAL TOOLS Tool No. Tool name/How to use GEN INFO Illustration Crankshaft installer set YU-90050 These tools are used to install the crankshaft. Adapter YM-33279 Spacer 90890-04060 YM-90070-A Adapter (#11) Spacer (crankshaft) These tools are used to install the crankshaft. Piston pin puller set 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.
SPECIAL TOOLS Tool No. Tool name/How to use GEN INFO Illustration Sheave fixed block 90890-04135 YM-04135 This tool is needed when removing or installing the secondary sheave spring. Flywheel puller 90890-01404 YM-01404 These tools are needed to remove the rotor. Damper rod holder (30 mm) 90890-01327 YM-01327 This tool is needed to loosen and tighten the steering stem bearing retainer. Oil filter wrench 90890-01426 YU-38411 This tool is needed to loosen or tighten the oil filter cartridge.
SPECIAL TOOLS Tool No. Tool name/How to use Compression gauge 90890-03081 YU-33223 Adapter 90890-04082 YU-33223-3 GEN INFO Illustration Compression gauge Adapter These tools are needed to measure engine compression. Pocket tester 90890-03112 YU-03112 This instrument is needed for checking the electrical system. Engine tachometer 90890-03113 This tool is needed for observing engine rpm. Inductive tachometer YU-8036-A This tool is needed for observing engine rpm.
SPECIAL TOOLS Tool No. Tool name/How to use GEN INFO Illustration Clutch holding tool 90890-04086 YM-91042 This tool is needed to hold the clutch carrier when removing or installing the carrier nut. Bearing retainer wrench 90890-04128 YM-04128 This tool is needed when removing or installing the middle driven pinion gear bearing retainer. Pinion gear fix clamp 90890-04129 YM-04129 This tool is used to hold the shift cam.
GENERAL SPECIFICATIONS SPEC SPECIFICATIONS GENERAL SPECIFICATIONS Item Model code: Dimensions: Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius Basic weight: With oil and full fuel tank Engine: Engine type Cylinder arrangement Displacement Bore × stroke Compression ratio Standard compression pressure (at sea level) Starting system Lubrication system: Oil type or grade: Engine oil Standard 5ND1, 5ND5 1,984 mm (78.1 in) 1,085 mm (42.
GENERAL SPECIFICATIONS Item Differential gear case oil Periodic oil change Total amount Radiator capacity (including all routes) Air filter: Fuel: Type Fuel tank capacity Fuel reserve amount Carburetor: Type/quantity Manufacturer Spark plug: Type/manufacturer Spark plug gap Clutch type: Transmission: Primary reduction system Secondary reduction system Secondary reduction ratio Transmission type Operation Single speed automatic Sub transmission ratio low high Reverse gear Chassis: Frame type Caster angle Cam
GENERAL SPECIFICATIONS Item Tire pressure (cold tire): Maximum load* Off-road riding front rear *Load in total weight of rider accessories Brake: Front brake type operation Rear brake type operation Suspension: Front suspension Rear suspension Shock absorber: Front shock absorber Rear shock absorber Wheel travel: Front wheel travel Rear wheel travel Electrical: Ignition system Generator system Battery type Battery capacity Headlight type: Bulb wattage × quantity: Headlight Brake/tail light Indicator lights
MAINTENANCE SPECIFICATIONS SPEC MAINTENANCE SPECIFICATIONS ENGINE Item Standard Cylinder head: Warp limit Limit ---- 0.03 mm (0.0012 in) Taper limit 84.500 ~ 84.510 mm (3.3268 ~ 3.3272 in) ---- Out of round limit ---- 84.600 mm (3.3307 in) 0.05 mm (0.0016 in) 0.01 mm (0.0004 in) Cylinder: Bore size Camshaft: Drive method Cam dimensions Chain drive (Left) ---- 40.62 ~ 40.72 mm (1.5992 ~ 1.6031 in) 32.18 ~ 32.28 mm (1.2669 ~ 1.2709 in) 40.62 ~ 40.72 mm (1.5992 ~ 1.6031 in) 32.18 ~ 32.
MAINTENANCE SPECIFICATIONS Item SPEC Standard Cam chain: Cam chain type/No. of links Cam chain adjustment method Rocker arm/rocker arm shaft: Bearing inside diameter Shaft outside diameter Arm-to-shaft clearance Valve, valve seat, valve guide: Valve clearance (cold) IN EX Limit DID SCR-0409 SDH/116 Automatic ------- 12.000 ~ 12.018 mm (0.4724 ~ 0.4731 in) 11.981 ~ 11.991 mm (0.4717 ~ 0.4721 in) 0.009 ~ 0.037 mm (0.0004 ~ 0.0015 in) 12.078 mm (0.4755 in) 11.951 mm (0.4705 in) 0.080 mm (0.
MAINTENANCE SPECIFICATIONS Item Standard Stem runout limit Valve seat width ---- IN Set length (valve closed) Compressed pressure (installed) ---- IN 39.9 mm (1.57 in) EX 39.9 mm (1.57 in) IN EX 33.6 mm (1.32 in) 33.6 mm (1.32 in) 37.9 mm (1.49 in) 37.9 mm (1.49 in) ------- IN 104.9 ~ 120.6 N (10.70 ~ 12.30 kg, 23.58 ~ 27.11 lb) 104.9 ~ 120.6 N (10.70 ~ 12.30 kg, 23.58 ~ 27.
MAINTENANCE SPECIFICATIONS Item Tilt limit SPEC Standard * IN EX Direction of winding (top view) IN EX Piston: Piston to cylinder clearance Piston size “D” Limit 2.5°/1.6 mm (2.5°/0.06 in) 2.5°/1.6 mm (2.5°/0.06 in) Clockwise Clockwise ------- 0.040 ~ 0.065 mm (0.0016 ~ 0.0026 in) 84.445 ~ 84.460 mm (3.3246 ~ 3.3252 in) 0.150 mm (0.0059 in) ---- 5 mm (0.20 in) 0.5 mm (0.0200 in) Intake side 20.004 ~ 20.015 mm (0.7876 ~ 0.7880 in) 19.991 ~ 20.000 mm (0.7870 ~ 0.7874 in) ---------20.045 mm (0.
MAINTENANCE SPECIFICATIONS Item SPEC Standard Limit 2nd ring B T Type Dimensions (B × T) End gap (installed) Side clearance Taper 1.0 × 3.6 mm (0.0394 × 0.1417 in) 0.40 ~ 0.60 mm (0.0157 ~ 0.0236 in) 0.02 ~ 0.06 mm (0.0008 ~ 0.0024 in) ------- 2.0 × 2.8 mm (0.0787 × 0.1102 in) 0.2 ~ 0.7 mm (0.0079 ~ 0.0276 in) ---- 62.95 ~ 63.00 mm (2.4783 ~ 2.4803 in) ---- ---- 0.95 mm (0.0374 in) 0.12 mm (0.
MAINTENANCE SPECIFICATIONS Item Standard Transmission: Main axle deflection limit ---- Drive axle deflection limit ---- Shifter: Shifter type Air filter oil grade: Carburetor: I. D.
MAINTENANCE SPECIFICATIONS Item SPEC Standard Cooling system: Radiator core Width Height Thickness Radiator cap opening pressure Radiator capacity Coolant reservoir Capacity From low to full level Water pump: Type Reduction ratio Thermostat: Valve opening temperature Valve full open temperature Valve lift-full open Shaft drive: Middle gear backlash Final gear backlash Differential gear backlash Limit 300 mm (11.8 in) 208 mm (8.19 in) 26 mm (1.02 in) 93.7 ~ 122.6 kPa (0.937 ~ 1.226 kg/cm2, 13.32 ~ 17.
MAINTENANCE SPECIFICATIONS Item Cylinder head tightening sequence: SPEC Standard Not For Resale 2 - 11 www.SmallEngineDiscount.
MAINTENANCE SPECIFICATIONS SPEC Tightening torques Part to be tightened Cylinder head oil passage Cylinder head (exhaust pipe) Cylinder head Camshaft sprocket cover baffle plate Camshaft bearing retainer Spark plug Coolant drain bolt (cylinder) Starter clutch Camshaft sprocket Timing chain tensioner cap Timing chain tensioner Timing chain guide (intake) Valve adjusting screw Radiator Oil pump assembly Oil pump Oil strainer cover Oil drain bolt Oil pump drive gear Oil delivery pipe Oil filter bolt Oil filt
MAINTENANCE SPECIFICATIONS Part to be tightened Part name Middle driven shaft drive pinion gear Middle drive shaft bearing housing Middle driven gear bearing retainer Nut Bolt Nut Thread Q’ty size M22 M8 M65 1 6 1 SPEC Tightening torque Nm 130 32 110 m·kg 13 3.2 11 Remarks ft·lb 94 Stake 23 80 LT Left-hand threads Yoke (middle driven gear) Middle driven gear bearing housing Middle driven shaft bearing retainer Nut Bolt Nut M14 M8 M55 1 4 1 97 25 80 9.7 2.5 8.
MAINTENANCE SPECIFICATIONS SPEC CHASSIS Item Steering system: Steering bearing type Front suspension: Shock absorber travel Fork spring free length Spring fitting length Spring rate Stroke Optional spring Rear suspension: Shock absorber travel Spring free length Spring fitting length Spring rate Stroke Optional spring Swingarm: Free play limit Front wheel: Type Rim size Rim material Rim runout limit Rear wheel: Type Rim size Rim material Rim runout limit Standard Limit Ball and race bearing ---- 99
MAINTENANCE SPECIFICATIONS Item Standard Front disc brake: Type Disc outside diameter × thickness Pad thickness inner Pad thickness Dual 200.0 × 3.5 mm (7.87 ~ 0.14 in) 4.5 mm (0.18 in) outer 4.5 mm (0.18 in) Master cylinder inside diameter Caliper cylinder inside diameter Brake fluid type Rear disc brake: Type Disc outside diameter × thickness Pad thickness inner 14 mm (0.55 in) 32 mm (1.
MAINTENANCE SPECIFICATIONS SPEC Tightening torques Part to be tightened Thread size Engine bracket (front-upper) and frame Engine bracket (front-lower) and frame Engine bracket (front-upper) and engine Engine bracket (front-lower) and engine Engine and frame Frame and bearing retainer (steering stem holder bearing) Select lever assembly and frame Swingarm Rear shock absorber and frame Final gear case and swingarm Final gear case and rear axle housing Swingarm and rear axle housing Differential gear case
MAINTENANCE SPECIFICATIONS Part to be tightened Front bumper and frame Front carrier and frame Front carrier and front bumper Rear carrier and frame Differential gear case filler bolt Differential gear case drain bolt Differential gear case and bearing housing Gear motor Final gear case oil filler bolt Final gear case oil drain bolt Bearing retainer (drive pinion gear) Final gear case and bearing housing Final gear case and bearing housing Battery holding bracket Footrest board and footrest bracket Yoke (dr
MAINTENANCE SPECIFICATIONS SPEC ELECTRICAL Item Voltage: Ignition system: Ignition timing (B.T.D.C.) C.D.I.: Magneto model/manufacturer Pickup coil resistance/color Rotor rotation direction sensing coil resistance/color C.D.I.
MAINTENANCE SPECIFICATIONS Item SPEC Standard Brush overall length 12.5 mm (0.49 in) Spring force 7.65 ~ 10.01 N (780 ~ 1,020 g, 27.54 ~ 36.03 oz) 28 mm (1.
HOW TO USE THE CONVERSION TABLE/ GENERAL TORQUE SPECIFICATIONS SPEC EB201000 EB202001 HOW TO USE THE CONVERSION TABLE GENERAL TORQUE SPECIFICATIONS All specification data in this manual are listed in SI and METRIC UNITS. Use this table to convert METRIC unit data to IMPERIAL unit data. Ex. This chart specifies torque for standard fasteners with standard I.S.O. pitch threads. Torque specifications for special components or assemblies are provided for each chapter of this manual.
LUBRICATION POINTS AND LUBRICANT TYPES SPEC LUBRICATION POINTS AND LUBRICANT TYPES ENGINE Lubrication points Lubricant type Oil seal lips (all) LS O-ring (all) LS Bearings (all) E Crank pin E Connecting rod (bearing) E Camshaft sprocket M Crankshaft E Piston surface/piston rings E Piston pin E Baffer boss E Valve stem/valve stem end M Rocker arm shaft E Rocker arm M Camshaft lobe/journal M Cylinder head bolt E Oil pump shaft, rotor, housing E Oil filter O-ring E Starter
COOLANT FLOW DIAGRAMS SPEC COOLANT FLOW DIAGRAMS 1 Radiator 2 Thermo switch 3 Fan motor È To coolant reservoir Not For Resale 2 - 22 www.SmallEngineDiscount.
COOLANT FLOW DIAGRAMS SPEC 1 Radiator 2 Thermostat È To coolant reservoir Not For Resale 2 - 23 www.SmallEngineDiscount.
OIL FLOW DIAGRAMS SPEC OIL FLOW DIAGRAMS 1 Camshaft 2 Crankshaft 3 Drive axle Not For Resale 2 - 24 www.SmallEngineDiscount.
OIL FLOW DIAGRAMS SPEC 1 Oil filter Not For Resale 2 - 25 www.SmallEngineDiscount.
OIL FLOW DIAGRAMS SPEC 1 Oil pump 2 Oil strainer Not For Resale 2 - 26 www.SmallEngineDiscount.
CABLE ROUTING SPEC CABLE ROUTING 1 Rear brake switch lead 2 Starter cable 3 Rear brake cable 4 Front brake hose 5 On-command four-wheel drive switch and differential gear lock switch 6 Throttle cable 7 Handlebar switch 8 Handlebar switch lead 9 Main switch lead 0 Fan motor breather hose A Differential gear case breather hose B Sub-wire harness (to gear motor) C On-command four-wheel drive switch differential gear lock switch lead Not For Resale 2 - 27 www.SmallEngineDiscount.
CABLE ROUTING SPEC È Fasten the on-command four-wheel drive switch and differential gear lock switch lead behind the handlebar with a plastic band. É Fasten the starter cable, handlebar switch lead and rear brake switch lead behind the handlebar with a plastic band. Ê Fasten the handlebar switch lead and rear brake switch lead behind the handlebar with a plastic band. Not For Resale 2 - 28 www.SmallEngineDiscount.
CABLE ROUTING SPEC 1 Sub-wire harness 2 Headlight lead 3 Auxiliary DC jack lead 4 Four-wheel drive relay 3 5 Fan motor breather hose 6 Differential gear case breather hose 7 Coolant reservoir breather hose 8 Meter assembly coupler Not For Resale 2 - 29 www.SmallEngineDiscount.
CABLE ROUTING 1 Starter cable 2 Cylinder head breather hose 3 Fuel hose 4 Carburetor drain hose 5 Coolant reservoir breather hose 6 Radiator outlet hose 7 Coolant reservoir hose 8 Sub-wire harness 9 Differential gear case breather hose 0 Thermo switch 2 SPEC È Insert the fuel tank breather hose into the hole of the handlebar cover.
CABLE ROUTING 1 Cylinder head breather hose 2 Final drive gear case breather hose 3 Wire harness 4 Starter motor lead 5 Negative battery lead 6 Air filter case check hose 7 Water pump breather hose 8 Radiator outlet hose 9 Starter cable 0 Float chamber air vent hose A Cylinder head breather hose SPEC B Fuel hose C Low-range switch D High-range switch E Neutral switch lead F Reverse switch lead G Rectifier/regulator Not For Resale 2 - 31 www.SmallEngineDiscount.
CABLE ROUTING SPEC È Fasten the wire harness with a plastic band. É Fasten the starter motor lead, wire harness, negative battery lead, final gear case breather hose, rectifier/regulator lead, low-range switch lead, high-range switch lead, neutral switch lead, reverse switch lead, speed sensor lead and A.C. magneto lead with a plastic band. Ê Fasten the wire harness, starter motor lead with a plastic band.
CABLE ROUTING 1 Throttle cable 2 Radiator inlet hose 3 Spark plug lead 4 Main switch 5 Wire harness 6 Rear brake light switch lead 7 Rear brake fluid reservoir hose 8 Select lever control cable 9 Rear brake cable 0 Rear brake hose SPEC È Fasten the radiator inlet hose and spark plug lead with a plastic band. Not For Resale 2 - 33 www.SmallEngineDiscount.
CABLE ROUTING SPEC 1 Front brake hose 2 Float chamber air vent hose 3 Throttle cable 4 Wire harness 5 Final drive gear case breather hose 6 Starter cable 7 Rear brake cable Not For Resale 2 - 34 www.SmallEngineDiscount.
CABLE ROUTING SPEC 1 Battery 2 Positive battery lead 3 Tail/brake light lead 4 CDI unit 5 Negative battery lead Not For Resale 2 - 35 www.SmallEngineDiscount.
CABLE ROUTING SPEC 1 Final drive gear case breather hose 2 Rear brake hose 3 Air filter case check hose Not For Resale 2 - 36 www.SmallEngineDiscount.
INTRODUCTION/ PERIODIC MAINTENANCE/LUBRICATION CHK ADJ EB300000 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments. 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.
PERIODIC MAINTENANCE/LUBRICATION CHK ADJ INITIAL ITEM ROUTINE Whichever comes first Front and rear suspension* • Check operation. • Correct if necessary. Steering system* • Check operation./Replace if damaged. • Check toe-in./Adjust if necessary. EVERY mile (km) 200 (320) 750 (1,200) 1,500 (2,400) 1,500 (2,400) 3,000 (4,800) hours 20 75 150 150 300 Drive shaft universal • Lubricate.** joint* Engine mount* • Check for cracks or damage. Front axle boots* • Check operation.
SEAT, CARRIERS, FENDERS AND FUEL TANK CHK ADJ SEAT, CARRIERS, FENDERS AND FUEL TANK SEAT AND SIDE PANELS Order 1 Job name/Part name Removing the seat and side panels Seat 2 3 4 5 Fuel tank side panel (left) Fuel tank side panel (right) Engine side panel Engine side cover Q’ty 1 Remarks Remove the parts in the order below. NOTE: Pull up the seat lock lever, then pull up on the rear of the seat. 1 1 1 1 For installation, reverse the removal procedure. Not For Resale 3-3 www.SmallEngineDiscount.
SEAT, CARRIERS, FENDERS AND FUEL TANK CHK ADJ FRONT CARRIER, FRONT BUMPER AND FRONT FENDER Order 1 2 3 4 5 6 7 8 9 10 Job name/Part name Removing the front carrier, front bumper and front fender Seat and fuel tank side panels Front carrier Front fender panel Engine skid plate Front bumper cover Front bumper Headlight coupler Front grill Main switch coupler Handlebar cover Fuel tank cover Q’ty Remarks Remove the parts in the order below. Refer to “SEAT AND SIDE PANELS”.
SEAT, CARRIERS, FENDERS AND FUEL TANK Order 11 12 13 14 15 16 17 Job name/Part name Meter assembly coupler Four-wheel drive relay 3 coupler Auxiliary DC jack connector Coolant reservoir breather hose Fan motor breather hose Differential gear case breather hose Front fender CHK ADJ Q’ty Remarks 3 Disconnect. 1 Disconnect. 2 Disconnect. 1 1 1 1 For installation, reverse the removal procedure. Not For Resale 3-5 www.SmallEngineDiscount.
SEAT, CARRIERS, FENDERS AND FUEL TANK CHK ADJ REAR CARRIER AND REAR FENDER Order 1 2 3 4 Job name/Part name Removing the rear carrier and rear fender Seat and fuel tank side panels Fuel tank Rear carrier Battery holding bracket Battery lead cover Battery lead Q’ty Remarks Remove the parts in the order below. Refer to “SEAT AND SIDE PANELS”. Refer to “FUEL TANK”. 1 1 1 2 Disconnect. CAUTION: First disconnect the negative lead, then disconnect the positive lead.
SEAT, CARRIERS, FENDERS AND FUEL TANK Order 8 9 10 Job name/Part name CDI unit Wire harness Rear fender Q’ty 1 1 1 CHK ADJ Remarks For installation, reverse the removal procedure. Not For Resale 3-7 www.SmallEngineDiscount.
SEAT, CARRIERS, FENDERS AND FUEL TANK CHK ADJ FUEL TANK Order Job name/Part name Removing the fuel tank Seat and fuel tank side panels Fuel tank cover Q’ty 1 Fuel hose 1 2 3 Fuel cock lever Fuel tank 1 1 4 5 6 Float chamber air vent hose Plastic band Rubber cover 1 4 1 Remarks Remove the parts in the order below. Refer to “SEAT AND SIDE PANELS”. Refer to “FRONT CARRIER, FRONT BUMPER AND FRONT FENDER”. NOTE: Before disconnecting the fuel hose, turn the fuel cock to “OFF”.
FOOTREST BOARDS CHK ADJ FOOTREST BOARDS Order 1 2 3 Job name/Part name Removing the footrest boards Fuel tank side panels Left footrest board Right footrest board Footrest bracket Q’ty Remarks Remove the parts in the order below. Refer to “SEAT AND SIDE PANELS”. 1 1 4 For installation, reverse the removal procedure. Not For Resale 3-9 www.SmallEngineDiscount.
ADJUSTING THE VALVE CLEARANCE CHK ADJ 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 compression stroke. 1.Remove: ● Seat ● Front carrier ● Front fender ● Fuel tank Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”. 2.Remove: ● Tappet cover (intake) 1 ● Tappet cover (exhaust) 2 3.Disconnect: ● Spark plug cap 3 4.Remove: ● Spark plug 5.
ADJUSTING THE VALVE CLEARANCE CHK ADJ 7.Check: ● Valve clearance Out of specification → Adjust. Valve clearance (cold): Intake: 0.06 ~ 0.10 mm (0.0024 ~ 0.0039 in) Exhaust: 0.16 ~ 0.20 mm (0.0063 ~ 0.0079 in) ***************************************************** Checking steps: ● Turn the crankshaft counterclockwise with a wrench. ● Align the “T” mark 1 on the rotor with the stationary pointer 2 on the crankcase cover.
ADJUSTING THE VALVE CLEARANCE CHK ADJ 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 counterclockwise with the valve adjusting tool 4 until the proper clearance is obtained. Tappet adjusting tool: P/N. YM-08035, 90890-01311 ● Hold the adjuster to prevent it from moving and then tighten the locknut. T. Locknut: 20 Nm (2.
ADJUSTING THE VALVE CLEARANCE/ ADJUSTING THE IDLING SPEED CHK ADJ 11.Install: ● Fuel tank ● Front fender ● Front carrier ● Seat Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”. ADJUSTING THE IDLING SPEED 1.Start the engine and let it warm up for several minutes. 2.Remove: ● Seat ● Fuel tank side panels Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”. 3.Attach: ● Inductive tachometer or engine tachometer (to the spark plug lead) Inductive tachometer: P/N. YU-8036-A Engine tachometer: P/N. 90890-03113 4.
ADJUSTING THE IDLING SPEED/ ADJUSTING THE THROTTLE LEVER FREE PLAY CHK ADJ 5.Adjust: ● Engine idling speed ***************************************************** Adjustment steps: ● Turn the throttle stop screw 1 in or out until the specified idling speed is obtained. Turning in Idling speed becomes higher. Turning out Idling speed becomes lower. ***************************************************** 6.Detach: ● Inductive or engine tachometer 7.
ADJUSTING THE THROTTLE LEVER FREE PLAY CHK ADJ 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”. 3.Adjust: ● Throttle lever free play ***************************************************** Adjustment steps: First step: ● Pull back the adjuster cover 1. ● Loosen the locknut 2 on the carburetor side.
ADJUSTING THE THROTTLE LEVER FREE PLAY/ ADJUSTING THE SPEED LIMITER CHK ADJ 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. the locknut 5. ● Push in the adjuster cover 4. ● Tighten WARNING After adjusting the free play, turn the handlebar to the right and left to make sure that the engine idling speed does not increase.
ADJUSTING THE SPEED LIMITER/ ADJUSTING THE STARTER CABLE CHK ADJ 2.Adjust: ● Speed limiter length ***************************************************** Speed limiter length adjustment steps: ● Loosen the locknut 1. ● Turn the adjuster 2 in or out until the specified speed limiter length is obtained. Turning in Speed limiter length is decreased. Turning out Speed limiter length is increased. ● Tighten the locknut.
ADJUSTING THE STARTER CABLE CHK ADJ 2.Adjust: ***************************************************** Adjustment steps: ● Disconnect the starter cable 1 from the carburetor body. NOTE: Do not remove the starter plunger 2 from the starter cable. ● Measure the starter plunger stroke distance a of the starter lever 3 fully close to fully open position. If the distance is out of specification adjust it as described below. Starter plunger stroke distance: 15 mm (0.
CHECKING THE SPARK PLUG CHK ADJ CHECKING THE SPARK PLUG 1.Remove: ● Seat ● Fuel tank side panel (right) Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”. 2.Remove: ● Spark plug 3.Check: ● Spark plug type Incorrect → Replace. Standard spark plug: DR8EA/NGK 4.Check: ● Electrode 1 Wear/damage → Replace. ● Insulator 2 Abnormal color → Replace. Normal color is a medium-to-light tan color. 5.Clean the spark plug with a spark plug cleaner or wire brush. 6.Measure: ● Plug gap a Use a wire gauge or feeler gauge.
CHECKING THE IGNITION TIMING CHK ADJ 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 (right) Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”. 2.Attach: ● Inductive tachometer or engine tachometer ● Timing light (to spark plug lead) Inductive tachometer: P/N. YU-8036-A Engine tachometer: P/N. 90890-03113 Timing light: P/N. YM-33277-A, 90890-03141 3.
CHECKING THE IGNITION TIMING/ MEASURING THE COMPRESSION PRESSURE CHK ADJ 4.Detach: ● Timing light ● Inductive tachometer or engine tachometer 5.Install: ● Seat ● Fuel tank side panel (right) Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”. MEASURING THE COMPRESSION PRESSURE NOTE: Insufficient compression pressure will result in a loss of performance. 1.Check: ● Valve clearance Out of specification → Adjust. Refer to “ADJUSTING THE VALVE CLEARANCE”. 2.
MEASURING THE COMPRESSION PRESSURE CHK ADJ 7.Measure: ● Compression pressure Above the maximum pressure: Check the cylinder head, valve surfaces, and piston crown for carbon deposits. Below the minimum pressure: Squirt a few drops of oil into the affected cylinder and measure again. ● Refer to the table below.
CHECKING THE ENGINE OIL LEVEL CHK ADJ 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 level mark 1 and minimum level mark 2. Oil level low → Add oil to the proper level. NOTE: Do not screw the dipstick 3 in when checking the oil level. Recommended oil: Follow the left chart.
CHANGING THE ENGINE OIL CHK ADJ CHANGING THE ENGINE OIL 1.Start the engine and let it warm up for several 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”. 4.Remove: ● Engine oil filler plug (dipstick) 1 5.Remove: ● Engine oil drain bolt 1 Drain the engine oil. ● Oil strainer cover 2 ● Compression spring 3 ● Oil strainer 4 6.Clean: ● Oil strainer 7.
CHANGING THE ENGINE OIL CHK ADJ the O-ring 3 of the new oil filter cartridge with a thin coat of engine oil. ● Lubricate CAUTION: Make sure that the O-ring 3 is positioned correctly in the groove of the oil filter cartridge. ● Tighten the new oil filter cartridge to specification with an oil filter wrench. T. Oil filter cartridge: 17 Nm (1.7 m • kg, 12 ft • lb) R. ***************************************************** 8.Install: ● Oil strainer ● Compression spring ● Oil strainer cover 1 T. R.
CHANGING THE ENGINE OIL/ CLEANING THE AIR FILTER CHK ADJ 13.Check: ● Engine oil pressure ***************************************************** ● Slightly loosen the oil gallery bolt 1. ● Start the engine and keep it idling until engine oil starts to seep from the oil gallery bolt. If no engine oil comes out after one minute, turn the engine off so that it will not seize. ● Check the engine oil passages, the oil filter cartridge and the oil pump for damage or leakage. Refer to “CRANKCASE” in CHAPTER 4.
CLEANING THE AIR FILTER CHK ADJ 1.Remove: ● Seat 2.Remove: ● Air filter case cover 1 3.Remove: ● Air filter element assembly 1 ● Air filter element cap ● Air filter element 2 Air filter element cap 3 Air filter element CAUTION: Never operate the engine with the air filter element removed. This will allow unfiltered air to enter, causing rapid wear and possible engine damage.
CLEANING THE AIR FILTER CHK ADJ 5.Clean: ● Air filter element ***************************************************** Cleaning steps: ● Wash the element gently, but thoroughly in solvent. WARNING Use a cleaning solvent which is designed to clean parts only. Never use gasoline or low flash point solvents as they may cause a fire or explosion. ● Squeeze the excess solvent out of the element and let it dry. CAUTION: Do not twist or wring out the element. This could damage the foam material.
CHECKING THE COOLANT LEVEL CHK ADJ CHECKING THE COOLANT LEVEL 1.Place the machine on a level surface. 2.Remove: ● Seat ● Fuel tank side panel (left) 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.
CHANGING THE COOLANT CHK ADJ CHANGING THE COOLANT 1.Remove: ● Seat ● Fuel tank side panel (left) ● Engine side cover ● Front carrier ● Engine skid plate ● Front fender Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”. ● Left footrest board Refer to “FOOTREST BOARDS”. 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.
CHANGING THE COOLANT CHK ADJ 8.Remove: ● Coolant drain bolt (cylinder) 1 (along with the copper washer) ● Coolant drain bolt (water pump) 2 (along with the copper washer) 9.Drain: ● Coolant 10.Check: ● Copper washer 1 ● Coolant drain bolt 2 Damage → Replace. 11.Install: ● Coolant drain bolt (water pump) T. R. ● 10 Nm (1.0 m • kg, 7.2 ft • lb) Coolant drain bolt (cylinder) T. R. 10 Nm (1.0 m • kg, 7.2 ft • lb) 12.
CHANGING THE COOLANT CHK ADJ 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. If coolant comes into contact with painted surfaces, immediately wash them with water. Do not mix different types of antifreeze. 13.Install: ● Radiator cap 14.
COOLANT TEMPERATURE WARNING LIGHT CHECK/ CHECKING THE V-BELT CHK ADJ COOLANT TEMPERATURE WARNING LIGHT CHECK 1 Coolant temperature warning light Coolant temperature warning light checking method Turn the main switch “ON” and the engine stop switch to “ ”. Coolant temperature warning light does not come on. Coolant temperature warning light comes on. Push start switch with transmission in “neutral”. Coolant temperature warning light comes on momentarily.
CHECKING THE V-BELT/ CLEANING THE SPARK ARRESTER CHK ADJ 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. the V-belt 1 from the primary sheave and secondary sheave. ● Remove ● Install the V-belt.
CLEANING THE SPARK ARRESTER CHK ADJ the bolt 1. ● Remove the tailpipe 2 by pulling it out of the muffler. ● Tap the tailpipe lightly with a soft-face hammer 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. ● Insert the bolt 1 and tighten it.
ADJUSTING THE REAR BRAKE CHK ADJ 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 a 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 Out of specification → Adjust. Rear brake pedal height: 70 ~ 80 mm (2.76 ~ 3.15 in) 1 Brake pedal 2 Footrest 3.
ADJUSTING THE REAR BRAKE CHK ADJ the locknut 4. ● Turn the adjusting bolt 5 until the brake pedal height is within the specified limits. ● Loosen Brake pedal height: 70 ~ 80 mm (2.76 ~ 3.15 in) ● Tighten the locknut 4. NOTE: When adjusting the brake pedal height make sure the locknut-to-adjusting bolt clearance a does not exceed 6 mm (0.24 in). the locknut 6. ● Pull up the brake outer cable and turn the brake cable adjusting (nut) 7 until the clearance b is within the specified limits.
CHECKING THE BRAKE FLUID LEVEL CHK ADJ CHECKING THE BRAKE FLUID LEVEL 1.Place the machine on a level surface. NOTE: When checking the brake fluid level, make sure that the top of the brake fluid reservoir top is horizontal. È 2.Remove: (rear brake) ● Front carrier ● Front fender panel Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”. 3.Check: ● Brake fluid level Fluid level is under “LOWER” level line 1 → Fill up.
CHECKING THE FRONT BRAKE PAD/ CHECKING THE REAR BRAKE PAD CHK ADJ CHECKING THE FRONT BRAKE PAD 1.Remove: ● Front wheels 2.Check: ● Brake pad Wear indicators groove 1 almost touch the brake disc → Replace the brake pads as a set. Refer to “FRONT AND REAR BRAKES” in CHAPTER 8. Brake pad wear limit a: 1 mm (0.04 in) 3.Operate the brake lever. 4.Install: ● Front wheels CHECKING THE REAR BRAKE PAD 1.Remove: ● Rear wheel (left) 2.
CHECKING THE BRAKE HOSE CHK ADJ CHECKING THE BRAKE HOSE 1.Remove: ● Seat ● Front carrier ● Front fender Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”. ● Right footrest board Refer to “FOOTREST BOARDS”. 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. 3.Check: ● Brake hose clamp Loosen → Tighten. 4.
BLEEDING THE HYDRAULIC BRAKE SYSTEM CHK ADJ BLEEDING THE HYDRAULIC BRAKE SYSTEM WARNING È Bleed the brake system if: ● The system has been disassembled. ● A brake hose or brake pipe have been loosened or removed. ● The brake fluid has been very low. ● The brake operation has been faulty. A loss of braking performance may occur if the brake system is not properly bled. 1.Bleed: ● Brake system ***************************************************** Air bleeding steps: a.
BLEEDING THE HYDRAULIC BRAKE SYSTEM/ ADJUSTING THE SELECT LEVER CONTROL CABLE AND SHIFT ROD CHK ADJ k.Add brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL”. WARNING Check the operation of the brake after bleeding the brake system.
ADJUSTING THE SELECT LEVER CONTROL CABLE AND SHIFT ROD/ ADJUSTING THE REAR BRAKE LIGHT SWITCH CHK ADJ ● When the brake begins to work “a = 20 ~ 30 mm (0.8 ~ 1.2 in)”, verify that the select lever can be shifted to REVERSE from NEUTRAL, to PARK from REVERSE and to NEUTRAL from REVERSE. ● Before the brake begins to work “a = 0 ~ 20 mm (0 ~ 0.8 in)”, verify that the select lever cannot be shifted to REVERSE from NEUTRAL, to REVERSE from PARK and to NEUTRAL from REVERSE.
ADJUSTING THE REAR BRAKE LIGHT SWITCH/ CHECKING THE FINAL GEAR OIL LEVEL CHK ADJ 2.Adjust: ● Rear brake light switch operation timing *********************************************** the main body 1 of the rear brake light switch so that it does not rotate and turn the adjusting nut 2 in direction a or b until the rear brake light comes on at the proper time. ● Hold Direction a Brake light comes on sooner. Direction b Brake light comes on later.
CHANGING THE FINAL GEAR OIL CHK ADJ CHANGING THE FINAL GEAR OIL 1.Place the machine on a level surface. 2.Remove: ● Final gear case protector 1 3.Place a receptacle under the final gear case. 4.Remove: ● Oil filler bolt ● Drain plug 1 5.Drain: ● Final gear oil T. R. 6.Install: ● Drain plug 23 Nm (2.3 m • kg, 17 ft • lb) NOTE: Check the gasket (drain plug). If it is damaged, replace it with a new one. 7.Fill: ● Final gear case Periodic oil change: 0.23 L (0.20 Imp qt, 0.24 US qt) Total amount: 0.
CHECKING THE DIFFERENTIAL GEAR OIL/ CHANGING THE DIFFERENTIAL GEAR OIL CHK ADJ CHECKING THE DIFFERENTIAL GEAR OIL 1.Place the machine on a level surface. 2.Remove: ● Oil filler bolt 1 3.Check: ● Oil level Oil level should be up to the brim of hole. Oil level low → Add oil to proper level. Recommended oil: SAE 80 API “GL-4” Hypoid gear oil Oil quantity (periodic oil change): 0.23 L (0.20 Imp qt, 0.24 US qt) CAUTION: Take care not allow foreign material to enter the gear case. T. R. 4.
CHANGING THE DIFFERENTIAL GEAR OIL/CHECKING THE CONSTANT VELOCITY JOINT DUST BOOT CHK ADJ T. 4.Drain: ● Differential gear oil 5.Install: 10 Nm (1.0 m • kg, 7.2 ft • lb) ● Drain plug R. NOTE: Check the gasket (drain plug). If it is damaged, replace it with new one. 6.Fill: ● Differential gear case Periodic oil change: 0.23 L (0.20 Imp qt, 0.24 US qt) Total amount: 0.28 L (0.25 Imp qt, 0.
CHECKING THE STEERING SYSTEM/ ADJUSTING THE TOE-IN CHK ADJ CHECKING THE STEERING SYSTEM 1.Place the machine on a level surface. 2.Check: ● Steering assembly bushings Move the handlebar up and down, and/or back and forth. Excessive play → Replace the steering stem bushings. 3.Check: ● Tie-rod ends Turn the handlebar to the left and/or right until it stops completely, then move the handlebar from the left to the right slightly. Tie-rod end has any vertical play → Replace the tie-rod end(s). 4.
ADJUSTING THE TOE-IN CHK ADJ the width È between the marks. ● Rotate the front tires 180° until the marks are exactly opposite one another. ● Measure the width É between the marks. ● Calculate the toe-in using the formula given below. ● Measure Toe-in = É – È ● If the toe-in is incorrect, adjust it. ***************************************************** 3.Adjust: ● Toe-in WARNING ● ● Be sure that both tie-rods are turned the same amount.
ADJUSTING THE FRONT SHOCK ABSORBER/ADJUSTING THE REAR SHOCK ABSORBER/CHECKING THE TIRE CHK ADJ ADJUSTING THE FRONT SHOCK ABSORBER WARNING Always adjust both front shock absorber spring preload to the same setting. Uneven adjustment can cause poor handling and loss of stability. 1.Adjust: ● Spring preload Turn the adjuster 1 to increase or decrease the spring preload. Standard position: 2 Minimum (Soft) position: 1 Maximum (Hard) position: 5 ADJUSTING THE REAR SHOCK ABSORBER 1.
CHECKING THE TIRE CHK ADJ 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. ● Manufacturer Size Type Front CHENG SHIN AT25 × 8-12 M911Y Rear CHENG SHIN AT25 × 10-12 M912Y ● TIRE PRESSURE 1)Recommended tire pressure Front 25 kPa (0.25 kg/cm2, 3.
CHECKING THE TIRE CHK ADJ 1.Measure: ● Tire pressure (cold tire pressure) Out of specification → Adjust. NOTE: ● The low-pressure tire gauge 1 is included as standard equipment. ● If dust or the like is stuck to this gauge, it will not provide the correct readings. Therefore, take two measurements of the tire’s pressure and use the second reading. Cold tire pressure Front Rear Standard 25 kPa (0.25 kg/cm2, 3.6 psi) 25 kPa (0.25 kg/cm2, 3.6 psi) Minimum 22 kPa (0.22 kg/cm2, 3.2 psi) 22 kPa (0.
CHECKING THE WHEEL/ CHECKING AND LUBRICATING THE CABLE CHK ADJ CHECKING THE WHEEL 1.Check: ● Wheels 1 Damage/bends → Replace. NOTE: Always balance the wheel when a tire or wheel has been changed or replaced. WARNING ● ● Never attempt even small repairs to the wheel. Ride conservatively after installing a tire to allow it to seat itself properly on the rim. CHECKING AND LUBRICATING THE CABLE WARNING A damaged cable sheath may cause corrosion and interfere with the cable movement.
LUBRICATING THE LEVERS, PEDAL, ETC. CHK ADJ LUBRICATING THE LEVERS, PEDAL, ETC. 1.Lubricate the pivoting parts. Recommended lubricant: Yamaha chain and cable lube or Engine oil Not For Resale 3 - 54 www.SmallEngineDiscount.
CHECKING THE BATTERY CHK ADJ 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. CAUTION: CHARGING METHOD ● This is a sealed type battery. Never remove the sealing caps.
CHECKING THE BATTERY CHK ADJ 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.) NOT SMOKE when charging or ● DO handling batteries. KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN. 1.Remove: ● Seat ● Battery holding bracket ● Battery lead cover Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”. 2.
CHECKING THE BATTERY CHK ADJ Open-circuit voltage Charging time 12.8 V or higher No charging is necessary. ● Check the condition of the battery using the following charts. Example: ● Open-circuit voltage = 12.0 V ● Charging time = 6.5 hours ● Charge condition of the battery = 20 ~ 30% ● Charging method for MF batteries CAUTION: ● ● ● ● ● ● If it is impossible to set the standard charging current, be careful not to overcharge. When charging the battery, be sure to remove it from the motorcycle.
CHK ADJ CHECKING THE BATTERY Charging method using a variable voltage charger Measure the open-circuit voltage prior to charging. Charger NOTE: Leave the battery unused for more than 30 minutes before measuring its open-circuit voltage. Ammeter NOTE: Connect a charger and ammeter to the battery and start charging. YES Is the amperage higher than the standard charging amperage written on the battery? Set the charging voltage to 16 ~ 17 V.
CHK ADJ CHECKING THE BATTERY Charging method using a constant voltage charger Measure the open-circuit voltage prior to charging. NOTE: Leave the battery unused for more than 30 minutes before measuring its open-circuit voltage. Connect a charger and ammeter to the battery and start charging. Is the amperage higher than the standard charging amperage written on the battery? YES Charge the battery until the charging voltage reaches 15 V. NO This type of battery charger cannot charge an MF battery.
CHECKING THE BATTERY/ CHECKING THE FUSE CHK ADJ 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. 8.Install: ● Battery lead cover ● Battery holding bracket ● Seat Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”.
CHECKING THE FUSE CHK ADJ NOTE: Set the tester to the “Ω × 1” position. Pocket tester: P/N. YU-03112, 90890-03112 ● If the tester indicates ∞, 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.
CHECKING THE FUSE/ADJUSTING THE HEADLIGHT BEAM/CHANGING THE HEADLIGHT BULB CHK ADJ 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. CHANGING THE HEADLIGHT BULB 1.Remove: ● Cover 1 2.Remove: ● Bulb holder 1 ● Bulb NOTE: Turn the bulb holder counterclockwise and remove the defective bulb.
CHANGING THE HEADLIGHT BULB CHK ADJ 3.Install: New ● Bulb Secure the new bulb with the headlight unit. CAUTION: Avoid touching the glass part of the bulb. Keep it free from oil; otherwise, the transparency of the glass, life of the bulb, and luminous flux will be adversely affected. If oil gets on the bulb, thoroughly clean it with a cloth moistened with alcohol or lacquer thinner. 4.Install: ● Bulb holder ● Cover Not For Resale 3 - 63 www.SmallEngineDiscount.
ENGINE REMOVAL ENG ENGINE ENGINE REMOVAL AIR DUCTS, MUFFLER AND EXHAUST PIPE Order Job name/Part name Removing the air ducts, muffler and exhaust pipe Engine oil Q’ty Drain. Refer to “CHANGING THE ENGINE OIL” in CHAPTER 3. Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK” in CHAPTER 3. Drain. Refer to “CHANGING THE COOLANT” in CHAPTER 3. Refer to “CARBURETOR” in CHAPTER 6.
ENGINE REMOVAL ENG 4 Order 6 7 8 9 Job name/Part name Final drive gear case breather hose Cylinder head breather hose Vacuum chamber breather hose Air filter case Q’ty 1 1 1 1 Remarks For installation, reverse the removal procedure. Not For Resale 4-2 www.SmallEngineDiscount.
ENGINE REMOVAL ENG SELECT LEVER UNIT AND COOLANT RESERVOIR Order 1 2 3 4 5 6 Job name/Part name Removing the select lever unit and coolant reservoir Shift arm Select lever shift rod Select lever unit Coolant reservoir breather hose Coolant reservoir hose Coolant reservoir Q’ty Remarks Remove the parts in the order below. 1 1 1 1 1 1 For installation, reverse the removal procedure. Not For Resale 4-3 www.SmallEngineDiscount.
ENGINE REMOVAL ENG HOSES AND LEADS Order 1 2 3 4 5 6 7 8 9 10 11 Job name/Part name Removing the hoses and leads Water pump inlet hose Cylinder head breather hose Spark plug lead Thermo switch 1 lead Starter motor lead A.C. magneto lead coupler Speed sensor lead coupler Reverse switch lead Neutral switch lead High-range switch Low-range switch Engine ground lead Q’ty 1 1 1 1 2 1 1 1 1 1 1 Remarks Remove the parts in the order below. Refer to “WATER PUMP” in CHAPTER 5.
ENGINE REMOVAL ENG ENGINE MOUNTING BOLTS Order 1 2 3 4 5 6 7 8 Job name/Part name Q’ty Remarks Removing the engine mounting bolts Remove the parts in the order below. Rear wheels Refer to “FRONT AND REAR WHEELS” in CHAPTER 8. Swingarm Refer to “REAR SHOCK ABSORBER AND SWINGARM” in CHAPTER 8.
ENGINE REMOVAL Order 9 Job name/Part name Engine assembly ENG Q’ty Remarks 1 NOTE: Remove the engine assembly from the left side of the machine. For installation, reverse the removal procedure. Not For Resale 4-6 www.SmallEngineDiscount.
ENGINE REMOVAL ENG INSTALLING THE ENGINE 1.Install: ● Engine bracket (front upper) 1 ● Engine mount bolt (front upper)/nut 2 ● Engine bracket bolt (front upper) 3 ● Engine bracket (front lower) 4 ● Engine mount bolt (front lower) 5 ● Engine bracket bolt (front lower) 6 ● Engine mount bolt (rear upper)/nut 7 ● Engine mount bolt (rear lower)/nut 8 NOTE: Do not fully tighten the bolts and nuts. 2.Tighten: ● Engine mount bolt (front upper)/nut 2 T. R. ● Engine bracket bolt (front upper) 3 T. R. ● R. R.
CYLINDER HEAD ENG CYLINDER HEAD Order 1 2 3 4 Job name/Part name Removing the cylinder head Fuel tank/rubber cover Front fender/air filter case Air duct assembly 1 Exhaust pipe/muffler Carburetor assembly Recoil starter/timing plug Thermostat Spark plug lead Spark plug Engine mount bolt (upper)/nut Engine bracket (upper) Q’ty Remarks Remove the parts in the order below. Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK” in CHAPTER 3. Refer to “ENGINE REMOVAL”. Refer to “CARBURETOR” in CHAPTER 6.
CYLINDER HEAD Order 5 6 7 8 9 10 11 12 13 14 15 Job name/Part name Cylinder head breather hose Camshaft sprocket cover/O-ring Tappet cover/O-ring Thermo switch 1 lead Timing chain tensioner cap bolt Timing chain tensioner/gasket Camshaft sprocket Cylinder head Cylinder head gasket Dowel pin O-ring ENG Q’ty Remarks 1 1/1 2/2 1 Disconnect. 1 1/1 Refer to “REMOVING/INSTALLING THE CYLINDER HEAD”. 1 1 1 2 1 For installation, reverse the removal procedure. Not For Resale 4-9 www.SmallEngineDiscount.
CYLINDER HEAD ENG REMOVING THE CYLINDER HEAD 1.Align: ● “T” mark (with stationary pointer) ***************************************************** Checking steps: ● Turn the crankshaft counterclockwise with a wrench. ● Align the “T” mark 1 on the rotor with the stationary pointer 2 on the crankcase cover. When the “T” mark is aligned with the stationary pointer, the piston is at the Top Dead Center (T.D.C.). NOTE: ● When the piston is at the Top Dead Center (T.D.C.
CYLINDER HEAD ENG NOTE: ● Fasten a safety wire to the timing chain to prevent it from falling into the crankcase. ● When removing the camshaft sprocket, it is not necessary to separate the timing chain. 5.Remove: ● Cylinder head NOTE: ● Loosen the 6 mm bolts first. ● Working in a crisscross pattern, loosen each 10 mm bolt 1/4 of a turn. After all the bolts are loosened, remove them. CHECKING THE TAPPET COVER 1.Check: ● Tappet covers 1 ● O-rings 2 Cracks/damage → Replace.
CYLINDER HEAD ENG CHECKING THE CYLINDER HEAD 1.Eliminate: ● Carbon deposits (from the combustion chambers) Use a rounded scraper. NOTE: Do not use a sharp instrument to avoid damaging or scratching: ● Spark plug threads ● Valve seats 2.Check: ● Cylinder head Scratches/damage → Replace. ● Cylinder head water jacket Mineral deposits/rust → Eliminate. 3.Measure: ● Cylinder head warpage Out of specification → Resurface. Cylinder head warpage: Less than 0.03 mm (0.
CYLINDER HEAD ENG T. INSTALLING THE CYLINDER HEAD 1.Install: ● Cylinder head 40 Nm (4.0 m • kg, 29 ft • lb) ● Bolt (M10) 10 Nm (1.0 m • kg, 7.2 ft • lb) ● Bolt (M6) R. T. R. NOTE: ● Lubricate the washer with engine oil. ● Tighten the bolts (M10) in two stages and a crisscross pattern. 2.Install: ● Camshaft sprocket ***************************************************** Installing steps: ● Rotate the camshaft to align the camshaft pin 1 with the cylinder head match mark 2.
CYLINDER HEAD ENG NOTE: Be sure the “I” mark 5 on the camshaft sprocket is aligned with the match mark 2 on the cylinder head. ● Force the camshaft clockwise and counterclockwise to remove timing chain slack. ● Insert a screwdriver into the timing chain tensioner hole and push the timing chain guide inward. ● While pushing the timing chain guide, be sure that the camshaft sprocket “I” mark 5 is aligned with the cylinder head match mark 2. ● If the marks are aligned, tighten the camshaft sprocket bolt.
CYLINDER HEAD ENG 4.Tighten: ● Camshaft sprocket bolt 1 T. R. 60 Nm (6.0 m • kg, 43 ft • lb) NOTE: Use the rotor holding tool 2 to hold the starter pulley. Rotor holding tool: P/N. YU-01235, 90890-01235 5.Check: ● Camshaft sprocket “I” mark ● Rotor “T” mark Out of alignment → Adjust. Not For Resale 4 - 15 www.SmallEngineDiscount.
CAMSHAFT, ROCKER ARMS AND VALVES ENG CAMSHAFT, ROCKER ARMS AND VALVES Order 1 2 3 4 5 6 7 8 9 10 11 Job name/Part name Removing the camshaft, rocker arms and valves Intake manifold/O-ring Thermo switch Oil check bolt Lock washer/bearing retainer Camshaft Rocker arm shaft/O-ring Rocker arm Locknut/valve adjuster Valve cotter Valve spring retainer Valve spring (outer) Q’ty 1/1 1 1 1/1 1 2/2 2 2/2 4 2 2 Remarks Remove the parts in the order below.
CAMSHAFT, ROCKER ARMS AND VALVES Order 12 13 14 15 16 Job name/Part name Valve spring (inner) Valve (intake) Valve (exhaust) Valve stem seal Valve spring seat Q’ty 2 1 1 2 2 ENG Remarks Refer to “REMOVING/INSTALLING THE VALVE AND VALVE SPRING”. For installation, reverse the removal procedure. Not For Resale 4 - 17 www.SmallEngineDiscount.
CAMSHAFT, ROCKER ARMS AND VALVES ENG REMOVING THE CAMSHAFT AND ROCKER ARM 1.Remove: ● Camshaft 1 NOTE: Screw in a M10 bolt 2 into the thread hole on the camshaft, and pull out the camshaft. 2.Remove: ● Rocker arm shafts (intake and exhaust) 1 ● Rocker arms 2 NOTE: Use a slide hammer 3 to remove the rocker arm shafts. Slide hammer set: P/N. YU-01083-A Slide hammer bolt (M6): P/N. 90890-01083 Weight: P/N. 90890-01084 REMOVING THE VALVE AND VALVE SPRING 1.
CAMSHAFT, ROCKER ARMS AND VALVES ENG 2.Remove: ● Valve cotters NOTE: Attach a valve spring compressor 1 between the valve spring retainer and the cylinder head to remove the valve cotters. Valve spring compressor: P/N. YM-04019, 90890-04019 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 40.52 mm (1.595 in) b 32.08 mm (1.263 in) Exhaust: a 40.52 mm (1.
CAMSHAFT, ROCKER ARMS AND VALVES ENG 2.Check: ● Rocker arms ● Rocker arm shafts Damage/wear → Replace. ***************************************************** Checking steps: ● Check the two contact areas on the rocker arms for signs of abnormal wear. 1) Rocker arm shaft hole 2) Camshaft lobe contact surface Excessive wear → Replace. ● Check the surface of the rocker arm shafts. Blue discoloration/pitting/scratches → Replace/check lubrication. ● Measure the inside diameter a of the rocker arm holes.
CAMSHAFT, ROCKER ARMS AND VALVES ENG 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) : 0.080 mm (0.0031 in) Exhaust: 0.030 ~ 0.057 mm (0.0012 ~ 0.0022 in) : 0.100 mm (0.0039 in) 2.
CAMSHAFT, ROCKER ARMS AND VALVES ENG 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: 1.0 ~ 1.4 mm (0.0394 ~ 0.0551 in) Exhaust: 0.8 ~ 1.2 mm (0.0315 ~ 0.0472 in) 5.Measure: ● Runout (valve stem) Out of specification → Replace. Runout limit: 0.01 mm (0.0004 in) NOTE: ● When installing a new valve always replace the guide.
CAMSHAFT, ROCKER ARMS AND VALVES ENG ***************************************************** Measurement steps: ● Apply Mechanic’s blueing dye (Dykem) b to the valve face. ● Install the valve into the cylinder head. ● Press the valve through the valve guide and onto the valve seat to make a clear pattern. ● Measure the valve seat width. Where the valve seat and valve face made contact, blueing will have been removed.
CAMSHAFT, ROCKER ARMS AND VALVES ENG ● Apply a fine lapping compound to the valve face and repeat the above steps. NOTE: After every lapping operation be sure to clean off all of the compound from the valve face and valve seat. ● Apply Mechanic’s blueing dye (Dykem) to the valve face. ● Install the valve into the cylinder head. ● Press the valve through the valve guide and onto the valve seat to make a clear pattern. ● Measure the valve seat width again.
CAMSHAFT, ROCKER ARMS AND VALVES ENG 12.Measure: ● Spring tilt a Out of specification → Replace. Spring tilt limit: Inner: 2.5°/1.6 mm (0.06 in) Outer: 2.5°/1.6 mm (0.06 in) INSTALLING THE VALVE AND VALVE SPRING 1.Apply: ● Molybdenum disulfide oil (onto the valve stem and valve stem seal) 2.Install: ● Valve spring seats ● Valve stem seals New ● Valves ● Valve springs (inner and outer) ● Valve spring retainers NOTE: Install the valve springs with the larger pitch a facing upwards. b Smaller pitch 3.
CAMSHAFT, ROCKER ARMS AND VALVES ENG INSTALLING THE CAMSHAFT AND ROCKER ARM 1.Apply: ● Engine oil (onto the rocker arm shafts) 2.Install: ● Rocker arms 1 ● Rocker arm shafts (intake and exhaust) 2 NOTE: Use a slide hammer bolt 3 to install the rocker arm shaft. 3.Install: ● Camshaft 1 NOTE: Install the camshaft pin hole a facing up. Not For Resale 4 - 26 www.SmallEngineDiscount.
CYLINDER AND PISTON ENG CYLINDER AND PISTON Order 1 2 3 4 5 6 7 8 9 10 Job name/Part name Removing the cylinder and piston Cylinder head Water pump outlet hose/pipe Coolant inlet joint Timing chain guide (exhaust) Cylinder/O-ring Cylinder gasket Dowel pin O-ring Piston pin clip Piston pin Piston Piston ring set Q’ty 1 1 1/1 1 2 1 2 1 1 1 Remarks Remove the parts in the order below. Refer to “CYLINDER HEAD”. Refer to “WATER PUMP” in CHAPTER 5. Refer to “INSTALLING THE CYLINDER”.
CYLINDER AND PISTON ENG REMOVING THE PISTON 1.Remove: ● Piston pin clips 1 ● Piston pin 2 ● Piston 3 NOTE: Before removing piston pin, deburr the clip groove and pin hole area. If the piston pin groove is deburred and the piston pin is still difficult to remove, use the piston pin puller 4. Piston pin puller: P/N. YU-01304, 90890-01304 CAUTION: Do not use a hammer to drive the piston pin out. 2.
CYLINDER AND PISTON ENG 2.Measure: ● Piston-to-cylinder clearance ***************************************************** Measurement steps: 1st step: ● Measure the cylinder bore “C” with the cylinder bore gauge. NOTE: Measure cylinder bore “C” by taking side-toside and front-to-back measurements of the cylinder. Then, find the average of the measurements. Cylinder bore “C” 84.500 ~ 84.510 mm (3.3268 ~ 3.3272 in) Max. taper “T” 0.05 mm (0.0016 in) Out of round “R” 0.01 mm (0.
CYLINDER AND PISTON ENG 3rd step: ● Find the piston-to-cylinder clearance with the following formula. Piston-to-cylinder clearance = Cylinder bore “C” – Piston skirt diameter “P” Piston-to-cylinder clearance: 0.040 ~ 0.065 mm (0.0016 ~ 0.0026 in) : 0.150 mm (0.0059 in) ● If out of specification, rebore or replace the cylinder, and replace the piston and piston rings as a set. ***************************************************** CHECKING THE PISTON RING 1.
CYLINDER AND PISTON ENG 3.Measure: ● Ring end gap Out of specification → Replace. NOTE: You cannot measure the end gap on the expander spacer of the oil control ring. If the oil control ring rails show excessive gap, replace all three rings. End gap Standard Limit Top ring 0.20 ~ 0.40 mm 0.65 mm (0.0079 ~ 0.0157 in) (0.0256 in) 2nd ring 0.40 ~ 0.60 mm 0.95 mm (0.0157 ~ 0.0236 in) (0.0374 in) Oil ring 0.2 ~ 0.7 mm (0.0079 ~ 0.0276 in) — CHECKING THE PISTON PIN 1.
CYLINDER AND PISTON ● If ENG out of specification, replace the piston. Piston pin-to-piston clearance: 0.004 ~ 0.024 mm (0.00016 ~ 0.00094 in) : 0.074 mm (0.0029 in) ***************************************************** INSTALLING THE PISTON 1.Install: ● Piston rings (onto the piston) NOTE: ● Be sure to install the piston rings so that the manufacturer’s marks or numbers are located on the upper side of the rings. ● Lubricate the piston and piston rings liberally with engine oil. 2.
CYLINDER AND PISTON ENG 4.Lubricate: ● Piston ● Piston rings ● Cylinder NOTE: Apply a liberal coating of engine oil. INSTALLING THE CYLINDER 1.Install: ● Cylinder NOTE: Install the cylinder with one hand while compressing the piston rings with the other hand. CAUTION: ● ● Be careful not to damage the timing chain damper during installation. Pass the timing chain through the timing chain cavity. Not For Resale 4 - 33 www.SmallEngineDiscount.
RECOIL STARTER AND A.C. MAGNETO ENG RECOIL STARTER AND A.C. MAGNETO Order Job name/Part name Removing the CDI magneto Engine oil Q’ty Seat and side panels Left footrest board 1 2 3 4 5 6 Recoil starter assembly A.C. magneto coupler Starter pulley Crankcase cover (left)/gasket Dowel pin Lead holder 1 2 1 1/1 2 1 Remarks Remove the parts in the order below. Drain. Refer to “CHANGING THE ENGINE OIL” in CHAPTER 3. Refer to “SEAT AND SIDE PANELS” in CHAPTER 3. Refer to “FOOTREST BOARDS” in CHAPTER 3.
RECOIL STARTER AND A.C. MAGNETO Order 7 8 9 10 11 12 13 14 15 Job name/Part name Pickup coil Stator assembly Rotor Starter wheel gear Woodruff key Washer Starter idle gear shaft Washer/bearing Starter idle gear Q’ty 1 1 1 1 1 1 1 1/1 1 ENG Remarks Refer to “REMOVING/INSTALLING THE A.C. MAGNETO”. For installation, reverse the removal procedure. Not For Resale 4 - 35 www.SmallEngineDiscount.
RECOIL STARTER AND A.C. MAGNETO Order 1 2 3 4 5 6 7 8 9 Job name/Part name Disassembling the recoil starter Cap Starter handle Friction plate Pawl spring Drive pawl Spring Sheave drum Rope Coil spring Q’ty 1 1 1 1 1 1 1 1 1 ENG Remarks Remove the parts in the order below. Refer to “DISASSEMBLING/ ASSEMBLING THE RECOIL STARTER”. For assembly, reverse the disassembly procedure. Not For Resale 4 - 36 www.SmallEngineDiscount.
RECOIL STARTER AND A.C. MAGNETO ENG REMOVING THE A.C. 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. Remove them after all of them are loosened. 3.Remove: ● Rotor 1 NOTE: Use the flywheel puller 2. Flywheel puller: P/N. YM-01404, 90890-01404 DISASSEMBLING THE RECOIL STARTER 1.
RECOIL STARTER AND A.C. MAGNETO ENG 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 rotor. T. R. Bolts (starter clutch): 30 Nm (3.
RECOIL STARTER AND A.C. MAGNETO ENG 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 → Replace. ASSEMBLING THE RECOIL STARTER 1.Install: ● Sheave drum 1 ● Rope 2 ● Pawl spring 3 ● Drive pawl 4 NOTE: Wind the rope 4-1/2 turns clockwise around the sheave drum. Then insert the rope into the drum slit a.
RECOIL STARTER AND A.C. MAGNETO ENG 2.Install: ● Starter spring 1 ● Sheave drum assembly 2 NOTE: ● Mesh the spring hook 3 with the case slit, then wind the spring clockwise into the case from the larger to smaller diameter. ● Mesh the sheave drum hook 4 with the spring hook 5. 3.Install: ● Spring 1 ● Friction plate 2 ● Nut NOTE: Insert the spring hooks into the pawl side holes. 4.Turn the sheave drum 3-turn clockwise to give preload to the spring. 5.
RECOIL STARTER AND A.C. MAGNETO ENG 2.Install: ● Woodruff key ● 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. 3.Install: ● Dowel pins ● Gasket New ● Crankcase cover (left) T. R. 10 Nm (1.0 m • kg, 7.2 ft • lb) NOTE: ● When installing the crankcase cover (left), use a long rod to hold the rotor in position from the outside.
PRIMARY AND SECONDARY SHEAVES ENG PRIMARY AND SECONDARY SHEAVES Order 1 2 3 4 5 6 7 Job name/Part name Removing the primary and secondary sheave Front fender Rear fender Right footrest board Exhaust pipe bracket Drive belt cover Rubber gasket Bearing housing Dowel pin Primary sliding sheave assembly V-belt Q’ty Remarks Remove the parts in the order below. Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK” in CHAPTER 3. 1 1 1 1 2 1 1 Refer to “REMOVING/INSTALLING THE PRIMARY AND SECONDARY SHEAVES”.
PRIMARY AND SECONDARY SHEAVES Order 8 9 Job name/Part name Primary fixed sheave Secondary sheave assembly Q’ty 1 1 ENG Remarks Refer to “REMOVING/INSTALLING THE PRIMARY AND SECONDARY SHEAVES”. For installation, reverse the removal procedure. Not For Resale 4 - 43 www.SmallEngineDiscount.
PRIMARY AND SECONDARY SHEAVES ENG PRIMARY SLIDING SHEAVE Order 1 2 3 4 5 6 7 8 9 Job name/Part name Disassembling the primary sliding sheave Primary pulley sheave cap Primary pulley slider Spacer Primary pulley cam Primary pulley weight Collar Oil seal Primary sliding sheave O-ring Q’ty Remarks Remove the parts in the order below. 1 4 4 1 8 1 2 1 1 Refer to “ASSEMBLING THE PRIMARY SHEAVE”. For assembly, reverse the disassembly procedure. Not For Resale 4 - 44 www.SmallEngineDiscount.
PRIMARY AND SECONDARY SHEAVES ENG SECONDARY SHEAVE Order 1 2 3 4 5 6 7 8 9 0 Job name/Part name Disassembling the secondary sheave Nut Spring seat Compression spring Spring seat Guide pin Secondary sliding sheave O-ring Secondary fixed sheave Oil seal Oil seal Q’ty 1 1 1 1 4 1 2 1 1 1 Remarks Remove the parts in the order below. Refer to “DISASSEMBLING/ ASSEMBLING THE SECONDARY SHEAVE”. For assembly, reverse the disassembly procedure. Not For Resale 4 - 45 www.SmallEngineDiscount.
PRIMARY AND SECONDARY SHEAVES ENG 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. YU-01880, 90890-01701 DISASSEMBLING THE SECONDARY SHEAVE 1.
PRIMARY AND SECONDARY SHEAVES ENG CHECKING THE PRIMARY SHEAVE 1.Check: ● Weight outside diameter a Out of specification → Replace the weight. Weight outside diameter: 30 mm (1.18 in) : 29.5 mm (1.16 in) 2.Check: ● Primary pulley slider ● Primary sliding sheave splines Wear/cracks/damage → Replace. ● Spacer ● Primary pulley cam Cracks/damage → Replace. 3.Check: ● Primary sliding sheave ● Primary fixed sheave Cracks/damage → Replace. CHECKING THE SECONDARY SHEAVE 1.
PRIMARY AND SECONDARY SHEAVES ENG ASSEMBLING THE PRIMARY SHEAVE 1.Clean: ● Primary sliding sheave face 1 ● Primary fixed sheave face 2 ● Collar 3 ● Weight 4 ● Primary pulley cam face NOTE: Remove any excess grease. 2.Install: ● Weight 1 NOTE: ● Apply Yamaha Grizzly grease (120 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. 3.
PRIMARY AND SECONDARY SHEAVES ENG 3.Apply: ® ● BEL-RAY assembly lube (to the guide pin sliding groove 1, and O-ring 2 New ) 4.Install: ● Spring seat ● Compression spring ● Spring seat ● Nut ***************************************************** Installing steps: ● Attach the sheave fixed block, locknut wrench and sheave spring compressor to the secondary sheave assembly. Sheave fixed block: P/N. YM-04135, 90890-04135 Locknut wrench: P/N. 90890-01348 Sheave spring compressor: P/N.
PRIMARY AND SECONDARY SHEAVES ENG INSTALLING THE PRIMARY AND SECONDARY SHEAVES 1.Install: ● Secondary sheave assembly ● V-belt ● Primary sheave assembly NOTE: ● Tightening the bolts 1 will push the secondary sliding sheave away, causing the gap between the secondary fixed and sliding sheaves to widen. ● Install the V-belt so that its arrow faces the direction show in the illustration. 2.Tighten: ● Nut (primary sheave) 1 T. R. ● 100 Nm (10.0 m • kg, 72 ft • lb) Nut (secondary sheave) 2 T. R.
CLUTCH ENG CLUTCH Order 1 2 3 4 5 6 Job name/Part name Removing the clutch Primary and secondary sheaves Q’ty Cover Clutch housing assembly Gasket/dowel pin One-way clutch bearing Nut Clutch carrier assembly 1 1 1/2 1 1 1 Remarks Remove the parts in the order below. Refer to “PRIMARY AND SECONDARY SHEAVES”. Refer to “REMOVING/INSTALLING THE CLUTCH”. For installation, reverse the removal procedure. Not For Resale 4 - 51 www.SmallEngineDiscount.
CLUTCH Order 1 2 3 4 5 6 7 8 Job name/Part name Disassembling the clutch housing Oil seal Circlip Bearing housing Circlip Bearing Circlip Bearing Clutch housing Q’ty ENG Remarks Remove the parts in the order below. 1 1 1 1 1 1 1 1 For assembly, reverse the disassembly procedure. Not For Resale 4 - 52 www.SmallEngineDiscount.
CLUTCH ENG 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. Clutch holding tool: P/N. YM-91042, 90890-04086 CHECKING THE CLUTCH 1.Check: ● Clutch housing 1 Heat damage/wear/damage → Replace.
CLUTCH ENG 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) T. INSTALLING THE CLUTCH 1.Install: ● Collar ● Clutch carrier assembly ● Nut 1 New 140 Nm (14.0 m • kg, 100 ft • lb) R. NOTE: ● Lubricate the nut with molybdenum disulfide oil. ● Use a clutch holding tool 2 to hold the clutch carrier assembly. Clutch holding tool: P/N. YM-91042, 90890-04086 2.
CLUTCH ENG 4.Install: ● Dowel pins ● Gasket New ● Clutch housing assembly T. R. 10 Nm (1.0 m • kg, 7.2 ft • lb) NOTE: ● Tighten the bolts in stages, using a crisscross pattern. ● After tightening the bolts, check that the clutch housing assembly to counterclockwise rotates smoothly. Not For Resale 4 - 55 www.SmallEngineDiscount.
CRANKCASE ENG CRANKCASE STARTER MOTOR, TIMING CHAIN AND OIL FILTER Order Job name/Part name Removing the starter motor, timing chain and oil filter Engine assembly Cylinder head Cylinder and piston Recoil starter and rotor Q’ty Primary and secondary sheaves 1 Clutch carrier assembly Oil pump drive gear/straight key 1/1 2 3 4 5 Oil pump driven gear Timing chain guide Timing chain Starter motor/O-ring 1 1 1 1/1 Remarks Remove the parts in the order below. Refer to “ENGINE REMOVAL”.
CRANKCASE Order 6 7 8 9 10 11 12 13 14 15 16 17 18 Job name/Part name Oil filter cartridge Speed sensor Shift cam stopper Low-range switch High-range switch Neutral switch Reverse switch Oil filler cap Bearing cover/gasket Oil delivery pipe Oil strainer cover/O-ring Compression spring Oil strainer Q’ty 1 1 1 1 1 1 1 1 1/1 1 1/1 1 1 ENG Remarks For installation, reverse the removal procedure. Not For Resale 4 - 57 www.SmallEngineDiscount.
CRANKCASE ENG CRANKCASE Order 1 2 3 4 5 6 Job name/Part name Separating the crankcase Shift lever cover/gasket Shift lever 1/O-ring Shift lever 2 assembly Crankcase (left) Dowel pin Crankcase (right) Q’ty 1/1 1/1 1 1 2 1 Remarks Remove the parts in the order below. Refer to “INSTALLING THE SHIFT LEVER”. Refer to “SEPARATING/ASSEMBLING THE CRANKCASE”. For installation, reverse the removal procedure. Not For Resale 4 - 58 www.SmallEngineDiscount.
CRANKCASE ENG CRANKCASE BEARING Order 1 2 3 Job name/Part name Removing the crankcase bearing Crankshaft and oil pump Transmission Middle drive/driven shaft Oil seal Bearing retainer Bearing Q’ty Remarks Remove the parts in the order below. Refer to “CRANKSHAFT AND OIL PUMP”. Refer to “TRANSMISSION”. Refer to “MIDDLE GEAR”. 2 2 10 For installation, reverse the removal procedure. Not For Resale 4 - 59 www.SmallEngineDiscount.
CRANKCASE ENG REMOVING THE OIL PUMP DRIVE GEAR 1.Straighten: ● Lock washer tab 2.Remove: ● Oil pump drive gear nut ***************************************************** Removal steps: ● Temporary install the clutch carrier assembly 1. ● Hold the clutch carrier assembly with a clutch holding tool 2 and loosen the oil pump drive gear nut. Clutch holding tool: P/N. YM-91042, 90890-04086 ● Remove the clutch carrier assembly.
CRANKCASE ● Remove ENG the left crankcase. CAUTION: Use a soft hammer to tap on one side of the crankcase. Tap only on reinforced portions of the crankcase. Do not tap on the crankcase mating surfaces. Work slowly and carefully. Make sure that the crankcase halves separate evenly. ● Remove the dowel pins. ***************************************************** CHECKING THE TIMING CHAIN AND GUIDE 1.Check: ● Timing chain Cracks/stiff → Replace the timing chain and camshaft sprocket as a set. 2.
CRANKCASE ENG CHECKING THE CRANKCASE 1.Thoroughly wash the case halves in a mild solvent. 2.Clean all the gasket mating surfaces and crankcase mating surfaces thoroughly. 3.Check: ● Crankcase Cracks/damage → Replace. ● Oil delivery passages Clogged → Blow out with compressed air. CHECKING THE BEARINGS 1.Check: ● Bearing Clean and lubricate, then rotate the inner race with a finger. Roughness → Replace. ASSEMBLING THE CRANKCASE 1.
CRANKCASE È ENG 4.Tighten: ● Crankcase bolts (follow the proper tightening sequence) T. R. 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: ● Crankshaft and transmission operation Unsmooth operation → Repair. INSTALLING THE SHIFT LEVER 1.Install: ● Shift lever 2 assembly 1 T. R. ● 14 Nm (1.
CRANKCASE ENG INSTALLING THE OIL PUMP DRIVE GEAR 1.Install: ● Straight key ● Oil pump drive gear ● Lock washer New ● Oil pump drive gear nut 2.Tighten: ● Oil pump drive gear nut T. R. 50 Nm (5.0 m • kg, 36 ft • lb) ***************************************************** Tightening steps: ● Temporary install the clutch carrier assembly 1. ● Hold the clutch carrier assembly with a clutch holding tool 2 and tighten the oil pump drive gear nut. Clutch holding tool: P/N.
CRANKSHAFT AND OIL PUMP ENG CRANKSHAFT AND OIL PUMP Order 1 2 3 4 5 Job name/Part name Removing the crankshaft and oil pump Crankcase separation Washer/circlip Oil pump assembly/gasket Balancer Crankshaft seal Crankshaft Q’ty Remarks Remove the parts in the order below. Refer to “CRANKCASE”. 1/1 1/1 1 2 1 Refer to “REMOVING THE CRANKSHAFT/INSTALLING THE CRANKSHAFT AND BALANCER”. For installation, reverse the removal procedure. Not For Resale 4 - 65 www.SmallEngineDiscount.
CRANKSHAFT AND OIL PUMP ENG OIL PUMP Order 1 2 3 4 5 6 7 Job name/Part name Disassembling the oil pump Rotor cover Pin Shaft Pin Inner rotor Outer rotor Oil pump housing Q’ty Remarks Remove the parts in the order below. 1 2 1 1 1 1 1 For assembly, reverse the disassembly procedure. Not For Resale 4 - 66 www.SmallEngineDiscount.
CRANKSHAFT AND OIL PUMP ENG REMOVING THE CRANKSHAFT 1.Remove: ● Crankshaft seal 1 NOTE: Mark a note of the position of each crankshaft seal so that they can be installed in the correct place and in the correct direction. 2.Remove: ● Crankshaft Use a crankcase separating tool 1. Crankcase separating tool: P/N. YU-01135-A, 90890-01135 CHECKING THE OIL PUMP 1.Check: ● Oil pump driven gear ● Oil pump housing ● Rotor cover Cracks/wear/damage → Replace. 2.
CRANKSHAFT AND OIL PUMP ENG 3.Check: ● Oil pump operation Unsmooth → Repeat steps #1 and #2 or replace the defective parts. CHECKING THE CRANKSHAFT 1.Measure: ● Crank width A Out of specification → Replace the crankshaft. Crank width: 62.95 ~ 63.00 mm (2.4783 ~ 2.4803 in) ● Side clearance D Out of specification → Replace the crankshaft. Big end side clearance: 0.25 ~ 0.75 mm (0.0098 ~ 0.0295 in) : 1.00 mm (0.0394 in) ● Runout C Out of specification → Replace the crankshaft. Runout limit: C1: 0.
CRANKSHAFT AND OIL PUMP ENG INSTALLING THE CRANKSHAFT AND BALANCER 1.Install: ● Crankshaft Crankshaft installer set 1: P/N. YU-90050 Buffer boss installer set 2: P/N. 90890-04088 Adapter #11 3: P/N. YM-33279 Spacer (crankshaft) 4: P/N. YM-90070-A, 90890-04060 NOTE: Hold the connecting rod at the Top Dead Center (T.D.C.) with one hand while turning the nut of the installing tool with the other. Operate the installing tool until the crankshaft bottoms against the bearing.
TRANSMISSION ENG TRANSMISSION Order 1 2 3 4 5 6 7 8 9 10 Job name/Part name Removing the transmission Crankcase separation Driven sprocket Chain Clutch dog 2 Shift fork “L” Spring Low wheel gear Secondary shaft Middle driven gear Drive axle assembly Guide bar Q’ty Remarks Remove the parts in the order below. Refer to “CRANKCASE”. 1 1 1 1 1 1 1 1 1 1 Not For Resale 4 - 70 www.SmallEngineDiscount.
TRANSMISSION Order 11 12 13 14 15 16 17 18 19 Job name/Part name Shift fork “R” Spring Shift cam Stopper wheel Clutch dog 1 High wheel gear Middle drive gear Stopper lever Spacer/O-ring Q’ty 1 1 1 1 1 1 1 1 1/1 ENG Remarks For installation, reverse the removal procedure. Not For Resale 4 - 71 www.SmallEngineDiscount.
TRANSMISSION ENG CHECKING THE SHIFT FORK 1.Check: ● Shift fork cam follower 1 ● Shift fork pawl 2 Scoring/bends/wear/damage → Replace. 2.Check: ● Guide bar Roll the guide bar on a flat surface. Bends → Replace. WARNING Do not attempt to straighten a bent guide bar. 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.
TRANSMISSION ENG CHECKING THE TRANSMISSION 1.Measure: ● Axle runout Use a centering device and a dial gauge. Out of specification → Replace the bent axle. Runout limit (drive axle): 0.06 mm (0.0024 in) 2.Check: ● Gear teeth Blue discoloration/pitting/wear → Replace. ● Mated dogs Rounded edges/cracks/missing portions → Replace. 3.Check: ● Gear movement Unsmooth → Repeat steps #1 and #2 or replace the defective parts. 4.Check: ● Circlip Bends/looseness/damage → Replace.
TRANSMISSION ENG CHECKING THE CHAIN 1.Check: ● Chain Cracks/shift → Replace the chain, secondary shaft and driven sprocket as a set. CHECKING THE STOPPER LEVER AND STOPPER WHEEL 1.Check: ● Stopper lever pawl 1 Bends/damage/wear → Replace the stopper lever and stopper wheel as a set. ● Stopper wheel 2 Damage/wear → Replace the stopper wheel and stopper lever as a set. ● Shaft 3 Bends/damage/wear → Replace. INSTALLING THE TRANSMISSION 1.
TRANSMISSION ENG 2.Check: ● Shift operation Unsmooth operation → Repair. NOTE: ● Oil each gear and bearing thoroughly. ● Before assembling the crankcase, be sure that the transmission is in neutral and that the gears turn freely. Not For Resale 4 - 75 www.SmallEngineDiscount.
MIDDLE GEAR ENG MIDDLE GEAR MIDDLE DRIVE SHAFT Order 1 2 3 4 Job name/Part name Removing the middle drive shaft Crankcase separation Transmission Bearing housing assembly Nut Middle drive pinion gear Shim 5 6 Middle drive shaft Bearing retainer Q’ty 1 1 1 Remarks Remove the parts in the order below. Refer to “CRANKCASE”. Refer to “TRANSMISSION”. Refer to “REMOVING/INSTALLING THE MIDDLE DRIVE SHAFT”. Refer to “SELECTING THE MIDDLE DRIVE AND DRIVEN GEAR SHIM”.
MIDDLE GEAR ENG MIDDLE DRIVEN SHAFT Order 1 2 3 4 5 6 Job name/Part name Removing the middle driven shaft Crankcase separation Circlip Bearing Universal joint Universal joint yoke Bearing housing/O-ring Shim 7 8 9 10 11 Middle drive pinion gear Bearing retainer Damper cam Spring Gear coupling Q’ty 4 4 2 2 1/1 1 1 1 1 1 Remarks Remove the parts in the order below. Refer to “CRANKCASE”. Refer to “REMOVING/INSTALLING THE MIDDLE DRIVEN SHAFT”.
MIDDLE GEAR Order 12 13 Job name/Part name Bearing retainer Middle driven shaft Q’ty 1 1 ENG Remarks For installation, reverse the removal procedure. Not For Resale 4 - 78 www.SmallEngineDiscount.
MIDDLE GEAR ENG REMOVING THE MIDDLE DRIVE SHAFT 1.Straighten: ● Punched portion of the nut (middle drive pinion gear) 2.Loosen: ● Nut (middle drive pinion gear) 1 NOTE: Secure the middle drive shaft in the vise with a clean rag. 3.Remove: ● Nut (middle drive pinion gear) ● Middle drive pinion gear ● Shim(s) REMOVING THE MIDDLE DRIVEN SHAFT 1.Remove: ● Universal joint ***************************************************** Removal steps: ● Remove the circlips 1. ● Place the U-joint in a press.
MIDDLE GEAR ENG 2.Remove: ● Nut 1 ● Washer ● Universal joint yoke NOTE: Use the universal joint holder 2 to hold the universal joint yoke. Universal joint holder: P/N. YM-04062, 90890-04062 3.Remove: ● Bearing housing assembly 1 ***************************************************** Removal steps: ● Clean the outside of the middle driven shaft. ● Place the middle driven shaft onto a hydraulic press.
MIDDLE GEAR ENG 5.Remove: ● Front drive shaft coupling ● Bearing retainer 1 ● Bearing NOTE: Attach the ring nut wrench 2. Ring nut wrench: P/N. YM-38404, 90890-01430 CAUTION: The middle driven shaft bearing retainer has left-handed threads. To loosen the retainer turn it clockwise. 6.Remove: ● Middle drive shaft 1 (with bearing) CHECKING THE PINION GEAR 1.Check: ● Damper cam surfaces Wear/scratches → Replace damper cam and driven pinion gear as a set. 2.Check: ● Damper spring Damage/cracks → Replace.
MIDDLE GEAR ENG 4.Check: ● O-ring Damage → Replace. ● Bearings Pitting/damage → Replace. 5.Check: ● U-joint movement Roughness → Replace U-joint. SELECTING THE MIDDLE DRIVE AND DRIVEN GEAR SHIM When the drive and driven gear, bearing housing assembly and/or crankcase replaced, be sure to adjust the gear shim 1. 1.
MIDDLE GEAR ENG Example: 1) If the bearing housing is marked “+04”, ..... a is 10.54. 2) b is 55 3) If the crankcase (right) is marked “66.03”, ..... c is 66.03. 4) Therefore, the shim thickness is 0.47 mm. A = 66.03 – 10.54 – 55 = 0.49 5) Round off hundredths digit and select appropriate shim(s). In the example above, the calculated shim thickness is 0.49 mm. The chart instructs you, however, to round off 9 to 10.
MIDDLE GEAR ENG Where: d = a numeral (usually a decimal number) on the bearing housing is either added to or subtracted from “76”. e = a numeral (usually a decimal number) on the middle driven pinion gear is either added to or subtracted from “59”. f = a numeral (usually a decimal number) on the middle driven pinion gear is either added to or subtracted from “79.5”. g = a numeral (usually a decimal number) on the left crankcase specifies a thickness of “95.8”.
MIDDLE GEAR ENG Shims are supplied in the following thickness. Middle drive pinion gear shim 0.10 0.15 0.20 0.30 Thickness (mm) 0.40 0.50 0.60 ***************************************************** INSTALLING THE MIDDLE DRIVEN SHAFT 1.Install: ● Bearing retainer 1 LT T. R. 80 Nm (8.0 m • kg, 58 ft • lb) NOTE: Attach the ring nut wrench 2. Ring nut wrench: P/N. YM-38404, 90890-01430 CAUTION: The middle driven shaft bearing retainer has left-handed threads.
MIDDLE GEAR ● Tighten ENG the bearing retainer. CAUTION: The middle driven shaft bearing retainer has left-handed threads. To tighten the retainer turn it counterclockwise. T. R. Bearing retainer: 110 Nm (11.0 m • kg, 80 ft • lb) ***************************************************** 3.Install: ● Shims 1 ● Bearing housing NOTE: Install the shims so that the tabs are positioned as shown in the illustration. 4.Install: ● Universal joint yoke (rear side) ● Washer 97 Nm (9.
MIDDLE GEAR ● Install ENG the bearing 1 onto the yoke. CAUTION: Check each bearing. The needles can easily fall out of their races. Slide the yoke back and forth on the bearings; the yoke will not go all the way onto a bearing if a needle is out of place. ● Press each bearing into the U-joint using a suitable socket. NOTE: The bearing must be inserted far enough into the U-joint so that the circlip can be installed. the circlips 2 into the groove of each bearing.
MIDDLE GEAR ENG the gear lash measurement tool 3 and dial gauge 4. ● Attach Gear lash measurement tool: P/N. YM-01467, 90890-01467 a 8.12 mm (0.32 in) ● Measure the gear lash while rotating the middle driven shaft back and forth. NOTE: Measure the gear lash at 4 positions. Rotate the middle driven gear 90° each time. ● If the gear lash is incorrect, adjust the gear lash by middle driven pinion gear shims and/ or middle drive pinion gear shim(s).
RADIATOR COOL COOLING SYSTEM RADIATOR Order Job name/Part name Removing the radiator Seat and fuel tank side panels Q’ty Front carrier, front bumper and front fender Left footrest board Coolant 1 2 3 4 Radiator fan coupler Thermo switch coupler Coolant reservoir hose Radiator fan breather hose 1 1 1 1 Remarks Remove the parts in the order below. Refer to “SEAT AND SIDE PANELS” in CHAPTER 3. Refer to “FRONT CARRIER, FRONT BUMPER AND FRONT FENDER” in CHAPTER 3.
RADIATOR COOL 5 Order 5 6 7 8 9 Job name/Part name Radiator inlet hose Radiator outlet hose Radiator Radiator fan Thermo switch Q’ty Remarks 1 Disconnect. 1 Disconnect. 1 1 1 For installation, reverse the removal procedure. Not For Resale 5-2 www.SmallEngineDiscount.
RADIATOR COOL CHECKING THE RADIATOR 1.Check: ● Radiator fins Obstruction → Clean. Apply compressed air to the rear of the radiator. Damage → Repair or replace. NOTE: Straighten any flattened fins with a thin, flathead screwdriver. 2.Check: ● Radiator hoses Cracks/damage → Replace. 3.Measure: ● Radiator cap opening pressure Below the specified pressure → Replace the radiator cap. Radiator cap opening pressure: 93.7 ~ 122.6 kPa (0.937 ~ 1.226 kg/cm2, 13.32 ~ 17.
RADIATOR COOL INSTALLING THE RADIATOR 1.Fill: ● Cooling system (with the specified amount of the recommended coolant) Refer to “CHANGING THE COOLANT” in CHAPTER 3. 2.Check: ● Cooling system Leaks → Repair or replace any faulty part. Not For Resale 5-4 www.SmallEngineDiscount.
THERMOSTAT COOL THERMOSTAT Order Job name/Part name Removing the thermostat Seat and fuel tank side panel (right) Q’ty Coolant 1 2 3 Radiator inlet hose Thermostat cover Thermostat Remarks Remove the parts in the order below. Refer to “SEAT AND SIDE PANELS” in CHAPTER 3. Drain. Refer to “CHANGING THE COOLANT” in CHAPTER 3. 1 1 1 For installation, reverse the removal procedure. Not For Resale 5-5 www.SmallEngineDiscount.
THERMOSTAT COOL CHECKING THE THERMOSTAT 1.Check: ● Thermostat 1 Does not open at 63.5 ~ 66.5 °C (146.3 ~ 151.7 °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 thermostat and thermometer’s indicated temperature.
WATER PUMP COOL WATER PUMP Order Job name/Part name Removing the water pump Seat, fuel tank side panel (left) and engine side cover Left footrest board Q’ty Coolant 1 2 3 4 5 6 7 Water pump outlet hose Water pump outlet pipe O-ring Radiator outlet hose Water pump breather hose Water pump assembly O-ring Remarks Remove the parts in the order below. Refer to “SEAT AND SIDE PANELS” in CHAPTER 3. Refer to “FOOTREST BOARDS” in CHAPTER 3. Drain. Refer to “CHANGING THE COOLANT” in CHAPTER 3.
WATER PUMP Order 1 2 3 4 5 6 7 8 9 0 Job name/Part name Disassembling the water pump Water pump housing cover Gasket Circlip Impeller Rubber damper holder Rubber damper Water pump seal Oil seal Bearing Water pump housing Q’ty COOL Remarks Remove the parts in the order below. 1 1 1 1 1 1 1 1 1 1 For assembly, reverse the disassembly procedure. Not For Resale 5-8 www.SmallEngineDiscount.
WATER PUMP COOL 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. 2 Water pump housing 3.Remove: ● Oil seal 1 ● Bearing 2 NOTE: Tap out the bearing and oil seal from the outside of the water pump housing. 3 Water pump housing CHECKING THE WATER PUMP 1.
WATER PUMP COOL 3.Measure: ● Impeller shaft tilt Out of specification → Replace. Max. impeller shaft tilt: 0.15 mm (0.006 in) 1 Straightedge 2 Impeller ASSEMBLING THE WATER PUMP 1.Install: ● Oil seal 1 New (into the water pump housing 2) NOTE: Install the oil seal with a socket 3 that matches its outside diameter. 2.Install: ● Water pump seal 1 New (into the water pump housing 2) NOTE: Before installing the water pump seal 1, apply tap water or coolant onto its outer surface.
WATER PUMP COOL 3.Install: ● Rubber damper 1 New ● Rubber damper holder 2 New NOTE: Before installing the rubber damper, apply tap water or coolant onto its outer surface. CAUTION: Make sure that the rubber damper and rubber damper holder are flush with the impeller. Not For Resale 5 - 11 www.SmallEngineDiscount.
CARBURETOR CARB CARBURETION CARBURETOR 6 Order 1 2 3 4 5 6 7 Job name/Part name Removing the carburetor Seat/fuel tank side panels/fuel tank/ rubber cover Drain hose Starter cable/starter plunger Vacuum chamber breather hose Carburetor assembly Throttle valve cover Throttle cable end Throttle cable Q’ty 1 1/1 1 1 1 1 2 Remarks Remove the parts in the order below. Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK” in CHAPTER 3. NOTE: After removing the carburetor assembly, remove the throttle cable.
CARBURETOR Order 1 2 3 4 5 6 7 8 9 0 A B Job name/Part name Disassembling the carburetor Float chamber air vent hose Throttle stop screw Vacuum chamber cover Spring Jet needle holder Spring Jet needle set Piston valve Coasting enricher Float chamber Drain screw Float C Needle valve set Q’ty 1 1 1 1 1 1 1 1 1 1 1 1 CARB Remarks Remove the parts in the order below. Refer to “ASSEMBLING THE CARBURETOR”. 1 Not For Resale 6-2 www.SmallEngineDiscount.
CARBURETOR Order D Job name/Part name Pilot jet Q’ty 1 CARB Remarks NOTE: Before disassembling the carburetor, make sure to note the number of times the pilot screw is turned out from the seated position to its set position. E F G H Main jet Needle jet Starter jet Pilot air jet 1 1 1 1 For assembly, reverse the disassembly procedure. Not For Resale 6-3 www.SmallEngineDiscount.
CARBURETOR CARB DISASSEMBLING THE CARBURETOR NOTE: Before disassembling the carburetor, make sure to note the number of times the pilot screw is turned out from the seated position to its set position. CHECKING THE CARBURETOR 1.Check: ● Carburetor body ● Float chamber Cracks/damage → Replace. ● Fuel passage Contamination → Clean as indicated. ● Carburetor body Contamination → Clean. ***************************************************** Cleaning steps: ● Wash the carburetor in a petroleum based solvent.
CARBURETOR CARB 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 ● Pilot air jet 4 ● Pilot jet 5 ● Starter jet 6 ● Starter plunger 7 Bends/wear/damage → Replace. ● Blockage → Blow out the jets with compressed air.
CARBURETOR CARB 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 reassembling, wash all of the parts in a clean petroleum based solvent. 1.Measure: ● Float height a Out of specification → Adjust. Float height (F.H.): 13 mm (0.
CARBURETOR CARB ADJUSTING THE FUEL LEVEL 1.Measure: ● Fuel level a Out of specification → Adjust. Fuel level: 4.0 ~ 5.0 mm (0.16 ~ 0.20 in) Above the float chamber mating surface ***************************************************** Measurement and adjustment steps: ● Place the machine on a level surface. ● Connect the fuel level gauge 1 to the drain pipe 2. Fuel level gauge: P/N. YM-01312-A, 90890-01312 the drain screw 3. ● Hold the gauge vertically next to the float chamber line.
TROUBLESHOOTING DRIV DRIVE TRAIN TROUBLESHOOTING The following conditions may indicate damaged shaft drive components: Symptoms 1.A pronounced hesitation or “jerky” movement during acceleration, deceleration, or sustained speed. (This must not be confused with engine surging or transmission characteristics.) 2.A “rolling rumble” noticeable at low speed; a high-pitched whine; a “clunk” from a shaft drive component or area. 3.
TROUBLESHOOTING DRIV CAUTION: Too little gear lash is extremely destructive to the gear teeth. If a test ride following reassembly indicates this condition, stop riding immediately to minimize gear damage. c.A slight “thunk” evident at low speed operation. This noise must be distinguished from normal machine operation. Diagnosis: Possible broken gear teeth. WARNING Stop riding immediately if broken gear teeth are suspected.
TROUBLESHOOTING DRIV Troubleshooting chart When basic condition “a” and “b” exist, check the following points: Elevate and spin both wheels. Feel for wheel bearing damage. YES Replace the wheel bearing. (Refer to “STEERING SYSTEM” and “REAR SHOCK ABSORBER AND SWINGARM” in CHAPTER 8.) NO Check the wheel nuts and hub nuts for tightness. NO Torque to specification. (Refer to “FRONT AND REAR WHEELS” in CHAPTER 8.) YES Check the constant velocity joint. Feel for bearing damage.
FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR DRIV FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR Order Job name/Part name Removing the front constant velocity joint and differential gear Engine skid plate (front) Front fender Differential gear oil Steering knuckle Q’ty Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK” in CHAPTER 3. Drain. Refer to “STEERING SYSTEM” in CHAPTER 8. Refer to “FRONT ARMS AND FRONT SHOCK ABSORBER” in CHAPTER 8. Refer to “FRONT AND REAR BRAKES” in CHAPTER 8.
FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR Order 4 5 6 Job name/Part name Differential gear Drive shaft Compression spring Q’ty 1 1 1 DRIV Remarks For installation, reverse the removal procedure. Not For Resale 7-5 www.SmallEngineDiscount.
FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR Order 1 2 3 4 5 6 7 8 9 Job name/Part name Disassembling the constant velocity joint Circlip Boot band Boot band Dust boot Circlip Double off-set joint Snap ring Ball bearing Joint shaft assembly Q’ty 1 2 2 2 1 1 1 1 1 DRIV Remarks Remove the parts in the order below. Refer to “ASSEMBLING THE FRONT CONSTANT VELOCITY JOINT”. For assembly, reverse the disassembly procedure. Not For Resale 7-6 www.SmallEngineDiscount.
FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR Order Q’ty 1 Job name/Part name Disassembling the differential gear Gear motor/O-ring 2 3 4 5 6 7 8 9 0 A Circlip Bearing Universal joint Universal joint yoke/O-ring Stopper bolt/shaft Shift fork sliding gear Shift fork Differential gear case cover Drive clutch Shim (left) 2 2 1 1/1 1/1 1 1 1 1 1/1 DRIV Remarks Remove the parts in the order below. NOTE: Be sure not to disassemble the gear motor or remove the pinion gear.
FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR Order B C D E F Job name/Part name Differential gear assembly Shim (right) Circlip/bearing Drive pinion gear Differential gear case Q’ty 1 1 1/1 1 1 DRIV Remarks For assembly, reverse the disassembly procedure. Not For Resale 7-8 www.SmallEngineDiscount.
FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR DRIV REMOVING 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. NOTE: It may be necessary to lightly tap the yoke with a punch. ● Repeat the steps for the opposite bearing. ● Remove the yoke.
FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR DRIV CHECKING THE CONSTANT VELOCITY JOINT 1.Check: ● Double off-set joint spline ● Ball joint spline ● Shaft spline Wear/damage → Replace. 2.Check: ● Dust boots Cracks/damage → Replace. CAUTION: Always use a new boot band. 3.Check: ● Balls and ball races ● Inner surface of double off-set joint Pitting/wear/damage → Replace. CHECKING THE DIFFERENTIAL GEAR 1.Check: ● Gear teeth Pitting/galling/wear → Replace drive pinion gear and ring gear as a set.
FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR È DRIV CHECKING THE GEAR MOTOR 1.Check: ● Gear motor ***************************************************** Checking steps: ● Connect two C size batteries to the gear motor terminals 1. (as shown illustration) CAUTION: É Do not use a 12 V battery to operate the pinion gear. È Check that the pinion gear 2 turns counterclockwise. É Check that the pinion gear 2 turns clockwise. NOTE: Be sure not to disassemble the gear motor or remove the pinion gear.
FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR DRIV 3.Check: ● Free play (thrust movement) Excessive play → Replace the joint assembly. ASSEMBLING THE DIFFERENTIAL GEAR 1.Measure: ● Gear lash Refer to “MEASURING AND ADJUSTING THE DIFFERENTIAL GEAR LASH”. 2.Install: ● Gear motor ***************************************************** 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.
FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR DRIV 3.Install: ● Universal joint yoke ● O-ring ● Washer ● Nut 62 Nm (6.2 m • kg, 45 ft • lb) Use a universal joint holder 1. LT T. R. Universal joint holder: P/N. YM-04062, 90890-04062 4.Check: ● Differential gear operation Unsmooth operation → Replace the differential gear assembly. Insert the double off-set joint into the differential gear, and turn the gear back and forth. INSTALLING THE UNIVERSAL JOINT 1.
FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR DRIV 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 gear. Otherwise, the ring gear will be damaged. 4.Attach: ● Gear lash measurement tool 1 ● Dial gauge 2 Gear lash measurement tool: P/N.
FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR DRIV 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. Too little gear lash Reduce shim thickness. Too large gear lash Increase shim thickness. ● If it is necessary to increase by more than 0.05 mm (0.
FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR DRIV 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. NOTE: ● Repeat this step several times to obtain an average figure.
REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT Order 1 2 3 4 5 6 Job name/Part name Removing the rear axle, final drive gear assembly and drive shaft Final gear oil Rear wheel hubs/brake disc Q’ty O-ring Rear axle/dust cover Trailer hitch bracket Final drive gear case breather hose Final drive gear Drive shaft 1 1/1 1 1 1 1 Remarks Remove the parts in the order below. Drain. Refer to “FRONT AND REAR WHEELS” in CHAPTER 8. Disconnect.
REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT Order Q’ty 1 2 Job name/Part name Disassembling the final drive gear Bolt Bolt 3 4 5 6 7 8 9 0 Bearing housing Oil seal/bearing Ring gear stopper Ring gear stopper shim Oil seal/bearing Ring gear shim Ring gear Thrust washer 1 1/1 1 1 1/1 1 1 1 2 6 DRIV Remarks Remove the parts in the order below. NOTE: Working in a crisscross pattern, loosen each bolt 1/4 of a turn. After all the bolts are loosened, remove them. Not For Resale 7 - 18 www.
REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT Order A B C D E F G H I Job name/Part name Bearing retainer/O-ring Oil seal Final drive pinion gear Collar Bearing Final drive pinion gear shim Final drive gear case/O-ring Bearing/oil seal Bearing Q’ty 1/1 1 1 1 1 1 1/1 1/1 1 DRIV Remarks Refer to “DISASSEMBLING/ ASSEMBLING THE FINAL DRIVE GEAR”. Refer to “REPLACING THE FINAL DRIVE ROLLER BEARING”. For assembly, reverse the disassembly procedure. Not For Resale 7 - 19 www.SmallEngineDiscount.
REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT DRIV REMOVING THE REAR AXLE 1.Remove: ● Rear axle 1 (with dust seal) ● O-ring CAUTION: ● ● Never directly tap the axle end with a hammer, since this will result in damage to the axle thread and spline. Attach a suitable socket 2 on the axle end and tap it with a soft hammer. Pull out the rear axle to the right. DISASSEMBLING THE FINAL DRIVE GEAR 1.Remove: ● Bearing retainer (final drive pinion gear) NOTE: Use a bearing retainer wrench 1.
REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT DRIV REPLACING THE FINAL DRIVE ROLLER BEARING 1.Remove: ● Roller bearing (ring gear) 1 Use a suitable press tool 2 and an appropriate support for the main housing. ● Oil seal 3 2.Remove: ● Roller bearing (final drive pinion gear) 1 ***************************************************** Removal steps: ● Heat the main housing only to 150 °C (302 °F). ● Remove the roller bearing outer race with an appropriately shaped punch 2.
REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT DRIV 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 housing are replaced, be sure to adjust the positions of the final drive pinion gear and ring gear using the shim(s). Final drive pinion gear shim selection 1.
DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT Shims are thicknesses. supplied in the following Final drive pinion gear shim Thickness (mm) 0.15 0.45 0.30 0.50 0.40 0.60 ***************************************************** Ring gear shim selection 1.Select: ● Ring gear shim(s) 1 ***************************************************** Selection steps: ● To find the ring gear shim thickness “B”, use the following formula.
DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT 5) Therefore, shim thickness “B” is 0.63. “B”= 45.53 + 1.05 – (34.95 + 11.00) = 46.58 – 45.95 = 0.63 6) Round off the hundredth digit and select the appropriate shim(s). In the example above, the calculated number is 0.63. The chart instructs you to round off 3 to 5 at the hundredth place. Thus, the shim thickness is 0.65 mm. Hundredths Rounded value 0, 1, 2 0 3, 4, 5, 6, 7 5 8, 9 10 Shims are thicknesses.
REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT DRIV ● Remove the ring gear assembly. ● Measure the thrust clearance. Calculate the width of the flattened Plastigauge® 1. Ring gear thrust clearance: 0.1 ~ 0.2 mm (0.004 ~ 0.008 in) ● If out of specification, select the correct washer. Thrust washer selection steps: ● Select a suitable thrust washer using the following chart. Thrust washer Thickness (mm) 1.0 1.3 1.45 1.6 1.9 1.1 1.35 1.5 1.7 2.0 1.2 1.4 1.55 1.8 2.
REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT DRIV Ring gear stopper clearance adjustment 1.Remove: ● Ring gear 1 ● Ring gear stopper 2 ● Shim(s) 3 4 Bearing housing È Left-hand threads 2.Select: ● Suitable shim(s) Shim 0.10 0.30 Thickness (mm) 0.15 0.40 0.20 0.50 3.Install: ● Shim(s) ● Ring gear stopper (left-hand threads) T. R. ● 9 Nm (0.9 m • kg, 6.5 ft • lb) Ring gear NOTE: Use LOCTITE on the ring gear stopper. 4.
REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT DRIV CHECKING THE DRIVE SHAFT 1.Check: ● Drive shaft (splines) Wear/damage → Replace. CHECKING THE FINAL DRIVE GEAR 1.Check: ● Final gear case 1 ● Bearing housing (ring gear) 2 Cracks/damage → Replace. NOTE: When the final gear case and/or the ring gear bearing housing are replaced, be sure to adjust the shim of the final drive pinion gear and/or ring gear. 2.Check: ● Gear teeth Pitting/galling/wear → Replace the drive pinion gear and ring gear as a set.
REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT DRIV 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 gear. Otherwise, the ring gear will be damaged. 4.Attach: ● Gear lash measurement tool 1 ● Dial gauge 2 Gear lash measurement tool: P/N.
DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT Final gear lash adjustment 1.Remove: ● Bearing housing 1 ● Ring gear shim(s) 2 ● Ring gear 3 ● Thrust washer 4 2.Adjust: ● Gear lash ***************************************************** Adjustment steps: ● Select a suitable shim(s) and thrust washer(s) using the following chart. Too little gear lash Reduce shim thickness. Too large gear lash Increase shim thickness. ● If increased by more than 0.2 mm (0.
REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT DRIV ASSEMBLING THE FINAL DRIVE GEAR 1.Install: ● Drive pinion gear (with shim(s) and bearing) (proper shim size as calculated) ● Bearing retainer (drive pinion gear) 1 T. R. 100 Nm (10.0 m • kg, 72 ft • lb) Use a bearing retainer wrench 2. CAUTION: ● ● Always use a new bearing. The final drive shaft bearing retainer has left-hand threads. Turn the retainer counterclockwise to tighten it. Bearing retainer wrench: P/N. YM-04050, 90890-04050 2.
REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT DRIV 3.Apply: ® ● Sealant (Quick Gasket ) (to the mating surfaces of the swingarm and the final drive gear case) Sealant (Quick gasket®): P/N. ACC-11001-05-01 Yamaha bond No.1215: P/N. 90890-85505 4.Install: ● Final drive gear ● Nuts ● Bolts LT T. R. LT 63 Nm (6.3 m • kg, 45 ft • lb) T. R. 63 Nm (6.3 m • kg, 45 ft • lb) 5.
FRONT AND REAR WHEELS CHAS CHASSIS FRONT AND REAR WHEELS FRONT WHEELS Order Job name/Part name Removing the front wheel Q’ty Remarks Remove the parts in the order below. Place the machine on a level surface. WARNING Securely support the machine so there is no danger of it falling over. 1 2 3 4 5 Front wheel Wheel cap Cotter pin Axle nut Brake caliper assembly 1 1 1 1 1 6 7 Wheel hub Brake disc 1 1 Refer to “INSTALLING THE WHEEL”. Refer to “INSTALLING THE WHEEL HUB”.
FRONT AND REAR WHEELS CHAS REAR WHEELS Order Job name/Part name Removing the rear wheel Q’ty Remarks Remove the parts in the order below. Place the machine on a level surface. WARNING Securely support the machine so there is no danger of it falling over. 1 2 3 4 5 6 7 8 9 Rear wheel Wheel cap Cotter pin Axle nut Wheel hub Brake caliper mounting bolt Brake disc bracket Brake disc Brake disc guard 2 2 2 2 2 2 1 1 1 Refer to “INSTALLING THE WHEEL”. Refer to “INSTALLING THE WHEEL HUB”.
FRONT AND REAR WHEELS CHAS CHECKING THE 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 → Adjust. WARNING After replacing the tire, ride conservatively to allow the tire to be properly seated in the rim. Failure to do so may cause an accident resulting in machine damage and possible operator injury.
FRONT AND REAR WHEELS CHAS CHECKING THE 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 Out of specification → Replace. Brake disc minimum thickness: 3 mm (0.12 in) T. INSTALLING THE WHEEL HUB 1.Install: ● Axle nut 150 Nm (15.0 m • kg, 110 ft • lb) ● Cotter pin 1 New R.
FRONT AND REAR WHEELS CHAS 2.Install: ● 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. 3.Tighten: ● Nuts (front wheel) T. R. ● 64 Nm (6.4 m • kg, 46 ft • lb) Nuts (rear wheel) T. R. 55 Nm (5.5 m • kg, 40 ft • lb) NOTE: Tighten the nuts in stages and in a crisscross pattern. Not For Resale 8-5 www.SmallEngineDiscount.
FRONT AND REAR BRAKES CHAS FRONT AND REAR BRAKES FRONT BRAKE PADS Order 1 2 3 4 Job name/Part name Removing the front brake pads Front wheel Brake caliper mounting bolt Brake pad holding bolt Brake pad/pad shim Pad spring Q’ty 2 2 2/1 1 Remarks Remove the parts in the order below. Refer to “FRONT AND REAR WHEELS”. Refer to “REPLACING THE FRONT BRAKE PAD”. For installation, reverse the removal procedure. Not For Resale 8-6 www.SmallEngineDiscount.
FRONT AND REAR BRAKES CHAS REAR BRAKE PADS Order 1 2 3 4 Job name/Part name Removing the rear brake pads Rear wheel (left) Brake caliper mounting bolt Brake pad holding bolt Brake pad/insulator/pad shim Pad spring Q’ty 2 2 2/2/2 1 Remarks Remove the parts in the order below. Refer to “FRONT AND REAR WHEELS”. Refer to “REPLACING THE REAR BRAKE PAD”. For installation, reverse the removal procedure. Not For Resale 8-7 www.SmallEngineDiscount.
FRONT AND REAR BRAKES CHAS CAUTION: Disc brake components rarely require disassembly.
FRONT AND REAR BRAKES CHAS ***************************************************** 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. ● Tighten the brake caliper bleed screw. T. Brake caliper bleed screw: 6 Nm (0.6 m • kg, 4.3 ft • lb) R. new brake pads, new pad shims 3 and a new brake pad spring.
FRONT AND REAR BRAKES CHAS 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. Brake pad wear limit: 1 mm (0.04 in) 2.Install: ● Brake pads ● Brake pad spring NOTE: Always install new brake pads, brake pad shims, insulator and brake pad spring as a set.
FRONT AND REAR BRAKES CHAS 3.Check: ● Brake fluid level Refer to “CHECKING THE BRAKE FLUID LEVEL” 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” in CHAPTER 3. Not For Resale 8 - 11 www.SmallEngineDiscount.
FRONT AND REAR BRAKES CHAS FRONT BRAKE MASTER CYLINDER Order 1 2 3 4 5 6 7 8 9 Job name/Part name Removing the front brake master cylinder Brake fluid On-command four-wheel drive switch and differential gear lock switch Brake fluid reservoir cap Brake fluid reservoir diaphragm Brake lever Union bolt Copper washer Brake hose Front brake light switch Brake master cylinder bracket Brake master cylinder Q’ty Remarks Remove the parts in the order below. Drain. Refer to “HANDLEBAR”.
FRONT AND REAR BRAKES Order 1 2 Job name/Part name Disassembling the front brake master cylinder Brake master cylinder kit Brake master cylinder Q’ty 1 1 CHAS Remarks Remove the parts in the order below. Refer to “ASSEMBLING THE FRONT BRAKE MASTER CYLINDER”. For assembly, reverse the disassembly procedure. Not For Resale 8 - 13 www.SmallEngineDiscount.
FRONT AND REAR BRAKES CHAS REAR BRAKE MASTER CYLINDER Order 1 2 3 4 5 6 7 8 9 Job name/Part name Removing the rear brake master cylinder Front fender Brake fluid Brake fluid reservoir cap Brake fluid reservoir diaphragm holder Brake fluid reservoir diaphragm Brake fluid reservoir Brake master cylinder cover Brake fluid reservoir hose Union bolt Copper washer Brake hose Q’ty Remarks Remove the parts in the order below. Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK” in CHAPTER 3. Drain.
FRONT AND REAR BRAKES Order 10 11 12 13 14 15 16 17 18 19 Job name/Part name Brake cable Bracket Brake master cylinder Hose joint Brake pedal Select lever control cable Rear brake light switch Bracket Bracket Brake master cylinder bracket CHAS Q’ty Remarks 1 Disconnect. 1 1 1 1 1 Disconnect. 1 1 1 1 For installation, reverse the removal procedure. Not For Resale 8 - 15 www.SmallEngineDiscount.
FRONT AND REAR BRAKES Order 1 2 Job name/Part name Disassembling the rear brake master cylinder Brake master cylinder kit Brake master cylinder Q’ty 1 1 CHAS Remarks Remove the parts in the order below. Refer to “ASSEMBLING THE REAR BRAKE MASTER CYLINDER”. For assembly, reverse the disassembly procedure. Not For Resale 8 - 16 www.SmallEngineDiscount.
FRONT AND REAR BRAKES CHAS È CHECKING THE MASTER CYLINDER 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. É È Front É Rear 2.Check: ● Front brake master cylinder reservoir 1 ● Front brake master cylinder reservoir diaphragm 2 Cracks/damage → Replace. 3.
FRONT AND REAR BRAKES CHAS 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 disassembled, replace the piston seals and dust seals. EB702060 ASSEMBLING THE REAR BRAKE MASTER CYLINDER WARNING ● All internal brake components should be cleaned and lubricated with new brake fluid only before installation.
FRONT AND REAR BRAKES CHAS INSTALLING THE FRONT BRAKE MASTER CYLINDER 1.Install: ● Brake master cylinder 1 ● Brake master cylinder bracket 2 T. R. 7 Nm (0.7 m • kg, 5.1 ft • lb) NOTE: The “UP” mark on the brake master cylinder bracket 2 should face up. T. 2.Install: ● Copper washers New ● Brake hose ● Union bolt 27 Nm (2.7 m • kg, 19 ft • lb) R. 60˚ NOTE: ● Tighten the union bolt while holding the brake hose as shown.
FRONT AND REAR BRAKES ● CHAS 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” in CHAPTER 3. 5.Check: ● Brake fluid level Brake fluid level is under the “LOWER” level line → Fill up. Refer to “CHECKING THE BRAKE FLUID LEVEL” in CHAPTER 3. T. INSTALLING THE REAR BRAKE MASTER CYLINDER 1.
FRONT AND REAR BRAKES CHAS 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. Refill with the same type of brake fluid: mixing brake fluids may result in a harmful chemical reaction and lead to poor brake performance.
FRONT AND REAR BRAKES CHAS FRONT BRAKE CALIPER Order 1 2 3 4 5 6 7 Job name/Part name Removing the front brake caliper Brake fluid Front wheel Union bolt Copper washer Brake hose Cap/retaining bolt Brake pad holding bolt Brake caliper mounting bolt Brake caliper assembly Q’ty 1 2 1 1/1 2 2 1 Remarks Remove the parts in the order below. Drain. Refer to “FRONT AND REAR WHEELS”. Disconnect. Loosen. Loosen. Refer to “INSTALLING THE FRONT BRAKE CALIPER”.
FRONT AND REAR BRAKES Order 1 2 3 4 5 6 7 8 9 Job name/Part name Disassembling the front brake caliper Brake pad holding bolt Brake pad/pad shim Pad spring Retaining bolt Caliper bracket Brake caliper piston Dust seal Caliper piston seal Bleed screw Q’ty 2 2/1 1 1 1 1 1 1 1 CHAS Remarks Remove the parts in the order below. Refer to “DISASSEMBLING/ ASSEMBLING THE FRONT AND REAR BRAKE CALIPER”. For assembly, reverse the disassembly procedure. Not For Resale 8 - 23 www.SmallEngineDiscount.
FRONT AND REAR BRAKES CHAS REAR BRAKE CALIPER Order 1 2 3 4 5 6 Job name/Part name Removing the rear brake caliper Brake fluid Rear wheel Union bolt Copper washer Brake hose Brake pad holding bolt Brake caliper mounting bolt Brake caliper assembly Q’ty 1 2 1 2 2 1 Remarks Remove the parts in the order below. Drain. Refer to “FRONT AND REAR WHEELS”. Disconnect. Loosen. Refer to “INSTALLING THE REAR BRAKE CALIPER”. For installation, reverse the removal procedure. Not For Resale 8 - 24 www.
FRONT AND REAR BRAKES Order 1 2 3 4 5 6 7 8 CHAS Job name/Part name Q’ty Remarks Disassembling the rear brake caliper Remove the parts in the order below. Brake pad holding bolt 2 Brake pad/insulator/pad shim 2/2/2 Pad spring 1 Caliper bracket 1 Brake caliper piston 1 Refer to “DISASSEMBLING/ Dust seal 1 ASSEMBLING THE FRONT AND REAR BRAKE CALIPER”. Caliper piston seal 1 Bleed screw 1 For assembly, reverse the disassembly procedure. Not For Resale 8 - 25 www.SmallEngineDiscount.
FRONT AND REAR BRAKES CHAS DISASSEMBLING THE FRONT AND REAR BRAKE CALIPER 1.Remove: ● Brake caliper piston ● Dust seal 1 ● Caliper piston seal 2 ***************************************************** Removal steps: ● Blow compressed air into the hose joint opening to force out the caliper piston from the brake caliper body. WARNING ● ● Never try to pry out the caliper piston. Cover the caliper piston with a rag. Be careful not to get injured when the piston is expelled from the master cylinder.
FRONT AND REAR BRAKES É ● CHAS Brake fluid delivery passage (brake caliper body) Blockage → Blow out with compressed air. WARNING Replace the caliper piston seal and dust seal whenever the brake caliper is disassembled. È Front É Rear ASSEMBLING THE FRONT AND REAR BRAKE CALIPER WARNING ● All internal brake components should be cleaned and lubricated with new brake fluid only before installation.
FRONT AND REAR BRAKES CHAS CAUTION: When installing the brake hose on the brake caliper, make sure that the brake pipe touches the projection a on the brake caliper. WARNING Proper brake hose routing is essential to insure safe motorcycle operation. Refer to “CABLE ROUTING” in CHAPTER 2. 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.
FRONT AND REAR BRAKES CHAS INSTALLING THE REAR BRAKE CALIPER 1.Install: ● Brake caliper assembly ● Brake caliper mounting bolt 1 T. R. ● ● Brake hose 2 Copper washers 3 New Union bolt 4 30 Nm (3.0 m • kg, 22 ft • lb) T. R. ● 30 Nm (3.0 m • kg, 22 ft • lb) 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.
STEERING SYSTEM CHAS STEERING SYSTEM HANDLEBAR Order Q’ty 4 5 6 Job name/Part name Removing the handlebar Handlebar cover Band On-command four-wheel drive switch and differential gear lock switch Master cylinder assembly/bracket Throttle lever assembly/bracket Rear brake switch 7 8 9 10 11 Rear brake lever/bracket Handlebar switch Handlebar grip Handlebar holder Handlebar 1/1 1 2 2 1 1 2 3 Remarks Remove the parts in the order below.
STEERING SYSTEM CHAS 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.Check: ● Handlebar Bends/cracks/damage → Replace. WARNING Do not attempt to straighten a bent handlebar as this may dangerously weaken the handlebar. INSTALLING THE HANDLEBAR 1.Install: ● Handlebar ● Handlebar holders T. R. 23 Nm (2.
STEERING SYSTEM CHAS INSTALLING THE MASTER CYLINDER ASSEMBLY 1.Install: ● Throttle lever assembly ● Master cylinder assembly T. R. 7 Nm (0.7 m • kg, 5.1 ft • lb) NOTE: The “UP” mark on the master cylinder bracket should face up. Not For Resale 8 - 32 www.SmallEngineDiscount.
STEERING SYSTEM CHAS STEERING STEM Order 1 2 3 4 5 6 7 8 9 10 Job name/Part name Removing the steering stem Handlebar Seat Front fender Lock washer Cable guide Steering stem bushing Collar Oil seal Tie rod end nut Tie rod Steering stem nut Pitman arm Steering stem Q’ty 1 1 2 2 2 2 2 1 1 1 Remarks Remove the parts in the order below. Refer to “HANDLEBAR”. Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK” in CHAPTER 3. Refer to “INSTALLING THE CABLE GUIDE”. Disconnect. Not For Resale 8 - 33 www.
STEERING SYSTEM Order 11 12 13 14 Job name/Part name Oil seal Bearing retainer Bearing Oil seal CHAS Q’ty Remarks 1 1 Refer to “REMOVING/INSTALLING THE BEARING RETAINER”. 1 1 For installation, reverse the removal procedure. Not For Resale 8 - 34 www.SmallEngineDiscount.
STEERING SYSTEM CHAS REMOVING THE BEARING RETAINER 1.Remove: ● Bearing retainer (steering stem) Damper rod holder: P/N. YM-01327, 90890-01327 CHECKING THE STEERING STEM 1.Check: ● 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 Wear/damage → Replace. INSTALLING THE BEARING RETAINER 1.Install: ● Bearing retainer (steering stem) T. R. 40 Nm (4.
STEERING SYSTEM CHAS TIE ROD AND STEERING KNUCKLE Order 1 2 3 4 5 6 7 8 Job name/Part name Removing the tie rod and steering knuckle Front fender Front wheel/brake disc Tie rod Brake disc guard Brake hose holder bolt Protector Nut Nut O-ring Steering knuckle Q’ty 1 1 1 1 1 1 1 1 Remarks Remove the parts in the order below. Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK” in CHAPTER 3. Refer to “FRONT AND REAR WHEELS”. Refer to “INSTALLING THE TIE ROD”. Refer to “REMOVING THE STEERING KNUCKLE”.
STEERING SYSTEM Order 9 10 11 12 13 14 15 Job name/Part name Oil seal Oil seal Bearing Spacer Circlip Rubber boot Ball joint Q’ty 1 1 2 1 1 1 1 CHAS Remarks For installation, reverse the removal procedure. Not For Resale 8 - 37 www.SmallEngineDiscount.
STEERING SYSTEM CHAS REMOVING THE STEERING KNUCKLE 1.Remove: ● Steering knuckle 1 NOTE: Use a general puller to separate the ball joint 2 and steering knuckle 1 or front lower arm 3. CHECKING THE TIE ROD 1.Check: ● Tie rod free play and movement Free play → Replace the tie rod end. Turns roughly → Replace the tie rod end. 2.Check: ● Tie rod ● Bends/damage → Replace. CHECKING THE STEERING KNUCKLE 1.Check: ● Steering knuckle Damage/pitting → Replace. 2.
STEERING SYSTEM CHAS Ball joint remover/installer set: P/N. YM-01474/90890-01474 Ball joint remover/installer attachment set: P/N. YM-01477 3 Body 4 Long bolt 5 6 7 8 9 0 Short bolt Remover washer Remover spacer Installer attachment Installer spacer Installer guide YM-01474 90890-01474 YM-01474 90890-01474 YM-01477 YM-01477 YM-01477 YM-01477 YM-01477 YM-01477 the body 3, short bolt 5, remover washer 6 and remover spacer 7 onto ball joint.
STEERING SYSTEM CHAS ● Attach the assembled ball joint remover/ installer, new ball joint B and installer attachment 8 to the steering knuckle C. NOTE: Do not tap or damage the top of the ball joint. the body 3 in place while turning in the long bolt 4 to install the new ball joint B into the steering knuckle C. ● Remove the ball joint remover/installer. ● Apply lithium-soap base grease to the new ball joint B. ● Install a new rubber boot and new circlip. ● Hold NOTE: Always use a new ball joint set.
STEERING SYSTEM ● Install CHAS 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” of the oil seal faces out. ***************************************************** INSTALLING THE TIE ROD 1.Install: ● Tie rods (left and right) T. R. 30 Nm (3.
FRONT ARMS AND FRONT SHOCK ABSORBER CHAS FRONT ARMS AND FRONT SHOCK ABSORBER Order 1 2 3 Job name/Part name Removing the front arms and front shock absorber Engine skid plate Front fender Front wheel/brake disc Air duct Brake disc guard Protector Q’ty Remarks Remove the parts in the order below. Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK” in CHAPTER 3. Refer to “FRONT AND REAR WHEELS”. 1 1 1 Not For Resale 8 - 42 www.SmallEngineDiscount.
FRONT ARMS AND FRONT SHOCK ABSORBER Order 4 5 6 7 8 9 10 11 12 13 Job name/Part name Nut Nut Bolt/nut Front lower arm/bushing Nut/bolt Front shock absorber Bolt/nut Front upper arm/bushing Circlip Ball joint Q’ty 1 1 2/2 1/2 2/2 1 2/2 1/2 1 1 CHAS Remarks Refer to “REMOVING THE FRONT ARMS” and “INSTALLING THE FRONT ARMS AND FRONT SHOCK ABSORBER”. For installation, reverse the removal procedure. Not For Resale 8 - 43 www.SmallEngineDiscount.
FRONT ARMS AND FRONT SHOCK ABSORBER CHAS 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 by moving it up and down. If the vertical movement is tight or rough, or if there is binding, check the bushings. ***************************************************** 2.
FRONT ARMS AND FRONT SHOCK ABSORBER CHAS ***************************************************** Replacement steps: ● Clean the outside of the front lower arm. ● Remove the circlip 1 and rubber boot 2. Use the ball joint remover and installer set. Ball joint remover/installer set: P/N. YM-01474/90890-01474 Ball joint remover/installer attachment set: P/N.
FRONT ARMS AND FRONT SHOCK ABSORBER CHAS ● Attach the assembled ball joint remover/ installer, new ball joint A and installer attachment 7 to the front lower arm B. NOTE: Do not tap or damage the top of the ball joint. the body 3 in place while turning in the long bolt 4 to install the new ball joint A into the front lower arm B. ● Remove the ball joint remover/installer. ● Apply lithium-soap base grease to the new ball joint A. ● Install a new rubber boot and new circlip.
FRONT ARMS AND FRONT SHOCK ABSORBER CHAS INSTALLING THE FRONT ARMS AND FRONT SHOCK ABSORBER 1.Install: ● Front arms ● Front shock absorber ***************************************************** Installation steps: ● Install the front upper arm 1 and front lower arm 2. NOTE: ● Lubricate the bolts 3 with lithium-soapbased grease. ● Be sure to position the bolts 3 so that the bolt head faces outward. ● Temporarily tighten the nuts 4. ● Install T. R. ● Install the front shock absorber 5. Nut 6: 45 Nm (4.
REAR SHOCK ABSORBER AND SWINGARM CHAS REAR SHOCK ABSORBER AND SWINGARM Order 1 2 3 4 5 6 7 Job name/Part name Removing the rear shock absorber and swingarm Rear wheel hubs/brake disc Rear brake caliper/brake hose Final drive gear assembly Q’ty Clip/washer/pin Nut/bolt Rear shock absorber Collar Trailer hitch bracket Final drive gear case breather hose Metal clamp 1/1/1 1/1 1 1 1 1 1 Remarks Remove the parts in the order below. Refer to “FRONT AND REAR WHEELS”. Refer to “FRONT AND REAR BRAKES”.
REAR SHOCK ABSORBER AND SWINGARM Order 8 9 10 11 Job name/Part name Rear axle housing Nut/bolt Swingarm/bushing Spring/rubber boot CHAS Q’ty Remarks 1 Refer to “INSTALLING THE REAR AXLE HOUSING”. 2/2 Refer to “REMOVING THE 1/2 SWINGARM”. 1/1 For installation, reverse the removal procedure. Not For Resale 8 - 49 www.SmallEngineDiscount.
REAR SHOCK ABSORBER AND SWINGARM CHAS REMOVING THE SWINGARM 1.Check: ● Swingarm free play ***************************************************** Checking steps: ● Check the tightening torque of the nuts (swingarm). T. Nut (swingarm): 82 Nm (8.2 m • kg, 59 ft • lb) R. the swingarm side play È by moving it from side to side. If side play is noticeable, check the bushing and frame pivot. ● Check the swingarm vertical movement É by moving it up and down.
REAR SHOCK ABSORBER AND SWINGARM CHAS CHECKING THE SWINGARM 1.Check: ● Swingarm 1 ● Rear axle housing 2 Bends/cracks/damage → Replace. 2.Check: ● Bushings 1 Wear/damage → Replace. CHECKING THE RUBBER BOOT 1.Check: ● Rubber boot 1 Damage → Replace. INSTALLING THE RUBBER BOOT 1.Apply: ● Adhesive (for rubber) (to the engine 1) 2.Install: ● Rubber boot 2 NOTE: Be sure to position the rubber boot so that the tang 3 faces towards the left. Not For Resale 8 - 51 www.SmallEngineDiscount.
REAR SHOCK ABSORBER AND SWINGARM CHAS INSTALLING THE REAR AXLE HOUSING 1.Install: ● Rear axle housing ● Final gear case assembly ● Rear axle (with dust seal) ***************************************************** Installation steps: ● Install the drive shaft. Refer to “REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT” in CHAPTER 7. ● Apply sealant (Quick Gasket®) to the mating surfaces of the swingarm and the final gear case.
ELECTRICAL COMPONENTS ELEC – + EB800000 ELECTRICAL ELECTRICAL COMPONENTS 1 Main switch 2 Front brake light switch 3 Rear brake switch 4 Thermo switch 1 5 Battery 6 Tail/brake light 7 Fuse box 8 Four-wheel drive relay 2 9 Four-wheel drive relay 1 0 Main fuse A Starter relay B CDI unit C Rectifier/regulator D Reverse switch E Neutral switch F High-range switch G Low-range switch H Speed sensor I Rear brake light switch J Gear motor K Thermo switch 2 L Fan M Headlight N Circuit breaker (fan) O Four-whe
CHECKING THE SWITCH ELEC – + 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. ● The pocket tester should be set to the “Ω × 1” range when testing the switch for continuity. ● Turn the switch on and off a few times when checking it.
CHECKING THE SWITCH ELEC Not For Resale 9-3 www.SmallEngineDiscount.
CHECKING THE SWITCH ELEC 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.
CHECKING THE SWITCH ELEC 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 Reverse switch 0 Neutral switch A High-range switch B Low-range switch C Fuse Not For Resale 9-5 www.SmallEngineDiscount.
CHECKING THE BULBS AND BULB SOCKETS ELEC – + EB801020 CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage or wear, proper connections, and also for continuity between the terminals. Damage/wear → Repair or replace the bulb, bulb socket or both. Improperly connected → Properly connect. Incorrect continuity reading → Repair or replace the bulb, bulb socket or both. TYPES OF BULBS The bulbs used on this machine are shown in the illustration on the left.
CHECKING THE BULBS AND BULB SOCKETS ELEC – + 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. Never pull the lead, otherwise it may be pulled out of the terminal in the coupler.
CHECKING THE BULBS AND BULB SOCKETS ELEC – + 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. YU-03112, 90890-03112 NOTE: Check each bulb socket for continuity in the same manner as described in the bulb section; however, note the following. ***************************************************** a.Install a good bulb into the bulb socket. b.
B B h (BLACK) (BLACK) Y Br Y Br W W W W/R W/G W W W R W/G W/L W/R W/G R Br/L W W W B B g i B Y L Y Br Br f W W W (BLACK) (BLACK) Y Br 1 R W/G W/R W/G W R W B L L B e L L B d R/B B R/B Br OFF ON 3 c (DARK GRAY) R/B L (BLACK) B W B R R Br Not For Resale 9-9 www.SmallEngineDiscount.
IGNITION SYSTEM ELEC – + EB802010 TROUBLESHOOTING IF THE IGNITION SYSTEM FAILS TO OPERATE (NO SPARK OR INTERMITTENT SPARK): Procedure Check: 1.Fuse (main, ignition) 2.Battery 3.Spark plug 4.Ignition spark gap 5.Spark plug cap resistance 6.Ignition coil resistance 7.Engine stop switch 8.Main switch 9.Pickup coil resistance 10.Charging/rotor rotation direction detection coil resistance 11.
IGNITION SYSTEM Spark plug gap: 0.6 ~ 0.7 mm (0.024 ~ 0.028 in) ELEC INCORRECT CORRECT Repair or replace the spark plug. 4.Ignition spark gap ● ● Disconnect the spark plug cap from the spark plug. Connect the dynamic spark tester 1 as shown. 2 Spark plug cap 3 Spark plug ● ● ● Turn the main switch to “ON”. Check the ignition spark gap. Crank the engine by pushing the starter switch, and increase the spark gap until a misfiring occurs. Minimum spark gap: 6.0 mm (0.
IGNITION SYSTEM * ELEC C0NTINUITY 6.Ignition coil resistance ● ● Disconnect the ignition coil connector from the wire harness. Connect the pocket tester (Ω × 1) to the ignition coil. Tester (+) lead → Orange lead terminal Tester (–) lead → Ignition coil base ● Check that the primary coil has the specified resistance. Primary coil resistance: 0.18 ~ 0.28 Ω at 20 °C (68 °F) ● Connect the pocket tester (Ω × 1k) to the ignition coil.
IGNITION SYSTEM * ELEC – C0NTINUITY INCORRECT 8.Main switch Refer to “CHECKING THE SWITCH”. CORRECT Replace the main switch. 9.Pickup coil resistance ● ● Disconnect the AC magneto coupler from the wire harness. Connect the pocket tester (Ω × 100) to the pickup coil terminal. Tester (+) lead → White/Red terminal 1 Tester (–) lead → White/Green terminal 2 ● Check the pickup coil for the specified resistance.
IGNITION SYSTEM * ELEC C0NTINUITY 11.Wiring connection ● Check the connections of the entire ignition system. Refer to “CIRCUIT DIAGRAM”. CORRECT POOR CONNECTION Properly connect the ignition system. Replace the CDI unit. Not For Resale 9 - 14 www.SmallEngineDiscount.
B B h Y Br/L W W W B B g Y L Y Br Br f W W W (BLACK) (BLACK) Y Br 1 Not For Resale 9 - 15 www.SmallEngineDiscount.
ELECTRIC STARTING SYSTEM ELEC – EB803020 TROUBLESHOOTING IF THE STARTER MOTOR FAILS TO OPERATE: Procedure Check: 1.Fuse (main, ignition) 2.Battery 3.Starter motor 4.Starter relay 5.Main switch 6.Engine stop switch 7.Start switch 8. Wiring connection (the entire starting system) NOTE: ● Remove the following part(s) before troubleshooting: 1)Seat 2)Fuel tank side panels 3)Fuel tank 4)Air cleaner case 5)Front carrier 6)Front fender panel ● Use the following special tool(s) for troubleshooting.
ELECTRIC STARTING SYSTEM * 3.Starter motor ● Connect the battery positive terminal 1 and starter motor cable 2 using a jumper lead 3 . Check the operation of the starter motor. * ● ● A wire that is used as a jumper lead must have the equivalent capacity or more as that of the battery lead, otherwise the jumper lead may burn. This check is likely to produce sparks, so be sure that no flammable gas or fluid is in the vicinity. Repair or replace the starter motor. TURNS 4.
ELECTRIC STARTING SYSTEM * ELEC 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 (left). INCORRECT 7.Start switch Refer to “CHECKING THE SWITCH”. CORRECT Replace the handlebar switch (left). EB803028 8.Wiring connection ● Check the connections of the entire starting system. Refer to “CIRCUIT DIAGRAM”.
ELECTRIC STARTING SYSTEM ELEC – + STARTER MOTOR Order 1 2 1 2 3 4 5 6 7 Job name/Part name Removing the starter motor Starter motor lead Starter motor/O-ring Disassembling the starter motor Bracket 1 Washer kit Bracket 2/bushing Shims Brush holder set Armature coil Yoke Q’ty Remarks Remove the parts in the order below. 1 1/1 Remove the parts in the order below. 1 1 1 1 1 Refer to “ASSEMBLING THE STARTER MOTOR”. For assembly, reverse the disassembly procedure. Not For Resale 9 - 19 www.
ELECTRIC STARTING SYSTEM ELEC – + CHECKING THE STARTER MOTOR 1.Check: ● 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) 27 mm (1.06 in) 3.Measure: ● Mica undercut b Out of specification → Scrape the mica using a hacksaw blade. Mica undercut: 0.7 mm (0.
ELECTRIC STARTING SYSTEM ELEC – + 5.Measure: ● Brush length a (each) Out of specification → Replace the brush holder set. Brush length: 12.5 mm (0.49 in) 5 mm (0.20 in) 6.Measure: ● Brush spring force Fatigue/out of specification → Replace the brush holder set. Brush spring force: 7.65 ~ 10.01 Nm (780 ~ 1,020 g, 27.54 ~ 36.03 oz) 7.Check: ● O-rings Wear/damage → Replace. ASSEMBLING THE STARTER MOTOR 1.
B B h (BLACK) (BLACK) Y Br Y Br W W W W/R W/G W W W R W/G W/L W/R W/G R Br/L W W W B B g i B Y L Y Br Br f W W W (BLACK) (BLACK) Y Br 1 R W/G W/R W/G W R W B L L B e L L B d R/B B R/B Br OFF ON 3 c (DARK GRAY) R/B L (BLACK) B W B R R Br Not For Resale 9 - 22 www.SmallEngineDiscount.
CHARGING SYSTEM ELEC – EB804010 TROUBLESHOOTING IF THE BATTERY IS NOT CHARGED: Procedure Check: 1.Fuse (main) 2.Battery 3.Charging voltage 4.Charging coil resistance 5.Wiring connections (the entire charging system) NOTE: ● Remove the following part(s) before troubleshooting: 1)Seat 2)Fuel tank side panels ● Use the following special tool(s) for troubleshooting. EB802011 Inductive tachometer: P/N. YU-8036-A Engine tachometer: P/N. 90890-03113 Pocket tester: P/N.
CHARGING SYSTEM ● ELEC – Start the engine and accelerate to about 3,000 r/min. Charging voltage: 14 V at 3,000 r/min NOTE: Use a fully charged battery. MEETS SPECIFICATION The charging circuit is not faulty. OUT OF SPECIFICATION EB804012 4.Charging coil resistance ● ● Disconnect the AC magneto coupler from the wire harness. Connect the pocket tester (Ω × 1) to the charging coils.
B B h (BLACK) (BLACK) Y Br Y Br W W W W/R W/G W W W R W/G W/L W/R W/G R Br/L W W W B B g i B Y L Y Br Br f W W W (BLACK) (BLACK) Y Br 1 R W/G W/R W/G W R W B L L B e L L B d R/B B R/B Br OFF ON 3 c (DARK GRAY) R/B L (BLACK) B W B R R Br Not For Resale 9 - 25 www.SmallEngineDiscount.
LIGHTING SYSTEM ELEC – EB805010 TROUBLESHOOTING IF THE HEADLIGHT AND/OR TAILLIGHT FAIL TO COME ON: Procedure Check: 1.Fuse (main, headlight) 2.Battery 3.Main switch 4.Light switch 5.Wiring connections (the entire lighting system) NOTE: ● Remove the following part(s) before troubleshooting: 1)Seat 2)Front carrier 3)Front fender panel ● Use the following special tool(s) for troubleshooting. EB802011 Pocket tester: P/N. YU-03112, 90890-03112 NO CONTINUITY 1.
LIGHTING SYSTEM * ELEC – + C0NTINUITY INCORRECT 3.Main switch Refer to “CHECKING THE SWITCH”. CORRECT Replace the main switch. INCORRECT 4.Light switch Refer to “CHECKING THE SWITCH”. CORRECT Light switch is faulty, replace the handlebar switch (left). EB805013 5.Wiring connection ● Check the connections of the entire lighting system. Refer to “WIRING DIAGRAM”. CORRECT POOR CONNECTION Properly connect the lighting system. Check the condition of each of the lighting system’s circuits.
LIGHTING SYSTEM ELEC – + 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 continuity. Replace the bulb and/or bulb socket. CONTINUITY 2.Voltage ● Connect the pocket tester (DC 20 V) to the headlight couplers. È É Tester (+) lead → Green terminal 1 or Yellow terminal 2 Tester (–) lead → Black terminal 3 È When the light switch is on “ É When the light switch is on “ ● ● ● ”. ”.
LIGHTING SYSTEM ELEC – + EB805021 2.If the taillight fails to come on: NO CONTINUITY 1.Bulb and bulb socket ● Check the bulb and bulb socket for continuity. Replace the bulb and/or bulb socket. CONTINUITY 2.Voltage ● 1 Connect the pocket tester (20 V) to the bulb socket coupler. L Y B Tester (+) lead → Blue lead 1 Tester (–) lead → Black lead 2 2 ● ● ● Turn the main switch to “ON”. Turn the light switch to “ ” or “ ”. Check the voltage (12 V) of the “Blue” lead on the bulb socket connector.
B B h (BLACK) (BLACK) Y Br Y Br W W W W/R W/G W W W R W/G W/L W/R W/G R Br/L W W W B B g i B Y L Y Br Br f W W W (BLACK) (BLACK) Y Br 1 R W/G W/R W/G W R W B L L B e L L B d R/B B R/B Br OFF ON 3 c (DARK GRAY) R/B L (BLACK) B W B R R Br Not For Resale 9 - 30 www.SmallEngineDiscount.
SIGNAL SYSTEM ELEC 3 Main switch 4 Backup fuse 5 Battery 6 Main fuse 9 Reverse switch 0 CDI unit D Speed sensor E Thermo switch 1 G Multi-function meter H Differential gear lock indicator light I Coolant temperature warning light J Reverse indicator light K Neutral indicator light L Park indicator light M High-range indicator light N Low-range indicator light O Low-range switch P High-range switch Q Neutral switch V On-command four-wheel drive switch and differential gear lock switch W Gear motor Z Igniti
SIGNAL SYSTEM ELEC – EB806010 TROUBLESHOOTING IF THE BRAKE LIGHT AND/OR INDICATOR LIGHT FAILS TO COME ON: Procedure Check: 1.Fuse (main, backup, ignition, signaling system) 2.Battery 3.Main switch 4.Wiring connections (the entire signal system) NOTE: ● Remove the following part(s) before troubleshooting: 1)Seat 2)Fuel tank 3)Air filter case 4)Front carrier 5)Front fender panel ● Use the following special tool(s) for troubleshooting. Pocket tester: P/N. YU-03112, 90890-03112 EB802011 1.
SIGNAL SYSTEM * ELEC C0NTINUITY INCORRECT 3.Main switch Refer to “CHECKING THE SWITCH”. CORRECT EB806011 POOR CONNECTION 4.Wiring connections ● Replace the main switch. 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 system’s circuits. Refer to “CHECKING THE SIGNAL SYSTEM”. Not For Resale 9 - 33 www.SmallEngineDiscount.
SIGNAL SYSTEM ELEC – + 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 continuity. CONTINUITY Replace the bulb and/or bulb socket. NO CONTINUITY 2.Brake light switches Refer to “CHECKING THE SWITCH”. CONTINUITY Replace the brake light switch. 3.Voltage ● Connect the pocket tester (DC 20 V) to the bulb socket connector.
SIGNAL SYSTEM ELEC EB806024 2.If the indicator lights fails to come on: NO CONTINUITY 1.Neutral switch Refer to “CHECKING THE SWITCH”. CONTINUITY Replace the neutral switch. NO CONTINUITY 2.High-range switch Refer to “CHECKING THE SWITCH”. CONTINUITY Replace the high-range switch. NO CONTINUITY 3.Low-range switch Refer to “CHECKING THE SWITCH”. CONTINUITY Replace the low-range switch. NO CONTINUITY 4.Reverse switch Refer to “CHECKING THE SWITCH”. CONTINUITY Replace the reverse switch.
SIGNAL SYSTEM ELEC – + 3.If the coolant temperature warning light does not come on: ● Check that the light comes on when the main switch is set to “ON”. ● Check that the light comes on when the coolant temperature is 120 ± 3 °C (248 ± 5.4 °F) or higher and that the light remains on when the coolant temperature drops to 113 °C (235.4 °F). 1.Thermo switch 1 ● ● ● ● Remove the thermo switch 1 from the cylinder head. Connect the pocket tester (Ω × 1) to the thermo switch 1 1.
B B h (BLACK) (BLACK) Y Br Y Br W W W W/R W/G W W W R W/G W/L W/R W/G R Br/L W W W B B g i B Y L Y Br Br f W W W (BLACK) (BLACK) Y Br 1 R W/G W/R W/G W R W B L L B e L L B d R/B B R/B Br OFF ON 3 c (DARK GRAY) R/B L (BLACK) B W B R R Br Not For Resale 9 - 37 www.SmallEngineDiscount.
COOLING SYSTEM ELEC – TROUBLESHOOTING IF THE FAN MOTOR DOES NOT MOVE: Procedure Check: 1.Fuse (main) 2.Battery 3.Main switch 4.Fan motor 5.Circuit breaker (fan motor) 6.Thermo switch 2 7.Wiring connection (the entire cooling system) NOTE: ● Remove the following part(s) before troubleshooting. 1)Seat 2)Front carrier 3)Front fender ● Use the following special tool(s) for troubleshooting. Pocket tester: P/N. YU-03112, 90890-03112 EB802011 NO CONTINUITY 1.Fuse (main) Refer to “CHECKING THE SWITCH”.
COOLING SYSTEM * ELEC 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 ● Check the operation of the fan motor. Replace the fan motor. TURNS 5.Circuit breaker (fan motor) ● ● Remove the circuit breaker from the wire harness. Connect the pocket tester (Ω × 1) to the circuit breaker.
COOLING SYSTEM * ELEC – 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 thermometer 3 to record the temperatures. Coolant temperature Continuity Thermo switch 2 Less than 86 ± 3 °C 1 NO (186.8 ± 5.4 °F) More than 86 ± 3 °C 2 YES (186.8 ± 5.4 °F) More than 80 ± 3 °C 3 YES (176 ± 5.
COOLING SYSTEM * C0NTINUITY EB803028 POOR CONNECTION 7.Wiring connection ● ELEC Check the connections of the entire starting system. Refer to “CIRCUIT DIAGRAM”. Properly connect the cooling system. CORRECT This circuit is not faulty. Not For Resale 9 - 41 www.SmallEngineDiscount.
W W W W/R W/G W W W R W/G W/L W/R W/G R 1 Br/L W W W Br f W W W R W/G W/R W/G W R W R/B L (BLACK) B W c B B h (BLACK) (BLACK) Y Br Y B B g i (BLACK) (BLACK) Y Br B Y L Y Br B L L B e (DARK GRAY) L L B d R/B 3 Main switch 5 Battery 6 Main fuse 0 CDI unit R Four-wheel drive fuse S Four-wheel drive relay 1 T Four-wheel drive relay 2 U Four-wheel drive relay 3 V On-command four-wheel drive switch and differential gear lock switch W Gear motor Br B R/B Br OFF ON
2WD/4WD SELECTING SYSTEM ELEC – + EB803020 TROUBLESHOOTING IF THE GEAR MOTOR FAILS TO OPERATE: Procedure Check: 1.Fuse (main, four-wheel drive) 2.Battery 3.Main switch 4.Four-wheel drive relay 1 5.Four-wheel drive relay 2 6.Four-wheel drive relay 3 7.On-command four-wheel drive switch and differential gear lock switch 8.Gear motor 9.
2WD/4WD SELECTING SYSTEM * ELEC 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.
2WD/4WD SELECTING SYSTEM * ELEC – + 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.
2WD/4WD SELECTING SYSTEM * ● ● + È Disconnect the gear motor coupler. Remove the gear motor from the differential 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). È Check that the pinion gear 2 turns counterclockwise. É Check that the pinion gear 2 turns clockwise. ● – C0NTINUITY 8.
STARTING FAILURE/HARD STARTING TRBL 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 checking, adjusting and replacing of parts.
STARTING FAILURE/HARD STARTING/POOR IDLE SPEED PERFORMANCE/POOR MEDIUM AND HIGH-SPEED PERFORMANCE COMPRESSION SYSTEM Cylinder and cylinder head ● Loose spark plug ● Loose cylinder head or cylinder ● Broken cylinder head gasket ● Broken cylinder gasket ● Worn, damaged or seized cylinder Piston and piston rings ● Improperly installed piston ring ● Worn, fatigued or broken piston ring ● Seized piston ring ● Seized or damaged piston TRBL SHTG Valve, camshaft and crankshaft ● Improperly sealed valve ● Improper
FAULTY DRIVE TRAIN TRBL SHTG FAULTY DRIVE TRAIN The following conditions may indicate damaged shaft drive components: Symptoms 1.A pronounced hesitation or “jerky” movement during acceleration, deceleration, or sustained speed. (This must not be confused with engine surging or transmission characteristics.) 2.A “rolling rumble” noticeable at low speed; a high-pitched whine; a “clunk” from a shaft drive component or area. 3.
FAULTY GEAR SHIFTING/ FAULTY CLUTCH PERFORMANCE TRBL SHTG FAULTY GEAR SHIFTING HARD SHIFTING Refer to “CLUTCH SLIPPING/DRAGGING-CLUTCH DRAGGING”.
FAULTY CLUTCH PERFORMANCE/ OVERHEATING/FAULTY BRAKE POOR SPEED PERFORMANCE V-belt ● Oil or grease on the V-belt Primary pulley weight ● Faulty operation ● Worn primary pulley weight Primary fixed sheave ● Worn primary fixed sheave TRBL SHTG Primary sliding sheave ● Worn primary sliding sheave Secondary fixed sheave ● Worn secondary fixed sheave Secondary sliding sheave ● Worn secondary sliding sheave OVERHEATING OVERHEATING Ignition system ● Improper spark plug gap ● Improper spark plug heat range ● Faul
SHOCK ABSORBER MALFUNCTION/UNSTABLE HANDLING/LIGHTING SYSTEM TRBL SHTG SHOCK ABSORBER MALFUNCTION MALFUNCTION ● Bent or damaged damper rod ● Damaged oil seal lip ● Fatigued shock absorber spring UNSTABLE HANDLING UNSTABLE HANDLING Handlebar ● Improperly installed or bent Steering ● Incorrect toe-in ● Bent steering stem ● Improperly installed steering stem ● Damaged bearing or bearing race ● Bent tie-rods ● Deformed steering knuckles Tires ● Uneven tire pressures on both sides ● Incorrect tire pressure ●
YFM450FAR WIRING DIAGRAM A W/B B B/R B Br Sb L/B L/B Sb Br R/BBr/B B/Y B/Y Br/B R/B WIRE HARNESS SUB-WIRE HARNESS 2 B/R B W/B WIRE HARNESS SUB-WIRE HARNESS 1 C D O B B O (GRAY) (GRAY) WIRE HARNESS SUB-WIRE HARNESS 3 W/R Sb Sb W/R L/W G/W G/W L/W (BLACK) (BLACK) WIRE HARNESS SUB-WIRE HARNESS 4 R/B L/W O B W Y/B B/Y R W/R W/G B/R G/L (BLACK) (BLACK) R W/G W/R W/G W/G R R W/G W/R W/G W/L W/R W W W W W W 1 W W W G/W W/B Sb G/R (BLACK) R W W W R 2 G/W B R 4 W R
YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN Not For Resale www.SmallEngineDiscount.com PRINTED IN U.S.A.
