1999-2005 YAMAHA YFM400 BIG BEAR ATV’S SERVICE MANUAL – PDF DOWNLOAD by www.heydownloads.com

YFM400FWNP SUPPLEMENTARY SERVICE MANUAL LIT-11616-15-22

5FU-F8197-E1

FOREWORD This Supplementary Service Manual has been prepared to introduce new service and new data for the YFM400FWNP. For complete information on service procedures, it is necessary to use this Supplementary Service Manual together with the following manual. YFM400FWNM/YFM400FWNMC SERVICE MANUAL: LIT-11616-13-22 (5FU-F8197-E0)

YFM400FWNP SUPPLEMENTARY SERVICE MANUAL ď&#x203A;&#x2122; 2001 by Yamaha Motor Corporation, U.S.A. First Edition, June 2001 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-11616-15-22

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. Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable. NOTE: Designs and specifications are subject to change without notice.

IMPORTANT INFORMATION Particularly important information is distinguished in this manual by the following notations. The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

WARNING

CAUTION: NOTE:

Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander or a person inspecting or repairing the machine. A CAUTION indicates special precautions that must be taken to avoid damage to the machine. A NOTE provides key information to make procedures easier or clearer.

HOW TO USE THIS MANUAL CONSTRUCTION OF THIS MANUAL This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”) 1st title 1:

This is a chapter with its symbol on the upper right of each page.

2nd title 2:

This title appears on the upper of each page on the left of the chapter symbol. (For the chapter “Periodic inspection and adjustment” the 3rd title appears.)

3rd title 3:

This is a final title.

MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspections. A set of particularly important procedure 4 is placed between a line of asterisks “*” with each procedure preceded by “●”. IMPORTANT FEATURES ● Data and a special tool are framed in a box preceded by a relevant symbol 5. ● An encircled numeral 6 indicates a part name, and an encircled alphabetical letter data or an alignment mark 7, the others being indicated by an alphabetical letter in a box 8. ● A condition of a faulty component will precede an arrow symbol 9 and the course of action will follow it. EXPLODED DIAGRAM Each chapter provides exploded diagrams before each disassembly section for ease in identifying correct disassembly and assembly procedures.

EB003000

GEN INFO

ILLUSTRATED SYMBOLS Illustrated symbols 1 to 9 are printed on the top right of each page and indicate the subject of each chapter.

SPEC

CHK ADJ

1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Carburetion 6 Drive train 7 Chassis 8 Electrical 9 Troubleshooting

ENG

CARB

DRIV

CHAS

–

ELEC

Illustrated symbols 0 to F are used to identify the specifications appearing in the text.

0 Filling fluid A Lubricant B Special tool C Torque D Wear limit, clearance E Engine speed F Ω, V, A

TRBL SHTG

E J

K B

M M

Illustrated symbols G to M in the exploded diagrams indicate the types of lubricants and lubrication points.

New

G Apply engine oil H Apply gear oil I Apply molybdenum disulfide oil J Apply wheel bearing grease K Apply lightweight lithium soap base grease L Apply molybdenum disulfide grease M Apply silicon grease

Illustrated symbols N to O in the exploded diagrams indicate where to apply a locking agent N and when to install a new part O. N Apply the locking agent (LOCTITE) O Replace

CONTENTS SPECIFICATIONS ........................................................................................... 1 GENERAL SPECIFICATIONS ................................................................. 1 MAINTENANCE SPECIFICATIONS ........................................................ 2 ENGINE................................................................................................ 2 CHASSIS.............................................................................................. 3 ELECTRICAL ....................................................................................... 4 CABLE ROUTING .................................................................................... 5 PERIODIC CHECKS AND ADJUSTMENTS ................................................. 16 INTRODUCTION .................................................................................... 16 PERIODIC MAINTENANCE/LUBRICATION INTERVALS ..................... 16 CHASSIS ................................................................................................ 18 ADJUSTING THE FRONT BRAKE .................................................... 18 ADJUSTING THE REAR BRAKE LIGHT SWITCH............................ 18 DRIVE TRAIN ................................................................................................. 19 CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR ............. 19 ASSEMBLING THE DIFFERENTIAL GEAR ...................................... 21 MEASURING AND ADJUSTING THE DIFFERENTIAL GEAR LASH .................................................... 22 ELECTRICAL ................................................................................................. 24 CHECKING THE SWITCH ..................................................................... 24 CHECKING THE SWITCH ................................................................. 24 CHECKING A SWITCH SHOWN IN THE MANUAL .......................... 24 IGNITION SYSTEM ................................................................................ 25 CIRCUIT DIAGRAM ........................................................................... 25 TROUBLESHOOTING ....................................................................... 26 ELECTRIC STARTING SYSTEM ........................................................... 31 CIRCUIT DIAGRAM ........................................................................... 31 TROUBLESHOOTING ....................................................................... 32 LIGHTING SYSTEM ............................................................................... 35 CIRCUIT DIAGRAM ........................................................................... 35 CHECKING THE LIGHTING SYSTEM .............................................. 36 SIGNAL SYSTEM ................................................................................... 37 CIRCUIT DIAGRAM ........................................................................... 37 TROUBLESHOOTING ....................................................................... 38 CHECKING THE SIGNAL SYSTEM .................................................. 40 2WD/4WD SELECTING SYSTEM ......................................................... 42 CIRCUIT DIAGRAM ........................................................................... 42 TROUBLESHOOTING ....................................................................... 43 YFM400FWNP WIRING DIAGRAM

GENERAL SPECIFICATIONS

SPEC

SPECIFICATIONS GENERAL SPECIFICATIONS Model

YFM400FWNP

Model code: Oil type or grade: Engine oil

5FUA (USA)

API service SE, SF, SG type or higher

Final gear oil Differential gear oil Differential gear case oil Periodic oil change Total amount Chassis: Frame type Caster angle Camber angle Kingpin angle Trail Tread (STD) Tread (STD) Toe-in Brake: Front brake Rear brake Bulb wattage × quantity: Headlight Tail/brake light Meter light Neutral indicator light Reverse indicator light Oil temperature warning light Four-wheel drive indicator light

SAE 80 API “GL-4” Hypoid gear oil SAE 80 API “GL-4” Hypoid gear oil 0.35 L (0.31 Imp qt, 0.37 US qt) 0.4 L (0.35 Imp qt, 0.42 US qt)

front rear

type operation type operation

Steel tube frame 4° 1° 13° 21 mm (0.83 in) 860 mm (33.86 in) 820 mm (32.28 in) 5 ~ 15 mm (0.20 ~ 0.59 in) Dual disc brake Right hand operation Drum brake Left hand and right foot operation 12 V 30 W/30 W × 2 12 V 5 W/21 W × 1 12 V 3.4 W × 1 12 V 1.7 W × 1 12 V 1.7 W × 1 12 V 1.7 W × 1 12 V 1.7 W × 1

–1–

MAINTENANCE SPECIFICATIONS

SPEC

MAINTENANCE SPECIFICATIONS ENGINE Model

YFM400FWNP

Cylinder:

Bore size Out of round limit * Measuring point <Wear limit> Rocker arm/rocker arm shaft: Bearing inside diameter <Limit> Shaft outside diameter <Limit> Arm-to-shaft clearance <Limit> Carburetor: I. D. mark Main jet Main air jet Jet needle Needle jet Pilot air jet Pilot air jet Pilot outlet Pilot jet Bypass 1 Bypass 2 Bypass 3 Valve seat size Starter jet Starter jet Throttle valve size Float height Fuel level Engine idle speed Intake vacuum

82.97 ~ 83.02 mm (3.267 ~ 3.269 in) 0.05 mm (0.0020 in) 40 mm (1.57 in) <83.15 mm (3.274 in)> 11.980 ~ 11.998 mm (0.4717 ~ 0.4724 in) <12.058 mm (0.4747 in)> 11.961 ~ 11.971 mm (0.4709 ~ 0.4713 in) <11.931 mm (0.4697 in)> 0.009 ~ 0.037 mm (0.0004 ~ 0.0015 in) <0.08 mm (0.0031 in)>

(M.J.) (M.A.J.) (J.N.) (N.J.) (P.A.J.1) (P.A.J.2) (P.O.) (P.J.) (B.P.1) (B.P.2) (B.P.3) (V.S.) (G.S.1) (G.S.2) (Th.V.) (F.H.) (F.L.)

5FUA 12 #112.5 #70 5EP4-55-3 P-0M (#826) #80 1.3 0.8 #17.5 0.8 0.8 0.8 2.0 #70 0.9 #100 12 ~ 14 mm (0.47 ~ 0.55 in) 3 ~ 4 mm (0.12 ~ 0.16 in) 1,450 ~ 1,550 r/min 33.3 kPa (250 mmHg, 10 inHg)

–2–

MAINTENANCE SPECIFICATIONS

SPEC

CHASSIS Model Front suspension: Shock absorber travel Fork spring free length Spring rate (K1) Stroke (K1) Optional spring Rear suspension: Shock absorber travel Spring free length Fitting length Spring rate (K1) Stroke (K1) Optional spring Brake lever & brake pedal: Brake lever free play (at lever end) Brake lever free play (left) Brake pedal position Brake pedal free play Throttle lever free play

YFM400FWNP 102 mm (4.02 in) 318.4 mm (12.5 in) 12.3 N/mm (1.25 kg/mm, 70.2 lb/in) 0 ~ 102 mm (0.00 ~ 4.02 in) No 100 mm (3.94 in) 296 mm (11.7 in) 253 mm (9.96 in) 30.4 N/mm (3.10 kg/mm, 174 lb/in) 0 ~ 100 mm (0.00 ~ 3.94 in) No 0 mm (0 in) 5 ~ 8 mm (0.20 ~ 0.31 in) 5 mm (0.2 in) 20 ~ 30 mm (0.8 ~ 1.2 in) 3 ~ 5 mm (0.1 ~ 0.2 in)

Tightening torques Part to be tightened

Thread size

M8 M8 M8 M10 M10 M10 M10 M12

–3–

Tightening torque Nm

m·kg

ft·lb

34 34 34 69 69 69 64 30

3.4 3.4 3.4 6.9 6.9 6.9 6.4 3.0

24 24 24 50 50 50 46 22

Remarks

MAINTENANCE SPECIFICATIONS

SPEC

ELECTRICAL Model

10° at 1,000 r/min 33° at 5,000 r/min Digital type

Ignition timing (B.T.D.C.)

Ignition system: Ignition timing (B.T.D.C.) Advanced timing (B.T.D.C.) Advancer type

YFM400FWNP

Engine speed (× 10³ r/min)

C.D.I.: Magneto model/manufacturer Pickup coil resistance/color C.D.I. unit model/manufacturer Rectifier: Regulator type Model/manufacturer No load regulated voltage Capacity Withstand voltage Circuit breaker: Type Amperage for individual circuit Main fuse Headlight fuse Ignition fuse Auxiliary DC jack fuse Carburetor warmer fuse Reserve fuse

F4T423/MITSUBISHI 459 ~ 561 Ω at 20 °C (68 °F)/White/Red – White/Green F8T38673/MITSUBISHI Semi conductor-short circuit SH640E-11/SHINDENGEN 14.1 ~ 14.9 V 14 A 200 V Fuse 30 A × 1 15 A × 1 10 A × 1 10 A × 1 10 A × 1 30 A × 1 15 A × 1 10 A × 1

–4–

CABLE ROUTING

SPEC

CABLE ROUTING È Fasten the front brake light switch lead and the on-command four-wheel drive switch lead with a plastic band. É Fasten the starter cable, rear brake lever switch lead, and handlebar switch (left) lead with a plastic band.

1 Rear brake cable 2 Starter cable 3 Front brake hose 4 Front brake light switch lead 5 On-command four-wheel drive switch lead 6 Throttle cable 7 Fuel tank breather hose 8 Rear brake lever switch lead 9 Handlebar switch (left) lead

–5–

CABLE ROUTING

SPEC

A Headlight lead B Gear motor and four-wheel drive switch lead C Differential gear case breather hose D Auxiliary DC jack connector E Speedometer cable F Front brake hose

1 Throttle cable 2 Reverse control cable 3 Rear brake cable 4 Handlebar switch (left) lead 5 Starter cable 6 Neutral indicator light, reverse indicator light, and meter light lead 7 Rear brake lever switch lead 8 Oil temperature warning light and four-wheel drive indicator light lead 9 Main switch lead 0 Fan motor lead

â&#x20AC;&#x201C;6â&#x20AC;&#x201C;

CABLE ROUTING

SPEC

È Fasten the headlight lead and fan motor lead with a plastic band. É Fasten the gear motor and four-wheel drive switch lead with a plastic band. Ê Clamp the gear motor and four-wheel drive switch lead and differential gear case breather hose. Ë Fasten the headlight lead with a plastic band.

–7–

CABLE ROUTING

SPEC

A Carburetor warmer lead B CDI magneto lead C Starter motor lead D Oil hose E Gear motor and four-wheel drive switch lead

1 Headlight lead 2 Fan motor lead 3 Final gear case breather hose 4 Main switch lead 5 Neutral indicator light, reverse indicator light, and meter light lead 6 Starter cable 7 Oil temperature warning light and four-wheel drive indicator light lead 8 Fuel tank breather hose 9 Air vent hose 0 Rear brake breather hose

È Pass the final gear case breather hose more than 50 mm (2.0 in) through the bracket. É Clamp the starter cable and final gear case breather hose with a plastic clamp. Ê Fasten the final gear case breather hose and carburetor warmer lead with a plastic clamp.

–8–

CABLE ROUTING

SPEC

C Speedometer cable D Reverse control cable E Starter motor lead F CDI magneto lead G Vacuum chamber breather hose

1 Carburetor warmer lead 2 Fuse box lead 3 Negative battery lead 4 Tail/brake light lead 5 Final gear case breather hose 6 Thermo unit lead 7 Carburetor overflow hose 8 Air vent hose 9 Rear brake breather hose 0 Wire harness A Gear position switch lead B Rear brake cable

È Clamp the wire harness and starter motor lead with a plastic clamp. É Clamp the wire harness and tail/brake lead light with a plastic clamp.

–9–

CABLE ROUTING

SPEC

Ê Route the rear brake breather hose behind the reverse control cable and rear brake cable from the area shown to the fuel tank mounting location. Ë Leave clearance between the rear brake cable, rear brake breather hose, thermo unit lead, reverse control cable, and speedometer cable in the area shown. Ì Route the gear position switch lead between the engine and the cables and hoses. Í Pass the air vent hose and rear brake breather hose through the hole in the fuel tank. Î Attach the rear brake cable to the rear brake breather hose with a clip. Ï 100 mm (3.9 in) Ð Pass the rear brake cable and rear brake cable breather hose through the guide. Ñ 57 mm (2.2 in) Ò Pass the rear brake breather hose through the hose guide. Ó Pass the final gear case breather hose through the hose guide.

– 10 –

CABLE ROUTING

SPEC

È Attach a clip to the wire harness. É Clamp the wire harness, rear brake cable, reverse control cable, and speedometer cable with a plastic clamp. Ê 140 ~ 160 mm (5.5 ~ 6.3 in) Ë Fasten the wire harness and spark plug lead to the frame with a plastic band. Ì Make sure that the oil hoses do not touch each other or the frame in the area shown. Í After routing the cables, bend the cable guide as shown.

1 Ignition coil 2 Wire harness 3 Speedometer cable 4 Rear brake cable 5 Reverse control cable 6 Headlight lead 7 Ignition coil lead 8 Oil hose 9 Throttle cable

– 11 –

CABLE ROUTING

SPEC

È Fasten the wire harness to the frame with a plastic band. É 20 ~ 40 mm (0.8 ~ 1.6 in)

1 Gear position switch lead 2 Thermo unit lead 3 Reverse control cable 4 Rear brake cable 5 Rear brake breather hose

– 12 –

CABLE ROUTING

SPEC

È Clamp the headlight lead (wire harness end) and differential gear case breather hose. É Pass the differential gear case breather hose more than 50 mm (2.0 in) through the bracket. Ê Fasten the wire harness and spark plug lead to the frame with a plastic band. Ë Fasten the wire harness to the frame with a plastic band. Ì Pass the rear brake breather hose and air vent hose more than 10 ~ 20 mm (0.4 ~ 0.8 in) through the hose guide on the duct.

1 Headlight lead 2 Auxiliary DC jack lead 3 Auxiliary DC jack 4 Throttle cable 5 Rear brake breather hose 6 Air vent hose 7 Carburetor warmer lead 8 Wire harness 9 Differential gear case breather hose 0 Fan motor lead

– 13 –

CABLE ROUTING Í Place the air vent hose on the left and the rear brake breather hose on the right. Î Clamp the wire harness and differential gear case breather hose to the frame. Ï Clamp the wire harness.

– 14 –

SPEC

CABLE ROUTING

SPEC

È Place the fan motor control unit coupler inside the battery box. É Do not pinch the leads.

1 Starter relay 2 Positive battery lead 3 Fan motor control unit 4 Battery 5 Rectifier/regulator 6 CDI unit 7 Negative battery lead 8 Fan motor relay 9 Four-wheel drive fuse 0 Fuse box

– 15 –

INTRODUCTION/ PERIODIC MAINTENANCE/LUBRICATION INTERVALS

CHK ADJ

EB300000

PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended inspections 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. All service technicians should be familiar with this entire chapter. EB301000

PERIODIC MAINTENANCE/LUBRICATION INTERVALS INITIAL ITEM

ROUTINE

1 month

Valves*

• Check valve clearance. • Adjust if necessary.

Spark plug

• Check condition. • Adjust gap and clean. • Replace if necessary.

Air filter

• Clean. • Replace if necessary.

Carburetor*

• Check and adjust idle speed/starter operation. • Adjust if necessary.

Cylinder head cover breather system*

• Check breather hose for cracks or damage. • Replace if necessary.

Exhaust system*

• Check leakage. • Retighten if necessary. • Replace gasket if necessary.

Spark arrester

• Clean.

Fuel line*

• Check fuel hose for cracks or damage. • Replace if necessary.

Engine oil

• Replace (Warm engine before draining).

Engine oil filter

• Replace.

Engine oil strainer

• Clean.

Final gear oil

• Check oil level/oil leakage. • Replace every 12 months.

Differential gear oil

EVERY 6 months

6 months

Every 20 ~ 40 hours (More often in wet or dusty areas.)

Front brake*

• Check operation/fluid leakage/see NOTE page 17. • Correct if necessary.

Rear brake*

• Check operation. • Adjust if necessary.

Clutch*

• Check operation. • Adjust if necessary.

Reverse release cable*

• Check operation. • Adjust if necessary.

Wheels*

• Check balance/damage/run out. • Repair if necessary.

Wheel bearings*

• Check bearing assembly for looseness/damage. • Replace if damaged.

Steering system*

• • • •

Check operation. Replace if damaged. Check toe-in. Adjust if necessary.

Drive shaft universal • Lubricate. joint* Front axle boots*

• Check operation. • Replace if damaged.

Fittings and Fasteners*

• Check all chassis fittings and fasteners. • Correct if necessary.

3 months

It is recommended that these items be serviced by a Yamaha dealer. – 16 –

1 year

PERIODIC MAINTENANCE/LUBRICATION INTERVALS

CHK ADJ

NOTE: ● Recommended brake fluid: DOT 4 ● Brake fluid replacement: 1.When disassembling the master cylinder or caliper, replace the brake fluid. Normally check the brake fluid level and add fluid as required. 2.On the inner parts of the master cylinder and caliper, replace the oil seals every two years. 3.Replace the brake hoses every four years, or if cracked or damaged.

– 17 –

ADJUSTING THE FRONT BRAKE/ ADJUSTING THE REAR BRAKE LIGHT SWITCH

CHK ADJ

CHASSIS ADJUSTING THE FRONT BRAKE 1.Check: ● Brake lever free play a Out of specification → Bleed the front brake system. Refer to “AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)” in CHAPTER 3. (Manual No.: 5FU-F8197-E0) Brake lever free play (at brake lever end): 0 mm (0 in) ADJUSTING THE REAR BRAKE LIGHT SWITCH NOTE: The rear brake light switch is operated by movement of the brake pedal. The rear brake light switch is properly adjusted when the brake light comes on just before the braking effect starts.

1.Check: ● Rear brake light operation timing Incorrect → Adjust. 2.Adjust: ● Rear brake light 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.

***********************************************

– 18 –

CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR

DRIV

DRIVE TRAIN CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR

Order 1 2 3 4 5 6 7 8 9 0 A B C

Job name/Part name Disassembling the differential gear Gear motor/O-ring Four-wheel drive switch Nut Washer Yoke Dust seal Circlip Drive gear/bearing/O-ring Stopper bolt/shaft Shift fork sliding gear Shift fork 2WD/4WD shift sleeve Differential gear case cover

Q’ty 1/1 1 1 1 1 1 1 1/1/1 1/1 1 1 1 1

– 19 –

Remarks Disassemble the parts in the order below.

CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR

Order D E F G H I

Job name/Part name Shim (left) Differential gear assembly Shim (right) Circlip/bearing Drive pinion gear Differential gear case

Q’ty

DRIV

Remarks

1 1 1/1 1 1 For assembly, reverse the disassembly procedure.

– 20 –

CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR

DRIV

ASSEMBLING THE DIFFERENTIAL GEAR 1.Measure: ● Gear lash Refer to “MEASURING AND ADJUSTING THE DIFFERENTIAL GEAR LASH”.

2.Install: ● Gear motor

*********************************************** Servomotor installation steps: ● Make sure that the gear motor and shift fork sliding gear are in the 2WD position. ● While aligning the gear motor stopper a with the differential gear case boss b, mesh the pinion gear (gear motor) and shift fork sliding gear together. ● Push the gear motor into the differential gear case. ● Rotate the gear motor counterclockwise until it lines up with the gear motor mounting hole. NOTE: When the gear motor is in this position, the spring inside the gear motor has been preloaded for positive engagement. ● Install

the gear motor bolts. ● Fill the differential with the specified grade and quantity of oil.

***********************************************

3.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.

– 21 –

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. YM-01467, 90890-01467 a Measuring point is 30 mm (1.18 in)

5.Measure: ● Gear lash Gently rotate the drive gear from engagement to engagement. Differential gear lash: 0.09 ~ 0.47 mm (0.004 ~ 0.019 in) NOTE: Measure the gear lash at four positions. Rotate the shaft 90° each time.

– 22 –

CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR

DRIV

Adjusting the differential gear lash 1.Remove: ● Shim(s) (left) 1 ● Differential gear assembly 2 ● Shim(s) (right) 3

2.Adjust: ● Gear lash

*********************************************** 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 (0.002 in): Reduce right shim thickness by 0.1 mm (0.004 in) for every 0.1 mm (0.004 in) of left shim increase. ● If it is necessary to reduce by more than 0.1 mm (0.004 in): Increase right shim thickness by 0.1 mm (0.004 in) for every 0.1 mm of left shim decreased. Ring gear shim (left and right)

Thickness (mm)

0.1 0.2 0.3 0.4

0.5 1.0 1.5

***********************************************

– 23 –

CHECKING THE SWITCH

ELEC

–

ELECTRICAL 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 A SWITCH SHOWN IN THE MANUAL The terminal connections for switches (main switch, handlebar switch, engine stop switch, light switch, etc.) are shown in a chart similar to the one on the left. This chart shows the switch positions in the column and the switch lead colors in the top row. For each switch position, “ ” indicates the terminals with continuity. The example chart shows that: 1 There is continuity between the “Red and Brown” leads when the switch is set to “ON”.

– 24 –

G/Y

– 25 –

Y B

R/W

[

(GRAY)

G/Y R/W

(GRAY)

Br G/Y

R W/G

W/L W/R

W/R W/G

W/G R

(BLACK)

R/W Y

Y R/W

Br/L

G B

L/B

Y B

R/W

(BLACK)

R/B R/W

L/B G

R/W R/B

G L/B

Y R/Y

Br/L

(BROWN)

L/B

B Sb

L/R Br/L

L/R

L/B

(BLACK)

L/B L/R

R Q

2WD 4WD

Br/L

Br/L Br/L

(BROWN)

L/B

L/G B

Br L/R

Br/L Br/L

Br/L R

Br/L

(BLACK)

4 R L/B L/W

L/B

L/W

(BLACK)

Br/L

R/B

W/L

W/L R/W

W Br/L

L/W R/B

W/R W/G

R/B W/L

Br/L W

G/Y

(BLACK)

Sb G/Y

W/L

L/B

(BLACK)

Br/L

O B

(BLACK)

W/G B

W/G

R/B

R/W

G/L

R/W

L G/L

L R/W Sb B

G/L

Sb G/L

Br G

(BLACK)

B Sb

FGH

W/L W/G

W/G W/L

R/W

R/B

R/W R/B

1 CDI magneto 3 Main switch 4 Battery 5 Main fuse 8 CDI unit 9 Ignition coil 0 Spark plug U Engine stop switch a Ignition fuse

R/W

ELEC

Y L

W G

Y G

OFF PUSH

R/Y

Y G

OFF ON

R/W

ON OFF

] ` a

L Y G

R/Y

R/B

Br/L R/W

R/Y Y

Y R/Y

Br/L R/W

(BLACK) (BLACK)

R/W

(BLACK)

R W

OFF LO HI

W W W

(BLACK)

R/W

W W W

W/R W/G

R W/G

R W/R W/G

R/B L/W O

IGNITION SYSTEM – +

EB802000

IGNITION SYSTEM

CIRCUIT DIAGRAM

IGNITION SYSTEM

ELEC

–

EB802010

TROUBLESHOOTING IF THE IGNITION SYSTEM FAILS TO OPERATE (NO SPARK OR INTERMITTENT SPARK):

Procedure Check: 1.Fuse (main and 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.Wiring connection (the entire ignition system)

NOTE: ● Remove the following part(s) before troubleshooting: 1)Seat 2)Front carrier 3)Front fender 4)Rear carrier 5)Rear fender ● Use the following special tool(s) for troubleshooting.

Dynamic spark tester: P/N. YM-34487 Pocket tester: P/N. YU-03112, 90890-03112

EB802011

NO CONTINUITY

1.Fuse (main and ignition) Refer to “CHECKING THE SWITCH”. CONTINUITY

Replace the fuse.

EB802012

2.Battery ●

INCORRECT

Check the battery condition. Refer to “BATTERY INSPECTION” in CHAPTER 3. (Manual No.: 5FU-F8197-E0) ●

Open-circuit voltage: 12.8 V or more at 20 °C (68 °F)

●

Clean the battery terminals. Recharge or replace the battery.

CORRECT 3.Spark plug ● ● ●

Standard spark plug: DR8EA

Check the spark plug condition. Check the spark plug type. Check the spark plug gap. Refer to “SPARK PLUG INSPECTION” in CHAPTER 3. (Manual No.: 5FU-F8197-E0) – 26 –

IGNITION SYSTEM

ELEC

INCORRECT

Spark plug gap: 0.6 ~ 0.7 mm (0.024 ~ 0.028 in) 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.

MEETS SPECIFICATION

Minimum spark gap: 6.0 mm (0.24 in)

The ignition system is not faulty.

OUT OF SPECIFICATION OR NO SPARK 5.Spark plug cap resistance ● ●

●

Remove the spark plug cap. Connect the pocket tester (Ω × 1k) to the spark plug cap.

OUT OF SPECIFICATION

Check that the spark plug cap has the specified resistance. Spark plug cap resistance: 10 kΩ at 20 °C (68 °F)

Replace the spark plug cap.

MEETS SPECIFICATION

– 27 –

–

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. Tester (+) lead → Orange lead terminal Tester (–) lead → Spark plug lead

●

Check that the secondary coil has the specified resistance. Secondary coil resistance: 6.32 ~ 9.48 kΩ at 20 °C (68 °F) BOTH MEET SPECIFICATION Replace the ignition coil. INCORRECT

7.Engine stop switch Refer to “CHECKING THE SWITCH”. CORRECT

Replace the handlebar switch (left).

– 28 –

–

IGNITION SYSTEM

ELEC

–

C0NTINUITY INCORRECT

8.Main switch Refer to “CHECKING THE SWITCH”. CORRECT

Replace the main switch.

9.Pickup coil resistance ●

●

Disconnect the CDI 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.

OUT OF SPECIFICATION

Pickup coil resistance: 459 ~ 561 Ω at 20 °C (68 °F) (White/Red – White/Green)

Replace the pickup coil/starter assembly.

MEETS SPECIFICATION 10.Charging/rotor rotation direction detection coil resistance ●

●

Disconnect the CDI magneto coupler from the wire harness. Connect the pocket tester (Ω × 100) to the charging/rotor rotation direction detection coil terminal. Tester (+) lead → Red terminal 1 Tester (–) lead → White/Blue terminal 2

●

Check the charging/rotor rotation direction detection coil for the specified resistance.

OUT OF SPECIFICATION

Rotor rotation direction detection coil resistance: 0.104 ~ 0.127 Ω at 20 °C (68 °F) (Red – White/Blue)

Replace the pickup coil/stator assembly.

MEETS SPECIFICATION

– 29 –

IGNITION SYSTEM

ELEC

11.Wiring connection ●

POOR CONNECTION

Check the connections of the entire ignition system. Refer to “CIRCUIT DIAGRAM”.

Properly connect the ignition system.

CORRECT Replace the CDI unit.

– 30 –

–

– 31 –

Y B

R/W

G/Y

[

(GRAY)

G/Y R/W

(GRAY)

Br G/Y

R W/G

W/L W/R

W/R W/G

W/G R

R/W Y

(BLACK)

Y R/W

Br/L

G B

L/B

Y B

R/W

(BLACK)

R/B R/W

L/B G

R/W R/B

G L/B

Y R/Y

Br/L

(BROWN)

L/B

B Sb

L/R Br/L

L/R

L/B

(BLACK)

L/B L/R

R Q

2WD 4WD

Br/L

Br/L Br/L

(BROWN)

L/B

L/G B

Br L/R

Br/L Br/L

Br/L R

Br/L

(BLACK)

4 R L/B L/W

L/B

L/W

(BLACK)

Br/L

R/B

W/L

W/L R/W

R/B W/L

Br/L W

G/Y

(BLACK)

W Br/L

L/W R/B

W/R W/G

R W/R W/G

R/B L/W O Sb G/Y

W/L

L/B

(BLACK)

Br/L

O B

(BLACK)

W/G B

W/G

R/B

R/W

G/L

R/W

L G/L

L R/W Sb B

G/L

Sb G/L

Br G

(BLACK)

B Sb

FGH

W/L W/G

W/G W/L

R/W

R/B

R/W

R/W R/B

ELEC

Y L

W G

Y G

OFF PUSH

R/Y

Y G

OFF ON

R/W

ON OFF

] ` a

L Y G

R/Y

R/B

Br/L R/W

R/Y Y

Y R/Y

Br/L R/W

(BLACK) (BLACK)

R/W

(BLACK)

R W

OFF LO HI

W W W

(BLACK)

R/W

W W W

W/R W/G

R W/G

3 Main switch 4 Battery 5 Main fuse 6 Starter relay 7 Starter motor 8 CDI unit 1 I Gear position switch U Engine stop switch V Start switch [ Brake lever switch a Ignition fuse

ELECTRIC STARTING SYSTEM – +

EB803000

ELECTRIC STARTING SYSTEM

CIRCUIT DIAGRAM

ELECTRIC STARTING SYSTEM

ELEC

–

EB803020

TROUBLESHOOTING IF THE STARTER MOTOR FAILS TO OPERATE:

Procedure Check: 1.Fuse (main and ignition) 2.Battery 3.Starter motor 4.Starter relay 5.Main switch 6.Engine stop switch 7.Gear position switch

8.Rear brake switch 9.Start switch 10.Wiring connection (the entire starting system)

NOTE: ● Remove the following part(s) before troubleshooting: 1)Seat 2)Rear carrier 3)Rear fender ● Use the following special tool(s) for troubleshooting.

Pocket tester: P/N. YU-03112, 90890-03112

EB802011

NO CONTINUITY

1.Fuse (main and ignition) Refer to “CHECKING THE SWITCH”. CONTINUITY

Replace the fuse.

EB802012

2.Battery ● ●

INCORRECT

Check the battery condition. Refer to “BATTERY INSPECTION” in CHAPTER 3. (Manual No.: 5FU-F8197-E0) ●

Open-circuit voltage: 12.8 V or more at 20 °C (68 °F)

●

CORRECT

– 32 –

Clean the battery terminals. Recharge or replace the battery.

ELECTRIC STARTING SYSTEM

C0NTINUITY

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.

●

ELEC

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.Starter relay

●

Remove the starter relay from the wire harness. Connect the pocket tester (Ω × 1) and the battery (12 V) to the starter relay terminals.

Battery (+) terminal → Blue/White terminal 1 Battery (–) terminal → Blue/Black terminal 2

NO CONTINUITY

Tester (+) lead → Red terminal 3 Tester (–) lead → Black terminal 4 ●

Replace the starter relay.

Check the starter relay for continuity. CONTINUITY

– 33 –

WARNING

DOES NOT TURN

●

–

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.Gear position switch Refer to “CHECKING THE SWITCH”. CORRECT

Replace the gear position switch.

INCORRECT

8.Rear brake switch Refer to “CHECKING THE SWITCH”. CORRECT

Replace the rear brake switch. INCORRECT

9.Start switch Refer to “CHECKING THE SWITCH”. CORRECT

Replace the handlebar switch (left).

EB803028

POOR CONNECTION

10.Wiring connection ●

Check the connections of the entire starting system. Refer to “CIRCUIT DIAGRAM”.

Properly connect the starting system.

– 34 –

–

G/Y

– 35 –

Y B

R/W

[

(GRAY)

G/Y R/W

(GRAY)

Br G/Y

R W/G

W/L W/R

W/R W/G

W/G R

(BLACK)

R/W Y

Y R/W

Br/L

G B

L/B

Y B

R/W

(BLACK)

R/B R/W

L/B G

R/W R/B

G L/B

Y R/Y

Br/L

(BROWN)

L/B

B Sb

L/R Br/L

L/R

L/B

(BLACK)

L/B L/R

R Q

2WD 4WD

Br/L

Br/L Br/L

(BROWN)

L/B

L/G B

Br L/R

Br/L Br/L

Br/L R

Br/L

(BLACK)

4 R L/B L/W

L/B

L/W

(BLACK)

Br/L

R/B

W/L

W/L R/W

W Br/L

L/W R/B

W/R W/G

R/B W/L

Br/L W

G/Y

(BLACK)

Sb G/Y

W/L

L/B

(BLACK)

Br/L

O B

(BLACK)

W/G B

W/G

R/B

R/W

G/L

R/W

L G/L

L R/W Sb B

G/L

Sb G/L

Br G

(BLACK)

B Sb

FGH

W/L W/G

W/G W/L

R/W

R/B

R/W R/B

3 Main switch 4 Battery 5 Main fuse F Meter light T Lights switch W Headlight X Tail/brake light ] Headlight fuse

R/W

ELEC

Y L

W G

Y G

OFF PUSH

R/Y

Y G

OFF ON

R/W

ON OFF

] ` a

L Y G

R/Y

R/B

Br/L R/W

R/Y Y

Y R/Y

Br/L R/W

(BLACK) (BLACK)

R/W

(BLACK)

OFF LO HI

W W W

(BLACK)

R/W

W W W

W/R W/G

R W/G

R W/R W/G

R/B L/W O

LIGHTING SYSTEM – +

EB805000

LIGHTING SYSTEM

CIRCUIT DIAGRAM

LIGHTING SYSTEM

ELEC

–

CHECKING THE LIGHTING SYSTEM 1.If the meter light 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 ●

Connect the pocket tester (DC 20 V) to the bulb socket coupler. Tester (+) lead → Blue terminal 1 Tester (–) lead → Black terminal 2

● ● ●

OUT OF SPECIFICATION

Turn the main switch to “ON”. Turn the lights switch to “LO” or “HI”. Check the voltage (12 V) of the “Blue” lead on the bulb socket coupler.

The wiring circuit from the main switch to the bulb socket coupler is faulty, repair it.

MEETS SPECIFICATION This circuit is not faulty.

– 36 –

G/Y

– 37 –

Y B

R/W

(GRAY)

G/Y R/W

(GRAY)

[

Br G/Y

W/L W/R

W/R W/G

R W/G

W/G R

R/W Y

(BLACK)

Y R/W

Br/L

G B

L/B

Y B

R/W

(BLACK)

R/B R/W

L/B G

R/W R/B

G L/B

Y R/Y

Br/L

(BROWN)

L/B

B Sb

L/R Br/L

L/R

L/B

(BLACK)

L/B L/R

R Q

2WD 4WD

Br/L

Br/L Br/L

(BROWN)

L/B

L/G B

Br L/R

Br/L Br/L

Br/L R

Br/L

(BLACK)

R R L/B L/W

L/B

L/W

(BLACK)

R/B

W/L

Br/L

W/L R/W

W Br/L

L/W R/B

W/R W/G

R/B W/L

Br/L W

G/Y

(BLACK)

W/L

L/B

W/L

L/B

(BLACK)

Sb G/Y

Br/L

O B

(BLACK)

W/G B

W/G

R/B

R/W

G/L

R/W

L G/L

L R/W Sb B

G/L

Sb G/L

Br G

(BLACK)

B Sb

FGH

W/L W/G

W/G W/L

R/W

B W

R/W

R/B

R/W R/B

3 Main switch 4 Battery 5 Main fuse D Fan motor control unit E Thermo unit G Reverse indicator light H Neutral indicator light I Gear position switch M Diode N Oil temperature warning light O Four-wheel drive indicator light R Four-wheel drive switch U Engine stop switch V Start switch X Tail/brake light Y Rear brake light switch Z Front brake light switch [ Brake lever switch a Ignition fuse C c Four-wheel drive fuse

ELEC

Y L

Y G

OFF PUSH

R/Y

R/W

Y G

OFF ON

ON OFF

] ` a

L Y G

R/Y

R/B

Br/L

R/W

R/Y Y

Y R/Y

Br/L

R/W

(BLACK) (BLACK)

R/W

(BLACK)

OFF LO HI

W W W

(BLACK)

R/W

W W W

W/R W/G

R W/G

R W/R W/G

R/B L/W O

SIGNAL SYSTEM – +

EB806000

SIGNAL SYSTEM

CIRCUIT DIAGRAM

SIGNAL SYSTEM

ELEC

–

EB806010

TROUBLESHOOTING IF THE INDICATOR LIGHT FAILS TO COME ON:

Procedure Check: 1.Fuse (main, ignition and four-wheel drive) 2.Battery 3.Main switch 4.Wiring connection (the entire signal system)

NOTE: ● Remove the following part(s) before troubleshooting: 1)Seat ● Use the following special tool(s) for troubleshooting.

Pocket tester: P/N. YU-03112, 90890-03112

EB802011

NO CONTINUITY

1.Fuse (main, ignition and four-wheel drive) Refer to “CHECKING THE SWITCH”. CONTINUITY

Replace the fuse.

EB802012

2.Battery ●

INCORRECT

Check the battery condition. Refer to “BATTERY INSPECTION” in CHAPTER 3. (Manual No.: 5FU-F8197-E0) ●

Open-circuit voltage: 12.8 V or more at 20 °C (68 °F)

●

CORRECT

– 38 –

Clean the battery terminals. Recharge or replace the battery.

SIGNAL SYSTEM

ELEC

C0NTINUITY INCORRECT

3.Main switch Refer to “CHECKING THE SWITCH”. CORRECT

Replace the main switch.

EB806011

POOR CONNECTION

4.Wiring connection ●

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”.

– 39 –

–

SIGNAL SYSTEM

ELEC

–

CHECKING THE SIGNAL SYSTEM 1.If the tail/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 switch.

3.Voltage ●

Connect the pocket tester (DC 20V) to the bulb socket connector. Tester (+) lead → Yellow terminal 1 Tester (–) lead → Black terminal 2

● ●

OUT OF SPECIFICATION

Turn the main switch to “ON”. Check the voltage (12 V) of the “Yellow” lead on the bulb socket connector.

The wiring circuit from the main switch to the bulb socket connector is faulty, repair it.

MEETS SPECIFICATION This circuit is not faulty.

– 40 –

SIGNAL SYSTEM

ELEC

–

2.If the four-wheel drive indicator light fails to come on: NO CONTINUITY

1.Bulb and bulb socket ●

Check the bulb and bulb socket for continuity. Replace the bulb and/or bulb socket. CONTINUITY NO CONTINUITY

2.Four-wheel drive switch Refer to “CHECKING THE SWITCH”. CONTINUITY

Replace the four-wheel drive switch.

3.Voltage ●

Connect the pocket tester (DC 20 V) to the bulb socket coupler. Tester (+) lead → Brown/Blue terminal 1 Tester (–) lead → Frame ground

● ●

OUT OF SPECIFICATION

Turn the main switch to “ON”. Check the voltage (12 V) of the “Brown/ Blue” lead on the bulb socket coupler.

The wiring circuit from the main switch to the bulb socket coupler is faulty, repair it.

MEETS SPECIFICATION This circuit is not faulty.

– 41 –

2WD/4WD SELECTING SYSTEM

–

ELEC

2WD/4WD SELECTING SYSTEM CIRCUIT DIAGRAM R/B L/W O

R W/R W/G

(BLACK) R R W/G

W/R W/G L/W R/B

W/R W/G W W

W W

W/G R

R W/G

W/R W/G

W/L W/R

Sb W W W

W W W

R B W

ON OFF

(BLACK)

G/Y

L/B L/W

(BLACK)

Br/L R

L/W

L/B

B Br/L

Br/L

\ Br/L

Y R/Y

R/W

P R/Y

R/Y Y

Br/L

R/W

] ` a P

R/W

Br/L Br/L

Br/L

R/B R/Y

L/B

R/W

OFF LO HI

Br/L

OFF ON

Y R/Y

L/B G

G L/B

OFF PUSH

Br L/R L/G B L/B

R/B R/W

(BLACK) L Y G

R/W R/B

2WD 4WD

(BROWN)

(BLACK)

L/R

B Sb

L/R Br/L

L/B

B Sb L/B Y G

Y G

(BROWN)

G Br/L

Y B

G/Y

R/W

[

Br G/Y Y

(GRAY) Y B

G/Y R/W B

R/W Y

L/R

L/B Sb

R Q

Y R/W

(BLACK) (BLACK)

(BLACK)

R/B

L/B L/R

(BLACK)

(GRAY) 3 Main switch Y L 4 Battery 5 Main fuse P On command four-wheel drive switch X Q Gear motor c Four-wheel drive fuse B

– 42 –

W/L

W Br/L

Br/L W

W/L R/W

R/B W/L

2WD/4WD SELECTING SYSTEM

ELEC

–

EB803020

TROUBLESHOOTING IF THE FOUR-WHEEL DRIVE INDICATOR LIGHT FAILS TO COME ON:

Procedure Check: 1.Fuse (main and four-wheel drive) 2.Battery 3.Main switch 4.On-command four-wheel drive switch

5.Gear motor 6.Wiring connection (the entire 2WD/4WD selecting 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 and four-wheel drive) Refer to “CHECKING THE SWITCH”. CONTINUITY

Replace the fuse.

EB802012

2.Battery ●

INCORRECT

Check the battery condition. Refer to “BATTERY INSPECTION” in CHAPTER 3. (Manual No.: 5FU-F8197-E0) ●

Open-circuit voltage: 12.8 V or more at 20 °C (68 °F)

●

Clean the battery terminals. Recharge or replace the battery.

CORRECT INCORRECT

3.Main switch Refer to “CHECKING THE SWITCH”. CORRECT

Replace the main switch.

– 43 –

2WD/4WD SELECTING SYSTEM

ELEC

–

C0NTINUITY INCORRECT

4.On command four-wheel drive switch Refer to “CHECKING THE SWITCH”. CORRECT

Replace the on command four-wheel drive select switch.

5.Gear motor ●

● ●

●

Check that the shift fork sliding gear is in the 2WD position. Disconnect the gear motor coupler. Remove the gear motor from the differential gear case. Connect the battery (12 V) to the gear motor terminals. 2WD → 4WD: Battery (+) terminal → Blue/Red terminal 1 Battery (–) terminal → Sky blue terminal 2 4WD → 2WD: Battery (+) terminal → Sky blue terminal 2 Battery (–) terminal → Blue/Black terminal 3

●

Make sure that the drive gear (shift fork sliding gear) operates correctly. INCORRECT

NOTE: When installing the differential gear case in the gear motor, refer to “CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR”.

Replace the gear motor.

CORRECT EB803028

6.Wiring connection ●

POOR CONNECTION

Check the connections of the entire 2WD/ 4WD selecting system. Refer to “CIRCUIT DIAGRAM”.

Properly connect the 2WD/4WD selecting system.

– 44 –

YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN

PRINTED IN U.S.A.

YFM400FWNP WIRING DIAGRAM R/B L/W O

R W/R W/G

Sb G/Y

(BLACK)

R R W/G

W/R W/G

W/R W/G W W

L/W R/B

W W

W/G R

R W/G

W/R W/G

W/L W/R

O B

Sb W W W

W W W

R B W

ON OFF

(BLACK)

G/Y

L/B L/W

(BLACK)

Br/L R

L/W

L/B Br/L

Br/L

R/B

B B

R/W Br/L

Br/L

Br/L R/W

R/B

\ Y R/Y

] ` a

Br/L Br/L

R/W B

P P

R/W

R/W R/B

W R/W

R/Y

W/G W/L

Br/L Br/L

Br/L

R/Y Y

Br/L

R/W

W/L W/G W

W/L W/G

W/G

W/G B R/B R/Y

L/B

R/W

OFF LO HI

(BLACK)

Y R/Y

L/B G

G L/B

OFF PUSH

Br L/R L/G B L/B

R/B R/W

(BLACK) L Y G

R/W R/B

2WD 4WD

(BROWN)

(BLACK)

L/R

B Sb

L/R Br/L

L/B

B Sb Y

L/B Y G

Y G

(BROWN)

R/W

W/L

L/B

Br/L

Y B

L/B

R/B

M W Br/L

Br/L W

W/L R/W

R/B W/L

L G/L

W/L

CDI magneto Rectifier/regulator Main switch Battery Main fuse Starter relay Starter motor CDI unit Ignition coil Spark plug Circuit breaker (fan motor) Fan motor relay Fan motor Fan motor control unit Thermo unit Meter light Reverse indicator light Neutral indicator light Gear position switch Thermo switch Carburetor warmer Auxiliary DC jack Diode Oil temperature warning light Four-wheel drive indicator light On command four-wheel drive switch Gear motor Four-wheel drive switch Handlebar switch (left) Lights switch Engine stop switch Start switch Headlight Tail/brake light Rear brake light switch Front brake light switch Brake lever switch Fuse box Headlight fuse Auxiliary DC jack fuse Ignition fuse Carburetor warmer fuse Four-wheel drive fuse

FGH

L W/L

C B

Br/L

OFF ON

1 2 3 4 5 6 7 8 9 0 A B C D E F G H I J K L M N O P Q R S T U V W X Y Z [ \ ] ^ a b c

B Sb

(BLACK)

B G/Y

R/W

[

Br G/Y Y

G/Y R/W B

R/W Y

L/B

(BLACK)

L R/W G/L Sb B

(BLACK) G/L

L/B L/R

R Q

Y R/W

G/L

(BLACK) (BLACK)

(BLACK)

(GRAY) Y B

L/R

(BLACK)

(GRAY)

I Br

G/L

Y L

X B

COLOR CODE B ............Black Br ...........Brown G............Green L.............Blue O............Orange

P............ Pink R............ Red Sb .......... Sky blue W........... White Y............ Yellow

Br/L ....... Brown/Blue G/L ........ Green/Blue G/Y........ Green/Yellow L/B......... Blue/Black L/G ........ Blue/Green

L/R .........Blue/Red L/W ........Blue/White R/B.........Red/Black R/W........Red/White R/Y.........Red/Yellow

W/G ....... White/Green W/L ........ White/Blue W/R ....... White/Red

YFM400 WNM/NMC Service Manual

YFM400FWNM/YFM400FWNMC SERVICE MANUAL ÂŠ1999 by Yamaha Motor Corporation, U.S.A. First Edition, June 1999 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. LlT-11616-13-22

NOTICE This manual was written by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and qualified mechanics. It is not possible to put an entire mechanic's education into one manual, so persons using this book to perform maintenance and repairs on Yamaha machines should have a basic understanding of the mechanical concepts and the procedures inherent in machine repair technology. Without such knowledge, attempted repairs or service to the machine may render it unfit to use and/or unsafe. Yamaha Motor Company, Ltd. is continually striving to improve all models manufactured by Yamaha. Modifications and significant changes in specifications or procedures will be forwarded to all Authorized Yamaha dealers and will, where applicable, appear in future editions of this manual.

NOTE: Designs and specifications are subject to change without notice.

PARTICULARLY IMPORTANT INFORMATION This material is distinguished by the following notation. The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

WARNING

Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the machine. A CAUTION indicates special precautions that must be taken to avoid damage to the machine.

NOTE:

A NOTE provides key information to make procedures easier or clearer.

HOW TO USE THIS MANUAL CONSTRUCTION OF THIS MANUAL This manual consists of chapters for the main categories of subjects. (See "1l1ustrated symbols")

1st titl e CD: 2nd title

®:

3rd title @:

This is a chapter with its symbol on the upper right of each page. This title appears on the upper of each page on the left of the chapter symbol. (For the chapter "Periodic inspection and adjustment" the 3rd title appears.) This is a final title.

IMPORTANT FEATURES • Data and a special tool are framed in a box preceded by a relevant symbol @. • An encircled numeral ® indicates a part name, and an encircled alphabetical letter data or an alignment mark (j), the others being indicated by an alphabetical letter in a box@. • A condition of a faulty component will precede an arrow symbol ® and the course of action will follow it. EXPLODED DIAGRAM Each chapter provides exploded diagrams before each disassembly section for ease in identifying correct disassembly and assembly procedures. 1/---r~~~~____________~__________________~

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INSPECTION AND REPAIR

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ENG ~~.

ICARBI.I IORlVHC..

@ Periodic inspections and adjustments @ Engine overhaul

® Carburetion ® Drive train (J) Chassis 1

ICHAslfP61 IELECIOI ITRBLI ? SHTG • I ~ ®

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General information

CV Specifications

® Electrical ® Troubleshooting

(J)

as thumb tabs to indicate the chapter's number and content.

ILLUSTRATED SYMBOLS (Refer to the illustration) Illustrated symbols CD to ® are designed

~ ~ OOJ @)

Illustrated symbols @ to @ are used to identify the specifications appearing in the text.

® Filling fluid ®

Lubricant

@ Special tool @ Tightening @ Wear limit, clearance @ Engine speed @.o, V, A

Illustrated symbols @ to @ in the exploded diagrams indicate grade of lubricant and location of lubrication point. @ Apply engine oil @ Apply gear oil @) Apply molybdenum disulfide oil

® Apply wheel

~ @

, ili

I~R

@ @ @ @

bearing grease Apply lightweight lithium-soap base grease Apply molybdenum disulfide grease Apply the locking agent (LOCTITE@) Use new one

TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC INSPECTION AND ADJUSTMENTS ENGINE OVERHAUL CARBURETION DRIVE TRAIN CHASSIS ELECTRICAL TROUBLESHOOTING

fIJe CHAS

o ELEC

CONTENTS CHAPTER 1. GENERAL INFORMATION MACHINE IDENTIFICATION ........................................................................ 1-1 VEHICLE IDENTIFICATION NUMBER .................................................. 1-1 MODEL LABEL ...................................................................................... 1-1 IMPORTANT INFORMATION ...................................................................... 1-2 PREPARATION FOR REMOVAL PROCEDURES ................................. 1-2 REPLACEMENT PARTS ........................................................................ 1-2 GASKETS, OIL SEALS AND O-RINGS ................................................ 1-2 LOCK WASHERS/PLATES AND COTTER PINS .................................. 1-3 BEARINGS AND OIL SEALS ................................................................ 1-3 CIRCLIPS ............................................................................................... 1-3 SPECIAL TOOLS ........................................................................................... 1-4

CHAPTER 2. SPECIFICATIONS GENERAL SPECIFICATIONS ....................................................................... 2-1 MAINTENANCE SPECIFICATIONS ............................................................. 2-4 ENGINE ................................................................................................. 2-4 CHASSIS ............................................................................................. 2-14 ELECTRICAL ........................................................................................ 2-18 HOW TO USE THE CONVERSION TABLE ................................................ 2-20 GENERAL TORQUE SPECIFICATIONS ..................................................... 2-20 LUBRICATION POINTS AND LUBRICANT TYPE ..................................... 2-21 ENGINE ................................................................................................ 2-21 LUBRICATION DIAGRAMS ........................................................................ 2-22 CABLE ROUTING ....................................................................................... 2-24

CHAPTER 3. PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION ........................................................................................... 3-1 PERIODIC MAINTENANCE/LUBRICATION ............................................... 3-1 SEAT, CARRIERS, FENDERS AND FUEL TANK ......................................... 3-3 REMOVAL ............................................................................................. 3-3 INSTALLATION ..................................................................................... 3-5 ENGINE ......................................................................................................... 3-8 VALVE CLEARANCE ADJUSTMENT ................................................... 3-8 TIMING CHAIN ADJUSTMENT ......................................................... 3-10 IDLING SPEED ADJUSTMENT .......................................................... 3-11 THROTTLE LEVER FREE PLAY ADJUSTMENT ................................ 3-12 SPEED LIMITER ADJUSTMENT ........................................................ 3-13 STARTER LEVER FREE PLAY ADJUSTMENT .................................. 3-14 SPARK PLUG INSPECTION ............................................................... 3-15 IGNITION TIMING CHECK ................................................................. 3-15 COMPRESSION PRESSURE MEASUREMENT ................................. 3-16 ENGINE OIL LEVEL INSPECTION ...................................................... 3-18 OIL TEMPERATURE WARNING LIGHT CHECK ................................ 3-19 ENGINE OIL REPLACEMENT ............................................................. 3-19 CLUTCH ADJUSTMENT .................................................................... 3-21 AIR FILTER CLEANING ....................................................................... 3-22 SPARK ARRESTER CLEANING .......................................................... 3-23 CHASSIS ..................................................................................................... 3-25 REAR BRAKE LEVER AND PEDAL ADJUSTMENT .......................... 3-25 FRONT BRAKE FLUID LEVEL INSPECTION ...................................... 3-27 FRONT BRAKE PAD INSPECTION ..................................................... 3-27 REAR BRAKE SHOE INSPECTION ..................................................... 3-28 BRAKE HOSE INSPECTION ............................................................... 3-28 AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) ............................... 3-28 REVERSE CONTROL CABLE ADJUSTMENT .................................... 3-30 SHIFT PEDAL ADJUSTMENT ............................................................ 3-30 FINAL GEAR OIL LEVEL INSPECTION .............................................. 3-31 FINAL GEAR OIL REPLACEMENT ..................................................... 3-31 DIFFERENTIAL GEAR OIL QUANTITY INSPECTION ........................ 3-32 DIFFERENTIAL GEAR OIL REPLACEMENT ....................................... 3-33 CONSTANT VELOCITY JOINT DUST BOOT INSPECTION .............. 3-34 STEERING SYSTEM INSPECTION .................................................... 3-35 TOE-IN ADJUSTMENT ....................................................................... 3-35 FRONT SHOCK ABSORBER ADJUSTMENT .................................... 3-37 REAR SHOCK ABSORBER ADJUSTMENT ....................................... 3-37 TIRE INSPECTION .............................................................................. 3-37 WHEEL INSPECTION .......................................................................... 3-40

CABLE INSPECTION AND LUBRICATION ........................................ 3-40 LEVERS, PEDAL, ETC. LUBRICATION ............................................... 3-40 ELECTRICAL ............................................................................................... 3-41 BATTERY INSPECTION ...................................................................... 3-41 FUSE INSPECTION ............................................................................. 3-46 HEADLIGHT BEAM ADJUSTMENT ................................................... 3-48 HEADLIGHT BULB REPLACEMENT .................................................. 3-48

CHAPTER 4. ENGINE OVERHAUL ENGINE REMOVAL ...................................................................................... 4-1 SEAT, CARRIERS, FENDERS AND FUEL TANK ................................. 4-1 ENGINE OIL .................................................. ;........................................ 4-1 CARBURETOR ...................................................................................... 4-1 EXHAUST PIPE AND MUFFLER .......................................................... 4-2 STARTER MOTOR ................................................................................ 4-2 OIL FILTER ............................................................................................ 4-3 REVERSE CONTROL CABLE ................................................................ 4-3 SHIFT PEDAL AND FOOTREST ........................................................... 4-3 SPARK PLUG ........................................................................................ 4-4 LEADS ................................................................................................... 4-4 REAR SHOCK ABSORBER AND SWINGARM .................................... 4-5 FRONT DRIVE SHAFT PROTECTOR .................................................... 4-6 FRONT FENDER BRACKET .................................................................. 4-6 ENGINE REMOVAL .............................................................................. 4-6 ENGINE DISASSEMBLY .............................................................................. 4-8 RECOIL STARTER ................................................................................. 4-8 CYLINDER HEAD AND CYLINDER ...................................................... 4-8 PISTON ................................................................................................ 4-11 CRANKCASE COVER (LEFT) .............................................................. 4-11 SHIFT SHAFT AND STARTER IDLE GEAR ........................................ 4-12 COl ROTOR AND TIMING CHAIN ...................................................... 4-13 CRANKCASE COVER (RIGHT) ........................................................... 4-13 CLUTCH ............................................................................................... 4-14 REVERSE SHIFT BRACKET ................................................................ 4-16 OIL PUMP AND BALANCER DRIVE GEARS ..................................... 4-16 CRANKCASE (LEFT) ..........................................,................................. 4-18 BALANCER WEIGHT AND TRANSMISSION .................................... 4-18 CRANKSHAFT ..................................................................................... 4-19 CAMSHAFT, ROCKER ARM AND VALVE ......................................... 4-20 OIL PUMP ............................................................................................ 4-22

INSPECTION AND REPAIR ........................................................................ 4-23 CYLINDER HEAD ................................................................................ 4-23 VALVE SEAT ....................................................................................... 4-24 VALVE AND VALVE GUIDE ............................................................... 4-26 VALVE SPRING ................................................................................... 4-27 CAMSHAFT ......................................................................................... 4-28 ROCKER ARM AND ROCKER ARM SHAFT ...................................... 4-29 TIMING CHAIN TENSIONER .............................................................. 4-29 TAPPET COVER AND SIDE COVER (CYLINDER HEAD) ................... 4-30 CYLINDER AND PISTON .................................................................... 4-30 PISTON RING ...................................................................................... 4-32 PISTON PIN ......................................................................................... 4-33 CRANKSHAFT ..................................................................................... 4-34 BALANCER DRIVE GEAR AND DRIVEN GEAR ................................. 4-35 PRIMARY GEARS ............................................................................... 4-35 PRIMARY CLUTCH ............................................................................. 4-35 SECONDARY CLUTCH ....................................................................... 4-36 OIL PUMP ............................................................................................ 4-38 SHIFTER AND TRANSMISSION ........................................................ 4-39 STARTER DRIVES ............................................................................... 4-41 STARTER PULLEY AND RECOIL STARTER ...................................... 4-42 OIL STRAINER, OIL FILTER AND OIL DELIVERY PIPES ................... 4-42 CRANKCASE ....................................................................................... 4-43 BEARINGS AND OIL SEALS .............................................................. 4-43 CIRCLIPS AND WASHERS ........................................ ,........................ 4-43 MIDDLE GEAR SERVICE ............................................................................ 4-44 REMOVAL ........................................................................................... 4-45 DISASSEMBLY ................................................................................... 4-45 INSPECTION ....................................................................................... 4-49 MIDDLE DRIVE AND DRIVEN GEAR SHIM SELECTION .................. 4-49 ASSEMBLY ......................................................................................... 4-52 INSTALLATION ................................................................................... 4-56 GEAR LASH MEASUREMENT ........................................................... 4-56 ENGINE ASSEMBLY AND ADJUSTMENT ............................................... 4-58 OIL PUMP ............................................................................................ 4-58 VALVE, CAMSHAFT AND ROCKER ARM ......................................... 4-59 VALVE, ROCKER ARM AND CAMSHAFT ......................................... 4-60 CRANKSHAFT ..................................................................................... 4-61 TRANSMISSION AND BALANCER WEIGHT .................................... 4-61 CRANKSHAFT AND TRANSMISSION .............................................. 4-62 CRANKCASE (LEFT) ........................................................................... 4-63 BALANCER DRIVE AND DRIVEN GEARS AND OIL PUMP .............. 4-65 BALANCER DRIVE GEARS AND OIL PUMP ..................................... 4-66 REVERSE SHIFT BRACKET ................................................................ 4-67 CLUTCH ............................................................................................... 4-68

CLUTCH ............................................................................................... 4-69 CRANKCASE COVER (RIGHT) ........................................................... 4-71 TIMING CHAIN AND CDI ROTOR ...................................................... 4-72 CDI ROTOR AND STARTER ............................................................... 4-73 SHIFTER .............................................................................................. 4-74 STARTER IDLE GEAR AND SHIFT SHAFT ........................................ 4-75 CRANKCASE COVER (LEFT) .............................................................. 4-76 PISTON AND CYLINDER .................................................................... 4-78 PISTON ................................................................................................ 4-79 CYLINDER AND CYLINDER HEAD .................................................... 4-79 CYLINDER HEAD ................................................................................ 4-81 RECOIL STARTER ............................................................................... 4-84 REMOUNTING THE ENGINE ............................................................. 4-85

CHAPTER 5. CARBURETION CARBURETOR .............................................................................................. 5-1 REMOVAL ............................................................................................. 5-2 DISASSEMBLY ..................................................................................... 5-3 INSPECTION ......................................................................................... 5-4 ASSEMBLY ........................................................................................... 5-7 INSTALLATION ..................................................................................... 5-8 FUEL LEVEL ADJUSTMENT ................................................................ 5-9

CHAPTER 6. DRIVE TRAIN TROUBLESHOOTING ................................................................................... 6-1 DIFFERENTIAL GEAR AND CONSTANT VELOCITY JOINTS .................... 6-4 REMOVAL ............................................................................................. 6-6 DISASSEMBLY ..................................................................................... 6-7 INSPECTION ....................................................................................... 6-10 ASSEMBLY ......................................................................................... 6-11 MEASUREMENT AND ADJUSTMENT ............................................. 6-15 INSTALLATION ................................................................................... 6-17 DIFFERENTIAL GEAR OPERATION CHECK ...................................... 6-19 REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT ............................ 6-20 REMOVAL ........................................................................................... 6-22 DISASSEMBLY ................................................................................... 6-23 INSPECTION ....................................................................................... 6-25 FINAL DRIVE PINION GEAR AND RING GEAR SHIM SELECTION ...................................................... 6-27

ASSEMBLY ......................................................................................... 6-30 FINAL GEAR LASH MEASUREMENT AND ADJUSTMENT ............ 6-34 INSTALLATION ................................................................................... 6-37

CHAPTER 7. CHASSIS FRONT AND REAR WHEELS ....................................................................... 7-1 REMOVAL ............................................................................................. 7-2 INSPECTION ......................................................................................... 7-4 INSTALLATION ..................................................................................... 7-4 FRONT BRAKE .............................................................................................. 7-6 BRAKE PAD REPLACEMENT ............................................................... 7-7 CALIPER DISASSEMBLY ..................................................................... 7-9 MASTER CYLINDER DISASSEMBLY ................................................ 7-10 INSPECTION AND REPAIR ................................................................ 7-11 CALIPER ASSEMBLY ......................................................................... 7-14 MASTER CYLINDER ASSEMBLY ...................................................... 7-17 REAR BRAKE .............................................................................................. 7 -20 REMOVAL ........................................................................................... 7-21 INSPECTION ....................................................................................... 7-22 INSTALLATION ................................................................................... 7-23 STEERING SYSTEM ................................................................................... 7 -26 REMOVAL ........................................................................................... 7-27 INSPECTION ....................................................................................... 7-30 INSTALLATION ................................................................................... 7-33 FRONT SHOCK ABSORBER AND FRONT ARM ....................................... 7-37 REMOVAL ........................................................................................... 7-38 INSPECTION ....................................................................................... 7-39 INSTALLATION ................................................................................... 7-41 REAR SHOCK ABSORBER AND SWINGARM .......................................... 7 -43 REMOVAL ........................................................................................... 7-44 INSPECTION ....................................................................................... 7-46 INSTALLATION ................................................................................... 7-47

CHAPTER 8. ELECTRICAL ELECTRICAL COMPONENTS ...................................................................... 8-1 CHECKING OF CONNECTIONS ................................................................... 8-2 IGNITION SYSTEM ...................................................................................... 8-3 CIRCUIT DIAGRAM .............................................................................. 8-3 TROUBLESHOOTING ........................................................................... 8-4 ELECTRICAL STARTING SYSTEM .............................................................. 8-9 CIRCUIT DIAGRAM .............................................................................. 8-9 STARTING CIRCUIT OPERATION ..................................................... 8-10 TROUBLESHOOTING ......................................................................... 8-11 STARTER MOTOR .............................................................................. 8-16 CHARGING SYSTEM ................................................................................. 8-21 CIRCUIT DIAGRAM ............................................................................ 8-21 TROUBLESHOOTING ......................................................................... 8-22 LIGHTING SYSTEM .................................................................................... 8-25 CIRCUIT DIAGRAM ............................................................................. 8-25 TROUBLE SHOOTING ......................................................................... 8-26 LIGHTING SYSTEM CHECK ................................................................ 8-29 SIGNAL SYSTEM ....................................................................................... 8-31 CIRCUIT DIAGRAM ............................................................................. 8-31 TROUBLE SHOOTING ......................................................................... 8-32 SIGNAL SYSTEM CHECK ................................................................... 8-34 COOLING SYSTEM ..................................................................................... 8-37 CIRCUIT DIAGRAM ............................................................................. 8-37 TROUBLE SHOOTING ......................................................................... 8-38 CARBURETOR WARMING SySTEM .......................................................... 8-42 CIRCUIT DIAGRAM ............................................................................. 8-42 TROUBLE SHOOTING ......................................................................... 8-43

CHAPTER 9. TROUBLESHOOTING STARTING FAILURE/HARD STARTING ..................................................... 9-1 FUEL SYSTEM ...................................................................................... 9-1 ELECTRICAL SYSTEM .......................................................................... 9-1 COMPRESSION SYSTEM .................................................................... 9-2 POOR IDLE SPEED PERFORMANCE ........................................................... 9-2 POOR IDLE SPEED PERFORMANCE ................................................... 9-2 POOR MEDIUM AND HIGH SPEED PERFORMANCE ................................ 9-2 POOR MEDIUM AND HIGH SPEED PERFORMANCE ........................ 9-2 FAULTY DRIVE TRAIN ................................................................................. 9-3 FAULTY GEAR SHIFTING ............................................................................ 9-4 HARD SHIFTING .................................................................................... 9-4 SHIFT PEDAL DOES NOT MOVE .......................................................... 9-4 JUMPS-OUT-OF GEAR ......................................................................... 9-4 CLUTCH SLIPPING/DRAGGING ........................................ ,.......................... 9-4 CLUTCH SLIPPING ................................................................................ 9-4 CLUTCH DRAGGING ............................................................................. 9-4 OVER HEATING ............................................................................................. 9-5 OVERHEATING ...................................................................................... 9-5 FAULTY BRAKE ............................................................................................. 9-5 POOR BRAKING EFFECT ...................................................................... 9-5 SHOCK ABSORBER MALFUNCTION ........................................................... 9-5 MALFUNCTION ..................................................................................... 9-5 UNSTABLE HANDLING ................................................................................ 9-6 UNSTABLE HANDLING ........................................................................ 9-6 LIGHTING SySTEM ....................................................................................... 9-6 HEADLIGHT DARK ................................................................................ 9-6 BULB BURNT OUT ................................................................................ 9-6

MACHINE IDENTIFICATION

I,~~~

IAI

GENERAL INFORMATION MACHINE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER The vehicle identification number CD is stamped into the left side of the frame.

MODEL LABEL The model label CD is affixed to the frame. This information will be needed to order spare parts.

1-1

IMPORTANT INFORMATION

II~~~ I

EB10l000

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.During machine disassembly, clean all parts and place them in trays in the order of disassembly. This will speed up assembly and allow for the correct installation of all parts. S.Keep all parts away from any source of fire.

EB10l0l0

REPLACEMENT PARTS 1.Use only genuine Yamaha parts for all replacements. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.

EB10l020

GASKETS, OIL SEALS AND O-RINGS 1.Replace all gaskets, seals and a-rings when overhauling the engine. All gasket surfaces, oil seal lips and a-rings must be cleaned. 2.Properly oil all mating parts and bearings during reassembly. Apply grease to the oil seal lips.

1-2

IMPORTANT INFORMATION

II~~~ Icltel

EB101030

LOCK WASHERS/PLATES AND COTTER PINS 1.Replace all lock washers/plates CD 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 1.1nstall 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. Oil bearings liberally when installing, if appropriate.

CD Oil

seal

::::::::1111111;::1::::: _________ Do not use compressed air to spin the bearings dry. This will damage the bearing surfaces.

CD Bearing

EB101050

CIRCLIPS 1.Check all circlips carefully before reassembly. Always replace piston pin clips after one use. Replace distorted circlips. When installing a circlip CD, make sure that the sharp-edged corner ÂŽ is positioned opposite the thrust @ it receives. See sectional view. @ Shaft

1-3

SPECIAL TOOLS

II~~~ I~I

Refer to the list provided to avoid errors when placing an order.

SPECIAL TOOLS The proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques.

PIN. YM- 00000, YU-DDDDD YS- 00000, YK-DDDDD ACC-DDDDD

For USA,

CDN

Except for USA,

PIN. 90890- 00000

CDN

1-A Valve adjusting tool 4 mm (0.16 in) PIN. YM-08035

FORTUNE UP This tool is necessary for adjusting the valve clearance.

1-8

2-A

Valve adjusting tool 4 mm (0.16 in) PIN. 90890-04133

PIN. YU-8036-A

This tool is necessary for adjusting the valve clearance.

This tool is needed to measure engine rpm.

2-8

3-A

Engine tachometer PIN. 90890-03113

Timing light PIN. YM-33277-A

This tool is needed to measure engine rpm.

This tool is necessary for checking ignition timing.

Inductive tachometer

3-8 Timing light PIN. 90890-03141

Compression gauge PIN. YU-33223 Adapter (M12) PIN. YU-33223-3

;~--~-_'_ fB! ~ ...

......

.....

......

...

... ...

... .... ... "

...._.

,I '----_!

This tool is necessary for checking ignition timing.

These gauge are used to measure the engine compression. 1- 4

SPECIAL TOOLS

/I~~~ /cite/

4-8

Fuel level gauge PIN. YM-01312-A PIN. 90890-01312

Compression gauge PIN. 90890-03081 Extension PIN. 90890-04082

This gauge is used to measure the engine compression.

This gauge is used to measure the fuel level in the float chamber.

1 Rotor holder PIN. YU-01235 PIN. 90890-01235

FOR ENGINE SERVICE

This tool is used to hold the clutch when removing or installing the clutch carrier securing nut.

2 Piston pin puller PIN. YU-01304 PIN. 90890-01304

Flywheel puller PIN. YM-1404 PIN. 90890-01404

This tool is used to remove the piston pin.

This tool is used to remove the COl rotor.

5-A

Universal clutch holder PIN. YM-91042

Sheave holder PIN. YU-01880 PIN. 90890-01701

This tool is used to hold the clutch when removing or installing the clutch boss securing nut.

This tool is used to holder the COl rotor when removing or installing the COl rotor.

5-8

Universal clutch holder PIN. 90890-04086

Crankcase separating tool PIN. YU-01135-A PIN. 90890-01135

This tool is used to hold the clutch when removing or installing the clutch boss securing nut.

This tool is used when removing the crankshaft. 1- 5

SPECIAL TOOLS

II~~~ I~I

8-A

7 Slide hammer bolt (M8) PIN. YU-01083-2 PIN. 90890-01085

Slide hammer bolt (M6) PIN. YU-01083-1 Weight PIN. YU-01083-3

This tool is used when removing the crankshaft.

These tools are used when removing the rocker arm shaft.

8-8 Slide hammer bolt (M6) PIN. 90890-01083 Weight PIN. 90890-01084

Valve spring compressor PIN. YM-04019 PIN. 90890-04019

These tools are used when removing the rocker arm shaft.

This tool is needed to remove and install the valve assemblies.

10-A

10-8

Valve guide remover and installer 7 mm (0.28 in) ÂŽ-::,.. Valve guide remover PIN. YM-01225-A-(j) ~ -Valve guide installer ~~~ ___ PIN. YM-04017-ÂŽ Valve guide reamer PIN. YM-01227-@

:;?

Ift\

These tools are used to remove, install and rebore the valve guide.

11-A

11-8

Universal joint holder

PIN. YM-04062

Universal joint holder PIN. 90890-04062

This tool is used to remove and install the universal joint.

12 Bearing retainer wrench PIN. YM-04128 PIN. 90890-04128

Ring nut wrench PIN. YM-38404 PIN. 90890-01430

This tool is used to remove and install the bearing retainer.

This tool is used to remove and install the bearing retainer. 1-6

SPECIAL TOOLS

II~~~ I~I

14 Pinion gear fix clamp PIN. YM-04129 PIN. 90890-04129

Gear lash measurement tool PIN. YM-01231 PIN. 90890-01231

This tool is used to hold the middle drive gear shaft.

This tool is used to measure the gear lash.

16-A

16-8

Crankshaft installer set PIN. YU-90050

Buffer boss installer set PIN. 90890-04088

()

These tools are used to install the crankshaft and oil pump drive gear.

These tools are used'to install the crankshaft and oil pump drive gear.

Adapter #11 PIN. YM-33279

Pot extension PIN. YM-33280

This tool is used to install the crankshaft and oil pump drive gear.

This tool is used to install the crankshaft.

~ Pot spacer PIN. YM-90070-A

20 Crank pot spacer PIN. YM-91044 PIN. 90890-04081

This tool is used to install the crankshaft and oil pump drive gear.

This tool is used to install the crankshaft.

21 Sealant (Quick Gasket®) PIN. ACC-QUICK-GS-KT YAMAHA bond No. 1215® PIN. 90890-85505

This sealant (bond) is used for crankcase mating surface, etc. 1-7

SPECIAL TOOLS

II~~~ IA'I

1 Hexagon wrench (44 mm) P/N. YM-01462 P/N.90890-01462

FOR DRIVE TRAIN SERVICE

These tool is used to remove and install the bearing retainer.

Bearing retainer wrench P/N. YM-04050 P/N.90890-04050

These tool is used to remove and install the final gear bearing retainer.

~ Damper rod holder P/N. YM-01327 P/N.90890-01327

FOR CHASSIS SERVICE

This tool is used to remove and install the bearing retainer for the steering shaft holder bearing.

W Ball joint remover/installer attachment set:

2 Ball joint remover/installer P/N. YM-01474 P/N.90890-01474

P/N. YM-01477

This tool is used to remove and install the ball joint.

1-A Dynamic spark tester P/N. YM-34487

FOR ELECTRICAL COMPONENTS This instrument is necessary for checking the ignition system components. 1- 8

SPECIAL TOOLS 1-8

II~~~ ,__,

Ignition checker PIN. 90890-06754

Pocket tester PIN. YU-03112 PIN. 90890-03112

This instrument is necessary for checking the ignition system components.

This instrument is invaluable for checking the electrical system.

1-9

GENERAL SPECIFICATIONS

ISPECI ~ I

SPECIFICATIONS GENERAL SPECIFICATIONS YFM400FWN

Model

5FU1 (Except for California) 5FU2 (for California)

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 x stroke Compression ratio Compression pressure (STD) Starting system Lubrication system: Oil type or grade: Engine oil 0° I:,! ,

10°

30°

50°

70°

90°

2,007 mm (79.0 in) 1,111 mm (43.7 in) 1,172 mm (46.1 in) 855 mm (33.7 in) 1,230 mm (48.4 in) 245 mm (9.65 in) 3,150 mm (124.0 in) 266 kg (586 Ib) Air-cooled 4-stroke, SOHC Forward-inclined single cylinder 386 cm 3 83.0 x 71.5 mm (3.27 x 2.81 in) 8.6:1 920 kPa (9.2 kg/cm2, 131 psi) at 350 r/min Electric and recoil starter Wet sump

110°

130°F

!YAMALuBE ! 4 (20W40f ! !or SAE20W40 !.! 1

i ~AMAL0BE

-+-_+1-~.: j SAE SJi30 i i i !

API service SE, SF, SG type or higher

4 (1bW30) o;r SAE

lb~o

i i

I I I I I !

Final gear oil Differential gear oil Oil capacity: Engine oil Periodic oil change With oil filter replacement Total amount Final gear case oil Periodic oil change Total amount

SAE80API IGL-4" Hypoid gear oil SAE80 or 80W-90API IGL-5" Hypoid gear oil for L.S.D. (Limited Slip Differential)

2.9 L (2.6 Imp qt, 3.1 US qt) 3 L (2.6 Imp qt, 3.2 US qt) 3.5 L (3.1 Imp qt, 3.7 US qt) 0.23 L (0.20 Imp qt, 0.24 US qt) 0.25 L (0.22 Imp qt, 0.26 US qt)

2- 1

GENERAL SPECIFICATIONS Model

YFM400FWN

Differential gear case oil Periodic oil change Total amount 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 Primary reduction ratio Secondary reduction system Secondary reduction ratio Transmission type Operation Gear ratio

Reverse gear Chassis: Frame type Caster angle Trail Tread (STD) Tread (STD) Toe-in Tire: Type Size Manufacturer Type

ISPECI ~ I

0.18 L (0.16Imp qt, 0.19 US qt) 0.2 L (0.18 Imp qt, 0.21 US qt) Dry type element Unleaded fuel 15 L (3.30 Imp gal, 3.96 US gal) 4.0 L (0.88 Imp gal, 1.06 US gal) BSR33/1 MIKUNI DR8EA NGK 0.6 - 0.7 mm (0.024 - 0.028 in) Wet, centrifugal automatic

1st 2nd 3rd 4th 5th

Spur gear 76/24(3.167) Shaft drive 28/24 x 24/18 x 33/09 (5.704) Constant mesh 5-speed forward, 1-speed reverse Left foot operation 40/12 (3.333) 34/18 (1.889) 30/22 (1.364) 25/26 (0.962) 19/27 (0.704) 22/17 x 35/15 (3.020) Steel tube frame 4Â·

front rear

front rear front rear front rear

21 mm (0.83 in) 860 mm (33.86 in) 820 mm (32.28 in) 0- 10 mm (0 - 0.39 in) Tubeless AT25 x 8-12 AT25 x 10-12 DUNLOP/CHENG SHIN DUNLOP/CHENG SHIN KT 404/C-9221 KT405B/C-9222 2-2

GENERAL SPECIFICATIONS Model

ISPECI ~ I

YFM400FWN

Tire pressure (cold tire): Off-road riding

Brake: Front brake Rear brake 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 x quantity: Headlight Taillight Meter light Neutral indicator light Reverse indicator light Oil temperature warning light

front rear

22 - 28 kPa (0.22 - 0.28 kg/cm 2 , 3.2 - 4.0 psi) 22 - 28 kPa (0.22 - 0.28 kg/cm 2 , 3.2 - 4.0 psi)

type operation type operation

Single disc brake Right hand operation Drum brake Left hand and right foot operation Double wishbone Swingarm (monocross) Coil spring/oil damper Coil spring/oil damper 150 mm (5.9 in) 150 mm (5.9 in) C.D.I. A.C. magneto YTX20L-BS 12 V 18 AH Krypton bulb 12 V 30 W/30 W x 2 12 V 7.5 W x 1 12 V 3.4 Wx 1 12V3.4Wx1 12 V 3.4 Wx 1 12 V 3.4 Wx 1

2-3

MAINTENANCE SPECIFICATIONS

ISPECI tr-" I

MAINTENANCE SPECIFICATIONS ENGINE

YFM400FWN

Model Cylinder head: Warp limit

0.05 mm (0.0020 in)

Cylinder:

Bore size Out of round limit Measuring point <Wear limit> Camshaft: Drive method Cam dimensions

82.97 - 83.02 mm (3.267 - 3.269 in) 0.01 mm (0.0004 in) 40 mm (1.57 in) <83.15 mm (3.274 inÂ»

Chain drive (Left)

c A

r-----BIntake

IIA"

"B"

"c" Exhaust

IIA" "B"

"c"

40.62 - 40.72 mm (1.599 - 1.603 in) 32.18 - 32.28 mm (1.267 - 1.271 in) 8.61 - 8.73 mm (0.339 - 0.344 in) 40.62 - 40.72 mm (1.599 - 1.603 in) 32.18 - 32.28 mm (1.267 - 1.271 in) 8.61 - 8.73 mm (0.339 - 0.344 in)

2-4

MAINTENANCE SPECIFICATIONS Model

ISPECI ~ I

YFM400FWN 0.03 mm (0.0012 in)

Camshaft runout limit

Cam chain: Cam chain type/No. of links Cam chain adjustment method Rocker arm/rocker arm shaft: Bearing inside diameter <Limit> Shaft outside diameter <Limit> Arm-to-shaft clearance <Limit> Valve, valve seat, valve guide: Valve clearance (cold) IN

BF05M/92 Automatic 12.000 - 12.018 mm (0.4724 - 0.4731 in) <12.078 mm (0.4755 in» 11.981 - 11.991 mm (0.4717 - 0.4721 in) <11.951 mm (0.4705 in» 0.009 - 0.037 mm (0.0004 - 0.0015 in) <0.08 mm (0.0031 in» 0.06 - 0.10 mm (0.002 - 0.004 in) 0.16 - 0.20 mm (0.006 - 0.008 in)

Valve dimensions

dA~ Head Diameter

"A" head diameter

~z IN IN

"c"

seat width

EX "0" margin thickness

EX Stem outside diameter

EX <Limit>

EX Guide inside diameter

EX <Limit>

~ID

Seat Width

Face Width

EX "B" face width

Margin Thickness

39.9 - 40.1 mm (1.571 - 1.579 in) 33.9 - 34.1 mm (1.335 - 1.343 in) 2.26 mm (0.089 in) 2.26 mm (0.089 in) 1.2 - 1.4 mm (0.047 - 0.055 in) 1.2 - 1.4 mm (0.047 - 0.055 in) 1.0 - 1.4 mm (0.039 - 0.055 in) 0.8 - 1.2 mm (0.031 - 0.047 in) 6.975 - 6.990 mm (0.2746 - 0.2752 6.955 - 6.970 mm (0.2738 - 0.2744 <6.95 mm (0.274 in» <6.915 mm (0.272 in» 7.000 - 7.012 mm (0.2756 - 0.2761 7.000 - 7.012 rnm (0.2756 - 0.2761 <7.03 mm (0.277 in» <7.03 mm (0.277 in»

2-5

in) in)

MAINTENANCE SPECIFICATIONS

YFM400FWN

Model Stem-to-guide clearance <Limit> Valve seat width Valve spring: Inner spring Free length <Limit> Set length (valve closed) Compressed pressure (installed) Tilt limit

Direction of winding (top view)

IN EX IN EX IN EX

0.010 - 0.037 mm (0.0004 -0.0015 in) 0.030 - 0.057 mm (0.0012 - 0.0022 in) <0.08 mm (0.003 in» <0.1 mm (0.004 in» 1.2 - 1.4 mm (0.0472 - 0.0551 in) 1.2 - 1.4 mm (0.0472 - 0.0551 in)

IN EX IN EX IN EX

39.9 mm (1.57 in) 39.9 mm (1.57 in) <37.9 mm (1.49 in» <37.9 mm (1.49 in» 33.6 mm (1.32 in) 33.6 mm (1.32 in)

IN EX IN EX

107 - 123 N 107 - 123 N 2.5°/1.6 mm 2.5°/1.6 mm

Counterclockwise Counterclockwise

Outer spring Free length

IN IN

EX Set length (valve closed)

(10.7 -12.3 kg, 23.6 - 27.1 Ib) (10.7 -12.3 kg, 23.6 - 27.1Ib) (2.5%.063 in) (2.5%.063 in)

n EX

<Limit>

ISPECI U-I

43.27 mm (1.70 in) 43.27 mm (1.70 in) <41.27 mm (1.62 in» <41.27 mm (1.62 in» 36.6 mm (1.44 in) 36.6 mm (1.44 in)

2-6

MAINTENANCE SPECIFICATIONS

YFM400FWN

Model Compressed pressure (installed) Tilt limit

Direction of winding (top view)

IN EX IN EX

230 - 266 N 230 - 266 N 2.5°/1.6 mm 2.5°/1.6 mm

IN EX

Clockwise Clockwise

Piston: Piston to cylinder clearance <Limit> Piston size "D"

Measuring point "H" Oversize 2nd Oversize 4th Piston off-set Piston off-set direction Piston pin bore inside diameter Piston pin outside diameter Piston rings: Top ring

Type Dimensions (B x T) End gap (installed) <Limit> Side clearance (installed) <Limit>

ISPECI ~ I

(23.0 - 26.6 kg, 50.7 - 58.7 Ib) (23.0 - 26.6 kg, 50.7 - 58.7 Ib) (2.5%.06 in) (2.5%.06 in)

0.04 - 0.06 mm (0.0016 - 0.0024 in) <0.15 mm (0.0059 in» 82.92 - 82.97 mm (3.265 - 3.267 in)

5.5 mm (0.217 in) 83.5 mm (3.287 in) 84 mm (3.307 in) 0.5 mm (0.02 in) Inside 19.004 - 19.015 mm (0.7482 - 0.7486 in) 18.990 - 18.995 mm (0.7476 - 0.7478 in)

Barrel 1.2 x 3.3 mm (0.047 x 0.130 in) 0.2 - 0.4 mm (0.008 - 0.016 in) <0.5 mm (0.020 in» 0.04 - 0.08 mm (0.002 - 0.003 in) <0.12 mm (0.005 in» 2-7

MAINTENANCE SPECIFICATIONS

ISPECI ~ I

YFM400FWN

Model 2nd ring

DB I Taper 1.5 x 3.4 mm (0.059 x 0.134 in) 0.2 - 0.4 mm (0.008 - 0.016 in) <0.5 mm (0.020 in» 0.03 - 0.07 mm (0.001 - 0.003 in) <0.12 mm (0.005 in»

Type Dimensions (B x T) End gap (installed) <Limit> Side clearance <Limit> Oil ring

~]B I Dimensions (B x T) End gap (installed) Crankshaft:

I 2.8 x 2.8 mm (0.110 x 0.110 in) 0.3 - 0.9 mm (0.012 - 0.035 in)

Crank width A" Runout limit C1 C2 Big end side clearance "B" <Limit> Big end radial clearance Small end free play "0" <Limit> Balancer: Balancer drive method II

58.95 - 59.00 mm (2.321 - 2.323 in) 0.03 mm (0.0012 in) 0.06 mm (0.0024 in) 0.35 - 0.85 mm (0.014 - 0.033 in) <1 mm (0.039 in» 0.010 - 0.025 mm (0.0004 - 0.0010 in) 0.8 - 1.0 mm (0.031 - 0.039 in) <2 mm (0.079 in» Gear

2-8

MAINTENANCE SPECIFICATIONS Model Clutch: Friction plate thickness Quantity Friction plate wear limit Clutch plate thickness Quantity Warp limit Clutch plate thickness Quantity Warp limit Clutch spring free length Quantity Minimum length Clutch release method Automatic centrifugal clutch: Clutch shoe thickness <Wear limit> Clutch shoe spring free length Clutch-in revolution Clutch-stall revolution Transmission: Main axle deflection limit Drive axle deflection limit Shifter: Shifter type Carburetor: I. D. mark Main jet Main air jet Jet needle Needle jet Pilot air jet Pilot air jet Pilot outlet Pilot jet Bypass 1 Bypass 2 Bypass 3 Valve seat size Starter jet Starter jet Throttle valve size Float height

ISPECI U-

YFM400FWN 2.94 - 3.06 mm (0.116 - 0.120 in) 7 2.8 mm (0.11 in) 1.5 - 1.7 mm (0.059 - 0.067 in) 4 0.2 mm (0.008 in) 1.9 - 2.1 mm (0.075 - 0.083 in) 2 0.2 mm (0.008 in) 40.1 mm (1.58 in) 5 39 mm (1.54 in) Inner push, cam push 2 mm (0.08 in) <1.5 mm (0.06 inÂť 42.5 mm (1.67 in) 1,800 - 2,000 r/min 3,150 - 3,500 r/min 0.08 mm (0.003 in) 0.08 mm (0.003 in)

(M.J.) (M.A.J.) (J.N.) (N.J.) (P.A.J.1) (P.A.J.2) (P.O.) (P.J.) (B.P.1) (B.P.2) (B.P.3) (V.S.) (G.S.1) (G.S.2) (Th.V.) (F.H.)

Cam drum and guide bar 5FU1 5FU2 5FU1 00 5FU2 10 f#112.5 f#70 5EP4-55-3 5EP9-55-1 P-OM (#826) ff#80 f1.3 0.8 f#17.5 f0.8 f0.8 f0.8 f2.0 ff#70 f0.9 f#100 12-14mm f(0.47 - 0.55 in)

2-9

MAINTENANCE SPECIFICATIONS

ISPECI u-I

YFM400FWN

Model

5FU2

5FU1 Fuel level

3 - 4mm (0.12 - 0.16 in) 1,450 - 1,550 r/min 33.3 kPa (250 mmHg, 10 inHg)

(F.L.)

Engine idle speed Intake vacuum Lubrication system: Oil filter type Oil pump type Tip clearance" A" or "B" <Limit> Side clearance Bypass valve setting pressure Relief valve operating pressure Oil pressure (hot) Pressure check location Shaft drive: Middle gear backlash Final gear backlash Lubrication chart:

~ ~

Wire mesh type Trochoid type 0.15 mm (0.006 in) <0.2 mm (0.008 in» 0.04 - 0.09 mm (0.002 - 0.004 in) 40 - 80 kPa (0.4 - 0.8 kg/cm2, 5.66 - 11.31 psi) 60 kPa (0.6 kg/cm2, 8.56 psi) 8 kPa (0.08 kg/cm2, 1.16 psi) at 1,500 r/min Cylinder head 0.1 - 0.3 mm (0.004 - 0.012 in) 0.1 - 0.2 mm (0.004 - 0.008 in)

Pressure feed

Splashed scavenge

I Crank pin

Camshaft

,,-_ .. ---"r- _____ ~

I I

•

Piston

•

1 Transmission 1

Clutch

,-.'

I' , :: ,,

1 Rocker

Oil cooler

arm 1

Valve

---------------

r Oil pump

\ \

---------

!!: : valve Bypass

_______ :

______ 1

_ _ _ _ _ .1

Relief valve:

,- - , ,, ,,

Piston pin

I Oil

Oilpon

2 - 10

strainer I

Timing chain area

MAINTENANCE SPECIFICATIONS

ISPECI ~ I

YFM400FWN

Model Crankcase tightening sequence:

Crankcase (right)

Crankcase (left)

CD - @ : M6 bolts @ - @: M8 bolts Cylinder head tightening sequence:

2 - 11

MAINTENANCE SPECIFICATIONS

ISPECI U-

Tightening torques Part to be tightened Cylinder head oil passage check Cylinder head (exhaust pipe) Cylinder head Breather plate Bearing retainer (camshaft)

Part name Union bolt

Stud bolt Bolt Bolt Bolt Bolt

Tightening torque Thread Q'ty size Nm m·kg ft·lb M6 M6 M10 MB M6

1 2 4 2 2

7 7 40 20 10

0.7 0.7 4.0 2.0 1.0

5.1 5.1 29 14 7.2

O.B

5.B

1 1 1

1.B

10 50

1.0 5.0

13 7.2 36

Spark plug Cylinder COl magneto

Bolt Bolt

M12 M6 M10

Balancer driven gear

Nut

M16

6.0

Nut Bolt Plug Bolt Bolt Screw Screw Plug Joint

M7 M10 M11 M6 M6 M6 M6 M35 M14 MB

20 60 23 10 10 7

2.0 6.0 2.3 1.0 1.0 0.7

14 43 17 7.2 7.2 5.1

O.B

5.B

32 50

3.2 5.0

1.B

35 7 16 20 7 20

3.5 . 0.7

Bolt Bolt Bolt Bolt Bolt Nut Bolt Screw

M6 MB MB M6 MB M6 M6 M6 MB M6

2 1 1 2 2 1 3 1 2 2 4 2 2 2 2 1 1 3 2 2 4

23 36 13 25 5.1 11 14 5.1 14

O.B

11 12 27

1.1 1.2 2.7

Torx screw

Bolt Bolt Nut Screw

MB MB M22 M6

Nut

M16

Valve adjusting screw Camshaft sprocket Timing chain tensioner cap Timing chain tensioner Timing chain guide (intake) Oil pump assembly Oil pump Oil drain plug Oil filter cover joint pipe Oil delivery pipe 2 (crankcase) Oil cooler hose Oil cooler Oil delivery pipe 1 (crankcase) Carburetor joint Air filter case Muffler and exhaust pipe Muffler and pipe Exhaust pipe protector Exhaust pipe Muffler Bearing retainer (crankcase) Bearing retainer (crankcase cover) Crankcase Starter one way clutch Clutch carrier Pressure plate Clutch boss

Union bolt

Nut Bolt Union bolt

2 - 12

1.6 2.0 0.7 2.0

5.B B.O B.7

Remarks

-(\] Use lock washer

Use lock washer

-(\]

-4~

O.B

5.B

-(\]

1.0

7.2

-(\]

3 6 1 5

26 30 140

2.6 3.0 14

19 22 100

-(\]

O.B

5.B

9.0

-4~ Stake Use lock washer

MAINTENANCE SPECIFICATIONS Part to be tightened

Part name

Middle drive shaft bearing Torx screw retainer Middle driven shaft drive pinion Nut gear Middle drive shaft bearing housBolt ing Middle driven gear bearing Nut retainer Nut Yoke (middle driven gear) Middle driven gear bearing housBolt ing Nut Yoke (middle driven shaft) Middle driven shaft bearing Nut retainer Torx screw Shift cam side plate Torx screw Shift cam segment Bolt Stopper lever

Thread Q'ty size

ISPECi U-

Tightening torque Remarks Nm

m·kg

ft·lb

2.5

M22

130

3.2

M65

110

M14

9.7

2.5

M14

9.7

-4~

M55

8.0

M6 M6 M6

1 1 1

12 12 10

1.2 1.2 1.0

8.7 8.7 7.2

-4~ -4~ -4~ Use lock washer

Stake

Stopper screw

Screw

2.2

Clutch adjuster locknut Reverse control shifter bracket Shift arm Shift rod Stator assembly Crankcase cover left-thrust washer Pickup coil Lead holder Ignition coil Thermo unit Gear position switch

Nut Bolt Bolt Nut Screw

M8 M6 M6 M6 M6

1 1 1 2 3

20 13 10 10 7

2.0 1.3 1.0 1.0 0.7

14 9.4 7.2 7.2 5.1

Screw

0.7

5.1

-4~

Bolt Bolt Bolt

M5 M5 M6 M12 M6

2 2 2 1 1

7 7 7 20 6

0.7 0.7 0.7 2.0 0.6

5.1 5.1 5.1 14 4.3

-4~

Bolt

2 - 13

-.a

MAINTENANCE SPECIFICATIONS

ISPECI tr-' I

CHASSIS YFM400FWN

Model Steering system: Steering bearing type Front suspension: Shock absorber travel Fork spring free length Spring rate Stroke Optional spring Rear suspension: Shock absorber travel Spring free length 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

Ball bearing

(K1) (K1 )

(K1 ) (K1 )

102 mm (4.02 in) 303.3 mm (11.9 in) 13.7 N/mm (1.37 kg/mm, 76.7 Ib/in) 0- 102 mm (0.00 - 4.02 in) No 100 mm (3.94 in) 299 mm (11.8 in) 253 mm (9.96 in) 30.4 N/mm (3.04 kg/mm, 170 Ib/in) 0- 100 mm (0.00 - 3.94 in) No

end side

1 mm (0.04 in) 1 mm (0.04 in)

radial lateral

Panel wheel 12 x 6.0AT Steel 2 mm (0.08 in) 2 mm (0.08 in)

radial lateral

Panel wheel 12 x 7.5AT Steel 2 mm (0.08 in) 2 mm (0.08 in)

Front disc brake: Type Disc outside diameter x thickness Pad thickness <Limit> Master cylinder inside diameter Caliper cylinder inside diameter Brake fluid type

Single 180 x 3.5 mm (7.09 x 0.14 in) 4.5 mm (0.18 in) <1.0 mm (0.04 inÂť 15.87 mm (0.62 in) 32 mm (1.26 in) DOT4

2 - 14

MAINTENANCE SPECIFICATIONS Model Rear drum brake: Type Brake drum inside diameter <Limit> Lining thickness <Limit> Brake lever & brake pedal: Brake lever free play (at lever end) Brake lever free play (left) Brake pedal position Brake pedal free play Throttle lever free play

ISPECI u-I

YFM400FWN Leading, tailing 160 mm (6.30 in) <161 mm (6.34 inÂť 4 mm (0.16 in) <2 mm (0.08 in> 2 - 5 mm (0.08 - 0.20 in) 5 - 7 mm (0.20 - 0.28 in) 5 mm (0.2 in) 20 - 30 mm (0.8 - 1.2 in) 3 - 5 mm (0.1 - 0.2 in)

2 - 15

MAINTENANCE SPECIFICATIONS

ISPECI 0-1

Tightening torques Tightening torque Part to be tightened

Thread size

Engine stay (front-upper) and frame Engine stay (front-lower) and frame Engine stay (front-upper) and engine Engine stay (front-lower) and engine Engine and frame (rear-upper) Engine and frame (rear-under) Frame and bearing retainer (steering shaft holder bearing) Pivot shaft (left) and frame Pivot shaft (right) and frame Pivot shaft (right) and nut Rear shock absorber and frame Rear gear case and swingarm Bearing housing and swingarm Differential gear case and frame Upper arm and frame Lower arm and frame Front shock absorber and frame Front shock absorber and upper arm Steering shaft and pitman arm Steering shaft holder and frame Steering shaft and handlebar holder Pitman arm and tie-rod end Tie-rod and locknut Steering knuckle and front arm Steering knuckle and tie-rod end Fuel tank and fuel cock Front wheel and wheel hub Front axle and wheel hub Front brake caliper and steering knuckle Front brake disc and wheel hub Brake disc guard and steering knuckle Rear wheel and rear wheel hub Rear axle and nut Rear brake camshaft and camshaft lever Swingarm and rear brake plate Swingarm and rear axle housing Front brake pipe nut Front brake hose union bolt Bleed screw Master cylinder and handlebar Footrest and frame 2 - 16

Remarks Nm

mÂˇkg

ftÂˇlb

MB MB MB M10 M10 M10

30 30 30 55 55 55

3.0 3.0 3.0 5.5 5.5 5.5

22 22 22 40 40 40

M42

4.0

M22 M22 M22 M12 M10 M10 M10 M10 M10 M10 M10 M12

130 6 130 50

13.0 0.6 13.0 5.0

4.B

55 64 45 45 45 45 91

5.5 6.4 4.5 4.5 4.5 4.5 9.1

94 4.3 94 36 35 40 46 32 32 32 32 66

2.3

MB M12 M12 M10 M12 M6 M10 M16 MB MB M6 M10 M16 M6 MB M12 M10 M10 MB M6 M10

23 30 40 25 30 5 64 150 30 30 7 55 150 9

2.3 3.0 4.0 2.5 3.0 0.5 6.4 15 3.0 3.0 0.7 5.5 15 0.9

17 22 29

2.B

105 19 27 6 7 64

10.5 1.9 2.7 0.6 0.7 6.4

1B 22 3.6 46 110 22 22 5.1 40 110 6.5 20 75 13 19 4.3 5.1 46

~ ~

Use lock washer

MAINTENANCE SPECIFICATIONS Part to be tightened

Thread size

M8 M6 M8 M8 M14 M14 M8 M16 M8 M10 M8 M65 M10 M8

Front carrier and frame Front carrier and front bumper Front bumper and frame Rear carrier and frame Final gear case oil filler bolt Final gear case oil drain bolt Differential gear case filler bolt Differential gear case drain bolt Universal joint yoke (differential gear case) Drive pinion gear (differential gear) Ring gear Differential gear case and bearing housing Differential gear case and bearing housing Bearing retainer (drive pinion gear) Final gear case and bearing housing Final gear case and bearing housing

2 - 17

ISPECI u-I

Tightening torque Nm

mÂˇkg

ftÂˇlb

34 11 34 34 23 25 12 12 110 100 50 48 26 100 40 23

3.4 1.1 3.4 3.4 2.3 2.5 1.2 1.2 11.0 10.0 5.0 4.8 2.6 10.0 4.0 2.3

24 8.0 24 24 17 18 8.7 8.7 80 72 36 35 19 72 29 17

Remarks

~ Stake

~ ~

MAINTENANCE SPECIFICATIONS

ISPECI ~ I

ELECTRICAL

YFM400FWN

Model 12 V

Voltage: Ignition system: Ignition timing (B.T.D.C.) Advanced timing (B.T.D.C.) Advancer type

10° at 1,000 r/min 33° at 5,000 r/min Digital type I

5FU1

"'- ~/

Cl c_

"E c..:i :Wei c " oI-

:2aj

.2l

f00

1/-

I I I

5FU2

Engine speed (x 103 r/min)

C.D.I.: Magneto model/manufacturer Pickup coil resistance/color C.D.I. unit model/manufacturer Ignition coil: Model/manufacturer Minimum spark gap Primary winding resistance Secondary winding resistance Spark plug cap: Type Resistance Charging system: Type Model/manufacturer Nominal output Charging coil resistance/color Rectifier: Model/manufacturer Capacity Withstand voltage

F4T423/MITSUBISHI 459 - 561 .Q at 20°C (68 °F)/White/Green White/Red F8T36471/MITSUBISHI 2JN/yAMAHA 6 mm (0.24 in) 0.18 - 0.28.Q at 20°C (68 OF) 6.32 - 9.48 k.Q at 20°C (68 OF) Resin type 10 k.Q A.C. magneto F4T463/MITSUBISHI 14 V 15 A at 5,000 r/min 0.70 - 0.86.Q at 20°C (68 °F)/White - White SH640/SHINDENGEN 14 A 200 V

2 - 18

MAINTENANCE SPECIFICATIONS

YFM400FWN

Model Electric starter system: Type Starter motor: Model/manufacturer Output Armature coil resistance Brush overall length <Limit> Spring force Commutator diameter <Wear limit> Mica undercut Starter relay: Model/manufacturer Amperage rating Coil winding resistance Fan motor relay: Model/man ufactu rer Coil winding resistance Thermo unit: Model/manufacturer Circuit breaker: Type Amperage for individual circuit Main fuse Headlight fuse Ignition fuse Auxiliary DC jack fuse Carburetor warmer fuse

ISPECI ~ I

Constant mesh type DB4DY/DENSO 0.7 kW 0.011 - 0.013 nat 20°C (68 OF) 12 mm (0.47 in) <8.5 mm (0.33 in» 650 - 950 g (22.9 - 33.5 oz) 28 mm (1.10 in) <27 mm (1.06 in» 0.6 mm (0.02 in) MS5F-561/JIDECO 180 A 4.18 - 4.62 n at 20°C (68°F) 29U/MATSUSHITA 72 - 88 n 4SH/DENSO Fuse 30 Ax 15 A x 10 A x 10 A x 10 Ax

2 - 19

1 1 1 1 1

ISPECI_ ..-

HOW TO USE THE CONVERSION TABLEI GENERAL TORQUE SPECIFICATIONS . EB201000

EB202001

HOW TO USE THE CONVERSION TABLE

SPECIFICATIONS

GENERAL TORQUE

This chart specifies torque for standard fasteners with standard I.S.0. pitch threads. Torque specifications for special components or assemblies are provided for each chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a crisscross fashion, in progressive stages, until the specified torque is reached. Unless otherwise specified, torque specifications require clean, dry threads. Components should be at room temperature.

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. MULTIPLIER

METRIC ** mm 2 mm

0.03937 0.03937

x x

IMPERIAL **in 0.08 in

= =

CONVERSION TABLE METRIC TO IMPERIAL Metric unit

Multiplier

Imperial unit

Torque

m·kg m·kg cm.kg cm·kg

7.233 86.794 0.0723 0.8679

ft·lb in·lb ft·lb in·lb

Weight

kg g

2.205 0.03527

Ib oz

Speed

km/hr

0.6214

mph

Distance

km m m cm mm

0.6214 3.281 1.094 0.3937 0.03937

mi ft yd in in

Volume/ Capacity

cc (cm 3 ) cc (cm 3 ) It (liter) It (liter)

0.03527 0.06102 0.8799 0.2199

oz (IMP liq.) cu·in qt (IMP liq.) gal (IMP liq.)

Misc.

kg/mm 55.997 kg/cm2 14.2234 Centigrade 9/5+32 ("C)

L...-->-_

A: Distance between flats 8: Outside thread diameter

A (nut)

Ib/in psi (I b/i n2) Fahrenheit ("F)

2 - 20

B (bolt)

General torque s pecifi cati 0 n s Nm

m-kg

ft-Ib

10 mm

6mm

0.6

4.3

12 mm

8mm

1.5

14 mm

10mm

3.0

17 mm

12 mm

5.5

19 mm

14mm

8.5

22 mm

16 mm

130

13.0

LUBRICATION POINTS AND LUBRICANT TYPE

ISPECI ~ I

LUBRICATION POINTS AND LUBRICANT TYPE ENGINE Lubricant type

Lubrication points

a-ring (all)

~ ~

Bearings (all)

-G

Valve stem/valve stem end

Connecting rod (bearing)

-G -G -G -G -G

Balancer drive gear

-.~

Piston surface/piston rings

-G

Piston pin

-G -G -G

Oil seal lips (all)

Camshaft (cam lobe) Cylinder head bolt/washer Crank pin

Oil pump shaft, rotor, housing Starter idle gear 1,2 Starter wheel gear

Primary driven gear

-G

Push rod

~ ~

Ball (push rod)

-G -G -G -G -G -G -G -G -G

Transmission gear (wheel/pinion) Axle (main/drive) Shift fork/guide bar Shift cam/shift shaft Reverse shift lever Shift ball holder/guide plate Clutch housing Gear coupling Driven cam Crankcase mating surfaces

Sealant (Quick Gasket®) Yamaha Bond No.1215

Starter lead grommet (left side crankcase)

Sealant (Quick Gasket®) Yamaha Bond No.1215

Neutral lead grommet (left side crankcase)

Sealant (Quick Gasket®) Yamaha Bond No.1215

2 - 21

LUBRICATION DIAGRAMS LUBRICATION DIAGRAMS CD Camshaft ® Main axle @ Drive axle @ Crankshaft ® Oil filter ® Oil pump (J) Idle axle ® Oil cooler ® Thermo switch

2 - 22

ISPECI U-I

LUBRICATION DIAGRAMS CD Camshaft ® Oil strainer

® Crankshaft ® Oil pump

@ Main axle @ Drive axle

(j) Idle axle

2 - 23

ISPECI a-I

CABLE ROUTING

ISPECI ~

CABLE ROUTING CD Rear brake switch ® Rear brake cable

® ®

@ Front brake hose @ Throttle cable ® Starter cable ® Handlebar switch lead (J) Neutral indicator light connector and reverse indicator light lead

® @ @ @

2 - 24

Oil temperature warning light Rear brake switch lead Main switch lead Fan motor lead Headlight coupler Differential gear case breather hose Auxiliary DC jack connector

CABLE ROUTING

ISPECI ~ I

[AI Fasten the handlebar switch lead, rear brake switch lead and starter cable to the handlebar with the plastic clamp. [ยง] Route the fuel tank breather hose through the hole in the handlebar cover.

2 - 25

CABLE ROUTING CD Headlight lead ® Fan motor lead

ISPECI u-I

@ Starter motor lead @ Vacuum chamber breather hose @ Rear brake breather hose @ Thermo unit @ Gear position switch @ Rear brake cable

® Starter cable @ Fuel tank breather hose ® Cylinder head breather hose ® Fuse box lead (j) Taillight lead ® Final gear case breather hose ® Thermo unit lead @) Carburetor overflow hose ® COl magneto lead

A-A

2 - 26

CABLE ROUTING

ISPECI ~ I

[A] Fasten the starter cable and final gear case

[Q] Fasten the wire harness and taillight lead with

breather hose with a plastic clamp and then insert the clamp hooks into the frame. [Â§] Fasten the final gear case breather hose and carburetor warmer lead with a plastic clamp and then insert the clamp hooks into the frame. [9 Fasten the wire harness and starter motor lead with a plastic clamp and then insert the clamp hooks into the frame.

a plastic clamp and then insert the clamp hooks into the frame. 50 mm (2.0 in) Pass the rear brake cable and rear brake breather hose through the metal guide. Pass the gear position switch between the engine and the frame. Pass the vacuum chamber breather hose and rear brake breather hose through the hole in the fuel tank.

[g] [ÂŁJ [Q]

[8]

A-A

2 - 27

CABLE ROUTING CD Ignition coil

ISPECI ~ I

[AJ Fasten the wire harness to the frame with a plastic band. [ill 20 - 40 mm (0.8 - 1.6 in) [9 Fasten the wire harness, rear brake cable and reverse control cable with a plastic clamp and than insert the clamp hooks into the frame. [Q] 140 - 160 mm (5.5 - 6.3 in) ~ Fasten the wire harness and spark plug lead to the frame.

® Rear brake cable @ Reverse control cable @ Thermo unit coupler ® Rear brake breather hose ® Throttle cable (J) Wire harness

A-A

2 - 28

CABLE ROUTING CD Headlight lead

ISPECI ~ I

@ Fan motor relay @ Fuse box @ Auxiliary DC jack connector

® Auxiliary DC jack @ Diode @ Starter relay ® Positive battery lead ® Fan motor control unit (J) Battery ® Rectifier/regulator ® COl unit @) Negative battery lead ® Starting circuit cut-off relay

IAI To the fan motor. [§] Fasten the headlight lead (wire harness side) and differential gear case breather hose to the frame with a plastic band. [g Fasten the wire harness and differential gear case breather hose to the frame with a plastic clamp.

A-A

2 - 29

INTRODUCTION/ PERIODIC MAINTENANCE/LUBRICATION

1'0.1

IINSP ADJ ~

PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable machine operation and a longer service life. In addition, the need for costly overhaul work will be greatly reduced. This information applies to machines already in service as well as new machines that are being prepared for sale. All service technicians should be familiar with this entire chapter.

PERIODIC MAINTENANCE/LUBRICATION INITIAL

ROUTINE

ITEM

EVERY

1 month 3 months 6 months 6 months

Valves*

• Check valve clearance. • Adjust if necessary.

Spark plug

• Check condition. • Adjust gap and clean. • Replace if necessary.

Air filter

• Clean. • Replace if necessary.

Carburetor*

• Check and adjust idle speed/starter operation. • Adjust if necessary.

Cylinder head cover breather system*

1 year

Every 20-40 hours (More often in wet or dusty areas.)

• Check breather hose for cracks or damage. • Replace if necessary.

Exhaust system*

• Check leakage. • Retighten if necessary. • Replace gasket if necessary.

Spark arrester

• Clean.

Fuelline*

• Check fuel hose for cracks or damage. • Replace if necessary.

Engine oil

• Replace (Warm engine before draining). • Replace.

Engine oil strainer

• Clean.

0 0 0

Engine oil filter

0 0 0

Final gear oil

• Check oil level/oil leakage. • Replace every 12 months.

Front brake*

• Check operation/fluid leakage/see NOTE. • Correct if necessary.

Rear brake*

• Check operation. • Adjust if necessary.

Clutch*

• Check operation. • Adjust if necessary.

Reverse release cable*

• Check operation. • Adjust if necessary.

Wheels*

• Check balance/damage/run out. • Repair if necessary.

Wheel bearings*

• Check bearing assembly for looseness/ damage. • Replace if damaged.

Differential gear oil

3-1

PERIODIC MAINTENANCE/LUBRICATION INITIAL

ROUTINE

ITEM

I'~gs

I_I

EVERY

1 month 3 months 6 months 6 months

Steering system*

• Check operation. • Replace if damaged. • Check toe-in. • Adjust if necessary.

Drive shaft universal joint

• Lubricate.

Front axle boots*

• Check operation. • Replace if damaged.

Fittings and Fasteners*

• Check all chassis fittings and fasteners. • Correct if necessary.

0 0

*It is recommended that these items be serviced by a Yamaha dealer.

NOTE: Recommended brake fluid: DOT 4 (If DOT 4 is not available, DOT 3 can be used.)

A WARNING Indicates a potential hazard that could result in serious injury or death.

3-2

1 year

SEAT. CARRIERS. FENDERS AND FUEL TANK

II~r

I_I

SEAT, CARRIERS, FENDERS AND FUEL TANK REMOVAL 1.Place the machine on a level place. 2.Remove: • Seat

NOTE:

Pull up the seat lock lever CD, then remove by pulling up on the rear of the seat.

3.Remove: • Front carrier

4.Remove: • Differential gear case guard

5.Remove: • Front bumper CD

6.Disconnect: • Headlight couplers 7.Pull back the rubber cover CD from auxiliary DC jack. a.Disconnect: • Auxiliary DC jack connectors ®

3-3

SEAT, CARRIERS, FENDERS AND FUEL TANK

-------------------------------------------------

IIANoSJP 1'0'1

_~ _

9_Remove: • Front Fender CD

10.Turn the fuel cock lever to "OFF". 11.Disconnect: • Fuel hose CD

NOTE:

OFF ~===d

Place a rug on the engine to absorb spilled fuel.

A WARNING Gasoline is highly flammable. Avoid spilling fuel on the hot engine.

12.Remove: • Fuel tank CD

NOTE: Remove the breather hoses @ from fuel tank.

3-4

and air duct

SEAT, CARRIERS, FENDERS AND FUEL TANK I IANoSJP

----------------------------------------------------

1'0)

13.Remove: • Battery holder CD 14.Disconnect: • Battery leads

:::l:!::g~wli,!~I~:;l::!lll

________

Disconnect the negative lead first and then disconnect the positive lead.

15.Remove: • Battery CD • Starting circuit cut-off relay ® • Fan motor relay @ 16.Disconnect: • Ground lead @ • Starter relay coupler ® • Fan motor control unit coupler • Fuse box coupler 17.Remove: • Rear carrier

18.Remove: • Air filter case mounting bolt CD • Rear fender ®

INSTALLATION Reverse the "REMOVAL" procedure. Note the following points. 1.lnstall: • Fuel tank CD Bolt: 10 Nm (1.0 m • kg, 7.2 ft· Ib)

3-5

SEAT, CARRIERS, FENDERS AND FUEL TANK

1'~5j

I_I

NOTE: • Insert the air intake manifold, vacuum chamber breather hose and rear brake breather hose into the fuel tank. Refer to "CABLE ROUTING". • Insert the fuel tank breather hose ® into the handlebar protector hole ®. Refer to "CABLE ROUTING". 2.1nstall: • Rear fender • Fan motor relay • Starter circuit cut-off relay • Battery • Battery holder 3.Connect: • Battery leads

ii::!!::§lielll,:;:i!i::: ________ Connect the positive lead first and then connect the negative lead.

4.lnstall: • Rear carrier

Bolt (rear carrier and frame): 34 Nm (3.4 m • kg, 24 ft • Ib)

5.lnstall: • Front fender • Front bumper

Bolt (front bumper): 34 Nm (3.4 m • kg, 24 ft • Ib)

3-6

IANoSJP 1·0)1 I -------------------------------------------------SEAT, CARRIERS, FENDERS AND FUEL TANK 6.lnstall: • Front carrier

Bolt (front carrier and frame): 34 Nm (3.4 m • kg, 24 ft • Ib) Nut (front carrier and front bumper): 11 Nm (1.1 m • kg, 8.0 ft ·Ib)

7.lnstall: • Seat

NOTE: Insert the lobe CD on the seat front into the receptacle CV on the frame, then push down the seat at the rear.

3-7

VALVE CLEARANCE ADJUSTMENT

I'~gf I~ I

ENGINE VALVE CLEARANCE ADJUSTMENT NOTE: • The valve clearance must be adjusted when the engine is cool to the touch. • Adjust the valve clearance when the 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) CD • Tappet cover (exhaust) CV 3.Disconnect: • Spark plug cap @ 4.Remove: • Spark plug

5.Remove: • Timing plug CD • Recoil starter CV

6.Check: • Valve clearance Out of specification

Adjust.

Valve clearance (cold): Intake: 0.06 - 0.10 mm (0.002 - 0.004 in)

Exhaust: 0.16 - 0.20 mm (0.006 - 0.008 in)

3-8

VALVE CLEARANCE ADJUSTMENT

1'~gS I_I

********************************* Checking steps: .Turn the crankshaft counterclockwise with a wrench . • Align the "T" mark CD on the rotor with the stationary pointer ® on the crankcase cover. When the "T" mark is aligned with the stationary pointer, the piston is at Top Dead Center (T.D.C.).

NOTE: T.D.C. on the compression stroke check: • Both rocker arms must have a valve clearance when the rotor match mark CD is aligned with the stationary pointer match mark®. • If not, give the crankshaft one counterclockwise turn to meet the above condition.

• Measure the valve clearance feeler gauge @.

using a

*********************************

/ 7.Adjust: • Valve clearance

********************************* Adjustment steps: • Loosen the locknut CD . • Insert a feeler gauge ® between the adjuster end and the valve end . • Turn the adjuster @ clockwise or counterclockwise with the valve adjusting tool @ until the proper clearance is obtained.

~ Valve adjusting tool: PIN. YM-08035, 90890-04133

<?' -

• Hold the adjuster to prevent it from moving and then tighten the locknut. Locknut: 20 Nm (2.0 m • kg, 14 ft· Ib)

3-9

VALVE CLEARANCE ADJUSTMENT/ TIMING CHAIN ADJUSTMENT

IINSP

ADJ

1'0.1 ~

_..;;;;...=-..I

L....,,;.,~;....;;;;...........

e Measure the

valve clearance. elf the clearance is incorrect, repeat the above steps until the proper clearance is obtained.

*********************************

8.lnstall: • Timing plug • Spark plug • Tappet cover (exhaust) • Tappet cover (intake) Spark plug: 18 Nm (1.8 m • kg, 13 ft· Ib)

NOTE: Install the tappet covers with the ridge facing up CD.

1KI Exhaust [g] Intake

9.lnstall:

• Fuel tank • Front fender • Front carrier • Seat Refer to "SEAT, CARRIERS, FENDERS AND FUEL TANK".

TIMING CHAIN ADJUSTMENT Adjustment free.

3 - 10

IDLING SPEED ADJUSTMENT

1'~gS

Itill

IDLING SPEED ADJUSTMENT 1.Start the engine and let it warm up for several minutes. 2.Attach: • Inductive tachometer or engine tachometer (to the spark plug lead) Inductive tachometer: PIN. YU-8036-A Engine tachometer: PIN. 90890-03113 3.Check: • Engine idling speed Out of specification ~ Adjust. Engine idling speed: 1,450 - 1,550 rlmin

4.Adjust: • Engine idling speed

********************************* Adjustment steps: • Turn the throttle stop screw CD in or out until the specified idling speed is obtained. Turning in

Idling speed becomes higher.

Turning out

Idling speed becomes lower.

********************************* 5.Detach: • Engine tachometer 6.Adjust: • Throttle lever free play Refer to "THROTTLE LEVER FREE PLAY ADJUSTMENT". Throttle lever free play: 3 - 5 mm (0.12 - 0.20 in)

3 - 11

THROTTLE LEVER FREE PLAY ADJUSTMENT

II~gj 14Iil1

THROTTLE LEVER FREE PLAY ADJUSTMENT NOTE: Engine idling speed should be adjusted properly before adjusting the throttle lever free play.

1.Check: • Throttle lever free play ® Out of specification -7 Adjust. Throttle lever free play: 3 - 5 mm (0.12 - 0.20 in)

2.Adjust: • Throttle lever free play

********************************* Adjustment steps: First step: • Pull back the adjuster cover CD. • Loosen the locknut @ on the carburetor side . • Turn the adjuster@ in or out until the correct free play is obtained. Turning in

Free play is increased.

Turning out Free play is decreased .

• Tighten the locknut @. • Push in the adjuster cover CD.

NOTE: If the free play cannot be adjusted here, adjust it at the throttle lever side of the cable.

3 - 12

THROTTLE LEVER FREE PLAY ADJUSTMENT/ SPEED LIMITER ADJUSTMENT

IINSP 1 to. ADJ ~

L-.::....:.=:;...;:~_-=:..=....I

Second step: • Pull back the adjuster cover @. • Loosen the locknut @ . • Turn the adjuster ® in or out until the correct free play is obtained. Turning in

Free play is increased.

Turning out Free play is decreased .

• Tighten the locknut @. • Push in the adjuster cover @.

A 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.

********************************* SPEED LIMITER ADJUSTMENT The speed limiter keeps the carburetor throttle from becoming fully-opened even when the throttle lever is applied to the maximum position. Screwing in the adjuster stops the engine speed from increasing.

1.Check: • Speed limiter length ® Out of specification ~ Adjust. Speed limiter length: 12 mm (0.47 in)

2.Adjust: • Speed limiter length

********************************* Speed limiter length adjustment steps: • Loosen the locknut CD . • Turn the adjuster ® in or out until the specified speed limiter length is obtained.

3 - 13

Ito) I

SPEED LIMITER ADJUSTMENT/ I'~~j STARTER LEVER FREE PLAY ADJUSTMENT. . ~. Turning in

Speed limiter length is decreased.

Turning out

Speed limiter length is increased.

• Tighten the locknut.

A WARNING • Particularly for a beginner rider, the speed limiter should be screwed in completely. Screw it out little by little as their riding technique improves. Never remove the speed limiter for a beginning rider. • For proper throttle lever operation do not turn out the adjuster more than 12 mm (0.47 in). Also, always adjust the throttle lever free play to 3 - 5 mm (0.12 - 0.20 in).

********************************* STARTER LEVER FREE PLAY ADJUSTMENT 1.Check: • Starter lever free play ® Out of specification -7 Adjust. Starter lever free play: 5.5 - 14.2 mm (0.22 - 0.56 in)

2.Adjust: • Starter lever free play

********************************* Adjustment steps: .Pull back the adjuster cover CD . • Loosen the locknut@ . • Turn the adjuster@ in or out until the correct free play is obtained. Turning in

Free play increased.

Turning out Free play decreased. • Tighten the locknut @. • Push in the adjuster cover CD.

A WARNING After adjusting the free play, turn the handlebar to right and left, and make sure that the engine idling speed does not increase.

********************************* 3 - 14

SPARK PLUG INSPECTION/IGNITION TIMING CHECK

I'~gr

I_I

SPARK PLUG INSPECTION 1.Remove: • Spark plug 2.lnspect: • Spark plug type Incorrect ~ Replace. Standard spark plug: DR8EA/NGK

3.1nspect: • Electrode CD Wear/damage ~ Replace. • Insulator ® Abnormal color ~ Replace. Normal color is a medium-to-light tan color. 4.Clean the spark plug with a spark plug cleaner or wire brush. 18040201

5.Measure: • Plug gap ® Use a wire gauge or feeler gauge. Out of specification ~ Regap. Spark plug gap: 0.6 - 0.7 mm (0.024 - 0.028 in)

18040201

6.Tighten: • Spark plug Spark plug: 18 Nm (1.8 m • kg, 13 ft· Ib)

NOTE: Before installing a spark plug, clean the gasket surface and plug surface. IGNITION TIMING CHECK NOTE: Engine idling speed and throttle cable free play should be adjusted properly before checking the ignition timing. 1.Attach: • Inductive tachometer or engine tachometer • Timing light (to spark plug lead) 3 - 15

IINSP I(0. I ADJ ~

IGNITION TIMING CHECKI COMPRESSION PRESSURE MEASUREMENT :

Inductive tachometer: PIN. YU-8036-A Engine tachometer: PIN. 90890-03113 Timing light: PIN. YM-33277-A, 90890-03141 2.Check: • Ignition timing

********************************* Checking steps: .Warm up the engine and keep it at the specified speed. ~

Engine speed: 1,450 - 1,550 rlmin

• Remove the timing plug CD . . • Visually check the stationary pointer ® to verify it is within the required firing range @ indicated on the flywheel. Incorrect firing range ~ Check the pulser coil assembly . • Install the timing plug.

*********************************

COMPRESSION PRESSURE MEASUREMENT NOTE: Insufficient compression pressure result in a loss of performance.

wi.ll

1.Check: • Valve clearance Out of specification ~ Adjust. Refer to "VALVE CLEARANCE ADJUSTMENT". 2.Start the engine and let it warm up for several minutes. 3.Stop the engine. 4.Remove: • Spark plug 3 - 16

to.

COMPRESSION PRESSURE MEASUREMENT I IANoSJP 1 ~ 1

-------------------------------------------------5.Attach: • Adapter CD • Compression gauge

Compression gauge: PIN. YU-33223, 90890-03081 Adapter: PIN. YU-33223-3, 90890-04082

6.Measure: • Compression pressure Above the maximum pressure: Inspect the cylinder head, valve surfaces, and piston crown for carbon deposits. Below the minimum pressure: Squirt a few drops of oil into the affected cylinder and measure again. • Refer to the table below. Compression pressure (with oil introduced into cylinder) Reading

Diagnosis

Higher than without oil

Worn or damaged pistons

Same as without oil

Defective ring(s), valves, cylinder head gasket or piston is possible.

Compression pressure (at sea level): Standard: 920 kPa (9.2 kg/cm 2 , 131 psi) Minimum: 750 kPa (7.5 kg/cm 2 , 108.8 psi) Maximum: 1,000 kPa (10.0 kg/cm 2 , 145 psi)

********************************* Measurement steps: .Crank over the engine with the electric starter (be sure the battery is fully charged) with the throttle wide-open until the compression reading on the gauge stabilizes.

WARNING

When cranking the engine, ground the spark plug lead to prevent sparking.

*********************************

3 - 17

Ito) I

COMPRESSION PRESSURE MEASUREMENT/ 1'~5j ENGINE OIL LEVEL INSPECTION . . ~ . 7.1nstall: • Spark plug

Spark plug: 18 Nm (1.8 m • kg, 13 ft· Ib)

ENGINE OIL LEVEL INSPECTION 1.Place the machine on a level surface. 2.1nspect: • Engine oil level Oil level should be between the maximum CD and minimum ® marks. Oil level low ~ Add oil to the proper level. NOTE: Do not screw the dipstick @ in when inspecting the oil level. 0° I:,

! I,

i SAE j

10°

30°

50°

70°

90°

I1 YAMALuBE I I Ior SAE'20W40 I 4 (20W40)

YAMAL0BE 4 (,hW30)

5130 ,

Recommended oil: Follow the left chart.

110°F

!:"

i l l

dr SAE ,6W30 i

NOTE: Recommended oil classification: API Service "SE", "SF" type or equivalent (e.g. "SF-SE-CC", "SF-SE-SO" etc.)

I I I I~ I

::::::::@Iggm:~::::::: Do not allow foreign material to enter the crankcase. 3.Start the engine and let it warm up for several minutes. 4.Stop the engine and inspect the oil level again. NOTE: Wait a few minutes until the oil settles before inspecting the oil level.

A WARNING Never remove the dipstick just after high speed operation because the heated oil could spurt out. Wait until the oil cools down before removing the dipstick.

3 - 18

OIL TEMPERATURE WARNING LIGHT CHECKI ENGINE OIL REPLACEMENT

IINSP I to)

ADJ

....

L...;....:.;;;;;;...;:;.....J~-=:-=

OIL TEMPERATURE WARNING LIGHT CHECK CD Oil temperature warning light

Oil temperature warning light checking method. Main switch "ON". Engine stop switch "RUN".

~-----------------------------------

Oil temperature warning light does not come on.

Oil temperature warning light comes on.

+ Push starter switch with transmission in "NEUTRAL".

+ Check engine oil temperature.

Oil temperature warning light comes on.

t Engine oil temperature and electrical circuit are OK. Go ahead with riding.

Oil temperature warning light does not come on.

Oil temperature is low.

Oil temperature is high.

~ Refer to "SIGNAL SYSTEM" in CHAPTER 8.

I Cool the engine oil. I

ENGINE OIL REPLACEMENT 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: • Dipstick CD • Drain plug (engine oil) ® (with O-ring, spring and strainer) Drain the crankcase of its oil.

3 - 19

ENGINE OIL REPLACEMENT

II~gS

1-.1

4.lf the oil filter is to be replaced during this oil change, remove the following parts and then reinstall them afterwards.

********************************* Replacement steps: .Remove the oil filter cover CD and oil filter element ® . • Check the O-rings @; ifthey are cracked or damaged, replace them with new ones . • Install the oil filter element and oil filter cover.

~ Bolt (oil filter cover): ~~ 10 Nm (1.0 m· kg, 7.2 ft ·Ib)

********************************* 5.lnstall: • Drain plug (engine oil)

:jjj:::I!_llj~::::j::

--------

Before reinstalling the drain plug CD, do not forget to install the a-ring ®, compression spring @ and oil strainer @. Drain plug (engine oil): 32 Nm (3.2 m • kg, 23 ft • Ib)

6.Fill: • Crankcase Refer to "ENGINE OIL LEVEL INSPECTION". Oil quantity: Total amount: 3.5 L (3.1 Imp qt, 3.7 US qt) Periodic oil change: 2.9 L (2.6 Imp qt, 3.1 US qt) With oil filter replacement: 3.0 L (2.6 Imp qt, 3.2 US qt) 7.lnstall: • Dipstick B.Warm up the engine for a few minutes, then stop the engine.

3 - 20

IANoSJP I -------------------------------------------------ENGINE OIL REPLACEMENT/CLUTCH ADJUSTMENT

1'0.1 ~

9.lnspect:

• Engine (for oil leaks) .Oillevel

10.lnspect: • Oil flow

********************************* Inspection steps: .Slightly loosen the oil gallery bolt CD in the cylinder head . • Start the engine and keep it idling until oil begins to seep from the oil gallery hole. If no oil comes out after one minute, stop the engine immediately so the engine will not seize. • Check the oil passages, oil filter, and oil pump for damage or leakage. Refer to "INSPECTION AND REPAIR" in CHAPTER 4. • Restart the engine after solving the problem(s), and recheck the oil pressure . • Stop the engine and tighten the oil gallery bolt (with gasket) to specification.

Bolt (oil gallery): 7 Nm (0.7 m· kg, 5.1 ft ·Ib)

*********************************

CLUTCH ADJUSTMENT 1.Adjust: • Free play

********************************* Adjustment steps: • Loosen the locknut CD . • Slowly turn the adjuster 0 counterclockwise until resistance is felt . • Then turn it clockwise 1/8 of a turn.

NOTE: Turn the adjuster counterclockwise to decrease the clutch free play and turn it clockwise to increase the free play.

:·;QAum~~N·~·:· Do not start the engine while increasing the clutch free play.

3 - 21

IANOSJP 1'0) 1 I ------------------------------------------------------CLUTCH ADJUSTMENT/AIR FILTER CLEANING

.Tighten the locknut.

Clutch locknut: 15 Nm (1.5 m • kg, 11 ft ·Ib)

*********************************

AIR FILTER CLEANING NOTE: There is a check hose CD at the bottom of the air filter case. If dust and/or water collects in this hose, clean the air filter element and air filter case.

1.Remove: • Seat Refer to "SEAT, CARRIERS, FENDERS AND FUEL TANK". • Air filter case cover CD

2.Remove: • Air filter assembly CD

3.Remove: • Air filter element CD • Foam cover ®

::::::::II_IN:~::::!::

- _______

The engine should never be run without the air filter; excessive piston and/or cylinder wear may result.

4.lnspect: • Air filter element CD • Foam cover ® Damage ~ Replace. 3 - 22

IANOSJP Ito) I I --------------------------------------------------------AIR FILTER CLEANING 5.Clean: • Air filter element Use compressed the inner surface 6.Clean: • Foam cover Use compressed the inner surface

air to blow off dust from of the element.

air to blow off dust from of the foam cover.

7.1nstall: • Foam cover (to air filter) 8.lnstall: • Air filter assembly NOTE: Make sure its sealing surface matches the sealing surface of the case so there is no air leak. 9.lnstall: • Air filter case cover • Seat Refer to "SEAT, CARRIERS, FENDERS AND FUEL TANK".

SPARK ARRESTER CLEANING 1.Clean: • Spark arrester

********************************* Cleaning steps:

A WARNING • Select a well-ventilated area free of combustible materials. • Always let the exhaust system cool before performing this operation. • Remove the bolt <D . • Start the engine and rev it up approximately twenty times while momentarily creating exhaust system back pressure by blocking the end of the muffler with a shop towel ®.

iJ-/1..t\ ,-

3 - 23

SPARK ARRESTER CLEANING

I'~gr

I_I

eStop the engine and allow the exhaust pipe to cool. el nsert the bolt CD and tighten it.

*********************************

3 - 24

REAR BRAKE LEVER AND PEDAL ADJUSTMENT

1'~5r Itill

CHASSIS REAR BRAKE LEVER AND PEDAL ADJUSTMENT

A WARNING Always adjust both the brake pedal and the rear brake lever whenever adjusting the rear brake.

1.Check: • Rear brake pedal free play ® • Rear brake lever free play (6) Out of specification ~ Adjust. Rear brake pedal free play ®: 20 - 30 mm (0.8 - 1.2 in) Rear brake lever free play (6): 5 - 7 mm (0.20 - 0.28 in)

2.Adjust: • Free play (rear brake lever) • Free play (brake pedal)

********************************* Rear brake lever and brake pedal free play adjustment steps:

NOTE: Before adjusting the free play, pump the brake pedal 2 to 3 times.

3 - 25

REAR BRAKE LEVER AND PEDAL ADJUSTMENT

jlANOSJP j'O.j ~

--------------------------------------------------------.Fully loosen the brake lever cable adjuster (drum) CD. • Turn the rear brake pedal rod adjuster @ until the brake pedal free play is within the specified limits.

Free play (brake pedal): 20 - 30 mm (0.8 - 1.2 in)

.Fully screw in the brake lever cable adjuster (handlebar) @. • Turn the brake lever cable adjuster (drum) CD clockwise until the gap © is within the specified limits.

Gap©: Zero - 1 mm (0.00 - 0.04 in)

.Inspect the free play (brake pedal) to see whether or not it is within the specified limits. If not, perform the above steps again.

Free play (brake pedal): 20 - 30 mm (0.8 - 1.2 in) • Loosen the locknut (handlebar) @. • Turn the brake lever cable adjuster (handlebar) @ until the free play (brake lever) is within the specified limits. Free play (brake lever): 5 - 7 mm (0.20 - 0.28 in) .Tighten the locknut (handlebar) @.

WARNING

After this adjustment is performed, lift the front and rear wheels off the ground by placing a block under the engine, and spin the rear wheels to ensure there is no brake drag. If any brake drag is noticed perform the above steps again.

*********************************

3 - 26

FRONT BRAKE FLUID LEVEL INSPECTION! FRONT BRAKE PAD INSPECTION

IINSP Ito) I ADJ ~

a....:.":'::;;"';::;--L._-=-=...I

FRONT BRAKE FLUID LEVEL INSPECTION 1.Place the machine on a level surface. NOTE: When inspecting the front brake fluid level, make sure that the top of the master cylinder top is horizontal.

2.lnspect: • Brake fluid level Fluid level is under "LOWER" level line @ ~ Fill up. Recommended brake fluid: DOT 4

NOTE: If DOT 4 is not available, DOT 3 can be used.

:::::::1.8;21@1:;::::::: - - - - - -__ Brake fluid may erode painted surfaces or plastic parts. Always clean up spilled fluid immediately.

A WARNING • Use only the recommended brake fluid; otherwise, the rubber seals may deteriorate, causing leakage and poor brake performance. • Refill with the same type of brake fluid; mixing fluids may result in a harmful chemical reaction and lead to poor performance. • Be careful that water does not enter the master cylinder when refilling. Water will significantly lower the boiling point of the fluid and may result in a vapor lock.

3 - 27

FRONT BRAKE PAD INSPECTION 1.Remove: • Front wheels 2.lnspect: • Brake pad Wear indicators G) almost touch the brake disc ~ Replace the brake pads as a set. Refer to "FRONT BRAKE" in CHAPTER 7. 3.0perate the brake lever. 4.lnstall: • Front wheels

REAR BRAKE SHOE INSPECTION/BRAKE HOSE INSPECTION/ AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)

IINSP ADJ

1'0.1 ~

J.....,;....=.;;;;;....;;;;;.--'-_~.-.....

REAR BRAKE SHOE INSPECTION 1.Apply the rear brake lever or brake pedal. 2.lnspect: • Wear indicator CD reaches the wear limit line @ 4 Replace the shoes as a set. Refer to "REAR BRAKE" in CHAPTER 7.

BRAKE HOSE INSPECTION 1.Remove: • Seat • Front carrier • Front fender Refer to "SEAT, CARRIERS, FENDERS AND FUEL TANK".

2.lnspect: • Brake hoses CD Cracks/wear/damage 4 Replace. 3.Check: • Brake hose clamp Loosen 4 Tighten. 4.Hold the machine in an upright position and apply the front or rear brake. 5.Check: • Brake hoses Active the brake lever several times. Fluid leakage 4 Replace the hose. Refer to "FRONT BRAKE" in CHAPTER 7. 6.lnstall: • Front fender • Front carrier • Seat Refer to "SEAT, CARRIERS, FENDERS AND FUEL TANK". AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)

A WARNING 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 3-28 _______________________________ _ the brake system is not properly bled.

1'0·1 1 -------------------------------------------------AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) . iANOSJP

1.Bleed: • Brake system

********************************* Air bleeding steps: a. Add the proper brake fluid to the reservoir. b. Install the diaphragm. Be careful not to spill any fluid or allow the reservoir to overflow. c. Connect the clear plastic hose CD tightly to the caliper bleed screw C?). d. Place the other end of the hose into a container. e. Slowly apply the brake lever several times. f. Pull the lever in and hold it. g. Loosen the bleed screw and allow the lever to travel towards its limit. h. Tighten the bleed screw when the lever limit has been reached, then release the lever. i. Repeat steps (e) to (h) until all the air bubbles have disappeared from the fluid. j. Tighten the bleed screw.

Bleed screw: 6 Nm (0.6 m • kg, 4.3 ft • Ib) NOTE: If bleeding is difficult, it may be necessary to let the brake fluid settle for a few hours. Repeat the bleeding procedure when the tiny bubbles in the system have disappeared. k. Add brake fluid to the proper level. Refer to "BRAKE FLUID LEVEL INSPECTION" .

A WARNING Check the operation of the brake after bleeding the brake system. *********************************

3 - 29

REVERSE CONTROL CABLE ADJUSTMENT! SHIFT PEDAL ADJUSTMENT

IINSP

ADJ

1'0)

L...:.-=~;.......J_-=;"";;;;:...J

REVERSE CONTROL CABLE ADJUSTMENT 1.Check: • Reverse control cable end length @ Out of specification -7 Adjust.

end length: I ~ Cable .:6.1 38 mm (1.5 in) 2.Adjust: • Reverse control cable end length

********************************* Adjustment steps: • Loosen the locknut CD . • Turn the adjuster CV in or out unit the specified cable end length is obtained. Turning in

Cable end length is decreased.

Turning out

Cable end length is increased.

• Tighten the locknut . • Check the reverse control cable slack. If the reverse control cable is slack, adjust it using the locknut @ and the adjuster @.

*********************************

SHIFT PEDAL ADJUSTMENT 1.Check: • Shift pedal height @ Out of specification -7 Adjust. Shift pedal height: 26 mm (1.02 in) 2.Adjust: • Shift pedal position

********************************* Adjustment steps: • Remove the shift rod cover. • Loosen the locknut CD. • Turn the shift pedal rod CV in or out to set the correct pedal height.

Turning in

Pedal is lowered.

Turning out

Pedal is raised.

• Ti g hten both lockn uts . • Install the shift rod cover.

********************************* 3 - 30

FINAL GEAR OIL LEVEL INSPECTIONI FINAL GEAR OIL REPLACEMENT

IINSP Ito) I ADJ ~

L-:..-==;....:.--L_..;;;;...~

FINAL GEAR OIL LEVEL INSPECTION 1.Place the machine on a level surface. 2.Remove: • Oil filler bolt <D 3,lnspect: .Oillevel Oil level should be up to the bottom brim @ of the hole. Oil level low ---jo Add oil to the proper level. ~

• \..J' .

Recommended oil: SAE 80 API IGL-4" Hypoid gear .','.

_________

::::::::g~g!IN:8:::::: Take care not to allow foreign material to enter the final gear case. 4.lnstall: • Oil filler bolt Oil filler bolt 23 Nm (2.3 m • kg, 17 ft • Ib)

FINAL GEAR OIL REPLACEMENT 1.Place the machine on a level surface. 2.Remove: • Final gear case protector <D 3.Place a receptacle under the final gear case.

4.Remove: • Oil filler bolt • Drain plug <D 5.Drain: • Final gear oil

3 - 31

Ito) I

FINAL GEAR OIL REPLACEMENT! II~gS DIFFERENTIAL GEAR OIL QUANTITY INSPECTION . . ~ _ 6.lnstall: • Drain plug

~ ""

Drain plug: 23 Nm (2.3 m· kg, 17 ft ·Ib)

NOTE: Check the gasket (drain plug). If it is damaged, replace it with a new one. 7.Fill: • Final gear case ~

• L.J

1 - - -....

Periodic oil change: 0.23 L (0.20 Imp qt, 0.24 US qt) Total amount: 0.25 L (0.22 Imp qt, 0.26 US qt) Recommended oil: SAE80 API"GL-4" Hypoid gear oil

:::IclutmIIE:::: ---------,.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.,.:.

Take care not to allow foreign material to enter the final gear case.

8.lnspect: .Oillevel Refer to "FINAL GEAR OIL LEVEL INSPECTION". 9.lnstall: • Oil filler bolt • Final gear case protector Oil filler bolt: 23 Nm (2.3 m • kg, 17 ft • Ib)

DIFFERENTIAL GEAR OIL QUANTITY INSPECTION 1.Place the machine on a level surface. 2.Place a receptacle under the differential gear case. 3.Remove: • Oil filter bolt • Drain plug CD

3 - 32

I I

DIFFERENTIAL GEAR OIL QUANTITY INSPECTIONI II~gS (0) DIFFERENTIAL GEAR OIL REPLACEMENT . . ~ . 4.Drain: • Differential gear oil 5.Check: • Differential gear oil quantity Out of specification ~ Add the recommended oil. Oil quantity: 0.1S L (0.16 Imp qt, 0.19 US qt) NOTE: If the oil has become dirty, replace if with new differential gear oil. 6.lnstall: • Drain plug Drain plug: 12 Nm (1.2 m • kg, S.7 ft· Ib) NOTE: Check the gasket (drain plug). If it is damaged, replace it with new one. 7.Fill: • Differential gear case Recommended oil: SAESO or SAE SOW-90 API "GL_ 5" Hypoid gear oil for L.S.D. (Limited Slip Differential)

iiiiiiiiglBlli;iiiiiii _________ Take care not to allow foreign material to enter the differential gear case. a.lnstall: • Oil filler bolt

~ ""

Oil filler bolt: 12 Nm (1.2 m • kg, S.7 ft • Ib)

DIFFERENTIAL GEAR OIL REPLACEMENT 1.Place the machine on a level surface. 2.Place a receptacle under the differential gear case.

3 - 33

Ito) I

DIFFERENTIAL GEAR OIL REPLACEMENTI II~gS CONSTANT VELOCITY JOINT DUST BOOT INSPECTION. . ~ . 2.Remove: • Oil filler bolt • Drain plug CD 3.Drain: • Differential gear oil 4.lnstall: • Drain plug

Drain plug: 12 Nm (1.2 m • kg, 8.7 ft ·Ib)

NOTE: Check the gasket (drain plug). If it is damaged, replace it with new one.

5.Fill: • Differential gear case Periodic oil change: 0.18 L (0.16 Imp qt, 0.19 US qt) Total amount: 0.2 L (0.18 Imp qt, 0.21 US qt) Recommended oil: SAE80 or SAE 80W-90 API "GL5" Hypoid gear oil for L.S.D. (Limited Slip Differential)

::::::::@IIIIII,:;:::::::: - -______ Take care not to allow foreign material to enter the differential gear case.

6.lnstall: • Oil filler bolt

Oil filler bolt: 12 Nm (1.2 m • kg, 8.7 ft ·Ib)

CONSTANT VELOCITY JOINT DUST BOOT INSPECTION 1.lnspect: • Dust boots CD Damage ~ Replace. Refer to "DIFFERENTIAL GEAR AND CONSTANT VELOCITY JOINT" in CHAPTER 6.

3 - 34

STEERING SYSTEM INSPECTION/ TOE-IN ADJUSTMENT

IINSP ADJ

1'0.1 ~

L.....;;."'::';;;;;"";;:=----L---";;;;"";;;;;;....,j

STEERING SYSTEM INSPECTION 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 shaft bushings.

3.Check: • Tie-rod ends Turn the handlebar completely to either the left or right, and then, while slowly turning the handlebar in the opposite direction, move the tie-rod up and down to check for vertical play. Tie-rod end has vertical play ~ Replace the tie-rod end.

4.Raise the front end of the machine so that there is no weight on the front wheels. 5.Check: • Ball joints and/or wheel bearings Move the wheels laterally back and forth. Excessive free play ~ Replace the front arms (upper and lower) and/or wheel bearings.

TOE-IN ADJUSTMENT 1.Place the machine on a level surface. 2.Measure: • Toe-in Out of specification

I~ 3 - 35

Adjust.

Toe-in: 0- 10 mm (0 - 0.39 in)

TOE-IN ADJUSTMENT

II~gS 14fil1

********************************* Toe-in measurement steps:

NOTE: Before measuring the toe-in, make sure that the tire pressure is correct. • Mark both front tire tread centers. • Raise the front end of the machine so that there is no weight on the front tires . • Face the handlebar straight ahead. • Measure the width ~ between the marks . • Rotate the front tires 180· until the marks are exactly opposite one another. • Measure the width lID between the marks . • Calculate the toe-in using the formula given below. Toe-in

=lID - ~

.If the toe-in is incorrect, adjust it.

********************************* 3.Adjust: • Toe-in

A WARNING • Be sure that both tie-rods are turned the same amount. If not, the machine will drift right or left even though the handlebar is positioned straight. This may lead to mishandling and an accident. • After setting the toe-in to specification, run the machine slowly for some distance with both hands lightly holding the handlebar and check that the handlebar responds correctly. If not, turn either the right or left tierod within the toe-in specification.

********************************* Adjustment steps: • Mark both tie-rods ends. This reference point will be needed during adjustment. • Loosen the locknuts (tie-rod end) CD of both tie-rods . • The same number of turns should be given to both the right and left tie-rods ® until the specified toe-in is obtained. This is to keep the length of the rods the same. • Tighten the rod end locknuts of both tie rods.

~ Locknut (rod end): ~~ 30 Nm (3.0 m • kg, 22 ft • Ib) 'J>-

********************************* 3 - 36

FRONT SHOCK ABSORBER ADJUSTMENT/REAR SHOCK ABSORBER ADJUSTMENT/TIRE INSPECTION

IINSP 1

ADJ

to. 1 ~

FRONT SHOCK ABSORBER ADJUSTMENT

WARNING

Always adjust both front shock absorber spring preload to the same setting. Uneven adjustment can cause poor handling and loss of stability.

1.Adjust: • Spring preload Turn the adjuster to increase or decrease the spring preload. Standard position: B Softest position: A Stiffest position: E

REAR SHOCK ABSORBER ADJUSTMENT 1.Adjust: • Spring preload Turn the adjuster to increase or decrease the spring preload. NOTE: The spring preload of the rear shock absorber can be adjusted to suit the rider's preference, weight, and the riding conditions. Standard position: B Softest position: A Stiffest position: E

TIRE INSPECTION

, A WARNING This model is equipped with low pressure tires. It is important that they be inflated correctly and maintained at the proper pressures.

3 - 37

TIRE INSPECTION

II~gr ~ I

• TIRE CHARACTERISTICS 1lTire 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 Front Rear

DUNLOP

Size

Type

AT25 x 8-12 KT404

CHENG SHIN AT25 x 8-12 C-9221 DUNLOP

AT25 x 10-12 KT405B

CHENG SHIN AT25 x 10-12 C-9222

• TIRE PRESSURE 1)Recommended tire pressure Front 25 kPa (0.25 kg/cm 2 , 3.6 psi) Rear 25 kPa (0.25 kg/cm 2 , 3.6 psi) 2)Tire pressure below the minimum specified could cause the tire to dislodge from the rim under severe riding conditions. The following are minimums: Front 22 kPa (0.22 kg/cm 2 , 3.2 psi) Rear 22 kPa (0.22 kg/cm 2 , 3.2 psi) 3)Use no more than Front 250 kPa (2.5 kg/cm 2, 36 psi) Rear 250 kPa (2.5 kg/cm 2 , 36 psi) when seating the tire beads. Higher pressures may cause the tire to burst. Inflate the tires very slowly and carefully. Fast inflation could cause the tire to burst. • MAXIMUM LOADING LIMIT 1)Vehicle load limits: 210 kg (463 Ib)* * Total weight of cargo, trailer hitch vertical load, rider, and accessories. 2)Storage box: 2 kg (4.4 Ib) 3)Trailer hitch: Horizontal load: 410 kg (904Ib) Total weight of trailer and cargo. Vertical load: 15 kg (33 Ib) Vertical weight on trailer hitch joint. Be extra careful of the machine balance and stability when towing a trailer.

3 - 38

TIRE INSPECTION

Cfill

II~gr I

1.Measure: • Tire pressure (cold tire pressure) Out of specification ~ Adjust.

NOTE: • The low-pressure tire gauge CD is included in the standard equipment. • If dust or the like is stuck to this gauge, it does not provide correct readings. Therefore, make two measurements on the tire pressure and get the second reading. Cold tire pressure Standard

Minimum

Maximum

Front

Rear

25 kPa (0.25 kg/cm 2 , 3.6 psi) 22 kPa (0.22 kg/cm 2, 3.2 psi) 28 kPa (0.28 kg/cm 2 , 4.0 psi)

A WARNING Uneven or improper tire pressure may adversely affect the handling of this machine and may cause loss of control. • Maintain proper tire pressures. • Set tire pressures when the tires are cold. • Tire pressures must be equal in both front tires and equal in both rear tires.

2.lnspect: • Tire surfaces Wear/damage

Replace.

Tire wear limit @: Front and rear: 3.0 mm (0.12 in)

WARNING

It is dangerous to ride with a worn-out tire. When tire wear is out of specification, replace the tire immediately.

3 - 39

WHEEL INSPECTION/CABLE INSPECTION AND 1'~gS (0)1 LUBRICATION/LEVERS, PEDAL, ETC. LUBRICATION. . ~ . WHEEL INSPECTION 1.lnspect: • Wheels CD Damage/bends

Replace.

NOTE: Always balance the wheel when a tire or wheel has been changed or replaced.

A 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. CABLE INSPECTION AND LUBRICATION

A WARNING A damaged cable sheath may cause corrosion and interfere with the cable movement. An unsafe condition may result so replace a damaged cable as soon as possible. 1.lnspect: • Cable sheath Damage ~ Replace. 2.Check: • Cable operation Unsmooth operation replace.

..-..

Lubricate or

Recommended lubricant: Yamaha chain and cable lube or SAE 10W30 motor oil

NOTE: Hold the cable end up and apply several drops of lubricant to the cable. 3.Apply: • Lithium soap base grease (onto end of the cable) LEVERS, PEDAL, ETC. LUBRICATION 1.Lubricate the pivoting parts. ~

3 - 40

Recommended lubricant: Yamaha chain and cable lube or SAE 10W30 motor oil

BATTERY INSPECTION

----------------------------------------------------------

jlANOSJP j'O.j ~

EB305000

ELECTRICAL BATTERY INSPECTION 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.

::::::::G.;J4m~IM:;::::::::

_ _ _ _ _ _ __

CHARGING METHOD • This is a sealed type battery. Never remove the sealing caps. If the sealing caps have been removed, the balance will not be maintained and battery performance will deteriorate. • Charging time, charging current and charging voltage for the MF battery are different from those of general type batteries. The MF battery should be charged as explained in "CHARGING METHOD". If the battery is overcharged, the electrolyte level will drop considerably. Therefore, take special care when charging the battery.

A WARNING Battery electrolyte is dangerous; it contains sulfuric acid which is poisonous and highly caustic. Always follow these preventive measures: . • Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury. • Wear protective eye gear when handling or working near batteries. Antidote (EXTERNAL): • SKIN - Wash with water. • EYES - Flush with water for 15 minutes and get immediate medical attention. Antidote (INTERNAL): • Drink large quantities of water or milk followed with milk of magnesia, beaten egg or vegetable oil. Get immediate medical attention.

3 - 41

BATTERY INSPECTION

I I

II~gs ~

Batteries generate explosive hydrogen gas. Always follow these preventive measures: • Charge batteries in a well-ventilated area. • Keep batteries away from fire, sparks or open flames (e.g., welding equipment, lighted cigarettes, etc.) • DO NOT SMOKE when charging or handling batteries. KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN. 1.Remove: • Seat Refer to "SEAT, CARRIERS, FENDERS AND FUEL TANK".

2.Disconnect: • Battery leads

::::::::g~_IN:;:~::::::

- - - -____

First disconnect the negative lead disconnect the positive lead @.

CD, then

3.Remove: • Battery holding bracket • Battery 4.Check: • Battery condition

********************************* Battery condition checking steps: .Connect a digital voltmeter to the battery terminals.

Tester (+) lead ~ battery (+) terminal Tester (-) lead ~ battery (-) terminal 18350601

NOTE: The charge state of an MF battery can be checked by measuring the open-circuit voltage (i.e. the voltage when the positive terminal is disconnected).

3 - 42

Open-circuit voltage

Charging time

12.8 V or higher

No charging is necessary.

BATTERY INSPECTION

.Check the condition of the battery using the following charts.

Relationship between the open-circuit voltage and the charging time at 20°C

13.0

Example:

12.5

.Open-circuit voltage = 12_0 V .Charging time = 6.5 hours • Charge condition of the battery = 20 - 30% .Charging method for MF batteries

12.0 11.5

6.5

Charging time (hours) . These values vary with the temperature, the condition of the battery plates, and the electrolyte level.

::::::::SID2N:;:::::::: • 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. (If charging has to be done with the battery mounted on the motorcycle, be sure to disconnect the wire at the negative terminaL) • Never remove the sealing caps of an MF battery. • Make sure that the charging clips are in full contact with the terminal and that they are not shorted together. (A corroded clip on the charger may cause the battery to generate heat in the contact area. A weak clip spring may cause sparks.) • Before removing the clips from the battery terminals, be sure to turn off the charger's power switch. • The open-circuit voltage variation for the MF battery, after charging, is shown below. As shown in the figure, the opencircuit voltage stabilizes about 30 minutes after charging has been completed. Therefore, wait 30 minutes after charging is completed before measuring the opencircuit voltage.

Ambient temperature 20°C

Charging ~

~17 ~16

~> 15

.'" 14 OJ 213 .~ 12

~11 0 10

I~gs I~ I

......

50 60 Time (minutes) Check the open-circuit voltage.

14 Ambient ~13~--~~-<~--+---~--~ temperature ~ 20°C

~12~--~--~----~~~~~

.~ 11 __--_+_----+----+--'-_+_r--___1

~101-----+-----+----+--L-+-1~---1 I

100

50 302520 0 Charging condition of the battery (%)

3 - 43

IANOSJP I(0) I I ---------------------------------------------------------_ ~_

BATTERY INSPECTION

Charging method using a variable voltage charger

NOTE :

Measure the open-circuit voltage prior to charging.

Charger Ammeter

EJ EJ EJ 0, l

Â°

.. A ..

~YES

Leave the battery unused for more than 30 minutes before measuring its open -circuit voltage.

NOTE:

Connect a charger and ammeter to the battery and start charging.

Set the charging voltage to 16 - 17 V. (lfthe charging voltage is lower. charging will be insufficient. if it is higher. the batterywill be over-charged.)

Is the amperage higher than the standard charging amperage written on the battery?

Adjust the charging voltage to 20 - 25 V.

t Adjust the voltage to obtain the standard charging amperage.

Monitor the amperage for 3 - 5 minutes. Is the standard charging amperage exceeded?

YES

NO If the amperage does not exceed the standard charging amperage after 5 minutes, replace the battery.

Set the timer to the charging time determined by the open -circuit voltage. Refer to "CHECKING AND CHARGING THE BATIERY."

If the required charging time exceeds 5 hours, it is advisable to check the charging amperage after 5 hours. If there is any change in the amperage, readjust the voltage to obtain the standard charging amperage. ~

Leave the battery unused for more than 30 minutes before measuring its open-circuit voltage. 12.8 V -+ Charging is complete. 12.0-12.7 V -+ Recharging is required. Under 12.0 V -+ Replace the battery.

3 - 44

IANOSJP Ito) I I -------------------------------------------------~.

BATTERY INSPECTION

Charging method using a constant voltage charger

NOTE: ________________________

Measure the open-circuit voltage prior to charging.

Leave the battery unused for more than 30 minutes before measuring its openÂˇcircuit voltage.

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?

Charge the battery until the charging voltage reaches 15 V. NOTE: __________________________

This type of battery charger cannot charge an MF battery. A variablevoltage charger is recommended.

Set the charging time to a maximum of 20 hours.

Charger

Leave the battery unused for more than 30 minutes before measuring its open-circuit voltage. 12.8 V ~ Charging is complete. 12.0-12.7 V ~ Recharging is required. Under 12.0 V ~ Replace the battery.

Ammeter Voltmeter

CAUTION: ________________________ Constant amperage chargers are not suitable for charging MF batteries.

3 - 45

1'0) 1

BATTERY INSPECTION/ 1'~gS FUSE INSPECTION . . ~ . 5.lnspect: • Battery terminals Dirty -7 Clean with a wire brush. Poor connection -7 Correct. NOTE: After cleaning the terminals, apply a light coat of grease.

6.lnstall: • Battery • Battery holding bracket 7.Connect: • Battery leads

::::::::il.~:Qm:~:::::::

--------

First, connect the positive lead connect the negative lead CV.

CD,

then

8.lnstall: • Seat Refer to "SEAT, CARRIERS, FENDERS AND FUEL TANK".

FUSE INSPECTION

::::::::Qi.!'lm:~:::::::

- _______

Always turn off the main switch when checking or replacing a fuse. Otherwise, a short circuit may occur.

1.Remove: • Seat Refer to "SEAT, CARRIERS, FENDERS AND FUEL TANK". 2.lnspect: • Fuses

********************************* Inspection steps: .Connect the pocket tester to the fuse and check it for continuity.

3 - 46

I'oal I ----------------------------------------------------------

FUSE INSPECTION . iANOSJP . ~ . NOTE: Set the tester to the ".0. x 1" position.

~ Pocket tester: PIN. YU-03112, 90890-03112

<7 -

• If the tester indicates 0, replace the fuse.

********************************* 18030103

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 . • If the fuse immediately blows again, check the electrical circuit.

********************************* Description Current rating

Quantity

Main

30A

Headlight

15A

Ignition

10A

Terminal (Auxiliary DC jack)

10A

Carburetor warmer

10A

Reserve

30A

Reserve

15A

Reserve

10 A

A WARNING Never use a fuse with a rating other than that specified. Never use other materials in place of a fuse. An improper fuse may cause extensive damage to the electrical system, a malfunction of the lighting and ignition systems and could possibly cause a fire.

4.lnstall: • Seat Refer to SEAT, CARRIERS, FENDERS AND FUEL TANK". II

3 - 47

HEADLIGHT BEAM ADJUSTMENT/ HEADLIGHT BULB REPLACEMENT

IINSP ADJ

1'0) I ~

J....,;;....;;.;;;;;...=.--L._-=-~

HEADLIGHT BEAM ADJUSTMENT 1.Adjust: • Headlight beam (vertically) Turn the adjuster CD in or out. Turning in

Headlight beam raised.

Turning out Headlight beam lowered.

HEADLIGHT BULB REPLACEMENT 1.Disconnect: • Headlight lead coupler 2.Remove: • Headlight assembly CD

3.Remove: • Headlight cover CD

4.Remove: • Cover CD • Bulb holder ® • Bulb

NOTE: Turn the bulb holder counterclockwise and remove the defective bulb.

A WARNING Keep flammable products and your hands away from the bulb while it is on, since it will be hot. Do not touch the bulb until it cools down.

3 - 48

HEADLIGHT BULB REPLACEMENT

-------------------------------------------------------5.lnstall:

IANOSJP J to) ~

• Bulb (new) Secure the new bulb with the headlight unit.

::::::):;11111:;::::::: - - - -____ 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. 6.lnstall: • Bulb holder • Cover • Headlight cover • Headlight assembly 7.Connect: • Headlight lead couplers

3 - 49

ENGINE REMOVAL

ENG ~.

ENGINE OVERHAUL ENGINE REMOVAL NOTE: ________________________ It is not necessary to remove the engine in order to remove the following components.

• Clutch • COl rotor

SEAT, CARRIERS, FENDERS AND FUEL TANK 1.Remove:

• • • • • •

Seat Front carrier Front fender Fuel tank Rear carrier Rear fender Refer to "SEAT, CARRIERS, FENDERS AND FUEL TANK" in CHAPTER 3.

ENGINE OIL 1.Drain: • Engine oil Refer to "ENGINE OIL REPLACEMENT" in CHAPTER 3.

CARBURETOR 1.Remove: • Carburetor assembly Refer to "CARBURETOR" in CHAPTER 3.

4· ,

ENGINE REMOVAL

ENG

2.Remove: • Cylinder head breather hose CD • Air filter case ® (with air duct and carburetor joint)

3.Remove: • Intake manifold

I EXHAUST PIPE AND MUFFLER 1.Remove:

• Muffler CD • Exhaust pipe • Gasket

STARTER MOTOR 1.Disconnect: • Starter motor lead 2.Remove: • Starter motor ®

4-2

ENGINE REMOVAL

ENG , _

OIL FILTER 1.Remove: • Oil filter cover CD • Oil filter element

REVERSE CONTROL CABLE 1.Remove: • Reverse control cable CD

********************************* Removal steps: • Pull back the boot • Remove the adjuster (ID. • Disconnect the reverse control cable from the cable holder @. • Unhook the cable end.

ev.

*********************************

SHIFT PEDAL AND FOOTREST 1.Remove: • Shift rod cover CD

2.Remove: • Shift pedal link

NOTE: For easier installation, mark the position @ on the shift shaft which aligns with the slot on the shift pedal link CD.

4-3

ENG

ENGINE REMOVAL 3.Remove: • Footrest (left)

4.Remove: • Adjuster (brake pedal) • Pin 0 • Spring @

5.Remove: • Spring CD • Footrest (right)

SPARK PLUG 1.Disconnect: • Spark plug cap 2.Remove: • Spark plug 0

LEADS 1.Disconnect: • Thermo unit coupler CD

4-4

ENGINE REMOVAL

ENG ,,_

2.Disconnect: • COl magneto couplers CD • Gear position switch coupler

REAR SHOCK ABSORBER AND SWINGARM 1.Place the machine on a level surface. 2.Block the front wheels and elevate the rear wheels by placing a suitable stand under the frame. 3.Remove: • Rear wheels Refer to "FRONT AND REAR WHEELS" in CHAPTER 7. 4.Remove: • Rear brake drum • Brake shoe plate Refer to "REAR BRAKE" in CHAPTER 7. 5.Remove: • Rear axle • Final gear case assembly Refer to "REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT" in CHAPTER 6.

6.Remove: • Bolt (rear shock absorber-upper)

7.Remove: • Clamp (rubber boot) CD • Pivot shaft (left) ® • Locknut (pivot shaft-right) @ • Pivot shaft (right) @

4-5

ENGINE REMOVAL

ENG "\,_

8.Pull the breather hoses and parking brake cable out of their guides. 9.Remove: • Rear shock absorber and swingarm

FRONT DRIVE SHAFT PROTECTOR 1.Remove: • Front drive shaft protector CD

FRONT FENDER BRACKET 1.Remove: • Front fender bracket CD

ENGINE REMOVAL 1.Remove: • Bolts (engine mounting-top) CD • Engine stay (upper) • Bolts (engine mounting-front) CV • Engine stay (front) • Bolts (engine mounting-rear) @

4-6

ENGINE REMOVAL

ENG , _

2.Remove: • Front drive shaft CD

NOTE: To remove the front drive shaft, move the engine to the left (counterclockwise).

3.Remove: • Engine (from the left side)

4-7

ENGINE DISASSEMBLY

ENG

ENGINE DISASSEMBLY RECOIL STARTER 1.Remove: • Recoil starter assembly CD • Gasket

2.Remove: • Cap CD • Starter handle

NOTE: ________________________ Before untying the knot @ above the starter handle, make a knot @ in the rope so that the rope is not pulled into the case.

3.Remove: • • • • • • •

1J.#---<7

Nut CD Friction plate ® Spring @ Drive pawl @ Pawl spring ® Sheave drum ® Coil spring (J)

CYLINDER HEAD AND CYLINDER 1.Remove: • Timing plug CD • O-ring ®

4-8

ENGINE DISASSEMBLY

ENG , _

2.Remove: • Side cover (cylinder head) • O-ring (side cover) • Tappet cover (exhaust) ® • Tappet cover (intake) @ • O-rings

3.Align: • "T" mark on the flywheel (with the stationary pointer on the crankcase cover)

********************************* T.O.C. alignment steps: • Turn the starter pulley counterclockwise with a wrench . • Align the "T" mark CD on the flywheel with the stationary pointer ® on the crankcase cover. When the "T" mark is aligned with the stationary pointer, the piston is at Top Dead Center (T.O.C.). NOTE: T.O.C. on compression stroke check: • Both rocker arms must have a valve clearance when the camshaft sprocket match mark @ is aligned with the cylinder head match mark @. • If not, give the crankshaft one counterclockwise turn to meet the above condition.

*********************************

4-9

ENGINE DISASSEMBLY

ENG ~.

4.Loosen: • Nut (camshaft sprocket) <D Use the rotor holder ® to hold the starter pulley.

~ Rotor holder: PIN. YU-01235, 90890-01235

<?' -

5.Loosen: • End plug (timing chain tensioner) 6.Remove: • Timing chain tensioner body ® • Gasket 7.Remove: • Camshaft sprocket cover • Camshaft sprocket

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. 8.Remove: • Bolts (cylinder head) • Cylinder head ®

NOTE: Loosen the bolts starting with the highest numbered one.

9.Remove: • Gasket (cylinder head) <D • Dowel pins ® • O-ring @ • Timing chain guide (exhaust) @

10.Remove: • Bolt (cylinder) CD • Cylindercg) • Gasket (cylinder) @ • Dowel pins @ • O-ring ®

4 - 10

ENG '\,.

ENGINE OISASSEMBL V PISTON 1.Remove: • Piston pin clip

NOTE: Before removing the piston pin clip, cover the crankcase with a clean rag so the clip will not accidentally drop into the crankcase.

2.Remove: • Piston pin • Piston ®

NOTE: Before removing the pisto!1 pin, deburr the clip groove and pin hole area. If the piston pin groove is deburred and piston pin is still difficult to remove, use a piston pin puller @. Piston pin puller: PIN. YU-01304, 90890-01304

::::::::91_11:;:,::::: _________ Do not use a hammer to drive the piston pin out.

CRANKCASE COVER (LEFT) 1.Remove: • Starter pulley CD Use the rotor holder ® to hold the starter pulley. Rotor holder: PIN. YU-01235, 90890-01235

2.Remove: • Crankcase cover (left) • Gasket • Dowel pins

NOTE: When removing the crankcase cover, the plain washer will falloff. Take care not to lose it.

4 - 11

ENGINE DISASSEMBLY

ENG , _

3.Remove: • Locknut CD • Washer® • a-ring @

4.Remove: • Stopper collar CD • Shift guide assembly ®

NOTE: __________________________ When removing the left crankcase cover, the stopper collar CD can easily fall off. Make sure that you do not lose this part.

5.Remove: • Lead holder CD • Stator assembly ® • Pickup coil assembly @

SHIFT SHAFT AND STARTER IDLE GEAR 1.Remove: • Shift shaft assembly CD • Washer

2.Remove: • Stopper lever CD • Spring ® • Oil delivery pipe 3 @ • a-rings

4 - 12

ENGINE DISASSEMBLY 3.Remove: • Starter idle gear #1 • Starter idle gear #2

ENG '\,.

CD ®

COl ROTOR AND TIMING CHAIN 1.Remove: • COl rotor CD Use a flywheel puller ®. Flywheel puller: PIN. YM-01404, 90890-01404

2.Remove: • Woodruff key CD • Starter wheel gear ® • Bearing @ • Plain washer @

3.Remove: • Timing chain guide (intake) • Timing chain ®

CRANKCASE COVER (RIGHT) 1.Remove: • Oil delivery pipe 2 CD • Copper washers

4 - 13

ENGINE DISASSEMBLY

ENG , _

2.Remove: • Dipstick CD • Reverse control lever ® • Reverse control cable holder @ • Crankcase cover (right) @ • Dowel pins • Gasket

NOTE: • Working in a crisscross pattern, loosen each bolt 1/4 of a turn. Remove them after all of them are loosened. • Before removing the crankcase cover, remove the dipstick.

CLUTCH 1.Straighten: • Punched portion clutch)

of the

nut (primary

2.Remove: • Nut (primary clutch) CD Use a sheave holder ® to hold the clutch housing. Sheave holder: PIN. YU-01880, 90890-01701

3.Remove: • Clutch carrier assembly • Clutch housing ® • Plain washer @

4 - '4

ENGINE DISASSEMBLY

ENG , _

NOTE: When removing the primary clutch housing, align the indentations in the secondary clutch housing ® and the primary gear @ with each other.

4.Remove: • Bolts (pressure plate) CD • Clutch springs @ • Pressure plate @ • Friction plates @ • Clutch plates ® (thickness: 1.6 mm - 4 pcs.) • Clutch plates ® (thickness: 2.0 mm - 2 pcs.)

NOTE: Loosen the pressure plate bolts in a crisscross pattern.

5.Remove: • Push rod #1 CD (with O-ring) • Ball @ • Push rod #2 @

6.Straighten: • Lock washer tabs (clutch boss) 7.Remove: • Nut (clutch boss) CD Use a clutch holding tool @ to hold the clutch boss. • Lock washer

Clutch holding tool: PIN. YM-91042, 90890-04086 4 - 15

ENGINE DISASSEMBLY

r----------=======

8.Remove: • Clutch boss <D • Thrust washer ® • Clutch housing @

REVERSE SHIFT BRACKET 1.Remove: • Lead holder <D • Gear position switch ®

2.Remove: • Washer <D • Reverse shift bracket assembly ®

3.Remove: • Thermo switch <D • Copper washer ®

OIL PUMP AND BALANCER DRIVE GEARS 1.Remove: • Oil pump assembly <D • Gasket (oil pump)

4 - 16

ENGINE DISASSEMBLY

ENG '\,.

2.Remove: • Oil delivery pipe 1 CD • Copper washers

3.Straighten: • Lock washer tabs (balancer driven gear) 4.Loosen: • Nut (balancer driven gear) CD

NOTE: ________________________ Place a copper plate @ between the teeth of the driven gear and drive gear to lock them.

5.Remove: • Nut (balancer driven gear) • Lock washer @ • Balancer driven gear @ • Straight key @

6.Remove: • Oil pump drive gear CD • Holding plate @ • Balancer drive gear @ • Springs@ • Pins ®

NOTE: • The balancer drive gear has six springs and three pins. Use care so they do not fall out when removing the balancer drive gear. • Using a two-leg puller ® when removing the oil pump drive gear CD and balancer drive gear @.

4 - 17

ENGINE DISASSEMBLY

ENG , _

CRANKCASE (LEFT) 1.Remove: • Torx screw CD • Shift cam segment ®

2.Remove: • Bolts (crankcase)

NOTE: • Working in a crisscross pattern, loosen all of the bolts 1/4 of a turn each. Remove them after all of them are loosened. • Loosen the bolts in decreasing numerical order. [AJ Right crankcase

1m Left crankcase

CD - @) : M6 bolts @ - @ : M8 bolts

3.Remove: • Crankcase (left) • Dowel pins

i:iiiiiRI.INliii:iii - - - - - - - -

Use a soft hammer to tap on the case half. Tap only on reinforced portions of the case. Do not tap on the gasket mating surface. Work slowly and carefully. Make sure the case halves separate evenly.

BALANCER WEIGHT AND TRANSMISSION NOTE: When removing the transmission gears, mark the gear tooth number to avoid confusion.

1.Remove: • Balancer weight CD

4· 18

ENGINE DISASSEMBLY

ENG , _

2.Remove: • Guide bar #1 (longer) CD • Guide bar #2 (shorter) ® • Shift fork ilL" @ • Shift fork "C" @ • Shift fork "R" ® • Shift cam ®

3.Remove: • Middle drive shaft assembly CD • Middle driven gear

4.Remove: • Main axle assembly CD • Drive axle assembly ® • Reverse wheel gear assembly @

CRANKSHAFT 1.Remove: • Crankshaft Use a crankcase separating tool slide hammer bolt ®.

and

Crankcase separating tool: PIN. YU-01135-A, 90890-01135 Slide hammer bolt (M8): PIN. YU-01083-2, 90890-01085

4 - 19

ENGINE DISASSEMBLY

ENG , _

CAMSHAFT, ROCKER ARM AND VALVE NOTE: With the engine mounted, the camshaft, rocker arm and valve can be maintained by removing the following parts. • • • • • • • •

Seat Front carrier Front fender Fuel tank Exhaust pipe Carburetor Ignition coil Engine stay (upper)

1.Straighten: • Lock washer tabs 2.Remove: • Bolts (camshaft) CD • Lock washer @ • Retainer@ 3.Attach: • Slide hammer set

Slide hammer bolt (M6): PIN. YU-01083-1, 90890-01083 Weight: PIN. YU-01083-3, 90890-01084

4.Remove: • Rocker arm shafts @ • Rocker arms • Wave washers

5.Remove: • Camshaft CD • Camshaft bearing @

NOTE: Screw in a M10 bolt @ into the thread hole on the camshaft, and pull out the camshaft.

4 - 20

ENGINE DISASSEMBLY

ENG , _

6.Check: • Valve sealing Leakage at valve seat -7 Inspect the valve face, valve seat and valve seat width. Refer to "INSPECTION AND REPAIR-; VALVE SEAT".

NOTE: ________________________ Before removing the internal parts (valve, valve spring, spring seat, etc.) of the cylinder head, the valve sealing should be checked.

********************************* Checking steps: .Pour a clean solvent CD into the intake and exhaust ports . • Check the valve sealing. There should be no leakage at the valve seats CV.

********************************* 7.Remove: • Valve cotter CD • Spring retainer CV • Valve spring (outer) G) • Valve spring (inner) 0 • Valve ® • Oil seal ® • Spring seat (J)

NOTE: Compress the valve spring using a valve spring compressor @ to remove the valve cotters CD. Valve spring compressor: PIN. YM-04019, 90890-04019 11171201

4 - 21

ENGINE DISASSEMBLY OIL PUMP 1.Remove: • • • • • • • •

4 - 22

Screw CD Pump housing Dowel pins @ Outer rotor @ Inner rotor ® Pin ® Pump cover (j) Pump shaft ®

ENG "'.

ENG ~. til

INSPECTION AND REPAIR

1..-_ _--'_..;;;.;;...;.;.......

INSPECTION AND REPAIR CYLINDER HEAD 1.Eliminate: • Carbon deposit (from the combustion chamber) Use a rounded scraper CD.

NOTE: Do not use a sharp instrument to avoid damaging or scratching: • Spark plug threads • Valve seat

11110106

2.lnspect: • Cylinder head Scratches/damage

3.Measure: • Warpage Out of specification

Replace.

Resurface.

Cylinder head warpage: Less than 0.05 mm (0.0020 in)

11110304

4.Resurface: • Cylinder head

********************************* Resurfacement steps: • Place a 400 - 600 grit wet sandpaper on the surface plate, and resurface the head using a figure-eight sanding pattern.

NOTE: Rotate the head several times to avoid removing too much material from one side.

*********************************

4 - 23

INSPECTION AND REPAIR

ENG , _

VALVE SEAT 1.Eliminate: • Carbon deposit (from valve face and valve seat) 2.1nspect: • Valve seat Pitting/wear ~ Replace the cylinder head and valve.

3.Measure: • Valve seat width ® Out of specification der head and valve.

I~ I1171603

Replace the cylin-

Valve seat width

Limit

Intake

1.2 - 1.4 mm (0.047 - 0.055 in)

1.6mm (0.063 in)

Exhaust

1.2 - 1.4 mm (0.047 - 0.055 in)

1.6mm (0.063 in)

********************************* Measurement steps: .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. Wherever the valve seat and valve face made contact, blueing will have been removed . • If the valve seat width is too wide, too narrow, or the seat has not centered, the cylinder head and valve must be replaced.

11171601

~------------------------------~

*********************************

4.Lap: • Valve face • Valve seat NOTE: When replacing the cylinder head, valve and valve guide, the valve seat and valve face should be lapped.

4 - 24

INSPECTION AND REPAIR

ENG ~.

********************************* Lapping steps: .Apply a coarse lapping compound to the valve face.

jiijjijigIIWJII:;i::::jjj ________ Be sure that no compound enters the gap between the valve stem and guide. 11171601

.Apply molybdenum disulfide oil to the valve stem . • Install the valve into the cylinder head . • Turn the valve until the valve face and valve seat are evenly polished, then clean off all of the compound.

NOTE: ________________________ To obtain the best lapping results, lightly tap the valve seat while rotating the valve back and forth between your hands . • Apply a fine lapping compound to the valve face and repeat the above steps.

NOTE: ________________________ Be sure to clean off all of the compound from the valve face and valve seat after every lapping operation . • 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.

11171501

*********************************

4 - 25

INSPECTION AND REPAIR

ENG

VALVE AND VALVE GUIDE 1.Measure: • Stem-to-guide clearance

Stem-to-guide clearance Valve guide inside diameter @ Valve stem diameter@ Out of specification guide.

L -______________________________ ~ 11170501

Replace the valve

Stem-to-guide clearance

Limit

Intake

0.010 - 0.037 mm (0.0004 - 0.0015 in)

0.08mm (0.0031 in)

Exhaust

0.030 - 0.057 mm (0.0012 - 0.0022 in)

0.10 mm (0.004 in)

G) Bore gauge 11172102

2.Replace: • Valve guide

********************************* Replacement steps: NOTE: Heat the cylinder head in an oven to 100°C (212 OF) to ease guide removal and installation and to maintain correct interference fit . • Remove the valve guide using a valve guide remover CD . • Install the valve guide (new) using a valve guide installer ® and valve guide remover

CD·

.After installing the valve guide, bore the valve guide using a valve guide reamer @ to obtain proper stem-to-guide clearance. Valve guide remover (7 mm): PIN. YM-01225-A, 90890-01225 Valve guide installer: PIN. YM-04017, 90890-04017 Valve guide reamer (7 mm): PIN. YM-01227, 90890-01227

*********************************

11170601

4 - 26

INSPECTION AND REPAIR

ENG , _

3.Eliminate: • Carbon deposits (from valve face) 4.lnspect: • Valve stem Broken/damage ~ Replace. • Valve face Pitting/wear ~ Grind the face. • Valve stem end Mushroom shape or diameter larger than rest of the stem ~ Replace. 5.Measure: • Margin thickness ® Out of specification ~ Replace.

®--ll-

Margin thickness: Intake: 1.0 - 1.4 mm (0.039 - 0.055 in) Exhaust: 0.8 - 1.2 mm (0.031 - 0.047 in) 6.Measure: • Runout (valve stem) Out of specification ~ Replace. Stem runout limit: 0.02 mm (0.0008 in) NOTE: • Always replace the guide if the valve is replaced. • Always replace the oil seal if the valve is removed.

I1l72103

VALVE SPRING 1.Measure: • Valve spring free length ® Out of specification ~ Replace.

11171902

4 - 27

Valve spring free length

Limit

Inner spring

39.9 mm (1.57 in)

37.9 mm (1.49 in)

Outer spring

43.27 mm (1.70 in)

41.27 mm (1.62 in)

INSPECTION AND REPAIR

ENG '\,_

2.Measure: • Valve spring installed force ® Out of specification ~ Replace. (E) Installed length

Valve spring installed force

Inner spring

11171904

-----+--+-- ©

(6)

33.6mm (1.32 in)

10.7 12.3 kg (23.6 27.1Ib)

3.Measure: • Spring tilt © Out of specification

11171903

Outer spring

(6)

36.6 mm (1.44 in)

23.0 26.6 kg (50.7 58.7Ib)

Replace.

Spring tilt limit

Inner spring

Outer spring

Less than 1.6 mm (0.06 in)

CAMSHAFT 1.lnspect: • Camshaft bushing • Camshaft needle bearing (in cylinder head) Wear/damage ~ Replace. • Cam lobes Pitting/scratches/blue discoloration ~ Replace. 2.Measure: • Cam lobes length ® and (6). Out of specification ~ Replace.

1115HlOi

I~ 11151002

4 - 28

Cam lobe limit ®

Cam lobe limit (6)

Intake

40.52 mm (1.595 in)

32.08 mm (1.263 in)

Exhaust

40.52 mm (1.595 in)

32.08 mm (1.263 in)

INSPECTION AND REPAIR

ENG

~ ~.

ROCKER ARM AND ROCKER ARM SHAFT 1.1nspect: • Rocker arm shaft Blue discoloration/grooves ~ Replace, then inspect the lubrication system.

11160301

2.lnspect: • Bore (rocker arm shaft) CD • Cam lobe contact surface ® • Adjuster surface @ Pitting/scratches/blue discoloration/wear ~ Replace, then inspect the lubrication system. 3.lnspect: • Wave washer Damage/expanded ~ Replace.

11160101

4.Measure: • Arm-to-shaft clearance Out of specification ~ Replace as a set.

Arm-to-shaft clearance Bore size (rocker arm shaft) ® Outside diameter (rocker arm shaft) (5)

~ --++---1--(5)

Arm-to-shaft clearance: 0.009 - 0.037 mm (0.0004 - 0.0015 in) <Limit:> 0.08 mm (0.0031 in)

111603112

TIMING CHAIN TENSIONER 1.lnspect: • Timing chain Cracks/stiff ~ Replace the timing chain and camshaft sprocket as a set.

4 - 29

INSPECTION AND REPAIR

ENG , _

2.lnspect: • Camshaft sprocket Wear/damage ~ Replace the camshaft sprocket and timing chain as a set.

CD 1/4 of a tooth ® Correct @ Roller @ Sprocket

3.lnspect: • Exhaust side timing chain guide CD • Intake side timing chain guide ® Wear/damage ~ Replace.

4.lnspect: • Tensioner rod CD • One-way cam ® • Gasket@ Damage ~ Replace.

TAPPET COVER AND SIDE COVER (CYLINDER HEAD) 1.lnspect: • Tappet cover (intake) CD • Tappet cover (exhaust) ® • Side cover (cylinder head) @ • a-ring @ Cracks/damage ~ Replace.

CYLINDER AND PISTON 1.lnspect: • Cylinder and piston walls Vertical scratches ~ Rebore or replace the cylinder and piston.

4 - 30

ENG

INSPECTION AND REPAIR

2.Eliminate: • Carbon deposits (from the piston crown and ring grooves)

3.Measure: • Piston-to-cylinder clearance

********************************* Measurement steps: First step • Measure cylinder bore "C" with a cylinder bore gauge CD. @ 40 mm (1.6 in) from the top of the cylinder

NOTE: Measure cylinder bore "C" in parallel to and at right angles to the cylinder matching surface. Then, find the average of the measurements.

Cylinder bore "c"

Standard

Wear limit

82.97 - 83.02 mm (3.267 - 3.269 in)

83.15 mm (3.274 in)

C= X+y 2 .If out of specification, rebore or replace the cylinder, and replace the piston and piston rings as a set. 2nd step • Measure piston skirt diameter "P" with a micrometer. (@ 5.5 mm (0.22 in) from the piston bottom edge Piston skirt diameter lip"

Standard

4 - 31

82.92 - 82.97 mm (3.265 - 3.267 in)

INSPECTION AND REPAIR

ENG

elf out of specification, replace the piston and piston rings as a set. 3rd step eFind the piston-to-cylinder clearance with the following formula. Piston-to-cylinder clearance Cylinder bore "C" Piston skirt diameter lip"

Piston-to-cylinder clearance: 0.04 - 0.06 mm (0.0016 - 0.0024 in) <Limit:> 0.15 mm (0.0059 in)

elf out of specification, rebore or replace the cylinder, and replace the piston and piston rings as a set.

*********************************

PISTON RING 1.Measure: • Ring side clearance Use a feeler gauge CD. Out of specification ~ Replace the piston and rings as a set. NOTE: Clean carbon from the piston ring grooves and rings before measuring the side clearance.

11221402

~------------------------------~

Side clearance Standard

Limit

Top ring

0.04 - 0.08 mm (0.002 - 0.003 in)

0.12mm· (0.005 in)

2nd ring

0.03 - 0.07 mm (0.001 - 0.003 in)

0.12mm (0.005 in)

2.Position: • Piston ring (in cylinder) NOTE: Insert a ring into the cylinder and push it approximately 40 mm (1.6 in) into the cylinder. Push the ring with the piston crown so that the ring will be at a right angle to the cylinder bore.

11221401

® 40 mm (1.6 in) 4 - 32

ENG , _

INSPECTION AND REPAIR 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

0.2 - 0.4 mm (0.008 - 0.016 in)

0.5mm (0.020 in)

2nd ring

0.2 - 0.4 mm (0.008 - 0.016 in)

0.5mm (0.020 in)

Oil ring

0.3 - 0.9 mm (0.012 - 0.035 in)

PISTON PIN 1.lnspect: • Piston pin Blue discoloration/grooves ~ Replace, then inspect the lubrication system. 2.Measure: • Piston pin-to-piston clearance

********************************* Measurement steps: • Measure the piston pin outside diameter

®. If out of specification, replace the piston pin. Outside diameter (piston pin): 18.990 - 18.995 mm (0.7476 - 0.7478 in) • Measure the piston inside diameter (Q) . • Calculate the piston pin-to-piston clearance with the following formula. Piston pin-to-piston clearance = Bore size (piston pin) (Q) Outside diameter (piston pin) ®

4 - 33

INSPECTION AND REPAIR

ENG ~. ~

elf out of specification, replace the piston. Piston pin-to-piston clearance: 0.009 - 0.025 mm (0.00035 - 0.00098 in) <Limit:> 0.07 mm (0.003 in)

*********************************

CRANKSHAFT 1.Measure: • Crank width ® Out of specification ~ Replace the crankshaft. Crank width: 58.95 - 59.00 mm (2.321 - 2.323 in)

• Side clearance @ Out of specification shaft.

Replace the crank-

Big end side clearance: 0.35 - 0.85 mm (0.014 - 0.033 in) <Limit:> 1 mm (0.039 in)

• Runout © Out of specification shaft.

11631008

Replace the crank-

Runout limit: C1: 0.03 mm (0.0012 in) C2: 0.06 mm (0.0024 in)

• Small end free play ® Out of specification ~ Replace the big end bearing, crank pin, connecting rod and/or side washer as a set. Small end free play: Standard: 0.8 - 1.0 mm (0.031 - 0.039 in) <Limit:> 2.0 mm (0.079 in)

4 - 34

INSPECTION AND REPAIR BALANCER DRIVE GEAR AND DRIVEN GEAR 1.lnspect: • Balancer drive gear teeth CD • Balancer driven gear teeth ® • Springs@ • Dowel pins @ Fatigue/wear/damage ~ Replace. • Buffer boss ® Fatigue/wear/damage ~ Replace the crankshaft.

PRIMARY GEARS 1.lnspect: • Primary drive gear teeth CD • Primary driven gear teeth ® Wear/damage ~ Replace both gears. Excessive noise during operation ~ Replace both gears.

PRIMARY CLUTCH 1.lnspect: • Clutch housing CD Heat damage/wear/damage ~ Replace. • One-way clutch bearing ® Chafing/wear/damage ~ Replace. NOTE: • Replace the one-way clutch assembly and clutch housing as a set. • The one-way clutch bearing must be installed with the flange side facing in.

4 - 35

ENG

INSPECTION AND REPAIR

********************************* Primary clutch operation .Install the clutch housing to the crankshaft and hold the crankshaft . • When turning the clutch housing counterclockwise ~, the clutch housing should turn freely. If not, the one-way clutch assembly is faulty. Replace it. • When turning the clutch housing clockwise [ID, the clutch housing and crankshaft should be engaged. If not, the one-way clutch assembly is faulty. Replace it.

IWl701

********************************* 2.1nspect: • Clutch shoe Heat damage ~ Replace. 3.Measure: • Clutch shoe thickness Out of specification ~ Replace. Clutch shoe thickness: 2.0 mm (0.08 in) Clutch shoe wear limit @: 1.5 mm (0.06 in)

SECONDARY CLUTCH 1.lnspect: • Clutch housing dogs Cracks/pitting (edges) Moderate ~ Deburr. Severe ~ Replace clutch housing. NOTE: Pitting on the friction plate dogs of the clutch housing will cause erratic operation. 2.lnspect: • Clutch boss splines Scoring/wear/damage clutch boss.

Replace the

NOTE: Scoring on the clutch plate splines will cause erratic operation.

4 - 36

INSPECTION AND REPAIR 3.Remove: • Pressure plate Cracks/damage

ENG ~~.

Replace.

4.lnspect: • Friction plate Damage/wear ~ Replace the friction plates as a set. S.Measure: • Friction plate thickness Measure at all four points. Out of specification ~ Replace the friction plates as a set.

11411101

Thickness: 2.94 - 3.06 mm (0.116 - 0.120 in) <Limit:> 2.8 mm (0.11 in)

6.lnspect: • Clutch plate Damage ~ Replace the clutch plates as a set. 7.Measure: • Clutch plate warpage Use a surface plate and a feeler gauge. Out of specification ~ Replace .

Type A" (4 pes.) II

Type "B" (2 pes.)

4 - 37

Thickness

Warp limit

1.5 - 1.7 mm (0.059 - 0.067 in)

0.2mm (0.008 in)

1.9 - 2.1 mm (0.075 - 0.083 in)

0.2mm (0.008 in)

ENG ~~.

INSPECTION AND REPAIR

a.lnspect: • Clutch spring Damage ~ Replace the springs as a set. 9.Measure: • Clutch spring free length @ Out of specification ~ Replace the springs as a set.

~4 I. ® .1

Free length @: 40.1 mm (1.58 in) <Limit:> 39 mm (1.54 in)

IW2!JIlI

10.lnspect: • Push rod #1 CD • O-ring @ • Ball @ • Push rod #2 @ Wear/cracks/damage

Replace.

11.lnspect: • O-ring CD • Adjuster@ • Shift guide #2 @ • Pawl holder @ • Shift guide #1 ® Bends/crack/damage

Replace.

OIL PUMP 1.Measure: • Tip clearance @ (between the inner rotor CD and the outer rotor @) • Side clearance CQ) (between the outer rotor @ and the pump housing @) Out of specification ~ Replace the oil pump. Tip clearance @: 0.15 mm (0.006 in) <Limit:> 0.2 mm (0.008 in) Side clearance CQ): 0.04 - 0.09 mm (0.002 - 0.004 in)

4 - 38

INSPECTION AND REPAIR

ENG ~. ~

2.lnspect: • Oil pump drive gear CD • Oil pump driven gear (g) Cracks/wear/damage ~ Replace.

SHIFTER AND TRANSMISSION 1.lnspect: • Shift fork cam follower CD • Shift fork pawl (g) Scoring/bends/wear ~ Replace.

11520201

2.lnspect: • Shift cam groove • Shift cam segment CD Wear/damage ~ Replace.

11530101

3.Check: • Shift fork movement Unsmooth operation ~ Replace the shift fork and/or guide bar.

11520ltll

4.lnspect: • Guide bar Roll the guide bar on a flat surface. Bends ~ Replace.

A WARNING Do not attempt to straighten a bent guide bar. 11520~Ol

4 - 39

INSPECTION AND REPAIR S.lnspect: • Shift shaft CD Bends/wear/damage

Replace.

6.1nspect: • Stopper lever CD Roller turns roughly ~ Replace. Bends/damage ~ Replace. 7.lnspect: • Return spring @ Cracks/damage ~ Replace.

a.lnspect: • Gear teeth Blue discoloration/pitting/wear ~ Replace. • Mated dogs Rounded edges/cracks/missing portions ~ Replace. 9.Check: • Gear movement Unsmooth operation ~ Replace. 10.Check: • Proper gear engagement (each gear) (to its counterpart) Incorrect ~ Reassemble. • Gear movement Roughness ~ Replace.

11650401

11.Measure: • Axle runout Use a centering device and a dial gauge

CD· Out of specification

Replace.

Runout limit: Less than 0.08 mm (0.003 in) 11650701

4 - 40

INSPECTION AND REPAIR ********************************* Transmission gear reassembling point: Press the 2nd pinion gear CV into the main axle @, as shown in the illustration.

********************************* 12.lnspect: • Circlips Bends/looseness/damage

Replace.

STARTER DRIVES 1.lnspect: • Starter one-way CD Cracks/damage ~ Replace. NOTE: The arrow mark on the starter clutch must face inward, away from the COl rotor.

~JlJ <8/'0 t---......;..a '\t)

Bolts (starter clutch): 30 Nm (3.0 m • kg, 22 ft • Ib) LOCTITE®

********************************* Starter clutch operation .Install the starter wheel gear to the starter clutch and hold the starter clutch . • When turning the starter wheel gear counterclockwise [6], the starter clutch and the wheel gear should be engaged. If not, the starter clutch is faulty. Replace it. .When turning the starter wheel gear clockwise 1]], the starter wheel gear should turn freely. If not, the starter clutch is faulty. Replace it.

*********************************

2.lnspect: • Starter idle gear teeth CD • Starter wheel gear teeth CV Burrs/chips/roughness/wear ~ Replace.

4·41

ENG ~. ~

INSPECTION AND REPAIR 3.lnspect: • Starter wheel gear (contacting surface) Pitting/wear/damage

Replace.

STARTER PULLEY AND RECOIL STARTER 1.lnspect: • Starter pulley Cracks/pitting ~ Deburr or replace.

2.lnspect: • Rope CD • Sheave drum @ • Drive pawl @ Wear/damage ~ Replace. • Coil spring @ • Pawl spring ® • Spring ® Fatigue ~ Replace.

OIL STRAINER, OIL FILTER AND OIL DELIVERY PIPES 1.lnspect: • Oil strainer CD • Oil filter @ • O-rings @ Damage ~ Replace.

2 3

4 - 42

INSPECTION AND REPAIR 2.lnspect: • Oil delivery pipes CD Cracks/damage ~ Replace. Clogged ~ Blowout with compressed air.

CRANKCASE 1.Thoroughly wash the case halves in a mild solvent. 2.Clean all the gasket mating surfaces and crankcase mating surfaces thoroughly. 3.lnspect: • Crankcase Cracks/damage ~ Replace. • Oil delivery passages Clogged ~ Blowout with compressed air. BEARINGS AND OIL SEALS 1.lnspect: • Bearing Clean and lubricate, then rotate the inner race with a finger. Roughness ~ Replace. 2.lnspect: • Oil seals Damage/wear

Replace.

CIRCLIPS AND WASHERS 1.lnspect: • Circlips • Washers Bends/looseness/damage

4 - 43

Replace.

MIDDLE GEAR SERVICE

ENG '\,.

MIDDLE GEAR SERVICE CD Universal joint yoke ® Oil seal

@) @ @ @ @

@ Bearing housing (1) Shim(s) ® a-ring ® Bearing (J) Bearing retainer ® Middle driven pinion gear ® Damper cam

Spring Gear coupling Middle driven shaft Middle drive pinion gear Middle drive shaft

MIDDLE GEAR LASH: 0.1 _ 0.3 mm (0.004 - 0.012 in) 3

25 Nm (2.5 m • kg, 18 ft • Ib)

97 Nm (9.7 m • kg, 70 ft • Ib) 80 Nm (8.0 m • kg, 58 ft· Ib)

4 - 44

MIDDLE GEAR SERVICE

ENG

REMOVAL 1.Remove: • Engine Refer to "ENGINE REMOVAL". 2.Remove: • Crankcase (left) Refer to "ENGINE DISASSEMBLY".

DISASSEMBLY Middle drive shaft assembly 1.Straighten: • Punched portion of the nut (middle drive pinion gear) 2.Loosen: • Nut (middle drive pinion gear) CD NOTE: Place a copper plate ® between the teeth of the drive gear and the driven gear to lock them. 3.Remove: • Middle drive shaft assembly @ • Middle driven gear

4.Remove: • Nut (middle drive pinion gear) • Middle drive pinion gear ® • Shim(s) @ • Middle drive shaft @

5.Remove: • Bearing retainer • Bearing ®

4 - 45

MIDDLE GEAR SERVICE

ENG ~~ •• ~

Middle driven shaft assembly 1.Remove: • Universal joint

********************************* Universal joint removal steps: .Remove the circlips CD . • Place the U-joint in a press . • With a suitable diameter pipe ® beneath the yoke @, press the bearing @ 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.

NOTE: ________________________

It may be necessary to lightly tap the yoke with a punch.

********************************* 2.Attach: • Universal joint holder (onto the universal joint yoke) Universal joint holder: PIN. YM-04062, 90890·04062

3.Remove: • Nut CD • Washer ® • Universal joint yoke @

4.Remove: • Bolts (bearing housing) • Shims ®

4 - 46

MIDDLE GEAR SERVICE

ENG , , _

5.Remove: • Middle driven pinion gear with bearing housing CD Lightly tap the end of the axle with a soft hammer. • Damper cam ® • Damper spring @ • Gear coupling @

6.Remove: • Bearing housing assembly CD

********************************* Bearing housing removal steps: .Clean the outside of the middle driven shaft. • Place the middle driven shaft onto a hydraulic press.

ji:ijjjjg$!YlI9i;ijijij - - - - - - - • Never directly press the shaft end with a hydraulic press, this will result in damage to the shaft thread. • Install the suitable socket ® on the shaft end to protect the thread from damage. • Press the shaft end and remove the bearing housing.

********************************* 7.Remove: • Bearing CD Use the bearing puller ®.

8.Remove: • Oil seal • Bearing retainer • Bearing Use the bearing retainer wrench

CD.

~ Bearing retainer wrench: PIN. YM-04128, 90890-04128

<1' -

NOTE: Bearing retainer has left-hand threads. 4 - 47

MIDDLE GEAR SERVICE

ENG '\,.

9.Attach: • Universal joint holder <D (onto the universal joint yoke)

Universal joint holder: PIN. YM-04062, 90890-04062

10.Remove: • • • •

Nut <D Washer® Universal joint yoke @ Dust cover G)

11.Remove: • Oil seal <D • Bearing retainer ® Use the ring nut wrench @.

~ Ring nut wrench: PIN. YM-38404, 90890-01430

<7' -

NOTE: ________________________ Bearing retainer has left-hand thread.

12.Remove: • Middle drive shaft (with bearing)

4 - 48

MIDDLE GEAR SERVICE

ENG

INSPECTION 1.lnspect: • Damper cam surfaces Wear/scratches ~ Replace damper and driven pinion gear as a set. 2.lnspect: • Damper spring Damage/cracks ~ Replace.

3.lnspect: • Gear teeth (drive pinion gear) CD • Gear teeth (driven pinion gear) ® Pitting/galling/wear ~ Replace. 4.lnspect: • O-ring Damage ~ Replace. • Bearings Pitting/damage ~ Replace. 5.Check: • U-joint movement Roughness ~ Replace U-joint.

MIDDLE DRIVE AND DRIVEN GEAR SHIM SELECTION When the drive and driven gear, bearing housing assembly and/or crankcase replaced, be sure to adjust the gear shim CD.

1.Select: • Middle drive gear shim CD • Middle driven gear shim ®

********************************* Middle drive and driven gear shim selection steps: .Position middle drive and driven gear by using shims CD and ® with their respective thickness calculated from information marked on crankcase, bearing housing and drive gear end. G) Shim thickness" A"

® Shim thickness 4 - 49

"8"

MIDDLE GEAR SERVICE

ENG ~.

eTo find shim thickness "A" use following formula: Middle drive pinion gear shim thickness: A" ® + (E) - © - @

Where: ® = a numeral (usually a decimal number) on the right crankcase specifies a thickness of "6.4". (E) = a numeral (usually a decimal number) on the left crankcase specifies a thickness of "65". © = a numeral (usually a decimal number) on the middle drive pinion gear is either added to or substracted from "55". @ = a numeral (usually a decimal number) on the bearing housing is either added to or substracted from "15.7". Example: 1) If the crankcase (right) is marked "6.30" ..... ® is 6.30 2) If the crankcase (left) is marked "65.01" ..... (E) is 65.01 3) If the middle drive pinion gear is marked +02" ..... © is 55.02 4) If the bearing housing is marked +02" ..... @ is 15.72 5) Therefore, the shim thickness is 0.57 mm II

= 6.30 + 65.01

- 55.02 - 15.72

= 0.57

6) Round off hundredths digit and select appropriate shim(s). . In the example above, the calculated shim thickness is 0.57 mm. The chart instructs you, however, to round off 7 to

4 - 50

Hundredths

Round value

0,1,2

3,4,5,6, 7

8,9

MIDDLE GEAR SERVICE

ENG ~.

Shims are supplied in the following thickness. Middle drive pinion gear shim

Thickness (mm)

0.10 0.15 0.20

0.30 0.40 0.50

eTo find shim thickness "8" use the following formula: Middle driven pinion gear shim thickness: "B" ® - CD + @ - CEi) - CD - 0.05

Where: ® = a numeral (usually a decimal number) on the bearing housing is either added to or substracted from "76". CD = a numeral (usually a decimal number) on the middle driven pinion gear is either added to or substracted from "59". @ = a numeral (usually a decimal number) on the middle driven pinion gear is either added to or substracted from "79.5". CEi) = a numeral (usually a decimal number) on the right crankcase specifies a thickness of "56.5". CD = a numeral (usually a decimal number) on the left crankcase specifies a thickness of "39.5". Example: 1) If the bearing housing is marked "-15" ..... ® is 75.85 2) If the driven pinion gear is marked" +02" ..... CD is 59.02 3) If the driven pinion gear is marked" +02" ..... @ is 79.52 4) If the crankcase (right) is marked "56.49" ••••• CEi) is 56.49 5) If the crankcase (left) is marked "39.49" ..... CD is 39.49 6) Therefore, the shim thickness is 0.32 mm

8 = 75.85 - 59.02 + 79.52 - 56.49 - 39.49 0.05 = 0.32 4 - 51

MIDDLE GEAR SERVICE

ENG " \ .

7) Round off hundredths digit and select appropriate shim(s). In the example above, the calculated shim thickness is 0.32 mm. The chart instructs you, however, to round off 2 to o. Hundredths

Round value

0, 1,2

3,4,5,6, 7

8,9

Shims are supplied in the following thickness. Middle drive pinion gear shim

Thickness (mm)

0.10 0.15 0.20 0.30

0.40 0.50 0.60

*********************************

ASSEMBLY Reverse the "DISASSEMBLY" procedures. Note the following points. Middle driven shaft assembly 1.lnstall: • Bearing retainer CD • Oil seal ® Use the ring nut wrench @.

Jfb

Ring nut wrench: PIN. YM-38404, 90890-01430

Bearing retainer: 80 Nm (8.0 m • kg, 58 ft • Ib) LOCTITE®

NOTE: Bearing retainer has left-hand thread.

4 - 52

MIDDLE GEAR SERVICE 2.1nstall: • Dust cover CD • Universal joint yoke • Washer@ • Nut@

ENG '\,.

3.Attach: • Universal joint holder CD (onto the universal joint yoke) Universal joint holder: PIN. YM-04062, 90890-04062

4.Tighten: • Nut (universal joint yoke) Nut (universal joint yoke): 97 Nm (9.7 m • kg, 70 ft· Ib) LOCTITE®

5.lnstall: • Bearing CD • Bearing retainer ® • Oil seal Use the bearing retainer wrench @.

Bearing retainer wrench: PIN. YM-04128, 90890-04128

Bearing retainer: 110 Nm (11.0 m· kg, 80 ft ·Ib) LOCTITE®

NOTE: Bearing retainer has a left-hand thread.

4 - 53

MIDDLE GEAR SERVICE

ENG ' \ , .

6.lnstall: • Shims CD • Bearing housing ® Bolt (bearing housing): 25 Nm (2.5 m • kg, 18 ft· Ib)

7.lnstall: • Universal joint yoke • Washer® • Nut@

8.Attach: • Universal joint holder CD (onto the universal joint yoke) Universal joint holder: PIN. YM-04062, 90890-04062

9.Tighten: • Nut Nut: 97 Nm (9.7 m • kg, 70 ft • Ib) LOCTITE®

10.lnstall: • Universal joint

********************************* Universal joint installation steps: .Install the opposite yoke into the U-joint . • Apply wheel bearing grease to the bearings.

4 - 54

MIDDLE GEAR SERVICE • Install the bearing

::::::::§~gIIN:;:::::::

ENG

~•

CD onto the yoke.

_______~_

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 .

• Install the circlips each bearing.

into the groove of

********************************* Middle drive shaft assembly 1.lnstall: • Bearing CD • Bearing retainer

Screw (bearing retainer): 25 Nm (2.5 m • kg, 18 ft· Ib) LOCTITE®

2.1nstall: • Middle drive shaft CD • Shim(s) ® • Middle drive pinion gear @ • Nut (middle drive pinion gear) @ NOTE: Always use a new nut (middle drive pinion gear).

3.lnstall: • Middle driven gear CD • Middle drive shaft assembly ® NOTE: When installing the middle drive shaft assembly, fit it onto the splines on the middle driven gear.

Bolt (bearing housing): 32 Nm (3.2 m • kg, 23 ft • Ib) LOCTITE® 4 - 55

MIDDLE GEAR SERVICE

ENG , , _

4.Tighten: • Nut (middle drive pinion gear) CD NOTE: ________________________ Place a copper plate ® between teeth of the drive gear and driven gear to lock them.

~ Nut (middle drive pinion gear): ~~ 130 Nm (13.0 m • kg, 94 ft· Ib) 5.Lock the threads with a drift punch.

INSTALLATION 1.lnstall: • Crankcase (left) • Engine Refer to "ENGINE ADJUSTMENT".

ASSEMBLY

AND

GEAR LASH MEASUREMENT 1.Measure: • Gear lash Middle gear lash: 0.1 .... 0.3 mm (0.004 .... 0.012 in)

********************************* Measurement steps: .Attach the pinion gear fix clamp middle drive shaft.

CD to

the

~ Pinion gear fix clamp: ~

PIN. YM-04129, 90890-04129

.Attach the gear lash measurement tool and dial gauge @.

~ Gear lash measurement tool: ~

PIN. YM-01231, 90890-01231

® 46 mm (1.8 in) 4 - 56

MIDDLE GEAR SERVICE

ENG

~ ~.

e 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 90Âˇ each time.

elf the gear lash is incorrect, adjust the gear lash by middle driven pinion gear shims and/or middle drive pinion gear shim(s).

*********************************

4 - 57

ENGINE ASSEMBLY AND ADJUSTMENT

ENG

ENGINE ASSEMBLY AND ADJUSTMENT

A WARNING For engine reassembly, replace the following parts with new ones. • • • • • •

a-ring Gasket Oil seal Copper washer Lock washer Circlip

OIL PUMP 1.Lubricate: • Inner rotor • Outer rotor • Pump shaft ~

• LJ

Recommended lubricant: Engine oil

2.lnstall: • Pump shaft CD (to pump cover ®) • • • • • •

Pin @ Inner rotor @ Outer rotor @ Dowel pins ® Pump housing Screw ®

Screw (pump housing): 7 Nm (0.7 m • kg, 5.1 ft • Ib) NOTE: • When installing the inner and outer rotors, make sure that the punch mark @ on these parts faces towards the driven gear. • When installing the inner rotor, align the pin @ in the pump shaft with the groove (E) on the inner rotor @.

. ..

3.Check: • Oil pump operation Unsmooth ~ Inspect and replace the defective parts. Refer to "INSPECTION AND REPAIR".

4 - 58

ENGINE ASSEMBLY AND ADJUSTMENT

ENG

VALVE, CAMSHAFT AND ROCKER ARM

CD Locknut (valve adjusting) ® Adjuster (valve adjusting)

@ Valve spring seat @Valve @ Bearing retainer @ Lock washer @ Bearing @ Camshaft @ Bearing @ Circlip @) Valve guide

@ Wave washer @ Rocker arm ® Rocker arm shaft ® O-ring (J) Valve cotter ® Valve spring retainer ® Oil seal @) Valve spring

VALVE CLEARANCE (COLD): Intake: 0.06 - 0.10 mm (0.002 - 0.004 in) Exhaust: 0.16 - 0.20 mm (0.006 - 0.008 in) VALVE SPRING TILT LIMIT: Inner spring: 2.5" or 1.6 mm (0.06 in) Outer spring: 2.5 or 1.6 mm (0.06 in)

STEM RUNOUT LIMIT: 0.02 mm (0.0008 in)

VALVE SEAT WIDTH LIMIT: 1.6 mm (0.06 in) 20 Nm (2.0 m· kg. 14 ft· Ib)

VALVE SPRING LENGTH LIMIT (FREE): Inner spring: 37.9 mm (1.49 in) Outer spring: 41.27 mm (1.62 in)

1m!)

f$~1m!)

{j--@

4 - 59

ENGINE ASSEMBLY AND ADJUSTMENT

ENG , , _

VALVE, ROCKER ARM AND CAMSHAFT 1.Apply: • High-quality molybdenum disulfide oil (to the valve stem and oil seal) 2.lnstall: • Valve spring seat CD • Oil seal ® • Valve @ • Valve spring (inner) @ • Valve spring (outer) ® • Spring retainer ® • Valve cotters (j) NOTE: Install the valve spring with the wider gapped coils facing up as shown.

® Larger pitch (b) Smaller pitch

NOTE: Compress the valve spring with the valve spring compressor @ and then, install the valve cotters.

11172002

Valve spring compressor: PIN. YM-04019, 90890-04019

11171201

3.Apply: • Engine oil (to the bearing of the camshaft) • High-quality molybdenum disulfide oil (to the rocker arm and shaft) 4.lnstall: • Camshaft (compression stroke as shown) CD • Rocker arm ® • Rocker arm shaft @ Bolt (camshatt bearing retainer) @: 8 Nm (0.8 m • kg, 5.8 tt • Ib)

NOTE: Bend the lock washer tab along a flat side of the nut.

A WARNING Always use a new lock washer. 4 - 60

ENGINE ASSEMBLY AND ADJUSTMENT

ENG ' \ .

CRANKSHAFT 1.1 nstall: • Crankshaft Crankshaft installer set: PIN. YU-90050 Buffer boss installer set: PIN. 90890-04088 Adapter #11: PIN. YM-33279 Pot extension: PIN. YM-33280 Crank pot spacer: PIN. YM-91044, 90890-04081 NOTE: • Install a suitable steel plate CD between the crank pot spacer and crankshaft installer set or buffer boss installer set. • Hold the connecting rod at 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.

:::::::1111111:;::::::,: _________ Apply engine oil to each bearing to protect the crankshaft against scratches and to make installation easier.

TRANSMISSION AND BALANCER WEIGHT 1.lnstall: • Main axle assembly CD • Drive axle assembly @ • Reverse wheel gear assembly @

2.lnstall: • Middle driven gear CD • Middle drive shaft assembly @ NOTE: When installing the middle drive shaft assembly, fit it onto the splines on the middle driven gear CD.

4 - 61

ENGINE ASSEMBLY AND ADJUSTMENT CRANKSHAFT AND TRANSMISSION

CD Middle drive gear ® 1st wheel gear

@) Middle drive shaft ® Main axle ® 4th pinion gear @ 3rd pinion gear ® 5th pinion gear @ 2nd pinion gear @ Reverse wheel gear 2 @ Crankshaft @) Balancer weight

@ Drive axle @ 4th wheel gear ® 3rd wheel gear ® 5th wheel gear (J) Reverse wheel gear 1 ® 2nd wheel gear ® Middle driven gear

I 8 Nm (0.8 m • kg, 5.8 ft· Ib) I

4 - 62

ENG , _

ENGINE ASSEMBLY AND ADJUSTMENT

ENG

~ ~ ••

Bolt (bearing housing): 32 Nm (3.2 m • kg, 23 ft • Ib) LOCTITEQ!)

3.lnstall: • Shift cam CD • Shift fork "R" ® • Shift fork "C" @ • Shift fork "L" @ • Guide bar #2 (shorter) ® • Guide bar #1 (longer) ® NOTE: Each shift fork is identified by a number cast on its side. All the numbers should face the right side.

4.Check: • Transmission and shifter operation Unsmooth operation ~ Repair. NOTE: • Oil each gear bearing thoroughly. • Shift the main transmission into neutral.

5.lnstall: • Balancer weight

CRANKCASE (LEFT) 1.Apply:

• Sealant CD (to the mating surfaces of both case halves) Sealant (Quick Gasket®): PIN. ACC-QUICK-GS-KT Yamaha bond No. 1215: PIN. 90890-85505 4 - 63

ENGINE ASSEMBLY AND ADJUSTMENT

ENG "\,_

2.lnstall: • Dowel pin ® 3.Fit the left crankcase onto the right case. Tap lightly on the case with a soft hammer.

:::::Iglg!IN:;:::::::: ________ Before installing and torquing the crankcase holding bolts, be sure to check whether the transmission is functioning properly by manually rotating the shift cam either way.

4.Tighten: • Bolts (crankcase) NOTE: • Tighten the bolts starting with the lowest numbered one. • Apply sealant to the bolt threads ®, ®, @. M6 bolt (crankcase): 10 Nm (1.0 m • kg, 7.2 ft· Ib) M8 bolt (crankcase): 26 Nm (2.6 m • kg, 19 ft • Ib) LOCTITE®

[A] Left crankcase

lID Right crankcase CD - @: M6 bolts @ - @: M8 bolts

5.Apply: • 4-stroke engine oil (to the crank pin, bearing and oil delivery hole) 6.Check: • Crankshaft and transmission operation Unsmooth operation ~ Repair.

7.lnstall: • Shift cam segment CD • Torx screw ®

Torx screw: 12 Nm (1.2 m • kg, 8.7 ft· Ib) 1---~~.;..! LOCTITE®

8.Check: • Transmission and shifter operation Unsmooth operation ~ Repair. 4 - 64

ENG

ENGINE ASSEMBLY AND ADJUSTMENT BALANCER DRIVE AND DRIVEN GEARS AND OIL PUMP

<D Oil pump drive gear

@) Bearing @ Balancer weight

® Washer @ Balancer drive gear @ Spring @Pin ® Oil pump driven gear (J) Oil pump assembly ® Gasket ® Balancer driven gear

I 60 Nm (6.0 m • kg, 43 ft • Ib) I

I 8 Nm (0.8 m • kg, 5.8 ft • Ib) I

J;10

4 - 65

ENGINE ASSEMBLY AND ADJUSTMENT

ENG , _

BALANCER DRIVE GEARS AND OIL PUMP 1.lnstall: • Balancer drive gear CD • Pins ® • Springs @ NOTE: • The balancer drive gear damper assembly is composed of six springs @ and three pins ®. Insert a spring into the buffer boss, then insert a spring with a pin in it. • Align the punch marks ® on the buffer boss and drive gear. 2.1nstall: • Holding plate CD • Oil pump drive gear ® Use the following tools. Pot spacer: PIN. YM-90070-A Adapter #11: PIN. YM-33279 Crankshaft installer set: PIN. YU-90050 Buffer boss installer set: PIN. 90890-04088

3.lnstall: • Balancer driven gear CD • Straight key ® • Lock washer • Nut (balancer driven gear) NOTE: • Align the punch marks ® on the drive and driven gear. • Be sure the tab of the lock washer engages the slot on the balancer shaft.

A WARNING Always use a new lock washer.

4 - 66

ENGINE ASSEMBLY AND ADJUSTMENT

ENG

4.Tighten: • Nut (balancer driven gear)

~ ~.

NOTE: Place a copper plate ® between the teeth of the driven gear and drive gear to lock them.

~ Nut (balancer driven gear): ~~ 60 Nm (6.0 m • kg, 43 ft • Ib) 5.Bend the lock washer tabs. 6.lnstall: • Copper washers • Oil delivery pipe 1 CD Bolt (oil delivery pipe 1): 16 Nm (1.6 m • kg, 11 ft· Ib)

A WARNING Always use new copper washers. 7.lnstall: • Gasket (oil pump) • Oil pump assembly

Screw (oil pump): 8 Nm (0.8 m • kg, 5.8 ft • Ib)

A WARNING Always use a new gasket. REVERSE SHIFT BRACKET 1.lnstall: • Copper washer CD • Thermo unit ® Thermo unit: 20 Nm (2.0 m • kg, 14 ft· Ib)

2.lnstall: • Reverse shift bracket assembly CD • Washer ® NOTE: • Hook the spring ends on the reverse shift bracket and crankcase. • Mesh the reverse shift bracket with the shift cam as shown.

4 - 67

ENGINE ASSEMBLY AND ADJUSTMENT CLUTCH CD Pressure plate ® Friction plates (red -

® Thrust washer ® Clutch housing

(secondary) @) Push rod #2 @ Clutch carrier assembly ® One-way clutch bearing @ Clutch housing (primary) @ Plain washer

7 pes.)

@ Clutch plates (thickness: 1.6 mm - 4 pes.) @ Clutch plate (thickness: 2.0 mm - 2 pes.) ® Push rod #1 ® O-ring (]) Clutch boss

8 Nm (0.8 m • kg, 5.8 ft· Ib)

ENG , _

A CLUTCH SPRING MINIMUM LENGTH: 39 mm (1.54 in) B CLUTCH PLATE WARP LIMIT: 0.2 mm (0.008 in) C CLUTCH SHOE WEAR LIMIT: 1.5 mm (0.06 in)

140 Nm (14 m • kg, 100 ft· Ib)

4 - 68

FRICTION PLATE WEAR LIMIT: 2.8 mm (0.11 in)

ENGINE ASSEMBLY AND ADJUSTMENT 3.lnstall: • Gear position switch • Lead holder ®

ENG , _

Bolt (gear position switch): 6 Nm (0.6 m • kg, 4.3 ft • Ib) LOCTITE®

CLUTCH 1.lnstall: • Clutch housing CD • Thrust washer ® • Clutch boss @ • Lock washer CV

A WARNING Always use a new lock washer. 2.lnstall: • Nut (clutch boss)

Nut (clutch boss): 90 Nm (9.0 m • kg, 6.5 ft • Ib)

Use a clutch holding tool clutch boss.

to hold the

~ Clutch holding tool: PIN. YM~91042, 90890-04086

#' -

3.Bend the lock washer tabs.

4.lnstall: • Push rod #2 CD • Ball ® • Push rod #1 @ (with O-ring) NOTE: Apply lithium soap base grease to the ball and push rods #1, #2.

4 - 69

ENGINE ASSEMBLY AND ADJUSTMENT

ENG

~ ~.

5.lnstall: • Friction plates CD • Clutch plates (thickness: 1.6 mm - 4 pcs) ® • Clutch plates (thickness: 2.0 mm - 2 pcs) @

NOTE: Mount friction and clutch plate alternately.

6.lnstall: • Pressure plate CD • Clutch springs • Bolts (pressure plate)

NOTE: • Align the punched mark ® on the clutch boss with the arrow mark (@ on the pressure plate. • Tighten the bolts (pressure plate) in stage, using a crisscross pattern. Bolt (pressure plate): 8 Nm (0.8 m • kg, 5.8 ft • Ib)

7.lnstall: • Plain washer CD • Clutch housing comp ® • Clutch carrier assembly @ • Nut (primary clutch) @

l1li

A WARNING Always use a new nut (primary clutch).

NOTE: • The one-way clutch bearing should be installed in the primary clutch housing with the mark "OUT SIDE" ® facing toward the clutch carrier assembly.

4 -70

ENGINE ASSEMBLY AND ADJUSTMENT

ENG , _

• The secondary clutch housing has two notches ® machined into it to permit the primary drive gear behind the primary clutch to clear the secondary clutch. Align one of these notches with the primary gear CQ) before installing the primary clutch assembly.

8.Tighten: • Nut (primary clutch)

NOTE: Place a copper washer ® between the teeth of the balancer drive gear and balancer driven gear to lock them.

~ "..

Nut (primary clutch): 140 Nm (14.0 m • kg, 100 ft· Ib)

9.Lock the threads with a drift punch.

A WARNING Always use a new nut.

CRANKCASE COVER (RIGHT) 1.lnstall:

• Gasket CD • Dowel pins

mil ®

A WARNING Always use a new gasket.

2.lnstall: • Crankcase cover (right) CD • Reverse control cable holder ® • Reverse control lever @ • Dipstick @ NOTE: • Apply the sealant to threads of the bolt (ID. • Tighten the bolts in stages, using a crisscross pattern. 4 - 71

ENGINE ASSEMBLY AND ADJUSTMENT

ENG , _

Bolt (crankcase cover-right): 10 Nm (1.0 m • kg, 7.2 ft· Ib)

3.1nstall: • Oil strainer CD • Spring @ • O-ring @ • Drain plug @ Drain plug: 32 Nm (3.2 m • kg, 23 ft • Ib)

4.lnstall: • Copper washers • Oil delivery pipe 2 CD

A WARNING Always use new copper washers.

~ ",.

Union bolt: 18 Nm (1.8 m • kg, 13 ft· Ib)

TIMING CHAIN AND COl ROTOR 1.lnstall: • Timing chain CD • Timing chain guide (intake) @ Timing chain guide (intake): 10 Nm (1.0 m • kg, 7.2 ft ·Ib) NOTE: ____________________________________________________________ Fasten a safety wire to the timing chain to prevent it from falling into the crankcase.

4 -72

ENG "".

ENGINE ASSEMBLY AND ADJUSTMENT COl ROTOR AND STARTER

® Stator assembly @) Pickup coil assembly @ Lead holder © Gasket @ Crankcase cover (left)

CD Starter idle gear #1 ® Starter idle gear #2 @ Woodruff key @ Bearing ® Washer ® Starter wheel gear (j) Starter clutch ® CDI rotor

30 Nm (3.0 m

kg, 22 ft

Ib)

-G

50 Nm (5.0 m

kg, 36 ft

Ib)

~' 10 Nm (1.0 m

7 Nm (0.7 m

kg, 5.1 ft olb)

4 -73

kg, 7.2 ft

Ib)

ENGINE ASSEMBLY AND ADJUSTMENT SHIFTER

CD Reverse control

@) Shift guide assembly @ Stopper collar @Adjuster @ O-ring ® Shift pedal link @ Shift rod @ Shift pedal @ Shift fork @) Shift fork guide bar

lever Washer @ Circlip Spring ® Reverse shift bracket ® Shift cam (j) Shift cam segment ® Stopper lever ® Shift shaft

22 Nm (2.2 m - kg, 16 ft - Ib)

10 Nm (1.0 m - kg, 1.2 ft -Ib)

e 20 Nm (2.0 m - kg, 14 ft - Ib)

4-74

ENGINE ASSEMBLY AND ADJUSTMENT

ENG "\,_

2.lnstall: • Plain washer CD • Bearing ® • Starter wheel gear @ • Woodruff key @ • COl 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.

STARTER IDLE GEAR AND SHIFT SHAFT 1.lnstall: • Starter idle gear #2 CD • Starter idle gear #1 ®

2.lnstall: • a-rings • Oil delivery pipe 3 CD • Spring ® • Stopper lever @ Bolt (oil delivery pipe 3): 10 Nm (1.0 m • kg, 7.2 ft ·Ib) Bolt (stopper lever): 10 Nm (1.0 m • kg, 7.2 ft· Ib) LOCTITE® NOTE: • Hook the spring ends on the stopper lever @ and crankcase boss @. • Mesh the stopper lever @ with the shift cam stopper.

4 -75

ENGINE ASSEMBLY AND ADJUSTMENT

ENG "\,_

3.lnstall: • Washer • Shift shaft assembly CD

NOTE: Hook the spring ends onto the stopper ®.

CRANKCASE COVER (LEFT) 1.lnstall: • Pickup coil assembly CD • Stator assembly ® • Lead holder G) Bolt (stator assembly): 7 Nm (0.7 m· kg, 5.1 ft ·Ib) LOCTITE® Bolt (pickup coil): 7 Nm (0.7 m • kg, 5.1 ft ·Ib) LOCTITE® Bolt (lead holder): 7 Nm (0.7 m • kg, 5.1 ft ·Ib)

2.Apply: • Molybdenum disulfide oil (to shift guide assembly)

3.lnstall: • Shift guide assembly CD • Stopper collar ®

NOTE: Install the shaft in the stopper collar as shown in the illustration, so that the tip of the shaft protrudes from the stopper collar.

4 -76

ENG '-\,_

ENGINE ASSEMBLY AND ADJUSTMENT 4.lnstall: • O-ring CD • Washer@ • Locknut@

5.lnstall: • Dowel pins • Gasket l1li • Crankcase cover (left)

Crankcase cover (left): 10 Nm (1.0 m • kg, 7.2 ft· Ib)

NOTE: • When installing the crankcase cover (left), use a long rod to hold the COl rotor in position from the outside. This will make assembly easier. Be careful not to damage the oil seal. • Tighten the bolts in stages, using a crisscross pattern.

A WARNING Always use a new gasket and a new copper washer. 6.lnstall: • Starter pulley CD

~ ",.

Starter pulley: 50 Nm (5.0 m· kg, 36 ft ·Ib)

Use a rotor holder @ to hold the starter pulley. Rotor holder: PIN. YU-01235, 90890-01235

NOTE: Before installing the starter pulley, do not forget to install the O-ring.

4 -77

ENGINE ASSEMBLY AND ADJUSTMENT

ENG

PISTON AND CYLINDER

CD Top ring ® Oil ring (lower) @ Oil ring (upper) @ Second ring ® Piston ® Circlip (J) Piston pin ® Cylinder ® Gasket @) Dowel pin

PISTON SIZE: 82.92 - 82.97 mm (3.265 - 3.267 in) PISTON RING END GAP LIMIT: 8 Top: 0.5 mm (0.02 in) 2nd: 0.5 mm (0.02 in)

PISTON RING SIDE CLEARANCE LIMIT: C Top: 0.12 mm (0.005 in) 2nd: 0.12 mm (0.005 in) 10 Nm (1.0 m • kg, 7.2 ft· Ib)

01~?~~~~~"'''''''

mm~ ~

4 -78

~ ~.

ENGINE ASSEMBLY AND ADJUSTMENT

ENG ,,_

PISTON 1.lnstall: • Piston rings (onto the piston) NOTE: Be sure to install the rings so that the manufacturer's marks or numbers are located on the top side of the rings.

2.lnstall: • Piston CD • Piston pin ® • Piston pin clip @ NOTE: • Apply engine oil to the piston pins. • Be sure that the arrow mark @ on the piston points to the exhaust side of the engine. • Before installing the piston pin clip, cover the crankcase with a clean rag to prevent the piston pin clip from falling into the crankcase.

3.Position: • Top ring • 2nd ring • Oil ring Offset the piston ring end gaps as @Top ring end Cb) Oil ring end (lower) © Oil ring end (upper) (d) 2nd ring end

CYLINDER AND CYLINDER HEAD 1.lnstall:

• • • • • •

4 -79

O-ring CD Dowel pins ® Gasket (cylinder) @ O-ring @ Cylinder(§) Bolt (cylinder) ®

shown~

ENGINE ASSEMBLY AND ADJUSTMENT .........

............ .

ENG

~ ~.

_________

~:::Ig~lmJ:QI:;:I::: Always use a new gasket (cylinder).

NOTE: Install the cylinder with one hand while compressing the piston rings with the other hand.

:~::::::§~m~lm:;::::::::

_________

• Be careful not to damage the timing chain damper during installation. • Pass the timing chain through the timing chain cavity. Bolt (cylinder): 10 Nm (1.0 m • kg, 7.2 ft ·Ib)

2.lnstall: • Timing chain guide (exhaust) CD • O-ring ® • Dowel pins @ • Gasket (cylinder head) @ mil

3.lnstall: • Cylinder head

NOTE: Attach a wire to the timing chain so that it does not fall into the crankcase. • Bolts (cylinder head)

NOTE: • Apply 4-stroke engine oil onto the washers. • Tighten the bolts starting with the lowest numbered one. Bolt (cylinder head) - M10: 40 Nm (4.0 m • kg, 29 ft • Ib) Bolt (cylinder head) - M8: 20 Nm (2.0 m • kg; 14 ft· Ib)

4 - 80

ENG ~. ~

ENGINE ASSEMBLY AND ADJUSTMENT CYLINDER HEAD

CD Spark plug ® Tappet cover (intake)

® Timing chain guide (intake) ® Camshaft sprocket

@ Tappet cover (exhaust) @ O-ring

® Timing chain

® Cylinder head ® Gasket

@ Camshaft sprocket cover @ Side cover

@) Timing chain guide (exhaust)

(j) Timing chain tensioner

18 Nm (1.8 m' kg, 13 ft 'Ib) 40 Nm (4.0 m • kg, 29 ft • Ib) 10 Nm (1.0 m' kg, 7.2 ft· Ib)

I 23 Nm (2.3 m • kg, 17 ft· Ib) I

7 Nm (0.7 m' kg, 5.1 ft 'Ib) 10 Nm (1.0 m' kg, 7.2 ft 'Ib)

A CYLINDER HEAD WARP LIMIT: 0.03 mm (0.0012 in)

60 Nm (6.0 m • kg, 43 ft· Ib)

& .

B-+-S::-:P::-A_R::-:-K-:-=-PL-.,.U--,-G=--::TY,......,.--:=P,--E/_M_A_N_U_F_A_C_T_U_R_E_R_:--j r 1 -O-N-m-(-1.-0-m-·-k-g,-7-.2-ft-·I-b-l) ID8EA/NGK C SPARK PLUG GAP: 0.6 - 0.7 mm (0.024 - 0.028 in)

.--------> 110Nm(1.0m'kg,7.2ft o lb)1

4 - 81

~~~

ENGINE ASSEMBLY AND ADJUSTMENT

ENG

4.lnstall: • Camshaft sprocket

********************************* Camshaft sprocket installing steps: • Rotate the camshaft to align the camshaft pin CD with the cylinder head match mark 0 . • Turn the starter pulley until the "T" mark @ is aligned with the stationary pointer @ on the crankcase cover. • Place the timing chain onto the camshaft sprocket. .Install the camshaft sprocket onto the camshaft and finger tighten the sprocket bolt.

~~~================~~ ~

NOTE: Be sure the match mark @ on the camshaft sprocket is aligned with the match mark 0 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 match mark @ is aligned with the cylinder head match mark 0 . • If the marks are aligned, tighten the camshaft sprocket bolt. If the marks are not aligned, change the meshing position of the camshaft sprocket and timing chain.

********************************* 5.lnstall: • Timing chain tensioner

********************************* Installation steps: • Remove the tensioner cap bolt CD, plain washer 0 and spring @. • Release the timing chain tensioner oneway cam @ and push the tension rod @ . • Install the tensioner ® with a new gasket (J) into the cylinder . •

~/:'7 ISY<Q;,

Bolt (tensioner body): 10 Nm (1.0 m • kg, 7,2 ft· Ib)

~I¥QmJQNi

----------------------

Always use a new gasket .

• Install the spring @, plain washer tensioner cap bolt CD. 4 - 82

and

ENG

ENGINE ASSEMBLY AND ADJUSTMENT ~~

Tensioner cap bolt: 23 Nm (2.3 m kg, 17 ft olb) 0

********************************* 6.lnstall: • Camshaft sprocket cover

7.Tighten: • Bolt (camshaft sprocket)

~J!'J g/~

Bolt (camshaft sprocket): 60 Nm (6.0 m kg, 43 ft Ib) 0

Use a rotor holder pulley.

to hold the starter

~ Rotor holder: PIN. VU-01235, 90890-01235

8.Check: • Camshaft sprocket mark • Rotor liT" mark Out of alignment --7 Adjust. 9.lnstall: • O-ring (exhaust tappet cover) • Tappet cover (exhaust) CD • O-ring (intake tappet cover) • Tappet cover (intake) ®

NOTE: • Install the tappet covers with the ridge facing up @. • Check the O-rings @ for damage. If damaged, replace.

Tappet cover: 10 Nm (1.0 m

kg, 7.2 ft olb)

10.lnstall: • O-ring (side cover) • Side cover (cylinder head)

Side cover (cylinder head): 10 Nm (1.0 m kg, 7.2 ft olb) 0

4 - 83

ENGINE ASSEMBLY AND ADJUSTMENT 11.lnstall: • Timing plug • O-ring ®

ENG , _

RECOIL STARTER 1.lnstall: • Sheave drum CD • Rope ® • Pawl spring @ • Drive pawl @ NOTE: Wind the rope 4-1/2 turns clockwise around the sheave drum. Then insert the rope into the drum slit ®.

2.1nstall: • Starter spring CD • Sheave drum assembly ® NOTE: • Mesh the spring hook @ with the case slit, then wind the spring clockwise into the case from the larger to smaller diameter. • Mesh the sheave drum hook @ with the spring hook ®.

3.lnstall: • Spring CD • Friction plate

• Nut NOTE: Insert the spring hooks into the pawl side holes.

4 - 84

ENG ,,_

ENGINE ASSEMBLY AND ADJUSTMENT

4.Turn the sheave drum 3-turns clockwise to give preload to the spring.

5.lnstall: • Starter handle

• Cap@

NOTE: • Pass the rope through the case hole and make a knot @ on the rope so that the rope is not pulled into the case. • Untie the knot @ after making a knot @ above the handle. 6.1nstall: • Gasket III!I • Recoil starter assembly CD

Recoil starter: 10 Nm (1.0 m

kg, 7.2 ft olb)

REMOUNTING THE ENGINE When remounting the engine, reverse the removal procedure. Note the following points.

A WARNING Securely support the machine so there is no danger of it falling over. 1.lnstall: • Engine (from the left side) 2.lnstall: • Front drive shaft CD

NOTE: When installing the front drive shaft, move the engine to the right (clockwise).

4 - 85

ENGINE ASSEMBLY AND ADJUSTMENT

ENG

3.lnstall: • Bolts (engine mounting-rear) CD • Engine stay (front) • Bolts (engine mounting stay-front) ® • Bolt (engine mounting-front) @ • Engine stay (upper) • Bolts (engine mounting stay-top) @ • Bolt (engine mounting-top) ®

NOTE: • All mounting bolts CD, ®, @, @ and ® should be installed from the right of the machine. • Install all of the bolts and nuts first and then tighten the bolts and nuts to specifications in the following order. 1st. Bolt (engine mounting staytop): 34 Nm (3.4 m • kg, 24 ft • Ib) 2nd. Nut (engine mounting-rear): 69 Nm (6.9 m • kg, 50 ft • Ib) 3rd. Nut (engine mounting stayfront): 34 Nm (3.4 m • kg, 24 ft • Ib) 4th. Nut (engine mounting-front): 69 Nm (6.9 m • kg, 50 ft • Ib) 5th. Nut (engine mounting-top): 34 Nm (3.4 m • kg, 24 ft • Ib)

4.lnstall: • Rear shock absorber and swingarm • Pivot shaft (left) • Pivot shaft (right) • Locknut (pivot shaft - right) • Covers Refer to "REAR SHOCK ABSORBER AND SWINGARM" in CHAPTER 7. 5.Pass the breather hoses and parking brake cable through their guides. 6.lnstall: • Spark plug Spark plug: 18 Nm (1.8 m • kg, 13 ft· Ib)

4 - 86

ENGINE ASSEMBLY AND ADJUSTMENT

ENG

~ ~.

7.lnstall: • Footrest (left and right) Bolt (footrest): 64 Nm (6.4 m • kg, 46 ft • Ib)

8.lnstall: • Shift pedal link

NOTE: Align the mark ® on the shift shaft with the slot (Q) on the shift pedal link.

~ Bolt (shift pedal link): ~~ 10 Nm (1.0 m • kg, 7.2 ft· Ib) 9.lnstall: • Oil filter element • Oil filter cover CD NOTE: Check the a-rings for damage, and replace if damaged.

~ ~

Bolt (oil filter cover): 10 Nm (1.0 m • kg, 7.2 ft ·Ib)

10.lnstall: • Starter motor

Bolt (starter motor): 10 Nm (1.0 m • kg, 7.2 ft· Ib)

11.lnstall: • Gasket • Exhaust pipe • Muffler (?)

Nut (exhaust pipe): 12 Nm (1.2 m • kg, 8.7 ft • Ib) Bolt (muffler): 27 Nm (2.7 m • kg, 19 ft • Ib) LOCTITE® Bolt (joint): 20 Nm (2.0 m • kg, 14 ft· Ib)

4 - 87

ENGINE ASSEMBLY AND ADJUSTMENT 12.lnstall: • Intake manifold

ENG ~.

Bolt (intake manifold): 20 Nm (2.0 m • kg, 14 ft • Ib)

I 13.lnstall: • Carburetor assembly Refer to "CARBURETOR" in CHAPTER 5. 14.Fill: • Engine oil Refer to "ENGINE OIL LEVEL INSPECTION" in CHAPTER 3. 15.Adjust: • Valve clearance Refer to "VALVE CLEARANCE ADJUSTMENT" in CHAPTER 3. 16.Adjust: • Idling speed Refer to "IDLING SPEED ADJUSTMENT" in CHAPTER 3. 17.Adjust: • Throttle lever free play Refer to "THROTTLE LEVER FREE PLAY" in CHAPTER 3.

4 - 88

~~~~~~~~~~~~C_A_R_BU_R_E_ro_R_ICARBI~1 CARBURETION

CARBURETOR CD Vacuum

® ® @

® (])

® ® @)

® ® @

chamber cover Spring Jet needle holder Spring Jet needle set Piston valve Air vent hose Pilot air jet Coasting enricher diaphragm Starter plunger Valve seat Needle valve set Pilot jet

Starter jet @ Needle jet @ Main jet ® Pilot screw set @ Float @) Throttle stop screw @ Overflow hose @ Carburetor warmer

SPECIFICATIONS 5FUOO MAIN JET (M.J.) #112.5 PILOT JET (P.J.) #17.5 JET NEEDLE (J.N.) 5EP4-55-3 NEEDLE JET (N.J.) P-OM (#826) FLOAT HEIGHT (F.H.) 12 - 14 mm (0.47 - 0.55 in) FUEL LEVEL ~ (F.L.) 3 - 4 mm (0.12 - 0.16 in) Above the float chamber mating surface ENGINE IDLING SPEED 1,450 - 1,550 r/min

10 MARK

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.

5-1

____________C_A_R_BU_R_E_T_OR_ cA~I~1 REMOVAL 1.Remove: • • • •

Seat Front carrier Front fender Fuel tank Refer to "SEAT, CARRIERS, FENDERS AND FUEL TANK" in CHAPTER 3.

2.Disconnect: • Starter cable CD 3.Remove: • Starter plunger 0

J)JJJJjJlllJJl

4.Disconnect: • Carburetor warmer connectors 5.Remove: • Air vent hose 0 • Overflow hose @ 6.Loosen: • Clamp screws @ 7.Remove: • Carburetor assembly 8.Remove: • Throttle valve cover • a-ring

9.Remove: • Throttle cable end

5-2

CARBURETOR

----------------------------------------------------------

ICARBI 'ill

10.Loosen: • Throttle cable adjusting nut CD 11.Remove: • Throttle cable CV

OISASSEMBL Y

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.

1.Remove: • Vacuum chamber cover CD • Spring CV • Jet needle holder @ • Spring @ • Jet needle set ® • Piston valve ®

2.Remove: • Carburetor warmer CD • Washer CV • Carburetor warmer terminal @

3.Remove: • Throttle stop screw • Float chamber CV • O-ring @

5-3

CARBURETOR

--------------------------------------------------------

ICARBI iii I

4.Remove: • Float pin CD • Float ® • Needle valve @

5.Remove: • Valve seat CD • Main jet ® • Needle jet @ • Pilot jet @ • Starter jet ® • Pilot screw set ®

6.Remove: • Pilot air jet CD

7.Remove: • Cover (coasting enricher) • Spring ® • Diaphragm @

INSPECTION 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.

5-4

~~~~~~~~~~~~C_A_R_BU_R_E_T_OR_ICARBI~I 1.lnspect: • Carburetor body • Starter jet CD • Float chamber Cracks/damage'~

Replace.

• Fuel passage Contamination ~ Clean as indicated. • Fuel chamber body Contamination ~ Clean.

********************************* Cleaning steps: .Wash the carburetor in a petroleum based solvent. (Do not use any caustic carburetor cleaning solution.) • Blowout all of the passages and jets with compressed air.

********************************* 2.lnspect: • Valve seat CD • Needle valve CV • O-ring @ Contamination/wear/damage as a set.

Replace

NOTE: Always replace the needle valve and valve seat as a set.

3.1nspect: • Float CD • Float tang CV Damage ~ Replace.

4.lnspect: • Main jet CD • Needle jet @ • Pilot jet @ • Starter jet @ • Pilot air jet ® Wear/damage ~ Replace. Contamination ~ Blowout the jets with compressed air. 5-5

_____________ CA_R_B_U_R_E_TO_R_ cARB ~1 S.lnspect: • Spring CD • Jet needle holder ® • Spring @ • Jet needle set @ • Piston valve ® Bends/wear/damage

-7

Replace.

6.lnspect: • Diaphragm (coasting enricher) CD • Spring ® • Cover@ Tears (diaphragm) /damage -7 Replace.

7.lnspect: • Starter plunger CD Bends/wear/damage -7 Replace. • Spring ® • O-ring @ • Plunger cap cover @ Damage -7 Replace.

a.lnspect: • Throttle stop screw • Pilot screw CD Contamination/wear -7 Replace. • O-ring ® Damage -7 Replace.

9.Check: • Free movement (piston valve) Sticks -7 Replace. Insert the piston valve into the carburetor body, and check for free movement. 10.Check: • Free movement (throttle valve) Sticks -7 Replace.

5-6

~~~~~~~~~~~~_C_A_R_B_UR_E_T_O_RICARBI~I ASSEMBLY Reverse the "DISASSEMBLY" procedure. Note the following points.

NOTE: Before assembling the carburetor, make sure to turn out the pilot screw the same number of times, as noted before disassembly, from the seated position to the set position.

::::::::D.!B:I!I:;:::::::: _________ • Before reassembling, wash all of the parts in a clean petroleum based solvent. • Always use a new gasket.

1.lnstall: • Diaphragm (coasting enricher) • Spring CV • Cover@

NOTE: Match the tab on the rubber diaphragm to the matching recess in the carburetor body.

2.Measure: • Float height ® Out of specification

Adjust.

Float height (F.H.): 12 - 14 mm (0.47 - 0.55 in)

********************************* Measurement and adjustment steps: • Hold the carburetor in an upside down position. • Measure the distance from the front mating surface of the float chamber (gasket removed) to the top of the float.

NOTE: The float arm should be resting on the needle valve, but not compressing it. • If the float height is not within the specification, inspect the valve seat and needle valve. 5-7

_ _ _ _ _ _ _ _ _ _ _ _C_A_R_BU_R_E_T_OR_ cA~I~1 elf either is worn, replace them both. elf both are fine, adjust the float height by bending the float tang CD on the float. e Recheck the float height.

*********************************

3.lnstall: • Carburetor warmer terminal • Washer@ • Carburetor warmer @

NOTE: Use "HEAT SINKER" when installing the carburetor warmer. "HEAT SINKER" is the name of a product, sold at most electrical appliance dealers. Carburetor warmer: 2.5 Nm (0.25 m • kg, 2.0 ft • Ib) HEAT SINKER

4.lnstall: • Piston valve

NOTE: Match the tab on the rubber diaphragm to the matching recess in the carburetor body.

INSTALLATION Reverse the "REMOVAL" procedure. Note the following points.

5-8

ICARBI ~ I ---------------------------------------------------------CARBURETOR

1.lnstall: • Carburetor assembly

Clamp screw: 2 Nm (0.2 m • kg, 1.4 ft ·Ib)

2.Adjust: • Idle speed Refer to "IDLE SPEED ADJUSTMENT". Engine idle speed: 1,450 - 1,550 rlmin

3.Adjust: • Throttle lever free play Refer to "THROTTLE CABLE FREE PLAY ADJUSTMENT". Throttle lever free play: 3 - 5 mm (0.12 - 0.20 in)

FUEL LEVEL ADJUSTMENT 1.Measure: • Fuel level ® Out of specification ~ Adjust. Fuel level: 3 - 4 mm (0.12 - 0.16 in) Above the float chamber mating surface

********************************* Fuel level measurement and adjustment steps: • Place the machine on a level surface . • Connect the fuel level gauge CD to the drain pipe ®.

~ Fuel level gauge:

<7 -

PIN. YM-01312-A, 90890-01312

• Loosen the drain screw G). 5-9

.Hold the gauge vertically next to the carburetor body line . • Measure the fuel level ® with the gauge . • If the fuel level is incorrect, adjust the fuel level. .Remove the carburetor. .Inspect the valve seat and needle valve . • If either is worn, replace them both . • If both are fine, adjust the float level by bending the float tang @ slightly . • Install the carburetor. • Recheck the fuel level.

*********************************

5 - 10

TROUBLESHOOTING 1DRIV 1

DRIVE TRAIN

TROUBLESHOOTING The following conditions may indicate damaged shaft drive components: Possible Causes

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.A locked-up condition of the shaft drive train mechanism, no power transmitted from the engine to the front and/or rear wheel.

A.Bearing damage. B.lmproper gear lash. C. Gear tooth damage. D. Broken drive shaft. E. Broken gear teeth.

F. Seizure due to lack of lubrication. G.Small foreign objects lodged between the moving parts.

NOTE: Areas A, B, and C above may be extremely difficult to diagnose. The symptoms are quite subtle and difficult to distinguish from normal machine operating noise. If there is reason to believe these components are damaged, remove the components and inspect them.

Inspection notes 1.lnvestigate any unusual noises.

********************************* The following "noises" may indicate a mechanical defect: a.A "rolling rumble" noise during coasting, acceleration, or deceleration. The noise increases with front and/or rear wheel speed, but it does not increase with higher engine or transmission speeds. Diagnosis: Possible wheel bearing damage. b.A "whining" noise that varies with acceleration and deceleration. Diagnosis: Possible incorrect reassembly, too-little gear lash.

6-,

IORIVI* .. -------------------------------------------------TROUBLESHOOTING

__________

:::::::§IB~N:;::::::j: 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.

A WARNING Stop riding immediately if broken gear teeth are suspected. This condition could result in the shaft drive assembly lockingup, causing loss of control of the machine and possible injury to the rider. ********************************* 2.lnspect: • Drained oil Drain plug shows large amounts of metal. Particles ~ Check the bearing for seizure.

NOTE: A small amount of metal particles in the oil is normal. 3.1nspect: • Oil leakage

********************************* Oil leakage inspection steps: .Clean the entire machine thoroughly, then dry it . • Apply a leak-localizing compound or dry powder spray to the shaft drive . • Road test the machine for the distance necessary to locate the leak. Leakage ~ Inspect the component housing, gasket, and/or seal for damage. Damage ~ Replace the component.

NOTE: • An apparent oil leak on a new or nearly new machine may be the result of a rustpreventative coating or excessive seal lubrication. • Always clean the machine and recheck the suspected location of an apparent leakage.

********************************* 6-2

TROUBLESHOOTING

IDRIVI-iC:...

Troubleshooting Chart When basic condition "a" and "b" exist, check the following points:

Elevate and spin both wheels. Feel for wheel bearing damage.

Check the wheel, hub and drum nuts for tightness.

Check the constant velocity joint. Feel for bearing damage.

YES

.. .. NO

Replace the wheel bearing. (Refer to "FRONT AND REAR WHEELS" in CHAPTER 7.)

Torque to specification. (Refer to "FRONT AND REAR WHEELS" in CHAPTER 7.)

Constant velocity joint bearings and differential gear bearings probably are not damaged. Repeat the test or remove the individual components.

L____________~I~ ~heck the rear brake adjustment.

RYES Check the rear axle. Feel for bearing damage.

Remove the rear axle. Check for axle bearing damage.

Remove the drive

. ....". Adjust per instructions. (Refer to "REAR BRAKE LEVER AND PEDAL ADJUSTMENT" in CHAPTER 3.)

.. NO

YES

s~aft components.

6-3

Rear axle bearings and rear drive shaft bearings probably are not damaged. Repeat the test or remove the individual components.

Replace the rear axle bearing. (Refer to "REAR AXLE/REAR FINAL GEAR AND REAR DRIVE SHAFT".)

DIFFERENTIAL GEAR AND CONSTANT VELOCITY JOINTS

*. .

1DRIV 1

DIFFERENTIAL GEAR AND CONSTANT VELOCITY JOINTS ® ®

Q) Universal joint ® Bearing @ Circlip @ Front drive shaft ® Washer ® Spring (j) Oil seal

® @ @ @

DIFFERENTIAL OIL:

TOTAL AMOUNT: 0.2 L (0.18 Imp qt, 0.21 US qt)

Bearing retainer Shim(s) Drive pinion gear Differential gear case Ring gear Differential gear assembly Bearing housing (ring gear)

TYPE: SAE 80 or 80 W 90 API"GL-5" C Hypoid gear oil for LSD (Limited Slip Differential)

110 Nm (11 m - kg, 80 ft -Ib)

50 Nm (5.0 m - kg, 36 ft - Ib)

12 Nm (1.2 m - kg, 8.7 ft -Ib)

GEAR LASH: 0.08 _ 0.24 mm (0.003 - 0.009 in)

71m\!1

STARTING TORQUE:

E 17 - 25 mm 14

(1.7 - 2.5 m - kg, 12 - 18 ft -Ib)

12 Nm (1.2 m - kg, 8.7 ft -Ib)

6-4

DIFFERENTIAL GEAR AND CONSTANT VELOCITY JOINTS

IDRIV

CD Circlip

® Double off-set joint @ Snap ring @ Dust boot ® Boot band ® Joint shaft (J) Ball joint

REPAIR PARTS KITS

l~ 5~~

6-5

----------1

lUiI

5 __

~_~a~

III

•

I(CJ!D

*. .

DIFFERENTIAL GEAR AND CONSTANT VELOCITY JOINTS 1DRIV 1 REMOVAL

1.Place the machine on a level surface. 2.Apply the parking brake. 3.Drain: • Differential gear oil Refer to "DIFFERENTIAL GEAR OIL REPLACEMENT" in CHAPTER 3. 4.Block the rear wheels, and elevate the front wheels by placing a suitable stand under the frame. 5.Remove: • Front wheels • Front wheel hubs Refer to "FRONT AND REAR WHEELS" in CHAPTER 7. • Steering knuckles Refer to "STEERING SYSTEM" in CHAPTER 7. 6.Remove: • Differential gear case guard 7.Remove: • Constant velocity joints CD • Circlips (double off-set joint)

8.Remove: • Front drive shaft protector CD

9.Remove:

•

Lower arms

VL1:.==------"-

6-6

DIFFERENTIAL GEAR AND CONSTANT VELOCITY JOINTS

IDRIV

10.Disconnect: • Differential gear case breather hose 11.Remove: • Differential gear case ®

12.Remove: • Front drive shaft • Spring ® • Washer • Circlips • Rubber covers

DISASSEMBLY Differential gear 1.Remove: • Universal joint

********************************* Universal joint removal steps: .Remove the circlips CD. • Place the U-joint in a press . • With a suitable diameter pipe ® beneath the yoke @, press the bearing @ 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.

NOTE: It may be necessary to lightly tap the yoke with a punch.

********************************* 2.Attach: • Universal joint holder (onto the universal joint yoke) Universal joint holder: PIN. YM-04062, 90890-04062

6-7

DIFFERENTIAL GEAR AND CONSTANT VELOCITY JOINTS

3.Remove: • Nut CD • Universal joint yoke • Oil seal @

DRIV 1

4.Remove: • M8 bolts (bearing housing) • M10 bolts (bearing housing)

NOTE: Working in a crisscross pattern, loosen each bolt 1/4 of a turn. Remove them after all of them are loosened.

5.Remove: • Bearing housing

6.Remove: • Shim(s) (left) CD • Differential gear assembly ® • Shim(s) (right) @

7.Remove: • Ring gear CD

NOTE: _________________________ The ring gear and the differential gear cover should be fastened together. Do not disassemble the differential gear.

6-8

DIFFERENTIAL GEAR AND CONSTANT VELOCITY JOINTS 1DRIV 1

t:gAi(J.mIQN·:· .•·: . _________ The differential gears are assembled into a proper unit at the factory by means of specialized equipment. Do not attempt to disassemble this unit. Disassembly will result in the malfunction of the unit. 8.Remove: • Bearing retainer

NOTE: Straighten the punched portion bearing retainer.

Use the hexagon wrench (44 mm)

of the

CV.

Hexagon wrench (44 mm): PIN. YM-01462, 90890-01462

9.Remove: • Drive pinion gear (together with the shim(s) and bearing) Tap lightly on the drive pinion gear end with a soft hammer.

'::::::§~um~IN:;'::

________

Drive pinion gear removal should be performed only if bearing replacement is necessary. Do not reuse the bearings or races after removal. Constant velocity joint 1.Remove: • Bands (double off-set joint)

NOTE: After removing the bands, slide the dust boot CV (double off-set joint) to the ball joint side.

2.Remove: • CircJip

NOTE: After removing the circJip, pulf out the shaft with the bearing.

6-9

DIFFERENTIAL GEAR AND CONSTANT VELOCITY JOINTS 1DRIV 1 3.Remove: • Snap ring CD • Ball bearing ® • Dust boot (double off-set joint)

4.Remove: • Bands (ball joint) CD • Dust boot (ball joint) ® (from the ball joint assembly @)

INSPECTION

Differential gear 1.lnspect: • Gear teeth Pitting/galling/wear ~ Replace front drive gear and ring gear as a set. • Bearing Pitting/damage ~ Replace. • Oil seal • a-ring Damage ~ Replace. 2.lnspect: • Drive shaft splines • Universal joints • Front drive gear splines Wear/damage ~ Replace. • Spring Fatigue ~ Replace. Move the spring up and down. 3.lnspect: • Front drive shaft Bends ~ Replace.

A WARNING Do not attempt to straighten a bent shaft; this may dangerously weaken the shaft.

6 - 10

DIFFERENTIAL GEAR AND CONSTANT VELOCITY JOINTS 1DRIV 1

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.

Constant velocity joint 1.1nspect: • Double off-set joint spline • Ball joint spline • Shaft spline Wear/damage ~ Replace. 2.1nspect: • Dust boots Cracks/damage ~ Replace.

3.lnspect: • Balls and ball races • Inner surface of double off-set joint Pitting/wear/damage ~ Replace.

4.Check: • Free play (thrust movement) Excessive play ~ Replace the joint assembly.

ASSEMBLY Reverse the "DISASSEMBLY" procedure. Note the following points. Differential gear 1.Lubricate: • Oil seals • O-rings

I_I 6 - 11

Lithium-soap base grease

DIFFERENTIAL GEAR AND CONSTANT VELOCITY JOINTS

IDRIV +:.. 1

2.lnstall: • Shim(s) • Bearing • Drive pinion gear • Bearing retainer Use the hexagon wrench (44 mm)

::·:.QA1.gm~~N·~·

CD.

_________

Always use a new bearing retainer.

Hexagon wrench (44 mm): PIN. YM-01462, 90890-01462 Bearing retainer: 100 Nm (10 m • kg, 72 ft· Ib)

3.Lock the thread

® with center punch.

4.lnstall: • Ring gear CD Bolt (ring gear): 50 Nm (5.0 m • kg, 36 ft • Ib) LOCTITE®

5.Apply: • Sealant (onto bearing housing mating surfaces) Quick gasket®: ACC-QUICK-GS-KT Yamaha bond No. 1215®: 90890-85505

6 - 12

DIFFERENTIAL GEAR AND CONSTANT VELOCITY JOINTS

IDRIV

6.Tighten: • M10 bolts (bearing housing) • M8 bolts (bearing housing) NOTE: ________________________ Tighten the bolts in stages, using a crisscross pattern.

M10 bolt (bearing housing): 48 Nm (4.8 m • kg, 35 ft • Ib) LOCTITE® M8 bolt (bearing housing): 26 Nm (2.6 m • kg, 19 ft· Ib)

7.Check: • Gear lash Out of specification -7 Adjust. Refer to "MEASUREMENT AND ADJUSTMENT".

8.lnstall: • Oil seal CD • Universal joint yoke @ • Nut@

9.Attach: • Universal joint holder (onto the universal joint yoke)

~ Universal joint holder: PIN. YM-04062, 90890-04062

<7' -

10.Tighten: • Nut Nut: 110 Nm (11.0 m • kg, 80 ft ·Ib) LOCTITE®

6 - 13

DIFFERENTIAL GEAR AND CONSTANT VELOCITY JOINTS

DRIV 1

11.lnstall: • Universal joint

********************************* Universal joint installation steps: .Install the opposite yoke into the U-joint . • Apply wheel bearing grease to the bearings . • Install the bearing CD onto the yoke.

________

::::::::§lgi~N:;:::::::: 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 . • Install the circlips (g) into the groove of each bearing.

*********************************

Constant velocity joint 1.Apply: • Molybdenum disulfide grease (into the ball joint assembly)

NOTE: Molybdenum disulfide grease is included in the repair kit. 2.lnstall: • Dust boot (ball joint) • Bands (ball joint) (g)

NOTE: After installing the bands, bend the band ends to secure them.

6 - 14

DIFFERENTIAL GEAR AND CONSTANT VELOCITY JOINTS 1DRIV 1 3.lnstall: • Dust boot (double off-set joint) Insert the shaft into the boot. • Ball bearing CD • Snap ring CV 4.Lubricate: • Ball bearing

...... Molybdenum disulfide grease

5.lnstall: • Ball bearing with shaft • Circlip CD (to the double off-set joint)

NOTE: • Before installing the ball bearing, apply molybdenum disulfide grease into the double off-set joint. • Cover the double off-set joint with the dust boot. 6.lnstall: • Bands (double off-set joint)

NOTE: ________________________ After installing the bands, bend the band ends to secure them.

7.Check: • Free play (thrust movement) Refer to "INSPECTION".

MEASUREMENT AND ADJUSTMENT Differential gear lash measurement 1.Remove: • Universal joint yoke • Bearing housing

6 - 15

DIFFERENTIAL GEAR AND CONSTANT VELOCITY JOINTS 1 DRIV 1

2.Secure the ring gear CD with the plates and bolts (8 mm) as shown.

3.Attach: • Gear lash measurement tool • Dial gauge ®

~ Gear lash measurement tool: PIN. YM-01231, 90890-01231

<?' -

4.Measure: • Gear lash Gently rotate the constant velocity joint from engagement to engagement. Over the specified limit ~ Adjust.

NOTE: Measure the gear lash at four positions. Rotate the ring gear 90· each time. Differential gear lash: 0.08 - 0.24 mm (0.003 - 0.009 in)

Differential gear lash adjustment 1.Remove: • Shim(s) (left) CD • Differential gear assembly ® • Shim(s) (right) @

2.Adjust: • Gear lash

********************************* 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. 6 - 16

DIFFERENTIAL GEAR AND CONSTANT VELOCITY JOINTS 1 DRIV

I*.

elf it is necessary to increase by more than 0.05 mm (0.002 in): Reduce right shim thickness by 0.05 mm (0.002 in) for every 0.05 mm of left shim increase. elf it is necessary to reduce by more than 0.05 mm (0.002 in): Increase right shim thickness by 0.05 mm (0.002 in) for every 0.05 mm of left shim decreased.

Ring gear shim (left and right)

Thickness (mm)

0.50 0.55 0.60 0.65 0.70 0.75 0.80 0.85

0.90 0.95 1.00 1.05 1.10 1.15 1.20 1.25

1.30 1.35 1.40 1.45 1.50 1.55 1.60

elf you cannot adjust the gear lash properly using the ring gear shim, use a drive pinion gear shim. e Remove the drive pinion gear. Refer to "DISASSEMBLY" . eSelect the suitable shim(s) CD. T oo-litt:le gear lash Reduce shim thickness. Too-large gear lash Increase shim thickness.

Drive pinion gear shim

Thickness (mm)

1.82 1.88 1.94

2.00 2.06 2.12

2.18

*********************************

INSTALLATION When installing the differential gear, reverse the "REMOVAL" procedures. Note the following points. 1.Lubricate: â&#x20AC;¢ Drive shaft splines

I_I 6 - 17

Lithium-soap base grease

DIFFERENTIAL GEAR AND CONSTANT VELOCITY JOINTS 2.lnstall: • Differential gear case

'ff7

6Y~

IDRIV I+::..1 CD

Nut (differential gear case): 64 Nm (6.4 m • kg, 46 ft • Ib)

3.Connect: • Differential gear case breather hose ®

4.lnstall: • Circlip (double off-set joint)

A WARNING Always use a new circlip.

5.Lubricate: • Constant velocity joints • Oil seals

I_I

Lithium-soap base grease

6.lnstall: • Constant velocity joints

7.lnstall: • Steering knuckles Refer to "STEERING SYSTEM" in CHAPTER 7. • Front wheel hubs • Front wheels Refer to "FRONT AND REAR WHEELS" in CHAPTER 7. 8.Fill: • Differential gear oil Refer to "DIFFERENTIAL GEAR OIL REPLACEMENT" in CHAPTER 3.

6 - 18

*. .

DIFFERENTIAL GEAR AND CONSTANT VELOCITY JOINTS 1 DRIV 1

DIFFERENTIAL GEAR OPERATION CHECK 1.Block the rear wheels, and elevate the front wheels by placing a suitable stand under the frame. 2.Remove the wheel cap and cotter pin from the axle nut (right or left). 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 . • During this test, the other front wheel will turn in the opposite direction. Front wheel starting torque: (differential gear preload): New unit: 17 - 25 Nm (1.7 - 2.5 m· kg, 12 -18ft ·Ib) Minimum: 10 Nm (1.0 m • kg, 7.2 ft· Ib) 4.0ut of specification, replace the differential gear assembly. 5.Within specification, install the cotter pin and wheel cap.

6 - 19

REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT Q) Oil seal

Â® Bearing @ Rear axle @ Dust cover

REAR AXLE RUNOUT LIMIT: 1.5 mm (0.06 in) 55 Nm (5.5 m . kg, 40 ft . Ib)

6 - 20

10m

IDRIVI*~1

REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT CD Bearing

housing Ring gear stopper shim @ Ring gear stopper (1) a-ring ® Oil seal ® Bearing (J) Ring gear shim ® Ring gear ® Thrust washer @) Bearing @Oil seal

@ @ @ @ @ @ @ @)

Bearing Drive pinion gear Final drive gear shim Bearing Bearing retainer a-ring Oil seal Collar ® Drive shaft @ Circlip @ Universal joint

FINAL GEAR OIL:

CAPACITY: 0.25 L (0.22 Imp qt, 0.26 US qt)

TYPE: SAE 80 API "GL-4" HYPOID GEAR OIL

GEAR LASH: 0.1 - 0.2 mm (0.004 - 0.008 in)

IDR1vl-F=..

@ Bearing

23 Nm (2.3 m • kg, 17 ft· Ib)

E SHIM(S):2

~----,~,

4-0-N-:-m---:'"(4-:-.-=-0-m-·-;k-g--:,2;;-;:9;-;ft;:--:·l~b7l)I

,< , / /

'-1

23 Nm (2.3 m • kg, 17ft·lb)

100 Nm (10.0 m • kg, 72 ft • Ib)

6 - 21

REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT DRIV 1"'::.. 1 REMOVAL

A WARNING Securely support the machine so there is no danger of it falling over.

1.Place the machine on a level surface.

2.Remove: • Rear wheels • Rear wheel hubs • Rear brake drum Refer to "FRONT AND REAR WHEELS" and "REAR BRAKE" in CHAPTER 7.

3.Remove: • Final gear 4.Drain: • Final gear Refer to MENT" in

case protector CD oil "FINAL GEAR OIL REPLACECHAPTER 3.

5.Remove: • a-ring CD • Washer ®

6.Remove: • Rear axle CD • Dust cover ®

!!!!!!!!II!YrnJ!ml,!!;:::::!!! _ _ _ _ _ _ __ • Never directly tap the axle end with a hammer, this will result in damage to the axle thread and spline.

6 - 22

REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT

IDRIVI..p.::..

• Attach a suitable socket ® on the axle end and tap it with a soft hammer. Pull out the rear axle to the left.

7.Remove: • Breather hose (final gear case) • Final gear case assembly ®

8.Remove: • Rear drive shaft CD

DISASSEMBLY 1.Remove: • Bolts (M8) (with washer) • Bolts (M10)

NOTE: Working in a crisscross pattern, loosen each bolts 1/4 of a turn. Remove them after all of them are loosened.

6 - 23

REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT

I I*~I DRIV

2.Remove: • Bearing housing CD • Shim(s) ® • Ring gear@ • Thrust washer(s) @

3.Remove: • Bearing retainer (drive shaft - final)

NOTE: • The final drive shaft bearing retainer has left-hand threads. Turn the retainer clockwise to loosen it. • When removing the bearing retainer, use the bearing retainer wrench CD.

~ Bearing retainer wrench: PIN. YM-04050, 90890-04050

7 -

4.Remove: • Drive pinion gear CD (together with the shim(s) ® and bearing @) Tap lightly on the final drive pinion gear end with a soft hammer.

:::!::!:§IBil;::::!!: ________ Final drive pinion gear removal should be performed only if bearing replacement is necessary. Do not reuse the bearings or races after removal.

6 - 24

*. .

REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT 1 DRIV 1

5.Remove: • Roller bearing (ring gear) CD Use a suitable press tool (g) and an appropriate support for the main housing. • Oil seal @

6.Remove: • Roller bearing (drive pinion gear)

********************************* Removal steps: • Heat the main housing only to 150°C (302 OF).

• Remove the roller bearing outer race with an appropriately shaped punch (g). • Remove the inner race from the final drive shaft.

NOTE: The removal of the final drive shaft roller bearing is difficult and seldom necessary.

*********************************

INSPECTION 1.lnspect: • Rear axle runout ® Out of specification

Replace.

it. WARNING Do not attempt to straighten a bent axle. Rear axle runout limit: 1.5 mm (0.06 in)

6 - 25

REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT

2.lnspect: • Oil seal CD Damage ~ Replace the oil seal CD and dust cover ® as a set. • Oil seal @ Damage ~ Replace. 3.Check: • Bearings @ Bearings allow play in the final gear housing and rear hub or the rear axle turns roughly ~ Replace.

/"'~~I WV~~ ~

IDRIVI-iC..

) / ~.

4.lnspect: • Gear teeth CD Pitting/galling/wear ~ Replace the drive pinion gear and ring gear as a set. • Oil seal ® • a-ring @ Damage ~ Replace. S.lnspect: • Bearings @ Damage ~ Replace.

NOTE: • Reusing roller bearings is acceptable, but Yamaha recommends installing new ones. Do not reuse the oil seal. • When the final drive pinion gear and/or ring gear are replaced, be sure to adjust the shim of the final drive pinion gear and/ or ring gear.

6.lnspect: • Drive shaft (splines) CD Wear/damage ~ Replace.

6 - 26

REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT

IDRIVI-F=..I

7.lnspect: • Final gear case CD • Bearing housing (ring gear) 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. FINAL DRIVE PINION GEAR AND RING GEAR SHIM SELECTION 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(s) selection 1.Select: • Final drive pinion gear shim(s) CD

********************************* Shim selection steps: eTo find the final drive pinion gear shim thickness" A", use the following formula. Final drive pinion gear shim thickness: "A"=@-<E>

"A"

®@

= a numeral (usually a decimal number)

on the final drive pinion gear is either added to or subtracted from "84". <E> = a numeral (usually a decimal number) on the final gear case is either added to or subtracted from "83".

6 - 27

REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT

IDRlvl-F=...

Example: 1) If "01" is stamped on the final drive pinion gear, ÂŽ = 84 + 0.01 = 84.01 2) If "50" is stamped on the final gear case, @ = 83 + 0.50 = 83.50 3) Therefore, "A" is 0.51. "A"= 84.01 - 83.50 = 0.51 4) Round off the hundredths digit and select the appropriate shim(s). In the example above, the calculated number is 0.51. The chart instructs you to round off 1 to 0 at the hundredth place. Thus, the shim thickness is 0.50 mm. Hundredths

Rounded value

0, 1,2

3,4,5,6, 7

8,9

Shims are supplied in the following thicknesses. Final drive pinion gear shim Thickness (mm)

0.30 0.40

0.50

*********************************

Ring gear shim(s) selection 1.Select: â&#x20AC;˘ Ring gear shim(s) CD

6 - 28

REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT

IDRIV I

********************************* Shim selection steps: eTo find ring gear shim thickness "8", use the following formula. Ring gear shim thickness: "8" © + @ - (@ + CD)

© = a numeral (usually a decimal number) on the final gear case is either added to or subtracted from 45. @ = a numeral (usually a decimal number) on outside of ring gear bearing housing and added to 1. @ = a numeral (usually a decimal number) on inside of ring gear either added to or subtracted from 35.00. CD = bearing thickness (considered constant).

thickness CD: I ~ Bearing .:6.1 11.00 mm Example: 1) If "53" is stamped on the final gear case, © = 45 + 0.53 = 45.53 2) If "05" is stamped on the ring gear bearing housing, @ = 1 + 0.05 = 1.05 3)

If "-05" is stamped on the ring gear,

@= 35 - 0.05 = 34.95 4) CD = is 11.00. 5)

Therefore, shim thickness "8" is, "8"= 45.53 + 1.05- (34.95 + 11.00) = 46.58 - 45.95

= 0.63 6)

6 - 29

Round off the hundredths 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

3,4,5,6, 7

8,9

REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT

I 1*..1 DRIV

Shims are supplied in the following thicknesses. Ring gear shim

Thickness (mm)

0.25 0.40

0.30 0.50

********************************* ASSEMBLY Reverse the "DISASSEMBLY" procedures. Note the following points. 1.lnstall: • Roller bearing (drive pinion gear)

********************************* Installation steps: .Heat the main housing only to 150°C (302 OF) .

• Install the roller bearing outer race using the proper adapter. • Install the inner race onto the drive shaft.

********************************* 2.lnstall: • Oil seal CD • Roller bearing ® Use a suitable press tool @ and a press to install the above components into the main housing.

6 - 30

REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT

IDRIVI-iC...

3.lnstall: • Drive pinion gear CD (with shim(s) ® and bearing @) Shim(s) ~ (proper size as calculated) • Bearing retainer (drive pinion gear) @

NOTE: • The bearing retainer has left-hand threads; turn the retainer counterclockwise to tighten it. • Before installing the bearing retainer, apply grease to the O-ring. • When installing the bearing retainer, use the bearing retainer wrench @.

Bearing retainer wrench: PIN. YM-04050, 90890-04050

Bearing retainer: 100 Nm (10.0 m • kg, 72 ft· Ib)

Thrust washer selection 1.Measure/select: • Ring gear thrust clearance

"c"

********************************* Thrust clearance measurement steps: .Place four pieces of Plastigauge® between the originally fitted thrust washer and the ring gear. .Install the ring gear assembly and tighten the bolts to specification. M8 Bolts (bearing housing): 23 Nm (2.3 m • kg, 17 ft • Ib) M10 Bolts (bearing housing): 40 Nm (4.0 m • kg, 29 ft • Ib) NOTE: Do not turn the drive shaft and ring gear when measuring the clearance with Plastigauge®.

lie"

6 - 31

+::. .

REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT 1DRIV 1

• Remove the ring gear assembly. • Measure the thrust clearance. Calculate the width of the flattened Plastigauge® CD. Ring gear thrust clearance: 0.1 - 0.2 mm (0.004 - 0.008 in) of specification, select the correct washer. Thrust washer selection steps: .Select a suitable thrust washer using the following chart. Thrust washer

Thickness (mm)

1.2 1.8

1.4 2.0

1.6

.Repeat the measurement steps until the ring gear thrust clearance is within the specified limits.

*********************************

Ring gear stopper shim selection 1.Measure: • Ring gear stopper clearance "0" Use a feeler gauge CD. Out of specification ~ Adjust. Ring gear stopper clearance "0": 0.30 - 0.60 mm (0.012 - 0.024 in)

Ring gear @ Ring gear stopper

6 - 32

REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT 1DRIV 1

Ring gear stopper clearance adjustment 1.Remove: • Ring gear CD • Ring gear stopper ® • Shim(s) @

o Bearing housing

~ Left-hand threads

2.Select: • Suitable shim(s) Shim Thickness (mm)

0.15

0.20

3.lnstall: • Shim(s) • Ring gear stopper (left-hand threads) • Ring gear Ring gear stopper: 9 Nm (0.9 m • kg, 6.5 ft • Ib) LOCTITE®

4.Measure: • Ring gear stopper clearance Out of specification ~ Repeat. Ring gear stopper clearance: 0.30 ... 0.60 mm (0.012 ... 0.024 in)

5.lnstall: • Thrust washer(s) CD • Ring gear ® • Shim(s) (proper size as calculated) @ • Bearing housing @

6 - 33

+::..

REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT 1DRIV 1

6.lnstall: • Bolts (M10) CD • Bolts (M8) ® (with washer)

NOTE: Tighten the bolts cross pattern.

stages using a criss-

M10 Bolt (bearing housing): 40 Nm (4.0 m • kg, 29 ft • Ib) M8 Bolt (bearing housing): 23 Nm (2.3 m • kg, 17 ft· Ib)

-++--

FINAL GEAR LASH MEASUREMENT AND ADJUSTMENT Final gear lash measurement 1.Secure the gear case in a vise or another supporting device~ 2.Remove: • Drain plug • Gasket 3.lnstall: • A bolt of the specified size CD (into the drain plug hole)

'.5 mm (0.06 in)

:::::::IIYlml:;::::::·: ________ Finger tighten the bolt until it holds the ring gear. Otherwise, the ring gear will be damaged.

4.Attach: • Gear lash measurement tool • Dial gauge ®

~ Gear lash measurement tool:

<7 ®

6 - 34

PIN. YM-01231, 90890-01231

Measuring point 21.5 mm

REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT I DRIV I

5.Measure: • Gear lash Gently rotate the gear coupling from engagement to engagement. Final gear lash: 0.1 - 0.2 mm (0.004 - 0.008 in)

NOTE: Measure the gear lash at four positions. Rotate the shaft 90· each time.

Final gear lash adjustment 1.Remove: • Bearing housing CD • Shim(s) • Ring gear@ • Thrust washer @

2.Adjust: • Gear lash

********************************* Adjustment steps: eSelect a suitable shim(s) and thrust washer(s) using the following chart. Too-little gear lash -7 Reduce shim thickness. Too-large gear lash -7 Increase shim thickness. elf it is necessary to increase by more than 0.2 mm (0.008 in): Reduce thrust washer thickness by 0.2 mm (0.008 in) for every 0.2 mm of ring gear shim increase. elf it is necessary to reduce by more than 0.2 mm (0.008 in):

6 - 35

REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT I DRIV

*. .

Increase thrust washer thickness by 0.2 mm (0.008 in) for every 0.2 mm of ring gear shim decrease. Ring gear shim 0.25 0.40

0.30 0.50

Thrust Washer

Thickness (mm)

1.2 1.8

1.4 2.0

1.6

*********************************

3.lnstall: • Thrust washer(s) CD • Ring gear ® • Shim(s) @ • Bearing housing @ M10 Bolt (bearing housing): 40 Nm (4.0 m • kg, 29 ft • Ib) M8Boit (bearing housing): 23 Nm (2.3 m • kg, 17 ft • Ib) 4.Measure: • Gear lash Incorrect ~ Repeat the "Final gear lash adjustment" steps. Final gear lash: 0.1 - 0.2 mm (0.004 - 0.008 in)

6 - 36

REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT

IDR1vl-F=..

INSTALLATION Reverse the "REMOVAL" procedures. Note the following points. 1.Lubricate: • Drive shaft • Coupling gear • O-ring • Oil seal • Bearing

l--tl

Lithium-soap base grease

2.lnstall: • Drive shaft CD (to the universal joint)

3.Apply: • Sealant CD (to the mating surfaces of the swingarm and final gear case) Quick gasket®: ACC-QUICK-GS-KT Yamaha bond No. 1215®: 90890-85505

4.1nstall: • Final gear case assembly CD • Breather hose (final gear case)

Nut (final gear case): 48 Nm (4.8 m • kg, 35 ft· Ib) LOCTITE® Bolt (final gear case bearing housing): 55 Nm (5.5 m • kg, 40 ft· Ib) LOCTITE®

6 - 37

REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT

5.lnstall: • Dust cover • Rear axle

-jD.~ cec tIi /.

IDR1vl-iC..

********************************* Installation steps: • Install the dust cover CD onto the rear axle.

..I

NOTE: Adjust the length ® to 225.5 mm (8.9 in) when install the dust cover .

• Install the rear axle (with dust cover) (1) . • Install the rear brake drum and rear wheel hub (right) . • Temporarily tighten the right axle nut@. NOTE: After tightening the rear axle nut @, the position of the dust cover CD will slightly move to protect the oil seal of the final gear case.

*********************************

6.lnstall: • Rear wheel hub (left) • Rear wheels Refer to "FRONT AND REAR WHEELS" in CHAPTER 7.

7.Fill: • Final gear case Refer to "FINAL GEAR OIL REPLACEMENT" in CHAPTER 3.

6 - 38

FRONT AND REAR WHEELS

ICHASId:Y61

CHASSIS FRONT AND REAR WHEELS Q) Wheel cap ® O-ring ® Cotter pin @Axle nut @ Plain washer ®Wheel nut ® Front wheel (j) Front wheel hub

TIRE AIR PRESSURE Front Cold Tire Pressure

Rear wheel

@ Rear wheel hub (right) @ Dust seal @ Rear wheel hub (left)

Standard

psi)

Minimum

22 kPa (0.22 kg/cm2, 3.2

22 kPa (0.22 kg/cm 2, 3.2

psi)

Maximum

28 kPa (0.28 kg/cm 2, 4.0

psi)

!II Tapered

wheel nuts are used for both the front and rear wheels. Install the nut with its tapered side towards the wheel.

55 Nm (5.5 m • kg, 40 ft • Ib)

1150 Nm (15 m • kg, 110 ft· Ib)

25 kPa (0.25 kg/cm 2, 3.6

TIRE SIZE: FRONT: AT25 x 8-12 REAR: AT25 x 10-12

RIM SIZE: FRONT: 12 x 6.0AT REAR: 12 x 7.5AT

WHEEL RUNOUT LIMIT: RADIAL: 2 mm (0.08 in) LATERAL: 2 mm (0.08 in)

TIRE WEAR LIMIT: 3 mm (0.12 in)

150 Nm (15 m • kg, 110 ft· Ib) 7-1

Rear

25 kPa (0.25 kg/cm 2, 3.6

FRONT AND REAR WHEELS

ICHAsldY61

REMOVAL Front wheels 1.Place the machine on a level surface. 2.Loosen: • Nuts (front wheel) Apply the front brake.

3.Block the rear wheels, and elevate the front wheels by placing the suitable stand under the frame. 4.Remove: • Nuts (front wheel) • Front wheel

5.Remove: • Wheel cap • Cotter pin CD • Nut (wheel hub) • Washer@

6.Remove: • Front brake caliper CD

NOTE: Do not depress the brake lever when the wheel is off the machine otherwise the brake pads will be forced shut.

7.Remove: • Front wheel hub CD (with brake disc)

7-2

FRONT AND REAR WHEELS

ICHAsldY61

8.Remove: • Front brake disc CD

Rear wheels 1.Place the machine on a level surface. 2.Loosen: • Nuts (rear wheel) Apply the rear brake. 3.Block the front wheels, and elevate the rear wheels by placing a suitable stand under frame.

4.Remove: • Nuts (rear wheel) • Rear wheel • Wheel cap

5.Remove: • Cotter pin CD • Axle nut ® • Plain washer @ • Wheel hub (right) @ • Wheel hub (left) ®

7-3

FRONT AND REAR WHEElS

ICHASI ~ I

INSPECTION 1.1nspect: • Wheel 2.Measure: • Wheel runout Over the specified limit ~ Replace the wheel or check the bearing play CD. Rim runout limits: Radial (g): 2.0 mm (0.08 in) Lateral @: 2.0 mm (0.08 in)

---------

3.Check: • Wheel balance Out of balance ~ Adjust.

A 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.

4.lnspect: • Wheel hub CD Cracks/damage ~ Replace. • Splines (wheel hub) (g) Wear/damage ~ Replace.

INSTALLATION When installing the front and rear wheels, reverse the "REMOVAL" procedure. Note the following points. Front wheel 1.Tighten: • Axle nut (front wheel) Axle nut (front wheel): 150 Nm (15 m • kg, 110 ft· Ib) 7-4

FRONT AND REAR WHEELS

,,-,:"\

:~~£\ IIIII

2.lnstall: • Cotter pin

------

ICHAsl4s61

DB!J

NOTE: Do not loosen the axle nut after torquing it. If the axle nut groove is not aligned with the cotter pin hole, align the groove with the hole by tightening the axle nut.

11"' II'" "I" It'" Ull' tllll

11'11

,, 1

" 11 11111

12040301

WARNING

Always use a new cotter pin.

3.Adjust: • Front brake free play Refer to "FRONT BRAKE ADJUSTMENT" in CHAPTER 3. 4.lnstall: • Front wheel NOTE: The arrow mark CD on the tire must point in the direction of rotation ~ of the wheel.

5.Tighten: • Nuts (front wheel)

A WARNING Tapered wheel nuts CD are used for both the front and rear wheels. Install the nut with its tapered side towards the wheel. ,

Nut (front wheel): 64 Nm (6.4 m • kg, 46 ft • Ib)

Rear wheel Refer to "FRONT WHEEL -INSTALLATION". 1.Lubricate: • Right wheel hub boss

I_I

Lithium-soap base grease

2.Tighten: • Axle nut (rear wheel) • Nuts (rear wheel) Axle nut (rear wheel): 150 Nm (15 m • kg, 110 ft ·Ib) Nut (rear wheel): 55 Nm (5.5 m • kg, 40 ft • Ib)

3.Adjust: • Rear brake lever and pedal free play Refer to "REAR BRAKE LEVER AND PEDAL ADJUSTMENT" in CHAPTER 3. 7-5

_________________________F_RO_N_T_B_R_A_K__ E FRONT BRAKE CD ®

Brake master cylinder Brake master cylinder phram holder @ Brake master cylinder phram @ Brake master cylinder ® Brake master cylinder ® Copper washer (J) Union bolt ® Brake hose

reservoir cap reservoir diareservoir dia-

kit

BRAKE FLUID TYPE: DOT 4

BRAKE PAD WEAR LIMIT: 1.0 mm (0.04 in)

BRAKE DISC WEAR LIMIT: 3.0 mm (0.12 in)

ICHASI~I

® Brake pipe @ @ @ @ @ @ @ @ @

Brake disc Bleed screw Retaining bolt Brake caliper Pad shim Brake pad Piston Piston seal Brake disc guard

23 Nm (2.3 m - kg, 17 ft - Ib)

--'

19 Nm (1.9 m -kg, 13 ft -Ib) 7Nm(O.7m-kg,5.1ft-lb) 27 Nm (2.7 m - kg, 19 ft - Ib) 30 Nm (3.0 m -kg, 22 ft -Ib) 6Nm(O.6m o kg,4.3ft o lb)

1~.1. ~~~-rl r'~ ~ ~

l1li ,,\

\ ~~

~''-J

~ \'0 ~~ ___ a ~-----

~~~

~1111

27 Nm (2.7 m - kg, 19 ft - Ib) 18 Nm (1.8 m - k , 13 ft - Ib) 7-6

FRONT BRAKE ::::::::~i\~m~iN:~:::::::

ICHAslflY6l

________

Disc brake components rarely require disassembly. DO NOT: • Disassemble components unless absolutely necessary. • Use solvents on internal brake components. • Use contaminated brake fluid for cleaning. Use only clean brake fluid. • Allow brake fluid to come in contact with the eyes, otherwise eye injury may occur. • Allow brake fluid to contact painted surfaces or plastic parts otherwise damage may occur. • Disconnect any hydraulic connection otherwise the entire system must be disassembled, drained, cleaned, and then properly filled and bled after reassembly.

BRAKE PAD REPLACEMENT NOTE: It is not necessary to disassemble the brake caliper and brake hose to replace the brake pads.

1.Remove: • Front wheel 2.Loosen: • Retaining bolts CD 3.Remove: • Front brake caliper @

4.Remove: • Retaining bolts

7-7

FRONT BRAKE 5.Remove: • Brake pads CD (with pad shim • Pad spring @

ICHASldsol

®)

NOTE: • When pad replacement is required, also replace the pad spring and shim. • Replace the pads as a set if either is found to be worn to the wear limit@.

Wear limit @: 1.0 mm (0.04 in)

..--I======:il~®

6.lnstall: • Pad shim (onto inside brake pad) • Pad spring • Brake pads

********************************* Installation steps: .Connect a suitable hose CD tightly to the caliper bleed screw ®. Then, place the other end of this hose into an open container. • Loosen the caliper bleed screw and push the pistons into the caliper with the finger. • Tighten the caliper bleed screw ®.

~ ...

Caliper bleed screw: 6 Nm (0.6 m • kg, 4.3 ft • Ib)

.Install the pad shim @ (new) onto the brake pad (new).

NOTE: The arrow mark @ on the pad shim must point in the direction of the disc rotation . • Install the pad spring (new) and brake pads (new).

********************************* 7-8

FRONT BRAKE

ICHASI6:s'6 I

7.lnstall: • Retaining bolts • Front brake caliper Retaining bolt: 18 Nm (1.8 m • kg, 13 ft ·Ib) Bolt (front brake caliper): 30 Nm (3.0 m • kg, 22 ft· Ib)

8.lnstall: • Front wheel 9.1nspect: • Brake fluid level Refer to "FRONT BRAKE FLUID LEVEL INSPECTION" in CHAPTER 3. @ "LOWER" level line

10.Check: • Brake lever operation A soft or spongy feeling ~ Bleed brake system. Refer to "AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)" in CHAPTER 3.

CALIPER DISASSEMBLY

NOTE: Before disassembling the front brake caliper, drain the brake hose, master cylinder, brake caliper and reservoir tank of their brake fluid. 1.Remove: • Front wheel 2.Loosen: • Union bolt • Retaining bolts • Retaining bolt (caliper bracket) 3.Remove: • Front brake caliper • Retaining bolts • Brake pads (with pad shim) • Pad spring Refer to "BRAKE PAD REPLACEMENT". 7-9

FRONT BRAKE 4.Remove: • Union bolt CD • Copper washers • Brake hose @

ICHAsldY61

NOTE: Place the open end of the hose into a container and pump the oil fluid out carefully.

5.Remove: • Caliper body CD • Caliper bracket ®

NOTE: Before removing the caliper body from the bracket, disconnect the dust boot from the guide shaft on the bracket.

6.Remove: • Piston • Piston seals

********************************* Removal steps: • Blow compressed air into the hose joint opening to force out the caliper piston from the caliper body. • Remove the piston seals.

WARNING

Never try to pry out the piston.

*********************************

MASTER CYLINDER DISASSEMBLY NOTE: Before disassembling the front brake master cylinder, drain the brake hose, master cylinder, brake caliper and reservoir tank of their brake fluid.

7 - 10

FRONT BRAKE

ICHAsldY61

1.Remove: • Brake lever CD • Spring • Union bolt ® • Copper washers G) • Brake hose @ NOTE: Hold a container under the master cylinder and under the hose end to collect remaining brake fluid. 2.Remove: • Brake master cylinder reservoir cap CD • Brake master cylinder reservoir diaphram holder • Brake master cylinder reservoir diaphram • Brake master cylinder ®

3.Remove: • Dust boot CD • Circlip ® • Brake master cylinder kit G) Drain the excess fluid.

INSPECTION AND REPAIR Recommended brake component replacement schedule: Brake pads

As required

Piston seal

Every two years

Brake hoses

Every two years

Brake fluid

Replace only when brakes are disassembled.

WARNING

All internal parts should be cleaned in new brake fluid only. Do not use solvents as they will cause seals to swell and distort.

7 - 11

_________________________F_RO_N_T_B_R_A_K__ E

ICHASI~I

1.lnspect: • Caliper piston CD Scratches/rust/wear ~ Replace caliper assembly. • Caliper cylinder ® Wear/scratches ~ Replace caliper assembly. • Caliper body @ Cracks/damage ~ Replace. • Oil delivery passage (caliper body) Blowout with compressed air.

A WARNING Replace the piston seal whenever the caliper is disassembled.

2.lnspect: • Brake master cylinder Wear/scratches ~ Replace the brake master cylinder assembly. • Brake master cylinder body Cracks/damage ~ Replace. • Oil delivery passage (master cylinder body) Blowout with compressed air. 3.lnspect: • Brake master cylinder kit Scratches/wear/damage ~ Replace as a set.

4.lnspect: • Brake master cylinder reservoir phragm Wear/damage ~ Replace. 5.lnspect: • Brake hose Cracks/wear/damage ~ Replace.

7 - 12

dia-

FRONT BRAKE

ICHAsldY61

6.Measure: • Brake pads (thickness) ® Out of specification ~ Replace .

.--t======::il~®

NOTE: • When pad replacement is required, also replace the pad spring and shims. • Replace the pads as a set if either is found to be worn to the wear limit ®.

Wear limit ®: 1.0 mm (0.04 in)

7.lnspect: • Brake disc Galling/damage

Replace.

8.Measure: • Brake disc deflection Out of specification ~ Inspect wheel runout. If wheel runout is in good condition, replace the brake disc(s). Maximum deflection: 0.15 mm (0.006 in) • Brake disc thickness ® Out of specification ~ Replace. Minimum thickness: 3.0 mm (0.12 in)

CD Dial 7 - 13

gauge

FRONT BRAKE

ICHASI fl::i61

NOTE: Tighten the bolts (brake disc) in stage using a crisscross pattern. Bolt (brake disc): 30 Nm (3.0 m • kg, 22 ft· Ib)

CALIPER ASSEMBLY

A WARNING • All internal parts should be cleaned in new brake fluid only. • Internal parts should be lubricated with brake fluid when installed. ~

Recommended brake fluid: DOT 4

• Replace the piston seals whenever a caliper is disassembled. 1.lnstall: • Piston seals • Piston CV

A WARNING Always use new piston seals.

2.lnstall: • Caliper bracket CD • Caliper body CV

NOTE: Apply the lithium soap base grease onto the caliper guide shaft and retaining bolt.

7 - 14

FRONT BRAKE 3.lnstall: • Brake caliper CD (temporarily) • Copper washers • Brake hose @ • Union bolt @

ICHASI ~ I

Union bolt: 27 Nm (2.7 m • kg, 19 ft ·Ib)

::::::::IIWlfJIN:;:::::: ________ When installing the brake hose on the caliper, make sure that the brake pipe touches the projection ® on the brake caliper.

A WARNING • Proper hose routing is essential to insure safe machine operation. Refer to "CABLE ROUTING" in CHAPTER 2. • Always use new copper washers.

4.Remove: • Brake caliper 5.1nstall: • Pad spring • Brake pads (with pad shim) • Retaining bolts • Front brake caliper Refer to "BRAKE PAD REPLACEMENT". Retaining bolt (caliper bracket): 28 Nm (2.8 m • kg, 20 ft· Ib) Retaining bolt: 18 Nm (1.8 m • kg, 13 ft· Ib) Bolt (front brake caliper): 30 Nm (3.0 m • kg, 22 ft • Ib)

7 - 15

_________________________F_RO_N_T_B_R_A_K__ E

ICHASI~I

6.Fill: • Reservoir tank Recommended brake fluid: DOT4

NOTE: If DOT 4 is not available, 3 can be used.

::::::::§~g;]J:gm:i::)):::)

_________

Brake fluid may erode painted surfaces or plastic parts. Always clean up spilled fluid immediately.

A WARNING • Use only the designated quality brake fluid: otherwise, the rubber seals may deteriorate, causing leakage and poor brake performance. • Refill with the same type of brake fluid: mixing fluids may result in a harmful chemical reaction and lead to poor performance. • Be careful that water does not enter the master cylinder when refilling. Water will significantly lower the boiling point of the fluid and may result in vapor lock.

7.Air bleed: • Brake system Refer to "AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)" in CHAPTER 3.

8.lnspect: • Brake fluid level Fluid level is under "LOWER" level line 4 Replenish. Refer to "FRONT BRAKE FLUID LEVEL INSPECTION" in CHAPTER 3.

® "LOWER"

7 - 16

level line

FRONT BRAKE

ICHAsldY61

MASTER CYLINDER ASSEMBLY

A WARNING • All internal parts should be cleaned in new brake fluid only. • Internal parts should be lubricated with brake fluid when installed. ~

Recommended brake fluid: DOT4

• Replace the piston seals and dust seals whenever a brake master cylinder is disassembled.

1.lnstall: • Brake master cylinder kit CD • Circlip ® • Dust boot @

2.lnstall: • Brake master cylinder CD

j ljl::l!ID.m'III,:;:·::j!: - - - - - - - • Install the brake master cylinder holder with the "UP" mark facing upward. • Align the end of the brake master cylinder holder with the punch mark ® in the handlebar. • Tighten first the upper bolt, then the lower bolt. Bolt (brake master cylinder holder): 7 Nm (0.7 m - kg, 5.1 ft -Ib)

7 - 17

FRONT BRAKE

ICHASI6S'61

3.lnstall: • Copper washers • Brake hose • Union bolt Union bolt: 27 Nm (2.7 m • kg, 19 ft· Ib) NOTE: • Tighten the union bolt while holding the brake hose as shown. • Check that the brake hose does not touch other parts (throttle cable, wire harness, leads, etc.) by turning the handlebar left and right, and correct if necessary.

A WARNING • Proper hose routing is essential to insure safe machine operation. Refer to "CABLE ROUTING" in CHAPTER 2. • Always use new copper washers. 4.lnstall: • Brake lever

5.Fill: • Brake master cylinder reservoir Recommended brake fluid: DOT4 NOTE: If DOT 4 is not available, 3 can be used. ::::::::§~lJimJjt::::::

_________

Brake fluid may erode painted surfaces or plastic parts. Always clean up spilled fluid immediately.

A WARNING • Use only the designated quality brake fluid: otherwise, the rubber seals may deteriorate, causing leakage and poor brake performance. 7 - 18

_________________________F_RO_N_T_B_R_A_K_E

ICHASI~I

• Refill with the same type of brake fluid: mixing fluids may result in a harmful chemical reaction and lead to poor performance. • Be careful that water does not enter the master cylinder when refilling. Water will significantly lower the boiling point of the fluid and may result in vapor lock.

6.Air bleed: • Brake system Refer to "AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)" in CHAPTER 3.

7.lnspect: • Brake fluid level Fluid level is under "LOWER" level line ~ Replenish. Refer to "FRONT BRAKE FLUID LEVEL INSPECTION" in CHAPTER 3. @ "LOWER" level line

7 - 19

_________________________R_EA_R_B_R_A_K_ElcHASI~1 REAR BRAKE CD Dust seal ® @ @

® ® (J)

® ® @

Brake drum cover Rear brake drum a-ring Plain washer Brake shoe spring Brake shoe Dust seal Brake camshaft a-ring

® Brake shoe plate @ Adjuster @Pin @ Spring @ Wear indicator plate @) Brake camshaft lever @ Brake rod @l Brake pedal @) Brake cable

BRAKE LINING WEAR LIMIT: 2 mm (0.08 in)

BRAKE DRUM WEAR LIMIT: 161 mm (6.34 in)

APPLY SEALANT (QUICK GASKET)® OR YAMAHA BOND NO. 1215®.

28 Nm (2.8 m • kg, 20 ft • Ib)

[g tl..-~----IJ..LJrx.

S Nm (O.S m • kg, 6.5 ft • Ib)

/' ~

7 - 20

__________________________R_EA_R_B_R_A_K_E

ICHASI~I

REMOVAL 1.Place the machine on a level surface. 2.Block the front wheels and elevate the rear wheels by placing a suitable stand under the frame. 3.Remove: • Rear wheel (right) • Rear wheel hub (right) Refer to "FRONT AND REAR WHEELS". 4.Remove: • Brake drum cover CD

5.Remove: • Brake drum

6.Remove: • Adjusters (brake lever and pedal) • Pins ® • Springs @ 7.Disconnect: • Brake cable (brake lever) @ • Brake rod (brake pedal) ® • Breather hose (rear brake) ®

8.Remove: • Brake shoes CD • Bearing retainer ® • Brake shoe plate @

7 - 21

R_EA_R_B_R_A_K_E ~A~~I

_____________

9.Remove: • Spring CD • Brake camshaft lever ® • Wear indicator plate @ • Brake camshaft @ • Plain washer

INSPECTION 1.lnspect: • Brake drum CD Cracks/damage ~ Replace. • Splines (wheel drum) ® Wear/damage ~ Replace.

2.lnspect: • Brake shoe plate CD • Pivot pin ® • Brake camshaft @ Bends/cracks/damage ~ Replace. • Dust seal @ Wear/damage ~ Replace.

3.lnspect: • Brake shoes CD • Brake shoe springs ® Cracks/damage ~ Replace as a set. NOTE: When replacing the brake shoes, replace the brake shoe springs at the same time.

4.lnspect: • Brake shoe lining surface Glazed areas ~ Remove. Use coarse sandpaper. NOTE: After using the sandpaper, wipe off the polished particles with a cloth. 1227lJf~)3

7 - 22

_________________________R_EA_R_B_R_A_KE_lcHAsl~1 5.Measure: • Brake shoe lining thickness ® Out of specification ~ Replace.

Measuring points

NOTE: Replace the brake shoes as a set if either is found to be worn to the wear limit. Brake lining thickness: 4.0 mm (0.16 in) <Wear limit>: 2.0 mm (0.08 in)

6.Measure: • Brake drum inside diameter ® Out of specification ~ Replace. Front brake drum inside diameter: 160 mm (6.30 in) <Wear limit>: 161 mm (6.34 in)

7.lnspect: • Brake drum inner surface Oil/scratches ~ Remove. Oil

Use a rag soaked in lacquer thinner or solvent.

Scratches

Use an emery cloth (lightly and evenly polishing).

INSTALLATION Reverse the "Removal" procedure. Note the following points. 1.Lubricate: • Brake camshaft CD • Pivot pin ®

I-I 7 - 23

Lithium-soap base grease

__________________________R_EA_R_B_R_A_K__ E

ICHASI~I

::::::::§III,IN}::::::: ________ During installation, lightly grease the brake camshaft and the pivot pin. Wipe off the excess grease.

2.lnstall: • Wear indicator pointer CD

NOTE: When installing the wear indicator pointer, fit the projection into a brake camshaft groove and align the pointer with the left end of the wear indicator scale ®.

3.lnstall: • Brake camshaft lever CD • Spring ® Bolt (camshaft lever): 9 Nm (0.9 m • kg, 6.5 ft • Ib)

NOTE: When installing the brake camshaft lever, align the punch mark @ on the brake camshaft lever and brake camshaft. 4.Apply: • Sealant@ (onto the mating surfaces of swingarm) Sealant (Quick Gasket)®: PIN. ACC-11001-05-01 Yamaha bond No. 1215®: PIN. 90890-85505

5.lnstall: • Brake shoe plate CD • Bearing retainer ® • Brake shoes @ Bolt (brake shoe plate): 28 Nm (2.8 m • kg, 20 ft· Ib)

7 - 24

_________________________R_EA_R_B_R_A_K_E cHAsl~1 6.Check: • Brake camshaft operation Unsmooth operation ~ Repair. 7.Lubricate: • Dust seal CD

I_I

Lithium-soap base grease

8.Connect: • Breather hose (rear brake) CD • Brake rod (brake lever) ® • Brake cable (brake pedal) @ 9.lnstall: • Springs @ • Pins ® • Adjusters (brake lever and pedal) ® • Brake drum • Brake drum cover 10.lnstall: • Rear wheel hub (right) • Rear wheel (right) Refer to "FRONT AND REAR WHEELS". Axle nut: 150 Nm (15 m • kg, 110 ft ·Ib) Nut (rear wheel): 55 Nm (5.5 m • kg, 40 ft • Ib)

11.Adjust: • Rear brake pedal free play • Rear brake lever free play Refer to "REAR BRAKE LEVER AND PEDAL ADJUSTMENT" in CHAPTER 3.

7 - 25

STEERING SYSTEM

STEERING SYSTEM CD Steering shaft bushing ® Oil @ @

® ® (J)

® ® @)

seal Steering shaft Oil seal Bearing Spacer Circlip Ball joint Rubber boot Steering knuckle

ICHASI6:Y61

@ a-ring @Washer @ Tie-rod end ® Tie-rod @ Oil seal @ Bearing retainer @ Bearing @Oil seal (ill) Pitman arm

23 Nm (2.3 m • kg, 17 ft • Ib)

! /0 E:J I

23 Nm (2.3 m • kg, 17 ft· Ib)

TOE-IN: 5 - 15 mm (0.29 - 0.59 in)

(Dm!J4 ........... ~

40 Nm (4.0 m • kg, 29 ft • Ib)

91 Nm (9.1 m • kg, 66 ft • Ib)

~@ o

---.j

30 Nm (3.0 m • kg, 22 ft • Ib)

40 Nm (4.0 m • kg, 29 ft • Ib)

30 Nm (3.0 m • kg, 22 ft • Ib)

7 - 26

STEERING SYSTEM

jCHASj ~ I

REMOVAL 1.Remove: • Front carrier • Front bumper • Front fender Refer to "SEAT, CARRIERS, FENDERS AND FUEL TANK" in CHAPTER 3.

2.Remove: • Throttle lever assembly CD • Master cylinder assembly @

3.Remove: • Bands CD • Rear brake lever holder @ • Handlebar switch @

4.Remove: • Handlebar cover CD 5.Disconnect: • Main switch coupler @ • Indicator light coupler @ • Oil temperature warning light connectors @

6.Remove: • Handlebar holder (upper) • Handlebar holder (lower) • Handlebar CD

--1~>::=====*=~ ~<...s::::::.~~~.r-r-r"'r~ 7 - 27

STEERING SYSTEM 7.Remove: • Reverse control knob

8.Remove: • Cotter pins CD • Nuts (tie-rod end) • Tie-rod ends • Steering shaft

jCHASjflY6j CD

9.Straighten: • Lock washer tabs 10.Remove: • Lock washer CD • Cable holder ® • Steering shaft bushings @ • Collars @ • Oil seals ®

11.Remove: • • • •

Clip CD Nut (steering shaft) Plain washer @ Pitman arm @

12.Remove: • Oil seals • Bearing retainer Use a damper rod holder. • Bearing Damper rod holder:

PIN. YM·01327, 90890·01327

7 - 28

STEERING SYSTEM

ICHAsldY61

13.Remove: • Front wheels • Front wheel hubs Refer to "FRONT AND REAR WHEELS".

14.Remove: • Brake disc guard CD • Brake hose holder ®

15.Remove: • Cotter pin CD • Nuts (tie-rod end) • Tie-rod @

16.Remove: • Cotter pins CD • Nuts (steering knuckle)

17.Remove: • Steering knuckle

NOTE: Use a general puller to separate the ball joint ® and steering knuckle CD or lower arm@. • Washer • a-ring 7 - 29

I lflY6l

STEERING SYSTEM CHAS INSPECTION 1.lnspect: • Steering shaft Bends ~ Replace.

A WARNING Do not attempt to straighten a bent shaft; this may dangerously weaken the shaft.

2.lnspect: • Oil seals G) • Steering shaft bushings (g) Wear/damage ~ Replace.

3.lnspect: • Handlebar Bends/cracks/damage

Replace.

A WARNING Do not attempt to straighten a bent handlebar as this may dangerously weaken the handlebar.

4.Check: • Tie-rod free play and movement Free play ~ Replace the tie-rod end. Turns roughly ~ Replace the tie-rod end.

5.lnspect: • Steering knuckle Damage/pitting ~ Replace.

7 - 30

STEERING SYSTEM

ICHAslflY6l

6.1nspect: • Ball joint Damage/pitting ~ Replace the ball joint. Free play ~ Replace the ball joint. Turns roughly ~ Replace the ball joint.

********************************* Ball joint replacement steps: .Clean the outside of the steering knuckle . • Remove the steering knuckle oil seal. .Remove the circlip CD and rubber boot ®. Use the ball joint remover and installer set.

Ball joint remover/installer set: PIN. YM-01474/90890-01474 Ball joint removerlinstaller attachment set: PIN. YM-01477

Body

YM-01474 90890-01474

Long bolt

YM-01474 90890-01474

Short bolt

YM-01477

Remover washer

YM-01477

(j)

Remover spacer

YM-01477

Installer attachment

YM-01477

® ®

Installer spacer

YM-01477

Installer guide

YM-01477

.Install the body @, short bolt @, remover washer ® and remover spacer (j) onto ball joint.

NOTE: • Remover washer ® must be aligned with the projection on the head of the ball joint. • Surface @ of the remover spacer (j) must be aligned with surface C@ of the steering knuckle.

• Hold the body Q) in place while turning in the short bolt @ to remove the ball joint ® from the steering knuckle . • Remove the ball joint remover/installer.

7 - 31

STEERING SYSTEM

ICHAslflY6l

.Install the long bolt @, installer spacer and installer guide ® onto the body @ .

• Attach the assembled ball joint remover/ installer, new ball joint ® and installer attachment ® to the steering knuckle @.

NOTE: Do not tap or damage the top of the ball joi nt. • Hold the body @ in place while turning in the long bolt @ to install the new ball joint ® into the steering knuckle @. • Remove the ball joint remover/installer . • Apply lithium-soap base grease to the new ball joint ® . • Install a new rubber boot and new circlip.

NOTE: Always use a new ball joint set . • Install a steering knuckle oil seal.

********************************* 7.lnspect: • Front wheel bearings Bearings allow play in the wheel hubs or the wheel turns roughly -7 Replace. • Oil seals Damage -7 Replace.

7 - 32

STEERING SYSTEM

ICHAsl6Y61

********************************* Front wheel bearing replacement steps: .Clean the outside of the steering knuckle. • Remove the oil seals CD. • Drive out the bearings (2).

A WARNING Eye protection is recommended using striking tools.

when

• Remove the spacer @ . • Apply lithium base grease to the bearings and oil seals . • Install the spacer to the steering knuckle . • Install the new bearings. NOTE: Install the outside bearing first.

::::::::!li]~lm~:::::::

_________

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.

*********************************

INSTALLATION Reverse the "REMOVAL" procedure. Note the following points. 1.Lubricate: • Bearing • Oil seal • Steering shaft bushing

I_I

Lithium-soap base grease

2.lnstall: • Washer • O-ring • Steering knuckle

Nut (steering knuckle - front arm): 25 Nm (2.5 m • kg, 18 ft· Ib)

A WARNING Always use a new cotter pin. 7 - 33

STEERING SYSTEM

ICHASIdY61

3.lnstall: • Tie-rods (left and right) NOTE: The tie-rod which must be installed on the out side has grooves CD. Nut (tie-rod end): 30 Nm (3.0 m • kg, 22 ft • Ib)

A WARNING Always use a new cotter pin.

4.lnstall: • Front wheel hubs • Front wheels Refer to "FRONT AND REAR WHEELS".

5.1nstall: • Bearing • Bearing retainer Use the damper rod holder. • Oil seal

Jfb

Damper rod holder: PIN. YM-01327, 90890-01327

Bearing retainer: 40 Nm (4.0 m • kg, 29 ft • Ib)

6.lnstall: • Steering shaft • Pitman arm • Tie-rod ends Nut (pitman arm): 91 Nm (9.1 m • kg, 66 ft· Ib) Nut (tie-rod end): 30 Nm (3.0 m • kg, 22 ft • Ib)

A WARNING Make sure the brake hoses and pipes are properly routed, and are not damaged or twisted.

7 - 34

STEERING SYSTEM

ICHASI6S0 I

7.lnstall: • Steering shaft bushings • Cable guide Bolt (steering shaft bushing): 23 Nm (2.3 m • kg, 17 ft • Ib)

A WARNING Always use a new lock washer.

a.Bend the lock washer tab along a flat side of the bolt. NOTE: Pass the cables and hoses through the cable guide. Refer to "CABLE ROUTING" in CHAPTER 2.

9.lnstall: • Handlebar • Handlebar holders (upper and lower) NOTE: • Insert the projection CD of the handlebar holder (lower) into the steering shaft hole. • The upper handlebar holder should be installed with the punched mark @ forward @.

::::::::§I)Bml:;::::::: ________ First tighten the bolts @ on the front side of the handlebar holder, and then tighten the bolts ® on the rear side. Bolt (handlebar holder): 23 Nm (2.3 m • kg, 17 ft • Ib)

10.lnstall: • Handlebar switch • Lever holder ® \

NOTE: Install the lever holder as shown.

-c--

® 80 mm

7 - 35

(3.1 in)

STEERING SYSTEM

I lflY6l CHAS

11.lnstall: • Throttle lever assembly • Brake master cylinder assembly

NOTE: • Align the end of brake master cylinder holder with the punch mark ® in the handlebar. • The "UP" mark on the master cylinder bracket should face up. 12.lnstall: • Front fender • Front bumper • Front carrier • Seat Refer to "SEAT, CARRIERS, FENDERS AND FUEL TANK" in CHAPTER 3. 13.Adjust: • Toe-in Refer to "TOE-IN ADJUSTMENT" in CHAPTER 3.

7 - 36

FRONT SHOCK ABSORBER AND FRONT ARM

ICHASl6s61

FRONT SHOCK ABSORBER AND FRONT ARM CD Bushing ® Front shock absorber @ Upper arm @ Circlip ® Ball joint ® Rubber boot (J) Lower arm ® Protector

I 45 Nm (4.5 m • kg, 32 ft • Ib)

FRONT SHOCK ABSORBER: STANDARD POSITION: B

7 - 37

STIFFEST POSITION: E

FRONT SHOCK ABSORBER AND FRONT ARM

ICHASlfls6l

REMOVAL 1.Remove: • Front wheels • Front wheel hubs Refer to "FRONT AND REAR WHEELS". • Steering knuckle Refer to "STEERING SYSTEM".

2.Remove: • Front shock absorber CD

3.Unhook: • Brake hose CD (from clamp)

4.Check: • Front arm free play

********************************* Checking steps: .Check the front arm side play ~ by moving it from side to side. If side play is noticeable, check the bushings. • Check the front arm vertical movement rn:J by moving it up and down. If the vertical movement is tight, binding or rough, check the bushings.

*********************************

7 - 38

FRONT SHOCK ABSORBER AND FRONT ARM

ICHASI ~ I

5.Remove: • Differential gear case guard

6.Remove: • Protector CD • Front upper arm ® • Front lower arm @

INSPECTION 1.lnspect: • Shock absorber rod Bends/damage ~ Replace the shock absorber assembly. • Shock absorber assembly Oil leaks ~ Replace the shock absorber assembly. • Spring Fatigue ~ Replace the shock absorber assembly. Move the spring up and down. 2.lnspect: • Front arm CD Bends/damage ~ Replace. • Bushings ® Wear/damage ~ Replace.

3.lnspect: • Ball joint Damage/pitting ~ Replace the ball joint. Free play ~ Replace the ball joint. Turns roughly ~ Replace the ball joint.

7 - 39

FRONT SHOCK ABSORBER AND FRONT ARM

ICHAslflY6l

********************************* Ball joint replacement steps: .Clean the outside of the front lower arm . • Remove the circlip CD and rubber boot ®. Use the ball joint remover and installer set.

Jfb

Ball joint remover/installer set: PIN. YM-01474/90890-01474

Ball joint remover/installer attachment set: PIN. YM-01477

Body

YM-01474 90890-01474

Long bolt

YM-01474 90890-01474

® ®

Remover washer

YM-01477

Remover spacer

YM-01477

(J)

Installer attachment

YM-01477

® ®

Installer spacer

YM-01477

Installer guide

YM-01477

• Install the body @, long bolt @, remover washer ® and remover spacer ® onto ball joint.

NOTE: Remover washer ® must be aligned with the projection on the head of the ball joint . • Hold the body @ in place while turning in the long bolt @ to remove the ball joint @) from the front lower arm . • Remove the ball joint remover/installer.

.Install the long bolt @, installer spacer and installer guide ® onto the body @.

7 - 40

FRONT SHOCK ABSORBER AND FRONT ARM

ICHAslflY6l

.Attach the assembled ball joint remover/ installer, new ball joint @ and installer attachment (J) to the front lower arm @.

NOTE: Do not tap or damage the top of the ball joint. • Hold the body @ in place while turning in the long bolt @ to install the new ball joint @ into the front lower arm @ . • Remove the ball joint remover/installer . • Apply lithium-soap base grease to the new ball joint @ . • Install a new rubber boot and new circlip.

NOTE: Always use a new ball joint set.

*********************************

INSTALLATION Reverse the "REMOVAL" procedure. Note the following points. 1.Lubricate: • Pivot bolts (front arm)

I_I

Lithium-soap base grease

2.lnstall: • Front upper arm CD • Front lower arm ® • Bolts • Nuts • Protector @

NOTE: • Be sure to position the bolts (upper and lower) so that the bolt head faces outward. • Temporarily tighten the nuts (front arm). 3.lnstall: • Front shock absorber CD

'\,;2/

e-"<Q;,

Nut (front shock absorber): 45 Nm (4.5 m • kg, 32 ft • Ib)

4.lnstall: • Steering knuckle Refer to "STEERING SYSTEM". 7 - 41

FRONT SHOCK ABSORBER AND FRONT ARM

ICHASl6s61

5.Tighten: • Nuts (front arm)

NOTE: Before tightening the nuts, adjust the length ® to 340 mm (13.4 in). Nut (front arm): 45 Nm (4.5 m • kg, 32 ft • Ib)

6.lnstall: • Front wheel hubs • Front wheels Refer to "FRONT AND REAR WHEELS". 7.Adjust: • Toe-in Refer to "TOE-IN CHAPTER 3.

7 - 42

ADJUSTMENT"

REAR SHOCK ABSORBER AND SWINGARM

ICHASIdY61

REAR SHOCK ABSORBER AND SWINGARM CD Rear shock absorber @ Spacer collar @ Locknut @ Pivot shaft ® O-ring ® Collar (J) Oil seal ® Taper roller bearing ® Swingarm @ Rubber boot

REAR SHOCK ABSORBER:

STANDARD POSITION: B

STIFFEST POSITION: E

SWINGARM FREE PLAY LIMIT: SIDE: 1 mm (0.04 in)

~ A

BCD E

130 Nm (13.0 m • kg, 94 ft· Ib)

17 Nm (1.7 m' kg, 12 ft 'Ib)

6 Nm (0.6 m • kg, 4.3 ft· Ib)

7 - 43

REAR SHOCK ABSORBER AND SWINGARM

ICHASIdY61

REMOVAL 1.Remove: • Rear wheels • Rear wheel hubs • Rear brake drum Refer to "FRONT AND REAR WHEELS". 2.Remove: • Brake shoe plate Refer to "REAR BRAKE". 3.Remove: • Rear axle (with dust seal) • Final gear case assembly Refer to "FINAL DRIVE GEAR AND DRIVE SHAFT" in CHAPTER 6. 4.Remove: • Muffler CD

5.Remove: • Cotter pin CD • Washer (g) • Shaft (shock absorber - lower) @ • Spacer collars

NOTE: When removing the lower shaft @, hold the swingarm so that it does not drop downwards when the shaft is removed. 6.Remove: • Bolt (rear shock absorber - upper) • Rear shock absorber CD

7.Pull the breather hoses CD and parking brake cable (g) out of their guides.

7 - 44

REAR SHOCK ABSORBER AND SWINGARM

ICHASI6Y61

8.Remove: • Covers (pivot shaft) 9.lnspect: • Swingarm free play

********************************* Inspection steps: .Check the tightening torque of the pivot shafts (swingarm) and locknuts (pivot shaft). Pivot shaft (left): 130 Nm (13.0 m • kg, 94 ft· Ib) Pivot shaft (right): 6 Nm (0.6 m • kg, 4.3 ft • Ib) Locknut (pivot shaft-right): 130 Nm (13.0 m • kg, 94 ft· Ib) .Check the swingarm side play @ by moving it from side to side. If side play is noticeable, check the spacer collar, bearing and frame pivot . • Check the swingarm vertical movement [ID by moving it up and down. If vertical movement is tight, binding or rough, check the spacer collar, bearing and frame pivot.

*********************************

10.Remove: • Clamp (rubber boot)

11.Remove: • Pivot shaft (left) CD • Locknut (pivot shaft-right) • Pivot shaft (right) @

7 - 45

REAR SHOCK ABSORBER AND SWINGARM 12.Remove: • Rear axle housing • Swingarm ®

ICHASI6Y61

13.Remove: • Collars CD • Oil seals ® • Bearings (swingarm) @ • a-rings @

INSPECTION 1.lnspect: • Shock absorber Oil leaks ~ Replace the shock absorber assembly. • Shock absorber rod Bends/damage ~ Replace the shock absorber assembly. • Spring Fatigue ~ Replace the shock absorber assembly. Move the spring up and down.

2.lnspect: • Swingarm CD • Rear axle housing ® Bends/cracks/damage

7 - 46

Replace.

REAR SHOCK ABSORBER AND SWINGARM

ICHAsl6Y61

3.lnspect: • Pivot shaft CD • Spacer collar ® Wear/damage ~ Replace.

4.lnspect: • Bearings (swingarm) CD Bearings allow play in the swingarm or the bearings turn roughly ~ Replace. • Oil seals ® • Collars @ • O-ring @ Wear/damage ~ Replace.

5.lnspect: • Rubber boot CD Damage ~ Replace.

INSTALLATION Reverse the "REMOVAL" procedures. Note the following points. 1.Lubricate: • Bearings • Oil seals • Collars • O-ring • Pivot shafts

I_I

7 - 47

Lithium-soap base grease

REAR SHOCK ABSORBER AND SWINGARM 2.Apply: • Adhesive (for rubber) (to the swingarm end 3.lnstall: • Rubber boot ®

ICHASIdY61 CD)

NOTE: Be sure to position the rubber boot so that the tang @ faces towards the left.

4.lnstall: • Swingarm • Pivot shaft (left) CD • Pivot shaft (right) ® • Locknut (pivot shaft-right) @ • Covers @

NOTE: Finger tighten the pivot shafts and locknut; do not torque them at this point. 5.Tighten: • Pivot shafts

********************************* Tightening steps: • Tighten the pivot shaft (left) to specification.

~ ""

Pivot shaft (left): 130 Nm (13.0 m • kg, 94 ft • Ib)

• Tighten the pivot shaft (right) until it contacts the collar.

~ ""

Pivot shaft (right): 6 Nm (0.6 m • kg, 4.3 ft • Ib)

• Tighten the locknut (pivot shaft-right) to specification.

~ If: Locknut (pivot shaft-right): ~~ 130 Nm (13.0 m • kg, 94 ft· Ib) *********************************

1- 48

REAR SHOCK ABSORBER AND SWINGARM

ICHAslflY6l

6.lnstall: • 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 6 . • Apply sealant (Quick Gasket®) to the mating surfaces of the swingarm and the final gear case . • Temporarily install the rear axle housing CD and final gear case assembly ® on the swingarm. The bolts and nuts @ - @ should be temporarily tightened . • Install the rear axle (with dust seal) ® from the left side of the machine. Refer to "REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT" in CHAPTER 6 . • Tighten the bolts and nuts @ - @ in the specified order. @ Nut (x4) @ Bolt (x4)

Bolt/nut (x4)

Nut@: 48 Nm (4.8 m • kg, 35 ft • Ib) lOCTITE® Bolt@: 55 Nm (5.5 m • kg, 40 ft • Ib) lOCTITE® Nut@: 105 Nm (10.5 m • kg, 75 ft· Ib)

*********************************

7.Lubricate: • Bushings (shock absorber-upper and lower)

I_I 7 - 49

Lithium-soap base grease

REAR SHOCK ABSORBER AND SWINGARM

ICHASI cf:lo I

8.Pass the breather hoses and parking brake cable through the guides. Refer to "CABLE ROUTING" in CHAPTER

9.lnstall: • Shock absorber Nut (shock absorber - upper): 50 Nm (5.0 m • kg, 36 ft • Ib)

NOTE: Lift up the swingarm to install the rear shock absorber. 10.lnstall: • Brake shoe plate Refer to "REAR BRAKE". 11.lnstall: • Rear brake drum • Rear wheel hubs • Rear wheels Refer to "FRONT WHEEL".

7 - 50

IELEC I0 I

elECTRICAL COMPONENTS

ELECTRICAL ELECTRICAL COMPONENTS CD Reverse indicator ® Main switch light ® Neutral indicator light @ Oil temperature warning light @ Main switch ® Rear brake switch ® Handlebar switch (j) Diode

@) @ @ @ @ @

Starter relay Rectifier/regulator COl unit Taillight Battery Fan motor control unit Starter circuit cutoff relay

@ Fan motor relay @ Fuse box @ Thermo unit @) Circuit breaker (fan motor) ® Fan @ Headlight @ Ignition coil @ Auxiliary DC jack

SPECIFICATIONS IGNITION COIL: PRIMARY

RESISTANCE

SECONDARY PICKUP COIL

0.18 - 0.28 Q 6.32 - 9.48 kQ 459 - 561 Q

STATOR COIL

0.70 - 0.86 Q

BATTERY:

CAPACITY: 12 V, 18 AH

8-1

CHECKING OF CONNECTIONS

I I0 ELEC

CHECKING OF CONNECTIONS Dealing with stains, rust, moisture, etc. on the connector. 1.Disconnect: • Connector 2.Dry each terminal with an air blower.

3.Connect and disconnect the connector two or three times. 4.Pull the lead to check that it will not come off. 5.lf the terminal comes off bend up the pin CD and reinsert the terminal into the connector.

6.Connect: • Connector

NOTE: The two connectors "click" together. 7.Check for continuity with a tester.

NOTE: • If there is no continuity clean the terminals. • Be sure to perform the steps 1 to 7 listed above when checking the wire harness. • For a field remedy, use a contact revitalizer available on the market. • Use the tester on the connector as shown.

8-2

QG')

:xJ

-l-

-2 » C)en

~-<

s:~

G')

:3 o 2

en -< en ~

CD CDI magneto @ Main switch @ Battery ® Main fuse ® CDI unit @) Ignition coil ® Spark plug ® Engine stop switch @ Ignition fuse

m m o r-

IGNITION SYSTEM

IELEC I0 I

TROUBLESHOOTING IF THE IGNITION SYSTEM SHOULD BECOME INOPERATIVE (NO SPARK OR INTERMITTENT SPARK).

Procedure Check: 1.Fuse (main and ignition) 2.Battery 3.Spark plug 4.lgnition spark gap 5.Spark plug cap resistance 6.lgnition coil resistance

7.Engine stop switch 8.Main switch 9.Pickup coil resistance 10.Charging/rotor rotation direction detection coil resistance 11.Wiring connection (Entire ignition system)

NOTE: • Remove the following parts before troubleshooting. 1)Seat 2)Front carrier 3)Front fender 4)Rear carrier 5)Rear fender • Use the following special tools for troubleshooting.

Dynamic spark tester: PIN. YM-34487 Ignition checker: PIN. 90890-06754 Pocket tester: PIN. YU-03112, 90890-03112

1.Fuses (main and ignition)

NO CONTINUITY

• Remove the fuses. • Connect the pocket tester (Q x 1) to the fuses. • Check the fuses for continuity.

Replace the fuse(s).

CONTINUITY INCORRECT

2.Battery • Check the battery condition. Refer to "BATTERY INSPECTION" in CHAPTER 3.

• Clean the battery terminals . • Recharge or replace the battery.

CORRECT

3.Spark plug

Standard spark plug: DR8EA/NGK

• Check the spark plug condition. • Check the spark plug type. • Check the spark plug gap. Refer to "SPARK PLUG INSPECTION" in CHAPTER 3.

8-4

IGNITION SYSTEM

INCORRECT

Spark plug gap: 0.6 - 0.7 mm (0.024 - 0.028 in)

IELEC I0 I

CORRECT

Repair or replace the spark plug.

4.lgnition spark gap • Disconnect the spark plug cap from the spark plug. • Connect the dynamic spark tester CD as shown.

® Spark plug cap @ 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. MEETS SPECIFICATION

Minimum spark gap: 6.0 mm (0.24 in)

OUTOF SPECIFICATION OR NO SPARK

•

The ignition system is good.

5.Spark plug cap resistance • Remove the spark plug cap. • Connect the pocket tester (0 x 1k) to the spark plug cap.

18040101

OUT OF SPECIFICATION

• Check the spark plug cap for the specified resistance.

Spark plug cap resistance: 10 kO at 20°C (68 OF)

Replace the spark plug cap.

MEETS

'V SPECIFICATION

* 8-5

IGNITION SYSTEM

ELEC

Tester (+) lead ~ Orange lead terminal Tester (-) lead ~ Ignition coil base

6.lgnition coil resistance • Disconnect the ignition coil connector from the wire harness. • Connect the pocket tester (.0 x 1) to the ignition coil.

Tester (+) lead ~ Ignition coil base Tester (-) lead ~ Spark plug lead

• Check the primary coil for the specified resistance.

I Iell

Primary coil resistance: 0.18 - 0.28 n at 20°C (68 OF)

• Connect the pocket tester (.0 x 1k) to the ignition coil.

• Check the secondary coil for the specified resistance. OUT OF SPECIFICATION

Secondary coil resistance: 6.32 - 9.48 kQ at 20°C (68 OF)

BOTH MEET ~ SPECIFICATION

Replace the ignition coil.

7.Engine stop switch • Disconnect the handlebar switch (left) coupler from the wire harness. • Check for continuity as follows: Black/White CD - Black ®

INCORRECT

Replace the handlebar switch (left).

CORRECT 8-6

IGNITION SYSTEM

IELEC I0 I

8.Main switch • Disconnect the main switch coupler from the wire harness. • Check for continuity as follows: Black/White CD - Black ®

INCORRECT 2

B B/W

IReplace the main switch.

CORRECT

9.Pickup coil resistance • Disconnect the COl magneto coupler from the wire harness. • Connect the pocket tester (0. x 100) to the COl magneto terminal.

• Check the pickup coil for the specified resistance.

-V

W/L W/R

OUT OF SPECIFICATION

Pickup coil resistance: 459 - 561 0. at 20·e (68 ·F) (White/Green - White/Red)

WIG

Tester (+) lead ~ White/Green terminal CD Tester (-) lead ~ White/Red terminal ®

Replace the pickup coil/stator assembly.

MEETS SPECIFICATION

8-7

IGNITION SYSTEM

IELEC I0 I

~ 10.Charging/rotor rotation direction detection coil resistance • Disconnect the COl magneto coupler from the wire harness. • Connect the pocket tester (Q x 100) to the COl magneto terminal. Tester (+) lead ~ Red terminal ill Tester (-) lead ~ White/Blue terminal

W/L W/R

• Check the charging/rotor rotation direction detection coil for the specified resistance.

OUT OF SPECIFICATION

:ar

Charging/rotor rotation direction detection coil resistance: 0.115 Q at 20°C (68 OF) (Red - White/Blue)

Replace the pickup coil/stator assembly.

MEET SPECIFICATION POOR CONNECTION

11.Wiring connection • Check the connections on the entire ignition system. Refer to "CIRCUIT DIAGRAM".

WIG

Properly connect the ignition system.

CORRECT

Replace the COl unit.

8-8

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-I

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G) @ Main switch @ Battery ® Main fuse ® Starter relay (j) Starter motor ® Starting circuit cut-off relay ® COl unit @ Rear brake switch @ Gear position switch @ Engine stop switch @ Start switch @ Ignition fuse

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ELECTRICAL STARTING SYSTEM

STARTING CIRCUIT OPERATION The starting circuit on this model consists of the starter motor, starter relay, starting circuit cut-off relay, rear brake switch, COl unit and gear position switch. If the main switch is on and the engine stop switch is in the RUN position the starter motor can be operated only if:

® L.:::==:::;.,

IELEC I0 I

r----

L/W - - - . . . . . ,

• The transmission is in neutral (the gear position switch is NEUTRAL). or • You pull in the rear brake lever (the rear brake switch is ON).

LIB

J,~ I

NOTE: The starter motor can be operated irrespective of the engine stop switch ("OFF" or "RUN"). However, the engine can be started only if the engine stop switch is in the "RUN" position.

..L (j) .---+--..... R/W~Br/L ........

The starting circuit cut-off relay prevents the starter from operating when the transmission is in gear or the select lever is in reverse and the rear brake lever is free. In this instance, the starting circuit cut-off relay is off so that current cannot reach the starter motor.

[§J

L/W

B .L -

B/W

® GIY

1 1 ®1 ®1 --

Sbl,

R/W

CD Main fuse ® Battery @ Starter relay @ Starter motor ® Starting circuit cut-off relay ® Start switch (J) Ignition fuse ® CDI unit ® Engine stop switch @) Rear brake switch ® Gear position switch [AJ TO MAIN SWITCH ffil FROM MAIN SWITCH

Neutrall ® --

8 - 10

ELECTRICAL STARTING SYSTEM

IELEC I0 I

TROUBLESHOOTING

ITHE STARTER MOTOR DOES NOT OPERATE. Procedure Check: 1.Fuses (main and ignition) 2.Battery 3.Starter motor 4.Starting circuit cut-off relay 5.Starter relay 6.Main switch

7.Engine stop switch 8.Gear position switch 9.Rear brake switch 10.Start switch 11.Wiring connection (the entire electric starting system)

NOTE: • Remove the following parts before troubleshooting. 1)Seat 2)Rear carrier 3)Rear fender • Use the following special tool for troubleshooting.

Pocket tester: PIN. YU-03112, 90890-03112

1.Fuses (main and ignition) NO CONTINUITY

• Remove the fuses. • Connect the pocket tester (Q x 1) to the fuses. • Check the fuses for continuity.

IReplace the fuse(s).

CONTINUITY

2.Battery INCORRECT

• Check the battery condition. Refer to "BATTERY INSPECTION" in CHAPTER 3.

• Clean the battery terminals . • Recharge or replace the battery.

CORRECT

8 - 11

ELECTRICAL STARTING SYSTEM

3.Starter motor

IELEC Iell

WARNING

• 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 .

• Connect the battery positive terminal CD and starter motor cable ® using a jumper lead @ • Check the starter motor for operation.

.....---, t_________ ~

, I

DOES NOT TURN

Repair or replace the starter motor.

18210801

TURNS

4.Starting circuit cut-off relay • Disconnect the starting circuit cut-off relay coupler from the wire harness. • Connect the pocket tester (.0. x 1) and the battery (12 V) to the starting circuit cutoff relay coupler terminals. Battery (+) terminal

-7

Red/White terminal CD Battery (-) terminal -7 Yellow/Black terminal ® Tester (+) terminal -7 Red/White terminal @ Tester (-) terminal -7 Blue/White terminal @

NO CONTINUITY

• Check the starting circuit cut-off relay for continuity.

CONTINUITY

Replace the starting circuit cut-off relay.

8 - 12

ELECTRICAL STARTING SYSTEM

IELEC I0 I

5.Starter relay • Disconnect the starter relay coupler from the wire harness. • Connect the pocket tester (Q x 1) and the battery (12 V) to the relay unit coupler terminals.

Battery (+) terminal ~ Blue/White terminal Battery (-) terminal ~ Blue/Black terminal

CD NO CONTINUITY

Tester (+) lead ~ Red terminal @ Tester (-) lead ~ Black terminal @

Replace the starter relay.

• Check the starter relay for continuity.

CONTINUITY

6.Main switch • Disconnect the main switch from the wire harness. • Check for continuity as follows: Red CD - Brown CV Black/White @ - Black @

coupler

INCORRECT

Replace the main switch.

CORRECT

8 - 13

ELECTRICAL STARTING SYSTEM

I Iell ELEC

~ 7.Engine stop switch • Disconnect the handlebar switch (left) coupler from the wire harness. • Check for continuity as follows: Black/White CD - Black CV

INCORRECT

IReplace the handlebar switch (left). ~

CORRECT

8.Gear position switch • Disconnect the gear position switch coupler from the wire harness. • Check for continuity as follows: Brown CD - Frame ground c

INCORRECT Br

JIb~ ~

IReplace the gear position switch.

CORRECT

8 - 14

ELECTRICAL STARTING SYSTEM

IELEC I0 I

9.Rear brake switch • Disconnect the rear brake switch coupler from the wire harness. • Check for continuity as follows: Black CD ~ Black @

~ B

Free ON

INCORRECT

~ ~

IReplace the rear brake switch.

CORRECT

10.Start switch • Disconnect the handlebar switch (left) coupler from wire harness. • Check for continuity as follows: Red/White CD - Black @

INCORRECT

IReplace the handlebar switch (left). ~

CORRECT

11.Wiring connection POOR CONNECTION

• Check the connections on the entire starting system. Refer to "CIRCUIT DIAGRAM".

IProperly connect the starting system.

8 - 15

ELECTRICAL STARTING SYSTEM

IELEC I0 I

STARTER MOTOR

<D a-ring

® Bearing @ Oil seal @ Armature coil assembly ® Yoke assembly ® Brush set

10 Nm (1.0 m

kg, 7.2 ft olb)

8 - 16

ARMATURE COIL: 0.011 - 0.013 Q

BRUSH WEAR LIMIT: 8.5 mm (0.33 in)

COMMUTATOR WEAR LIMIT: 27 mm (1.06 in)

MICA UNDERCUT: 0.6 mm (0.02 in)

ELECTRICAL STARTING SYSTEM

IELEC I0

Removal 1.Disconnect: • Negative battery lead • Starter motor lead CD

:::i:i::i,f\WmigN;:i:ii:: - - - - - - - Disconnect the negative battery lead first and then disconnect the starter motor lead

CD. 2.Remove: • Starter motor ® Disassembly 1.Remove:

• Bolts CD • O-rings

2.Remove: • Bracket CD • O-ring ® • Washer • Shim • Yoke@ • Armature @ • Brush assembly ® • Shim ® • O-ring (j)

Inspection and repair 1.lnspect: • Commutator Dirty ~ Clean it with #600 grit sandpaper. 2.Measure: • Commutator diameter ® Out of specification ~ Replace. 18210101

8 - 17

ELECTRICAL STARTING SYSTEM

IELEC I0 I

Outside diameter: 28 mm (1.10 in) <Wear limit:> 27 mm (1.06 in)

3.Measure: • Mica undercut @ Out of specification ~ Scrape the mica using a hacksaw blade.

Mica undercut: 0.6 mm (0.02 in)

NOTE: Scrape the mica to the proper measurement using a hacksaw blade which has been grounded to fit the commutator.

18210901

4.lnspect: • Armature coil (insulation/continuity) Defects ~ Replace the starter motor.

*********************************

Armature coil inspecting steps: .Connect the pocket tester for the continuity check CD and insulation check ®. • Measure the armature resistances. 18210201

Armature coil resistance: Continuity check CD: 0.011 - 0.013 Q at 20°C (68 OF) Insulation check ®: More than 1 MQ at 20°C (68 OF) .,f the resistance is incorrect, replace the starter motor.

*********************************

8 - 18

ELECTRICAL STARTING SYSTEM

IELEC Iell

5.Measure: • Brush length ® (each) Out of specification ~ Replace the brush. Brush length: 12.0 mm (0.47 in) <Wear limit:> 8.5 mm (0.33 in) 18210401

6.Measure: • Brush spring force Fatigue/out of specification a set.

Replace as

Brush spring force: 650 - 950 g (22.9 - 33.5 oz)

7.lnspect: • Bearing CD • Oil seal (g) • Bushing @ • O-rings Wear/damage

Replace.

Assembly Reverse the "Disassembly" procedures. Note the following points. 1.Apply: • Lithium-soap base grease (onto the oil seal lips and a-rings)

2.lnstall: • Brush seat CD

NOTE:

Align the slot ® on the brush seat with the slot (@ on the housing.

8 - 19

ELECTRICAL STARTING SYSTEM

IELEC I[:=J I

3.lnstall: • Yoke • Bracket

NOTE:

Align the match marks ® on the yoke with the match mark @ and bolt hole © on the bracket.

4.lnstall: • O-rings CD • Bolts ®

:p\lwmJQNi:::- ________ Always use new a-rings.

Installation 1.lnstall: • Starter motor

NOTE: Applya light coat of grease to the O-ring

~)'f &~

Bolt (yoke assembly): 10 Nm (1.0 m • kg, 7.2 ft ·Ib)

Refer to "ENGINE ASSEMBLY ADJUSTMENT" in CHAPTER 4.

8 - 20

CD.

AND

CHARGING SYSTEM

I I0 I ELEC

CHARGING SYSTEM CIRCUIT DIAGRAM

CD COl magneto ®

Rectifier/regulator

@ Battery

® 8 - 21

Main fuse

CHARGING SYSTEM

I I0 ELEC

TROUBLESHOOTING

THE BATTERY IS NOT CHARGED.

Procedure Check: 1.Fuse (main) 2.Battery 3.Charging voltage

4.Charging coil resistance 5.Wiring connection (the entire charging system)

NOTE: • Remove the following parts before troubleshooting. 1)Seat 2)Rear carrier 3)Rear fender • Use the following special tool(s) for troubleshooting.

Inductive tachometer: PIN. YU-8036-A

Engine tachometer: PIN. 90890-03113

Pocket tester: PIN. YU-03112, 90890-03112

1.Fuse (main) NO CONTINUITY

• Remove the fuse. • Connect the pocket tester (.Q x 1) to the fuse. • Check the fuse for continuity.

Replace the fuse.

{},. CONTINUITY 2.Battery INCORRECT

• Check the battery condition. Refer to "BATTERY INSPECTION" in CHAPTER 3.

• Clean the battery terminals . • Recharge or replace the battery.

{},. CORRECT

8 - 22

IflEe Iell

CHARGING SYSTEM

~ 3.Charging voltage

IDc 20vi IQ~Q

• Connect the inductive tachometer or engine tachometer to the spark plug lead. • Connect the pocket tester (DC 20V) to the battery.

-=.J

Tester (+) lead --? Battery (+) terminal Tester (-) lead --? Battery (-) terminal • Start the engine and accelerate to about 3,000 r/min. • Check the charging voltage.

Charging voltage: 14 Vat 3,000 r/min

MEETS SPECIFICATION

NOTE: Use a fully charged battery .

The charging circuit is good.

• OUTOF . . SPECIFICATION Tester (+) lead --? White lead CD Tester (-) lead --? White lead ®

4.Charging coil resistance • Disconnect the CDI magneto coupler from the wire harness. • Connect the pocket tester fin x 1" to the COl magneto terminal. • Measure the stator coil resistance.

Tester (+) lead --? White lead CD Tester (-) lead --? White lead @

Charging coil resistance: 0.70 - 0.86 n at 20 'c (68 'F)

OUT OF SPECIFICATION

l' Replace the pickup coil/stator assembly.

BOTH MEET SPECIFICATION

8 - 23

CHARGING SYSTEM

IELEe I0 I

5.Wiring connection POOR CONNECTION

â&#x20AC;¢ Check the connections on the entire charging system. Refer to "CIRCUIT DIAGRAM".

Properly connect the charging system.

CORRECT

IReplace the rectifier/regulator.

8 - 24

LIGHTING SYSTEM LIGHTING SYSTEM CIRCUIT DIAGRAM

8 - 25

IELEe I0 I

LIGHTING SYSTEM

IELEC I0 I

TROUBLESHOOTING THE HEADLIGHT AND/OR TAILLIGHT DO NOT COME ON.

Procedure Check: 1.Fuses (main and headlight) 2.Battery 3.Main switch 4.Lights switch

5.Wiring connection (the entire lighting system)

NOTE: • Remove the following parts before troubleshooting. 1)Seat • Use the following special tool for troubleshooting.

Pocket tester: PIN. YU-03112, 90890-03112

1.Fuses (main and headlight) NO CONTINUITY

• Remove the fuses. • Connect the pocket tester (.Q x 1) to the fuses. • Check the fuses for continuity.

IReplace the fuse(s).

CONTINUITY

2.Battery INCORRECT

• Check the battery condition. Refer to "BATTERY INSPECTION" in CHAPTER 3.

• Clean the battery terminals . • Recharge or replace the battery.

CORRECT

8 - 26

LIGHTING SYSTEM

ELEC

II~ I

3.Main switch • Disconnect the main switch coupler from the wire harness. • Check for continuity as follows: Red CD - Brown @

INCORRECT

IReplace the main switch. ~

CORRECT

4.Lights switch

• Disconnect the handlebar switch (left) coupler from wire harness. • Turn the lights switch to "LO" or "HI". • Check for continuity as follows: Brown CD - Blue @ • Turn the lights switch to "LO". • Check for continuity as follows: Brown CD - Green @ • Turn the lights switch to "HI". • Check for continuity as follows: Brown CD - Yellow@

INCORRECT

CORRECT

The lights switch is faulty, replace the handlebar switch (left).

8 - 27

LIGHTING SYSTEM

IELEC I0 I

~ S.Wiring connection POOR CONNECTION

â&#x20AC;¢ Check the connections on the entire lighting system. Refer to "WIRING DIAGRAM".

IProperly connect the lighting system.

CORRECT

Check the condition of each circuit of the lighting system. Refer to "LiGHTING SYSTEM CHECK".

8 - 28

LIGHTING SYSTEM

I Iell ELEC

LIGHTING SYSTEM CHECK 1.The headlight does not come on.

1.Bulb and bulb socket NO CONTINUITY

• Check the bulb and bulb socket for continuity.

IReplace the bulb and/or bulb socket.

CONTINUITY

2.Voltage • Connect the pocket tester (DC 20V) to the headlight couplers. A

Headlight: Tester (+) lead Tester (-) lead

~ ~ ~

Green terminal CD Yellow terminal ® Black terminal @

[AJ When the lights switch is in the "LO" position.

rm When the lights switch

is in the "HI" posi-

tion.

OUT OF SPECIFICATION

• Turn the main switch to "ON". • Turn the lights switch to the "LO" or "HI" position. • Check for voltage (12 V) on the "Green" and "Yellow" leads at the bulb socket connectors.

-V

The wiring circuit from the main switch to the bulb socket connectors is faulty, repair it.

MEETS SPECIFICATION

IThis circuit is good.

8 - 29

LIGHTING SYSTEM

IELEC Iell

2.The taillight does not 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 20V) to the bulb socket connector.

L B

Tester (+) lead ~ Blue terminal CD Tester (-) lead ~ Black terminal ®

I I

OUT OF SPECIFICATION

• Turn the main switch to "ON". • Turn the lights switch to the "LO" or "HI" position. • Check for voltage (12 V) on the "Blue" lead at the bulb socket connector.

~ The wiring circuit from the main switch to the bulb socket connector is faulty, repair it.

MEETS SPECIFICATION

This circuit is good.

8 - 30

@ Main switch @ Battery ® Main fuse @) Fan motor control unit @ Thermo unit @) Diode @) Oil temperature warning light ® Reverse indicator light @ Neutral indicator light @ Gear position switch ®> Starter switch @ Ignition fuse

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SIGNAL SYSTEM

IELEC Iell

TROUBLESHOOTING

THE INDICATOR LIGHTS DO NOT COME ON.

Procedure Check: 1.Fuses (main and ignition) 2.Battery 3.Main switch 4.Wiring connection

NOTE: • Remove the following parts before troubleshooting. 1)Seat • Use the following special tool for troubleshooting.

Pocket tester: PIN. YU-03112, 90890-03112

1.Fuses (main and ignition)

NO CONTINUITY

• Remove the fuses. • Connect the pocket tester (Q x 1) to the fuses. • Check the fuses for continuity.

Replace the fuse(s).

CONTINUITY

2.Battery INCORRECT

• Check the battery condition. Refer to "BATTERY INSPECTION" in CHAPTER 3.

• Clean the battery terminals . • Recharge or replace the battery.

CORRECT

8 - 32

SIGNAL SYSTEM

IELEC I0 I

3.Main switch • Disconnect the main switch coupler from the wire harness. • Check for continuity as follows: Red CD - Brown ®

INCORRECT

IReplace the main switch. ~

CORRECT

4.Wiring connection POOR CONNECTION

• Check the connections on the entire signal system. Refer to "WIRING DIAGRAM".

IProperly connect the signal system.

CORRECT

Check the condition of each circuit of the signal system. Refer to "SIGNAL SYSTEM CHECK".

8 - 33

SIGNAL SYSTEM

ELEC

11::1 I

SIGNAL SYSTEM CHECK 1.The neutral indicator light and reverse indicator light do not 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.

2.Gear position switch • Disconnect the gear position switch coupler from the wire harness. • Check for continuity as follows: Brown CD - Frame ground Green ® - Frame ground

NO CONTINUITY

Replace the gear position switch.

CONTINUITY

3.Voltage • Connect the pocket tester (DC 20V) to the meter coupler.

GIL

Tester (+) lead -7 Brown lead CD Tester (-) lead -7 Frame ground [A] Neutral indicator light

rm Reverse indicator light

OUT OF SPECIFICATION

• Turn the main switch to "ON". • Check for voltage (12 V).

n -V

•

MEETS SPECIFICATION

The wiring circuit from the main switch to the bulb socket connector is faulty, repair it.

This circuit is good.

8 - 34

SIGNAL SYSTEM

IELEC I0 I

2.lf the oil temperature warning light does not come on when the start switch is pushed on, or if the oil temperature warning light does not come on when the temperature is high (more than 147.5 - 162.5 °C (297.5 - 324.5 OF)): NO CONTINUITY

1.Bulb and bulb socket • Check the bulb and bulb socket for continuity.

Replace the bulb and/or bulb socket.

CONTINUITY

2.Thermo unit • Remove the thermo unit from the crankcase. • Connect the pocket tester (0. x 10) to the thermo unit CD. • Immerse the thermo unit in engine oil

ev·

• Measure the resistance. Thermo unit resistance: 150°C (302 OF): 307 - 3390. 170°C (338 OF): 209 - 231 0.

A WARNING Handle the thermo unit with special care. Never subject it to a strong shock or allow it to be dropped. Should it be dropped, it must be replaced.

BAD CONDITION

Thermo unit: 20 Nm (2.0 m • kg, 14 ft· Ib) Three bond sealock® #10

Replace the thermo unit.

GOOD ~CONDITION 3.Voltage • Connect the pocket tester (DC 20V) to the bulb socket connector. Tester (+) lead ~ Brown lead CD Tester (-) lead ~ Frame ground Br W/L

I I

8 - 35

OUT OF SPECIFICATION

• Turn the main switch to "ON". • Check the voltage (12 V).

n V

MEETS SPECIFICATION

The wiring circuit from the main switch to the bulb socket connector is faulty, repair it.

4.Diode • Remove the diode from the wire harness. • Check for continuity as follows: Red/White CD - White/Blue CV

INCORRECT

Blue/Black CD -; White/Blue CV Continuity

1Replace the diode.

White/Blue CV -; Blue/Black CD No continuity

CORRECT

5.Start switch • Disconnect the handlebar switch (left) coupler from wire harness. • Check for continuity as follows: Red/White CD - Black CV

INCORRECT

.1 Replace the

CORRECT

1Replace the fan motor control unit.

8 - 36

handlebar switch (left).

@ Main switch @ Battery ® Main fuse ® Circuit breaker (fan motor) @ Fan motor relay @ Fan motor @ Fan motor control unit ® Thermo unit ® Ignition fuse

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COOLING SYSTEM

ELEC

II~ I

TROUBLESHOOTING

ITHE FAN MOTOR DOES NOT MOVE. Procedure Check: 1.Fuses (main and ignition) 2.Battery 3.Main switch 4.Fan motor

5.Circuit breaker (fan motor) 6.Fan motor relay 7.Thermo unit 8.Wiring connection

NOTE: • Remove the following parts before troubleshooting. 1)Seat 2)Front carrier 3)Front fender • Use the following special tool for troubleshooting.

Pocket tester: PIN. YU-03112, 90890-03112

1.Fuses (main and ignition) NO CONTINUITY

• Remove the fuses. • Connect the pocket tester (Q x 1) to the fuses. • Check the fuses for continuity.

IReplace the fuse(s}.

CONTINUITY

2.Battery INCORRECT

• Check the battery condition. Refer to "BATTERY INSPECTION" in CHAPTER 3.

• Clean the battery terminals . • Recharge or replace the battery.

CORRECT

8 - 38

COOLING SYSTEM

IELEC I0 I

3.Main switch • Disconnect the main switch coupler from the wire harness. • Check for continuity as follows: Red ill - Brown @

INCORRECT

IReplace the main switch. ~

CORRECT

4.Fan motor • Disconnect the fan motor coupler. • Connect the battery (12 V) as shown. Battery (+) lead ~ Blue terminal ill Battery (-) lead ~ Black terminal @

DOES NOT TURN

IReplace the fan motor.

• Check the operation of the fan motor.

TURNS

8 - 39

COOLING SYSTEM

IELEC I0 I

5.Circuit breaker (fan motor) • Remove the circuit breaker from the wire harness. • Connect the pocket tester (Q x 1) to the circuit breaker.

OUT OF SPECIFICATION

•

Circuit breaker resistance: Zero Q at 20°C (68 Of)

Replace the circuit breaker.

MEETS SPECIFICATION

6.Fan motor relay

---- ----w---- -----;

• Remove the fan motor relay from the wire harness. • Connect the pocket tester (Q x 1) and the battery (12 V) to the fan motor relay terminals.

I :

R/W

~~~~~~

terminal ~ Red/White terminal CD Battery (-) terminal ~ White terminal CV Battery

(+)

Tester (+) lead ~ Red/Black terminal @ Tester (-) lead ~ Blue terminal @ NO CONTINUITY

• Check the fan motor relay for continuity.

I I

________________ I

CONTINUITY

Replace the fan motor relay.

8 - 40

______________________ CO_O_L_IN_G_S_Y_S_TE_M_IELECIE=J1 7.Thermo unit • Remove the thermo unit from the crankcase. • Connect the pocket tester (Q x 10) to the thermo unit CD. • Immerse the thermo unit in engine oil

0· • Measure the resistance. Thermo unit resistance: 150°C (302 OF): 307 - 339 Q 220°C (428 OF): 209 - 231 Q

WARNING

Handle the thermo unit with special care. Never subject it to strong shock or allow it to be dropped. Should it be dropped, it must be replaced.

BAD CONDITION

Thermo unit: 20 Nm (2.0 m • kg, 14 ft· Ib) Three bond sealock® #10

Replace the thermo unit.

GOOD CONDITION

8.Wiring connection POOR CONNECTION

• Check the connections on the entire cooling system. Refer to "CIRCUIT DIAGRAM".

Properly connect the cooling system.

CORRECT

IReplace the fan motor control unit.

8 - 41

CARBURETOR WARMING SYSTEM CARBURETOR WARMING SYSTEM CIRCUIT DIAGRAM

8 - 42

IElEC I0 I

CARBURETOR WARMING SYSTEM

IELEC I0

TROUBLESHOOTING THE CARBURETOR WARMING SYSTEM FAILS TO OPERATE.

Procedure Check: 1.Fuses (main and carburetor warmer) 2.Battery 3.Main switch 4.Thermo switch

5.Carburetor warmer 6.Wiring connection

NOTE: • Remove the following parts before troubleshooting. 1)Seat 2)Front carrier 3)Front fender • Use the following special tool for troubleshooting.

Pocket tester: PIN. YU-03112, 90890-03112

NO CONTINUITY 1.Fuses (main and carburetor warmer) • Remove the fuses. • Connect the pocket tester (Q x 1) to the fuses. • Check the fuses for continuity.

IReplace the fuse(s).

CONTINUITY INCORRECT

2.Battery • Check the battery condition. Refer to "BATTERY INSPECTION" in CHAPTER 3.

• Clean the battery terminals. • Recharge or replace the battery.

CORRECT

8 - 43

CARBURETOR WARMING SYSTEM

IELEC I0 I

3.Main switch • Disconnect the main switch from the wire harness. • Check for continuity as follows: Red CD - Brown ®

coupler

INCORRECT

IReplace the main switch. ~

CORRECT

4.Thermo switch • Remove the thermo switch from the wire harness. • Connect the pocket tester (Q x 1) to the thermo switch connectors.

Tester (+) lead ~ Yellow lead CD Tester (-) lead ~ Yellow lead ® • Immerse the thermo switch in a container filled with water @. • Place a thermometer @ in the water. • Slowly heat the water, than let it cool to the specified temperature as indicated in the table. • Check the thermo switch for continuity at the temperatures indicated in the table.

~ZZZZZ~ZZZZZ::l

8±3°C (46.4 ± 37.4 OF)

[AJ The thermo switch circuit is open.

1m The thermo switch circuit is closed.

8 - 44

16±5°C (60.8 ± 41°F)

CARBURETOR WARMING SYSTEM Test step

Water temperature

Continuity

Less than 16 ~ 5 °C (60.8 ~ 41°F)

YES

More than 16 ~ 5 °C (60.8 ~ 41°F)

More than 8 ~ 3 °C (46.4 ~ 37.4 OF)

Less than 8 ~ 3 °C (46.4 ~ 37.4 OF)

YES

BAD CONDITION

Test steps 1 & 2: Heating phase Test steps 3 & 4: Cooling phase

n -V

IELEC I0 I

Replace the thermo switch.

GOOD CONDITION

5.Carburetor warmer • Remove the carburetor warmer from the carburetor. • Connect the pocket tester to the carburetor warmer. Tester (+) lead ~ Carburetor warmer terminal CD Tester (-) lead ~ Carburetor warmer body ®

IN CORRECT

• Measure the carburetor warmer resistance.

Carburetor warmer resistance: 6 - 12 Q at 20°C

Replace the carburetor warmer.

CORRECT

6.Wiring connection POOR CONNECTION

• Check the connections on the entire carburetor warming system. Refer to "CIRCUIT DIAGRAM".

Properly connect the carburetor warming system.

8 - 45

LI ? I THRTBG S I --------------------------------------------------------STARTING FAILURE/HARD STARTING

TROUBLESHOOTING

NOTE: ____________________________________________________________ The following troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to troubleshooting. Refer to the relative procedure in this manual for inspection, adjustment and replacement of parts.

STARTING FAILURE/HARD STARTING FUEL SYSTEM Fuel tank

Carburetor • Deteriorated or contaminated fuel • Clogged pilot jet • Clogged pilot air passage • Sucked-in air • Deformed float • Worn needle valve • Improperly sealed valve seat • Improperly adjusted fuel level • Improperly set pilot jet • Clogged starter jet • Starter plunger malfunction Air filter • Clogged air filter element

• Empty • Clogged fuel filter • Clogged fuel strainer • Clogged fuel breather hose • Deteriorated or contaminated fuel Fuel cock • Clogged fuel hose

ELECTRICAL SYSTEM Spark plug • Improper plug gap • Worn electrodes • Wire between terminals broken • Improper heat range • Faulty spark plug cap Ignition coil • Broken or shorted primary/secondary • Faulty spark plug lead • Broken body COl system • Faulty CDI unit • Faulty pickup coil • Faulty charging/rotor rotation direction coil • Broken woodruff key

Switches and wiring • Faulty main switch • Faulty engine stop switch • Broken or shorted wiring • Faulty gear position switch • Faulty start switch • Faulty rear brake switch Starter motor • Faulty starter motor • Faulty starter relay • Faulty starter circuit cut-off relay • Faulty starter clutch

9-1

STARTING FAILURE/HARD STARTING/POOR IDLE SPEED I TRBLI PERFORMANCE/POOR MEDIUM AND HIGH SPEED PERFORMANCESHTG COMPRESSION SYSTEM Cylinder and cylinder head • Loose spark plug • Loose cylinder head or cylinder • Broken cylinder head 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

?•

Valve, camshaft and crankshaft • Improperly sealed valve • Improperly contacted valve and valve seat • Improper valve timing • Broken valve spring • Seized camshaft • Seized crankshaft

POOR IDLE SPEED PERFORMANCE POOR IDLE SPEED PERFORMANCE Carburetor • Improperly returned starter plunger • Loose pilot jet • Clogged pilot jet • Clogged pilot air jet • Improperly adjusted idle speed (Throttle stop screw) • Improper throttle cable play • Flooded carburetor

Electrical system • Faulty spark plug • Faulty COl unit • Faulty pickup coil • Faulty charging/rotor rotation direction coil • Faulty ignition coil Valve train • Improperly adjusted valve clearance Air filter • Clogged air filter element

POOR MEDIUM AND HIGH SPEED PERFORMANCE POOR MEDIUM AND HIGH SPEED PERFORMANCE Refer to "STARTING FAILURE/HARD STARTING" and "POOR IDLE SPEED PERFORMANCEvalve train". Carburetor Air filter • Improper jet needle clip position • Clogged air filter element • Improperly adjusted fuel level • Clogged or loose main jet • Deteriorated or contaminated fuel

9-2

FAULTV DRIVE TRAIN

IJn~~

FAULTV DRIVE TRAIN The following conditions may indicate damaged shaft drive components: Symptoms

Possible Causes

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.A locked-up condition of the shaft drive mechanism, no power transmitted from the engine to the front and/or rear wheels.

A.Bearing damage. B.lmproper gear lash. C.Gear tooth damage. D.Broken drive shaft. E.Broken gear teeth. F.Seizure due to lack of lubrication. G.Small foreign objects lodged between the moving parts.

9-3

FAULTY GEAR SHIFTING/ ISTHRTBGLI·? CLUTCH SLIPPING/DRAGGING _ _ FAULTY GEAR SHIFTING HARD SHIFTING Refer to "CLUTCH SLIPPING/DRAGGING-CLUTCH DRAGGING". SHIFT PEDAL DOES NOT MOVE Shift shaft • Bent shift shaft Shift cam, shift fork • Groove jammed with impurities • Seized shift fork • Bent shift fork guide bar

Transmission • Seized transmission gear • Jammed impurities • Incorrectly assembled transmission Shift guide • Broken shift guide

JUMPS-OUT-OF GEAR Shift shaft • Improperly adjusted shift lever position • Worn shift shaft lever • Improperly returned stopper lever Shift fork • Worn shift fork

Shift cam • Improper thrust play • Worn shift cam groove Transmission • Worn gear dog

CLUTCH SLIPPING/DRAGGING CLUTCH SLIPPING Clutch • Improperly adjusted clutch lever free play • Loose clutch spring (primary and/or secondary) • Fatigued clutch spring (primary and/or secondary) • Worn friction plate • Worn clutch plate • Worn clutch shoe (primary)

Engine oil • Low oil level • Improper viscosity (low) • Deterioration

CLUTCH DRAGGING Clutch • Improperly adjusted clutch release lever free play • Improper engagement of the release lever and push rod • Warped clutch plate • Swollen friction plate • Broken clutch boss

Engine oil • Improper oil level • Improper viscosity (high) • Deterioration

9-4

OVERHEATING/FAULTY BRAKE/ ISTHRTBGLI SHOCK ABSORBER MALFUNCTION . .

? I.

OVERHEATING OVERHEATING Ignition system • Improper spark plug gap • Improper spark plug heat range • Faulty COl unit Fuel system • Improper carburetor main jet (improper setting) • Improper fuel level • Clogged air filter element Compression system • Heavy carbon build.:.up

Engine oil • Improper oil level • Improper oil viscosity • Inferior oil quality Brake • Brake drag Oil cooling system • Clogged or damaged oil cooler

FAULTY BRAKE POOR BRAKING EFFECT Front disc brake • Worn brake pads • Worn disc • Air in brake fluid • Leaking brake fluid • Faulty master cylinder kit cup • Faulty caliper kit seal • Loose union bolt • Broken brake hose and pipe • Oily or greasy disc/brake pads • Improper brake fluid level

Rear drum brake • Worn brake shoe lining • Worn brake drum • Oily or greasy brake shoe lining • Oily or greasy brake drum • Improperly adjusted brake free play • Improper brake cam lever position • Fatigue/damaged return spring

SHOCK ABSORBER MALFUNCTION MALFUNCTION • Bent or damaged damper rod • Damaged oil seal lip • Fatigued shock absorber spring

9-5

UNSTABLE HANDLING/LIGHTING SYSTEM

---------------------------------------------------------UNSTABLE HANDLING UNSTABLE HANDLING Handlebar • Improperly installed or bent Steering • Incorrect toe-in • Bent steering shaft • Improperly installed steering shaft • Damaged bearing or bearing race • Bent tie-rods • Deformed steering knuckles Tires • Uneven tire pressures on both sides • Incorrect tire pressure • Uneven tire wear

THRTBGLI? IS

Wheels • Deformed wheel • Loose bearing • Bent or loose wheel axle • Excessive wheel run-out Frame • Bent • Damaged frame Swingarm • Worn bearing or bushing • Bent or damaged

LIGHTING SYSTEM HEADLIGHT DARK • Improper bulb • Too many electric accessories • Hard charging (broken charging coil and/ or faulty rectifier/regulator) • Incorrect connection • Improperly grounded • Poor contacts (main or lights switch) • Bulb life expired

BULB BURNT OUT • Improper bulb • Faulty battery • Faulty rectifier/regulator • Improperly grounded • Faulty main and/or lights switch • Bulb life expired

9-6

YFM400FWN WIRING DIAGRAM

<D ® ®

'/GIW/L IW/RI R

@ ~Wll-----------------------------------------------------------

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COl magneto Rectifier/regulator Main switch Battery Main fuse Starter relay Starter motor Starting circuit cut-off relay COl unit Ignition coil Spark plug Rear brake switch Circuit breaker (fan motor) Fan motor relay Fan motor Fan motor control unit Thermo unit Diode Oil temperature warning light Auxiliary DC jack Reverse indicator light Neutral indicator light Gear position switch Thermo switch Carburetor warmer Headlight Taillight Handlebar switch (left) Lights switch Engine stop switch Starter switch Fuse box Headlight fuse Auxiliary DC jack fuse Ignition fuse Carburetor warmer fuse

l@jl @J

1l!I'

1 GIL

i~t--t

~!~y-

COLOR CODE B ............ Black Br .......... Brown G ........... Green L ............ Blue o ........... Orange P ............ Pink R............ Red

Sb ......... Sky blue W .......... White V ........... Vellow B/W ....... Black/White Br/L. ...... Brown/Blue G/L ........ Green/Blue G/Y ........ Green/Yellow

LIB ......... Blue/Black L!W ........ Blue/White R/B ......... Red/Black R/W ........ Red/White R/Y ......... Red/Yellow WIG ....... White/Green W/L ........ White/Blue

W/R ....... White/Red V/B. ........ Vellow/Black

.YAMAHA

LlT-11616-13-34

5GW-f8197-EO

FOREWORD This Supplementary Service Manual has been prepared to introduce new service and new data for the YFM400NMNFM400NMC. For complete information on service procedures, it is necessary to use this Supplementary Service Manual together with the following manual. YFM400FWNM/YFM400FWNMC SERVICE MANUAL: 5FU-F8197-EO

YFM400NM/YFM400NMC SUPPLEMENTARY SERVICE MANUAL Â© 1999 by Yamaha Motor Corporation, U.S.A. First Edition, July 1999 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. LlT-11616-13-34

NOTE: Designs and specifications are subject to change without notice.

PARTICULARLY IMPORTANT INFORMATION This material is distinguished by the following notation. The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

A. WARNING

NOTE:

A NOTE provides key information to make procedures easier or clearer.

HOW TO USE THIS MANUAL CONSTRUCTION OF THIS MANUAL This manual consists of chapters for the main categories of subjects. (See "Illustrated symbols") 1st title

CD:

2nd title

®:

3rd title @:

MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspections. A set of particularly important procedure @ is placed between a line of asterisks "*,, with each procedure preceded by "e". IMPORTANT FEATURES • Data and a special tool are framed in a box preceded by a relevant symbol @. • An encircled numeral ® indicates a part name, and an encircled alphabetical letter data or an alignment mark (f), the others being indicated by an alphabetical letter in a box @. • A condition of a faulty component will precede an arrow symbol ® and the course of action will follow it. EXPLODED DIAGRAM Each chapter provides exploded diagrams before each disassembly section for ease in identifying correct disassembly and assembly procedures. 1

2r-~~====~~~~~~~= 3

•

_______ FR_ON_TF_OR_K

-Cranksh.ltl Use the c.enkC •••• lpareung 1001 '1

ICHASI~

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·Oule.lork lub .. :' S<;fitlch"sIBendSID"m~9'" --0 Repla~p

PJDiIIIIIIII _ __

Oo ....'.tnmpltoll ••,ghl.n.b.nl in .... fO ... IUb ••• th' ....... d.nl.rou.l, w •• ken th.tube

INSPECTtON AND REPAIR CYLINDt:R HEAD

UI •• rou~.dsc .. pe,

NOn"----_ Ta"eu.eIOevQ,dedem-a,nlllh•• P8.kplull

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!':gSI-1 ENG ~. ICARBI iii I IORlvl-F=..1 ~

(J)

ILLUSTRATED SYMBOLS (Refer to the illustration) Illustrated symbols CD to ® are designed as thumb tabs to indicate the chapter's number and content.

<D General information ® Specifications @ Periodic inspections and adjustments @ Engine overhaul ® Carburetion ® Drive train (J) Chassis ® Electrical ® Troubleshooting

ICHAsldYOl IElEClol ®

IJ~~~ ? I ®

I~I

[g]

~ @

~ ~ ~ ~

Illustrated symbols @) to @ are used to identify the specifications appearing in the text. @) Filling fluid ® Lubricant @ Special tool @ Tightening @ Wear limit, clearance @) Engine speed @)n, V, A

Illustrated symbols @ to @ in the exploded diagrams indicate grade of lubricant and location of lubrication point. @ Apply engine oil @) Apply gear oil @) Apply molybdenum disulfide oil @ Apply wheel bearing grease @ Apply lightweight lithium-soap base grease @ Apply molybdenum disulfide grease @ Apply the locking agent (LOCTITE@) @ Use new one

CONTENTS SPECIFICATIONS ............................................................................................. 1 GENERAL SPECIFICATIONS ................................................................... 1 MAINTENANCE SPECIFICATIONS ......................................................... 2 CHASSIS ..............................................................................................2 CABLE ROUTING .....................................................................................3 PERIODIC INSPECTIONS AND ADJUSTMENTS ........................................... 5 INTRODUCTION ....................................................................................... 5 PERIODIC MAINTENANCE/LUBRICATION ............................................ 5 ENGINE OVERHAUL ........................................................................................7 ENGINE REMOVAL ..................................................................................7 SEAT, CARRIERS, FENDERS AND FUEL TANK ................................ 7 ENGINE OIL ..........................................................................................7 CARBURETOR ......................................................................................7 EXHAUST PIPE AND MUFFLER ......................................................... 8 STARTER MOTOR ...............................................................................8 OIL FILTER ............................................................................................9 REVERSE CONTROL CABLE ............................................................... 9 SHIFT PEDAL AND FOOTREST .......................................................... 9 SPARK PLUG ..................................................................................... 10 LEADS ................................................................................................ 10 REAR SHOCK ABSORBER AND SWINGARM ................................. 11 FRONT FENDER BRACKET ............................................................... 12 ENGINE REMOVAL ............................................................................ 12 MIDDLE GEAR SERVICE ........................................................................ 13 REMOVAL .......................................................................................... 14 DISASSEMBLY .................................................................................. 14 INSPECTION ...................................................................................... 17 MIDDLE DRIVE AND DRIVEN GEAR SHIM SELECTION ................. 17 ASSEMBLY ........................................................................................ 20 INSTALLATION .................................................................................. 23 GEAR LASH MEASUREMENT .......................................................... 23 ENGINE ASSEMBLY AND ADJUSTMENT ........................................... 25 REMOUNTING THE ENGINE ............................................................ 25 CHASSIS .........................................................................................................28 FRONT AND REAR WHEELS ................................................................. 28 REMOVAL ...........................................................................................29

GENERAL SPECIFICATIONS

ISPECI u-I

SPECIFICATIONS GENERAL SPECIFICATIONS Model

YFM400N

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 Chassis: Frame type Caster angle Trail Tread (STD) Tread (STD) Toe-in Tire: Type Size Manufacturer Type

5GW1 (Except for California) 5GW2 (For California) 2,007 mm (79.0 in) 1,125 mm (44.3 in) 1,172 mm (46.1 in) 855 mm (33.7 in) 1,230 mm (48.4 in) 245 mm (9.65 in) 3,000 mm (118.1 in) 252 kg (556 Ib) Steel tube frame 4Â· front rear

front rear front rear front rear

21 mm (0.83 in) 860 mm (33.86 in) 845 mm (33.27 in) 0- 10 mm (0 - 0.39 in) Tubeless AT25 x 8-12 AT25 x 11-10 DUNLOP DUNLOP KT121 KT125

-1-

MAINTENANCE SPECIFICATIONS

ISPECI U-I

MAINTENANCE SPECIFICATIONS CHASSIS

Model Rear wheel: Type Rim size Rim material Rim runout limit

YFM400N

radial lateral

Panel wheel 10 x 9.0AT Steel 2 mm (0.08 in) 2 mm (0.08 in)

-2-

CABLE ROUTING CABLE ROUTING <D Rear brake switch

® ®

ISPECI ~

Oil temperature warning light Rear brake switch lead @) Main switch lead @ Fan motor lead ® Headlight coupler @ Auxiliary DC jack connector

® ®

Rear brake cable Front brake hose @ Throttle cable ® Starter cable ® Handlebar switch lead (J) Neutral indicator light connector and reverse indicator light lead

-3-

CABLE ROUTING

ISPECI ~ I

[A] Fasten the handlebar switch lead, rear brake switch lead and starter cable to the handlebar with the plastic clamp. 1m Route the fuel tank breather hose through the hole in the handlebar cover.

-4-

Ii:gS I. (~ I.

INTRODUCTION/ PERIODIC MAINTENANCE/LUBRICATION .

PERIODIC MAINTENANCE/LUBRICATION ITEM

EVERY

INITIAL

ROUTINE

1 month 3 months 6 months 6 months

Valves*

• Check valve clearance. • Adjust if necessary.

Spark plug

• Check condition. • Adjust gap and clean. • Replace if necessary.

Air filter

• Clean. • Replace if necessary.

Carburetor*

• Check and adjust idle speed/starter operation. • Adjust if necessary.

Cylinder head cover breather system*

1 year

Every 20 - 40 hours (More often in wet or dusty areas.)

• Check breather hose for cracks or damage. • Replace if necessary.

Exhaust system*

• Check leakage. • Retighten if necessary. • Replace gasket if necessary.

Spark arrester

• Clean.

Fuelline*

• Check fuel hose for cracks or damage. • Replace if necessary.

Engine oil

• Replace (Warm engine before draining). • Replace.

Engine oil strainer

• Clean.

0 0 0

Engine oil filter

0 0 0

Final gear oil

• Check oil level/oil leakage. • Replace every 12 months.

Front brake*

• Check operation/fluid leakage/see NOTE. • Correct if necessary.

Rear brake*

• Check operation. • Adjust if necessary.

Clutch*

• Check operation. • Adjust if necessary.

Reverse release cable*

• Check operation. • Adjust if necessary.

Wheels*

• Check balance/damage/run out. • Repair if necessary.

Wheel bearings*

• Check bearing assembly for looseness/ damage. • Replace if damaged.

-5-

IANOSJP Ito) I I --------------------------------------------------------~

PERIODIC MAINTENANCE/LUBRICATION

EVERY

INITIAL

ROUTINE

ITEM

1 month 3 months 6 months 6 months

Steering system*

• Check operation. • Replace if damaged. • Check toe-in. • Adjust if necessary.

Drive shaft universal joint

• Lubricate.

Fittings and Fasteners*

• Check all chassis fittings and fasteners. • Correct if necessary.

*It is recommended that these items be serviced by a Yamaha dealer.

NOTE: Recommended brake fluid: DOT 4 (If DOT 4 is not available, DOT 3 can be used.)

A WARNING Indicates a potential hazard that could result in serious injury or death.

-6-

1 year

ENGINE REMOVAL

ENG ~.

ENGINE OVERHAUL ENGINE REMOVAL NOTE: It is not necessary to remove the engine in order to remove the following components.

• Clutch • CDI rotor

SEAT, CARRIERS, FENDERS AND FUEL TANK 1.Remove:

• • • • • •

Seat Front carrier Front fender Fuel tank Rear carrier Rear fender Refer to "SEAT, CARRIERS, FENDERS AND FUEL TANK" in CHAPTER 3.

ENGINE OIL 1.Drain: • Engine oil Refer to "ENGINE OIL REPLACEMENT" in CHAPTER 3.

CARBURETOR 1.Remove: • Carburetor assembly Refer to "CARBURETOR" in CHAPTER 3.

-7-

ENGINE REMOVAL

til ENG "'.

2.Remove: • Cylinder head breather hose Q) • Air filter case ® (with air duct and carburetor joint)

3.Remove: • Intake manifold Q)

I EXHAUST PIPE AND MUFFLER 1.Remove: • Muffler Q) • Exhaust pipe ® • Gasket

STARTER MOTOR 1.Disconnect: • Starter motor lead Q) 2.Remove: • Starter motor ®

-8-

ENGINE REMOVAL

ENG "".

OIL FILTER 1.Remove: • Oil filter cover CD • Oil filter element

REVERSE CONTROL CABLE 1.Remove: • Reverse control cable CD

********************************* Removal steps: • Pull back the boot ® . • Remove the adjuster (ID. • Disconnect the reverse control cable from the cable holder @. • Unhook the cable end.

*********************************

SHIFT PEDAL AND FOOTREST 1.Remove: • Shift rod cover CD

2.Remove: • Shift pedal link CD NOTE: For easier installation, mark the position @ on the shift shaft which aligns with the slot on the shift pedal link CD.

-9-

ENGINE REMOVAL

ENG \ , .

3.Remove: • Footrest (left) G)

4.Remove: • Adjuster (brake pedal) G) • Pin® • Spring @

5.Remove: • Spring G) • Footrest (right)

SPARK PLUG 1.Disconnect: • Spark plug cap G) 2.Remove: • Spark plug ®

LEADS 1.Disconnect: • Thermo unit coupler G)

)

-10-

ENGINE REMOVAL

ENG \ , .

2.Disconnect: • CDI magneto couplers CD • Gear position switch coupler ®

6.Remove: • Bolt (rear shock absorber-upper)

7.Remove: • Clamp (rubber boot) CD • Pivot shaft (left) ® • Locknut (pivot shaft-right) @ • Pivot shaft (right) @

-11 -

ENGINE REMOVAL

ENG , _

8.Pull the breather hoses and parking brake cable out of their guides. 9.Remove: • Rear shock absorber and swingarm

FRONT FENDER BRACKET 1.Remove: • Front fender bracket CD

ENGINE REMOVAL 1.Remove: • Bolts (engine mounting-top) CD • Engine stay (upper) • Bolts (engine mounting-front) ® • Engine stay (front) • Bolts (engine mounting-rear) @

2.Remove: • Engine (from the left side)

-12 -

MIDDLE GEAR SERVICE MIDDLE GEAR SERVICE CD Universal joint yoke ® Oil seal

@) Middle drive shaft

@ Bearing housing @Shim(s) ® a-ring ® Bearing (J) Bearing retainer ® Middle driven pinion gear ® Middle drive pinion gear

MIDDLE GEAR LASH: 0.1 - 0.3 mm (0.004 - 0.012 in)

97 Nm (9.7 m • kg, 70 ft • Ib)

25 Nm (2.5 m • kg, 18 ft· Ib)

32 Nm (3.2 m • kg, 23 ft • Ib)

-13-

ENG '\,.

MIDDLE GEAR SERVICE

ENG ~.

REMOVAL 1.Remove:

• Engine Refer to IIENGINE REMOVAL II . 2.Remove: • Crankcase (left) Refer to IIENGINE DISASSEMBLY".

OISASSEMBLV Middle drive shaft assembly 1.Straighten: • Punched portion of the nut (middle drive pinion gear) 2.Loosen: • Nut (middle drive pinion gear) CD NOTE: Place a copper plate ® between the teeth of the drive gear and the driven gear to lock them.

3.Remove: • Middle drive shaft assembly @ • Middle driven gear

4.Remove: • Nut (middle drive pinion gear) • Middle drive pinion gear ® • Shim(s) @ • Middle drive shaft G)

5.Remove: • Bearing retainer CD • Bearing ®

- 14-

MIDDLE GEAR SERVICE

ENG '\,.

Middle driven shaft assembly 1.Remove: • Universal joint

********************************* Universal joint removal steps: • Remove the circlips CD. • Place the U-joint in a press . • With a suitable diameter pipe ® beneath the yoke @, press the bearing @ 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. NOTE: It may be necessary to lightly tap the yoke with a punch.

********************************* 2.Attach: • Universal joint holder (onto the universal joint yoke) Universal joint holder:

PIN. YM-04062, 90890-04062

3.Remove: • Nut CD • Washer ® • Universal joint yoke @

4.Remove: • Bolts (bearing housing) • Shims ®

-15 -

MIDDLE GEAR SERVICE

ENG '\,.

5.Remove: • Middle driven pinion gear with bearing housing CD Lightly tap the end of the axle with a soft hammer.

6.Remove: • Bearing housing assembly CD

********************************* Bearing housing removal steps: .Clean the outside of the middle driven shaft . • Place the middle driven shaft onto a hydraulic press.

:::::::111111:;:::::::: ________ • Never directly press the shaft end with a hydraulic press, this will result in damage to the shaft thread. • Install the suitable socket ® on the shaft end to protect the thread from damage. • Press the shaft end and remove the bearing housing.

********************************* 7.Remove: • Bearing CD Use the bearing puller

®.

8.Remove: • Oil seal • Bearing retainer • Bearing Use the bearing retainer wrench

CD.

~ Bearing retainer wrench:

<7 -

PIN. YM-04128, 90890-04128

NOTE: Bearing retainer has left-hand threads. -16-

MIDDLE GEAR SERVICE

ENG " .

INSPECTION 1.lnspect: • Damper cam surfaces Wear/scratches ~ Replace damper and driven pinion gear as a set. 2.lnspect: • Damper spring Damage/cracks ~ Replace.

3.1nspect: • Gear teeth (drive pinion gear) <D • Gear teeth (driven pinion gear) ® Pitting/galling/wear ~ Replace. 4.1nspect: • O-ring Damage ~ Replace. • Bearings Pitting/damage ~ Replace. S.Check: • U-joint movement Roughness ~ Replace U-joint.

MIDDLE DRIVE AND DRIVEN GEAR SHIM SELECTION When the drive and driven gear, bearing housing assembly and/or crankcase replaced, be sure to adjust the gear shim <D.

1.Select: • Middle drive gear shim <D • Middle driven gear shim ®

********************************* Middle drive and driven gear shim selection steps: • Position middle drive and driven gear by using shims <D and ® with their respective thickness calculated from information marked on crankcase, bearing housing and drive gear end. <D Shim thickness" A" ® Shim thickness "8" -17-

MIDDLE GEAR SERVICE

ENG \ ,. .

Where: ® = a numeral (usually a decimal number) on the right crankcase specifies a thickness of "6.4". (@ = a numeral (usually a decimal number) on the left crankcase specifies a thickness of "65". © = a numeral (usually a decimal number) on the middle drive pinion gear is either added to or substracted from

"55". @ = a numeral (usually a decimal number) on the bearing housing is either added to or substracted from "15.7". Example: 1) If the crankcase (right) is marked "6.30" ..... ® is 6.30 2) If the crankcase (left) is marked "65.01" ..... (@ is 65.01 3) If the middle drive pinion gear is marked "+02" ..... © is 55.02 4) If the bearing housing is marked "+02" ..... @ is 15.72 5) Therefore, the shim thickness is 0.57 mm

A = 6.30 + 65.01 - 55.02 - 15.72 = 0.57 6) Round off hundredths digit and select appropriate shim(s). In the example above, the calculated shim thickness is 0.57 mm. The chart instructs you, however, to round off 7 to

-18-

Hundredths

Round value

0,1,2

3,4,5,6, 7

8,9

MIDDLE GEAR SERVICE

ENG ~.

Shims are supplied in the following thickness. Middle drive pinion gear shim

Thickness (mm)

0.10 0.15 0.20

0.30 0.40 0.50

eTa find shim thickness "8" use the following formula: Middle driven pinion gear shim thickness: liB" ® - CD + ® - (6) - CD - 0.05

"59" .

® = a numeral (usually a decimal number) on the middle driven pinion gear is either added to or substracted from

"79.5" . (6) = a numeral (usually a decimal number) on the right crankcase specifies a thickness of "56.5". CD = a numeral (usually a decimal number) on the left crankcase specifies a thickness of "39.5". Example: 1) Ifthe bearing housing is marked "-15" ..... ® is 75.85 2) Ifthe driven pinion gear is marked "+02" ..... CD is 59.02 3) If the driven pinion gear is marked +02" ..... ® is 79.52 4) If the crankcase (right) is marked "56.49" ..... (6) is 56.49 5) If the crankcase (left) is marked "39.49" ..... CD is 39.49 6) Therefore, the shim thickness is 0.32 mm II

8 = 75.85 - 59.02 + 79.52 - 56.49 - 39.49 0.05 = 0.32 -19 -

MIDDLE GEAR SERVICE

ENG \ ,. .

7) Round off hundredths digit and select appropriate shim(s). In the example above, the calculated shim thickness is 0.32 mm. The chart instructs you, however, to round off 2 to o. Hundredths

Round value

0,1,2

3,4,5,6, 7

8,9

Shims are supplied in the following thickness. Middle drive pinion gear shim

Thickness (mm)

0.10 0.15 0.20 0.30

0.40 0.50 0.60

*********************************

ASSEMBLY Reverse the "DISASSEMBLY" procedures. Note the following points. Middle driven shaft assembly 1.lnstall: • Bearing CD • Bearing retainer ® • Oil seal Use the bearing retainer wrench @.

~l'------7A\l ---

Bearing retainer wrench: PIN. YM-04128, 90890-04128 Bearing retainer: 110 Nm (11.0 m· kg, 80 ft ·Ib) LOCTITE®

NOTE: Bearing retainer has a left-hand thread.

-20-

MIDDLE GEAR SERVICE

ENG

2.lnstall: • Shims CD • Bearing housing ® Bolt (bearing housing): 25 Nm (2.5 m • kg, 18 ft • Ib)

3.lnstall: • Universal joint yoke • Washer® • Nut@

4.Attach: • Universal joint holder CD (onto the universal joint yoke) Universal joint holder: PIN. YM-04062, 90890-04062

5.Tighten: • Nut Nut: 97 Nm (9.7 m • kg, 70 ft· Ib) LOCTITE®

6.lnstall: • Universal joint

********************************* Universal joint installation steps: • Install the opposite yoke into the U-joint . • Apply wheel bearing grease to the bearings.

- 21 -

MIDDLE GEAR SERVICE .Install the bearing

ENG "\,_

CD onto the yoke.

:::::::1111111,:;:::::::: ________ 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 . • Install the circlips each bearing.

into the groove of

********************************* Middle drive shaft assembly 1.lnstall: • Bearing CD • Bearing retainer ® Screw (bearing retainer): 25 Nm (2.5 m • kg, 18 ft • Ib) LOCTITE®

2.lnstall: • Middle drive shaft CD • Shim(s) ® • Middle drive pinion gear @ • Nut (middle drive pinion gear) @ NOTE: Always use a new nut (middle drive pinion gear). 3.lnstall: • Middle driven gear CD • Middle drive shaft assembly ® NOTE: When installing the middle drive shaft assembly, fit it onto the splines on the middle driven gear. Bolt (bearing housing): 32 Nm (3.2 m • kg, 23 ft • Ib) LOCTITE® -22-

MIDDLE GEAR SERVICE

ENG \ , .

4.Tighten: • Nut (middle drive pinion gear)

NOTE: Place a copper plate ® between teeth of the drive gear and driven gear to lock them.

~)if &~

Nut (middle drive pinion gear): 130 Nm (13.0 m • kg, 94 ft ·Ib)

5.Lock the threads with a drift punch.

INSTALLATION 1.lnstall: • Crankcase (left) • Engine Refer to "ENGINE ADJUSTMENT".

ASSEMBLY

AND

GEAR LASH MEASUREMENT 1.Measure: • Gear lash Middle gear lash: 0.1 ... 0.3 mm (0.004 ... 0.012 in)

********************************* Measurement steps: .Attach the pinion gear fix clamp middle drive shaft.

CD to the

~ Pinion gear fix clamp: PIN. YM-04129, 90890-04129

<7 -

.Attach the gear lash measurement tool and dial gauge @.

~ Gear lash measurement tool: PIN. YM-01231, 90890-01231

<7 ® -23-

46 mm (1.8 in)

ENG , _

MIDDLE GEAR SERVICE

e 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. 0

elfthe gear lash is incorrect, adjust the gear lash by middle driven pinion gear shims and/or middle drive pinion gear shim(s).

*********************************

-24-

ENGINE ASSEMBLY AND ADJUSTMENT

ENG '\,.

ENGINE ASSEMBLY AND ADJUSTMENT REMOUNTING THE ENGINE When remounting the engine, reverse the removal procedure. Note the following points.

WARNING Securely support the machine so there is no danger of it falling over. 1.lnstall: • Engine (from the left side)

2.lnstall: • Bolts (engine mounting-rear) CD • Engine stay (front) • Bolts (engine mounting stay-front) ® • Bolt (engine mounting-front) @ • Engine stay (upper) • Bolts (engine mounting stay-top) @ • Bolt (engine mounting-top) ® NOTE: • All mounting bolts CD, ®, @, @ and ® should be installed from the right of the machine. • Install all of the bolts and nuts first and then tighten the bolts and nuts to specifications in the following order. 1st. Bolt (engine mounting staytop): 34 Nm (3.4 m • kg, 24 ft • Ib) 2nd. Nut (engine mounting-rear): 69 Nm (6.9 m • kg, 50 ft • Ib) 3rd. Nut (engine mounting stayfront): 34 Nm (3.4 m • kg, 24 ft • Ib) 4th. Nut (engine mounting-front): 69 Nm (6.9 m • kg, 50 ft ·Ib) 5th. Nut (engine mounting-top): 34 Nm (3.4 m • kg, 24 ft • Ib)

-25-

ENGINE ASSEMBLV AND ADJUSTMENT

ENG ~.

3.lnstall: • Rear shock absorber and swingarm • Pivot shaft (left) • Pivot shaft (right) • Locknut (pivot shaft - right) • Covers Refer to IIREAR SHOCK ABSORBER AND SWINGARM II in CHAPTER 7. 4.Pass the breather hoses and parking brake cable through their guides. 5.lnstall: • Spark plug Spark plug: 18 Nm (1.8 m • kg, 13 ft· Ib)

6.lnstall: • Footrest (left and right) ,

Bolt (footrest): 64 Nm (6.4 m • kg, 46 ft • Ib)

7.lnstall: • Shift pedal link CD NOTE: Align the mark ® on the shift shaft with the slot (b) on the shift pedal link.

~jJ

Bolt (shift pedal link): &~ 10 Nm (1.0 m • kg, 7.2 ft· Ib)

8.lnstall: • Oil filter element • Oil filter cover CD NOTE: Check the a-rings for damage, and replace if damaged.

Bolt (oil filter cover): 10 Nm (1.0 m • kg, 7.2 ft· Ib) -26-

ENGINE ASSEMBLY AND ADJUSTMENT

ENG

9.lnstall: • Starter motor

~)l]

Bolt (starter motor): 10 Nm (1.0 m • kg, 7.2 ft • Ib)

10.lnstall: • Gasket • Exhaust pipe ill • Muffler ® Nut (exhaust pipe): 12 Nm (1.2 m • kg, 8.7 ft· Ib) Bolt (muffler): 27 Nm (2.7 m • kg, 19 ft· Ib) LOCTITE® Bolt (joint): 20 Nm (2.0 m • kg, 14 ft • Ib)

11.lnstall: • Intake manifold

~ ~

ill

Bolt (intake manifold): 20 Nm (2.0 m· kg, 14 ft ·Ib)

12.lnstall: • Carburetor assembly Refer to "CARBURETOR" in CHAPTER 5. 13.Fill: • Engine oil Refer to "ENGINE OIL LEVEL INSPECTION" in CHAPTER 3. 14.Adjust: • Valve clearance Refer to "VALVE CLEARANCE ADJUSTMENT" in CHAPTER 3. 15.Adjust: • Idling speed Refer to "IDLING SPEED ADJUSTMENT" in CHAPTER 3. 16.Adjust: • Throttle lever free play Refer to "THROTTLE LEVER FREE PLAY" in CHAPTER 3.

-27 -

FRONT AND REAR WHEELS

ICHASldsOl

CHASSIS FRONT AND REAR WHEELS CD Wheel cap ® O-ring

TIRE AIR PRESSURE Front Cold Tire Pressure

® Cotter pin

® Front wheel axle

@Axlenut @ Plain washer ®Wheel nut ® Front wheel (J) Front wheel hub

@) Rear wheel ® Rear wheel hub (right) ® Dust seal @ Rear wheel hub (left)

[1J Tapered wheel nuts are used for both the front and rear wheels. Install the nut with its tapered side towards the wheel.

55 Nm (5.5 m • kg, 40 ft • Ib)

Standard

psi)

Minimum

22 kPa (0.22 kg/cm 2, 3.2

psi)

Maximum

28 kPa (0.28 kg/cm 2, 4.0

28 kPa (0.28 kg/cm 2 , 4.0

psi)

25 kPa (0.25 kg/cm 2 , 3.6

TIRE SIZE: FRONT: AT25 x 8-12 REAR: AT25 x 11-10

RIM SIZE: FRONT: 12 x 6.0AT REAR: 10 x 9.0AT

WHEEL RUNOUT LIMIT: RADIAL: 2 mm (0.08 in) LATERAL: 2 mm (0.08 in)

TIRE WEAR LIMIT: 3 mm (0.12 in)

150 Nm (15 m • kg, 110 ft· Ib)

150 Nm (15 m • kg, 110 ft· Ib) -28-

Rear

25 kPa (0.25 kg/cm 2, 3.6

FRONT AND REAR WHEELS

ICHAslflY6l

REMOVAL Front wheels 1.Place the machine on a level surface. 2.Loosen: • Nuts (front wheel) Apply the front brake.

3.Block the rear wheels, and elevate the front wheels by placing the suitable stand under the frame. 4.Remove: • Nuts (front wheel) • Front wheel

5.Remove: • Wheel cap • Cotter pin CD • Nut (wheel hub) • Washer@

6.Remove: • Front brake caliper CD

NOTE: Do not depress the brake lever when the wheel is off the machine otherwise the brake pads will be forced shut.

7.Remove: • Front wheel hub CD (with brake disc) • Front wheel axle ® • O-ring • Plain washer

-29-

FRONT AND REAR WHEELS

r------::::::=::::----------,

8.Remove: â&#x20AC;¢ Front brake disc CD

-30-

ICHASI6J61

EBU00438

READ THIS MANUAL CAREFULLY! It contains important safety information.

WARNING Improper ATV use can result in SEVERE INJURY or DEATH.

BEER BEER

ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR

NEVER USE ON PUBLIC ROADS

NEVER CARRY PASSENGERS

NEVER USE WITH DRUGS OR ALCOHOL

OWNER’S MANUAL

NEVER operate:

ALWAYS: without proper training or instruction. use proper riding techniques to avoid at speeds too fast for your skills or the vehicle overturns on hills and rough conditions. terrain and in turns. on public roads-a collision can occur with avoid paved surfaces-pavement may another vehicle. seriously affect handling and control. with a passenger-passengers affect balance and steering and increase risk of losing control. LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. (For replacement manual, call 1-800-532-1558)

YFM400FT WARNING

YAMAHA MOTOR CO., LTD.

PRINTED IN USA 2004.04-1.0×1 CR (E)

LIT-11626-18-08

This ATV should not be ridden by anyone under 16 years of age.

5FU-F8199-15

EBU00776

U5FU15.book Page 1 Thursday, April 8, 2004 1:29 PM

EBU00941

INTRODUCTION

Congratulations on your purchase of the Yamaha YFM400F. It represents the result of many years of Yamaha experience in the production of fine sporting, touring, and pace-setting racing machines. With the purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields. This manual will provide you with a good basic understanding of the features and operation of this ATV. This manual includes important safety information. It provides information about special techniques and skills necessary to ride your ATV. It also includes basic maintenance and inspection procedures. If you have any questions regarding the operation or maintenance of your ATV, please consult a Yamaha dealer. AN IMPORTANT SAFETY MESSAGE: ● READ THIS MANUAL TOGETHER WITH TIPS FOR THE ATV RIDER CAREFULLY AND COMPLETELY BEFORE OPERATING YOUR ATV. MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS. ● PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE ATV. ● NEVER OPERATE AN ATV WITHOUT PROPER TRAINING OR INSTRUCTION. FREE TRAINING IS AVAILABLE TO ANYONE WHO BUYS A NEW ATV. CALL 1-800-887-2887 FOR MORE INFORMATION. ● THIS ATV, AND ANY OTHER ATV OVER 90cc, SHOULD NOT BE RIDDEN BY ANYONE UNDER 16 YEARS OF AGE.

U5FU15.book Page 1 Thursday, April 8, 2004 1:29 PM

EBU00801

IMPORTANT MANUAL INFORMATION

FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH. Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

WARNING

CAUTION: NOTE:

U5FU15.book Page 2 Thursday, April 8, 2004 1:29 PM

EBU15000

IMPORTANT NOTICE

This ATV is designed and manufactured for OFF-ROAD use only. It is illegal and unsafe to operate this ATV on any public street, road or highway. This ATV complies with all applicable OFF-ROAD noise level and spark arrester laws and regulations in effect at the time of manufacture. Please check your local riding laws and regulations before operating this ATV.

EBU01067

AFFIX DEALER LABEL HERE

YFM400FT OWNER’S MANUAL ©2004 by Yamaha Motor Corporation, U.S.A. 1st edition, April 2004 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. P/N LIT-11626-18-08

U5FU15.book Page 1 Thursday, April 8, 2004 1:29 PM

EBU00014

WARNING Indicates a potential hazard that could result in serious injury or death.

CONTENTS 1

LOCATION OF THE WARNING AND SPECIFICATION LABELS....... 1-1

SAFETY INFORMATION.................. 2-1

DESCRIPTION AND MACHINE IDENTIFICATION ............................. 3-1 Identification number records.......... 3-2 Key identification number................ 3-2 Vehicle identification number .......... 3-3 Model label ...................................... 3-3

CONTROL FUNCTIONS...................4-1 Main switch ......................................4-1 Indicator and warning lights .............4-2 Speedometer ...................................4-4 Fuel gauge .......................................4-4 Handlebar switches .........................4-5 Throttle lever ....................................4-7 Speed limiter ....................................4-8 Front brake lever..............................4-9 Brake pedal and rear brake lever ...............................................4-9 Parking brake.................................4-10 Shift pedal ......................................4-11 Reverse knob ................................4-11 Recoil starter..................................4-12 Fuel tank cap .................................4-13 Fuel cock........................................4-13 Starter (choke) ...............................4-14 Seat................................................4-15 Storage box....................................4-16 Front carrier ...................................4-16 Rear carrier ....................................4-16

U5FU15.book Page 2 Thursday, April 8, 2004 1:29 PM

Front shock absorber adjustment................................... 4-17 Rear shock absorber adjustment................................... 4-18 Auxiliary DC jack........................... 4-19 5

PRE-OPERATION CHECKS ........... 5-1 Front and rear brakes ..................... 5-3 Fuel ................................................. 5-5 Engine oil ........................................ 5-7 Final gear oil.................................... 5-7 Differential gear oil .......................... 5-8 Throttle lever ................................... 5-8 Fittings and fasteners...................... 5-8 Lights............................................... 5-8 Switches.......................................... 5-8 Tires ................................................ 5-9 How to measure tire pressure....... 5-11 Tire wear limit................................ 5-12

OPERATION ..................................... 6-1 Starting a cold engine...................... 6-1 Starting a warm engine ................... 6-3 Warming up ..................................... 6-3 Reverse knob operation and reverse driving ............................... 6-4 Shifting............................................. 6-5 To start out and accelerate.............. 6-5 To decelerate................................... 6-6 Engine break-in ............................... 6-7 Parking............................................. 6-8 Parking on a slope........................... 6-9 Accessories and loading ............... 6-10

RIDING YOUR ATV .......................... 7-1 Getting to know your ATV ............... 7-3 Ride with care and good judgement...................................... 7-4 Be careful where you ride.............. 7-16 Turning your ATV .......................... 7-23 Climbing uphill ............................... 7-25 Riding downhill .............................. 7-30 Crossing a slope............................ 7-32

U5FU15.book Page 3 Thursday, April 8, 2004 1:29 PM

Crossing through shallow water.... 7-34 Riding over rough terrain............... 7-36 Sliding and skidding ...................... 7-38 What to do if ................................. 7-40 What to do .................................... 7-40 8

PERIODIC MAINTENANCE AND ADJUSTMENT.................................. 8-1 Ownerâ&#x20AC;&#x2122;s manual and tool kit............ 8-1 Periodic maintenance/ lubrication ...................................... 8-3 Engine oil and oil filter element ....... 8-6 Final gear oil .................................. 8-11 Differential gear oil......................... 8-14 Axle boots...................................... 8-16 Spark plug inspection.................... 8-17 Air filter element cleaning .............. 8-18 Spark arrester cleaning ................. 8-21 Carburetor adjustment................... 8-22 Idle speed adjustment ................... 8-23 Valve clearance adjustment .......... 8-24 Reverse lock release cable adjustment................................... 8-24

Throttle lever adjustment ...............8-24 Front brake pad check ...................8-25 Rear brake shoe inspection...........8-25 Brake fluid level check ...................8-26 Brake fluid replacement .................8-27 Front brake lever free play.............8-28 Brake pedal and rear brake lever adjustment ...................................8-29 Adjusting the rear brake light switch ...........................................8-32 Clutch adjustment ..........................8-33 Cable inspection and lubrication....8-34 Brake and shift pedal/ brake lever lubrication..................8-34 Wheel removal...............................8-35 Wheel installation...........................8-35 Battery............................................8-37 Battery maintenance......................8-38 Fuse replacement ..........................8-39 Replacing a headlight bulb ............8-41 Headlight beam adjustment...........8-43 Tail/brake light bulb replacement .................................8-44

U5FU15.book Page 4 Thursday, April 8, 2004 1:29 PM

Troubleshooting ............................ 8-45 Troubleshooting chart ................... 8-47 9

CLEANING AND STORAGE............ 9-1 A. Cleaning...................................... 9-1 B. Storage ....................................... 9-3

SPECIFICATIONS.......................... 10-1

NOISE REGULATION.................... 11-1

MAINTENANCE RECORD ............ 12-1

ATV LIMITED WARRANTY............ 13-1

YAMAHA EXTENDED SERVICE (Y.E.S.) ........................................... 14-1

U5FU15.book Page 1 Thursday, April 8, 2004 1:29 PM

EBU00464

LOCATION OF THE WARNING AND SPECIFICATION LABELS

1-1

U5FU15.book Page 2 Thursday, April 8, 2004 1:29 PM

Read and understand all of the labels on your machine. They contain important information for safe and proper operation of your ATV.

1 2 3

Never remove any labels from your ATV. If a label becomes difficult to read or comes off, a replacement label is available from your Yamaha dealer.

4 5 6

WARNING O ve r l o a d i n g t h i s AT V o r c a r r y i n g c a r g o i m p r o p e r l y c a n c h a n g e h a n d l i n g . s t a b i l i t y a n d b ra k i n g p e r fo r m a n c e a n d c a n l e a d t o a n a c c i d e n t . N eve r ex c e e d t h e m a x i mu m f r o n t c a r g o l i m i t o f : 40kg (88 lbs) N E V E R s i t o n t h e c a r r i e r. R e fe r t o i n s t r u c t i o n s i n t h e O w n e r ' s M a nu a l .

YAMAHA

7 8 9 10

5ND-F4877-00

11 12 13 14

1-2

U5FU15.book Page 3 Thursday, April 8, 2004 1:29 PM

WARNING

MAXIMUM .LOADING LIMIT

O ve r l o a d i n g t h i s AT V o r c a r r y i n g c a r g o i m p r o p e r l y c a n c h a n g e h a n d l i n g . s t a b i l i t y a n d b ra k i n g p e r fo r m a n c e a n d c a n l e a d t o a n a c c i d e n t . N eve r ex c e e d t h e m a x i mu m r e a r c a r g o l i m i t o f : 80kg (176 lbs) N E V E R s i t o n t h e c a r r i e r. R e fe r t o i n s t r u c t i o n s i n t h e O w n e r ' s M a nu a l .

YAMAHA

PULLING LOAD: TONGUE WEIGHT:

5ND-F4897-00

4020 904 147 33

(410kgf) N lbf ( 15kgf) N lbf 5FU-F151K-00

1-3

U5FU15.book Page 4 Thursday, April 8, 2004 1:29 PM

1-4

U5FU15.book Page 1 Thursday, April 8, 2004 1:29 PM

EBU13351

SAFETY INFORMATION AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An ATV handles differently from other vehicles including motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers such as turning and riding on hills or over obstacles, if you fail to take proper precautions. SEVERE INJURY OR DEATH can result if you do not follow these instructions: ● Read this manual and all labels carefully and follow the operating procedures described. ● Never operate an ATV without proper training or instruction. Take a Training Course. Beginners should receive training from a certified instructor. Contact an authorized ATV dealer or call 1-800-887-2887 to find out about the training courses nearest you. ● Always follow the age recommendation: – A child under 16 years old should never operate an ATV with engine size greater than 90cc. ● Never allow a child under age 16 to operate an ATV without adult supervision, and never allow continued use of an ATV by a child if he or she does not have the abilities to operate it safely. ● Never carry a passenger on an ATV.

2-1

U5FU15.book Page 2 Thursday, April 8, 2004 1:29 PM

● ● ●

● ● ● ●

● ● ●

Always avoid operating an ATV on any paved surfaces, including sidewalks, driveways, parking lots and streets. Never operate an ATV on any public street, road or highway, even a dirt or gravel one. Never operate an ATV without wearing an approved motorcycle helmet that fits properly. You should also wear eye protection (goggles or face shield), gloves, boots, a long-sleeved shirt or jacket, and long pants. Never consume alcohol or drugs before or while operating this ATV. Never operate at speeds too fast for your skills or the conditions. Always go at a speed that is proper for the terrain, visibility, operating conditions, and your experience. Never attempt wheelies, jumps, or other stunts. Always inspect your ATV each time you use it to make sure it is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in this manual. Always keep both hands on the handlebars and both feet on the footboards of the ATV during operation. Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to changing terrain conditions when operating the ATV. Never operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain. Always be especially cautious on these kinds of terrain.

2-2

1 2 3 4 5 6 7 8 9 10 11 12 13 14

U5FU15.book Page 3 Thursday, April 8, 2004 1:29 PM

● ● ●

●

Always follow proper procedures for turning as described in this manual. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speed. Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting larger hills. Always follow proper procedures for climbing hills as described in this manual. Check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly or make sudden gear changes. Never go over the top of a hill at high speed. Always follow proper procedures for going down hills and for braking on hills as described in this manual. Check the terrain carefully before you start down any hill. Shift your weight backward. Never go down a hill at high speed. Avoid going down a hill at an angle that would cause the vehicle to lean sharply to one side. Go straight down the hill where possible. Always follow proper procedures for crossing the side of a hill as described in this manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV. Never attempt to turn the ATV around on any hill until you have mastered the turning technique described in this manual on level ground. Avoid crossing the side of a steep hill if possible.

2-3

U5FU15.book Page 4 Thursday, April 8, 2004 1:29 PM

●

Always use proper procedures if you stall or roll backwards when climbing a hill. To avoid stalling, use the proper gear and maintain a steady speed when climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual. Dismount on the uphill side or to a side if pointed straight uphill. Turn the ATV around and remount, following the procedure described in this manual. Always check for obstacles before operating in a new area. Never attempt to operate over large obstacles, such as large rocks or fallen trees. Always follow proper procedures when operating over obstacles as described in this manual. Always be careful when skidding or sliding. Learn to safely control skidding or sliding by practicing at low speeds and on level, smooth terrain. On extremely slippery surfaces, such as ice, go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control. Never operate an ATV in fast flowing water or in water deeper than that recommended in this manual. Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them several times to let friction dry out the linings. Always be sure there are no obstacles or people behind you when you operate in reverse. When it is safe to proceed in reverse, go slowly.

2-4

U5FU15.book Page 5 Thursday, April 8, 2004 1:29 PM

● ● ● ●

Always use the size and type of tires specified in this manual. Always maintain proper tire pressure as described in this manual. Never modify an ATV through improper installation or use of accessories. Never exceed the stated load capacity for an ATV. Cargo should be properly distributed and securely attached. Reduce speed and follow instructions in this manual for carrying cargo or pulling a trailer. Allow greater distance for braking.

FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Products Safety Commission at 1-800-638-2772, or the ATV Distributor’s Safety Hotline at 1-800-852-5344.

2-5

U5FU15.book Page 6 Thursday, April 8, 2004 1:29 PM

WARNING

When transporting the ATV in another vehicle, be sure it is kept upright and that the fuel cock is in the â&#x20AC;&#x153;OFFâ&#x20AC;? position. Otherwise, fuel may leak out of the carburetor or fuel tank. WHAT CAN HAPPEN Gasoline is poisonous and can cause injuries. HOW TO AVOID THE HAZARD If you should swallow some gasoline or inhale a lot of gasoline vapor, or get some gasoline in your eyes, see your doctor immediately. If gasoline spills on your skin, wash with soap and water. If gasoline spills on your clothing, change your clothes.

POTENTIAL HAZARD Improper handling of gasoline. WHAT CAN HAPPEN Gasoline can catch fire and you could be burned. HOW TO AVOID THE HAZARD Always turn off the engine when refueling. Do not refuel immediately after the engine has been running and is still very hot. Do not spill gasoline on the engine or exhaust pipe/muffler when refueling. Never refuel while smoking, or in the vicinity of sparks, open flames, or other sources of ignition such as the pilot lights of water heaters and clothes dryers.

2-6

U5FU15.book Page 7 Thursday, April 8, 2004 1:29 PM

WARNING POTENTIAL HAZARD Starting or running the engine in a closed area. WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. HOW TO AVOID THE HAZARD Always operate your ATV in an area with adequate ventilation.

2-7

U5FU15.book Page 1 Thursday, April 8, 2004 1:29 PM

EBU00032

DESCRIPTION AND MACHINE IDENTIFICATION 1 2 3 4 5 6 7 1. Spark arrester 2. Rear carrier 3. Seat 4. Auxiliary DC jack 5. Front carrier 6. Brake pedal 7. Headlights 8. Fuel cock 9. Recoil starter 10. Tail/brake light 11. Rear wheel 12. Shift pedal 13. Front wheel

14. Rear brake lever 15. Parking brake lock plate 16. Starter (choke) 17. Speedometer 18. Reverse knob 19. On command four-wheel drive switch 20. Front brake lever 21. Throttle lever 22. Fuel gauge 23. Main switch 24. Left handlebar switches

NOTE: The machine you have purchased may differ slightly from those shown in the figures of this manual. 3-1

8 9 10 11 12 13 14

U5FU15.book Page 2 Thursday, April 8, 2004 1:29 PM

EBU00600

EBU00035

Identification number records Record the key identification number, vehicle identification number and model label information in the spaces provided for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen. 1. KEY IDENTIFICATION NUMBER:

Key identification number The key identification number is stamped on the key as shown in the following illustration. This number can be used for ordering a new key.

2. VEHICLE IDENTIFICATION NUMBER:

1. Key identification number

3. MODEL LABEL INFORMATION:

3-2

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EBU00036

EBU00787

Vehicle identification number The vehicle identification number is stamped into the frame.

Model label The model label is affixed to the location in the illustration. Record the information on this label in the space provided. This information will be needed to order spare parts from your Yamaha dealer.

1. Vehicle identification number

NOTE: The vehicle identification number is used to identify your machine.

1. Model label

3-3

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EBU00039

CONTROL FUNCTIONS WARNING Indicates a potential hazard that could result in serious injury or death. EBU12490

Main switch Functions of the respective switch positions are as follows: ON: The engine can be started only at this position and the headlights, taillight and meter lighting come on when the light switch is on. OFF: All electrical circuits are switched off. The key can be removed in this position.

4-1

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EBU00802

EBU01140

Indicator and warning lights

Oil temperature warning light “ ” When the oil temperature reaches a specified level, this light comes on to warn that the engine oil temperature is too hot. If the light comes on during operation, stop the engine as soon as it is safe to do so and allow the engine to cool down for about 10 minutes.

CAUTION:

1 2 3 4 5

●

1. 2. 3. 4.

●

Reverse indicator light “REVERSE” Neutral indicator light “NEUTRAL” Oil temperature warning light “ ” Four-wheel-drive indicator light “ ”

The engine may overheat if the ATV is overloaded. If this happens, reduce the load to specification. Restart after making sure that the light is out. Continuous use while the light is on may cause damage to the engine.

6 7 8 9 10

EBU00044

Reverse indicator light “REVERSE” This indicator light comes on when the transmission is in reverse.

EBU00605

EBU00045

NOTE: Due to the synchronizing mechanism in the differential gear case, the light may not come on until the ATV starts moving.

Neutral indicator light “NEUTRAL” This indicator light comes on when the transmission is in neutral.

Four-wheel-drive indicator light “ ” This indicator light comes on when the 2WD/ 4WD switch is in the 4WD position.

4-2

12 13 14

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EBU00733

Oil temperature warning light checking method

ACB-10E Turn the main switch to “ON” and the engine stop switch to “ ”.

Oil temperature warning light does not come on.

Oil temperature warning light comes on.

Push start switch with the transmission in neutral.

Check engine oil temperature.

Oil temperature warning light comes on momentarily.

Oil temperature warning light does not come on.

Oil temperature is low.

Oil temperature is high.

Allow to cool. Engine oil temperature and electrical circuit are OK. Go ahead with riding.

Ask a Yamaha dealer to inspect the electrical circuit.

4-3

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EBU00051

EBU00052

Speedometer The speedometer shows riding speed. This speedometer is equipped with an odometer and trip odometer. The trip odometer can be reset to “0” with the reset knob. Use the trip odometer to estimate how far you can ride on a tank of fuel before going to reserve. This information will enable you to plan fuel stops in the future.

Fuel gauge The fuel gauge indicates the amount of fuel in the fuel tank. When the needle reaches the red line, refill the tank at the first opportunity.

1. Fuel gauge

1. 2. 3. 4.

2. Red line

NOTE: If the machine runs out of fuel, move the fuel cock lever to the “RES” position. Approximately 4.0 L (0.88 Imp gal, 1.06 US gal) of fuel will be remaining in the tank.

Reset knob Speedometer Odometer Trip odometer 4-4

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EBU00053

EBU00607

Handlebar switches

Start switch “ ” The starter motor cranks the engine when this switch is pushed.

CAUTION: _

See starting instructions prior to starting the engine. (See page 6-1 for details.) _

EBU12510

Light switch “ / /OFF” Set the switch to “ ” to turn on the low beams, the taillight and the meter lighting. Set the switch to “ ” to turn on the high beams, the taillight and the meter lighting. Set the switch to “OFF” to turn off all the lights.

1. Light switch “ / /OFF” 2. Engine stop switch “ / ” 3. Start switch “ ”

EBU12050

CAUTION:

Engine stop switch “ / ” Make sure that the engine stop switch is set to “ ” before starting the engine. The engine stop switch controls ignition and can be used at all times to stop the engine, especially in an emergency. The engine will not start or run when the engine stop switch is set to “ ”.

Do not use the headlights with the engine turned off for more than thirty minutes. The battery may discharge to the point that the starter motor will not operate properly. If this should happen, remove the battery and recharge it. _

4-5

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EBU00601

On-Command four-wheel drive switch “2WD/4WD” To change from two-wheel drive (2WD) to four-wheel drive (4WD), stop the ATV and set the switch to the 4WD position. To change from four-wheel drive (4WD) to two-wheel drive (2WD), stop the ATV and set the switch to the 2WD position.

WARNING POTENTIAL HAZARD Changing from 2WD to 4WD or from 4WD to 2WD while the ATV is moving. WHAT CAN HAPPEN The ATV handles differently in 2WD than in 4WD in some circumstances. Changing from 2WD to 4WD or from 4WD to 2WD while moving may cause the ATV to unexpectedly handle differently. This could distract the operator and increase the risk of losing control and an accident. HOW TO AVOID THE HAZARD Always stop the ATV before changing from 2WD to 4WD or vice-versa.

1. On-Command four-wheel drive swich “2WD/4WD”

4-6

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EBU00062

Throttle lever Once the engine is running, movement of the throttle lever will increase the engine speed. Regulate the speed of the machine by varying the throttle position. Because the throttle is spring-loaded, the machine will decelerate, and the engine will return to an idle any time the hand is removed from the throttle lever.

Before starting the engine, check the throttle to be sure it is operating smoothly. Make sure it returns to the idle position as soon as the lever is released.

WARNING POTENTIAL HAZARD Malfunction of throttle. WHAT CAN HAPPEN The throttle could be hard to operate, making it difficult to speed up or slow down when you need to. This could cause an accident. HOW TO AVOID THE HAZARD Check the operation of the throttle lever before you start the engine. If it does not work smoothly, check for the cause. Correct the problem before riding the ATV. Consult a Yamaha dealer if you canâ&#x20AC;&#x2122;t find or solve the problem yourself.

1. Throttle lever

4-7

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EBU11590

Speed limiter The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. Turning in the adjusting screw limits the maximum engine power available and decreases the maximum speed of the ATV.

WARNING POTENTIAL HAZARD Improper adjustment of the speed limiter and throttle. WHAT CAN HAPPEN The throttle cable could be damaged. Improper throttle operation could result. You could lose control, have an accident or be injured. HOW TO AVOID THE HAZARD Do not turn the adjusting screw out more than 12 mm (0.47 in). Always make sure the throttle lever free play is adjusted to 3â&#x20AC;&#x201C;5 mm (0.12â&#x20AC;&#x201C;0.20 in). See page 8-24.

1. Locknut 2. Adjusting screw a. No more than 12 mm (0.47 in)

4-8

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EBU00070

Front brake lever The front brake lever is located on the right handlebar. Pull it toward the handlebar to apply the front brake.

1. Brake pedal

1. Front brake lever

EBU00732

Brake pedal and rear brake lever The brake pedal is located on the right side of the ATV and the rear brake lever is located on the left handlebar. Push down on the pedal or pull the lever toward the handlebar to apply the rear brake.

1. Rear brake lever

4-9

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EBU00074

Parking brake Use the parking brake when you have to start the engine or park the machine, especially on a slope. Apply the rear brake lever and push down the lock plate to apply the parking brake. Squeeze the rear brake lever to release the parking brake.

WARNING POTENTIAL HAZARD Improper use of the parking brake. WHAT CAN HAPPEN The ATV could start moving unexpectedly if the parking brake is not applied before starting the engine. This could cause loss of control or a collision. The brake could overheat if you ride the ATV without releasing the parking brake. You could lose braking performance which could cause an accident. You could also wear out the brakes prematurely. HOW TO AVOID THE HAZARD Always set the parking brake before starting the engine. Always be sure you have released the parking brake before you begin to ride.

1. Lock plate

4-10

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EBU00084

EBU01028

Shift pedal This machine is equipped with a constantmesh 5-speed forward and 1-speed reverse transmission. The shift pedal is located on the left side of the engine. Reverse is at the bottom position. Neutral is one position above reverse.

Reverse knob “REV” The reverse knob is used to shift into reverse gear. Refer to the “Reverse knob operation and reverse driving” section (page 6-4) before operating this machine in reverse gear.

1. Reverse knob “REV” 1. Shift pedal

N. Neutral position

R. Reverse position

4-11

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EBU00590

Recoil starter Firmly grasp the handle and pull slightly until engagement can be felt. Then pull forcefully, being careful not to pull the rope all the way out.

WARNING POTENTIAL HAZARD Starting the engine in gear and/or starting the engine without setting the parking brake. WHAT CAN HAPPEN The ATV could start to move unexpectedly, which could cause an accident. HOW TO AVOID THE HAZARD Put the transmission in neutral and set the parking brake before starting the engine.

1. Recoil starter

4-12

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EBU00092

EBU00093

Fuel tank cap Remove the fuel tank cap by turning it counterclockwise.

Fuel cock The fuel cock supplies fuel from the fuel tank to the carburetor. The fuel cock has three positions. OFF: With the lever in this position fuel will not flow. Always turn the lever to this position when the engine is not running. ON: With the lever in this position, fuel flows to the carburetor. Normal riding is done with the lever in this position. RES: This indicates reserve. If you run out of fuel while riding, turn the lever to this position. THEN FILL THE FUEL TANK AT THE FIRST OPPORTUNITY. After refuelling, return the fuel cock lever to the “ON” position.

1. Fuel tank cap

4-13

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EBU00095

Starter (choke) “ ” Starting a cold engine requires a richer air-fuel mixture. A separate starter circuit supplies this mixture. Move in direction a to turn on the starter (choke). Move in direction b to turn off the starter (choke). Refer to “Starting a cold engine” for proper operation. (See pages 6-1–6-3.)

1. Starter (choke) “

4-14

”

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EBU00567

Seat To remove the seat, pull the seat lock lever upward and pull up the seat at the rear.

1. Seat holder (Ă&#x2014; 2)

1. Seat lock lever

To install the seat, insert the projections on the front of the seat into the seat holders and push down on the seat at the rear. NOTE: Make sure that the seat is securely fitted.

4-15

2. Projection (Ă&#x2014; 2)

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EBU00581

EBU00582

Storage box

Front carrier Maximum load limit: 40 kg (88 lb)

Maximum load limit: 2.0 kg (4.4 lb)

CAUTION: EBU00583

To protect from damage, do not put metal products, like tools or sharply edged products directly in the storage box. If they must be stored, wrap them in appropriate cushion material.

Rear carrier Maximum load limit: 80 kg (176 lb)

4-16

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EBU01104

Front shock absorber adjustment The spring preload can be adjusted to suit the riderâ&#x20AC;&#x2122;s weight and riding conditions. Adjust the spring preload as follows. To increase the spring preload, turn the adjusting ring in direction a. To decrease the spring preload, turn the adjusting ring in direction b.

Standard position: B A - Minimum (soft) E - Maximum (hard)

1. Special wrench

1. Spring preload adjusting ring

2. Position indicator

NOTE: A special wrench can be obtained at a Yamaha dealer to make this adjustment. _

4-17

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EBU01103

Rear shock absorber adjustment The spring preload can be adjusted to suit the riderâ&#x20AC;&#x2122;s weight and riding conditions. Adjust the spring preload as follows: To increase the spring preload, turn the adjusting ring in direction a. To decrease the spring preload, turn the adjusting ring in direction b.

WARNING POTENTIAL HAZARD Improper shock absorber adjustment. WHAT CAN HAPPEN Uneven adjustment can cause poor handling and loss of stability, which could lead to an accident. HOW TO AVOID THE HAZARD Always adjust the shock absorbers on the left and right side to the same setting.

1. Spring preload adjusting ring

2. Position indicator

NOTE: A special wrench can be obtained at a Yamaha dealer to make this adjustment. _

4-18

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EBU01002

Auxiliary DC jack The auxiliary DC jack is located at the front right side of the ATV. The auxiliary DC jack can be used for suitable work lights, radios, etc. The auxiliary DC jack should only be used when the engine is running. 1. Set the light switch to “OFF”. 2. Start the engine. (See pages 6-1–6-3.) 3. Open the auxiliary DC jack cap, and then insert the accessory power plug into the jack.

Standard position: B A - Minimum (soft) E - Maximum (hard)

Maximum rated capacity for the auxiliary DC jack: DC 12 V, 120 W (10 A)

1. Special wrench

4. When the auxiliary DC jack is not being used, cover it with the cap.

4-19

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CAUTION: _

●

1. Auxiliary DC jack

2. Auxiliary DC jack cap ●

Do not use accessories requiring more than the above maximum capacity. This may overload the circuit and cause the fuse to blow. If accessories are used without the engine running or with the headlights turned on, the battery will lose its charge and engine starting may become difficult. Do not use an automotive cigarette lighter or other accessories with a plug that gets hot because the jack can be damaged.

EBU00112

WARNING Indicates a potential hazard that could result in serious injury or death. 4-20

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PRE-OPERATION CHECKS Before using this machine, check the following points: ITEM

ROUTINE

PAGE

Front brake

• Check operation, free play, fluid level and fluid leakage. • Fill with DOT 4 brake fluid if necessary.

5-3–5-4, 8-25–8-28

Rear brake

• Check operation, condition and free play. • Adjust if necessary.

Fuel

• Check fuel level. • Fill with fuel if necessary.

Engine oil

• Check oil level. • Fill with oil if necessary.

Final gear oil/ Differential gear oil

• Check for leakage.

Throttle

• Check for proper throttle cable operation and free play.

5-8, 8-24

Wheels and tires

• Check tire pressure, wear and damage.

5-9–5-12, 8-35–8-36

Fittings and fasteners

• Check all fittings and fasteners.

5-3–5-4, 8-25, 8-29–8-32 5-5–5-6 5-7, 8-6–8-10 5-7–5-8, 8-11–8-16

Lights and switches

• Check for proper operation.

Axle boots

• Check for damage.

5-8 5-8, 8-41–8-45 8-16

5-1

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WARNING 1

POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV. WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure the ATV is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the Ownerâ&#x20AC;&#x2122;s Manual.

2 3 4 5 6 7 8 9 10 11 12 13 14

5-2

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EBU12521

Front and rear brakes Brake levers and brake pedal ● Check for correct free play in the front brake lever. If the free play is incorrect, have a Yamaha dealer adjust it. ● Check for correct free play in the rear brake lever and brake pedal. If the free play is incorrect, adjust it. (See pages 8-29–8-31.) ● Check operation of the levers and pedal. They should move smoothly and there should be a firm feeling when the brake is applied. If not, have a Yamaha dealer inspect them.

Brake fluid leakage (front brake) Check to see if any brake fluid is leaking out of the hose, joint or brake fluid reservoir of the front brake. Apply the brake firmly for one minute. If the lever moves slowly inward, there may be a leak in the brake system. If there is any leakage, the brake system should be inspected by a Yamaha dealer. Brake operation Test the brakes at slow speed after starting out to make sure they are working properly. If the brakes do not provide proper braking performance, inspect the brake pads and shoes for wear. (See page 8-25.)

Brake fluid level (front brake) Check the brake fluid level. Add fluid if necessary. (See pages 8-26–8-27.) Recommended brake fluid: DOT 4

5-3

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WARNING POTENTIAL HAZARD Riding with improperly operating brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. HOW TO AVOID THE HAZARD Always check the brakes at the start of every ride. Do not ride the ATV if you find any problem with the brakes. If a problem cannot be corrected by the adjustment procedures provided in this manual, have a Yamaha dealer check for the cause.

5-4

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EBU01085

Fuel Make sure there is sufficient gasoline in the tank.

Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number ([R+M]/2) of 86 or higher, or research octane number of 91 or higher. If knocking or pinging occurs, use a different brand of gasoline or premium unleaded fuel. Unleaded fuel will give you longer spark plug life and reduced maintenance cost.

Recommended fuel: UNLEADED GASOLINE ONLY Fuel tank capacity: Total: 15.0 L (3.30 Imp gal, 3.96 US gal) Reserve: 4.0 L (0.88 Imp gal, 1.06 US gal)

CAUTION: _

Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to internal engine parts, such as the valves and piston rings, as well as to the exhaust system. _

5-5

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Gasohol There are two types of gasohol; gasohol containing ethanol and that containing methanol. Gasohol containing ethanol can be used if ethanol content does not exceed 10%. Gasohol containing methanol is not recommended by Yamaha because it may cause fuel system damage or vehicle performance problems.

1. Fuel level

WARNING POTENTIAL HAZARD Improper care when refueling. WHAT CAN HAPPEN Fuel can spill, which can cause a fire and severe injury. Fuel expands when it heats up. If the fuel tank is overfilled, fuel could spill out due to heat from the engine or the sun. HOW TO AVOID THE HAZARD Do not overfill the fuel tank. Be careful not to spill fuel, especially on the engine or exhaust pipe. Wipe up any spilled fuel immediately. Be sure the fuel tank cap is closed securely. Do not refuel right after the engine has been running and is still very hot.

2. Fuel tank filler tube

5-6

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EBU10842

EBU00493

Engine oil Make sure the engine oil is at the specified level. Add oil as necessary. (See pages 8-6– 8-10.)

Final gear oil Make sure the final gear oil is at the specified level. Add oil as necessary. (See pages 8-11– 8-13 for details.)

CAUTION:

Recommended oil: SAE 80 API GL-4 Hypoid gear oil

●

In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemical additives. Do not use oils with a diesel specification of “CD” or oils of a higher quality than specified. In addition, do not use oils labeled “ENERGY CONSERVING II” or higher. Make sure that no foreign material enters the crankcase.

If desired, an SAE 80W90 hypoid gear oil may be used for all conditions. NOTE: GL-4 is a quality and additive rating, GL-5 or GL-6 rated hypoid gear oils may also be used.

Recommended engine oil type and quantity: See page 10-2.

5-7

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EBU00678

EBU10030

Differential gear oil Make sure the differential gear oil is at the specified level. Add oil as necessary. (See pages 8-14â&#x20AC;&#x201C;8-16 for details.)

Lights Check the headlights and tail/brake light to make sure they are in working condition. Repair as necessary for proper operation.

Recommended oil: SAE 80 API GL-4 Hypoid gear oil

EBU11700

Switches Check the operation of all switches. Have a Yamaha dealer repair as necessary for proper operation.

EBU01083

Throttle lever Check to see that the throttle lever operates correctly. It must open smoothly and spring back to the idle position when released. Have a Yamaha dealer repair as necessary for proper operation. EBU11620

Fittings and fasteners Always check the tightness of chassis fittings and fasteners before a ride. Take the machine to a Yamaha dealer or refer to the Service Manual for correct tightening torque. 5-8

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EBU00157

Tires

2. The tires should be set to the recommended pressure: ● Recommended tire pressure Front 25 kPa (0.25 kgf/cm2, 3.6 psi) Rear 25 kPa (0.25 kgf/cm2, 3.6 psi) ● Check and adjust tire pressures when the tires are cold. ● Tire pressures must be equal on both sides. 3. Tire pressure below the minimum specified could cause the tire to dislodge from the rim under severe riding conditions. The following are minimums: Front 22 kPa (0.22 kgf/cm2, 3.2 psi) Rear 22 kPa (0.22 kgf/cm2, 3.2 psi)

WARNING POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or uneven tire pressure. WHAT CAN HAPPEN Use of improper tires on this ATV, or operation of this ATV with improper or uneven tire pressure, may cause loss of control, increasing your risk of accident. HOW TO AVOID THE HAZARD 1. The tires listed below have been approved by Yamaha Motor Co., Ltd. for this model. Other tire combinations are not recommended. Manufacturer

Size

Type

Front

MAXXIS

AT25 × 8-12

C9221

Rear

MAXXIS

AT25 × 10-12

C9222

5-9

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4. Use no more than the following pressures when seating the tire beads. Front 250 kPa (2.5 kgf/cm2, 36 psi) Rear 250 kPa (2.5 kgf/cm2, 36 psi) Higher pressures may cause the tire to burst. Inflate the tires very slowly and carefully. Fast inflation could cause the tire to burst.

5-10

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EBU00159

How to measure tire pressure Use the low-pressure tire gauge. NOTE: The low-pressure tire gauge is included as standard equipment. Make two measurements of the tire pressure and use the second reading. Dust or dirt in the gauge could cause the first reading to be incorrect. Set pressure with tires cold. Set tire pressures to the following specifications: Recommended pressure

Minimum

Maximum

Front

25 kPa (0.25 kgf/cm2, 3.6 psi)

22 kPa (0.22 kgf/cm2, 3.2 psi)

28 kPa (0.28 kgf/cm2, 4.0 psi)

Rear

25 kPa (0.25 kgf/cm2, 3.6 psi)

22 kPa (0.22 kgf/cm2, 3.2 psi)

28 kPa (0.28 kgf/cm2, 4.0 psi)

1. Low-pressure tire gauge

5-11

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EBU00160

Tire wear limit When the tire groove decreases to 3 mm (0.12 in) due to wear, replace the tire.

a. Tire wear limit

5-12

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EBU00161

EBU00749

OPERATION

Starting a cold engine

WARNING

POTENTIAL HAZARD Freezing control cables in cold weather. WHAT CAN HAPPEN You could be unable to control the ATV, which could lead to an accident or collision. HOW TO AVOID THE HAZARD When riding in cold weather, always make sure all control cables work smoothly before you begin riding.

Indicates a potential hazard that could result in serious injury or death.

WARNING POTENTIAL HAZARD Operating ATV without being familiar with all controls. WHAT CAN HAPPEN Loss of control, which could cause an accident or injury. HOW TO AVOID THE HAZARD Read the Owner’s Manual carefully. If there is a control or function you do not understand, ask your Yamaha dealer.

1. Set the parking brake. 2. Turn the fuel cock to “ON”. 3. Turn the main switch to “ON” and the engine stop switch to “ ”. 4. Shift the transmission into neutral.

6-1

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Position 3: Cold engine start- ambient temperature above 25 °C (80 °F) and warm engine start position.

NOTE: ● When the transmission is in neutral, the neutral indicator light should come on. If the light does not come on, ask a Yamaha dealer to inspect it. ● The engine can be started in any gear if the rear brake lever is applied. However, it is recommended to shift into neutral before starting the engine. _

1 2 3 4 5 6

5. Use the starter (choke) in reference to the figure: Position 1: Cold engine start- ambient temperature below 5 °C (40 °F). Position 2: Cold engine start- ambient temperature at 0 °C (30 °F)–30 °C (90 °F) and warming up position.

8 9 10 a. Starter (choke) 2. Half open

1. Fully-open 3. Closed

6. Completely close the throttle lever and start the engine by pushing the start switch.

11 12 13 14

6-2

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NOTE: ● If the engine fails to start, release the start switch, then push the start switch again. Pause a few seconds before the next attempt. Each cranking should be as short as possible to preserve battery energy. Do not crank the engine more than 10 seconds on each attempt. ● If the battery is discharged, pull the recoil starter to start the engine.

CAUTION:

See the “Engine break-in” section prior to operating the engine for the first time. _

EBU00180

Starting a warm engine To start a warm engine, refer to the “Starting a cold engine” section. The starter (choke) should not be used. The throttle should be opened slightly.

7. If the engine is started with the starter (choke) in position 1, the starter (choke) should be returned to position 2 to warm up the engine. If the engine is started with the starter (choke) in position 2, keep the starter (choke) in this position to warm up the engine. 8. Continue warming up the engine until it idles smoothly and return the starter (choke) to position 3 before riding.

EBU00182

Warming up To get maximum engine life, always warm up the engine before starting off. Never accelerate hard with a cold engine! To see whether or not the engine is warm, check if it responds to the throttle normally with the starter (choke) turned off.

6-3

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EBU01952

Reverse knob operation and reverse driving

NOTE: When in reverse, the reverse indicator light should be on. If the light does not come on, ask a Yamaha dealer to inspect the ATV. _

CAUTION: _

Before shifting, stop the ATV and return the throttle lever to its closed position. Otherwise the transmission may be damaged.

4. Check behind you for people or obstacles, then release the brake. 5. Open the throttle lever gradually and continue to watch to the rear while backing.

1. Bring the ATV to a complete stop and return the throttle lever to the closed position with the transmission in neutral. 2. While applying the rear brake lever or brake pedal, turn the reverse knob clockwise with your right hand. 3. Shift the transmission into reverse by pressing down on the shift pedal.

WARNING POTENTIAL HAZARD Improperly operating in reverse. WHAT CAN HAPPEN You could hit an obstacle or person behind you, resulting in serious injury. HOW TO AVOID THE HAZARD When you shift into reverse, make sure there are no obstacles or people behind you. When it is safe to proceed, go slowly.

6-4

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EBU12951

Shifting This model has a 5-speed forward and 1-speed reverse transmission with centrifugal automatic clutch. The transmission allows you to control the amount of power you have available at a given speed or for starting, accelerating, climbing hills, etc. To shift into neutral, return the throttle lever to the closed position and repeatedly depress the shift pedal until it stops. To shift into reverse, first shift into neutral, and then turn the reverse knob as explained on page 6-4. Depress the shift pedal, and then release the reverse knob.

CAUTION: _

Do not coast for long periods with the engine off, and do not tow the ATV a long distance. Even in the neutral position, the transmission is only properly lubricated when the engine is running. Inadequate lubrication may cause damage. _

EBU00205

To start out and accelerate: 1. Release the throttle lever.

CAUTION: Always close the throttle while shifting gears. Otherwise, damage to the engine and drive train may result. 2. Shift into first gear and release the shift pedal. 3. Open the throttle gradually. 1. Shift pedal

N. Neutral position

R. Reverse position 6-5

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EBU00207

To decelerate: When slowing down or stopping, release the throttle and apply the brakes smoothly and evenly. As you slow down, shift to a lower gear. Be sure that the engine has sufficiently slowed before engaging a lower gear. Improper use of the brakes or shifting can cause the tires to lose traction, reducing control and increasing the possibility of an accident.

4. Once the machine has attained adequate speed, release the throttle lever. 5. Shift into second gear and release the shift pedal. 6. Open the throttle gradually. 7. Follow the same procedure when shifting to the next higher gear.

WARNING POTENTIAL HAZARD Opening the throttle before releasing the shift pedal. WHAT CAN HAPPEN The machine could wheelie. This would increase the chance of an accident, including overturn. HOW TO AVOID THE HAZARD Release the shift pedal before opening the throttle. Open the throttle gradually.

WARNING POTENTIAL HAZARD Engaging a lower gear when the engine speed is too high. WHAT CAN HAPPEN The wheels could stop rotating. This could cause loss of control, an accident and injury. It could also cause engine or drive train damage. HOW TO AVOID THE HAZARD Make sure the engine has sufficiently slowed before shifting to a lower gear. 6-6

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EBU02092

Engine break-in There is never a more important period in the life of your machine than the period between zero and 20 hours. For this reason, we ask that you carefully read the following material. Because the engine is brand new, you must not put an excessive load on it for the first several hours of running. During the first 20 hours, the various parts in the engine wear and polish themselves to the correct operating clearances. During this period, prolonged full throttle operation or any condition which might result in excessive engine heating must be avoided. However, momentary (2â&#x20AC;&#x201C;3 seconds maximum) full throttle operation under load does not harm the engine.

Each full throttle acceleration sequence should be followed with a substantial rest period for the engine by cruising at lower r/min so the engine can rid itself of the temporary build up of heat. If any abnormality is noticed during this period, consult a Yamaha dealer. 0â&#x20AC;&#x201C;10 hours: Avoid continuous operation above half throttle. Allow a cooling off period of five to ten minutes after every hour of operation. Vary the speed of the machine from time to time. Do not operate it at one set throttle position.

6-7

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EBU00211

10–20 hours: Avoid prolonged operation above 3/4 throttle. Rev the machine freely through the gears but do not use full throttle at any time.

Parking When parking, stop the engine and shift into neutral. Turn the fuel cock to “OFF” and apply the parking brake.

After break-in: Avoid prolonged full throttle operation. Vary speeds occasionally.

1. Locked position

6-8

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EBU12960

Parking on a slope

1. Bring the ATV to a stop by applying the brakes in low gear. 2. Stop the engine. 3. With the rear brake lever and pedal applied, apply the parking brake and slowly release the brake pedal.

WARNING POTENTIAL HAZARD Parking on a hill or other incline. WHAT CAN HAPPEN The ATV could roll out of control, increasing the chance of an accident. HOW TO AVOID THE HAZARD Avoid parking on hills or other inclines. If you must park on an incline, put the ATV in low gear, apply the parking brake, and block the front and rear wheels with rocks or other objects. Do not park the ATV at all on hills that are so steep you could not walk up them easily.

6-9

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EBU00221

Accessories and loading

●

EBU00222

Accessories Accessories can affect the handling and control of your ATV. Keep the following in mind when considering an accessory or operating an ATV which has accessories. ● Choose only accessories designed for your ATV. Your Yamaha dealer has a variety of genuine Yamaha accessories. Other accessories may also be available on the market. However, it is not possible for Yamaha to test all non-Yamaha accessories, nor have any control over the quality or suitability of them. Choose a genuine Yamaha accessory, or one that is equivalent in design and quality.

●

6-10

Accessories should be rigidly and securely mounted. An accessory which can shift position or come off while you are riding could affect your ability to control the ATV. Do not mount an accessory where it could interfere with your ability to control the ATV. Examples include (but are not limited to) a heavy or bulky object attached to the handlebars which could make steering difficult, an accessory that limits your ability to move around on the seat, or one that limits your view. Use extra caution when riding an ATV with accessories. The ATV may handle differently than it does without accessories.

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EBU05881

Loading Cargo or a trailer can change the stability and handling of an ATV. You must use common sense and good judgment when carrying cargo or towing a trailer. Keep the following points in mind: ● Never exceed the weight limits shown. An overloaded ATV can be unstable.

●

MAXIMUM LOADING LIMIT ● Vehicle loading limit (total weight of cargo, rider and accessories, and tongue weight): 210 kg (463 lb) ● Front carrier: 40 kg (88 lb) ● Rear carrier: 80 kg (176 lb) ● Storage box: 2.0 kg (4.4 lb) ● Trailer hitch: Pulling load (total weight of trailer and cargo): 410 kgf (904 lbf) Tongue weight (vertical weight on trailer hitch point): 15 kgf (33 lbf)

●

6-11

Do not exceed the maximum tongue weight. You can measure tongue weight with a bathroom scale. Put the tongue of the loaded trailer on the scale with the tongue at hitch height. Adjust the load in the trailer, if necessary, to reduce the weight on hitch. If you are carrying cargo and towing a trailer, include the tongue weight in the maximum vehicle load limit. Load cargo on the carrier as close to the center of the vehicle as possible. Put cargo at the rear of the front carrier and at the front of the rear carrier. Center the load from side to side. Tie down cargo securely to the carriers. Make sure cargo in the trailer cannot move around. A shifting load can cause an accident. Make sure the load does not interfere with controls or your ability to see where you are going.

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●

● ● ●

Ride more slowly than you would without a load. The more weight you carry, the slower you should go. Although conditions vary, it is good practice not to exceed 2nd gear whenever you are carrying heavier loads or when towing a trailer. Allow more braking distance. A heavier vehicle takes longer to stop. Avoid making sharp turns unless at very slow speeds. Avoid hills and rough terrain. Choose terrain carefully. Added weight affects the stability and handling of the ATV.

WARNING POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and securely attached. Reduce speed when carrying cargo or pulling a trailer. Allow greater distance for braking.

6-12

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EBU13451

WARNING _

Indicates a potential hazard that could result in serious injury or death.

6-13

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Riding

Your ATV

7-1

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7-2

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WARNING _

Indicates a potential hazard that could result in serious injury or death. GETTING TO KNOW YOUR ATV This ATV is mainly for utility use, but may also be used for recreation. This section, Riding your ATV, provides general ATV riding instructions for recreational riding. The skills and techniques described in this section, however, are appropriate for all types of riding. Riding your ATV requires special skills acquired through practice over a period of time. Take the time to learn the basic techniques well before attempting more difficult maneuvers.

begin to ride, be sure you have read this Ownerâ&#x20AC;&#x2122;s Manual completely and understand the operation of the controls. Pay particular attention to the safety information on pages 2-1â&#x20AC;&#x201C; 2-7. Please also read all caution and warning labels on your ATV.

Riding your new ATV can be a very enjoyable activity, providing you with hours of pleasure. But it is essential to familiarize yourself with the operation of the ATV to achieve the skill necessary to enjoy riding safely. Before you 7-3

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RIDE WITH CARE AND GOOD JUDGEMENT

HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course offered by Yamaha. They should then regularly practice the skills learned in the course and the operating techniques described in this Ownerâ&#x20AC;&#x2122;s Manual. For more information about the training course, contact an authorized ATV dealer or call 1-800-887-2887.

Get training if you are inexperienced. Beginners or inexperienced riders should get training from a certified instructor. Become familiar with this ATV at slow speeds first, even if you are an experienced operator. Do not attempt to operate at maximum performance until you are totally familiar with the ATVâ&#x20AC;&#x2122;s handling and performance characteristics.

Riding your ATV requires skills acquired through practice over a period of time. Take the time to learn the basic techniques well before attempting more difficult maneuvers.

WARNING POTENTIAL HAZARD Operating this ATV without proper instruction. WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain. 7-4

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Not recommended for children under 16 years of age.

WARNING POTENTIAL HAZARD Failure to follow the age recommendations for this ATV. WHAT CAN HAPPEN Use by children of ATVs that are not recommended for their age can lead to severe injury or death of the child. HOW TO AVOID THE HAZARD A child under 16 should never operate an ATV with engine size greater than 90cc.

7-5

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This ATV is designed to carry operator and cargo only â&#x20AC;&#x201C; passengers prohibited.

WARNING POTENTIAL HAZARD Carrying a passenger on this ATV. WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV. Could cause an accident, resulting in harm to you and/ or your passenger. HOW TO AVOID THE HAZARD Never carry a passenger. The long seat is to allow the operator to shift position as needed during operation. It is not for carrying passengers.

7-6

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Apparel

Operating without protective clothing increases your chances of severe injury in the event of an accident. HOW TO AVOID THE HAZARD Always wear an approved motorcycle helmet that fits properly. You should also wear: eye protection (goggles or face shield) gloves boots long-sleeved shirt or jacket long pants

WARNING POTENTIAL HAZARD Operating this ATV without wearing an approved motorcycle helmet, eye protection and protective clothing. WHAT CAN HAPPEN Operating without an approved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident. Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident.

7-7

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Do not operate after consuming alcohol or drugs. Operatorâ&#x20AC;&#x2122;s performance capability is reduced by the influence of alcohol or drugs.

WARNING POTENTIAL HAZARD Operating this ATV after consuming alcohol or drugs. WHAT CAN HAPPEN Could seriously affect your judgment. Could cause you to react more slowly. Could affect your balance and perception. Could result in an accident. HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV.

7-8

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Pre-operation checks Always perform the pre-operation checks listed on page 5-1 before riding for safety and proper care of the ATV.

WARNING POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or uneven tire pressure. WHAT CAN HAPPEN Use of improper tires on this ATV, or operation of this ATV with improper or uneven tire pressure, may cause loss of control, increasing your risk of an accident. HOW TO AVOID THE HAZARD Always use the size and type tires specified in the Owner’s Manual for this vehicle on pages 5-9–5-10. Always maintain proper tire pressure as described in the Owner’s Manual on page 5-11.

WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV. WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure the ATV is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the Owner’s Manual.

7-9

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Speed limiter For riders less experienced with this model, this model is equipped with a speed limiter in the throttle lever housing. The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. Turning the adjusting screw in limits the maximum engine power available and decreases the maximum speed of the ATV. Turning the adjusting screw in decreases top speed and turning it out increases top speed.

WARNING _

Indicates a potential hazard that could result in serious injury or death. Do not operate at speeds too fast for your skills or the conditions.

WARNING POTENTIAL HAZARD Operating this ATV at speeds too fast for your skills or the conditions. WHAT CAN HAPPEN Increases your chances of losing control of the ATV, which can result in an accident. HOW TO AVOID THE HAZARD Always go at a speed that is proper for the terrain, visibility and operating conditions, and your experience.

1. Locknut 7-10

2. Adjusting screw

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Loading and accessories Use extra caution when riding the ATV with additional loads, such as accessories or cargo. The ATV’s handling may be adversely affected. Reduce your speed when adding additional loads.

7-11

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During operation Always keep your feet on the footboards during operation. Otherwise your feet may contact the rear wheels.

WARNING POTENTIAL HAZARD Removing hands from handlebars or feet from footboards during operation. WHAT CAN HAPPEN Removing even one hand or foot can reduce your ability to control the ATV or could cause you to lose your balance and fall off of the ATV. If you remove a foot from a footboard, your foot or leg may come into contact with the rear wheels, which could injure you or cause an accident. HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footboards of your ATV during operation.

7-12

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Avoid wheelies and jumping. You may lose control of the ATV or overturn.

WARNING POTENTIAL HAZARD Attempting wheelies, jumps, and other stunts. WHAT CAN HAPPEN Increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt stunts, such as wheelies or jumps. Donâ&#x20AC;&#x2122;t try to show off.

7-13

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Modifications

WARNING POTENTIAL HAZARD Operating this ATV with improper modifications. WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situations could lead to an accident. HOW TO AVOID THE HAZARD Never modify this ATV through improper installation or use of accessories. All parts and accessories added to this vehicle should be genuine Yamaha or equivalent components designed for use on this ATV and should be installed and used according to instructions. If you have questions, consult an authorized ATV dealer.

7-14

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Exhaust system The exhaust system on the ATV is very hot during and following operation. To prevent burns, avoid touching the exhaust system. Park the ATV in a place where pedestrians or children are not likely to touch it.

WARNING POTENTIAL HAZARD Hot exhaust system. WHAT CAN HAPPEN Dry grass or brush or other combustible material accumulated around the engine area could catch fire. Someone touching the exhaust system during or after operation could be burned. HOW TO AVOID THE HAZARD Do not operate, idle, or park the ATV in dry grass or other dry ground cover. Keep the engine area free of dry grass, brush, or other combustible material. Do not touch the hot exhaust system. Do not park the ATV in a place where others might be likely to touch it. 7-15

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BE CAREFUL WHERE YOU RIDE This ATV is designed for off-road use only. Riding on paved surfaces can cause loss of control.

WARNING POTENTIAL HAZARD Operating this ATV on paved surfaces. WHAT CAN HAPPEN ATVs are designed for off-road use only. Paved surfaces may seriously affect handling and control of the ATV, and may cause the vehicle to go out of control. HOW TO AVOID THE HAZARD Always avoid paved surfaces, including sidewalks, driveways, parking lots and streets.

7-16

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Do not ride on any public road, street, or highway. Riding on public roads can result in collisions with other vehicles.

WARNING POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN You can collide with another vehicle. HOW TO AVOID THE HAZARD Never operate this ATV on any public street, road or highway, even a dirt or gravel one. In many states it is illegal to operate ATVs on public streets, roads and highways.

7-17

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Know the terrain where you ride. Ride cautiously in unfamiliar areas. Stay alert for holes, rocks, or roots in the terrain, and other hidden hazards which may cause the ATV to upset.

WARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain. WHAT CAN HAPPEN You can come upon hidden rocks, bumps, or holes, without enough time to react. Could result in the ATV overturning or going out of control. HOW TO AVOID THE HAZARD Go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to changing terrain conditions when operating the ATV.

7-18

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WARNING POTENTIAL HAZARD Failure to use extra care when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Could cause loss of traction or vehicle control, which could result in an accident, including an overturn. HOW TO AVOID THE HAZARD Do not operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain. Always be especially cautious on these kinds of terrain.

7-19

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When riding in an area where you might not easily be seen, such as desert terrain, mount a caution flag on the ATV. DO NOT use the flag pole bracket as a trailer hitch.

WHAT CAN HAPPEN You could be in a collision. You could be injured. HOW TO AVOID THE HAZARD Always mount a caution flag on the ATV to make you more visible. Watch carefully for other vehicles. Do not ride in areas posted “no trespassing”. Do not ride on private property without getting permission.

WARNING POTENTIAL HAZARD Operating in areas where you might not be seen by other off-road vehicles. 7-20

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With the engine idling, lift the shift pedal to the 1st gear position and then release the parking brake. Apply the throttle slowly and smoothly. The centrifugal clutch will engage and you will start to accelerate. Once the ATV has attained adequate speed, release the throttle and lift the shift pedal to the 2nd gear position. Release the shift pedal and apply the throttle smoothly. Use this same procedure as you move into the higher gears. Be sure to coordinate the use of the throttle and shift pedal properly. If the throttle is applied too abruptly or if the throttle is not released during shifting, or if the shift pedal is not released before applying the throttle, the front wheels may lift off the ground resulting in a loss of directional control. Avoid higher speeds until you are thoroughly familiar with the operation of your ATV.

Select a large, flat area off-road to become familiar with your ATV. Make sure that this area is free of obstacles and other riders. You should practice control of the throttle, brakes, shifting procedures, and turning techniques in this area before trying more difficult terrain. Always avoid riding on paved surfaces: the ATV is designed for off-road use only, and handling maneuvers are more difficult to perform on pavement. Set the parking brake and follow the instruction on page 6-1 to start the engine. Once it has warmed up you are ready to begin riding your ATV. As you get on the ATV, be sure not to accidentally move the shift pedal. Remember that the engine and exhaust pipe will be hot when riding and afterwards; do not allow skin or clothing to come in contact with these components.

7-21

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CAUTION:

WARNING

Do not shift gears without releasing the throttle. Damage to the engine or drive train may occur.

POTENTIAL HAZARD Engaging a lower gear when the engine speed is too high. WHAT CAN HAPPEN The wheels could stop rotating. This could cause loss of control, an accident and injury. It could also cause engine or drive train damage. HOW TO AVOID THE HAZARD Make sure the engine has sufficiently slowed before shifting to a lower gear.

When slowing down or stopping, release the throttle and apply the brakes smoothly and evenly. As you slow down, shift to a lower gear. Be sure that the engine has sufficiently slowed before engaging a lower gear. Improper use of the brakes or shifting can cause the tires to lose traction, reducing control and increasing the possibility of an accident.

7-22

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TURNING YOUR ATV To achieve maximum traction while riding offroad, the two rear wheels are mounted solidly on one axle and turn together at the same speed. Therefore, unless the wheel on the inside of the turn is allowed to slip or lose some traction, the ATV will resist turning. A special turning technique must be used to allow the ATV to make turns quickly and easily. It is essential that this skill be learned first at low speed.

HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in this Ownerâ&#x20AC;&#x2122;s Manual. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at speeds too fast for your skills or the conditions. As you approach a curve, slow down and begin to turn the handlebars in the desired direction. As you do so, put your weight on the footboard to the outside of the turn (opposite your desired direction) and lean your upper body into the turn. Use the throttle to maintain an even speed through the turn. This maneuver will let the wheel on the inside of the turn slip slightly, allowing the ATV to make the turn properly.

WARNING POTENTIAL HAZARD Turning improperly. WHAT CAN HAPPEN ATV could go out of control, causing a collision or overturn.

7-23

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Once you have learned this technique you should be able to perform it at higher speeds or in tighter curves. Improper riding procedures such as abrupt throttle changes, excessive braking, incorrect body movements, or too much speed for the sharpness of the turn may cause the ATV to tip. If the ATV begins to tip over to the outside while negotiating a turn, lean more to the inside. It may also be necessary to gradually let off on the throttle and steer to the outside of the turn to avoid tipping over. Remember: Avoid higher speeds until you are thoroughly familiar with the operation of your ATV.

This procedure should be practiced at slow speed many times in a large off-road area with no obstacles. If an incorrect technique is used, your ATV may continue to go straight. If the ATV doesnâ&#x20AC;&#x2122;t turn, come to a stop and then practice the procedure again. If the riding surface is slippery or loose, it may help to position more of your weight over the front wheels by moving forward on the seat. 7-24

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CLIMBING UPHILL Use proper riding techniques to avoid vehicle overturns on hills. Be sure that you can maneuver your ATV well on flat ground before attempting any incline and then practice riding first on gentle slopes. Try more difficult climbs only after you have developed your skill. In all cases avoid inclines with slippery or loose surfaces, or obstacles that might cause you to lose control.

HOW TO AVOID THE HAZARD Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting large hills. It is important when climbing a hill to make sure that your weight is transferred forward on the ATV. This can be accomplished by leaning forward and, on steeper inclines, standing on the footboards and leaning forward over the handlebars.

WARNING POTENTIAL HAZARD Operating on excessively steep hills. WHAT CAN HAPPEN The vehicle can overturn more easily on extremely steep hills than on level surfaces or small hills.

7-25

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WARNING

An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill.

POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in this Ownerâ&#x20AC;&#x2122;s Manual. Always check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly or make sudden gear changes. The ATV could flip over backwards. Never go over the top of any hill at high speed.

7-26

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If you are climbing a hill and you find that you have not properly judged your ability to make it to the top, you should turn the ATV around while you still have forward motion (provided you have the room to do so) and go down the hill.

When crossing the side of a hill: Always follow proper procedures as described in the Ownerâ&#x20AC;&#x2122;s Manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV.

WARNING POTENTIAL HAZARD Improperly crossing hills or turning on hills. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in the Ownerâ&#x20AC;&#x2122;s Manual on level ground. Be very careful when turning on any hill. Avoid crossing the side of a steep hill if possible. 7-27

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If your ATV has stalled or stopped and you believe you can continue up the hill, restart carefully to make sure you do not lift the front wheels which could cause you to lose control. If you are unable to continue up the hill, dismount the ATV on the uphill side. Physically turn the ATV around and then descend the hill. If you start to roll backwards, DO NOT apply either brake abruptly. If you are in 2WD, apply only the front brake. When this ATV is in 4WD, all wheels (front and rear) are interconnected by the drive train. This means that applying either the front brake or the rear will brake all wheels. When descending hills, using either brake lever or the brake pedal will brake the wheels on the downhill side. Avoid sudden application of either the front or rear brake because the wheels on the uphill side could come off the ground. The ATV could easily tip over backwards. Apply both the front and rear brakes gradually, or dismount the ATV immediately on the uphill side.

WARNING POTENTIAL HAZARD Stalling, rolling backwards or improperly dismounting while climbing a hill. WHAT CAN HAPPEN Could result in ATV overturning. HOW TO AVOID THE HAZARD Use proper gear and maintain steady speed when climbing a hill. If you lose all forward speed: Keep weight uphill. Apply the brakes. Lock parking brake, after you are stopped.

7-28

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Dismount on uphill side or to a side if pointed straight uphill. Turn the ATV around and remount, following the procedure described in the Ownerâ&#x20AC;&#x2122;s Manual.

If you begin rolling backwards: Keep weight uphill. 2WD: Never apply the rear brake while rolling backwards. Apply the front brake. When fully stopped, apply the rear brake as well, and then lock the parking brake. 4WD: Apply both front and rear brakes gradually. When fully stopped, lock the parking brake.

7-29

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RIDING DOWNHILL When riding your ATV downhill, shift your weight as far to the rear and uphill side of the ATV as possible. Move back on the seat and sit with your arms straight. Engine compression will do most of the braking for you. For maximum engine compression braking effect, change to 4WD before beginning to descend the hill and choose a low gear which will allow the engine compression to do most of the braking for you. Improper braking may cause a loss of traction. Use caution while descending a hill with loose or slippery surfaces. Braking ability and traction may be adversely affected by these surfaces. Improper braking may also cause a loss of traction.

When this ATV is in 4WD, all wheels (front and rear) are interconnected by the drive train. This means that applying either the front brake or the rear brake will brake all wheels. When descending hills, using either brake lever or the brake pedal will brake the wheels on the downhill side. Avoid sudden application of either the front or rear brake because the wheels on the uphill side could come off the ground. Apply both the front and rear brakes gradually. Whenever possible, ride your ATV straight downhill. Avoid sharp angles which could allow the ATV to tip or roll over. Carefully choose your path and ride no faster than you will be able to react to obstacles which may appear.

7-30

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WARNING POTENTIAL HAZARD Going down a hill improperly. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for going down hills as described in this Ownerâ&#x20AC;&#x2122;s Manual. Note: a special technique is required when braking as you go down a hill. Always check the terrain carefully before you start down any hill. Shift your weight backward. Never go down a hill at high speed. Avoid going down a hill at an angle that would cause the vehicle to lean sharply to one side. Go straight down the hill where possible.

7-31

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CROSSING A SLOPE Traversing a sloping surface on your ATV requires you to properly position your weight to maintain proper balance. Be sure that you have learned the basic riding skills on flat ground before attempting to cross a sloping surface. Avoid slopes with slippery surfaces or rough terrain that may upset your balance.

If your ATV does begin to tip over, gradually steer in the downhill direction if there are no obstacles in your path. As you regain proper balance, gradually steer again in the direction you wish to travel.

As you travel across a slope, lean your body in the uphill direction. It may be necessary to correct the steering when riding on loose surfaces by pointing the front wheels slightly uphill. When riding on slopes be sure not to make sharp turns either up or down hill.

7-32

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CROSSING THROUGH SHALLOW WATER The ATV can be used to cross slow moving, shallow water of up to a maximum of 35 cm (14 inches) in depth. Before entering the water, choose your path carefully. Enter where there is no sharp drop off, and avoid rocks or other obstacles which may be slippery or upset the ATV. Drive slowly and carefully.

Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them several times to let friction dry out the linings.

WARNING POTENTIAL HAZARD Operating this ATV through deep or fast flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident. HOW TO AVOID THE HAZARD Never operate this ATV in fast flowing water or in water deeper than that specified in your Ownerâ&#x20AC;&#x2122;s Manual.

7-34

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Test your brakes after leaving the water. Do not continue to ride your ATV without verifying that you have regained proper braking ability.

CAUTION: _

After riding your ATV in water, be sure to drain the trapped water by removing the check hose at the bottom of the air filter case. Wash the ATV in fresh water if it has been operated in salt water or muddy conditions. _

1. Check hose

7-35

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RIDING OVER ROUGH TERRAIN Riding over rough terrain should be done with caution. Look out for obstacles which could cause damage to the ATV or could lead to an upset or accident. Be sure to keep your feet firmly mounted on the footboards at all times. Avoid jumping the ATV as loss of control and damage to the ATV may result.

WARNING POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Could cause loss of control or a collision. Could cause the ATV to overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for obstacles. Never attempt to ride over large obstacles, such as large rocks or fallen trees. When you go over obstacles, always follow proper procedures as described in the Ownerâ&#x20AC;&#x2122;s Manual.

7-36

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7-37

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SLIDING AND SKIDDING Care should be used when riding on loose or slippery surfaces since the ATV may slide. If unexpected and uncorrected, sliding could lead to an accident.

If the rear wheels of your ATV start to slide sideways, control can usually be regained (if there is room to do so) by steering in the direction of the slide. Applying the brakes or accelerating is not recommended until you have corrected the slide.

To reduce the tendency for the front wheels to slide in loose or slippery conditions, positioning your weight over the front wheels will sometimes help.

7-38

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With practice, over a period of time, skill at controlled sliding can be developed. The terrain should be chosen carefully before attempting such maneuvers, since both stability and control are reduced. Bear in mind that sliding maneuvers should always be avoided on extremely slippery surfaces such as ice, since all control may be lost.

WARNING POTENTIAL HAZARD Skidding or sliding improperly. WHAT CAN HAPPEN You may lose control of this ATV. You may also regain traction unexpectedly, which may cause the ATV to overturn. HOW TO AVOID THE HAZARD Learn to safely control skidding or sliding by practicing at low speeds and on level, smooth terrain. On extremely slippery surfaces, such as ice, go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control.

7-39

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WHAT TO DO IF ... This section is designed to be a reference guide only. Be sure to read each section on riding techniques completely.

●

WHAT TO DO ... ● If your ATV doesn’t turn when you want it to: Bring the ATV to a stop and practice the turning maneuvers again. Be sure you are putting your weight on the footboard to the outside of the turn. Position your weight over the front wheels for better control. (See pages 7-23–7-24.) ● If your ATV begins to tip while turning: Lean more into the turn to regain balance. If necessary, gradually let off the throttle and/ or steer to the outside of the turn. (See pages 7-23–7-24.)

●

7-40

If your ATV starts to slide sideways: Steer in the direction of the slide if you have the room. Applying the brakes or accelerating is not recommended until you have corrected the slide. (See pages 7-38–7-39.) If your ATV can’t make it up a hill you are trying to climb: Turn the ATV around if you still have forward speed. If not, stop, dismount on the uphill side of the ATV and physically turn the ATV around. If the ATV starts to slip backwards, DO NOT USE THE REAR BRAKE - the ATV may tip over on top of you. Dismount the ATV on the uphill side. (See pages 7-25–7-29.)

U5FU15.book Page 41 Thursday, April 8, 2004 1:29 PM

●

If your ATV is traversing a sloping surface: Be sure to ride with your weight positioned towards the uphill side of the ATV to maintain proper balance. If the ATV starts to tip, steer down the hill (if there are no obstacles in your way) to regain balance. If you discover that the ATV is going to tip over, dismount on the uphill side. (See pages 7-32– 7-33.) If your ATV encounters shallow water: Ride slowly and carefully through slow moving water, watching for obstacles. Be sure to let water drain from the ATV and CHECK YOUR BRAKES FOR PROPER OPERATION when you come out of the water. Do not continue to ride your ATV until you have regained adequate braking ability. (See pages 7-34–7-35.)

WARNING _

Indicates a potential hazard that could result in serious injury or death. 7-41

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EBU00515

PERIODIC MAINTENANCE AND ADJUSTMENT

Have a Yamaha dealer perform service if you are not familiar with machine service.

Periodic inspection, adjustment and lubrication will keep your machine in the safest and most efficient condition possible. Safety is an obligation of the machine owner. The most important points of machine inspection, adjustment and lubrication are explained on the following pages.

EBU12990

Owner’s manual and tool kit You are recommended to put this owner’s manual in the vinyl bag and always carry it on the bottom of the seat as shown. Put the owner’s tool kit and low-pressure tire gauge in the storage box.

WARNING POTENTIAL HAZARD Servicing an engine while it is running. WHAT CAN HAPPEN Moving parts can catch clothing or parts of the body, causing injury. Electrical components can cause shocks or can start fires. HOW TO AVOID THE HAZARD Turn off the engine when performing maintenance unless otherwise specified.

1. Owner’s manual 8-1

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WARNING

1. Ownerâ&#x20AC;&#x2122;s tool kit

POTENTIAL HAZARD Operating this ATV with improper modifications. WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situations could lead to an accident. HOW TO AVOID THE HAZARD Never modify this ATV through improper installation or use of accessories. All parts and accessories added to this vehicle should be genuine Yamaha or equivalent components designed for use on this ATV and should be installed and used according to instructions. If you have questions, consult an authorized Yamaha ATV dealer.

2. Low-pressure tire gauge

The service information included in this manual is intended to provide you, the owner, with the necessary information for completing your own preventive maintenance and minor repairs. The tools provided in the Ownerâ&#x20AC;&#x2122;s tool kit are sufficient for this purpose, except that a torque wrench is also necessary to properly tighten nuts and bolts. NOTE: If you do not have a torque wrench available during a service operation requiring one, take your machine to a Yamaha dealer to check the torque settings and adjust them as necessary. _

8-2

1 2 3 4 5 6 7 8 9 10 11 12 13 14

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EBU02611

PERIODIC MAINTENANCE/LUBRICATION NOTE: _

● ●

For ATVs not equipped with an odometer or an hour meter, follow the month maintenance intervals. For ATVs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance intervals. However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance intervals should be followed.

ITEM

Valves* Spark plug* Air filter element Carburetor* Crankcase breather system* Exhaust system* Spark arrester Fuel line* Engine oil

Whichever month comes first km (mi) hours

ROUTINE

• • • • • • • • • • • • • • • • • •

Check valve clearance. Adjust if necessary. Check condition. Adjust gap and clean. Replace if necessary. Clean. Replace if necessary. Check and adjust idle speed/starter operation. Adjust if necessary. Check breather hose for cracks or damage. Replace if necessary. Check leakage. Tighten if necessary. Replace gasket if necessary. Clean. Check fuel hose for cracks or damage. Replace if necessary. Replace (Warm engine before draining).

8-3

1 320 (200) 20

INITIAL 3 1,200 (750) 75

6 2,400 (1,500) 150

EVERY 6 12 2,400 4,800 (1,500) (3,000) 150 300

Every 20–40 hours (More often in wet or dusty areas.)

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ITEM

Engine oil filter element Engine oil strainer Final gear oil Differential gear oil Front brake* Rear brake* Clutch* Reverse release cable* Wheels* Wheel bearings* Front and rear suspension* Steering system* Drive shaft universal joint* Axle boots* Fittings and fasteners*

Whichever month comes first km (mi) hours

ROUTINE

• Clean. • Clean. • Check oil level/oil leakage. • Replace every 12 months. • • • • • • • • • • • • • • • • • • • • • • •

Check operation/fluid leakage/see NOTE page 8-5. Correct if necessary. Check operation. Adjust if necessary. Check operation. Adjust if necessary. Check operation. Adjust if necessary. Check balance/damage/runout. Repair if necessary. Check bearing assemblies for looseness/damage. Replace if damaged. Check operation. Correct if necessary. Check operation. Replace if damaged. Check toe-in. Adjust if necessary. Lubricate with lithium-soap-based grease. Check operation. Replace if damaged. Check all chassis fittings and fasteners. Correct if necessary.

8-4

1 320 (200) 20

INITIAL 3 1,200 (750) 75

6 2,400 (1,500) 150

EVERY 6 12 2,400 4,800 (1,500) (3,000) 150 300

U5FU15.book Page 5 Thursday, April 8, 2004 1:29 PM

ITEM

Lights and switches*

Whichever month comes first km (mi) hours

ROUTINE

1 320 (200) 20

INITIAL 3 1,200 (750) 75

6 2,400 (1,500) 150

EVERY 6 12 2,400 4,800 (1,500) (3,000) 150 300

• Check operation. • Adjust headlight beams.

* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.

NOTE: ● Recommended brake fluid: DOT 4 ● Brake fluid replacement:

• When disassembling the master cylinder or caliper, replace the brake fluid. Normally check the brake fluid level and add fluid as required. • On the inner parts of the master cylinder and caliper, replace the oil seals every two years. • Replace the brake hoses every four years, or if cracked or damaged.

WARNING _

Indicates a potential hazard that could result in serious injury or death.

8-5

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EBU11812

Engine oil and oil filter element The engine oil level should be checked before each ride. In addition, the oil must be changed and the oil filter element cleaned at the intervals specified in the periodic maintenance and lubrication chart. To check the engine oil level 1. Place the ATV on a level surface. 2. Warm up the engine for several minutes, and then turn it off. 3. Wait a few minutes until the oil level settles before checking. 4. Remove the engine oil filler cap, and then wipe the dipstick off with a clean rag. Insert the dipstick in the filler hole (without screwing it in), and then remove it again to check the oil level.

1. Engine oil filler cap

1. Dipstick 3. Minimum level mark 8-6

2. Maximum level mark

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NOTE: The oil level should be between the minimum and maximum level marks.

To change the engine oil (with or without oil filter element cleaning) 1. Place the ATV on a level surface. 2. Warm up the engine for several minutes, and then turn it off. 3. Place a container under the engine to collect the used oil. 4. Remove the engine oil filler cap, and then remove the engine oil drain bolt to drain the oil from the crankcase.

5. If the engine oil is at or below the minimum level mark, add sufficient oil of the recommended type to raise it to the correct level.

CAUTION: _

Be sure no foreign material enters the crankcase. _

6. Insert the dipstick into the oil filler hole, and then tighten the engine oil filler cap.

1. Engine oil drain bolt 3. Compression spring

8-7

2. O-ring 4. Oil strainer

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6. Clean the oil strainer and oil filter element with solvent. 7. Check the O-ring for damage and replace it if necessary.

CAUTION: _

When removing the engine oil drain bolt, the compression spring, oil strainer and O-ring will fall out. Take care not to lose these parts. _

NOTE: Skip steps 5â&#x20AC;&#x201C;9 if the oil filter element is not being cleaned. _

5. Remove the oil filter cover by removing the bolts, and then remove the oil filter element. 1. O-ring

2. Oil filter element

8. Install the oil filter element and O-ring. NOTE: Make sure the O-ring is seated properly. _

1. Oil filter cover

2. Oil filter cover bolt (Ă&#x2014; 3)

8-8

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9. Install the oil filter cover by installing the bolts, and then tighten them to the specified torque.

11. Add the specified amount of the recommended engine oil, and then install and tighten the engine oil filler cap. Recommended oil: See page 10-2. Oil quantity: Without oil filter element replacement: 2.90 L (2.55 Imp qt, 3.07 US qt) With oil filter element replacement: 3.00 L (2.64 Imp qt, 3.17 US qt)

Tightening torque: Oil filter cover bolt: 10 Nm (1.0 m路kgf, 7.2 ft路lbf) 10. Install the oil strainer, compression spring, O-ring and engine oil drain bolt. Tighten the engine oil drain bolt to the specified torque.

CAUTION: _

Before installing the engine oil drain bolt, be sure to install the O-ring, compression spring and oil strainer. _

Tightening torque: Engine oil drain bolt: 32 Nm (3.2 m路kgf, 23 ft路lbf)

8-9

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CAUTION: _

●

12. Start the engine, and then let it idle for several minutes while checking it for oil leakage. If oil is leaking, immediately turn the engine off and check for the cause. 13. Turn the engine off, and then check the oil level and correct it if necessary.

8-10

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EBU11453

Final gear oil Checking the final gear oil 1. Place the ATV on a level surface. 2. Remove the oil filler bolt, and then check the oil level in the final gear case. NOTE: The oil level should be at the brim of the filler hole. _

3. If the oil is below the brim of the filler hole, add sufficient oil of the recommended type to raise it to the correct level.

1. Final gear oil 3. Final gear oil filler bolt

2. Correct oil level

4. Install the oil filler bolt, and then tighten it to the specified torque.

CAUTION: _

Be sure no foreign material enters the final gear case.

Tightening torque: Final gear oil filler bolt: 23 Nm (2.3 mÂˇkgf, 17 ftÂˇlbf)

8-11

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Replacing the final gear oil 1. Remove the final gear case cover by removing the bolts.

1. Final gear case cover

2. Place the ATV on a level surface. 3. Place a container under the final gear case to collect the used oil. 4. Remove the oil filler bolt and the drain bolt to drain the oil.

2. Bolt (× 2)

1. Final gear oil drain bolt

5. Install the drain bolt, and then tighten it to the specified torque. Tightening torque: Final gear oil drain bolt: 23 Nm (2.3 m·kgf, 17 ft·lbf) 8-12

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6. Add the recommended final gear oil to the brim of the filler hole.

Tightening torque: Final gear case cover bolt: 17 Nm (1.7 m路kgf, 13 ft路lbf)

Recommended oil: SAE 80 API GL-4 Hypoid gear oil Oil quantity: 0.23 L (0.20 Imp qt, 0.24 US qt)

CAUTION: _

Be sure no foreign material enters the final gear case. _

7. Install the oil filler bolt, and then tighten it to the specified torque. Tightening torque: Final gear oil filler bolt: 23 Nm (2.3 m路kgf, 17 ft路lbf) 8. Check for oil leakage. If oil leakage is found, check for the cause. 9. Install the final gear case cover bolts, and then tighten them to the specified torque. 8-13

U5FU15.book Page 14 Thursday, April 8, 2004 1:29 PM

EBU07063

Differential gear oil Checking the differential gear oil 1. Place the ATV on a level surface. 2. Remove the differential gear oil filler bolt and check the oil level. It should be up to the brim of the filler hole. If the level is low, add sufficient oil of the recommended type to raise it to the specified level.

CAUTION: _

1. Differential gear oil filler bolt 2. Proper oil level 3. Differential gear oil

Be sure no foreign material enters the differential gear case. _

3. Install the differential gear oil filler bolt, and then tighten it to the specified torque. Tightening torque: Differential gear oil filler bolt: 23 Nm (2.3 mÂˇkgf, 17 ftÂˇlbf)

8-14

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Replacing the differential gear oil 1. Place the ATV on a level surface. 2. Place a container under the differential gear case to collect the used oil. 3. Remove the differential gear oil filler bolt and differential gear oil drain bolt to drain the oil.

4. Install the differential gear oil drain bolt and tighten it to the specified torque. Tightening torque: Differential gear oil drain bolt: 10 Nm (1.0 mÂˇkgf, 7 ftÂˇlbf) 5. Fill the differential gear case with the recommended oil. Recommended oil: SAE 80 API GL-4 Hypoid gear oil Oil quantity: 0.35 L (0.31 Imp qt, 0.37 US qt)

CAUTION: _

Be sure no foreign material enters the differential gear case.

1. Differential gear oil drain bolt

8-15

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EBU00862

6. Install the differential gear oil filler bolt, and then tighten it to the specified torque. Tightening torque: Differential gear oil filler bolt: 23 Nm (2.3 m·kgf, 17 ft·lbf)

Axle boots Check the protective boots for holes or tears. If any damage is found, have them replaced by a Yamaha dealer.

7. Check for oil leakage. If oil leakage is found, check for the cause.

1. Axle boot (× 2)

8-16 1. Axle boot (× 2)

U5FU15.book Page 17 Thursday, April 8, 2004 1:29 PM

EBU11820

Spark plug inspection The spark plug is an important engine component and is easy to inspect. The condition of the spark plug can indicate the condition of the engine. For example, a very white center electrode porcelain color could indicate an intake air leak or carburetion problem for that cylinder. Do not attempt to diagnose such problems yourself. Instead, take the ATV to a Yamaha dealer. You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode. If electrode erosion becomes excessive, you should replace the spark plug with one of the proper type.

Before installing the spark plug, measure the electrode gap with a wire thickness gauge and adjust it to specification. Spark plug gap: 0.6–0.7 mm (0.024–0.028 in)

a. Spark plug gap

When installing the spark plug, always clean the gasket surface and its mating surface. Wipe off any grime from the threads and tighten it to the specified torque.

Standard spark plug: DR8EA (NGK)

Tightening torque: Spark plug: 17.5 Nm (1.75 m·kgf, 12.5 ft·lbf) 8-17

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EBU13010

Air filter element cleaning NOTE: There is a check hose at the bottom of the air filter case. If dust or water collects in this hose, empty the hose and clean the air filter element and air filter case. _

1. Air filter case cover

2. Holder (Ă&#x2014; 3)

3. Pull the air filter element out.

1. Check hose

1. Remove the seat. (See page 4-15 for seat removal and installation procedures.) 2. Remove the air filter case cover by unhooking the holders.

1. Air filter element 8-18

U5FU15.book Page 19 Thursday, April 8, 2004 1:29 PM

4. Remove the foam cover from the air filter element.

1. Air filter element

5. Tap the element lightly to remove most of the dust and dirt. Blow out the remaining dirt with compressed air as shown. If the air filter element is damaged, replace it.

2. Foam cover

6. Wash the foam cover gently but thoroughly in water or solvent.

8-19

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10. Install the air filter element. 11. Install the air filter case cover by fastening the holders. 12. Install the seat.

WARNING POTENTIAL HAZARD Using low flash point solvents or gasoline to clean the foam cover. WHAT CAN HAPPEN Low flash point solvents or gasoline can catch fire or explode. HOW TO AVOID THE HAZARD Use parts cleaning solvent to clean the foam cover.

NOTE: The air filter element should be cleaned every 20–40 hours. It should be cleaned more often if the ATV is operated in extremely dusty areas. Each time air filter element maintenance is performed, check the air inlet to the air filter case for obstructions. Check the air filter element rubber joint to the carburetor and manifold fittings for an airtight seal. Tighten all fittings securely to avoid the possibility of unfiltered air entering the engine. _

7. Squeeze the excess water or solvent out of the foam cover and let it dry.

CAUTION: _

● ●

Do not twist the foam cover when squeezing it. Do not apply oil to the foam cover.

8. Inspect the foam cover. If damaged, replace it. 9. Install the foam cover onto the air filter element. 8-20

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EBU00754

Spark arrester cleaning Select a well-ventilated area free of combustible materials and make sure the exhaust pipe and muffler are cool. 1. Remove the purging bolt.

CAUTION: _

Never operate the engine with the air filter element removed. This will allow unfiltered air to enter, causing rapid engine wear and possible engine damage. Additionally, operation without the air filter element will affect carburetor jetting with subsequent poor performance and possible engine overheating. _

1. Purging bolt

2. Start the engine and rev it up approximately twenty times while momentarily creating exhaust system back pressure by blocking the end of the muffler with a shop towel. 3. Stop the engine and allow the exhaust pipe to cool. 4. Install the purging bolt and tighten it. 8-21

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EBU00296

Carburetor adjustment The carburetor is a vital part of the engine and requires very sophisticated adjustment. Most adjusting should be left to a Yamaha dealer who has the professional knowledge and experience to do so. However, the idling speed may be performed by the owner as a part of the usual maintenance routine.

WARNING POTENTIAL HAZARD Improperly purging the exhaust system. Hot exhaust system. WHAT CAN HAPPEN Could injure the eyes. Could cause burns. Could cause carbon monoxide poisoning, possibly leading to death. Could start a fire. HOW TO AVOID THE HAZARD When cleaning the spark arrester: Always let the exhaust system cool prior to touching exhaust components. Always wear eye protection, and make sure no one is behind the vehicle. Never run the engine in an enclosed area. Make sure there are no combustible materials in the area.

CAUTION: The carburetor was set at the Yamaha factory after many tests. If the settings are disturbed by someone without sufficient technical knowledge, poor engine performance and damage may result.

8-22

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EBU13020

Idle speed adjustment NOTE: A diagnostic tachometer must be used for this procedure. _

1. Start the engine and warm it up for a few minutes at approximately 1,000 to 2,000 r/min. Occasionally rev the engine to 4,000 to 5,000 r/min. The engine is warm when it quickly responds to the throttle. 2. Connect the tachometer to the spark plug lead, and then set the idle to the specified idling speed by adjusting the throttle stop screw. Turn the screw in direction a to increase the engine speed, and in direction b to decrease the engine speed.

1. Throttle stop screw

Specified idle speed: 1,450â&#x20AC;&#x201C;1,550 r/min

8-23

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EBU00303

EBU00307

Valve clearance adjustment The correct valve clearance changes with use, resulting in improper fuel/air supply or engine noise. To prevent this, the valve clearance must be adjusted regularly. This adjustment however, should be left to a professional Yamaha service technician.

Throttle lever adjustment NOTE: Adjust the engine idling speed before adjusting the throttle lever free play. 1. Loosen the locknut. 2. Turn the adjusting bolt until the throttle lever free play is 3â&#x20AC;&#x201C;5 mm (0.12â&#x20AC;&#x201C;0.20 in). 3. Tighten the locknut.

EBU03060

Reverse lock release cable adjustment The reverse lock release cable stretches with use, resulting in improper function. To prevent this, the cable must be adjusted regularly. This adjustment, however, should be left to a Yamaha dealer.

1. Locknut a. Throttle lever free play

8-24

2. Adjusting bolt

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EBU13031

EBU00313

Front brake pad check Inspect the brake pads for damage and wear. If the brake pad thickness is less than 1 mm (0.04 in), have a Yamaha dealer replace the pads as a set.

Rear brake shoe inspection A wear indicator is provided on the rear brake. This indicator allows checking of brake shoe wear without disassembling the brake. Apply the rear brake and check the position of the indicator. If the indicator reaches the wear limit line, ask a Yamaha dealer to replace shoes as a set.

a. Brake pad thickness

1. Wear indicator

8-25

2. Wear limit line

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EBU13040

Brake fluid level check Insufficient brake fluid may let air enter the brake system, possibly causing the brakes to become ineffective. Before riding, check that the brake fluid is above the minimum level mark and replenish if necessary. A low brake fluid level may indicate worn brake pads and/or brake system leakage. If the brake fluid level is low, be sure to check the brake pads for wear and the brake system for leakage. Observe these precautions: ● When checking the brake fluid level, make sure the top of the brake fluid reservoir is level. ● Use only the designated quality brake fluid, otherwise, the rubber seals may deteriorate, causing leakage and poor brake performance.

1. Minimum level mark ●

●

Recommended brake fluid: DOT 4

8-26

Refill with the same type of brake fluid. Mixing fluids may result in a harmful chemical reaction and lead to poor brake performance. Be careful that water does not enter the brake fluid reservoir when refilling. Water will significantly lower the boiling point of the fluid and may result in vapor lock.

U5FU15.book Page 27 Thursday, April 8, 2004 1:29 PM

EBU11860

●

Brake fluid replacement Complete fluid replacement should be done only by trained Yamaha service personnel. Have a Yamaha dealer replace the following components during periodic maintenance or when they are damaged or leaking. ● Replace the oil seals every two years. ● Replace the brake hoses every four years.

Brake fluid may deteriorate painted surfaces or plastic parts. Always clean up spilled fluid immediately. Have a Yamaha dealer check the cause if the brake fluid level goes down.

8-27

U5FU15.book Page 28 Thursday, April 8, 2004 1:29 PM

EBU11870

Front brake lever free play The front brake lever should have a free play of zero mm (zero in) at the lever end. If not, have a Yamaha dealer check the brake system.

WARNING POTENTIAL HAZARD Operating with improperly serviced or adjusted brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. HOW TO AVOID THE HAZARD After servicing: sure the brakes operate ● Make smoothly and that the free play is correct. ● Make sure the brakes do not drag. ● Make sure the brakes are not spongy. All air must be bled from the brake system. Replacement of brake components requires professional knowledge. These procedures should be performed by a Yamaha dealer.

a. Front brake lever free play

8-28

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EBU13052

Brake pedal and rear brake lever adjustment Brake pedal free play adjustment 1. Fully loosen the adjusting nut on the brake cable.

2. Turn the adjusting nut on the brake rod until the free play is 20â&#x20AC;&#x201C;30 mm (0.79â&#x20AC;&#x201C; 1.18 in).

a. Brake pedal free play

1. Adjusting nut (brake cable) 2. Adjusting nut (brake rod)

8-29

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Brake lever free play adjustment 1. Loosen the locknut and fully turn in the adjusting bolt at the brake lever.

1. Locknut

2. Turn in the adjusting nut on brake cable to provide a gap of 0â&#x20AC;&#x201C;1 mm (0â&#x20AC;&#x201C;0.04 in) between the camshaft lever and the pin.

2. Adjusting bolt

1. Adjusting nut (brake cable)

8-30

a. Gap

U5FU15.book Page 31 Thursday, April 8, 2004 1:29 PM

3. Turn the adjusting bolt until the free play at the brake lever pivot is 5–7 mm (0.20– 0.28 in).

WARNING POTENTIAL HAZARD Operating with improperly serviced or adjusted brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. HOW TO AVOID THE HAZARD After servicing: ● Make sure the brakes operate smoothly and that the free play is correct. ● Make sure the brakes do not drag. Replacement of brake components requires professional knowledge. These procedures should be performed by a Yamaha dealer.

1. Locknut 2. Adjusting bolt a. Rear brake lever free play

4. Tighten the locknut.

8-31

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EBU00834

Adjusting the rear brake light switch The rear brake light switch, which is activated by the brake pedal and brake levers, is properly adjusted when the brake light comes on just before braking takes effect. If necessary, adjust the brake light switch as follows. Turn the adjusting nut while holding the rear brake light switch in place. To make the brake light come on earlier, turn the adjusting nut in direction a. To make the brake light come on later, turn the adjusting nut in direction b.

1. Rear brake light switch 2. Rear brake light switch adjusting nut 8-32

U5FU15.book Page 33 Thursday, April 8, 2004 1:29 PM

EBU00346

Clutch adjustment 1. Loosen the locknut. 2. Slowly turn the adjusting bolt counterclockwise until resistance is felt. Then, turn it 1/8 turn clockwise.

1. Locknut

3. Tighten the locknut to specification. Tightening torque: 20 Nm (2.0 mÂˇkgf, 15 ftÂˇlbf) NOTE: Turn the adjusting bolt counterclockwise to decrease the clutch free play and turn it clockwise to increase the free play.

2. Adjusting bolt

8-33

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EBU00356

Cable inspection and lubrication

Lubricate the inner cables and the cable ends. If the cables do not operate smoothly, ask a Yamaha dealer to replace them.

WARNING POTENTIAL HAZARD Damaged control cables. WHAT CAN HAPPEN Corrosion can result when the outer covering of control cables becomes damaged. Cables can also become frayed or kinked. Operation of controls could be restricted, which could cause an accident or injury. HOW TO AVOID THE HAZARD Inspect cables frequently. Replace damaged cables.

Recommended lubricant: Yamaha chain and cable lube or SAE 10W30 motor oil

EBU00727

Brake and shift pedal/brake lever lubrication Lubricate the pivoting parts of each lever and pedal. Recommended lubricant: Lithium-soap-based grease (all-purpose grease)

8-34

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EBU01112

EBU01121

Wheel removal 1. Loosen the wheel nuts. 2. Elevate the ATV and place a suitable stand under the frame. 3. Remove the nuts from the wheel. 4. Remove the wheel.

Wheel installation 1. Install the wheel and the nuts. NOTE: â&#x2014;? Tapered nuts are used for both the front and rear wheels. Install the nut with its tapered side towards the wheel. â&#x2014;? The arrow mark on the tire must point toward the rotating direction of the wheel. _

1. Tapered nut

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1. Arrow mark

2. Lower the ATV so that the wheel is on the ground. 3. Tighten the wheel nuts to the specified torque. Wheel nut torque: Front: 64 Nm (6.4 m路kgf, 46 ft路lbf) Rear: 55 Nm (5.5 m路kgf, 40 ft路lbf)

8-36

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EBU00380

Battery This machine is equipped with a sealed-type battery. Therefore it is not necessary to check the electrolyte or add distilled water in the battery. If the battery seems to have discharged, consult a Yamaha dealer.

HOW TO AVOID THE HAZARD Avoid contact with skin, eyes or clothing. Always shield eyes when working near batteries. Keep out of reach of children. Antidote: EXTERNAL: Flush with water. INTERNAL: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or vegetable oil. Get prompt medical attention. EYES: Flush with water for 15 minutes and get prompt medical attention. Keep batteries away from sparks, flames, cigarettes or other sources of ignition. Ventilate when charging or using in a closed space.

CAUTION: Do not try to remove the sealing caps of the battery cells. You may damage the battery.

WARNING POTENTIAL HAZARD Failure to handle batteries or battery electrolyte carefully. WHAT CAN HAPPEN You could be poisoned. You could be severely burned by the sulfuric acid in battery electrolyte. Batteries produce explosive gases. 8-37

U5FU15.book Page 38 Thursday, April 8, 2004 1:29 PM

EBU00385

Battery maintenance 1. When the machine is not used for a month or longer, remove the battery and store it in a cool, dark place. Completely recharge the battery before reinstallation.

CAUTION: A special battery charger (constant voltage/ampere or constant voltage) is required for recharging a sealed-type battery. Using a conventional battery charger may shorten the battery life. 2. Always make sure the connections are correct when putting the battery back in the machine.

8-38

U5FU15.book Page 39 Thursday, April 8, 2004 1:29 PM

EBU00853

Fuse replacement 1. The main fuse case and the fuse box are located under the seat. 2. If a fuse is blown, turn off the main switch and install a new fuse of the specified amperage. Then turn on the switches. If the fuse immediately blows again, consult a Yamaha dealer. Specified fuses: Main fuse: Headlight fuse: Ignition fuse: Auxiliary DC jack fuse: Carburetor warmer fuse: Four-wheel-drive fuse:

1. Main fuse

30 A 15 A 10 A 10 A 10 A 3A

2. Four-wheel-drive fuse 3. Spare main fuse

1. Headlight fuse 3. Auxiliary DC jack fuse 5. Spare fuse (Ă&#x2014; 2) 8-39

2. Ignition fuse 4. Carburetor warmer fuse

U5FU15.book Page 40 Thursday, April 8, 2004 1:29 PM

WARNING POTENTIAL HAZARD Using an improper fuse. WHAT CAN HAPPEN An improper fuse can cause damage to the electrical system which could lead to a fire. HOW TO AVOID THE HAZARD Always use a fuse of the specified rating. Never use a material in place of the proper fuse.

CAUTION: _

To prevent accidental short-circuiting, turn off the main switch when checking or replacing a fuse. _

8-40

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EBU13061

Replacing a headlight bulb If a headlight bulb burns out, replace the bulb as follows. 1. Remove the headlight assembly by removing the screws. 2. Disconnect the headlight coupler.

1. Screw (Ă&#x2014; 3)

4. Remove the headlight bulb holder cover. 5. Push the headlight bulb holder inward, turn it counterclockwise, and then remove the defective bulb. 1. Screw (Ă&#x2014; 2)

2. Headlight coupler

3. Remove the headlight unit from the headlight assembly by removing the screws.

8-41

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6. Put a new headlight bulb into position, and then secure it in place with the bulb holder.

1. Headlight bulb holder cover

2. Headlight bulb holder

WARNING POTENTIAL HAZARD A headlight bulb is hot when it is on and immediately after it is turned off. WHAT CAN HAPPEN You can be burned, or a fire could start if the bulb touches something flammable. HOW TO AVOID THE HAZARD Wait for the bulb to cool before touching or removing it.

1. Do not touch the glass part of the bulb.

CAUTION: _

Do not touch the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the luminosity of the bulb, and the bulb life will be adversely affected. Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with alcohol or thinner. 8-42

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EBU01089

Headlight beam adjustment

7. Install the headlight bulb holder cover.

CAUTION:

Make sure the headlight bulb holder cover is securely fitted over the bulb holder and seated against the reflector.

It is advisable to have a Yamaha dealer make this adjustment. _

To raise the beam, turn the adjusting screw in direction a. To lower the beam, turn the adjusting screw in direction b.

8. Place the headlight unit in the original position, and then install the screws. 9. Connect the headlight coupler. 10. Place the headlight assembly in the original position, and then install the screws. 11. Adjust the headlight beam if necessary.

1. Headlight beam adjusting screw (Ă&#x2014; 2)

8-43

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EBU09452

Tail/brake light bulb replacement 1. Open the storage box. (See page 4-16.) 2. Remove the nuts together with the washers.

1. Bulb holder

4. Remove the defective bulb from the bulb holder by pushing it inward and turning it counterclockwise. 1. Storage box

2. Nut (Ă&#x2014; 2)

3. Remove the bulb holder (together with the bulb) by turning it counterclockwise.

8-44

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EBU00412

1. Bulb holder

Troubleshooting Although Yamaha machines receive a rigid inspection before shipment from the factory, trouble may occur during operation. Any problem in the fuel, compression, or ignition systems can cause poor starting and loss of power. The troubleshooting chart describes a quick, easy procedure for making checks. If your machine requires any repair, take it to a Yamaha dealer. The skilled technicians at a Yamaha dealership have the tools, experience, and knowhow to properly service your machine. Use only genuine Yamaha parts on your machine. Imitation parts may look like Yamaha parts, but they are often inferior. Consequently, they have a shorter service life and can lead to expensive repair bills.

2. Bulb

5. Install a new bulb in the bulb holder by pushing it inward and turning it clockwise. 6. Install the bulb holder (together with the bulb) by turning it clockwise. 7. Install the washers, and then install the nuts. 8. Close the storage box.

8-45

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WARNING POTENTIAL HAZARD Checking the fuel system while smoking or near an open flame. WHAT CAN HAPPEN Fuel can ignite or explode, causing severe injury or property damage. HOW TO AVOID THE HAZARD Do not smoke when checking the fuel system. Make sure there are no open flames or sparks in the area, including pilot lights from water heaters or furnaces.

8-46

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EBU00440

Troubleshooting chart Turn the fuel cock lever to “ON”.

There is fuel.

Turn the fuel cock lever to “OFF”.

Remove the fuel hose from the fuel cock.

Some fuel.

Turn the fuel cock lever to “RES”.

Restart the engine.

No fuel.

Supply fuel.

1. Fuel Check if there is fuel in the fuel tank.

2. Compression Use the electric starter to see if there is compression.

3. Ignition

There is compression.

Compression normal.

No compression.

Ask a Yamaha dealer to inspect.

Wet

Dry

Wipe clean with dry cloth.

Attach spark plug cap and ground to chassis.

Use the electric starter.

Battery is good.

Engine turns over slowly.

Check the battery lead connections, and charge the battery if necessary.

Ignition system is normal.

Adjust the spark plug gap or replace the spark plug.

Use the electric starter.

8-47

Fuel cock is clogged.

Spark is weak.

No spark.

Engine turns over quickly.

No fuel.

Clean the fuel cock.

Spark is good.

Remove the spark plug and check the electrodes.

4. Battery

Check the fuel flow.

Ask a Yamaha dealer to inspect.

U5FU15.book Page 1 Thursday, April 8, 2004 1:29 PM

EBU00419

CLEANING AND STORAGE

CAUTION:

Excessive water pressure may cause water seepage and deterioration of wheel bearings, brakes, transmission seals and electrical devices. Many expensive repair bills have resulted from improper high pressure detergent applications such as those available in coin-operated car washers.

A. CLEANING Frequent, thorough cleaning of your machine will not only enhance its appearance but will improve its general performance and extend the useful life of many components. 1. Before cleaning the machine: a. Block off the end of the exhaust pipe to prevent water entry. A plastic bag and strong rubber band may be used. b. Make sure the spark plug and all filler caps are properly installed. 2. If the engine case is excessively greasy, apply degreaser with a paint brush. Do not apply degreaser to the wheel axles. 3. Rinse the dirt and degreaser off with a garden hose. Use only enough pressure to do the job.

1 2 3 4 5 6 7

4. Once the majority of the dirt has been hosed off, wash all surfaces with warm water and mild, detergent-type soap. An old toothbrush or bottle brush is handy for hard-to-get-at places. 5. Rinse the machine off immediately with clean water and dry all surfaces with a chamois, clean towel or soft absorbent cloth.

8 9 10 11 12 13 14

9-1

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6. Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy. 7. Automotive type wax may be applied to all painted and chrome plated surfaces. Avoid combination cleaner-waxes. Many contain abrasives which may mar the paint or protective finish. When finished, start the engine and let it idle for several minutes.

WARNING POTENTIAL HAZARD Operation with wet brakes after washing. WHAT CAN HAPPEN Wet brakes may have reduced stopping ability, increasing the chance of an accident. HOW TO AVOID THE HAZARD Test the brakes after washing. Apply the brakes several times at slow speeds to let friction dry out the linings.

9-2

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EBU00530

B. STORAGE Long term storage (60 days or more) of your machine will require some preventive procedures to guard against deterioration. After thoroughly cleaning the machine, prepare for storage as follows: 1. Fill the fuel tank with fresh fuel and add the specified amount of Yamaha Fuel Stabilizer and Conditioner or an equivalent product.

2. Remove the spark plug, pour about one tablespoon of SAE 10W30 or 20W40 motor oil in the spark plug hole and reinstall the spark plug. Ground the spark plug wire and turn the engine over several times to coat the cylinder wall with oil. 3. Lubricate all control cables. 4. Block up the frame to raise all wheels off the ground. 5. Tie a plastic bag over the exhaust pipe outlet to prevent moisture from entering. 6. If storing in a humid or salt-air atmosphere, coat all exposed metal surfaces with a light film of oil. Do not apply oil to any rubber parts or the seat cover.

Specified amount: 1 oz of stabilizer to each gallon of fuel (or 7.5 cc of stabilizer to each liter of fuel) NOTE: Use of fuel stabilizer and conditioner eliminates the need to drain the fuel system. Consult a Yamaha dealer if the fuel system needs to be drained instead.

9-3

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7. Remove the battery and charge it. Store it in a dry place and recharge it once a month. Do not store the battery in an excessively warm or cold place (less than 0 째C (30 째F) or more than 30 째C (90 째F)). NOTE: Make any necessary repairs before storing the machine.

9-4

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EBU00428

SPECIFICATIONS 1 MODEL

YFM400F

Dimension: Overall length Overall width Overall height Seat height Wheel base Ground clearance Minimum turning radius

2,007 mm ( 79.0 in) 1,111 mm ( 43.7 in) 1,172 mm ( 46.1 in) 855 mm ( 33.7 in) 1,230 mm ( 48.4 in) 245 mm ( 9.65 in) 3,150 mm (124.0 in)

2 3 4 5 6 7

Basic weight: With oil and full fuel tank

266 kg (586 lb)

Engine: Engine type Cylinder arrangement Displacement Bore × Stroke Compression ratio Starting system Lubrication system

Air cooled, 4-stroke, SOHC Single cylinder, Forward inclined 386 cm3 83.0 × 71.5 mm (3.27 × 2.81 in) 8.6 : 1 Electric starter and recoil starter Wet sump

9 10 11 12 13 14

10-1

U5FU15.book Page 2 Thursday, April 8, 2004 1:29 PM

MODEL

YFM400F

Engine oil: Type

0˚

10˚

30˚

50˚

70˚

90˚

110˚

130˚F

YAMALUBE 4 (20W40) or SAE 20W40 YAMALUBE 4 (10W30) or SAE 10W30 SAE 5W30

-20˚

Recommended engine oil classification:

-10˚

0˚

10˚

20˚

30˚

40˚

50˚C

API Service SE, SF, SG type or higher CAUTION: In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemical additives. Do not use oils with a diesel specification of “CD” or oils of a higher quality than specified. In addition, do not use oils labeled “ENERGY CONSERVING II” or higher.

Quantity: Without oil filter element replacement With oil filter element replacement

2.90 L (2.55 Imp qt, 3.07 US qt) 3.00 L (2.64 Imp qt, 3.17 US qt)

10-2

U5FU15.book Page 3 Thursday, April 8, 2004 1:29 PM

MODEL

YFM400F

Final gear oil: Type Quantity

SAE 80 API GL-4 Hypoid gear oil 0.23 L (0.20 lmp qt, 0.24 US qt)

Differential gear oil: Type Quantity

SAE 80 API GL-4 Hypoid gear oil 0.35 L (0.31 Imp qt, 0.37 US qt)

Air filter:

Dry element

Fuel: Type Tank capacity Reserve amount

UNLEADED GASOLINE ONLY 15.0 L (3.30 Imp gal, 3.96 US gal) 4.0 L (0.88 Imp gal, 1.06 US gal)

Carburetor: Type/manufacturer

BSR33 / MIKUNI

Spark plug: Type/manufacturer Gap

DR8EA / NGK 0.6–0.7 mm (0.024–0.028 in)

Clutch type:

Wet, centrifugal automatic

10-3

U5FU15.book Page 4 Thursday, April 8, 2004 1:29 PM

MODEL Transmission: Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Transmission type Operation Gear raito:

YFM400F Spur gear 76/24 (3.166) Shaft drive 28/24 × 24/18 × 33/09 (5.703) Constant mesh 5-speed forward, 1-speed reverse Left foot operation 40/12 (3.333) 34/18 (1.888) 30/22 (1.363) 25/26 (0.961) 19/27 (0.703) 22/17 × 35/15 (3.019)

1st 2nd 3rd 4th 5th

Reverse gear Chassis: Frame type Caster angle Trail

Steel tube frame 4° 21 mm (0.83 in)

Tire: Type Size: Front Size: Rear

Tubeless AT25 × 8-12 AT25 × 10-12

Brake: Front brake type Operation Rear brake type Operation

Dual disc brake Right hand operation Drum brake Left hand and right foot operation 10-4

U5FU15.book Page 5 Thursday, April 8, 2004 1:29 PM

MODEL

YFM400F

Suspension: Front Rear

Double wishbone Swingarm (monocross)

Shock absorber: Front Rear

Coil spring / oil damper Coil spring / oil damper

Wheel travel: Front wheel travel Rear wheel travel

150 mm (5.91 in) 150 mm (5.91 in)

Electrical: Ignition system Generator system Battery type/voltage, capacity

DC. C.D.I. A.C. magneto YTX20L-BS/12 V, 18 Ah

Headlight type:

Krypton bulb

Bulb voltage, wattage × quantity: Headlight Tail/brake light Meter lighting Indicator/warning light: Neutral Reverse Oil temparature Four-wheel-drive

12 V, 30 W/30 W × 2 12 V, 5 W/21 W × 1 12 V, 3.4 W × 1 12 V, 1.7 W × 1 12 V, 1.7 W × 1 12 V, 1.7 W × 1 12 V, 1.7 W × 1

10-5

U5FU15.book Page 6 Thursday, April 8, 2004 1:29 PM

MODEL

YFM400F

Specified fuses: Main fuse Headlight fuse Ignition fuse Auxiliary DC jack fuse Carburetor warmer fuse Four-wheel-drive fuse

30 A 15 A 10 A 10 A 10 A 3A

10-6

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EBU00430

NOISE REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. “AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW.” These acts include tampering with the following systems; i.e., modification, removal, etc.

Exhaust system

Muffler Exhaust pipe Silencer

Intake system

Air cleaner case Air cleaner element Intake duct

11-1

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EBU13653 1-

MAINTENANCE RECORD

Copies of work orders and/or receipts for parts you purchase and install will be required to document maintenance done in accordance with the warranty. The chart below is printed only as a reminder to you that the maintenance work is required. It is not acceptable proof of maintenance work. ACL-06E

1 2 3 4 5

MAINTENANCE INTERVAL

DATE OF SERVICE

MILEAGE

SERVICING DEALER NAME AND ADDRESS

REMARKS

month

km (mi)

hours

320 (200)

7 8

1,200 (750)

2,400 (1,500)

150

4,800 (3,000)

300

7,200 (4,500)

450

9,600 (6,000)

600

12,000 (7,500)

750

14,400 (9,000)

900

16,800 (10,500) 1,050

19,200 (12,000) 1,200

21,600 (13,500) 1,350

24,000 (15,000) 1,500

11 12 13 14

12-1

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EBU00432

YAMAHA MOTOR CORPORATION, U.S.A. ATV LIMITED WARRANTY

13-1

U5FU15.book Page 2 Thursday, April 8, 2004 1:29 PM

1 2 3 4 5 6 7 8 9 10 9 9 13 14

13-2

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EBU00435

YAMAHA EXTENDED SERVICE (Y.E.S.)

14-1

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1 2 3 4 5 6 7 8 9 10 9 9 9 EBU00436

WARNING Indicates a potential hazard that could result in serious injury or death. 14-2

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EBU00437

EBU00438

READ THIS MANUAL CAREFULLY! It contains important safety information.

WARNING Improper ATV use can result in SEVERE INJURY or DEATH.

BEER BEER

ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR

NEVER USE ON PUBLIC ROADS

NEVER CARRY PASSENGERS

NEVER USE WITH DRUGS OR ALCOHOL

OWNER’S MANUAL

NEVER operate:

YFM400FT WARNING

YAMAHA MOTOR CO., LTD.

PRINTED IN USA 2004.04-1.0×1 CR (E)

LIT-11626-18-08

This ATV should not be ridden by anyone under 16 years of age.

5FU-F8199-15