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Yamaha 5KM2-AE1, Service Manual

The Yamaha 5KM2-AE1 is a high-quality product that serves as the perfect companion for those seeking exceptional performance. With its comprehensive service manual, users can easily access all the necessary information they need for efficient operation and maintenance. Download this manual for free from 88.208.23.73:8080 and experience the full potential of your Yamaha 5KM2-AE1.

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CHAPTER 9.

ELECTRICAL

ELECTRICAL COMPONENTS 

..................................................................... 9-1

CHECKING THE SWITCH 

............................................................................ 9-2

CHECKING THE SWITCH  .................................................................... 9-2
CHECKING A SWITCH SHOWN IN THE MANUAL  ............................. 9-2
CHECKING THE SWITCH CONTINUITY  ............................................. 9-3

CHECKING THE BULBS AND BULB SOCKETS 

....................................... 9-5

TYPES OF BULBS ................................................................................ 9-5
CHECKING THE CONDITION OF THE BULBS  ................................... 9-5
CHECKING THE CONDITION OF THE BULB SOCKETS  ................... 9-7

IGNITION SYSTEM 

...................................................................................... 9-8

CIRCUIT DIAGRAM  .............................................................................. 9-8
TROUBLESHOOTING .......................................................................... 9-9

ELECTRIC STARTING SYSTEM 

............................................................... 9-14

CIRCUIT DIAGRAM  ............................................................................ 9-14
STARTING CIRCUIT OPERATION  .................................................... 9-15
TROUBLESHOOTING ........................................................................ 9-16
STARTER MOTOR  ............................................................................. 9-20
CHECKING THE STARTER MOTOR  ................................................. 9-21
ASSEMBLING THE STARTER MOTOR ............................................. 9-22

CHARGING SYSTEM 

................................................................................. 9-23

CIRCUIT DIAGRAM  ............................................................................ 9-23
TROUBLESHOOTING ........................................................................ 9-24

LIGHTING SYSTEM 

................................................................................... 9-26

CIRCUIT DIAGRAM  ............................................................................ 9-26
TROUBLESHOOTING ........................................................................ 9-27
CHECKING THE LIGHTING SYSTEM  ............................................... 9-29

SIGNAL SYSTEM 

....................................................................................... 9-31

CIRCUIT DIAGRAM  ............................................................................ 9-31
TROUBLESHOOTING ........................................................................ 9-33
CHECKING THE SIGNAL SYSTEM  ................................................... 9-35

COOLING SYSTEM 

.................................................................................... 9-46

CIRCUIT DIAGRAM  ............................................................................ 9-46
TROUBLESHOOTING   ....................................................................... 9-47

Summary of Contents for 5KM2-AE1

Page 1: ...YFM660F P 5KM2 AE1 SERVICEMANUAL 2002 ...

Page 2: ......

Page 3: ... P 2002 SERVICE MANUAL 2001 by Yamaha Motor Co Ltd First edition May 2001 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited ...

Page 4: ...fications and sig nificant 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 ...

Page 5: ...ntify parts and clarify procedure steps there are exploded diagrams at the start of each removal and disassembly section 1 An easy to see exploded diagram 4 is provided for removal and disassembly jobs 2 Numbers 5 are given in the order of the jobs in the exploded diagram A number that is enclosed by a circle indicates a disassembly step 3 An explanation of jobs and notes is presented in an easy t...

Page 6: ...D Special tool E Torque F Wear limit clearance G Engine speed H Ω V A Illustrated symbols I to N in the exploded diagrams indicate the types of lubricants and lubrication points I Apply engine oil J Apply gear oil K Apply molybdenum disulfide oil L Apply wheel bearing grease M Apply lightweight lithium soap base grease N Apply molybdenum disulfide grease Illustrated symbols O to P in the exploded ...

Page 7: ...AL INFORMATION GEN INFO 1 SPECIFICATIONS SPEC 2 PERIODIC CHECKS AND ADJUSTMENTS CHK ADJ 3 ENGINE ENG 4 COOLING SYSTEM COOL 5 CARBURETION CARB 6 DRIVE TRAIN DRIV 7 CHASSIS CHAS 8 ELECTRICAL ELEC 9 TROUBLESHOOTING TRBL SHTG 10 ...

Page 8: ......

Page 9: ...GEN INFO 1 ...

Page 10: ... 1 1 FEATURES 1 2 FRONT DIFFERENTIAL 1 2 TRANSMISSION 1 9 IMPORTANT INFORMATION 1 10 PREPARATION FOR REMOVAL PROCEDURES 1 10 REPLACEMENT PARTS 1 10 GASKETS OIL SEALS AND O RINGS 1 10 LOCK WASHERS PLATES AND COTTER PINS 1 11 BEARINGS AND OIL SEALS 1 11 CIRCLIPS 1 11 CHECKING OF CONNECTIONS 1 12 SPECIAL TOOLS 1 13 ...

Page 11: ...GEN INFO ...

Page 12: ...FORMATION MACHINE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the left side of the frame MODEL LABEL The model label 1 is affixed to the frame This information will be needed to order spare parts ...

Page 13: ...RONT DIFFERENTIAL 1 Adapter 2 Drive clutch 3 Differential side gear left 4 Differential pinion gear 5 Ring gear 6 Differential side gear right 7 Drive pinion gear 8 Gear motor È To front wheel É From the middle gear FEATURES ...

Page 14: ...ront drive shaft drive pinion gear 7 ring gear 5 differential pinion gear 4 In the 2WD mode the left differential side gear 3 and the drive clutch 2 are not engaged therefore the left side gear runs idle and does not transmit power to the left front constant velocity joint ...

Page 15: ...tch 2 adapter 1 left front constant velocity joint Meanwhile power from the differential pinion gear 4 is transmitted to the right front constant veloc ity joint via the right differential side gear 6 The ring gear 5 and the drive clutch 2 are not engaged at this time Therefore the rotational differ ence that occurs between the right and left wheels while the handlebar is being turned is absorbed ...

Page 16: ... Meanwhile because the ring gear 5 and the drive clutch 2 are engaged the ring gear 5 the drive clutch 2 and the right differential side gear 6 become locked coaxially Thus power is transmitted as follows differential pinion gear 4 right differential pinion gear 6 right front constant veloc ity joint When the ATV is in the 4WD Diff Lock mode the right and left wheels rotate constantly at the same ...

Page 17: ... lock indicator light in the speedometer unit will flash to alert the driver that the control is on standby When the ATV is stopped the control transfers to the condition described in 2 2 When the ATV is stopped The gear motor operates to connect the drive clutch to the differential case thus resulting in the differential lock condition When this occurs the differential gear lock indicator light i...

Page 18: ...1 7 FEATURES Shift mechanism A new shift mechanism with a parking position has been added to the YFM660F 1 Shift cam 2 Shift fork guide bar 3 Drive axle 4 Stopper lever shaft L L H N R P H N R P 1 2 3 4 1 2 3 4 ...

Page 19: ...Then the stopper lever tab pushes against the drive axle stopper to lock the drive axle 3 Not synchronized If the stopper lever tab and the drive axle stopper are not synchronized the torsion spring is compressed As a result the spring pushes the stopper lever tab against the drive axle stopper and waits until the synchronization is completed When the stop lever tab and the drive axle are synchron...

Page 20: ... When the transmission is in either the low or high mode the drive axle is driven via the sec ondary shaft and gear Therefore the rotation of the drive axle is the opposite of the second ary shaft R Reverse mode When the transmission is in the reverse mode the drive axle is driven via the drive chain Therefore the rotation of the drive axle is the same as the secondary shaft As a result the rotati...

Page 21: ...parts and place them in trays in the order of disas sembly This will speed up assembly and allow for the correct installation of all parts 5 Keep all parts away from any source of fire EB101010 REPLACEMENT PARTS 1 Use only genuine Yamaha parts for all replacements Use oil and grease recom mended by Yamaha for all lubrication jobs Other brands may be similar in function and appearance but inferior ...

Page 22: ...oil seals apply a light coat ing of lightweight lithium base grease to the seal lips Oil bearings liberally when install ing if appropriate 1 Oil seal CAUTION Do not use compressed air to spin the bearings dry This will damage the bearing surfaces 1 Bearing EB101050 CIRCLIPS 1 Check all circlips carefully before reassem bly Always replace piston pin clips after one use Replace distorted circlips W...

Page 23: ...terminals several times 3 Check Connector leads Looseness Bend up the pin 1 and con nect the terminals 4 Connect Connector terminals NOTE The two terminals click together 5 Check Continuity using a pocket tester NOTE If there is no continuity clean the terminals When checking the wire harness be sure to perform steps 1 to 3 As a quick remedy use a contact revitalizer available at most part stores ...

Page 24: ...tool is used to install the crankshaft Bolt 90890 01083 Weight 90890 01084 Set YU 01083 A Slide hammer bolt M6 weight set These tools are used to remove the rocker arm shaft 90890 01135 YU 01135 A Crankcase separating tool This tool is used to separate the crank case 90890 01229 YM 01230 Coupling gear middle shaft tool This tool is needed when removing or installing the coupling gear nut 90890 012...

Page 25: ...sed to check the cooling sys tem 90890 01327 YM 01327 Damper rod holder 30 mm This tool is needed to loosen and tighten the steering stem bearing retainer 90890 01348 Locknut wrench This tool is needed when removing or installing the secondary sheave spring 90890 01352 YU 33984 Radiator cap tester adapter This tool is used to check the cooling sys tem 90890 01404 YM 01404 Flywheel puller These too...

Page 26: ...ne compression 90890 03112 YU 03112 Pocket tester This instrument is needed for checking the electrical system 90890 03113 Engine tachometer This tool is needed for observing engine rpm 90890 03141 YM 33277 A Timing light This tool is necessary for checking igni tion timing Compressor 90890 04019 YM 04019 Attachment 90890 01243 Valve spring compressor Valve spring compressor attachment This tool i...

Page 27: ...tall the valve guide 90890 04066 YM 04066 Valve guide reamer ø 6 This tool is needed to rebore the new valve guide 90890 04086 YM 91042 Universal clutch holder This tool is needed to hold the clutch car rier when removing or installing the car rier nut 90890 04128 YM 04128 Bearing retainer wrench This tool is needed when removing or installing the middle driven pinion gear bearing retainer 90890 0...

Page 28: ...1215 Sealant Quick Gasket This sealant bond is used on crankcase mating surfaces etc YM 34487 Dynamic spark tester This instrument is necessary for checking the ignition system components YU 8036 A Inductive tachometer This tool is needed for observing engine rpm YU 90050 Crankshaft installer set These tools are used to install the crank shaft Tool No Tool name How to use Illustration ...

Page 29: ......

Page 30: ...SPEC 2 ...

Page 31: ...TENANCE SPECIFICATIONS 2 4 ENGINE 2 4 CHASSIS 2 14 ELECTRICAL 2 18 HOW TO USE THE CONVERSION TABLE 2 20 GENERAL TORQUE SPECIFICATIONS 2 20 LUBRICATION POINTS AND LUBRICANT TYPES 2 21 ENGINE 2 21 COOLANT FLOW DIAGRAMS 2 22 OIL FLOW DIAGRAMS 2 24 CABLE ROUTING 2 27 ...

Page 32: ...SPEC ...

Page 33: ...ith oil and full fuel tank 290 kg 639 lb Engine Engine type Liquid cooled 4 stroke SOHC Cylinder arrangement Forward inclined single cylinder Displacement 660 cm3 Bore stroke 100 84 mm 3 94 3 31 in Compression ratio 9 1 1 Standard compression pressure at sea level 1 324 kPa 13 24 kg cm2 188 31 psi at 850 r min Starting system Electric and recoil starter Lubrication system Wet sump Oil type or grad...

Page 34: ...a Fuel tank capacity 20 L 4 4 lmp gal 5 3 US gal Fuel reserve amount 3 5 L 0 77 lmp gal 0 92 US gal Carburetor Type quantity BSR42 1 Manufacturer MIKUNI Spark plug Type manufacturer DPR8EA 9 NGK Spark plug gap 0 8 0 9 mm 0 03 0 04 in Clutch type Wet centrifugal automatic Transmission Primary reduction system V belt Secondary reduction system Shaft drive Secondary reduction ratio 39 24 24 18 33 9 7...

Page 35: ...ration Right hand operation Rear brake type Single disc brake operation Left hand and right foot operation Suspension Front suspension Double wishbone Rear suspension Double wishbone Shock absorber Front shock absorber Coil spring oil damper Rear shock absorber Coil spring oil damper Wheel travel Front wheel travel 170 mm 6 69 in Rear wheel travel 225 mm 8 86 in Electrical Ignition system DC C D I...

Page 36: ...ring point 50 mm 1 97 in Camshaft Drive method Chain drive Left Cam dimensions Intake A 35 69 35 79 mm 1 4051 1 4091 in 35 59 mm 1 4012 in B 30 06 30 16 mm 1 1835 1 1874 in 29 96 mm 1 1795 in C 5 53 5 73 mm 0 2177 0 2256 in Exhaust A 36 5 36 6 mm 1 4370 1 4409 in 36 4 mm 1 4331 in B 30 11 30 21 mm 1 1854 1 1894 in 30 01 mm 1 1815 in C 6 29 6 49 mm 0 2476 0 2555 in Camshaft runout limit 0 03 mm 0 0...

Page 37: ... 1 2638 in B face width IN 2 25 mm 0 0900 in EX 2 26 mm 0 0890 in C seat width IN 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in EX 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in D margin thickness IN 0 85 1 15 mm 0 0335 0 0452 in EX 0 85 1 15 mm 0 0335 0 0452 in Stem outside diameter IN 5 975 5 990 mm 0 2352 0 2358 in 5 945 mm 0 2341 in EX 5 960 5 975 mm 0 2346 0 2352 in 5 930 mm 0 2335 in Guide insi...

Page 38: ...N 32 63 mm 1 28 in 31 0 mm 1 22 in EX 36 46 mm 1 44 in 34 6 mm 1 36 in Set length valve closed IN 27 5 mm 1 08 in EX 31 0 mm 1 22 in Compressed pressure installed IN 100 0 115 7 N 10 2 11 8 kg 22 48 26 01 lb EX 120 6 138 3 N 12 3 14 1 kg 27 11 31 09 lb Tilt limit IN 2 5 1 4 mm 2 5 0 06 in EX 2 5 1 6 mm 2 5 0 06 in Direction of winding top view IN Clockwise EX Clockwise Item Standard Limit ...

Page 39: ...set direction Intake side Piston pin bore inside diameter 22 004 22 015 mm 0 8663 0 8667 in 22 045 mm 0 8679 in Piston pin outside diameter 21 991 22 000 mm 0 8658 0 8661 in 21 971 mm 0 8650 in Piston rings Top ring Type Barrel Dimensions B T 1 2 3 8 mm 0 0472 0 1496 in End gap installed 0 30 0 45 mm 0 0118 0 0177 in 0 70 mm 0 0276 in Side clearance installed 0 04 0 08 mm 0 0016 0 0031 in 0 13 mm ...

Page 40: ... Side clearance 0 06 0 15 mm 0 0024 0 0059 in Crankshaft Crank width A 74 95 75 00 mm 2 9508 2 9528 in Runout limit C1 0 03 mm 0 0012 in C2 0 03 mm 0 0012 in Big end side clearance D 0 35 0 65 mm 0 0138 0 0256 in 1 0 mm 0 0394 in Big end radial clearance E 0 010 0 025 mm 0 0004 0 0010 in Balancer Balancer drive method Gear Automatic centrifugal clutch Clutch shoe thickness 1 5 mm 0 06 in 1 0 mm 0 ...

Page 41: ...ss 3 B P 3 0 8 Pilot screw turns out 3 Valve seat size V S 3 0 Starter jet G S 1 55 Starter jet G S 2 0 8 Throttle valve size Th V 105 Float height F H 13 mm 0 51 in Fuel level F L 4 5 mm 0 18 in Engine idle speed 1 450 1 550 r min Intake vacuum 30 7 33 3 kPa 230 250 mmHg 9 07 9 83 inHg Oil pump Oil filter type Foam Oil pump type Trochoid Tip clearance A or B 0 03 0 10 mm 0 0012 0 0039 in 0 15 mm ...

Page 42: ... Water pump Type Single suction centrifugal pump Reduction ratio 32 31 1 032 Thermostat Valve opening temperature 50 54 C 122 0 129 2 F Valve full open temperature 70 C 158 F Valve lift full open 8 mm 0 31 in Shaft drive Middle gear backlash 0 1 0 3 mm 0 004 0 012 in Final gear backlash 0 1 0 2 mm 0 004 0 008 in Differential gear backlash 0 05 0 25 mm 0 002 0 010 in Lubrication chart Item Standard...

Page 43: ...2 11 SPEC MAINTENANCE SPECIFICATIONS Item Standard Cylinder head tightening sequence ...

Page 44: ...2 10 1 0 7 2 Valve adjusting screw Nut M6 5 14 1 4 10 Radiator Bolt M6 2 7 0 7 5 1 Coolant drain bolt Bolt M6 1 10 1 0 7 2 Engine oil drain bolt Bolt M14 1 30 3 0 22 Oil delively pipe 1 Union bolt M8 2 18 1 8 13 Oil delively pipe 2 Union bolt M14 2 35 3 5 25 Oil delively pipe 3 Union bolt M10 1 20 2 0 14 Bolt M6 1 10 1 0 7 2 Oil filter cartridge M20 1 17 1 7 12 Oil filter bolt Union bolt M20 1 63 ...

Page 45: ...4 1 97 9 7 70 Yoke middle driven gear Nut M14 1 97 9 7 70 Middle driven gear bearing housing Bolt M8 4 25 2 5 18 Middle driven shaft bearing retainer Nut M55 1 80 8 0 58 LT Left hand threads Sift arm Bolt M6 1 14 1 4 10 Shift rod Nut M8 2 15 1 5 11 Shift lever Bolt M6 1 14 1 4 10 Shift control cable M12 1 6 0 6 4 3 Select lever unit Bolt M8 3 15 1 5 11 Gear position switch Bolt M6 2 7 0 7 5 1 Reve...

Page 46: ...1 0 86 mm 0 3 39 in Optional spring No Rear suspension Shock absorber travel 95 mm 3 74 in Spring free length 277 mm 10 91 in for CDN 284 mm 11 18 in for Europe Oceania Spring fitting length 235 5 mm 9 27 in Spring rate K1 36 4 N mm 3 71 kg mm 207 84 lb in Stroke K1 0 95 mm 0 3 74 in Optional spring No Front wheel Type Panel wheel Rim size 12 6 0 AT Rim material Aluminum Rim runout limit radial 2 ...

Page 47: ...26 in Brake fluid type DOT 4 Rear disc brake Type Single Disc outside diameter thickness 150 0 8 5 mm 5 91 0 33 in Pad thickness inner 7 0 mm 0 28 in 1 mm 0 04 in Pad thickness outer 7 0 mm 0 28 in 1 mm 0 04 in Master cylinder inside diameter 14 mm 0 55 in Caliper cylinder inside diameter 22 65 mm 0 89 in Brake fluid type DOT 4 Brake lever and brake pedal Brake lever free play left 0 5 2 mm 0 02 0...

Page 48: ... Front brake hose union bolt M10 27 2 7 19 Rear brake master cylinder and master cylinder bracket M6 23 2 3 17 Rear brake hose union bolt M10 30 3 0 22 Front brake caliper retaining bolt M8 23 2 3 17 Front brake caliper bleed screw M8 6 0 6 4 3 Rear brake caliper and drive pinion gear bearing housing M10 40 4 0 29 Rear brake caliper bleed screw M8 6 0 6 4 3 Handlebar holder M8 20 2 0 14 Steering s...

Page 49: ... cover and differential gear case M8 25 2 5 18 Gear motor and differential gear case cover M8 13 1 3 9 4 Universal joint yoke and drive pinion gear M14 62 6 2 45 Final drive gear case and frame M10 55 5 5 40 Final drive gear case filler plug M20 23 2 3 16 Final drive gear case drain bolt M14 23 2 3 16 Final drive gear oil check bolt M8 10 1 0 7 2 Ring gear bearing housing and final drive gear case...

Page 50: ...nce 6 32 9 48 kΩ at 20 C 68 F Spark plug cap Type Resin type Resistance 10 kΩ Charging system Type A C magneto generator Model manufacturer F4T496 MITSUBISHI Nominal output 14 V 21 A at 5 000 r min Charging coil resistance color 0 32 0 43 Ω at 20 C 68 F White White Rectifier regulator Regulator type Semi conductor shortcircuit Model manufacturer SH650D 11 SHINDENGEN No load regulated voltage DC 14...

Page 51: ... 3 4 8 Ω Electric fan Running rpm 2 880 r min Thermostat switch Thermostat switch 1 Model manufacturer 5KM DENSO Thermostat switch 2 Model manufacturer 5GM NIPPON THERMOSTAT Circuit breaker Type Fuse Amperage for individual circuit Main fuse 30 A 1 Headlight fuse 15 A 1 Ignition fuse 10 A 1 Auxiliary DC jack fuse 10 A 1 Four wheel drive fuse 3 A 1 Signaling system fuse 10 A 1 Backup fuse odometer ...

Page 52: ...s should be at room temperature A Distance between flats B Outside thread diameter METRIC MULTIPLIER IMPERIAL mm 0 03937 in 2 mm 0 03937 0 08 in 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 lb 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...

Page 53: ...ournal M Cylinder head bolt E Oil pump shaft rotor housing M Oil filter O ring LS Starter idle gear shaft M Transmission gear wheel pinion M Axle main drive M Shift fork guide bar E Shift cam shift shaft shift cam stopper ball E Shift lever select lever shift guide LS Shift cam lever M Stopper lever E Clutch carrier assembly E One way bearing M Drive chain sprocket E Crankcase mating surfaces Seal...

Page 54: ...RAMS COOLANT FLOW DIAGRAMS 1 Radiator 2 Radiator cap 3 Thermo switch 4 Radiator inlet hose 5 Thermostat assembly breather hose 6 Water pump outlet pipe 7 Water pump outlet hose 8 Radiator outlet hose 7 7 8 1 2 3 4 5 6 7 B B A B B ...

Page 55: ...2 23 SPEC COOLANT FLOW DIAGRAMS 1 Thermostat 2 Radiator inlet hose 3 Radiator 4 Radiator outlet hose 1 2 3 4 ...

Page 56: ...2 24 SPEC OIL FLOW DIAGRAMS OIL FLOW DIAGRAMS 1 Camshaft 2 Oil delively pipe 2 3 Oil delively piep 3 4 Crankshaft 4 1 2 3 ...

Page 57: ...2 25 SPEC OIL FLOW DIAGRAMS 1 Oil delively pipe 1 2 Oil delively pipe 2 3 Oil delively pipe 3 4 Oil pump 5 Oil strainer 4 5 3 2 1 ...

Page 58: ...2 26 SPEC OIL FLOW DIAGRAMS 1 Oil filter 2 Oil delively pipe 2 3 Oil delively pipe 1 4 Drive axle 5 Relief valve 6 Oil pump 7 Oil strainer 7 6 5 4 3 1 2 ...

Page 59: ...l gear lock switch lead 8 Front brake light switch lead 9 Handlebar switch lead 0 Rear brake light switch lead A Fan motor lead B Sub wire harness to gear motor C Differential gear case breather hose È Fasten the horn switch lead front brake light switch lead and on command four wheel drive switch and differential gear lock switch lead with a plastic band 4 5 8 7 2 9 0 A C B Í Ì Ê Ë 3 1 2 3 4 5 È ...

Page 60: ...and Install the plastic band facing inward Ë Fasten the gear motor lead and differential gear case breather hose with a plastic band Be sure not to pinch the hose Install the plastic band facing inward Ì Pass the brake hose through the hose guide Í Fasten the on command four wheel drive switch and differential gear lock switch lead front brake light switch lead handlebar switch lead and rear brake...

Page 61: ...ake light switch on command four wheel drive switch and differential gear lock switch handlebar switch and rear brake light switch É After routing all leads and couplers fasten them together with a plastic band Ê Pass the on command four wheel drive switch and differential gear lock switch lead and head light lead through the guide on the front fender Ë Pass the coolant reservoir breather hose and...

Page 62: ...2 30 SPEC CABLE ROUTING Ì Pass the fan motor breather hose through the guide on the front fender Í Pass the headlight lead through the guide on the front fender 1 8 7 3 6 5 4 3 2 Ê É Í Ì Ë È ...

Page 63: ...gnition coil coupler under the front fender É Pass the starter cable through the cable guide at the front of plastic cover Ê Route the fuel tank breather hose behind the plastic cover Ë Insert the fuel tank breather hose into the hole into the handlebar cover Ì Make sure that the starter cable does not have any slack between the cable holder plastic cover and the plastic clamp C C A B C C A B 4 3 ...

Page 64: ...ot to pinch the hoses Install the plastic band facing inward Ð Fasten the gear motor lead and differential gear case breather hose with a plastic band Be sure not to pinch the hose Install the plastic band facing inward Ñ Clamp the water pump inlet hose and thermo switch 2 lead with a plastic clamp Ò Fasten the thermo switch 2 lead fan motor lead coolant reservoir breather hose coolant reservoir h...

Page 65: ...hose 8 Ground lead 9 Speed sensor lead 0 AC magneto lead A Carburetor breather hose B Starter cable C Fuel hose D Thermo switch 1 lead E Reverse switch lead F AC magneto coupler G Gear position switch coupler H Speed sensor coupler I Radiator fan breather hose J Rectifier regulator lead K Water pump breather hose B B A C D A B B 4 3 2 1 9 8 Ë Ê É È 5 C 6 7 0 A 7 J 2 I F H G D E 8 C B D Í Î E E D K...

Page 66: ... in the following order ground lead reverse switch lead speed sensor lead gear position switch lead and AC magneto lead Ê Pass the final drive gear case breather hose through the hole in air duct assembly 3 Ë To the rear fender Ì 70 90 mm 2 8 3 5 in Í Clamp the thermostat assembly breather hose and carburetor breather hose with the cable guide Î Face the coupler release tab upward B B A C D A B B ...

Page 67: ...ver hole Ð Insert a clamp into the third hole from the top of the rectifier regulator bracket and then clamp the final drive gear case breather hose with the clamp B B A C D A B B 4 3 2 1 9 8 Ë Ê É È 5 C 6 7 0 A 7 J 2 I F H G D E 8 C B D Í Î E E D K E E Ð 3Ï Ì CABLE ROUTING ...

Page 68: ...7 Rear brake light switch lead 8 Spark plug lead 9 Fan motor breather hose 0 Fan motor lead A Bake fluid reservoir hose B Rear brake hose È Pass the rear brake cable and throttle cable through the cable guide É Pass the rear brake light switch lead and the main switch lead and auxiliary DC jack lead over the front fender B A 0 9 8 7 6 5 4 3 2 1 È É Ê Ë Í Ì ...

Page 69: ...nstalling the ignition coil face the spark lead to the right side of the frame Ì To the rear fender hole Í Pass the brake light switch lead on the inside of the rear brake cable and select lever control cable and through the cable guide of the brake master cylinder cover B A 0 9 8 7 6 5 4 3 2 1 È É Ê Ë Í Ì ...

Page 70: ...l drive relay 2 6 Four wheel drive relay 1 7 Positive battery lead 8 Starter motor lead 9 Wire harness È Pass the tail brake light lead through the lead guide É Position the wire harness tape at the end of the rear fender guide Ê Pass the wire harness through the cable guide of rear fender A A 1 8 7 6 5 4 3 2 9 Ê É È A A ...

Page 71: ...Fan motor breather hose È Pass the thermo sensor 1 lead through the lead guide É Pass the crankcase breather hose through the hose guide Ê Pass the fuel sender lead through the lead guide Ë Pass the select lever control cable through the hole of the select lever unit bracket Ì Clamp the starter cable with a plastic clamp Í Pass the throttle cable through the cable guide C C B A A B C C 0 6 9 4 3 2...

Page 72: ...E ROUTING Î Fasten the speed sensor coupler thermo switch 1 lead reverse switch lead ground lead gear position switch lead and AC magneto couplers with a band C C B A A B C C 0 6 9 4 3 2 1 8 7 6 5 Ê É È Î Ì Ë A A 8 Í ...

Page 73: ...CHK ADJ 3 ...

Page 74: ... 9 FUEL TANK 3 10 FOOTREST BOARDS 3 12 ENGINE 3 13 ADJUSTING THE VALVE CLEARANCE 3 13 ADJUSTING THE TIMING CHAIN 3 16 ADJUSTING THE IDLING SPEED 3 16 ADJUSTING THE THROTTLE LEVER FREE PLAY 3 17 ADJUSTING THE SPEED LIMITER 3 19 ADJUSTING THE STARTER CABLE 3 21 CHECKING THE SPARK PLUG 3 22 CHECKING THE IGNITION TIMING 3 23 MEASURING THE COMPRESSION PRESSURE 3 24 CHECKING THE ENGINE OIL LEVEL 3 26 CH...

Page 75: ... 48 CHANGING THE FINAL GEAR OIL 3 48 CHECKING THE DIFFERENTIAL GEAR OIL 3 49 CHANGING THE DIFFERENTIAL GEAR OIL 3 50 CHECKING THE CONSTANT VELOCITY JOINT DUST BOOT 3 51 CHECKING THE STEERING SYSTEM 3 51 ADJUSTING THE TOE IN 3 51 ADJUSTING THE FRONT SHOCK ABSORBER 3 53 ADJUSTING THE REAR SHOCK ABSORBER 3 54 CHECKING THE TIRE 3 54 CHECKING THE WHEEL 3 56 CHECKING AND LUBRICATING THE CABLE 3 57 LUBRI...

Page 76: ...lant every 24 months Spark plug See page 3 22 Check condition Adjust gap and clean Replace if necessary Air filter See page 3 29 Clean Replace if necessary Every 20 40 hours More often in wet or dusty areas Carburetor See page 3 16 Check and adjust idle speed starter operation Adjust if necessary Crankcase breather system Check breather hose for cracks or damage Replace if necessary Exhaust system...

Page 77: ...RNING Indicates a potential hazard that could result in serious injury or death Front and rear suspension See page 8 48 8 53 Check operation Correct if necessary Steering system See page 3 51 Check operation replace if damaged Check toe in adjust if necessary Rear upper and lower knuckle piv ots Lubricate Drive shaft universal joint Lubricate Engine mount Check for cracks or damage Front and rear ...

Page 78: ...name Part name Q ty Remarks Removing the seat and side panels Remove the parts in the order below 1 Seat 1 NOTE Pull up the seat lock lever then pull up on the rear of the seat 2 Fuel tank side panel left 1 3 Fuel tank side panel right 1 4 Engine side panel 1 5 Engine side cover 1 For installation reverse the removal procedure ...

Page 79: ... Part name Q ty Remarks Removing the front carrier front bumper and front grill Remove the parts in the order below Seat and fuel tank side panels Refer to SEAT AND SIDE PANELS 1 Cap 2 2 Front carrier cover 2 3 Front carrier 1 4 Front fender panel 1 5 Engine skid plate front 1 6 Front bumper protector 2 7 Front bumper 1 8 Headlight coupler 2 Disconnect 9 Front grill 1 For installation reverse the ...

Page 80: ...l tank cover and front fender Remove the parts in the order below Seat and fuel tank side panels Refer to SEAT AND SIDE PANELS Front carrier front bumper and front grill Refer to FRONT CARRIER FRONT BUMPER AND FRONT GRILL 1 Handlebar cover 1 2 Fuel tank cover 1 3 Meter assembly coupler 3 Disconnect 4 Meter assembly 1 5 Band 1 6 Sub wire harness 1 coupler 2 Disconnect 7 Handlebar switch left couple...

Page 81: ...9 Front brake light switch coupler 1 Disconnect 10 Rear brake light switch coupler 1 Disconnect 11 Main switch coupler 1 Disconnect 12 Auxiliary DC jack coupler 1 Disconnect 13 Fan motor breather hose 1 14 Differential gear case breather hose 1 15 Coolant reservoir breather hose 1 16 Coolant reservoir cover 1 17 Front fender 1 For installation reverse the removal procedure ...

Page 82: ...s Removing the rear carrier and rear fender Remove the parts in the order below Seat and fuel tank side panels Refer to SEAT AND SIDE PANELS 1 Rear carrier cover 2 2 Rear carrier 1 3 Rear carrier bracket 1 4 Rear fender panel 1 5 Battery holding bracket 1 6 Battery lead cover 1 7 Battery lead 2 Disconnect CAUTION First disconnect the negative lead then disconnect the positive lead ...

Page 83: ... Nm 0 7 m kg 5 1 ft Ib 12 9 Order Job name Part name Q ty Remarks 8 Battery 9 Starter relay ground lead 1 Disconnect 10 Taillight connector 3 Disconnect 11 Crankcase breather hose 1 12 Clamp screw 1 Loosen 13 Air filter case 1 14 Rear fender 1 For installation reverse the removal procedure ...

Page 84: ...ID PLATE REAR T R 9 Nm 0 9 m kg 6 5 ft Ib 2 1 Order Job name Part name Q ty Remarks Removing the engine skid plate center and engine skid plate rear Remove the parts in the order below 1 Engine skid plate center 1 2 Engine skid plate rear 1 For installation reverse the removal procedure ...

Page 85: ... Seat and side panels Refer to SEAT AND SIDE PANELS Fuel tank cover Refer to HANDLEBAR COVER FUEL TANK COVER AND FRONT FENDER 1 Fuel sender coupler 1 Disconnect 2 Fuel hose 1 NOTE Before disconnecting the fuel hose turn the fuel cock to OFF 3 Fuel cock lever 1 4 Fuel tank 1 NOTE When installing the fuel tank pass the fuel tank breather hose through the hole in the handlebar protector ...

Page 86: ...8 4 10 7 6 5 2 1 Order Job name Part name Q ty Remarks 5 Clamp 1 6 Vacuum chamber breather hose 1 7 Differential gear case breather hose 1 8 Crankcase breather hose 1 9 Plastic band 3 10 Bushing 2 11 Plastic cover 1 For installation reverse the removal procedure ...

Page 87: ... 4 4 2 1 4 12 8 12 8 Order Job name Part name Q ty Remarks Removing the footrest boards Remove the parts in the order below Fuel tank side panels Refer to SEAT AND SIDE PANELS 1 Footrest 2 2 Left footrest board 1 3 Right footrest board 1 4 Footrest bracket 4 For installation reverse the removal procedure ...

Page 88: ... touch Adjust the valve clearance when the piston is at the Top Dead Center T D C on the com pression stroke 1 Remove Seat Front carrier Front fender Fuel tank Engine side cover Refer to SEAT CARRIERS FENDERS AND FUEL TANK 2 Remove Tappet cover intake 1 Tappet covers exhaust 2 3 Disconnect Spark plug cap 3 4 Remove Spark plug 5 Remove Recoil starter 1 ...

Page 89: ...n the I mark 1 on the rotor with the sta tionary pointer 2 on the crankcase cover When the I mark is aligned with the station ary pointer the piston is at the Top Dead Center T D C NOTE When the piston is at the Top Dead Center T D C on the compression stroke there should be clearance between the valve stem tips and their respective rocker arm adjusting screws If there is no clearance rotate the c...

Page 90: ...n tighten the locknut Measure the valve clearance If the clearance is incorrect repeat the above steps until the proper clearance is obtained Tappet adjusting tool P N YM 08035 90890 01311 T R Locknut 14 Nm 1 4 m kg 10 ft lb 9 Install All removed parts NOTE Install all removed parts in the reverse order of their disassembly Note the following points 10 Install Recoil starter Spark plug Tappet cove...

Page 91: ...ADJUSTING THE TIMING CHAIN Adjustment free ADJUSTING THE IDLING SPEED 1 Start the engine and let it warm up for sev eral minutes 2 Remove Seat Fuel tank side panels Refer to SEAT CARRIERS FENDERS AND FUEL TANK 3 Attach Tachometer to the spark plug lead 4 Check Engine idling speed Out of specification Adjust Inductive tachometer P N YU 8036 A Engine tachometer P N 90890 03113 Engine idling speed 1 ...

Page 92: ...ter 7 Adjust Throttle lever free play Refer to ADJUSTING THE THROTTLE LEVER FREE PLAY 8 Install Fuel tank side panels Seat Refer to SEAT CARRIERS FENDERS AND FUEL TANK Turning in Idling speed becomes higher Turning out Idling speed becomes lower Throttle lever free play 3 5 mm 0 12 0 20 in ADJUSTING THE THROTTLE LEVER FREE PLAY NOTE Engine idling speed should be adjusted prop erly before adjusting...

Page 93: ...ND FUEL TANK 3 Adjust Throttle lever free play Adjustment steps First step Pull back the adjuster cover 1 Loosen the locknut 2 on the carburetor side Turn the adjuster 3 in or out until the correct free play is obtained Tighten the locknut 2 Push in the adjuster cover 1 NOTE If the free play cannot be adjusted here adjust it at the throttle lever side of the cable Turning in Free play is increased...

Page 94: ...ft to make sure that the engine idling speed does not increase Turning in Free play is increased Turning out Free play is decreased 4 Install Fuel tank side panel right Seat Refer to SEAT CARRIERS FENDERS AND FUEL TANK ADJUSTING THE SPEED LIMITER The speed limiter keeps the carburetor throttle from becoming fully opened even when the throttle lever is applied to the maximum posi tion Screwing in t...

Page 95: ...r a beginner rider the speed limiter should be screwed in com pletely 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 Turning in Speed limiter length is decreased Turning...

Page 96: ...escribed below È Fully closed position É Fully open position Pull back the boot 4 Loosen the locknut 5 Turn the adjuster 6 in or out until the correct distance is obtained Tighten the locknut 5 Push in the boot 4 Connect the starter cable to the carburetor WARNING After adjusting the cable turn the handle bar to right and left and make sure that the engine idling speed dose not increase 3 Install ...

Page 97: ...ar damage Replace Insulator 2 Abnormal color Replace Normal color is a medium to light tan color 4 Clean the spark plug with a spark plug cleaner or wire brush 5 Measure Plug gap a Use a wire gauge or feeler gauge Out of specification Regap 6 lnstall Spark plug NOTE Before installing a spark plug clean the gasket surface and plug surface Spark plug gap 0 8 0 9 mm 0 031 0 035 in T R 18 Nm 1 8 m kg ...

Page 98: ...Ignition timing Checking steps Warm up the engine and keep it at the speci fied speed Remove the recoil starter 1 Remove the timing plug 2 Visually check the stationary pointer 3 to verify it is within the required firing range 4 indicated on the flywheel Incorrect firing range Check the pulser coil assembly Install the timing plug Install the recoil starter Inductive tachometer P N YU 8036 A Engi...

Page 99: ... MEASURING THE COMPRESSION PRESSURE NOTE Insufficient compression pressure will result in a loss of performance 1 Check Valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEAR ANCE 2 Start the engine and let it warm up for sev eral minutes 3 Stop the engine 4 Remove Spark plug 5 Attach Adapter Compression gauge 1 Compression gauge P N YU 33223 90890 03081 Adapter P N YU 3322...

Page 100: ...wide open until the compres sion reading on the gauge stabilizes WARNING When cranking the engine ground the spark plug lead to prevent sparking 7 Install Spark plug 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 se...

Page 101: ...l NOTE Recommended oil classification API Service SE SF type or equivalent e g SF SE CC SF SE SD etc CAUTION Do not allow foreign material to enter the crankcase 4 Start the engine and let it warm up for sev eral minutes 5 Stop the engine and check the oil level again NOTE Wait a few minutes until the oil settles before inspecting the oil level WARNING Never remove the dipstick just after high spe...

Page 102: ...engine oil from the crank case 5 If the oil filter cartridge is also to be replaced perform the following procedure Replacement steps Remove the oil filter cartridge 1 with an oil filter wrench 2 Lubricate the O ring 3 of the new oil filter cartridge with a thin coat of engine oil CAUTION Make sure that the O ring 3 is positioned correctly in the groove of the oil filter car tridge Tighten the new...

Page 103: ...E ENGINE OIL LEVEL 11 Check Engine oil pressure Slightly loosen the oil gallery bolt 1 Start the engine and keep it idling until engine oil starts to seep from the oil gallery bolt If no engine oil comes out after one minute turn the engine off so that it will not seize Check the engine oil passages the oil filter cartridge and the oil pump for damage or leakage Refer to CRANKSHAFT AND OIL PUMP in...

Page 104: ...ank side panel left Seat Refer to SEAT CARRIERS FENDERS AND FUEL TANK T R Oil gallery bolt 7 Nm 0 7 m kg 5 1 ft lb CLEANING THE AIR FILTER NOTE There is a check hose 1 at the bottom of the air filter case If dust and or water collects in this hose clean the air filter element and air fil ter case 1 Remove Seat Fuel tank cover Refer to SEAT CARRIERS FENDERS AND FUEL TANK 2 Remove Air filter case co...

Page 105: ...ment removed This will allow unfiltered air to enter causing rapid wear and possi ble engine damage Additionally operation without the filter element will affect carbu retor tuning with subsequent poor perfor mance and possible engine overheating 4 Check Air filter element Damaged Replace 5 Clean Air filter element Cleaning steps Wash the element gently but thoroughly in solvent WARNING Use a clea...

Page 106: ...he element should be wet but not dripping 6 Install Air filter element Air filter case cover NOTE Insert the lobes 1 on the filter element into the receptacles 2 on the filter case To prevent air leaks make sure that the seal ing surface of the element matches the seal ing surface of the case 7 Install Fuel tank cover Seat Refer to SEAT CARRIERS FENDERS AND FUEL TANK CHECKING THE COOLANT LEVEL 1 P...

Page 107: ...concentration of the coolant Use only distilled water However soft water may be used if distilled water is not available 4 Start the engine warm it up for several min utes and then turn it off 5 Check Coolant level NOTE Before checking the coolant level wait a few minutes until the coolant has settled 6 Install Fuel tank side panel left Seat Refer to SEAT CARRIERS FENDERS AND FUEL TANK CHANGING TH...

Page 108: ...e do not remove the radiator cap when the engine is hot Scalding hot fluid and steam may be blown out which could cause seri ous injury When the engine has cooled open the radiator cap as follows Place a thick rag or a towel over the radia tor cap and slowly turn the radiator cap counterclockwise toward the detent to allow any residual pressure to escape When the hissing sound has stopped turn the...

Page 109: ...ial care WARNING If coolant splashes in your eyes thor oughly wash them with water and consult a doctor If coolant splashes on your clothes quickly wash it away with water and then with soap and water If coolant is swallowed induce vomiting and get immediate medical attention Recommended antifreeze High quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines Mixing ...

Page 110: ...ifferent types of antifreeze 13 Install Radiator cap 14 Fill Coolant reservoir with the recommended coolant to the maxi mum level mark a 15 Install Coolant reservoir cap 16 Start the engine warm it up for several min utes and then turn it off 17 Check Coolant level Refer to CHECKING THE COOLANT LEVEL NOTE Before inspecting the coolant level wait a few minutes until the coolant has settled 18 Insta...

Page 111: ...Crankcase cover right Refer to PRIMARY AND SECONDARY SHEAVES in CHAPTER 4 2 Check V belt 1 Cracks wear scaling chipping Replace Oil grease Check primary sheave and secondary sheave 3 Measure V belt width 2 Out of specification Replace V belt width 33 2 mm 1 31 in Limit 29 9 mm 1 18 in ...

Page 112: ... belt 1 from the primary sheave and secondary sheave Install the V belt NOTE Install the V belt so that its arrow faces the direction shown in the illustration Remove the bolts CLEANING THE SPARK ARRESTER 1 Clean Spark arrester Cleaning steps WARNING Select a well ventilated area free of com bustible materials Always let the exhaust system cool before performing this operation Do not start the eng...

Page 113: ... the inner contact surfaces of the muffler Insert the tailpipe 2 into the muffler and align the bolt holes Insert the bolt 1 and tighten it 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 Stop the engine and allow the exhaust pipe to cool CLEANING THE SPARK ARRESTER ...

Page 114: ...e play b Out of specification Adjust Rear brake lever free play 0 5 2 mm 0 02 0 08 in 2 Check Rear brake pedal height a Out of specification Adjust Rear brake pedal height 45 mm 1 77 in 3 Adjust Rear brake lever free play Rear brake pedal height Adjustment steps Loosen the locknut handlebar 1 and fully screw in the brake lever cable adjuster han dlebar 2 Remove the rear brake master cylinder cover...

Page 115: ...ht 45 mm 1 77 in Loosen the locknut 6 Pull up the brake outer cable and turn the brake cable adjusting nut 7 until the clear ance c is within the specified limits NOTE Make sure the pin 8 is all the way to the right of the link plate hole Hold the adjusting nut 7 and tighten the locknut 6 Clearance c 1 mm 0 04 in Turn the brake lever cable adjuster handle bar 2 until the rear brake lever free play...

Page 116: ...els to ensure there is no brake drag If any brake drag is noticed perform the above steps again CHECKING THE BRAKE FLUID LEVEL 1 Place the machine on a level surface NOTE When inspecting the brake fluid level make sure that the top of the brake fluid reservoir top is horizontal 2 Remove Rear brake master cylinder cover 1 3 Check Brake fluid level Fluid level is under LOWER level line 1 Fill up È F...

Page 117: ...ill with the same type of brake fluid mixing fluids may result in a harmful chemical reaction and lead to poor perfor mance 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 4 Install rear brake Front fender panel Front carrier Refer to SEAT CARRIERS FENDERS AND FUEL TANK ...

Page 118: ...r 4 Install Front wheels Brake pad wear limit a 1 mm 0 04 in CHECKING THE REAR BRAKE PAD 1 Remove Rear wheel left 2 Check Brake pad Wear indicator groove 1 almost disap peared Replace the brake pads as a set Refer to FRONT AND REAR BRAKES in CHAPTER 8 3 Operate the brake lever or brake pedal 4 Install Rear wheel left Brake pad wear limit a 1 mm 0 04 in CHECKING THE BRAKE HOSE 1 Remove Seat Front c...

Page 119: ...ear brake 3 Check Brake hose clamp Loosen Tighten 4 Install Right footrest board Refer to FOOTREST BOARDS Front fender Front carrier Seat Refer to SEAT CARRIERS FENDERS AND FUEL TANK BLEEDING THE HYDRAULIC BRAKE SYSTEM 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...

Page 120: ...old it g Loosen the bleed screw and allow the lever or pedal to travel towards its limit h Tighten the bleed screw when the lever or pedal limit has been reached then release the lever or pedal i Repeat steps e to h until all the air bub bles have disappeared from the fluid j Tighten the bleed screw NOTE If bleeding is difficult it may be necessary to let the brake fluid settle for a few hours Rep...

Page 121: ...hift rod Adjustment steps Control cable Make sure the select lever is in NEUTRAL Adjust the control cable so there is zero free play in the cable When the adjustment is correct slack in the return spring 1 will be taken up NOTE In some cases it will be necessary to further adjust the cable with the locknuts 2 arrange ment that holds the cable to its mount When the brake begins to work a 25 40 mm 1...

Page 122: ...ghten the locknuts 1 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 Hold the main body 1 of the rear brake light s...

Page 123: ...If no gear oil seeps out change the final gear oil Refer to CHANGING THE FINAL GEAR OIL CHANGING THE FINAL GEAR OIL 1 Place the machine on a level surface 2 Place a container under the final gear case to collect the used oil 3 Remove Oil filler bolt Drain plug 1 4 Drain Final gear oil 5 Install Drain plug NOTE Check the gasket drain plug If it is damaged replace it with a new one T R 23 Nm 2 3 m k...

Page 124: ... CHECKING THE DIFFERENTIAL GEAR OIL 1 Place the machine on a level surface 2 Remove Oil filter bolt 1 3 Check Oil level Oil level should be up to the brim of hole Oil level low Add oil to proper level CAUTION Take care not allow foreign material to enter the differential gear case 4 Install Oil filter bolt Recommended oil SAE 80 API GL 4 Hypoid gear oil Oil quantity periodic oil change 0 28 L 0 25...

Page 125: ...h new one T R 10 Nm 1 0 m kg 7 2 ft lb 6 Fill Differential gear case NOTE If gear oil is filled to the brim of the oil filler hole oil may start leaking from the differential gear case breather hose Therefore check the quantity of the oil not its level CAUTION Take care not to allow foreign material to enter the differential gear case 7 Install Oil filler bolt Periodic oil change 0 28 L 0 25 Imp q...

Page 126: ...he steering stem bushings 3 Check Tie rod ends Turn the handlebar to the left and or right until it stops completely then move the han dlebar from the left to the right slightly Tie rod end has any vertical play Replace the tie rod end s 4 Raise the front end of the machine so that there is no weight on the front wheels 5 Check Ball joints and or wheel bearings Move the wheels laterally back and f...

Page 127: ... the toe in using the formula given below If the toe in is incorrect adjust it Toe in É È 3 Adjust Toe in 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 mis handling and an accident After setting the toe in to specification run the machine slowly for some distance with both ...

Page 128: ...ined This is to keep the length of the rods the same Tighten the rod end locknuts of both tie rods NOTE Adjust the rod ends so that A and B are equal T R Locknut rod end 15 Nm 1 5 m kg 11 ft lb ADJUSTING THE FRONT SHOCK ABSORBER WARNING Always adjust both front shock absorber spring preload to the same setting Uneven adjustment can cause poor handling and loss of stability 1 Adjust Spring preload ...

Page 129: ... Minimum Soft position 1 Maximum Hard position 5 CHECKING THE TIRE WARNING This model is equipped with low pressure tires It is important that they be inflated correctly and maintained at the proper pressures TIRE CHARACTERISTICS 1 Tire characteristics influence the handling of ATV s The tires listed below have been approved by Yamaha Motor Co Ltd for this model If other tire combinations are used...

Page 130: ...tion could cause the tire to burst MAXIMUM LOADING LIMIT 1 Vehicle load limit total weight of cargo rider and accessories and tongue weight 220 kg 485 lb 2 Front carrier 45 kg 99 lb 3 Rear carrier 85 kg 187 lb 4 Storage box 2 0 kg 4 4 lb 5 Trailer hitch Pulling load total weight of trailer and cargo 550 kg 1 212 lb Tongue weight vertical weight on trailer hitch point 15 kg 33 lb Be extra careful o...

Page 131: ...angerous to ride with a worn out tire When tire wear is out of specification replace the tire immediately Cold tire pressure Front Rear Standard 35 kPa 0 35 kg cm2 5 0 psi 30 kPa 0 30 kg cm2 4 3 psi Minimum 32 kPa 0 32 kg cm2 4 6 psi 27 kPa 0 27 kg cm2 3 9 psi Maximum 38 kPa 0 38 kg cm2 5 5 psi 33 kPa 0 33 kg cm2 4 8 psi Tire wear limit a Front and rear 3 0 mm 0 12 in CHECKING THE WHEEL 1 Check Wh...

Page 132: ...interfere with the cable move ment An unsafe condition may result so replace a damaged cable as soon as possi ble 1 Check Cable sheath Damage Replace 2 Check Cable operation Unsmooth operation Lubricate or replace 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 Recommended lubricant Yamaha chain and cable lube or E...

Page 133: ...ttery are different from those of general type bat teries 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 bat tery WARNING Battery electrolyte is dangerous it con tains sulfuric acid which is poisonous and highly caustic Always follow these preventive measures A...

Page 134: ...holding bracket Battery lead cover Refer to SEAT CARRIERS FENDERS AND FUEL TANK 2 Disconnect Battery leads CAUTION First disconnect the negative lead 1 then disconnect the positive lead 2 3 Remove Battery 4 Check Battery condition Checking steps Connect a digital voltmeter to the battery ter minals NOTE The charge state of an MF battery can be checked by measuring the open circuit voltage i e the ...

Page 135: ... 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 bat tery 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 open circuit voltage stabilizes about 30 min utes after charging has been completed ...

Page 136: ... amperage exceeded NO YES If the amperage does not exceed the standard charging amperage after 5 minutes replace the battery 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 ...

Page 137: ... V 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 This type of battery charger cannot charge an MF battery A variable voltage charger is recommended Leave the battery unused for more than 30 minutes before measuring its open circuit voltage NOTE Set the charg...

Page 138: ...st connect the positive lead 1 then connect the negative lead 2 8 Install Battery lead cover Battery holding bracket Seat Refer to SEAT CARRIERS FENDERS AND FUEL TANK CHECKING THE FUSE CAUTION 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 Inspect Fuses Checking steps Connect the poc...

Page 139: ...s again check the electrical circuit 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 Description Current rating Quantity Main 30 A 1 Headlight 15 A 1 Ignition 10 A 1 Terminal Auxiliary D...

Page 140: ...UEL TANK ADJUSTING THE HEADLIGHT BEAM 1 Adjust Headlight beam vertically Turn the adjuster 1 in or out Turning in Headlight beam raised Turning out Headlight beam lowered CHANGING THE HEADLIGHT BULB 1 Remove Front carrier Front fender panel Refer to SEAT CARRIERS FENDERS AND FUEL TANK 2 Disconnect Headlight lead couplers 1 3 Remove Cover 1 ...

Page 141: ... 5 Install Bulb Secure the new bulb with the headlight unit CAUTION Avoid touching the glass part of the bulb Keep it free from oil otherwise the trans parency of the glass life of the bulb and luminous flux will be adversely affected If oil gets on the bulb thoroughly clean it with a cloth moistened with alcohol or lac quer thinner 6 Install Bulb holder Cover Cover 7 Connect Headlight lead couple...

Page 142: ...ENG 4 ...

Page 143: ...ND CYLINDER HEAD 4 16 REMOVING THE CAMSHAFT AND CYLINDER HEAD 4 18 CHECKING THE CAMSHAFT 4 19 CHECKING THE CAMSHAFT SPROCKET 4 19 CHECKING THE DECOMPRESSION SYSTEM 4 19 CHECKING THE TIMING CHAIN GUIDE 4 20 CHECKING THE TIMING CHAIN TENSIONER 4 20 CHECKING THE CYLINDER HEAD 4 20 INSTALLING THE CAMSHAFT AND CYLINDER HEAD 4 21 VALVES AND VALVE SPRINGS 4 24 REMOVING THE VALVE AND VALVE SPRING 4 25 CHE...

Page 144: ... GEAR 4 49 PRIMARY AND SECONDARY SHEAVES 4 51 PRIMARY SHEAVE 4 53 SECONDARY SHEAVE 4 54 REMOVING THE PRIMARY AND SECONDARY SHEAVES 4 55 DISASSEMBLING THE SECONDARY SHEAVE 4 55 CHEKING THE PRIMARY SHEAVE 4 56 CHECKING THE SECONDARY SHEAVE 4 56 ASSEMBLING THE PRIMARY SHEAVE 4 57 ASSEMBLING THE SECONDARY SHEAVE 4 57 INSTALLING THE PRIMARY AND SECONDARY SHEAVES 4 59 CLUTCH 4 60 REMOVING THE CLUTCH 4 6...

Page 145: ... 82 CHECKING THE HIGH WHEEL GEAR AND MIDDLE DRIVE GEAR 4 82 CHECKING THE SECONDARY SHAFT AND DRIVEN SPROCKET 4 83 CHECKING THE CHAIN 4 83 CHECKING THE STOPPER LEVER AND STOPPER WHEEL 4 83 ASSEMBLING THE SHIFT FORK ASSEMBLY 4 84 INSTALLING THE TRANSMISSION 4 84 MIDDLE GEAR 4 85 MIDDLE DRIVE SHAFT 4 85 MIDDLE DRIVEN SHAFT 4 86 REMOVING THE MIDDLE DRIVE SHAFT 4 88 REMOVING THE MIDDLE DRIVEN SHAFT 4 8...

Page 146: ...ENG ...

Page 147: ...il Drain Refer to CHANGING THE ENGINE OIL in CHAPTER 3 Engine side panel engine side cover Refer to SEAT CARRIERS FEND ERS AND FUEL TANK in CHAPTER 3 Front and rear fender footrest boards Fuel tank rubber cover Carburetor assembly Refer to CARBURETOR in CHAPTER 6 1 Protector 1 2 Air duct assembly 1 1 3 Exhaust pipe protector 1 4 Muffler 1 5 Exhaust pipe gasket 2 2 6 Exhaust pipe stay 1 7 Air duct ...

Page 148: ...4 2 ENG Order Job name Part name Q ty Remarks 8 Air duct assembly 3 1 For installation reverse the removal procedure ENGINE REMOVAL ...

Page 149: ... lever unit and coolant reservoir Remove the parts in the order below Coolant Drain Refer to CHANGING THE COOLANT in CHAPTER 3 1 Shift arm 1 2 Select lever shift rod 1 3 Select lever unit 1 4 Coolant reservoir breather hose 1 5 Coolant reservoir hose 1 6 Coolant reservoir 1 For installation reverse the removal procedure ...

Page 150: ...to THERMOSTAT in CHAPTER 5 Water pump assembly Refer to WATER PUMP in CHAPTER 5 1 Spark plug lead 1 2 Crankcase breather hose 1 3 Thermo switch lead 1 4 Starter motor lead 1 5 AC magneto lead coupler 2 6 Speed sensor lead coupler 1 7 Neutral switch lead coupler 1 8 Reverse switch lead 1 Green White 9 Engine ground lead 1 For installation reverse the removal procedure ...

Page 151: ...parts in the order below Engine skid plate front Refer to SEAT CARRIERS FENDERS AND FUEL TANK in CHAPTER 3 Engine skid plate center Engine skid plate rear Rear wheels Refer to REAR WHEELS AND BRAKE DISC in CHAPTER 8 Final drive gear assembly Refer to REAR CONSTANT VELOCITY JOINTS AND FINAL DRIVE GEAR AND DRIVE SHAFT in CHAPTER 7 ...

Page 152: ... nuts and then tighten them to full torque specifica tions Refer to INSTALLING THE ENGINE 2 Engine mounting bolt rear upper 2 3 Engine mounting bolt rear lower nut 1 1 4 Engine assembly 1 5 Rubber damper nut rear 2 6 Rubber damper rear 2 7 Rubber damper front 2 8 Engine mounting bolt front 4 9 Engine bracket right 1 10 Engine bracket left 1 For installation reverse the removal procedure ...

Page 153: ...ear upper 6 Rubber damper nut front 7 NOTE Do not fully tighten the bolts and nuts 2 Tighten Engine mounting bolt front 1 Rubber damper nut rear 3 Engine mounting bolt rear lower 5 Engine mounting bolt rear upper 6 Rubber damper nut front 7 T R 33 Nm 3 3 m kg 24 ft lb T R 42 Nm 4 2 m kg 30 ft lb T R 56 Nm 5 6 m kg 40 ft lb T R 10 Nm 1 0 m kg 7 2 ft lb T R 42 Nm 4 2 m kg 30 ft lb ENGINE REMOVAL ...

Page 154: ...front fender Refer to SEAT CARRIERS FEND ERS AND FUEL TANK in CHAPTER 3 Fuel tank plastic cover Recoil starter timing plug Refer to ADJUSTING THE VALVE CLEARANCE in CHAPTER 3 Select lever unit Refer to ENGINE REMOVAL 1 Union bolt 3 2 Copper washer 7 3 Oil delivery pipe 3 1 4 Oil delivery pipe 2 1 5 Spark plug 1 6 Tappet cover intake 1 7 Tappet cover exhaust 2 ...

Page 155: ... 9 ENG CYLINDER HEAD COVER Order Job name Part name Q ty Remarks 8 Cylinder head cover 1 Refer to REMOVING INSTALLING THE CYLINDER HEAD COVER 9 Dowel pin 2 For installation reverse the removal procedure ...

Page 156: ...D C NOTE When the piston is at the top dead center T D C on the compression stroke there should be clearance between the valve stem tips and their respective rocker arm adjusting screws If there is no clearance rotate the crankshaft counterclockwise one turn 2 Remove Cylinder head cover NOTE Loosen each bolt 1 4 of a turn at a time in stages and in a crisscross pattern After all the bolts are loos...

Page 157: ...alant Quick Gasket 1 to the mating surfaces of the cylinder head and cylinder head cover 2 Install Cylinder head cover Washers 1 Bolts 2 Bolt 25 mm 3 Bolt 40 mm 4 Bolt 55 mm 5 Bolt 115 mm 6 Bolt 130 mm NOTE Tighten the cylinder head cover bolts in stages using a crisscross pattern Sealant Quick Gasket 1 P N ACC 11001 05 01 Yamaha bond No 1215 P N 90890 85505 T R 10 Nm 1 0 m kg 7 2 ft lb ...

Page 158: ...the parts in the order below Cylinder head cover Refer to CYLINDER HEAD COVER 1 Plug O ring 1 1 2 Bolt 2 3 Rocker arm shaft 2 1 Refer to REMOVING INSTALLING THE ROCKER ARM 4 Rocker arm 3 1 5 Rocker arm shaft 3 O ring 1 1 6 Rocker arm 4 1 7 Rocker arm shaft 1 O ring 1 1 8 Rocker arm 1 1 9 Rocker arm 2 1 ...

Page 159: ...4 13 ENG ROCKER ARMS Order Job name Part name Q ty Remarks 10 Spring 4 11 Locknut 5 12 Valve adjuster 5 For installation reverse the removal procedure ...

Page 160: ... 2 Blue discoloration pitting scratches Replace 2 Check Rocker arms Rocker arm shafts Damage wear Replace Checking steps Check the two contact areas on the rocker arms for signs of abnormal wear 1 Rocker arm shaft hole 2 Camshaft lobe contact surface Excessive wear Replace Check the surface of the rocker arm shafts Blue discoloration pitting scratches Replace check lubrication Measure the inside d...

Page 161: ...defective part s Rocker arm shaft outside diameter 11 976 11 991 mm 0 4715 0 4721 in Rocker arm to shaft standard clearance 0 009 0 042 mm 0 0004 0 0017 in INSTALLING THE ROCKER ARM 1 Apply Engine oil onto the rocker arm shafts 2 Install Rocker arms 1 Rocker arm shafts 2 NOTE The thread hole a of the rocker arm shaft must face to the outside After installation make sure that the thread hole a of t...

Page 162: ... CARBURETOR in CHAPTER 6 Thermostat Refer to THERMOSTAT in CHAPTER 5 Thermostat assembly breather hose Refer to WATER PUMP in CHAPTER 5 Muffler exhaust pipe Refer to ENGINE REMOVAL Thermo switch lead Refer to HOSES AND LEADS Cylinder head cover Refer to CYLINDER HEAD COVER 1 Timing chain tensioner cap bolt 1 Refer to REMOVING INSTALLING THE CAMSHAFT AND CYLINDER HEAD 2 Timing chain tensioner gaske...

Page 163: ...FT AND CYLINDER HEAD Order Job name Part name Q ty Remarks 6 Camshaft 1 7 Thermo switch 1 8 Cylinder head 1 9 Cylinder head gasket 1 10 Dowel pin 2 11 Carburetor joint 1 For installation reverse the removal procedure ...

Page 164: ...ssor cam guide plates Camshaft sprocket Camshaft 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 4 Remove Cylinder head NOTE Loosen the bolts in the proper sequence Follow the numerical order shown in the illus tration Loosen each bolt 1 4 of a turn at a time until all o...

Page 165: ...0 mm 1 4331 in b 30 01 mm 1 1815 in CHECKING THE CAMSHAFT SPROCKET 1 Check Camshaft sprocket Wear damage Replace the camshaft sprocket and timing chain as a set a 1 4 of a tooth b Correct 1 Timing chain 2 Sprocket CHECKING THE DECOMPRESSION SYSTEM 1 Check Decompression system Checking steps Check while the camshaft sprocket is installed on the camshaft Check that the decompressor lever pin 1 proje...

Page 166: ... until it stops b Removing the screwdriver and slowly release the timing chain tensioner rod c Make sure that the timing chain tensioner rod comes out of the timing chain tensioner housing smoothly If there is rough move ment replace the timing chain tensioner CHECKING THE CYLINDER HEAD 1 Eliminate Carbon deposits from the combustion chambers Use a rounded scraper NOTE Do not use a sharp instrumen...

Page 167: ...lace a 400 600 grit wet sandpaper on the surface plate and resurface the head using a figure eight sanding pattern NOTE To ensure an even surface rotate the cylinder head several times Cylinder head warpage Less than 0 05 mm 0 002 in INSTALLING THE CAMSHAFT AND CYLINDER HEAD 1 Install Cylinder head Bolts M9 1 6 Bolt M6 7 NOTE Tighten the bolts in the proper sequence Follow the numerical order show...

Page 168: ...t during the cam shaft installation Temporarily install the camshaft sprocket on the camshaft Do not install the bolts Then install the timing chain on the camshaft sprocket NOTE Make sure the small holes 3 on the camshaft face upward Align the notches 4 on the decompressor cams with the projections 5 on the decom pressor spring lever then install the cam shaft sprocket on the camshaft NOTE Check ...

Page 169: ...iver 1 until it stops c With the screwdriver still inserted into the timing chain tensioner install the timing chain tensioner and gasket onto the cylinder block Then tighten the timing chain ten sioner bolts to the specified torque WARNING Always use a new gasket NOTE The UP mark on the timing chain tensioner should face up d Remove the screwdriver make sure that the timing chain tensioner rod re...

Page 170: ...arts in the order below Cylinder head Refer to CAMSHAFT AND CYLINDER HEAD 1 Valve cotter 10 Refer to REMOVING INSTALLING THE VALVE AND VALVE SPRING 2 Valve spring retainer 5 3 Intake valve spring 3 4 Exhaust valve spring 2 5 Intake valve 3 6 Exhaust valve 2 7 Valve stem seal 5 8 Valve spring seat 5 For installation reverse the removal procedure ...

Page 171: ...eps Pour a clean solvent 1 into the intake and exhaust ports Check that the valve seals properly There should be no leakage at the valve seat 2 2 Remove Valve cotters NOTE Attach a valve spring compressor 1 and valve spring compressor attachment 2 between the valve spring retainer and the cylinder head to remove the valve cotters Valve spring compressor P N YM 04019 90890 04019 Valve spring compre...

Page 172: ...acement steps NOTE To ease guide removal installation and to maintain correct fit heat the cylinder head to 100 C 212 F in an oven Remove the valve guide using a valve guide remover 1 Install the new valve guide using a valve guide remover 1 and valve guide installer 2 After installing the valve guide bore the valve guide using a valve guide reamer 3 to obtain proper stem to guide clearance NOTE A...

Page 173: ...e Margin thickness Intake 0 85 1 15 mm 0 0335 0 0452 in Exhaust 0 85 1 15 mm 0 0335 0 0452 in 5 Measure Runout valve stem Out of specification Replace NOTE When installing a new valve always replace the guide If the valve is removed or replaced always replace the oil seal 6 Eliminate Carbon deposits from the valve face and valve seat 7 Check Valve seats Pitting wear Reface the valve seat Runout li...

Page 174: ...l have been removed If the valve seat is too wide too narrow or the seat is not centered the valve seat must be refaced Valve seat width Intake 0 9 1 1 mm 0 0354 0 0433 in Limit 1 6 mm 0 0630 in Exhaust 0 9 1 1 mm 0 0354 0 0433 in Limit 1 6 mm 0 0630 in 9 Lap Valve face Valve seat NOTE After refacing the valve seat or replacing the valve and valve guide the valve seat and valve face should be lapp...

Page 175: ...r every lapping operation be sure to clean off all of the compound from the valve face and valve seat Apply Mechanic s blueing dye Dykem to the valve face Install the valve into the cylinder head Press the valve through the valve guide and onto the valve seat to make a clear pattern Measure the valve seat width again If the valve seat width is out of specification reface and relap the valve seat 1...

Page 176: ...30 14 10 kg 27 11 31 09 lb at 1 22 in 12 Measure Spring tilt a Out of specification Replace Spring tilt limit Intake 2 5 1 4 mm 0 06 in Exhaust 2 5 1 6 mm 0 06 in INSTALLING THE VALVE AND VALVE SPRING 1 Apply Molybdenum disulfide oil onto the valve stem and valve stem seal 2 Install Valve spring seats Valve stem seals Valves Valve springs Valve spring retainers NOTE Install the valve springs with ...

Page 177: ...alve spring compressor 1 and valve spring compressor attachment 2 Valve spring compressor P N YM 04019 90890 04019 Valve spring compressor attachment P N 90890 01243 4 To secure the valve cotters onto the valve stem lightly tap the valve tip with a piece of wood CAUTION Hitting the valve tip with excessive force could damage the valve ...

Page 178: ...ump outlet hose Refer to WATER PUMP in CHAPTER 5 Cylinder head Refer to CAMSHAFT AND CYLINDER HEAD 1 Coolant inlet joint 1 2 Cylinder O ring 1 1 Refer to INSTALLING THE CYLINDER 3 Cylinder gasket 1 4 Dowel pin 2 5 Piston pin clip 2 Refer to REMOVING INSTALLING THE PISTON 6 Piston pin 1 7 Piston 1 8 Piston ring set 1 For installation reverse the removal procedure ...

Page 179: ...ller 4 CAUTION Do not use a hammer to drive the piston pin out 2 Remove Piston rings NOTE Spread the end gaps apart while at the same time lifting the piston ring over the top of the piston crown as shown in the illustration Piston pin puller P N YU 01304 90890 01304 CHECKING THE CYLINDER AND PISTON 1 Check Cylinder and piston walls Vertical scratches Rebore or replace the cylinder and the piston ...

Page 180: ... edge If out of specification replace the piston and piston rings as a set 3rd step Find the piston to cylinder clearance with the following formula If out of specification rebore or replace the cylinder and replace the piston and piston rings as a set Standard Wear limit Cylinder bore C 100 005 100 055 mm 3 9372 3 9392 in 100 100 mm 3 9404 in C Piston skirt diameter P Standard 99 945 99 995 mm 3 ...

Page 181: ...iston ring in cylinder NOTE Insert a ring into the cylinder and push it approximately 50 mm 2 0 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 a 50 mm 2 0 in 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...

Page 182: ... replace the piston INSTALLING THE PISTON 1 Install Piston rings onto the piston NOTE Be sure to install the piston rings so that the manufacturer s marks or numbers are located on the upper side of the rings Lubricate the piston and piston rings liberally with engine oil Outside diameter piston pin 21 991 22 000 mm 0 8658 0 8661 in Limit 21 971 mm 0 8650 in Piston pin bore inside diameter 22 004 ...

Page 183: ...Before installing the piston pin clip cover the crankcase with a clean rag to prevent the piston pin clip from falling into the crankcase 4 Lubricate Piston Piston rings Cylinder NOTE Apply a liberal coating of engine oil INSTALLING THE CYLINDER 1 Install Cylinder O ring Bolts M10 Bolts M6 NOTE Install the cylinder with one hand while com pressing the piston rings with the other hand CAUTION Be ca...

Page 184: ...NG THE ENGINE OIL in CHAPTER 3 Coolant Drain Refer to CHANGING THE COOLANT in CHAPTER 3 Seat and side panels engine side cover Refer to SEAT AND SIDE PANELS in CHAPTER 3 Left footrest board Refer to FOOTREST BOARDS in CHAPTER 3 Select lever unit Refer to SELECT LEVER UNIT AND RESERVOIR Water pump assembly Refer to WATER PUMP in CHAPTER 5 1 Recoil starter assembly 1 2 AC magneto coupler 2 Disconnec...

Page 185: ... MAGNETO 4 Crankcase cover left gasket 1 1 5 Dowel pin 2 6 Lead holder 1 7 Pickup coil 1 8 Starter assembly 1 9 CDI rotor 1 Refer to REMOVING INSTALLING THE AC MAGNETO 10 Woodruff key 1 11 Starter wheel gear 1 12 Washer 1 13 Starter idle gear shaft 1 14 Bearing 1 15 Starter idle gear 1 For installation reverse the removal procedure ...

Page 186: ...ing the recoil starter Remove the parts in the order below 1 Cap 1 Refer to DISASSEMBLING ASSEM BLING THE RECOIL STARTER 2 Starter handle 1 3 Friction plate 1 4 Pawl spring 1 5 Drive pawl 1 6 Spring 1 7 Sheave drum 1 8 Rope 1 9 Coil spring 1 For assembly reverse the disassembly procedure ...

Page 187: ... in a crisscross pattern loosen each bolt 1 4 of a turn Remove them after all of them are loosened 3 Remove CDI rotor 1 NOTE Use the flywheel puller 2 Flywheel puller P N YM 01404 90890 01404 DISASSEMBLING THE RECOIL STARTER 1 Remove Cap 1 Starter handle 2 NOTE Before untying the knot 3 above the starter handle make a knot 4 in the rope so that the rope is not pulled into the case CHECKING THE AC ...

Page 188: ...tch and hold the starter clutch When turning the starter wheel gear counter clockwise È 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 clock wise É the starter wheel gear should turn freely If not the starter clutch is faulty Replace it T R Bolts starter clutch 30 Nm 3 0 m kg 22 ft lb LOCTITE 2 Check Gear t...

Page 189: ...NG THE RECOIL STARTER 1 Check Rope 1 Sheave drum 2 Drive pawl 3 Wear damage Replace Coil spring 4 Pawl spring 5 Spring 6 Fatigue Replace ASSEMBLEING THE RECOIL STARTER 1 Install Sheave drum 1 Rope 2 Pawl spring 3 Drive pawl 4 NOTE Wind the rope 4 1 2 turns clockwise around the sheave drum Then insert the rope into the drum slit a ...

Page 190: ...tion plate 2 Nut NOTE Insert the spring hooks into the pawl side holes 4 Turn the sheave drum 3 turn clockwise to give preload to the spring 5 Install Starter handle 1 Cap 2 NOTE Pass the rope through the case hole and make a knot 3 on the rope so that the rope is not pulled into the case Untie the knot 3 after making a knot 4 above the handle INSTALLING THE AC MAGNETO 1 Apply Sealant Quick Gasket...

Page 191: ... left NOTE When installing the crankcase cover left use a long rod to hold the CDI rotor in posi tion from the outside This will make assem bly easier Be careful not to damage the oil seal Tighten the bolts in stages using a criss cross pattern New T R 10 Nm 1 0 m kg 7 2 ft lb 4 Install Starter pulley 1 NOTE Use a rotor holding tool 2 to hold the starter pulley NOTE Before installing the starter p...

Page 192: ...r unit Select lever shift rod NOTE Before installing the select lever shift rod make sure that the select lever and shift cam is in the NEUTRAL position 6 Adjust Select lever shift rod Refer to ADJUSTING THE SELECT LEVER CONTROL CABLE AND SHIFT ROD in CHAPTER 3 ...

Page 193: ...the order below Starter wheel gear Refer to RECOIL STARTER AND AC MAGNETO 1 Nut lock washer 1 1 2 Balancer driven oil pump drive gear 1 Refer to REMOVING INSTALLING THE BALANCER DRIVE GEAR AND BAL ANCER DRIVEN GEAR 3 Chain 1 4 Straight key 1 5 Oil pump driven gear 1 6 Plate 1 7 Balancer drive gear 1 8 Spring 8 9 Pin 4 10 Buffer boss 1 For installation reverse the removal procedure ...

Page 194: ...late 2 between the teeth of the balancer drive gear 3 and balancer driven gear 4 REMOVING THE BALANCER DRIVE GEAR AND BUFFER BOSS 1 Remove Plate 1 Balancer drive gear 2 Springs 3 Pins 4 Buffer boss 5 NOTE Using a three leg puller 6 when removing the balancer drive gear 2 and buffer boss 5 CHECKING THE OIL PUMP DRIVE 1 Check Oil pump drive gear 1 Oil pump driven gear 2 Cracks wear damage Replace ...

Page 195: ...n Replace the balancer drive gear and balancer driven gear as a set INSTALLING THE BALANCER DRIVE GEAR AND BALANCER DRIVEN GEAR 1 Install Pin Spring Balancer drive gear onto the buffer boss NOTE Align the punch mark a on the balancer drive gear with the hole b to the buffer boss 2 Install Balancer drive gear Balancer driven gear NOTE Align the punch mark a on the balancer drive gear with the punch...

Page 196: ...ear nut 1 NOTE Place an aluminum plate 2 between the teeth of the balancer drive gear 3 and bal ancer driven gear 4 Apply the molybdenum disulfide grease to the thread of axles and nuts 4 Bend the lock washer tabs along the bal ancer driven gear nut New T R 140 Nm 14 0 m kg 100 ft lb ...

Page 197: ...1 0 m kg 7 2 ft Ib Order Job name Part name Q ty Remarks Removing the primary and second ary sheave Remove the parts in the order below Front fender Refer to SEAT CARRIERS FENDERS AND FUEL TANK in CHAPTER 3 Rear fender Right footrest boards Air duct assembly Refer to ENGINE REMOVAL 1 Drive belt cover 1 2 Rubber gasket 1 3 Bearing housing 1 4 Dowel pin 2 5 Primary sheave assembly 1 Refer to REMOVIN...

Page 198: ... kg 7 2 ft Ib T R 120 Nm 12 0 m kg 85 ft lb 10 10 9 7 6 8 5 4 3 2 1 12 7 T R 10 Nm 1 0 m kg 7 2 ft Ib Order Job name Part name Q ty Remarks 7 Primary fixed sheave 1 Refer to REMOVING INSTALLING THE PRIMARY AND SECONDARY SHEAVES 8 Secondary sheave assembly 1 9 Drive belt case 1 10 Rubber gasket 2 For installation reverse the removal procedure ...

Page 199: ...rimary sheave Remove the parts in the order below 1 Primary pulley sheave cap 1 Refer to ASSEMBLING THE PRIMARY SHEAVE 2 Primary pulley slider 4 3 Spacer 4 4 Primary pulley cam 1 5 Primary pulley weight 8 6 Collar 1 7 Oil seal 2 8 Primary sliding sheave 1 9 O ring 1 For assembly reverse the disassembly procedure ...

Page 200: ...dary sheave Remove the parts in the order below 1 Nut 1 Refer to DISASSEMBLING ASSEM BLING SECONDARY SHEAVE 2 Spring seat 1 3 Compression spring 1 4 Spring seat 1 5 Guide pin 4 6 Secondary sliding sheave 1 7 O ring 2 8 Secondary fixed sheave 1 9 Oil seal 1 0 Oil seal 1 For assembly reverse the disassembly procedure ...

Page 201: ...Nut 1 Removing steps Attach the sheave fixed block 2 locknut wrench 3 and sheave spring compressor 4 to the secondary sheave assembly Place the sheave fixed block in a vise and secure it Tighten the sheave spring compressor nut 5 and compress the spring Loosen the nut 1 with the locknut wrench 3 Remove the nut 1 Remove the sheave spring compressor and locknut wrench Sheave fixed block P N YM 04135...

Page 202: ... Replace 3 Check Primary sliding sheave Primary fixed sheave Cracks damage Replace CHECKING THE SECONDARY SHEAVE 1 Check Secondary fixed sheave smooth operation Secondary sliding sheave smooth operation Scratches damage Replace as a set 2 Check Torque cam groove 1 Wear damage Replace 3 Check Guide pin 2 Wear damage Replace 4 Check Secondary sheave spring Damage Replace 5 Measure Secondary sheave s...

Page 203: ... of the weight and install Apply Yamaha Grizzly grease to the inner surface of the collar Apply Yamaha Grizzly grease to the inner surface of the primary sliding sheave 3 Install Spacer Slider 1 Cam 2 Primary sliding sheave cap T R 3 Nm 0 3 m kg 2 2 ft lb ASSEMBLING THE SECONDARY SHEAVE 1 Apply BEL RAY assembly lube to the secondary sliding sheave 1 inner surface and oil seals BEL RAY assembly lub...

Page 204: ...r to the secondary sheave assembly Place the sheave fixed block in a vise and secure it Tighten the sheave spring compressor nut 1 and compress the spring Install the nut 2 and tighten it to the speci fied torque using the locknut wrench Remove the sheave spring compressor locknut wrench and sheave fixed block Sheave fixed block P N YM 04135 90890 04135 Locknut wrench P N 90890 01348 Sheave spring...

Page 205: ...the gap between the secondary fixed and sliding sheaves to widen Install the V belt so that its arrow faces the direction show in the illustration 2 Tighten Nut primary sheave 1 Nut secondary sheave 2 NOTE Use the sheave holder 3 to hold the primary sheave First tighten the nut primary sheave 1 then tighten the nut secondary sheave 2 Sheave holder P N YU 01880 90890 01701 T R 100 Nm 10 0 m kg 72 f...

Page 206: ...ts in the order below Primary and secondary sheaves Refer to PRIMARY AND SECONDARY SHEAVES 1 Clutch housing assembly 1 Refer to REMOVING AND INSTALL ING THE CLUTCH 2 Gasket dowel pin 1 2 3 One way clutch bearing 1 4 Nut 1 5 Clutch carrier assembly 1 For installation reverse the removal procedure ...

Page 207: ... Q ty Remarks Disassembling the clutch housing Remove the parts in the order below 1 Oil seal 1 2 Circlip 1 3 Bearing housing 1 4 Circlip 1 5 Bearing 1 6 Circlip 1 7 Bearing 1 8 Clutch housing 1 For assembly reverse the disassembly procedure ...

Page 208: ...amage 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 Checking steps Install the one way clutch bearing and clutch carrier assembly to the clutch housing and hold the clutch carrier assembly When turning the clutch housing clockwise È the clutch housing should turn freely If not the one way clu...

Page 209: ...LUTCH 1 Install Collar Clutch carrier assembly Nut 1 NOTE Use a clutch holding tool 2 to hold the clutch carrier assembly 2 Lock the threads with a drift punch Clutch holding tool P N YM 91042 90890 04086 New T R 160 Nm 16 0 m kg 115 ft lb 3 Install One way clutch bearing NOTE The one way clutch bearing should be installed in the clutch carrier assembly with the arrow mark a facing toward the clut...

Page 210: ... pins Gasket Clutch housing assembly NOTE Tighten the bolts in stages using a criss cross pattern After tightening the bolts check that the clutch housing assembly to counterclockwise rotates smoothly New T R 10 Nm 1 0 m kg 7 2 ft lb ...

Page 211: ...er below Engine assembly Refer to ENGINE REMOVAL Cylinder head Refer to CAMSHAFT AND CYLINDER HEAD Cylinder and piston Refer to CYLINDER AND PISTON Recoil starter and CDI rotor Refer to RECOIL STARTER AND AC MAGNETO Primary and secondary sheaves Refer to PRIMARY AND SECONDARY SHEAVES Clutch carrier assembly Refer to CLUTCH 1 Timing chain guide 1 2 Timing chain 1 3 Starter motor O ring 1 1 ...

Page 212: ...name Part name Q ty Remarks 4 Oil filter 1 5 Speed sensor 1 6 Shift cam stopper 1 7 Gear position switch 1 8 Reverse switch 1 9 Oil filler cap 1 10 Oil delivery pipe 1 11 Drain plug 1 For installation reverse the removal procedure ...

Page 213: ... Job name Part name Q ty Remarks Separating the crankcase Remove the parts in the order below 1 Shift lever cover gasket 1 1 Refer to INSTALLING SHIFT LEVER 2 Dowel pin 1 3 Shift lever 1 O ring 1 1 4 Shift lever 2 assembly 1 5 Crankcase left 1 Refer to SEPARATING ASSEMBLING THE CRANKCASE 6 Dowel pin 2 7 Crankcase right 1 For installation reverse the removal procedure ...

Page 214: ...me Q ty Remarks Removing the crankcase bearing Remove the parts in the order below Crankshaft and oil pump Refer to CRANKSHAFT AND OIL PUMP Transmission Refer to TRANSMISSION Middle drive driven shaft Refer to MIDDLE GEAR 1 O ring collar 1 1 2 Oil seal 1 3 Bearing retainer 1 4 Bearing 8 For installation reverse the removal procedure ...

Page 215: ...se a soft hammer to tap on one side of the crankcase Tap only on reinforced portions of the crankcase Do not tap on the crank case mating surfaces Work slowly and carefully Make sure that the crankcase halves separate evenly Remove the dowel pins È É CHECKING THE TIMING CHAIN AND GUIDE 1 Check Timing chain Cracks stiff Replace the timing chain and camshaft sprocket as a set 2 Check Intake side tim...

Page 216: ...then rotate the inner race with a finger Roughness Replace ASSEMBLING THE CRANKCASE 1 Apply Sealant Quick Gasket 1 to the mating surfaces of both case halves Sealant Quick Gasket P N ACC 11001 05 01 Yamaha bond No 1215 P N 90890 85505 2 Install Dowel pin 2 3 Fit the left crankcase onto the right case Tap lightly on the case with a soft hammer CAUTION Before installing and torquing the crank case h...

Page 217: ... m kg 7 2 ft lb 5 Apply 4 stroke engine oil to the crank pin bearing and oil delivery hole 6 Check Crankshaft and transmission operation Unsmooth operation Repair INSTALLATING THE SHIFT LEVER 1 Install Shift lever 2 assembly 1 Shift lever 1 2 NOTE When installing the shift lever 1 align the punch mark a on the shift lever 1 with the punch marks b on the shift lever 2 T R 14 Nm 1 4 m kg 10 ft lb ...

Page 218: ...il pump Remove the parts in the order below Crankcase separation Refer to CRANKCASE 1 Oil strainer O ring 1 1 2 Oil pump assembly gasket 1 1 3 Balancer 1 Refer to REMOVING THE CRANK SHAFT INSTALLING THE CRANK SHAFT AND BALANCER 4 Plate 1 5 Relief valve assembly 1 6 Crankshaft 1 For installation reverse the removal procedure ...

Page 219: ... Order Job name Part name Q ty Remarks Disassembling the oil pump Remove the parts in the order below 1 Rotor cover 1 2 Pin 2 3 Shaft 1 4 Pin 1 5 Inner rotor 1 6 Outer rotor 1 7 Oil pump housing 1 For assembly reverse the disassembly procedure ...

Page 220: ... wear damage Replace 2 Measure Tip clearance a between the inner rotor 1 and the outer rotor 2 Side clearance b between the outer rotor 2 and the pump housing 3 Out of specification Replace the oil pump Tip clearance a 0 03 0 10 mm 0 0012 0 0039 in Limit 0 15 mm 0 006 in Side clearance b 0 03 0 10 mm 0 0012 0 0039 in Limit 0 12 mm 0 005 in 3 Check Oil pump operation Unsmooth Repeat steps 1 and 2 o...

Page 221: ... wear Replace the defective parts s CHECKING THE OIL STRAINER 1 Check Oil strainer 1 O ring 2 Damage Replace Contaminants Clean with engine oil ASSEMBLING THE OIL PUMP 1 Install Inner rotor Outer rotor Oil pump shaft with the recommended lubricant Recommended lubricant Engine oil CRANKSHAFT AND OIL PUMP ...

Page 222: ...lace the crank shaft Crankshaft reassembling point The crankshaft 1 and the crank pin 2 oil pas sages must be properly interconnected with a tolerance of less than 1 mm 0 04 in CAUTION The buffer boss and woodruff key should be replaced when removed from the crank shaft Crank width 74 95 75 00 mm 2 9508 2 9528 in Big end side clearance 0 35 0 65mm 0 0138 0 0256 in Limit 1 0 mm 0 040 in Runout limi...

Page 223: ...ate the installing tool until the crankshaft bottoms against the bearing CAUTION Apply engine oil to each bearing to protect the crankshaft against scratches and to make installation easier Crankshaft installer pot 1 P N 90890 01274 Crankshaft installer bolt 2 P N 90890 01275 Crankshaft installer set 3 P N YU 90050 Adapter 4 P N YM 90069 90890 04059 Spacer crankshaft installer 5 P N YM 91044 90890...

Page 224: ... the parts in the order below Crankcase separation Refer to CRANKCASE Middle driven gear Refer to MIDDLE GEAR 1 Low wheel gear 1 2 Shift cam 1 3 Shift fork assembly 1 4 Short spring 1 White painting 5 Shift fork 1 1 6 Long spring 1 7 Shift fork 2 1 8 Guide bar 1 9 Secondary shaft 1 10 Drive axle assembly 1 ...

Page 225: ...4 79 ENG TRANSMISSION Order Job name Part name Q ty Remarks 11 Chain 1 12 Shaft 1 13 Stopper lever 1 14 Spring 1 15 Stopper cam 1 For installation reverse the removal procedure ...

Page 226: ...me Q ty Remarks Disassembling the drive axle assembly Remove the parts in the order below 1 Clutch dog 1 2 High wheel gear 1 3 Middle drive gear 1 4 Stopper wheel 1 5 Driven sprocket 1 6 Drive axle 1 For assembly reverse the disassembly procedure ...

Page 227: ...hift fork cam followers Remove the shift cam Remove the shift fork assembly 2 Remove Secondary shaft 1 Drive axle assembly 2 Chain 3 NOTE Remove the secondary shaft drive axle assembly and chain as a set CHECKING THE SHIFT FORK 1 Check Shift fork cam follower 1 Shift fork pawl 2 Scoring bends wear damage Replace 2 Check Guide bar Roll the guide bar on a flat surface Bends Replace WARNING Do not at...

Page 228: ...Check Shift cam grooves Scratches wear damage Replace CHECKING THE DRIVE AXLE 1 Measure Axle runout Use a centering device and a dial gauge Out of specification Replace the bent axle Runout limit drive axle 0 03 mm 0 001 in CHECKING THE HIGH WHEEL GEAR AND MIDDLE DRIVE GEAR 1 Check Gear teeth Blue discoloration pitting wear Replace Mated dogs Rounded edges cracks missing portions Replace ...

Page 229: ...ent Unsmooth Repeat steps 1 or replace the defective parts 3 Check Circlip Bends looseness damage Replace CHECKING THE CHAIN 1 Check Chain Cracks shift Replace the chain secondary shaft and driven sprocket as a set CHECKING THE STOPPER LEVER AND STOPPER WHEEL 1 Check Stopper lever pawl 1 Bends damage wear Replace the stopper lever and stopper wheel as a set Stopper wheel 2 Damage wear Replace the ...

Page 230: ...NG THE TRANSMISSION 1 Install Stopper lever Shaft 1 Chain 2 Drive axle assembly 3 Secondary shaft 4 Shift fork assembly 5 Shift cam 6 Low wheel gear 2 Check Shift operation Unsmooth operation Repair NOTE Oil each gear and bearing thoroughly Before assembling the crankcase be sure that the transmission is in neutral and that the gears turn freely ...

Page 231: ...in the order below Crankcase separation Refer to CRANKCASE 1 Bearing housing 1 2 Middle driven gear 1 3 Nut 1 Refer to REMOVING INSTALLING THE MIDDLE DRIVE SHAFT 4 Middle drive pinion gear 1 5 Shim Refer to MIDDLE DRIVE AND DRIVEN GEAR SHIM SELECTION 6 Middle drive shaft 1 7 Bearing retainer 2 For installation reverse the removal procedure ...

Page 232: ... separation Refer to CRANKCASE 1 Circlip 2 Refer to INSTALLING REMOVING THE MIDDLE DRIVEN SHAFT 2 Bearing 2 3 Universal joint 1 4 Universal joint yoke 1 5 Coupling gear 1 6 Bearing housing O ring 1 1 7 Shim Refer to MIDDLE DRIVE AND DRIVEN GEAR SHIM SELECTION 8 Middle driven pinion gear 1 Refer to REMOVING INSTALLING THE MIDDLE DRIVEN SHAFT 9 Bearing retainer 1 ...

Page 233: ...4 87 ENG MIDDLE GEAR Order Job name Part name Q ty Remarks 10 Bearing retainer 1 11 Middle driven shaft 1 For installation reverse the removal procedure ...

Page 234: ...ive pinion gear Middle drive pinion gear Shim s REMOVING THE MIDDLE DRIVEN SHAFT 1 Remove Universal joint Removal steps Remove the circlips 1 Place the U joint in a press With a suitable diameter pipe 2 beneath the yoke 3 press the bearing 4 into the pipe as shown NOTE It may be necessary to lightly tap the yoke with a punch Repeat the steps for the opposite bearing Remove the yoke NOTE It may be ...

Page 235: ...der P N YM 04062 Coupling gear middle shaft tool P N YM 01230 90890 0229 4 Remove Bearing housing assembly 1 Removal steps Clean the outside of the middle driven shaft Place the middle driven shaft onto a hydrau lic press CAUTION Never directly press the shaft end with a hydraulic press this will result in damage to the shaft thread Install the suitable socket 2 on the shaft end to protect the thr...

Page 236: ...hreads To loosen the retainer turn it clockwise Remove the bearing retainer and bearing Bearing retainer wrench P N YM 04128 90890 04128 6 Remove Front drive shaft coupling Oil seal 1 Bearing retainer 2 Bearing NOTE Attach the ring nut wrench 3 CAUTION The middle driven shaft bearing retainer has left handed threads To loosen the retainer turn it clockwise Ring nut wrench P N YM 38404 90890 01430 ...

Page 237: ...n the drive and driven gear bearing hous ing assembly and or crankcase replaced be sure to adjust the gear shim 1 and 2 1 Select Middle drive gear shim 1 Middle driven gear shim 2 Selection steps Position middle drive and driven gear by using shims 1 and 2 with their respective thickness calculated from information marked on crankcase bearing housing and drive gear end 1 Shim thickness A 2 Shim th...

Page 238: ... 7 52 2 b is 17 3 c is 55 4 If the crankcase right is marked 64 98 d is 64 98 5 Therefore the shim thickness is 0 50 mm A 7 52 64 98 17 55 0 50 6 Round off hundredths digit and select appropriate shim s In the example above the calculated shim thickness is 0 50 mm The chart instructs you however to round off 0 to 0 Shims are supplied in the following thickness Hundredths Round value 0 1 2 0 3 4 5 ...

Page 239: ... middle driven pinion gear is either added to or subtracted from 80 5 h a numeral usually a decimal number on the left crankcase specifies a thick ness of 97 29 i a numeral usually a decimal number on the right crankcase specifies a thickness of 1 67 Example 1 If the bearing housing is marked 06 e is 75 94 2 If the driven pinion gear is marked 0 f is 60 00 3 If the driven pinion gear is marked 13 ...

Page 240: ... thickness Hundredths Round value 0 1 2 0 3 4 5 6 7 5 8 9 10 Middle drive pinion gear shim Thickness mm 0 10 0 40 0 15 0 50 0 20 0 60 0 30 INSTALLING THE MIDDLE DRIVEN SHAFT 1 Install Bearing retainer 1 NOTE Attach the ring nut wrench 2 CAUTION The middle driven shaft bearing retainer has left handed threads To tighten the retainer turn it counterclockwise Ring nut wrench P N YM 38404 90890 01430 ...

Page 241: ...ded threads To tighten the retainer turn it counterclockwise 3 Install Shims 1 Bearing housing NOTE Install the shims so that the tabs are positioned as shown in the illustration Bearing retainer wrench P N YM 04128 90890 04128 T R Bearing retainer 110 Nm 11 0 m kg 80 ft lb LT 4 Install Universal joint yoke rear side Washer Nut 1 NOTE Use the universal joint holder 2 to hold the yoke Universal joi...

Page 242: ...ings 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 2 into the groove of each bearing INSTALLING THE MIDDLE DRIVE SHAFT 1 Tighten Nut middle drive pinion gear 1 NOTE Secure the middle drive s...

Page 243: ...le driven gear Middle gear lash 0 1 0 3 mm 0 004 0 012 in Attach the gear lash measurement tool 3 and dial gauge 4 a 46 mm 1 8 in Measure the gear lash while rotating the mid dle driven shaft back and forth NOTE Measure the gear lash at 4 positions Rotate the middle driven gear 90 each time If the gear lash is incorrect adjust the gear lash by middle driven pinion gear shims and or middle drive pi...

Page 244: ......

Page 245: ...COOL 5 ...

Page 246: ...R 5 1 CHECKING THE RADIATOR 5 3 INSTALLING THE RADIATOR 5 4 THERMOSTAT 5 5 CHECKING THE THERMOSTAT 5 6 INSTALLING THE THERMOSTAT 5 6 WATER PUMP 5 7 DISASSEMBLING THE WATER PUMP 5 9 CHECKING THE WATER PUMP 5 9 ASSEMBLING THE WATER PUMP 5 10 ...

Page 247: ...COOL ...

Page 248: ...ER 3 Front carrier front bumper and front grill Refer to FRONT CARRIER FRONT BUMPER AND FRONT GRILL in CHAP TER 3 Handlebar cover fuel tank cover and front fender Refer to HANDLEBAR COVER FUEL TANK COVER AND FRONT FENDER in CHAPTER 3 Left footrest board Refer to FOOTREST BOARDS in CHAPTER 3 Coolant Drain Refer to CHANGING THE COOLANT in CHAPTER 3 1 Plastic clamp 1 2 Thermo switch coupler 1 Disconn...

Page 249: ... R 28 Nm 2 8 m kg 20 ft Ib 3 5 1 6 2 8 9 7 4 Order Job name Part name Q ty Remarks 5 Radiator inlet hose 1 Disconnect 6 Radiator outlet hose 1 Disconnect 7 Radiator 1 8 Radiator fan 1 9 Thermo switch 1 For installation reverse the removal procedure ...

Page 250: ...sure Below the specified pressure Replace the radiator cap Measurement steps Install the radiator cap tester 1 and adapter 2 onto the radiator cap 3 Apply the specified pressure for ten seconds and make sure that there is no drop in pres sure 4 Check Radiator fan Damage Replace Malfunction Check and repair Refer to COOLING SYSTEM in CHAPTER 9 Radiator cap opening pressure 93 3 122 7 kPa 0 933 1 22...

Page 251: ...DIATOR INSTALLING THE RADIATOR 1 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT in CHAPTER 3 2 Check Cooling system Leaks Repair or replace any faulty part ...

Page 252: ...s Removing the thermostat Remove the parts in the order below Seat and fuel tank side panel right Refer to SEAT AND SIDE PANELS in CHAPTER 3 Coolant Drain Refer to CHANGING THE COOLANT in CHAPTER 3 1 Radiator inlet hose 1 2 Thermostat cover 1 3 Thermostat 1 For installation reverse the removal procedure ...

Page 253: ...r È Fully closed É Fully open NOTE If the accuracy of the thermostat is in doubt replace it A faulty thermostat could cause seri ous overheating or overcooling 2 Check Thermostat housing cover Thermostat housing Cracks damage Replace Temperature Opening INSTALLING THE THERMOSTAT 1 Install Thermostat 1 Thermostat housing cover NOTE Install the thermostat with its breather hole a facing up 2 Fill Co...

Page 254: ...ft and engine side cover Refer to SEAT AND SIDE PANELS in CHAPTER 3 Left footrest board Refer to FOOTREST BOARDS in CHAPTER 3 Coolant reservoir Refer to ENGINE REMOVAL in CHAP TER 4 1 Thermostat assembly bypass hose 1 2 Radiator outlet hose 1 3 Water pump outlet hose 1 4 Water pump outlet pipe 1 5 O ring 1 6 Water pump assembly 1 7 O ring 1 8 Water pump breather hose 1 For installation reverse the...

Page 255: ...the water pump Remove the parts in the order below 1 Water pump housing cover 1 2 Gasket 1 3 Circlip 1 4 Impeller 1 5 Rubber damper holder 1 6 Rubber damper 1 7 Water pump seal 1 8 Oil seal 1 9 Bearing 1 0 Water pump housing 1 For assembly reverse the disassembly procedure ...

Page 256: ...inside of the water pump housing 2 Water pump housing 3 Remove Bearing 1 Oil seal 2 NOTE Tap out the bearing and oil seal from the out side of the water pump housing 3 Water pump housing CHECKING THE WATER PUMP 1 Check Water pump housing cover 1 Water pump housing 2 Impeller 3 Rubber damper 4 Rubber damper holder 5 Cracks damage wear Replace 2 Check Water pump seal Oil seal Water pump outlet pipe ...

Page 257: ...nstall Water pump seal 1 into the water pump housing 2 CAUTION Never lubricate the water pump seal sur face with oil or grease NOTE Install the water pump seal with the special tools È Push down Mechanical seal installer 3 P N YM 33221 90890 04078 Middle driven shaft bearing driver 4 P N YM 04058 1 90890 04058 New 3 Install Rubber damper 1 Rubber damper holder 2 NOTE Before installing the rubber d...

Page 258: ...ure Impeller shaft tilt Out of specification Repeat steps 3 and 4 CAUTION Make sure that the rubber damper and rub ber damper holder are flush with the impel ler 1 Straightedge 2 Impeller Max impeller shaft tilt 0 15 mm 0 006 in ...

Page 259: ......

Page 260: ...CARB 6 ...

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

Page 262: ...CARB ...

Page 263: ...o SEAT CARRIERS FENDERS AND FUEL TANK in CHAPTER 3 Exhaust pipe protector 1 Refer to ENGINE REMOVAL in CHAP TER 3 1 Vacuum chamber breather hose 1 2 Starter cable starter plunger 1 1 3 Throttle valve cover 1 4 Throttle cable end 1 5 Throttle cable 1 6 Carburetor joint air filter case 1 7 Carburetor assembly 1 8 Drain hose 1 9 Carburetor joint intake manifold 1 For installation reverse the removal ...

Page 264: ...rts in the order below 1 Throttle stop screw 1 2 Vacuum chamber cover 1 3 Spring 1 4 Jet needle holder 1 5 Spring 1 6 Jet needle set 1 7 Piston valve 1 8 Coasting enricher diaphragm 1 9 Pilot air jet 1 0 Drain screw 1 A Float chamber 1 B Float 1 Refer to ASSEMBLING THE CARBURE TOR C Needle valve set 1 ...

Page 265: ...Job name Part name Q ty Remarks D Pilot screw set 1 Refer to ASSEMBLING THE CARBURE TOR E Main jet 1 F Needle jet 1 Refer to ASSEMBLING THE CARBURE TOR G Pilot jet 1 H Starter jet 1 For assembly reverse the disassembly procedure ...

Page 266: ...ation Clean Cleaning steps Wash the carburetor in a petroleum based solvent Do not use any caustic carburetor cleaning solution Blow out all of the passages and jets with compressed air 2 Check Float 1 Float tang 2 Damage Replace 3 Check Valve seat 1 Needle valve 2 O ring 3 Contamination wear damage Replace as a set NOTE Always replace the needle valve and valve seat as a set ...

Page 267: ...hamber cover 1 Spring 2 Cracks damage Replace 6 Check Diaphragm coasting enricher 1 Spring 2 Cover 3 Tears diaphragm damage Replace 7 Check Jet needle 1 Main jet 2 Needle jet 3 Pilot air jet 4 Pilot jet 5 Pilot screw 6 Starter jet 7 Starter plunger 8 Bends wear damage Replace Blockage Blow out the jets with com pressed air ...

Page 268: ...clean petroleum based solvent 1 Install Pilot screw 1 Pilot screw setting 3 2 Measure Float height a Out of specification Adjust Measurement and adjustment steps Hold the carburetor in an upside down posi tion 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...

Page 269: ...gauge 1 to the drain pipe 2 Loosen the drain screw 3 Hold the gauge vertically next to the float chamber line Measure the fuel level a 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 bend ing the float tang 4 slightly Install the carbureto...

Page 270: ......

Page 271: ...DRIV 7 ...

Page 272: ... INSTALLING THE UNIVERSAL JOINT 7 14 MEASURING AND ADJUSTING THE DIFFERENTIAL GEAR LASH 7 15 CHECKING THE DIFFERENTIAL GEAR OPERATION 7 17 REAR CONSTANT VELOCITY JOINT FINAL DRIVE GEAR AND DRIVE SHAFT 7 18 ASSEMBLING THE REAR CONSTANT VELOCITY JOINT 7 22 REMOVING AND DISASSEMBLING THE FINAL DRIVE ROLLER BEARING 7 23 POSITIONING THE FINAL DRIVE PINION GEAR AND RING GEAR 7 24 CHECKING THE DRIVE SHAF...

Page 273: ...DRIV ...

Page 274: ...ched 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 Improper 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 Inspection notes 1 Invest...

Page 275: ...ossible injury to the rider 2 Inspect Drained oil Drained oil shows large amounts of metal particles Check the bearing for seizure NOTE A small amount of metal particles in the oil is normal 3 Inspect 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 nec essary ...

Page 276: ...AND BRAKE DISC in CHAPTER 8 YES Check the front constant velocity joint Feel for bearing damage NO Constant velocity joint bearings and differ ential gear bearings are probably not dam aged Repeat the test or remove the individual components YES Check the rear brake adjustment NO Adjust per instructions Refer to ADJUSTING THE REAR BRAKE in CHAPTER 3 YES Check the rear constant velocity joint Feel ...

Page 277: ...ne skid plate front Front fender Refer to SEAT CARRIERS FENDERS AND FUEL TANK in CHAPTER 3 Differential gear oil Drain Steering knuckle Refer to STEERING SYSTEM in CHAP TER 8 Front arms lower Refer to FRONT ARMS AND FRONT SHOCK ABSORBER in CHAPTER 8 Brake master cylinder cover Refer to FRONT AND REAR BRAKES in CHAPTER 8 1 Constant velocity joint 2 2 Gear motor coupler on command four wheel drive s...

Page 278: ...TY JOINTS AND DIFFERENTIAL GEAR LS LS LS T R 55 Nm 5 5 m kg 40 ft Ib LS 1 6 5 3 2 1 4 Order Job name Part name Q ty Remarks 4 Differential gear 1 5 Drive shaft 1 6 Compression spring 1 For installation reverse the removal procedure ...

Page 279: ...g the constant velocity joint Remove the parts in the order below 1 Circlip 1 2 Boot band 2 Refer to ASSEMBLING THE FRONT CONSTANT VELOCITY JOINT 3 Boot band 2 4 Dust boot 2 5 Circlip 1 6 Double off set joint 1 7 Snap ring 1 8 Ball bearing 1 9 Joint shaft assembly 1 For assembly reverse the disassembly procedure ...

Page 280: ... below 1 Gear motor O ring 1 1 NOTE Be sure not to disassemble gear motor and remove the pinion gear 2 Circlip 2 Refer to DISASSEMBLING AND ASSEMBLING THE UNIVERSAL JOINT 3 Bearing 2 4 Universal joint 1 5 Universal joint yoke O ring 1 1 6 Stopper bolt shaft 1 1 7 Shift fork sliding gear 1 8 Shift fork 1 9 Differential gear case cover 1 0 Drive clutch 1 A Shim left ...

Page 281: ...Y JOINTS AND DIFFERENTIAL GEAR Order Job name Part name Q ty Remarks B Differential gear assembly 1 C Shim right 1 D Circlip bearing 1 1 E Drive pinion gear 1 F Differential gear case 1 For assembly reverse the disassembly procedure ...

Page 282: ...press the bearing 4 into the pipe as shown NOTE It may be necessary to lightly tap the yoke with a punch Repeat the steps for the opposite bearing Remove the yoke NOTE it may be necessary to lightly tap the yoke with a punch 2 Remove Universal joint yoke Use a universal joint holder 1 Universal joint holder P N YM 04062 90890 04062 FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR ...

Page 283: ... to dis assemble this unit Disassembly will result in the malfunction of the unit CHECKING THE CONSTANT VELOCITY JOINT 1 Check Double off set joint spline Ball joint spline Shaft spline Wear damage Replace 2 Check Dust boots Cracks damage Replace CAUTION Always use a new boot band 3 Check Balls and ball races Inner surface of double off set joint Pitting wear damage Replace CHECKING THE DIFFERENTI...

Page 284: ...G THE GEAR MOTOR 1 Check Gear motor Checking steps Connect two C size batteries to the gear motor terminals 1 as shown illustration CAUTION Do not use a 12 V battery to operate the pinion gear È Check that the pinion gear 2 turns counter clockwise É Check that the pinion gear 2 turns clockwise NOTE Be sure not to disassemble gear motor and remove the pinion gear È É ASSEMBLING THE FRONT CONSTANT V...

Page 285: ...ands NOTE The new boot bands may differ from the orig inal ones The dust boots should be fastened with the boot bands 3 at the grooves in the joint shaft Molybdenum disulfide grease 40 g 1 4 oz per dust boot New 3 Check Free play thrust movement Excessive play Replace the joint assem bly ASSEMBLING THE DIFFERENTIAL GEAR 1 Measure Gear lash Refer to MEASURING AND ADJUSTING THE DIFFERENTIAL GEAR LAS...

Page 286: ... Insert 8 mm bolts 6 into the gear motor 7 and use them as a guide to set the motor on the differential gear assembly 8 so that the shift fork sliding gear 9 does not move CAUTION If the position of the shift fork sliding gear is moved the position of the differential gear and the indicator light display may dif fer and the 2WD or differential lock mode may not be activated Remove the 8 mm bolts a...

Page 287: ...stall the opposite yoke into the U joint Apply wheel bearing grease to the bearings Install the bearing 1 onto the yoke CAUTION Check each bearing The needles can eas ily fall out of their races Slide the yoke back and forth on the bearings the yoke will not go all the way onto a bearing if a needle is out of plate Press each bearing into the U joint using a suitable socket NOTE The bearing must b...

Page 288: ...he bolt until it holds the ring gear Otherwise the ring gear will be dam aged 4 Attach Gear lash measurement tool 1 Dial gauge 2 a Measuring point is 21 mm 0 83 in 5 Measure Gear lash Gently rotate the gear coupling from engage ment to engagement NOTE Measure the gear lash at four positions Rotate the shaft 90 each time Gear lash measurement tool P N YM 01467 90890 01467 Differential gear lash 0 0...

Page 289: ...educe 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 Too little gear lash Reduce shim thick ness Too large gear lash Increase shim thick ness Ring gear shim left and right Thickness mm 0 1 1 0 0 2 1 5 0 3 2 0 0 4...

Page 290: ...ear 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 4 Out of specification Replace the differen tial gear assembly 5 Within specification Install the new cotter pin and wheel cap T R Front wheel starting torque differential gear preload New unit 17 25 Nm 1 7 2 5 m kg 12 18 ft l...

Page 291: ...nt final drive gear assembly and drive shaft Remove the parts in the order below Final gear oil Drain Rear arm lower Refer to REAR ARMS AND REAR SHOCK ABSORBER in CHAPTER 8 Brake caliper assembly Refer to REAR BRAKE CALIPER in CHAPTER 8 1 Rear constant velocity joint 2 2 Final drive gear case breather hose 1 Disconnect 3 Final drive gear assembly 1 4 Compression spring 1 5 Coupling gear 1 6 Drive ...

Page 292: ...ng the rear constant velocity joint Remove the parts in the order below 1 Dust cover 1 2 Circlip 1 3 Boot band 2 Refer to CONSTANT VELOCITY JOINT ASSEMBLY 4 Boot band 2 5 Dust boot 2 6 Circlip 1 7 Double off set joint 1 8 Snap ring 1 9 Ball bearing 1 0 Joint shaft assembly 1 For assembly reverse the disassembly procedure ...

Page 293: ...s in the order below Rear brake disc Refer to REAR WHEELS AND BRAKE DISC in CHAPTER 8 1 Boss 1 2 Ring gear stopper shim 1 3 Ring gear stopper 1 4 Bolt 2 NOTE Working in a crisscross pattern loosen each bolt 1 4 of a turn After all the bolts are loosened remove them 5 Bolt 6 6 Ring gear bearing housing 1 7 Oil seal 1 8 Bearing 1 9 Ring gear shim 1 0 Ring gear 1 ...

Page 294: ...NG THE FINAL DRIVE GEAR D Oil seal 1 E Inner race 1 F Final drive pinion gear 1 G Bearing retainer 1 H Bearing 1 I Pinion gear bearing housing 1 J Final drive gear case 1 K Oil seal 1 L Bearing 1 Refer to REMOVING AND DISASSEM BLING THE FINAL DRIVE ROLLER BEARING M Bearing 1 Refer to REMOVING AND DISASSEM BLING THE FINAL DRIVE ROLLER BEARING For assembly reverse the disassembly procedure ...

Page 295: ...y lithium soap base grease into the dust boots Install the dust boots Install the dust boot bands NOTE The new boot bands may differ from the orig inal ones The dust boots should be fastened with the boot bands 3 at the grooves in the joint shaft Lithium soap base grease 50 g 1 8 oz per dust boot rear wheel side 60 g 2 3 oz per dust boot final gear case side New 3 Check Free play thrust movement E...

Page 296: ...roller bearing outer race with an appropriately shaped punch 2 Remove the inner race from the final drive pinion gear NOTE The removal of the final drive pinion gear roller bearing is difficult and seldom necessary 3 Install Roller bearing final drive pinion gear Installation steps Heat the main housing only to 150 C 302 F Install the roller bearing outer race using the proper adapter Install the ...

Page 297: ...on gear shim thick ness A use the following formula a 92 5 mm b a numeral usually a decimal number on the pinion gear bearing housing either added to 34 c a numeral usually a decimal number on the pinion gear bearing housing either added to 55 d a numeral usually a decimal number on the final drive gear case either added to 112 Example 1 a 92 5 2 If 98 is stamped on the pinion gear bearing housing...

Page 298: ...ue 0 1 2 0 3 4 5 6 7 5 8 9 10 Final drive pinion gear shim Thickness mm 0 15 0 30 0 40 0 45 0 50 0 60 Ring gear shim selection 1 Select Ring gear shim s 1 Selection steps To find the ring gear shim thickness B use the following formula e a numeral usually a decimal number on the final drive gear case either added to 50 f a numeral usually a decimal number on the outside of the ring gear bearing ho...

Page 299: ... 95 4 h 14 00 5 Therefore shim thickness B is 0 48 B 50 98 1 55 34 95 14 00 49 43 48 95 0 48 6 Round off the hundredth digit and select the appropriate shim s In the example above the calculated number is 0 48 The chart instructs you to round off 8 to 10 at the hundredth place Thus the shim thickness is 0 50 mm Shims are supplied in the following thick nesses Bearing thickness h 14 00 mm Hundredth...

Page 300: ...ing the clearance with Plasti gauge Remove the ring gear assembly Measure the thrust clearance Calculate the width of the flattened Plastigauge 1 If out of specification select the correct washer T R M8 Bolts bearing housing 23 Nm 2 3 m kg 17 ft lb M10 Bolts bearing housing 40 Nm 4 0 m kg 29 ft lb Ring gear thrust clearance 0 1 0 2 mm 0 004 0 008 in Selection steps Select a suitable thrust washer ...

Page 301: ...cation Adjust 2 Ring gear 3 Ring gear stopper Ring gear stopper clearance D 0 30 0 60 mm 0 012 0 024 in 2 Remove Nut 1 3 Loosen Ring gear stopper 2 Adjusting steps Turn the ring gear stopper in or out until to the specified clearance Ring gear stopper clearance 0 3 0 6 mm 0 012 0 024 in 4 Install Nut Ring gear NOTE Use LOCTITE on the ring gear stopper T R 16 Nm 1 6 m kg 11 ft lb ...

Page 302: ...or the ring gear bearing housing are replaced be sure to adjust the shim of the final drive pinion gear and or ring gear 2 Check Gear teeth Pitting galling wear Replace the drive pin ion gear and ring gear as a set Oil seals O rings Damage Replace 3 Check Bearings Damage Replace NOTE Reusing roller bearings is acceptable but Yamaha recommends installing new ones Do not reuse the oil seal When the ...

Page 303: ...size 1 into the drain plug hole CAUTION Finger tighten the bolt until it holds the ring gear Otherwise the ring gear will be dam aged 4 Attach Gear lash measurement tool 1 Dial gauge 2 a Measuring point is 22 mm 0 87 in Gear lash measurement tool P N YM 01231 90890 01231 5 Measure Gear lash Gently rotate the gear coupling from engage ment to engagement NOTE Measure the gear lash at four positions ...

Page 304: ...d by more than 0 2 mm 0 008 in Reduce the thrust washer thickness by 0 2 mm 0 008 in for every 0 2 mm of ring gear shim increase If reduced by more than 0 2 mm 0 008 in Increase the thrust washer thickness by 0 2 mm 0 008 in for every 0 2 mm that the ring gear shim is decreased Too little gear lash Reduce shim thick ness Too large gear lash Increase shim thick ness Ring gear shim Thickness mm 0 25...

Page 305: ...rive gear operation Unsmooth operation Replace the final drive gear assembly Insert the double off set joint into the final drive gear and turn the gear back and forth INSTALLING THE FINAL DRIVE GEAR 1 Lubricate Drive shaft Coupling gear O ring Oil seal Bearing 2 Install Drive shaft Coupling gear 3 Install Final drive gear Nuts Recommended lubricant Yamaha Grizzly grease T R 55 Nm 5 5 m kg 40 ft l...

Page 306: ...CHAS 8 ...

Page 307: ...EAR BRAKE PADS 8 11 REPLACING THE FRONT BRAKE PAD 8 12 REPLACING THE REAR BRAKE PAD 8 14 FRONT BRAKE MASTER CYLINDER 8 16 REAR BRAKE MASTER CYLINDER 8 18 CHECKING THE MASTER CYLINDER 8 21 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER 8 22 ASSEMBLING THE REAR BRAKE MASTER CYLINDER 8 22 INSTALLING THE FRONT BRAKE MASTER CYLINDER 8 23 INSTALLING THE REAR BRAKE MASTER CYLINDER 8 24 FRONT BRAKE CALIPER 8 ...

Page 308: ...ND STEERING KNUCKLE 8 43 REMOVING THE STEERING KNUCKLE 8 44 CHECKING THE TIE ROD 8 44 CHECKING THE STEERING KNUCKLE 8 44 CHECKING THE BALL JOINT 8 45 CHECKING THE TIE ROD 8 45 FRONT ARMS AND FRONT SHOCK ABSORBER 8 46 REMOVING THE FRONT ARMS 8 48 CHECKING THE FRONT ARM 8 48 CHECKING THE FRONT SHOCK ABSORBER 8 48 INSTALLING THE FRONT ARMS AND FRONT SHOCK ABSORBER 8 49 REAR KNUCKLE AND STABILIZER 8 5...

Page 309: ... 145 ft lb T R 55 Nm 5 5 m kg 40 ft Ib 1 Order Job name Part name Q ty Remarks Removing the front wheel Remove the parts in the order below Place the machine on a level surface WARNING Securely support the machine so there is no danger of it falling over 1 Front wheel 1 Refer to INSTALLING THE FRONT WHEEL 2 Wheel cap 1 Refer to INSTALLING THE FRONT WHEEL HUB 3 Cotter pin 1 4 Axle nut 1 ...

Page 310: ...0 Nm 20 0 m kg 145 ft lb T R 55 Nm 5 5 m kg 40 ft Ib 1 Order Job name Part name Q ty Remarks 5 Brake caliper assembly 1 NOTE Do not squeeze the brake lever when the brake caliper is off of the brake disc as the brake pads will be forced shut 6 Front wheel hub 1 7 Brake disc 1 For installation reverse the removal procedure ...

Page 311: ...Out of balance Adjust Wheel runout limit Radial 2 2 0 mm 0 08 in Lateral 3 2 0 mm 0 08 in 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 CHECKING THE FRONT WHEEL HUB 1 Check Wheel hub 1 Cracks damage Replace Splines wheel hub 2 Wear damage Replace...

Page 312: ...mum deflection 0 15 mm 0 006 in Brake disc minimum thickness 3 mm 0 12 in INSTALLING THE FRONT WHEEL HUB 1 Install Axle nut Cotter pin 1 NOTE Do not apply oil to the seat of the nut 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 T R 200 Nm 20 0 m kg 145 ft lb New INSTALLING THE FR...

Page 313: ...8 5 CHAS FRONT WHEELS AND BRAKE DISCS 2 Tighten Nuts wheel 1 WARNING Tapered wheel nuts 1 are used for both the front and rear wheels Install each nut with its tapered side towards the wheel ...

Page 314: ...Remarks Removing the rear wheel Remove the parts in the order below Place the machine on a level surface WARNING Securely support the machine so there is no danger of it falling over 1 Rear wheel 1 Refer to INSTALLING THE REAR WHEEL 2 Wheel cap 1 Refer to INSTALLING THE REAR WHEEL HUB 3 Cotter pin 1 4 Axle nut 1 5 Rear wheel hub 1 For installation reverse the removal procedure ...

Page 315: ...art name Q ty Remarks Disassembling the rear brake disc Remove the parts in the order below Brake caliper assembly Refer to REAR BRAKE CALIPER Final drive gear Refer to FINAL DRIVE GEAR AND DRIVE SHAFT in CHAPTER 7 1 Rear brake disc plate 1 2 Rear brake disc 1 For assembly reverse the disassembly produce ...

Page 316: ...t limit Radial 2 0 mm 0 08 in Lateral 2 0 mm 0 08 in CHECKING THE REAR WHEEL HUB 1 Check Wheel hub 1 Cracks damage Replace Splines wheel hub 2 Wear damage Replace CHECKING THE REAR BRAKE DISC 1 Check Brake disc Galling damage Replace 2 Measure Brake disc deflection Out of specification Replace Brake disc thickness a Out of specification Replace Brake disc maximum deflection 0 1 mm 0 004 in Brake d...

Page 317: ...FRONT WHEEL HUB 2 Adjust Rear brake lever and pedal free play Refer to ADJUSTING THE REAR BRAKE LEVER AND PEDAL in CHAPTER 3 INSTALLING THE REAR WHEEL 1 Install Wheel Refer to INSTALLING THE FRONT WHEEL 2 Tighten Nuts wheel Refer to INSTALLING THE FRONT WHEEL REAR WHEELS AND BRAKE DISC ...

Page 318: ...the front brake pads Remove the parts in the order below Front wheel Refer to FRONT WHEELS 1 Brake caliper mounting bolt 2 Refer to REPLACING THE FRONT BRAKE PAD 2 Brake pad holding bolt 2 3 Brake pad pad shim 2 1 4 Pad spring 1 For installation reverse the removal procedure FRONT AND REAR BRAKES ...

Page 319: ...emarks Removing the rear brake pads Remove the parts in the order below Rear wheel left Refer to REAR WHEELS AND BRAKE DISC 1 Brake pad holding bolt plug 1 Refer to REPLACING THE REAR BRAKE PAD 2 Brake pad holding bolt 1 3 Pad spring 1 4 Brake pad insulator pad shim 2 2 2 For installation reverse the removal procedure ...

Page 320: ...aces or plastic parts as this may cause damage disconnect any hydraulic connection as this would require the entire brake sys tem to be disassembled drained cleaned properly filled and bled after reassembly REPLACING THE FRONT BRAKE PAD NOTE It is not necessary to disassemble the brake caliper and brake hose to replace the brake pads 1 Measure Brake pad wear limit a Out of specification Replace th...

Page 321: ...d shims 3 and a new brake pad spring Install the retaining bolts and brake caliper NOTE The arrow mark a on the pad shim must point in the direction of the disc rotation T R Brake caliper bleed screw 6 Nm 0 6 m kg 4 3 ft lb T R Brake pad holding bolt 18 Nm 1 8 m kg 13 ft lb Brake caliper mounting bolt 30 Nm 3 0 m kg 22 ft lb 3 Check Brake fluid level Refer to CHECKING THE BRAKE FLUID LEVEL in CHAP...

Page 322: ...ke pad spring as a set Installation steps Connect a suitable hose 1 tightly to the brake caliper bleed screw 2 Put the other end of this hose into an open container Loosen the brake caliper bleed screw and using a finger push the caliper piston into the brake caliper Tighten the brake caliper bleed screw Install new brake pads new insulator new pad shims and a new brake pad spring Install the reta...

Page 323: ...ck Brake fluid level Refer to CHECKING THE BRAKE FLUID LEVEL INSPECTION in CHAPTER 3 4 Check Brake lever or brake pedal operation Soft or spongy feeling Bleed the rear brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in CHAPTER 3 ...

Page 324: ...ke fluid Drain On command four wheel drive switch Refer to HANDLEBAR 1 Brake fluid reservoir cap 1 2 Brake fluid reservoir diaphragm 1 3 Brake lever 1 4 Union bolt 1 Refer to INSTALLING THE FRONT BRAKE MASTER CYLINDER 5 Copper washer 2 6 Brake hose 1 7 Front brake switch 1 8 Brake master cylinder bracket 1 9 Brake master cylinder 1 For installation reverse the removal procedure ...

Page 325: ...name Q ty Remarks Disassembling the front brake mas ter cylinder Remove the parts in the order below 1 Dust boot 1 Refer to ADJUSTING THE FRONT BRAKE MASTER CYLINDER 2 Circlip 1 3 Brake master cylinder kit 1 For assembly reverse the disassembly procedure ...

Page 326: ...me Part name Q ty Remarks Removing the rear brake master cyl inder Remove the parts in the order below Right footrest board Refer to FOOTREST BOARDS in CHAPTER 3 Brake fluid Drain 1 Brake master cylinder cover 1 2 Brake fluid reservoir cap 1 3 Brake fluid reservoir diaphragm holder 1 4 Brake fluid reservoir diaphragm 1 5 Brake fluid reservoir 1 6 Brake fluid reservoir hose 1 ...

Page 327: ...m kg 22 ft Ib 8 9 11 12 7 10 1 2 3 4 5 6 New New Order Job name Part name Q ty Remarks 7 Union bolt 1 Refer to INSTALLING THE REAR BRAKE MASTER CYLINDER 8 Copper washer 2 9 Brake hose 1 10 Circlip 1 11 Brake master cylinder 1 12 Hose joint 1 1 For installation reverse the removal procedure ...

Page 328: ...name Q ty Remarks Disassembling the rear brake mas ter cylinder Remove the parts in the order below 1 Brake master cylinder kit 1 Refer to ASSEMBLING THE REAR BRAKE MASTER CYLINDER 2 Brake master cylinder 1 For assembly reverse the disassembly procedure ...

Page 329: ... delivery passage brake master cylinder body Blockage Blow out with compressed air È Front É Rear É 2 Check Brake master cylinder kit Scratches wear damage Replace as a set È Front É Rear È É 3 Check Front brake master cylinder reservoir 1 Front brake master cylinder reservoir dia phragm 2 Cracks damage Replace 4 Check Rear brake fluid reservoir 1 Rear brake fluid reservoir diaphragm 2 Cracks dama...

Page 330: ...e fluid DOT 4 EB702060 ASSEMBLING THE REAR BRAKE MASTER CYLINDER WARNING All internal brake components should be cleaned and lubricated with new brake fluid only before installation Whenever a master cylinder is disassem bled replace the piston seals and dust seals 1 Install Brake master cylinder kit Nut 1 Joint 2 NOTE Turn the adjusting bolt 3 until the clearance a is within the specified limits ...

Page 331: ...wire harness leads etc Correct if necessary WARNING Proper brake hose routing is essential to insure safe machine operation Refer to CABLE ROUTING 3 Fill Brake fluid reservoir CAUTION Brake fluid may damage painted surfaces or plastic parts Always clean up spilled brake fluid immediately WARNING Use only the designated quality brake fluid other brake fluids may deteriorate the rubber seals causing...

Page 332: ... Check Brake fluid level Brake fluid level is under the LOWER level line Fill up Refer to CHECKING THE BRAKE FLUID LEVEL in CHAPTER 3 INSTALLING THE REAR BRAKE MASTER CYLINDER 1 Install Copper washers 1 Brake hose 2 Union bolt 3 CAUTION When installing the brake hose onto the brake master cylinder make sure the brake pipe touches the projection a as shown WARNING Proper brake hose routing is essen...

Page 333: ...e type of brake fluid mixing brake fluids may result in a harm ful chemical reaction and lead to poor brake performance Be careful that water does not enter the brake master cylinder when refilling Water will significantly lower the boiling point of the brake fluid and may result in vapor lock Recommended brake fluid DOT 4 3 Air bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in CH...

Page 334: ... the order below Brake fluid Drain Front wheel Refer to FRONT WHEELS 1 Union bolt 1 Refer to INSTALLING THE FRONT BRAKE CALIPER 2 Copper washer 2 3 Brake hose 1 Disconnect 4 Cap retaining bolt 1 1 Loosen 5 Brake pad holding bolt 2 Loosen 6 Brake caliper mounting bolt 2 7 Brake caliper assembly 1 For installation reverse the removal procedure ...

Page 335: ...the order below 1 Brake pad holding bolt 2 2 Brake pad pad shim 2 1 3 Pad spring 1 4 Retaining bolt 1 5 Caliper bracket 1 6 Brake caliper piston 1 Refer to DISASSEMBLING THE FRONT BRAKE CALIPER ASSEM BLING THE FRONT BRAKE CALIPER 7 Dust seal 1 8 Caliper piston seal 1 9 Bleed screw 1 For assembly reverse the disassembly procedure ...

Page 336: ...rt name Q ty Remarks Removing the rear brake caliper Remove the parts in the order below Brake fluid Drain Rear wheel Refer to REAR WHEELS 1 Brake hose holder 1 Refer to INSTALLAING THE REAR BRAKE CALI PER 2 Union bolt 1 3 Copper washer 2 4 Brake hose 1 Disconnect 5 Brake caliper mounting bolt 2 6 Brake caliper assembly 1 For installation reverse the removal procedure ...

Page 337: ...e order below 1 Brake pad holding bolt plug 1 2 Brake pad holding bolt 1 3 Pad spring 1 4 Brake pad insulator pad shim 2 2 2 5 Brake caliper piston 4 Refer to DISASSEMBLING THE REAR BRAKE CALIPER ASSEMBLING THE REAR BRAKE CALIPER 6 Dust seal 4 7 Caliper piston seal 4 8 Bleed screw 2 For assembly reverse the disassembly procedure ...

Page 338: ...on with a rag Be careful not to get injured when the piston is expelled from the master cylinder Remove the caliper piston seals DISASSEMBLING THE REAR BRAKE CALIPER 1 Remove Brake caliper piston Dust seals 1 Caliper piston seals 2 Removal steps Secure the left side brake caliper piston with a peace of wood a Blow compressed air into the hose joint opening b to force out the caliper piston from th...

Page 339: ... years Brake hoses Every two years Brake fluid Replace when braked are disas sembled 1 Check Brake caliper piston 1 Scratches rust wear Replace the brake caliper assembly Brake caliper cylinder 2 Wear scratches Replace the brake caliper assembly Brake caliper body 3 Cracks damage Replace Brake fluid delivery passage brake caliper body Blockage Blow out with compressed air WARNING Replace the calip...

Page 340: ...led 1 Install Caliper piston seal 1 Dust seal 2 Recommended brake fluid DOT 4 New New 2 Install Brake caliper piston 1 INSTALLING THE FRONT BRAKE CALIPER 1 Install Brake caliper assembly Brake caliper mounting bolt 1 Brake hose 2 Copper washers 3 Union bolt 4 T R 30 Nm 3 0 m kg 22 ft lb New T R 27 Nm 2 7 m kg 19 ft lb CAUTION When installing the brake hose on the brake caliper make sure that the b...

Page 341: ... leakage and poor brake performance Refill with the same type of brake fluid mixing brake fluids may result in a harm ful chemical reaction and lead to poor brake performance Be careful that water does not enter the master cylinder when refilling Water will significantly lower the boiling point of the brake fluid and may result in vapor lock 3 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRA...

Page 342: ...ould be cleaned and lubricated with new brake fluid only before installation Replace the caliper piston seal whenever a brake caliper is disassembled 1 Install Caliper piston seal 1 Dust seal 2 Recommended brake fluid DOT 4 New New 2 Install Brake caliper piston 1 FRONT AND REAR BRAKES ...

Page 343: ... may deteriorate the rubber seals causing leakage and poor brake performance Refill with the same type of brake fluid mixing brake fluids may result in a harm ful chemical reaction and lead to poor brake performance Be careful that water does not enter the master cylinder when refilling Water will significantly lower the boiling point of the brake fluid and may result in vapor lock 3 Air bleed Bra...

Page 344: ... differential gear lock switch 1 Refer to INSTALLING THE MASTER CYLINDER ASSEMBLY 4 Master cylinder assembly bracket 1 1 5 Throttle lever assembly bracket 1 1 6 Rear brake switch 1 Refer to REMOVING THE REAR BRAKE SWITCH 7 Rear brake lever bracket 1 1 Refer to INSTALLING THE REAR BRAKE LEVER 8 Handlebar switch 1 9 Handlebar grip 2 10 Handlebar holder 2 Refer to INSTALLING THE HANDLEBAR 11 Handleba...

Page 345: ...dle bar as this may dangerously weaken the handlebar INSTALLING THE HANDLEBAR 1 Install Handlebar Handlebar holders NOTE The upper handlebar holder should be installed with the punched mark 1 forward 2 CAUTION First tighten the bolts 3 on the front side of the handlebar holder and then tighten the bolts 4 on the rear side T R 20 Nm 2 0 m kg 14 ft lb INSTALLING THE REAR BRAKE LEVER 1 Install Handle...

Page 346: ...AS STEERING SYSTEM INSTALLING THE MASTER CYLINDER ASSEMBLY 1 Install Throttle lever assembly Master cylinder assembly NOTE The UP mark on the master cylinder bracket should face up T R 7 Nm 0 7 m kg 5 1 ft lb ...

Page 347: ...rder Job name Part name Q ty Remarks Removing the steering Remove the parts in the order below Handlebar Refer to HANDLEBAR Seat Refer to SEAT CARRIERS FEND ERS AND FUEL TANK in CHAPTER 3 Front fender 1 Lock washer 1 Refer to INSTALLING THE CABLE GUIDE 2 Cable guide 1 3 Steering stem bushing 2 4 Collar 2 5 Oil seal 2 6 Tie rod end nut 2 7 Tie rod 2 Disconnect 8 Steering stem nut 1 9 Pitman arm 1 1...

Page 348: ... m kg 18 ft Ib 6 11 12 13 8 9 14 4 10 5 3 5 3 2 1 New New T R 65 Nm 6 5 m kg 47 ft Ib LT LS LS LS LS 7 Order Job name Part name Q ty Remarks 11 Oil seal 1 12 Bearing retainer 1 Refer to REMOVING INSTALLING THE BEARING RETAINER 13 Bearing 1 14 Oil seal 1 For installation reverse the removal procedure ...

Page 349: ...ttempt to straighten a bent stem this may dangerously weaken the stem 2 Check Oil seals 1 Steering stem bushings 2 Wear damage Replace INSTALLING THE BEARING RETAINER 1 Install Bearing retainer steering stem Damper rod holder 30 mm P N YM 01327 90890 01327 T R 40 Nm 4 0 m kg 29 ft lb INSTALLING THE STEERING STEM 1 Install Steering stem NOTE The steering stem should be installed with the paint mark...

Page 350: ...ING THE CABLE GUIDE 1 Install Cable guide Lock washer 2 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 CHAP TER 2 New T R 23 Nm 2 3 m kg 17 ft lb ...

Page 351: ... Part name Q ty Remarks Removing the tie rod and steering knuckle Remove the parts in the order below Front fender Refer to SEAT CARRIERS FENDERS AND FUEL TANK in CHAPTER 3 Front wheel brake disc Refer to FRONT WHEELS 1 Tie rod 1 Refer to INSTALLING THE TIE ROD 2 Brake disc guard 1 3 Front protector 1 4 Bolt washer nut 1 1 1 5 Nut 1 6 O ring 1 7 Brake hose holder bolt 1 8 Steering knuckle 1 Refer ...

Page 352: ...ds damage Replace CHECKING THE STEERING KNUCKLE 1 Check Steering knuckle Damage pitting Replace 2 Check Front wheel bearings Bearings allow play in the wheel hubs or the wheel turns roughly Replace Oil seals Damage Replace Replacement steps Clean the outside of the steering knuckle Remove the oil seals 1 Drive out the bearings 2 WARNING Eye protection is recommended when using striking tools Remov...

Page 353: ...When installing the oil seals the seal side of the oil seal faces out CHECKING THE BALL JOINT 1 Check Ball joint Damage pitting Replace the front arm Free play Replace the front arm Turns roughly Replace the front arm CHECKING THE TIE ROD 1 Install Tie rods left and right NOTE The tie rod which must be installed on the out side has grooves 1 T R 25 Nm 2 5 m kg 18 ft lb 2 Adjust Toe in Refer to ADJ...

Page 354: ...R 7 Nm 0 7 m kg 5 1 ft Ib T R 25 Nm 2 5 m kg 18 ft Ib LS 4 New 10 6 LS 10 10 Order Job name Part name Q ty Remarks Removing the front arms and front shock absorber Remove the parts in the order below Engine skid plate front Refer to SEAT CARRIERS FEND ERS AND FUEL TANK in CHAPTER 3 Front fender Front wheel brake disc Refer to FRONT AND REAR WHEELS 1 Air duct 1 2 Brake disc guard 1 3 Front protecto...

Page 355: ... R 25 Nm 2 5 m kg 18 ft Ib LS 4 New 10 6 LS 10 10 Order Job name Part name Q ty Remarks 4 Bolt washer nut 1 1 1 Refer to REMOVING THE FRONT ARMS and INSTALLING THE FRONT ARMS AND FRONT SHOCK ABSORBER 5 Nut 1 6 Bolt nut 2 2 7 Front arm lower bushing 1 2 8 Nut bolt 2 2 9 Front shock absorber collar 1 1 10 Bolt nut 2 2 11 Front arm upper bushing 1 2 For installation reverse the removal procedure ...

Page 356: ...p and down If the vertical movement is tight or rough or if there is binding check the bushings 2 Remove Front arms CHECKING THE FRONT ARM 1 Check Front arms 1 Bends damage Replace 2 Check Bushings 2 Wear damage Replace CHECKING THE FRONT SHOCK ABSORBER 1 Check Shock absorber rod Bends damage Replace the shock absorber assembly Shock absorber assembly Oil leaks Replace the shock absorber assembly ...

Page 357: ...with lithium soap base grease Be sure to position the bolts 3 so that the bolt head faces outward Temporarily tighten the nuts 4 Install the front shock absorber 5 Install the ball joints Install the new cotter pins Tighten the nuts 4 NOTE Before tightening the nuts 4 adjust the length a to 324 mm 12 8 in T R Nut 6 45 Nm 4 5 m kg 32 ft lb T R Nut 7 25 Nm 2 5 m kg 18 ft lb Nut 8 48 Nm 4 8 m kg 35 f...

Page 358: ...2 3 5 4 4 5 1 LS LS Order Job name Part name Q ty Remarks Removing the rear knuckle and stabilizer Remove the parts in the order below Rear wheel hubs Refer to REAR WHEELS AND BRAKE DISC 1 Rear protector 1 2 O ring 1 3 Rear knuckle 1 4 Spacer cover 4 5 Spacer 2 6 Stabilizer joint 2 7 Brake hose holder 1 8 Stabilizer holder 2 9 Bushing 2 10 Stabilizer 1 For installation reverse the removal procedur...

Page 359: ...arings 2 WARNING Eye protection is recommended when using striking tools Remove the spacer 3 Apply lithium base grease to the bearings and oil seals Install the spacer to the rear knuckle Install the new bearings NOTE Install the outside bearing first CAUTION Do not strike the center race or balls of the bearing Contact should be made only with the outer race Install a new oil seal NOTE When insta...

Page 360: ...me Part name Q ty Remarks Removing the rear arms and rear shock absorber Remove the parts in the order below Rear protector rear knuckle stabilizer Refer to REAR KNUCKLE AND STABI LIZER 1 Nut bolt 2 2 2 Rear arm upper bushing washer 1 2 2 3 Nut bolt 2 2 4 Rear shock absorber 1 5 Nut bolt 2 2 6 Rear arm lower bushing 1 2 For installation reverse the removal procedure REAR ARMS AND REAR SHOCK ABSORB...

Page 361: ...place the shock absorber assembly Spring Move the spring up and down Fatigue Replace the shock absorber assembly CHECKING THE REAR ARMS AND REAR SHOCK ABSORBER 1 Install Rear arms Rear shock absorber Installation steps Install the rear arm upper 1 and rear arm lower 2 NOTE Lubricate the bolts 3 with lithium soap base grease Be sure to position the bolts 3 so that the bolt head faces outward Tempor...

Page 362: ...tall the rear knuckle Tighten the nuts 4 NOTE Before tightening the nuts 4 adjust the length a to 334 mm 13 1 in T R Nut 6 45 Nm 4 5 m kg 32 ft lb T R Nut 7 45 Nm 4 5 m kg 32 ft lb T R Nut 4 45 Nm 4 5 m kg 32 ft lb REAR ARMS AND REAR SHOCK ABSORBER ...

Page 363: ...ELEC 9 ...

Page 364: ... CIRCUIT DIAGRAM 9 8 TROUBLESHOOTING 9 9 ELECTRIC STARTING SYSTEM 9 14 CIRCUIT DIAGRAM 9 14 STARTING CIRCUIT OPERATION 9 15 TROUBLESHOOTING 9 16 STARTER MOTOR 9 20 CHECKING THE STARTER MOTOR 9 21 ASSEMBLING THE STARTER MOTOR 9 22 CHARGING SYSTEM 9 23 CIRCUIT DIAGRAM 9 23 TROUBLESHOOTING 9 24 LIGHTING SYSTEM 9 26 CIRCUIT DIAGRAM 9 26 TROUBLESHOOTING 9 27 CHECKING THE LIGHTING SYSTEM 9 29 SIGNAL SYS...

Page 365: ... ELEC 2WD 4WD SELECTING SYSTEM 9 51 CIRCUIT DIAGRAM 9 51 TROUBLESHOOTING 9 52 ...

Page 366: ...nder 7 Battery 8 Circuit breaker fan 9 Fuse box 0 Four wheel drive relay 3 A Four wheel drive relay 2 B Four wheel drive relay 1 C CDI unit D Starter relay E Main fuse F Rectifier regulator G Speed sensor H Reverse switch I Gear position switch J Gear motor K Rear brake light switch L Thermo switch 2 M Fan N Ignition coil 4 5 6 7 8 9 0 C D E B A F G H I J K L M N 1 2 3 ...

Page 367: ... and off a few times when checking it Pocket tester P N YU 03112 90890 03112 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 t...

Page 368: ...erminals Poor connection no continuity Correct or replace The coupler locations are circled L B Y G Br L B BLACK 1 4 5 B 6 2 3 R B R W PUSH Br L Y G B R W L B L G Br L Br R L R Sb Br Gy G R B R B L B 2WD 4WD LOCK L G L B L R Sb Gy Br G R B BLACK GRAY P L Gy W ON OFF R Br Br L Br B OFF ON P P Br Br Y BLACK 7 B B BLACK 8 9 0 A B B ...

Page 369: ...itch 3 Start switch 4 On command four wheel drive switch and differential gear lock switch 5 Main switch 6 Rear brake light switch 7 Front brake light switch 8 Rear brake switch 9 Horn switch for Europe and Oceania 0 Gear position switch A Reverse switch B Fuse ...

Page 370: ... shown in the illustration on the left Bulbs A and B are used for headlights and usually use a bulb holder which must be detached before removing the bulb The majority of these bulbs can be removed from their respective socket by turning them coun terclockwise Bulb C is used for turn signal and brake tail lights and can be removed from the socket by pushing and turning the bulb counter clockwise B...

Page 371: ...bulb and the luminous flux will be adversely affected If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 2 Check Bulb for continuity with the pocket tester No continuity Replace NOTE Before checking for continuity set the pocket tester to 0 and to the Ω 1 range a Connect the tester positive probe to terminal 1 and the tester negative probe ...

Page 372: ...ulb socket for continuity in the same manner as described in the bulb section however note the following a Install a good bulb into the bulb socket b Connect the pocket tester probes to the respective leads of the bulb socket c Check the bulb socket for continuity If any of the readings indicate no continuity replace the bulb socket Pocket tester P N YU 03112 90890 03112 CHECKING THE BULBS AND BUL...

Page 373: ...Br L Y W B B B B Br L L B B L Y G R B R G W Sb WIRE HARNESS IGNITION COIL LEAD C WIRE HARNESS B WIRE HARNESS SUB WIRE HARNESS SUB WIRE HARNESS A B B R W B W B B B R C C 1 8 4 5 6 7 A 9 C B D E G H I J K L M O N P Q R a f 3 Br L c d Br L Br L b U V Z L B R B Br B Br B Y Sb L B R B Br B Br B Y Sb R W R W G W G W W 2 R R G R R Br Br Br L R Br L G L B Y L R Y B R B R B L W L W L R L R W R W R Sb Sb B ...

Page 374: ... tank side panels 3 Front carrier 4 Front fender Use the following special tool s for trouble shooting Dynamic spark tester P N YM 34487 Ignition checker P N 90890 06754 Pocket tester P N YU 03112 90890 03112 EB802011 CONTINUITY 1 Fuse main ignition Refer to CHECKING THE SWITCH NO CONTINUITY Replace the fuse EB802012 CORRECT 2 Battery Check the battery condition Refer to CHECKING THE BATTERY in CH...

Page 375: ...itch and increase the spark gap until a misfiring occurs Minimum spark gap 6 0 mm 0 24 in MEETS SPECIFICATION The ignition system is not faulty For Europe and Oceania OUT OF SPECIFICATION OR NO SPARK 4 Ignition spark gap Disconnect the spark plug cap from the spark plug Connect the ignition checker 1 as shown 2 Spark plug cap Turn the main switch to ON Check the ignition spark gap a Crank the engi...

Page 376: ...tance Spark plug cap resistance 10 kΩ at 20 C 68 F OUT OF SPECIFICATION Replace the spark plug cap 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 speci fied resistance Primary coil resistance 0 18 0 28 Ω at 2...

Page 377: ...o CHECKING THE SWITCH INCORRECT Replace the handlebar switch left CORRECT 8 Main switch Refer to CHECKING THE SWITCH INCORRECT Replace the main switch 9 Pickup coil resistance Disconnect the AC magneto coupler from the wire harness Connect the pocket tester Ω 100 to the pickup coil terminal Tester lead White Red terminal 1 Tester lead White Green terminal 2 MEETS SPECIFICATION Check the pickup coi...

Page 378: ...al 1 Tester lead White Blue terminal 2 MEETS SPECIFICATION Check the charging rotor rotation direction detection coil for the specified resistance Rotor rotation direction sensing coil resistance 0 063 0 077 Ω at 20 C 68 F Red White Blue OUT OF SPECIFICATION Replace the pickup coil stator assembly CORRECT 11 Wiring connection Check the connections of the entire ignition system Refer to CIRCUIT DIA...

Page 379: ... L L B B L Y G R B R G W Sb WIRE HARNESS IGNITION COIL LEAD C WIRE HARNESS B WIRE HARNESS SUB WIRE HARNESS SUB WIRE HARNESS A B B R W B W B B B R C C 1 8 4 5 6 7 A 9 C B D E G H I J K L M O N P Q R a f 3 Br L c d Br L Br L b U V Z L B R B Br B Br B Y Sb L B R B Br B Br B Y Sb R W R W G W G W W 2 R R G R R Br Br Br L R Br L G L B Y L R Y B R B R B L W L W L R L R W R W R Sb Sb B L B Sb Br B T k S X...

Page 380: ...p switch is in the RUN position the starter motor can be operated only if 1 Main fuse 2 Battery 3 Starter relay 4 Starter motor 5 Start switch 6 Ignition fuse 7 Engine stop switch 8 CDI unit 9 Rear brake switch 0 Gear position switch È TO MAIN SWITCH É FROM MAIN SWITCH The transmission is in neutral the neutral switch is closed or The transmission is in park the rear brake switch is closed The rea...

Page 381: ...llowing part s before trouble shooting 1 Seat 2 Fuel tank side panels 3 Fuel tank 4 Air cleaner case 5 Front carrier 6 Front fender panel Use the following special tool s for trouble shooting Pocket tester P N YU 03112 90890 03112 EB802011 CONTINUITY 1 Fuse main ignition Refer to CHECKING THE SWITCH NO CONTINUITY Replace the fuse EB802012 CORRECT 2 Battery Check the battery condition Refer to CHEC...

Page 382: ... lead may burn This check is likely to produce sparks so be sure that no flammable gas or fluid is in the vicinity DOES NOT TURN Repair or replace the starter motor 4 Starter relay Remove the starter relay from the wire har ness Connect the pocket tester Ω 1 and the battery 12 V to the starter relay terminals CONTINUITY Battery terminal Blue White terminal 1 Battery terminal Blue Black terminal 2 ...

Page 383: ...he main switch CORRECT 6 Engine stop switch Refer to CHECKING THE SWITCH INCORRECT Replace the handlebar switch right CORRECT 7 Gear position switch Refer to CHECKING THE SWITCH INCORRECT Replace the gear position switch CORRECT 8 Rear brake switch Refer to CHECKING THE SWITCH INCORRECT Replace the rear brake switch ...

Page 384: ...nuity as follows Tester positive probe Blue Red 1 Tester negative probe Black Yellow 2 Continu ity Tester positive probe Black Yellow 2 Tester negative probe Blue Red 1 No conti nuity NOTE When you switch the tester s positive and negative probes the readings in the left chart will be reversed INCORRECT Replace the diode EB803028 11 Wiring connection Check the connections of the entire starting sy...

Page 385: ...s in the order below 1 Starter motor lead 1 2 Starter motor O ring 1 1 Disassembling the starter motor Remove the parts in the order below 1 Bracket 1 1 Refer to ASSEMBLING THE STARTER MOTOR 2 Washer kit 3 Bracket 2 1 4 Shims 5 Brush seat 1 brush seat 2 1 2 6 Armature coil 1 7 Yoke 1 For assembly reverse the disassembly procedure ...

Page 386: ... using a hacksaw blade which has been grounded to fit the commutator Outside diameter 28 mm 1 10 in Wear limit 27 mm 1 06 in Mica undercut 0 7 mm 0 03 in 4 Inspect Armature coil insulation continuity Defects Replace the starter motor Inspection steps Connect the pocket tester for the continuity check 1 and insulation check 2 Measure the armature resistances If the resistance is incorrect replace t...

Page 387: ...tigue out of specification Replace as a set Brush spring force 7 65 10 01 Nm 780 1 020 g 27 5 36 0 oz 7 Inspect Oil seal Bushing O rings Wear damage Replace ASSEMBLING THE STARTER MOTOR 1 Install Brush seat 1 1 NOTE Align the projection a on the brush seat 1 with the slot b on the yoke 2 Install Yoke Brackets NOTE Align the match marks a on the yoke with the match marks b on the brackets ...

Page 388: ...Y G W G W L W L B Br L Br L Br Br Br L Y W B B B B Br L L B B L Y G R B R G W Sb WIRE HARNESS IGNITION COIL LEAD C WIRE HARNESS B WIRE HARNESS SUB WIRE HARNESS SUB WIRE HARNESS A B B R W B W B B B R C C 1 8 4 5 6 7 A 9 C B D E G H I J K L M O N P Q R a f 3 Br L c d Br L Br L b U V Z L B R B Br B Br B Y Sb L B R B Br B Br B Y Sb R W R W G W G W W 2 R R G R R Br Br Br L R Br L G L B Y L R Y B R B R ...

Page 389: ...YU 8036 A Engine tachometer P N 90890 03113 Pocket tester P N YU 03112 90890 03112 EB802011 CONTINUITY 1 Fuse main Refer to CHECKING THE SWITCH NO CONTINUITY Replace the fuse EB802012 CORRECT 2 Battery Check the battery condition Refer to CHECKING THE BATTERY in CHAPTER 3 Open circuit voltage 12 8 V or more at 20 C 68 F INCORRECT Clean the battery terminals Recharge or replace the battery EB804011...

Page 390: ...ire harness Connect the pocket tester Ω 1 to the charging coils Tester lead White terminal 1 Tester lead White terminal 2 Tester lead White terminal 1 Tester lead White terminal 3 Measure the stator coil resistance Charging coil resistance 0 32 0 43 Ω at 20 C 68 F OUT OF SPECIFICATION Replace the pickup coil stator assembly EB804015 CORRECT 5 Wiring connections Check the connections of the entire ...

Page 391: ... L Br L Br Br Br L Y W B B B B Br L L B B L Y G R B R G W Sb WIRE HARNESS IGNITION COIL LEAD C WIRE HARNESS B WIRE HARNESS SUB WIRE HARNESS SUB WIRE HARNESS A B B R W B W B B B R C C 1 8 4 5 6 7 A 9 C B D E G H I J K L M O N P Q R a f 3 Br L c d Br L Br L b U V Z L B R B Br B Br B Y Sb L B R B Br B Br B Y Sb R W R W G W G W W 2 R R G R R Br Br Br L R Br L G L B Y L R Y B R B R B L W L W L R L R W ...

Page 392: ...ouble shooting 1 Seat 2 Front carrier 3 Front fender panel Use the following special tool s for trouble shooting Pocket tester P N YU 03112 90890 03112 EB802011 CONTINUITY 1 Fuse main headlight Refer to CHECKING THE SWITCH NO CONTINUITY Replace the fuse EB802012 CORRECT 2 Battery Check the battery condition Refer to CHECKING THE BATTERY in CHAPTER 3 Open circuit voltage 12 8 V or more at 20 C 68 F...

Page 393: ... CHECKING THE SWITCH INCORRECT Light switch is faulty replace the handlebar switch left EB805013 CORRECT 5 Wiring connection Check the connections of the entire lighting system Refer to WIRING DIAGRAM Check the condition of each of the lighting system s circuits Refer to CHECKING THE LIGHTING SYS TEM POOR CONNECTION Properly connect the lighting system ...

Page 394: ...o the headlight couplers Tester lead Green terminal 1 or Yellow terminal 2 Tester lead Black terminal 3 È When the lights switch is on LO É When the lights switch is on HI È É MEETS SPECIFICATION Turn the main switch to ON Turn the lights switch to LO or HI Check the voltage 12 V of the Green and Yellow leads on the bulb socket con nector This circuit is not faulty OUT OF SPECIFICATION The wiring ...

Page 395: ...2 Voltage Connect the pocket tester 20 V to the bulb socket coupler Tester lead Blue lead 1 Tester lead Black lead 2 MEETS 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 connector This circuit is not faulty OUT OF SPECIFICATION The wiring circuit from the main switch to the bulb socket connector is faulty repai...

Page 396: ...B L W R W G Y B R B B Y B Y G W G W L W L B Br L Br L Br Br Br L Y W B B B B Br L L B B L Y G R B R G W Sb WIRE HARNESS IGNITION COIL LEAD C WIRE HARNESS B WIRE HARNESS SUB WIRE HARNESS SUB WIRE HARNESS A B B R W B W B B B R C C 1 8 4 5 6 7 A 9 C B D E G H I J K L M O N P Q R a f 3 Br L c d Br L Br L b U V Z L B R B Br B Br B Y Sb L B R B Br B Br B Y Sb R W R W G W G W W 2 R R G R R Br Br Br L R B...

Page 397: ...nt temperature indicator light I Reverse indicator light J Neutral indicator light K Park indicator light L High range indicator light M Low range indicator light N Gear position switch P Fuel sender Q Thermo switch 1 Z Gear motor Ignition fuse f Signaling system fuse g Rear brake light switch h Front brake light switch i Brake tail light j Horn switch k Horn ...

Page 398: ...hooting 1 Seat 2 Fuel tank 3 Air cleaner case 4 Front carrier 5 Front fender panel Use the following special tool s for trouble shooting Pocket tester P N YU 03112 90890 03112 EB802011 CONTINUITY 1 Fuse main ignition signaling system Refer to CHECKING THE SWITCH NO CONTINUITY Replace the fuse EB802012 CORRECT 2 Battery Check the battery condition Refer to CHECKING THE BATTERY in CHAPTER 3 Open cir...

Page 399: ...RRECT Replace the main switch EB806011 CORRECT 4 Wiring connections Check the connections of the entire signal system Refer to CIRCUIT DIAGRAM Check the condition of each of the signal sys tem s circuits Refer to CHECKING THE SIGNAL SYS TEM POOR CONNECTION Properly connect the signal system ...

Page 400: ...E SWITCH NO CONTINUITY Replace the brake light switch 3 Voltage Connect the pocket tester DC 20 V to the bulb socket connector Tester lead Yellow terminal 1 Tester lead Black terminal 2 MEETS SPECIFICATION Turn the main switch to ON Turn the lights switch to LO or HI Check the voltage 12 V of the Yellow lead on the bulb socket connector This circuit is not faulty OUT OF SPECIFICATION The wiring ci...

Page 401: ...sition switch Refer to CHECKING THE SWITCH NO CONTINUITY Replace the gear position switch 3 Voltage Connect the pocket tester DC 20 V to the bulb socket coupler Tester lead Red White terminal 1 Tester lead Sky blue terminal 2 MEETS SPECIFICATION Turn the main switch to ON Check the voltage 12 V This circuit is not faulty OUT OF SPECIFICATION The wiring circuit from the main switch to the bulb sock...

Page 402: ...itch Refer to CHECKING THE SWITCH NO CONTINUITY Replace the gear position switch 3 Voltage Connect the pocket tester DC 20 V to the bulb socket coupler Tester lead Red White terminal 1 Tester lead Blue Red terminal 2 MEETS SPECIFICATION Turn the main switch to ON Check the voltage 12 V This circuit is not faulty OUT OF SPECIFICATION The wiring circuit from the main switch to the bulb socket connec...

Page 403: ...ition switch Refer to CHECKING THE SWITCH NO CONTINUITY Replace the gear position switch 3 Voltage Connect the pocket tester DC 20 V to the bulb socket coupler Tester lead Red White terminal 1 Tester lead Blue White terminal 2 MEETS SPECIFICATION Turn the main switch to ON Check the voltage 12 V This circuit is not faulty OUT OF SPECIFICATION The wiring circuit from the main switch to the bulb soc...

Page 404: ...tion switch Refer to CHECKING THE SWITCH NO CONTINUITY Replace the gear position switch 3 Voltage Connect the pocket tester DC 20 V to the bulb socket coupler Tester lead Red White terminal 1 Tester lead White Red terminal 2 MEETS SPECIFICATION Turn the main switch to ON Check the voltage 12 V This circuit is not faulty OUT OF SPECIFICATION The wiring circuit from the main switch to the bulb socke...

Page 405: ...rse switch Refer to CHECKING THE SWITCH NO CONTINUITY Replace the reverse switch 3 Voltage Connect the pocket tester DC 20 V to the bulb socket coupler Tester lead Red White terminal 1 Tester lead Green Blue terminal 2 MEETS SPECIFICATION Turn the main switch to ON Check the voltage 12 V Replace the CDI unit OUT OF SPECIFICATION The wiring circuit from the main switch to the bulb socket connector ...

Page 406: ...ster Ω 1 to the thermo switch 1 Immerse the thermo switch 1 in coolant 2 Check the thermo switch 1 for continuity While heating the coolant use a thermome ter 3 to record the temperatures Test step Water temperature Good condition Thermo switch 1 1 0 103 C 32 217 4 F 2 More than 110 3 C 230 5 4 F 3 110 103 C 230 217 4 F 4 Less than 103 C 217 4 F Tests 1 2 Heat up tests Tests 3 4 Cool down tests Co...

Page 407: ...minal 1 Tester lead Frame ground MEETS SPECIFICATION Turn the main switch to ON Check the voltage 12 V OUT OF SPECIFICATION The wiring circuit from the main switch to the bulb socket connector is faulty repair it CORRECT 4 Start switch Refer to CHECKING THE SWITCH This circuit is not faulty INCORRECT Replace the handlebar switch left ...

Page 408: ...CONTINUITY 2 Four wheel drive switch Refer to CHECKING THE SWITCH NO CONTINUITY Replace the four wheel drive switch 3 Voltage Connect the pocket tester DC 20 V to the bulb socket lead Tester lead Black Red terminal 1 Tester lead Frame ground MEETS SPECIFICATION Turn the main switch to ON Check the voltage 12 V This circuit is not faulty OUT OF SPECIFICATION The wiring circuit from the main switch ...

Page 409: ...ster lead Frame ground MEETS SPECIFICATION HORN IS NOT SOUNDED Turn the main switch to ON Push the horn switch Check for voltage 12 V on the Pink lead at the horn terminal 3 Horn Disconnect the black lead at the horn termi nal Connect a jumper lead 1 to the horn termi nal and ground the jumper lead Turn the main switch to ON OUT OF SPECIFICATION The wiring circuit from the main switch to the bulb ...

Page 410: ...e horn connector at the horn terminal Tester lead Black lead 1 Tester lead Frame ground MEETS SPECIFICATION Turn the main switch to ON Push the horn switch Check for voltage 12 V on the Black lead at the horn terminal Adjust or replace horn OUT OF SPECIFICATION Replace horn ...

Page 411: ...r L Br Br Br L Y W B B B B Br L L B B L Y G R B R G W Sb WIRE HARNESS IGNITION COIL LEAD C WIRE HARNESS B WIRE HARNESS SUB WIRE HARNESS SUB WIRE HARNESS A B B R W B W B B B R C C 1 8 4 5 6 7 A 9 C B D E G H I J K L M O N P Q R a f 3 Br L c d Br L Br L b U V Z L B R B Br B Br B Y Sb L B R B Br B Br B Y Sb R W R W G W G W W 2 R R G R R Br Br Br L R Br L G L B Y L R Y B R B R B L W L W L R L R W R W ...

Page 412: ...ier 3 Front fender Use the following special tool s for trouble shooting Pocket tester P N YU 03112 90890 03112 EB802011 CONTINUITY 1 Fuse main Refer to CHECKING THE SWITCH NO CONTINUITY Replace the fuse EB802012 CORRECT 2 Battery Check the battery condition Refer to CHECKING THE BATTERY in CHAPTER 3 Open circuit voltage 12 8 V or more at 20 C 68 F INCORRECT Clean the battery terminals Recharge or...

Page 413: ... Battery lead Black terminal 2 Check the operation of the fan motor DOES NOT TURN Replace the fan motor MEETS SPECIFICATION 5 Circuit breaker fan motor Remove the circuit breaker from the wire harness Connect the pocket tester Ω 1 to the cir cuit breaker Circuit breaker resistance Zero Ω at 20 C 68 F OUT OF SPECIFICATION Replace the circuit breaker ...

Page 414: ...emperatures Test step Water temperature Good condition Thermo switch 2 1 Less than 75 3 C 167 5 4 F 2 More than 75 3 C 167 5 4 F 3 More than 68 C 154 4 F 4 Less than 68 C 154 4 F Tests 1 2 Heat up tests Tests 3 4 Cool down tests Continuity No continuity WARNING Handle the thermo switch 2 with special care Never subject it to a strong shock or allow it to be dropped Should it be dropped it must be ...

Page 415: ...LING SYSTEM C0NTINUITY EB803028 CORRECT 7 Wiring connection Check the connections of the entire starting system Refer to CIRCUIT DIAGRAM This circuit is not faulty POOR CONNECTION Properly connect the cooling system ...

Page 416: ... HARNESS IGNITION COIL LEAD C WIRE HARNESS B WIRE HARNESS SUB WIRE HARNESS SUB WIRE HARNESS A B B R W B W B B B R C C 1 8 4 5 6 7 A 9 C B D E G H I J K L M O N P Q R a f 3 Br L c d Br L Br L b U V Z L B R B Br B Br B Y Sb L B R B Br B Br B Y Sb R W R W G W G W W 2 R R G R R Br Br Br L R Br L G L B Y L R Y B R B R B L W L W L R L R W R W R Sb Sb B L B Sb Br B T k S X Y B L R B Br L Br R Br R Br B B...

Page 417: ...em NOTE Remove the following part s before trouble shooting 1 Seat 2 Front carrier 3 Front fender Use the following special tool s for trouble shooting Pocket tester P N YU 03112 90890 03112 EB802011 CONTINUITY 1 Fuse main four wheel drive Refer to CHECKING THE SWITCH NO CONTINUITY Replace the fuse EB802012 CORRECT 2 Battery Check the battery condition Refer to CHECKING THE BATTERY in CHAPTER 3 Op...

Page 418: ... Brown Red terminal 5 Check the four wheel drive relay 1 for con tinuity NO CONTINUITY Replace the four wheel drive relay 1 CONTINUITY 5 Four wheel drive relay 2 Remove the four wheel drive relay 2 from the wire harness Connect the pocket tester Ω 1 and the battery 12 V to the four wheel drive relay 2 terminals Tester lead Black Yellow terminal 1 Tester lead Black terminal 2 Battery terminal Brown...

Page 419: ...ter lead Yellow Black terminal 2 Battery terminal Brown Red terminal 1 Battery terminal Yellow Black terminal 2 Tester lead Blue Red terminal 3 Tester lead Gray terminal 4 Check the four wheel drive relay 3 for con tinuity NO CONTINUITY Replace the four wheel drive relay 3 CORRECT 7 On command four wheel drive switch and differential gear lock switch Refer to CHECKING THE SWITCH INCORRECT Replace ...

Page 420: ...ear 2 turns counter clockwise É Check that the pinion gear 2 turns clockwise Make sure that the drive gear shift fork sliding gear operates correctly NOTE When installing the differential gear case in the gear motor refer to FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR in CHAPTER 7 INCORRECT Replace the gear motor EB803028 CORRECT 9 Wiring connection Check the connections of the entire 2WD...

Page 421: ......

Page 422: ...TRBL SHTG 10 ...

Page 423: ...VE TRAIN 10 3 FAULTY GEAR SHIFTING 10 4 HARD SHIFTING 10 4 SHIFT LEVER DOES NOT MOVE 10 4 JUMPS OUT OF GEAR 10 4 FAULTY CLUTCH PERFORMANCE 10 4 ENGINE OPERATES BUT MACHINE WILL NOT MOVE 10 4 CLUTCH SLIPPING 10 4 POOR STARTING PERFORMANCE 10 4 POOR SPEED PERFORMANCE 10 5 OVERHEATING 10 5 OVERHEATING 10 5 FAULTY BRAKE 10 5 POOR BRAKING EFFECT 10 5 SHOCK ABSORBER MALFUNCTION 10 6 MALFUNCTION 10 6 UNS...

Page 424: ...TRBL SHTG ...

Page 425: ... Improper heat range Faulty spark plug cap Ignition coil Broken or shorted primary secondary Faulty spark plug lead Broken body CDI system Faulty CDI unit Faulty pickup coil Faulty charging rotor rotation direction coil Broken woodruff key Carburetor Deteriorated or contaminated fuel Clogged pilot jet Clogged pilot air passage Sucked in air Deformed float Worn needle valve Improperly sealed valve ...

Page 426: ...E 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 CDI unit Faulty pickup coil Faulty charging rotor rotation direction coil Faulty ignition coil Valve train ...

Page 427: ...uses 1 A pronounced hesitation or jerky movement during acceleration deceleration or sustained speed This must not be confused with engine surging or transmission characteris tics 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 mech anism no power transmitted from the engine to the front and or ...

Page 428: ...per lever Shift fork Worn shift fork Shift cam Improper thrust play Worn shift cam groove Transmission Worn gear dog FAULTY CLUTCH PERFORMANCE ENGINE OPERATES BUT MACHINE WILL NOT MOVE V belt Bent damaged or worn V belt V belt slips Primary pulley cam and primary pulley slider Damaged or worn primary pulley cam Damaged or worn primary pulley slider Transmission Damaged transmission gears CLUTCH SL...

Page 429: ...tion system Improper spark plug gap Improper spark plug heat range Faulty CDI 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 EFFEC...

Page 430: ...Deformed steering knuckles Tires Uneven tire pressures on both sides Incorrect tire pressure Uneven tire wear Wheels Deformed wheel Loose bearing Bent or loose wheel axle Excessive wheel runout Frame Bent Damaged frame LIGHTING SYSTEM HEADLIGHT DARK Improper bulb Too many electric accessories Hard charging broken charging coil and or faulty rectifier regulator Incorrect connection Improperly groun...

Page 431: ... G B R W B R W W L W L W L G R G Y G Y G L W e e h g R Y R W R Y R B L B R W R W i j Y Br B Br B Y PUSH OFF ON B B B R P Br F L R B P Br W B R Y B G L 1 AC magneto 2 Rectifier regulator 3 Main switch 4 Backup fuse 5 Battery 6 Main fuse 7 Starter relay 8 Starter motor 9 Reverse switch 0 CDI unit A Rear brake switch B Ignition coil C Spark plug D Speed sensor E Meter assembly F Multi function meter ...

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