Page 1 YFM450FAR SERVICE MANUAL LIT-11616-16-01 5ND-F8197-10 Not For Resale www.SmallEngineDiscount.com...
Page 2 YFM450FAR SERVICE MANUAL ©2002 by Yamaha Motor Corporation, U.S.A. First Edition, March 2002 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. LIT-11616-16-01 Not For Resale...
Page 3: Important Information
EB001000 NOTICE This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha machine has a basic understanding of the mechanical ideas and the procedures of machine repair.
Page 4: How To Use This Manual
EB002000 HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”) 1st title 1: This is the title of the chapter with its symbol in the upper right corner of each page. 2nd title 2: This title indicates the section of the chapter and only appears on the first page of each section.
Page 5 EB003000 ILLUSTRATED SYMBOLS Illustrated symbols 1 to 0 are printed on the SPEC INFO top right of each page and indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Cooling system 6 Carburetion 7 Drive train COOL...
Page 6 TABLE OF CONTENTS GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC CHECKS AND ADJUSTMENTS ENGINE COOLING SYSTEM COOL CARBURETION CARB DRIVE TRAIN DRIV CHASSIS CHAS – ELECTRICAL ELEC TROUBLESHOOTING TRBL SHTG Not For Resale www.SmallEngineDiscount.com...
Page 7: Table Of Contents
CONTENTS CHAPTER 1. GENERAL INFORMATION MACHINE IDENTIFICATION ................ 1-1 VEHICLE IDENTIFICATION NUMBER ..........1-1 MODEL LABEL ..................1-1 FEATURES ....................1-2 LIQUID COOLING ENGINE ..............1-2 PARK POSITION ................... 1-2 FRONT DIFFERENTIAL ................ 1-3 IMPORTANT INFORMATION ............... 1-8 PREPARATION FOR REMOVAL PROCEDURES ....... 1-8 REPLACEMENT PARTS ...............
Page 8: Periodic Checks And
COOLANT FLOW DIAGRAMS ..............2-22 OIL FLOW DIAGRAMS ................2-24 CABLE ROUTING ..................2-27 CHAPTER 3. PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION ................... 3-1 PERIODIC MAINTENANCE/LUBRICATION ..........3-1 SEAT, CARRIERS, FENDERS AND FUEL TANK ........3-3 SEAT AND SIDE PANELS ..............3-3 FRONT CARRIER, FRONT BUMPER AND FRONT FENDER .....
Page 9 CHASSIS ....................3-36 ADJUSTING THE REAR BRAKE ............3-36 CHECKING THE BRAKE FLUID LEVEL ..........3-38 CHECKING THE FRONT BRAKE PAD ..........3-39 CHECKING THE REAR BRAKE PAD ..........3-39 CHECKING THE BRAKE HOSE ............3-40 BLEEDING THE HYDRAULIC BRAKE SYSTEM ....... 3-41 ADJUSTING THE SELECT LEVER CONTROL CABLE AND SHIFT ROD ................
Page 10 CAMSHAFT, ROCKER ARMS AND VALVES ........... 4-16 REMOVING THE CAMSHAFT AND ROCKER ARM ......4-18 REMOVING THE VALVE AND VALVE SPRING ........ 4-18 CHECKING THE CAMSHAFT ............. 4-19 CHECKING THE ROCKER ARM AND CAMSHAFT ......4-19 CHECKING THE VALVE AND VALVE SPRING ......... 4-21 INSTALLING THE VALVE AND VALVE SPRING .......
Page 11 CRANKCASE ....................4-56 STARTER MOTOR, TIMING CHAIN AND OIL FILTER ...... 4-56 CRANKCASE ..................4-58 CRANKCASE BEARING ..............4-59 REMOVING THE OIL PUMP DRIVE GEAR ........4-60 SEPARATING THE CRANKCASE ............4-60 CHECKING THE TIMING CHAIN AND GUIDE ........4-61 CHECKING THE OIL STRAINER AND OIL DELIVERY PIPE ....
Page 12 CHAPTER 5. COOLING SYSTEM RADIATOR ....................5-1 CHECKING THE RADIATOR ..............5-3 INSTALLING THE RADIATOR .............. 5-4 THERMOSTAT ....................5-5 CHECKING THE THERMOSTAT ............5-6 INSTALLING THE THERMOSTAT ............5-6 WATER PUMP ....................5-7 DISASSEMBLING THE WATER PUMP ..........5-9 CHECKING THE WATER PUMP ............
Page 13 REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT ......7-17 REMOVING THE REAR AXLE ............7-20 DISASSEMBLING THE FINAL DRIVE GEAR ........7-20 REPLACING THE FINAL DRIVE ROLLER BEARING ......7-21 POSITIONING THE FINAL DRIVE PINION GEAR AND RING GEAR ................7-22 CHECKING THE REAR AXLE ............
Page 14 STEERING SYSTEM .................. 8-30 HANDLEBAR ..................8-30 REMOVING THE REAR BRAKE SWITCH ......... 8-31 CHECKING THE HANDLEBAR ............8-31 INSTALLING THE HANDLEBAR ............8-31 INSTALLING THE REAR BRAKE LEVER .......... 8-31 INSTALLING THE MASTER CYLINDER ASSEMBLY ......8-32 STEERING STEM ................8-33 REMOVING THE BEARING RETAINER ..........
Page 15 CHECKING THE BULBS AND BULB SOCKETS ........9-6 TYPES OF BULBS ................9-6 CHECKING THE CONDITION OF THE BULBS ........9-6 CHECKING THE CONDITION OF THE BULB SOCKETS ....9-8 IGNITION SYSTEM ..................9-9 CIRCUIT DIAGRAM ................9-9 TROUBLESHOOTING ................ 9-10 ELECTRIC STARTING SYSTEM ...............
Page 16 CHAPTER 10. TROUBLESHOOTING STARTING FAILURE/HARD STARTING ........... 10-1 FUEL SYSTEM ..................10-1 ELECTRICAL SYSTEM ............... 10-1 COMPRESSION SYSTEM ..............10-2 POOR IDLE SPEED PERFORMANCE ............10-2 POOR IDLE SPEED PERFORMANCE ..........10-2 POOR MEDIUM AND HIGH-SPEED PERFORMANCE ......10-2 POOR MEDIUM AND HIGH-SPEED PERFORMANCE ..... 10-2 FAULTY DRIVE TRAIN ................
Page 17: Chapter 1. General Information
MACHINE IDENTIFICATION INFO GENERAL INFORMATION MACHINE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the left side of the frame. MODEL LABEL The model label 1 is affixed to the frame. This information will be needed to order spare parts.
Page 18: Features
FEATURES INFO FEATURES LIQUID COOLING ENGINE Compact liquid cooled 45° inclined engine. A liquid cooling system has been incorporated for stable power and engine endurance. 1 Radiator 2 Thermo switch 3 Fan motor PARK POSITION When the drive select lever is shifted into the park position, a stopper lever is engaged into the stopper gear preventing the drive select lever and transmission from moving.
Page 19: Front Differential
FEATURES INFO FRONT DIFFERENTIAL 1 Adapter 7 Drive pinion gear 2 Drive clutch 8 Gear motor 3 Differential side gear (left) 4 Differential pinion gear È To front wheel 5 Ring gear É From the middle gear 6 Differential side gear (right) Not For Resale 1 - 3 www.SmallEngineDiscount.com...
Page 20 FEATURES INFO Power is transmitted as follows: middle gear → front drive shaft → drive pinion gear 7 → ring gear 5 → differential pinion gear 4. In the 2WD mode, the left differential side gear 3 and the drive clutch 2 are not engaged, therefore, the left side gear runs idle and does not transmit power to the left front constant velocity joint.
Page 21 FEATURES INFO When the 4WD mode is selected, the gear motor is operated, and the drive clutch 2 moves to the right and engages with the left differential side gear 3. Accordingly, power is transmitted as follows: ring gear 5 → differential pinion gear 4 → left differential side gear 3 → drive clutch 2 → adapter 1 →...
Page 22 FEATURES INFO 4WD (Diff-Lock) When the 4WD (Diff-Lock) mode is selected, the gear motor moves the drive clutch 2 further to the right, which causes the ring gear 5 and the drive clutch 2 to engage. As a result, power is transmitted directly from the ring gear 5 to the drive clutch 2, then to the left front constant velocity joint via the adapter 1.
Page 23 FEATURES INFO In addition, the 4WD (Diff-Lock) mode can be engaged only when the ATV is stopped. Even if an attempt is made to select this mode when the ATV is traveling, it will only result in a standby condition (i.e., when the differential lock select switch and the differential gear are not matched). (1) When the ATV is traveling Even if the 4WD (Diff-Lock) mode is selected, the gear motor will stand by, instead of operating.
Page 24: Important Information
5.Keep all parts away from any source of fire. EB101010 REPLACEMENT PARTS 1.Use only genuine Yamaha parts for all replacements. grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.
Page 25: Lock Washers/Plates And Cotter Pins
IMPORTANT INFORMATION INFO EB101030 LOCK WASHERS/PLATES AND COTTER PINS 1.Replace all lock washers/plates 1 and cotter pins after removal. Bend lock tabs along the bolt or nut flats after the bolt or nut has been tightened to specification. EB101040 BEARINGS AND OIL SEALS 1.Install bearings and oil seals so that the manufacturer’s marks or numbers are visible.
Page 26: Checking Of Connections
CHECKING OF CONNECTIONS INFO EB801000 CHECKING OF CONNECTIONS Check connectors stains, rust, moisture, etc. 1.Disconnect: Connector 2.Check: Connector Moisture → Dry each terminal with an air blower. Stains/rust → Connect and disconnect the terminals several times. 3.Check: Connector leads Looseness → Bend up the pin 1 and connect the terminals.
Page 27: Special Tools
SPECIAL TOOLS INFO EB102001 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools; this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools may differ by shape and part number from country to country.
Page 28 SPECIAL TOOLS INFO Tool No. Tool name/How to use Illustration Crankshaft installer set YU-90050 These tools are used to install the crankshaft. Adapter (#11) Adapter Spacer (crankshaft) YM-33279 Spacer 90890-04060 These tools are used to install the YM-90070-A crankshaft. Piston pin puller set 90890-01304 YU-01304 This tool is used to remove the piston...
Page 29 SPECIAL TOOLS INFO Tool No. Tool name/How to use Illustration Sheave fixed block 90890-04135 This tool is needed when removing or YM-04135 installing the secondary sheave spring. Flywheel puller 90890-01404 YM-01404 These tools are needed to remove the rotor. Damper rod holder (30 mm) 90890-01327 This tool is needed to loosen and YM-01327...
Page 30 SPECIAL TOOLS INFO Tool No. Tool name/How to use Illustration Compression gauge Compression gauge 90890-03081 Adapter YU-33223 Adapter These tools are needed to measure 90890-04082 YU-33223-3 engine compression. Pocket tester 90890-03112 YU-03112 This instrument is needed for checking the electrical system. Engine tachometer 90890-03113 This tool is needed for observing...
Page 31 This instrument is necessary for checking the ignition system components. Dynamic spark tester This instrument is necessary for YM-34487 checking the ignition system components. Yamaha bond No. 1215 Bond ® Sealant (Quick Gasket 90890-85505 Sealant This sealant (bond) is used on ACC-11001-05-01 crankcase mating surfaces, etc.
Page 32: Chapter 2. Specifications
SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Model code: 5ND1, 5ND5 Dimensions: Overall length 1,984 mm (78.1 in) Overall width 1,085 mm (42.7 in) Overall height 1,120 mm (44.1 in) Seat height 827 mm (32.6 in) Wheelbase 1,233 mm (48.5 in) Minimum ground clearance 245 mm (9.7 in) Minimum turning radius...
Page 33 SPEC GENERAL SPECIFICATIONS Item Standard Differential gear case oil Periodic oil change 0.23 L (0.20 Imp qt, 0.24 US qt) Total amount 0.28 L (0.25 Imp qt, 0.30 US qt) Radiator capacity (including all routes) 1.32 L (1.16 Imp qt, 1.40 US qt) Air filter: Wet type element Fuel:...
Page 34 SPEC GENERAL SPECIFICATIONS Item Standard Tire pressure (cold tire): Maximum load* 210 kg (463 lb) Off-road riding front 22 ~ 28 kPa (0.22 ~ 0.28 kg/cm , 3.2 ~ 4.0 psi) rear 22 ~ 28 kPa (0.22 ~ 0.28 kg/cm , 3.2 ~ 4.0 psi) *Load in total weight of rider accessories Brake:...
Page 35: Maintenance Specifications
SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Cylinder head: Warp limit ---- 0.03 mm (0.0012 in) Cylinder: Bore size 84.500 ~ 84.510 mm 84.600 mm (3.3268 ~ 3.3272 in) (3.3307 in) Taper limit ---- 0.05 mm (0.0016 in) Out of round limit ---- 0.01 mm...
Page 36 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Cam chain: Cam chain type/No. of links DID SCR-0409 SDH/116 ---- Cam chain adjustment method Automatic ---- Rocker arm/rocker arm shaft: Bearing inside diameter 12.000 ~ 12.018 mm 12.078 mm (0.4724 ~ 0.4731 in) (0.4755 in) Shaft outside diameter 11.981 ~ 11.991 mm...
Page 37 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Stem runout limit ---- 0.01 mm (0.0004 in) Valve seat width 1.2 ~ 1.4 mm ---- (0.0472 ~ 0.0551 in) 1.2 ~ 1.4 mm ---- (0.0472 ~ 0.0551 in) Valve spring: Inner spring Free length 39.9 mm (1.57 in) 37.9 mm (1.49 in)
Page 38 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Tilt limit 2.5°/1.6 mm (2.5°/0.06 in) 2.5°/1.6 mm (2.5°/0.06 in) Direction of winding (top view) Clockwise ---- Clockwise ---- Piston: Piston to cylinder clearance 0.040 ~ 0.065 mm 0.150 mm (0.0016 ~ 0.0026 in) (0.0059 in) Piston size “D”...
Page 39 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit 2nd ring Type Taper ---- Dimensions (B × T) 1.0 × 3.6 mm ---- (0.0394 × 0.1417 in) End gap (installed) 0.40 ~ 0.60 mm 0.95 mm (0.0157 ~ 0.0236 in) (0.0374 in) Side clearance 0.02 ~ 0.06 mm 0.12 mm (0.0008 ~ 0.0024 in)
Page 40 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Transmission: Main axle deflection limit ---- 0.06 mm (0.0024 in) Drive axle deflection limit ---- 0.06 mm (0.0024 in) Shifter: Shifter type Shift cam and guide bar ---- Air filter oil grade: Engine oil ---- Carburetor: I.
Page 41 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Cooling system: Radiator core Width 300 mm (11.8 in) ---- Height 208 mm (8.19 in) ---- Thickness 26 mm (1.02 in) ---- Radiator cap opening pressure 93.7 ~ 122.6 kPa (0.937 ~ ---- 1.226 kg/cm , 13.32 ~ 17.43 psi) Radiator capacity 0.70 L (0.62 Imp qt, 0.74 US qt)
Page 42 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Cylinder head tightening sequence: Not For Resale 2 - 11 www.SmallEngineDiscount.com...
Page 43 SPEC MAINTENANCE SPECIFICATIONS Tightening torques Tightening torque Part Thread Part to be tightened Q’ty Remarks name size m·kg ft·lb Cylinder head oil passage Union bolt Cylinder head (exhaust pipe) Stud bolt Cylinder head Bolt Bolt Camshaft sprocket cover baffle Bolt plate Camshaft bearing retainer Bolt...
Page 44 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part Thread Part to be tightened Q’ty Remarks name size m·kg ft·lb Middle driven shaft drive pinion gear Stake Middle drive shaft bearing housing Bolt Middle driven gear bearing retainer Left-hand threads Yoke (middle driven gear) Middle driven gear bearing housing Bolt Middle driven shaft bearing retainer...
Page 45: Chassis
SPEC MAINTENANCE SPECIFICATIONS CHASSIS Item Standard Limit Steering system: Steering bearing type Ball and race bearing ---- Front suspension: Shock absorber travel 99 mm (3.90 in) ---- Fork spring free length 265 mm (10.43 in) ---- Spring fitting length 215.8 mm (8.50 in) ---- Spring rate (K1)
Page 46 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Front disc brake: Type Dual ---- Disc outside diameter × thickness 200.0 × 3.5 mm (7.87 ~ 0.14 in) ---- Pad thickness inner 4.5 mm (0.18 in) 1 mm (0.04 in) Pad thickness outer 4.5 mm (0.18 in) 1 mm (0.04 in)
Page 47 SPEC MAINTENANCE SPECIFICATIONS Tightening torques Tightening torque Part to be tightened Thread size Remarks m·kg ft·lb Engine bracket (front-upper) and frame Engine bracket (front-lower) and frame Engine bracket (front-upper) and engine Engine bracket (front-lower) and engine Engine and frame Frame and bearing retainer (steering stem holder bearing) Select lever assembly and frame Swingarm...
Page 48 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Remarks m·kg ft·lb Front bumper and frame Front carrier and frame Front carrier and front bumper Rear carrier and frame Differential gear case filler bolt Differential gear case drain bolt Differential gear case and bearing housing Gear motor Final gear case oil filler bolt...
Page 49: Electrical
SPEC MAINTENANCE SPECIFICATIONS ELECTRICAL Item Standard Limit Voltage: 12 V ---- Ignition system: Ignition timing (B.T.D.C.) 10°/ 1,500 r/min ---- C.D.I.: Magneto model/manufacturer F4T46471/MITSUBISHI ---- 459 ~ 561 Ω at 20 °C (68 °F)/ Pickup coil resistance/color ---- White/Red – White/Green 0.085 ~ 0.105 Ω...
Page 50 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Brush overall length 12.5 mm (0.49 in) 5 mm (0.20 in) Spring force 7.65 ~ 10.01 N (780 ~ 1,020 g, ---- 27.54 ~ 36.03 oz) Commutator diameter 28 mm (1.10 in) 27 mm (1.06 in) Mica undercut 0.7 mm (0.03 in)
Page 51: How To Use The Conversion Table
HOW TO USE THE CONVERSION TABLE/ SPEC GENERAL TORQUE SPECIFICATIONS EB201000 EB202001 HOW TO USE THE CONVERSION GENERAL TORQUE TABLE SPECIFICATIONS All specification data in this manual are listed in This chart specifies torque for standard SI and METRIC UNITS. fasteners with standard I.S.O.
Page 52: Lubrication Points And Lubricant Types
Clutch housing One-way bearing Drive chain/sprocket Driven cam Front drive shaft collar ® Sealant (Quick Gasket Crankcase mating surfaces Yamaha Bond No.1215 ® Stater lead grommet Sealant (Quick Gasket (left side crankcase) Yamaha Bond No.1215 Not For Resale 2 - 21...
Page 53: Coolant Flow Diagrams
SPEC COOLANT FLOW DIAGRAMS COOLANT FLOW DIAGRAMS 1 Radiator 2 Thermo switch 3 Fan motor È To coolant reservoir Not For Resale 2 - 22 www.SmallEngineDiscount.com...
Page 54 SPEC COOLANT FLOW DIAGRAMS 1 Radiator 2 Thermostat È To coolant reservoir Not For Resale 2 - 23 www.SmallEngineDiscount.com...
Page 55: Oil Flow Diagrams
SPEC OIL FLOW DIAGRAMS OIL FLOW DIAGRAMS 1 Camshaft 2 Crankshaft 3 Drive axle Not For Resale 2 - 24 www.SmallEngineDiscount.com...
Page 56 SPEC OIL FLOW DIAGRAMS 1 Oil filter Not For Resale 2 - 25 www.SmallEngineDiscount.com...
Page 57 SPEC OIL FLOW DIAGRAMS 1 Oil pump 2 Oil strainer Not For Resale 2 - 26 www.SmallEngineDiscount.com...
Page 58: Cable Routing
SPEC CABLE ROUTING CABLE ROUTING 1 Rear brake switch lead 9 Main switch lead 2 Starter cable 0 Fan motor breather hose 3 Rear brake cable A Differential gear case breather hose 4 Front brake hose B Sub-wire harness (to gear motor) 5 On-command four-wheel drive switch and C On-command four-wheel drive switch and differential gear lock switch...
Page 59 SPEC CABLE ROUTING È Fasten the on-command four-wheel drive switch and differential gear lock switch lead behind the handlebar with a plastic band. É Fasten the starter cable, handlebar switch lead and rear brake switch lead behind the handlebar with a plastic band.
Page 60 SPEC CABLE ROUTING 1 Sub-wire harness 2 Headlight lead 3 Auxiliary DC jack lead 4 Four-wheel drive relay 3 5 Fan motor breather hose 6 Differential gear case breather hose 7 Coolant reservoir breather hose 8 Meter assembly coupler Not For Resale 2 - 29 www.SmallEngineDiscount.com...
Page 61 SPEC CABLE ROUTING 1 Starter cable È Insert the fuel tank breather hose into the hole of 2 Cylinder head breather hose the handlebar cover. 3 Fuel hose É Fasten the sub-wire harness, differential gear 4 Carburetor drain hose case breather hose, coolant reservoir hose, 5 Coolant reservoir breather hose coolant reservoir breather hose, thermo switch 6 Radiator outlet hose...
Page 62 SPEC CABLE ROUTING 1 Cylinder head breather hose B Fuel hose 2 Final drive gear case breather hose C Low-range switch 3 Wire harness D High-range switch 4 Starter motor lead E Neutral switch lead 5 Negative battery lead F Reverse switch lead 6 Air filter case check hose G Rectifier/regulator 7 Water pump breather hose...
Page 63 SPEC CABLE ROUTING È Fasten the wire harness with a plastic band. É Fasten the starter motor lead, wire harness, negative battery lead, final gear case breather hose, rectifier/regulator lead, low-range switch lead, high-range switch lead, neutral switch lead, reverse switch lead, speed sensor lead and A.C.
Page 64 SPEC CABLE ROUTING 1 Throttle cable È Fasten the radiator inlet hose and spark plug 2 Radiator inlet hose lead with a plastic band. 3 Spark plug lead 4 Main switch 5 Wire harness 6 Rear brake light switch lead 7 Rear brake fluid reservoir hose 8 Select lever control cable 9 Rear brake cable...
Page 65 SPEC CABLE ROUTING 1 Front brake hose 2 Float chamber air vent hose 3 Throttle cable 4 Wire harness 5 Final drive gear case breather hose 6 Starter cable 7 Rear brake cable Not For Resale 2 - 34 www.SmallEngineDiscount.com...
Page 66 SPEC CABLE ROUTING 1 Battery 2 Positive battery lead 3 Tail/brake light lead 4 CDI unit 5 Negative battery lead Not For Resale 2 - 35 www.SmallEngineDiscount.com...
Page 67 SPEC CABLE ROUTING 1 Final drive gear case breather hose 2 Rear brake hose 3 Air filter case check hose Not For Resale 2 - 36 www.SmallEngineDiscount.com...
Page 68: Chapter 3. Periodic Checks And Adjustments
INTRODUCTION/ PERIODIC MAINTENANCE/LUBRICATION EB300000 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and a longer service life. The need for costly overhaul work will be greatly reduced. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale.
Page 69 • Replace if damaged. Fittings and • Check all chassis fittings and fasteners. fasteners* • Correct if necessary. It is recommended that these items be serviced by a Yamaha dealer. ** Lithium-soap-based grease NOTE: Recommended brake fluid: DOT 4 Brake fluid replacement: 1.When disassembling the master cylinder or caliper, replace the brake fluid.
Page 70: Seat, Carriers, Fenders And Fuel Tank
SEAT, CARRIERS, FENDERS AND FUEL TANK SEAT, CARRIERS, FENDERS AND FUEL TANK SEAT AND SIDE PANELS Order Job name/Part name Q’ty Remarks Removing the seat and side panels Remove the parts in the order below. Seat NOTE: Pull up the seat lock lever, then pull up on the rear of the seat.
Page 71: Front Carrier, Front Bumper And Front Fender
SEAT, CARRIERS, FENDERS AND FUEL TANK FRONT CARRIER, FRONT BUMPER AND FRONT FENDER Order Job name/Part name Q’ty Remarks Removing the front carrier, front Remove the parts in the order below. bumper and front fender Seat and fuel tank side panels Refer to “SEAT AND SIDE PANELS”.
Page 72 SEAT, CARRIERS, FENDERS AND FUEL TANK Order Job name/Part name Q’ty Remarks Meter assembly coupler Disconnect. Four-wheel drive relay 3 coupler Disconnect. Auxiliary DC jack connector Disconnect. Coolant reservoir breather hose Fan motor breather hose Differential gear case breather hose Front fender For installation, reverse the removal procedure.
Page 73: Rear Carrier And Rear Fender
SEAT, CARRIERS, FENDERS AND FUEL TANK REAR CARRIER AND REAR FENDER Order Job name/Part name Q’ty Remarks Removing the rear carrier and rear Remove the parts in the order below. fender Seat and fuel tank side panels Refer to “SEAT AND SIDE PANELS”. Fuel tank Refer to “FUEL TANK”.
Page 74 SEAT, CARRIERS, FENDERS AND FUEL TANK Order Job name/Part name Q’ty Remarks CDI unit Wire harness Rear fender For installation, reverse the removal procedure. Not For Resale 3 - 7 www.SmallEngineDiscount.com...
Page 75: Fuel Tank
SEAT, CARRIERS, FENDERS AND FUEL TANK FUEL TANK Order Job name/Part name Q’ty Remarks Removing the fuel tank Remove the parts in the order below. Seat and fuel tank side panels Refer to “SEAT AND SIDE PANELS”. Fuel tank cover Refer to “FRONT CARRIER, FRONT BUMPER AND FRONT FENDER”.
Page 76: Footrest Boards
FOOTREST BOARDS FOOTREST BOARDS 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”. Left footrest board Right footrest board Footrest bracket For installation, reverse the removal procedure.
Page 77: Engine
ADJUSTING THE VALVE CLEARANCE ENGINE ADJUSTING THE VALVE CLEARANCE NOTE: The valve clearance must be adjusted when the engine is cool to the touch. Adjust the valve clearance when the piston is at the Top Dead Center (T.D.C.) on the compression stroke.
Page 78 ADJUSTING THE VALVE CLEARANCE 7.Check: Valve clearance Out of specification → Adjust. Valve clearance (cold): Intake: 0.06 ~ 0.10 mm (0.0024 ~ 0.0039 in) Exhaust: 0.16 ~ 0.20 mm (0.0063 ~ 0.0079 in) ***************************************************** Checking steps: Turn the crankshaft counterclockwise with a wrench.
Page 79 ADJUSTING THE VALVE CLEARANCE 8.Adjust: Valve clearance ***************************************************** Adjustment steps: Loosen the locknut 1. Insert a feeler gauge 2 between the adjuster end and the valve end. Turn adjuster clockwise counterclockwise with the valve adjusting tool 4 until the proper clearance is obtained. Tappet adjusting tool: P/N.
Page 80: Adjusting The Idling Speed
ADJUSTING THE VALVE CLEARANCE/ ADJUSTING THE IDLING SPEED 11.Install: Fuel tank Front fender Front carrier Seat Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”. ADJUSTING THE IDLING SPEED 1.Start the engine and let it warm up for several minutes. 2.Remove: Seat Fuel tank side panels Refer to “SEAT, CARRIERS, FENDERS...
Page 81: Adjusting The Throttle Lever Free Play
ADJUSTING THE IDLING SPEED/ ADJUSTING THE THROTTLE LEVER FREE PLAY 5.Adjust: Engine idling speed ***************************************************** Adjustment steps: Turn the throttle stop screw 1 in or out until the specified idling speed is obtained. Idling speed becomes Turning in higher. Idling speed becomes Turning out lower.
Page 82 ADJUSTING THE THROTTLE LEVER FREE PLAY 1.Check: Throttle lever free play a Out of specification → Adjust. Throttle lever free play: 3 ~ 5 mm (0.12 ~ 0.20 in) 2.Remove: Seat Fuel tank side panel (right) Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”.
Page 83: Adjusting The Speed Limiter
ADJUSTING THE THROTTLE LEVER FREE PLAY/ ADJUSTING THE SPEED LIMITER Second step: Pull back the adjuster cover 4. Loosen the locknut 5. Turn the adjuster 6 in or out until the correct free play is obtained. Turning in Free play is increased. Turning out Free play is decreased.
Page 84: Adjusting The Starter Cable
ADJUSTING THE SPEED LIMITER/ ADJUSTING THE STARTER CABLE 2.Adjust: Speed limiter length ***************************************************** Speed limiter length adjustment steps: Loosen the locknut 1. Turn the adjuster 2 in or out until the specified speed limiter length is obtained. Speed limiter length is Turning in decreased.
Page 85 ADJUSTING THE STARTER CABLE 2.Adjust: ***************************************************** Adjustment steps: Disconnect the starter cable 1 from the carburetor body. NOTE: Do not remove the starter plunger 2 from the starter cable. Measure the starter plunger stroke distance a of the starter lever 3 fully close to fully open position.
Page 86: Checking The Spark Plug
CHECKING THE SPARK PLUG CHECKING THE SPARK PLUG 1.Remove: Seat Fuel tank side panel (right) Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”. 2.Remove: Spark plug 3.Check: Spark plug type Incorrect → Replace. Standard spark plug: DR8EA/NGK 4.Check: Electrode 1 Wear/damage →...
Page 87: Checking The Ignition Timing
CHECKING THE IGNITION TIMING CHECKING THE IGNITION TIMING NOTE: Engine idling speed and throttle cable free play should be adjusted properly before checking the ignition timing. 1.Remove: Seat Fuel tank side panel (right) Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”. 2.Attach: Inductive tachometer or engine tachometer Timing light...
Page 88: Measuring The Compression Pressure
CHECKING THE IGNITION TIMING/ MEASURING THE COMPRESSION PRESSURE 4.Detach: Timing light Inductive tachometer or engine tachometer 5.Install: Seat Fuel tank side panel (right) Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”. MEASURING THE COMPRESSION PRESSURE NOTE: Insufficient compression pressure will result in a loss of performance.
Page 89 MEASURING THE COMPRESSION PRESSURE 7.Measure: Compression pressure Above the maximum pressure: Check the cylinder head, valve surfaces, and piston crown for carbon deposits. Below the minimum pressure: Squirt a few drops of oil into the affected cylinder and measure again. Refer to the table below.
Page 90: Checking The Engine Oil Level
CHECKING THE ENGINE OIL LEVEL CHECKING THE ENGINE OIL LEVEL 1.Place the machine on a level surface. 2.Remove: Engine side panel Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”. 3.Check: Engine oil level Oil level should be between the maximum level mark 1 and minimum level mark 2.
Page 91: Changing The Engine Oil
CHANGING THE ENGINE OIL CHANGING THE ENGINE OIL 1.Start the engine and let it warm up for several minutes. 2.Stop the engine and place an oil pan under the engine. 3.Remove: Seat Fuel tank side panel (left) Engine side cover Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”.
Page 92 CHANGING THE ENGINE OIL 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 cartridge. Tighten the new oil filter cartridge to specification with an oil filter wrench.
Page 93: Cleaning The Air Filter
CHANGING THE ENGINE OIL/ CLEANING THE AIR FILTER 13.Check: Engine oil pressure ***************************************************** Slightly loosen the oil gallery bolt 1. Start the engine and keep it idling until engine oil starts to seep from the oil gallery bolt. If no engine oil comes out after one minute, turn the engine off so that it will not seize.
Page 94 CLEANING THE AIR FILTER 1.Remove: Seat 2.Remove: Air filter case cover 1 3.Remove: Air filter element assembly 1 Air filter element cap Air filter element 2 Air filter element cap 3 Air filter element CAUTION: Never operate the engine with the air filter element removed.
Page 95 CLEANING THE AIR FILTER 5.Clean: Air filter element ***************************************************** Cleaning steps: Wash the element gently, but thoroughly in solvent. WARNING Use a cleaning solvent which is designed to clean parts only. Never use gasoline or low flash point solvents as they may cause a fire or explosion.
Page 96: Checking The Coolant Level
CHECKING THE COOLANT LEVEL CHECKING THE COOLANT LEVEL 1.Place the machine on a level surface. 2.Remove: Seat Fuel tank side panel (left) 3.Check: Coolant level The coolant level should be between the minimum level mark a and maximum level mark b. Below the minimum level mark →...
Page 97: Changing The Coolant
CHANGING THE COOLANT CHANGING THE COOLANT 1.Remove: Seat Fuel tank side panel (left) Engine side cover Front carrier Engine skid plate Front fender Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”. Left footrest board Refer to “FOOTREST BOARDS”. 2.Remove: Plastic band 1 Coolant reservoir bolts 2 Coolant reservoir cap 3 3.Disconnect:...
Page 98 CHANGING THE COOLANT 8.Remove: Coolant drain bolt (cylinder) 1 (along with the copper washer) Coolant drain bolt (water pump) 2 (along with the copper washer) 9.Drain: Coolant 10.Check: Copper washer 1 Coolant drain bolt 2 Damage → Replace. 11.Install: Coolant drain bolt (water pump) 10 Nm (1.0 m •...
Page 99 CHANGING THE COOLANT CAUTION: Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant, check, and if necessary, correct the antifreeze concentration of the coolant. Use only distilled water. However, soft water may be used if distilled water is not available.
Page 100: Coolant Temperature Warning Light Check
Coolant temperature Coolant temperature warning warning light comes on light does not come on. momentarily. Coolant temperature and Ask a Yamaha dealer to electrical circuit are OK. Go check the electrical circuit. ahead with riding. CHECKING THE V-BELT 1.Remove: Right footrest board Crankcase cover (right) Refer to “PRIMARY AND SECONDARY...
Page 101: Cleaning The Spark Arrester
CHECKING THE V-BELT/ CLEANING THE SPARK ARRESTER 4.Replace: V-belt ***************************************************** Replacing steps: Install the bolts 1 (90101-06016) into the secondary fixed sheave hold. NOTE: Tightening the bolts 1 will push the secondary sliding sheave away, causing the gap between the secondary fixed and sliding sheaves to widen.
Page 102 CLEANING THE SPARK ARRESTER Remove the bolt 1. Remove the tailpipe 2 by pulling it out of the muffler. Tap the tailpipe lightly with a soft-face hammer or suitable tool, then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe and the inner contact surfaces of the muffler.
Page 103: Chassis
ADJUSTING THE REAR BRAKE CHASSIS ADJUSTING THE REAR BRAKE WARNING Always adjust both the brake pedal and the rear brake lever whenever adjusting the rear brake. 1.Check: Rear brake lever free play a Out of specification → Adjust. Rear brake lever free play: 0.5 ~ 2 mm (0.02 ~ 0.08 in) 2.Check: Rear brake pedal height a...
Page 104 ADJUSTING THE REAR BRAKE Loosen the locknut 4. Turn the adjusting bolt 5 until the brake pedal height is within the specified limits. Brake pedal height: 70 ~ 80 mm (2.76 ~ 3.15 in) Tighten the locknut 4. NOTE: When adjusting the brake pedal height make sure the locknut-to-adjusting bolt clearance a does not exceed 6 mm (0.24 in).
Page 105: Checking The Brake Fluid Level
CHECKING THE BRAKE FLUID LEVEL CHECKING THE BRAKE FLUID LEVEL 1.Place the machine on a level surface. NOTE: When checking the brake fluid level, make sure that the top of the brake fluid reservoir top is horizontal. 2.Remove: (rear brake) Front carrier Front fender panel Refer to “SEAT, CARRIERS, FENDERS...
Page 106: Checking The Front Brake Pad
CHECKING THE FRONT BRAKE PAD/ CHECKING THE REAR BRAKE PAD CHECKING THE FRONT BRAKE PAD 1.Remove: Front wheels 2.Check: Brake pad Wear indicators groove 1 almost touch the brake disc → Replace the brake pads as a set. Refer to “FRONT AND REAR BRAKES” in CHAPTER 8.
Page 107: Checking The Brake Hose
CHECKING THE BRAKE HOSE CHECKING THE BRAKE HOSE 1.Remove: Seat Front carrier Front fender Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”. Right footrest board Refer to “FOOTREST BOARDS”. 2.Check: Front brake hoses 1 Rear brake hoses 2 Cracks/wear/damage → Replace. Fluid leakage →...
Page 108: Bleeding The Hydraulic Brake System
BLEEDING THE HYDRAULIC BRAKE SYSTEM 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 been faulty. A loss of braking performance may occur if È...
Page 109: Adjusting The Select Lever Control Cable And Shift Rod
BLEEDING THE HYDRAULIC BRAKE SYSTEM/ ADJUSTING THE SELECT LEVER CONTROL CABLE AND SHIFT ROD k.Add brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL”. WARNING Check the operation of the brake after bleeding the brake system. ***************************************************** ADJUSTING THE SELECT LEVER CONTROL CABLE AND SHIFT ROD...
Page 110 ADJUSTING THE SELECT LEVER CONTROL CABLE AND SHIFT ROD/ ADJUSTING THE REAR BRAKE LIGHT SWITCH When the brake begins to work “a = 20 ~ 30 mm (0.8 ~ 1.2 in)”, verify that the select lever can be shifted to REVERSE from NEUTRAL, to PARK from REVERSE and to NEUTRAL from REVERSE.
Page 111: Adjusting The Rear Brake Light Switch
ADJUSTING THE REAR BRAKE LIGHT SWITCH/ CHECKING THE FINAL GEAR OIL LEVEL 2.Adjust: Rear brake light switch operation timing *********************************************** Hold the main body 1 of the rear brake light switch so that it does not rotate and turn the adjusting nut 2 in direction a or b until the rear brake light comes on at the proper time.
Page 112: Changing The Final Gear Oil
CHANGING THE FINAL GEAR OIL CHANGING THE FINAL GEAR OIL 1.Place the machine on a level surface. 2.Remove: Final gear case protector 1 3.Place a receptacle under the final gear case. 4.Remove: Oil filler bolt Drain plug 1 5.Drain: Final gear oil 6.Install: Drain plug 23 Nm (2.3 m •...
Page 113: Checking The Differential Gear Oil
CHECKING THE DIFFERENTIAL GEAR OIL/ CHANGING THE DIFFERENTIAL GEAR OIL CHECKING THE DIFFERENTIAL GEAR OIL 1.Place the machine on a level surface. 2.Remove: Oil filler bolt 1 3.Check: Oil level Oil level should be up to the brim of hole. Oil level low →...
Page 114: Checking The Constant Velocity Joint Dust Boot
CHANGING THE DIFFERENTIAL GEAR OIL/CHECKING THE CONSTANT VELOCITY JOINT DUST BOOT 4.Drain: Differential gear oil 5.Install: Drain plug 10 Nm (1.0 m • kg, 7.2 ft • lb) NOTE: Check the gasket (drain plug). If it is damaged, replace it with new one. 6.Fill: Differential gear case Periodic oil change:...
Page 115: Checking The Steering System
CHECKING THE STEERING SYSTEM/ ADJUSTING THE TOE-IN CHECKING THE STEERING SYSTEM 1.Place the machine on a level surface. 2.Check: Steering assembly bushings Move the handlebar up and down, and/or back and forth. Excessive play → Replace the steering stem bushings. 3.Check: Tie-rod ends Turn the handlebar to the left and/or right...
Page 116 ADJUSTING THE TOE-IN Measure the width È between the marks. Rotate the front tires 180° until the marks are exactly opposite one another. Measure the width É between the marks. Calculate the toe-in using the formula given below. Toe-in = É – È If the toe-in is incorrect, adjust it.
Page 117: Adjusting The Front Shock Absorber
ADJUSTING THE FRONT SHOCK ABSORBER/ADJUSTING THE REAR SHOCK ABSORBER/CHECKING THE TIRE ADJUSTING THE FRONT SHOCK ABSORBER WARNING Always adjust both front shock absorber spring preload to the same setting. Uneven adjustment can cause poor handling and loss of stability. 1.Adjust: Spring preload Turn the adjuster 1 to increase or decrease the spring preload.
Page 118: Checking The Tire
CHECKING THE TIRE TIRE CHARACTERISTICS 1)Tire characteristics influence handling of ATV’s. The tires listed below have been approved by Yamaha Motor Co., Ltd. for this model. If other tire combinations used, they adversely affect your machine’s handling characteristics and are therefore not recommended.
Page 119 CHECKING THE TIRE 1.Measure: Tire pressure (cold tire pressure) Out of specification → Adjust. NOTE: The low-pressure tire gauge 1 is included as standard equipment. If dust or the like is stuck to this gauge, it will not provide the correct readings. Therefore, take two measurements of the tire’s pressure and use the second reading.
Page 120: Checking The Wheel
Cable sheath Damage → Replace. 2.Check: Cable operation Unsmooth operation → Lubricate or replace. Recommended lubricant: Yamaha chain and cable lube or Engine oil NOTE: Hold the cable end up and apply several drops of lubricant to the cable. 3.Apply:...
Page 121: Lubricating The Levers, Pedal, Etc
LUBRICATING THE LEVERS, PEDAL, ETC. LUBRICATING THE LEVERS, PEDAL, ETC. 1.Lubricate the pivoting parts. Recommended lubricant: Yamaha chain and cable lube or Engine oil Not For Resale 3 - 54 www.SmallEngineDiscount.com...
Page 122: Electrical
CHECKING THE BATTERY EB305000 ELECTRICAL CHECKING THE BATTERY NOTE: Since the MF battery is a sealed type battery, it is not possible to measure the specific gravity of the electrolyte in order to check the charge state of the battery. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals.
Page 123 CHECKING THE BATTERY Batteries generate explosive hydrogen gas. Always follow these preventive measures: Charge batteries in a well-ventilated area. Keep batteries away from fire, sparks or open flames (e.g., welding equipment, lighted cigarettes, etc.) DO NOT SMOKE when charging or handling batteries.
Page 124 CHECKING THE BATTERY Open-circuit Charging time voltage No charging is 12.8 V or higher necessary. Check the condition of the battery using the following charts. Example: Open-circuit voltage = 12.0 V Charging time = 6.5 hours Charge condition of the battery = 20 ~ 30% Charging method for MF batteries CAUTION: If it is impossible to set the standard...
Page 125 CHECKING THE BATTERY Charging method using a variable voltage charger NOTE: Leave the battery unused for Measure the open-circuit more than 30 minutes before measuring its open-circuit voltage. voltage prior to charging. Charger Ammeter NOTE: Set the charging voltage to Connect a charger and 16 ~ 17 V.
Page 126 CHECKING THE BATTERY Charging method using a constant voltage charger NOTE: Leave the battery unused for Measure the open-circuit more than 30 minutes before voltage prior to charging. measuring its open-circuit voltage. Connect a charger and ammeter to the battery and start charging.
Page 127: Checking The Fuse
CHECKING THE BATTERY/ CHECKING THE FUSE 5.Check: Battery terminals Dirty → Clean with a wire brush. Poor connection → Correct. NOTE: After cleaning the terminals, apply a light coat of grease. 6.Install: Battery 7.Connect: Battery leads CAUTION: First, connect the positive lead 1, then connect the negative lead 2.
Page 128 CHECKING THE FUSE NOTE: Set the tester to the “Ω × 1” position. Pocket tester: P/N. YU-03112, 90890-03112 If the tester indicates ∞, replace the fuse. ***************************************************** 3.Replace: Blown fuse ***************************************************** Replacement steps: Turn off the ignition. Install a new fuse of the proper amperage. Turn on switches to verify operation of the related electrical devices.
Page 129: Adjusting The Headlight Beam
CHECKING THE FUSE/ADJUSTING THE HEADLIGHT BEAM/CHANGING THE HEADLIGHT BULB 4.Install: Seat Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”. ADJUSTING THE HEADLIGHT BEAM 1.Adjust: Headlight beam (vertically) Turn the adjuster 1 in or out. Turning in Headlight beam raised. Turning out Headlight beam lowered. CHANGING THE HEADLIGHT BULB 1.Remove: Cover 1...
Page 130: Changing The Headlight Bulb
CHANGING THE HEADLIGHT BULB 3.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 transparency of the glass, life of the bulb, and luminous flux will be adversely affected.
Page 131: Chapter 4. Engine
ENGINE REMOVAL ENGINE ENGINE REMOVAL AIR DUCTS, MUFFLER AND EXHAUST PIPE Order Job name/Part name Q’ty Remarks Removing the air ducts, muffler and Remove the parts in the order below. exhaust pipe Engine oil Drain. Refer to “CHANGING THE ENGINE OIL” in CHAPTER 3.
Page 132 ENGINE REMOVAL Order Job name/Part name Q’ty Remarks Final drive gear case breather hose Cylinder head breather hose Vacuum chamber breather hose Air filter case For installation, reverse the removal procedure. Not For Resale 4 - 2 www.SmallEngineDiscount.com...
Page 133: Select Lever Unit And Coolant Reservoir
ENGINE REMOVAL SELECT LEVER UNIT AND COOLANT RESERVOIR Order Job name/Part name Q’ty Remarks Removing the select lever unit and Remove the parts in the order below. coolant reservoir Shift arm Select lever shift rod Select lever unit Coolant reservoir breather hose Coolant reservoir hose Coolant reservoir For installation, reverse the removal...
Page 134: Hoses And Leads
ENGINE REMOVAL HOSES AND LEADS Order Job name/Part name Q’ty Remarks Removing the hoses and leads Remove the parts in the order below. Water pump inlet hose Refer to “WATER PUMP” in CHAPTER 5. Cylinder head breather hose Spark plug lead Thermo switch 1 lead Starter motor lead A.C.
Page 135: Engine Mounting Bolts
ENGINE REMOVAL ENGINE MOUNTING BOLTS Order Job name/Part name Q’ty Remarks Removing the engine mounting bolts Remove the parts in the order below. Rear wheels Refer to “FRONT AND REAR WHEELS” in CHAPTER 8. Swingarm Refer to “REAR SHOCK ABSORBER AND SWINGARM”...
Page 136 ENGINE REMOVAL Order Job name/Part name Q’ty Remarks Engine assembly NOTE: Remove the engine assembly from the left side of the machine. For installation, reverse the removal procedure. Not For Resale 4 - 6 www.SmallEngineDiscount.com...
Page 137: Installing The Engine
ENGINE REMOVAL INSTALLING THE ENGINE 1.Install: Engine bracket (front upper) 1 Engine mount bolt (front upper)/nut 2 Engine bracket bolt (front upper) 3 Engine bracket (front lower) 4 Engine mount bolt (front lower) 5 Engine bracket bolt (front lower) 6 Engine mount bolt (rear upper)/nut 7 Engine mount bolt (rear lower)/nut 8 NOTE:...
Page 138: Cylinder Head
CYLINDER HEAD CYLINDER HEAD Order Job name/Part name Q’ty Remarks Removing the cylinder head Remove the parts in the order below. Fuel tank/rubber cover Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK” in CHAPTER 3. Front fender/air filter case Air duct assembly 1 Refer to “ENGINE REMOVAL”.
Page 139 CYLINDER HEAD Order Job name/Part name Q’ty Remarks Cylinder head breather hose Camshaft sprocket cover/O-ring Tappet cover/O-ring Thermo switch 1 lead Disconnect. Timing chain tensioner cap bolt Timing chain tensioner/gasket Refer to “REMOVING/INSTALLING THE CYLINDER HEAD”. Camshaft sprocket Cylinder head Cylinder head gasket Dowel pin O-ring...
Page 140: Removing The Cylinder Head
CYLINDER HEAD REMOVING THE CYLINDER HEAD 1.Align: “T” mark (with stationary pointer) ***************************************************** Checking steps: Turn the crankshaft counterclockwise with a wrench. Align the “T” mark 1 on the rotor with the stationary pointer 2 on the crankcase cover. When the “T” mark is aligned with the stationary pointer, the piston is at the Top Dead Center (T.D.C.).
Page 141: Checking The Tappet Cover
CYLINDER HEAD NOTE: Fasten a safety wire to the timing chain to prevent it from falling into the crankcase. When removing the camshaft sprocket, it is not necessary to separate the timing chain. 5.Remove: Cylinder head NOTE: Loosen the 6 mm bolts first. Working in a crisscross pattern, loosen each 10 mm bolt 1/4 of a turn.
Page 142: Checking The Cylinder Head
CYLINDER HEAD CHECKING THE CYLINDER HEAD 1.Eliminate: Carbon deposits (from the combustion chambers) Use a rounded scraper. NOTE: Do not use a sharp instrument to avoid damaging or scratching: Spark plug threads Valve seats 2.Check: Cylinder head Scratches/damage → Replace. Cylinder head water jacket Mineral deposits/rust →...
Page 143: Installing The Cylinder Head
CYLINDER HEAD INSTALLING THE CYLINDER HEAD 1.Install: Cylinder head Bolt (M10) 40 Nm (4.0 m • kg, 29 ft • lb) Bolt (M6) 10 Nm (1.0 m • kg, 7.2 ft • lb) NOTE: Lubricate the washer with engine oil. Tighten the bolts (M10) in two stages and a crisscross pattern.
Page 144 CYLINDER HEAD NOTE: Be sure the “I” mark 5 on the camshaft sprocket is aligned with the match mark 2 on the cylinder head. Force camshaft clockwise counterclockwise to remove timing chain slack. Insert a screwdriver into the timing chain tensioner hole and push the timing chain guide inward.
Page 145 CYLINDER HEAD 4.Tighten: Camshaft sprocket bolt 1 60 Nm (6.0 m • kg, 43 ft • lb) NOTE: Use the rotor holding tool 2 to hold the starter pulley. Rotor holding tool: P/N. YU-01235, 90890-01235 5.Check: Camshaft sprocket “I” mark Rotor “T”...
Page 146: Camshaft, Rocker Arms And Valves
CAMSHAFT, ROCKER ARMS AND VALVES CAMSHAFT, ROCKER ARMS AND VALVES Order Job name/Part name Q’ty Remarks Removing the camshaft, rocker Remove the parts in the order below. arms and valves Intake manifold/O-ring Thermo switch Oil check bolt Lock washer/bearing retainer Camshaft Refer to “REMOVING/INSTALLING THE Rocker arm shaft/O-ring...
Page 147: Refer To "Removing/Installing The Valve And Valve Spring
CAMSHAFT, ROCKER ARMS AND VALVES Order Job name/Part name Q’ty Remarks Valve spring (inner) Valve (intake) Refer to “REMOVING/INSTALLING THE Valve (exhaust) VALVE AND VALVE SPRING”. Valve stem seal Valve spring seat For installation, reverse the removal procedure. Not For Resale 4 - 17 www.SmallEngineDiscount.com...
Page 148: Removing The Valve And Valve Spring
CAMSHAFT, ROCKER ARMS AND VALVES REMOVING THE CAMSHAFT AND ROCKER 1.Remove: Camshaft 1 NOTE: Screw in a M10 bolt 2 into the thread hole on the camshaft, and pull out the camshaft. 2.Remove: Rocker arm shafts (intake and exhaust) 1 Rocker arms 2 NOTE: Use a slide hammer 3 to remove the rocker...
Page 149: Checking The Camshaft
CAMSHAFT, ROCKER ARMS AND VALVES 2.Remove: Valve cotters NOTE: Attach a valve spring compressor 1 between the valve spring retainer and the cylinder head to remove the valve cotters. Valve spring compressor: P/N. YM-04019, 90890-04019 CHECKING THE CAMSHAFT 1.Check: Cam lobes Pitting/scratches/blue discoloration →...
Page 150: Rocker Arm
CAMSHAFT, ROCKER ARMS AND VALVES 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 →...
Page 151: Checking The Valve And Valve Spring
CAMSHAFT, ROCKER ARMS AND VALVES CHECKING THE VALVE AND VALVE SPRING 1.Measure: Stem-to-guide clearance Stem-to-guide clearance = valve guide inside diameter a – valve stem diameter b Out of specification → Replace the valve guide. Clearance (stem to guide): Intake: 0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in) <Limit>: 0.080 mm (0.0031 in)
Page 152 CAMSHAFT, ROCKER ARMS AND VALVES 3.Check: Valve face Pitting/wear → Grind the face. Valve stem end Mushroom shape or diameter larger than the body of the stem → Replace. 4.Measure: Margin thickness a Out of specification → Replace. Margin thickness: Intake: 1.0 ~ 1.4 mm (0.0394 ~ 0.0551 in) Exhaust:...
Page 153 CAMSHAFT, ROCKER ARMS AND VALVES ***************************************************** Measurement steps: Apply Mechanic’s blueing dye (Dykem) b to the valve face. Install the valve into the cylinder head. Press the valve through the valve guide and onto the valve seat to make a clear pattern. Measure the valve seat width.
Page 154 CAMSHAFT, ROCKER ARMS AND VALVES Apply a fine lapping compound to the valve face and repeat the above steps. NOTE: After every lapping operation be sure to clean off all of the compound from the valve face and valve seat. Apply Mechanic’s blueing dye (Dykem) to the valve face.
Page 155: Installing The Valve And Valve Spring
CAMSHAFT, ROCKER ARMS AND VALVES 12.Measure: Spring tilt a Out of specification → Replace. Spring tilt limit: Inner: 2.5°/1.6 mm (0.06 in) Outer: 2.5°/1.6 mm (0.06 in) INSTALLING THE VALVE AND VALVE SPRING 1.Apply: Molybdenum disulfide oil (onto the valve stem and valve stem seal) 2.Install: Valve spring seats Valve stem seals...
Page 156: Installing The Camshaft And Rocker Arm
CAMSHAFT, ROCKER ARMS AND VALVES INSTALLING THE CAMSHAFT AND ROCKER ARM 1.Apply: Engine oil (onto the rocker arm shafts) 2.Install: Rocker arms 1 Rocker arm shafts (intake and exhaust) 2 NOTE: Use a slide hammer bolt 3 to install the rocker arm shaft.
Page 157: Cylinder And Piston
CYLINDER AND PISTON CYLINDER AND PISTON Order Job name/Part name Q’ty Remarks Removing the cylinder and piston Remove the parts in the order below. Cylinder head Refer to “CYLINDER HEAD”. Water pump outlet hose/pipe Refer to “WATER PUMP” in CHAPTER 5. Coolant inlet joint Timing chain guide (exhaust) Cylinder/O-ring...
Page 158: Removing The Piston
CYLINDER AND PISTON REMOVING THE PISTON 1.Remove: Piston pin clips 1 Piston pin 2 Piston 3 NOTE: Before removing piston pin, deburr the clip groove and pin hole area. If the piston pin groove is deburred and the piston pin is still difficult to remove, use the piston pin puller 4.
Page 159 CYLINDER AND PISTON 2.Measure: Piston-to-cylinder clearance ***************************************************** Measurement steps: 1st step: Measure the cylinder bore “C” with the cylinder bore gauge. NOTE: Measure cylinder bore “C” by taking side-to- side and front-to-back measurements of the cylinder. Then, find the average of the measurements.
Page 160: Checking The Piston Ring
CYLINDER AND PISTON 3rd step: Find the piston-to-cylinder clearance with the following formula. Piston-to-cylinder clearance = Cylinder bore “C” – Piston skirt diameter “P” Piston-to-cylinder clearance: 0.040 ~ 0.065 mm (0.0016 ~ 0.0026 in) <Limit>: 0.150 mm (0.0059 in) If out of specification, rebore or replace the cylinder, and replace the piston and piston rings as a set.
Page 161: Checking The Piston Pin
CYLINDER AND PISTON 3.Measure: Ring end gap Out of specification → Replace. NOTE: You cannot measure the end gap on the expander spacer of the oil control ring. If the oil control ring rails show excessive gap, replace all three rings. End gap Standard Limit...
Page 162: Installing The Piston
CYLINDER AND PISTON If out of specification, replace the piston. Piston pin-to-piston clearance: 0.004 ~ 0.024 mm (0.00016 ~ 0.00094 in) <Limit>: 0.074 mm (0.0029 in) ***************************************************** INSTALLING THE PISTON 1.Install: Piston rings (onto the piston) NOTE: Be sure to install the piston rings so that the manufacturer’s marks numbers...
Page 163: Installing The Cylinder
CYLINDER AND PISTON 4.Lubricate: Piston Piston rings Cylinder NOTE: Apply a liberal coating of engine oil. INSTALLING THE CYLINDER 1.Install: Cylinder NOTE: Install the cylinder with one hand while compressing the piston rings with the other hand. CAUTION: Be careful not to damage the timing chain damper during installation.
Page 164: Recoil Starter And A.c. Magneto
RECOIL STARTER AND A.C. MAGNETO RECOIL STARTER AND A.C. MAGNETO Order Job name/Part name Q’ty Remarks Removing the CDI magneto Remove the parts in the order below. Engine oil Drain. Refer to “CHANGING THE ENGINE OIL” in CHAPTER 3. Seat and side panels Refer to “SEAT AND SIDE PANELS”...
Page 165 RECOIL STARTER AND A.C. MAGNETO Order Job name/Part name Q’ty Remarks Pickup coil Stator assembly Rotor Refer to “REMOVING/INSTALLING THE Starter wheel gear A.C. MAGNETO”. Woodruff key Washer Starter idle gear shaft Washer/bearing Starter idle gear For installation, reverse the removal procedure.
Page 166 RECOIL STARTER AND A.C. MAGNETO Order Job name/Part name Q’ty Remarks Disassembling the recoil starter Remove the parts in the order below. Starter handle Friction plate Pawl spring Refer to “DISASSEMBLING/ Drive pawl ASSEMBLING THE RECOIL STARTER”. Spring Sheave drum Rope Coil spring For assembly, reverse the disassembly...
Page 167: Removing The A.c. Magneto
RECOIL STARTER AND A.C. MAGNETO REMOVING THE A.C. MAGNETO 1.Remove: Starter pulley 1 NOTE: Use the rotor holding tool 2 to hold the starter pulley. Rotor holding tool: P/N. YU-01235, 90890-01235 2.Remove: Crankcase cover (left) Gasket Dowel pins NOTE: Working in a crisscross pattern, loosen each bolt 1/4 of a turn.
Page 168: Checking The Starter Clutch
RECOIL STARTER AND A.C. MAGNETO CHECKING THE STARTER CLUTCH 1.Check: Starter one-way clutch 1 Cracks/damage → Replace. Bolts 2 (starter clutch) Loose → Replace with a new one, and clinch the end of the bolt. NOTE: The arrow mark on the starter clutch must face inward, away from the rotor.
Page 169: Checking The Starter Pulley
RECOIL STARTER AND A.C. MAGNETO CHECKING THE STARTER PULLEY 1.Check: Starter pulley Cracks/pitting → Deburr or replace. CHECKING THE RECOIL STARTER 1.Check: Rope 1 Sheave drum 2 Drive pawl 3 Wear/damage → Replace. Coil spring 4 Pawl spring 5 Spring 6 Fatigue →...
Page 170: Installing The A.c. Magneto
Untie the knot 3 after making a knot 4 above the handle. INSTALLING THE A.C. MAGNETO 1.Apply: ® Sealant (Quick Gasket (into the slit) ® Sealant (Quick Gasket P/N. ACC-11001-05-01 Yamaha bond No. 1215: P/N. 90890-85505 Not For Resale 4 - 40 www.SmallEngineDiscount.com...
Page 171 RECOIL STARTER AND A.C. MAGNETO 2.Install: Woodruff key Rotor NOTE: Before installing the rotor, clean the outside of the crankshaft and the inside of the rotor. After installing the rotor, check that the rotor rotates smoothly. If not, reinstall the key and rotor.
Page 172: Primary And Secondary Sheaves
PRIMARY AND SECONDARY SHEAVES PRIMARY AND SECONDARY SHEAVES Order Job name/Part name Q’ty Remarks Removing the primary and Remove the parts in the order below. secondary sheave Front fender Refer to “SEAT, CARRIERS, FENDERS Rear fender AND FUEL TANK” in CHAPTER 3. Right footrest board Exhaust pipe bracket Drive belt cover...
Page 173 PRIMARY AND SECONDARY SHEAVES Order Job name/Part name Q’ty Remarks Primary fixed sheave Refer to “REMOVING/INSTALLING THE PRIMARY AND SECONDARY Secondary sheave assembly SHEAVES”. For installation, reverse the removal procedure. Not For Resale 4 - 43 www.SmallEngineDiscount.com...
Page 174: Primary Sliding Sheave
PRIMARY AND SECONDARY SHEAVES PRIMARY SLIDING SHEAVE Order Job name/Part name Q’ty Remarks Disassembling the primary sliding Remove the parts in the order below. sheave Primary pulley sheave cap Primary pulley slider Spacer Primary pulley cam Refer to “ASSEMBLING THE PRIMARY Primary pulley weight SHEAVE”.
Page 175: Secondary Sheave
PRIMARY AND SECONDARY SHEAVES SECONDARY SHEAVE Order Job name/Part name Q’ty Remarks Disassembling the secondary Remove the parts in the order below. sheave Spring seat Compression spring Refer to “DISASSEMBLING/ Spring seat ASSEMBLING THE SECONDARY Guide pin SHEAVE”. Secondary sliding sheave O-ring Secondary fixed sheave Oil seal...
Page 176: Removing The Primary And Secondary Sheaves
PRIMARY AND SECONDARY SHEAVES REMOVING THE PRIMARY AND SECONDARY SHEAVES 1.Loosen: Nut (secondary sheave) 1 Nut (primary sheave) 2 NOTE: Use the sheave holder 3 to hold the primary sheave. First, loosen the nut (secondary sheave) 2, then loosen the nut (primary sheave) 1. Sheave holder: P/N.
Page 177: Checking The Primary Sheave
PRIMARY AND SECONDARY SHEAVES CHECKING THE PRIMARY SHEAVE 1.Check: Weight outside diameter a Out of specification → Replace the weight. Weight outside diameter: 30 mm (1.18 in) <Limit>: 29.5 mm (1.16 in) 2.Check: Primary pulley slider Primary sliding sheave splines Wear/cracks/damage →...
Page 178: Assembling The Primary Sheave
Remove any excess grease. 2.Install: Weight 1 NOTE: Apply Yamaha Grizzly grease (120 g) to the whole outer surface of the weight and install. Apply Yamaha Grizzly grease to the inner surface of the collar. Apply Yamaha Grizzly grease to the inner surface of the primary sliding sheave.
Page 179 PRIMARY AND SECONDARY SHEAVES 3.Apply: ® BEL-RAY assembly lube (to the guide pin sliding groove 1, and O-ring 4.Install: Spring seat Compression spring Spring seat ***************************************************** Installing steps: Attach the sheave fixed block, locknut wrench and sheave spring compressor to the secondary sheave assembly.
Page 180: Installing The Primary And Secondary Sheaves
PRIMARY AND SECONDARY SHEAVES INSTALLING THE PRIMARY AND SECONDARY SHEAVES 1.Install: Secondary sheave assembly V-belt Primary sheave assembly NOTE: Tightening the bolts 1 will push the secondary sliding sheave away, causing the gap between the secondary fixed and sliding sheaves to widen. Install the V-belt so that its arrow faces the direction show in the illustration.
Page 181: Clutch
CLUTCH CLUTCH Order Job name/Part name Q’ty Remarks Removing the clutch Remove the parts in the order below. Primary and secondary sheaves Refer to “PRIMARY AND SECONDARY SHEAVES”. Cover Clutch housing assembly Gasket/dowel pin Refer to “REMOVING/INSTALLING THE CLUTCH”. One-way clutch bearing Clutch carrier assembly For installation, reverse the removal procedure.
Page 182 CLUTCH Order Job name/Part name Q’ty Remarks Disassembling the clutch housing Remove the parts in the order below. Oil seal Circlip Bearing housing Circlip Bearing Circlip Bearing Clutch housing For assembly, reverse the disassembly procedure. Not For Resale 4 - 52 www.SmallEngineDiscount.com...
Page 183: Removing The Clutch
CLUTCH REMOVING THE CLUTCH 1.Remove: Clutch housing assembly Gasket Dowel pins NOTE: Working in crisscross pattern, loosen each bolt 1/4 of a turn. Remove them after all of them are loosened. 2.Straighten: Punched portion of the nut 1. 3.Remove: Nut 1 NOTE: Use a clutch holding tool 2 to hold the clutch carrier assembly.
Page 184: Installing The Clutch
CLUTCH 2.Check: Clutch shoe Heat damage → Replace. 3.Measure: Clutch shoe thickness Out of specification → Replace. Clutch shoe thickness: 1.5 mm (0.06 in) Clutch shoe wear limit a: 1.0 mm (0.04 in) INSTALLING THE CLUTCH 1.Install: Collar Clutch carrier assembly Nut 1 140 Nm (14.0 m •...
Page 185 CLUTCH 4.Install: Dowel pins Gasket Clutch housing assembly 10 Nm (1.0 m • kg, 7.2 ft • lb) NOTE: Tighten the bolts in stages, using a crisscross pattern. After tightening the bolts, check that the clutch housing assembly to counterclockwise rotates smoothly.
Page 186: Crankcase
CRANKCASE CRANKCASE STARTER MOTOR, TIMING CHAIN AND OIL FILTER Order Job name/Part name Q’ty Remarks Removing the starter motor, timing Remove the parts in the order below. chain and oil filter Engine assembly Refer to “ENGINE REMOVAL”. Cylinder head Refer to “CYLINDER HEAD”. Cylinder and piston Refer to “CYLINDER AND PISTON”.
Page 187: Crankcase
CRANKCASE Order Job name/Part name Q’ty Remarks Oil filter cartridge Speed sensor Shift cam stopper Low-range switch High-range switch Neutral switch Reverse switch Oil filler cap Bearing cover/gasket Oil delivery pipe Oil strainer cover/O-ring Compression spring Oil strainer For installation, reverse the removal procedure.
Page 188 CRANKCASE CRANKCASE Order Job name/Part name Q’ty Remarks Separating the crankcase Remove the parts in the order below. Shift lever cover/gasket Refer to “INSTALLING THE SHIFT Shift lever 1/O-ring LEVER”. Shift lever 2 assembly Crankcase (left) Refer to “SEPARATING/ASSEMBLING Dowel pin THE CRANKCASE”.
Page 189: Crankcase Bearing
CRANKCASE CRANKCASE BEARING Order Job name/Part name Q’ty Remarks Removing the crankcase bearing Remove the parts in the order below. Crankshaft and oil pump Refer to “CRANKSHAFT AND OIL PUMP”. Transmission Refer to “TRANSMISSION”. Middle drive/driven shaft Refer to “MIDDLE GEAR”. Oil seal Bearing retainer Bearing...
Page 190: Removing The Oil Pump Drive Gear
CRANKCASE REMOVING THE OIL PUMP DRIVE GEAR 1.Straighten: Lock washer tab 2.Remove: Oil pump drive gear nut ***************************************************** Removal steps: Temporary install the clutch carrier assembly Hold the clutch carrier assembly with a clutch holding tool 2 and loosen the oil pump drive gear nut.
Page 191: Checking The Timing Chain And Guide
CRANKCASE Remove the left crankcase. CAUTION: Use a soft hammer to tap on one side of the crankcase. Tap only on reinforced portions of the crankcase. Do not tap on the crankcase mating surfaces. Work slowly and carefully. Make sure that the crankcase halves separate evenly.
Page 192: Checking The Crankcase
Sealant (Quick Gasket (to the mating surfaces of both case halves) ® Sealant (Quick Gasket P/N. ACC-11001-05-01 Yamaha bond No. 1215: P/N. 90890-85505 2.Install: Dowel pin 2 3.Fit the left crankcase onto the right case. Tap lightly on the case with a soft hammer.
Page 193: Installing The Shift Lever
CRANKCASE 4.Tighten: È Crankcase bolts (follow the proper tightening sequence) 10 Nm (1.0 m • kg, 7.2 ft • lb) È Right crankcase É Left crankcase NOTE: Tighten the bolts in stages, using a crisscross pattern. É 5.Apply: 4-stroke engine oil (to the crank pin, bearing and oil delivery hole) 6.Check:...
Page 194: Installing The Oil Pump Drive Gear
CRANKCASE INSTALLING THE OIL PUMP DRIVE GEAR 1.Install: Straight key Oil pump drive gear Lock washer Oil pump drive gear nut 2.Tighten: Oil pump drive gear nut 50 Nm (5.0 m • kg, 36 ft • lb) ***************************************************** Tightening steps: Temporary install the clutch carrier assembly Hold the clutch carrier assembly with a clutch holding tool 2 and tighten the oil pump drive...
Page 195: Crankshaft And Oil Pump
CRANKSHAFT AND OIL PUMP CRANKSHAFT AND OIL PUMP Order Job name/Part name Q’ty Remarks Removing the crankshaft and oil Remove the parts in the order below. pump Crankcase separation Refer to “CRANKCASE”. Washer/circlip Oil pump assembly/gasket Balancer Refer to “REMOVING THE Crankshaft seal CRANKSHAFT/INSTALLING THE CRANKSHAFT AND BALANCER”.
Page 196: Oil Pump
CRANKSHAFT AND OIL PUMP OIL PUMP Order Job name/Part name Q’ty Remarks Disassembling the oil pump Remove the parts in the order below. Rotor cover Shaft Inner rotor Outer rotor Oil pump housing For assembly, reverse the disassembly procedure. Not For Resale 4 - 66 www.SmallEngineDiscount.com...
Page 197: Removing The Crankshaft
CRANKSHAFT AND OIL PUMP REMOVING THE CRANKSHAFT 1.Remove: Crankshaft seal 1 NOTE: Mark a note of the position of each crankshaft seal so that they can be installed in the correct place and in the correct direction. 2.Remove: Crankshaft Use a crankcase separating tool 1. Crankcase separating tool: P/N.
Page 198: Checking The Crankshaft
CRANKSHAFT AND OIL PUMP 3.Check: Oil pump operation Unsmooth → Repeat steps #1 and #2 or replace the defective parts. CHECKING THE CRANKSHAFT 1.Measure: Crank width A Out of specification → Replace the crankshaft. Crank width: 62.95 ~ 63.00 mm (2.4783 ~ 2.4803 in) Side clearance D Out of specification →...
Page 199: Installing The Crankshaft And Balancer
CRANKSHAFT AND OIL PUMP INSTALLING THE CRANKSHAFT AND BALANCER 1.Install: Crankshaft Crankshaft installer set 1: P/N. YU-90050 Buffer boss installer set 2: P/N. 90890-04088 Adapter #11 3: P/N. YM-33279 Spacer (crankshaft) 4: P/N. YM-90070-A, 90890-04060 NOTE: Hold the connecting rod at the Top Dead Center (T.D.C.) with one hand while turning the nut of the installing tool with the other.
Page 200: Transmission
TRANSMISSION TRANSMISSION Order Job name/Part name Q’ty Remarks Removing the transmission Remove the parts in the order below. Crankcase separation Refer to “CRANKCASE”. Driven sprocket Chain Clutch dog 2 Shift fork “L” Spring Low wheel gear Secondary shaft Middle driven gear Drive axle assembly Guide bar Not For Resale...
Page 201 TRANSMISSION Order Job name/Part name Q’ty Remarks Shift fork “R” Spring Shift cam Stopper wheel Clutch dog 1 High wheel gear Middle drive gear Stopper lever Spacer/O-ring For installation, reverse the removal procedure. Not For Resale 4 - 71 www.SmallEngineDiscount.com...
Page 202: Checking The Shift Fork
TRANSMISSION CHECKING THE SHIFT FORK 1.Check: Shift fork cam follower 1 Shift fork pawl 2 Scoring/bends/wear/damage → Replace. 2.Check: Guide bar Roll the guide bar on a flat surface. Bends → Replace. WARNING Do not attempt to straighten a bent guide bar.
Page 203: Checking The Transmission
TRANSMISSION CHECKING THE TRANSMISSION 1.Measure: Axle runout Use a centering device and a dial gauge. Out of specification → Replace the bent axle. Runout limit (drive axle): 0.06 mm (0.0024 in) 2.Check: Gear teeth Blue discoloration/pitting/wear → Replace. Mated dogs Rounded edges/cracks/missing portions →...
Page 204: Checking The Chain
TRANSMISSION 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 →...
Page 205 TRANSMISSION 2.Check: Shift operation Unsmooth operation → Repair. NOTE: Oil each gear and bearing thoroughly. Before assembling the crankcase, be sure that the transmission is in neutral and that the gears turn freely. Not For Resale 4 - 75 www.SmallEngineDiscount.com...
Page 206: Middle Gear
MIDDLE GEAR MIDDLE GEAR MIDDLE DRIVE SHAFT Order Job name/Part name Q’ty Remarks Removing the middle drive shaft Remove the parts in the order below. Crankcase separation Refer to “CRANKCASE”. Transmission Refer to “TRANSMISSION”. Bearing housing assembly Refer to “REMOVING/INSTALLING THE MIDDLE DRIVE SHAFT”.
Page 207 MIDDLE GEAR MIDDLE DRIVEN SHAFT Order Job name/Part name Q’ty Remarks Removing the middle driven shaft Remove the parts in the order below. Crankcase separation Refer to “CRANKCASE”. Circlip Bearing Refer to “REMOVING/INSTALLING THE Universal joint MIDDLE DRIVEN SHAFT”. Universal joint yoke Bearing housing/O-ring Shim Refer to “SELECTING THE MIDDLE...
Page 208: Middle Driven Shaft
MIDDLE GEAR Order Job name/Part name Q’ty Remarks Bearing retainer Middle driven shaft For installation, reverse the removal procedure. Not For Resale 4 - 78 www.SmallEngineDiscount.com...
Page 209: Removing The Middle Drive Shaft
MIDDLE GEAR REMOVING THE MIDDLE DRIVE SHAFT 1.Straighten: Punched portion of the nut (middle drive pinion gear) 2.Loosen: Nut (middle drive pinion gear) 1 NOTE: Secure the middle drive shaft in the vise with a clean rag. 3.Remove: Nut (middle drive pinion gear) Middle drive pinion gear Shim(s) REMOVING THE MIDDLE DRIVEN SHAFT...
Page 210 MIDDLE GEAR 2.Remove: Nut 1 Washer Universal joint yoke NOTE: Use the universal joint holder 2 to hold the universal joint yoke. Universal joint holder: P/N. YM-04062, 90890-04062 3.Remove: Bearing housing assembly 1 ***************************************************** Removal steps: Clean the outside of the middle driven shaft. Place the middle driven shaft onto a hydraulic press.
Page 211: Checking The Pinion Gear
MIDDLE GEAR 5.Remove: Front drive shaft coupling Bearing retainer 1 Bearing NOTE: Attach the ring nut wrench 2. Ring nut wrench: P/N. YM-38404, 90890-01430 CAUTION: The middle driven shaft bearing retainer has left-handed threads. To loosen the retainer turn it clockwise. 6.Remove: Middle drive shaft 1 (with bearing)
Page 212: Selecting The Middle Drive And Driven Gear Shim
MIDDLE GEAR 4.Check: O-ring Damage → Replace. Bearings Pitting/damage → Replace. 5.Check: U-joint movement Roughness → Replace U-joint. SELECTING THE MIDDLE DRIVE AND DRIVEN GEAR SHIM When the drive and driven gear, bearing housing assembly and/or crankcase replaced, be sure to adjust the gear shim 1. 1.Select: Middle drive gear shim 1 Middle driven gear shim 2...
Page 213 MIDDLE GEAR Example: 1) If the bearing housing is marked “+04”, ..a is 10.54. 2) b is 55 3) If the crankcase (right) is marked “66.03”, ..c is 66.03. 4) Therefore, the shim thickness is 0.47 mm. A = 66.03 – 10.54 – 55 = 0.49 5) Round off hundredths digit and select appropriate shim(s).
Page 214 MIDDLE GEAR Where: d = a numeral (usually a decimal number) on the bearing housing is either added to or subtracted from “76”. e = a numeral (usually a decimal number) on the middle driven pinion gear is either added to or subtracted from “59”. f = a numeral (usually a decimal number) on the middle driven pinion gear is either added to or subtracted from...
Page 215: Installing The Middle Driven Shaft
MIDDLE GEAR Shims are supplied in the following thickness. Middle drive pinion gear shim 0.10 0.40 0.15 0.50 Thickness (mm) 0.20 0.60 0.30 ***************************************************** INSTALLING THE MIDDLE DRIVEN SHAFT 1.Install: Bearing retainer 1 80 Nm (8.0 m • kg, 58 ft • lb) NOTE: Attach the ring nut wrench 2.
Page 216 MIDDLE GEAR Tighten the bearing retainer. CAUTION: The middle driven shaft bearing retainer has left-handed threads. To tighten the retainer turn it counterclockwise. Bearing retainer: 110 Nm (11.0 m • kg, 80 ft • lb) ***************************************************** 3.Install: Shims 1 Bearing housing NOTE: Install the shims so that the tabs are positioned as shown in the illustration.
Page 217: Installing The Middle Drive Shaft
MIDDLE GEAR Install the bearing 1 onto the yoke. CAUTION: Check each bearing. The needles can easily fall out of their races. Slide the yoke back and forth on the bearings; the yoke will not go all the way onto a bearing if a needle is out of place.
Page 218 MIDDLE GEAR Attach the gear lash measurement tool 3 and dial gauge 4. Gear lash measurement tool: P/N. YM-01467, 90890-01467 a 8.12 mm (0.32 in) Measure the gear lash while rotating the middle driven shaft back and forth. NOTE: Measure the gear lash at 4 positions. Rotate the middle driven gear 90°...
Page 219: Chapter 5. Cooling System
COOL RADIATOR COOLING SYSTEM RADIATOR Order Job name/Part name Q’ty Remarks Removing the radiator Remove the parts in the order below. Seat and fuel tank side panels Refer to “SEAT AND SIDE PANELS” in CHAPTER 3. Front carrier, front bumper and front Refer to “FRONT CARRIER, FRONT fender BUMPER AND FRONT FENDER”...
Page 220 COOL RADIATOR Order Job name/Part name Q’ty Remarks Radiator inlet hose Disconnect. Radiator outlet hose Disconnect. Radiator Radiator fan Thermo switch For installation, reverse the removal procedure. Not For Resale 5 - 2 www.SmallEngineDiscount.com...
Page 221: Checking The Radiator
COOL RADIATOR CHECKING THE RADIATOR 1.Check: Radiator fins Obstruction → Clean. Apply compressed air to the rear of the radiator. Damage → Repair or replace. NOTE: Straighten any flattened fins with a thin, flat- head screwdriver. 2.Check: Radiator hoses Cracks/damage → Replace. 3.Measure: Radiator cap opening pressure Below the specified pressure →...
Page 222: Installing The Radiator
COOL RADIATOR INSTALLING THE RADIATOR 1.Fill: Cooling system (with specified amount recommended coolant) Refer to “CHANGING THE COOLANT” in CHAPTER 3. 2.Check: Cooling system Leaks → Repair or replace any faulty part. Not For Resale 5 - 4 www.SmallEngineDiscount.com...
Page 223: Thermostat
COOL THERMOSTAT THERMOSTAT Order Job name/Part name Q’ty Remarks Removing the thermostat Remove the parts in the order below. Seat and fuel tank side panel (right) Refer to “SEAT AND SIDE PANELS” in CHAPTER 3. Coolant Drain. Refer to “CHANGING THE COOLANT” in CHAPTER 3.
Page 224: Checking The Thermostat
COOL THERMOSTAT CHECKING THE THERMOSTAT 1.Check: Thermostat 1 Does not open at 63.5 ~ 66.5 °C (146.3 ~ 151.7 °F) → Replace. ***************************************************** Checking steps: Suspend the thermostat in a container filled with water. Slowly heat the water. Place a thermometer in the water. While stirring water,...
Page 225: Water Pump
COOL WATER PUMP WATER PUMP Order Job name/Part name Q’ty Remarks Removing the water pump Remove the parts in the order below. Seat, fuel tank side panel (left) and Refer to “SEAT AND SIDE PANELS” in engine side cover CHAPTER 3. Left footrest board Refer to “FOOTREST BOARDS”...
Page 226 COOL WATER PUMP Order Job name/Part name Q’ty Remarks Disassembling the water pump Remove the parts in the order below. Water pump housing cover Gasket Circlip Impeller Rubber damper holder Rubber damper Water pump seal Oil seal Bearing Water pump housing For assembly, reverse the disassembly procedure.
Page 227: Disassembling The Water Pump
COOL WATER PUMP DISASSEMBLING THE WATER PUMP 1.Remove: Rubber damper holder 1 Rubber damper 2 (from the impeller, with a thin, flathead screwdriver) NOTE: Do not scratch the impeller shaft. 2.Remove: Water pump seal 1 NOTE: Tap out the water pump seal from the inside of the water pump housing.
Page 228: Assembling The Water Pump
COOL WATER PUMP 3.Measure: Impeller shaft tilt Out of specification → Replace. Max. impeller shaft tilt: 0.15 mm (0.006 in) 1 Straightedge 2 Impeller ASSEMBLING THE WATER PUMP 1.Install: Oil seal 1 (into the water pump housing 2) NOTE: Install the oil seal with a socket 3 that matches its outside diameter.
Page 229 COOL WATER PUMP 3.Install: Rubber damper 1 Rubber damper holder 2 NOTE: Before installing the rubber damper, apply tap water or coolant onto its outer surface. CAUTION: Make sure that the rubber damper and rubber damper holder are flush with the impeller.
Page 230: Chapter 6. Carburetion
CARB CARBURETOR CARBURETION CARBURETOR Order Job name/Part name Q’ty Remarks Removing the carburetor Remove the parts in the order below. Seat/fuel tank side panels/fuel tank/ Refer to “SEAT, CARRIERS, FENDERS rubber cover AND FUEL TANK” in CHAPTER 3. Drain hose Starter cable/starter plunger Vacuum chamber breather hose Carburetor assembly...
Page 231 CARB CARBURETOR Order Job name/Part name Q’ty Remarks Disassembling the carburetor Remove the parts in the order below. Float chamber air vent hose Throttle stop screw Vacuum chamber cover Spring Jet needle holder Spring Jet needle set Piston valve Coasting enricher Float chamber Drain screw Float...
Page 232 CARB CARBURETOR Order Job name/Part name Q’ty Remarks Pilot jet NOTE: Before disassembling the carburetor, make sure to note the number of times the pilot screw is turned out from the seated position to its set position. Main jet Needle jet Starter jet Pilot air jet For assembly, reverse the disassembly...
Page 233: Disassembling The Carburetor
CARB CARBURETOR DISASSEMBLING THE CARBURETOR NOTE: Before disassembling the carburetor, make sure to note the number of times the pilot screw is turned out from the seated position to its set position. CHECKING THE CARBURETOR 1.Check: Carburetor body Float chamber Cracks/damage →...
Page 234 CARB CARBURETOR 4.Check: Piston valve 1 Scratches/wear/damage → Replace. Rubber diaphragm 2 Tears → Replace. 5.Check: Vacuum chamber cover 1 Spring 2 Cracks/damage → Replace. 6.Check: Diaphragm (coasting enricher) 1 Spring 2 Cover 3 Tears (diaphragm) /damage → Replace. 7.Check: Jet needle 1 Main jet 2 Needle jet 3...
Page 235: Assembling The Carburetor
CARB CARBURETOR 8.Check: Free movement (piston valve) Sticks → Replace the piston valve guide and the piston valve. Insert the piston valve into the carburetor body, and check for free movement. 9.Check: Free movement (throttle valve) Sticks → Replace. ASSEMBLING THE CARBURETOR CAUTION: Before reassembling, wash all of the parts in a clean petroleum based solvent.
Page 236: Adjusting The Fuel Level
CARB CARBURETOR ADJUSTING THE FUEL LEVEL 1.Measure: Fuel level a Out of specification → Adjust. Fuel level: 4.0 ~ 5.0 mm (0.16 ~ 0.20 in) Above the float chamber mating surface ***************************************************** Measurement and adjustment steps: Place the machine on a level surface. Connect the fuel level gauge 1 to the drain pipe 2.
Page 237: Chapter 7. Drive Train
DRIV TROUBLESHOOTING DRIVE TRAIN TROUBLESHOOTING The following conditions may indicate damaged shaft drive components: Symptoms Possible Causes 1.A pronounced hesitation or “jerky” movement A.Bearing damage. during acceleration, deceleration, or sustained B. Improper gear lash. speed. (This must not be confused with engine surging transmission...
Page 238 DRIV TROUBLESHOOTING CAUTION: Too little gear lash is extremely destructive to the gear teeth. If a test ride following reassembly indicates this condition, stop riding immediately to minimize gear damage. c.A slight “thunk” evident at low speed operation. This noise must be distinguished from normal machine operation.
Page 239 DRIV TROUBLESHOOTING Troubleshooting chart When basic condition “a” and “b” exist, check the following points: Elevate and spin both wheels. Feel for Replace the wheel bearing. wheel bearing damage. (Refer to “STEERING SYSTEM” and “REAR SHOCK ABSORBER SWINGARM” in CHAPTER 8.) Check the wheel nuts and hub nuts for Torque to specification.
Page 240: Front Constant Velocity Joints And Differential Gear
FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR Order Job name/Part name Q’ty Remarks Removing the front constant Remove the parts in the order below. velocity joint and differential gear Engine skid plate (front) Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”...
Page 241 FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR Order Job name/Part name Q’ty Remarks Differential gear Drive shaft Compression spring For installation, reverse the removal procedure. Not For Resale 7 - 5 www.SmallEngineDiscount.com...
Page 242 FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR Order Job name/Part name Q’ty Remarks Disassembling the constant velocity Remove the parts in the order below. joint Circlip Boot band Boot band Dust boot Circlip Refer to “ASSEMBLING THE FRONT CONSTANT VELOCITY JOINT”. Double off-set joint Snap ring Ball bearing...
Page 243 FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR Order Job name/Part name Q’ty Remarks Disassembling the differential gear Remove the parts in the order below. Gear motor/O-ring NOTE: Be sure not to disassemble the gear motor or remove the pinion gear. Circlip Bearing Refer to “REMOVING/INSTALLING THE...
Page 244 FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR Order Job name/Part name Q’ty Remarks Differential gear assembly Shim (right) Circlip/bearing Drive pinion gear Differential gear case For assembly, reverse the disassembly procedure. Not For Resale 7 - 8 www.SmallEngineDiscount.com...
Page 245: Removing The Universal Joint
FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR REMOVING THE UNIVERSAL JOINT 1.Remove: Universal joint ***************************************************** Removal steps: Remove the circlips 1. Place the U-joint in a press. With a suitable diameter pipe 2 beneath the yoke 3, press the bearing 4 into the pipe as shown.
Page 246: Checking The Constant Velocity Joint
FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR 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 →...
Page 247: Checking The Gear Motor
FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR CHECKING THE GEAR MOTOR È 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 É...
Page 248: Assembling The Differential Gear
FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR 3.Check: Free play (thrust movement) Excessive play → Replace the joint assembly. ASSEMBLING THE DIFFERENTIAL GEAR 1.Measure: Gear lash Refer to “MEASURING AND ADJUSTING THE DIFFERENTIAL GEAR LASH”. 2.Install: Gear motor ***************************************************** Installation steps: Slide the shift fork sliding gear 1, which is installed to the differential gear, to the left to...
Page 249: Installing The Universal Joint
FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR 3.Install: Universal joint yoke O-ring Washer 62 Nm (6.2 m • kg, 45 ft • lb) Use a universal joint holder 1. Universal joint holder: P/N. YM-04062, 90890-04062 4.Check: Differential gear operation Unsmooth operation →...
Page 250: Measuring And Adjusting The Differential Gear Lash
FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR MEASURING AND ADJUSTING THE DIFFERENTIAL GEAR LASH Measuring the differential gear lash 1.Secure the gear case in a vise or another supporting device. 2.Remove: Drain plug Gasket 3.Install: A bolt of the specified size 1 (into the drain plug hole) CAUTION: Finger tighten the bolt until it holds the ring...
Page 251 FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR Adjusting differential gear lash 1.Remove: Shim(s) (left) 1 Differential gear assembly 2 Shim(s) (right) 3 2.Adjust: Gear lash ***************************************************** Adjustment steps: Select the suitable shims using the following chart. Reduce shim Too little gear lash thickness.
Page 252: Checking The Differential Gear Operation
FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR CHECKING THE DIFFERENTIAL GEAR OPERATION 1.Block the rear wheels, and elevate the front wheels by placing a suitable stand under the frame. 2.Remove the wheel cap and cotter pin from the axle nut (right or left). 3.Measure the starting torque of the front wheel (i.e., differential gear preload) with the torque wrench.
Page 253: Rear Axle/Final Drive Gear And Drive Shaft
DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT Order Job name/Part name Q’ty Remarks Removing the rear axle, final drive Remove the parts in the order below. gear assembly and drive shaft Final gear oil Drain.
Page 254 DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT Order Job name/Part name Q’ty Remarks Disassembling the final drive gear Remove the parts in the order below. Bolt NOTE: Bolt Working in a crisscross pattern, loosen each bolt 1/4 of a turn. After all the bolts are loosened, remove them.
Page 255 DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT Order Job name/Part name Q’ty Remarks Bearing retainer/O-ring Oil seal Refer to “DISASSEMBLING/ Final drive pinion gear ASSEMBLING THE FINAL DRIVE Collar GEAR”. Bearing Final drive pinion gear shim Final drive gear case/O-ring Bearing/oil seal Refer to “REPLACING THE FINAL DRIVE ROLLER BEARING”.
Page 256: Disassembling The Final Drive Gear
DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT REMOVING THE REAR AXLE 1.Remove: Rear axle 1 (with dust seal) O-ring CAUTION: Never directly tap the axle end with a hammer, since this will result in damage to the axle thread and spline. Attach a suitable socket 2 on the axle end and tap it with a soft hammer.
Page 257 DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT REPLACING THE FINAL DRIVE ROLLER BEARING 1.Remove: Roller bearing (ring gear) 1 Use a suitable press tool 2 and an appropriate support for the main housing. Oil seal 3 2.Remove: Roller bearing (final drive pinion gear) 1 ***************************************************** Removal steps: Heat the main housing only to 150 °C...
Page 258: Positioning The Final Drive Pinion Gear And Ring Gear
DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT POSITIONING THE FINAL DRIVE PINION GEAR AND RING GEAR When the final drive pinion gear, ring gear, final gear case and/or ring gear bearing housing are replaced, be sure to adjust the positions of the final drive pinion gear and ring gear using the shim(s).
Page 259 DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT Shims supplied following thicknesses. Final drive pinion gear shim 0.15 0.30 0.40 Thickness (mm) 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.
Page 260 DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT 5) Therefore, shim thickness “B” is 0.63. “B”= 45.53 + 1.05 – (34.95 + 11.00) = 46.58 – 45.95 = 0.63 6) Round off the hundredth digit and select the appropriate shim(s). In the example above, the calculated number is 0.63.
Page 261 DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT Remove the ring gear assembly. Measure the thrust clearance. Calculate the ® width of the flattened Plastigauge Ring gear thrust clearance: 0.1 ~ 0.2 mm (0.004 ~ 0.008 in) If out of specification, select the correct washer.
Page 262: Checking The Rear Axle
DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT Ring gear stopper clearance adjustment 1.Remove: Ring gear 1 Ring gear stopper 2 Shim(s) 3 4 Bearing housing È Left-hand threads 2.Select: Suitable shim(s) Shim 0.10 0.15 0.20 Thickness (mm) 0.30 0.40 0.50 3.Install: Shim(s)
Page 263: Checking The Drive Shaft
Bearings Damage → Replace. NOTE: Reusing roller bearings is acceptable, but Yamaha recommends installing new ones. Do not reuse the oil seal. When the final drive pinion gear and/or ring gear are replaced, be sure to adjust the shim of the final drive pinion gear and/or ring gear.
Page 264: Measurement And Adjusting The Final Gear Lash
DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT MEASUREMENT AND ADJUSTING THE FINAL GEAR LASH Final gear lash measurement 1.Secure the gear case in a vise or another supporting device. 2.Remove: Drain plug Gasket 3.Install: A bolt of the specified size 1 (into the drain plug hole) CAUTION: Finger tighten the bolt until it holds the ring...
Page 265 DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT Final gear lash adjustment 1.Remove: Bearing housing 1 Ring gear shim(s) 2 Ring gear 3 Thrust washer 4 2.Adjust: Gear lash ***************************************************** Adjustment steps: Select suitable shim(s) thrust washer(s) using the following chart. Reduce shim Too little gear lash thickness.
Page 266: Assembling The Final Drive Gear
DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT ASSEMBLING THE FINAL DRIVE GEAR 1.Install: Drive pinion gear (with shim(s) and bearing) (proper shim size as calculated) Bearing retainer (drive pinion gear) 1 100 Nm (10.0 m • kg, 72 ft • lb) Use a bearing retainer wrench 2.
Page 267 Sealant (Quick Gasket (to the mating surfaces of the swingarm and the final drive gear case) ® Sealant (Quick gasket P/N. ACC-11001-05-01 Yamaha bond No.1215: P/N. 90890-85505 4.Install: Final drive gear Nuts 63 Nm (6.3 m • kg, 45 ft • lb) Bolts 63 Nm (6.3 m •...
Page 268: Chapter 8. Chassis
CHAS FRONT AND REAR WHEELS CHASSIS FRONT AND REAR WHEELS FRONT WHEELS 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.
Page 269: Rear Wheels
CHAS FRONT AND REAR WHEELS REAR WHEELS Order Job name/Part name Q’ty 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. Rear wheel Refer to “INSTALLING THE WHEEL”.
Page 270: Checking The Wheel
CHAS FRONT AND REAR WHEELS CHECKING THE WHEEL 1.Check: Wheel 2.Measure: Wheel runout Over the specified limit → Replace the wheel or check the wheel bearing play 1. Wheel runout limit: Radial 2: 2.0 mm (0.08 in) Lateral 3: 2.0 mm (0.08 in) 3.Check: Wheel balance Out of balance →...
Page 271: Checking The Brake Disc
CHAS FRONT AND REAR WHEELS CHECKING THE BRAKE DISC 1.Check: Brake disc Galling/damage → Replace. 2.Measure: Brake disc deflection Out of specification → Check the wheel runout. If wheel runout is within the limits, replace the brake disc. Brake disc maximum deflection: 0.15 mm (0.006 in) Brake disc thickness a Out of specification →...
Page 272 CHAS FRONT AND REAR WHEELS 2.Install: Nuts (wheel) 1 WARNING Tapered wheel nuts 1 are used for both the front and rear wheels. Install each nut with its tapered side towards the wheel. 3.Tighten: Nuts (front wheel) 64 Nm (6.4 m • kg, 46 ft • lb) Nuts (rear wheel) 55 Nm (5.5 m •...
Page 273: Front And Rear Brakes
CHAS FRONT AND REAR BRAKES FRONT AND REAR BRAKES FRONT BRAKE PADS Order Job name/Part name Q’ty Remarks Removing the front brake pads Remove the parts in the order below. Front wheel Refer to “FRONT AND REAR WHEELS”. Brake caliper mounting bolt Brake pad holding bolt Refer to “REPLACING THE FRONT BRAKE PAD”.
Page 274: Rear Brake Pads
CHAS FRONT AND REAR BRAKES REAR BRAKE PADS Order Job name/Part name Q’ty Remarks Removing the rear brake pads Remove the parts in the order below. Rear wheel (left) Refer to “FRONT AND REAR WHEELS”. Brake caliper mounting bolt Brake pad holding bolt Refer to “REPLACING THE REAR BRAKE PAD”.
Page 275: Replacing The Front Brake Pad
CHAS FRONT AND REAR BRAKES CAUTION: Disc brake components rarely require disassembly. DO NOT: disassemble components unless absolutely necessary; solvents internal brake components; use spent brake fluid for cleaning; (use only clean brake fluid) allow brake fluid to come in contact with the eyes, as this may cause eye injury;...
Page 276 CHAS FRONT AND REAR BRAKES ***************************************************** Installation steps: Connect a suitable hose 1 tightly to the brake caliper bleed screw 2. Put the other end of this hose into an open container. Loosen the brake caliper bleed screw and, using a finger, push the caliper piston into the brake caliper.
Page 277: Replacing The Rear Brake Pad
CHAS FRONT AND REAR BRAKES REPLACING THE REAR BRAKE PAD NOTE: It is not necessary to disassemble the brake caliper and brake hose to replace the brake pads. 1.Measure: Brake pad wear limit a Out of specification → Replace the brake pad as a set.
Page 278 CHAS FRONT AND REAR BRAKES 3.Check: Brake fluid level Refer to “CHECKING THE BRAKE FLUID LEVEL” in CHAPTER 3. 4.Check: Brake lever or brake pedal operation Soft or spongy feeling → Bleed the rear brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM”...
Page 279: Front Brake Master Cylinder
CHAS FRONT AND REAR BRAKES FRONT BRAKE MASTER CYLINDER Order Job name/Part name Q’ty Remarks Removing the front brake master Remove the parts in the order below. cylinder Brake fluid Drain. On-command four-wheel drive switch Refer to “HANDLEBAR”. and differential gear lock switch Brake fluid reservoir cap Brake fluid reservoir diaphragm Brake lever...
Page 280 CHAS FRONT AND REAR BRAKES Order Job name/Part name Q’ty Remarks Disassembling the front brake Remove the parts in the order below. master cylinder Brake master cylinder kit Refer to “ASSEMBLING THE FRONT BRAKE MASTER CYLINDER”. Brake master cylinder For assembly, reverse the disassembly procedure.
Page 281: Rear Brake Master Cylinder
CHAS FRONT AND REAR BRAKES REAR BRAKE MASTER CYLINDER Order Job name/Part name Q’ty Remarks Removing the rear brake master Remove the parts in the order below. cylinder Front fender Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK” in CHAPTER 3. Brake fluid Drain.
Page 282 CHAS FRONT AND REAR BRAKES Order Job name/Part name Q’ty Remarks Brake cable Disconnect. Bracket Brake master cylinder Hose joint Brake pedal Select lever control cable Disconnect. Rear brake light switch Bracket Bracket Brake master cylinder bracket For installation, reverse the removal procedure.
Page 283 CHAS FRONT AND REAR BRAKES Order Job name/Part name Q’ty Remarks Disassembling the rear brake Remove the parts in the order below. master cylinder Brake master cylinder kit Refer to “ASSEMBLING THE REAR BRAKE MASTER CYLINDER”. Brake master cylinder For assembly, reverse the disassembly procedure.
Page 284: Checking The Master Cylinder
CHAS FRONT AND REAR BRAKES CHECKING THE MASTER CYLINDER È 1.Check: Brake master cylinder 1 Wear/scratches → Replace the brake master cylinder assembly. Brake master cylinder body Cracks/damage → Replace. Brake fluid delivery passage (brake master cylinder body) Blockage → Blow out with compressed air. È...
Page 285: Assembling The Front Brake Master Cylinder
CHAS FRONT AND REAR BRAKES EB702060 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER WARNING All internal brake components should be cleaned and lubricated with new brake fluid only before installation. Recommended brake fluid: DOT 4 Whenever master cylinder disassembled, replace the piston seals and dust seals.
Page 286: Installing The Front Brake Master Cylinder
CHAS FRONT AND REAR BRAKES INSTALLING THE FRONT BRAKE MASTER CYLINDER 1.Install: Brake master cylinder 1 Brake master cylinder bracket 2 7 Nm (0.7 m • kg, 5.1 ft • lb) NOTE: The “UP” mark on the brake master cylinder bracket 2 should face up.
Page 287: Installing The Rear Brake Master Cylinder
CHAS FRONT AND REAR BRAKES Be careful that water does not enter the brake master cylinder when refilling. Water will significantly lower the boiling point of the brake fluid and may result in vapor lock. 4.Air bleed: Brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM”...
Page 288 CHAS FRONT AND REAR BRAKES 2.Fill: Brake fluid reservoir Recommended brake fluid: DOT 4 CAUTION: Brake fluid may damage painted surfaces or plastic parts. Always clean up spilled brake fluid immediately. WARNING Use only the designated quality brake fluid: other brake fluids may deteriorate the rubber seals, causing leakage and poor brake performance.
Page 289: Front Brake Caliper
CHAS FRONT AND REAR BRAKES FRONT BRAKE CALIPER Order Job name/Part name Q’ty Remarks Removing the front brake caliper Remove the parts in the order below. Brake fluid Drain. Front wheel Refer to “FRONT AND REAR WHEELS”. Union bolt Copper washer Brake hose Disconnect.
Page 290 CHAS FRONT AND REAR BRAKES Order Job name/Part name Q’ty Remarks Disassembling the front brake Remove the parts in the order below. caliper Brake pad holding bolt Brake pad/pad shim Pad spring Retaining bolt Caliper bracket Brake caliper piston Refer to “DISASSEMBLING/ Dust seal ASSEMBLING THE FRONT AND REAR BRAKE CALIPER”.
Page 291: Rear Brake Caliper
CHAS FRONT AND REAR BRAKES REAR BRAKE CALIPER Order Job name/Part name Q’ty Remarks Removing the rear brake caliper Remove the parts in the order below. Brake fluid Drain. Rear wheel Refer to “FRONT AND REAR WHEELS”. Union bolt Copper washer Refer to “INSTALLING Brake hose Disconnect.
Page 292 CHAS FRONT AND REAR BRAKES Order Job name/Part name Q’ty Remarks Disassembling the rear brake caliper Remove the parts in the order below. Brake pad holding bolt Brake pad/insulator/pad shim 2/2/2 Pad spring Caliper bracket Brake caliper piston Refer to “DISASSEMBLING/ Dust seal ASSEMBLING THE FRONT AND REAR BRAKE CALIPER”.
Page 293: Disassembling The Front And Rear Brake Caliper
CHAS FRONT AND REAR BRAKES DISASSEMBLING THE FRONT AND REAR BRAKE CALIPER 1.Remove: Brake caliper piston Dust seal 1 Caliper piston seal 2 ***************************************************** Removal steps: Blow compressed air into the hose joint opening to force out the caliper piston from the brake caliper body.
Page 294: Assembling The Front And Rear Brake Caliper
CHAS FRONT AND REAR BRAKES Brake fluid delivery passage (brake caliper É body) Blockage → Blow out with compressed air. WARNING Replace the caliper piston seal and dust seal whenever brake caliper disassembled. È Front É Rear ASSEMBLING THE FRONT AND REAR BRAKE CALIPER WARNING All internal brake components should be...
Page 295 CHAS FRONT AND REAR BRAKES CAUTION: When installing the brake hose on the brake caliper, make sure that the brake pipe touches the projection a on the brake caliper. WARNING Proper brake hose routing is essential to insure safe motorcycle operation. Refer to “CABLE ROUTING”...
Page 296: Installing The Rear Brake Caliper
CHAS FRONT AND REAR BRAKES INSTALLING THE REAR BRAKE CALIPER 1.Install: Brake caliper assembly Brake caliper mounting bolt 1 30 Nm (3.0 m • kg, 22 ft • lb) Brake hose 2 Copper washers 3 Union bolt 4 30 Nm (3.0 m • kg, 22 ft • lb) 2.Fill: Brake reservoir Recommended brake fluid:...
Page 297: Handlebar
CHAS STEERING SYSTEM STEERING SYSTEM HANDLEBAR Order Job name/Part name Q’ty Remarks Removing the handlebar Remove the parts in the order below. Handlebar cover Band On-command four-wheel drive switch and differential gear lock switch Refer to “INSTALLING THE MASTER Master cylinder assembly/bracket CYLINDER ASSEMBLY”.
Page 298: Removing The Rear Brake Switch
CHAS STEERING SYSTEM REMOVING THE REAR BRAKE SWITCH 1.Remove: Rear brake switch 1 NOTE: Push the fastener when removing the rear brake switch out of the rear brake lever holder. CHECKING THE HANDLEBAR 1.Check: Handlebar Bends/cracks/damage → Replace. WARNING Do not attempt to straighten a bent handlebar as this may dangerously weaken the handlebar.
Page 299: Installing The Master Cylinder Assembly
CHAS STEERING SYSTEM INSTALLING THE MASTER CYLINDER ASSEMBLY 1.Install: Throttle lever assembly Master cylinder assembly 7 Nm (0.7 m • kg, 5.1 ft • lb) NOTE: The “UP” mark on the master cylinder bracket should face up. Not For Resale 8 - 32 www.SmallEngineDiscount.com...
Page 300: Steering Stem
CHAS STEERING SYSTEM STEERING STEM Order Job name/Part name Q’ty Remarks Removing the steering stem Remove the parts in the order below. Handlebar Refer to “HANDLEBAR”. Seat Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK” in CHAPTER 3. Front fender Lock washer Refer to “INSTALLING THE CABLE GUIDE”.
Page 301 CHAS STEERING SYSTEM Order Job name/Part name Q’ty Remarks Oil seal Bearing retainer Refer to “REMOVING/INSTALLING THE BEARING RETAINER”. Bearing Oil seal For installation, reverse the removal procedure. Not For Resale 8 - 34 www.SmallEngineDiscount.com...
Page 302: Removing The Bearing Retainer
CHAS STEERING SYSTEM REMOVING THE BEARING RETAINER 1.Remove: Bearing retainer (steering stem) Damper rod holder: P/N. YM-01327, 90890-01327 CHECKING THE STEERING STEM 1.Check: Steering stem Bends → Replace. WARNING Do not attempt to straighten a bent stem; this may dangerously weaken the stem. 2.Check: Oil seals 1 Steering stem bushings 2...
Page 303: Tie Rod And Steering Knuckle
CHAS STEERING SYSTEM TIE ROD AND STEERING KNUCKLE Order Job name/Part name Q’ty Remarks Removing the tie rod and steering Remove the parts in the order below. knuckle Front fender Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK” in CHAPTER 3. Front wheel/brake disc Refer to “FRONT AND REAR WHEELS”.
Page 304 CHAS STEERING SYSTEM Order Job name/Part name Q’ty Remarks Oil seal Oil seal Bearing Spacer Circlip Rubber boot Ball joint For installation, reverse the removal procedure. Not For Resale 8 - 37 www.SmallEngineDiscount.com...
Page 305: Removing The Steering Knuckle
CHAS STEERING SYSTEM REMOVING THE STEERING KNUCKLE 1.Remove: Steering knuckle 1 NOTE: Use a general puller to separate the ball joint 2 and steering knuckle 1 or front lower arm CHECKING THE TIE ROD 1.Check: Tie rod free play and movement Free play →...
Page 306 CHAS STEERING SYSTEM Ball joint remover/installer set: P/N. YM-01474/90890-01474 Ball joint remover/installer attachment set: P/N. YM-01477 YM-01474 Body 90890-01474 YM-01474 Long bolt 90890-01474 Short bolt YM-01477 Remover washer YM-01477 Remover spacer YM-01477 Installer attachment YM-01477 Installer spacer YM-01477 Installer guide YM-01477 Install the body 3, short bolt 5, remover washer 6 and remover spacer 7 onto ball...
Page 307 CHAS STEERING SYSTEM Attach the assembled ball joint remover/ installer, new ball joint B and installer attachment 8 to the steering knuckle C. NOTE: Do not tap or damage the top of the ball joint. Hold the body 3 in place while turning in the long bolt 4 to install the new ball joint B into the steering knuckle C.
Page 308: Installing The Tie Rod
CHAS STEERING SYSTEM Install the new bearings. NOTE: Install the outside bearing first. CAUTION: Do not strike the center race or balls of the bearing. Contact should be made only with the outer race. Install a new oil seal. NOTE: When installing the oil seals, the “seal side”...
Page 309: Front Arms And Front Shock Absorber
CHAS FRONT ARMS AND FRONT SHOCK ABSORBER FRONT ARMS AND FRONT SHOCK ABSORBER Order Job name/Part name Q’ty Remarks Removing the front arms and front Remove the parts in the order below. shock absorber Engine skid plate Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”...
Page 310 CHAS FRONT ARMS AND FRONT SHOCK ABSORBER Order Job name/Part name Q’ty Remarks Bolt/nut Refer to “REMOVING THE FRONT Front lower arm/bushing ARMS” and “INSTALLING THE FRONT ARMS AND FRONT SHOCK Nut/bolt ABSORBER”. Front shock absorber Bolt/nut Front upper arm/bushing Circlip Ball joint For installation, reverse the removal...
Page 311: Removing The Front Arms
CHAS FRONT ARMS AND FRONT SHOCK ABSORBER REMOVING THE FRONT ARMS 1.Check: Front arm free play ***************************************************** Checking steps: Check the front arm side play È by moving it from side to side. If side play is noticeable, check the bushings. Check the front arm vertical movement É...
Page 312 CHAS FRONT ARMS AND FRONT SHOCK ABSORBER ***************************************************** Replacement steps: Clean the outside of the front lower arm. Remove the circlip 1 and rubber boot 2. Use the ball joint remover and installer set. Ball joint remover/installer set: P/N. YM-01474/90890-01474 Ball joint remover/installer attachment set: P/N.
Page 313 CHAS FRONT ARMS AND FRONT SHOCK ABSORBER Attach the assembled ball joint remover/ installer, new ball joint A and installer attachment 7 to the front lower arm B. NOTE: Do not tap or damage the top of the ball joint. Hold the body 3 in place while turning in the long bolt 4 to install the new ball joint A into the front lower arm B.
Page 314: Installing The Front Arms And Front Shock Absorber
CHAS FRONT ARMS AND FRONT SHOCK ABSORBER INSTALLING THE FRONT ARMS AND FRONT SHOCK ABSORBER 1.Install: Front arms Front shock absorber ***************************************************** Installation steps: Install the front upper arm 1 and front lower arm 2. NOTE: Lubricate the bolts 3 with lithium-soap- based grease.
Page 315: Rear Shock Absorber And Swingarm
CHAS REAR SHOCK ABSORBER AND SWINGARM REAR SHOCK ABSORBER AND SWINGARM Order Job name/Part name Q’ty Remarks Removing the rear shock absorber Remove the parts in the order below. and swingarm Rear wheel hubs/brake disc Refer to “FRONT AND REAR WHEELS”. Rear brake caliper/brake hose Refer to “FRONT AND REAR BRAKES”.
Page 316 CHAS REAR SHOCK ABSORBER AND SWINGARM Order Job name/Part name Q’ty Remarks Rear axle housing Refer to “INSTALLING THE REAR AXLE HOUSING”. Nut/bolt Refer to “REMOVING THE SWINGARM”. Swingarm/bushing Spring/rubber boot For installation, reverse the removal procedure. Not For Resale 8 - 49 www.SmallEngineDiscount.com...
Page 317: Removing The Swingarm
CHAS REAR SHOCK ABSORBER AND SWINGARM REMOVING THE SWINGARM 1.Check: Swingarm free play ***************************************************** Checking steps: Check the tightening torque of the nuts (swingarm). Nut (swingarm): 82 Nm (8.2 m • kg, 59 ft • lb) Check the swingarm side play È by moving it from side to side.
Page 318: Checking The Swingarm
CHAS REAR SHOCK ABSORBER AND SWINGARM CHECKING THE SWINGARM 1.Check: Swingarm 1 Rear axle housing 2 Bends/cracks/damage → Replace. 2.Check: Bushings 1 Wear/damage → Replace. CHECKING THE RUBBER BOOT 1.Check: Rubber boot 1 Damage → Replace. INSTALLING THE RUBBER BOOT 1.Apply: Adhesive (for rubber) (to the engine 1)
Page 319: Installing The Rear Axle Housing
CHAS REAR SHOCK ABSORBER AND SWINGARM INSTALLING THE REAR AXLE HOUSING 1.Install: Rear axle housing Final gear case assembly Rear axle (with dust seal) ***************************************************** Installation steps: Install the drive shaft. Refer to “REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT” in CHAPTER 7. ®...
Page 320: Chapter 9. Electrical
– ELEC ELECTRICAL COMPONENTS EB800000 ELECTRICAL ELECTRICAL COMPONENTS 1 Main switch 8 Four-wheel drive D Reverse switch L Fan 2 Front brake light E Neutral switch M Headlight relay 2 9 Four-wheel drive F High-range switch N Circuit breaker (fan) switch 3 Rear brake switch G Low-range switch...
Page 321: Checking The Switch
– ELEC CHECKING THE SWITCH CHECKING THE SWITCH CHECKING THE SWITCH Use a pocket tester to check the terminals for continuity. If the continuity is faulty at any point, replace the switch. Pocket tester: P/N. YU-03112, 90890-03112 NOTE: Set the pocket tester to “0” before starting the test.
Page 322 – ELEC CHECKING THE SWITCH Not For Resale 9 - 3 www.SmallEngineDiscount.com...
Page 323: Checking The Switch Continuity
– ELEC CHECKING THE SWITCH CHECKING THE SWITCH CONTINUITY Refer to “CHECKING THE SWITCH” and check for continuity between lead terminals. Poor connection, no continuity → Correct or replace. The coupler locations are circled. Br L Y G R/B R/W PUSH (BLACK) L/B L/G...
Page 324 – ELEC CHECKING THE SWITCH 1 Light switch 2 Engine stop switch 3 Start switch 4 On-command four-wheel drive switch and differential gear lock switch 5 Main switch 6 Rear brake light switch 7 Front brake light switch 8 Rear brake switch 9 Reverse switch 0 Neutral switch A High-range switch...
Page 325: Checking The Bulbs And Bulb Sockets
– ELEC CHECKING THE BULBS AND BULB SOCKETS EB801020 CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage or wear, proper connections, and also for continuity between the terminals. Damage/wear → Repair or replace the bulb, bulb socket or both.
Page 326 – ELEC CHECKING THE BULBS AND BULB SOCKETS WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. CAUTION: Be sure to hold the socket firmly when removing the bulb.
Page 327: Checking The Condition Of The Bulbs
– ELEC CHECKING THE BULBS AND BULB SOCKETS CHECKING THE CONDITION OF THE BULB SOCKETS The following procedure applies to all of the bulb sockets. 1.Check: Bulb socket (for continuity) (with the pocket tester) No continuity → Replace. Pocket tester: P/N.
Page 328: Ignition System
– ELEC IGNITION SYSTEM EB802000 IGNITION SYSTEM CIRCUIT DIAGRAM Not For Resale 9 - 9 www.SmallEngineDiscount.com...
Page 329: Troubleshooting
– ELEC IGNITION SYSTEM EB802010 TROUBLESHOOTING IF THE IGNITION SYSTEM FAILS TO OPERATE (NO SPARK OR INTERMITTENT SPARK): Procedure Check: 1.Fuse (main, ignition) 7.Engine stop switch 2.Battery 8.Main switch 3.Spark plug 9.Pickup coil resistance 4.Ignition spark gap 10.Charging/rotor rotation direction detection 5.Spark plug cap resistance coil resistance 6.Ignition coil resistance...
Page 330 – ELEC IGNITION SYSTEM INCORRECT Spark plug gap: 0.6 ~ 0.7 mm (0.024 ~ 0.028 in) CORRECT Repair or replace the spark plug. 4.Ignition spark gap Disconnect the spark plug cap from the spark plug. Connect the dynamic spark tester 1 as shown.
Page 331 – ELEC IGNITION SYSTEM C0NTINUITY 6.Ignition coil resistance Disconnect the ignition coil connector from the wire harness. Connect the pocket tester (Ω × 1) to the ignition coil. Tester (+) lead → Orange lead terminal Tester (–) lead → Ignition coil base Check that the primary coil has the specified resistance.
Page 332 – ELEC IGNITION SYSTEM C0NTINUITY INCORRECT 8.Main switch Refer to “CHECKING THE SWITCH”. CORRECT Replace the main switch. 9.Pickup coil resistance Disconnect the AC magneto coupler from the wire harness. Connect the pocket tester (Ω × 100) to the pickup coil terminal. Tester (+) lead →...
Page 333 – ELEC IGNITION SYSTEM C0NTINUITY 11.Wiring connection POOR CONNECTION Check the connections of the entire ignition system. Refer to “CIRCUIT DIAGRAM”. Properly connect the ignition system. CORRECT Replace the CDI unit. Not For Resale 9 - 14 www.SmallEngineDiscount.com...
Page 334: Electric Starting System
– ELEC ELECTRIC STARTING SYSTEM EB803000 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM Not For Resale 9 - 15 www.SmallEngineDiscount.com...
Page 335: Troubleshooting
– ELEC ELECTRIC STARTING SYSTEM EB803020 TROUBLESHOOTING IF THE STARTER MOTOR FAILS TO OPERATE: Procedure Check: 6.Engine stop switch 1.Fuse (main, ignition) 7.Start switch 2.Battery 8. Wiring connection (the entire starting 3.Starter motor system) 4.Starter relay 5.Main switch NOTE: Pocket tester: Remove following part(s)
Page 336 – ELEC ELECTRIC STARTING SYSTEM C0NTINUITY WARNING 3.Starter motor A wire that is used as a jumper lead must Connect the battery positive terminal 1 have the equivalent capacity or more as and starter motor cable 2 using a jumper that of the battery lead, otherwise the lead 3 jumper lead may burn.
Page 337 – ELEC ELECTRIC STARTING SYSTEM C0NTINUITY INCORRECT 5.Main switch Refer to “CHECKING THE SWITCH”. CORRECT Replace the main switch. INCORRECT 6.Engine stop switch Refer to “CHECKING THE SWITCH”. CORRECT Replace the handlebar switch (left). INCORRECT 7.Start switch Refer to “CHECKING THE SWITCH”. CORRECT Replace the handlebar switch (left).
Page 338 – ELEC ELECTRIC STARTING SYSTEM STARTER MOTOR Order Job name/Part name Q’ty Remarks Removing the starter motor Remove the parts in the order below. Starter motor lead Starter motor/O-ring Disassembling the starter motor Remove the parts in the order below. Bracket 1 Washer kit Bracket 2/bushing...
Page 339: Checking The Starter Motor
– ELEC ELECTRIC STARTING SYSTEM CHECKING THE STARTER MOTOR 1.Check: Commutator Dirty → Clean it with #600 grit sandpaper. 2.Measure: Commutator diameter a Out of specification → Replace the starter motor. Outside diameter: 28 mm (1.10 in) <Wear limit:> 27 mm (1.06 in) 3.Measure: Mica undercut b Out of specification →...
Page 340: Assembling The Starter Motor
– ELEC ELECTRIC STARTING SYSTEM 5.Measure: Brush length a (each) Out of specification → Replace the brush holder set. Brush length: 12.5 mm (0.49 in) <Wear limit:> 5 mm (0.20 in) 6.Measure: Brush spring force Fatigue/out of specification → Replace the brush holder set.
Page 341: Charging System
– ELEC CHARGING SYSTEM EB804000 CHARGING SYSTEM CIRCUIT DIAGRAM 1 A.C. magneto 2 Rectifier/regulator 5 Battery 6 Main fuse Not For Resale 9 - 22 www.SmallEngineDiscount.com...
Page 342: Troubleshooting
– ELEC CHARGING SYSTEM EB804010 TROUBLESHOOTING IF THE BATTERY IS NOT CHARGED: Procedure Check: 1.Fuse (main) 4.Charging coil resistance 2.Battery 5.Wiring connections 3.Charging voltage (the entire charging system) NOTE: Inductive tachometer: Remove following part(s) before P/N. YU-8036-A troubleshooting: Engine tachometer: 1)Seat P/N.
Page 343 – ELEC CHARGING SYSTEM Start the engine and accelerate to about 3,000 r/min. MEETS SPECIFICATION Charging voltage: 14 V at 3,000 r/min NOTE: Use a fully charged battery. The charging circuit is not faulty. OUT OF SPECIFICATION EB804012 4.Charging coil resistance Disconnect the AC magneto coupler from the wire harness.
Page 344: Lighting System
– ELEC LIGHTING SYSTEM EB805000 LIGHTING SYSTEM CIRCUIT DIAGRAM Not For Resale 9 - 25 www.SmallEngineDiscount.com...
Page 345: Troubleshooting
– ELEC LIGHTING SYSTEM EB805010 TROUBLESHOOTING IF THE HEADLIGHT AND/OR TAILLIGHT FAIL TO COME ON: Procedure Check: 4.Light switch 1.Fuse (main, headlight) 5.Wiring connections 2.Battery (the entire lighting system) 3.Main switch NOTE: Pocket tester: Remove following part(s) before P/N. YU-03112, 90890-03112 troubleshooting: 1)Seat 2)Front carrier...
Page 346 – ELEC LIGHTING SYSTEM C0NTINUITY INCORRECT 3.Main switch Refer to “CHECKING THE SWITCH”. CORRECT Replace the main switch. INCORRECT 4.Light switch Refer to “CHECKING THE SWITCH”. Light switch is faulty, replace the handlebar CORRECT switch (left). EB805013 5.Wiring connection POOR CONNECTION Check the connections of the entire lighting system.
Page 347: Checking The Lighting System
– ELEC LIGHTING SYSTEM EB805020 CHECKING THE LIGHTING SYSTEM 1.If the headlights fail to come on: NO CONTINUITY 1.Bulb and bulb socket Check the bulb and bulb socket for continuity. Replace the bulb and/or bulb socket. CONTINUITY 2.Voltage Connect the pocket tester (DC 20 V) to the headlight couplers.
Page 348 – ELEC LIGHTING SYSTEM EB805021 2.If the taillight fails to come on: NO CONTINUITY 1.Bulb and bulb socket Check the bulb and bulb socket for continuity. Replace the bulb and/or bulb socket. CONTINUITY 2.Voltage Connect the pocket tester (20 V) to the bulb socket coupler.
Page 349: Signal System
– ELEC SIGNAL SYSTEM EB806000 SIGNAL SYSTEM CIRCUIT DIAGRAM Not For Resale 9 - 30 www.SmallEngineDiscount.com...
Page 350 – ELEC SIGNAL SYSTEM 3 Main switch 4 Backup fuse 5 Battery 6 Main fuse 9 Reverse switch 0 CDI unit D Speed sensor E Thermo switch 1 G Multi-function meter H Differential gear lock indicator light I Coolant temperature warning light J Reverse indicator light K Neutral indicator light L Park indicator light...
Page 351: Troubleshooting
– ELEC SIGNAL SYSTEM EB806010 TROUBLESHOOTING IF THE BRAKE LIGHT AND/OR INDICATOR LIGHT FAILS TO COME ON: Procedure Check: 1.Fuse (main, backup, ignition, signaling system) 2.Battery 3.Main switch 4.Wiring connections (the entire signal system) NOTE: Pocket tester: Remove following part(s) before P/N.
Page 352 – ELEC SIGNAL SYSTEM C0NTINUITY INCORRECT 3.Main switch Refer to “CHECKING THE SWITCH”. CORRECT Replace the main switch. EB806011 POOR CONNECTION 4.Wiring connections Check the connections of the entire signal system. Refer to “CIRCUIT DIAGRAM”. Properly connect the signal system. CORRECT Check the condition of each of the signal system’s circuits.
Page 353: Checking The Signal System
– ELEC SIGNAL SYSTEM CHECKING THE SIGNAL SYSTEM 1.If the brake light fails to come on: 1.Bulb and bulb socket NO CONTINUITY Check the bulb and bulb socket for continuity. CONTINUITY Replace the bulb and/or bulb socket. NO CONTINUITY 2.Brake light switches Refer to “CHECKING THE SWITCH”.
Page 354 – ELEC SIGNAL SYSTEM EB806024 2.If the indicator lights fails to come on: NO CONTINUITY 1.Neutral switch Refer to “CHECKING THE SWITCH”. CONTINUITY Replace the neutral switch. NO CONTINUITY 2.High-range switch Refer to “CHECKING THE SWITCH”. CONTINUITY Replace the high-range switch. NO CONTINUITY 3.Low-range switch Refer to “CHECKING THE SWITCH”.
Page 355 – ELEC SIGNAL SYSTEM 3.If the coolant temperature warning light does not come on: Check that the light comes on when the main switch is set to “ON”. Check that the light comes on when the coolant temperature is 120 ± 3 °C (248 ± 5.4 °F) or higher and that the light remains on when the coolant temperature drops to 113 °C (235.4 °F).
Page 356: Cooling System
– ELEC COOLING SYSTEM COOLING SYSTEM CIRCUIT DIAGRAM Not For Resale 9 - 37 www.SmallEngineDiscount.com...
Page 357: Troubleshooting
– ELEC COOLING SYSTEM TROUBLESHOOTING IF THE FAN MOTOR DOES NOT MOVE: Procedure Check: 1.Fuse (main) 6.Thermo switch 2 2.Battery 7.Wiring connection 3.Main switch (the entire cooling system) 4.Fan motor 5.Circuit breaker (fan motor) NOTE: Pocket tester: Remove following part(s) before P/N.
Page 358 – ELEC COOLING SYSTEM C0NTINUITY 4.Fan motor Disconnect the fan motor coupler. Connect the battery (12 V) as shown. Battery (+) lead → Blue terminal 1 Battery (–) lead → Black terminal 2 DOES NOT TURN Replace the fan motor. Check the operation of the fan motor.
Page 359 – ELEC COOLING SYSTEM C0NTINUITY 6.Thermo switch 2 Remove the thermo switch 2 from the radiator. Connect the pocket tester (Ω × 10) to the thermo switch 2 1. Immerse the thermo switch 2 in coolant 2. Check the thermo switch 2 for continuity. While heating coolant...
Page 360 – ELEC COOLING SYSTEM C0NTINUITY EB803028 POOR CONNECTION 7.Wiring connection Check the connections of the entire starting system. Refer to “CIRCUIT DIAGRAM”. Properly connect the cooling system. CORRECT This circuit is not faulty. Not For Resale 9 - 41 www.SmallEngineDiscount.com...
Page 361: 2Wd/4Wd Selecting System
– ELEC 2WD/4WD SELECTING SYSTEM 2WD/4WD SELECTING SYSTEM CIRCUIT DIAGRAM 3 Main switch 5 Battery 6 Main fuse 0 CDI unit R Four-wheel drive fuse S Four-wheel drive relay 1 T Four-wheel drive relay 2 U Four-wheel drive relay 3 V On-command four-wheel drive switch and differential gear lock switch W Gear motor...
Page 362: Chapter 10. Troubleshooting
– ELEC 2WD/4WD SELECTING SYSTEM EB803020 TROUBLESHOOTING IF THE GEAR MOTOR FAILS TO OPERATE: Procedure Check: 1.Fuse (main, four-wheel drive) 7.On-command four-wheel drive switch and 2.Battery differential gear lock switch 3.Main switch 8.Gear motor 4.Four-wheel drive relay 1 9.Wiring connections 5.Four-wheel drive relay 2 (the entire 2WD/4WD selecting system) 6.Four-wheel drive relay 3...
Page 363 – ELEC 2WD/4WD SELECTING SYSTEM C0NTINUITY 4.Four-wheel drive relay 1 Remove the four-wheel drive relay 1 from the wire harness. Connect the pocket tester (Ω × 1) and the battery (12 V) to the four-wheel drive relay 1 terminals. Tester (+) lead → Brown/Black terminal 1 Tester (–) lead →...
Page 364 – ELEC 2WD/4WD SELECTING SYSTEM C0NTINUITY 6.Four-wheel drive relay 3 Remove the four-wheel drive relay 3 from the wire harness. Connect the pocket tester (Ω × 1) and the battery (12 V) to the four-wheel drive relay 3 terminals. Tester (+) lead → Brown/Red terminal 1 Tester (–) lead →...
Page 365 – ELEC 2WD/4WD SELECTING SYSTEM C0NTINUITY È 8.Gear motor Disconnect the gear motor coupler. Remove gear motor from differential gear case. Refer to “FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR” in CHAPTER 7. Connect two C size batteries to the gear motor terminals 1 (as shown illustrations).
Page 366: Starting Failure/Hard Starting
TRBL STARTING FAILURE/HARD STARTING SHTG TROUBLESHOOTING NOTE: The following troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to troubleshooting. Refer to the relative procedure in this manual for checking, adjusting and replacing of parts. STARTING FAILURE/HARD STARTING FUEL SYSTEM Fuel tank...
Page 367: Compression System
TRBL STARTING FAILURE/HARD STARTING/POOR IDLE SPEED SHTG PERFORMANCE/POOR MEDIUM AND HIGH-SPEED PERFORMANCE COMPRESSION SYSTEM Cylinder and cylinder head Valve, camshaft and crankshaft Loose spark plug Improperly sealed valve Loose cylinder head or cylinder Improperly contacted valve and valve seat Broken cylinder head gasket Improper valve timing Broken cylinder gasket Broken valve spring...
Page 368: Faulty Drive Train
TRBL FAULTY DRIVE TRAIN SHTG FAULTY DRIVE TRAIN The following conditions may indicate damaged shaft drive components: Symptoms Possible Causes 1.A pronounced hesitation or “jerky” movement A.Bearing damage. during acceleration, deceleration, or sustained speed. (This must not be confused with B.Improper gear lash.
Page 369: Faulty Gear Shifting
FAULTY GEAR SHIFTING/ TRBL FAULTY CLUTCH PERFORMANCE SHTG FAULTY GEAR SHIFTING HARD SHIFTING Refer to “CLUTCH SLIPPING/DRAGGING-CLUTCH DRAGGING”. SHIFT LEVER DOES NOT MOVE Shift shaft Transmission Bent shift shaft Seized transmission gear Shift cam, shift fork Jammed impurities Groove jammed with impurities Incorrectly assembled transmission Seized shift fork Shift guide...
Page 370: Poor Speed Performance
FAULTY CLUTCH PERFORMANCE/ TRBL OVERHEATING/FAULTY BRAKE SHTG POOR SPEED PERFORMANCE V-belt Primary sliding sheave Oil or grease on the V-belt Worn primary sliding sheave Primary pulley weight Secondary fixed sheave Faulty operation Worn secondary fixed sheave Worn primary pulley weight Secondary sliding sheave Primary fixed sheave Worn secondary sliding sheave...
Page 371: Shock Absorber Malfunction
SHOCK ABSORBER MALFUNCTION/UNSTABLE TRBL HANDLING/LIGHTING SYSTEM SHTG SHOCK ABSORBER MALFUNCTION MALFUNCTION Bent or damaged damper rod Damaged oil seal lip Fatigued shock absorber spring UNSTABLE HANDLING UNSTABLE HANDLING Handlebar Wheels Improperly installed or bent Deformed wheel Steering Loose bearing Incorrect toe-in Bent or loose wheel axle Bent steering stem Excessive wheel runout...
Page 372 YFM450FAR WIRING DIAGRAM 1 A.C. magneto 2 Rectifier/regulator 3 Main switch W/R Sb Sb W/R Br Sb L/B L/B Sb Br W/B B B/R B/R B W/B 4 Backup fuse R/BBr/B B/Y B/Y Br/B R/B L/W G/W G/W L/W (GRAY)
Page 373 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U.S.A. Not For Resale www.SmallEngineDiscount.com...

Yamaha YFM450FAR Service Manual

Machine Identification

Chapter 1. General Information

Features

Important Information

Checking of Connections

Special Tools

General Specifications

Chapter 2. Specifications

Maintenance Specifications

How to Use the Conversion Table

General Torque Specifications

Lubrication Points and Lubricant Types

Coolant Flow Diagrams

Oil Flow Diagrams

Cable Routing

Introduction

Periodic Maintenance/Lubrication

Chapter 3. Periodic Checks and Adjustments

Seat, Carriers, Fenders and Fuel Tank

Footrest Boards

Engine

Chassis

Electrical

Engine Removal

Chapter 4. Engine

Cylinder Head

Camshaft, Rocker Arms and Valves

Cylinder and Piston

Recoil Starter and A.C. Magneto

Primary and Secondary Sheaves

Clutch

Crankcase

Crankshaft and Oil Pump

Transmission

Middle Gear

Radiator

Chapter 5. Cooling System

Thermostat

Water Pump

Carburetor

Chapter 6. Carburetion

Troubleshooting

Chapter 7. Drive Train

Front Constant Velocity Joints and Differential Gear

Rear Axle/Final Drive Gear and Drive Shaft

Front and Rear Wheels

Chapter 8. Chassis

Front and Rear Brakes

Front Arms and Front Shock Absorber

Rear Shock Absorber and Swingarm

Electrical Components

Chapter 9. Electrical

Checking the Switch

Checking the Bulbs and Bulb Sockets

Ignition System

Electric Starting System

Charging System

Lighting System

Signal System

Quick Links

Troubleshooting

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Summary of Contents for Yamaha YFM450FAR