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Yamaha GRIZZLY Ultramatic YFM660FP Service Manual

Other manuals for GRIZZLY Ultramatic YFM660FP: Owner's Manual, Owner's Manual

Summary of GRIZZLY Ultramatic YFM660FP

  • Page 1

    Yfm660fp servicemanual lit-11616-15-01 5km-28197-e0

  • Page 2

    Yfm660fp service manual ©2001 by yamaha motor corporation, u.S.A. First edition, may 2001 all rights reserved. Any reproduction or unauthorized use without the written permission of yamaha motor corporation, u.S.A. Is expressly prohibited. Printed in u.S.A. Lit-11616-15-01.

  • Page 3: Notice

    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 y...

  • 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...

  • Page 5: Gen

    Eb003000 illustrated symbols illustrated symbols 1 to 0 are printed on the 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 8 chassis 9 electrical 0 troubles...

  • Page 7: Table of Contents

    Table of contents general information gen info 1 specifications spec 2 periodic checks and adjustments chk adj 3 engine eng 4 cooling system cool 5 carburetion carb 6 drive train driv 7 chassis chas 8 electrical elec 9 troubleshooting trbl shtg 10 – +.

  • Page 8: Contents

    Contents chapter 1. General information machine identification ........................................................................ 1-1 vehicle identification number ................................................. 1-1 model label ...................................................................

  • Page 9: Chapter 3.

    Lubrication points and lubricant types .................................. 2-21 engine ............................................................................................... 2-21 coolant flow diagrams ................................................................... 2-22 oil flow diagrams ...

  • Page 10: Chapter 4.

    Chassis .................................................................................................... 3-39 adjusting the rear brake ........................................................ 3-39 checking the brake fluid level ............................................. 3-41 checking the fron...

  • Page 11

    Rocker arms ......................................................................................... 4-12 removing the rocker arm ....................................................... 4-14 checking the rocker arm ........................................................ 4-14 installing the rocker ...

  • Page 12

    Checking the balancer drive ................................................. 4-49 installing the balancer drive gear and balancer driven gear ................................................... 4-49 primary and secondary sheaves ................................................. 4-51 primary sheave ...

  • Page 13: Chapter 5.

    Transmission ......................................................................................... 4-78 removing the transmission .................................................... 4-81 checking the shift fork ........................................................... 4-81 checking the shift ...

  • Page 14: Chapter 6.

    Chapter 6. Carburetion carburetor ............................................................................................. 6-1 disassembling the carburetor ............................................... 6-4 checking the carburetor ......................................................... 6-4 a...

  • Page 15: Chapter 8.

    Chapter 8. Chassis front wheels and brake discs ....................................................... 8-1 front wheels .................................................................................. 8-1 checking the front wheel ........................................................ 8-3 checki...

  • Page 16

    Steering system .................................................................................. 8-36 handlebar ....................................................................................... 8-36 removing the rear brake switch ......................................... 8-37 checking the ha...

  • Page 17: Chapter 9.

    Chapter 9. Electrical electrical components ..................................................................... 9-1 checking the switch ............................................................................ 9-2 checking the switch ................................................................

  • Page 18: Chapter 10.

    Cooling system .................................................................................... 9-47 circuit diagram ............................................................................ 9-47 troubleshooting ....................................................................... 9-48 2wd/...

  • Page 19

    Shock absorber malfunction ....................................................... 10-6 malfunction ................................................................................... 10-6 unstable handling ............................................................................. 10-6 unstable h...

  • Page 20: Gen

    1 - 1 gen info machine identification 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 21: Gen

    Gen info 1 - 2 features front differential 1 adapter 2 drive clutch 3 differential side gear (left) 4 differential pinion gear 5 ring gear 6 differential side gear (right) 7 drive pinion gear 8 gear motor È to front wheel É from the middle gear features 1.

  • Page 22: Gen

    Gen info 1 - 3 features 2wd power is transmitted as follows: middle gear → front drive shaft → drive pinion gear 7 → ring gear 5 → differential pinion gear 4. In the 2wd mode, the left differential side gear 3 and the drive clutch 2 are not engaged, therefore, the left side gear runs idle and does n...

  • Page 23: Gen

    Gen info 1 - 4 features 4wd when the 4wd mode is selected, the gear motor is operated, and the drive clutch 2 moves to the right and engages with the left differential side gear 3. Accordingly, power is transmitted as follows: ring gear 5 → differential pinion gear 4 → left differential side gear 3 ...

  • Page 24: Gen

    Gen info 1 - 5 features 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 transmit- ted directly from the ring gear 5 to the drive clutch 2, the...

  • Page 25: Gen

    Gen info 1 - 6 features 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 condi- tion (i.E., when the differential lock select switch and the differential gear ...

  • Page 26: Gen

    Gen info 1 - 7 features shift mechanism a new shift mechanism with a parking position has been added to the yfm660f. 1.Shift cam 2.Shift fork guide bar 3.Drive axle 4.Stopper lever shaft l l h n r p h n r p 1 2 3 4 1 2 3 4.

  • Page 27: Gen

    Gen info 1 - 8 features parking (1) l (low), h (high), n (neutral), and r (reverse) positions the end of the stopper lever is held by the return spring 1. Then, the stopper lever tab is sepa- rated from the drive axle stopper to free the drive axle. (2) p (park) position when the drive select lever ...

  • Page 28: Gen

    Gen info 1 - 9 features transmission to create a compact, 3-axle transmission, a chain drive has been adopted for the reverse transmis- sion. 1 secondary shaft 2 drive axle 3 middle drive shaft 4 low wheel gear 5 chain 1 secondary shaft 2 drive axle l (low) or h (high) mode when the transmission is ...

  • Page 29: Gen

    1 - 10 gen info eb101000 important information preparation for removal procedures 1.Remove all dirt, mud, dust and foreign mate- rial before removal and disassembly. 2.Use proper tools and cleaning equipment. Refer to the “special tools” section. 3.When disassembling the machine, always keep mated p...

  • Page 30: Gen

    1 - 11 gen info eb101030 lock washers/plates and cotter pins 1.Replace all lock washers/plates 1 and cotter pins after removal. Bend lock tabs along the bolt or nut flats after the bolt or nut has been tightened to specification. Eb101040 bearings and oil seals 1.Install bearings and oil seals so th...

  • Page 31: Gen

    1 - 12 gen info checking of connections eb801000 checking of connections check the connectors for stains, rust, mois- ture, 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: ...

  • Page 32: Gen

    Gen info 1 - 13 special tools 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 di...

  • Page 33: Gen

    Gen info 1 - 14 special tools 90890-01304 yu-01304 piston pin puller this tool is used to remove the piston pin. 90890-01311 yu-08035 tappet adjusting tool (3 mm) this tool is necessary for adjusting the valve clearance. 90890-01312 ym-01312-a fuel level gauge this gauge is used to measure the fuel ...

  • Page 34: Gen

    Gen info 1 - 15 special tools 90890-01430 ym-38404 ring nut wrench this tool is needed to removing and installing the middle driven shaft bearing retainer. 90890-01467 ym-01467 gear lash measurement tool this tool is used to measure the gear lash. 90890-01701 yu-01880 sheave holder this tool is need...

  • Page 35: Gen

    Gen info 1 - 16 special tools adapter 90890-04059 ym-90069 spacer 90890-04081 ym-91044 adapter spacer (crankshaft installer) these tools are used to install the crank- shaft. 90890-04062 ym-04062 universal joint holder this tool is needed when removing or installing the universal joint yoke nut. 908...

  • Page 36: Gen

    Gen info 1 - 17 special tools 90890-06754 ignition checker this instrument is necessary for checking the ignition system components. Bond 90890-85505 sealant acc-11001-05-01 yamaha bond no. 1215 sealant (quick gasket ® ) this sealant (bond) is used on crankcase mating surfaces, etc. Ym-34487 dynamic...

  • Page 37: Spec

    2 - 1 spec general specifications specifications general specifications item standard model code: 5km1 5km5 dimensions: overall length 2,085 mm (82.1 in) overall width 1,150 mm (45.3 in) overall height 1,210 mm (47.6 in) seat height 880 mm (34.6 in) wheelbase 1,275 mm (50.2 in) minimum ground cleara...

  • Page 38: Spec

    2 - 2 spec general specifications differential gear case oil periodic oil change 0.28 l (0.25 lmp qt, 0.30 us qt) total amount 0.33 l (0.29 lmp qt, 0.35 us qt) radiator capacity (including all routes) 1.8 l (1.58 lmp qt, 1.90 us qt) air filter: wet type element fuel: type unleaded fuel fuel tank cap...

  • Page 39: Spec

    2 - 3 spec general specifications tire pressure (cold tire): maximum load* 220 kg (485 lb) off-road riding front 32 ~ 38 kpa (0.32 ~ 0.38 kg/cm 2 , 4.6 ~ 5.5 psi) rear 27 ~ 33 kpa (0.27 ~ 0.33 kg/cm 2 , 3.9 ~ 4.8 psi) *load in total weight of rider accessories brake: front brake type dual disc brake...

  • Page 40: Spec

    2 - 4 spec maintenance specifications maintenance specifications engine item standard limit cylinder head: warp limit ---- 0.03 mm (0.0012 in) cylinder: bore size 100.005 ~ 100.055 mm (3.9372 ~ 3.9392 in) 100.1 mm (3.94 in) measuring point 50 mm (1.97 in) ---- camshaft: drive method chain drive (lef...

  • Page 41: Spec

    2 - 5 spec maintenance specifications cam chain: cam chain type/no. Of links 92rh2010j/126m ---- cam chain adjustment method automatic ---- rocker arm/rocker arm shaft: bearing inside diameter 12.000 ~ 12.018 mm (0.4724 ~ 0.4731 in) ---- shaft outside diameter 11.976 ~ 11.991 mm (0.4715 ~ 0.4721 in)...

  • Page 42: Spec

    2 - 6 spec maintenance specifications stem runout limit ---- 0.01 mm (0.0004 in) valve seat width in 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) ---- ex 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) ---- valve spring: inner spring free length in 32.63 mm (1.28 in) 31.0 mm (1.22 in) ex 36.46 mm (1.44 in) 34.6 mm (1.36 in)...

  • Page 43: Spec

    2 - 7 spec maintenance specifications piston: piston to cylinder clearance 0.05 ~ 0.07 mm (0.0020 ~ 0.0028 in) 0.15 mm (0.0059 in) piston size “d” 99.945 ~ 99.995 mm (3.9348 ~ 3.9368 in) ---- measuring point “h” 2.5 mm (0.10 in) ---- piston off-set 1.0 mm (0.0394 in) ---- offset direction intake sid...

  • Page 44: Spec

    2 - 8 spec maintenance specifications 2nd ring type taper ---- dimensions (b × t) 1.2 × 4.0 mm (0.0472 × 0.1575 in) ---- end gap (installed) 0.30 ~ 0.45 mm (0.0118 ~ 0.0177 in) 0.80 mm (0.0315 in) side clearance 0.03 ~ 0.07 mm (0.0012 ~ 0.0028 in) 0.13 mm (0.0051 in) oil ring dimensions (b × t) 2.5 ...

  • Page 45: Spec

    2 - 9 spec maintenance specifications 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. D. Mark 5km1 00 ---- main jet (m.J) #15...

  • Page 46: Spec

    2 - 10 spec maintenance specifications radiator cap opening pressure 93.3 ~ 122.7 kpa (0.933 ~ 1.227 kg/cm 2 , 13.53 ~ 17.79 psi) ---- radiator capacity 0.78 l (0.69 imp qt, 0.82 us qt) ---- coolant reservoir capacity 0.3 l (0.26 imp qt, 0.32 us qt) ---- from low to full level 0.165 l (0.15 imp qt, ...

  • Page 47: Spec

    2 - 11 spec maintenance specifications item standard cylinder head tightening sequence:.

  • Page 48: Spec

    2 - 12 spec maintenance specifications tightening torques part to be tightened part name thread size q’ty tightening torque remarks nm m·kg ft·lb cylinder head (exhaust pipe) stad bolt m8 4 15 1.5 11 cylinder head bolt m9 4 38 3.8 27 bolt m9 2 38 3.8 27 bolt m6 1 10 1.0 7.2 spark plug — m12 1 18 1.8...

  • Page 49: Spec

    2 - 13 spec maintenance specifications primary sheave assembly nut m16 1 120 12.0 85 secondary sheave assembly nut m16 1 100 10.0 72 secondary sheave spring retainer nut m36 1 90 9.0 65 clutch carrier assembly nut m22 1 160 16.0 115 balancer driven gear nut m18 1 110 11.0 80 middle driven shaft bear...

  • Page 50: Spec

    2 - 14 spec maintenance specifications chassis item standard limit steering system: steering bearing type ball and race bearing ---- front suspension: shock absorber travel 86 mm (3.39 in) ---- fork spring free length 295 mm (11.61 in) ---- spring fitting length 235.5 mm (9.27 in) ---- spring rate (...

  • Page 51: Spec

    2 - 15 spec maintenance specifications front disc brake: type dual ---- disc outside diameter × thickness 220.0 × 3.5 mm (8.66 × 0.14 in) ---- pad thickness inner 4.2 mm (0.17 in) 1 mm (0.04 in) pad thickness outer 4.2 mm (0.17 in) 1 mm (0.04 in) master cylinder inside diameter 14 mm (0.55 in) ---- ...

  • Page 52: Spec

    2 - 16 spec maintenance specifications tightening torques part to be tightened thread size tightening torque remarks nm m·kg ft·lb engine bracket and engine m8 33 3.3 24 engine bracket and rubber damper (front) m8 33 3.3 24 engine bracket and rubber damper (front) m6 10 1.0 7.2 engine and rubber dam...

  • Page 53: Spec

    2 - 17 spec maintenance specifications rear knuckle and rear frame (upper) m10 45 4.5 32 rear knuckle and rear frame (lower) m10 45 4.5 32 rear shock absorber and frame m10 45 4.5 32 rear shock absorber and rear arm (lower) m10 45 4.5 32 rear arm (upper) and frame m10 45 4.5 32 rear arm (lower) and ...

  • Page 54: Spec

    2 - 18 spec maintenance specifications electrical item standard limit voltage: 12 v ---- ignition system: ignition timing (b.T.D.C.) 12°/ 1,500 r/min ---- advancer type digital type ---- c.D.I.: magneto model/manufacturer f4t46471/mitsubishi ---- pickup coil resistance/color 459 ~ 561 Ω at 20 °c (68...

  • Page 55: Spec

    2 - 19 spec maintenance specifications starter relay model/manufacturer ms5f-561/jideco ---- amperage rating 180 a ---- coil winding resistance 4.18 ~ 4.62 Ω at 20 °c (68 °f) ---- electric fan: running rpm 2,880 r/min ---- thermostat switch: thermostat switch 1 model/manufacturer 5km/denso ---- ther...

  • Page 56: Spec

    2 - 20 spec eb201000 how to use the conversion table all specification data in this manual are listed in si and metric units. Use this table to convert metric unit data to imperial unit data. Ex. Conversion table eb202001 general torque specifications this chart specifies torque for standard fasten-...

  • Page 57: Spec

    2 - 21 spec lubrication points and lubricant types engine lubrication points lubricant type oil seal lips (all) ls o-ring (all) ls bearings (all) e crank pin e connecting rod (bearing) e camshaft sprocket/timing chain m crankshaft e piston surface/piston rings e piston pin e baffer boss e valve stem...

  • Page 58: Spec

    2 - 22 spec coolant flow diagrams coolant flow diagrams 1 radiator 2 radiator cap 3 thermo switch 4 radiator inlet hose 5 thermostat assembly breather hose 6 water pump outlet pipe 7 water pump outlet hose 8 radiator outlet hose 7 7 8 1 2 3 4 5 6 7 b b a b - b.

  • Page 59: Spec

    2 - 23 spec coolant flow diagrams 1 thermostat 2 radiator inlet hose 3 radiator 4 radiator outlet hose 1 2 3 4.

  • Page 60: Spec

    2 - 24 spec oil flow diagrams oil flow diagrams 1 camshaft 2 oil delively pipe 2 3 oil delively piep 3 4 crankshaft 4 1 2 3.

  • Page 61: Spec

    2 - 25 spec oil flow diagrams 1 oil delively pipe 1 2 oil delively pipe 2 3 oil delively pipe 3 4 oil pump 5 oil strainer 4 5 3 2 1.

  • Page 62: Spec

    2 - 26 spec oil flow diagrams 1 oil filter 2 oil delively pipe 2 3 oil delively pipe 1 4 drive axle 5 relief valve 6 oil pump 7 oil strainer 7 6 5 4 3 1 2.

  • Page 63: Spec

    2 - 27 spec cable routing cable routing 1 rear brake light switch 2 rear brake cable 3 starter cable 4 front brake hose 5 throttle cable 6 on-command four-wheel drive switch and differ- ential gear lock switch lead 7 front brake light switch lead 8 handlebar switch lead 9 rear brake light switch lea...

  • Page 64: Spec

    2 - 28 spec cable routing É fasten the front brake light switch lead, and the on-command four-wheel drive switch and differ- ential gear lock switch lead behind the handle- bar with a plastic band. Ê fasten the handlebar switch lead and rear brake switch lead behind the handlebar with a plastic band...

  • Page 65: Spec

    2 - 29 spec Î pass the brake hose through the hose guide. Ï fasten the on-command four-wheel drive switch and differential gear lock switch lead, front brake light switch lead, handlebar switch lead, and rear brake light switch lead on the front side on the steering stem with a plastic locking tie. ...

  • Page 66: Spec

    2 - 30 spec cable routing 1 park brake light switch 2 on-command four-wheel drive switch and differ- ential gear lock switch lead 3 headlight lead 4 coolant reservoir breather hose 5 differential gear case breather hose 6 fan motor breather hose 7 main switch lead 8 auxiliary dc jack lead È to the f...

  • Page 67: Spec

    2 - 31 spec cable routing Ì pass the fan motor breather hose through the guide on the front fender. Í pass the headlight lead through the guide on the front fender. 1 8 7 3 6 5 4 3 2 Ê É Í Ì Ë È.

  • Page 68: Spec

    2 - 32 spec cable routing 1 coolant reservoir hose 2 fan motor lead 3 ignition coil coupler 4 starter cable 5 fuel tank breather hose 6 coolant reservoir breather hose 7 gear motor lead 8 differential gear case breather hose 9 thermo switch 2 lead È connect the ignition coil coupler under the front ...

  • Page 69: Spec

    2 - 33 spec cable routing Í slacken the coolant reservoir hose, and then insert it between the frame and the water pump inlet. Be sure not to pinch the hose. Î fasten the coolant reservoir hose and water pump inlet hose with a plastic band. Be sure to not pinch the hoses. Install the plastic band fa...

  • Page 70: Spec

    2 - 34 spec cable routing 1 fuel sender lead 2 differential gear case breather hose 3 vacuum chamber breather hose 4 starter motor lead 5 wireharness 6 gear position switch lead 7 final drive gear case breather hose 8 ground lead 9 speed sensor lead 0 ac magneto lead a carburetor breather hose b sta...

  • Page 71: Spec

    2 - 35 spec cable routing È fasten the final drive gear case breather hose, speed sensor lead, ground lead, gear position switch lead, ac magneto lead, wire harness, and reverse indicator light lead with a plastic locking tie. Be careful not to pinch the breather hose. É fasten the leads in the foll...

  • Page 72: Spec

    2 - 36 spec Ï pass the vacuum chamber breather hose through the plastic cover hole. Ð insert a clamp into the third hole from the top of the rectifier/regulator bracket, and then clamp the final drive gear case breather hose with the clamp. B - b a c d a b b 4 3 2 1 9 8 Ë Ê É È 5 c 6 7 0 a 7 j 2 i f...

  • Page 73: Spec

    2 - 37 spec cable routing 1 gear position switch 2 reverse switch 3 crankcase breather hose 4 select lever control cable 5 rear brake cable 6 front brake hose 7 rear brake light switch lead 8 spark plug lead 9 fan motor breather hose 0 fan motor lead a bake fluid reservoir hose b rear brake hose È p...

  • Page 74: Spec

    2 - 38 spec cable routing Ê clamp the spark plug lead and radiator inlet hose with a plastic clamp. Ë when installing the ignition coil, face the spark lead to the right side of the frame. Ì to the rear fender hole Í pass the brake light switch lead on the inside of the rear brake cable and select l...

  • Page 75: Spec

    2 - 39 spec cable routing 1 negative battery lead 2 tail/brake light lead 3 fuse box 4 four-wheel drive relay 3 5 four-wheel drive relay 2 6 four-wheel drive relay 1 7 positive battery lead 8 starter motor lead 9 wire harness È pass the tail/brake light lead through the lead guide. É position the wi...

  • Page 76: Spec

    2 - 40 spec cable routing 1 front brake hose 2 throttle cable 3 thermo switch 1 lead 4 crankcase breather hose 5 fuel sender lead 6 differential gear case breather hose 7 starter cable 8 select lever control cable 9 wire harness 0 fan motor breather hose È pass the thermo sensor 1 lead through the l...

  • Page 77: Spec

    2 - 41 spec cable routing Î fasten the speed sensor coupler, thermo switch 1 lead, reverse switch lead, ground lead, gear position switch lead, and ac magneto couplers with a band. C c b a - a b c - c 0 6 9 4 3 2 1 8 7 6 5 Ê É È Î Ì Ë a a 8 Í.

  • Page 78: Chk

    3 - 1 chk adj introduction/periodic maintenance/ lubrication intervals eb300000 periodic checks and adjustments introduction this chapter includes all information necessary to perform recommended inspections and adjust- ments. These preventive maintenance procedures, if followed, will ensure more re...

  • Page 79: Chk

    3 - 2 chk adj periodic maintenance/lubrication intervals * 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. N...

  • Page 80: Chk

    3 - 3 chk adj seat, carriers, fenders and fuel tank seat, carriers, fenders and fuel tank seat and side panels 4 5 2 3 1 (6) order job name/part name q’ty remarks removing the seat and side panels remove the parts in the order below. 1 seat 1 note: pull up the seat lock lever, then pull up on the re...

  • Page 81: Chk

    3 - 4 chk adj seat, carriers, fenders and fuel tank front carrier, front bumper and front grill t r . . 33 nm (3.3 m • kg, 24 ft • ib) t r . . 33 nm (3.3 m • kg, 24 ft • ib) t r . . 9 nm (0.9 m • kg, 6.5 ft • ib) 1 4 3 2 2 7 9 8 6 (6) 5 (8) lt order job name/part name q’ty remarks removing the front...

  • Page 82: Chk

    3 - 5 chk adj seat, carriers, fenders and fuel tank handlebar cover, fuel tank cover and front fender 4 17 16 (6) 5 13 11 12 10 9 8 7 6 14 15 (6) 1 2 3 order job name/part name q’ty remarks removing the handlebar cover, fuel tank cover and front fender remove the parts in the order below. Seat and f...

  • Page 83: Chk

    3 - 6 chk adj seat, carriers, fenders and fuel tank 4 17 16 (6) 5 13 11 12 10 9 8 7 6 14 15 (6) 1 2 3 order job name/part name q’ty remarks 8 rear brake switch coupler 1 disconnect. 9 front brake light switch coupler 1 disconnect. 10 rear brake light switch coupler 1 disconnect. 11 main switch coupl...

  • Page 84: Chk

    3 - 7 chk adj seat, carriers, fenders and fuel tank rear carrier and rear fender (6) (8) (6) (4) 11 13 14 4 10 3 8 6 5 7 2 1 t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) 12 9 order job name/part name q’ty remarks removing the rear carrier and rear fender remove the parts in the order below. Seat and fuel ...

  • Page 85: Chk

    3 - 8 chk adj seat, carriers, fenders and fuel tank (6) (8) (6) (4) 11 13 14 4 10 3 8 6 5 7 2 1 t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) 12 9 order job name/part name q’ty remarks 8 battery 9 starter relay ground lead 1 disconnect. 10 taillight connector 3 disconnect. 11 crankcase breather hose 1 12 c...

  • Page 86: Chk

    3 - 9 chk adj seat, carriers, fenders and fuel tank engine skid plate (center) and engine skid plate (rear) t r . . 9 nm (0.9 m • kg, 6.5 ft • ib) 2 1 order job name/part name q’ty remarks removing the engine skid plate (center) and engine skid plate (rear) remove the parts in the order below. 1 eng...

  • Page 87: Chk

    3 - 10 chk adj seat, carriers, fenders and fuel tank fuel tank 9 9 3 10 11 8 4 10 7 6 5 2 1 order job name/part name q’ty remarks removing the fuel tank remove the parts in the order below. Seat and side panels refer to “seat and side panels”. Fuel tank cover refer to “handlebar cover, fuel tank cov...

  • Page 88: Chk

    3 - 11 chk adj seat, carriers, fenders and fuel tank 9 9 3 10 11 8 4 10 7 6 5 2 1 order job name/part name q’ty remarks 5 clamp 1 6 vacuum chamber breather hose 1 7 differential gear case breather hose 1 8 crankcase breather hose 1 9 plastic band 3 10 bushing 2 11 plastic cover 1 for installation, r...

  • Page 89: Chk

    3 - 12 chk adj footrest boards footrest boards t r . . 9 nm (0.9 m • kg, 6.5 ft • ib) t r . . 33 nm (3.3 m • kg, 24 ft • ib) 1 3 4 4 2 1 (4) (12) (8) (12) (8) order job name/part name q’ty remarks removing the footrest boards remove the parts in the order below. Fuel tank side panels refer to “seat ...

  • Page 90: Chk

    3 - 13 chk adj 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 com- pression stroke. 1.Remove: ● seat ● front c...

  • Page 91: Chk

    3 - 14 chk adj adjusting the valve clearance 6.Remove: ● timing plug 1 7.Check: ● valve clearance out of specification → adjust. Valve clearance (cold): intake: 0.10 ~ 0.15 mm (0.0039 ~ 0.0059 in) exhaust: 0.15 ~ 0.20 mm (0.0059 ~ 0.0079 in) ***************************************************** chec...

  • Page 92: Chk

    3 - 15 chk adj 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 the adjuster 3 clockwise or counter- clockwise with th...

  • Page 93: Chk

    3 - 16 chk adj adjusting the valve clearance/adjusting the timing chain/ adjusting the idling speed 11.Install: ● engine side cover ● fuel tank ● front fender ● front carrier ● seat refer to “seat, carriers, fenders and fuel tank”. Adjusting the timing chain adjustment free. Adjusting the idling spe...

  • Page 94: Chk

    3 - 17 chk adj 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. *************************...

  • Page 95: Chk

    3 - 18 chk adj 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”. 3.Adjust: ● throttle lever ...

  • Page 96: Chk

    3 - 19 chk adj 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. ● tighten the locknut 5. ● push in the adjuster cover 4. Warning after ad...

  • Page 97: Chk

    3 - 20 chk adj adjusting the speed limiter 2.Adjust: ● speed limiter length ***************************************************** adjustment steps: ● loosen the locknut 1. ● turn the adjuster 2 in or out until the speci- fied speed limiter length is obtained. ● tighten the locknut. Warning ● particu...

  • Page 98: Chk

    3 - 21 chk adj adjusting the starter cable 1.Remove: ● seat ● fuel tank side panel (left) 2.Adjust: ***************************************************** adjustment steps: ● disconnect the starter cable 1 from the car- buretor body. Note: do not remove the starter plunger 2 from the starter cable. ●...

  • Page 99: Chk

    3 - 22 chk adj checking the spark plug/ checking the ignition timing checking the spark plug 1.Remove: ● spark plug 2.Check: ● spark plug type incorrect → replace. Standard spark plug: dpr8ea-9/ngk 3.Check: ● electrode 1 wear/damage → replace. ● insulator 2 abnormal color → replace. Normal color is ...

  • Page 100: Chk

    3 - 23 chk adj 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 (left) ● engine side cover refer to “seat, carriers, fenders and fu...

  • Page 101: Chk

    3 - 24 chk adj checking the ignition timing/ measuring the compression pressure 4.Detach: ● timing light ● tachometer 5.Install: ● engine side cover ● fuel tank side panel (left) ● seat refer to “seat, carriers, fenders and fuel tank”. Measuring the compression pressure note: insufficient compressio...

  • Page 102: Chk

    3 - 25 chk adj 6.Measure: ● compression pressure above the maximum pressure: inspect the cylinder head, valve surfaces, and piston crown for carbon deposits. Below the minimum pressure: squirt a few drops of oil into the affected cyl- inder and measure again. Refer to the table below. **************...

  • Page 103: Chk

    3 - 26 chk adj 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 1 and minimum 2 marks. Oil level low ...

  • Page 104: Chk

    3 - 27 chk adj changing the engine oil changing the engine oil 1.Start the engine and let it warm up for sev- eral minutes. 2.Stop the engine and place an oil pan under the engine. 3.Remove: ● seat ● fuel tank side panel (left) ● engine side cover refer to “seat, carriers, fenders and fuel tank”. 4....

  • Page 105: Chk

    3 - 28 chk adj changing the engine oil 6.Install: ● engine oil drain bolt 1 t r . . 30 nm (3.0 m • kg, 22 ft • lb) 7.Fill: ● crankcase (with sufficient oil to reach the specified level) refer to “checking the engine oil level”. 8.Install: ● engine oil filler plug 9.Warm up the engine for a few minut...

  • Page 106: Chk

    3 - 29 chk adj changing the engine oil ● start the engine after solving the problem(-s) and check the engine oil pressure again. ● tighten the oil gallery bolt to specification. ***************************************************** 12.Install: ● engine side cover ● fuel tank side panel (left) ● seat...

  • Page 107: Chk

    3 - 30 chk adj cleaning the air filter 3.Remove: ● air filter element assembly 1 ● air filter element cap ● air filter element note: when removing the air filter element, rotate the air filter element cap 1/4 of a turn and remove the element. 2 air filter element cap 3 air filter element caution: ne...

  • Page 108: Chk

    3 - 31 chk adj cleaning the air filter/ checking the coolant level ● squeeze the excess solvent out of the ele- ment and let it dry. Caution: do not twist or wring out the element. This could damage the foam material. ● apply engine oil to the element. ● squeeze out the excess oil. Note: the element...

  • Page 109: Chk

    3 - 32 chk adj checking the coolant level/ changing the coolant 3.Check: ● coolant level the coolant level should be between the minimum level mark a and maximum level mark b. Below the minimum level mark → add the recommended coolant to the proper level. Caution: ● adding water instead of coolant l...

  • Page 110: Chk

    3 - 33 chk adj changing the coolant 2.Remove: ● plastic band 1 ● coolant reservoir bolts 2 ● coolant reservoir cap 3 3.Disconnect: ● coolant reservoir breather hose 4 4.Drain: ● coolant (from the coolant reservoir) 5.Connect: ● coolant reservoir breather hose 6.Install: ● coolant reservoir bolts ● p...

  • Page 111: Chk

    3 - 34 chk adj changing the coolant 10.Check: ● copper washer 1 ● coolant drain bolt 2 damage → replace. 11.Install: ● coolant drain bolt (water pump) t r . . 10 nm (1.0 m • kg, 7.2 ft • lb) 12.Fill: ● cooling system (with the specified amount of the recom- mended coolant) handling notes for coolant...

  • Page 112: Chk

    3 - 35 chk adj 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 ...

  • Page 113: Chk

    3 - 36 chk adj checking the coolant temperature warning light/checking the v-belt checking the coolant temperature warning light 1 coolant temperature indicator light checking the v-belt 1.Remove: ● right footrest board ● crankcase cover (right) refer to “primary and secondary sheaves” in chapter 4....

  • Page 114: Chk

    3 - 37 chk adj 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 awa...

  • Page 115: Chk

    3 - 38 chk adj ● tap the tailpipe lightly with a soft-face ham- mer or suitable tool, then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe and the inner contact surfaces of the muffler. ● insert the tailpipe 2 into the muffler and align the bolt holes. ...

  • Page 116: Chk

    3 - 39 chk adj 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 b out of specification → adjust. Rear brake lever free play: 0.5 ~ 2 mm (0.02 ~ 0.08 i...

  • Page 117: Chk

    3 - 40 chk adj adjusting the rear brake ● loosen the locknut 4. ● turn the adjusting bolt 5 until the brake pedal height is within the specified limits. ● tighten the locknut 4. Note: when adjusting the brake pedal height make sure the locknut-to-adjusting bolt clearance b does not exceed 2 mm (0.08...

  • Page 118: Chk

    3 - 41 chk adj adjusting the rear brake/ checking the brake fluid level ● adjust the select lever control cable. Refer to “adjusting the select lever control cable and shift rod”. ● install the rear brake master cylinder cover. Warning after this adjustment is performed, lift the front and rear whee...

  • Page 119: Chk

    3 - 42 chk adj checking the brake fluid level warning ● use only the designed quality brake fluid: otherwise, the rubber seals may deterio- rate, causing leakage and poor brake per- formance. ● refill with the same type of brake fluid; mixing fluids may result in a harmful chemical reaction and lead...

  • Page 120: Chk

    3 - 43 chk adj checking the front brake pad/checking the rear brake pad/checking the brake hose checking the front brake pad 1.Remove: ● front wheels 2.Check: ● brake pad wear indicators 1 almost touch the brake disc → replace the brake pads as a set. Refer to “front and rear brakes” in chapter 8. 3...

  • Page 121: Chk

    3 - 44 chk adj checking the brake hose/ bleeding the hydraulic brake system 2.Check: ● front brake hoses 1 ● rear brake hoses 2 cracks/wear/damage → replace. Fluid leakage → replace the hose. Refer to “front and rear brakes” in chapter 8. Note: hold the machine in an upright position and apply the f...

  • Page 122: Chk

    3 - 45 chk adj bleeding the hydraulic brake system 1.Bleed: ● brake system ***************************************************** air bleeding steps: a. Add the proper brake fluid to the reservoir. B. Install the diaphragm. Be careful not to spill any fluid or allow the reservoir to overflow. C. Conn...

  • Page 123: Chk

    3 - 46 chk adj adjusting the select lever control cable and shift rod adjusting the select lever control cable and shift rod 1 neutral 2 high 3 low 4 reverse 5 park 6 control cable 7 select lever shift rod warning before moving the select lever, bring the machine to a complete stop and return the th...

  • Page 124: Chk

    3 - 47 chk adj adjusting the select lever control cable and shift rod/ adjusting the rear brake light switch ● check that locknuts 2 are tightened cor- rectly. ● if the operation of the select lever is incor- rect, adjust the select lever control cable 3 with the adjuster 4. Select lever shift rod: ...

  • Page 125: Chk

    3 - 48 chk adj checking the final gear oil level 1.Place the machine on a level place. 2.Loosen: ● oil check bolt 1 note: ● loosen the slightly. ● do not remove the bolt, otherwise the gear oil may come out. 3.Check: check that gear oil seeps out from where the check bolt was loosened. If no gear oi...

  • Page 126: Chk

    3 - 49 chk adj 6.Fill: ● final gear case caution: take care not to allow foreign material to enter the final gear case. 7.Install: ● oil filler bolt periodic oil change: 0.28 l (0.25 imp qt, 0.30 us qt) total amount: 0.33 l (0.29 imp qt, 0.35 us qt) recommended oil: sae 80 api “gl-4” hypoid gear oil...

  • Page 127: Chk

    3 - 50 chk adj changing the differential gear oil changing the differential gear oil 1.Place the machine on a level surface. 2.Place a receptacle under the differential gear case. 3.Remove: ● oil filler bolt ● drain plug 1 4.Drain: ● differential gear oil 5.Install: ● drain plug note: check the gask...

  • Page 128: Chk

    3 - 51 chk adj checking the constant velocity joint dust boot/checking the steering system/adjusting the toe-in checking the constant velocity joint dust boot 1.Check: ● dust boots 1 damage → replace. Refer to “front constant velocity joints and differential gear” in chapter 7. Checking the steering...

  • Page 129: Chk

    3 - 52 chk adj adjusting the toe-in ***************************************************** measurement steps: note: before measuring the toe-in, make sure that the tire pressure is correct. ● mark both front tire tread centers. ● raise the front end of the machine so that there is no weight on the fr...

  • Page 130: Chk

    3 - 53 chk adj adjusting the toe-in/ adjusting the front shock absorber ***************************************************** adjustment steps: ● mark both tie-rods ends. This reference point will be needed during adjustment. ● loosen the locknuts (tie-rod end) 1 of both tie-rods. ● the same number ...

  • Page 131: Chk

    3 - 54 chk adj adjusting the rear shock absorber/ checking the tire adjusting the rear shock absorber 1.Remove: ● rear wheels 2.Adjust: ● spring preload turn the adjuster 1 to increase or decrease the spring preload. Note: the spring preload of the rear shock absorber can be adjusted to suit the rid...

  • Page 132: Chk

    3 - 55 chk adj checking the tire ● tire pressure 1)recommended tire pressure front 35 kpa (0.35 kg/cm 2 , 5.0 psi) rear 30 kpa (0.30 kg/cm 2 , 4.3 psi) 2)tire pressure below the minimum specifi- cation could cause the tire to dislodge from the rim under severe riding condi- tions. The following are ...

  • Page 133: Chk

    3 - 56 chk adj warning uneven or improper tire pressure may adversely affect the handling of this machine and may cause loss of control. ● maintain proper tire pressures. ● set tire pressures when the tires are cold. ● tire pressures must be equal in both front tires and equal in both rear tires. 2....

  • Page 134: Chk

    3 - 57 chk adj checking the wheel/checking and lubricating the cable/lubricating the levers, pedal, etc. Warning ● never attempt even small repairs to the wheel. ● ride conservatively after installing a tire to allow it to seat itself properly on the rim. Checking and lubricating the cable warning a...

  • Page 135: Chk

    3 - 58 chk adj 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 che...

  • Page 136: Chk

    3 - 59 chk adj 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 chargin...

  • Page 137: Chk

    3 - 60 chk adj checking the battery ● 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 138: Chk

    3 - 61 chk adj checking the battery charging method using a variable voltage charger measure the open-circuit voltage prior to charging. Connect a charger and ammeter to the battery and start charging. Is the amperage higher than the standard charging amperage written on the battery? No yes charger ...

  • Page 139: Chk

    3 - 62 chk adj checking the battery charging method using a constant voltage charger measure the open-circuit voltage prior to charging. Connect a charger and ammeter to the battery and start charging. No yes is the amperage higher than the standard charging amperage written on the battery? Charge t...

  • Page 140: Chk

    3 - 63 chk adj 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...

  • Page 141: Chk

    3 - 64 chk adj checking the fuse note: set the tester to the “ Ω × 1” position. ● if the tester indicates o, replace the fuse. ***************************************************** pocket tester: p/n. Yu-03112, 90890-03112 3.Replace: ● blown fuse *****************************************************...

  • Page 142: Chk

    3 - 65 chk adj 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...

  • Page 143: Chk

    3 - 66 chk adj changing the headlight bulb 4.Remove: ● cover 1 ● bulb holder 2 ● bulb note: turn the bulb holder counterclockwise and remove the defective bulb. Warning keep flammable products and your hands away from the bulb while it is on, since it will be hot. Do not touch the bulb until it cool...

  • Page 144: Eng

    4 - 1 eng 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 exhaust pipe remove the parts in the order below. Engine oil drain. Refer to “changing the engine oil” in chapter 3. Engine side panel/engine s...

  • Page 145: Eng

    4 - 2 eng order job name/part name q’ty remarks 8 air duct assembly 3 1 for installation, reverse the removal procedure. Engine removal 4.

  • Page 146: Eng

    4 - 3 eng engine removal select lever unit and coolant reservoir order job name/part name q’ty remarks removing the select lever unit and coolant reservoir remove the parts in the order below. Coolant drain. Refer to “changing the coolant” in chapter 3. 1 shift arm 1 2 select lever shift rod 1 3 sel...

  • Page 147: Eng

    4 - 4 eng 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. Radiator inlet hose refer to “thermostat” in chapter 5. Water pump assembly refer to “water pump” in chapter 5. 1 spark plug lead 1 2 crankcase breather ho...

  • Page 148: Eng

    4 - 5 eng engine removal engine mounting bolts order job name/part name q’ty remarks removing the engine mounting bolt remove the parts in the order below. Engine skid plate (front) refer to “seat, carriers, fenders and fuel tank” in chapter 3. Engine skid plate (center) engine skid plate (rear) rea...

  • Page 149: Eng

    4 - 6 eng engine removal order job name/part name q’ty remarks 1 rubber damper nut (front) 2 note: remove the engine assembly from the left side of the machine. Caution: install all of the bolts/nuts and then tighten them to full torque specifica- tions. Refer to “installing the engine”. 2 engine mo...

  • Page 150: Eng

    4 - 7 eng installing the engine 1.Install: ● engine mounting bolt (front) 1 ● rubber damper (front) 2 ● rubber damper nut (rear) 3 ● engine assembly 4 ● engine mounting bolt (rear lower)/nut 5 ● engine mounting bolt (rear upper) 6 ● rubber damper nut (front) 7 note: do not fully tighten the bolts an...

  • Page 151: Eng

    4 - 8 eng cylinder head cover cylinder head cover order job name/part name q’ty remarks removing the cylinder head cover remove the parts in the order below. Seat/front fender refer to “seat, carriers, fend- ers and fuel tank” in chapter 3. Fuel tank/plastic cover recoil starter/timing plug refer to...

  • Page 152: Eng

    4 - 9 eng cylinder head cover order job name/part name q’ty remarks 8 cylinder head cover 1 refer to “removing/installing the cylinder head cover”. 9 dowel pin 2 for installation, reverse the removal procedure..

  • Page 153: Eng

    4 - 10 eng cylinder head cover removing the cylinder head cover 1.Align: ● “i” mark (with stationary pointer) ***************************************************** checking steps: ● turn the crankshaft counterclockwise with a wrench. ● align the “i” mark 1 on the rotor with the sta- tionary pointer ...

  • Page 154: Eng

    4 - 11 eng cylinder head cover checking the tappet cover 1.Check: ● tappet cover (intake) 1 ● tappet cover (exhaust) 2 cracks/damage → replace. ● o-ring 3 new installing the cylinder head cover 1.Apply: ● sealant (quick gasket ) 1 (to the mating surfaces of the cylinder head and cylinder head cover)...

  • Page 155: Eng

    4 - 12 eng rocker arms rocker arms order job name/part name q’ty remarks removing the rocker arm remove the parts in the order below. Cylinder head cover refer to “cylinder head cover”. 1 plug/o-ring 1/1 2 bolt 2 3 rocker arm shaft 2 1 refer to “removing/installing the rocker arm”. 4 rocker arm 3 1 ...

  • Page 156: Eng

    4 - 13 eng rocker arms order job name/part name q’ty remarks 10 spring 4 11 locknut 5 12 valve adjuster 5 for installation, reverse the removal procedure..

  • Page 157: Eng

    4 - 14 eng rocker arms removing the rocker arm 1.Remove: ● rocker arm shafts 1 ● rocker arms 2 note: use a slide hammer bolt 3 and weight 4 to remove the rocker arm shafts. Slide hammer set: p/n. Yu-01083-a slide hammer bolt (m6): p/n. 90890-01083 weight: p/n. 90890-01084 checking the rocker arm 1.C...

  • Page 158: Eng

    4 - 15 eng rocker arms ● measure the outside diameter b of the rocker arm shafts. Out of specification → replace. ● calculate the clearance by subtracting the rocker arm shaft outside diameter from the rocker arm inside diameter. Clearance greater than 0.08 mm (0.003 in) → replace the defective part...

  • Page 159: Eng

    4 - 16 eng camshaft and cylinder head camshaft and cylinder head order job name/part name q’ty remarks removing the camshaft and cylin- der head remove the parts in the order below. Seat/front fender refer to “seat, fenders and fuel tank” in chapter 3. Fuel tank/plastic covers carburetors refer to “...

  • Page 160: Eng

    4 - 17 eng camshaft and cylinder head order job name/part name q’ty remarks 6 camshaft 1 7 thermo switch 1 8 cylinder head 1 9 cylinder head gasket 1 10 dowel pin 2 11 carburetor joint 1 for installation, reverse the removal procedure..

  • Page 161: Eng

    4 - 18 eng camshaft and cylinder head removing the camshaft and cylinder head 1.Loosen: ● camshaft sprocket bolts 1 2.Loosen: ● timing chain tensioner cap bolt 3.Remove: ● timing chain tensioner ● timing chain guide (exhaust) ● decompressor cam guide plates ● camshaft sprocket ● camshaft note: ● fas...

  • Page 162: Eng

    4 - 19 eng camshaft and cylinder head checking the camshaft 1.Check: ● cam lobes pitting/scratches/blue discoloration → replace. 2.Measure: ● cam lobes length a and b. Out of specification → replace. Camshaft lobe limit: intake: a 35.59 mm (1.4012 in) b 29.96 mm (1.1795 in) exhaust: a 36.40 mm (1.43...

  • Page 163: Eng

    4 - 20 eng camshaft and cylinder head checking the timing chain guide 1.Check: ● exhaust side timing chain guide wear/damage → replace. Checking the timing chain tensioner 1.Check: ● timing chain tensioner cracks/damage/rough movement → replace. ***************************************************** ...

  • Page 164: Eng

    4 - 21 eng camshaft and cylinder head 3.Measure: ● cylinder head warpage out of specification → resurface. ***************************************************** measurement and resurfacing steps: ● place a straightedge and a feeler gauge across the cylinder head. ● use a feeler gauge to measure the ...

  • Page 165: Eng

    4 - 22 eng camshaft and cylinder head 2.Install: ● camshaft ● camshaft sprocket ***************************************************** installation steps: ● turn the crankshaft counterclockwise with a wrench. ● align the “i” mark 1 on the rotor with the sta- tionary pointer 2 on the crankcase cover. ...

  • Page 166: Eng

    4 - 23 eng camshaft and cylinder head ● install the decompressor cam guide plates 9 and camshaft sprocket bolts 0. Note: insert a screwdriver into the timing chain ten- sioner hole and push the timing chain guide inward. ● remove the retaining wire. **************************************************...

  • Page 167: Eng

    4 - 24 eng valves and valve springs valves and valve springs order job name/part name q’ty remarks removing the valve and valve spring remove the parts in the order below. Cylinder head refer to “camshaft and cylinder head”. 1 valve cotter 10 refer to “removing/installing the valve and valve spring”...

  • Page 168: Eng

    4 - 25 eng valves and valve springs removing the valve and valve spring 1.Check: ● valve sealing leakage at the valve seat → inspect the valve face, valve seat and valve seat width. Refer to “checking the valve and valve spring”. ***************************************************** checking steps: ...

  • Page 169: Eng

    4 - 26 eng valves and valve springs checking the valve and valve spring 1.Measure: ● stem-to-guide clearance out of specification → replace the valve guide. Stem-to-guide clearance = valve guide inside diameter a – valve stem diameter b clearance (stem to guide): intake: 0.010 ~ 0.037 mm (0.0004 ~ 0...

  • Page 170: Eng

    4 - 27 eng valves and valve springs 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: 0.85 ~ 1.15 mm (0.0335 ~ 0.0452 i...

  • Page 171: Eng

    4 - 28 eng valves and valve springs 8.Measure: ● valve seat width a out of specification → reface the valve seat. ***************************************************** measurement steps: ● apply mechanic’s blueing dye (dykem) b to the valve face. ● install the valve into the cylinder head. ● press t...

  • Page 172: Eng

    4 - 29 eng valves and valve springs ● install the valve into the cylinder head. ● turn the valve until the valve face and valve seat are evenly polished, then clean off all of the compound. Note: for best lapping results, lightly tap the valve seat while rotating the valve back and forth between you...

  • Page 173: Eng

    4 - 30 eng valves and valve springs 11.Measure: ● compressed spring force a out of specification → replace. B installed length compressed spring force: intake: 100.0 ~ 115.7 n at 27.5 mm (10.20 ~ 11.80 kg, 22.48 ~ 26.01 lb at 1.08 in) exhaust: 120.6 ~ 138.3 n at 31.0 mm (12.30 ~ 14.10 kg, 27.11 ~ 31...

  • Page 174: Eng

    4 - 31 eng valves and valve springs 3.Install: ● valve cotters note: install the valve cotters while compressing the valve spring with the valve spring compressor 1 and valve spring compressor attachment 2. Valve spring compressor: p/n. Ym-04019, 90890-04019 valve spring compressor attachment: p/n. ...

  • Page 175: Eng

    4 - 32 eng 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. Water pump outlet hose refer to “water pump” in chapter 5. Cylinder head refer to “camshaft and cylinder head”. 1 coolant inlet joint 1 2 cyl...

  • Page 176: Eng

    4 - 33 eng cylinder and piston removing the piston 1.Remove: ● piston pin clips 1 ● piston pin 2 ● piston 3 note: ● put identification marks on each piston head for reference during reinstallation. ● before removing each piston pin, deburr the clip groove and pin hole area. If the piston pin groove ...

  • Page 177: Eng

    4 - 34 eng cylinder and piston note: measure cylinder bore “c” in parallel to and at right angles to the cylinder matching surface. Then, find the average of the measurements. ● if out of specification, rebore or replace the cylinder, and replace the piston and piston rings as a set. 2nd step: ● mea...

  • Page 178: Eng

    4 - 35 eng cylinder and piston checking the piston ring 1.Measure: ● ring side clearance use a feeler gauge. Out of specification → replace the piston and rings as a set. Note: clean carbon from the piston ring grooves and rings before measuring the side clearance. Side clearance standard limit top ...

  • Page 179: Eng

    4 - 36 eng cylinder and piston checking the piston pin 1.Check: ● piston pin blue discoloration/grooves → replace, then inspect the lubrication system. 2.Measure: ● piston pin-to-piston clearance ***************************************************** measurement steps: ● measure the piston pin outsid...

  • Page 180: Eng

    4 - 37 eng cylinder and piston 2.Position: ● top ring ● 2nd ring ● oil ring offset the piston ring end gaps as shown. A top ring end b oil ring end (lower) c oil ring end (upper) d 2nd ring end 3.Install: ● piston 1 ● piston pin 2 ● piston pin clips 3 note: ● apply engine oil onto the piston pin, pi...

  • Page 181: Eng

    4 - 38 eng recoil starter and ac magneto recoil starter and ac magneto order job name/part name q’ty remarks removing the ac magneto remove the parts in the order below. Engine oil drain. Refer to “changing the engine oil” in chapter 3. Coolant drain. Refer to “changing the coolant” in chapter 3. Se...

  • Page 182: Eng

    4 - 39 eng recoil starter and ac magneto order job name/part name q’ty remarks 3 starter pulley 1 refer to “removing/installing the ac magneto”. 4 crankcase cover (left)/gasket 1/1 5 dowel pin 2 6 lead holder 1 7 pickup coil 1 8 starter assembly 1 9 cdi rotor 1 refer to “removing/installing the ac m...

  • Page 183: Eng

    4 - 40 eng recoil starter and ac magneto order job name/part name q’ty remarks disassembling the recoil starter remove the parts in the order below. 1 cap 1 refer to “disassembling/assem- bling the recoil starter”. 2 starter handle 1 3 friction plate 1 4 pawl spring 1 5 drive pawl 1 6 spring 1 7 she...

  • Page 184: Eng

    4 - 41 eng recoil starter and ac magneto removing the ac 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, ...

  • Page 185: Eng

    4 - 42 eng recoil starter and ac 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 cdi ...

  • Page 186: Eng

    4 - 43 eng recoil starter and ac 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 → replace. Assembl...

  • Page 187: Eng

    4 - 44 eng recoil starter and ac magneto 2.Install: ● starter spring 1 ● sheave drum assembly 2 note: ● mesh the spring hook 3 with the case slit, then wind the spring clockwise into the case from the larger to smaller diameter. ● mesh the sheave drum hook 4 with the spring hook 5. 3.Install: ● spri...

  • Page 188: Eng

    4 - 45 eng recoil starter and ac magneto 2.Install: ● woodruff key ● cdi rotor note: ● before installing the rotor, clean the outside of the crankshaft and the inside of the rotor. ● after installing the rotor, check that the rotor rotates smoothly. If not, reinstall the key and rotor. 3.Install: ● ...

  • Page 189: Eng

    4 - 46 eng recoil starter and ac magneto 5.Install: ● select lever unit ● select lever shift rod note: before installing the select lever shift rod, make sure that the select lever and shift cam is in the neutral position. 6.Adjust: ● select lever shift rod refer to “adjusting the select lever contr...

  • Page 190: Eng

    4 - 47 eng balancer gears and oil pump gears balancer gears and oil pump gears order job name/part name q’ty remarks removing the balancer gears and oil pump gears remove the parts in the order below. Starter wheel gear refer to “recoil starter and ac magneto”. 1 nut/lock washer 1/1 2 balancer drive...

  • Page 191: Eng

    4 - 48 eng balancer gears and oil pump gears removing the balancer drive gear and balancer driven gear 1.Straighten the lock washer tabs. 2.Loosen: ● balancer driven gear nut 1 note: place an aluminum plate 2 between the teeth of the balancer drive gear 3 and balancer driven gear 4. Removing the bal...

  • Page 192: Eng

    4 - 49 eng balancer gears and oil pump gears checking the balancer drive 1.Check: ● balancer drive gear 1 ● balancer driven gear 2 damage/wear → replace the balancer drive gear and balancer driven gear as a set. Excessive noise during operation → replace the balancer drive gear and balancer driven g...

  • Page 193: Eng

    4 - 50 eng balancer gears and oil pump gears 3.Install: ● lock washer ● balancer driven gear nut 1 note: ● place an aluminum plate 2 between the teeth of the balancer drive gear 3 and bal- ancer driven gear 4. ● apply the molybdenum disulfide grease to the thread of axles and nuts. 4.Bend the lock w...

  • Page 194: Eng

    4 - 51 eng primary and secondary sheaves primary and secondary sheaves t r . . 100 nm (10.0 m • kg, 72 ft • lb) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 120 nm (12.0 m • kg, 85 ft • lb) 10 10 9 7 6 8 5 4 3 2 1 (12...

  • Page 195: Eng

    4 - 52 eng primary and secondary sheaves t r . . 100 nm (10.0 m • kg, 72 ft • lb) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 120 nm (12.0 m • kg, 85 ft • lb) 10 10 9 7 6 8 5 4 3 2 1 (12) (7) t r . . 10 nm (1.0 m • k...

  • Page 196: Eng

    4 - 53 eng primary and secondary sheaves primary sheave order job name/part name q’ty remarks disassembling the primary sheave remove the parts in the order below. 1 primary pulley sheave cap 1 refer to “assembling the primary sheave”. 2 primary pulley slider 4 3 spacer 4 4 primary pulley cam 1 5 pr...

  • Page 197: Eng

    4 - 54 eng primary and secondary sheaves secondary sheave order job name/part name q’ty remarks disassembly the secondary sheave remove the parts in the order below. 1 nut 1 refer to “disassembling/assem- bling secondary sheave”. 2 spring seat 1 3 compression spring 1 4 spring seat 1 5 guide pin 4 6...

  • Page 198: Eng

    4 - 55 eng removing the primary and secondary sheaves 1.Loosen: ● nut (secondary sheave) 1 ● nut (primary sheave) 2 note: ● use the sheave holder 3 to hold the primary sheave. ● first, loosen the nut (secondary sheave) 2, then loosen the nut (primary sheave) 1. Sheave holder: p/n. Yu-01880, 90890-01...

  • Page 199: Eng

    4 - 56 eng primary and secondary sheaves cheking the primary sheave 1.Check: ● weight outside diameter a out of specification → replace the weight. Weight outside diameter: 30 mm (1.18 in) : 29.5 mm (1.16 in) 2.Check: ● primary puller slider ● primary sliding sheave splines wear/cracks/damage → repl...

  • Page 200: Eng

    4 - 57 eng primary and secondary sheaves assembling the primary sheave 1.Clean: ● primary sliding sheave face 1 ● primary fixed sheave face 2 ● collar 3 ● weight 4 ● primary sliding sheave cam face note: remove any excess grease. 2.Install: ● weight 1 note: ● apply yamaha grizzly grease (90 g) to th...

  • Page 201: Eng

    4 - 58 eng primary and secondary sheaves 3.Apply: ● bel-ray assembly lube ® (to the guide pin sliding groove 1, and o- ring 2 ) new 4.Install: ● spring seat ● compression spring ● spring seat ● nut ***************************************************** installing steps: ● attach the sheave fixed bloc...

  • Page 202: Eng

    4 - 59 eng 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 second- ary sliding sheave away, causing the gap between the secondary fixed and sliding sheave...

  • Page 203: Eng

    4 - 60 eng 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”. 1 clutch housing assembly 1 refer to “removing and install- ing the clutch”. 2 gasket/dowel pin 1/2 3 one-wa...

  • Page 204: Eng

    4 - 61 eng clutch order job name/part name q’ty remarks disassembling the clutch housing remove the parts in the order below. 1 oil seal 1 2 circlip 1 3 bearing housing 1 4 circlip 1 5 bearing 1 6 circlip 1 7 bearing 1 8 clutch housing 1 for assembly, reverse the disassembly procedure..

  • Page 205: Eng

    4 - 62 eng 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 ...

  • Page 206: Eng

    4 - 63 eng 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 note: use ...

  • Page 207: Eng

    4 - 64 eng clutch 4.Install: ● dowel pins ● gasket ● clutch housing assembly note: ● tighten the bolts in stages, using a criss- cross pattern. ● after tightening the bolts, check that the clutch housing assembly to counterclockwise rotates smoothly. New t r . . 10 nm (1.0 m • kg, 7.2 ft • lb).

  • Page 208: Eng

    4 - 65 eng crankcase crankcase starter motor, timing chain and oil filter order job name/part name q’ty remarks remove the starter motor, timing chain and oil filter remove the parts in the order below. Engine assembly refer to “engine removal”. Cylinder head refer to “camshaft and cylinder head”. C...

  • Page 209: Eng

    4 - 66 eng crankcase order job name/part name q’ty remarks 4 oil filter 1 5 speed sensor 1 6 shift cam stopper 1 7 gear position switch 1 8 reverse switch 1 9 oil filler cap 1 10 oil delivery pipe 1 11 drain plug 1 for installation, reverse the removal procedure..

  • Page 210: Eng

    4 - 67 eng crankcase crankcase t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 14 nm (1.4 m • kg, 10 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) (7) 7 6 6 4 2 1 3 5 order job name/part name q’ty remarks separating the crankcase remove the parts in the ord...

  • Page 211: Eng

    4 - 68 eng crankcase crankcase bearing t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) lt lt ls e e e e e 4 4 4 4 3 4 1 2 4 4 4 new 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”. Transmissi...

  • Page 212: Eng

    4 - 69 eng crankcase separating the crankcase 1.Separate: ● left crankcase ● right crankcase ***************************************************** separation steps: ● remove the crankcase bolts. Note: ● loosen each bolt 1/4 of a turn at a time and after all the bolts are loosened, remove them. ● loo...

  • Page 213: Eng

    4 - 70 eng crankcase checking the crankcase 1.Thoroughly wash the case halves in a mild solvent. 2.Clean all the gasket mating surfaces and crankcase mating surfaces thoroughly. 3.Check: ● crankcase cracks/damage → replace. ● oil delivery passages clogged → blow out with compressed air. Checking the...

  • Page 214: Eng

    4 - 71 eng crankcase 4.Tighten: ● crankcase bolts (follow the proper tightening sequence) È right crankcase É left crankcase note: tighten the bolts in stages, using a crisscross pattern. È É t r . . 10 nm (1.0 m • kg, 7.2 ft • lb) 5.Apply: ● 4-stroke engine oil (to the crank pin, bearing and oil de...

  • Page 215: Eng

    4 - 72 eng crankshaft and oil pump crankshaft and oil pump order job name/part name q’ty remarks removing the crankshaft and oil pump remove the parts in the order below. Crankcase separation refer to “crankcase”. 1 oil strainer/o-ring 1/1 2 oil pump assembly/gasket 1/1 3 balancer 1 refer to “removi...

  • Page 216: Eng

    4 - 73 eng 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. 1 rotor cover 1 2 pin 2 3 shaft 1 4 pin 1 5 inner rotor 1 6 outer rotor 1 7 oil pump housing 1 for assembly, reverse the disassembly procedure..

  • Page 217: Eng

    4 - 74 eng crankshaft and oil pump removing the crankshaft 1.Remove: ● crankshaft use a crankcase separating tool 1. Crankcase separating tool: p/n. Yu-01135-a, 90890-01135 checking the oil pump 1.Check: ● rotor housings ● rotor cover cracks/wear/damage → replace. 2.Measure: ● tip clearance a (betwe...

  • Page 218: Eng

    4 - 75 eng checking the relief valve 1.Check: ● relief valve body 1 ● relief valve 2 ● spring 3 ● o-ring 4 damage/wear → replace the defective parts(s). Checking the oil strainer 1.Check: ● oil strainer 1 ● o-ring 2 damage → replace. Contaminants → clean with engine oil. Assembling the oil pump 1.In...

  • Page 219: Eng

    4 - 76 eng crankshaft and oil pump checking the crankshaft 1.Measure: ● crank width a out of specification → replace the crank- shaft. ● side clearance d out of specification → replace the crank- shaft. ● runout c out of specification → replace the crank- shaft. *************************************...

  • Page 220: Eng

    4 - 77 eng crankshaft and oil pump installing the crankshaft and balancer 1.Install: ● crankshaft note: hold the connecting rod at the top dead cen- ter (t.D.C.) with one hand while turning the nut of the installing tool with the other. Operate the installing tool until the crankshaft bottoms agains...

  • Page 221: Eng

    4 - 78 eng 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”. Middle driven gear refer to “middle gear”. 1 low wheel gear 1 2 shift cam 1 3 shift fork assembly 1 4 short spring 1 wh...

  • Page 222: Eng

    4 - 79 eng transmission order job name/part name q’ty remarks 11 chain 1 12 shaft 1 13 stopper lever 1 14 spring 1 15 stopper cam 1 for installation, reverse the removal procedure..

  • Page 223: Eng

    4 - 80 eng transmission order job name/part name q’ty remarks disassembling the drive axle assembly remove the parts in the order below. 1 clutch dog 1 2 high wheel gear 1 3 middle drive gear 1 4 stopper wheel 1 5 driven sprocket 1 6 drive axle 1 for assembly, reverse the disassembly procedure..

  • Page 224: Eng

    4 - 81 eng transmission removing the transmission 1.Remove: ● sift cam 1 ● sift fork assembly 2 ***************************************************** removing steps: ● pull out the guide bar from the left crank- case. ● push down on the drive shaft, and then slide the shift fork assembly to remove t...

  • Page 225: Eng

    4 - 82 eng transmission 3.Check: ● shift fork movement (on the guide bar) unsmooth operation → replace the shift fork and the guide bar. 4.Check: ● spring cracks/damage → replace. Checking the shift cam 1.Check: ● shift cam grooves scratches/wear/damage → replace. Checking the drive axle 1.Measure: ...

  • Page 226: Eng

    4 - 83 eng transmission 2.Check: ● gear movement unsmooth → repeat steps #1 or replace the defective parts. 3.Check: ● circlip bends/looseness/damage → replace. Checking the secondary shaft and driven sprocket 1.Check ● gear teeth blue discoloration/pitting/wear → replace. 2.Check: ● gear movement u...

  • Page 227: Eng

    4 - 84 eng transmission assembling the shift fork assembly 1.Install: ● guide bar 1 ● shift fork 2 2 ● long spring 3 ● shift fork 1 4 ● short spring 5 installing the transmission 1.Install: ● stopper lever ● shaft 1 ● chain 2 ● drive axle assembly 3 ● secondary shaft 4 ● shift fork assembly 5 ● shif...

  • Page 228: Eng

    4 - 85 eng 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”. 1 bearing housing 1 2 middle driven gear 1 3 nut 1 refer to “removing/installing the middle driv...

  • Page 229: Eng

    4 - 86 eng middle gear middle driven shaft order job name/part name q’ty remarks disassembling the middle driven shaft remove the parts in the order below. Crankcase separation refer to “crankcase”. 1 circlip 2 refer to “installing/removing the middle driven shaft”. 2 bearing 2 3 universal joint 1 4...

  • Page 230: Eng

    4 - 87 eng middle gear order job name/part name q’ty remarks 10 bearing retainer 1 11 middle driven shaft 1 for installation, reverse the removal procedure..

  • Page 231: Eng

    4 - 88 eng middle gear removing the middle drive shaft 1.Straighten: ● punched portion of the nut (middle drive pin- ion 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 pini...

  • Page 232: Eng

    4 - 89 eng middle gear 2.Remove: ● nut 1 ● washer ● universal joint yoke note: use the universal joint holder 2 to hold the universal joint yoke. 3.Remove: ● nut 1 ● washer ● coupling gear 2 note: use the coupling gear/middle shaft tool 3 to hold the coupling gear. Universal joint holder: p/n. Ym-04...

  • Page 233: Eng

    4 - 90 eng middle gear 5.Remove: ● bearing retainer ● bearing ***************************************************** removal steps: ● attach the folded rag 1. ● secure the bearing housing edge in the vise. ● attach the bearing retainer wrench 2. Caution: the middle driven shaft bearing retainer has l...

  • Page 234: Eng

    4 - 91 eng middle gear checking the pinion gear 1.Check ● gear teeth (drive pinion gear) 1 ● gear teeth (driven pinion gear) 2 pitting/galling/wear → replace. 2.Check ● o-ring damage → replace. ● bearings pitting/damage → replace. 3.Check: ● u-joint movement roughness → replace u-joint. Middle drive...

  • Page 235: Eng

    4 - 92 eng middle gear where: a = a numeral (usually a decimal number) on the bearing housing is either added to or subtracted from “7.5”. B = 17.0 c = 55.0 d = a numeral (usually a decimal number) on the right crankcase specifies a thickness of “64.98”. Example: 1) if the bearing housing is marked ...

  • Page 236: Eng

    4 - 93 eng middle gear ● to find shim thickness “b” use the following formula: middle driven pinion gear shim thick- ness: “b” = e – f + g – h + i – 0.05 where: e = a numeral (usually a decimal number) on the bearing housing is either added to or subtracted from “76”. F = a numeral (usually a decima...

  • Page 237: Eng

    4 - 94 eng middle gear 6) round off hundredths digit and select appropriate shim(s). In the example above, the calculated shim thickness is 0.64 mm. The chart instructs you, however, to round off 4 to 5. Shims are supplied in the following thickness. *************************************************...

  • Page 238: Eng

    4 - 95 eng middle gear 2.Install: ● bearing retainer 1 ***************************************************** installation steps: ● attach the folded rag 2. ● secure the bearing housing edge in the vise. ● attach the bearing retainer wrench 3. ● tighten the bearing retainer. Caution: the middle drive...

  • Page 239: Eng

    4 - 96 eng middle gear 5.Install: ● universal joint ***************************************************** installation steps: ● install the opposite yoke into the u-joint. ● apply wheel bearing grease to the bearings. ● install the bearing 1 onto the yoke. Caution: check each bearing. The needles ca...

  • Page 240: Eng

    4 - 97 eng middle gear measuring the middle gear backlash 1.Measure: ● gear lash ***************************************************** measurement steps: ● temporary install the right crankcase. ● wrap a rag 2 around a screwdriver 3, and then insert it into the installation hole 1 of the left crankc...

  • Page 241: Cool

    5 - 1 cool radiator cooling system radiator t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 28 nm (2.8 m • kg, 20 ft • ib) 3 5 1 6 2 8 9 7 4 order job name/part name q’ty remarks removing the radiator remove the parts in the order below. Seat and side panels refer to “seat and side panels” in chapter...

  • Page 242: Cool

    5 - 2 cool radiator t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 28 nm (2.8 m • kg, 20 ft • ib) 3 5 1 6 2 8 9 7 4 order job name/part name q’ty remarks 5 radiator inlet hose 1 disconnect. 6 radiator outlet hose 1 disconnect. 7 radiator 1 8 radiator fan 1 9 thermo switch 1 for installation, reverse...

  • Page 243: Cool

    5 - 3 cool radiator checking the radiator 1.Check: ● radiator fins obstruction → clean. Apply compressed air to the rear of the radia- tor. Damage → repair or replace. Note: straighten any flattened fins with a thin, flat- head screwdriver. 2.Check: ● radiator hoses cracks/damage → replace. 3.Measur...

  • Page 244: Cool

    5 - 4 cool radiator installing the radiator 1.Fill: ● cooling system (with the specified amount of the recom- mended coolant) refer to “changing the coolant” in chapter 3. 2.Check: ● cooling system leaks → repair or replace any faulty part..

  • Page 245: Cool

    5 - 5 cool thermostat thermostat 3 2 1 t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) 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 ...

  • Page 246: Cool

    5 - 6 cool thermostat checking the thermostat 1.Check: ● thermostat 1 does not open at 50 ~ 54 °c (122 ~ 158 °f) → replace. ***************************************************** checking steps: ● suspend the thermostat in a container filled with water. ● slowly heat the water. ● place a thermometer ...

  • Page 247: Cool

    5 - 7 cool water pump water pump 6 7 new ls 8 1 ls 5 new t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) 2 4 3 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 engine side cover refer to “seat and side panels” in chapter...

  • Page 248: Cool

    5 - 8 cool water pump order job name/part name q’ty remarks disassembling the water pump remove the parts in the order below. 1 water pump housing cover 1 2 gasket 1 3 circlip 1 4 impeller 1 5 rubber damper holder 1 6 rubber damper 1 7 water pump seal 1 8 oil seal 1 9 bearing 1 0 water pump housing ...

  • Page 249: Cool

    5 - 9 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 ho...

  • Page 250: Cool

    5 - 10 cool water pump assembling the water pump 1.Install: ● oil seal 1 (into the water pump housing 2) note: ● before installing the oil seal, apply tap water or coolant onto its outer surface. ● install the oil seal with a socket 3 that matches its outside diameter. New 2.Install: ● water pump se...

  • Page 251: Cool

    5 - 11 cool water pump 4.Measure: ● impeller shaft tilt out of specification → repeat steps (3) and (4). Caution: make sure that the rubber damper and rub- ber damper holder are flush with the impel- ler. 1 straightedge 2 impeller max. Impeller shaft tilt: 0.15 mm (0.006 in).

  • Page 252: Carb

    6 - 1 carb carburetor carburetion carburetor 6 3 4 8 5 9 2 2 7 1 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 1 refer to “seat, carriers, fenders and fuel tank” in chapter 3. Exhaust pipe protector 1 refer to ...

  • Page 253: Carb

    6 - 2 carb carburetor order job name/part name q’ty remarks disassembling the carburetor remove the parts in the order below. 1 throttle stop screw 1 2 vacuum chamber cover 1 3 spring 1 4 jet needle holder 1 5 spring 1 6 jet needle set 1 7 piston valve 1 8 coasting enricher diaphragm 1 9 pilot air j...

  • Page 254: Carb

    6 - 3 carb carburetor order job name/part name q’ty remarks d main jet 1 e needle jet 1 refer to “assembling the carbure- tor”. F pilot jet 1 g starter jet 1 for assembly, reverse the disassembly procedure..

  • Page 255: Carb

    6 - 4 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 → replace. ...

  • Page 256: Carb

    6 - 5 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: ●...

  • Page 257: Carb

    6 - 6 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 note: befor...

  • Page 258: Carb

    6 - 7 carb carburetor ● if either is worn, replace them both. ● if both are fine, adjust the float height by bending the float tang 1 on the float. ● recheck the float height. ***************************************************** adjusting the fuel level 1.Measure: ● fuel level a out of specificatio...

  • Page 259: Driv

    7 - 1 driv troubleshooting drive train troubleshooting the following conditions may indicate damaged shaft drive components: note: areas a, b, and c above may be extremely difficult to diagnose. The symptoms are quite subtle and difficult to distinguish from normal machine operating noise. If there ...

  • Page 260: Driv

    7 - 2 driv troubleshooting caution: too little gear lash is extremely destructive to the gear teeth. If a test ride following reas- sembly indicates this condition, stop riding immediately to minimize gear damage. C.A slight “thunk” evident at low speed opera- tion. This noise must be distinguished ...

  • Page 261: Driv

    7 - 3 driv troubleshooting troubleshooting chart when basic condition “a” and “b” exist, check the following points: elevate and spin both wheels. Feel for wheel bearing damage. Yes replace the wheel bearing. (refer to “steering system” and “rear knuckle and stabilizer” in chapter 8.) no check the w...

  • Page 262: Driv

    7 - 4 driv front constant velocity joints and differential gear front constant velocity joints and differential gear ls ls ls t r . . 55 nm (5.5 m • kg, 40 ft • ib) ls 1 6 5 3 2 1 4 order job name/part name q’ty remarks removing the front constant veloc- ity joint and differential gear remove the pa...

  • Page 263: Driv

    7 - 5 driv front constant velocity joints and differential gear ls ls ls t r . . 55 nm (5.5 m • kg, 40 ft • ib) ls 1 6 5 3 2 1 4 order job name/part name q’ty remarks 4 differential gear 1 5 drive shaft 1 6 compression spring 1 for installation, reverse the removal procedure..

  • Page 264: Driv

    7 - 6 driv front constant velocity joints and differential gear order job name/part name q’ty remarks disassembling the constant velocity joint remove the parts in the order below. 1 circlip 1 2 boot band 2 refer to “assembling the front constant velocity joint” 3 boot band 2 4 dust boot 2 5 circlip...

  • Page 265: Driv

    7 - 7 driv front constant velocity joints and differential gear order job name/part name q’ty remarks disassembling the differential gear remove the parts in the order below. 1 gear motor/o-ring 1/1 note: be sure not to disassemble gear motor and remove the pinion gear. 2 circlip 2 refer to “disasse...

  • Page 266: Driv

    7 - 8 driv front constant velocity joints and differential gear order job name/part name q’ty remarks b differential gear assembly 1 c shim (right) 1 d circlip/bearing 1/1 e drive pinion gear 1 f differential gear case 1 for assembly, reverse the disassembly procedure..

  • Page 267: Driv

    7 - 9 driv disassembling 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. Not...

  • Page 268: Driv

    7 - 10 driv front constant velocity joints and differential gear removing the ring gear 1.Remove: ● ring gear 1 note: the ring gear and the differential gear cover should be fastened together. Do not disassem- ble the differential gear. Caution: the differential gears are assembled into a proper uni...

  • Page 269: Driv

    7 - 11 driv front constant velocity joints and differential gear 2.Check: ● drive shaft splines ● universal joints ● front drive gear splines wear/damage → replace. ● spring fatigue → replace. Move the spring up and down. 3.Check: ● front drive shaft bends → replace. Warning do not attempt to straig...

  • Page 270: Driv

    7 - 12 driv front constant velocity joints and differential gear 2.Install: ● dust boots 1 ● boot bands 2, 3 ***************************************************** installation steps: ● apply molybdenum disulfide grease into the dust boots. ● install the dust boots. ● install the dust boot bands. Not...

  • Page 271: Driv

    7 - 13 driv front constant velocity joints and differential gear ***************************************************** installation steps: ● slide the shift fork sliding gear 1, which is installed to the differential gear, to the left to put it into the 2wd mode. ● connect two c size batteries to th...

  • Page 272: Driv

    7 - 14 driv front constant velocity joints and differential gear 4.Check: ● differential gear operation unsmooth operation → replace the differen- tial gear assembly. Insert the double off-set joint into the differ- ential gear, and turn the gear back and forth. Installing the universal joint 1.Inst...

  • Page 273: Driv

    7 - 15 driv measuring and adjusting the differential gear lash measuring the differential gear lash 1.Secure the gear case in a vise or another supporting device. 2.Remove: ● drain plug ● gasket 3.Install: ● a bolt of the specified size 1 (into the drain plug hole) caution: finger tighten the bolt u...

  • Page 274: Driv

    7 - 16 driv adjusting differential gear lash 1.Remove: ● shim(s) (left) 1 ● differential gear assembly 2 ● shim(s) (right) 3 2.Adjust: ● gear lash ***************************************************** adjustment steps: ● select the suitable shims using the following chart. ● if it is necessary to in...

  • Page 275: Driv

    7 - 17 driv checking the differential gear operation 1.Block the rear wheels, and elevate the front wheels by placing a suitable stand under the frame. 2.Remove the wheel cap and cotter pin from the axle nut (right or left). 3.Measure the starting torque of the front wheel (i.E., differential gear p...

  • Page 276: Driv

    7 - 18 driv rear constant velocity joint/final drive gear and drive shaft rear constant velocity joint/final drive gear and drive shaft 1 3 5 6 4 1 2 t r . . 55 nm (5.5 m • kg, 40 ft • ib) order job name/part name q’ty remarks removing the rear constant velocity joint, final drive gear assembly and ...

  • Page 277: Driv

    7 - 19 driv rear constant velocity joint/final drive gear and drive shaft order job name/part name q’ty remarks disassembling the rear constant velocity joint remove the parts in the order below. 1 dust cover 1 2 circlip 1 3 boot band 2 refer to “constant velocity joint assembly”. 4 boot band 2 5 du...

  • Page 278: Driv

    7 - 20 driv rear constant velocity joint/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. Rear brake disc refer to “rear wheels and brake disc” in chapter 8. 1 boss 1 2 ring gear stopper shim 1 3 ring gear ...

  • Page 279: Driv

    7 - 21 driv rear constant velocity joint/final drive gear and drive shaft order job name/part name q’ty remarks a thrust washer 1 b final drive pinion gear shim 1 c o-ring 1 refer to “assembling the final drive gear”. D oil seal 1 e inner race 1 f final drive pinion gear 1 g bearing retainer 1 h bea...

  • Page 280: Driv

    7 - 22 driv rear constant velocity joint/final drive gear and drive shaft assembling the rear constant velocity joint 1.Apply: ● lithium-soap base grease (into the ball joint assembly) 2.Install: ● dust boots 1 ● boot bands 2, 3 ***************************************************** installation step...

  • Page 281: Driv

    7 - 23 driv rear constant velocity joint/final drive gear and drive shaft removing and disassembling the final drive roller bearing 1.Remove: ● roller bearing (ring gear) 1 use a suitable press tool 2 and an appropri- ate support for the main housing. 2.Remove: ● roller bearing (final drive pinion g...

  • Page 282: Driv

    7 - 24 driv rear constant velocity joint/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 hous- ing are replaced, be sure to adjust the posi- tions of the final drive pinion ge...

  • Page 283: Driv

    7 - 25 driv rear constant velocity joint/final drive gear and drive shaft 6) round off the hundredth digit and select the appropriate shim(s). In the example above, the calculated number is 0.97. The chart instructs you to round off 7 to 5 at the hundredth place. Thus, the shim thickness is 0.95 mm....

  • Page 284: Driv

    7 - 26 driv rear constant velocity joint/final drive gear and drive shaft h =bearing thickness (considered constant) example: 1) if “98” is stamped on the final drive gear case, e = 50 + 0.98 = 50.98 2) if “55” is stamped on the ring gear bear- ing housing, f = 1 + 0.55 = 1.55 3) if “–05” is stamped...

  • Page 285: Driv

    7 - 27 driv rear constant velocity joint/final drive gear and drive shaft thrust washer selection 1.Measure/select: ● ring gear thrust clearance “c” ***************************************************** measurement steps: ● place four pieces of plastigauge ® between the originally fitted thrust wash...

  • Page 286: Driv

    7 - 28 driv rear constant velocity joint/final drive gear and drive shaft adjusting the ring gear stopper 1.Measure: ● ring gear stopper clearance “d” use a feeler gauge 1. Out of specification → adjust. 2 ring gear 3 ring gear stopper ring gear stopper clearance “d”: 0.30 ~ 0.60 mm (0.012 ~ 0.024 i...

  • Page 287: Driv

    7 - 29 driv rear constant velocity joint/final drive gear and drive shaft checking the drive shaft 1.Check: ● drive shaft (splines) 1 ● coupling gear (splines) 2 wear/damage → replace. 1 2 checking the final drive gear 1.Check: ● final drive gear case 1 ● ring gear bearing housing 2 cracks/damage → ...

  • Page 288: Driv

    7 - 30 driv rear constant velocity joint/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 dra...

  • Page 289: Driv

    7 - 31 driv rear constant velocity joint/final drive gear and drive shaft final gear lash adjustment 1.Remove: ● bearing housing 1 ● ring gear shim(s) 2 ● ring gear 3 ● thrust washer 4 2.Adjust: ● gear lash ***************************************************** adjustment steps: ● select a suitable s...

  • Page 290: Driv

    7 - 32 driv rear constant velocity joint/final drive gear and drive shaft assembling the final drive gear 1.Adjust: ● final gear lash refer to “measurement and adjust- ing the final gear lash”. 2.Check: ● final drive gear operation unsmooth operation → replace the final drive gear assembly. Insert t...

  • Page 291: Chas

    8 - 1 chas front wheels and brake discs chassis front wheels and brake discs front wheels t r . . 30 nm (3.0 m • kg, 22 ft • ib) t r . . 30 nm (3.0 m • kg, 22 ft • ib) 5 7 6 4 3 2 new lt lt t r . . 200 nm (20.0 m • kg, 145 ft • lb) t r . . 55 nm (5.5 m • kg, 40 ft • ib) 1 order job name/part name q’...

  • Page 292: Chas

    8 - 2 chas front wheels and brake discs t r . . 30 nm (3.0 m • kg, 22 ft • ib) t r . . 30 nm (3.0 m • kg, 22 ft • ib) 5 7 6 4 3 2 new lt lt t r . . 200 nm (20.0 m • kg, 145 ft • lb) t r . . 55 nm (5.5 m • kg, 40 ft • ib) 1 order job name/part name q’ty remarks 5 brake caliper assembly 1 note: do not...

  • Page 293: Chas

    8 - 3 chas front wheels and brake discs checking the front wheel 1.Check: ● wheel 2.Measure: ● wheel runout over the specified limit → replace the wheel or check the wheel bearing play 1. 3.Check: ● wheel balance out of balance → adjust. Wheel runout limit: radial 2: 2.0 mm (0.08 in) lateral 3: 2.0 ...

  • Page 294: Chas

    8 - 4 chas front wheels and brake discs checking the front 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 thickness a out of specif...

  • Page 295: Chas

    8 - 5 chas front wheels and brake discs 2.Tighten: ● nuts (wheel) 1 warning tapered wheel nuts 1 are used for both the front and rear wheels. Install each nut with its tapered side towards the wheel..

  • Page 296: Chas

    8 - 6 chas rear wheels and brake disc rear wheels and brake disc rear wheels new 2 3 4 5 t r . . 55 nm (5.5 m • kg, 40 ft • ib) t r . . 200 nm (20.0 m • kg, 145 ft • lb) 1 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 ...

  • Page 297: Chas

    8 - 7 chas rear wheels and brake disc rear brake disc (6) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) 1 2 order job name/part name q’ty remarks disassembling the rear brake disc remove the parts in the order below. Brake caliper assembly refer to “rear brake caliper”. Final drive gear refer to “final dr...

  • Page 298: Chas

    8 - 8 chas checking the rear wheel 1.Check: ● wheel refer to “checking the front wheel”. 2.Measure: ● wheel runout refer to “checking the front wheel”. Over the specified limit → replace. 3.Check: ● wheel balance refer to “checking the front wheel”. Out of balance → adjust. Wheel runout limit: radia...

  • Page 299: Chas

    8 - 9 chas installing the rear wheel hub 1.Install: ● cotter pin refer to “installing the front wheel hub”. 2.Adjust: ● rear brake lever and pedal free play refer to “adjusting the rear brake lever and pedal” in chapter 3. Installing the rear wheel 1.Install: ● wheel refer to “installing the front w...

  • Page 300: Chas

    8 - 10 chas 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 wheels”. 1 brake caliper mounting bolt 2 refer to “replacing the front brake pad”. 2 brake pad holding bolt 2 3 brak...

  • Page 301: Chas

    8 - 11 chas front and rear brakes rear brake pads t r . . 18 nm (1.8 m • kg, 13 ft • ib) 1 2 3 4 4 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 “rear wheels and brake disc”. 1 brake pad holding bolt plug 1 refer to...

  • Page 302: Chas

    8 - 12 chas front and rear brakes caution: disc brake components rarely require dis- assembly. Do not: ● disassemble components unless abso- lutely necessary; ● use solvents on internal brake compo- nents; ● use spent brake fluid for cleaning; (use only clean brake fluid) ● allow brake fluid to come...

  • Page 303: Chas

    8 - 13 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 ...

  • Page 304: Chas

    8 - 14 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. Brake pad wear limit: 1 mm (0.04 in) 2.Instal...

  • Page 305: Chas

    8 - 15 chas front and rear brakes 3.Check: ● brake fluid level refer to “checking the brake fluid level inspection” in chapter 3. 4.Check: ● brake lever or brake pedal operation soft or spongy feeling → bleed the rear brake system. Refer to “bleeding the hydraulic brake system” in chapter 3..

  • Page 306: Chas

    8 - 16 chas front and rear brakes front brake master cylinder order job name/part name q’ty remarks removing the front brake master cylinder remove the parts in the order below. Brake fluid drain. On command four-wheel drive switch refer to “handlebar”. 1 brake fluid reservoir cap 1 2 brake fluid re...

  • Page 307: Chas

    8 - 17 chas front and rear brakes order job name/part name q’ty remarks disassembling the front brake mas- ter cylinder remove the parts in the order below. 1 dust boot 1 refer to “adjusting the front brake master cylinder”. 2 circlip 1 3 brake master cylinder kit 1 for assembly, reverse the disasse...

  • Page 308: Chas

    8 - 18 chas front and rear brakes rear brake master cylinder u ppe r r owe t r . . 23 nm (2.3 m • kg, 17 ft • ib) t r . . 30 nm (3.0 m • kg, 22 ft • ib) 8 9 11 12 7 10 1 2 3 4 5 6 new new order job name/part name q’ty remarks removing the rear brake master cyl- inder remove the parts in the order be...

  • Page 309: Chas

    8 - 19 chas front and rear brakes u ppe r r owe t r . . 23 nm (2.3 m • kg, 17 ft • ib) t r . . 30 nm (3.0 m • kg, 22 ft • ib) 8 9 11 12 7 10 1 2 3 4 5 6 new new order job name/part name q’ty remarks 7 union bolt 1 refer to “installing the rear brake master cylinder”. 8 copper washer 2 9 brake hose 1...

  • Page 310: Chas

    8 - 20 chas front and rear brakes order job name/part name q’ty remarks disassembling the rear brake mas- ter cylinder remove the parts in the order below. 1 brake master cylinder kit 1 refer to “assembling the rear brake master cylinder”. 2 brake master cylinder 1 for assembly, reverse the disassem...

  • Page 311: Chas

    8 - 21 chas front and rear brakes checking the master cylinder 1.Check: ● brake master cylinder 1 wear/scratches → replace the brake master cylinder assembly. ● brake master cylinder body cracks/damage → replace. ● brake fluid delivery passage (brake master cylinder body) blockage → blow out with co...

  • Page 312: Chas

    8 - 22 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. ● whenever a master cylinder is disassem- bled, replace the piston seals and dust seals. Recom...

  • Page 313: Chas

    8 - 23 chas front and rear brakes installing the front brake master cylinder 1.Install: ● brake master cylinder 1 note: the “up” mark on the brake master cylinder bracket should face up. T r . . 7 nm (0.7 m • kg, 5.1 ft • lb) 2.Install: ● copper washers ● brake hose ● union bolt note: ● tighten the ...

  • Page 314: Chas

    8 - 24 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” in chapter 3...

  • Page 315: Chas

    8 - 25 chas front and rear brakes 2.Fill: ● brake fluid reservoir caution: brake fluid may damage painted surfaces or plastic parts. Always clean up spilled brake fluid immediately. Warning ● use only the designated quality brake fluid: other brake fluids may deteriorate the rubber seals, causing le...

  • Page 316: Chas

    8 - 26 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 wheels”. 1 union bolt 1 refer to “installing the front brake caliper”. 2 copper washer 2 3 ...

  • Page 317: Chas

    8 - 27 chas front and rear brakes order job name/part name q’ty remarks disassembling the front brake cali- per remove the parts in the order below. 1 brake pad holding bolt 2 2 brake pad/pad shim 2/1 3 pad spring 1 4 retaining bolt 1 5 caliper bracket 1 6 brake caliper piston 1 refer to “disassembl...

  • Page 318: Chas

    8 - 28 chas front and rear brakes rear brake caliper t r . . 40 nm (4.0 m • kg, 29 ft • ib) t r . . 30 nm (3.0 m • kg, 22 ft • ib) 5 2 3 4 6 new 1 t r . . 30 nm (3.0 m • kg, 22 ft • ib) order job name/part name q’ty remarks removing the rear brake caliper remove the parts in the order below. Brake f...

  • Page 319: Chas

    8 - 29 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. 1 brake pad holding bolt plug 1 2 brake pad holding bolt 1 3 pad spring 1 4 brake pad/insulator/pad shim 2/2/2 5 brake caliper piston 4 refer to “disassem...

  • Page 320: Chas

    8 - 30 chas front and rear brakes disassembling the brake caliper 1.Remove: ● brake caliper piston ● dust seal 1 ● caliper piston seal 2 ***************************************************** removal steps: ● blow compressed air into the hose joint opening a to force out the caliper piston from the b...

  • Page 321: Chas

    8 - 31 chas eb702040 checking the front and rear brake caliper warning all internal brake components should be cleaned in new brake fluid only. Do not use solvents as they will cause seals to swell and distort. Recommended brake component replace- ment schedule: brake pads as required piston seal, d...

  • Page 322: Chas

    8 - 32 chas front and rear brakes assembling the front brake caliper warning ● all internal brake components should be cleaned and lubricated with new brake fluid only before installation. ● replace the caliper piston seal whenever a brake caliper is disassembled. 1.Install: ● caliper piston seal 1 ...

  • Page 323: Chas

    8 - 33 chas front and rear brakes warning proper brake hose routing is essential to insure safe motorcycle operation. Refer to “cable routing”. 2.Fill: ● brake reservoir caution: brake fluid may damage painted surfaces or plastic parts. Always clean up spilled brake fluid immediately. Warning ● use ...

  • Page 324: Chas

    8 - 34 chas assembling the rear brake caliper warning ● all internal brake components should be cleaned and lubricated with new brake fluid only before installation. ● replace the caliper piston seal whenever a brake caliper is disassembled. 1.Install: ● caliper piston seal 1 ● dust seal 2 recommend...

  • Page 325: Chas

    8 - 35 chas front and rear brakes installing the rear brake caliper 1.Install: ● brake caliper assembly ● brake caliper mounting bolt ● brake hose ● copper washers ● union bolt t r . . 30 nm (3.0 m • kg, 22 ft • lb) new t r . . 30 nm (3.0 m • kg, 22 ft • lb) 2.Fill: ● brake reservoir caution: brake ...

  • Page 326: Chas

    8 - 36 chas steering system steering system handlebar t r . . 20 nm (2.0 m • kg, 14 ft • ib) 6 7 8 9 2 10 10 7 4 1 2 5 4 11 9 3 5 order job name/part name q’ty remarks removing the handlebar remove the parts in the order below. 1 handlebar cover 1 2 band 4 3 on-command four-wheel drive switch and di...

  • Page 327: Chas

    8 - 37 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.Inspect: ● handlebar bends/cracks/damage → replace. Warning do not attempt to straighten...

  • Page 328: Chas

    8 - 38 chas steering system installing the master cylinder assembly 1.Install: ● throttle lever assembly ● master cylinder assembly note: the “up” mark on the master cylinder bracket should face up. T r . . 7 nm (0.7 m • kg, 5.1 ft • lb).

  • Page 329: Chas

    8 - 39 chas steering system steering stem t r . . 23 nm (2.3 m • kg, 17 ft • ib) t r . . 180 nm (18.0 m • kg, 130 ft • lb) t r . . 25 nm (2.5 m • kg, 18 ft • ib) 6 11 12 13 8 9 14 4 10 5 3 5 3 2 1 new new t r . . 65 nm (6.5 m • kg, 47 ft • ib) lt ls ls ls ls 7 order job name/part name q’ty remarks r...

  • Page 330: Chas

    8 - 40 chas steering system t r . . 23 nm (2.3 m • kg, 17 ft • ib) t r . . 180 nm (18.0 m • kg, 130 ft • lb) t r . . 25 nm (2.5 m • kg, 18 ft • ib) 6 11 12 13 8 9 14 4 10 5 3 5 3 2 1 new new t r . . 65 nm (6.5 m • kg, 47 ft • ib) lt ls ls ls ls 7 order job name/part name q’ty remarks 11 oil seal 1 1...

  • Page 331: Chas

    8 - 41 chas steering system removing the bearing retainer 1.Remove: ● bearing retainer (steering stem) damper rod holder (30 mm): p/n. Ym-01327, 90890-01327 checking the steering stem 1.Inspect: ● steering stem bends → replace. Warning do not attempt to straighten a bent stem; this may dangerously w...

  • Page 332: Chas

    8 - 42 chas steering system installing the cable guide 1.Install ● cable guide ● lock washer 2.Bend the lock washer tab along a flat side of the bolt. Note: pass the cables and hoses through the cable guide. Refer to “cable routing” in chap- ter 2. New t r . . 23 nm (2.3 m • kg, 17 ft • lb).

  • Page 333: Chas

    8 - 43 chas steering system tie rod and steering knuckle t r . . 25 nm (2.5 m • kg, 18 ft • ib) t r . . 25 nm (2.5 m • kg, 18 ft • ib) t r . . 25 nm (2.5 m • kg, 18 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 48 nm (4.8 m • kg, 35 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) 3 4 5 8 ...

  • Page 334: Chas

    8 - 44 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. Checking the tie rod 1.Check: ● tie rod free play and movement free play → replace the tie rod end. Turns roughly → replace the tie r...

  • Page 335: Chas

    8 - 45 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” of the oil ...

  • Page 336: Chas

    8 - 46 chas front arms and front shock absorber front arms and front shock absorber t r . . 45 nm (4.5 m • kg, 32 ft • ib) 8 10 1 6 5 7 3 7 2 8 11 8 9 8 new t r . . 48 nm (4.8 m • kg, 35 ft • ib) t r . . 45 nm (4.5 m • kg, 32 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 25 nm (2.5 m • kg,...

  • Page 337: Chas

    8 - 47 chas front arms and front shock absorber t r . . 45 nm (4.5 m • kg, 32 ft • ib) 8 10 1 6 5 7 3 7 2 8 11 8 9 8 new t r . . 48 nm (4.8 m • kg, 35 ft • ib) t r . . 45 nm (4.5 m • kg, 32 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 25 nm (2.5 m • kg, 18 ft • ib) ls 4 new 10 6 ls 10 10 ...

  • Page 338: Chas

    8 - 48 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 f...

  • Page 339: Chas

    8 - 49 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 arm (upper) 1 and front arm (lower) 2. Note: ● lubricate the...

  • Page 340: Chas

    8 - 50 chas rear knuckle and stabilizer rear knuckle and stabilizer t r . . 30 nm (3.0 m • kg, 22 ft • ib) t r . . 48 nm (4.8 m • kg, 35 ft • ib) t r . . 48 nm (4.8 m • kg, 35 ft • ib) t r . . 45 nm (4.5 m • kg, 32 ft • ib) 8 9 6 7 8 9 10 6 4 4 2 3 5 4 4 5 1 ls ls order job name/part name q’ty remar...

  • Page 341: Chas

    8 - 51 chas rear knuckle and stabilizer checking the rear knuckle 1.Check: ● rear knuckle damage/pitting → replace. 2.Check: ● rear wheel bearings bearings allow play in the wheel hubs or the wheel turns roughly → replace. ● oil seals damage → replace. ***********************************************...

  • Page 342: Chas

    8 - 52 chas rear arms and rear shock absorber 1 3 1 5 5 2 2 4 3 6 3 6 5 1 1 5 t r . . 45 nm (4.5 m • kg, 32 ft • ib) t r . . 45 nm (4.5 m • kg, 32 ft • ib) t r . . 45 nm (4.5 m • kg, 32 ft • ib) t r . . 45 nm (4.5 m • kg, 32 ft • ib) order job name/part name q’ty remarks removing the rear arms and r...

  • Page 343: Chas

    8 - 53 chas checking the rear arm 1.Check: ● rear arms 1 bends/damage → replace. 2.Check: ● bushings 2 wear/damage → replace. Checking the rear shock absorber 1.Check: ● shock absorber rod bends/damage → replace the shock absorber assembly. ● shock absorber assembly oil leaks → replace the shock abs...

  • Page 344: Chas

    8 - 54 chas ● install the rear shock absorber 5. ● install the rear knuckle. ● tighten the nuts 4. Note: before tightening the nuts 4, adjust the length a to 334 mm (13.1 in). ***************************************************** t r . . Nut 6: 45 nm (4.5 m • kg, 32 ft • lb) t r . . Nut 7: 45 nm (4....

  • Page 345: Elec

    9 - 1 – + elec electrical components eb800000 electrical electrical components 1 main switch 2 diode 3 thermo switch 1 4 front brake light switch 5 rear brake switch 6 fuel sender 7 battery 8 circuit breaker (fan) 9 fuse box 0 four-wheel drive relay 3 a four-wheel drive relay 2 b four-wheel drive re...

  • Page 346: Elec

    9 - 2 – + 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. Note: ● set the pocket tester to “0” before starting the test. ● the pocket tester should be set to the ...

  • Page 347: Elec

    9 - 3 – + elec checking the switch.

  • Page 348: Elec

    9 - 4 – + 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. L b y g br l/b (black) 1 4 5 b 6 2 3 r/b r/w push br l y g b r/w...

  • Page 349: Elec

    9 - 5 – + 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 horn switch (for europe and oceania) 0 gear position s...

  • Page 350: Elec

    9 - 6 – + 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 con- tinuity between the terminals. Damage/wear → repair or replace the bulb, bulb socket or both. Improperly connected...

  • Page 351: Elec

    9 - 7 – + 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. Never pull the lead, otherwise it may be pu...

  • Page 352: Elec

    9 - 8 – + elec checking the condition of the bulb sockets the following procedure applies to all of the bulb sockets. 1.Check: ● bulb socket (for continuity) (with the pocket tester) no continuity → replace. Note: check each bulb socket for continuity in the same manner as described in the bulb sect...

  • Page 353: Elec

    9 - 9 – + elec ignition system eb802000 ignition system circuit diagram 2wd 4wd lock on off b b r l/ wl /b r /b l/ w w /r b /y r o w /g b sb g /w w /b g /r (black) (black) (black) (black) (gray) (gray) (black) (black) (black) r w /g w /lw /r w /g r w /rw /g l/ g l/ b l/ r sb r /y l/ b l b y g l/ g l...

  • Page 354: Elec

    9 - 10 – + elec ignition system eb802010 troubleshooting procedure check: 1.Fuse (main, ignition) 2.Battery 3.Spark plug 4.Ignition spark gap 5.Spark plug cap resistance 6.Ignition coil resistance if the ignition system fails to operate (no spark or intermittent spark): 7.Engine stop switch 8.Main s...

  • Page 355: Elec

    9 - 11 – + elec ignition system correct spark plug gap: 0.8 ~ 0.9 mm (0.03 ~ 0.04 in) incorrect repair or replace the spark plug. Out of specification or no spark 4.Ignition spark gap ● disconnect the spark plug cap from the spark plug. ● connect the dynamic spark tester 1 as shown. 2 spark plug cap...

  • Page 356: Elec

    9 - 12 – + 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 h...

  • Page 357: Elec

    9 - 13 – + elec ignition system c0ntinuity correct 8.Main switch refer to “checking the switch”. * incorrect replace the main switch. 9.Pickup coil resistance ● disconnect the ac magneto coupler from the wire harness. ● connect the pocket tester ( Ω × 100) to the pickup coil terminal. Tester (+) lea...

  • Page 358: Elec

    9 - 14 – + elec ignition system c0ntinuity correct 11.Wiring connection ● check the connections of the entire ignition system. Refer to “circuit diagram”. Replace the cdi unit. * poor connection properly connect the ignition system..

  • Page 359: Elec

    9 - 15 – + elec electric starting system eb803000 electric starting system circuit diagram 2wd 4wd lock on off b b r l/ wl /b r /b l/ w w /r b /y r o w /g b sb g /w w /b g /r (black) (black) (black) (black) (gray) (gray) (black) (black) (black) r w /g w /lw /r w /g r w /rw /g l/ g l/ b l/ r sb r /y ...

  • Page 360: Elec

    9 - 16 – + elec electric starting system starting circuit operation the starting circuit on this model consists of the starter motor, starter relay, rear brake switch, rear brake switch cdi unit and gear position switch. If the main switch is on and the engine stop switch is in the run position, the...

  • Page 361: Elec

    9 - 17 – + elec electric starting system eb803020 troubleshooting procedure check: 1.Fuse (main, ignition) 2.Battery 3.Starter motor 4.Starter relay 5.Main switch 6.Engine stop switch 7.Gear position switch if the starter motor fails to operate: 8.Rear brake switch 9.Start switch 10.Diode 11.Wiring ...

  • Page 362: Elec

    9 - 18 – + elec electric starting system c0ntinuity turns 3.Starter motor ● connect the battery positive terminal 1 and starter motor cable 2 using a jumper lead 3 . ● check the operation of the starter motor. * * warning ● a wire that is used as a jumper lead must have the equivalent capacity or mo...

  • Page 363: Elec

    9 - 19 – + elec electric starting system c0ntinuity correct 5.Main switch refer to “checking the switch”. * incorrect replace the main switch. Correct 6.Engine stop switch refer to “checking the switch”. Incorrect replace the handlebar switch (right). Correct 7.Gear position switch refer to “checkin...

  • Page 364: Elec

    9 - 20 – + elec electric starting system c0ntinuity correct 9.Start switch refer to “checking the switch”. * incorrect replace the handlebar switch (left). Correct 10.Diode ● remove the diode from the coupler. ● connect the pocket tester ( Ω × 1) to the diode terminals as shown. ● check the diode fo...

  • Page 365: Elec

    9 - 21 – + 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. 1 starter motor lead 1 2 starter motor/o-ring 1/1 disassembling the starter motor remove the parts in the order below. 1 bracket 1 1 refer to “...

  • Page 366: Elec

    9 - 22 – + elec electric starting system checking the starter motor 1.Inspect: ● commutator dirty → clean it with #600 grit sandpaper. 2.Measure: ● commutator diameter a out of specification → replace the starter motor. 3.Measure: ● mica undercut b out of specification → scrape the mica using a hack...

  • Page 367: Elec

    9 - 23 – + elec electric starting system 5.Measure: ● brush length a (each) out of specification → replace the brush. Brush length: 12.5 mm (0.49 in) 5 mm (0.20 in) 6.Measure: ● brush spring force fatigue/out of specification → replace as a set. Brush spring force: 7.65 ~ 10.01 nm (780 ~ 1,020 g, 27...

  • Page 368: Elec

    9 - 24 – + elec charging system eb804000 charging system circuit diagram 2wd 4wd lock on off b b r l/ wl /b r /b l/ w w /r b /y r o w /g b sb g /w w /b g /r (black) (black) (black) (black) (gray) (gray) (black) (black) (black) r w /g w /lw /r w /g r w /rw /g l/ g l/ b l/ r sb r /y l/ b l b y g l/ g ...

  • Page 369: Elec

    9 - 25 – + elec charging system eb804010 troubleshooting procedure check: 1.Fuse (main) 2.Battery 3.Charging voltage if the battery is not charged: 4.Charging coil resistance 5.Wiring connections (the entire charging system) note: ● remove the following part(s) before trouble- shooting: 1)seat 2)fue...

  • Page 370: Elec

    9 - 26 – + elec charging system out of specification ● start the engine and accelerate to about 3,000 r/min. Charging voltage: 14 v at 1,000 r/min note: use a fully charged battery. Meets specification the charging circuit is not faulty. Eb804012 meets specification 4.Charging coil resistance ● disc...

  • Page 371: Elec

    9 - 27 – + elec lighting system eb805000 lighting system circuit diagram 2wd 4wd lock on off b b r l/ wl /b r /b l/ w w /r b /y r o w /g b sb g /w w /b g /r (black) (black) (black) (black) (gray) (gray) (black) (black) (black) r w /g w /lw /r w /g r w /rw /g l/ g l/ b l/ r sb r /y l/ b l b y g l/ g ...

  • Page 372: Elec

    9 - 28 – + elec lighting system eb805010 troubleshooting procedure check: 1.Fuse (main, headlight) 2.Battery 3.Main switch if the headlight and/or taillight fail to come on: 4.Light switch 5.Wiring connections (the entire lighting system) note: ● remove the following part(s) before trouble- shooting...

  • Page 373: Elec

    9 - 29 – + elec lighting system c0ntinuity correct 3.Main switch refer to “checking the switch”. * incorrect replace the main switch. Correct 4.Light switch refer to “checking the switch”. Incorrect light switch is faulty, replace the handlebar switch (left). Eb805013 correct 5.Wiring connection ● c...

  • Page 374: Elec

    9 - 30 – + elec lighting system eb805020 checking the lighting system 1.If the headlights fail to come on: continuity 1.Bulb and bulb socket ● check the bulb and bulb socket for continu- ity. No continuity replace the bulb and/or bulb socket. 2.Voltage ● connect the pocket tester (dc 20 v) to the he...

  • Page 375: Elec

    9 - 31 – + elec lighting system eb805021 2.If the taillight fails to come on: continuity 1.Bulb and bulb socket ● check the bulb and bulb socket for continu- ity. No continuity replace the bulb and/or bulb socket. 2.Voltage ● connect the pocket tester (20 v) to the bulb socket coupler. Tester (+) le...

  • Page 376: Elec

    9 - 32 – + elec signal system eb806000 signal system circuit diagram 2wd 4wd lock on off b b r l/ wl /b r /b l/ w w /r b /y r o w /g b sb g /w w /b g /r (black) (black) (black) (black) (gray) (gray) (black) (black) (black) r w /g w /lw /r w /g r w /rw /g l/ g l/ b l/ r sb r /y l/ b l b y g l/ g l/ b...

  • Page 377: Elec

    9 - 33 – + elec signal system 3 main switch 5 battery 6 main fuse 9 reverse switch 0 cdi unit f multi-function meter g differential gear lock indicator light h coolant temperature indicator light i reverse indicator light j neutral indicator light k park indicator light l high-range indicator light ...

  • Page 378: Elec

    9 - 34 – + elec signal system eb806010 troubleshooting procedure check: 1.Fuse (main, ignition, signaling system) 2.Battery 3.Main switch 4.Wiring connections (the entire signal system) if the brake light and/or indicator light fails to come on: if the horn fails to sound: note: ● remove the followi...

  • Page 379: Elec

    9 - 35 – + elec signal system c0ntinuity correct 3.Main switch refer to “checking the switch”. * incorrect replace the main switch. Eb806011 correct 4.Wiring connections ● check the connections of the entire signal system. Refer to “circuit diagram”. Check the condition of each of the signal sys- te...

  • Page 380: Elec

    9 - 36 – + elec signal system checking the signal system 1.If the brake light fails to come on: continuity 1.Bulb and bulb socket ● check the bulb and bulb socket for continu- ity. No continuity replace the bulb and/or bulb socket. Continuity 2.Brake light switches refer to “checking the switch”. No...

  • Page 381: Elec

    9 - 37 – + elec signal system eb806024 2.If the neutral indicator light fails to come on: continuity 1.Neutral indicator light led ● check the led of the neutral indicator light. Refer to “checking the leds”. No continuity replace the meter assembly. Continuity 2.Gear position switch refer to “check...

  • Page 382: Elec

    9 - 38 – + elec signal system 3.If the park indicator light fails to come on: continuity 1.Park indicator light led ● check the led of the park indicator light. Refer to “checking the leds”. No continuity replace the meter assembly. Continuity 2.Gear position switch refer to “checking the switch”. N...

  • Page 383: Elec

    9 - 39 – + elec signal system 4.If the high-range indicator light fails to come on: continuity 1.High-range indicator light led ● check the led of the high-range indicator light. Refer to “checking the leds”. No continuity replace the meter assembly. Continuity 2.Gear position switch refer to “check...

  • Page 384: Elec

    9 - 40 – + elec signal system 5.If the low-range indicator light fails to come on: continuity 1.Low-range indicator light led ● check the led of the low-range indicator light. Refer to “checking the leds”. No continuity replace the meter assembly. Continuity 2.Gear position switch refer to “checking...

  • Page 385: Elec

    9 - 41 – + elec signal system 6.If the reverse indicator light fails to come on: continuity 1.Reverse indicator light led ● check the led of the reverse indicator light. Refer to “checking the leds”. No continuity replace the meter assembly. Continuity 2.Reverse switch refer to “checking the switch”...

  • Page 386: Elec

    9 - 42 – + elec signal system 7.If the coolant temperature indicator light does not come on when the main switch to “on”, or if the coolant temperature indicator light does not come on when the temperature is high (more than 107 ~ 113 °c (224.6 ~ 235.4 °f)): continuity 1.Coolant temperature indicato...

  • Page 387: Elec

    9 - 43 – + elec signal system c0ntinuity 3.Voltage ● connect the pocket tester (dc 20 v) to the bulb socket connector. Tester (+) lead → white/blue terminal 1 tester (–) lead → frame ground * meets specification ● turn the main switch to “on”. ● check the voltage (12 v). Out of specification the wir...

  • Page 388: Elec

    9 - 44 – + elec signal system 8.If the differential gear lock indicator light led fails to come on: continuity 1.Differential gear lock indicator light ● check the led of the differential gear lock indicator light. Refer to “checking the leds”. No continuity replace the meter assembly. Continuity 2....

  • Page 389: Elec

    9 - 45 – + elec signal system 9.Horn does not sound. (for europe and oce- ania) correct 1.Horn switch refer to “checking the switch”. Incorrect replace horn switch. 2.Voltage ● connect the pocket tester (dc 20 v) to the horn connector at the horn terminal. Tester (+) lead → pink lead 1 tester (–) le...

  • Page 390: Elec

    9 - 46 – + elec signal system 4.Voltage ● connect the pocket tester (dc 20 v) to the horn connector at the horn terminal. Tester (+) lead → black lead 1 tester (–) lead → frame ground * meets specification ● turn the main switch to “on”. ● push the horn switch. ● check for voltage (12 v) on the “bla...

  • Page 391: Elec

    9 - 47 – + elec cooling system cooling system circuit diagram 2wd 4wd lock on off b b r l/ wl /b r /b l/ w w /r b /y r o w /g b sb g /w w /b g /r (black) (black) (black) (black) (gray) (gray) (black) (black) (black) r w /g w /lw /r w /g r w /rw /g l/ g l/ b l/ r sb r /y l/ b l b y g l/ g l/ b l/ r s...

  • Page 392: Elec

    9 - 48 – + elec cooling system troubleshooting procedure check: 1.Fuse (main) 2.Battery 3.Main switch 4.Fan motor 5.Circuit breaker (fan motor) if the fan motor does not move: 6.Thermo switch 2 7.Wiring connection (the entire cooling system) note: ● remove the following part(s) before trouble- shoot...

  • Page 393: Elec

    9 - 49 – + elec cooling system c0ntinuity turns 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 ● check the operation of the fan motor. * does not turn replace the fan motor. Meets specifica...

  • Page 394: Elec

    9 - 50 – + elec cooling system c0ntinuity good condition 6.Thermo switch 2 ● remove the thermo switch 2 from the radiator. ● connect the pocket tester ( Ω × 10) to the thermo switch 2 1. ● immerse the thermo switch 2 in coolant 2. ● check the thermo switch 2 for continuity. While heating the coolant...

  • Page 395: Elec

    9 - 51 – + elec cooling system c0ntinuity eb803028 correct 7.Wiring connection ● check the connections of the entire starting system. Refer to “circuit diagram”. This circuit is not faulty. * poor connection properly connect the cooling system..

  • Page 396: Elec

    9 - 52 – + elec 2wd/4wd selecting system 2wd/4wd selecting system circuit diagram 2wd 4wd lock on off b b r l/ wl /b r /b l/ w w /r b /y r o w /g b sb g /w w /b g /r (black) (black) (black) (black) (gray) (gray) (black) (black) (black) r w /g w /lw /r w /g r w /rw /g l/ g l/ b l/ r sb r /y l/ b l b ...

  • Page 397: Elec

    9 - 53 – + elec 2wd/4wd selecting system eb803020 troubleshooting procedure check: 1.Fuse (main, four-wheel drive) 2.Battery 3.Main switch 4.Four-wheel drive relay 1 5.Four-wheel drive relay 2 6.Four-wheel drive relay 3 if the four-wheel drive indicator fails to come on: 7.On-command four-wheel driv...

  • Page 398: Elec

    9 - 54 – + elec 2wd/4wd selecting system c0ntinuity continuity 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 teste...

  • Page 399: Elec

    9 - 55 – + elec 2wd/4wd selecting system c0ntinuity continuity 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 ...

  • Page 400: Elec

    9 - 56 – + elec 2wd/4wd selecting system c0ntinuity correct 8.Gear motor ● disconnect the gear motor coupler. ● remove the gear motor from the differen- tial gear case. Refer to “front constant velocity joints and differential gear” in chapter 7. ● connect two c size batteries to the gear motor term...

  • Page 401: Trbl

    10 - 1 trbl shtg starting failure/hard starting troubleshooting note: the following troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to troubleshooting. Refer to the relative procedure in this manual for inspection, adjustment and replaceme...

  • Page 402: Trbl

    10 - 2 trbl shtg starting failure/hard starting/poor idle speed performance/poor medium and high-speed performance compression system cylinder and cylinder head ● loose spark plug ● loose cylinder head or cylinder ● broken cylinder head gasket ● broken cylinder gasket ● worn, damaged or seized cylin...

  • Page 403: Trbl

    10 - 3 trbl shtg faulty drive train faulty drive train the following conditions may indicate damaged shaft drive components: note: areas a, b, and c above may be extremely difficult to diagnose. The symptoms are quite subtle and difficult to distinguish from normal machine operating noise. If there ...

  • Page 404: Trbl

    10 - 4 trbl shtg faulty gear shifting/ faulty clutch performance faulty gear shifting hard shifting refer to “clutch slipping/dragging-clutch dragging”. Shift lever does not move shift shaft ● bent shift shaft shift cam, shift fork ● groove jammed with impurities ● seized shift fork ● bent shift for...

  • Page 405: Trbl

    10 - 5 trbl shtg faulty clutch performance/ overheating/faulty brake poor speed performance v-belt ● oil or grease on the v-belt primary pulley weight ● faulty operation ● worn primary pulley weight primary fixed sheave ● worn primary fixed sheave primary sliding sheave ● worn primary sliding sheave...

  • Page 406: Trbl

    10 - 6 trbl shtg shock absorber malfunction malfunction ● bent or damaged damper rod ● damaged oil seal lip ● fatigued shock absorber spring shock absorber malfunction/unstable handling/lighting system unstable handling unstable handling handlebar ● improperly installed or bent steering ● incorrect ...

  • Page 407

    Yamaha motor co., ltd. 2500 shingai iwata shizuoka japan printed in u.S.A..

  • Page 408

    Yfm660fp wiring diagram 2wd 4wd lock on off b b r l/ wl /b r /b l/ w w /r b /y r o w /g b sb g /w w /b g /r (black) (black) (black) (black) (gray) (gray) (black) (black) (black) r w /g w /lw /r w /g r w /rw /g l/ g l/ b l/ r sb r /y l/ b l b y g l/ g l/ b l/ r sb l b y g br l/ b gy br g /r b gy br g...