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Yamaha YFM400FAR Service Manual

Other manuals for YFM400FAR: Owner's Manual, Assembly Manual

Summary of YFM400FAR

  • Page 1

    Lit-11616-16-02 5te-f8197-10 yfm400far service manual.

  • Page 2

    Yfm400far service manual ©2002 by yamaha motor corporation, u.S.A. First edition, april 2002 all rights reserved. Any reproduction or unauthorized use without the written permission of yamaha motor corporation, u.S.A. Is expressly prohibited. Printed in u.S.A. Lit-11616-16-02.

  • 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 6: 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 7: Contents

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

  • Page 8: Chapter 3.

    Chapter 3. Periodic checks and adjustments introduction ........................................................................................... 3-1 periodic maintenance/lubrication ................................................ 3-1 seat, carriers, fenders and fuel tank ...........................

  • Page 9: Chapter 4.

    Checking the constant velocity joint dust boots ...... 3-46 checking the steering system .............................................. 3-47 adjusting the toe-in ................................................................... 3-47 adjusting the front shock absorbers ................................

  • Page 10

    Cylinder and piston ........................................................................... 4-27 removing the piston .................................................................. 4-28 checking the timing chain guide ........................................... 4-28 checking the cylinder and ...

  • Page 11: Chapter 5.

    Crankshaft and oil pump ................................................................ 4-65 oil pump ........................................................................................... 4-66 removing the crankshaft ....................................................... 4-67 checking the oi...

  • Page 12: Chapter 6.

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

  • Page 13: Chapter 8.

    Chapter 8. Chassis front and rear wheels ...................................................................... 8-1 front wheels .................................................................................. 8-1 rear wheels ...........................................................................

  • Page 14: Chapter 9.

    Front arms and front shock absorbers ................................ 8-40 removing the front arms ........................................................ 8-42 checking the front arms ......................................................... 8-42 checking the front shock absorber .....................

  • Page 15: Chapter 10.

    Lighting system .................................................................................... 9-25 circuit diagram ............................................................................ 9-25 troubleshooting ........................................................................ 9-26 ch...

  • Page 16

    Overheating .......................................................................................... 10-5 overheating .................................................................................. 10-5 faulty brake ..................................................................................

  • Page 17: 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 18: Gen

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

  • Page 19: Gen

    1 - 3 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 tha...

  • Page 20: Gen

    1 - 4 gen info checking of connections eb801000 checking of connections check the connectors for stains, rust, moisture, etc. 1.Disconnect: ● connector 2.Check: ● connector moisture → dry each terminal with an air blower. Stains/rust → connect and disconnect the terminals several times. 3.Check: ● c...

  • Page 21: Gen

    Gen info 1 - 5 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 dif...

  • Page 22: Gen

    Gen info 1 - 6 special tools yu-90050 crankshaft installer set these tools are used to install the crankshaft. Adapter ym-33279 spacer 90890-04060 ym-90070-a adapter #11 spacer (crankshaft) these tools are used to install the crankshaft. 90890-01304 yu-01304 piston pin puller set this tool is used t...

  • Page 23: Gen

    Gen info 1 - 7 special tools 90890-04135 ym-04135 sheave fixed block this tool is needed when removing or installing the secondary sheave spring. 90890-01404 ym-01404 flywheel puller these tools are needed to remove the rotor. 90890-01327 ym-01327 damper rod holder (30 mm) this tool is needed to loo...

  • Page 24: Gen

    Gen info 1 - 8 special tools compression gauge 90890-03081 yu-33223 adapter 90890-04082 yu-33223-3 compression gauge adapter these tools are needed to measure engine compression. 90890-03112 yu-03112-c pocket tester this instrument is needed for checking the electrical system. 90890-03113 engine tac...

  • Page 25: Gen

    Gen info 1 - 9 special tools 90890-04086 ym-91042 clutch holding tool this tool is needed to hold the clutch carrier when removing or installing the carrier nut. 90890-04128 ym-04128 bearing retainer wrench this tool is needed when removing or installing the middle driven pinion gear bearing retaine...

  • Page 26: Spec

    2 - 1 spec specifications general specifications item standard model code: 5te1, 5te5 dimensions: overall length 1,984 mm (78.1 in) overall width 1,085 mm (42.7 in) overall height 1,120 mm (44.1 in) seat height 827 mm (32.6 in) wheelbase 1,233 mm (48.5 in) minimum ground clearance 245 mm (9.7 in) mi...

  • Page 27: Spec

    2 - 2 spec differential gear case oil periodic oil change 0.35 l (0.31 imp qt, 0.37 us qt) total amount 0.40 l (0.35 imp qt, 0.42 us qt) radiator capacity (including all routes) 1.32 l (1.16 imp qt, 1.40 us qt) air filter: wet type element fuel: type unleaded fuel fuel tank capacity 15 l (3.3 imp ga...

  • Page 28: Spec

    2 - 3 spec tire pressure (cold tire): maximum load* 210 kg (463 lb) off-road riding front 22 ~ 28 kpa (0.22 ~ 0.28 kg/cm 2 , 3.2 ~ 4.0 psi) rear 22 ~ 28 kpa (0.22 ~ 0.28 kg/cm 2 , 3.2 ~ 4.0 psi) *load in total weight of rider accessories brakes: front brake type dual disc brake operation right hand ...

  • Page 29: Spec

    2 - 4 spec maintenance specifications engine item standard limit cylinder head: warp limit ---- 0.03 mm (0.0012 in) cylinder: bore size 84.500 ~ 84.510 mm (3.3268 ~ 3.3272 in) 84.600 mm (3.3307 in) taper limit ---- 0.05 mm (0.0016 in) out of round limit ---- 0.01 mm (0.0004 in) camshaft: drive metho...

  • Page 30: Spec

    2 - 5 spec cam chain: cam chain type/no. Of links did scr-0409 sdh/116 ---- cam chain adjustment method automatic ---- rocker arm/rocker arm shaft: bearing inside diameter 12.000 ~ 12.018 mm (0.4724 ~ 0.4731 in) 12.078 mm (0.4755 in) shaft outside diameter 11.981 ~ 11.991 mm (0.4717 ~ 0.4721 in) 11....

  • Page 31: Spec

    2 - 6 spec stem runout limit ---- 0.01 mm (0.0004 in) valve seat width in 1.2 ~ 1.4 mm (0.0472 ~ 0.0551 in) ---- ex 1.2 ~ 1.4 mm (0.0472 ~ 0.0551 in) ---- valve spring: inner spring free length in 39.9 mm (1.57 in) 37.9 mm (1.49 in) ex 39.9 mm (1.57 in) 37.9 mm (1.49 in) set length (valve closed) in...

  • Page 32: Spec

    2 - 7 spec tilt limit in 2.5°/1.6 mm (2.5°/0.06 in) ex 2.5°/1.6 mm (2.5°/0.06 in) direction of winding (top view) in clockwise ---- ex clockwise ---- piston: piston to cylinder clearance 0.040 ~ 0.065 mm (0.0016 ~ 0.0026 in) 0.150 mm (0.0059 in) piston size “d” 84.445 ~ 84.460 mm (3.3246 ~ 3.3252 in...

  • Page 33: Spec

    2 - 8 spec 2nd ring type taper ---- dimensions (b × t) 1.2 × 3.6 mm (0.04724 × 0.1417 in) ---- end gap (installed) 0.40 ~ 0.60 mm (0.0157 ~ 0.0236 in) 0.95 mm (0.0374 in) side clearance 0.03 ~ 0.07 mm (0.0012 ~ 0.0028 in) 0.13 mm (0.0051 in) oil ring dimensions (b × t) 2.8 × 2.8 mm (0.1102 × 0.1102 ...

  • Page 34: Spec

    2 - 9 spec 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 5te1 00 ---- main jet (m.J) #132.5 ---- main air jet (m.A....

  • Page 35: Spec

    2 - 10 spec cooling system: radiator core width 300 mm (11.8 in) ---- height 208 mm (8.19 in) ---- thickness 26 mm (1.02 in) ---- radiator cap opening pressure 93.7 ~ 122.6 kpa (0.937 ~ 1.226 kg/cm 2 , 13.32 ~ 17.43 psi) ---- radiator capacity 0.70 l (0.62 imp qt, 0.74 us qt) ---- coolant reservoir ...

  • Page 36: Spec

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

  • Page 37: Spec

    2 - 12 spec tightening torques part to be tightened part name thread size q’ty tightening torque remarks nm m·kg ft·lb cylinder head oil passage union bolt m6 1 7 0.7 5.1 cylinder head (exhaust pipe) stud bolt m8 2 15 1.5 11 cylinder head bolt m10 4 40 4.0 29 bolt m6 2 10 1.0 7.2 camshaft sprocket c...

  • Page 38: Spec

    2 - 13 spec middle driven shaft drive pinion gear nut m22 1 130 13 94 stake middle drive shaft bearing housing bolt m8 6 32 3.2 23 middle driven gear bearing retainer nut m65 1 110 11 80 lt left-hand threads yoke (middle driven gear) nut m14 1 97 9.7 70 lt middle driven gear bearing housing bolt m8 ...

  • Page 39: Spec

    2 - 14 spec chassis item standard limit steering system: steering bearing type ball and race bearing ---- front suspension: shock absorber travel 99 mm (3.90 in) ---- fork spring free length 265 mm (10.43 in) ---- spring fitting length 215.8 mm (8.50 in) ---- spring rate (k1) 15 n/mm (1.53 kg/mm, 85...

  • Page 40: Spec

    2 - 15 spec front disc brake: type dual ---- disc outside diameter × thickness 200.0 × 3.5 mm (7.87 ~ 0.14 in) ---- pad thickness inner 4.5 mm (0.18 in) 1 mm (0.04 in) pad thickness outer 4.5 mm (0.18 in) 1 mm (0.04 in) master cylinder inside diameter 14 mm (0.55 in) ---- caliper cylinder inside dia...

  • Page 41: Spec

    2 - 16 spec tightening torques part to be tightened thread size tightening torque remarks nm m·kg ft·lb engine bracket (front-upper) and frame m8 33 3.3 24 engine bracket (front-lower) and frame m8 33 3.3 24 engine bracket (front-upper) and engine m10 42 4.2 30 engine bracket (front-lower) and engin...

  • Page 42: Spec

    2 - 17 spec front bumper and frame m8 33 3.3 24 front carrier and frame m8 33 3.3 24 front carrier and front bumper m8 33 3.3 24 rear carrier and frame m8 33 3.3 24 differential gear case filler bolt m14 23 2.3 17 differential gear case drain bolt m10 10 1.0 7 differential gear case and bearing hous...

  • Page 43: Spec

    2 - 18 spec electrical item standard limit voltage: 12 v ---- ignition system: ignition timing (b.T.D.C.) 10°/ 1,500 r/min ---- c.D.I.: magneto model/manufacturer f4t46472/mitsubishi ---- pickup coil resistance/color 459 ~ 561 Ω at 20 °c (68 °f)/ white/red – white/green ---- rotor rotation direction...

  • Page 44: Spec

    2 - 19 spec brush overall length 12.5 mm (0.49 in) 5 mm (0.20 in) spring force 7.65 ~ 10.01 n (780 ~ 1,020 g, 27.54 ~ 36.03 oz) ---- commutator diameter 28 mm (1.10 in) 27 mm (1.06 in) mica undercut 0.7 mm (0.03 in) ---- starter relay model/manufacturer ms5f-561/jideco ---- amperage rating 180 a ---...

  • Page 45: 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 fastene...

  • Page 46: Spec

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

  • Page 47: Spec

    2 - 22 spec coolant flow diagrams 1 radiator 2 thermo switch (radiator) 3 fan motor È to coolant reservoir coolant flow diagrams.

  • Page 48: Spec

    2 - 23 spec 1 radiator 2 thermostat È to coolant reservoir coolant flow diagrams.

  • Page 49: Spec

    2 - 24 spec oil flow diagrams 1 camshaft 2 crankshaft 3 drive axle oil flow diagrams.

  • Page 50: Spec

    2 - 25 spec 1 oil filter oil flow diagrams.

  • Page 51: Spec

    2 - 26 spec 1 oil pump 2 oil strainer oil flow diagrams.

  • Page 52: Spec

    2 - 27 spec cable routing 1 rear brake switch lead 2 starter cable 3 rear brake cable 4 front brake hose 5 on-command four-wheel drive switch 6 throttle cable 7 handlebar switch 8 handlebar switch lead 9 main switch lead 0 fan motor breather hose a differential gear case breather hose b sub-wire har...

  • Page 53: Spec

    2 - 28 spec È fasten the on-command four-wheel drive switch lead behind the handlebar with a plastic band. É fasten the starter cable, handlebar switch lead and rear brake switch lead behind the handlebar with a plastic band. Ê fasten the handlebar switch lead and rear brake switch lead behind the h...

  • Page 54: Spec

    2 - 29 spec 1 sub-wire harness 2 headlight lead 3 auxiliary dc jack lead 4 meter assembly coupler 5 differential gear case breather hose 6 coolant reservoir breather hose 7 fan motor breather hose cable routing.

  • Page 55: Spec

    2 - 30 spec 1 starter cable 2 cylinder head breather hose 3 fuel hose 4 carburetor drain hose 5 rear brake lever cable 6 coolant reservoir breather hose 7 radiator outlet hose 8 coolant reservoir hose 9 sub-wire harness 0 differential gear case breather hose a thermo switch (radiator) b speedometer ...

  • Page 56: Spec

    2 - 31 spec 1 cylinder head breather hose 2 final drive gear case breather hose 3 rear brake breather hose 4 wire harness 5 starter motor lead 6 negative battery lead 7 rear brake lever cable 8 air filter case check hose 9 water pump breather hose 0 radiator outlet hose a starter cable b float chamb...

  • Page 57: Spec

    2 - 32 spec È fasten the wire harness with a plastic band. É fasten the starter motor lead, wire harness, negative battery lead, final drive gear case breather hose, rear brake breather hose, rectifier/regulator lead, gear position switch lead and a.C. Magneto lead with a plastic band. Ê fasten the ...

  • Page 58: Spec

    2 - 33 spec 1 throttle cable 2 radiator inlet hose 3 spark plug lead 4 main switch 5 wire harness 6 rear brake light switch lead 7 select lever control cable 8 rear brake pedal cable È fasten the radiator inlet hose and spark plug lead with a plastic band. Cable routing.

  • Page 59: Spec

    2 - 34 spec 1 front brake hose 2 float chamber air vent hose 3 throttle cable 4 wire harness 5 final drive gear case breather hose 6 rear brake breather hose 7 starter cable 8 rear brake lever cable cable routing.

  • Page 60: Spec

    2 - 35 spec 1 battery 2 negative battery lead 3 tail/brake light lead 4 cdi unit 5 positive battery lead cable routing.

  • Page 61: Spec

    2 - 36 spec 1 rear brake pedal cable 2 final drive gear case breather hose 3 rear brake breather hose 4 rear brake lever cable 5 air filter case check hose cable routing.

  • Page 62: Chk

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

  • Page 63: Chk

    3 - 2 chk adj periodic maintenance/lubrication * it is recommended that these items be serviced by a yamaha dealer. Note: ● recommended brake fluid: dot 4 ● brake fluid replacement: 1.When disassembling the master cylinder or caliper, replace the brake fluid. Normally check the brake fluid level and...

  • Page 64: Chk

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

  • Page 65: Chk

    3 - 4 chk adj seat, carriers, fenders and fuel tank front carrier, front bumper and front fender order job name/part name q’ty remarks removing the front carrier, front bumper and front fender remove the parts in the order below. Seat and fuel tank side panels refer to “seat and side panels”. 1 fron...

  • Page 66: Chk

    3 - 5 chk adj seat, carriers, fenders and fuel tank order job name/part name q’ty remarks 11 auxiliary dc jack connector 2 disconnect. 12 meter assembly coupler 3 disconnect. 13 speedometer cable 1 disconnect. 14 coolant reservoir breather hose 1 15 fan motor breather hose 1 16 differential gear cas...

  • Page 67: Chk

    3 - 6 chk adj seat, carriers, fenders and fuel tank rear carrier and rear fender order job name/part name q’ty remarks removing the rear carrier and rear fender remove the parts in the order below. Seat and fuel tank side panels refer to “seat and side panels”. Fuel tank refer to “fuel tank”. 1 rear...

  • Page 68: Chk

    3 - 7 chk adj seat, carriers, fenders and fuel tank order job name/part name q’ty remarks 8 c.D.I. Unit 1 9 wire harness 1 10 rear fender 1 for installation, reverse the removal procedure..

  • Page 69: Chk

    3 - 8 chk adj seat, carriers, fenders and fuel tank fuel tank order job name/part name q’ty remarks removing the fuel tank remove the parts in the order below. Seat and fuel tank side panels refer to “seat and side panels”. Fuel tank cover refer to “front carrier, front bumper and front fender”. 1 f...

  • Page 70: Chk

    3 - 9 chk adj footrest boards footrest boards order job name/part name q’ty remarks removing the footrest boards remove the parts in the order below. Fuel tank side panels refer to “seat and side panels”. 1 left footrest board 1 2 right footrest board 1 3 footrest bracket 4 for installation, reverse...

  • Page 71: Chk

    3 - 10 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 compression stroke. 1.Remove: ● seat ● front car...

  • Page 72: Chk

    3 - 11 chk adj adjusting the valve clearance 7.Check: ● valve clearance out of specification → adjust. ***************************************************** checking steps: ● turn the crankshaft counterclockwise with a wrench. ● align the “t” mark 1 on the rotor with the stationary pointer 2 on the ...

  • Page 73: Chk

    3 - 12 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 counterclockwise with the ...

  • Page 74: Chk

    3 - 13 chk adj adjusting the valve clearance/ adjusting the idling speed 11.Install: ● fuel tank ● front fender ● front carrier ● seat refer to “seat, carriers, fenders and fuel tank”. Adjusting the idling speed 1.Start the engine and let it warm up for several minutes. 2.Remove: ● seat ● fuel tank ...

  • Page 75: Chk

    3 - 14 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 76: Chk

    3 - 15 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 77: Chk

    3 - 16 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 78: Chk

    3 - 17 chk adj adjusting the speed limiter/ adjusting the starter cable 2.Adjust: ● speed limiter length ***************************************************** speed limiter length adjustment steps: ● loosen the locknut 1. ● turn the adjuster 2 in or out until the specified speed limiter length is ob...

  • Page 79: Chk

    3 - 18 chk adj adjusting the starter cable 2.Adjust: ***************************************************** adjustment steps: ● disconnect the starter cable 1 from the carburetor body. Note: do not remove the starter plunger 2 from the starter cable. ● measure the starter plunger stroke distance a of...

  • Page 80: Chk

    3 - 19 chk adj checking the spark plug checking the spark plug 1.Remove: ● seat ● fuel tank side panel (right) refer to “seat, carriers, fenders and fuel tank”. 2.Remove: ● spark plug 3.Check: ● spark plug type incorrect → replace. Standard spark plug: dr8ea/ngk 4.Check: ● electrode 1 wear/damage → ...

  • Page 81: Chk

    3 - 20 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 (right) refer to “seat, carriers, fenders and fuel tank”. 2.Attach:...

  • Page 82: Chk

    3 - 21 chk adj 4.Detach: ● timing light ● inductive self-powered tachometer or engine tachometer 5.Install: ● seat ● fuel tank side panel (right) refer to “seat, carriers, fenders and fuel tank”. Measuring the compression pressure note: insufficient compression pressure will result in a loss of perf...

  • Page 83: Chk

    3 - 22 chk adj measuring the compression pressure 7.Measure: ● compression pressure above the maximum pressure: check the cylinder head, valve surfaces, and piston crown for carbon deposits. Below the minimum pressure: squirt a few drops of oil into the affected cylinder and measure again. ● refer t...

  • Page 84: Chk

    3 - 23 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 level mark 1 and minimum level mark 2...

  • Page 85: Chk

    3 - 24 chk adj changing the engine oil changing the engine oil 1.Start the engine and let it warm up for several minutes. 2.Stop the engine and place an oil pan under the engine. 3.Remove: ● seat ● fuel tank side panel (left) ● engine side cover refer to “seat, carriers, fenders and fuel tank”. 4.Re...

  • Page 86: Chk

    3 - 25 chk adj ● lubricate the o-ring 3 of the new oil filter cartridge with a thin coat of engine oil. Caution: make sure that the o-ring 3 is positioned correctly in the groove of the oil filter cartridge. ● tighten the new oil filter cartridge to specification with an oil filter wrench. *********...

  • Page 87: Chk

    3 - 26 chk adj changing the engine oil/ cleaning the air filter 13.Check: ● engine oil pressure ***************************************************** ● slightly loosen the oil gallery bolt 1. ● start the engine and keep it idling until engine oil starts to seep from the oil gallery bolt. If no engin...

  • Page 88: Chk

    3 - 27 chk adj cleaning the air filter 1.Remove: ● seat refer to “seat, carriers, fenders and fuel tank”. 2.Remove: ● air filter case cover 1 3.Remove: ● air filter element assembly 1 ● air filter element cap ● air filter element 2 air filter element cap 3 air filter element caution: never operate t...

  • Page 89: Chk

    3 - 28 chk adj cleaning the air filter 5.Clean: ● air filter element ***************************************************** cleaning steps: ● wash the element gently, but thoroughly in solvent. Warning use a cleaning solvent which is designed to clean parts only. Never use gasoline or low flash point...

  • Page 90: Chk

    3 - 29 chk adj checking the coolant level checking the coolant level 1.Place the machine on a level surface. 2.Remove: ● seat ● fuel tank side panel (left) refer to “seat, carriers, fenders and fuel tank”. 3.Check: ● coolant level the coolant level should be between the minimum level mark a and maxi...

  • Page 91: Chk

    3 - 30 chk adj changing the coolant changing the coolant 1.Remove: ● seat ● fuel tank side panel (left) ● engine side cover ● front carrier ● engine skid plate ● front fender refer to “seat, carriers, fenders and fuel tank”. ● left footrest board refer to “footrest boards”. 2.Remove: ● plastic band ...

  • Page 92: Chk

    3 - 31 chk adj changing the coolant 8.Remove: ● coolant drain bolt (cylinder) 1 (along with the copper washer) ● coolant drain bolt (water pump) 2 (along with the copper washer) 9.Drain: ● coolant 10.Check: ● copper washer 1 ● coolant drain bolt 2 damage → replace. 11.Install: ● coolant drain bolt (...

  • Page 93: Chk

    3 - 32 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 94: Chk

    3 - 33 chk adj checking the coolant temperature warning light/checking the v-belt checking the coolant temperature warning light 1 coolant temperature warning light turn the main switch “on” and the engine stop switch to “ ”. Coolant temperature warning light checking method coolant temperature warn...

  • Page 95: Chk

    3 - 34 chk adj checking the v-belt 4.Replace: ● v-belt ***************************************************** replacing steps: ● install the bolts 1 (90101-06016) into the secondary fixed sheave hold. Note: tightening the bolts 1 will push the secondary sliding sheave away, causing the gap between th...

  • Page 96: Chk

    3 - 35 chk adj cleaning the spark arrester cleaning the spark arrester 1.Clean: ● spark arrester ***************************************************** cleaning steps: warning ● select a well-ventilated area free of combustible materials. ● always let the exhaust system cool before performing this op...

  • Page 97: Chk

    3 - 36 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 pedal free play a ● rear brake lever free play b out of specification → adjust. Rear brake pedal free ...

  • Page 98: Chk

    3 - 37 chk adj adjusting the rear brake ● turn the brake lever cable adjusting nut (drum) 3 clockwise until the gap a is within the specified limits. Gap a: 0 ~ 1 mm (0.00 ~ 0.04 in) ● checking the rear brake pedal free play to see whether or not it is within the specified limits. If not, perform th...

  • Page 99: Chk

    3 - 38 chk adj checking the front brake fluid level 1.Place the machine on a level surface. Note: when checking the front brake fluid level, make sure that the top of the master cylinder top is horizontal. 2.Check: ● brake fluid level fluid level is under “lower” level line 1 → fill up. Caution: bra...

  • Page 100: Chk

    3 - 39 chk adj checking the front brake pads/ checking the rear brake shoes checking the front brake pads 1.Remove: ● front wheel 2.Check: ● brake pads wear indicator groove 1 almost touch the brake disc → replace the brake pads as a set. Refer to “front brake” in chapter 8. 3.Operate the brake leve...

  • Page 101: Chk

    3 - 40 chk adj checking the brake hoses checking the brake hoses 1.Remove: ● seat ● front carrier ● front fender refer to “seat, carriers, fenders and fuel tank”. 2.Check: note: hold the machine in an upright position and apply the parking brake. ● front brake hoses 1 cracks/wear/damage → replace. F...

  • Page 102: Chk

    3 - 41 chk adj bleeding the hydraulic brake system bleeding the hydraulic brake system warning bleed the brake system if: ● the system has been disassembled. ● a brake hose or brake pipe have been loosened or removed. ● the brake fluid has been very low. ● the brake operation has been faulty. A loss...

  • Page 103: Chk

    3 - 42 chk adj bleeding the hydraulic brake system/ adjusting the select lever control cable and shift rod warning check the operation of the brake after bleeding the brake system. ***************************************************** adjusting the select lever control cable and shift rod 1 neutral ...

  • Page 104: Chk

    3 - 43 chk adj adjusting the select lever control cable and shift rod/ adjusting the rear brake light switch ● when the brake begins to work “ a = 20 ~ 30 mm (0.8 ~ 1.2 in)”, verify that the select lever can be shifted to reverse from neutral, to neutral from reverse. ● before the brake begins to wo...

  • Page 105: Chk

    3 - 44 chk adj adjusting the rear brake light switch/ checking the final gear oil level 2.Adjust: ● rear brake light switch operation timing *********************************************** ● hold the main body 1 of the rear brake light switch so that it does not rotate and turn the adjusting nut 2 i...

  • Page 106: Chk

    3 - 45 chk adj changing the final gear oil changing the final gear oil 1.Place the machine on a level surface. 2.Remove: ● final gear case protector 1 3.Place a receptacle under the final gear case. 4.Remove: ● oil filler bolt ● drain plug 1 5.Drain: ● final gear oil 6.Install: ● drain plug note: ch...

  • Page 107: Chk

    3 - 46 chk adj changing the differential gear oil/checking the constant velocity joint dust boots 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 ...

  • Page 108: Chk

    3 - 47 chk adj checking the steering system 1.Place the machine on a level surface. 2.Check: ● steering assembly bushings move the handlebar up and down, and/or back and forth. Excessive play → replace the steering stem bearing. 3.Check: ● tie-rod ends turn the handlebar to the left and/or right unt...

  • Page 109: Chk

    3 - 48 chk adj ● measure the width È between the marks. ● rotate the front tires 180° until the marks are exactly opposite one another. ● measure the width É between the marks. ● calculate the toe-in using the formula given below. ● if the toe-in is incorrect, adjust it. ****************************...

  • Page 110: Chk

    3 - 49 chk adj adjusting the front shock absorbers/adjusting the rear shock absorber/checking the tires adjusting the front shock absorbers warning always adjust both front shock absorber spring preload to the same setting. Uneven adjustment can cause poor handling and loss of stability. 1.Adjust: ●...

  • Page 111: Chk

    3 - 50 chk adj checking the tires ● tire characteristics 1)tire characteristics influence the handling of atvs. The tires listed below have been approved by yamaha motor co., ltd. For this model. If other tire combinations are used, they can adversely affect your machine’s handling characteristics a...

  • Page 112: Chk

    3 - 51 chk adj checking the tires 1.Measure: ● tire pressure (cold tire pressure) out of specification → adjust. Note: ● the low-pressure tire gauge 1 is included as standard equipment. ● if dust or the like is stuck to this gauge, it will not provide the correct readings. Therefore, take two measur...

  • Page 113: Chk

    3 - 52 chk adj checking the wheels/ checking and lubricating the cables checking the wheels 1.Check: ● wheel 1 damage/bends → replace. Note: always balance the wheel when a tire or wheel has been changed or replaced. Warning ● never attempt even small repairs to the wheel. ● ride conservatively afte...

  • Page 114: Chk

    3 - 53 chk adj lubricating the levers, pedal, etc. Lubricating the levers, pedal, etc. 1.Lubricate the pivoting parts. Recommended lubricant: lithium soap base grease.

  • Page 115: Chk

    3 - 54 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 ch...

  • Page 116: Chk

    3 - 55 chk adj batteries generate explosive hydrogen gas. Always follow these preventive measures: ● charge batteries in a well-ventilated area. ● keep batteries away from fire, sparks or open flames (e.G., welding equipment, lighted cigarettes, etc.) ● do not smoke when charging or handling batteri...

  • Page 117: Chk

    3 - 56 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 118: Chk

    3 - 57 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 119: Chk

    3 - 58 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 120: Chk

    3 - 59 chk adj checking the battery/ checking the fuses 5.Check: ● battery terminals dirty → clean with a wire brush. Note: after cleaning the terminals, apply a light coat of grease. 6.Install: ● battery 7.Connect: ● battery leads caution: first, connect the positive lead 1, then connect the negati...

  • Page 121: Chk

    3 - 60 chk adj checking the fuses note: set the tester to the “ Ω × 1” position. ● if the tester indicates ∞, replace the fuse. ***************************************************** pocket tester: p/n. Yu-03112-c, 90890-03112 3.Replace: ● blown fuse(s) ***********************************************...

  • Page 122: Chk

    3 - 61 chk adj checking the fuses/adjusting the headlight beams/changing the headlight bulb warning never use a fuse with a rating other than that specified. Never use other materials in place of a fuse. An improper fuse may cause extensive damage to the electrical system, a malfunction of the light...

  • Page 123: Chk

    3 - 62 chk adj changing the headlight bulb 2.Remove: ● bulb holder 1 ● 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 cools down. 3....

  • Page 124: 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. Front and rear fender/foot...

  • Page 125: Eng

    4 - 2 eng engine removal order job name/part name q’ty remarks 6 final drive gear case breather hose 1 7 rear brake breather hose 1 8 cylinder head breather hose 1 9 vacuum chamber breather hose 1 10 air filter case 1 for installation, reverse the removal procedure..

  • Page 126: 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. 1 select lever shift rod 1 2 select lever unit 1 3 coolant reservoir breather hose 1 4 coolant reservoir ho...

  • Page 127: 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. Water pump inlet hose refer to “water pump” in chapter 5. 1 cylinder head breather hose 1 2 spark plug lead 1 disconnect. 3 thermo switch (cylinder head) l...

  • Page 128: Eng

    4 - 5 eng engine removal engine mounting bolts order job name/part name q’ty remarks removing the engine mounting bolts remove the parts in the order below. Rear wheels refer to “front and rear wheels” in chapter 8. Swingarm refer to “rear shock absorber and swingarm” in chapter 8. 1 engine mounting...

  • Page 129: Eng

    4 - 6 eng engine removal order job name/part name q’ty remarks 9 engine assembly 1 note: remove the engine assembly from the left side of the machine. For installation, reverse the removal procedure..

  • Page 130: Eng

    4 - 7 eng installing the engine 1.Install: ● engine bracket (front upper) 1 ● engine mounting bolt (front upper)/nut 2 ● engine bracket bolt (front upper) 3 ● engine bracket (front lower) 4 ● engine mounting bolt (front lower) 5 ● engine bracket bolt (front lower) 6 ● engine mounting bolt (rear uppe...

  • Page 131: Eng

    4 - 8 eng cylinder head cylinder head order job name/part name q’ty remarks removing the cylinder head remove the parts in the order below. Fuel tank/rubber cover refer to “seat, carriers, fenders and fuel tank” in chapter 3. Front fender/air filter case air duct assembly 1 refer to “engine removal”...

  • Page 132: Eng

    4 - 9 eng cylinder head order job name/part name q’ty remarks 5 cylinder head breather hose 1 6 camshaft sprocket cover/o-ring 1/1 7 tappet cover/o-ring 2/2 8 thermo switch (cylinder head) lead 1 disconnect. 9 timing chain tensioner cap bolt 1 refer to “removing/installing the cylinder head”. 10 tim...

  • Page 133: Eng

    4 - 10 eng cylinder head removing the cylinder head 1.Align: ● “t” mark (with stationary pointer) ***************************************************** checking steps: ● turn the crankshaft counterclockwise with a wrench. ● align the “t” mark 1 on the rotor with the stationary pointer 2 on the crank...

  • Page 134: Eng

    4 - 11 eng cylinder head note: ● fasten a safety wire to the timing chain to prevent it from falling into the crankcase. ● when removing the camshaft sprocket, it is not necessary to separate the timing chain. 5.Remove: ● cylinder head note: ● loosen the 6 mm bolts first. ● working in a crisscross p...

  • Page 135: Eng

    4 - 12 eng cylinder head checking the cylinder head 1.Eliminate: ● carbon deposits (from the combustion chambers) use a rounded scraper. Note: do not use a sharp instrument to avoid damaging or scratching: ● spark plug threads ● valve seats 2.Check: ● cylinder head scratches/damage → replace. ● cyli...

  • Page 136: Eng

    4 - 13 eng cylinder head installing the cylinder head 1.Install: ● cylinder head ● bolts (m10) ● bolts (m6) note: ● lubricate the washer with engine oil. ● tighten the bolts (m10) in two stages and a crisscross pattern. T r . . 40 nm (4.0 m • kg, 29 ft • lb) t r . . 10 nm (1.0 m • kg, 7.2 ft • lb) 2...

  • Page 137: Eng

    4 - 14 eng cylinder head note: be sure the “i” mark 5 on the camshaft sprocket is aligned with the match mark 2 on the cylinder head. ● force the camshaft clockwise and counterclockwise to remove timing chain slack. ● insert a screwdriver into the timing chain tensioner hole and push the timing chai...

  • Page 138: Eng

    4 - 15 eng cylinder head 4.Tighten: ● camshaft sprocket bolt 1 note: use the rotor holding tool 2 to hold the starter pulley. 5.Check: ● camshaft sprocket “i” mark ● rotor “t” mark out of alignment → adjust. Rotor holding tool: p/n. Yu-01235, 90890-01235 t r . . 60 nm (6.0 m • kg, 43 ft • lb).

  • Page 139: Eng

    4 - 16 eng camshaft, rocker arms and valves camshaft, rocker arms and valves order job name/part name q’ty remarks removing the camshaft, rocker arms and valves remove the parts in the order below. 1 intake manifold/o-ring 1/1 2 thermo switch (cylinder head) 1 3 oil check bolt 1 4 lock washer/bearin...

  • Page 140: Eng

    4 - 17 eng camshaft, rocker arms and valves order job name/part name q’ty remarks 12 valve spring (inner) 2 refer to “removing/installing the valves and valve springs”. 13 valve (intake) 1 14 valve (exhaust) 1 15 valve stem seal 2 16 valve spring seat 2 for installation, reverse the removal procedur...

  • Page 141: Eng

    4 - 18 eng camshaft, rocker arms and valves removing the camshaft and rocker arms 1.Remove: ● camshaft 1 note: screw in a m10 bolt 2 into the thread hole on the camshaft, and pull out the camshaft. 2.Remove: ● rocker arm shafts (intake and exhaust) 1 ● rocker arms 2 note: use a slide hammer 3 to rem...

  • Page 142: Eng

    4 - 19 eng camshaft, rocker arms and valves 2.Remove: ● valve cotters note: attach a valve spring compressor 1 between the valve spring retainer and the cylinder head to remove the valve cotters. Checking the camshaft 1.Check: ● cam lobes pitting/scratches/blue discoloration → replace. 2.Measure: ● ...

  • Page 143: Eng

    4 - 20 eng camshaft, rocker arms and valves 2.Check: ● rocker arms ● rocker arm shafts damage/wear → replace. ***************************************************** checking steps: ● check the two contact areas on the rocker arms for signs of abnormal wear. 1) rocker arm shaft hole 2) camshaft lobe c...

  • Page 144: Eng

    4 - 21 eng camshaft, rocker arms and valves checking the valves and valve springs 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 (...

  • Page 145: Eng

    4 - 22 eng camshaft, rocker arms and valves 3.Check: ● valve face pitting/wear → grind the face. ● valve stem end mushroom shape or diameter larger than the body of the stem → replace. 4.Measure: ● margin thickness a out of specification → replace. Margin thickness: intake: 1.0 ~ 1.4 mm (0.0394 ~ 0....

  • Page 146: Eng

    4 - 23 eng camshaft, rocker arms and valves ***************************************************** measurement steps: ● apply mechanic’s blueing dye (dykem) b to the valve face. ● install the valve into the cylinder head. ● press the valve through the valve guide and onto the valve seat to make a cle...

  • Page 147: Eng

    4 - 24 eng camshaft, rocker arms and valves ● apply a fine lapping compound to the valve face and repeat the above steps. Note: after every lapping operation, be sure to clean off all of the compound from the valve face and valve seat. ● apply mechanic’s blueing dye (dykem) to the valve face. ● inst...

  • Page 148: Eng

    4 - 25 eng camshaft, rocker arms and valves 12.Measure: ● spring tilt a out of specification → replace. Spring tilt limit: inner: 2.5°/1.6 mm (0.06 in) outer: 2.5°/1.6 mm (0.06 in) installing the valves and valve springs 1.Apply: ● molybdenum disulfide oil (onto the valve stem and valve stem seal) 2...

  • Page 149: Eng

    4 - 26 eng camshaft, rocker arms and valves installing the camshaft and rocker arms 1.Apply: ● engine oil (onto the rocker arm shafts) 2.Install: ● rocker arms 1 ● rocker arm shafts (intake and exhaust) 2 note: use a slide hammer bolt 3 to install the rocker arm shafts. 3.Install: ● camshaft 1 note:...

  • Page 150: Eng

    4 - 27 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. Cylinder head refer to “cylinder head”. Water pump outlet hose/pipe refer to “water pump” in chapter 5. 1 coolant inlet joint 1 2 timing chai...

  • Page 151: Eng

    4 - 28 eng cylinder and piston removing the piston 1.Remove: ● piston pin clips 1 ● piston pin 2 ● piston 3 note: before removing piston pin, deburr the clip groove and pin hole area. If the piston pin groove is deburred and the piston pin is still difficult to remove, use the piston pin puller 4. C...

  • Page 152: Eng

    4 - 29 eng cylinder and piston 2.Measure: ● piston-to-cylinder clearance ***************************************************** measurement steps: 1st step: ● measure the cylinder bore “c” with the cylinder bore gauge. Note: measure cylinder bore “c” by taking side-to- side and front-to-back measurem...

  • Page 153: Eng

    4 - 30 eng cylinder and piston 3rd step: ● find the piston-to-cylinder clearance with the following formula. ● if out of specification, rebore or replace the cylinder, and replace the piston and piston rings as a set. ***************************************************** piston-to-cylinder clearance...

  • Page 154: Eng

    4 - 31 eng cylinder and piston 3.Measure: ● ring end gap out of specification → replace. Note: you cannot measure the end gap on the expander spacer of the oil control ring. If the oil control ring rails show excessive gap, replace all three rings. End gap standard limit top ring 0.20 ~ 0.40 mm (0.0...

  • Page 155: Eng

    4 - 32 eng cylinder and piston ● if out of specification, replace the piston. ***************************************************** piston pin-to-piston clearance: 0.004 ~ 0.024 mm (0.00016 ~ 0.00094 in) : 0.074 mm (0.0029 in) installing the piston 1.Install: ● piston rings (onto the piston) note: ●...

  • Page 156: Eng

    4 - 33 eng cylinder and piston 4.Lubricate: ● piston ● piston rings ● cylinder note: apply a liberal coating of engine oil. Installing the cylinder 1.Install: ● cylinder note: install the cylinder with one hand while compressing the piston rings with the other hand. Caution: ● be careful not to dama...

  • Page 157: Eng

    4 - 34 eng recoil starter and a.C. Magneto recoil starter and a.C. Magneto order job name/part name q’ty remarks removing the a.C. Magneto remove the parts in the order below. Engine oil drain. Refer to “changing the engine oil” in chapter 3. Seat and side panels refer to “seat and side panels” in c...

  • Page 158: Eng

    4 - 35 eng recoil starter and a.C. Magneto order job name/part name q’ty remarks 7 pickup coil 1 8 stator assembly 1 9 rotor 1 refer to “removing/installing the a.C. Magneto”. 10 starter wheel gear 1 11 woodruff key 1 12 washer 1 13 starter idle gear shaft 1 14 washer/bearing 1/1 15 starter idle gea...

  • Page 159: Eng

    4 - 36 eng recoil starter and a.C. Magneto order job name/part name q’ty remarks disassembling the recoil starter remove the parts in the order below. 1 cap 1 refer to “disassembling/ assembling the recoil starter”. 2 starter handle 1 3 friction plate 1 4 pawl spring 1 5 drive pawl 1 6 spring 1 7 sh...

  • Page 160: Eng

    4 - 37 eng recoil starter and a.C. Magneto removing the a.C. Magneto 1.Remove: ● starter pulley 1 note: use the rotor holding tool 2 to hold the starter pulley. 2.Remove: ● crankcase cover (left) ● gasket ● dowel pins note: working in a crisscross pattern, loosen each bolt 1/4 of a turn. Remove them...

  • Page 161: Eng

    4 - 38 eng recoil starter and a.C. Magneto checking the starter clutch 1.Check: ● starter one-way clutch 1 cracks/damage → replace. ● bolts 2 (starter clutch) loose → replace with a new one, and clinch the end of the bolt. Note: the arrow mark on the starter clutch must face inward, away from the ro...

  • Page 162: Eng

    4 - 39 eng recoil starter and a.C. Magneto checking the starter pulley 1.Check: ● starter pulley cracks/pitting → deburr or replace. Checking the recoil starter 1.Check: ● rope 1 ● sheave drum 2 ● drive pawl 3 wear/damage → replace. ● coil spring 4 ● pawl spring 5 ● spring 6 fatigue → replace. Assem...

  • Page 163: Eng

    4 - 40 eng recoil starter and a.C. 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: ● sp...

  • Page 164: Eng

    4 - 41 eng recoil starter and a.C. Magneto 2.Install: ● woodruff key ● rotor note: ● before installing the rotor, clean the outside of the crankshaft and the inside of the rotor. ● after installing the rotor, check that the rotor rotates smoothly. If not, reinstall the key and rotor. 3.Install: ● do...

  • Page 165: Eng

    4 - 42 eng primary and secondary sheaves primary and secondary sheaves order job name/part name q’ty remarks removing the primary and secondary sheaves remove the parts in the order below. Front fender refer to “seat, carriers, fenders and fuel tank” in chapter 3. Rear fender right footrest board re...

  • Page 166: Eng

    4 - 43 eng primary and secondary sheaves order job name/part name q’ty remarks 8 primary fixed sheave 1 refer to “removing/installing the primary and secondary sheaves”. 9 secondary sheave assembly 1 for installation, reverse the removal procedure..

  • Page 167: Eng

    4 - 44 eng primary and secondary sheaves primary sliding sheave order job name/part name q’ty remarks disassembling the primary sliding sheave remove the parts in the order below. 1 primary sliding sheave cap 1 refer to “assembling the primary sheave”. 2 primary pulley slider 4 3 spacer 4 4 primary ...

  • Page 168: Eng

    4 - 45 eng primary and secondary sheaves secondary sheave order job name/part name q’ty remarks disassembling the secondary sheave remove the parts in the order below. 1 nut 1 refer to “disassembling/ assembling the secondary sheave”. 2 spring seat 1 3 compression spring 1 4 spring seat 1 5 guide pi...

  • Page 169: Eng

    4 - 46 eng primary and secondary sheaves removing the primary and secondary sheaves 1.Loosen: ● nut (secondary sheave) 1 ● nut (primary sheave) 2 note: ● use the sheave holder 3 to hold the primary sheave. ● first, loosen the nut (secondary sheave) 2, then loosen the nut (primary sheave) 1. Sheave h...

  • Page 170: Eng

    4 - 47 eng primary and secondary sheaves checking the primary sheave 1.Check: ● weight outside diameter a out of specification → replace the weight. Weight outside diameter: 30 mm (1.18 in) : 29.5 mm (1.16 in) 2.Check: ● primary pulley sliders ● primary sliding sheave splines wear/cracks/damage → re...

  • Page 171: Eng

    4 - 48 eng primary and secondary sheaves assembling the primary sheave 1.Clean: ● primary sliding sheave face 1 ● primary fixed sheave face 2 ● collar 3 ● weights 4 ● primary pulley cam face note: remove any excess grease. 2.Install: ● weights 1 note: ● apply yamaha grizzly grease (120 g) to the who...

  • Page 172: Eng

    4 - 49 eng primary and secondary sheaves 3.Apply: ● bel-ray assembly lube ® (to all guide pin sliding grooves 1, and o-rings 2 ) new 4.Install: ● spring seat ● compression spring ● spring seat ● nut ***************************************************** installing steps: ● attach the sheave fixed blo...

  • Page 173: Eng

    4 - 50 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 secondary sliding sheave away, causing the gap between the secondary fixed and sliding sheaves ...

  • Page 174: Eng

    4 - 51 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 cover 1 2 clutch housing assembly 1 refer to “removing/installing the clutch”. 3 gasket/dowel pin 1/2 4 on...

  • Page 175: Eng

    4 - 52 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 176: Eng

    4 - 53 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 177: Eng

    4 - 54 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: ● clutch carrier assembly ● nut 1 note: ● lubricate t...

  • Page 178: Eng

    4 - 55 eng clutch 4.Install: ● dowel pins ● gasket ● clutch housing assembly note: ● tighten the bolts in stages, using a crisscross 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 179: Eng

    4 - 56 eng crankcase crankcase starter motor, timing chain and oil filter order job name/part name q’ty remarks removing 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 “cylinder head”. Cylinder and...

  • Page 180: Eng

    4 - 57 eng crankcase order job name/part name q’ty remarks 6 oil filter cartridge 1 7 speed sensor 1 8 shift cam stopper 1 9 neutral switch 1 10 reverse switch 1 11 oil filler cap 1 12 gear unit 1 13 bearing cover/gasket 1/1 14 oil delivery pipe 1 15 oil strainer cover/o-ring 1/1 16 compression spri...

  • Page 181: Eng

    4 - 58 eng crankcase crankcase order job name/part name q’ty remarks separating the crankcase remove the parts in the order below. 1 engine side cover bracket 1 refer to “installing the shift lever”. 2 shift lever assembly 1 3 crankcase (left) 1 refer to “separating/assembling the crankcase”. 4 dowe...

  • Page 182: Eng

    4 - 59 eng crankcase crankcase bearings order job name/part name q’ty remarks removing the crankcase bearings remove the parts in the order below. Crankshaft and oil pump refer to “crankshaft and oil pump”. Transmission refer to “transmission”. Middle drive/driven shaft refer to “middle gear”. 1 oil...

  • Page 183: Eng

    4 - 60 eng crankcase removing the oil pump drive gear 1.Straighten: ● lock washer tab 2.Remove: ● oil pump drive gear nut ***************************************************** removal steps: ● temporarily install the clutch carrier assembly 1. ● hold the clutch carrier assembly with a clutch holding...

  • Page 184: Eng

    4 - 61 eng crankcase ● remove the left crankcase. Caution: use a soft hammer to tap on one side of the crankcase. Tap only on reinforced portions of the crankcase. Do not tap on the crankcase mating surfaces. Work slowly and carefully. Make sure that the crankcase halves separate evenly. ● remove th...

  • Page 185: Eng

    4 - 62 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 186: Eng

    4 - 63 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, bearings and oil d...

  • Page 187: Eng

    4 - 64 eng crankcase installing the oil pump drive gear 1.Install: ● straight key ● oil pump drive gear ● lock washer ● oil pump drive gear nut new 2.Tighten: ● oil pump drive gear nut ***************************************************** tightening steps: ● temporary install the clutch carrier asse...

  • Page 188: Eng

    4 - 65 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 washer/circlip 1/1 2 oil pump assembly/gasket 1/1 3 balancer 1 refer to “removing th...

  • Page 189: Eng

    4 - 66 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 190: Eng

    4 - 67 eng crankshaft and oil pump removing the crankshaft 1.Remove: ● crankshaft seal 1 note: mark a note of the position of each crankshaft seal so that they can be installed in the correct place and in the correct direction. 2.Remove: ● crankshaft use a crankcase separating tool 1. Crankcase sepa...

  • Page 191: Eng

    4 - 68 eng crankshaft and oil pump 3.Check: ● oil pump operation unsmooth → repeat steps #1 and #2 or replace the defective parts. Checking the crankshaft 1.Measure: ● crank width a out of specification → replace the crankshaft. ● side clearance d out of specification → replace the crankshaft. ● run...

  • Page 192: Eng

    4 - 69 eng crankshaft and oil pump installing the crankshaft and balancer 1.Install: ● crankshaft note: hold the connecting rod at the top dead center (t.D.C.) with one hand while turning the nut of the installing tool with the other. Operate the installing tool until the crankshaft bottoms against ...

  • Page 193: Eng

    4 - 70 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”. 1 driven sprocket 1 2 chain 1 3 guide bar 1 4 shift fork 1 5 clutch dog 1 6 low wheel gear 1 7 secondary shaft 1 8 midd...

  • Page 194: Eng

    4 - 71 eng transmission order job name/part name q’ty remarks 10 shift cam 1 11 middle drive gear 1 12 spacer/o-ring 1/1 for installation, reverse the removal procedure..

  • Page 195: Eng

    4 - 72 eng transmission checking the shift forks 1.Check: ● shift fork cam follower 1 ● shift fork pawls 2 scoring/bends/wear/damage → replace. 2.Check: ● guide bar roll the guide bar on a flat surface. Bends → replace. Warning do not attempt to straighten a bent guide bar. 3.Check: ● shift fork mov...

  • Page 196: Eng

    4 - 73 eng transmission 2.Check: ● gear teeth blue discoloration/pitting/wear → replace. ● mated dogs rounded edges/cracks/missing portions → replace. 3.Check: ● gear movement unsmooth → repeat steps #1 and #2 or replace the defective parts. 4.Check: ● circlips bends/looseness/damage → replace. Chec...

  • Page 197: Eng

    4 - 74 eng transmission installing the transmission 1.Install: ● shift cam 1 ● drive axle assembly 2 ● clutch dog 3 ● shift fork 4 ● guide bar 5 note: install the shift fork with the “l” mark facing towards the left side of the crankcase. Be sure that the shift fork guide pin is properly seated in t...

  • Page 198: Eng

    4 - 75 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”. Transmission refer to “transmission”. 1 bearing housing assembly 1 2 nut 1 refer to “removing/in...

  • Page 199: Eng

    4 - 76 eng middle gear middle driven shaft order job name/part name q’ty remarks removing the middle driven shaft remove the parts in the order below. Crankcase separation refer to “crankcase”. 1 circlip 2 refer to “removing/installing the middle driven shaft”. 2 bearing 2 3 universal joint 1 4 univ...

  • Page 200: Eng

    4 - 77 eng middle gear order job name/part name q’ty remarks 12 front drive shaft coupling 1 13 bearing retainer 1 14 middle driven shaft 1 for installation, reverse the removal procedure..

  • Page 201: Eng

    4 - 78 eng middle gear removing the middle drive shaft 1.Straighten: ● punched portion of the nut (middle drive pinion gear) 2.Loosen: ● nut (middle drive pinion gear) 1 note: secure the middle drive shaft in the vise with a clean rag. 3.Remove: ● nut (middle drive pinion gear) ● middle drive pinion...

  • Page 202: Eng

    4 - 79 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: ● bearing housing assembly 1 ***************************************************** removal steps: ● clean the outside of the middle driven shaft...

  • Page 203: Eng

    4 - 80 eng middle gear 5.Remove: ● front drive shaft coupling ● bearing retainer 1 ● bearing note: attach the ring nut wrench 2. Caution: the middle driven shaft bearing retainer has left-handed threads. To loosen the bearing retainer, turn it clockwise. Ring nut wrench: p/n. Ym-38404, 90890-01430 6...

  • Page 204: Eng

    4 - 81 eng middle gear 4.Check: ● o-ring damage → replace. ● bearings pitting/damage → replace. 5.Check: ● u-joint movement roughness → replace u-joint. Selecting the middle drive and driven gear shims when the drive and driven gear, bearing housing assembly and/or crankcase are replaced, be sure to...

  • Page 205: Eng

    4 - 82 eng middle gear example: 1) if the bearing housing is marked “+04”, ..... A is 10.54. 2) b is 55 3) if the crankcase (right) is marked “66.03”, ..... C is 66.03. 4) therefore, the shim thickness is 0.47 mm. A = 66.03 – 10.54 – 55 = 0.49 5) round off hundredths digit and select appropriate shi...

  • Page 206: Eng

    4 - 83 eng middle gear where: d = a numeral (usually a decimal number) on the bearing housing is either added to or subtracted from “76”. E = a numeral (usually a decimal number) on the middle driven pinion gear is either added to or subtracted from “59”. F = a numeral (usually a decimal number) on ...

  • Page 207: Eng

    4 - 84 eng middle gear shims are supplied in the following thickness. ***************************************************** middle drive pinion gear shim thickness (mm) 0.10 0.40 0.15 0.50 0.20 0.60 0.30 installing the middle driven shaft 1.Install: ● bearing retainer 1 note: attach the ring nut wre...

  • Page 208: Eng

    4 - 85 eng middle gear ● tighten the bearing retainer. Caution: the middle driven shaft bearing retainer has left-handed threads. To tighten the bearing retainer, turn it counterclockwise. ***************************************************** 3.Install: ● shims 1 ● bearing housing note: install the ...

  • Page 209: Eng

    4 - 86 eng middle gear ● install each bearings 1 onto the yoke. Caution: check each bearing. The needles can easily fall out of their races. Slide the yoke back and forth on the bearings; the yoke will not go all the way onto a bearing if a needle is out of place. ● press each bearing into the u-joi...

  • Page 210: Eng

    4 - 87 eng middle gear ● attach the gear lash measurement tool 3 and dial gauge 4. A measuring point is 8.12 mm (0.32 in) ● measure the gear lash while rotating the middle driven shaft back and forth. Note: measure the gear lash at 4 positions. Rotate the middle driven gear 90° each time. ● if the g...

  • Page 211: Cool

    5 - 1 cool radiator cooling system radiator order job name/part name q’ty remarks removing the radiator remove the parts in the order below. Seat and fuel tank side panels refer to “seat and side panels” in chapter 3. Front carrier, front bumper and front fender refer to “front carrier, front bumper...

  • Page 212: Cool

    5 - 2 cool radiator 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 (radiator) 1 for installation, reverse the removal procedure. 5.

  • Page 213: Cool

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

  • Page 214: Cool

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

  • Page 215: Cool

    5 - 5 cool thermostat thermostat order job name/part name q’ty remarks removing the thermostat remove the parts in the order below. Seat and fuel tank side panel (right) refer to “seat and side panels” in chapter 3. Coolant drain. Refer to “changing the coolant” in chapter 3. 1 radiator inlet hose 1...

  • Page 216: Cool

    5 - 6 cool thermostat checking the thermostat 1.Check: ● thermostat 1 does not open at 63.5 ~ 66.5 °c (146.3 ~ 151.7 °f) → replace. ***************************************************** checking steps: ● suspend the thermostat in a container filled with water. ● slowly heat the water. ● place a ther...

  • Page 217: Cool

    5 - 7 cool water pump water pump order job name/part name q’ty remarks removing the water pump remove the parts in the order below. Seat, fuel tank side panel (left) and engine side cover refer to “seat and side panels” in chapter 3. Left footrest board refer to “footrest boards” in chapter 3. Coola...

  • Page 218: 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 219: 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 220: Cool

    5 - 10 cool water pump 3.Measure: ● impeller shaft tilt out of specification → replace. 1 straightedge 2 impeller max. Impeller shaft tilt: 0.15 mm (0.006 in) assembling the water pump 1.Install: ● oil seal 1 (into the water pump housing 2) note: install the oil seal with a socket 3 that matches its...

  • Page 221: Cool

    5 - 11 cool water pump 3.Install: ● rubber damper 1 ● rubber damper holder 2 note: before installing the rubber damper, apply tap water or coolant onto its outer surface. Caution: make sure that the rubber damper and rubber damper holder are flush with the impeller. New new.

  • Page 222: Carb

    6 - 1 carb carburetor carburetion carburetor order job name/part name q’ty remarks removing the carburetor remove the parts in the order below. Seat/fuel tank side panels/fuel tank/ rubber cover refer to “seat, carriers, fenders and fuel tank” in chapter 3. 1 drain hose 1 2 starter cable/starter plu...

  • Page 223: Carb

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

  • Page 224: Carb

    6 - 3 carb carburetor order job name/part name q’ty remarks d pilot jet 1 note: before disassembling the carburetor, make sure to note the number of times the pilot screw is turned out from the seated position to its set position. E main jet 1 f needle jet 1 g starter jet 1 h pilot air jet 1 for ass...

  • Page 225: 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 226: 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 227: 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 caution: be...

  • Page 228: 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 229: 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 230: Driv

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

  • Page 231: 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 bearings. (refer to “steering system” and “rear shock absorber and swingarm” in chapter 8.) no check...

  • Page 232: Driv

    7 - 4 driv front constant velocity joints and differential gear front constant velocity joints and differential gear order job name/part name q’ty remarks removing the front constant velocity joints and differential gear remove the parts in the order below. Engine skid plate (front) front fender ref...

  • Page 233: Driv

    7 - 5 driv front constant velocity joints and differential gear order job name/part name q’ty remarks 4 differential gear 1 5 drive shaft 1 6 compression spring 1 7 coupling gear 1 for installation, reverse the removal procedure..

  • Page 234: Driv

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

  • Page 235: Driv

    7 - 7 driv front constant velocity joints and differential gear order job name/part name q’ty remarks differential gear remove the parts in the order below. 1 gear motor/o-ring 1/1 2 four-wheel drive switch 1 3 dust seal 1 4 circlip 1 5 coupling gear/bearing/circlip 1/1/1 6 stopper bolt/shaft 1/1 7 ...

  • Page 236: Driv

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

  • Page 237: Driv

    7 - 9 driv removing the differential gear assembly 1.Remove: ● differential gear assembly 1 note: the ring gear and the differential gear cover should be fastened together. Do not disassemble the differential gear assembly. Caution: the differential gears are assembled into a proper unit at the fact...

  • Page 238: Driv

    7 - 10 driv front constant velocity joints and differential gear checking the differential gear 1.Check: ● gear teeth pitting/galling/wear → replace drive pinion gear and differential gear assembly as a set. ● bearing pitting/damage → replace. ● oil seal ● o-ring damage → replace. 2.Check: ● drive s...

  • Page 239: Driv

    7 - 11 driv front constant velocity joints and differential gear ● install the dust boots. ● install the dust boot bands. Note: ● the new boot bands may differ from the original ones. ● the dust boots should be fastened with the dust boot bands 3 at the grooves in the joint shaft. ******************...

  • Page 240: Driv

    7 - 12 driv front constant velocity joints and differential gear 3.Check: ● differential gear operation unsmooth operation → replace the differential gear assembly. Insert the double off-set joint into the differential gear, and turn the gear back and forth. Measuring and adjusting the differential ...

  • Page 241: Driv

    7 - 13 driv front constant velocity joints and differential gear adjusting differential gear lash 1.Remove: ● shim(s) (left) 1 ● differential gear assembly 2 ● shim(s) (right) 3 2.Adjust: ● gear lash ***************************************************** adjustment steps: ● select the suitable shims ...

  • Page 242: Driv

    7 - 14 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 243: Driv

    7 - 15 driv rear axle/final drive gear and drive shaft rear axle/final drive gear and drive shaft order job name/part name q’ty remarks removing the rear axle, final drive gear assembly and drive shaft remove the parts in the order below. Final gear oil drain. Refer to “changing the final gear oil” ...

  • Page 244: Driv

    7 - 16 driv rear axle/final drive gear and drive shaft order job name/part name q’ty remarks disassembling the final drive gear remove the parts in the order below. 1 bolt 2 2 bolt 6 3 bearing housing 1 4 oil seal/bearing 1/1 5 ring gear stopper 1 6 ring gear stopper shim 7 oil seal/bearing 1/1 8 ri...

  • Page 245: Driv

    7 - 17 driv rear axle/final drive gear and drive shaft order job name/part name q’ty remarks a bearing retainer/o-ring 1/1 refer to “disassembling/ assembling the final drive gear”. B oil seal 1 c final drive pinion gear 1 d collar 1 e bearing 1 f final drive pinion gear shim g final drive gear case...

  • Page 246: Driv

    7 - 18 driv rear axle/final drive gear and drive shaft removing the rear axle 1.Remove: ● rear axle 1 (with dust seal) ● o-ring caution: ● never directly tap the axle end with a hammer, since this will result in damage to the axle thread and spline. ● attach a suitable socket 2 on the axle end and t...

  • Page 247: Driv

    7 - 19 driv rear axle/final drive gear and drive shaft replacing the final drive roller bearings 1.Remove: ● roller bearing (ring gear) 1 use a suitable press tool 2 and an appropriate support for the main housing. ● oil seal 3 2.Remove: ● roller bearing (final drive pinion gear) 1 *****************...

  • Page 248: Driv

    7 - 20 driv rear axle/final drive gear and drive shaft positioning the final drive pinion gear and ring gear when the final drive pinion gear, ring gear, final gear case and/or ring gear bearing housing are replaced, be sure to adjust the positions of the final drive pinion gear and ring gear using ...

  • Page 249: Driv

    7 - 21 driv rear axle/final drive gear and drive shaft shims are supplied in the following thicknesses. ***************************************************** final drive pinion gear shim thickness (mm) 0.15 0.30 0.40 0.45 0.50 0.60 ring gear shim selection 1.Select: ● ring gear shim(s) *************...

  • Page 250: Driv

    7 - 22 driv rear axle/final drive gear and drive shaft 5) therefore, shim thickness “b” is 0.63. “b”= 45.53 + 1.05 – (34.95 + 11.00) = 46.58 – 45.95 = 0.63 6) round off the hundredth digit and select the appropriate shim(s). In the example above, the calculated number is 0.63. The chart instructs yo...

  • Page 251: Driv

    7 - 23 driv rear axle/final drive gear and drive shaft ● remove the ring gear assembly. ● measure the thrust clearance. Calculate the width of the flattened plastigauge ® 1. ● if out of specification, select the correct washer. Ring gear thrust clearance: 0.1 ~ 0.2 mm (0.004 ~ 0.008 in) thrust washe...

  • Page 252: Driv

    7 - 24 driv rear axle/final drive gear and drive shaft ring gear stopper clearance adjustment 1.Remove: ● ring gear 1 ● ring gear stopper 2 ● shim(s) 3 4 bearing housing È left-hand threads 2.Select: ● suitable shim(s) shim thickness (mm) 0.10 0.15 0.20 0.30 0.40 0.50 3.Install: ● shim(s) ● ring gea...

  • Page 253: Driv

    7 - 25 driv rear axle/final drive gear and drive shaft checking the drive shaft 1.Check: ● drive shaft (splines) wear/damage → replace. Checking the final drive gear 1.Check: ● final gear case 1 ● bearing housing (ring gear) 2 cracks/damage → replace. Note: when the final gear case and/or the ring g...

  • Page 254: Driv

    7 - 26 driv rear axle/final drive gear and drive shaft measurement and adjusting the final gear lash final gear lash measurement 1.Secure the gear case in a vise or another supporting device. 2.Remove: ● drain plug ● gasket 3.Install: ● a bolt of the specified size 1 (into the drain plug hole) cauti...

  • Page 255: Driv

    7 - 27 driv rear axle/final drive gear and drive shaft final gear lash adjustment 1.Remove: ● bearing housing 1 ● ring gear shim(s) 2 ● ring gear 3 ● thrust washer 4 2.Adjust: ● gear lash ***************************************************** adjustment steps: ● select suitable shim(s) and thrust was...

  • Page 256: Driv

    7 - 28 driv rear axle/final drive gear and drive shaft assembling the final drive gear 1.Install: ● drive pinion gear (with shim(s) and bearing) (proper shim size as calculated) ● bearing retainer (drive pinion gear) 1 use a bearing retainer wrench 2. Caution: ● always use a new bearing. ● the final...

  • Page 257: Driv

    7 - 29 driv rear axle/final drive gear and drive shaft 3.Apply: ● sealant (quick gasket ® ) (to the mating surfaces of the swingarm and the final drive gear case) sealant (quick gasket ® ): p/n. Acc-11001-05-01 yamaha bond no.1215: p/n. 90890-85505 4.Install: ● final drive gear ● nuts ● bolts lt t r...

  • Page 258: Chas

    8 - 1 chas front and rear wheels chassis front and rear wheels front wheels order job name/part name q’ty remarks removing the front wheels remove the parts in the order below. Place the machine on a level surface. Warning securely support the machine so there is no danger of it falling over. 1 fron...

  • Page 259: Chas

    8 - 2 chas front and rear wheels rear wheels order job name/part name q’ty remarks removing the rear wheels remove the parts in the order below. Place the machine on a level surface. Warning securely support the machine so there is no danger of it falling over. 1 wheel cap 2 2 rear wheel 2 refer to ...

  • Page 260: Chas

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

  • Page 261: Chas

    8 - 4 chas front and rear wheels checking the brake discs 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 specification → re...

  • Page 262: Chas

    8 - 5 chas front and rear wheels 2.Install: ● nuts (wheel) 1 warning tapered wheel nuts 1 are used for both the front and rear wheels. Install each nut with its tapered side towards the wheel. 3.Tighten: ● nuts (front wheels) ● nuts (rear wheels) note: tighten the nuts in stages and in a crisscross ...

  • Page 263: Chas

    8 - 6 chas front brake front brake front brake pads order job name/part name q’ty remarks removing the front brake pads remove the parts in the order below. Front wheel refer to “front and rear wheels”. 1 brake caliper mounting bolt 2 refer to “replacing the front brake pads”. 2 brake pad holding bo...

  • Page 264: Chas

    8 - 7 chas front brake caution: disc brake components rarely require disassembly. Do not: ● disassemble components unless absolutely necessary; ● use solvents on internal brake components; ● use spent brake fluid for cleaning; (use only clean brake fluid) ● allow brake fluid to come in contact with ...

  • Page 265: Chas

    8 - 8 chas front brake ***************************************************** installation steps: ● connect a suitable hose 1 tightly to the brake caliper bleed screw 2. Put the other end of this hose into an open container. ● loosen the brake caliper bleed screw and, using a finger, push the caliper...

  • Page 266: Chas

    8 - 9 chas front brake 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. 1 brake fluid reservoir cap 1 2 brake fluid reservoir diaphragm 1 3 brake lever 1 4 union bolt 1 refer to “install...

  • Page 267: Chas

    8 - 10 chas front brake order job name/part name q’ty remarks disassembling the front brake master cylinder remove the parts in the order below. 1 brake master cylinder kit 1 refer to “assembling the front brake master cylinder”. 2 brake master cylinder 1 for assembly, reverse the disassembly proced...

  • Page 268: Chas

    8 - 11 chas front brake checking the master cylinder 1.Check: ● brake master cylinder 1 wear/scratches → replace the brake master cylinder assembly. ● brake master cylinder body cracks/damage → replace. ● brake fluid delivery passage (brake master cylinder body) blockage → blow out with compressed a...

  • Page 269: Chas

    8 - 12 chas front brake installing the front brake master cylinder 1.Install: ● brake master cylinder 1 ● brake master cylinder bracket 2 note: the “up” mark on the brake master cylinder bracket 2 should face up. T r . . 7 nm (0.7 m • kg, 5.1 ft • lb) 2.Install: ● copper washers ● brake hose ● union...

  • Page 270: Chas

    8 - 13 chas front brake ● be careful that water does not enter the brake master cylinder when refilling. Water will significantly lower the boiling point of the brake fluid and may result in vapor lock. 4.Air bleed: ● brake system refer to “bleeding the hydraulic brake system” in chapter 3. 5.Check:...

  • Page 271: Chas

    8 - 14 chas front brake front brake caliper order job name/part name q’ty remarks removing the front brake calipers remove the parts in the order below. Brake fluid drain. Front wheel refer to “front and rear wheels”. 1 union bolt 1 refer to “installing the front brake calipers”. 2 copper washer 2 3...

  • Page 272: Chas

    8 - 15 chas front brake order job name/part name q’ty remarks disassembling the front brake calipers 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 “disassembling/ assemb...

  • Page 273: Chas

    8 - 16 chas front brake disassembling the front brake calipers 1.Remove: ● brake caliper piston ● dust seal 1 ● caliper piston seal 2 ***************************************************** removal steps: ● blow compressed air into the hose joint opening to force out the caliper piston from the brake ...

  • Page 274: Chas

    8 - 17 chas front brake ● brake fluid delivery passage (brake caliper body) blockage → blow out with compressed air. Warning replace the caliper piston seal and dust seal whenever the brake caliper is disassembled. Assembling the front brake calipers warning ● all internal brake components should be...

  • Page 275: Chas

    8 - 18 chas front brake caution: when installing the brake hose on the brake caliper, make sure that the brake pipe touches the projection a on the brake caliper. Warning proper brake hose routing is essential to insure safe motorcycle operation. Refer to “cable routing” in chapter 2. 2.Fill: ● brak...

  • Page 276: Chas

    8 - 19 chas rear brake rear brake order job name/part name q’ty remarks removing the rear brake lever remove the parts in the order below. 1 rear brake switch 1 2 rear brake lever cable 1 3 rear brake lever holder bracket 1 4 rear brake lever holder 1 5 rear brake lever 1 for installation, reverse t...

  • Page 277: Chas

    8 - 20 chas rear brake order job name/part name q’ty remarks removing the rear brake pedal remove the parts in the order below. 1 rear brake light switch cover 1 2 rear brake pedal cable 1 3 brake pedal 1 4 select lever control cable 1 5 rear brake light switch 1 6 bracket 1 for installation, revers...

  • Page 278: Chas

    8 - 21 chas rear brake order job name/part name q’ty remarks removing the rear brake drum remove the parts in the order below. Rear wheel (left) refer to “front and rear wheels” 1 brake drum cover 1 2 dust seal 1 3 brake drum 1 4 adjusting nut 2 5 pin 2 6 spring 2 7 rear brake lever cable 1 8 rear b...

  • Page 279: Chas

    8 - 22 chas order job name/part name q’ty remarks 11 brake camshaft lever 1 12 brake shoe wear indicator 1 13 brake camshaft 1 14 o-ring 2 15 dust seal 1 16 brake shoe plate 1 for installation, reverse the removal procedure. Rear brake.

  • Page 280: Chas

    8 - 23 chas rear brake removing the rear brake 1.Remove: ● rear wheel (left) ● rear wheel hub (left) refer to “front and rear wheels”. 2.Remove: ● brake drum cover 1 3.Remove: ● brake drum 1 4.Remove: ● adjusting nuts 1 ● pins 2 ● springs 3 5.Disconnect: ● rear brake lever cable 4 ● rear brake pedal...

  • Page 281: Chas

    8 - 24 chas rear brake 7.Remove: ● spring 1 ● brake camshaft lever 2 ● brake shoe wear indicator 3 ● brake camshaft 4 checking the rear brake 1.Check: ● brake drum 1 cracks/damage → replace. ● splines (wheel drum) 2 wear/damage → replace. 2.Check: ● brake shoe plate 1 ● pivot pin 2 ● brake camshaft ...

  • Page 282: Chas

    8 - 25 chas rear brake 5.Measure: ● brake shoe lining thickness a out of specification → replace. 1 measuring points note: replace the brake shoes as a set if either is worn to the wear limit. Brake shoe lining thickness limit: 2.0 mm (0.08 in) 6.Measure: ● brake drum inside diameter a out of specif...

  • Page 283: Chas

    8 - 26 chas rear brake caution: during installation, lightly grease the brake camshaft and the pivot pin. Wipe off the excess grease. 2.Install: ● brake shoe wear indicator 1 note: when installing the wear indicator pointer, fit the projection into a brake camshaft groove and align the pointer with ...

  • Page 284: Chas

    8 - 27 chas rear brake 6.Check: ● brake camshaft operation unsmooth operation → repair. 7.Lubricate: ● dust seal 1 lithium-soap base grease 8.Connect: ● rear brake lever cable 1 ● rear brake pedal cable 2 9.Install: ● springs 3 ● pins 4 ● adjusting nuts 5 ● brake drum ● brake drum cover 10.Install: ...

  • Page 285: Chas

    8 - 28 chas steering system steering system handlebar 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 1 refer to “installing the master cylinder assembly”. 4 master cylinder assembly/b...

  • Page 286: Chas

    8 - 29 chas steering system removing the rear brake switch 1.Remove: ● rear brake switch 1 note: push the fastener when removing the rear brake switch out of the rear brake lever holder. Checking the handlebar 1.Check: ● handlebar bends/cracks/damage → replace. Warning do not attempt to straighten a...

  • Page 287: Chas

    8 - 30 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 288: Chas

    8 - 31 chas steering system steering stem order job name/part name q’ty remarks removing the steering stem remove the parts in the order below. Handlebar refer to “handlebar”. Seat refer to “seat, carriers, fenders and fuel tank” in chapter 3. Front fender 1 lock washer 1 refer to “installing the ca...

  • Page 289: Chas

    8 - 32 chas steering system order job name/part name q’ty remarks 11 oil seal 1 12 bearing retainer 1 refer to “removing/installing the bearing retainer”. 13 bearing 1 14 oil seal 1 for installation, reverse the removal procedure..

  • Page 290: Chas

    8 - 33 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.Check: ● steering stem bends → replace. Warning do not attempt to straighten a bent stem; this may dangerously wea...

  • Page 291: Chas

    8 - 34 chas steering system tie rods and steering knuckles order job name/part name q’ty remarks removing the tie rods and steering knuckles remove the parts in the order below. Front fender refer to “seat, carriers, fenders and fuel tank” in chapter 3. Front wheel/brake disc refer to “front and rea...

  • Page 292: Chas

    8 - 35 chas steering system order job name/part name q’ty remarks 9 oil seal 1 10 oil seal 1 11 bearing 2 12 spacer 1 13 circlip 1 14 rubber boot 1 15 ball joint 1 for installation, reverse the removal procedure..

  • Page 293: Chas

    8 - 36 chas steering system removing the steering knuckles 1.Remove: ● steering knuckle 1 note: use a general puller to separate the ball joints 2 from the steering knuckle 1 or the front lower arm 3. Checking the tie rods 1.Check: ● tie rod free play and movement free play → replace the tie rod end...

  • Page 294: Chas

    8 - 37 chas steering system ● install the body 3, short bolt 5, remover washer 6 and remover spacer 7 onto ball joint. Note: ● remover washer 6 must be aligned with the projection on the head of the ball joint. ● surface a of the remover spacer 7 must be aligned with surface b of the steering knuckl...

  • Page 295: Chas

    8 - 38 chas ● attach the assembled ball joint remover/ installer, new ball joint b and installer attachment 8 to the steering knuckle c. Note: do not tap or damage the top of the ball joint. ● hold the body 3 in place while turning in the long bolt 4 to install the new ball joint b into the steering...

  • Page 296: Chas

    8 - 39 chas ● 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 the new oil seals. Note: when installing the oil seals, the “seal side” of the oil seal faces ou...

  • Page 297: Chas

    8 - 40 chas front arms and front shock absorbers front arms and front shock absorbers order job name/part name q’ty remarks removing the front arms and front shock absorbers remove the parts in the order below. Engine skid plate refer to “seat, carriers, fenders and fuel tank” in chapter 3. Front fe...

  • Page 298: Chas

    8 - 41 chas front arms and front shock absorbers order job name/part name q’ty remarks 4 nut 1 refer to “removing the front arms” and “installing the front arms and front shock absorber”. 5 nut 1 6 bolt/nut 2/2 7 front lower arm/bushing 1/2 8 nut/bolt 2/2 9 front shock absorber 1 10 bolt/nut 2/2 11 ...

  • Page 299: Chas

    8 - 42 chas front arms and front shock absorbers 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 ...

  • Page 300: Chas

    8 - 43 chas ***************************************************** replacement steps: ● clean the outside of the front lower arm. ● remove the circlip 1 and rubber boot 2. Use the ball joint remover and installer set. ● install the body 3, long bolt 4, remover washer 5 and remover spacer 6 onto ball ...

  • Page 301: Chas

    8 - 44 chas front arms and front shock absorbers ● attach the assembled ball joint remover/ installer, new ball joint a and installer attachment 7 to the front lower arm b. Note: do not tap or damage the top of the ball joint. ● hold the body 3 in place while turning in the long bolt 4 to install th...

  • Page 302: Chas

    8 - 45 chas front arms and front shock absorbers installing the front arms and front shock absorber 1.Install: ● front arms ● front shock absorber ***************************************************** installation steps: ● install the front upper arm 1 and front lower arm 2. Note: ● lubricate the bo...

  • Page 303: Chas

    8 - 46 chas rear shock absorber and swingarm rear shock absorber and swingarm order job name/part name q’ty remarks removing the rear shock absorber and swingarm remove the parts in the order below. Rear wheel hubs refer to “front and rear wheels”. Rear brake drum refer to “rear brake”. Rear brake l...

  • Page 304: Chas

    8 - 47 chas rear shock absorber and swingarm order job name/part name q’ty remarks 8 rear axle housing 1 refer to “installing the rear axle housing”. 9 nut/bolt 2/2 refer to “removing the swingarm”. 10 swingarm/bushing 1/2 11 spring/rubber boot 1/1 for installation, reverse the removal procedure..

  • Page 305: Chas

    8 - 48 chas rear shock absorber and swingarm removing the swingarm 1.Check: ● swingarm free play ***************************************************** checking steps: ● check the tightening torque of the nuts (swingarm). ● check the swingarm side play È by moving it from side to side. If side play i...

  • Page 306: Chas

    8 - 49 chas rear shock absorber and swingarm checking the swingarm 1.Check: ● swingarm 1 ● rear axle housing 2 bends/cracks/damage → replace. 2.Check: ● bushings 1 wear/damage → replace. Checking the rubber boot 1.Check: ● rubber boot 1 damage → replace. Installing the rubber boot 1.Apply: ● adhesiv...

  • Page 307: Chas

    8 - 50 chas rear shock absorber and swingarm installing the rear axle housing 1.Install: ● rear axle housing ● final gear case assembly ● rear axle (with dust seal) ***************************************************** installation steps: ● install the drive shaft. Refer to “rear axle/final drive ge...

  • Page 308: Elec

    9 - 1 – + elec electrical components eb800000 electrical electrical components 1 main switch 2 front brake light switch 3 rear brake switch 4 thermo switch (cylinder head) 5 battery 6 tail/brake light 7 fuse box 8 main fuse 9 starter relay 0 cdi unit a rectifier/regulator b reverse switch c neutral ...

  • Page 309: Elec

    9 - 2 – + elec checking the switches checking the switches checking a 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 th...

  • Page 310: Elec

    9 - 3 – + elec checking the switches.

  • Page 311: Elec

    9 - 4 – + elec checking the switches checking the switch continuity refer to “checking the switches” 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 a 6 2 3 r/b r/w push br l y g b...

  • Page 312: Elec

    9 - 5 – + elec checking the switches 1 light switch 2 engine stop switch 3 start switch 4 on-command four-wheel drive switch 5 main switch 6 rear brake light switch 7 front brake light switch 8 rear brake switch 9 neutral switch 0 reverse switch a fuses.

  • Page 313: 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 continuity between the terminals. Damage/wear → repair or replace the bulb, bulb socket or both. Improperly connected →...

  • Page 314: Elec

    9 - 7 – + elec checking the bulbs and bulb sockets warning since the headlight bulbs 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 p...

  • Page 315: 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 316: Elec

    9 - 9 – + elec ignition system eb802000 ignition system circuit diagram br /l r /y p l /b w /l w /l l /b n r w /g w /lw /r w /g r w /rw /g w ww w ww 1 w /g w /r w /g r w w w w w w 2 b r br /l br /l br r r br 3 v q (bla ck) br ww w r l /wl /b b b g /w g /w g /w b b r r r r r b b l /w 7 5 4 6 o r b o ...

  • Page 317: 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 318: Elec

    9 - 11 – + elec ignition system correct spark plug gap: 0.6 ~ 0.7 mm (0.024 ~ 0.028 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 c...

  • Page 319: 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 320: Elec

    9 - 13 – + elec ignition system c0ntinuity correct 8.Main switch refer to “checking the switches”. * 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 terminals. Tester (+) ...

  • Page 321: Elec

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

  • Page 322: Elec

    9 - 15 – + elec electric starting system eb803000 electric starting system circuit diagram br /l r /y p l /b w /l w /l l /b n r w /g w /lw /r w /g r w /rw /g w ww w ww 1 w /g w /r w /g r w w w w w w 2 b r br /l br /l br r r br 3 v q (bla ck) br ww w r l /wl /b b b g /w g /w g /w b b r r r r r b b l ...

  • Page 323: Elec

    9 - 16 – + 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.Start switch if the starter motor fails to operate: 8. Wiring connections (the entire starting system) note: ● rem...

  • Page 324: Elec

    9 - 17 – + 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 325: Elec

    9 - 18 – + elec electric starting system c0ntinuity correct 5.Main switch refer to “checking the switches”. * incorrect replace the main switch. Correct 6.Engine stop switch refer to “checking the switches”. Incorrect replace the handlebar switch (left). Correct 7.Start switch refer to “checking the...

  • Page 326: Elec

    9 - 19 – + 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 327: Elec

    9 - 20 – + elec electric starting system checking the starter motor 1.Check: ● commutator dirty → clean it with #600 grit sandpaper. 2.Measure: ● commutator diameter a out of specification → replace the starter motor. 3.Measure: ● mica undercut b out of specification → scrape the mica using a hacksa...

  • Page 328: Elec

    9 - 21 – + elec electric starting system 5.Measure: ● brush length a (each) out of specification → replace the brush holder set. Brush length: 12.5 mm (0.49 in) 5 mm (0.20 in) 6.Measure: ● brush spring force fatigue/out of specification → replace the brush holder set. Brush spring force: 7.65 ~ 10.0...

  • Page 329: Elec

    9 - 22 – + elec charging system eb804000 charging system circuit diagram br /l r /y p l /b w /l w /l l /b n r w /g w /lw /r w /g r w /rw /g w ww w ww 1 w /g w /r w /g r w w w w w w 2 b r br /l br /l br r r br 3 v q (bla ck) br ww w r l /wl /b b b g /w g /w g /w b b r r r r r b b l /w 7 5 4 6 o r b o...

  • Page 330: Elec

    9 - 23 – + 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 troubleshooting: 1)seat 2)fuel ...

  • Page 331: Elec

    9 - 24 – + elec charging system out of specification ● start the engine and accelerate to about 5,000 r/min. Charging voltage: 14 v at 5,000 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 332: Elec

    9 - 25 – + elec lighting system eb805000 lighting system circuit diagram br /l r /y p l /b w /l w /l l /b n r w /g w /lw /r w /g r w /rw /g w ww w ww 1 w /g w /r w /g r w w w w w w 2 b r br /l br /l br r r br 3 v q (bla ck) br ww w r l /wl /b b b g /w g /w g /w b b r r r r r b b l /w 7 5 4 6 o r b o...

  • Page 333: Elec

    9 - 26 – + elec lighting system eb805010 troubleshooting procedure check: 1.Fuses (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 troubleshooting:...

  • Page 334: Elec

    9 - 27 – + elec lighting system c0ntinuity correct 3.Main switch refer to “checking the switches”. * incorrect replace the main switch. Correct 4.Light switch refer to “checking the switches”. Incorrect light switch is faulty, replace the handlebar switch (left). Eb805013 correct 5.Wiring connection...

  • Page 335: Elec

    9 - 28 – + 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 continuity. No continuity replace the bulb and/or bulb socket. 2.Voltage ● connect the pocket tester (dc 20 v) to the head...

  • Page 336: Elec

    9 - 29 – + 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 continuity. No continuity replace the bulb and/or bulb socket. 2.Voltage ● connect the pocket tester (20 v) to the bulb socket coupler. Tester (+) lead...

  • Page 337: Elec

    9 - 30 – + elec lighting system eb805021 3.If the speedometer light fails to come on: continuity 1.Bulb and bulb socket ● check the bulb and bulb socket for continuity. No continuity replace the bulb and/or bulb socket. 2.Voltage ● connect the pocket tester (20 v) to the bulb socket coupler. Tester ...

  • Page 338: Elec

    9 - 31 – + elec lighting system.

  • Page 339: Elec

    9 - 32 – + elec signal system eb806000 signal system circuit diagram br /l r /y p l /b w /l w /l l /b n r w /g w /lw /r w /g r w /rw /g w ww w ww 1 w /g w /r w /g r w w w w w w 2 b r br /l br /l br r r br 3 v q (bla ck) br ww w r l /wl /b b b g /w g /w g /w b b r r r r r b b l /w 7 5 4 6 o r b o o o...

  • Page 340: Elec

    9 - 33 – + elec signal system 3 main switch 4 battery 5 main fuse 8 cdi unit a reverse switch b neutral switch f coolant temperature warning light g four-wheel drive indicator light h thermo switch (cylinder head) i four-wheel drive fuse k gear motor n diode o ignition fuse s engine stop switch t st...

  • Page 341: Elec

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

  • Page 342: Elec

    9 - 35 – + elec signal system c0ntinuity correct 3.Main switch refer to “checking the switches”. * 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 syste...

  • Page 343: 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 continuity. No continuity replace the bulb and/or bulb socket. Continuity 2.Brake light switches refer to “checking the switches”. No...

  • Page 344: Elec

    9 - 37 – + elec signal system eb806024 2.If the neutral indicator light fails to come on: continuity 1.Bulb and bulb socket ● check the bulb and bulb socket for continuity. No continuity replace the bulb and/or bulb socket. Continuity 2.Neutral switch refer to “checking the switches”. No continuity ...

  • Page 345: Elec

    9 - 38 – + elec signal system 3.If the reverse indicator light fails to come on: continuity 1.Bulb and bulb socket ● check the bulb and bulb socket for continuity. No continuity replace the bulb and/or bulb socket. Continuity 2.Reverse switch refer to “checking the switches”. No continuity replace t...

  • Page 346: Elec

    9 - 39 – + elec signal system 4.If the coolant temperature warning light does not come on: ● check that the light comes on when the main switch is set to “on”. ● check that the light comes on when the coolant temperature is 120 ± 3 °c (248 ± 5.4 °f) or higher and that the light remains on when the c...

  • Page 347: Elec

    9 - 40 – + elec signal system c0ntinuity good condition warning handle the thermo switch (cylinder head) with special care. Never subject it to a strong shock or allow it to be dropped. Should it be dropped, it must be replaced. T r . . Thermo switch (cylinder head): 8 nm (0.8 m • kg, 5.8 ft • lb) t...

  • Page 348: Elec

    9 - 41 – + elec signal system c0ntinuity correct 4.Diode ● remove the diode from the coupler. ● connect the pocket tester ( Ω × 1) to the diode terminals as shown. ● check the diode for continuity as follows. Tester (+) lead → blue/black terminal 1 tester (–) lead → white/blue terminal 2 continuity ...

  • Page 349: Elec

    9 - 42 – + elec signal system 5.If the four-wheel drive indicator light fails to come on: continuity 1.Bulb and bulb socket ● check the bulb and bulb socket for continuity. No continuity replace the bulb and/or bulb socket. 2.Voltage ● connect the pocket tester (dc 20 v) to the bulb socket lead. Tes...

  • Page 350: Elec

    9 - 43 – + elec cooling system cooling system circuit diagram br /l r /y p l /b w /l w /l l /b n r w /g w /lw /r w /g r w /rw /g w ww w ww 1 w /g w /r w /g r w w w w w w 2 b r br /l br /l br r r br 3 v q (bla ck) br ww w r l /wl /b b b g /w g /w g /w b b r r r r r b b l /w 7 5 4 6 o r b o o o b /y 0...

  • Page 351: Elec

    9 - 44 – + 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 (radiator) 7.Wiring connections (the entire cooling system) note: ● remove the following part(s) before trou...

  • Page 352: Elec

    9 - 45 – + 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 353: Elec

    9 - 46 – + elec cooling system c0ntinuity good condition 6.Thermo switch (radiator) ● remove the thermo switch (radiator) from the radiator. ● connect the pocket tester ( Ω × 10) to the thermo switch (radiator) 1. ● immerse the thermo switch (radiator) in coolant 2. ● check the thermo switch (radiat...

  • Page 354: Elec

    9 - 47 – + elec cooling system c0ntinuity eb803028 correct 7.Wiring connections ● 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 355: Elec

    9 - 48 – + elec 2wd/4wd selecting system 2wd/4wd selecting system circuit diagram br /l r /y p l /b w /l w /l l /b n r w /g w /lw /r w /g r w /rw /g w ww w ww 1 w /g w /r w /g r w w w w w w 2 b r br /l br /l br r r br 3 v q (bla ck) br ww w r l /wl /b b b g /w g /w g /w b b r r r r r b b l /w 7 5 4 ...

  • Page 356: Elec

    9 - 49 – + elec 2wd/4wd selecting system eb803020 troubleshooting procedure check: 1.Fuses (main, four-wheel drive) 2.Battery 3.Main switch if the gear motor fails to operate: 4.On-command four-wheel drive switch 5.Gear motor 6.Wiring connections (the entire 2wd/4wd selecting system) note: ● remove ...

  • Page 357: Elec

    9 - 50 – + elec 2wd/4wd selecting system c0ntinuity correct 4.On-command four-wheel drive switch refer to “checking the switches”. * incorrect replace the on-command four-wheel drive switch. Correct 5.Gear motor ● check that the shift fork sliding gear is in the 2wd position. ● disconnect the gear m...

  • Page 358: Elec

    9 - 51 – + elec 2wd/4wd selecting system eb803028 correct 6.Wiring connections ● check the connections of the entire 2wd/ 4wd selecting system. Refer to “circuit diagram”. Replace the cdi unit. Poor connection properly connect the 2wd/4wd selecting system..

  • Page 359: 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 checking, adjusting and replacing of...

  • Page 360: 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 361: 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 362: 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 363: 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 364: 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 365

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

  • Page 366

    Yfm400far wiring diagram br/l r/y p l/b w/l w/l l/b n r w/g w/l w/r w/g r w/r w/g w w w w w w 1 w/g w/r w/g r w w w w w w 2 b r br/l br/l br r r br 3 v q (black) b r w w w r l/w l/b b b g/w g/w g/w b b r r r r r b b l/w 7 5 4 6 o r b o o o b/y 0 9 w/r w/g l/w g/l b/w b/w b/w g/w r/b sb g/l sb g/w b/...

  • Page 367: Lit-11616-17-32

    Lit-11616-17-32 5uh-f8197-10 yfm350fas supplementary service manual.

  • Page 368: Foreword

    Foreword this supplementary service manual has been prepared to introduce new service and data for the yfm350fas. For complete service information procedures it is necessary to use this supplemen- tary service manual together with the following manual. Yfm400far service manual: lit-11616-16-02 (5te-...

  • Page 369: 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 370: 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 371: 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 372: Contents

    Contents general information special tools ..................................................................................... 1 specifications general specifications ................................................................. 2 maintenance specifications .......................................

  • Page 373

    Primary and secondary sheaves ............................................. 54 primary sliding sheave ............................................................ 56 secondary sheave ..................................................................... 57 assembling the primary sheave .................

  • Page 374

    Troubleshooting faulty gear shifting ................................................................... 104 hard shifting ............................................................................. 104 shift lever does not move ................................................... 104 jumps out of ...

  • Page 375: Gen

    Gen info – 1 – special tools general information 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. S...

  • Page 376: Spec

    – 2 – spec specifications general specifications item standard model code: 5uh1 dimensions: overall length 1,984 mm (78.1 in) overall width 1,085 mm (42.7 in) overall height 1,120 mm (44.1 in) seat height 827 mm (32.6 in) wheelbase 1,233 mm (48.5 in) minimum ground clearance 245 mm (9.7 in) minimum ...

  • Page 377: Spec

    – 3 – spec differential gear case oil periodic oil change 0.35 l (0.31 imp qt, 0.37 us qt) total amount 0.40 l (0.35 imp qt, 0.42 us qt) air filter: wet type element fuel: type unleaded gasoline only fuel tank capacity 13.5 l (2.97 imp gal, 3.57 us gal) fuel reserve amount 3.3 l (0.73 imp gal, 0.87 ...

  • Page 378: Spec

    – 4 – spec tire pressure (cold tire): maximum load* 210 kg (463 lb) off-road riding front 22 ~ 28 kpa (0.22 ~ 0.28 kg/cm 2 , 3.2 ~ 4.0 psi) rear 22 ~ 28 kpa (0.22 ~ 0.28 kg/cm 2 , 3.2 ~ 4.0 psi) *load in total weight of rider accessories brakes: front brake type dual disc brake operation right hand ...

  • Page 379: Spec

    – 5 – spec maintenance specifications engine item standard limit cylinder head: warp limit ---- 0.03 mm (0.0012 in) cylinder: bore size 82.970 ~ 83.020 mm (3.2665 ~ 3.2685 in) 83.100 mm (3.2720 in) taper limit ---- 0.05 mm (0.0016 in) out of round limit ---- 0.01 mm (0.0004 in) camshaft: drive metho...

  • Page 380: Spec

    – 6 – spec cam chain: cam chain type/no. Of links 92rh2005/110 ---- cam chain adjustment method automatic ---- rocker arm/rocker arm shaft: rocker arm inside diameter 11.980 ~ 11.998 mm (0.4717 ~ 0.4724 in) 12.058 mm (0.4747 in) rocker arm shaft outside diameter 11.961 ~ 11.971 mm (0.4709 ~ 0.4713 i...

  • Page 381: Spec

    – 7 – spec stem runout limit ---- 0.01 mm (0.0004 in) valve seat width in 1.2 ~ 1.4 mm (0.0472 ~ 0.0551 in) ---- ex 1.2 ~ 1.4 mm (0.0472 ~ 0.0551 in) ---- valve spring: inner spring free length in 39.9 mm (1.57 in) 37.9 mm (1.49 in) ex 39.9 mm (1.57 in) 37.9 mm (1.49 in) set length (valve closed) in...

  • Page 382: Spec

    – 8 – spec outer spring free length in 43.27 mm (1.70 in) 41.27 mm (1.62 in) ex 43.27 mm (1.70 in) 41.27 mm (1.62 in) set length (valve closed) in 36.6 mm (1.44 in) ---- ex 36.6 mm (1.44 in) ---- compressed pressure (installed) in 235.4 ~ 251.1 n (24.0 ~ 25.6 kg, 52.92 ~ 56.45 lb) ---- ex 235.4 ~ 25...

  • Page 383: Spec

    – 9 – spec piston rings: top ring type barrel ---- dimensions (b × t) 1.2 × 3.3 mm (0.05 × 0.13 in) ---- end gap (installed) 0.20 ~ 0.40 mm (0.008 ~ 0.016 in) 0.65 mm (0.0256 in) side clearance (installed) 0.03 ~ 0.08 mm (0.0012 ~ 0.0032 in) 0.13 mm (0.0051 in) 2nd ring type taper ---- dimensions (b...

  • Page 384: Spec

    – 10 – spec balancer: balancer drive method gear ---- automatic centrifugal clutch: clutch shoe thickness 1.5 mm (0.06 in) 1.0 mm (0.04 in) clutch-in revolution 1,950 ~ 2,350 r/min ---- clutch-stall revolution 3,350 ~ 3,850 r/min ---- transmission: main axle deflection limit ---- 0.08 mm (0.0031 in)...

  • Page 385: Spec

    – 11 – spec oil pump: oil filter type foam ---- oil pump type trochoid ---- tip clearance 0.15 mm (0.006 in) 0.20 mm (0.008 in) side clearance 0.04 ~ 0.09 mm (0.002 ~ 0.004 in) ---- bypass valve setting pressure 78 ~ 118 kpa (0.78 ~ 1.18 kg/cm 2 , 11.3 ~ 17.1 psi) ---- oil pressure (hot) 20 kpa (0.2...

  • Page 386: Spec

    – 12 – spec cylinder head tightening sequence: item standard limit 5 2 4 1 6 3 maintenance specifications.

  • Page 387: Spec

    – 13 – spec tightening torques part to be tightened part name thread size q’ty tightening torque remarks nm m·kg ft·lb cylinder head (exhaust pipe) stud bolt m6 2 7 0.7 5.1 cylinder head bolt m10 4 32 3.2 23 bolt m8 2 20 2.0 14 camshaft bearing retainer bolt m6 2 8 0.8 5.8 spark plug — m12 1 18 1.8 ...

  • Page 388: Spec

    – 14 – spec pickup coil bolt m5 2 7 0.7 5.1 starter one-way clutch bolt m8 3 30 3.0 22 lt recoil starter bolt m6 4 10 1.0 7.2 lt clutch carrier assembly nut m22 1 140 14.0 100 stake. Clutch housing assembly bolt m6 8 10 1.0 7.2 middle drive shaft end cover bolt m6 2 10 1.0 7.2 lt middle drive shaft ...

  • Page 389: Spec

    – 15 – spec chassis item standard limit steering system: steering bearing type ball and race bearing ---- front suspension: shock absorber travel 99 mm (3.90 in) ---- spring free length 265 mm (10.43 in) ---- spring fitting length 231.9 mm (9.13 in) ---- spring rate (k1) 13.5 n/mm (1.35 kg/mm, 75.60...

  • Page 390: Spec

    – 16 – spec front disc brake: type dual ---- disc outside diameter × thickness 200.0 × 3.5 mm (7.87 × 0.14 in) ---- pad thickness inner 4.5 mm (0.18 in) 1 mm (0.04 in) pad thickness outer 4.5 mm (0.18 in) 1 mm (0.04 in) master cylinder inside diameter 14 mm (0.55 in) ---- caliper cylinder inside dia...

  • Page 391: Spec

    – 17 – spec tightening torques part to be tightened thread size tightening torque remarks nm m·kg ft·lb engine bracket (front-upper) and frame m8 33 3.3 24 engine bracket (front-lower) and frame m8 33 3.3 24 engine bracket (front-upper) and engine m10 42 4.2 30 engine bracket (front-lower) and engin...

  • Page 392: Spec

    – 18 – spec master cylinder and handlebar m6 7 0.7 5.1 footrest bracket and frame m8 16 1.6 11 front bumper and frame m8 34 3.4 24 front carrier and frame m8 34 3.4 24 front carrier and front bumper m8 34 3.4 24 rear carrier and frame m8 34 3.4 24 engine skid plate m6 7 0.7 5.1 differential gear oil...

  • Page 393: Spec

    – 19 – spec electrical item standard limit voltage: 12 v ---- ignition system: ignition timing (b.T.D.C.) 10°/ 1,500 r/min ---- advancer type digital ---- c.D.I.: magneto model/manufacturer f4t475/mitsubishi ---- pickup coil resistance/color 459 ~ 561 Ω at 20 °c (68 °f)/ white/red – white/green ----...

  • Page 394: Spec

    – 20 – spec brush overall length 12.0 mm (0.47 in) 4 mm (0.16 in) spring force 7.65 ~ 10.01 n (780 ~ 1,021 g, 27.53 ~ 36.04 oz) ---- commutator diameter 28 mm (1.10 in) 27 mm (1.06 in) mica undercut 0.7 mm (0.03 in) ---- starter relay model/manufacturer ms5f-561/jideco ---- amperage rating 180 a ---...

  • Page 395: Spec

    – 21 – spec lubrication points and lubricant types engine lubrication points lubricant type oil seal lip (all) ls bearing (all) e o-ring (all) ls crank pin e connecting rod (bearing) e piston surface/piston rings e piston pin e timing chain sprocket inner surface (crankshaft) m buffer boss e cranksh...

  • Page 396: Spec

    – 22 – spec oil flow diagrams 1 camshaft 2 crankshaft 3 oil pump 4 oil strainer oil flow diagrams.

  • Page 397: Spec

    – 23 – spec 1 thermo unit 2 oil pump 3 oil filter È to oil cooler É from oil cooler oil flow diagrams.

  • Page 398: Spec

    – 24 – spec 1 crankshaft 2 oil filter oil flow diagrams.

  • Page 399: Spec

    – 25 – spec 1 oil cooler 2 oil cooler outlet pipe 3 oil cooler inlet pipe È from engine É to engine a 1 È É a 1 3 2 2 3 oil flow diagrams.

  • Page 400: Spec

    – 26 – spec cable routing 1 rear brake switch lead 2 starter cable 3 rear brake lever cable 4 front brake hose 5 on-command four-wheel drive switch lead 6 on-command four-wheel drive switch 7 throttle cable 8 handlebar switch lead 9 handlebar switch 0 main switch lead a differential gear case breath...

  • Page 401: Spec

    – 27 – spec È fasten the on-command four-wheel drive switch lead behind the handlebar with a plastic band. É fasten the starter cable, handlebar switch lead and rear brake switch lead behind the handlebar with a plastic band. Ê fasten the handlebar switch lead and rear brake switch lead behind the h...

  • Page 402: Spec

    – 28 – spec 1 headlight lead 2 oil temperature warning light 3 four-wheel drive indicator light 4 reverse indicator light 5 neutral indicator light 6 indicator light/warning light couplers 7 differential gear case breather hose 8 wire harness È fasten the wire harness with a plastic band. Cable rout...

  • Page 403: Spec

    – 29 – spec 1 fuel tank breather hose 2 starter cable 3 cylinder head breather hose 4 rear brake lever cable 5 oil cooler hose 6 gear motor lead 7 differential gear case breather hose 8 fan motor lead È insert the fuel tank breather hose into the hole of the handlebar cover. É fasten the starter cab...

  • Page 404: Spec

    – 30 – spec 1 cylinder head breather hose 2 fuel hose 3 final drive gear case breather hose 4 rear brake breather hose 5 wire harness 6 starter motor lead 7 negative battery lead 8 rear brake lever cable 9 air filter case check hose 0 thermo unit lead a a.C. Magneto lead b rectifier/regulator c reve...

  • Page 405: Spec

    – 31 – spec È fasten the wire harness with a plastic band. É fasten the wire harness, starter motor lead, and negative battery lead with a plastic band. Ê fasten the final drive gear case breather hose, rear brake breather hose, ground lead, and a.C. Magneto lead with a plastic band. Ë fasten the re...

  • Page 406: Spec

    – 32 – spec 1 throttle cable 2 spark plug lead 3 main switch 4 wire harness 5 select lever control cable 6 rear brake light switch lead 7 rear brake pedal cable È fasten the select lever control cable, rear brake light switch lead, and spark plug lead with a plastic band. É fasten the select lever c...

  • Page 407: Spec

    – 33 – spec 1 front brake hose 2 throttle cable 3 wire harness 4 final drive gear case breather hose 5 rear brake breather hose 6 float chamber air vent hose 7 starter cable 8 rear brake lever cable cable routing.

  • Page 408: Chk

    – 34 – chk adj introduction/ periodic maintenance/lubrication eb300000 periodic checks and adjustments introduction this chapter includes all information necessary to perform recommended checks and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle o...

  • Page 409: Chk

    – 35 – chk adj periodic maintenance/lubrication * since these items require special tools, data and technical skills, have a yamaha dealer perform the service. Note: ● recommended brake fluid: dot 4 ● brake fluid replacement: ● when disassembling the master cylinder or caliper, replace the brake flu...

  • Page 410: Chk

    – 36 – chk adj seat, carriers, fenders and fuel tank seat, carriers, fenders and fuel tank seat, front carrier, front bumper and front fender 2 4 6 7 8 5 10 3 11 1 9 (8) (6) (6) t r . . 34 nm (3.4 m • kg, 24 ft • ib) t r . . 34 nm (3.4 m • kg, 24 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) order...

  • Page 411: Chk

    – 37 – chk adj seat, carriers, fenders and fuel tank 2 4 6 7 8 5 10 3 11 1 9 (8) (6) (6) t r . . 34 nm (3.4 m • kg, 24 ft • ib) t r . . 34 nm (3.4 m • kg, 24 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) order job name/part name q’ty remarks 10 indicator lights assembly coupler 2 disconnect. 11 in...

  • Page 412: Chk

    – 38 – chk adj seat, carriers, fenders and fuel tank fuel tank order job name/part name q’ty remarks removing the fuel tank remove the parts in the order below. Seat and fuel tank cover refer to “seat, carriers, fenders and fuel tank”. 1 fuel hose 1 note: before disconnecting the fuel hose, turn the...

  • Page 413: Chk

    – 39 – chk adj checking the oil temperature warning light engine checking the oil temperature warning light 1 oil temperature warning light turn the main switch to “on” and the engine stop switch to “ ”. Oil temperature warning light does not come on. Oil temperature warning light comes on. Check en...

  • Page 414: Eng

    – 40 – eng cylinder head engine cylinder head order job name/part name q’ty remarks removing the cylinder head remove the parts in the order below. Fuel tank/rubber cover refer to “seat, carriers, fenders and fuel tank”. Front fender air duct assembly 1/air filter case refer to “engine removal” in c...

  • Page 415: Eng

    – 41 – eng cylinder head order job name/part name q’ty remarks 5 cylinder head breather hose 1 6 camshaft sprocket cover/o-ring 1/1 7 tappet cover/o-ring 2/2 8 timing chain tensioner cap bolt 1 refer to “removing the cylinder head” and “installing the cylinder head” in chapter 4. (manual no.: 5te-f8...

  • Page 416: Eng

    – 42 – eng camshaft, rocker arms and valves camshaft, rocker arms and valves order job name/part name q’ty remarks removing the camshaft, rocker arms and valves remove the parts in the order below. 1 intake manifold/o-ring 1/1 2 oil gallery bolt 1 3 lock washer/bearing retainer 1/1 4 camshaft 1 refe...

  • Page 417: Eng

    – 43 – eng camshaft, rocker arms and valves order job name/part name q’ty remarks 8 valve cotter 4 refer to “removing the valves and valve springs” and “installing the valves and valve springs” in chapter 4. (manual no.: 5te-f8197-10) 9 valve spring retainer 2 10 valve spring (outer) 2 11 valve spri...

  • Page 418: Eng

    – 44 – 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. Cylinder head refer to “cylinder head”. 1 cylinder/o-ring 1/1 refer to “installing the cylinder” in chapter 4. (manual no.: 5te-f8197-10) 2 c...

  • Page 419: Eng

    – 45 – eng recoil starter and a.C. Magneto recoil starter and a.C. Magneto order job name/part name q’ty remarks removing the a.C. Magneto remove the parts in the order below. Engine oil drain. Refer to “changing the engine oil” in chapter 3. (manual no.: 5te-f8197-10) seat and fuel tank cover refer...

  • Page 420: Eng

    – 46 – eng recoil starter and a.C. Magneto order job name/part name q’ty remarks 7 lead holder 1 8 pickup coil 1 9 stator assembly 1 10 starter idle gear shaft 1 11 starter idle gear 1 12 rotor 1 refer to “removing the a.C. Magneto” and “installing the a.C. Magneto” in chapter 4. (manual no.: 5te-f8...

  • Page 421: Eng

    – 47 – eng balancer gears and oil pump order job name/part name q’ty remarks removing the balancer gears and oil pump remove the parts in the order below. Starter wheel gear refer to “recoil starter and a.C. Magneto”. 1 plate 1 2 nut/lock washer 1/1 3 balancer driven gear 1 refer to “removing the ba...

  • Page 422: Eng

    – 48 – eng balancer gears and oil pump order job name/part name q’ty remarks 7 balancer drive gear 1 8 spring 8 9 pin 4 10 oil pump assembly/gasket 1/1 for installation, reverse the removal procedure..

  • Page 423: Eng

    – 49 – eng balancer gears and oil pump oil pump e t r . . 5 nm (0.5 m • kg, 3.6 ft • ib) 2 3 6 5 4 1 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 1 3 oil pump driven gear 1 4 inner rotor 1 5 outer rotor 1 6 oil pump housi...

  • Page 424: Eng

    – 50 – eng balancer gears and oil pump 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 balancer ...

  • Page 425: Eng

    – 51 – eng balancer gears and oil pump installing the balancer drive gear and balancer driven gear 1.Install: ● pin ● spring ● balancer drive gear (onto the buffer boss) note: align the punch mark a on the balancer drive gear with the keyway b on the crankshaft. 2.Install: ● plate note: install the ...

  • Page 426: Eng

    – 52 – eng oil cooler oil cooler 1 5 2 new 3 t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 21 nm (2.1 m • kg, 15 ft • ib) t r . . 35 nm (3.5 m • kg, 25 ft • ib) 4 t r . . 6 nm (0.6 m • kg, 4.3 ft • ib) 6 t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) new order job name/part name q’ty remarks removing the o...

  • Page 427: Eng

    – 53 – eng oil cooler 1 5 2 new 3 t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 21 nm (2.1 m • kg, 15 ft • ib) t r . . 35 nm (3.5 m • kg, 25 ft • ib) 4 t r . . 6 nm (0.6 m • kg, 4.3 ft • ib) 6 t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) new order job name/part name q’ty remarks 3 oil outlet hose/o-ring ...

  • Page 428: Eng

    – 54 – eng primary and secondary sheaves primary and secondary sheaves 7 6 8 5 4 4 3 2 1 (14) (9) 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 . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 100 nm (10.0 m • kg, 72 ft • lb) t...

  • Page 429: Eng

    – 55 – eng primary and secondary sheaves 7 6 8 5 4 4 3 2 1 (14) (9) 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 . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 100 nm (10.0 m • kg, 72 ft • lb) t r . . 100 nm (10.0 m • kg, 72...

  • Page 430: Eng

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

  • Page 431: Eng

    – 57 – eng primary and secondary sheaves secondary sheave order job name/part name q’ty remarks disassembling the secondary sheave remove the parts in the order below. 1 nut 1 refer to “disassembling the secondary sheave” in chapter 4. (manual no.: 5te-f8197-10) refer to “assembling the secondary sh...

  • Page 432: Eng

    – 58 – eng primary and secondary sheaves assembling the primary sheave 1.Clean: ● primary sliding sheave face 1 ● primary fixed sheave face 2 ● collar 3 ● weights 4 ● primary pulley cam face note: remove any excess grease. 2.Install: ● weights 1 note: ● apply yamaha grizzly grease (90 g) to the whol...

  • Page 433: Eng

    – 59 – eng primary and secondary sheaves 3.Install: ● guide pins 1 4.Apply: ● bel-ray assembly lube ® (to all guide pin sliding grooves 1, and o-rings 2 ) new 5.Install: ● spring seat ● compression spring ● spring seat ● nut ***************************************************** installing steps: ● a...

  • Page 434: Eng

    – 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 the clutch” and “installing the clutch” in chapter 4. (manual...

  • Page 435: Eng

    – 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 436: Eng

    – 62 – eng crankcase crankcase starter motor, timing chain and oil filter t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) 3 8 10 9 t r . . 25 nm (2.5 m • kg, 18 ft • ib) t r . . 17 nm (1.7 m • kg, 12 ft • ib) t r . . 17 nm (1.7 m • kg, 12 ft • ib) t r . . 23 nm (2.3 m • kg, 17 ft • ib) t r . . 50 nm (5.0 m ...

  • Page 437: Eng

    – 63 – eng crankcase t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) 3 8 10 9 t r . . 25 nm (2.5 m • kg, 18 ft • ib) t r . . 17 nm (1.7 m • kg, 12 ft • ib) t r . . 17 nm (1.7 m • kg, 12 ft • ib) t r . . 23 nm (2.3 m • kg, 17 ft • ib) t r . . 50 nm (5.0 m • kg, 36 ft • ib) 2 4 5 6 7 11 1 t r . . 68 nm (6.8 m...

  • Page 438: Eng

    – 64 – eng crankcase crankcase 5 3 4 6 3 2 1 ls (12) 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 . . 20 nm (2.0 m • kg, 14 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 . . 10 nm (1.0 m • kg, 7.2 ft • ib) 7 order j...

  • Page 439: Eng

    – 65 – eng crankcase crankcase bearings order job name/part name q’ty remarks removing the crankcase bearings remove the parts in the order below. Crankshaft and balancer refer to “crankshaft”. Transmission refer to “transmission”. Middle drive/driven shaft refer to “middle gear”. 1 o-ring/collar 1/...

  • Page 440: Eng

    – 66 – 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 441: Eng

    – 67 – eng crankcase 4.Tighten: ● crankcase bolts 1 (follow the proper tightening sequence) ● crankcase bolts 2 (follow the proper tightening sequence) È right crankcase É left crankcase note: tighten the bolts in stages, using a crisscross pattern. 5.Apply: ● 4-stroke engine oil (to the crank pin, ...

  • Page 442: Eng

    – 68 – eng crankshaft crankshaft 3 2 1 t r . . 4 nm (0.4 m • kg, 2.9 ft • ib) order job name/part name q’ty remarks removing the crankshaft remove the parts in the order below. Crankcase separation refer to “crankcase”. 1 oil strainer 1 2 balancer 1 refer to “removing the crank- shaft” and “installi...

  • Page 443: Eng

    – 69 – eng crankshaft removing the crankshaft 1.Remove: ● crankshaft seal 1 note: mark a note of the position of each crankshaft seal so that they can be installed in the correct place and in the correct direction. 2.Remove: ● crankshaft use a crankcase separating tool 1. Crankcase separating tool: ...

  • Page 444: Eng

    – 70 – 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”. 1 driven sprocket 1 2 chain 1 3 secondary shaft 1 4 guide bar 1 5 shift fork 1 6 clutch dog 1 7 drive axle assembly 1 8...

  • Page 445: Eng

    – 71 – eng transmission installing the transmission 1.Install: ● shift shaft 1 ● drive axle assembly 2 ● clutch dog 3 ● shift fork 4 ● guide bar 5 note: install the shift fork with the “l” mark facing towards the left side of the crankcase. Be sure that the shift fork guide pin is properly seated in...

  • Page 446: Eng

    – 72 – 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 assembly 1 2 middle driven gear 1 3 nut 1 refer to “removing the middle drive ...

  • Page 447: Eng

    – 73 – eng middle gear middle driven shaft order job name/part name q’ty remarks removing the middle driven shaft remove the parts in the order below. Crankcase separation refer to “crankcase”. 1 circlip 2 refer to “removing the middle driven shaft” and “installing the middle driven shaft” in chapte...

  • Page 448: Eng

    – 74 – eng middle gear order job name/part name q’ty remarks 12 front drive shaft coupling 1 13 bearing retainer 1 14 middle driven shaft 1 for installation, reverse the removal procedure..

  • Page 449: Eng

    – 75 – eng middle gear selecting the middle drive and driven gear shims when the drive and driven gear, bearing housing assembly and/or crankcase are replaced, be sure to adjust the gear shims. 1.Select: ● middle drive gear shim 1 ● middle driven gear shim 2 *****************************************...

  • Page 450: Eng

    – 76 – eng middle gear example: 1) if the bearing housing is marked “–2”, ..... A is 4.48. 2) b is 15.0 3) c is 55 4) if the crankcase (right) is marked “75.01”, ..... D is 75.01. 5) therefore, the shim thickness is 0.53 mm. A = 75.01 – 4.48 – 15.0 – 55 = 0.53 6) round off hundredths digit and selec...

  • Page 451: Eng

    – 77 – eng middle gear 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 decimal number) on the middle driven pinion gear is either added to or subtracted from “59”. G = a numeral (usually a decimal number) on ...

  • Page 452: Eng

    – 78 – eng middle gear shims are supplied in the following thickness. ***************************************************** middle drive pinion gear shim thickness (mm) 0.10 0.40 0.15 0.50 0.20 0.60 0.30

  • Page 453: Driv

    – 79 – driv front constant velocity joints and differential gear drive train front constant velocity joints and differential gear order job name/part name q’ty remarks removing the front constant velocity joints and differential gear remove the parts in the order below. Engine skid plate (front) fro...

  • Page 454: Driv

    – 80 – driv front constant velocity joints and differential gear order job name/part name q’ty remarks 2 gear motor coupler/four-wheel drive switch connector 1/1 disconnect. 3 differential gear case breather hose 1 disconnect. 4 differential gear 1 5 drive shaft 1 6 compression spring 1 7 coupling g...

  • Page 455: Driv

    – 81 – driv front constant velocity joints and differential gear measuring and adjusting the differential gear lash measuring the differential gear lash 1.Secure the gear case in a vise or another supporting device. 2.Remove: ● drain plug ● gasket 3.Install: ● a bolt of the specified size 1 (into th...

  • Page 456: Driv

    – 82 – driv front constant velocity joints and differential gear adjusting differential gear lash 1.Remove: ● shim(s) (left) 1 ● differential gear assembly 2 ● shim(s) (right) 3 2.Adjust: ● gear lash ***************************************************** adjustment steps: ● select the suitable shims ...

  • Page 457: Chas

    – 83 – chas rear brake chassis rear brake order job name/part name q’ty remarks removing the rear brake drum remove the parts in the order below. Rear wheel (left) refer to “front and rear wheels” in chapter 8. (manual no.: 5te-f8197-10) 1 brake drum cover 1 refer to “removing the rear brake” in cha...

  • Page 458: Chas

    – 84 – chas rear brake order job name/part name q’ty remarks 13 brake camshaft lever 1 refer to “removing the rear brake” in chapter 8. (manual no.: 5te-f8197-10) refer to “installing the rear brake”. 14 brake shoe wear indicator 1 15 brake camshaft 1 16 o-ring 2 17 dust seal 1 18 brake shoe plate 1...

  • Page 459: Chas

    – 85 – chas rear brake checking the rear brake 1.Check: ● brake drum 1 cracks/damage → replace. ● splines 2 wear/damage → replace. 2.Check: ● brake shoe plate 1 ● pivot pins 2 ● brake camshaft 3 bends/cracks/damage → replace. ● dust seal 4 wear/damage → replace. 3.Check: ● brake shoes 1 ● brake shoe...

  • Page 460: Chas

    – 86 – chas rear brake 5.Measure: ● brake shoe lining thickness a out of specification → replace. 1 measuring points note: replace the brake shoes as a set if either is worn to the wear limit. Brake shoe lining thickness limit: 2.0 mm (0.08 in) 6.Measure: ● brake drum inside diameter a out of specif...

  • Page 461: Chas

    – 87 – chas rear brake caution: during installation, lightly grease the brake camshaft and the pivot pin. Wipe off the excess grease. 2.Install: ● brake shoe wear indicator 1 note: when installing the wear indicator pointer, fit the projection into a brake camshaft groove and align the pointer with ...

  • Page 462: Chas

    – 88 – chas rear brake 6.Check: ● brake camshaft operation unsmooth operation → repair. 7.Lubricate: ● dust seal 1 lithium-soap-based grease 8.Connect: ● rear brake lever cable 1 ● rear brake pedal cable 2 9.Install: ● springs 3 ● pins 4 ● adjusting nuts 5 ● brake drum ● brake drum cover 10.Install:...

  • Page 463: Chas

    – 89 – chas steering system steering system steering stem order job name/part name q’ty remarks removing the steering stem remove the parts in the order below. Handlebar refer to “handlebar” in chapter 8. (manual no.: 5te-f8197-10) seat refer to “seat, carriers, fenders and fuel tank”. Front fender ...

  • Page 464: Chas

    – 90 – chas steering system order job name/part name q’ty remarks 11 oil seal 1 12 bearing retainer 1 refer to “removing the bearing retainer” and “installing the bearing retainer” in chapter 8. (manual no.: 5te-f8197-10) 13 bearing 1 14 oil seal 1 for installation, reverse the removal procedure..

  • Page 465: Chas

    – 91 – chas front arms and front shock absorbers front arms and front shock absorbers order job name/part name q’ty remarks removing the front arms and front shock absorbers remove the parts in the order below. Engine skid plate refer to “seat, carriers, fenders and fuel tank”. Front fender front wh...

  • Page 466: Chas

    – 92 – chas front arms and front shock absorbers order job name/part name q’ty remarks 4 nut 1 refer to “removing the front arms” and “installing the front arms and front shock absorber” in chapter 8. (manual no.: 5te-f8197-10) 5 nut 1 6 bolt/nut 2/2 7 front lower arm/bushing 1/2 8 bolt/nut 2/2 9 fr...

  • Page 467: Elec

    – 93 – – + elec electric starting system electrical 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 for installation, reverse the removal procedure. Disassem...

  • Page 468: Elec

    – 94 – – + elec electric starting system assembling the starter motor 1.Install: ● brush holder set 1 note: align the projection a on the brush seat with the slot b on the bracket. 2.Install: ● yoke ● brackets note: align the match marks a on the yoke with the match marks b on the brackets..

  • Page 469: Elec

    – 95 – – + elec signal system eb806000 signal system circuit diagram br /l r /y r w /g w /lw /r w /g r w /rw /g w ww w ww w /g w /r w /g r w w w w w w b r br /l br /l br r (bla ck) br ww w r l /wl /b b b g /w b b r r r r r b b l /w o r w /l o b /y b b /w b /w w /r w /g l /w sb b /w g /w g /l w /y r ...

  • Page 470: Elec

    – 96 – – + elec signal system 3 main switch 4 battery 5 main fuse 8 cdi unit a thermo unit b reverse switch c neutral switch g oil temperature warning light h four-wheel drive indicator light i diode j four-wheel drive fuse l gear motor m ignition fuse o signaling system fuse r engine stop switch s ...

  • Page 471: Elec

    – 97 – – + elec signal system 1.If the oil temperature warning light does not come on: ● check that the light comes on when the start switch is pushed on. ● check that the light comes on when the oil temperature is 145 °c (293 °f) or higher. Continuity 1.Bulb and bulb socket check the bulb and bulb ...

  • Page 472: Elec

    – 98 – – + elec signal system c0ntinuity 4.Diode ● remove the diode from the coupler. ● connect the pocket tester ( Ω × 1) to the diode terminals as shown. ● check the diode for continuity as follows. * correct tester (+) lead → blue/black terminal 1 tester (–) lead → white/blue terminal 2 continuit...

  • Page 473: Elec

    – 99 – – + elec cooling system cooling system circuit diagram br /l r /y w w w b r br /l br /l br r (bla ck) br ww w r l /wl /b b b g /w b b r r r r r b b l /w o r w /l o b /y b b /w b /w w /r w /g l /w sb b /w g /w g /l w /y r /b dg dg g /l w /y w /l b /w sb g /w b /y dg (black) r /b l /w r ob w /r...

  • Page 474: Elec

    – 100 – – + elec cooling system troubleshooting procedure check: 1.Fuses (main, ignition) 2.Battery 3.Main switch 4.Fan motor 5.Circuit breaker (fan motor) 6.Fan motor relay if the fan motor does not move: 7.Thermo unit 8.Wiring connections (the entire cooling system) note: ● remove the following pa...

  • Page 475: Elec

    – 101 – – + elec cooling system c0ntinuity turns 4.Fan motor ● disconnect the fan motor coupler. ● connect the battery (12 v) as shown. Battery (+) lead → red terminal 1 battery (–) lead → black terminal 2 ● check the operation of the fan motor. * does not turn replace the fan motor. Meets specifica...

  • Page 476: Elec

    – 102 – – + elec cooling system c0ntinuity continuity 6.Fan motor relay ● remove the fan motor relay from the wire harness. ● connect the pocket tester ( Ω × 1) and the battery (12 v) to the fan motor relay terminals. Tester (+) lead → red/black terminal 1 tester (–) lead → blue terminal 2 battery (...

  • Page 477: Elec

    – 103 – – + elec cooling system c0ntinuity eb803028 correct 8.Wiring connections ● check the connections of the entire starting system. Refer to “circuit diagram”. Replace the cdi unit. * poor connection properly connect the cooling system..

  • Page 478: Trbl

    – 104 – trbl shtg faulty gear shifting/ overheating troubleshooting note: the following troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to troubleshooting. Refer to the relative procedure in this manual for checking, adjusting and replacin...

  • Page 479: Trbl

    – 105 – trbl shtg faulty brake ebs00549 faulty brake poor braking effect front disc brake ● worn brake pads ● worn disc ● air in brake fluid ● leaking brake fluid ● faulty master cylinder kit cup ● faulty caliper kit seal ● loose union bolt ● broken brake hose and pipe ● oily or greasy disc/brake pa...

  • Page 480

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

  • Page 481

    Yfm350fas wiring diagram br/l r/y r w/g w/l w/r w/g r w/r w/g w w w w w w w/g w/r w/g r w w w w w w b r br/l br/l br r (black) b r w w w r l/w l/b b b g/w b b r r r r r b b l/w o r w/l o b/y b b/w b/w w/r w/g l/w sb b/w g/w g/l w/y r/b dg dg g/l w/y w/l b/w sb g/w b/y dg (black) r/b l/w r o b w/r w/...