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Yamaha YFM450FAR Service Manual

Other manuals for YFM450FAR: Owner's Manual, Service Manual
Manual is about: 5nd2-ae1

Summary of YFM450FAR

  • Page 1

    Lit-11616-16-01 5nd-f8197-10 yfm450far service manual not for resale www.Smallenginediscount.Com.

  • Page 2

    Yfm450far service manual ©2002 by yamaha motor corporation, u.S.A. First edition, march 2002 all rights reserved. Any reproduction or unauthorized use without the written permission of yamaha motor corporation, u.S.A. Is expressly prohibited. Printed in u.S.A. Lit-11616-16-01 not for resale www.Smal...

  • 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 ...

  • 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 – + not for resale www.Smallenginediscount.Com.

  • Page 7: Contents

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

  • Page 8: Chapter 3.

    Coolant flow diagrams ................................................................... 2-22 oil flow diagrams .............................................................................. 2-24 cable routing ....................................................................................... 2...

  • Page 9: Chapter 4.

    Chassis .................................................................................................... 3-36 adjusting the rear brake ........................................................ 3-36 checking the brake fluid level ............................................. 3-38 checking the fron...

  • Page 10

    Camshaft, rocker arms and valves ........................................... 4-16 removing the camshaft and rocker arm .......................... 4-18 removing the valve and valve spring ................................ 4-18 checking the camshaft ........................................................

  • Page 11

    Crankcase .............................................................................................. 4-56 starter motor, timing chain and oil filter ...................... 4-56 crankcase ...................................................................................... 4-58 crankcase bearing...

  • Page 12: Chapter 5.

    Chapter 5. Cooling system radiator .................................................................................................... 5-1 checking the radiator ................................................................ 5-3 installing the radiator ................................................

  • Page 13: Chapter 8.

    Rear axle/final drive gear and drive shaft ........................... 7-17 removing the rear axle ............................................................ 7-20 disassembling the final drive gear ..................................... 7-20 replacing the final drive roller bearing ...................

  • Page 14: Chapter 9.

    Steering system .................................................................................. 8-30 handlebar ....................................................................................... 8-30 removing the rear brake switch ......................................... 8-31 checking the ha...

  • Page 15

    Checking the bulbs and bulb sockets ........................................ 9-6 types of bulbs ................................................................................ 9-6 checking the condition of the bulbs ................................... 9-6 checking the condition of the bulb sockets ...

  • Page 16: Chapter 10.

    Chapter 10. Troubleshooting starting failure/hard starting ................................................... 10-1 fuel system .................................................................................... 10-1 electrical system ...................................................................

  • 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 features liquid cooling engine compact liquid cooled 45 ° inclined engine. A liquid cooling system has been incorporated for stable power and engine endurance. 1 radiator 2 thermo switch 3 fan motor park position when the drive select lever is shifted into the park position, a stopper...

  • Page 19: Gen

    Gen info 1 - 3 features front differential 1 adapter 2 drive clutch 3 differential side gear (left) 4 differential pinion gear 5 ring gear 6 differential side gear (right) 7 drive pinion gear 8 gear motor È to front wheel É from the middle gear not for resale www.Smallenginediscount.Com.

  • Page 20: Gen

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

  • Page 21: Gen

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

  • Page 22: Gen

    Gen info 1 - 6 features 4wd (diff-lock) when the 4wd (diff-lock) mode is selected, the gear motor moves the drive clutch 2 further to the right, which causes the ring gear 5 and the drive clutch 2 to engage. As a result, power is transmitted directly from the ring gear 5 to the drive clutch 2, then ...

  • Page 23: Gen

    Gen info 1 - 7 features in addition, the 4wd (diff-lock) mode can be engaged only when the atv is stopped. Even if an attempt is made to select this mode when the atv is traveling, it will only result in a standby condition (i.E., when the differential lock select switch and the differential gear ar...

  • Page 24: Gen

    1 - 8 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 pa...

  • Page 25: Gen

    1 - 9 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 26: Gen

    1 - 10 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: ● ...

  • Page 27: Gen

    Gen info 1 - 11 special tools eb102001 special tools the following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools; this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools may di...

  • Page 28: Gen

    Gen info 1 - 12 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 use...

  • Page 29: Gen

    Gen info 1 - 13 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 lo...

  • Page 30: Gen

    Gen info 1 - 14 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 pocket tester this instrument is needed for checking the electrical system. 90890-03113 engine tach...

  • Page 31: Gen

    Gen info 1 - 15 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 retain...

  • Page 32: Spec

    2 - 1 spec specifications general specifications item standard model code: 5nd1, 5nd5 dimensions: overall length 1,984 mm (78.1 in) overall width 1,085 mm (42.7 in) overall height 1,120 mm (44.1 in) seat height 827 mm (32.6 in) wheelbase 1,233 mm (48.5 in) minimum ground clearance 245 mm (9.7 in) mi...

  • Page 33: Spec

    2 - 2 spec differential gear case oil periodic oil change 0.23 l (0.20 imp qt, 0.24 us qt) total amount 0.28 l (0.25 imp qt, 0.30 us qt) radiator capacity (including all routes) 1.32 l (1.16 imp qt, 1.40 us qt) air filter: wet type element fuel: type unleaded fuel fuel tank capacity 15 l (3.3 lmp ga...

  • Page 34: 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 brake: front brake type dual disc brake operation right hand o...

  • Page 35: 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 36: 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 37: 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 38: 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 ~...

  • Page 39: Spec

    2 - 8 spec 2nd ring type taper ---- dimensions (b × t) 1.0 × 3.6 mm (0.0394 × 0.1417 in) ---- end gap (installed) 0.40 ~ 0.60 mm (0.0157 ~ 0.0236 in) 0.95 mm (0.0374 in) side clearance 0.02 ~ 0.06 mm (0.0008 ~ 0.0024 in) 0.12 mm (0.0047 in) oil ring dimensions (b × t) 2.0 × 2.8 mm (0.0787 × 0.1102 i...

  • Page 40: 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 5nd1 00 ---- main jet (m.J) #131.3 ---- main air jet (m.A....

  • Page 41: 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 42: Spec

    2 - 11 spec cylinder head tightening sequence: item standard limit maintenance specifications not for resale www.Smallenginediscount.Com.

  • Page 43: 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 spro...

  • Page 44: 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 45: 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 46: 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 47: 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 e...

  • Page 48: 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 16 differential gear case drain bolt m10 10 1.0 7 differential gear case and bearing hous...

  • Page 49: 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 f4t46471/mitsubishi ---- pickup coil resistance/color 459 ~ 561 Ω at 20 ° c (68 ° f)/ white/red – white/green ---- rotor rotation direc...

  • Page 50: 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 51: 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 52: Spec

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

  • Page 53: Spec

    2 - 22 spec coolant flow diagrams 1 radiator 2 thermo switch 3 fan motor È to coolant reservoir coolant flow diagrams not for resale www.Smallenginediscount.Com.

  • Page 54: Spec

    2 - 23 spec 1 radiator 2 thermostat È to coolant reservoir coolant flow diagrams not for resale www.Smallenginediscount.Com.

  • Page 55: Spec

    2 - 24 spec oil flow diagrams 1 camshaft 2 crankshaft 3 drive axle oil flow diagrams not for resale www.Smallenginediscount.Com.

  • Page 56: Spec

    2 - 25 spec 1 oil filter oil flow diagrams not for resale www.Smallenginediscount.Com.

  • Page 57: Spec

    2 - 26 spec 1 oil pump 2 oil strainer oil flow diagrams not for resale www.Smallenginediscount.Com.

  • Page 58: 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 and differential gear lock switch 6 throttle cable 7 handlebar switch 8 handlebar switch lead 9 main switch lead 0 fan motor breather hose a differential gear...

  • Page 59: Spec

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

  • Page 60: Spec

    2 - 29 spec 1 sub-wire harness 2 headlight lead 3 auxiliary dc jack lead 4 four-wheel drive relay 3 5 fan motor breather hose 6 differential gear case breather hose 7 coolant reservoir breather hose 8 meter assembly coupler cable routing not for resale www.Smallenginediscount.Com.

  • Page 61: Spec

    2 - 30 spec 1 starter cable 2 cylinder head breather hose 3 fuel hose 4 carburetor drain hose 5 coolant reservoir breather hose 6 radiator outlet hose 7 coolant reservoir hose 8 sub-wire harness 9 differential gear case breather hose 0 thermo switch 2 È insert the fuel tank breather hose into the ho...

  • Page 62: Spec

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

  • Page 63: 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 gear case breather hose, rectifier/regulator lead, low-range switch lead, high-range switch lead, neutral switch lead, reverse switch lead, speed sensor lead and a.C...

  • Page 64: Spec

    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 rear brake fluid reservoir hose 8 select lever control cable 9 rear brake cable 0 rear brake hose È fasten the radiator inlet hose and spark plug lead with a plastic ban...

  • Page 65: 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 starter cable 7 rear brake cable cable routing not for resale www.Smallenginediscount.Com.

  • Page 66: Spec

    2 - 35 spec 1 battery 2 positive battery lead 3 tail/brake light lead 4 cdi unit 5 negative battery lead cable routing not for resale www.Smallenginediscount.Com.

  • Page 67: Spec

    2 - 36 spec 1 final drive gear case breather hose 2 rear brake hose 3 air filter case check hose cable routing not for resale www.Smallenginediscount.Com.

  • Page 68: 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 69: Chk

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

  • Page 70: 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 se...

  • Page 71: 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...

  • Page 72: Chk

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

  • Page 73: 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 ” ...

  • Page 74: Chk

    3 - 7 chk adj seat, carriers, fenders and fuel tank order job name/part name q ’ ty remarks 8 cdi unit 1 9 wire harness 1 10 rear fender 1 for installation, reverse the removal procedure. Not for resale www.Smallenginediscount.Com.

  • Page 75: 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...

  • Page 76: 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, re...

  • Page 77: 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 78: 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 th...

  • Page 79: 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 80: 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 ta...

  • Page 81: 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 82: 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 lev...

  • Page 83: 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 84: 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 85: 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 86: 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 87: 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.Atta...

  • Page 88: Chk

    3 - 21 chk adj 4.Detach: ● timing light ● inductive tachometer or engine tachometer 5.Install: ● seat ● fuel tank side panel (right) refer to “ seat, carriers, fenders and fuel tank ” . Measuring the compression pressure note: insufficient compression pressure will result in a loss of performance. 1...

  • Page 89: 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 90: 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 mar...

  • Page 91: 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...

  • Page 92: 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 93: 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 94: Chk

    3 - 27 chk adj cleaning the air filter 1.Remove: ● seat 2.Remove: ● air filter case cover 1 3.Remove: ● air filter element assembly 1 ● air filter element cap ● air filter element 2 air filter element cap 3 air filter element caution: never operate the engine with the air filter element removed. Thi...

  • Page 95: 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 96: 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) 3.Check: ● coolant level the coolant level should be between the minimum level mark a and maximum level mark b. Below the minimum level mark → a...

  • Page 97: 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...

  • Page 98: 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 99: 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 100: Chk

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

  • Page 101: Chk

    3 - 34 chk adj checking the v-belt/ cleaning the spark arrester 4.Replace: ● v-belt ***************************************************** replacing steps: ● install the bolts 1 (90101-06016) into the secondary fixed sheave hold. Note: tightening the bolts 1 will push the secondary sliding sheave awa...

  • Page 102: Chk

    3 - 35 chk adj cleaning the spark arrester ● remove the bolt 1. ● remove the tailpipe 2 by pulling it out of the muffler. ● tap the tailpipe lightly with a soft-face hammer or suitable tool, then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe and the i...

  • Page 103: 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 lever free play a out of specification → adjust. Rear brake lever free play: 0.5 ~ 2 mm (0.02 ~ 0.08 i...

  • Page 104: Chk

    3 - 37 chk adj adjusting the rear brake ● loosen the locknut 4. ● turn the adjusting bolt 5 until the brake pedal height is within the specified limits. ● tighten the locknut 4. Note: when adjusting the brake pedal height make sure the locknut-to-adjusting bolt clearance a does not exceed 6 mm (0.24...

  • Page 105: Chk

    3 - 38 chk adj checking the brake fluid level 1.Place the machine on a level surface. Note: when checking the brake fluid level, make sure that the top of the brake fluid reservoir top is horizontal. 2.Remove: (rear brake) ● front carrier ● front fender panel refer to “ seat, carriers, fenders and f...

  • Page 106: Chk

    3 - 39 chk adj checking the front brake pad/ checking the rear brake pad checking the front brake pad 1.Remove: ● front wheels 2.Check: ● brake pad wear indicators groove 1 almost touch the brake disc → replace the brake pads as a set. Refer to “ front and rear brakes ” in chapter 8. 3.Operate the b...

  • Page 107: Chk

    3 - 40 chk adj checking the brake hose checking the brake hose 1.Remove: ● seat ● front carrier ● front fender refer to “ seat, carriers, fenders and fuel tank ” . ● right footrest board refer to “ footrest boards ” . 2.Check: ● front brake hoses 1 ● rear brake hoses 2 cracks/wear/damage → replace. ...

  • Page 108: 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 109: Chk

    3 - 42 chk adj bleeding the hydraulic brake system/ adjusting the select lever control cable and shift rod k.Add brake fluid to the proper level. Refer to “ checking the brake fluid level ” . Warning check the operation of the brake after bleeding the brake system. **********************************...

  • Page 110: 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 park from reverse and to neutral from reverse. ● be...

  • Page 111: 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 112: 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 113: Chk

    3 - 46 chk adj checking the differential gear oil/ changing the differential gear oil checking the differential gear oil 1.Place the machine on a level surface. 2.Remove: ● oil filler bolt 1 3.Check: ● oil level oil level should be up to the brim of hole. Oil level low → add oil to proper level. Cau...

  • Page 114: Chk

    3 - 47 chk adj changing the differential gear oil/checking the constant velocity joint dust boot 4.Drain: ● differential gear oil 5.Install: ● drain plug note: check the gasket (drain plug). If it is damaged, replace it with new one. T r . . 10 nm (1.0 m • kg, 7.2 ft • lb) 6.Fill: ● differential gea...

  • Page 115: Chk

    3 - 48 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 bushings. 3.Check: ● tie-rod ends turn the handlebar to the left and/or right un...

  • Page 116: Chk

    3 - 49 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 117: Chk

    3 - 50 chk adj adjusting the front shock absorber/adjusting the rear shock absorber/checking the tire adjusting the front shock absorber warning always adjust both front shock absorber spring preload to the same setting. Uneven adjustment can cause poor handling and loss of stability. 1.Adjust: ● sp...

  • Page 118: Chk

    3 - 51 chk adj checking the tire ● tire characteristics 1)tire characteristics influence the handling of atv ’ s. The tires listed below have been approved by yamaha motor co., ltd. For this model. If other tire combinations are used, they can adversely affect your machine ’ s handling characteristi...

  • Page 119: Chk

    3 - 52 chk adj checking the tire 1.Measure: ● tire pressure (cold tire pressure) out of specification → adjust. Note: ● the low-pressure tire gauge 1 is included as standard equipment. ● if dust or the like is stuck to this gauge, it will not provide the correct readings. Therefore, take two measure...

  • Page 120: Chk

    3 - 53 chk adj checking the wheel/ checking and lubricating the cable checking the wheel 1.Check: ● wheels 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 after ...

  • Page 121: Chk

    3 - 54 chk adj lubricating the levers, pedal, etc. Lubricating the levers, pedal, etc. 1.Lubricate the pivoting parts. Recommended lubricant: yamaha chain and cable lube or engine oil not for resale www.Smallenginediscount.Com.

  • Page 122: Chk

    3 - 55 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 123: Chk

    3 - 56 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 124: Chk

    3 - 57 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 125: Chk

    3 - 58 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 126: Chk

    3 - 59 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 127: Chk

    3 - 60 chk adj checking the battery/ checking the fuse 5.Check: ● battery terminals dirty → clean with a wire brush. Poor connection → correct. Note: after cleaning the terminals, apply a light coat of grease. 6.Install: ● battery 7.Connect: ● battery leads caution: first, connect the positive lead ...

  • Page 128: Chk

    3 - 61 chk adj checking the fuse note: set the tester to the “ Ω × 1 ” position. ● if the tester indicates ∞, replace the fuse. ***************************************************** 3.Replace: ● blown fuse ***************************************************** replacement steps: ● turn off the igniti...

  • Page 129: Chk

    3 - 62 chk adj checking the fuse/adjusting the headlight beam/changing the headlight bulb 4.Install: ● seat refer to “ seat, carriers, fenders and fuel tank ” . Adjusting the headlight beam 1.Adjust: ● headlight beam (vertically) turn the adjuster 1 in or out. Turning in headlight beam raised. Turni...

  • Page 130: Chk

    3 - 63 chk adj changing the headlight bulb 3.Install: ● bulb secure the new bulb with the headlight unit. Caution: avoid touching the glass part of the bulb. Keep it free from oil; otherwise, the transparency of the glass, life of the bulb, and luminous flux will be adversely affected. If oil gets o...

  • Page 131: 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/...

  • Page 132: Eng

    4 - 2 eng engine removal order job name/part name q ’ ty remarks 6 final drive gear case breather hose 1 7 cylinder head breather hose 1 8 vacuum chamber breather hose 1 9 air filter case 1 for installation, reverse the removal procedure. 4 not for resale www.Smallenginediscount.Com.

  • Page 133: 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 shift arm 1 2 select lever shift rod 1 3 select lever unit 1 4 coolant reservoir breather hose 1 5 cool...

  • Page 134: 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 3 thermo switch 1 lead 1 4 starter motor ...

  • Page 135: 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 mo...

  • Page 136: 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. Not for resale www.Smallenginediscount.Com.

  • Page 137: Eng

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

  • Page 138: 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 rem...

  • Page 139: 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 1 lead 1 disconnect. 9 timing chain tensioner cap bolt 1 refer to “ removing/installing the cylinder head ” . 10 timing chain...

  • Page 140: 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 c...

  • Page 141: 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 142: 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 143: Eng

    4 - 13 eng cylinder head installing the cylinder head 1.Install: ● cylinder head ● bolt (m10) ● bolt (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.I...

  • Page 144: 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 ch...

  • Page 145: 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) no...

  • Page 146: 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 1 3 oil check bolt 1 4 lock washer/bearing retainer 1/1...

  • Page 147: 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 valve and valve spring ” . 13 valve (intake) 1 14 valve (exhaust) 1 15 valve stem seal 2 16 valve spring seat 2 for installation, reverse the removal proce...

  • Page 148: Eng

    4 - 18 eng camshaft, rocker arms and valves removing the camshaft and rocker arm 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 remo...

  • Page 149: 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 150: 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 151: Eng

    4 - 21 eng camshaft, rocker arms and valves checking the valve and valve spring 1.Measure: ● stem-to-guide clearance out of specification → replace the valve guide. Stem-to-guide clearance = valve guide inside diameter a – valve stem diameter b clearance (stem to guide): intake: 0.010 ~ 0.037 mm (0....

  • Page 152: 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 153: 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 c...

  • Page 154: 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. ● ins...

  • Page 155: 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 valve and valve spring 1.Apply: ● molybdenum disulfide oil (onto the valve stem and valve stem seal)...

  • Page 156: Eng

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

  • Page 157: 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 timi...

  • Page 158: 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 159: 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 meas...

  • Page 160: 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 161: 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 162: 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 163: 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 164: 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 cdi magneto remove the parts in the order below. Engine oil drain. Refer to “ changing the engine oil ” in chapter 3. Seat and side panels refer to “ seat and side panels ”...

  • Page 165: 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 idl...

  • Page 166: 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...

  • Page 167: 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 168: 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 169: 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 170: 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 171: 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 172: 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 sheave remove the parts in the order below. Front fender refer to “ seat, carriers, fenders and fuel tank ” in chapter 3. Rear fender right footrest board...

  • Page 173: 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. Not for resale www.Smallenginediscount.Com.

  • Page 174: 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 pulley sheave cap 1 refer to “ assembling the primary sheave ” . 2 primary pulley slider 4 3 spacer 4 4 prim...

  • Page 175: 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 gui...

  • Page 176: 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 177: 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 slider ● primary sliding sheave splines wear/cracks/damage → rep...

  • Page 178: 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 ● weight 4 ● primary pulley cam face note: remove any excess grease. 2.Install: ● weight 1 note: ● apply yamaha grizzly grease (120 g) to the whole...

  • Page 179: Eng

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

  • Page 180: 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 181: 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 ...

  • Page 182: 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. Not for res...

  • Page 183: 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 184: 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: ● collar ● clutch carrier assembly ● nut 1 note: ● lu...

  • Page 185: 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) not for...

  • Page 186: 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 ” . Cyli...

  • Page 187: 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 low-range switch 1 10 high-range switch 1 11 neutral switch 1 12 reverse switch 1 13 oil filler cap 1 14 bearing cover/gasket 1/1 15 oil delivery pipe 1 16 oil strainer cove...

  • Page 188: 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 shift lever cover/gasket 1/1 refer to “ installing the shift lever ” . 2 shift lever 1/o-ring 1/1 3 shift lever 2 assembly 1 4 crankcase (left) 1 refer to “ separati...

  • Page 189: Eng

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

  • Page 190: 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: ● temporary install the clutch carrier assembly 1. ● hold the clutch carrier assembly with a clutch holding t...

  • Page 191: 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 192: 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 193: 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, bearing and oil de...

  • Page 194: 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 195: 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 “ remov...

  • Page 196: 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. Not for ...

  • Page 197: 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 198: 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 199: 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 200: 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 clutch dog 2 1 4 shift fork “ l ” 1 5 spring 1 6 low wheel gear 1 7 secondary shaf...

  • Page 201: Eng

    4 - 71 eng transmission order job name/part name q ’ ty remarks 11 shift fork “ r ” 1 12 spring 1 13 shift cam 1 14 stopper wheel 1 15 clutch dog 1 1 16 high wheel gear 1 17 middle drive gear 1 18 stopper lever 1 19 spacer/o-ring 1/1 for installation, reverse the removal procedure. Not for resale ww...

  • Page 202: Eng

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

  • Page 203: Eng

    4 - 73 eng transmission checking the transmission 1.Measure: ● axle runout use a centering device and a dial gauge. Out of specification → replace the bent axle. Runout limit (drive axle): 0.06 mm (0.0024 in) 2.Check: ● gear teeth blue discoloration/pitting/wear → replace. ● mated dogs rounded edges...

  • Page 204: Eng

    4 - 74 eng transmission checking the chain 1.Check: ● chain cracks/shift → replace the chain, secondary shaft and driven sprocket as a set. Checking the stopper lever and stopper wheel 1.Check: ● stopper lever pawl 1 bends/damage/wear → replace the stopper lever and stopper wheel as a set. ● stopper...

  • Page 205: Eng

    4 - 75 eng transmission 2.Check: ● shift operation unsmooth operation → repair. Note: ● oil each gear and bearing thoroughly. ● before assembling the crankcase, be sure that the transmission is in neutral and that the gears turn freely. Not for resale www.Smallenginediscount.Com.

  • Page 206: Eng

    4 - 76 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 “ re...

  • Page 207: Eng

    4 - 77 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 4 refer to “ removing/installing the middle driven shaft ” . 2 bearing 4 3 universal joint ...

  • Page 208: Eng

    4 - 78 eng middle gear order job name/part name q ’ ty remarks 12 bearing retainer 1 13 middle driven shaft 1 for installation, reverse the removal procedure. Not for resale www.Smallenginediscount.Com.

  • Page 209: Eng

    4 - 79 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 210: Eng

    4 - 80 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 211: Eng

    4 - 81 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 retainer turn it clockwise. Ring nut wrench: p/n. Ym-38404, 90890-01430 6.Remove: ...

  • Page 212: Eng

    4 - 82 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 shim when the drive and driven gear, bearing housing assembly and/or crankcase replaced, be sure to adju...

  • Page 213: Eng

    4 - 83 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 appropria...

  • Page 214: Eng

    4 - 84 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 numbe...

  • Page 215: Eng

    4 - 85 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 216: Eng

    4 - 86 eng middle gear ● tighten the bearing retainer. Caution: the middle driven shaft bearing retainer has left-handed threads. To tighten the retainer turn it counterclockwise. ***************************************************** 3.Install: ● shims 1 ● bearing housing note: install the shims so ...

  • Page 217: Eng

    4 - 87 eng middle gear ● install the bearing 1 onto the yoke. Caution: check each bearing. The needles can easily fall out of their races. Slide the yoke back and forth on the bearings; the yoke will not go all the way onto a bearing if a needle is out of place. ● press each bearing into the u-joint...

  • Page 218: Eng

    4 - 88 eng middle gear ● attach the gear lash measurement tool 3 and dial gauge 4. A 8.12 mm (0.32 in) ● measure the gear lash while rotating the middle driven shaft back and forth. Note: measure the gear lash at 4 positions. Rotate the middle driven gear 90 ° each time. ● if the gear lash is incorr...

  • Page 219: 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 220: 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 1 for installation, reverse the removal procedure. 5 not for resale www.Smallenginediscount.Com.

  • Page 221: 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. Note: straighten any flattened fins with a thin, flat- head screwdriver. 2.Check: ● radiator hoses cracks/damage → replace. 3.Measure:...

  • Page 222: 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. Not for resale www.Smallenginediscount.Com.

  • Page 223: 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 224: 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 225: 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 226: 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 227: 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 228: 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 229: 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 not for resale www.Smalle...

  • Page 230: 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 231: 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 232: 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 233: 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 234: 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 235: 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 236: Carb

    6 - 7 carb carburetor adjusting the fuel level 1.Measure: ● fuel level a out of specification → adjust. ***************************************************** measurement and adjustment steps: ● place the machine on a level surface. ● connect the fuel level gauge 1 to the drain pipe 2. ● loosen the d...

  • Page 237: 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 238: 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 239: Driv

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

  • Page 240: 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 joint and differential gear remove the parts in the order below. Engine skid plate (front) front fender refe...

  • Page 241: 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 for installation, reverse the removal procedure. Not for resale www.Smallenginediscount.Com.

  • Page 242: Driv

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

  • Page 243: Driv

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

  • Page 244: Driv

    7 - 8 driv front constant velocity joints and differential gear order job name/part name q’ty remarks b differential gear assembly 1 c shim (right) 1 d circlip/bearing 1/1 e drive pinion gear 1 f differential gear case 1 for assembly, reverse the disassembly procedure. Not for resale www.Smallengine...

  • Page 245: Driv

    7 - 9 driv removing the universal joint 1.Remove: ● universal joint ***************************************************** removal steps: ● remove the circlips 1. ● place the u-joint in a press. ● with a suitable diameter pipe 2 beneath the yoke 3, press the bearing 4 into the pipe as shown. Note: it...

  • Page 246: Driv

    7 - 10 driv front constant velocity joints and differential gear checking the constant velocity joint 1.Check: ● double off-set joint spline ● ball joint spline ● shaft spline wear/damage → replace. 2.Check: ● dust boots cracks/damage → replace. Caution: always use a new boot band. 3.Check: ● balls ...

  • Page 247: Driv

    7 - 11 driv front constant velocity joints and differential gear checking the gear motor 1.Check: ● gear motor ***************************************************** checking steps: ● connect two c size batteries to the gear motor terminals 1. (as shown illustration) caution: do not use a 12 v batter...

  • Page 248: Driv

    7 - 12 driv front constant velocity joints and differential gear 3.Check: ● free play (thrust movement) excessive play → replace the joint assembly. Assembling the differential gear 1.Measure: ● gear lash refer to “measuring and adjusting the differential gear lash”. 2.Install: ● gear motor ********...

  • Page 249: Driv

    7 - 13 driv front constant velocity joints and differential gear 3.Install: ● universal joint yoke ● o-ring ● washer ● nut use a universal joint holder 1. Universal joint holder: p/n. Ym-04062, 90890-04062 lt t r . . 62 nm (6.2 m • kg, 45 ft • lb) 4.Check: ● differential gear operation unsmooth oper...

  • Page 250: Driv

    7 - 14 driv measuring and adjusting the differential gear lash measuring the differential gear lash 1.Secure the gear case in a vise or another supporting device. 2.Remove: ● drain plug ● gasket 3.Install: ● a bolt of the specified size 1 (into the drain plug hole) caution: finger tighten the bolt u...

  • Page 251: Driv

    7 - 15 driv adjusting differential gear lash 1.Remove: ● shim(s) (left) 1 ● differential gear assembly 2 ● shim(s) (right) 3 2.Adjust: ● gear lash ***************************************************** adjustment steps: ● select the suitable shims using the following chart. ● if it is necessary to in...

  • Page 252: Driv

    7 - 16 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 253: Driv

    7 - 17 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. Rear wheel hubs/brake disc refer to “fr...

  • Page 254: Driv

    7 - 18 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 1 7 oil seal/bearing 1/1 8 ...

  • Page 255: Driv

    7 - 19 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 1 g final drive gear ca...

  • Page 256: Driv

    7 - 20 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 257: Driv

    7 - 21 driv rear axle/final drive gear and drive shaft replacing the final drive roller bearing 1.Remove: ● roller bearing (ring gear) 1 use a suitable press tool 2 and an appropriate support for the main housing. ● oil seal 3 2.Remove: ● roller bearing (final drive pinion gear) 1 ******************...

  • Page 258: Driv

    7 - 22 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 259: Driv

    7 - 23 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) 1 ***********...

  • Page 260: Driv

    7 - 24 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 261: Driv

    7 - 25 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 262: Driv

    7 - 26 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 263: Driv

    7 - 27 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 264: Driv

    7 - 28 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 265: Driv

    7 - 29 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 a suitable shim(s) and thrust w...

  • Page 266: Driv

    7 - 30 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 267: Driv

    7 - 31 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 268: 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 wheel remove the parts in the order below. Place the machine on a level surface. Warning securely support the machine so there is no danger of it falling over. 1 front...

  • Page 269: Chas

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

  • Page 270: Chas

    8 - 3 chas front and rear wheels checking the wheel 1.Check: ● wheel 2.Measure: ● wheel runout over the specified limit → replace the wheel or check the wheel bearing play 1. 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 271: Chas

    8 - 4 chas front and rear wheels checking the brake disc 1.Check: ● brake disc galling/damage → replace. 2.Measure: ● brake disc deflection out of specification → check the wheel runout. If wheel runout is within the limits, replace the brake disc. ● brake disc thickness a out of specification → rep...

  • Page 272: 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 wheel) ● nuts (rear wheel) note: tighten the nuts in stages and in a crisscross pa...

  • Page 273: Chas

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

  • Page 274: Chas

    8 - 7 chas front and rear brakes rear brake pads order job name/part name q’ty remarks removing the rear brake pads remove the parts in the order below. Rear wheel (left) refer to “front and rear wheels”. 1 brake caliper mounting bolt 2 refer to “replacing the rear brake pad”. 2 brake pad holding bo...

  • Page 275: Chas

    8 - 8 chas front and rear brakes 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 con...

  • Page 276: Chas

    8 - 9 chas front and rear brakes ***************************************************** installation steps: ● connect a suitable hose 1 tightly to the brake caliper bleed screw 2. Put the other end of this hose into an open container. ● loosen the brake caliper bleed screw and, using a finger, push t...

  • Page 277: Chas

    8 - 10 chas front and rear brakes replacing the rear brake pad note: it is not necessary to disassemble the brake caliper and brake hose to replace the brake pads. 1.Measure: ● brake pad wear limit a out of specification → replace the brake pad as a set. Brake pad wear limit: 1 mm (0.04 in) 2.Instal...

  • Page 278: Chas

    8 - 11 chas front and rear brakes 3.Check: ● brake fluid level refer to “checking the brake fluid level” in chapter 3. 4.Check: ● brake lever or brake pedal operation soft or spongy feeling → bleed the rear brake system. Refer to “bleeding the hydraulic brake system” in chapter 3. Not for resale www...

  • Page 279: Chas

    8 - 12 chas front and rear brakes front brake master cylinder order job name/part name q’ty remarks removing the front brake master cylinder remove the parts in the order below. Brake fluid drain. On-command four-wheel drive switch and differential gear lock switch refer to “handlebar”. 1 brake flui...

  • Page 280: Chas

    8 - 13 chas front and rear brakes 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 disassem...

  • Page 281: Chas

    8 - 14 chas front and rear brakes rear brake master cylinder order job name/part name q’ty remarks removing the rear brake master cylinder remove the parts in the order below. Front fender refer to “seat, carriers, fenders and fuel tank” in chapter 3. Brake fluid drain. 1 brake fluid reservoir cap 1...

  • Page 282: Chas

    8 - 15 chas front and rear brakes order job name/part name q’ty remarks 10 brake cable 1 disconnect. 11 bracket 1 12 brake master cylinder 1 13 hose joint 1 14 brake pedal 1 15 select lever control cable 1 disconnect. 16 rear brake light switch 1 17 bracket 1 18 bracket 1 19 brake master cylinder br...

  • Page 283: Chas

    8 - 16 chas front and rear brakes order job name/part name q’ty remarks disassembling the rear brake master cylinder remove the parts in the order below. 1 brake master cylinder kit 1 refer to “assembling the rear brake master cylinder”. 2 brake master cylinder 1 for assembly, reverse the disassembl...

  • Page 284: Chas

    8 - 17 chas front and rear brakes checking the master cylinder 1.Check: ● brake master cylinder 1 wear/scratches → replace the brake master cylinder assembly. ● brake master cylinder body cracks/damage → replace. ● brake fluid delivery passage (brake master cylinder body) blockage → blow out with co...

  • Page 285: Chas

    8 - 18 chas front and rear brakes eb702060 assembling the front brake master cylinder warning ● all internal brake components should be cleaned and lubricated with new brake fluid only before installation. ● whenever a master cylinder is disassembled, replace the piston seals and dust seals. Recomme...

  • Page 286: Chas

    8 - 19 chas front and rear brakes 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. 2.Install: ● copper washers ● brake hose ● union bolt note: ● tighten the uni...

  • Page 287: Chas

    8 - 20 chas front and rear brakes ● be careful that water does not enter the brake master cylinder when refilling. Water will significantly lower the boiling point of the brake fluid and may result in vapor lock. 4.Air bleed: ● brake system refer to “bleeding the hydraulic brake system” in chapter 3...

  • Page 288: Chas

    8 - 21 chas front and rear brakes 2.Fill: ● brake fluid reservoir caution: brake fluid may damage painted surfaces or plastic parts. Always clean up spilled brake fluid immediately. Warning ● use only the designated quality brake fluid: other brake fluids may deteriorate the rubber seals, causing le...

  • Page 289: Chas

    8 - 22 chas front and rear brakes front brake caliper order job name/part name q’ty remarks removing the front brake caliper remove the parts in the order below. Brake fluid drain. Front wheel refer to “front and rear wheels”. 1 union bolt 1 refer to “installing the front brake caliper”. 2 copper wa...

  • Page 290: Chas

    8 - 23 chas front and rear brakes order job name/part name q’ty remarks disassembling the front brake caliper 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 “disassemblin...

  • Page 291: Chas

    8 - 24 chas front and rear brakes rear brake caliper order job name/part name q’ty remarks removing the rear brake caliper remove the parts in the order below. Brake fluid drain. Rear wheel refer to “front and rear wheels”. 1 union bolt 1 refer to “installing the rear brake caliper”. 2 copper washer...

  • Page 292: Chas

    8 - 25 chas front and rear brakes order job name/part name q’ty remarks disassembling the rear brake caliper remove the parts in the order below. 1 brake pad holding bolt 2 2 brake pad/insulator/pad shim 2/2/2 3 pad spring 1 4 caliper bracket 1 5 brake caliper piston 1 refer to “disassembling/ assem...

  • Page 293: Chas

    8 - 26 chas front and rear brakes disassembling the front and rear brake caliper 1.Remove: ● brake caliper piston ● dust seal 1 ● caliper piston seal 2 ***************************************************** removal steps: ● blow compressed air into the hose joint opening to force out the caliper pist...

  • Page 294: Chas

    8 - 27 chas front and rear brakes ● 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. È front É rear assembling the front and rear brake caliper warning ● all in...

  • Page 295: Chas

    8 - 28 chas front and rear brakes caution: when installing the brake hose on the brake caliper, make sure that the brake pipe touches the projection a on the brake caliper. Warning proper brake hose routing is essential to insure safe motorcycle operation. Refer to “cable routing” in chapter 2. 2.Fi...

  • Page 296: Chas

    8 - 29 chas front and rear brakes installing the rear brake caliper 1.Install: ● brake caliper assembly ● brake caliper mounting bolt 1 ● brake hose 2 ● copper washers 3 ● union bolt 4 t r . . 30 nm (3.0 m • kg, 22 ft • lb) new t r . . 30 nm (3.0 m • kg, 22 ft • lb) 2.Fill: ● brake reservoir caution...

  • Page 297: Chas

    8 - 30 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 and differential gear lock switch 1 refer to “installing the master cylinder assem...

  • Page 298: Chas

    8 - 31 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 299: Chas

    8 - 32 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) not for resale www.Smallenginediscount.Com.

  • Page 300: Chas

    8 - 33 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 301: Chas

    8 - 34 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. Not for resale www.Smallenginediscount.Com.

  • Page 302: Chas

    8 - 35 chas steering system removing the bearing retainer 1.Remove: ● bearing retainer (steering stem) damper rod holder: p/n. Ym-01327, 90890-01327 checking the steering stem 1.Check: ● steering stem bends → replace. Warning do not attempt to straighten a bent stem; this may dangerously weaken the ...

  • Page 303: Chas

    8 - 36 chas steering system tie rod and steering knuckle order job name/part name q’ty remarks removing the tie rod and steering knuckle remove the parts in the order below. Front fender refer to “seat, carriers, fenders and fuel tank” in chapter 3. Front wheel/brake disc refer to “front and rear wh...

  • Page 304: Chas

    8 - 37 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. Not for resale www.Smallenginediscount.Com.

  • Page 305: Chas

    8 - 38 chas steering system removing the steering knuckle 1.Remove: ● steering knuckle 1 note: use a general puller to separate the ball joint 2 and steering knuckle 1 or front lower arm 3. Checking the tie rod 1.Check: ● tie rod free play and movement free play → replace the tie rod end. Turns roug...

  • Page 306: Chas

    8 - 39 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 307: Chas

    8 - 40 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 308: Chas

    8 - 41 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 a new oil seal. Note: when installing the oil seals, the “seal side” of the oil seal faces out. ...

  • Page 309: Chas

    8 - 42 chas front arms and front shock absorber front arms and front shock absorber order job name/part name q’ty remarks removing the front arms and front shock absorber remove the parts in the order below. Engine skid plate refer to “seat, carriers, fenders and fuel tank” in chapter 3. Front fende...

  • Page 310: Chas

    8 - 43 chas front arms and front shock absorber 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 f...

  • Page 311: Chas

    8 - 44 chas front arms and front shock absorber removing the front arms 1.Check: ● front arm free play ***************************************************** checking steps: ● check the front arm side play È by moving it from side to side. If side play is noticeable, check the bushings. ● check the f...

  • Page 312: Chas

    8 - 45 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 313: Chas

    8 - 46 chas front arms and front shock absorber ● attach the assembled ball joint remover/ installer, new ball joint a and installer attachment 7 to the front lower arm b. Note: do not tap or damage the top of the ball joint. ● hold the body 3 in place while turning in the long bolt 4 to install the...

  • Page 314: Chas

    8 - 47 chas front arms and front shock absorber installing the front arms and front shock absorber 1.Install: ● front arms ● front shock absorber ***************************************************** installation steps: ● install the front upper arm 1 and front lower arm 2. Note: ● lubricate the bol...

  • Page 315: Chas

    8 - 48 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/brake disc refer to “front and rear wheels”. Rear brake caliper/brake hose refer to “...

  • Page 316: Chas

    8 - 49 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. No...

  • Page 317: Chas

    8 - 50 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 318: Chas

    8 - 51 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 319: Chas

    8 - 52 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 320: 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 1 5 battery 6 tail/brake light 7 fuse box 8 four-wheel drive relay 2 9 four-wheel drive relay 1 0 main fuse a starter relay b cdi unit c rectifi...

  • Page 321: Elec

    9 - 2 – + elec checking the switch checking the switch checking the switch use a pocket tester to check the terminals for continuity. If the continuity is faulty at any point, replace the switch. Note: ● set the pocket tester to “0” before starting the test. ● the pocket tester should be set to the ...

  • Page 322: Elec

    9 - 3 – + elec checking the switch not for resale www.Smallenginediscount.Com.

  • Page 323: Elec

    9 - 4 – + elec checking the switch checking the switch continuity refer to “checking the switch” and check for continuity between lead terminals. Poor connection, no continuity → correct or replace. * the coupler locations are circled. L b y g br l/b (black) 1 4 5 c 6 2 3 r/b r/w push br l y g b r/w...

  • Page 324: Elec

    9 - 5 – + elec checking the switch 1 light switch 2 engine stop switch 3 start switch 4 on-command four-wheel drive switch and differential gear lock switch 5 main switch 6 rear brake light switch 7 front brake light switch 8 rear brake switch 9 reverse switch 0 neutral switch a high-range switch b ...

  • Page 325: 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 326: Elec

    9 - 7 – + elec checking the bulbs and bulb sockets warning since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. Caution: ● be sure to hold the socket firmly when removing the bulb. Never pull the lead, otherwise it may be pu...

  • Page 327: 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 328: Elec

    9 - 9 – + elec ignition system eb802000 ignition system circuit diagram w /b b b /r b /r b w /b c d ob bo lb bl yb r bb b /y b bb (gra y) (gra y) d wire harness sub-wire harness 4 br sb l /b r /b br /b b /y l /b sb br b /y br /b r /b br y l l /b gb ly r /y bg l /b ws b g /l l/ wb /rw /l g /l sb w w ...

  • Page 329: 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 330: 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 331: 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 332: Elec

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

  • Page 333: Elec

    9 - 14 – + elec ignition system c0ntinuity correct 11.Wiring connection ● check the connections of the entire ignition system. Refer to “circuit diagram”. Replace the cdi unit. * poor connection properly connect the ignition system. Not for resale www.Smallenginediscount.Com.

  • Page 334: Elec

    9 - 15 – + elec electric starting system eb803000 electric starting system circuit diagram w /b b b /r b /r b w /b c d ob bo lb bl yb r bb b /y b bb (gra y) (gra y) d wire harness sub-wire harness 4 br sb l /b r /b br /b b /y l /b sb br b /y br /b r /b br y l l /b gb ly r /y bg l /b ws b g /l l/ wb ...

  • Page 335: 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 if the starter motor fails to operate: 6.Engine stop switch 7.Start switch 8. Wiring connection (the entire starting system) note: ● remo...

  • Page 336: 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 337: Elec

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

  • Page 338: 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 339: 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 340: 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 341: Elec

    9 - 22 – + elec charging system eb804000 charging system circuit diagram w /b b b /r b /r b w /b c d ob bo lb bl yb r bb b /y b bb (gra y) (gra y) d wire harness sub-wire harness 4 br sb l /b r /b br /b b /y l /b sb br b /y br /b r /b br y l l /b gb ly r /y bg l /b ws b g /l l/ wb /rw /l g /l sb w w...

  • Page 342: 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 343: Elec

    9 - 24 – + elec charging system out of specification ● start the engine and accelerate to about 3,000 r/min. Charging voltage: 14 v at 3,000 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 344: Elec

    9 - 25 – + elec lighting system eb805000 lighting system circuit diagram off w /b b b /r b /r b w /b c d ob bo lb bl yb r bb b /y b bb (gra y) (gra y) d wire harness sub-wire harness 4 br sb l /b r /b br /b b /y l /b sb br b /y br /b r /b br y l l /b gb ly r /y bg l /b ws b g /l l/ wb /rw /l g /l sb...

  • Page 345: Elec

    9 - 26 – + elec lighting system eb805010 troubleshooting procedure check: 1.Fuse (main, headlight) 2.Battery 3.Main switch if the headlight and/or taillight fail to come on: 4.Light switch 5.Wiring connections (the entire lighting system) note: ● remove the following part(s) before troubleshooting: ...

  • Page 346: Elec

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

  • Page 347: 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 348: 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 349: Elec

    9 - 30 – + elec signal system eb806000 signal system circuit diagram 2wd 4wd lock w /b b b /r b /r b w /b c d ob bo lb bl yb r bb b /y b bb (gra y) (gra y) d wire harness sub-wire harness 4 br sb l /b r /b br /b b /y l /b sb br b /y br /b r /b br y l l /b gb ly r /y bg l /b ws b g /l l/ wb /rw /l g ...

  • Page 350: Elec

    9 - 31 – + elec signal system 3 main switch 4 backup fuse 5 battery 6 main fuse 9 reverse switch 0 cdi unit d speed sensor e thermo switch 1 g multi-function meter h differential gear lock indicator light i coolant temperature warning light j reverse indicator light k neutral indicator light l park ...

  • Page 351: Elec

    9 - 32 – + elec signal system eb806010 troubleshooting procedure check: 1.Fuse (main, backup, ignition, signaling system) 2.Battery 3.Main switch 4.Wiring connections (the entire signal system) if the brake light and/or indicator light fails to come on: note: ● remove the following part(s) before tr...

  • Page 352: Elec

    9 - 33 – + elec signal system c0ntinuity correct 3.Main switch refer to “checking the switch”. * incorrect replace the main switch. Eb806011 correct 4.Wiring connections ● check the connections of the entire signal system. Refer to “circuit diagram”. Check the condition of each of the signal system’...

  • Page 353: Elec

    9 - 34 – + 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 switch”. No c...

  • Page 354: Elec

    9 - 35 – + elec signal system eb806024 2.If the indicator lights fails to come on: continuity 1.Neutral switch refer to “checking the switch”. No continuity replace the neutral switch. Continuity 2.High-range switch refer to “checking the switch”. No continuity replace the high-range switch. Continu...

  • Page 355: Elec

    9 - 36 – + elec signal system 3.If the coolant temperature warning light does not come on: ● check that the light comes on when the main switch is set to “on”. ● check that the light comes on when the coolant temperature is 120 ± 3 °c (248 ± 5.4 °f) or higher and that the light remains on when the c...

  • Page 356: Elec

    9 - 37 – + elec cooling system cooling system circuit diagram w /b b b /r b /r b w /b c d ob bo lb bl yb r bb b /y b bb (gra y) (gra y) d wire harness sub-wire harness 4 br sb l /b r /b br /b b /y l /b sb br b /y br /b r /b br y l l /b gb ly r /y bg l /b ws b g /l l/ wb /rw /l g /l sb w w /lb /rl /w...

  • Page 357: Elec

    9 - 38 – + elec cooling system troubleshooting procedure check: 1.Fuse (main) 2.Battery 3.Main switch 4.Fan motor 5.Circuit breaker (fan motor) if the fan motor does not move: 6.Thermo switch 2 7.Wiring connection (the entire cooling system) note: ● remove the following part(s) before troubleshootin...

  • Page 358: Elec

    9 - 39 – + 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 359: Elec

    9 - 40 – + elec cooling system c0ntinuity good condition 6.Thermo switch 2 ● remove the thermo switch 2 from the radiator. ● connect the pocket tester ( Ω × 10) to the thermo switch 2 1. ● immerse the thermo switch 2 in coolant 2. ● check the thermo switch 2 for continuity. While heating the coolant...

  • Page 360: Elec

    9 - 41 – + elec cooling system c0ntinuity eb803028 correct 7.Wiring connection ● check the connections of the entire starting system. Refer to “circuit diagram”. This circuit is not faulty. * poor connection properly connect the cooling system. Not for resale www.Smallenginediscount.Com.

  • Page 361: Elec

    9 - 42 – + elec 2wd/4wd selecting system 2wd/4wd selecting system circuit diagram w /b b b /r b /r b w /b c d ob bo lb bl yb r bb b /y b bb (gra y) (gra y) d wire harness sub-wire harness 4 br sb l /b r /b br /b b /y l /b sb br b /y br /b r /b br y l l /b gb ly r /y bg l /b ws b g /l l/ wb /rw /l g ...

  • Page 362: Elec

    9 - 43 – + elec 2wd/4wd selecting system eb803020 troubleshooting procedure check: 1.Fuse (main, four-wheel drive) 2.Battery 3.Main switch 4.Four-wheel drive relay 1 5.Four-wheel drive relay 2 6.Four-wheel drive relay 3 if the gear motor fails to operate: 7.On-command four-wheel drive switch and dif...

  • Page 363: Elec

    9 - 44 – + elec 2wd/4wd selecting system c0ntinuity continuity 4.Four-wheel drive relay 1 ● remove the four-wheel drive relay 1 from the wire harness. ● connect the pocket tester ( Ω × 1) and the battery (12 v) to the four-wheel drive relay 1 terminals. Tester (+) lead → brown/black terminal 1 teste...

  • Page 364: Elec

    9 - 45 – + elec 2wd/4wd selecting system c0ntinuity continuity 6.Four-wheel drive relay 3 ● remove the four-wheel drive relay 3 from the wire harness. ● connect the pocket tester ( Ω × 1) and the battery (12 v) to the four-wheel drive relay 3 terminals. Tester (+) lead → brown/red terminal 1 tester ...

  • Page 365: Elec

    9 - 46 – + elec 2wd/4wd selecting system c0ntinuity correct 8.Gear motor ● disconnect the gear motor coupler. ● remove the gear motor from the differential gear case. Refer to “front constant velocity joints and differential gear” in chapter 7. ● connect two c size batteries to the gear motor termin...

  • Page 366: 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 367: 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 368: 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 369: 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 370: 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 371: 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 372

    Yfm450far wiring diagram w/b b b/r b/r b w/b c d o b b o l b b l y br b b b/y b b b (gray) (gray) d wire harness sub-wire harness 4 br sb l/b r/b br/b b/y l/b sb br b/y br/b r/b br y l l/b g b l y r/y b g l/b w sb g/l l/w b/r w/l g/l sb w w/l b/r l/w w/r sb l/w g/w sb w/r g/w l/w w/b l/y br w/r l/y ...

  • Page 373

    Yamaha motor co., ltd. 2500 shingai iwata shizuoka japan printed in u.S.A. Not for resale www.Smallenginediscount.Com.