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Yamaha YFM660RN Service Manual

Manual is about: Yamaha Atv

Summary of YFM660RN

  • Page 1

    Yfm660rn yfm660rnc servicemanual lit-11616-14-21 5lp-28197-e0

  • Page 2: 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 3: 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 4: Gen

    Eb003000 illustrated symbols illustrated symbols 1 to 9 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 chassis 5 engine 6 cooling system 7 carburetion 8 electrical 9 troubleshooting illust...

  • Page 5: Table of Contents

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

  • Page 6: Chapter 1.

    Chapter 1. General information machine identification ........................................................................ 1-1 vehicle identification number ................................................. 1-1 model label ............................................................................

  • Page 7: Gen

    Gen info 1 spec 2 chk adj 3 chas 4 eng 5 cool 6 carb 7 elec 8 trbl shtg 9 – + chapter 3. Periodic checks and adjustments introduction ........................................................................................... 3-1 periodic maintenance/lubrication intervals .......................... ...

  • Page 8: Chapter 4.

    Checking the tire ........................................................................ 3-47 checking the wheel .................................................................... 3-49 checking and lubricating the cable ................................... 3-49 lubricating the levers and pedal .....

  • Page 9: Gen

    Gen info 1 spec 2 chk adj 3 chas 4 eng 5 cool 6 carb 7 elec 8 trbl shtg 9 – + checking the front and rear brake caliper ................... 4-34 assembling the front brake caliper .................................. 4-35 assembling the rear brake caliper .................................... 4-36 inst...

  • Page 10: Chapter 5.

    Chapter 5. Engine engine removal ...................................................................................... 5-1 muffler and exhaust pipes ....................................................... 5-1 left footrest ...............................................................................

  • Page 11: Gen

    Gen info 1 spec 2 chk adj 3 chas 4 eng 5 cool 6 carb 7 elec 8 trbl shtg 9 – + clutch ...................................................................................................... 5-43 removing the clutch ................................................................. 5-47 removing the pri...

  • Page 12: Chapter 6.

    Transmission ......................................................................................... 5-72 main axle ......................................................................................... 5-74 drive axle ...............................................................................

  • Page 13: Gen

    Gen info 1 spec 2 chk adj 3 chas 4 eng 5 cool 6 carb 7 elec 8 trbl shtg 9 – + chapter 8. Electrical electrical components ..................................................................... 8-1 checking the switch ............................................................................ 8-2 che...

  • Page 14: Chapter 9.

    Chapter 9. Troubleshooting starting failure/hard starting ..................................................... 9-1 fuel system ...................................................................................... 9-1 electrical system ..................................................................

  • Page 15: 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 air filter case cover. This information will be needed to ord...

  • Page 16: Gen

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

  • Page 17: Gen

    1 - 3 gen info eb101030 lock washers/plates and cotter pins 1.Replace all lock washers/plates 1 and cotter pins after removal. Bend lock tabs along the bolt or nut flats after the bolt or nut has been tightened to specification. Eb101040 bearings and oil seals 1.Install bearings and oil seals so tha...

  • Page 18: Gen

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

  • Page 19: Gen

    1 - 5 gen info special tools eb102001 special tools the following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools; this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools may dif...

  • Page 20: Gen

    1 - 6 gen info special tools 90890-01304 yu-01304 piston pin puller this tool is used to remove the piston pin. 90890-01311 ym-08035 tappet adjusting tool (3 mm) this tool is necessary for adjusting the valve clearance. 90890-01312 ym-01312-a fuel level gauge this gauge is used to measure the fuel l...

  • Page 21: Gen

    1 - 7 gen info special tools 90890-01469 ym-01469 oil filter wrench this tool is needed to loosen or tighten the oil filter cartridge. 90890-01474 ym-01474 ball joint remover/installer set these tools are used to removing or installing the ball joint. 90890-01480 ym-01480 ball joint remover/installe...

  • Page 22: Gen

    1 - 8 gen info special tools middle driven shaft bearing driver 90890-04058 ym-04058-1 mechanical seal installer 90890-04078 ym-33221 middle driven shaft bearing driver mechanical seal installer these tools are used to install the water pump seal. 90890-04064 ym-4064-a valve guide remover (ø 6) this...

  • Page 23: Spec

    2 - 1 spec specifications general specifications item standard model code: 5lp1 : (except for california) 5lp3 : (for california) dimensions: overall length 1,830 mm (72.0 in) overall width 1,100 mm (43.3 in) overall height 1,150 mm (45.3 in) seat height 860 mm (33.9 in) wheelbase 1,245 mm (49.0 in)...

  • Page 24: Spec

    2 - 2 spec carburetor: type/quantity bsr33/2 manufacturer mikuni spark plug: type/manufacturer dpr8ea-9/ngk spark plug gap 0.8 ~ 0.9 mm (0.031 ~ 0.035 in) clutch type: wet, multiple disc transmission: primary reduction system spur gear primary reduction ratio 71/34 (2.088) secondary reduction system...

  • Page 25: Spec

    2 - 3 spec tire pressure (cold tire): maximum load* 100 kg (220 lb) off-road riding front 27.5 kpa (0.275 kg/cm 2 , 4.0 psi) rear 27.5 kpa (0.275 kg/cm 2 , 4.0 psi) *load in total weight of cargo, rider and acces- sories brake: front brake type dual disc brake operation right hand operation rear bra...

  • Page 26: Spec

    2 - 4 spec maintenance specifications engine item standard limit cylinder head: warp limit ---- 0.05 mm (0.002 in) cylinder: bore size 100.005 ~ 100.045 mm (3.9372 ~ 3.9388 in) 100.1 mm (3.94 in) measuring point * 50 mm (2.0 in) ---- camshaft: drive method chain drive (left) ---- camshaft cap inside...

  • Page 27: Spec

    2 - 5 spec camshaft runout limit ---- 0.03 mm (0.0012 in) timing chain: timing chain type/no. Of links 75-rh2015/126 ---- timing chain adjustment method automatic ---- rocker arm/rocker arm shaft: shaft outside diameter 11.976 ~ 11.991 mm (0.4715 ~ 0.4721 in) ---- arm-to-shaft clearance 0.009 ~ 0.04...

  • Page 28: Spec

    2 - 6 spec stem-to-guide clearance in 0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in) 0.08 mm (0.0031 in) ex 0.025 ~ 0.052 mm (0.0010 ~ 0.0020 in) 0.10 mm (0.0039 in) stem runout limit ---- 0.01 mm (0.0004 in) valve seat width in 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) 1.6 mm (0.0630 in) ex 0.9 ~ 1.1 mm (0.0354 ~ 0...

  • Page 29: Spec

    2 - 7 spec piston: piston to cylinder clearance 0.05 ~ 0.07 mm (0.0020 ~ 0.0028 in) 0.15 mm (0.0059 in) piston size “d” 99.945 ~ 99.995 mm (3.9348 ~ 3.9368 in) ---- measuring point “h” 2.5 mm (0.10 in) ---- piston off-set 1.0 mm (0.04 in) ---- piston pin bore inside diameter 22.004 ~ 22.015 mm (0.86...

  • Page 30: Spec

    2 - 8 spec crankshaft: crank width “a” 74.95 ~ 75.00 mm (2.9508 ~ 2.9528 in) ---- runout limit c1 ---- 0.03 mm (0.0012 in) c2 ---- 0.03 mm (0.0012 in) big end side clearance “d” 0.32 ~ 0.64 mm (0.0126 ~ 0.0252 in) 1.0 mm (0.0394 in) big end radial clearance “e” 0.010 ~ 0.025 mm (0.0004 ~ 0.0010 in) ...

  • Page 31: Spec

    2 - 9 spec transmission: main axle deflection limit ---- 0.08 mm (0.0031 in) drive axle deflection limit ---- 0.08 mm (0.0031 in) shifter: shifter type shift drum and guide bar ---- decompression device: device type auto decomp ---- air filter oil grade: engine oil ---- carburetors: i. D. Mark 5lp1 ...

  • Page 32: Spec

    2 - 10 spec cooling system: radiator core width 219 mm (8.62 in) ---- height 300 mm (11.8 in) ---- depth 16 mm (0.63 in) ---- radiator cap opening pressure 95 ~ 125 kpa (0.95 ~ 1.25 kg/cm 2 , 13.8 ~ 18.1 psi) ---- radiator capacity 0.55 l (0.48 imp qt, 0.58 us qt) ---- coolant reservoir capacity 0.2...

  • Page 33: Spec

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

  • Page 34: 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 (exhaust pipe) stud bolt m6 4 7 0.7 5.1 cylinder head bolt m9 4 38 3.8 27 bolt m9 2 38 3.8 27 bolt m6 1 10 1.0 7.2 spark plug — m12 1 18 1.8 13 cylinder head cover bol...

  • Page 35: Spec

    2 - 13 spec bearing retainer screw m6 4 7 0.7 5.1 lt ac magneto rotor nut m14 1 150 15.0 110 starter clutch bolt m6 6 16 1.6 11 lt balancer driven gear nut m18 1 140 14.0 100 m use a lock washer. Primary drive gear nut m20 1 150 15.0 110 m use a lock washer. Clutch spring bolt m6 5 8 0.8 5.8 clutch ...

  • Page 36: Spec

    2 - 14 spec chassis item standard limit steering system: steering bearing type ball and race bearing ---- front suspension: shock absorber travel 110 mm (4.33 in) ---- fork spring free length 316.5 mm (12.46 in) ---- spring fitting length 293.5 mm (11.56 in) ---- spring rate (k1) 19.6 n/mm (2.00 kg/...

  • Page 37: Spec

    2 - 15 spec front disc brake: type dual ---- disc outside diameter × thickness 161.0 × 3.5 mm (6.34 × 0.14 in) ---- pad thickness inner 4.2 mm (0.17 in) 1 mm (0.04 in) pad thickness outer 4.2 mm (0.17 in) 1 mm (0.04 in) master cylinder inside diameter 12.7 mm (0.50 in) ---- caliper cylinder inside d...

  • Page 38: Spec

    2 - 16 spec tightening torques part to be tightened thread size tightening torque remarks nm m·kg ft·lb engine bracket (upper) and frame m8 33 3.3 24 engine bracket (upper) and engine m10 40 4.0 29 engine bracket (lower) and frame m10 56 5.6 40 engine bracket (lower) and engine m10 56 5.6 40 engine ...

  • Page 39: Spec

    2 - 17 spec hinweis: note: apply locking agent (loctite ® ) to ring nuts threads. 1st: tighten the inside ring nut 55 nm (5.5 m • kg, 40 ft • lb). 2nd: tighten the outside ring nut while holding the inside ring nut 190 nm (19 m • kg, 140 ft • lb). 3rd: loosen the inside ring nut while holding the ou...

  • Page 40: Spec

    2 - 18 spec electrical item standard limit voltage: 12 v ---- ignition system: ignition timing (b.T.D.C.) 12°/ 1,500 r/min ---- advancer type digital type ---- c.D.I.: magneto model/manufacturer f4t260/mitsubishi ---- pickup coil resistance/color 445 ~ 545 Ω at 20 °c (68 °f)/ white/red – white/green...

  • Page 41: Spec

    2 - 19 spec starter relay model/manufacturer ms5f-721/jideco ---- amperage rating 180 a ---- coil winding resistance 4.18 ~ 4.62 Ω at 20 °c (68 °f) ---- thermostat switch: thermostat switch 1 model/manufacturer 5gh/nippon thermostat ---- thermostat switch 2 model/manufacturer 5lp/nippon thermostat -...

  • Page 42: Spec

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

  • Page 43: 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 primary drive gear/primary driven gea...

  • Page 44: Spec

    2 - 22 spec coolant flow diagrams 1 radiator 2 radiator fan 3 radiator outlet hose 4 water pump inlet hose 5 water pump 6 water jacket outlet pipe 7 thermostat inlet hose 8 thermostat 9 radiator inlet hose 0 thermo switch 2 a thermo switch 1 coolant flow diagrams.

  • Page 45: Spec

    2 - 23 spec oil flow diagrams 1 oil tank 2 oil pipe 2 3 oil pipe 1 oil flow diagrams.

  • Page 46: Spec

    2 - 24 spec 1 oil delivery pipe 2 2 oil delivery pipe 1 3 oil filter 4 crankshaft 5 oil pump oil flow diagrams.

  • Page 47: Spec

    2 - 25 spec 1 oil pipe 2 2 drive axle 3 main axle 4 engine oil drain bolt (engine) 5 oil pipe 1 6 oil strainer 7 shift drum oil flow diagrams.

  • Page 48: Spec

    2 - 26 spec 1 oil delivery pipe 2 2 oil filter cartridge 3 oil pump rotor 1 4 oil pump rotor 2 5 oil pipe 1 6 main axle oil flow diagrams.

  • Page 49: Spec

    2 - 27 spec cable routing 1 parking brake cable 2 starter cable 3 clutch cable 4 throttle cable 5 front brake hose 6 front brake switch 7 park switch È fasten the handlebar switch lead, park switch lead and clutch switch lead to the handlebar with the plastic band. É fasten the front brake switch le...

  • Page 50: Spec

    2 - 28 spec 1 front brake hose 2 throttle cable 3 main switch lead 4 indicator light lead 5 clutch cable 6 parking brake cable 7 starter cable 8 coolant reservoir hose 9 wire harness 0 ignition coil lead a headlight lead coupler (left) b brake pipe c headlight lead coupler (right) d radiator fan bre...

  • Page 51: Spec

    2 - 29 spec 1 throttle cable 2 fuel tank breather hose 3 fuel hose 4 carburetor air vent hose 5 negative battery lead 6 ac magneto lead 7 thermo switch 1 8 coolant reservoir hose 9 starter cable È put the wire harness and coolant reservoir hose with the plastic holder. É fasten the wire harness, ac ...

  • Page 52: Spec

    2 - 30 spec 1 coolant reservoir hose 2 carburetor air vent hose 3 reservoir tank breather hose 4 rectifier/regulator 5 cdi unit 6 negative battery lead 7 ac magneto lead 8 wire harness 9 starter motor lead 0 tail/brake light lead a rectifier/regulator lead È pass the negative battery lead between th...

  • Page 53: Spec

    2 - 31 spec 1 radiator fan breather hose 2 reverse control cable 3 parking brake cable 4 clutch cable È fasten the reverse control cable to the frame with the plastic band. É 15 ~ 25 mm (0.59 ~ 0.98 in) cable routing.

  • Page 54: Spec

    2 - 32 spec 1 rear brake hose 2 parking brake cable 3 negative battery lead 4 ac magneto lead 5 crankcase breather hose 6 carburetor drain hose 7 rear brake switch 8 speed sensor 9 speed sensor lead 0 rear brake switch lead cable routing.

  • Page 55: Spec

    2 - 33 spec 1 thermo switch 1 lead 2 headlight lead (right) 3 radiator fan breather hose 4 thermo switch 2 lead 5 carburetor breather hose 6 headlight lead (left) 7 wire harness 8 coolant reservoir hose È fasten the fan motor lead, headlight lead (right) and thermo switch 1 lead to the frame with th...

  • Page 56: Spec

    2 - 34 spec 1 positive battery lead 2 tail/brake light lead 3 coolant reservoir breather hose 4 negative battery lead 5 coolant reservoir hose 6 starter motor lead 7 wire harness 8 rectifier/regulator lead È fasten the wire harness with the plastic clamp. É fasten the starter motor lead and starter ...

  • Page 57: Chk

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

  • Page 58: Chk

    3 - 2 chk adj periodic maintenance/lubrication intervals note: ● recommended brake fluid: dot 4 ● brake fluid replacement: 1.When disassembling the master cylinder or caliper cylinder, replace the brake fluid. Normally check the brake fluid level and add fluid as required. 2.On the inner parts of th...

  • Page 59: Chk

    3 - 3 chk adj seat, fenders and fuel tank seat, fenders and fuel tank seat, front panel, footrest guards and engine skid plate order job name/part name q’ty remarks removing the seat, front panel, foot- rest guard and engine skid plate remove the parts in the order below. 1 seat 1 note: pull back th...

  • Page 60: Chk

    3 - 4 chk adj seat, fenders and fuel tank headlights and front fender order job name/part name q’ty remarks removing the headlight and front fender remove the parts in the order below. Seat and front panel refer to “seat, front panel, foot- rest guards and engine skid plate”. 1 headlight coupler 2 d...

  • Page 61: Chk

    3 - 5 chk adj seat, fenders and fuel tank rear fender order job name/part name q’ty remarks removing the rear fender remove the parts in the order below. Seat refer to “seat, front panel, foot- rest guards and engine skid plate”. Front fender refer to “headlights and front fender”. 1 battery holding...

  • Page 62: Chk

    3 - 6 chk adj seat, 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 front panel refer to “seat, front panel, foot- rest guards and engine skid plate”. Front fender refer to “headlights and front fender”. 1 fue...

  • Page 63: Chk

    3 - 7 chk adj seat, fenders and fuel tank order job name/part name q’ty remarks 4 rubber cover 1 1 5 rubber cover 2 1 6 hose holder 2 for installation, reverse the removal pro- cedure..

  • Page 64: Chk

    3 - 8 chk adj adjusting the valve clearance engine adjusting the valve clearance note: ● the valve clearance must be adjusted when the engine is cool to the touch. ● adjust the valve clearance when the piston is at the top dead center (t.D.C.) on the com- pression stroke. 1.Remove: ● seat ● front fe...

  • Page 65: Chk

    3 - 9 chk adj adjusting the valve clearance 6.Check: ● valve clearance out of specification → adjust. *********************************************** checking steps: ● turn the crankshaft counterclockwise with a wrench. ● align the “i” mark 1 on the rotor with the sta- tionary pointer 2 on the crank...

  • Page 66: Chk

    3 - 10 chk adj adjusting the valve clearance 7.Adjust: ● valve clearance *********************************************** adjustment steps: ● loosen the locknut 1 . ● insert a feeler gauge 2 between the adjuster end and the valve end. ● turn the adjuster 3 clockwise or counter- clockwise with the tap...

  • Page 67: Chk

    3 - 11 chk adj adjusting the valve clearance/adjusting the timing chain/adjusting the idling speed 10.Install: ● fuel tank ● front fender ● seat refer to “seat, fenders and fuel tank”. Adjusting the timing chain adjustment free. Adjusting the idling speed 1.Start the engine and let it warm up for se...

  • Page 68: Chk

    3 - 12 chk adj adjusting the idling speed/ adjusting the throttle lever free play 4.Adjust: ● engine idling speed *********************************************** adjustment steps: ● turn the throttle stop screw 1 in or out until the specified idling speed is obtained. *******************************...

  • Page 69: Chk

    3 - 13 chk adj adjusting the throttle lever free play 2.Adjust: ● throttle lever free play *********************************************** adjustment steps: first step: ● pull back the adjuster cover 1 . ● loosen the locknut 2 on the carburetor side. ● turn the adjuster 3 in or out until the correct...

  • Page 70: Chk

    3 - 14 chk adj adjusting the speed limiter adjusting the speed limiter the speed limiter keeps the carburetor throttle from becoming fully-opened even when the throttle lever is applied to the maximum posi- tion. Screwing in the adjuster stops the engine speed from increasing. 1.Check: ● speed limit...

  • Page 71: Chk

    3 - 15 chk adj adjusting the starter cable adjusting the starter cable 1.Adjust: ● starter cable *********************************************** adjustment steps: ● disconnect the starter cable 1 from the car- buretor body. Note: do not remove the starter plunger 2 from the starter cable. ● measure ...

  • Page 72: Chk

    3 - 16 chk adj checking the spark plug 1.Remove: ● spark plug 2.Check: ● spark plug type incorrect → replace. Standard spark plug: dpr8ea-9/ngk 3.Check: ● electrode 1 wear/damage → replace. ● insulator 2 abnormal color → replace. Normal color is a medium-to-light tan color. 4.Clean the spark plug wi...

  • Page 73: Chk

    3 - 17 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.Attach: ● tachometer ● timing light (to spark plug lead) timing light: p/n. Ym-33277-a, 90890-03141 2.Che...

  • Page 74: Chk

    3 - 18 chk adj measuring the compression pressure measuring the compression pressure note: insufficient compression pressure will result in a loss of performance. 1.Check: ● valve clearance out of specification → adjust. Refer to “adjusting the valve clear- ance”. 2.Start the engine and let it warm ...

  • Page 75: Chk

    3 - 19 chk adj measuring the compression pressure/ checking the engine oil level *********************************************** measurement steps: ● crank over the engine with the electric starter (be sure the battery is fully charged) with the throttle fully-open until the compres- sion reading on...

  • Page 76: Chk

    3 - 20 chk adj checking the engine oil level/ changing the engine oil 3.Check: ● engine oil level oil level should be between the minimum level mark a and the maximum level mark b . Low oil level → add oil to the proper level. Note: ● wait a few minutes until the oil settles before inspecting the oi...

  • Page 77: Chk

    3 - 21 chk adj changing the engine oil 4.Remove: ● dipstick 1 ● engine oil drain bolt (oil tank) 2 ● engine oil drain bolt (crankcase) 3 drain the engine oil from the oil tank and crankcase. 5.If the oil filter cartridge is also to be replaced, perform the following procedure. **********************...

  • Page 78: Chk

    3 - 22 chk adj changing the engine oil ● tighten the new oil filter cartridge to specifi- cation with an oil filter wrench. *********************************************** 6.Install: ● engine oil drain bolt (crankcase) ● engine oil drain bolt (oil tank) 7.Fill: ● oil tank (with the specified amount ...

  • Page 79: Chk

    3 - 23 chk adj changing the engine oil/ adjusting the clutch cable 11.Check: ● engine oil pressure *********************************************** ● slightly loosen the oil gallery bolt 1 . ● start the engine and keep it idling until engine oil starts to seep from the oil gallery bolt. If no engine ...

  • Page 80: Chk

    3 - 24 chk adj adjusting the clutch cable/ cleaning the air filter 2.Adjust: ● clutch lever free play *********************************************** adjustment steps: ● pull the rubber cover 1 off. ● loosen the locknut 2 and finger tighten the adjusting bolt 3 . ● loosen the locknut 4 . ● turn the ...

  • Page 81: Chk

    3 - 25 chk adj cleaning the air filter 4.Remove: ● air filter element assembly 1 ● air filter element cap 2 ● air filter element 3 note: when removing the air filter element, rotate the air filter element cap 1/4 of a turn and remove the element. Caution: never operate the engine with the air filter...

  • Page 82: Chk

    3 - 26 chk adj cleaning the air filter caution: do not twist or wring out the element. This could damage the foam material. ● apply engine oil to the element. ● squeeze out the excess oil. Note: the element should be wet but not dripping. *********************************************** 7.Install: ● ...

  • Page 83: Chk

    3 - 27 chk adj checking the coolant level 1.Place the machine on a level surface. 2.Check: ● coolant level the coolant level should be between the minimum level mark a and maximum level mark b . Below the minimum level mark → add the recommended coolant to the proper level. Caution: ● adding water i...

  • Page 84: Chk

    3 - 28 chk adj changing the coolant 4.Drain: ● coolant (from the coolant reservoir) 5.Connect: ● coolant reservoir hose 6.Remove: ● radiator cap 1 warning a hot radiator is under pressure. Therefore, do not remove the radiator cap when the engine is hot. Scalding hot fluid and steam may be blown out...

  • Page 85: Chk

    3 - 29 chk adj changing the coolant 11.Fill: ● cooling system (with the specified amount of the recom- mended coolant) handling notes for coolant coolant is potentially harmful and should be handled with special care. Warning ● if coolant splashes in your eyes, thor- oughly wash them with water and ...

  • Page 86: Chk

    3 - 30 chk adj changing the coolant 13.Fill: ● coolant reservoir (with the recommended coolant to the proper level) 14.Install: ● coolant reservoir cap 15.Start the engine, warm it up for several min- utes, and then turn it off. 16.Check: ● coolant level refer to “checking the coolant level”. Note: ...

  • Page 87: Chk

    3 - 31 chk adj checking the coolant temperature warning light/cleaning the spark arrester checking the coolant temperature warning light 1 coolant temperature warning light cleaning the spark arrester 1.Clean: ● spark arrester *********************************************** cleaning steps: warning ●...

  • Page 88: Chk

    3 - 32 chk adj ● tap the tailpipe lightly with a soft-face ham- mer or suitable tool, then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe and the inner contact surfaces of the muffler. ● insert the tailpipe into the muffler and align the bolt holes. ● ...

  • Page 89: Chk

    3 - 33 chk adj adjusting the front brake/ adjusting the rear brake chassis adjusting the front brake 1.Check: ● brake lever free play a out of specification → bleed the front brake system. Refer to “air bleeding (hydraulic brake system)”. Brake lever free play (at the brake lever end): 0 mm (0 in) a...

  • Page 90: Chk

    3 - 34 chk adj adjusting the rear brake/ adjusting the parking brake warning after this adjustment is performed, lift the rear wheels off the ground by placing a block under the engine, and spin the rear wheels to ensure there is no brake drag. If any brake drag is noticed perform the above steps ag...

  • Page 91: Chk

    3 - 35 chk adj adjusting the parking brake/ checking the brake fluid level warning after this adjustment is performed, lift the rear wheels off the ground by placing a block under the engine, and spin the rear wheels to ensure there is no brake drag. If any brake drag is noticed perform the above st...

  • Page 92: Chk

    3 - 36 chk adj checking the front brake pad/ checking the rear brake pad/ adjusting the rear brake light switch checking the front brake pad 1.Remove: ● front wheels 2.Check: ● brake pad wear indicators 1 almost in contact with the brake disc → replace the brake pads as a set. Refer to “front and re...

  • Page 93: Chk

    3 - 37 chk adj adjusting the rear brake light switch/ checking the brake hose 1.Check: ● rear brake light operation timing incorrect → adjust. 2.Adjust: ● rear brake light operation timing *********************************************** ● hold the main body 1 of the rear brake light switch so that i...

  • Page 94: Chk

    3 - 38 chk adj checking the brake hose/ bleeding the hydraulic brake system 6.Install: ● front fender ● seat refer to “seat, fenders and fuel tank”. Bleeding the hydraulic brake system warning bleed the brake system if: ● the system has been disassembled. ● a brake hose or brake pipe have been loose...

  • Page 95: Chk

    3 - 39 chk adj j. Tighten the bleed screw. Note: if bleeding is difficult, it may be necessary to let the brake fluid settle for a few hours. Repeat the bleeding procedure when the tiny bubbles in the system have disappeared. K. Add brake fluid to the proper level. Refer to “checking the brake fluid...

  • Page 96: Chk

    3 - 40 chk adj adjusting the reverse control cable/ adjusting the drive chain slack adjusting the reverse control cable 1.Check: ● reverse knob free play a out of specification → adjust. Reverse knob free play: 0 mm (0 in) 2.Adjust: *********************************************** adjustment steps: ●...

  • Page 97: Chk

    3 - 41 chk adj adjusting the drive chain slack 3.Measure: ● drive chain slack a out of specification → adjust. Drive chain slack: 30 ~ 45 mm (1.18 ~ 1.77 in) 4.Adjust: ● drive chain slack *********************************************** adjustment steps: ● loosen the hub nuts 1 . ● loosen the locknut...

  • Page 98: Chk

    3 - 42 chk adj checking the steering system/ adjusting the toe-in checking the steering system 1.Place the machine on a level surface. 2.Check: ● steering assembly bushings move the handlebar up and down, and/or back and forth. Excessive play → replace the steering stem bushings. 3.Check: ● tie-rod ...

  • Page 99: Chk

    3 - 43 chk adj *********************************************** toe-in measurement steps: note: before measuring the toe-in, make sure that the tire pressure is correct. ● mark both front tire tread centers. ● raise the front end of the machine so that there is no weight on the front tires. ● face th...

  • Page 100: Chk

    3 - 44 chk adj *********************************************** adjustment steps: ● mark both tie-rods ends. This reference point will be needed during adjustment. ● loosen the locknuts (tie-rod end) 1 of both tie-rods. ● the same number of turns should be given to both the right and left tie-rods 2 ...

  • Page 101: Chk

    3 - 45 chk adj adjusting the rear shock absorber 1.Adjust: ● spring preload *********************************************** adjustment steps: ● elevate the rear wheels by placing a suitable stand under the frame. ● loosen the locknut 1 . ● turn the adjusting ring 2 in direction a or b . Note: ● be s...

  • Page 102: Chk

    3 - 46 chk adj 2.Adjust: ● rebound damping force *********************************************** adjustment steps: ● turn the adjusting screw 1 in direction a or b . Caution: do not force the adjuster past the minimum or maximum extent of adjustment. The adjuster may be damaged. ********************...

  • Page 103: Chk

    3 - 47 chk adj adjusting the rear shock absorber/ checking the tire caution: do not forc the adjuster past the minimum or maximum extent of adjustment. The adjuster may be damaged. *********************************************** checking the tire warning this model is equipped with low pressure tire...

  • Page 104: Chk

    3 - 48 chk adj checking the tire ● maximum loading limit 1)vehicle load limit (total weight of cargo, rider and accessories, and tongue weight): 100 kg (220 lb) 1.Measure: ● tire pressure (cold tire pressure) out of specification → adjust. Note: ● the low-pressure tire gauge 1 is included as standar...

  • Page 105: Chk

    3 - 49 chk adj checking the tire/checking the wheel/ checking and lubricating the cable 2.Check: ● tire surfaces wear/damage → replace. Warning it is dangerous to ride with a worn-out tire. When tire wear is out of specification, replace the tire immediately. Tire wear limit a : front and rear: 3.0 ...

  • Page 106: Chk

    3 - 50 chk adj checking and lubricating the cable/ lubricating the levers and pedal 1.Check: ● cable sheath damage → replace. 2.Check: ● cable operation unsmooth operation → lubricate or replace. Note: hold the cable end up and apply several drops of lubricant to the cable. 3.Apply: ● lithium soap b...

  • Page 107: Chk

    3 - 51 chk adj checking the battery eb305000 electrical checking the battery note: since the mf battery is a sealed type battery, it is not possible to measure the specific gravity of the electrolyte in order to check the charge state of the battery. Therefore the charge of the battery has to be che...

  • Page 108: Chk

    3 - 52 chk adj checking the battery batteries generate explosive hydrogen gas. Always follow these preventive measures: ● charge batteries in a well-ventilated area. ● keep batteries away from fire, sparks or open flames (e.G., welding equipment, lighted cigarettes, etc.). ● do not smoke when chargi...

  • Page 109: Chk

    3 - 53 chk adj ● 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 charging current, be...

  • Page 110: Chk

    3 - 54 chk adj checking the battery charging method using a variable voltage charger.

  • Page 111: Chk

    3 - 55 chk adj checking the battery charging method using a constant voltage charger.

  • Page 112: Chk

    3 - 56 chk adj checking the battery/checking the fuse 5.Check: ● battery terminals dirty → clean with a wire brush. Poor connection → correct. Note: after cleaning the terminals, apply a light coat of grease. 6.Install: ● battery 7.Connect: ● battery leads caution: first, connect the positive lead 1...

  • Page 113: Chk

    3 - 57 chk adj checking the fuse note: set the tester to the “ Ω × 1” position. ● if the tester indicates 0, replace the fuse. *********************************************** pocket tester: p/n. Yu-03112, 90890-03112 3.Replace: ● blown fuse *********************************************** replacement...

  • Page 114: Chk

    3 - 58 chk adj adjusting the headlight beam/ replacing the headlight bulb adjusting the headlight beam 1.Adjust: ● headlight beam (vertically) *********************************************** adjustment steps: ● loosen the screw 1 . ● slide the headlight lens unit under. ● tighten the screw 1 . *****...

  • Page 115: Chk

    3 - 59 chk adj replacing the headlight bulb 3.Remove: ● cover 1 ● bulb holder 2 ● bulb note: turn the bulb holder counterclockwise and remove the defective bulb. Warning keep flammable products and your hands away from the bulb while it is on, since it will be hot. Do not touch the bulb until it coo...

  • Page 116: Chas

    4 - 1 chas front wheels chassis front 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 cotter pin 1 refer to “...

  • Page 117: Chas

    4 - 2 chas front wheels order job name/part name q’ty remarks 6 wheel hub 1 7 brake disc 1 for installation, reverse the removal pro- cedure..

  • Page 118: Chas

    4 - 3 chas front 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) warnin...

  • Page 119: Chas

    4 - 4 chas front wheels 2.Check: ● wheel bearings wheel hub play/wheel turns roughly → replace. *********************************************** wheel bearing replacement steps: ● clean wheel hub exterior. ● drive bearing out by pushing spacer aside and tapping around perimeter of bearing inner race....

  • Page 120: Chas

    4 - 5 chas front wheels installing wheel hub 1.Install: ● axle nut 1 ● cotter pin 2 note: do not loosen the axle nut after torquing it. If the axle nut groove is not aligned with the cot- ter pin hole, align the groove with the hole by tightening the axle nut. T r . . 70 nm (7.0 m • kg, 50 ft • lb) ...

  • Page 121: Chas

    4 - 6 chas rear wheels, wheel axle and hub rear wheels, wheel axle and hub 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 ove...

  • Page 122: Chas

    4 - 7 chas rear wheels, wheel axle and hub wheel axle and hub order job name/part name q’ty remarks removing the wheel axle and hub remove the parts in the order below. 1 nut 2 refer to “installing the nuts (rear axle)”. 2 locknut 2 refer to “removing the rear axle”. 3 adjusting bolt 2 4 rear axle 1...

  • Page 123: Chas

    4 - 8 chas rear wheels, wheel axle and hub order job name/part name q’ty remarks 6 brake disc 1 7 driven sprocket 1 8 brake caliper bracket 1 9 hub 1 for installation, reverse the removal pro- cedure..

  • Page 124: Chas

    4 - 9 chas rear wheels, wheel axle and hub removing the rear axle 1.Place the machine on a level surface. 2.Loosen: ● nuts (rear axle) 1 note: ● apply the brake pedal so that the rear axle does not turn, when loosening the nuts. ● use a axle nut wrench (50 mm) 2 . Axle nut wrench (50 mm): p/n. Ym-37...

  • Page 125: Chas

    4 - 10 chas rear wheels, wheel axle and hub 7.Remove: ● rear axle 1 caution: ● never directly tap the axle end with a hammer, since this will result in damage to the axle thread and spline. ● attach a suitable socket 2 on the axle end and tap it with a soft hammer. Pull out the rear axle to the righ...

  • Page 126: Chas

    4 - 11 chas rear wheels, wheel axle and hub checking the hub 1.Check: ● hub bearings refer to “front wheels-wheel hub inspection”. Checking the brake disc refer to “front wheels”. Installing the nuts (rear axle) 1.Tighten: nuts (rear axle) 1 , 2 *********************************************** nuts t...

  • Page 127: Chas

    4 - 12 chas rear wheels, wheel axle and hub installing the wheel hub refer to “front wheels”. Installing the wheel 1.Install: ● wheel note: the wording on the tire “side facing out- wards” 1 must be facing outwards..

  • Page 128: Chas

    4 - 13 chas front and rear brakes front and rear brakes front brake pads order job name/part name q’ty remarks removing the front brake pad remove the parts in the order below. Front wheel/wheel hub refer to “front wheels”. 1 brake pad holding bolt 2 refer to “replacing the front brake pad”. 2 brake...

  • Page 129: Chas

    4 - 14 chas front and rear brakes rear brake pads order job name/part name q’ty remarks removing rear brake pad remove the parts in the order below. 1 brake caliper mounting bolt 1 refer to “replacing the rear brake pad”. 2 brake caliper mounting bolt 1 3 brake pad holding bolt 2 4 lock washer 1 5 b...

  • Page 130: Chas

    4 - 15 chas front and rear brakes caution: disc brake components rarely require dis- assembly. Do not: ● disassemble components unless abso- lutely necessary; ● use solvents on internal brake compo- nents; ● use spent brake fluid for cleaning; (use only clean brake fluid) ● allow brake fluid to come...

  • Page 131: Chas

    4 - 16 chas front and rear brakes *********************************************** installation steps: ● connect a suitable hose 1 tightly to the brake caliper bleed screw 2 . Put the other end of this hose into an open container. ● loosen the brake caliper bleed screw and, using a finger, push the c...

  • Page 132: Chas

    4 - 17 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.Remove: ● brake pads a wear limit note: replace the brake pads as a set if either is found to be worn to the wear limit. 2.Install: ● ...

  • Page 133: Chas

    4 - 18 chas front and rear brakes ● bend the lock washer tabs along a flat side of the bolts. *********************************************** t r . . Brake pad holding bolt: 18 nm (1.8 m • kg, 13 ft • lb) brake caliper mounting bolt: 28 nm (2.8 m • kg, 20 ft • lb) 3.Check: ● brake fluid level refer ...

  • Page 134: Chas

    4 - 19 chas front and rear brakes front brake master cylinder order job name/part name q’ty remarks removing front brake master cylin- der remove the parts in the order below. Brake fluid drain. 1 brake fluid reservoir cap 1 2 brake fluid reservoir diaphragm 1 3 front brake switch 1 4 brake lever 1 ...

  • Page 135: Chas

    4 - 20 chas front and rear brakes order job name/part name q’ty remarks disassembling the front brake mas- ter cylinder remove the parts in the order below. 1 dust boot 1 refer to “assembling the front and rear brake master cylin- der”. 2 circlip 1 3 brake master cylinder kit 1 for assembly, reverse...

  • Page 136: Chas

    4 - 21 chas front and rear brakes rear brake master cylinder order job name/part name q’ty remarks removing the rear brake master cyl- inder remove the parts in the order below. Right footrest guard refer to “seat, fenders and fuel tank” in chapter 3. Brake fluid drain. 1 brake fluid reservoir cover...

  • Page 137: Chas

    4 - 22 chas front and rear brakes order job name/part name q’ty remarks 8 union bolt 1 refer to “installing the rear brake master cylinder”. 9 copper washer 2 10 brake hose 1 11 brake master cylinder 1 for installation, reverse the removal pro- cedure..

  • Page 138: Chas

    4 - 23 chas front and rear brakes order job name/part name q’ty remarks disassembling the rear brake mas- ter cylinder remove the parts in the order below. 1 hose joint 1 2 brake master cylinder kit 1 refer to “assembling the front and rear brake master cylin- der”. 3 brake master cylinder 1 for ass...

  • Page 139: Chas

    4 - 24 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 140: Chas

    4 - 25 chas front and rear brakes eb702060 assembling the front and rear brake master cylinder warning ● all internal brake components should be cleaned and lubricated with new brake fluid only before installation. ● whenever a master cylinder is disassem- bled, replace the piston seals and dust sea...

  • Page 141: Chas

    4 - 26 chas front and rear brakes 3.Fill: ● brake fluid reservoir caution: brake fluid may damage painted surfaces or plastic parts. Always clean up spilled brake fluid immediately. Warning ● use only the designated quality brake fluid: other brake fluids may deteriorate the rubber seals, causing le...

  • Page 142: Chas

    4 - 27 chas front and rear brakes installing the rear brake master cylinder 1.Install: ● copper washers 1 ● brake hose 2 ● union bolt 3 caution: when installing the brake hose onto the brake master cylinder, make sure the brake pipe touches the projection a as shown. Warning proper brake hose routin...

  • Page 143: Chas

    4 - 28 chas 3.Air bleed: ● brake system refer to “bleeding the hydraulic brake system” in chapter 3. 4.Check: ● brake fluid level brake fluid level is below the “lower” level line → add the recommended brake fluid to the proper level. Refer to “checking the brake fluid level” in chapter 3. Front and...

  • Page 144: Chas

    4 - 29 chas front and rear brakes front brake calipers order job name/part name q’ty remarks removing the front brake caliper remove the parts in the order below. Brake fluid drain. Front wheel refer to “front wheels”. 1 union bolt 1 refer to “installing the front brake cal- iper”. 2 copper washer 2...

  • Page 145: Chas

    4 - 30 chas front and rear brakes order job name/part name q’ty remarks disassembling the front brake cali- per remove the parts in the order below. 1 brake pad holding bolt 2 2 brake pad/pad shim 2/1 3 brake pad spring 1 4 retaining bolt 1 5 caliper bracket 1 6 brake caliper piston 1 refer to “disa...

  • Page 146: Chas

    4 - 31 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. 1 parking brake cable 1 disconnect. 2 union bolt 1 refer to “installing the rear brake cali- per”. 3 copper washer 2 4 br...

  • Page 147: Chas

    4 - 32 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 adjusting bolt 1 2 locknut 1 3 parking brake lever 1 4 parking brake case mounting bolt 2 5 parking brake case 1 6 gasket 1 7 spring 1 8 nut 1 9 bearing...

  • Page 148: Chas

    4 - 33 chas front and rear brakes order job name/part name q’ty remarks b brake pad/pad shim 2/1 c brake pad spring 1 d retaining bolt 1 e caliper bracket 1 f brake caliper piston 1 refer to “disassembling the front and rear brake caliper/assem- bling the rear brake caliper”. G dust seal 1 h caliper...

  • Page 149: Chas

    4 - 34 chas front and rear brakes disassembling the front and rear brake caliper 1.Remove: ● brake caliper piston ● dust seal 1 ● caliper piston seal 2 *********************************************** removal steps: ● blow compressed air into the hose joint opening to force out the caliper piston fro...

  • Page 150: Chas

    4 - 35 chas front and rear brakes 1.Check: ● brake caliper piston 1 scratches/rust/wear → replace the brake caliper assembly. ● brake caliper cylinder 2 wear/scratches → replace the brake caliper assembly. ● brake caliper body 3 cracks/damage → replace. ● brake fluid delivery passage (brake caliper ...

  • Page 151: Chas

    4 - 36 chas front and rear brakes assembling the rear brake caliper warning ● all internal brake components should be cleaned and lubricated with new brake fluid only before installation. ● replace the caliper piston seal whenever a brake caliper is disassembled. 1.Install: ● o-ring 1 ● caliper pist...

  • Page 152: Chas

    4 - 37 chas front and rear brakes installing the front brake caliper 1.Install: ● brake caliper assembly ● brake caliper mounting bolts 1 ● brake hose 2 ● copper washers 3 ● union bolt 4 caution: when installing the brake hose on the brake caliper, make sure that the brake pipe touches the projectio...

  • Page 153: Chas

    4 - 38 chas 4.Check: ● brake fluid level brake fluid level is below the “lower” level line → add the recommended brake fluid to the proper level. Refer to “checking the brake fluid level” in chapter 3. Installing the rear brake caliper 1.Install: ● brake caliper assembly ● brake caliper mounting bol...

  • Page 154: Chas

    4 - 39 chas warning ● use only the designated quality brake fluid: other brake fluids may deteriorate the rubber seals, causing leakage and poor brake performance. ● refill with the same type of brake fluid: mixing brake fluids may result in a harmful chemical reaction and lead to poor brake perform...

  • Page 155: Chas

    4 - 40 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 2 3 front brake switch 1 refer to “removing the front brake switch, park switch and clutch switch”. 4 brake master cylind...

  • Page 156: Chas

    4 - 41 chas steering system order job name/part name q’ty remarks 11 handlebar grip 2 refer to “removing/installing the handlebar grip”. 12 handlebar cover bracket 2 refer to “installing the handle- bar”. 13 handlebar holder 2 14 handlebar 1 for installation, reverse the removal pro- cedure..

  • Page 157: Chas

    4 - 42 chas steering system removing the front brake switch, park switch and clutch switch 1.Remove: ● front brake switch 1 ● park switch ● clutch switch note: ● push the fastener when removing the front brake switch out of the brake master cylin- der. ● push the fastener when removing the park swit...

  • Page 158: Chas

    4 - 43 chas steering system installing the handlebar 1.Install: ● handlebar ● handlebar holders ● handlebar cover brackets note: the upper handlebar holder should be installed with the punched mark 1 forward 2 . Caution: first tighten the bolts 3 on the front side of the handlebar holder, and then t...

  • Page 159: Chas

    4 - 44 chas installing the brake master cylinder 1.Install: ● throttle lever assembly ● collar ● brake master cylinder note: ● engage the indentations a in the collar with the lobes b on the throttle lever assembly and brake master cylinder. ● the “up” mark on the brake master cylinder bracket shoul...

  • Page 160: Chas

    4 - 45 chas steering system steering stem order job name/part name q’ty remarks removing the steering stem remove the parts in the order below. Front fender refer to “seat, fenders and fuel tank” in chapter 3. Fuel tank handlebar refer to “handlebar”. 1 pitman arm 1 2 lock washer 1 refer to “install...

  • Page 161: Chas

    4 - 46 chas steering system order job name/part name q’ty remarks 9 bearing retainer 1 refer to “removing/installing the bearing retainer”. 10 bearing 1 for installation, reverse the removal pro- cedure..

  • Page 162: Chas

    4 - 47 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 1 bends → replace. Warning do not attempt to straighten a bent stem; this may dangerously weaken th...

  • Page 163: Chas

    4 - 48 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 wheel/brake disc refer to “front wheels”. 1 tie-rod 2 refer to “installing the tie-rod”. 2 pitman arm 1 3 brake disc gua...

  • Page 164: Chas

    4 - 49 chas steering system removing the steering knuckle 1.Remove: ● steering knuckle 1 note: use a general puller to separate the ball joint 2 and steering knuckle. Checking the tie-rod 1.Check: ● tie-rod free play and movement free play → replace the tie-rod end. Turns roughly → replace the tie-r...

  • Page 165: Chas

    4 - 50 chas front arms and front shock absorbers front arms and front shock absorbers order job name/part name q’ty remarks removing the front arm and front shock absorber remove the parts in the order below. Front wheel/brake disc refer to “front wheels”. 1 front bumper 1 2 brake disc guard (inner)...

  • Page 166: Chas

    4 - 51 chas front arms and front shock absorbers order job name/part name q’ty remarks 12 nut/bolt 1/1 13 front shock absorber/collar 1/1 14 steering knuckle 1 15 dust cover 6 16 collar 1 17 collar 2 18 bushing 6 19 circlip 1 20 rubber boot 1 21 ball joint 1 for installation, reverse the removal pro...

  • Page 167: Chas

    4 - 52 chas front arms and front shock absorbers removing the front arm 1.Check: ● front arm free play *********************************************** checking steps: ● check the front arm side play È by moving it from side to side. If side play is noticeable, check the bushings. ● check the front a...

  • Page 168: Chas

    4 - 53 chas front arms and front shock absorbers checking the ball joint 1.Check: ● ball joint (front arm-upper) damage/pitting → replace the front arm (upper). Free play → replace the front arm. Turns roughly → replace the front arm (upper). 2.Check: ● ball joint (front arm-lower) damage/pitting → ...

  • Page 169: Chas

    4 - 54 chas ● attach the assembled ball joint remover/ installer, new ball joint a , installer spacer 7 and installer washer 8 to the front lower arm 0 . Note: ● do not tap or damage the top of the ball joint. ● installer spacer 7 must be aligned with the projection on the head of the ball joint a ....

  • Page 170: Chas

    4 - 55 chas rear shock absorber and relay arm rear shock absorber and relay arm order job name/part name q’ty remarks removing the rear shock absorber and relay arm remove the parts in the order below. Rear wheels and hub refer to “rear wheels, wheel axle and hub”. 1 metal screw clamp 2 2 self-locki...

  • Page 171: Chas

    4 - 56 chas rear shock absorber and relay arm order job name/part name q’ty remarks 9 self-locking nut/bolt 1/1 10 relay arm 1 11 spacer/oil seal/bushing 1/2/2 refer to “installing the relay arm and connecting arm”. 12 connecting arm 1 13 dust cover 4 14 spacer 1 15 spacer 1 16 bushing 4 refer to “i...

  • Page 172: Chas

    4 - 57 chas rear shock absorber and relay arm handling the rear shock absorber and gas cylinder warning this rear shock absorber and gas cylinder contain highly compressed nitrogen gas. Before handling the rear shock absorber or gas cylinder, read and make sure you understand the following informati...

  • Page 173: Chas

    4 - 58 chas rear shock absorber and relay arm removing the rear shock absorber 1.Remove: ● connecting arm-to-frame bolt ● rear shock absorber upper bolt note: while removing the connecting arm-to-frame bolt, hold the swingarm so that it does not drop down. Checking the rear shock absorber 1.Check: ●...

  • Page 174: Chas

    4 - 59 chas rear shock absorber and relay arm installing the relay arm and connecting arm 1.Install: ● bushing 1 (to connecting arm) note: apply the lithium soap base grease on the bushing when installing. Installed depth of bushing a : 1 mm (0.04 in) 2.Install: ● bushing 1 ● oil seal 2 (to relay ar...

  • Page 175: Chas

    4 - 60 chas swingarm and drive chain swingarm and drive chain order job name/part name q’ty remarks removing the swingarm and drive chain remove the parts in the order below. Rear wheels and hub refer to “rear wheels, wheel axle and hub”. Rear shock absorber refer to “rear shock absorber and relay a...

  • Page 176: Chas

    4 - 61 chas swingarm and drive chain order job name/part name q’ty remarks 8 nut 1 refer to “installing the drive sprocket”. 9 lock washer 1 10 drive sprocket 1 11 drive chain 1 12 collar 1 13 spacer 1 14 oil seal 1 15 bearing 1 16 dust cover/oil seal/washer 1/1/1 17 spacer 1 18 oil seal 2 19 bushin...

  • Page 177: Chas

    4 - 62 chas swingarm and drive chain note: before removing the drive chain and the sprockets, measure the drive chain slack and a ten link section of the drive chain. Removing the swingarm 1.Check: ● swingarm free play *********************************************** checking steps: ● check the tight...

  • Page 178: Chas

    4 - 63 chas swingarm and drive chain 2.Check: ● pivot shaft roll the axle on a flat surface. Bends → replace. Warning do not attempt to straighten a bent pivot shaft. 3.Clean: ● pivot shaft ● collar ● spacers ● bearings ● bushings 4.Check: ● spacers ● oil seals damage/wear → replace. ● bearings ● bu...

  • Page 179: Chas

    4 - 64 chas swingarm and drive chain 2.Check: ● drive chain stiffness → clean and lubricate or replace. 3.Clean: ● drive chain *********************************************** ● wipe the drive chain with a clean cloth. ● put the drive chain in kerosine and remove any remaining dirt. ● remove the driv...

  • Page 180: Chas

    4 - 65 chas swingarm and drive chain 5.Lubricate: ● drive chain recommended lubricant: engine oil or chain lubricant suitable for o-ring chains 6.Check: ● drive sprocket ● driven sprocket more than 1/4 tooth a wear → replace the drive chain sprockets as a set. Bent teeth → replace the drive chain sp...

  • Page 181: Eng

    5 - 1 eng engine removal engine engine removal muffler and exhaust pipes order job name/part name q’ty remarks removing the muffler and exhaust pipes remove the parts in the order below. Seat/left footrest guard/engine refer to “seat, fenders and fuel tank” in chapter 3. Skid plate front and rear fe...

  • Page 182: Eng

    5 - 2 eng engine removal left footrest order job name/part name q’ty remarks removing the left footrest remove the parts in the order below. 1 locknut 1 2 locknut 1 left-hand threads 3 adjusting rod 1 4 left footrest guard bracket 1 5 left footrest 1 for installation, reverse the removal pro- cedure...

  • Page 183: Eng

    5 - 3 eng engine removal leads, cables and hoses order job name/part name q’ty remarks removing the leads, cables and hoses remove the parts in the order below. Engine oil drain. Coolant drain. Water jacket outlet pipe refer to “thermostat” in chapter 6. Radiator outlet hose refer to “water pump” in...

  • Page 184: Eng

    5 - 4 eng engine removal order job name/part name q’ty remarks 4 coupler 5 disconnect. 5 speed sensor/o-ring 1/1 6 neutral switch lead/reverse switch lead 1/1 7 ground lead 1 8 clutch cable 1 9 parking brake cable 1 10 reverse control cable 1 11 oil pipe 2 1 disconnect. 12 oil pipe 1 1 disconnect. 1...

  • Page 185: Eng

    5 - 5 eng engine removal engine mounting bolts order job name/part name q’ty remarks removing the engine mounting bolt remove the parts in the order below. 1 engine mounting bolt (upper)/nut 1/1 2 engine bracket bolt (upper) 4 caution: install all of the bolts/nuts and then tighten them to full torq...

  • Page 186: Eng

    5 - 6 eng engine removal order job name/part name q’ty remarks 11 engine assembly 1 note: remove the engine assembly from the left side of the machine. For installation, reverse the removal pro- cedure..

  • Page 187: Eng

    5 - 7 eng installing the engine 1.Install: ● engine brackets (lower) 1 ● engine bracket bolts (lower) 2 ● engine brackets (middle) 3 ● engine mounting bolt (lower)/nut 4 ● engine mounting bolt (middle)/nut 5 ● engine bracket (upper) 6 ● engine bracket bolts (upper) 7 ● engine mounting bolt (upper)/n...

  • Page 188: Eng

    5 - 8 eng cylinder head cover cylinder head cover order job name/part name q’ty remarks removing the cylinder head cover remove the parts in the order below. Seat/front fender refer to “seat, fenders and fuel tank” in chapter 3. Fuel tank/rubber cover 2 1 engine mounting bolt/nut 1/1 2 engine bracke...

  • Page 189: Eng

    5 - 9 eng cylinder head cover order job name/part name q’ty remarks 10 cylinder head cover 1 refer to “removing/installing cyl- inder head cover”. 11 dowel pin 2 for installation, reverse the removal pro- cedure..

  • Page 190: Eng

    5 - 10 eng cylinder head cover removing the cylinder head cover 1.Align: ● “i” mark (with stationary pointer) *********************************************** checking steps: ● turn the crankshaft counterclockwise with a wrench. ● align the “i” mark 1 on the rotor with the sta- tionary pointer 2 on t...

  • Page 191: Eng

    5 - 11 eng cylinder head cover checking the tappet cover 1.Check: ● tappet cover (intake) 1 ● tappet cover (exhaust) 2 ● o-ring 3 new installing the cylinder head cover 1.Apply: ● sealant (quick gasket ) 1 (to the mating surfaces of the cylinder head and cylinder head cover) 2.Install: ● cylinder he...

  • Page 192: Eng

    5 - 12 eng rocker arms rocker arms order job name/part name q’ty remarks removing the rocker arm remove the parts in the order below. Cylinder head cover refer to “cylinder head cover”. 1 plug/o-ring 1/1 2 bolt 2 3 rocker arm shaft 2/o-ring 1/1 refer to “removing/installing the rocker arm”. 4 rocker...

  • Page 193: Eng

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

  • Page 194: Eng

    5 - 14 eng rocker arms removing the rocker arm 1.Remove: ● rocker arm shafts 1 ● rocker arms 2 note: use a slide hammer bolt 3 and weight 4 to remove the rocker arm shafts. Slide hammer set: p/n. Yu-01083-a slide hammer bolt (m6): p/n. 90890-01083 weight: p/n. 90890-01084 checking the rocker arm 1.C...

  • Page 195: Eng

    5 - 15 eng rocker arms ● measure the outside diameter b of the rocker arm shafts. Out of specification → replace. ● calculate the clearance by subtracting the rocker arm shaft outside diameter from the rocker arm inside diameter. Clearance greater than 0.08 mm (0.003 in) → replace the defective part...

  • Page 196: Eng

    5 - 16 eng camshaft and cylinder head camshaft and cylinder head order job name/part name q’ty remarks removing the camshaft and cylin- der head remove the parts in the order below. Seat/front fender refer to “seat, fenders and fuel tank” in chapter 3. Fuel tank/rubber covers carburetors refer to “c...

  • Page 197: Eng

    5 - 17 eng camshaft and cylinder head order job name/part name q’ty remarks 6 camshaft 1 refer to “camshaft and cylinder head”. 7 cylinder head 1 8 cylinder head gasket 1 9 dowel pin 2 10 carburetor joint 1 1 11 carburetor joint 2 1 for installation, reverse the removal pro- cedure..

  • Page 198: Eng

    5 - 18 eng camshaft and cylinder head removing the camshaft and cylin- der head 1.Loosen: ● camshaft sprocket bolts 1 2.Loosen: ● timing chain tensioner cap bolt 3.Remove: ● timing chain tensioner ● timing chain guide (exhaust) ● decompressor cam guide plates ● camshaft sprocket note: ● fasten a saf...

  • Page 199: Eng

    5 - 19 eng camshaft and cylinder head checking the camshaft 1.Check: ● cam lobes pitting/scratches/blue discoloration → replace. 2.Measure: ● cam lobes length a and b . Out of specification → replace. Camshaft lobe limit: intake: a 35.59 mm (1.4012 in) b 30.05 mm (1.1831 in) exhaust: a 36.40 mm (1.4...

  • Page 200: Eng

    5 - 20 eng camshaft and cylinder head checking the timing chain guide 1.Check: ● exhaust side timing chain guide wear/damage → replace. Checking the timing chain ten- sioner 1.Check: ● one-way cam operation (tensioner) unsmooth operation → replace. Checking the cylinder head 1.Eliminate: ● carbon de...

  • Page 201: Eng

    5 - 21 eng camshaft and cylinder head 3.Measure: ● cylinder head warpage out of specification → resurface. *********************************************** warpage measurement and resurfacing steps: ● place a straightedge and a feeler gauge across the cylinder head. ● use a feeler gauge to measure th...

  • Page 202: Eng

    5 - 22 eng camshaft and cylinder head 2.Install: ● camshaft ● camshaft sprocket *********************************************** installation steps: ● turn the crankshaft counterclockwise with a wrench. ● align the “i” mark 1 on the rotor with the sta- tionary pointer 2 on the crankcase cover. When t...

  • Page 203: Eng

    5 - 23 eng camshaft and cylinder head ● install the decompressor cam guide plates 9 and camshaft sprocket bolts 0 . ● remove the retaining wire. *********************************************** t r . . Camshaft sprocket bolt: 20 nm (2.0 m • kg, 14 ft • lb) 3.Install: ● timing chain tensioner ********...

  • Page 204: Eng

    5 - 24 eng valves and valve springs valves and valve springs order job name/part name q’ty remarks removing the valve and valve spring remove the parts in the order below. Cylinder head refer to “camshaft and cylinder head”. 1 valve cotter 10 refer to “removing/installing the valve and valve spring”...

  • Page 205: Eng

    5 - 25 eng valves and valve springs removing the valve and valve spring 1.Check: ● valve sealing leakage at the valve seat → inspect the valve face, valve seat and valve seat width. Refer to “valve and valve spring inspection”. *********************************************** checking steps: ● pour a...

  • Page 206: Eng

    5 - 26 eng valves and valve springs checking the valve and valve spring 1.Measure: ● stem-to-guide clearance out of specification → replace the valve guide. Stem-to-guide clearance = valve guide inside diameter a – valve stem diameter b clearance (stem to guide): intake: 0.010 ~ 0.037 mm (0.0004 ~ 0...

  • Page 207: Eng

    5 - 27 eng valves and valve springs 3.Check: ● valve face pitting/wear → grind the face. ● valve stem end mushroom shape or diameter larger than the body of the stem → replace. 4.Measure: ● margin thickness a out of specification → replace. Margin thickness: intake: 0.85 ~ 1.15 mm (0.0335 ~ 0.0453 i...

  • Page 208: Eng

    5 - 28 eng valves and valve springs 8.Measure: ● valve seat width a out of specification → reface the valve seat. *********************************************** measurement steps: ● apply mechanic’s blueing dye (dykem) b to the valve face. ● install the valve into the cylinder head. ● press the val...

  • Page 209: Eng

    5 - 29 eng valves and valve springs ● install the valve into the cylinder head. ● turn the valve until the valve face and valve seat are evenly polished, then clean off all of the compound. Note: for best lapping results, lightly tap the valve seat while rotating the valve back and forth between you...

  • Page 210: Eng

    5 - 30 eng valves and valve springs 11.Measure: ● compressed spring force a out of specification → replace. B installed length compressed spring force: inner: 149 ~ 173 n at 27.2 mm (15.19 ~ 17.64 kg, 33.50 ~ 38.89 lb at 1.07 in) outer: 165 ~ 191 n at 30.7 mm (16.83 ~ 19.49 kg, 37.09 ~ 42.94 lb at 1...

  • Page 211: Eng

    5 - 31 eng valves and valve springs 3.Install: ● valve cotters note: install the valve cotters while compressing the valve spring with the valve spring compressor 1 and attachment 2 . Valve spring compressor: p/n. Ym-04019, 90890-04019 valve spring compressor attachment: p/n. 90890-01243 4.To secure...

  • Page 212: Eng

    5 - 32 eng cylinder and piston cylinder and piston order job name/part name q’ty remarks removing the cylinder and piston remove the parts in the order below. Water jacket inlet housing refer to “water pump” in chapter 6. Cylinder head refer to “camshaft and cylinder head”. 1 cable guide 1 2 cylinde...

  • Page 213: Eng

    5 - 33 eng cylinder and piston removing the piston 1.Remove: ● piston pin clips 1 ● piston pin 2 ● piston 3 note: ● put identification marks on each piston head for reference during reinstallation. ● before removing each piston pin, deburr the clip groove and pin hole area. If the piston pin groove ...

  • Page 214: Eng

    5 - 34 eng cylinder and piston note: measure cylinder bore “c” in parallel to and at right angles to the cylinder matching surface. Then, find the average of the measurements. ● if out of specification, rebore or replace the cylinder, and replace the piston and piston rings as a set. 2nd step: ● mea...

  • Page 215: Eng

    5 - 35 eng cylinder and piston checking the piston ring 1.Measure: ● ring side clearance use a feeler gauge. Out of specification → replace the piston and rings as a set. Note: clean carbon from the piston ring grooves and rings before measuring the side clearance. Side clearance standard limit top ...

  • Page 216: Eng

    5 - 36 eng cylinder and piston checking the piston pin inspection 1.Check: ● piston pin blue discoloration/grooves → replace, then inspect the lubrication system. 2.Measure: ● piston pin-to-piston clearance *********************************************** measurement steps: ● measure the piston pin o...

  • Page 217: Eng

    5 - 37 eng cylinder and piston 2.Position: ● top ring ● 2nd ring ● oil ring offset the piston ring end gaps as shown. A top ring end b oil ring end (lower) c oil ring end (upper) d 2nd ring end 3.Install: ● piston 1 ● piston pin 2 ● piston pin clips 3 note: ● apply engine oil onto the piston pin, pi...

  • Page 218: Eng

    5 - 38 eng ac magneto ac magneto order job name/part name q’ty remarks removing the ac magneto remove the parts in the order below. Engine oil drain. Shift pedal link disconnect. 1 oil pipe 1 1 disconnect. 2 ac magneto coupler 2 3 starter idle gear cover/gasket 1/1 4 dowel pin 1 5 starter idle gear ...

  • Page 219: Eng

    5 - 39 eng ac magneto order job name/part name q’ty remarks 9 dowel pin/o-ring 3/2 10 lead holder 1 11 pickup coil 1 12 stator assembly 1 13 starter idle gear 2 1 14 starter idle gear 2 shaft 1 15 bearing 1 16 ac magneto rotor 1 refer to “removing/installing the ac magneto rotor”. 17 starter wheel g...

  • Page 220: Eng

    5 - 40 eng ac magneto removing the ac magneto rotor 1.Remove: ● ac magneto cover note: loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2.Remove: ● ac magneto rotor nut 1 ● washer note: ● while holding the ac mag...

  • Page 221: Eng

    5 - 41 eng ac magneto checking the starter clutch 1.Check: ● starter one-way clutch 1 cracks/damage → replace. ● bolts 2 (starter clutch) loose → replace. Note: the arrow mark on the starter clutch must face inward, away from the ac magneto rotor. *********************************************** chec...

  • Page 222: Eng

    5 - 42 eng ac magneto installing the ac magneto rotor 1.Apply: ● sealant (quick gasket ® ) 1 (into the slit) sealant (quick gasket ® ): p/n. Acc-11001-05-01 yamaha bond no. 1215 ® : p/n. 90890-85505 2.Install: ● woodruff key ● ac magneto rotor note: ● before installing the rotor, clean the outside o...

  • Page 223: Eng

    5 - 43 eng clutch clutch order job name/part name q’ty remarks removing the clutch cover remove the parts in the order below. Engine assembly refer to “engine removal”. 1 oil filter bolt 1 2 union bolt 2 3 copper washer 4 4 oil delivery pipe 1 1 5 union bolt 2 6 copper washer 4 7 oil delivery pipe 2...

  • Page 224: Eng

    5 - 44 eng clutch order job name/part name q’ty remarks removing the pull lever shaft remove the parts in the order below. 1 circlip 1 2 pull lever 1 3 pull lever spring 1 4 bolt 1 5 pull lever shaft 1 6 oil seal 1 7 bearing 1 8 bearing 1 for installation, reverse the removal pro- cedure..

  • Page 225: Eng

    5 - 45 eng clutch order job name/part name q’ty remarks removing the clutch remove the parts in the order below. 1 clutch spring 5 refer to “installing the clutch”. 2 pressure plate 1 3 pull rod 1 4 bearing 1 5 friction plate 2 2 inside diameter = 116 mm (4.57 in) 6 clutch plate 7 7 friction plate 1...

  • Page 226: Eng

    5 - 46 eng clutch order job name/part name q’ty remarks 11 thrust washer 1 12 clutch housing 1 refer to “installing the clutch”. 13 lock washer 1 refer to “removing/installing the primary drive gear and bal- ancer driven gear”. 14 balancer driven gear 1 15 straight key 1 16 lock washer 1 17 primary ...

  • Page 227: Eng

    5 - 47 eng clutch removing the clutch 1.Remove: ● clutch cover note: loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2.Straighten the lock washer tab. 3.Loosen: ● clutch boss nut 1 note: while holding the clutch...

  • Page 228: Eng

    5 - 48 eng clutch checking the friction plate the following procedure applies to all of the friction plates. 1.Check: ● friction plate damage/wear → replace the friction plates as a set. 2.Measure: ● friction plate thickness out of specification → replace the friction plates as a set. Note: measure ...

  • Page 229: Eng

    5 - 49 eng clutch checking the clutch spring the following procedure applies to all of the clutch springs. 1.Check: ● clutch spring damage → replace the clutch springs as a set. 2.Measure: ● clutch spring free length a out of specification → replace the clutch springs as a set. Clutch spring free le...

  • Page 230: Eng

    5 - 50 eng clutch checking the pull lever shaft and pull rod 1.Check: ● pull lever shaft pinion gear teeth a ● pull rod teeth b damage/wear → replace the pull lever shaft and pull rod as a set. 2.Check: ● pull rod bearing damage/wear → replace. Checking the primary drive 1.Check: ● primary drive gea...

  • Page 231: Eng

    5 - 51 eng clutch installing the primary drive gear and balancer driven gear 1.Install: ● dowel pin ● spring ● balancer drive gear (onto the primary drive gear) note: align the punch mark a on the balancer drive gear with the punch mark b on the primary drive gear. 2.Install: ● primary drive gear ● ...

  • Page 232: Eng

    5 - 52 eng clutch installing the clutch 1.Install: ● clutch housing 1 note: ● make sure that the primary driven gear teeth and primary drive gear teeth mesh correctly. ● make sure that the oil pump drive gear teeth and oil pump driven gear teeth mesh cor- rectly. 2.Tighten: ● clutch boss nut 1 note:...

  • Page 233: Eng

    5 - 53 eng clutch 5.Install: ● clutch spring note: tighten the bolts in stages, using a crisscross pattern. T r . . 8 nm (0.8 m • kg, 5.8 ft • lb) 6.Install: ● clutch cover note: be sure to mesh the pull lever shaft with the pull rod teeth to ensure that the mark a on pull lever 1 is at the closest ...

  • Page 234: Eng

    5 - 54 eng oil pump oil pump order job name/part name q’ty remarks removing the oil pump remove the parts in the order below. Clutch refer to “clutch”. 1 circlip 1 2 oil pump driven gear 1 3 oil pump 1 4 oil pump gasket 1 5 o-ring 2 for installation, reverse the removal pro- cedure..

  • Page 235: Eng

    5 - 55 eng oil pump order job name/part name q’ty remarks disassembling the oil pump remove the parts in the order below. 1 oil pump housing 1/oil seal 1/1 2 oil pump outer rotor 1 1 3 dowel pin 1 4 oil pump inner rotor 1 1 5 oil pump housing cover/oil seal 1/1 6 dowel pin 2 7 oil pump shaft 1 8 dow...

  • Page 236: Eng

    5 - 56 eng oil pump checking the oil pump 1.Check: ● oil pump driven gear ● oil pump housings ● oil pump housing cover cracks/wear/damage → replace. 2.Measure: ● tip clearance a (between the inner rotor 1 and the outer rotor 2 ) ● side clearance b (between the outer rotor 2 and the pump housing 3 ) ...

  • Page 237: Eng

    5 - 57 eng shift shaft shift shaft order job name/part name q’ty remarks removing the shift shaft remove the parts in the order below. Clutch refer to “clutch”. 1 shift arm 1 refer to “installing the shift shaft”. 2 shift shaft 1 3 shift shaft spring 1 4 collar 1 5 roller 1 6 stopper lever 1 refer t...

  • Page 238: Eng

    5 - 58 eng shift shaft order job name/part name q’ty remarks 9 shift guide 1 refer to “installing the shift lever”. 10 shift lever 1 11 pawl 2 12 pawl pin 2 13 spring 2 14 segment 1 15 oil seal 1 for installation, reverse the removal pro- cedure..

  • Page 239: Eng

    5 - 59 eng shift shaft checking the shift shaft 1.Check: ● shift shaft 1 bends/damage/wear → replace. ● shift shaft spring 2 damage/wear → replace. Checking the stopper lever 1.Check: ● stopper lever 1 bends/damage → replace. Roller turns roughly → replace the stopper lever. ● stopper spring 2 damag...

  • Page 240: Eng

    5 - 60 eng shift shaft 2.Install: ● springs 1 ● pawl pins 2 ● pawls 3 ● shift guide 4 (to the shift lever) 3.Install: ● shift lever assembly 1 ● shift guide 2 note: the shift lever assembly is installed at the same time as the shift guide. Installing the stopper lever 1.Install: ● roller ● stopper l...

  • Page 241: Eng

    5 - 61 eng shift shaft installing the shift shaft 1.Install: ● roller 1 ● collar ● shift shaft spring ● shift shaft 2 note: ● install the end of the shift shaft spring onto the shift shaft spring stopper 3 . ● install the end of the shift shaft lever onto the roller 1 . 2.Install: ● shift arm 1 ● bo...

  • Page 242: Eng

    5 - 62 eng crankcase crankcase timing chain and speed sensor rotor order job name/part name q’ty remarks removing the timing chain and speed sensor rotor remove the parts in the order below. Engine assembly refer to “engine removal”. Cylinder head cover refer to “cylinder head cover”. Cylinder head ...

  • Page 243: Eng

    5 - 63 eng crankcase order job name/part name q’ty remarks 3 reverse shift lever 1 4 reverse shift lever spring 1 5 circlip 1 6 neutral switch 1 7 reverse switch 1 8 oil pipe joint 1 9 circlip 1 10 wave washer 1 11 speed sensor rotor 1 12 circlip 1 for installation, reverse the removal pro- cedure..

  • Page 244: Eng

    5 - 64 eng crankcase crankcase order job name/part name q’ty remarks separating the crankcase remove the parts in the order below. 1 right crankcase 1 refer to “crankcase”. 2 dowel pin 2 3 dowel pin/o-ring 1/1 4 left crankcase 1 5 oil strainer 1 6 cover 1 7 oil strainer gasket 1 for installation, re...

  • Page 245: Eng

    5 - 65 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 balancer refer to “crankshaft and bal- ancer”. Transmission refer to “transmission”. 1 oil seal retainer 1 2 oil seal 3 3 bearing retainer 3...

  • Page 246: Eng

    5 - 66 eng crankcase separating the crankcase 1.Separate: ● left crankcase ● right crankcase *********************************************** separation steps: ● remove the crankcase bolts. Note: ● loosen each bolt 1/4 of a turn at a time and after all the bolts are loosened, remove them. ● loosen th...

  • Page 247: Eng

    5 - 67 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 248: Eng

    5 - 68 eng crankcase 3.Fit the right crankcase onto the left crank- case. Tap lightly on the case with a soft ham- mer. Caution: before installing and torquing the crank- case holding bolts, be sure to check whether the transmission is functioning properly by manually rotating the shift cam in both ...

  • Page 249: Eng

    5 - 69 eng crankshaft and balancer crankshaft and balancer order job name/part name q’ty remarks removing the crankshaft and bal- ancer remove the parts in the order below. Crankcase separate. Refer to “crankcase”. 1 balancer 1 2 crankshaft 1 refer to “removing/installing the crankshaft”. For instal...

  • Page 250: Eng

    5 - 70 eng crankshaft and balancer removing the crankshaft 1.Remove: ● crankshaft use a crankcase separating tool 1 . Crankcase separating tool: p/n. Yu-01135-a, 90890-01135 checking the crankshaft 1.Measure: ● crank width a out of specification → replace the crank- shaft. ● side clearance d out of ...

  • Page 251: Eng

    5 - 71 eng crankshaft and balancer installing the crankshaft 1.Install: ● crankshaft note: hold the connecting rod at the top dead cen- ter (tdc) with one hand while turning the nut of the installing tool with the other. Operate the installing tool until the crankshaft bottoms against the bearing. C...

  • Page 252: Eng

    5 - 72 eng transmission transmission order job name/part name q’ty remarks removing the transmission remove the parts in the order below. Crankcase separate. Refer to “crankcase”. 1 shift fork guide bar (short) 1 refer to “installing the transmis- sion”. 2 shift fork “c” 1 3 shift fork guide bar (lo...

  • Page 253: Eng

    5 - 73 eng transmission order job name/part name q’ty remarks 11 counter axle 1 12 counter gear 1 for installation, reverse the removal pro- cedure..

  • Page 254: Eng

    5 - 74 eng transmission main axle order job name/part name q’ty remarks disassembling the main axle remove the parts in the order below. 1 reverse pinion gear 1 2 4th pinion gear 1 3 2nd/3rd pinion gear 1 4 circlip 1 refer to “assembling the main axle and drive axle”. 5 toothed washer 1 6 5th pinion...

  • Page 255: Eng

    5 - 75 eng transmission drive axle order job name/part name q’ty remarks disassembling the drive axle remove the parts in the order below. 1 washer 1 2 1st wheel gear 1 3 5th wheel gear 1 4 circlip 3 refer to “assembling the main axle and drive axle”. 5 toothed washer 3 6 3rd wheel gear 1 7 toothed ...

  • Page 256: Eng

    5 - 76 eng transmission order job name/part name q’ty remarks a 4th wheel gear 1 b reverse wheel gear 1 c collar 1 d drive axle 1 for assembly, reverse the disassembly procedure..

  • Page 257: Eng

    5 - 77 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 258: Eng

    5 - 78 eng transmission 2.Measure: ● drive axle runout (with a centering device and dial gauge 1 ) out of specification → replace the drive axle. Maximum drive axle runout: 0.08 mm (0.0031 in) 3.Check: ● transmission gears blue discoloration/pitting/wear → replace the defective gear(s). ● transmissi...

  • Page 259: Eng

    5 - 79 eng transmission 2.Install: ● reverse pinion gear 1 note: press the reverse pinion gear into the main axle 2 , as shown in the illustration. A 115.65 ~ 115.85 mm (4.553 ~ 4.561 in) installing the transmission 1.Install: ● shift drum 1 ● shift fork “l” 2 ● shift fork “r” 3 ● shift fork guide b...

  • Page 260: Cool

    6 - 1 cool radiator cooling system radiator order job name/part name q’ty remarks removing the radiator remove the parts in the order below. Front panel and front fender refer to “seat, fenders and fuel tank” in chapter 3. Coolant drain. 1 radiator fan coupler 1 disconnect. 2 thermo switch coupler 1...

  • Page 261: Cool

    6 - 2 cool radiator order job name/part name q’ty remarks 11 coolant reservoir 1 12 coolant reservoir cap 1 for installation, reverse the removal pro- cedure..

  • Page 262: Cool

    6 - 3 cool radiator checking the radiator 1.Check: ● radiator fins obstruction → clean. Apply compressed air to the rear of the radia- tor. Damage → repair or replace. Ote: straighten any flattened fins with a thin, flat- head screwdriver. 2.Check: ● radiator hoses cracks/damage → replace. 3.Measure...

  • Page 263: Cool

    6 - 4 cool radiator installing the radiator 1.Fill: ● cooling system (with the specified amount of the recom- mended coolant) refer to “changing the coolant” in chapter 3. 2.Check: ● cooling system leaks → repair or replace any faulty part..

  • Page 264: Cool

    6 - 5 cool thermostat thermostat order job name/part name q’ty remarks removing the thermostat remove the parts in the order below. Front panel and front fender refer to “seat, fenders and fuel tank” in chapter 3. Coolant drain. Radiator refer to “radiator”. 1 radiator inlet hose 1 2 front fender br...

  • Page 265: Cool

    6 - 6 cool thermostat order job name/part name q’ty remarks disassembling the thermostat remove the parts in the order listed. 1 thermostat cover 1 refer to “assembling the thermo- stat”. 2 o-ring 1 3 thermostat 1 4 thermostat housing 1 for assembly, reverse the disassembly procedure..

  • Page 266: Cool

    6 - 7 cool thermostat checking the thermostat 1.Check: ● thermostat 1 does not open at 69 ~ 73 °c (156.2 ~ 163.4 °f) → replace. *********************************************** checking steps: ● suspend the thermostat in a container filled with water. ● slowly heat the water. ● place a thermometer in...

  • Page 267: Cool

    6 - 8 cool water pump water pump order job name/part name q’ty remarks removing the water pump remove the parts in the order below. Coolant drain. 1 radiator outlet hose 1 disconnect. 2 water pump outlet hose 1 3 water pump assembly 1 4 o-ring 1 5 water jacket inlet housing 1 6 o-ring 1 for installa...

  • Page 268: Cool

    6 - 9 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 o-ring 1 3 circlip 1 4 impeller shaft gear 1 5 pin 1 6 circlip 1 7 impeller 1 refer to “disassembling/assem- bling the thermostat”. 8 impeller ...

  • Page 269: Cool

    6 - 10 cool water pump order job name/part name q’ty remarks 0 rubber damper 1 refer to “disassembling/assem- bling the thermostat”. A water pump seal 1 b oil seal 1 c bearing 1 d water pump housing 1 for assembly, reverse the disassembly procedure..

  • Page 270: Cool

    6 - 11 cool water pump disassembling the water pump 1.Remove: ● impeller shaft 1 ote: tap out the impeller shaft from the impeller. 2.Remove: ● rubber damper holder 1 ● rubber damper 2 (from the impeller, with a thin, flathead screwdriver) ote: do not scratch the impeller. 3.Remove: ● water pump sea...

  • Page 271: Cool

    6 - 12 cool water pump 2.Check: ● water pump seal ● oil seal ● water pump outlet pipe cracks/damage/wear → replace. ● bearing rough movement → replace. New assembling the water pump 1.Install: ● oil seal 1 (into the water pump housing 2 ) ote: ● before installing the oil seal, apply tap water or coo...

  • Page 272: Cool

    6 - 13 cool water pump 4.Measure: ● impeller shaft tilt out of specification → repeat steps (3) and (4). Caution: make sure that the rubber damper and rub- ber damper holder are bottom with the impeller. 1 straightedge 2 impeller max. Impeller shaft tilt: 0.15 mm (0.006 in).

  • Page 273: Carb

    7 - 1 carb carburetors carburetion carburetors order job name/part name q’ty remarks removing the carburetors remove the parts in the order below. Seat/front fender/fuel tank/rubber cover 2 refer to “seat, fenders and fuel tank” in chapter 3. 1 air vent hose 2 2 float chamber breather hose 1 3 start...

  • Page 274: Carb

    7 - 2 carb carburetors order job name/part name q’ty remarks separating the carburetors remove the parts in the order below. 1 drain hose 2 2 plate 1 3 connecting bolt/spacer 2/2 4 spring 1 5 hose joint 1 6 pipe 1 7 carburetor 2 1 8 carburetor 1 1 for installation, reverse the separating procedure..

  • Page 275: Carb

    7 - 3 carb carburetors order job name/part name q’ty remarks disassembling the carburetor remove the parts in the order below. 1 throttle stop screw 1 2 vacuum chamber cover 1 3 spring 1 4 jet needle holder 1 5 spring 1 6 jet needle set 1 7 piston valve 1 8 float chamber 1 9 drain screw 1 0 float 1 ...

  • Page 276: Carb

    7 - 4 carb carburetors order job name/part name q’ty remarks b pilot jet 1 c pilot screw set 1 refer to “disassembling/ assembling the carburetor”. Ote: 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 positi...

  • Page 277: Carb

    7 - 5 carb carburetors disassembling the carburetor ote: 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 278: Carb

    7 - 6 carb carburetors 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: ● jet needle 1 ● main jet 2 ● needle jet 3 ● pilot air jet 4 ● pilot jet 5 ● pilot screw 6 ● starter ...

  • Page 279: Carb

    7 - 7 carb carburetors assembling the carburetor caution: before reassembling, wash all of the parts in a clean petroleum based solvent. 1.Install: ● pilot screw 1 ote: before assembling the carburetor, make sure to turn out the pilot screw the same number of times, as noted before disassembly, from...

  • Page 280: Carb

    7 - 8 carb carburetors 3.Install: ● carburetor 1 ● carburetor 2 ● pipe ● hose joint ● spring ote: ● install the throttle valve lever 1 onto carburetor 2 between the spring 2 and synchronizing screw 3 . ● make sure the throttle valves operate smoothly and that the synchronization is correct. Adjustin...

  • Page 281: Carb

    7 - 9 carb carburetors ● remove the carburetor. ● inspect the valve seat and needle valve. ● if either is worn, replace them both. ● if both are fine, adjust the float level by bending the float tang 4 slightly. ● install the carburetor. ● recheck the fuel level. ************************************...

  • Page 282: Elec

    8 - 1 – + elec electrical components eb800000 electrical electrical components 1 main switch 2 front brake switch 3 indicator light 4 circuit breaker (fan) 5 park switch 6 clutch switch 7 handlebar switch (left) 8 fuse 9 starter relay 0 tail/brake light a rectifier/regulator b cdi unit c battery d n...

  • Page 283: Elec

    8 - 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. Ote: ● set the pocket tester to “0” before starting the test. ● the pocket tester should be set to the “...

  • Page 284: Elec

    8 - 3 – + 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..

  • Page 285: Elec

    8 - 4 – + elec checking the switch 1 lights switch 2 engine stop switch 3 start switch 4 main switch 5 front brake switch 6 clutch switch 7 park switch 8 fuse 9 reverse switch 0 neutral switch a rear brake switch.

  • Page 286: Elec

    8 - 5 – + elec ignition system eb802000 ignition system circuit diagram 1 ac magneto 3 main switch 4 battery 5 fu se 0 cdi unit a ignition coil b sp ar k plu g p engine stop switch.

  • Page 287: Elec

    8 - 6 – + elec ignition system eb802010 troubleshooting procedure check: 1.Fuse 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 switch 9.Pickup coi...

  • Page 288: Elec

    8 - 7 – + elec ignition system correct spark plug gap: 0.8 ~ 0.9 mm (0.031 ~ 0.035 in) incorrect repair or replace the spark plug. For usa and cdn 4.Ignition spark gap ● disconnect the spark plug cap from the spark plug. ● connect the dynamic spark tester 1 as shown. 2 spark plug cap 3 spark plug ● ...

  • Page 289: Elec

    8 - 8 – + elec ignition system 5.Spark plug cap resistance ● remove the spark plug cap. ● connect the pocket tester ( Ω × 1k) to the spark plug cap. * meets specification ● check that the spark plug cap has the specified resistance. Spark plug cap resistance: 10 k Ω at 20 °c (68 °f) out of specifica...

  • Page 290: Elec

    8 - 9 – + elec ignition system both meet specification ● connect the pocket tester ( Ω × 1k) to the ignition coil. Tester (+) lead → orange lead terminal tester (–) lead → spark plug lead ● check that the secondary coil has the specified resistance. Secondary coil resistance: 6.32 ~ 9.48 k Ω at 20 °...

  • Page 291: Elec

    8 - 10 – + elec ignition system c0ntinuity meets specification 10.Charging/rotor rotation direction detec- tion coil resistance ● disconnect the ac magneto coupler from the wire harness. ● connect the pocket tester ( Ω × 100) to the charging/rotor rotation direction detection coil terminal. Tester (...

  • Page 292: Elec

    8 - 11 – + elec electric starting system eb803000 electric starting system circuit diagram 3 main switch 4 ba tt e ry 5 fuse 6 s tar te r re lay 7 s tar te r mo to r 8 c lutch switch 9 p a rk switch 0 cd i u n it j neutral switch p en gin e stop switch q s tart switch.

  • Page 293: Elec

    8 - 12 – + elec electric starting system starting circuit operation the starting circuit on this model consists of the starter motor, starter relay, clutch switch, cdi unit and neutral switch. If the main switch is on and the engine stop switch is in the run position, the starter motor can be operat...

  • Page 294: Elec

    8 - 13 – + elec electric starting system eb803020 troubleshooting procedure check: 1.Fuse 2.Battery 3.Starter motor 4.Starter relay 5.Main switch 6.Engine stop switch if the starter motor fails to operate: 7.Start switch 8.Neutral switch 9.Clutch switch 10.Wiring connection (the entire starting sys-...

  • Page 295: Elec

    8 - 14 – + 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 296: Elec

    8 - 15 – + elec electric starting system c0ntinuity correct 6.Engine stop switch refer to “checking the switch”. * incorrect replace the handlebar switch (right). Correct 7.Start switch refer to “checking the switch”. Incorrect replace the handlebar switch (left). Correct 8.Neutral switch refer to “...

  • Page 297: Elec

    8 - 16 – + 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. Exhaust pipe refer to “engine removal”. 1 parking brake cable 1 disconnect. 2 starter motor lead 1 3 starter motor/o-ring 1/1 disassembling the...

  • Page 298: Elec

    8 - 17 – + 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 299: Elec

    8 - 18 – + elec electric starting system 5.Measure: ● brush length a (each) out of specification → replace the brush. Brush length: 12.5 mm (0.49 in) 5 mm (0.20 in) 6.Measure: ● brush spring force fatigue/out of specification → replace as a set. Brush spring force: 7.65 ~ 10.01 nm (27.5 ~ 36.0 oz) 7...

  • Page 300: Elec

    8 - 19 – + elec charging system eb804000 charging system circuit diagram 1 ac magneto 2 rectifier/regulator 4 battery 5 fuse.

  • Page 301: Elec

    8 - 20 – + elec charging system eb804010 troubleshooting procedure check: 1.Fuse 2.Battery 3.Charging voltage if the battery is not charged: 4.Charging coil resistance 5.Wiring connections (the entire charging system) ote: ● remove the following part(s) before trouble- shooting: 1)seat ● use the fol...

  • Page 302: Elec

    8 - 21 – + elec charging system out of specification ● start the engine and accelerate to about 5,000 r/min. Charging voltage: 14 v at 5,000 r/min meets specification the charging circuit is not faulty. Eb804012 meets specification 4.Charging coil resistance ● disconnect the ac magneto coupler from ...

  • Page 303: Elec

    8 - 22 – + elec lighting system eb805000 lighting system circuit diagram 3 main switch 4 battery 5 fuse o lights switch r headlight s tail/brake light.

  • Page 304: Elec

    8 - 23 – + elec lighting system eb805010 troubleshooting procedure check: 1.Fuse 2.Battery 3.Main switch if the headlight and/or tail/brake light fail to come on: 4.Lights switch 5.Wiring connections (the entire lighting system) ote: ● remove the following part(s) before trouble- shooting: 1)seat 2)...

  • Page 305: Elec

    8 - 24 – + elec lighting system c0ntinuity correct 3.Main switch refer to “checking the switch”. * incorrect replace the main switch. Correct 4.Lights switch refer to “checking the switch”. Incorrect lights switch is faulty, replace the handlebar switch (left). Eb805013 correct 5.Wiring connection ●...

  • Page 306: Elec

    8 - 25 – + elec lighting system eb805020 checking the lighting system 1.If the headlights fail to come on: continuity 1.Bulb and bulb socket ● check the bulb and bulb socket for continu- ity. No continuity replace the bulb and/or bulb socket. 2.Voltage ● connect the pocket tester (dc 20v) to the hea...

  • Page 307: Elec

    8 - 26 – + elec lighting system eb805021 2.If the tail/brake light fails to come on: continuity 1.Bulb and bulb socket ● check the bulb and bulb socket for continu- ity. No continuity replace the bulb and/or bulb socket. 2.Voltage ● connect the pocket tester (20 v) to the bulb socket coupler. Tester...

  • Page 308: Elec

    8 - 27 – + elec signal system eb806000 signal system circuit diagram 3 main switch 4 battery 5 fuse 0 cdi unit c speed sensor g coolant temperature wa rn ing lig ht h reverse indicator light i neutral i ndicator light j neutral switch k r e verse switch l di o d e m thermo switch 2 p engine st op s ...

  • Page 309: Elec

    8 - 28 – + elec signal system eb806010 troubleshooting procedure check: 1.Fuse 2.Battery 3.Main switch 4.Wiring connections (the entire signal system) if the tail/brake light and/or indicator light fails to come on: ote: ● remove the following part(s) before trouble- shooting: 1)seat 2)front fender ...

  • Page 310: Elec

    8 - 29 – + elec signal system c0ntinuity correct 3.Main switch refer to “checking the switch”. * incorrect replace the main switch. Eb806011 correct 4.Wiring connections ● check the connections of the entire signal system. Refer to “circuit diagram”. Check the condition of each of the signal sys- te...

  • Page 311: Elec

    8 - 30 – + elec signal system checking the signal system 1.If the tail/brake light fails to come on: continuity 1.Bulb and bulb socket ● check the bulb and bulb socket for continu- ity. No continuity replace the bulb and/or bulb socket. Continuity 2.Brake switches refer to “checking the switch”. No ...

  • Page 312: Elec

    8 - 31 – + elec signal system eb806024 2.If the neutral indicator light fails to come on: continuity 1.Bulb and bulb socket ● check the bulb and bulb socket for continu- ity. No continuity replace the bulb and/or bulb socket. Continuity 2.Neutral switch refer to “checking the switch”. No continuity ...

  • Page 313: Elec

    8 - 32 – + elec signal system 3.If the reverse indicator light fails to come on: continuity 1.Bulb and bulb socket ● check the bulb and bulb socket for continu- ity. No continuity replace the bulb and/or bulb socket. Continuity 2.Reverse switch refer to “checking the switch”. No continuity replace t...

  • Page 314: Elec

    8 - 33 – + elec signal system 4.If the coolant temperature warning light does not come on when the start switch is pushed on, or if the coolant temperature warning light does not come on when the temperature is high (more than 117 ~ 123 °c (242.6 ~ 253.4 °f)): continuity 1.Bulb and bulb socket ● che...

  • Page 315: Elec

    8 - 34 – + elec signal system c0ntinuity 3.Voltage ● connect the pocket tester (dc 20v) to the bulb socket coupler. Tester (+) lead → red/black terminal 1 tester (–) lead → white/blue terminal 2 * meets specification ● turn the main switch to “on”. ● check the voltage (12 v). Out of specification th...

  • Page 316: Elec

    8 - 35 – + elec signal system c0ntinuity correct 5.Start switch refer to “checking the switch”. This circuit is not faulty. * incorrect replace the handlebar switch (left)..

  • Page 317: Elec

    8 - 36 – + elec cooling system cooling system circuit diagram 3 main switch 4 battery 5 fu se d circ uit breaker (f an mot o r) e t hermo switch 1 f f an mo to r.

  • Page 318: Elec

    8 - 37 – + elec cooling system troubleshooting procedure check: 1.Fuse 2.Battery 3.Main switch 4.Fan motor 5.Circuit breaker (fan motor) if the fan motor does not move: 6.Thermo switch 1 7.Wiring connection (the entire cooling system) ote: ● remove the following part(s) before trouble- shooting. 1)s...

  • Page 319: Elec

    8 - 38 – + 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 320: Elec

    8 - 39 – + elec cooling system c0ntinuity good condition 6.Thermo switch 1 ● remove the thermo switch from the radia- tor. ● connect the pocket tester ( Ω × 10) to the thermo switch 1 . ● immerse the thermo switch in coolant 2 . ● check the thermo switch for continuity. While heating the coolant use...

  • Page 321: Elec

    8 - 40 – + elec cooling system c0ntinuity eb803028 correct 7.Wiring connection ● check the connections of the entire starting system. Refer to “circuit diagram”. This circuit is not faulty. * poor connection properly connect the cooling system..

  • Page 322: Trbl

    9 - 1 trbl shtg starting failure/hard starting troubleshooting note: the following troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to troubleshooting. Refer to the relative procedure in this manual for inspection, adjustment and replacemen...

  • Page 323: Trbl

    9 - 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 cylind...

  • Page 324: Trbl

    9 - 3 trbl shtg faulty gear shifting/ clutch slipping/dragging faulty gear shifting hard shifting refer to “clutch dragging”. Shift pedal does not move shift shaft ● bent shift shaft shift drum and shift fork ● groove jammed with impurities ● seized shift fork ● bent shift fork guide bar transmissio...

  • Page 325: Trbl

    9 - 4 trbl shtg overheating/over cooling/ faulty brake overheating overheating ignition system ● improper spark plug gap ● improper spark plug heat range ● faulty cdi unit fuel system ● improper carburetor main jet (improper setting) ● improper fuel level ● clogged air filter element compression sys...

  • Page 326: Trbl

    9 - 5 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 327

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

  • Page 328

    Yfm660r wiring diagram 1 ac magneto 2 rectifier/regulator 3 main switch 4 battery 5 fuse 6 starter relay 7 starter motor 8 clutch switch 9 park switch 0 cd i unit a ignition coil b spark plug c speed sens or d circuit breaker (fan motor) e thermo switch 1 f fan motor g coolant temperature warning li...