Yamaha YFM400FAR Service Manual
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Yamaha YFM400FAR Service Manual

Yamaha YFM400FAR Service Manual

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Table of Contents

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YFM400FAR
SERVICE MANUAL
LIT-11616-16-02
5TE-F8197-10

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Summary of Contents for Yamaha YFM400FAR

  • Page 1 YFM400FAR SERVICE MANUAL LIT-11616-16-02 5TE-F8197-10...
  • Page 2 YFM400FAR SERVICE MANUAL ©2002 by Yamaha Motor Corporation, U.S.A. First Edition, April 2002 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. LIT-11616-16-02...

  • Page 3: Important Information

    EB001000 NOTICE This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha machine has a basic understanding of the mechanical ideas and the procedures of machine repair.
  • Page 4 EB002000 HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”) 1st title 1: This is the title of the chapter with its symbol in the upper right corner of each page. 2nd title 2: This title indicates the section of the chapter and only appears on the first page of each section.
  • Page 5 EB003000 ILLUSTRATED SYMBOLS Illustrated symbols 1 to 0 are printed on the SPEC INFO top right of each page and indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Cooling system 6 Carburetion 7 Drive train COOL...
  • Page 6 TABLE OF CONTENTS GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC CHECKS AND ADJUSTMENTS ENGINE COOLING SYSTEM COOL CARBURETION CARB DRIVE TRAIN DRIV CHASSIS CHAS – ELECTRICAL ELEC TROUBLESHOOTING TRBL SHTG...

  • Page 7: Table Of Contents

    CONTENTS CHAPTER 1. GENERAL INFORMATION MACHINE IDENTIFICATION ................ 1-1 VEHICLE IDENTIFICATION NUMBER ..........1-1 MODEL LABEL ..................1-1 IMPORTANT INFORMATION ............... 1-2 PREPARATION FOR REMOVAL PROCEDURES ....... 1-2 REPLACEMENT PARTS ............... 1-2 GASKETS, OIL SEALS AND O-RINGS ..........1-2 LOCK WASHERS/PLATES AND COTTER PINS ......... 1-3 BEARINGS AND OIL SEALS ..............

  • Page 8: Periodic Checks And

    CHAPTER 3. PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION ................... 3-1 PERIODIC MAINTENANCE/LUBRICATION ..........3-1 SEAT, CARRIERS, FENDERS AND FUEL TANK ........3-3 SEAT AND SIDE PANELS ..............3-3 FRONT CARRIER, FRONT BUMPER AND FRONT FENDER ..... 3-4 REAR CARRIER AND REAR FENDER ..........3-6 FUEL TANK ...................
  • Page 9 CHECKING THE CONSTANT VELOCITY JOINT DUST BOOTS ..3-46 CHECKING THE STEERING SYSTEM ..........3-47 ADJUSTING THE TOE-IN ..............3-47 ADJUSTING THE FRONT SHOCK ABSORBERS ......3-49 ADJUSTING THE REAR SHOCK ABSORBER ........3-49 CHECKING THE TIRES ..............3-49 CHECKING THE WHEELS ..............3-52 CHECKING AND LUBRICATING THE CABLES ........
  • Page 10 CYLINDER AND PISTON ................4-27 REMOVING THE PISTON ..............4-28 CHECKING THE TIMING CHAIN GUIDE ........... 4-28 CHECKING THE CYLINDER AND PISTON ........4-28 CHECKING THE PISTON RINGS ............4-30 CHECKING THE PISTON PIN ............4-31 INSTALLING THE PISTON ..............4-32 INSTALLING THE CYLINDER ............
  • Page 11 CRANKSHAFT AND OIL PUMP ..............4-65 OIL PUMP ................... 4-66 REMOVING THE CRANKSHAFT ............4-67 CHECKING THE OIL PUMP ............... 4-67 CHECKING THE CRANKSHAFT ............4-68 INSTALLING THE CRANKSHAFT AND BALANCER ......4-69 TRANSMISSION ..................4-70 CHECKING THE SHIFT FORKS ............4-72 CHECKING THE SHIFT CAM .............

  • Page 12: Carburetion

    CHAPTER 6. CARBURETION CARBURETOR ..................... 6-1 DISASSEMBLING THE CARBURETOR ..........6-4 CHECKING THE CARBURETOR ............6-4 ASSEMBLING THE CARBURETOR ............. 6-6 ADJUSTING THE FUEL LEVEL ............6-7 CHAPTER 7. DRIVE TRAIN TROUBLESHOOTING .................. 7-1 FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR ..7-4 REMOVING THE DIFFERENTIAL GEAR ASSEMBLY ......
  • Page 13 CHAPTER 8. CHASSIS FRONT AND REAR WHEELS ..............8-1 FRONT WHEELS .................. 8-1 REAR WHEELS ..................8-2 CHECKING THE WHEELS ..............8-3 CHECKING THE WHEEL HUBS ............8-3 CHECKING THE BRAKE DISCS ............8-4 INSTALLING THE WHEEL HUBS ............8-4 INSTALLING THE WHEELS ..............
  • Page 14 FRONT ARMS AND FRONT SHOCK ABSORBERS ........ 8-40 REMOVING THE FRONT ARMS ............8-42 CHECKING THE FRONT ARMS ............8-42 CHECKING THE FRONT SHOCK ABSORBER ......... 8-44 INSTALLING THE FRONT ARMS AND FRONT SHOCK ABSORBER ............8-45 REAR SHOCK ABSORBER AND SWINGARM ......... 8-46 REMOVING THE SWINGARM ............
  • Page 15 LIGHTING SYSTEM ..................9-25 CIRCUIT DIAGRAM ................9-25 TROUBLESHOOTING ................ 9-26 CHECKING THE LIGHTING SYSTEM ..........9-28 SIGNAL SYSTEM ..................9-32 CIRCUIT DIAGRAM ................9-32 TROUBLESHOOTING ................ 9-34 CHECKING THE SIGNAL SYSTEM ........... 9-36 COOLING SYSTEM ..................9-43 CIRCUIT DIAGRAM ................9-43 TROUBLESHOOTING ...............
  • Page 16 OVERHEATING ..................10-5 OVERHEATING .................. 10-5 FAULTY BRAKE ..................10-5 POOR BRAKING EFFECT ..............10-5 SHOCK ABSORBER MALFUNCTION ............10-6 MALFUNCTION ................... 10-6 UNSTABLE HANDLING ................10-6 UNSTABLE HANDLING ..............10-6 LIGHTING SYSTEM ..................10-6 HEADLIGHT DARK ................10-6 BULB BURNT OUT ................10-6...

  • Page 17: Chapter 1. General Information

    MACHINE IDENTIFICATION INFO GENERAL INFORMATION MACHINE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the left side of the frame. MODEL LABEL The model label 1 is affixed to the frame. This information will be needed to order spare parts.

  • Page 18: Important Information

    5.Keep all parts away from any source of fire. EB101010 REPLACEMENT PARTS 1.Use only genuine Yamaha parts for all replacements. grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.

  • Page 19: Lock Washers/Plates And Cotter Pins

    IMPORTANT INFORMATION INFO EB101030 LOCK WASHERS/PLATES AND COTTER PINS 1.Replace all lock washers/plates 1 and cotter pins after removal. Bend lock tabs along the bolt or nut flats after the bolt or nut has been tightened to specification. EB101040 BEARINGS AND OIL SEALS 1.Install bearings and oil seals so that the manufacturer’s marks or numbers are visible.

  • Page 20: Checking Of Connections

    CHECKING OF CONNECTIONS INFO EB801000 CHECKING OF CONNECTIONS Check connectors stains, rust, moisture, etc. 1.Disconnect: Connector 2.Check: Connector Moisture → Dry each terminal with an air blower. Stains/rust → Connect and disconnect the terminals several times. 3.Check: Connector leads Looseness → Bend up the pin 1 and connect the terminals.

  • Page 21: Special Tools

    SPECIAL TOOLS INFO EB102001 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools; this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools may differ by shape and part number from country to country.
  • Page 22 SPECIAL TOOLS INFO Tool No. Tool name/How to use Illustration Crankshaft installer set YU-90050 These tools are used to install the crankshaft. Adapter #11 Adapter Spacer (crankshaft) YM-33279 Spacer 90890-04060 These tools are used to install the YM-90070-A crankshaft. Piston pin puller set 90890-01304 YU-01304 This tool is used to remove the piston...
  • Page 23 SPECIAL TOOLS INFO Tool No. Tool name/How to use Illustration Sheave fixed block 90890-04135 This tool is needed when removing or YM-04135 installing the secondary sheave spring. Flywheel puller 90890-01404 YM-01404 These tools are needed to remove the rotor. Damper rod holder (30 mm) 90890-01327 This tool is needed to loosen and YM-01327...
  • Page 24 SPECIAL TOOLS INFO Tool No. Tool name/How to use Illustration Compression gauge Compression gauge 90890-03081 Adapter YU-33223 Adapter These tools are needed to measure 90890-04082 YU-33223-3 engine compression. Pocket tester 90890-03112 YU-03112-C This instrument is needed for checking the electrical system. Engine tachometer 90890-03113 This tool is needed for observing...
  • Page 25 This instrument is necessary for checking the ignition system components. Dynamic spark tester YM-34487 This instrument is necessary for checking the ignition system components. Yamaha bond No. 1215 Bond ® Sealant (Quick Gasket 90890-85505 Sealant This sealant (bond) is used on ACC-11001-05-01 crankcase mating surfaces, etc.

  • Page 26: Chapter 2. Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Model code: 5TE1, 5TE5 Dimensions: Overall length 1,984 mm (78.1 in) Overall width 1,085 mm (42.7 in) Overall height 1,120 mm (44.1 in) Seat height 827 mm (32.6 in) Wheelbase 1,233 mm (48.5 in) Minimum ground clearance 245 mm (9.7 in) Minimum turning radius...
  • Page 27 SPEC GENERAL SPECIFICATIONS Item Standard Differential gear case oil Periodic oil change 0.35 L (0.31 Imp qt, 0.37 US qt) Total amount 0.40 L (0.35 Imp qt, 0.42 US qt) Radiator capacity (including all routes) 1.32 L (1.16 Imp qt, 1.40 US qt) Air filter: Wet type element Fuel:...
  • Page 28 SPEC GENERAL SPECIFICATIONS Item Standard Tire pressure (cold tire): Maximum load* 210 kg (463 lb) Off-road riding front 22 ~ 28 kPa (0.22 ~ 0.28 kg/cm , 3.2 ~ 4.0 psi) rear 22 ~ 28 kPa (0.22 ~ 0.28 kg/cm , 3.2 ~ 4.0 psi) *Load in total weight of rider accessories Brakes:...

  • Page 29: Maintenance Specifications

    SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Cylinder head: Warp limit ---- 0.03 mm (0.0012 in) Cylinder: Bore size 84.500 ~ 84.510 mm 84.600 mm (3.3268 ~ 3.3272 in) (3.3307 in) Taper limit ---- 0.05 mm (0.0016 in) Out of round limit ---- 0.01 mm...
  • Page 30 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Cam chain: Cam chain type/No. of links DID SCR-0409 SDH/116 ---- Cam chain adjustment method Automatic ---- Rocker arm/rocker arm shaft: Bearing inside diameter 12.000 ~ 12.018 mm 12.078 mm (0.4724 ~ 0.4731 in) (0.4755 in) Shaft outside diameter 11.981 ~ 11.991 mm...
  • Page 31 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Stem runout limit ---- 0.01 mm (0.0004 in) Valve seat width 1.2 ~ 1.4 mm ---- (0.0472 ~ 0.0551 in) 1.2 ~ 1.4 mm ---- (0.0472 ~ 0.0551 in) Valve spring: Inner spring Free length 39.9 mm (1.57 in) 37.9 mm (1.49 in)
  • Page 32 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Tilt limit 2.5°/1.6 mm (2.5°/0.06 in) 2.5°/1.6 mm (2.5°/0.06 in) Direction of winding (top view) Clockwise ---- Clockwise ---- Piston: Piston to cylinder clearance 0.040 ~ 0.065 mm 0.150 mm (0.0016 ~ 0.0026 in) (0.0059 in) Piston size “D”...
  • Page 33 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit 2nd ring Type Taper ---- Dimensions (B × T) 1.2 × 3.6 mm ---- (0.04724 × 0.1417 in) End gap (installed) 0.40 ~ 0.60 mm 0.95 mm (0.0157 ~ 0.0236 in) (0.0374 in) Side clearance 0.03 ~ 0.07 mm 0.13 mm (0.0012 ~ 0.0028 in)
  • Page 34 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Transmission: Main axle deflection limit ---- 0.06 mm (0.0024 in) Drive axle deflection limit ---- 0.06 mm (0.0024 in) Shifter: Shifter type Shift cam and guide bar ---- Air filter oil grade: Engine oil ---- Carburetor: I.
  • Page 35 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Cooling system: Radiator core Width 300 mm (11.8 in) ---- Height 208 mm (8.19 in) ---- Thickness 26 mm (1.02 in) ---- Radiator cap opening pressure 93.7 ~ 122.6 kPa (0.937 ~ ---- 1.226 kg/cm , 13.32 ~ 17.43 psi) Radiator capacity 0.70 L (0.62 Imp qt, 0.74 US qt)
  • Page 36 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Cylinder head tightening sequence: 2 - 11...
  • Page 37 SPEC MAINTENANCE SPECIFICATIONS Tightening torques Tightening torque Part Thread Part to be tightened Q’ty Remarks name size m·kg ft·lb Cylinder head oil passage Union bolt Cylinder head (exhaust pipe) Stud bolt Cylinder head Bolt Bolt Camshaft sprocket cover baffle Bolt plate Camshaft bearing retainer Bolt...
  • Page 38 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part Thread Part to be tightened Q’ty Remarks name size m·kg ft·lb Middle driven shaft drive pinion gear Stake Middle drive shaft bearing housing Bolt Middle driven gear bearing retainer Left-hand threads Yoke (middle driven gear) Middle driven gear bearing housing Bolt Middle driven shaft bearing retainer...

  • Page 39: Chassis

    SPEC MAINTENANCE SPECIFICATIONS CHASSIS Item Standard Limit Steering system: Steering bearing type Ball and race bearing ---- Front suspension: Shock absorber travel 99 mm (3.90 in) ---- Fork spring free length 265 mm (10.43 in) ---- Spring fitting length 215.8 mm (8.50 in) ---- Spring rate (K1)
  • Page 40 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Front disc brake: Type Dual ---- Disc outside diameter × thickness 200.0 × 3.5 mm (7.87 ~ 0.14 in) ---- Pad thickness inner 4.5 mm (0.18 in) 1 mm (0.04 in) Pad thickness outer 4.5 mm (0.18 in) 1 mm (0.04 in)
  • Page 41 SPEC MAINTENANCE SPECIFICATIONS Tightening torques Tightening torque Part to be tightened Thread size Remarks m·kg ft·lb Engine bracket (front-upper) and frame Engine bracket (front-lower) and frame Engine bracket (front-upper) and engine Engine bracket (front-lower) and engine Engine and frame Frame and bearing retainer (steering stem holder bearing) Select lever assembly and frame Swingarm...
  • Page 42 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Remarks m·kg ft·lb Front bumper and frame Front carrier and frame Front carrier and front bumper Rear carrier and frame Differential gear case filler bolt Differential gear case drain bolt Differential gear case and bearing housing Gear motor Final gear case oil filler bolt...

  • Page 43: Electrical

    Rotor rotation direction sensing coil ---- resistance/color Red – White/Blue C.D.I. unit model/manufacturer F8T38679/MITSUBISHI ---- Ignition coil: Model/manufacturer 2JN/YAMAHA ---- Minimum spark gap 6 mm (0.24 in) ---- 0.18 ~ 0.28 Ω at 20 °C (68 °F) Primary winding resistance ---- Secondary winding resistance 6.32 ~ 9.48 kΩ...
  • Page 44 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Brush overall length 12.5 mm (0.49 in) 5 mm (0.20 in) Spring force 7.65 ~ 10.01 N (780 ~ 1,020 g, ---- 27.54 ~ 36.03 oz) Commutator diameter 28 mm (1.10 in) 27 mm (1.06 in) Mica undercut 0.7 mm (0.03 in)

  • Page 45: How To Use The Conversion Table

    HOW TO USE THE CONVERSION TABLE/ SPEC GENERAL TORQUE SPECIFICATIONS EB201000 EB202001 HOW TO USE THE CONVERSION GENERAL TORQUE TABLE SPECIFICATIONS All specification data in this manual are listed in This chart specifies torque for standard SI and METRIC UNITS. fasteners with standard I.S.O.

  • Page 46: Lubrication Points And Lubricant Types

    Shift cam lever Clutch housing One-way bearing Drive chain/sprocket Driven cam Front drive shaft collar ® Sealant (Quick Gasket Crankcase mating surface Yamaha Bond No.1215 ® Stator lead grommet Sealant (Quick Gasket (left side crankcase) Yamaha Bond No.1215 2 - 21...

  • Page 47: Coolant Flow Diagrams

    SPEC COOLANT FLOW DIAGRAMS COOLANT FLOW DIAGRAMS 1 Radiator 2 Thermo switch (radiator) 3 Fan motor È To coolant reservoir 2 - 22...
  • Page 48 SPEC COOLANT FLOW DIAGRAMS 1 Radiator 2 Thermostat È To coolant reservoir 2 - 23...

  • Page 49: Oil Flow Diagrams

    SPEC OIL FLOW DIAGRAMS OIL FLOW DIAGRAMS 1 Camshaft 2 Crankshaft 3 Drive axle 2 - 24...
  • Page 50 SPEC OIL FLOW DIAGRAMS 1 Oil filter 2 - 25...
  • Page 51 SPEC OIL FLOW DIAGRAMS 1 Oil pump 2 Oil strainer 2 - 26...

  • Page 52: Cable Routing

    SPEC CABLE ROUTING CABLE ROUTING 1 Rear brake switch lead 0 Fan motor breather hose 2 Starter cable A Differential gear case breather hose 3 Rear brake cable B Sub-wire harness (to gear motor) 4 Front brake hose C On-command four-wheel drive switch lead 5 On-command four-wheel drive switch 6 Throttle cable 7 Handlebar switch...
  • Page 53 SPEC CABLE ROUTING È Fasten the on-command four-wheel drive switch lead behind the handlebar with a plastic band. É Fasten the starter cable, handlebar switch lead and rear brake switch lead behind the handlebar with a plastic band. Ê Fasten the handlebar switch lead and rear brake switch lead behind the handlebar with a plastic band. 2 - 28...
  • Page 54 SPEC CABLE ROUTING 1 Sub-wire harness 2 Headlight lead 3 Auxiliary DC jack lead 4 Meter assembly coupler 5 Differential gear case breather hose 6 Coolant reservoir breather hose 7 Fan motor breather hose 2 - 29...
  • Page 55 SPEC CABLE ROUTING 1 Starter cable B Speedometer cable 2 Cylinder head breather hose 3 Fuel hose È Insert the fuel tank breather hose into the hole of 4 Carburetor drain hose the handlebar cover. 5 Rear brake lever cable É...
  • Page 56 SPEC CABLE ROUTING 1 Cylinder head breather hose B Float chamber air vent hose 2 Final drive gear case breather hose C Cylinder head breather hose 3 Rear brake breather hose D Fuel hose 4 Wire harness E A.C. magneto lead 5 Starter motor lead F Gear position switch lead 6 Negative battery lead...
  • Page 57 SPEC CABLE ROUTING È Fasten the wire harness with a plastic band. É Fasten the starter motor lead, wire harness, negative battery lead, final drive gear case breather hose, rear brake breather hose, rectifier/regulator lead, gear position switch lead and A.C. magneto lead with a plastic band.
  • Page 58 SPEC CABLE ROUTING 1 Throttle cable È Fasten the radiator inlet hose and spark plug 2 Radiator inlet hose lead with a plastic band. 3 Spark plug lead 4 Main switch 5 Wire harness 6 Rear brake light switch lead 7 Select lever control cable 8 Rear brake pedal cable 2 - 33...
  • Page 59 SPEC CABLE ROUTING 1 Front brake hose 2 Float chamber air vent hose 3 Throttle cable 4 Wire harness 5 Final drive gear case breather hose 6 Rear brake breather hose 7 Starter cable 8 Rear brake lever cable 2 - 34...
  • Page 60 SPEC CABLE ROUTING 1 Battery 2 Negative battery lead 3 Tail/brake light lead 4 CDI unit 5 Positive battery lead 2 - 35...
  • Page 61 SPEC CABLE ROUTING 1 Rear brake pedal cable 2 Final drive gear case breather hose 3 Rear brake breather hose 4 Rear brake lever cable 5 Air filter case check hose 2 - 36...

  • Page 62: Chapter 3. Periodic Checks And Adjustments

    INTRODUCTION/ PERIODIC MAINTENANCE/LUBRICATION EB300000 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and a longer service life. The need for costly overhaul work will be greatly reduced. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale.
  • Page 63 Fittings and • Check all chassis fittings and fasteners. fasteners* • Correct if necessary. It is recommended that these items be serviced by a Yamaha dealer. NOTE: Recommended brake fluid: DOT 4 Brake fluid replacement: 1.When disassembling the master cylinder or caliper, replace the brake fluid. Normally check the brake fluid level and add fluid as required.

  • Page 64: Seat, Carriers, Fenders And Fuel Tank

    SEAT, CARRIERS, FENDERS AND FUEL TANK SEAT, CARRIERS, FENDERS AND FUEL TANK SEAT AND SIDE PANELS Order Job name/Part name Q’ty Remarks Removing the seat and side panels Remove the parts in the order below. Seat NOTE: Pull up the seat lock lever, then pull up on the rear of the seat.

  • Page 65: Front Carrier, Front Bumper And Front Fender

    SEAT, CARRIERS, FENDERS AND FUEL TANK FRONT CARRIER, FRONT BUMPER AND FRONT FENDER Order Job name/Part name Q’ty Remarks Removing the front carrier, front Remove the parts in the order below. bumper and front fender Seat and fuel tank side panels Refer to “SEAT AND SIDE PANELS”.
  • Page 66 SEAT, CARRIERS, FENDERS AND FUEL TANK Order Job name/Part name Q’ty Remarks Auxiliary DC jack connector Disconnect. Meter assembly coupler Disconnect. Speedometer cable Disconnect. Coolant reservoir breather hose Fan motor breather hose Differential gear case breather hose Front fender For installation, reverse the removal procedure.

  • Page 67: Rear Carrier And Rear Fender

    SEAT, CARRIERS, FENDERS AND FUEL TANK REAR CARRIER AND REAR FENDER Order Job name/Part name Q’ty Remarks Removing the rear carrier and rear Remove the parts in the order below. fender Seat and fuel tank side panels Refer to “SEAT AND SIDE PANELS”. Fuel tank Refer to “FUEL TANK”.
  • Page 68 SEAT, CARRIERS, FENDERS AND FUEL TANK Order Job name/Part name Q’ty Remarks C.D.I. unit Wire harness Rear fender For installation, reverse the removal procedure. 3 - 7...

  • Page 69: Fuel Tank

    SEAT, CARRIERS, FENDERS AND FUEL TANK FUEL TANK Order Job name/Part name Q’ty Remarks Removing the fuel tank Remove the parts in the order below. Seat and fuel tank side panels Refer to “SEAT AND SIDE PANELS”. Fuel tank cover Refer to “FRONT CARRIER, FRONT BUMPER AND FRONT FENDER”.

  • Page 70: Footrest Boards

    FOOTREST BOARDS FOOTREST BOARDS Order Job name/Part name Q’ty Remarks Removing the footrest boards Remove the parts in the order below. Fuel tank side panels Refer to “SEAT AND SIDE PANELS”. Left footrest board Right footrest board Footrest bracket For installation, reverse the removal procedure.

  • Page 71: Engine

    ADJUSTING THE VALVE CLEARANCE ENGINE ADJUSTING THE VALVE CLEARANCE NOTE: The valve clearance must be adjusted when the engine is cool to the touch. Adjust the valve clearance when the piston is at the Top Dead Center (T.D.C.) on the compression stroke.
  • Page 72 ADJUSTING THE VALVE CLEARANCE 7.Check: Valve clearance Out of specification → Adjust. Valve clearance (cold): Intake: 0.06 ~ 0.10 mm (0.0024 ~ 0.0039 in) Exhaust: 0.16 ~ 0.20 mm (0.0063 ~ 0.0079 in) ***************************************************** Checking steps: Turn the crankshaft counterclockwise with a wrench.
  • Page 73 ADJUSTING THE VALVE CLEARANCE 8.Adjust: Valve clearance ***************************************************** Adjustment steps: Loosen the locknut 1. Insert a feeler gauge 2 between the adjuster end and the valve end. Turn adjuster clockwise counterclockwise with the valve adjusting tool 4 until the proper clearance is obtained. Tappet adjusting tool: P/N.

  • Page 74: Adjusting The Idling Speed

    ADJUSTING THE VALVE CLEARANCE/ ADJUSTING THE IDLING SPEED 11.Install: Fuel tank Front fender Front carrier Seat Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”. ADJUSTING THE IDLING SPEED 1.Start the engine and let it warm up for several minutes. 2.Remove: Seat Fuel tank side panels Refer to “SEAT, CARRIERS, FENDERS...

  • Page 75: Adjusting The Throttle Lever Free Play

    ADJUSTING THE IDLING SPEED/ ADJUSTING THE THROTTLE LEVER FREE PLAY 5.Adjust: Engine idling speed ***************************************************** Adjustment steps: Turn the throttle stop screw 1 in or out until the specified idling speed is obtained. Idling speed becomes Turning in higher. Idling speed becomes Turning out lower.
  • Page 76 ADJUSTING THE THROTTLE LEVER FREE PLAY 1.Check: Throttle lever free play a Out of specification → Adjust. Throttle lever free play: 3 ~ 5 mm (0.12 ~ 0.20 in) 2.Remove: Seat Fuel tank side panel (right) Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”.

  • Page 77: Adjusting The Speed Limiter

    ADJUSTING THE THROTTLE LEVER FREE PLAY/ ADJUSTING THE SPEED LIMITER Second step: Pull back the adjuster cover 4. Loosen the locknut 5. Turn the adjuster 6 in or out until the correct free play is obtained. Turning in Free play is increased. Turning out Free play is decreased.

  • Page 78: Adjusting The Starter Cable

    ADJUSTING THE SPEED LIMITER/ ADJUSTING THE STARTER CABLE 2.Adjust: Speed limiter length ***************************************************** Speed limiter length adjustment steps: Loosen the locknut 1. Turn the adjuster 2 in or out until the specified speed limiter length is obtained. Speed limiter length is Turning in decreased.
  • Page 79 ADJUSTING THE STARTER CABLE 2.Adjust: ***************************************************** Adjustment steps: Disconnect the starter cable 1 from the carburetor body. NOTE: Do not remove the starter plunger 2 from the starter cable. Measure the starter plunger stroke distance a of the starter lever 3 fully close to fully open position.

  • Page 80: Checking The Spark Plug

    CHECKING THE SPARK PLUG CHECKING THE SPARK PLUG 1.Remove: Seat Fuel tank side panel (right) Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”. 2.Remove: Spark plug 3.Check: Spark plug type Incorrect → Replace. Standard spark plug: DR8EA/NGK 4.Check: Electrode 1 Wear/damage →...

  • Page 81: Checking The Ignition Timing

    CHECKING THE IGNITION TIMING CHECKING THE IGNITION TIMING NOTE: Engine idling speed and throttle cable free play should be adjusted properly before checking the ignition timing. 1.Remove: Seat Fuel tank side panel (right) Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”. 2.Attach: Inductive self-powered tachometer or engine tachometer...

  • Page 82: Measuring The Compression Pressure

    CHECKING THE IGNITION TIMING/ MEASURING THE COMPRESSION PRESSURE 4.Detach: Timing light Inductive self-powered tachometer or engine tachometer 5.Install: Seat Fuel tank side panel (right) Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”. MEASURING THE COMPRESSION PRESSURE NOTE: Insufficient compression pressure will result in a loss of performance.
  • Page 83 MEASURING THE COMPRESSION PRESSURE 7.Measure: Compression pressure Above the maximum pressure: Check the cylinder head, valve surfaces, and piston crown for carbon deposits. Below the minimum pressure: Squirt a few drops of oil into the affected cylinder and measure again. Refer to the table below.

  • Page 84: Checking The Engine Oil Level

    CHECKING THE ENGINE OIL LEVEL CHECKING THE ENGINE OIL LEVEL 1.Place the machine on a level surface. 2.Remove: Engine side panel Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”. 3.Check: Engine oil level Oil level should be between the maximum level mark 1 and minimum level mark 2.

  • Page 85: Changing The Engine Oil

    CHANGING THE ENGINE OIL CHANGING THE ENGINE OIL 1.Start the engine and let it warm up for several minutes. 2.Stop the engine and place an oil pan under the engine. 3.Remove: Seat Fuel tank side panel (left) Engine side cover Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”.
  • Page 86 CHANGING THE ENGINE OIL Lubricate the O-ring 3 of the new oil filter cartridge with a thin coat of engine oil. CAUTION: Make sure that the O-ring 3 is positioned correctly in the groove of the oil filter cartridge. Tighten the new oil filter cartridge to specification with an oil filter wrench.

  • Page 87: Cleaning The Air Filter

    CHANGING THE ENGINE OIL/ CLEANING THE AIR FILTER 13.Check: Engine oil pressure ***************************************************** Slightly loosen the oil gallery bolt 1. Start the engine and keep it idling until engine oil starts to seep from the oil gallery bolt. If no engine oil comes out after one minute, turn the engine off so that it will not seize.
  • Page 88 CLEANING THE AIR FILTER 1.Remove: Seat Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”. 2.Remove: Air filter case cover 1 3.Remove: Air filter element assembly 1 Air filter element cap Air filter element 2 Air filter element cap 3 Air filter element CAUTION: Never operate the engine with the air filter element removed.
  • Page 89 CLEANING THE AIR FILTER 5.Clean: Air filter element ***************************************************** Cleaning steps: Wash the element gently, but thoroughly in solvent. WARNING Use a cleaning solvent which is designed to clean parts only. Never use gasoline or low flash point solvents as they may cause a fire or explosion.

  • Page 90: Checking The Coolant Level

    CHECKING THE COOLANT LEVEL CHECKING THE COOLANT LEVEL 1.Place the machine on a level surface. 2.Remove: Seat Fuel tank side panel (left) Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”. 3.Check: Coolant level The coolant level should be between the minimum level mark a and maximum level mark b.

  • Page 91: Changing The Coolant

    CHANGING THE COOLANT CHANGING THE COOLANT 1.Remove: Seat Fuel tank side panel (left) Engine side cover Front carrier Engine skid plate Front fender Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”. Left footrest board Refer to “FOOTREST BOARDS”. 2.Remove: Plastic band 1 Coolant reservoir bolts 2 Coolant reservoir cap 3 3.Disconnect:...
  • Page 92 CHANGING THE COOLANT 8.Remove: Coolant drain bolt (cylinder) 1 (along with the copper washer) Coolant drain bolt (water pump) 2 (along with the copper washer) 9.Drain: Coolant 10.Check: Copper washer 1 Coolant drain bolt 2 Damage → Replace. 11.Install: Coolant drain bolt (water pump) 10 Nm (1.0 m •...
  • Page 93 CHANGING THE COOLANT CAUTION: Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant, check, and if necessary, correct the antifreeze concentration of the coolant. Use only distilled water. However, soft water may be used if distilled water is not available.

  • Page 94: Checking The Coolant Temperature Warning Light

    Coolant temperature Coolant temperature warning warning light comes on light does not come on. momentarily. Coolant temperature and Ask a Yamaha dealer to electrical circuit are OK. Go check the electrical circuit. ahead with riding. CHECKING THE V-BELT 1.Remove: Right footrest board Refer to “FOOTREST BOARDS”.

  • Page 95: Checking The V-Belt

    CHECKING THE V-BELT 4.Replace: V-belt ***************************************************** Replacing steps: Install the bolts 1 (90101-06016) into the secondary fixed sheave hold. NOTE: Tightening the bolts 1 will push the secondary sliding sheave away, causing the gap between the secondary fixed and sliding sheaves to widen.

  • Page 96: Cleaning The Spark Arrester

    CLEANING THE SPARK ARRESTER CLEANING THE SPARK ARRESTER 1.Clean: Spark arrester ***************************************************** Cleaning steps: WARNING Select a well-ventilated area free of combustible materials. Always let the exhaust system cool before performing this operation. Do not start the engine when removing the tailpipe from the muffler.

  • Page 97: Chassis

    ADJUSTING THE REAR BRAKE CHASSIS ADJUSTING THE REAR BRAKE WARNING Always adjust both the brake pedal and the rear brake lever whenever adjusting the rear brake. 1.Check: Rear brake pedal free play a Rear brake lever free play b Out of specification → Adjust. Rear brake pedal free play: 20 ~ 30 mm (0.80 ~ 1.18 in) Rear brake lever free play:...
  • Page 98 ADJUSTING THE REAR BRAKE Turn the brake lever cable adjusting nut (drum) 3 clockwise until the gap a is within the specified limits. Gap a: 0 ~ 1 mm (0.00 ~ 0.04 in) Checking the rear brake pedal free play to see whether or not it is within the specified limits.

  • Page 99: Checking The Front Brake Fluid Level

    CHECKING THE FRONT BRAKE FLUID LEVEL CHECKING THE FRONT BRAKE FLUID LEVEL 1.Place the machine on a level surface. NOTE: When checking the front brake fluid level, make sure that the top of the master cylinder top is horizontal. 2.Check: Brake fluid level Fluid level is under “LOWER”...

  • Page 100: Checking The Front Brake Pads

    CHECKING THE FRONT BRAKE PADS/ CHECKING THE REAR BRAKE SHOES CHECKING THE FRONT BRAKE PADS 1.Remove: Front wheel 2.Check: Brake pads Wear indicator groove 1 almost touch the brake disc → Replace the brake pads as a set. Refer to “FRONT BRAKE” in CHAPTER 8. Brake pad wear limit a: 1 mm (0.04 in) 3.Operate the brake lever.

  • Page 101: Checking The Brake Hoses

    CHECKING THE BRAKE HOSES CHECKING THE BRAKE HOSES 1.Remove: Seat Front carrier Front fender Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”. 2.Check: NOTE: Hold the machine in an upright position and apply the parking brake. Front brake hoses 1 Cracks/wear/damage →...

  • Page 102: Bleeding The Hydraulic Brake System

    BLEEDING THE HYDRAULIC BRAKE SYSTEM BLEEDING THE HYDRAULIC BRAKE SYSTEM WARNING Bleed the brake system if: The system has been disassembled. A brake hose or brake pipe have been loosened or removed. The brake fluid has been very low. The brake operation has been faulty. A loss of braking performance may occur if the brake system is not properly bled.

  • Page 103: Adjusting The Select Lever Control Cable And Shift Rod

    BLEEDING THE HYDRAULIC BRAKE SYSTEM/ ADJUSTING THE SELECT LEVER CONTROL CABLE AND SHIFT ROD WARNING Check the operation of the brake after bleeding the brake system. ***************************************************** ADJUSTING THE SELECT LEVER CONTROL CABLE AND SHIFT ROD 1 NEUTRAL 2 FORWARD 3 REVERSE 4 Control cable 5 Select lever shift rod...
  • Page 104 ADJUSTING THE SELECT LEVER CONTROL CABLE AND SHIFT ROD/ ADJUSTING THE REAR BRAKE LIGHT SWITCH When the brake begins to work “a = 20 ~ 30 mm (0.8 ~ 1.2 in)”, verify that the select lever can be shifted to REVERSE from NEUTRAL, to NEUTRAL from REVERSE.

  • Page 105: Adjusting The Rear Brake Light Switch

    ADJUSTING THE REAR BRAKE LIGHT SWITCH/ CHECKING THE FINAL GEAR OIL LEVEL 2.Adjust: Rear brake light switch operation timing *********************************************** Hold the main body 1 of the rear brake light switch so that it does not rotate and turn the adjusting nut 2 in direction a or b until the rear brake light comes on at the proper time.

  • Page 106: Changing The Final Gear Oil

    CHANGING THE FINAL GEAR OIL CHANGING THE FINAL GEAR OIL 1.Place the machine on a level surface. 2.Remove: Final gear case protector 1 3.Place a receptacle under the final gear case. 4.Remove: Oil filler bolt Drain plug 1 5.Drain: Final gear oil 6.Install: Drain plug 23 Nm (2.3 m •...

  • Page 107: Changing The Differential Gear Oil

    CHANGING THE DIFFERENTIAL GEAR OIL/CHECKING THE CONSTANT VELOCITY JOINT DUST BOOTS CHANGING THE DIFFERENTIAL GEAR OIL 1.Place the machine on a level surface. 2.Place a receptacle under the differential gear case. 3.Remove: Oil filler bolt Drain plug 1 4.Drain: Differential gear oil 5.Install: Drain plug 10 Nm (1.0 m •...

  • Page 108: Checking The Steering System

    CHECKING THE STEERING SYSTEM/ ADJUSTING THE TOE-IN CHECKING THE STEERING SYSTEM 1.Place the machine on a level surface. 2.Check: Steering assembly bushings Move the handlebar up and down, and/or back and forth. Excessive play → Replace the steering stem bearing. 3.Check: Tie-rod ends Turn the handlebar to the left and/or right...
  • Page 109 ADJUSTING THE TOE-IN Measure the width È between the marks. Rotate the front tires 180° until the marks are exactly opposite one another. Measure the width É between the marks. Calculate the toe-in using the formula given below. Toe-in = É – È If the toe-in is incorrect, adjust it.

  • Page 110: Adjusting The Rear Shock Absorber

    ADJUSTING THE FRONT SHOCK ABSORBERS/ADJUSTING THE REAR SHOCK ABSORBER/CHECKING THE TIRES ADJUSTING THE FRONT SHOCK ABSORBERS WARNING Always adjust both front shock absorber spring preload to the same setting. Uneven adjustment can cause poor handling and loss of stability. 1.Adjust: Spring preload Turn the adjuster 1 to increase or decrease the spring preload.

  • Page 111: Checking The Tires

    CHECKING THE TIRES TIRE CHARACTERISTICS 1)Tire characteristics influence handling of ATVs. The tires listed below have been approved by Yamaha Motor Co., Ltd. for this model. If other tire combinations used, they adversely affect your machine’s handling characteristics and are therefore not recommended.
  • Page 112 CHECKING THE TIRES 1.Measure: Tire pressure (cold tire pressure) Out of specification → Adjust. NOTE: The low-pressure tire gauge 1 is included as standard equipment. If dust or the like is stuck to this gauge, it will not provide the correct readings. Therefore, take two measurements of the tire’s pressure and use the second reading.

  • Page 113: Checking The Wheels

    Cable sheath Damage → Replace. 2.Check: Cable operation Unsmooth operation → Lubricate or replace. Recommended lubricant: Yamaha chain and cable lube or Engine oil NOTE: Hold the cable end up and apply several drops of lubricant to the cable. 3.Apply:...

  • Page 114: Lubricating The Levers, Pedal, Etc

    LUBRICATING THE LEVERS, PEDAL, ETC. LUBRICATING THE LEVERS, PEDAL, ETC. 1.Lubricate the pivoting parts. Recommended lubricant: Lithium soap base grease 3 - 53...

  • Page 115: Electrical

    CHECKING THE BATTERY EB305000 ELECTRICAL CHECKING THE BATTERY NOTE: Since the MF battery is a sealed-type battery, it is not possible to measure the specific gravity of the electrolyte in order to check the charge state of the battery. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals.
  • Page 116 CHECKING THE BATTERY Batteries generate explosive hydrogen gas. Always follow these preventive measures: Charge batteries in a well-ventilated area. Keep batteries away from fire, sparks or open flames (e.g., welding equipment, lighted cigarettes, etc.) DO NOT SMOKE when charging or handling batteries.
  • Page 117 CHECKING THE BATTERY Open-circuit Charging time voltage No charging is 12.8 V or higher necessary. Check the condition of the battery using the following charts. Example: Open-circuit voltage = 12.0 V Charging time = 6.5 hours Charge condition of the battery = 20 ~ 30% Charging method for MF batteries CAUTION: If it is impossible to set the standard...
  • Page 118 CHECKING THE BATTERY Charging method using a variable voltage charger NOTE: Leave the battery unused for Measure the open-circuit more than 30 minutes before measuring its open-circuit voltage. voltage prior to charging. Charger Ammeter NOTE: Set the charging voltage to Connect a charger and 16 ~ 17 V.
  • Page 119 CHECKING THE BATTERY Charging method using a constant voltage charger NOTE: Leave the battery unused for Measure the open-circuit more than 30 minutes before voltage prior to charging. measuring its open-circuit voltage. Connect a charger and ammeter to the battery and start charging.

  • Page 120: Checking The Fuses

    CHECKING THE BATTERY/ CHECKING THE FUSES 5.Check: Battery terminals Dirty → Clean with a wire brush. NOTE: After cleaning the terminals, apply a light coat of grease. 6.Install: Battery 7.Connect: Battery leads CAUTION: First, connect the positive lead 1, then connect the negative lead 2.
  • Page 121 CHECKING THE FUSES NOTE: Set the tester to the “Ω × 1” position. Pocket tester: P/N. YU-03112-C, 90890-03112 If the tester indicates ∞, replace the fuse. ***************************************************** 3.Replace: Blown fuse(s) ***************************************************** Replacement steps: Turn off the ignition. Install a new fuse of the proper amperage. Turn on switches to verify operation of the related electrical devices.

  • Page 122: Adjusting The Headlight Beams

    CHECKING THE FUSES/ADJUSTING THE HEADLIGHT BEAMS/CHANGING THE HEADLIGHT BULB WARNING Never use a fuse with a rating other than that specified. Never use other materials in place of a fuse. An improper fuse may cause extensive damage to the electrical system, a malfunction of the lighting and ignition systems and could possibly cause a fire.

  • Page 123: Changing The Headlight Bulb

    CHANGING THE HEADLIGHT BULB 2.Remove: Bulb holder 1 Bulb NOTE: Turn the bulb holder counterclockwise and remove the defective bulb. WARNING Keep flammable products and your hands away from the bulb while it is on, since it will be hot. Do not touch the bulb until it cools down.

  • Page 124: Chapter 4. Engine

    ENGINE REMOVAL ENGINE ENGINE REMOVAL AIR DUCTS, MUFFLER AND EXHAUST PIPE Order Job name/Part name Q’ty Remarks Removing the air ducts, muffler and Remove the parts in the order below. exhaust pipe Engine oil Drain. Refer to “CHANGING THE ENGINE OIL” in CHAPTER 3.
  • Page 125 ENGINE REMOVAL Order Job name/Part name Q’ty Remarks Final drive gear case breather hose Rear brake breather hose Cylinder head breather hose Vacuum chamber breather hose Air filter case For installation, reverse the removal procedure. 4 - 2...

  • Page 126: Select Lever Unit And Coolant Reservoir

    ENGINE REMOVAL SELECT LEVER UNIT AND COOLANT RESERVOIR Order Job name/Part name Q’ty Remarks Removing the select lever unit and Remove the parts in the order below. coolant reservoir Select lever shift rod Select lever unit Coolant reservoir breather hose Coolant reservoir hose Coolant reservoir For installation, reverse the removal...

  • Page 127: Hoses And Leads

    ENGINE REMOVAL HOSES AND LEADS Order Job name/Part name Q’ty Remarks Removing the hoses and leads Remove the parts in the order below. Water pump inlet hose Refer to “WATER PUMP” in CHAPTER 5. Cylinder head breather hose Spark plug lead Thermo switch (cylinder head) lead Starter motor lead Disconnect.

  • Page 128: Engine Mounting Bolts

    ENGINE REMOVAL ENGINE MOUNTING BOLTS Order Job name/Part name Q’ty Remarks Removing the engine mounting bolts Remove the parts in the order below. Rear wheels Refer to “FRONT AND REAR WHEELS” in CHAPTER 8. Swingarm Refer to “REAR SHOCK ABSORBER AND SWINGARM”...
  • Page 129 ENGINE REMOVAL Order Job name/Part name Q’ty Remarks Engine assembly NOTE: Remove the engine assembly from the left side of the machine. For installation, reverse the removal procedure. 4 - 6...

  • Page 130: Installing The Engine

    ENGINE REMOVAL INSTALLING THE ENGINE 1.Install: Engine bracket (front upper) 1 Engine mounting bolt (front upper)/nut 2 Engine bracket bolt (front upper) 3 Engine bracket (front lower) 4 Engine mounting bolt (front lower) 5 Engine bracket bolt (front lower) 6 Engine mounting bolt (rear upper)/nut 7 Engine mounting bolt (rear lower)/nut 8 NOTE:...

  • Page 131: Cylinder Head

    CYLINDER HEAD CYLINDER HEAD Order Job name/Part name Q’ty Remarks Removing the cylinder head Remove the parts in the order below. Fuel tank/rubber cover Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK” in CHAPTER 3. Front fender/air filter case Air duct assembly 1 Refer to “ENGINE REMOVAL”.
  • Page 132 CYLINDER HEAD Order Job name/Part name Q’ty Remarks Cylinder head breather hose Camshaft sprocket cover/O-ring Tappet cover/O-ring Thermo switch (cylinder head) lead Disconnect. Timing chain tensioner cap bolt Timing chain tensioner/gasket Refer to “REMOVING/INSTALLING THE CYLINDER HEAD”. Camshaft sprocket Cylinder head Cylinder head gasket Dowel pin O-ring...

  • Page 133: Removing The Cylinder Head

    CYLINDER HEAD REMOVING THE CYLINDER HEAD 1.Align: “T” mark (with stationary pointer) ***************************************************** Checking steps: Turn the crankshaft counterclockwise with a wrench. Align the “T” mark 1 on the rotor with the stationary pointer 2 on the crankcase cover. When the “T” mark is aligned with the stationary pointer, the piston is at the Top Dead Center (T.D.C.).

  • Page 134: Checking The Tappet Covers

    CYLINDER HEAD NOTE: Fasten a safety wire to the timing chain to prevent it from falling into the crankcase. When removing the camshaft sprocket, it is not necessary to separate the timing chain. 5.Remove: Cylinder head NOTE: Loosen the 6 mm bolts first. Working in a crisscross pattern, loosen each 10 mm bolt 1/4 of a turn.

  • Page 135: Checking The Cylinder Head

    CYLINDER HEAD CHECKING THE CYLINDER HEAD 1.Eliminate: Carbon deposits (from the combustion chambers) Use a rounded scraper. NOTE: Do not use a sharp instrument to avoid damaging or scratching: Spark plug threads Valve seats 2.Check: Cylinder head Scratches/damage → Replace. Cylinder head water jacket Mineral deposits/rust →...

  • Page 136: Installing The Cylinder Head

    CYLINDER HEAD INSTALLING THE CYLINDER HEAD 1.Install: Cylinder head Bolts (M10) 40 Nm (4.0 m • kg, 29 ft • lb) Bolts (M6) 10 Nm (1.0 m • kg, 7.2 ft • lb) NOTE: Lubricate the washer with engine oil. Tighten the bolts (M10) in two stages and a crisscross pattern.
  • Page 137 CYLINDER HEAD NOTE: Be sure the “I” mark 5 on the camshaft sprocket is aligned with the match mark 2 on the cylinder head. Force camshaft clockwise counterclockwise to remove timing chain slack. Insert a screwdriver into the timing chain tensioner hole and push the timing chain guide inward.
  • Page 138 CYLINDER HEAD 4.Tighten: Camshaft sprocket bolt 1 60 Nm (6.0 m • kg, 43 ft • lb) NOTE: Use the rotor holding tool 2 to hold the starter pulley. Rotor holding tool: P/N. YU-01235, 90890-01235 5.Check: Camshaft sprocket “I” mark Rotor “T”...

  • Page 139: Camshaft, Rocker Arms And Valves

    CAMSHAFT, ROCKER ARMS AND VALVES CAMSHAFT, ROCKER ARMS AND VALVES Order Job name/Part name Q’ty Remarks Removing the camshaft, rocker Remove the parts in the order below. arms and valves Intake manifold/O-ring Thermo switch (cylinder head) Oil check bolt Lock washer/bearing retainer Camshaft Refer to “REMOVING/INSTALLING THE Rocker arm shaft/O-ring...
  • Page 140 CAMSHAFT, ROCKER ARMS AND VALVES Order Job name/Part name Q’ty Remarks Valve spring (inner) Valve (intake) Refer to “REMOVING/INSTALLING THE Valve (exhaust) VALVES AND VALVE SPRINGS”. Valve stem seal Valve spring seat For installation, reverse the removal procedure. 4 - 17...

  • Page 141: Removing The Camshaft And Rocker Arms

    CAMSHAFT, ROCKER ARMS AND VALVES REMOVING THE CAMSHAFT AND ROCKER ARMS 1.Remove: Camshaft 1 NOTE: Screw in a M10 bolt 2 into the thread hole on the camshaft, and pull out the camshaft. 2.Remove: Rocker arm shafts (intake and exhaust) 1 Rocker arms 2 NOTE: Use a slide hammer 3 to remove the rocker...

  • Page 142: Checking The Camshaft

    CAMSHAFT, ROCKER ARMS AND VALVES 2.Remove: Valve cotters NOTE: Attach a valve spring compressor 1 between the valve spring retainer and the cylinder head to remove the valve cotters. Valve spring compressor: P/N. YM-04019, 90890-04019 CHECKING THE CAMSHAFT 1.Check: Cam lobes Pitting/scratches/blue discoloration →...
  • Page 143 CAMSHAFT, ROCKER ARMS AND VALVES 2.Check: Rocker arms Rocker arm shafts Damage/wear → Replace. ***************************************************** Checking steps: Check the two contact areas on the rocker arms for signs of abnormal wear. 1) Rocker arm shaft hole 2) Camshaft lobe contact surface Excessive wear →...

  • Page 144: Checking The Valves And Valve Springs

    CAMSHAFT, ROCKER ARMS AND VALVES CHECKING THE VALVES AND VALVE SPRINGS 1.Measure: Stem-to-guide clearance Stem-to-guide clearance = valve guide inside diameter a – valve stem diameter b Out of specification → Replace the valve guide. Clearance (stem to guide): Intake: 0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in) <Limit>: 0.080 mm (0.0031 in)
  • Page 145 CAMSHAFT, ROCKER ARMS AND VALVES 3.Check: Valve face Pitting/wear → Grind the face. Valve stem end Mushroom shape or diameter larger than the body of the stem → Replace. 4.Measure: Margin thickness a Out of specification → Replace. Margin thickness: Intake: 1.0 ~ 1.4 mm (0.0394 ~ 0.0551 in) Exhaust:...
  • Page 146 CAMSHAFT, ROCKER ARMS AND VALVES ***************************************************** Measurement steps: Apply Mechanic’s blueing dye (Dykem) b to the valve face. Install the valve into the cylinder head. Press the valve through the valve guide and onto the valve seat to make a clear pattern. Measure the valve seat width.
  • Page 147 CAMSHAFT, ROCKER ARMS AND VALVES Apply a fine lapping compound to the valve face and repeat the above steps. NOTE: After every lapping operation, be sure to clean off all of the compound from the valve face and valve seat. Apply Mechanic’s blueing dye (Dykem) to the valve face.

  • Page 148: Installing The Valves And Valve Springs

    CAMSHAFT, ROCKER ARMS AND VALVES 12.Measure: Spring tilt a Out of specification → Replace. Spring tilt limit: Inner: 2.5°/1.6 mm (0.06 in) Outer: 2.5°/1.6 mm (0.06 in) INSTALLING THE VALVES AND VALVE SPRINGS 1.Apply: Molybdenum disulfide oil (onto the valve stem and valve stem seal) 2.Install: Valve spring seat Valve stem seal...

  • Page 149: Installing The Camshaft And Rocker Arms

    CAMSHAFT, ROCKER ARMS AND VALVES INSTALLING THE CAMSHAFT AND ROCKER ARMS 1.Apply: Engine oil (onto the rocker arm shafts) 2.Install: Rocker arms 1 Rocker arm shafts (intake and exhaust) 2 NOTE: Use a slide hammer bolt 3 to install the rocker arm shafts.
  • Page 150 CYLINDER AND PISTON CYLINDER AND PISTON Order Job name/Part name Q’ty Remarks Removing the cylinder and piston Remove the parts in the order below. Cylinder head Refer to “CYLINDER HEAD”. Water pump outlet hose/pipe Refer to “WATER PUMP” in CHAPTER 5. Coolant inlet joint Timing chain guide (exhaust) Cylinder/O-ring...

  • Page 151: Checking The Timing Chain Guide

    CYLINDER AND PISTON REMOVING THE PISTON 1.Remove: Piston pin clips 1 Piston pin 2 Piston 3 NOTE: Before removing piston pin, deburr the clip groove and pin hole area. If the piston pin groove is deburred and the piston pin is still difficult to remove, use the piston pin puller 4.
  • Page 152 CYLINDER AND PISTON 2.Measure: Piston-to-cylinder clearance ***************************************************** Measurement steps: 1st step: Measure the cylinder bore “C” with the cylinder bore gauge. NOTE: Measure cylinder bore “C” by taking side-to- side and front-to-back measurements of the cylinder. Then, find the average of the measurements.

  • Page 153: Checking The Piston Rings

    CYLINDER AND PISTON 3rd step: Find the piston-to-cylinder clearance with the following formula. Piston-to-cylinder clearance = Cylinder bore “C” – Piston skirt diameter “P” Piston-to-cylinder clearance: 0.040 ~ 0.065 mm (0.0016 ~ 0.0026 in) <Limit>: 0.150 mm (0.0059 in) If out of specification, rebore or replace the cylinder, and replace the piston and piston rings as a set.

  • Page 154: Checking The Piston Pin

    CYLINDER AND PISTON 3.Measure: Ring end gap Out of specification → Replace. NOTE: You cannot measure the end gap on the expander spacer of the oil control ring. If the oil control ring rails show excessive gap, replace all three rings. End gap Standard Limit...

  • Page 155: Installing The Piston

    CYLINDER AND PISTON If out of specification, replace the piston. Piston pin-to-piston clearance: 0.004 ~ 0.024 mm (0.00016 ~ 0.00094 in) <Limit>: 0.074 mm (0.0029 in) ***************************************************** INSTALLING THE PISTON 1.Install: Piston rings (onto the piston) NOTE: Be sure to install the piston rings so that the manufacturer’s marks numbers...

  • Page 156: Installing The Cylinder

    CYLINDER AND PISTON 4.Lubricate: Piston Piston rings Cylinder NOTE: Apply a liberal coating of engine oil. INSTALLING THE CYLINDER 1.Install: Cylinder NOTE: Install the cylinder with one hand while compressing the piston rings with the other hand. CAUTION: Be careful not to damage the timing chain damper during installation.

  • Page 157: Recoil Starter And A.c. Magneto

    RECOIL STARTER AND A.C. MAGNETO RECOIL STARTER AND A.C. MAGNETO Order Job name/Part name Q’ty Remarks Removing the A.C. magneto Remove the parts in the order below. Engine oil Drain. Refer to “CHANGING THE ENGINE OIL” in CHAPTER 3. Seat and side panels Refer to “SEAT AND SIDE PANELS”...
  • Page 158 RECOIL STARTER AND A.C. MAGNETO Order Job name/Part name Q’ty Remarks Pickup coil Stator assembly Rotor Refer to “REMOVING/INSTALLING THE Starter wheel gear A.C. MAGNETO”. Woodruff key Washer Starter idle gear shaft Washer/bearing Starter idle gear For installation, reverse the removal procedure.
  • Page 159 RECOIL STARTER AND A.C. MAGNETO Order Job name/Part name Q’ty Remarks Disassembling the recoil starter Remove the parts in the order below. Starter handle Friction plate Pawl spring Refer to “DISASSEMBLING/ Drive pawl ASSEMBLING THE RECOIL STARTER”. Spring Sheave drum Rope Coil spring For assembly, reverse the disassembly...

  • Page 160: Removing The A.c. Magneto

    RECOIL STARTER AND A.C. MAGNETO REMOVING THE A.C. MAGNETO 1.Remove: Starter pulley 1 NOTE: Use the rotor holding tool 2 to hold the starter pulley. Rotor holding tool: P/N. YU-01235, 90890-01235 2.Remove: Crankcase cover (left) Gasket Dowel pins NOTE: Working in a crisscross pattern, loosen each bolt 1/4 of a turn.

  • Page 161: Checking The Starter Clutch

    RECOIL STARTER AND A.C. MAGNETO CHECKING THE STARTER CLUTCH 1.Check: Starter one-way clutch 1 Cracks/damage → Replace. Bolts 2 (starter clutch) Loose → Replace with a new one, and clinch the end of the bolt. NOTE: The arrow mark on the starter clutch must face inward, away from the rotor.

  • Page 162: Checking The Starter Pulley

    RECOIL STARTER AND A.C. MAGNETO CHECKING THE STARTER PULLEY 1.Check: Starter pulley Cracks/pitting → Deburr or replace. CHECKING THE RECOIL STARTER 1.Check: Rope 1 Sheave drum 2 Drive pawl 3 Wear/damage → Replace. Coil spring 4 Pawl spring 5 Spring 6 Fatigue →...

  • Page 163: Installing The A.c. Magneto

    Untie the knot 3 after making a knot 4 above the handle. INSTALLING THE A.C. MAGNETO 1.Apply: ® Sealant (Quick Gasket (into the slit) ® Sealant (Quick Gasket P/N. ACC-11001-05-01 Yamaha bond No. 1215: P/N. 90890-85505 4 - 40...
  • Page 164 RECOIL STARTER AND A.C. MAGNETO 2.Install: Woodruff key Rotor NOTE: Before installing the rotor, clean the outside of the crankshaft and the inside of the rotor. After installing the rotor, check that the rotor rotates smoothly. If not, reinstall the key and rotor.

  • Page 165: Primary And Secondary Sheaves

    PRIMARY AND SECONDARY SHEAVES PRIMARY AND SECONDARY SHEAVES Order Job name/Part name Q’ty Remarks Removing the primary and Remove the parts in the order below. secondary sheaves Front fender Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK” in CHAPTER 3. Rear fender Right footrest board Refer to “FOOTREST BOARDS”...
  • Page 166 PRIMARY AND SECONDARY SHEAVES Order Job name/Part name Q’ty Remarks Primary fixed sheave Refer to “REMOVING/INSTALLING THE PRIMARY AND SECONDARY Secondary sheave assembly SHEAVES”. For installation, reverse the removal procedure. 4 - 43...

  • Page 167: Primary Sliding Sheave

    PRIMARY AND SECONDARY SHEAVES PRIMARY SLIDING SHEAVE Order Job name/Part name Q’ty Remarks Disassembling the primary sliding Remove the parts in the order below. sheave Primary sliding sheave cap Primary pulley slider Spacer Primary pulley cam Refer to “ASSEMBLING THE PRIMARY Primary pulley weight SHEAVE”.

  • Page 168: Secondary Sheave

    PRIMARY AND SECONDARY SHEAVES SECONDARY SHEAVE Order Job name/Part name Q’ty Remarks Disassembling the secondary Remove the parts in the order below. sheave Spring seat Compression spring Refer to “DISASSEMBLING/ Spring seat ASSEMBLING THE SECONDARY Guide pin SHEAVE”. Secondary sliding sheave O-ring Secondary fixed sheave Oil seal...

  • Page 169: Removing The Primary And Secondary Sheaves

    PRIMARY AND SECONDARY SHEAVES REMOVING THE PRIMARY AND SECONDARY SHEAVES 1.Loosen: Nut (secondary sheave) 1 Nut (primary sheave) 2 NOTE: Use the sheave holder 3 to hold the primary sheave. First, loosen the nut (secondary sheave) 2, then loosen the nut (primary sheave) 1. Sheave holder: P/N.

  • Page 170: Checking The Primary Sheave

    PRIMARY AND SECONDARY SHEAVES CHECKING THE PRIMARY SHEAVE 1.Check: Weight outside diameter a Out of specification → Replace the weight. Weight outside diameter: 30 mm (1.18 in) <Limit>: 29.5 mm (1.16 in) 2.Check: Primary pulley sliders Primary sliding sheave splines Wear/cracks/damage →...

  • Page 171: Assembling The Primary Sheave

    NOTE: Remove any excess grease. 2.Install: Weights 1 NOTE: Apply Yamaha Grizzly grease (120 g) to the whole outer surface of the weights and install. Apply Yamaha Grizzly grease to the inner surface of the collar. Apply Yamaha Grizzly grease to the inner surface of the primary sliding sheave.
  • Page 172 PRIMARY AND SECONDARY SHEAVES 3.Apply: ® BEL-RAY assembly lube (to all guide pin sliding grooves 1, and O-rings 2 4.Install: Spring seat Compression spring Spring seat ***************************************************** Installing steps: Attach the sheave fixed block, locknut wrench and sheave spring compressor to the secondary sheave assembly.

  • Page 173: Installing The Primary And Secondary Sheaves

    PRIMARY AND SECONDARY SHEAVES INSTALLING THE PRIMARY AND SECONDARY SHEAVES 1.Install: Secondary sheave assembly V-belt Primary sheave assembly NOTE: Tightening the bolts 1 will push the secondary sliding sheave away, causing the gap between the secondary fixed and sliding sheaves to widen. Install the V-belt so that its arrow faces the direction show in the illustration.

  • Page 174: Clutch

    CLUTCH CLUTCH Order Job name/Part name Q’ty Remarks Removing the clutch Remove the parts in the order below. Primary and secondary sheaves Refer to “PRIMARY AND SECONDARY SHEAVES”. Cover Clutch housing assembly Gasket/dowel pin Refer to “REMOVING/INSTALLING THE CLUTCH”. One-way clutch bearing Clutch carrier assembly For installation, reverse the removal procedure.
  • Page 175 CLUTCH Order Job name/Part name Q’ty Remarks Disassembling the clutch housing Remove the parts in the order below. Oil seal Circlip Bearing housing Circlip Bearing Circlip Bearing Clutch housing For assembly, reverse the disassembly procedure. 4 - 52...

  • Page 176: Removing The Clutch

    CLUTCH REMOVING THE CLUTCH 1.Remove: Clutch housing assembly Gasket Dowel pins NOTE: Working in crisscross pattern, loosen each bolt 1/4 of a turn. Remove them after all of them are loosened. 2.Straighten: Punched portion of the nut 1. 3.Remove: Nut 1 NOTE: Use a clutch holding tool 2 to hold the clutch carrier assembly.

  • Page 177: Installing The Clutch

    CLUTCH 2.Check: Clutch shoe Heat damage → Replace. 3.Measure: Clutch shoe thickness Out of specification → Replace. Clutch shoe thickness: 1.5 mm (0.06 in) Clutch shoe wear limit a: 1.0 mm (0.04 in) INSTALLING THE CLUTCH 1.Install: Clutch carrier assembly Nut 1 140 Nm (14.0 m •...
  • Page 178 CLUTCH 4.Install: Dowel pins Gasket Clutch housing assembly 10 Nm (1.0 m • kg, 7.2 ft • lb) NOTE: Tighten the bolts in stages, using a crisscross pattern. After tightening the bolts, check that the clutch housing assembly to counterclockwise rotates smoothly.

  • Page 179: Crankcase

    CRANKCASE CRANKCASE STARTER MOTOR, TIMING CHAIN AND OIL FILTER Order Job name/Part name Q’ty Remarks Removing the starter motor, timing Remove the parts in the order below. chain and oil filter Engine assembly Refer to “ENGINE REMOVAL”. Cylinder head Refer to “CYLINDER HEAD”. Cylinder and piston Refer to “CYLINDER AND PISTON”.

  • Page 180: Crankcase

    CRANKCASE Order Job name/Part name Q’ty Remarks Oil filter cartridge Speed sensor Shift cam stopper Neutral switch Reverse switch Oil filler cap Gear unit Bearing cover/gasket Oil delivery pipe Oil strainer cover/O-ring Compression spring Oil strainer For installation, reverse the removal procedure.
  • Page 181 CRANKCASE CRANKCASE Order Job name/Part name Q’ty Remarks Separating the crankcase Remove the parts in the order below. Engine side cover bracket Refer to “INSTALLING THE SHIFT LEVER”. Shift lever assembly Crankcase (left) Refer to “SEPARATING/ASSEMBLING Dowel pin THE CRANKCASE”. Crankcase (right) For installation, reverse the removal procedure.

  • Page 182: Crankcase Bearings

    CRANKCASE CRANKCASE BEARINGS Order Job name/Part name Q’ty Remarks Removing the crankcase bearings Remove the parts in the order below. Crankshaft and oil pump Refer to “CRANKSHAFT AND OIL PUMP”. Transmission Refer to “TRANSMISSION”. Middle drive/driven shaft Refer to “MIDDLE GEAR”. Oil seal Bearing retainer Bearing...

  • Page 183: Removing The Oil Pump Drive Gear

    CRANKCASE REMOVING THE OIL PUMP DRIVE GEAR 1.Straighten: Lock washer tab 2.Remove: Oil pump drive gear nut ***************************************************** Removal steps: Temporarily install clutch carrier assembly 1. Hold the clutch carrier assembly with a clutch holding tool 2 and loosen the oil pump drive gear nut.

  • Page 184: Checking The Timing Chain And Guide

    CRANKCASE Remove the left crankcase. CAUTION: Use a soft hammer to tap on one side of the crankcase. Tap only on reinforced portions of the crankcase. Do not tap on the crankcase mating surfaces. Work slowly and carefully. Make sure that the crankcase halves separate evenly.

  • Page 185: Checking The Crankcase

    Sealant (Quick Gasket (to the mating surfaces of both case halves) ® Sealant (Quick Gasket P/N. ACC-11001-05-01 Yamaha bond No. 1215: P/N. 90890-85505 2.Install: Dowel pins 2 3.Fit the left crankcase onto the right case. Tap lightly on the case with a soft hammer.

  • Page 186: Installing The Shift Lever

    CRANKCASE È 4.Tighten: Crankcase bolts (follow the proper tightening sequence) 10 Nm (1.0 m • kg, 7.2 ft • lb) È Right crankcase É Left crankcase NOTE: Tighten the bolts in stages, using a crisscross pattern. É 5.Apply: 4-stroke engine oil (to the crank pin, bearings and oil delivery hole) 6.Check:...

  • Page 187: Installing The Oil Pump Drive Gear

    CRANKCASE INSTALLING THE OIL PUMP DRIVE GEAR 1.Install: Straight key Oil pump drive gear Lock washer Oil pump drive gear nut 2.Tighten: Oil pump drive gear nut 50 Nm (5.0 m • kg, 36 ft • lb) ***************************************************** Tightening steps: Temporary install the clutch carrier assembly 1.

  • Page 188: Crankshaft And Oil Pump

    CRANKSHAFT AND OIL PUMP CRANKSHAFT AND OIL PUMP Order Job name/Part name Q’ty Remarks Removing the crankshaft and oil Remove the parts in the order below. pump Crankcase separation Refer to “CRANKCASE”. Washer/circlip Oil pump assembly/gasket Balancer Refer to “REMOVING THE Crankshaft seal CRANKSHAFT/INSTALLING THE CRANKSHAFT AND BALANCER”.

  • Page 189: Oil Pump

    CRANKSHAFT AND OIL PUMP OIL PUMP Order Job name/Part name Q’ty Remarks Disassembling the oil pump Remove the parts in the order below. Rotor cover Shaft Inner rotor Outer rotor Oil pump housing For assembly, reverse the disassembly procedure. 4 - 66...

  • Page 190: Removing The Crankshaft

    CRANKSHAFT AND OIL PUMP REMOVING THE CRANKSHAFT 1.Remove: Crankshaft seal 1 NOTE: Mark a note of the position of each crankshaft seal so that they can be installed in the correct place and in the correct direction. 2.Remove: Crankshaft Use a crankcase separating tool 1. Crankcase separating tool: P/N.

  • Page 191: Checking The Crankshaft

    CRANKSHAFT AND OIL PUMP 3.Check: Oil pump operation Unsmooth → Repeat steps #1 and #2 or replace the defective parts. CHECKING THE CRANKSHAFT 1.Measure: Crank width A Out of specification → Replace the crankshaft. Crank width: 62.95 ~ 63.00 mm (2.4783 ~ 2.4803 in) Side clearance D Out of specification →...
  • Page 192 CRANKSHAFT AND OIL PUMP INSTALLING THE CRANKSHAFT AND BALANCER 1.Install: Crankshaft Crankshaft installer set 12: P/N. YU-90050 Buffer boss installer set 23: P/N. 90890-04088 Crankshaft installer bolt 1: P/N. 90890-01275 Adapter #11 3: P/N. YM-33279 Spacer (crankshaft): P/N. YM-90070-A, 90890-04060 NOTE: Hold the connecting rod at the Top Dead Center (T.D.C.) with one hand while turning...

  • Page 193: Transmission

    TRANSMISSION TRANSMISSION Order Job name/Part name Q’ty Remarks Removing the transmission Remove the parts in the order below. Crankcase separation Refer to “CRANKCASE”. Driven sprocket Chain Guide bar Shift fork Clutch dog Low wheel gear Secondary shaft Middle driven gear Drive axle assembly 4 - 70...
  • Page 194 TRANSMISSION Order Job name/Part name Q’ty Remarks Shift cam Middle drive gear Spacer/O-ring For installation, reverse the removal procedure. 4 - 71...

  • Page 195: Checking The Shift Forks

    TRANSMISSION CHECKING THE SHIFT FORKS 1.Check: Shift fork cam follower 1 Shift fork pawls 2 Scoring/bends/wear/damage → Replace. 2.Check: Guide bar Roll the guide bar on a flat surface. Bends → Replace. WARNING Do not attempt to straighten a bent guide bar.

  • Page 196: Checking The Secondary Shaft And Driven Sprocket

    TRANSMISSION 2.Check: Gear teeth Blue discoloration/pitting/wear → Replace. Mated dogs Rounded edges/cracks/missing portions → Replace. 3.Check: Gear movement Unsmooth → Repeat steps #1 and #2 or replace the defective parts. 4.Check: Circlips Bends/looseness/damage → Replace. CHECKING THE SECONDARY SHAFT AND DRIVEN SPROCKET 1.Check: Gear teeth...

  • Page 197: Installing The Transmission

    TRANSMISSION INSTALLING THE TRANSMISSION 1.Install: Shift cam 1 Drive axle assembly 2 Clutch dog 3 Shift fork 4 Guide bar 5 NOTE: Install the shift fork with the “L” mark facing towards the left side of the crankcase. Be sure that the shift fork guide pin is properly seated in the shift drum groove.

  • Page 198: Middle Gear

    MIDDLE GEAR MIDDLE GEAR MIDDLE DRIVE SHAFT Order Job name/Part name Q’ty Remarks Removing the middle drive shaft Remove the parts in the order below. Crankcase separation Refer to “CRANKCASE”. Transmission Refer to “TRANSMISSION”. Bearing housing assembly Refer to “REMOVING/INSTALLING THE MIDDLE DRIVE SHAFT”.
  • Page 199 MIDDLE GEAR MIDDLE DRIVEN SHAFT Order Job name/Part name Q’ty Remarks Removing the middle driven shaft Remove the parts in the order below. Crankcase separation Refer to “CRANKCASE”. Circlip Bearing Refer to “REMOVING/INSTALLING THE Universal joint MIDDLE DRIVEN SHAFT”. Universal joint yoke Bearing housing/O-ring Shim Refer to “SELECTING THE MIDDLE...

  • Page 200: Middle Driven Shaft

    MIDDLE GEAR Order Job name/Part name Q’ty Remarks Front drive shaft coupling Bearing retainer Middle driven shaft For installation, reverse the removal procedure. 4 - 77...

  • Page 201: Removing The Middle Drive Shaft

    MIDDLE GEAR REMOVING THE MIDDLE DRIVE SHAFT 1.Straighten: Punched portion of the nut (middle drive pinion gear) 2.Loosen: Nut (middle drive pinion gear) 1 NOTE: Secure the middle drive shaft in the vise with a clean rag. 3.Remove: Nut (middle drive pinion gear) Middle drive pinion gear Shim(s) REMOVING THE MIDDLE DRIVEN SHAFT...
  • Page 202 MIDDLE GEAR 2.Remove: Nut 1 Washer Universal joint yoke NOTE: Use the universal joint holder 2 to hold the universal joint yoke. Universal joint holder: P/N. YM-04062, 90890-04062 3.Remove: Bearing housing assembly 1 ***************************************************** Removal steps: Clean the outside of the middle driven shaft. Place the middle driven shaft onto a hydraulic press.

  • Page 203: Checking The Pinion Gears

    MIDDLE GEAR 5.Remove: Front drive shaft coupling Bearing retainer 1 Bearing NOTE: Attach the ring nut wrench 2. Ring nut wrench: P/N. YM-38404, 90890-01430 CAUTION: The middle driven shaft bearing retainer has left-handed threads. To loosen the bearing retainer, turn it clockwise. 6.Remove: Middle driven shaft 1 (with bearing)

  • Page 204: Selecting The Middle Drive And Driven Gear Shims

    MIDDLE GEAR 4.Check: O-ring Damage → Replace. Bearings Pitting/damage → Replace. 5.Check: U-joint movement Roughness → Replace U-joint. SELECTING THE MIDDLE DRIVE AND DRIVEN GEAR SHIMS When the drive and driven gear, bearing housing assembly and/or crankcase are replaced, be sure to adjust the gear shims. 1.Select: Middle drive gear shim 1 Middle driven gear shim 2...
  • Page 205 MIDDLE GEAR Example: 1) If the bearing housing is marked “+04”, ..a is 10.54. 2) b is 55 3) If the crankcase (right) is marked “66.03”, ..c is 66.03. 4) Therefore, the shim thickness is 0.47 mm. A = 66.03 – 10.54 – 55 = 0.49 5) Round off hundredths digit and select appropriate shim(s).
  • Page 206 MIDDLE GEAR Where: d = a numeral (usually a decimal number) on the bearing housing is either added to or subtracted from “76”. e = a numeral (usually a decimal number) on the middle driven pinion gear is either added to or subtracted from “59”. f = a numeral (usually a decimal number) on the middle driven pinion gear is either added to or subtracted from...

  • Page 207: Installing The Middle Driven Shaft

    MIDDLE GEAR Shims are supplied in the following thickness. Middle drive pinion gear shim 0.10 0.40 0.15 0.50 Thickness (mm) 0.20 0.60 0.30 ***************************************************** INSTALLING THE MIDDLE DRIVEN SHAFT 1.Install: Bearing retainer 1 80 Nm (8.0 m • kg, 58 ft • lb) NOTE: Attach the ring nut wrench 2.
  • Page 208 MIDDLE GEAR Tighten the bearing retainer. CAUTION: The middle driven shaft bearing retainer has left-handed threads. To tighten the bearing retainer, turn it counterclockwise. Bearing retainer: 110 Nm (11.0 m • kg, 80 ft • lb) ***************************************************** 3.Install: Shims 1 Bearing housing NOTE: Install the shims so that the tabs are positioned...

  • Page 209: Installing The Middle Drive Shaft

    MIDDLE GEAR Install each bearings 1 onto the yoke. CAUTION: Check each bearing. The needles can easily fall out of their races. Slide the yoke back and forth on the bearings; the yoke will not go all the way onto a bearing if a needle is out of place.
  • Page 210 MIDDLE GEAR Attach the gear lash measurement tool 3 and dial gauge 4. Gear lash measurement tool: P/N. YM-01467, 90890-01467 a Measuring point is 8.12 mm (0.32 in) Measure the gear lash while rotating the middle driven shaft back and forth. NOTE: Measure the gear lash at 4 positions.

  • Page 211: Chapter 5. Cooling System

    COOL RADIATOR COOLING SYSTEM RADIATOR Order Job name/Part name Q’ty Remarks Removing the radiator Remove the parts in the order below. Seat and fuel tank side panels Refer to “SEAT AND SIDE PANELS” in CHAPTER 3. Front carrier, front bumper and front Refer to “FRONT CARRIER, FRONT fender BUMPER AND FRONT FENDER”...
  • Page 212 COOL RADIATOR Order Job name/Part name Q’ty Remarks Radiator inlet hose Disconnect. Radiator outlet hose Disconnect. Radiator Radiator fan Thermo switch (radiator) For installation, reverse the removal procedure. 5 - 2...

  • Page 213: Checking The Radiator

    COOL RADIATOR CHECKING THE RADIATOR 1.Check: Radiator fins Obstruction → Clean. Apply compressed air to the rear of the radiator. Damage → Repair or replace the radiator. NOTE: Straighten any flattened fins with a thin, flat- head screwdriver. 2.Check: Radiator hoses Cracks/damage →...

  • Page 214: Installing The Radiator

    COOL RADIATOR INSTALLING THE RADIATOR 1.Fill: Cooling system (with specified amount recommended coolant) Refer to “CHANGING THE COOLANT” in CHAPTER 3. 2.Check: Cooling system Leaks → Repair or replace any faulty part. 5 - 4...

  • Page 215: Thermostat

    COOL THERMOSTAT THERMOSTAT Order Job name/Part name Q’ty Remarks Removing the thermostat Remove the parts in the order below. Seat and fuel tank side panel (right) Refer to “SEAT AND SIDE PANELS” in CHAPTER 3. Coolant Drain. Refer to “CHANGING THE COOLANT” in CHAPTER 3.

  • Page 216: Checking The Thermostat

    COOL THERMOSTAT CHECKING THE THERMOSTAT 1.Check: Thermostat 1 Does not open at 63.5 ~ 66.5 °C (146.3 ~ 151.7 °F) → Replace. ***************************************************** Checking steps: Suspend the thermostat in a container filled with water. Slowly heat the water. Place a thermometer in the water. While stirring water,...

  • Page 217: Water Pump

    COOL WATER PUMP WATER PUMP Order Job name/Part name Q’ty Remarks Removing the water pump Remove the parts in the order below. Seat, fuel tank side panel (left) and Refer to “SEAT AND SIDE PANELS” in engine side cover CHAPTER 3. Left footrest board Refer to “FOOTREST BOARDS”...
  • Page 218 COOL WATER PUMP Order Job name/Part name Q’ty Remarks Disassembling the water pump Remove the parts in the order below. Water pump housing cover Gasket Circlip Impeller Rubber damper holder Rubber damper Water pump seal Oil seal Bearing Water pump housing For assembly, reverse the disassembly procedure.

  • Page 219: Disassembling The Water Pump

    COOL WATER PUMP DISASSEMBLING THE WATER PUMP 1.Remove: Rubber damper holder 1 Rubber damper 2 (from the impeller, with a thin, flathead screwdriver) NOTE: Do not scratch the impeller shaft. 2.Remove: Water pump seal 1 NOTE: Tap out the water pump seal from the inside of the water pump housing.

  • Page 220: Assembling The Water Pump

    COOL WATER PUMP 3.Measure: Impeller shaft tilt Out of specification → Replace. Max. impeller shaft tilt: 0.15 mm (0.006 in) 1 Straightedge 2 Impeller ASSEMBLING THE WATER PUMP 1.Install: Oil seal 1 (into the water pump housing 2) NOTE: Install the oil seal with a socket 3 that matches its outside diameter.
  • Page 221 COOL WATER PUMP 3.Install: Rubber damper 1 Rubber damper holder 2 NOTE: Before installing the rubber damper, apply tap water or coolant onto its outer surface. CAUTION: Make sure that the rubber damper and rubber damper holder are flush with the impeller.

  • Page 222: Chapter 6. Carburetion

    CARB CARBURETOR CARBURETION CARBURETOR Order Job name/Part name Q’ty Remarks Removing the carburetor Remove the parts in the order below. Seat/fuel tank side panels/fuel tank/ Refer to “SEAT, CARRIERS, FENDERS rubber cover AND FUEL TANK” in CHAPTER 3. Drain hose Starter cable/starter plunger Vacuum chamber breather hose Carburetor assembly...
  • Page 223 CARB CARBURETOR Order Job name/Part name Q’ty Remarks Disassembling the carburetor Remove the parts in the order below. Float chamber air vent hose Throttle stop screw Vacuum chamber cover Spring Jet needle holder Spring Jet needle set Piston valve Coasting enricher Float chamber Drain screw Float...
  • Page 224 CARB CARBURETOR Order Job name/Part name Q’ty Remarks Pilot jet NOTE: Before disassembling the carburetor, make sure to note the number of times the pilot screw is turned out from the seated position to its set position. Main jet Needle jet Starter jet Pilot air jet For assembly, reverse the disassembly...

  • Page 225: Disassembling The Carburetor

    CARB CARBURETOR DISASSEMBLING THE CARBURETOR NOTE: Before disassembling the carburetor, make sure to note the number of times the pilot screw is turned out from the seated position to its set position. CHECKING THE CARBURETOR 1.Check: Carburetor body Float chamber Cracks/damage →...
  • Page 226 CARB CARBURETOR 4.Check: Piston valve 1 Scratches/wear/damage → Replace. Rubber diaphragm 2 Tears → Replace. 5.Check: Vacuum chamber cover 1 Spring 2 Cracks/damage → Replace. 6.Check: Diaphragm (coasting enricher) 1 Spring 2 Cover 3 Tears (diaphragm) /damage → Replace. 7.Check: Jet needle 1 Main jet 2 Needle jet 3...

  • Page 227: Assembling The Carburetor

    CARB CARBURETOR 8.Check: Free movement (piston valve) Sticks → Replace the piston valve guide and the piston valve. Insert the piston valve into the carburetor body, and check for free movement. 9.Check: Free movement (throttle valve) Sticks → Replace. ASSEMBLING THE CARBURETOR CAUTION: Before reassembling, wash all of the parts in a clean petroleum-based solvent.

  • Page 228: Adjusting The Fuel Level

    CARB CARBURETOR If either is worn, replace them both. If both are fine, adjust the float height by bending the float tang 1 on the float. Recheck the float height. ***************************************************** ADJUSTING THE FUEL LEVEL 1.Measure: Fuel level a Out of specification → Adjust. Fuel level: 4.0 ~ 5.0 mm (0.16 ~ 0.20 in) Above the float chamber mating...

  • Page 229: Chapter 7. Drive Train

    DRIV TROUBLESHOOTING DRIVE TRAIN TROUBLESHOOTING The following conditions may indicate damaged shaft drive components: Symptoms Possible Causes 1.A pronounced hesitation or “jerky” movement A.Bearing damage. during acceleration, deceleration, or sustained B. Improper gear lash. speed. (This must not be confused with engine surging transmission...
  • Page 230 DRIV TROUBLESHOOTING CAUTION: Too little gear lash is extremely destructive to the gear teeth. If a test ride following reassembly indicates this condition, stop riding immediately to minimize gear damage. c.A slight “thunk” evident at low speed operation. This noise must be distinguished from normal machine operation.
  • Page 231 DRIV TROUBLESHOOTING Troubleshooting chart When basic condition “a” and “b” exist, check the following points: Elevate and spin both wheels. Feel for Replace the wheel bearings. wheel bearing damage. (Refer to “STEERING SYSTEM” and “REAR SHOCK ABSORBER SWINGARM” in CHAPTER 8.) Check the wheel nuts and hub nuts for Torque to specification.

  • Page 232: Front Constant Velocity Joints And Differential Gear

    FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR Order Job name/Part name Q’ty Remarks Removing the front constant Remove the parts in the order below. velocity joints and differential gear Engine skid plate (front) Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”...
  • Page 233 FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR Order Job name/Part name Q’ty Remarks Differential gear Drive shaft Compression spring Coupling gear For installation, reverse the removal procedure. 7 - 5...
  • Page 234 FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR Order Job name/Part name Q’ty Remarks Disassembling the constant velocity Remove the parts in the order below. joints Circlip Boot band Boot band Dust boot Circlip Refer to “ASSEMBLING THE FRONT CONSTANT VELOCITY JOINTS”. Double off-set joint Circlip Ball bearing...
  • Page 235 FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR Order Job name/Part name Q’ty Remarks Differential gear Remove the parts in the order below. Gear motor/O-ring Four-wheel drive switch Dust seal Circlip Coupling gear/bearing/circlip 1/1/1 Stopper bolt/shaft Shift fork sliding gear Shift fork 2WD/4WD shift sleeve Differential gear case cover/O-ring...
  • Page 236 FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR Order Job name/Part name Q’ty Remarks Shim (right) Circlip/bearing Drive pinion gear Differential gear case For assembly, reverse the disassembly procedure. 7 - 8...

  • Page 237: Removing The Differential Gear Assembly

    FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR REMOVING THE DIFFERENTIAL GEAR ASSEMBLY 1.Remove: Differential gear assembly 1 NOTE: The ring gear and the differential gear cover should fastened together. disassemble the differential gear assembly. CAUTION: The differential gears are assembled into a proper unit at the factory by means of specialized equipment.

  • Page 238: Checking The Differential Gear

    FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR CHECKING THE DIFFERENTIAL GEAR 1.Check: Gear teeth Pitting/galling/wear → Replace drive pinion gear and differential gear assembly as a set. Bearing Pitting/damage → Replace. Oil seal O-ring Damage → Replace. 2.Check: Drive shaft splines Universal joints Front drive gear splines Wear/damage →...

  • Page 239: Assembling The Differential Gear

    FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR Install the dust boots. Install the dust boot bands. NOTE: The new boot bands may differ from the original ones. The dust boots should be fastened with the dust boot bands 3 at the grooves in the joint shaft.

  • Page 240: Measuring And Adjusting The Differential Gear Lash

    FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR 3.Check: Differential gear operation Unsmooth operation → Replace the differential gear assembly. Insert the double off-set joint into the differential gear, and turn the gear back and forth. MEASURING AND ADJUSTING THE DIFFERENTIAL GEAR LASH Measuring the differential gear lash 1.Secure the gear case in a vise or another...
  • Page 241 FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR Adjusting differential gear lash 1.Remove: Shim(s) (left) 1 Differential gear assembly 2 Shim(s) (right) 3 2.Adjust: Gear lash ***************************************************** Adjustment steps: Select the suitable shims using the following chart. Reduce shim Too little gear lash thickness.

  • Page 242: Checking The Differential Gear Operation

    FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR CHECKING THE DIFFERENTIAL GEAR OPERATION 1.Block the rear wheels, and elevate the front wheels by placing a suitable stand under the frame. 2.Remove the wheel cap and cotter pin from the axle nut (right or left). 3.Measure the starting torque of the front wheel (i.e., differential gear preload) with the torque wrench.

  • Page 243: Rear Axle/Final Drive Gear And Drive Shaft

    DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT Order Job name/Part name Q’ty Remarks Removing the rear axle, final drive Remove the parts in the order below. gear assembly and drive shaft Final gear oil Drain.
  • Page 244 DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT Order Job name/Part name Q’ty Remarks Disassembling the final drive gear Remove the parts in the order below. Bolt NOTE: Bolt Working in a crisscross pattern, loosen each bolt 1/4 of a turn. After all the bolts are loosened, remove them.
  • Page 245 DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT Order Job name/Part name Q’ty Remarks Bearing retainer/O-ring Oil seal Refer to “DISASSEMBLING/ Final drive pinion gear ASSEMBLING THE FINAL DRIVE Collar GEAR”. Bearing Final drive pinion gear shim Final drive gear case/O-ring Bearing/oil seal Refer to “REPLACING THE FINAL DRIVE ROLLER BEARINGS”.

  • Page 246: Removing The Rear Axle

    DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT REMOVING THE REAR AXLE 1.Remove: Rear axle 1 (with dust seal) O-ring CAUTION: Never directly tap the axle end with a hammer, since this will result in damage to the axle thread and spline. Attach a suitable socket 2 on the axle end and tap it with a soft hammer.

  • Page 247: Replacing The Final Drive Roller Bearings

    DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT REPLACING THE FINAL DRIVE ROLLER BEARINGS 1.Remove: Roller bearing (ring gear) 1 Use a suitable press tool 2 and an appropriate support for the main housing. Oil seal 3 2.Remove: Roller bearing (final drive pinion gear) 1 ***************************************************** Removal steps: Heat the main housing only to 150 °C...

  • Page 248: Positioning The Final Drive Pinion Gear And Ring Gear

    DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT POSITIONING THE FINAL DRIVE PINION GEAR AND RING GEAR When the final drive pinion gear, ring gear, final gear case and/or ring gear bearing housing are replaced, be sure to adjust the positions of the final drive pinion gear and ring gear using shim(s).
  • Page 249 DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT Shims supplied following thicknesses. Final drive pinion gear shim 0.15 0.30 0.40 Thickness (mm) 0.45 0.50 0.60 ***************************************************** Ring gear shim selection 1.Select: Ring gear shim(s) ***************************************************** Selection steps: To find the ring gear shim thickness “B”, use the following formula.
  • Page 250 DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT 5) Therefore, shim thickness “B” is 0.63. “B”= 45.53 + 1.05 – (34.95 + 11.00) = 46.58 – 45.95 = 0.63 6) Round off the hundredth digit and select the appropriate shim(s). In the example above, the calculated number is 0.63.
  • Page 251 DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT Remove the ring gear assembly. Measure the thrust clearance. Calculate the ® width of the flattened Plastigauge Ring gear thrust clearance: 0.1 ~ 0.2 mm (0.004 ~ 0.008 in) If out of specification, select the correct washer.

  • Page 252: Checking The Rear Axle

    DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT Ring gear stopper clearance adjustment 1.Remove: Ring gear 1 Ring gear stopper 2 Shim(s) 3 4 Bearing housing È Left-hand threads 2.Select: Suitable shim(s) Shim 0.10 0.15 0.20 Thickness (mm) 0.30 0.40 0.50 3.Install: Shim(s)

  • Page 253: Checking The Drive Shaft

    Bearings Damage → Replace. NOTE: Reusing roller bearings is acceptable, but Yamaha recommends installing new ones. Do not reuse oil seals. When the final drive pinion gear and/or ring gear are replaced, be sure to adjust the shim of the final drive pinion gear and/or ring gear.

  • Page 254: Measurement And Adjusting The Final Gear Lash

    DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT MEASUREMENT AND ADJUSTING THE FINAL GEAR LASH Final gear lash measurement 1.Secure the gear case in a vise or another supporting device. 2.Remove: Drain plug Gasket 3.Install: A bolt of the specified size 1 (into the drain plug hole) CAUTION: Finger tighten the bolt until it holds the ring...
  • Page 255 DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT Final gear lash adjustment 1.Remove: Bearing housing 1 Ring gear shim(s) 2 Ring gear 3 Thrust washer 4 2.Adjust: Gear lash ***************************************************** Adjustment steps: Select suitable shim(s) and thrust washer(s) using the following chart. Reduce shim Too little gear lash thickness.

  • Page 256: Assembling The Final Drive Gear

    DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT ASSEMBLING THE FINAL DRIVE GEAR 1.Install: Drive pinion gear (with shim(s) and bearing) (proper shim size as calculated) Bearing retainer (drive pinion gear) 1 100 Nm (10.0 m • kg, 72 ft • lb) Use a bearing retainer wrench 2.
  • Page 257 Sealant (Quick Gasket (to the mating surfaces of the swingarm and the final drive gear case) ® Sealant (Quick gasket P/N. ACC-11001-05-01 Yamaha bond No.1215: P/N. 90890-85505 4.Install: Final drive gear Nuts 63 Nm (6.3 m • kg, 45 ft • lb) Bolts 63 Nm (6.3 m •...

  • Page 258: Chapter 8. Chassis

    CHAS FRONT AND REAR WHEELS CHASSIS FRONT AND REAR WHEELS FRONT WHEELS Order Job name/Part name Q’ty Remarks Removing the front wheels Remove the parts in the order below. Place the machine on a level surface. WARNING Securely support the machine so there is no danger of it falling over.

  • Page 259: Rear Wheels

    CHAS FRONT AND REAR WHEELS REAR WHEELS Order Job name/Part name Q’ty Remarks Removing the rear wheels Remove the parts in the order below. Place the machine on a level surface. WARNING Securely support the machine so there is no danger of it falling over. Wheel cap Rear wheel Refer to “INSTALLING THE WHEELS”.

  • Page 260: Checking The Wheels

    CHAS FRONT AND REAR WHEELS CHECKING THE WHEELS 1.Check: Wheel 2.Measure: Wheel runout Over the specified limit → Replace the wheel or check the wheel bearing plays 1. Wheel runout limit: Radial 2: 2.0 mm (0.08 in) Lateral 3: 2.0 mm (0.08 in) 3.Check: Wheel balance Out of balance →...

  • Page 261: Checking The Brake Discs

    CHAS FRONT AND REAR WHEELS CHECKING THE BRAKE DISCS 1.Check: Brake disc Galling/damage → Replace. 2.Measure: Brake disc deflection Out of specification → Check the wheel runout. If wheel runout is within the limits, replace the brake disc. Brake disc maximum deflection: 0.15 mm (0.006 in) Brake disc thickness a Out of specification →...
  • Page 262 CHAS FRONT AND REAR WHEELS 2.Install: Nuts (wheel) 1 WARNING Tapered wheel nuts 1 are used for both the front and rear wheels. Install each nut with its tapered side towards the wheel. 3.Tighten: Nuts (front wheels) 64 Nm (6.4 m • kg, 46 ft • lb) Nuts (rear wheels) 55 Nm (5.5 m •...

  • Page 263: Front Brake

    CHAS FRONT BRAKE FRONT BRAKE FRONT BRAKE PADS Order Job name/Part name Q’ty Remarks Removing the front brake pads Remove the parts in the order below. Front wheel Refer to “FRONT AND REAR WHEELS”. Brake caliper mounting bolt Brake pad holding bolt Refer to “REPLACING THE FRONT BRAKE PADS”.

  • Page 264: Replacing The Front Brake Pads

    CHAS FRONT BRAKE CAUTION: Disc brake components rarely require disassembly. DO NOT: disassemble components unless absolutely necessary; solvents internal brake components; use spent brake fluid for cleaning; (use only clean brake fluid) allow brake fluid to come in contact with the eyes, as this may cause eye injury;...
  • Page 265 CHAS FRONT BRAKE ***************************************************** Installation steps: Connect a suitable hose 1 tightly to the brake caliper bleed screw 2. Put the other end of this hose into an open container. Loosen the brake caliper bleed screw and, using a finger, push the caliper piston into the brake caliper.

  • Page 266: Front Brake Master Cylinder

    CHAS FRONT BRAKE FRONT BRAKE MASTER CYLINDER Order Job name/Part name Q’ty Remarks Removing the front brake master Remove the parts in the order below. cylinder Brake fluid Drain. Brake fluid reservoir cap Brake fluid reservoir diaphragm Brake lever Union bolt Copper washer Brake hose Refer to “INSTALLING THE FRONT...
  • Page 267 CHAS FRONT BRAKE Order Job name/Part name Q’ty Remarks Disassembling the front brake Remove the parts in the order below. master cylinder Brake master cylinder kit Refer to “ASSEMBLING THE FRONT BRAKE MASTER CYLINDER”. Brake master cylinder For assembly, reverse the disassembly procedure.

  • Page 268: Checking The Master Cylinder

    CHAS FRONT BRAKE CHECKING THE MASTER CYLINDER 1.Check: Brake master cylinder 1 Wear/scratches → Replace the brake master cylinder assembly. Brake master cylinder body Cracks/damage → Replace. Brake fluid delivery passage (brake master cylinder body) Blockage → Blow out with compressed air. 2.Check: Front brake master cylinder reservoir 1 Front...

  • Page 269: Installing The Front Brake Master Cylinder

    CHAS FRONT BRAKE INSTALLING THE FRONT BRAKE MASTER CYLINDER 1.Install: Brake master cylinder 1 Brake master cylinder bracket 2 7 Nm (0.7 m • kg, 5.1 ft • lb) NOTE: The “UP” mark on the brake master cylinder bracket 2 should face up. 2.Install: Copper washers Brake hose...
  • Page 270 CHAS FRONT BRAKE Be careful that water does not enter the brake master cylinder when refilling. Water will significantly lower the boiling point of the brake fluid and may result in vapor lock. 4.Air bleed: Brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM”...

  • Page 271: Front Brake Caliper

    CHAS FRONT BRAKE FRONT BRAKE CALIPER Order Job name/Part name Q’ty Remarks Removing the front brake calipers Remove the parts in the order below. Brake fluid Drain. Front wheel Refer to “FRONT AND REAR WHEELS”. Union bolt Copper washer Brake hose Disconnect.
  • Page 272 CHAS FRONT BRAKE Order Job name/Part name Q’ty Remarks Disassembling the front brake Remove the parts in the order below. calipers Brake pad holding bolt Brake pad/pad shim Pad spring Retaining bolt Caliper bracket Brake caliper piston Refer to “DISASSEMBLING/ Dust seal ASSEMBLING THE FRONT BRAKE CALIPERS”.

  • Page 273: Disassembling The Front Brake Calipers

    CHAS FRONT BRAKE DISASSEMBLING THE FRONT BRAKE CALIPERS 1.Remove: Brake caliper piston Dust seal 1 Caliper piston seal 2 ***************************************************** Removal steps: Blow compressed air into the hose joint opening to force out the caliper piston from the brake caliper body. WARNING Never try to pry out the caliper piston.

  • Page 274: Assembling The Front Brake Calipers

    CHAS FRONT BRAKE Brake fluid delivery passage (brake caliper body) Blockage → Blow out with compressed air. WARNING Replace the caliper piston seal and dust seal whenever brake caliper disassembled. ASSEMBLING THE FRONT BRAKE CALIPERS WARNING All internal brake components should be cleaned and lubricated with new brake fluid only before installation.
  • Page 275 CHAS FRONT BRAKE CAUTION: When installing the brake hose on the brake caliper, make sure that the brake pipe touches the projection a on the brake caliper. WARNING Proper brake hose routing is essential to insure safe motorcycle operation. Refer to “CABLE ROUTING”...

  • Page 276: Rear Brake

    CHAS REAR BRAKE REAR BRAKE Order Job name/Part name Q’ty Remarks Removing the rear brake lever Remove the parts in the order below. Rear brake switch Rear brake lever cable Rear brake lever holder bracket Rear brake lever holder Rear brake lever For installation, reverse the removal procedure.
  • Page 277 CHAS REAR BRAKE Order Job name/Part name Q’ty Remarks Removing the rear brake pedal Remove the parts in the order below. Rear brake light switch cover Rear brake pedal cable Brake pedal Select lever control cable Rear brake light switch Bracket For installation, reverse the removal procedure.
  • Page 278 CHAS REAR BRAKE Order Job name/Part name Q’ty Remarks Removing the rear brake drum Remove the parts in the order below. Rear wheel (left) Refer to “FRONT AND REAR WHEELS” Brake drum cover Dust seal Brake drum Adjusting nut Spring Rear brake lever cable Rear brake pedal cable Brake shoe...
  • Page 279 CHAS REAR BRAKE Order Job name/Part name Q’ty Remarks Brake camshaft lever Brake shoe wear indicator Brake camshaft O-ring Dust seal Brake shoe plate For installation, reverse the removal procedure. 8 - 22...

  • Page 280: Removing The Rear Brake

    CHAS REAR BRAKE REMOVING THE REAR BRAKE 1.Remove: Rear wheel (left) Rear wheel hub (left) Refer to “FRONT AND REAR WHEELS”. 2.Remove: Brake drum cover 1 3.Remove: Brake drum 1 4.Remove: Adjusting nuts 1 Pins 2 Springs 3 5.Disconnect: Rear brake lever cable 4 Rear brake pedal cable 5 6.Remove: Brake shoes 1...

  • Page 281: Checking The Rear Brake

    CHAS REAR BRAKE 7.Remove: Spring 1 Brake camshaft lever 2 Brake shoe wear indicator 3 Brake camshaft 4 CHECKING THE REAR BRAKE 1.Check: Brake drum 1 Cracks/damage → Replace. Splines (wheel drum) 2 Wear/damage → Replace. 2.Check: Brake shoe plate 1 Pivot pin 2 Brake camshaft 3 Bends/cracks/damage →...

  • Page 282: Installing The Rear Brake

    CHAS REAR BRAKE 5.Measure: Brake shoe lining thickness a Out of specification → Replace. 1 Measuring points NOTE: Replace the brake shoes as a set if either is worn to the wear limit. Brake shoe lining thickness limit: 2.0 mm (0.08 in) 6.Measure: Brake drum inside diameter a Out of specification →...
  • Page 283 4.Apply: Sealant 4 (onto the mating surfaces of swingarm) ® Sealant (Quick Gasket) P/N. ACC-11001-05-01 Yamaha bond No. 1215: P/N. 90890-85505 5.Install: Brake shoe plate 1 Bearing retainer 2 Brake shoes 3 Spring 4 Bolt (brake shoe plate): 28 Nm (2.8 m •...
  • Page 284 CHAS REAR BRAKE 6.Check: Brake camshaft operation Unsmooth operation → Repair. 7.Lubricate: Dust seal 1 Lithium-soap base grease 8.Connect: Rear brake lever cable 1 Rear brake pedal cable 2 9.Install: Springs 3 Pins 4 Adjusting nuts 5 Brake drum Brake drum cover 10.Install: Rear wheel hub (left) Rear wheel (left)

  • Page 285: Steering System

    CHAS STEERING SYSTEM STEERING SYSTEM HANDLEBAR Order Job name/Part name Q’ty Remarks Removing the handlebar Remove the parts in the order below. Handlebar cover Band On-command four-wheel drive switch Refer to “INSTALLING THE MASTER Master cylinder assembly/bracket CYLINDER ASSEMBLY”. Throttle lever assembly/bracket Rear brake switch Refer to “REMOVING THE REAR BRAKE SWITCH”.

  • Page 286: Removing The Rear Brake Switch

    CHAS STEERING SYSTEM REMOVING THE REAR BRAKE SWITCH 1.Remove: Rear brake switch 1 NOTE: Push the fastener when removing the rear brake switch out of the rear brake lever holder. CHECKING THE HANDLEBAR 1.Check: Handlebar Bends/cracks/damage → Replace. WARNING Do not attempt to straighten a bent handlebar as this may dangerously weaken the handlebar.

  • Page 287: Installing The Master Cylinder Assembly

    CHAS STEERING SYSTEM INSTALLING THE MASTER CYLINDER ASSEMBLY 1.Install: Throttle lever assembly Master cylinder assembly 7 Nm (0.7 m • kg, 5.1 ft • lb) NOTE: The “UP” mark on the master cylinder bracket should face up. 8 - 30...

  • Page 288: Steering Stem

    CHAS STEERING SYSTEM STEERING STEM Order Job name/Part name Q’ty Remarks Removing the steering stem Remove the parts in the order below. Handlebar Refer to “HANDLEBAR”. Seat Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK” in CHAPTER 3. Front fender Lock washer Refer to “INSTALLING THE CABLE GUIDE”.
  • Page 289 CHAS STEERING SYSTEM Order Job name/Part name Q’ty Remarks Oil seal Bearing retainer Refer to “REMOVING/INSTALLING THE BEARING RETAINER”. Bearing Oil seal For installation, reverse the removal procedure. 8 - 32...

  • Page 290: Removing The Bearing Retainer

    CHAS STEERING SYSTEM REMOVING THE BEARING RETAINER 1.Remove: Bearing retainer (steering stem) Damper rod holder (30 mm): P/N. YM-01327, 90890-01327 CHECKING THE STEERING STEM 1.Check: Steering stem Bends → Replace. WARNING Do not attempt to straighten a bent stem; this may dangerously weaken the stem. 2.Check: Oil seals 1 Steering stem bushings 2...

  • Page 291: Tie Rods And Steering Knuckles

    CHAS STEERING SYSTEM TIE RODS AND STEERING KNUCKLES Order Job name/Part name Q’ty Remarks Removing the tie rods and steering Remove the parts in the order below. knuckles Front fender Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK” in CHAPTER 3. Front wheel/brake disc Refer to “FRONT AND REAR WHEELS”.
  • Page 292 CHAS STEERING SYSTEM Order Job name/Part name Q’ty Remarks Oil seal Oil seal Bearing Spacer Circlip Rubber boot Ball joint For installation, reverse the removal procedure. 8 - 35...

  • Page 293: Removing The Steering Knuckles

    CHAS STEERING SYSTEM REMOVING THE STEERING KNUCKLES 1.Remove: Steering knuckle 1 NOTE: Use a general puller to separate the ball joints 2 from the steering knuckle 1 or the front lower arm 3. CHECKING THE TIE RODS 1.Check: Tie rod free play and movement Free play →...
  • Page 294 CHAS STEERING SYSTEM Ball joint remover/installer set: P/N. YM-01474/90890-01474 Ball joint remover/installer attachment set: P/N. YM-01477 YM-01474 Body 90890-01474 YM-01474 Long bolt 90890-01474 Short bolt YM-01477 Remover washer YM-01477 Remover spacer YM-01477 Installer attachment YM-01477 Installer spacer YM-01477 Installer guide YM-01477 Install the body 3, short bolt 5, remover washer 6 and remover spacer 7 onto ball...
  • Page 295 CHAS STEERING SYSTEM Attach the assembled ball joint remover/ installer, new ball joint B and installer attachment 8 to the steering knuckle C. NOTE: Do not tap or damage the top of the ball joint. Hold the body 3 in place while turning in the long bolt 4 to install the new ball joint B into the steering knuckle C.

  • Page 296: Installing The Tie Rods

    CHAS STEERING SYSTEM Install the new bearings. NOTE: Install the outside bearing first. CAUTION: Do not strike the center race or balls of the bearing. Contact should be made only with the outer race. Install the new oil seals. NOTE: When installing the oil seals, the “seal side”...

  • Page 297: Front Arms And Front Shock Absorbers

    CHAS FRONT ARMS AND FRONT SHOCK ABSORBERS FRONT ARMS AND FRONT SHOCK ABSORBERS Order Job name/Part name Q’ty Remarks Removing the front arms and front Remove the parts in the order below. shock absorbers Engine skid plate Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”...
  • Page 298 CHAS FRONT ARMS AND FRONT SHOCK ABSORBERS Order Job name/Part name Q’ty Remarks Bolt/nut Refer to “REMOVING THE FRONT Front lower arm/bushing ARMS” and “INSTALLING THE FRONT ARMS AND FRONT SHOCK Nut/bolt ABSORBER”. Front shock absorber Bolt/nut Front upper arm/bushing Circlip Ball joint For installation, reverse the removal...

  • Page 299: Checking The Front Arms

    CHAS FRONT ARMS AND FRONT SHOCK ABSORBERS REMOVING THE FRONT ARMS 1.Check: Front arm free play ***************************************************** Checking steps: Check the front arm side play È by moving it from side to side. If side play is noticeable, check the bushings. Check the front arm vertical movement É...
  • Page 300 CHAS FRONT ARMS AND FRONT SHOCK ABSORBERS ***************************************************** Replacement steps: Clean the outside of the front lower arm. Remove the circlip 1 and rubber boot 2. Use the ball joint remover and installer set. Ball joint remover/installer set: P/N. YM-01474/90890-01474 Ball joint remover/installer attachment set: P/N.

  • Page 301: Checking The Front Shock Absorber

    CHAS FRONT ARMS AND FRONT SHOCK ABSORBERS Attach the assembled ball joint remover/ installer, new ball joint A and installer attachment 7 to the front lower arm B. NOTE: Do not tap or damage the top of the ball joint. Hold the body 3 in place while turning in the long bolt 4 to install the new ball joint A into the front lower arm B.

  • Page 302: Installing The Front Arms And Front Shock Absorber

    CHAS FRONT ARMS AND FRONT SHOCK ABSORBERS INSTALLING THE FRONT ARMS AND FRONT SHOCK ABSORBER 1.Install: Front arms Front shock absorber ***************************************************** Installation steps: Install the front upper arm 1 and front lower arm 2. NOTE: Lubricate the bolts 3 with lithium-soap- based grease.

  • Page 303: Rear Shock Absorber And Swingarm

    CHAS REAR SHOCK ABSORBER AND SWINGARM REAR SHOCK ABSORBER AND SWINGARM Order Job name/Part name Q’ty Remarks Removing the rear shock absorber Remove the parts in the order below. and swingarm Rear wheel hubs Refer to “FRONT AND REAR WHEELS”. Rear brake drum Refer to “REAR BRAKE”.
  • Page 304 CHAS REAR SHOCK ABSORBER AND SWINGARM Order Job name/Part name Q’ty Remarks Rear axle housing Refer to “INSTALLING THE REAR AXLE HOUSING”. Nut/bolt Refer to “REMOVING THE SWINGARM”. Swingarm/bushing Spring/rubber boot For installation, reverse the removal procedure. 8 - 47...

  • Page 305: Removing The Swingarm

    CHAS REAR SHOCK ABSORBER AND SWINGARM REMOVING THE SWINGARM 1.Check: Swingarm free play ***************************************************** Checking steps: Check the tightening torque of the nuts (swingarm). Nut (swingarm): 82 Nm (8.2 m • kg, 59 ft • lb) Check the swingarm side play È by moving it from side to side.

  • Page 306: Checking The Swingarm

    CHAS REAR SHOCK ABSORBER AND SWINGARM CHECKING THE SWINGARM 1.Check: Swingarm 1 Rear axle housing 2 Bends/cracks/damage → Replace. 2.Check: Bushings 1 Wear/damage → Replace. CHECKING THE RUBBER BOOT 1.Check: Rubber boot 1 Damage → Replace. INSTALLING THE RUBBER BOOT 1.Apply: Adhesive (for rubber) (to the engine 1)

  • Page 307: Installing The Rear Axle Housing

    CHAS REAR SHOCK ABSORBER AND SWINGARM INSTALLING THE REAR AXLE HOUSING 1.Install: Rear axle housing Final gear case assembly Rear axle (with dust seal) ***************************************************** Installation steps: Install the drive shaft. Refer to “REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT” in CHAPTER 7. ®...

  • Page 308: Chapter 9. Electrical

    – ELEC ELECTRICAL COMPONENTS EB800000 ELECTRICAL ELECTRICAL COMPONENTS 1 Main switch 7 Fuse box E Rear brake light K Ignition coil 2 Front brake light 8 Main fuse switch 9 Starter relay F Gear motor switch 3 Rear brake switch 0 CDI unit G Thermo switch 4 Thermo switch...

  • Page 309: Checking The Switches

    – ELEC CHECKING THE SWITCHES CHECKING THE SWITCHES CHECKING A SWITCH Use a pocket tester to check the terminals for continuity. If the continuity is faulty at any point, replace the switch. Pocket tester: P/N. YU-03112-C, 90890-03112 NOTE: Set the pocket tester to “0” before starting the test.
  • Page 310 – ELEC CHECKING THE SWITCHES 9 - 3...

  • Page 311: Checking The Switch Continuity

    – ELEC CHECKING THE SWITCHES CHECKING THE SWITCH CONTINUITY Refer to “CHECKING THE SWITCHES” and check for continuity between lead terminals. Poor connection, no continuity → Correct or replace. The coupler locations are circled. Br L Y G R/B R/W PUSH (BLACK) Br L/R L/G B L/B...
  • Page 312 – ELEC CHECKING THE SWITCHES 1 Light switch 2 Engine stop switch 3 Start switch 4 On-command four-wheel drive switch 5 Main switch 6 Rear brake light switch 7 Front brake light switch 8 Rear brake switch 9 Neutral switch 0 Reverse switch A Fuses 9 - 5...

  • Page 313: Checking The Bulbs And Bulb Sockets

    – ELEC CHECKING THE BULBS AND BULB SOCKETS EB801020 CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage or wear, proper connections, and also for continuity between the terminals. Damage/wear → Repair or replace the bulb, bulb socket or both.
  • Page 314 – ELEC CHECKING THE BULBS AND BULB SOCKETS WARNING Since the headlight bulbs gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. CAUTION: Be sure to hold the socket firmly when removing the bulb.

  • Page 315: Checking The Condition Of The Bulb Sockets

    – ELEC CHECKING THE BULBS AND BULB SOCKETS CHECKING THE CONDITION OF THE BULB SOCKETS The following procedure applies to all of the bulb sockets. 1.Check: Bulb socket (for continuity) (with the pocket tester) No continuity → Replace. Pocket tester: P/N.

  • Page 316: Ignition System

    – ELEC IGNITION SYSTEM EB802000 IGNITION SYSTEM CIRCUIT DIAGRAM 9 - 9...

  • Page 317: Troubleshooting

    – ELEC IGNITION SYSTEM EB802010 TROUBLESHOOTING IF THE IGNITION SYSTEM FAILS TO OPERATE (NO SPARK OR INTERMITTENT SPARK): Procedure Check: 1.Fuse (main, ignition) 7.Engine stop switch 2.Battery 8.Main switch 3.Spark plug 9.Pickup coil resistance 4.Ignition spark gap 10.Charging/rotor rotation direction detection 5.Spark plug cap resistance coil resistance 6.Ignition coil resistance...
  • Page 318 – ELEC IGNITION SYSTEM INCORRECT Spark plug gap: 0.6 ~ 0.7 mm (0.024 ~ 0.028 in) CORRECT Repair or replace the spark plug. 4.Ignition spark gap Disconnect the spark plug cap from the spark plug. Connect the dynamic spark tester 1 as shown.
  • Page 319 – ELEC IGNITION SYSTEM C0NTINUITY 6.Ignition coil resistance Disconnect the ignition coil connector from the wire harness. Connect the pocket tester (Ω × 1) to the ignition coil. Tester (+) lead → Orange lead terminal Tester (–) lead → Ignition coil base Check that the primary coil has the specified resistance.
  • Page 320 – ELEC IGNITION SYSTEM C0NTINUITY INCORRECT 8.Main switch Refer to “CHECKING THE SWITCHES”. CORRECT Replace the main switch. 9.Pickup coil resistance Disconnect the AC magneto coupler from the wire harness. Connect the pocket tester (Ω × 100) to the pickup coil terminals. Tester (+) lead →...
  • Page 321 – ELEC IGNITION SYSTEM C0NTINUITY 11.Wiring connections POOR CONNECTION Check the connections of the entire ignition system. Refer to “CIRCUIT DIAGRAM”. Properly connect the ignition system. CORRECT Replace the CDI unit. 9 - 14...

  • Page 322: Electric Starting System

    – ELEC ELECTRIC STARTING SYSTEM EB803000 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM 9 - 15...

  • Page 323: Troubleshooting

    – ELEC ELECTRIC STARTING SYSTEM EB803020 TROUBLESHOOTING IF THE STARTER MOTOR FAILS TO OPERATE: Procedure Check: 8. Wiring connections (the entire starting 1.Fuse (main, ignition) system) 2.Battery 3.Starter motor 4.Starter relay 5.Main switch 6.Engine stop switch 7.Start switch NOTE: Pocket tester: Remove following part(s)
  • Page 324 – ELEC ELECTRIC STARTING SYSTEM C0NTINUITY WARNING 3.Starter motor A wire that is used as a jumper lead must Connect the battery positive terminal 1 have the equivalent capacity or more as and starter motor cable 2 using a jumper that of the battery lead, otherwise the lead 3 jumper lead may burn.
  • Page 325 – ELEC ELECTRIC STARTING SYSTEM C0NTINUITY INCORRECT 5.Main switch Refer to “CHECKING THE SWITCHES”. CORRECT Replace the main switch. INCORRECT 6.Engine stop switch Refer to “CHECKING THE SWITCHES”. CORRECT Replace the handlebar switch (left). INCORRECT 7.Start switch Refer to “CHECKING THE SWITCHES”. CORRECT Replace the handlebar switch (left).

  • Page 326: Starter Motor

    – ELEC ELECTRIC STARTING SYSTEM STARTER MOTOR Order Job name/Part name Q’ty Remarks Removing the starter motor Remove the parts in the order below. Starter motor lead Starter motor/O-ring Disassembling the starter motor Remove the parts in the order below. Bracket 1 Washer kit Bracket 2/bushing...

  • Page 327: Checking The Starter Motor

    – ELEC ELECTRIC STARTING SYSTEM CHECKING THE STARTER MOTOR 1.Check: Commutator Dirty → Clean it with #600 grit sandpaper. 2.Measure: Commutator diameter a Out of specification → Replace the starter motor. Outside diameter: 28 mm (1.10 in) <Wear limit:> 27 mm (1.06 in) 3.Measure: Mica undercut b Out of specification →...

  • Page 328: Assembling The Starter Motor

    – ELEC ELECTRIC STARTING SYSTEM 5.Measure: Brush length a (each) Out of specification → Replace the brush holder set. Brush length: 12.5 mm (0.49 in) <Wear limit:> 5 mm (0.20 in) 6.Measure: Brush spring force Fatigue/out of specification → Replace the brush holder set.

  • Page 329: Charging System

    – ELEC CHARGING SYSTEM EB804000 CHARGING SYSTEM CIRCUIT DIAGRAM 9 - 22...

  • Page 330: Troubleshooting

    – ELEC CHARGING SYSTEM EB804010 TROUBLESHOOTING IF THE BATTERY IS NOT CHARGED: Procedure Check: 1.Fuse (main) 4.Charging coil resistance 2.Battery 5.Wiring connections 3.Charging voltage (the entire charging system) NOTE: Inductive self-powered tachometer: Remove following part(s) before P/N. YU-8036-B troubleshooting: Engine tachometer: 1)Seat P/N.
  • Page 331 – ELEC CHARGING SYSTEM Start the engine and accelerate to about 5,000 r/min. MEETS SPECIFICATION Charging voltage: 14 V at 5,000 r/min NOTE: Use a fully charged battery. The charging circuit is not faulty. OUT OF SPECIFICATION EB804012 4.Charging coil resistance Disconnect the AC magneto coupler from the wire harness.

  • Page 332: Circuit Diagram

    – ELEC LIGHTING SYSTEM EB805000 LIGHTING SYSTEM CIRCUIT DIAGRAM 9 - 25...

  • Page 333: Troubleshooting

    – ELEC LIGHTING SYSTEM EB805010 TROUBLESHOOTING IF THE HEADLIGHT AND/OR TAILLIGHT FAIL TO COME ON: Procedure Check: 4.Light switch 1.Fuses (main, headlight) 5.Wiring connections 2.Battery (the entire lighting system) 3.Main switch NOTE: Pocket tester: Remove following part(s) before P/N. YU-03112-C, 90890-03112 troubleshooting: 1)Seat 2)Front carrier...
  • Page 334 – ELEC LIGHTING SYSTEM C0NTINUITY INCORRECT 3.Main switch Refer to “CHECKING THE SWITCHES”. CORRECT Replace the main switch. INCORRECT 4.Light switch Refer to “CHECKING THE SWITCHES”. Light switch is faulty, replace the handlebar CORRECT switch (left). EB805013 5.Wiring connections POOR CONNECTION Check the connections of the entire lighting system.

  • Page 335: Checking The Lighting System

    – ELEC LIGHTING SYSTEM EB805020 CHECKING THE LIGHTING SYSTEM 1.If the headlights fail to come on: NO CONTINUITY 1.Bulb and bulb socket Check the bulb and bulb socket for continuity. Replace the bulb and/or bulb socket. CONTINUITY 2.Voltage Connect the pocket tester (DC 20 V) to the headlight couplers.
  • Page 336 – ELEC LIGHTING SYSTEM EB805021 2.If the taillight fails to come on: NO CONTINUITY 1.Bulb and bulb socket Check the bulb and bulb socket for continuity. Replace the bulb and/or bulb socket. CONTINUITY 2.Voltage Connect the pocket tester (20 V) to the bulb socket coupler.
  • Page 337 – ELEC LIGHTING SYSTEM EB805021 3.If the speedometer light fails to come on: NO CONTINUITY 1.Bulb and bulb socket Check the bulb and bulb socket for continuity. Replace the bulb and/or bulb socket. CONTINUITY 2.Voltage Connect the pocket tester (20 V) to the bulb socket coupler.
  • Page 338 – ELEC LIGHTING SYSTEM 9 - 31...

  • Page 339: Signal System

    – ELEC SIGNAL SYSTEM EB806000 SIGNAL SYSTEM CIRCUIT DIAGRAM 9 - 32...
  • Page 340 – ELEC SIGNAL SYSTEM 3 Main switch 4 Battery 5 Main fuse 8 CDI unit A Reverse switch B Neutral switch F Coolant temperature warning light G Four-wheel drive indicator light H Thermo switch (cylinder head) I Four-wheel drive fuse K Gear motor N Diode O Ignition fuse...

  • Page 341: Troubleshooting

    – ELEC SIGNAL SYSTEM EB806010 TROUBLESHOOTING IF THE BRAKE LIGHT AND/OR AN INDICATOR LIGHT FAILS TO COME ON: Procedure Check: 1.Fuses (main, four-wheel drive, ignition, signaling system) 2.Battery 3.Main switch 4.Wiring connections (the entire signal system) NOTE: Pocket tester: Remove following part(s) before...
  • Page 342 – ELEC SIGNAL SYSTEM C0NTINUITY INCORRECT 3.Main switch Refer to “CHECKING THE SWITCHES”. CORRECT Replace the main switch. EB806011 POOR CONNECTION 4.Wiring connections Check the connections of the entire signal system. Refer to “CIRCUIT DIAGRAM”. Properly connect the signal system. CORRECT Check the condition of each of the signal system’s circuits.

  • Page 343: Checking The Signal System

    – ELEC SIGNAL SYSTEM CHECKING THE SIGNAL SYSTEM 1.If the brake light fails to come on: 1.Bulb and bulb socket NO CONTINUITY Check the bulb and bulb socket for continuity. CONTINUITY Replace the bulb and/or bulb socket. NO CONTINUITY 2.Brake light switches Refer to “CHECKING THE SWITCHES”.
  • Page 344 – ELEC SIGNAL SYSTEM EB806024 2.If the neutral indicator light fails to come on: 1.Bulb and bulb socket NO CONTINUITY Check the bulb and bulb socket for continuity. CONTINUITY Replace the bulb and/or bulb socket. NO CONTINUITY 2.Neutral switch Refer to “CHECKING THE SWITCHES”. CONTINUITY Replace the neutral switch.
  • Page 345 – ELEC SIGNAL SYSTEM 3.If the reverse indicator light fails to come on: 1.Bulb and bulb socket NO CONTINUITY Check the bulb and bulb socket for continuity. CONTINUITY Replace the bulb and/or bulb socket. NO CONTINUITY 2.Reverse switch Refer to “CHECKING THE SWITCHES”. CONTINUITY Replace the reverse switch.
  • Page 346 – ELEC SIGNAL SYSTEM 4.If the coolant temperature warning light does not come on: Check that the light comes on when the main switch is set to “ON”. Check that the light comes on when the coolant temperature is 120 ± 3 °C (248 ± 5.4 °F) or higher and that the light remains on when the coolant temperature drops to 113 °C (235.4 °F).
  • Page 347 – ELEC SIGNAL SYSTEM C0NTINUITY WARNING Handle the thermo switch (cylinder head) with special care. Never subject it to a strong shock or allow it to be dropped. Should it be dropped, it BAD CONDITION must be replaced. Thermo switch (cylinder head): 8 Nm (0.8 m •...
  • Page 348 – ELEC SIGNAL SYSTEM C0NTINUITY 4.Diode Remove the diode from the coupler. Connect the pocket tester (Ω × 1) to the diode terminals as shown. Check the diode for continuity as follows. Tester (+) lead → NOTE: Blue/Black terminal 1 When you switch the tester’s positive and Continuity Tester (–) lead →...
  • Page 349 – ELEC SIGNAL SYSTEM 5.If the four-wheel drive indicator light fails to come on: 1.Bulb and bulb socket NO CONTINUITY Check the bulb and bulb socket for continuity. CONTINUITY Replace the bulb and/or bulb socket. 2.Voltage Connect the pocket tester (DC 20 V) to the bulb socket lead.

  • Page 350: Cooling System

    – ELEC COOLING SYSTEM COOLING SYSTEM CIRCUIT DIAGRAM 9 - 43...

  • Page 351: Troubleshooting

    – ELEC COOLING SYSTEM TROUBLESHOOTING IF THE FAN MOTOR DOES NOT MOVE: Procedure Check: 1.Fuse (main) 6.Thermo switch (radiator) 2.Battery 7.Wiring connections (the entire cooling system) 3.Main switch 4.Fan motor 5.Circuit breaker (fan motor) NOTE: Pocket tester: Remove following part(s) before P/N.
  • Page 352 – ELEC COOLING SYSTEM C0NTINUITY 4.Fan motor Disconnect the fan motor coupler. Connect the battery (12 V) as shown. Battery (+) lead → Blue terminal 1 Battery (–) lead → Black terminal 2 DOES NOT TURN Replace the fan motor. Check the operation of the fan motor.
  • Page 353 – ELEC COOLING SYSTEM C0NTINUITY 6.Thermo switch (radiator) Remove the thermo switch (radiator) from the radiator. Connect the pocket tester (Ω × 10) to the thermo switch (radiator) 1. Immerse the thermo switch (radiator) in coolant 2. Check the thermo switch (radiator) for continuity.
  • Page 354 – ELEC COOLING SYSTEM C0NTINUITY EB803028 POOR CONNECTION 7.Wiring connections Check the connections of the entire starting system. Refer to “CIRCUIT DIAGRAM”. Properly connect the cooling system. CORRECT This circuit is not faulty. 9 - 47...

  • Page 355: 2Wd/4Wd Selecting System

    – ELEC 2WD/4WD SELECTING SYSTEM 2WD/4WD SELECTING SYSTEM CIRCUIT DIAGRAM 9 - 48...

  • Page 356: Troubleshooting

    – ELEC 2WD/4WD SELECTING SYSTEM EB803020 TROUBLESHOOTING IF THE GEAR MOTOR FAILS TO OPERATE: Procedure Check: 1.Fuses (main, four-wheel drive) 4.On-command four-wheel drive switch 2.Battery 5.Gear motor 3.Main switch 6.Wiring connections (the entire 2WD/4WD selecting system) NOTE: Pocket tester: Remove following part(s) before...
  • Page 357 – ELEC 2WD/4WD SELECTING SYSTEM C0NTINUITY INCORRECT 4.On-command four-wheel drive switch Refer to “CHECKING THE SWITCHES”. CORRECT Replace the on-command four-wheel drive switch. 5.Gear motor Check that the shift fork sliding gear is in the 2WD position. Disconnect the gear motor coupler. Remove the gear motor from the differen- tial gear case.
  • Page 358 – ELEC 2WD/4WD SELECTING SYSTEM EB803028 POOR CONNECTION 6.Wiring connections Check the connections of the entire 2WD/ 4WD selecting system. Refer to “CIRCUIT DIAGRAM”. Properly connect the 2WD/4WD selecting system. CORRECT Replace the CDI unit. 9 - 51...

  • Page 359: Starting Failure/Hard Starting

    TRBL STARTING FAILURE/HARD STARTING SHTG TROUBLESHOOTING NOTE: The following troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to troubleshooting. Refer to the relative procedure in this manual for checking, adjusting and replacing of parts. STARTING FAILURE/HARD STARTING FUEL SYSTEM Fuel tank...

  • Page 360: Compression System

    TRBL STARTING FAILURE/HARD STARTING/POOR IDLE SPEED SHTG PERFORMANCE/POOR MEDIUM AND HIGH-SPEED PERFORMANCE COMPRESSION SYSTEM Cylinder and cylinder head Valve, camshaft and crankshaft Loose spark plug Improperly sealed valve Loose cylinder head or cylinder Improperly contacted valve and valve seat Broken cylinder head gasket Improper valve timing Broken cylinder gasket Broken valve spring...

  • Page 361: Faulty Drive Train

    TRBL FAULTY DRIVE TRAIN SHTG FAULTY DRIVE TRAIN The following conditions may indicate damaged shaft drive components: Symptoms Possible Causes 1.A pronounced hesitation or “jerky” movement A.Bearing damage. during acceleration, deceleration, or sustained speed. (This must not be confused with B.Improper gear lash.

  • Page 362: Faulty Gear Shifting

    TRBL FAULTY GEAR SHIFTING/ FAULTY CLUTCH PERFORMANCE SHTG FAULTY GEAR SHIFTING HARD SHIFTING Refer to “CLUTCH SLIPPING/DRAGGING-CLUTCH DRAGGING”. SHIFT LEVER DOES NOT MOVE Shift shaft Transmission Bent shift shaft Seized transmission gear Shift cam, shift fork Jammed impurities Groove jammed with impurities Incorrectly assembled transmission Seized shift fork Shift guide...

  • Page 363: Poor Speed Performance

    TRBL FAULTY CLUTCH PERFORMANCE/ OVERHEATING/FAULTY BRAKE SHTG POOR SPEED PERFORMANCE V-belt Primary sliding sheave Oil or grease on the V-belt Worn primary sliding sheave Primary pulley weight Secondary fixed sheave Faulty operation Worn secondary fixed sheave Worn primary pulley weight Secondary sliding sheave Primary fixed sheave Worn secondary sliding sheave...

  • Page 364: Shock Absorber Malfunction

    TRBL SHOCK ABSORBER MALFUNCTION/UNSTABLE HANDLING/LIGHTING SYSTEM SHTG SHOCK ABSORBER MALFUNCTION MALFUNCTION Bent or damaged damper rod Damaged oil seal lip Fatigued shock absorber spring UNSTABLE HANDLING UNSTABLE HANDLING Handlebar Wheels Improperly installed or bent Deformed wheel Steering Loose bearing Incorrect toe-in Bent or loose wheel axle Bent steering stem Excessive wheel runout...
  • Page 365 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U.S.A.
  • Page 366 YFM400FAR WIRING DIAGRAM 1 A.C. magneto 2 Rectifier/regulator 3 Main switch Sb G/W G/W Sb Br/W R/B Sb Br/W R/B L/W 4 Battery W/R W/G (BLACK) (BLACK) (BLACK) (BLACK) 5 Main fuse SUB-WIRE SUB-WIRE SUB-WIRE (BLACK) (BLACK) (BLACK) WIRE HARNESS...
  • Page 367 YFM350FAS SUPPLEMENTARY SERVICE MANUAL LIT-11616-17-32 5UH-F8197-10...
  • Page 368 This Supplementary Service Manual has been prepared to introduce new service and data for the YFM350FAS. For complete service information procedures it is necessary to use this Supplemen- tary Service Manual together with the following manual. YFM400FAR SERVICE MANUAL: LIT-11616-16-02 (5TE-F8197-10) YFM350FAS SUPPLEMENTARY SERVICE MANUAL ©2003 by Yamaha Motor Corporation, U.S.A.
  • Page 369 EB001000 NOTICE This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha machine has a basic understanding of the mechanical ideas and the procedures of machine repair.
  • Page 370 EB002000 HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”) 1st title 1: This is the title of the chapter with its symbol in the upper right corner of each page. 2nd title 2: This title indicates the section of the chapter and only appears on the first page of each section.
  • Page 371 EB003000 ILLUSTRATED SYMBOLS Illustrated symbols 1 to 0 are printed on the SPEC INFO top right of each page and indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Cooling system 6 Carburetion 7 Drive train COOL...
  • Page 372 CONTENTS GENERAL INFORMATION SPECIAL TOOLS ..................1 SPECIFICATIONS GENERAL SPECIFICATIONS ..............2 MAINTENANCE SPECIFICATIONS ............5 ENGINE ....................5 CHASSIS .................... 15 ELECTRICAL ..................19 LUBRICATION POINTS AND LUBRICANT TYPES ......21 ENGINE ....................21 OIL FLOW DIAGRAMS ................22 CABLE ROUTING ..................
  • Page 373 PRIMARY AND SECONDARY SHEAVES ..........54 PRIMARY SLIDING SHEAVE ............56 SECONDARY SHEAVE ..............57 ASSEMBLING THE PRIMARY SHEAVE ........... 58 ASSEMBLING THE SECONDARY SHEAVE ........58 CLUTCH ....................60 CRANKCASE ..................62 STARTER MOTOR, TIMING CHAIN AND OIL FILTER ..... 62 CRANKCASE ..................
  • Page 374 TROUBLESHOOTING FAULTY GEAR SHIFTING ..............104 HARD SHIFTING ................104 SHIFT LEVER DOES NOT MOVE ........... 104 JUMPS OUT OF GEAR ..............104 OVERHEATING ................... 104 OVERHEATING ................104 FAULTY BRAKE ................... 105 POOR BRAKING EFFECT ............... 105 YFM350FAS WIRING DIAGRAM...

  • Page 375: General Information

    SPECIAL TOOLS INFO GENERAL INFORMATION EB102001 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools; this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools may differ by shape and part number from country to country.

  • Page 376: Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Model code: 5UH1 Dimensions: Overall length 1,984 mm (78.1 in) Overall width 1,085 mm (42.7 in) Overall height 1,120 mm (44.1 in) Seat height 827 mm (32.6 in) Wheelbase 1,233 mm (48.5 in) Minimum ground clearance 245 mm (9.7 in) Minimum turning radius...
  • Page 377 SPEC GENERAL SPECIFICATIONS Item Standard Differential gear case oil Periodic oil change 0.35 L (0.31 Imp qt, 0.37 US qt) Total amount 0.40 L (0.35 Imp qt, 0.42 US qt) Air filter: Wet type element Fuel: Type Unleaded gasoline only Fuel tank capacity 13.5 L (2.97 Imp gal, 3.57 US gal) Fuel reserve amount...
  • Page 378 SPEC GENERAL SPECIFICATIONS Item Standard Tire pressure (cold tire): Maximum load* 210 kg (463 lb) Off-road riding front 22 ~ 28 kPa (0.22 ~ 0.28 kg/cm , 3.2 ~ 4.0 psi) rear 22 ~ 28 kPa (0.22 ~ 0.28 kg/cm , 3.2 ~ 4.0 psi) *Load in total weight of rider accessories Brakes:...

  • Page 379: Maintenance Specifications

    SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Cylinder head: Warp limit ---- 0.03 mm (0.0012 in) Cylinder: Bore size 82.970 ~ 83.020 mm 83.100 mm (3.2665 ~ 3.2685 in) (3.2720 in) Taper limit ---- 0.05 mm (0.0016 in) Out of round limit ---- 0.01 mm...
  • Page 380 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Cam chain: Cam chain type/No. of links 92RH2005/110 ---- Cam chain adjustment method Automatic ---- Rocker arm/rocker arm shaft: Rocker arm inside diameter 11.980 ~ 11.998 mm 12.058 mm (0.4717 ~ 0.4724 in) (0.4747 in) Rocker arm shaft outside diameter 11.961 ~ 11.971 mm 11.931 mm...
  • Page 381 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Stem runout limit ---- 0.01 mm (0.0004 in) Valve seat width 1.2 ~ 1.4 mm ---- (0.0472 ~ 0.0551 in) 1.2 ~ 1.4 mm ---- (0.0472 ~ 0.0551 in) Valve spring: Inner spring Free length 39.9 mm (1.57 in) 37.9 mm (1.49 in)
  • Page 382 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Outer spring Free length 43.27 mm (1.70 in) 41.27 mm (1.62 in) 43.27 mm (1.70 in) 41.27 mm (1.62 in) Set length (valve closed) 36.6 mm (1.44 in) ---- 36.6 mm (1.44 in) ---- Compressed pressure (installed) 235.4 ~ 251.1 N...
  • Page 383 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Piston rings: Top ring Type Barrel ---- Dimensions (B × T) 1.2 × 3.3 mm (0.05 × 0.13 in) ---- End gap (installed) 0.20 ~ 0.40 mm 0.65 mm (0.008 ~ 0.016 in) (0.0256 in) Side clearance (installed) 0.03 ~ 0.08 mm 0.13 mm...
  • Page 384 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Balancer: Balancer drive method Gear ---- Automatic centrifugal clutch: Clutch shoe thickness 1.5 mm (0.06 in) 1.0 mm (0.04 in) Clutch-in revolution 1,950 ~ 2,350 r/min ---- Clutch-stall revolution 3,350 ~ 3,850 r/min ---- Transmission: Main axle deflection limit ----...
  • Page 385 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Oil pump: Oil filter type Foam ---- Oil pump type Trochoid ---- Tip clearance 0.15 mm (0.006 in) 0.20 mm (0.008 in) Side clearance 0.04 ~ 0.09 mm ---- (0.002 ~ 0.004 in) Bypass valve setting pressure 78 ~ 118 kPa (0.78 ~ 1.18 kg/cm ---- 11.3 ~ 17.1 psi)
  • Page 386 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Cylinder head tightening sequence: – 12 –...
  • Page 387 SPEC MAINTENANCE SPECIFICATIONS Tightening torques Tightening torque Part Thread Part to be tightened Q’ty Remarks name size m·kg ft·lb Cylinder head (exhaust pipe) Stud bolt Cylinder head Bolt Bolt Camshaft bearing retainer Bolt Spark plug — Oil gallery bolt Bolt Cylinder Bolt Starter pulley...
  • Page 388 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part Thread Part to be tightened Q’ty Remarks name size m·kg ft·lb Pickup coil Bolt Starter one-way clutch Bolt Recoil starter Bolt Clutch carrier assembly 14.0 100 Stake. Clutch housing assembly Bolt Middle drive shaft end cover Bolt Torx Middle drive shaft bearing retainer...

  • Page 389: Chassis

    SPEC MAINTENANCE SPECIFICATIONS CHASSIS Item Standard Limit Steering system: Steering bearing type Ball and race bearing ---- Front suspension: Shock absorber travel 99 mm (3.90 in) ---- Spring free length 265 mm (10.43 in) ---- Spring fitting length 231.9 mm (9.13 in) ---- Spring rate (K1)
  • Page 390 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Front disc brake: Type Dual ---- Disc outside diameter × thickness 200.0 × 3.5 mm (7.87 × 0.14 in) ---- Pad thickness inner 4.5 mm (0.18 in) 1 mm (0.04 in) Pad thickness outer 4.5 mm (0.18 in) 1 mm (0.04 in)
  • Page 391 SPEC MAINTENANCE SPECIFICATIONS Tightening torques Tightening torque Part to be tightened Thread size Remarks m·kg ft·lb Engine bracket (front-upper) and frame Engine bracket (front-lower) and frame Engine bracket (front-upper) and engine Engine bracket (front-lower) and engine Engine and frame (rear-upper) Engine and frame (rear-lower) Frame and bearing retainer (steering stem holder bearing)
  • Page 392 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Remarks m·kg ft·lb Master cylinder and handlebar Footrest bracket and frame Front bumper and frame Front carrier and frame Front carrier and front bumper Rear carrier and frame Engine skid plate Differential gear oil filler bolt Differential gear oil drain bolt Differential gear case and bearing housing...

  • Page 393: Electrical

    Rotor rotation direction sensing coil ---- resistance/color Red – White/Blue C.D.I. unit model/manufacturer F8T40371/MITSUBISHI ---- Ignition coil: Model/manufacturer 2JN/YAMAHA ---- Minimum spark gap 6 mm (0.24 in) ---- 0.18 ~ 0.28 Ω at 20 °C (68 °F) Primary winding resistance ---- Secondary winding resistance 6.32 ~ 9.48 kΩ...
  • Page 394 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Brush overall length 12.0 mm (0.47 in) 4 mm (0.16 in) Spring force 7.65 ~ 10.01 N (780 ~ 1,021 g, ---- 27.53 ~ 36.04 oz) Commutator diameter 28 mm (1.10 in) 27 mm (1.06 in) Mica undercut 0.7 mm (0.03 in)

  • Page 395: Lubrication Points And Lubricant Types

    Gear coupling (middle driven shaft) Shift shaft Shift fork/guide bar Shift shaft stopper ball Shift lever collar ® Sealant (Quick Gasket Crankcase mating surface Yamaha Bond No.1215 ® Sealant (Quick Gasket Stator lead grommet (left side crankcase) Yamaha Bond No.1215 – 21 –...

  • Page 396: Oil Flow Diagrams

    SPEC OIL FLOW DIAGRAMS OIL FLOW DIAGRAMS 1 Camshaft 2 Crankshaft 3 Oil pump 4 Oil strainer – 22 –...
  • Page 397 SPEC OIL FLOW DIAGRAMS 1 Thermo unit 2 Oil pump 3 Oil filter È To oil cooler É From oil cooler – 23 –...
  • Page 398 SPEC OIL FLOW DIAGRAMS 1 Crankshaft 2 Oil filter – 24 –...
  • Page 399 SPEC OIL FLOW DIAGRAMS 1 Oil cooler 2 Oil cooler outlet pipe 3 Oil cooler inlet pipe È From engine É To engine È É – 25 –...

  • Page 400: Cable Routing

    SPEC CABLE ROUTING CABLE ROUTING 1 Rear brake switch lead 0 Main switch lead 2 Starter cable A Differential gear case breather hose 3 Rear brake lever cable B Gear motor lead 4 Front brake hose 5 On-command four-wheel drive switch lead 6 On-command four-wheel drive switch 7 Throttle cable 8 Handlebar switch lead...
  • Page 401 SPEC CABLE ROUTING È Fasten the on-command four-wheel drive switch lead behind the handlebar with a plastic band. É Fasten the starter cable, handlebar switch lead and rear brake switch lead behind the handlebar with a plastic band. Ê Fasten the handlebar switch lead and rear brake switch lead behind the handlebar with a plastic band. Ë...
  • Page 402 SPEC CABLE ROUTING 1 Headlight lead 2 Oil temperature warning light 3 Four-wheel drive indicator light 4 Reverse indicator light 5 Neutral indicator light 6 Indicator light/warning light couplers 7 Differential gear case breather hose 8 Wire harness È Fasten the wire harness with a plastic band. –...
  • Page 403 SPEC CABLE ROUTING 1 Fuel tank breather hose È Insert the fuel tank breather hose into the hole of 2 Starter cable the handlebar cover. 3 Cylinder head breather hose É Fasten the starter cable with a plastic band. 4 Rear brake lever cable Ê...
  • Page 404 SPEC CABLE ROUTING 1 Cylinder head breather hose B Rectifier/regulator 2 Fuel hose C Reverse switch lead 3 Final drive gear case breather hose D Neutral switch lead 4 Rear brake breather hose E Carburetor drain hose 5 Wire harness F Float chamber air vent hose 6 Starter motor lead 7 Negative battery lead...
  • Page 405 SPEC CABLE ROUTING È Fasten the wire harness with a plastic band. É Fasten the wire harness, starter motor lead, and negative battery lead with a plastic band. Ê Fasten the final drive gear case breather hose, rear brake breather hose, ground lead, and A.C. magneto lead with a plastic band.
  • Page 406 SPEC CABLE ROUTING 1 Throttle cable È Fasten the select lever control cable, rear brake 2 Spark plug lead light switch lead, and spark plug lead with a 3 Main switch plastic band. 4 Wire harness É Fasten the select lever control cable and rear 5 Select lever control cable brake light switch lead with a plastic band.
  • Page 407 SPEC CABLE ROUTING 1 Front brake hose 2 Throttle cable 3 Wire harness 4 Final drive gear case breather hose 5 Rear brake breather hose 6 Float chamber air vent hose 7 Starter cable 8 Rear brake lever cable – 33 –...

  • Page 408: Periodic Checks And Adjustments

    INTRODUCTION/ PERIODIC MAINTENANCE/LUBRICATION EB300000 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and a longer service life. The need for costly overhaul work will be greatly reduced. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale.
  • Page 409 • Correct if necessary. • Check operation. Lights and switches* • Adjust headlight beams. Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. NOTE: Recommended brake fluid: DOT 4 Brake fluid replacement: When disassembling the master cylinder or caliper, replace the brake fluid.

  • Page 410: Seat, Carriers, Fenders And Fuel Tank

    SEAT, CARRIERS, FENDERS AND FUEL TANK SEAT, CARRIERS, FENDERS AND FUEL TANK SEAT, FRONT CARRIER, FRONT BUMPER AND FRONT FENDER 34 Nm (3.4 m kg, 24 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 34 Nm (3.4 m kg, 24 ft •...
  • Page 411 SEAT, CARRIERS, FENDERS AND FUEL TANK 34 Nm (3.4 m kg, 24 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 34 Nm (3.4 m kg, 24 ft • • Order Job name/Part name Q’ty Remarks Indicator lights assembly coupler Disconnect.

  • Page 412: Fuel Tank

    SEAT, CARRIERS, FENDERS AND FUEL TANK FUEL TANK Order Job name/Part name Q’ty Remarks Removing the fuel tank Remove the parts in the order below. Seat and fuel tank cover Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”. Fuel hose NOTE: Before disconnecting the fuel hose, turn the fuel cock to “OFF”.

  • Page 413: Engine

    CHECKING THE OIL TEMPERATURE WARNING LIGHT ENGINE CHECKING THE OIL TEMPERATURE WARNING LIGHT 1 Oil temperature warning light Oil temperature warning light checking method Turn the main switch to “ON” and the engine stop switch to “ ”. Oil temperature warning Oil temperature warning light does not come on.

  • Page 414: Engine

    CYLINDER HEAD ENGINE CYLINDER HEAD Order Job name/Part name Q’ty Remarks Removing the cylinder head Remove the parts in the order below. Fuel tank/rubber cover Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”. Front fender Air duct assembly 1/air filter case Refer “ENGINE REMOVAL”...
  • Page 415 CYLINDER HEAD Order Job name/Part name Q’ty Remarks Cylinder head breather hose Camshaft sprocket cover/O-ring Tappet cover/O-ring Timing chain tensioner cap bolt Refer to “REMOVING THE CYLINDER Timing chain tensioner/gasket HEAD” “INSTALLING CYLINDER HEAD” in CHAPTER 4. Camshaft sprocket (Manual No.: 5TE-F8197-10) Cylinder head Cylinder head gasket Dowel pin...

  • Page 416: Camshaft, Rocker Arms And Valves

    CAMSHAFT, ROCKER ARMS AND VALVES CAMSHAFT, ROCKER ARMS AND VALVES Order Job name/Part name Q’ty Remarks Removing the camshaft, rocker Remove the parts in the order below. arms and valves Intake manifold/O-ring Oil gallery bolt Lock washer/bearing retainer Camshaft Refer to “REMOVING THE CAMSHAFT AND ROCKER ARMS”...
  • Page 417 CAMSHAFT, ROCKER ARMS AND VALVES Order Job name/Part name Q’ty Remarks Valve cotter Valve spring retainer Refer to “REMOVING THE VALVES Valve spring (outer) AND VALVE SPRINGS” and Valve spring (inner) “INSTALLING THE VALVES AND Valve (intake) VALVE SPRINGS” in CHAPTER 4. Valve (exhaust) (Manual No.: 5TE-F8197-10) Valve stem seal...

  • Page 418: Cylinder And Piston

    CYLINDER AND PISTON CYLINDER AND PISTON Order Job name/Part name Q’ty Remarks Removing the cylinder and piston Remove the parts in the order below. Cylinder head Refer to “CYLINDER HEAD”. Cylinder/O-ring Refer to “INSTALLING THE CYLINDER” in CHAPTER 4. (Manual No.: 5TE-F8197-10) Cylinder gasket Dowel pin Dowel pin/O-ring...

  • Page 419: Recoil Starter And A.c. Magneto

    RECOIL STARTER AND A.C. MAGNETO RECOIL STARTER AND A.C. MAGNETO Order Job name/Part name Q’ty Remarks Removing the A.C. magneto Remove the parts in the order below. Engine oil Drain. Refer to “CHANGING THE ENGINE OIL” in CHAPTER 3. (Manual No.: 5TE-F8197-10) Seat and fuel tank cover Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”.
  • Page 420 RECOIL STARTER AND A.C. MAGNETO Order Job name/Part name Q’ty Remarks Lead holder Pickup coil Stator assembly Starter idle gear shaft Starter idle gear Rotor Refer to “REMOVING THE A.C. MAGNETO” and “INSTALLING THE Starter wheel gear A.C. MAGNETO” in CHAPTER 4. Woodruff key (Manual No.: 5TE-F8197-10).

  • Page 421: Balancer Gears And Oil Pump

    BALANCER GEARS AND OIL PUMP BALANCER GEARS AND OIL PUMP Order Job name/Part name Q’ty Remarks Removing the balancer gears and oil Remove the parts in the order below. pump Starter wheel gear Refer to “RECOIL STARTER AND A.C. MAGNETO”. Plate Nut/lock washer Balancer driven gear...
  • Page 422 BALANCER GEARS AND OIL PUMP Order Job name/Part name Q’ty Remarks Balancer drive gear Spring Oil pump assembly/gasket For installation, reverse the removal procedure. – 48 –...

  • Page 423: Oil Pump

    BALANCER GEARS AND OIL PUMP OIL PUMP 5 Nm (0.5 m kg, 3.6 ft • • Order Job name/Part name Q’ty Remarks Disassembling the oil pump Remove the parts in the order below. Rotor cover Oil pump driven gear Inner rotor Outer rotor Oil pump housing For assembly, reverse the disassembly...

  • Page 424: Removing The Balancer Drive Gear And Balancer Driven Gear

    BALANCER GEARS AND OIL PUMP REMOVING THE BALANCER DRIVE GEAR AND BALANCER DRIVEN GEAR 1.Straighten the lock washer tabs. 2.Loosen: Balancer driven gear nut 1 NOTE: Place an aluminum plate 2 between the teeth of the balancer drive gear 3 and balancer driven gear 4.

  • Page 425: Installing The Balancer Drive Gear And

    BALANCER GEARS AND OIL PUMP INSTALLING THE BALANCER DRIVE GEAR AND BALANCER DRIVEN GEAR 1.Install: Spring Balancer drive gear (onto the buffer boss) NOTE: Align the punch mark a on the balancer drive gear with the keyway b on the crankshaft. 2.Install: Plate NOTE:...

  • Page 426: Oil Cooler

    OIL COOLER OIL COOLER 7 Nm (0.7 m kg, 5.1 ft • • 6 Nm (0.6 m kg, 4.3 ft • • 35 Nm (3.5 m kg, 25 ft • • 21 Nm (2.1 m kg, 15 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 427 OIL COOLER 7 Nm (0.7 m kg, 5.1 ft • • 6 Nm (0.6 m kg, 4.3 ft • • 35 Nm (3.5 m kg, 25 ft • • 21 Nm (2.1 m kg, 15 ft • • 7 Nm (0.7 m kg, 5.1 ft •...

  • Page 428: Primary And Secondary Sheaves

    PRIMARY AND SECONDARY SHEAVES PRIMARY AND SECONDARY SHEAVES 10 Nm (1.0 m kg, 7.2 ft • • 100 Nm (10.0 m kg, 72 ft • • 100 Nm (10.0 m kg, 72 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 429 PRIMARY AND SECONDARY SHEAVES 10 Nm (1.0 m kg, 7.2 ft • • 100 Nm (10.0 m kg, 72 ft • • 100 Nm (10.0 m kg, 72 ft • • 10 Nm (1.0 m kg, 7.2 ft • • (14) 10 Nm (1.0 m kg, 7.2 ft...

  • Page 430: Primary Sliding Sheave

    PRIMARY AND SECONDARY SHEAVES PRIMARY SLIDING SHEAVE Order Job name/Part name Q’ty Remarks Disassembling the primary sliding Remove the parts in the order below. sheave Primary sliding sheave cap Primary pulley slider Spacer Primary pulley cam Refer to “ASSEMBLING THE PRIMARY Primary pulley weight SHEAVE”.

  • Page 431: Secondary Sheave

    PRIMARY AND SECONDARY SHEAVES SECONDARY SHEAVE Order Job name/Part name Q’ty Remarks Disassembling the secondary Remove the parts in the order below. sheave Spring seat Refer to “DISASSEMBLING THE Compression spring SECONDARY SHEAVE” in Spring seat CHAPTER 4. (Manual No.: 5TE-F8197-10) Guide pin Refer to “ASSEMBLING THE Secondary sliding sheave...

  • Page 432: Assembling The Secondary Sheave

    NOTE: Remove any excess grease. 2.Install: Weights 1 NOTE: Apply Yamaha Grizzly grease (90 g) to the whole outer surface of the weights and install. Apply Yamaha Grizzly grease to the inner surface of the collar. Apply Yamaha Grizzly grease to the inner surface of the primary sliding sheave.
  • Page 433 PRIMARY AND SECONDARY SHEAVES 3.Install: Guide pins 1 4.Apply: ® BEL-RAY assembly lube (to all guide pin sliding grooves 1, and O-rings 2 5.Install: Spring seat Compression spring Spring seat ***************************************************** Installing steps: Attach the sheave fixed block, locknut wrench and sheave spring compressor to the secondary sheave assembly.

  • Page 434: Clutch

    CLUTCH CLUTCH Order Job name/Part name Q’ty Remarks Removing the clutch Remove the parts in the order below. Primary and secondary sheaves Refer to “PRIMARY AND SECONDARY SHEAVES”. Clutch housing assembly Refer to “REMOVING THE CLUTCH” Gasket and “INSTALLING THE CLUTCH” in CHAPTER 4.
  • Page 435 CLUTCH Order Job name/Part name Q’ty Remarks Disassembling the clutch housing Remove the parts in the order below. Oil seal Circlip Bearing housing Circlip Bearing Circlip Bearing Clutch housing For assembly, reverse the disassembly procedure. – 61 –...

  • Page 436: Crankcase

    CRANKCASE CRANKCASE STARTER MOTOR, TIMING CHAIN AND OIL FILTER 10 Nm (1.0 m kg, 7.2 ft • • 25 Nm (2.5 m kg, 18 ft • • 17 Nm (1.7 m kg, 12 ft • • 20 Nm (2.0 m kg, 14 ft •...
  • Page 437 CRANKCASE 10 Nm (1.0 m kg, 7.2 ft • • 25 Nm (2.5 m kg, 18 ft • • 17 Nm (1.7 m kg, 12 ft • • 20 Nm (2.0 m kg, 14 ft • • 10 Nm (1.0 m kg, 7.2 ft •...

  • Page 438: Crankcase

    CRANKCASE CRANKCASE 14 Nm (1.4 m kg, 10 ft • • 20 Nm (2.0 m kg, 14 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • (12) 10 Nm (1.0 m kg, 7.2 ft •...

  • Page 439: Crankcase Bearings

    CRANKCASE CRANKCASE BEARINGS Order Job name/Part name Q’ty Remarks Removing the crankcase bearings Remove the parts in the order below. Crankshaft and balancer Refer to “CRANKSHAFT”. Transmission Refer to “TRANSMISSION”. Middle drive/driven shaft Refer to “MIDDLE GEAR”. O-ring/collar Oil seal Bearing retainer Bearing For installation, reverse the removal...

  • Page 440: Separating The Crankcase

    Sealant (Quick Gasket (to the mating surfaces of both case halves) ® Sealant (Quick Gasket P/N. ACC-11001-05-01 Yamaha bond No. 1215: P/N. 90890-85505 2.Install: Dowel pins 2 3.Fit the right crankcase onto the left case. Tap lightly on the case with a soft hammer.
  • Page 441 CRANKCASE È 4.Tighten: Crankcase bolts 1 20 Nm (2.0 m • kg, 14 ft • lb) (follow the proper tightening sequence) Crankcase bolts 2 10 Nm (1.0 m • kg, 7.2 ft • lb) (follow the proper tightening sequence) È Right crankcase É...

  • Page 442: Crankshaft

    CRANKSHAFT CRANKSHAFT 4 Nm (0.4 m kg, 2.9 ft • • Order Job name/Part name Q’ty Remarks Removing the crankshaft Remove the parts in the order below. Crankcase separation Refer to “CRANKCASE”. Oil strainer Balancer Refer to “REMOVING THE CRANK- SHAFT”...

  • Page 443: Removing The Crankshaft

    CRANKSHAFT REMOVING THE CRANKSHAFT 1.Remove: Crankshaft seal 1 NOTE: Mark a note of the position of each crankshaft seal so that they can be installed in the correct place and in the correct direction. 2.Remove: Crankshaft Use a crankcase separating tool 1. Crankcase separating tool: P/N.

  • Page 444: Transmission

    TRANSMISSION TRANSMISSION Order Job name/Part name Q’ty Remarks Removing the transmission Remove the parts in the order below. Crankcase separation Refer to “CRANKCASE”. Driven sprocket Chain Secondary shaft Guide bar Shift fork Clutch dog Drive axle assembly Shift shaft stopper Shift shaft For installation, reverse the removal procedure.

  • Page 445: Installing The Transmission

    TRANSMISSION INSTALLING THE TRANSMISSION 1.Install: Shift shaft 1 Drive axle assembly 2 Clutch dog 3 Shift fork 4 Guide bar 5 NOTE: Install the shift fork with the “L” mark facing towards the left side of the crankcase. Be sure that the shift fork guide pin is properly seated in the shift shaft groove.

  • Page 446: Middle Gear

    MIDDLE GEAR MIDDLE GEAR MIDDLE DRIVE SHAFT Order Job name/Part name Q’ty Remarks Removing the middle drive shaft Remove the parts in the order below. Crankcase separation Refer to “CRANKCASE”. Bearing housing assembly Middle driven gear Refer to “REMOVING THE MIDDLE DRIVE SHAFT”...

  • Page 447: Middle Driven Shaft

    MIDDLE GEAR MIDDLE DRIVEN SHAFT Order Job name/Part name Q’ty Remarks Removing the middle driven shaft Remove the parts in the order below. Crankcase separation Refer to “CRANKCASE”. Circlip Refer to “REMOVING THE MIDDLE Bearing DRIVEN SHAFT” and “INSTALLING THE Universal joint MIDDLE DRIVEN SHAFT”...
  • Page 448 MIDDLE GEAR Order Job name/Part name Q’ty Remarks Front drive shaft coupling Bearing retainer Middle driven shaft For installation, reverse the removal procedure. – 74 –...

  • Page 449: Selecting The Middle Drive And Driven Gear Shims

    MIDDLE GEAR SELECTING THE MIDDLE DRIVE AND DRIVEN GEAR SHIMS When the drive and driven gear, bearing housing assembly and/or crankcase are replaced, be sure to adjust the gear shims. 1.Select: Middle drive gear shim 1 Middle driven gear shim 2 ***************************************************** Selection steps: Position middle drive and driven gear by...
  • Page 450 MIDDLE GEAR Example: 1) If the bearing housing is marked “–2”, ..a is 4.48. 2) b is 15.0 3) c is 55 4) If the crankcase (right) is marked “75.01”, ..d is 75.01. 5) Therefore, the shim thickness is 0.53 mm. A = 75.01 –...
  • Page 451 MIDDLE GEAR Where: e = a numeral (usually a decimal number) on the bearing housing is either added to or subtracted from “76”. f = a numeral (usually a decimal number) on the middle driven pinion gear is either added to or subtracted from “59”. g = a numeral (usually a decimal number) on the middle driven pinion gear is either added to or subtracted from...
  • Page 452 MIDDLE GEAR Shims are supplied in the following thickness. Middle drive pinion gear shim 0.10 0.40 0.15 0.50 Thickness (mm) 0.20 0.60 0.30 ***************************************************** – 78 –...

  • Page 453: Drive Train

    FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR DRIVE TRAIN FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR Order Job name/Part name Q’ty Remarks Removing the front constant Remove the parts in the order below. velocity joints and differential gear Engine skid plate (front) Refer to “SEAT, CARRIERS, FENDERS Front fender AND FUEL TANK”.
  • Page 454 FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR Order Job name/Part name Q’ty Remarks Gear motor coupler/four-wheel drive Disconnect. switch connector Differential gear case breather hose Disconnect. Differential gear Drive shaft Compression spring Coupling gear For installation, reverse the removal procedure.

  • Page 455: Measuring And Adjusting The Differential

    FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR MEASURING AND ADJUSTING THE DIFFERENTIAL GEAR LASH Measuring the differential gear lash 1.Secure the gear case in a vise or another supporting device. 2.Remove: Drain plug Gasket 3.Install: A bolt of the specified size 1 (into the drain plug hole) CAUTION: Finger tighten the bolt until it holds the ring...
  • Page 456 FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR Adjusting differential gear lash 1.Remove: Shim(s) (left) 1 Differential gear assembly 2 Shim(s) (right) 3 2.Adjust: Gear lash ***************************************************** Adjustment steps: Select the suitable shims using the following chart. Reduce shim Too little gear lash thickness.

  • Page 457: Rear Brake

    CHAS REAR BRAKE CHASSIS REAR BRAKE Order Job name/Part name Q’ty Remarks Removing the rear brake drum Remove the parts in the order below. Rear wheel (left) Refer to “FRONT AND REAR WHEELS” in CHAPTER 8. (Manual No.: 5TE-F8197-10) Brake drum cover Dust seal Brake drum Adjusting nut...
  • Page 458 CHAS REAR BRAKE Order Job name/Part name Q’ty Remarks Brake camshaft lever Refer to “REMOVING THE REAR BRAKE” in CHAPTER 8. Brake shoe wear indicator (Manual No.: 5TE-F8197-10) Brake camshaft Refer to “INSTALLING THE REAR O-ring BRAKE”. Dust seal Brake shoe plate For installation, reverse the removal procedure.

  • Page 459: Checking The Rear Brake

    CHAS REAR BRAKE CHECKING THE REAR BRAKE 1.Check: Brake drum 1 Cracks/damage → Replace. Splines 2 Wear/damage → Replace. 2.Check: Brake shoe plate 1 Pivot pins 2 Brake camshaft 3 Bends/cracks/damage → Replace. Dust seal 4 Wear/damage → Replace. 3.Check: Brake shoes 1 Brake shoe springs 2 Cracks/damage →...

  • Page 460: Installing The Rear Brake

    CHAS REAR BRAKE 5.Measure: Brake shoe lining thickness a Out of specification → Replace. 1 Measuring points NOTE: Replace the brake shoes as a set if either is worn to the wear limit. Brake shoe lining thickness limit: 2.0 mm (0.08 in) 6.Measure: Brake drum inside diameter a Out of specification →...
  • Page 461 4.Apply: Sealant 3 (onto the mating surfaces of swingarm) ® Sealant (Quick Gasket) P/N. ACC-11001-05-01 Yamaha bond No. 1215: P/N. 90890-85505 5.Install: Brake shoe plate 1 Bearing retainer 2 Brake shoes 3 Spring 4 Plate 5...
  • Page 462 CHAS REAR BRAKE 6.Check: Brake camshaft operation Unsmooth operation → Repair. 7.Lubricate: Dust seal 1 Lithium-soap-based grease 8.Connect: Rear brake lever cable 1 Rear brake pedal cable 2 9.Install: Springs 3 Pins 4 Adjusting nuts 5 Brake drum Brake drum cover 10.Install: Rear wheel hub (left) Rear wheel (left)

  • Page 463: Steering System

    CHAS STEERING SYSTEM STEERING SYSTEM STEERING STEM Order Job name/Part name Q’ty Remarks Removing the steering stem Remove the parts in the order below. Handlebar Refer to “HANDLEBAR” in CHAPTER 8. (Manual No.: 5TE-F8197-10) Seat Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”.
  • Page 464 CHAS STEERING SYSTEM Order Job name/Part name Q’ty Remarks Oil seal Bearing retainer Refer to “REMOVING THE BEARING RETAINER” and “INSTALLING THE BEARING RETAINER” in CHAPTER 8. (Manual No.: 5TE-F8197-10) Bearing Oil seal For installation, reverse the removal procedure. – 90 –...

  • Page 465: Front Arms And Front Shock Absorbers

    CHAS FRONT ARMS AND FRONT SHOCK ABSORBERS FRONT ARMS AND FRONT SHOCK ABSORBERS Order Job name/Part name Q’ty Remarks Removing the front arms and front Remove the parts in the order below. shock absorbers Engine skid plate Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”.
  • Page 466 CHAS FRONT ARMS AND FRONT SHOCK ABSORBERS Order Job name/Part name Q’ty Remarks Refer to “REMOVING THE FRONT Bolt/nut ARMS” and “INSTALLING THE FRONT Front lower arm/bushing ARMS AND FRONT SHOCK Bolt/nut ABSORBER” in CHAPTER 8. Front shock absorber (Manual No.: 5TE-F8197-10) Bolt/nut Front upper arm/bushing Circlip...

  • Page 467: Electrical

    – ELEC ELECTRIC STARTING SYSTEM ELECTRICAL ELECTRIC STARTING SYSTEM STARTER MOTOR Order Job name/Part name Q’ty Remarks Removing the starter motor Remove the parts in the order below. Starter motor lead Starter motor/O-ring For installation, reverse the removal procedure. Disassembling the starter motor Remove the parts in the order below.

  • Page 468: Assembling The Starter Motor

    – ELEC ELECTRIC STARTING SYSTEM ASSEMBLING THE STARTER MOTOR 1.Install: Brush holder set 1 NOTE: Align the projection a on the brush seat with the slot b on the bracket. 2.Install: Yoke Brackets NOTE: Align the match marks a on the yoke with the match marks b on the brackets.

  • Page 469: Signal System

    – ELEC SIGNAL SYSTEM EB806000 SIGNAL SYSTEM CIRCUIT DIAGRAM – 95 –...
  • Page 470 – ELEC SIGNAL SYSTEM 3 Main switch 4 Battery 5 Main fuse 8 CDI unit A Thermo unit B Reverse switch C Neutral switch G Oil temperature warning light H Four-wheel drive indicator light I Diode J Four-wheel drive fuse L Gear motor M Ignition fuse O Signaling system fuse...
  • Page 471 – ELEC SIGNAL SYSTEM 1.If the oil temperature warning light does not come on: Check that the light comes on when the start switch is pushed on. Check that the light comes on when the oil temperature is 145 °C (293 °F) or higher. NO CONTINUITY 1.Bulb and bulb socket Check the bulb and bulb socket for...
  • Page 472 – ELEC SIGNAL SYSTEM C0NTINUITY 4.Diode Remove the diode from the coupler. Connect the pocket tester (Ω × 1) to the diode terminals as shown. Check the diode for continuity as follows. NOTE: When you switch the tester’s positive and negative probes, the readings in the left chart Tester (+) lead →...

  • Page 473: Cooling System

    – ELEC COOLING SYSTEM COOLING SYSTEM CIRCUIT DIAGRAM – 99 –...

  • Page 474: Troubleshooting

    – ELEC COOLING SYSTEM TROUBLESHOOTING IF THE FAN MOTOR DOES NOT MOVE: Procedure Check: 1.Fuses (main, ignition) 7.Thermo unit 2.Battery 8.Wiring connections (the entire cooling system) 3.Main switch 4.Fan motor 5.Circuit breaker (fan motor) 6.Fan motor relay NOTE: Pocket tester: Remove following part(s)
  • Page 475 – ELEC COOLING SYSTEM C0NTINUITY 4.Fan motor Disconnect the fan motor coupler. Connect the battery (12 V) as shown. Battery (+) lead → Red terminal 1 Battery (–) lead → Black terminal 2 DOES NOT TURN Replace the fan motor. Check the operation of the fan motor.
  • Page 476 – ELEC COOLING SYSTEM C0NTINUITY 6.Fan motor relay Remove the fan motor relay from the wire harness. Connect the pocket tester (Ω × 1) and the battery (12 V) to the fan motor relay terminals. R/W R/B Tester (+) lead → Red/Black terminal 1 Tester (–) lead →...
  • Page 477 – ELEC COOLING SYSTEM C0NTINUITY EB803028 POOR CONNECTION 8.Wiring connections Check the connections of the entire starting system. Refer to “CIRCUIT DIAGRAM”. Properly connect the cooling system. CORRECT Replace the CDI unit. – 103 –...

  • Page 478: Troubleshooting

    TRBL FAULTY GEAR SHIFTING/ OVERHEATING SHTG TROUBLESHOOTING NOTE: The following troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to troubleshooting. Refer to the relative procedure in this manual for checking, adjusting and replacing of parts.

  • Page 479: Faulty Brake

    TRBL FAULTY BRAKE SHTG EBS00549 FAULTY BRAKE POOR BRAKING EFFECT Front disc brake Worn brake pads Worn disc Air in brake fluid Leaking brake fluid Faulty master cylinder kit cup Faulty caliper kit seal Loose union bolt Broken brake hose and pipe Oily or greasy disc/brake pads Improper brake fluid level Rear drum brake...
  • Page 480 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U.S.A.

  • Page 481: Yfm350Fas Wiring Diagram

    YFM350FAS WIRING DIAGRAM 1 A.C. magneto R/B L/W 2 Rectifier/regulator W/R W/G 3 Main switch (BLACK) (BLACK) (BLACK) 4 Battery 5 Main fuse 6 Starter relay 7 Starter motor W/G R R W/G W/R W/G W/L W/R 8 CDI unit 9 Ignition coil 0 Spark plug A Thermo unit...

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