Yamaha 4XV1-AE1 Manuals

Manuals and User Guides for Yamaha 4XV1-AE1. We have 1 Yamaha 4XV1-AE1 manual available for free PDF download: Service Manual

Yamaha 4XV1-AE1 Service Manual

Yamaha 4XV1-AE1 Service Manual (419 pages)

Brand: Yamaha | Category: Motorcycle | Size: 9.47 MB

Table of Contents

Chapter 2

3
- Manual Information
  3
- Specifications
  3
  - How to Use this Manual
    4
  - Symbols
    5
  - Chapter Titles
    6
  - Troubleshooting Trbl
    6
  - Table of Contents
    8
  - General Information
    8
Chapter 1

10
- General Information
  10
- Motorcycle Identification
  10
  - Vehicle Identification Number
    10
  - Model Code
    10
- Important Information
  11
  - Preparation for Removal and Disassembly
    11
  - Replacement Parts
    11
  - Gaskets, Oil Seals and O-Rings
    11
  - Using a Dynamometer
    12
  - Lock Washers/Plates and Cotter Pins
    12
  - Bearings and Coiil Seals
    12
  - Circlips
    12
- Checking the Connections
  13
- Special Tools
  14
  - Specifications
    19
  - General Specifications
    21
  - Engine Specifications
    22
  - Chassis Specifications
    31
  - Electrical Specifications
    35
  - Conversion Table
    38
  - General Tightening Torques
    38
  - Engine Tightening Torques
    39
  - Crankcase Tightening Sequence
    41
  - Chassis Tightening Torques
    42
  - Engine Lubrication Points and Lubricant Types
    43
  - Chassis Lubrication Points and Lubricant Types
    44
  - Oil Flow Diagrams
    45
  - Coolant Flow Diagrams
    49
  - Cable Routing
    53
  - Periodic Checks and Adjustments
    66
  - Introduction
    68
  - Periodic Maintenance and Lubrication Intervals
    68
Chapter 3

68
- Periodic Checks and Adjustments
  68
- Seats
  70
- Fuel Tank
  71
- Cowlings
  72
- Removal
  73
- Installation
  73
- Air Filter Case and Ignition Coil Plate
  74
- Removal
  75
- Installation
  75
- Engine
  76
- Adjusting the Valve Clearance
  76
- Valve Pad Selection Table
  80
  - Exhaust
    80
  - Intake
    80
  - Synchronizing the Carburetors
    81
  - Adjusting the Engine Idling Speed
    83
  - Adjusting the Throttle Cable Free Play
    85
  - Handlebar Side
    86
  - Checking the Spark Plugs
    87
  - Checking the Ignition Timing
    88
  - Measuring the Compression Pressure
    89
  - Checking the Engine Oil Level
    91
  - Changing the Engine Oil
    92
  - Adjusting the Clutch Cable Free Play
    95
  - Engine Side
    95
  - Checking the Carburetor Joints
    96
  - Cleaning the Air Filter Element
    96
  - Checking the Crankcase Breather Hose
    97
  - Checking the Fuel Hoses and Fuel Filter
    97
  - Checking the Crankcase Breather Hose
    98
  - Checking the Exhaust System
    98
  - Adjusting the Exup Cables
    99
  - Checking the Coolant Level
    100
  - Checking the Cooling System
    101
  - Changing the Coolant
    102
  - Adjusing the Front Brake
    105
  - Adjusting the Rear Brake
    105
  - Chassis
    105
  - Checking the Brake Fluid Level
    107
  - Adjusting the Rear Brake Light Switch
    108
  - Checking the Brake Pads
    108
  - Bleeding the Hydraulic Brake System
    109
  - Checking the Brake Hoses
    109
  - Adjusting the Drive Chain Slack
    111
  - Adjusting the Shift Pedal
    111
  - Checking and Adjusting the Steering Head
    113
  - Lubricating the Drive Chain
    113
  - Checking the Front Fork
    116
  - Adjusting the Front Fork Legs
    117
    
    Spring Preload
    117
    
    Compression Damping
    118
    
    Rebound Damping
    118
  - Adjusting the Rear Shock Absorber Assembly
    119
  - Checking the Tires
    121
  - Checking the Wheels
    123
  - Checking and Lubricating the Cables
    124
  - Lubricating the Levers and Pedals
    124
  - Lubricating the Rear Suspension
    124
  - Lubricating the Sidestand
    124
  - Checking and Charging the Battery
    125
  - Electrical System
    125
    
    First Aid in Case of Bodily Contact
    125
    
    Charging Method Using a Variable-Voltage Charger
    128
    
    Charging Method Using a Constant-Voltage Charger
    129
  - Checking the Fuses
    130
  - Replacing the Headlight Bulbs
    132
  - Adjusting the Headlight Beams
    133
- Overhauling the Engine
  135
Chapter 4

137
- Overhauling the Engine
  137
- Engine
  137
  - Installing the Engine
    143
  - Cam Shaft
    144
  - Removing the Camshafts
    145
    
    Removing the Camshafts
    147
    
    Checking the Camshafts
    148
    
    Checking the Timing Chain, Cam Shaft Sprockets and Timing Chain Guides
    149
    
    Checking the Timing Chain Tensioner
    150
    
    Installing the Cam Shafts
    151
  - Cylinder Head
    154
  - Removing the Cylinder Head
    154
    
    Checking the Cylinder Head
    155
    
    Removing the Cylinder Head
    155
    
    Installing the Cylinder Head
    156
    
    Valves and Valve Springs
    157
    
    Removing the Valves
    159
    
    Checking the Valves and Valve Guides
    160
    
    Checking the Valve Seats
    162
    
    Checking the Valve Springs
    164
    
    Checking the Valve Lifters
    165
    
    Installing the Valves
    165
  - Generator
    168
  - Installing the Generator
    169
  - Removing the Generator
    169
  - Pickup Coil
    171
  - Installing the Pickup Coil Rotor
    173
  - Removing the Pickup Coil Rotor
    173
  - Clutch
    175
  - Removing the Clutch
    177
    
    Checking the Friction Plates
    179
    
    Removing the Clutch
    179
    
    Chcking the Clutch Plates
    180
    
    Checking the Clutch Housing
    180
    
    Checking the Clutch Spring Plate
    180
    
    Checking the Clutch Boss
    181
    
    Checking the Pressure Plate
    181
    
    Checking the Pull Lever Shaft and Pull Rod
    181
  - Checking the Starter Clutch
    181
  - Installing the Clutch
    182
  - Shift Shaft
    185
    
    Checking the Shift Shaft
    186
    
    Checking the Stopper Lever
    186
    
    Installing the Shift Shaft
    186
  - Oil Pan and Oil Pump
    187
  - Removing the Oil Pan
    187
    
    Checking the Oil Pump
    190
    
    Removing the Oil Pan
    190
    
    Assembling the Oil Pump
    191
    
    Checking the Oil Delivery Pipe and Oil Pipe
    191
    
    Checking the Oil Strainer
    191
    
    Checking the Relief Valve
    191
    
    Installing the Oil Pan
    192
    
    Installing the Oil Pump
    192
    
    Installing the Oil Strainer
    192
  - Crankcase
    193
    
    Disassembling the Crankcase
    196
    
    Checking the Bearings and Oil Seals
    197
  - Checking the Sprockets and Chains
    197
    
    Cheking the Crankcase
    197
    
    Assembling the Crankcase
    198
  - Connecting Rods and Pistons
    200
  - Removing the Connecting Rods and Pistons
    200
    
    Removing the Connecting Rods and Pistons
    201
    
    Checking the Cylinders and Pistons
    202
    
    Checking the Piston Rings
    203
    
    Checking the Piston Pins
    204
  - Checking the Big End Bearings
    205
  - Installing the Pistons and Connecting Rods
    207
  - Removing the Crankshaft
    210
  - Checking the Crankshaft Journal Bearings
    211
    
    Removing the Crankshaft
    211
    
    Crankshaft Journal Bearing Color Code
    213
    
    Installing the Crankshaft
    214
  - Removing the Transmission
    215
    
    Checking the Shift Forks
    221
    
    Removing the Transmission
    221
    
    Checking the Shift Drum Assembly
    222
    
    Checking the Transmission
    222
  - Installing the Transmission
    223
  - Cooling System
    226
  - Radiator
    228
  - Checking the Radiator
    230
  - Installing the Radiator
    231
  - Oil Cooler
    232
  - Checking the Oil Cooler
    233
  - Installing the Oil Cooler
    233
  - Thermostat Assembly
    235
  - Assembling the Thermostat Assembly
    238
  - Checking the Thermostat
    238
  - Installing the Thermostat Assembly
    239
  - Water Pump
    240
  - Checking the Water Pump
    242
  - Disassembling the Water Pump
    242
  - Assembling the Water Pump
    243
  - Carburetors
    247
  - Checking the Carburetors
    254
  - Assembling the Carburetors
    256
  - Installing the Carburetors
    258
  - Measuring and Adjusting the Fuel Level
    259
  - Checking and Adjusting the Throttle Position Sensor
    260
  - Checking the Fuel Pump
    263
Chapter 7. Chassis

268
- Front Wheel and Brake Discs
  268
- Disassembling the Front Wheel
  269
  - Disassembling the Front Wheel
    270
  - Removing the Front Wheel
    270
  - Checking the Front Wheel
    271
  - Checking the Brake Discs
    272
  - Assembling the Front Wheel
    273
  - Adjusting the Front Wheel Static Balance
    274
  - Installing the Front Wheel
    274
  - Rear Wheel, Brake Disc, and Rear Wheel Sprocket
    277
  - Removing the Rear Wheel
    277
    
    Checking the Rear Wheel
    280
    
    Removing the Rear Wheel
    280
    
    Checking and Replacing the Rear Wheel Sprocket
    281
    
    Checking the Rear Wheel Drive Hub
    281
    
    Adjusting the Rear Wheel Static Balance
    282
    
    Installing the Rear Wheel
    282
  - Front and Rear Brakes
    283
    
    Replacing the Front Brake Pads
    285
    
    Replacing the Rear Brake Pads
    287
  - Disassembling the Front Brake Master Cylinder
    292
  - Disassembling the Rear Brake Master Cylinder
    294
    
    Checking the Front and Rear Brake Master Cylinder
    295
    
    Disassembling the Front Brake Master Cylinder
    295
    
    Disassembling the Rear Brake Master Cylinder
    295
  - Master Cylinders
    295
    
    Assembling and Installing the Front Brake Master Cylinder
    296
    
    Assembling the Rear Brake Master Cylinder
    298
  - Disassembling the Front Brake Calipers
    301
  - Disassembling the Rear Brake Caliper
    303
    
    Disassembling the Fornt Brake Calipers
    304
    
    Disassembling the Rear Brake Caliper
    305
    
    Checking the Front and Rear Brake Calipers
    306
    
    Assembling and Installing the Front Brake Calipers
    307
    
    Assembling and Installing the Rear Brake Caliper
    309
  - Front Fork
    311
  - Removing the Front Fork Legs
    311
    
    Disassembling the Front Fork Legs
    314
    
    Removing the Front Fork Legs
    314
    
    Checking the Front Fork Legs
    316
    
    Assembling the Front Fork Legs
    317
    
    Installing the Front Fork Legs
    322
  - Removing the Handlebars
    323
  - Checking the Handlebars
    325
    
    Removing the Handlebars
    325
    
    Installing the Handlebars
    326
  - Removing the Lower Bracket
    328
  - Steering Head
    328
    
    Checking the Steering Head
    330
    
    Removing the Lower Bracket
    330
    
    Installiing the Steering Head
    331
  - Rear Shock Absorber Assembly
    333
    
    Disposing of a Rear Shock Absorber and Gas Cylinder
    334
    
    Handling the Rear Shock Absorberband Gas Cylinder
    334
    
    Checking the Rear Shock Absorber Assembly and Gas Cylinder
    335
    
    Removing the Rear Shock Absorber Assembly
    335
  - Checking the Relay Arm and Connecting Arm
    336
  - Installing the Rear Shock Absorber Assembly
    336
  - Swingarm and Drive Chain
    337
  - Removing the Swingarm
    339
  - Checking the Swingarm
    340
  - Removing the Drive Chain
    340
  - Checking the Drive Chain
    341
  - Installing the Swingarm
    343
  - Electrical
    345
Chapter 8

347
- Electrical Components
  347
- Instrument Functions
  348
- Indicator Lights
  348
- Oil Level/Coolant Temperature Warning Light
  348
- Combination Meter
  349
  - Odometer and Trip Meters
    349
  - Clock
    350
  - Checking Switch Continuity
    351
  - Switches
    351
  - Checking the Switches
    352
  - Checking the Bulbs and Bulb Sockets
    354
  - Checking the Condition of the Bulbs
    354
  - Types of Bulbs
    354
  - Checking the Condition of the Bulb Sockets
    356
  - Checking the Leds
    356
  - Circuit Diagram
    357
  - Ignition System
    357
  - Troubleshooting
    358
  - Circuit Diagram
    362
  - Electric Starting System
    362
  - Starting Circuit Cutoff System Operation
    363
  - Troubleshooting
    364
  - Starter Motor
    368
    
    Checking the Starter Motor
    370
    
    Assembling the Starter Motor
    371
  - Charging System
    372
  - Circuit Diagram
    372
  - Circuit Diagram
    375
  - Lighting System
    375
  - Circuit Diagram
    381
  - Signaling System
    381
  - Checking the Signaling System
    384
  - Circuit Diagram
    390
  - Cooling System
    390
  - Circuit Diagram
    394
  - Fuel Pump System
    394
  - Fuel Pump Circuit Operation
    395
  - Circuit Diagram
    399
  - Exup System
    399
  - Self-Diagnosis
    403
  - Self-Diagnosis
    404
    
    Throttle Position Sensor
    404
    
    Exup
    405
    
    Fuel Level Indicator Light
    406
    
    Fuel Sender
    406
    
    Electrical Systems
    412
    
    Fuel System
    412
  - Troubleshooting
    412
  - Electrical Systems
    413
  - Faulty Gear Shifting
    413
  - Fuel System
    413
  - Incorrect Engine Idling Speed
    413
  - Jumps out of Gear
    413
  - Poor Medium-And-High-Speed Performance
    413
  - Shift Pedal Does Not Move
    413
  - Shifting Is Difficult
    413
  - Starting Problems
    413
  - Chassis
    414
  - Clutch Drags
    414
  - Clutch Slips
    414
  - Cooling System
    414
  - Electrical Systems
    414
  - Engine
    414
  - Faulty Clutch
    414
  - Fuel System
    414
  - Overcooling
    414
  - Overheating
    414
  - Starting Problems
    412
  - Faulty Front Fork Legs
    415
  - Poor Braking Performance
    415
  - Unstable Handling
    415
  - Faulty Lighting and Signaling Systems
    416
  - Wiring Diagram
    418

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