Yamaha YFM700RV 2009 Service Manual
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Yamaha YFM700RV 2009 Service Manual

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YFM700RV
SERVICE MANUAL
1S3-28197-E0

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Summary of Contents for Yamaha YFM700RV 2009

  • Page 1 YFM700RV SERVICE MANUAL 1S3-28197-E0...
  • Page 2 EBS00000 YFM700RV SERVICE MANUAL ©2005 by Yamaha Motor Co., Ltd. First edition, May 2005 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
  • Page 3 EBS00002 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 vehicle has a basic understanding of the mechanical ideas and the procedures of vehicle repair.
  • Page 4 EBS00004 HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual consists of chapters for the main categories of subjects. (See “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: General Information

    EBS00006 SYMBOLS The following symbols are not relevant to SPEC every vehicle. INFO Symbols 1 to 9 indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Cooling system 6 Fuel injection system 7 Chassis COOL 8 Electrical...

  • Page 6: Table Of Contents

    EBS00008 TABLE OF CONTENTS GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC CHECKS AND ADJUSTMENTS ENGINE COOLING SYSTEM COOL FUEL INJECTION SYSTEM CHASSIS CHAS – ELECTRICAL ELEC TROUBLESHOOTING TRBL SHTG...
  • Page 7 INFO CHAPTER 1 GENERAL INFORMATION VEHICLE IDENTIFICATION................1-1 VEHICLE IDENTIFICATION NUMBER .............1-1 MODEL LABEL..................1-1 FEATURES...................... 1-2 OUTLINE OF THE FI SYSTEM..............1-2 FI SYSTEM....................1-3 SELF-ADJUSTING PARKING BRAKE MECHANISM....... 1-4 IMPORTANT INFORMATION ................. 1-7 PREPARATION FOR REMOVAL AND DISASSEMBLY......1-7 REPLACEMENT PARTS................1-7 GASKETS, OIL SEALS AND O-RINGS ............

  • Page 8: General Information

    VEHICLE IDENTIFICATION INFO EBS00009 GENERAL INFORMATION VEHICLE IDENTIFICATION EBS00010 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the left side of the frame. EBS00011 MODEL LABEL The model label 1 is affixed to the air filter case cover. This information will be needed to order spare parts.

  • Page 9: Features

    FEATURES INFO EAS20170 FEATURES OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the opti- mum air-fuel ratio in accordance with the engine operating conditions and the atmospheric tempera- ture.

  • Page 10: Fi System

    FEATURES INFO FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at only 324 kPa (3.24 kg/cm , 46.1 psi). Accord- ingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the passage remains open.

  • Page 11: Self-Adjusting Parking Brake Mechanism

    FEATURES INFO SELF-ADJUSTING PARKING BRAKE MECHANISM Usually, for vehicles equipped with a parking brake that must be adjusted manually, it is necessary to adjust the adjusting bolt 5 to achieve the proper clearance between the brake caliper piston 7 and the adjusting bolt 5. This adjustment procedure is unnecessary for vehicles equipped with a self-adjusting parking brake mechanism.
  • Page 12 FEATURES INFO Parking Brake Operation 1 Parking brake arm 4 Adjusting bolt sleeve 2 Parking brake shaft 5 Brake caliper piston 3 Adjusting bolt 6 Brake pad When the parking brake is operated, the parking brake cable turns the parking brake arm 1. The rotation of the parking brake arm is changed to axial thrust in the parking brake shaft 2 and the adjusting bolt 3 is pushed against the adjusting bolt sleeve 4.
  • Page 13 FEATURES INFO Parking Brake Operation È É Ê 1 Brake caliper piston 3 Adjusting bolt 2 Nut 4 Adjusting bolt sleeve When the brake pedal is operated, the brake fluid pressure in the master cylinder increases and the brake caliper piston 1 and the nut 2 are pushed. When there is proper clearance between the brake caliper piston and the brake pad, no other parts move because the movement of the brake caliper piston and the nut is absorbed by the backlash of the threads of the nut and the adjusting bolt 3.

  • Page 14: Important Information

    5. Keep all parts away from any source of fire. EBS00014 REPLACEMENT PARTS 1. Use only genuine Yamaha parts for all replacements. Use oil and grease recom- mended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.

  • Page 15: Lock Washers/Plates And Cotter Pins

    IMPORTANT INFORMATION INFO EBS00016 LOCK WASHERS/PLATES AND COTTER PINS After removal, replace all lock washers/plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut. EBS00017 BEARINGS AND OIL SEALS Install bearings and oil seals so that the manu-...

  • Page 16: Checking The Connections

    IMPORTANT INFORMATION INFO EBS00019 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: • lead • coupler • connector 2. Check: • lead • coupler • connector Moisture → Dry with an air blower. Rust/stains →...

  • Page 17: Special Tools

    SPECIAL TOOLS INFO EBS00021 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 18 SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Adapter (M16) Adapter #13 90890-04130 YM-04059 This tool is used to install the crankshaft. Spacer (crankshaft installer) Pot spacer 90890-04081 YM-91044 This tool is used to install the crankshaft. Piston pin puller set Piston pin puller 90890-01304 YU-01304...
  • Page 19 SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Steering nut wrench Spanner wrench 90890-01443 YU-33975 This tool is needed to loosen and tighten the front shock absorber and rear shock absorber locknuts. Ball joint remover 90890-01474 YM-01474 This tool is used to remove or install the ball joints.
  • Page 20 SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Pocket tester Analog pocket tester 90890-03112 YU-03112-C This instrument is needed for checking the electrical system. Timing light Inductive clamp timing light 90890-03141 YU-03141 This tool is necessary for checking ignition timing. Pressure gauge 90890-03153 YU-03153...
  • Page 21 SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Middle driven shaft bearing driver Bearing driver (40 mm) 90890-04058 YM-04058 This tool is used to install the water pump seal. Mechanical seal installer Water pump seal installer 90890-04132 YM-33221-A This tool is used to install the water pump seal.
  • Page 22 SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Yamaha bond No. 1215 (Three bond No. 1215) 90890-85505 This bond is used on crankcase mating surfaces, etc. 1 - 15...

  • Page 23: Spec

    SPEC CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS ................ 2-1 ENGINE SPECIFICATIONS ................2-4 CHASSIS SPECIFICATIONS ................2-12 ELECTRICAL SPECIFICATIONS ..............2-14 TIGHTENING TORQUES ................2-16 ENGINE TIGHTENING TORQUES ............2-16 CHASSIS TIGHTENING TORQUES ............2-19 HOW TO USE THE CONVERSION TABLE..........2-22 GENERAL TIGHTENING TORQUE SPECIFICATIONS.......2-22 LUBRICATION POINTS AND LUBRICANT TYPES ........

  • Page 24: Specifications

    SPEC GENERAL SPECIFICATIONS EBS01001 SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Model code 1S31 (For Oceania) 1S32 (For CDN) 1S33 (For Europe) Dimensions Overall length 1,845 mm (72.6 in) Overall width 1,170 mm (46.1 in) Overall height 1,130 mm (44.5 in) Seat height 815 mm (32.1 in) Wheelbase 1,280 mm (50.4 in)
  • Page 25 SPEC GENERAL SPECIFICATIONS Item Standard Oil capacity Engine oil Periodic oil change 1.75 L (1.54 Imp qt, 1.85 US qt) With oil filter replacement 1.85 L (1.63 Imp qt, 1.96 US qt) Total amount 2.30 L (2.02 Imp qt, 2.43 US qt) Radiator capacity (including all routes) 1.61 L (1.42 Imp qt, 1.70 US qt) Air filter...
  • Page 26 SPEC GENERAL SPECIFICATIONS Item Standard Tire Type Tubeless AT21 × 7-10 Size front AT20 × 10-9 rear Manufacturer front DUNLOP rear DUNLOP Type front KT341 Radial rear KT345 Radial Tire pressure (cold tire) Maximum load* 100 kg (220 lb) Off-road riding front 27.5 kPa (0.28 kg/cm , 4.0 psi)

  • Page 27: Engine Specifications

    SPEC ENGINE SPECIFICATIONS EBS01002 ENGINE SPECIFICATIONS Item Standard Limit Cylinder head Maximum warpage ---- 0.03 mm (0.0012 in) Cylinder Bore 102.000 ~ 102.010 mm (4.0157 ~ 4.0161 in) 102.080 mm (4.0189 in) Measuring point 50.0 mm (1.97 in) ---- Out of round 0.05 mm (0.002 in) Camshaft...
  • Page 28 SPEC ENGINE SPECIFICATIONS Item Standard Limit Rocker arm/rocker arm shaft Rocker arm inside diameter 12.000 ~ 12.018 mm (0.4724 ~ 0.4731 in) ---- Shaft outside diameter 11.981 ~ 11.991 mm (0.4717 ~ 0.4721 in) ---- Arm-to-shaft clearance 0.009 ~ 0.037 mm (0.0004 ~ 0.0015 in) ---- Valve, valve seat, valve guide Valve clearance–intake (cold)
  • Page 29 SPEC ENGINE SPECIFICATIONS Item Standard Limit Valve stem runout ---- 0.01 mm (0.0004 in) Valve seat width Intake 1.0 ~ 1.2 mm (0.0394 ~ 0.0472 in) 1.6 mm (0.0630 in) Exhaust 1.0 ~ 1.2 mm (0.0394 ~ 0.0472 in) 1.6 mm (0.0630 in) Valve spring Free length...
  • Page 30 SPEC ENGINE SPECIFICATIONS Item Standard Limit Piston Piston-to-cylinder clearance 0.030 ~ 0.055 mm (0.0012 ~ 0.0022 in) 0.13 mm (0.0051 in) Diameter “D” 101.955 ~ 101.970 mm ---- (4.0140 ~ 4.0146 in) Height “H” 10 mm (0.39 in) ---- Offset 0.5 mm (0.0197 in) ---- Offset direction...
  • Page 31 SPEC ENGINE SPECIFICATIONS Item Standard Limit Oil ring Dimensions (B × T) 2.50 × 3.40 mm (0.10 × 0.13 in) ---- End gap (installed) 0.20 ~ 0.70 mm (0.008 ~ 0.028 in) ---- Ring side clearance 0.060 ~ 0.150 mm (0.0024 ~ 0.0059 in) ---- Crankshaft Crank width “A”...
  • Page 32 SPEC ENGINE SPECIFICATIONS Item Standard Limit Transmission Maximum main axle runout ---- 0.08 mm (0.0031 in) Maximum drive axle runout ---- 0.08 mm (0.0031 in) Shifting mechanism Shift mechanism type Shift drum and guide bar ---- Decompression device Device type Auto decomp ---- Air filter oil grade...
  • Page 33 SPEC ENGINE SPECIFICATIONS Lubrication chart Cylinder head Counter axle Decompression Camshaft To oil tank Main axle Oil delivery pipe Oil tank inlet pipe Drive axle A.C. magneto cover From oil tank Oil filter Right crankcase element Left Oil tank outlet crankcase hose joint Drain bolt...
  • Page 34 SPEC ENGINE SPECIFICATIONS Cylinder head tightening sequence 2 - 11...

  • Page 35: Chassis Specifications

    SPEC CHASSIS SPECIFICATIONS EBS01003 CHASSIS SPECIFICATIONS Item Standard Limit Steering system Steering bearing type Ball and race bearing ---- Front suspension Shock absorber travel 115.0 mm (4.53 in) ---- Spring free length 269.0 mm (10.59 in) ---- Installed length 260.5 mm (10.26 in) ---- Spring rate (K1) 21.60 N/mm (2.20 kg/mm, 123.33 lb/in)
  • Page 36 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Front disc brake Type Dual ---- Disc outside diameter × thickness 161.0 × 3.5 mm (6.34 × 0.14 in) ---- Pad thickness inner 4.3 mm (0.17 in) 1.0 mm (0.04 in) Pad thickness outer 4.3 mm (0.17 in) 1.0 mm (0.04 in)

  • Page 37: Electrical Specifications

    SPEC ELECTRICAL SPECIFICATIONS EBS01004 ELECTRICAL SPECIFICATIONS Item Standard Limit System voltage 12 V ---- Ignition system Ignition timing (B.T.D.C.) 9.0°/1,600 r/min ---- Advancer type Digital type ---- Transistorized coil ignition 192 ~ 288 Ω at 20 °C (68 °F)/ Crankshaft position sensor resis- ---- tance/color blue/yellow-green/white...
  • Page 38 SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit Starter relay Model/manufacturer 2768106-A/JIDECO ---- Amperage rating 180.0 A ---- 4.18 ~ 4.62 Ω at 20 °C (68 °F) Coil winding resistance ---- Circuit breaker Circuit breaker type Fuse ---- Fuses Main fuse 20 A ---- Headlight fuse 15 A...

  • Page 39: Tightening Torques

    SPEC TIGHTENING TORQUES EBS01005 TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Tightening torque Thread Part to be tightened Part name Q’ty Remarks size Nm m · kg ft · lb Cylinder head (exhaust pipe) Stud bolt Cylinder head Bolt Cylinder head Bolt Cylinder head Bolt Spark plug...
  • Page 40 SPEC TIGHTENING TORQUES Tightening torque Thread Part to be tightened Part name Q’ty Remarks size Nm m · kg ft · lb Oil filter cover drain bolt Bolt Oil filter cover Bolt Check screw (oil filter cover) Screw Oil delivery pipe Union bolt Oil delivery pipe Bolt...
  • Page 41 SPEC TIGHTENING TORQUES Tightening torque Thread Part to be tightened Part name Q’ty Remarks size Nm m · kg ft · lb Reverse switch — Neutral switch — NOTE: Temporarily tighten the cylinder bolts to 15 Nm (1.5 m · kg, 11 ft · lb), and then tighten them to 50 Nm (5.0 m ·...

  • Page 42: Chassis Tightening Torques

    SPEC TIGHTENING TORQUES EBS01006 CHASSIS TIGHTENING TORQUES Tightening torque Part to be tightened Thread size Remarks Nm m · kg ft · lb Engine upper bracket Engine mounting bolt (upper) Engine lower bracket Engine mounting bolt (middle) Engine mounting bolt (lower) Swingarm pivot shaft, engine, and frame 10.0 Middle frame and rear frame...
  • Page 43 SPEC TIGHTENING TORQUES Tightening torque Part to be tightened Thread size Remarks Nm m · kg ft · lb Driven sprocket and sprocket bracket Front brake caliper and brake hose Front brake pad retaining bolt Brake caliper bleed screw Front brake master cylinder and handlebar Front brake master cylinder and brake lever Front brake master cylinder and brake hose Throttle lever assembly and handlebar...
  • Page 44 SPEC TIGHTENING TORQUES NOTE: 1. Apply a rust preventive lubricant to the threads on both sides of the rear axle and to the wheel hub surfaces that contact the rear axle washers. 2. Tighten the rear axle nuts 200 Nm (20.0 m · kg, 145 ft · lb). 3.

  • Page 45: How To Use The Conversion Table

    HOW TO USE THE CONVERSION TABLE/ SPEC GENERAL TIGHTENING TORQUE SPECIFICATIONS EBS00022 EBS00023 HOW TO USE THE CONVERSION GENERAL TIGHTENING TORQUE TABLE SPECIFICATIONS All specification data in this manual are listed This chart specifies tightening torques for stan- in SI and METRIC UNITS. dard fasteners with a standard ISO thread Use this table to convert METRIC unit data to pitch.

  • Page 46: Lubrication Points And Lubricant Types

    Clutch pull rod Transmission gears (wheel and pinion) Shift drum Shift forks Shift lever assembly Shift shaft Reverse shift shaft Yamaha bond No. 1215 Crankcase mating surface (Three bond No. 1215) Yamaha bond No. 1215 A.C. magneto lead grommet (A.C. magneto cover) (Three bond No.

  • Page 47: Coolant Flow Diagrams

    SPEC COOLANT FLOW DIAGRAMS EBS00025 COOLANT FLOW DIAGRAMS È Install the radiator inlet hose onto the thermostat 1 Thermostat cover 2 Fast idle plunger outlet hose cover pipe, making sure that it contacts the 3 Radiator inlet hose cover and its yellow paint mark is facing out- 4 Radiator ward.
  • Page 48 SPEC COOLANT FLOW DIAGRAMS Ë Position the screw clamp so that its screw can Ð Make sure that the end of the screw clamp does be tightened from the right side of the vehicle. not protrude past the side of the radiator outlet Ì...
  • Page 49 SPEC COOLANT FLOW DIAGRAMS É Install the coolant reservoir hose onto the radia- 1 Radiator 2 Radiator fan breather hose tor pipe, making sure that it contacts the radia- 3 Fuel tank shield tor. Ê Pass the coolant reservoir hose and radiator fan 4 Coolant reservoir breather hose 5 Coolant reservoir breather hose through the guide on the fuel tank...
  • Page 50 SPEC COOLANT FLOW DIAGRAMS È From radiator 1 Water pump outlet hose É Install the water pump outlet hose onto the water 2 Water pump 3 Water pump breather hose jacket inlet housing, making sure to align the yel- 4 Water jacket inlet housing low paint mark on the hose with the projection on the water jacket inlet housing.

  • Page 51: Oil Flow Diagrams

    SPEC OIL FLOW DIAGRAMS EBS00026 OIL FLOW DIAGRAMS 1 Oil tank breather hose 2 Oil tank outlet hose 3 Oil tank inlet hose 4 Oil tank 2 - 28...
  • Page 52 SPEC OIL FLOW DIAGRAMS 1 Oil delivery pipe 2 Oil filter 3 Oil pump 2 - 29...
  • Page 53 SPEC OIL FLOW DIAGRAMS 1 Oil filter 2 Oil pump driven gear 3 Oil pump rotor 1 4 Oil pump rotor 2 5 Oil pipe joint 6 Main axle 7 Counter axle 2 - 30...
  • Page 54 SPEC OIL FLOW DIAGRAMS 1 Oil strainer 2 Oil pump rotor 2 3 Oil pump rotor 1 4 Oil pump driven gear È To oil tank È 2 - 31...
  • Page 55 SPEC OIL FLOW DIAGRAMS 1 Balancer 1 2 Crankshaft 2 - 32...

  • Page 56: Cable Routing

    SPEC CABLE ROUTING EBS00028 CABLE ROUTING 1 Handlebar switch lead 0 Coolant reservoir breather hose 2 Clutch switch lead A Coolant reservoir hose 3 Parking brake cable B Radiator fan motor lead 4 Clutch cable C Main switch lead 5 Front brake hose 6 Front brake light switch lead 7 Throttle cable 8 Indicator light assembly lead...
  • Page 57 SPEC CABLE ROUTING È Fasten the handlebar switch lead and clutch Í Route the coolant reservoir breather hose under switch lead with the plastic bands at the bends in the wire harness and over the handlebar switch the handlebar. lead, clutch switch lead, front brake light switch É...
  • Page 58 SPEC CABLE ROUTING Ð Route the radiator fan breather hose and coolant Ó Secure the plastic band by inserting the projection reservoir hose in front of the front brake light on the band into the hole in the frame, and then switch lead, main switch lead, handlebar switch fasten the wire harness and radiator fan motor lead, clutch switch lead and indicator light assem-...
  • Page 59 SPEC CABLE ROUTING Ø Pass the radiator fan breather hose, coolant res- Ú Pass the throttle cable, clutch cable, parking ervoir hose, front brake light switch lead, main brake cable, front brake light switch lead, main switch lead, handlebar switch lead, clutch switch switch lead, handlebar switch lead, clutch switch lead, and indicator light assembly lead through lead, indicator light assembly lead and radiator...
  • Page 60 SPEC CABLE ROUTING 1 Coolant reservoir hose B Resistor 2 Radiator fan breather hose C Headlight lead 3 Throttle cable D Main switch lead 4 Fuel tank breather hose E Handlebar switch lead 5 Fuel hose F Clutch switch lead 6 Oil tank inlet hose G Front brake light switch lead 7 Reverse control cable...
  • Page 61 SPEC CABLE ROUTING È Route the coolant reservoir hose in front of the Ì Route the wire harness to the inside of the radiator fan breather hose, and then connect it to frame. Í Connect the A.C. magneto lead, wire sub lead, the radiator.
  • Page 62 SPEC CABLE ROUTING Ï Route the reverse control cable under the oil Ñ Route the resistor lead over the frame, making tank outlet hose. sure that its coupler is positioned to the inside of Ð Pass the plastic band through the space the frame.
  • Page 63 SPEC CABLE ROUTING Ó Pass the radiator fan breather hose and coolant Ô Pass the wire harness through the rubber reservoir hose, then the front brake light switch damper. Õ Route the fuel hose to the outside of the wire lead, main switch lead, handlebar switch lead, clutch switch lead, and indicator light assembly harness.
  • Page 64 SPEC CABLE ROUTING 1 A.C. magneto lead B Battery box 2 Lean angle sensor lead C Starter motor lead 3 Negative battery lead D Speed sensor lead 4 Crankcase breather hose E Rear brake light switch lead 5 Starter relay lead F Wire sub lead 6 Relay unit G Reverse switch lead...
  • Page 65 SPEC CABLE ROUTING È Route the leads that branch off from the wire Ë Secure the plastic band by inserting the projec- harness over the crankcase breather hose, then tion on the band into the hole in the frame, and towards the right side of the vehicle, making then fasten the wire harness at the center of its sure that they do not contact the frame.
  • Page 66 SPEC CABLE ROUTING Í When installing the tail/brake light cover and Ð Fasten the radiator fan motor relay lead and tail/ rear fender, be sure not to pinch the tail/brake brake light lead with the plastic band, making light lead between the frame and the cover. sure to face the end of the band downward.
  • Page 67 SPEC CABLE ROUTING Ñ Secure the plastic band by inserting the projec- Õ Route the wire sub lead as shown in the illustra- tion on the band into the hole in the frame. tion. The longer lead past the end of the protec- Ò...
  • Page 68 SPEC CABLE ROUTING × Fasten the speed sensor lead, rear brake light Ù Secure the plastic band by inserting the projec- switch lead, A.C. magneto lead, negative battery tion on the band into the hole in the frame, and lead and wire sub lead with the plastic band. then fasten the wire harness and starter motor Face the end of the plastic band inward.
  • Page 69 SPEC CABLE ROUTING 1 Intake air pressure sensor lead B Fuel pump 2 Fuel injector lead C Fuel hose 3 Intake air pressure sensor D Fuel pump lead 4 Throttle position sensor E Front brake light switch lead 5 Throttle position sensor lead F Radiator fan breather hose 6 Intake air temperature sensor lead G Indicator light assembly lead...
  • Page 70 SPEC CABLE ROUTING Ì Route the negative battery lead connector as M Clutch switch lead N Main switch lead shown. Í Connect the A.C. magneto lead, wire sub lead, È To coolant temperature sensor rear brake switch lead, and speed sensor lead in É...
  • Page 71 SPEC CABLE ROUTING Ò Pass the indicator light assembly lead through the guide on the radiator cover. Ó Fasten the leads with the holder at the section before the intake air temperature sensor lead branches off from the other leads. Ò...
  • Page 72 SPEC CABLE ROUTING 1 Radiator fan motor relay C Tail/brake light lead 2 Headlight relay È Route the starter motor lead under the starter 3 Fuse box 4 Relay unit relay lead. É Make sure that the self-diagnosis signal coupler 5 Relay unit lead 6 Self-diagnosis signal lead is positioned above the relay unit lead, fuse box...
  • Page 73 SPEC CABLE ROUTING 1 Radiator inlet hose B Throttle position sensor lead 2 Fast idle plunger outlet hose C Coolant temperature sensor 3 Reverse control cable D Hose (air-filter-joint-to-throttle-body-right-side) 4 Ignition coil lead (red/black) E Coolant temperature sensor lead 5 Rectifier/regulator lead F Intake air pressure sensor 6 Ignition coil lead (orange) G Fuel injector lead...
  • Page 74 SPEC CABLE ROUTING Ê Make sure that the rear brake light switch lead M Wire harness N Spark plug lead does not contact the swingarm. There should be O Rectifier/regulator no slack in the rear brake light switch lead P Ignition coil between the holder shown in the illustration and the holder on the left side of the vehicle.
  • Page 75 SPEC CABLE ROUTING Í Secure the plastic band by inserting the projec- Ð Route the leads that branch off from the wire tion on the band into the hole in the frame, and harness over the fast idle plunger outlet hose then fasten the leads where the throttle position and to the right of the hose (air filter joint to right sensor lead branches off from the other leads,...
  • Page 76 SPEC CABLE ROUTING Ó Fasten the rectifier/regulator lead with the plastic Ö Fasten the reverse control cable to the frame band. Face the end of the plastic band down- with the plastic band, making sure to face the ward. end of the band downward. Ô...

  • Page 77: Chk Adj

    CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION....................3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM ......................3-1 GENERAL MAINTENANCE AND LUBRICATION CHART......3-2 PERIODIC MAINTENANCE/LUBRICATION ..........3-3 SEAT, FENDERS AND FUEL TANK .............. 3-5 REMOVING THE FUEL TANK ..............3-11 REMOVING THE FUEL PUMP ...............3-11 INSTALLING THE FUEL PUMP..............3-12 INSTALLING THE FUEL HOSE ..............3-12...
  • Page 78 CHASSIS ....................... 3-40 ADJUSTING THE FRONT BRAKE ............3-40 ADJUSTING THE REAR BRAKE............3-40 ADJUSTING THE PARKING BRAKE............3-41 CHECKING THE BRAKE FLUID LEVEL..........3-42 CHECKING THE FRONT BRAKE PADS ..........3-43 CHECKING THE REAR BRAKE PADS ..........3-43 ADJUSTING THE REAR BRAKE LIGHT SWITCH .........3-44 CHECKING THE BRAKE HOSES............

  • Page 79: Periodic Checks And Adjustments

    However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance intervals should be followed. • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.

  • Page 80: General Maintenance And Lubrication Chart

    GENERAL MAINTENANCE AND LUBRICATION CHART GENERAL MAINTENANCE AND LUBRICATION CHART INITIAL EVERY month Whichever ITEM ROUTINE comes first 1300 2500 2500 5000 (mi) (200) (800) (1600) (1600) (3200) hours • Clean. Every 20 ~ 40 hours Air filter element • Replace if necessary. (more often in wet or dusty areas) •...

  • Page 81: Periodic Maintenance/Lubrication

    However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance intervals should be followed. • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
  • Page 82 PERIODIC MAINTENANCE/LUBRICATION INITIAL EVERY month Whichever ITEM ROUTINE comes first 1,200 2,400 2,400 4,800 (mi) (200) (750) (1,500) (1,500) (3,000) hours Engine oil • Replace (Warm engine before draining). Engine oil filter ele- • Replace. ment • Check coolant leakage. Cooling system •...

  • Page 83: Seat, Fenders And Fuel Tank

    SEAT, FENDERS AND FUEL TANK EBS00033 SEAT, FENDERS AND FUEL TANK 4 Nm (0.4 m kg, 2.9 ft • • 16 Nm (1.6 m kg, 11 ft • • 13 Nm (1.3 m kg, 9.4 ft • • 13 Nm (1.3 m kg, 9.4 ft •...
  • Page 84 SEAT, FENDERS AND FUEL TANK EBS00036 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 85 SEAT, FENDERS AND FUEL TANK EBS00039 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 9 Nm (0.9 m kg, 6.5 ft • • 4 Nm (0.4 m kg, 2.9 ft •...
  • Page 86 SEAT, FENDERS AND FUEL TANK 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 9 Nm (0.9 m kg, 6.5 ft • • 4 Nm (0.4 m kg, 2.9 ft • •...
  • Page 87 SEAT, FENDERS AND FUEL TANK EBS00042 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks Removing the fuel tank Remove the parts in the order listed.
  • Page 88 SEAT, FENDERS AND FUEL TANK 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks Fuel pump Refer to “REMOVING THE FUEL PUMP” and “INSTALLING THE FUEL PUMP”.

  • Page 89: Removing The Fuel Tank

    SEAT, FENDERS AND FUEL TANK REMOVING THE FUEL TANK 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: • fuel hose connector holder • fuel hose CAUTION: • Be sure to disconnect the fuel hose by hand.

  • Page 90: Installing The Fuel Pump

    SEAT, FENDERS AND FUEL TANK CAUTION: • Do not drop the fuel pump or give it a strong shock. • Do not touch the base section of the fuel sender. INSTALLING THE FUEL PUMP 1. Install: • fuel pump gasket •...

  • Page 91: Engine

    ADJUSTING THE VALVE CLEARANCE EAS00049 ENGINE ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: • Valve clearance adjustment should be made on a cold engine, at room temperature. • When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke.
  • Page 92 ADJUSTING THE VALVE CLEARANCE 6. Measure: • valve clearance Out of specification → Adjust. Valve clearance (cold) Intake valve 0.09 ~ 0.13 mm (0.0035 ~ 0.0051 in) Exhaust valve 0.16 ~ 0.20 mm (0.0063 ~ 0.0079 in) M MMM M MMM M MMM M MMM M MMM...
  • Page 93 ADJUSTING THE VALVE CLEARANCE d. Hold the adjusting screw to prevent it from moving and tighten the locknut to the speci- fied torque. Locknut 14 Nm (1.4 m · kg, 10 ft · lb) e. Measure the valve clearance again. f.

  • Page 94: Adjusting The Exhaust Gas Volume (For Europe And Oceania Only)

    ADJUSTING THE EXHAUST GAS VOLUME (For Europe and Oceania only) EAS00869 ADJUSTING THE EXHAUST GAS VOLUME (For Europe and Oceania only) NOTE: Be sure to set the CO density level to stan- dard, and then adjust the exhaust gas volume. 1.
  • Page 95 ADJUSTING THE EXHAUST GAS VOLUME (For Europe and Oceania only)/ ADJUSTING THE ENGINE IDLING SPEED 9. Change the CO adjustment volume by pressing the “UP” and “DOWN” buttons. NOTE: FI Diagnostic Tool The CO adjustment volume and engine idling 1600pm speed appear on the LCD of the FI diagnostic tool.

  • Page 96: Adjusting The Engine Idling Speed

    ADJUSTING THE ENGINE IDLING SPEED/ ADJUSTING THE THROTTLE LEVER FREE PLAY 5. Detach: • tachometer 6. Adjust: • throttle lever free play Refer to “ADJUSTING THE THROTTLE LEVER FREE PLAY”. Throttle lever free play 2 ~ 4 mm (0.08 ~ 0.16 in) EBS00052 ADJUSTING THE THROTTLE LEVER FREE PLAY...

  • Page 97: Adjusting The Speed Limiter

    ADJUSTING THE THROTTLE LEVER FREE PLAY/ ADJUSTING THE SPEED LIMITER e. Slide the rubber cover to its original posi- tion. NOTE: If the free play cannot be adjusted here, adjust it at the throttle lever side of the cable. Second step: f.

  • Page 98: Checking The Spark Plug

    ADJUSTING THE SPEED LIMITER/ CHECKING THE SPARK PLUG 2. Adjust: • speed limiter length M MMM M MMM M MMM M MMM M MMM a. Loosen the locknut 1. b. Turn the adjusting screw 2 in or out until the specified speed limiter length is obtained.

  • Page 99: Checking The Ignition Timing

    CHECKING THE SPARK PLUG/ CHECKING THE IGNITION TIMING 5. Measure: • spark plug gap a Use a wire gauge or thickness gauge. Out of specification → Regap. Spark plug gap 0.7 ~ 0.8 mm (0.028 ~ 0.031 in) 6. Tighten: •...

  • Page 100: Measuring The Compression Pressure

    CHECKING THE IGNITION TIMING/ MEASURING THE COMPRESSION PRESSURE b. Remove the timing mark accessing screw c. Visually check the stationary pointer a to verify it is within the required firing range b indicated on the flywheel. Incorrect firing range → Check the pulser coil assembly.
  • Page 101 MEASURING THE COMPRESSION PRESSURE 5. Attach: • extension • compression gauge 1 Compression gauge 90890-03081 Engine compression tester YU-33223 Extension 90890-04082 6. Measure: • compression pressure Out of specification → Refer to steps (c) and (d). Compression pressure (at sea level) Minimum 392 kPa (3.92 kg/cm...

  • Page 102: Checking The Engine Oil Level

    MEASURING THE COMPRESSION PRESSURE/ CHECKING THE ENGINE OIL LEVEL d. If the compression pressure is below the minimum specification, squirt a few drops of oil into the cylinder and measure again. Refer to the following table. Compression pressure (with oil applied into the cylinder) Reading Diagnosis Piston ring(s) wear...
  • Page 103 CHECKING THE ENGINE OIL LEVEL 3. Check: • engine oil level Oil level should be between the minimum level mark a and the maximum level mark Low oil level → Add oil to the proper level. NOTE: • Wait a few minutes until the oil settles before checking the oil level.

  • Page 104: Changing The Engine Oil

    CHANGING THE ENGINE OIL EBS00067 CHANGING THE ENGINE OIL 1. Start the engine, warm it up for several min- utes, and then turn it off. 2. Place a container under the engine oil drain bolt. 3. Remove: • engine oil filler bolt 1 •...
  • Page 105 CHANGING THE ENGINE OIL c. Install the new oil filter element and the oil filter element cover. Oil filter element cover bolt 10 Nm (1.0 m · kg, 7.2 ft · lb) L LLL L LLL L LLL L LLL L LLL 9.
  • Page 106 CHANGING THE ENGINE OIL 12.Install: • dipstick • engine oil filler bolt 12 Nm (1.2 m · kg, 8.7 ft · lb) 13.Start the engine, warm it up for several min- utes, and then turn it off. 14.Check: • engine (for engine oil leaks) 15.Check: •...

  • Page 107: Adjusting The Clutch Cable

    ADJUSTING THE CLUTCH CABLE/ CLEANING THE AIR FILTER ELEMENT EBS00070 ADJUSTING THE CLUTCH CABLE 1. Check: • clutch lever free play a Out of specification → Adjust. Clutch lever free play (at the clutch lever end) 5 ~ 10 mm (0.20 ~ 0.39 in) 2.
  • Page 108 CLEANING THE AIR FILTER ELEMENT 1. Remove: • seat Refer to “SEAT, FENDERS AND FUEL TANK”. 2. Remove: • air filter case cover 1 3. Remove: • wing bolt 1 • air filter element 2 • air filter element frame 3 CAUTION: The engine should never be run without the air filter;...

  • Page 109: Checking The Throttle Body Joint

    CAUTION: Do not twist or wring out the element. This could damage the foam material. c. Apply Yamaha foam air filter oil or other quality foam air filter oil to the element. d. Squeeze out the excess oil. NOTE: The element should be wet but not dripping.

  • Page 110: Checking The Fuel Hose

    CHECKING THE FUEL HOSE/ CHECKING THE BREATHER HOSES EAS00096 CHECKING THE FUEL HOSE 1. Remove: • seat • front fender • fuel tank Refer to “SEAT, FENDERS AND FUEL TANK”. 2. Check: • fuel hose 1 Cracks/damage → Replace. Loose connection → Connect properly. 3.

  • Page 111: Checking The Coolant Level

    CHECKING THE COOLANT LEVEL/ CHANGING THE COOLANT EBS00076 CHECKING THE COOLANT LEVEL 1. Place the vehicle on a level surface. 2. Check: • coolant level The coolant level should be between the minimum level mark a and maximum level mark b. Below the minimum level mark →...
  • Page 112 CHANGING THE COOLANT 5. Remove: • radiator cap 1 WARNING A hot radiator is under pressure. Therefore, do not remove the radiator cap when the engine is hot. Scalding hot fluid and steam may be blown out, which could cause seri- ous injury.
  • Page 113 CHANGING THE COOLANT 11.Fill: • cooling system (with the specified amount of the recom- mended coolant) Recommended antifreeze High-quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines Mixing ratio 1:1 (antifreeze:water) Quantity Total amount 1.61 L (1.42 Imp qt, 1.70 US qt) Coolant reservoir capacity 0.25 L (0.22 Imp qt, 0.26 US qt) Handling notes for coolant...

  • Page 114: Checking The Cooling System

    CHANGING THE COOLANT/ CHECKING THE COOLING SYSTEM 14.Fill: • coolant reservoir (with the recommended coolant to the maxi- mum level mark a) 15.Install: • coolant reservoir cap 16.Start the engine, warm it up for several min- utes, and then stop it. 17.Check: •...

  • Page 115: Checking The Coolant Temperature Warning Light

    CHECKING THE COOLANT TEMPERATURE WARNING LIGHT EBS00077 CHECKING THE COOLANT TEMPERATURE WARNING LIGHT 1 Coolant temperature warning light Coolant temperature warning light checking method Turn the main switch “ON” and the engine stop switch to “RUN”. Coolant temperature warning Coolant temperature warning light does not come on.

  • Page 116: Checking The Exhaust System

    CHECKING THE EXHAUST SYSTEM/ CLEANING THE SPARK ARRESTER EAS00099 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the exhaust pipe gaskets. 1. Check: • exhaust pipes 1 • muffler 2 • muffler protector 3 • exhaust pipe protector 4 Cracks/damage →...
  • Page 117 CLEANING THE SPARK ARRESTER a. Remove the bolt 1. b. Remove the tailpipe 2 by pulling it out of the muffler. c. Tap the tailpipe lightly with a soft-face ham- mer or suitable tool, then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe and inside of the tail pipe housing.

  • Page 118: Chassis

    ADJUSTING THE FRONT BRAKE/ ADJUSTING THE REAR BRAKE EBS00080 CHASSIS ADJUSTING THE FRONT BRAKE 1. Measure: • brake lever free play a Out of specification → Bleed the front brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM”. Brake lever free play (at the end of the brake lever) 0 mm (0 in) EBS00085...

  • Page 119: Adjusting The Parking Brake

    ADJUSTING THE REAR BRAKE/ ADJUSTING THE PARKING BRAKE WARNING After this adjustment is performed, lift the front and rear wheels off the ground by placing a block under the engine, and spin the rear wheels to ensure there is no brake drag.

  • Page 120: Checking The Brake Fluid Level

    CHECKING THE BRAKE FLUID LEVEL EBS00087 CHECKING THE BRAKE FLUID LEVEL 1. Place the vehicle on a level surface. NOTE: When checking the brake fluid level, make sure that the top of the brake master cylinder reservoir top and the brake fluid reservoir top is horizontal.

  • Page 121: Checking The Front Brake Pads

    CHECKING THE FRONT BRAKE PADS/ CHECKING THE REAR BRAKE PADS EBS00088 CHECKING THE FRONT BRAKE PADS 1. Remove: • front wheels Refer to “FRONT AND REAR WHEELS” in chapter 7. 2. Check: • brake pads Wear indicators 1 almost touch the brake disc →...

  • Page 122: Adjusting The Rear Brake Light Switch

    ADJUSTING THE REAR BRAKE LIGHT SWITCH/ CHECKING THE BRAKE HOSES ADJUSTING THE REAR BRAKE LIGHT SWITCH NOTE: • The rear brake light switch is operated by movement of the brake pedal. • The rear brake light switch is properly adjusted when the brake light comes on just before the braking effect starts.

  • Page 123: Bleeding The Hydraulic Brake System

    CHECKING THE BRAKE HOSES/ BLEEDING THE HYDRAULIC BRAKE SYSTEM 5. Check: • brake hoses Apply the brake lever or brake pedal sev- eral times. Fluid leakage → Replace the hoses. Refer to “FRONT AND REAR BRAKES” in chapter 7. 6. Install: •...
  • Page 124 BLEEDING THE HYDRAULIC BRAKE SYSTEM 1. Bleed: È • hydraulic brake system M MMM M MMM M MMM M MMM M MMM a. Fill the brake fluid reservoir to the proper level with the recommended brake fluid. b. Install the diaphragm (brake master cylinder reservoir or brake fluid reservoir).

  • Page 125: Adjusting The Shift Pedal

    ADJUSTING THE SHIFT PEDAL/ ADJUSTING THE REVERSE CONTROL CABLE EBS00098 ADJUSTING THE SHIFT PEDAL 1. Measure: • shift pedal height a Out of specification → Adjust. Shift pedal height 48 mm (1.89 in) 2. Adjust: • shift pedal position M MMM M MMM M MMM M MMM...

  • Page 126: Adjusting The Drive Chain Slack

    ADJUSTING THE REVERSE CONTROL CABLE/ ADJUSTING THE DRIVE CHAIN SLACK 2. Adjust: • reverse knob free play M MMM M MMM M MMM M MMM M MMM a. Pull the boots 1 and 2 off. b. Loosen the locknut 3. c.
  • Page 127 ADJUSTING THE DRIVE CHAIN SLACK 2. Adjust: • drive chain slack M MMM M MMM M MMM M MMM M MMM NOTE: The drive chain slack is adjusted by the rota- tion of the rear axle hub. a. Loosen the rear axle pinch bolts 1. NOTE: Loosen the rear axle pinch bolts in the proper sequence as shown.

  • Page 128: Checking The Steering System

    CHECKING THE STEERING SYSTEM/ ADJUSTING THE TOE-IN EBS00106 CHECKING THE STEERING SYSTEM 1. Place the vehicle on a level surface. 2. Check: • steering assembly bushings Move the handlebar up and down, and/or back and forth. Excessive play → Replace the steering stem bushings.
  • Page 129 ADJUSTING THE TOE-IN b. Face the handlebar straight ahead. c. Measure the width È between the marks. d. Rotate the front tires 180° until the marks are exactly opposite one another. e. Measure the width É between the marks. f. Calculate the toe-in using the formula given below.

  • Page 130: Checking The Front And Rear Shock Absorbers

    CHECKING THE FRONT AND REAR SHOCK ABSORBERS/ ADJUSTING THE FRONT SHOCK ABSORBERS EBS00109 È CHECKING THE FRONT AND REAR SHOCK ABSORBERS 1. Place the vehicle on a level surface. 2. Check: • damper rod Bends/damage → Replace the rear shock absorber assembly.

  • Page 131: Adjusting The Front Shock Absorbers

    ADJUSTING THE FRONT SHOCK ABSORBERS/ ADJUSTING THE REAR SHOCK ABSORBER 1. Adjust: • spring preload Turn the adjuster 1 in direction a or b. Spring preload is Direction a increased (suspension is harder). Spring preload is Direction b decreased (suspension is softer).
  • Page 132 ADJUSTING THE REAR SHOCK ABSORBER NOTE: • Be sure to remove all dirt and mud from around the locknut and adjusting ring before adjustment. • The length of the spring (installed) changes 1.5 mm (0.06 in) per turn of the adjuster. CAUTION: Never attempt to turn the adjusting ring beyond the maximum or minimum setting.
  • Page 133 ADJUSTING THE REAR SHOCK ABSORBER 4. Adjust: • rebound damping force M MMM M MMM M MMM M MMM M MMM • Turn the adjusting screw 1 in direction a or b. Rebound damping force Direction a is increased. Rebound damping force Direction b is decreased.

  • Page 134: Checking The Tires

    • TIRE CHARACTERISTICS 1) Tire characteristics influence the han- dling of ATVs. The tires listed below have been approved by Yamaha Motor Co., Ltd. for this model. If other tire com- binations are used, they can adversely affect your vehicle’s handling character- istics and are therefore not recom- mended.
  • Page 135 CHECKING THE TIRES 1. Measure: • 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 136: Checking The Wheels

    • cable operation → Unsmooth operation Lubricate 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: • lithium-soap-based grease (onto end of the cable)

  • Page 137: Lubricating The Levers And Pedals

    LUBRICATING THE LEVERS AND PEDALS EBS00118 LUBRICATING THE LEVERS AND PEDALS Lubricate the pivoting point and metal-to-metal moving parts of the levers and pedals. Recommended lubricant Lithium-soap-based grease 3 - 59...

  • Page 138: Electrical System

    CHECKING AND CHARGING THE BATTERY EBS00120 ELECTRICAL SYSTEM CHECKING AND CHARGING THE BATTERY WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: • Wear protective eye gear when handling or working near batteries.
  • Page 139 CHECKING AND CHARGING THE BATTERY NOTE: Since MF batteries are sealed, it is not possi- ble to check the charge state of the battery by measuring the specific gravity of the electro- lyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals.
  • Page 140 CHECKING AND CHARGING THE BATTERY b. Check the charge of the battery, as shown in the charts and the following example. Example c. Open-circuit voltage = 12.0 V d. Charging time = 6.5 hours e. Charge of the battery = 20 ~ 30% L LLL L LLL L LLL...
  • Page 141 CHECKING AND CHARGING THE BATTERY • If the battery becomes hot to the touch at any time during the charging process, disconnect the battery charger and let the battery cool before reconnecting it. Hot batteries can explode! • As shown in the following illustration, the open-circuit voltage of an MF battery sta- bilizes about 30 minutes after charging has been completed.
  • Page 142 CHECKING AND CHARGING THE BATTERY Charging method using a variable-current (voltage) charger Charger Ammeter NOTE: Measure the open-circuit Leave the battery unused for voltage prior to charging. more than 30 minutes before measuring its open-circuit voltage. Connect a charger and NOTE: ammeter to the battery and Set the charging voltage to 16 ~...
  • Page 143 CHECKING AND CHARGING THE BATTERY Charging method using a constant voltage charger NOTE: Measure the open-circuit Leave the battery unused for voltage prior to charging. more than 30 minutes before measuring its open-circuit voltage. Connect a charger and ammeter to the battery and start charging.

  • Page 144: Checking The Fuses

    CHECKING AND CHARGING THE BATTERY/ CHECKING THE FUSES 6. Install: • battery 7. Connect: • battery leads (to the battery terminals) CAUTION: First, connect the positive battery lead 1, and then the negative battery lead 2. 8. Check: • battery terminals Dirt →...
  • Page 145 CHECKING THE FUSES 2. Check: • fuse M MMM M MMM M MMM M MMM M MMM a. Connect the pocket tester to the fuse and check the continuity. NOTE: Set the pocket tester selector to “Ω × 1”. Pocket tester 90890-03112 Analog pocket tester YU-03112-C...

  • Page 146: Adjusting The Headlight Beams

    CHECKING THE FUSES/ ADJUSTING THE HEADLIGHT BEAMS/ REPLACING A HEADLIGHT BULB WARNING Never use a fuse with an amperage rating other than that specified. Improvising or using a fuse with the wrong amperage rat- ing may cause extensive damage to the electrical system, cause the lighting and ignition systems to malfunction and could possibly cause a fire.

  • Page 147: Replacing A Headlight Bulb

    REPLACING A HEADLIGHT BULB 3. Remove: • bulb holder 1 • bulb NOTE: Push the headlight bulb holder inward, turn it 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.

  • Page 148: Eng

    CHAPTER 4 ENGINE ENGINE REMOVAL ..................4-1 MUFFLER AND EXHAUST PIPES ............4-1 INSTALLING THE EXHAUST PIPES AND MUFFLER ......4-2 OIL TANK ....................4-3 LEADS, CABLES AND HOSES ..............4-4 ENGINE MOUNTING BOLTS ..............4-6 INSTALLING THE ENGINE............... 4-8 CYLINDER HEAD.................... 4-9 REMOVING THE CYLINDER HEAD............4-11 CHECKING THE CYLINDER HEAD ............4-12 CHECKING THE TAPPET COVERS AND CAMSHAFT SPROCKET COVER..........
  • Page 149 CLUTCH ......................4-47 REMOVING THE CLUTCH ..............4-51 REMOVING THE PRIMARY DRIVE GEAR AND BALANCER DRIVEN GEAR ............4-52 CHECKING THE FRICTION PLATES.............4-52 CHECKING THE CLUTCH PLATES ............4-53 CHECKING THE CLUTCH SPRINGS.............4-53 CHECKING THE CLUTCH HOUSING ............4-54 CHECKING THE CLUTCH BOSS............4-54 CHECKING THE PRESSURE PLATE ............4-54 CHECKING THE PULL LEVER SHAFT AND PULL ROD ......4-54 CHECKING THE PRIMARY DRIVE GEARS ..........4-55...
  • Page 150 TRANSMISSION.................... 4-77 MAIN AXLE ..................... 4-79 DRIVE AXLE ................... 4-80 COUNTER AXLE..................4-82 CHECKING THE SHIFT FORKS............. 4-83 CHECKING THE SHIFT DRUM ASSEMBLY..........4-83 CHECKING THE TRANSMISSION ............4-83 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE ......4-84 INSTALLING THE TRANSMISSION ............4-85...

  • Page 151: Engine

    ENGINE REMOVAL EBS00198 ENGINE ENGINE REMOVAL MUFFLER AND EXHAUST PIPES 38 Nm (3.8 m kg, 27 ft • • 18 Nm (1.8 m kg, 13 ft • • 20 Nm (2.0 m kg, 14 ft • • 8 Nm (0.8 m kg, 5.8 ft •...

  • Page 152: Installing The Exhaust Pipes And Muffler

    ENGINE REMOVAL INSTALLING THE EXHAUST PIPES AND MUFFLER 1. Install: • gasket 1 (to muffler) NOTE: Install the gasket with the chamfer a, located on an inner rim of the gasket, and the chamfer b, located on an outer rim of the gasket, as shown.

  • Page 153: Oil Tank

    ENGINE REMOVAL OIL TANK 16 Nm (1.6 m kg, 11 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft •...

  • Page 154: Leads, Cables And Hoses

    ENGINE REMOVAL EBS00204 LEADS, CABLES AND HOSES Order Job/Part Q’ty Remarks Removing the leads, cables and Remove the parts in the order listed. hoses Coolant Drain. Right foot protector/air filter case/bat- Refer to “SEAT, FENDERS AND FUEL tery/fuel tank TANK” in chapter 3. Rear brake light switch/right footrest Refer to “REAR BRAKE MASTER CYL- INDER”...
  • Page 155 ENGINE REMOVAL Order Job/Part Q’ty Remarks Coolant temperature sensor coupler Disconnect. Plastic band Wire sub lead coupler Speed sensor coupler A.C. magneto coupler Disconnect. Crankshaft position sensor coupler Disconnect. Rear brake light switch coupler Rear brake light switch lead Wire sub lead Ground lead Clutch cable Parking brake cable...

  • Page 156: Engine Mounting Bolts

    ENGINE REMOVAL EBS00205 ENGINE MOUNTING BOLTS 33 Nm (3.3 m kg, 24 ft • • 40 Nm (4.0 m kg, 29 ft • • 100 Nm (10.0 m kg, 72 ft • • 66 Nm (6.6 m kg, 48 ft •...

  • Page 157: Engine Assembly

    ENGINE REMOVAL 33 Nm (3.3 m kg, 24 ft • • 40 Nm (4.0 m kg, 29 ft • • 100 Nm (10.0 m kg, 72 ft • • 66 Nm (6.6 m kg, 48 ft • • 41 Nm (4.1 m kg, 30 ft •...

  • Page 158: Installing The Engine

    ENGINE REMOVAL EBS00206 INSTALLING THE ENGINE 1. Install: • swingarm • pivot shaft • washer • pivot shaft nut NOTE: Do not fully tighten the pivot shaft nut. 2. Install: • engine mounting bolt (lower)/nut • engine lower bracket (left) •...

  • Page 159: Cylinder Head

    CYLINDER HEAD EBS00218 CYLINDER HEAD 20 Nm (2.0 m kg, 14 ft 33 Nm (3.3 m kg, 24 ft • • • • 13 Nm (1.3 m kg, 9.4 ft • • 40 Nm (4.0 m kg, 29 ft • •...
  • Page 160 CYLINDER HEAD 20 Nm (2.0 m kg, 14 ft 33 Nm (3.3 m kg, 24 ft • • • • 13 Nm (1.3 m kg, 9.4 ft • • 40 Nm (4.0 m kg, 29 ft • • 35 Nm (3.5 m kg, 25 ft •...

  • Page 161: Removing The Cylinder Head

    CYLINDER HEAD EBS00220 REMOVING THE CYLINDER HEAD 1. Align: • “I” mark a on the A.C. magneto rotor (with the stationary pointer b on the A.C. magneto cover) M MMM M MMM M MMM M MMM M MMM a. Turn the crankshaft counterclockwise. b.

  • Page 162: Checking The Cylinder Head

    CYLINDER HEAD EBS00230 CHECKING THE CYLINDER HEAD 1. Eliminate: • combustion chamber carbon deposits (with a rounded scraper) NOTE: Do not use a sharp instrument to avoid damag- ing or scratching: • spark plug bore threads • valve seats 2. Check: •...

  • Page 163: Checking The Tappet Covers And Camshaft Sprocket Cover

    CYLINDER HEAD EBS00227 CHECKING THE TAPPET COVERS AND CAMSHAFT SPROCKET COVER 1. Check: • tappet covers 1 • camshaft sprocket cover 2 Damage/wear → Replace the defective part(s). EBS00229 CHECKING THE TIMING CHAIN TENSIONER 1. Check: • timing chain tensioner Cracks/damage →...
  • Page 164 CYLINDER HEAD 2. Install: • cylinder head • cylinder head bolts NOTE: • Lubricate the cylinder head bolt 1 and 2 threads and mating surface with molybde- num disulfide grease. • Lubricate the cylinder head bolts 3 threads and mating surface with engine oil. •...
  • Page 165 CYLINDER HEAD NOTE: • When installing the camshaft sprocket, be sure to keep the timing chain as tight as pos- sible at the exhaust end of the chain. • Align the projection on the camshaft with the slot in the camshaft sprocket. CAUTION: Do not turn the crankshaft when installing the camshaft to avoid damage or improper...
  • Page 166 CYLINDER HEAD 7. Check: • “I” mark a NOTE: Check that the “I” mark on the A.C. magneto rotor is aligned with the stationary pointer b on the A.C. magneto cover. • “I” mark c NOTE: Check that the “I” mark on the camshaft sprocket is aligned with the stationary pointer d on the cylinder head.

  • Page 167: Rocker Arms And Camshaft

    ROCKER ARMS AND CAMSHAFT EBS00235 ROCKER ARMS AND CAMSHAFT 14 Nm (1.4 m kg, 10 ft • • 14 Nm (1.4 m kg, 10 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Removing the rocker arms and cam- Remove the parts in the order listed.
  • Page 168 ROCKER ARMS AND CAMSHAFT 14 Nm (1.4 m kg, 10 ft • • 14 Nm (1.4 m kg, 10 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Decompressor lever pin Refer to “REMOVING THE ROCKER ARMS AND CAMSHAFT”...

  • Page 169: Removing The Rocker Arms And Camshaft

    ROCKER ARMS AND CAMSHAFT EBS00238 REMOVING THE ROCKER ARMS AND CAMSHAFT 1. Loosen: • locknuts • adjusting screws 2. Remove: • camshaft retainer 1 3. Remove: • intake rocker arm shaft • exhaust rocker arm shaft • intake rocker arm •...

  • Page 170: Checking The Decompression System

    ROCKER ARMS AND CAMSHAFT 2. Measure: • camshaft lobe dimensions a and b Out of specification → Replace the cam- shaft. Camshaft lobe dimensions Intake a 43.300 ~ 43.400 mm (1.7047 ~ 1.7087 in) <Limit>: 43.200 mm (1.7008 in) b 37.026 ~ 37.126 mm (1.4577 ~ 1.4617 in) <Limit>: 36.926 mm (1.4538 in)

  • Page 171: Checking The Rocker Arms And Rocker Arm Shafts

    ROCKER ARMS AND CAMSHAFT EBS00239 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS The following procedure applies to both of the rocker arms and rocker arm shafts. 1. Check: • rocker arm Damage/wear → Replace. 2. Check: • rocker arm shaft Blue discoloration/excessive wear/pitting/ scratches →...

  • Page 172: Installing The Camshaft And Rocker Arms

    ROCKER ARMS AND CAMSHAFT 5. Calculate: • rocker-arm-to-rocker-arm-shaft clearance NOTE: Calculate the clearance by subtracting the rocker arm shaft outside diameter from the rocker arm inside diameter. Out of specification → Replace the defec- tive part(s). Rocker-arm-to-rocker-arm-shaft clearance 0.009 ~ 0.037 mm (0.0004 ~ 0.0015 in) EAS00243 INSTALLING THE CAMSHAFT AND...
  • Page 173 ROCKER ARMS AND CAMSHAFT 3. Install: • decompressor lever pin 1 • decompressor lever 2 NOTE: Install the decompressor lever pin 1 and decompressor lever 2 in the camshaft 3 as shown in the illustration. 4. Install: • camshaft 1 NOTE: Install the camshaft so that its projection a becomes horizontal.

  • Page 174: Valves And Valve Springs

    VALVES AND VALVE SPRINGS EBS00234 VALVES AND VALVE SPRINGS Order Job/Part Q’ty Remarks Removing the valves and valve Remove the parts in the order listed. springs Cylinder head Refer to “CYLINDER HEAD”. Rocker arms/rocker arm shafts/cam- Refer to “ROCKER ARMS AND CAM- shaft SHAFT”.

  • Page 175: Removing The Valves And Valve Springs

    VALVES AND VALVE SPRINGS EAS00238 REMOVING THE VALVES AND VALVE SPRINGS The following procedure applies to all of the valves and related components. NOTE: Before removing the internal parts of the cylin- der head (e.g., valves, valve springs, valve seats), make sure the valves properly seal. 1.

  • Page 176: Checking The Valves And Valve Springs

    VALVES AND VALVE SPRINGS 3. Remove: • valve spring retainer 1 • valve spring 2 • valve stem seal 3 • valve spring seat 4 • valve 5 NOTE: Identify the position of each part very carefully so that it can be reinstalled in its original place. EBS00240 CHECKING THE VALVES AND VALVE SPRINGS...
  • Page 177 VALVES AND VALVE SPRINGS 2. Replace: • valve guide NOTE: To ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100 °C (212 °F) in an oven. M MMM M MMM M MMM M MMM M MMM a.
  • Page 178 VALVES AND VALVE SPRINGS 5. Measure: • valve stem runout Out of specification → Replace. Valve stem runout 0.010 mm (0.0004 in) NOTE: • When installing a new valve, always replace the valve guide. • If the valve is removed or replaced, always replace the valve stem seal.
  • Page 179 VALVES AND VALVE SPRINGS 9. Lap: • valve face • valve seat NOTE: After refacing the valve seat or replacing the valve and valve guide, the valve seat and valve face should be lapped. M MMM M MMM M MMM M MMM M MMM a.
  • Page 180 VALVES AND VALVE SPRINGS 10.Measure: • valve spring free length a Out of specification → Replace. Valve spring free length Intake 38.79 mm (1.53 in) <Limit>: 36.85 mm (1.45 in) Exhaust 38.79 mm (1.53 in) <Limit>: 36.85 mm (1.45 in) 11.Measure: •...

  • Page 181: Installing The Valves And Valve Springs

    VALVES AND VALVE SPRINGS EBS00241 INSTALLING THE VALVES AND VALVE SPRINGS The following procedure applies to all of the valves and related components. 1. Deburr: • valve stem end (with an oil stone) 2. Lubricate: • valve stem 1 • valve stem seal 2 (with the recommended lubricant) Recommended lubricant Molybdenum disulfide oil...
  • Page 182 VALVES AND VALVE SPRINGS 4. Install: • valve cotters NOTE: Install the valve cotters while compressing the valve spring with the valve spring compressor 1 and attachment 2. Valve spring compressor 90890-04019, YM-04019 Valve spring compressor attach- ment 90890-01243 Valve spring compressor adapter (26 mm) YM-01253-1 5.

  • Page 183: Cylinder And Piston

    CYLINDER AND PISTON EBS00245 CYLINDER AND PISTON 1st 15Nm (1.5 m kg, 11 ft • • 2nd 50Nm (5.0m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft •...

  • Page 184: Removing The Piston

    CYLINDER AND PISTON EBS00247 REMOVING THE PISTON 1. Remove: • piston pin clips 1 • piston pin 2 • piston 3 NOTE: Before removing the piston pin, deburr the clip groove and pin hole area. If the clip groove is deburred and the piston pin is still difficult to remove, use the piston pin puller 4.
  • Page 185 CYLINDER AND PISTON 2. Measure: • piston-to-cylinder clearance M MMM M MMM M MMM M MMM M MMM a. Measure the cylinder bore “C” with a cylin- der bore gauge. NOTE: Measure the cylinder bore “C” in parallel to and at right angles to the crankshaft.

  • Page 186: Checking The Piston Rings

    CYLINDER AND PISTON f. If out of specification, replace the cylinder, and the piston and piston rings as a set. L LLL L LLL L LLL L LLL L LLL EBS00250 CHECKING THE PISTON RINGS 1. Measure: • piston ring side clearance Out of specification →...

  • Page 187: Checking The Piston Pin

    CYLINDER AND PISTON 3. Measure: • piston ring end gap Out of specification → Replace the piston ring. NOTE: The oil ring expander spacer’s end gap cannot be measured. If the oil ring rail’s gap is exces- sive, replace all three piston rings. Piston ring end gap Top ring 0.20 ~ 0.35 mm...

  • Page 188: Installing The Piston And Cylinder

    CYLINDER AND PISTON 3. Measure: • piston pin bore inside diameter b Out of specification → Replace the piston. Piston pin bore inside diameter 23.004 ~ 23.015 mm (0.9057 ~ 0.9061 in) <Limit>: 23.045 mm (0.9073 in) 4. Calculate: • piston-pin-to-piston-pin-bore clearance Out of specification →...
  • Page 189 CYLINDER AND PISTON 2. Install: • piston 1 • piston pin 2 • piston pin clips 3 NOTE: • Apply engine oil to the piston pin. • Make sure the punch mark a on the piston points towards the exhaust side of the cylin- der.
  • Page 190 CYLINDER AND PISTON 7. Install: • cylinder bolts NOTE: Lubricate the cylinder bolt 1 threads and mat- ing surface with engine oil. 8. Tighten: • cylinder bolts 1 (1st) 15 Nm (1.5 m · kg, 11 ft · lb) • cylinder bolts 1 (2nd) 50 Nm (5.0 m ·...

  • Page 191: A.c. Magneto

    A.C. MAGNETO EBS00256 A.C. MAGNETO 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • (14) 7 Nm (0.7 m kg, 5.1 ft • • 30 Nm (3.0 m kg, 22 ft •...
  • Page 192 A.C. MAGNETO 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • (14) 7 Nm (0.7 m kg, 5.1 ft • • 30 Nm (3.0 m kg, 22 ft • • 60 Nm (6.0 m kg, 43 ft 10 Nm (1.0 m kg, 7.2 ft...

  • Page 193: Removing The A.c. Magneto Rotor

    A.C. MAGNETO EBS00259 REMOVING THE A.C. MAGNETO ROTOR 1. Remove: • A.C. magneto cover NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2.

  • Page 194: Checking The Starter Clutch

    A.C. MAGNETO EBS00263 CHECKING THE STARTER CLUTCH 1. Check: • starter one-way clutch 1 Cracks/damage → Replace. • bolts 2 Loose → Replace with a new one, and clinch the end of the bolt. Starter clutch bolt 30 Nm (3.0 m · kg, 22 ft · lb) ®...

  • Page 195: Checking The Torque Limiter

    NOTE: Align the projection a on the stator coil with the slot b in the A.C. magneto cover. 2. Apply: • Yamaha bond No. 1215 (Three bond No. 1215) 1 (into the slit) Yamaha bond No. 1215 (Three bond No. 1215) 90890-85505 3.
  • Page 196 A.C. MAGNETO 4. Tighten: • A.C. magneto rotor nut 1 60 Nm (6.0 m · kg, 43 ft · lb) NOTE: While holding the A.C. magneto rotor 2 with the sheave holder 3, tighten the A.C. mag- neto rotor nut. Sheave holder 90890-01701 Primary clutch holder...

  • Page 197: Clutch

    CLUTCH EBS00293 CLUTCH 10 Nm (1.0 m kg, 7.2 ft • • 12 Nm (1.2 m kg, 8.7 ft • • 10 Nm (1.0 m kg, 7.2 ft • • (14) 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty...
  • Page 198 CLUTCH EBS00294 Order Job/Part Q’ty Remarks Removing the pull lever shaft Remove the parts in the order listed. Circlip Pull lever Pull lever spring Circlip Pull lever shaft Oil seal Bearing Bearing For installation, reverse the removal pro- cedure. 4 - 48...
  • Page 199 CLUTCH EBS00291 8 Nm (0.8 m kg, 5.8 ft • • 60 Nm (6.0 m kg, 43 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 110 Nm (11.0 m kg, 80 ft • • 60 Nm (6.0 m kg, 43 ft 95 Nm (9.5 m kg, 68 ft...
  • Page 200 CLUTCH 8 Nm (0.8 m kg, 5.8 ft • • 60 Nm (6.0 m kg, 43 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 110 Nm (11.0 m kg, 80 ft • • 60 Nm (6.0 m kg, 43 ft 95 Nm (9.5 m kg, 68 ft...

  • Page 201: Removing The Clutch

    CLUTCH EBS00297 REMOVING THE CLUTCH 1. Remove: • clutch cover NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Straighten the clutch boss nut staked point 3.

  • Page 202: Removing The Primary Drive Gear And Balancer Driven Gear

    CLUTCH EBS00298 REMOVING THE PRIMARY DRIVE GEAR AND BALANCER DRIVEN GEAR 1. Straighten the lock washer tabs. 2. Loosen: • balancer driven gear 1 nut 1 • primary drive gear nut 2 • balancer driven gear 2 nut 3 NOTE: •...

  • Page 203: Checking The Clutch Plates

    CLUTCH Friction plate 1 thickness 2.92 ~ 3.08 mm (0.115 ~ 0.121 in) <Limit>: 2.82 mm (0.111 in) Friction plate 2 thickness 2.90 ~ 3.10 mm (0.114 ~ 0.122 in) <Limit>: 2.8 mm (0.110 in) EBS00301 CHECKING THE CLUTCH PLATES The following procedure applies to all of the clutch plates.

  • Page 204: Checking The Clutch Housing

    CLUTCH EBS00303 CHECKING THE CLUTCH HOUSING 1. Check: • clutch housing dogs Damage/pitting/wear → Deburr the clutch housing dogs or replace the clutch housing. NOTE: Pitting on the clutch housing dogs will cause erratic clutch operation. EBS00304 CHECKING THE CLUTCH BOSS 1.

  • Page 205: Checking The Primary Drive Gears

    CLUTCH EBS00307 CHECKING THE PRIMARY DRIVE GEARS 1. Check: • primary drive gear 1 • primary driven gear 2 Damage/wear → Replace the primary drive gear and clutch housing as a set. → Excessive noise during operation Replace the primary drive gear and clutch housing as a set.

  • Page 206: Installing The Clutch

    CLUTCH 2. Tighten: • balancer driven gear 2 nut 1 60 Nm (6.0 m · kg, 43 ft · lb) • primary drive gear nut 2 110 Nm (11.0 m · kg, 80 ft · lb) • balancer driven gear 1 nut 3 60 Nm (6.0 m ·...
  • Page 207 CLUTCH 2. Install: • clutch boss assembly 1 NOTE: • If the wire circlip 2 has been removed, care- fully install a new one. • Install the clutch damper spring 3 with the “OUTSIDE” mark facing out. 3. Install: • clutch boss 1 •...
  • Page 208 CLUTCH 6. Install: • pull lever spring 1 • pull lever 2 • washer • circlip NOTE: • Install the pull lever with the “UP” mark facing • Align the mark a on the pull lever with the stationary pointer b on the clutch cover. •...

  • Page 209: Oil Pump

    OIL PUMP EBS00315 OIL PUMP Order Job/Part Q’ty Remarks Removing the oil pump Remove the parts in the order listed. Clutch housing Refer to “CLUTCH”. Oil baffle plate 1 Circlip Oil pump driven gear Oil baffle plate 2 Oil pump Oil pump gasket O-ring For installation, reverse the removal pro-...
  • Page 210 OIL PUMP Order Job/Part Q’ty Remarks Disassembling the oil pump Remove the parts in the order listed. Oil pump housing 1/oil seal Oil pump outer rotor 1 Dowel pin Oil pump inner rotor 1 Oil pump housing cover/oil seal Dowel pin Oil pump shaft Dowel pin Oil pump inner rotor 2...

  • Page 211: Checking The Oil Pump

    OIL PUMP EBS00317 CHECKING THE OIL PUMP 1. Check: • oil pump driven gear 1 • oil pump housing 1 2 • oil pump housing cover 3 • oil pump housing 2 4 Cracks/damage/wear → Replace. 2. Measure: • inner-rotor-to-outer-rotor-tip clearance a •...

  • Page 212: Assembling The Oil Pump

    OIL PUMP EBS00318 ASSEMBLING THE OIL PUMP 1. Install: • oil pump outer rotor 2 1 • oil pump inner rotor 2 2 (to the oil pump housing 2) • oil pump housing 7 Nm (0.7 m · kg, 5.1 ft · lb) NOTE: Align the match mark a on the inner rotor 2 with the match mark b on the outer rotor 2.

  • Page 213: Shift Shaft

    SHIFT SHAFT SHIFT SHAFT Order Job/Part Q’ty Remarks Removing the shift shaft Remove the parts in the order listed. Clutch housing Refer to “CLUTCH”. Shift pedal Shift shaft Refer to “INSTALLING THE SHIFT Shift shaft spring LEVER”. Stopper lever/washer Stopper lever spring Roller Shift guide Shift lever assembly...
  • Page 214 SHIFT SHAFT Order Job/Part Q’ty Remarks Shift drum segment Refer to “INSTALLING THE SHIFT LEVER”. For installation, reverse the removal pro- cedure. 4 - 64...

  • Page 215: Checking The Shift Shaft

    SHIFT SHAFT EBS01018 CHECKING THE SHIFT SHAFT 1. Check: • shift shaft 1 Bends/damage/wear → Replace. • shift shaft spring 2 Damage/wear → Replace. EBS01019 CHECKING THE STOPPER LEVER 1. Check: • stopper lever 1 Bends/damage → Replace. Roller turns roughly → Replace the stopper lever.

  • Page 216: Installing The Shift Shaft

    SHIFT SHAFT 2. Install: • springs 1 • pawl pins 2 • pawls 3 • shift guide 4 (to the pawl holder) 3. Install: • shift lever assembly 1 • shift guide 2 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: The shift lever assembly is installed at the same time as the shift guide.

  • Page 217: Crankcase

    CRANKCASE EBS00320 CRANKCASE Order Job/Part Q’ty Remarks Separating the crankcase Remove the parts in the order listed. Engine assembly Refer to “ENGINE REMOVAL”. Piston Refer to “CYLINDER AND PISTON”. A.C. magneto Refer to “A.C. MAGNETO”. Balancer driven gears Refer to “CLUTCH”. Oil pump Refer to “OIL PUMP”.
  • Page 218 CRANKCASE Order Job/Part Q’ty Remarks Reverse shift lever Reverse shift lever spring Circlip Right crankcase Refer to “SEPARATING THE CRANK- CASE”. Left crankcase Dowel pin Dowel pin/O-ring Oil strainer For installation, reverse the removal pro- cedure. 4 - 68...

  • Page 219: Crankcase Bearings

    CRANKCASE EBS00321 CRANKCASE BEARINGS 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Removing the crankcase bearings Remove the parts in the order listed. Crankshaft Refer to “CRANKSHAFT”.

  • Page 220: Separating The Crankcase

    CRANKCASE EBS00332 SEPARATING THE CRANKCASE 1. Separate: • right crankcase 1 • left crankcase 2 M MMM M MMM M MMM M MMM M MMM a. Remove the crankcase bolts. NOTE: • Loosen each bolt 1/4 of a turn at a time and after all the bolts are loosened, remove them.

  • Page 221: Checking The Timing Chain And Guide

    CRANKCASE EBS00335 CHECKING THE TIMING CHAIN AND GUIDE 1. Check: • timing chain Cracks/stiffness → Replace the timing chain and camshaft as a set. 2. Check: • timing chain guide (intake side) Wear/damage → Replace. EBS00339 CHECKING THE BEARINGS AND OIL SEALS 1.

  • Page 222: Assembling The Crankcase

    È Right crankcase É Left crankcase 2. Apply: • Yamaha bond No. 1215 (Three bond No. 1215) 1 (to the mating surfaces of both case halves) Yamaha bond No. 1215 (Three bond No. 1215) 90890-85505 3.
  • Page 223 CRANKCASE 4. Fit the right crankcase onto the left crank- case. Tap lightly on the case with a soft hammer. CAUTION: Before installing and torquing the crank- case holding bolts, be sure to check whether the transmission is functioning properly by manually rotating the shift drum in both directions.

  • Page 224: Crankshaft

    CRANKSHAFT CRANKSHAFT CRANKSHAFT AND BALANCER Order Job/Part Q’ty Remarks Removing the crankshaft and bal- Remove the parts in the order listed. ancer Crankcase Separate. Refer to “CRANKCASE”. Balancer 1 Balancer 2 Crankshaft Refer to “REMOVING THE CRANK- SHAFT” and “INSTALLING THE CRANK- SHAFT”.

  • Page 225: Removing The Crankshaft

    CRANKSHAFT EBS00336 REMOVING THE CRANKSHAFT 1. Remove: • crankshaft 1 Use a crankcase separating tool 2. Crankcase separating tool 90890-01135 Crankcase separator YU-01135-B EBS00360 CHECKING THE CRANKSHAFT 1. Measure: • crank width a Out of specification → Replace the crank- shaft.

  • Page 226: Installing The Crankshaft

    CRANKSHAFT M MMM M MMM M MMM M MMM M MMM a. The crankshaft 1 and the crankshaft pin 2 oil passages must be properly intercon- nected with a tolerance of less than 1 mm (0.04 in). L LLL L LLL L LLL L LLL L LLL...

  • Page 227: Transmission

    TRANSMISSION EAS00345 TRANSMISSION Order Job/Part Q’ty Remarks Removing the transmission, shift Remove the parts in the order listed. drum, and shift forks Crankcase Separate. Refer to “CRANKCASE”. Spacer Circlip Washer Reverse wheel gear 2 Spacer 4 - 77...
  • Page 228 TRANSMISSION Order Job/Part Q’ty Remarks Counter axle assembly Shift drum Shift fork “R” Refer to “INSTALLING THE TRANSMIS- Shift fork “C” SION”. Shift fork “L” Drive axle assembly Main axle assembly Reverse shift shaft For installation, reverse the removal pro- cedure.

  • Page 229: Main Axle

    TRANSMISSION EBS00347 MAIN AXLE Order Job/Part Q’ty Remarks Disassembling the main axle Remove the parts in the order listed. Circlip 2nd pinion gear Toothed lock washer Toothed washer retainer 4th pinion gear Toothed spacer Toothed washer Refer to “ASSEMBLING THE MAIN AXLE AND DRIVE AXLE”.
  • Page 230 TRANSMISSION EBS00348 DRIVE AXLE Order Job/Part Q’ty Remarks Disassembling the drive axle Remove the parts in the order listed. Circlip Washer Refer to “ASSEMBLING THE MAIN AXLE AND DRIVE AXLE”. Reverse wheel gear 2 Spacer Dog clutch Circlip Refer to “ASSEMBLING THE MAIN AXLE AND DRIVE AXLE”.
  • Page 231 TRANSMISSION Order Job/Part Q’ty Remarks 4th wheel gear 2nd wheel gear Spacer Drive axle For assembly, reverse the disassembly procedure. 4 - 81...

  • Page 232: Counter Axle

    TRANSMISSION COUNTER AXLE Order Job/Part Q’ty Remarks Disassembling the counter axle Remove the parts in the order listed. Circlip Washer Spacer Reverse wheel gear 1 Counter axle For assembly, reverse the disassembly procedure. 4 - 82...

  • Page 233: Checking The Shift Forks

    TRANSMISSION EBS00350 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks. 1. Check: • shift fork cam follower 1 • shift fork pawl 2 Bends/damage/scoring/wear → Replace the shift fork. 2. Check: • shift fork movement Rough movement →...

  • Page 234: Assembling The Main Axle And Drive Axle

    TRANSMISSION 2. Check: • transmission gears Blue discoloration/pitting/wear → Replace the defective gear(s). • transmission gear dogs Cracks/damage/rounded edges → Replace the defective gear(s). 3. Check: • transmission gear engagement (each pinion gear to its respective wheel gear) Incorrect → Reassemble the transmission axle assemblies.

  • Page 235: Installing The Transmission

    TRANSMISSION EBS00356 INSTALLING THE TRANSMISSION 1. Install: • drive axle assembly 1 • main axle assembly 2 • shift fork “L” 3 (to drive axle) • shift fork “C” 4 (to main axle) • shift fork “R” 5 (to drive axle) •...

  • Page 236: Cool

    COOL CHAPTER 5 COOLING SYSTEM RADIATOR ...................... 5-1 CHECKING THE RADIATOR..............5-3 INSTALLING THE RADIATOR..............5-4 THERMOSTAT ....................5-5 CHECKING THE THERMOSTAT.............. 5-6 INSTALLING THE THERMOSTAT............5-6 WATER PUMP....................5-7 DISASSEMBLING THE WATER PUMP............ 5-9 CHECKING THE WATER PUMP .............. 5-9 ASSEMBLING THE WATER PUMP............5-10...

  • Page 237: Cooling System

    COOL RADIATOR EBS00125 COOLING SYSTEM RADIATOR 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks Removing the radiator Remove the parts in the order listed. Front fender Refer to “SEAT, FENDERS AND FUEL TANK”...
  • Page 238 COOL RADIATOR 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks Coolant reservoir Coolant reservoir cap For installation, reverse the removal pro- cedure. 5 - 2...

  • Page 239: Checking The Radiator

    COOL RADIATOR EBS00127 CHECKING THE RADIATOR 1. Check: • radiator fins Obstruction → Clean. Apply compressed air to the rear of the radi- ator. Damage → Repair or replace. NOTE: Straighten any flattened fins with a thin, flat- head screwdriver. 2.

  • Page 240: Installing The Radiator

    COOL RADIATOR EBS00128 INSTALLING THE RADIATOR 1. Fill: • cooling system (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT” in chapter 3. 2. Check: • cooling system Leaks → Repair or replace any faulty part. 3.

  • Page 241: Thermostat

    COOL THERMOSTAT EBS00129 THERMOSTAT 18 Nm (1.8 m kg, 13 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Removing the thermostat Remove the parts in the order listed. Front fender Refer to “SEAT, FENDERS AND FUEL TANK”...

  • Page 242: Checking The Thermostat

    COOL THERMOSTAT EBS00132 CHECKING THE THERMOSTAT 1. Check: • thermostat 1 Does not open at 69 ~ 73 °C (156.2 ~ 163.4 °F) → Replace. M MMM M MMM M MMM M MMM M MMM a. Suspend the thermostat in a container filled with water.

  • Page 243: Water Pump

    COOL WATER PUMP EBS00134 WATER PUMP 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Removing the water pump Remove the parts in the order listed.
  • Page 244 COOL WATER PUMP EBS00135 11 Nm (1.1 m kg, 8.0 ft • • Order Job/Part Q’ty Remarks Disassembling the water pump Remove the parts in the order listed. Water pump housing cover Gasket Circlip Impeller shaft gear Refer to “ASSEMBLING THE WATER PUMP”.

  • Page 245: Disassembling The Water Pump

    COOL WATER PUMP EBS00138 DISASSEMBLING THE WATER PUMP 1. Remove: • water pump seal 1 NOTE: Tap out the water pump seal from the inside of the water pump housing. 2 Water pump housing 2. Remove: • bearing 1 • oil seal 2 NOTE: Tap out the bearing and oil seal from the out- side of the water pump housing.

  • Page 246: Assembling The Water Pump

    COOL WATER PUMP EBS00140 ASSEMBLING THE WATER PUMP 1. Install: • oil seal 1 0.5~1.0 mm (into the water pump housing 2) (0.02~0.04 in) NOTE: • Before installing the oil seal, apply tap water or coolant onto its out surface. •...
  • Page 247 CHAPTER 6 FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM................6-1 CIRCUIT DIAGRAM .................. 6-2 ECU’S SELF-DIAGNOSTIC FUNCTION........... 6-4 SELF-DIAGNOSTIC FUNCTION TABLE ..........6-5 TROUBLESHOOTING CHART ..............6-6 DIAGNOSTIC MODE ................6-7 TROUBLESHOOTING DETAILS ............6-11 CHECKING THE SPEED SENSOR ............6-25 CHECKING THE INTAKE AIR PRESSURE SENSOR ......6-26 CHECKING THE INTAKE AIR TEMPERATURE SENSOR ....6-27 THROTTLE BODY..................

  • Page 248: Fuel Injection System

    FUEL INJECTION SYSTEM EAS00894 FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM 1 Engine trouble warning light 8 Battery E Crankshaft position sensor 2 Ignition coil 9 Intake air temperature sensor F Fuel injector 3 Fuel tank 0 ECU G Coolant temperature sensor 4 Fuel hose A Air filter case H Spark plug...

  • Page 249: Circuit Diagram

    FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM 6 - 2...
  • Page 250 FUEL INJECTION SYSTEM 1 Crankshaft position sensor 4 Main switch 5 Fuel injector system fuse 6 Battery 7 Main fuse B Fuel pump relay E Engine trouble warning light H Neutral indicator light J Self-diagnosis signal coupler K ECU L Ignition coil M Spark plug N Fuel injector O Intake air temperature sensor...

  • Page 251: Ecu's Self-Diagnostic Function

    FUEL INJECTION SYSTEM ECU’S SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the engine control sys- tem is operating normally. If this function detects a malfunction in the system, it immediately oper- ates the engine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.

  • Page 252: Self-Diagnostic Function Table

    FUEL INJECTION SYSTEM EAS27380 SELF-DIAGNOSTIC FUNCTION TABLE If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illu- minates the engine trouble warning light and provides the engine with alternate operating instruc- tions that are appropriate for the type of malfunction.

  • Page 253: Troubleshooting Chart

    FUEL INJECTION SYSTEM EAS00904 TROUBLESHOOTING CHART Engine operation is not normal or the engine trouble warning light is on. * Engine trouble warning light may not come on even if the engine operation is not normal. The engine trouble warning light comes on. The engine trouble warning light does not come on.

  • Page 254: Diagnostic Mode

    FUEL INJECTION SYSTEM EAS00905 DIAGNOSTIC MODE It is possible to monitor the sensor output data or check the activation of actuators with the FI diagnostic tool connected to the vehicle and set to the normal mode or the diagnostic moni- toring mode.
  • Page 255 FUEL INJECTION SYSTEM Setting the diagnostic mode 1. Turn the main switch to “OFF” and set the engine stop switch to “RUN”. 2. Disconnect the wire harness coupler from the fuel pump. 3. Remove the self-diagnosis signal coupler cap, and then connect the FI diagnostic tool 1 as shown.
  • Page 256 FUEL INJECTION SYSTEM Diagnostic code table Fault Symptom Probable cause of malfunction Diagnostic code No. code No. • Open or short circuit in wire harness. • Defective crankshaft position sensor. No normal signals are received from • Malfunction in pickup rotor. —...
  • Page 257 FUEL INJECTION SYSTEM Sensor operation table Diagnos- tic code Item FI diagnostic tool display Checking method Throttle angle • Fully closed position 15 ~ 20 Check with throttle fully closed. • Fully opened position 95 ~ 100 Check with throttle fully open. Pressure difference Displays the intake air pressure.

  • Page 258: Troubleshooting Details

    FUEL INJECTION SYSTEM Actuator operation table • Actuator operation Set the engine stop switch to “OFF” and then to “RUN”. Diagnos- tic code Item Actuation Checking method Actuates the ignition coil for five times every second. Check the spark five times. Ignition coil Illuminates the “WARNING”...
  • Page 259 FUEL INJECTION SYSTEM Fault code No. 12 Symptom No normal signals are received from the crankshaft posi- tion sensor. Diagnostic code No. — — Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of crankshaft Check for looseness or pinching. Cranking the position sensor.
  • Page 260 FUEL INJECTION SYSTEM Fault code No. 13 Symptom Intake air pressure sensor: open or short circuit detected. Diagnostic code No. D03 Intake air pressure sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •...
  • Page 261 FUEL INJECTION SYSTEM Fault code No. 14 Symptom Intake air pressure sensor: hose system malfunction (clogged or detached hose). Diagnostic code No. D03 Intake air pressure sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Intake air pressure sensor hose •...
  • Page 262 FUEL INJECTION SYSTEM Fault code No. 15 Symptom Throttle position sensor: open or short circuit detected. Diagnostic code No. D01 Throttle position sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of throttle posi- • Check for looseness or pinching. Turning the tion sensor.
  • Page 263 FUEL INJECTION SYSTEM Fault code No. 16 Symptom Stuck throttle position sensor detected. Diagnostic code No. D01 Throttle position sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of throttle posi- • Check the installed area for Reinstated by tion sensor.
  • Page 264 FUEL INJECTION SYSTEM Fault code No. 22 Symptom Intake air temperature sensor: open or short circuit detected. Diagnostic code No. D05 Intake air temperature sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of air tempera- Check for looseness or pinching.
  • Page 265 FUEL INJECTION SYSTEM Fault code No. 30 Symptom The vehicle has overturned. Diagnostic code No. D08 Lean angle sensor Order Item/components and probable Check or maintenance job Reinstatement cause method The vehicle has overturned. Raise the vehicle upright. Turning the main switch to Installed condition of the lean Check for looseness or pinching.
  • Page 266 FUEL INJECTION SYSTEM Fault code No. 33 Symptom Malfunction detected in the primary lead of the ignition coil. Diagnostic code No. D30 Ignition coil Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the connector and cou- Starting the •...
  • Page 267 FUEL INJECTION SYSTEM Fault code No. 41 Symptom Lean angle sensor: open or short circuit detected. Diagnostic code No. D08 Lean angle sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •...
  • Page 268 FUEL INJECTION SYSTEM Fault code No. 42 Symptom A. No normal signals are received from the speed sensor. B. Open circuit is detected in the neutral switch. Diagnostic code No. A D07 Speed sensor D21 Neutral switch Order Item/components and probable Check or maintenance job Reinstatement cause...
  • Page 269 FUEL INJECTION SYSTEM Fault code No. 42 Symptom A. No normal signals are received from the speed sensor. B. Open circuit is detected in the neutral switch. Diagnostic code No. A D07 Speed sensor D21 Neutral switch Order Item/components and probable Check or maintenance job Reinstatement cause...
  • Page 270 FUEL INJECTION SYSTEM Fault code No. 43 Symptom The ECU is unable to monitor the battery voltage (an open or short circuit in the line to the ECU). Diagnostic code No. D09 Fuel system voltage Order Item/components and probable Check or maintenance job Reinstatement cause method...
  • Page 271 FUEL INJECTION SYSTEM Fault code No. 46 Symptom Power supply to the fuel injection system is not normal. Diagnostic code No. — — Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Starting the •...

  • Page 272: Checking The Speed Sensor

    FUEL INJECTION SYSTEM EAS28240 CHECKING THE SPEED SENSOR 1. Check: • speed sensor output voltage Out of specification → Replace. Output voltage reading cycle 0.6 V to 4.8 V to 0.6 V to 4.8 V M MMM M MMM M MMM M MMM M MMM a.

  • Page 273: Checking The Intake Air Pressure Sensor

    FUEL INJECTION SYSTEM EAS28410 CHECKING THE INTAKE AIR PRESSURE SENSOR 1. Check: • intake air pressure sensor output voltage B/L P/L Out of specification → Replace. Intake pressure sensor output voltage 3.00 ~ 4.00 V M MMM M MMM M MMM M MMM M MMM a.

  • Page 274: Checking The Intake Air Temperature Sensor

    FUEL INJECTION SYSTEM CHECKING THE INTAKE AIR TEMPERATURE SENSOR 1. Remove: • air temperature sensor Br/W B/W WARNING • Handle the air temperature sensor with special care. • Never subject the air temperature sensor to strong shocks. If the air temperature sensor is dropped, replace it.

  • Page 275: Throttle Body

    THROTTLE BODY EAS00909 THROTTLE BODY 3 Nm (0.3 m kg, 2.2 ft • • 13 14 4 Nm (0.4 m kg, 2.9 ft • • Order Job/Part Q’ty Remarks Removing the throttle body Remove the parts in the order listed. Fuel tank shield Refer to “SEAT, FENDERS AND FUEL TANK”...
  • Page 276 THROTTLE BODY 3 Nm (0.3 m kg, 2.2 ft • • 13 14 4 Nm (0.4 m kg, 2.9 ft • • Order Job/Part Q’ty Remarks Fast idle plunger inlet hose Fast idle plunger outlet hose Disconnect. Intake air pressure sensor hose Intake air pressure sensor Intake manifold clamp screw Loosen.
  • Page 277 THROTTLE BODY EAS00910 Order Job/Part Q’ty Remarks Removing the injector Remove the parts in the order listed. Throttle position sensor Fuel injection pipe Fuel injector Fast idle plunger unit Throttle body CAUTION: The throttle body should not be disas- sembled. For installation, reverse the removal pro- cedure.

  • Page 278: Checking The Injector

    THROTTLE BODY EAS00912 CHECKING THE INJECTOR 1. Check: • injector Damage → Replace. EAS00913 CHECKING THE THROTTLE BODY 1. Check: • throttle body Cracks/damage → Replace the throttle body. 2. Check: • fuel passages Obstructions → Clean. M MMM M MMM M MMM M MMM M MMM...

  • Page 279: Checking The Fuel Pump And Pressure Regulator Operation

    THROTTLE BODY 5. Check: • throttle position sensor Refer to “CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR”. EAS00915 CHECKING THE FUEL PUMP AND PRESSURE REGULATOR OPERATION 1. Check: • pressure regulator operation M MMM M MMM M MMM M MMM M MMM a.

  • Page 280: Checking And Adjusting The Throttle Position Sensor

    THROTTLE BODY EAS00916 CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR NOTE: Before adjusting the throttle position sensor, the engine idling speed should be properly adjusted. 1. Check: • throttle position sensor M MMM M MMM M MMM M MMM M MMM a.
  • Page 281 THROTTLE BODY Slot is worn or broken → Replace the throt- tle position sensor. NOTE: Check mainly that the resistance changes gradually when opening the throttle, since the readings (from closed to wide-open throttle) may differ slightly from those specified. Throttle position sensor resis- tance 0 ~ 5 ±...

  • Page 282: Chas

    CHAS CHAPTER 7 CHASSIS FRONT AND REAR WHEELS ................ 7-1 FRONT WHEELS ..................7-1 REAR WHEELS ..................7-3 CHECKING THE WHEELS ............... 7-4 CHECKING THE WHEEL HUBS............... 7-4 CHECKING THE BRAKE DISCS .............. 7-5 INSTALLING THE FRONT WHEEL HUB BEARINGS ......7-6 INSTALLING THE FRONT BRAKE DISCS..........
  • Page 283 CHAS STEERING SYSTEM ..................7-44 HANDLEBAR................... 7-44 REMOVING THE FRONT BRAKE LIGHT SWITCH AND CLUTCH SWITCH .................7-46 REMOVING THE HANDLEBAR GRIPS..........7-46 CHECKING THE HANDLEBAR ..............7-46 INSTALLING THE HANDLEBAR ............7-47 INSTALLING THE HANDLEBAR GRIPS ..........7-47 INSTALLING THE CLUTCH LEVER ............7-48 INSTALLING THE BRAKE MASTER CYLINDER ........

  • Page 284: Front And Rear Wheels

    CHAS FRONT AND REAR WHEELS EBS00378 CHASSIS FRONT AND REAR WHEELS FRONT WHEELS Order Job/Part Q’ty Remarks Removing the front wheels Remove the parts in the order listed. The following procedure applies to both of the front wheels. Place the vehicle on a level surface. WARNING Securely support the vehicle so there is no danger of it falling over.
  • Page 285 CHAS FRONT AND REAR WHEELS Order Job/Part Q’ty Remarks Brake caliper assembly NOTE: Do not squeeze the brake lever when the brake caliper is off of the brake discs as the brake pads will be forced shut. Wheel hub Brake disc For installation, reverse the removal pro- cedure.

  • Page 286: Rear Wheels

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

  • Page 287: Checking The Wheels

    CHAS FRONT AND REAR WHEELS EBS00383 CHECKING THE WHEELS 1. Check: • wheels 2. Measure: • wheel runout Over the specified limit → Replace the wheel or check the wheel bearing play 1. Wheel runout limit Radial 2: 2.0 mm (0.08 in) Lateral 3: 2.0 mm (0.08 in) 3.

  • Page 288: Checking The Brake Discs

    CHAS FRONT AND REAR WHEELS 2. Check: • wheel bearings Wheel hub play/wheel turns roughly → Replace. M MMM M MMM M MMM M MMM M MMM a. Clean wheel hub exterior. b. Drive bearing out by pushing spacer aside and tapping around perimeter of bearing inner race.

  • Page 289: Installing The Front Wheel Hub Bearings

    CHAS FRONT AND REAR WHEELS INSTALLING THE FRONT WHEEL HUB BEARINGS 1. Install: • bearings 1 NOTE: Face the oil seal side of the bearing inward. INSTALLING THE FRONT BRAKE DISCS 1. Install: • brake discs NOTE: Install the brake discs with their spot-faced side facing the bolt heads.

  • Page 290: Installing The Front Wheel Hubs

    CHAS FRONT AND REAR WHEELS EBS00390 INSTALLING THE FRONT WHEEL HUBS 1. Install: • front axle nuts 1 70 Nm (7.0 m · kg, 50 ft · lb) • cotter pins 2 NOTE: Do not loosen the axle nut after torquing it. If an axle nut slot is not aligned with the cotter pin hole on either side of the axle, further tighten the axle nut until a slot is aligned with...

  • Page 291: Rear Axle And Rear Axle Hub

    CHAS REAR AXLE AND REAR AXLE HUB EBS00382 REAR AXLE AND REAR AXLE HUB Order Job/Part Q’ty Remarks Removing the rear axle and rear axle Remove the parts in the order listed. Rear wheels/rear wheel hubs Refer to “FRONT AND REAR WHEELS”. Bolt Refer to “REMOVING THE REAR AXLE”...
  • Page 292 CHAS REAR AXLE AND REAR AXLE HUB Order Job/Part Q’ty Remarks Brake disc/brake disc bracket Refer to “REMOVING THE REAR Rear axle AXLE”. Circlip Driven sprocket/sprocket bracket Refer to “INSTALLING THE DRIVEN SPROCKET”. Circlip Brake caliper bracket Spacer Rear axle hub Oil seal Bearing Bearing...

  • Page 293: Removing The Rear Brake Caliper

    CHAS REAR AXLE AND REAR AXLE HUB REMOVING THE REAR BRAKE CALIPER NOTE: If the rear brake caliper cannot be removed easily, first remove the brake pad, next remove the caliper. EBS00393 REMOVING THE REAR AXLE 1. Place the vehicle on a level surface. 2.

  • Page 294: Checking The Rear Axle

    CHAS REAR AXLE AND REAR AXLE HUB 7. Remove: • rear axle 1 (with driven sprocket) 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, then pull out the rear axle to the left.

  • Page 295: Checking The Brake Disc

    CHAS REAR AXLE AND REAR AXLE HUB CHECKING THE BRAKE DISC 1. Check: • brake disc Refer to “FRONT AND REAR WHEELS”. INSTALLING THE DRIVEN SPROCKET 1. Install: • driven sprocket NOTE: Make sure that the blunt-edged corner a of the driven sprocket is facing outward.
  • Page 296 CHAS REAR AXLE AND REAR AXLE HUB 3. Tighten: • nut 1 M MMM M MMM M MMM M MMM M MMM a. Tighten the nut with rear axle nut wrench 46 mm 2 to specification while holding the rear axle. Rear axle nut wrench (46 mm) 90890-01498 Axle nut wrench (46 mm)

  • Page 297: Front And Rear Brakes

    CHAS FRONT AND REAR BRAKES EBS00400 FRONT AND REAR BRAKES FRONT BRAKE PADS 17 Nm (1.7 m kg, 12 ft • • 28 Nm (2.8 m kg, 20 ft Ib) • Order Job/Part Q’ty Remarks Removing the front brake pads Remove the parts in the order listed.

  • Page 298: Rear Brake Pads

    CHAS FRONT AND REAR BRAKES EBS00401 REAR BRAKE PADS 17 Nm (1.7 m kg, 12 ft • • 34 Nm (3.4 m kg, 24 ft • • Order Job/Part Q’ty Remarks Removing the rear brake pads Remove the parts in the order listed. Brake caliper mounting bolt Brake pad retaining bolt Refer to “REPLACING THE REAR...

  • Page 299: Replacing The Front Brake Pads

    CHAS FRONT AND REAR BRAKES EBS00402 CAUTION: Disc brake components rarely require dis- assembly. DO NOT: • disassemble components unless abso- lutely necessary; • use solvents on internal brake compo- nents; • use spent brake fluid for cleaning; (use only clean brake fluid) •...
  • Page 300 CHAS FRONT AND REAR BRAKES 2. Install: • brake pads • brake pad spring NOTE: Always install new brake pads and brake pad spring as a set. M MMM M MMM M MMM M MMM M MMM a. Connect a suitable hose 1 tightly to the brake caliper bleed screw 2.

  • Page 301: Replacing The Rear Brake Pads

    CHAS FRONT AND REAR BRAKES EBS00405 REPLACING THE REAR BRAKE PADS NOTE: It is not necessary to disassemble the brake caliper and brake hose to replace the brake pads. 1. Remove: • brake pads a wear limit NOTE: Replace the brake pads as a set if either is found to be worn to the wear limit.
  • Page 302 CHAS FRONT AND REAR BRAKES d. Install new brake pads, a new insulator, a new pad shim, a new pad spring, and the rear brake caliper. NOTE: Align the projection c on the piston side of the brake pad with the lower recess in the brake caliper piston.

  • Page 303: Front Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EBS00407 FRONT BRAKE MASTER CYLINDER Order Job/Part Q’ty Remarks Removing the front brake master Remove the parts in the order listed. cylinder Brake fluid Drain. Brake fluid reservoir cap Brake fluid reservoir diaphragm Front brake light switch Brake lever Union bolt Copper washer...
  • Page 304 CHAS FRONT AND REAR BRAKES EBS00409 Order Job/Part Q’ty Remarks Disassembling the front brake mas- Remove the parts in the order listed. ter cylinder Dust boot Refer to “ASSEMBLING THE FRONT Circlip BRAKE MASTER CYLINDER”. Brake master cylinder kit For assembly, reverse the disassembly procedure.

  • Page 305: Rear Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EBS00410 REAR BRAKE MASTER CYLINDER 4 Nm (0.4 m kg, 2.9 ft • • 20 Nm (2.0 m kg, 14 ft • • 30 Nm (3.0 m kg, 22 ft • • 20 Nm (2.0 m kg, 14 ft •...
  • Page 306 CHAS FRONT AND REAR BRAKES 4 Nm (0.4 m kg, 2.9 ft • • 20 Nm (2.0 m kg, 14 ft • • 30 Nm (3.0 m kg, 22 ft • • 20 Nm (2.0 m kg, 14 ft • •...
  • Page 307 CHAS FRONT AND REAR BRAKES EBS00411 Order Job/Part Q’ty Remarks Disassembling the rear brake mas- Remove the parts in the order listed. ter cylinder Hose joint Brake master cylinder kit Refer to “ASSEMBLING THE REAR Brake master cylinder BRAKE MASTER CYLINDER”. For assembly, reverse the disassembly procedure.

  • Page 308: Removing The Front Brake Light Switch

    CHAS FRONT AND REAR BRAKES EBS00446 REMOVING THE FRONT BRAKE LIGHT SWITCH 1. Remove: • front brake light switch 1 NOTE: Push the fastener when removing the front brake light switch out of the brake master cylin- der. EBS00413 È CHECKING THE MASTER CYLINDERS 1.

  • Page 309: Assembling The Front Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES 4. Check: • rear brake fluid reservoir 1 • rear brake fluid reservoir diaphragm 2 Cracks/damage → Replace. EBS00415 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER WARNING • All internal brake components should be cleaned and lubricated with new brake fluid only before installation.

  • Page 310: Installing The Front Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EBS00418 INSTALLING THE FRONT BRAKE MASTER CYLINDER 1. Install: • brake master cylinder 1 7 Nm (0.7 m · kg, 5.1 ft · lb) NOTE: • The “UP” mark on the brake master cylinder bracket should face up. •...
  • Page 311 CHAS FRONT AND REAR BRAKES 3. Fill: • brake master cylinder reservoir Recommended brake fluid DOT 4 CAUTION: Brake fluid may damage painted surfaces or plastic parts. Always clean up spilled brake fluid immediately. WARNING • Use only the designated quality brake fluid: other brake fluids may deteriorate the rubber seals, causing leakage and poor brake performance.

  • Page 312: Installing The Rear Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EBS00419 INSTALLING THE REAR BRAKE MASTER CYLINDER 1. Install: • copper washers • brake hose 1 • union bolt 2 30 Nm (3.0 m · kg, 22 ft · lb) CAUTION: When installing the brake hose onto the brake master cylinder, make sure the brake hose is installed between the stoppers a and b on brake master cylinder as shown.
  • Page 313 CHAS FRONT AND REAR BRAKES 3. Air bleed: • brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. 4. Check: • brake fluid level Brake fluid level is under the “LOWER” level line → Add the recommended brake fluid to the proper level.

  • Page 314: Front Brake Calipers

    CHAS FRONT AND REAR BRAKES EBS00421 FRONT BRAKE CALIPERS 17 Nm (1.7 m kg, 12 ft • • 28 Nm (2.8 m kg, 20 ft • • 27 Nm (2.7 m kg, 19 ft • • Order Job/Part Q’ty Remarks Removing the front brake calipers Remove the parts in the order listed.
  • Page 315 CHAS FRONT AND REAR BRAKES EBS00423 17 Nm (1.7 m kg, 12 ft • • 6 Nm (0.6 m kg, 4.3 ft • • Order Job/Part Q’ty Remarks Disassembling the front brake cali- Remove the parts in the order listed. pers The following procedure applies to both of the front brake calipers.

  • Page 316: Rear Brake Caliper

    CHAS FRONT AND REAR BRAKES EBS00424 REAR BRAKE CALIPER 30 Nm (3.0 m kg, 22 ft • • 34 Nm (3.4 m kg, 24 ft • • Order Job/Part Q’ty Remarks Removing the rear brake caliper Remove the parts in the order listed. Brake fluid Drain.
  • Page 317 CHAS FRONT AND REAR BRAKES EBS00425 Order Job/Part Q’ty Remarks Disassembling the rear brake cali- Remove the parts in the order listed. Adjusting bolt Locknut Parking brake arm Refer to “ASSEMBLING THE REAR Parking brake shaft BRAKE CALIPER”. Rubber boot Parking brake bracket mounting bolt Parking brake case bracket Parking brake case...
  • Page 318 CHAS FRONT AND REAR BRAKES Order Job/Part Q’ty Remarks Brake caliper piston Refer to “DISASSEMBLING THE REAR Dust seal BRAKE CALIPER” and “ASSEMBLING THE REAR BRAKE CALIPER”. Caliper piston seal Bleed screw For assembly, reverse the disassembly procedure. 7 - 35...

  • Page 319: Removing The Rear Brake Caliper

    CHAS FRONT AND REAR BRAKES REMOVING THE REAR BRAKE CALIPER NOTE: If the rear brake caliper cannot be removed easily, first remove the brake pad, next remove the caliper. EBS00427 DISASSEMBLING THE FRONT BRAKE CALIPERS 1. Remove: • brake caliper pistons •...

  • Page 320: Disassembling The Rear Brake Caliper

    CHAS FRONT AND REAR BRAKES DISASSEMBLING THE REAR BRAKE CALIPER 1. Remove: • brake caliper piston 1 • dust seal 2 • caliper piston seal 3 M MMM M MMM M MMM M MMM M MMM a. Turn the brake caliper piston counterclock- wise to remove it.

  • Page 321: Assembling The Front Brake Calipers

    CHAS FRONT AND REAR BRAKES 1. Check: È • brake caliper pistons 1 Scratches/rust/wear → Replace the brake caliper assembly. • brake caliper cylinders 2 Wear/scratches → Replace the brake cali- per assembly. • brake caliper body 3 Cracks/damage → Replace. •...

  • Page 322: Assembling The Rear Brake Caliper

    CHAS FRONT AND REAR BRAKES EBS00432 ASSEMBLING THE REAR BRAKE CALIPER WARNING • All internal brake components should be cleaned and lubricated with new brake fluid only before installation. Recommended brake fluid DOT 4 • Replace the caliper piston seal and dust seal whenever a brake caliper is disas- sembled.

  • Page 323: Installing The Front Brake Calipers

    CHAS FRONT AND REAR BRAKES EBS00434 INSTALLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the front brake calipers. 1. Install: • brake caliper assembly • brake caliper mounting bolts 1 28 Nm (2.8 m · kg, 20 ft · lb) •...

  • Page 324: Installing The Rear Brake Caliper

    CHAS FRONT AND REAR BRAKES 3. Air bleed: • brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. 4. Check: • brake fluid level Brake fluid level is below the “LOWER” level line → Add the recommended brake fluid to the proper level.
  • Page 325 CHAS FRONT AND REAR BRAKES 2. Fill: • brake fluid reservoir Recommended brake fluid DOT 4 CAUTION: Brake fluid may damage painted surfaces or plastic parts. Always clean up spilled brake fluid immediately. WARNING • Use only the designated quality brake fluid: other brake fluids may deteriorate the rubber seals, causing leakage and poor brake performance.
  • Page 326 CHAS FRONT AND REAR BRAKES 5. Adjust: • parking brake cable end length a M MMM M MMM M MMM M MMM M MMM a. Loosen the locknut 1 and adjusting bolt 2. b. Slide back the rubber cover 3. c.

  • Page 327: Steering System

    CHAS STEERING SYSTEM EBS00444 STEERING SYSTEM HANDLEBAR 7 Nm (0.7 m kg, 5.1 ft • • 23 Nm (2.3 m kg, 17 ft • • 4 Nm (0.4 m kg, 2.9 ft • • 4 Nm (0.4 m kg, 2.9 ft •...
  • Page 328 CHAS STEERING SYSTEM 7 Nm (0.7 m kg, 5.1 ft • • 23 Nm (2.3 m kg, 17 ft • • 4 Nm (0.4 m kg, 2.9 ft • • 4 Nm (0.4 m kg, 2.9 ft • • 7 Nm (0.7 m kg, 5.1 ft •...

  • Page 329: Removing The Front Brake Light Switch And Clutch Switch

    CHAS STEERING SYSTEM EBS00446 REMOVING THE FRONT BRAKE LIGHT SWITCH AND CLUTCH SWITCH 1. Remove: • front brake light switch 1 • clutch switch NOTE: • Push the fastener when removing the front brake light switch out of the brake master cyl- inder.

  • Page 330: Installing The Handlebar

    CHAS STEERING SYSTEM EBS00449 INSTALLING THE HANDLEBAR 1. Install: • handlebar • handlebar holders 23 Nm (2.3 m · kg, 17 ft · lb) NOTE: • Install the handlebar within 3.3° from the hor- izontal line shown in the illustration. •...

  • Page 331: Installing The Clutch Lever

    CHAS STEERING SYSTEM EBS00452 INSTALLING THE CLUTCH LEVER 1. Install: • handlebar switch 1 • clutch lever • clutch lever bracket 2 NOTE: Install the clutch lever bracket as shown. a 53 ~ 54 mm (2.09 ~ 2.13 in) EBS00453 INSTALLING THE BRAKE MASTER CYLINDER 1.

  • Page 332: Steering Stem

    CHAS STEERING SYSTEM EBS00454 STEERING STEM Order Job/Part Q’ty Remarks Removing the steering stem Remove the parts in the order listed. Front fender/fuel tank Refer to “SEAT, FENDERS AND FUEL TANK” in chapter 3. Pitman arm Refer to “INSTALLING THE PITMAN ARM”.
  • Page 333 CHAS STEERING SYSTEM Order Job/Part Q’ty Remarks Bearing retainer Refer to “REMOVING THE BEARING RETAINER” and “INSTALLING THE BEARING RETAINER”. Bearing For installation, reverse the removal pro- cedure. 7 - 50...

  • Page 334: Removing The Bearing Retainer

    CHAS STEERING SYSTEM EBS00455 REMOVING THE BEARING RETAINER 1. Remove: • bearing retainer Damper rod holder (30 mm) 90890-01327, YM-01327 EBS00456 CHECKING THE STEERING STEM 1. Check: • steering stem 1 Bends → Replace. WARNING Do not attempt to straighten a bent stem; this may dangerously weaken the stem.

  • Page 335: Installing The Pitman Arm

    CHAS STEERING SYSTEM INSTALLING THE PITMAN ARM 1. Install: • pitman arm • washer • nut 180 Nm (18.0 m · kg, 130 ft · lb) • clip NOTE: Make sure that the threads of the steering stem, washers, nuts, and the installation sur- faces of the pitman arm are free of grease and oil.

  • Page 336: Tie-Rods And Steering Knuckles

    CHAS STEERING SYSTEM EBS00460 TIE-RODS AND STEERING KNUCKLES Order Job/Part Q’ty Remarks Removing the tie-rods and steering Remove the parts in the order listed. knuckles The following procedure applies to both of the tie-rods and steering knuckles. Front wheel/brake disc Refer to “FRONT AND REAR WHEELS”.

  • Page 337: Removing The Steering Knuckles

    CHAS STEERING SYSTEM EBS00461 REMOVING THE STEERING KNUCKLES 1. Remove: • steering knuckles 1 NOTE: Use a general puller to separate the ball joint 2 and steering knuckle. EBS00462 CHECKING THE TIE-RODS 1. Check: • tie-rod free play and movement Free play →...

  • Page 338: Front Arms And Front Shock Absorber Assemblies

    FRONT ARMS AND FRONT SHOCK ABSORBER CHAS ASSEMBLIES EBS00468 FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES Order Job/Part Q’ty Remarks Removing the front arms and front Remove the parts in the order listed. shock absorber assemblies The following procedure applies to both of the front arms and front shock absorber assemblies.
  • Page 339 FRONT ARMS AND FRONT SHOCK ABSORBER CHAS ASSEMBLIES Order Job/Part Q’ty Remarks Spacer Spacer Bushing Circlip Rubber boot/boot retaining ring Ball joint For installation, reverse the removal pro- cedure. 7 - 56...

  • Page 340: Removing The Front Arms

    FRONT ARMS AND FRONT SHOCK ABSORBER CHAS ASSEMBLIES EBS00469 REMOVING THE FRONT ARMS 1. Check: • front arm free play M MMM M MMM M MMM M MMM M MMM a. Check the front arm side play È by moving È...

  • Page 341: Checking The Ball Joints

    FRONT ARMS AND FRONT SHOCK ABSORBER CHAS ASSEMBLIES EBS00472 CHECKING THE BALL JOINTS The following procedure applies to both of the front arm ball joints. 1. Check: • ball joint (upper front arm) Damage/pitting → Replace the upper front arm. Free play →...

  • Page 342: Installing The Front Arms

    FRONT ARMS AND FRONT SHOCK ABSORBER CHAS ASSEMBLIES f. Attach the assembled ball joint remover/ installer, new ball joint (with rubber boot and retaining ring) B, installer spacer 8 and installer washer 9 to the lower front arm A. NOTE: •...

  • Page 343: Rear Shock Absorber And Relay Arm

    CHAS REAR SHOCK ABSORBER AND RELAY ARM EBS00484 REAR SHOCK ABSORBER AND RELAY ARM 55 Nm (5.5 m kg, 40 ft • • 43 Nm (4.3 m kg, 31 ft • • 43 Nm (4.3 m kg, 31 ft • •...
  • Page 344 CHAS REAR SHOCK ABSORBER AND RELAY ARM 55 Nm (5.5 m kg, 40 ft • • 43 Nm (4.3 m kg, 31 ft • • 43 Nm (4.3 m kg, 31 ft • • 55 Nm (5.5 m kg, 40 ft •...

  • Page 345: Handling The Rear Shock Absorber And Gas Cylinder

    CHAS REAR SHOCK ABSORBER AND RELAY ARM EBS00485 HANDLING THE REAR SHOCK ABSORBER AND GAS CYLINDER WARNING This rear shock absorber and gas cylinder contain highly compressed nitrogen gas. Before handling the rear shock absorber or gas cylinder, read and make sure you understand the following information.

  • Page 346: Removing The Rear Shock Absorber

    CHAS REAR SHOCK ABSORBER AND RELAY ARM EBS00487 REMOVING THE REAR SHOCK ABSORBER 1. Remove: • relay arm-to-rear shock absorber lower bolt • rear shock absorber upper bolt NOTE: While removing the relay arm-to-rear shock absorber lower bolt, hold the swingarm so that it does not drop down.

  • Page 347: Installing The Relay Arm And Connecting Arm

    CHAS REAR SHOCK ABSORBER AND RELAY ARM INSTALLING THE RELAY ARM AND CONNECTING ARM 1. Install: • bushings 1 (to connecting arm) NOTE: Apply lithium-soap-based grease on the bush- ings when installing. Installed depth of bushing a 1.0 mm (0.04 in) 2.

  • Page 348: Swingarm And Drive Chain

    CHAS SWINGARM AND DRIVE CHAIN EBS00492 SWINGARM AND DRIVE CHAIN Order Job/Part Q’ty Remarks Removing the swingarm and drive Remove the parts in the order below. chain Rear axle hub Refer to “REAR AXLE AND REAR AXLE HUB”. Rear shock absorber Refer to “REAR SHOCK ABSORBER AND RELAY ARM”.
  • Page 349 CHAS SWINGARM AND DRIVE CHAIN Order Job/Part Q’ty Remarks Drive sprocket nut Refer to “INSTALLING THE DRIVE Lock washer SPROCKET”. Drive sprocket Drive chain Dust cover/washer Spacer Oil seal Bushing Refer to “INSTALLING THE SWING- ARM”. Bearing For installation, reverse the removal pro- cedure.

  • Page 350: Removing The Swingarm

    CHAS SWINGARM AND DRIVE CHAIN EBS00493 NOTE: Before removing the drive chain and the sprockets, measure the drive chain slack and a 15-link section of the drive chain. EBS00494 REMOVING THE SWINGARM 1. Check: • swingarm free play M MMM M MMM M MMM M MMM...

  • Page 351: Checking The Drive Chain

    CHAS SWINGARM AND DRIVE CHAIN 2. Check: • pivot shaft Roll the axle on a flat surface. Bends → Replace. WARNING Do not attempt to straighten a bent pivot shaft. 3. Clean: • pivot shaft • spacers • bearings • bushings Recommended cleaning solvent Kerosene 4.
  • Page 352 CHAS SWINGARM AND DRIVE CHAIN 2. Check: • drive chain Stiffness → Clean and lubricate or replace. 3. Clean: • drive chain M MMM M MMM M MMM M MMM M MMM a. Wipe the drive chain with a clean cloth. b.

  • Page 353: Installing The Swingarm

    CHAS SWINGARM AND DRIVE CHAIN 6. Check: • drive sprocket • driven sprocket More than 1/4 tooth a wear → Replace the drive chain sprockets as a set. Bent teeth → Replace the drive chain sprockets as a set. b Correct 1 Drive chain roller 2 Drive chain sprocket EBS00497...

  • Page 354: Elec

    – ELEC CHAPTER 8 ELECTRICAL ELECTRICAL COMPONENTS................ 8-1 CHECKING SWITCH CONTINUITY..............8-2 CHECKING THE SWITCHES................8-3 CHECKING THE BULBS AND BULB SOCKETS .......... 8-5 TYPES OF BULBS ..................8-5 CHECKING THE CONDITION OF THE BULBS ........8-5 CHECKING THE CONDITION OF THE BULB SOCKETS .......8-7 IGNITION SYSTEM ..................

  • Page 355: Electrical Components

    – ELEC ELECTRICAL COMPONENTS EBS00500 ELECTRICAL ELECTRICAL COMPONENTS 1 Main switch 7 Battery D Relay unit K Coolant temperature 2 Indicator light assem- 8 Starter relay E Tail/brake light sensor 9 Main fuse F ECU L Ignition coil 3 Front brake light 0 Circuit breaker (fan) G Speed sensor M Rectifier/regulator...

  • Page 356: Checking Switch Continuity

    – ELEC CHECKING SWITCH CONTINUITY EBS01028 CHECKING SWITCH CONTINUITY Check each switch for continuity with the pocket tester. If the continuity reading is incor- rect, check the wiring connections and if nec- essary, replace the switch. CAUTION: Never insert the tester probes into the cou- pler terminal slots 1.

  • Page 357: Checking The Switches

    – ELEC CHECKING THE SWITCHES EBS01029 CHECKING THE SWITCHES Check each switch for damage or wear, proper connections, and also for continuity between the ter- minals. Refer to “CHECKING SWITCH CONTINUITY”. Damage/wear → Repair or replace. Improperly connected → Properly connect. Incorrect continuity reading →...
  • Page 358 – ELEC CHECKING THE SWITCHES 1 Light switch 2 Engine stop switch 3 Start switch 4 Main switch 5 Front brake light switch 6 Clutch switch 7 Fuses 8 Reverse switch 9 Neutral switch 0 Rear brake light switch 8 - 4...

  • Page 359: Checking The Bulbs And Bulb Sockets

    – ELEC CHECKING THE BULBS AND BULB SOCKETS EBS01030 CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage or wear, proper connections, and also for con- tinuity between the terminals. Damage/wear → Repair or replace the bulb, bulb socket or both.
  • Page 360 – ELEC CHECKING THE BULBS AND BULB SOCKETS CAUTION: • Be sure to hold the socket firmly when removing the bulb. Never pull the lead, otherwise it may be pulled out of the ter- minal in the coupler. • Avoid touching the glass part of the head- light bulb to keep it free from oil, other- wise the transparency of the glass, the life of the bulb, and the luminous flux will...

  • Page 361: 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 90890-03112 Analog pocket tester...

  • Page 362: Ignition System

    – ELEC IGNITION SYSTEM EBS00503 IGNITION SYSTEM CIRCUIT DIAGRAM 8 - 8...

  • Page 363: Troubleshooting

    – ELEC IGNITION SYSTEM EBS01045 EBS01043 TROUBLESHOOTING 1. Main and ignition fuses The ignition system fails to operate (no • Check the main and ignition fuses for con- spark or intermittent spark). tinuity. Refer to “CHECKING THE FUSES” in Check: chapter 3.
  • Page 364 – ELEC IGNITION SYSTEM EBS01032 EBS01034 3. Spark plug 4. Ignition spark gap • Check the condition of the spark plug. • Disconnect the ignition coil from the spark • Check the spark plug type. plug. • Measure the spark plug gap. •...
  • Page 365 – ELEC IGNITION SYSTEM EBS01036 EBS01038 5. Spark plug cap resistance 6. Ignition coil resistance • Remove the spark plug cap from the spark • Disconnect the ignition coil connectors plug lead. from the ignition coil terminals. • Connect the pocket tester (“Ω × 1k” range) •...
  • Page 366 – ELEC IGNITION SYSTEM EBS01041 EBS01040 7. Main switch 9. Crankshaft position sensor resistance • Check the main switch for continuity. • Disconnect the crankshaft position sensor Refer to “CHECKING THE SWITCHES”. coupler from the wire harness. • Connect the pocket tester (Ω × 100) to the •...
  • Page 367 – ELEC IGNITION SYSTEM EBS01047 10.Lean angle sensor 11.Wiring • Remove the lean angle sensor. • Check the entire ignition system’s wiring. • Connect the lean angle sensor terminals Refer to “CIRCUIT DIAGRAM”. and lean angle sensor coupler terminals • Is the ignition system’s wiring properly with jumper leads as shown.

  • Page 368: Electric Starting System

    – ELEC ELECTRIC STARTING SYSTEM EBS00506 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM 8 - 14...

  • Page 369: Starting Circuit Cut-Off System Operation

    – ELEC ELECTRIC STARTING SYSTEM EBS00508 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION The starting circuit on this model consists of the starter motor, starter relay, clutch switch, and neutral switch. If the main switch is on and the engine stop switch is in the RUN position, the starter motor can be operated only if: •...

  • Page 370: Troubleshooting

    – ELEC ELECTRIC STARTING SYSTEM EBS01050 EBS01044 TROUBLESHOOTING 2. Battery The starter motor fails to turn. • Check the condition of the battery. Refer to “CHECKING AND CHARGING Check: THE BATTERY” in chapter 3. 1. main and ignition fuses 2. battery Minimum open-circuit voltage 3.
  • Page 371 – ELEC ELECTRIC STARTING SYSTEM EBS01052 EBS01053 4. Relay unit (starting circuit cut-off relay) 5. Relay unit (diode) • Remove the relay unit from the wire har- • Remove the relay unit from the wire har- ness. ness. • Connect the pocket tester (Ω × 1) and bat- •...
  • Page 372 – ELEC ELECTRIC STARTING SYSTEM EBS01054 EBS01042 6. Starter relay 8. Engine stop switch • Remove the starter relay. • Check the engine stop switch for continu- • Connect the pocket tester (Ω × 1) and bat- ity. tery (12 V) to the starter relay as shown. Refer to “CHECKING THE SWITCHES”.
  • Page 373 – ELEC ELECTRIC STARTING SYSTEM EBS01059 12.Wiring • Check the entire starting system’s wiring. Refer to “CIRCUIT DIAGRAM”. • Is the starting system’s wiring properly connected and without defects? The starting system Properly connect or circuit is OK. repair starting system’s wiring.

  • Page 374: Starter Motor

    – ELEC STARTER MOTOR EBS01061 STARTER MOTOR 5 Nm (0.5 m kg, 3.6 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Removing the starter motor Remove the parts in the order listed. Exhaust pipe Refer to “ENGINE REMOVAL”...
  • Page 375 – ELEC STARTER MOTOR EBS01062 Order Job/Part Q’ty Remarks Disassembling the starter motor Remove the parts in the order listed. O-ring Front bracket Square ring Lock washer Shim Armature assembly Refer to “ASSEMBLING THE STARTER MOTOR”. Starter motor yoke Brush holder assembly Square ring Shim Rear bracket...

  • Page 376: Checking The Starter Motor

    – ELEC STARTER MOTOR EBS01064 CHECKING THE STARTER MOTOR 1. Check: • commutator Dirt → Clean with 600-grit sandpaper. 2. Measure: • commutator diameter a Out of specification → Replace the starter motor. Commutator wear limit 27 mm (1.06 in) 3.

  • Page 377: Assembling The Starter Motor

    – ELEC STARTER MOTOR b. If any resistance is out of specification, replace the starter motor. L LLL L LLL L LLL L LLL L LLL 5. Measure: • brush length a Out of specification → Replace the brushes as a set. Brush length wear limit 5.0 mm (0.20 in) 6.
  • Page 378 – ELEC STARTER MOTOR 2. Install: • yoke • bracket NOTE: Align the match marks a on the yoke with the match mark b on the front bracket and the rear bracket. 8 - 24...

  • Page 379: Charging System

    – ELEC CHARGING SYSTEM EBS00516 CHARGING SYSTEM CIRCUIT DIAGRAM G/Y O/B Br Lg G/L W/L (GRAY) Br O/B G/Y W/L G/L Sb L/Y B/L G/W L/Y Br/G L/W Br (BLACK) Br/L R (GRAY) (GRAY) Br/G Br/L Br/L B R/L Br/L Br/Y B/Y B Br/L...

  • Page 380: Troubleshooting

    – ELEC CHARGING SYSTEM EBS01065 EBS01044 TROUBLESHOOTING 2. Battery The battery is not being charged. • Check the condition of the battery. Refer to “CHECKING AND CHARGING Check: THE BATTERY” in chapter 3. 1. main fuse 2. battery Minimum open-circuit voltage 3.
  • Page 381 – ELEC CHARGING SYSTEM EBS01066 EBS0110 3. Charging voltage 4. Stator coil resistance • Connect the engine tachometer to the • Disconnect the A.C. magneto coupler from spark plug lead. the wire harness. • Connect the pocket tester (Ω × 1) to the •...

  • Page 382: Lighting System

    – ELEC LIGHTING SYSTEM EBS00518 LIGHTING SYSTEM CIRCUIT DIAGRAM G/Y O/B Br Lg G/L W/L (GRAY) Br O/B G/Y W/L G/L Sb L/Y B/L G/W L/Y Br/G L/W Br (BLACK) Br/L R (GRAY) (GRAY) Br/G Br/L Br/L B R/L Br/L Br/Y B/Y B Br/L...

  • Page 383: Troubleshooting

    – ELEC LIGHTING SYSTEM EBS01067 EBS01044 TROUBLESHOOTING 2. Battery Any of the following fail to light: head- • Check the condition of the battery. light, tail/brake light. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: 1. main and headlight fuses Minimum open-circuit voltage 2.

  • Page 384: Checking The Lighting System

    – ELEC LIGHTING SYSTEM EBS01069 2. Headlight relay 5. Wiring • Remove the headlight relay. • Connect the pocket tester (Ω × 1) and bat- • Check the entire lighting system’s wiring. Refer to “CIRCUIT DIAGRAM”. tery (12 V) to the headlight relay as shown. •...
  • Page 385 – ELEC LIGHTING SYSTEM 2. The tail light fails to come on. 3. Voltage 1. Tail/brake light • Connect the pocket tester (DC 20 V) to the headlight couplers as shown. • Disconnect the tail/brake light coupler (tail/ È When the light switch is set to “LO” brake light assembly side).
  • Page 386 – ELEC LIGHTING SYSTEM 2. Voltage • Connect the pocket tester (DC 20 V) to the tail/brake light coupler as shown. Tail/brake light coupler (wire harness side) Tail/brake light Positive tester probe → blue 1 Negative tester probe → black 2 •...

  • Page 387: Signaling System

    – ELEC SIGNALING SYSTEM EBS00521 SIGNALING SYSTEM CIRCUIT DIAGRAM 8 - 33...

  • Page 388: Troubleshooting

    – ELEC SIGNALING SYSTEM EBS01073 EBS01044 TROUBLESHOOTING 2. Battery Any of the following fail to light: brake • Check the condition of the battery. light or an indicator light. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: 1.

  • Page 389: Checking The Signaling System

    – ELEC SIGNALING SYSTEM EBS01075 3. Voltage CHECKING THE SIGNALING SYSTEM EBS01076 • Connect the pocket tester (DC 20 V) to the 1. The brake light fails to come on. tail/brake light coupler (wire harness side) as shown. 1. Tail/brake light Positive tester probe →...
  • Page 390 – ELEC SIGNALING SYSTEM EBS01077 EBS01053 2. The neutral indicator light fails to come on. 3. Relay unit (diode) 1. Indicator light assembly • Remove the relay unit from the wire har- • Disconnect the indicator light assembly ness. • Connect the pocket tester (Ω × 1) to the coupler from the wire harness.
  • Page 391 – ELEC SIGNALING SYSTEM EBS01083 4. Voltage 3. The reverse indicator light fails to come on. • Connect the pocket tester (DC 20 V) to the 1. Indicator light assembly indicator light assembly coupler (wire har- • Disconnect the indicator light assembly ness side) as shown.
  • Page 392 – ELEC SIGNALING SYSTEM EBS01083 3. Voltage 4. The coolant temperature warning light does not come on when the main switch is set to • Connect the pocket tester (DC 20 V) to the “ON”, or if the coolant temperature warning indicator light assembly coupler (wire har- light does not come on when the tempera- ness side) as shown.
  • Page 393 – ELEC SIGNALING SYSTEM EBS00812 2. Coolant temperature sensor • Remove the coolant temperature sensor from the cylinder head. • Connect the pocket tester (Ω × 10) to the coolant temperature sensor 1 as shown. • Immerse the coolant temperature sensor in a container filled with coolant 2.
  • Page 394 – ELEC SIGNALING SYSTEM 5. The fuel level warning light fails to come on. 3. Voltage 1. Indicator light assembly • Connect the pocket tester (DC 20 V) to the indicator light assembly coupler (wire har- • Disconnect the indicator light assembly ness side) as shown.
  • Page 395 – ELEC SIGNALING SYSTEM 2. Fuel sender 3. Resistor • Drain the fuel from the fuel tank and then • Disconnect the resistor coupler from the remove the fuel pump (fuel sender) from wire harness. • Connect the pocket tester (Ω × 100) to the the fuel tank.

  • Page 396: Cooling System

    – ELEC COOLING SYSTEM EBS00532 COOLING SYSTEM CIRCUIT DIAGRAM 8 - 42...
  • Page 397 – ELEC COOLING SYSTEM EBS01085 EBS01044 TROUBLESHOOTING 2. Battery The radiator fan motor fails to turn. • Check the condition of the battery. Refer to “CHECKING AND CHARGING Check: THE BATTERY” in chapter 3. 1. main and ignition fuses 2. battery Minimum open-circuit voltage 3.
  • Page 398 – ELEC COOLING SYSTEM EBS01086 5. Radiator fan motor relay 4. Radiator fan motor • Remove the radiator fan motor relay from • Disconnect the radiator fan motor coupler the wire harness. • Connect the pocket tester (Ω × 1) and bat- from the wire harness.
  • Page 399 – ELEC COOLING SYSTEM EBS01089 6. Circuit breaker (fan motor) 7. Coolant temperature sensor • Remove the circuit breaker from the wire • Remove the coolant temperature sensor harness. from the cylinder head. NOTE: • Connect the pocket tester (Ω × 10) to the The circuit breaker 1 is attached to the wire coolant temperature sensor 1 as shown.
  • Page 400 – ELEC COOLING SYSTEM EBS01090 8. Wiring • Check the entire cooling system’s wiring. Refer to “CIRCUIT DIAGRAM”. • Is the cooling system’s wiring properly connected and without defects? Replace the ECU. Properly connect or repair cooling system’s wiring. • Does the coolant temperature sensor operate properly? Replace the coolant temperature sensor.

  • Page 401: Trbl Shtg

    TRBL SHTG CHAPTER 9 TROUBLESHOOTING STARTING FAILURE/HARD STARTING ............9-1 FUEL SYSTEM..................9-1 ELECTRICAL SYSTEM................9-1 COMPRESSION SYSTEM................ 9-1 POOR IDLE SPEED PERFORMANCE ............9-2 POOR IDLE SPEED PERFORMANCE.............9-2 POOR MEDIUM AND HIGH-SPEED PERFORMANCE........9-2 POOR MEDIUM AND HIGH-SPEED PERFORMANCE ......9-2 FAULTY GEAR SHIFTING................9-2 HARD SHIFTING..................9-2 SHIFT PEDAL DOES NOT MOVE ............

  • Page 402: Starting Failure/Hard Starting

    TRBL STARTING FAILURE/HARD STARTING SHTG EBS00537 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 check, adjustment and replacement of parts.

  • Page 403: Poor Idle Speed Performance

    POOR IDLE SPEED PERFORMANCE/ TRBL POOR MEDIUM AND HIGH-SPEED PERFORMANCE/ SHTG FAULTY GEAR SHIFTING EBS00538 POOR IDLE SPEED PERFORMANCE POOR IDLE SPEED PERFORMANCE Electrical system Valve train • Faulty spark plug • Improperly adjusted valve clearance • Faulty ECU Air filter •...

  • Page 404: Clutch Slipping/Dragging

    CLUTCH SLIPPING/DRAGGING/ TRBL OVERHEATING/OVERCOOLING SHTG EBS00545 CLUTCH SLIPPING/DRAGGING CLUTCH SLIPPING Clutch Engine oil • Loose clutch spring • Low oil level • Fatigued clutch spring • Improper quality (low viscosity) • Worn friction plate • Deteriorated oil • Worn clutch plate •...

  • Page 405: Faulty Brake

    FAULTY BRAKE/ TRBL SHOCK ABSORBER MALFUNCTION/ SHTG UNSTABLE HANDLING EBS00550 FAULTY BRAKE POOR BRAKING EFFECT Disc brake • Worn brake pads • Worn disc • Air in brake fluid • Leaking brake fluid • Faulty master cylinder kit cup • Faulty caliper kit seal •...

  • Page 406: Lighting System

    TRBL LIGHTING SYSTEM SHTG EBS00553 LIGHTING SYSTEM HEADLIGHT DOES NOT COME ON HEADLIGHT BULB BURNT OUT • Improper bulb • Improper bulb • Too many electrical accessories • Faulty battery • Hard charging (broken stator coil and/or • Faulty rectifier/regulator faulty rectifier/regulator) •...
  • Page 407 YFM700RV 2006 WIRING DIAGRAM 1 Crankshaft position sensor COLOR CODE 2 A.C. magneto B ....Black 3 Rectifier/regulator Br ...Brown 4 Main switch G....Green 5 Fuel injection system fuse L.....Blue 6 Battery Lg...Light green 7 Main fuse O....Orange 8 Starter relay P ....Pink 9 Starter motor R ....Red...
  • Page 408 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN...
  • Page 409 YFM700RV 2006 YFM700RV 2006 WIRING DIAGRAM SCHÉMA DE CÂBLAGE G/W Sb Sb G/W (GRAY) (GRAY) Br/W MAIN HARNESS WIRE SUB LEAD G/Y O/B Br R/L R/B Lg G/L W/L (GLAY) (GRAY) Br O/B G/Y W/L G/L Sb L/Y B/L G/W L/Y Br/W B/W (BLACK) Br/W...

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