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Yamaha Grizzly550 User Manual

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Summary of Contents for Yamaha Grizzly550

  • Page 2 Information Layout In the bookmarks to the left you will find the information divided into different color coded segments: Primary Information This is the core information for this vehicle. Use this segment as your major point of reference and information. Supplementary Information (if available) These segments are updates and additions to the core...
  • Page 3 EAS20100 1. Serviceable with engine mounted SYMBOLS 2. Filling fluid The following symbols are used in this manual 3. Lubricant for easier understanding. 4. Special tool 5. Tightening torque The following symbols are not relevant to every 6. Wear limit, clearance vehicle.

  • Page 5: Table Of Contents

    EAS20110 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM DRIVE TRAIN ELECTRICAL SYSTEM TROUBLESHOOTING techsparkstudio.com...

  • Page 7: General Information

    GENERAL INFORMATION 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 OUTLINE OF THE EPS (ELECTRIC POWER STEERING) SYSTEM (YFM5FGP/YFM7FGP only)..............1-5 EPS (ELECTRIC POWER STEERING) SYSTEM BLOCK DIAGRAM (YFM5FGP/YFM7FGP only)..............1-7 INSTRUMENT FUNCTIONS ..............

  • Page 8: Identification

    IDENTIFICATION EAS20130 IDENTIFICATION EAS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the front left side of the frame. EAS20150 MODEL LABEL The model label “1” is affixed to the location shown in the illustration. This information will be needed to order spare parts.

  • Page 9: Features

    FEATURES EAS20170 FEATURES EAS28P1031 OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective carburetor.

  • Page 10: Fi System

    FEATURES EAS28P1032 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 kgf/cm², 46.1 psi). Accordingly, 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 FEATURES techsparkstudio.com...

  • Page 12: Outline Of The Eps (Electric Power Steering) System (Yfm5Fgp/Yfm7Fgp Only)

    FEATURES EAS28P1033 OUTLINE OF THE EPS (ELECTRIC POWER STEERING) SYSTEM (YFM5FGP/YFM7FGP only)
  • Page 13 FEATURES 1. Speed information from speed sensor b. Twists torsion bar 2. Engine starting RPM information from ECU c. Sends the torque sensor signal 3. Battery d. EPS control unit calculates assist power 4. Steering stem e. Electricity output switched by EPS control unit 5.

  • Page 14: Eps (Electric Power Steering) System Block Diagram (Yfm5Fgp/Yfm7Fgp Only)

    FEATURES EAS28P1034 EPS (ELECTRIC POWER STEERING) SYSTEM BLOCK DIAGRAM (YFM5FGP/YFM7FGP only)
  • Page 15 FEATURES 1. EPS unit 2. Torque sensor 3. EPS motor 4. EPS control unit 5. Battery 6. Engine rpm signal 7. Coolant temperature sensor signal 8. Crankshaft position sensor signal 9. Speed sensor signal 10. ECU (engine control unit) 11. Intake air temperature sensor signal 12.

  • Page 16: Instrument Functions

    FEATURES Clock mode EAS28P1035 INSTRUMENT FUNCTIONS Pushing the “CLOCK” button switches the dis- play between the clock mode “CLOCK” and the Multifunction display hour meter mode “HOUR” in the following order: CLOCK → HOUR → CLOCK To set the clock: 1.
  • Page 17 FEATURES Self-diagnosis device 1. Fault code display This model is equipped with a self-diagnosis de- vice for various electrical circuits. If any of those circuits are defective, the multi- function display will indicate a two-digit fault code. If the multifunction display indicates such a fault code, note the code number, and check the vehicle.

  • Page 18: Important Information

    5. Keep all parts away from any source of fire. EAS20200 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.

  • Page 19: Bearings And Oil Seals

    IMPORTANT INFORMATION EAS20230 BEARINGS AND OIL SEALS Install bearings “1” and oil seals “2” so that the manufacturer marks or numbers are visible. When installing oil seals “2”, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if appropriate.

  • Page 20: Checking The Connections

    CHECKING THE CONNECTIONS EAS20250 CHECKING THE CONNECTIONS Pocket tester 90890-03112 Check the leads, couplers, and connectors for Analog pocket tester stains, rust, moisture, etc. YU-03112-C 1. Disconnect: • Lead • Coupler • If there is no continuity, clean the terminals. •...

  • Page 21: Special Tools

    SPECIAL TOOLS EAS20260 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes.
  • Page 22 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Compression gauge 90890-03081 Engine compression tester YU-33223 Extension 90890-04082 Oil filter wrench 3-11 90890-01426 YU-38411 Belt tension gauge 3-28 90890-03170 Rear drive belt tension gauge YM-03170 Ring nut wrench 3-31, 3-32 90890-01268 Spanner wrench YU-01268 Ball joint remover...
  • Page 23 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Weight 5-18 90890-01084 YU-01083-3 YU-01083-3 Valve spring compressor 5-22, 5-27 90890-04019 YM-04019 Valve spring compressor attachment 5-22, 5-27 90890-01243 Valve spring compressor adapter (26 mm) YM-01253-1 Valve guide remover (ø6) 5-23 90890-04064 Valve guide remover (6.0 mm) YM-04064-A Valve guide installer (ø6)
  • Page 24 5-38, 5-50, Primary clutch holder 5-54 YS-01880-A Flywheel puller 5-36 90890-01362 Heavy duty puller YU-33270-B Yamaha bond No. 1215 5-38, 5-66 90890-85505 (Three Bond No.1215®) Digital circuit tester 5-42, 7-7 90890-03174 Model 88 Multimeter with tachometer YU-A1927 Sheave fixed block...
  • Page 25 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Locknut wrench 5-50, 5-53 90890-01348 YM-01348 Sheave spring compressor 5-50, 5-53 90890-04134 YM-04134 Universal clutch holder 5-58, 5-59 90890-04086 YM-91042 Crankcase separating tool 5-70 90890-01135 Crankcase separator YU-01135-B techsparkstudio.com 1-18...
  • Page 26 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Crankshaft installer pot 5-72 90890-01274 Installing pot YU-90058 YU-90058/YU-90059 Crankshaft installer bolt 5-72 90890-01275 Bolt YU-90060 Adapter (M16) 5-72 90890-04130 Adapter #13 YM-04059 Spacer (crankshaft installer) 5-72 90890-04081 Pot spacer YM-91044 YM-91044 Spacer 5-72 ø35...
  • Page 27 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Bearing retainer wrench 5-83, 5-84 90890-04128 Middle gear bearing retainer YM-04128 Ring nut wrench 5-83, 5-84 90890-01430 YM-38404 Final gear backlash band 5-86, 8-29 90890-01511 Middle drive gear lash tool YM-01230 Radiator cap tester 90890-01325 Radiator pressure tester YU-24460-01...
  • Page 28 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Middle driven shaft bearing driver 90890-04058 Bearing driver 40 mm YM-04058 Pressure gauge 90890-03153 YU-03153 Fuel pressure adapter 90890-03176 YM-03176 Boots band installation tool 8-9, 8-11, 8-22, 90890-01526 8-24 YM-01526 Ring gear fix bolt (M10) 8-13 90890-01527 YM-01527...

  • Page 29: Specifications

    SPECIFICATIONS GENERAL SPECIFICATIONS ................ 2-1 ENGINE SPECIFICATIONS ................2-2 CHASSIS SPECIFICATIONS ................2-10 ELECTRICAL SPECIFICATIONS ..............2-13 TIGHTENING TORQUES ................2-16 GENERAL TIGHTENING TORQUE SPECIFICATIONS......2-16 ENGINE TIGHTENING TORQUES............2-17 CHASSIS TIGHTENING TORQUES............2-20 LUBRICATION POINTS AND LUBRICANT TYPES ........2-24 ENGINE....................2-24 LUBRICATION SYSTEM CHART AND DIAGRAMS........2-27 LUBRICATION DIAGRAMS ..............

  • Page 30: General Specifications

    GENERAL SPECIFICATIONS EAS29110 GENERAL SPECIFICATIONS Model Model 28P1, 28P5 (YFM5FGY) 34D1, 34D5, 34D8 (YFM5FGPY) 5C0A, 5C0C (YFM7FGY) 43P1, 43P5, 43P8, 43PA (YFM7FGPY) Dimensions Overall length 2065 mm (81.3 in) Overall width 1180 mm (46.5 in) Overall height 1240 mm (48.8 in) Seat height 905 mm (35.6 in) Wheelbase...

  • Page 31: Engine Specifications

    ENGINE SPECIFICATIONS EAS29120 ENGINE SPECIFICATIONS Engine Engine type Liquid cooled 4-stroke, SOHC Displacement 558.0 cm³ (YFM5FGY/YFM5FGPY) 686.0 cm³ (YFM7FGY/YFM7FGPY) Cylinder arrangement Forward-inclined single cylinder Bore × stroke 92.0 × 84.0 mm (3.62 × 3.31 in) (YFM5FGY/YFM5FGPY) 102.0 × 84.0 mm (4.02 × 3.31 in) (YFM7FGY/YFM7FGPY) Compression ratio 9.30 :1 (YFM5FGY/YFM5FGPY)
  • Page 32 ENGINE SPECIFICATIONS Oil filter Oil filter type Cartridge (paper) Oil pump Oil pump type Trochoid Inner-rotor-to-outer-rotor-tip clearance Less than 0.12 mm (0.0047 in) Limit 0.20 mm (0.0079 in) Outer-rotor-to-oil-pump-housing clearance 0.090–0.170 mm (0.0035–0.0067 in) Limit 0.24 mm (0.0094 in) Oil-pump-housing-to-inner-and-outer-rotor clearance 0.03–0.10 mm (0.0012–0.0039 in) Limit...
  • Page 33 ENGINE SPECIFICATIONS Camshaft lobe dimensions Intake A 43.488–43.588 mm (1.7121–1.7161 in) Limit 43.388 mm (1.7082 in) Intake B 36.959–37.059 mm (1.4551–1.4590 in) Limit 36.859 mm (1.4511 in) Exhaust A 43.129–43.229 mm (1.6980–1.7019 in) Limit 43.029 mm (1.6941 in) Exhaust B 37.007–37.107 mm (1.4570–1.4609 in) Limit 36.907 mm (1.4530 in)
  • Page 34 ENGINE SPECIFICATIONS Valve face width B (exhaust) 2.26 mm (0.0890 in) Valve seat width C (intake) 1.00–1.20 mm (0.0394–0.0472 in) Limit 1.60 mm (0.0630 in) Valve seat width C (exhaust) 1.00–1.20 mm (0.0394–0.0472 in) Limit 1.60 mm (0.0630 in) Valve margin thickness D (intake) 0.80–1.20 mm (0.0315–0.0472 in) Limit 0.4 mm (0.02 in)
  • Page 35 ENGINE SPECIFICATIONS Spring rate K1 (intake) 34.18 N/mm (3.49 kgf, 195.16 lbf) Spring rate K2 (intake) 44.14 N/mm (4.50 kgf, 252.04 lbf) Spring rate K1 (exhaust) 34.18 N/mm (3.49 kgf, 195.16 lbf) Spring rate K2 (exhaust) 44.14 N/mm (4.50 kgf, 252.04 lbf) Installed compression spring force (intake) 171.00–197.00 N (17.44–20.09 kgf, 38.44–...
  • Page 36 ENGINE SPECIFICATIONS Limit 22.971 mm (0.9044 in) Piston-pin-to-piston-pin-bore clearance 0.004–0.024 mm (0.0002–0.0009 in) Limit 0.0740 mm (0.0029 in) Piston ring Top ring Ring type Barrel Dimensions (B × T) 1.20 × 3.50 mm (0.05 × 0.14 in) (YFM5FGY/YFM5FGPY) 1.20 × 3.80 mm (0.05 × 0.15 in) (YFM7FGY/YFM7FGPY) End gap (installed) 0.20–0.35 mm (0.008–0.014 in)
  • Page 37 ENGINE SPECIFICATIONS Runout limit C 0.030 mm (0.0012 in) Big end side clearance D 0.350–0.650 mm (0.0138–0.0256 in) Balancer Balancer drive method Gear Automatic centrifugal clutch Clutch type Wet, centrifugal automatic Clutch shoe thickness 1.5 mm (0.06 in) Limit 1.0 mm (0.04 in) Clutch-in revolution 2000–2100 r/min (YFM5FGY/YFM5FGPY) 1950–2050 r/min (YFM7FGY/YFM7FGPY)
  • Page 38 ENGINE SPECIFICATIONS Fuel pump Pump type Electrical Model/manufacturer 3B4/DENSO Throttle body Type/quantity 40EIS/1 Manufacturer MIKUNI ID mark 28P1 00 (YFM5FGY/YFM5FGPY) 43P1 00 (YFM7FGY/YFM7FGPY) Throttle valve size Fuel injector Model/quantity 297510–1010/1 Manufacturer DENSO Idling condition Engine idling speed 1550–1650 r/min Intake vacuum 33.0 kPa (248 mmHg, 9.7 inHg) (YFM5FGY/YFM5FGPY) 35.0 kPa (263 mmHg, 10.3 inHg)

  • Page 39: Chassis Specifications

    CHASSIS SPECIFICATIONS EAS29130 CHASSIS SPECIFICATIONS Chassis Frame type Steel tube frame Caster angle 5.0° Camber angle 0.0° Kingpin angle 11.0° Kingpin offset 0.0 mm (0.00 in) Trail 26.0 mm (1.02 in) Tread rear (STD) 915.0 mm (36.02 in) Tread front (STD) 940.0 mm (37.01 in) Toe-in (with tire touching the ground) 0.0–10.0 mm (0.00–0.39 in)
  • Page 40 CHASSIS SPECIFICATIONS Front brake Type Dual disc brake Operation Right hand operation Front brake lever free play (lever end) 0 mm (0 in) Front disc brake Disc outside diameter × thickness 220.0 × 3.5 mm (8.66 × 0.14 in) Brake disc thickness limit 3.0 mm (0.12 in) Brake disc deflection limit 0.1 mm (0.004 in)
  • Page 41 CHASSIS SPECIFICATIONS Spring preload adjusting positions Minimum Standard Maximum Rear suspension Type Double wishbone Spring/shock absorber type Coil spring/oil damper Wheel travel 230 mm (9.1 in) Rear shock absorber assembly travel 109.2 mm (4.30 in) Spring free length 318.1 mm (12.52 in) (YFM5FGY/YFM5FGPY) 314.5 mm (12.38 in) (YFM7FGY/YFM7FGPY) Installed length 270.6 mm (10.65 in) (YFM5FGY/YFM5FGPY)

  • Page 42: Electrical Specifications

    Coolant temperature sensor resistance 2.45 kΩ at 20 °C (68 °F) 290–354 Ω at 80 °C (176 °F) Ignition coil Model/manufacturer 2JN/YAMAHA Minimum ignition spark gap 6.0 mm (0.24 in) 2.16–2.64 Ω at 20 °C (68 °F) Primary coil resistance Secondary coil resistance 8.64–12.96 kΩ...
  • Page 43 ELECTRICAL SPECIFICATIONS Headlight Bulb type Halogen bulb Bulb voltage, wattage × quantity 12 V, 35.0/35.0 W × 2 Headlight 12 V, 5.0/21.0 W × 1 Tail/brake light Meter lighting Indicator and warning lights Neutral indicator light Reverse indicator light Coolant temperature warning light Park indicator light On-Command four-wheel-drive/differential gear lock indicator...
  • Page 44 ELECTRICAL SPECIFICATIONS Headlight relay Model/manufacturer G8HN-1C4T-DJ/OMRON 94.5–115.5 Ω Coil resistance Four-wheel-drive motor relay 3 Model/manufacturer ACM33211/MATSUSHITA 86.4–105.6 Ω Coil resistance Four-wheel-drive motor relay 1, 2 Model/manufacturer G8HN-1C4T-DJ/OMRON 94.5–115.5 Ω Coil resistance Circuit breaker Circuit breaker type Fuse Fuses Main fuse 40.0 A Headlight fuse 15.0 A...

  • Page 45: Tightening Torques

    TIGHTENING TORQUES EAS20320 TIGHTENING TORQUES EAS20330 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for special com- ponents or assemblies are provided for each chapter of this manual. To avoid warpage, tight- en multi-fastener assemblies in a crisscross pat- tern and progressive stages until the specified tightening torque is reached.

  • Page 46: Engine Tightening Torques

    TIGHTENING TORQUES EAS20340 ENGINE TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Exhaust pipe nut 14 Nm (1.4 m·kg, 10 ft·lb) Muffler bolt 20 Nm (2.0 m·kg, 14 ft·lb) Muffler and muffler bracket bolt 20 Nm (2.0 m·kg, 14 ft·lb) Spark arrester bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Purging bolt...
  • Page 47 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Oil check bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Cylinder head air bleed bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Camshaft sprocket bolt 20 Nm (2.0 m·kg, 14 ft·lb) Decompression assembly bolt 20 Nm (2.0 m·kg, 14 ft·lb) Valve adjusting screw locknut 14 Nm (1.4 m·kg, 10 ft·lb)
  • Page 48 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Middle drive pinion gear nut 190 Nm (19.0 m·kg, 140 ft·lb) Stake. Middle drive shaft bearing hous- 32 Nm (3.2 m·kg, 23 ft·lb) ing bolt Stake. Middle drive shaft bearing retain- 29 Nm (2.9 m·kg, 21 ft·lb) er bolt Front drive shaft yoke nut (middle...

  • Page 49: Chassis Tightening Torques

    TIGHTENING TORQUES EAS20350 CHASSIS TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Engine mounting bolt (front lower 42 Nm (4.2 m·kg, 30 ft·lb) side) Engine mounting bolt (front upper 10 Nm (1.0 m·kg, 7.2 ft·lb) side) Engine mounting bolt (rear lower 42 Nm (4.2 m·kg, 30 ft·lb) side) Engine mounting bolt (rear up-...
  • Page 50 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Front fender bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) Rear carrier bolt 34 Nm (3.4 m·kg, 24 ft·lb) Rear carrier bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) Rear carrier bracket bolt 53 Nm (5.3 m·kg, 38 ft·lb) Rear fender bolt 7 Nm (0.7 m·kg, 5.1 ft·lb)
  • Page 51 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Stabilizer holder bolt 30 Nm (3.0 m·kg, 22 ft·lb) Handlebar holder bolt 20 Nm (2.0 m·kg, 14 ft·lb) Front brake master cylinder hold- 7 Nm (0.7 m·kg, 5.1 ft·lb) er bolt Rear brake master cylinder hold- 7 Nm (0.7 m·kg, 5.1 ft·lb) er bolt...
  • Page 52 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Differential gear oil drain bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Differential case cover bolt 24 Nm (2.4 m·kg, 17 ft·lb) Differential motor bolt 11 Nm (1.1 m·kg, 8.0 ft·lb) Front drive shaft yoke nut (differ- 62 Nm (6.2 m·kg, 45 ft·lb) ential case side) Final drive assembly nut...

  • Page 53: Lubrication Points And Lubricant Types

    LUBRICATION POINTS AND LUBRICANT TYPES EAS20360 LUBRICATION POINTS AND LUBRICANT TYPES EAS20370 ENGINE Lubrication point Lubricant Oil seal lips Bearings O-rings Cylinder head bolts Crankshaft pin Connecting rod big end thrust surface Crankshaft sprocket Inner race (crankshaft) Buffer boss (crankshaft) Crankshaft seal Piston pin Piston rings and ring grooves...
  • Page 54 Shift lever 1 Shift lever 1 gear teeth and shift lever 2 gear teeth Stopper lever stopper Bearing (final drive pinion gear) Bearing (final drive case) Yamaha bond AC magneto lead grommet No.1215 (Three bond No.1215®) Yamaha bond Crankcase mating surface No.1215 (Three bond...
  • Page 55 LUBRICATION POINTS AND LUBRICANT TYPES techsparkstudio.com 2-26...

  • Page 56: Lubrication System Chart And Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20410 LUBRICATION DIAGRAMS 2-27...
  • Page 57 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil delivery pipe 1 2. Oil delivery pipe 2 3. Oil filter cartridge 4. Oil strainer 5. Drive axle 6. Relief valve assembly 7. Reverse idle gear shaft techsparkstudio.com 2-28...
  • Page 58 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-29...
  • Page 59 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Camshaft 2. Crankshaft 3. Oil strainer 4. Oil pump rotor 5. Oil pump driven gear techsparkstudio.com 2-30...

  • Page 60: Cooling System Diagrams

    COOLING SYSTEM DIAGRAMS EAS20420 COOLING SYSTEM DIAGRAMS 2-31...
  • Page 61 COOLING SYSTEM DIAGRAMS 1. Coolant reservoir hose 2. Radiator inlet hose 3. Coolant reservoir 4. Water pump 5. Water pump outlet pipe 6. Water pump outlet hose 7. Radiator outlet hose 8. Radiator techsparkstudio.com 2-32...

  • Page 62: Cable Routing

    CABLE ROUTING EAS20430 CABLE ROUTING 5 6 7 2-33...
  • Page 63 CABLE ROUTING 1. Front brake light switch lead R. Pass the final drive case breather hose through the guide on the meter bracket. 2. On-command four-wheel-drive motor switch and differential gear lock switch lead S. Fasten the front brake light switch lead, on- command four-wheel-drive motor switch and 3.
  • Page 64 CABLE ROUTING 1 2 3 ‚ 2-35...
  • Page 65 CABLE ROUTING 1. Coolant reservoir hose R. YFM5FG/YFM7FG 2. Radiator fan motor breather hose 3. Differential case breather hose 4. EPS motor breather hose (YFM5FGP/YFM7FGP only) 5. Ground lead 6. Coolant reservoir breather hose 7. Throttle cable 8. Fuel injector lead 9.
  • Page 66 CABLE ROUTING 4 5 6 7 12 13 14 15 2-37...
  • Page 67 CABLE ROUTING 1. Wire harness L. Face the end of the plastic band inward. 2. Fuel hose M. Pass the plastic band through the hole in the plastic cover, and then fasten the wire harness, 3. Intake air temperature sensor lead final drive case breather hose, ground lead, and 4.
  • Page 68 CABLE ROUTING 2-39...
  • Page 69 CABLE ROUTING 1. Tail/brake light lead 2. Rectifier/regulator lead 3. AC magneto lead 4. Speed sensor lead 5. Final drive case breather hose 6. Fuel hose 7. Fuel pump lead 8. Wire harness A. To tail/brake light B. Fasten the tail/brake light lead to the frame with plastic locking ties, making sure to face the end of each tie downward.
  • Page 70 CABLE ROUTING 2-41...
  • Page 71 CABLE ROUTING 1. Left headlight lead L. Pass the coolant reservoir breather hose through the guides on the plastic cover and electrical 2. Four-wheel-drive motor relay 1 components tray and route it under the positive 3. Four-wheel-drive motor relay 2 battery lead and starter motor lead.
  • Page 72 CABLE ROUTING 11 10 2-43...
  • Page 73 CABLE ROUTING 1. Throttle cable 2. Rear brake hose 3. Rear brake cable 4. Front brake hose 5. Negative battery lead 6. Final drive case breather hose 7. Starter motor lead 8. Throttle body breather hose 9. Intake air pressure sensor lead 10.
  • Page 74 CABLE ROUTING 2-45...
  • Page 75 CABLE ROUTING 1. Front brake pipe 2. Rear brake pipe 3. Front brake hose 4. Rear brake hose A. Pass the front brake hose through the holder. B. Fasten the front brake hose with the holder. C. Pass the rear brake pipe through the holder. D.
  • Page 76 CABLE ROUTING 2-47...

  • Page 77: Periodic Checks And Adjustments

    PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE ................3-1 INTRODUCTION ..................3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM ....................3-1 GENERAL MAINTENANCE AND LUBRICATION CHART .......3-1 ENGINE ......................3-4 ADJUSTING THE VALVE CLEARANCE ..........3-4 ADJUSTING THE THROTTLE LEVER FREE PLAY ........3-6 ADJUSTING THE SPEED LIMITER............3-6 CHECKING THE SPARK PLUG ...............
  • Page 78 CHASSIS ....................... 3-20 ADJUSTING THE FRONT DISC BRAKE..........3-20 ADJUSTING THE REAR DISC BRAKE ..........3-20 CHECKING THE BRAKE FLUID LEVEL..........3-21 CHECKING THE FRONT BRAKE PADS ..........3-21 CHECKING THE REAR BRAKE PADS ..........3-22 CHECKING THE FRONT BRAKE HOSES ..........3-22 CHECKING THE REAR BRAKE HOSES..........
  • Page 79 techsparkstudio.com...

  • Page 80: Periodic Maintenance

    However, keep in mind that if the ATV isn’t used for a long period of time, the month mainte- nance 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 81 PERIODIC MAINTENANCE INITIAL EVERY month CHECK OR MAINTENANCE Whichever ITEM 1300 2500 2500 5000 comes first km (mi) (200) (800) (1600) (1600) (3200) hours • Check for cracks or other damage, and replace if √ √ √ √ necessary. Brake hoses •...
  • Page 82 PERIODIC MAINTENANCE EBU23070 • The air filter needs more frequent service if you are riding in unusually wet or dusty areas. • Hydraulic brake service • Regularly check and, if necessary, correct the brake fluid level. • Every two years replace the internal components of the brake master cylinders and calipers, and change the brake fluid.

  • Page 83: Engine

    ENGINE EAS20472 ENGINE EAS20520 ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. • Valve clearance adjustment should be made on a cold engine, at room temperature. • When the valve clearance is to be measured or 6.
  • Page 84 ENGINE Out of specification → Adjust. Valve adjusting screw locknut 14 Nm (1.4 m·kg, 10 ft·lb) Thickness gauge 90890-03079 e. Measure the valve clearance again. Narrow gauge set YM-34483 f. If the valve clearance is still out of specifica- tion, repeat all of the valve clearance adjust- ment steps until the specified clearance is obtained.

  • Page 85: Adjusting The Throttle Lever Free Play

    ENGINE EAS20660 ADJUSTING THE THROTTLE LEVER FREE If the free play cannot be adjusted here, adjust it PLAY at the handlebar side of the cable. 1. Check: • Throttle lever free play “a” L LLL L LLL L LLL L LLL L LLL Out of specification →...

  • Page 86: Checking The Spark Plug

    ENGINE 2. Adjust: Manufacturer/model • Speed limiter length “a” NGK/LMAR6A-9 M MMM M MMM M MMM M MMM M MMM a. Loosen the locknut “1”. 5. Check: b. Turn the adjuster “2” in direction “b” or “c” until • Electrode “1” the specified speed limiter length is obtained.

  • Page 87: Checking The Ignition Timing

    ENGINE Incorrect firing range → Check the ignition 10.Install: • Right side panel system. Refer to “GENERAL CHASSIS” on page 4-1. When checking the ignition timing, make sure EAS20700 CHECKING THE IGNITION TIMING that the timing light cord does not come in con- tact with the exhaust muffler.

  • Page 88: Checking The Engine Oil Level

    ENGINE c. If the compression pressure is above the ECA28P1041 NOTICE maximum specification, check the cylinder Before removing the spark plug, use com- head, valve surfaces and piston crown for pressed air to blow away any dirt accumulat- carbon deposits. Carbon deposits →...

  • Page 89: Changing The Engine Oil

    ENGINE ECA28P1009 NOTICE Do not allow foreign materials to enter the crankcase. To obtain an accurate oil level reading, the dip- stick must be inserted completely into the oil fil- ter hole. 5. Check the engine oil level again. ECA28P1010 NOTICE Be sure the engine oil is at the correct level, otherwise engine damage may result.
  • Page 90 ENGINE 6. Drain: Engine oil drain bolt • Engine oil 30 Nm (3.0 m·kg, 22 ft·lb) (completely from the crankcase) 7. If the oil filter cartridge is also to be replaced, 10.Fill: perform the following procedure. • Crankcase M MMM M MMM M MMM M MMM...

  • Page 91: Cleaning The Air Filter Element

    ENGINE ECA28P1011 NOTICE Oil check bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) The engine should never be run without the air filter; excessive piston and/or cylinder L LLL L LLL L LLL L LLL L LLL wear may result. EAS20951 CLEANING THE AIR FILTER ELEMENT 1.

  • Page 92: Checking The V-Belt

    ENGINE V-belt width 33.3 mm (1.31 in) Limit 30.0 mm (1.18 in) 6. Apply the recommended oil to the entire sur- face of the air filter element and then carefully pat the air filter element on a clean cloth to re- move the excess oil.

  • Page 93: Checking The Throttle Body Joint

    ENGINE • Rear fender Refer to “GENERAL CHASSIS” on page 4-1. • V-belt cooling exhaust duct Refer to “ENGINE REMOVAL” on page 5-1. 2. Check: • Fuel hose “1” Cracks/damage → Replace. Loose connection → Connect properly. c. Install the V-belt. Install the V-belt so that its arrow faces the direc- tion shown in the illustration.

  • Page 94: Checking The Exhaust System

    ENGINE • Left side panel M MMM M MMM M MMM M MMM M MMM EWA28P1009 Refer to “GENERAL CHASSIS” on page 4-1. WARNING • Select a well-ventilated area free of com- EAS21080 CHECKING THE EXHAUST SYSTEM bustible materials. 1. Check: •...

  • Page 95: Checking The Coolant Level

    ENGINE 3. If the coolant is at or below the minimum level g. Start the engine and rev it up approximately mark, remove the left side panel. twenty times while momentarily creating ex- Refer to “GENERAL CHASSIS” on page 4-1. haust system back pressure by blocking the 4.

  • Page 96: Changing The Coolant

    ENGINE 4. Drain: • Coolant (from the coolant reservoir) 5. Connect: • Coolant reservoir hose 6. Remove: • Radiator cap “1” EWA13030 WARNING A hot radiator is under pressure. Therefore, do not remove the radiator cap when the en- gine is hot. Scalding hot fluid and steam may be blown out, which could cause serious in- jury.
  • Page 97 ENGINE EWA13040 WARNING • If coolant splashes in your eyes, thorough- ly wash them with water and consult a doc- tor. • If coolant splashes on your clothes, quickly wash it away with water and then with soap and water. •...
  • Page 98 ENGINE 15.Start the engine, warm it up for ten minutes, and then rev the engine five times. 16.Pour the recommended coolant into the radi- ator until it is full. 17.Stop the engine and allow it to cool. If the coolant level has dropped after the engine has cooled, add sufficient coolant until it reaches the top of the radiator, and then in- stall the radiator cap.

  • Page 99: Chassis

    CHASSIS 2. Check: EAS29360 CHASSIS • Brake pedal free play “a” Out of specification → Adjust. EAS21170 ADJUSTING THE FRONT DISC BRAKE Brake pedal free play 1. Check: 0.0–5.0 mm (0.00–0.20 in) • Front brake lever free play “a” Out of specification → Bleed the front brake system.

  • Page 100: Checking The Brake Fluid Level

    CHASSIS A. Front brake h. Adjust the drive select lever control cable. B. Rear brake Refer to “ADJUSTING THE DRIVE SELECT EWA13090 LEVER CONTROL CABLE AND SHIFT WARNING ROD” on page 3-24. • Use only the designated brake fluid. Other EWA14900 brake fluids may cause the rubber seals to WARNING...

  • Page 101: Checking The Rear Brake Pads

    CHASSIS 1. Remove: EAS21280 CHECKING THE FRONT BRAKE HOSES • Front wheels The following procedure applies to all of the Refer to “FRONT WHEELS” on page 4-14. brake hoses and brake hose clamps. 2. Operate the brake. 1. Check: 3. Check: •...

  • Page 102: Checking The Rear Brake Hose Protectors

    CHASSIS 3. Install: • Rear wheels Refer to “REAR WHEELS” on page 4-18. EAS21350 BLEEDING THE HYDRAULIC BRAKE SYSTEM EWA13100 WARNING Bleed the hydraulic brake system whenever: • the system is disassembled. • a brake hose is loosened, disconnected or 2.

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

    CHASSIS 3. Install: • Rear wheels Refer to “REAR WHEELS” on page 4-18. EAS29220 ADJUSTING THE DRIVE SELECT LEVER CONTROL CABLE AND SHIFT ROD ECA28P1012 NOTICE Before moving the drive select lever, bring the vehicle to a complete stop and return the throttle lever to its closed position.

  • Page 104: Checking The Final Gear Oil Level

    CHASSIS M MMM M MMM M MMM M MMM M MMM Drive select lever shift control cable: a. Make sure that the drive select lever is in “N” (neutral). b. Squeeze the brake lever 20 mm (0.79 in) “a”, loosen the locknut “1”, and then adjust the shift control cable “2”...

  • Page 105: Changing The Final Gear Oil

    CHASSIS Final gear oil drain bolt 23 Nm (2.3 m·kg, 17 ft·lb) 7. Fill: • Final drive case (with the specified amount of the recom- mended final gear oil) Total amount 0.25 L (0.26 US qt, 0.22 Imp.qt) 4. Install: Periodic oil change •...

  • Page 106: Changing The Differential Gear Oil

    CHASSIS Periodic oil change 0.22 L (0.23 US qt, 0.19 Imp.qt) Total amount 0.23 L (0.24 US qt, 0.20 Imp.qt) Type SAE 80 API GL-4 Hypoid gear ECA16170 NOTICE Take care not to allow foreign material to en- 4. Install: ter the differential case.

  • Page 107: Checking The Steering System

    CHASSIS L LLL L LLL L LLL L LLL L LLL 4. Raise the front end of the vehicle so that there is no weight on the front wheels. 5. Check: • Ball joints and wheel bearings Move the wheels laterally back and forth. Excessive free play →...

  • Page 108: Adjusting The Toe-In

    CHASSIS d. Tighten the steering stem bracket bolts to specification. Steering stem bracket bolt 51 Nm (5.1 m·kg, 37 ft·lb) LOCTITE® e. Tighten the steering stem joint bolts to speci- fication. Steering stem joint bolt 35 Nm (3.5 m·kg, 25 ft·lb) L LLL L LLL L LLL...

  • Page 109: Checking The Front Shock Absorber Assemblies

    CHASSIS d. Tighten the rod end locknuts of both tie-rods. Tie-rod end locknut 15 Nm (1.5 m·kg, 11 ft·lb) Adjust the tie-rod ends so that “A” and “B” are equal. C. Forward L LLL L LLL L LLL L LLL L LLL 3.

  • Page 110: Adjusting The Front Shock Absorber Assemblies

    CHASSIS Refer to “FRONT ARMS AND FRONT Spring preload adjusting positions SHOCK ABSORBER ASSEMBLIES” on Minimum page 4-59. 3. Check: Standard • Operation Pump the front shock absorber assembly up Maximum and down several times. Rough operation → Replace front shock ab- sorber assembly.

  • Page 111: Adjusting The Rear Shock Absorber Assemblies

    Tire characteristics influence the handling of Ring nut wrench vehicles. The tires listed below have been 90890-01268 approved by Yamaha Motor Co., Ltd. for this Spanner wrench model. If other tire combinations are used, YU-01268 they can adversely affect your vehicle’s han- dling characteristics and are therefore not recommended.
  • Page 112 CHASSIS • Use no more than the following pressures Tire air pressure (measured on when seating the tire beads. cold tires) Front Recommended 250 kPa (2.5 kgf/cm², 36 psi) Front Rear 35 kPa (0.35 kgf/cm², 5.0 psi) 250 kPa (2.5 kgf/cm², 36 psi) Rear Higher pressures and fast inflation may 30 kPa (0.30 kgf/cm², 4.4 psi)

  • Page 113: Checking The Wheels

    CHASSIS EAS21690 CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the in- ner and outer cables. EWA13270 WARNING Damaged outer cable may cause the cable to corrode and interfere with its movement. Re- place damaged outer cable and inner cables as soon as possible.

  • Page 114: Electrical System

    ELECTRICAL SYSTEM • Headlight bulb “2” EAS21750 ELECTRICAL SYSTEM EWA13320 WARNING EAS21760 Since the headlight bulb gets extremely hot, CHECKING AND CHARGING THE BATTERY keep flammable products and your hands Refer to “ELECTRICAL COMPONENTS” on away from the bulb until it has cooled down. page 9-75.
  • Page 115 ELECTRICAL SYSTEM Direction “a” Headlight beam is raised. Direction “b” Headlight beam is lowered. L LLL L LLL L LLL L LLL L LLL techsparkstudio.com 3-36...
  • Page 116 ELECTRICAL SYSTEM 3-37...
  • Page 117 CHASSIS GENERAL CHASSIS..................4-1 INSTALLING THE REAR FENDER............4-6 INSTALLING THE FOOTREST BOARDS..........4-12 FRONT WHEELS ..................4-14 REMOVING THE FRONT WHEELS ............4-15 CHECKING THE FRONT WHEELS............4-15 CHECKING THE FRONT WHEEL HUBS ..........4-15 INSTALLING THE FRONT BRAKE DISCS..........4-16 INSTALLING THE FRONT WHEEL HUBS ..........
  • Page 118 HANDLEBAR ....................4-44 REMOVING THE HANDLEBAR..............4-46 CHECKING THE HANDLEBAR ..............4-46 INSTALLING THE HANDLEBAR ............4-46 STEERING STEM..................4-48 CHECKING THE STEERING STEM ............4-52 INSTALLING THE STEERING STEM (for YFM5FG/YFM7FG) ....4-52 INSTALLING THE STEERING STEM (for YFM5FGP/YFM7FGP) ..4-52 INSTALLING THE PITMAN ARM (for YFM5FG/YFM7FG) .....4-53 INSTALLING THE PITMAN ARM (for YFM5FGP/YFM7FGP) ....
  • Page 119 techsparkstudio.com...

  • Page 120: General Chassis

    GENERAL CHASSIS EAS21830 GENERAL CHASSIS Removing the engine skid plates 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Front engine skid plate Center engine skid plate Rear engine skid plate For installation, reverse the removal proce- dure.
  • Page 121 GENERAL CHASSIS Removing the seat and side panels Order Job/Parts to remove Q’ty Remarks Seat Pull up the seat lock lever, then pull up on the rear of the seat. Battery cover Fuel tank cover Left side panel Right side panel Dipstick accessing panel For installation, reverse the removal proce- dure.
  • Page 122 GENERAL CHASSIS Removing the front carrier and front guard 26 Nm (2.6 m kg, 19 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 34 Nm (3.4 m kg, 24 ft • • 26 Nm (2.6 m kg, 19 ft •...
  • Page 123 GENERAL CHASSIS Removing the front fenders and front grill 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/Parts to remove Q’ty Remarks Refer to “Removing the seat and side pan-...
  • Page 124 GENERAL CHASSIS Removing the rear carrier and rear fender 34 Nm (3.4 m kg, 24 ft • • 53 Nm (5.3 m kg, 38 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 53 Nm (5.3 m kg, 38 ft •...

  • Page 125: Installing The Rear Fender

    GENERAL CHASSIS EAS28P1002 INSTALLING THE REAR FENDER 1. Install: • Rear fender Rear fender bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) The bolts may be tightened to the specified torque in any tightening sequence. However, in- stall the front bolts “1” and tighten them tempo- rarily before installing the rear bolts “2”.
  • Page 126 GENERAL CHASSIS Removing the electrical components tray 1/2 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “Removing the front fenders and Front fender/Front grill front grill”.
  • Page 127 GENERAL CHASSIS Removing the electrical components tray 1/2 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks ECU bracket Radiator fan motor coupler Disconnect. For installation, reverse the removal proce- dure.
  • Page 128 GENERAL CHASSIS Removing the electrical components tray 2/2 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/Parts to remove Q’ty Remarks Starter relay coupler Disconnect.
  • Page 129 GENERAL CHASSIS Removing the electrical components tray 2/2 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/Parts to remove Q’ty Remarks Differential motor coupler Disconnect.
  • Page 130 GENERAL CHASSIS Removing the footrest boards 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 • • 53 Nm (5.3 m kg, 38 ft •...

  • Page 131: Installing The Footrest Boards

    GENERAL CHASSIS EAS28P1003 INSTALLING THE FOOTREST BOARDS The following procedure applies to both of the footrest boards. 1. Install: • Footrest board Footrest board bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) Tighten the footrest board bolts to the specified torque in the proper tightening sequence as shown.
  • Page 132 GENERAL CHASSIS Removing the air filter case 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “Removing the seat and side pan- Seat/Side panels els”. Air filter case cover Air filter element Air filter element frame Intake air temperature sensor coupler Disconnect.

  • Page 133: Front Wheels

    FRONT WHEELS EAS21870 FRONT WHEELS Removing the front wheels and brake discs 30 Nm (3.0 m kg, 22 ft • • 260 Nm (26.0 m kg, 190 ft • • 30 Nm (3.0 m kg, 22 ft • • 55 Nm (5.5 m kg, 40 ft •...

  • Page 134: Removing The Front Wheels

    FRONT WHEELS EAS21890 REMOVING THE FRONT WHEELS 1. Place the vehicle on a level surface. 2. Elevate: • Front wheels Place the vehicle on a suitable stand so that the front wheels are elevated. 3. Remove: • Front brake calipers Do not apply the brake lever when removing the brake calipers.

  • Page 135: Installing The Front Brake Discs

    FRONT WHEELS 2. Check: EAS28P1009 INSTALLING THE FRONT BRAKE DISCS • Brake disc The following procedure applies to both of the Refer to “CHECKING THE FRONT BRAKE front brake discs. DISCS” on page 4-26 1. Install: EAS28P1011 • Brake disc INSTALLING THE FRONT WHEELS The following procedure applies to both of the Brake disc bolt...
  • Page 136 FRONT WHEELS 4-17...

  • Page 137: Rear Wheels

    REAR WHEELS EAS22020 REAR WHEELS Removing the rear wheels and brake discs 30 Nm (3.0 m kg, 22 ft • • 260 Nm (26.0 m kg, 190 ft • • 30 Nm (3.0 m kg, 22 ft • • 55 Nm (5.5 m kg, 40 ft •...

  • Page 138: Removing The Rear Wheels

    REAR WHEELS EAS22040 REMOVING THE REAR WHEELS 1. Place the vehicle on a level surface. 2. Elevate: • Rear wheels Place the vehicle on a suitable stand so that the rear wheels are elevated. 3. Remove: • Rear brake calipers EAS28P1012 INSTALLING THE REAR BRAKE DISCS Do not apply the brake lever and depress the...

  • Page 139: Installing The Rear Wheels

    REAR WHEELS 2. Check: • Brake disc Refer to “CHECKING THE REAR BRAKE DISCS” on page 4-38. EAS28P1014 INSTALLING THE REAR WHEELS The following procedure applies to both of the rear wheels. 1. Install: • Wheel The arrow mark “1” on the tire must point in the direction of wheel rotation.

  • Page 140: Front Brake

    FRONT BRAKE EAS22210 FRONT BRAKE Removing the front brake pads 5 Nm (0.5 m kg, 3.6 ft • • 17 Nm (1.7 m kg, 12 ft • • 30 Nm (3.0 m kg, 22 ft • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of...
  • Page 141 FRONT BRAKE Removing the front brake master cylinder 7 Nm (0.7 m kg, 5.1 ft • • 6 Nm (0.6 m kg, 4.3 ft • • 6 Nm (0.6 m kg, 4.3 ft • • 27 Nm (2.7 m kg, 19 ft •...
  • Page 142 FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Dust boot Circlip Brake master cylinder kit Brake master cylinder body For assembly, reverse the disassembly pro- cedure. 4-23...
  • Page 143 FRONT BRAKE Removing the front brake calipers 17 Nm (1.7 m kg, 12 ft • • 27 Nm (2.7 m kg, 19 ft • • 30 Nm (3.0 m kg, 22 ft • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers.
  • Page 144 FRONT BRAKE Disassembling the front brake calipers 5 Nm (0.5 m kg, 3.6 ft • • 17 Nm (1.7 m kg, 12 ft • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers. Brake pad holding bolt Brake pad Brake pad spring...

  • Page 145: Introduction

    FRONT BRAKE EAS22220 INTRODUCTION EWA14100 WARNING Disc brake components rarely require disas- sembly. Therefore, always follow these pre- ventive measures: • Never disassemble brake components un- less absolutely necessary. • If any connection on the hydraulic brake system is disconnected, the entire brake L LLL L LLL L LLL...

  • Page 146: Replacing The Front Brake Pads

    FRONT BRAKE d. Measure the brake disc deflection. M MMM M MMM M MMM M MMM M MMM a. Connect a clear plastic hose “1” tightly to the e. If out of specification, repeat the adjustment bleed screw “2”. Put the other end of the hose steps until the brake disc deflection is within into an open container.

  • Page 147: Checking The Front Brake Calipers

    FRONT BRAKE Recommended brake component replace- Before disassembling the brake caliper, drain ment schedule the brake fluid from the entire brake system. Brake pads If necessary 1. Remove: Piston seals, dust Every two years • Brake caliper piston “1” seals •...

  • Page 148: Installing The Front Brake Calipers

    FRONT BRAKE • Whenever a brake caliper is disassembled, EWA13090 WARNING replace the brake caliper piston seal and • Use only the designated brake fluid. Other dust seal. brake fluids may cause the rubber seals to deteriorate, causing leakage and poor Recommended fluid brake performance.

  • Page 149: Assembling The Front Brake Master Cylinder

    FRONT BRAKE 4. Check: Brake hose union bolt • Brake hoses 27 Nm (2.7 m·kg, 19 ft·lb) Cracks/damage/wear → Replace. EWA13530 EAS22520 WARNING ASSEMBLING THE FRONT BRAKE MASTER CYLINDER Proper brake hose routing is essential to in- EWA28P1008 sure safe vehicle operation. Refer to “CABLE WARNING ROUTING”...
  • Page 150 FRONT BRAKE c. Fit the hole “b” in the front brake lever cover over the nut. L LLL L LLL L LLL L LLL L LLL 4. Fill: • Brake master cylinder reservoir (with the specified amount of the recom- mended brake fluid) Recommended fluid DOT 4...

  • Page 151: Rear Brake

    REAR BRAKE EAS22550 REAR BRAKE Removing the rear brake pads 5 Nm (0.5 m kg, 3.6 ft • • 30 Nm (3.0 m kg, 22 ft • • 17 Nm (1.7 m kg, 12 ft • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of...
  • Page 152 REAR BRAKE Removing the rear brake master cylinder 7 Nm (0.7 m kg, 5.1 ft • • 6 Nm (0.6 m kg, 4.3 ft • • 6 Nm (0.6 m kg, 4.3 ft • • 27 Nm (2.7 m kg, 19 ft •...
  • Page 153 REAR BRAKE Removing the rear brake master cylinder 7 Nm (0.7 m kg, 5.1 ft • • 6 Nm (0.6 m kg, 4.3 ft • • 6 Nm (0.6 m kg, 4.3 ft • • 27 Nm (2.7 m kg, 19 ft •...
  • Page 154 REAR BRAKE Disassembling the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Dust boot Circlip Brake master cylinder kit Brake master cylinder body For assembly, reverse the disassembly pro- cedure. 4-35...
  • Page 155 REAR BRAKE Removing the rear brake calipers 17 Nm (1.7 m kg, 12 ft • • 30 Nm (3.0 m kg, 22 ft • • 27 Nm (2.7 m kg, 19 ft • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the rear brake calipers.
  • Page 156 REAR BRAKE Disassembling the rear brake calipers 5 Nm (0.5 m kg, 3.6 ft • • 17 Nm (1.7 m kg, 12 ft • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the rear brake calipers. Brake pad holding bolt Brake pad Brake pad spring...

  • Page 157: Introduction

    REAR BRAKE Refer to “CHECKING THE FRONT BRAKE EAS22560 INTRODUCTION DISCS” on page 4-26. EWA14100 WARNING Brake disc thickness limit Disc brake components rarely require disas- 3.0 mm (0.12 in) sembly. Therefore, always follow these pre- ventive measures: 5. Adjust: •...

  • Page 158: Removing The Rear Brake Master Cylinder

    REAR BRAKE EAS28P1004 REMOVING THE REAR BRAKE MASTER Always install new brake pads and a brake pad CYLINDER spring as a set. 1. Remove: • Brake lever M MMM M MMM M MMM M MMM M MMM a. Connect a clear plastic hose “1” tightly to the •...

  • Page 159: Checking The Rear Brake Calipers

    REAR BRAKE b. Remove the brake caliper dust seal and EAS22650 ASSEMBLING THE REAR BRAKE CALIPERS brake caliper piston seal. The following procedure applies to both of the L LLL L LLL L LLL L LLL L LLL brake calipers. EAS22640 EWA28P1003 CHECKING THE REAR BRAKE CALIPERS...

  • Page 160: Checking The Rear Brake Master Cylinder

    REAR BRAKE 5. Check: ECA28P1014 NOTICE • Brake lever and pedal operation Soft or spongy feeling → Bleed the brake sys- When installing the brake hose onto the brake caliper, make sure the brake pipe tem. touches the projection “a” on the brake cali- Refer to “BLEEDING THE HYDRAULIC per.
  • Page 161 REAR BRAKE • Brake lever • Align the end of the brake master cylinder hold- Brake lever pivot bolt er with the punch mark “a” on the handlebar. 6 Nm (0.6 m·kg, 4.3 ft·lb) • Install the brake master cylinder holder with the Brake lever pivot nut “UP”...
  • Page 162 REAR BRAKE ECA13540 NOTICE Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 6. Bleed: • Brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-23. 7. Check: • Brake fluid level Below the minimum level mark →...
  • Page 163 HANDLEBAR EAS22840 HANDLEBAR Removing the handlebar 20 Nm (2.0 m kg, 14 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Handlebar cover Plastic band On-command four-wheel-drive motor switch and differential gear lock switch Throttle lever assembly holder Throttle lever assembly Front brake light switch connector...
  • Page 164 HANDLEBAR Removing the handlebar 20 Nm (2.0 m kg, 14 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Handlebar For installation, reverse the removal proce- dure. 4-45...

  • Page 165: Handlebar

    HANDLEBAR EAS22860 REMOVING THE HANDLEBAR 1. Place the vehicle on a level surface. 2. Remove: • Handlebar grip “1” Blow compressed air between the left handlebar end and the handlebar grip, and gradually push the grip off the handlebar. EAS22880 CHECKING THE HANDLEBAR 1.
  • Page 166 HANDLEBAR • Install the brake master cylinder holder so that the gaps between the brake master cylinder and the brake master cylinder holder are equal. L LLL L LLL L LLL L LLL L LLL 4. Install: • Left handlebar switch •...

  • Page 167: Steering Stem

    STEERING STEM EAS29540 STEERING STEM Removing the steering stem (for YFM5FG/YFM7FG) 51 Nm (5.1 m kg, 37 ft • • 23 Nm (2.3 m kg, 17 ft • • 30 Nm (3.0 m kg, 22 ft • • 25 Nm (2.5 m kg, 18 ft •...
  • Page 168 STEERING STEM Removing the steering stem (for YFM5FG/YFM7FG) 51 Nm (5.1 m kg, 37 ft • • 23 Nm (2.3 m kg, 17 ft • • 30 Nm (3.0 m kg, 22 ft • • 25 Nm (2.5 m kg, 18 ft •...
  • Page 169 STEERING STEM Removing the steering stem (for YFM5FGP/YFM7FGP) 51 Nm (5.1 m kg, 37 ft • • 23 Nm (2.3 m kg, 17 ft • • 51 Nm (5.1 m kg, 37 ft • • 125 Nm (12.5 m kg, 90 ft •...
  • Page 170 STEERING STEM Removing the steering stem (for YFM5FGP/YFM7FGP) 51 Nm (5.1 m kg, 37 ft • • 23 Nm (2.3 m kg, 17 ft • • 51 Nm (5.1 m kg, 37 ft • • 125 Nm (12.5 m kg, 90 ft •...

  • Page 171: Checking The Steering Stem

    STEERING STEM EAS29560 EAS28P1015 CHECKING THE STEERING STEM INSTALLING THE STEERING STEM (for 1. Check: YFM5FGP/YFM7FGP) • Steering stem Bends → Replace. 7 12 17 EWA15030 WARNING Do not attempt to straighten a bent stem; this may dangerously weaken the stem. 2.

  • Page 172: Installing The Pitman Arm (For Yfm5Fg/Yfm7Fg)

    STEERING STEM • Steering stem bolts “13” • Pass the cable and hoses through the cable (temporarily tighten) guide. Refer to “CABLE ROUTING” on page 2-33. Apply lithium-soap-based grease to the oil seals and steering stem bushings. 4. Install: • Collar “14” •...
  • Page 173 STEERING STEM Align the punch mark “a” on the EPS unit with the groove “b” in the pitman arm. techsparkstudio.com 4-54...
  • Page 174 TIE-RODS AND STEERING KNUCKLES EAS29660 TIE-RODS AND STEERING KNUCKLES Removing the tie-rods and steering knuckles 25 Nm (2.5 m kg, 18 ft • • 25 Nm (2.5 m kg, 18 ft • • 7 Nm (0.7 m kg, 5.1 ft •...

  • Page 175: Tie-Rods And Steering Knuckles

    TIE-RODS AND STEERING KNUCKLES EAS29670 M MMM M MMM M MMM M MMM M MMM REMOVING THE STEERING KNUCKLES a. Clean the surface of the steering knuckle. The following procedure applies to both of the b. Remove the circlip “2”. steering knuckles.
  • Page 176 TIE-RODS AND STEERING KNUCKLES • Do not tap or damage the top of the ball joint. Ball joint remover 90890-01474 YM-01474 Ball joint remover attachment set 90890-01480 Ball joint adapter set YM-01480 Ball joint remover short shaft set 90890-01514 c. Remove the ball joint “4”. YM-01514 Use a ball joint remover “5”...

  • Page 177: Installing The Tie-Rods

    TIE-RODS AND STEERING KNUCKLES b. Tighten the nut “b”. i. Install a new circlip. L LLL L LLL L LLL L LLL L LLL L LLL L LLL L LLL L LLL L LLL EAS29700 INSTALLING THE TIE-RODS The following procedure applies to both of the tie-rods.

  • Page 178: Front Arms And Front Shock Absorber Assemblies

    FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES EAS29710 FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES Removing the front arms and front shock absorber assemblies 45 Nm (4.5 m kg, 32 ft • • 45 Nm (4.5 m kg, 32 ft •...
  • Page 179 FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES Removing the front arms and front shock absorber assemblies 45 Nm (4.5 m kg, 32 ft • • 45 Nm (4.5 m kg, 32 ft • • 7 Nm (0.7 m kg, 5.1 ft •...

  • Page 180: Checking The Front Arms

    FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES • Front shock absorber rod EAS29730 CHECKING THE FRONT ARMS Bends/damage → Replace the front shock The following procedure applies to both of the absorber assembly. front upper arms and front lower arms. •...

  • Page 181: Installing The Front Arms And Front Shock Absorber Assemblies

    FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES g. Hold the base “11” in place while turning in Long bolt the long bolt “5” to install the new ball joint Body 90890-01474 “13” into the front upper arm “12”. YM-01474 Guide bolt h.

  • Page 182: Installing The Front Arm Protectors

    FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES Upper steering knuckle nut 25 Nm (2.5 m·kg, 18 ft·lb) Lower steering knuckle nut 30 Nm (3.0 m·kg, 22 ft·lb) d. Install the new cotter pins. e. Tighten the front upper and lower arm nuts “4”...

  • Page 183: Rear Knuckles And Stabilizer

    REAR KNUCKLES AND STABILIZER EAS29800 REAR KNUCKLES AND STABILIZER Removing the rear knuckles and stabilizer 51 Nm (5.1 m kg, 37 ft • • 30 Nm (3.0 m kg, 22 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 184 REAR KNUCKLES AND STABILIZER Removing the rear knuckles and stabilizer 51 Nm (5.1 m kg, 37 ft • • 30 Nm (3.0 m kg, 22 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft •...

  • Page 185: Checking The Rear Knuckles And Rear Wheel Bearings

    REAR KNUCKLES AND STABILIZER EAS29810 CHECKING THE REAR KNUCKLES AND Rear arm protector nut REAR WHEEL BEARINGS 7 Nm (0.7 m·kg, 5.1 ft·lb) The following procedure applies to both of the Rear arm protector holder nut rear knuckles and rear wheel bearings. 7 Nm (0.7 m·kg, 5.1 ft·lb) 1.
  • Page 186 REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES EAS29840 REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES Removing the rear arms and rear shock absorber assemblies 45 Nm (4.5 m kg, 32 ft • • 45 Nm (4.5 m kg, 32 ft •...

  • Page 187: Rear Arms And Rear Shock Absorber Assemblies

    REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES • Rear shock absorber rod EAS29850 CHECKING THE REAR ARMS Bends/damage → Replace the rear shock The following procedure applies to both of the absorber assembly. rear upper arms and rear lower arms. •...
  • Page 188 REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES L LLL L LLL L LLL L LLL L LLL 4-69...

  • Page 189: Engine

    ENGINE ENGINE REMOVAL ..................5-1 INSTALLING THE MUFFLER ..............5-2 INSTALLING THE V-BELT COOLING DUCTS......... 5-2 INSTALLING THE DRIVE SELECT LEVER UNIT ........5-5 INSTALLING THE ENGINE............... 5-9 CYLINDER HEAD..................5-10 REMOVING THE CYLINDER HEAD............5-12 CHECKING THE CYLINDER HEAD ............5-12 CHECKING THE CAMSHAFT SPROCKET..........5-13 CHECKING THE TAPPET COVERS AND CAMSHAFT SPROCKET COVER ................
  • Page 190 ELECTRIC STARTER ...................5-40 CHECKING THE STARTER MOTOR .............5-42 ASSEMBLING THE STARTER MOTOR..........5-43 BALANCER GEARS AND OIL PUMP GEARS ..........5-44 REMOVING THE BALANCER DRIVEN GEAR AND OIL PUMP DRIVEN GEAR ..................5-45 CHECKING THE OIL PUMP DRIVE ............5-45 CHECKING THE BALANCER DRIVE .............5-45 INSTALLING THE BALANCER DRIVE GEAR, BALANCER DRIVEN GEAR, AND OIL PUMP DRIVEN GEAR .........5-45 PRIMARY AND SECONDARY SHEAVES............5-47...
  • Page 191 TRANSMISSION.................... 5-73 REMOVING THE TRANSMISSION ............5-76 CHECKING THE SHIFT FORKS............. 5-76 CHECKING THE SHIFT DRUM ..............5-76 CHECKING THE TRANSMISSION ............5-76 CHECKING THE SECONDARY SHAFT..........5-77 CHECKING THE STOPPER LEVER AND STOPPER WHEEL....5-77 ASSEMBLING THE SHIFT FORK ASSEMBLY ........5-77 INSTALLING THE SHIFT FORKS AND SHIFT DRUM......

  • Page 192: Engine Removal

    ENGINE REMOVAL EAS23710 ENGINE REMOVAL Removing the V-belt cooling ducts, muffler and exhaust pipe 7 Nm (0.7 m kg, 5.1 ft • • 20 Nm (2.0 m kg, 14 ft • • 14 Nm (1.4 m kg, 10 ft • •...

  • Page 193: Installing The Muffler

    ENGINE REMOVAL EAS28P1023 INSTALLING THE MUFFLER 1. Install: • Gaskets “1” • Exhaust pipe “2” • Exhaust pipe nuts “3” Exhaust pipe nut 14 Nm (1.4 m·kg, 10 ft·lb) 2. Install: • Muffler bracket “4” • Muffler bracket bolts “5” Muffler bracket bolt 20 Nm (2.0 m·kg, 14 ft·lb) 3.
  • Page 194 ENGINE REMOVAL L LLL L LLL L LLL L LLL L LLL L LLL L LLL L LLL L LLL L LLL 2. Install: • V-belt cooling exhaust duct joint “1” • V-belt cooling exhaust duct “2” M MMM M MMM M MMM M MMM M MMM...
  • Page 195 ENGINE REMOVAL Removing the drive select lever unit 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 • • 14 Nm (1.4 m kg, 10 ft •...

  • Page 196: Installing The Drive Select Lever Unit

    ENGINE REMOVAL EAS28P1025 INSTALLING THE DRIVE SELECT LEVER UNIT 1. Install: • Shift arm “1” • Drive select lever unit “2” • Drive select lever shift rod “3” Shift arm bolt 14 Nm (1.4 m·kg, 10 ft·lb) LOCTITE® Drive select lever unit bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) Drive select lever shift rod lock- 7 Nm (0.7 m·kg, 5.1 ft·lb)
  • Page 197 ENGINE REMOVAL Disconnecting the leads, cables and hoses 17 Nm (1.7 m kg, 12 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Footrest board/Air filter case 4-1. Throttle body assembly Refer to “THROTTLE BODY” on page 7-4. Fuel tank/Fuel tank shield Refer to “FUEL TANK”...
  • Page 198 ENGINE REMOVAL Disconnecting the leads, cables and hoses 17 Nm (1.7 m kg, 12 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “PRIMARY AND SECONDARY Drive belt case SHEAVES” on page 5-47. Cylinder head breather hose Coolant temperature sensor coupler Disconnect.
  • Page 199 ENGINE REMOVAL Removing the engine 42 Nm (4.2 m kg, 30 ft • • 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 • •...

  • Page 200: Installing The Engine

    ENGINE REMOVAL EAS23720 INSTALLING THE ENGINE Engine mounting bolt (front low- 1. Install: er side) • Rubber dampers (front side) “1” 42 Nm (4.2 m·kg, 30 ft·lb) • Engine mounting bolts (front lower side) “2” Engine mounting bolt (front up- per side) •...

  • Page 201: Cylinder Head

    CYLINDER HEAD EAS24100 CYLINDER HEAD Removing the cylinder head 20 Nm (2.0 m kg, 14 ft 20 Nm (2.0 m kg, 14 ft • • • • 10 Nm (1.0 m kg, 7.2 ft 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 202 CYLINDER HEAD Removing the cylinder head 20 Nm (2.0 m kg, 14 ft 20 Nm (2.0 m kg, 14 ft • • • • 10 Nm (1.0 m kg, 7.2 ft 10 Nm (1.0 m kg, 7.2 ft • • •...

  • Page 203: Removing The Cylinder Head

    CYLINDER HEAD 4. Remove: EAS24130 REMOVING THE CYLINDER HEAD • Timing chain tensioner 1. Align: (along with the gasket) • “I” mark “a” on the AC magneto rotor • Camshaft sprocket (with the stationary pointer “b” on the AC • Timing chain magneto cover) M MMM M MMM...

  • Page 204: Checking The Camshaft Sprocket

    CYLINDER HEAD 3. Measure: • Cylinder head warpage Out of specification → Resurface the cylinder head. Warpage limit 0.03 mm (0.0012 in) M MMM M MMM M MMM M MMM M MMM a. Place a straightedge “1” and a thickness gauge “2”...

  • Page 205: Installing The Cylinder Head

    CYLINDER HEAD d. Align the “I” mark “c” on the camshaft sprock- EAS24230 INSTALLING THE CYLINDER HEAD et with the stationary pointer “d” on the cylin- 1. Install: der head. • Cylinder head gasket e. Install the timing chain “2” onto the camshaft •...
  • Page 206 CYLINDER HEAD Install the gasket with its beaded side facing the timing chain tensioner end. d. Install the spring, copper washer and timing chain tensioner cap bolt. Timing chain tensioner cap bolt 20 Nm (2.0 m·kg, 14 ft·lb) 7. Tighten: •...
  • Page 207 CYLINDER HEAD 8. Measure: • Valve clearance Out of specification → Adjust. Refer to “ADJUSTING THE VALVE CLEAR- ANCE” on page 3-4. techsparkstudio.com 5-16...

  • Page 208: Rocker Arms And Camshaft

    ROCKER ARMS AND CAMSHAFT EAS28P1027 ROCKER ARMS AND CAMSHAFT Removing the 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 •...

  • Page 209: Removing The Rocker Arms And Camshaft

    ROCKER ARMS AND CAMSHAFT EAS23770 REMOVING THE ROCKER ARMS AND Camshaft lobe dimensions CAMSHAFT Intake A 1. Loosen: 43.488–43.588 mm (1.7121– • Locknuts 1.7161 in) Limit • Valve clearance adjusting screws 43.388 mm (1.7082 in) 2. Remove: Intake B • Intake rocker arm shaft 36.959–37.059 mm (1.4551–...

  • Page 210: Checking The Decompression System

    ROCKER ARMS AND CAMSHAFT Rocker arm inside diameter 12.000–12.018 mm (0.4724– 0.4731 in) EAS28P1028 CHECKING THE DECOMPRESSION SYSTEM 1. Check: • Decompression system M MMM M MMM M MMM M MMM M MMM 4. Measure: a. Check the decompression system with the •...
  • Page 211 ROCKER ARMS AND CAMSHAFT • Apply engine oil to the bearing. Install the camshaft so that the pins “a” become • Install the bearing so that the seal is facing “a” horizontal. the camshaft. Installed depth 0 mm (0 in) 5.
  • Page 212 VALVES AND VALVE SPRINGS EAS24270 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-10. Refer to “ROCKER ARMS AND CAM- Rocker arms/Rocker arm shafts/Camshaft SHAFT”...

  • Page 213: Valves And Valve Springs

    VALVES AND VALVE SPRINGS EAS24280 REMOVING THE VALVES The following procedure applies to all of the valves and related components. Before removing the internal parts of the cylinder head (e.g., valves, valve springs, valve seats), make sure the valves properly seal. 1.
  • Page 214 VALVES AND VALVE SPRINGS b. Install the new valve guide with the valve Valve-stem-to-valve-guide clear- guide installer “2” and valve guide remover ance (intake) “1”. 0.010–0.037 mm (0.0004–0.0015 Valve guide position Limit 12.7–13.1 mm (0.50–0.52 in) 0.080 mm (0.0031 in) Valve-stem-to-valve-guide clear- ance (exhaust) 0.025–0.052 mm (0.0010–0.0020...

  • Page 215: Checking The Valve Seats

    VALVES AND VALVE SPRINGS 4. Check: EAS24300 CHECKING THE VALVE SEATS • Valve face The following procedure applies to all of the Pitting/wear → Grind the valve face. valves and valve seats. • Valve stem end 1. Eliminate: Mushroom shape or diameter larger than the •...

  • Page 216: Checking The Valve Springs

    VALVES AND VALVE SPRINGS Where the valve seat and valve face contacted one another, the blueing will have been re- moved. L LLL L LLL L LLL L LLL L LLL 4. Lap: • Valve face • Valve seat e. Apply a fine lapping compound to the valve After replacing the cylinder head or replacing the face and repeat the above steps.

  • Page 217: Installing The Valves

    VALVES AND VALVE SPRINGS Free length (intake) Spring tilt (intake) 40.38 mm (1.59 in) 2.5°/1.80 mm Limit Spring tilt (exhaust) 38.36 mm (1.51 in) 2.5°/1.80 mm Free length (exhaust) 40.38 mm (1.59 in) Limit 38.36 mm (1.51 in) EAS24340 INSTALLING THE VALVES The following procedure applies to all of the valves and related components.
  • Page 218 VALVES AND VALVE SPRINGS • Valve “3” • Valve spring “4” • Valve spring retainer “5” (into the cylinder head) • Make sure each valve is installed in its original place. • Install the valve springs with the larger pitch “a” facing up.

  • Page 219: Cylinder And Piston

    CYLINDER AND PISTON EAS24350 CYLINDER AND PISTON Removing the cylinder and piston 1st 15 Nm (1.5 m kg, 11 ft • • 2nd 50 Nm (5.0m kg, 36 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty...

  • Page 220: Removing The Piston

    CYLINDER AND PISTON EAS24380 REMOVING THE PISTON When removing a piston ring, open the end gap 1. Remove: with your fingers and lift the other side of the ring • Piston pin clips “1” over the piston crown. • Piston pin “2” •...

  • Page 221: Checking The Piston Rings

    CYLINDER AND PISTON • Piston-to-cylinder clearance = Bore Cylinder bore “C” - 92.000–92.010 mm (3.6220– Piston skirt diameter “D” 3.6224 in) (YFM5FGY/YFM5FGPY) 102.000–102.010 mm (4.0157– Piston-to-cylinder clearance 4.0161 in) 0.030–0.055 mm (0.0012–0.0022 (YFM7FGY/YFM7FGPY) Wear limit Limit 92.080 mm (3.6252 in) 0.10 mm (0.0039 in) (YFM5FGY/YFM5FGPY) (YFM5FGY/YFM5FGPY)

  • Page 222: Checking The Piston Pin

    CYLINDER AND PISTON EAS24440 CHECKING THE PISTON PIN 1. Check: • Piston pin Blue discoloration/grooves → Replace the piston pin and then check the lubrication sys- tem. 2. Measure: • Piston pin outside diameter “a” Out of specification → Replace the piston pin. 2.

  • Page 223: Installing The Piston And Cylinder

    CYLINDER AND PISTON • Dowel pins Piston-pin-to-piston-pin-bore 4. Lubricate: clearance • Piston 0.004–0.024 mm (0.0002–0.0009 • Piston rings • Cylinder Limit (with the recommended lubricant) 0.0740 mm (0.0029 in) Recommended lubricant EAS24450 Engine oil INSTALLING THE PISTON AND CYLINDER 1. Install: 5.
  • Page 224 CYLINDER AND PISTON 8. Tighten: • Cylinder bolts “1” • Cylinder bolts (timing chain side) “2” Cylinder bolt 15 Nm (1.5 m·kg, 11 ft·lb) 50 Nm (5.0 m·kg, 36 ft·lb) Cylinder bolt (timing chain side) 10 Nm (1.0 m·kg, 7.2 ft·lb) 5-33...

  • Page 225: Ac Magneto And Starter Clutch

    AC MAGNETO AND STARTER CLUTCH EAS28P1029 AC MAGNETO AND STARTER CLUTCH Removing the AC magneto and starter clutch 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 30 Nm (3.0 m kg, 22 ft •...
  • Page 226 AC MAGNETO AND STARTER CLUTCH Removing the AC magneto and starter clutch 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 30 Nm (3.0 m kg, 22 ft • • 7 Nm (0.7 m kg, 5.1 ft •...

  • Page 227: Removing The Ac Magneto Rotor

    AC MAGNETO AND STARTER CLUTCH EAS24490 ECA13880 REMOVING THE AC MAGNETO ROTOR NOTICE 1. Remove: To protect the end of the crankshaft, place an • Lead holder “1” appropriate sized socket between the fly- • AC magneto cover wheel puller set center bolt and the crank- shaft.

  • Page 228: Checking The Stator Coil And Crankshaft Position Sensor

    AC MAGNETO AND STARTER CLUTCH c. When turning the starter wheel gear clock- wise “B”, it should turn freely; otherwise, the starter clutch is faulty and must be replaced. EAS28P1038 CHECKING THE STATOR COIL AND CRANKSHAFT POSITION SENSOR 1. Check: L LLL L LLL L LLL...

  • Page 229: Installing The Ac Magneto

    Primary clutch holder YS-01880-A 2. Apply: • Sealant “1” (onto the crankshaft position sensor/stator assembly lead grommet) Yamaha bond No. 1215 5. Install: 90890-85505 • AC magneto cover (Three Bond No.1215®) • Lead holder “1” • AC magneto cover bolts AC magneto cover bolt 10 Nm (1.0 m·kg, 7.2 ft·lb)
  • Page 230 AC MAGNETO AND STARTER CLUTCH 5-39...

  • Page 231: Electric Starter

    ELECTRIC STARTER EAS24780 ELECTRIC STARTER Removing the starter motor 10 Nm (1.0 m kg, 7.2 ft • • 11 Nm (1.1 m kg, 8.0 ft • • Order Job/Parts to remove Q’ty Remarks Muffler Refer to “ENGINE REMOVAL” on page 5-1. Starter motor lead Disconnect.
  • Page 232 ELECTRIC STARTER Disassembling the starter motor 11 Nm (1.1 m kg, 8.0 ft • • 5 Nm (0.5 m kg, 3.6 ft • • Order Job/Parts to remove Q’ty Remarks Starter motor front cover Starter motor rear cover Brush holder set Armature assembly Starter motor yoke For assembly, reverse the disassembly pro-...

  • Page 233: Checking The Starter Motor

    ELECTRIC STARTER EAS24790 CHECKING THE STARTER MOTOR 1. Check: • Commutator Dirt → Clean with 600 grit sandpaper. 2. Measure: • Mica undercut “a” Out of specification → Cut the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commutator. Mica undercut (depth) L LLL L LLL...

  • Page 234: Assembling The Starter Motor

    ELECTRIC STARTER 7. Check: • Bearing • Oil seal Damage/wear → Replace the defective part(s). EAS24800 ASSEMBLING THE STARTER MOTOR 1. Install: • Starter motor yoke “1” • Starter motor front cover “2” • Starter motor rear cover “3” Align the alignment marks “a” on the starter mo- tor yoke with the match marks “b”...

  • Page 235: Balancer Gears And Oil Pump Gears

    BALANCER GEARS AND OIL PUMP GEARS EAS28P1040 BALANCER GEARS AND OIL PUMP GEARS Removing the balancer gears and oil pump gears Order Job/Parts to remove Q’ty Remarks Refer to “AC MAGNETO AND STARTER Starter wheel gear CLUTCH” on page 5-34. Lock washer Balancer driven gear Oil pump drive gear...

  • Page 236: Removing The Balancer Driven Gear And Oil Pump Driven Gear

    BALANCER GEARS AND OIL PUMP GEARS EAS28P1041 REMOVING THE BALANCER DRIVEN GEAR AND OIL PUMP DRIVEN GEAR 1. Straighten the lock washer tabs. 2. Loosen: • Balancer driven gear nut “1” • Oil pump driven gear nut “2” Place an aluminum plate “3” between the teeth of the balancer drive gear “4”...
  • Page 237 BALANCER GEARS AND OIL PUMP GEARS 4. Bend the lock washer tabs along the balancer driven gear nut and oil pump driven gear nut. techsparkstudio.com 5-46...

  • Page 238: Primary And Secondary Sheaves

    PRIMARY AND SECONDARY SHEAVES EAS28P1045 PRIMARY AND SECONDARY SHEAVES Removing the primary and secondary sheaves 10 Nm (1.0 m kg, 7.2 ft • • (11) 10 Nm (1.0 m kg, 7.2 ft • • 140 Nm (14.0 m kg, 100 ft •...
  • Page 239 Disassembling the primary sheave Order Job/Parts to remove Q’ty Remarks Primary sheave cap Primary sheave slider Primary sheave cam Primary sheave weight Collar Oil seal Primary sliding sheave O-ring For assembly, reverse the disassembly pro- cedure. * Apply Yamaha Grizzly grease. techsparkstudio.com 5-48...
  • Page 240 PRIMARY AND SECONDARY SHEAVES Disassembling the secondary sheave Order Job/Parts to remove Q’ty Remarks Spring seat Compression spring Spring seat Guide pin Secondary sliding sheave O-ring Secondary fixed sheave Oil seal For assembly, reverse the disassembly pro- cedure. * Apply BEL-RAY assembly lube®. 5-49...

  • Page 241: Removing The Primary And Secondary Sheaves

    PRIMARY AND SECONDARY SHEAVES f. Remove the sheave spring compressor and EAS28P1046 REMOVING THE PRIMARY AND locknut wrench. SECONDARY SHEAVES 1. Loosen: • Secondary sheave nut “1” • Primary sheave nut “2” • Use the sheave holder “3” to hold the primary sheave.

  • Page 242: Checking The Primary Sheave

    PRIMARY AND SECONDARY SHEAVES EAS24680 EAS24700 CHECKING THE PRIMARY SHEAVE CHECKING THE PRIMARY SHEAVE 1. Check: SLIDERS • Primary sliding sheave splines The following procedure applies to all of the pri- Wear/cracks/damage → Replace. mary sheave sliders. • Primary sheave cam 1.

  • Page 243: Assembling The Primary Sheave

    • Apply Yamaha Grizzly grease (90 g) to the whole outer surface of the weights and install. • Apply Yamaha Grizzly grease (2.5 g) to the in- ner surface of the collar. • Apply Yamaha Grizzly grease (2.5 g) to the in- ner surface of the primary sliding sheave.
  • Page 244 PRIMARY AND SECONDARY SHEAVES • Secondary fixed sheave “2” 6. Install: (with the recommended lubricant) • Spring seat • Compression spring Recommended lubricant • Spring seat BEL-RAY assembly lube® • Nut M MMM M MMM M MMM M MMM M MMM a.

  • Page 245: Installing The Primary And Secondary Sheaves

    PRIMARY AND SECONDARY SHEAVES EAS28P1047 INSTALLING THE PRIMARY AND To check that the primary sheave weights “1” SECONDARY SHEAVES are installed correctly, make sure that the sec- 1. Install: ondary sheave “2”, primary sheave “3”, and V- • Secondary sheave belt “4”...
  • Page 246 PRIMARY AND SECONDARY SHEAVES 5-55...

  • Page 247: Clutch

    CLUTCH EAS25061 CLUTCH Removing the clutch Order Job/Parts to remove Q’ty Remarks Refer to “PRIMARY AND SECONDARY Primary sheave/Secondary sheave SHEAVES” on page 5-47. Clutch housing assembly Gasket Dowel pin One-way clutch bearing Clutch carrier assembly For installation, reverse the removal proce- dure.
  • Page 248 CLUTCH Disassembling the clutch housing assembly Order Job/Parts to remove Q’ty Remarks Oil seal Circlip Bearing housing Circlip Bearing Circlip Bearing Clutch housing For assembly, reverse the disassembly pro- cedure. 5-57...

  • Page 249: Removing The Clutch

    CLUTCH • One-way clutch bearing EAS25070 REMOVING THE CLUTCH Chafing/wear/damage → Replace. 1. Remove: • Clutch housing assembly • Replace the one-way clutch assembly and • Gasket clutch housing as a set. • Dowel pins • The one-way clutch bearing must be installed with the flange side facing in.

  • Page 250: Assembling The Clutch Housing

    CLUTCH Clutch carrier assembly nut 190 Nm (19.0 m·kg, 140 ft·lb) ECA28P1033 NOTICE The clutch carrier assembly nut has left- handed threads. To tighten the clutch carrier assembly nut, turn it counterclockwise. Use a clutch holding tool “2” to hold the clutch EAS28P1037 ASSEMBLING THE CLUTCH HOUSING carrier assembly.
  • Page 251 CLUTCH • Tighten the bolts in stages, using a crisscross pattern. • After tightening the bolts, check that the clutch housing assembly rotates smoothly. techsparkstudio.com 5-60...

  • Page 252: Crankcase

    CRANKCASE EAS25540 CRANKCASE Removing the timing chain and oil filter cartridge 7 Nm (0.7 m kg, 5.1 ft • • 17 Nm (1.7 m kg, 12 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 30 Nm (3.0 m kg, 22 ft •...
  • Page 253 CRANKCASE Removing the timing chain and oil filter cartridge 7 Nm (0.7 m kg, 5.1 ft • • 17 Nm (1.7 m kg, 12 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 30 Nm (3.0 m kg, 22 ft •...
  • Page 254 CRANKCASE Separating the crankcase 10 Nm (1.0 m kg, 7.2 ft 18 Nm (1.8 m kg, 13 ft • • • • 18 Nm (1.8 m kg, 13 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 255 CRANKCASE Removing the crankcase bearings 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “CRANKSHAFT AND OIL PUMP” Crankshaft/Oil pump on page 5-68. Transmission Refer to “TRANSMISSION” on page 5-73 Middle drive shaft/Middle driven shaft Refer to “MIDDLE GEAR”...

  • Page 256: Separating The Crankcase

    CRANKCASE EAS25560 SEPARATING THE CRANKCASE 1. Remove: • Crankcase bolts • Lead holders Loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2.

  • Page 257: Checking The Crankcase

    M6 × 30 mm “3” • Sealant “1” (onto the crankcase mating surfaces) Tighten the bolts in stages, using a crisscross pattern. Yamaha bond No. 1215 90890-85505 (Three Bond No.1215®) • Apply two coats of sealant to the area “a” shown in the illustration.

  • Page 258: Installing The Shift Lever

    CRANKCASE A. Right crankcase B. Left crankcase 8. Apply: • 4-stroke engine oil (to the crankshaft pin, bearings and oil deliv- ery hole) 9. Check: • Crankshaft and transmission operation Rough operation → Repair. EAS28P1052 INSTALLING THE SHIFT LEVER 1. Install: •...

  • Page 259: Crankshaft And Oil Pump

    CRANKSHAFT AND OIL PUMP EAS28P1053 CRANKSHAFT AND OIL PUMP Removing the crankshaft and oil pump 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE”...
  • Page 260 CRANKSHAFT AND OIL PUMP Disassembling the oil pump 5 Nm (0.5 m kg, 3.6 ft • • Order Job/Parts to remove Q’ty Remarks Oil pump housing cover Oil pump shaft Inner rotor Outer rotor Oil pump housing For assembly, reverse the disassembly pro- cedure.

  • Page 261: Removing The Crankshaft

    CRANKSHAFT AND OIL PUMP EAS28P1054 REMOVING THE CRANKSHAFT Inner-rotor-to-outer-rotor-tip 1. Remove: clearance • Crankshaft “1” Less than 0.12 mm (0.0047 in) Limit 0.20 mm (0.0079 in) • Remove the crankshaft with the crankcase Outer-rotor-to-oil-pump-housing separating tool “2”. clearance • Make sure the crankcase separating tool is 0.090–0.170 mm (0.0035–0.0067 centered over the crankshaft.

  • Page 262: Checking The Oil Strainer

    CRANKSHAFT AND OIL PUMP EAS24990 CHECKING THE OIL STRAINER 1. Check: • Oil strainer Damage → Replace. Contaminants → Clean with solvent. EAS28P1055 CHECKING THE CRANKSHAFT 1. Measure: • Crankshaft width A “a” Out of specification → Replace the crank- 4.

  • Page 263: Installing The Crankshaft

    CRANKSHAFT AND OIL PUMP 3. Check: ECA28P1035 NOTICE • Oil pump operation Apply engine oil to each bearing to protect Refer to “CHECKING THE OIL PUMP” on the crankshaft against scratches and to page 5-70. make installation easier. EAS28P1056 INSTALLING THE CRANKSHAFT 1.

  • Page 264: Transmission

    TRANSMISSION EAS26241 TRANSMISSION Removing the transmission, shift drum and shift forks Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-61 Middle driven gear Refer to “MIDDLE GEAR” on page 5-79 Shift drum Shift fork assembly Shift fork “R”...
  • Page 265 TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks Washer Collar High wheel gear Washer Clutch dog Circlip Washer Collar Low wheel gear Washer Circlip Middle drive gear Circlip Washer Bearing Reverse wheel gear Stopper wheel techsparkstudio.com 5-74...
  • Page 266 TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks Drive axle For assembly, reverse the disassembly pro- cedure. 5-75...

  • Page 267: Removing The Transmission

    TRANSMISSION EAS26250 REMOVING THE TRANSMISSION 1. Remove: • Shift drum “1” • Shift fork assembly “2” M MMM M MMM M MMM M MMM M MMM a. Pull out the guide bar from the left crankcase. b. Push down on the drive shaft, and then slide the shift fork assembly to remove the shift fork cam followers.

  • Page 268: Checking The Secondary Shaft

    TRANSMISSION • Stopper wheel “2” Damage/wear → Replace the stopper wheel and stopper lever as a set. • Stopper lever shaft “3” Bends/damage/wear → Replace. 2. Check: • Transmission gears Blue discoloration/pitting/wear → Replace the defective gear(s). • Transmission gear dogs Cracks/damage/rounded edges →...
  • Page 269 TRANSMISSION Install the shift forks “6” with the “L” mark “a” and “R” mark “b” facing towards the left and right sides of the crankcase respectively. 2. Check: • Shift operation Rough operation → Repair. • Oil each gear and bearing thoroughly. •...

  • Page 270: Middle Gear

    MIDDLE GEAR EAS25710 MIDDLE GEAR Removing the middle drive shaft 190 Nm (19.0 m kg, 140 ft • • Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-61. Bearing housing Middle drive pinion gear nut Middle drive pinion gear Refer to “ALIGNING THE MIDDLE GEAR”...
  • Page 271 MIDDLE GEAR Removing the middle driven shaft Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-61. Front drive shaft yoke nut (middle gear side) Front drive shaft yoke (middle gear side) Middle driven pinion gear assembly Rear drive shaft yoke nut (middle gear side) Rear drive shaft yoke (middle gear side) Bearing housing...
  • Page 272 MIDDLE GEAR Removing the middle driven shaft Order Job/Parts to remove Q’ty Remarks Middle driven shaft For installation, reverse the removal proce- dure. 5-81...

  • Page 273: Removing The Middle Drive Shaft

    MIDDLE GEAR EAS28P1062 REMOVING THE MIDDLE DRIVE SHAFT Coupling gear/middle shaft tool 1. Straighten: 90890-01229 • Punched portion of the middle drive pinion Gear holder gear nut YM-01229 2. Loosen: • Middle drive pinion gear nut “1” Wrap the middle drive shaft in a folded rag, and then secure it in a vise.

  • Page 274: Checking The Pinion Gears

    MIDDLE GEAR • Install a suitable socket “2” on the middle Ring nut wrench driven pinion gear end to protect the thread 90890-01430 from damage. YM-38404 c. Press the middle driven pinion gear end and remove the bearing housing. ECA28P1038 NOTICE The middle driven shaft bearing retainer has left-handed threads.

  • Page 275: Installing The Bearing And Oil Seals

    MIDDLE GEAR • Bearings Ring nut wrench Pitting/damage → Replace. 90890-01430 YM-38404 EAS28P1065 INSTALLING THE BEARING AND OIL SEALS 1. Install: ECA28P1039 NOTICE • Bearing “1” The middle driven shaft bearing retainer has • Oil seal “2” left-handed threads. To tighten the retainer •...

  • Page 276: Installing The Middle Drive Shaft

    MIDDLE GEAR 5. Install: L LLL L LLL L LLL L LLL L LLL • Front drive shaft yoke (middle gear side) “1” 3. Install: • Washer • Middle driven pinion gear shim(s) “1” • Front drive shaft yoke nut (middle gear side) •...

  • Page 277: Measuring The Middle Gear Backlash

    MIDDLE GEAR EAS25890 MEASURING THE MIDDLE GEAR BACKLASH 1. Measure: • Middle gear backlash Out of specification → Refer to “ALIGNING THE MIDDLE GEAR” on page 5-87. Middle gear backlash 0.10–0.30 mm (0.004–0.012 in) M MMM M MMM M MMM M MMM M MMM 2.

  • Page 278: Aligning The Middle Gear

    MIDDLE GEAR e. If the gear lash is incorrect, adjust the gear M MMM M MMM M MMM M MMM M MMM a. Position the middle gears with the appropri- lash by middle driven pinion gear shims ate shim(s) that has had its respective thick- and/or middle drive pinion gear shim(s).
  • Page 279 MIDDLE GEAR Therefore, “A” is 1.40. “g” = a numeral (usually a decimal number) “A” = 9.01 + 64.97 - 17.0 - 55.0 - 0.58 = 1.40 on the middle driven pinion gear is either add- Round off hundredths digit and select appro- ed to or subtracted from “49.0”...
  • Page 280 MIDDLE GEAR Middle driven pinion gear shim Thickness (mm) 0.10 0.15 0.20 0.30 0.40 0.50 0.60 L LLL L LLL L LLL L LLL L LLL If the left crankcase is marked “99.99”, “i” is 99.99 If the right crankcase is marked “8.17”, “j”...

  • Page 281: Cooling System

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

  • Page 282: Radiator

    RADIATOR EAS26380 RADIATOR Removing the radiator 7 Nm (0.7 m kg, 5.1 ft 7 Nm (0.7 m kg, 5.1 ft • • • • Order Job/Parts to remove Q’ty Remarks Front fenders/Front guard/Left footrest board/Air Refer to “GENERAL CHASSIS” on page filter case 4-1.
  • Page 283 RADIATOR Removing the radiator 7 Nm (0.7 m kg, 5.1 ft 7 Nm (0.7 m kg, 5.1 ft • • • • Order Job/Parts to remove Q’ty Remarks Radiator fan For installation, reverse the removal proce- dure. techsparkstudio.com...

  • Page 284: Checking The Radiator

    RADIATOR EAS26390 CHECKING THE RADIATOR 1. Check: • Radiator fins Obstruction → Clean. Apply compressed air to the rear of the radia- tor. Damage → Repair or replace. Straighten any flattened fins with a thin, flat-head screwdriver. b. Apply the specified pressure for ten seconds and make sure there is no drop in pressure.

  • Page 285: Thermostat

    THERMOSTAT EAS26440 THERMOSTAT Removing the thermostat 18 Nm (1.8 m kg, 13 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Air filter case 4-1.

  • Page 286: Checking The Thermostat

    THERMOSTAT 2. Check: EAS26450 CHECKING THE THERMOSTAT • Thermostat housing cover 1. Check: • Thermostat housing (cylinder head) • Thermostat Cracks/damage → Replace. Does not open at 50–54 °C (122–129.2 °F) → Replace. EAS26480 INSTALLING THE THERMOSTAT 1. Install: • Copper washer •...
  • Page 287 THERMOSTAT 5. Measure: • Radiator cap opening pressure Below the specified pressure → Replace the radiator cap. Refer to “CHECKING THE RADIATOR” on page 6-3. techsparkstudio.com...

  • Page 288: Water Pump

    WATER PUMP EAS26500 WATER PUMP Removing the 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/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS”...
  • Page 289 WATER PUMP Removing the 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/Parts to remove Q’ty Remarks Bearing Oil seal For installation, reverse the removal proce- dure.

  • Page 290: Disassembling The Water Pump

    WATER PUMP EAS26510 EAS26560 DISASSEMBLING THE WATER PUMP ASSEMBLING THE WATER PUMP 1. Remove: 1. Install: • Water pump seal “1” • Oil seal “1” (into the AC magneto cover “2”) Remove the water pump seal from the inside of the AC magneto cover “2”.
  • Page 291 WATER PUMP 3. Mechanical seal installer 4. Middle driven shaft bearing driver A. Push down. 3. Measure: • Impeller shaft tilt Out of specification → Replace. Impeller shaft tilt limit 0.15 mm (0.006 in) 1. Straightedge 2. Impeller 4. Install: •...
  • Page 292 WATER PUMP 6-11...

  • Page 293: Fuel System

    FUEL SYSTEM FUEL TANK..................... 7-1 REMOVING THE FUEL TANK ..............7-2 REMOVING THE FUEL PUMP ..............7-2 CHECKING THE FUEL PUMP BODY............7-2 CHECKING THE FUEL TANK BREATHER HOSE JOINT .......7-2 INSTALLING THE FUEL PUMP..............7-2 INSTALLING THE FUEL TANK..............7-3 THROTTLE BODY................... 7-4 REMOVING THE THROTTLE BODY ASSEMBLY ........7-6 CHECKING THE INJECTOR ..............

  • Page 294: Fuel Tank

    FUEL TANK EAS26620 FUEL TANK Removing the 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/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS”...

  • Page 295: Removing The Fuel Tank

    FUEL TANK EAS26630 REMOVING THE FUEL TANK Do not set the fuel tank down on the installation 1. Extract the fuel in the fuel tank through the surface of the fuel pump. Be sure to lean the fuel fuel tank cap with a pump. tank in an upright position.

  • Page 296: Installing The Fuel Tank

    FUEL TANK EAS28P1021 INSTALLING THE FUEL TANK 1. Install: • Dampers “1” Fit the projections on each damper into the 3rd and 4th holes in the frame. Determine the 3rd and 4th holes by counting outward from the cen- ter hole in the frame. 2.

  • Page 297: Throttle Body

    THROTTLE BODY EAS26970 THROTTLE BODY Removing the throttle body 3 Nm (0.3 m kg, 2.2 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Air filter case 4-1. Intake air pressure sensor coupler Disconnect. Throttle position sensor coupler Disconnect.
  • Page 298 THROTTLE BODY Disassembling the throttle body assembly Order Job/Parts to remove Q’ty Remarks Intake air pressure sensor Intake air pressure sensor hose Throttle position sensor Injector fuel rail Fuel injector ECA28P1021 NOTICE Throttle body The throttle body should not be disas- sembled.

  • Page 299: Removing The Throttle Body Assembly

    THROTTLE BODY b. Blow out all of the passages with compressed EAS28P1036 REMOVING THE THROTTLE BODY air. ASSEMBLY L LLL L LLL L LLL L LLL L LLL 1. Disconnect: • Fuel hose EAS28P1022 INSTALLING THE THROTTLE BODY ECA28P1022 ASSEMBLY NOTICE 1.

  • Page 300: Checking The Fuel Pressure

    THROTTLE BODY e. Start the engine. EAS27010 CHECKING THE FUEL PRESSURE f. Measure the fuel pressure. Out of specification → Replace the fuel 1. Check: • Fuel pressure pump. M MMM M MMM M MMM M MMM M MMM a. Remove the rear fender. Fuel pressure Refer to “GENERAL CHASSIS”...
  • Page 301 THROTTLE BODY c. Turn the main switch to “ON”. d. Measure the throttle position sensor voltage. e. Adjust the throttle position sensor angle so that the voltage is within the specified range. Throttle position sensor output voltage 0.63–0.73 V (yellow–black/blue) f.
  • Page 302 THROTTLE BODY...

  • Page 303: Drive Train

    DRIVE TRAIN TROUBLESHOOTING..................8-1 CHECKING NOISES ................. 8-1 TROUBLESHOOTING CHART ..............8-2 FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFERENTIAL ASSEMBLY AND FRONT DRIVE SHAFT .............8-3 DISASSEMBLING THE FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES ................... 8-9 CHECKING THE FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES ................... 8-9 ASSEMBLING THE FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES ..................

  • Page 304: Troubleshooting

    TROUBLESHOOTING EAS29890 TROUBLESHOOTING The following conditions may indicate damaged shaft drive components: Symptoms Possible Causes 1. A pronounced hesitation or “jerky” movement A. Bearing damage. during acceleration, deceleration, or sus- B. Improper gear backlash. tained speed. (This must not be confused C.

  • Page 305: Troubleshooting Chart

    TROUBLESHOOTING • Always clean the vehicle and recheck the sus- pected location of an apparent leakage. L LLL L LLL L LLL L LLL L LLL EAS29910 TROUBLESHOOTING CHART When basic conditions (a) and (b) exist, check the following points: YES →...

  • Page 306: Front Constant Velocity Shaft Assemblies, Differential Assembly And Front Drive Shaft

    FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFEREN- TIAL ASSEMBLY AND FRONT DRIVE SHAFT EAS29920 FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFERENTIAL ASSEMBLY AND FRONT DRIVE SHAFT Removing the front constant velocity shaft assemblies, differential assembly and front drive shaft 55 Nm (5.5 m kg, 40 ft •...
  • Page 307 FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFEREN- TIAL ASSEMBLY AND FRONT DRIVE SHAFT Removing the front constant velocity shaft assemblies, differential assembly and front drive shaft 55 Nm (5.5 m kg, 40 ft • • 55 Nm (5.5 m kg, 40 ft •...
  • Page 308 FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFEREN- TIAL ASSEMBLY AND FRONT DRIVE SHAFT Disassembling the front constant velocity shaft assemblies Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front constant velocity shaft assemblies. Clip Boot band Boot band Dust boot Clip...
  • Page 309 FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFEREN- TIAL ASSEMBLY AND FRONT DRIVE SHAFT Disassembling the front constant velocity shaft assemblies Order Job/Parts to remove Q’ty Remarks Constant velocity shaft For assembly, reverse the disassembly pro- cedure. A: Wheel side B: Differential side techsparkstudio.com...
  • Page 310 FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFEREN- TIAL ASSEMBLY AND FRONT DRIVE SHAFT Disassembling the differential assembly 24 Nm (2.4 m kg, 17 ft • • 23 Nm (2.3 m kg, 17 ft • • 62 Nm (6.2 m kg, 45 ft •...
  • Page 311 FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFEREN- TIAL ASSEMBLY AND FRONT DRIVE SHAFT Disassembling the differential assembly 24 Nm (2.4 m kg, 17 ft • • 23 Nm (2.3 m kg, 17 ft • • 62 Nm (6.2 m kg, 45 ft •...

  • Page 312: Disassembling The Front Constant Velocity Shaft Assemblies

    FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFEREN- TIAL ASSEMBLY AND FRONT DRIVE SHAFT EAS29930 DISASSEMBLING THE FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES The following procedure applies to both of the front constant velocity shaft assemblies. 1. Remove: • Boot bands • Clip “1” •...

  • Page 313: Assembling The Front Constant Velocity Shaft Assemblies

    FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFEREN- TIAL ASSEMBLY AND FRONT DRIVE SHAFT • Ball bearing “1” EAS29990 ASSEMBLING THE FRONT CONSTANT • Circlip “2” VELOCITY SHAFT ASSEMBLIES • Double offset joint “3” The following procedure applies to both of the front constant velocity shaft assemblies.

  • Page 314: Removing The Differential Gear Assembly

    FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFEREN- TIAL ASSEMBLY AND FRONT DRIVE SHAFT • The dust boots should be fastened with the ECA16200 NOTICE boot bands “3” and “5” at the grooves in the The ring gear and differential gear are as- constant velocity shaft.

  • Page 315: Assembling The Differential Assembly

    FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFEREN- TIAL ASSEMBLY AND FRONT DRIVE SHAFT M MMM M MMM M MMM M MMM M MMM a. Connect two C-size batteries to the differen- tial motor terminals “1” (as shown in the illus- trations). ECA28P1018 NOTICE •...

  • Page 316: Measuring The Differential Gear Backlash

    FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFEREN- TIAL ASSEMBLY AND FRONT DRIVE SHAFT d. Remove the 6 mm bolts, and then install the motor with the differential motor bolts. Differential motor bolt 11 Nm (1.1 m·kg, 8.0 ft·lb) L LLL L LLL L LLL L LLL L LLL...
  • Page 317 FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFEREN- TIAL ASSEMBLY AND FRONT DRIVE SHAFT b. Measure the differential gear backlash again. L LLL L LLL L LLL L LLL L LLL techsparkstudio.com 8-14...

  • Page 318: Rear Constant Velocity Shaft Assemblies, Final Drive Assembly And Rear Drive Shaft

    REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE ASSEMBLY AND REAR DRIVE SHAFT EAS30050 REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE ASSEMBLY AND REAR DRIVE SHAFT Removing the rear constant velocity shaft assemblies, final drive assembly and rear drive shaft 55 Nm (5.5 m kg, 40 ft •...
  • Page 319 REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE ASSEMBLY AND REAR DRIVE SHAFT Removing the rear constant velocity shaft assemblies, final drive assembly and rear drive shaft 55 Nm (5.5 m kg, 40 ft • • 66 Nm (6.6 m kg, 48 ft •...
  • Page 320 REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE ASSEMBLY AND REAR DRIVE SHAFT Disassembling the rear constant velocity shaft assemblies Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the rear constant velocity shaft assemblies. Clip Boot band Boot band Dust boot Clip...
  • Page 321 REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE ASSEMBLY AND REAR DRIVE SHAFT Disassembling the rear constant velocity shaft assemblies Order Job/Parts to remove Q’ty Remarks Constant velocity shaft For assembly, reverse the disassembly pro- cedure. A: Wheel side B: Final drive side techsparkstudio.com 8-18...
  • Page 322 REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE ASSEMBLY AND REAR DRIVE SHAFT Disassembling the final drive assembly 23 Nm (2.3 m kg, 17 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 23 Nm (2.3 m kg, 17 ft •...
  • Page 323 REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE ASSEMBLY AND REAR DRIVE SHAFT Disassembling the final drive assembly 23 Nm (2.3 m kg, 17 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 23 Nm (2.3 m kg, 17 ft •...
  • Page 324 REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE ASSEMBLY AND REAR DRIVE SHAFT Disassembling the final drive assembly 23 Nm (2.3 m kg, 17 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 23 Nm (2.3 m kg, 17 ft •...

  • Page 325: Disassembling The Rear Constant Velocity Shaft Assemblies

    REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE ASSEMBLY AND REAR DRIVE SHAFT EAS30060 DISASSEMBLING THE REAR CONSTANT VELOCITY SHAFT ASSEMBLIES The following procedure applies to both of the rear constant velocity shaft assemblies. 1. Remove: • Boot bands • Clip “1” •...

  • Page 326: Assembling The Rear Constant Velocity Shaft Assemblies

    REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE ASSEMBLY AND REAR DRIVE SHAFT • Ball bearing “1” EAS30070 ASSEMBLING THE REAR CONSTANT • Circlip “2” VELOCITY SHAFT ASSEMBLIES • Double offset joint “3” The following procedure applies to both of the rear constant velocity shaft assemblies.

  • Page 327: Disassembling The Final Drive Pinion Gear Assembly

    REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE ASSEMBLY AND REAR DRIVE SHAFT • The dust boots should be fastened with the M MMM M MMM M MMM M MMM M MMM a. Place a folded rag as shown. boot bands “3” and “5” at the grooves in the b.

  • Page 328: Assembling The Final Drive Case

    REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE ASSEMBLY AND REAR DRIVE SHAFT f. Repeat steps (d) and (e) until the starting EAS28P1019 ASSEMBLING THE FINAL DRIVE CASE torque is within specification. 1. Install: • Oil seals “1” • Be careful not to exceed the specified starting Installed depth of oil seal “a”...

  • Page 329: Selecting The Final Driven Pinion Gear Shim (Final Drive Case Side) And Thrust Washer

    REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE ASSEMBLY AND REAR DRIVE SHAFT = 99.99 Therefore, “A” is 0.58. “A” = 55 + (67.75 - 22.18) - 99.99 = 0.58 Round off the hundredth digit and select the appropriate shim(s). In the example above, the calculated number is 0.58.
  • Page 330 REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE ASSEMBLY AND REAR DRIVE SHAFT “f” = a numeral (usually a decimal number) on If “-12” is stamped on the outside of the final the final driven pinion gear either added to or driven pinion gear, subtracted from “51.0”...

  • Page 331: Selecting The Final Driven Pinion Gear Shim (Final Drive Case Cover Side)

    REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE ASSEMBLY AND REAR DRIVE SHAFT Thrust washer “2” Do not turn the final drive pinion gear, wheel Thickness (mm) gear, and driven pinion gear when measuring 4.50 4.80 5.10 5.40 the clearance with Plastigauge®. c.

  • Page 332: Measuring The Final Gear Backlash

    REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE ASSEMBLY AND REAR DRIVE SHAFT e. If out of specification, remove the originally fit- ted shim(s), and then select the correct shim(s). L LLL L LLL L LLL L LLL L LLL 2. Select: •...

  • Page 333: Adjusting The Final Gear Backlash

    REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE ASSEMBLY AND REAR DRIVE SHAFT Final gear backlash is in- Thinner shim creased. Final gear backlash is de- Thicker shim creased. b. If increased by more than 0.2 mm (0.008 in): Reduce the final driven pinion gear shim (final drive case cover side) “4”...
  • Page 334 REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE ASSEMBLY AND REAR DRIVE SHAFT 8-31...
  • Page 335 ELECTRICAL SYSTEM IGNITION SYSTEM ..................9-1 CIRCUIT DIAGRAM .................. 9-1 TROUBLESHOOTING ................9-3 ELECTRIC STARTING SYSTEM ..............9-5 CIRCUIT DIAGRAM .................. 9-5 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION ......9-7 TROUBLESHOOTING ................9-9 CHARGING SYSTEM..................9-11 CIRCUIT DIAGRAM ................9-11 TROUBLESHOOTING ................9-13 LIGHTING SYSTEM ..................9-15 CIRCUIT DIAGRAM ................
  • Page 336 EPS (ELECTRIC POWER STEERING) SYSTEM (for YFM5FGP/YFM7FGP) ................9-63 CIRCUIT DIAGRAM ................9-63 EPS CONTROL UNIT’S SELF-DIAGNOSTIC FUNCTION .....9-65 EPS WARNING LIGHT DURING NORMAL OPERATION......9-65 DIAGNOSTIC MODE ................9-66 SELF-DIAGNOSTIC FUNCTION TABLE (EPS SYSTEM)......9-69 TROUBLESHOOTING DETAILS (EPS SYSTEM) ........9-70 ELECTRICAL COMPONENTS..............9-75 CHECKING THE SWITCHES ..............9-79 CHECKING THE BULBS AND BULB SOCKETS ........
  • Page 337 techsparkstudio.com...

  • Page 338: Ignition System

    IGNITION SYSTEM EAS27090 IGNITION SYSTEM EAS27100 CIRCUIT DIAGRAM...
  • Page 339 IGNITION SYSTEM 1. Crankshaft position sensor 4. Main switch 5. Frame ground 6. Main fuse 8. Battery 20.ECU (engine control unit) 21.Ignition coil 22.Spark plug 29.Lean angle sensor 54.Engine stop switch 59.Ignition fuse techsparkstudio.com...

  • Page 340: Troubleshooting

    IGNITION SYSTEM EAS27130 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). • Before troubleshooting, remove the following part(s): 1. Seat 2. Battery cover 3. Right side panel 4. V-belt cooling exhaust duct NG → 1. Check the fuses. (Main and ignition) Replace the fuse(s).
  • Page 341 IGNITION SYSTEM NG → 8. Check the main switch. Refer to “CHECKING THE Replace the main switch. SWITCHES” on page 9-79. OK ↓ NG → 9. Check the engine stop switch. The engine stop switch is faulty. Replace Refer to “CHECKING THE the left handlebar switch.

  • Page 342: Electric Starting System

    ELECTRIC STARTING SYSTEM EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM...
  • Page 343 ELECTRIC STARTING SYSTEM 4. Main switch 5. Frame ground 6. Main fuse 8. Battery 10.Starter relay 11.Starter motor 16.Diode 1 20.ECU (engine control unit) 30.Gear position switch 54.Engine stop switch 55.Start switch 59.Ignition fuse 60.Signaling system fuse 62.Rear brake light switch techsparkstudio.com...

  • Page 344: Starting Circuit Cut-Off System Operation

    ELECTRIC STARTING SYSTEM EAS27180 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switch circuits are closed), the starter motor can only operate if at least one of the following conditions is met: •...
  • Page 345 ELECTRIC STARTING SYSTEM 1. Battery 2. Main fuse 3. Main switch 4. Ignition fuse 5. Engine stop switch 6. Start switch 7. Signaling system fuse 8. Rear brake light switch 9. ECU (engine control unit) 10. Park switch (gear position switch) 11.

  • Page 346: Troubleshooting

    ELECTRIC STARTING SYSTEM EAS27190 TROUBLESHOOTING The starter motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Seat 2. Battery cover 3. Side covers NG → 1. Check the fuses. (Main, ignition and signaling sys- tem) Replace the fuse(s). Refer to “CHECKING THE FUS- ES”...
  • Page 347 ELECTRIC STARTING SYSTEM NG → 9. Check the rear brake light switch. Refer to “CHECKING THE Replace the rear brake light switch. SWITCHES” on page 9-79. OK ↓ NG → 10.Check the gear position switch. Refer to “CHECKING THE Replace the gear position switch. SWITCHES”...

  • Page 348: Charging System

    CHARGING SYSTEM EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM Gy B (BLACK) (GRAY) Br/B R/W L/Y R/Y (BLACK) Br/B R Br/L Br Br Br/L R Br/L (BLACK) Br/L Br/L Br/Y Br/L 9-11...
  • Page 349 CHARGING SYSTEM 2. AC magneto 3. Rectifier/regulator 5. Frame ground 6. Main fuse 8. Battery techsparkstudio.com 9-12...

  • Page 350: Troubleshooting

    CHARGING SYSTEM EAS27230 TROUBLESHOOTING The battery is not being charged. • Before troubleshooting, remove the following part(s): 1. Seat 2. Battery cover 3. Right side cover 4. V-belt cooling exhaust duct NG → 1. Check the fuse. (Main) Replace the fuse. Refer to “CHECKING THE FUS- ES”...
  • Page 351 CHARGING SYSTEM techsparkstudio.com 9-14...

  • Page 352: Lighting System

    LIGHTING SYSTEM EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM Gy B W R G B (BLACK) W R G B (GRAY) (GRAY) (GRAY) Br/B R/W L/Y R/Y (BLACK) ( BL (BLACK) Br/B R Br/L Br Br Br/L R Br/B Br/L (BLACK) Br/L Br/R Br/L...
  • Page 353 LIGHTING SYSTEM 4. Main switch 5. Frame ground 6. Main fuse 8. Battery 53.Light switch 57.Headlight 58.Headlight relay 61.Headlight fuse 65.Tail/brake light techsparkstudio.com 9-16...

  • Page 354: Troubleshooting

    LIGHTING SYSTEM EAS27260 TROUBLESHOOTING Any of the following fail to light: headlight or taillight. • Before troubleshooting, remove the following part(s): 1. Seat 2. Battery cover 3. Tail/brake light cover NG → 1. Check the condition of each bulb and bulb socket. Refer to “CHECKING THE BULBS Replace the bulb(s) and bulb socket(s).
  • Page 355 LIGHTING SYSTEM techsparkstudio.com 9-18...

  • Page 356: Signaling System

    SIGNALING SYSTEM EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM 9-19...
  • Page 357 SIGNALING SYSTEM 4. Main switch 5. Frame ground 6. Main fuse 8. Battery 18.Reverse switch 20.ECU (engine control unit) 25.Coolant temperature sensor 26.Speed sensor 30.Gear position switch 32.Multifunction meter 34.Coolant temperature warning light 35.Park indicator light 36.Reverse indicator light 37.Neutral indicator light 38.High-range indicator light 39.Low-range indicator light 41.Fuel sender...

  • Page 358: Troubleshooting

    SIGNALING SYSTEM EAS27290 TROUBLESHOOTING • Any of the following fail to light: warning light, brake light or an indicator light. • Before troubleshooting, remove the following part(s): 1. Seat 2. Battery cover 3. Side panels 4. V-belt cooling exhaust duct 5.
  • Page 359 SIGNALING SYSTEM NG → 2. Check the front brake light switch. Refer to “CHECKING THE Replace the front brake light switch. SWITCHES” on page 9-79. OK ↓ NG → 3. Check the rear brake light switch. Refer to “CHECKING THE Replace the rear brake light switch.
  • Page 360 SIGNALING SYSTEM NG → 2. Check the entire signaling system wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM” on system wiring. page 9-19. OK ↓ Replace the meter assembly or ECU. The differential gear lock indicator light and /or four-wheel-drive motor indicator light fails to come on. NG →...
  • Page 361 SIGNALING SYSTEM NG → 2. Check the entire signaling system wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM” on system wiring. page 9-19. OK ↓ Replace the meter assembly or ECU. The coolant temperature warning light fails to come on. NG →...
  • Page 362 SIGNALING SYSTEM NG → 2. Check the entire signaling system wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM” on system wiring. page 9-19. OK ↓ Replace the meter assembly or ECU. 9-25...
  • Page 363 SIGNALING SYSTEM techsparkstudio.com 9-26...

  • Page 364: Cooling System

    COOLING SYSTEM EAS27300 COOLING SYSTEM EAS27310 CIRCUIT DIAGRAM 9-27...
  • Page 365 COOLING SYSTEM 4. Main switch 5. Frame ground 6. Main fuse 8. Battery 20.ECU (engine control unit) 25.Coolant temperature sensor 59.Ignition fuse 66.Radiator fan motor 67.Radiator fan motor circuit breaker 68.Radiator fan motor relay 69.Radiator fan motor fuse techsparkstudio.com 9-28...

  • Page 366: Troubleshooting

    COOLING SYSTEM EAS27320 TROUBLESHOOTING The radiator fan motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Seat 2. Battery cover 3. Side panels 4. Front fenders NG → 1. Check the fuses. (Main, ignition and radiator fan mo- tor) Replace the fuse(s).
  • Page 367 COOLING SYSTEM NG → 8. Check the entire cooling system wiring. Properly connect or repair the cooling sys- Refer to “CIRCUIT DIAGRAM” on tem wiring. page 9-27. OK ↓ Replace the ECU. techsparkstudio.com 9-30...

  • Page 368: Fuel Injection System

    FUEL INJECTION SYSTEM EAS27330 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM 9-31...
  • Page 369 FUEL INJECTION SYSTEM 1. Crankshaft position sensor 4. Main switch 5. Frame ground 6. Main fuse 8. Battery 9. Fuel injection system fuse 17.Fuel injection system relay 19.ISC (idle speed control) unit 20.ECU (engine control unit) 21.Ignition coil 22.Spark plug 23.Fuel injector 24.Intake air temperature sensor 25.Coolant temperature sensor...

  • Page 370: Ecu Self-Diagnostic Function

    FUEL INJECTION SYSTEM EAS27350 ECU SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the en- gine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.
  • Page 371 FUEL INJECTION SYSTEM Self-diagnostic function table Able / un- Fault Able / un- Item Symptom able to code No. able to start drive No normal signals are received Crankshaft position from the crankshaft position sen- Unable Unable sensor sor. Intake air pressure Intake air pressure sensor–open sensor Able...

  • Page 372: Troubleshooting Method

    FUEL INJECTION SYSTEM Able / un- Fault Able / un- Item Symptom able to code No. able to start drive Faulty ECU memory. (When this ECU internal malfunc- malfunction is detected in the tion Unable Unable ECU, the fault code number might (memory check error) not appear on the meter.) Communication error with the meter...

  • Page 373: Diagnostic Mode

    FUEL INJECTION SYSTEM 5. Erase the malfunction history in the diagnos- If a malfunction is detected in the sensors or tic mode. Refer to “Sensor operation table (di- actuators, repair or replace all faulty parts. agnostic code No.d62)”. If no malfunction is detected in the sensors and actuators, check and repair inner parts of The engine operation is not normal but the the engine.
  • Page 374 FUEL INJECTION SYSTEM “d01 d70” “d70 d01” 6. Verify the operation of the sensor or actuator. • Sensor operation The data representing the operating conditions of the sensor appears on the multifunction meter. • Actuator operation Set the engine stop switch to “ON” to operate the actuator. If the engine stop switch is set to “ON”, set it to “OFF”, and then set it to “ON”...
  • Page 375 FUEL INJECTION SYSTEM Fault Diagnostic code Symptom Probable cause of malfunction code No. • Open or short circuit in wire harness. Intake air temperature sen- • Defective intake temperature sensor. sor: open or short circuit • Malfunction in ECU. detected. •...
  • Page 376 FUEL INJECTION SYSTEM Fault Diagnostic code Symptom Probable cause of malfunction code No. Faulty ECU memory. (When this malfunction is • Malfunction in ECU. (The program and data detected in the ECU, the are not properly written on or read from the —...
  • Page 377 FUEL INJECTION SYSTEM Diag- nostic Item Meter display Checking method code Neutral switch Shift the transmission. • Neutral • In gear EEPROM fault code dis- — play • No history • History exists Malfunction history code — display • No history •...

  • Page 378: Troubleshooting Details

    FUEL INJECTION SYSTEM Diag- nostic Item Actuation Checking method code Actuates the fuel injection system relay five times in one-second intervals. The engine trouble warning Check the operating sound light also flashes five times. Fuel injection system of the fuel injection system (The engine trouble warning relay five times.
  • Page 379 FUEL INJECTION SYSTEM Fault code No. 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 posi- Check for looseness or pinching. Cranking the tion sensor engine.
  • Page 380 FUEL INJECTION SYSTEM Fault code No. Symptom Intake air pressure sensor: open or short circuit detected. Diagnostic code No. Intake air pressure sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Setting the •...
  • Page 381 FUEL INJECTION SYSTEM Fault code No. Symptom Intake air pressure sensor: hose line malfunction (clogged or detached hose). Diagnostic code No. Intake air pressure sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Intake air pressure sensor hose. •...
  • Page 382 FUEL INJECTION SYSTEM Fault code No. Symptom Throttle position sensor: open or short circuit detected. Diagnostic code No. Throttle position sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of throttle position • Check for looseness or pinch- Setting the sensor.
  • Page 383 FUEL INJECTION SYSTEM Fault code No. Symptom Stuck throttle position sensor detected. Diagnostic code No. Throttle position sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of throttle position • Check the installed area for Reinstated by sensor.
  • Page 384 FUEL INJECTION SYSTEM Fault code No. Symptom Intake air temperature sensor: open or short circuit de- tected. Diagnostic code No. Intake air temperature sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of intake air tem- Check for looseness or pinching.
  • Page 385 FUEL INJECTION SYSTEM Fault code No. Symptom Malfunction detected in the primary lead of the ignition coil. Diagnostic code No. Ignition coil Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the connector and cou- Starting the en- •...
  • Page 386 FUEL INJECTION SYSTEM Fault code No. Symptom Engine speed is high when the engine is idling. Diagnostic code No. ISC valve Order Item/components and probable Check or maintenance job Reinstatement cause method Fuel injection system fuse is blown. • Check the fuel injection system ISC valve re- fuse.
  • Page 387 FUEL INJECTION SYSTEM Fault code No. Symptom Fuel injector: open or short circuit detected. Diagnostic code No. Fuel injector Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the couplers for any pins Cranking the •...
  • Page 388 FUEL INJECTION SYSTEM Fault code No. Symptom No normal signals are received from the speed sensor. Diagnostic code No. Speed sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Starting the en- •...
  • Page 389 FUEL INJECTION SYSTEM Fault code No. Symptom Power supply to the fuel injector and fuel pump is not nor- mal. Diagnostic code No. Fuel system voltage Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Starting the en- •...
  • Page 390 FUEL INJECTION SYSTEM Fault code No. 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 en- •...
  • Page 391 FUEL INJECTION SYSTEM techsparkstudio.com 9-54...

  • Page 392: Fuel Pump System

    FUEL PUMP SYSTEM EAS27550 FUEL PUMP SYSTEM EAS27560 CIRCUIT DIAGRAM 9-55...
  • Page 393 FUEL PUMP SYSTEM 4. Main switch 5. Frame ground 6. Main fuse 8. Battery 9. Fuel injection system fuse 17.Fuel injection system relay 20.ECU (engine control unit) 42.Fuel pump 43.Diode 2 54.Engine stop switch 59.Ignition fuse techsparkstudio.com 9-56...

  • Page 394: Troubleshooting

    FUEL PUMP SYSTEM EAS27570 TROUBLESHOOTING If the fuel pump fails to operate. • Before troubleshooting, remove the following part(s): 1. Seat 2. Battery cover 3. Rear fender NG → 1. Check the fuses. (Main, ignition and fuel injection system) Replace the fuse(s). Refer to “CHECKING THE FUS- ES”...
  • Page 395 FUEL PUMP SYSTEM techsparkstudio.com 9-58...

  • Page 396: 2Wd/4Wd Selecting System

    2WD/4WD SELECTING SYSTEM EAS30200 2WD/4WD SELECTING SYSTEM EAS30210 CIRCUIT DIAGRAM 9-59...
  • Page 397 2WD/4WD SELECTING SYSTEM 4. Main switch 5. Frame ground 6. Main fuse 8. Battery 20.ECU (engine control unit) 44.Four-wheel-drive motor relay 1 45.Four-wheel-drive motor relay 2 46.Four-wheel-drive motor relay 3 47.On-command four-wheel-drive motor switch and differential lock switch 48.Differential motor 49.Four-wheel-drive motor fuse techsparkstudio.com 9-60...

  • Page 398: Troubleshooting

    2WD/4WD SELECTING SYSTEM EAS30220 TROUBLESHOOTING The four-wheel-drive motor indicator light fails to come on. • Before troubleshooting, remove the following part(s): 1. Seat 2. Battery cover NG → 1. Check the fuses. (Main and four-wheel-drive motor) Replace the fuse(s). Refer to “CHECKING THE FUS- ES”...
  • Page 399 2WD/4WD SELECTING SYSTEM NG → 8. Check the differential motor. Refer to “CHECKING THE DIF- Replace the differential motor. FERENTIAL MOTOR” on page 8-11. OK ↓ NG → 9. Check the entire 2WD/4WD select- ing system wiring. Properly connect or repair the 2WD/4WD Refer to “CIRCUIT DIAGRAM”...

  • Page 400: Eps (Electric Power Steering) System (For Yfm5Fgp/Yfm7Fgp)

    EPS (ELECTRIC POWER STEERING) SYSTEM (for YFM5FGP/YFM7FGP) EAS30230 EPS (ELECTRIC POWER STEERING) SYSTEM (for YFM5FGP/YFM7FGP) EAS30240 CIRCUIT DIAGRAM 9-63...
  • Page 401 EPS (ELECTRIC POWER STEERING) SYSTEM (for YFM5FGP/YFM7FGP) 4. Main switch 5. Frame ground 6. Main fuse 7. EPS fuse 8. Battery 12.EPS torque sensor 13.EPS motor 14.EPS (electric power steering) control unit 15.EPS self-diagnosis signal connectors 20.ECU (engine control unit) 26.Speed sensor 40.EPS warning light 59.Ignition fuse...

  • Page 402: Eps Control Unit's Self-Diagnostic Function

    EPS (ELECTRIC POWER STEERING) SYSTEM (for YFM5FGP/YFM7FGP) EAS30250 EPS CONTROL UNIT’S SELF-DIAGNOSTIC FUNCTION The EPS control unit is equipped with a self-diagnostic function. If this function detects a malfunction in the EPS system, it lights the EPS warning light to alert the rider that a malfunction has occurred in the system.

  • Page 403: Diagnostic Mode

    EPS (ELECTRIC POWER STEERING) SYSTEM (for YFM5FGP/YFM7FGP) a. Main switch f. Off b. EPS warning light (no malfunction detected) g. Comes on. c. EPS warning light (malfunction detected) h. Initial lighting: 2 seconds d. OFF i. Goes off. e. ON EAS30270 DIAGNOSTIC MODE Setting the diagnostic mode (present and past malfunctions)
  • Page 404 EPS (ELECTRIC POWER STEERING) SYSTEM (for YFM5FGP/YFM7FGP) • Present malfunction signaling mode: Currently detected fault codes are signaled. • Past malfunction signaling mode: Both previously detected fault codes and currently detected fault codes are signaled. Signaling method Example 1: Fault code No. 23 0.5 ×...
  • Page 405 EPS (ELECTRIC POWER STEERING) SYSTEM (for YFM5FGP/YFM7FGP) Example 2: No malfunctions are detected 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 a. EPS self-diagnosis signal connector b. EPS warning light c. Disconnected d. Comes on. e. Goes off. f. Grounded g.

  • Page 406: Self-Diagnostic Function Table (Eps System)

    EPS (ELECTRIC POWER STEERING) SYSTEM (for YFM5FGP/YFM7FGP) EAS30280 SELF-DIAGNOSTIC FUNCTION TABLE (EPS SYSTEM) Fault Probable cause of mal- Item Symptom code No. function • Open or short circuit in wire harness. No normal signals are received • Malfunction in torque EPS torque sensor from the torque sensor.

  • Page 407: Troubleshooting Details (Eps System)

    EPS (ELECTRIC POWER STEERING) SYSTEM (for YFM5FGP/YFM7FGP) EAS30290 TROUBLESHOOTING DETAILS (EPS SYSTEM) The malfunction history is stored even if the main switch is turned to “OFF”, therefore, be sure to erase the history (present and past malfunction signaling modes) after repairing the cause of the EPS system malfunction.
  • Page 408 EPS (ELECTRIC POWER STEERING) SYSTEM (for YFM5FGP/YFM7FGP) Fault code No. 21 Symptom Speed sensor: open or short circuit detected. Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Starting the en- •...
  • Page 409 EPS (ELECTRIC POWER STEERING) SYSTEM (for YFM5FGP/YFM7FGP) Fault code No. 41,42, Symptom EPS motor: open or short circuit detected. 43,45 Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Setting the •...
  • Page 410 EPS (ELECTRIC POWER STEERING) SYSTEM (for YFM5FGP/YFM7FGP) Fault code No. 54 Symptom Relay contacts in the EPS control unit are welded togeth- Order Item/components and probable Check or maintenance job Reinstatement cause method Malfunction in EPS control unit. Replace the EPS control unit. Setting the main switch to “OFF”.
  • Page 411 EPS (ELECTRIC POWER STEERING) SYSTEM (for YFM5FGP/YFM7FGP) techsparkstudio.com 9-74...

  • Page 412: Electrical Components

    ELECTRICAL COMPONENTS EAS27972 ELECTRICAL COMPONENTS 9-75...
  • Page 413 ELECTRICAL COMPONENTS 1. Four-wheel-drive motor relay 1 2. Four-wheel-drive motor relay 2 3. Headlight relay 4. Fuel injection system fuse 5. Starter relay 6. EPS fuse (YFM5FGP/YFM7FGP only) 7. Main fuse 8. Fuse box (ignition, headlights, four-wheel- drive motor, radiator fan motor, signaling system, auxiliary DC jack) 9.
  • Page 414 ELECTRICAL COMPONENTS 9-77...
  • Page 415 ELECTRICAL COMPONENTS 1. Lean angle sensor 2. Radiator fan motor relay 3. Fuel injection system relay 4. Four-wheel drive motor relay 3 5. Front brake light switch 6. Rear brake light switch 7. Intake air temperature sensor 8. Intake air pressure sensor 9.

  • Page 416: Checking The Switches

    ELECTRICAL COMPONENTS EAS27980 CHECKING THE SWITCHES Br/Y Br/Y R Br/L Br R Br/L Br R/Y L Y R/Y Y (GRAY) PUSH LOCK Gy W (GRAY) (BLACK) 9-79...
  • Page 417 ELECTRICAL COMPONENTS 1. Main switch 2. Light switch 3. Engine stop switch 4. Start switch 5. Override switch 6. On-command four-wheel-drive motor switch and differential gear lock switch 7. Four-wheel-drive motor switch (differential motor) 8. Gear position switch 9. Reverse switch 10.
  • Page 418 ELECTRICAL COMPONENTS Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. ECA14370 NOTICE Never insert the tester probes into the coupler terminal slots “a”. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.

  • Page 419: Checking The Bulbs And Bulb Sockets

    ELECTRICAL COMPONENTS EAS27990 EWA28P1001 CHECKING THE BULBS AND BULB WARNING SOCKETS Since headlight bulbs get extremely hot, keep flammable products and your hands Do not check any of the lights that use LEDs. away from them until they have cooled down.

  • Page 420: Checking The Fuses

    ELECTRICAL COMPONENTS Checking the condition of the bulb sockets The following procedure applies to all of the bulb Set the pocket tester selector to “Ω × 1”. sockets. 1. Check: Pocket tester • Bulb socket (for continuity) 90890-03112 (with the pocket tester) Analog pocket tester No continuity →...

  • Page 421: Checking And Charging The Battery

    ELECTRICAL COMPONENTS • Charging time, charging amperage and EWA13310 WARNING charging voltage for a VRLA (Valve Regu- Never use a fuse with an amperage rating lated Lead Acid) battery are different from other than that specified. Improvising or us- those of conventional batteries. The VRLA ing a fuse with the wrong amperage rating (Valve Regulated Lead Acid) battery should may cause extensive damage to the electri-...
  • Page 422 ELECTRICAL COMPONENTS EWA13300 WARNING • The charge state of a VRLA (Valve Regulated Do not quick charge a battery. Lead Acid) battery can be checked by measur- ing its open-circuit voltage (i.e., the voltage ECA28P1003 NOTICE when the positive battery terminal is discon- •...
  • Page 423 ELECTRICAL COMPONENTS f. If charging requires more than 5 hours, it is advisable to check the charging current after a lapse of 5 hours. If there is any change in the amperage, readjust the voltage to obtain the standard charging current. g.

  • Page 424: Checking The Relays

    ELECTRICAL COMPONENTS Starter relay ECA13630 NOTICE First, connect the positive battery lead “1”, and then the negative battery lead “2”. Br/B R/W L/Y R/Y 1. Positive battery terminal 2. Negative battery terminal 3. Positive tester probe 4. Negative tester probe 8.
  • Page 425 ELECTRICAL COMPONENTS Fuel injection system relay Second step: 1. Positive battery terminal 1. Positive battery terminal 2. Negative battery terminal 2. Negative battery terminal 3. Positive tester probe 3. Positive tester probe 4. Negative tester probe 4. Negative tester probe 5.

  • Page 426: Checking The Diode

    ELECTRICAL COMPONENTS Second step: Second step: L/R B Br/R L/G B Br/R Br/R Br/R Br/B 1. Positive battery terminal 1. Positive battery terminal 2. Negative battery terminal 2. Negative battery terminal 3. Positive tester probe 3. Positive tester probe 4. Negative tester probe 4.

  • Page 427: Checking The Spark Plug Cap

    ELECTRICAL COMPONENTS The pocket tester or the analog pocket tester readings are shown in the following table. No continuity Positive tester probe → yel- low/white “1” Negative tester probe → yellow “2” Continuity Positive tester probe → yellow c. Measure the spark plug cap resistance. “2”...

  • Page 428: Checking The Ignition Spark Gap

    ELECTRICAL COMPONENTS Secondary coil resistance Ignition checker 8.64–12.96 kΩ at 20 °C (68 °F) 90890-06754 Opama pet-4000 spark checker M MMM M MMM M MMM M MMM M MMM YM-34487 a. Disconnect the spark plug cap from the igni- tion coil. b.

  • Page 429: Checking The Lean Angle Sensor

    ELECTRICAL COMPONENTS e. Measure the lean angle sensor output volt- age. L LLL L LLL L LLL L LLL L LLL EAS28940 CHECKING THE STARTER MOTOR OPERATION 1. Check: • Starter motor operation Does not operate → Perform the electric starting system troubleshooting, starting with b.

  • Page 430: Checking The Rectifier/Regulator

    ELECTRICAL COMPONENTS • Positive tester probe Pocket tester red “1” 90890-03112 • Negative tester probe Analog pocket tester black “2” YU-03112-C • Positive tester probe white “1” • Negative tester probe white “2” • Positive tester probe white “1” • Negative tester probe white “3”...

  • Page 431: Checking The Speed Sensor

    ELECTRICAL COMPONENTS • Positive tester probe white “1” • Negative tester probe black/blue “2” B B/W b. Move the fuel sender float to the minimum “3” and maximum “4” level positions. b. Set the main switch to “ON”. c. Elevate the rear wheels and slowly rotate them.

  • Page 432: Checking The Radiator Fan Motor Circuit Breaker

    ELECTRICAL COMPONENTS EAS28P1001 EAS28260 CHECKING THE RADIATOR FAN MOTOR CHECKING THE COOLANT TEMPERATURE CIRCUIT BREAKER SENSOR 1. Remove: 1. Remove: • Radiator fan motor circuit breaker • Coolant temperature sensor (from the wire harness) EWA14130 WARNING • Handle the coolant temperature sensor The radiator fan motor circuit breaker “1”...

  • Page 433: Checking The Throttle Position Sensor

    ELECTRICAL COMPONENTS EAS28300 CHECKING THE THROTTLE POSITION Intake air pressure sensor output SENSOR voltage 1. Remove: 3.75–4.25 V • Throttle position sensor M MMM M MMM M MMM M MMM M MMM (from the throttle body) a. Connect the pocket tester (DC 20 V) to the in- 2.

  • Page 434: Checking The Eps Motor (For Yfm5Fgp/Yfm7Fgp)

    ELECTRICAL COMPONENTS M MMM M MMM M MMM M MMM M MMM a. Connect the pocket tester (Ω × 100) to the in- Continuity Positive tester probe → red “1” take air temperature sensor terminal as Negative tester probe → black shown.
  • Page 435 ELECTRICAL COMPONENTS Pocket tester 90890-03112 Analog pocket tester YU-03112-C • Positive tester probe → red “1” • Negative tester probe → black “2” b. Measure the EPS torque sensor resistance. L LLL L LLL L LLL L LLL L LLL techsparkstudio.com 9-98...
  • Page 436 ELECTRICAL COMPONENTS 9-99...
  • Page 437 TROUBLESHOOTING TROUBLESHOOTING...................10-1 GENERAL INFORMATION ..............10-1 STARTING FAILURES................10-1 INCORRECT ENGINE IDLING SPEED ..........10-1 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ......10-2 FAULTY DRIVE TRAIN ................10-2 FAULTY GEAR SHIFTING..............10-2 SHIFT LEVER DOES NOT MOVE ............10-2 JUMPS OUT OF GEAR................10-2 FAULTY CLUTCH ...................10-3 OVERHEATING ..................10-3 OVERCOOLING..................10-3 POOR BRAKING PERFORMANCE............

  • Page 438: Troubleshooting

    TROUBLESHOOTING • Sucked-in air EAS28451 TROUBLESHOOTING Electrical system EAS28460 1. Battery GENERAL INFORMATION • Discharged battery • Faulty battery The following guide for troubleshooting does not 2. Fuse(s) cover all the possible causes of trouble. It should • Blown, damaged or incorrect fuse be helpful, however, as a guide to basic trouble- •...

  • Page 439: Poor Medium-And-High-Speed Performance

    TROUBLESHOOTING Electrical system • Broken AC magneto rotor woodruff key 1. Battery 5. Valve train • Discharged battery • Improperly adjusted valve clearance • Faulty battery • Improperly adjusted valve timing 2. Spark plug EAS28510 • Incorrect spark plug gap POOR MEDIUM-AND-HIGH-SPEED •...

  • Page 440: Faulty Clutch

    TROUBLESHOOTING Transmission EAS28600 OVERHEATING • Worn gear dog Engine EAS28580 FAULTY CLUTCH 1. Clogged coolant passages 2. Cylinder head and piston Engine operates but vehicle will not move • Heavy carbon buildup 1. V-belt 3. Engine oil • Damaged or worn V-belt •...

  • Page 441: Poor Braking Performance

    TROUBLESHOOTING EAS28620 EAS28710 POOR BRAKING PERFORMANCE FAULTY LIGHTING OR SIGNALING SYSTEM • Worn brake pad Headlight does not come on • Worn brake disc • Wrong headlight bulb • Air in hydraulic brake system • Too many electrical accessories • Leaking brake fluid •...

  • Page 442: Wiring Diagram

    52. Left handlebar switch EAS28740 EAS28750 WIRING DIAGRAM COLOR CODE 53. Light switch Black 54. Engine stop switch YFM5FGY/YFM5FGPY/ Brown 55. Start switch YFM7FGY/YFM7FGPY 2009 Green 56. Override switch 1. Crankshaft position sensor Gray 57. Headlight 2. AC magneto Blue 58.
  • Page 443 YFM5FGY/YFM5FGPY/YFM7FGY/YFM7FGPY 2009 WIRING DIAGRAM (BLACK) (BLACK) (BLACK) (GRAY) (GRAY) (GRAY) (GRAY) (BLACK) ( BLACK ) (BLACK) ( BLACK ) (BLACK) (GREEN) (BLACK) (BLACK) (BLACK) (GRAY) (GRAY) (BLACK) (BLACK) PUSH (BLACK) (BLACK) (BLACK) (BLACK) (GRAY) LOCK (GRAY) (GRAY) (GRAY) (BLACK) (GRAY) techsparkstudio.com...

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