Yamaha EX570ER Manuals

Manuals and User Guides for Yamaha EX570ER. We have 1 Yamaha EX570ER manual available for free PDF download: Service Manual

Yamaha EX570ER Service Manual

Yamaha EX570ER Service Manual (441 pages)

Brand: Yamaha | Category: Offroad Vehicle | Size: 9.95 MB

Table of Contents

Illustrated Symbols
1
Index
2
Table of Contents
3
Chapter 1

9
- Engine Serial Number
  9
- Frame Serial Number
  9
Machine Identification

9
Important Information

10
Special Tools

12
- Circlips
  12
- Fortune up
  12
- For Engineservice
  13
- For Electrical Service
  14
Chapter 2

15
Periodic Inspections and

15
Introduction

15
Periodic Maintenance Table

15
Engine

15
- Spark Plug
  15
- Oil Filter Inspection
  15
- Fuel Line Inspection
  15
- Fuel Filter Inspection
  15
  - Side Cowling Removal and Installation
    17
  - Spark Plug
    17
  - Oil Pump - Air Bleeding
    18
  - Oil Pump Cable Adjustment
    19
  - Engine Oil Line Inspection
    20
  - Oil Filter Inspection
    20
  - Fuel Line Inspection
    20
  - Fuel Filter Inspection
    21
  - Coolant Replacement
    21
  - Cooling System - Air Bleeding
    24
  - Water Pump Belt Deflection Adjustment
    25
  - Engine Idle Speed Adjustment
    26
  - Throttle Cable Adjustment
    27
  - Throttle Override System (TORS) Check
    28
  - Starter (Choke) Cable Adjustment
    28
  - Exhaust Systeem Inspection
    29
  - Power Train Check
    29
  - Drive V-Belt Check
    29
  - Engagement Speed Check
    31
  - Brake Adjustment
    32
  - Drive Chain
    32
  - Drive Chain Slack Adjustment
    34
  - Track Tension Adjustment
    35
  - Slide Runner Inspection
    36
  - Chassis Ski/Ski Runner Check
    37
  - Steering System Free Play Check
    37
  - Steering System Toe-Out Adjustment
    37
  - Lubrication
    38
  - Electrical
    39
  - Headlight and Meter Light Bulb Replacement
    39
  - Headlight Beam Adjustment
    41
  - Tail/Brake Light Bulb Replacement
    41
  - Battery Inspection
    42
  - Fuse Inspection
    44
  - Carburetor Tuning
    45
  - Carburetor Tuning Guide
    47
  - Carburetor - Low Speed Tuning
    49
  - Carburetor - Middle Range and High Speed Tuning
    50
  - Main Jet Selection Chart
    51
  - Carburetor Troubleshooting
    52
  - Clutch Tuning
    54
  - Clutch Setting Data
    55
  - Primary Spring
    55
  - Gearing Selection
    56
  - Gear Ratio Chart
    56
  - Slide Rail Suspension Tuning
    57
  - High Altitude Tuning (Gearing)
    57
  - Stopper Band Setting
    57
  - Spring Preload
    58
  - High Altitude Tuning
    59
  - Chassis
    60
  - Steering System Diagram
    60
  - Steering Removal
    61
  - Steering Inspection
    63
  - Steering Installation
    64
  - Ski
    67
  - Ski Removal
    68
  - Ski Inspection
    68
  - Ski Installation
    68
  - Front Suspension
    70
  - Front Suspension Removal
    71
  - Front Suspension Inspection
    73
  - Front Suspension Installation
    74
  - Power Train
    76
  - Primary Sheave and Drive V-Belt View
    76
  - Primary Sheave and Drive V-Belt Removal
    77
  - Primary Sheave and Drive V-Belt Disassembly
    77
  - Primary Sheave and Drive V-Belt Inspection
    79
  - Primary Sheave and Drive V-Belt Assembly
    81
  - Primary Sheave and Drive V-Belt Installation
    84
  - Secondary Sheave View
    85
  - Secondary Sheave Removal
    86
  - Secondary Sheave Disassembly
    86
  - Secondary Sheave Inspection
    87
  - Secondary Sheave Assembly
    88
  - Secondary Sheave Installation
    89
  - Sheave Distance and Offset Adjustment
    90
  - Drive Chain Housing and Jackshaft View
    93
  - Drive Chain Housing and Jackshaft Removal
    94
  - Drive Chain Housing and Jackshaft Inspection
    96
  - Drive Chain Housing and Jackshaft Installation
    97
  - Brake View
    98
  - Brake Removal
    99
  - Brake Disassembly
    99
  - Brake Inspection
    100
  - Brake Assembly and Installation
    101
  - Slide Rail Suspension View
    104
  - Slide Rail Suspension Removal and Disassembly
    106
  - Slide Rail Suspension Inspection
    108
  - Slide Rail Suspension Assembly
    110
  - Slide Rail Suspension Installation
    111
  - Front Axle and Track View
    112
  - Front Axle and Track Installation
    113
  - Engine Overhaul
    114
  - Engine Removal
    114
  - Battery Leads
    114
  - Hoses
    114
  - Cable and Leads
    115
  - Oil Tank
    115
  - Starter Motor
    115
  - Engine Removal and Disassembly
    116
  - Recoil Starter
    116
  - Oil Pump
    116
  - Water Pump
    116
  - Cylinder Head and Cylinder
    117
  - Piston
    118
  - Engine Inspection and Repair
    119
  - Crankcase and Crankshaft
    119
  - Cylinder Head Inspection and Repair
    119
  - Cylinder and Piston Inspection
    120
  - Piston Rings Inspection
    122
  - Piston Pin and Bearing Inspection
    123
  - Crankshaft Inspection
    124
  - Crankcase Inspection
    125
  - Oil Pump Stroke Adjustment
    125
  - Engine Assembly and Adjustment
    128
  - Crankcase and Crankshaft Assembly
    128
  - Piston, Cylinder and Cylinder Head Assembly
    131
  - CDI Magneto
    133
  - Water Pump Installation
    135
  - Oil Pump Installation
    135
  - Remounting Engine
    135
  - Recoil Starter View
    136
  - Recoil Starter Removal
    137
  - Recoil Starter Disassembly
    137
  - Recoil Starter Inspection
    138
  - Recoil Starter Assembly and Installation
    138
  - Cooling System
    141
  - Coolant Flow Diagram
    141
  - Cooling Line
    142
  - Cooling System Removal
    143
  - Cooling System Inspection
    145
  - Cooling System Installation
    146
  - Carburetor View
    147
  - Carburetor Removal
    148
  - Carburetor Disassembly
    149
  - Carburetor Inspection
    150
  - Carburetor Assembly
    151
  - Carburetor Installation
    152
  - Fuel Level Adjustment
    152
  - Fuel Pump Operation Check
    153
  - Electrical System
    155
  - Circuit Diagram
    155
  - Electrical Components
    157
  - Electrical Starting System Circuit Diagram
    159
  - Electrical Starting System Troubleshooting
    161
  - Starter Motor Does Not Operate
    161
  - Starter Motor View
    163
  - Starter Motor Removal and Disassembly
    164
  - Starter Motor Inspection
    165
  - Starter Motor Assembly
    167
  - Starter Motor Installation
    168
  - Charging System Circuit Diagram
    169
  - Charging System Troubleshooting
    171
  - Battery Is Not Charged
    171
  - Battery Inspection and Storage
    172
  - Charging Coil
    173
  - Ignition System Circuit Diagram
    175
  - Ignition System Troubleshooting
    177
  - No Spark or Weak Spark
    177
  - TORS Indicator Light Does Not Come on
    179
  - Source Coil and Pickup Coil
    180
  - Handlebar Switch
    181
  - Carburetor Switch
    181
  - Main Switch
    182
  - Lighting System Circuit Diagram
    183
  - Lighting System Troubleshooting
    185
  - Headlight Beam Switch Check
    186
  - Lighting Coil Check
    186
  - Signal System Circuit Diagram
    187
  - Signal System Troubleshooting
    189
  - Brake Light Does Not Come on
    189
  - "Water Temp" Indicator Does Not Come on
    190
  - Brake Light Switch Check
    191
  - Thermo System Check
    191
  - Grip Warmer System Circuit Diagram
    193
  - Grip Warmer System Troubleshooting
    195
  - Grip Warmer Switch Inspection
    196
  - Grip Warmer Coil Inspection
    196
  - General Specifications
    197
  - Maintenance Specifications
    199
  - Engine Data
    199
  - Power Train Data
    203
  - Chassis Data
    207
  - Electrical Data
    209
  - General Torque Specifications
    211
  - Definition of Units
    211
  - Cable Routing
    212
  - Wiring Diagrams
    217

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