Yamaha YFM660FR Service manual

YFM660FR
5KM2-AE2
SUPPLEMENTARY
SERVICE MANUAL
FOREWORD
This Supplementary Service Manual has been prepared to introduce new service and data for the
YFM660FR. For complete service information procedures it is necessary to use this Supplementary
Service Manual together with the following manual.
YFM660F(P) 2002 SERVICE MANUAL: 5KM2-AE1
YFM660FR
SUPPLEMENTARY
SERVICE MANUAL
©2002 by Yamaha Motor Co., Ltd.
First edition, June 2002
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
EB001000
NOTICE
This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one
manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on
Yamaha machine has a basic understanding of the mechanical ideas and the procedures of
machine repair. Repairs attempted by anyone without this knowledge are likely to render the
machine unsafe and unfit for use.
Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers
and will appear in future editions of this manual where applicable.
NOTE:
Designs and specifications are subject to change without notice.
IMPORTANT INFORMATION
Particularly important information is distinguished in this manual by the following notations.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
WARNING
CAUTION:
NOTE:
Failure to follow WARNING instructions could result in severe injury or death
to the machine operator, a bystander or a person inspecting or repairing the
machine.
A CAUTION indicates special precautions that must be taken to avoid damage to the machine.
A NOTE provides key information to make procedures easier or clearer.
EB002000
HOW TO USE THIS MANUAL
MANUAL ORGANIZATION
This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”)
1st title 1: This is the title of the chapter with its symbol in the upper right corner of each page.
2nd title 2: This title indicates the section of the chapter and only appears on the first page of each
section. It is located in the upper left corner of the page.
3rd title 3: This title indicates a sub-section that is followed by step-by-step procedures accompanied by corresponding illustrations.
EXPLODED DIAGRAMS
To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each
removal and disassembly section.
1. An easy-to-see exploded diagram 4 is provided for removal and disassembly jobs.
2. Numbers 5 are given in the order of the jobs in the exploded diagram. A number that is enclosed
by a circle indicates a disassembly step.
3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks
6. The meanings of the symbol marks are given on the next page.
4. A job instruction chart 7 accompanies the exploded diagram, providing the order of jobs, names
of parts, notes in jobs, etc.
5. For jobs requiring more information, the step-by-step format supplements 8 are given in addition
to the exploded diagram and the job instruction chart.
1
EB003000
2
GEN
INFO
ILLUSTRATED SYMBOLS
Illustrated symbols 1 to 0 are printed on the
top right of each page and indicate the subject
of each chapter.
SPEC
3
4
CHK
ADJ
1 General information
2 Specifications
3 Periodic checks and adjustments
4 Engine
5 Cooling system
6 Carburetion
7 Drive train
8 Chassis
9 Electrical
0 Troubleshooting
ENG
5
6
COOL
CARB
7
8
CHAS
DRIV
9
0
–
ELEC
TRBL
SHTG
+
A
Illustrated symbols A to H are used to identify
the specifications appearing in the text.
B
C
D
E
F
A Can be serviced with engine mounted
B Filling fluid
C Lubricant
D Special tool
E Torque
F Wear limit, clearance
G Engine speed
H Ω, V, A
T.
R.
G
H
I
J
Illustrated symbols I to N in the exploded
diagrams indicate the types of lubricants and
lubrication points.
K
G
E
L
M
M
B
N
M
LS
O
P
LT
New
I Apply engine oil
J Apply gear oil
K Apply molybdenum disulfide oil
L Apply wheel bearing grease
M Apply lightweight lithium-soap-based grease
N Apply molybdenum disulfide grease
Illustrated symbols O to P in the exploded
diagrams indicate where to apply a locking
agent O and when to install a new part P.
O Apply the locking agent (LOCTITE)
P Replace
CONTENTS
GENERAL INFORMATION ..............................................................................1
SPECIAL TOOLS ......................................................................................1
SPECIFICATIONS ............................................................................................2
GENERAL SPECIFICATIONS ..................................................................2
MAINTENANCE SPECIFICATIONS .........................................................3
ENGINE ................................................................................................3
ELECTRICAL ........................................................................................3
TIGHTENING TORQUES .........................................................................4
CABLE ROUTING .....................................................................................5
PERIODIC CHECKS AND ADJUSTMENTS ..................................................12
INTRODUCTION .....................................................................................12
PERIODIC MAINTENANCE/LUBRICATION ...........................................12
SEAT, CARRIERS, FENDERS AND FUEL TANK ..................................14
FRONT CARRIER, FRONT BUMPER AND FRONT GRILL ..............14
FUEL TANK ........................................................................................15
FOOTREST BOARDS .............................................................................17
ENGINE ...................................................................................................18
CHECKING THE STARTER CABLE ..................................................18
ENGINE ..........................................................................................................19
CAMSHAFT AND CYLINDER HEAD ......................................................19
RECOIL STARTER AND AC MAGNETO ...............................................21
CHECKING THE STARTER CLUTCH ................................................23
MIDDLE GEAR ........................................................................................24
MIDDLE DRIVEN SHAFT ...................................................................24
REMOVING THE MIDDLE DRIVEN SHAFT ......................................26
INSTALLING THE MIDDLE DRIVEN SHAFT .....................................28
DRIVE TRAIN .................................................................................................30
FRONT CONSTANT VELOCITY JOINTS
AND DIFFERENTIAL GEAR ...............................................................30
DISASSEMBLING THE DIFFERENTIAL GEAR .................................34
CHECKING THE DIFFERENTIAL GEAR ...........................................34
ASSEMBLING THE DIFFERENTIAL GEAR .......................................35
CHASSIS ........................................................................................................37
FRONT WHEELS AND BRAKE DISCS ..................................................37
FRONT WHEELS ................................................................................37
REAR WHEELS AND BRAKE DISC .......................................................39
REAR WHEELS ..................................................................................39
STEERING SYSTEM ..............................................................................40
TIE ROD AND STEERING KNUCKLE ................................................40
CHECKING THE STEERING KNUCKLE ............................................42
REAR KNUCKLE AND STABILIZER ......................................................43
CHECKING THE REAR KNUCKLE ....................................................44
REAR ARMS AND REAR SHOCK ABSORBER .....................................45
SPECIAL TOOLS
GEN
INFO
GENERAL INFORMATION
EB102001
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use
only the appropriate special tools; this will help prevent damage caused by the use of inappropriate
tools or improvised techniques. Special tools may differ by shape and part number from country to
country. In such a case, two types are provided.
When placing an order, refer to the list provided below to avoid any mistakes.
For US and CDN
P/N. YM-, YU-, YS-, YK-, ACCExcept for US and CDN
P/N. 90890Tool No.
Tool name/How to use
Coupling gear holding tool
90890-01486
YM-01486
This tool is needed when removing or
installing the coupling gear nut.
–1–
Illustration
GENERAL SPECIFICATIONS
SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item
Model code:
Bulb wattage × quantity:
Headlight
Tail/brake light
Indicator lights
Neutral
Fuel
Reverse
Coolant temperature warning
Park position
High gear
Low gear
Diff-lock
Standard
5KM9: (for CDN)
5KMB: (for Europe)
5KMC: (for Oceania)
12 V 30 W/30 W × 2
12 V 5 W/21 W × 1
LED × 1
LCD × 1
LED × 1
LED × 1
LED × 1
LED × 1
LED × 1
LED × 1
–2–
MAINTENANCE SPECIFICATIONS
SPEC
MAINTENANCE SPECIFICATIONS
ENGINE
Item
Oil pump:
Oil filter type
Oil pump type
Tip clearance “A” or “B”
Side clearance
Bypass valve setting pressure
Oil pressure (hot)
Pressure check location
Standard
Foam
Trochoid
0.03 ~ 0.10 mm
(0.0012 ~ 0.0039 in)
0.03 ~ 0.10 mm
(0.0012 ~ 0.0039 in)
441 ~ 637 kPa (4.41 ~
6.37 kg/cm2, 62.7 ~ 90.6 psi)
65 kPa (0.65 kg/cm2, 9.2 psi) at
1,500 r/min
Cylinder head
Limit
------0.15 mm
(0.006 in)
0.17 mm
(0.007 in)
----------
ELECTRICAL
Item
C.D.I.:
Magneto model/manufacturer
Pickup coil resistance/color
Rotor rotation direction sensing coil resistance/color
C.D.I. unit model/manufacturer
Charging system:
Type
Model/manufacturer
Nominal output
Charging coil resistance/color
Standard
Limit
F4T46972/MITSUBISHI
459 ~ 561 Ω at 20 °C (68 °F)/
White/Red – White/Green
0.063 ~ 0.077 Ω at 20 °C (68 °F)/
Red – White/Blue
F8T38671/MITSUBISHI
-------
A.C. magneto generator
F4T469/MITSUBISHI
14 V 21 A at 5,000 r/min
0.32 ~ 0.43 Ω at 20 °C (68 °F)/
White – White
-------------
–3–
-------
TIGHTENING TORQUES
SPEC
TIGHTENING TORQUES
Engine tightening torques
Part to be tightened
Exhaust pipe protector
Oil seal retainer
Part
name
Bolt
Screw
Thread
Q’ty
size
M6
M5
5
2
Tightening torque
Nm
m·kg
ft·lb
11
7
1.1
0.7
8
5.1
Remarks
Chassis tightening torques
Part to be tightened
Thread size
Front wheel hub and constant velocity joint
Rear wheel hub and constant velocity joint
Front brake master cylinder and handlebar
M20
M20
M8
–4–
Tightening torque
Remarks
Nm
m·kg
ft·lb
260
260
7
26.0
26.0
0.7
190 Stake
190 Stake
5.1
LT
CABLE ROUTING
SPEC
CABLE ROUTING
1 Fuel sender lead
2 Differential gear case and final
drive gear case breather hose
3 Vacuum chamber breather hose
4 Starter motor lead
5 Wire harness
6 Gear position switch lead
7 Final drive gear case breather
hose
8 Ground lead
9 Speed sensor lead
0 AC magneto lead
A Carburetor breather hose
B Starter cable
C Fuel hose
D Thermo switch 1 lead
E Reverse switch lead
F AC magneto coupler
G Gear position switch coupler
H Speed sensor coupler
I Radiator fan breather hose
J Rectifier/regulator lead
K Water pump breather hose
1
È
K
2
C
A
3
4
B
5
ÉÊ
E-E
6Ë
D
B
7
Ì
E
E
A
Í
0
9
I
8
I
5
7
2
B
Ï
8
E
D
7
F
C
H
D
J
G
3Î C
B-B
A
–5–
D
CABLE ROUTING
SPEC
È Fasten the final drive gear case breather hose, speed sensor lead, ground lead, gear position switch lead,
AC magneto lead, wire harness, and reverse indicator light lead with a plastic locking tie. Be careful not to
pinch the breather hose.
É Fasten the leads in the following order: ground lead, reverse switch lead, speed sensor lead, gear position
switch lead, and AC magneto lead.
Ê Pass the final drive gear case breather hose through the hole in air duct assembly 3.
Ë To the rear fender
Ì 70 ~ 90 mm (2.8 ~ 3.5 in)
Í Clamp the thermostat assembly breather hose and carburetor breather hose with the cable guide.
1
È
K
2
C
A
3
4
B
5
ÉÊ
E-E
6Ë
D
B
7
Ì
E
E
A
Í
0
9
I
8
I
5
7
2
B
Ï
8
E
D
7
F
C
H
D
J
G
3Î C
B-B
A
–6–
D
CABLE ROUTING
SPEC
Î Pass the vacuum chamber breather hose through the plastic cover hole.
Ï Insert a hook into the third hole from the bottom of the rectifier/regulator bracket, and then fasten the final
drive gear case breather hose onto the hook.
1
È
K
2
C
A
3
4
B
5
ÉÊ
E-E
6Ë
D
B
7
Ì
E
E
A
Í
0
9
I
8
I
5
7
2
B
Ï
8
E
D
7
F
C
H
D
J
G
3Î C
B-B
A
–7–
D
CABLE ROUTING
1 Gear position switch
2 Reverse switch
3 Crankcase breather hose
4 Select lever control cable
5 Rear brake cable
6 Front brake hose
7 Rear brake light switch lead
8 Spark plug lead
9 Fan motor breather hose
0 Fan motor lead
A Brake fluid reservoir hose
SPEC
B Rear brake hose
È Pass the rear brake cable and throttle cable
through the cable guide.
É Pass the rear brake light switch lead, main switch
lead and auxiliary DC jack lead over the front
fender.
6
5
12
7É
Ì
Ê 8Ë
È
3
9
4
0
B
A
–8–
Í
CABLE ROUTING
SPEC
Ê Clamp the spark plug lead and radiator inlet hose with a plastic clip.
Ë When installing the ignition coil, face the spark plug lead to the right side of the frame.
Ì To the rear fender hole
Í Pass the brake light switch lead on the inside of the rear brake cable and select lever control cable, and
through the cable guide of the brake master cylinder cover.
6
5
12
7É
Ì
Ê 8Ë
È
3
9
4
0
B
A
–9–
Í
SPEC
CABLE ROUTING
1 Front brake hose
2 Throttle cable
3 Thermo switch 1 lead
4 Crankcase breather hose
5 Fuel sender lead
6 Differential gear case breather hose
7 Starter cable
8 Select lever control cable
9 Wire harness
0 Fan motor breather hose
È Pass the thermo sensor 1 lead through the lead
guide.
É Pass the crankcase breather hose through the
hose guide.
Ê Pass the fuel sender lead through the lead
guide.
Ë Pass the select lever control cable through the
hole of the select lever unit bracket.
Ì Clamp the starter cable with a cable holder.
Í Pass the throttle cable through the cable guide.
8
Í
A-A
Ì
8
Ë
1
A
A
2
7
C
B
Î
C
6
3
È
B
É
0
6
5
9
4
Ê
– 10 –
C-C
SPEC
CABLE ROUTING
Î Fasten the wire harness speed sensor coupler, thermo switch 1 lead, reverse switch lead, and ground lead
with a plastic locking tie.
8
Í
A-A
Ì
8
Ë
1
A
A
2
7
C
B
Î
C
6
3
È
B
É
0
6
5
9
4
Ê
– 11 –
C-C
INTRODUCTION/PERIODIC MAINTENANCE/
LUBRICATION
CHK
ADJ
EB300000
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION
This chapter includes all information necessary to perform recommended inspections and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle
operation and a longer service life. The need for costly overhaul work will be greatly reduced. This
information applies to vehicles already in service as well as to new vehicles that are being prepared
for sale. All service technicians should be familiar with this entire chapter.
EBU00261
PERIODIC MAINTENANCE/LUBRICATION
INITIAL
ITEM
ROUTINE
Whichever
comes first
Valves*
• Check valve clearance.
• Adjust if necessary.
Cooling system
• Check coolant leakage.
• Repair if necessary.
• Replace coolant every 24 months.
Spark plug
• Check condition.
• Adjust gap and clean.
• Replace if necessary.
Air filter
• Clean.
• Replace if necessary.
Carburetor*
• Check and adjust idle speed/starter operation.
• Adjust if necessary.
Crankcase breather
system*
• Check breather hose for cracks or damage.
• Replace if necessary.
Exhaust system*
• Check for leakage.
• Retighten if necessary.
• Replace gasket(s) if necessary.
Fuel line*
• Check fuel hose for cracks or damage.
• Replace if necessary.
Engine oil
• Replace (Warm engine before draining).
Engine oil filter cartridge
• Replace.
Final gear oil
Differential gear oil
EVERY
km
(mile)
320
(200)
1,200
(750)
2,400
(1,500)
2,400
(1,500)
4,800
(3,000)
hours
20
75
150
150
300
Every 20 ~ 40 hours
(More often in wet or dusty areas.)
• Check oil level/oil leakage.
• Replace.
Front brake*
• Check operation/fluid leakage/see NOTE page 13.
• Correct if necessary.
Rear brake*
• Check operation/fluid leakage/see NOTE page 13.
• Correct if necessary.
V-belt*
• Check operation.
• Check for cracks or damage.
Wheels*
• Check balance/damage/runout.
• Repair if necessary.
– 12 –
PERIODIC MAINTENANCE/LUBRICATION
CHK
ADJ
INITIAL
ITEM
ROUTINE
Whichever
comes first
EVERY
km
(mile)
320
(200)
1,200
(750)
2,400
(1,500)
2,400
(1,500)
4,800
(3,000)
hours
20
75
150
150
300
Wheel bearing*
• Check bearing assemblies for looseness/damage.
• Replace if damaged.
Front and rear
suspension*
• Check operation.
• Correct if necessary.
Steering system*
• Check operation/Replace if damaged.
• Check toe-in/Adjust if necessary.
Rear upper and lower
• Lubricate.**
knuckle pivots*
Drive shaft universal
• Lubricate.**
joint*
Engine mount*
• Check for cracks or damage.
Front and rear axle
boots*
• Check operation.
• Replace if damaged.
Stabilizer bushes*
• Check for cracks or damage.
Fittings and Fasteners*
• Check all chassis fittings and fasteners.
• Correct if necessary.
* It is recommended that these items be serviced by a Yamaha dealer.
** Lithium-soap-based grease
NOTE:
● Recommended brake fluid: DOT 4
● Brake fluid replacement:
1.When disassembling the master cylinder or caliper, replace the brake fluid. Normally check the
brake fluid level and add fluid as required.
2.On the inner parts of the master cylinder and caliper, replace the oil seals every two years.
3.Replace the brake hoses every four years, or if cracked or damaged.
WARNING
Indicates a potential hazard that could result in serious injury or death.
– 13 –
SEAT, CARRIERS, FENDERS AND FUEL TANK
CHK
ADJ
SEAT, CARRIERS, FENDERS AND FUEL TANK
FRONT CARRIER, FRONT BUMPER AND FRONT GRILL
T.
R.
1
33 Nm (3.3 m • kg, 24 ft • Ib)
(8)
2
2
4
3
7
9
8
6
(6)
T.
R.
33 Nm (3.3 m • kg, 24 ft • Ib)
LT
5
T.
R.
Order
1
2
3
4
5
6
7
8
9
Job name/Part name
Removing the front carrier, front
bumper and front grill
Seat and fuel tank side panels
Cap
Front carrier cover
Front carrier
Front fender panel
Engine skid plate (front)
Front bumper protector
Front bumper
Headlight coupler
Front grill
Q’ty
9 Nm (0.9 m • kg, 6.5 ft • Ib)
Remarks
Remove the parts in the order below.
Refer to “SEAT AND SIDE PANELS” in
CHAPTER 3. (Manual No.: 5KM2-AE1)
2
2
1
1
1
2
1
2
1
Disconnect.
For installation, reverse the removal
procedure.
– 14 –
SEAT, CARRIERS, FENDERS AND FUEL TANK
CHK
ADJ
FUEL TANK
1
4
2
5
8
6
10
11
7
10
9
3
9
Order
Job name/Part name
Removing the fuel tank
Seat and side panels
Q’ty
Fuel tank cover
1
2
Fuel sender coupler
Fuel hose
1
1
3
4
Fuel cock lever
Fuel tank
1
1
– 15 –
Remarks
Remove the parts in the order below.
Refer to “SEAT AND SIDE PANELS” in
CHAPTER 3. (Manual No.: 5KM2-AE1)
Refer to “HANDLEBAR COVER, FUEL
TANK COVER AND FRONT FENDER” in
CHAPTER 3. (Manual No.: 5KM2-AE1)
Disconnect.
NOTE:
Before disconnecting the fuel hose, turn
the fuel cock to “OFF”.
NOTE:
When installing the fuel tank, pass the
fuel tank breather hose through the hole
in the handlebar protector.
SEAT, CARRIERS, FENDERS AND FUEL TANK
CHK
ADJ
1
4
2
5
8
6
10
11
7
10
9
3
9
Order
5
6
7
8
9
10
11
Job name/Part name
Clamp
Vacuum chamber breather hose
Differential gear case breather hose
Crankcase breather hose
Plastic band
Bushing
Plastic cover
Q’ty
1
1
1
1
3
2
1
Remarks
For installation, reverse the removal
procedure.
– 16 –
CHK
ADJ
FOOTREST BOARDS
FOOTREST BOARDS
T.
R.
1
9 Nm (0.9 m • kg, 6.5 ft • Ib)
(4)
1
(8)
2
(12)
3
4
(12)
(8)
T.
R.
Order
1
2
3
4
Job name/Part name
Removing the footrest boards
Fuel tank side panels
Footrest
Left footrest board
Right footrest board
Footrest bracket
Q’ty
4
33 Nm (3.3 m • kg, 24 ft • Ib)
Remarks
Remove the parts in the order below.
Refer to “SEAT AND SIDE PANELS” in
CHAPTER 3. (Manual No.: 5KM2-AE1)
2
1
1
2
For installation, reverse the removal
procedure.
– 17 –
CHECKING THE STARTER CABLE
CHK
ADJ
ENGINE
CHECKING THE STARTER CABLE
1.Remove:
● Seat
● Fuel tank side panel (left)
2.Check:
● Starter cable
Unsmooth operation → Replace.
*****************************************************
Checking steps:
● Disconnect the starter cable 1 from the carburetor body.
NOTE:
Do not remove the starter plunger 2 from the
starter cable.
● Measure
the starter plunger stroke distance
a of the starter lever 3 from the fully closed
to fully open positions.
Starter plunger stroke distance:
15 mm (0.59 in)
È Fully closed position
É Fully open position
● Connect
the starter cable to the carburetor.
WARNING
After checking the cable, turn the handlebar right and left, and make sure that the
engine idling speed does not increase.
*****************************************************
3.Install:
● Fuel tank side panel (left)
● Seat
– 18 –
CAMSHAFT AND CYLINDER HEAD
ENG
ENGINE
CAMSHAFT AND CYLINDER HEAD
Order
Job name/Part name
Removing the camshaft and cylinder head
Seat/front fender
Fuel tank/plastic covers
Q’ty
Carburetors
Thermostat
Thermostat assembly breather hose
Muffler/exhaust pipe
Thermo switch lead
– 19 –
Remarks
Remove the parts in the order below.
Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK” in CHAPTER 3.
(Manual No.: 5KM2-AE1)
Refer to “CARBURETOR” in CHAPTER
6. (Manual No.: 5KM2-AE1)
Refer to “THERMOSTAT” in CHAPTER 5.
(Manual No.: 5KM2-AE1)
Refer to “WATER PUMP” in CHAPTER 5.
(Manual No.: 5KM2-AE1)
Refer to “ENGINE REMOVAL” in CHAPTER 4. (Manual No.: 5KM2-AE1)
Refer to “HOSES AND LEADS” in CHAPTER 4. (Manual No.: 5KM2-AE1)
CAMSHAFT AND CYLINDER HEAD
Order
Job name/Part name
Cylinder head cover
Q’ty
1
2
3
4
5
6
7
8
9
10
11
Timing chain tensioner cap bolt
Timing chain tensioner/gasket
Timing chain guide (exhaust)
Decompressor cam guide plate
Camshaft sprocket
Camshaft
Thermo switch
Cylinder head
Cylinder head gasket
Dowel pin
Carburetor joint
1
1/1
1
2
1
1
1
1
1
2
1
ENG
Remarks
Refer to “CYLINDER HEAD COVER” in
CHAPTER 4. (Manual No.: 5KM2-AE1)
Refer to “REMOVING/INSTALLING THE
CAMSHAFT AND CYLINDER HEAD” in
CHAPTER 4. (Manual No.: 5KM2-AE1)
For installation, reverse the removal
procedure.
– 20 –
RECOIL STARTER AND AC MAGNETO
ENG
RECOIL STARTER AND AC MAGNETO
Order
Job name/Part name
Removing the AC magneto
Engine oil
Q’ty
Coolant
Seat and side panels/engine side cover
Left footrest board
Select lever unit
Water pump assembly
1
2
Recoil starter assembly
AC magneto coupler
1
2
– 21 –
Remarks
Remove the parts in the order below.
Drain.
Refer to “CHANGING THE ENGINE OIL”
in CHAPTER 3. (Manual No.: 5KM2-AE1)
Drain.
Refer to “CHANGING THE COOLANT” in
CHAPTER 3. (Manual No.: 5KM2-AE1)
Refer to “SEAT AND SIDE PANELS” in
CHAPTER 4. (Manual No.: 5KM2-AE1)
Refer to “FOOTREST BOARDS”.
Refer to “SELECT LEVER UNIT AND
COOLANT RESERVOIR” in CHAPTER 4.
(Manual No.: 5KM2-AE1)
Refer to “WATER PUMP” in CHAPTER 5.
(Manual No.: 5KM2-AE1)
Disconnect.
RECOIL STARTER AND AC MAGNETO
Order
3
4
5
6
7
8
9
10
11
12
13
14
15
Job name/Part name
Starter pulley
Crankcase cover (left)/gasket
Dowel pin
Lead holder
Pickup coil
Starter assembly
CDI rotor
Woodruff key
Starter wheel gear
Washer
Starter idle gear shaft
Bearing
Starter idle gear
Q’ty
1
1/1
2
1
1
1
1
1
1
1
1
1
1
ENG
Remarks
Refer to “REMOVING/INSTALLING THE
AC MAGNETO” in CHAPTER 4.
(Manual No.: 5KM2-AE1)
Refer to “REMOVING/INSTALLING THE
AC MAGNETO” in CHAPTER 4.
(Manual No.: 5KM2-AE1)
For installation, reverse the removal
procedure.
– 22 –
RECOIL STARTER AND AC MAGNETO
ENG
CHECKING THE STARTER CLUTCH
1.Check:
● Starter clutch 1
Cracks/damage → Replace.
● Bolts 2 (starter clutch)
Loose → Replace with new ones, and clinch
the end of the bolts.
NOTE:
The arrow mark on the starter clutch must face
inward, away from the CDI rotor.
T.
R.
Bolts (starter clutch):
30 Nm (3.0 m • kg, 22 ft • lb)
LOCTITE®
*****************************************************
Checking steps:
● Install the starter wheel gear onto the starter
clutch, and hold the starter clutch.
NOTE:
Install the starter wheel gear with the groove
1 facing the CDI rotor.
● Turn
the starter wheel gear counterclockwise
È to check that the starter clutch and wheel
gear engage.
If the starter clutch and wheel gear do not
engaged, replace the starter clutch.
● Turn the starter wheel gear clockwise É to
check the starter wheel gear for smooth
operation.
If operation is not smooth, replace the starter
clutch.
*****************************************************
2.Check:
● Gear teeth (starter idle) 1
● Gear teeth (starter wheel) 2
Burrs/clips/roughness/wear → Replace.
3.Check:
● Starter wheel gear
(contacting surface)
Damage/pitting/wear → Replace.
– 23 –
MIDDLE GEAR
ENG
MIDDLE GEAR
MIDDLE DRIVEN SHAFT
Order
Job name/Part name
Disassembling the middle driven
shaft
Crankcase separation
Q’ty
1
2
3
4
Front drive shaft coupling
Coupling gear
Bearing housing/O-ring
Shim
1
1
1/1
5
6
Middle driven pinion gear
Bearing retainer
1
1
Remarks
Remove the parts in the order below.
Refer to “CRANKCASE” in CHAPTER 4.
(Manual No.: 5KM2-AE1)
– 24 –
Refer to “INSTALLING/REMOVING THE
MIDDLE DRIVEN SHAFT”.
Refer to “MIDDLE DRIVE AND DRIVEN
GEAR SHIM SELECTION”.
(Manual No.: 5KM2-AE1)
Refer to “REMOVING/INSTALLING THE
MIDDLE DRIVEN SHAFT”.
MIDDLE GEAR
Order
7
8
Job name/Part name
Bearing retainer
Middle driven shaft
Q’ty
1
1
ENG
Remarks
For installation, reverse the removal
procedure.
– 25 –
MIDDLE GEAR
ENG
REMOVING THE MIDDLE DRIVEN SHAFT
1.Remove:
● Nut 1
● Washer
● Front drive shaft coupling
1
2
NOTE:
Use the coupling gear holding tool 2 to hold
the front drive shaft coupling.
Coupling gear holding tool:
P/N. YM-01486, 90890-01486
2.Remove:
● Nut 1
● Washer
● Coupling gear 2
NOTE:
Use the coupling gear/middle shaft tool 3 to
hold the coupling gear.
Coupling gear/middle shaft tool
P/N. YM-01230, 90890-01229
3.Remove:
● Bearing housing assembly 1
*****************************************************
Removal steps:
● Clean the outside of the middle driven shaft.
● Place the middle driven shaft onto a hydraulic press.
CAUTION:
●
●
Never directly press the shaft end with a
hydraulic press, this will result in damage
to the shaft thread.
Install the suitable socket 2 on the shaft
end to protect the thread from damage.
● Press
the shaft end and remove the bearing
housing.
*****************************************************
– 26 –
MIDDLE GEAR
ENG
4.Remove:
● Bearing retainer
● Bearing
*****************************************************
Removal steps:
● Place a rag 1 in the vise.
● Secure the bearing housing edge in the vise.
● Attach the bearing retainer wrench 2.
Bearing retainer wrench:
P/N. YM-04128, 90890-04128
CAUTION:
The middle driven shaft bearing retainer
has left-handed threads. To loosen the
retainer, turn it clockwise.
● Remove
the bearing retainer and bearing.
*****************************************************
5.Remove:
● Front drive shaft coupling
● Oil seal 1
● Bearing retainer 2
● Bearing
NOTE:
Attach the ring nut wrench 3.
Ring nut wrench:
P/N. YM-38404, 90890-01430
CAUTION:
The middle driven shaft bearing retainer
has left-handed threads. To loosen the
retainer, turn it clockwise.
6.Remove:
● Middle drive shaft 1
(with bearing)
– 27 –
MIDDLE GEAR
ENG
INSTALLING THE MIDDLE DRIVEN SHAFT
1.Install:
● Bearing retainer 1
LT
T.
R.
80 Nm (8.0 m • kg, 58 ft • lb)
NOTE:
Attach the ring nut wrench 2.
Ring nut wrench:
P/N. YM-38404, 90890-01430
CAUTION:
The middle driven shaft bearing retainer
has left-handed threads. To tighten the
retainer, turn it counterclockwise.
2.Install:
● Bearing retainer 1
LT
*****************************************************
Installation steps:
● Place a rag 2 in the vise.
● Secure the bearing housing edge in the vise.
● Attach the bearing retainer wrench 3.
Bearing retainer wrench:
P/N. YM-04128, 90890-04128
● Tighten
the bearing retainer.
CAUTION:
The middle driven shaft bearing retainer
has left-handed threads. To tighten the
retainer, turn it counterclockwise.
T.
R.
Bearing retainer:
110 Nm (11.0 m • kg, 80 ft • lb)
*****************************************************
3.Install:
● Shims 1
● Bearing housing
NOTE:
Install the shims so that the tabs are positioned
as shown in the illustration.
– 28 –
MIDDLE GEAR
ENG
4.Install:
● Front drive shaft coupling
● Washer
97 Nm (9.7 m • kg, 70 ft • lb)
● Nut 1
LT
T.
R.
1
NOTE:
Use the coupling gear holding tool 2 to hold
the front drive shaft coupling.
2
Coupling gear holding tool:
P/N. YM-01486, 90890-01486
– 29 –
FRONT CONSTANT VELOCITY JOINTS AND
DIFFERENTIAL GEAR
DRIV
DRIVE TRAIN
FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR
1
LS
6
4
5
3
LS
2
LS
LS
T.
R.
55 Nm (5.5 m • kg, 40 ft • Ib)
1
Order
Job name/Part name
Removing the front constant velocity joint and differential gear
Engine skid plate (front)
Front fender
Q’ty
Refer to “SEAT, CARRIERS, FENDERS
AND FUEL TANK” in CHAPTER 3.
(Manual No.: 5KM2-AE1)
Drain.
Refer to “STEERING SYSTEM” in CHAPTER 8. (Manual No.: 5KM2-AE1)
Refer to “FRONT ARMS AND FRONT
SHOCK ABSORBER” in CHAPTER 8.
(Manual No.: 5KM2-AE1)
Refer to “FRONT AND REAR BRAKES”
in CHAPTER 8. (Manual No.: 5KM2-AE1)
Differential gear oil
Steering knuckle
Front arms (lower)
Brake master cylinder cover
1
2
Constant velocity joint
Gear motor coupler/on-command fourwheel drive switch and differential gear
lock switch coupler
Remarks
Remove the parts in the order below.
2
1/1
– 30 –
Disconnect.
FRONT CONSTANT VELOCITY JOINTS AND
DIFFERENTIAL GEAR
DRIV
1
LS
6
4
5
3
LS
2
LS
LS
T.
R.
55 Nm (5.5 m • kg, 40 ft • Ib)
1
Order
3
4
5
6
Job name/Part name
Differential gear case breather hose
Differential gear
Compression spring
Drive shaft assembly
Q’ty
Remarks
1
Disconnect.
1
1
1
For installation, reverse the removal
procedure.
– 31 –
FRONT CONSTANT VELOCITY JOINTS AND
DIFFERENTIAL GEAR
Order
Q’ty
1
Job name/Part name
Disassembling the differential gear
Gear motor/O-ring
2
Coupling gear/O-ring
1/1
3
4
5
6
7
8
Sttoper bolt/shaft
Shift fork sliding gear
Shift fork
Differential gear case cover
Drive clutch
Shim (left)
1/1
1
1
1
1
1/1
– 32 –
DRIV
Remarks
Remove the parts in the order below.
NOTE:
Do not disassemble the gear motor or
remove the pinion gear.
Refer to “DISASSEMBLING/ASSEMBLING THE DIFFERENTIAL GEAR”.
FRONT CONSTANT VELOCITY JOINTS AND
DIFFERENTIAL GEAR
Order
9
0
A
B
C
Job name/Part name
Differential gear assembly
Shim (right)
Circlip/bearing
Drive pinion gear
Differential gear case
Q’ty
1
DRIV
Remarks
1/1
1
1
For assembly, reverse the disassembly
procedure.
– 33 –
FRONT CONSTANT VELOCITY JOINTS AND
DIFFERENTIAL GEAR
1
DRIV
DISASSEMBLING THE DIFFERENTIAL
GEAR
1.Remove:
● Coupling gear
Use a coupling gear holding tool 1.
Coupling gear holding tool:
P/N. YM-01486, 90890-01486
CHECKING THE DIFFERENTIAL GEAR
1.Check:
● Gear teeth
Pitting/galling/wear → Replace drive pinion
gear and ring gear as a set.
● Bearing
Pitting/damage → Replace.
● Oil seal
● O-ring
Damage → Replace.
2.Check:
● Drive shaft splines
● Front drive gear splines
Wear/damage → Replace.
● Spring
Fatigue → Replace.
Move the spring up and down.
3.Check:
● Dust boots
Cracks/damage → Replace the front drive
shaft assembly.
4.Check:
● Front drive shaft
Bends → Replace the front drive shaft
assembly.
WARNING
Do not attempt to straighten a bent shaft;
this may dangerously weaken the shaft.
– 34 –
FRONT CONSTANT VELOCITY JOINTS AND
DIFFERENTIAL GEAR
DRIV
5.Check:
● Front drive shaft assembly operation
Unsmooth operation → Replace the front
drive shaft assembly.
ASSEMBLING THE DIFFERENTIAL GEAR
1.Measure:
● Gear lash
Refer to “MEASURING AND ADJUSTING
THE DIFFERENTIAL GEAR LASH”. in
CHAPTER 7. (Manual No.: 5KM2-AE1)
2.Install:
● Gear motor
*****************************************************
Installation steps:
● Slide the shift fork sliding gear 1, which is
installed to the differential gear, to the left to
put it into the 2WD mode.
● Connect two C size batteries to the gear
motor terminal 2 to operate the pinion gear
3. Operate the pinion gear until the paint
mark 4 on the gear is aligned with the paint
mark 5 on the gear motor case.
CAUTION:
Do not use a 12 V battery to operate the
pinion gear.
8 mm bolts 6 into the gear motor 7
and use them as a guide to set the motor on
the differential gear assembly 8 so that the
shift fork sliding gear 9 does not move.
● Insert
CAUTION:
If the position of the shift fork sliding gear
is moved, the position of the differential
gear and the indicator light display may differ, and the 2WD or differential lock mode
may not be activated.
● Remove
the 8 mm bolts, and then install the
motor with the gear motor bolts.
T.
Bolts (gear motor)
13 Nm (1.3 m • kg, 9.4 ft • lb)
R.
*****************************************************
– 35 –
FRONT CONSTANT VELOCITY JOINTS AND
DIFFERENTIAL GEAR
1
DRIV
3.Install:
● Coupling gear
● O-ring
● Washer
● Nut
62 Nm (6.2 m • kg, 45 ft • lb)
Use a coupling gear holding tool 1.
LT
T.
R.
Coupling gear holding tool:
P/N. YM-01486, 90890-01486
4.Check:
● Differential gear operation
Unsmooth operation → Replace the differential gear assembly.
Insert the double off-set joint into the differential gear, and then turn the gear back and
forth.
– 36 –
FRONT WHEELS AND BRAKE DISCS
CHAS
CHASSIS
FRONT WHEELS AND BRAKE DISCS
FRONT WHEELS
T.
R.
30 Nm (3.0 m • kg, 22 ft • Ib)
LT
LT
T.
R.
260 Nm (26.0 m • kg, 190 ft • lb)
3 New
1
2
6
4
5
T.
R.
30 Nm (3.0 m • kg, 22 ft • Ib)
T.
R.
Order
Job name/Part name
Removing the front wheel
Q’ty
55 Nm (5.5 m • kg, 40 ft • Ib)
Remarks
Remove the parts in the order below.
Place the machine on a level surface.
WARNING
Securely support the machine so there
is no danger of it falling over.
1
Front wheel
1
2
3
Wheel cap
Axle nut
1
1
– 37 –
Refer to “INSTALLING THE FRONT
WHEEL” in CHAPTER 8.
(Manual No.: 5KM2-AE1)
Refer to “INSTALLING THE FRONT
WHEEL HUB” in CHAPTER 8.
(Manual No.: 5KM2-AE1)
FRONT WHEELS AND BRAKE DISCS
CHAS
T.
R.
30 Nm (3.0 m • kg, 22 ft • Ib)
LT
LT
T.
R.
260 Nm (26.0 m • kg, 190 ft • lb)
3 New
1
2
6
4
5
T.
R.
30 Nm (3.0 m • kg, 22 ft • Ib)
T.
R.
Order
4
5
6
Job name/Part name
Brake caliper assembly
Front wheel hub
Brake disc
Q’ty
1
55 Nm (5.5 m • kg, 40 ft • Ib)
Remarks
NOTE:
Do not squeeze the brake lever when the
brake caliper is off of the brake disc as
the brake pads will be forced shut.
1
1
For installation, reverse the removal
procedure.
– 38 –
REAR WHEELS AND BRAKE DISC
CHAS
REAR WHEELS AND BRAKE DISC
REAR WHEELS
T.
R.
260 Nm (26.0 m • kg, 190 ft • lb)
T.
R.
55 Nm (5.5 m • kg, 40 ft • Ib)
3 New
2
4
1
Order
Job name/Part name
Removing the rear wheel
Q’ty
Remarks
Remove the parts in the order below.
Place the machine on a level surface.
WARNING
Securely support the machine so there
is no danger of it falling over.
1
Rear wheel
1
2
3
Wheel cap
Axle nut
1
1
4
Rear wheel hub
1
Refer to “INSTALLING THE REAR
WHEEL” in CHAPTER 8.
(Manual No.: 5KM2-AE1)
Refer to “INSTALLING THE REAR
WHEEL HUB” in CHAPTER 8.
(Manual No.: 5KM2-AE1)
For installation, reverse the removal
procedure.
– 39 –
STEERING SYSTEM
CHAS
STEERING SYSTEM
TIE ROD AND STEERING KNUCKLE
New
T.
R.
25 Nm (2.5 m • kg, 18 ft • Ib)
6
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
1
LS
T.
R.
25 Nm (2.5 m • kg, 18 ft • Ib)
4
New
2
7
3
4
5
New
T
.
R.
Job name/Part name
Removing the tie rod and steering
knuckle
Front fender
1
Front wheel/brake disc
Tie rod
2
3
4
5
Brake disc guard
Front protector
Bolt/washer/nut
Nut
R.
R.
25 Nm (2.5 m • kg, 18 ft • Ib)
T.
T.
Order
New
48 Nm (4.8 m • kg, 35 ft • Ib)
Q’ty
1
1
1
1/1/1
1
– 40 –
7 Nm (0.7 m • kg, 5.1 ft • Ib)
Remarks
Remove the parts in the order below.
Refer to “SEAT, CARRIERS, FENDERS
AND FUEL TANK” in CHAPTER 3.
(Manual No.: 5KM2-AE1)
Refer to “FRONT WHEELS”.
Refer to “INSTALLING THE TIE ROD” in
CHAPTER 8. (Manual No.: 5KM2-AE1)
STEERING SYSTEM
CHAS
New
T.
R.
25 Nm (2.5 m • kg, 18 ft • Ib)
6
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
1
LS
T.
R.
25 Nm (2.5 m • kg, 18 ft • Ib)
4
New
2
7
3
4
5
New
T
.
R.
Job name/Part name
Brake hose holder bolt
Steering knuckle
R.
R.
25 Nm (2.5 m • kg, 18 ft • Ib)
T.
T.
Order
6
7
New
48 Nm (4.8 m • kg, 35 ft • Ib)
7 Nm (0.7 m • kg, 5.1 ft • Ib)
Q’ty
Remarks
1
1
Refer to “REMOVING THE STEERING
KNUCKLE” in CHAPTER 8.
(Manual No.: 5KM2-AE1)
For installation, reverse the removal
procedure.
– 41 –
STEERING SYSTEM
CHAS
CHECKING THE STEERING KNUCKLE
1.Check:
● Steering knuckle
Damage/pitting → Replace.
2
1
2.Check:
● Front wheel bearings
Bearings allow play in the wheel hubs or
unsmooth wheel operation → Replace.
● Oil seals
Damage → Replace.
*****************************************************
Replacement steps:
● Clean the outside of the steering knuckle.
● Remove the circlip 1.
● Drive out the bearing 2.
WARNING
Eye protection is recommended when
using striking tools.
● Apply
lithium-soap-based grease to the bear-
ing.
● Install
the new bearing.
CAUTION:
Do not strike the center race or balls of the
bearing. Contact should be made only with
the outer race.
● Install
a new circlip.
*****************************************************
– 42 –
CHAS
REAR KNUCKLE AND STABILIZER
REAR KNUCKLE AND STABILIZER
7
T.
6
R.
30 Nm (3.0 m • kg, 22 ft • Ib)
8
5
7
8
9
5
T.
R.
48 Nm (4.8 m • kg, 35 ft • Ib)
T.
R.
45 Nm (4.5 m • kg, 32 ft • Ib)
T.
R.
48 Nm (4.8 m • kg, 35 ft • Ib)
3
LS
4
3
1
3
LS
Order
1
2
3
4
5
6
7
8
9
2
4
3
Job name/Part name
Removing the rear knuckle and
stabilizer
Rear wheel hubs
Rear protector
Rear knuckle
Spacer cover
Spacer
Stabilizer joint
Brake hose holder
Stabilizer holder
Bushing
Stabilizer
Q’ty
Remarks
Remove the parts in the order below.
Refer to “REAR WHEELS AND BRAKE
DISC”.
1
1
4
2
2
1
2
2
1
For installation, reverse the removal
procedure.
– 43 –
REAR KNUCKLE AND STABILIZER
CHAS
CHECKING THE REAR KNUCKLE
1.Check:
● Rear knuckle
Damage/pitting → Replace.
2.Check:
● Rear wheel bearings
Bearings allow play in the wheel hubs or
unsmooth wheel operation → Replace.
● Oil seals
Damage → Replace.
2
1
*****************************************************
Replacement steps:
● Clean the outside of the rear knuckle.
● Remove the circlip 1.
● Drive out the bearing 2.
WARNING
Eye protection is recommended when
using striking tools.
● Apply
lithium-soap-based grease to the bearing.
● Install the new bearing.
CAUTION:
Do not strike the center race or balls of the
bearing. Contact should be made only with
the outer race.
● Install
a new circlip.
*****************************************************
– 44 –
REAR ARMS AND REAR SHOCK ABSORBER
CHAS
REAR ARMS AND REAR SHOCK ABSORBER
T.
3
R.
T.
R.
45 Nm (4.5 m • kg, 32 ft • Ib)
45 Nm (4.5 m • kg, 32 ft • Ib)
1
1
1
5
1
5
2
2
5
5
T.
R.
6
4
6
3
3
T.
R.
Order
1
2
3
4
5
6
45 Nm (4.5 m • kg, 32 ft • Ib)
Job name/Part name
Removing the rear arms and rear
shock absorber
Rear protector/rear knuckle/stabilizer
Q’ty
Nut/bolt
Rear arm (upper)/bushing/washer
Nut/bolt
Rear shock absorber
Nut/bolt
Rear arm (lower)/bushing
2/2
1/2/1
2/2
1
2/2
1/2
45 Nm (4.5 m • kg, 32 ft • Ib)
Remarks
Remove the parts in the order below.
Refer to “REAR KNUCKLE AND STABILIZER”.
For installation, reverse the removal
procedure.
– 45 –
YAMAHA MOTOR CO., LTD.
2500 SHINGAI IWATA SHIZUOKA JAPAN