YFM450FAR
SERVICE MANUAL
LIT-11616-16-01
5ND-F8197-10
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YFM450FAR
SERVICE MANUAL
©2002 by Yamaha Motor Corporation, U.S.A.
First Edition, March 2002
All rights reserved. Any reproduction or
unauthorized use without the written
permission of Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in U.S.A.
LIT-11616-16-01
Not For Resale
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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.
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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.
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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 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
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TABLE OF CONTENTS
GENERAL INFORMATION
SPECIFICATIONS
PERIODIC CHECKS AND
ADJUSTMENTS
ENGINE
COOLING SYSTEM
CARBURETION
DRIVE TRAIN
CHASSIS
GEN
INFO
1
SPEC
2
CHK
ADJ
3
ENG
4
COOL
5
CARB
6
DRIV
7
CHAS
8
–
ELECTRICAL
TROUBLESHOOTING
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+
ELEC
9
TRBL
SHTG
10
CONTENTS
CHAPTER 1.
GENERAL INFORMATION
MACHINE IDENTIFICATION ........................................................................ 1-1
VEHICLE IDENTIFICATION NUMBER ................................................. 1-1
MODEL LABEL ...................................................................................... 1-1
FEATURES ................................................................................................... 1-2
LIQUID COOLING ENGINE .................................................................. 1-2
PARK POSITION ................................................................................... 1-2
FRONT DIFFERENTIAL ........................................................................ 1-3
IMPORTANT INFORMATION ....................................................................... 1-8
PREPARATION FOR REMOVAL PROCEDURES ............................... 1-8
REPLACEMENT PARTS ....................................................................... 1-8
GASKETS, OIL SEALS AND O-RINGS ................................................ 1-8
LOCK WASHERS/PLATES AND COTTER PINS ................................. 1-9
BEARINGS AND OIL SEALS ................................................................ 1-9
CIRCLIPS .............................................................................................. 1-9
CHECKING OF CONNECTIONS ................................................................ 1-10
SPECIAL TOOLS ........................................................................................ 1-11
CHAPTER 2.
SPECIFICATIONS
GENERAL SPECIFICATIONS ...................................................................... 2-1
MAINTENANCE SPECIFICATIONS ............................................................. 2-4
ENGINE ................................................................................................. 2-4
CHASSIS ............................................................................................. 2-14
ELECTRICAL ...................................................................................... 2-18
HOW TO USE THE CONVERSION TABLE ............................................... 2-20
GENERAL TORQUE SPECIFICATIONS ................................................... 2-20
LUBRICATION POINTS AND LUBRICANT TYPES .................................. 2-21
ENGINE ............................................................................................... 2-21
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COOLANT FLOW DIAGRAMS ................................................................... 2-22
OIL FLOW DIAGRAMS .............................................................................. 2-24
CABLE ROUTING ....................................................................................... 2-27
CHAPTER 3.
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION ........................................................................................... 3-1
PERIODIC MAINTENANCE/LUBRICATION ................................................ 3-1
SEAT, CARRIERS, FENDERS AND FUEL TANK ....................................... 3-3
SEAT AND SIDE PANELS .................................................................... 3-3
FRONT CARRIER, FRONT BUMPER AND FRONT FENDER ............. 3-4
REAR CARRIER AND REAR FENDER ................................................ 3-6
FUEL TANK ........................................................................................... 3-8
FOOTREST BOARDS .................................................................................. 3-9
ENGINE ....................................................................................................... 3-10
ADJUSTING THE VALVE CLEARANCE ............................................ 3-10
ADJUSTING THE IDLING SPEED ...................................................... 3-13
ADJUSTING THE THROTTLE LEVER FREE PLAY .......................... 3-14
ADJUSTING THE SPEED LIMITER .................................................... 3-16
ADJUSTING THE STARTER CABLE ................................................. 3-17
CHECKING THE SPARK PLUG ......................................................... 3-19
CHECKING THE IGNITION TIMING ................................................... 3-20
MEASURING THE COMPRESSION PRESSURE .............................. 3-21
CHECKING THE ENGINE OIL LEVEL ................................................ 3-23
CHANGING THE ENGINE OIL ........................................................... 3-24
CLEANING THE AIR FILTER .............................................................. 3-26
CHECKING THE COOLANT LEVEL ................................................... 3-29
CHANGING THE COOLANT ............................................................... 3-30
COOLANT TEMPERATURE WARNING LIGHT CHECK ................... 3-33
CHECKING THE V-BELT .................................................................... 3-33
CLEANING THE SPARK ARRESTER ................................................ 3-34
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CHASSIS .................................................................................................... 3-36
ADJUSTING THE REAR BRAKE ........................................................ 3-36
CHECKING THE BRAKE FLUID LEVEL ............................................. 3-38
CHECKING THE FRONT BRAKE PAD .............................................. 3-39
CHECKING THE REAR BRAKE PAD ................................................. 3-39
CHECKING THE BRAKE HOSE ......................................................... 3-40
BLEEDING THE HYDRAULIC BRAKE SYSTEM ............................... 3-41
ADJUSTING THE SELECT LEVER CONTROL CABLE
AND SHIFT ROD ............................................................................. 3-42
ADJUSTING THE REAR BRAKE LIGHT SWITCH ............................. 3-43
CHECKING THE FINAL GEAR OIL LEVEL ........................................ 3-44
CHANGING THE FINAL GEAR OIL .................................................... 3-45
CHECKING THE DIFFERENTIAL GEAR OIL ..................................... 3-46
CHANGING THE DIFFERENTIAL GEAR OIL .................................... 3-46
CHECKING THE CONSTANT VELOCITY JOINT DUST BOOT ........ 3-47
CHECKING THE STEERING SYSTEM .............................................. 3-48
ADJUSTING THE TOE-IN ................................................................... 3-48
ADJUSTING THE FRONT SHOCK ABSORBER ................................ 3-50
ADJUSTING THE REAR SHOCK ABSORBER .................................. 3-50
CHECKING THE TIRE ........................................................................ 3-50
CHECKING THE WHEEL .................................................................... 3-53
CHECKING AND LUBRICATING THE CABLE ................................... 3-53
LUBRICATING THE LEVERS, PEDAL, ETC. ..................................... 3-54
ELECTRICAL .............................................................................................. 3-55
CHECKING THE BATTERY ................................................................ 3-55
CHECKING THE FUSE ....................................................................... 3-60
ADJUSTING THE HEADLIGHT BEAM ............................................... 3-62
CHANGING THE HEADLIGHT BULB ................................................. 3-62
CHAPTER 4.
ENGINE
ENGINE REMOVAL ...................................................................................... 4-1
AIR DUCTS, MUFFLER AND EXHAUST PIPE .................................... 4-1
SELECT LEVER UNIT AND COOLANT RESERVOIR ......................... 4-3
HOSES AND LEADS ............................................................................. 4-4
ENGINE MOUNTING BOLTS ............................................................... 4-5
INSTALLING THE ENGINE ................................................................... 4-7
CYLINDER HEAD ......................................................................................... 4-8
REMOVING THE CYLINDER HEAD ................................................... 4-10
CHECKING THE TAPPET COVER ..................................................... 4-11
CHECKING THE TIMING CHAIN TENSIONER .................................. 4-11
CHECKING THE CAMSHAFT SPROCKET ........................................ 4-11
CHECKING THE CYLINDER HEAD ................................................... 4-12
INSTALLING THE CYLINDER HEAD ................................................. 4-13
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CAMSHAFT, ROCKER ARMS AND VALVES ........................................... 4-16
REMOVING THE CAMSHAFT AND ROCKER ARM .......................... 4-18
REMOVING THE VALVE AND VALVE SPRING ................................ 4-18
CHECKING THE CAMSHAFT ............................................................. 4-19
CHECKING THE ROCKER ARM AND CAMSHAFT ........................... 4-19
CHECKING THE VALVE AND VALVE SPRING ................................. 4-21
INSTALLING THE VALVE AND VALVE SPRING ............................... 4-25
INSTALLING THE CAMSHAFT AND ROCKER ARM ......................... 4-26
CYLINDER AND PISTON ........................................................................... 4-27
REMOVING THE PISTON .................................................................. 4-28
CHECKING THE TIMING CHAIN GUIDE ........................................... 4-28
CHECKING THE CYLINDER AND PISTON ....................................... 4-28
CHECKING THE PISTON RING ......................................................... 4-30
CHECKING THE PISTON PIN ............................................................ 4-31
INSTALLING THE PISTON ................................................................. 4-32
INSTALLING THE CYLINDER ............................................................ 4-33
RECOIL STARTER AND A.C. MAGNETO ................................................ 4-34
REMOVING THE A.C. MAGNETO ...................................................... 4-37
DISASSEMBLING THE RECOIL STARTER ....................................... 4-37
CHECKING THE CDI MAGNETO ....................................................... 4-37
CHECKING THE STARTER CLUTCH ................................................ 4-38
CHECKING THE STARTER PULLEY ................................................. 4-39
CHECKING THE RECOIL STARTER ................................................. 4-39
ASSEMBLING THE RECOIL STARTER ............................................. 4-39
INSTALLING THE A.C. MAGNETO .................................................... 4-40
PRIMARY AND SECONDARY SHEAVES ................................................. 4-42
PRIMARY SLIDING SHEAVE ............................................................. 4-44
SECONDARY SHEAVE ...................................................................... 4-45
REMOVING THE PRIMARY AND SECONDARY SHEAVES ............. 4-46
DISASSEMBLING THE SECONDARY SHEAVE ................................ 4-46
CHECKING THE PRIMARY SHEAVE ................................................ 4-47
CHECKING THE SECONDARY SHEAVE .......................................... 4-47
ASSEMBLING THE PRIMARY SHEAVE ............................................ 4-48
ASSEMBLING THE SECONDARY SHEAVE ...................................... 4-48
INSTALLING THE PRIMARY AND SECONDARY SHEAVES ............ 4-50
CLUTCH ...................................................................................................... 4-51
REMOVING THE CLUTCH ................................................................. 4-53
CHECKING THE CLUTCH .................................................................. 4-53
INSTALLING THE CLUTCH ................................................................ 4-54
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CRANKCASE .............................................................................................. 4-56
STARTER MOTOR, TIMING CHAIN AND OIL FILTER ...................... 4-56
CRANKCASE ...................................................................................... 4-58
CRANKCASE BEARING ..................................................................... 4-59
REMOVING THE OIL PUMP DRIVE GEAR ....................................... 4-60
SEPARATING THE CRANKCASE ...................................................... 4-60
CHECKING THE TIMING CHAIN AND GUIDE ................................... 4-61
CHECKING THE OIL STRAINER AND OIL DELIVERY PIPE ............ 4-61
CHECKING THE CRANKCASE .......................................................... 4-62
CHECKING THE BEARINGS .............................................................. 4-62
ASSEMBLING THE CRANKCASE ...................................................... 4-62
INSTALLING THE SHIFT LEVER ....................................................... 4-63
INSTALLING THE OIL PUMP DRIVE GEAR ...................................... 4-64
CRANKSHAFT AND OIL PUMP ................................................................ 4-65
OIL PUMP ........................................................................................... 4-66
REMOVING THE CRANKSHAFT ....................................................... 4-67
CHECKING THE OIL PUMP ............................................................... 4-67
CHECKING THE CRANKSHAFT ........................................................ 4-68
INSTALLING THE CRANKSHAFT AND BALANCER ......................... 4-69
TRANSMISSION ......................................................................................... 4-70
CHECKING THE SHIFT FORK ........................................................... 4-72
CHECKING THE SHIFT CAM ............................................................. 4-72
CHECKING THE TRANSMISSION ..................................................... 4-73
CHECKING THE SECONDARY SHAFT
AND DRIVEN SPROCKET .............................................................. 4-73
CHECKING THE CHAIN ..................................................................... 4-74
CHECKING THE STOPPER LEVER AND STOPPER WHEEL .......... 4-74
INSTALLING THE TRANSMISSION ................................................... 4-74
MIDDLE GEAR ........................................................................................... 4-76
MIDDLE DRIVE SHAFT ...................................................................... 4-76
MIDDLE DRIVEN SHAFT .................................................................... 4-77
REMOVING THE MIDDLE DRIVE SHAFT ......................................... 4-79
REMOVING THE MIDDLE DRIVEN SHAFT ....................................... 4-79
CHECKING THE PINION GEAR ......................................................... 4-81
SELECTING THE MIDDLE DRIVE AND DRIVEN GEAR SHIM ......... 4-82
INSTALLING THE MIDDLE DRIVEN SHAFT ..................................... 4-85
INSTALLING THE MIDDLE DRIVE SHAFT ........................................ 4-87
MEASURING THE MIDDLE GEAR BACKLASH ................................. 4-87
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CHAPTER 5.
COOLING SYSTEM
RADIATOR .................................................................................................... 5-1
CHECKING THE RADIATOR ................................................................ 5-3
INSTALLING THE RADIATOR .............................................................. 5-4
THERMOSTAT .............................................................................................. 5-5
CHECKING THE THERMOSTAT .......................................................... 5-6
INSTALLING THE THERMOSTAT ........................................................ 5-6
WATER PUMP .............................................................................................. 5-7
DISASSEMBLING THE WATER PUMP ................................................ 5-9
CHECKING THE WATER PUMP .......................................................... 5-9
ASSEMBLING THE WATER PUMP .................................................... 5-10
CHAPTER 6.
CARBURETION
CARBURETOR ............................................................................................. 6-1
DISASSEMBLING THE CARBURETOR ............................................... 6-4
CHECKING THE CARBURETOR ......................................................... 6-4
ASSEMBLING THE CARBURETOR ..................................................... 6-6
ADJUSTING THE FUEL LEVEL ............................................................ 6-7
CHAPTER 7.
DRIVE TRAIN
TROUBLESHOOTING .................................................................................. 7-1
FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR ..... 7-4
REMOVING THE UNIVERSAL JOINT .................................................. 7-9
REMOVING THE RING GEAR .............................................................. 7-9
CHECKING THE CONSTANT VELOCITY JOINT .............................. 7-10
CHECKING THE DIFFERENTIAL GEAR ............................................ 7-10
CHECKING THE GEAR MOTOR ........................................................ 7-11
ASSEMBLING THE FRONT CONSTANT VELOCITY JOINT ............. 7-11
ASSEMBLING THE DIFFERENTIAL GEAR ....................................... 7-12
INSTALLING THE UNIVERSAL JOINT ............................................... 7-13
MEASURING AND ADJUSTING
THE DIFFERENTIAL GEAR LASH ................................................. 7-14
CHECKING THE DIFFERENTIAL GEAR OPERATION ..................... 7-16
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REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT ........................... 7-17
REMOVING THE REAR AXLE ............................................................ 7-20
DISASSEMBLING THE FINAL DRIVE GEAR ..................................... 7-20
REPLACING THE FINAL DRIVE ROLLER BEARING ........................ 7-21
POSITIONING THE FINAL DRIVE PINION GEAR
AND RING GEAR ............................................................................ 7-22
CHECKING THE REAR AXLE ............................................................ 7-26
CHECKING THE DRIVE SHAFT ......................................................... 7-27
CHECKING THE FINAL DRIVE GEAR ............................................... 7-27
MEASUREMENT AND ADJUSTING THE FINAL GEAR LASH .......... 7-28
ASSEMBLING THE FINAL DRIVE GEAR ........................................... 7-30
INSTALLING THE FINAL DRIVE GEAR ............................................. 7-30
CHAPTER 8.
CHASSIS
FRONT AND REAR WHEELS ...................................................................... 8-1
FRONT WHEELS .................................................................................. 8-1
REAR WHEELS .................................................................................... 8-2
CHECKING THE WHEEL ...................................................................... 8-3
CHECKING THE WHEEL HUB ............................................................. 8-3
CHECKING THE BRAKE DISC ............................................................. 8-4
INSTALLING THE WHEEL HUB ........................................................... 8-4
INSTALLING THE WHEEL .................................................................... 8-4
FRONT AND REAR BRAKES ...................................................................... 8-6
FRONT BRAKE PADS .......................................................................... 8-6
REAR BRAKE PADS ............................................................................. 8-7
REPLACING THE FRONT BRAKE PAD ............................................... 8-8
REPLACING THE REAR BRAKE PAD ............................................... 8-10
FRONT BRAKE MASTER CYLINDER ................................................ 8-12
REAR BRAKE MASTER CYLINDER .................................................. 8-14
CHECKING THE MASTER CYLINDER .............................................. 8-17
ASSEMBLING THE FRONT BRAKE MASTER CYLINDER ............... 8-18
ASSEMBLING THE REAR BRAKE MASTER CYLINDER .................. 8-18
INSTALLING THE FRONT BRAKE MASTER CYLINDER .................. 8-19
INSTALLING THE REAR BRAKE MASTER CYLINDER .................... 8-20
FRONT BRAKE CALIPER ................................................................... 8-22
REAR BRAKE CALIPER ..................................................................... 8-24
DISASSEMBLING THE FRONT AND REAR BRAKE CALIPER ........ 8-26
CHECKING THE FRONT AND REAR BRAKE CALIPER ................... 8-26
ASSEMBLING THE FRONT AND REAR BRAKE CALIPER .............. 8-27
INSTALLING THE FRONT BRAKE CALIPER .................................... 8-27
INSTALLING THE REAR BRAKE CALIPER ....................................... 8-29
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STEERING SYSTEM .................................................................................. 8-30
HANDLEBAR ....................................................................................... 8-30
REMOVING THE REAR BRAKE SWITCH ......................................... 8-31
CHECKING THE HANDLEBAR .......................................................... 8-31
INSTALLING THE HANDLEBAR ........................................................ 8-31
INSTALLING THE REAR BRAKE LEVER .......................................... 8-31
INSTALLING THE MASTER CYLINDER ASSEMBLY ........................ 8-32
STEERING STEM ............................................................................... 8-33
REMOVING THE BEARING RETAINER ............................................ 8-35
CHECKING THE STEERING STEM ................................................... 8-35
INSTALLING THE BEARING RETAINER ........................................... 8-35
INSTALLING THE CABLE GUIDE ...................................................... 8-35
TIE ROD AND STEERING KNUCKLE ................................................ 8-36
REMOVING THE STEERING KNUCKLE ........................................... 8-38
CHECKING THE TIE ROD .................................................................. 8-38
CHECKING THE STEERING KNUCKLE ............................................ 8-38
INSTALLING THE TIE ROD ................................................................ 8-41
FRONT ARMS AND FRONT SHOCK ABSORBER ................................... 8-42
REMOVING THE FRONT ARMS ........................................................ 8-44
CHECKING THE FRONT ARM ........................................................... 8-44
CHECKING THE FRONT SHOCK ABSORBER ................................. 8-46
INSTALLING THE FRONT ARMS
AND FRONT SHOCK ABSORBER ................................................. 8-47
REAR SHOCK ABSORBER AND SWINGARM ......................................... 8-48
REMOVING THE SWINGARM ............................................................ 8-50
CHECKING THE REAR SHOCK ABSORBER .................................... 8-50
CHECKING THE SWINGARM ............................................................ 8-51
CHECKING THE RUBBER BOOT ...................................................... 8-51
INSTALLING THE RUBBER BOOT .................................................... 8-51
INSTALLING THE REAR AXLE HOUSING ........................................ 8-52
CHAPTER 9.
ELECTRICAL
ELECTRICAL COMPONENTS ..................................................................... 9-1
CHECKING THE SWITCH ............................................................................ 9-2
CHECKING THE SWITCH .................................................................... 9-2
CHECKING A SWITCH SHOWN IN THE MANUAL ............................. 9-2
CHECKING THE SWITCH CONTINUITY ............................................. 9-4
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CHECKING THE BULBS AND BULB SOCKETS ........................................ 9-6
TYPES OF BULBS ................................................................................ 9-6
CHECKING THE CONDITION OF THE BULBS ................................... 9-6
CHECKING THE CONDITION OF THE BULB SOCKETS ................... 9-8
IGNITION SYSTEM ....................................................................................... 9-9
CIRCUIT DIAGRAM .............................................................................. 9-9
TROUBLESHOOTING ........................................................................ 9-10
ELECTRIC STARTING SYSTEM ............................................................... 9-15
CIRCUIT DIAGRAM ............................................................................ 9-15
TROUBLESHOOTING ........................................................................ 9-16
STARTER MOTOR ............................................................................. 9-19
CHECKING THE STARTER MOTOR ................................................. 9-20
ASSEMBLING THE STARTER MOTOR ............................................. 9-21
CHARGING SYSTEM ................................................................................. 9-22
CIRCUIT DIAGRAM ............................................................................ 9-22
TROUBLESHOOTING ........................................................................ 9-23
LIGHTING SYSTEM .................................................................................... 9-25
CIRCUIT DIAGRAM ............................................................................ 9-25
TROUBLESHOOTING ........................................................................ 9-26
CHECKING THE LIGHTING SYSTEM ................................................ 9-28
SIGNAL SYSTEM ....................................................................................... 9-30
CIRCUIT DIAGRAM ............................................................................ 9-30
TROUBLESHOOTING ........................................................................ 9-32
CHECKING THE SIGNAL SYSTEM ................................................... 9-34
COOLING SYSTEM .................................................................................... 9-37
CIRCUIT DIAGRAM ............................................................................ 9-37
TROUBLESHOOTING ....................................................................... 9-38
2WD/4WD SELECTING SYSTEM .............................................................. 9-42
CIRCUIT DIAGRAM ............................................................................ 9-42
TROUBLESHOOTING ........................................................................ 9-43
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CHAPTER 10.
TROUBLESHOOTING
STARTING FAILURE/HARD STARTING ................................................... 10-1
FUEL SYSTEM .................................................................................... 10-1
ELECTRICAL SYSTEM ....................................................................... 10-1
COMPRESSION SYSTEM .................................................................. 10-2
POOR IDLE SPEED PERFORMANCE ...................................................... 10-2
POOR IDLE SPEED PERFORMANCE ............................................... 10-2
POOR MEDIUM AND HIGH-SPEED PERFORMANCE ............................. 10-2
POOR MEDIUM AND HIGH-SPEED PERFORMANCE ..................... 10-2
FAULTY DRIVE TRAIN .............................................................................. 10-3
FAULTY GEAR SHIFTING ......................................................................... 10-4
HARD SHIFTING ................................................................................. 10-4
SHIFT LEVER DOES NOT MOVE ...................................................... 10-4
JUMPS OUT OF GEAR ....................................................................... 10-4
FAULTY CLUTCH PERFORMANCE ......................................................... 10-4
ENGINE OPERATES BUT MACHINE WILL NOT MOVE ................... 10-4
CLUTCH SLIPPING ............................................................................ 10-4
POOR STARTING PERFORMANCE .................................................. 10-4
POOR SPEED PERFORMANCE ........................................................ 10-5
OVERHEATING .......................................................................................... 10-5
OVERHEATING .................................................................................. 10-5
FAULTY BRAKE ......................................................................................... 10-5
POOR BRAKING EFFECT .................................................................. 10-5
SHOCK ABSORBER MALFUNCTION ....................................................... 10-6
MALFUNCTION ................................................................................... 10-6
UNSTABLE HANDLING ............................................................................. 10-6
UNSTABLE HANDLING ...................................................................... 10-6
LIGHTING SYSTEM .................................................................................... 10-6
HEADLIGHT DARK ............................................................................. 10-6
BULB BURNT OUT ............................................................................. 10-6
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MACHINE IDENTIFICATION
GEN
INFO
GENERAL INFORMATION
MACHINE IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number 1
stamped into the left side of the frame.
is
MODEL LABEL
The model label 1 is affixed to the frame. This
information will be needed to order spare
parts.
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1-1
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FEATURES
GEN
INFO
FEATURES
LIQUID COOLING ENGINE
Compact liquid cooled 45° inclined engine. A
liquid cooling system has been incorporated
for stable power and engine endurance.
1 Radiator
2 Thermo switch
3 Fan motor
PARK POSITION
When the drive select lever is shifted into the
park position, a stopper lever is engaged into
the stopper gear preventing the drive select
lever and transmission from moving.
When the drive select lever is at the “L”, “H”,
“N”, or “R” positions, the stopper lever end 1
is moved away from the stopper gear 2 by the
return spring 3.
When the drive select lever is in the “P”
position, the lever cam 4 at the side of the
shift cam 5 lifts the stopper lever end 6 and
the stopper lever end locks the drive axle 7.
When the stopper lever end 1 is not
synchronized, a torsion spring 8 retains the
rotation force of the shift cam 5 until it is
synchronized.
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1
FEATURES
GEN
INFO
FRONT DIFFERENTIAL
1 Adapter
2 Drive clutch
3 Differential side gear (left)
4 Differential pinion gear
5 Ring gear
6 Differential side gear (right)
7 Drive pinion gear
8 Gear motor
È To front wheel
É From the middle gear
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FEATURES
GEN
INFO
2WD
Power is transmitted as follows: middle gear → front drive shaft → drive pinion gear 7 → ring gear
5 → differential pinion gear 4. In the 2WD mode, the left differential side gear 3 and the drive
clutch 2 are not engaged, therefore, the left side gear runs idle and does not transmit power to the
left front constant velocity joint.
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FEATURES
GEN
INFO
4WD
When the 4WD mode is selected, the gear motor is operated, and the drive clutch 2 moves to the
right and engages with the left differential side gear 3. Accordingly, power is transmitted as follows:
ring gear 5 → differential pinion gear 4 → left differential side gear 3 → drive clutch 2 → adapter
1 → left front constant velocity joint.
Meanwhile, power from the differential pinion gear 4 is transmitted to the right front constant
velocity joint via the right differential side gear 6.
The ring gear 5 and the drive clutch 2 are not engaged at this time. Therefore, the rotational
difference that occurs between the right and left wheels, while the handlebar is being turned, is
absorbed by the difference in the rotational speeds of the ring gear 5 and the left differential side
gear 3.
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FEATURES
GEN
INFO
4WD (Diff-Lock)
When the 4WD (Diff-Lock) mode is selected, the gear motor moves the drive clutch 2 further to the
right, which causes the ring gear 5 and the drive clutch 2 to engage. As a result, power is
transmitted directly from the ring gear 5 to the drive clutch 2, then to the left front constant velocity
joint via the adapter 1.
Meanwhile, because the ring gear 5 and the drive clutch 2 are engaged, the ring gear 5, the drive
clutch 2, and the right differential side gear 6 become locked coaxially. Thus, power is transmitted
as follows: differential pinion gear 4 → right differential pinion gear 6 → right front constant
velocity joint.
When the ATV is in the 4WD (Diff-Lock) mode, the right and left wheels rotate constantly at the
same speed, which affects the maneuverability of the ATV (e.g., making it difficult to steer).
Therefore, the maximum traveling speed is limited to 35 km/h (22 mph).
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FEATURES
GEN
INFO
In addition, the 4WD (Diff-Lock) mode can be engaged only when the ATV is stopped. Even if an
attempt is made to select this mode when the ATV is traveling, it will only result in a standby
condition (i.e., when the differential lock select switch and the differential gear are not matched).
(1) When the ATV is traveling
Even if the 4WD (Diff-Lock) mode is selected, the gear motor will stand by, instead of operating.
Therefore, the ATV can be driven in the normal 4WD mode. When this occurs, the differential gear
lock indicator light “
” in the speedometer unit will flash to alert the driver that the control is on
standby. When the ATV is stopped, the control transfers to the condition described in (2).
DIFF.
LOCK
(2) When the ATV is stopped
The gear motor operates to connect the drive clutch to the differential case, thus resulting in the
differential lock condition. When this occurs, the differential gear lock indicator light “
” in the
speedometer unit changes to a constant illumination.
* Until the drive clutch and the differential case mesh together (i.e., the splines are unmeshed) the
engine misfires to control the engine speed. During this time, the differential gear lock indicator light
in the speedometer unit continues to flash.
DIFF.
LOCK
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IMPORTANT INFORMATION
GEN
INFO
EB101000
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL
PROCEDURES
1.Remove all dirt, mud, dust and foreign
material before removal and disassembly.
2.Use proper tools and cleaning equipment.
Refer to the “SPECIAL TOOLS” section.
3.When disassembling the machine, always
keep mated parts together. This includes
gears, cylinder, piston and other parts that
have been “mated” through normal wear.
Mated parts must always be reused or
replaced as an assembly.
4.During machine disassembly, clean all parts
and place them in trays in the order of
disassembly. This will speed up assembly
and allow for the correct installation of all
parts.
5.Keep all parts away from any source of fire.
EB101010
REPLACEMENT PARTS
1.Use only genuine Yamaha parts for all
replacements.
Use
oil
and
grease
recommended by Yamaha for all lubrication
jobs. Other brands may be similar in function
and appearance, but inferior in quality.
EB101020
GASKETS, OIL SEALS AND O-RINGS
1.Replace all gaskets, seals and O-rings when
overhauling the engine. All gasket surfaces,
oil seal lips and O-rings must be cleaned.
2.Properly oil all mating parts and bearings
during reassembly. Apply grease to the oil
seal lips.
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IMPORTANT INFORMATION
GEN
INFO
EB101030
LOCK WASHERS/PLATES AND COTTER
PINS
1.Replace all lock washers/plates 1 and cotter
pins after removal. Bend lock tabs along the
bolt or nut flats after the bolt or nut has been
tightened to specification.
EB101040
BEARINGS AND OIL SEALS
1.Install bearings and oil seals so that the
manufacturer’s marks or numbers are visible.
When installing oil seals, apply a light
coating of lightweight lithium base grease to
the seal lips. Oil bearings liberally when
installing, if appropriate.
1 Oil seal
CAUTION:
Do not use compressed air to spin the
bearings dry. This will damage the bearing
surfaces.
1 Bearing
EB101050
CIRCLIPS
1.Check
all
circlips
carefully
before
reassembly. Always replace piston pin clips
after one use. Replace distorted circlips.
When installing a circlip 1, make sure that
the sharp-edged corner 2 is positioned
opposite the thrust 3 it receives. See
sectional view.
4 Shaft
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CHECKING OF CONNECTIONS
GEN
INFO
EB801000
CHECKING OF CONNECTIONS
Check the connectors
moisture, etc.
for
stains,
rust,
1.Disconnect:
● Connector
2.Check:
● Connector
Moisture → Dry each terminal with an air
blower.
Stains/rust → Connect and disconnect the
terminals several times.
3.Check:
● Connector leads
Looseness → Bend up the pin 1 and
connect the terminals.
4.Connect:
● Connector terminals
NOTE:
The two terminals “click” together.
5.Check:
● Continuity (using a pocket tester)
NOTE:
● If there is no continuity, clean the terminals.
● When checking the wire harness be sure to
perform steps 1 to 3.
● As a quick remedy, use a contact revitalizer
available at most part stores.
● Check the connector with a pocket tester as
shown.
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SPECIAL TOOLS
GEN
INFO
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.
Bolt
90890-01083
Weight
90890-01084
Set
YU-01083-A
Tool name/How to use
Illustration
Slide hammer bolt (M6)/weight/set
These tools are used to remove the
rocker arm shaft.
Crankcase separating tool
90890-01135
YU-01135-A
This tool is used to separate the
crankcase.
Valve guide remover (7.0 mm)
90890-01225
YM-01225-A
This tool is needed to remove and
install the valve guide.
Valve guide installer (7.0 mm)
90890-04017
YM-04017
This tool is needed to install the valve
guide.
Valve guide reamer (7.0 mm)
90890-01227
YM-01227
90890-01235
YU-01235
90890-04088
Bolt
90890-01275
This tool is needed to rebore the new
valve guide.
Rotor holding tool
This tool is needed to hold the starter
pulley when removing/installing the
starter pulley bolt or camshaft
sprocket bolts.
Buffer boss installer set
Crankshaft installer bolt
These tools are used to install the
crankshaft.
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SPECIAL TOOLS
Tool No.
Tool name/How to use
GEN
INFO
Illustration
Crankshaft installer set
YU-90050
These tools are used to install the
crankshaft.
Adapter
YM-33279
Spacer
90890-04060
YM-90070-A
Adapter (#11)
Spacer (crankshaft)
These tools are used to install the
crankshaft.
Piston pin puller set
90890-01304
YU-01304
This tool is used to remove the piston
pin.
Tappet adjusting tool (3 mm)
90890-01311
YU-08035
This tool is necessary for adjusting
the valve clearance.
Fuel level gauge
90890-01312
YM-01312-A
This gauge is used to measure the
fuel level in the float chamber.
Radiator cap tester
90890-01325
YU-24460-01
This tool is used to check the cooling
system.
Adapter
90890-01352
YU-33984
This tool is used to check the cooling
system.
Locknut wrench
90890-01348
This tool is needed when removing or
installing the secondary sheave
spring.
Sheave spring compressor
90890-04134
YM-04134
This tool is needed when removing or
installing the secondary sheave
spring.
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SPECIAL TOOLS
Tool No.
Tool name/How to use
GEN
INFO
Illustration
Sheave fixed block
90890-04135
YM-04135
This tool is needed when removing or
installing the secondary sheave
spring.
Flywheel puller
90890-01404
YM-01404
These tools are needed to remove
the rotor.
Damper rod holder (30 mm)
90890-01327
YM-01327
This tool is needed to loosen and
tighten the steering stem bearing
retainer.
Oil filter wrench
90890-01426
YU-38411
This tool is needed to loosen or
tighten the oil filter cartridge.
Ring nut wrench
90890-01430
YM-38404
This tool is needed to removing and
installing the middle driven shaft
bearing retainer.
Gear lash measurement tool
90890-01467
YM-01467
90890-01475
YM-01475
This tool is used to measure the gear
lash.
Ball joint remover/installer set
90890-01474
YM-01474
This tool is used to remove and install
the ball joint.
Ball joint remover/installer attachment
set
YM-01477
This tool is used to remove and install
the ball joint.
Sheave holder
90890-01701
YU-01880
This tool is needed to hold the
primary sheave when removing or
installing the sheave bolts.
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SPECIAL TOOLS
Tool No.
Tool name/How to use
Compression gauge
90890-03081
YU-33223
Adapter
90890-04082
YU-33223-3
GEN
INFO
Illustration
Compression gauge
Adapter
These tools are needed to measure
engine compression.
Pocket tester
90890-03112
YU-03112
This instrument is needed for
checking the electrical system.
Engine tachometer
90890-03113
This tool is needed for observing
engine rpm.
Inductive tachometer
YU-8036-A
This tool is needed for observing
engine rpm.
Timing light
90890-03141
YM-33277-A
This tool is necessary for checking
ignition timing.
Valve spring compressor
90890-04019
YM-04019
This tool is needed to remove and
install the valve assemblies.
Middle driven shaft
bearing driver
90890-04058
YM-04058-1
Mechanical seal installer
90890-04078
YM-33221
Middle driven shaft bearing driver
Mechanical seal installer
These tools are used to install the
water pump seal.
Bearing retainer wrench
90890-04050
YM-04050
This tool is needed when removing or
installing the final drive shaft bearing
retainer.
Universal joint holder
90890-04062
YM-04062
This tool is needed when removing or
installing the universal joint yoke nut.
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SPECIAL TOOLS
Tool No.
Tool name/How to use
GEN
INFO
Illustration
Clutch holding tool
90890-04086
YM-91042
This tool is needed to hold the clutch
carrier when removing or installing
the carrier nut.
Bearing retainer wrench
90890-04128
YM-04128
This tool is needed when removing or
installing the middle driven pinion
gear bearing retainer.
Pinion gear fix clamp
90890-04129
YM-04129
This tool is used to hold the shift cam.
Ignition checker
This instrument is necessary for
checking the ignition system
components.
90890-06754
Dynamic spark tester
This instrument is necessary for
checking the ignition system
components.
YM-34487
Bond
90890-85505
Sealant
ACC-11001-05-01
Yamaha bond No. 1215
Sealant (Quick Gasket®)
This sealant (bond) is used on
crankcase mating surfaces, etc.
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GENERAL SPECIFICATIONS
SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item
Model code:
Dimensions:
Overall length
Overall width
Overall height
Seat height
Wheelbase
Minimum ground clearance
Minimum turning radius
Basic weight:
With oil and full fuel tank
Engine:
Engine type
Cylinder arrangement
Displacement
Bore × stroke
Compression ratio
Standard compression pressure (at sea level)
Starting system
Lubrication system:
Oil type or grade:
Engine oil
Standard
5ND1, 5ND5
1,984 mm (78.1 in)
1,085 mm (42.7 in)
1,120 mm (44.1 in)
827 mm (32.6 in)
1,233 mm (48.5 in)
245 mm (9.7 in)
3,000 mm (118.1 in)
267 kg (589 lb)
Liquid-cooled 4-stroke, SOHC
Forward-inclined single cylinder
421 cm3
84.5 × 75.0 mm (3.33 × 2.95 in)
10 : 1
1,270 kPa (12.7 kg/cm2, 181 psi) at 700 r/min
Electric and recoil starter
Wet sump
API service SE, SF, SG type or higher
Final gear oil
Differential gear oil
Oil capacity:
Engine oil
Periodic oil change
With oil filter replacement
Total amount
Final gear case oil
Periodic oil change
Total amount
SAE 80API “GL-4” Hypoid Gear Oil
SAE 80API “GL-4” Hypoid Gear Oil
2.3 L (2.0 Imp qt, 2.4 US qt)
2.4 L (2.1 lmp qt, 2.5 US qt)
2.6 L (2.3 lmp qt, 2.7 US qt)
0.23 L (0.20 Imp qt, 0.24 US qt)
0.25 L (0.22 Imp qt, 0.26 US qt)
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GENERAL SPECIFICATIONS
Item
Differential gear case oil
Periodic oil change
Total amount
Radiator capacity (including all routes)
Air filter:
Fuel:
Type
Fuel tank capacity
Fuel reserve amount
Carburetor:
Type/quantity
Manufacturer
Spark plug:
Type/manufacturer
Spark plug gap
Clutch type:
Transmission:
Primary reduction system
Secondary reduction system
Secondary reduction ratio
Transmission type
Operation
Single speed automatic
Sub transmission ratio
low
high
Reverse gear
Chassis:
Frame type
Caster angle
Camber angle
Kingpin angle
Kingpin offset
Trail
Tread (STD)
front
rear
Toe-in
Tire:
Type
Size
front
rear
Manufacturer
front
rear
Type
front
rear
SPEC
Standard
0.23 L (0.20 Imp qt, 0.24 US qt)
0.28 L (0.25 Imp qt, 0.30 US qt)
1.32 L (1.16 Imp qt, 1.40 US qt)
Wet type element
Unleaded fuel
15 L (3.3 lmp gal, 3.9 US gal)
4.5 L (0.99 Imp gal, 1.19 US gal)
BSR33/1
MIKUNI
DR8EA/NGK
0.6 ~ 0.7 mm (0.024 ~ 0.028 in)
Wet, centrifugal automatic
V-belt
Spur gear
39/24 × 24/18 × 33/9 (7.944)
V-belt automatic
Left hand operation
2.55 ~ 0.75 : 1
45/16 (2.813)
38/23 (1.652)
29/17 (1.706)
Steel tube frame
4°
1°
11°
–5 mm (–0.2 in)
21 mm (0.83 in)
850 mm (33.46 in)
825 mm (32.48 in)
0 ~ 10 mm (0 ~ 0.39 in)
Tubeless
AT25 × 8–12
AT25 × 10–12
CHENG SHIN
CHENG SHIN
M911Y
M912Y
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GENERAL SPECIFICATIONS
Item
Tire pressure (cold tire):
Maximum load*
Off-road riding
front
rear
*Load in total weight of rider accessories
Brake:
Front brake
type
operation
Rear brake
type
operation
Suspension:
Front suspension
Rear suspension
Shock absorber:
Front shock absorber
Rear shock absorber
Wheel travel:
Front wheel travel
Rear wheel travel
Electrical:
Ignition system
Generator system
Battery type
Battery capacity
Headlight type:
Bulb wattage × quantity:
Headlight
Brake/tail light
Indicator lights
Neutral
Reverse
Coolant temperature
Park position
High gear
Low gear
Diff-lock
SPEC
Standard
210 kg (463 lb)
22 ~ 28 kPa (0.22 ~ 0.28 kg/cm2, 3.2 ~ 4.0 psi)
22 ~ 28 kPa (0.22 ~ 0.28 kg/cm2, 3.2 ~ 4.0 psi)
Dual disc brake
Right hand operation
Single disc brake
Left hand and right foot operation
Double wishbone
Swingarm (monocross)
Coil spring/oil damper
Coil spring/oil damper
160 mm (6.30 in)
180 mm (7.09 in)
D.C. C.D.I.
A.C. magneto
YTX20L-BS
12 V 18 Ah
Krypton bulb
12 V 30 W/30 W × 2
12 V 21 W/5 W
LED × 1
LED × 1
LED × 1
LED × 1
LED × 1
LED × 1
LED × 1
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MAINTENANCE SPECIFICATIONS
SPEC
MAINTENANCE SPECIFICATIONS
ENGINE
Item
Standard
Cylinder head:
Warp limit
Limit
----
0.03 mm
(0.0012 in)
Taper limit
84.500 ~ 84.510 mm
(3.3268 ~ 3.3272 in)
----
Out of round limit
----
84.600 mm
(3.3307 in)
0.05 mm
(0.0016 in)
0.01 mm
(0.0004 in)
Cylinder:
Bore size
Camshaft:
Drive method
Cam dimensions
Chain drive (Left)
----
40.62 ~ 40.72 mm
(1.5992 ~ 1.6031 in)
32.18 ~ 32.28 mm
(1.2669 ~ 1.2709 in)
40.62 ~ 40.72 mm
(1.5992 ~ 1.6031 in)
32.18 ~ 32.28 mm
(1.2669 ~ 1.2709 in)
----
40.52 mm
(1.5953 in)
32.08 mm
(1.2630 in)
40.52 mm
(1.5953 in)
32.08 mm
(1.2630 in)
0.03 mm
(0.0012 in)
A
B
Intake
“A”
“B”
Exhaust
“A”
“B”
Camshaft runout limit
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MAINTENANCE SPECIFICATIONS
Item
SPEC
Standard
Cam chain:
Cam chain type/No. of links
Cam chain adjustment method
Rocker arm/rocker arm shaft:
Bearing inside diameter
Shaft outside diameter
Arm-to-shaft clearance
Valve, valve seat, valve guide:
Valve clearance (cold)
IN
EX
Limit
DID SCR-0409 SDH/116
Automatic
-------
12.000 ~ 12.018 mm
(0.4724 ~ 0.4731 in)
11.981 ~ 11.991 mm
(0.4717 ~ 0.4721 in)
0.009 ~ 0.037 mm
(0.0004 ~ 0.0015 in)
12.078 mm
(0.4755 in)
11.951 mm
(0.4705 in)
0.080 mm
(0.0031 in)
0.06 ~ 0.10 mm
(0.0024 ~ 0.0039 in)
0.16 ~ 0.20 mm
(0.0063 ~ 0.0079 in)
-------
Valve dimensions
B
C
D
A
Head Diameter
“A” head diameter
Face Width
IN
EX
“B” face width
“C” seat width
IN
EX
IN
EX
“D” margin thickness
IN
EX
Stem outside diameter
IN
EX
Guide inside diameter
IN
EX
Stem-to-guide clearance
IN
EX
Seat Width
Margin Thickness
39.9 ~ 40.1 mm
(1.5708 ~ 1.5787 in)
33.9 ~ 34.1 mm
(1.3346 ~ 1.3425 in)
2.26 mm (0.0890 in)
2.26 mm (0.0890 in)
1.2 ~ 1.4 mm
(0.0472 ~ 0.0551 in)
1.2 ~ 1.4 mm
(0.0472 ~ 0.0551 in)
1.0 ~ 1.4 mm
(0.0394 ~ 0.0551 in)
0.8 ~ 1.2 mm
(0.0315 ~ 0.0472 in)
6.975 ~ 6.990 mm
(0.2746 ~ 0.2752 in)
6.955 ~ 6.970 mm
(0.2738 ~ 0.2744 in)
7.000 ~ 7.012 mm
(0.2756 ~ 0.2761 in)
7.000 ~ 7.012 mm
(0.2756 ~ 0.2761 in)
0.010 ~ 0.037 mm
(0.0004 ~ 0.0015 in)
0.030 ~ 0.057 mm
(0.0012 ~ 0.0022 in)
Not For Resale
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------------1.6 mm
(0.0630 in)
1.6 mm
(0.0630 in)
------6.950 mm
(0.2736 in)
6.915 mm
(0.2722 in)
7.030 mm
(0.2768 in)
7.030 mm
(0.2768 in)
0.080 mm
(0.0031 in)
0.100 mm
(0.0039 in)
MAINTENANCE SPECIFICATIONS
Item
Standard
Stem runout limit
Valve seat width
----
IN
Set length (valve closed)
Compressed pressure
(installed)
----
IN
39.9 mm (1.57 in)
EX
39.9 mm (1.57 in)
IN
EX
33.6 mm (1.32 in)
33.6 mm (1.32 in)
37.9 mm
(1.49 in)
37.9 mm
(1.49 in)
-------
IN
104.9 ~ 120.6 N (10.70 ~
12.30 kg, 23.58 ~ 27.11 lb)
104.9 ~ 120.6 N (10.70 ~
12.30 kg, 23.58 ~ 27.11 lb)
EX
Tilt limit
*
IN
Outer spring
Free length
Set length (valve closed)
Compressed pressure
(installed)
----
------2.5°/1.6 mm
(2.5°/0.06 in)
2.5°/1.6 mm
(2.5°/0.06 in)
EX
Direction of winding
(top view)
Limit
0.01 mm
(0.0004 in)
1.2 ~ 1.4 mm
(0.0472 ~ 0.0551 in)
1.2 ~ 1.4 mm
(0.0472 ~ 0.0551 in)
EX
Valve spring:
Inner spring
Free length
SPEC
IN
EX
Counterclockwise
Counterclockwise
-------
IN
43.27 mm (1.70 in)
EX
43.27 mm (1.70 in)
IN
EX
36.6 mm (1.44 in)
36.6 mm (1.44 in)
41.27 mm
(1.62 in)
41.27 mm
(1.62 in)
-------
IN
235.4 ~ 251.1 N (24.00 ~
25.60 kg, 52.91 ~ 56.45 lb)
235.4 ~ 251.1 N (24.00 ~
25.60 kg, 52.91 ~ 56.45 lb)
EX
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-------
MAINTENANCE SPECIFICATIONS
Item
Tilt limit
SPEC
Standard
*
IN
EX
Direction of winding
(top view)
IN
EX
Piston:
Piston to cylinder clearance
Piston size “D”
Limit
2.5°/1.6 mm
(2.5°/0.06 in)
2.5°/1.6 mm
(2.5°/0.06 in)
Clockwise
Clockwise
-------
0.040 ~ 0.065 mm
(0.0016 ~ 0.0026 in)
84.445 ~ 84.460 mm
(3.3246 ~ 3.3252 in)
0.150 mm
(0.0059 in)
----
5 mm (0.20 in)
0.5 mm (0.0200 in)
Intake side
20.004 ~ 20.015 mm
(0.7876 ~ 0.7880 in)
19.991 ~ 20.000 mm
(0.7870 ~ 0.7874 in)
---------20.045 mm
(0.7892 in)
19.971 mm
(0.7863 in)
Barrel
1.0 × 3.1 mm
(0.03937 × 0.1220 in)
0.20 ~ 0.40 mm
(0.0079 ~ 0.0157 in)
0.03 ~ 0.07 mm
(0.0012 ~ 0.0028 in)
-------
H
D
Measuring point “H”
Piston off-set
Offset direction
Piston pin bore inside diameter
Piston pin outside diameter
Piston rings:
Top ring
B
T
Type
Dimensions (B × T)
End gap (installed)
Side clearance (installed)
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0.65 mm
(0.0256 in)
0.12 mm
(0.0047 in)
MAINTENANCE SPECIFICATIONS
Item
SPEC
Standard
Limit
2nd ring
B
T
Type
Dimensions (B × T)
End gap (installed)
Side clearance
Taper
1.0 × 3.6 mm
(0.0394 × 0.1417 in)
0.40 ~ 0.60 mm
(0.0157 ~ 0.0236 in)
0.02 ~ 0.06 mm
(0.0008 ~ 0.0024 in)
-------
2.0 × 2.8 mm
(0.0787 × 0.1102 in)
0.2 ~ 0.7 mm
(0.0079 ~ 0.0276 in)
----
62.95 ~ 63.00 mm
(2.4783 ~ 2.4803 in)
----
----
0.95 mm
(0.0374 in)
0.12 mm
(0.0047 in)
Oil ring
B
T
Dimensions (B × T)
End gap (installed)
----
Crankshaft:
E
C2
C1
B
A
Crank width “A”
Runout limit C1
C2
Big end side clearance “B”
Big end radial clearance “E”
Balancer:
Balancer drive method
Automatic centrifugal clutch:
Clutch shoe thickness
Clutch-in revolution
Clutch-stall revolution
---0.25 ~ 0.75 mm
(0.0098 ~ 0.0295 in)
0.010 ~ 0.025 mm
(0.0004 ~ 0.0010 in)
0.03 mm
(0.0012 in)
0.03 mm
(0.0012 in)
1.00 mm
(0.0394 in)
----
Gear
----
1.5 mm (0.06 in)
1.0 mm
(0.04 in)
-------
1,960 ~ 2,240 r/min
3,300 ~ 3,900 r/min
Not For Resale
2-8
www.SmallEngineDiscount.com
MAINTENANCE SPECIFICATIONS
Item
Standard
Transmission:
Main axle deflection limit
----
Drive axle deflection limit
----
Shifter:
Shifter type
Air filter oil grade:
Carburetor:
I. D. mark
Main jet
Main air jet
Jet needle
Needle jet
Pilot air jet
Pilot air jet
Pilot outlet
Pilot jet
Bypass 1
Bypass 2
Bypass 3
Valve seat size
Starter jet
Starter jet
Throttle valve size
Float height
Fuel level
Engine idle speed
Intake vacuum
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
SPEC
(M.J)
(M.A.J)
(J.N)
(N.J)
(P.A.J.1)
(P.A.J.2)
(P.O)
(P.J)
(B.P.1)
(B.P.2)
(B.P.3)
(V.S)
(G.S.1)
(G.S.2)
(Th.V)
(F.H)
(F.L)
Limit
0.06 mm
(0.0024 in)
0.06 mm
(0.0024 in)
Shift cam and guide bar
Engine oil
-------
5ND1 00
#131.3
#50
5EP13-55-3
P-0M
#80
1.3
0.95
#17.5
0.8
0.8
0.8
2.0
#70
0.9
#90
13 mm (0.51 in)
4.0 ~ 5.0 mm (0.16 ~ 0.20 in)
1,450 ~ 1,550 r/min
32 kPa (240 mmHg, 9.45 inHg)
-------------------------------------------
Foam
Trochoid
0.15 mm (0.006 in)
------0.20 mm
(0.008 in)
----
0.04 ~ 0.09 mm
(0.002 ~ 0.004 in)
78 ~ 118 kPa (0.78 ~
1.18 kg/cm2, 11.3 ~ 17.11 psi)
7 kPa (0.07 kg/cm2, 1.02 psi) at
1,500 r/min
Cylinder head
Not For Resale
2-9
www.SmallEngineDiscount.com
----------------
----------
MAINTENANCE SPECIFICATIONS
Item
SPEC
Standard
Cooling system:
Radiator core
Width
Height
Thickness
Radiator cap opening pressure
Radiator capacity
Coolant reservoir
Capacity
From low to full level
Water pump:
Type
Reduction ratio
Thermostat:
Valve opening temperature
Valve full open temperature
Valve lift-full open
Shaft drive:
Middle gear backlash
Final gear backlash
Differential gear backlash
Limit
300 mm (11.8 in)
208 mm (8.19 in)
26 mm (1.02 in)
93.7 ~ 122.6 kPa (0.937 ~
1.226 kg/cm2, 13.32 ~ 17.43 psi)
0.70 L (0.62 Imp qt, 0.74 US qt)
-------------
0.39 L (0.34 Imp qt, 0.41 US qt)
0.15 L (0.13 Imp qt, 0.16 US qt)
-------
Single suction centrifugal pump
38/32 (1.188)
----
----
63.5 ~ 66.5 °C (146.3 ~ 151.7 °F) ---80 °C (176 °F)
---3 mm (0.12 in)
---0.1 ~ 0.3 mm (0.004 ~ 0.012 in)
0.1 ~ 0.2 mm (0.004 ~ 0.008 in)
0.05 ~ 0.25 mm
(0.0020 ~ 0.0098 in)
----------
Lubrication chart:
Pressure feed
Splashed scavenge
Cam Shaft
Rocker Arm
Crank Pin
Valve
Oil Filter
Piston
Piston Pin
Bypass
Valve
Clutch
Transmission
Timing Chain Area
Oil Pump
Oil Strainer
Not For Resale
2 - 10
www.SmallEngineDiscount.com
MAINTENANCE SPECIFICATIONS
Item
Cylinder head tightening sequence:
SPEC
Standard
Not For Resale
2 - 11
www.SmallEngineDiscount.com
Limit
MAINTENANCE SPECIFICATIONS
SPEC
Tightening torques
Part to be tightened
Cylinder head oil passage
Cylinder head (exhaust pipe)
Cylinder head
Camshaft sprocket cover baffle
plate
Camshaft bearing retainer
Spark plug
Coolant drain bolt (cylinder)
Starter clutch
Camshaft sprocket
Timing chain tensioner cap
Timing chain tensioner
Timing chain guide (intake)
Valve adjusting screw
Radiator
Oil pump assembly
Oil pump
Oil strainer cover
Oil drain bolt
Oil pump drive gear
Oil delivery pipe
Oil filter bolt
Oil filter cartridge
Intake manifold
Muffler and exhaust pipe
Exhaust pipe
Muffler
Exhaust pipe stay
Crankcase cover
Oil seal retainer
Drive belt case cover
Crankcase oil passage plug
Bearing retainer (right crankcase)
Plug (right crankcase)
Bearing retainer (left crankcase)
Crankcase cover (left)
Recoil starter
Starter one-way clutch
Clutch carrier assembly
Middle drive shaft bearing retainer
Part
name
Union bolt
Stud bolt
Bolt
Bolt
Bolt
Bolt
—
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Nut
Bolt
Screw
Screw
Plug
Bolt
Nut
Union bolt
Union bolt
—
Bolt
Bolt
Nut
Bolt
Bolt
Screw
Screw
Bolt
Plug
Screw
Bolt
Bolt
Bolt
Bolt
Bolt
Nut
Torx
screw
Thread
Q’ty
size
Tightening torque
M6
M8
M10
M6
M6
1
2
4
2
2
Nm
7
15
40
10
10
M6
M12
M6
M10
M10
M11
M6
M6
M7
M6
M6
M6
M35
M14
M14
M8
M20
M20
M8
M8
M8
M10
M6
M6
M5
M6
M18
M6
M8
M6
M6
M6
M8
M22
M8
2
1
1
1
1
1
2
2
2
2
3
1
1
1
1
2
1
1
2
2
2
2
2
4
3
12
1
1
1
2
12
4
6
1
4
8
18
10
50
60
23
11
10
20
7
8
7
32
23
50
18
63
17
20
15
20
25
14
8
7
10
55
11
15
10
10
10
30
140
25
m·kg
0.7
1.5
4.0
1.0
1.0
0.8
1.8
1.0
5.0
6.0
2.3
1.1
1.0
2.0
0.7
0.8
0.7
3.2
2.3
5.0
1.8
6.3
1.7
2.0
1.5
2.0
2.5
1.4
0.8
0.7
1.0
5.5
1.1
1.5
1.0
1.0
1.0
3.0
14
2.5
ft·lb
5.1
11
29
7.2
7.2
Remarks
5.8
13
7.2
36
43
17
8.0
7.2
14
5.1
5.8
5.1
23
17
36
13
45
12
14
11
14
18
10
5.8
5.1
7.2
40
8.0
11
7.2
7.2
7.2
22
100 Stake
18
Not For Resale
2 - 12
www.SmallEngineDiscount.com
LT
LT
E
LT
LT
LT
LT
LT
LT
MAINTENANCE SPECIFICATIONS
Part to be tightened
Part
name
Middle driven shaft drive pinion gear
Middle drive shaft bearing housing
Middle driven gear bearing retainer
Nut
Bolt
Nut
Thread
Q’ty
size
M22
M8
M65
1
6
1
SPEC
Tightening torque
Nm
130
32
110
m·kg
13
3.2
11
Remarks
ft·lb
94 Stake
23
80
LT
Left-hand threads
Yoke (middle driven gear)
Middle driven gear bearing housing
Middle driven shaft bearing retainer
Nut
Bolt
Nut
M14
M8
M55
1
4
1
97
25
80
9.7
2.5
8.0
70
18
58
Bolt
Nut
Nut
Nut
Nut
Bolt
—
Bolt
—
Screw
—
—
Screw
Bolt
Bolt
—
Bolt
—
Bolt
Bolt
Bolt
Bolt
Screw
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Nut
Bolt
Bolt
Bolt
—
—
M6
M8
M16
M16
M36
M6
M12
M8
M14
M6
M10
M10
M6
M5
M6
PT1/8
M6
M18
M6
M6
M6
M6
M4
M6
M6
M6
M6
M6
M6
M14
M6
M6
M6
M10
M10
1
2
1
1
1
1
1
3
1
1
1
1
3
2
2
1
1
1
4
1
2
1
4
8
5
2
4
3
1
1
2
1
2
1
1
14
15
100
100
90
14
6
15
18
2
20
20
7
7
7
8
10
28
10
10
10
10
3
10
10
10
10
10
10
97
10
10
10
20
20
1.4
1.5
10.0
10.0
9.0
1.4
0.6
1.5
1.8
0.2
2.0
2.0
0.7
0.7
0.7
0.8
1.0
2.8
1.0
1.0
1.0
1.0
0.3
1.0
1.0
1.0
1.0
1.0
1.0
9.7
1.0
1.0
1.0
2.0
2.0
10
11
72
72
65
10
4.3
11
13
1.4
14
14
5.1
5.1
5.1
5.8
7.2
20
7.2
7.2
7.2
7.2
2.2
7.2
7.2
7.2
7.2
7.2
7.2
70
7.2
7.2
7.2
14
14
LT
LT
Left-hand threads
Shift arm
Shift rod
Primary sheave assembly
Secondary sheave assembly
Secondary sheave spring retainer
Shift lever 2
Shift control cable
Select lever unit
Shift cam ball holding bolt
CDI unit
Neutral switch
Reverse switch
Stator assembly
Pickup coil
Ignition coil
Thermo switch (cylinder head)
Speed sensor
Thermo switch (radiator)
Tappet covers
Coolant drain bolt (water pump)
Coolant inlet joint
Bearing housing
Primary pulley sheave cap
Clutch housing assembly
Clutch housing assembly cover
Starter motor
Shift lever cover
Crankcase (right)
Stopper lever
Yoke (middle driven shaft)
Thermostat cover
Water pump outlet pipe
Water pump assembly
Low-range switch
High-range switch
Not For Resale
2 - 13
www.SmallEngineDiscount.com
LT
LT
LT
LT
LT
MAINTENANCE SPECIFICATIONS
SPEC
CHASSIS
Item
Steering system:
Steering bearing type
Front suspension:
Shock absorber travel
Fork spring free length
Spring fitting length
Spring rate
Stroke
Optional spring
Rear suspension:
Shock absorber travel
Spring free length
Spring fitting length
Spring rate
Stroke
Optional spring
Swingarm:
Free play limit
Front wheel:
Type
Rim size
Rim material
Rim runout limit
Rear wheel:
Type
Rim size
Rim material
Rim runout limit
Standard
Limit
Ball and race bearing
----
99 mm (3.90 in)
265 mm (10.43 in)
215.8 mm (8.50 in)
15 N/mm (1.53 kg/mm, 85.68 lb/in)
0 ~ 99 mm (0 ~ 3.90 in)
No
-------------------
126 mm (4.96 in)
317 mm (12.48 in)
283 mm (11.14 in)
30.4 N/mm
(3.10 kg/mm, 173.60 lb/in)
0 ~ 126 mm (0 ~ 4.96 in)
No
-------------
end
----
side
----
1 mm
(0.04 in)
1 mm
(0.04 in)
radial
Panel wheel
12 × 6.0 AT
Steel
----
lateral
----
radial
Panel wheel
12 × 7.5 AT
Steel
----
lateral
----
(K1)
(K1)
(K1)
(K1)
Not For Resale
2 - 14
www.SmallEngineDiscount.com
-------
---------2 mm
(0.08 in)
2 mm
(0.08 in)
---------2 mm
(0.08 in)
2 mm
(0.08 in)
MAINTENANCE SPECIFICATIONS
Item
Standard
Front disc brake:
Type
Disc outside diameter × thickness
Pad thickness
inner
Pad thickness
Dual
200.0 × 3.5 mm (7.87 ~ 0.14 in)
4.5 mm (0.18 in)
outer
4.5 mm (0.18 in)
Master cylinder inside diameter
Caliper cylinder inside diameter
Brake fluid type
Rear disc brake:
Type
Disc outside diameter × thickness
Pad thickness
inner
14 mm (0.55 in)
32 mm (1.26 in)
DOT 4
Pad thickness
outer
Master cylinder inside diameter
Caliper cylinder inside diameter
Brake fluid type
Brake lever and brake pedal:
Brake lever free play (pivot)
Brake pedal position
Throttle lever free play
SPEC
front
rear
Single
220.0 × 3.5 mm (8.66 ~ 0.14 in)
5.6 mm (0.22 in)
Limit
------1 mm
(0.04 in)
1 mm
(0.04 in)
----------
14 mm (0.55 in)
32.03 mm (1.26 in)
DOT 4
------1 mm
(0.04 in)
1 mm
(0.04 in)
----------
0 mm (0 in)
0.5 ~ 2 mm (0.02 ~ 0.08 in)
70 ~ 80 mm (2.76 ~ 3.15 in)
3 ~ 5 mm (0.12 ~ 0.20 in)
-------------
5.6 mm (0.22 in)
Not For Resale
2 - 15
www.SmallEngineDiscount.com
MAINTENANCE SPECIFICATIONS
SPEC
Tightening torques
Part to be tightened
Thread size
Engine bracket (front-upper) and frame
Engine bracket (front-lower) and frame
Engine bracket (front-upper) and engine
Engine bracket (front-lower) and engine
Engine and frame
Frame and bearing retainer (steering stem holder
bearing)
Select lever assembly and frame
Swingarm
Rear shock absorber and frame
Final gear case and swingarm
Final gear case and rear axle housing
Swingarm and rear axle housing
Differential gear case and frame
Front arm and frame
Front shock absorber and frame
Front shock absorber and upper front arm
Steering stem, pitman arm and frame
Steering stem holder and frame
Steering stem and handlebar holder
Pitman arm and tie-rod end
Tie-rod and locknut
Steering knuckle and upper front arm
Steering knuckle and lower front arm
Steering knuckle and tie-rod
Fuel tank and fuel cock
Front wheel and wheel hub
Front axle and wheel hub
Steering knuckle and brake caliper
Front brake disc and wheel hub
Rear wheel and rear wheel hub
Rear axle and nut
Rear axle housing and rear brake caliper
Rear brake disc and brake disc bracket
Front brake pipe nut
Front brake hose union bolt
Rear brake hose union bolt
Bleed screw
Master cylinder and handlebar
Footrest and frame
Tightening torque
Nm
m·kg
ft·lb
M8
M8
M10
M10
M10
M42
33
33
42
42
56
40
3.3
3.3
4.2
4.2
5.6
4.0
24
24
30
30
40
29
M8
M12
M12
M10
M10
M10
M10
M10
M10
M10
M14
M8
23
82
82
63
63
63
55
45
45
45
130
23
2.3
8.2
8.2
6.3
6.3
6.3
5.5
4.5
4.5
4.5
13.0
2.3
17
60
60
45
46
46
40
32
32
32
94
17
M8
M12
M12
M12
M12
M12
M6
M10
M16
M8
M8
M10
M16
M8
M8
M10
M10
M10
M8
M6
M8
23
30
40
30
30
30
4
64
150
30
30
55
150
30
28
19
27
30
6
7
16
2.3
3.0
4.0
3.0
3.0
3.0
0.4
6.4
15.0
3.0
3.0
5.5
15.0
3.0
2.8
1.9
2.7
3.0
0.6
0.7
1.6
17
22
29
22
22
22
2.9
46
110
22
22
40
110
22
20
13
19
22
4.3
5.1
11
Not For Resale
2 - 16
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Remarks
LT
LS
LS
Use lock
washer
LS
LT
LT
MAINTENANCE SPECIFICATIONS
Part to be tightened
Front bumper and frame
Front carrier and frame
Front carrier and front bumper
Rear carrier and frame
Differential gear case filler bolt
Differential gear case drain bolt
Differential gear case and bearing housing
Gear motor
Final gear case oil filler bolt
Final gear case oil drain bolt
Bearing retainer (drive pinion gear)
Final gear case and bearing housing
Final gear case and bearing housing
Battery holding bracket
Footrest board and footrest bracket
Yoke (drive pinion gear)
Trailer hitch bracket
Front brake pad holding bolt
Rear brake pad holding bolt
Rear brake master cylinder bracket
Brake outer cable bracket
Brake master cylinder cover
Front brake caliper retaining bolt
Air duct (front)
Thread size
M8
M8
M8
M8
M14
M10
M8
M8
M14
M14
M65
M10
M8
M6
M6
M12
M10
M10
M10
M8
M8
M6
M8
M6
SPEC
Tightening torque
Nm
m·kg
ft·lb
33
33
33
33
23
10
25
13
23
23
100
40
23
7
7
62
32
18
18
23
23
7
30
7
3.3
3.3
3.3
3.3
2.3
1.0
2.5
1.3
2.3
2.3
10.0
4.0
2.3
0.7
0.7
6.2
3.2
1.8
1.8
2.3
2.3
0.7
3.0
0.7
24
24
24
24
16
7
18
9.4
16
16
72
29
17
5.1
5.1
45
23
13
13
17
17
5.1
22
5.1
Not For Resale
2 - 17
www.SmallEngineDiscount.com
Remarks
MAINTENANCE SPECIFICATIONS
SPEC
ELECTRICAL
Item
Voltage:
Ignition system:
Ignition timing (B.T.D.C.)
C.D.I.:
Magneto model/manufacturer
Pickup coil resistance/color
Rotor rotation direction sensing coil
resistance/color
C.D.I. unit model/manufacturer
Ignition coil:
Model/manufacturer
Minimum spark gap
Primary winding resistance
Secondary winding resistance
Spark plug cap:
Type
Resistance
Charging system:
Type
Model/manufacturer
Nominal output
Charging coil resistance/color
Rectifier/regulator:
Regulator type
No load regulated voltage (DC)
Model/manufacturer
Capacity
Withstand voltage
Electric starter system:
Type
Starter motor
Model/manufacturer
Output
Armature coil resistance
Standard
Limit
12 V
----
10°/ 1,500 r/min
----
F4T46471/MITSUBISHI
459 ~ 561 Ω at 20 °C (68 °F)/
White/Red – White/Green
0.085 ~ 0.105 Ω at 20 °C (68 °F)/
Red – White/Blue
F8T38678/MITSUBISHI
-------------
2JN/MORIYAMA
6 mm (0.24 in)
0.18 ~ 0.28 Ω at 20 °C (68 °F)
6.32 ~ 9.48 kΩ at 20 °C (68 °F)
-------------
Resin type
10 kΩ
-------
A.C. magneto generator
F4T464/MITSUBISHI
14 V 14 A at 3,000 r/min
0.41 ~ 0.61 Ω at 20 °C (68 °F)/
White – White
-------------
Semi conductor-short circuit
14.1 ~ 14.9 V
SH640E-11/SHINDENGEN
14 A
200 V
----------------
Constantmesh type
----
SM-13/MITSUBA
0.8 kW
0.025 ~ 0.035 Ω at 20 °C (68 °F)
----------
Not For Resale
2 - 18
www.SmallEngineDiscount.com
MAINTENANCE SPECIFICATIONS
Item
SPEC
Standard
Brush overall length
12.5 mm (0.49 in)
Spring force
7.65 ~ 10.01 N (780 ~ 1,020 g,
27.54 ~ 36.03 oz)
28 mm (1.10 in)
Commutator diameter
Mica undercut
Starter relay
Model/manufacturer
Amperage rating
Coil winding resistance
Four-wheel drive relay 1:
Model/manufacturer
Coil winding resistance
Four-wheel drive relay 2:
Model/manufacturer
Coil winding resistance
Four-wheel drive relay 3:
Model/manufacturer
Coil winding resistance
Electric fan:
Running rpm
Thermostat switch:
Thermostat switch 1
Model/manufacturer
Thermostat switch 2
Model/manufacturer
Circuit breaker:
Type
Amperage for individual circuit
Main fuse
Headlight fuse
Ignition fuse
Auxiliary DC jack fuse
Four-wheel drive fuse
Signaling system fuse
Back up fuse (odometer)
Reserve
Reserve
Reserve
Reserve
Limit
5 mm
(0.20 in)
----
0.7 mm (0.03 in)
27 mm
(1.06 in)
----
MS5F-561/JIDECO
180 A
4.18 ~ 4.62 Ω at 20 °C (68 °F)
----------
5DM/OMRON
94.5 ~ 115.5 Ω at 20 °C (68 °F)
-------
5DM/OMRON
94.5 ~ 115.5 Ω at 20 °C (68 °F)
-------
29U/MATSUSHITA
72 ~ 88 Ω at 20 °C (68 °F)
-------
3,500 r/min
----
5KM/DENSO
----
5ND/NIPPON THERMOSTAT
----
Fuse
----
30 A × 1
15 A × 1
10 A × 1
10 A × 1
3A×1
10 A × 1
10 A × 1
30 A × 1
15 A × 1
10 A × 1
3A×1
----------------------------------
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HOW TO USE THE CONVERSION TABLE/
GENERAL TORQUE SPECIFICATIONS
SPEC
EB201000
EB202001
HOW TO USE THE CONVERSION
TABLE
GENERAL TORQUE
SPECIFICATIONS
All specification data in this manual are listed in
SI and METRIC UNITS.
Use this table to convert METRIC unit data to
IMPERIAL unit data.
Ex.
This chart specifies torque for standard
fasteners with standard I.S.O. pitch threads.
Torque specifications for special components
or assemblies are provided for each chapter of
this manual. To avoid warpage, tighten multifastener assemblies in a crisscross fashion, in
progressive stages, until the specified torque is
reached. Unless otherwise specified, torque
specifications require clean, dry threads.
Components should be at room temperature.
METRIC
MULTIPLIER
** mm ×
0.03937
=
×
2 mm
0.03937
=
IMPERIAL
** in
0.08 in
CONVERSION TABLE
METRIC TO IMPERIAL
Metric unit
Multiplier
Imperial unit
Torque
m·kg
m·kg
cm·kg
cm·kg
7.233
86.794
0.0723
0.8679
ft·lb
in·lb
ft·lb
in·lb
Weight
kg
g
2.205
0.03527
lb
oz
Speed
km/hr
0.6214
mph
Distance
km
m
m
cm
mm
0.6214
3.281
1.094
0.3937
0.03937
mi
ft
yd
in
in
0.03527
0.06102
0.8799
0.2199
oz (IMP liq.)
cu·in
qt (IMP liq.)
gal (IMP liq.)
cc (cm3)
Volume/Ca cc (cm3)
lt (liter)
pacity
lt (liter)
Misc.
kg/mm
55.997
kg/cm2
14.2234
Centigrade
9/5+32
(°C)
lb/in
psi (lb/in2)
Fahrenheit (°F)
A: Distance between flats
B: Outside thread diameter
A
(nut)
B
(bolt)
10 mm
General torque
specifications
Nm
m•kg
ft•lb
6 mm
6
0.6
4.3
12 mm
8 mm
15
1.5
11
14 mm
10 mm
30
3.0
22
17 mm
12 mm
55
5.5
40
19 mm
14 mm
85
8.5
61
22 mm
16 mm
130
13.0
94
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LUBRICATION POINTS AND LUBRICANT TYPES
SPEC
LUBRICATION POINTS AND LUBRICANT TYPES
ENGINE
Lubrication points
Lubricant type
Oil seal lips (all)
LS
O-ring (all)
LS
Bearings (all)
E
Crank pin
E
Connecting rod (bearing)
E
Camshaft sprocket
M
Crankshaft
E
Piston surface/piston rings
E
Piston pin
E
Baffer boss
E
Valve stem/valve stem end
M
Rocker arm shaft
E
Rocker arm
M
Camshaft lobe/journal
M
Cylinder head bolt
E
Oil pump shaft, rotor, housing
E
Oil filter O-ring
E
Starter idle gear shaft
E
Transmission gear (wheel/pinion)
M
Axle (main/drive)
M
Shift fork/guide bar
E
Shift cam/shift shaft/shift cam stopper ball
E
Shift lever (select lever)/shift guide
LS
Shift cam lever
M
Stopper lever
E
Clutch housing
E
One-way bearing
M
Drive chain/sprocket
Driven cam
E
M
Front drive shaft collar
E
Crankcase mating surfaces
Sealant (Quick Gasket®)
Yamaha Bond No.1215
Stater lead grommet
(left side crankcase)
Sealant (Quick Gasket®)
Yamaha Bond No.1215
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COOLANT FLOW DIAGRAMS
SPEC
COOLANT FLOW DIAGRAMS
1 Radiator
2 Thermo switch
3 Fan motor
È To coolant reservoir
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COOLANT FLOW DIAGRAMS
SPEC
1 Radiator
2 Thermostat
È To coolant reservoir
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OIL FLOW DIAGRAMS
SPEC
OIL FLOW DIAGRAMS
1 Camshaft
2 Crankshaft
3 Drive axle
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OIL FLOW DIAGRAMS
SPEC
1 Oil filter
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OIL FLOW DIAGRAMS
SPEC
1 Oil pump
2 Oil strainer
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CABLE ROUTING
SPEC
CABLE ROUTING
1 Rear brake switch lead
2 Starter cable
3 Rear brake cable
4 Front brake hose
5 On-command four-wheel drive switch and
differential gear lock switch
6 Throttle cable
7 Handlebar switch
8 Handlebar switch lead
9 Main switch lead
0 Fan motor breather hose
A Differential gear case breather hose
B Sub-wire harness (to gear motor)
C On-command four-wheel drive switch
differential gear lock switch lead
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and
CABLE ROUTING
SPEC
È Fasten the on-command four-wheel drive switch and differential gear lock switch lead behind the
handlebar with a plastic band.
É Fasten the starter cable, handlebar switch lead and rear brake switch lead behind the handlebar with a
plastic band.
Ê Fasten the handlebar switch lead and rear brake switch lead behind the handlebar with a plastic band.
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CABLE ROUTING
SPEC
1 Sub-wire harness
2 Headlight lead
3 Auxiliary DC jack lead
4 Four-wheel drive relay 3
5 Fan motor breather hose
6 Differential gear case breather hose
7 Coolant reservoir breather hose
8 Meter assembly coupler
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CABLE ROUTING
1 Starter cable
2 Cylinder head breather hose
3 Fuel hose
4 Carburetor drain hose
5 Coolant reservoir breather hose
6 Radiator outlet hose
7 Coolant reservoir hose
8 Sub-wire harness
9 Differential gear case breather hose
0 Thermo switch 2
SPEC
È Insert the fuel tank breather hose into the hole of
the handlebar cover.
É Fasten the sub-wire harness, differential gear
case breather hose, coolant reservoir hose,
coolant reservoir breather hose, thermo switch
lead 2 and fan motor breather hose with a plastic
band.
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CABLE ROUTING
1 Cylinder head breather hose
2 Final drive gear case breather hose
3 Wire harness
4 Starter motor lead
5 Negative battery lead
6 Air filter case check hose
7 Water pump breather hose
8 Radiator outlet hose
9 Starter cable
0 Float chamber air vent hose
A Cylinder head breather hose
SPEC
B Fuel hose
C Low-range switch
D High-range switch
E Neutral switch lead
F Reverse switch lead
G Rectifier/regulator
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CABLE ROUTING
SPEC
È Fasten the wire harness with a plastic band.
É Fasten the starter motor lead, wire harness, negative battery lead, final gear case breather hose,
rectifier/regulator lead, low-range switch lead, high-range switch lead, neutral switch lead, reverse switch
lead, speed sensor lead and A.C. magneto lead with a plastic band.
Ê Fasten the wire harness, starter motor lead with a plastic band.
Ë Fasten the low-range switch lead, high-range switch lead, neutral switch lead, reverse switch lead, speed
sensor lead, A.C. magneto lead, rectifier/regulator lead and negative battery lead with a plastic band.
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CABLE ROUTING
1 Throttle cable
2 Radiator inlet hose
3 Spark plug lead
4 Main switch
5 Wire harness
6 Rear brake light switch lead
7 Rear brake fluid reservoir hose
8 Select lever control cable
9 Rear brake cable
0 Rear brake hose
SPEC
È Fasten the radiator inlet hose and spark plug
lead with a plastic band.
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CABLE ROUTING
SPEC
1 Front brake hose
2 Float chamber air vent hose
3 Throttle cable
4 Wire harness
5 Final drive gear case breather hose
6 Starter cable
7 Rear brake cable
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CABLE ROUTING
SPEC
1 Battery
2 Positive battery lead
3 Tail/brake light lead
4 CDI unit
5 Negative battery lead
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CABLE ROUTING
SPEC
1 Final drive gear case breather hose
2 Rear brake hose
3 Air filter case check hose
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INTRODUCTION/
PERIODIC MAINTENANCE/LUBRICATION
CHK
ADJ
EB300000
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION
This chapter includes all information necessary to perform recommended checks 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.
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 element
• 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.
• Tighten if necessary.
• Replace gasket(s) if necessary.
Spark arrester
• Clean.
Fuel line*
• Check fuel hose for cracks or damage.
• Replace if necessary.
Engine oil
• Replace. (Warm engine before draining.)
Engine oil filter
cartridge
• Replace.
Engine oil strainer*
• Clean.
Final gear oil
• Check oil level/oil leakage.
• Replace every 12 months.
Differential gear oil
EVERY
mile
(km)
200
(320)
750
(1,200)
1,500
(2,400)
1,500
(2,400)
3,000
(4,800)
hours
20
75
150
150
300
Front brake*
• Check operation/fluid leakage. (See NOTE page 3-2.)
• Correct if necessary.
Rear brake*
• Check operation/fluid leakage. (See NOTE page 3-2.)
• Correct if necessary.
V-belt*
• Check operation.
• Check for cracks or damage.
Wheels*
• Check balance/damage/runout.
• Repair if necessary.
Wheel bearing*
• Check bearing assemblies for looseness/damage.
• Replace if damaged.
3
Every 20–40 hours
(More often in wet or dusty areas.)
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PERIODIC MAINTENANCE/LUBRICATION
CHK
ADJ
INITIAL
ITEM
ROUTINE
Whichever
comes first
Front and rear
suspension*
• Check operation.
• Correct if necessary.
Steering system*
• Check operation./Replace if damaged.
• Check toe-in./Adjust if necessary.
EVERY
mile
(km)
200
(320)
750
(1,200)
1,500
(2,400)
1,500
(2,400)
3,000
(4,800)
hours
20
75
150
150
300
Drive shaft universal
• Lubricate.**
joint*
Engine mount*
• Check for cracks or damage.
Front axle boots*
• Check operation.
• Replace if damaged.
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.
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SEAT, CARRIERS, FENDERS AND FUEL TANK
CHK
ADJ
SEAT, CARRIERS, FENDERS AND FUEL TANK
SEAT AND SIDE PANELS
Order
1
Job name/Part name
Removing the seat and side panels
Seat
2
3
4
5
Fuel tank side panel (left)
Fuel tank side panel (right)
Engine side panel
Engine side cover
Q’ty
1
Remarks
Remove the parts in the order below.
NOTE:
Pull up the seat lock lever, then pull up on
the rear of the seat.
1
1
1
1
For installation, reverse the removal
procedure.
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SEAT, CARRIERS, FENDERS AND FUEL TANK
CHK
ADJ
FRONT CARRIER, FRONT BUMPER AND FRONT FENDER
Order
1
2
3
4
5
6
7
8
9
10
Job name/Part name
Removing the front carrier, front
bumper and front fender
Seat and fuel tank side panels
Front carrier
Front fender panel
Engine skid plate
Front bumper cover
Front bumper
Headlight coupler
Front grill
Main switch coupler
Handlebar cover
Fuel tank cover
Q’ty
Remarks
Remove the parts in the order below.
Refer to “SEAT AND SIDE PANELS”.
1
1
1
1
1
2
1
1
1
1
Disconnect.
Disconnect.
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SEAT, CARRIERS, FENDERS AND FUEL TANK
Order
11
12
13
14
15
16
17
Job name/Part name
Meter assembly coupler
Four-wheel drive relay 3 coupler
Auxiliary DC jack connector
Coolant reservoir breather hose
Fan motor breather hose
Differential gear case breather hose
Front fender
CHK
ADJ
Q’ty
Remarks
3
Disconnect.
1
Disconnect.
2
Disconnect.
1
1
1
1
For installation, reverse the removal
procedure.
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SEAT, CARRIERS, FENDERS AND FUEL TANK
CHK
ADJ
REAR CARRIER AND REAR FENDER
Order
1
2
3
4
Job name/Part name
Removing the rear carrier and rear
fender
Seat and fuel tank side panels
Fuel tank
Rear carrier
Battery holding bracket
Battery lead cover
Battery lead
Q’ty
Remarks
Remove the parts in the order below.
Refer to “SEAT AND SIDE PANELS”.
Refer to “FUEL TANK”.
1
1
1
2
Disconnect.
CAUTION:
First disconnect the negative lead,
then disconnect the positive lead.
5
6
7
Battery
Starter relay ground lead
Tail/brake light connector
1
3
Disconnect.
Disconnect.
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SEAT, CARRIERS, FENDERS AND FUEL TANK
Order
8
9
10
Job name/Part name
CDI unit
Wire harness
Rear fender
Q’ty
1
1
1
CHK
ADJ
Remarks
For installation, reverse the removal
procedure.
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SEAT, CARRIERS, FENDERS AND FUEL TANK
CHK
ADJ
FUEL TANK
Order
Job name/Part name
Removing the fuel tank
Seat and fuel tank side panels
Fuel tank cover
Q’ty
1
Fuel hose
1
2
3
Fuel cock lever
Fuel tank
1
1
4
5
6
Float chamber air vent hose
Plastic band
Rubber cover
1
4
1
Remarks
Remove the parts in the order below.
Refer to “SEAT AND SIDE PANELS”.
Refer to “FRONT CARRIER, FRONT
BUMPER AND FRONT FENDER”.
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
of the handlebar protector.
For installation, reverse the removal
procedure.
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FOOTREST BOARDS
CHK
ADJ
FOOTREST BOARDS
Order
1
2
3
Job name/Part name
Removing the footrest boards
Fuel tank side panels
Left footrest board
Right footrest board
Footrest bracket
Q’ty
Remarks
Remove the parts in the order below.
Refer to “SEAT AND SIDE PANELS”.
1
1
4
For installation, reverse the removal
procedure.
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ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
ENGINE
ADJUSTING THE VALVE CLEARANCE
NOTE:
● The valve clearance must be adjusted when
the engine is cool to the touch.
● Adjust the valve clearance when the piston is
at the Top Dead Center (T.D.C.) on the
compression stroke.
1.Remove:
● Seat
● Front carrier
● Front fender
● Fuel tank
Refer to “SEAT, CARRIERS, FENDERS
AND FUEL TANK”.
2.Remove:
● Tappet cover (intake) 1
● Tappet cover (exhaust) 2
3.Disconnect:
● Spark plug cap 3
4.Remove:
● Spark plug
5.Remove:
● Recoil starter 1
6.Remove:
● Timing plug 1
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ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
7.Check:
● Valve clearance
Out of specification → Adjust.
Valve clearance (cold):
Intake:
0.06 ~ 0.10 mm
(0.0024 ~ 0.0039 in)
Exhaust:
0.16 ~ 0.20 mm
(0.0063 ~ 0.0079 in)
*****************************************************
Checking steps:
● Turn the crankshaft counterclockwise with a
wrench.
● Align the “T” mark 1 on the rotor with the
stationary pointer 2 on the crankcase cover.
When the “T” mark is aligned with the
stationary pointer, the piston is at the Top
Dead Center (T.D.C.).
NOTE:
● When the piston is at the Top Dead Center
(T.D.C.) on the compression stroke, there
should be clearance between the valve stem
tips and their respective rocker arm adjusting
screws.
● If there is no clearance, rotate the crankshaft
counterclockwise one turn.
● Measure
the valve clearance using a feeler
gauge 3.
*****************************************************
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ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
8.Adjust:
● Valve clearance
*****************************************************
Adjustment steps:
● Loosen the locknut 1.
● Insert a feeler gauge 2 between the adjuster
end and the valve end.
● Turn
the adjuster 3 clockwise or
counterclockwise with the valve adjusting
tool 4 until the proper clearance is obtained.
Tappet adjusting tool:
P/N. YM-08035, 90890-01311
● Hold
the adjuster to prevent it from moving
and then tighten the locknut.
T.
Locknut:
20 Nm (2.0 m • kg, 14 ft • lb)
R.
● Measure
the valve clearance.
● If the clearance is incorrect, repeat the above
steps until the proper clearance is obtained.
*****************************************************
9.Install:
● All removed parts
NOTE:
Install all removed parts in the reverse order of
their disassembly. Note the following points.
10.Install:
● Recoil starter
LT
T.
R.
R.
●
Spark plug
Tappet covers
T.
●
10 Nm (1.0 m • kg, 7.2 ft • lb)
18 Nm (1.8 m • kg, 13 ft • lb)
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • lb)
NOTE:
Install the tappet covers with the ridge facing
up È.
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ADJUSTING THE VALVE CLEARANCE/
ADJUSTING THE IDLING SPEED
CHK
ADJ
11.Install:
● Fuel tank
● Front fender
● Front carrier
● Seat
Refer to “SEAT, CARRIERS, FENDERS
AND FUEL TANK”.
ADJUSTING THE IDLING SPEED
1.Start the engine and let it warm up for
several minutes.
2.Remove:
● Seat
● Fuel tank side panels
Refer to “SEAT, CARRIERS, FENDERS
AND FUEL TANK”.
3.Attach:
● Inductive tachometer or engine tachometer
(to the spark plug lead)
Inductive tachometer:
P/N. YU-8036-A
Engine tachometer:
P/N. 90890-03113
4.Check:
● Engine idling speed
Out of specification → Adjust.
Engine idling speed:
1,450 ~ 1,550 r/min
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ADJUSTING THE IDLING SPEED/
ADJUSTING THE THROTTLE LEVER FREE PLAY
CHK
ADJ
5.Adjust:
● Engine idling speed
*****************************************************
Adjustment steps:
● Turn the throttle stop screw 1 in or out until
the specified idling speed is obtained.
Turning in
Idling speed becomes
higher.
Turning out
Idling speed becomes
lower.
*****************************************************
6.Detach:
● Inductive or engine tachometer
7.Adjust:
● Throttle lever free play
Refer to “ADJUSTING THE THROTTLE
LEVER FREE PLAY”.
Throttle lever free play:
3 ~ 5 mm (0.12 ~ 0.20 in)
8.Install:
● Fuel tank side panels
● Seat
Refer to “SEAT, CARRIERS, FENDERS
AND FUEL TANK”.
ADJUSTING THE THROTTLE LEVER FREE
PLAY
NOTE:
Engine idling speed should be adjusted
properly before adjusting the throttle lever free
play.
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ADJUSTING THE THROTTLE LEVER FREE PLAY
CHK
ADJ
1.Check:
● Throttle lever free play a
Out of specification → Adjust.
Throttle lever free play:
3 ~ 5 mm (0.12 ~ 0.20 in)
2.Remove:
● Seat
● Fuel tank side panel (right)
Refer to “SEAT, CARRIERS, FENDERS
AND FUEL TANK”.
3.Adjust:
● Throttle lever free play
*****************************************************
Adjustment steps:
First step:
● Pull back the adjuster cover 1.
● Loosen the locknut 2 on the carburetor side.
● Turn the adjuster 3 in or out until the correct
free play is obtained.
Turning in
Free play is increased.
Turning out Free play is decreased.
the locknut 2.
in the adjuster cover 1.
● Tighten
● Push
NOTE:
If the free play cannot be adjusted here, adjust
it at the throttle lever side of the cable.
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ADJUSTING THE THROTTLE LEVER FREE PLAY/
ADJUSTING THE SPEED LIMITER
CHK
ADJ
Second step:
● Pull back the adjuster cover 4.
● Loosen the locknut 5.
● Turn the adjuster 6 in or out until the correct
free play is obtained.
Turning in
Free play is increased.
Turning out Free play is decreased.
the locknut 5.
● Push in the adjuster cover 4.
● Tighten
WARNING
After adjusting the free play, turn the
handlebar to the right and left to make sure
that the engine idling speed does not
increase.
*****************************************************
4.Install:
● Fuel tank side panel (right)
● Seat
Refer to “SEAT, CARRIERS, FENDERS
AND FUEL TANK”.
ADJUSTING THE SPEED LIMITER
The speed limiter keeps the carburetor throttle
from becoming fully-opened even when the
throttle lever is applied to the maximum
position. Screwing in the adjuster stops the
engine speed from increasing.
1.Check:
● Speed limiter length a
Out of specification → Adjust.
Speed limiter length:
12 mm (0.47 in)
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ADJUSTING THE SPEED LIMITER/
ADJUSTING THE STARTER CABLE
CHK
ADJ
2.Adjust:
● Speed limiter length
*****************************************************
Speed limiter length adjustment steps:
● Loosen the locknut 1.
● Turn the adjuster 2 in or out until the
specified speed limiter length is obtained.
Turning in
Speed limiter length is
decreased.
Turning out
Speed limiter length is
increased.
● Tighten
the locknut.
WARNING
●
●
Particularly for a beginner rider, the
speed limiter should be screwed in
completely. Screw it out little by little as
their riding technique improves. Never
remove the speed limiter for a beginning
rider.
For proper throttle lever operation do not
turn out the adjuster more than 12 mm
(0.47 in). Also, always adjust the throttle
lever free play to 3 ~ 5 mm (0.12 ~ 0.20 in).
*****************************************************
ADJUSTING THE STARTER CABLE
1.Remove:
● Seat
● Fuel tank side panel (left)
Refer to “SEAT, CARRIERS, FENDERS
AND FUEL TANK”.
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ADJUSTING THE STARTER CABLE
CHK
ADJ
2.Adjust:
*****************************************************
Adjustment 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 fully close to fully
open position. If the distance is out of
specification adjust it as described below.
Starter plunger stroke distance:
15 mm (0.59 in)
È Fully closed position
É Fully open position
back the boot 4.
the locknut 5.
● Turn the adjuster 6 in or out until the correct
free play is obtained.
● Pull
● Loosen
Turning in
Free play increased.
Turning out Free play decreased.
the locknut 5.
● Push in the boot 4.
● Connect the starter cable to the carburetor.
● Tighten
WARNING
After adjusting the cable, turn the
handlebar to right and left, and make sure
that the engine idling speed does not
increase.
*****************************************************
3.Install:
● Fuel tank side panel (left)
● Seat
Refer to “SEAT, CARRIERS, FENDERS
AND FUEL TANK”.
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CHECKING THE SPARK PLUG
CHK
ADJ
CHECKING THE SPARK PLUG
1.Remove:
● Seat
● Fuel tank side panel (right)
Refer to “SEAT, CARRIERS, FENDERS
AND FUEL TANK”.
2.Remove:
● Spark plug
3.Check:
● Spark plug type
Incorrect → Replace.
Standard spark plug:
DR8EA/NGK
4.Check:
● Electrode 1
Wear/damage → Replace.
● Insulator 2
Abnormal color → Replace.
Normal color is a medium-to-light tan color.
5.Clean the spark plug with a spark plug
cleaner or wire brush.
6.Measure:
● Plug gap a
Use a wire gauge or feeler gauge.
Out of specification → Regap.
Spark plug gap:
0.6 ~ 0.7 mm (0.024 ~ 0.028 in)
T.
R.
7.Tighten:
● Spark plug
18 Nm (1.8 m • kg, 13 ft • lb)
NOTE:
Before installing a spark plug, clean the gasket
surface and plug surface.
8.Install:
● Fuel tank side panel (right)
● Seat
Refer to “SEAT, CARRIERS, FENDERS
AND FUEL TANK”.
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CHECKING THE IGNITION TIMING
CHK
ADJ
CHECKING THE IGNITION TIMING
NOTE:
Engine idling speed and throttle cable free play
should be adjusted properly before checking
the ignition timing.
1.Remove:
● Seat
● Fuel tank side panel (right)
Refer to “SEAT, CARRIERS, FENDERS
AND FUEL TANK”.
2.Attach:
● Inductive tachometer or engine tachometer
● Timing light
(to spark plug lead)
Inductive tachometer:
P/N. YU-8036-A
Engine tachometer:
P/N. 90890-03113
Timing light:
P/N. YM-33277-A, 90890-03141
3.Check:
● Ignition timing
*****************************************************
Checking steps:
● Warm up the engine and keep it at the
specified speed.
Engine speed:
1,450 ~ 1,550 r/min
the recoil starter 1.
the timing plug 2.
● Visually check the stationary pointer 3 to
verify it is within the required firing range 4
indicated on the flywheel.
Incorrect firing range → Check the pulser coil
assembly.
● Install the timing plug.
● Install the recoil starter.
● Remove
● Remove
T.
R.
Recoil starter bolt:
10 Nm (1.0 m • kg, 7.2 ft • Ib)
LOCTITE®
*****************************************************
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CHECKING THE IGNITION TIMING/
MEASURING THE COMPRESSION PRESSURE
CHK
ADJ
4.Detach:
● Timing light
● Inductive tachometer or engine tachometer
5.Install:
● Seat
● Fuel tank side panel (right)
Refer to “SEAT, CARRIERS, FENDERS
AND FUEL TANK”.
MEASURING THE COMPRESSION
PRESSURE
NOTE:
Insufficient compression pressure will result in
a loss of performance.
1.Check:
● Valve clearance
Out of specification → Adjust.
Refer to “ADJUSTING THE VALVE
CLEARANCE”.
2.Start the engine and let it warm up for
several minutes.
3.Stop the engine.
4.Remove:
● Seat
● Fuel tank side panel (right)
Refer to “SEAT, CARRIERS, FENDERS
AND FUEL TANK”.
5.Remove:
● Spark plug
6.Attach:
● Adapter
● Compression gauge 1
Compression gauge:
P/N. YU-33223, 90890-03081
Adapter:
P/N. YU-33223-3, 90890-04082
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MEASURING THE COMPRESSION PRESSURE
CHK
ADJ
7.Measure:
● Compression pressure
Above the maximum pressure:
Check the cylinder head, valve surfaces, and
piston crown for carbon deposits.
Below the minimum pressure:
Squirt a few drops of oil into the affected
cylinder and measure again.
● Refer to the table below.
Compression pressure
(with oil introduced into cylinder)
Reading
Diagnosis
Higher than
Worn or damaged pistons
without oil
Same as
without oil
Defective ring(s), valves,
cylinder head gasket or
piston is possible.
Compression pressure
(at sea level):
Standard:
1,270 kPa (12.7 kg/cm2, 181 psi)
Minimum:
1,105 kPa (11.1 kg/cm2, 158 psi)
Maximum:
1,422 kPa (14.2 kg/cm2, 202 psi)
*****************************************************
Measurement steps:
● Crank over the engine with the electric
starter (be sure the battery is fully charged)
with the throttle wide-open until the
compression reading on the gauge
stabilizes.
WARNING
When cranking the engine, ground the
spark plug lead to prevent sparking.
*****************************************************
T.
8.Install:
18 Nm (1.8 m • kg, 13 ft • lb)
● Spark plug
9.Remove:
● Fuel tank side panel (right)
● Seat
Refer to “SEAT, CARRIERS, FENDERS
AND FUEL TANK”.
R.
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CHECKING THE ENGINE OIL LEVEL
CHK
ADJ
CHECKING THE ENGINE OIL LEVEL
1.Place the machine on a level surface.
2.Remove:
● Engine side panel
Refer to “SEAT, CARRIERS, FENDERS
AND FUEL TANK”.
3.Check:
● Engine oil level
Oil level should be between the maximum
level mark 1 and minimum level mark 2.
Oil level low → Add oil to the proper level.
NOTE:
Do not screw the dipstick 3 in when checking
the oil level.
Recommended oil:
Follow the left chart.
NOTE:
Recommended oil classification:
API Service “SE”, “SF” type or equivalent (e.g.
“SF–SE–CC”, “SF–SE–SD” etc.)
CAUTION:
Do not allow foreign material to enter the
crankcase.
4.Start the engine and let it warm up for
several minutes.
5.Stop the engine and check the oil level
again.
NOTE:
Wait a few minutes until the oil settles before
checking the oil level.
WARNING
Never remove the dipstick just after high
speed operation because the heated oil
could spurt out. Wait until the oil cools
down before removing the dipstick.
6.Install:
● Engine side panel
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CHANGING THE ENGINE OIL
CHK
ADJ
CHANGING THE ENGINE OIL
1.Start the engine and let it warm up for
several minutes.
2.Stop the engine and place an oil pan under
the engine.
3.Remove:
● Seat
● Fuel tank side panel (left)
● Engine side cover
Refer to “SEAT, CARRIERS, FENDERS
AND FUEL TANK”.
4.Remove:
● Engine oil filler plug (dipstick) 1
5.Remove:
● Engine oil drain bolt 1
Drain the engine oil.
● Oil strainer cover 2
● Compression spring 3
● Oil strainer 4
6.Clean:
● Oil strainer
7.If the oil filter cartridge is also to be replaced,
perform the following procedure.
*****************************************************
Replacement steps:
● Remove the oil filter cartridge 1 with an oil
filter wrench 2.
Oil filter wrench:
P/N. YU-38411, 90890-01426
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CHANGING THE ENGINE OIL
CHK
ADJ
the O-ring 3 of the new oil filter
cartridge with a thin coat of engine oil.
● Lubricate
CAUTION:
Make sure that the O-ring 3 is positioned
correctly in the groove of the oil filter
cartridge.
● Tighten
the new oil filter cartridge to
specification with an oil filter wrench.
T.
Oil filter cartridge:
17 Nm (1.7 m • kg, 12 ft • lb)
R.
*****************************************************
8.Install:
● Oil strainer
● Compression spring
● Oil strainer cover 1
T.
R.
●
32 Nm (3.2 m • kg, 23 ft • lb)
Engine oil drain bolt 2
T.
R.
23 Nm (2.3 m • kg, 17 ft • lb)
9.Fill:
● Crankcase
Refer to “CHECKING THE ENGINE OIL
LEVEL”.
Oil quantity:
Periodic oil change:
2.3 L (2.0 Imp qt, 2.4 US qt)
With oil filter replacement:
2.4 L (2.1 Imp qt, 2.5 US qt)
Total amount:
2.6 L (2.3 Imp qt, 2.7 US qt)
10.Install:
● Engine oil filler plug
11.Warm up the engine for a few minutes, then
stop the engine.
12.Check:
● Engine
(for engine oil leaks)
● Oil level
● Refer to “CHECKING THE ENGINE OIL
LEVEL”.
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CHANGING THE ENGINE OIL/
CLEANING THE AIR FILTER
CHK
ADJ
13.Check:
● Engine oil pressure
*****************************************************
● Slightly loosen the oil gallery bolt 1.
● Start the engine and keep it idling until
engine oil starts to seep from the oil gallery
bolt. If no engine oil comes out after one
minute, turn the engine off so that it will not
seize.
● Check the engine oil passages, the oil filter
cartridge and the oil pump for damage or
leakage. Refer to “CRANKCASE” in
CHAPTER 4.
● Start the engine after solving the problem(-s)
and check the engine oil pressure again.
● Tighten the oil gallery bolt to specification.
Oil gallery bolt:
7 Nm (0.7 m • kg, 5.1 ft • lb)
*****************************************************
14.Install:
● Engine side cover
● Fuel tank side panel (left)
● Seat
Refer to “SEAT, CARRIERS, FENDERS
AND FUEL TANK”.
CLEANING THE AIR FILTER
NOTE:
There is a check hose 1 at the bottom of the
air filter case. If dust and/or water collects in
this hose, clean the air filter element and air
filter case.
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CLEANING THE AIR FILTER
CHK
ADJ
1.Remove:
● Seat
2.Remove:
● Air filter case cover 1
3.Remove:
● Air filter element assembly 1
● Air filter element cap
● Air filter element
2 Air filter element cap
3 Air filter element
CAUTION:
Never operate the engine with the air filter
element removed. This will allow unfiltered
air to enter, causing rapid wear and
possible engine damage. Additionally,
operation without the filter element will
affect carburetor tuning with subsequent
poor performance and possible engine
overheating.
4.Check:
● Air filter element
Damaged → Replace.
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CLEANING THE AIR FILTER
CHK
ADJ
5.Clean:
● Air filter element
*****************************************************
Cleaning steps:
● Wash the element gently, but thoroughly in
solvent.
WARNING
Use a cleaning solvent which is designed
to clean parts only. Never use gasoline or
low flash point solvents as they may cause
a fire or explosion.
● Squeeze
the excess solvent out of the
element and let it dry.
CAUTION:
Do not twist or wring out the element. This
could damage the foam material.
● Apply
engine oil to the element.
out the excess oil.
● Squeeze
NOTE:
The element should be wet but not dripping.
*****************************************************
6.Install:
● Air filter element
● Air filter case cover
NOTE:
To prevent air leaks make sure that the sealing
surface of the element matches the sealing
surface of the case.
●
Seat
Refer to “SEAT, CARRIERS, FENDERS
AND FUEL TANK”.
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CHECKING THE COOLANT LEVEL
CHK
ADJ
CHECKING THE COOLANT LEVEL
1.Place the machine on a level surface.
2.Remove:
● Seat
● Fuel tank side panel (left)
3.Check:
● Coolant level
The coolant level should be between the
minimum level mark a and maximum level
mark b.
Below the minimum level mark → Add the
recommended coolant to the proper level.
CAUTION:
●
●
Adding water instead of coolant lowers
the antifreeze content of the coolant. If
water is used instead of coolant, check
and if necessary, correct the antifreeze
concentration of the coolant.
Use only distilled water. However, soft
water may be used if distilled water is not
available.
4.Start the engine, warm it up for several
minutes, and then turn it off.
5.Check:
● Coolant level
NOTE:
Before checking the coolant level, wait a few
minutes until the coolant has settled.
6.Install:
● Fuel tank side panel (left)
● Seat
Refer to “SEAT, CARRIERS, FENDERS
AND FUEL TANK”.
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CHANGING THE COOLANT
CHK
ADJ
CHANGING THE COOLANT
1.Remove:
● Seat
● Fuel tank side panel (left)
● Engine side cover
● Front carrier
● Engine skid plate
● Front fender
Refer to “SEAT, CARRIERS, FENDERS
AND FUEL TANK”.
● Left footrest board
Refer to “FOOTREST BOARDS”.
2.Remove:
● Plastic band 1
● Coolant reservoir bolts 2
● Coolant reservoir cap 3
3.Disconnect:
● Coolant reservoir breather hose 4
4.Drain:
● Coolant
(from the coolant reservoir)
5.Connect:
● Coolant reservoir breather hose
6.Install:
● Coolant reservoir bolts
● Plastic band
7.Remove:
● Radiator cap 1
WARNING
A hot radiator is under pressure. Therefore,
do not remove the radiator cap when the
engine is hot. Scalding hot fluid and steam
may be blown out, which could cause
serious injury. When the engine has
cooled, open the radiator cap as follows:
Place a thick rag or a towel over the
radiator cap and slowly turn the radiator
cap counterclockwise toward the detent to
allow any residual pressure to escape.
When the hissing sound has stopped, turn
the radiator cap counterclockwise while
pressing down on it and then remove it.
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CHANGING THE COOLANT
CHK
ADJ
8.Remove:
● Coolant drain bolt (cylinder) 1
(along with the copper washer)
● Coolant drain bolt (water pump) 2
(along with the copper washer)
9.Drain:
● Coolant
10.Check:
● Copper washer 1
● Coolant drain bolt 2
Damage → Replace.
11.Install:
● Coolant drain bolt (water pump)
T.
R.
●
10 Nm (1.0 m • kg, 7.2 ft • lb)
Coolant drain bolt (cylinder)
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • lb)
12.Fill:
● Cooling system
(with the specified
recommended coolant)
amount
of
the
Recommended antifreeze
High-quality ethylene glycol
antifreeze containing corrosion
inhibitors for aluminum engines
Mixing ratio
1:1 (antifreeze:water)
Quantity
Total amount
1.32 L (1.16 Imp qt, 1.40 US qt)
Coolant reservoir capacity
0.39 L (0.34 Imp qt, 0.41 US qt)
Handling notes for coolant
Coolant is potentially harmful and should be
handled with special care.
WARNING
●
●
●
If coolant splashes in your eyes,
thoroughly wash them with water and
consult a doctor.
If coolant splashes on your clothes,
quickly wash it away with water and then
with soap and water.
If coolant is swallowed, induce vomiting
and get immediate medical attention.
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CHANGING THE COOLANT
CHK
ADJ
CAUTION:
●
●
●
●
Adding water instead of coolant lowers
the antifreeze content of the coolant. If
water is used instead of coolant, check,
and if necessary, correct the antifreeze
concentration of the coolant.
Use only distilled water. However, soft
water may be used if distilled water is not
available.
If coolant comes into contact with painted
surfaces, immediately wash them with
water.
Do not mix different types of antifreeze.
13.Install:
● Radiator cap
14.Fill:
● Coolant reservoir
(with the recommended coolant to the
maximum level mark a)
15.Install:
● Coolant reservoir cap
16.Start the engine, warm it up for several
minutes, and then turn it off.
17.Check:
● Coolant level
Refer to “CHECKING THE COOLANT
LEVEL”.
NOTE:
Before checking the coolant level, wait a few
minutes until the coolant has settled.
18.Install:
● Left footrest board
Refer to “FOOTREST BOARDS”.
● Front fender
● Engine skid plate
● Front carrier
● Engine side cover
● Fuel tank side panel (left)
● Seat
Refer to “SEAT, CARRIERS, FENDERS
AND FUEL TANK”.
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COOLANT TEMPERATURE WARNING LIGHT CHECK/
CHECKING THE V-BELT
CHK
ADJ
COOLANT TEMPERATURE WARNING
LIGHT CHECK
1 Coolant temperature warning light
Coolant temperature warning light checking method
Turn the main switch “ON” and
the engine stop switch to “
”.
Coolant temperature warning
light does not come on.
Coolant temperature warning
light comes on.
Push start switch with
transmission in “neutral”.
Coolant temperature
warning light comes on
momentarily.
Coolant temperature and
electrical circuit are OK. Go
ahead with riding.
Coolant temperature warning
light does not come on.
Ask a Yamaha dealer to
check the electrical circuit.
CHECKING THE V-BELT
1.Remove:
● Right footrest board
● Crankcase cover (right)
Refer to “PRIMARY AND SECONDARY
SHEAVES” in CHAPTER 4.
2.Check:
● V-belt 1
Cracks/wear/scaling/chipping → Replace.
Oil/grease → Check primary sheave and
secondary sheave.
3.Measure:
● V-belt width 2
Out of specification → Replace.
V-belt width:
30.7 mm (1.21 in)
<Limit:> 27.6 mm (10.9 in)
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CHECKING THE V-BELT/
CLEANING THE SPARK ARRESTER
CHK
ADJ
4.Replace:
● V-belt
*****************************************************
Replacing steps:
● Install the bolts 1 (90101-06016) into the
secondary fixed sheave hold.
NOTE:
Tightening the bolts 1 will push the secondary
sliding sheave away, causing the gap between
the secondary fixed and sliding sheaves to
widen.
the V-belt 1 from the primary
sheave and secondary sheave.
● Remove
● Install
the V-belt.
NOTE:
Install the V-belt so that its arrow faces the
direction shown in the illustration.
● Remove
the bolts.
*****************************************************
CLEANING THE SPARK ARRESTER
1.Clean:
● Spark arrester
*****************************************************
Cleaning steps:
WARNING
●
●
●
Select a well-ventilated area free of
combustible materials.
Always let the exhaust system cool
before performing this operation.
Do not start the engine when removing
the tailpipe from the muffler.
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CLEANING THE SPARK ARRESTER
CHK
ADJ
the bolt 1.
● Remove the tailpipe 2 by pulling it out of the
muffler.
● Tap the tailpipe lightly with a soft-face
hammer or suitable tool, then use a wire
brush to remove any carbon deposits from
the spark arrester portion of the tailpipe and
the inner contact surfaces of the muffler.
● Insert the tailpipe 2 into the muffler and
align the bolt holes.
● Insert the bolt 1 and tighten it.
● Remove
*****************************************************
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ADJUSTING THE REAR BRAKE
CHK
ADJ
CHASSIS
ADJUSTING THE REAR BRAKE
WARNING
Always adjust both the brake pedal and the
rear brake lever whenever adjusting the
rear brake.
1.Check:
● Rear brake lever free play a
Out of specification → Adjust.
Rear brake lever free play:
0.5 ~ 2 mm (0.02 ~ 0.08 in)
2.Check:
● Rear brake pedal height a
Out of specification → Adjust.
Rear brake pedal height:
70 ~ 80 mm (2.76 ~ 3.15 in)
1 Brake pedal
2 Footrest
3.Adjust:
● Rear brake lever free play
● Rear brake pedal height
*****************************************************
Adjustment steps:
● Loosen the locknut (handlebar) 1 and fully
screw in the brake lever cable adjuster
(handlebar) 2.
● Remove the rear brake master cylinder cover
3.
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ADJUSTING THE REAR BRAKE
CHK
ADJ
the locknut 4.
● Turn the adjusting bolt 5 until the brake
pedal height is within the specified limits.
● Loosen
Brake pedal height:
70 ~ 80 mm (2.76 ~ 3.15 in)
● Tighten
the locknut 4.
NOTE:
When adjusting the brake pedal height make
sure the locknut-to-adjusting bolt clearance a
does not exceed 6 mm (0.24 in).
the locknut 6.
● Pull up the brake outer cable and turn the
brake cable adjusting (nut) 7 until the
clearance b is within the specified limits.
● Loosen
Clearance b:
Less than 1 mm (0.04 in)
NOTE:
Make sure the pin 8 is all the way to the right
of the link plate hole.
the adjusting nut 7 and tighten the
locknut 6.
● Turn the brake lever cable adjuster
(handlebar) 2 until the rear brake lever free
play c is within the specified limits.
● Hold
Rear brake lever free play:
0.5 ~ 2 mm (0.02 ~ 0.08 in)
Tighten the locknut (handlebar) 1.
● Adjust the select lever control cable.
Refer to “ADJUSTING THE SELECT LEVER
CONTROL CABLE AND SHIFT ROD”.
● Install the rear brake master cylinder cover.
WARNING
After this adjustment is performed, lift the
front and rear wheels off the ground by
placing a block under the engine, and spin
the rear wheels to ensure there is no brake
drag. If any brake drag is noticed perform
the above steps again.
*****************************************************
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CHECKING THE BRAKE FLUID LEVEL
CHK
ADJ
CHECKING THE BRAKE FLUID LEVEL
1.Place the machine on a level surface.
NOTE:
When checking the brake fluid level, make
sure that the top of the brake fluid reservoir top
is horizontal.
È
2.Remove: (rear brake)
● Front carrier
● Front fender panel
Refer to “SEAT, CARRIERS, FENDERS
AND FUEL TANK”.
3.Check:
● Brake fluid level
Fluid level is under “LOWER” level line 1 →
Fill up.
Recommended brake fluid:
DOT 4
É
È Front brake
É Rear brake
CAUTION:
Brake fluid may erode painted surfaces or
plastic parts. Always clean up spilled fluid
immediately.
WARNING
●
●
●
Use only the designed quality brake fluid:
otherwise, the rubber seals may
deteriorate, causing leakage and poor
brake performance.
Refill with the same type of brake fluid;
mixing fluids may result in a harmful
chemical reaction and lead to poor
performance.
Be careful that water does not enter the
master cylinder when refilling. Water will
significantly lower the boiling point of the
fluid and may result in a vapor lock.
4.Install: (rear brake)
● Front fender panel
● Front carrier
Refer to “SEAT, CARRIERS, FENDERS
AND FUEL TANK”.
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CHECKING THE FRONT BRAKE PAD/
CHECKING THE REAR BRAKE PAD
CHK
ADJ
CHECKING THE FRONT BRAKE PAD
1.Remove:
● Front wheels
2.Check:
● Brake pad
Wear indicators groove 1 almost touch the
brake disc → Replace the brake pads as a
set.
Refer to “FRONT AND REAR BRAKES” in
CHAPTER 8.
Brake pad wear limit a:
1 mm (0.04 in)
3.Operate the brake lever.
4.Install:
● Front wheels
CHECKING THE REAR BRAKE PAD
1.Remove:
● Rear wheel (left)
2.Check:
● Brake pad
Wear
indicator
groove
1
almost
disappeared → Replace the brake pads as a
set.
Refer to “FRONT AND REAR BRAKES” in
CHAPTER 8.
Brake pad wear limit a:
1 mm (0.04 in)
3.Operate the brake lever or brake pedal.
4.Install:
● Rear wheel (left)
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CHECKING THE BRAKE HOSE
CHK
ADJ
CHECKING THE BRAKE HOSE
1.Remove:
● Seat
● Front carrier
● Front fender
Refer to “SEAT, CARRIERS, FENDERS
AND FUEL TANK”.
● Right footrest board
Refer to “FOOTREST BOARDS”.
2.Check:
● Front brake hoses 1
● Rear brake hoses 2
Cracks/wear/damage → Replace.
Fluid leakage → Replace the hose.
Refer to “FRONT AND REAR BRAKES” in
CHAPTER 8.
NOTE:
Hold the machine in an upright position and
apply the front or rear brake.
3.Check:
● Brake hose clamp
Loosen → Tighten.
4.Install:
● Right footrest board
Refer to “FOOTREST BOARDS”.
● Front fender
● Front carrier
● Seat
Refer to “SEAT, CARRIERS, FENDERS
AND FUEL TANK”.
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BLEEDING THE HYDRAULIC BRAKE SYSTEM
CHK
ADJ
BLEEDING THE HYDRAULIC BRAKE
SYSTEM
WARNING
È
Bleed the brake system if:
● The system has been disassembled.
● A brake hose or brake pipe have been
loosened or removed.
● The brake fluid has been very low.
● The brake operation has been faulty.
A loss of braking performance may occur if
the brake system is not properly bled.
1.Bleed:
● Brake system
*****************************************************
Air bleeding steps:
a.Add the proper brake fluid to the reservoir.
b.Install the diaphragm. Be careful not to spill
any fluid or allow the reservoir to overflow.
É
c.Connect the clear plastic hose 1 tightly to
the caliper bleed screw 2.
È Front
É Rear
d.Place the other end of the hose into a
container.
e.Slowly apply the brake lever or pedal several
times.
f. Pull the lever in or push down on the pedal
and hold it.
g.Loosen the bleed screw and allow the lever
or pedal to travel towards its limit.
h.Tighten the bleed screw when the lever or
pedal limit has been reached, then release
the lever or pedal.
i. Repeat steps (e) to (h) until all the air
bubbles have disappeared from the fluid.
j. Tighten the bleed screw.
T.
Bleed screw:
6 Nm (0.6 m • kg, 4.3 ft • lb)
R.
NOTE:
If bleeding is difficult, it may be necessary to
let the brake fluid settle for a few hours.
Repeat the bleeding procedure when the tiny
bubbles in the system have disappeared.
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BLEEDING THE HYDRAULIC BRAKE SYSTEM/
ADJUSTING THE SELECT LEVER CONTROL CABLE AND SHIFT ROD
CHK
ADJ
k.Add brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL”.
WARNING
Check the operation of the brake after
bleeding the brake system.
*****************************************************
ADJUSTING THE SELECT LEVER
CONTROL CABLE AND SHIFT ROD
1 NEUTRAL
2 HIGH
3 LOW
4 REVERSE
5 PARK
6 Control cable
7 Select lever shift rod
WARNING
Before moving the select lever, bring the
machine to a complete stop and return the
throttle lever to its closed position.
Otherwise the transmission may be
damaged.
1.Adjust:
● Rear brake pedal free play
Refer to “ADJUSTING THE REAR BRAKE”.
2.Adjust:
● Select lever control cable
● Select lever shift rod
*****************************************************
Adjustment steps:
Control cable:
● Make sure the select lever is in NEUTRAL.
● Adjust the control cable so there is zero free
play in the cable. When the adjustment is
correct, slack in the return spring 1 will be
taken up.
NOTE:
In some cases it will be necessary to further
adjust the cable with the locknuts 2
arrangement that holds the cable to its mount.
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ADJUSTING THE SELECT LEVER CONTROL CABLE AND SHIFT ROD/
ADJUSTING THE REAR BRAKE LIGHT SWITCH
CHK
ADJ
● When
the brake begins to work “a = 20 ~
30 mm (0.8 ~ 1.2 in)”, verify that the select
lever can be shifted to REVERSE from
NEUTRAL, to PARK from REVERSE and to
NEUTRAL from REVERSE.
● Before the brake begins to work “a = 0 ~
20 mm (0 ~ 0.8 in)”, verify that the select
lever cannot be shifted to REVERSE from
NEUTRAL, to REVERSE from PARK and to
NEUTRAL from REVERSE.
● Check that locknuts 2 are tightened
correctly.
● If the operation of the select lever is
incorrect, adjust the select lever control cable
3 with the adjuster 4.
Select lever shift rod:
● Make sure the select lever is in NEUTRAL.
● Loosen both locknuts 1.
● Adjust the shift rod length for smooth and
correct shifting.
● Tighten the locknuts 1.
*****************************************************
ADJUSTING THE REAR BRAKE LIGHT
SWITCH
NOTE:
The rear brake light switch is operated by
movement of the brake pedal.
The rear brake light switch is properly adjusted
when the brake light comes on just before the
braking effect starts.
1.Check:
● Brake light operation timing
Incorrect → Adjust.
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ADJUSTING THE REAR BRAKE LIGHT SWITCH/
CHECKING THE FINAL GEAR OIL LEVEL
CHK
ADJ
2.Adjust:
● Rear brake light switch operation timing
***********************************************
the main body 1 of the rear brake light
switch so that it does not rotate and turn the
adjusting nut 2 in direction a or b until the
rear brake light comes on at the proper time.
● Hold
Direction a
Brake light comes on
sooner.
Direction b
Brake light comes on
later.
***********************************************
CHECKING THE FINAL GEAR OIL LEVEL
1.Place the machine on a level place.
2.Remove:
● Oil filler bolt 1
3.Check:
● Oil level
Oil level should be up to the brim of the hole.
Oil level low → Add oil to the proper level.
Recommended oil:
SAE 80 API “GL-4” Hypoid gear
oil
CAUTION:
Take care not allow foreign material to
enter the final gear case.
T.
R.
4.Install:
● Oil filler bolt
23 Nm (2.3 m • kg, 17 ft • lb)
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CHANGING THE FINAL GEAR OIL
CHK
ADJ
CHANGING THE FINAL GEAR OIL
1.Place the machine on a level surface.
2.Remove:
● Final gear case protector 1
3.Place a receptacle under the final gear case.
4.Remove:
● Oil filler bolt
● Drain plug 1
5.Drain:
● Final gear oil
T.
R.
6.Install:
● Drain plug
23 Nm (2.3 m • kg, 17 ft • lb)
NOTE:
Check the gasket (drain plug). If it is damaged,
replace it with a new one.
7.Fill:
● Final gear case
Periodic oil change:
0.23 L (0.20 Imp qt, 0.24 US qt)
Total amount:
0.25 L (0.22 Imp qt, 0.26 US qt)
Recommended oil:
SAE 80 API “GL-4” Hypoid gear
oil
CAUTION:
Take care not to allow foreign material to
enter the final gear case.
T.
8.Check:
● Oil level
Refer to “CHECKING THE FINAL GEAR OIL
LEVEL”.
9.Install:
23 Nm (2.3 m • kg, 17 ft • lb)
● Oil filler bolt
● Final gear case protector
R.
T.
R.
16 Nm (1.6 m • kg, 11 ft • lb)
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CHECKING THE DIFFERENTIAL GEAR OIL/
CHANGING THE DIFFERENTIAL GEAR OIL
CHK
ADJ
CHECKING THE DIFFERENTIAL GEAR OIL
1.Place the machine on a level surface.
2.Remove:
● Oil filler bolt 1
3.Check:
● Oil level
Oil level should be up to the brim of hole.
Oil level low → Add oil to proper level.
Recommended oil:
SAE 80 API “GL-4” Hypoid gear
oil
Oil quantity (periodic oil change):
0.23 L (0.20 Imp qt, 0.24 US qt)
CAUTION:
Take care not allow foreign material to
enter the gear case.
T.
R.
4.Install:
● Oil filler bolt
23 Nm (2.3 m • kg, 17 ft • lb)
CHANGING THE DIFFERENTIAL GEAR OIL
1.Place the machine on a level surface.
2.Place a receptacle under the differential gear
case.
3.Remove:
● Oil filler bolt
● Drain plug 1
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CHANGING THE DIFFERENTIAL GEAR OIL/CHECKING
THE CONSTANT VELOCITY JOINT DUST BOOT
CHK
ADJ
T.
4.Drain:
● Differential gear oil
5.Install:
10 Nm (1.0 m • kg, 7.2 ft • lb)
● Drain plug
R.
NOTE:
Check the gasket (drain plug). If it is damaged,
replace it with new one.
6.Fill:
● Differential gear case
Periodic oil change:
0.23 L (0.20 Imp qt, 0.24 US qt)
Total amount:
0.28 L (0.25 Imp qt, 0.30 US qt)
Recommended oil:
SAE 80 API “GL-4” Hypoid gear
oil
NOTE:
If gear oil is filled to the brim of the oil filler
hole, oil may start leaking from the differential
gear case breather hose. Therefore, check the
quantity of the oil, not its level.
CAUTION:
Take care not to allow foreign material to
enter the differential gear case.
T.
R.
7.Install:
● Oil filler bolt
23 Nm (2.3 m • kg, 17 ft • lb)
CHECKING THE CONSTANT VELOCITY
JOINT DUST BOOT
1.Check:
● Dust boots 1
Damage → Replace.
Refer to “FRONT CONSTANT VELOCITY
JOINTS AND DIFFERENTIAL GEAR” in
CHAPTER 7.
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CHECKING THE STEERING SYSTEM/
ADJUSTING THE TOE-IN
CHK
ADJ
CHECKING THE STEERING SYSTEM
1.Place the machine on a level surface.
2.Check:
● Steering assembly bushings
Move the handlebar up and down, and/or
back and forth.
Excessive play → Replace the steering stem
bushings.
3.Check:
● Tie-rod ends
Turn the handlebar to the left and/or right
until it stops completely, then move the
handlebar from the left to the right slightly.
Tie-rod end has any vertical play → Replace
the tie-rod end(s).
4.Raise the front end of the machine so that
there is no weight on the front wheels.
5.Check:
● Ball joints and/or wheel bearings
Move the wheels laterally back and forth.
Excessive free play → Replace the front
arms (upper and lower) and/or wheel
bearings.
ADJUSTING THE TOE-IN
1.Place the machine on a level surface.
2.Measure:
● Toe-in
Out of specification → Adjust.
Toe-in:
0 ~ 10 mm (0 ~ 0.39 in)
(with tire touching the ground)
*****************************************************
Measurement steps:
NOTE:
Before measuring the toe-in, make sure that
the tire pressure is correct.
● Mark
both front tire tread centers.
● Face the handlebar straight ahead.
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ADJUSTING THE TOE-IN
CHK
ADJ
the width È between the marks.
● Rotate the front tires 180° until the marks are
exactly opposite one another.
● Measure the width É between the marks.
● Calculate the toe-in using the formula given
below.
● Measure
Toe-in = É – È
● If
the toe-in is incorrect, adjust it.
*****************************************************
3.Adjust:
● Toe-in
WARNING
●
●
Be sure that both tie-rods are turned the
same amount. If not, the machine will drift
right or left even though the handlebar is
positioned straight. This may lead to
mishandling and an accident.
After setting the toe-in to specification,
run the machine slowly for some distance
with both hands lightly holding the
handlebar and check that the handlebar
responds correctly. If not, turn either the
right or left tie-rod within the toe-in
specification.
t
*****************************************************
Adjustment steps:
● Mark both tie-rods ends.
This reference point will be needed during
adjustment.
● Loosen the locknuts (tie-rod end) 1 of both
tie-rods.
● The same number of turns should be given
to both the right and left tie-rods 2 until the
specified toe-in is obtained. This is to keep
the length of the rods the same.
● Tighten the rod end locknuts of both tie rods.
T.
Locknut (rod end):
40 Nm (4.0 m • kg, 29 ft • lb)
R.
NOTE:
Adjust the rod ends so that A and B are equal.
*****************************************************
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ADJUSTING THE FRONT SHOCK ABSORBER/ADJUSTING THE REAR
SHOCK ABSORBER/CHECKING THE TIRE
CHK
ADJ
ADJUSTING THE FRONT SHOCK
ABSORBER
WARNING
Always adjust both front shock absorber
spring preload to the same setting. Uneven
adjustment can cause poor handling and
loss of stability.
1.Adjust:
● Spring preload
Turn the adjuster 1 to increase or decrease
the spring preload.
Standard position: 2
Minimum (Soft) position: 1
Maximum (Hard) position: 5
ADJUSTING THE REAR SHOCK
ABSORBER
1.Adjust:
● Spring preload
Turn the adjuster 1 to increase or decrease
the spring preload.
NOTE:
The spring preload of the rear shock absorber
can be adjusted to suit the rider’s preference,
weight, and the riding conditions.
Standard position: 2
Minimum (Soft) position: 1
Maximum (Hard) position: 5
CHECKING THE TIRE
WARNING
This model is equipped with low pressure
tires. It is important that they be inflated
correctly and maintained at the proper
pressures.
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CHECKING THE TIRE
CHK
ADJ
TIRE CHARACTERISTICS
1)Tire
characteristics
influence
the
handling of ATV’s. The tires listed below
have been approved by Yamaha Motor
Co., Ltd. for this model. If other tire
combinations are used, they can
adversely affect your machine’s handling
characteristics and are therefore not
recommended.
●
Manufacturer
Size
Type
Front
CHENG SHIN AT25 × 8-12 M911Y
Rear
CHENG SHIN AT25 × 10-12 M912Y
● TIRE PRESSURE
1)Recommended tire pressure
Front 25 kPa (0.25 kg/cm2, 3.6 psi)
Rear 25 kPa (0.25 kg/cm2, 3.6 psi)
2)Tire pressure below the minimum
specification could cause the tire to
dislodge from the rim under severe riding
conditions.
The following are minimums:
Front 22 kPa (0.22 kg/cm2, 3.2 psi)
Rear 22 kPa (0.22 kg/cm2, 3.2 psi)
3)Use no more than
Front 250 kPa (2.5 kg/cm2, 36 psi)
Rear 250 kPa (2.5 kg/cm2, 36 psi)
when seating the tire beads. Higher
pressures may cause the tire to burst.
Inflate the tires slowly and carefully.
Fast inflation could cause the tire to
burst.
● MAXIMUM LOADING LIMIT
1)Vehicle load limit (total weight of cargo,
rider and accessories, and tongue
weight): 210 kg (463 lb)
2)Front carrier: 40 kg (88 lb)
3)Rear carrier: 80 kg (176 lb)
4)Storage box: 2.0 kg (4.4 lb)
5)Trailer hitch:
Pulling load (total weight of trailer and
cargo): 500 kg (1,102 lb)
Tongue weight (vertical weight on trailer
hitch point): 15 kg (33 lb)
Be extra careful of the machine balance
and stability when towing a trailer.
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CHECKING THE TIRE
CHK
ADJ
1.Measure:
● Tire pressure (cold tire pressure)
Out of specification → Adjust.
NOTE:
● The low-pressure tire gauge 1 is included
as standard equipment.
● If dust or the like is stuck to this gauge, it will
not provide the correct readings. Therefore,
take two measurements of the tire’s pressure
and use the second reading.
Cold tire
pressure
Front
Rear
Standard
25 kPa
(0.25 kg/cm2,
3.6 psi)
25 kPa
(0.25 kg/cm2,
3.6 psi)
Minimum
22 kPa
(0.22 kg/cm2,
3.2 psi)
22 kPa
(0.22 kg/cm2,
3.2 psi)
Maximum
28 kPa
(0.28 kg/cm2,
4.0 psi)
28 kPa
(0.28 kg/cm2,
4.0 psi)
WARNING
Uneven or improper tire pressure may
adversely affect the handling of this
machine and may cause loss of control.
● Maintain proper tire pressures.
● Set tire pressures when the tires are cold.
● Tire pressures must be equal in both front
tires and equal in both rear tires.
2.Check:
● Tire surfaces
Wear/damage → Replace.
Tire wear limit a:
Front and rear: 3.0 mm (0.12 in)
WARNING
It is dangerous to ride with a worn-out tire.
When tire wear is out of specification,
replace the tire immediately.
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CHECKING THE WHEEL/
CHECKING AND LUBRICATING THE CABLE
CHK
ADJ
CHECKING THE WHEEL
1.Check:
● Wheels 1
Damage/bends → Replace.
NOTE:
Always balance the wheel when a tire or wheel
has been changed or replaced.
WARNING
●
●
Never attempt even small repairs to the
wheel.
Ride conservatively after installing a tire
to allow it to seat itself properly on the
rim.
CHECKING AND LUBRICATING THE
CABLE
WARNING
A damaged cable sheath may cause
corrosion and interfere with the cable
movement. An unsafe condition may result
so replace a damaged cable as soon as
possible.
1.Check:
● Cable sheath
Damage → Replace.
2.Check:
● Cable operation
Unsmooth operation → Lubricate or replace.
Recommended lubricant:
Yamaha chain and cable lube or
Engine oil
NOTE:
Hold the cable end up and apply several drops
of lubricant to the cable.
3.Apply:
● Lithium-soap-based grease
(onto end of the cable)
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LUBRICATING THE LEVERS, PEDAL, ETC.
CHK
ADJ
LUBRICATING THE LEVERS, PEDAL, ETC.
1.Lubricate the pivoting parts.
Recommended lubricant:
Yamaha chain and cable lube or
Engine oil
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CHECKING THE BATTERY
CHK
ADJ
EB305000
ELECTRICAL
CHECKING THE BATTERY
NOTE:
Since the MF battery is a sealed type battery, it
is not possible to measure the specific gravity
of the electrolyte in order to check the charge
state of the battery. Therefore, the charge of
the battery has to be checked by measuring
the voltage at the battery terminals.
CAUTION:
CHARGING METHOD
● This is a sealed type battery. Never
remove the sealing caps. If the sealing
caps have been removed, the balance will
not
be
maintained
and
battery
performance will deteriorate.
time, charging current and
● Charging
charging voltage for the MF battery are
different from those of general type
batteries. The MF battery should be
charged as explained in “CHARGING
METHOD”. If the battery is overcharged,
the
electrolyte
level
will
drop
considerably. Therefore, take special care
when charging the battery.
WARNING
Battery electrolyte is dangerous; it
contains sulfuric acid which is poisonous
and highly caustic.
Always follow these preventive measures:
● Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye
injury.
● Wear protective eye gear when handling
or working near batteries.
Antidote (EXTERNAL):
● SKIN - Wash with water.
● EYES - Flush with water for 15 minutes
and get immediate medical attention.
Antidote (INTERNAL):
● Drink large quantities of water or milk
followed with milk of magnesia, beaten
egg or vegetable oil. Get immediate
medical attention.
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CHECKING THE BATTERY
CHK
ADJ
Batteries generate explosive hydrogen gas.
Always follow these preventive measures:
● Charge batteries in a well-ventilated area.
● Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,
lighted cigarettes, etc.)
NOT SMOKE when charging or
● DO
handling batteries.
KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.
1.Remove:
● Seat
● Battery holding bracket
● Battery lead cover
Refer to “SEAT, CARRIERS, FENDERS
AND FUEL TANK”.
2.Disconnect:
● Battery leads
CAUTION:
First disconnect the negative lead 1, then
disconnect the positive lead 2.
3.Remove:
● Battery
4.Check:
● Battery condition
*****************************************************
Battery condition checking steps:
● Connect a digital voltmeter to the battery
terminals.
Tester (+) lead → battery (+) terminal
Tester (–) lead → battery (–) terminal
NOTE:
The charge state of an MF battery can be
checked by measuring the open-circuit voltage
(i.e. the voltage when the positive terminal is
disconnected).
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CHECKING THE BATTERY
CHK
ADJ
Open-circuit
voltage
Charging time
12.8 V or higher
No charging is
necessary.
● Check
the condition of the battery using the
following charts.
Example:
● Open-circuit voltage = 12.0 V
● Charging time = 6.5 hours
● Charge condition of the battery = 20 ~ 30%
● Charging method for MF batteries
CAUTION:
●
●
●
●
●
●
If it is impossible to set the standard
charging current, be careful not to
overcharge.
When charging the battery, be sure to
remove it from the motorcycle. (If
charging has to be done with the battery
mounted on the motorcycle, be sure to
disconnect the wire at the negative
terminal.)
Never remove the sealing caps of an MF
battery.
Make sure that the charging clips are in
full contact with the terminal and that they
are not shorted together. (A corroded clip
on the charger may cause the battery to
generate heat in the contact area. A weak
clip spring may cause sparks.)
Before removing the clips from the
battery terminals, be sure to turn off the
charger’s power switch.
The open-circuit voltage variation for the
MF battery, after charging, is shown
below. As shown in the figure, the opencircuit voltage stabilizes about 30
minutes after charging has been
completed. Therefore, wait 30 minutes
after charging is completed before
measuring the open-circuit voltage.
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CHK
ADJ
CHECKING THE BATTERY
Charging method using a variable voltage charger
Measure the open-circuit
voltage prior to charging.
Charger
NOTE:
Leave the battery unused for
more than 30 minutes before
measuring its open-circuit voltage.
Ammeter
NOTE:
Connect a charger and
ammeter to the battery and
start charging.
YES
Is the amperage higher
than the standard charging
amperage written on the
battery?
Set the charging voltage to
16 ~ 17 V. (If the charging
voltage is lower, charging will
be insufficient, if it is higher,
the battery will be overcharged.)
NO
Adjust the charging voltage to
20 ~ 25 V.
Adjust the voltage to obtain the
standard charging amperage.
YES
Monitor the amperage for 3 ~
5 minutes. Is the standard
charging amperage exceeded?
NO
Set the timer to the charging
time determined by the opencircuit voltage.
Refer to “CHECKING THE
BATTERY”.
If the amperage does not
exceed the standard charging
amperage after 5 minutes,
replace the battery.
If the required charging time exceeds 5 hours, it is advisable to check the
charging amperage after 5 hours. If there is any change in the amperage,
readjust the voltage to obtain the standard charging amperage.
Leave the battery unused for more than 30 minutes before measuring its
open-circuit voltage.
12.8 V → Charging is complete.
12.0 ~ 12.7 V → Recharging is required.
Under 12.0 V → Replace the battery.
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CHK
ADJ
CHECKING THE BATTERY
Charging method using a constant voltage charger
Measure the open-circuit
voltage prior to charging.
NOTE:
Leave the battery unused for
more than 30 minutes before
measuring its open-circuit voltage.
Connect a charger and
ammeter to the battery and
start charging.
Is the amperage higher
than the standard charging
amperage written on the
battery?
YES
Charge the battery until the charging
voltage reaches 15 V.
NO
This type of battery charger cannot
charge an MF battery. A variable
voltage charger is recommended.
NOTE:
Set the charging time to a
maximum of 20 hours.
Charger
Leave the battery unused for more than 30
minutes before measuring its open-circuit
voltage.
12.8 V → Charging is complete.
12.0 ~ 12.7 V → Recharging is required.
Under 12.0 V → Replace the battery.
Ammeter
Voltmeter
CAUTION:
Constant amperage chargers are
not suitable for charging MF
batteries.
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CHECKING THE BATTERY/
CHECKING THE FUSE
CHK
ADJ
5.Check:
● Battery terminals
Dirty → Clean with a wire brush.
Poor connection → Correct.
NOTE:
After cleaning the terminals, apply a light coat
of grease.
6.Install:
● Battery
7.Connect:
● Battery leads
CAUTION:
First, connect the positive lead 1, then
connect the negative lead 2.
8.Install:
● Battery lead cover
● Battery holding bracket
● Seat
Refer to “SEAT, CARRIERS, FENDERS
AND FUEL TANK”.
CHECKING THE FUSE
CAUTION:
Always turn off the main switch when
checking or replacing a fuse. Otherwise, a
short circuit may occur.
1.Remove:
● Seat
Refer to “SEAT, CARRIERS, FENDERS
AND FUEL TANK”.
2.Check:
● Fuses
*****************************************************
Checking steps:
● Connect the pocket tester to the fuse and
check it for continuity.
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CHECKING THE FUSE
CHK
ADJ
NOTE:
Set the tester to the “Ω × 1” position.
Pocket tester:
P/N. YU-03112, 90890-03112
● If
the tester indicates ∞, replace the fuse.
*****************************************************
3.Replace:
● Blown fuse
*****************************************************
Replacement steps:
● Turn off the ignition.
● Install a new fuse of the proper amperage.
● Turn on switches to verify operation of the
related electrical devices.
● If the fuse immediately blows again, check
the electrical circuit.
*****************************************************
Description Current rating
Quantity
Main
30 A
1
Headlight
15 A
1
Ignition
10 A
1
Terminal
(Auxiliary
DC jack)
10 A
1
4WD (Fourwheel drive)
3A
1
Signaling
system fuse
10 A
1
Backup fuse
(odometer)
10 A
1
Reserve
30 A
1
Reserve
15 A
1
Reserve
10 A
1
Reserve
3A
1
WARNING
Never use a fuse with a rating other than
that specified. Never use other materials in
place of a fuse. An improper fuse may cause
extensive damage to the electrical system, a
malfunction of the lighting and ignition
systems and could possibly cause a fire.
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CHECKING THE FUSE/ADJUSTING THE HEADLIGHT
BEAM/CHANGING THE HEADLIGHT BULB
CHK
ADJ
4.Install:
● Seat
Refer to “SEAT, CARRIERS, FENDERS
AND FUEL TANK”.
ADJUSTING THE HEADLIGHT BEAM
1.Adjust:
● Headlight beam (vertically)
Turn the adjuster 1 in or out.
Turning in
Headlight beam raised.
Turning out Headlight beam lowered.
CHANGING THE HEADLIGHT BULB
1.Remove:
● Cover 1
2.Remove:
● Bulb holder 1
● Bulb
NOTE:
Turn the bulb holder counterclockwise and
remove the defective bulb.
WARNING
Keep flammable products and your hands
away from the bulb while it is on, since it
will be hot. Do not touch the bulb until it
cools down.
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CHANGING THE HEADLIGHT BULB
CHK
ADJ
3.Install:
New
● Bulb
Secure the new bulb with the headlight unit.
CAUTION:
Avoid touching the glass part of the bulb.
Keep it free from oil; otherwise, the
transparency of the glass, life of the bulb,
and luminous flux will be adversely
affected. If oil gets on the bulb, thoroughly
clean it with a cloth moistened with alcohol
or lacquer thinner.
4.Install:
● Bulb holder
● Cover
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ENGINE REMOVAL
ENG
ENGINE
ENGINE REMOVAL
AIR DUCTS, MUFFLER AND EXHAUST PIPE
Order
Job name/Part name
Removing the air ducts, muffler and
exhaust pipe
Engine oil
Q’ty
Drain.
Refer to “CHANGING THE ENGINE OIL”
in CHAPTER 3.
Refer to “SEAT, CARRIERS, FENDERS
AND FUEL TANK” in CHAPTER 3.
Drain.
Refer to “CHANGING THE COOLANT” in
CHAPTER 3.
Refer to “CARBURETOR” in CHAPTER 6.
Front and rear fender/footrest boards
Fuel tank/rubber cover
Coolant
1
2
3
4
5
Carburetor assembly
Air duct assembly 1
Muffler
Exhaust pipe stay 1
Exhaust pipe/gasket
Air duct assembly 2
Remarks
Remove the parts in the order below.
1
1
1
1/1
1
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ENGINE REMOVAL
ENG
4
Order
6
7
8
9
Job name/Part name
Final drive gear case breather hose
Cylinder head breather hose
Vacuum chamber breather hose
Air filter case
Q’ty
1
1
1
1
Remarks
For installation, reverse the removal
procedure.
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ENGINE REMOVAL
ENG
SELECT LEVER UNIT AND COOLANT RESERVOIR
Order
1
2
3
4
5
6
Job name/Part name
Removing the select lever unit and
coolant reservoir
Shift arm
Select lever shift rod
Select lever unit
Coolant reservoir breather hose
Coolant reservoir hose
Coolant reservoir
Q’ty
Remarks
Remove the parts in the order below.
1
1
1
1
1
1
For installation, reverse the removal
procedure.
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ENGINE REMOVAL
ENG
HOSES AND LEADS
Order
1
2
3
4
5
6
7
8
9
10
11
Job name/Part name
Removing the hoses and leads
Water pump inlet hose
Cylinder head breather hose
Spark plug lead
Thermo switch 1 lead
Starter motor lead
A.C. magneto lead coupler
Speed sensor lead coupler
Reverse switch lead
Neutral switch lead
High-range switch
Low-range switch
Engine ground lead
Q’ty
1
1
1
1
2
1
1
1
1
1
1
Remarks
Remove the parts in the order below.
Refer to “WATER PUMP” in CHAPTER 5.
Green/White
Sky blue
Blue/White
White/Red
For installation, reverse the removal
procedure.
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ENGINE REMOVAL
ENG
ENGINE MOUNTING BOLTS
Order
1
2
3
4
5
6
7
8
Job name/Part name
Q’ty
Remarks
Removing the engine mounting bolts
Remove the parts in the order below.
Rear wheels
Refer to “FRONT AND REAR WHEELS”
in CHAPTER 8.
Swingarm
Refer to “REAR SHOCK ABSORBER
AND SWINGARM” in CHAPTER 8.
Engine mounting bolt (rear-lower)/nut
1/1
Engine mounting bolt (rear-upper)/nut
1/1
CAUTION:
Engine bracket bolt (front-lower)
4
Install all of the bolts/nuts and then
Engine mounting bolt (font-lower)
2
tighten
them
to
full
torque
Engine bracket (front-lower)
2
specifications.
Engine bracket bolt (front-upper)
2
Engine mounting bolt (front-upper)/nut
1/1 Refer to “INSTALLING THE ENGINE”.
Engine bracket (front-upper)
1
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ENGINE REMOVAL
Order
9
Job name/Part name
Engine assembly
ENG
Q’ty
Remarks
1 NOTE:
Remove the engine assembly from the
left side of the machine.
For installation, reverse the removal
procedure.
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ENGINE REMOVAL
ENG
INSTALLING THE ENGINE
1.Install:
● Engine bracket (front upper) 1
● Engine mount bolt (front upper)/nut 2
● Engine bracket bolt (front upper) 3
● Engine bracket (front lower) 4
● Engine mount bolt (front lower) 5
● Engine bracket bolt (front lower) 6
● Engine mount bolt (rear upper)/nut 7
● Engine mount bolt (rear lower)/nut 8
NOTE:
Do not fully tighten the bolts and nuts.
2.Tighten:
● Engine mount bolt (front upper)/nut 2
T.
R.
●
Engine bracket bolt (front upper) 3
T.
R.
●
R.
R.
33 Nm (3.3 m • kg, 24 ft • lb)
Engine mount bolt (rear upper)/nut 7
T.
R.
●
42 Nm (4.2 m • kg, 30 ft • lb)
Engine bracket bolt (front lower) 6
T.
●
33 Nm (3.3 m • kg, 24 ft • lb)
Engine mount bolt (front lower) 5
T.
●
42 Nm (4.2 m • kg, 30 ft • lb)
56 Nm (5.6 m • kg, 40 ft • lb)
Engine mount bolt (rear lower)/nut 8
T.
R.
56 Nm (5.6 m • kg, 40 ft • lb)
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CYLINDER HEAD
ENG
CYLINDER HEAD
Order
1
2
3
4
Job name/Part name
Removing the cylinder head
Fuel tank/rubber cover
Front fender/air filter case
Air duct assembly 1
Exhaust pipe/muffler
Carburetor assembly
Recoil starter/timing plug
Thermostat
Spark plug lead
Spark plug
Engine mount bolt (upper)/nut
Engine bracket (upper)
Q’ty
Remarks
Remove the parts in the order below.
Refer to “SEAT, CARRIERS, FENDERS
AND FUEL TANK” in CHAPTER 3.
Refer to “ENGINE REMOVAL”.
Refer to “CARBURETOR” in CHAPTER 6.
Refer to “ADJUSTING THE VALVE
CLEARANCE” in CHAPTER 3.
Refer to “THERMOSTAT” in CHAPTER 5.
1
1
1/1
1
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CYLINDER HEAD
Order
5
6
7
8
9
10
11
12
13
14
15
Job name/Part name
Cylinder head breather hose
Camshaft sprocket cover/O-ring
Tappet cover/O-ring
Thermo switch 1 lead
Timing chain tensioner cap bolt
Timing chain tensioner/gasket
Camshaft sprocket
Cylinder head
Cylinder head gasket
Dowel pin
O-ring
ENG
Q’ty
Remarks
1
1/1
2/2
1
Disconnect.
1
1/1 Refer to “REMOVING/INSTALLING THE
CYLINDER HEAD”.
1
1
1
2
1
For installation, reverse the removal
procedure.
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CYLINDER HEAD
ENG
REMOVING THE CYLINDER HEAD
1.Align:
● “T” mark
(with stationary pointer)
*****************************************************
Checking steps:
● Turn the crankshaft counterclockwise with a
wrench.
● Align the “T” mark 1 on the rotor with the
stationary pointer 2 on the crankcase cover.
When the “T” mark is aligned with the
stationary pointer, the piston is at the Top
Dead Center (T.D.C.).
NOTE:
● When the piston is at the Top Dead Center
(T.D.C.) on the compression stroke, there
should be clearance between the valve stem
tips and their respective rocker arm adjusting
screws.
● If there is no clearance, rotate the crankshaft
counterclockwise one turn.
*****************************************************
2.Loosen:
● Camshaft sprocket bolt 1
NOTE:
Use the rotor holding tool 2 to hold the starter
pulley.
Rotor holding tool:
P/N. YU-01235, 90890-01235
3.Loosen:
● Timing chain tensioner cap bolt
4.Remove:
● Timing chain tensioner
● Camshaft sprocket
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CYLINDER HEAD
ENG
NOTE:
● Fasten a safety wire to the timing chain to
prevent it from falling into the crankcase.
● When removing the camshaft sprocket, it is
not necessary to separate the timing chain.
5.Remove:
● Cylinder head
NOTE:
● Loosen the 6 mm bolts first.
● Working in a crisscross pattern, loosen each
10 mm bolt 1/4 of a turn. After all the bolts
are loosened, remove them.
CHECKING THE TAPPET COVER
1.Check:
● Tappet covers 1
● O-rings 2
Cracks/damage → Replace.
CHECKING THE TIMING CHAIN
TENSIONER
1.Check:
● One-way cam operation (tensioner)
Unsmooth operation → Replace.
CHECKING THE CAMSHAFT SPROCKET
1.Check:
● Camshaft sprocket
Wear/damage → Replace the camshaft
sprocket and timing chain as a set.
a 1/4 of a tooth
b Correct
1 Timing chain
2 Sprocket
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CYLINDER HEAD
ENG
CHECKING THE CYLINDER HEAD
1.Eliminate:
● Carbon
deposits (from the combustion
chambers)
Use a rounded scraper.
NOTE:
Do not use a sharp instrument to avoid
damaging or scratching:
● Spark plug threads
● Valve seats
2.Check:
● Cylinder head
Scratches/damage → Replace.
● Cylinder head water jacket
Mineral deposits/rust → Eliminate.
3.Measure:
● Cylinder head warpage
Out of specification → Resurface.
Cylinder head warpage:
Less than 0.03 mm (0.0012 in)
*****************************************************
Measurement and resurfacing steps:
● Place a straightedge and a feeler gauge
across the cylinder head.
● Use a feeler gauge to measure the warpage.
● If the warpage is out of specification,
resurface the cylinder head.
● Place a 400 ~ 600 grit wet sandpaper on the
surface plate, and resurface the head using
a figure-eight sanding pattern.
NOTE:
To ensure an even surface rotate the cylinder
head several times.
*****************************************************
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CYLINDER HEAD
ENG
T.
INSTALLING THE CYLINDER HEAD
1.Install:
● Cylinder head
40 Nm (4.0 m • kg, 29 ft • lb)
● Bolt (M10)
10 Nm (1.0 m • kg, 7.2 ft • lb)
● Bolt (M6)
R.
T.
R.
NOTE:
● Lubricate the washer with engine oil.
● Tighten the bolts (M10) in two stages and a
crisscross pattern.
2.Install:
● Camshaft sprocket
*****************************************************
Installing steps:
● Rotate the camshaft to align the camshaft
pin 1 with the cylinder head match mark 2.
● Turn the crankshaft counterclockwise with a
wrench.
● Align the “T” mark 3 on the rotor with the
stationary pointer 4 on the crankcase cover.
When the “T” mark is aligned with the
stationary pointer, the piston is at the Top
Dead Center (T.D.C.).
CAUTION:
Do not turn the crankshaft during the
camshaft sprocket installation.
● Place
the timing chain onto the camshaft
sprocket.
● Install the camshaft sprocket onto the
camshaft and finger tighten the sprocket bolt.
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CYLINDER HEAD
ENG
NOTE:
Be sure the “I” mark 5 on the camshaft
sprocket is aligned with the match mark 2 on
the cylinder head.
● Force
the
camshaft
clockwise
and
counterclockwise to remove timing chain slack.
● Insert a screwdriver into the timing chain
tensioner hole and push the timing chain
guide inward.
● While pushing the timing chain guide, be
sure that the camshaft sprocket “I” mark 5 is
aligned with the cylinder head match mark
2.
● If the marks are aligned, tighten the camshaft
sprocket bolt. If the marks are not aligned,
change the meshing position of the camshaft
sprocket and timing chain.
*****************************************************
3.Install:
● Timing chain tensioner
*****************************************************
Installation steps:
● Remove the tensioner cap bolt 1, washer 2
and spring 3.
● Release the timing chain tensioner one-way
cam 4 and push the tensioner rod 5 all the
way in.
● Install the tensioner 6 with a new gasket into
the cylinder.
T.
R.
Bolts (timing chain tensioner):
11 Nm (1.1 m • kg, 8.0 ft • lb)
WARNING
Always use a new gasket.
● Install
the spring, washer and cap bolt.
T.
R.
Cap bolt (timing chain tensioner):
23 Nm (2.3 m • kg, 17 ft • lb)
*****************************************************
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CYLINDER HEAD
ENG
4.Tighten:
● Camshaft sprocket bolt 1
T.
R.
60 Nm (6.0 m • kg, 43 ft • lb)
NOTE:
Use the rotor holding tool 2 to hold the starter
pulley.
Rotor holding tool:
P/N. YU-01235, 90890-01235
5.Check:
● Camshaft sprocket “I” mark
● Rotor “T” mark
Out of alignment → Adjust.
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CAMSHAFT, ROCKER ARMS AND VALVES
ENG
CAMSHAFT, ROCKER ARMS AND VALVES
Order
1
2
3
4
5
6
7
8
9
10
11
Job name/Part name
Removing the camshaft, rocker
arms and valves
Intake manifold/O-ring
Thermo switch
Oil check bolt
Lock washer/bearing retainer
Camshaft
Rocker arm shaft/O-ring
Rocker arm
Locknut/valve adjuster
Valve cotter
Valve spring retainer
Valve spring (outer)
Q’ty
1/1
1
1
1/1
1
2/2
2
2/2
4
2
2
Remarks
Remove the parts in the order below.
Refer to “REMOVING/INSTALLING THE
CAMSHAFT AND ROCKER ARM”.
Refer to “REMOVING/INSTALLING THE
VALVE AND VALVE SPRING”.
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CAMSHAFT, ROCKER ARMS AND VALVES
Order
12
13
14
15
16
Job name/Part name
Valve spring (inner)
Valve (intake)
Valve (exhaust)
Valve stem seal
Valve spring seat
Q’ty
2
1
1
2
2
ENG
Remarks
Refer to “REMOVING/INSTALLING THE
VALVE AND VALVE SPRING”.
For installation, reverse the removal
procedure.
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CAMSHAFT, ROCKER ARMS AND VALVES
ENG
REMOVING THE CAMSHAFT AND ROCKER
ARM
1.Remove:
● Camshaft 1
NOTE:
Screw in a M10 bolt 2 into the thread hole on
the camshaft, and pull out the camshaft.
2.Remove:
● Rocker arm shafts (intake and exhaust) 1
● Rocker arms 2
NOTE:
Use a slide hammer 3 to remove the rocker
arm shafts.
Slide hammer set:
P/N. YU-01083-A
Slide hammer bolt (M6):
P/N. 90890-01083
Weight:
P/N. 90890-01084
REMOVING THE VALVE AND VALVE
SPRING
1.Check:
● Valve sealing
Leakage at the valve seat → Check the valve
face, valve seat and valve seat width.
Refer to “CHECKING THE VALVE AND
VALVE SPRING”.
*****************************************************
Checking steps:
● Pour a clean solvent 1 into the intake and
exhaust ports.
● Check that the valve seals properly.
There should be no leakage at the valve seat
2.
*****************************************************
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CAMSHAFT, ROCKER ARMS AND VALVES
ENG
2.Remove:
● Valve cotters
NOTE:
Attach a valve spring compressor 1 between
the valve spring retainer and the cylinder head
to remove the valve cotters.
Valve spring compressor:
P/N. YM-04019, 90890-04019
CHECKING THE CAMSHAFT
1.Check:
● Cam lobes
Pitting/scratches/blue discoloration →
Replace.
2.Measure:
● Cam lobes length a and b.
Out of specification → Replace.
Camshaft lobe limit:
Intake:
a 40.52 mm (1.595 in)
b 32.08 mm (1.263 in)
Exhaust:
a 40.52 mm (1.595 in)
b 32.08 mm (1.263 in)
CHECKING THE ROCKER ARM AND
CAMSHAFT
1.Check:
● Camshaft lobe contact surface 1
● Valve adjusters 2
Blue discoloration/pitting/scratches →
Replace.
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CAMSHAFT, ROCKER ARMS AND VALVES
ENG
2.Check:
● Rocker arms
● Rocker arm shafts
Damage/wear → Replace.
*****************************************************
Checking steps:
● Check the two contact areas on the rocker
arms for signs of abnormal wear.
1) Rocker arm shaft hole
2) Camshaft lobe contact surface
Excessive wear → Replace.
● Check the surface of the rocker arm shafts.
Blue discoloration/pitting/scratches →
Replace/check lubrication.
● Measure the inside diameter a of the rocker
arm holes.
Out of specification → Replace.
Rocker arm inside diameter:
12.000 ~ 12.018 mm
(0.4724 ~ 0.4731 in)
the outside diameter b of the
rocker arm shafts.
Out of specification → Replace.
● Measure
Rocker arm outside diameter:
11.981 ~ 11.991 mm
(0.4717 ~ 0.4721 in)
● Calculate
the clearance by subtracting the
rocker arm shaft outside diameter from the
rocker arm inside diameter.
Clearance greater than 0.08 mm (0.003 in)
→ Replace the defective part(s).
Rocker arm to shaft standard
clearance:
0.009 ~ 0.037 mm
(0.0004 ~ 0.0015 in)
*****************************************************
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CAMSHAFT, ROCKER ARMS AND VALVES
ENG
CHECKING THE VALVE AND VALVE
SPRING
1.Measure:
● Stem-to-guide clearance
Stem-to-guide clearance =
valve guide inside diameter a –
valve stem diameter b
Out of specification → Replace the valve
guide.
Clearance (stem to guide):
Intake:
0.010 ~ 0.037 mm
(0.0004 ~ 0.0015 in)
<Limit>: 0.080 mm (0.0031 in)
Exhaust:
0.030 ~ 0.057 mm
(0.0012 ~ 0.0022 in)
<Limit>: 0.100 mm (0.0039 in)
2.Replace:
● Valve guide
*****************************************************
Replacement steps:
NOTE:
To ease guide removal, installation and to
maintain correct fit, heat the cylinder head to
100 °C (212 °F) in an oven.
● Remove
the valve guide using a valve guide
remover 1.
● Install the new valve guide using a valve
guide remover 1 and valve guide installer
2.
● After installing the valve guide, bore the
valve guide using a valve guide reamer 3 to
obtain proper stem-to-guide clearance.
Valve guide remover (7.0 mm):
P/N. YM-01225-A, 90890-01225
Valve guide installer (7.0 mm):
P/N. YM-04017, 90890-04017
Valve guide reamer (7.0 mm):
P/N. YM-01227, 90890-01227
NOTE:
After replacing the valve guide reface the valve
seat.
*****************************************************
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CAMSHAFT, ROCKER ARMS AND VALVES
ENG
3.Check:
● Valve face
Pitting/wear → Grind the face.
● Valve stem end
Mushroom shape or diameter larger than the
body of the stem → Replace.
4.Measure:
● Margin thickness a
Out of specification → Replace.
Margin thickness:
Intake:
1.0 ~ 1.4 mm (0.0394 ~ 0.0551 in)
Exhaust:
0.8 ~ 1.2 mm (0.0315 ~ 0.0472 in)
5.Measure:
● Runout (valve stem)
Out of specification → Replace.
Runout limit:
0.01 mm (0.0004 in)
NOTE:
● When installing a new valve always replace
the guide.
● If the valve is removed or replaced always
replace the oil seal.
6.Eliminate:
● Carbon deposits
(from the valve face and valve seat)
7.Check:
● Valve seats
Pitting/wear → Reface the valve seat.
8.Measure:
● Valve seat width a
Out of specification → Reface the valve seat.
Valve seat width:
Intake:
1.2 ~ 1.4 mm (0.0472 ~ 0.0551 in)
<Limit>: 1.6 mm (0.0630 in)
Exhaust:
1.2 ~ 1.4 mm (0.0472 ~ 0.0551 in)
<Limit>: 1.6 mm (0.0630 in)
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CAMSHAFT, ROCKER ARMS AND VALVES
ENG
*****************************************************
Measurement steps:
● Apply Mechanic’s blueing dye (Dykem) b to
the valve face.
● Install the valve into the cylinder head.
● Press the valve through the valve guide and
onto the valve seat to make a clear pattern.
● Measure the valve seat width. Where the
valve seat and valve face made contact,
blueing will have been removed.
● If the valve seat is too wide, too narrow, or
the seat is not centered, the valve seat must
be refaced.
*****************************************************
9.Lap:
● Valve face
● Valve seat
NOTE:
After refacing the valve seat or replacing the
valve and valve guide, the valve seat and
valve face should be lapped.
*****************************************************
Lapping steps:
● Apply a coarse lapping compound to the
valve face.
CAUTION:
Do not let the compound enter the gap
between the valve stem and the guide.
● Apply
molybdenum disulfide oil to the valve
stem.
● Install the valve into the cylinder head.
● Turn the valve until the valve face and valve
seat are evenly polished, then clean off all of
the compound.
NOTE:
For best lapping results, lightly tap the valve
seat while rotating the valve back and forth
between your hands.
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CAMSHAFT, ROCKER ARMS AND VALVES
ENG
● Apply
a fine lapping compound to the valve
face and repeat the above steps.
NOTE:
After every lapping operation be sure to clean
off all of the compound from the valve face and
valve seat.
● Apply
Mechanic’s blueing dye (Dykem) to the
valve face.
● Install the valve into the cylinder head.
● Press the valve through the valve guide and
onto the valve seat to make a clear pattern.
● Measure the valve seat width again. If the
valve seat width is out of specification, reface
and relap the valve seat.
*****************************************************
10.Measure:
● Valve spring free length a
Out of specification → Replace.
Free length (valve spring):
Inner:
39.9 mm (1.57 in)
<Limit>: 37.9 mm (1.49 in)
Outer:
43.27 mm (1.70 in)
<Limit>: 41.27 mm (1.62 in)
11.Measure:
● Compressed spring force a
Out of specification → Replace.
b Installed length
Compressed spring force:
Inner:
104.9 ~ 120.6 N at 33.6 mm
(10.70 ~ 12.30 kg,
23.58 ~ 27.11 lb at 1.32 in)
Outer:
235.4 ~ 251.1 N at 36.6 mm
(24.00 ~ 25.60 kg,
52.91 ~ 56.45 lb at 1.44 in)
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CAMSHAFT, ROCKER ARMS AND VALVES
ENG
12.Measure:
● Spring tilt a
Out of specification → Replace.
Spring tilt limit:
Inner:
2.5°/1.6 mm (0.06 in)
Outer:
2.5°/1.6 mm (0.06 in)
INSTALLING THE VALVE AND VALVE
SPRING
1.Apply:
● Molybdenum disulfide oil
(onto the valve stem and valve stem seal)
2.Install:
● Valve spring seats
● Valve stem seals
New
● Valves
● Valve springs (inner and outer)
● Valve spring retainers
NOTE:
Install the valve springs with the larger pitch a
facing upwards.
b Smaller pitch
3.Install:
● Valve cotters
NOTE:
Install the valve cotters while compressing the
valve spring with the valve spring compressor
1.
Valve spring compressor:
P/N. YM-04019, 90890-04019
4.To secure the valve cotters onto the valve
stem, lightly tap the valve tip with a piece of
wood.
CAUTION:
Hitting the valve tip with excessive force
could damage the valve.
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CAMSHAFT, ROCKER ARMS AND VALVES
ENG
INSTALLING THE CAMSHAFT AND
ROCKER ARM
1.Apply:
● Engine oil
(onto the rocker arm shafts)
2.Install:
● Rocker arms 1
● Rocker arm shafts (intake and exhaust) 2
NOTE:
Use a slide hammer bolt 3 to install the rocker
arm shaft.
3.Install:
● Camshaft 1
NOTE:
Install the camshaft pin hole a facing up.
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CYLINDER AND PISTON
ENG
CYLINDER AND PISTON
Order
1
2
3
4
5
6
7
8
9
10
Job name/Part name
Removing the cylinder and piston
Cylinder head
Water pump outlet hose/pipe
Coolant inlet joint
Timing chain guide (exhaust)
Cylinder/O-ring
Cylinder gasket
Dowel pin
O-ring
Piston pin clip
Piston pin
Piston
Piston ring set
Q’ty
1
1
1/1
1
2
1
2
1
1
1
Remarks
Remove the parts in the order below.
Refer to “CYLINDER HEAD”.
Refer to “WATER PUMP” in CHAPTER 5.
Refer to “INSTALLING THE CYLINDER”.
Refer to “REMOVING/INSTALLING THE
PISTON”.
For installation, reverse the removal
procedure.
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CYLINDER AND PISTON
ENG
REMOVING THE PISTON
1.Remove:
● Piston pin clips 1
● Piston pin 2
● Piston 3
NOTE:
Before removing piston pin, deburr the clip
groove and pin hole area. If the piston pin
groove is deburred and the piston pin is still
difficult to remove, use the piston pin puller 4.
Piston pin puller:
P/N. YU-01304, 90890-01304
CAUTION:
Do not use a hammer to drive the piston
pin out.
2.Remove:
● Piston rings
NOTE:
Spread the end gaps apart while at the same
time lifting the piston ring over the top of the
piston crown.
CHECKING THE TIMING CHAIN GUIDE
1.Check:
● Exhaust side timing chain guide
Wear/damage → Replace.
CHECKING THE CYLINDER AND PISTON
1.Check:
● Cylinder and piston walls
Vertical scratches → Rebore or replace the
cylinder and the piston.
● Cylinder water jacket
Mineral deposits/rust → Eliminate.
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CYLINDER AND PISTON
ENG
2.Measure:
● Piston-to-cylinder clearance
*****************************************************
Measurement steps:
1st step:
● Measure the cylinder bore “C” with the
cylinder bore gauge.
NOTE:
Measure cylinder bore “C” by taking side-toside and front-to-back measurements of the
cylinder. Then, find the average of the
measurements.
Cylinder bore “C”
84.500 ~ 84.510 mm
(3.3268 ~ 3.3272 in)
Max. taper “T”
0.05 mm
(0.0016 in)
Out of round “R”
0.01 mm
(0.0004 in)
“C”= maximum of D1 ~ D6
“T”= maximum of D1, or D2 –
maximum of D5 or D6
“R”= maximum of D1, D3 or D5 –
minimum of D2, D4 or D6
● If
out of specification, replace the cylinder,
and the piston and piston rings as a set.
2nd step:
● Measure piston skirt diameter “P” with a
micrometer.
a 5.0 mm (0.20 in) from the piston bottom edge
Piston skirt diameter “P”
Standard
84.445 ~ 84.460 mm
(3.3246 ~ 3.3252)
● If
out of specification, replace the piston and
piston rings as a set.
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CYLINDER AND PISTON
ENG
3rd step:
● Find the piston-to-cylinder clearance with the
following formula.
Piston-to-cylinder clearance =
Cylinder bore “C” –
Piston skirt diameter “P”
Piston-to-cylinder clearance:
0.040 ~ 0.065 mm
(0.0016 ~ 0.0026 in)
<Limit>: 0.150 mm (0.0059 in)
● If
out of specification, rebore or replace the
cylinder, and replace the piston and piston
rings as a set.
*****************************************************
CHECKING THE PISTON RING
1.Measure:
● Ring side clearance
Use a feeler gauge.
Out of specification → Replace the piston
and rings as a set.
NOTE:
Clean carbon from the piston ring grooves and
rings before measuring the side clearance.
Side clearance
Standard
Limit
Top
ring
0.12 mm
0.03 ~ 0.07 mm
(0.0012 ~ 0.0028 in) (0.0047 in)
2nd
ring
0.12 mm
0.02 ~ 0.06 mm
(0.0047
in)
(0.0008 ~ 0.0024 in)
2.Position:
● Piston ring
(in cylinder)
NOTE:
Insert a ring into the cylinder and push it
approximately 40 mm (1.6 in) into the cylinder.
Push the ring with the piston crown so that the
ring will be at a right angle to the cylinder bore.
a 40 mm (1.6 in)
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CYLINDER AND PISTON
ENG
3.Measure:
● Ring end gap
Out of specification → Replace.
NOTE:
You cannot measure the end gap on the
expander spacer of the oil control ring. If the oil
control ring rails show excessive gap, replace
all three rings.
End gap
Standard
Limit
Top
ring
0.20 ~ 0.40 mm
0.65 mm
(0.0079 ~ 0.0157 in) (0.0256 in)
2nd
ring
0.40 ~ 0.60 mm
0.95 mm
(0.0157 ~ 0.0236 in) (0.0374 in)
Oil
ring
0.2 ~ 0.7 mm
(0.0079 ~ 0.0276 in)
—
CHECKING THE PISTON PIN
1.Check:
● Piston pin
Blue discoloration/grooves → Replace, then
check the lubrication system.
2.Measure:
● Piston pin-to-piston clearance
*****************************************************
Measurement steps:
● Measure the piston pin outside diameter a.
If out of specification, replace the piston pin.
Outside diameter (piston pin):
19.991 ~ 20.000 mm
(0.7870 ~ 0.7874 in)
<Limit>: 19.971 mm (0.7863 in)
● Measure
the piston inside diameter b.
Piston pin bore inside diameter:
20.004 ~ 20.015 mm
(0.7876 ~ 0.7880 in)
<Limit>: 20.045 mm (0.7892 in)
● Calculate
the piston pin-to-piston clearance
with the following formula.
Piston pin-to-piston clearance =
Bore size (piston pin) b –
Outside diameter (piston pin) a
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CYLINDER AND PISTON
● If
ENG
out of specification, replace the piston.
Piston pin-to-piston clearance:
0.004 ~ 0.024 mm
(0.00016 ~ 0.00094 in)
<Limit>: 0.074 mm (0.0029 in)
*****************************************************
INSTALLING THE PISTON
1.Install:
● Piston rings
(onto the piston)
NOTE:
● Be sure to install the piston rings so that the
manufacturer’s marks or numbers are
located on the upper side of the rings.
● Lubricate the piston and piston rings liberally
with engine oil.
2.Position:
● Top ring
● 2nd ring
● Oil ring
Offset the piston ring end gaps as shown.
a Top ring end
b Oil ring end (upper)
c Oil ring end (lower)
d 2nd ring end
3.Install:
● Piston 1
● Piston pin 2
● Piston pin clips 3 New
NOTE:
● Apply engine oil onto the piston pin, piston
ring and piston.
● Be sure that the arrow mark a on the piston
points to the exhaust side of the engine.
● Before installing the piston pin clip, cover the
crankcase with a clean rag to prevent the
piston pin clip from falling into the crankcase.
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CYLINDER AND PISTON
ENG
4.Lubricate:
● Piston
● Piston rings
● Cylinder
NOTE:
Apply a liberal coating of engine oil.
INSTALLING THE CYLINDER
1.Install:
● Cylinder
NOTE:
Install the cylinder with one hand while
compressing the piston rings with the other
hand.
CAUTION:
●
●
Be careful not to damage the timing chain
damper during installation.
Pass the timing chain through the timing
chain cavity.
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RECOIL STARTER AND A.C. MAGNETO
ENG
RECOIL STARTER AND A.C. MAGNETO
Order
Job name/Part name
Removing the CDI magneto
Engine oil
Q’ty
Seat and side panels
Left footrest board
1
2
3
4
5
6
Recoil starter assembly
A.C. magneto coupler
Starter pulley
Crankcase cover (left)/gasket
Dowel pin
Lead holder
1
2
1
1/1
2
1
Remarks
Remove the parts in the order below.
Drain.
Refer to “CHANGING THE ENGINE OIL”
in CHAPTER 3.
Refer to “SEAT AND SIDE PANELS” in
CHAPTER 3.
Refer to “FOOTREST BOARDS” in
CHAPTER 3.
Disconnect.
Refer to “REMOVING/INSTALLING THE
A.C. MAGNETO”.
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RECOIL STARTER AND A.C. MAGNETO
Order
7
8
9
10
11
12
13
14
15
Job name/Part name
Pickup coil
Stator assembly
Rotor
Starter wheel gear
Woodruff key
Washer
Starter idle gear shaft
Washer/bearing
Starter idle gear
Q’ty
1
1
1
1
1
1
1
1/1
1
ENG
Remarks
Refer to “REMOVING/INSTALLING THE
A.C. MAGNETO”.
For installation, reverse the removal
procedure.
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RECOIL STARTER AND A.C. MAGNETO
Order
1
2
3
4
5
6
7
8
9
Job name/Part name
Disassembling the recoil starter
Cap
Starter handle
Friction plate
Pawl spring
Drive pawl
Spring
Sheave drum
Rope
Coil spring
Q’ty
1
1
1
1
1
1
1
1
1
ENG
Remarks
Remove the parts in the order below.
Refer to “DISASSEMBLING/
ASSEMBLING THE RECOIL
STARTER”.
For assembly, reverse the disassembly
procedure.
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RECOIL STARTER AND A.C. MAGNETO
ENG
REMOVING THE A.C. MAGNETO
1.Remove:
● Starter pulley 1
NOTE:
Use the rotor holding tool 2 to hold the starter
pulley.
Rotor holding tool:
P/N. YU-01235, 90890-01235
2.Remove:
● Crankcase cover (left)
● Gasket
● Dowel pins
NOTE:
Working in a crisscross pattern, loosen each
bolt 1/4 of a turn. Remove them after all of
them are loosened.
3.Remove:
● Rotor 1
NOTE:
Use the flywheel puller 2.
Flywheel puller:
P/N. YM-01404, 90890-01404
DISASSEMBLING THE RECOIL STARTER
1.Remove:
● Cap 1
● Starter handle 2
NOTE:
Before untying the knot 3 above the starter
handle, make a knot 4 in the rope so that the
rope is not pulled into the case.
CHECKING THE CDI MAGNETO
1.Check:
● Stator assembly
● Pickup coil
Damage → Replace.
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RECOIL STARTER AND A.C. MAGNETO
ENG
CHECKING THE STARTER CLUTCH
1.Check:
● Starter one-way clutch 1
Cracks/damage → Replace.
● Bolts 2 (starter clutch)
Loose → Replace with a new one, and clinch
the end of the bolt.
NOTE:
The arrow mark on the starter clutch must face
inward, away from the rotor.
T.
R.
Bolts (starter clutch):
30 Nm (3.0 m • kg, 22 ft • lb)
LOCTITE®
*****************************************************
Checking steps:
● Install the starter wheel gear to the starter
clutch, and hold the starter clutch.
● When turning the starter wheel gear
counterclockwise È, the starter clutch and
the wheel gear should be engaged.
If not, the starter clutch is faulty. Replace it.
● When turning the starter wheel gear
clockwise É, the starter wheel gear should
turn freely.
If not, the starter clutch is faulty. Replace it.
*****************************************************
2.Check:
● Gear teeth (starter idle) 1
● Gear teeth (starter wheel) 2
Burrs/chips/roughness/wear → Replace.
3.Check:
● Starter wheel gear
(contacting surface)
Damage/pitting/wear → Replace.
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RECOIL STARTER AND A.C. MAGNETO
ENG
CHECKING THE STARTER PULLEY
1.Check:
● Starter pulley
Cracks/pitting → Deburr or replace.
CHECKING THE RECOIL STARTER
1.Check:
● Rope 1
● Sheave drum 2
● Drive pawl 3
Wear/damage → Replace.
● Coil spring 4
● Pawl spring 5
● Spring 6
Fatigue → Replace.
ASSEMBLING THE RECOIL STARTER
1.Install:
● Sheave drum 1
● Rope 2
● Pawl spring 3
● Drive pawl 4
NOTE:
Wind the rope 4-1/2 turns clockwise around
the sheave drum. Then insert the rope into the
drum slit a.
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RECOIL STARTER AND A.C. MAGNETO
ENG
2.Install:
● Starter spring 1
● Sheave drum assembly 2
NOTE:
● Mesh the spring hook 3 with the case slit,
then wind the spring clockwise into the case
from the larger to smaller diameter.
● Mesh the sheave drum hook 4 with the
spring hook 5.
3.Install:
● Spring 1
● Friction plate 2
● Nut
NOTE:
Insert the spring hooks into the pawl side
holes.
4.Turn the sheave drum 3-turn clockwise to
give preload to the spring.
5.Install:
● Starter handle 1
● Cap 2
NOTE:
● Pass the rope through the case hole and
make a knot 3 on the rope so that the rope
is not pulled into the case.
● Untie the knot 3 after making a knot 4
above the handle.
INSTALLING THE A.C. MAGNETO
1.Apply:
®
● Sealant (Quick Gasket ) 1
(into the slit)
Sealant (Quick Gasket®):
P/N. ACC-11001-05-01
Yamaha bond No. 1215:
P/N. 90890-85505
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RECOIL STARTER AND A.C. MAGNETO
ENG
2.Install:
● Woodruff key
● Rotor
NOTE:
● Before installing the rotor, clean the outside
of the crankshaft and the inside of the rotor.
● After installing the rotor, check that the rotor
rotates smoothly. If not, reinstall the key and
rotor.
3.Install:
● Dowel pins
● Gasket New
● Crankcase cover (left)
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • lb)
NOTE:
● When installing the crankcase cover (left),
use a long rod to hold the rotor in position
from the outside. This will make assembly
easier. Be careful not to damage the oil seal.
● Tighten
the bolts in stages, using a
crisscross pattern.
4.Install:
● Starter pulley 1
T.
R.
50 Nm (5.0 m • kg, 36 ft • lb)
NOTE:
Use a rotor holding tool 2 to hold the starter
pulley.
Rotor holding tool:
P/N. YU-01235, 90890-01235
NOTE:
Before installing the starter pulley, do not
forget to install the O-ring.
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PRIMARY AND SECONDARY SHEAVES
ENG
PRIMARY AND SECONDARY SHEAVES
Order
1
2
3
4
5
6
7
Job name/Part name
Removing the primary and
secondary sheave
Front fender
Rear fender
Right footrest board
Exhaust pipe bracket
Drive belt cover
Rubber gasket
Bearing housing
Dowel pin
Primary sliding sheave assembly
V-belt
Q’ty
Remarks
Remove the parts in the order below.
Refer to “SEAT, CARRIERS, FENDERS
AND FUEL TANK” in CHAPTER 3.
1
1
1
1
2
1
1
Refer to “REMOVING/INSTALLING THE
PRIMARY AND SECONDARY
SHEAVES”.
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PRIMARY AND SECONDARY SHEAVES
Order
8
9
Job name/Part name
Primary fixed sheave
Secondary sheave assembly
Q’ty
1
1
ENG
Remarks
Refer to “REMOVING/INSTALLING THE
PRIMARY AND SECONDARY
SHEAVES”.
For installation, reverse the removal
procedure.
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PRIMARY AND SECONDARY SHEAVES
ENG
PRIMARY SLIDING SHEAVE
Order
1
2
3
4
5
6
7
8
9
Job name/Part name
Disassembling the primary sliding
sheave
Primary pulley sheave cap
Primary pulley slider
Spacer
Primary pulley cam
Primary pulley weight
Collar
Oil seal
Primary sliding sheave
O-ring
Q’ty
Remarks
Remove the parts in the order below.
1
4
4
1
8
1
2
1
1
Refer to “ASSEMBLING THE PRIMARY
SHEAVE”.
For assembly, reverse the disassembly
procedure.
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PRIMARY AND SECONDARY SHEAVES
ENG
SECONDARY SHEAVE
Order
1
2
3
4
5
6
7
8
9
0
Job name/Part name
Disassembling the secondary
sheave
Nut
Spring seat
Compression spring
Spring seat
Guide pin
Secondary sliding sheave
O-ring
Secondary fixed sheave
Oil seal
Oil seal
Q’ty
1
1
1
1
4
1
2
1
1
1
Remarks
Remove the parts in the order below.
Refer to “DISASSEMBLING/
ASSEMBLING THE SECONDARY
SHEAVE”.
For assembly, reverse the disassembly
procedure.
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PRIMARY AND SECONDARY SHEAVES
ENG
REMOVING THE PRIMARY AND
SECONDARY SHEAVES
1.Loosen:
● Nut (secondary sheave) 1
● Nut (primary sheave) 2
NOTE:
● Use the sheave holder 3 to hold the primary
sheave.
● First, loosen the nut (secondary sheave) 2,
then loosen the nut (primary sheave) 1.
Sheave holder:
P/N. YU-01880, 90890-01701
DISASSEMBLING THE SECONDARY
SHEAVE
1.Remove:
● Nut 1
*****************************************************
Removing steps:
● Attach the sheave fixed block 2, locknut
wrench 3 and sheave spring compressor 4
to the secondary sheave assembly.
Sheave fixed block:
P/N. YM-04135, 90890-04135
Locknut wrench:
P/N. 90890-01348
Sheave spring compressor:
P/N. YM-04134, 90890-04134
● Place
the sheave fixed block in a vise and
secure it.
● Tighten the sheave spring compressor nut 5
and compress the spring.
● Loosen the nut 1 with the locknut wrench
3.
● Remove the nut 1.
● Remove the sheave spring compressor and
locknut wrench.
*****************************************************
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PRIMARY AND SECONDARY SHEAVES
ENG
CHECKING THE PRIMARY SHEAVE
1.Check:
● Weight outside diameter a
Out of specification → Replace the weight.
Weight outside diameter:
30 mm (1.18 in)
<Limit>: 29.5 mm (1.16 in)
2.Check:
● Primary pulley slider
● Primary sliding sheave splines
Wear/cracks/damage → Replace.
● Spacer
● Primary pulley cam
Cracks/damage → Replace.
3.Check:
● Primary sliding sheave
● Primary fixed sheave
Cracks/damage → Replace.
CHECKING THE SECONDARY SHEAVE
1.Check:
● Secondary fixed sheave smooth operation
● Secondary sliding sheave smooth operation
Scratches/damage → Replace as a set.
2.Check:
● Torque cam groove 1
Wear/damage → Replace.
3.Check:
● Guide pin 2
Wear/damage → Replace.
4.Check:
● Secondary sheave spring
Damage → Replace.
5.Measure:
● Secondary sheave spring free length a
Out of specification → Replace the
secondary sheave spring.
Free length:
121.4 mm (4.78 in)
<Limit>: 115.33 mm (4.54 in)
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PRIMARY AND SECONDARY SHEAVES
ENG
ASSEMBLING THE PRIMARY SHEAVE
1.Clean:
● Primary sliding sheave face 1
● Primary fixed sheave face 2
● Collar 3
● Weight 4
● Primary pulley cam face
NOTE:
Remove any excess grease.
2.Install:
● Weight 1
NOTE:
● Apply Yamaha Grizzly grease (120 g) to the
whole outer surface of the weight and install.
● Apply Yamaha Grizzly grease to the inner
surface of the collar.
● Apply Yamaha Grizzly grease to the inner
surface of the primary sliding sheave.
3.Install:
● Spacer
● Slider 1
● Primary pulley cam 2
● Primary sliding sheave cap
T.
R.
3 Nm (0.3 m • kg, 2.2 ft • lb)
ASSEMBLING THE SECONDARY SHEAVE
1.Apply:
®
● BEL-RAY assembly lube
(to the secondary sliding sheave 1 inner
surface and oil seals)
®
● BEL-RAY assembly lube
(to the bearings, oil seals and inner surface
of the secondary fixed sheave 2)
2.Install:
● Guide pin 1
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PRIMARY AND SECONDARY SHEAVES
ENG
3.Apply:
®
● BEL-RAY assembly lube
(to the guide pin sliding groove 1, and O-ring
2 New )
4.Install:
● Spring seat
● Compression spring
● Spring seat
● Nut
*****************************************************
Installing steps:
● Attach the sheave fixed block, locknut
wrench and sheave spring compressor to the
secondary sheave assembly.
Sheave fixed block:
P/N. YM-04135, 90890-04135
Locknut wrench:
P/N. 90890-01348
Sheave spring compressor:
P/N. YM-04134, 90890-04134
● Place
the sheave fixed block in a vise and
secure it.
● Tighten the sheave spring compressor nut 1
and compress the spring.
● Install the nut 2 and tighten it to the
specified torque using the locknut wrench.
T.
R.
Nut:
90 Nm (9.0 m • kg, 65 ft • lb)
● Remove
the sheave spring compressor,
locknut wrench, and sheave fixed block.
*****************************************************
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PRIMARY AND SECONDARY SHEAVES
ENG
INSTALLING THE PRIMARY AND
SECONDARY SHEAVES
1.Install:
● Secondary sheave assembly
● V-belt
● Primary sheave assembly
NOTE:
● Tightening
the bolts 1 will push the
secondary sliding sheave away, causing the
gap between the secondary fixed and sliding
sheaves to widen.
● Install the V-belt so that its arrow faces the
direction show in the illustration.
2.Tighten:
● Nut (primary sheave) 1
T.
R.
●
100 Nm (10.0 m • kg, 72 ft • lb)
Nut (secondary sheave) 2
T.
R.
100 Nm (10.0 m • kg, 72 ft • lb)
NOTE:
● Use the sheave holder 3 to hold the primary
sheave.
● First, tighten the nut (primary sheave) 1,
then tighten the nut (secondary sheave) 2.
Sheave holder:
P/N. YU-01880, 90890-01701
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CLUTCH
ENG
CLUTCH
Order
1
2
3
4
5
6
Job name/Part name
Removing the clutch
Primary and secondary sheaves
Q’ty
Cover
Clutch housing assembly
Gasket/dowel pin
One-way clutch bearing
Nut
Clutch carrier assembly
1
1
1/2
1
1
1
Remarks
Remove the parts in the order below.
Refer to “PRIMARY AND SECONDARY
SHEAVES”.
Refer to “REMOVING/INSTALLING THE
CLUTCH”.
For installation, reverse the removal
procedure.
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CLUTCH
Order
1
2
3
4
5
6
7
8
Job name/Part name
Disassembling the clutch housing
Oil seal
Circlip
Bearing housing
Circlip
Bearing
Circlip
Bearing
Clutch housing
Q’ty
ENG
Remarks
Remove the parts in the order below.
1
1
1
1
1
1
1
1
For assembly, reverse the disassembly
procedure.
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CLUTCH
ENG
REMOVING THE CLUTCH
1.Remove:
● Clutch housing assembly
● Gasket
● Dowel pins
NOTE:
Working in crisscross pattern, loosen each bolt
1/4 of a turn. Remove them after all of them
are loosened.
2.Straighten:
● Punched portion of the nut 1.
3.Remove:
● Nut 1
NOTE:
Use a clutch holding tool 2 to hold the clutch
carrier assembly.
Clutch holding tool:
P/N. YM-91042, 90890-04086
CHECKING THE CLUTCH
1.Check:
● Clutch housing 1
Heat damage/wear/damage → Replace.
● One-way clutch bearing 2
Chafing/wear/damage → Replace.
NOTE:
● Replace the one-way clutch assembly and
clutch housing as a set.
● The one-way clutch bearing 2 must be
installed with the arrow mark side facing up.
*****************************************************
Checking steps:
● Install the one-way clutch bearing and clutch
carrier assembly to the clutch housing and
hold the clutch carrier assembly.
● When turning the clutch carrier assembly
clockwise È, the clutch carrier assembly
should turn freely.
If not, the one-way clutch assembly is faulty.
Replace it.
● When turning the clutch carrier assembly
counterclockwise É, the clutch housing and
clutch carrier assembly should be engaged.
If not, the one-way clutch assembly is faulty.
Replace it.
*****************************************************
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CLUTCH
ENG
2.Check:
● Clutch shoe
Heat damage → Replace.
3.Measure:
● Clutch shoe thickness
Out of specification → Replace.
Clutch shoe thickness:
1.5 mm (0.06 in)
Clutch shoe wear limit a:
1.0 mm (0.04 in)
T.
INSTALLING THE CLUTCH
1.Install:
● Collar
● Clutch carrier assembly
● Nut 1 New
140 Nm (14.0 m • kg, 100 ft • lb)
R.
NOTE:
● Lubricate the nut with molybdenum disulfide
oil.
● Use a clutch holding tool 2 to hold the clutch
carrier assembly.
Clutch holding tool:
P/N. YM-91042, 90890-04086
2.Lock the threads with a drift punch.
3.Install:
● One-way clutch bearing
NOTE:
The one-way clutch bearing should be
installed in the clutch carrier assembly with the
arrow mark a facing toward the clutch
housing.
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CLUTCH
ENG
4.Install:
● Dowel pins
● Gasket New
● Clutch housing assembly
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • lb)
NOTE:
● Tighten
the bolts in stages, using a
crisscross pattern.
● After tightening the bolts, check that the
clutch housing assembly to counterclockwise
rotates smoothly.
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CRANKCASE
ENG
CRANKCASE
STARTER MOTOR, TIMING CHAIN AND OIL FILTER
Order
Job name/Part name
Removing the starter motor, timing
chain and oil filter
Engine assembly
Cylinder head
Cylinder and piston
Recoil starter and rotor
Q’ty
Primary and secondary sheaves
1
Clutch carrier assembly
Oil pump drive gear/straight key
1/1
2
3
4
5
Oil pump driven gear
Timing chain guide
Timing chain
Starter motor/O-ring
1
1
1
1/1
Remarks
Remove the parts in the order below.
Refer to “ENGINE REMOVAL”.
Refer to “CYLINDER HEAD”.
Refer to “CYLINDER AND PISTON”.
Refer to “RECOIL STARTER AND A.C.
MAGNETO”.
Refer to “PRIMARY AND SECONDARY
SHEAVES”.
Refer to “CLUTCH”.
Refer to “REMOVING/INSTALLING THE
OIL PUMP DRIVE GEAR”.
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CRANKCASE
Order
6
7
8
9
10
11
12
13
14
15
16
17
18
Job name/Part name
Oil filter cartridge
Speed sensor
Shift cam stopper
Low-range switch
High-range switch
Neutral switch
Reverse switch
Oil filler cap
Bearing cover/gasket
Oil delivery pipe
Oil strainer cover/O-ring
Compression spring
Oil strainer
Q’ty
1
1
1
1
1
1
1
1
1/1
1
1/1
1
1
ENG
Remarks
For installation, reverse the removal
procedure.
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CRANKCASE
ENG
CRANKCASE
Order
1
2
3
4
5
6
Job name/Part name
Separating the crankcase
Shift lever cover/gasket
Shift lever 1/O-ring
Shift lever 2 assembly
Crankcase (left)
Dowel pin
Crankcase (right)
Q’ty
1/1
1/1
1
1
2
1
Remarks
Remove the parts in the order below.
Refer to “INSTALLING THE SHIFT
LEVER”.
Refer to “SEPARATING/ASSEMBLING
THE CRANKCASE”.
For installation, reverse the removal
procedure.
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CRANKCASE
ENG
CRANKCASE BEARING
Order
1
2
3
Job name/Part name
Removing the crankcase bearing
Crankshaft and oil pump
Transmission
Middle drive/driven shaft
Oil seal
Bearing retainer
Bearing
Q’ty
Remarks
Remove the parts in the order below.
Refer to “CRANKSHAFT AND OIL
PUMP”.
Refer to “TRANSMISSION”.
Refer to “MIDDLE GEAR”.
2
2
10
For installation, reverse the removal
procedure.
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CRANKCASE
ENG
REMOVING THE OIL PUMP DRIVE GEAR
1.Straighten:
● Lock washer tab
2.Remove:
● Oil pump drive gear nut
*****************************************************
Removal steps:
● Temporary install the clutch carrier assembly
1.
● Hold the clutch carrier assembly with a clutch
holding tool 2 and loosen the oil pump drive
gear nut.
Clutch holding tool:
P/N. YM-91042, 90890-04086
● Remove
the clutch carrier assembly.
*****************************************************
È
SEPARATING THE CRANKCASE
1.Separate:
● Left crankcase
*****************************************************
Separation steps:
● Remove the crankcase bolts.
É
NOTE:
● Loosen each bolt 1/4 of a turn at a time and
after all the bolts are loosened, remove
them.
● Loosen
the bolts in stages, using a
crisscross pattern.
È Left crankcase
É Right crankcase
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CRANKCASE
● Remove
ENG
the left crankcase.
CAUTION:
Use a soft hammer to tap on one side of the
crankcase. Tap only on reinforced portions
of the crankcase. Do not tap on the
crankcase mating surfaces. Work slowly
and carefully. Make sure that the crankcase
halves separate evenly.
● Remove
the dowel pins.
*****************************************************
CHECKING THE TIMING CHAIN AND GUIDE
1.Check:
● Timing chain
Cracks/stiff → Replace the timing chain and
camshaft sprocket as a set.
2.Check:
● Intake side timing chain guide
Wear/damage → Replace.
CHECKING THE OIL STRAINER AND OIL
DELIVERY PIPE
1.Check:
● Oil strainer 1
2.Check:
● Oil delivery pipe
Cracks/damage → Replace.
Clogged → Blow out with compressed air.
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CRANKCASE
ENG
CHECKING THE CRANKCASE
1.Thoroughly wash the case halves in a mild
solvent.
2.Clean all the gasket mating surfaces and
crankcase mating surfaces thoroughly.
3.Check:
● Crankcase
Cracks/damage → Replace.
● Oil delivery passages
Clogged → Blow out with compressed air.
CHECKING THE BEARINGS
1.Check:
● Bearing
Clean and lubricate, then rotate the inner
race with a finger.
Roughness → Replace.
ASSEMBLING THE CRANKCASE
1.Apply:
®
● Sealant (Quick Gasket ) 1
(to the mating surfaces of both case halves)
Sealant (Quick Gasket®):
P/N. ACC-11001-05-01
Yamaha bond No. 1215:
P/N. 90890-85505
2.Install:
● Dowel pin 2
3.Fit the left crankcase onto the right case. Tap
lightly on the case with a soft hammer.
CAUTION:
Before installing and torquing the
crankcase holding bolts, be sure to check
whether the transmission is functioning
properly by manually rotating the shift cam
in both directions.
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CRANKCASE
È
ENG
4.Tighten:
● Crankcase bolts
(follow the proper tightening sequence)
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • lb)
È Right crankcase
É Left crankcase
NOTE:
Tighten the bolts in stages, using a crisscross
pattern.
É
5.Apply:
● 4-stroke engine oil
(to the crank pin, bearing and oil delivery
hole)
6.Check:
● Crankshaft and transmission operation
Unsmooth operation → Repair.
INSTALLING THE SHIFT LEVER
1.Install:
● Shift lever 2 assembly 1
T.
R.
●
14 Nm (1.4 m • kg, 10 ft • lb)
Shift lever 1 2
NOTE:
When installing the shift lever 1, align the
punch mark a on the shift lever 1 with the
punch marks b on the shift lever 2.
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CRANKCASE
ENG
INSTALLING THE OIL PUMP DRIVE GEAR
1.Install:
● Straight key
● Oil pump drive gear
● Lock washer New
● Oil pump drive gear nut
2.Tighten:
● Oil pump drive gear nut
T.
R.
50 Nm (5.0 m • kg, 36 ft • lb)
*****************************************************
Tightening steps:
● Temporary install the clutch carrier assembly
1.
● Hold the clutch carrier assembly with a clutch
holding tool 2 and tighten the oil pump drive
gear nut.
Clutch holding tool:
P/N. YM-91042, 90890-04086
● Remove
the clutch carrier assembly.
*****************************************************
3.Bend the lock washer tab.
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CRANKSHAFT AND OIL PUMP
ENG
CRANKSHAFT AND OIL PUMP
Order
1
2
3
4
5
Job name/Part name
Removing the crankshaft and oil
pump
Crankcase separation
Washer/circlip
Oil pump assembly/gasket
Balancer
Crankshaft seal
Crankshaft
Q’ty
Remarks
Remove the parts in the order below.
Refer to “CRANKCASE”.
1/1
1/1
1
2
1
Refer to “REMOVING THE
CRANKSHAFT/INSTALLING THE
CRANKSHAFT AND BALANCER”.
For installation, reverse the removal
procedure.
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CRANKSHAFT AND OIL PUMP
ENG
OIL PUMP
Order
1
2
3
4
5
6
7
Job name/Part name
Disassembling the oil pump
Rotor cover
Pin
Shaft
Pin
Inner rotor
Outer rotor
Oil pump housing
Q’ty
Remarks
Remove the parts in the order below.
1
2
1
1
1
1
1
For assembly, reverse the disassembly
procedure.
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CRANKSHAFT AND OIL PUMP
ENG
REMOVING THE CRANKSHAFT
1.Remove:
● Crankshaft seal 1
NOTE:
Mark a note of the position of each crankshaft
seal so that they can be installed in the correct
place and in the correct direction.
2.Remove:
● Crankshaft
Use a crankcase separating tool 1.
Crankcase separating tool:
P/N. YU-01135-A, 90890-01135
CHECKING THE OIL PUMP
1.Check:
● Oil pump driven gear
● Oil pump housing
● Rotor cover
Cracks/wear/damage → Replace.
2.Measure:
● Tip clearance a
(between the inner rotor 1 and the outer
rotor 2)
● Side clearance b
(between the outer rotor 2 and the pump
housing 3)
Out of specification → Replace the oil pump.
Tip clearance a:
0.15 mm (0.006 in)
<Limit>: 0.20 mm (0.008 in)
Side clearance b:
0.04 ~ 0.09 mm (0.002 ~ 0.004 in)
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CRANKSHAFT AND OIL PUMP
ENG
3.Check:
● Oil pump operation
Unsmooth → Repeat steps #1 and #2 or
replace the defective parts.
CHECKING THE CRANKSHAFT
1.Measure:
● Crank width A
Out of specification → Replace the
crankshaft.
Crank width:
62.95 ~ 63.00 mm
(2.4783 ~ 2.4803 in)
●
Side clearance D
Out of specification → Replace the
crankshaft.
Big end side clearance:
0.25 ~ 0.75 mm
(0.0098 ~ 0.0295 in)
<Limit>: 1.00 mm (0.0394 in)
●
Runout C
Out of specification → Replace the
crankshaft.
Runout limit:
C1: 0.03 mm (0.0012 in)
C2: 0.03 mm (0.0012 in)
*****************************************************
Crankshaft reassembling point:
The crankshaft 1 and the crank pin 2 oil
passages must be properly interconnected
with a tolerance of less than 1 mm (0.04 in).
*****************************************************
CAUTION:
The buffer boss and woodruff key should
be replaced when removed from the
crankshaft.
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CRANKSHAFT AND OIL PUMP
ENG
INSTALLING THE CRANKSHAFT AND
BALANCER
1.Install:
● Crankshaft
Crankshaft installer set 1:
P/N. YU-90050
Buffer boss installer set 2:
P/N. 90890-04088
Adapter #11 3:
P/N. YM-33279
Spacer (crankshaft) 4:
P/N. YM-90070-A, 90890-04060
NOTE:
Hold the connecting rod at the Top Dead
Center (T.D.C.) with one hand while turning
the nut of the installing tool with the other.
Operate the installing tool until the crankshaft
bottoms against the bearing.
CAUTION:
Apply engine oil to each bearing to protect
the crankshaft against scratches and to
make installation easier.
2.Install:
● Crankshaft seal
NOTE:
Install the crankshaft seals in the correct place
and in the correct direction.
3.Install:
● Balancer 1
NOTE:
Align the punch marks a on the drive and
driven gear.
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TRANSMISSION
ENG
TRANSMISSION
Order
1
2
3
4
5
6
7
8
9
10
Job name/Part name
Removing the transmission
Crankcase separation
Driven sprocket
Chain
Clutch dog 2
Shift fork “L”
Spring
Low wheel gear
Secondary shaft
Middle driven gear
Drive axle assembly
Guide bar
Q’ty
Remarks
Remove the parts in the order below.
Refer to “CRANKCASE”.
1
1
1
1
1
1
1
1
1
1
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TRANSMISSION
Order
11
12
13
14
15
16
17
18
19
Job name/Part name
Shift fork “R”
Spring
Shift cam
Stopper wheel
Clutch dog 1
High wheel gear
Middle drive gear
Stopper lever
Spacer/O-ring
Q’ty
1
1
1
1
1
1
1
1
1/1
ENG
Remarks
For installation, reverse the removal
procedure.
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TRANSMISSION
ENG
CHECKING THE SHIFT FORK
1.Check:
● Shift fork cam follower 1
● Shift fork pawl 2
Scoring/bends/wear/damage → Replace.
2.Check:
● Guide bar
Roll the guide bar on a flat surface.
Bends → Replace.
WARNING
Do not attempt to straighten a bent guide
bar.
3.Check:
● Shift fork movement
(on the guide bar)
Unsmooth operation → Replace the shift fork
and the guide bar.
4.Check:
● Spring
Cracks/damage → Replace.
CHECKING THE SHIFT CAM
1.Check:
● Shift cam grooves
Scratches/wear/damage → Replace.
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TRANSMISSION
ENG
CHECKING THE TRANSMISSION
1.Measure:
● Axle runout
Use a centering device and a dial gauge.
Out of specification → Replace the bent axle.
Runout limit (drive axle):
0.06 mm (0.0024 in)
2.Check:
● Gear teeth
Blue discoloration/pitting/wear → Replace.
● Mated dogs
Rounded edges/cracks/missing portions →
Replace.
3.Check:
● Gear movement
Unsmooth → Repeat steps #1 and #2 or
replace the defective parts.
4.Check:
● Circlip
Bends/looseness/damage → Replace.
CHECKING THE SECONDARY SHAFT AND
DRIVEN SPROCKET
1.Check:
● Gear teeth
Blue discoloration/pitting/wear → Replace.
2.Check:
● Gear movement
Unsmooth → Repeat steps #1 or replace the
defective parts.
3.Check:
● Circlip
● Bends/looseness/damage → Replace.
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TRANSMISSION
ENG
CHECKING THE CHAIN
1.Check:
● Chain
Cracks/shift → Replace the chain, secondary
shaft and driven sprocket as a set.
CHECKING THE STOPPER LEVER AND
STOPPER WHEEL
1.Check:
● Stopper lever pawl 1
Bends/damage/wear → Replace the stopper
lever and stopper wheel as a set.
● Stopper wheel 2
Damage/wear → Replace the stopper wheel
and stopper lever as a set.
● Shaft 3
Bends/damage/wear → Replace.
INSTALLING THE TRANSMISSION
1.Install:
● Shift cam
● Washer
● Spring (short)
● Shift fork “R” 1
● Drive axle assembly 2
● Guide bar 3
● Clutch dog 2 4
● Spring (long) 5
● Shift fork “L” 6
NOTE:
Install the shift fork with the “R” mark facing
towards the right side of the crankcase and the
shift fork with the “L” mark facing towards the
left side of the crankcase. Be sure that the shift
fork guide pin is properly seated in the shift
drum groove.
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TRANSMISSION
ENG
2.Check:
● Shift operation
Unsmooth operation → Repair.
NOTE:
● Oil each gear and bearing thoroughly.
● Before assembling the crankcase, be sure
that the transmission is in neutral and that
the gears turn freely.
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MIDDLE GEAR
ENG
MIDDLE GEAR
MIDDLE DRIVE SHAFT
Order
1
2
3
4
Job name/Part name
Removing the middle drive shaft
Crankcase separation
Transmission
Bearing housing assembly
Nut
Middle drive pinion gear
Shim
5
6
Middle drive shaft
Bearing retainer
Q’ty
1
1
1
Remarks
Remove the parts in the order below.
Refer to “CRANKCASE”.
Refer to “TRANSMISSION”.
Refer to “REMOVING/INSTALLING THE
MIDDLE DRIVE SHAFT”.
Refer to “SELECTING THE MIDDLE
DRIVE AND DRIVEN GEAR SHIM”.
1
2
For installation, reverse the removal
procedure.
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MIDDLE GEAR
ENG
MIDDLE DRIVEN SHAFT
Order
1
2
3
4
5
6
Job name/Part name
Removing the middle driven shaft
Crankcase separation
Circlip
Bearing
Universal joint
Universal joint yoke
Bearing housing/O-ring
Shim
7
8
9
10
11
Middle drive pinion gear
Bearing retainer
Damper cam
Spring
Gear coupling
Q’ty
4
4
2
2
1/1
1
1
1
1
1
Remarks
Remove the parts in the order below.
Refer to “CRANKCASE”.
Refer to “REMOVING/INSTALLING THE
MIDDLE DRIVEN SHAFT”.
Refer to “SELECTING THE MIDDLE
DRIVE AND DRIVEN GEAR SHIM”.
Refer to “REMOVING/INSTALLING THE
MIDDLE DRIVEN SHAFT”.
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MIDDLE GEAR
Order
12
13
Job name/Part name
Bearing retainer
Middle driven shaft
Q’ty
1
1
ENG
Remarks
For installation, reverse the removal
procedure.
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MIDDLE GEAR
ENG
REMOVING THE MIDDLE DRIVE SHAFT
1.Straighten:
● Punched portion of the nut (middle drive
pinion gear)
2.Loosen:
● Nut (middle drive pinion gear) 1
NOTE:
Secure the middle drive shaft in the vise with a
clean rag.
3.Remove:
● Nut (middle drive pinion gear)
● Middle drive pinion gear
● Shim(s)
REMOVING THE MIDDLE DRIVEN SHAFT
1.Remove:
● Universal joint
*****************************************************
Removal steps:
● Remove the circlips 1.
● Place the U-joint in a press.
● With a suitable diameter pipe 2 beneath the
yoke 3, press the bearing 4 into the pipe as
shown.
NOTE:
It may be necessary to lightly tap the yoke with
a punch.
● Repeat
the steps for the opposite bearing.
● Remove the yoke.
NOTE:
It may be necessary to lightly tap the yoke with
a punch.
*****************************************************
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MIDDLE GEAR
ENG
2.Remove:
● Nut 1
● Washer
● Universal joint yoke
NOTE:
Use the universal joint holder 2 to hold the
universal joint yoke.
Universal joint holder:
P/N. YM-04062, 90890-04062
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.
*****************************************************
4.Remove:
● Bearing retainer
● Bearing
*****************************************************
Removal steps:
● Attach the folded rag 1.
● 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.
*****************************************************
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MIDDLE GEAR
ENG
5.Remove:
● Front drive shaft coupling
● Bearing retainer 1
● Bearing
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 loosen the
retainer turn it clockwise.
6.Remove:
● Middle drive shaft 1
(with bearing)
CHECKING THE PINION GEAR
1.Check:
● Damper cam surfaces
Wear/scratches → Replace damper cam and
driven pinion gear as a set.
2.Check:
● Damper spring
Damage/cracks → Replace.
3.Check:
● Gear teeth (drive pinion gear) 1
● Gear teeth (driven pinion gear) 2
Pitting/galling/wear → Replace.
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MIDDLE GEAR
ENG
4.Check:
● O-ring
Damage → Replace.
● Bearings
Pitting/damage → Replace.
5.Check:
● U-joint movement
Roughness → Replace U-joint.
SELECTING THE MIDDLE DRIVE AND
DRIVEN GEAR SHIM
When the drive and driven gear, bearing
housing assembly and/or crankcase replaced,
be sure to adjust the gear shim 1.
1.Select:
● Middle drive gear shim 1
● Middle driven gear shim 2
*****************************************************
Selection steps:
● Position middle drive and driven gear by
using shims 1 and 2 with their respective
thickness calculated from information
marked on crankcase, bearing housing and
drive gear end.
1 Shim thickness “A”
2 Shim thickness “B”
● To
find shim thickness “A” use following
formula:
Middle drive pinion gear shim thickness:
“A” = c – a – b
Where:
a = a numeral (usually a decimal number)
on the bearing housing is either added
to or subtracted from “10.5”.
b = drive pinion gear to driven pinion gear
center distance (considered constant
“55”).
c = a numeral (usually a decimal number)
on the right crankcase specifies a
thickness of “66”.
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MIDDLE GEAR
ENG
Example:
1) If the bearing housing is marked “+04”,
..... a is 10.54.
2) b is 55
3) If the crankcase (right) is marked “66.03”,
..... c is 66.03.
4) Therefore, the shim thickness is 0.47 mm.
A = 66.03 – 10.54 – 55
= 0.49
5) Round off hundredths digit and select
appropriate shim(s).
In the example above, the calculated shim
thickness is 0.49 mm. The chart instructs
you, however, to round off 9 to 10.
Hundredths
Round value
0, 1, 2
0
3, 4, 5, 6, 7
5
8, 9
10
Shims are supplied in the following thickness.
Middle drive pinion gear shim
Thickness (mm)
0.10
0.15
0.20
0.30
0.40
0.50
● To
find shim thickness “B” use the following
formula:
Middle driven pinion gear
thickness:
“B” = d – e + f – g – 0.05
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shim
MIDDLE GEAR
ENG
Where:
d = a numeral (usually a decimal number)
on the bearing housing is either added
to or subtracted from “76”.
e = a numeral (usually a decimal number)
on the middle driven pinion gear is
either added to or subtracted from “59”.
f = a numeral (usually a decimal number)
on the middle driven pinion gear is
either added to or subtracted from
“79.5”.
g = a numeral (usually a decimal number)
on the left crankcase specifies a
thickness of “95.8”.
Example:
1) If the bearing housing is marked “+03”,
..... d is 76.03.
2) If the driven pinion gear is marked “+02”,
..... e is 59.02.
3) If the driven pinion gear is marked “–10”,
..... f is 79.40.
4) If the crankcase (left) is marked “95.79”,
..... g is 95.79.
5) Therefore, the shim thickness is 0.57 mm.
B = 76.03 – 59.02 + 79.40 – 95.79 – 0.05
= 0.57
6) Round off hundredths digit and select
appropriate shim(s).
In the example above, the calculated shim
thickness is 0.57 mm. The chart instructs
you, however, to round off 7 to 5.
Hundredths
Round value
0, 1, 2
0
3, 4, 5, 6, 7
5
8, 9
10
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MIDDLE GEAR
ENG
Shims are supplied in the following thickness.
Middle drive pinion gear shim
0.10
0.15
0.20
0.30
Thickness (mm)
0.40
0.50
0.60
*****************************************************
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:
● Attach the folded rag 2.
● Secure the bearing housing edge in the vise.
● Attach the bearing retainer wrench 3.
Bearing retainer wrench:
P/N. YM-04128, 90890-04128
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MIDDLE GEAR
● Tighten
ENG
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.
4.Install:
● Universal joint yoke (rear side)
● Washer
97 Nm (9.7 m • kg, 70 ft • lb)
● Nut 1
LT
T.
R.
NOTE:
Use the universal joint holder 2 to hold the
yoke.
Universal joint holder:
P/N. YM-04062, 90890-04062
5.Install:
● Universal joint
*****************************************************
Installation steps:
● Install the opposite yoke into the U-joint.
● Apply wheel bearing grease to the bearings.
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MIDDLE GEAR
● Install
ENG
the bearing 1 onto the yoke.
CAUTION:
Check each bearing. The needles can
easily fall out of their races. Slide the yoke
back and forth on the bearings; the yoke
will not go all the way onto a bearing if a
needle is out of place.
● Press
each bearing into the U-joint using a
suitable socket.
NOTE:
The bearing must be inserted far enough into
the U-joint so that the circlip can be installed.
the circlips 2 into the groove of each
bearing.
● Install
*****************************************************
INSTALLING THE MIDDLE DRIVE SHAFT
1.Tighten:
● Nut (middle drive pinion gear) 1 New
T.
R.
130 Nm (13.0 m • kg, 94 ft • lb)
NOTE:
Secure the middle drive shaft in the vise with a
clean rag.
2.Lock the threads with a drift punch.
MEASURING THE MIDDLE GEAR
BACKLASH
1.Measure:
● Gear lash
Middle gear lash:
0.1 ~ 0.3 mm (0.004 ~ 0.012 in)
*****************************************************
Measurement steps:
● Temporarily install the right crankcase.
● Wrap a rag 2 around a screwdriver 3, and
then insert it into the installation hole 1 of
the left crankcase speed sensor to hold the
middle driven gear.
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MIDDLE GEAR
ENG
the gear lash measurement tool 3
and dial gauge 4.
● Attach
Gear lash measurement tool:
P/N. YM-01467, 90890-01467
a 8.12 mm (0.32 in)
● Measure
the gear lash while rotating the
middle driven shaft back and forth.
NOTE:
Measure the gear lash at 4 positions. Rotate
the middle driven gear 90° each time.
● If
the gear lash is incorrect, adjust the gear
lash by middle driven pinion gear shims and/
or middle drive pinion gear shim(s).
*****************************************************
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RADIATOR
COOL
COOLING SYSTEM
RADIATOR
Order
Job name/Part name
Removing the radiator
Seat and fuel tank side panels
Q’ty
Front carrier, front bumper and front
fender
Left footrest board
Coolant
1
2
3
4
Radiator fan coupler
Thermo switch coupler
Coolant reservoir hose
Radiator fan breather hose
1
1
1
1
Remarks
Remove the parts in the order below.
Refer to “SEAT AND SIDE PANELS” in
CHAPTER 3.
Refer to “FRONT CARRIER, FRONT
BUMPER AND FRONT FENDER” in
CHAPTER 3.
Refer to “FOOTREST BOARDS” in
CHAPTER 3.
Drain.
Refer to “CHANGING THE COOLANT” in
CHAPTER 3.
Disconnect.
Disconnect.
Disconnect.
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RADIATOR
COOL
5
Order
5
6
7
8
9
Job name/Part name
Radiator inlet hose
Radiator outlet hose
Radiator
Radiator fan
Thermo switch
Q’ty
Remarks
1
Disconnect.
1
Disconnect.
1
1
1
For installation, reverse the removal
procedure.
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RADIATOR
COOL
CHECKING THE RADIATOR
1.Check:
● Radiator fins
Obstruction → Clean.
Apply compressed air to the rear of the
radiator.
Damage → Repair or replace.
NOTE:
Straighten any flattened fins with a thin, flathead screwdriver.
2.Check:
● Radiator hoses
Cracks/damage → Replace.
3.Measure:
● Radiator cap opening pressure
Below the specified pressure → Replace the
radiator cap.
Radiator cap opening pressure:
93.7 ~ 122.6 kPa
(0.937 ~ 1.226 kg/cm2,
13.32 ~ 17.43 psi)
*****************************************************
Measurement steps:
● Install the radiator cap tester 1 and adapter
2 onto the radiator cap 3.
Radiator cap tester:
P/N. YU-24460-01, 90890-01325
Adapter:
P/N. YU-33984, 90890-01352
● Apply
the specified pressure for ten seconds
and make sure that there is no drop in
pressure.
*****************************************************
4.Check:
● Radiator fan
Damage → Replace.
Malfunction → Check and repair.
Refer to “COOLING SYSTEM” in CHAPTER
9.
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RADIATOR
COOL
INSTALLING THE RADIATOR
1.Fill:
● Cooling system
(with the specified amount of the
recommended coolant)
Refer to “CHANGING THE COOLANT” in
CHAPTER 3.
2.Check:
● Cooling system
Leaks → Repair or replace any faulty part.
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THERMOSTAT
COOL
THERMOSTAT
Order
Job name/Part name
Removing the thermostat
Seat and fuel tank side panel (right)
Q’ty
Coolant
1
2
3
Radiator inlet hose
Thermostat cover
Thermostat
Remarks
Remove the parts in the order below.
Refer to “SEAT AND SIDE PANELS” in
CHAPTER 3.
Drain.
Refer to “CHANGING THE COOLANT” in
CHAPTER 3.
1
1
1
For installation, reverse the removal
procedure.
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THERMOSTAT
COOL
CHECKING THE THERMOSTAT
1.Check:
● Thermostat 1
Does not open at 63.5 ~ 66.5 °C (146.3 ~
151.7 °F) → Replace.
*****************************************************
Checking steps:
● Suspend the thermostat in a container filled
with water.
● Slowly heat the water.
● Place a thermometer in the water.
● While stirring the water, observe the
thermostat and thermometer’s indicated
temperature.
*****************************************************
1 Thermostat
2 Thermometer
3 Water
4 Container
È Fully closed
É Fully open
NOTE:
If the accuracy of the thermostat is in doubt,
replace it. A faulty thermostat could cause
serious overheating or overcooling.
2.Check:
● Thermostat cover
Cracks/damage → Replace.
INSTALLING THE THERMOSTAT
1.Install:
● Thermostat 1
● Thermostat cover
NOTE:
Install the thermostat with its breather hole a
toward the projection b.
2.Fill:
● Cooling system
(with the specified amount of the
recommended coolant)
Refer to “CHANGING THE COOLANT” in
CHAPTER 3.
3.Check:
● Cooling system
Leak → Repair or replace any faulty part.
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WATER PUMP
COOL
WATER PUMP
Order
Job name/Part name
Removing the water pump
Seat, fuel tank side panel (left) and
engine side cover
Left footrest board
Q’ty
Coolant
1
2
3
4
5
6
7
Water pump outlet hose
Water pump outlet pipe
O-ring
Radiator outlet hose
Water pump breather hose
Water pump assembly
O-ring
Remarks
Remove the parts in the order below.
Refer to “SEAT AND SIDE PANELS” in
CHAPTER 3.
Refer to “FOOTREST BOARDS” in
CHAPTER 3.
Drain.
Refer to “CHANGING THE COOLANT” in
CHAPTER 3.
1
1
1
1
1
1
1
For installation, reverse the removal
procedure.
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WATER PUMP
Order
1
2
3
4
5
6
7
8
9
0
Job name/Part name
Disassembling the water pump
Water pump housing cover
Gasket
Circlip
Impeller
Rubber damper holder
Rubber damper
Water pump seal
Oil seal
Bearing
Water pump housing
Q’ty
COOL
Remarks
Remove the parts in the order below.
1
1
1
1
1
1
1
1
1
1
For assembly, reverse the disassembly
procedure.
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WATER PUMP
COOL
DISASSEMBLING THE WATER PUMP
1.Remove:
● Rubber damper holder 1
● Rubber damper 2
(from the impeller, with a thin, flathead
screwdriver)
NOTE:
Do not scratch the impeller shaft.
2.Remove:
● Water pump seal 1
NOTE:
Tap out the water pump seal from the inside of
the water pump housing.
2 Water pump housing
3.Remove:
● Oil seal 1
● Bearing 2
NOTE:
Tap out the bearing and oil seal from the
outside of the water pump housing.
3 Water pump housing
CHECKING THE WATER PUMP
1.Check:
● Water pump housing cover 1
● Water pump housing 2
● Impeller 3
● Rubber damper 4
● Rubber damper holder 5
Cracks/damage/wear → Replace.
2.Check:
● Water pump outlet pipe
Cracks/damage/wear → Replace.
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WATER PUMP
COOL
3.Measure:
● Impeller shaft tilt
Out of specification → Replace.
Max. impeller shaft tilt:
0.15 mm (0.006 in)
1 Straightedge
2 Impeller
ASSEMBLING THE WATER PUMP
1.Install:
● Oil seal 1
New
(into the water pump housing 2)
NOTE:
Install the oil seal with a socket 3 that
matches its outside diameter.
2.Install:
● Water pump seal 1
New
(into the water pump housing 2)
NOTE:
Before installing the water pump seal 1, apply
tap water or coolant onto its outer surface.
CAUTION:
Never lubricate the water pump seal
surface with oil or grease.
NOTE:
Install the water pump seal with the special
tools.
Mechanical seal installer 3:
P/N. YM-33221, 90890-04078
Middle driven shaft bearing driver
4:
P/N. YM-04058-1, 90890-04058
È Push down.
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WATER PUMP
COOL
3.Install:
● Rubber damper 1
New
● Rubber damper holder 2
New
NOTE:
Before installing the rubber damper, apply tap
water or coolant onto its outer surface.
CAUTION:
Make sure that the rubber damper and
rubber damper holder are flush with the
impeller.
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CARBURETOR
CARB
CARBURETION
CARBURETOR
6
Order
1
2
3
4
5
6
7
Job name/Part name
Removing the carburetor
Seat/fuel tank side panels/fuel tank/
rubber cover
Drain hose
Starter cable/starter plunger
Vacuum chamber breather hose
Carburetor assembly
Throttle valve cover
Throttle cable end
Throttle cable
Q’ty
1
1/1
1
1
1
1
2
Remarks
Remove the parts in the order below.
Refer to “SEAT, CARRIERS, FENDERS
AND FUEL TANK” in CHAPTER 3.
NOTE:
After removing the carburetor assembly,
remove the throttle cable.
For installation, reverse the removal
procedure.
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CARBURETOR
Order
1
2
3
4
5
6
7
8
9
0
A
B
Job name/Part name
Disassembling the carburetor
Float chamber air vent hose
Throttle stop screw
Vacuum chamber cover
Spring
Jet needle holder
Spring
Jet needle set
Piston valve
Coasting enricher
Float chamber
Drain screw
Float
C
Needle valve set
Q’ty
1
1
1
1
1
1
1
1
1
1
1
1
CARB
Remarks
Remove the parts in the order below.
Refer to “ASSEMBLING THE
CARBURETOR”.
1
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CARBURETOR
Order
D
Job name/Part name
Pilot jet
Q’ty
1
CARB
Remarks
NOTE:
Before disassembling the carburetor,
make sure to note the number of times
the pilot screw is turned out from the
seated position to its set position.
E
F
G
H
Main jet
Needle jet
Starter jet
Pilot air jet
1
1
1
1
For assembly, reverse the disassembly
procedure.
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CARBURETOR
CARB
DISASSEMBLING THE CARBURETOR
NOTE:
Before disassembling the carburetor, make
sure to note the number of times the pilot
screw is turned out from the seated position to
its set position.
CHECKING THE CARBURETOR
1.Check:
● Carburetor body
● Float chamber
Cracks/damage → Replace.
● Fuel passage
Contamination → Clean as indicated.
● Carburetor body
Contamination → Clean.
*****************************************************
Cleaning steps:
● Wash the carburetor in a petroleum based
solvent.
(Do not use any caustic carburetor cleaning
solution.)
● Blow out all of the passages and jets with
compressed air.
*****************************************************
2.Check:
● Float 1
● Float tang 2
Damage → Replace.
3.Check:
● Valve seat 1
● Needle valve 2
● O-ring 3
Contamination/wear/damage → Replace as
a set.
NOTE:
Always replace the needle valve and valve
seat as a set.
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CARBURETOR
CARB
4.Check:
● Piston valve 1
Scratches/wear/damage → Replace.
● Rubber diaphragm 2
Tears → Replace.
5.Check:
● Vacuum chamber cover 1
● Spring 2
Cracks/damage → Replace.
6.Check:
● Diaphragm (coasting enricher) 1
● Spring 2
● Cover 3
Tears (diaphragm) /damage → Replace.
7.Check:
● Jet needle 1
● Main jet 2
● Needle jet 3
● Pilot air jet 4
● Pilot jet 5
● Starter jet 6
● Starter plunger 7
Bends/wear/damage → Replace.
● Blockage → Blow out the jets with
compressed air.
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CARBURETOR
CARB
8.Check:
● Free movement (piston valve)
Sticks → Replace the piston valve guide and
the piston valve.
Insert the piston valve into the carburetor
body, and check for free movement.
9.Check:
● Free movement (throttle valve)
Sticks → Replace.
ASSEMBLING THE CARBURETOR
CAUTION:
Before reassembling, wash all of the parts
in a clean petroleum based solvent.
1.Measure:
● Float height a
Out of specification → Adjust.
Float height (F.H.):
13 mm (0.51 in)
*****************************************************
Measurement and adjustment steps:
● Hold the carburetor in an upside down
position.
● Measure the distance from the mating
surface of the float chamber (gasket
removed) to the top of the float.
NOTE:
The float arm should be resting on the needle
valve, but not compressing it.
● If
the float height is not within the
specification, check the valve seat and
needle valve.
● If either is worn, replace them both.
● If both are fine, adjust the float height by
bending the float tang 1 on the float.
● Recheck the float height.
*****************************************************
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CARBURETOR
CARB
ADJUSTING THE FUEL LEVEL
1.Measure:
● Fuel level a
Out of specification → Adjust.
Fuel level:
4.0 ~ 5.0 mm (0.16 ~ 0.20 in)
Above the float chamber mating
surface
*****************************************************
Measurement and adjustment steps:
● Place the machine on a level surface.
● Connect the fuel level gauge 1 to the drain
pipe 2.
Fuel level gauge:
P/N. YM-01312-A, 90890-01312
the drain screw 3.
● Hold the gauge vertically next to the float
chamber line.
● Measure the fuel level a with the gauge.
● If the fuel level is incorrect, adjust the fuel
level.
● Remove the carburetor.
● Check the valve seat and needle valve.
● If either is worn, replace them both.
● If both are fine, adjust the float level by
bending the float tang 4 slightly.
● Install the carburetor.
● Recheck the fuel level.
● Loosen
*****************************************************
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TROUBLESHOOTING
DRIV
DRIVE TRAIN
TROUBLESHOOTING
The following conditions may indicate damaged shaft drive components:
Symptoms
1.A pronounced hesitation or “jerky” movement
during acceleration, deceleration, or sustained
speed. (This must not be confused with
engine
surging
or
transmission
characteristics.)
2.A “rolling rumble” noticeable at low speed; a
high-pitched whine; a “clunk” from a shaft
drive component or area.
3.A locked-up condition of the shaft drive train
mechanism, no power transmitted from the
engine to the front and/or rear wheel.
Possible Causes
A.Bearing damage.
B. Improper gear lash.
C.Gear tooth damage.
D. Broken drive shaft.
E.Broken gear teeth.
F. Seizure due to lack of lubrication.
G.Small foreign objects lodged between the
moving parts.
NOTE:
Areas A, B, and C above may be extremely difficult to diagnose. The symptoms are quite subtle and
difficult to distinguish from normal machine operating noise. If there is reason to believe these
components are damaged, remove the components and check them.
1.Check:
● Unusual noises
*****************************************************
The following “noises” may indicate a
mechanical defect:
a.A “rolling rumble” noise during coasting,
acceleration, or deceleration. The noise
increases with front and/or rear wheel speed,
but it does not increase with higher engine or
transmission speeds.
Diagnosis: Possible wheel bearing damage.
b.A “whining” noise that varies with
acceleration and deceleration.
Diagnosis: Possible incorrect reassembly,
too-little gear lash.
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TROUBLESHOOTING
DRIV
CAUTION:
Too little gear lash is extremely destructive to
the gear teeth. If a test ride following
reassembly indicates this condition, stop
riding immediately to minimize gear damage.
c.A slight “thunk” evident at low speed
operation. This noise must be distinguished
from normal machine operation.
Diagnosis: Possible broken gear teeth.
WARNING
Stop riding immediately if broken gear
teeth are suspected. This condition could
result in the shaft drive assembly locking
up, causing loss of control of the machine
and possible injury to the rider.
*****************************************************
2.Check:
● Drained oil
Drained oil shows large amounts of metal
particles → Check the bearing for seizure.
NOTE:
A small amount of metal particles in the oil is
normal.
3.Check:
● Oil leakage
*****************************************************
Checking steps:
● Clean the entire machine thoroughly, then
dry it.
● Apply a leak-localizing compound or dry
powder spray to the shaft drive.
● Road test the machine for the distance
necessary to locate the leak.
Leakage → Check the component housing,
gasket, and/or seal for damage.
Damage → Replace the component.
NOTE:
● An apparent oil leak on a new or nearly new
machine may be the result of a rustpreventative coating or excessive seal
lubrication.
● Always clean the machine and recheck the
suspected location of an apparent leakage.
*****************************************************
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7
TROUBLESHOOTING
DRIV
Troubleshooting chart
When basic condition “a” and “b” exist, check the following points:
Elevate and spin both wheels. Feel for
wheel bearing damage.
YES
Replace the wheel bearing.
(Refer to “STEERING SYSTEM” and
“REAR
SHOCK
ABSORBER
AND
SWINGARM” in CHAPTER 8.)
NO
Check the wheel nuts and hub nuts for
tightness.
NO
Torque to specification.
(Refer to “FRONT AND REAR WHEELS”
in CHAPTER 8.)
YES
Check the constant velocity joint. Feel for
bearing damage.
NO
Constant velocity joint bearings and
differential gear bearings are probably not
damaged. Repeat the test or remove the
individual components.
YES
Check the rear brake adjustment.
NO
Adjust per instructions.
(Refer to “ADJUSTING
BRAKE” in CHAPTER 3.)
THE
REAR
YES
Check the rear axle. Feel for bearing
damage.
NO
Rear axle bearings and rear drive shaft
bearings are probably not damaged.
Repeat the test or remove the individual
components.
YES
Remove the rear axle. Check for axle
bearing damage.
YES
Replace the rear axle bearing.
(Refer to “REAR AXLE/FINAL DRIVE
GEAR AND DRIVE SHAFT”.)
NO
Remove the drive shaft components.
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FRONT CONSTANT VELOCITY JOINTS AND
DIFFERENTIAL GEAR
DRIV
FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR
Order
Job name/Part name
Removing the front constant
velocity joint and differential gear
Engine skid plate (front)
Front fender
Differential gear oil
Steering knuckle
Q’ty
Refer to “SEAT, CARRIERS, FENDERS
AND FUEL TANK” in CHAPTER 3.
Drain.
Refer to “STEERING SYSTEM” in
CHAPTER 8.
Refer to “FRONT ARMS AND FRONT
SHOCK ABSORBER” in CHAPTER 8.
Refer to “FRONT AND REAR BRAKES”
in CHAPTER 8.
Front arms (lower)
Brake master cylinder cover
1
2
3
Constant velocity joint
Gear motor coupler/on-command fourwheel drive switch and differential gear
lock switch coupler
Differential gear case breather hose
Remarks
Remove the parts in the order below.
2
1/1
Disconnect.
1
Disconnect.
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FRONT CONSTANT VELOCITY JOINTS AND
DIFFERENTIAL GEAR
Order
4
5
6
Job name/Part name
Differential gear
Drive shaft
Compression spring
Q’ty
1
1
1
DRIV
Remarks
For installation, reverse the removal
procedure.
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FRONT CONSTANT VELOCITY JOINTS AND
DIFFERENTIAL GEAR
Order
1
2
3
4
5
6
7
8
9
Job name/Part name
Disassembling the constant velocity
joint
Circlip
Boot band
Boot band
Dust boot
Circlip
Double off-set joint
Snap ring
Ball bearing
Joint shaft assembly
Q’ty
1
2
2
2
1
1
1
1
1
DRIV
Remarks
Remove the parts in the order below.
Refer to “ASSEMBLING THE FRONT
CONSTANT VELOCITY JOINT”.
For assembly, reverse the disassembly
procedure.
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FRONT CONSTANT VELOCITY JOINTS AND
DIFFERENTIAL GEAR
Order
Q’ty
1
Job name/Part name
Disassembling the differential gear
Gear motor/O-ring
2
3
4
5
6
7
8
9
0
A
Circlip
Bearing
Universal joint
Universal joint yoke/O-ring
Stopper bolt/shaft
Shift fork sliding gear
Shift fork
Differential gear case cover
Drive clutch
Shim (left)
2
2
1
1/1
1/1
1
1
1
1
1/1
DRIV
Remarks
Remove the parts in the order below.
NOTE:
Be sure not to disassemble the gear
motor or remove the pinion gear.
Refer to “REMOVING/INSTALLING THE
UNIVERSAL JOINT”.
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FRONT CONSTANT VELOCITY JOINTS AND
DIFFERENTIAL GEAR
Order
B
C
D
E
F
Job name/Part name
Differential gear assembly
Shim (right)
Circlip/bearing
Drive pinion gear
Differential gear case
Q’ty
1
1
1/1
1
1
DRIV
Remarks
For assembly, reverse the disassembly
procedure.
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FRONT CONSTANT VELOCITY JOINTS AND
DIFFERENTIAL GEAR
DRIV
REMOVING THE UNIVERSAL JOINT
1.Remove:
● Universal joint
*****************************************************
Removal steps:
● Remove the circlips 1.
● Place the U-joint in a press.
● With a suitable diameter pipe 2 beneath the
yoke 3, press the bearing 4 into the pipe as
shown.
NOTE:
It may be necessary to lightly tap the yoke with
a punch.
● Repeat
the steps for the opposite bearing.
● Remove the yoke.
NOTE:
it may be necessary to lightly tap the yoke with
a punch.
*****************************************************
2.Remove:
● Universal joint yoke
Use a universal joint holder 1.
Universal joint holder:
P/N. YM-04062, 90890-04062
REMOVING THE RING GEAR
1.Remove:
● Ring gear 1
NOTE:
The ring gear and the differential gear cover
should be fastened together. Do not
disassemble the differential gear assembly.
CAUTION:
The differential gears are assembled into a
proper unit at the factory by means of
specialized equipment. Do not attempt to
disassemble this unit. Disassembly will
result in the malfunction of the unit.
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FRONT CONSTANT VELOCITY JOINTS AND
DIFFERENTIAL GEAR
DRIV
CHECKING THE CONSTANT VELOCITY
JOINT
1.Check:
● Double off-set joint spline
● Ball joint spline
● Shaft spline
Wear/damage → Replace.
2.Check:
● Dust boots
Cracks/damage → Replace.
CAUTION:
Always use a new boot band.
3.Check:
● Balls and ball races
● Inner surface of double off-set joint
Pitting/wear/damage → Replace.
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
● Universal joints
● Front drive gear splines
Wear/damage → Replace.
● Spring
Fatigue → Replace.
Move the spring up and down.
3.Check:
Front drive shaft
Bends → Replace.
●
WARNING
Do not attempt to straighten a bent shaft;
this may dangerously weaken the shaft.
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FRONT CONSTANT VELOCITY JOINTS AND
DIFFERENTIAL GEAR
È
DRIV
CHECKING THE GEAR MOTOR
1.Check:
● Gear motor
*****************************************************
Checking steps:
● Connect two C size batteries to the gear
motor terminals 1. (as shown illustration)
CAUTION:
É
Do not use a 12 V battery to operate the
pinion gear.
È Check that the pinion gear 2 turns
counterclockwise.
É Check that the pinion gear 2 turns clockwise.
NOTE:
Be sure not to disassemble the gear motor or
remove the pinion gear.
*****************************************************
ASSEMBLING THE FRONT CONSTANT
VELOCITY JOINT
1.Apply:
● Molybdenum disulfide grease
(into the ball joint assembly)
NOTE:
Molybdenum disulfide grease is included in the
repair kit.
2.Install:
● Dust boots 1
● Dust boot bands 2, 3 New
*****************************************************
Installation steps:
● Apply molybdenum disulfide grease into the
dust boots.
Molybdenum disulfide grease:
40 g (1.4 oz) per dust boot
● Install
● Install
the dust boots.
the dust boot bands.
NOTE:
● The new boot bands may differ from the
original ones.
● The dust boots should be fastened with the
dust boot bands 3 at the grooves in the joint
shaft.
*****************************************************
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FRONT CONSTANT VELOCITY JOINTS AND
DIFFERENTIAL GEAR
DRIV
3.Check:
● Free play (thrust movement)
Excessive play → Replace the joint
assembly.
ASSEMBLING THE DIFFERENTIAL GEAR
1.Measure:
● Gear lash
Refer to “MEASURING AND ADJUSTING
THE DIFFERENTIAL GEAR LASH”.
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, and operate it 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.
*****************************************************
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FRONT CONSTANT VELOCITY JOINTS AND
DIFFERENTIAL GEAR
DRIV
3.Install:
● Universal joint yoke
● O-ring
● Washer
● Nut
62 Nm (6.2 m • kg, 45 ft • lb)
Use a universal joint holder 1.
LT
T.
R.
Universal joint holder:
P/N. YM-04062, 90890-04062
4.Check:
● Differential gear operation
Unsmooth operation → Replace the
differential gear assembly.
Insert the double off-set joint into the
differential gear, and turn the gear back and
forth.
INSTALLING THE UNIVERSAL JOINT
1.Install:
● Universal joint
*****************************************************
Installation steps:
● Install the opposite yoke into the U-joint.
● Apply wheel bearing grease to the bearings.
● Install the bearing 1 onto the yoke.
CAUTION:
Check each bearing. The needles can
easily fall out of their races. Slide the yoke
back and forth on the bearings; the yoke
will not go all the way onto a bearing if a
needle is out of place.
● Press
each bearing into the U-joint using a
suitable socket.
NOTE:
The bearing must be inserted far enough into
the U-joint so that the circlip can be installed.
the circlips 2 into the groove of each
bearing.
● Install
*****************************************************
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FRONT CONSTANT VELOCITY JOINTS AND
DIFFERENTIAL GEAR
DRIV
MEASURING AND ADJUSTING THE
DIFFERENTIAL GEAR LASH
Measuring the differential gear lash
1.Secure the gear case in a vise or another
supporting device.
2.Remove:
● Drain plug
● Gasket
3.Install:
● A bolt of the specified size 1
(into the drain plug hole)
CAUTION:
Finger tighten the bolt until it holds the ring
gear. Otherwise, the ring gear will be
damaged.
4.Attach:
● Gear lash measurement tool 1
● Dial gauge 2
Gear lash measurement tool:
P/N. YM-01467, 90890-01467
a Measuring point is 21 mm (0.83 in)
5.Measure:
● Gear lash
Gently rotate the gear coupling
engagement to engagement.
from
Differential gear lash:
0.05 ~ 0.25 mm
(0.0020 ~ 0.0098 in)
NOTE:
Measure the gear lash at four positions. Rotate
the shaft 90° each time.
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FRONT CONSTANT VELOCITY JOINTS AND
DIFFERENTIAL GEAR
DRIV
Adjusting differential gear lash
1.Remove:
● Shim(s) (left) 1
● Differential gear assembly 2
● Shim(s) (right) 3
2.Adjust:
● Gear lash
*****************************************************
Adjustment steps:
● Select the suitable shims using the following
chart.
Too little gear lash
Reduce shim
thickness.
Too large gear lash
Increase shim
thickness.
● If
it is necessary to increase by more than
0.05 mm (0.002 in):
Reduce right shim thickness by 0.1 mm
(0.004 in) for every 0.1 mm (0.004 in) of left
shim increase.
● If it is necessary to reduce by more than
0.1 mm (0.004 in):
Increase right shim thickness by 0.1 mm
(0.004 in) for every 0.1 mm of left shim
decreased.
Ring gear shim (left and right)
Thickness (mm)
0.1
0.4
1.5
0.2
0.5
2.0*
0.3
1.0
2.5*
* Right only
*****************************************************
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FRONT CONSTANT VELOCITY JOINTS AND
DIFFERENTIAL GEAR
DRIV
CHECKING THE DIFFERENTIAL GEAR
OPERATION
1.Block the rear wheels, and elevate the front
wheels by placing a suitable stand under the
frame.
2.Remove the wheel cap and cotter pin from
the axle nut (right or left).
3.Measure the starting torque of the front
wheel (i.e., differential gear preload) with the
torque wrench.
NOTE:
● Repeat this step several times to obtain an
average figure.
● During this test, the other front wheel will turn
in the opposite direction.
T.
R.
Front wheel starting torque:
(differential gear preload):
New unit:
17 ~ 25 Nm
(1.7 ~ 2.5 m • kg, 12 ~ 18 ft • lb)
Minimum:
10 Nm (1.0 m • kg, 7.2 ft • lb)
4.Out of specification → Replace the
differential gear assembly.
5.Within specification → Install the new cotter
pin and wheel cap.
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REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT
DRIV
REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT
Order
1
2
3
4
5
6
Job name/Part name
Removing the rear axle, final drive
gear assembly and drive shaft
Final gear oil
Rear wheel hubs/brake disc
Q’ty
O-ring
Rear axle/dust cover
Trailer hitch bracket
Final drive gear case breather hose
Final drive gear
Drive shaft
1
1/1
1
1
1
1
Remarks
Remove the parts in the order below.
Drain.
Refer to “FRONT AND REAR WHEELS”
in CHAPTER 8.
Disconnect.
Refer to “REMOVING/
INSTALLING THE
REAR AXLE”.
For installation, reverse the removal
procedure.
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REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT
Order
Q’ty
1
2
Job name/Part name
Disassembling the final drive gear
Bolt
Bolt
3
4
5
6
7
8
9
0
Bearing housing
Oil seal/bearing
Ring gear stopper
Ring gear stopper shim
Oil seal/bearing
Ring gear shim
Ring gear
Thrust washer
1
1/1
1
1
1/1
1
1
1
2
6
DRIV
Remarks
Remove the parts in the order below.
NOTE:
Working in a crisscross pattern, loosen
each bolt 1/4 of a turn. After all the bolts
are loosened, remove them.
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REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT
Order
A
B
C
D
E
F
G
H
I
Job name/Part name
Bearing retainer/O-ring
Oil seal
Final drive pinion gear
Collar
Bearing
Final drive pinion gear shim
Final drive gear case/O-ring
Bearing/oil seal
Bearing
Q’ty
1/1
1
1
1
1
1
1/1
1/1
1
DRIV
Remarks
Refer to “DISASSEMBLING/
ASSEMBLING THE FINAL DRIVE
GEAR”.
Refer to “REPLACING THE FINAL
DRIVE ROLLER BEARING”.
For assembly, reverse the disassembly
procedure.
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REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT
DRIV
REMOVING THE REAR AXLE
1.Remove:
● Rear axle 1
(with dust seal)
● O-ring
CAUTION:
●
●
Never directly tap the axle end with a
hammer, since this will result in damage
to the axle thread and spline.
Attach a suitable socket 2 on the axle
end and tap it with a soft hammer. Pull out
the rear axle to the right.
DISASSEMBLING THE FINAL DRIVE GEAR
1.Remove:
● Bearing retainer (final drive pinion gear)
NOTE:
Use a bearing retainer wrench 1.
Bearing retainer wrench:
P/N. YM-04050, 90890-04050
CAUTION:
The final drive shaft bearing retainer has
left-handed threads. To loosen the retainer,
turn it clockwise.
2.Remove:
● Final drive pinion gear assembly
With a soft hammer, lightly tap on the final
drive pinion gear end.
CAUTION:
Removal of the final drive pinion gear
should only be performed if gear
replacement is necessary.
WARNING
Always use new bearings and races.
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REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT
DRIV
REPLACING THE FINAL DRIVE ROLLER
BEARING
1.Remove:
● Roller bearing (ring gear) 1
Use a suitable press tool 2 and an
appropriate support for the main housing.
● Oil seal 3
2.Remove:
● Roller bearing (final drive pinion gear) 1
*****************************************************
Removal steps:
● Heat the main housing only to 150 °C
(302 °F).
● Remove the roller bearing outer race with an
appropriately shaped punch 2.
● Remove the inner race from the final drive
pinion gear.
NOTE:
The removal of the final drive pinion gear roller
bearing is difficult and seldom necessary.
*****************************************************
3.Install:
● Roller bearing (final drive pinion gear) New
*****************************************************
Installation steps:
● Heat the main housing only to 150 °C
(302 °F).
● Install the roller bearing outer race using the
proper adapter.
● Install the inner race onto the drive pinion
gear.
*****************************************************
4.Install:
● Oil seal 1 New
● Roller bearing 2
Use a suitable press tool 3 and a press to
install the above components into the main
housing.
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REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT
DRIV
POSITIONING THE FINAL DRIVE PINION
GEAR AND RING GEAR
When the final drive pinion gear, ring gear,
final gear case and/or ring gear bearing
housing are replaced, be sure to adjust the
positions of the final drive pinion gear and ring
gear using the shim(s).
Final drive pinion gear shim selection
1.Select:
● Final drive pinion gear shim(s) 1
*****************************************************
Selection steps:
● To find the final drive pinion gear shim
thickness “A”, use the following formula.
Final drive pinion gear shim thickness:
“A” = a – b
a = a numeral (usually a decimal number)
on the final drive pinion gear either
added to or subtracted from “84”
b = a numeral (usually a decimal number)
on the final gear case either added to or
subtracted from “83”
Example:
1) If “01” is stamped on the final drive
pinion gear,
a = 84 + 0.01 = 84.01
2) If “50” is stamped on the final gear case,
b = 83 + 0.50 = 83.50
3) Therefore, “A” is 0.51.
“A”= 84.01 – 83.50
= 0.51
4) Round off the hundredth digit and select
the appropriate shim(s).
In the example above, the calculated
number is 0.51. The chart instructs you
to round off 1 to 0 at the hundredth
place. Thus, the shim thickness is
0.50 mm.
Hundredths
Rounded value
0, 1, 2
0
3, 4, 5, 6, 7
5
8, 9
10
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DRIV
REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT
Shims are
thicknesses.
supplied
in
the
following
Final drive pinion gear shim
Thickness (mm)
0.15
0.45
0.30
0.50
0.40
0.60
*****************************************************
Ring gear shim selection
1.Select:
● Ring gear shim(s) 1
*****************************************************
Selection steps:
● To find the ring gear shim thickness “B”, use
the following formula.
Ring gear shim thickness:
“B” = c + d – (e + f)
c = a numeral (usually a decimal number)
on the final gear case either added to or
subtracted from 45
d = a numeral (usually a decimal number)
on the outside of the ring gear bearing
housing and added to 1
e = a numeral (usually a decimal number)
on the inside of the ring gear either
added to or subtracted from 35.00
f = bearing thickness (considered constant)
Bearing thickness f:
11.00 mm
Example:
1) If “53” is stamped on the final gear case,
c = 45 + 0.53 = 45.53
2) If “05” is stamped on the ring gear
bearing housing,
d = 1 + 0.05
= 1.05
3) If “– 05” is stamped on the ring gear,
e = 35 – 0.05
= 34.95
4) f = 11.00.
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DRIV
REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT
5) Therefore, shim thickness “B” is 0.63.
“B”= 45.53 + 1.05 – (34.95 + 11.00)
= 46.58 – 45.95
= 0.63
6) Round off the hundredth digit and select
the appropriate shim(s).
In the example above, the calculated
number is 0.63. The chart instructs you
to round off 3 to 5 at the hundredth
place.
Thus, the shim thickness is 0.65 mm.
Hundredths
Rounded value
0, 1, 2
0
3, 4, 5, 6, 7
5
8, 9
10
Shims are
thicknesses.
supplied
in
the
following
Ring gear shim
Thickness (mm)
0.25
0.40
0.30
0.45
0.35
0.50
*****************************************************
Thrust washer selection
1.Measure/select:
● Ring gear thrust clearance “C”
*****************************************************
Measurement steps:
● Place four pieces of Plastigauge® between
the originally fitted thrust washer and the ring
gear.
● Install the ring gear assembly and tighten the
bolts to specification.
T.
R.
M8 Bolts (bearing housing):
23 Nm (2.3 m • kg, 17 ft • lb)
M10 Bolts (bearing housing):
40 Nm (4.0 m • kg, 29 ft • lb)
NOTE:
Do not turn the drive pinion gear and ring gear
when
measuring
the
clearance
with
®
Plastigauge .
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REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT
DRIV
● Remove
the ring gear assembly.
● Measure the thrust clearance. Calculate the
width of the flattened Plastigauge® 1.
Ring gear thrust clearance:
0.1 ~ 0.2 mm (0.004 ~ 0.008 in)
● If
out of specification, select the correct
washer.
Thrust washer selection steps:
● Select a suitable thrust washer using the
following chart.
Thrust washer
Thickness (mm)
1.0
1.3
1.45
1.6
1.9
1.1
1.35
1.5
1.7
2.0
1.2
1.4
1.55
1.8
2.1
● Repeat
the measurement steps until the ring
gear thrust clearance is within the specified
limits.
*****************************************************
Ring gear stopper shim selection
1.Measure:
● Ring gear stopper clearance “D”
Use a feeler gauge 1.
Out of specification → Adjust.
Ring gear stopper clearance “D”:
0.30 ~ 0.60 mm (0.012 ~ 0.024 in)
2 Ring gear
3 Ring gear stopper
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REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT
DRIV
Ring gear stopper clearance adjustment
1.Remove:
● Ring gear 1
● Ring gear stopper 2
● Shim(s) 3
4 Bearing housing
È Left-hand threads
2.Select:
● Suitable shim(s)
Shim
0.10
0.30
Thickness (mm)
0.15
0.40
0.20
0.50
3.Install:
● Shim(s)
● Ring gear stopper (left-hand threads)
T.
R.
●
9 Nm (0.9 m • kg, 6.5 ft • lb)
Ring gear
NOTE:
Use LOCTITE on the ring gear stopper.
4.Measure:
● Ring gear stopper clearance
Out of specification → Repeat adjustment
steps.
Ring gear stopper clearance:
0.30 ~ 0.60 mm (0.012 ~ 0.024 in)
CHECKING THE REAR AXLE
1.Check:
● Rear axle runout a
Out of specification → Replace.
WARNING
Do not attempt to straighten a bent axle.
Rear axle runout limit:
1.5 mm (0.06 in)
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REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT
DRIV
CHECKING THE DRIVE SHAFT
1.Check:
● Drive shaft (splines)
Wear/damage → Replace.
CHECKING THE FINAL DRIVE GEAR
1.Check:
● Final gear case 1
● Bearing housing (ring gear) 2
Cracks/damage → Replace.
NOTE:
When the final gear case and/or the ring gear
bearing housing are replaced, be sure to
adjust the shim of the final drive pinion gear
and/or ring gear.
2.Check:
● Gear teeth
Pitting/galling/wear → Replace the drive
pinion gear and ring gear as a set.
● Oil seals
● O-rings
Damage → Replace.
3.Check:
● Bearings
Damage → Replace.
NOTE:
● Reusing roller bearings is acceptable, but
Yamaha recommends installing new ones.
Do not reuse the oil seal.
● When the final drive pinion gear and/or ring
gear are replaced, be sure to adjust the shim
of the final drive pinion gear and/or ring gear.
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REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT
DRIV
MEASUREMENT AND ADJUSTING THE
FINAL GEAR LASH
Final gear lash measurement
1.Secure the gear case in a vise or another
supporting device.
2.Remove:
● Drain plug
● Gasket
3.Install:
● A bolt of the specified size 1
(into the drain plug hole)
CAUTION:
Finger tighten the bolt until it holds the ring
gear. Otherwise, the ring gear will be
damaged.
4.Attach:
● Gear lash measurement tool 1
● Dial gauge 2
Gear lash measurement tool:
P/N. YM-01475, 90890-01475
a Measuring point is 31.46 mm (1.24 in)
5.Measure:
● Gear lash
Gently rotate the gear coupling
engagement to engagement.
from
Final gear lash:
0.1 ~ 0.2 mm (0.004 ~ 0.008 in)
NOTE:
Measure the gear lash at four positions. Rotate
the shaft 90° each time.
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DRIV
REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT
Final gear lash adjustment
1.Remove:
● Bearing housing 1
● Ring gear shim(s) 2
● Ring gear 3
● Thrust washer 4
2.Adjust:
● Gear lash
*****************************************************
Adjustment steps:
● Select a suitable shim(s) and thrust
washer(s) using the following chart.
Too little gear lash
Reduce shim
thickness.
Too large gear lash
Increase shim
thickness.
● If
increased by more than 0.2 mm (0.008 in):
Reduce the thrust washer thickness by
0.2 mm (0.008 in) for every 0.2 mm
(0.008 in) of ring gear shim increase.
● If reduced by more than 0.2 mm (0.008 in):
Increase the thrust washer thickness by
0.2 mm (0.008 in) for every 0.2 mm
(0.008 in) that the ring gear shim is
decreased.
Ring gear shim
Thickness (mm)
0.25
0.40
0.30
0.45
0.35
0.50
1.0
1.3
1.45
1.6
1.9
1.1
1.35
1.5
1.7
2.0
1.2
1.4
1.55
1.8
2.1
Thrust washer
Thickness (mm)
*****************************************************
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REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT
DRIV
ASSEMBLING THE FINAL DRIVE GEAR
1.Install:
● Drive pinion gear (with shim(s) and bearing)
(proper shim size as calculated)
● Bearing retainer (drive pinion gear) 1
T.
R.
100 Nm (10.0 m • kg, 72 ft • lb)
Use a bearing retainer wrench 2.
CAUTION:
●
●
Always use a new bearing.
The final drive shaft bearing retainer has
left-hand threads. Turn the retainer
counterclockwise to tighten it.
Bearing retainer wrench:
P/N. YM-04050, 90890-04050
2.Adjust:
● Final gear lash
Refer
to
“MEASUREMENT
AND
ADJUSTING THE FINAL GEAR LASH”.
INSTALLING THE FINAL DRIVE GEAR
1.Lubricate:
● Drive shaft
● Coupling gear
● O-ring
● Oil seal
● Bearing
Lithium-soap-based grease
2.Install:
● Drive shaft 1
(to the universal joint)
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REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT
DRIV
3.Apply:
®
● Sealant (Quick Gasket )
(to the mating surfaces of the swingarm and
the final drive gear case)
Sealant (Quick gasket®):
P/N. ACC-11001-05-01
Yamaha bond No.1215:
P/N. 90890-85505
4.Install:
● Final drive gear
● Nuts
● Bolts
LT
T.
R.
LT
63 Nm (6.3 m • kg, 45 ft • lb)
T.
R.
63 Nm (6.3 m • kg, 45 ft • lb)
5.Install:
● Dust cover
● Rear axle
*****************************************************
Installation steps:
● Install the dust cover 1 onto the rear axle.
NOTE:
Adjust the length a to 210.1 mm (8.3 in) when
install the dust cover.
the rear axle (with dust cover) 2.
● Install the rear brake disc and rear wheel hub
(left).
● Temporarily tighten the left axle nut 3.
● Install
NOTE:
After tightening the rear axle nut 3, the
position of the dust cover 1 will slightly move
to protect the oil seal of the final gear case.
*****************************************************
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FRONT AND REAR WHEELS
CHAS
CHASSIS
FRONT AND REAR WHEELS
FRONT WHEELS
Order
Job name/Part name
Removing the front 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
2
3
4
5
Front wheel
Wheel cap
Cotter pin
Axle nut
Brake caliper assembly
1
1
1
1
1
6
7
Wheel hub
Brake disc
1
1
Refer to “INSTALLING THE WHEEL”.
Refer to “INSTALLING THE WHEEL
HUB”.
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.
For installation, reverse the removal
Not For Resale
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8
FRONT AND REAR WHEELS
CHAS
REAR WHEELS
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
2
3
4
5
6
7
8
9
Rear wheel
Wheel cap
Cotter pin
Axle nut
Wheel hub
Brake caliper mounting bolt
Brake disc bracket
Brake disc
Brake disc guard
2
2
2
2
2
2
1
1
1
Refer to “INSTALLING THE WHEEL”.
Refer to “INSTALLING THE WHEEL
HUB”.
For installation, reverse the removal
procedure.
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FRONT AND REAR WHEELS
CHAS
CHECKING THE WHEEL
1.Check:
● Wheel
2.Measure:
● Wheel runout
Over the specified limit → Replace the wheel
or check the wheel bearing play 1.
Wheel runout limit:
Radial 2: 2.0 mm (0.08 in)
Lateral 3: 2.0 mm (0.08 in)
3.Check:
● Wheel balance
Out of balance → Adjust.
WARNING
After replacing the tire, ride conservatively
to allow the tire to be properly seated in the
rim. Failure to do so may cause an accident
resulting in machine damage and possible
operator injury.
CHECKING THE WHEEL HUB
1.Check:
● Wheel hub 1
Cracks/damage → Replace.
● Splines (wheel hub) 2
Wear/damage → Replace.
Not For Resale
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FRONT AND REAR WHEELS
CHAS
CHECKING THE BRAKE DISC
1.Check:
● Brake disc
Galling/damage → Replace.
2.Measure:
● Brake disc deflection
Out of specification → Check the wheel
runout.
If wheel runout is within the limits, replace
the brake disc.
Brake disc maximum deflection:
0.15 mm (0.006 in)
●
Brake disc thickness a
Out of specification → Replace.
Brake disc minimum thickness:
3 mm (0.12 in)
T.
INSTALLING THE WHEEL HUB
1.Install:
● Axle nut
150 Nm (15.0 m • kg, 110 ft • lb)
● Cotter pin 1 New
R.
NOTE:
Do not loosen the axle nut after torquing it. If
the axle nut groove is not aligned with the
cotter pin hole, align the groove with the hole
by tightening the axle nut.
INSTALLING THE WHEEL
1.Install:
● Wheel
NOTE:
The arrow mark 1 on the tire must point in the
direction of rotation È of the wheel.
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FRONT AND REAR WHEELS
CHAS
2.Install:
● Nuts (wheel) 1
WARNING
Tapered wheel nuts 1 are used for both the
front and rear wheels. Install each nut with
its tapered side towards the wheel.
3.Tighten:
● Nuts (front wheel)
T.
R.
●
64 Nm (6.4 m • kg, 46 ft • lb)
Nuts (rear wheel)
T.
R.
55 Nm (5.5 m • kg, 40 ft • lb)
NOTE:
Tighten the nuts in stages and in a crisscross
pattern.
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FRONT AND REAR BRAKES
CHAS
FRONT AND REAR BRAKES
FRONT BRAKE PADS
Order
1
2
3
4
Job name/Part name
Removing the front brake pads
Front wheel
Brake caliper mounting bolt
Brake pad holding bolt
Brake pad/pad shim
Pad spring
Q’ty
2
2
2/1
1
Remarks
Remove the parts in the order below.
Refer to “FRONT AND REAR WHEELS”.
Refer to “REPLACING THE FRONT
BRAKE PAD”.
For installation, reverse the removal
procedure.
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FRONT AND REAR BRAKES
CHAS
REAR BRAKE PADS
Order
1
2
3
4
Job name/Part name
Removing the rear brake pads
Rear wheel (left)
Brake caliper mounting bolt
Brake pad holding bolt
Brake pad/insulator/pad shim
Pad spring
Q’ty
2
2
2/2/2
1
Remarks
Remove the parts in the order below.
Refer to “FRONT AND REAR WHEELS”.
Refer to “REPLACING THE REAR
BRAKE PAD”.
For installation, reverse the removal
procedure.
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FRONT AND REAR BRAKES
CHAS
CAUTION:
Disc brake components rarely require
disassembly. DO NOT:
components
unless
● disassemble
absolutely necessary;
solvents
on
internal
brake
● use
components;
● use spent brake fluid for cleaning; (use
only clean brake fluid)
● allow brake fluid to come in contact with
the eyes, as this may cause eye injury;
● splash brake fluid onto painted surfaces or
plastic parts, as this may cause damage;
● disconnect any hydraulic connection, as
this would require the entire brake
system to be disassembled, drained,
cleaned, properly filled and bled after
reassembly.
REPLACING THE FRONT BRAKE PAD
NOTE:
It is not necessary to disassemble the brake
caliper and brake hose to replace the brake
pads.
1.Measure:
● Brake pad wear limit a
Out of specification → Replace the brake
pad as a set.
Brake pad wear limit:
1 mm (0.04 in)
2.Install:
● Brake pads
● Brake pad spring
NOTE:
Always install new brake pads, brake pad shim
and brake pad spring as a set.
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FRONT AND REAR BRAKES
CHAS
*****************************************************
Installation steps:
● Connect a suitable hose 1 tightly to the
brake caliper bleed screw 2. Put the other
end of this hose into an open container.
● Loosen the brake caliper bleed screw and,
using a finger, push the caliper piston into
the brake caliper.
● Tighten the brake caliper bleed screw.
T.
Brake caliper bleed screw:
6 Nm (0.6 m • kg, 4.3 ft • lb)
R.
new brake pads, new pad shims 3
and a new brake pad spring.
● Install the retaining bolts and brake caliper.
● Install
NOTE:
The arrow mark a on the pad shim must point
in the direction of the disc rotation.
T.
R.
Brake pad holding bolt:
18 Nm (1.8 m • kg, 13 ft • lb)
Brake caliper mounting bolt:
30 Nm (3.0 m • kg, 22 ft • lb)
*****************************************************
3.Check:
● Brake fluid level
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in CHAPTER 3.
4.Check:
● Brake lever operation
Soft or spongy feeling → Bleed the front
brake system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in CHAPTER 3.
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FRONT AND REAR BRAKES
CHAS
REPLACING THE REAR BRAKE PAD
NOTE:
It is not necessary to disassemble the brake
caliper and brake hose to replace the brake
pads.
1.Measure:
● Brake pad wear limit a
Out of specification → Replace the brake
pad as a set.
Brake pad wear limit:
1 mm (0.04 in)
2.Install:
● Brake pads
● Brake pad spring
NOTE:
Always install new brake pads, brake pad
shims, insulator and brake pad spring as a set.
*****************************************************
Installation steps:
● Connect a suitable hose 1 tightly to the
brake caliper bleed screw 2. Put the other
end of this hose into an open container.
● Loosen the brake caliper bleed screw and,
using a finger, push the caliper piston into
the brake caliper.
● Tighten the brake caliper bleed screw.
T.
Brake caliper bleed screw:
6 Nm (0.6 m • kg, 4.3 ft • lb)
R.
● Install
new brake pads, new insulator, new
pad shims and a new brake pad spring.
● Install the holding bolts and brake caliper.
T.
R.
Brake pad holding bolt:
18 Nm (1.8 m • kg, 13 ft • lb)
Brake caliper mounting bolt:
30 Nm (3.0 m • kg, 22 ft • lb)
*****************************************************
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FRONT AND REAR BRAKES
CHAS
3.Check:
● Brake fluid level
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in CHAPTER 3.
4.Check:
● Brake lever or brake pedal operation
Soft or spongy feeling → Bleed the rear
brake system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in CHAPTER 3.
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FRONT AND REAR BRAKES
CHAS
FRONT BRAKE MASTER CYLINDER
Order
1
2
3
4
5
6
7
8
9
Job name/Part name
Removing the front brake master
cylinder
Brake fluid
On-command four-wheel drive switch
and differential gear lock switch
Brake fluid reservoir cap
Brake fluid reservoir diaphragm
Brake lever
Union bolt
Copper washer
Brake hose
Front brake light switch
Brake master cylinder bracket
Brake master cylinder
Q’ty
Remarks
Remove the parts in the order below.
Drain.
Refer to “HANDLEBAR”.
1
1
1
1
2
1
1
1
1
Refer to “INSTALLING THE FRONT
BRAKE MASTER CYLINDER”.
For installation, reverse the removal
procedure.
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FRONT AND REAR BRAKES
Order
1
2
Job name/Part name
Disassembling the front brake
master cylinder
Brake master cylinder kit
Brake master cylinder
Q’ty
1
1
CHAS
Remarks
Remove the parts in the order below.
Refer to “ASSEMBLING THE FRONT
BRAKE MASTER CYLINDER”.
For assembly, reverse the disassembly
procedure.
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FRONT AND REAR BRAKES
CHAS
REAR BRAKE MASTER CYLINDER
Order
1
2
3
4
5
6
7
8
9
Job name/Part name
Removing the rear brake master
cylinder
Front fender
Brake fluid
Brake fluid reservoir cap
Brake fluid reservoir diaphragm holder
Brake fluid reservoir diaphragm
Brake fluid reservoir
Brake master cylinder cover
Brake fluid reservoir hose
Union bolt
Copper washer
Brake hose
Q’ty
Remarks
Remove the parts in the order below.
Refer to “SEAT, CARRIERS, FENDERS
AND FUEL TANK” in CHAPTER 3.
Drain.
1
1
1
1
1
1
1
2
1
Refer to “INSTALLING THE REAR
BRAKE MASTER CYLINDER”.
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FRONT AND REAR BRAKES
Order
10
11
12
13
14
15
16
17
18
19
Job name/Part name
Brake cable
Bracket
Brake master cylinder
Hose joint
Brake pedal
Select lever control cable
Rear brake light switch
Bracket
Bracket
Brake master cylinder bracket
CHAS
Q’ty
Remarks
1
Disconnect.
1
1
1
1
1
Disconnect.
1
1
1
1
For installation, reverse the removal
procedure.
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FRONT AND REAR BRAKES
Order
1
2
Job name/Part name
Disassembling the rear brake
master cylinder
Brake master cylinder kit
Brake master cylinder
Q’ty
1
1
CHAS
Remarks
Remove the parts in the order below.
Refer to “ASSEMBLING THE REAR
BRAKE MASTER CYLINDER”.
For assembly, reverse the disassembly
procedure.
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FRONT AND REAR BRAKES
CHAS
È
CHECKING THE MASTER CYLINDER
1.Check:
● Brake master cylinder 1
Wear/scratches → Replace the brake master
cylinder assembly.
● Brake master cylinder body
Cracks/damage → Replace.
● Brake fluid delivery passage
(brake master cylinder body)
Blockage → Blow out with compressed air.
É
È Front
É Rear
2.Check:
● Front brake master cylinder reservoir 1
● Front
brake master cylinder reservoir
diaphragm 2
Cracks/damage → Replace.
3.Check:
● Rear brake fluid reservoir 1
● Rear brake fluid reservoir diaphragm 2
Cracks/damage → Replace.
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FRONT AND REAR BRAKES
CHAS
EB702060
ASSEMBLING THE FRONT BRAKE
MASTER CYLINDER
WARNING
●
All internal brake components should be
cleaned and lubricated with new brake
fluid only before installation.
Recommended brake fluid:
DOT 4
●
Whenever
a
master
cylinder
is
disassembled, replace the piston seals
and dust seals.
EB702060
ASSEMBLING THE REAR BRAKE MASTER
CYLINDER
WARNING
●
All internal brake components should be
cleaned and lubricated with new brake
fluid only before installation.
Recommended brake fluid:
DOT 4
●
Whenever
a
master
cylinder
is
disassembled, replace the piston seals
and dust seals.
1.Install:
● Brake master cylinder kit
● Nut 1
● Joint 2
NOTE:
Turn the adjusting bolt 3 until the clearance a
is within the specified limits when install the
joint 2.
Clearance a:
4 ~ 6 mm (0.16 ~ 0.24 in)
2.Tighten:
● Nut 1
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FRONT AND REAR BRAKES
CHAS
INSTALLING THE FRONT BRAKE MASTER
CYLINDER
1.Install:
● Brake master cylinder 1
● Brake master cylinder bracket 2
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • lb)
NOTE:
The “UP” mark on the brake master cylinder
bracket 2 should face up.
T.
2.Install:
● Copper washers New
● Brake hose
● Union bolt
27 Nm (2.7 m • kg, 19 ft • lb)
R.
60˚
NOTE:
● Tighten the union bolt while holding the
brake hose as shown.
● Turn the handlebar to the left and to the right
to check that the brake hose does not touch
other parts (throttle cable, wire harness,
leads, etc.). Correct if necessary.
WARNING
Proper brake hose routing is essential to
insure safe machine operation. Refer to
“CABLE ROUTING” in CHAPTER 2.
3.Fill:
● Brake fluid reservoir
Recommended brake fluid:
DOT 4
CAUTION:
Brake fluid may damage painted surfaces
or plastic parts. Always clean up spilled
brake fluid immediately.
WARNING
●
●
Use only the designated quality brake
fluid: other brake fluids may deteriorate
the rubber seals, causing leakage and
poor brake performance.
Refill with the same type of brake fluid:
mixing brake fluids may result in a
harmful chemical reaction and lead to
poor brake performance.
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FRONT AND REAR BRAKES
●
CHAS
Be careful that water does not enter the
brake master cylinder when refilling.
Water will significantly lower the boiling
point of the brake fluid and may result in
vapor lock.
4.Air bleed:
● Brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in CHAPTER 3.
5.Check:
● Brake fluid level
Brake fluid level is under the “LOWER” level
line → Fill up.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in CHAPTER 3.
T.
INSTALLING THE REAR BRAKE MASTER
CYLINDER
1.Install:
● Copper washers 1 New
● Brake hose 2
● Union bolt 3
30 Nm (3.0 m • kg, 22 ft • lb)
R.
CAUTION:
When installing the brake hose onto the
brake master cylinder, make sure the brake
pipe touches the projection a as shown.
WARNING
Proper brake hose routing is essential to
insure safe machine operation. Refer to
“CABLE ROUTING” in CHAPTER 2.
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FRONT AND REAR BRAKES
CHAS
2.Fill:
● Brake fluid reservoir
Recommended brake fluid:
DOT 4
CAUTION:
Brake fluid may damage painted surfaces
or plastic parts. Always clean up spilled
brake fluid immediately.
WARNING
●
●
●
Use only the designated quality brake
fluid: other brake fluids may deteriorate
the rubber seals, causing leakage and
poor brake performance.
Refill with the same type of brake fluid:
mixing brake fluids may result in a
harmful chemical reaction and lead to
poor brake performance.
Be careful that water does not enter the
brake master cylinder when refilling.
Water will significantly lower the boiling
point of the brake fluid and may result in
vapor lock.
3.Air bleed:
● Brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in CHAPTER 3.
4.Check:
● Brake fluid level
Brake fluid level is under the “LOWER” level
line → Fill up.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in CHAPTER 3.
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FRONT AND REAR BRAKES
CHAS
FRONT BRAKE CALIPER
Order
1
2
3
4
5
6
7
Job name/Part name
Removing the front brake caliper
Brake fluid
Front wheel
Union bolt
Copper washer
Brake hose
Cap/retaining bolt
Brake pad holding bolt
Brake caliper mounting bolt
Brake caliper assembly
Q’ty
1
2
1
1/1
2
2
1
Remarks
Remove the parts in the order below.
Drain.
Refer to “FRONT AND REAR WHEELS”.
Disconnect.
Loosen.
Loosen.
Refer to “INSTALLING
THE FRONT BRAKE
CALIPER”.
For installation, reverse the removal
procedure.
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FRONT AND REAR BRAKES
Order
1
2
3
4
5
6
7
8
9
Job name/Part name
Disassembling the front brake
caliper
Brake pad holding bolt
Brake pad/pad shim
Pad spring
Retaining bolt
Caliper bracket
Brake caliper piston
Dust seal
Caliper piston seal
Bleed screw
Q’ty
2
2/1
1
1
1
1
1
1
1
CHAS
Remarks
Remove the parts in the order below.
Refer to “DISASSEMBLING/
ASSEMBLING THE FRONT AND REAR
BRAKE CALIPER”.
For assembly, reverse the disassembly
procedure.
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FRONT AND REAR BRAKES
CHAS
REAR BRAKE CALIPER
Order
1
2
3
4
5
6
Job name/Part name
Removing the rear brake caliper
Brake fluid
Rear wheel
Union bolt
Copper washer
Brake hose
Brake pad holding bolt
Brake caliper mounting bolt
Brake caliper assembly
Q’ty
1
2
1
2
2
1
Remarks
Remove the parts in the order below.
Drain.
Refer to “FRONT AND REAR WHEELS”.
Disconnect.
Loosen.
Refer to “INSTALLING
THE REAR BRAKE
CALIPER”.
For installation, reverse the removal
procedure.
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FRONT AND REAR BRAKES
Order
1
2
3
4
5
6
7
8
CHAS
Job name/Part name
Q’ty
Remarks
Disassembling the rear brake caliper
Remove the parts in the order below.
Brake pad holding bolt
2
Brake pad/insulator/pad shim
2/2/2
Pad spring
1
Caliper bracket
1
Brake caliper piston
1
Refer to “DISASSEMBLING/
Dust seal
1
ASSEMBLING THE FRONT AND REAR
BRAKE CALIPER”.
Caliper piston seal
1
Bleed screw
1
For assembly, reverse the disassembly
procedure.
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FRONT AND REAR BRAKES
CHAS
DISASSEMBLING THE FRONT AND REAR
BRAKE CALIPER
1.Remove:
● Brake caliper piston
● Dust seal 1
● Caliper piston seal 2
*****************************************************
Removal steps:
● Blow compressed air into the hose joint
opening to force out the caliper piston from
the brake caliper body.
WARNING
●
●
Never try to pry out the caliper piston.
Cover the caliper piston with a rag. Be
careful not to get injured when the piston
is expelled from the master cylinder.
● Remove
the caliper piston seals.
*****************************************************
EB702040
CHECKING THE FRONT AND REAR BRAKE
CALIPER
Recommended brake component
replacement schedule:
Brake pads
As required
Piston seal, dust seal Every two years
Brake hoses
Every two years
Brake fluid
Replace when
brakes are
disassembled.
WARNING
All internal brake components should be
cleaned in new brake fluid only. Do not use
solvents as they will cause seals to swell
and distort.
È
1.Check:
● Brake caliper piston 1
Scratches/rust/wear → Replace the brake
caliper assembly.
● Brake caliper cylinder 2
Wear/scratches → Replace the brake caliper
assembly.
● Brake caliper body 3
Cracks/damage → Replace.
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FRONT AND REAR BRAKES
É
●
CHAS
Brake fluid delivery passage (brake caliper
body)
Blockage → Blow out with compressed air.
WARNING
Replace the caliper piston seal and dust
seal whenever the brake caliper is
disassembled.
È Front
É Rear
ASSEMBLING THE FRONT AND REAR
BRAKE CALIPER
WARNING
●
All internal brake components should be
cleaned and lubricated with new brake
fluid only before installation.
Recommended brake fluid:
DOT 4
●
Replace the caliper piston seal whenever
a brake caliper is disassembled.
1.Install:
● Caliper piston seal 1 New
● Dust seal 2 New
2.Install:
● Brake caliper piston 1
INSTALLING THE FRONT BRAKE CALIPER
1.Install:
● Brake caliper assembly
● Brake caliper mounting bolt 1
T.
R.
●
●
T.
R.
●
30 Nm (3.0 m • kg, 22 ft • lb)
Brake hose 2
Copper washers 3 New
Union bolt 4
27 Nm (2.7 m • kg, 19 ft • lb)
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FRONT AND REAR BRAKES
CHAS
CAUTION:
When installing the brake hose on the
brake caliper, make sure that the brake
pipe touches the projection a on the brake
caliper.
WARNING
Proper brake hose routing is essential to
insure safe motorcycle operation. Refer to
“CABLE ROUTING” in CHAPTER 2.
2.Fill:
● Brake reservoir
Recommended brake fluid:
DOT 4
CAUTION:
Brake fluid may damage painted surfaces
or plastic parts. Always clean up spilled
brake fluid immediately.
WARNING
●
●
●
Use only the designated quality brake
fluid: other brake fluids may deteriorate
the rubber seals, causing leakage and
poor brake performance.
Refill with the same type of brake fluid:
mixing brake fluids may result in a
harmful chemical reaction and lead to
poor brake performance.
Be careful that water does not enter the
master cylinder when refilling. Water will
significantly lower the boiling point of the
brake fluid and may result in vapor lock.
3.Air bleed
● Brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in CHAPTER 3.
4.Check:
● Brake fluid level
Brake fluid level is under the “LOWER” level
line → Fill up.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in CHAPTER 3.
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FRONT AND REAR BRAKES
CHAS
INSTALLING THE REAR BRAKE CALIPER
1.Install:
● Brake caliper assembly
● Brake caliper mounting bolt 1
T.
R.
●
●
Brake hose 2
Copper washers 3 New
Union bolt 4
30 Nm (3.0 m • kg, 22 ft • lb)
T.
R.
●
30 Nm (3.0 m • kg, 22 ft • lb)
2.Fill:
● Brake reservoir
Recommended brake fluid:
DOT 4
CAUTION:
Brake fluid may damage painted surfaces
or plastic parts. Always clean up spilled
brake fluid immediately.
WARNING
●
●
●
Use only the designated quality brake
fluid: other brake fluids may deteriorate
the rubber seals, causing leakage and
poor brake performance.
Refill with the same type of brake fluid:
mixing brake fluids may result in a
harmful chemical reaction and lead to
poor brake performance.
Be careful that water does not enter the
master cylinder when refilling. Water will
significantly lower the boiling point of the
brake fluid and may result in vapor lock.
3.Air bleed
● Brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in CHAPTER 3.
4.Check:
● Brake fluid level
Brake fluid level is under the “LOWER” level
line → Fill up.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in CHAPTER 3.
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STEERING SYSTEM
CHAS
STEERING SYSTEM
HANDLEBAR
Order
Q’ty
4
5
6
Job name/Part name
Removing the handlebar
Handlebar cover
Band
On-command four-wheel drive switch
and differential gear lock switch
Master cylinder assembly/bracket
Throttle lever assembly/bracket
Rear brake switch
7
8
9
10
11
Rear brake lever/bracket
Handlebar switch
Handlebar grip
Handlebar holder
Handlebar
1/1
1
2
2
1
1
2
3
Remarks
Remove the parts in the order below.
1
4
1
1/1
1/1
1
Refer to “INSTALLING THE MASTER
CYLINDER ASSEMBLY”.
Refer to “REMOVING THE REAR
BRAKE SWITCH”.
Refer to “INSTALLING THE REAR
BRAKE LEVER”.
Refer to “INSTALLING THE
HANDLEBAR”.
For installation, reverse the removal
procedure.
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STEERING SYSTEM
CHAS
REMOVING THE REAR BRAKE SWITCH
1.Remove:
● Rear brake switch 1
NOTE:
Push the fastener when removing the rear
brake switch out of the rear brake lever holder.
CHECKING THE HANDLEBAR
1.Check:
● Handlebar
Bends/cracks/damage → Replace.
WARNING
Do not attempt to straighten a bent
handlebar as this may dangerously weaken
the handlebar.
INSTALLING THE HANDLEBAR
1.Install:
● Handlebar
● Handlebar holders
T.
R.
23 Nm (2.3 m • kg, 17 ft • lb)
NOTE:
The upper handlebar holder should be
installed with the punched mark 1 forward 2.
CAUTION:
First tighten the bolts 3 on the front side of
the handlebar holder, and then tighten the
bolts 4 on the rear side.
INSTALLING THE REAR BRAKE LEVER
1.Install:
● Handlebar switch 1
● Rear brake lever
● Lever bracket 2
NOTE:
Install the lever bracket as shown.
a 80 mm (3.1 in)
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STEERING SYSTEM
CHAS
INSTALLING THE MASTER CYLINDER
ASSEMBLY
1.Install:
● Throttle lever assembly
● Master cylinder assembly
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • lb)
NOTE:
The “UP” mark on the master cylinder bracket
should face up.
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STEERING SYSTEM
CHAS
STEERING STEM
Order
1
2
3
4
5
6
7
8
9
10
Job name/Part name
Removing the steering stem
Handlebar
Seat
Front fender
Lock washer
Cable guide
Steering stem bushing
Collar
Oil seal
Tie rod end nut
Tie rod
Steering stem nut
Pitman arm
Steering stem
Q’ty
1
1
2
2
2
2
2
1
1
1
Remarks
Remove the parts in the order below.
Refer to “HANDLEBAR”.
Refer to “SEAT, CARRIERS, FENDERS
AND FUEL TANK” in CHAPTER 3.
Refer to “INSTALLING THE CABLE
GUIDE”.
Disconnect.
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STEERING SYSTEM
Order
11
12
13
14
Job name/Part name
Oil seal
Bearing retainer
Bearing
Oil seal
CHAS
Q’ty
Remarks
1
1
Refer to “REMOVING/INSTALLING THE
BEARING RETAINER”.
1
1
For installation, reverse the removal
procedure.
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STEERING SYSTEM
CHAS
REMOVING THE BEARING RETAINER
1.Remove:
● Bearing retainer (steering stem)
Damper rod holder:
P/N. YM-01327, 90890-01327
CHECKING THE STEERING STEM
1.Check:
● Steering stem
Bends → Replace.
WARNING
Do not attempt to straighten a bent stem;
this may dangerously weaken the stem.
2.Check:
● Oil seals 1
● Steering stem bushings 2
Wear/damage → Replace.
INSTALLING THE BEARING RETAINER
1.Install:
● Bearing retainer (steering stem)
T.
R.
40 Nm (4.0 m • kg, 29 ft • lb)
Damper rod holder:
P/N. YM-01327, 90890-01327
T.
INSTALLING THE CABLE GUIDE
1.Install
● Cable guide
● Lock washer
New
● Bolts
23 Nm (2.3 m • kg, 17 ft • lb)
2.Bend the lock washer tab along a flat side of
the bolt.
R.
NOTE:
Pass the cables and hoses through the cable
guide. Refer to “CABLE ROUTING” in
CHAPTER 2.
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STEERING SYSTEM
CHAS
TIE ROD AND STEERING KNUCKLE
Order
1
2
3
4
5
6
7
8
Job name/Part name
Removing the tie rod and steering
knuckle
Front fender
Front wheel/brake disc
Tie rod
Brake disc guard
Brake hose holder bolt
Protector
Nut
Nut
O-ring
Steering knuckle
Q’ty
1
1
1
1
1
1
1
1
Remarks
Remove the parts in the order below.
Refer to “SEAT, CARRIERS, FENDERS
AND FUEL TANK” in CHAPTER 3.
Refer to “FRONT AND REAR WHEELS”.
Refer to “INSTALLING THE TIE ROD”.
Refer to “REMOVING THE STEERING
KNUCKLE”.
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STEERING SYSTEM
Order
9
10
11
12
13
14
15
Job name/Part name
Oil seal
Oil seal
Bearing
Spacer
Circlip
Rubber boot
Ball joint
Q’ty
1
1
2
1
1
1
1
CHAS
Remarks
For installation, reverse the removal
procedure.
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STEERING SYSTEM
CHAS
REMOVING THE STEERING KNUCKLE
1.Remove:
● Steering knuckle 1
NOTE:
Use a general puller to separate the ball joint
2 and steering knuckle 1 or front lower arm
3.
CHECKING THE TIE ROD
1.Check:
● Tie rod free play and movement
Free play → Replace the tie rod end.
Turns roughly → Replace the tie rod end.
2.Check:
● Tie rod
● Bends/damage → Replace.
CHECKING THE STEERING KNUCKLE
1.Check:
● Steering knuckle
Damage/pitting → Replace.
2.Check:
● Ball joint
Damage/pitting → Replace the ball joint.
Free play → Replace the ball joint.
Turns roughly → Replace the ball joint.
*****************************************************
Replacement steps:
● Clean the outside of the steering knuckle.
● Remove the steering knuckle oil seal.
● Remove the circlip 1 and rubber boot 2.
Use the ball joint remover and installer set.
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STEERING SYSTEM
CHAS
Ball joint remover/installer set:
P/N. YM-01474/90890-01474
Ball joint remover/installer
attachment set:
P/N. YM-01477
3
Body
4
Long bolt
5
6
7
8
9
0
Short bolt
Remover washer
Remover spacer
Installer attachment
Installer spacer
Installer guide
YM-01474
90890-01474
YM-01474
90890-01474
YM-01477
YM-01477
YM-01477
YM-01477
YM-01477
YM-01477
the body 3, short bolt 5, remover
washer 6 and remover spacer 7 onto ball
joint.
● Install
NOTE:
● Remover washer 6 must be aligned with the
projection on the head of the ball joint.
● Surface a of the remover spacer 7 must be
aligned with surface b of the steering
knuckle.
the body 3 in place while turning in the
short bolt 5 to remove the ball joint A from
the steering knuckle.
● Remove the ball joint remover/installer.
● Hold
the long bolt 4, installer spacer 9
and installer guide 0 onto the body 3.
● Install
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STEERING SYSTEM
CHAS
● Attach
the assembled ball joint remover/
installer, new ball joint B and installer
attachment 8 to the steering knuckle C.
NOTE:
Do not tap or damage the top of the ball joint.
the body 3 in place while turning in the
long bolt 4 to install the new ball joint B into
the steering knuckle C.
● Remove the ball joint remover/installer.
● Apply lithium-soap base grease to the new
ball joint B.
● Install a new rubber boot and new circlip.
● Hold
NOTE:
Always use a new ball joint set.
● Install
a steering knuckle oil seal.
*****************************************************
3.Check:
● Front wheel bearings
Bearings allow play in the wheel hubs or the
wheel turns roughly → Replace.
● Oil seals
Damage → Replace.
*****************************************************
Replacement steps:
● Clean the outside of the steering knuckle.
● Remove the oil seals 1.
● Drive out the bearings 2.
WARNING
Eye protection is recommended when
using striking tools.
the spacer 3.
lithium base grease to the bearings
and oil seals.
● Install the spacer to the steering knuckle.
● Remove
● Apply
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STEERING SYSTEM
● Install
CHAS
the new bearings.
NOTE:
Install the outside bearing first.
CAUTION:
Do not strike the center race or balls of the
bearing. Contact should be made only with
the outer race.
● Install
a new oil seal.
NOTE:
When installing the oil seals, the “seal side” of
the oil seal faces out.
*****************************************************
INSTALLING THE TIE ROD
1.Install:
● Tie rods (left and right)
T.
R.
30 Nm (3.0 m • kg, 22 ft • lb)
NOTE:
The tie rod which must be installed on the out
side has grooves 1.
2.Adjust:
● Toe-in
Refer to “ADJUSTING THE TOE-IN” in
CHAPTER 3.
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FRONT ARMS AND FRONT SHOCK ABSORBER
CHAS
FRONT ARMS AND FRONT SHOCK ABSORBER
Order
1
2
3
Job name/Part name
Removing the front arms and front
shock absorber
Engine skid plate
Front fender
Front wheel/brake disc
Air duct
Brake disc guard
Protector
Q’ty
Remarks
Remove the parts in the order below.
Refer to “SEAT, CARRIERS, FENDERS
AND FUEL TANK” in CHAPTER 3.
Refer to “FRONT AND REAR WHEELS”.
1
1
1
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FRONT ARMS AND FRONT SHOCK ABSORBER
Order
4
5
6
7
8
9
10
11
12
13
Job name/Part name
Nut
Nut
Bolt/nut
Front lower arm/bushing
Nut/bolt
Front shock absorber
Bolt/nut
Front upper arm/bushing
Circlip
Ball joint
Q’ty
1
1
2/2
1/2
2/2
1
2/2
1/2
1
1
CHAS
Remarks
Refer to “REMOVING THE FRONT
ARMS” and “INSTALLING THE FRONT
ARMS AND FRONT SHOCK
ABSORBER”.
For installation, reverse the removal
procedure.
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FRONT ARMS AND FRONT SHOCK ABSORBER
CHAS
REMOVING THE FRONT ARMS
1.Check:
● Front arm free play
*****************************************************
Checking steps:
● Check the front arm side play È by moving it
from side to side.
If side play is noticeable, check the bushings.
● Check the front arm vertical movement É by
moving it up and down.
If the vertical movement is tight or rough, or if
there is binding, check the bushings.
*****************************************************
2.Remove:
● Front arms
CHECKING THE FRONT ARM
1.Check:
● Front arms
Bends/damage → Replace.
2.Check:
● Bushings
Wear/damage → Replace.
3.Check:
● Ball joint
Damage/pitting → Replace the ball joint.
Free play → Replace the ball joint.
Turns roughly → Replace the ball joint.
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FRONT ARMS AND FRONT SHOCK ABSORBER
CHAS
*****************************************************
Replacement steps:
● Clean the outside of the front lower arm.
● Remove the circlip 1 and rubber boot 2.
Use the ball joint remover and installer set.
Ball joint remover/installer set:
P/N. YM-01474/90890-01474
Ball joint remover/installer
attachment set:
P/N. YM-01477
3
Body
4
Long bolt
5
6
7
8
9
Remover washer
Remover spacer
Installer attachment
Installer spacer
Installer guide
YM-01474
90890-01474
YM-01474
90890-01474
YM-01477
YM-01477
YM-01477
YM-01477
YM-01477
the body 3, long bolt 4, remover
washer 5 and remover spacer 6 onto ball
joint.
● Install
NOTE:
Remover washer 5 must be aligned with the
projection on the head of the ball joint.
the body 3 in place while turning in the
long bolt 4 to remove the ball joint 0 from
the front lower arm.
● Remove the ball joint remover/installer.
● Hold
the long bolt 4, installer spacer 8
and installer guide 9 onto the body 3.
● Install
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FRONT ARMS AND FRONT SHOCK ABSORBER
CHAS
● Attach
the assembled ball joint remover/
installer, new ball joint A and installer
attachment 7 to the front lower arm B.
NOTE:
Do not tap or damage the top of the ball joint.
the body 3 in place while turning in the
long bolt 4 to install the new ball joint A into
the front lower arm B.
● Remove the ball joint remover/installer.
● Apply lithium-soap base grease to the new
ball joint A.
● Install a new rubber boot and new circlip.
● Hold
NOTE:
Always use a new ball joint set.
*****************************************************
CHECKING THE FRONT SHOCK
ABSORBER
1.Check:
● Shock absorber rod
Bends/damage → Replace the shock
absorber assembly.
● Shock absorber assembly
Oil leaks → Replace the shock absorber
assembly.
● Spring
Fatigue → Replace the shock absorber
assembly.
Move the spring up and down.
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FRONT ARMS AND FRONT SHOCK ABSORBER
CHAS
INSTALLING THE FRONT ARMS AND
FRONT SHOCK ABSORBER
1.Install:
● Front arms
● Front shock absorber
*****************************************************
Installation steps:
● Install the front upper arm 1 and front lower
arm 2.
NOTE:
● Lubricate the bolts 3 with lithium-soapbased grease.
● Be sure to position the bolts 3 so that the
bolt head faces outward.
● Temporarily tighten the nuts 4.
● Install
T.
R.
● Install
the front shock absorber 5.
Nut 6:
45 Nm (4.5 m • kg, 32 ft • lb)
the ball joints.
T.
Nut 7:
30 Nm (3.0 m • kg, 22 ft • lb)
R.
● Install
the new cotter pins.
● Tighten the nuts 4.
NOTE:
Before tightening the nuts 4, adjust the length
a to 310 mm (12.2 in).
T.
R.
Nut 4:
45 Nm (4.5 m • kg, 32 ft • lb)
*****************************************************
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REAR SHOCK ABSORBER AND SWINGARM
CHAS
REAR SHOCK ABSORBER AND SWINGARM
Order
1
2
3
4
5
6
7
Job name/Part name
Removing the rear shock absorber
and swingarm
Rear wheel hubs/brake disc
Rear brake caliper/brake hose
Final drive gear assembly
Q’ty
Clip/washer/pin
Nut/bolt
Rear shock absorber
Collar
Trailer hitch bracket
Final drive gear case breather hose
Metal clamp
1/1/1
1/1
1
1
1
1
1
Remarks
Remove the parts in the order below.
Refer to “FRONT AND REAR WHEELS”.
Refer to “FRONT AND REAR BRAKES”.
Refer to “REAR AXLE/FINAL DRIVE GEAR
AND DRIVE SHAFT” in CHAPTER 7.
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REAR SHOCK ABSORBER AND SWINGARM
Order
8
9
10
11
Job name/Part name
Rear axle housing
Nut/bolt
Swingarm/bushing
Spring/rubber boot
CHAS
Q’ty
Remarks
1
Refer to “INSTALLING THE REAR AXLE
HOUSING”.
2/2 Refer to “REMOVING THE
1/2 SWINGARM”.
1/1
For installation, reverse the removal
procedure.
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REAR SHOCK ABSORBER AND SWINGARM
CHAS
REMOVING THE SWINGARM
1.Check:
● Swingarm free play
*****************************************************
Checking steps:
● Check the tightening torque of the nuts
(swingarm).
T.
Nut (swingarm):
82 Nm (8.2 m • kg, 59 ft • lb)
R.
the swingarm side play È by moving
it from side to side.
If side play is noticeable, check the bushing
and frame pivot.
● Check the swingarm vertical movement É
by moving it up and down.
If vertical movement is tight or rough, or if
there is binding, check the bushing and
frame pivot.
● Check
*****************************************************
2.Remove:
● Nuts
● Bolts
● Swingarm
CHECKING THE REAR SHOCK ABSORBER
1.Check:
● Shock absorber
Oil leaks → Replace the shock absorber
assembly.
● Shock absorber rod
Bends/damage → Replace the shock
absorber assembly.
● Spring
Fatigue → Replace the shock absorber
assembly.
Move the spring up and down.
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REAR SHOCK ABSORBER AND SWINGARM
CHAS
CHECKING THE SWINGARM
1.Check:
● Swingarm 1
● Rear axle housing 2
Bends/cracks/damage → Replace.
2.Check:
● Bushings 1
Wear/damage → Replace.
CHECKING THE RUBBER BOOT
1.Check:
● Rubber boot 1
Damage → Replace.
INSTALLING THE RUBBER BOOT
1.Apply:
● Adhesive (for rubber)
(to the engine 1)
2.Install:
● Rubber boot 2
NOTE:
Be sure to position the rubber boot so that the
tang 3 faces towards the left.
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REAR SHOCK ABSORBER AND SWINGARM
CHAS
INSTALLING THE REAR AXLE HOUSING
1.Install:
● Rear axle housing
● Final gear case assembly
● Rear axle
(with dust seal)
*****************************************************
Installation steps:
● Install the drive shaft.
Refer to “REAR AXLE/FINAL DRIVE GEAR
AND DRIVE SHAFT” in CHAPTER 7.
● Apply sealant (Quick Gasket®) to the mating
surfaces of the swingarm and the final gear
case.
● Temporarily install the rear axle housing 1
and final gear case assembly 2 on the
swingarm. The bolts and nuts 3 ~ 5 should
be temporarily tightened.
● Install the rear axle (with dust seal) 6 from
the left side of the machine.
Refer to “REAR AXLE/FINAL DRIVE GEAR
AND DRIVE SHAFT” in CHAPTER 7.
● Tighten the bolts and nuts 3 ~ 5 in the
specified order.
3 Nut (×4)
4 Bolt (×4)
5 Bolt/nut (×4)
T.
R.
Nut 3:
63 Nm (6.3 m • kg, 45 ft • lb)
LOCTITE®
Bolt 4:
63 Nm (6.3 m • kg, 45 ft • lb)
LOCTITE®
Nut 5:
63 Nm (6.3 m • kg, 45 ft • lb)
*****************************************************
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ELECTRICAL COMPONENTS
ELEC
–
+
EB800000
ELECTRICAL
ELECTRICAL COMPONENTS
1 Main switch
2 Front brake light
switch
3 Rear brake switch
4 Thermo switch 1
5 Battery
6 Tail/brake light
7 Fuse box
8 Four-wheel drive
relay 2
9 Four-wheel drive
relay 1
0 Main fuse
A Starter relay
B CDI unit
C Rectifier/regulator
D Reverse switch
E Neutral switch
F High-range switch
G Low-range switch
H Speed sensor
I Rear brake light switch
J Gear motor
K Thermo switch 2
L Fan
M Headlight
N Circuit breaker (fan)
O Four-wheel drive relay 3
P Ignition coil
4
1
2
5
3
6
P
7
O
9
8
0
N
M
A
B
C
D
L
E
F
G
K
J
I
H
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9
CHECKING THE SWITCH
ELEC
–
+
CHECKING THE SWITCH
CHECKING THE SWITCH
Use a pocket tester to check the terminals for
continuity. If the continuity is faulty at any
point, replace the switch.
Pocket tester:
P/N. YU-03112, 90890-03112
NOTE:
● Set the pocket tester to “0” before starting
the test.
● The pocket tester should be set to the “Ω × 1”
range when testing the switch for continuity.
● Turn the switch on and off a few times when
checking it.
R Br/L R Br
OFF
ON
Br
R
Br/L R
CHECKING A SWITCH SHOWN IN THE
MANUAL
The terminal connections for switches (main
switch, handlebar switch, engine stop switch,
light switch, etc.) are shown in a chart similar
to the one on the left.
This chart shows the switch positions in the
column and the switch lead colors in the top
row.
For each switch position, “
” indicates
the terminals with continuity.
The example chart shows that:
There is continuity between red and brown/
blue, and between red and brown when the
switch is set to “ON”.
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CHECKING THE SWITCH
ELEC
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–
+
CHECKING THE SWITCH
ELEC
CHECKING THE SWITCH CONTINUITY
Refer to “CHECKING THE SWITCH” and check for continuity between lead terminals.
Poor connection, no continuity → Correct or replace.
The coupler locations are circled.
*
1
2
Br L Y G
3
L/B B
R/W R/B
OFF
Br Y L
L/B G B
PUSH
R/B R/W
(BLACK)
C
4
L/B L/G L/R Sb Br Gy G/R B
2WD
L/R L/G
4WD
Sb L/B
LOCK
(BLACK)
G/R Gy
B
Br
(GRAY)
5
RRBr/L
Br/LBr R Br
Br R
R Br/L Br
Br/L R
OFF
ON
ON
OFF
6
B
B
(BLACK)
7
B
B
(BLACK)
8
9
B
0
A
B
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B
–
+
CHECKING THE SWITCH
ELEC
1 Light switch
2 Engine stop switch
3 Start switch
4 On-command four-wheel drive switch and differential gear lock switch
5 Main switch
6 Rear brake light switch
7 Front brake light switch
8 Rear brake switch
9 Reverse switch
0 Neutral switch
A High-range switch
B Low-range switch
C Fuse
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–
+
CHECKING THE BULBS AND BULB SOCKETS
ELEC
–
+
EB801020
CHECKING THE BULBS AND
BULB SOCKETS
Check each bulb and bulb socket for damage
or wear, proper connections, and also for
continuity between the terminals.
Damage/wear → Repair or replace the bulb,
bulb socket or both.
Improperly connected → Properly connect.
Incorrect continuity reading → Repair or
replace the bulb, bulb socket or both.
TYPES OF BULBS
The bulbs used on this machine are shown in
the illustration on the left.
● Bulbs A and B are used for headlights and
usually use a bulb holder which must be
detached before removing the bulb. The
majority of these bulbs can be removed from
their respective socket by turning them
counterclockwise.
● Bulb C is used for turn signal and brake/tail
lights and can be removed from the socket
by pushing and turning the bulb
counterclockwise.
● Bulbs D and E are used for meter and
indicator lights and can be removed from
their respective socket by carefully pulling
them out.
CHECKING THE CONDITION OF THE
BULBS
The following procedure applies to all of the
bulbs.
1.Remove:
● Bulb
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CHECKING THE BULBS AND BULB SOCKETS
ELEC
–
+
WARNING
Since the headlight bulb gets extremely
hot, keep flammable products and your
hands away from the bulb until it has
cooled down.
CAUTION:
●
●
Be sure to hold the socket firmly when
removing the bulb. Never pull the lead,
otherwise it may be pulled out of the
terminal in the coupler.
Avoid touching the glass part of the
headlight bulb to keep it free from oil,
otherwise the transparency of the glass,
the life of the bulb and the luminous flux
will be adversely affected. If the headlight
bulb gets soiled, thoroughly clean it with
a cloth moistened with alcohol or lacquer
thinner.
2.Check:
● Bulb (for continuity)
(with the pocket tester)
No continuity → Replace.
Pocket tester
P/N. YU-03112, 90890-03112
NOTE:
Before checking for continuity, set the pocket
tester to “0” and to the “Ω × 1” range.
*****************************************************
a.Connect the tester positive probe to terminal
1 and the tester negative probe to terminal
2, and check the continuity.
b.Connect the tester positive probe to terminal
1 and the tester negative probe to terminal
3, and check the continuity.
c.If either of the readings indicate no
continuity, replace the bulb.
*****************************************************
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CHECKING THE BULBS AND BULB SOCKETS
ELEC
–
+
CHECKING THE CONDITION OF THE BULB
SOCKETS
The following procedure applies to all of the
bulb sockets.
1.Check:
● Bulb socket (for continuity)
(with the pocket tester)
No continuity → Replace.
Pocket tester:
P/N. YU-03112, 90890-03112
NOTE:
Check each bulb socket for continuity in the
same manner as described in the bulb section;
however, note the following.
*****************************************************
a.Install a good bulb into the bulb socket.
b.Connect the pocket tester probes to the
respective leads of the bulb socket.
c.Check the bulb socket for continuity. If any of
the readings indicate no continuity, replace
the bulb socket.
*****************************************************
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B B
h
(BLACK) (BLACK)
Y Br
Y
Br
W
W W
W/R W/G
W
W W
R W/G
W/L W/R
W/G R
Br/L
W
W
W
B B
g
i
B
Y L
Y
Br
Br
f
W
W
W
(BLACK) (BLACK)
Y Br
1
R
W/G
W/R
W/G
W
R
W
B
L
L
B
e
L
L
B
d
R/B
B
R/B
Br
OFF
ON
3
c
(DARK GRAY)
R/B L
(BLACK)
B
W
B
R
R
Br
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b
B
B
Y G
G Y
B
Y G
B
B
Y G
^
R/B
R/W
R/W
Z
Br/L
R/G
PUSH
_
a
SUB-WIRE
HARNESS 2
G Y
B
Y G
b
OFF
R/Y
R/Y
[
L Y G
R Br/L
Br/L R
Br/L
R Br
R
4
WIRE HARNESS
L/B Sb Br
B/Y Br/B R/B
Br Sb L/B
B
R/BBr/B B/Y
Br R
]
\
Br/L
R
SUB-WIRE
HARNESS 1
WIRE HARNESS
2
B/R B W/B
W/B B B/R
A
O B
L/B
B
Y R/Y
B
Br Y
L
(BLACK)
R/W R/B
(BLACK)
R/B R/W
L/B G B
B
B
B
R
P
B
Sb W/R
G/W L/W
R
L/B
L/W
B
Br/B
Br
G/R
Gy
B
W
B
B/R
W/B A W/B
W/B
B/R
B
B
Q
Sb
D
Sb
B/Y B
B B
A
B/Y
B/Y
0
C
B
L/Y
P
L/W
R/G
Br
B/R
W/B
G/L
Sb
G/R
W
O
(BLACK)
Sb G/R
G/W W/B
G
O
W/R
D
L/Y
W
B
B
W/L
O
W/R
L/W
D
W
C
B/W
F
W Sb G/L
(GRAY)
W/L B/R L/W
G/L Sb W
(GRAY)
L/W B/R W/L
L/Y W/B
W/R Br
(GRAY)
Br W/R
W/B L/Y
(GRAY)
B
G/R R/G
B
R/G G/R
1 A.C. magneto
3 Main switch
5 Battery
6 Main fuse
0 CDI unit
A Rear brake switch
B Ignition coil
C Spark plug
Z Ignition fuse
^ Engine stop switch
H I J K L M N
E
B
L/Y W
W/L
B
D
P O/R
C
B
–
B
B
B/Y
R
W/R
W/G
L/W
R/B
G/W
Y/B
G/R
Sb
G/L
(BLACK)
B/Y R W/R W/G
(BLACK)
Y/B
G/L
W
B/R
R/B L/W O B
ELEC
B
A
B
A
L/R
T
9
G/W
D
G/W
B/Y Br/B W/B B/R B
B
Br/B
Br/B
B
B B/Y Br/B
B
B
W/B B/R
L/B Br
Sb B/Y
Sb
L/R
L/G
L/B
Y/B
Gy
L/G
S
Br/R
Br/R
(BLACK)
(BLACK)
Br/R
Br/R
B/Y
Br/R
Br/R B L/R
Br/B
Br/R
Br/R B L/G
SUB-WIRE
HARNESS 4
2WD
4WD
LOCK
V
L/B B Br Sb
(GRAY)
B Br
(GRAY)
G/R Gy
(BLACK)
(BLACK)
Br B
Sb L/B
Gy G/R
L/R L/G
L/B Sb
Br/R L/R
Y/B Gy
Br/R
L/R
Br/R
U
L/W L/B
Br/L
R
6
WIRE HARNESS
(BLACK)
L/W G/W
D
W/R Sb
(BLACK)
L/G L/R
Y
X
Br/L
8
B
B
7
5R
R
SUB-WIRE
HARNESS 3
R
B G L/B
L
B O
(GRAY)
R
WIRE HARNESS
(GRAY)
C
IGNITION SYSTEM
+
EB802000
IGNITION SYSTEM
CIRCUIT DIAGRAM
IGNITION SYSTEM
ELEC
–
+
EB802010
TROUBLESHOOTING
IF THE IGNITION SYSTEM FAILS TO OPERATE (NO SPARK OR INTERMITTENT SPARK):
Procedure
Check:
1.Fuse (main, ignition)
2.Battery
3.Spark plug
4.Ignition spark gap
5.Spark plug cap resistance
6.Ignition coil resistance
7.Engine stop switch
8.Main switch
9.Pickup coil resistance
10.Charging/rotor rotation direction detection
coil resistance
11.Wiring connection (the entire ignition
system)
NOTE:
● Remove
the following part(s) before
troubleshooting:
1)Seat
2)Fuel tank side panels
3)Front carrier
4)Front fender
● Use
the following special tool(s) for
troubleshooting.
EB802011
Dynamic spark tester:
P/N. YM-34487
Ignition checker:
P/N. 90890-06754
Pocket tester:
P/N. YU-03112, 90890-03112
NO CONTINUITY
1.Fuse (main, ignition)
Refer to “CHECKING THE SWITCH”.
CONTINUITY
Replace the fuse.
EB802012
2.Battery
●
INCORRECT
Check the battery condition.
Refer to “CHECKING THE BATTERY” in
CHAPTER 3.
Open-circuit voltage:
12.8 V or more at 20 °C (68 °F)
●
●
Clean the battery terminals.
Recharge or replace the battery.
CORRECT
3.Spark plug
●
●
●
Check the spark plug condition.
Check the spark plug type.
Check the spark plug gap.
Refer to “CHECKING THE SPARK PLUG”
in CHAPTER 3.
Standard spark plug:
DR8EA/NGK
Not For Resale
9 - 10
www.SmallEngineDiscount.com
IGNITION SYSTEM
Spark plug gap:
0.6 ~ 0.7 mm (0.024 ~ 0.028 in)
ELEC
INCORRECT
CORRECT
Repair or replace the spark plug.
4.Ignition spark gap
●
●
Disconnect the spark plug cap from the
spark plug.
Connect the dynamic spark tester 1 as
shown.
2 Spark plug cap
3 Spark plug
●
●
●
Turn the main switch to “ON”.
Check the ignition spark gap.
Crank the engine by pushing the starter
switch, and increase the spark gap until a
misfiring occurs.
Minimum spark gap:
6.0 mm (0.24 in)
MEETS SPECIFICATION
The ignition system is not faulty.
OUT OF
SPECIFICATION
OR NO SPARK
5.Spark plug cap resistance
●
●
●
Remove the spark plug cap.
Connect the pocket tester (Ω × 1k) to the
spark plug cap.
Check that the spark plug cap has the
specified resistance.
Spark plug cap resistance:
10 kΩ at 20 °C (68 °F)
OUT OF SPECIFICATION
Replace the spark plug cap.
MEETS
SPECIFICATION
*
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9 - 11
www.SmallEngineDiscount.com
–
+
IGNITION SYSTEM
*
ELEC
C0NTINUITY
6.Ignition coil resistance
●
●
Disconnect the ignition coil connector from
the wire harness.
Connect the pocket tester (Ω × 1) to the
ignition coil.
Tester (+) lead → Orange lead terminal
Tester (–) lead → Ignition coil base
●
Check that the primary coil has the
specified resistance.
Primary coil resistance:
0.18 ~ 0.28 Ω at 20 °C (68 °F)
●
Connect the pocket tester (Ω × 1k) to the
ignition coil.
Tester (+) lead → Orange lead terminal
Tester (–) lead → Spark plug lead
●
Check that the secondary coil has the
specified resistance.
Secondary coil resistance:
6.32 ~ 9.48 kΩ at 20 °C (68 °F)
OUT OF SPECIFICATION
BOTH MEET
SPECIFICATION
Replace the ignition coil.
INCORRECT
7.Engine stop switch
Refer to “CHECKING THE SWITCH”.
CORRECT
Replace the handlebar switch (left).
*
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9 - 12
www.SmallEngineDiscount.com
–
+
IGNITION SYSTEM
*
ELEC
–
C0NTINUITY
INCORRECT
8.Main switch
Refer to “CHECKING THE SWITCH”.
CORRECT
Replace the main switch.
9.Pickup coil resistance
●
●
Disconnect the AC magneto coupler from
the wire harness.
Connect the pocket tester (Ω × 100) to the
pickup coil terminal.
Tester (+) lead → White/Red terminal 1
Tester (–) lead → White/Green terminal 2
●
Check the pickup coil for the specified
resistance.
Pickup coil resistance:
459 ~ 561 Ω at 20 °C (68 °F)
(White/Red – White/Green)
OUT OF SPECIFICATION
Replace the pickup coil/stator assembly.
MEETS
SPECIFICATION
10.Charging/rotor rotation direction detection
coil resistance
●
●
Disconnect the AC magneto coupler from
the wire harness.
Connect the pocket tester (Ω × 100) to the
charging/rotor rotation direction detection
coil terminal.
Tester (+) lead → Red terminal 1
Tester (–) lead → White/Blue terminal 2
●
Check the charging/rotor rotation direction
detection coil for the specified resistance.
Rotor rotation direction sensing
coil resistance:
0.085 ~ 0.105 Ω at 20 °C (68 °F)
(Red – White/Blue)
OUT OF SPECIFICATION
Replace the pickup coil/stator assembly.
MEETS
SPECIFICATION
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9 - 13
www.SmallEngineDiscount.com
*
+
IGNITION SYSTEM
*
ELEC
C0NTINUITY
11.Wiring connection
●
Check the connections of the entire ignition
system.
Refer to “CIRCUIT DIAGRAM”.
CORRECT
POOR CONNECTION
Properly connect the ignition system.
Replace the CDI unit.
Not For Resale
9 - 14
www.SmallEngineDiscount.com
–
+
B B
h
Y
Br/L
W
W
W
B B
g
Y L
Y
Br
Br
f
W
W
W
(BLACK) (BLACK)
Y Br
1
Not For Resale
9 - 15
www.SmallEngineDiscount.com
B
3 Main switch
i
5 Battery
6 Main fuse
7 Starter relay
8 Starter motor
0 CDI unit
Z Ignition fuse
^ Engine stop switch
a Start switch
(BLACK) (BLACK)
Y Br
Br
W
W W
W/R W/G
W
W W
R W/G
W/L W/R
W/G R
R
W/G
W/R
W/G
W
R
W
B
L
L
B
e
L
L
B
d
R/B
B
R/B
Br
OFF
ON
3
c
(DARK GRAY)
R/B L
(BLACK)
B
W
B
R
R
Br
B
B
Y G
b
G Y
B
Y G
B
B
Y G
^
R/B
R/W
R/W
Z
Br/L
R/G
PUSH
_
a
SUB-WIRE
HARNESS 2
G Y
B
Y G
b
OFF
R/Y
R/Y
[
L Y G
R Br/L
Br/L R
Br/L
R Br
R
4
WIRE HARNESS
L/B Sb Br
B/Y Br/B R/B
Br Sb L/B
B
R/BBr/B B/Y
Br R
]
\
Br/L
R
SUB-WIRE
HARNESS 1
WIRE HARNESS
2
B/R B W/B
W/B B B/R
A
O B
L/B
B
Y R/Y
B
Br Y
L
(BLACK)
R/W R/B
(BLACK)
R/B R/W
L/B G B
B
B
B
R
P
B
Sb W/R
G/W L/W
R
L/B
L/W
B
Br/B
Br
G/R
Gy
B
W
B
B/R
W/B A W/B
W/B
B/R
B
B
Q
Sb
D
Sb
B/Y B
B B
A
B/Y
B/Y
0
C
B
L/Y
P
L/W
R/G
Br
B/R
W/B
G/L
Sb
G/R
W
O
(BLACK)
Sb G/R
G/W W/B
G
O
W/R
D
L/Y
W
B
B
W/L
O
W/R
L/W
D
W
C
B/W
F
W Sb G/L
(GRAY)
W/L B/R L/W
G/L Sb W
(GRAY)
L/W B/R W/L
L/Y W/B
W/R Br
(GRAY)
Br W/R
W/B L/Y
(GRAY)
B
G/R R/G
B
R/G G/R
H I J K L M N
E
B
L/Y W
W/L
B
D
P O/R
C
B
–
B
B
B/Y
R
W/R
W/G
L/W
R/B
G/W
Y/B
G/R
Sb
G/L
(BLACK)
B/Y R W/R W/G
(BLACK)
Y/B
G/L
W
B/R
R/B L/W O B
ELEC
B
A
B
A
L/R
T
9
G/W
D
G/W
B/Y Br/B W/B B/R B
B
Br/B
Br/B
B
B B/Y Br/B
B
B
W/B B/R
L/B Br
Sb B/Y
Sb
L/R
L/G
L/B
Y/B
Gy
L/G
S
Br/R
Br/R
(BLACK)
(BLACK)
Br/R
Br/R
B/Y
Br/R
Br/R B L/R
Br/B
Br/R
Br/R B L/G
SUB-WIRE
HARNESS 4
2WD
4WD
LOCK
V
L/B B Br Sb
(GRAY)
B Br
(GRAY)
G/R Gy
(BLACK)
(BLACK)
Br B
Sb L/B
Gy G/R
L/R L/G
L/B Sb
Br/R L/R
Y/B Gy
Br/R
L/R
Br/R
U
L/W L/B
Br/L
R
6
WIRE HARNESS
(BLACK)
L/W G/W
D
W/R Sb
(BLACK)
L/G L/R
Y
X
Br/L
8
B
B
7
5R
R
SUB-WIRE
HARNESS 3
R
B G L/B
L
B O
(GRAY)
R
WIRE HARNESS
(GRAY)
C
ELECTRIC STARTING SYSTEM
+
EB803000
ELECTRIC STARTING SYSTEM
CIRCUIT DIAGRAM
ELECTRIC STARTING SYSTEM
ELEC
–
EB803020
TROUBLESHOOTING
IF THE STARTER MOTOR FAILS TO OPERATE:
Procedure
Check:
1.Fuse (main, ignition)
2.Battery
3.Starter motor
4.Starter relay
5.Main switch
6.Engine stop switch
7.Start switch
8. Wiring connection (the entire starting
system)
NOTE:
● Remove
the following part(s) before
troubleshooting:
1)Seat
2)Fuel tank side panels
3)Fuel tank
4)Air cleaner case
5)Front carrier
6)Front fender panel
● Use
the following special tool(s) for
troubleshooting.
Pocket tester:
P/N. YU-03112, 90890-03112
EB802011
NO CONTINUITY
1.Fuse (main, ignition)
Refer to “CHECKING THE SWITCH”.
CONTINUITY
Replace the fuse.
EB802012
2.Battery
●
INCORRECT
Check the battery condition.
Refer to “CHECKING THE BATTERY” in
CHAPTER 3.
Open-circuit voltage:
12.8 V or more at 20 °C (68 °F)
●
●
Clean the battery terminals.
Recharge or replace the battery.
CORRECT
*
Not For Resale
9 - 16
www.SmallEngineDiscount.com
+
ELECTRIC STARTING SYSTEM
*
3.Starter motor
●
Connect the battery positive terminal 1
and starter motor cable 2 using a jumper
lead 3 .
Check the operation of the starter motor.
*
●
●
A wire that is used as a jumper lead must
have the equivalent capacity or more as
that of the battery lead, otherwise the
jumper lead may burn.
This check is likely to produce sparks, so
be sure that no flammable gas or fluid is
in the vicinity.
Repair or replace the starter motor.
TURNS
4.Starter relay
●
Remove the starter relay from the wire
harness.
Connect the pocket tester (Ω × 1) and the
battery (12 V) to the starter relay terminals.
Battery (+) terminal →
Blue/White terminal 1
Battery (–) terminal →
Blue/Black terminal 2
NO CONTINUITY
Tester (+) lead → Red terminal 3
Tester (–) lead → Black terminal 4
●
+
WARNING
DOES NOT TURN
●
–
C0NTINUITY
*
●
ELEC
Check the starter relay for continuity.
Replace the starter relay.
CONTINUITY
*
Not For Resale
9 - 17
www.SmallEngineDiscount.com
ELECTRIC STARTING SYSTEM
*
ELEC
C0NTINUITY
INCORRECT
5.Main switch
Refer to “CHECKING THE SWITCH”.
CORRECT
Replace the main switch.
INCORRECT
6.Engine stop switch
Refer to “CHECKING THE SWITCH”.
CORRECT
Replace the handlebar switch (left).
INCORRECT
7.Start switch
Refer to “CHECKING THE SWITCH”.
CORRECT
Replace the handlebar switch (left).
EB803028
8.Wiring connection
●
Check the connections of the entire starting
system.
Refer to “CIRCUIT DIAGRAM”.
POOR CONNECTION
Properly connect the starting system.
Not For Resale
9 - 18
www.SmallEngineDiscount.com
–
+
ELECTRIC STARTING SYSTEM
ELEC
–
+
STARTER MOTOR
Order
1
2
1
2
3
4
5
6
7
Job name/Part name
Removing the starter motor
Starter motor lead
Starter motor/O-ring
Disassembling the starter motor
Bracket 1
Washer kit
Bracket 2/bushing
Shims
Brush holder set
Armature coil
Yoke
Q’ty
Remarks
Remove the parts in the order below.
1
1/1
Remove the parts in the order below.
1
1
1
1
1
Refer to “ASSEMBLING THE STARTER
MOTOR”.
For assembly, reverse the disassembly
procedure.
Not For Resale
9 - 19
www.SmallEngineDiscount.com
ELECTRIC STARTING SYSTEM
ELEC
–
+
CHECKING THE STARTER MOTOR
1.Check:
● Commutator
Dirty → Clean it with #600 grit sandpaper.
2.Measure:
● Commutator diameter a
Out of specification → Replace the starter
motor.
Outside diameter:
28 mm (1.10 in)
<Wear limit:>
27 mm (1.06 in)
3.Measure:
● Mica undercut b
Out of specification → Scrape the mica using
a hacksaw blade.
Mica undercut:
0.7 mm (0.03 in)
NOTE:
Scrape the mica to the proper measurement
using a hacksaw blade which has been
grounded to fit the commutator.
4.Check:
● Armature coil (insulation/continuity)
Defects → Replace the starter motor.
*****************************************************
Checking steps:
● Connect the pocket tester for the continuity
check 1 and insulation check 2.
● Measure the armature resistances.
Armature coil resistance:
Continuity check 1:
0.025 ~ 0.035 Ω at 20 °C (68 °F)
Insulation check 2:
More than 1 MΩ at 20 °C (68 °F)
● If
the resistance is incorrect, replace the
starter motor.
*****************************************************
Not For Resale
9 - 20
www.SmallEngineDiscount.com
ELECTRIC STARTING SYSTEM
ELEC
–
+
5.Measure:
● Brush length a (each)
Out of specification → Replace the brush
holder set.
Brush length:
12.5 mm (0.49 in)
<Wear limit:>
5 mm (0.20 in)
6.Measure:
● Brush spring force
Fatigue/out of specification → Replace the
brush holder set.
Brush spring force:
7.65 ~ 10.01 Nm
(780 ~ 1,020 g, 27.54 ~ 36.03 oz)
7.Check:
● O-rings
Wear/damage → Replace.
ASSEMBLING THE STARTER MOTOR
1.Install:
● Brush holder set 1
NOTE:
Align the projection a on the brush seat 1 with
the slot b on the yoke.
2.Install:
● Yoke
● Brackets
NOTE:
Align the match marks a on the yoke with the
match marks b on the brackets.
Not For Resale
9 - 21
www.SmallEngineDiscount.com
B B
h
(BLACK) (BLACK)
Y Br
Y
Br
W
W W
W/R W/G
W
W W
R W/G
W/L W/R
W/G R
Br/L
W
W
W
B B
g
i
B
Y L
Y
Br
Br
f
W
W
W
(BLACK) (BLACK)
Y Br
1
R
W/G
W/R
W/G
W
R
W
B
L
L
B
e
L
L
B
d
R/B
B
R/B
Br
OFF
ON
3
c
(DARK GRAY)
R/B L
(BLACK)
B
W
B
R
R
Br
Not For Resale
9 - 22
www.SmallEngineDiscount.com
B
B
Y G
b
G Y
B
Y G
B
B
Y G
^
R/B
R/W
R/W
Z
Br/L
R/G
PUSH
_
a
SUB-WIRE
HARNESS 2
G Y
B
Y G
b
OFF
R/Y
R/Y
[
L Y G
R Br/L
Br/L R
Br/L
R Br
R
4
WIRE HARNESS
L/B Sb Br
B/Y Br/B R/B
Br Sb L/B
B
R/BBr/B B/Y
Br R
]
\
Br/L
R
SUB-WIRE
HARNESS 1
WIRE HARNESS
2
B/R B W/B
W/B B B/R
A
O B
L/B
B
Y R/Y
B
Br Y
L
(BLACK)
R/W R/B
(BLACK)
R/B R/W
L/B G B
B
B
B
R
P
B
Sb W/R
G/W L/W
R
L/B
L/W
B
Br/B
Br
G/R
Gy
B
W
B
B/R
W/B A W/B
W/B
B/R
B
B
Q
Sb
D
Sb
B/Y B
B B
A
B/Y
B/Y
0
C
B
L/Y
P
L/W
R/G
Br
B/R
W/B
G/L
Sb
G/R
W
O
(BLACK)
Sb G/R
G/W W/B
G
O
W/R
D
L/Y
W
B
B
W/L
O
W/R
L/W
D
W
C
B/W
F
W Sb G/L
(GRAY)
W/L B/R L/W
G/L Sb W
(GRAY)
L/W B/R W/L
L/Y W/B
W/R Br
(GRAY)
Br W/R
W/B L/Y
(GRAY)
B
G/R R/G
B
R/G G/R
H I J K L M N
E
B
L/Y W
W/L
B
D
P O/R
C
B
–
1 A.C. magneto
2 Rectifier/regulator
5 Battery
6 Main fuse
B
B
B/Y
R
W/R
W/G
L/W
R/B
G/W
Y/B
G/R
Sb
G/L
(BLACK)
B/Y R W/R W/G
(BLACK)
Y/B
G/L
W
B/R
R/B L/W O B
ELEC
B
A
B
A
L/R
T
9
G/W
D
G/W
B/Y Br/B W/B B/R B
B
Br/B
Br/B
B
B B/Y Br/B
B
B
W/B B/R
L/B Br
Sb B/Y
Sb
L/R
L/G
L/B
Y/B
Gy
L/G
S
Br/R
Br/R
(BLACK)
(BLACK)
Br/R
Br/R
B/Y
Br/R
Br/R B L/R
Br/B
Br/R
Br/R B L/G
SUB-WIRE
HARNESS 4
2WD
4WD
LOCK
V
L/B B Br Sb
(GRAY)
B Br
(GRAY)
G/R Gy
(BLACK)
(BLACK)
Br B
Sb L/B
Gy G/R
L/R L/G
L/B Sb
Br/R L/R
Y/B Gy
Br/R
L/R
Br/R
U
L/W L/B
Br/L
R
6
WIRE HARNESS
(BLACK)
L/W G/W
D
W/R Sb
(BLACK)
L/G L/R
Y
X
Br/L
8
B
B
7
5R
R
SUB-WIRE
HARNESS 3
R
B G L/B
L
B O
(GRAY)
R
WIRE HARNESS
(GRAY)
C
CHARGING SYSTEM
+
EB804000
CHARGING SYSTEM
CIRCUIT DIAGRAM
CHARGING SYSTEM
ELEC
–
EB804010
TROUBLESHOOTING
IF THE BATTERY IS NOT CHARGED:
Procedure
Check:
1.Fuse (main)
2.Battery
3.Charging voltage
4.Charging coil resistance
5.Wiring connections
(the entire charging system)
NOTE:
● Remove
the following part(s) before
troubleshooting:
1)Seat
2)Fuel tank side panels
● Use
the following special tool(s) for
troubleshooting.
EB802011
Inductive tachometer:
P/N. YU-8036-A
Engine tachometer:
P/N. 90890-03113
Pocket tester:
P/N. YU-03112, 90890-03112
NO CONTINUITY
1.Fuse (main)
Refer to “CHECKING THE SWITCH”.
CONTINUITY
Replace the fuse.
EB802012
2.Battery
●
INCORRECT
Check the battery condition.
Refer to “CHECKING THE BATTERY” in
CHAPTER 3.
Open-circuit voltage:
12.8 V or more at 20 °C (68 °F)
●
●
Clean the battery terminals.
Recharge or replace the battery.
CORRECT
EB804011
3.Charging voltage
●
●
Connect the engine tachometer to the
spark plug lead #1.
Connect the pocket tester (DC 20 V) to the
battery.
Tester (+) lead → Battery (+) terminal
Tester (–) lead → Battery (–) terminal
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9 - 23
www.SmallEngineDiscount.com
+
CHARGING SYSTEM
●
ELEC
–
Start the engine and accelerate to about
3,000 r/min.
Charging voltage:
14 V at 3,000 r/min
NOTE:
Use a fully charged battery.
MEETS SPECIFICATION
The charging circuit is not faulty.
OUT OF
SPECIFICATION
EB804012
4.Charging coil resistance
●
●
Disconnect the AC magneto coupler from
the wire harness.
Connect the pocket tester (Ω × 1) to the
charging coils.
Tester (+) lead → White terminal 1
Tester (–) lead → White terminal 2
Tester (+) lead → White terminal 1
Tester (–) lead → White terminal 3
●
OUT OF SPECIFICATION
Measure the stator coil resistance.
Charging coil resistance:
0.41 ~ 0.61 Ω at 20 °C (68 °F)
Replace the pickup coil/stator assembly.
MEETS
SPECIFICATION
EB804015
5.Wiring connections
●
Check the connections of the entire
charging system.
Refer to “CIRCUIT DIAGRAM”.
CORRECT
POOR CONNECTION
Properly connect the charging system.
Replace the rectifier/regulator.
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9 - 24
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+
B B
h
(BLACK) (BLACK)
Y Br
Y
Br
W
W W
W/R W/G
W
W W
R W/G
W/L W/R
W/G R
Br/L
W
W
W
B B
g
i
B
Y L
Y
Br
Br
f
W
W
W
(BLACK) (BLACK)
Y Br
1
R
W/G
W/R
W/G
W
R
W
B
L
L
B
e
L
L
B
d
R/B
B
R/B
Br
OFF
ON
3
c
(DARK GRAY)
R/B L
(BLACK)
B
W
B
R
R
Br
Not For Resale
9 - 25
www.SmallEngineDiscount.com
B
B
Y G
b
G Y
B
Y G
B
B
Y G
^
R/B
R/W
R/W
Z
Br/L
R/G
PUSH
_
a
SUB-WIRE
HARNESS 2
G Y
B
Y G
b
OFF
R/Y
R/Y
[
L Y G
R Br/L
Br/L R
Br/L
R Br
R
4
WIRE HARNESS
L/B Sb Br
B/Y Br/B R/B
Br Sb L/B
B
R/BBr/B B/Y
Br R
]
\
Br/L
R
SUB-WIRE
HARNESS 1
WIRE HARNESS
2
B/R B W/B
W/B B B/R
A
O B
L/B
B
Y R/Y
B
Br Y
L
(BLACK)
R/W R/B
(BLACK)
R/B R/W
L/B G B
B
B
B
R
P
B
Sb W/R
G/W L/W
R
L/B
L/W
Br/B
B
B/Y
Sb
Br
Br/B
G/R
Gy
B
W
B
B/R
W/B A W/B
W/B
B/R
B
B
Q
Sb
D
Sb
B/Y B
B B
A
B/Y
B/Y
0
C
B
L/Y
P
L/W
R/G
Br
B/R
W/B
G/L
Sb
G/R
W
O
(BLACK)
Sb G/R
G/W W/B
G
O
W/R
D
L/Y
W
B
B
W/L
O
W/R
L/W
D
W
C
B/W
F
W Sb G/L
(GRAY)
W/L B/R L/W
G/L Sb W
(GRAY)
L/W B/R W/L
L/Y W/B
W/R Br
(GRAY)
Br W/R
W/B L/Y
(GRAY)
B
G/R R/G
B
R/G G/R
3 Main switch
5 Battery
6 Main fuse
[ Headlight fuse
] Light switch
b Headlight
i Tail/brake light
H I J K L M N
E
B
L/Y W
W/L
B
D
P O/R
C
B
–
B
B
B/Y
R
W/R
W/G
L/W
R/B
G/W
Y/B
G/R
Sb
G/L
(BLACK)
B/Y R W/R W/G
(BLACK)
Y/B
G/L
W
B/R
R/B L/W O B
ELEC
B
A
B
A
L/R
T
9
G/W
D
G/W
B/Y Br/B W/B B/R B
B
Br/B
Br/B
B
B
W/B B/R
L/B Br
Sb B/Y
B
B
L/R
L/G
L/B
Y/B
Gy
L/G
S
Br/R
Br/R
(BLACK)
(BLACK)
Br/R
Br/R
B/Y
Br/R
Br/R B L/R
Br/B
Br/R
Br/R B L/G
SUB-WIRE
HARNESS 4
2WD
4WD
LOCK
V
L/B B Br Sb
(GRAY)
B Br
(GRAY)
G/R Gy
(BLACK)
(BLACK)
Br B
Sb L/B
Gy G/R
L/R L/G
L/B Sb
Br/R L/R
Y/B Gy
Br/R
L/R
Br/R
U
L/W L/B
Br/L
R
6
WIRE HARNESS
(BLACK)
L/W G/W
D
W/R Sb
(BLACK)
L/G L/R
Y
X
Br/L
8
B
B
7
5R
R
SUB-WIRE
HARNESS 3
R
B G L/B
L
B O
(GRAY)
R
WIRE HARNESS
(GRAY)
C
LIGHTING SYSTEM
+
EB805000
LIGHTING SYSTEM
CIRCUIT DIAGRAM
LIGHTING SYSTEM
ELEC
–
EB805010
TROUBLESHOOTING
IF THE HEADLIGHT AND/OR TAILLIGHT FAIL TO COME ON:
Procedure
Check:
1.Fuse (main, headlight)
2.Battery
3.Main switch
4.Light switch
5.Wiring connections
(the entire lighting system)
NOTE:
● Remove
the following part(s) before
troubleshooting:
1)Seat
2)Front carrier
3)Front fender panel
● Use
the following special tool(s) for
troubleshooting.
EB802011
Pocket tester:
P/N. YU-03112, 90890-03112
NO CONTINUITY
1.Fuse (main, headlight)
Refer to “CHECKING THE SWITCH”.
CONTINUITY
Replace the fuse.
EB802012
2.Battery
●
INCORRECT
Check the battery condition.
Refer to “CHECKING THE BATTERY” in
CHAPTER 3.
Open-circuit voltage:
12.8 V or more at 20 °C (68 °F)
●
●
Clean the battery terminals.
Recharge or replace the battery.
CORRECT
*
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+
LIGHTING SYSTEM
*
ELEC
–
+
C0NTINUITY
INCORRECT
3.Main switch
Refer to “CHECKING THE SWITCH”.
CORRECT
Replace the main switch.
INCORRECT
4.Light switch
Refer to “CHECKING THE SWITCH”.
CORRECT
Light switch is faulty, replace the handlebar
switch (left).
EB805013
5.Wiring connection
●
Check the connections of the entire lighting
system.
Refer to “WIRING DIAGRAM”.
CORRECT
POOR CONNECTION
Properly connect the lighting system.
Check the condition of each of the lighting
system’s circuits.
Refer to “CHECKING THE LIGHTING
SYSTEM”.
Not For Resale
9 - 27
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LIGHTING SYSTEM
ELEC
–
+
EB805020
CHECKING THE LIGHTING SYSTEM
1.If the headlights fail to come on:
NO CONTINUITY
1.Bulb and bulb socket
●
Check the bulb and bulb socket for
continuity.
Replace the bulb and/or bulb socket.
CONTINUITY
2.Voltage
●
Connect the pocket tester (DC 20 V) to the
headlight couplers.
È
É
Tester (+) lead →
Green terminal 1 or Yellow terminal 2
Tester (–) lead → Black terminal 3
È When the light switch is on “
É When the light switch is on “
●
●
●
”.
”.
Turn the main switch to “ON”.
Turn the light switch to “
” or “
”.
Check the voltage (12 V) of the “Green”
and “Yellow” leads on the bulb socket
connector.
OUT OF SPECIFICATION
The wiring circuit from the main switch to the
bulb socket connector is faulty, repair it.
MEETS
SPECIFICATION
This circuit is not faulty.
Not For Resale
9 - 28
www.SmallEngineDiscount.com
LIGHTING SYSTEM
ELEC
–
+
EB805021
2.If the taillight fails to come on:
NO CONTINUITY
1.Bulb and bulb socket
●
Check the bulb and bulb socket for
continuity.
Replace the bulb and/or bulb socket.
CONTINUITY
2.Voltage
●
1
Connect the pocket tester (20 V) to the bulb
socket coupler.
L
Y
B
Tester (+) lead → Blue lead 1
Tester (–) lead → Black lead 2
2
●
●
●
Turn the main switch to “ON”.
Turn the light switch to “
” or “
”.
Check the voltage (12 V) of the “Blue” lead
on the bulb socket connector.
MEETS
SPECIFICATION
OUT OF SPECIFICATION
The wiring circuit from the main switch to the
bulb socket connector is faulty, repair it.
This circuit is not faulty.
Not For Resale
9 - 29
www.SmallEngineDiscount.com
B B
h
(BLACK) (BLACK)
Y Br
Y
Br
W
W W
W/R W/G
W
W W
R W/G
W/L W/R
W/G R
Br/L
W
W
W
B B
g
i
B
Y L
Y
Br
Br
f
W
W
W
(BLACK) (BLACK)
Y Br
1
R
W/G
W/R
W/G
W
R
W
B
L
L
B
e
L
L
B
d
R/B
B
R/B
Br
OFF
ON
3
c
(DARK GRAY)
R/B L
(BLACK)
B
W
B
R
R
Br
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9 - 30
www.SmallEngineDiscount.com
B
B
Y G
b
G Y
B
Y G
B
B
Y G
^
R/B
R/W
R/W
Z
Br/L
R/G
PUSH
_
a
SUB-WIRE
HARNESS 2
G Y
B
Y G
b
OFF
R/Y
R/Y
[
L Y G
R Br/L
Br/L R
Br/L
R Br
R
4
WIRE HARNESS
L/B Sb Br
B/Y Br/B R/B
Br Sb L/B
B
R/BBr/B B/Y
Br R
]
\
Br/L
R
SUB-WIRE
HARNESS 1
WIRE HARNESS
2
B/R B W/B
W/B B B/R
A
O B
L/B
B
Y R/Y
B
Br Y
L
(BLACK)
R/W R/B
(BLACK)
R/B R/W
L/B G B
B
B
B
R
P
B
Sb W/R
G/W L/W
R
L/B
L/W
B
Br/B
Br
G/R
Gy
B
W
B
B/R
W/B A W/B
W/B
B/R
B
B
Q
Sb
D
Sb
B/Y B
B B
A
B/Y
B/Y
0
C
B
L/Y
P
L/W
R/G
Br
B/R
W/B
G/L
Sb
G/R
W
O
(BLACK)
Sb G/R
G/W W/B
G
O
W/R
D
L/Y
W
B
B
W/L
O
W/R
L/W
D
W
C
B/W
F
W Sb G/L
(GRAY)
W/L B/R L/W
G/L Sb W
(GRAY)
L/W B/R W/L
L/Y W/B
W/R Br
(GRAY)
Br W/R
W/B L/Y
(GRAY)
B
G/R R/G
B
R/G G/R
H I J K L M N
E
B
L/Y W
W/L
B
D
P O/R
C
B
–
B
B
B/Y
R
W/R
W/G
L/W
R/B
G/W
Y/B
G/R
Sb
G/L
(BLACK)
B/Y R W/R W/G
(BLACK)
Y/B
G/L
W
B/R
R/B L/W O B
ELEC
B
A
B
A
L/R
T
9
G/W
D
G/W
B/Y Br/B W/B B/R B
B
Br/B
Br/B
B
B B/Y Br/B
B
B
W/B B/R
L/B Br
Sb B/Y
Sb
L/R
L/G
L/B
Y/B
Gy
L/G
S
Br/R
Br/R
(BLACK)
(BLACK)
Br/R
Br/R
B/Y
Br/R
Br/R B L/R
Br/B
Br/R
Br/R B L/G
SUB-WIRE
HARNESS 4
2WD
4WD
LOCK
V
L/B B Br Sb
(GRAY)
B Br
(GRAY)
G/R Gy
(BLACK)
(BLACK)
Br B
Sb L/B
Gy G/R
L/R L/G
L/B Sb
Br/R L/R
Y/B Gy
Br/R
L/R
Br/R
U
L/W L/B
Br/L
R
6
WIRE HARNESS
(BLACK)
L/W G/W
D
W/R Sb
(BLACK)
L/G L/R
Y
X
Br/L
8
B
B
7
5R
R
SUB-WIRE
HARNESS 3
R
B G L/B
L
B O
(GRAY)
R
WIRE HARNESS
(GRAY)
C
SIGNAL SYSTEM
+
EB806000
SIGNAL SYSTEM
CIRCUIT DIAGRAM
SIGNAL SYSTEM
ELEC
3 Main switch
4 Backup fuse
5 Battery
6 Main fuse
9 Reverse switch
0 CDI unit
D Speed sensor
E Thermo switch 1
G Multi-function meter
H Differential gear lock indicator light
I Coolant temperature warning light
J Reverse indicator light
K Neutral indicator light
L Park indicator light
M High-range indicator light
N Low-range indicator light
O Low-range switch
P High-range switch
Q Neutral switch
V On-command four-wheel drive switch and differential gear lock switch
W Gear motor
Z Ignition fuse
f Signaling system fuse
g Front brake light switch
h Rear brake light switch
i Tail/brake light
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www.SmallEngineDiscount.com
–
+
SIGNAL SYSTEM
ELEC
–
EB806010
TROUBLESHOOTING
IF THE BRAKE LIGHT AND/OR INDICATOR LIGHT FAILS TO COME ON:
Procedure
Check:
1.Fuse (main, backup, ignition, signaling system)
2.Battery
3.Main switch
4.Wiring connections
(the entire signal system)
NOTE:
● Remove
the following part(s) before
troubleshooting:
1)Seat
2)Fuel tank
3)Air filter case
4)Front carrier
5)Front fender panel
● Use
the following special tool(s) for
troubleshooting.
Pocket tester:
P/N. YU-03112, 90890-03112
EB802011
1.Fuse (main, backup, ignition, signaling system)
NO CONTINUITY
Refer to “CHECKING THE SWITCH”.
CONTINUITY
Replace the fuse.
EB802012
2.Battery
●
INCORRECT
Check the battery condition.
Refer to “CHECKING THE BATTERY” in
CHAPTER 3.
Open-circuit voltage:
12.8 V or more at 20 °C (68 °F)
●
●
Clean the battery terminals.
Recharge or replace the battery.
CORRECT
*
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9 - 32
www.SmallEngineDiscount.com
+
SIGNAL SYSTEM
*
ELEC
C0NTINUITY
INCORRECT
3.Main switch
Refer to “CHECKING THE SWITCH”.
CORRECT
EB806011
POOR CONNECTION
4.Wiring connections
●
Replace the main switch.
Check the connections of the entire signal
system.
Refer to “CIRCUIT DIAGRAM”.
Properly connect the signal system.
CORRECT
Check the condition of each of the signal
system’s circuits.
Refer to “CHECKING THE SIGNAL
SYSTEM”.
Not For Resale
9 - 33
www.SmallEngineDiscount.com
–
+
SIGNAL SYSTEM
ELEC
–
+
CHECKING THE SIGNAL SYSTEM
1.If the brake light fails to come on:
1.Bulb and bulb socket
●
NO CONTINUITY
Check the bulb and bulb socket for
continuity.
CONTINUITY
Replace the bulb and/or bulb socket.
NO CONTINUITY
2.Brake light switches
Refer to “CHECKING THE SWITCH”.
CONTINUITY
Replace the brake light switch.
3.Voltage
●
Connect the pocket tester (DC 20 V) to the
bulb socket connector.
Tester (+) lead → Yellow terminal 1
Tester (–) lead → Black terminal 2
●
●
●
Turn the main switch to “ON”.
Pull in the brake lever or push down on the
brake pedal.
Check the voltage (12 V) of the “Yellow”
lead on the bulb socket connector.
OUT OF SPECIFICATION
The wiring circuit from the main switch to the
bulb socket connector is faulty, repair it.
MEETS
SPECIFICATION
This circuit is not faulty.
Not For Resale
9 - 34
www.SmallEngineDiscount.com
SIGNAL SYSTEM
ELEC
EB806024
2.If the indicator lights fails to come on:
NO CONTINUITY
1.Neutral switch
Refer to “CHECKING THE SWITCH”.
CONTINUITY
Replace the neutral switch.
NO CONTINUITY
2.High-range switch
Refer to “CHECKING THE SWITCH”.
CONTINUITY
Replace the high-range switch.
NO CONTINUITY
3.Low-range switch
Refer to “CHECKING THE SWITCH”.
CONTINUITY
Replace the low-range switch.
NO CONTINUITY
4.Reverse switch
Refer to “CHECKING THE SWITCH”.
CONTINUITY
Replace the reverse switch.
NO CONTINUITY
5.Four-wheel drive switch
Refer to “CHECKING THE SWITCH”.
CONTINUITY
Replace the four-wheel drive switch.
Replace the meter assembly.
Not For Resale
9 - 35
www.SmallEngineDiscount.com
–
+
SIGNAL SYSTEM
ELEC
–
+
3.If the coolant temperature warning light does not come on:
● Check that the light comes on when the main switch is set to “ON”.
● Check that the light comes on when the coolant temperature is 120 ± 3 °C (248 ± 5.4 °F) or higher
and that the light remains on when the coolant temperature drops to 113 °C (235.4 °F).
1.Thermo switch 1
●
●
●
●
Remove the thermo switch 1 from the
cylinder head.
Connect the pocket tester (Ω × 1) to the
thermo switch 1 1.
Immerse the thermo switch 1 in coolant 2.
Check the thermo switch 1 for continuity.
While heating the coolant use a thermometer
3 to record the temperatures.
Coolant temperature
Continuity
Thermo switch 1
Less than 120 ± 3 °C
1
NO
(248 ± 5.4 °F)
More than 120 ± 3 °C
2
YES
(248 ± 5.4 °F)
More than 113 °C
3
YES
(235.4 °F)
Less than 113 °C
4
NO
(235.4 °F)
Test steps 1 & 2: Heating phase
Test steps 3 & 4: Cooling phase
Test
step
È The thermo switch 1 circuit is open and the
coolant temperature warning light is off.
É The thermo switch 1 circuit is closed and the
coolant temperature warning light is come on.
É
È
113 ˚C
(235.4 ˚F)
120 ± 3 ˚C
(248 ± 5.4 ˚F)
WARNING
Handle the thermo switch 1 with special
care.
Never subject it to a strong shock or allow
it to be dropped. Should it be dropped, it
must be replaced.
T.
R.
Thermo switch 1:
8 Nm (0.8 m • kg, 5.8 ft • lb)
Three bond sealock® #10
BAD CONDITION
Replace the thermo switch 1.
GOOD
CONDITION
Replace the meter assembly.
Not For Resale
9 - 36
www.SmallEngineDiscount.com
B B
h
(BLACK) (BLACK)
Y Br
Y
Br
W
W W
W/R W/G
W
W W
R W/G
W/L W/R
W/G R
Br/L
W
W
W
B B
g
i
B
Y L
Y
Br
Br
f
W
W
W
(BLACK) (BLACK)
Y Br
1
R
W/G
W/R
W/G
W
R
W
B
L
L
B
e
L
L
B
d
R/B
B
R/B
Br
OFF
ON
3
c
(DARK GRAY)
R/B L
(BLACK)
B
W
B
R
R
Br
Not For Resale
9 - 37
www.SmallEngineDiscount.com
B
B
Y G
b
G Y
B
Y G
B
B
Y G
^
R/B
R/W
R/W
Z
Br/L
R/G
G Y
B
Y G
b
OFF
R/Y
R/Y
[
L Y G
R Br/L
Br/L R
Br/L
R Br
R
4
PUSH
_
a
SUB-WIRE
HARNESS 2
B/Y Br/B R/B
R/BBr/B B/Y
WIRE HARNESS
L/B Sb Br
B
Br Sb L/B
Br R
]
\
Br/L
R
SUB-WIRE
HARNESS 1
WIRE HARNESS
2
B/R B W/B
W/B B B/R
A
L/B
B
Y R/Y
L
(BLACK)
R/W R/B
(BLACK)
R/B R/W
L/B G B
Br Y
B G L/B
L
B
B
B
B
R
5R
P
B
B
Br/B
Br
G/R
Gy
B
W
B
B/R
W/B A W/B
W/B
B/R
B
B
Q
Sb
D
Sb
B/Y B
B B
A
B/Y
B/Y
0
C
B
L/Y
P
L/W
R/G
Br
B/R
W/B
G/L
Sb
G/R
W
O
(BLACK)
Sb G/R
G/W W/B
G
O
W/R
D
L/Y
W
B
B
W/L
O
W/R
L/W
D
W
C
B/W
F
W Sb G/L
(GRAY)
W/L B/R L/W
G/L Sb W
(GRAY)
L/W B/R W/L
L/Y W/B
W/R Br
(GRAY)
Br W/R
W/B L/Y
(GRAY)
B
G/R R/G
B
R/G G/R
H I J K L M N
E
B
L/Y W
W/L
B
D
P O/R
C
B
–
B
B
B/Y
R
W/R
W/G
L/W
R/B
G/W
Y/B
G/R
Sb
G/L
(BLACK)
B/Y R W/R W/G
(BLACK)
Y/B
G/L
W
B/R
R/B L/W O B
3 Main switch
5 Battery
6 Main fuse
c Circuit breaker (fan motor)
d Thermo switch 2
e Fan motor
ELEC
B
A
B
A
L/R
T
9
G/W
D
G/W
B/Y Br/B W/B B/R B
B
Br/B
Br/B
B
B B/Y Br/B
B
B
W/B B/R
L/B Br
Sb B/Y
Sb
L/R
L/G
L/B
Y/B
Gy
L/G
S
Br/R
Br/R
(BLACK)
(BLACK)
Br/R
Br/R
B/Y
Br/R
Br/R B L/R
Br/B
Br/R
Br/R B L/G
SUB-WIRE
HARNESS 4
2WD
4WD
LOCK
V
L/B B Br Sb
(GRAY)
B Br
(GRAY)
G/R Gy
(BLACK)
(BLACK)
Br B
Sb L/B
Gy G/R
L/R L/G
U
L/B Sb
Br/R L/R
Y/B Gy
Br/R
L/R
Br/R
R
Br/L
L/B
L/W
L/W L/B
R
WIRE HARNESS
6
R
G/W L/W
(BLACK)
L/W G/W
(BLACK)
Sb W/R
D
W/R Sb
L/G L/R
Y
X
Br/L
8
B
B
7
R
SUB-WIRE
HARNESS 3
(GRAY)
B O
R
WIRE HARNESS
(GRAY)
O B
C
COOLING SYSTEM
+
COOLING SYSTEM
CIRCUIT DIAGRAM
COOLING SYSTEM
ELEC
–
TROUBLESHOOTING
IF THE FAN MOTOR DOES NOT MOVE:
Procedure
Check:
1.Fuse (main)
2.Battery
3.Main switch
4.Fan motor
5.Circuit breaker (fan motor)
6.Thermo switch 2
7.Wiring connection
(the entire cooling system)
NOTE:
● Remove
the following part(s) before
troubleshooting.
1)Seat
2)Front carrier
3)Front fender
● Use
the following special tool(s) for
troubleshooting.
Pocket tester:
P/N. YU-03112, 90890-03112
EB802011
NO CONTINUITY
1.Fuse (main)
Refer to “CHECKING THE SWITCH”.
CONTINUITY
Replace the fuse.
EB802012
2.Battery
●
INCORRECT
Check the battery condition.
Refer to “CHECKING THE BATTERY” in
CHAPTER 3.
Open-circuit voltage:
12.8 V or more at 20 °C (68 °F)
●
●
Clean the battery terminals.
Recharge or replace the battery.
CORRECT
INCORRECT
3.Main switch
Refer to “CHECKING THE SWITCH”.
CORRECT
Replace the main switch.
*
Not For Resale
9 - 38
www.SmallEngineDiscount.com
+
COOLING SYSTEM
*
ELEC
C0NTINUITY
4.Fan motor
●
●
Disconnect the fan motor coupler.
Connect the battery (12 V) as shown.
Battery (+) lead → Blue terminal 1
Battery (–) lead → Black terminal 2
DOES NOT TURN
●
Check the operation of the fan motor.
Replace the fan motor.
TURNS
5.Circuit breaker (fan motor)
●
●
Remove the circuit breaker from the wire
harness.
Connect the pocket tester (Ω × 1) to the
circuit breaker.
OUT OF SPECIFICATION
Circuit breaker resistance:
Zero Ω at 20 °C (68 °F)
Replace the circuit breaker.
MEETS
SPECIFICATION
*
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–
+
COOLING SYSTEM
*
ELEC
–
C0NTINUITY
6.Thermo switch 2
●
●
●
●
Remove the thermo switch 2 from the
radiator.
Connect the pocket tester (Ω × 10) to the
thermo switch 2 1.
Immerse the thermo switch 2 in coolant 2.
Check the thermo switch 2 for continuity.
While heating the coolant use a
thermometer
3
to
record
the
temperatures.
Coolant temperature
Continuity
Thermo switch 2
Less than 86 ± 3 °C
1
NO
(186.8 ± 5.4 °F)
More than 86 ± 3 °C
2
YES
(186.8 ± 5.4 °F)
More than 80 ± 3 °C
3
YES
(176 ± 5.4 °F)
Less than 80 ± 3 °C
4
NO
(176 ± 5.4 °F)
Test steps 1 & 2: Heating phase
Test steps 3 & 4: Cooling phase
Test
step
È The thermo switch 2 circuit is open and the
radiator fan is off.
É The thermo switch 2 circuit is closed and the
radiator fan is on.
É
È
80 ± 3 ˚C
(176 ± 5.4 ˚F)
86 ± 3 ˚C
(186.8 ± 5.4 ˚F)
WARNING
Handle the thermo switch 2 with special
care.
Never subject it to a strong shock or
allow it to be dropped. Should it be
dropped, it must be replaced.
T.
R.
Thermo switch 2:
28 Nm (2.8 m • kg, 20 ft • lb)
Three bond sealock® #10
BAD CONDITION
Replace the thermo switch 2.
GOOD
CONDITION
*
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9 - 40
www.SmallEngineDiscount.com
+
COOLING SYSTEM
*
C0NTINUITY
EB803028
POOR CONNECTION
7.Wiring connection
●
ELEC
Check the connections of the entire starting
system.
Refer to “CIRCUIT DIAGRAM”.
Properly connect the cooling system.
CORRECT
This circuit is not faulty.
Not For Resale
9 - 41
www.SmallEngineDiscount.com
–
+
W
W W
W/R W/G
W
W W
R W/G
W/L W/R
W/G R
1
Br/L
W
W
W
Br
f
W
W
W
R
W/G
W/R
W/G
W
R
W
R/B L
(BLACK)
B
W
c
B B
h
(BLACK) (BLACK)
Y Br
Y
B B
g
i
(BLACK) (BLACK)
Y Br
B
Y L
Y
Br
B
L
L
B
e
(DARK GRAY)
L
L
B
d
R/B
3 Main switch
5 Battery
6 Main fuse
0 CDI unit
R Four-wheel drive fuse
S Four-wheel drive relay 1
T Four-wheel drive relay 2
U Four-wheel drive relay 3
V On-command four-wheel drive switch and
differential gear lock switch
W Gear motor
Br
B
R/B
Br
OFF
ON
3
B
R
R
Br
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9 - 42
www.SmallEngineDiscount.com
B
B
Y G
b
G Y
B
Y G
B
B
Y G
^
R/B
R/W
R/W
Z
Br/L
R/G
PUSH
_
a
SUB-WIRE
HARNESS 2
G Y
B
Y G
b
OFF
R/Y
R/Y
[
L Y G
R Br/L
Br/L R
Br/L
R Br
R
4
WIRE HARNESS
L/B Sb Br
B/Y Br/B R/B
Br Sb L/B
B
R/BBr/B B/Y
Br R
]
\
Br/L
R
SUB-WIRE
HARNESS 1
WIRE HARNESS
2
B/R B W/B
W/B B B/R
A
O B
L/B
B
Y R/Y
B
Br Y
L
(BLACK)
R/W R/B
(BLACK)
R/B R/W
L/B G B
B
B
B
R
P
B
Sb W/R
G/W L/W
R
L/B
L/W
B
Br/B
Br
G/R
Gy
B
W
B
B/R
W/B A W/B
W/B
B/R
B
B
Q
Sb
D
Sb
B/Y B
B B
A
B/Y
B/Y
0
C
B
L/Y
P
L/W
R/G
Br
B/R
W/B
G/L
Sb
G/R
W
O
(BLACK)
Sb G/R
G/W W/B
G
O
W/R
D
L/Y
W
B
B
W/L
O
W/R
L/W
D
W
C
B/W
F
W Sb G/L
(GRAY)
W/L B/R L/W
G/L Sb W
(GRAY)
L/W B/R W/L
L/Y W/B
W/R Br
(GRAY)
Br W/R
W/B L/Y
(GRAY)
B
G/R R/G
B
R/G G/R
H I J K L M N
E
B
L/Y W
W/L
B
D
P O/R
C
B
–
B
B
B/Y
R
W/R
W/G
L/W
R/B
G/W
Y/B
G/R
Sb
G/L
(BLACK)
B/Y R W/R W/G
(BLACK)
Y/B
G/L
W
B/R
R/B L/W O B
ELEC
B
A
B
A
L/R
T
9
G/W
D
G/W
B/Y Br/B W/B B/R B
B
Br/B
Br/B
B
B B/Y Br/B
B
B
W/B B/R
L/B Br
Sb B/Y
Sb
L/R
L/G
L/B
Y/B
Gy
L/G
S
Br/R
Br/R
(BLACK)
(BLACK)
Br/R
Br/R
B/Y
Br/R
Br/R B L/R
Br/B
Br/R
Br/R B L/G
SUB-WIRE
HARNESS 4
2WD
4WD
LOCK
V
L/B B Br Sb
(GRAY)
B Br
(GRAY)
G/R Gy
(BLACK)
(BLACK)
Br B
Sb L/B
Gy G/R
L/R L/G
L/B Sb
Br/R L/R
Y/B Gy
Br/R
L/R
Br/R
U
L/W L/B
Br/L
R
6
WIRE HARNESS
(BLACK)
L/W G/W
D
W/R Sb
(BLACK)
L/G L/R
Y
X
Br/L
8
B
B
7
5R
R
SUB-WIRE
HARNESS 3
R
B G L/B
L
B O
(GRAY)
R
WIRE HARNESS
(GRAY)
C
2WD/4WD SELECTING SYSTEM
+
2WD/4WD SELECTING SYSTEM
CIRCUIT DIAGRAM
2WD/4WD SELECTING SYSTEM
ELEC
–
+
EB803020
TROUBLESHOOTING
IF THE GEAR MOTOR FAILS TO OPERATE:
Procedure
Check:
1.Fuse (main, four-wheel drive)
2.Battery
3.Main switch
4.Four-wheel drive relay 1
5.Four-wheel drive relay 2
6.Four-wheel drive relay 3
7.On-command four-wheel drive switch and
differential gear lock switch
8.Gear motor
9.Wiring connections
(the entire 2WD/4WD selecting system)
NOTE:
● Remove
the following part(s) before
troubleshooting:
1)Seat
2)Front carrier
3)Front fender
● Use
the following special tool(s) for
troubleshooting.
Pocket tester:
P/N. YU-03112, 90890-03112
EB802011
1.Fuse (main, four-wheel drive)
NO CONTINUITY
Refer to “CHECKING THE SWITCH”.
CONTINUITY
Replace the fuse.
EB802012
2.Battery
●
INCORRECT
Check the battery condition.
Refer to “CHECKING THE BATTERY” in
CHAPTER 3.
Open-circuit voltage:
12.8 V or more at 20 °C (68 °F)
●
●
Clean the battery terminals.
Recharge or replace the battery.
CORRECT
INCORRECT
3.Main switch
Refer to “CHECKING THE SWITCH”.
CORRECT
*
Replace the main switch.
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9 - 43
www.SmallEngineDiscount.com
2WD/4WD SELECTING SYSTEM
*
ELEC
C0NTINUITY
4.Four-wheel drive relay 1
●
●
Remove the four-wheel drive relay 1 from
the wire harness.
Connect the pocket tester (Ω × 1) and the
battery (12 V) to the four-wheel drive relay
1 terminals.
Tester (+) lead →
Brown/Black terminal 1
Tester (–) lead → Black terminal 2
Battery (+) terminal →
Brown/Red terminal 3
Battery (–) terminal →
Blue/Green terminal 4
Tester (+) lead →
Brown/Black terminal 1
Tester (–) lead → Brown/Red terminal 5
●
Check the four-wheel drive relay 1 for
continuity.
NO CONTINUITY
Replace the four-wheel drive relay 1.
CONTINUITY
5.Four-wheel drive relay 2
●
●
Remove the four-wheel drive relay 2 from
the wire harness.
Connect the pocket tester (Ω × 1) and the
battery (12 V) to the four-wheel drive relay
2 terminals.
Tester (+) lead →
Black/Yellow terminal 1
Tester (–) lead → Black terminal 2
Battery (+) terminal →
Brown/Red terminal 3
Battery (–) terminal →
Blue/Red terminal 4
Tester (+) lead →
Black/Yellow terminal 1
Tester (–) lead → Brown/Red terminal 5
●
Check the four-wheel drive relay 2 for
continuity.
NO CONTINUITY
Replace the four-wheel drive relay 2.
CONTINUITY
*
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–
+
2WD/4WD SELECTING SYSTEM
*
ELEC
–
+
C0NTINUITY
6.Four-wheel drive relay 3
●
●
Remove the four-wheel drive relay 3 from
the wire harness.
Connect the pocket tester (Ω × 1) and the
battery (12 V) to the four-wheel drive relay
3 terminals.
Tester (+) lead →
Brown/Red terminal 1
Tester (–) lead →
Yellow/Black terminal 2
Battery (+) terminal →
Brown/Red terminal 1
Battery (–) terminal →
Yellow/Black terminal 2
Tester (+) lead → Blue/Red terminal 3
Tester (–) lead → Gray terminal 4
●
Check the four-wheel drive relay 3 for
continuity.
NO CONTINUITY
Replace the four-wheel drive relay 3.
CONTINUITY
7.On-command four-wheel drive switch and
differential gear lock switch
INCORRECT
Refer to “CHECKING THE SWITCH”.
CORRECT
Replace the on-command four-wheel drive
switch and differential gear lock switch.
*
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9 - 45
www.SmallEngineDiscount.com
2WD/4WD SELECTING SYSTEM
*
●
●
+
È
Disconnect the gear motor coupler.
Remove the gear motor from the
differential gear case.
Refer to “FRONT CONSTANT VELOCITY
JOINTS AND DIFFERENTIAL GEAR” in
CHAPTER 7.
Connect two C size batteries to the gear
motor terminals 1 (as shown illustrations).
È Check that the pinion gear 2 turns
counterclockwise.
É Check that the pinion gear 2 turns clockwise.
●
–
C0NTINUITY
8.Gear motor
●
ELEC
É
Make sure that the drive gear (shift fork
sliding gear) operates correctly.
NOTE:
When installing the differential gear case in
the gear motor, refer to “FRONT CONSTANT
VELOCITY JOINTS AND DIFFERENTIAL
GEAR” in CHAPTER 7.
CORRECT
INCORRECT
Replace the gear motor.
EB803028
9.Wiring connection
●
Check the connections of the entire 2WD/
4WD selecting system.
Refer to “CIRCUIT DIAGRAM”.
CORRECT
POOR CONNECTION
Properly connect the 2WD/4WD selecting
system.
Replace the CDI unit.
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9 - 46
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STARTING FAILURE/HARD STARTING
TRBL
SHTG
TROUBLESHOOTING
NOTE:
The following troubleshooting does not cover all the possible causes of trouble. It should be helpful,
however, as a guide to troubleshooting. Refer to the relative procedure in this manual for checking,
adjusting and replacing of parts.
STARTING FAILURE/HARD STARTING
FUEL SYSTEM
Fuel tank
● Empty
● Clogged fuel filter
● Clogged fuel strainer
● Clogged fuel breather hose
● Deteriorated or contaminated fuel
Fuel cock
● Clogged fuel hose
ELECTRICAL SYSTEM
Spark plug
● Improper plug gap
● Worn electrodes
● Wire between terminals broken
● Improper heat range
● Faulty spark plug cap
Ignition coil
● Broken or shorted primary/secondary
● Faulty spark plug lead
● Broken body
CDI system
● Faulty CDI unit
● Faulty pickup coil
● Faulty charging/rotor rotation direction coil
● Broken woodruff key
Carburetor
● Deteriorated or contaminated fuel
● Clogged pilot jet
● Clogged pilot air passage
● Sucked-in air
● Deformed float
● Worn needle valve
● Improperly sealed valve seat
● Improperly adjusted fuel level
● Improperly set pilot jet
● Clogged starter jet
● Starter plunger malfunction
Air filter
● Clogged air filter element
Switches and wiring
● Faulty main switch
● Faulty engine stop switch
● Broken or shorted wiring
● Faulty neutral switch
● Faulty reverse switch
● Faulty low-range switch
● Faulty high-range switch
● Faulty start switch
● Faulty rear brake switch
Starter motor
● Faulty starter motor
● Faulty starter relay
● Faulty starter clutch
Not For Resale
10 - 1
www.SmallEngineDiscount.com
10
STARTING FAILURE/HARD STARTING/POOR IDLE SPEED
PERFORMANCE/POOR MEDIUM AND HIGH-SPEED PERFORMANCE
COMPRESSION SYSTEM
Cylinder and cylinder head
● Loose spark plug
● Loose cylinder head or cylinder
● Broken cylinder head gasket
● Broken cylinder gasket
● Worn, damaged or seized cylinder
Piston and piston rings
● Improperly installed piston ring
● Worn, fatigued or broken piston ring
● Seized piston ring
● Seized or damaged piston
TRBL
SHTG
Valve, camshaft and crankshaft
● Improperly sealed valve
● Improperly contacted valve and valve seat
● Improper valve timing
● Broken valve spring
● Seized camshaft
● Seized crankshaft
POOR IDLE SPEED PERFORMANCE
POOR IDLE SPEED PERFORMANCE
Carburetor
● Improperly returned starter plunger
● Loose pilot jet
● Clogged pilot jet
● Clogged pilot air jet
● Improperly adjusted idle speed
(Throttle stop screw)
● Improper throttle cable play
● Flooded carburetor
Electrical system
● Faulty spark plug
● Faulty CDI unit
● Faulty pickup coil
● Faulty charging/rotor rotation direction coil
● Faulty ignition coil
Valve train
● Improperly adjusted valve clearance
Air filter
● Clogged air filter element
POOR MEDIUM AND HIGH-SPEED PERFORMANCE
POOR MEDIUM AND HIGH-SPEED PERFORMANCE
Refer to “STARTING FAILURE/HARD STARTING” and “POOR IDLE SPEED PERFORMANCEVALVE TRAIN”.
Air filter
Carburetor
● Improper jet needle clip position
● Clogged air filter element
● Improperly adjusted fuel level
● Clogged or loose main jet
● Deteriorated or contaminated fuel
Not For Resale
10 - 2
www.SmallEngineDiscount.com
FAULTY DRIVE TRAIN
TRBL
SHTG
FAULTY DRIVE TRAIN
The following conditions may indicate damaged shaft drive components:
Symptoms
1.A pronounced hesitation or “jerky” movement
during acceleration, deceleration, or sustained
speed. (This must not be confused with
engine
surging
or
transmission
characteristics.)
2.A “rolling rumble” noticeable at low speed; a
high-pitched whine; a “clunk” from a shaft
drive component or area.
3.A locked-up condition of the shaft drive
mechanism, no power transmitted from the
engine to the front and/or rear wheels.
Possible Causes
A.Bearing damage.
B.Improper gear lash.
C.Gear tooth damage.
D.Broken drive shaft.
E.Broken gear teeth.
F.Seizure due to lack of lubrication.
G.Small foreign objects lodged between the
moving parts.
NOTE:
Areas A, B, and C above may be extremely difficult to diagnose. The symptoms are quite subtle and
difficult to distinguish from normal machine operating noise. If there is reason to believe these
components are damaged, remove the components and check them.
Not For Resale
10 - 3
www.SmallEngineDiscount.com
FAULTY GEAR SHIFTING/
FAULTY CLUTCH PERFORMANCE
TRBL
SHTG
FAULTY GEAR SHIFTING
HARD SHIFTING
Refer to “CLUTCH SLIPPING/DRAGGING-CLUTCH DRAGGING”.
SHIFT LEVER DOES NOT MOVE
Shift shaft
● Bent shift shaft
Shift cam, shift fork
● Groove jammed with impurities
● Seized shift fork
● Bent shift fork guide bar
JUMPS OUT OF GEAR
Shift shaft
● Improperly adjusted shift lever position
● Worn shift shaft lever
● Improperly returned stopper lever
Shift fork
● Worn shift fork
Transmission
● Seized transmission gear
● Jammed impurities
● Incorrectly assembled transmission
Shift guide
● Broken shift guide
Shift cam
● Improper thrust play
● Worn shift cam groove
Transmission
● Worn gear dog
FAULTY CLUTCH PERFORMANCE
ENGINE OPERATES BUT MACHINE WILL NOT MOVE
V-belt
Transmission
● Bent, damaged or worn V-belt
● Damaged transmission gears
● V-belt slips
Primary pulley cam and primary pulley slider
● Damaged or worn primary pulley cam
● Damaged or worn primary pulley slider
CLUTCH SLIPPING
Clutch spring
● Damaged, loose or worn clutch shoe spring
Clutch shoe
● Damaged or worn clutch shoe
POOR STARTING PERFORMANCE
V-belt
● V-belt slips
● Oil or grease on the V-belt
Primary sliding sheave
● Faulty operation
● Worn pin groove
● Worn pin
Primary sliding sheave
● Seized primary sliding sheave
Clutch shoe
● Bent, damaged or worn clutch shoe
Not For Resale
10 - 4
www.SmallEngineDiscount.com
FAULTY CLUTCH PERFORMANCE/
OVERHEATING/FAULTY BRAKE
POOR SPEED PERFORMANCE
V-belt
● Oil or grease on the V-belt
Primary pulley weight
● Faulty operation
● Worn primary pulley weight
Primary fixed sheave
● Worn primary fixed sheave
TRBL
SHTG
Primary sliding sheave
● Worn primary sliding sheave
Secondary fixed sheave
● Worn secondary fixed sheave
Secondary sliding sheave
● Worn secondary sliding sheave
OVERHEATING
OVERHEATING
Ignition system
● Improper spark plug gap
● Improper spark plug heat range
● Faulty CDI unit
Fuel system
● Improper carburetor main jet
(improper setting)
● Improper fuel level
● Clogged air filter element
Compression system
● Heavy carbon build-up
Engine oil
● Improper oil level
● Improper oil viscosity
● Inferior oil quality
Cooling system
● Low coolant level
● Damaged or leaking radiator
● Faulty radiator cap
● Bent or damaged radiator fin
● Damaged or faulty water pump
● Thermostat stays closed
● Clogged or damaged oil cooler
● Damaged hose
● Improperly connected hose
● Damaged pipe
● Improperly connected pipe
Brake
● Brake drag
FAULTY BRAKE
POOR BRAKING EFFECT
● Worn brake pads
● Worn disc
● Air in brake fluid
● Leaking brake fluid
● Faulty master cylinder kit cup
● Faulty caliper kit seal
● Loose union bolt
● Broken brake hose and pipe
● Oily or greasy disc/brake pads
● Improper brake fluid level
Not For Resale
10 - 5
www.SmallEngineDiscount.com
SHOCK ABSORBER MALFUNCTION/UNSTABLE
HANDLING/LIGHTING SYSTEM
TRBL
SHTG
SHOCK ABSORBER MALFUNCTION
MALFUNCTION
● Bent or damaged damper rod
● Damaged oil seal lip
● Fatigued shock absorber spring
UNSTABLE HANDLING
UNSTABLE HANDLING
Handlebar
● Improperly installed or bent
Steering
● Incorrect toe-in
● Bent steering stem
● Improperly installed steering stem
● Damaged bearing or bearing race
● Bent tie-rods
● Deformed steering knuckles
Tires
● Uneven tire pressures on both sides
● Incorrect tire pressure
● Uneven tire wear
Wheels
● Deformed wheel
● Loose bearing
● Bent or loose wheel axle
● Excessive wheel runout
Frame
● Bent
● Damaged frame
LIGHTING SYSTEM
HEADLIGHT DARK
● Improper bulb
● Too many electric accessories
● Hard charging (broken charging coil and/or
faulty rectifier/regulator)
● Incorrect connection
● Improperly grounded
● Poor contacts (main or light switch)
● Bulb life expired
BULB BURNT OUT
● Improper bulb
● Faulty battery
● Faulty rectifier/regulator
● Improperly grounded
● Faulty main and/or light switch
● Bulb life expired
Not For Resale
10 - 6
www.SmallEngineDiscount.com
YFM450FAR WIRING DIAGRAM
A
W/B B B/R
B
Br Sb L/B
L/B Sb Br
R/BBr/B B/Y
B/Y Br/B R/B
WIRE HARNESS
SUB-WIRE
HARNESS 2
B/R B W/B
WIRE HARNESS
SUB-WIRE
HARNESS 1
C
D
O B
B O
(GRAY)
(GRAY)
WIRE HARNESS
SUB-WIRE
HARNESS 3
W/R Sb
Sb W/R
L/W G/W
G/W L/W
(BLACK)
(BLACK)
WIRE HARNESS
SUB-WIRE
HARNESS 4
R/B L/W O B
W
Y/B
B/Y R W/R W/G
B/R
G/L
(BLACK)
(BLACK)
R
W/G
W/R
W/G
W/G R
R W/G
W/R W/G
W/L W/R
W
W W
W
W W
1
W
W
W
G/W W/B
Sb G/R
(BLACK)
R
W
W
W
R
2
G/W
B
R
4
W
R
D
R
B
W
R
5R
R/G
R
W
B
R
R
6
7
G/W
L/W L/B
W/R
W/G
L/W
R/B
G/W
Y/B
G/R
Sb
G/L
O
B
B
R
C
B
0
L/Y
W
B
W
D
P O/R
W/B
B/R
B/W
L/Y W
B/Y
R
C
L/W
(BLACK)
B
B
O
C
B
B
9
L/B
B/Y
3
B
OFF
ON
Br/L
Br R
R Br
Br/L R
R Br/L
B
B
A
8
W/L
B B
Br
B
E
B/Y B
L/Y
W
W Sb G/L
F
W/L
L/W B/R W/L
(GRAY)
L/Y W/B
R/G G/R
W/R Br
B
(GRAY)
Br
Br/L
Br/L
Br/L
Br/L
G/L Sb W
Br/L
W/L B/R L/W
f
c
[
Br
Z
R/Y
X
R
R/W
Br/B
Br/R
Br/R B L/G
B/Y
Br/R
Br/R B L/R
(BLACK)
(BLACK)
Br/R
Br/R
Br/R
Br/R
Br/R
R/B
P
S
B
Br
Br
h
Y Br
R/B
g
Y Br
B B
B B
\
R/B
R/W
R/Y
]
d
R/B L
L
^
Y
L/B
Br Y
L
Y
B
(DARK GRAY)
B
L/G
L/R
W/R
L/W
D
PUSH
R/B R/W
Y
L
(BLACK)
L Y G
Br/R
L/R
B
Y/B
Gy
U
Y/B Gy
B
R/W R/B
L
B
B
B
L
Y G
b
e
L
Y G
b
L/G L/R
L/R L/G
L/B Sb
Sb L/B
(BLACK)
(BLACK)
Gy G/R
G/R Gy
Y G
Y G
Br B
B Br
B
B
(GRAY)
(GRAY)
B
B
G/R
Gy
Sb
D
V
Sb
G Y
B
B
L/W
W/R
2WD
4WD
LOCK
Q
L/B
B
G Y
B
D
L/R
L/G
Br/R L/R
(BLACK)
Y L
i
G
B/Y
L/B G B
_
OFF
T
Sb
Br
B
P
O
Br/B
B
Br/B
B
B B/Y Br/B
B
B
W/B B/R
L/B Br
Sb B/Y
W/B A W/B
A
B/R
L/B B Br Sb
W
B/Y Br/B W/B B/R B
B
W/B L/Y
G/R R/G
Br W/R
B
(GRAY)
H I J K L M N
R/G
Br
B/R
W/B
G/L
Sb
G/R
Br/B
B G L/B
a
(BLACK) (BLACK)
(BLACK) (BLACK)
Y R/Y
(GRAY)
1
2
3
4
5
6
7
8
9
0
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
S
T
U
V
W
X
Y
Z
[
\
]
^
a
b
c
d
e
f
g
h
i
A.C. magneto
Rectifier/regulator
Main switch
Backup fuse
Battery
Main fuse
Starter relay
Starter motor
Reverse switch
CDI unit
Rear brake switch
Ignition coil
Spark plug
Speed sensor
Thermo switch 1
Meter assembly
Multi-function meter
Differential gear lock indicator light
Coolant temperature warning light
Reverse indicator light
Neutral indicator light
Park indicator light
High-range indicator light
Low-range indicator light
Low-range switch
High-range switch
Neutral switch
Four-wheel drive fuse
Four-wheel drive relay 1
Four-wheel drive relay 2
Four-wheel drive relay 3
On-command four-wheel drive switch and
differential gear lock switch
Gear motor
Auxiliary DC jack fuse
Auxiliary DC jack
Ignition fuse
Headlight fuse
Handlebar switch (left)
Light switch
Engine stop switch
Start switch
Headlight
Circuit breaker (fan motor)
Thermo switch 2
Fan motor
Signaling system fuse
Front brake light switch
Rear brake light switch
Tail/brake light
B
B
A
B
COLOR CODE
B ............Black
Br ...........Brown
G............Green
L.............Blue
O............Orange
P ............Pink
R ............Red
Sb ..........Sky blue
Gy ..........Gray
W ...........White
Y ............Yellow
B/R.........Black/Red
B/Y.........Black/Yellow
Br/B........Brown/Black
Br/L ........Brown/Blue
Br/R .......Brown/Red
G/L.........Green/Blue
G/R ........Green/Red
G/W........Green/White
G/Y.........Green/Yellow
L/B .........Blue/Black
L/G .........Blue/Green
L/R .........Blue/Red
L/W ........Blue/White
L/Y .........Blue/Yellow
R/B.........Red/Black
R/G ........Red/Green
Not For Resale
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R/W ....... Red/White
R/Y ........ Red/Yellow
W/B ....... White/Black
W/G....... White/Green
W/L ....... White/Blue
W/R ....... White/Red
Y/B ........ Yellow/Black
YAMAHA MOTOR CO., LTD.
2500 SHINGAI IWATA SHIZUOKA JAPAN
Not For Resale
www.SmallEngineDiscount.com
PRINTED IN U.S.A.