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Summary of Contents for Yamaha 2016 Grizzly yfm700gplg

YFM7FGPW

SERVICE MANUAL

LIT-11616-20-11 3B4-28197-10

EBS00001

YFM7FGPWSERVICE MANUAL

©2006 by Yamaha Motor Corporation, U.S.A. First Edition, May 2006

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-11616-20-11

EBS00002

NOTICEThis manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealersand their qualified mechanics. It is not possible to include all the knowledge of a mechanic in onemanual, so it is assumed that anyone who uses this book to perform maintenance and repairs onYamaha vehicle has a basic understanding of the mechanical ideas and the procedures of vehiclerepair. Repairs attempted by anyone without this knowledge are likely to render the vehicle unsafeand unfit for use.

This model has been designed and manufactured to perform within certain specifications in regardto performance and emissions. Proper service with the correct tools is necessary to ensure that thevehicle will operate as designed. If there is any question about a service procedure, it is imperativethat you contact a Yamaha dealer for any service information changes that apply to this model. Thispolicy is intended to provide the customer with the most satisfaction from his vehicle and to conformto federal environmental quality objectives.

Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and sig-nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealersand will appear in future editions of this manual where applicable.

NOTE:_

• This Service Manual contains information regarding periodic maintenance to the emission controlsystem. Please read this material carefully.

• Designs and specifications are subject to change without notice.

EBS00003

IMPORTANT INFORMATIONParticularly important information is distinguished in this manual by the following notations.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOURSAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death tothe vehicle operator, a bystander or a person checking or repairing the vehicle.

A CAUTION indicates special precautions that must be taken to avoid damageto the vehicle.

A NOTE provides key information to make procedures easier or clearer.

WARNING

CAUTION:

NOTE:

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HOW TO USE THIS MANUALMANUAL ORGANIZATIONThis manual consists of chapters for the main categories of subjects. (See “symbols”)1st title 1: This is the title of the chapter with its symbol in the upper right corner of each page.2nd title 2: This title indicates the section of the chapter and only appears on the first page of eachsection. 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 accompa-nied by corresponding illustrations.

EXPLODED DIAGRAMSTo help identify parts and clarify procedure steps, there are exploded diagrams at the start of eachremoval 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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SYMBOLSThe following symbols are not relevant toevery vehicle. Symbols 1 to 0 indicate the subject of eachchapter.1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Cooling system 6 Fuel injection system7 Drive train 8 Chassis 9 Electrical 0 Troubleshooting

Symbols A to H indicate the followingA Can be serviced with engine mounted B Filling fluid C Lubricant D Special tool E Torque F Wear limit, clearance G Engine speed H Electrical data (Ω, V, A)

Symbols I to N in the exploded diagramsindicate the types of lubricants and lubricationpoints.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 greaseSymbols O to P in the exploded diagramsindicate where to apply a locking agent O andwhen to install a new part P.O Apply the locking agent (LOCTITE®) P Replace

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

GENINFO SPEC

CHKADJ ENG

COOL FI

DRIV CHAS

– +ELEC TRBLSHTG

T R..

E G M

B LS M

LT New

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TABLE OF CONTENTSGENERAL INFORMATION GEN

INFO 1

SPECIFICATIONSSPEC 2

PERIODIC CHECKS AND ADJUSTMENTS CHK

ADJ 3

ENGINEENG 4

COOLING SYSTEMCOOL 5

FUEL INJECTION SYSTEMFI 6

DRIVE TRAINDRIV 7

CHASSISCHAS 8

ELECTRICALELEC 9

TROUBLESHOOTING TRBL SHTG 10

– +

CONTENTS

CHAPTER 1GENERAL INFORMATION

VEHICLE IDENTIFICATION………………………………………………………………….1-1VEHICLE IDENTIFICATION NUMBER ……………………………………………..1-1MODEL LABEL………………………………………………………………………………1-1

FEATURES…………………………………………………………………………………………1-2OUTLINE OF THE FI SYSTEM………………………………………………………..1-2FI SYSTEM……………………………………………………………………………………1-3OUTLINE OF THE EPS (ELECTRIC POWER STEERING) SYSTEM……1-4EPS (ELECTRIC POWER STEERING) SYSTEM BLOCK DIAGRAM …..1-5INSTRUMENT FUNCTIONS ……………………………………………………………1-6

IMPORTANT INFORMATION ……………………………………………………………….1-9PREPARATION FOR REMOVAL AND DISASSEMBLY………………………1-9REPLACEMENT PARTS…………………………………………………………………1-9GASKETS, OIL SEALS AND O-RINGS …………………………………………….1-9LOCK WASHERS/PLATES AND COTTER PINS ……………………………..1-10BEARINGS AND OIL SEALS …………………………………………………………1-10CIRCLIPS ……………………………………………………………………………………1-10CHECKING THE CONNECTIONS………………………………………………….1-11

SPECIAL TOOLS ………………………………………………………………………………1-12

CHAPTER 2SPECIFICATIONS

GENERAL SPECIFICATIONS ………………………………………………………………2-1

ENGINE SPECIFICATIONS ………………………………………………………………….2-5

CHASSIS SPECIFICATIONS ………………………………………………………………2-12

ELECTRICAL SPECIFICATIONS ………………………………………………………..2-14

TIGHTENING TORQUES ……………………………………………………………………2-16ENGINE TIGHTENING TORQUES…………………………………………………2-16CHASSIS TIGHTENING TORQUES……………………………………………….2-19

HOW TO USE THE CONVERSION TABLE…………………………………………..2-22

GENERAL TIGHTENING TORQUE SPECIFICATIONS………………………….2-22

LUBRICATION POINTS AND LUBRICANT TYPES ………………………………2-23ENGINE………………………………………………………………………………………2-23

COOLANT FLOW DIAGRAMS ……………………………………………………………2-25

OIL FLOW DIAGRAMS ………………………………………………………………………2-26

CABLE ROUTING ……………………………………………………………………………..2-28

CHAPTER 3PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION………………………………………………………………………………….3-1

PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM ……………………………………………………………………………………………3-1

GENERAL MAINTENANCE AND LUBRICATION CHART……………………….3-2

ENGINE SKID PLATES, SEAT, CARRIERS AND FENDERS …………………..3-4ENGINE SKID PLATES…………………………………………………………………..3-4SEAT AND SIDE PANELS………………………………………………………………3-5FRONT CARRIER AND FRONT GUARD ………………………………………….3-6FRONT FENDERS AND FRONT GRILL……………………………………………3-8REAR CARRIER AND REAR FENDER …………………………………………….3-9

ELECTRICAL COMPONENTS TRAY…………………………………………………..3-10ELECTRICAL COMPONENTS TRAY 1/2 ………………………………………..3-10ELECTRICAL COMPONENTS TRAY 2/2 ………………………………………..3-12

FOOTREST BOARDS ………………………………………………………………………..3-14

AIR FILTER CASE …………………………………………………………………………….3-15

ENGINE ……………………………………………………………………………………………3-16ADJUSTING THE VALVE CLEARANCE …………………………………………3-16ADJUSTING THE ENGINE IDLING SPEED …………………………………….3-19ADJUSTING THE THROTTLE LEVER FREE PLAY …………………………3-20ADJUSTING THE SPEED LIMITER………………………………………………..3-22CHECKING THE SPARK PLUG …………………………………………………….3-23CHECKING THE IGNITION TIMING……………………………………………….3-24MEASURING THE COMPRESSION PRESSURE…………………………….3-25CHECKING THE ENGINE OIL LEVEL…………………………………………….3-28CHANGING THE ENGINE OIL ………………………………………………………3-29CLEANING THE AIR FILTER ELEMENT…………………………………………3-31CHECKING THE THROTTLE BODY JOINT…………………………………….3-33CHECKING THE FUEL HOSE ……………………………………………………….3-34CHECKING THE BREATHER HOSES ……………………………………………3-34CHECKING THE COOLANT LEVEL……………………………………………….3-35CHANGING THE COOLANT………………………………………………………….3-35CHECKING THE COOLING SYSTEM …………………………………………….3-39CHECKING THE COOLANT TEMPERATURE WARNING LIGHT………3-40CHECKING THE V-BELT………………………………………………………………3-41CHECKING THE EXHAUST SYSTEM…………………………………………….3-42CLEANING THE SPARK ARRESTER …………………………………………….3-43

CHASSIS ………………………………………………………………………………………….3-44ADJUSTING THE FRONT BRAKE …………………………………………………3-44ADJUSTING THE REAR BRAKE……………………………………………………3-44CHECKING THE BRAKE FLUID LEVEL………………………………………….3-46CHECKING THE FRONT BRAKE PADS …………………………………………3-47CHECKING THE REAR BRAKE PADS …………………………………………..3-48CHECKING THE REAR BRAKE HOSE PROTECTORS ……………………3-48CHECKING THE BRAKE HOSES…………………………………………………..3-49BLEEDING THE HYDRAULIC BRAKE SYSTEM ……………………………..3-49ADJUSTING THE SELECT LEVER CONTROL CABLE AND SHIFT ROD ………………………………………………………………………………..3-51CHECKING THE FINAL GEAR OIL LEVEL ……………………………………..3-53CHANGING THE FINAL GEAR OIL………………………………………………..3-53CHECKING THE DIFFERENTIAL GEAR OIL LEVEL………………………..3-55CHANGING THE DIFFERENTIAL GEAR OIL ………………………………….3-55CHECKING THE CONSTANT VELOCITY JOINT DUST BOOTS ……….3-56CHECKING THE STEERING SYSTEM …………………………………………..3-57ADJUSTING THE TOE-IN……………………………………………………………..3-59CHECKING THE FRONT AND REAR SHOCK ABSORBERS ……………3-60ADJUSTING THE FRONT SHOCK ABSORBERS ……………………………3-61ADJUSTING THE REAR SHOCK ABSORBERS………………………………3-62CHECKING THE TIRES………………………………………………………………..3-62CHECKING THE WHEELS ……………………………………………………………3-65CHECKING AND LUBRICATING THE CABLES ………………………………3-65LUBRICATING THE LEVERS AND PEDALS …………………………………..3-66

ELECTRICAL SYSTEM………………………………………………………………………3-67CHECKING AND CHARGING THE BATTERY…………………………………3-67CHECKING THE FUSES ………………………………………………………………3-73ADJUSTING THE HEADLIGHT BEAMS………………………………………….3-76REPLACING THE HEADLIGHT BULBS ………………………………………….3-76

CHAPTER 4ENGINE

ENGINE REMOVAL …………………………………………………………………………….4-1AIR DUCTS, MUFFLER AND EXHAUST PIPE ………………………………….4-1SELECT LEVER UNIT ……………………………………………………………………4-3LEADS, CABLES AND HOSES ……………………………………………………….4-4ENGINE MOUNTING BOLTS ………………………………………………………….4-6INSTALLING THE ENGINE……………………………………………………………..4-8INSTALLING THE SELECT LEVER UNIT …………………………………………4-9

CYLINDER HEAD………………………………………………………………………………4-10REMOVING THE CYLINDER HEAD……………………………………………….4-12CHECKING THE CAMSHAFT SPROCKET……………………………………..4-13CHECKING THE TAPPET COVERS ………………………………………………4-13CHECKING THE TIMING CHAIN TENSIONER………………………………..4-13CHECKING THE CYLINDER HEAD ……………………………………………….4-14INSTALLING THE CYLINDER HEAD ……………………………………………..4-15

ROCKER ARMS AND CAMSHAFT ……………………………………………………..4-18REMOVING THE ROCKER ARMS AND CAMSHAFT……………………….4-20CHECKING THE CAMSHAFT………………………………………………………..4-20CHECKING THE DECOMPRESSION SYSTEM……………………………….4-21CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS ……..4-21INSTALLING THE CAMSHAFT AND ROCKER ARMS ……………………..4-22

VALVES AND VALVE SPRINGS…………………………………………………………4-25REMOVING THE VALVES AND VALVE SPRINGS ………………………….4-26CHECKING THE VALVES AND VALVE SPRINGS …………………………..4-27INSTALLING THE VALVES AND VALVE SPRINGS …………………………4-31

CYLINDER AND PISTON……………………………………………………………………4-34REMOVING THE PISTON …………………………………………………………….4-35CHECKING THE CYLINDER AND PISTON …………………………………….4-35CHECKING THE PISTON RINGS…………………………………………………..4-37CHECKING THE PISTON PIN ……………………………………………………….4-38INSTALLING THE PISTON AND CYLINDER …………………………………..4-39

AC MAGNETO…………………………………………………………………………………..4-42REMOVING THE AC MAGNETO ROTOR……………………………………….4-45CHECKING THE STATOR COIL AND CRANKSHAFT POSITION SENSOR ……………………………………………………………………………………4-46CHECKING THE STARTER CLUTCH …………………………………………….4-46CHECKING THE TORQUE LIMITER………………………………………………4-47INSTALLING THE AC MAGNETO ROTOR ……………………………………..4-47

BALANCER GEARS AND OIL PUMP GEARS ……………………………………..4-49REMOVING THE BALANCER DRIVEN GEAR AND OIL PUMP DRIVEN GEAR……………………………………………………………………………4-51CHECKING THE OIL PUMP DRIVE ……………………………………………….4-51CHECKING THE BALANCER DRIVE ……………………………………………..4-51INSTALLING THE BALANCER DRIVE GEAR, BALANCER DRIVEN GEAR, AND OIL PUMP DRIVEN GEAR…………………………………………4-52

PRIMARY AND SECONDARY SHEAVES…………………………………………….4-53PRIMARY SHEAVE………………………………………………………………………4-55SECONDARY SHEAVE ………………………………………………………………..4-56REMOVING THE PRIMARY AND SECONDARY SHEAVES ……………..4-57DISASSEMBLING THE SECONDARY SHEAVE………………………………4-57CHECKING THE PRIMARY SHEAVE …………………………………………….4-58CHECKING THE SECONDARY SHEAVE ……………………………………….4-58ASSEMBLING THE PRIMARY SHEAVE …………………………………………4-59ASSEMBLING THE SECONDARY SHEAVE……………………………………4-60INSTALLING THE PRIMARY AND SECONDARY SHEAVES…………….4-62

CLUTCH …………………………………………………………………………………………..4-63REMOVING THE CLUTCH ……………………………………………………………4-65CHECKING THE CLUTCH…………………………………………………………….4-66INSTALLING THE CLUTCH…………………………………………………………..4-67

CRANKCASE ……………………………………………………………………………………4-68TIMING CHAIN AND OIL FILTER …………………………………………………..4-68CRANKCASE ………………………………………………………………………………4-70CRANKCASE BEARINGS……………………………………………………………..4-71SEPARATING THE CRANKCASE………………………………………………….4-72CHECKING THE TIMING CHAIN AND GUIDE…………………………………4-72CHECKING THE RELIEF VALVE …………………………………………………..4-72CHECKING THE BEARINGS…………………………………………………………4-73CHECKING THE CRANKCASE ……………………………………………………..4-73ASSEMBLING THE CRANKCASE………………………………………………….4-73INSTALLING THE SHIFT LEVER …………………………………………………..4-74

CRANKSHAFT AND OIL PUMP ………………………………………………………….4-75OIL PUMP …………………………………………………………………………………..4-76REMOVING THE CRANKSHAFT …………………………………………………..4-77CHECKING THE OIL PUMP ………………………………………………………….4-77CHECKING THE OIL STRAINER …………………………………………………..4-78CHECKING THE CRANKSHAFT ……………………………………………………4-78ASSEMBLING THE OIL PUMP………………………………………………………4-79INSTALLING THE CRANKSHAFT ………………………………………………….4-79

TRANSMISSION………………………………………………………………………………..4-81DRIVE AXLE ……………………………………………………………………………….4-83REMOVING THE TRANSMISSION ………………………………………………..4-85CHECKING THE SHIFT FORKS…………………………………………………….4-85CHECKING THE SHIFT DRUM ……………………………………………………..4-86CHECKING THE TRANSMISSION …………………………………………………4-86CHECKING THE SECONDARY SHAFT………………………………………….4-87CHECKING THE STOPPER LEVER AND STOPPER WHEEL…………..4-87ASSEMBLING THE SHIFT FORK ASSEMBLY ………………………………..4-87INSTALLING THE TRANSMISSION ……………………………………………….4-88

MIDDLE GEAR ………………………………………………………………………………….4-89MIDDLE DRIVE SHAFT ………………………………………………………………..4-89MIDDLE DRIVEN SHAFT………………………………………………………………4-90REMOVING THE MIDDLE DRIVE SHAFT ………………………………………4-92REMOVING THE MIDDLE DRIVEN SHAFT…………………………………….4-93CHECKING THE PINION GEARS ………………………………………………….4-95SELECTING MIDDLE DRIVE AND DRIVEN GEAR SHIMS……………….4-96INSTALLING THE BEARING AND OIL SEALS ………………………………..4-99INSTALLING THE MIDDLE DRIVEN SHAFT …………………………………4-100INSTALLING THE MIDDLE DRIVE SHAFT ……………………………………4-102MEASURING THE MIDDLE GEAR BACKLASH……………………………..4-102

CHAPTER 5COOLING SYSTEM

RADIATOR …………………………………………………………………………………………5-1CHECKING THE RADIATOR…………………………………………………………..5-3INSTALLING THE RADIATOR…………………………………………………………5-4

THERMOSTAT ……………………………………………………………………………………5-5CHECKING THE THERMOSTAT……………………………………………………..5-6INSTALLING THE THERMOSTAT……………………………………………………5-6

WATER PUMP…………………………………………………………………………………….5-7DISASSEMBLING THE WATER PUMP…………………………………………….5-9CHECKING THE WATER PUMP ……………………………………………………..5-9ASSEMBLING THE WATER PUMP………………………………………………..5-10

CHAPTER 6FUEL INJECTION SYSTEM

FUEL INJECTION SYSTEM………………………………………………………………….6-1CIRCUIT DIAGRAM ……………………………………………………………………….6-3ECU SELF-DIAGNOSTIC FUNCTION………………………………………………6-5SELF-DIAGNOSTIC FUNCTION TABLE …………………………………………..6-6TROUBLESHOOTING CHART ………………………………………………………..6-7DIAGNOSTIC MODE ……………………………………………………………………..6-8TROUBLESHOOTING DETAILS ……………………………………………………6-12CHECKING THE INTAKE AIR PRESSURE SENSOR ………………………6-26CHECKING THE INTAKE AIR TEMPERATURE SENSOR ………………..6-26

FUEL TANK………………………………………………………………………………………6-28REMOVING THE FUEL TANK ……………………………………………………….6-30REMOVING THE FUEL PUMP ………………………………………………………6-30CHECKING THE FUEL PUMP BODY……………………………………………..6-31CHECKING THE ROLLOVER VALVE …………………………………………….6-31INSTALLING THE FUEL PUMP……………………………………………………..6-31INSTALLING THE FUEL HOSE ……………………………………………………..6-32

THROTTLE BODY……………………………………………………………………………..6-33REMOVING THE THROTTLE BODY ASSEMBLY ……………………………6-36CHECKING THE FUEL INJECTOR ………………………………………………..6-36CHECKING THE THROTTLE BODY ………………………………………………6-36INSTALLING THE THROTTLE BODY ASSEMBLY…………………………..6-37CHECKING THE FUEL PUMP AND PRESSURE REGULATOR OPERATION ………………………………………………………………………………6-38CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR ……………………………………………………………………………………6-39

CHAPTER 7DRIVE TRAIN

TROUBLESHOOTING………………………………………………………………………….7-1CHECKING NOISES………………………………………………………………………7-1TROUBLESHOOTING CHART ………………………………………………………..7-3

FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR……..7-4REMOVING THE DIFFERENTIAL GEAR ASSEMBLY………………………7-10CHECKING THE FRONT CONSTANT VELOCITY JOINTS……………….7-10CHECKING THE DIFFERENTIAL GEARS ………………………………………7-11CHECKING THE DIFFERENTIAL GEAR MOTOR ……………………………7-11ASSEMBLING THE FRONT CONSTANT VELOCITY JOINTS …………..7-12ASSEMBLING THE DIFFERENTIAL GEARS…………………………………..7-13MEASURING THE DIFFERENTIAL GEAR LASH …………………………….7-14ADJUSTING THE DIFFERENTIAL GEAR LASH………………………………7-15CHECKING THE DIFFERENTIAL GEAR OPERATION …………………….7-16

REAR CONSTANT VELOCITY JOINTS AND FINAL DRIVE GEAR ………..7-17ASSEMBLING THE REAR CONSTANT VELOCITY JOINTS……………..7-24DISASSEMBLING THE FINAL DRIVE PINION GEAR ASSEMBLY…….7-25POSITIONING THE FINAL DRIVE PINION GEAR AND RING GEAR …7-25ADJUSTING THE FINAL DRIVE PINION GEAR BACKLASH …………….7-25ADJUSTING THE FINAL DRIVEN PINION GEAR BACKLASH ………….7-27MEASURING THE FINAL DRIVEN PINION GEAR THRUST WASHER CLEARANCE……………………………………………………………….7-29MEASURING THE WHEEL GEAR THRUST CLEARANCE ……………….7-30CHECKING THE REAR DRIVE SHAFT…………………………………………..7-31CHECKING THE FINAL DRIVE ASSEMBLY……………………………………7-31MEASUREMENT THE FINAL GEAR LASH……………………………………..7-32ADJUSTING THE FINAL GEAR LASH ……………………………………………7-33ASSEMBLING THE FINAL DRIVE PINION GEAR ASSEMBLY………….7-34ASSEMBLING THE FINAL GEAR CASE…………………………………………7-35

CHAPTER 8CHASSIS

FRONT AND REAR WHEELS ………………………………………………………………8-1FRONT WHEELS …………………………………………………………………………..8-1REAR WHEELS …………………………………………………………………………….8-3CHECKING THE WHEELS ……………………………………………………………..8-5CHECKING THE WHEEL HUBS………………………………………………………8-5CHECKING THE BRAKE DISCS ……………………………………………………..8-6INSTALLING THE BRAKE DISCS ……………………………………………………8-6INSTALLING THE WHEEL HUBS…………………………………………………….8-6INSTALLING THE WHEELS ……………………………………………………………8-7

FRONT AND REAR BRAKES……………………………………………………………….8-8FRONT BRAKE PADS ……………………………………………………………………8-8REAR BRAKE PADS………………………………………………………………………8-9REPLACING THE FRONT AND REAR BRAKE PADS………………………8-10FRONT BRAKE MASTER CYLINDER…………………………………………….8-12REAR BRAKE MASTER CYLINDER ………………………………………………8-15CHECKING THE MASTER CYLINDERS…………………………………………8-18ASSEMBLING THE FRONT AND REAR BRAKE MASTER CYLINDERS ……………………………………………………………………………….8-18INSTALLING THE FRONT BRAKE MASTER CYLINDER………………….8-19INSTALLING THE REAR BRAKE MASTER CYLINDER ……………………8-21FRONT BRAKE CALIPERS …………………………………………………………..8-23REAR BRAKE CALIPERS……………………………………………………………..8-25DISASSEMBLING THE FRONT AND REAR BRAKE CALIPERS ……….8-27CHECKING THE FRONT AND REAR BRAKE CALIPERS ………………..8-27ASSEMBLING THE FRONT AND REAR BRAKE CALIPERS …………….8-28INSTALLING THE FRONT AND REAR BRAKE CALIPERS ………………8-29

STEERING SYSTEM ………………………………………………………………………….8-31HANDLEBAR……………………………………………………………………………….8-31REMOVING THE HANDLEBAR GRIPS…………………………………………..8-33CHECKING THE HANDLEBAR ……………………………………………………..8-33INSTALLING THE HANDLEBAR ……………………………………………………8-33INSTALLING THE HANDLEBAR GRIPS …………………………………………8-34INSTALLING THE REAR BRAKE MASTER CYLINDER ……………………8-34INSTALLING THE FRONT BRAKE MASTER CYLINDER………………….8-35INSTALLING THE THROTTLE LEVER ASSEMBLY …………………………8-35STEERING STEM ………………………………………………………………………..8-36CHECKING THE STEERING STEM ……………………………………………….8-38INSTALLING THE STEERING STEM ……………………………………………..8-38INSTALLING THE PITMAN ARM……………………………………………………8-40TIE-RODS AND STEERING KNUCKLES ………………………………………..8-41REMOVING THE STEERING KNUCKLES ………………………………………8-43CHECKING THE TIE-RODS ………………………………………………………….8-43CHECKING THE STEERING KNUCKLES……………………………………….8-43INSTALLING THE TIE-RODS ………………………………………………………..8-46

FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES ………….8-47REMOVING THE FRONT ARMS ……………………………………………………8-49CHECKING THE FRONT ARMS…………………………………………………….8-49CHECKING THE FRONT SHOCK ABSORBERS……………………………..8-51INSTALLING THE FRONT ARMS AND FRONT SHOCK ABSORBERS ……………………………………………………………………………..8-51

REAR KNUCKLES AND STABILIZER …………………………………………………8-52CHECKING THE REAR KNUCKLES ………………………………………………8-54CHECKING THE STABILIZER……………………………………………………….8-54

REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES ……………..8-55CHECKING THE REAR ARMS ………………………………………………………8-57CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES…………….8-57INSTALLING THE REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES……………………………………………………………………………..8-58

CHAPTER 9ELECTRICAL

ELECTRICAL COMPONENTS………………………………………………………………9-1

CHECKING SWITCH CONTINUITY……………………………………………………….9-4

CHECKING THE SWITCHES………………………………………………………………..9-5

CHECKING THE BULBS AND BULB SOCKETS ……………………………………9-7TYPES OF BULBS…………………………………………………………………………9-7CHECKING THE CONDITION OF THE BULBS …………………………………9-8CHECKING THE CONDITION OF THE BULB SOCKETS …………………..9-9

IGNITION SYSTEM ……………………………………………………………………………9-10CIRCUIT DIAGRAM ……………………………………………………………………..9-10TROUBLESHOOTING ………………………………………………………………….9-11

ELECTRIC STARTING SYSTEM …………………………………………………………9-16CIRCUIT DIAGRAM ……………………………………………………………………..9-16STARTING CIRCUIT OPERATION…………………………………………………9-17TROUBLESHOOTING ………………………………………………………………….9-18

STARTER MOTOR…………………………………………………………………………….9-22CHECKING THE STARTER MOTOR ……………………………………………..9-24ASSEMBLING THE STARTER MOTOR………………………………………….9-26

CHARGING SYSTEM…………………………………………………………………………9-27CIRCUIT DIAGRAM ……………………………………………………………………..9-27TROUBLESHOOTING ………………………………………………………………….9-28

LIGHTING SYSTEM …………………………………………………………………………..9-30CIRCUIT DIAGRAM ……………………………………………………………………..9-30TROUBLESHOOTING ………………………………………………………………….9-31CHECKING THE LIGHTING SYSTEM…………………………………………….9-32

SIGNALING SYSTEM ………………………………………………………………………..9-34CIRCUIT DIAGRAM ……………………………………………………………………..9-34TROUBLESHOOTING ………………………………………………………………….9-36CHECKING THE SIGNALING SYSTEM ………………………………………….9-37

COOLING SYSTEM……………………………………………………………………………9-45CIRCUIT DIAGRAM ……………………………………………………………………..9-45TROUBLESHOOTING ………………………………………………………………….9-46

FUEL PUMP SYSTEM………………………………………………………………………..9-50CIRCUIT DIAGRAM ……………………………………………………………………..9-50TROUBLESHOOTING ………………………………………………………………….9-51

2WD/4WD SELECTING SYSTEM………………………………………………………..9-53CIRCUIT DIAGRAM ……………………………………………………………………..9-53TROUBLESHOOTING ………………………………………………………………….9-54

EPS (ELECTRIC POWER STEERING) SYSTEM…………………………………..9-58CIRCUIT DIAGRAM ……………………………………………………………………..9-58EPS CONTROL UNIT’S SELF-DIAGNOSTIC FUNCTION …………………9-59EPS WARNING LIGHT DURING NORMAL OPERATION………………….9-60DIAGNOSTIC MODE ……………………………………………………………………9-61SELF-DIAGNOSTIC FUNCTION TABLE (EPS SYSTEM)………………….9-64TROUBLESHOOTING DETAILS (EPS SYSTEM) …………………………….9-65CHECKING THE EPS MOTOR………………………………………………………9-69CHECKING THE EPS TORQUE SENSOR………………………………………9-69

CHAPTER 10TROUBLESHOOTING

STARTING FAILURE/HARD STARTING ……………………………………………..10-1FUEL SYSTEM…………………………………………………………………………….10-1ELECTRICAL SYSTEM…………………………………………………………………10-1COMPRESSION SYSTEM…………………………………………………………….10-2

POOR IDLE SPEED PERFORMANCE …………………………………………………10-2POOR IDLE SPEED PERFORMANCE……………………………………………10-2

POOR MEDIUM AND HIGH-SPEED PERFORMANCE…………………………..10-2POOR MEDIUM AND HIGH-SPEED PERFORMANCE …………………….10-2

FAULTY DRIVE TRAIN ………………………………………………………………………10-3

FAULTY GEAR SHIFTING………………………………………………………………….10-4HARD SHIFTING………………………………………………………………………….10-4SHIFT LEVER DOES NOT MOVE ………………………………………………….10-4JUMPS OUT OF GEAR…………………………………………………………………10-4

FAULTY CLUTCH PERFORMANCE ……………………………………………………10-4ENGINE OPERATES BUT VEHICLE WILL NOT MOVE ……………………10-4CLUTCH SLIPPING ……………………………………………………………………..10-4POOR STARTING PERFORMANCE………………………………………………10-4POOR SPEED PERFORMANCE……………………………………………………10-5

OVERHEATING…………………………………………………………………………………10-5OVERHEATING …………………………………………………………………………..10-5

OVERCOOLING ………………………………………………………………………………..10-5COOLING SYSTEM ……………………………………………………………………..10-5

FAULTY BRAKE ……………………………………………………………………………….10-5POOR BRAKING EFFECT…………………………………………………………….10-5

SHOCK ABSORBER MALFUNCTION …………………………………………………10-6MALFUNCTION……………………………………………………………………………10-6

UNSTABLE HANDLING……………………………………………………………………..10-6UNSTABLE HANDLING ………………………………………………………………..10-6

LIGHTING SYSTEM …………………………………………………………………………..10-6HEADLIGHT DOES NOT COME ON ………………………………………………10-6BULB BURNT OUT ………………………………………………………………………10-6

1 —

GENINFOVEHICLE IDENTIFICATION

EBS00009

GENERAL INFORMATION VEHICLE IDENTIFICATIONEBS00010

VEHICLE IDENTIFICATION NUMBERThe vehicle identification number 1 isstamped into the front left side of the frame.

EBS00011

MODEL LABELThe model label 1 is affixed at the location inthe illustration. This information will be neededto order spare parts.

1

GENINFOFEATURES

1

EAS20170

FEATURESOUTLINE OF THE FI SYSTEMThe main function of a fuel supply system is to provide fuel to the combustion chamber at the opti-mum air-fuel ratio in accordance with the engine operating conditions and the atmospheric tempera-ture. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to thecombustion chamber is created by the volume of the intake air and the fuel that is metered by the jetused in the respective carburetor.Despite the same volume of intake air, the fuel volume requirement varies with the engine operatingconditions, such as acceleration, deceleration, or operating under a heavy load. Carburetors thatmeter the fuel through the use of jets have been provided with various auxiliary devices, so that anoptimum air-fuel ratio can be achieved to accommodate the constant changes in the operating con-ditions of the engine.As the requirements for the engine to deliver more performance and cleaner exhaust gasesincrease, it becomes necessary to control the air-fuel ratio in a more precise and finely tuned man-ner. To accommodate this need, this model has adopted an electronically controlled fuel injection(FI) system, in place of the conventional carburetor system. This system can achieve an optimumair-fuel ratio required by the engine at all times by using a microprocessor that regulates the fuelinjection volume according to the engine operating conditions detected by various sensors.The adoption of the FI system has resulted in a highly precise fuel supply, improved engineresponse, better fuel economy, and reduced exhaust emissions.

1 ECU (engine control unit)2 Lean angle sensor3 Fuel injection system relay4 Engine trouble warning light5 Intake air pressure sensor6 TPS (throttle position sensor)7 Intake air temperature sensor8 Fuel injector

9 Fuel pump0 Speed sensorA Crankshaft position sensorB Coolant temperature sensorC Spark plugD Ignition coil

1 2 3 4 56 7 8 9

0ABCD

1 — 2

GENINFOFEATURES

FI SYSTEMThe fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintainsthe fuel pressure that is applied to the fuel injector at only 324 kPa (3.24 kg/cm2, 46.1 psi). Accord-ingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens,causing the fuel to be injected into the intake manifold only during the time the passage remainsopen. Therefore, the longer the length of time the fuel injector is energized (injection duration), thegreater the volume of fuel that is supplied. Conversely, the shorter the length of time the fuel injectoris energized (injection duration), the lesser the volume of fuel that is supplied.The injection duration and the injection timing are controlled by the ECU. Signals that are input fromthe throttle position sensor, crankshaft position sensor, intake air pressure sensor, intake air tem-perature sensor, coolant temperature sensor, lean angle sensor and speed sensor enable the ECUto determine the injection duration. The injection timing is determined through the signals from thecrankshaft position sensor. As a result, the volume of fuel that is required by the engine can be sup-plied at all times in accordance with the driving conditions.Illustration is for reference only.

1 Fuel pump2 Fuel injector3 Ignition coil4 ECU (engine control unit)5 Speed sensor6 Lean angle sensor7 Coolant temperature sensor8 Crankshaft position sensor9 Intake air pressure sensor0 Throttle body

A Throttle position sensorB Intake air temperature sensorC Air filter case

È Fuel systemÉ Air systemÊ Control system

C

21

3

5

6

7

8

9

0

B

È

É

Ê

A

4

1 — 3

GENINFOFEATURES

OUTLINE OF THE EPS (ELECTRIC POWER STEERING) SYSTEM

CAUTION:

To prevent accidental damage to the EPS unit, it must not be disassembled.

Engine starting RPM information from ECU

Battery4. EPS control unit

calculates assist power

5. Electricity outputswitched by EPS

control unit

6. Activates EPS motor

3. Sends the torque sensor signal

1. Operates steering

2. Twists torsion bar

EPS motor Torque sensor

EPS unit

Steering stem

EPS control unit

Speed information from speed sensor

1 — 4

GENINFOFEATURES

EPS (ELECTRIC POWER STEERING) SYSTEM BLOCK DIAGRAM

EPS UNIT

Torque sensor EPS motor

EPS control unit

Battery

Engine rpm signal

Meter assemblyMultifunction displayOdometer/Tripmeter A/Tripmeter B/Clock/Fuel meter/Gear position

Indicator and warning lightsEPS warning/Engine trouble warning/Coolant temperature warning/Reverse indicator/Neutral indicator/Park indicator/High-range indicator/Low-range indicator/Differential lock

• FI and EPS self-diagnostic error codes

Coolant temperature sensor signal

Crankshaft position sensor signal

Speed sensor signal

ECUFuel injector

Fuel pump

Ignition coilIntake air temperature sensor signal

Throttle position sensor signal

Intake air pressure sensor signal

Lean angle sensor signal

1 — 5

1 —

GENINFO

1

2

3

4 5

67

FEATURES

INSTRUMENT FUNCTIONSEBU27291

Multifunction display1 “CLOCK” button 2 “RESET” button 3 “SELECT” button 4 Speedometer 5 Fuel meter 6 Clock/Hour meter7 Odometer/Tripmeter A/Tripmeter B

The multifunction display is equipped with thefollowing:• a speedometer (which shows the riding

speed) • an odometer (which shows the total dis-

tance traveled) • two tripmeters (which show the distance

traveled since they were last set to zero)• a clock • an hour meter (which shows the total time

the key has been turned to “ON”) • a fuel meter • a self-diagnosis device

Odometer and tripmeter modesPushing the “SELECT” button switches thedisplay between the odometer mode “ODO”and the tripmeter modes “A” and “B” in the fol-lowing order: ODO → TRIP A → TRIP B → ODOTo reset a tripmeter, select it by pushing the“SELECT” button, and then push the “RESET”button for at least three seconds. The tripme-ters can be used to estimate the distance thatcan be traveled with a full tank of fuel. Thisinformation will enable you to plan future fuelstops.

NOTE:Holding in the “SELECT” button and then turn-ing the key to “ON” switches the displaybetween “mph” and “km/h”.

6

1 —

GENINFOFEATURES

1

2

3

Clock modePushing the “CLOCK” button switches the dis-play between the clock mode “CLOCK” andthe hour meter mode “HOUR” in the followingorder:CLOCK → HOUR → CLOCK

To set the clock1. Set the display to the clock mode.2. Push the “SELECT” button and “RESET”

button together for at least three seconds. 3. When the hour digits start flashing, push

the “RESET” button to set the hours.4. Push the “SELECT” button, and the

minute digits will start flashing.5. Push the “RESET” button to set the min-

utes. 6. Push the “SELECT” button and then

release it to start the clock.

Fuel meterThe fuel meter indicates the amount of fuel inthe fuel tank. The display segments of the fuelmeter disappear from “F” (full) towards “E”(empty) as the fuel level decreases. When the“E” segment disappears and the fuel levelwarning indicator flashes, refuel as soon aspossible.

NOTE:This fuel meter is equipped with a self-diagno-sis system. If the electrical circuit is defective,all the display segments and fuel level warningindicator will start flashing. If this occurs, checkthe electrical circuit.Refer to “SIGNALING SYSTEM” in chapter 9.

1 Fuel level warning indicator 2 Fuel meter 3 “E” segment

7

1 —

GENINFOFEATURES

1

Self-diagnosis deviceThis model is equipped with a self-diagnosisdevice for various electrical circuits.If any of those circuits are defective, the multi-function display will indicate a two-digit errorcode. If the multifunction display indicatessuch an error code, note the code number, andcheck the vehicle.ECB00810

CAUTION:

If the multifunction display indicates an errorcode, the vehicle should be checked as soonas possible in order to avoid engine damage.

1 Error code display

8

1 —

GENINFOIMPORTANT INFORMATION

EBS00013

IMPORTANT INFORMATIONPREPARATION FOR REMOVAL AND DISASSEMBLY1. Before removal and disassembly remove all

dirt, mud, dust and foreign material. 2. Use only the proper tools and cleaning

equipment. Refer to “SPECIAL TOOLS”.

3. When disassembling always keep matedparts together. This includes gears, cylin-ders, pistons and other parts that have been“mated” through normal wear. Mated partsmust always be reused or replaced as anassembly.

4. During disassembly, clean all of the partsand place them in trays in the order of dis-assembly. This will speed up assembly andallow for the correct installation of all parts.

5. Keep all parts away from any source of fire.

EBS00014

REPLACEMENT PARTS1. Use only genuine Yamaha parts for all

replacements. Use oil and grease recom-mended by Yamaha for all lubrication jobs.Other brands may be similar in function andappearance, but inferior in quality.

EBS00015

GASKETS, OIL SEALS AND O-RINGS1. When overhauling the engine, replace all

gaskets, seals and O-rings. All gasket sur-faces, oil seal lips and O-rings must becleaned.

2. During reassembly properly oil all matingparts and bearings, and lubricate the oilseal lips with grease.

9

1 — 1

GENINFOIMPORTANT INFORMATION

EBS00016

LOCK WASHERS/PLATES AND COTTER PINSAfter removal, replace all lock washers/plates1 and cotter pins. After the bolt or nut hasbeen tightened to specification, bend the locktabs along a flat of the bolt or nut.

EBS00017

BEARINGS AND OIL SEALSInstall bearings and oil seals so that the manu-facturer’s marks or numbers are visible. Wheninstalling oil seals, lubricate the oil seal lipswith a light coat of lithium-soap-based grease.Oil bearings liberally when installing, if appro-priate.1 Oil seal

CAUTION:_

Do not spin the bearing with compressedair because this will damage the bearingsurfaces.

1 Bearing

EBS00018

CIRCLIPSBefore reassembly, check all circlips carefullyand replace damaged or distorted circlips.Always replace piston pin clips after one use.When installing a circlip 1, make sure thesharp-edged corner 2 is positioned oppositethe thrust 3 that the circlip receives.4 Shaft

0

1 — 1

GENINFOIMPORTANT INFORMATION

EBS00019

CHECKING THE CONNECTIONSCheck the leads, couplers, and connectors forstains, rust, moisture, etc.1. Disconnect: • lead • coupler • connector

2. Check: • lead • coupler • connector

Moisture → Dry with an air blower. Rust/stains → Connect and disconnect sev-eral times.

3. Check: • all connections

Loose connection → Connect properly.

NOTE:_

If the pin 1 on the terminal is flattened, bend itup.

4. Connect: • lead • coupler • connector

NOTE:_

Make sure all connections are tight.

5. Check: • continuity (with the pocket tester)

NOTE:_

• If there is no continuity, clean the terminals. • When checking the wire harness, perform

steps (1) to (3). • As a quick remedy, use a contact revitalizer

available at most part stores.

Pocket tester 90890-03112

Analog pocket testerYU-03112-C

1

GENINFOSPECIAL TOOLS

EBS00021

SPECIAL TOOLSThe following special tools are necessary for complete and accurate tune-up and assembly. Useonly the appropriate special tools; this will help prevent damage caused by the use of inappropriatetools or improvised techniques. Special tools may differ by shape and part number from country tocountry. 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-, ACC- Except for US and CDN

P/N. 90890-

Tool No. Tool name/How to use Illustration

90890-01083YU-01083-1

Slide hammer boltSlide hammer bolt 6 mm

This tool is used to remove the rocker arm shaft.

90890-01084YU-01083-3

Weight

This tool is used to remove the rocker arm shaft.

90890-01135YU-01135-B

Crankcase separating toolCrankcase separator

This tool is used to separate the crank-case.

90890-01229YM-01229

Coupling gear/middle shaft toolGear holder

This tool is needed when removing or installing the coupling gear nut.

90890-01243YM-01253-1

Valve spring compressor attachmentValve spring compressor adapter (26 mm)

This tool is needed to remove and install the valve assemblies.

YU-01083-3

1 — 12

GENINFOSPECIAL TOOLS

90890-01274YU-90058YU-90059

Crankshaft installer potInstalling potPot installer

This tool is used to install the crankshaft.

90890-01275YU-90060

Crankshaft installer boltBolt

This tool is used to install the crankshaft.

90890-01304YU-01304

Piston pin puller setPiston pin puller

This tool is used to remove the piston pin.

90890-01309YU-90059

SpacerPot spacer

This tool is used to install the crankshaft.

90890-01311YM-08035-A

Tappet adjusting toolValve adjuster 3 mm & 4 mm

This tool is necessary for adjusting the valve clearance.

Tool No. Tool name/How to use Illustration

YU-90058/YU-90059

YU-01304

ø35

1 — 13

GENINFOSPECIAL TOOLS

90890-01325YU-24460-01

Radiator cap testerRadiator pressure tester

This tool is used to check the cooling sys-tem.

90890-01348YM-01348

Locknut wrench

This tool is needed when removing or installing the secondary sheave spring.

90890-01352YU-33984

Radiator cap tester adapterRadiator pressure tester adapter

This tool is used to check the cooling sys-tem.

90890-01362YU-33270-B

Flywheel pullerHeavy duty puller

This tool is used to remove the AC mag-neto rotor.

90890-01426YU-38411

Oil filter wrench

This tool is needed to loosen or tighten the oil filter cartridge.

90890-01430YM-38404

Ring nut wrench

This tool is needed to removing and installing the middle driven shaft bearing retainer.

Tool No. Tool name/How to use Illustration

YU-24460-01

YU-33984

1 — 14

GENINFOSPECIAL TOOLS

90890-01474YM-01474

Ball joint remover

These tools are used to removing or installing the ball joints.

90890-01475YM-01475

Gear lash measurement toolMiddle drive gear lash tool

This tool is used to measure the gear lash.

90890-01480YM-01480

Ball joint remover attachment setBall joint adapter set

These tools are used to removing or installing the ball joints.

90890-01511

Final gear backlash band

This tool is needed when measuring the final gear backlash.

90890-01514

Ball joint remover short shaft set

These tools are used to removing or installing the ball joints.

90890-01701YS-01880-A

Sheave holderPrimary clutch holder

This tool is needed to hold the primary sheave when removing or installing the sheave nuts.

90890-03079YM-34483

Thickness gaugeNarrow gauge set

This tool is used to measure the valve clearance.

90890-03081YU-33223

Compression gaugeEngine compression tester

This tool is needed to measure engine compression.

90890-03112YU-03112-C

Pocket testerAnalog pocket tester

This instrument is needed for checking the electrical systems.

Tool No. Tool name/How to use Illustration

1 — 15

GENINFOSPECIAL TOOLS

90890-03141YU-03141

Timing lightInductive clamp timing light

This tool is necessary for checking igni-tion timing.

90890-03153YU-03153

Pressure gauge

This tool is used to measure fuel pres-sure.

90890-03170YM-03170

Belt tension gaugeRear drive belt tension gauge

This tool is used to measure the steering tension.

90890-03174YU-A1927

Digital circuit testerModel 88 Multimeter with tachometer

This tool is used to check the electrical systems.

90890-03176YM-03176

Fuel pressure adapter

This tool is used to measure fuel pres-sure.

90890-04019YM-04019

Valve spring compressor

This tool is used to remove or install the valve assemblies.

90890-04058YM-04058

Middle driven shaft bearing driverBearing driver 40 mm

This tool is used to install the water pump seal.

90890-04064YM-04064-A

Valve guide remover (ø6)Valve guide remover (6.0 mm)

This tool is needed to remove and install the valve guides.

90890-04065YM-04065-A

Valve guide installer (ø6)Valve guide installer (6.0 mm)

This tool is needed to install the valve guides.

Tool No. Tool name/How to use Illustration

1 — 16

GENINFOSPECIAL TOOLS

90890-04066YM-04066

Valve guide reamer (ø6)Valve guide reamer (6.0 mm)

This tool is needed to rebore the new valve guides.

90890-04081YM-91044

Spacer (crankshaft installer)Pot spacer

This tool is used to install the crankshaft.

90890-04082

Extension

This tool is used to measure engine com-pression.

90890-04086YM-91042

Universal clutch holder

This tool is needed to hold the clutch car-rier when removing or installing the car-rier nut.

90890-04128YM-04128

Bearing retainer wrenchMiddle gear bearing retainer

This tool is needed when removing or installing the bearing retainers.

90890-04130YM-04059

Adapter (M16)Adapter #13

This tool is used to install the crankshaft.

90890-04132YM-33221-A

Mechanical seal installerWater pump seal installer

This tool is used to install the water pump seal.

Tool No. Tool name/How to use Illustration

YM-91044

1 — 17

GENINFOSPECIAL TOOLS

90890-04134YM-04134

Sheave spring compressor

This tool is needed when removing or installing the secondary sheave spring.

90890-04135YM-04135

Sheave fixed blockSheave fixed bracket

This tool is needed when removing or installing the secondary sheave spring.

90890-06754YM-34487

Ignition checkerOpama pet-4000 spark checker

This instrument is necessary for checking the ignition system components.

90890-06760YU-39951-B

Digital tachometer

This tool is needed for checking engine rpm.

90890-85505

Yamaha bond No. 1215(Three bond No.1215®)

This bond is used on crankcase mating surfaces, etc.

Tool No. Tool name/How to use Illustration

1 — 18

SPECGENERAL SPECIFICATIONS

EBS01001

SPECIFICATIONSGENERAL SPECIFICATIONS

Item Standard

Model code3B413B453B48

DimensionsOverall length 2,065 mm (81.3 in)Overall width 1,180 mm (46.5 in)Overall height 1,240 mm (48.8 in)Seat height 905 mm (35.6 in)Wheelbase 1,250 mm (49.2 in)Minimum ground clearance 275 mm (10.8 in)Minimum turning radius 3,200 mm (126.0 in)

Basic weightWith oil and fuel 294.0 kg (648 lb)

EngineEngine type Liquid-cooled 4-stroke, SOHCCylinder arrangement Forward-inclined single cylinderDisplacement 686.0 cm3 (41.86 cu. in)Bore × stroke 102.0 × 84.0 mm (4.02 × 3.31 in)Compression ratio 9.20 : 1Standard compression pressure (at sea level) 450 kPa (4.50 kg/cm2, 64.0 psi)Starting system Electric starter

Lubrication system Wet sumpOil type or grade

Engine oilAPI service SE, SF, SG type or higherJASO standard MA

Final gear oil SAE 80 API GL-4 Hypoid gear oilDifferential gear oil SAE 80 API GL-4 Hypoid gear oil

0° 10° 30° 50° 70° 90° 110°

-20° -10° 0° 10° 20° 30° 40°

130°F

50°C

YAMALUBE4 (20W40) or SAE 20W40

YAMALUBE4 (10W30) or SAE 10W30

SAE 5W30

2 — 1

SPECGENERAL SPECIFICATIONS

2

Oil quantityEngine oil

Periodic oil change 2.00 L (1.76 Imp qt, 2.11 US qt)With oil filter replacement 2.10 L (1.85 Imp qt, 2.22 US qt)Total amount 2.40 L (2.11 Imp qt, 2.54 US qt)

Final gear oilPeriodic oil change 0.20 L (0.18 Imp qt, 0.21 US qt)Total amount 0.25 L (0.22 Imp qt, 0.26 US qt)

Differential gear case oilPeriodic oil change 0.215 L (0.19 Imp qt, 0.23 US qt)Total amount 0.23 L (0.20 Imp qt, 0.24 US qt)

Radiator capacity (including all routes) 1.99 L (1.75 Imp qt, 2.10 US qt)Air filter Wet type elementFuel

Type Unleaded gasoline onlyFuel tank capacity 20.0 L (4.40 Imp gal, 5.28 US gal)Fuel reserve amount 4.5 L (0.99 Imp gal, 1.19 US gal)

Fuel injectorType/quantity 297500-1010/1Manufacturer DENSO

Spark plugType/manufacturer CR8E/NGKSpark plug gap 0.7 ~ 0.8 mm (0.028 ~ 0.031 in)

Clutch type Wet, centrifugal automaticTransmission

Primary reduction system V-beltSecondary reduction system Shaft driveSecondary reduction ratio 41/21 × 24/18 × 33/9 (9.544)Transmission type V-belt automaticOperation Left hand operationSingle speed automatic 2.380 ~ 0.700 : 1Sub transmission ratio low 31/16 (1.938)

high 29/25 (1.160)Reverse gear 23/14 × 28/23 (2.000)

ChassisFrame type Steel tube frameCaster angle 5.0°Camber angle 0°Kingpin angle 11.0°Kingpin offset 0 mm (0 in)Trail 26.0 mm (1.02 in)Tread front (STD) 940.0 mm (37.01 in)Tread rear (STD) 915.0 mm (37.01 in)Toe-in (with tires touching the ground) 0 ~ 10.0 mm (0 ~ 0.39 in)

Item Standard

2 — 2

SPECGENERAL SPECIFICATIONS

TireType front Tubeless

rear TubelessSize front AT25 × 8-12

rear AT25 × 10-12Manufacturer/model front DUNLOP/KT421

rear DUNLOP/KT425Tire pressure (cold tire)

Maximum load* 220.0 kg (485 lb)Off-road riding front 32 ~ 38 kPa (0.32 ~ 0.38 kg/cm2, 4.6 ~ 5.5 psi)

rear 27 ~ 33 kPa (0.27 ~ 0.33 kg/cm2, 3.9 ~ 4.8 psi)*Load is total weight of cargo, rider, accesso-ries, and tongue

BrakeFront brake type Dual disc brake

operation Right hand operationRear brake type Dual disc brake

operation Left hand and right foot operationSuspension

Front suspension Double wishboneRear suspension Double wishbone

Shock absorberFront shock absorber Coil spring/oil damperRear shock absorber Coil spring/oil damper

Wheel travelFront wheel travel 180 mm (7.1 in)Rear wheel travel 230 mm (9.1 in)

Electrical systemIgnition system Transistorized coil ignition (digital)Generator system AC magnetoBattery type YTX20L-BSBattery capacity 12 V 18.0 Ah

Bulb type Halogen bulb

Item Standard

2 — 3

SPECGENERAL SPECIFICATIONS

Bulb voltage/wattage × quantityHeadlight 12 V 35.0 W/35.0 W × 2Tail/brake light 12 V 21.0/5.0 W × 1Indicator light

Neutral indicator light LEDReverse indicator light LEDCoolant temperature warning light LEDEngine trouble warning light LEDEPS warning light LEDPark indicator light LEDOn-command four-wheel drive/differential gear lock indicator

LCD

High-range indicator light LEDLow-range indicator light LEDDifferential gear lock indicator light LED

Item Standard

2 — 4

SPECENGINE SPECIFICATIONS

EBS01002

ENGINE SPECIFICATIONS

Item Standard Limit

Cylinder headMaximum warpage —- 0.03 mm

(0.0012 in)

CylinderBore 102.000 ~ 102.010 mm

(4.0157 ~ 4.0161 in)102.080 mm(4.0189 in)

Measuring point 50.0 mm (1.97 in) —-

Maximum taper 0.05 mm(0.002 in)

Out of round 0.05 mm(0.002 in)

CamshaftDrive system Chain drive (left) —-Camshaft lobe dimensions

Intake measurement “A” 43.488 ~ 43.588 mm (1.7121 ~ 1.7161 in) 43.388 mm (1.7082 in)

“B” 36.959 ~ 37.059 mm (1.4551 ~ 1.4590 in) 36.859 mm (1.4511 in)

Exhaust measurement “A” 43.129 ~ 43.229 mm (1.6980 ~ 1.7019 in) 43.029 mm (1.6941 in)

“B” 37.007 ~ 37.107 mm (1.4570 ~ 1.4609 in) 36.907 mm (1.4530 in)

Maximum camshaft runout —- 0.015 mm (0.0006 in)

A

B

2 — 5

SPECENGINE SPECIFICATIONS

Timing chainModel/number of links 98XRH2010/126 —-Tensioning system Automatic —-

Rocker arm/rocker arm shaftRocker arm inside diameter 12.000 ~ 12.018 mm (0.4724 ~ 0.4731 in) —-Shaft outside diameter 11.981 ~ 11.991 mm (0.4717 ~ 0.4721 in) —-Arm-to-shaft clearance 0.009 ~ 0.037 mm (0.0004 ~ 0.0015 in) —-Rocker-arm-to-rocker-arm-shaft clearance

0.009 ~ 0.037 mm (0.0004 ~ 0.0015 in) —-

Valve, valve seat, valve guideValve clearance–intake (cold) 0.09 ~ 0.13 mm (0.0035 ~ 0.0051 in) —-Valve clearance–exhaust (cold) 0.16 ~ 0.20 mm (0.0063 ~ 0.0079 in) —-Valve dimensions

Valve head diameter “A”Intake 37.90 ~ 38.10 mm (1.4921 ~ 1.5000 in) —-Exhaust 31.90 ~ 32.10 mm (1.2559 ~ 1.2638 in) —-

Valve face width “B”Intake 2.26 mm (0.0890 in) —-Exhaust 2.26 mm (0.0890 in) —-

Valve seat width “C”Intake 1.00 ~ 1.20 mm (0.0394 ~ 0.0472 in) 1.60 mm

(0.0630 in)Exhaust 1.00 ~ 1.20 mm (0.0394 ~ 0.0472 in) 1.60 mm

(0.0630 in)Valve margin thickness “D”

Intake 0.80 ~ 1.20 mm (0.0315 ~ 0.0472 in) —-Exhaust 0.80 ~ 1.20 mm (0.0315 ~ 0.0472 in) —-

Valve stem diameterIntake 5.975 ~ 5.990 mm (0.2352 ~ 0.2358 in) 5.945 mm

(0.2341 in)Exhaust 5.960 ~ 5.975 mm (0.2346 ~ 0.2352 in) 5.930 mm

(0.2335 in)Valve guide inside diameter

Intake 6.000 ~ 6.012 mm (0.2362 ~ 0.2367 in) 6.050 mm (0.2382 in)

Exhaust 6.000 ~ 6.012 mm (0.2362 ~ 0.2367 in) 6.050 mm (0.2382 in)

Item Standard Limit

B C

DA

Head Diameter Face Width Seat Width Margin Thickness

2 — 6

SPECENGINE SPECIFICATIONS

Valve-stem-to-valve-guide clearanceIntake 0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in) 0.080 mm

(0.0031 in)Exhaust 0.025 ~ 0.052 mm (0.0010 ~ 0.0020 in) 0.100 mm

(0.0039 in)Valve stem runout —- 0.040 mm

(0.0016 in)

Valve seat widthIntake 1.00 ~ 1.20 mm (0.0394 ~ 0.0472 in) 1.60 mm

(0.0630 in)Exhaust 1.00 ~ 1.20 mm (0.0394 ~ 0.0472 in) 1.60 mm

(0.0630 in)Valve spring

Free lengthIntake 38.79 mm (1.53 in) 36.85 mm

(1.45 in)Exhaust 38.79 mm (1.53 in) 36.85 mm

(1.45 in)Installed length (valve closed)

Intake 35.00 mm (1.38 in) —-Exhaust 35.00 mm (1.38 in) —-

Compressed spring force (installed)Intake 169 ~ 199 N

(17.23 ~ 20.29 kgf, 37.99 ~ 44.73 lb)—-

Exhaust 169 ~ 199 N (17.23 ~ 20.29 kgf, 37.99 ~ 44.73 lb)

—-

Spring tilt

Intake —- 2.5°/1.70 mm(2.5°/0.067 in)

Exhaust —- 2.5°/1.70 mm(2.5°/0.067 in)

Winding direction (top view)Intake Clockwise —-Exhaust Clockwise —-

Item Standard Limit

2 — 7

SPECENGINE SPECIFICATIONS

PistonPiston-to-cylinder clearance 0.030 ~ 0.055 mm (0.0012 ~ 0.0022 in) 0.13 mm

(0.0051 in)Diameter “D” 101.955 ~ 101.970 mm

(4.0140 ~ 4.0146 in)—-

Height “H” 10.0 mm (0.39 in) —-Offset 0.50 mm (0.0197 in) —-Offset direction Intake side —-Piston pin bore inside diameter 23.004 ~ 23.015 mm (0.9057 ~ 0.9061 in) 23.045 mm

(0.9073 in)Piston pin outside diameter 22.991 ~ 23.000 mm (0.9052 ~ 0.9055 in) 22.971 mm

(0.9044 in)Piston-pin-to-piston-pin-bore clear-ance

0.004 ~ 0.024 mm (0.0002 ~ 0.0009 in) 0.074 mm (0.0029 in)

Piston ringsTop ring

Ring type Barrel —-Dimensions (B × T) 1.20 × 3.80 mm (0.05 × 0.15 in) —-End gap (installed) 0.20 ~ 0.35 mm (0.008 ~ 0.014 in) 0.60 mm

(0.024 in)Ring side clearance 0.030 ~ 0.070 mm (0.0012 ~ 0.0028 in) 0.12 mm

(0.0047 in)2nd ring

Ring type Taper —-Dimensions (B × T) 1.20 × 4.00 mm (0.05 × 0.16 in) —-End gap (installed) 0.75 ~ 0.90 mm (0.030 ~ 0.035 in) 1.25 mm

(0.049 in)Ring side clearance 0.030 ~ 0.070 mm (0.0012 ~ 0.0028 in) 0.13 mm

(0.0051 in)

Item Standard Limit

H

D

TB

BT

2 — 8

SPECENGINE SPECIFICATIONS

Oil ring

Dimensions (B × T) 2.50 × 2.80 mm (0.10 × 0.11 in) —-End gap (installed) 0.20 ~ 0.70 mm (0.008 ~ 0.028 in) —-Ring side clearance 0.060 ~ 0.150 mm (0.0024 ~ 0.0059 in) —-

Crankshaft

Crank width “A” 74.95 ~ 75.00 mm (2.951 ~ 2.953 in) —-Maximum runout “C” —- 0.030 mm

(0.0012 in)Big end side clearance “D” 0.350 ~ 0.650 mm (0.0138 ~ 0.0256 in) 1.0 mm

(0.04 in)Big end radial clearance “E” 0.010 ~ 0.025 mm (0.0004 ~ 0.0010 in) —-Small end free play “F” 0.16 ~ 0.40 mm (0.0063 ~ 0.0157 in) —-

BalancerBalancer drive method Gear —-

Automatic centrifugal clutchClutch shoe thickness 1.5 mm (0.06 in) 1.0 mm

(0.04 in)Clutch-in revolution 1,850 ~ 2,250 r/min —-Clutch-stall revolution 3,500 ~ 4,100 r/min —-

TransmissionMaximum main axle runout —- 0.06 mm

(0.0024 in)Maximum drive axle runout —- 0.06 mm

(0.0024 in)Shifting mechanism

Shift mechanism type Shift drum and guide bar —-Decompression device

Device type Auto decomp —-Air filter oil grade Foam air filter oil or equivalent oil —-Throttle body

Model/manufacturer × quantity 44EIS/MIKUNI × 1 —-Engine idle speed 1,350 ~ 1,450 r/min —-Intake vacuum 35.0 kPa (263 mmHg, 10.3 inHg) —-

Item Standard Limit

B

T

CC

F

D

A

E

2 — 9

SPECENGINE SPECIFICATIONS

Fuel pumpPump type Electrical —-Model/manufacturer 3B4/DENSO —-

Oil filter type Cartridge (paper) —-Oil pump

Oil pump type Trochoid —-Inner-rotor-to-outer-rotor-tip clear-ance

Less than 0.12 mm (0.0047 in) 0.20 mm (0.0079 in)

Outer-rotor-to-oil-pump-housingclearance

0.090 ~ 0.170 mm (0.0035 ~ 0.0067 in) 0.24 mm (0.0094 in)

Oil-pump-housing-to-inner-and-outer-rotor clearance

0.03 ~ 0.10 mm (0.0012 ~ 0.0039 in) 0.17 mm (0.0067 in)

Oil pressure (hot) 50.0 kPa at 1,600 r/min (0.50 kg/cm2 at 1,600 r/min, 7.1 psi at 1,600 r/min)

—-

Pressure check location Cylinder head —-Cooling system

Radiator coreWidth 340.0 mm (13.39 in) —-Height 248.2 mm (9.77 in) —-Depth 22.0 mm (0.87 in) —-

Radiator cap opening pressure 93.3 ~ 122.7 kPa (0.933 ~ 1.227 kg/cm2, 13.27 ~ 17.45 psi)

—-

Coolant reservoir capacityUp to the maximum level mark 0.17 L (0.15 Imp qt, 0.18 US qt) —-From low to full level 0.14 L (0.12 Imp qt, 0.15 US qt) —-

Water pumpWater pump type Single-suction centrifugal pump —-Reduction ratio 32/31 (1.032) —-

Shaft driveMiddle gear backlash 0.10 ~ 0.30 mm (0.004 ~ 0.012 in) —-Final gear backlash 0.10 ~ 0.20 mm (0.0039 ~ 0.0079 in) —-Differential gear backlash 0.05 ~ 0.25 mm (0.0020 ~ 0.0098 in) —-

Item Standard Limit

2 — 10

SPECENGINE SPECIFICATIONS

Cylinder head tightening sequence

3

1

4

27

8

5

6

2 — 11

SPECCHASSIS SPECIFICATIONS

EBS01003

CHASSIS SPECIFICATIONS

Item Standard Limit

Steering systemSteering bearing type Ball and race bearing —-Steering tension 50 N (5.0 kgf) —-

Front suspensionShock absorber travel 90.7 mm (3.57 in) —-Spring free length 292.0 mm (11.50 in) —-Installed length 237.0 mm (9.33 in) —-Spring rate (K1) 23.00 N/mm (2.35 kg/mm, 131.33 lb/in) —-Spring stroke (K1) 0 ~ 90.7 mm (0 ~ 3.57 in) —-Optional spring available No —-

Rear suspensionShock absorber travel 109.2 mm (4.30 in) —-Spring free length 314.5 mm (12.38 in) —-Installed length 271.0 mm (10.67 in) —-Spring rate (K1) 33.50 N/mm (3.42 kg/mm, 191.28 lb/in) —-Spring rate (K2) 36.00 N/mm (3.67 kg/mm, 205.56 lb/in) —-Spring stroke (K1) 0 ~ 46.5 mm (0 ~ 1.83 in) —-Spring stroke (K2) 46.5 ~ 109.2 mm (1.83 ~ 4.30 in) —-Optional spring available No —-

Front wheelType Panel wheel —-Rim size 12 × 6.0 AT —-Rim material Aluminum —-Maximum radial wheel runout —- 2.0 mm

(0.08 in)Maximum lateral wheel runout —- 2.0 mm

(0.08 in)Rear wheel

Type Panel wheel —-Rim size 12 × 7.5 AT —-Rim material Aluminum —-Maximum radial wheel runout —- 2.0 mm

(0.08 in)Maximum lateral wheel runout —- 2.0 mm

(0.08 in)

2 — 12

SPECCHASSIS SPECIFICATIONS

Front disc brakeType Dual —-Disc outside diameter × thickness 220.0 × 3.5 mm (8.66 × 0.14 in) —-Brake disc minimum thickness 3.0 mm (0.12 in) —-Brake disc maximum deflection 0.1 mm (0.004 in) —-Pad thickness inner 4.4 mm (0.17 in) 1.0 mm

(0.04 in)Pad thickness outer 4.4 mm (0.17 in) 1.0 mm

(0.04 in)Master cylinder inside diameter 12.70 mm (0.50 in) —-Caliper cylinder inside diameter 33.96 mm (1.34 in) —-Brake fluid type DOT 4 —-

Rear disc brakeType Dual —-Disc outside diameter × thickness 205.0 × 3.5 mm (8.07 × 0.14 in) —-Brake disc minimum thickness 3.0 mm (0.12 in) —-Brake disc maximum deflection 0.1 mm (0.004 in) —-Pad thickness inner 5.8 mm (0.23 in) 1.0 mm

(0.04 in)Pad thickness outer 5.8 mm (0.23 in) 1.0 mm

(0.04 in)Master cylinder inside diameter 12.70 mm (0.50 in) —-Caliper cylinder inside diameter 33.96 mm (1.34 in) —-Brake fluid type DOT 4 —-

Brake lever and brake pedalBrake pedal position 56.7 mm (2.23 in) —-Brake pedal free play 0 ~ 5.0 mm (0 ~ 0.20 in) —-Throttle lever free play 3.0 ~ 5.0 mm (0.12 ~ 0.20 in) —-

Item Standard Limit

2 — 13

SPECELECTRICAL SPECIFICATIONS

EBS01004

ELECTRICAL SPECIFICATIONS

Item Standard Limit

System voltage 12 V —-Ignition system

Ignition timing (B.T.D.C.) 12°/1,400 r/min —-Advancer type Digital —-

Transistorized coil ignitionCrankshaft position sensor resis-tance/color

459 ~ 561 Ω at 20 °C (68 °F)/black-green/yellow

—-

ECUModel/manufacturer 3B4/MITSUBISHI —-

Ignition coilModel/manufacturer JO226/DENSO —-Minimum ignition spark gap 6.0 mm (0.24 in) —-Primary coil resistance 3.4 ~ 4.6 Ω at 20 °C (68 °F) —-Secondary coil resistance 10.4 ~ 15.6 kΩ at 20 °C (68 °F) —-

Spark plug capMaterial Resin —-Resistance 10.0 kΩ —-

AC magnetoModel/manufacturer F4T393/MITSUBISHI —-Standard output 14.0 V 35.0 A at 5,000 r/min —-Stator coil resistance/color 0.108 ~ 0.132 Ω at 20 °C (68 °F)/

white-white—-

Rectifier/regulatorType Semiconductor-short-circuit —-Model/manufacturer FH012AA/SHINDENGEN —-No load regulated voltage (DC) 14.2 ~ 14.8 V —-Rectifier capacity 50.0 A —-Withstand voltage 40.0 V —-

Electric starting systemType Constant mesh —-

Starter motorModel/manufacturer SM-13/MITSUBA —-Power output 0.80 kW —-Armature coil resistance 0.0250 ~ 0.0350 Ω at 20 °C (68 °F) —-Brush overall length 12.5 mm (0.49 in) 5.00 mm

(0.20 in)Spring force 7.65 ~ 10.01 N

(780 ~ 1,021 gf, 27.54 ~ 36.03 oz)—-

Commutator diameter 28.0 mm (1.10 in) 27.0 mm (1.06 in)

Mica undercut 0.70 mm (0.03 in) —-

2 — 14

SPECELECTRICAL SPECIFICATIONS

Starter relayModel/manufacturer 2768113-A/JIDECO —-Amperage rating 180.0 A —-Coil winding resistance 4.18 ~ 4.62 Ω at 20 °C (68 °F) —-

Fuel gaugeSender unit resistance (full) 19.00 ~ 21.00 Ω —-Sender unit resistance (empty) 139.00 ~ 141.00 Ω —-

Starting circuit cut-off relayModel/manufacturer ACM33211/MATSUSHITA —-Coil resistance 96.0 Ω —-

Radiator fan motor relayModel/manufacturer ACM33211/MATSUSHITA —-Coil resistance 96.0 Ω —-

Circuit breakerCircuit breaker type Fuse —-Fuses

Main fuse 40.0 A —-Headlight fuse 15.0 A —-Signaling system fuse 5.0 A —-Ignition fuse 10.0 A —-Auxiliary DC jack fuse 15.0 A —-Fuel injection system fuse 15.0 A —-Four-wheel-drive motor fuse 10.0 A —-EPS fuse 40.0 A —-Radiator fan motor fuse 15.0 A —-Spare fuse 40.0 A

15.0 A10.0 A5.0 A

—————-

Item Standard Limit

2 — 15

SPECTIGHTENING TORQUES

EBS01005

TIGHTENING TORQUESENGINE TIGHTENING TORQUES

Item Part nameThread

sizeQ’ty

Tightening torqueRemarks

Nm m · kg ft · lb

Cylinder head (exhaust pipe) Stud bolt M8 4 15 1.5 11Cylinder head Bolt M9 4 35 3.5 25 M

Cylinder head Bolt M9 2 38 3.8 27 E

Cylinder head Bolt M6 2 10 1.0 7.2Spark plug — M10 1 13 1.3 9.4Oil gallery bolt Union bolt M8 1 10 1.0 7.2

Cylinder Bolt M10 4 50 5.0 36See NOTE.

AC magneto rotor Nut M16 1 70 7.0 50

Balancer driven gear Nut M18 1 80 8.0 58Use a lock washer.

Thermostat cover Bolt M6 2 10 1.0 7.2Cylinder head air bleed bolt Bolt M6 1 10 1.0 7.2Valve adjusting screw Nut M6 4 14 1.4 10Decompression assembly Bolt M7 2 20 2.0 14Timing chain guide (intake side) Bolt M6 2 10 1.0 7.2 LT

Timing chain tensioner cap Bolt M16 1 20 2.0 14Timing chain tensioner Bolt M6 2 10 1.0 7.2Bearing retainer (camshaft) Bolt M6 2 10 1.0 7.2 LT

Camshaft sprocket cover Bolt M6 2 10 1.0 7.2Tappet cover Bolt M6 8 10 1.0 7.2Camshaft sprocket Bolt M7 2 20 2.0 14Crankcase Bolt M8 2 26 2.6 19

Bolt M6 4 10 1.0 7.2Bolt M6 8 10 1.0 7.2

Engine oil drain bolt Bolt M14 1 30 3.0 22Oil filter cartridge — M20 1 17 1.7 12Oil filter cartridge union bolt Union bolt M20 1 68 6.8 49 E

Oil delivery pipe Union bolt M14 2 35 3.5 25Oil delivery pipe Union bolt M10 1 20 2.0 14Oil pump Bolt M6 3 10 1.0 7.2

Oil pump driven gear Nut M10 1 22 2.2 16Use a lock washer.

Bearing retainer (crankcase) Bolt M6 2 10 1.0 7.2 LT

Exhaust pipe protector Bolt M6 2 7 0.7 5.1Muffler and frame Bolt M8 1 20 2.0 14Muffler and muffler bracket Bolt M8 2 20 2.0 14Exhaust pipe Nut M8 4 20 2.0 14Water pump housing Bolt M6 2 10 1.0 7.2Coolant drain bolt Bolt M6 1 10 1.0 7.2Water pump air bleed bolt Bolt M6 1 10 1.0 7.2

E

2 — 16

SPECTIGHTENING TORQUES

Water pump outlet pipe Bolt M6 1 10 1.0 7.2Water jacket joint Bolt M6 2 10 1.0 7.2Timing chain guide Bolt M6 2 10 1.0 7.2 LT

Crankshaft end accessing screw — M36 1 10 1.0 7.2Timing mark accessing screw — M14 1 6 0.6 4.3Drive belt cover Bolt M6 12 10 1.0 7.2Bearing housing (primary sheave assembly)

Bolt M6 4 10 1.0 7.2

AC magneto/crankshaft position sen-sor lead holder

Bolt M5 2 7 0.7 5.1 LT

Starter one-way clutch Screw M8 3 30 3.0 22 LT

Clutch housing assembly Bolt M6 9 10 1.0 7.2

Clutch carrier assembly Nut M22 1 190 19.0 140

Left-hand threadStake.

Middle drive pinion gear nut Nut M22 1 180 18.0 130 Stake.Middle driven shaft bearing housing Bolt M8 4 32 3.2 23Middle drive shaft bearing retainer Bolt M6 4 29 2.9 21Front drive shaft coupling gear nut (middle gear side)

Nut M16 1 115 11.5 85

Middle driven shaft bearing retainer Nut M55 1 80 8.0 58Left-hand thread

Middle driven pinion gear bearing retainer

Nut M60 1 130 13.0 94Left-hand thread

Rear drive shaft coupling gear nut (middle gear side)

Nut M16 1 150 15.0 110 LT

Middle driven pinion gear bearing housing

Bolt M8 4 25 2.5 18

Primary sheave assembly Nut M16 1 140 14.0 100Secondary sheave spring retainer Nut M36 1 90 9.0 65Secondary sheave assembly Nut M16 1 100 10.0 72Shift lever 2 assembly Bolt M6 1 14 1.4 10Shift drum stopper Bolt M14 1 18 1.8 13Stopper lever stopper Bolt M14 1 18 1.8 13Stator coil assembly Bolt M6 3 7 0.7 5.1 LT

Crankshaft position sensor Bolt M5 2 7 0.7 5.1 LT

Coolant temperature sensor — M12 1 18 1.8 13Gear position switch Bolt M6 2 7 0.7 5.1Reverse switch — M10 1 17 1.7 12Speed sensor Bolt M6 1 10 1.0 7.2

Item Part nameThread

sizeQ’ty

Tightening torqueRemarks

Nm m · kg ft · lb

M

LT

LT

2 — 17

SPECTIGHTENING TORQUES

NOTE:Temporarily tighten the cylinder bolts to 15 Nm (1.5 m · kg, 11 ft · lb) and then tighten them to 50 Nm(5.0 m · kg, 36 ft · lb).

2 — 18

SPECTIGHTENING TORQUES

EBS01006

CHASSIS TIGHTENING TORQUES

Part to be tightened Thread sizeTightening torque

RemarksNm m · kg ft · lb

Engine and front rubber damper M10 42 4.2 30Engine and front rubber damper M6 10 1.0 7.2 LT

Engine and rear rubber damper M10 42 4.2 30Engine and rear rubber damper M6 10 1.0 7.2 LT

Rubber damper and frame M10 42 4.2 30Differential gear case and frame M10 55 5.5 40Differential gear case and frame M10 55 5.5 40 LT

Final gear case and frame M10 55 5.5 40Radiator and frame M6 7 0.7 5.1Coolant reservoir and frame M6 7 0.7 5.1Shift arm M6 14 1.4 10Select lever shift rod locknut M8 15 1.5 11Select lever unit and frame M6 7 0.7 5.1Select lever guide and frame M6 7 0.7 5.1Front grill and front grill bracket M6 7 0.7 5.1Front grill bracket and frame M6 7 0.7 5.1Front fender and frame M6 7 0.7 5.1Rear fender and frame M6 7 0.7 5.1Radiator bracket and frame M6 7 0.7 5.1Rear upper arm and frame M10 45 4.5 32 LS

Rear lower arm and frame M10 45 4.5 32 LS

Rear shock absorber and frame M10 45 4.5 32Rear shock absorber and rear lower arm M10 45 4.5 32Rear knuckle and rear upper arm M10 45 4.5 32Rear knuckle and rear lower arm M10 45 4.5 32Rear brake hose guide and rear lower arm M6 7 0.7 5.1Stabilizer joint and stabilizer M10 50 5.0 36Stabilizer joint and rear lower arm M10 50 5.0 36Stabilizer holder and frame M8 30 3.0 22Rear arm protector and rear lower arm M6 7 0.7 5.1Front upper arm and frame M10 45 4.5 32 LS

Front lower arm and frame M10 45 4.5 32 LS

Front shock absorber and frame M10 45 4.5 32Front shock absorber and front lower arm M10 45 4.5 32Front brake hose holder and front upper arm M6 7 0.7 5.1

Select lever shift rod end M10 15 1.5 11Left-handthread

Steering stem bushing and steering stem bracket M8 23 2.3 17Steering stem joint bolt M8 30 3.0 22 LT

EPS unit and frame M8 30 3.0 22 LT

Steering stem bracket and frame M10 50 5.0 36 LT

Steering stem bearing and frame M10 50 5.0 36 LT

2 — 19

SPECTIGHTENING TORQUES

Pitman arm nut M16 210 21.0 150EPS motor cover M6 7 0.7 5.1Pitman arm and tie-rod M10 25 2.5 18Steering knuckle and tie-rod M10 25 2.5 18Steering knuckle and front lower arm M12 30 3.0 22Front arm protector and front lower arm M6 7 0.7 5.1Fuel tank and fuel pump M6 7 0.7 5.1Fuel tank and frame M6 7 0.7 5.1Fuel tank side cover and frame M6 7 0.7 5.1Front wheel and front wheel hub M10 55 5.5 40Front wheel axle nut M20 260 26.0 190 Stake.Front brake caliper and steering knuckle M8 30 3.0 22Front brake caliper bleed screw M8 5 0.5 3.6Front brake disc and front wheel hub M8 30 3.0 22 LT

Rear brake disc and rear wheel hub M8 30 3.0 22 LT

Rear wheel and rear wheel hub M10 55 5.5 40Rear wheel axle nut M20 260 26.0 190 Stake.Rear brake caliper and rear knuckle M8 30 3.0 22Rear brake caliper bleed screw M8 5 0.5 3.6Brake pad holding bolt M6 17 1.7 12Rear knuckle and brake disc guard M6 7 0.7 5.1Steering knuckle and brake disc guard M6 7 0.7 5.1Brake master cylinder and brake master cylinder holder

M6 7 0.7 5.1

Brake lever pivot M6 6 0.6 4.3Siliconegrease

Handlebar holder and steering shaft M8 20 2.0 14Brake hose joint and frame M6 10 1.0 7.2Brake hose joint and brake hose M10 19 1.9 13Brake hose union bolt M10 27 2.7 19Rear knuckle and brake hose protector M6 7 0.7 5.1Footrest bracket and frame M10 53 5.3 38Footrest board and footrest bracket M6 7 0.7 5.1Footrest and footrest board M6 7 0.7 5.1Brake pedal adjusting nut M6 7 0.7 5.1Shift control cable and shift lever cover M14 17 1.7 12Front guard and frame M8 26 2.6 19Front carrier and front guard M8 26 2.6 19Front carrier and front carrier bracket M8 26 2.6 19Front carrier bracket and frame M8 26 2.6 19Front carrier and front fender M6 7 0.7 5.1Rear carrier and rear carrier bracket M8 34 3.4 24Rear carrier bracket and frame M10 48 4.8 35

Part to be tightened Thread sizeTightening torque

RemarksNm m · kg ft · lb

2 — 20

SPECTIGHTENING TORQUES

Rear carrier and rear fender M6 7 0.7 5.1Engine skid plates M6 7 0.7 5.1Trailer hitch and frame M10 55 5.5 40Battery holding bracket M6 7 0.7 5.1Battery bracket and fitting screw M6 7 0.7 5.1Fitting screw and frame M6 7 0.7 5.1Electrical components tray and frame M6 7 0.7 5.1Differential gear case filler bolt M14 23 2.3 17Differential gear case drain bolt M10 10 1.0 7.2Differential gear case cover and differential gear case

M8 24 2.4 17

Differential gear motor and differential gear case cover

M6 11 1.1 8.0

Front drive shaft coupling gear and differential drive pinion gear

M14 62 6.2 45 LT

Final gear case filler plug M14 23 2.3 17Final gear case drain bolt M14 23 2.3 17Final gear oil level check bolt M8 10 1.0 7.2Final gear case and final gear case cover M8 23 2.3 17Final drive pinion gear bearing housing and final gear case

M8 23 2.3 17

Part to be tightened Thread sizeTightening torque

RemarksNm m · kg ft · lb

2 — 21

SPECHOW TO USE THE CONVERSION TABLE/

GENERAL TIGHTENING TORQUE SPECIFICATIONS

EBS00022

HOW TO USE THE CONVERSION TABLEAll specification data in this manual are listedin SI and METRIC UNITS. Use this table to convert METRIC unit data toIMPERIAL unit data.

CONVERSION TABLE

EBS00023

GENERAL TIGHTENING TORQUE SPECIFICATIONSThis chart specifies tightening torques for stan-dard fasteners with a standard ISO threadpitch. Tightening torque specifications for spe-cial components or assemblies are providedfor each chapter of this manual. To avoidwarpage, tighten multi-fastener assemblies ina crisscross pattern and progressive stagesuntil the specified tightening torque is reached.Unless otherwise specified, tightening torquespecifications require clean, dry threads. Com-ponents should be at room temperature.A: Distance between flatsB: Outside thread diameter

Ex.

METRIC MULTIPLIER IMPERIAL

** mm × 0.03937 = ** in

2 mm × 0.03937 = 0.08 in

METRIC TO IMPERIAL

Torque

Metric unit Multiplier Imperial unit

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

Volume/Capacity

cc (cm3) cc (cm3) lt (liter) lt (liter)

0.03527 0.06102 0.8799 0.2199

oz (IMP liq.) cu · in qt (IMP liq.) gal (IMP liq.)

Misc.

kg/mm kg/cm2 Centigrade(°C)

55.997 14.2234 9/5+32

lb/in psi (lb/in2) Fahrenheit(°F)

A(nut)

B(bolt)

General tightening torques

Nm m · kg ft · lb

10 mm 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

2 — 22

SPECLUBRICATION POINTS AND LUBRICANT TYPES

EBS00024

LUBRICATION POINTS AND LUBRICANT TYPESENGINE

Lubrication point Lubricant

Oil seal lips LS

Bearings E

O-ring LS

Cylinder head bolts M

Crankshaft pin E

Connecting rod big end thrust surface E

Crankshaft sprocket M

Inner race (crankshaft) E

Buffer boss (crankshaft) E

Crankshaft seal E

Piston pin E

Piston and ring groove E

Valve stems (intake and exhaust) M

Valve stem ends (intake and exhaust) M

Rocker arm shafts E

Camshaft lobes M

Decompressor lever pin E

Decompressor lever spring E

Rocker arms (intake and exhaust) M

Oil pump shaft E

O-ring (oil filter cartridge) LS

Water pump impeller shaft M

Dipstick mating surface E

Starter idler gear inner surface E

Starter idler gear shaft E

Starter wheel gear E

Torque limiter E

Clutch housing shaft end LS

Clutch carrier assembly E

One-way clutch bearing E

Clutch dog and middle drive gear M

Reverse idle gear shaft E

Middle driven shaft splines M

Shift drum E

Shift forks and shift fork guide bar E

Ball (shift drum stopper) E

Stopper lever and stopper lever shaft E

2 — 23

SPECLUBRICATION POINTS AND LUBRICANT TYPES

Shift lever 2 inner surface LS

Shift lever 1 E

Shift lever 1 gear teeth and shift lever 2 gear teeth E

Stopper lever stopper E

Bearing (final drive pinion gear assembly) G

Bearing (final gear) G

AC magneto lead grommetYamaha bond No.1215(Three bond No.1215®)

Crankcase mating surfaceYamaha bond No.1215(Three bond No.1215®)

Lubrication point Lubricant

2 — 24

SPECCOOLANT FLOW DIAGRAMS

EBS00025

COOLANT FLOW DIAGRAMS1 Coolant reservoir hose2 Radiator inlet hose3 Fast idle plunger outlet hose4 Coolant reservoir5 Water pump6 Water pump outlet pipe7 Water pump outlet hose8 Radiator outlet hose9 Radiator

0 Fast idle plunger inlet hose

A

A

3

01 2 3 4

9

8 7 6 5

2 — 25

SPECOIL FLOW DIAGRAMS

EBS00026

OIL FLOW DIAGRAMS1 Oil delivery pipe2 Oil filter cartridge3 Oil strainer4 Drive axle5 Relief valve assembly6 Reverse idle gear shaft

B

B

B-B

1

2

34

2

6

5

2 — 26

SPECOIL FLOW DIAGRAMS

1 Camshaft2 Crankshaft3 Oil strainer4 Oil pump rotor5 Oil pump driven gear

1

2

45 3

2 — 27

SPECCABLE ROUTING

EBS00028

CABLE ROUTING1 Front brake light switch lead2 On-command four-wheel-drive motor switch and

differential gear lock switch lead3 Front brake hose4 Throttle cable 5 Rear brake cable6 Shift control cable7 Rear brake hose8 Left handlebar switch lead

9 Rear brake light switch lead0 Radiator fan motor breather hoseA Differential gear case breather hoseB EPS motor breather hoseC Radiator fan motor leadD Meter assembly leadE Final gear case breather hose

BB

AA

È

Ï

Î

Í

Ì

Ø

Ù

Ù

×

Ë

Ê

É

4

5

6 78

9

2

1

D

C

8

9

E

A

0

8

9

0

2

1

Ñ0

ÒA

Ó

Ô

Õ

Ö

B

321

CC

C-C

D-D

A-A

B-B

ÐÐ

Ú

D

D

Ú

2 — 28

SPECCABLE ROUTING

È Pass the front brake hose and throttle cablethrough the guide on the handlebar cover.

É Pass the rear brake cable, shift control cable,and rear brake hose through the guide on thehandlebar cover.

Ê Route the rear brake cable, shift control cable,and rear brake hose in front of the left handlebarswitch lead and rear brake light switch lead.

Ë Pass the rear brake hose and throttle cablethrough the guide, making sure to route thecable behind the hose.

Ì Pass the rear brake cable and shift control cablethrough the guide.

Í Pass the front brake hose through the guide.Î Route the throttle cable behind the rear brake

cable and shift control cable.

BB

AA

È

Ï

Î

Í

Ì

Ø

Ù

Ù

×

Ë

Ê

É

4

5

6 78

9

2

1

D

C

8

9

E

A

0

8

9

0

2

1

Ñ0

ÒA

Ó

Ô

Õ

Ö

B

321

CC

C-C

D-D

A-A

B-B

ÐÐ

Ú

D

D

Ú

2 — 29

SPECCABLE ROUTING

Ï Route the front brake light switch lead, on-com-mand four-wheel-drive motor switch and differ-ential gear lock switch lead, left handlebarswitch lead, and rear brake light switch lead overthe throttle cable, rear brake cable, and shiftcontrol cable, then to the front of where thecables cross.

Ð Fasten the left handlebar switch lead and rearbrake light switch lead with the plastic bands atthe bends in the handlebar, making sure to routethe leads under the handlebar and to face theends of the bands forward.

Ñ Pass the radiator fan motor breather hosethrough the guide on the meter bracket, makingsure to face the end of the hose downward.

Ò Pass the differential gear case breather hosethrough the guide on the meter bracket, makingsure to face the end of the hose downward.

BB

AA

È

Ï

Î

Í

Ì

Ø

Ù

Ù

×

Ë

Ê

É

4

5

6 78

9

2

1

D

C

8

9

E

A

0

8

9

0

2

1

Ñ0

ÒA

Ó

Ô

Õ

Ö

B

321

CC

C-C

D-D

A-A

B-B

ÐÐ

Ú

D

D

Ú

2 — 30

SPECCABLE ROUTING

Ó Pass the EPS motor breather hose through theguide on the meter bracket, making sure to facethe end of the hose downward.

Ô Route the radiator fan motor breather hose anddifferential gear case breather hose in front ofthe frame.

Õ Fasten the differential gear case breather hoseto the frame with the plastic band, making sureto face the end of the band inward.

Ö Route the differential gear case breather hose tothe inside of the frame.

× Fasten the front brake light switch lead, on-com-mand four-wheel-drive motor switch and differ-ential gear lock switch lead, left handlebarswitch lead, and rear brake light switch lead witha plastic locking tie. Be sure to fasten the plasticlocking tie above the couplers and fasten itaround the protective sleeves of the leads, notthe leads themselves.

Ø Pass the final gear case breather hose throughthe guide on the meter bracket, making sure toface the end of the hose downward.

BB

AA

È

Ï

Î

Í

Ì

Ø

Ù

Ù

×

Ë

Ê

É

4

5

6 78

9

2

1

D

C

8

9

E

A

0

8

9

0

2

1

Ñ0

ÒA

Ó

Ô

Õ

Ö

B

321

CC

C-C

D-D

A-A

B-B

ÐÐ

Ú

D

D

Ú

2 — 31

SPECCABLE ROUTING

Ù Fasten the front brake light switch lead and on-command four-wheel-drive motor switch and dif-ferential gear lock switch lead with the plasticbands at the bends in the handlebar, makingsure to route the leads under the handlebar andto face the ends of the bands forward.

Ú 20 ~ 50 mm (0.79 ~ 1.97 in)

BB

AA

È

Ï

Î

Í

Ì

Ø

Ù

Ù

×

Ë

Ê

É

4

5

6 78

9

2

1

D

C

8

9

E

A

0

8

9

0

2

1

Ñ0

ÒA

Ó

Ô

Õ

Ö

B

321

CC

C-C

D-D

A-A

B-B

ÐÐ

Ú

D

D

Ú

2 — 32

SPECCABLE ROUTING

1 Coolant reservoir hose2 Radiator fan motor breather hose3 Differential gear case breather hose4 EPS motor breather hose5 Ground lead6 Coolant reservoir breather hose7 Throttle cable8 Fuel injector lead9 Final gear case breather hose0 Speed sensor leadA Crankshaft position sensor lead

B Differential gear motor leadC EPS torque sensor leadD Fast idle plunger outlet hoseE Radiator outlet hoseF Gear position switch leadG Reverse switch leadH Shift control cableI Starter motor lead

È Face the end of the coolant reservoir breatherhose downward.

Ó

Ò

Ñ

Ð

Ï

Ô

Õ Õ

Ú

×

Ø

Ø

Ù

Ö

Î Í

È É

Ê Ë

Ì

1

D

C

BD 5

E

F

0

9

A

G

5

I

H

1

4

C1

4

E

A

23 5 6 7

8

9

0

A

4

E

E

A

AB

B

C

C

D

A-A

E-E

B-B C-C

D

2 — 33

SPECCABLE ROUTING

É Route the ground lead, radiator fan motorbreather hose, differential gear case breatherhose, and EPS motor breather hose to the insideof the fast idle plunger outlet hose.

Ê Pass the radiator fan motor breather hosethrough the larger diameter guide.

Ë Route the coolant reservoir breather hose to theoutside of the fast idle plunger outlet hose.

Ì Route the fuel injector lead under the fuel hose.

Í Fasten the radiator outlet hose to the frame withthe plastic band, making sure to face the end ofthe band inward.

Î Route the EPS motor breather hose under thecoolant reservoir hose.

Ï Place the EPS torque sensor lead and differen-tial gear motor lead in the holder, and then insertthe ends of the holder into the hole in the stay onthe frame.

Ð Route the differential gear case breather hose tothe inside of the frame.

Ó

Ò

Ñ

Ð

Ï

Ô

Õ Õ

Ú

×

Ø

Ø

Ù

Ö

Î Í

È É

Ê Ë

Ì

1

D

C

BD 5

E

F

0

9

A

G

5

I

H

1

4

C1

4

E

A

23 5 6 7

8

9

0

A

4

E

E

A

AB

B

C

C

D

A-A

E-E

B-B C-C

D

2 — 34

SPECCABLE ROUTING

Ñ Fasten the differential gear case breather hoseto the frame with the plastic band, making sureto face the end of the band inward.

Ò Attach the ground lead terminal to the frameusing the bolt.

Ó Route the radiator fan motor breather hose anddifferential gear case breather hose to the insideof the fast idle plunger outlet hose and radiatoroutlet hose.

Ô Make sure that the catch of the holder is facingoutward.

Õ Face the end of the plastic band inward.Ö Route the fuel tank drain hose and position the

end of the hose as shown in the illustration.× Pass the speed sensor lead, AC magneto lead,

and final gear case breather hose through theguide in the order listed.

Ø Route the speed sensor lead, AC magneto lead,and final gear case breather hose to the right ofthe reverse switch.

Ù Route the final gear case breather hose abovethe reverse switch lead and ground leads.

Ó

Ò

Ñ

Ð

Ï

Ô

Õ Õ

Ú

×

Ø

Ø

Ù

Ö

Î Í

È É

Ê Ë

Ì

1

D

C

BD 5

E

F

0

9

A

G

5

I

H

1

4

C1

4

E

A

23 5 6 7

8

9

0

A

4

E

E

A

AB

B

C

C

D

A-A

E-E

B-B C-C

D

2 — 35

SPECCABLE ROUTING

Ú Route the shift control cable under the gear posi-tion switch lead, speed sensor lead, and crank-shaft position sensor lead.

Ó

Ò

Ñ

Ð

Ï

Ô

Õ Õ

Ú

×

Ø

Ø

Ù

Ö

Î Í

È É

Ê Ë

Ì

1

D

C

BD 5

E

F

0

9

A

G

5

I

H

1

4

C1

4

E

A

23 5 6 7

8

9

0

A

4

E

E

A

AB

B

C

C

D

A-A

E-E

B-B C-C

D

2 — 36

SPECCABLE ROUTING

1 Wire harness2 Fuel injector lead3 Fuel hose4 Intake air temperature sensor lead5 Final gear case breather hose6 Ground lead7 Starter motor lead8 Air filter case breather hose9 Main switch lead0 Auxiliary DC jack leadA EPS motor lead

B Differential gear motor leadC EPS torque sensor leadD Radiator fan motor leadE Radiator inlet hoseF EPS motor breather hoseG Spark plug leadH Rear brake cableI Shift control cableJ Fuel tank drain hoseK Gear position switch leadL AC magneto lead

A

A

B

B

F

F

E

E D

C

C

D

A-A B-B C-C

D-D E-E F-F

È

Ï

Î

Í

É

3

2

1

N

M

L

K

J

L

5

1

N

6

1

B

AC

G

I

HI

O

B

P

7

1

75 6

Ð

Ó

Ô

Ñ

Ò

Ì

Ê

Ë

I H G

F

E

90A B C D4

5 67 8

2 — 37

SPECCABLE ROUTING

M Speed sensor leadN Coolant temperature sensor leadO EPS motor lead couplerP EPS torque sensor lead coupler

È Route the fuel hose between the wire harnessand the fuel tank drain hose.

É Route the coolant temperature sensor leadabove the fast idle plunger inlet hose.

Ê Route the final gear case breather hose abovethe V-belt cooling duct 1.

Ë Route the radiator fan motor lead between theelectrical components tray and the radiator inlethose.

Ì Fasten the radiator fan motor lead to the framewith the plastic band, making sure to face theend of the band inward.

Í Route the fuel tank drain hose to the inside ofthe leads and fuel hose, making sure to positionthe end of the drain hose as shown in the illus-tration.

A

A

B

B

F

F

E

E D

C

C

D

A-A B-B C-C

D-D E-E F-F

È

Ï

Î

Í

É

3

2

1

N

M

L

K

J

L

5

1

N

6

1

B

AC

G

I

HI

O

B

P

7

1

75 6

Ð

Ó

Ô

Ñ

Ò

Ì

Ê

Ë

I H G

F

E

90A B C D4

5 67 8

2 — 38

SPECCABLE ROUTING

Î Fasten the final gear case breather hose,ground lead, starter motor lead, fuel injectorlead, coolant temperature sensor lead, AC mag-neto lead, and wire harness with the plasticband, making sure to position the band near thesplit in the wire harness.

Ï Route the fuel injector lead and coolant temper-ature sensor lead to the inside of the groundlead, starter motor lead, final drive gear casebreather hose, and wire harness.

Ð Face the end of the plastic band inward.Ñ Pass the plastic band through the hole in the

plastic cover, and then fasten the leads andhose with the band, making sure to face the endof the band downward.

Ò Insert the projection on the coupler into the holein the frame from the inside of the frame.

Ó Face the end of the plastic band inward.Ô Fasten the spark plug lead with the larger diam-

eter section of each holder.

A

A

B

B

F

F

E

E D

C

C

D

A-A B-B C-C

D-D E-E F-F

È

Ï

Î

Í

É

3

2

1

N

M

L

K

J

L

5

1

N

6

1

B

AC

G

I

HI

O

B

P

7

1

75 6

Ð

Ó

Ô

Ñ

Ò

Ì

Ê

Ë

I H G

F

E

90A B C D4

5 67 8

2 — 39

SPECCABLE ROUTING

1 Tail/brake light lead2 Rectifier/regulator lead3 AC magneto lead4 Speed sensor lead5 Final gear case breather hose6 Fuel hose7 Fuel pump lead8 Wire harness

È To tail/brake light É Fasten the tail/brake light lead to the frame with

a plastic locking tie, making sure to face the endof the tie downward.

Ê Install the plastic band near the split in the wireharness.

Ë Route the tail/brake light lead to the outside ofthe frame.

Ì Face the end of the plastic band downward.Í Pass the final gear case breather hose through

the guide.

É

Ë

Ì

Ì Í

È

Ê1 2 3

45

7

6

2

1

6 8

3

5

3

A

A

B

B

C

C

A-A B-B C-C

2 — 40

SPECCABLE ROUTING

1 Left headlight lead2 Negative battery lead3 Right headlight lead4 Radiator fan motor lead5 EPS control unit lead6 Auxiliary DC jack lead7 Main switch lead8 Final gear case breather hose9 Starter motor lead0 Differential gear motor leadA Ignition coil lead

B Meter leadC Lean angle sensor leadD Coolant reservoir breather hoseE Positive battery leadF Coolant reservoir hoseG EPS motor breather hoseH Differential gear case breather hoseI Radiator fan motor breather hoseJ Ground leadK Relay leadL Wire harness

K

C

C

AA

DDE

E

F

F

E-E F-F

C-C D-D

B-BA-A

G-G

È

Ô

Ó

Ñ

Ò

Ð Í

Ì

É

Ë

ÊÉ

I

H

G

D

C

B 5

0A

9 8

L

C

6

4

5

3

7

E

F

3

4

5

K

L L

5

Õ

Ï Î

Ö

D

G

2

HI

134

J

12

G

B

G

K

2

5

M

L

B

2 — 41

SPECCABLE ROUTING

M Joint coupler lead

È To left headlightÉ Connect the headlight lead coupler, and then

fasten the coupler with the holder on the electri-cal components tray.

Ê Route the negative battery lead along the guideon the electrical components tray.

Ë To right headlightÌ Place the couplers on the inside of the electrical

components tray.

Í To main switch and auxiliary DC jackÎ Fasten the left handlebar switch lead, on-com-

mand four-wheel-drive motor switch and differ-ential gear lock switch lead, front brake lightswitch lead, and rear brake light switch lead withthe clamp.

Ï Fasten the joint coupler lead with the clamp.Ð Pass the coolant reservoir breather hose

through the guides on the plastic cover and elec-trical components tray and route it under thepositive battery lead and starter motor lead.

K

C

C

AA

DDE

E

F

F

E-E F-F

C-C D-D

B-BA-A

G-G

È

Ô

Ó

Ñ

Ò

Ð Í

Ì

É

Ë

ÊÉ

I

H

G

D

C

B 5

0A

9 8

L

C

6

4

5

3

7

E

F

3

4

5

K

L L

5

Õ

Ï Î

Ö

D

G

2

HI

134

J

12

G

B

G

K

2

5

M

L

B

2 — 42

SPECCABLE ROUTING

Ñ Route the hoses under the positive battery lead,and then route them upward, to the inside of thecoolant reservoir breather hose.

Ò Fasten the coolant reservoir breather hose withthe holder on the electrical components tray.

Ó Fasten the coolant reservoir hose with theholder on the electrical components tray.

Ô Pass the hoses and ground lead through theopening in the electrical components tray.

Õ Route the coolant reservoir breather hose abovethe other hoses.

Ö Route the hoses to the inside of the bolt.

K

C

C

AA

DDE

E

F

F

E-E F-F

C-C D-D

B-BA-A

G-G

È

Ô

Ó

Ñ

Ò

Ð Í

Ì

É

Ë

ÊÉ

I

H

G

D

C

B 5

0A

9 8

L

C

6

4

5

3

7

E

F

3

4

5

K

L L

5

Õ

Ï Î

Ö

D

G

2

HI

134

J

12

G

B

G

K

2

5

M

L

B

2 — 43

SPECCABLE ROUTING

1 Throttle cable2 Rear brake hose3 Rear brake cable4 Front brake hose5 Negative battery lead6 Final gear case breather hose7 Starter motor lead8 Intake air pressure sensor lead9 TPS lead0 Intake air temperature sensor leadA Fuel injector lead

B Coolant temperature sensor leadC Rectifier/regulator leadD AC magneto leadE Fuel hoseF Tail/brake light leadG Fuel pump leadH Fast idle plunger outlet hoseI Wire harness

È Route the final gear case breather hose on topof the leads.

C C

B

B

B-B C-C

ÏH

ÎÉ

Ë

Ì

ÍÑ

G

8

B

9

0

A

CD

E

F

0I

F

Ë

Ê

A A5

4

6

7

È1

2

3

A-A

Ð1

9

2 — 44

SPECCABLE ROUTING

É To engineÊ To air filter caseË Route the fuel injector lead and coolant temper-

ature sensor lead to the outside of the frame.Ì Pass the tail/brake light lead through the hole in

the rear fender.Í Fasten the tail/brake light lead with the holder,

making sure that the coupler is positioned to therear of the holder.

Î Route the throttle cable under the plastic cover.

Ï Route the fast idle plunger outlet hose above theplastic cover.

Ð Pass the throttle cable through the guide on theplastic cover.

Ñ Insert the projection on the wire harness holderinto the hole in the plastic cover.

C C

B

B

B-B C-C

ÏH

ÎÉ

Ë

Ì

ÍÑ

G

8

B

9

0

A

CD

E

F

0I

F

Ë

Ê

A A5

4

6

7

È1

2

3

A-A

Ð1

9

2 — 45

CHKADJ

INTRODUCTION/PERIODIC MAINTENANCE CHARTFOR THE EMISSION CONTROL SYSTEM

3

EBS00029

PERIODIC CHECKS AND ADJUSTMENTSINTRODUCTIONThis chapter includes all information necessary to perform recommended checks and adjustments.These preventive maintenance procedures, if followed, will ensure more reliable vehicle operationand a longer service life. The need for costly overhaul work will be greatly reduced. This informationapplies to vehicles already in service as well as to new vehicles that are being prepared for sale. Allservice technicians should be familiar with this entire chapter.EBU21742

PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEMNOTE:• For ATVs not equipped with an odometer or an hour meter, follow the month maintenance inter-

vals.• For ATVs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance

intervals. However, keep in mind that if the ATV isn’t used for a long period of time, the monthmaintenance intervals should be followed.

• Items marked with an asterisk should be performed by a Yamaha dealer as they require specialtools, data and technical skills.

NO. ITEMCHECK OR MAINTE-

NANCE JOB

Whichever comes first

INITIAL EVERY

month 1 3 6 6 12

km(mi)

320 (200)

1300 (800)

2500 (1600)

2500 (1600)

5000 (3200)

hours 20 80 160 160 320

1 * Fuel line• Check fuel hoses for cracks or other damage, and

replace if necessary.√ √ √

2 Spark plug• Check condition and clean, regap, or replace if nec-

essary.√ √ √ √ √

3 * Valves • Check valve clearance and adjust if necessary. √ √ √ √

4 * Fuel injection • Check and adjust engine idle speed. √ √ √ √ √

5 *Crankcase breather system

• Check breather hose for cracks or other damage, and replace if necessary.

√ √ √

6 * Exhaust system

• Check for leakage and replace gasket(s) if neces-sary.

• Check for looseness and tighten all screw clamps and joints if necessary.

√ √ √

7 Spark arrester • Clean. √ √ √

3 — 1

CHKADJGENERAL MAINTENANCE AND LUBRICATION CHART

EBU21863

GENERAL MAINTENANCE AND LUBRICATION CHART

NO. ITEMCHECK OR MAINTE-

NANCE JOB

Whichever comes first

INITIAL EVERY

month 1 3 6 6 12

km(mi)

320 (200)

1300 (800)

2500 (1600)

2500 (1600)

5000 (3200)

hours 20 80 160 160 320

1 Air filter element • Clean and replace if necessary.Every 20–40 hours (more often in wet or dusty

areas)

2 * Front brake

• Check operation and correct if necessary. • Check fluid level and ATV for fluid leakage, and

correct if necessary.√ √ √ √ √

• Replace brake pads. Whenever worn to the limit

3 * Rear brake

• Check operation and correct if necessary.• Check brake pedal free play and adjust if neces-

sary.• Check fluid level and ATV for fluid leakage, and

correct if necessary.

√ √ √ √ √

• Replace brake pads. Whenever worn to the limit

4 * Brake hoses

• Check for cracks or other damage, and replace if necessary.

√ √ √ √

• Replace. Every 4 years

5 *Rear brake hose protectors

• Check for wear, cracks or other damage, and replace if necessary.

√ √ √ √ √

6 * Wheels• Check runout and for damage, and replace if nec-

essary.√ √ √ √

7 * Tires

• Check tread depth and for damage, and replace if necessary.

• Check air pressure and balance, and correct if nec-essary.

√ √ √ √

8 * Wheel bearings• Check for looseness or damage, and replace if

necessary.√ √ √ √

9 *Upper and lower arm pivots

• Lubricate with lithium-soap-based grease. √ √ √

10 * V-belt• Check for wear, cracks or other damage, and

replace if necessary.√ √ √ √

11 *Drive shaft univer-sal joint

• Lubricate with lithium-soap-based grease. √ √ √

12 * Chassis fasteners• Make sure that all nuts, bolts, and screws are prop-

erly tightened.√ √ √ √ √

13 *Shock absorber assemblies

• Check operation and correct if necessary. • Check for oil leakage and replace if necessary.

√ √ √

14 * Stabilizer bushes• Check for cracks or other damage, and replace if

necessary.√ √ √

15 * Knuckle pivots • Lubricate with lithium-soap-based grease. √ √ √

16 * Knuckle shafts • Lubricate with lithium-soap-based grease. √ √ √

17 * Steering shaft • Lubricate with lithium-soap-based grease. √ √ √

18 * Steering system • Check operation and repair or replace if damaged. • Check toe-in and adjust if necessary.

√ √ √ √ √

19 * Engine mount • Check for cracks or other damage, and replace if

necessary.√ √ √

20 * Axle boots• Check for cracks or other damage, and replace if

necessary.√ √ √ √ √

21 Engine oil• Change.• Check ATV for oil leakage, and correct if neces-

sary.√ √ √ √

3 — 2

CHKADJGENERAL MAINTENANCE AND LUBRICATION CHART

EBU23070

NOTE:• The air filter needs more frequent service if you are riding in unusually wet or dusty areas. • Hydraulic brake service

• Regularly check and, if necessary, correct the brake fluid level.• Every two years replace the internal components of the brake master cylinders and calipers, and

change the brake fluid.• Replace the brake hoses every four years and if cracked or damaged.

22Engine oil filter cartridge

• Replace. √ √ √

23 Differential gear oil• Change.• Check ATV for oil leakage, and correct if neces-

sary.√ √

24 Final gear oil• Change.• Check ATV for oil leakage, and correct if neces-

sary.√ √

25 Cooling system

• Check coolant level and ATV for coolant leakage, and correct if necessary.

√ √ √ √ √

• Replace coolant. Every 2 years

26 *Moving parts and cables

• Lubricate. √ √ √ √

27 *Drive select lever safety system cable

• Check operation and adjust or replace if necessary. √ √ √

28 *Throttle lever housing and cable

• Check operation and correct if necessary.• Check throttle cable free play and adjust if neces-

sary.• Lubricate throttle lever housing and cable.

√ √ √ √ √

29 *Front and rear brake switches

• Check operation and correct if necessary. √ √ √ √ √

30 *Lights and switches

• Check operation and correct if necessary. • Adjust headlight beams.

√ √ √ √ √

NO. ITEMCHECK OR MAINTE-

NANCE JOB

Whichever comes first

INITIAL EVERY

month 1 3 6 6 12

km(mi)

320 (200)

1300 (800)

2500 (1600)

2500 (1600)

5000 (3200)

hours 20 80 160 160 320

3 — 3

CHKADJ

ENGINE SKID PLATES, SEAT, CARRIERS ANDFENDERS

ENGINE SKID PLATES, SEAT, CARRIERS AND FENDERSENGINE SKID PLATES

1

2

3

T R..

7 Nm (0.7 m • kg, 5.1 ft • Ib)

Order Job/Part Q’ty RemarksRemoving the engine skid plates Remove the parts in the order listed.

1 Front engine skid plate 12 Center engine skid plate 13 Rear engine skid plate 1

For installation, reverse the removal pro-cedure.

3 — 4

CHKADJ

ENGINE SKID PLATES, SEAT, CARRIERS ANDFENDERS

SEAT AND SIDE PANELS

6

4

13

2

5

Order Job/Part Q’ty RemarksRemoving the seat and side panels Remove the parts in the order listed.

1 Seat 1 NOTE:Pull up the seat lock lever, then pull up onthe rear of the seat.

2 Battery cover 13 Fuel tank cover 14 Left side panel 15 Right side panel 16 Dipstick accessing panel 1

For installation, reverse the removal pro-cedure.

3 — 5

CHKADJ

ENGINE SKID PLATES, SEAT, CARRIERS ANDFENDERS

EBS00037

FRONT CARRIER AND FRONT GUARD

3 4 4

5

61

22

78

(4)(4)

T R..

26 Nm (2.6 m • kg, 19 ft • Ib)

T R..

7 Nm (0.7 m • kg, 5.1 ft • Ib)

T R..

7 Nm (0.7 m • kg, 5.1 ft • Ib)

T R..

26 Nm (2.6 m • kg, 19 ft • Ib)

Order Job/Part Q’ty RemarksRemoving the front carrier and front guard

Remove the parts in the order listed.

Front engine skid plate Refer to “ENGINE SKID PLATES”.Seat/side panels Refer to “SEAT AND SIDE PANELS”.

1 Front carrier 12 Front carrier bracket 23 Battery holding bracket 14 Battery lead 2 Disconnect.

CAUTION:

First disconnect the negative battery lead, then disconnect the positive lead.

5 Battery 16 Upper panel 1

3 — 6

CHKADJ

ENGINE SKID PLATES, SEAT, CARRIERS ANDFENDERS

3 4 4

5

61

22

78

(4)(4)

T R..

26 Nm (2.6 m • kg, 19 ft • Ib)

T R..

7 Nm (0.7 m • kg, 5.1 ft • Ib)

T R..

7 Nm (0.7 m • kg, 5.1 ft • Ib)

T R..

26 Nm (2.6 m • kg, 19 ft • Ib)

Order Job/Part Q’ty Remarks7 Front guard 18 Front guard cover 2

For installation, reverse the removal pro-cedure.

3 — 7

CHKADJ

ENGINE SKID PLATES, SEAT, CARRIERS ANDFENDERS

FRONT FENDERS AND FRONT GRILL

6

5

1

(3)

(3)2

3

4

4

1

5

T R..

7 Nm (0.7 m • kg, 5.1 ft • Ib)

T R..

7 Nm (0.7 m • kg, 5.1 ft • Ib)

T R..

7 Nm (0.7 m • kg, 5.1 ft • Ib)

Order Job/Part Q’ty RemarksRemoving the front fenders and front grill

Remove the parts in the order listed.

Seat/side panels Refer to “SEAT AND SIDE PANELS”.Front carrier/front guard Refer to “FRONT CARRIER AND FRONT

GUARD”.1 Front fender inner panel 22 Auxiliary DC jack coupler 1 Disconnect.3 Main switch coupler 1 Disconnect.4 Front fender 25 Headlight coupler 2 Disconnect.6 Front grill 1

For installation, reverse the removal pro-cedure.

3 — 8

CHKADJ

ENGINE SKID PLATES, SEAT, CARRIERS ANDFENDERS

EBS00040

REAR CARRIER AND REAR FENDER

41

2

(4) 2

5

3

6 (6)

(6)

T R..

7 Nm (0.7 m • kg, 5.1 ft • Ib)

T R..

7 Nm (0.7 m • kg, 5.1 ft • Ib)

T R..

48 Nm (4.8 m • kg, 35 ft • Ib)

T R..

48 Nm (4.8 m • kg, 35 ft • Ib)

T R..

34 Nm (3.4 m • kg, 24 ft • Ib)

Order Job/Part Q’ty RemarksRemoving the rear carrier and rear fender

Remove the parts in the order listed.

Seat/side panels Refer to “SEAT AND SIDE PANELS”.1 Rear carrier 12 Rear carrier bracket 23 Storage compartment 14 Tail/brake light cover 15 Tail/brake light connector 3 Disconnect.6 Rear fender 1

For installation, reverse the removal pro-cedure.

3 — 9

CHKADJELECTRICAL COMPONENTS TRAY

ELECTRICAL COMPONENTS TRAYELECTRICAL COMPONENTS TRAY 1/2

2

2

3

5

1

6

6

6

6

7

8

910

11 12

1513

14

4

T R..

7 Nm (0.7 m • kg, 5.1 ft • Ib)

Order Job/Part Q’ty RemarksRemoving the electrical compo-nents tray

Remove the parts in the order listed.

Front fender/front grill Refer to “FRONT FENDERS AND FRONT GRILL”.

1 Battery holding bracket 12 Battery lead 2 Disconnect.

CAUTION:

First disconnect the negative batterylead, then disconnect the positivelead.

3 Battery 14 Lean angle sensor coupler 1 Disconnect.5 Lean angle sensor 16 EPS control unit coupler 5 Disconnect.

3 — 10

CHKADJELECTRICAL COMPONENTS TRAY

2

2

3

5

1

6

6

6

6

7

8

910

11 12

1513

14

4

T R..

7 Nm (0.7 m • kg, 5.1 ft • Ib)

Order Job/Part Q’ty Remarks7 EPS (electric power steering) control

unit1

8 Four-wheel-drive motor relay 3 19 Rear brake relay 1

10 Four-wheel-drive motor relay 2 111 Four-wheel-drive motor relay 1 112 Headlight relay 113 Radiator fan motor coupler 1 Disconnect.14 ECU coupler 1 Disconnect.15 ECU (engine control unit) 1

For installation, reverse the removal pro-cedure.

3 — 11

CHKADJELECTRICAL COMPONENTS TRAY

ELECTRICAL COMPONENTS TRAY 2/2

4

3

2

18

1

56

12

17

13

20

16

15

(4)1914

78 9

10

11

T R..

7 Nm (0.7 m • kg, 5.1 ft • Ib)

T R..

7 Nm (0.7 m • kg, 5.1 ft • Ib)

Order Job/Part Q’ty RemarksRemoving the electrical compo-nents tray

Remove the parts in the order listed.

1 Starter relay coupler 1 Disconnect.2 Starter relay 13 Fuse box 14 EPS fuse 15 Main fuse 16 Spare fuse 17 Radiator fan motor relay 18 Fuel injection system relay 19 Starting circuit cut-off relay 1

10 Left handlebar switch coupler 2 Disconnect.11 On-command four-wheel-drive motor

switch and differential gear lock switch coupler

2 Disconnect.

3 — 12

CHKADJELECTRICAL COMPONENTS TRAY

4

3

2

18

1

56

12

17

13

20

16

15

(4)1914

78 9

10

11

T R..

7 Nm (0.7 m • kg, 5.1 ft • Ib)

T R..

7 Nm (0.7 m • kg, 5.1 ft • Ib)

Order Job/Part Q’ty Remarks12 Front brake light switch connector 2 Disconnect.13 Rear brake light switch connector 2 Disconnect.14 Meter assembly coupler 1 Disconnect.15 Meter assembly 116 Frame ground terminal 117 Ignition coil connector 2 Disconnect.18 Differential gear motor coupler 1 Disconnect.19 Wire harness 120 Electrical components tray 1

For installation, reverse the removal pro-cedure.

3 — 13

CHKADJFOOTREST BOARDS

EBS00045

FOOTREST BOARDS

(4)

(5)

(4)

(5)

(5)

(5)

1

(4)

1

2

32

3

(4)

T R..

7 Nm (0.7 m • kg, 5.1 ft • Ib)

T R..

7 Nm (0.7 m • kg, 5.1 ft • Ib)

T R..

7 Nm (0.7 m • kg, 5.1 ft • Ib)

T R..

53 Nm (5.3 m • kg, 38 ft • Ib)

T R..

53 Nm (5.3 m • kg, 38 ft • Ib)

Order Job/Part Q’ty RemarksRemoving the footrest boards Remove the parts in the order listed.Seat/side panels Refer to “SEAT AND SIDE PANELS”.

1 Footrest 22 Footrest board 23 Footrest bracket 2

For installation, reverse the removal pro-cedure.

3 — 14

CHKADJAIR FILTER CASE

AIR FILTER CASE

New

New

1

2

39

10

4

8

7

6

5

Order Job/Part Q’ty RemarksRemoving the air filter case Remove the parts in the order listed.Seat/side panels Refer to “SEAT AND SIDE PANELS”.

1 Air filter case cover 12 Air filter element 13 Air filter element frame 14 Air filter case joint clamp screw 1 Loosen.5 Intake air temperature sensor coupler 1 Disconnect.6 Breather hose (air filter case to throttle

body)1 Disconnect.

7 Breather hose (air filter case to fast idle plunger unit)

1 Disconnect.

8 Cylinder head breather hose 1 Disconnect.9 Intake air temperature sensor 1

10 Air filter case 1For installation, reverse the removal pro-cedure.

3 — 15

3 — 1

CHKADJ

1

1

2

ADJUSTING THE VALVE CLEARANCE

EAS00049

ENGINEADJUSTING THE VALVE CLEARANCEThe following procedure applies to all of thevalves.

NOTE:• Valve clearance adjustment should be made

on a cold engine, at room temperature.• When the valve clearance is to be measured

or adjusted, the piston must be at top deadcenter (TDC) on the compression stroke.

1. Remove:• left side panel

Refer to “SEAT AND SIDE PANELS”.• front fender

Refer to “FRONT FENDERS AND FRONTGRILL”.

• footrest boardRefer to “FOOTREST BOARDS”.

• air filter caseRefer to “AIR FILTER CASE”.

2. Remove:• fast idle plunger unit 1

3. Remove:• intake tappet cover 1• exhaust tappet cover• camshaft sprocket cover 2

6

3 — 1

CHKADJADJUSTING THE VALVE CLEARANCE

1

2

1

2

a

b

d

c

4. Disconnect:• spark plug cap 1

5. Remove:• spark plug 2

6. Remove:• timing mark accessing screw 1• crankshaft end accessing screw 2

7. Measure:• valve clearance

Out of specification → Adjust.

a. Turn the crankshaft counterclockwise.b. When the piston is at the top dead center

(TDC) on the compression stroke, align the“I” mark a on the AC magneto rotor withthe stationary pointer b on the AC magnetocover.

NOTE:To position the piston at top dead center (TDC)on the compression stroke, align the “I” markc on the camshaft sprocket with the stationarypointer d on the cylinder head, as shown inthe illustration.

Valve clearance (cold) Intake valve

0.09 ~ 0.13 mm (0.0035 ~ 0.0051 in)

Exhaust valve 0.16 ~ 0.20 mm (0.0063 ~ 0.0079 in)

7

3 — 1

CHKADJADJUSTING THE VALVE CLEARANCE

1

34

2

1

c. Measure the valve clearance with a thick-ness gauge 1.

Out of specification → Adjust.

Thickness gauge90890-03079

Narrow gauge setYM-34483

8. Adjust:• valve clearance

a. Loosen the locknut 1.b. Insert a thickness gauge 2 between the

end of the adjusting screw and the valve tip.c. Turn the adjusting screw 3 with the tappet

adjusting tool 4 until the specified valveclearance is obtained.

d. Hold the adjusting screw to prevent it frommoving and tighten the locknut to the speci-fied torque.

e. Measure the valve clearance again.f. If the valve clearance is still out of specifica-

tion, repeat all of the valve clearance adjust-ment steps until the specified clearance isobtained.

9. Install:• timing mark accessing screw

• crankshaft end accessing screw

10.Install:• spark plug

11.Connect:• spark plug cap

Tappet adjusting tool90890-01311

Valve adjuster 3 mm & 4 mmYM-08035-A

T R..

Locknut14 Nm (1.4 m · kg, 10 ft · lb)

T R..

6 Nm (0.6 m · kg, 4.3 ft · lb)

T R..

10 Nm (1.0 m · kg, 7.2 ft · lb)

T R..

13 Nm (1.3 m · kg, 9.4 ft · lb)

8

3 — 1

CHKADJ

ADJUSTING THE VALVE CLEARANCE/ADJUSTING THE ENGINE IDLING SPEED

1

New

12.Install:• O-ring• camshaft sprocket cover

• O-ring 1• intake tappet cover

• O-ring• exhaust tappet cover

13.Install:• fast idle plunger unit

14.Install:• air filter case

Refer to “AIR FILTER CASE”.• footrest board

Refer to “FOOTREST BOARDS”.• front fender

Refer to “FRONT FENDERS AND FRONTGRILL”.

• left side panelRefer to “SEAT AND SIDE PANELS”.

New

T R..

10 Nm (1.0 m · kg, 7.2 ft · lb)

New

T R..

10 Nm (1.0 m · kg, 7.2 ft · lb)New

T R..

10 Nm (1.0 m · kg, 7.2 ft · lb)

EBS00051

ADJUSTING THE ENGINE IDLING SPEED1. Remove:• fuel tank cover

Refer to “SEAT AND SIDE PANELS”.2. Start the engine and let it warm up for sev-

eral minutes.3. Attach:• tachometer

(to the spark plug lead)

4. Measure:• engine idling speed

Out of specification → Adjust.

Digital tachometer90890-06760, YU-39951-B

Engine idling speed1,350 ~ 1,450 r/min

9

3 — 2

CHKADJ

ADJUSTING THE ENGINE IDLING SPEED/ADJUSTING THE THROTTLE LEVER FREE PLAY

ba

1

5. Adjust:• engine idling speed

a. Turn the idle speed adjusting screw 1 indirection a or b until the specified idlingspeed is obtained.

6. Detach:• tachometer

7. Adjust:• throttle lever free play

Refer to “ADJUSTING THE THROTTLELEVER FREE PLAY”.

8. Install:• fuel tank cover

Refer to “SEAT AND SIDE PANELS”.

Direction a Idling speed becomes higher.

Direction b Idling speed becomes lower.

Throttle lever free play3.0 ~ 5.0 mm (0.12 ~ 0.20 in)

EBS00052

ADJUSTING THE THROTTLE LEVER FREE PLAY

NOTE:_

Engine idling speed should be adjusted prop-erly before adjusting the throttle lever freeplay.

1. Measure:• throttle lever free play a

Out of specification → Adjust.

2. Remove:• left side panel

Refer to “SEAT AND SIDE PANELS”.

Throttle lever free play3.0 ~ 5.0 mm (0.12 ~ 0.20 in)

0

3 — 2

CHKADJADJUSTING THE THROTTLE LEVER FREE PLAY

13 a

b

2

3. Adjust:• throttle lever free play

First step:a. Slide back the rubber cover 1.b. Loosen the locknut 2 on the throttle body

side.c. Turn the adjusting nut 3 in direction a or

b until the correct free play is obtained.

d. Tighten the locknut.e. Slide the rubber cover to its original posi-

tion.

NOTE:_

If the free play cannot be adjusted here, adjustit at the throttle lever side of the cable.

Direction a Free play is increased.

Direction b Free play is decreased.

Second step:f. Slide back the rubber cover 4.g. Loosen the locknut 5.h. Turn the adjusting bolt 6 in direction c or

d until the correct free play is obtained.

i. Tighten the locknut.j. Slide the rubber cover to its original posi-

tion.

WARNING_

After adjusting the free play, turn the han-dlebar to the right and left to make surethat the engine idling speed does notincrease.

4. Install:• left side panel

Refer to “SEAT AND SIDE PANELS”.

Direction c Free play is increased.

Direction d Free play is decreased.

1

3 — 2

CHKADJADJUSTING THE SPEED LIMITER

EBS00053

ADJUSTING THE SPEED LIMITERThe speed limiter keeps the throttle frombecoming fully-opened even when the throttlelever is applied to the maximum position.Screwing in the adjusting screw stops theengine speed from increasing.1. Measure: • speed limiter length a

Out of specification → Adjust.

2. Adjust:• speed limiter length

a. Loosen the locknut 1.b. Turn the adjuster 2 in direction b or c

until the specified speed limiter length isobtained.

c. Tighten the locknut.

WARNING_

• Particularly for a beginner rider, thespeed limiter should be screwed in com-pletely. Screw it out little by little as theirriding technique improves. Never removethe speed limiter for a beginning rider.

• For proper throttle lever operation do notturn out the adjuster more than 12 mm(0.47 in). Also, always adjust the throttlelever free play to 3.0 ~ 5.0 mm (0.12 ~0.20 in).

Speed limiter lengthLess than 12 mm (0.47 in)

Direction b Speed limiter length is decreased.

Direction c Speed limiter length is increased.

2

3 — 2

CHKADJCHECKING THE SPARK PLUG

EBS00057

CHECKING THE SPARK PLUG1. Remove:• right side panel

Refer to “SEAT AND SIDE PANELS”.2. Disconnect:• spark plug cap

3. Remove:• spark plug

4. Check:• spark plug type

Incorrect → Change.

Standard spark plugCR8E/NGK

5. Check:• electrode 1

Wear/damage → Replace.• insulator 2

Abnormal color → Replace.Normal color is a medium-to-light tan color.

6. Clean:• spark plug

(with a spark plug cleaner or wire brush)

7. Measure:• spark plug gap a

Use a wire gauge or thickness gauge.Out of specification → Regap.

8. Tighten:• spark plug

NOTE:_

Before installing a spark plug, clean the gasketsurface and plug surface.

9. Connect:• spark plug cap

10.Install:• right side panel

Refer to “SEAT AND SIDE PANELS”.

Spark plug gap0.7 ~ 0.8 mm (0.028 ~ 0.031 in)

T R..

13 Nm (1.3 m · kg, 9.4 ft · lb)

3

3 — 2

CHKADJCHECKING THE IGNITION TIMING

1

EBS00058

CHECKING THE IGNITION TIMING

NOTE:_

Engine idling speed and throttle cable free playshould be adjusted properly before checkingthe ignition timing.

1. Remove:• left side panel• right side panel

Refer to “SEAT AND SIDE PANELS”.• footrest board

Refer to “FOOTREST BOARDS”.2. Attach:• tachometer• timing light

(to spark plug lead)

Digital tachometer90890-06760, YU-39951-B

Timing light90890-03141

Inductive clamp timing lightYU-03141

3. Check:• ignition timing

a. Warm up the engine and keep it at thespecified speed.

b. Remove the timing mark accessing screw1.

Engine speed 1,350 ~ 1,450 r/min

4

3 — 2

CHKADJ

CHECKING THE IGNITION TIMING/MEASURING THE COMPRESSION PRESSURE

a

b

c. Visually check the stationary pointer a toverify it is within the required firing range bindicated on the AC magneto rotor.Incorrect firing range → Check the pulsercoil assembly.

NOTE:When checking the ignition timing, make surethat the timing light cord does not come in con-tact with the exhaust muffler.

d. Install the timing mark accessing screw.

4. Detach:• timing light• tachometer

5. Install:• footrest board

Refer to “FOOTREST BOARDS”.• right side panel• left side panel

Refer to “SEAT AND SIDE PANELS”.

T R..

Timing mark accessing screw6 Nm (0.6 m · kg, 4.3 ft · lb)

EBS00061

MEASURING THE COMPRESSION PRESSURE

NOTE:_

Insufficient compression pressure will result ina loss of performance.

1. Measure:• valve clearance

Out of specification → Adjust.Refer to “ADJUSTING THE VALVECLEARANCE”.

2. Start the engine, warm it up for several min-utes, and then turn it off.

3. Remove:• right side panel

Refer to “SEAT AND SIDE PANELS”.• V-belt cooling duct 2

Refer to “ENGINE REMOVAL” in chapter 4.

5

3 — 2

CHKADJMEASURING THE COMPRESSION PRESSURE

2

1

4. Disconnect:• spark plug cap

5. Remove:• spark plug

CAUTION:_

Before removing a spark plug, use com-pressed air to blow away any dirt accumu-lated in the spark plug well to prevent itfrom falling into the cylinder.

6. Attach:• extension 1• compression gauge 2

7. Measure:• compression pressure

Out of specification → Refer to steps (c)and (d).

a. Set the main switch to “ON”.

Compression gauge90890-03081

Engine compression testerYU-33223

Extension90890-04082

Compression pressure (at sea level)

Minimum392 kPa (3.92 kg/cm2, 55.8 psi)

Standard 450 kPa (4.50 kg/cm2, 64.0 psi)

Maximum 504 kPa (5.04 kg/cm2, 71.7 psi)

6

3 — 2

CHKADJMEASURING THE COMPRESSION PRESSURE

b. With the throttle wide open, crank theengine until the reading on the compressiongauge stabilizes.

WARNING_

To prevent sparking, ground the spark pluglead before cranking the engine.

c. If the compression pressure is above themaximum specification, check the cylinderhead, valve surfaces and piston crown forcarbon deposits.Carbon deposits → Eliminate.

d. If the compression pressure is below theminimum specification, squirt a few drops ofoil into the cylinder and measure again. Refer to the following table.

8. Install: • spark plug

9. Connect:• spark plug cap

10.Install:• V-belt cooling duct 2

Refer to “ENGINE REMOVAL” in chapter 4.• right side panel

Refer to “SEAT AND SIDE PANELS”.

Compression pressure (with oil applied into the cylinder)

Reading Diagnosis

Higher than without oil

Piston ring(s) wear or damage → Repair.

Same as without oil

Piston, valves, cylinder head gasket or piston rings possibly defective → Repair.

T R..

13 Nm (1.3 m · kg, 9.4 ft · lb)

7

3 — 2

CHKADJCHECKING THE ENGINE OIL LEVEL

ba

0˚ 10˚ 30˚ 50˚ 70˚ 90˚ 110˚ 130˚F

YAMALUBE 4 (10W30) or SAE 10W30

SAE 5W30

-20˚ -10˚ 0˚ 10˚ 20˚ 30˚ 40˚ 50˚C

YAMALUBE 4 (20W40) or SAE 20W40

EBS00064

CHECKING THE ENGINE OIL LEVEL1. Place the vehicle on a level surface.2. Check the engine oil level on a cold engine.

NOTE:_

If the engine was started before checking theoil level, be sure to warm up the engine suffi-ciently, and then wait at least 10 minutes untilthe oil settles for an accurate reading.

3. Remove:• dipstick accessing panel

Refer to “SEAT AND SIDE PANELS”.

4. Check: • engine oil level

Oil level should be between the minimumlevel mark a and maximum level mark b.Oil level low → Add oil to the proper level.

NOTE:To obtain an accurate oil level reading, the dip-stick must be inserted completely into the oilfilter hole.

CAUTION:

Do not allow foreign material to enter thecrankcase.

5. Check the engine oil level again.

CAUTION:

Be sure the engine oil is at the correctlevel, otherwise engine damage may result.

Recommended engine oil typeYAMALUBE 4, SAE5W30, SAE10W30 or SAE20W40

Recommended engine oil gradeAPI service SG type or higher, JASO standard MA

8

3 — 2

CHKADJ

CHECKING THE ENGINE OIL LEVEL/CHANGING THE ENGINE OIL

1

1

12

6. Install:• dipstick accessing panel

Refer to “SEAT AND SIDE PANELS”.

EBS00069

CHANGING THE ENGINE OIL1. Start the engine, warm it up for several min-

utes, and then turn it off.2. Place a container under the engine oil drain

bolt.3. Remove:• dipstick accessing panel

Refer to “SEAT AND SIDE PANELS”.

4. Remove:• dipstick 1

5. Remove:• engine oil drain bolt 1

(along with the gasket)6. Drain:• engine oil

(completely from the crankcase)

7. If the oil filter cartridge is also to bereplaced, perform the following procedure.

a. Remove the oil filter cartridge 1 with an oilfilter wrench 2.

Oil filter wrench90890-01426, YU-38411

9

3 — 3

CHKADJCHANGING THE ENGINE OIL

b. Lubricate the O-ring 3 of the new oil filtercartridge with a thin coat of engine oil.

CAUTION:_

Make sure the O-ring 3 is positioned cor-rectly in the groove of the oil filter car-tridge.

c. Tighten the new oil filter cartridge to specifi-cation with an oil filter wrench.

8. Check:• engine oil drain bolt gasket

Damage → Replace.9. Install:• engine oil drain bolt

(along with the gasket)

10.Fill:• crankcase

(with the specified amount of the recom-mended engine oil)

11.Install:• dipstick

12.Start the engine, warm it up for several min-utes, and then turn it off.

13.Check:• engine

(for engine oil leaks)14.Check:• engine oil level

Refer to “CHECKING THE ENGINE OILLEVEL”.

T R..

Oil filter cartridge17 Nm (1.7 m · kg, 12 ft · lb)

QuantityTotal amount

2.40 L (2.11 Imp qt, 2.54 US qt)Without oil filter cartridge replacement

2.00 L (1.76 Imp qt, 2.11 US qt)With oil filter cartridge replace-ment

2.10 L (1.85 Imp qt, 2.22 US qt)

T R..

30 Nm (3.0 m · kg, 22 ft · lb)

0

3 — 3

CHKADJ

CHANGING THE ENGINE OIL/CLEANING THE AIR FILTER ELEMENT

1

1

1

15.Check:• engine oil pressure

a. Slightly loosen the oil gallery bolt 1.b. Start the engine and keep it idling until

engine oil starts to seep from the oil gallerybolt. If no engine oil comes out after oneminute, turn the engine off so that it will notseize.

c. Check the engine oil passages, the oil filtercartridge and the oil pump for damage orleakage. Refer to “CRANKSHAFT AND OILPUMP” in chapter 4.

d. Start the engine after solving the problem(s)and check the engine oil pressure again.

e. Tighten the oil gallery bolt to specification.

T R..

Oil gallery bolt10 Nm (1.0 m · kg, 7.2 ft · lb)

EBS00073

CLEANING THE AIR FILTER ELEMENT1. Remove:• fuel tank cover• left side panel• right side panel

Refer to “SEAT AND SIDE PANELS”.

NOTE:_

There are two check hoses 1 at the bottom ofthe air filter case. If dust and/or water collectsin them, clean the air filter element, air filtermesh and air filter case.

1

3 — 3

CHKADJCLEANING THE AIR FILTER ELEMENT

1

2. Remove:• air filter case cover 1

3. Remove:• air filter element 1• air filter element frame 2

CAUTION:_

The engine should never be run without theair filter; excessive piston and/or cylinderwear may result.

4. Check:• air filter element• air filter element frame

Damage → Replace.5. Clean:• air filter element

Use compressed air to blow off dust fromthe inner surface of the element.

a. Wash the element gently, but thoroughly insolvent.

WARNING_

Use a cleaning solvent which is designedto clean parts only. Never use gasoline orlow flash point solvents as they may causea fire or explosion.

b. Squeeze the excess solvent out of the ele-ment and let it dry.

CAUTION:_

Do not twist or wring out the element. Thiscould damage the foam material.

c. Apply Yamaha foam air filter oil or otherquality foam air filter oil to the element.

2

3 — 3

CHKADJ

CLEANING THE AIR FILTER ELEMENT/CHECKING THE THROTTLE BODY JOINT

1

d. Squeeze out the excess oil.

NOTE:_

The element should be wet but not dripping.

6. Install:• air filter element frame• air filter element

NOTE:_

Make sure its sealing surface matches thesealing surface of the case so there is no airleak.

7. Install:• air filter case cover

8. Install:• right side panel• left side panel• fuel tank cover

Refer to “SEAT AND SIDE PANELS”.

EAS00094

CHECKING THE THROTTLE BODY JOINT1. Remove:• left side panel

Refer to “SEAT AND SIDE PANELS”.2. Check:• throttle body joint 1

Cracks/damage → Replace.Refer to “THROTTLE BODY” in chapter 6.

3. Install:• left side panel

Refer to “SEAT AND SIDE PANELS”.

3

3 — 3

CHKADJ

CHECKING THE FUEL HOSE/CHECKING THE BREATHER HOSES

1

132

EAS00096

CHECKING THE FUEL HOSE1. Remove:• seat• right side panel

Refer to “SEAT AND SIDE PANELS”.• rear fender

Refer to “REAR CARRIER AND REARFENDER”.

• V-belt cooling duct 2Refer to “ENGINE REMOVAL” in chapter 4.

2. Check:• fuel hose 1

Cracks/damage → Replace.Loose connection → Connect properly.

3. Install:• V-belt cooling duct 2

Refer to “ENGINE REMOVAL” in chapter 4.• rear fender

Refer to “REAR CARRIER AND REARFENDER”.

• right side panel• seat

Refer to “SEAT AND SIDE PANELS”.

EAS00098

CHECKING THE BREATHER HOSES1. Remove:• left side panel

Refer to “SEAT AND SIDE PANELS”.• air filter case

Refer to “AIR FILTER CASE”.2. Check:• cylinder head breather hose 1• breather hose (air filter case to throttle

body) 2• breather hose (air filter case to fast idle

plunger unit) 3Cracks/damage → Replace.Loose connection → Connect properly.

CAUTION:

Make sure the breather hoses are routedcorrectly.

4

3 — 3

CHKADJ

CHECKING THE COOLANT LEVEL/CHANGING THE COOLANT

FULL

LOW

1

a

EBS00076

CHECKING THE COOLANT LEVEL1. Place the vehicle on a level surface.

NOTE:The coolant level must be checked on a coldengine since the level varies with engine tem-perature.

2. Check:• coolant level

The coolant level should be between theminimum level mark a and maximum levelmark b in the coolant reservoir.

CAUTION:_

• Adding water instead of coolant lowersthe antifreeze content of the coolant. Ifwater is used instead of coolant, checkand if necessary, correct the antifreezeconcentration of the coolant.

• Use only distilled water. However, softwater may be used if distilled water is notavailable.

3. If the coolant is at or below the minimumlevel mark, remove the left side panel. Refer to “SEAT AND SIDE PANELS”.

4. Remove the reservoir cap 1, add coolantor distilled water to the maximum level marka, install the reservoir cap, and then installthe panel.

Coolant reservoir capacity (up to the maximum level mark):

0.17 L (0.15 Imp qt, 0.18 US qt)

EBS00075

CHANGING THE COOLANT1. Remove:• right side panel• left side panel

Refer to “SEAT AND SIDE PANELS”.• front carrier• upper panel

Refer to “FRONT CARRIER AND FRONTGUARD”.

5

3 — 3

CHKADJCHANGING THE COOLANT

1

2

1

1

2. Remove:• coolant reservoir cap 1

3. Disconnect:• coolant reservoir hose 2

4. Drain:• coolant

(from the coolant reservoir)5. Connect:• coolant reservoir hose

6. Remove:• radiator cap 1

WARNING_

A hot radiator is under pressure. Therefore,do not remove the radiator cap when theengine is hot. Scalding hot fluid and steammay be blown out, which could cause seri-ous injury. When the engine has cooled,open the radiator cap as follows:Place a thick rag or a towel over the radia-tor cap and slowly turn the radiator capcounterclockwise toward the detent toallow any residual pressure to escape.When the hissing sound has stopped,press down on the radiator cap and turn itcounterclockwise to remove.

7. Remove:• coolant drain bolt 1

(along with the copper washer)8. Drain:• coolant

(from the engine and radiator)

9. Check:• coolant drain bolt 1

Damage → Replace.10.Install:• copper washer 2• coolant drain bolt

New

T R..

10 Nm (1.0 m · kg, 7.2 ft · lb)

6

3 — 3

CHKADJCHANGING THE COOLANT

11.Fill:• cooling system

(with the specified amount of the recom-mended coolant)

Handling notes for coolantCoolant is potentially harmful and should behandled with special care.

WARNING_

• If coolant splashes in your eyes, thor-oughly wash them with water and consulta doctor.

• If coolant splashes on your clothes,quickly wash it away with water and thenwith soap and water.

• If coolant is swallowed, induce vomitingand get immediate medical attention.

CAUTION:_

• Adding water instead of coolant lowersthe antifreeze content of the coolant. Ifwater is used instead of coolant, check,and if necessary, correct the antifreezeconcentration of the coolant.

• Use only distilled water. However, if dis-tilled water is not available, soft watermay be used.

• If coolant comes into contact with paintedsurfaces, immediately wash them withwater.

• Do not mix different types of antifreeze.

Recommended antifreezeHigh-quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum enginesMixing ratio

1:1 (antifreeze:water)Quantity

Total amount1.99 L (1.75 Imp qt, 2.10 US qt)

Coolant reservoir capacity (upto the maximum level mark)

0.17 L (0.15 Imp qt, 0.18 US qt)

From minimum to maximumlevel mark

0.14 L (0.12 Imp qt, 0.15 US qt)

7

3 — 3

CHKADJCHANGING THE COOLANT

FULL

LOW

1

a

1

2

3

12.Fill:• coolant reservoir

(with the recommended coolant to the maxi-mum level mark a)

13.Install:• coolant reservoir cap 1

14.Bleed:• coolant system

a. Remove the V-belt cooling duct 2 1.b. Loosen the water pump air bleed bolt 2,

without removing it, to allow all of the air toescape from the air bleed bolt hole.

c. When coolant begins to flow out of the bolthole, tighten the water pump air bleed boltto specification.

d. Loosen the cylinder head air bleed bolt 3,without removing it, to allow all of the air toescape from the air bleed bolt hole.

e. When coolant begins to flow out of the bolthole, tighten the cylinder head air bleed boltto specification.

f. Install the V-belt cooling duct 2.

15.Start the engine, warm it up for ten minutes,and then rev the engine five times.

16.Pour the recommended coolant into theradiator until it is full.

17.Stop the engine and allow it to cool. If thecoolant level has dropped after the enginehas cooled, add sufficient coolant until itreaches the top of the radiator, and theninstall the radiator cap.

18.Start the engine, and then check for coolantleakage.

T R..

Water pump air bleed bolt10 Nm (1.0 m · kg, 7.2 ft · lb)

T R..

Cylinder head air bleed bolt10 Nm (1.0 m · kg, 7.2 ft · lb)

8

3 — 3

CHKADJ

CHANGING THE COOLANT/CHECKING THE COOLING SYSTEM

1

2

3

4

5

6

7

8

9

19.Install:• upper panel• front carrier

Refer to “FRONT CARRIER AND FRONTGUARD”.

• left side panel• right side panel

Refer to “SEAT AND SIDE PANELS”.

EAS00104

CHECKING THE COOLING SYSTEM1. Remove:• front fenders

Refer to “FRONT FENDERS AND FRONTGRILL”.

• left footrest boardRefer to “FOOTREST BOARDS”.

2. Check:• radiator 1• radiator inlet hose 2• coolant reservoir 3• coolant reservoir hose 4• radiator outlet hose 5• water jacket 6• water pump outlet hose 7• water pump outlet pipe 8• water pump housing 9

Cracks/damage → Replace.Refer to “COOLING SYSTEM” in chapter 5.

3. Install:• left footrest board

Refer to “FOOTREST BOARDS”.• front fenders

Refer to “FRONT FENDERS AND FRONTGRILL”.

9

3 — 4

CHKADJ

CHECKING THE COOLANT TEMPERATURE WARNINGLIGHT

1

EBS00077

CHECKING THE COOLANT TEMPERATURE WARNING LIGHT1 Coolant temperature warning light

Coolant temperature warning light checking method

Turn the main switch “ON” and theengine stop switch to “RUN”.

Coolant temperature warninglight does not come on.

Coolant temperature warninglight comes on.

Push start switch with transmissionin “neutral”.

Coolant temperaturewarning light comes onmomentarily.

Coolant temperature warninglight does not come on.

Check the electrical circuit. Refer to“SIGNALING SYSTEM” in chapter 9.

Coolant temperature andelectrical circuit are OK.Go ahead with riding.

0

3 — 4

CHKADJCHECKING THE V-BELT

EBS00078

CHECKING THE V-BELT1. Remove:• drive belt cover

Refer to “PRIMARY AND SECONDARYSHEAVES” in chapter 4.

2. Check:• V-belt 1

Cracks/wear/scaling/chipping → Replace.Oil/grease → Check primary sheave andsecondary sheave.

3. Measure:• V-belt width 2

Out of specification → Replace.

V-belt width31.7 mm (1.25 in)<Limit>: 31.3 mm (1.23 in)

4. Replace:• V-belt

a. Install the bolts 1 (90101-06016) into thesecondary fixed sheave hold.

NOTE:_

Tightening the bolts 1 will push the secondarysliding sheave away, causing the gap betweenthe secondary fixed and sliding sheaves towiden.

b. Remove the V-belt 1 from the primarysheave and secondary sheave.

1

3 — 4

CHKADJ

CHECKING THE V-BELT/CHECKING THE EXHAUST SYSTEM

46

5

1

6

7

89

3

8

2 5

0

c. Install the V-belt.

NOTE:_

Install the V-belt so that its arrow faces thedirection shown in the illustration.

d. Remove the bolts.

EAS00099

CHECKING THE EXHAUST SYSTEMThe following procedure applies to all of theexhaust pipe gaskets.1. Check:• exhaust pipe 1• muffler 2• exhaust pipe protector 3• muffler bracket 4• springs 5

Cracks/damage → Replace.• gaskets 6

Exhaust gas leaks → Replace.2. Check:• tightening torques

T R..

Exhaust pipe nut 720 Nm (2.0 m · kg, 14 ft · lb)

Muffler and muffler bracket bolt 820 Nm (2.0 m · kg, 14 ft · lb)

Muffler bolt 920 Nm (2.0 m · kg, 14 ft · lb)

Exhaust pipe protector bolt 07 Nm (0.7 m · kg, 5.1 ft · lb)

2

3 — 4

CHKADJCLEANING THE SPARK ARRESTER

1

2

2

3

CLEANING THE SPARK ARRESTER1. Clean:• spark arrester

WARNING

• Select a well-ventilated area free of com-bustible materials.

• Always let the exhaust system coolbefore performing this operation.

• Do not start the engine when removingthe tailpipe from the muffler.

• Make sure that the transmission is in neu-tral.

a. Remove the bolts 1.b. Remove the tailpipe 2 by pulling it out of

the muffler and the gasket.c. Tap the tailpipe lightly with a soft-face ham-

mer or suitable tool, then use a wire brushto remove any carbon deposits from thespark arrester portion of the tailpipe andinside of the tail pipe housing.

d. Install the gasket, and then insert thetailpipe into the muffler and align the boltholes.

e. Insert the bolts 1 and tighten them.

f. Remove the purging bolt 3.g. Start the engine and rev it up approximately

twenty times while momentarily creatingexhaust system back pressure by blockingthe end of the muffler with a shop towel.

h. Stop the engine and allow the exhaust pipeto cool.

i. Install the purging bolt 3 and tighten it.

T R..

Bolt10 Nm (1.0 m · kg, 7.2 ft · lb)

T R..

Purging bolt27 Nm (2.7 m · kg, 19 ft · lb)

3

3 — 4

CHKADJ

ADJUSTING THE FRONT BRAKE/ADJUSTING THE REAR BRAKE

a

a

b

EBS00080

CHASSISADJUSTING THE FRONT BRAKE1. Measure:• front brake lever free play a

Out of specification → Bleed the front brakesystem.Refer to “BLEEDING THE HYDRAULICBRAKE SYSTEM”.

Front brake lever free play(at the end of the brake lever)

0 mm (0 in)

EBS00085

ADJUSTING THE REAR BRAKE

WARNING_

Always adjust both the brake pedal and therear brake lever whenever adjusting therear brake.

1. Measure:• rear brake lever free play a

Out of specification → Bleed the rear brakesystem.Refer to “BLEEDING THE HYDRAULICBRAKE SYSTEM”.

Rear brake lever free play (at the end of the brake lever)

0 mm (0 in)

2. Measure:• brake pedal free play b

Out of specification → Adjust.

Brake pedal free play0 ~ 5.0 mm (0 ~ 0.20 in)

4

3 — 4

CHKADJADJUSTING THE REAR BRAKE

2

1

3a

4

b

3. Measure:• brake pedal height c

Out of specification → Adjust.

d Measuring points

Brake pedal height56.7 mm (2.23 in)

4. Adjust:• brake pedal free play• brake pedal height

5. Remove:• front fender inner panel

Refer to “FRONT FENDERS AND FRONTGRILL”.

a. Loosen the locknut 1.b. Turn the adjusting bolt 2 until the brake

pedal height is within the specified limits.

c. Tighten the locknut 1.

d. Loosen the locknut 3.e. Turn the adjusting nut 4 in direction a or

b until the specified brake pedal free play isobtained.

f. Tighten the locknut 3.

Brake pedal height56.7 mm (2.23 in)

T R..

Locknut7 Nm (0.7 m · kg, 5.1 ft · lb)

Direction a Brake pedal free play is increased.

Direction b Brake pedal free play is decreased.

T R..

Locknut7 Nm (0.7 m · kg, 5.1 ft · lb)

5

3 — 4

CHKADJ

ADJUSTING THE REAR BRAKE/CHECKING THE BRAKE FLUID LEVEL

a

È

a

É

g. Adjust the shift control cable.Refer to “ADJUSTING THE SELECTLEVER CONTROL CABLE AND SHIFTROD”.

WARNING_

After this adjustment is performed, lift thefront and rear wheels off the ground byplacing a block under the engine, and spinthe rear wheels to ensure there is no brakedrag. If any brake drag is noticed performthe above steps again.

6. Install:• front fender inner panel

Refer to “FRONT FENDERS AND FRONTGRILL”.

EBS00087

CHECKING THE BRAKE FLUID LEVEL1. Place the vehicle on a level surface.

NOTE:_

When checking the brake fluid level, makesure that the top of the brake fluid reservoir topis horizontal.

2. Check:• brake fluid level

Below the minimum level mark a → Addthe recommended brake fluid to the properlevel.

È Front brakeÉ Rear brake

WARNING_

• Use only the designated brake fluid.Other brake fluids may cause the rubberseals to deteriorate, causing leakage andpoor brake performance.

Recommended brake fluidDOT 4

6

3 — 4

CHKADJ

CHECKING THE BRAKE FLUID LEVEL/CHECKING THE FRONT BRAKE PADS

a

• Refill with the same type of brake fluidthat is already in the system. Mixingbrake fluids may result in a harmfulchemical reaction, leading to poor brakeperformance.

• When refilling, be careful that water doesnot enter the brake fluid reservoir. Waterwill significantly lower the boiling point ofthe brake fluid and could cause vaporlock.

CAUTION:_

Brake fluid may damage painted surfacesand plastic parts. Therefore, always cleanup any spilt brake fluid immediately.

NOTE:_

In order to ensure a correct reading of thebrake fluid level, make sure that the top of thebrake master cylinder reservoir is horizontal.

EBS00088

CHECKING THE FRONT BRAKE PADS1. Remove:• front wheels

Refer to “FRONT AND REAR WHEELS” inchapter 8.

2. Check:• brake pads

Wear indicator groove a almost disap-peared → Replace the brake pads as a set.Refer to “FRONT AND REAR BRAKES” inchapter 8.

3. Operate the brake lever.4. Install:• front wheels

Refer to “FRONT AND REAR WHEELS” inchapter 8.

Brake pad wear limit a1.0 mm (0.04 in)

7

3 — 4

CHKADJ

CHECKING THE REAR BRAKE PADS/CHECKING THE REAR BRAKE HOSE PROTECTORS

a

2

1

EBS00089

CHECKING THE REAR BRAKE PADS1. Remove:• rear wheels

Refer to “FRONT AND REAR WHEELS” inchapter 8.

2. Check:• brake pads

Wear indicator groove a almost disap-peared → Replace the brake pads as a set. Refer to “FRONT AND REAR BRAKES” inchapter 8.

3. Operate the brake lever or brake pedal.4. Install:• rear wheels

Refer to “FRONT AND REAR WHEELS” inchapter 8.

Brake pad wear limit a1.0 mm (0.04 in)

CHECKING THE REAR BRAKE HOSE PROTECTORS1. Remove:• rear wheels

Refer to “FRONT AND REAR WHEELS” inchapter 8.

2. Check:• rear brake hose protectors 1

Wear indicator 2 becomes visible →Replace the rear brake hose protector.Refer to “REAR KNUCKLES AND STABI-LIZER” in chapter 8.

3. Install:• rear wheels

Refer to “FRONT AND REAR WHEELS” inchapter 8.

8

3 — 4

CHKADJ

CHECKING THE BRAKE HOSES/BLEEDING THE HYDRAULIC BRAKE SYSTEM

1

2

1 1

2 2

EBS00092

CHECKING THE BRAKE HOSES1. Check:• front brake hoses 1• rear brake hoses 2

Cracks/wear/damage → Replace.2. Check:• brake hose holders

Loosen → Tighten.3. Hold the vehicle in an upright position and

apply the front or rear brake.4. Check:• brake hoses

Apply the brake lever several times.Fluid leakage → Replace the hoses.Refer to “FRONT AND REAR BRAKES” inchapter 8.

EBS00094

BLEEDING THE HYDRAULIC BRAKE SYSTEM

WARNING_

Bleed the hydraulic brake system when-ever:• the system is disassembled,• a brake hose is loosened, disconnected

or replaced,• the brake fluid level is very low,• brake operation is faulty.

NOTE:_

• Be careful not to spill any brake fluid or allowthe brake master cylinder reservoir to over-flow.

9

3 — 5

CHKADJBLEEDING THE HYDRAULIC BRAKE SYSTEM

2 1

È

2

1

É

• When bleeding the hydraulic brake system,make sure there is always enough brakefluid before applying the brake. Ignoring thisprecaution could allow air to enter thehydraulic brake system, considerably length-ening the bleeding procedure.

• If bleeding is difficult, it may be necessary tolet the brake fluid settle for a few hours.Repeat the bleeding procedure when the tinybubbles in the hose have disappeared.

1. Remove:• rear wheel

Refer to “FRONT AND REAR WHEELS” inchapter 8.

2. Bleed:• hydraulic brake system

a. Fill the brake master cylinder reservoir tothe proper level with the recommendedbrake fluid.

b. Install the diaphragm (brake master cylinderreservoir).

c. Connect a clear plastic hose 1 tightly to thebleed screw 2.

È FrontÉ Reard. Place the other end of the hose into a con-

tainer.e. Slowly apply the brake several times.f. Fully squeeze the brake lever or fully

depress the brake pedal and hold it in posi-tion.

g. Loosen the bleed screw.

NOTE:_

Loosening the bleed screw will release thepressure and cause the brake lever to contactthe handlebar grip or the brake pedal to fullyextend.

h. Tighten the bleed screw and then releasethe brake lever or brake pedal.

i. Repeat steps (e) to (h) until all of the airbubbles have disappeared from the brakefluid in the plastic hose.

j. Tighten the bleed screw to specification.

T R..

Bleed screw5 Nm (0.5 m · kg, 3.6 ft · lb)

0

3 — 5

CHKADJ

BLEEDING THE HYDRAULIC BRAKE SYSTEM/ADJUSTING THESELECT LEVER CONTROL CABLE AND SHIFT ROD

12

3

45

7

6

k. Fill the brake master cylinder reservoir tothe proper level with the recommendedbrake fluid.Refer to “CHECKING THE BRAKE FLUIDLEVEL”.

WARNING_

After bleeding the hydraulic brake system,check the brake operation.

3. Install:• rear wheel

Refer to “FRONT AND REAR WHEELS” inchapter 8.

EBS00100

ADJUSTING THE SELECT LEVER CONTROL CABLE AND SHIFT ROD1 NEUTRAL2 HIGH3 LOW4 REVERSE5 PARK6 Control cable7 Select lever shift rod

WARNING_

Before moving the select lever, bring thevehicle to a complete stop and return thethrottle lever to its closed position. Other-wise the transmission may be damaged.

1. Adjust:• brake pedal free play

Refer to “ADJUSTING THE REAR BRAKE”.2. Remove:• left side panel

Refer to “SEAT AND SIDE PANELS”.

1

3 — 5

CHKADJ

ADJUSTING THE SELECT LEVER CONTROL CABLEAND SHIFT ROD

a

312

1

a

3. Adjust:• shift control cable• shift rod

Shift control cable:a. Make sure that the select lever is in NEU-

TRAL.b. Squeeze the brake lever 30 mm (1.18 in) a,

loosen the locknut 1, and then adjust theshift control cable 2 with the adjuster 3 sothat the select lever can be shifted toREVERSE from NEUTRAL, and to PARKfrom REVERSE.

c. Release the brake lever so that a is 0 mm(0 in), and then verify that the select levercannot be shifted to REVERSE from NEU-TRAL, or to PARK from REVERSE.

d. If the operation of the select lever is incor-rect, repeat steps (a) to (c).

e. Tighten the locknut.

Shift rod:a. Make sure that the select lever and trans-

mission are in HIGH.b. Loosen both locknuts 1.c. Adjust the length a of the shift rod to

413 mm (16.3 in).d. Tighten the locknuts.

e. Start the engine, and then check that theselect lever can be shifted to each shiftposition and that the appropriate indicatorlight comes on when the lever is in eachposition.

f. Adjust the shift control cable again.

T R..

Locknut15 Nm (1.5 m · kg, 11 ft · lb)

2

3 — 5

CHKADJ

CHECKING THE FINAL GEAR OIL LEVEL/CHANGING THE FINAL GEAR OIL

1

2

1

1

EBS00101

CHECKING THE FINAL GEAR OIL LEVEL1. Place the vehicle on a level place.2. Remove:• final gear oil level check bolt 1

3. Check:• oil level

Oil level should be up to the bottom brim 2of the hole.Oil level low → Add oil to the proper level.

CAUTION:_

Take care not allow foreign material toenter the final gear case.

4. Install:• final gear oil level check bolt

Recommended oilSAE80 API GL-4 Hypoid gear oil

T R..

10 Nm (1.0 m · kg, 7.2 ft · lb)

EBS00102

CHANGING THE FINAL GEAR OIL1. Place the vehicle on a level surface.2. Remove:• final gear oil filler bolt 1

3. Place a receptacle under the final gearcase.

4. Remove:• final gear oil level check bolt• final gear oil drain bolt 1

5. Drain:• final gear oil

3

3 — 5

CHKADJCHANGING THE FINAL GEAR OIL

6. Install:• final gear oil drain bolt

NOTE:_

Check the gasket (drain bolt). If it is damaged,replace it with a new one.

7. Fill:• final gear case

CAUTION:_

Take care not to allow foreign material toenter the final gear case.

8. Check:• oil level

Refer to “CHECKING THE FINAL GEAROIL LEVEL”.

9. Install:• final gear oil level check bolt

• final gear oil filler bolt

Periodic oil change0.20 L (0.18 Imp qt, 0.21 US qt)

Total amount0.25 L (0.22 Imp qt, 0.26 US qt)

Recommended oilSAE80 API GL-4 Hypoid gear oil

T R..

23 Nm (2.3 m · kg, 17 ft · lb)

T R..

10 Nm (1.0 m · kg, 7.2 ft · lb)

T R..

23 Nm (2.3 m · kg, 17 ft · lb)

4

3 — 5

CHKADJ

CHECKING THE DIFFERENTIAL GEAR OIL LEVEL/CHANGING THE DIFFERENTIAL GEAR OIL

1

2

1

EBS00103

CHECKING THE DIFFERENTIAL GEAR OIL LEVEL1. Place the vehicle on a level surface.2. Remove:• differential gear oil filler bolt 1

3. Check:• oil level

Oil level should be up to the brim 2 of hole.Oil level low → Add oil to proper level.

CAUTION:_

Take care not allow foreign material toenter the differential gear case.

4. Install:• differential gear oil filler bolt

Recommended oilSAE80 API GL-4 Hypoid gear oil

T R..

23 Nm (2.3 m · kg, 17 ft · lb)

EBS00104

CHANGING THE DIFFERENTIAL GEAR OIL1. Place the vehicle on a level surface.2. Place a receptacle under the differential

gear case.

3. Remove:• differential gear oil filler bolt• differential gear oil drain bolt 1

4. Drain:• differential gear oil

5. Install:• differential gear oil drain bolt

T R..

10 Nm (1.0 m · kg, 7.2 ft · lb)

5

3 — 5

CHKADJ

CHANGING THE DIFFERENTIAL GEAR OIL/CHECKINGTHE CONSTANT VELOCITY JOINT DUST BOOTS

11

È

1 1

É

6. Fill:• differential gear case

NOTE:_

If gear oil is filled to the brim of the oil fillerhole, oil may start leaking from the differentialgear case breather hose. Therefore, check thequantity of the oil, not its level.

CAUTION:_

Take care not to allow foreign material toenter the differential gear case.

7. Install:• differential gear oil filler bolt

Periodic oil change0.215 L (0.19 Imp qt, 0.23 US qt)

Total amount0.23 L (0.20 Imp qt, 0.24 US qt)

Recommended oilSAE80 API GL-4 Hypoid gear oil

T R..

23 Nm (2.3 m · kg, 17 ft · lb)

EBS00105

CHECKING THE CONSTANT VELOCITY JOINT DUST BOOTS1. Check:• dust boots 1

Damage → Replace.Refer to “FRONT CONSTANT VELOCITYJOINTS AND DIFFERENTIAL GEAR” and“REAR CONSTANT VELOCITY JOINTSAND FINAL DRIVE GEAR” in chapter 7.

È FrontÉ Rear

6

3 — 5

CHKADJCHECKING THE STEERING SYSTEM

1

EBS00106

CHECKING THE STEERING SYSTEM1. Place the vehicle on a level surface.2. Check:• steering assembly bushings

Move the handlebar up and down, and/orback and forth.Excessive play → Replace the steeringstem bushings.

3. Check:• tie-rod ends

Turn the handlebar to the left and/or rightuntil it stops completely, then move the han-dlebar 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 vehicle so thatthere 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 frontarms (upper and lower) and/or wheel bear-ings.

6. Measure:• steering tension

Above specification → Adjust.

a. Turn the main switch to “OFF”.b. Place the vehicle on a suitable stand so that

the front wheels are elevated.c. Point the front wheels straight ahead.d. Hold the belt tension gauge 1 at a 90°

angle to the handlebar, push the gaugeagainst the handlebar, and then record themeasurement when the handlebar starts toturn.

Steering tension50 N (5.0 kgf)

7

3 — 5

CHKADJCHECKING THE STEERING SYSTEM

1

2

3

Belt tension gauge90890-03170

Rear drive belt tension gaugeYM-03170

7. Adjust:• steering tension

a. Remove the electrical components tray.Refer to “ELECTRICAL COMPONENTSTRAY”.

b. Loosen the steering stem bracket bolts 1,steering stem bearing bolts 2, and steeringstem joint bolts 3 completely.

NOTE:After loosening the bolts, be sure to check thatthe steering stem joint moves smoothly on theserrations of the steering stem and shaft of theEPS unit.

c. Tighten the steering stem bearing bolts tospecification.

d. Tighten the steering stem bracket bolts tospecification.

e. Tighten the steering stem joint bolts tospecification.

f. Measure the steering tension again.g. Repeat the above procedure until the steer-

ing tension is below specification.

T R..

Steering stem bearing bolt50 Nm (5.0 m · kg, 36 ft · lb)LOCTITE®

T R..

Steering stem bracket bolt50 Nm (5.0 m · kg, 36 ft · lb)LOCTITE®

T R..

Steering stem joint bolt30 Nm (3.0 m · kg, 22 ft · lb)LOCTITE®

8

3 — 5

CHKADJADJUSTING THE TOE-IN

EBS00108

ADJUSTING THE TOE-IN1. Place the vehicle on a level surface.2. Measure:• toe-in

Out of specification → Adjust.

NOTE:_

Before measuring the toe-in, make sure thatthe tire pressure is correct.

a. Mark both front tire tread centers.b. Face the handlebar straight ahead.c. Measure the width È between the marks.d. Rotate the front tires 180° until the marks

are exactly opposite one another.e. Measure the width É between the marks.f. Calculate the toe-in using the formula given

below.

g. If the toe-in is incorrect, adjust it.Ê Forward

3. Adjust:• toe-in

WARNING_

• Be sure that both tie-rods are turned thesame amount. If not, the vehicle will driftright or left even though the handlebar ispositioned straight. This may lead to mis-handling and an accident.

• After setting the toe-in to specification,run the vehicle slowly for some distancewith both hands lightly holding the han-dlebar and check that the handlebarresponds correctly. If not, turn either theright or left tie-rod within the toe-in speci-fication.

a. Mark both tie-rods ends.This reference point will be needed duringadjustment.

Toe-in0 ~ 10 mm (0 ~ 0.39 in)(with tires touching the ground)

Toe-in = É – È

9

3 — 6

CHKADJ

ADJUSTING THE TOE-IN/CHECKING THE FRONT ANDREAR SHOCK ABSORBERS

1 1

22

b. Loosen the locknuts (tie-rod end) 1 of bothtie-rods.

c. The same number of turns should be givento both the right and left tie-rods 2 until thespecified toe-in is obtained. This is to keepthe length of the rods the same.

d. Tighten the rod end locknuts of both tierods.

NOTE:_

Adjust the rod ends so that A and B are equal.

T R.

.

Locknut (rod end)15 Nm (1.5 m · kg, 11 ft · lb)

EBS00109

CHECKING THE FRONT AND REAR SHOCK ABSORBERS1. Place the vehicle on a level place.2. Check:• damper rod

Bends/damage → Replace the front/rearshock absorber assembly.Refer to “FRONT ARMS AND FRONTSHOCK ABSORBER ASSEMBLIES” and“REAR ARMS AND REAR SHOCKABSORBER ASSEMBLIES” in chapter 8.

• oil leakageExcessive oil leakage → Replace the front/rear shock absorber assembly.Refer to “FRONT ARMS AND FRONTSHOCK ABSORBER ASSEMBLIES” and“REAR ARMS AND REAR SHOCKABSORBER ASSEMBLIES” in chapter 8.

• springFatigue → Replace the front/rear shockabsorber assembly.Refer to “FRONT ARMS AND FRONTSHOCK ABSORBER ASSEMBLIES” and“REAR ARMS AND REAR SHOCKABSORBER ASSEMBLIES” in chapter 8.

0

3 — 6

CHKADJ

CHECKING THE FRONT AND REAR SHOCK ABSORBERS/ADJUSTING THE FRONT SHOCK ABSORBERS

È

É

1 2 3 4 5

ab

1

3. Check:• operation

Pump the shock absorbers up and down forseveral times.Unsmooth operation → Replace front/rearshock absorber.Refer to “FRONT ARMS AND FRONTSHOCK ABSORBER ASSEMBLIES” and“REAR ARMS AND REAR SHOCKABSORBER ASSEMBLIES” in chapter 8.

È Front shock absorberÉ Rear shock absorber

EBS00110

ADJUSTING THE FRONT SHOCK ABSORBERS

WARNING_

Always adjust the spring preload for bothfront shock absorber to the same setting.Uneven adjustment can cause poor han-dling and loss of stability.

1. Adjust:• spring preload

Turn the adjuster 1 in direction a or b.

Direction aSpring preload is increased (suspension is harder).

Direction bSpring preload is decreased (suspension is softer).

Standard position: 2Minimum position: 1Maximum position: 5

1

3 — 6

CHKADJ

ADJUSTING THE REAR SHOCK ABSORBERS/CHECKING THE TIRES

1 2 3 4 5 1

a

b

EBS00112

ADJUSTING THE REAR SHOCK ABSORBERS

WARNING_

Always adjust the spring load for both rearshock absorber spring preload to the samesetting. Uneven adjustment can cause poorhandling and loss of stability.

1. Adjust:• spring preload

Turn the adjuster 1 in direction a or b.

Direction aSpring preload is increased (suspension is harder).

Direction bSpring preload is decreased (suspension is softer).

Standard position: 2Minimum position: 1Maximum position: 5

EBS00115

CHECKING THE TIRES

WARNING_

This model is equipped with low pressuretires. It is important that they be inflatedcorrectly and maintained at the properpressures.• TIRE CHARACTERISTICS1) Tire characteristics influence the han-

dling of ATVs. The tires listed belowhave been approved by Yamaha MotorCo., Ltd. for this model. If other tire com-binations are used, they can adverselyaffect your vehicle’s handling character-istics and are therefore not recom-mended.

2

3 — 6

CHKADJCHECKING THE TIRES

• TIRE PRESSURE1) Recommended tire pressure

Front 35 kPa (0.35 kg/cm2, 5.0 psi)Rear 30 kPa (0.30 kg/cm2, 4.3 psi)

2) Tire pressure below the minimum speci-fication could cause the tire to dislodgefrom the rim under severe riding condi-tions.The following are minimums:Front 32 kPa (0.32 kg/cm2, 4.6 psi)Rear 27 kPa (0.27 kg/cm2, 3.9 psi)

3) Use no more thanFront 250 kPa (2.5 kg/cm2, 36 psi)Rear 250 kPa (2.5 kg/cm2, 36 psi)when seating the tire beads. Higherpressures may cause the tire to burst.Inflate the tires slowly and carefully.Fast inflation could cause the tire toburst.

• MAXIMUM LOADING LIMIT1) Vehicle load limits: 220 kg (485 lb)

*Total weight of the cargo, trailer hitchvertical load, rider, and accessories.

2) Front carrier: 45.0 kg (99 lb)3) Rear carrier: 85.0 kg (187 lb)4) Front storage box: 0.5 kg (1 lb)5) Rear storage box: 2.0 kg (4 lb)6) Trailer hitch:Pulling load (total weight of trailer andcargo): 5,390 N (550 kg, 1,212 lb)Tongue weight (vertical weight on trailerhitch point): 147 N (15 kg, 33 lb)Be extra careful of the vehicle balance andstability when towing a trailer.

Manufacturer Size Type

Front DUNLOPAT25 ×

8-12KT421

Rear DUNLOPAT25 × 10-12

KT425

3

3 — 6

CHKADJCHECKING THE TIRES

1. Measure:• tire pressure

Out of specification → Adjust.

NOTE:_

• The low-pressure tire gauge 1 is includedas standard equipment.

• If dust or the like is stuck to this gauge, it willnot provide the correct readings. Therefore,take two measurements of the tire’s pressureand use the second reading.

WARNING_

Uneven or improper tire pressure mayadversely affect the handling of this vehicleand 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.

WARNING_

It is dangerous to ride with a worn-out tire.When tire wear is out of specification,replace the tire immediately.

Cold tire pressure

Front Rear

Standard35 kPa

(0.35 kg/cm2, 5.0 psi)

30 kPa (0.30 kg/cm2,

4.3 psi)

Minimum32 kPa

(0.32 kg/cm2, 4.6 psi)

27 kPa (0.27 kg/cm2,

3.9 psi)

Maximum38 kPa

(0.38 kg/cm2, 5.5 psi)

33 kPa (0.33 kg/cm2,

4.8 psi)

Tire wear limit aFront and rear: 3 mm (0.12 in)

4

3 — 6

CHKADJ

CHECKING THE WHEELS/CHECKING AND LUBRICATING THE CABLES

EBS00116

CHECKING THE WHEELS1. Check:• wheel 1

Damage/bends → Replace.

NOTE:_

Always balance the wheel when a tire or wheelhas been changed or replaced.

WARNING_

• Never attempt even small repairs to thewheel.

• Ride conservatively after installing a tireto allow it to seat itself properly on therim.

EBS00117

CHECKING AND LUBRICATING THE CABLES

WARNING_

A damaged cable sheath may cause corro-sion and interfere with the cable move-ment. An unsafe condition may result, soreplace a damaged cable as soon as possi-ble.

1. Check:• cable sheath

Damage → Replace.2. Check:• cable operation

Unsmooth operation → Lubricate orreplace.

NOTE:_

Hold the cable end up and apply several dropsof lubricant to the cable.

3. Apply:• lithium-soap-based grease

(onto end of the cable)

Recommended lubricantYamaha chain and cable lube or engine oil

5

3 — 6

CHKADJLUBRICATING THE LEVERS AND PEDALS

EBS00118

LUBRICATING THE LEVERS AND PEDALSLubricate the pivoting point and metal-to-metalmoving parts of the levers and pedals.

Recommended lubricantLithium-soap-based grease

6

3 — 6

CHKADJCHECKING AND CHARGING THE BATTERY

EBS00120

ELECTRICAL SYSTEMCHECKING AND CHARGING THE BATTERY

WARNING_

Batteries generate explosive hydrogen gasand contain electrolyte which is made ofpoisonous and highly caustic sulfuric acid. Therefore, always follow these preventivemeasures:• Wear protective eye gear when handling

or working near batteries.• Charge batteries in a well-ventilated area.• Keep batteries away from fire, sparks or

open flames (e.g., welding equipment,lighted cigarettes).

• DO NOT SMOKE when charging or han-dling batteries.

• KEEP BATTERIES AND ELECTROLYTEOUT OF REACH OF CHILDREN.

• Avoid bodily contact with electrolyte as itcan cause severe burns or permanent eyeinjury.

FIRST AID IN CASE OF BODILY CONTACT:EXTERNAL• Skin — Wash with water.• Eyes — Flush with water for 15 minutes

and get immediate medical attention.INTERNAL• Drink large quantities of water or milk fol-

lowed with milk of magnesia, beaten eggor vegetable oil. Get immediate medicalattention.

CAUTION:_

• This is a sealed battery. Never remove thesealing caps because the balancebetween cells will not be maintained andbattery performance will deteriorate.

• Charging time, charging amperage andcharging voltage for an MF battery are dif-ferent from those of conventional batter-ies. The MF battery should be charged asexplained in the charging method illustra-tions. If the battery is overcharged, theelectrolyte level will drop considerably.Therefore, take special care when charg-ing the battery.

7

3 — 6

CHKADJ

1

2

CHECKING AND CHARGING THE BATTERY

NOTE:_

Since MF batteries are sealed, it is not possi-ble to check the charge state of the battery bymeasuring the specific gravity of the electro-lyte. Therefore, the charge of the battery has tobe checked by measuring the voltage at thebattery terminals.

1. Remove:• battery cover

Refer to “SEAT AND SIDE PANELS”.• front carrier• battery holding bracket

Refer to “FRONT CARRIER AND FRONTGUARD”.

2. Disconnect:• battery leads

(from the battery terminals)

CAUTION:_

First, disconnect the negative battery lead1, and then the positive battery lead 2.

3. Remove:• battery

4. Check:• battery charge

a. Connect a pocket tester to the battery termi-nals.

NOTE:_

• The charge state of an MF battery can bechecked by measuring its open-circuit volt-age (i.e., the voltage when the positive termi-nal is disconnected).

• No charging is necessary when the open-cir-cuit voltage equals or exceeds 12.8 V.

Positive tester probe →positive battery terminal

Negative tester probe →negative battery terminal

8

3 — 6

CHKADJCHECKING AND CHARGING THE BATTERY

Ope

n-ci

rcui

t vol

tage

(V

) Relationship between the open-circuit volt-age and the charging time at 20 °C (68 °F)

Charging time (hours)

These values vary with the temperature and thecondition of the battery plates.

Ope

n-ci

rcui

t vol

tage

(V

)

Charging Ambient temperature20 °C (68 °F)

Time (minutes)Check the open-circuit voltage.

Ope

n-ci

rcui

t vol

tage

(V

)

Ambienttemperature20 °C (68 °F)

Charging condition of the battery (%)

b. Check the charge of the battery, as shownin the charts and the following example.

Examplec. Open-circuit voltage = 12.0 Vd. Charging time = 6.5 hourse. Charge of the battery = 20 ~ 30%

5. Charge:• battery

(refer to the appropriate charging methodillustration)

WARNING_

Do not quick charge a battery.

CAUTION:_

• Never remove the MF battery sealingcaps.

• Do not use a high-rate battery chargersince it forces a high-amperage currentinto the battery quickly and can causebattery overheating and battery platedamage.

• If it is impossible to regulate the chargingcurrent on the battery charger, be carefulnot to overcharge the battery.

• When charging a battery, be sure toremove it from the vehicle. (If charginghas to be done with the battery mountedon the vehicle, disconnect the negativebattery lead from the battery terminal.)

• To reduce the chance of sparks, do notplug in the battery charger until the bat-tery charger leads are connected to thebattery.

• Before removing the battery charger leadclips from the battery terminals, be sureto turn off the battery charger.

• Make sure the battery charger lead clipsare in full contact with the battery termi-nal and that they are not shorted. A cor-roded battery charger lead clip maygenerate heat in the contact area and aweak clip spring may cause sparks.

9

3 — 7

CHKADJCHECKING AND CHARGING THE BATTERY

• If the battery becomes hot to the touch atany time during the charging process,disconnect the battery charger and let thebattery cool before reconnecting it. Hotbatteries can explode!

• As shown in the following illustration, theopen-circuit voltage of an MF battery sta-bilizes about 30 minutes after charginghas been completed. Therefore, wait 30minutes after charging is completedbefore measuring the open-circuit volt-age.

0

CHKADJCHECKING AND CHARGING THE BATTERY

Charging method using a variable-current (voltage) charger

Measure the open-circuitvoltage prior to charging.

Connect a charger andammeter to the battery andstart charging.

Is the amperage higherthan the standard chargingamperage written on thebattery?

Adjust the charging voltage to20 ~ 25 V.

Adjust the voltage to obtain thestandard charging amperage.

Monitor the amperage for3 ~ 5 minutes. Is the standardcharging amperage exceeded?

Set the timer to the chargingtime determined by the open-circuit voltage. Refer to “CHECKING ANDCHARGING THE BATTERY”.

If the amperage does notexceed the standard chargingamperage after 5 minutes,replace the battery.

If the required charging time exceeds 5 hours, it is advisable to check thecharging 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 itsopen-circuit voltage. 12.8 V → Charging is complete. 12.0 ~ 12.7 V → Recharging is required. Under 12.0 V → Replace the battery.

NOTE:Leave the battery unused formore than 30 minutes beforemeasuring its open-circuit voltage.

NOTE:Set the charging voltage to 16 ~17 V. (If the charging voltage islower, charging will be insufficient,if it is higher, the battery will beover-charged.)

NOYES

NO

YES

ChargerAmmeter

3 — 71

CHKADJCHECKING AND CHARGING THE BATTERY

Charging method using a constant voltage charger

Measure the open-circuitvoltage prior to charging.

NOTE:Set the charging time to a maxi-mum of 20 hours.

Connect a charger andammeter to the batteryand start charging.

Is the amperage higherthan the standard charg-ing amperage written onthe battery?

Charge the battery until the chargingvoltage reaches 15 V. This type of battery charger cannot

charge an MF battery. A variable-voltage charger is recommended.

Leave the battery unused for more than30 minutes before measuring its open-cir-cuit voltage. 12.8 V → Charging is complete. 12.0 ~ 12.7 V → Recharging is required. Under 12.0 V → Replace the battery.

Constant amperage chargers are notsuitable for charging MF batteries.

CAUTION:

NOTE:Leave the battery unused formore than 30 minutes beforemeasuring its open-circuit voltage.

Charger

AmmeterVoltmeter

NOYES

3 — 72

3 — 7

CHKADJ

CHECKING AND CHARGING THE BATTERY/CHECKING THE FUSES

2

1

6. Install:• battery

7. Connect:• battery leads

(to the battery terminals)

CAUTION:_

First, connect the positive battery lead 1,and then the negative battery lead 2.

8. Check:• battery terminals

Dirt → Clean with a wire brush.Loose connection → Connect properly.

9. Lubricate:• battery terminals

10.Install:• battery holding bracket• front carrier

Refer to “FRONT CARRIER AND FRONTGUARD”.

• battery coverRefer to “SEAT AND SIDE PANELS”.

Recommended lubricantDielectric grease

EBS00121

CHECKING THE FUSESThe following procedure applies to all of thefuses.

CAUTION:_

To avoid a short circuit, always set themain switch to “OFF” when checking orreplacing a fuse.

1. Remove:• battery cover

Refer to “SEAT AND SIDE PANELS”.

3

3 — 7

CHKADJCHECKING THE FUSES

2. Check:• fuse

a. Connect the pocket tester to the fuse andcheck the continuity.

NOTE:_

Set the pocket tester selector to “Ω × 1”.

b. If the pocket tester indicates “∞”, replacethe fuse.

3. Replace:• blown fuse

a. Set the main switch to “OFF”.b. Install a new fuse of the correct amperage.c. Set on the switches to verify if the electrical

circuit is operational.

Pocket tester90890-03112

Analog pocket testerYU-03112-C

4

3 — 7

CHKADJCHECKING THE FUSES

d. If the fuse immediately blows again, checkthe electrical circuit.

WARNING_

Never use a fuse with an amperage ratingother than that specified. Improvising orusing a fuse with the wrong amperage rat-ing may cause extensive damage to theelectrical system, cause the lighting andignition systems to malfunction and couldpossibly cause a fire.

4. Install:• battery cover

Refer to “SEAT AND SIDE PANELS”.

ItemsAmperage

ratingQ’ty

Main fuse 40 A 1

EPS fuse 40 A 1

Fuel injection system fuse

15 A 1

Ignition fuse 10 A 1

Headlight fuse 15 A 1

Four-wheel-drive motor fuse

10 A 1

Radiator fan motor fuse

15 A 1

Signaling sys-tem fuse

5 A 1

Auxiliary DC jack fuse

15 A 1

Spare fuse

40 A15 A10 A5 A

1211

5

3 — 7

CHKADJ

ADJUSTING THE HEADLIGHT BEAMS/REPLACING THE HEADLIGHT BULBS

a b

1

1

1

1

EBS00122

ADJUSTING THE HEADLIGHT BEAMS1. Adjust:• headlight beam (vertically)

a. Turn the adjusting screw 1 in direction aor b.

Direction a Headlight beam is raised.

Direction b Headlight beam is lowered.

EBS00124

REPLACING THE HEADLIGHT BULBS1. Remove:• cover at the rear of the headlight 1

2. Remove:• headlight bulb cover 1

3. Disconnect:• headlight coupler 1

6

3 — 7

CHKADJREPLACING THE HEADLIGHT BULBS

1

2

4. Remove:• headlight bulb holder 1• headlight bulb 2

NOTE:_

Unhook the headlight bulb holder, and thenremove the defective bulb.

WARNING_

Keep flammable products and your handsaway from the bulb while it is on, as it willbe hot. Do not touch the bulb until it coolsdown.

5. Install: • 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 trans-parency of the glass, life of the bulb, andluminous flux will be adversely affected. Ifoil gets on the bulb, thoroughly clean itwith a cloth moistened with alcohol or lac-quer thinner.

6. Install:• headlight bulb holder

7. Connect:• headlight coupler

8. Install:• headlight bulb cover• cover at the rear of the headlight

New

7

ENGENGINE REMOVAL

EBS00200

ENGINEENGINE REMOVALAIR DUCTS, MUFFLER AND EXHAUST PIPE

4

9

4

1

7

6

5

3

8

2

T R..

7 Nm (0.7 m • kg, 5.1 ft • Ib)

T R..

20 Nm (2.0 m • kg, 14 ft • Ib)

T R..

20 Nm (2.0 m • kg, 14 ft • Ib)

New

New

Order Job/Part Q’ty RemarksRemoving the air ducts, muffler and exhaust pipe

Remove the parts in the order listed.

Front fender/rear fender Refer to “ENGINE SKID PLATES, SEAT, CARRIERS AND FENDERS” in chapter 3.

Left footrest board Refer to “FOOTREST BOARDS” in chap-ter 3.

Air filter case Refer to “AIR FILTER CASE” in chapter 3.

Meter assembly Refer to “ELECTRICAL COMPONENTS TRAY” in chapter 3.

1 V-belt cooling duct 2 12 V-belt cooling duct 1 13 Exhaust pipe protector 14 Spring 25 Muffler 1

4 — 1

ENGENGINE REMOVAL

4

4

9

4

1

7

6

5

3

8

2

T R..

7 Nm (0.7 m • kg, 5.1 ft • Ib)

T R..

20 Nm (2.0 m • kg, 14 ft • Ib)

T R..

20 Nm (2.0 m • kg, 14 ft • Ib)

New

New

Order Job/Part Q’ty Remarks6 Gasket 17 Muffler bracket 18 Exhaust pipe 19 Gasket 2

For installation, reverse the removal pro-cedure.

4 — 2

ENGENGINE REMOVAL

EBS00202

SELECT LEVER UNIT

3

1

2

LS

T R..

7 Nm (0.7 m • kg, 5.1 ft • Ib)

T R..

15 Nm (1.5 m • kg, 11 ft • Ib)

T R..

15 Nm (1.5 m • kg, 11 ft • Ib)

T R..

7 Nm (0.7 m • kg, 5.1 ft • Ib)

T R..

14 Nm (1.4 m • kg, 10 ft • Ib)

Order Job/Part Q’ty RemarksRemoving the select lever unit Remove the parts in the order listed.

1 Select lever shift rod 1Refer to “INSTALLING THE SELECT LEVER UNIT”.

2 Select lever unit 13 Shift arm 1

For installation, reverse the removal pro-cedure.

4 — 3

ENGENGINE REMOVAL

EBS00204

LEADS, CABLES AND HOSES

7

8

25

61

410

3

9

Order Job/Part Q’ty RemarksRemoving the leads, cables and hoses

Remove the parts in the order listed.

Footrest board Refer to “FOOTREST BOARDS” in chap-ter 3.

Air filter case Refer to “AIR FILTER CASE” in chapter 3.

Throttle body assembly Refer to “THROTTLE BODY” in chapter 6.

Fuel tank/fuel tank shield Refer to “FUEL TANK” in chapter 6.Coolant reservoir Refer to “RADIATOR” in chapter 5.Thermostat Refer to “THERMOSTAT” in chapter 5.Water pump assembly Refer to “WATER PUMP” in chapter 5.Oil delivery pipe Refer to “CYLINDER HEAD”.Final gear case assembly Refer to “REAR CONSTANT VELOCITY

JOINTS AND FINAL DRIVE GEAR” in chapter 7.

4 — 4

ENGENGINE REMOVAL

7

8

25

61

410

3

9

Order Job/Part Q’ty RemarksStarter motor Refer to “STARTER MOTOR” in chapter

9.Drive belt case Refer to “PRIMARY AND SECONDARY

SHEAVES”.1 Cylinder head breather hose 12 Fast idle plunger inlet hose 13 Coolant temperature sensor coupler 1 Disconnect.4 Spark plug cap 15 Shift control cable 1 Disconnect.6 Reverse switch lead 1 Disconnect.7 Speed sensor coupler 1 Disconnect.8 Crankshaft position sensor coupler 1 Disconnect.9 AC magneto coupler 1 Disconnect.

10 Gear position switch coupler 1 Disconnect.For installation, reverse the removal pro-cedure.

4 — 5

ENGENGINE REMOVAL

EBS00205

ENGINE MOUNTING BOLTS

T R..

42 Nm (4.2 m • kg, 30 ft • Ib)

T R..

42 Nm (4.2 m • kg, 30 ft • Ib)

T R..

42 Nm (4.2 m • kg, 30 ft • Ib)

T R..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

T R..

10 Nm (1.0 m • kg, 7.2 ft • Ib)T R.

.

10 Nm (1.0 m • kg, 7.2 ft • Ib)

T R..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

LTLT

LT

LT

LT

4

9

7

7

9

8

8

1

5

32

3 2

6

6

Order Job/Part Q’ty RemarksRemoving the engine mounting bolts

Remove the parts in the order listed.

1 Rubber damper nut (front side) 2Refer to “INSTALLING THE ENGINE”.2 Engine mounting bolt (rear upper side) 2

3 Engine mounting bolt (rear lower side) 24 Engine 1

5 Rubber damper nut (rear side) 2

CAUTION:

Make sure that the engine does notstrike the brake pipe when removingit.

NOTE:_

Remove the engine from the left sideof the vehicle.

4 — 6

ENGENGINE REMOVAL

T R..

42 Nm (4.2 m • kg, 30 ft • Ib)

T R..

42 Nm (4.2 m • kg, 30 ft • Ib)

T R..

42 Nm (4.2 m • kg, 30 ft • Ib)

T R..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

T R..

10 Nm (1.0 m • kg, 7.2 ft • Ib)T R.

.

10 Nm (1.0 m • kg, 7.2 ft • Ib)

T R..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

LTLT

LT

LT

LT

4

9

7

7

9

8

8

1

5

32

3 2

6

6

Order Job/Part Q’ty Remarks6 Rubber damper (rear side) 2

Refer to “INSTALLING THE ENGINE”.7 Engine mounting bolt (front upper side) 28 Engine mounting bolt (front lower side) 29 Rubber damper (front side) 2

For installation, reverse the removal pro-cedure.

4 — 7

4 —

ENGENGINE REMOVAL

3

7

95

8

1

4

48

6

7

23

2

1

EBS00207

INSTALLING THE ENGINE1. Install:• rubber dampers (front side) 1• engine mounting bolts (front lower side) 2• engine mounting bolts (front upper side) 3• rubber dampers (rear side) 4• rubber damper nuts (rear side) 5• engine 6• engine mounting bolts (rear lower side) 7• engine mounting bolts (rear upper side) 8• rubber damper nuts (front side) 9

CAUTION:

Make sure that the engine does not strikethe brake pipe when installing it.

NOTE:_

Do not fully tighten the bolts and nuts.

2. Tighten:• engine mounting bolts (front lower side) 2

• engine mounting bolts (front upper side) 3

• engine mounting bolts (rear lower side) 7

• engine mounting bolts (rear upper side) 8

• rubber damper nuts (front side) 9

• rubber damper nuts (rear side) 5

T R..

42 Nm (4.2 m · kg, 30 ft · lb)

LT

T R..

10 Nm (1.0 m · kg, 7.2 ft · lb)

T R..

42 Nm (4.2 m · kg, 30 ft · lb)

LT

T R..

10 Nm (1.0 m · kg, 7.2 ft · lb)

T R..

42 Nm (4.2 m · kg, 30 ft · lb)

T R..

42 Nm (4.2 m · kg, 30 ft · lb)

8

4 —

ENG

2

1

3

a

N

N

ENGINE REMOVAL

INSTALLING THE SELECT LEVER UNIT1. Install:• shift arm 1• select lever unit 2

• select lever shift rod 3

NOTE:• Make sure that the select lever and transmis-

sion are in NEUTRAL.• The installed length a of the shift rod is

413 mm (16.3 in).

T R..

14 Nm (1.4 m · kg, 10 ft · lb)

T R..

7 Nm (0.7 m · kg, 5.1 ft · lb)

T R..

15 Nm (1.5 m · kg, 11 ft · lb)

9

ENGCYLINDER HEAD

EBS00218

CYLINDER HEAD

New

T R..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

T R..

6 Nm (0.6 m • kg, 4.3 ft • Ib)

T R..

20 Nm (2.0 m • kg, 14 ft • Ib)

T R..

38 Nm (3.8 m • kg, 27 ft • Ib)

New

New

T R..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

LS

LS

E

T R..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

LS

New

T R..

20 Nm (2.0 m • kg, 14 ft • Ib)

1312

LS

4

3

T R..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

T R..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

New

LS

T R..

20 Nm (2.0 m • kg, 14 ft • Ib)

T R..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

T R..

35 Nm (3.5 m • kg, 25 ft • Ib)

New

T R..

35 Nm (3.5 m • kg, 25 ft • Ib)

New

T R..

13 Nm (1.3 m • kg, 9.4 ft • Ib)

T R..

35 Nm (3.5 m • kg, 25 ft • Ib)

M

(4)5

1

2

New

6

16

15

1110

9

5

(4)7

14

8

NewE

Order Job/Part Q’ty RemarksRemoving the cylinder head Remove the parts in the order listed.Throttle body assembly Refer to “THROTTLE BODY” in chapter

6.Thermostat/coolant temperature sen-sor

Refer to “THERMOSTAT” in chapter 5.

Air ducts/exhaust pipe Refer to “ENGINE REMOVAL”.1 Spark plug cap 1 Disconnect.2 Spark plug 13 Cylinder head breather hose 14 Camshaft sprocket cover 15 Tappet cover 26 Fast idle plunger inlet hose 17 Oil delivery pipe 18 Oil gallery bolt 1

4 — 10

ENGCYLINDER HEAD

New

T R..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

T R..

6 Nm (0.6 m • kg, 4.3 ft • Ib)

T R..

20 Nm (2.0 m • kg, 14 ft • Ib)

T R..

38 Nm (3.8 m • kg, 27 ft • Ib)

New

New

T R..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

LS

LS

E

T R..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

LS

New

T R..

20 Nm (2.0 m • kg, 14 ft • Ib)

1312

LS

4

3

T R..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

T R..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

New

LS

T R..

20 Nm (2.0 m • kg, 14 ft • Ib)

T R..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

T R..

35 Nm (3.5 m • kg, 25 ft • Ib)

New

T R..

35 Nm (3.5 m • kg, 25 ft • Ib)

New

T R..

13 Nm (1.3 m • kg, 9.4 ft • Ib)

T R..

35 Nm (3.5 m • kg, 25 ft • Ib)

M

(4)5

1

2

New

6

16

15

1110

9

5

(4)7

14

8

NewE

Order Job/Part Q’ty Remarks9 Timing chain tensioner cap bolt 1

Refer to “REMOVING THE CYLINDER HEAD” and “INSTALLING THE CYLIN-DER HEAD”.

10 Timing chain tensioner 111 Gasket 112 Camshaft sprocket 113 Decompressor assembly 114 Cylinder head 115 Cylinder head gasket 116 Dowel pin 2

For installation, reverse the removal pro-cedure.

4 — 11

4 — 1

ENGCYLINDER HEAD

a

b

d

c

1

2

EBS00220

REMOVING THE CYLINDER HEAD1. Align:• “I” mark on the AC magneto rotor

(with the stationary pointer on the AC mag-neto cover)

a. Turn the crankshaft counterclockwise.b. When the piston is at the top dead center

(TDC) on the compression stroke, align the“I” mark a on the AC magneto rotor withthe stationary pointer b on the AC magnetocover.

NOTE:To position the piston at top dead center (TDC)on the compression stroke, align the “I” markc on the camshaft sprocket with the stationarypointer d on the cylinder head, as shown inthe illustration.

2. Loosen:• camshaft sprocket bolts 1• decompressor assembly bolts 2

NOTE:While holding the AC magneto rotor nut with awrench, loosen the camshaft sprocket boltsand decompressor assembly bolts.

3. Loosen:• timing chain tensioner cap bolt

4. Remove:• timing chain tensioner

(along with the gasket)• camshaft sprocket• timing chain

NOTE:_

To prevent the timing chain from falling into thecrankcase, fasten it with a wire.

2

4 — 1

ENGCYLINDER HEAD

6

85

72

1

4

3

5. Remove:• cylinder head

NOTE:_

• Loosen the bolts in the proper sequence asshown.

• Loosen each bolt 1/2 of a turn at a time. Afterall of the bolts are fully loosened, removethem.

EBS00224

CHECKING THE CAMSHAFT SPROCKET1. Check:• camshaft sprocket

Wear/damage → Replace the camshaftsprocket and timing chain as a set.

a 1/4 of a toothb Correct1 Roller2 Sprocket

EBS00227

CHECKING THE TAPPET COVERS1. Check:• tappet covers• camshaft sprocket cover

Cracks/damage → Replace.

EBS00229

CHECKING THE TIMING CHAIN TENSIONER1. Check:• timing chain tensioner

Cracks/damage → Replace.2. Check:• one-way cam operation

Rough movement → Replace the timingchain tensioner.

3. Check:• timing chain tensioner cap bolt• spring• one-way cam• timing chain tensioner rod

Damage/wear → Replace the defectivepart(s).

3

4 — 1

ENGCYLINDER HEAD

1

2

EBS00230

CHECKING THE CYLINDER HEAD1. Eliminate:• combustion chamber carbon deposits

(with a rounded scraper)

NOTE:_

Do not use a sharp instrument to avoid damag-ing or scratching:• spark plug bore threads• valve seats

2. Check:• cylinder head

Damage/scratches → Replace.• cylinder head water jacket

Mineral deposits/rust → Eliminate.

3. Measure:• cylinder head warpage

Out of specification → Resurface the cylin-der head.

a. Place a straightedge 1 and a thicknessgauge 2 across the cylinder head.

b. Measure the warpage.c. If the limit is exceeded, resurface the cylin-

der head as follows.d. Place a 400 ~ 600 grit wet sandpaper on

the surface plate and resurface the cylinderhead using a figure-eight sanding pattern.

NOTE:_

To ensure an even surface, rotate the cylinderhead several times.

Maximum cylinder head warpage0.03 mm (0.0012 in)

4

4 — 1

ENGCYLINDER HEAD

3

14

27

8

5

6

4

2

3

43

1

a

b

d

c

2

4

4

3

1

EBS00232

INSTALLING THE CYLINDER HEAD1. Install:• dowel pins• cylinder head gasket

2. Install:• cylinder head• cylinder head bolts

NOTE:_

• Lubricate the cylinder head bolt 1 and 2threads and mating surface with molybde-num disulfide grease.

• Lubricate the cylinder head bolts 3 threadsand mating surface with engine oil.

3. Tighten:• cylinder head bolts 1: = 135 mm (5.31 in)

• cylinder head bolts 2: = 145 mm (5.71 in)

• cylinder head bolts 3

• cylinder head bolts 4

NOTE:_

Tighten the cylinder head bolts in the propertightening sequence as shown and torquethem in two stages.

New

T R..

35 Nm (3.5 m · kg, 25 ft · lb)

T R..

35 Nm (3.5 m · kg, 25 ft · lb)

T R..

38 Nm (3.8 m · kg, 27 ft · lb)

T R..

10 Nm (1.0 m · kg, 7.2 ft · lb)

4. Install:• decompressor assembly• camshaft sprocket

(onto the camshaft)

a. Install the decompressor assembly onto thecamshaft, and then finger tighten thedecompressor assembly bolts 1.

b. Turn the crankshaft counterclockwise.c. Align the “I” mark a on the AC magneto

rotor with the stationary pointer b on theAC magneto cover.

d. Install the timing chain 2 onto the camshaftsprocket 3, then the camshaft sprocketonto the camshaft, and then finger tightenthe camshaft sprocket bolts 4.

e. Make sure the “I” mark c on the camshaftsprocket with the stationary pointer d onthe cylinder head.

5

4 — 1

ENGCYLINDER HEAD

New

New6

32

1

4

5

NOTE:_

When installing the camshaft sprocket, keepthe timing chain as tense as possible on theexhaust side.

CAUTION:_

Do not turn the crankshaft when installingthe camshaft to avoid damage or impropervalve timing.

f. Remove the wire from the timing chain.

5. Install:• timing chain tensioner

a. Remove the timing chain tensioner cap bolt1, copper washer 2 and spring 3.

b. Release the timing chain tensioner one-waycam 4 and push the timing chain tensionerrod 5 all the way into the timing chain ten-sioner housing.

c. Install the timing chain tensioner and gasket6 onto the cylinder.

NOTE:Install the gasket with its beaded side facingthe timing chain tensioner end.

d. Install the spring and timing chain tensionercap bolt.

6. Turn:• crankshaft

(several turns counterclockwise)

T R..

Timing chain tensioner bolt10 Nm (1.0 m · kg, 7.2 ft · lb)

T R..

Timing chain tensioner cap bolt20 Nm (2.0 m · kg, 14 ft · lb)

6

4 — 1

ENGCYLINDER HEAD

a

b

d

c

1

2

7. Check:• “I” mark a

NOTE:Check that the “I” mark on the AC magnetorotor is aligned with the stationary pointer bon the AC magneto cover.

• “I” mark c

NOTE:Check that the “I” mark on the camshaftsprocket is aligned with the stationary pointerd on the cylinder head.

Out of alignment → Correct.Repeat steps (4) to (7), if necessary.

8. Tighten:• camshaft sprocket bolts 1

• decompressor assembly bolts 2

NOTE:• While holding the AC magneto rotor nut with

a wrench, tighten the camshaft sprocketbolts and decompressor assembly bolts.

• After tightening the decompressor assemblybolts, check that decompressor assemblymoves smoothly.

CAUTION:_

Be sure to tighten the camshaft sprocketbolts to the specified torque to avoid thepossibility of the bolts coming loose anddamaging the engine.

9. Measure:• valve clearance

Out of specification → Adjust.Refer to “ADJUSTING THE VALVECLEARANCE” in chapter 3.

T R..

20 Nm (2.0 m · kg, 14 ft · lb)

T R..

20 Nm (2.0 m · kg, 14 ft · lb)

7

ENGROCKER ARMS AND CAMSHAFT

EBS00235

ROCKER ARMS AND CAMSHAFT

E

E

E LT

1

79

82

E

10

4

2

3

5

5 5

5

E

E

6

6

66

E

T R..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

T R..

14 Nm (1.4 m • kg, 10 ft • Ib)

T R..

14 Nm (1.4 m • kg, 10 ft • Ib)

Order Job/Part Q’ty RemarksRemoving the rocker arms and cam-shaft

Remove the parts in the order listed.

Cylinder head Refer to “CYLINDER HEAD”.1 Bearing retainer 1

Refer to “REMOVING THE ROCKER ARMS AND CAMSHAFT” and “INSTALLING THE CAMSHAFT AND ROCKER ARMS”.

2 Rocker arm shaft 23 Intake rocker arm 14 Exhaust rocker arm 15 Locknut 46 Valve adjusting screw 47 Camshaft 1

8 Decompressor lever 1

CAUTION:

Do not disassemble the camshaftassembly.

4 — 18

ENGROCKER ARMS AND CAMSHAFT

E

E

E LT

1

79

82

E

10

4

2

3

5

5 5

5

E

E

6

6

66

E

T R..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

T R..

14 Nm (1.4 m • kg, 10 ft • Ib)

T R..

14 Nm (1.4 m • kg, 10 ft • Ib)

Order Job/Part Q’ty Remarks9 Decompressor lever pin 1 Refer to “REMOVING THE ROCKER

ARMS AND CAMSHAFT” and “INSTALLING THE CAMSHAFT AND ROCKER ARMS”.

10 Bearing 1

For installation, reverse the removal pro-cedure.

4 — 19

4 — 2

ENGROCKER ARMS AND CAMSHAFT

12

EBS00237

REMOVING THE ROCKER ARMS AND CAMSHAFT1. Loosen:• locknuts• valve adjusting screws

2. Remove:• intake rocker arm shaft• exhaust rocker arm shaft• intake rocker arm• exhaust rocker arm

NOTE:_

Remove the rocker arm shafts with the slidehammer bolt 1 and weight 2.

EBS00223

CHECKING THE CAMSHAFT1. Check:• cam lobes

Pitting/scratches/blue discoloration → Replace.

2. Measure:• cam lobe dimensions a and b

Out of specification → Replace.

Slide hammer bolt90890-01083

Slide hammer bolt 6 mmYU-01083-1

Weight90890-01084, YU-01083-3

Camshaft lobe dimensionsIntakea 43.488 ~ 43.588 mm

(1.7121 ~ 1.7161 in)<Limit>:

43.388 mm (1.7082 in)b 36.959 ~ 37.059 mm

(1.4551 ~ 1.4590 in)<Limit>:

36.859 mm (1.4511 in)Exhausta 43.129 ~ 43.229 mm

(1.6980 ~ 1.7019 in)<Limit>:

43.029 mm (1.6941 in)b 37.007 ~ 37.107 mm

(1.4570 ~ 1.4609 in)<Limit>:

36.907 mm (1.4530 in)

0

4 — 2

ENGROCKER ARMS AND CAMSHAFT

2

1

3. Measure:• camshaft runout

Out of specification → Replace.

Camshaft runout limit0.015 mm (0.0006 in)

EBS00225

CHECKING THE DECOMPRESSION SYSTEM1. Check:• decompression system

a. Check the decompression system with thecamshaft sprocket installed on the decom-pressor lever and pin installed in the cam-shaft.

b. Check that the decompressor lever pin 1projects from the camshaft.

c. Check that the decompressor cam 2

moves smoothly.

EBS00239

CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTSThe following procedure applies to both of therocker arms and rocker arm shafts.1. Check:• rocker arm

Damage/wear → Replace.2. Check:• rocker arm shaft

Blue discoloration/excessive wear/pitting/scratches → Replace or check the lubrica-tion system.

3. Measure:• rocker arm inside diameter

Out of specification → Replace.

Rocker arm inside diameter12.000 ~ 12.018 mm (0.4724 ~ 0.4731 in)

1

4 — 2

ENGROCKER ARMS AND CAMSHAFT

1

a b

4. Measure:• rocker arm shaft outside diameter

Out of specification → Replace.

5. Calculate:• rocker-arm-to-rocker-arm-shaft clearance

NOTE:_

Calculate the clearance by subtracting therocker arm shaft outside diameter from therocker arm inside diameter.

Out of specification → Replace the defectivepart(s).

Rocker arm shaft outside diame-ter

11.981 ~ 11.991 mm (0.4717 ~ 0.4721 in)

Rocker-arm-to-rocker-arm-shaft clearance

0.009 ~ 0.037 mm (0.0004 ~ 0.0015 in)

EAS00243

INSTALLING THE CAMSHAFT AND ROCKER ARMS1. Install:• bearing 1

(onto the cylinder head)

NOTE:• Apply engine oil to the bearing.• Install the bearing so that the seal is facinga the camshaft.

Installed depth b0 mm (0 in)

2

4 — 2

ENGROCKER ARMS AND CAMSHAFT

3

1

2

1

a

2. Lubricate:• camshaft• decompressor lever pin• decompressor lever

Recommended lubricantEngine oil

3. Install:• decompressor lever pin 1• decompressor lever 2

NOTE:_

Install the decompressor lever pin 1 anddecompressor lever 2 in the camshaft 3 asshown in the illustration.

4. Install:• camshaft 1

NOTE:Install the camshaft so that its projection abecomes horizontal.

5. Lubricate:• rocker arm shafts

Recommended lubricantEngine oil

3

4 — 2

ENGROCKER ARMS AND CAMSHAFT

3

2

1

6. Install:• exhaust rocker arm 1• exhaust rocker arm shaft 2• intake rocker arm• intake rocker arm shaft

NOTE:_

• Use a slide hammer bolt 3 to install therocker arm shaft.

• Make sure the rocker arm shafts (intake andexhaust) are completely pushed into the cyl-inder head.

Slide hammer bolt90890-01083

Slide hammer bolt 6 mmYU-01083-1

4

ENGVALVES AND VALVE SPRINGS

EBS00234

VALVES AND VALVE SPRINGS

M

M

M

M

MNew

NewNew

New7

6

5

5 4

4

3

2

1

6

77

6

3

2

3

21

2

3

6

7

8

8

Order Job/Part Q’ty RemarksRemoving the valves and valve springs

Remove the parts in the order listed.

Cylinder head Refer to “CYLINDER HEAD”. Rocker arms/rocker arm shafts/cam-shaft

Refer to “ROCKER ARMS AND CAM-SHAFT”.

1 Valve cotter 8

Refer to “REMOVING THE VALVES AND VALVE SPRINGS” and “INSTALL-ING THE VALVES AND VALVE SPRINGS”.

2 Valve spring retainer 43 Valve spring 44 Exhaust valve 25 Intake valve 26 Valve stem seal 47 Valve spring seat 48 Valve guide 4 Refer to “CHECKING THE VALVES AND

VALVE SPRINGS”.For installation, reverse the removal pro-cedure.

4 — 25

4 — 2

ENGVALVES AND VALVE SPRINGS

EBS00238

REMOVING THE VALVES AND VALVE SPRINGSThe following procedure applies to all of thevalves and related components.

NOTE:_

Before removing the internal parts of the cylin-der head (e.g., valves, valve springs, valveseats), make sure the valves properly seal.

1. Check:• valve sealing

Leakage at the valve seat → Check thevalve face, valve seat, and valve seat width. Refer to “CHECKING THE VALVES ANDVALVE SPRINGS”.

a. Pour a clean solvent a into the intake andexhaust ports.

b. Check that the valve seals properly.There should be no leakage at the valveseat 1.

2. Remove:• valve cotters

NOTE:_

Attach a valve spring compressor 1 andattachment 2 between the valve springretainer and the cylinder head to remove thevalve cotters.

Valve spring compressor 90890-04019, YM-04019

Valve spring compressor attach-ment

90890-01243Valve spring compressor adapter (26 mm)

YM-01253-1

6

4 — 2

ENGVALVES AND VALVE SPRINGS

3. Remove: • valve spring retainer 1 • valve spring 2 • valve 3• valve stem seal 4 • valve spring seat 5

NOTE:_

Identify the position of each part very carefullyso that it can be reinstalled in its original place.

EBS00240

CHECKING THE VALVES AND VALVE SPRINGSThe following procedure applies to all of thevalves and valve guides. 1. Measure:• valve-stem-to-valve-guide clearance

Out of specification → Replace the valveguide.

Stem-to-guide clearance =valve guide inside diameter a -valve stem diameter b

Stem-to-guide clearanceIntake

0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in)<Limit>: 0.08 mm (0.0031 in)

Exhaust0.025 ~ 0.052 mm (0.0010 ~ 0.0020 in)<Limit>: 0.10 mm (0.0039 in)

7

4 — 2

ENGVALVES AND VALVE SPRINGS

2. Replace:• valve guide

NOTE:_

To ease valve guide removal and installation,and to maintain the correct fit, heat the cylinderhead to 100 °C (212 °F) in an oven.

a. Remove the valve guide using a valve guideremover 1.

b. Install the new valve guide using a valveguide remover 1 and valve guide installer2.

c. After installing the valve guide, bore thevalve guide using a valve guide reamer 3to obtain proper stem-to-guide clearance.

NOTE:_

After replacing the valve guide, reface thevalve seat.

3. Check:• valve face

Pitting/wear → Grind the face.• valve stem end

Mushroom shape or diameter larger thanthe body of the valve stem → Replace.

Valve guide position a12.7 ~ 13.1 mm (0.50 ~ 0.52 in)

Valve guide remover (ø6) 90890-04064

Valve guide remover (6.0 mm)YM-04064-A

Valve guide installer (ø6) 90890-04065

Valve guide installer (6.0 mm)YM-04065-A

Valve guide reamer (ø6) 90890-04066

Valve guide reamer (6.0 mm)YM-04066

8

4 — 2

ENGVALVES AND VALVE SPRINGS

4. Measure:• margin thickness a

Out of specification → Replace.

Margin thickness0.80 ~ 1.20 mm (0.0315 ~ 0.0472 in)

5. Measure:• valve stem runout

Out of specification → Replace.

NOTE:_

• When installing a new valve, always replacethe valve guide.

• If the valve is removed or replaced, alwaysreplace the valve stem seal.

6. Eliminate:• carbon deposits

(from the valve face and valve seat)7. Check:• valve seats

Pitting/wear → Reface the valve seat.

Runout limit0.040 mm (0.0016 in)

8. Measure:• valve seat width a

Out of specification → Reface the valveseat.

a. Apply Mechanic’s blueing dye (Dykem) b tothe valve face.

b. Install the valve into the cylinder head.c. Press the valve through the valve guide and

onto the valve seat to make a clear pattern. d. Measure the valve seat width. Where the

valve seat and valve face made contact,blueing will have been removed.

Valve seat width1.00 ~ 1.20 mm (0.0394 ~ 0.0472 in)<Limit>: 1.60 mm (0.0630 in)

9

4 — 3

ENGVALVES AND VALVE SPRINGS

e. If the valve seat is too wide, too narrow, orthe seat is not centered, the valve seat mustbe refaced.

9. Lap:• valve face• valve seat

NOTE:_

After refacing the valve seat or replacing thevalve and valve guide, the valve seat andvalve face should be lapped.

a. Apply a coarse lapping compound to thevalve face.

CAUTION:_

Do not let the compound enter the gapbetween the valve stem and the valveguide.

b. Apply molybdenum disulfide oil to the valvestem.

c. Install the valve into the cylinder head.

d. Turn the valve until the valve face and valveseat are evenly polished, then clean off allof the compound.

NOTE:_

For best lapping results, lightly tap the valveseat while rotating the valve back and forthbetween your hands.

e. Apply a fine lapping compound to the valveface and repeat the above steps.

NOTE:_

After every lapping operation be sure to cleanoff all of the compound from the valve face andvalve seat.

f. Apply Mechanic’s blueing dye (Dykem) tothe valve face.

g. Install the valve into the cylinder head.

0

4 — 3

ENGVALVES AND VALVE SPRINGS

h. Press the valve through the valve guide andonto the valve seat to make a clear pattern.

i. Measure the valve seat width again. If thevalve seat width is out of specification,reface and relap the valve seat.

10.Measure:• valve spring free length a

Out of specification → Replace.

Valve spring free length38.79 mm (1.53 in)<Limit>: 36.85 mm (1.45 in)

11.Measure:• compressed spring force a

Out of specification → Replace.b Installed length

Compressed spring force169.0 ~ 199.0 N at 35.00 mm(17.23 ~ 20.29 kg at 35.00 mm,37.99 ~ 44.73 lb at 1.38 in)

12.Measure:• spring tilt a

Out of specification → Replace.

Spring tilt limit2.5°/1.70 mm (0.067 in)

EBS00241

INSTALLING THE VALVES AND VALVE SPRINGSThe following procedure applies to all of thevalves and related components.1. Deburr: • valve stem end

(with an oil stone)

1

4 — 3

ENGVALVES AND VALVE SPRINGS

2. Lubricate: • valve stem 1

(with the recommended lubricant)

Recommended lubricant Molybdenum disulfide oil

3. Install:• valve spring seats 1• valve stem seals 2• valves 3• valve springs 4• valve spring retainers 5

NOTE:_

Install the valve springs with the larger pitch afacing upwards.

b Smaller pitch

4. Install:• valve cotters

NOTE:_

Install the valve cotters while compressing thevalve spring with the valve spring compressor1 and attachment 2.

Valve spring compressor 90890-04019, YM-04019

Valve spring compressor attach-ment

90890-01243Valve spring compressor adapter (26 mm)

YM-01253-1

2

4 — 3

ENGVALVES AND VALVE SPRINGS

5. To secure the valve cotters onto the valvestem, lightly tap the valve tip with a piece ofwood.

CAUTION:_

Hitting the valve tip with excessive forcecould damage the valve.

3

ENGCYLINDER AND PISTON

EBS00245

CYLINDER AND PISTON

T R..

1st 15 Nm (1.5 m • kg, 11 ft • lb)2nd 50 Nm (5.0m • kg, 36 ft • lb)

T R..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

E

E

E

E

E

1

2

7

3

4

4

5

6

5

109

8

New

New

New

Order Job/Part Q’ty RemarksRemoving the cylinder and piston Remove the parts in the order listed.Cylinder head Refer to “CYLINDER HEAD”.Water jacket joint Refer to “WATER PUMP” in chapter 5.

1 Timing chain guide (exhaust side) 12 Cylinder 1

Refer to “INSTALLING THE PISTON AND CYLINDER”.

3 Cylinder gasket 14 Dowel pin 25 Piston pin clip 2

Refer to “REMOVING THE PISTON” and “INSTALLING THE PISTON AND CYLINDER”.

6 Piston pin 17 Piston 18 Top ring 19 2nd ring 1

10 Oil ring 1For installation, reverse the removal pro-cedure.

4 — 34

4 — 3

ENGCYLINDER AND PISTON

12

3

EBS00247

REMOVING THE PISTON1. Remove:• piston pin clips 1• piston pin 2• piston 3

NOTE:_

• Before removing the piston pin clips, coverthe crankcase opening with a clean rag toprevent the piston pin clips from falling intothe crankcase.

• Before removing the piston pin, deburr thepiston pin clip grooves and the piston pinbore area. If both areas are deburred and thepiston pin is still difficult to remove, remove itwith the piston pin puller set 4.

CAUTION:_

Do not use a hammer to drive the pistonpin out.

Piston pin puller set90890-01304

Piston pin pullerYU-01304

2. Remove:• piston rings

NOTE:_

Spread the end gaps apart while at the sametime lifting the piston ring over the top of thepiston crown, as shown in the illustration.

EBS00249

CHECKING THE CYLINDER AND PISTON1. Check:• piston wall• cylinder wall

Vertical scratches → Rebore or replace thecylinder, and replace the piston and pistonrings as a set.

5

4 — 3

ENGCYLINDER AND PISTON

2. Measure: • piston-to-cylinder clearance

a. Measure the cylinder bore “C” with a cylin-der bore gauge.

NOTE:_

Measure the cylinder bore “C” in parallel to andat right angles to the crankshaft. Then, find theaverage of the measurements.

b. If out of specification, replace the cylinder,and the piston and piston rings as a set.

c. Measure piston skirt diameter “P” with themicrometer.

a 10 mm (0.39 in) from the bottom edge of the pis-ton

d. If out of specification, replace the piston andpiston rings as a set.

e. Calculate the piston-to-cylinder clearancewith the following formula.

Cylinder bore “C”

102.000 ~ 102.010 mm(4.0157 ~ 4.0161 in)

Taper limit “T” 0.05 mm (0.002 in)

Out of round “R” 0.05 mm (0.002 in)

“C” = Maximum D

“T” = (Maximum D1 or D2) – (Maximum D5 or D6)

“R” = (Maximum D1, D3 or D5) – (Minimum D2, D4 or D6)

Piston size “P”

Standard 101.955 ~ 101.970 mm(4.0140 ~ 4.0146 in)

Piston-to-cylinder clearance = Cylinder bore “C” –Piston skirt diameter “P”

Piston-to-cylinder clearance 0.030 ~ 0.055 mm (0.0012 ~ 0.0022 in)<Limit>: 0.13 mm (0.051 in)

6

4 — 3

ENGCYLINDER AND PISTON

f. If out of specification, replace the cylinder,and the piston and piston rings as a set.

EBS00250

CHECKING THE PISTON RINGS1. Measure:• piston ring side clearance

Out of specification → Replace the pistonand piston rings as a set.

NOTE:_

Before measuring the piston ring side clear-ance, eliminate any carbon deposits from thepiston ring grooves and piston rings.

Piston ring side clearance Top ring

0.030 ~ 0.070 mm (0.0012 ~ 0.0028 in) <Limit>: 0.12 mm (0.0047 in)

2nd ring 0.030 ~ 0.070 mm (0.0012 ~ 0.0028 in) <Limit>: 0.13 mm (0.0051 in)

2. Install:• piston ring

(into the cylinder)

NOTE:_

Level the piston ring into the cylinder with thepiston crown.

a 50 mm (1.97 in)

3. Measure:• piston ring end gap

Out of specification → Replace the pistonring.

NOTE:_

The oil ring expander spacer’s end gap cannotbe measured. If the oil ring rail’s gap is exces-sive, replace all three piston rings.

7

4 — 3

ENGCYLINDER AND PISTON

Piston ring end gap Top ring

0.20 ~ 0.35 mm (0.008 ~ 0.014 in) <Limit>: 0.60 mm (0.024 in)

2nd ring 0.75 ~ 0.90 mm (0.030 ~ 0.035 in) <Limit>: 1.25 mm (0.049 in)

Oil ring 0.20 ~ 0.70 mm (0.008 ~ 0.028 in)

EBS00251

CHECKING THE PISTON PIN1. Check:• piston pin

Blue discoloration/grooves → Replace thepiston pin and then check the lubricationsystem.

2. Measure:• piston pin outside diameter a

Out of specification → Replace the pistonpin.

Piston pin outside diameter 22.991 ~ 23.000 mm (0.9052 ~ 0.9055 in)<Limit>: 22.971 mm (0.9044 in)

3. Measure:• piston pin bore inside diameter b

Out of specification → Replace the piston.

Piston pin bore inside diameter 23.004 ~ 23.015 mm (0.9057 ~ 0.9061 in)<Limit>: 23.045 mm (0.9073 in)

8

4 — 3

ENGCYLINDER AND PISTON

4. Calculate:• piston-pin-to-piston-pin-bore clearance

Out of specification → Replace the pistonpin and piston as a set.

Piston-pin-to-piston-pin-bore clearance =Piston pin bore diameter b –Piston pin outside diameter a

Piston-pin-to-piston clearance0.004 ~ 0.024 mm (0.0002 ~ 0.0009 in)<Limit>: 0.074 mm (0.0029 in)

EBS00252

INSTALLING THE PISTON AND CYLINDER1. Install: • top ring 1 • 2nd ring 2 • oil ring expander 3• lower oil ring rail 4 • upper oil ring rail 5

NOTE:_

Be sure to install the piston rings so that themanufacturer’s marks or numbers face up.

9

4 — 4

ENGCYLINDER AND PISTON

2

3

1

a

New

e a

b

d c

120˚

120˚ 120˚

45˚ 45˚

90˚

È

1

2. Install: • piston 1 • piston pin 2 • piston pin clips 3

NOTE:_

• Apply engine oil to the piston pin. • Make sure the punch mark a on the piston

points towards the exhaust side of the cylin-der.

• Before installing the piston pin clips, coverthe crankcase opening with a clean rag toprevent the clips from falling into the crank-case.

3. Install: • cylinder gasket• dowel pins

4. Lubricate: • piston • piston rings • cylinder

(with the recommended lubricant)

Recommended lubricant Engine oil

New

New

5. Offset: • piston ring end gaps

a Top ring b Oil ring expanderc Upper oil ring rail d Lower oil ring rail e 2nd ringÈ Exhaust side

6. Install: • cylinder 1• timing chain guide (exhaust side)

NOTE:_

• While compressing the piston rings with onehand, install the cylinder with the other hand.

• Pass the timing chain and timing chain guide(exhaust side) through the timing chain cav-ity.

0

4 — 4

ENGCYLINDER AND PISTON

1 1

2

2

E E

7. Install:• cylinder bolts

NOTE:Lubricate the cylinder bolt 1 threads and mat-ing surface with engine oil.

8. Tighten:• cylinder bolts 1 (1st)

• cylinder bolts 1 (2nd)

• cylinder bolts (timing chain side) 2

T R..

15 Nm (1.5 m · kg, 11 ft · lb)

T R..

50 Nm (5.0 m · kg, 36 ft · lb)T R.

.

10 Nm (1.0 m · kg, 7.2 ft · lb)

1

ENGAC MAGNETO

EBS00256

AC MAGNETO

LTLT

LT

6

61

2

LT

New4

5

LSLT

16

12

11

14

13

17

E

E

E

10

15

E

New

9

78

3

(10)

T R..

7 Nm (0.7 m • kg, 5.1 ft • Ib)

T R..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

T R..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

T R..

6 Nm (0.6 m • kg, 4.3 ft • Ib)

T R..

30 Nm (3.0 m • kg, 22 ft • Ib)

LTLT

E

T R..

70 Nm (7.0 m • kg, 50 ft • lb)

T R..

7 Nm (0.7 m • kg, 5.1 ft • Ib)

T R..

7 Nm (0.7 m • kg, 5.1 ft • Ib)

LT

LT

Order Job/Part Q’ty RemarksRemoving the AC magneto Remove the parts in the order listed.Engine oil Drain.

Refer to “CHANGING THE ENGINE OIL” in chapter 3.

Coolant Drain.Refer to “CHANGING THE COOLANT” in chapter 3.

Left footrest board Refer to “FOOTREST BOARDS” in chap-ter 3.

Select lever unit Refer to “SELECT LEVER UNIT”.Water pump Refer to “WATER PUMP” in chapter 5.

1 AC magneto coupler 1 Disconnect.2 Crankshaft position sensor coupler 1 Disconnect.3 Lead holder 1 Refer to “REMOVING THE AC MAG-

NETO ROTOR” and “INSTALLING THE AC MAGNETO ROTOR”.

4 AC magneto cover 1

4 — 42

ENGAC MAGNETO

LTLT

LT

6

61

2

LT

New4

5

LSLT

16

12

11

14

13

17

E

E

E

10

15

E

New

9

78

3

(10)

T R..

7 Nm (0.7 m • kg, 5.1 ft • Ib)

T R..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

T R..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

T R..

6 Nm (0.6 m • kg, 4.3 ft • Ib)

T R..

30 Nm (3.0 m • kg, 22 ft • Ib)

LTLT

E

T R..

70 Nm (7.0 m • kg, 50 ft • lb)

T R..

7 Nm (0.7 m • kg, 5.1 ft • Ib)

T R..

7 Nm (0.7 m • kg, 5.1 ft • Ib)

LT

LT

Order Job/Part Q’ty Remarks5 AC magneto cover gasket 16 Dowel pin 27 Lead holder 18 Crankshaft position sensor 19 Stator coil 1

10 Torque limiter 111 Starter idle gear 112 Starter idle gear shaft 113 AC magneto rotor 1 Refer to “REMOVING THE AC MAG-

NETO ROTOR” and “INSTALLING THE AC MAGNETO ROTOR”.

14 Starter clutch 115 Woodruff key 116 Starter wheel gear 1

4 — 43

ENGAC MAGNETO

LTLT

LT

6

61

2

LT

New4

5

LSLT

16

12

11

14

13

17

E

E

E

10

15

E

New

9

78

3

(10)

T R..

7 Nm (0.7 m • kg, 5.1 ft • Ib)

T R..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

T R..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

T R..

6 Nm (0.6 m • kg, 4.3 ft • Ib)

T R..

30 Nm (3.0 m • kg, 22 ft • Ib)

LTLT

E

T R..

70 Nm (7.0 m • kg, 50 ft • lb)

T R..

7 Nm (0.7 m • kg, 5.1 ft • Ib)

T R..

7 Nm (0.7 m • kg, 5.1 ft • Ib)

LT

LT

Order Job/Part Q’ty Remarks17 Washer 1

For installation, reverse the removal pro-cedure.

4 — 44

4 — 4

ENGAC MAGNETO

1

3

2

1

2

1

EBS00259

REMOVING THE AC MAGNETO ROTOR1. Remove:• lead holder 1• AC magneto cover

NOTE:_

Loosen each bolt 1/4 of a turn at a time, instages and in a crisscross pattern. After all ofthe bolts are fully loosened, remove them.

2. Remove:• AC magneto rotor nut 1• washer

NOTE:_

• While holding the AC magneto rotor 2 withthe sheave holder 3, loosen the AC mag-neto rotor nut.

• Do not allow the sheave holder to touch theprojection on the rotor.

Sheave holder90890-01701

Primary clutch holderYS-01880-A

3. Remove:• AC magneto rotor 1

(with the starter clutch)• woodruff key

CAUTION:

To protect the end of the crankshaft, placean appropriate sized socket between theflywheel puller set center bolt and thecrankshaft.

NOTE:• Use the flywheel puller 2.• Install the flywheel puller bolts to the

threaded holes of the starter clutch.• Make sure the flywheel puller is centered

over the AC magneto rotor.

5

4 — 4

ENGAC MAGNETO

2

1

LT

1

2

É

È

Flywheel puller90890-01362

Heavy duty pullerYU-33270-B

EBS00262

CHECKING THE STATOR COIL AND CRANKSHAFT POSITION SENSOR1. Check:• stator coil 1• crankshaft position sensor 2

Damage → Replace the crankshaft positionsensor/stator assembly.

EBS00263

CHECKING THE STARTER CLUTCH1. Check:• starter one-way clutch 1

Cracks/damage → Replace.• bolts 2

Loose → Replace with a new one, andclinch the end of the bolt.

NOTE:_

The arrow mark on the starter clutch must faceinward, away from the AC magneto rotor.

a. Install the starter wheel gear to the starterclutch, and hold the starter clutch.

b. When turning the starter wheel gearcounter clockwise È, the starter clutch andthe wheel gear should be engaged.If not, the starter clutch is faulty. Replace it.

c. When turning the starter wheel gear clock-wise É, the starter wheel gear should turnfreely.If not, the starter clutch is faulty. Replace it.

T R..

Starter clutch bolt30 Nm (3.0 m · kg, 22 ft · lb)LOCTITE®

6

4 — 4

ENGAC MAGNETO

1

a

b

1

2. Check:• starter idle gear teeth• starter wheel gear teeth

Burrs/clips/roughness/wear → Replace.3. Check:• starter wheel gear

(contacting surface)Damage/pitting/wear → Replace.

CHECKING THE TORQUE LIMITER• torque limiter

Damage/wear → Replace.

NOTE:Do not disassemble the torque limiter.

EBS00268

INSTALLING THE AC MAGNETO ROTOR1. Install:• stator coil 1

NOTE:Align the projection a on the stator coil withthe slot b in the AC magneto cover.

T R..

Stator coil bolt7 Nm (0.7 m · kg, 5.1 ft · lb)

LT

T R..

7 Nm (0.7 m · kg, 5.1 ft · lb)

2. Apply:• Sealant 1

(into the slit)

Yamaha bond No. 121590890-85505(Three bond No.1215®)

7

4 — 4

ENGAC MAGNETO

3

2

1

1

3. Install:• woodruff key• AC magneto rotor

NOTE:_

• Before installing the rotor, clean the outsideof the crankshaft and the inside of the rotor.

• After installing the rotor, check that the rotorrotates smoothly. If not, reinstall the key androtor.

4. Tighten:• AC magneto rotor nut 1

NOTE:_

While holding the AC magneto rotor 2 with thesheave holder 3, tighten the AC magnetorotor nut.

Sheave holder90890-01701

Primary clutch holderYS-01880-A

T R..

70 Nm (7.0 m · kg, 50 ft · lb)

5. Install:• AC magneto cover• lead holder 1• AC magneto cover bolts

NOTE:_

Tighten the AC magneto cover bolts in stages,using a crisscross pattern.

T R..

10 Nm (1.0 m · kg, 7.2 ft · lb)

8

ENGBALANCER GEARS AND OIL PUMP GEARS

BALANCER GEARS AND OIL PUMP GEARS

Order Job/Part Q’ty RemarksRemoving the balancer gears and oil pump gears

Remove the parts in the order listed.

Starter wheel gear Refer to “AC MAGNETO”.1 Lock washer 1 Refer to “REMOVING THE BALANCER

DRIVEN GEAR AND OIL PUMP DRIVEN GEAR” and “INSTALLING THE BALANCER DRIVE GEAR, BALANCER DRIVEN GEAR, AND OIL PUMP DRIVEN GEAR”.

2 Balancer driven gear 1

3 Oil pump drive gear 14 Chain 15 Straight key 1

4 — 49

ENGBALANCER GEARS AND OIL PUMP GEARS

Order Job/Part Q’ty Remarks6 Lock washer 1 Refer to “REMOVING THE BALANCER

DRIVEN GEAR AND OIL PUMP DRIVEN GEAR” and “INSTALLING THE BAL-ANCER DRIVE GEAR, BALANCER DRIVEN GEAR, AND OIL PUMP DRIVEN GEAR”.

7 Oil pump driven gear 18 Plate 19 Spring 8 Refer to “REMOVING THE BALANCER

DRIVEN GEAR AND OIL PUMP DRIVEN GEAR” and “INSTALLING THE BALANCER DRIVE GEAR, BALANCER DRIVEN GEAR, AND OIL PUMP DRIVEN GEAR”.

10 Pin 411 Balancer drive gear 1

For installation, reverse the removal pro-cedure.

4 — 50

4 — 5

ENG

5

4

3

1

2

BALANCER GEARS AND OIL PUMP GEARS

REMOVING THE BALANCER DRIVEN GEAR AND OIL PUMP DRIVEN GEAR1. Straighten the lock washer tabs.2. Loosen:• balancer driven gear nut 1• oil pump driven gear nut 2

NOTE:Place an aluminum plate 3 between the teethof the balancer drive gear 4 and balancerdriven gear 5, then loosen the nuts.

CHECKING THE OIL PUMP DRIVE1. Check:• oil pump drive gear• oil pump driven gear

Cracks/wear/damage → Replace.

CHECKING THE BALANCER DRIVE1. Check:• balancer drive gear• balancer driven gear

Damage/wear → Replace the balancerdrive gear and balancer driven gear as aset.Excessive noise during operation →Replace the balancer drive gear and bal-ancer driven gear as a set.

1

4 — 5

ENG

2

3

c

a b

1

5

2

3

4

1

BALANCER GEARS AND OIL PUMP GEARS

INSTALLING THE BALANCER DRIVE GEAR, BALANCER DRIVEN GEAR, AND OIL PUMP DRIVEN GEAR1. Install:• pin• spring• balancer drive gear

(onto the buffer boss)

NOTE:Align the punch mark a on the balancer drivegear with the hole b to the buffer boss.

2. Install:• balancer drive gear 1• balancer driven gear 2• oil pump driven gear 3

NOTE:• Align the punch mark a on the balancer

drive gear with the punch mark b on the bal-ancer driven gear.

• Install the oil pump driven gear with the “3B4”mark c facing out.

3. Install:• lock washers• oil pump driven gear nut 1

• balancer driven gear nut 2

NOTE:• Place an aluminum plate 3 between the

teeth of the balancer drive gear 4 and bal-ancer driven gear 5, then tighten the nuts.

• Apply the engine oil to the thread of axlesand nuts.

4. Bend the lock washer tabs along the bal-ancer driven gear nut and oil pump drivengear nut.

New

T R..

22 Nm (2.2 m · kg, 16 ft · lb)

T R..

80 Nm (8.0 m · kg, 58 ft · lb)

2

ENGPRIMARY AND SECONDARY SHEAVES

EBS00269

PRIMARY AND SECONDARY SHEAVES

2

3

45

6

7

(8)9

10

4

11

8

(11)

NewNew

New

New

E

T R..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

T R..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

T R..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

1

T R..

100 Nm (10.0 m • kg, 72 ft • lb)

T R..

140 Nm (14.0 m • kg, 100 ft • lb)

LS

T R..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

Order Job/Part Q’ty RemarksRemoving the primary and second-ary sheaves

Remove the parts in the order listed.

Front fender/rear fender Refer to “ENGINE SKID PLATES, SEAT, CARRIERS AND FENDERS” in chapter 3.

Right footrest board Refer to “FOOTREST BOARDS” in chap-ter 3.

Air ducts Refer to “ENGINE REMOVAL”.1 Drive belt cover 12 Rubber gasket 13 Bearing housing 14 Dowel pin 25 Primary sheave assembly 1 Refer to “REMOVING THE PRIMARY

AND SECONDARY SHEAVES” and “INSTALLING THE PRIMARY AND SECONDARY SHEAVES”.

6 V-belt 17 Primary fixed sheave 18 Secondary sheave assembly 1

4 — 53

ENGPRIMARY AND SECONDARY SHEAVES

2

3

45

6

7

(8)9

10

4

11

8

(11)

NewNew

New

New

E

T R..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

T R..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

T R..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

1

T R..

100 Nm (10.0 m • kg, 72 ft • lb)

T R..

140 Nm (14.0 m • kg, 100 ft • lb)

LS

T R..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

Order Job/Part Q’ty Remarks9 Drive belt case 1

10 Rubber gasket 111 Rubber gasket 1

For installation, reverse the removal pro-cedure.

4 — 54

ENGPRIMARY AND SECONDARY SHEAVES

EBS00270

PRIMARY SHEAVE

Order Job/Part Q’ty RemarksDisassembling the primary sheave Remove the parts in the order listed.

1 Primary pulley sheave cap 1

Refer to “ASSEMBLING THE PRIMARY SHEAVE”.

2 Primary pulley slider 43 Primary pulley cam 14 Primary pulley weight 85 Collar 16 Oil seal 27 Primary sliding sheave 18 O-ring 1

For assembly, reverse the disassembly procedure.

4 — 55

ENGPRIMARY AND SECONDARY SHEAVES

EBS00271

SECONDARY SHEAVE

Order Job/Part Q’ty RemarksDisassembling the secondary sheave

Remove the parts in the order listed.

1 Nut 1

Refer to “DISASSEMBLING THE SEC-ONDARY SHEAVE” and “ASSEMBLING THE SECONDARY SHEAVE”.

2 Spring seat 13 Compression spring 14 Spring seat 15 Guide pin 46 Secondary sliding sheave 17 O-ring 28 Secondary fixed sheave 19 Oil seal 2

For assembly, reverse the disassembly procedure.

4 — 56

4 — 5

ENGPRIMARY AND SECONDARY SHEAVES

EBS00272

REMOVING THE PRIMARY AND SECONDARY SHEAVES1. Loosen:• secondary sheave nut 1• primary sheave nut 2

NOTE:_

• Use the sheave holder 3 to hold the primarysheave.

• First, loosen the secondary sheave nut 2,then loosen the primary sheave nut 1.

Sheave holder90890-01701

Primary clutch holderYS-01880-A

EBS00273

DISASSEMBLING THE SECONDARY SHEAVE1. Remove:• nut 1

a. Attach the sheave fixed block 2, locknutwrench 3 and sheave spring compressor4 to the secondary sheave assembly.

b. Place the sheave fixed block in a vise andsecure it.

c. Tighten the sheave spring compressor nut5 and compress the spring.

d. Loosen the nut 1 with the locknut wrench3.

e. Remove the nut 1.f. Remove the sheave spring compressor and

locknut wrench.

Sheave fixed block90890-04135

Sheave fixed bracketYM-04135

Locknut wrench90890-01348, YM-01348

Sheave spring compressor90890-04134, YM-04134

7

4 — 5

ENGPRIMARY AND SECONDARY SHEAVES

EBS00274

CHECKING THE PRIMARY SHEAVE1. Check:• weight outside diameter a

Out of specification → Replace the weight.

Weight outside diameter30 mm (1.18 in)<Limit>: 29.5 mm (1.16 in)

2. Check:• primary pulley slider• primary sliding sheave splines

Wear/cracks/damage → Replace.• primary pulley cam

Cracks/damage → Replace.3. Check:• primary sliding sheave• primary fixed sheave

Cracks/damage → Replace.

EBS00275

CHECKING THE SECONDARY SHEAVE1. Check:• secondary fixed sheave smooth operation • secondary sliding sheave smooth operation

Scratches/damage → Replace as a set.

2. Check:• torque cam grooves 1

Wear/damage → Replace.3. Check:• guide pins 2

Wear/damage → Replace.4. Check:• secondary sheave spring

Damage → Replace.

8

4 — 5

ENGPRIMARY AND SECONDARY SHEAVES

5. Measure:• secondary sheave spring free length a

Out of specification → Replace the second-ary sheave spring.

Free length130.6 mm (5.14 in)<Limit>: 128.0 mm (5.04 in)

EBS00276

ASSEMBLING THE PRIMARY SHEAVE1. Clean:• primary sliding sheave face 1• primary fixed sheave face 2• collar 3• weights 4• primary sliding sheave cam face

NOTE:_

Remove any excess grease.

2. Install:• weights 1

NOTE:_

• Apply Yamaha Grizzly grease (90 g) to thewhole outer surface of the weights andinstall.

• Apply Yamaha Grizzly grease (2.5 g) to theinner surface of the collar.

• Apply Yamaha Grizzly grease (2.5 g) to theinner surface of the primary sliding sheave.

9

4 — 6

ENGPRIMARY AND SECONDARY SHEAVES

3. Install:• slider 1• cam 2• primary sliding sheave cap

T R..

3 Nm (0.3 m · kg, 2.2 ft · lb)

EBS00277

ASSEMBLING THE SECONDARY SHEAVE1. Apply:• BEL-RAY assembly lube®

(to the secondary sliding sheave 1 innersurface and oil seals)

• BEL-RAY assembly lube®

(to the bearings, oil seals and inner surfaceof the secondary fixed sheave 2)

2. Install:• guide pins 1

3. Apply:• BEL-RAY assembly lube®

(to the guide pin sliding grooves 1, and oilseals 2 )New

0

4 — 6

ENGPRIMARY AND SECONDARY SHEAVES

4. Install:• spring seat• compression spring• spring seat• nut

a. Attach the sheave fixed block, locknutwrench and sheave spring compressor tothe secondary sheave.

b. Place the sheave fixed block in a vise andsecure it.

c. Tighten the sheave spring compressor nut1 and compress the spring.

d. Install the nut 2 and tighten it to the speci-fied torque using the locknut wrench.

e. Remove the sheave spring compressor,locknut wrench, and sheave fixed block.

Sheave fixed block90890-04135

Sheave fixed bracketYM-04135

Locknut wrench90890-01348, YM-01348

Sheave spring compressor90890-04134, YM-04134

T R..

Nut90 Nm (9.0 m · kg, 65 ft · lb)

1

4 — 6

ENGPRIMARY AND SECONDARY SHEAVES

EBS00279

INSTALLING THE PRIMARY AND SECONDARY SHEAVES1. Install:• secondary sheave• V-belt• primary sheave

NOTE:_

• Tightening the bolts 1 will push the second-ary sliding sheave away, causing the gapbetween the secondary fixed and slidingsheaves to widen.

• Install the V-belt so that its arrow faces thedirection shown in the illustration.

2. Tighten:• primary sheave nut 1

• secondary sheave nut 2

NOTE:_

• Use the sheave holder 3 to hold the primarysheave.

• First, tighten the primary sheave nut 1, thentighten the secondary sheave nut 2.

Sheave holder90890-01701

Primary clutch holderYS-01880-A

T R..

140 Nm (14.0 m · kg, 100 ft · lb)

T R..

100 Nm (10.0 m · kg, 72 ft · lb)

2

ENGCLUTCH

EBS00291

CLUTCH

Order Job/Part Q’ty RemarksRemoving the clutch Remove the parts in the order listed.Primary sheave/secondary sheave Refer to “PRIMARY AND SECONDARY

SHEAVES”.1 Clutch housing assembly 1

Refer to “REMOVING THE CLUTCH” and “INSTALLING THE CLUTCH”.

2 Gasket 13 Dowel pin 24 One-way clutch bearing 15 Nut 16 Clutch carrier assembly 1

For installation, reverse the removal pro-cedure.

4 — 63

ENGCLUTCH

EBS00292

Order Job/Part Q’ty RemarksDisassembling the clutch housing assembly

Remove the parts in the order listed.

1 Oil seal 12 Circlip 13 Bearing housing 14 Circlip 15 Bearing 16 Circlip 17 Bearing 18 Clutch housing 1

For assembly, reverse the disassembly procedure.

4 — 64

4 — 6

ENGCLUTCH

EBS00296

REMOVING THE CLUTCH1. Remove:• clutch housing assembly• gasket• dowel pins

NOTE:_

Working in crisscross pattern, loosen each bolt1/4 of a turn. Remove them after all of themare loosened.

2. Straighten:• punched portion of the nut 1

3. Remove:• nut 1

CAUTION:

The clutch carrier assembly nut has left-handed threads. To loosen the clutch car-rier assembly nut turn it clockwise.

NOTE:_

Use a clutch holding tool 2 to hold the clutchcarrier assembly.

Universal clutch holder90890-04086, YM-91042

5

4 — 6

ENGCLUTCH

EBS00299

CHECKING THE CLUTCH1. Check:• clutch housing

Heat damage/wear/damage → Replace.• one-way clutch bearing

Chafing/wear/damage → Replace.

NOTE:_

• Replace the one-way clutch assembly andclutch housing as a set.

• The one-way clutch bearing must beinstalled with the flange side facing in.

2. Check:• one-way clutch operation

a. Install the one-way clutch bearing andclutch carrier assembly to the clutch hous-ing and hold the clutch carrier assembly.

b. When turning the clutch housing clockwiseÈ, the clutch housing should turn freely.If not, the one-way clutch assembly isfaulty.Replace it.

c. When turning the clutch housing counter-clockwise É, the clutch housing and crank-shaft should be engaged.If not, the one-way clutch assembly isfaulty.Replace it.

3. Check:• clutch shoe

Heat damage → Replace.

4. Measure:• clutch shoe thickness

Out of specification → Replace.

Clutch shoe thickness1.5 mm (0.06 in)

Clutch shoe wear limit a1.0 mm (0.04 in)

6

4 — 6

ENGCLUTCH

EBS00309

INSTALLING THE CLUTCH1. Install:• clutch carrier assembly• nut 1

CAUTION:

The clutch carrier assembly nut has left-handed threads. To tighten the clutch car-rier assembly nut turn it counterclockwise.

NOTE:Use a clutch holding tool 2 to hold the clutchcarrier assembly.

2. Lock the threads with a drift punch.

Universal clutch holder90890-04086, YM-91042

New

T R..

190 Nm (19.0 m · kg, 140 ft · lb)

3. Install:• one-way clutch bearing

NOTE:_

The one-way clutch bearing should beinstalled in the clutch carrier assembly with the“OUT SIDE” mark a facing toward the clutchhousing.

4. Install:• dowel pins• gasket• clutch housing assembly

NOTE:_

• Tighten the bolts in stages, using a criss-cross pattern.

• After tightening the bolts, check that theclutch housing assembly rotates smoothly.

New

T R..

10 Nm (1.0 m · kg, 7.2 ft · lb)

7

ENGCRANKCASE

EBS00319

CRANKCASE TIMING CHAIN AND OIL FILTER

LTT R.

.

7 Nm (0.7 m • kg, 5.1 ft • Ib)

T R..

17 Nm (1.7 m • kg, 12 ft • Ib)

T R..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

T R..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

T R..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

T R..

68 Nm (6.8 m • kg, 49 ft • Ib)

T R..

30 Nm (3.0 m • kg, 22 ft • Ib)

T R..

17 Nm (1.7 m • kg, 12 ft • Ib)

New

New

New

New

New

New

New

New

LS

LS

LS

LS

LT

E

E

LTLT

LTLT

LS

2

5

69

8

1

7

4

3

Order Job/Part Q’ty RemarksRemoving the timing chain and oil filter

Remove the parts in the order listed.

Engine Refer to “ENGINE REMOVAL”.Cylinder head Refer to “CYLINDER HEAD”.Cylinder/piston Refer to “CYLINDER AND PISTON”.AC magneto rotor/starter wheel gear Refer to “AC MAGNETO”.Balancer driven gear/oil pump driven gear

Refer to “BALANCER GEARS AND OIL PUMP GEARS”.

Primary sheave assembly/secondary sheave assembly

Refer to “PRIMARY AND SECONDARY SHEAVES”.

Clutch carrier assembly Refer to “CLUTCH”.1 Timing chain guide (intake side) 12 Timing chain guide 13 Timing chain 14 Oil filter cartridge 1

4 — 68

ENGCRANKCASE

LTT R.

.

7 Nm (0.7 m • kg, 5.1 ft • Ib)

T R..

17 Nm (1.7 m • kg, 12 ft • Ib)

T R..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

T R..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

T R..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

T R..

68 Nm (6.8 m • kg, 49 ft • Ib)

T R..

30 Nm (3.0 m • kg, 22 ft • Ib)

T R..

17 Nm (1.7 m • kg, 12 ft • Ib)

New

New

New

New

New

New

New

New

LS

LS

LS

LS

LT

E

E

LTLT

LTLT

LS

2

5

69

8

1

7

4

3

Order Job/Part Q’ty Remarks5 Speed sensor 16 Dipstick 17 Relief valve assembly 18 Reverse switch 19 Gear position switch 1

For installation, reverse the removal pro-cedure.

4 — 69

ENGCRANKCASE

EBS00320

CRANKCASE

T R..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

T R..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

T R..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

T R..

26 Nm (2.6 m • kg, 19 ft • Ib) T R..

14 Nm (1.4 m • kg, 10 ft • Ib)

T R..

18 Nm (1.8 m • kg, 13 ft • Ib)

T R..

18 Nm (1.8 m • kg, 13 ft • Ib)

New

NewNew

New

LS

LS

E

E

E

E

14

2(4)

3

7

5

6

9

9

10

8

Order Job/Part Q’ty RemarksSeparating the crankcase Remove the parts in the order listed.

1 Shift lever cover 1

Refer to “INSTALLING THE SHIFT LEVER”.

2 Gasket 13 Dowel pin 14 Shift lever 1 15 Shift lever 2 assembly 16 Shift drum stopper 1 Spring identification color: red7 Stopper lever stopper 1 Spring identification color: yellow8 Right crankcase 1 Refer to “SEPARATING THE CRANK-

CASE” and “ASSEMBLING THE CRANKCASE”.

9 Dowel pin 210 Left crankcase 1

For installation, reverse the removal pro-cedure.

4 — 70

ENGCRANKCASE

EBS00321

CRANKCASE BEARINGS

T R..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

.

E

EE

E

EE

New

New

LS

LS

7

7 7

7

7

7

7

E

LTLT4

7

3

21

56

LT

Order Job/Part Q’ty RemarksRemoving the crankcase bearings Remove the parts in the order listed.Crankshaft/oil pump Refer to “CRANKSHAFT AND OIL

PUMP”.Transmission Refer to “TRANSMISSION”.Middle drive shaft/middle driven shaft Refer to “MIDDLE GEAR”.

1 Collar 12 O-ring 13 Oil seal 14 Bearing retainer 15 Spacer 16 Crank seal 27 Bearing 9

For installation, reverse the removal pro-cedure.

4 — 71

4 — 7

ENGCRANKCASE

È

É

4

3

21

EBS00332

SEPARATING THE CRANKCASE1. Separate:• right crankcase• left crankcase

a. Remove the lead holders and crankcasebolts.

NOTE:_

• Loosen each bolt 1/4 of a turn at a time andafter all the bolts are loosened, removethem.

• Loosen the bolts in numerical order (seenumbers on the illustration).

È Left crankcaseÉ Right crankcaseb. Remove the right crankcase.

CAUTION:_

Use a soft hammer to tap on one side of thecrankcase. Tap only on reinforced portionsof the crankcase. Do not tap on the crank-case mating surfaces. Work slowly andcarefully. Make sure that the crankcasehalves separate evenly.

c. Remove the dowel pins.

EBS00335

CHECKING THE TIMING CHAIN AND GUIDE1. Check:• timing chain

Cracks/stiff → Replace the timing chain andcamshaft sprocket as a set.

2. Check:• intake side timing chain guide

Wear/damage → Replace.

CHECKING THE RELIEF VALVE1. Check:• spring seat 1• spring 2 • relief valve body 3 • relief valve 4

Damage/wear → Replace the defectivepart(s).

2

4 — 7

ENGCRANKCASE

2

2

1a

EBS00339

CHECKING THE BEARINGS1. Check:• bearings

Clean and lubricate, then rotate the innerrace with a finger.Roughness → Replace.

EBS00338

CHECKING THE CRANKCASE1. 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.

EBS00342

ASSEMBLING THE CRANKCASE1. Apply:• sealant 1

(to the mating surfaces of both case halves)

NOTE:Apply two coats of sealant to the area ashown in the illustration.

2. Install:• dowel pins 2

Yamaha bond No. 121590890-85505(Three bond No.1215®)

3

4 — 7

ENGCRANKCASE

È

É

3. Fit the right crankcase onto the left crank-case. Tap lightly on the case with a softhammer.

CAUTION:_

Before installing and torquing the crank-case holding bolts, be sure to checkwhether the transmission is functioningproperly by manually rotating the shiftdrum in both directions.

4. Install:• lead holder• crankcase bolts

5. Tighten:• crankcase bolts

(follow the proper tightening sequence)

È Right crankcaseÉ Left crankcase

NOTE:_

Tighten the bolts in stages, using a crisscrosspattern.

6. Apply:• 4-stroke engine oil

(to the crankshaft pin, bearing and oil deliv-ery hole)

7. Check:• crankshaft and transmission operation

Unsmooth operation → Repair.

INSTALLING THE SHIFT LEVER1. Install:• shift lever 2 assembly 1

• shift lever 1 2

NOTE:When installing the shift lever 1, align thepunch mark a on the shift lever 1 with thepunch marks b on the shift lever 2.

T R..

10 Nm (1.0 m · kg, 7.2 ft · lb)

T R..

14 Nm (1.4 m · kg, 10 ft · lb)

4

ENGCRANKSHAFT AND OIL PUMP

EBS00326

CRANKSHAFT AND OIL PUMP

3

4

2

1

T R..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

T R..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

New

Order Job/Part Q’ty RemarksRemoving the crankshaft and oil pump

Remove the parts in the order listed.

Crankcase Separate.Refer to “CRANKCASE”.

1 Oil pump 12 Gasket 13 Balancer 14 Crankshaft 1 Refer to “REMOVING THE CRANK-

SHAFT” and “INSTALLING THE CRANK-SHAFT”.For installation, reverse the removal pro-cedure.

4 — 75

ENGCRANKSHAFT AND OIL PUMP

EBS00327

OIL PUMP

E

6

3

2

5

4

1E

T R..

5 Nm (0.5 m • kg, 3.6 ft • Ib)

Order Job/Part Q’ty RemarksDisassembling the oil pump Remove the parts in the order listed.

1 Oil pump housing cover 12 Pin 13 Oil pump shaft 14 Oil pump inner rotor 15 Oil pump outer rotor 16 Oil pump housing 1

For assembly, reverse the disassembly procedure.

4 — 76

4 — 7

ENGCRANKSHAFT AND OIL PUMP

2

1

EBS00336

REMOVING THE CRANKSHAFT1. Remove:• crankshaft 1

Use a crankcase separating tool 2.

Crankcase separating tool90890-01135

Crankcase separatorYU-01135-B

EBS00331

CHECKING THE OIL PUMP1. Check:• oil pump housing• oil pump housing cover

Cracks/wear/damage → Replace.2. Measure:• inner-rotor-to-outer-rotor-tip clearance a • outer-rotor-to-oil-pump-housing clearance b

• oil-pump-housing-to-inner-rotor-and-outer-rotor clearance c Out of specification → Replace the oilpump.

1 Inner rotor 2 Outer rotor 3 Oil pump housing

3. Check: • oil pump operation

Rough movement → Repeat steps (1) and(2) or replace the defective part(s).

Inner-rotor-to-outer-rotor-tip clearance

Less than 0.12 mm (0.0047 in)<Limit>: 0.20 mm (0.0079 in)

Outer-rotor-to-oil-pump-housing clearance

0.090 ~ 0.170 mm(0.0035 ~ 0.0067 in)<Limit>: 0.24 mm (0.0094 in)

Oil-pump-housing-to-inner-rotor-and-outer-rotor clearance

0.030 ~ 0.100 mm(0.0012 ~ 0.0039 in)<Limit>: 0.17 mm (0.0067 in)

7

4 — 7

ENGCRANKSHAFT AND OIL PUMP

a

c

d

c

CHECKING THE OIL STRAINER1. Check:• oil strainer

Damage → Replace.Contaminants → Clean with engine oil.

EBS00360

CHECKING THE CRANKSHAFT1. Measure:• crank width a

Out of specification → Replace the crank-shaft.

2. Measure:• side clearance d

Out of specification → Replace the crank-shaft.

3. Measure:• runout c

Out of specification → Replace the crank-shaft.

Crank width74.95 ~ 75.00 mm(2.951 ~ 2.953 in)

Big end side clearance0.350 ~ 0.650 mm (0.0138 ~ 0.0256 in)<Limit>: 1.0 mm (0.04 in)

Runout limit0.030 mm (0.0012 in)

8

4 — 7

ENGCRANKSHAFT AND OIL PUMP

1 2

3

5

4a

a

1

5

6

4

23

EBS00318

ASSEMBLING THE OIL PUMP1. Install:• oil pump housing 1• oil pump outer rotor 2• oil pump inner rotor 3• oil pump shaft 4• pin 5

NOTE:_

When installing the oil pump shaft 4 align thepin 5 with the groove a in the inner rotor 3.

EBS00362

INSTALLING THE CRANKSHAFT1. Install:• crankshaft 1

Crankshaft installer pot 290890-01274

Installing potYU-90058

Pot installerYU-90059

Crankshaft installer bolt 390890-01275

BoltYU-90060

Adapter (M16) 490890-04130

Adapter #13YM-04059

Spacer (crankshaft installer) 590890-04081

Pot spacerYM-91044

Spacer 690890-01309

Pot spacerYU-90059

9

4 — 8

ENGCRANKSHAFT AND OIL PUMP

NOTE:_

Hold the connecting rod at the Top Dead Cen-ter (TDC) with one hand while turning the nutof the installing tool with the other. Operate theinstalling tool until the crankshaft bottomsagainst the bearing.

CAUTION:_

Apply engine oil to each bearing to protectthe crankshaft against scratches and tomake installation easier.

0

ENGTRANSMISSION

EBS00345

TRANSMISSION

M

1

7

6

8

5

10

1211

9

4

3

2

New

New

New

New

New

E

E

E

E

Order Job/Part Q’ty RemarksRemoving the transmission Remove the parts in the order listed.Crankcase Separate.

Refer to “CRANKCASE”.Middle driven gear Refer to “MIDDLE GEAR”.

1 Shift drum 1

Refer to “REMOV-ING THE TRANS-MISSION” and “INSTALLING THE TRANSMISSION”.

2 Shift fork assembly 13 Shift fork “R” 14 Spring 1 Refer to “ASSEM-

BLING THE SHIFT FORK ASSEMBLY”.

5 Shift fork “L” 16 Shift fork guide bar 1

7 Secondary shaft 18 Drive axle assembly 19 Reverse idle gear 1

10 Reverse idle gear shaft 1

4 — 81

ENGTRANSMISSION

M

1

7

6

8

5

10

1211

9

4

3

2

New

New

New

New

New

E

E

E

E

Order Job/Part Q’ty Remarks11 Stopper lever 1 Refer to “REMOVING THE TRANSMIS-

SION” and “INSTALLING THE TRANS-MISSION”.

12 Stopper lever shaft 1

For installation, reverse the removal pro-cedure.

4 — 82

ENGTRANSMISSION

EBS00348

DRIVE AXLE

1

A

C

D

E

F

H

G

B

0

2

3

4

5

67

8

9

MM

M

M

M

M

M

New

New

New

Order Job/Part Q’ty RemarksDisassembling the drive axle assembly

Remove the parts in the order listed.

1 Washer 12 Collar 13 High wheel gear 14 Washer 15 Clutch dog 16 Circlip 17 Washer 18 Collar 19 Low wheel gear 10 Washer 1A Circlip 1B Middle drive gear 1C Circlip 1

4 — 83

ENGTRANSMISSION

1

A

C

D

E

F

H

G

B

0

2

3

4

5

67

8

9

MM

M

M

M

M

M

New

New

New

Order Job/Part Q’ty RemarksD Washer 1E Bearing 1F Reverse wheel gear 1G Stopper wheel 1H Drive axle 1

For assembly, reverse the disassembly procedure.

4 — 84

4 — 8

ENGTRANSMISSION

REMOVING THE TRANSMISSION1. Remove:• shift drum 1 • shift fork assembly 2