Yamaha 5TE-F8197-10, LIT-11616-16-02 user guide

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YFM400FAR

SERVICE MANUAL

LIT-11616-16-02 5TE-F8197-10

YFM400FAR

SERVICE MANUAL

First Edition, April 2002

unauthorized use without the written

permission of Yamaha Motor Corporation, U.S.A.

is expressly prohibited.

Printed in U.S.A.

LIT-11616-16-02

EB001000

NOTICE

This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha machine has a basic understanding of the mechanical ideas and the procedures of machine repair. Repairs attempted by anyone without this knowledge are likely to render the machine unsafe and unfit for use.

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

OTE:

Designs and specifications are subject to change without notice.

IMPORTANT INFORMATION

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

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

WARNING

CAUTION:

NOTE:

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

A CAUTION indicates special precautions that must be taken to avoid damage to the machine.

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

EB002000

HOW TO USE THIS MANUAL

MANUAL ORGANIZATION

This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”)

1st title 1: This is the title of the chapter with its symbol in the upper right corner of each page.

2nd title 2: This title indicates the section of the chapter and only appears on the first page of each section. It is located in the upper left corner of the page.

3rd title 3: This title indicates a sub-section that is followed by step-by-step procedures accompanied by corresponding illustrations.

EXPLODED DIAGRAMS

To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section.

1. An easy-to-see exploded diagram 4 is provided for removal and disassembly jobs.

2. Numbers 5 are given in the order of the jobs in the exploded diagram. A number that is enclosed by a circle indicates a disassembly step.

3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks

. 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.

GEN

INFO

SPEC

CHK

ENG

ADJ

COOL

CARB

EB003000

ILLUSTRATED SYMBOLS

Illustrated symbols 1 to 0 are printed on the top right of each page and indicate the subject of each chapter.

General information

Specifications

Periodic checks and adjustments

Engine

Cooling system

Carburetion

Drive train

Chassis

Electrical

Troubleshooting

DRIV

–+

ELEC

CHAS

TRBL SHTG

Illustrated symbols A to H are used to identify the specifications appearing in the text.

Can be serviced with engine mounted

Filling fluid

Lubricant

Special tool

Torque

Wear limit, clearance

Engine speed

, V, A

Ω

IJK

New

LMN

Illustrated symbols I to N in the exploded diagrams indicate the types of lubricants and lubrication points.

Apply engine oil

Apply gear oil

Apply molybdenum disulfide oil

Apply wheel bearing grease

Apply lithium-soap-based grease

Apply molybdenum disulfide grease

Illustrated symbols O to P in the exploded diagrams indicate where to apply a locking agent O and when to install a new part P.

Apply the locking agent (LOCTITE

Replace

)

GENERAL INFORMATION

SPECIFICATIONS

PERIODIC CHECKS AND ADJUSTMENTS

ENGINE

COOLING SYSTEM

GEN

INFO

SPEC

CHK

ADJ

ENG

COOL

CARBURETION

DRIVE TRAIN

CHASSIS

ELECTRICAL

TROUBLESHOOTING

CARB

DRIV

CHAS

– +

ELEC

TRBL SHTG

CONTENTS

CHAPTER 1.

GENERAL INFORMATION

MACHINE IDENTIFICATION

VEHICLE IDENTIFICATION NUMBER ................................................. 1-1

MODEL LABEL ...................................................................................... 1-1

IMPORTANT INFORMATION

PREPARATION FOR REMOVAL PROCEDURES ............................... 1-2

REPLACEMENT PARTS ....................................................................... 1-2

GASKETS, OIL SEALS AND O-RINGS ................................................ 1-2

LOCK WASHERS/PLATES AND COTTER PINS ................................. 1-3

BEARINGS AND OIL SEALS ................................................................ 1-3

CIRCLIPS ..............................................................................................1-3

CHECKING OF CONNECTIONS

SPECIAL TOOLS

..........................................................................................1-5

........................................................................1-1

.......................................................................1-2

.................................................................. 1-4

CHAPTER 2.

SPECIFICATIONS

GENERAL SPECIFICATIONS

MAINTENANCE SPECIFICATIONS

ENGINE .................................................................................................2-4

CHASSIS ............................................................................................. 2-14

ELECTRICAL ......................................................................................2-18

HOW TO USE THE CONVERSION TABLE

GENERAL TORQUE SPECIFICATIONS

LUBRICATION POINTS AND LUBRICANT TYPES

ENGINE ...............................................................................................2-21

COOLANT FLOW DIAGRAMS

OIL FLOW DIAGRAMS

CABLE ROUTING

..............................................................................2-24

.......................................................................................2-27

......................................................................2-1

............................................................. 2-4

............................................... 2-20

................................................... 2-20

.................................. 2-21

................................................................... 2-22

CHAPTER 3.

PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION

PERIODIC MAINTENANCE/LUBRICATION

SEAT, CARRIERS, FENDERS AND FUEL TANK

SEAT AND SIDE PANELS .................................................................... 3-3

FRONT CARRIER, FRONT BUMPER AND FRONT FENDER ............. 3-4

REAR CARRIER AND REAR FENDER ................................................ 3-6

FUEL TANK ........................................................................................... 3-8

FOOTREST BOARDS

ENGINE

.......................................................................................................3-10

ADJUSTING THE VALVE CLEARANCE ............................................ 3-10

ADJUSTING THE IDLING SPEED ......................................................3-13

ADJUSTING THE THROTTLE LEVER FREE PLAY .......................... 3-14

ADJUSTING THE SPEED LIMITER .................................................... 3-16

ADJUSTING THE STARTER CABLE .................................................3-17

CHECKING THE SPARK PLUG ......................................................... 3-19

CHECKING THE IGNITION TIMING ................................................... 3-20

MEASURING THE COMPRESSION PRESSURE .............................. 3-21

CHECKING THE ENGINE OIL LEVEL ................................................ 3-23

CHANGING THE ENGINE OIL ...........................................................3-24

CLEANING THE AIR FILTER .............................................................. 3-26

CHECKING THE COOLANT LEVEL ...................................................3-29

CHANGING THE COOLANT ............................................................... 3-30

CHECKING THE COOLANT TEMPERATURE WARNING LIGHT ..... 3-33

CHECKING THE V-BELT ....................................................................3-33

CLEANING THE SPARK ARRESTER ................................................ 3-34

...........................................................................................3-1

................................................ 3-1

....................................... 3-3

..................................................................................3-9

CHASSIS

ADJUSTING THE REAR BRAKE ........................................................ 3-36

CHECKING THE FRONT BRAKE FLUID LEVEL ............................... 3-38

CHECKING THE FRONT BRAKE PADS ............................................ 3-39

CHECKING THE REAR BRAKE SHOES ............................................ 3-39

CHECKING THE BRAKE HOSES ....................................................... 3-40

BLEEDING THE HYDRAULIC BRAKE SYSTEM ............................... 3-41

ADJUSTING THE SELECT LEVER CONTROL CABLE AND

ADJUSTING THE REAR BRAKE LIGHT SWITCH ............................. 3-43

CHECKING THE FINAL GEAR OIL LEVEL ........................................ 3-44

CHANGING THE FINAL GEAR OIL ....................................................3-45

CHANGING THE DIFFERENTIAL GEAR OIL .................................... 3-46

....................................................................................................3-36

SHIFT ROD ..................................................................................... 3-42

CHECKING THE CONSTANT VELOCITY JOINT DUST BOOTS ...... 3-46

CHECKING THE STEERING SYSTEM .............................................. 3-47

ADJUSTING THE TOE-IN ...................................................................3-47

ADJUSTING THE FRONT SHOCK ABSORBERS ............................. 3-49

ADJUSTING THE REAR SHOCK ABSORBER .................................. 3-49

CHECKING THE TIRES ......................................................................3-49

CHECKING THE WHEELS ................................................................. 3-52

CHECKING AND LUBRICATING THE CABLES ................................3-52

LUBRICATING THE LEVERS, PEDAL, ETC. ..................................... 3-53

ELECTRICAL .............................................................................................. 3-54

CHECKING THE BATTERY ................................................................3-54

CHECKING THE FUSES .................................................................... 3-59

ADJUSTING THE HEADLIGHT BEAMS ............................................. 3-61

CHANGING THE HEADLIGHT BULB ................................................. 3-61

CHAPTER 4.

ENGINE

ENGINE REMOVAL ...................................................................................... 4-1

AIR DUCTS, MUFFLER AND EXHAUST PIPE .................................... 4-1

SELECT LEVER UNIT AND COOLANT RESERVOIR ......................... 4-3

HOSES AND LEADS ............................................................................. 4-4

ENGINE MOUNTING BOLTS ...............................................................4-5

INSTALLING THE ENGINE ................................................................... 4-7

CYLINDER HEAD .........................................................................................4-8

REMOVING THE CYLINDER HEAD ................................................... 4-10

CHECKING THE TAPPET COVERS .................................................. 4-11

CHECKING THE TIMING CHAIN TENSIONER .................................. 4-11

CHECKING THE CAMSHAFT SPROCKET ........................................4-11

CHECKING THE CYLINDER HEAD ................................................... 4-12

INSTALLING THE CYLINDER HEAD ................................................. 4-13

CAMSHAFT, ROCKER ARMS AND VALVES ........................................... 4-16

REMOVING THE CAMSHAFT AND ROCKER ARMS ........................ 4-18

REMOVING THE VALVES AND VALVE SPRINGS ........................... 4-18

CHECKING THE CAMSHAFT ............................................................. 4-19

CHECKING THE ROCKER ARMS AND CAMSHAFT ........................ 4-19

CHECKING THE VALVES AND VALVE SPRINGS ............................ 4-21

INSTALLING THE VALVES AND VALVE SPRINGS .......................... 4-25

INSTALLING THE CAMSHAFT AND ROCKER ARMS ...................... 4-26

CYLINDER AND PISTON ........................................................................... 4-27

REMOVING THE PISTON ..................................................................4-28

CHECKING THE TIMING CHAIN GUIDE ........................................... 4-28

CHECKING THE CYLINDER AND PISTON ....................................... 4-28

CHECKING THE PISTON RINGS ....................................................... 4-30

CHECKING THE PISTON PIN ............................................................ 4-31

INSTALLING THE PISTON ................................................................. 4-32

INSTALLING THE CYLINDER ............................................................ 4-33

RECOIL STARTER AND A.C. MAGNETO ................................................ 4-34

REMOVING THE A.C. MAGNETO ...................................................... 4-37

DISASSEMBLING THE RECOIL STARTER ....................................... 4-37

CHECKING THE A.C. MAGNETO ...................................................... 4-37

CHECKING THE STARTER CLUTCH ................................................ 4-38

CHECKING THE STARTER PULLEY .................................................4-39

CHECKING THE RECOIL STARTER ................................................. 4-39

ASSEMBLING THE RECOIL STARTER .............................................4-39

INSTALLING THE A.C. MAGNETO .................................................... 4-40

PRIMARY AND SECONDARY SHEAVES ................................................. 4-42

PRIMARY SLIDING SHEAVE ............................................................. 4-44

SECONDARY SHEAVE ...................................................................... 4-45

REMOVING THE PRIMARY AND SECONDARY SHEAVES ............. 4-46

DISASSEMBLING THE SECONDARY SHEAVE ................................ 4-46

CHECKING THE PRIMARY SHEAVE ................................................4-47

CHECKING THE SECONDARY SHEAVE .......................................... 4-47

ASSEMBLING THE PRIMARY SHEAVE ............................................ 4-48

ASSEMBLING THE SECONDARY SHEAVE ...................................... 4-48

INSTALLING THE PRIMARY AND SECONDARY SHEAVES ............ 4-50

CLUTCH ......................................................................................................4-51

REMOVING THE CLUTCH ................................................................. 4-53

CHECKING THE CLUTCH ..................................................................4-53

INSTALLING THE CLUTCH ................................................................4-54

CRANKCASE ..............................................................................................4-56

STARTER MOTOR, TIMING CHAIN AND OIL FILTER ...................... 4-56

CRANKCASE ......................................................................................4-58

CRANKCASE BEARINGS ................................................................... 4-59

REMOVING THE OIL PUMP DRIVE GEAR .......................................4-60

SEPARATING THE CRANKCASE ...................................................... 4-60

CHECKING THE TIMING CHAIN AND GUIDE ................................... 4-61

CHECKING THE OIL STRAINER AND OIL DELIVERY PIPE ............ 4-61

CHECKING THE CRANKCASE .......................................................... 4-62

CHECKING THE BEARINGS .............................................................. 4-62

ASSEMBLING THE CRANKCASE ...................................................... 4-62

INSTALLING THE SHIFT LEVER ....................................................... 4-63

INSTALLING THE OIL PUMP DRIVE GEAR ...................................... 4-64

CRANKSHAFT AND OIL PUMP ................................................................ 4-65

OIL PUMP ........................................................................................... 4-66

REMOVING THE CRANKSHAFT .......................................................4-67

CHECKING THE OIL PUMP ............................................................... 4-67

CHECKING THE CRANKSHAFT ........................................................ 4-68

INSTALLING THE CRANKSHAFT AND BALANCER ......................... 4-69

TRANSMISSION .........................................................................................4-70

CHECKING THE SHIFT FORKS ......................................................... 4-72

CHECKING THE SHIFT CAM ............................................................. 4-72

CHECKING THE TRANSMISSION ..................................................... 4-72

CHECKING THE SECONDARY SHAFT AND

DRIVEN SPROCKET ...................................................................... 4-73

CHECKING THE CHAIN ..................................................................... 4-73

INSTALLING THE TRANSMISSION ................................................... 4-74

MIDDLE GEAR ...........................................................................................4-75

MIDDLE DRIVE SHAFT ...................................................................... 4-75

MIDDLE DRIVEN SHAFT .................................................................... 4-76

REMOVING THE MIDDLE DRIVE SHAFT .........................................4-78

REMOVING THE MIDDLE DRIVEN SHAFT .......................................4-78

CHECKING THE PINION GEARS ......................................................4-80

SELECTING THE MIDDLE DRIVE AND DRIVEN GEAR SHIMS ....... 4-81

INSTALLING THE MIDDLE DRIVEN SHAFT ..................................... 4-84

INSTALLING THE MIDDLE DRIVE SHAFT ........................................ 4-86

MEASURING THE MIDDLE GEAR BACKLASH ................................. 4-86

CHAPTER 5.

COOLING SYSTEM

RADIATOR .................................................................................................... 5-1

CHECKING THE RADIATOR ................................................................5-3

INSTALLING THE RADIATOR ..............................................................5-4

THERMOSTAT ..............................................................................................5-5

CHECKING THE THERMOSTAT .......................................................... 5-6

INSTALLING THE THERMOSTAT ........................................................ 5-6

WATER PUMP ..............................................................................................5-7

DISASSEMBLING THE WATER PUMP ................................................ 5-9

CHECKING THE WATER PUMP .......................................................... 5-9

ASSEMBLING THE WATER PUMP .................................................... 5-10

CHAPTER 6.

CARBURETION

CARBURETOR

DISASSEMBLING THE CARBURETOR ...............................................6-4

CHECKING THE CARBURETOR ......................................................... 6-4

ASSEMBLING THE CARBURETOR .....................................................6-6

ADJUSTING THE FUEL LEVEL ............................................................ 6-7

.............................................................................................6-1

CHAPTER 7.

DRIVE TRAIN

TROUBLESHOOTING

FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR

REMOVING THE DIFFERENTIAL GEAR ASSEMBLY ......................... 7-9

CHECKING THE CONSTANT VELOCITY JOINTS .............................. 7-9

CHECKING THE DIFFERENTIAL GEAR ............................................ 7-10

ASSEMBLING THE FRONT CONSTANT VELOCITY JOINTS .......... 7-10

ASSEMBLING THE DIFFERENTIAL GEAR ....................................... 7-11

MEASURING AND ADJUSTING THE DIFFERENTIAL

GEAR LASH .................................................................................... 7-12

CHECKING THE DIFFERENTIAL GEAR OPERATION ..................... 7-14

..................................................................................7-1

..... 7-4

REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT

REMOVING THE REAR AXLE ............................................................ 7-18

DISASSEMBLING THE FINAL DRIVE GEAR ..................................... 7-18

REPLACING THE FINAL DRIVE ROLLER BEARINGS ..................... 7-19

POSITIONING THE FINAL DRIVE PINION GEAR AND

RING GEAR .....................................................................................7-20

CHECKING THE REAR AXLE ............................................................ 7-24

CHECKING THE DRIVE SHAFT ......................................................... 7-25

CHECKING THE FINAL DRIVE GEAR ............................................... 7-25

MEASUREMENT AND ADJUSTING THE FINAL GEAR LASH .......... 7-26

ASSEMBLING THE FINAL DRIVE GEAR ........................................... 7-28

INSTALLING THE FINAL DRIVE GEAR ............................................. 7-28

........................... 7-15

CHAPTER 8.

CHASSIS

FRONT AND REAR WHEELS

FRONT WHEELS .................................................................................. 8-1

REAR WHEELS ....................................................................................8-2

CHECKING THE WHEELS ................................................................... 8-3

CHECKING THE WHEEL HUBS ........................................................... 8-3

CHECKING THE BRAKE DISCS .......................................................... 8-4

INSTALLING THE WHEEL HUBS ......................................................... 8-4

INSTALLING THE WHEELS ................................................................. 8-4

FRONT BRAKE

FRONT BRAKE PADS .......................................................................... 8-6

REPLACING THE FRONT BRAKE PADS ............................................ 8-7

FRONT BRAKE MASTER CYLINDER .................................................. 8-9

CHECKING THE MASTER CYLINDER .............................................. 8-11

ASSEMBLING THE FRONT BRAKE MASTER CYLINDER ...............8-11

INSTALLING THE FRONT BRAKE MASTER CYLINDER .................. 8-12

FRONT BRAKE CALIPER ................................................................... 8-14

DISASSEMBLING THE FRONT BRAKE CALIPERS .......................... 8-16

CHECKING THE FRONT BRAKE CALIPERS .................................... 8-16

ASSEMBLING THE FRONT BRAKE CALIPERS ................................ 8-17

INSTALLING THE FRONT BRAKE CALIPERS .................................. 8-17

............................................................................................8-6

......................................................................8-1

REAR BRAKE

REMOVING THE REAR BRAKE ......................................................... 8-23

CHECKING THE REAR BRAKE ......................................................... 8-24

INSTALLING THE REAR BRAKE ....................................................... 8-25

STEERING SYSTEM

HANDLEBAR ....................................................................................... 8-28

REMOVING THE REAR BRAKE SWITCH .........................................8-29

CHECKING THE HANDLEBAR .......................................................... 8-29

INSTALLING THE HANDLEBAR ........................................................ 8-29

INSTALLING THE REAR BRAKE LEVER .......................................... 8-29

INSTALLING THE MASTER CYLINDER ASSEMBLY ........................ 8-30

STEERING STEM ............................................................................... 8-31

REMOVING THE BEARING RETAINER ............................................8-33

CHECKING THE STEERING STEM ................................................... 8-33

INSTALLING THE BEARING RETAINER ........................................... 8-33

INSTALLING THE CABLE GUIDE ...................................................... 8-33

TIE RODS AND STEERING KNUCKLES ........................................... 8-34

REMOVING THE STEERING KNUCKLES ......................................... 8-36

CHECKING THE TIE RODS ............................................................... 8-36

CHECKING THE STEERING KNUCKLES .......................................... 8-36

INSTALLING THE TIE RODS ............................................................. 8-39

.............................................................................................8-19

..................................................................................8-28

FRONT ARMS AND FRONT SHOCK ABSORBERS ................................ 8-40

REMOVING THE FRONT ARMS ........................................................ 8-42

CHECKING THE FRONT ARMS ......................................................... 8-42

CHECKING THE FRONT SHOCK ABSORBER ................................. 8-44

INSTALLING THE FRONT ARMS AND

FRONT SHOCK ABSORBER .......................................................... 8-45

REAR SHOCK ABSORBER AND SWINGARM ......................................... 8-46

REMOVING THE SWINGARM ............................................................ 8-48

CHECKING THE REAR SHOCK ABSORBER .................................... 8-48

CHECKING THE SWINGARM ............................................................ 8-49

CHECKING THE RUBBER BOOT ...................................................... 8-49

INSTALLING THE RUBBER BOOT .................................................... 8-49

INSTALLING THE REAR AXLE HOUSING ........................................8-50

CHAPTER 9.

ELECTRICAL

ELECTRICAL COMPONENTS ..................................................................... 9-1

CHECKING THE SWITCHES .......................................................................9-2

CHECKING A SWITCH ......................................................................... 9-2

CHECKING A SWITCH SHOWN IN THE MANUAL .............................9-2

CHECKING THE SWITCH CONTINUITY ............................................. 9-4

CHECKING THE BULBS AND BULB SOCKETS ........................................ 9-6

TYPES OF BULBS ................................................................................ 9-6

CHECKING THE CONDITION OF THE BULBS ................................... 9-6

CHECKING THE CONDITION OF THE BULB SOCKETS ................... 9-8

IGNITION SYSTEM ....................................................................................... 9-9

CIRCUIT DIAGRAM .............................................................................. 9-9

TROUBLESHOOTING ........................................................................9-10

ELECTRIC STARTING SYSTEM ...............................................................9-15

CIRCUIT DIAGRAM ............................................................................ 9-15

TROUBLESHOOTING ........................................................................9-16

STARTER MOTOR .............................................................................9-19

CHECKING THE STARTER MOTOR ................................................. 9-20

ASSEMBLING THE STARTER MOTOR .............................................9-21

CHARGING SYSTEM ................................................................................. 9-22

CIRCUIT DIAGRAM ............................................................................ 9-22

TROUBLESHOOTING ........................................................................9-23

LIGHTING SYSTEM ....................................................................................9-25

CIRCUIT DIAGRAM ............................................................................ 9-25

TROUBLESHOOTING ........................................................................9-26

CHECKING THE LIGHTING SYSTEM ................................................ 9-28

SIGNAL SYSTEM ....................................................................................... 9-32

CIRCUIT DIAGRAM ............................................................................ 9-32

TROUBLESHOOTING ........................................................................9-34

CHECKING THE SIGNAL SYSTEM ...................................................9-36

COOLING SYSTEM ....................................................................................9-43

CIRCUIT DIAGRAM ............................................................................ 9-43

TROUBLESHOOTING .......................................................................9-44

2WD/4WD SELECTING SYSTEM .............................................................. 9-48

CIRCUIT DIAGRAM ............................................................................ 9-48

TROUBLESHOOTING ........................................................................9-49

CHAPTER 10.

TROUBLESHOOTING

STARTING FAILURE/HARD STARTING ................................................... 10-1

FUEL SYSTEM .................................................................................... 10-1

ELECTRICAL SYSTEM ....................................................................... 10-1

COMPRESSION SYSTEM .................................................................. 10-2

POOR IDLE SPEED PERFORMANCE ...................................................... 10-2

POOR IDLE SPEED PERFORMANCE ...............................................10-2

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

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

FAULTY DRIVE TRAIN .............................................................................. 10-3

FAULTY GEAR SHIFTING ......................................................................... 10-4

HARD SHIFTING ................................................................................. 10-4

SHIFT LEVER DOES NOT MOVE ...................................................... 10-4

JUMPS OUT OF GEAR ....................................................................... 10-4

FAULTY CLUTCH PERFORMANCE .........................................................10-4

ENGINE OPERATES BUT MACHINE WILL NOT MOVE ................... 10-4

CLUTCH SLIPPING ............................................................................10-4

POOR STARTING PERFORMANCE ..................................................10-4

POOR SPEED PERFORMANCE ........................................................10-5

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

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

FAULTY BRAKE .........................................................................................10-5

POOR BRAKING EFFECT ..................................................................10-5

SHOCK ABSORBER MALFUNCTION ....................................................... 10-6

MALFUNCTION ...................................................................................10-6

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

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

LIGHTING SYSTEM ....................................................................................10-6

HEADLIGHT DARK ............................................................................. 10-6

BULB BURNT OUT ............................................................................. 10-6

MACHINE IDENTIFICATION

GENERAL INFORMATION

MACHINE IDENTIFICATION

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number 1 is stamped into the left side of the frame.

MODEL LABEL

The model label 1 is affixed to the frame. This information will be needed to order spare parts.

GEN

INFO

1 - 1

IMPORTANT INFORMATION

EB101000

IMPORTANT INFORMATION

PREPARATION FOR REMOVAL PROCEDURES

1.Remove all dirt, mud, dust and foreign material before removal and disassembly.

2.Use proper tools and cleaning equipment. Refer to the “SPECIAL TOOLS” section.

3.When disassembling the machine, always keep mated parts together. This includes gears, cylinder, piston and other parts that have been “mated” through normal wear. Mated parts must always be reused or replaced as an assembly.

4.During machine disassembly, clean all parts and place them in trays in the order of disassembly. This will speed up assembly and allow for the correct installation of all parts.

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

GEN

INFO

EB101010

REPLACEMENT PARTS

1.Use only genuine Yamaha parts for all replacements. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.

EB101020

GASKETS, OIL SEALS AND O-RINGS

1.Replace all gaskets, seals and O-rings when overhauling the engine. All gasket surfaces, oil seal lips and O-rings must be cleaned.

2.Properly oil all mating parts and bearings during reassembly. Apply grease to the oil seal lips.

1 - 2

IMPORTANT INFORMATION

EB101030

LOCK WASHERS/PLATES AND COTTER PINS

1.Replace all lock washers/plates 1 and cotter pins after removal. Bend lock tabs along the bolt or nut flats after the bolt or nut has been tightened to specification.

EB101040

BEARINGS AND OIL SEALS

1.Install bearings and oil seals so that the manufacturer’s marks or numbers are visible. When installing oil seals, apply a light coating of lightweight lithium base grease to the seal lips. Oil bearings liberally when installing, if appropriate.

Oil seal

GEN

INFO

CAUTION:

Do not use compressed air to spin the bearings dry. This will damage the bearing surfaces.

Bearing

EB101050

CIRCLIPS

1.Check all circlips carefully before reassembly. Always replace piston pin clips after one use. Replace distorted circlips. When installing a circlip 1, make sure that the sharp-edged corner 2 is positioned opposite the thrust 3 it receives. See sectional view.

Shaft

1 - 3

CHECKING OF CONNECTIONS

EB801000

CHECKING OF CONNECTIONS

Check the connectors for stains, rust, moisture, etc.

1.Disconnect:

●

Connector

2.Check:

●

Connector Moisture → Dry each terminal with an air blower. Stains/rust → Connect and disconnect the terminals several times.

3.Check:

●

Connector leads Looseness → Bend up the pin 1 and connect the terminals.

GEN

INFO

4.Connect:

●

Connector terminals

OTE:

The two terminals “click” together.

5.Check:

●

Continuity (using a pocket tester)

OTE:

●

If there is no continuity, clean the terminals.

●

When checking the wire harness be sure to perform steps 1 to 3.

●

As a quick remedy, use a contact revitalizer available at most part stores.

●

Check the connector with a pocket tester as shown.

1 - 4

GEN

SPECIAL TOOLS

EB102001

SPECIAL TOOLS

The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools; this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools may differ by shape and part number from country to country. In such a case, two types are provided. When placing an order, refer to the list provided below to avoid any mistakes.

For US and CDN

P/N. YM-, YU-, YS-, YK-, ACC-

Except for US and CDN

P/N. 90890-

Tool No. Tool name/How to use Illustration

INFO

Bolt

90890-01083

Weight

90890-01084

Set

YU-01083-A

90890-01135

YU-01135-A

90890-01225

YM-01225-A

90890-04017

YM-04017

Slide hammer bolt (M6)/weight/set

These tools are used to remove the rocker arm shafts.

Crankcase separating tool

This tool is used to separate the crankcase.

Valve guide remover (7.0 mm)

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

Valve guide installer (7.0 mm)

This tool is needed to install the valve guides.

Valve guide reamer (7.0 mm)

90890-01227

YM-01227

90890-01235

YU-01235

90890-04088

Bolt

90890-01275

This tool is needed to rebore the new valve guides.

Rotor holding tool This tool is needed to hold the starter pulley when removing/installing the starter pulley bolt or camshaft sprocket bolt.

Buffer boss installer set Crankshaft installer bolt

These tools are used to install the crankshaft.

1 - 5

GEN

SPECIAL TOOLS

Tool No. Tool name/How to use Illustration

Crankshaft installer set

YU-90050

These tools are used to install the crankshaft.

INFO

Adapter

YM-33279

Spacer

90890-04060

YM-90070-A

90890-01304

YU-01304

90890-01311

YU-08035

90890-01312

YM-01312-A

Adapter #11 Spacer (crankshaft)

These tools are used to install the crankshaft.

Piston pin puller set

This tool is used to remove the piston pin.

Tappet adjusting tool

This tool is necessary for adjusting the valve clearance.

Fuel level gauge

This gauge is used to measure the fuel level in the float chamber.

Radiator cap tester

90890-01325 YU-24460-01

90890-01352

YU-33984

90890-01348

YM-01348

90890-04134

YM-04134

This tool is used to check the cooling systems.

Adapter

This tool is used to check the cooling systems.

Locknut wrench

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

Sheave spring compressor

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

1 - 6

GEN

SPECIAL TOOLS

Tool No. Tool name/How to use Illustration

Sheave fixed block

INFO

90890-04135

YM-04135

90890-01404

YM-01404

90890-01327

YM-01327

90890-01426

YU-38411

90890-01430

YM-38404

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

Flywheel puller

These tools are needed to remove the rotor.

Damper rod holder (30 mm)

This tool is needed to loosen and tighten the steering stem bearing retainers.

Oil filter wrench

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

Ring nut wrench

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

90890-01467

YM-01467

90890-01475

YM-01475

90890-01474

YM-01474

YM-01477

90890-01701

YS-01880-A

Gear lash measurement tool

This tool is used to measure the gear lash.

Ball joint remover/installer set

This tool is used to remove and install the ball joints.

Ball joint remover/installer attachment set

This tool is used to remove and install the ball joints.

Sheave holder

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

1 - 7

GEN

SPECIAL TOOLS

Tool No. Tool name/How to use Illustration

INFO

Compression gauge

90890-03081

YU-33223

Adapter

90890-04082

YU-33223-3

90890-03112

YU-03112-C

90890-03113

YU-8036-B

Compression gauge Adapter

These tools are needed to measure engine compression.

Pocket tester

This instrument is needed for checking the electrical system.

Engine tachometer

This tool is needed for observing engine rpm.

Inductive self-powered tachometer

This tool is needed for observing engine rpm.

Timing light

90890-03141

YM-33277-A

90890-04019

YM-04019

Middle driven shaft

bearing driver

90890-04058

YM-04058-1

Mechanical seal installer

90890-04078

YM-33221

90890-04050

YM-04050

90890-04062

YM-04062

This tool is necessary for checking ignition timing.

Valve spring compressor

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

Middle driven shaft bearing driver Mechanical seal installer

These tools are used to install the water pump seals.

Bearing retainer wrench

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

Universal joint holder

This tool is needed when removing or installing the universal joint yoke nuts.

1 - 8

GEN

SPECIAL TOOLS

Tool No. Tool name/How to use Illustration

Clutch holding tool

INFO

90890-04086

YM-91042

90890-04128

YM-04128

90890-04129

YM-04129

90890-06754

This tool is needed to hold the clutch carrier when removing or installing the carrier nut.

Bearing retainer wrench

This tool is needed when removing or installing the middle driven pinion gear bearing retainers.

Pinion gear fix clamp

This tool is used to hold the shift cam.

Ignition checker

This instrument is necessary for checking the ignition system components.

Dynamic spark tester

YM-34487

Bond

90890-85505

Sealant

ACC-11001-05-01

This instrument is necessary for checking the ignition system components.

Yamaha bond No. 1215 Sealant (Quick Gasket

This sealant (bond) is used on crankcase mating surfaces, etc.

)

1 - 9

GENERAL SPECIFICATIONS

SPECIFICATIONS

GENERAL SPECIFICATIONS

Item Standard

Model code: 5TE1, 5TE5 Dimensions:

Overall length 1,984 mm (78.1 in) Overall width 1,085 mm (42.7 in) Overall height 1,120 mm (44.1 in) Seat height 827 mm (32.6 in) Wheelbase 1,233 mm (48.5 in) Minimum ground clearance 245 mm (9.7 in) Minimum turning radius 3,000 mm (118.1 in)

Basic weight:

With oil and full fuel tank 265 kg (584 lb)

Engine:

Engine type Liquid-cooled 4-stroke, SOHC Cylinder arrangement Forward-inclined single cylinder Displacement 401 cm Bore × stroke 84.5 × 71.5 mm (3.33 × 2.81 in) Compression ratio 10.5 : 1 Standard compression pressure (at sea level) 1,400 kPa (14.0 kg/cm

Starting system Electric and recoil starter Lubrication system: Wet sump Oil type or grade:

Engine oil

SPEC

, 203 psi) at 750 r/min

API service SE, SF, SG type or higher

Final gear oil SAE 80API “GL-4” Hypoid Gear Oil

Differential gear oil SAE 80API “GL-4” Hypoid Gear Oil Oil capacity:

Engine oil

Periodic oil change 2.3 L (2.0 Imp qt, 2.4 US qt) With oil filter replacement 2.4 L (2.1 Imp qt, 2.5 US qt) Total amount 2.6 L (2.3 Imp qt, 2.7 US qt)

Final gear case oil

Periodic oil change 0.23 L (0.20 Imp qt, 0.24 US qt) Total amount 0.25 L (0.22 Imp qt, 0.26 US qt)

2 - 1

GENERAL SPECIFICATIONS

Item Standard

Differential gear case oil

Periodic oil change 0.35 L (0.31 Imp qt, 0.37 US qt) Total amount 0.40 L (0.35 Imp qt, 0.42 US qt)

Radiator capacity (including all routes) 1.32 L (1.16 Imp qt, 1.40 US qt) Air filter: Wet type element Fuel:

Type Unleaded fuel

Fuel tank capacity 15 L (3.3 Imp gal, 3.9 US gal)

Fuel reserve amount 4.5 L (0.99 Imp gal, 1.19 US gal) Carburetor:

Type/quantity BSR33/1

Manufacturer MIKUNI Spark plug:

Type/manufacturer DR8EA/NGK

Spark plug gap 0.6 ~ 0.7 mm (0.024 ~ 0.028 in) Clutch type: Wet, centrifugal automatic Transmission:

Primary reduction system V-belt

Secondary reduction system Spur gear

Secondary reduction ratio 39/24 × 24/18 × 33/9 (7.944)

Transmission type V-belt automatic

Operation Left hand operation

Single speed automatic 2.55 ~ 0.75 : 1

Sub transmission ratio 38/23 (1.652)

Reverse gear 29/17 (1.706) Chassis:

Frame type Steel tube frame

Caster angle 4°

Camber angle 1°

Kingpin angle 11°

Kingpin offset 0 mm (0 in)

Trail 21 mm (0.83 in)

Tread (STD) front 850 mm (33.46 in)

rear 825 mm (32.48 in)

Toe-in 0 ~ 10 mm (0 ~ 0.39 in) Tires:

Type Tubeless

Size front AT25 × 8–12

rear AT25 × 10–12

Manufacturer front MAXXIS

rear MAXXIS

Type front M911Y

rear M912Y

SPEC

2 - 2

GENERAL SPECIFICATIONS

Item Standard

Tire pressure (cold tire):

Maximum load* 210 kg (463 lb)

Off-road riding front 22 ~ 28 kPa (0.22 ~ 0.28 kg/cm

rear 22 ~ 28 kPa (0.22 ~ 0.28 kg/cm *Load in total weight of rider accessories Brakes:

Front brake type Dual disc brake

operation Right hand operation

Rear brake type Drum brake

operation Left hand and right foot operation Suspension:

Front suspension Double wishbone Rear suspension Swingarm (monocross)

Shock absorbers:

Front shock absorber Coil spring/oil damper Rear shock absorber Coil spring/oil damper

Wheel travel:

Front wheel travel 160 mm (6.30 in) Rear wheel travel 180 mm (7.09 in)

Electrical:

Ignition system D.C. C.D.I. Generator system A.C. magneto Battery type YTX14AH

Battery capacity 12 V 12 Ah Headlight type: Halogen bulb Bulb wattage × quantity:

Headlight 12 V 30 W/30 W × 2

Tail/brake light 12 V 5 W/21 W

Meter light 14 V 3 W × 1

Indicator lights

Neutral 12 V 1.7 W × 1 Reverse 12 V 1.7 W × 1 Coolant temperature 12 V 1.7 W × 1 Four-wheel drive 14 V 1.7 W × 1

SPEC

, 3.2 ~ 4.0 psi)

2 - 3

MAINTENANCE SPECIFICATIONS

SPEC

MAINTENANCE SPECIFICATIONS

ENGINE

Item Standard Limit

Cylinder head:

Warp limit ---- 0.03 mm

(0.0012 in)

Cylinder:

Bore size 84.500 ~ 84.510 mm

(3.3268 ~ 3.3272 in)

Taper limit ---- 0.05 mm

Out of round limit ---- 0.01 mm

Camshaft:

Drive method Chain drive (left) ----

Cam dimensions

84.600 mm (3.3307 in)

(0.0016 in)

(0.0004 in)

Intake “A” 40.62 ~ 40.72 mm

(1.5992 ~ 1.6031 in)

“B” 32.18 ~ 32.28 mm

(1.2669 ~ 1.2709 in)

Exhaust “A” 40.62 ~ 40.72 mm

(1.5992 ~ 1.6031 in)

“B” 32.18 ~ 32.28 mm

(1.2669 ~ 1.2709 in)

Camshaft runout limit ---- 0.03 mm

40.52 mm (1.5953 in)

32.08 mm (1.2630 in)

40.52 mm (1.5953 in)

32.08 mm (1.2630 in)

(0.0012 in)

2 - 4

MAINTENANCE SPECIFICATIONS

SPEC

Item Standard Limit

Cam chain:

Cam chain type/No. of links DID SCR-0409 SDH/116 ----

Cam chain adjustment method Automatic ---Rocker arm/rocker arm shaft:

Bearing 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)

Valves, valve seats, valve guides:

Valve clearance (cold) IN 0.06 ~ 0.10 mm

(0.0024 ~ 0.0039 in)

EX 0.16 ~ 0.20 mm

(0.0063 ~ 0.0079 in)

Valve dimensions

12.078 mm (0.4755 in)

11.951 mm (0.4705 in)

0.080 mm (0.0031 in)

----

Head Diameter

Face Width

Seat Width

Margin Thickness

“A” head diameter IN 39.9 ~ 40.1 mm

(1.5708 ~ 1.5787 in)

EX 33.9 ~ 34.1 mm

(1.3346 ~ 1.3425 in)

“B” face width IN 2.26 mm (0.0890 in) ----

EX 2.26 mm (0.0890 in) ----

“C” seat width IN 1.2 ~ 1.4 mm

(0.0472 ~ 0.0551 in)

EX 1.2 ~ 1.4 mm

(0.0472 ~ 0.0551 in)

“D” margin thickness IN 1.0 ~ 1.4 mm

(0.0394 ~ 0.0551 in)

EX 0.8 ~ 1.2 mm

(0.0315 ~ 0.0472 in)

Stem outside diameter IN 6.975 ~ 6.990 mm

(0.2746 ~ 0.2752 in)

EX 6.955 ~ 6.970 mm

(0.2738 ~ 0.2744 in)

Guide inside diameter IN 7.000 ~ 7.012 mm

(0.2756 ~ 0.2761 in)

EX 7.000 ~ 7.012 mm

(0.2756 ~ 0.2761 in)

Stem-to-guide clearance IN 0.010 ~ 0.037 mm

(0.0004 ~ 0.0015 in)

EX 0.030 ~ 0.057 mm

(0.0012 ~ 0.0022 in)

----

1.6 mm (0.0630 in)

----

6.950 mm (0.2736 in)

6.915 mm (0.2722 in)

7.030 mm (0.2768 in)

0.080 mm (0.0031 in)

0.100 mm (0.0039 in)

2 - 5

MAINTENANCE SPECIFICATIONS

Item Standard Limit

Stem runout limit ---- 0.01 mm

SPEC

(0.0004 in)

Valve seat width IN 1.2 ~ 1.4 mm

(0.0472 ~ 0.0551 in)

EX 1.2 ~ 1.4 mm

(0.0472 ~ 0.0551 in)

Valve spring:

Inner spring

Free length IN 39.9 mm (1.57 in) 37.9 mm

EX 39.9 mm (1.57 in) 37.9 mm

Set length (valve closed) IN 33.6 mm (1.32 in) ----

EX 33.6 mm (1.32 in) ----

Compressed pressure (installed) IN 104.9 ~ 120.6 N (10.70 ~

12.30 kg, 23.58 ~ 27.11 lb)

EX 104.9 ~ 120.6 N (10.70 ~

12.30 kg, 23.58 ~ 27.11 lb)

Tilt limit IN 2.5°/1.6 mm

EX 2.5°/1.6 mm

----

(1.49 in)

----

(2.5°/0.06 in)

Direction of winding (top view) IN Counterclockwise ----

EX Counterclockwise ----

Outer spring

Free length IN 43.27 mm (1.70 in) 41.27 mm

(1.62 in)

EX 43.27 mm (1.70 in) 41.27 mm

(1.62 in)

Set length (valve closed) IN 36.6 mm (1.44 in) ----

EX 36.6 mm (1.44 in) ----

Compressed pressure (installed) IN 235.4 ~ 251.1 N (24.00 ~

25.60 kg, 52.91 ~ 56.45 lb)

EX 235.4 ~ 251.1 N (24.00 ~

25.60 kg, 52.91 ~ 56.45 lb)

----

2 - 6

MAINTENANCE SPECIFICATIONS

Item Standard Limit

Tilt limit IN 2.5°/1.6 mm

Direction of winding (top view) IN Clockwise ----

Piston:

Piston to cylinder clearance 0.040 ~ 0.065 mm

Piston size “D” 84.445 ~ 84.460 mm

EX 2.5°/1.6 mm

EX Clockwise ----

(0.0016 ~ 0.0026 in)

(3.3246 ~ 3.3252 in)

SPEC

(2.5°/0.06 in)

0.150 mm (0.0059 in)

----

Measuring point “H” 5 mm (0.20 in) ----

Piston offset 0.5 mm (0.0200 in) ----

Offset direction Intake side ----

Piston pin bore inside diameter 20.004 ~ 20.015 mm

(0.7876 ~ 0.7880 in)

Piston pin outside diameter 19.991 ~ 20.000 mm

(0.7870 ~ 0.7874 in)

Piston rings:

Top ring

Type Barrel ---Dimensions (B × T) 1.2 × 3.1 mm

(0.04724 × 0.1220 in)

End gap (installed) 0.20 ~ 0.40 mm

(0.0079 ~ 0.0157 in)

Side clearance (installed) 0.03 ~ 0.08 mm

(0.0012 ~ 0.0031 in)

20.045 mm (0.7892 in)

19.971 mm (0.7863 in)

----

0.65 mm (0.0256 in)

0.13 mm (0.0051 in)

2 - 7

MAINTENANCE SPECIFICATIONS

Item Standard Limit

2nd ring

Type Taper ---Dimensions (B × T) 1.2 × 3.6 mm

(0.04724 × 0.1417 in)

End gap (installed) 0.40 ~ 0.60 mm

(0.0157 ~ 0.0236 in)

Side clearance 0.03 ~ 0.07 mm

(0.0012 ~ 0.0028 in)

Oil ring

SPEC

----

0.95 mm (0.0374 in)

0.13 mm (0.0051 in)

Dimensions (B × T) 2.8 × 2.8 mm

(0.1102 × 0.1102 in)

End gap (installed) 0.2 ~ 0.7 mm

(0.0079 ~ 0.0276 in)

Crankshaft:

Crank width “A” 62.95 ~ 63.00 mm

Runout limit C1 ---- 0.03 mm

C2 ---- 0.03 mm

Big end side clearance “B” 0.25 ~ 0.75 mm

Big end radial clearance “E” 0.010 ~ 0.025 mm

Balancer:

Balancer drive method Gear ---Automatic centrifugal clutch:

Clutch shoe thickness 1.5 mm (0.06 in) 1.0 mm

Clutch-in revolution 1,960 ~ 2,240 r/min ----

Clutch-stall revolution 3,300 ~ 3,900 r/min ----

(2.4783 ~ 2.4803 in)

(0.0098 ~ 0.0295 in)

(0.0004 ~ 0.0010 in)

----

(0.0012 in)

1.00 mm (0.0394 in)

----

(0.04 in)

2 - 8

MAINTENANCE SPECIFICATIONS

Item Standard Limit

Transmission:

Main axle deflection limit ---- 0.06 mm

Drive axle deflection limit ---- 0.06 mm

Shifter:

Shifter type Shift cam and guide bar ---Air filter oil grade: Engine oil ---Carburetor:

I. D. mark 5TE1 00 ----

Main jet (M.J) #132.5 ----

Main air jet (M.A.J) #50 ----

Jet needle (J.N) 5EP13-55-3 ----

Needle jet (N.J) P-0M ----

Pilot air jet (P.A.J.1) #80 ----

Pilot air jet (P.A.J.2) 1.3 ----

Pilot outlet (P.O) 0.95 ----

Pilot jet (P.J) #17.5 ----

Bypass 1 (B.P.1) 0.8 ----

Bypass 2 (B.P.2) 0.8 ----

Bypass 3 (B.P.3) 0.8 ----

Valve seat size (V.S) 2.0 ----

Starter jet (G.S.1) #75 ----

Starter jet (G.S.2) 0.9 ----

Throttle valve size (Th.V) #90 ----

Float height (F.H) 13 mm (0.51 in) ----

Fuel level (F.L) 4.0 ~ 5.0 mm (0.16 ~ 0.20 in) ----

Engine idle speed 1,450 ~ 1,550 r/min ----

Intake vacuum 32 kPa (240 mmHg, 9.45 inHg) ---Oil pump:

Oil filter type Foam ----

Oil pump type Trochoid ----

Tip clearance “A” or “B” 0.15 mm (0.006 in) 0.20 mm

Side clearance 0.04 ~ 0.09 mm

(0.002 ~ 0.004 in)

Bypass valve setting pressure 78 ~ 118 kPa (0.78 ~

1.18 kg/cm

Oil pressure (hot) 7 kPa (0.07 kg/cm

1,500 r/min

Pressure check location Cylinder head ----

, 11.3 ~ 17.11 psi)

, 1.02 psi) at

SPEC

(0.0024 in)

(0.008 in)

----

2 - 9

MAINTENANCE SPECIFICATIONS

SPEC

Item Standard Limit

Cooling system:

Radiator core

Width 300 mm (11.8 in) ---Height 208 mm (8.19 in) ---Thickness 26 mm (1.02 in) ----

Radiator cap opening pressure 93.7 ~ 122.6 kPa (0.937 ~

1.226 kg/cm

, 13.32 ~ 17.43 psi) Radiator capacity 0.70 L (0.62 Imp qt, 0.74 US qt) ---Coolant reservoir

Capacity 0.39 L (0.34 Imp qt, 0.41 US qt) ---From low to full level 0.15 L (0.13 Imp qt, 0.16 US qt) ----

Water pump:

Type Single-suction centrifugal pump ---Reduction ratio 38/32 (1.188)

Thermostat:

Valve opening temperature 63.5 ~ 66.5 °C (146.3 ~ 151.7 °F) ---- Valve full open temperature 80 °C (176 °F) ---- Valve lift-full open 3 mm (0.12 in) ----

Shaft drive:

Middle gear backlash 0.1 ~ 0.3 mm (0.004 ~ 0.012 in) ---Final gear backlash 0.1 ~ 0.2 mm (0.004 ~ 0.008 in) ---Differential gear backlash 0.10 ~ 0.50 mm

(0.004 ~ 0.020 in)

Lubrication chart:

----

Pressure feed

Splashed scavenge

Piston

Clutch

Crank Pin

Piston Pin

Oil Filter

Bypass

Oil Pump

Valve

Camshaft

Rocker Arm

Transmission

Timing Chain Area

Valve

Oil Strainer

2 - 10

MAINTENANCE SPECIFICATIONS

Item Standard Limit

Cylinder head tightening sequence:

SPEC

2 - 11

Tightening torques

MAINTENANCE SPECIFICATIONS

SPEC

Part to be tightened

Cylinder head oil passage Cylinder head (exhaust pipe)

Part

name

Union bolt

Stud bolt

Thread

size

Q’ty

M6 1 7 0.7 5.1 M8 2 15 1.5 11

Tightening torque

Remarks

Nm m·kg ft·lb

Cylinder head Bolt M10 4 40 4.0 29

Bolt M6 2 10 1.0 7.2

Camshaft sprocket cover baffle

Bolt M6 2 10 1.0 7.2

plate Camshaft bearing retainer Bolt M6 2 8 0.8 5.8 Spark plug — M12 1 18 1.8 13 Coolant drain bolt (cylinder) Bolt M6 1 10 1.0 7.2 Starter clutch Bolt M10 1 50 5.0 36 Camshaft sprocket Bolt M10 1 60 6.0 43 Timing chain tensioner cap Bolt M11 1 23 2.3 17 Timing chain tensioner Bolt M6 2 11 1.1 8.0 Timing chain guide (intake) Bolt M6 2 10 1.0 7.2 Valve adjusting screw Nut M7 2 20 2.0 14 Radiator Bolt M6 2 7 0.7 5.1 Oil pump assembly Screw M6 3 8 0.8 5.8 Oil pump Screw M6 1 7 0.7 5.1 Oil strainer cover Plug M35 1 32 3.2 23 Oil drain bolt Bolt M14 1 23 2.3 17 Oil pump drive gear Nut M14 1 50 5.0 36 Oil delivery pipe Oil filter bolt

Union bolt

M8 2 18 1.8 13

M20 1 63 6.3 45 Oil filter cartridge — M20 1 17 1.7 12 Intake manifold Bolt M8 2 20 2.0 14 Muffler and exhaust pipe Bolt M8 2 15 1.5 11 Exhaust pipe Nut M8 2 20 2.0 14 Muffler Bolt M10 2 25 2.5 18 Exhaust pipe bracket Bolt M6 2 14 1.4 10 Crankcase cover Screw M6 4 8 0.8 5.8 Oil seal retainer Screw M5 3 7 0.7 5.1 Drive belt case cover Bolt M6 12 10 1.0 7.2 Crankcase oil passage plug Plug M18 1 55 5.5 40 Bearing retainer (right crankcase) Screw M6 1 11 1.1 8.0 Plug (right crankcase) Bolt M8 1 15 1.5 11 Bearing retainer (left crankcase) Bolt M6 2 10 1.0 7.2 Crankcase cover (left) Bolt M6 12 10 1.0 7.2 Recoil starter

Bolt M6 4 10 1.0 7.2 Starter one-way clutch Bolt M8 6 30 3.0 22 Clutch carrier assembly Nut M22 1 140 14 100 Stake Middle drive shaft bearing retainer Torx

M8 4 25 2.5 18

screw

2 - 12

MAINTENANCE SPECIFICATIONS

SPEC

Part to be tightened

Part

name

Thread

size

Q’ty

Tightening torque

Remarks

Nm m·kg ft·lb

Middle driven shaft drive pinion gear Nut M22 1 130 13 94 Stake Middle drive shaft bearing housing Bolt M8 6 32 3.2 23 Middle driven gear bearing retainer Nut M65 1 110 11 80

Left-hand threads

Yoke (middle driven gear) Nut M14 1 97 9.7 70 Middle driven gear bearing housing Bolt M8 4 25 2.5 18 Middle driven shaft bearing retainer Nut M55 1 80 8.0 58

Left-hand threads

Shift rod Nut M8 2 15 1.5 11 Primary sliding sheave assembly Nut M16 1 100 10.0 72 Secondary sheave assembly Nut M16 1 100 10.0 72 Secondary sheave spring retainer Nut M36 1 90 9.0 65 Shift lever 2 Bolt M6 1 14 1.4 10 Shift control cable — M12 1 6 0.6 4.3 Select lever unit Bolt M8 3 15 1.5 11 Shift cam stopper — M14 1 18 1.8 13 CDI unit Screw M6 1 2 0.2 1.4 Neutral switch — M10 1 20 2.0 14 Reverse switch — M10 1 20 2.0 14 Stator assembly Screw M6 3 7 0.7 5.1 Pickup coil Bolt M5 2 7 0.7 5.1 Ignition coil Bolt M6 2 7 0.7 5.1 Thermo switch (cylinder head) — PT1/8 1 8 0.8 5.8 Speed sensor Bolt M6 1 10 1.0 7.2 Thermo switch (radiator) — M18 1 28 2.8 20 Tappet covers Bolt M6 4 10 1.0 7.2 Coolant drain bolt (water pump) Bolt M6 1 10 1.0 7.2 Coolant inlet joint Bolt M6 2 10 1.0 7.2 Bearing housing Bolt M6 1 10 1.0 7.2 Primary pulley sheave cap Screw M4 4 3 0.3 2.2 Clutch housing assembly Bolt M6 8 10 1.0 7.2 Clutch housing assembly cover Bolt M6 5 10 1.0 7.2 Starter motor Bolt M6 2 10 1.0 7.2 Engine side cover bracket Bolt M6 2 10 1.0 7.2 Crankcase Bolt M6 17 10 1.0 7.2 Thermostat cover Bolt M6 2 10 1.0 7.2 Water pump outlet pipe Bolt M6 1 10 1.0 7.2 Water pump assembly Bolt M6 2 10 1.0 7.2 Gear unit Bolt M6 2 10 1.0 7.2

Screw M6 1 7 0.7 5.1

2 - 13

MAINTENANCE SPECIFICATIONS

CHASSIS

Item Standard Limit

Steering system:

Steering bearing type Ball and race bearing ----

Front suspension:

Shock absorber travel 99 mm (3.90 in) ---Fork spring free length 265 mm (10.43 in) ---Spring fitting length 215.8 mm (8.50 in) ---Spring rate (K1) 15 N/mm (1.53 kg/mm, 85.68 lb/in) ---Stroke (K1) 0 ~ 99 mm (0 ~ 3.90 in) ---Optional spring No ----

Rear suspension:

Shock absorber travel 126 mm (4.96 in) ---Spring free length 317 mm (12.48 in) ---Spring fitting length 283 mm (11.14 in) ---Spring rate (K1) 30.4 N/mm

(3.10 kg/mm, 173.60 lb/in) Stroke (K1) 0 ~ 126 mm (0 ~ 4.96 in) ---Optional spring No ----

Swingarm:

Free play limit end ---- 1 mm

side ---- 1 mm

Front wheel:

Type Panel wheel ---Rim size 12 × 6.0 AT ---Rim material Steel ---Rim runout limit radial ---- 2 mm

lateral ---- 2 mm

Rear wheel:

Type Panel wheel ---Rim size 12 × 7.5 AT ---Rim material Steel ---Rim runout limit radial ---- 2 mm

lateral ---- 2 mm

SPEC

----

(0.04 in)

(0.08 in)

2 - 14

MAINTENANCE SPECIFICATIONS

Item Standard Limit

Front disc brake:

Type Dual ---Disc outside diameter × thickness 200.0 × 3.5 mm (7.87 ~ 0.14 in) ---Pad thickness inner 4.5 mm (0.18 in) 1 mm

Pad thickness outer 4.5 mm (0.18 in) 1 mm

Master cylinder inside diameter 14 mm (0.55 in) ---Caliper cylinder inside diameter 32 mm (1.26 in) ---Brake fluid type DOT 4 ----

Rear drum brake:

Type Leading, trailing ---Brake drum inside diameter 160 mm (6.30 in) 161 mm

Lining thickness 4.0 mm (0.16 in) 2 mm

Brake lever and brake pedal:

Brake lever free play (pivot) front 0 mm (0 in) ----

rear 3 ~ 5 mm (0.12 ~ 0.20 in) ---Brake pedal free play 20 ~ 30 mm (0.79 ~ 1.18 in) ---Throttle lever free play 3 ~ 5 mm (0.12 ~ 0.20 in) ----

SPEC

(0.04 in)

(6.34 in)

(0.08 in)

2 - 15

Tightening torques

MAINTENANCE SPECIFICATIONS

SPEC

Part to be tightened Thread size

Remarks

Nm m·kg ft·lb

Engine bracket (front-upper) and frame M8 33 3.3 24 Engine bracket (front-lower) and frame M8 33 3.3 24 Engine bracket (front-upper) and engine M10 42 4.2 30 Engine bracket (front-lower) and engine M10 42 4.2 30 Engine and frame M10 56 5.6 40

Tightening torque

Frame and bearing retainer (steering stem holder

M42 40 4.0 29

bearing) Select lever assembly and frame M8 23 2.3 17 Swingarm M12 82 8.2 60 Rear shock absorber and frame M12 82 8.2 60 Final gear case and swingarm M10 63 6.3 45

Final gear case and rear axle housing M10 63 6.3 46 Swingarm and rear axle housing M10 63 6.3 46 Differential gear case and frame M10 55 5.5 40 Front arm and frame M10 45 4.5 32

Front shock absorber and frame M10 45 4.5 32 Front shock absorber and upper front arm M10 45 4.5 32 Steering stem, pitman arm and frame M14 130 13.0 94

Steering stem holder and frame M8 23 2.3 17 Use lock

washer Steering stem and handlebar holder M8 23 2.3 17 Pitman arm and tie-rod end M12 30 3.0 22 Tie-rod and locknut M12 40 4.0 29 Steering knuckle and upper front arm M12 30 3.0 22 Steering knuckle and lower front arm M12 30 3.0 22

Steering knuckle and tie-rod M12 30 3.0 22 Fuel tank and fuel cock M6 4 0.4 2.9 Front wheel and wheel hub M10 64 6.4 46 Front axle and wheel hub M16 150 15.0 110 Steering knuckle and brake caliper M8 30 3.0 22 Front brake disc and wheel hub M8 30 3.0 22

Rear wheel and rear wheel hub M10 55 5.5 40 Rear axle and nut M16 150 15.0 110 Brake drum cover and brake shoe plate M6 28 2.8 20

Front brake pipe nut M10 19 1.9 13 Front brake hose union bolt M10 27 2.7 19 Bleed screw M8 6 0.6 4.3 Master cylinder and handlebar M6 7 0.7 5.1 Footrest and frame M8 16 1.6 11

2 - 16

MAINTENANCE SPECIFICATIONS

SPEC

Part to be tightened Thread size

Tightening torque

Nm m·kg ft·lb

Front bumper and frame M8 33 3.3 24 Front carrier and frame M8 33 3.3 24 Front carrier and front bumper M8 33 3.3 24 Rear carrier and frame M8 33 3.3 24 Differential gear case filler bolt M14 23 2.3 17 Differential gear case drain bolt M10 10 1.0 7 Differential gear case and bearing housing M8 25 2.5 18 Gear motor M8 13 1.3 9.4 Final gear case oil filler bolt M14 23 2.3 17 Final gear case oil drain bolt M14 23 2.3 17 Bearing retainer (drive pinion gear) M65 100 10.0 72 Final gear case and bearing housing M10 40 4.0 29 Final gear case and bearing housing M8 23 2.3 17 Battery holding bracket M6 7 0.7 5.1 Footrest board and footrest bracket M6 7 0.7 5.1 Yoke (drive pinion gear) M12 62 6.2 45 Trailer hitch bracket M10 32 3.2 23 Front brake pad holding bolt M10 18 1.8 13 Rear brake light switch bracket M8 23 2.3 17 Rear brake light switch cover M6 7 0.7 5.1 Front brake caliper retaining bolt M8 30 3.0 22 Air duct (front) M6 7 0.7 5.1 Rear brake lever holder bracket M6 7 0.7 5.1 Rear brake lever (bolt) M6 7 0.7 5.1 Rear brake lever (nut) M6 7 0.7 5.1 Brake camshaft lever M6 9 0.9 6.5 Four-wheel drive switch M10 20 2.0 14

Remarks

2 - 17

MAINTENANCE SPECIFICATIONS

ELECTRICAL

Item Standard Limit

Voltage: 12 V ---Ignition system:

Ignition timing (B.T.D.C.) 10°/ 1,500 r/min ----

C.D.I.:

Magneto model/manufacturer F4T46472/MITSUBISHI ---Pickup coil resistance/color 459 ~ 561 Ω at 20 °C (68 °F)/

White/Red – White/Green

Rotor rotation direction sensing coil resistance/color

C.D.I. unit model/manufacturer F8T38679/MITSUBISHI ----

Ignition coil:

Model/manufacturer 2JN/YAMAHA ---Minimum spark gap 6 mm (0.24 in) ---Primary winding resistance 0.18 ~ 0.28 Ω at 20 °C (68 °F) ---Secondary winding resistance 6.32 ~ 9.48 kΩ at 20 °C (68 °F) ----

Spark plug cap:

Type Resin ---Resistance 10 kΩ ----

Charging system:

Type A.C. magneto generator ---Model/manufacturer F4T464/MITSUBISHI ---Nominal output 14 V 17.5 A at 5,000 r/min ---Charging coil resistance/color 0.46 ~ 0.62 Ω at 20 °C (68 °F)/

Rectifier/regulator:

Regulator type Semi conductor-short circuit ---No-load regulated voltage (DC) 14.1 ~ 14.9 V ---Model/manufacturer SH640E-11/SHINDENGEN ---Capacity 14 A ---Withstand voltage 200 V ----

Electric starter system:

Type Constant mesh ---Starter motor

Model/manufacturer SM-13/MITSUBA ---Output 0.8 kW ---Armature coil resistance 0.025 ~ 0.035 Ω at 20 °C (68 °F) ----

0.085 ~ 0.105 Ω at 20 °C (68 °F)/ Red – White/Blue

White – White

SPEC

----

2 - 18

MAINTENANCE SPECIFICATIONS

Item Standard Limit

Brush overall length 12.5 mm (0.49 in) 5 mm

Spring force 7.65 ~ 10.01 N (780 ~ 1,020 g,

27.54 ~ 36.03 oz)

Commutator diameter 28 mm (1.10 in) 27 mm

Mica undercut 0.7 mm (0.03 in) ----

Starter relay

Model/manufacturer MS5F-561/JIDECO ---Amperage rating 180 A ---Coil winding resistance 4.18 ~ 4.62 Ω at 20 °C (68 °F) ----

Electric fan:

Running rpm 3,500 r/min ----

Thermostat switch:

Thermostat switch (cylinder head)

Model/manufacturer 4BA/DENSO ----

Thermostat switch (radiator)

Model/manufacturer 5ND/NIPPON THERMOSTAT ----

Circuit breakers:

Type Fuse ---Amperage for individual circuit

Main fuse 30 A × 1 ---Headlight fuse 15 A × 1 ---Ignition fuse 10 A × 1 ---Auxiliary DC jack fuse 10 A × 1 ---Four-wheel drive fuse 3 A × 1 ---Signaling system fuse 10 A × 1 ---Reserve 30 A × 1 ---Reserve 15 A × 1 ---Reserve 10 A × 1 ---Reserve 3 A × 1 ----

SPEC

(0.20 in)

----

(1.06 in)

2 - 19

HOW TO USE THE CONVERSION TABLE/

GENERAL TORQUE SPECIFICATIONS

SPEC

EB201000

HOW TO USE THE CONVERSION TABLE

All specification data in this manual are listed in SI and METRIC UNITS. Use this table to convert METRIC unit data to IMPERIAL unit data. Ex.

METRIC MULTIPLIER IMPERIAL

** mm

2 mm

CONVERSION TABLE

Torque

Weight

Speed km/hr 0.6214 mph

Distance

Volume/ Capacity

Misc.

0.03937 = ** in

0.03937 = 0.08 in

METRIC TO IMPERIAL

Metric unit Multiplier Imperial unit

m·kg m·kg cm·kg cm·kg

kg g

km m m cm mm

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

kg/mm kg/cm Centigrade (°C)

)

7.233

86.794

0.0723

0.8679

2.205

0.03527lboz

0.6214

3.281

1.094

0.3937

0.03937

0.03527

0.06102

0.8799

0.2199

55.997

14.2234 9/5+32

ft·lb in·lb ft·lb in·lb

mi ft yd in in

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

lb/in psi (lb/in Fahrenheit (°F)

)

EB202001

GENERAL TORQUE SPECIFICATIONS

This chart specifies torque for standard fasteners with standard I.S.O. pitch threads. Torque specifications for special components or assemblies are provided for each chapter of this manual. To avoid warpage, tighten multifastener assemblies in a crisscross fashion, in progressive stages, until the specified torque is reached. Unless otherwise specified, torque specifications require clean, dry threads. Components should be at room temperature.

A: Distance between flats B: Outside thread diameter

(nut)

(bolt)

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

General torque

specifications

Nm m•kg ft•lb

2 - 20

17 mm 12 mm 55 5.5 40

19 mm 14 mm 85 8.5 61

22 mm 16 mm 130 13.0 94

LUBRICATION POINTS AND LUBRICANT TYPES

ENGINE

Lubrication points Lubricant type

SPEC

Oil seal lip (all)

O-ring (all)

Bearing (all)

Crank pin

Connecting rod (bearing)

Camshaft sprocket

Crankshaft

Piston surface/piston rings

Piston pin

Buffer boss

Valve stem/valve stem end

Rocker arm shaft

Rocker arm

Camshaft lobe/journal

Cylinder head bolt

Oil pump shaft, rotor, housing

Oil filter O-ring

Starter idle gear shaft

Transmission gear (wheel/pinion)

Axle (main/drive)

Shift fork/guide bar

Shift cam/shift shaft/shift cam stopper

Shift guide

Shift cam lever

Clutch housing

One-way bearing

Drive chain/sprocket

Driven cam

Front drive shaft collar

Crankcase mating surface

Stator lead grommet (left side crankcase)

Sealant (Quick Gasket Yamaha Bond No.1215

)

2 - 21

COOLANT FLOW DIAGRAMS

1 Radiator 2 Thermo switch (radiator) 3 Fan motor

È To coolant reservoir

SPEC

2 - 22

1 Radiator 2 Thermostat

È To coolant reservoir

COOLANT FLOW DIAGRAMS

SPEC

2 - 23

OIL FLOW DIAGRAMS

1 Camshaft 2 Crankshaft 3 Drive axle

OIL FLOW DIAGRAMS

SPEC

2 - 24

1 Oil filter

OIL FLOW DIAGRAMS

SPEC

2 - 25

1 Oil pump 2 Oil strainer

OIL FLOW DIAGRAMS

SPEC

2 - 26

CABLE ROUTING

1 Rear brake switch lead 2 Starter cable 3 Rear brake cable 4 Front brake hose 5 On-command four-wheel drive switch 6 Throttle cable 7 Handlebar switch 8 Handlebar switch lead 9 Main switch lead

CABLE ROUTING

0 Fan motor breather hose A Differential gear case breather hose B Sub-wire harness (to gear motor) C On-command four-wheel drive switch lead

SPEC

2 - 27

CABLE ROUTING

È Fasten the on-command four-wheel drive switch lead behind the handlebar with a plastic band. É Fasten the starter cable, handlebar switch lead and rear brake switch lead behind the handlebar with a

plastic band.

Ê Fasten the handlebar switch lead and rear brake switch lead behind the handlebar with a plastic band.

SPEC

2 - 28

1 Sub-wire harness 2 Headlight lead 3 Auxiliary DC jack lead 4 Meter assembly coupler 5 Differential gear case breather hose 6 Coolant reservoir breather hose 7 Fan motor breather hose

CABLE ROUTING

SPEC

2 - 29

CABLE ROUTING

SPEC

1 Starter cable 2 Cylinder head breather hose 3 Fuel hose 4 Carburetor drain hose 5 Rear brake lever cable 6 Coolant reservoir breather hose 7 Radiator outlet hose 8 Coolant reservoir hose 9 Sub-wire harness 0 Differential gear case breather hose A Thermo switch (radiator)

B Speedometer cable

È Insert the fuel tank breather hose into the hole of

the handlebar cover.

É Fasten the sub-wire harness, differential gear

case breather hose, coolant reservoir hose, coolant reservoir breather hose, thermo switch (radiator) lead and fan motor breather hose with a plastic band.

2 - 30

CABLE ROUTING

SPEC

1 Cylinder head breather hose 2 Final drive gear case breather hose 3 Rear brake breather hose 4 Wire harness 5 Starter motor lead 6 Negative battery lead 7 Rear brake lever cable 8 Air filter case check hose 9 Water pump breather hose 0 Radiator outlet hose A Starter cable

B Float chamber air vent hose C Cylinder head breather hose D Fuel hose E A.C. magneto lead F Gear position switch lead G Neutral switch H Reverse switch I Rectifier/regulator

2 - 31

CABLE ROUTING

È Fasten the wire harness with a plastic band. É Fasten the starter motor lead, wire harness, negative battery lead, final drive gear case breather hose, rear

brake breather hose, rectifier/regulator lead, gear position switch lead and A.C. magneto lead with a plastic band.

Ê Fasten the wire harness, starter motor lead with a plastic band. Ë Fasten the gear position switch lead, A.C. magneto lead, rectifier/regulator lead and negative battery lead

with a plastic band.

SPEC

2 - 32

CABLE ROUTING

SPEC

1 Throttle cable 2 Radiator inlet hose 3 Spark plug lead 4 Main switch 5 Wire harness 6 Rear brake light switch lead 7 Select lever control cable 8 Rear brake pedal cable

È Fasten the radiator inlet hose and spark plug

lead with a plastic band.

2 - 33

1 Front brake hose 2 Float chamber air vent hose 3 Throttle cable 4 Wire harness 5 Final drive gear case breather hose 6 Rear brake breather hose 7 Starter cable 8 Rear brake lever cable

CABLE ROUTING

SPEC

2 - 34

1 Battery 2 Negative battery lead 3 Tail/brake light lead 4 CDI unit 5 Positive battery lead

CABLE ROUTING

SPEC

2 - 35

1 Rear brake pedal cable 2 Final drive gear case breather hose 3 Rear brake breather hose 4 Rear brake lever cable 5 Air filter case check hose

CABLE ROUTING

SPEC

2 - 36

INTRODUCTION/

PERIODIC MAINTENANCE/LUBRICATION

EB300000

CHK

ADJ

PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION

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

PERIODIC MAINTENANCE/LUBRICATION

INITIAL EVERY

ITEM ROUTINE

Valves*

Cooling system

Spark plug

Air filter element

Carburetor*

Crankcase breather system*

Exhaust system*

Spark arrester

Fuel line*

Engine oil

Engine oil filter cartridge

Engine oil strainer*

Final gear oil

Differential gear oil

Front brake*

Rear brake

V-belt*

Wheels*

Wheel bearing*

• Check valve clearance.

• Adjust if necessary.

• Check coolant leakage.

• Repair if necessary.

• Replace coolant every 24 months.

• Check condition.

• Adjust gap and clean.

• Replace if necessary.

• Clean.

• Replace if necessary.

• Check and adjust idle speed/starter operation.

• Adjust if necessary.

• Check breather hose for cracks or damage.

• Replace if necessary.

• Check for leakage.

• Tighten if necessary.

• Replace gasket(s) if necessary.

• Clean.

• Check fuel hose for cracks or damage.

• Replace if necessary.

• Replace. (Warm engine before draining.)

• Replace.

• Clean.

• Check for oil leakage.

• Replace every 12 months.

• Check operation/fluid leakage. (See NOTE page 3-2.)

• Correct if necessary.

• Check operation.

• Adjust if necessary.

• Check operation.

• Check for cracks or damage.

• Check balance/damage/runout.

• Repair if necessary.

• Check bearing assemblies for looseness/damage.

• Replace if damaged.

month3 months6 months6 months1 year

Every 20–40 hours

(More often in wet or dusty areas.)

3 - 1

CHK

PERIODIC MAINTENANCE/LUBRICATION

INITIAL EVERY

ITEM ROUTINE

Front and rear suspension*

Steering system*

Axle boots*

Fittings and fasteners*

• Check operation.

• Correct if necessary.

• Check operation./Replace if damaged.

• Check toe-in./Adjust if necessary.

• Check operation.

• Replace if damaged.

• Check all chassis fittings and fasteners.

• Correct if necessary.

* It is recommended that these items be serviced by a Yamaha dealer.

OTE:

●

Recommended brake fluid: DOT 4

●

Brake fluid replacement:

1.When disassembling the master cylinder or caliper, replace the brake fluid. Normally check the brake fluid level and add fluid as required.

2.On the inner parts of the master cylinder and caliper, replace the oil seals every two years.

3.Replace the brake hoses every four years, or if cracked or damaged.

month3 months6 months6 months1 year

ADJ

WARNING

Indicates a potential hazard that could result in serious injury or death.

3 - 2

SEAT, CARRIERS, FENDERS AND FUEL TANK

SEAT AND SIDE PANELS

CHK

ADJ

Order Job name/Part name Q’ty Remarks

Removing the seat and side panels

1Seat 1

2 Fuel tank side panel (left) 1 3 Fuel tank side panel (right) 1 4 Engine side panel 1 5 Engine side cover 1

Remove the parts in the order below.

OTE:

Pull up the seat lock lever, then pull up on the rear of the seat.

For installation, reverse the removal procedure.

3 - 3

SEAT, CARRIERS, FENDERS AND FUEL TANK

FRONT CARRIER, FRONT BUMPER AND FRONT FENDER

CHK

ADJ

Order Job name/Part name Q’ty Remarks

Removing the front carrier, front bumper and front fender

Seat and fuel tank side panels Refer to “SEAT AND SIDE PANELS”. 1 Front carrier 1 2 Front fender panel 1 3 Engine skid plate 1 4 Front bumper cover 1 5 Front bumper 1 6 Headlight coupler 2 Disconnect. 7 Front grill 1 8 Main switch coupler 1 Disconnect. 9 Handlebar cover 1

10 Fuel tank cover 1

Remove the parts in the order below.

3 - 4

SEAT, CARRIERS, FENDERS AND FUEL TANK

CHK

ADJ

Order Job name/Part name Q’ty Remarks

11 Auxiliary DC jack connector 2 Disconnect. 12 Meter assembly coupler 3 Disconnect. 13 Speedometer cable 1 Disconnect. 14 Coolant reservoir breather hose 1 15 Fan motor breather hose 1 16 Differential gear case breather hose 1 17 Front fender 1

For installation, reverse the removal procedure.

3 - 5

SEAT, CARRIERS, FENDERS AND FUEL TANK

REAR CARRIER AND REAR FENDER

CHK

ADJ

Order Job name/Part name Q’ty Remarks

Removing the rear carrier and rear

fender

Seat and fuel tank side panels Refer to “SEAT AND SIDE PANELS”.

Fuel tank Refer to “FUEL TANK”. 1 Rear carrier 1 2 Battery holding bracket 1 3 Battery lead cover 1 4 Battery lead 2 Disconnect.

Remove the parts in the order below.

CAUTION:

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

5 Battery 6 Starter relay ground lead 1 Disconnect. 7 Tail/brake light connector 3 Disconnect.

3 - 6

SEAT, CARRIERS, FENDERS AND FUEL TANK

CHK

ADJ

Order Job name/Part name Q’ty Remarks

8 C.D.I. unit 1 9 Wire harness 1

10 Rear fender 1

For installation, reverse the removal procedure.

3 - 7

FUEL TANK

SEAT, CARRIERS, FENDERS AND FUEL TANK

CHK

ADJ

Order Job name/Part name Q’ty Remarks

Removing the fuel tank

Seat and fuel tank side panels Refer to “SEAT AND SIDE PANELS”.

Fuel tank cover Refer to “FRONT CARRIER, FRONT

1 Fuel hose 1

2 Fuel cock lever 1 3 Fuel tank 1

4 Float chamber air vent hose 1 5 Plastic band 4 6 Rubber cover 1

Remove the parts in the order below.

BUMPER AND FRONT FENDER”.

OTE:

Before disconnecting the fuel hose, turn the fuel cock to “OFF”.

OTE:

When installing the fuel tank, pass the fuel tank breather hose through the hole of the handlebar protector.

For installation, reverse the removal procedure.

3 - 8

FOOTREST BOARDS

CHK

ADJ

Order Job name/Part name Q’ty Remarks

Removing the footrest boards

Fuel tank side panels Refer to “SEAT AND SIDE PANELS”. 1 Left footrest board 1 2 Right footrest board 1 3 Footrest bracket 4

Remove the parts in the order below.

For installation, reverse the removal procedure.

3 - 9

ADJUSTING THE VALVE CLEARANCE

ENGINE

ADJUSTING THE VALVE CLEARANCE

OTE:

●

The valve clearance must be adjusted when the engine is cool to the touch.

●

Adjust the valve clearance when the piston is at the Top Dead Center (T.D.C.) on the compression stroke.

1.Remove:

●

Seat

●

Front carrier

●

Front fender

●

Fuel tank Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”.

CHK

ADJ

2.Remove:

●

Tappet cover (intake) 1

●

Tappet cover (exhaust) 2

3.Disconnect:

●

Spark plug cap 3

4.Remove:

●

Spark plug

5.Remove:

●

Recoil starter 1

6.Remove:

●

Timing plug 1

3 - 10

ADJUSTING THE VALVE CLEARANCE

7.Check:

●

Valve clearance Out of specification → Adjust.

Valve clearance (cold):

Intake:

0.06 ~ 0.10 mm (0.0024 ~ 0.0039 in)

Exhaust:

0.16 ~ 0.20 mm (0.0063 ~ 0.0079 in)

*****************************************************

Checking steps:

●

Turn the crankshaft counterclockwise with a wrench.

●

Align the “T” mark 1 on the rotor with the stationary pointer 2 on the crankcase cover. When the “T” mark is aligned with the stationary pointer, the piston is at the Top Dead Center (T.D.C.).

CHK

ADJ

OTE:

●

When the piston is at the Top Dead Center (T.D.C.) on the compression stroke, there should be clearance between the valve stem tips and their respective rocker arm adjusting screws.

●

If there is no clearance, rotate the crankshaft counterclockwise one turn.

●

Measure the valve clearance using a feeler gauge 3.

*****************************************************

3 - 11

ADJUSTING THE VALVE CLEARANCE

8.Adjust:

●

Valve clearance

*****************************************************

Adjustment steps:

●

Loosen the locknut 1.

●

Insert a feeler gauge 2 between the adjuster end and the valve end.

●

Turn the adjuster 3 clockwise or counterclockwise with the valve adjusting tool 4 until the proper clearance is obtained.

Tappet adjusting tool:

P/N. YM-08035, 90890-01311

●

Hold the adjuster to prevent it from moving, and then tighten the locknut.

Locknut:

20 Nm (2.0 m • kg, 14 ft • lb)

CHK

ADJ

●

Measure the valve clearance.

●

If the clearance is incorrect, repeat the above steps until the proper clearance is obtained.

*****************************************************

9.Install:

●

All removed parts

OTE:

Install all removed parts in the reverse order of their disassembly. Note the following points.

3 - 12

10.Install:

●

Recoil starter

●

Spark plug

●

Tappet covers

10 Nm (1.0 m • kg, 7.2 ft • lb)

18 Nm (1.8 m • kg, 13 ft • lb)

10 Nm (1.0 m • kg, 7.2 ft • lb)

OTE:

Install the tappet covers with the ridge facing up È.

ADJUSTING THE VALVE CLEARANCE/

ADJUSTING THE IDLING SPEED

11.Install:

●

Fuel tank

●

Front fender

●

Front carrier

●

Seat Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”.

CHK

ADJ

ADJUSTING THE IDLING SPEED

1.Start the engine and let it warm up for several minutes.

2.Remove:

●

Seat

●

Fuel tank side panels Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”.

3.Attach:

●

Inductive self-powered tachometer or engine tachometer (to the spark plug lead)

Inductive self-powered tachometer:

P/N. YU-8036-B

Engine tachometer:

P/N. 90890-03113

4.Check:

●

Engine idling speed Out of specification → Adjust.

3 - 13

Engine idling speed:

1,450 ~ 1,550 r/min

ADJUSTING THE IDLING SPEED/

ADJUSTING THE THROTTLE LEVER FREE PLAY

5.Adjust:

●

Engine idling speed

*****************************************************

Adjustment steps:

●

Turn the throttle stop screw 1 in or out until the specified idling speed is obtained.

CHK

ADJ

Turning in

Turning out

Idling speed becomes higher.

Idling speed becomes lower.

*****************************************************

6.Detach:

●

Inductive or engine tachometer

7.Adjust:

●

Throttle lever free play Refer to “ADJUSTING THE THROTTLE LEVER FREE PLAY”.

Throttle lever free play:

3 ~ 5 mm (0.12 ~ 0.20 in)

8.Install:

●

Fuel tank side panels

●

Seat Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”.

3 - 14

ADJUSTING THE THROTTLE LEVER FREE PLAY

OTE:

Engine idling speed should be adjusted properly before adjusting the throttle lever free play.

ADJUSTING THE THROTTLE LEVER FREE PLAY

1.Check:

●

Throttle lever free play a Out of specification → Adjust.

Throttle lever free play:

3 ~ 5 mm (0.12 ~ 0.20 in)

2.Remove:

●

Seat

●

Fuel tank side panel (right) Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”.

CHK

ADJ

3.Adjust:

●

Throttle lever free play

*****************************************************

Adjustment steps: First step:

●

Pull back the adjuster cover 1.

●

Loosen the locknut 2 on the carburetor side.

●

Turn the adjuster 3 in or out until the correct free play is obtained.

Turning in Free play is increased.

Turning out Free play is decreased.

●

Tighten the locknut 2.

●

Push in the adjuster cover 1.

OTE:

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

3 - 15

ADJUSTING THE THROTTLE LEVER FREE PLAY/

ADJUSTING THE SPEED LIMITER

Second step:

●

Pull back the adjuster cover 4.

●

Loosen the locknut 5.

●

Turn the adjuster 6 in or out until the correct free play is obtained.

Turning in Free play is increased.

Turning out Free play is decreased.

●

Tighten the locknut 5.

●

Push in the adjuster cover 4.

WARNING

After adjusting the free play, turn the handlebar to the right and left to make sure that the engine idling speed does not increase.

*****************************************************

CHK

ADJ

4.Install:

●

Fuel tank side panel (right)

●

Seat Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”.

ADJUSTING THE SPEED LIMITER

The speed limiter keeps the carburetor throttle from becoming fully-opened even when the throttle lever is applied to the maximum position. Screwing in the adjuster stops the engine speed from increasing.

1.Check:

●

Speed limiter length a Out of specification → Adjust.

3 - 16

Speed limiter length:

12 mm (0.47 in)

ADJUSTING THE SPEED LIMITER/

ADJUSTING THE STARTER CABLE

2.Adjust:

●

Speed limiter length

*****************************************************

Speed limiter length adjustment steps:

●

Loosen the locknut 1.

●

Turn the adjuster 2 in or out until the specified speed limiter length is obtained.

CHK

ADJ

Turning in

Turning out

●

Tighten the locknut.

Speed limiter length is decreased.

Speed limiter length is increased.

WARNING

Particularly for a beginner rider, the

●

speed limiter should be screwed in completely. Screw it out little by little as their riding technique improves. Never remove the speed limiter for a beginning rider. For proper throttle lever operation do not

●

turn out the adjuster more than 12 mm (0.47 in). Also, always adjust the throttle lever free play to 3 ~ 5 mm (0.12 ~ 0.20 in).

*****************************************************

3 - 17

ADJUSTING THE STARTER CABLE

1.Remove:

●

Seat

●

Fuel tank side panel (left) Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”.

ADJUSTING THE STARTER CABLE

2.Adjust:

*****************************************************

Adjustment steps:

●

Disconnect the starter cable 1 from the carburetor body.

OTE:

Do not remove the starter plunger 2 from the starter cable.

●

Measure the starter plunger stroke distance a of the starter lever 3 fully close to fully open position. If the distance is out of specification adjust it as described below.

Starter plunger stroke distance:

15 mm (0.59 in)

Fully closed position

Fully open position

●

Pull back the boot 4.

●

Loosen the locknut 5.

●

Turn the adjuster 6 in or out until the correct free play is obtained.

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Turning in Free play increased.

Turning out Free play decreased.

●

Tighten the locknut 5.

●

Push in the boot 4.

●

Connect the starter cable to the carburetor.

WARNING

After adjusting the cable, turn the handlebar to right and left, and make sure that the engine idling speed does not increase.

*****************************************************

3.Install:

●

Fuel tank side panel (left)

●

Seat Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”.

3 - 18

CHECKING THE SPARK PLUG

1.Remove:

●

Seat

●

Fuel tank side panel (right) Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”.

2.Remove:

●

Spark plug

3.Check:

●

Spark plug type Incorrect → Replace.

Standard spark plug:

DR8EA/NGK

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4.Check:

●

Electrode 1 Wear/damage → Replace.

●

Insulator 2 Abnormal color → Replace. Normal color is a medium-to-light tan color.

5.Clean the spark plug with a spark plug cleaner or wire brush.

6.Measure:

●

Plug gap a Use a wire gauge or feeler gauge. Out of specification → Regap.

Spark plug gap:

0.6 ~ 0.7 mm (0.024 ~ 0.028 in)

7.Tighten:

18 Nm (1.8 m • kg, 13 ft • lb)

●

Spark plug

OTE:

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

3 - 19

8.Install:

●

Fuel tank side panel (right)

●

Seat Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”.

CHECKING THE IGNITION TIMING

OTE:

Engine idling speed and throttle cable free play should be adjusted properly before checking the ignition timing.

1.Remove:

●

Seat

●

Fuel tank side panel (right) Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”.

2.Attach:

●

Inductive self-powered tachometer or engine tachometer

●

Timing light (to spark plug lead)

Inductive self-powered tachometer:

P/N. YU-8036-B

Engine tachometer:

P/N. 90890-03113

Timing light:

P/N. YM-33277-A, 90890-03141

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3.Check:

●

Ignition timing

*****************************************************

Checking steps:

●

Warm up the engine and keep it at the specified speed.

Engine speed:

1,450 ~ 1,550 r/min

●

Remove the recoil starter 1.

●

Remove the timing plug 2.

●

Visually check the stationary pointer 3 to verify it is within the required firing range 4 indicated on the flywheel. Incorrect firing range → Check the pickup coil.

●

Install the timing plug.

●

Install the recoil starter.

Recoil starter bolt:

10 Nm (1.0 m • kg, 7.2 ft • Ib)

LOCTITE

3 - 20

*****************************************************

CHECKING THE IGNITION TIMING/

MEASURING THE COMPRESSION PRESSURE

4.Detach:

●

Timing light

●

Inductive self-powered tachometer or engine tachometer

5.Install:

●

Seat

●

Fuel tank side panel (right) Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”.

MEASURING THE COMPRESSION PRESSURE

OTE:

Insufficient compression pressure will result in a loss of performance.

1.Check:

●

Valve clearance Out of specification → Adjust. Refer to “ADJUSTING THE VALVE CLEARANCE”.

2.Start the engine and let it warm up for several minutes.

3.Stop the engine.

4.Remove:

●

Seat

●

Fuel tank side panel (right) Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”.

5.Remove:

●

Spark plug

6.Attach:

●

Adapter

●

Compression gauge 1

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3 - 21

Compression gauge:

P/N. YU-33223, 90890-03081

Adapter:

P/N. YU-33223-3, 90890-04082

MEASURING THE COMPRESSION PRESSURE

7.Measure:

●

Compression pressure Above the maximum pressure: Check the cylinder head, valve surfaces, and piston crown for carbon deposits. Below the minimum pressure: Squirt a few drops of oil into the affected cylinder and measure again.

●

Refer to the table below.

Compression pressure

(with oil introduced into cylinder)

Reading Diagnosis

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Higher than without oil

Same as without oil

Worn or damaged pistons

Defective ring(s), valves, cylinder head gasket or piston is possible.

Compression pressure (at sea level):

Standard:

1,400 kPa (14 kg/cm

, 203 psi)

Minimum:

1,218 kPa (12.2 kg/cm

, 177 psi)

Maximum:

1,568 kPa (15.7 kg/cm

, 227 psi)

*****************************************************

Measurement steps:

●

Crank over the engine with the electric starter (be sure the battery is fully charged) with the throttle wide-open until the compression reading on the gauge stabilizes.

3 - 22

WARNING

When cranking the engine, ground the spark plug lead to prevent sparking.

*****************************************************

8.Install:

18 Nm (1.8 m • kg, 13 ft • lb)

●

Spark plug

9.Remove:

●

Fuel tank side panel (right)

●

Seat Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”.

CHECKING THE ENGINE OIL LEVEL

1.Place the machine on a level surface.

2.Remove:

●

Engine side panel Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”.

3.Check:

●

Engine oil level Oil level should be between the maximum level mark 1 and minimum level mark 2. Oil level low → Add oil to the proper level.

OTE:

Do not screw the dipstick 3 in when checking the oil level.

Recommended oil:

Follow the left chart.

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OTE:

Recommended oil classification: API Service “SE”, “SF” type or equivalent (e.g. “SF–SE–CC”, “SF–SE–SD” etc.)

CAUTION:

Do not allow foreign material to enter the crankcase.

4.Start the engine and let it warm up for several minutes.

5.Stop the engine and check the oil level again.

OTE:

Wait a few minutes until the oil settles before checking the oil level.

WARNING

Never remove the dipstick just after high speed operation because the heated oil could spurt out. Wait until the oil cools down before removing the dipstick.

3 - 23

6.Install:

●

Engine side panel Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”.

CHANGING THE ENGINE OIL

1.Start the engine and let it warm up for several minutes.

2.Stop the engine and place an oil pan under the engine.

3.Remove:

●

Seat

●

Fuel tank side panel (left)

●

Engine side cover Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”.

4.Remove:

●

Engine oil filler plug (dipstick) 1

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5.Remove:

●

Engine oil drain bolt 1 Drain the engine oil.

●

Oil strainer cover 2

●

Compression spring 3

●

Oil strainer 4

6.Clean:

●

Oil strainer 4

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

3 - 24

*****************************************************

Replacement steps:

●

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

Oil filter wrench:

P/N. YU-38411, 90890-01426

CHANGING THE ENGINE OIL

●

Lubricate the O-ring 3 of the new oil filter cartridge with a thin coat of engine oil.

CAUTION:

Make sure that the O-ring 3 is positioned correctly in the groove of the oil filter cartridge.

●

Tighten the new oil filter cartridge to specification with an oil filter wrench.

Oil filter cartridge:

*****************************************************

17 Nm (1.7 m • kg, 12 ft • lb)

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8.Install:

●

Oil strainer

●

Compression spring

●

Oil strainer cover 1

32 Nm (3.2 m • kg, 23 ft • lb)

●

Engine oil drain bolt 2

23 Nm (2.3 m • kg, 17 ft • lb)

9.Fill:

●

Crankcase Refer to “CHECKING THE ENGINE OIL LEVEL”.

Oil quantity:

Periodic oil change:

2.3 L (2.0 Imp qt, 2.4 US qt)

With oil filter replacement:

2.4 L (2.1 Imp qt, 2.5 US qt)

Total amount:

2.6 L (2.3 Imp qt, 2.7 US qt)

10.Install:

●

Engine oil filler plug

11.Warm up the engine for a few minutes, then stop the engine.

12.Check:

●

Engine (for engine oil leaks)

●

Oil level Refer to “CHECKING THE ENGINE OIL LEVEL”.

3 - 25

CHANGING THE ENGINE OIL/

CLEANING THE AIR FILTER

13.Check:

●

Engine oil pressure

*****************************************************

●

Slightly loosen the oil gallery bolt 1.

●

Start the engine and keep it idling until engine oil starts to seep from the oil gallery bolt. If no engine oil comes out after one minute, turn the engine off so that it will not seize.

●

Check the engine oil passages, the oil filter cartridge and the oil pump for damage or leakage. Refer to “CRANKCASE” in CHAPTER 4.

●

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

●

Tighten the oil gallery bolt to specification.

Oil gallery bolt:

7 Nm (0.7 m • kg, 5.1 ft • lb)

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*****************************************************

14.Install:

●

Engine side cover

●

Fuel tank side panel (left)

●

Seat Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”.

CLEANING THE AIR FILTER

OTE:

There is a check hose 1 at the bottom of the air filter case. If dust and/or water collects in this hose, clean the air filter element and air filter case.

3 - 26

CLEANING THE AIR FILTER

1.Remove:

●

Seat Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”.

2.Remove:

●

Air filter case cover 1

3.Remove:

●

Air filter element assembly 1

●

Air filter element cap

●

Air filter element

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Air filter element cap

Air filter element

CAUTION:

Never operate the engine with the air filter element removed. This will allow unfiltered air to enter, causing rapid wear and possible engine damage. Additionally, operation without the filter element will affect carburetor tuning with subsequent poor performance and possible engine overheating.

4.Check:

●

Air filter element Damaged → Replace.

3 - 27

CLEANING THE AIR FILTER

5.Clean:

●

Air filter element

*****************************************************

Cleaning steps:

●

Wash the element gently, but thoroughly in solvent.

WARNING

Use a cleaning solvent which is designed to clean parts only. Never use gasoline or low flash point solvents as they may cause a fire or explosion.

●

Squeeze the excess solvent out of the element and let it dry.

CAUTION:

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

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●

Apply engine oil to the element.

●

Squeeze out the excess oil.

OTE:

The element should be wet but not dripping.

*****************************************************

6.Install:

●

Air filter element assembly

●

Air filter case cover

OTE:

To prevent air leaks make sure that the sealing surface of the element matches the sealing surface of the case.

●

Seat Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”.

3 - 28

CHECKING THE COOLANT LEVEL

1.Place the machine on a level surface.

2.Remove:

●

Seat

●

Fuel tank side panel (left) Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”.

3.Check:

●

Coolant level The coolant level should be between the minimum level mark a and maximum level mark b. Below the minimum level mark → Add the recommended coolant to the proper level.

CAUTION:

Adding water instead of coolant lowers

●

the antifreeze content of the coolant. If water is used instead of coolant, check and if necessary, correct the antifreeze concentration of the coolant. Use only distilled water. However, soft

●

water may be used if distilled water is not available.

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4.Start the engine, warm it up for several minutes, and then turn it off.

5.Check:

●

Coolant level

OTE:

Before checking the coolant level, wait a few minutes until the coolant has settled.

6.Install:

●

Fuel tank side panel (left)

●

Seat Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”.

3 - 29

CHANGING THE COOLANT

1.Remove:

●

Seat

●

Fuel tank side panel (left)

●

Engine side cover

●

Front carrier

●

Engine skid plate

●

Front fender Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”.

●

Left footrest board Refer to “FOOTREST BOARDS”.

2.Remove:

●

Plastic band 1

●

Coolant reservoir bolts 2

●

Coolant reservoir cap 3

3.Disconnect:

●

Coolant reservoir breather hose 4

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4.Drain:

●

Coolant (from the coolant reservoir)

5.Connect:

●

Coolant reservoir breather hose

6.Install:

●

Coolant reservoir bolts

●

Plastic band

7.Remove:

●

Radiator cap 1

WARNING

A hot radiator is under pressure. Therefore, do not remove the radiator cap when the engine is hot. Scalding hot fluid and steam may be blown out, which could cause serious injury. When the engine has cooled, open the radiator cap as follows: Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap counterclockwise toward the detent to allow any residual pressure to escape. When the hissing sound has stopped, turn the radiator cap counterclockwise while pressing down on it and then remove it.

3 - 30

CHANGING THE COOLANT

8.Remove:

●

Coolant drain bolt (cylinder) 1 (along with the copper washer)

●

Coolant drain bolt (water pump) 2 (along with the copper washer)

9.Drain:

●

Coolant

10.Check:

●

Copper washer 1

●

Coolant drain bolt 2 Damage → Replace.

11.Install:

●

Coolant drain bolt (water pump)

10 Nm (1.0 m • kg, 7.2 ft • lb)

●

Coolant drain bolt (cylinder)

10 Nm (1.0 m • kg, 7.2 ft • lb)

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12.Fill:

●

Cooling system (with the specified amount of the recommended coolant)

Recommended antifreeze

High-quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines

Mixing ratio

1:1 (antifreeze:water)

Quantity

Total amount

1.32 L (1.16 Imp qt, 1.40 US qt)

Coolant reservoir capacity

0.39 L (0.34 Imp qt, 0.41 US qt)

Handling notes for coolant

Coolant is potentially harmful and should be handled with special care.

WARNING

If coolant splashes in your eyes,

●

thoroughly wash them with water and consult a doctor. If coolant splashes on your clothes,

●

quickly wash it away with water and then with soap and water. If coolant is swallowed, induce vomiting

●

and get immediate medical attention.

3 - 31

CHANGING THE COOLANT

CAUTION:

Adding water instead of coolant lowers

●

the antifreeze content of the coolant. If water is used instead of coolant, check, and if necessary, correct the antifreeze concentration of the coolant. Use only distilled water. However, soft

●

water may be used if distilled water is not available. If coolant comes into contact with painted

●

surfaces, immediately wash them with water. Do not mix different types of antifreeze.

●

13.Install:

●

Radiator cap

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14.Fill:

●

Coolant reservoir (with the recommended coolant to the maximum level mark a)

15.Install:

●

Coolant reservoir cap

16.Start the engine, warm it up for several minutes, and then turn it off.

17.Check:

●

Coolant level Refer to “CHECKING THE COOLANT LEVEL”.

OTE:

Before checking the coolant level, wait a few minutes until the coolant has settled.

18.Install:

●

Left footrest board Refer to “FOOTREST BOARDS”.

●

Front fender

●

Engine skid plate

●

Front carrier

●

Engine side cover

●

Fuel tank side panel (left)

●

Seat Refer to “SEAT, CARRIERS, FENDERS AND FUEL TANK”.

3 - 32

CHECKING THE COOLANT TEMPERATURE WARNING

LIGHT/CHECKING THE V-BELT

CHECKING THE COOLANT TEMPERATURE WARNING LIGHT

1 Coolant temperature warning light

Coolant temperature warning light checking method

Turn the main switch “ON” and the engine stop switch to “”.

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Coolant temperature warning light does not come on.

Push start switch with transmission in “neutral”.

Coolant temperature warning light comes on momentarily.

Coolant temperature and electrical circuit are OK. Go ahead with riding.

Coolant temperature warning light does not come on.

Ask a Yamaha dealer to check the electrical circuit.

CHECKING THE V-BELT

1.Remove:

●

Right footrest board Refer to “FOOTREST BOARDS”.

●

Crankcase cover (right) Refer to “PRIMARY AND SECONDARY SHEAVES” in CHAPTER 4.

2.Check:

●

V-belt 1 Cracks/wear/scaling/chipping → Replace. Oil/grease → Check primary sheave and secondary sheave.

3.Measure:

●

V-belt width 2 Out of specification → Replace.

Coolant temperature warning light comes on.

3 - 33

V-belt width:

30.7 mm (1.21 in) <Limit:> 27.6 mm (1.09 in)

CHECKING THE V-BELT

4.Replace:

●

V-belt

*****************************************************

Replacing steps:

●

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

OTE:

Tightening the bolts 1 will push the secondary sliding sheave away, causing the gap between the secondary fixed and sliding sheaves to widen.

●

Remove the V-belt 1 from the primary sheave and secondary sheave.

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●

Install the V-belt.

OTE:

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

●

Remove the bolts.

*****************************************************

3 - 34

CLEANING THE SPARK ARRESTER

1.Clean:

●

Spark arrester

*****************************************************

Cleaning steps:

WARNING

Select a well-ventilated area free of

●

combustible materials. Always let the exhaust system cool

●

before performing this operation. Do not start the engine when removing

●

the tailpipe from the muffler.

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●

Remove the bolts 1.

●

Remove the tailpipe 2 by pulling it out of the muffler.

●

Tap the tailpipe lightly with a soft-face hammer or suitable tool, then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe and the inner contact surfaces of the muffler.

●

Insert the tailpipe 2 into the muffler and align the bolt holes.

●

Insert the bolts 1 and tighten it.

*****************************************************

3 - 35

ADJUSTING THE REAR BRAKE

CHASSIS

ADJUSTING THE REAR BRAKE

WARNING

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

1.Check:

●

Rear brake pedal free play a

●

Rear brake lever free play b Out of specification → Adjust.

Rear brake pedal free play:

20 ~ 30 mm (0.80 ~ 1.18 in)

Rear brake lever free play:

3 ~ 5 mm (0.12 ~ 0.20 in)

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3 - 36

2.Adjust:

●

Rear brake lever free play

●

Rear brake pedal free play

*****************************************************

Adjustment steps:

●

Loosen the locknut (handlebar) 1 and fully screw in the brake lever cable adjuster (handlebar) 2.

●

Fully loosen the brake lever cable adjusting nut (drum) 3.

●

Turn the rear brake pedal cable adjusting nut 4 until the brake pedal free play is within the specified limits.

Rear brake pedal free play:

20 ~ 30 mm (0.8 ~ 1.2 in)

ADJUSTING THE REAR BRAKE

●

Turn the brake lever cable adjusting nut (drum) 3 clockwise until the gap a is within the specified limits.

Gap a:

0 ~ 1 mm (0.00 ~ 0.04 in)

●

Checking the rear brake pedal free play to see whether or not it is within the specified limits. If not, perform the above steps again.

Rear brake pedal free play:

20 ~ 30 mm (0.8 ~ 1.2 in)

●

Turn the brake lever cable adjusting nut (handlebar) 2 until the rear brake lever free play b is within the specified limits.

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Rear brake lever free play:

3 ~ 5 mm (0.12 ~ 0.20 in)

●

Tighten the locknut (handlebar) 1.

●

Adjust the select lever control cable. Refer to “ADJUSTING THE SELECT LEVER CONTROL CABLE AND SHIFT ROD”.

WARNING

After this adjustment is performed, lift the front and rear wheels off the ground by placing a block under the engine, and spin the rear wheels to ensure there is no brake drag. If any brake drag is noticed perform the above steps again.

*****************************************************

3 - 37

CHECKING THE FRONT BRAKE FLUID LEVEL

1.Place the machine on a level surface.

OTE:

When checking the front brake fluid level, make sure that the top of the master cylinder top is horizontal.

2.Check:

●

Brake fluid level Fluid level is under “LOWER” level line 1 → Fill up.

Recommended brake fluid:

DOT 4

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CAUTION:

Brake fluid may erode painted surfaces or plastic parts. Always clean up spilled fluid immediately.

WARNING

Use only the designed quality brake fluid:

●

otherwise, the rubber seals may deteriorate, causing leakage and poor brake performance. Refill with the same type of brake fluid;

●

mixing fluids may result in a harmful chemical reaction and lead to poor performance. Be careful that water does not enter the

●

master cylinder when refilling. Water will significantly lower the boiling point of the fluid and may result in a vapor lock.

3 - 38

CHECKING THE FRONT BRAKE PADS/

CHECKING THE REAR BRAKE SHOES

CHECKING THE FRONT BRAKE PADS

1.Remove:

●

Front wheel

2.Check:

●

Brake pads Wear indicator groove 1 almost touch the brake disc → Replace the brake pads as a set. Refer to “FRONT BRAKE” in CHAPTER 8.

Brake pad wear limit a:

1 mm (0.04 in)

3.Operate the brake lever.

4.Install:

●

Front wheel

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CHECKING THE REAR BRAKE SHOES

1.Operate the brake lever or brake pedal.

2.Check:

●

Wear indicator 1 Reaches the wear limit line 2 → Replace the brake shoes as a set. Refer to “REAR BRAKE” in CHAPTER 8.

3 - 39

Yamaha 5TE-F8197-10, LIT-11616-16-02 user guide

Specifications and Main Features

Frequently Asked Questions

User Manual

HOW TO USE THIS MANUAL

ILLUSTRATED SYMBOLS

TABLE OF CONTENTS

MACHINE IDENTIFICATION

IMPORTANT INFORMATION

CHECKING OF CONNECTIONS

SPECIAL TOOLS

GENERAL SPECIFICATIONS

MAINTENANCE SPECIFICATIONS

LUBRICATION POINTS AND LUBRICANT TYPES

COOLANT FLOW DIAGRAMS

CABLE ROUTING

SEAT, CARRIERS, FENDERS AND FUEL TANK

FOOTREST BOARDS

ENGINE

CHASSIS