This manual was produced by the Yamaha Motor Company, Ltd. 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. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles
should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit for use.
This model has been designed and manufactured to perform within certain specifications in regard to
performance and emissions. Proper service with the correct tools is necessary to ensure that the vehicle will operate as designed. If there is any question about a service procedure, it is imperative that you
contact a Yamaha dealer for any service information changes that apply to this model. This policy is
intended to provide the customer with the most satisfaction from his vehicle and to conform to federal
environmental quality objectives.
Yamaha Motor Company, Ltd. is continually striving to improve all of 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.
IP
• This Service Manual contains information regarding periodic maintenance to the emission control system. Please read this material carefully.
• Designs and specifications are subject to change without notice.
EAS20081
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following notations.
This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to
avoid possible injury or death.
WARNING
NOTICE
TIP
A WARNING indicates a hazardous situation which, if not avoided, could
result in death or serious injury.
A NOTICE indicates special precautions that must be taken to avoid
damage to the vehicle or other property.
A TIP provides key information to make procedures easier or clearer.
Page 4
EAS20090
HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid
out with the individual steps in sequential order.
• The manual is divided into chapters and each chapter is divided into sections. The current section title
“1” is shown at the top of each page.
• Sub-section titles “2” appear in smaller print than the section title.
• To help identify parts and clarify procedure steps, there are exploded diagrams “3” at the start of each
removal and disassembly section.
• Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a disassembly step.
• Symbols “5” indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
• A job instruction chart “6” accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.
• Jobs “7” requiring more information (such as special tools and technical data) are described sequentially.
1
3
NOTICE
7
2
4
5
6
Page 5
EAS20100
T
SYMBOLS
The following symbols are used in this manual
for easier understanding.
IP
The following symbols are not relevant to every
vehicle.
CHECKING THE CONNECTIONS ................................................................ 1-13
SPECIAL TOOLS .......................................................................................... 1-14
Page 10
EAS20130
IDENTIFICATION
EAS20140
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number “1” is stamped
into the front left side of the frame.
EAS20150
MODEL LABEL
The model label “1” is affixed to the location
shown in the illustration. This information will be
needed to order spare parts.
IDENTIFICATION
1-1
Page 11
FEATURES
EAS20170
FEATURES
EAS28P1031
OUTLINE OF THE FI SYSTEM
The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum
air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In
the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion
chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the
respective carburetor.
Despite the same volume of intake air, the fuel volume requirement varies with the engine operating
conditions, such as acceleration, deceleration, or operating under a heavy load. Carburetors that meter
the fuel through the use of jets have been provided with various auxiliary devices, so that an optimum
air-fuel ratio can be achieved to accommodate the constant changes in the operating conditions of the
engine.
As the requirements for the engine to deliver more performance and cleaner exhaust gases increase,
it becomes necessary to control the air-fuel ratio in a more precise and finely tuned manner. To accommodate this need, this model has adopted an electronically controlled fuel injection (FI) system, in place
of the conventional carburetor system. This system can achieve an optimum air-fuel ratio required by
the engine at all times by using a microprocessor that regulates the fuel injection volume according to
the engine operating conditions detected by various sensors.
The adoption of the FI system has resulted in a highly precise fuel supply, improved engine response,
better fuel economy, and reduced exhaust emissions.
12346 7 8910
1. ECU (engine control unit)
2. Lean angle sensor
3. Fuel injection system relay
4. Engine trouble warning light
5. ISC (idle speed control) unit
6. Intake air pressure sensor
7. TPS (throttle position sensor)
8. Intake air temperature sensor
5
1112131415
9. Fuel injector
10.Fuel pump
11.Speed sensor
12.Crankshaft position sensor
13.Coolant temperature sensor
14.Spark plug
15.Ignition coil
1-2
Page 12
FEATURES
EAS28P1032
FI SYSTEM
The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the
fuel pressure that is applied to the fuel injector at only 324 kPa (3.24 kgf/cm², 46.1 psi). Accordingly,
when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causing
the fuel to be injected into the intake manifold only during the time the passage remains open. Therefore, the longer the length of time the fuel injector is energized (injection duration), the greater the volume of fuel that is supplied. Conversely, the shorter the length of time the fuel injector is energized
(injection duration), the lesser the volume of fuel that is supplied.
The injection duration and the injection timing are controlled by the ECU. Signals that are input from the
throttle position sensor, crankshaft position sensor, intake air pressure sensor, intake air temperature
sensor, coolant temperature sensor, lean angle sensor and speed sensor enable the ECU to determine
the injection duration. The injection timing is determined through the signals from the crankshaft position sensor. As a result, the volume of fuel that is required by the engine can be supplied at all times in
accordance with the driving conditions.
Illustration is for reference only.
1
14
B
13
1. Fuel pump
2. Fuel injector
3. Ignition coil
4. ECU (engine control unit)
5. Speed sensor
6. Lean angle sensor
7. Coolant temperature sensor
8. Crankshaft position sensor
9. Intake air pressure sensor
10.Throttle body
11.ISC (idle speed control) unit
12.Throttle position sensor
12
11
C
5
4
6
2
A
7
3
10
9
8
13.Intake air temperature sensor
14.Air filter case
A. Fuel system
B. Air system
C. Control system
1-3
Page 13
FEATURES
1-4
Page 14
FEATURES
EAS28P1033
OUTLINE OF THE EPS (ELECTRIC POWER STEERING) SYSTEM (YFM5FGP/YFM7FGP only)
12
3da
e
f
5
c
4
b
6
8
7
1-5
Page 15
FEATURES
1. Speed information from speed sensor
2. Engine starting RPM information from ECU
3. Battery
4. Steering stem
5. EPS control unit
6. EPS motor
7. Torque sensor
8. EPS unit
a. Operates steering
ECA28P1027
NOTICE
b. Twists torsion bar
c. Sends the torque sensor signal
d. EPS control unit calculates assist power
e. Electricity output switched by EPS control unit
f. Activates EPS motor
To prevent accidental damage to the EPS unit, it must not be disassembled.
1-6
Page 16
FEATURES
EAS28P1034
EPS (ELECTRIC POWER STEERING) SYSTEM BLOCK DIAGRAM (YFM5FGP/YFM7FGP only)
1
2
4
5
3
7
8
9
6
11
12
13
18
10
17
16
15
14
1-7
Page 17
1. EPS unit
2. Torque sensor
3. EPS motor
4. EPS control unit
5. Battery
6. Engine rpm signal
7. Coolant temperature sensor signal
8. Crankshaft position sensor signal
9. Speed sensor signal
10.ECU (engine control unit)
11.Intake air temperature sensor signal
12.Throttle position sensor signal
13.Intake air pressure sensor signal
14.Lean angle sensor signal
15.Ignition coil
16.Fuel pump
17.Fuel injector
18.Meter assembly
• Multifunction display:
Speedometer/Odometer/Tripmeter A/Trip
meter B/Clock/Fuel meter/Gear position
• Indicator and warning lights: EPS
warning/Engine trouble warning/Coolant
temperature warning/Reverse
indicator/Neutral indicator/Park
indicator/High-range indicator/Low-range
indicator/Differential lock
• FI and EPS self-diagnostic fault codes
FEATURES
1-8
Page 18
FEATURES
T
T
EAS28P1035
INSTRUMENT FUNCTIONS
Multifunction display
45
3
2
1
67
1. “CLOCK” button
2. “RESET” button
3. “SELECT” button
4. Speedometer
5. Fuel meter
6. Clock/Hour meter
7. Odometer/Tripmeter A/Tripmeter B
The multifunction display is equipped with the
following:
• a speedometer (which shows the riding speed)
• an odometer (which shows the total distance
traveled)
• two tripmeters (which show the distance traveled since they were last set to zero)
• a clock
• an hour meter (which shows the total time the
engine has been running)
• a fuel meter
• a self-diagnosis device
Odometer and tripmeter modes
Pushing the “SELECT” button switches the display between the odometer mode “ODO” and
the tripmeter modes “A” and “B” in the following
order:
ODO → TRIP A → TRIP B → ODO
To reset a tripmeter, select it by pushing the “SE-
LECT” button, and then push the “RESET” but-
ton for at least three seconds. The tripmeters
can be used to estimate the distance that can be
traveled with a full tank of fuel. This information
will enable you to plan future fuel stops.
IP
Pushing and holding in the “SELECT” button,
and turning the key to “ON” while the button is
pushed, switches the display between “mph”
and “km/h”.
Clock mode
Pushing the “CLOCK” button switches the display between the clock mode “CLOCK” and the
hour meter mode “HOUR” in the following order:
CLOCK → HOUR → CLOCK
To set the clock:
1. Set the display to the clock mode.
2. Push the “SELECT” button and “RESET” but-
ton together for at least three seconds.
3. When the hour digits start flashing, push the
“RESET” button to set the hours.
4. Push the “SELECT” button, and the minute
digits will start flashing.
5. Push the “RESET” button to set the minutes.
6. Push the “SELECT” button and then release
it to start the clock.
Fuel meter
1
2
3
1. Fuel level warning indicator
2. Fuel meter
3. “E” segment
The fuel meter indicates the amount of fuel in the
fuel tank. The display segments of the fuel meter
disappear from “F” (full) towards “E” (empty) as
the fuel level decreases. When the “E” segment
disappears and the fuel level warning indicator
flashes, refuel as soon as possible.
IP
This fuel meter is equipped with a self-diagnosis
system. If the electrical circuit is defective, all the
display segments and fuel level warning indicator will start flashing. If this occurs, check the
electrical circuit.
Refer to “SIGNALING SYSTEM” on page 9-19.
1-9
Page 19
Self-diagnosis device
1
1. Fault code display
This model is equipped with a self-diagnosis device for various electrical circuits.
If any of those circuits are defective, the multifunction display will indicate a two-digit fault
code. If the multifunction display indicates such
a fault code, note the code number, and check
the vehicle.
ECA28P1028
NOTICE
If the multifunction display indicates a fault
code, the vehicle should be checked as soon
as possible in order to avoid engine damage.
FEATURES
1-10
Page 20
EAS20180
IMPORTANT INFORMATION
EAS20190
PREPARATION FOR REMOVAL AND
DISASSEMBLY
1. Before removal and disassembly, remove all
dirt, mud, dust and foreign material.
2. Use only the proper tools and cleaning equipment.
Refer to “SPECIAL TOOLS” on page 1-14.
3. When disassembling, always keep mated
parts together. This includes gears, cylinders,
pistons and other parts that have been “mated” through normal wear. Mated parts must
always be reused or replaced as an assembly.
IMPORTANT INFORMATION
EAS20210
GASKETS, OIL SEALS AND O-RINGS
1. When overhauling the engine, replace all
gaskets, seals and O-rings. All gasket surfaces, oil seal lips and O-rings must be cleaned.
2. During reassembly, properly oil all mating
parts and bearings and lubricate the oil seal
lips with grease.
4. During disassembly, clean all of the 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.
EAS20200
REPLACEMENT PARTS
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.
1. Oil
2. Lip
3. Spring
4. Grease
EAS20220
LOCK WASHERS/PLATES AND COTTER
PINS
After removal, replace all lock washers/plates
“1” and cotter pins. After the bolt or nut has been
tightened to specification, bend the lock tabs
along a flat of the bolt or nut.
1-11
Page 21
EAS20230
BEARINGS AND OIL SEALS
Install bearings “1” and oil seals “2” so that the
manufacturer marks or numbers are visible.
When installing oil seals “2”, lubricate the oil seal
lips with a light coat of lithium-soap-based
grease. Oil bearings liberally when installing, if
appropriate.
ECA13300
NOTICE
Do not spin the bearing with compressed air
because this will damage the bearing surfaces.
IMPORTANT INFORMATION
EAS20240
CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips. Always replace piston pin clips after one use.
When installing a circlip “1”, make sure the
sharp-edged corner “2” is positioned opposite
the thrust “3” that the circlip receives.
1-12
Page 22
EAS20250
T
T
T
CHECKING THE CONNECTIONS
Check the leads, couplers, and connectors for
stains, rust, moisture, etc.
1. Disconnect:
• Lead
• Coupler
• Connector
2. Check:
• Lead
• Coupler
• Connector
Moisture → Dry with an air blower.
Rust/stains → Connect and disconnect sev-
eral times.
CHECKING THE CONNECTIONS
Pocket tester
90890-03112
IP
• If there is no continuity, clean the terminals.
• When checking the wire harness, perform
steps (1) to (3).
• As a quick remedy, use a contact revitalizer
available at most part stores.
Analog pocket tester
YU-03112-C
3. Check:
• All connections
Loose connection → Connect properly.
IP
If the pin “1” on the terminal is flattened, bend it
up.
4. Connect:
• Lead
• Coupler
• Connector
IP
Make sure all connections are tight.
5. Check:
• Continuity
(with the pocket tester)
1-13
Page 23
SPECIAL TOOLS
T
EAS20260
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use only
the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools
or improvised techniques. Special tools, part numbers or both may differ depending on the country.
When placing an order, refer to the list provided below to avoid any mistakes.
IP
• For U.S.A. and Canada, use part numbers starting with “YM-”, “YU-”, or “ACC-”.
• For others, use part numbers starting with “90890-”.
Tool name/Tool No.Illustration
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
Thickness gauge
90890-03079
Narrow gauge set
YM-34483
Tappet adjusting tool
90890-01311
Six piece tappet set
YM-A5970
Overall length2065 mm (81.3 in)
Overall width1180 mm (46.5 in)
Overall height1240 mm (48.8 in)
Seat height905 mm (35.6 in)
Wheelbase1250 mm (49.2 in)
Ground clearance275 mm (10.8 in)
Minimum turning radius3200 mm (126 in)
Weight
With oil and fuel294.0 kg (648 lb)
Maximum loading limit220.0 kg (485 lb)
(Total weight of rider, cargo, accessories, and
tongue)
Recommended fuelUnleaded gasoline only
Fuel tank capacity20.0 L (5.28 US gal, 4.40 Imp.gal)
Fuel reserve amount4.5 L (1.19 US gal, 0.99 Imp.gal)
Engine oil
Lubrication systemWet sump
TypeYAMALUBE 4 5W-30 or 10W-40 or 20W-50,
SAE 5W-30 or SAE 10W-40 or SAE 20W-50
Recommended engine oil gradeAPI service SG type or higher, JASO standard
MA
Engine oil quantity
Total amount2.40 L (2.54 US qt, 2.11 Imp.qt)
Without oil filter cartridge replacement2.00 L (2.11 US qt, 1.76 Imp.qt)
With oil filter cartridge replacement2.10 L (2.22 US qt, 1.85 Imp.qt)
TypeSAE 80 API GL-4 Hypoid gear oil
Total amount0.25 L (0.26 US qt, 0.22 Imp.qt)
Periodic oil change0.20 L (0.21 US qt, 0.18 Imp.qt)
Differential gear oil
TypeSAE 80 API GL-4 Hypoid gear oil
Total amount0.23 L (0.24 US qt, 0.20 Imp.qt)
Periodic oil change0.22 L (0.23 US qt, 0.19 Imp.qt)
2-2
Page 34
ENGINE SPECIFICATIONS
Oil filter
Oil filter typeCartridge (paper)
Oil pump
Oil pump typeTrochoid
Inner-rotor-to-outer-rotor-tip clearanceLess than 0.12 mm (0.0047 in)
Limit0.20 mm (0.0079 in)
Outer-rotor-to-oil-pump-housing clearance0.090–0.170 mm (0.0035–0.0067 in)
Limit0.24 mm (0.0094 in)
Oil-pump-housing-to-inner-and-outer-rotor
clearance0.03–0.10 mm (0.0012–0.0039 in)
Limit0.17 mm (0.0067 in)
Pressure check locationCylinder head
Cooling system
Radiator capacity (including all routes)1.99 L (2.10 US qt, 1.75 Imp.qt)
Coolant reservoir capacity (up to the maximum level
mark)0.24 L (0.25 US qt, 0.21 Imp.qt)
From low to full level0.14 L (0.15 US qt, 0.12 Imp.qt)
Radiator cap opening pressure93.3–122.7 kPa (0.95–1.25 kgf/cm², 13.5–17.8
Model/manufacturer3B4/NIPPON THERMOSTAT
Valve opening temperature50–54 °C (122–129 °F)
Valve full open temperature70 °C (158 °F)
Valve lift (full open)7.0 mm (0.28 in)
Radiator core
Width248.2 mm (9.77 in)
Height340 mm (13.4 in)
Depth22 mm (0.87 in)
Water pump
Water pump typeSingle suction centrifugal pump
Reduction ratio32/31 (1.032)
Impeller shaft tilt limit0.15 mm (0.006 in)
Spark plug
Manufacturer/modelNGK/LMAR6A-9
Spark plug gap0.8–0.9 mm (0.031–0.035 in)
Cylinder head
Volume51.40–54.40 cm³ (YFM5FGY/YFM5FGPY)
56.70–60.30 cm³ (YFM7FGY/YFM7FGPY)
Warpage limit0.03 mm (0.0012 in)
Camshaft
Drive systemChain drive (left)
2-3
Page 35
ENGINE SPECIFICATIONS
Camshaft lobe dimensions
Intake A43.488–43.588 mm (1.7121–1.7161 in)
Limit43.388 mm (1.7082 in)
Intake B36.959–37.059 mm (1.4551–1.4590 in)
Limit36.859 mm (1.4511 in)
Exhaust A43.129–43.229 mm (1.6980–1.7019 in)
Limit43.029 mm (1.6941 in)
Exhaust B37.007–37.107 mm (1.4570–1.4609 in)
Limit36.907 mm (1.4530 in)
A
B
Camshaft runout limit0.015 mm (0.0006 in)
Timing chain
Model/number of links98XRH2010/126
Tensioning systemAutomatic
Rocker arm/rocker arm shaft
Rocker arm inside diameter12.000–12.018 mm (0.4724–0.4731 in)
Rocker arm shaft outside diameter11.981–11.991 mm (0.4717–0.4721 in)
Rocker-arm-to-rocker-arm-shaft clearance0.009–0.037 mm (0.0004–0.0015 in)
Valve, valve seat, valve guide
Valve clearance (cold)
Intake0.09–0.13 mm (0.0035–0.0051 in)
Exhaust0.16–0.20 mm (0.0063–0.0079 in)
Valve dimensions
Valve head diameter A (intake)32.90–33.10 mm (1.2953–1.3031 in)
(YFM5FGY/YFM5FGPY)
37.90–38.10 mm (1.4921–1.5000 in)
(YFM7FGY/YFM7FGPY)
Valve head diameter A (exhaust)27.90–28.10 mm (1.0984–1.1063 in)
(YFM5FGY/YFM5FGPY)
31.90–32.10 mm (1.2559–1.2638 in)
(YFM7FGY/YFM7FGPY)
A
Valve face width B (intake)2.26 mm (0.0890 in)
2-4
Page 36
ENGINE SPECIFICATIONS
Valve face width B (exhaust)2.26 mm (0.0890 in)
B
Valve seat width C (intake)1.00–1.20 mm (0.0394–0.0472 in)
Limit1.60 mm (0.0630 in)
Valve seat width C (exhaust)1.00–1.20 mm (0.0394–0.0472 in)
Limit1.60 mm (0.0630 in)
C
Valve margin thickness D (intake)0.80–1.20 mm (0.0315–0.0472 in)
Limit0.4 mm (0.02 in)
Valve margin thickness D (exhaust)0.80–1.20 mm (0.0315–0.0472 in)
Limit0.4 mm (0.02 in)
D
Valve stem diameter (intake)5.975–5.990 mm (0.2352–0.2358 in)
Limit5.945 mm (0.2341 in)
Valve stem diameter (exhaust)5.960–5.975 mm (0.2346–0.2352 in)
Limit5.930 mm (0.2335 in)
Valve guide inside diameter (intake)6.000–6.012 mm (0.2362–0.2367 in)
Limit6.050 mm (0.2382 in)
Valve guide inside diameter (exhaust)6.000–6.012 mm (0.2362–0.2367 in)
Limit6.050 mm (0.2382 in)
Valve-stem-to-valve-guide clearance (intake)0.010–0.037 mm (0.0004–0.0015 in)
Limit0.080 mm (0.0031 in)
Valve-stem-to-valve-guide clearance (exhaust)0.025–0.052 mm (0.0010–0.0020 in)
Limit0.100 mm (0.0039 in)
Valve stem runout0.040 mm (0.0016 in)
Cylinder head valve seat width (intake)1.00–1.20 mm (0.0394–0.0472 in)
Cylinder head valve seat width (exhaust)1.00–1.20 mm (0.0394–0.0472 in)
Valve spring
Free length (intake)40.38 mm (1.59 in)
Limit38.36 mm (1.51 in)
Free length (exhaust)40.38 mm (1.59 in)
Limit38.36 mm (1.51 in)
Installed length (intake)35.00 mm (1.38 in)
Installed length (exhaust)35.00 mm (1.38 in)
2-5
Page 37
ENGINE SPECIFICATIONS
Spring rate K1 (intake)34.18 N/mm (3.49 kgf, 195.16 lbf)
Spring rate K2 (intake)44.14 N/mm (4.50 kgf, 252.04 lbf)
Spring rate K1 (exhaust)34.18 N/mm (3.49 kgf, 195.16 lbf)
Spring rate K2 (exhaust)44.14 N/mm (4.50 kgf, 252.04 lbf)
Installed compression spring force (intake)171.00–197.00 N (17.44–20.09 kgf, 38.44–
44.29 lbf)
Installed compression spring force (exhaust)171.00–197.00 N (17.44–20.09 kgf, 38.44–
44.29 lbf)
Spring tilt (intake)2.5°/1.80 mm
Spring tilt (exhaust)2.5°/1.80 mm
Winding direction (intake)Clockwise
Winding direction (exhaust)Clockwise
Cylinder
Bore92.000–92.010 mm (3.6220–3.6224 in)
(YFM5FGY/YFM5FGPY)
102.000–102.010 mm (4.0157–4.0161 in)
(YFM7FGY/YFM7FGPY)
Wear limit92.080 mm (3.6252 in)
(YFM5FGY/YFM5FGPY)
102.080 mm (4.0189 in)
(YFM7FGY/YFM7FGPY)
Taper limit0.05 mm (0.002 in)
Out of round limit0.05 mm (0.002 in)
Piston
Piston-to-cylinder clearance0.030–0.055 mm (0.0012–0.0022 in)
Limit0.10 mm (0.0039 in) (YFM5FGY/YFM5FGPY)
0.13 mm (0.0051 in) (YFM7FGY/YFM7FGPY)
Diameter D91.955–91.970 mm (3.6203–3.6209 in)
(YFM5FGY/YFM5FGPY)
101.955–101.970 mm (4.0140–4.0146 in)
(YFM7FGY/YFM7FGPY)
Height H10.0 mm (0.39 in)
H
D
Offset0.50 mm (0.0197 in)
Offset directionIntake side
Piston pin bore inside diameter23.004–23.015 mm (0.9057–0.9061 in)
Limit23.045 mm (0.9073 in)
Piston pin outside diameter22.991–23.000 mm (0.9052–0.9055 in)
2-6
Page 38
ENGINE SPECIFICATIONS
Limit22.971 mm (0.9044 in)
Piston-pin-to-piston-pin-bore clearance0.004–0.024 mm (0.0002–0.0009 in)
Limit0.0740 mm (0.0029 in)
Piston ring
Top ring
Ring typeBarrel
Dimensions (B × T)1.20 × 3.50 mm (0.05 × 0.14 in)
(YFM5FGY/YFM5FGPY)
1.20 × 3.80 mm (0.05 × 0.15 in)
(YFM7FGY/YFM7FGPY)
B
T
End gap (installed)0.20–0.35 mm (0.008–0.014 in)
Limit0.60 mm (0.024 in)
Ring side clearance0.030–0.070 mm (0.0012–0.0028 in)
Limit0.12 mm (0.0047 in)
2nd ring
Ring typeTaper
Dimensions (B × T)1.20 × 4.00 mm (0.05 × 0.16 in)
B
T
End gap (installed)0.75–0.90 mm (0.03–0.04 in)
Limit1.25 mm (0.049 in)
Ring side clearance0.020–0.060 mm (0.0008–0.0024 in)
(YFM5FGY/YFM5FGPY)
0.030–0.070 mm (0.0012–0.0028 in)
(YFM7FGY/YFM7FGPY)
Limit0.12 mm (0.0047 in) (YFM5FGY/YFM5FGPY)
0.13 mm (0.0051 in) (YFM7FGY/YFM7FGPY)
Oil ring
Dimensions (B × T)2.00 × 2.80 mm (0.08 × 0.11 in)
(YFM5FGY/YFM5FGPY)
2.50 × 2.80 mm (0.10 × 0.11 in)
(YFM7FGY/YFM7FGPY)
B
T
End gap (installed)0.20–0.70 mm (0.01–0.03 in)
Ring side clearance0.04–0.13 mm (0.0016–0.0051 in)
(YFM5FGY/YFM5FGPY)
0.060–0.150 mm (0.0024–0.0059 in)
(YFM7FGY/YFM7FGPY)
Crankshaft
Width A74.95–75.00 mm (2.951–2.953 in)
2-7
Page 39
ENGINE SPECIFICATIONS
Runout limit C0.030 mm (0.0012 in)
Big end side clearance D0.350–0.650 mm (0.0138–0.0256 in)
CC
D
A
Balancer
Balancer drive methodGear
Automatic centrifugal clutch
Clutch typeWet, centrifugal automatic
Clutch shoe thickness1.5 mm (0.06 in)
Limit1.0 mm (0.04 in)
Clutch-in revolution2000–2100 r/min (YFM5FGY/YFM5FGPY)
(YFM7FGY/YFM7FGPY)
Water temperature85.0–95.0 °C (185.0–203.0 °F)
(YFM5FGY/YFM5FGPY)
75.0–85.0 °C (167.0–185.0 °F)
(YFM7FGY/YFM7FGPY)
Oil temperature80.0–90.0 °C (176.0–194.0 °F)
(YFM5FGY/YFM5FGPY)
55.0–65.0 °C (131.00–149.0 °F)
(YFM7FGY/YFM7FGPY)
Throttle lever free play3.0–5.0 mm (0.12–0.20 in)
Speed limiter lengthLess than 12 mm (0.47 in)
Shaft drive
Middle gear backlash0.10–0.30 mm (0.004–0.012 in)
Final gear backlash0.10–0.20 mm (0.004–0.008 in)
Differential gear backlash0.05–0.25 mm (0.002–0.010 in)
2-9
Page 41
CHASSIS SPECIFICATIONS
EAS29130
CHASSIS SPECIFICATIONS
Chassis
Frame typeSteel tube frame
Caster angle5.0°
Camber angle0.0°
Kingpin angle11.0°
Kingpin offset0.0 mm (0.00 in)
Trail26.0 mm (1.02 in)
Tread rear (STD)915.0 mm (36.02 in)
Tread front (STD)940.0 mm (37.01 in)
Toe-in (with tire touching the ground)0.0–10.0 mm (0.00–0.39 in)
Front wheel
Wheel typePanel wheel
Rim size12 × 6.0 AT
Rim materialSteel (for models equipped with steel wheels)
Aluminum (for models equipped with aluminum
wheels)
Wheel travel180 mm (7.1 in)
Radial wheel runout limit2.0 mm (0.08 in)
Lateral wheel runout limit2.0 mm (0.08 in)
Rear wheel
Wheel typePanel wheel
Rim size12 × 7.5 AT
Rim materialSteel (for models equipped with steel wheels)
Aluminum (for models equipped with aluminum
wheels)
Wheel travel230 mm (9.1 in)
Radial wheel runout limit2.0 mm (0.08 in)
Lateral wheel runout limit2.0 mm (0.08 in)
TypeDual disc brake
OperationRight hand operation
Front brake lever free play (lever end)0 mm (0 in)
Front disc brake
Disc outside diameter × thickness220.0 × 3.5 mm (8.66 × 0.14 in)
Brake disc thickness limit3.0 mm (0.12 in)
Brake disc deflection limit0.1 mm (0.004 in)
Brake pad lining thickness (inner)4.4 mm (0.17 in)
Limit1.0 mm (0.04 in)
Brake pad lining thickness (outer)4.4 mm (0.17 in)
Limit1.0 mm (0.04 in)
Master cylinder inside diameter12.70 mm (0.50 in)
Caliper cylinder inside diameter33.96 mm (1.34 in)
Recommended fluidDOT 4
Rear brake
TypeDual disc brake
OperationLeft hand and right foot operation
Rear brake lever free play (lever end)0 mm (0 in)
Brake pedal free play0.0–5.0 mm (0.00–0.20 in)
Rear disc brake
Disc outside diameter × thickness205.0 × 3.5 mm (8.07 × 0.14 in)
Brake disc thickness limit3.0 mm (0.12 in)
Brake disc deflection limit0.1 mm (0.004 in)
Brake pad lining thickness (inner)5.8 mm (0.23 in)
Limit1.0 mm (0.04 in)
Brake pad lining thickness (outer)5.8 mm (0.23 in)
Limit1.0 mm (0.04 in)
Master cylinder inside diameter12.70 mm (0.50 in)
Caliper cylinder inside diameter33.96 mm (1.34 in)
Recommended fluidDOT 4
Steering
Steering bearing typeBall and race bearing
Steering tension50 N (5.0 kgf) (YFM5FGPY/YFM7FGPY)
Front suspension
TypeDouble wishbone
Spring/shock absorber typeCoil spring/oil damper
Wheel travel180 mm (7.1 in)
Shock absorber travel90.2 mm (3.55 in) (YFM5FGY/YFM5FGPY)
90.7 mm (3.57 in) (YFM7FGY/YFM7FGPY)
Spring free length292.0 mm (11.50 in)
Installed length233.1 mm (9.18 in) (YFM5FGY/YFM5FGPY)
233.5 mm (9.19 in) (YFM7FGY/YFM7FGPY)
Spring rate K123.00 N/mm (2.35 kgf/mm, 131.33 lb/in)
Spring stroke K10.0–90.2 mm (0.00–3.55 in)
(YFM5FGY/YFM5FGPY)
0.0–90.7 mm (0.00–3.57 in)
(YFM7FGY/YFM7FGPY)
Optional spring availableNo
2-11
Page 43
CHASSIS SPECIFICATIONS
Spring preload adjusting positions
Minimum1
Standard3
Maximum5
Rear suspension
TypeDouble wishbone
Spring/shock absorber typeCoil spring/oil damper
Wheel travel230 mm (9.1 in)
Rear shock absorber assembly travel109.2 mm (4.30 in)
Spring free length318.1 mm (12.52 in) (YFM5FGY/YFM5FGPY)
314.5 mm (12.38 in) (YFM7FGY/YFM7FGPY)
Installed length270.6 mm (10.65 in) (YFM5FGY/YFM5FGPY)
267.5 mm (10.53 in) (YFM7FGY/YFM7FGPY)
Spring rate K131.00 N/mm (3.16 kgf/mm, 177.01 lb/in)
(YFM5FGY/YFM5FGPY)
33.50 N/mm (3.42 kgf/mm, 191.29 lb/in)
(YFM7FGY/YFM7FGPY)
Spring rate K236.00 N/mm (3.67 kgf/mm, 205.56 lb/in)
(YFM7FGY/YFM7FGPY)
Spring stroke K10.0–109.2 mm (0.00–4.30 in)
(YFM5FGY/YFM5FGPY)
0.0–43.0 mm (0.00–1.69 in)
(YFM7FGY/YFM7FGPY)
Spring stroke K243.0–109.2 mm (1.69–4.30 in)
(YFM7FGY/YFM7FGPY)
Optional spring availableNo
Spring preload adjusting positions
Crankshaft position sensor resistance459–561 Ω at 20 °C (68 °F)
Intake air pressure sensor output voltage3.75–4.25 V
Intake air temperature sensor resistance290–390 Ω at 80 °C (176 °F)
Coolant temperature sensor resistance2.45 kΩ at 20 °C (68 °F)
290–354 Ω at 80 °C (176 °F)
Ignition coil
Model/manufacturer2JN/YAMAHA
Minimum ignition spark gap6.0 mm (0.24 in)
Primary coil resistance2.16–2.64 Ω at 20 °C (68 °F)
Secondary coil resistance8.64–12.96 kΩ at 20 °C (68 °F)
Spark plug cap
MaterialResin
Resistance10.0 kΩ
AC magneto
Model/manufacturerF4T39373/MITSUBISHI
Standard output14.0 V 34.0 A at 5,000 r/min
Stator coil resistance0.108–0.132 Ω at 20 °C (68 °F)
Rectifier/regulator
Regulator typeSemi conductor-short circuit
Model/manufacturerFH012AA/SHINDENGEN
Regulated voltage (DC)14.2–14.8 V
Rectifier capacity (DC)50.0 A
Withstand voltage40.0 V
Battery
ModelYTX20L-BS
Voltage, capacity12 V, 18.0 Ah
ManufacturerGS YUASA
Ten hour rate amperage1.8 A
2-13
Page 45
ELECTRICAL SPECIFICATIONS
Headlight
Bulb typeHalogen bulb
Bulb voltage, wattage × quantity
Headlight12 V, 35.0/35.0 W × 2
Tail/brake light12 V, 5.0/21.0 W × 1
Meter lightingEL
Indicator and warning lights
Neutral indicator lightLED
Reverse indicator lightLED
Coolant temperature warning lightLED
Park indicator lightLED
On-Command four-wheel-drive/differential gear lock
Model/manufacturerSM-17/MITSUBA
Power output0.80 kW
Armature coil resistance0.0050–0.0150 Ω at 20 °C (68 °F)
Brush overall length12.0 mm (0.47 in)
Limit6.50 mm (0.26 in)
Brush spring force6.02–6.51 N (614–664 gf, 21.69–23.45 oz)
Mica undercut (depth)0.70 mm (0.03 in)
Starter relay
Model/manufacturer2768113-A/JIDECO
Amperage180.0 A
Coil resistance4.18–4.62 Ω at 20 °C (68 °F)
Fuel sender unit
Sender unit resistance (full)19.00–21.00 Ω
Sender unit resistance (empty)139.00–141.00 Ω
Main fuse40.0 A
Headlight fuse15.0 A
Signaling system fuse5.0 A
Ignition fuse15.0 A
Radiator fan motor fuse20.0 A
Auxiliary DC jack fuse15.0 A
Fuel injection system fuse15.0 A
Four-wheel-drive motor fuse15.0 A
EPS fuse40.0 A (YFM5FGPY/YFM7FGPY)
Spare fuse40.0 A
Spare fuse20.0 A
Spare fuse15.0 A
Spare fuse5.0 A
2-15
Page 47
EAS20320
TIGHTENING TORQUES
EAS20330
GENERAL TIGHTENING TORQUE
SPECIFICATIONS
This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch.
Tightening torque specifications for special components or assemblies are provided for each
chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a crisscross pattern and progressive stages until the specified
tightening torque is reached. Unless otherwise
specified, tightening torque specifications require clean, dry threads. Components should be
at room temperature.
TIGHTENING TORQUES
A. Distance between flats
B. Outside thread diameter
General tightening
A (nut) B (bolt)
torques
Nmm·kgft·lb
10 mm6 mm60.64.3
12 mm8 mm151.511
14 mm10 mm303.022
17 mm12 mm555.540
19 mm14 mm858.561
22 mm16 mm13013.094
2-16
Page 48
EAS20340
ENGINE TIGHTENING TORQUES
TIGHTENING TORQUES
Item
Thread
size
Q’tyTightening torqueRemarks
Exhaust pipe nutM8414 Nm (1.4 m·kg, 10 ft·lb)
Muffler boltM8120 Nm (2.0 m·kg, 14 ft·lb)
Muffler and muffler bracket boltM8220 Nm (2.0 m·kg, 14 ft·lb)
Shift lever 1 gear teeth and shift lever 2 gear teeth
Stopper lever stopper
Bearing (final drive pinion gear)
Bearing (final drive case)
AC magneto lead grommet
Crankcase mating surface
E
E
E
E
LS
E
E
E
G
G
Yamaha bond
No.1215 (Three bond
No.1215®)
Yamaha bond
No.1215 (Three bond
No.1215®)
2-25
Page 57
LUBRICATION POINTS AND LUBRICANT TYPES
2-26
Page 58
LUBRICATION SYSTEM CHART AND DIAGRAMS
EAS20390
LUBRICATION SYSTEM CHART AND DIAGRAMS
EAS20410
LUBRICATION DIAGRAMS
1
1
2
A
3
A
5
7
4
3
A-A
2-27
6
Page 59
1. Oil delivery pipe 1
2. Oil delivery pipe 2
3. Oil filter cartridge
4. Oil strainer
5. Drive axle
6. Relief valve assembly
7. Reverse idle gear shaft
LUBRICATION SYSTEM CHART AND DIAGRAMS
2-28
Page 60
LUBRICATION SYSTEM CHART AND DIAGRAMS
1
2
345
2-29
Page 61
1. Camshaft
2. Crankshaft
3. Oil strainer
4. Oil pump rotor
5. Oil pump driven gear
LUBRICATION SYSTEM CHART AND DIAGRAMS
2-30
Page 62
EAS20420
COOLING SYSTEM DIAGRAMS
123
COOLING SYSTEM DIAGRAMS
8
7654
2-31
Page 63
1. Coolant reservoir hose
2. Radiator inlet hose
3. Coolant reservoir
4. Water pump
5. Water pump outlet pipe
6. Water pump outlet hose
7. Radiator outlet hose
8. Radiator
COOLING SYSTEM DIAGRAMS
2-32
Page 64
EAS20430
CABLE ROUTING
CABLE ROUTING
1234
H
G
F
E
2
1
A
5 6 7
8
9
B
C
D
A-A
1 2
8 9
B-B
C-C
11
D-D
8
U
9
A
B
A
S
R
T
1011
Q
16
15
14
T
D
13
I
B
10
J
11
K
L
12
M
CC
D
N
P
O
2-33
Page 65
CABLE ROUTING
1. Front brake light switch lead
2. On-command four-wheel-drive motor switch and
differential gear lock switch lead
3. Front brake hose
4. Throttle cable
5. Rear brake cable
6. Shift control cable
7. Rear brake hose
8. Left handlebar switch lead
9. Rear brake light switch lead
10. Differential case breather hose
11. Radiator fan motor breather hose
12. EPS motor breather hose (YFM5FGP/YFM7FGP
only)
13. Radiator fan motor lead
14. Meter assembly lead
15. EPS control unit lead (YFM5FGP/YFM7FGP only)
16. Final drive case breather hose
A. Pass the front brake hose and throttle cable
through the guide on the handlebar cover.
B. Pass the rear brake cable, shift control cable, and
rear brake hose through the guide on the
handlebar cover.
C. Route the rear brake cable, shift control cable, and
rear brake hose in front of the left handlebar switch
lead and rear brake light switch lead.
D. Pass the rear brake hose and throttle cable
through the guide, making sure to route the cable
behind the hose.
E. Pass the rear brake cable and shift control cable
through the guide.
F. Pass the front brake hose through the guide.
G. Route the throttle cable behind the rear brake
cable and shift control cable.
H. Route the front brake light switch lead, on-
command four-wheel-drive motor switch and
differential gear lock switch lead, left handlebar
switch lead, and rear brake light switch lead over
the throttle cable, rear brake cable, and shift
control cable, then to the front of where the cables
cross.
I. Fasten the left handlebar switch lead and rear
brake light switch lead with the plastic bands at the
bends in the handlebar, making sure to route the
leads under the handlebar and to face the ends of
the bands forward.
J. Pass the differential case breather hose through
the guide on the meter bracket.
K. Pass the radiator fan motor breather hose through
the guide on the meter bracket.
L. Pass the EPS motor breather hose through the
guide on the meter bracket. (YFM5FGP/YFM7FGP
only)
M. Route the radiator fan motor breather hose and
differential case breather hose in front of the frame.
N. Fasten the differential case breather hose to the
frame with the plastic band, making sure to face
the end of the band inward.
O. Route the differential case breather hose to the
inside of the frame.
P. To differential assembly
Q. Fasten the meter assembly lead and EPS control
unit lead (YFM5FGP/YFM7FGP only) with a plastic
locking tie. Be sure to fasten the plastic locking tie
around the protective sleeves of the leads, not the
leads themselves.
R. Pass the final drive case breather hose through the
guide on the meter bracket.
S. Fasten the front brake light switch lead, on-
command four-wheel-drive motor switch and
differential gear lock switch lead, left handlebar
switch lead, and rear brake light switch lead with a
plastic locking tie. Be sure to fasten the plastic
locking tie above the couplers and fasten it around
the protective sleeves of the leads, not the leads
themselves.
T. 20
–50 mm (0.79–1.97 in)
U. Fasten the front brake light switch lead and on-
command four-wheel-drive motor switch and
differential gear lock switch lead with the plastic
bands at the bends in the handlebar, making sure
to route the leads under the handlebar and to face
the ends of the bands forward.
2-34
Page 66
CABLE ROUTING
J
H
15
G
6
A
5
4
3
2
1
7
8
B
A
B
I
B
A
C
D
9
C
10
11
12
1314
5
CDEF
A-A
Q
13
K
B-BB-B
Q
13
15
K
R
13
9
1
4
K
R
13
1
4
K
1
19
1
L
D
16
M
11
N
12
N
N O
10
‚
17
P
5
18
C-CC-C
2-35
Page 67
CABLE ROUTING
1. Coolant reservoir hose
2. Radiator fan motor breather hose
3. Differential case breather hose
4. EPS motor breather hose (YFM5FGP/YFM7FGP
only)
5. Ground lead
6. Coolant reservoir breather hose
7. Throttle cable
8. Fuel injector lead
9. Fuel tank drain hose
10. Final drive case breather hose
11. Speed sensor lead
12. AC magneto/crankshaft position sensor lead
13. Radiator outlet hose
14. Differential motor lead
15. EPS torque sensor lead (YFM5FGP/YFM7FGP
only)
16. Gear position switch lead
17. Reverse switch lead
18. Shift control cable
19. Starter motor lead
A. Face the end of the coolant reservoir breather
hose downward.
B. Route the fuel injector lead to the inside of the fuel
tank drain hose.
C. Pass the AC magneto/crankshaft position sensor
lead through the holder.
D. Fasten the radiator outlet hose to the frame with
the plastic band, making sure to face the end of the
band inward.
E. Route the EPS motor breather hose under the
coolant reservoir hose. (YFM5FGP/YFM7FGP
only)
F. Place the EPS torque sensor lead
(YFM5FGP/YFM7FGP only) and differential motor
lead in the holder, and then insert the ends of the
holder into the hole in the stay on the frame.
G. Route the differential case breather hose to the
inside of the frame.
H. Fasten the differential case breather hose to the
frame with the plastic band, making sure to face
the end of the band inward.
I. Attach the ground lead terminal to the frame using
the bolt.
J. Route the radiator fan motor breather hose and
differential case breather hose to the inside of the
radiator outlet hose.
K. Face the end of the plastic band inward.
L. Route the fuel tank drain hose as shown in the
illustration.
M. Pass the speed sensor lead, AC
magneto/crankshaft position sensor lead, and final
drive case breather hose through the guide in the
order listed.
N. Route the speed sensor lead, AC
magneto/crankshaft position sensor lead, and final
drive case breather hose to the right of the reverse
switch.
O. Route the final drive case breather hose above the
reverse switch lead and ground leads.
P. Route the shift control cable under the gear
position switch lead, speed sensor lead, and AC
magneto/crankshaft position sensor lead.
Q. YFM5FGP/YFM7FGP
R. YFM5FG/YFM7FG
2-36
Page 68
CABLE ROUTING
21
8
25
J
24
23
22
4
3
2
A
1
K
5 6
7
BCDE
9
8
C
B
10
11
12
13
14
15
F
B
A
A
F
D
D
E
G
16
G
F
E
G
17
I
27
L
4
24
25
5
8
6
1
A-AB-B
13
27
Q
5
4
6
1
TU
12
13
14
R
20
M
13
19
18
R
18
H
NO
C
S
20
19
D-DE-EE-EF-FG-G
26
17
P
9
20
2-37
Page 69
CABLE ROUTING
1. Wire harness
2. Fuel hose
3. Intake air temperature sensor lead
4. Final drive case breather hose
5. Ground lead
6. Starter motor lead
7. Air filter case breather hose
8. Coolant temperature sensor lead
9. Throttle body breather hose
10. Main switch lead
11. Auxiliary DC jack lead
12. EPS motor lead (YFM5FGP/YFM7FGP only)
13. Differential motor lead
14. EPS torque sensor lead (YFM5FGP/YFM7FGP
only)
15. Radiator fan motor lead
16. Radiator inlet hose
17. EPS motor breather hose (YFM5FGP/YFM7FGP
only)
A. Route the fuel hose between the wire harness and
the fuel tank drain hose.
B. Route the air filter case breather hose to the
outside of the leads, and then fasten the hose with
the holder on V-belt cooling intake duct joint.
C. Route the throttle body breather hose under the
coolant temperature sensor lead.
D. Route the EPS motor breather hose
(YFM5FGP/YFM7FGP only) and radiator fan motor
breather hose above the V-belt cooling intake duct.
E. Route the final drive case breather hose above the
V-belt cooling intake duct.
F. Route the radiator fan motor lead between the
electrical components tray and the radiator inlet
hose.
G. Fasten the radiator fan motor lead and radiator fan
motor breather hose to the frame with the plastic
band, making sure to face the end of the band
inward.
H. Route the spark plug lead to the outside of the rear
brake cable and shift control cable.
I. Route the fuel tank drain hose to the inside of the
leads and fuel hose, making sure to position the
end of the drain hose as shown in the illustration.
J. Fasten the final drive case breather hose, ground
lead, starter motor lead, fuel injector lead, coolant
temperature sensor lead, AC magneto/crankshaft
position sensor lead, and wire harness with the
plastic band, making sure to position the band near
the split in the wire harness.
K. Route the fuel injector lead and coolant
temperature sensor lead to the inside of the ground
lead, starter motor lead, final drive case breather
hose, and wire harness.
L. Face the end of the plastic band inward.
M. Pass the plastic band through the hole in the
plastic cover, and then fasten the wire harness,
final drive case breather hose, ground lead, and
starter motor lead with the band, making sure to
face the end of the band downward.
N. The ends of the EPS motor breather hose
(YFM5FGP/YFM7FGP only) and radiator fan motor
breather hose should extend rearward past the
inlet of air filter case as shown in the illustration.
O. Route the EPS motor breather hose
(YFM5FGP/YFM7FGP only) and radiator fan motor
breather hose under the air chamber.
P. Route the EPS motor breather hose
(YFM5FGP/YFM7FGP only) and radiator fan motor
breather hose rearward and pass them through the
guide.
Q. Insert the projection on each coupler into the hole
in the frame from the inside of the frame.
(YFM5FGP/YFM7FGP only)
R. Face the end of the plastic band inward.
S. Fasten the spark plug lead with the larger diameter
section of each holder.
T. YFM5FGP/YFM7FGP
U. YFM5FG/YFM7FG
2-38
Page 70
CABLE ROUTING
B
1
2
3
A
A
D
C
B
B
A
C
C
5
4
7
6
E
A-A
1
6
2
3
B-BC-C
E
8
3
5
F
2-39
Page 71
1. Tail/brake light lead
2. Rectifier/regulator lead
3. AC magneto lead
4. Speed sensor lead
5. Final drive case breather hose
6. Fuel hose
7. Fuel pump lead
8. Wire harness
A. To tail/brake light
B. Fasten the tail/brake light lead to the frame with
plastic locking ties, making sure to face the end of
each tie downward.
C. Install the plastic band near the split in the wire
harness.
D. Route the tail/brake light lead to the outside of the
frame.
E. Face the end of the plastic band downward.
F. Pass the final drive case breather hose through the
guide.
CABLE ROUTING
2-40
Page 72
CABLE ROUTING
30
456732
B
33
32
31
P
O
29
1
BB
A
B
N
AA
M
28
27
26
8
C
D
9
10
11
E
12
13
25
24
23
17
1819
GH
31
11
I
Q
34
R
L
965
7
K
33
3222
202122
J
F
14
15
16
7
B-B
A-A
2-41
Page 73
CABLE ROUTING
1. Left headlight lead
2. Four-wheel-drive motor relay 1
3. Four-wheel-drive motor relay 2
4. Headlight relay
5. Battery
6. ECU (engine control unit)
7. Negative battery lead
8. Right headlight lead
9. EPS (electric power steering) control unit
(YFM5FGP/YFM7FGP only)
10. Radiator fan motor lead
11. EPS control unit lead (YFM5FGP/YFM7FGP only)
12. Auxiliary DC jack lead
13. Main switch lead
14. Radiator fan motor relay
15. Fuel injection system relay
16. Four-wheel-drive motor relay 3
17. Final drive case breather hose
18. Starter motor lead
19. Differential motor lead
20. Meter assembly lead
21. Lean angle sensor lead
22. Coolant reservoir breather hose
23. Fuse box
24. Spare fuse
25. Main fuse
26. EPS fuse (YFM5FGP/YFM7FGP only)
27. Starter relay
28. Positive battery lead
29. Ground lead
30. Coolant reservoir hose
31. EPS motor breather hose (YFM5FGP/YFM7FGP
only)
32. Differential case breather hose
33. Radiator fan motor breather hose
34. Wire harness
A. To left headlight
B. Connect the headlight coupler, and then fasten the
coupler with the holder on the electrical
components tray.
C. To right headlight
D. Route the negative battery lead along the guide on
the electrical components tray.
E. Place the couplers on the inside of the electrical
components tray.
F. To main switch and auxiliary DC jack
G. Route the starter motor lead above the leads in the
electrical components tray.
H. Fasten the EPS control unit lead with the holder.
(YFM5FGP/YFM7FGP only)
I. Fasten the meter assembly lead and EPS control
unit lead (YFM5FGP/YFM7FGP only) with the twist
tie.
J. Fasten the left handlebar switch lead, on-
command four-wheel-drive motor switch and
differential gear lock switch lead, front brake light
switch lead, and rear brake light switch lead with
the holder.
K. Fasten the joint coupler lead with the holder.
L. Pass the coolant reservoir breather hose through
the guides on the plastic cover and electrical
components tray and route it under the positive
battery lead and starter motor lead.
M. Route the hoses under the positive battery lead,
and then route them upward, to the inside of the
coolant reservoir breather hose.
N. Fasten the coolant reservoir breather hose with the
holder on the electrical components tray.
O. Fasten the coolant reservoir hose with the holder
on the electrical components tray.
P. Pass the hoses and ground lead through the
opening in the electrical components tray.
Q. Route the coolant reservoir breather hose above
the other hoses.
R. Route the hoses to the inside of the screw.
2-42
Page 74
CABLE ROUTING
4
3
2
1
A
20
19
5
6
7
C
8
9
E
F
G
10
11
12
13
14
15
16
17
B
D
H
H
AA
B
B
1
K
I
A-A
CC
11
14
L
10
18
18
J
B-BC-C
2-43
Page 75
1. Throttle cable
2. Rear brake hose
3. Rear brake cable
4. Front brake hose
5. Negative battery lead
6. Final drive case breather hose
7. Starter motor lead
8. Throttle body breather hose
9. Intake air pressure sensor lead
10. TPS lead
11. Intake air temperature sensor lead
12. Fuel injector lead
13. Coolant temperature sensor lead
14. Wire harness
15. AC magneto lead
16. Rectifier/regulator lead
17. Fuel hose
18. Tail/brake light lead
19. Fuel pump lead
20. ISC unit lead
A. Route the throttle cable under the plastic cover.
B. Route the final drive case breather hose on top of
the leads.
C. Fasten the radiator fan motor breather hose and
throttle body breather hose with the holder.
D. Route the intake air pressure sensor lead to the
front of the throttle body breather hose and above
the ISC unit lead.
E. Fasten the ISC unit lead with the holder.
F. To engine
G. To air filter case
H. Route the fuel injector lead and coolant
temperature sensor lead to the outside of the
frame.
I. Pass the tail/brake light lead through the hole in
the rear fender.
J. Fasten the tail/brake light lead with the holder,
making sure that the coupler is positioned to the
rear of the holder.
K. Pass the throttle cable through the guide on the
plastic cover.
L. Insert the projection on the wire harness holder
into the hole in the plastic cover.
CABLE ROUTING
2-44
Page 76
CABLE ROUTING
2
1
A
3
A
3
B
B
A
2
C
D
2
B-B
B
B
4
B
C
B
C
4
E
E
D
D
E
E-EC
E
4
F
2-45
Page 77
1. Front brake pipe
2. Rear brake pipe
3. Front brake hose
4. Rear brake hose
A. Pass the front brake hose through the holder.
B. Fasten the front brake hose with the holder.
C. Pass the rear brake pipe through the holder.
D. Fasten the rear brake pipe with the holder.
E. Pass the rear brake hose through the holder.
F. Fasten the rear brake hose with the holder.
CHECKING AND CHARGING THE BATTERY....................................... 3-35
CHECKING THE FUSES ........................................................................3-35
REPLACING THE HEADLIGHT BULBS .................................................3-35
ADJUSTING THE HEADLIGHT BEAMS................................................. 3-35
Page 81
Page 82
PERIODIC MAINTENANCE
T
EAS20450
PERIODIC MAINTENANCE
EAS20460
INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments. If
followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer service life and reduce the need for costly overhaul work. 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.
EBU21742
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM
IP
• For ATVs not equipped with an odometer or an hour meter, follow the month maintenance intervals.
• For ATVs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance in-
tervals. However, keep in mind that if the ATV isn’t used for a long period of time, the month mainte-
nance intervals should be followed.
• Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools,
data and technical skills.
INITIALEVERY
NO.ITEM
1* Fuel line
2Spark plug
3* Valves• Check valve clearance and adjust if necessary.√√√√
Crankcase breather
4*
system
5* Exhaust system
6Spark arrester• Clean.√√√
EBU21864
CHECK OR MAINTENANCE
• Check fuel hoses for cracks or other damage, and replace if necessary.
• Check condition and clean, regap, or replace if necessary.
• Check breather hose for cracks or other damage,
and replace if necessary.
• Check for leakage and replace gasket(s) if necessary.
• Check for looseness and tighten all screw clamps
and joints if necessary.
JOB
Whichever
comes first
month136612
320
km (mi)
hours2080160160320
(200)
1300
(800)
√√√√√
2500
(1600)
2500
(1600)
√√√
√√√
√√√
GENERAL MAINTENANCE AND LUBRICATION CHART
INITIALEVERY
month136612
320
km (mi)
(200)
1300
(800)
2500
(1600)
2500
(1600)
NO.ITEM
CHECK OR MAINTENANCE
JOB
Whichever
comes first
5000
(3200)
5000
(3200)
hours2080160160320
1Air filter element• Clean and replace if necessary.
• Check operation and correct if necessary.
2* Front brake
3* Rear brake
• Check fluid level and ATV for fluid leakage, and correct if necessary.
• Replace brake pads.Whenever worn to the limit
• Check operation and correct if necessary.
• Check brake pedal free play and adjust if necessary.
• Check fluid level and ATV for fluid leakage, and cor-
rect if necessary.
• Replace brake pads.Whenever worn to the limit
3-1
Every 20–40 hours (more often in wet or
√√√√√
√√√√√
dusty areas)
Page 83
PERIODIC MAINTENANCE
INITIALEVERY
NO.ITEM
4* Brake hoses
Rear brake hose pro-
5*
tectors
6* Wheels
7* Tires
8* Wheel hub bearings
9* V-belt
10 *Chassis fasteners
11 *
12 *Stabilizer bushes
13 *Rear knuckle pivots• Lubricate with lithium-soap-based grease.√√√
14 *Steering shaft• Lubricate with lithium-soap-based grease.√√√
15 *Steering system
16 *Engine mount
17 *Axle boots
18Engine oil
19
20Differential gear oil
21Final gear oil
22Cooling system
23 *
24 *
25 *
26 *
27 *Lights and switches
Shock absorber assemblies
Engine oil filter cartridge
Moving parts and cables
Drive select lever
safety system cable
Throttle lever housing and cable
Front and rear brake
switches
CHECK OR MAINTENANCE
• Check for cracks or other damage, and replace if
necessary.
• Replace.Every 4 years
• Check for wear, cracks or other damage, and replace
if necessary.
• Check runout and for damage, and replace if necessary.
• Check tread depth and for damage, and replace if
necessary.
• Check air pressure and balance, and correct if necessary.
• Check for looseness or damage, and replace if necessary.
• Check for wear, cracks or other damage, and replace
if necessary.
• Make sure that all nuts, bolts, and screws are properly tightened.
• Check operation and correct if necessary.
• Check for oil leakage and replace if necessary.
• Check for cracks or other damage, and replace if
necessary.
• Check operation and repair or replace if damaged.
• Check toe-in and adjust if necessary.
• Check for cracks or other damage, and replace if
necessary.
• Check for cracks or other damage, and replace if
necessary.
• Change.
• Check ATV for oil leakage, and correct if necessary.
• Replace.√√√
• Change.
• Check ATV for oil leakage, and correct if necessary.
• Change.
• Check ATV for oil leakage, and correct if necessary.
• Check coolant level and ATV for coolant leakage,
and correct if necessary.
• Replace coolant.Every 2 years
• Lubricate.√√√√
• Check operation and adjust or replace if necessary.√√√
• Check operation and correct if necessary.
• Check throttle cable free play and adjust if neces-
sary.
• Lubricate throttle lever housing and cable.
• Check operation and correct if necessary.√√√√√
• Check operation and correct if necessary.
• Adjust headlight beams.
JOB
Whichever
comes first
month136612
320
km (mi)
hours2080160160320
(200)
1300
(800)
√√√√√
√√√√
√√√√
√√√√
√√√√
√√√√√
√√√√√
√√√√√
√√√√
√√
√√
√√√√√
√√√√√
√√√√√
2500
(1600)
√√√√
2500
(1600)
√√√
√√√
√√√
5000
(3200)
3-2
Page 84
PERIODIC MAINTENANCE
T
EBU23070
IP
• The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
• Hydraulic brake service
• Regularly check and, if necessary, correct the brake fluid level.
• Every two years replace the internal components of the brake master cylinders and calipers, and
change the brake fluid.
• Replace the brake hoses every four years and if cracked or damaged.
3-3
Page 85
EAS20472
T
T
ENGINE
ENGINE
EAS20520
ADJUSTING THE VALVE CLEARANCE
The following procedure applies to all of the
valves.
IP
• Valve clearance adjustment should be made
on a cold engine, at room temperature.
• When the valve clearance is to be measured or
adjusted, the piston must be at top dead center
(TDC) on the compression stroke.
1. Remove:
• Left side panel
• Right side panel
• Front fender
• Footrest board
• Air filter case
Refer to “GENERAL CHASSIS” on page 4-1.
2. Remove:
• Intake tappet cover “1”
• Exhaust tappet cover
• Camshaft sprocket cover “2”
1
1
2
6. Measure:
• Valve clearance
Out of specification → Adjust.
Valve clearance (cold)
Intake
0.09–0.13 mm (0.0035–0.0051 in)
Exhaust
0.16–0.20 mm (0.0063–0.0079 in)
▼▼▼▼▼ ▼▼▼▼▼ ▼▼▼▼▼ ▼▼▼▼▼ ▼▼▼▼▼ ▼▼▼▼▼▼▼
a. Turn the crankshaft counterclockwise.
b. When the piston is at TDC on the compres-
sion stroke, align the “I” mark “a” on the AC
magneto rotor with the stationary pointer “b”
on the AC magneto cover.
2
3. Disconnect:
• Spark plug cap “1”
4. Remove:
• Spark plug “2”
2
5. Remove:
• Timing mark accessing screw “1”
• Crankshaft end accessing screw “2”
a
b
IP
To position the piston at TDC on the compression stroke, align the “I” mark “c” on the camshaft
1
sprocket with the stationary pointer “d” on the
cylinder head, as shown in the illustration.
d
c
c. Measure the valve clearance with a thickness
gauge “1”.
3-4
Page 86
ENGINE
Out of specification → Adjust.
Thickness gauge
90890-03079
Narrow gauge set
YM-34483
1
▲▲▲▲▲ ▲▲▲▲▲ ▲▲▲▲▲ ▲▲▲▲▲ ▲▲▲▲▲ ▲▲▲▲▲▲▲
7. Adjust:
• Valve clearance
▼▼▼▼▼ ▼▼▼▼▼ ▼▼▼▼▼ ▼▼▼▼▼ ▼▼▼▼▼ ▼▼▼▼▼▼▼
a. Loosen the locknut “1”.
b. Insert a thickness gauge “2” between the end
of the adjusting screw and the valve tip.
c. Turn the adjusting screw “3” in direction “a” or
“b” with the tappet adjusting tool “4” until the
specified valve clearance is obtained.
Tappet adjusting tool
90890-01311
Six piece tappet set
YM-A5970
Valve adjusting screw locknut
T
.
R
14 Nm (1.4 m·kg, 10 ft·lb)
.
e. Measure the valve clearance again.
f. If the valve clearance is still out of specifica-
tion, repeat all of the valve clearance adjustment steps until the specified clearance is
obtained.
▲▲▲▲▲ ▲▲▲▲▲ ▲▲▲▲▲ ▲▲▲▲▲ ▲▲▲▲▲ ▲▲▲▲▲▲▲
8. Install:
• Timing mark accessing screw
• Crankshaft end accessing screw
Timing mark accessing screw
T
.
R
6 Nm (0.6 m·kg, 4.3 ft·lb)
.
Crankshaft end accessing screw
10 Nm (1.0 m·kg, 7.2 ft·lb)
9. Install:
• Spark plug
Spark plug
T
.
R
13 Nm (1.3 m·kg, 9.4 ft·lb)
.
10.Connect:
• Spark plug cap
11.Install:
• O-rings “1”
New
• Camshaft sprocket cover
• Intake tappet cover
• Exhaust tappet cover
Direction “a”
Valve clearance is increased.
Direction “b”
Valve clearance is decreased.
b
4
3
1
a
2
d. Hold the adjusting screw to prevent it from
moving and tighten the locknut to specification.
Camshaft sprocket cover bolt
T
.
R
10 Nm (1.0 m·kg, 7.2 ft·lb)
.
Tappet cover bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
1
New
12.Install:
• Air filter case
• Footrest board
• Front fender
• Right side panel
• Left side panelRefer to “GENERAL CHASSIS” on page 4-1.
3-5
Page 87
ENGINE
T
EAS20660
ADJUSTING THE THROTTLE LEVER FREE
PLAY
1. Check:
• Throttle lever free play “a”
Out of specification → Adjust.
Throttle lever free play
3.0–5.0 mm (0.12–0.20 in)
2WD
4WD
a
2. Remove:
• Left side panel
Refer to “GENERAL CHASSIS” on page 4-1.
3. Adjust:
• Throttle lever free play
IP
If the free play cannot be adjusted here, adjust it
at the handlebar side of the cable.
▲▲▲▲▲ ▲▲▲▲▲ ▲▲▲▲▲ ▲▲▲▲▲ ▲▲▲▲▲ ▲▲▲▲▲▲▲
▼▼▼▼▼ ▼▼▼▼▼ ▼▼▼▼▼ ▼▼▼▼▼ ▼▼▼▼▼ ▼▼▼▼▼▼▼
Handlebar side
a. Slide back the rubber cover “1”.
b. Loosen the locknut “2”.
c. Turn the adjusting bolt “3” in direction “a” or
“b” until the correct free play is obtained.
Direction “a”
Free play is increased.
Direction “b”
Free play is decreased.
b
23
a
2WD
4WD
1
▼▼▼▼▼ ▼▼▼▼▼ ▼▼▼▼▼ ▼▼▼▼▼ ▼▼▼▼▼ ▼▼▼▼▼▼▼
Throttle body side
a. Slide back the rubber cover “1”.
b. Loosen the locknut “2” on the throttle body
side.
c. Turn the adjusting nut “3” in direction “a” or “b”
until the correct free play is obtained.
Direction “a”
Free play is increased.
Direction “b”
Free play is decreased.
b
2
1
a
3
d. Tighten the locknut.
e. Slide the rubber cover to its original position.
d. Tighten the locknut.
e. Slide the rubber cover to its original position.
EWA28P1004
WARNING
After adjusting the free play, turn the handlebar to the right and left to make sure that the
engine idling speed does not increase.
▲▲▲▲▲ ▲▲▲▲▲ ▲▲▲▲▲ ▲▲▲▲▲ ▲▲▲▲▲ ▲▲▲▲▲▲▲
4. Install:
• Left side panel
Refer to “GENERAL CHASSIS” on page 4-1.
EAS29170
ADJUSTING THE SPEED LIMITER
The speed limiter keeps the throttle from becoming fully-opened even when the throttle lever is
applied to the maximum position. Screwing in
the adjusting screw stops the engine speed from
increasing.
1. Measure:
• Speed limiter length
Out of specification → Adjust.
Speed limiter length
Less than 12 mm (0.47 in)
3-6
Page 88
ENGINE
T
2. Adjust:
• Speed limiter length “a”
▼▼▼▼▼ ▼▼▼▼▼ ▼▼▼▼▼ ▼▼▼▼▼ ▼▼▼▼▼ ▼▼▼▼▼▼▼
a. Loosen the locknut “1”.
b. Turn the adjuster “2” in direction “b” or “c” until
the specified speed limiter length is obtained.
Direction “b”
Speed limiter length is decreased.
Direction “c”
Speed limiter length is increased.
a
1
2
b
c
c. Tighten the locknut.
EWA14880
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 the specified length. Also, always adjust the throttle
cable free play to within specification.
Manufacturer/model
NGK/LMAR6A-9
5. Check:
• Electrode “1”
Damage/wear → Replace the spark plug.
• Insulator “2”
Abnormal color → Replace the spark plug.
Normal color is medium-to-light tan.
6. Clean:
• Spark plug
(with a spark plug cleaner or wire brush)
7. Measure:
• Spark plug gap “a”
(with a wire thickness gauge)
Out of specification → Regap.
Spark plug gap
0.8–0.9 mm (0.031–0.035 in)
▲▲▲▲▲ ▲▲▲▲▲ ▲▲▲▲▲ ▲▲▲▲▲ ▲▲▲▲▲ ▲▲▲▲▲▲▲
EAS20690
CHECKING THE SPARK PLUG
1. Remove:
• Right side panel
Refer to “GENERAL CHASSIS” on page 4-1.
2. Disconnect:
• Spark plug cap
8. Install:
• Spark plug
3. Remove:
• Spark plug
ECA13330
NOTICE
Before removing the spark plug, blow away
any dirt accumulated in the spark plug well
with compressed air to prevent it from falling
IP
Before installing the spark plug, clean the spark
plug and gasket surface.
T
.
R
.
Spark plug
13 Nm (1.3 m·kg, 9.4 ft·lb)
into the cylinder.
9. Connect:
4. Check:
• Spark plug cap
• Spark plug type
Incorrect → Change.
3-7
Page 89
ENGINE
T
T
T
10.Install:
• Right side panel
Refer to “GENERAL CHASSIS” on page 4-1.
EAS20700
CHECKING THE IGNITION TIMING
IP
Prior to checking the ignition timing, check the
wiring connections of the entire ignition system.
Make sure all connections are tight and free of
corrosion.
1. Remove:
• Left side panel
• Right side panel
• Footrest board
Refer to “GENERAL CHASSIS” on page 4-1.
2. Connect:
• Timing light
(onto the spark plug lead)
• Digital tachometer
(onto the spark plug lead)
Digital tachometer
90890-06760
YU-39951-B
Timing light
90890-03141
Inductive clamp timing light
YU-03141
3. Check:
• Ignition timing
▼▼▼▼▼ ▼▼▼▼▼ ▼▼▼▼▼ ▼▼▼▼▼ ▼▼▼▼▼ ▼▼▼▼▼▼▼
a. Start the engine, warm it up for several min-
utes, and then let it run at the specified engine idling speed.
Engine idling speed
1550–1650 r/min
b. Remove the timing mark accessing screw
“1”.
1
c. Visually check the stationary pointer “a” to
verify it is within the required firing range “b”
indicated on the AC magneto rotor.
Incorrect firing range → Check the ignition
system.
IP
When checking the ignition timing, make sure
that the timing light cord does not come in contact with the exhaust muffler.
b
a
d. Install the timing mark accessing screw.
Timing mark accessing screw
T
.
R
▲▲▲▲▲ ▲▲▲▲▲ ▲▲▲▲▲ ▲▲▲▲▲ ▲▲▲▲▲ ▲▲▲▲▲▲▲
6 Nm (0.6 m·kg, 4.3 ft·lb)
.
4. Detach:
• Timing light
• Tachometer
5. Install:
• Footrest board
• Right side panel
• Left side panel
Refer to “GENERAL CHASSIS” on page 4-1.
EAS20710
MEASURING THE COMPRESSION
PRESSURE
IP
Insufficient compression pressure will result in a
loss of performance.
1. Measure:
• Valve clearance
Out of specification → Adjust.
Refer to “ADJUSTING THE VALVE CLEARANCE” on page 3-4.
2. Start the engine, warm it up for several minutes, and then turn it off.
3. Remove:
• Right side panel
Refer to “GENERAL CHASSIS” on page 4-1.
4. Disconnect:
• Spark plug cap
5. Remove:
• Spark plug
3-8
Page 90
ENGINE
T
ECA28P1041
NOTICE
Before removing the spark plug, use compressed air to blow away any dirt accumulated in the spark plug well to prevent it from
falling into the cylinder.
6. Attach:
• Extension “1”
• Compression gauge “2”
Compression gauge
90890-03081
Engine compression tester
YU-33223
Extension
90890-04082
2
1
c. If the compression pressure is above the
maximum specification, check the cylinder
head, valve surfaces and piston crown for
carbon deposits.
Carbon deposits → Eliminate.
d. If the compression pressure is below the min-
imum specification, pour a teaspoonful of engine oil into the spark plug bore and measure
again.
Refer to the following table.
Compression pressure (with oil applied into
the cylinder)
ReadingDiagnosis
Higher than without
oil
Piston ring(s) wear or
damage → Repair.
Piston, valves, cylinder head gasket or
Same as without oil
piston ring(s) possibly defective → Repair.
▲▲▲▲▲ ▲▲▲▲▲ ▲▲▲▲▲ ▲▲▲▲▲ ▲▲▲▲▲ ▲▲▲▲▲▲▲
8. Install:
• Spark plug
7. Measure:
• Compression pressure
Out of specification → Refer to steps (c) and
(d).
a. Set the main switch to “ON”.
b. With the throttle wide open, crank the engine
until the reading on the compression gauge
stabilizes.
EWA28P1005
WARNING
To prevent sparking, ground the spark plug
lead before cranking the engine.
Spark plug
T
.
R
13 Nm (1.3 m·kg, 9.4 ft·lb)
.
9. Connect:
• Spark plug cap
10.Install:
• Right side panel
Refer to “GENERAL CHASSIS” on page 4-1.
EAS20750
CHECKING THE ENGINE OIL LEVEL
1. Place the vehicle on a level surface.
2. Check the engine oil level on a cold engine.
IP
If the engine was started before checking the oil
level, be sure to warm up the engine sufficiently,
and then wait at least 10 minutes until the oil settles for an accurate reading.
3. Remove:
• Dipstick accessing panel
Refer to “GENERAL CHASSIS” on page 4-1.
4. Check:
• Engine oil level
The engine oil level should be between the
minimum level mark “a” and maximum level
mark “b”.
Below the minimum level mark → Add the
recommended engine oil to the proper level.
3-9
Page 91
ECA28P1009
T
NOTICE
Do not allow foreign materials to enter the
crankcase.
IP
To obtain an accurate oil level reading, the dipstick must be inserted completely into the oil filter hole.
ENGINE
5. Check the engine oil level again.
ECA28P1010
NOTICE
Be sure the engine oil is at the correct level,
otherwise engine damage may result.
b
a
Type
YAMALUBE 4 5W-30 or 10W-40
or 20W-50, SAE 5W-30 or SAE
10W-40 or SAE 20W-50
Recommended engine oil grade
API service SG type or higher,
JASO standard MA
0
1030
YAMALUBE 4 20W-50 or SAE 20W-50
YAMALUBE 4 10W-40 or SAE 10W-40
YAMALUBE 4 5W-30 or SAE 5W-30
-20
-100
ECA28P1004
NOTICE
50
10
90
70
304050˚C
20
110
130˚F
• Engine oil also lubricates the clutch and the
wrong oil types or additives could cause
clutch slippage. Therefore, do not add any
chemical additives or use engine oils with a
grade of CD “c” or higher and do not use
oils labeled “ENERGY CONSERVING II”
“d”.
• Do not allow foreign materials to enter the
crankcase.
6. Install:
• Dipstick accessing panel
Refer to “GENERAL CHASSIS” on page 4-1.
EAS20780
CHANGING THE ENGINE OIL
1. Start the engine, warm it up for several minutes, and then turn it off.
2. Place a container under the engine oil drain
bolt.
3. Remove:
• Dipstick accessing panel
Refer to “GENERAL CHASSIS” on page 4-1.
4. Remove:
• Dipstick “1”
1
5. Remove:
• Engine oil drain bolt “1”
(along with the gasket)
1
3-10
Page 92
ENGINE
6. Drain:
• Engine oil
(completely from the crankcase)
7. If the oil filter cartridge is also to be replaced,
perform the following procedure.
▼▼▼▼▼ ▼▼▼▼▼ ▼▼▼▼▼ ▼▼▼▼▼ ▼▼▼▼▼ ▼▼▼▼▼▼▼
a. Remove the oil filter cartridge “1” with an oil
filter wrench “2”.
Oil filter wrench
90890-01426
YU-38411
2
1
b. Lubricate the O-ring “3” of the new oil filter
cartridge with a thin coat of engine oil.
ECA13390
NOTICE
Make sure the O-ring “3” is positioned cor-
rectly in the groove of the oil filter cartridge.
Engine oil drain bolt
T
.
R
30 Nm (3.0 m·kg, 22 ft·lb)
.
10.Fill:
• Crankcase
(with the specified amount of the recommended engine oil)
Engine oil quantity
Total amount
2.40 L (2.54 US qt, 2.11 Imp.qt)
Without oil filter cartridge replacement
2.00 L (2.11 US qt, 1.76 Imp.qt)
With oil filter cartridge replacement
2.10 L (2.22 US qt, 1.85 Imp.qt)
11.Install:
• Dipstick
12.Start the engine, warm it up for several minutes, and then turn it off.
13.Check:
• Engine
(for engine oil leaks)
14.Check:
• Engine oil level
Refer to “CHECKING THE ENGINE OIL
LEVEL” on page 3-9.
15.Check:
• Engine oil pressure
▼▼▼▼▼ ▼▼▼▼▼ ▼▼▼▼▼ ▼▼▼▼▼ ▼▼▼▼▼ ▼▼▼▼▼▼▼
a. Slightly loosen the oil check bolt “1”.
c. Tighten the new oil filter cartridge to specifi-
cation with an oil filter wrench.
Oil filter cartridge
T
.
R
▲▲▲▲▲ ▲▲▲▲▲ ▲▲▲▲▲ ▲▲▲▲▲ ▲▲▲▲▲ ▲▲▲▲▲▲▲
17 Nm (1.7 m·kg, 12 ft·lb)
.
8. Check:
• Engine oil drain bolt gasket
Damage → Replace.
9. Install:
• Engine oil drain bolt
(along with the gasket)
1
b. Start the engine and keep it idling until engine
oil starts to seep from the oil check bolt. If no
engine oil comes out after one minute, turn
the engine off so that it will not seize.
c. Check the engine oil passages, the oil filter
cartridge and the oil pump for damage or
leakage. Refer to “CRANKSHAFT AND OIL
PUMP” on page 5-68.
d. Start the engine after solving any problems
and check the engine oil pressure again.
e. Tighten the oil check bolt to specification.
3-11
Page 93
T
T
Oil check bolt
T
.
R
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EAS20951
10 Nm (1.0 m·kg, 7.2 ft·lb)
.
CLEANING THE AIR FILTER ELEMENT
1. Remove:
• Fuel tank cover
• Left side panel
• Right side panelRefer to “GENERAL CHASSIS” on page 4-1.
IP
There are two check hoses “1” at the bottom of
the air filter case. If dust and/or water collects in
them, clean the air filter element, air filter mesh
and air filter case.
ENGINE
ECA28P1011
NOTICE
The engine should never be run without the
air filter; excessive piston and/or cylinder
wear may result.
2. Remove:
• Air filter case cover “1”
1
4. Check:
• Air filter element
• Air filter element frame
Damage → Replace.
5. Clean:
• Air filter element
(with solvent)
1
EWA13020
WARNING
Never use low flash point solvents, such as
gasoline, to clean the air filter element. Such
solvents may cause a fire or an explosion.
ECA13430
NOTICE
Do not twist the air filter element when
squeezing it.
1
IP
After cleaning, carefully pat the air filter element
on a clean cloth to remove the excess solvent.
3. Remove:
• Air filter element “1”
• Air filter element frame “2”
3-12
Page 94
6. Apply the recommended oil to the entire sur-
T
T
face of the air filter element and then carefully
pat the air filter element on a clean cloth to remove the excess oil. The air filter element
should be wet but not dripping.
ENGINE
V-belt width
33.3 mm (1.31 in)
Limit
30.0 mm (1.18 in)
Air filter oil grade
Foam air filter oil
7. Install:
• Air filter element frame
• Air filter element
• Air filter case cover
(along with the gasket)
IP
Make sure the air filter element and air filter element frame are properly installed in the air filter
case.
8. Install:
• Right side panel
• Left side panel
• Fuel tank cover
Refer to “GENERAL CHASSIS” on page 4-1.
EAS20970
CHECKING THE V-BELT
1. Remove:
• Drive belt cover
Refer to “PRIMARY AND SECONDARY
SHEAVES” on page 5-47.
2. Check:
• V-belt “1”
Cranks/damage/wear → Replace.
Grease/oil → Clean the primary and secondary sheaves.
Refer to “REPLACING THE V-BELT” on
page 3-13.
3. Measure:
• V-belt width “a”
Out of specification → Replace.
Refer to “REPLACING THE V-BELT” on
page 3-13.
4. Install:
• Drive belt cover
Refer to “PRIMARY AND SECONDARY
SHEAVES” on page 5-47.
EAS28P1006
REPLACING THE V-BELT
1. Replace:
• V-belt
▼▼▼▼▼ ▼▼▼▼▼ ▼▼▼▼▼ ▼▼▼▼▼ ▼▼▼▼▼ ▼▼▼▼▼▼▼
a. Install the bolts “1” (90101-06016) into the
secondary fixed sheave holes.
IP
Tightening the bolts “1” will push the secondary
sliding sheave away, causing the gap between
the secondary fixed and sliding sheaves to widen.
b. Remove the V-belt “2” from the primary
sheave and secondary sheave.
3-13
Page 95
ENGINE
T
• Rear fender
Refer to “GENERAL CHASSIS” on page 4-1.
• V-belt cooling exhaust duct
Refer to “ENGINE REMOVAL” on page 5-1.
Make sure the cylinder head breather hose is
routed correctly.
1
3. Install:
• Left side panel
1
2
Refer to “GENERAL CHASSIS” on page 4-1.
EAS21030
CHECKING THE FUEL LINE
1. Remove:
• Seat
• Right side panel
3. Install:
• Air filter case
3-14
Page 96
ENGINE
• Left side panel
Refer to “GENERAL CHASSIS” on page 4-1.
EAS21080
CHECKING THE EXHAUST SYSTEM
1. Check:
• Exhaust pipe “1”
• Muffler “2”
• Exhaust pipe protector “3”
• Muffler bracket “4”
• Springs “5”
Cracks/damage → Replace.
• Gaskets “6”
Exhaust gas leaks → Replace.
2. Check:
• Tightening torque
Exhaust pipe nut “7”
T
.
R
14 Nm (1.4 m·kg, 10 ft·lb)
.
Muffler and muffler bracket bolt
“8”
20 Nm (2.0 m·kg, 14 ft·lb)
Muffler bolt “9”
20 Nm (2.0 m·kg, 14 ft·lb)
Exhaust pipe protector bolt “10”
7 Nm (0.7 m·kg, 5.1 ft·lb)
▼▼▼▼▼ ▼▼▼▼▼ ▼▼▼▼▼ ▼▼▼▼▼ ▼▼▼▼▼ ▼▼▼▼▼▼▼
EWA28P1009
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.
• Make sure that the transmission is in neutral.
a. Remove the bolts “1”.
b. Remove the tailpipe “2” by pulling it out of the
muffler and the gasket.
1
2
8
3
9
8
2
5
4
6
EAS28970
6
5
CLEANING THE SPARK ARRESTER
1. Clean:
• Spark arrester
10
1
c. Tap the tailpipe lightly with a soft-face ham-
mer 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.
d. Install the gasket, and then insert the tailpipe
2
7
into the muffler and align the bolt holes.
e. Insert the bolts “1” and tighten them.
Spark arrester bolt
T
.
R
10 Nm (1.0 m·kg, 7.2 ft·lb)
.
f. Remove the purging bolt “3”.
3-15
Page 97
ENGINE
T
3
g. Start the engine and rev it up approximately
twenty times while momentarily creating exhaust system back pressure by blocking the
end of the muffler with a shop towel.
h. Stop the engine and allow the exhaust pipe to
cool.
i. Install the purging bolt and tighten it.
Purging bolt
T
.
R
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EAS21110
27 Nm (2.7 m·kg, 19 ft·lb)
.
CHECKING THE COOLANT LEVEL
1. Place the vehicle on a level surface.
IP
The coolant level must be checked on a cold engine since the level varies with engine temperature.
2. 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.
ECA13470
NOTICE
• 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, if distilled water is not available, soft water may
be used.
3. If the coolant is at or below the minimum level
mark, remove the left side panel.
Refer to “GENERAL CHASSIS” on page 4-1.
4. Remove the reservoir cap “1”, add coolant or
distilled water to the maximum level mark “a”,
install the reservoir cap, and then install the
panel.
Coolant reservoir capacity (up to
the maximum level mark)
0.24 L (0.25 US qt, 0.21 Imp.qt)
1
a
EAS21120
CHECKING THE COOLING SYSTEM
1. Remove:
• Front fenders
• Left footrest board
Refer to “GENERAL CHASSIS” on page 4-1.
2. Check:
• Radiator “1”
• Radiator inlet hose “2”
• Coolant reservoir “3”
• Coolant reservoir hose “4”
• Radiator outlet hose “5”
• Water jacket joint “6”
• Water pump outlet hose “7”
• Water pump outlet pipe “8”
• Water pump housing “9”
Cracks/damage → Replace.
Refer to “RADIATOR” on page 6-1 and “WATER PUMP” on page 6-7.
3-16
Page 98
T
2
4
1
5
6
7
8
3. Install:
• Left footrest board
• Front fenders
Refer to “GENERAL CHASSIS” on page 4-1.
EAS21130
CHANGING THE COOLANT
1. Remove:
• Right side panel
• Left side panel
• Front carrier
• Upper panel
Refer to “GENERAL CHASSIS” on page 4-1.
2. Remove:
• Coolant reservoir cap “1”
3. Disconnect:
• Coolant reservoir hose “2”
ENGINE
1
2
3
4. Drain:
• Coolant
(from the coolant reservoir)
5. Connect:
• Coolant reservoir hose
6. Remove:
• Radiator cap “1”
EWA13030
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:
9
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, press down on the radiator cap and turn it counterclockwise to remove.
1
7. Remove:
• Coolant drain bolt “1”
(along with the copper washer)
IP
Place a container under the engine, and then remove the coolant drain bolt. (Use a trough “2” or
a similar object as shown to prevent coolant
from spilling on the engine guard.)
3-17
Page 99
1
8. Drain:
• Coolant
(from the engine and radiator)
9. Check:
• Coolant drain bolt “1”
Damage → Replace.
10.Install:
• Copper washer “2”
New
• Coolant drain bolt
Coolant drain bolt
T
.
R
10 Nm (1.0 m·kg, 7.2 ft·lb)
.
ENGINE
EWA13040
WARNING
• If coolant splashes in your eyes, thorough-
ly wash them with water and consult a doc-
2
tor.
• 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.
ECA13480
NOTICE
• 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, if dis-
tilled water is not available, soft water may
be used.
• If coolant comes into contact with painted
surfaces, immediately wash them with water.
• Do not mix different types of antifreeze.
11.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)
Radiator capacity (including all
routes)
1.99 L (2.10 US qt, 1.75 Imp.qt)
Coolant reservoir capacity (up to
the maximum level mark)
0.24 L (0.25 US qt, 0.21 Imp.qt)
12.Fill:
• Coolant reservoir
(with the recommended coolant to the maximum level mark “a”)
13.Install:
• Coolant reservoir cap “1”
1
FULL
a
LO
W
14.Bleed:
• Coolant system
▼▼▼▼▼ ▼▼▼▼▼ ▼▼▼▼▼ ▼▼▼▼▼ ▼▼▼▼▼ ▼▼▼▼▼▼▼
a. Remove the V-belt cooling exhaust duct “1”.
Handling notes for coolant
Coolant is potentially harmful and should be
handled with special care.
3-18
Page 100
1
b. Loosen the water pump air bleed bolt “2”,
without removing it, to allow all of the air to escape from the air bleed bolt hole.
2
ENGINE
15.Start the engine, warm it up for ten minutes,
and then rev the engine five times.
16.Pour the recommended coolant into the radiator until it is full.
17.Stop the engine and allow it to cool. If the
coolant level has dropped after the engine
has cooled, add sufficient coolant until it
reaches the top of the radiator, and then install the radiator cap.
18.Start the engine, and then check for coolant
leakage.
• Coolant level
Refer to “CHECKING THE COOLANT LEVEL” on page 3-16.
19.Install:
• Upper panel
• Front carrier
• Left side panel
• Right side panel
Refer to “GENERAL CHASSIS” on page 4-1.
c. When coolant begins to flow out of the bolt
hole, tighten the water pump air bleed bolt to
specification.
Water pump air bleed bolt
T
.
R
10 Nm (1.0 m·kg, 7.2 ft·lb)
.
d. Loosen the cylinder head air bleed bolt “3”,
without removing it, to allow all of the air to escape from the air bleed bolt hole.
3
e. When coolant begins to flow out of the bolt
hole, tighten the cylinder head air bleed bolt
to specification.
Cylinder head air bleed bolt
T
.
R
10 Nm (1.0 m·kg, 7.2 ft·lb)
.
f. Install the V-belt cooling exhaust duct.
▲▲▲▲▲ ▲▲▲▲▲ ▲▲▲▲▲ ▲▲▲▲▲ ▲▲▲▲▲ ▲▲▲▲▲▲▲
3-19
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