YAMAHA YFM5FGY, YFM5FGPY, YFM7FGY, YFM7FGPY User Manual

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Page 1

2009

SERVICE MANUAL

YFM5FGY

YFM5FGPY

YFM7FGY

YFM7FGPY

LIT-11616-22-19 34D-28197-10

Page 2

EAS20050

YFM5FGY/YFM5FGPY/YFM7FGY/YFM7FGPY

SERVICE MANUAL

First edition, May 2008

Any reproduction or unauthorized use

without the written permission of

Yamaha Motor Corporation, U.S.A.

is expressly prohibited.

Printed in U.S.A.

LIT-11616-22-19

Page 3

EAS20071

IMPORTANT

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.

• 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.

NOTICE

Page 5

EAS20100

SYMBOLS

The following symbols are used in this manual for easier understanding.

The following symbols are not relevant to every vehicle.

1 2 3

4 5 6

1. Serviceable with engine mounted

2. Filling fluid

3. Lubricant

4. Special tool

5. Tightening torque

6. Wear limit, clearance

7. Engine speed

8. Electrical data

9. Engine oil

10.Gear oil

11.Molybdenum disulfide oil

12.Brake fluid

13.Wheel bearing grease

14.Lithium-soap-based grease

15.Molybdenum disulfide grease

16.Silicone grease

17.Apply locking agent (LOCTITE®).

18.Replace the part with a new one.

9 10

11 12

13 14

15 16

17 18

New

Page 6

Page 7

EAS20110

TABLE OF CONTENTS

GENERAL INFORMATION

SPECIFICATIONS

PERIODIC CHECKS AND ADJUSTMENTS

CHASSIS

ENGINE

COOLING SYSTEM

FUEL SYSTEM

DRIVE TRAIN

ELECTRICAL SYSTEM

TROUBLESHOOTING

Page 8

Page 9

GENERAL INFORMATION

IDENTIFICATION ............................................................................................1-1

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

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

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

OUTLINE OF THE FI SYSTEM................................................................. 1-2

FI SYSTEM................................................................................................ 1-3

OUTLINE OF THE EPS (ELECTRIC POWER STEERING) SYSTEM

(YFM5FGP/YFM7FGP only)..................................................................... 1-5

EPS (ELECTRIC POWER STEERING) SYSTEM BLOCK DIAGRAM

(YFM5FGP/YFM7FGP only)..................................................................... 1-7

INSTRUMENT FUNCTIONS ..................................................................... 1-9

IMPORTANT INFORMATION .......................................................................1-11

PREPARATION FOR REMOVAL AND DISASSEMBLY......................... 1-11

REPLACEMENT PARTS......................................................................... 1-11

GASKETS, OIL SEALS AND O-RINGS .................................................. 1-11

LOCK WASHERS/PLATES AND COTTER PINS ...................................1-11

BEARINGS AND OIL SEALS ..................................................................1-12

CIRCLIPS ................................................................................................1-12

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.

1 2 3 4 6 7 8 9 10

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

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. 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

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)

3 d a

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)

1-7

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

EAS28P1035

INSTRUMENT FUNCTIONS

Multifunction display

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.

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. 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.

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. 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

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

• 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.

If the pin “1” on the terminal is flattened, bend it up.

4. Connect:

• Lead

• Coupler

• Connector

Make sure all connections are tight.

5. Check:

• Continuity (with the pocket tester)

1-13

Page 23

SPECIAL TOOLS

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.

• 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

Reference

pages

1-13, 9-81, 9-82, 9-83, 9-87, 9-89, 9-90, 9-91, 9-92, 9-93, 9-94, 9-95, 9-96, 9-97, 9-98

3-5

YM-A5970

ø9ø8 ø10

ø3 ø4

Digital tachometer

3-8 90890-06760 YU-39951-B

Timing light

3-8 90890-03141 Inductive clamp timing light YU-03141

1-14

Page 24

SPECIAL TOOLS

Tool name/Tool No. Illustration

Compression gauge 90890-03081 Engine compression tester YU-33223

Extension 90890-04082

Oil filter wrench 90890-01426 YU-38411

Belt tension gauge 90890-03170 Rear drive belt tension gauge YM-03170

Reference

pages

3-9

3-11

3-28

Ring nut wrench 90890-01268 Spanner wrench YU-01268

Ball joint remover 90890-01474 YM-01474

Ball joint remover attachment set 90890-01480 Ball joint adapter set YM-01480

Ball joint remover short shaft set 90890-01514 YM-01514

3-31, 3-32

4-57, 4-61

4-57

Slide hammer bolt 90890-01083 Slide hammer bolt 6 mm YU-01083-1

5-18, 5-20

1-15

Page 25

SPECIAL TOOLS

Tool name/Tool No. Illustration

Weight 90890-01084 YU-01083-3

Valve spring compressor 90890-04019 YM-04019

Valve spring compressor attachment 90890-01243 Valve spring compressor adapter (26 mm) YM-01253-1

Reference

pages

5-18

YU-01083-3

5-22, 5-27

Valve guide remover (ø6) 90890-04064 Valve guide remover (6.0 mm) YM-04064-A

Valve guide installer (ø6) 90890-04065 Valve guide installer (6.0 mm) YM-04065-A

Valve guide reamer (ø6) 90890-04066 Valve guide reamer (6.0 mm) YM-04066

5-23

1-16

Page 26

SPECIAL TOOLS

Tool name/Tool No. Illustration

Piston pin puller set 90890-01304 Piston pin puller YU-01304

Sheave holder 90890-01701 Primary clutch holder YS-01880-A

Flywheel puller 90890-01362 Heavy duty puller YU-33270-B

Reference

pages

5-29

YU-01304

5-36, 5-37,

5-38, 5-50,

5-54

5-36

Yamaha bond No. 1215 90890-85505 (Three Bond No.1215®)

Digital circuit tester 90890-03174 Model 88 Multimeter with tachometer YU-A1927

Sheave fixed block 90890-04135 Sheave fixed bracket YM-04135

5-38, 5-66

5-42, 7-7

5-50, 5-53

1-17

Page 27

SPECIAL TOOLS

Tool name/Tool No. Illustration

Locknut wrench 90890-01348 YM-01348

Sheave spring compressor 90890-04134 YM-04134

Reference

pages

5-50, 5-53

Universal clutch holder 90890-04086 YM-91042

Crankcase separating tool 90890-01135 Crankcase separator YU-01135-B

5-58, 5-59

5-70

1-18

Page 28

SPECIAL TOOLS

Tool name/Tool No. Illustration

Crankshaft installer pot 90890-01274 Installing pot YU-90058

Crankshaft installer bolt 90890-01275 Bolt YU-90060

Adapter (M16) 90890-04130 Adapter #13 YM-04059

Reference

pages

5-72

YU-90058/YU-90059

5-72

Spacer (crankshaft installer) 90890-04081 Pot spacer YM-91044

Spacer 90890-01309 Pot spacer YU-90059

Coupling gear/middle shaft tool 90890-01229 Gear holder YM-01229

YM-91044

ø35

5-72

5-82, 5-85

1-19

Page 29

SPECIAL TOOLS

Tool name/Tool No. Illustration

Bearing retainer wrench 90890-04128 Middle gear bearing retainer YM-04128

Ring nut wrench 90890-01430 YM-38404

Final gear backlash band 90890-01511 Middle drive gear lash tool YM-01230

Radiator cap tester 90890-01325 Radiator pressure tester YU-24460-01

Reference

pages

5-83, 5-84

5-86, 8-29

6-3

Radiator cap tester adapter 90890-01352 Radiator pressure tester adapter YU-33984

Mechanical seal installer 90890-04132 Water pump seal installer YM-33221-A

YU-24460-01

6-3

YU-33984

6-9

1-20

Page 30

SPECIAL TOOLS

Tool name/Tool No. Illustration

Middle driven shaft bearing driver 90890-04058 Bearing driver 40 mm YM-04058

Pressure gauge 90890-03153 YU-03153

Fuel pressure adapter 90890-03176 YM-03176

Boots band installation tool 90890-01526 YM-01526

Reference

pages

6-9

7-7

8-9, 8-11, 8-22,

8-24

Ring gear fix bolt (M10) 90890-01527 YM-01527

Gear lash measurement tool 90890-01475 Middle drive gear lash tool YM-01475

Ring gear fix bolt (M14) 90890-01524 YM-01524

Ignition checker 90890-06754 Opama pet-4000 spark checker YM-34487

8-13

M10×P1.25

8-13

8-29

M14×P1.5

9-91

1-21

Page 31

SPECIFICATIONS

GENERAL SPECIFICATIONS ........................................................................2-1

ENGINE SPECIFICATIONS ............................................................................ 2-2

CHASSIS SPECIFICATIONS ........................................................................2-10

ELECTRICAL SPECIFICATIONS ................................................................. 2-13

TIGHTENING TORQUES .............................................................................. 2-16

GENERAL TIGHTENING TORQUE SPECIFICATIONS......................... 2-16

ENGINE TIGHTENING TORQUES.........................................................2-17

CHASSIS TIGHTENING TORQUES....................................................... 2-20

LUBRICATION POINTS AND LUBRICANT TYPES ....................................2-24

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

LUBRICATION SYSTEM CHART AND DIAGRAMS.................................... 2-27

LUBRICATION DIAGRAMS ....................................................................2-27

COOLING SYSTEM DIAGRAMS ..................................................................2-31

CABLE ROUTING ......................................................................................... 2-33

Page 32

GENERAL SPECIFICATIONS

EAS29110

GENERAL SPECIFICATIONS

Model

Model 28P1, 28P5 (YFM5FGY)

34D1, 34D5, 34D8 (YFM5FGPY) 5C0A, 5C0C (YFM7FGY) 43P1, 43P5, 43P8, 43PA (YFM7FGPY)

Dimensions

Overall length 2065 mm (81.3 in) Overall width 1180 mm (46.5 in) Overall height 1240 mm (48.8 in) Seat height 905 mm (35.6 in) Wheelbase 1250 mm (49.2 in) Ground clearance 275 mm (10.8 in) Minimum turning radius 3200 mm (126 in)

Weight

With oil and fuel 294.0 kg (648 lb) Maximum loading limit 220.0 kg (485 lb)

(Total weight of rider, cargo, accessories, and tongue)

2-1

Page 33

ENGINE SPECIFICATIONS

EAS29120

ENGINE SPECIFICATIONS

Engine

Engine type Liquid cooled 4-stroke, SOHC Displacement 558.0 cm³ (YFM5FGY/YFM5FGPY)

686.0 cm³ (YFM7FGY/YFM7FGPY)

Cylinder arrangement Forward-inclined single cylinder Bore × stroke 92.0 × 84.0 mm (3.62 × 3.31 in)

(YFM5FGY/YFM5FGPY)

102.0 × 84.0 mm (4.02 × 3.31 in) (YFM7FGY/YFM7FGPY)

Compression ratio 9.30 :1 (YFM5FGY/YFM5FGPY)

9.20 :1 (YFM7FGY/YFM7FGPY)

Standard compression pressure (at sea level) 480 kPa (4.8 kgf/cm², 68.3 psi)

(YFM5FGY/YFM5FGPY) 450 kPa (4.5 kgf/cm², 64.0 psi) (YFM7FGY/YFM7FGPY)

Minimum–maximum 420–540 kPa (4.2–5.4 kgf/cm², 59.7–76.8 psi)

(YFM5FGY/YFM5FGPY) 390–500 kPa (3.9–5.0 kgf/cm², 55.5–71.1 psi) (YFM7FGY/YFM7FGPY)

Starting system Electric starter

Fuel

Recommended fuel Unleaded gasoline only Fuel tank capacity 20.0 L (5.28 US gal, 4.40 Imp.gal) Fuel reserve amount 4.5 L (1.19 US gal, 0.99 Imp.gal)

Engine oil

Lubrication system Wet sump 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

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)

Oil pressure (hot) 50.0 kPa/1600 r/min (0.50 kgf/cm²/1600 r/min,

7.3 psi/1600 r/min)

Final gear oil

Type SAE 80 API GL-4 Hypoid gear oil Total amount 0.25 L (0.26 US qt, 0.22 Imp.qt) Periodic oil change 0.20 L (0.21 US qt, 0.18 Imp.qt)

Differential gear oil

Type SAE 80 API GL-4 Hypoid gear oil Total amount 0.23 L (0.24 US qt, 0.20 Imp.qt) Periodic oil change 0.22 L (0.23 US qt, 0.19 Imp.qt)

2-2

Page 34

ENGINE SPECIFICATIONS

Oil filter

Oil filter type Cartridge (paper)

Oil pump

Oil pump type Trochoid Inner-rotor-to-outer-rotor-tip clearance Less than 0.12 mm (0.0047 in) Limit 0.20 mm (0.0079 in) Outer-rotor-to-oil-pump-housing clearance 0.090–0.170 mm (0.0035–0.0067 in) Limit 0.24 mm (0.0094 in) Oil-pump-housing-to-inner-and-outer-rotor

clearance 0.03–0.10 mm (0.0012–0.0039 in) Limit 0.17 mm (0.0067 in) Pressure check location Cylinder 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 level 0.14 L (0.15 US qt, 0.12 Imp.qt)

Radiator cap opening pressure 93.3–122.7 kPa (0.95–1.25 kgf/cm², 13.5–17.8

psi)

Valve relief pressure 4.9 kPa (0.05 kgf/cm², 0.7 psi)

Thermostat

Model/manufacturer 3B4/NIPPON THERMOSTAT Valve opening temperature 50–54 °C (122–129 °F) Valve full open temperature 70 °C (158 °F) Valve lift (full open) 7.0 mm (0.28 in)

Radiator core

Width 248.2 mm (9.77 in) Height 340 mm (13.4 in) Depth 22 mm (0.87 in)

Water pump

Water pump type Single suction centrifugal pump Reduction ratio 32/31 (1.032) Impeller shaft tilt limit 0.15 mm (0.006 in)

Spark plug

Manufacturer/model NGK/LMAR6A-9 Spark plug gap 0.8–0.9 mm (0.031–0.035 in)

Cylinder head

Volume 51.40–54.40 cm³ (YFM5FGY/YFM5FGPY)

56.70–60.30 cm³ (YFM7FGY/YFM7FGPY)

Warpage limit 0.03 mm (0.0012 in)

Camshaft

Drive system Chain drive (left)

2-3

Page 35

ENGINE SPECIFICATIONS

Camshaft lobe dimensions

Intake A 43.488–43.588 mm (1.7121–1.7161 in) Limit 43.388 mm (1.7082 in) Intake B 36.959–37.059 mm (1.4551–1.4590 in) Limit 36.859 mm (1.4511 in) Exhaust A 43.129–43.229 mm (1.6980–1.7019 in) Limit 43.029 mm (1.6941 in) Exhaust B 37.007–37.107 mm (1.4570–1.4609 in) Limit 36.907 mm (1.4530 in)

Camshaft runout limit 0.015 mm (0.0006 in)

Timing chain

Model/number of links 98XRH2010/126 Tensioning system Automatic

Rocker arm/rocker arm shaft

Rocker arm inside diameter 12.000–12.018 mm (0.4724–0.4731 in) Rocker arm shaft outside diameter 11.981–11.991 mm (0.4717–0.4721 in) Rocker-arm-to-rocker-arm-shaft clearance 0.009–0.037 mm (0.0004–0.0015 in)

Valve, valve seat, valve guide

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)

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)

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)

Valve seat width C (intake) 1.00–1.20 mm (0.0394–0.0472 in) Limit 1.60 mm (0.0630 in) Valve seat width C (exhaust) 1.00–1.20 mm (0.0394–0.0472 in) Limit 1.60 mm (0.0630 in)

Valve margin thickness D (intake) 0.80–1.20 mm (0.0315–0.0472 in) Limit 0.4 mm (0.02 in) Valve margin thickness D (exhaust) 0.80–1.20 mm (0.0315–0.0472 in) Limit 0.4 mm (0.02 in)

Valve stem diameter (intake) 5.975–5.990 mm (0.2352–0.2358 in) Limit 5.945 mm (0.2341 in) Valve stem diameter (exhaust) 5.960–5.975 mm (0.2346–0.2352 in) Limit 5.930 mm (0.2335 in) Valve guide inside diameter (intake) 6.000–6.012 mm (0.2362–0.2367 in) Limit 6.050 mm (0.2382 in) Valve guide inside diameter (exhaust) 6.000–6.012 mm (0.2362–0.2367 in) Limit 6.050 mm (0.2382 in) Valve-stem-to-valve-guide clearance (intake) 0.010–0.037 mm (0.0004–0.0015 in) Limit 0.080 mm (0.0031 in) Valve-stem-to-valve-guide clearance (exhaust) 0.025–0.052 mm (0.0010–0.0020 in) Limit 0.100 mm (0.0039 in) Valve stem runout 0.040 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) Limit 38.36 mm (1.51 in) Free length (exhaust) 40.38 mm (1.59 in) Limit 38.36 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

Bore 92.000–92.010 mm (3.6220–3.6224 in)

(YFM5FGY/YFM5FGPY)

102.000–102.010 mm (4.0157–4.0161 in)

(YFM7FGY/YFM7FGPY)

Wear limit 92.080 mm (3.6252 in)

(YFM5FGY/YFM5FGPY)

102.080 mm (4.0189 in)

(YFM7FGY/YFM7FGPY) Taper limit 0.05 mm (0.002 in) Out of round limit 0.05 mm (0.002 in)

Piston

Piston-to-cylinder clearance 0.030–0.055 mm (0.0012–0.0022 in) Limit 0.10 mm (0.0039 in) (YFM5FGY/YFM5FGPY)

0.13 mm (0.0051 in) (YFM7FGY/YFM7FGPY)

Diameter D 91.955–91.970 mm (3.6203–3.6209 in)

(YFM5FGY/YFM5FGPY)

101.955–101.970 mm (4.0140–4.0146 in)

(YFM7FGY/YFM7FGPY) Height H 10.0 mm (0.39 in)

Offset 0.50 mm (0.0197 in) Offset direction Intake side Piston pin bore inside diameter 23.004–23.015 mm (0.9057–0.9061 in) Limit 23.045 mm (0.9073 in) Piston pin outside diameter 22.991–23.000 mm (0.9052–0.9055 in)

2-6

Page 38

ENGINE SPECIFICATIONS

Limit 22.971 mm (0.9044 in) Piston-pin-to-piston-pin-bore clearance 0.004–0.024 mm (0.0002–0.0009 in) Limit 0.0740 mm (0.0029 in)

Piston ring

Top ring

Ring type Barrel 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)

End gap (installed) 0.20–0.35 mm (0.008–0.014 in) Limit 0.60 mm (0.024 in) Ring side clearance 0.030–0.070 mm (0.0012–0.0028 in) Limit 0.12 mm (0.0047 in)

2nd ring

Ring type Taper Dimensions (B × T) 1.20 × 4.00 mm (0.05 × 0.16 in)

End gap (installed) 0.75–0.90 mm (0.03–0.04 in) Limit 1.25 mm (0.049 in) Ring side clearance 0.020–0.060 mm (0.0008–0.0024 in)

(YFM5FGY/YFM5FGPY)

0.030–0.070 mm (0.0012–0.0028 in)

(YFM7FGY/YFM7FGPY)

Limit 0.12 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)

End gap (installed) 0.20–0.70 mm (0.01–0.03 in) Ring side clearance 0.04–0.13 mm (0.0016–0.0051 in)

(YFM5FGY/YFM5FGPY)

0.060–0.150 mm (0.0024–0.0059 in)

(YFM7FGY/YFM7FGPY)

Crankshaft

Width A 74.95–75.00 mm (2.951–2.953 in)

2-7

Page 39

ENGINE SPECIFICATIONS

Runout limit C 0.030 mm (0.0012 in) Big end side clearance D 0.350–0.650 mm (0.0138–0.0256 in)

Balancer

Balancer drive method Gear

Automatic centrifugal clutch

Clutch type Wet, centrifugal automatic Clutch shoe thickness 1.5 mm (0.06 in) Limit 1.0 mm (0.04 in) Clutch-in revolution 2000–2100 r/min (YFM5FGY/YFM5FGPY)

1950–2050 r/min (YFM7FGY/YFM7FGPY) Clutch-stall revolution 3500–3600 r/min (YFM5FGY/YFM5FGPY)

3550–3650 r/min (YFM7FGY/YFM7FGPY)

V-belt

V-belt width 33.3 mm (1.31 in) Limit 30.0 mm (1.18 in)

Transmission

Transmission type V-belt automatic Primary reduction system V-belt Secondary reduction system Shaft drive Secondary reduction ratio 41/21 × 24/18 × 33/9 (9.544) Operation Left hand operation Single speed automatic 2.380–0.700 :1 Low range 31/16 (1.938) High range 31/27 (1.148) Reverse gear 23/14 × 28/23 (2.000) Drive axle runout limit 0.06 mm (0.0024 in)

Shifting mechanism

Shift mechanism type Shift drum and guide bar Shift fork-R, -L thickness 5.76–5.89 mm (0.227–0.232 in)

Decompression device

Device type Auto decomp

Air filter

Air filter element Wet element Air filter oil grade Foam air filter oil

2-8

Page 40

ENGINE SPECIFICATIONS

Fuel pump

Pump type Electrical Model/manufacturer 3B4/DENSO

Throttle body

Type/quantity 40EIS/1 Manufacturer MIKUNI ID mark 28P1 00 (YFM5FGY/YFM5FGPY)

43P1 00 (YFM7FGY/YFM7FGPY) Throttle valve size #50

Fuel injector

Model/quantity 297510–1010/1 Manufacturer DENSO

Idling condition

Engine idling speed 1550–1650 r/min Intake vacuum 33.0 kPa (248 mmHg, 9.7 inHg)

(YFM5FGY/YFM5FGPY)

35.0 kPa (263 mmHg, 10.3 inHg)

(YFM7FGY/YFM7FGPY) Water temperature 85.0–95.0 °C (185.0–203.0 °F)

(YFM5FGY/YFM5FGPY)

75.0–85.0 °C (167.0–185.0 °F)

(YFM7FGY/YFM7FGPY) Oil temperature 80.0–90.0 °C (176.0–194.0 °F)

(YFM5FGY/YFM5FGPY)

55.0–65.0 °C (131.00–149.0 °F)

(YFM7FGY/YFM7FGPY) Throttle lever free play 3.0–5.0 mm (0.12–0.20 in) Speed limiter length Less than 12 mm (0.47 in)

Shaft drive

Middle gear backlash 0.10–0.30 mm (0.004–0.012 in) Final gear backlash 0.10–0.20 mm (0.004–0.008 in) Differential gear backlash 0.05–0.25 mm (0.002–0.010 in)

2-9

Page 41

CHASSIS SPECIFICATIONS

EAS29130

CHASSIS SPECIFICATIONS

Chassis

Frame type Steel tube frame Caster angle 5.0° Camber angle 0.0° Kingpin angle 11.0° Kingpin offset 0.0 mm (0.00 in) Trail 26.0 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 type Panel wheel Rim size 12 × 6.0 AT Rim material Steel (for models equipped with steel wheels)

Aluminum (for models equipped with aluminum

wheels) Wheel travel 180 mm (7.1 in) Radial wheel runout limit 2.0 mm (0.08 in) Lateral wheel runout limit 2.0 mm (0.08 in)

Rear wheel

Wheel type Panel wheel Rim size 12 × 7.5 AT Rim material Steel (for models equipped with steel wheels)

Aluminum (for models equipped with aluminum

wheels) Wheel travel 230 mm (9.1 in) Radial wheel runout limit 2.0 mm (0.08 in) Lateral wheel runout limit 2.0 mm (0.08 in)

Front tire

Type Tubeless Size AT25 × 8–12 Manufacturer/model DUNLOP/KT421 Wear limit (front) 3 mm (0.12 in)

Rear tire

Type Tubeless Size AT25 × 10–12 Manufacturer/model DUNLOP/KT425 Wear limit (rear) 3 mm (0.12 in)

Tire air pressure (measured on cold tires)

Recommended

Front 35 kPa (0.35 kgf/cm², 5.0 psi) Rear 30 kPa (0.30 kgf/cm², 4.4 psi)

Minimum

Front 32 kPa (0.32 kgf/cm², 4.6 psi) Rear 27 kPa (0.27 kgf/cm², 4.0 psi)

2-10

Page 42

CHASSIS SPECIFICATIONS

Front brake

Type Dual disc brake Operation Right hand operation Front brake lever free play (lever end) 0 mm (0 in) Front disc brake

Disc outside diameter × thickness 220.0 × 3.5 mm (8.66 × 0.14 in) Brake disc thickness limit 3.0 mm (0.12 in) Brake disc deflection limit 0.1 mm (0.004 in) Brake pad lining thickness (inner) 4.4 mm (0.17 in) Limit 1.0 mm (0.04 in) Brake pad lining thickness (outer) 4.4 mm (0.17 in) Limit 1.0 mm (0.04 in) Master cylinder inside diameter 12.70 mm (0.50 in) Caliper cylinder inside diameter 33.96 mm (1.34 in) Recommended fluid DOT 4

Rear brake

Type Dual disc brake Operation Left hand and right foot operation Rear brake lever free play (lever end) 0 mm (0 in) Brake pedal free play 0.0–5.0 mm (0.00–0.20 in) Rear disc brake

Disc outside diameter × thickness 205.0 × 3.5 mm (8.07 × 0.14 in) Brake disc thickness limit 3.0 mm (0.12 in) Brake disc deflection limit 0.1 mm (0.004 in) Brake pad lining thickness (inner) 5.8 mm (0.23 in) Limit 1.0 mm (0.04 in) Brake pad lining thickness (outer) 5.8 mm (0.23 in) Limit 1.0 mm (0.04 in) Master cylinder inside diameter 12.70 mm (0.50 in) Caliper cylinder inside diameter 33.96 mm (1.34 in) Recommended fluid DOT 4

Steering

Steering bearing type Ball and race bearing Steering tension 50 N (5.0 kgf) (YFM5FGPY/YFM7FGPY)

Front suspension

Type Double wishbone Spring/shock absorber type Coil spring/oil damper Wheel travel 180 mm (7.1 in) Shock absorber travel 90.2 mm (3.55 in) (YFM5FGY/YFM5FGPY)

90.7 mm (3.57 in) (YFM7FGY/YFM7FGPY) Spring free length 292.0 mm (11.50 in) Installed length 233.1 mm (9.18 in) (YFM5FGY/YFM5FGPY)

233.5 mm (9.19 in) (YFM7FGY/YFM7FGPY) Spring rate K1 23.00 N/mm (2.35 kgf/mm, 131.33 lb/in) Spring stroke K1 0.0–90.2 mm (0.00–3.55 in)

(YFM5FGY/YFM5FGPY)

0.0–90.7 mm (0.00–3.57 in)

(YFM7FGY/YFM7FGPY)

Optional spring available No

2-11

Page 43

CHASSIS SPECIFICATIONS

Spring preload adjusting positions

Minimum 1 Standard 3 Maximum 5

Rear suspension

Type Double wishbone Spring/shock absorber type Coil spring/oil damper Wheel travel 230 mm (9.1 in) Rear shock absorber assembly travel 109.2 mm (4.30 in) Spring free length 318.1 mm (12.52 in) (YFM5FGY/YFM5FGPY)

314.5 mm (12.38 in) (YFM7FGY/YFM7FGPY) Installed length 270.6 mm (10.65 in) (YFM5FGY/YFM5FGPY)

267.5 mm (10.53 in) (YFM7FGY/YFM7FGPY) Spring rate K1 31.00 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 K2 36.00 N/mm (3.67 kgf/mm, 205.56 lb/in)

(YFM7FGY/YFM7FGPY)

Spring stroke K1 0.0–109.2 mm (0.00–4.30 in)

(YFM5FGY/YFM5FGPY)

0.0–43.0 mm (0.00–1.69 in)

(YFM7FGY/YFM7FGPY)

Spring stroke K2 43.0–109.2 mm (1.69–4.30 in)

(YFM7FGY/YFM7FGPY) Optional spring available No Spring preload adjusting positions

Minimum 1 Standard 3 Maximum 5

2-12

Page 44

ELECTRICAL SPECIFICATIONS

EAS29140

ELECTRICAL SPECIFICATIONS

Voltage

System voltage 12 V

Ignition system

Ignition system TCI (digital) Advancer type Digital Ignition timing (B.T.D.C.) 5.0°/1600 r/min

Engine control unit

Model/manufacturer F8T83872/MITSUBISHI

(YFM5FGY/YFM5FGPY)

F8T83874/MITSUBISHI

(YFM7FGY/YFM7FGPY)

Fuel injection sensor

Crankshaft position sensor resistance 459–561 Ω at 20 °C (68 °F) Intake air pressure sensor output voltage 3.75–4.25 V Intake air temperature sensor resistance 290–390 Ω at 80 °C (176 °F) Coolant temperature sensor resistance 2.45 kΩ at 20 °C (68 °F)

290–354 Ω at 80 °C (176 °F)

Ignition coil

Model/manufacturer 2JN/YAMAHA Minimum ignition spark gap 6.0 mm (0.24 in) Primary coil resistance 2.16–2.64 Ω at 20 °C (68 °F) Secondary coil resistance 8.64–12.96 kΩ at 20 °C (68 °F)

Spark plug cap

Material Resin Resistance 10.0 kΩ

AC magneto

Model/manufacturer F4T39373/MITSUBISHI Standard output 14.0 V 34.0 A at 5,000 r/min Stator coil resistance 0.108–0.132 Ω at 20 °C (68 °F)

Rectifier/regulator

Regulator type Semi conductor-short circuit Model/manufacturer FH012AA/SHINDENGEN Regulated voltage (DC) 14.2–14.8 V Rectifier capacity (DC) 50.0 A Withstand voltage 40.0 V

Battery

Model YTX20L-BS Voltage, capacity 12 V, 18.0 Ah Manufacturer GS YUASA Ten hour rate amperage 1.8 A

2-13

Page 45

ELECTRICAL SPECIFICATIONS

Headlight

Bulb type Halogen bulb

Bulb voltage, wattage × quantity

Headlight 12 V, 35.0/35.0 W × 2 Tail/brake light 12 V, 5.0/21.0 W × 1 Meter lighting EL

Indicator and warning lights

Neutral indicator light LED Reverse indicator light LED Coolant temperature warning light LED Park indicator light LED On-Command four-wheel-drive/differential gear lock

indicator LCD Engine trouble warning light LED High-range indicator light LED Low-range indicator light LED Differential gear lock indicator light LED EPS warning light LED (YFM5FGPY/YFM7FGPY)

Electric starting system

System type Constant mesh

Starter motor

Model/manufacturer SM-17/MITSUBA Power output 0.80 kW Armature coil resistance 0.0050–0.0150 Ω at 20 °C (68 °F) Brush overall length 12.0 mm (0.47 in) Limit 6.50 mm (0.26 in) Brush spring force 6.02–6.51 N (614–664 gf, 21.69–23.45 oz) Mica undercut (depth) 0.70 mm (0.03 in)

Starter relay

Model/manufacturer 2768113-A/JIDECO Amperage 180.0 A Coil resistance 4.18–4.62 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

Auxiliary DC output

Jack capacity 12 V, 10.0 A (120 W)

Fan motor relay

Model/manufacturer ACM33211/MATSUSHITA Coil resistance 86.4–105.6 Ω

Fuel injection system relay

Model/manufacturer ACM33211/MATSUSHITA Coil resistance 86.4–105.6 Ω

2-14

Page 46

ELECTRICAL SPECIFICATIONS

Headlight relay

Model/manufacturer G8HN-1C4T-DJ/OMRON Coil resistance 94.5–115.5 Ω

Four-wheel-drive motor relay 3

Model/manufacturer ACM33211/MATSUSHITA Coil resistance 86.4–105.6 Ω

Four-wheel-drive motor relay 1, 2

Model/manufacturer G8HN-1C4T-DJ/OMRON Coil resistance 94.5–115.5 Ω

Circuit breaker

Circuit breaker type Fuse

Fuses

Main fuse 40.0 A Headlight fuse 15.0 A Signaling system fuse 5.0 A Ignition fuse 15.0 A Radiator fan motor fuse 20.0 A Auxiliary DC jack fuse 15.0 A Fuel injection system fuse 15.0 A Four-wheel-drive motor fuse 15.0 A EPS fuse 40.0 A (YFM5FGPY/YFM7FGPY) Spare fuse 40.0 A Spare fuse 20.0 A Spare fuse 15.0 A Spare fuse 5.0 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

Nm m·kg ft·lb

10 mm 6 mm 6 0.6 4.3

12 mm 8 mm 15 1.5 11

14 mm 10 mm 30 3.0 22

17 mm 12 mm 55 5.5 40

19 mm 14 mm 85 8.5 61

22 mm 16 mm 130 13.0 94

2-16

Page 48

EAS20340

ENGINE TIGHTENING TORQUES

TIGHTENING TORQUES

Item

Thread

size

Q’ty Tightening torque Remarks

Exhaust pipe nut M8 4 14 Nm (1.4 m·kg, 10 ft·lb)

Muffler bolt M8 1 20 Nm (2.0 m·kg, 14 ft·lb)

Muffler and muffler bracket bolt M8 2 20 Nm (2.0 m·kg, 14 ft·lb)

Spark arrester bolt M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb)

Purging bolt M10 1 27 Nm (2.7 m·kg, 19 ft·lb)

Exhaust pipe protector bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)

Crankshaft end accessing screw M36 1 10 Nm (1.0 m·kg, 7.2 ft·lb)

Timing mark accessing screw M14 1 6 Nm (0.6 m·kg, 4.3 ft·lb)

AC magneto cover bolt M6 11 10 Nm (1.0 m·kg, 7.2 ft·lb)

AC magneto rotor nut M16 1 60 Nm (6.0 m·kg, 43 ft·lb)

AC magneto/crankshaft position sensor lead holder bolt

M5 2 7 Nm (0.7 m·kg, 5.1 ft·lb)

Starter clutch bolt M8 3 30 Nm (3.0 m·kg, 22 ft·lb)

Drive belt cover bolt M6 12 10 Nm (1.0 m·kg, 7.2 ft·lb)

Drive belt case bolt M6 8 10 Nm (1.0 m·kg, 7.2 ft·lb)

Bearing housing bolt (primary sheave assembly)

Bearing retainer bolt (bearing housing)

M6 4 10 Nm (1.0 m·kg, 7.2 ft·lb)

M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb)

Primary sheave assembly nut M16 1 140 Nm (14.0 m·kg, 100 ft·lb)

Secondary sheave assembly nut M16 1 100 Nm (10.0 m·kg, 72 ft·lb)

Secondary sheave spring retaining nut

M36 1 90 Nm (9.0 m·kg, 65 ft·lb)

Clutch housing assembly bolt M6 9 10 Nm (1.0 m·kg, 7.2 ft·lb)

Clutch carrier assembly nut M22 1 190 Nm (19.0 m·kg, 140 ft·lb)

Cylinder bolt M10 4 50 Nm (5.0 m·kg, 36 ft·lb)

Cylinder bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)

Cylinder head stud bolt (exhaust pipe)

M8 4 15 Nm (1.5 m·kg, 11 ft·lb)

Cylinder head bolt M9 4 35 Nm (3.5 m·kg, 25 ft·lb)

Cylinder head bolt M9 2 38 Nm (3.8 m·kg, 27 ft·lb)

Cylinder head bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)

Tappet cover bolt M6 8 10 Nm (1.0 m·kg, 7.2 ft·lb)

Camshaft sprocket cover bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)

Thermostat cover bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)

Left-hand

thread Stake.

See TIP.

2-17

Page 49

TIGHTENING TORQUES

Item

Thread

size

Q’ty Tightening torque Remarks

Oil check bolt M8 1 10 Nm (1.0 m·kg, 7.2 ft·lb)

Cylinder head air bleed bolt M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb)

Camshaft sprocket bolt M7 2 20 Nm (2.0 m·kg, 14 ft·lb)

Decompression assembly bolt M7 2 20 Nm (2.0 m·kg, 14 ft·lb)

Valve adjusting screw locknut M6 4 14 Nm (1.4 m·kg, 10 ft·lb)

Bearing retainer bolt (camshaft) M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)

Timing chain guide bolt (intake side)

M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)

Timing chain tensioner cap bolt M16 1 20 Nm (2.0 m·kg, 14 ft·lb)

Timing chain tensioner bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)

Oil delivery pipe 1 union bolt M8 2 18 Nm (1.8 m·kg, 13 ft·lb)

Oil delivery pipe 2 union bolt M14 2 35 Nm (3.5 m·kg, 25 ft·lb)

Oil delivery pipe 2 union bolt M10 1 20 Nm (2.0 m·kg, 14 ft·lb)

Oil delivery pipe 2 bolt M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb)

Crankcase bolt M8 3 26 Nm (2.6 m·kg, 19 ft·lb)

Crankcase bolt M6 4 10 Nm (1.0 m·kg, 7.2 ft·lb)

Crankcase bolt M6 9 10 Nm (1.0 m·kg, 7.2 ft·lb)

Dipstick guide bolt M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb)

Engine oil drain bolt M14 1 30 Nm (3.0 m·kg, 22 ft·lb)

Oil filter cartridge M20 1 17 Nm (1.7 m·kg, 12 ft·lb)

Oil filter cartridge union bolt M20 1 30 Nm (3.0 m·kg, 22 ft·lb)

Timing chain guide bolt (lower) M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)

Bearing retainer bolt (crankcase) M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)

Oil pump bolt M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb)

Oil pump housing cover screw M5 1 5 Nm (0.5 m·kg, 3.6 ft·lb)

Oil pump driven gear nut M10 1 22 Nm (2.2 m·kg, 16 ft·lb)

Balancer driven gear nut M18 1 80 Nm (8.0 m·kg, 58 ft·lb)

Water pump housing bolt M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb)

Coolant drain bolt M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb)

Water pump air bleed bolt M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb)

Water pump outlet pipe bolt M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb)

Water jacket joint bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)

Shift lever cover bolt M6 4 10 Nm (1.0 m·kg, 7.2 ft·lb)

Use a

lock

washer.

Use a

lock

washer.

Shift lever 2 assembly bolt M6 1 14 Nm (1.4 m·kg, 10 ft·lb)

Shift drum stopper bolt M14 1 18 Nm (1.8 m·kg, 13 ft·lb)

Stopper lever stopper bolt M14 1 18 Nm (1.8 m·kg, 13 ft·lb)

2-18

Page 50

TIGHTENING TORQUES

Item

Thread

size

Q’ty Tightening torque Remarks

Middle drive pinion gear nut M22 1 190 Nm (19.0 m·kg, 140 ft·lb) Stake.

Middle drive shaft bearing housing bolt

Middle drive shaft bearing retainer bolt

Front drive shaft yoke nut (middle gear side)

Middle driven shaft bearing retainer

Middle driven pinion gear bearing housing bolt

Middle driven pinion gear bearing retainer

Rear drive shaft yoke nut (middle gear side)

M8 4 32 Nm (3.2 m·kg, 23 ft·lb)

M8 4 29 Nm (2.9 m·kg, 21 ft·lb)

M16 1 115 Nm (11.5 m·kg, 85 ft·lb)

M55 1 80 Nm (8.0 m·kg, 58 ft·lb)

M8 4 25 Nm (2.5 m·kg, 18 ft·lb)

M60 1 130 Nm (13.0 m·kg, 94 ft·lb)

M16 1 150 Nm (15.0 m·kg, 110 ft·lb)

Stake.

Left-hand

thread

Left-hand

thread

Starter motor bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)

Starter motor lead nut M6 1 11 Nm (1.1 m·kg, 8.0 ft·lb)

Spark plug M10 1 13 Nm (1.3 m·kg, 9.4 ft·lb)

Stator coil assembly bolt M6 3 7 Nm (0.7 m·kg, 5.1 ft·lb)

Crankshaft position sensor bolt M5 2 7 Nm (0.7 m·kg, 5.1 ft·lb)

Coolant temperature sensor M12 1 18 Nm (1.8 m·kg, 13 ft·lb)

Gear position switch bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)

Reverse switch M10 1 17 Nm (1.7 m·kg, 12 ft·lb)

Speed sensor bolt M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb)

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

Cylinder head tightening sequence:

2-19

Page 51

EAS20350

CHASSIS TIGHTENING TORQUES

TIGHTENING TORQUES

Item

Engine mounting bolt (front lower side)

Engine mounting bolt (front upper side)

Engine mounting bolt (rear lower side)

Engine mounting bolt (rear upper side)

Thread

size

Q’ty Tightening torque Remarks

M10 2 42 Nm (4.2 m·kg, 30 ft·lb)

M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)

M10 2 42 Nm (4.2 m·kg, 30 ft·lb)

M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)

Rubber damper nut (front side) M10 2 42 Nm (4.2 m·kg, 30 ft·lb)

Rubber damper nut (rear side) M10 2 42 Nm (4.2 m·kg, 30 ft·lb)

Trailer hitch bolt M10 2 55 Nm (5.5 m·kg, 40 ft·lb)

Drive select lever unit bolt M6 3 7 Nm (0.7 m·kg, 5.1 ft·lb)

Drive select lever guide bolt M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)

Shift arm bolt M6 1 14 Nm (1.4 m·kg, 10 ft·lb)

Shift control cable nut M14 1 17 Nm (1.7 m·kg, 12 ft·lb)

Drive select lever shift rod locknut (select lever unit side)

Drive select lever shift rod locknut (shift arm side)

Brake pedal free play adjusting nut

M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)

M8 1 7 Nm (0.7 m·kg, 5.1 ft·lb)

Left-hand

thread

Radiator bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)

Radiator bracket bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)

Coolant reservoir bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)

Fuel tank bolt M6 4 7 Nm (0.7 m·kg, 5.1 ft·lb)

Fuel pump nut M6 6 7 Nm (0.7 m·kg, 5.1 ft·lb)

Fuel tank side cover bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)

Fuel tank breather hose joint bolt M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)

Throttle body joint clamp screw M5 2 3 Nm (0.3 m·kg, 2.2 ft·lb)

Engine skid plate bolt M6 8 7 Nm (0.7 m·kg, 5.1 ft·lb)

Footrest bracket bolt M10 8 53 Nm (5.3 m·kg, 38 ft·lb)

Footrest board bolt M6 8 7 Nm (0.7 m·kg, 5.1 ft·lb)

Footrest bolt M6 4 7 Nm (0.7 m·kg, 5.1 ft·lb)

Front carrier bolt M8 4 26 Nm (2.6 m·kg, 19 ft·lb)

Front carrier bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)

Front carrier bracket bolt M8 2 34 Nm (3.4 m·kg, 24 ft·lb)

Front guard bolt M8 4 26 Nm (2.6 m·kg, 19 ft·lb)

Front grill bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)

Front grill bracket bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)

2-20

Page 52

TIGHTENING TORQUES

Item

Thread

size

Q’ty Tightening torque Remarks

Front fender bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)

Rear carrier bolt M8 4 34 Nm (3.4 m·kg, 24 ft·lb)

Rear carrier bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)

Rear carrier bracket bolt M10 4 53 Nm (5.3 m·kg, 38 ft·lb)

Rear fender bolt M6 4 7 Nm (0.7 m·kg, 5.1 ft·lb)

Front wheel nut M10 8 55 Nm (5.5 m·kg, 40 ft·lb)

Front wheel axle nut M20 2 260 Nm (26.0 m·kg, 190 ft·lb) Stake.

Rear wheel nut M10 8 55 Nm (5.5 m·kg, 40 ft·lb)

Rear wheel axle nut M20 2 260 Nm (26.0 m·kg, 190 ft·lb) Stake.

Front brake caliper bolt M8 4 30 Nm (3.0 m·kg, 22 ft·lb)

Front brake disc bolt M8 8 30 Nm (3.0 m·kg, 22 ft·lb)

Rear brake caliper bolt M8 4 30 Nm (3.0 m·kg, 22 ft·lb)

Rear brake disc bolt M8 8 30 Nm (3.0 m·kg, 22 ft·lb)

Brake hose union bolt M10 6 27 Nm (2.7 m·kg, 19 ft·lb)

Brake pad holding bolt M6 4 17 Nm (1.7 m·kg, 12 ft·lb)

Brake caliper bleed screw M8 4 5 Nm (0.5 m·kg, 3.6 ft·lb)

Steering knuckle and front upper arm nut

M10 2 25 Nm (2.5 m·kg, 18 ft·lb)

Steering knuckle and front lower arm nut

M12 2 30 Nm (3.0 m·kg, 22 ft·lb)

Steering knuckle and tie-rod nut M10 2 25 Nm (2.5 m·kg, 18 ft·lb)

Front upper arm nut M10 4 45 Nm (4.5 m·kg, 32 ft·lb)

Front lower arm nut M10 4 45 Nm (4.5 m·kg, 32 ft·lb)

Front shock absorber nut M10 4 45 Nm (4.5 m·kg, 32 ft·lb)

Front brake disc guard bolt M6 6 7 Nm (0.7 m·kg, 5.1 ft·lb)

Front brake hose holder bolt M6 4 7 Nm (0.7 m·kg, 5.1 ft·lb)

Front arm protector nut M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)

Rear arm protector holder nut M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)

Rear knuckle nut M10 4 45 Nm (4.5 m·kg, 32 ft·lb)

Rear upper arm nut M10 4 45 Nm (4.5 m·kg, 32 ft·lb)

Rear lower arm nut M10 4 45 Nm (4.5 m·kg, 32 ft·lb)

Rear shock absorber nut M10 4 45 Nm (4.5 m·kg, 32 ft·lb)

Rear brake disc guard bolt M6 6 7 Nm (0.7 m·kg, 5.1 ft·lb)

Rear brake hose guide bolt M6 4 7 Nm (0.7 m·kg, 5.1 ft·lb)

Rear arm protector nut M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)

Rear arm protector holder nut M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)

Rear brake hose protector bolt M6 4 7 Nm (0.7 m·kg, 5.1 ft·lb)

Stabilizer joint nut M10 4 51 Nm (5.1 m·kg, 37 ft·lb)

2-21

Page 53

TIGHTENING TORQUES

Item

Thread

size

Q’ty Tightening torque Remarks

Stabilizer holder bolt M8 4 30 Nm (3.0 m·kg, 22 ft·lb)

Handlebar holder bolt M8 4 20 Nm (2.0 m·kg, 14 ft·lb)

Front brake master cylinder holder bolt

Rear brake master cylinder holder bolt

M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)

Front brake lever pivot bolt M6 1 6 Nm (0.6 m·kg, 4.3 ft·lb)

Front brake lever pivot nut M6 1 6 Nm (0.6 m·kg, 4.3 ft·lb)

Rear brake lever pivot bolt M6 1 6 Nm (0.6 m·kg, 4.3 ft·lb)

Rear brake lever pivot nut M6 1 6 Nm (0.6 m·kg, 4.3 ft·lb)

Front brake hose joint bolt M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb)

Rear brake hose joint bolt M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb)

Brake pipe locknut M10 3 19 Nm (1.9 m·kg, 13 ft·lb)

Steering stem bushing bolt M8 2 23 Nm (2.3 m·kg, 17 ft·lb)

Left-hand

thread

Left-hand

thread

Steering stem bracket bolt M10 2 51 Nm (5.1 m·kg, 37 ft·lb)

Steering stem support bolt (for YFM5FG/YFM7FG)

Pitman arm nut (for YFM5FG/YFM7FG)

Steering stem bearing bolt (for YFM5FGP/YFM7FGP)

Steering stem bearing nut (for YFM5FGP/YFM7FGP)

Steering stem joint bolt (for YFM5FGP/YFM7FGP)

EPS unit bolt (for YFM5FGP/YFM7FGP)

Pitman arm nut (for YFM5FGP/YFM7FGP)

EPS motor cover bolt (for YFM5FGP/YFM7FGP)

M8 4 30 Nm (3.0 m·kg, 22 ft·lb)

M14 1 190 Nm (19.0 m·kg, 140 ft·lb)

M10 2 51 Nm (5.1 m·kg, 37 ft·lb)

M22 1 125 Nm (12.5 m·kg, 90 ft·lb)

M8 2 35 Nm (3.5 m·kg, 25 ft·lb)

M8 4 30 Nm (3.0 m·kg, 22 ft·lb)

M16 1 210 Nm (21.0 m·kg, 150 ft·lb)

M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)

Pitman arm and tie-rod nut M10 2 25 Nm (2.5 m·kg, 18 ft·lb)

Tie-rod end locknut (pitman arm side)

M10 2 15 Nm (1.5 m·kg, 11 ft·lb)

Tie-rod end locknut (front wheel side)

M10 2 15 Nm (1.5 m·kg, 11 ft·lb)

Differential assembly nut M10 1 55 Nm (5.5 m·kg, 40 ft·lb)

Differential assembly bolt M10 2 55 Nm (5.5 m·kg, 40 ft·lb)

Differential gear oil filler bolt M14 1 23 Nm (2.3 m·kg, 17 ft·lb)

2-22

Left-hand

thread

Page 54

TIGHTENING TORQUES

Item

Differential gear oil drain bolt M10 1 10 Nm (1.0 m·kg, 7.2 ft·lb)

Differential case cover bolt M8 5 24 Nm (2.4 m·kg, 17 ft·lb)

Differential motor bolt M6 3 11 Nm (1.1 m·kg, 8.0 ft·lb)

Front drive shaft yoke nut (differential case side)

Final drive assembly nut M10 2 66 Nm (6.6 m·kg, 48 ft·lb)

Final gear oil filler bolt M14 1 23 Nm (2.3 m·kg, 17 ft·lb)

Final gear oil drain bolt M14 1 23 Nm (2.3 m·kg, 17 ft·lb)

Final gear oil level check bolt M8 1 10 Nm (1.0 m·kg, 7.2 ft·lb)

Final drive case cover bolt M8 11 23 Nm (2.3 m·kg, 17 ft·lb)

Final drive pinion gear bearing housing bolt

Electrical components tray bolt M6 3 7 Nm (0.7 m·kg, 5.1 ft·lb)

Battery holding bracket fitting screw

Battery holding bracket nut M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)

ECU (engine control unit) bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)

Thread

size

M14 1 62 Nm (6.2 m·kg, 45 ft·lb)

M8 4 23 Nm (2.3 m·kg, 17 ft·lb)

M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)

Q’ty Tightening torque Remarks

ECU bracket bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)

Rectifier/regulator bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)

Ignition coil bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)

Frame ground bolt M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)

2-23

Page 55

LUBRICATION POINTS AND LUBRICANT TYPES

EAS20360

LUBRICATION POINTS AND LUBRICANT TYPES

EAS20370

ENGINE

Lubrication point Lubricant

Oil seal lips

Bearings

O-rings

Cylinder head bolts

Crankshaft pin

Connecting rod big end thrust surface

Crankshaft sprocket

Inner race (crankshaft)

Buffer boss (crankshaft)

Crankshaft seal

Piston pin

Piston rings and ring grooves

Valve stems (intake and exhaust)

Valve stem seal (intake and exhaust)

Rocker arm shafts

Camshaft lobes

Decompressor lever pin

Decompressor lever

Rocker arms (intake and exhaust)

Oil pump shaft

O-ring (oil filter cartridge)

Water pump impeller shaft

Dipstick mating surface

Starter idler gear inner surface

Starter idler gear shaft

Starter wheel gear

Torque limiter

Clutch housing shaft end

Clutch carrier assembly

One-way clutch bearing

Clutch dog and middle drive gear

Reverse idle gear shaft

Middle driven shaft splines

2-24

Page 56

LUBRICATION POINTS AND LUBRICANT TYPES

Lubrication point Lubricant

Shift drum

Shift forks and shift fork guide bar

Ball (shift drum stopper)

Stopper lever and stopper lever shaft

Shift lever 2 inner surface

Shift lever 1

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

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

A-A

2-27

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

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

1 2 3

COOLING SYSTEM DIAGRAMS

7 6 5 4

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

1 2 3 4

5 6 7

A-A

1 2

8 9

B-B

C-C

D-D

1011

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

1314

CDEF

A-A

B-B B-B

N O

‚

C-C C-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

5 6

B C D E

A-A B-B

T U

N O

D-D E-E E-E F-F G-G

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)

18. Spark plug lead

19. Rear brake cable

20. Shift control cable

21. Fuel tank drain hose

22. Gear position switch lead

23. Speed sensor lead

24. AC magneto/crankshaft position sensor lead

25. Fuel injector lead

26. Radiator fan motor breather hose

27. EPS torque sensor coupler (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

A-A

B-B C-C

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

4 5 6 732

B B

A A

M 28

1819

9 6 5

32 22

202122

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

A A

A-A

B-B C-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

B-B

E-EC

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.

CABLE ROUTING

2-46

Page 78

CABLE ROUTING

2-47

Page 79

PERIODIC CHECKS AND ADJUSTMENTS

PERIODIC MAINTENANCE ............................................................................ 3-1

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

PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL

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

GENERAL MAINTENANCE AND LUBRICATION CHART .......................3-1

ENGINE ...........................................................................................................3-4

ADJUSTING THE VALVE CLEARANCE .................................................. 3-4

ADJUSTING THE THROTTLE LEVER FREE PLAY ................................ 3-6

ADJUSTING THE SPEED LIMITER.......................................................... 3-6

CHECKING THE SPARK PLUG ...............................................................3-7

CHECKING THE IGNITION TIMING.........................................................3-8

MEASURING THE COMPRESSION PRESSURE.................................... 3-8

CHECKING THE ENGINE OIL LEVEL...................................................... 3-9

CHANGING THE ENGINE OIL ............................................................... 3-10

CLEANING THE AIR FILTER ELEMENT................................................3-12

CHECKING THE V-BELT........................................................................ 3-13

REPLACING THE V-BELT ......................................................................3-13

CHECKING THE THROTTLE BODY JOINT........................................... 3-14

CHECKING THE FUEL LINE ..................................................................3-14

CHECKING THE BREATHER HOSES ................................................... 3-14

CHECKING THE EXHAUST SYSTEM.................................................... 3-15

CLEANING THE SPARK ARRESTER ....................................................3-15

CHECKING THE COOLANT LEVEL....................................................... 3-16

CHECKING THE COOLING SYSTEM ....................................................3-16

CHANGING THE COOLANT...................................................................3-17

Page 80

CHASSIS ....................................................................................................... 3-20

ADJUSTING THE FRONT DISC BRAKE................................................3-20

ADJUSTING THE REAR DISC BRAKE ..................................................3-20

CHECKING THE BRAKE FLUID LEVEL.................................................3-21

CHECKING THE FRONT BRAKE PADS ................................................3-21

CHECKING THE REAR BRAKE PADS ..................................................3-22

CHECKING THE FRONT BRAKE HOSES ............................................. 3-22

CHECKING THE REAR BRAKE HOSES................................................ 3-22

CHECKING THE REAR BRAKE HOSE PROTECTORS ........................3-23

BLEEDING THE HYDRAULIC BRAKE SYSTEM ...................................3-23

ADJUSTING THE DRIVE SELECT LEVER CONTROL CABLE AND

SHIFT ROD ............................................................................................3-24

CHECKING THE FINAL GEAR OIL LEVEL ............................................3-25

CHANGING THE FINAL GEAR OIL........................................................3-26

CHECKING THE DIFFERENTIAL GEAR OIL LEVEL............................. 3-26

CHANGING THE DIFFERENTIAL GEAR OIL ........................................3-27

CHECKING THE CONSTANT VELOCITY SHAFT ASSEMBLY

DUST BOOTS ........................................................................................3-27

CHECKING THE STEERING SYSTEM .................................................. 3-28

ADJUSTING THE TOE-IN.......................................................................3-29

CHECKING THE FRONT SHOCK ABSORBER ASSEMBLIES .............3-30

ADJUSTING THE FRONT SHOCK ABSORBER ASSEMBLIES ............3-31

CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES................ 3-31

ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLIES ..............3-32

CHECKING THE TIRES..........................................................................3-32

CHECKING THE WHEELS ..................................................................... 3-34

CHECKING AND LUBRICATING THE CABLES ....................................3-34

LUBRICATING THE LEVERS .................................................................3-34

LUBRICATING THE PEDAL ................................................................... 3-34

ELECTRICAL SYSTEM................................................................................. 3-35

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

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

• 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.

INITIAL EVERY

NO. ITEM

1 * Fuel line

2 Spark plug

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

Crankcase breather

4 *

system

5 * Exhaust system

6 Spark 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

month 1 3 6 6 12

320

km (mi)

hours 20 80 160 160 320

(200)

1300 (800)

√ √ √ √ √

2500

(1600)

2500

(1600)

√ √ √

GENERAL MAINTENANCE AND LUBRICATION CHART

INITIAL EVERY

month 1 3 6 6 12

320

km (mi)

(200)

1300 (800)

2500

(1600)

2500

(1600)

NO. ITEM

CHECK OR MAINTENANCE

JOB

Whichever

comes first

5000

(3200)

5000

(3200)

hours 20 80 160 160 320

1 Air 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

INITIAL EVERY

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

18 Engine oil

20 Differential gear oil

21 Final gear oil

22 Cooling 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

month 1 3 6 6 12

320

km (mi)

hours 20 80 160 160 320

(200)

1300 (800)

√ √ √ √ √

√ √ √ √

√ √ √ √ √

√ √ √ √

√√

√ √ √ √ √

2500

(1600)

√ √ √ √

2500

(1600)

√ √ √

5000

(3200)

3-2

Page 84

PERIODIC MAINTENANCE

EBU23070

• 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

ENGINE

EAS20520

ADJUSTING THE VALVE CLEARANCE

The following procedure applies to all of the valves.

• 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”

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.

3. Disconnect:

• Spark plug cap “1”

4. Remove:

• Spark plug “2”

5. Remove:

• Timing mark accessing screw “1”

• Crankshaft end accessing screw “2”

To position the piston at TDC on the compression stroke, align the “I” mark “c” on the camshaft

sprocket with the stationary pointer “d” on the cylinder head, as shown in the illustration.

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

▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲

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

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

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

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.

d. Hold the adjusting screw to prevent it from

moving and tighten the locknut to specification.

Camshaft sprocket cover bolt

10 Nm (1.0 m·kg, 7.2 ft·lb)

Tappet cover bolt

10 Nm (1.0 m·kg, 7.2 ft·lb)

New

12.Install:

• Air filter case

• Footrest board

• Front fender

• Right side panel

• Left side panel Refer to “GENERAL CHASSIS” on page 4-1.

3-5

Page 87

ENGINE

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

2. Remove:

• Left side panel Refer to “GENERAL CHASSIS” on page 4-1.

3. Adjust:

• Throttle lever free play

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.

2WD

4WD

▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼

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.

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

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.

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

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

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

10.Install:

• Right side panel Refer to “GENERAL CHASSIS” on page 4-1.

EAS20700

CHECKING THE IGNITION TIMING

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”.

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.

When checking the ignition timing, make sure that the timing light cord does not come in contact with the exhaust muffler.

d. Install the timing mark accessing screw.

Timing mark accessing screw

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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

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

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

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)

Reading Diagnosis

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.

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8. Install:

• Spark plug

7. Measure:

• Compression pressure

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

Standard compression pressure (at sea level)

480 kPa (4.8 kgf/cm², 68.3 psi) (YFM5FGY/YFM5FGPY) 450 kPa (4.5 kgf/cm², 64.0 psi) (YFM7FGY/YFM7FGPY)

Minimum–maximum

420–540 kPa (4.2–5.4 kgf/cm²,

59.7–76.8 psi) (YFM5FGY/YFM5FGPY) 390–500 kPa (3.9–5.0 kgf/cm²,

55.5–71.1 psi) (YFM7FGY/YFM7FGPY)

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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

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.

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

NOTICE

Do not allow foreign materials to enter the crankcase.

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

10 30

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

-10 0

ECA28P1004

NOTICE

30 40 50˚C

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”

5. Remove:

• Engine oil drain bolt “1” (along with the gasket)

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.

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a. Remove the oil filter cartridge “1” with an oil

filter wrench “2”.

Oil filter wrench

90890-01426 YU-38411

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

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

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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

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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)

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

Oil check bolt

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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 panel Refer to “GENERAL CHASSIS” on page 4-1.

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”

4. Check:

• Air filter element

• Air filter element frame

Damage → Replace.

5. Clean:

• Air filter element

(with solvent)

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.

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-

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)

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

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a. Install the bolts “1” (90101-06016) into the

secondary fixed sheave holes.

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.

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Page 95

ENGINE

• Rear fender Refer to “GENERAL CHASSIS” on page 4-1.

• V-belt cooling exhaust duct Refer to “ENGINE REMOVAL” on page 5-1.

2. Check:

• Fuel hose “1” Cracks/damage → Replace. Loose connection → Connect properly.

c. Install the V-belt.

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

d. Remove the bolts.

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EAS21020

CHECKING THE THROTTLE BODY JOINT

1. Remove:

• Left side panel Refer to “GENERAL CHASSIS” on page 4-1.

2. Check:

• Throttle body joint “1” Cracks/damage → Replace.

3. Install:

• V-belt cooling exhaust duct Refer to “ENGINE REMOVAL” on page 5-1.

• Rear fender

• Right side panel

• Seat

Refer to “GENERAL CHASSIS” on page 4-1.

EAS21050

CHECKING THE BREATHER HOSES

1. Remove:

• Left side panel

• Air filter case

Refer to “GENERAL CHASSIS” on page 4-1.

2. Check:

• Cylinder head breather hose “1”

• Throttle body breather hose “2”

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

ECA14920

NOTICE

Make sure the cylinder head breather hose is routed correctly.

3. Install:

• Left side panel

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”

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.

EAS28970

CLEANING THE SPARK ARRESTER

1. Clean:

• Spark arrester

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

into the muffler and align the bolt holes.

e. Insert the bolts “1” and tighten them.

Spark arrester bolt

10 Nm (1.0 m·kg, 7.2 ft·lb)

f. Remove the purging bolt “3”.

3-15

Page 97

ENGINE

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

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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.

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)

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

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

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:

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.

7. Remove:

• Coolant drain bolt “1”

(along with the copper washer)

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

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

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-

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”

FULL

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

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.

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

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.

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

10 Nm (1.0 m·kg, 7.2 ft·lb)

f. Install the V-belt cooling exhaust duct.

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3-19