Yfmgoofwa '97 (K) Service Manual 01997 by Yamaha

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1
YFMGOOFWA '97(K)
SERVICE MANUAL
01997 by Yamaha Motor Co., Ltd.
First Edition, April 1997
All rights reserved.Any reproduction or
unauthorized use without the written
-permission of Yamaha Motor Co., Ltd.
is expressly prohibited.
1 EBOOlWO
NOTICE
This manual was produced by the Yamaha Motor Company primarily for use by Yamaha
dealers and their qualified mechanics. It is not possible to include all the knowledge of a
mechanic in one manual, so it is assumed that anyone w h o uses this book to perform main-
tenance and repairs o n Yamaha machine has a basic understanding of the mechanical ideas
and the procedures of machine repair. Repairs attempted by anyone without this knowledge
are likely to render the machine unsafe andunfit for use.
Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications
and significant changes in specifications or procedures will be forwarded to all authorized
Yamaha dealers andwill appear in future editions of this manual where applicable.
NOTE:
Designs and specificationsare subject to change withoutnotice.
\-a
IMPORTANT INFORMATION
Particularly important information is distinguished in this manual by the following notations.
A The
Safety
Alert
Symbol
means AITENTION! BECOME ALERT! YOUR
SAFEW IS INVOLVED!
m I . Failure to follow WARNING instructions could resultin severe injury or
death to the machine operator, a bystander or a person inspecting or
repairing the machine.
@?@$@$?@?
*$<&&&&:&-,&;~ A CAUTION indicatesspecialprecautions that must betaken to avoid
damage to the machine.
i,
NOTE: A NOTE provides key information to make

procedures easier or clearer.
E000200o
IA-
HOW TO USE THIS MANUAL
MANUAL ORGANIZATION
This manual consists of chapters for the main categories o f subjects. (See "Illustrated sym-
bols")
1st title 0:
This is the title of the chapter with its symbol in the upper right corner of each
page.
2nd title0: of page
This title indicates the section of the chapter and only appears on the first
each section. It is located in the upper left cornerof the page.
3rd title 0:
This title indicates a sub-section that is followed by step-by-step procedures
accompanied by corresponding illustrations.
EXPLODED DIAGRAMS
To help identify parts and clarify proceduresteps, there are exploded diagrams at the start
of
each removal and disassembly section.
1. An easy-to-see exploded diagram@ is provided for removaland disassembly jobs.
2. Numbers @ are given in the order of the jobs in the exploded diagram. A number that is
-4
losed bya circle indicates a disassemblystep.
3. An explanation of jobs and notesis presented in an easy-to-read way by theuse of symbol
marks 8. The meanings of the symbol marks are given on the next page.
4. A job instruction chart 0accompanies the exploded diagram, providing the order of jobs,
names of parts, notes in jobs, etc.
5. For jobs requiring more information, the step-by-step format supplements @ are given in
addition to the exploded diagram and the job instruction chart.
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E0003000
ILLUSTRATED SYMBOLS
0 0
Illustrated symbols 0 to @ are printed on
1- 0
1- 0
t h e top right of each page and indicate the
subject of each chapter.
@ General information
rn1 -
@ Specifications
0Periodic inspections and adjustments
@ Engine
@ Carburetion
0Drive train
0 0 @ Chassis
8Electrical
pi-pqpqqq
0 8
@ Troubleshooting
L i q q1 6-3 Illustratedsymbols @ to 0 areused to

b
m[pq
0
identify the specifications appearing in the
text.
@ Can be serviced with engine mounted
0Filling fluid
@ Lubricant
I
Bl @ Fl
0
I
@
~
I
0 Special tool
@Torque
@I Wear limit, clearance
@ Engine speed
8 Q, V, A
FiJ
@ ~ @ ~ @ ~ l
'd
Illustrated symbols @ to @ in the exploded

I@ I
lh & A 1
69 @ diagramsindicatethetypes of lubricants
and lubrication points.
@Apply engine oil
@Apply gear oil
0 @ @ @ Apply molybdenum disulfide oil
@ Apply wheel bearinggrease
@ Apply lightweight lithium-soapbase grease
-==i-=am @ Apply molybdenum disulfide grease
Illustrated, symbols@ to @ in the exploded
@ I@ diagrams indicate where to apply a locking
I A
I I
rn I
agent @I and whento install a new part @.
@ Apply the locking agent(LOCTITE@)
@ Replace
!
I
~ ~~~ ~ ~-
~~ ~~ ~ ~~
CHAPTER TITLES
0
-
GENERAL INFORMATION
I ~~ 1--- I
P
SPECIFICATIONS
PERIODIC INSPECTION AND Qk

ADJUSTMENT ADJ
INSP
-.-I
ENGINE OVERHAUL
CARBURETION
+z+
DRIVE TRAIN
1 &%
b-. CHASSIS
ELECTRICAL r l
3
TROUBLESHOOTING 0
..
CHAPTER 1.
1- m
GENERAL INFORMATION
MACHINE IDENTIFICATION ........................................................................ 8-3

VEHICLE IDENTIFICATION NUMBER ................................................. B-3
MODEL LABEL ..................................................................................... B-3
FEATURES ................................................................................................... B-3
IMPORTANT INFORMATION ...................................................................... B-6

PREPARATION FOR REMOVAL PROCEDURES ................................. B-6
REPLACEMENT PARTS ....................................................................... E-6
GASKETS, OIL SEALS AND O-RINGS ................................................ B-6
LOCK WASHERVPLATES AND COVER PINS ................................. E-6
BEARINGS AND OIL SEALS ............................................................... B-6
ClRCLlPS ............................................................................................... B-6
.-.
CHECKING OF CONNECTIONS .................................................................. B-7
SPECIAL TOOLS .......................................................................................... B-7
.-.
MACHINE IDENTlFlCATlON
GENERAL INFORMATION
m
pG
INFO 0
-
MACHINE IDENTIRCATION
VEHICLE IDENTIFICATION NUMBER
Thevehicleidentificationnumber 0 is
stamped into the left side of the frame.
I MODEL LABEL
The model label 0 is affixed to the frame.
This information will beneeded to order
spare parts.
I 1
'e
1 FEATURES 1-
c FEATURES
Transmission of power
The V-belt transmission system, combined
with a high torque engine, allows easy and
comfortable driving a t all power ranges.
Power Transmission
Crankshaft 0
I
3-
Centrifugal
clutch @ -
L
Clutch housing @
I
\y
Sheave shaft @
1
Primary sheave @
L
V-belt @
L
Secondary sheave @)
L
Main axle @
1
Drive axle @
1
Drive pinion gear shaft @
1
Pinion driven gear shaft@I
I I
Clutch & Engine brake

The engine brake functions when thethrot- .
tle lever is returned by the constant-contact
type V-belt and one-way clutch.
b e
Operation is as follows.
a) When the engine speed reaches approxi-:
mately 1,900 r/min, the centrifugal clutch :
0 presses against the clutch housing @ -
and the drive force is transmitted to the
sheave shaft 0.
b l During deceleration, whentheengine
speed is less than 1,900 r/min, the cen-
trifugal clutch@ releases from theclutch
housing 0 and the one way clutch @
continuesto transmit brakingforceto
the engine.
~~ ~ ..-
FEATURES m
INFO 0
- p
Explanation of Operation
AL - - El a - El Idling
The centrifugal clutch is separated from
I
a
a,
the clutchhousing,andnopoweris
transmitted to the primarysheave.
a,
Q
HAccelerating
v) The centrifugal clutch comes in contact
Times - with theclutchhousing,

transmitted to the primary
and power is
sheave. The
primary sheave (or secondary sheave) is
in constant contact with the V-belt and
transmits power.
ElRunning at Constant Speed
The centrifugal clutch is in contact with
the clutch housing so power is transmit-
ted.
n Decelerating
When the throttle leveris returned, the V-
belt is always in contact with the sheave,
so the inertia force of the wheels is trans-
\-
mitted to the engine, and the engine brake

functions. Also, when the engine is run-
ningat less than 1900 r/min with the
clutch in (for example, when idling and
going down hill), the engine brake func-
tions by way of the one-way clutch.
u
+-' b / @ 0
Cooling the V-belt Chamber
@ Exhaust duct
0 Intake duct
.,.,xY.-.*,:-.-
of
There are fins located around the outside
the primary sheave and they coolthe inside
of the V-belt chamber.
q+g&!@$
<&<,>A..<,A:&'
Make sure that water, dirt, etc., do not get
inside the chamber through ducts @ andI
@.
.-
I FEATURES
Auto-Decompression
1-
Auto-decompression of the centrifugal
mechanism is used in this vehicle.
-
From approximately0 700 r/min, the gover-
nor's weights @ are pulled inward by the
springs @,causing the decompression lever
0to turn clockwise. As a result, the pin @ in
the decompression lever is forced up and the
exhaust valve's rocker arm is pushed and
compression is slightly reduced.
When engine revolution exceeds 700 r/min,
theweightsareforced out, causing the
decompression lever toturn counterclock-
wise.Thepin is thenforced down by the
spring.
0-700 RPM 700 RPM-
@F@J I % @
(] ._..
Cam surfaceA . / \,
'..\- '., \
-..... ../
I J
On command 4WD
2WD position When 4WD is selected using the 2WD/4WD
\ 4w9 position p Q select switch, the gear motor 0 operates
for approximately 1.5 seconds, the pinion
.- gear @ turns and the shift fork sliding gear
@ movesapproximately 8 mm (0.31 in.)
together with the shift fork.
@- At this time, if the splines of the input shaft
@ and drive pinion gear @ do not mesh,
the 2WD/4WD shift sleeve 0does not shift
completely into4WD and the4WD indicator
light does not light.
If the splines of the input shaft @ and drive
pinion gear @ mesh, the2WD/4WDshift
sleeve 0is shifted completely into 4WD by
theforce of thespringinsidethegear
motor and the4WD indicator light lights.
Installthe gear motorbythefollowing
I method so thatthespringinsidethegear
motor will act with the appropriate force.
t I
FEATURES 1-
Gear motor installation steps
-
ric
1) Apply lightweightlithium-soapbase
grease to the gear motor's O-ring.
2) Make sure the gear motorand shift fork
sliding gear are in the 2WD position.
If their position is not correct, position
them in the 2WD position.
3) While aligning the gear motor's stopper
@ with the differential gear case's boss
1 I
@, meshthepinion gear (gear motor)
and shift fork sliding gear together.
4) Push the gear motor into the differen-
tial gear case.
5) Rotate the gear motor counterclock-
wise approximately 37" k 6" and align it
with the gear motor's mounting hole.
In this way, the initial load is applied to
the spring inside thegear motor.
6) Fasten the gear motor with the bolt(s).
Y
t I
I %
Bolt (gear motor):
I 13 Nm (1.3 m kg, 9.4 ft Ib)
Lubrication
i
A wet sump lubrication system is used.

Two oil pump rotors are usedindepen-
dently for lubrication and for sending oil to
the oil cooler.
@ Plug
@ Spring
0 Strainer
@ Pipe
@ Rotor for lubrication
@ Rotor for oil cooler
0 Oilfilter
r @ Reliefvalve
@ Oillevelgauge
@ Thermoswitch
NOTE:
When disassembling the left side crankcase
@, remove the followingparts to avoid
obstructing the right side crankcase: plug
@, spring @, strainer @, and pipe0.
I I
1
4 FEATURES
Rear shock absorber
1-
Thespringratecanbeadjustedwiththe
remote lever, which is connectedto the
spring rate adjuster with linkage.
NOTE:
Thespringratecannotbeadjustedwhen
the ATV is loaded.
I
~~ ~
At the "Soft" position a, thesuspension

operates with the combined spring rate of
Force (kgf)
both springs. At the "Hard" position @, the
spacer 8is moved down causing the upper
0 spring to have a shorter stroke and the bot-
tom spring is infull operation.
@
:,
,* 0
0 ..
.-
.- - 0
Distance
@ SOH posltion
-__--
~~
@ Hard position ol usual Iwo step spring

- @Hard posilion o! this system
I I
Revolution and Speed Limiter

This An/ is equipped with an engine speed
*[1 f $ P l l
CDI unit control function.
r----------------
1) Over-revolutionlimitersystem
timing control Pickup cod Duringnormal operation(except
in
reverse), the engine speed will be kept
bl
I
below 7,800 r/min.
____
I
__.._.._______, 2) Speedlimitersystem
When the reverse indicator light comes
on, the signal from the speed sensor is
~
switch e " e ~ e sensor
speed ~ ~ ~
detected andthesystemisactivated
relay
4 -
- -
-
when the vehicle speed reaches 20 krnl
h. At this time, if the signal should not
Reverse reach the CDI unit because the speed
indicator light
sensor is broken or the coupler is dis-
connected, the enginespeedwillbe
kept below 2,500 r/min.
-I
For battery
I I
IMPORTANT
EBlOlOOO
INFO
INFORMATION T &
e I pF
PREPARATION FOR REMOVAL
PROCEDURES
1.Remove all dirt, mud, dust and foreign
material before removaland disassembly.
2.Use proper tools and cleaning equipment.
Refer to the "SPECIAL TOOLS" section.
3.When disassembling the machine, always
keep mated parts together. This includes
gears, cylinder,pistonandotherparts
that have been "mated" through normal
wear. Mated parts must always be reused
or replaced as an assembly.
4.Duringmachinedisassembly,clean all
parts and place them in trays in the order
of disassembly. This will speed up assern-
bly and allow for the correct installation
of
W
all parts.
5.Keep all parts away from any source of
fire.
Eatomlo
REPLACEMENT PARTS
1.Use only genuine Yamahaparts for all
replacements. Use oil and grease recorn-
mended by Yamahafor al! lubrication
lu
jobs. Other brands may be similar in func-
tion and appearance, but inferior in qual-
ity.
Ea101020
GASKETS, OIL SEALS AND O-RINGS
1.Replace all gaskets, seals andO-rings
when overhauling the engine. All gasket
surfaces, oil seal lips and O-rings must be
cleaned.
2.Properly oil all mating parts and bearings
duringreassembly. Apply grease to the
oil seal lips.
EB101030
1-1
LOCK WASHERS/PLATES AND COTTER
PINS
1.Replace all lockwashers/plates 0 and
cotter pins after removal. Bend lock tabs
along the bolt ornut flats after the bolt or
nut has been tightenedto specification.
. EB101040
BEARINGS AND OIL SEALS
1.lnstall bearings and oil seals so that the
manufacturer's marks or numbersare vis-
ible. Wheninstalling oil seals, apply a
.-.
light coating of lightweight lithium base
grease to the seal lips. Oil bearings liber-
ally when installing, if appropriate.
0Oil seal
m.w3
I" ,:;:;;;-.
.$&&qQjyy.;
,..AI*-..
...,-.. :
-: x;.,.-:<.
.*;;.- .,,. . - .
Do notuse compressed air t o spin the bear-
ings dry. This will damage the bearingsur-
faces.
@ Bearing
€0101050
ClRCLlPS
1.Check all circlipscarefullybefore reas-
sembly.Alwaysreplacepiston pin clips
after one use. Replace distorted circlips.
c ,
Wheninstalling a circlip makesure a,
that thesharp-edgedcorner @ isposi-
tioned opposite the thrust 0 it receives.
See sectional view.
303.031
@ Shaft
I
CHECKING OF CONNECTIONS ) G E N I I pF
INFO 0
-
z _-
l EBBOlOOD
CHECKING OF CONNECTIONS
Check the connectors for stains, rust, rnois-
ture, etc.
1.Disconnect:
Connector
2.Check:
Connector
Moisture -+ Dry each terminal with an air
blower.
Stains/rust 4 Connect and disconnect the
terminals several times.
4
3.Check:
Connector leads
Looseness -+ Bend up the pin 0and con-
nect the terminals.
A )
- -
I I 4.Connect:
Connector terminals
NOTE:
The two terminals "click" together.
I I
1a 5.Check:
Continuity (using pocket tester)
I NOTE:
r
If there is no continuity, clean the termi-
nals.
When checking the wire harness be sure
to perform steps1 to 3.
I 1 As a quick remedy, use a contact revital-
I I izer available at most part stores.
Check the connector with a pocket tester
as shown.
i
E8102001
SPECIAL TOOLS
number from country to country. In such
For US and CDN

PIN. YM-, YU-, YS-, YK-, ACC-
Except for US and CDN
PIN. 90890-
SPECIAL TOOLS -
The following special tools are necessary for complete and accurate tune-up and assembly.
Use only the appropriate special tools; this will help prevent damage caused by the use of
inappropriate tools or improvised techniques. Special tools may differ
a case, two types are provided.
by shape and part
When placing an order, refer to t h e list provided belowto avoid any mistakes.
These tools are used to remove the
90890-01085
YU-01083-2
90890-01135
YU-01135-A
This tool is used to separate the
90890-01225
YM-01225-A
This tool is needed to remove and
90890-04017
Valve guide reamer (7.0 rnm)

90890-01227
This tool is needed to rebore the new
90890-01231
-
SPECIAL TOOLS pT
&a -
INFO
-
p
Tool No.
- -
90890-01235 This tool is needed to hold thestarter

YU-01235 puller when removing /installingthe
starter puller bolt or camshaft
sprocket bolts.
- -
Crankshaft installer pot
Pot Crankshaft installer bolt
90890-01274
Bolt
90890-01275 These tools are usedto install the
crankshaft. -
- I -
Crankshaft installer set A
YU-90050
- -
~
~
These tools are used to install the
crankshaft.
I
q
o
/
@u
-
Adaoter Adapter (M10)
\-’ 90890-0 1383
YM-01383
Spacer
90890-04081
YM-91044
-
Spacer (crankshaft installer)
These tools are used to install the

crankshaft. I @@ -
Spacer
90890-01016
This tool is used to install the crank-
shaft.
@
f
y
l
- I -
Piston pin puller
I /,
90890-01304
YU-01304
ton
Thispin.
toolis used to removethe pis-
O Q
- I -
Tappet
. . adjusting
- tool (3 mm)
2
-‘-’ 1 1
90890-0 13
YU-08035
-
This tool is necessary for adjusting
the valve clearance. // 9
‘
-
Fuel level gauge
118
90890-01312
YM-01312-A
~~ -
This gauge is used to measure the
fuel level in the float
Locknut wrench
chamber. u -
.
90890-01 348
-
This tool isneeded when removing
or installing the secondary sheave
spring. I
/ -
I SPECIAL TOOLS1- -
Tool No. Tool name / How to use Illustration
-
Sheave spring compressor
90890-04134
YM-04134 This tool is needed when removing
or installing the secondary sheave
spring.
-
I
II I
Sheave fixed block

I
II YM-04135
90890-04135 This tool is needed when removing
or installing thesecondary sheave
@
I spring. I -
90890-0 1362
These tools are needed to remove
-
I_
I
90890-01375
I
This tool is needed to loosen and
tighten the steering stem bearing
retainer.
,
fB -
I [Ring n u t wrench
1
I
I
YM-38404
90890-01430
retainer. I
This tool is needed to removing and
installing the middle driven shaft
bearing
Gear lash measurement tool
I
B -
90890-01467
YM-01467
This tool isused to measure the gear
lash.
a
-
Sheave holder
_. - 90890-01701
1 YU-01880 This tool is needed to hold the pri-

man/ sheave when removing or
I I
installing the sheave bolts.
I
L+ -
This instrument is needed for check-

I I
ing theelectrical system.
I -
SPECIAL TOOLS1-1 pF
- 7
-
-
Tool No.
__
TOOI name I HOW t o use I
I
Illustration
-
Engine tachometer
goago-03113
This tool is needed for observing
engine rpm.
- __ -
Inductive tachometer
YU-8036-1
This tool is needed for observing
engine rpm.
-_ -
Timing light
90890-03141
YM-33277-A
This tool is necessary for checking
ignition timing.
-. ~
I -
Valve spring compressor
k d
90890-04019
YM-04019
This tool is needed to remove and
install the valve assemblies.
-. I -
Bearing retainer wrench
90890-04050
YM-04050
-.
This tool is needed when removing
or installing the final drive shaft bear-
- retainer.
inq
Universal joint holder
!
@ -
90890-04062
YM-04062
'-, goago-04086
-
This tool is needed when removing
or installing the universal joint yoke
nut.
_ _ _
Clutch holding tool

_ ~ I
6 -
YM-91042 This tool isneeded to hold theclutch

carrier when removing or installing
-
the carrier nut.
I - I -
Bearing retainer wrench
90890-04128
YM-04128 This tool is needed when removing
or installing the middle driven pinion
gear bearing retainer.
~ - ~ ~-~ I -
Pinion gear fix clamp
90890-04129
YM-04129
' This tool is used to hold theshift
L - cam. I -
r
SPECIAL TOOLS 1-
Tool No. Tool name / How t o use Illustration
I ! -
Ignition checker
90890-06754 This instrument is necessary for

checking the ignitionsystem compo-
nents.
I -
Dynamic spark tester
YM-34487 This instrument is necessary for

checking the ignition system compo-
nents.
I I -
I Yamaha bond No. 1215 I
Q
Bond Sealant (Quick Gasket@)
90890-85505 2.&&
Sealant
ACC-11001-05-01 This sealant (bond) is used on crank-
. case mating surfaces, etc.

-
x,-
--
CHAPTER 2.
1- m
SPECIFICATIONS
GENERAL SPECIFICATIONS ....................................................................... C-3
MAINTENANCE SPECIFICATIONS ............................................................. C-4

ENGINE ................................................................................................. C-4
CHASSIS ............................................................................................... C-9
ELECTRICAL ....................................................................................... C-11
HOW TO USETHE CONVERSION TABLE ............................................... C-12
GENERAL TORQUE SPECIFICATIONS ...................................................... C-12
LUBRICATION POINTS AND LUBRICANT TYPES ................................... C-13

.- . ENGINE ............................................................................................... c-13
LUBRICATION DIAGRAMS ................................................................ :......C-13
CABLE ROUTING ....................................................................................... C-15
...
L.
J
GENERAL SPECIFICATIONS rT-l E
SPEC p
SPECIFICATIONS
GENERAL SPECIFICATIONS
,
Item Standard
Model code: 4WV1 : USA
I
4WV2 : CDN -
Dimensions:
Overall length 2,079 mm (81.9 in)
Overall width 1,161 mm (45.7 in)
Overall height 1,215 mm (47.8 in)
Seat height 865 m m (34.1 in)
Wheelbase 1,254 m m (49.3 in)
Minimum groundclearance 178 mrn (25.4 in)
Minimum turning radius 3,100 m m (122 in)
Basic weight:
With oil and full fueltank 307 kg (139 Ib)
-
igine:
'k,,Engine type Air-cooled 4-stroke, SOHC
Cylinder arrangement Forward-inclined single cylinder
Displacement 595 cm3
Bore x stroke 95 x 84 mm (3.74 x 3.31 in)
Compression ratio 8.5 :I
Starting system Electric and recoil starter
Lubrication system: Wet sump
Oil type orgrade:
Engine oil
0" IO" 30" 50° 70' 90" 110°F
1 ! I I I I I I
i YAMALUBE 4 (20W40):or SAE:20W40 i
- ; * :
SAMALUEE4 ( & W ~ OdI SAE lkwlw30
c
!
i
iSAE 5W30 j
<: -*
L
j j i i j
"\
I -_
-20. -10. 0. 100 200 30" 40% .
Final gearoil SAE80API "GL-4" Hypoid Gear Oil
Differential gear oil SAE80API "GL-4" Hypoid Gear Oil
Oil capacity:
Engine oil
Periodic oil change 1.9 L (1.67 Imp qt, 2.0 US qt)
With oil filter replacement 2 L (1.67 Imp qt, 2.1 US qt)
Total amount 2.6 L (2.29 Imp qt, 2.7 US qt)
Final gear case oil
Periodic oil change 0.19 L (0.17 Imp qt, 0.20 US qt)
Total amount 0.22 L (0.20Imp qt, 0.23 US qt)
Differential gear case oil
Periodic oil change 0.67 L (0.59Imp qt, 0.71 US qt)
Total amount 0.7 L (0.62 i m p qt, 0.74 US qt)
. Oil cooler capacity (including all routes)
-- 0.23 L (0.20 i m p qt, 0.24 US qt)
1 r
En SPEC p
Item Standard
Air filter: Wet type element
Fuel:
Type Regular gasoline
Fuel tank capacity 19 L (16.7 Imp qt, 20 US qt)
Fuel reserve amount - 3 L (2.64 Imp
. qt,
. 3.2 US qt)
Carburetor:
Type I quantity BST40/1
Manufacturer - MlKUNl
Spark plug:
Type DP8EA-9 : USA
DPR8EA-9 : CDN
3
Manufacturer NGK
Spark plug gap - -
- 0.8 0.9 mm (0.031 0.035 in)
Clutch type - Wet, centrifugal automatic
Transmission:
Primary reduction system V-belt
Secondary reduction system Spur gear
I
Secondary reduction ratio 34/25 x 24118 x 3319 (6.649)
Transmission type Single speed automatic (V-belt type)
Operation Left hand operation
Single speed automatic 2.45 0.70 -
Sub transmission
ratio low 38/14 (2.714)
high 30116 (1.875)
Reverse gear 30113 x 27119 (3.279)
Chassis:
Frame type Steel tube frame
Frame type Pressed and steel tube frame
Caster angle 3'
Camber angle 1"
Kingpin angle 14"
Kingpin offset 0 mm (0in)
'-Trail 15.5 mm (0.61 in)
L------
Tread (STD) 858 mm (33.8 in)
Tread (STD)
Toe-in
Tire:
front
'd
-
874 mm (34.4 in)
-
- 5 5 mm (-0.20 0.20 in)
TY Pe Tubeless
Size front AT25~8-12
rear AT25~10-10
Manufacturer front DUNLOP
rear DUNLOP
Type front KT-I22
rear KT- 1 26
I
- ___I_
GENERAL SPEC
SPECIFICATIONS 1( C13c 1c
Item Standard
Tire pressure (cold tire):
Maximum load-except motorcycle 220 kg (485 Ib)
riding Off-road front - -
27 33 kPa (0.27 0.33 kg/cm2, 3.8 -. 4.7 psi)
rear -
24.5 30.5 kPa
-
(0.245 -. 0.305 kg/cm2, 3.5 4.3 psi)
Brake:
brake Front t Y Pe Dual disc brake
operation Right hand operation
Rear brake t Y Pe Drum brake
operation Left hand and right foot operation
Suspension:
Front suspension Strut
Rear suspension Swingarm (monocross)
Shock absorber:
Front shock absorber Coil spring / o i l damper
Rear shock absorber Coil spring / o i l damper
w h e e l travel:
Front wheel travel 160 m m (6.30in)
Rear wheel travel 190 mm (7.48 in)
Electrical:
Ignition system C.D.I.
Generator system A.C. magneto
Battery type YTX20L-BS
Battery capacity 12 V 18 AH
Headlight type: Krypton bulb
Bulb wattagex quantity:
Headlight 12v30w130wx2
Tail / brake light 12v7.5 w x 1
Meter light 12V1.7Wxl
Indicator lights:
Neutral 1 2 V 1.7 W x 1
1
4
Reverse 1 2 V 1.7 W x 1
Oil temperature 12V3.4Wxl
4WD 12V3.4Wxl
1
MAINTENANCE SPECIFICATIONS
SPECIFICATIONS
MAINTENANCE 1-
ENGINE
Item Standard Limit
Cylinder head:
Warp limit 0.03 rnm (0.0012 in) 0.10 mrn
(0.004 in)
x
Cylinder:
Bore size 94.97 - 95.02 mm (3.739 - 3.741 in) 95.1 mm
(3.744 in)
*
n
Measuring point 40 mrn (1.6 in) ____
---- --J*
\ z
Out of round limit ____ 0.01 rnm

(0.0004 in)
Camshaft:
Drive method Chain drive (Left) ____
Cam cap inside diameter -
23.000 23.021 r n r n __-_
-
(0.9055 0.9063 in)
____
22.967 -,22.980 mrn
Camshaft outside diameter
-
(0.9042 0.9047 in)
-
@
Shaft-to-cap clearance 0.020 0.054 mm ____
(0.0008 -.0.0021 in)
Cam dimensions
\_ ,
Intake A" -
36.47 36.57 mm 36.37 mrn
'I
-
(1.436 1.440 in) (1.433 in)
B" -
30.06 30.16 mm 29.96 mrn
"
(1.183 1.187 in) - (1.180 in)

----
C" 6.37 ..6.67 mrn
-
"
(0.251 0.263 in)

Exhaust A" -
36.62 36.72 mm 36.52 mm
I(
-
(1.442 1.446 in) (1.438 in)
B" -
30.11 30.16 mrn 30.01 mm
-
"
(1.185 1.187 in) (1.181 in)

C -
6.52 6.82 mm ____
-
" "
(0.257 0.269 in)

-~~~ ~~
MAINTENANCE SPEC
SPECIFICATIONS 1 p 1 E
-e-
Item Standard Limit
Camshaft runout limit ---- 0.03 mm
(0.0012 in)
_____
-.--JL--
__
Cam chain:
Cam chain type/ No. of links 75RH2015J/126 ----
Cam chain adjustment method Automatic ----
Rocker arm / rocker armshaft:
Shaft outside diameter 11.985- 11.991 mm ----
-
(0.4719 0.4721 in)
Arm-to-shaft
clearance -
0.009 0.033 mm -_--
i
-
(0.0004 0.0013 in)
'.Valve, valve seat, valve guide:
clearance
'lalve
(cold) IN -
0.05 0.10 mm ____
.4
-
(0.002 0.004 in)
EX -
0.12 0.17 mm ____
-
(0.005 0.007 in)
Valve dimensions:
I
Head Dia Face Width Seat Width Margin Thickness
"A" head diameter IN --
36.9 37.1 mm
(1.453 1.461 in)
____
EX -
31.9 32.1 mm --__
-
(1.256 1.264 in)
"B" face width IN 2.26 mm (0.089 in) ----
EX 2.26 mm (0.089in) ____
,--' "C" seat width IN - -
1.0 1.2 mm (0.039 0.047 in) l . 6 mm
(0.063 in)
EX 1.0 -1.2 m m (0.039 - 0.047 in) 1.6 mm
(0.063 in)
"D" margin thickness IN --
1.35 1.65 mm
(0.053 0.065 in)
1.2 mm
(0.047 in)
EX 1.15 -,1.45 mm 1.0 mm
-
(0.045 0.057 in) (0.039 in)
Stem
outside diameter IN --
6.975 7.025 mm
(0.2746 0.2766 in)
____
EX -
6.975 7.025 rnm ____
-
(0.2746 0.2766 in)
Guide inside diameter IN --
6.495 6.505 mm
(0.2557 0.2561 in)
----
EX --
6.495 6.505 mm
(0.2557 0.2561 in)
----
r
T
1- - -
-
Stem-to-guide
clearance
IN
Item
-_ Standard
-
0.010 0.037 mrn
-.
(0.0004 0.0015 in)
-I
- Limit
0.08 mrn
(0.003 in)
-
EX 0.030-.0.057 rnm ' 0.10 rnrn
_---
-
(0.0012 0.0022 in) (0.004 in)
Stem runout limit 0.01 mrn
~ (0.0°04 in'
Valve seat width IN 1.1 rnm (0.043 in) ____

EX _ _ mrn (0.043
1.1 . in) ~ ~~~ -
____ -
Valve spring:
Inner spring:
Free length IN 40.1 rnm (1.58 in) 38.1 mm
L,
(1.50 in)
EX 40.1 mm (1.58 in) 38.1 mm
(1.50 in)
Set
length
(valve
closed) IN 31.2 mm (1.23 in) ____
EX 31.2 mm (1.23 in) _-__
Compressed pressure
(installed) IN -
73 89 N ____
-
(7.3 8.9 kg, 16.1 - 19.2 Ib)
EX -
73 89 N ----
-
(7.3 8.9 kg, 16.1 - 19.2 Ib)
Tilt limits IN 2.57 1.7 mm
(2.5'/0.067 in1
EX 2.5"/ 1.7 mm
(2.570.067 in1
-li--*
( I
Direction of winding
ew) (top Counterclockwise ----
EX Counterclockwise -_--
Outer spring:
Free length IN 43.8 mm (1.72 in) 41.6 mm
(1.64 in)
EX 43.8 mm {I
.72 in) 41.6 mm
(1.64in)
Set length
(valve
closed) IN 34.2 mm (1.35 in) __--
EX 2 34.2 mm (1.35 in) - ____ L
-
MAINTENANCE SPEC
SPECIFICATIONS TI
/E p
Item Standard Limit
Compressed pressure
(installed) IN -
152 186 N _-__
(15.2 -, 18.6 kg, 33.5 - 41.0 Ib)
EX 152 -, 186 N ---_
Tilt limit* IN
-
(15.2 18.6 kg, 33.5 - 41.0 Ib)
2.5Y1.9 mm
(2.5'/0.075 in)
EX 2.571.9 mm
(2.570.075 in)
w
(top view)
AL
Direction of winding
IN
EX
Clockwise
Clockwise
---_
_---
Piston:
Piston to cylinderclearance -
0.045 0.065 rnm 0.15 mm
-
(0.0018 0.0026 in) (0.0059 in)
Piston size "D" -
94.915 94.965 mm ----
-
(3.737 3.739 in)
Measuring point "H" 5 mm (0.20 in) ----

Piston off-set 2 mm (0.08in) ----
Piston pin bore inside diameter -
22.004 22.015 mm ----
-
(0.8663 0.8667 in)
"--Piston pin outside diameter -
21.991 22.000 mm ----
Piston rings:
-
(0.8658 0.8661 in)
Top ring:
Type
pp Barrel ---_
Dimensions (Bx T) 1.2 x 3.8 mm (0.047x 0.150 in) ----
End gap (installed) -
0.30 0.45 mm 0.7 m m
-
(0.012 0.018 in) (0.028 in)
Side clearance (installed) -
0.04 0.08 m m 0.13 mm
-
(0.001 0.003 in) (0.005in)
1 MAINTENANCE SPECIFICATIONS
E rv l
SPEC
Item Standard Limit
2nd ring:
3I
w
Type Plain ____
Dimensions (6 x T) 1.2 x 3.8 mm (0.047 - 0.150 in) ----
End gap (installed) -
0.30 0.45 mm 0.8 mm
-
(0,012 0.018 in) (0.031 in)
Side clearance -
0.03 0.07 mm 0.13 mm
-
(0.001 0.002 in) (0.005 in)
Oil ring:
E 3
ITI
Dimensions ( B x T) 2.5 x 3.4 m m (0.098 - 0.134 in) ----
cl End gap(installed) -
0.2 0.7 m m (0.008 - 0.028 in) ----
Crankshaft:
D
*p
Crank width "A"
ky4
-
74.95 75.00 mm
-
(2.951 2.953 in)
----
____
Runout limit C1 0.03 mm

(0.0012 in)
c2 ---- 0.03 mm
(0.0012 in)
-- .. Big end side clearance"D" -
0.35 0.65 mm 1.0 mm
-
(0.014 0.026 in) (0.040 in)
Big end radial clearance "E" -
0.010 0.025 mm ----
-
(0.0004 0.0010 in)
----
Small end free play"F" 0.8 mm (0.0315 in)
Balancer:
Balancer drive method Gear ____
Shifter:
Shifter type Cam drum and guide bar -_--
Decompression device:
Type Auto decomp ----
Air filteroil grade: Engine o i l ----
Itern
MAINTENANCESPECIFICATIONS
Limit Standard
I
SPEC p
B
Carburetor:
1. 0.mark 4 w v 00 ____
Main (M.J) # I 45 --__
Main air jet
(M.A.J) 0.6 ---_
J e t needle (J.N) 6HH23-94-3 ----
Needle (N.J) Y-OM (#782) _---
air Pilot (P.A.J.l) 0.7 ----
Pilot air jet (P.A.J.2) 1.O ----
et Pilot (P.0) 1.1 ----
Pilot (P.J) #42.5 ____
Bypass 1 (B.P.l) I .o -___
Bypass 2 (B.P.2) 0.8 ____
Bypass 3 (e.p.3) 0.8 ____
w Pilot (P.S) 3 1/2 ----
seat Valve size (V.S) 2.8 ----
jet Starter (G.S.1) #I 00 ----
valve
Throttle size (Th.V) #I 10 ----
Float height (F.H) 14.7 mm (0.59 in) -___
Fuel (F.I-1 -
2 3 mm (0.08 -. 0.12 in)
____
____
Engine idle speed 1.350 -. 1.450 rlmin
Intake vacuum 30.8 kPa (231 mmHg, 9.09 inHg) ----
Lubrication system:
Oil filter type Paper type ____
Trochoid type --__
Oil pump type
Tip clearance "A" or "6" -
0.09 0.15 rnm 0.23 m m
-
(0.004 0.006 in) (0.009 in)
Side clearance -
0.03 0.08 mm 0.15 mm
-
(0.001 0.003 in) (0.006 in)
Bypass valve setting pressure - -
40 80 kPa (0.4 0.8 kg/cm2, ----
5.69 -.11.38 psi)
Relief valve operating pressure -
350 450 kPa (3.5 - 4.5 kg/cm2, ----
-
49.8 64.0 psi)
.. hafr drive:
Middle gear backlash 0.1 - 0.3 mm (0.004 - 0.012 in) . ----
Final gear backlash 0.1 - 0.2 mm (0.004 - 0.008 in) ----

0.05 - 0.25 mm ----
Differential gear backlash
(0.002 - 0.010 in)
1 MAINTENANCESPECIFICATIONS
En SPEC p
Item Standard
Lubrication chart:
-
>-I Pressure feed
Splashed scavenge
- - ---- - -
.
Crankcase tightening sequence:
Crankcase (left) Crankcase (right)
!
1
-
7
@ @ : M6 bolts
-
@ @ : M8 bolts
- Y
I
Item
MAINTENANCESPECIFICATIONS
E
Standard
nE SPEC p
Cylinder head tightening sequence:
\i-c
I Tightening torques
MAINTENANCE SPECIFICATIONS m
I
SPEC p
I I
I Part to be tightened
1 1 I Tightening torque
- Remarks
1 1
n K e size Q'ty
Thread Nm m-kg ft.lb
I
Cylinder
head(exhaust
pipe) Stud bolt M6 4 7 0.7 5.1
Cylinder head M8 4 29 2.9 21
M6 1 10 7.2 1.0
Stud bolt MI0 2 20 2.0 14
Nut M8 2 22 2.2 16
Spark plug - MI2 1 18 1.8 13
Cylinder Bolt M6 1 10 1.0 7.2
Nut MI0 4 42 4.2 30
Starter pulley Bolt MI0 1 50 5.0 36
Camshaft sprocket Bolt M7 2 20 2.0 14
Timing chain tensionercap Bolt M16 1 20 2.0 14
Timing chain tensioner Bolt M6 2 IO 1.0 7.2 -a
T;ming chain guide (intake) Bolt M6 2 10 1.0 7.2 -4
.cker arm shaft stopper Bolt M6 2 10 1.0 7.2
Valve adjusting screw Nut M6 4 14 1.4 10
Oil pump assembly Bolt M6 3 10 1.0 7.2
Oil pump Screw M6 1 7 0.7 5.1
Oil drain plug Plug M35 1 32 3.2 23
Plug MI4 1 23 2.3 17
Oil filter cover Bolt M6 3 10 1.0 7.2
Oil cooler hose Nut M22 2 35 25 3.5
Oil cooler Bolt M6 2 7 5.1 0.7
~n Bolt M6 3 8 5.8 0.8
Carburetor joint Bolt M6 4 10 1.0 7.2
Air duct 2 Bolt M6 1 8 0.8 5.8 -a
Muffler and exhaust pipe Bolt M8 1 20 2.0 14
Muffler and pipe Bolt M6 1 8 0.8 5.8
Muffler protector 1 Bolt M6 6 11 1.1 8.0 -a
d f f l e r protector 2 Bolt M6 4 14 1.4 10
Exhaust pipe protector Bolt M6 3 14 1.4 10
Exhaust pipe Nut M6 4 12 1.2 8.7
Muffler Bolt M8 2 26 2.6 19 -d
Bearing retainer (crankcase) Screw M6 3 7 0.7 5.1
Crankcase Bolt M8 4 31 3.1 22
Bolt M6 15 10 1.0 7.2
Stud bolt M I 0 4 20 2.0 14
Clutch housing cover protector Screw M6 3 7 0.7 5.1
Clutch carrier assembly Nut M22 1 140 14 100 Stake
Middle drive shaft bearing Torx
M8 4 29 2.9 21
retainer screw
Middle driven shaft drive pinion
Nut M22 1 145 14.5 105 Stake
lgear
!Middle driveshaftbearinghousing}Bolt 1 MI0 6 33 3.3 24
retainer
Part to be tightened
Middle drivengear bearing
Yoke (middle driven gear)

MAINTENANCE
-
Part
name
Nut
Nut
l[~~~i
size
MI4
(2: [I
IC
SPEC
SPECIFICATIONS F
Middle driven gear bearing hous-

Bolt M8 4
ing
~
Yoke (middle driven shaft) Nut MI4 1
Middle driven shaft bearing
Nut M55 1
iretainer
Shift arm Bolt M6 1
iShift rod Nut M6 2
'Primary sheave assembly Nut MI6 1
ISecondary sheave assembly Nut MI6 1
Secondary sheave spring retainer Nut M36 1
Select lever unit bracket Bolt M6 3
=-Iect lever unit Bolt M8 3
- A f t cam ball holding bolt - MI4 1
Neutral switch - "I0 2
Stator coil Screw M6 3
Pickup coil Bolt M5 2
Lead holder Bolt M6 2
Ignition coil Bolt M6 2
Thermo unit - M12 1
cr
- ._
I MAINTENANCESPECIFICATIONS
En
SPEC p
CHASSIS
item
- Standard
- Limit
-
I - _. -
Steering system:
Steering- bearing- type -
Ball bearing ----
.. - -. -
Front suspension:
-_--
te
1 Shock absorber travel
Fork spring free length
Spring (K1)
151 m m (5.94in)
396 m m (15.6in)
1 N/mm (1 kg/mm, 56.00 Ib/in)
No
____
__--
__--
Optional spring - . ~~
-. -
Rear suspension:
Shock absorber travel 122.5 mm (4.82 in) ----
Spring 1 free length 274.9 m m (10.82in) __-_
Spring 2 free length 107.8 rnm (4.24in) __--
Spring 1 fitting length 235.7 mm (9.28in) __--
' Spring 2 fittinglength
Spring rate (K1)
90.5 mm (3.56in) __--
3 N/mm (3 kg/mrn, 168.0 Ib/in) ----
(K2) 4.39 N/mm -__-
W'
(4.39kg/mrn, 245.8 Ib/in)
Optional spring No --_-
Stroke (soft) (KI) - -
0 90 m m (0.00 3.54 in) __--
(K2) - -
90.0 122.5 m m (3.54 4.82 in) ___-
(hard) Stroke (KI) -
0 27 mm (0.00 .. 1.06 in) ----
-
~
(K2)
.~
-.
..
27.0 122.5 mm (1.06 4.82 inl-- --_- -
Swingarm:
Free play limit end __-- I mrn
! (0.04 in)
I side ---- 1 mm
I _. _ _ (0.04in) -
Front wheel:
1 Type Disc wheel ___-
Rim size 12 x 6.5AT ----
I Rim material Steel ----
Rim
limit
runout radial ---- 2 rnm
1
~ Rear wheel:
lateral
-.
----
(0.08 in)
2 mm
- (0.08 in) -
Type
1 Disc wheel ___-
Rim size 10 x 8.0AT ___-
1
Rim material Steel ----
diallimit
runout
Rim --_- 2mm
(0.08in)
lateral ---- 2 mm
- L
(0.08 in) .
1
IIC-
MAINTENANCE SPEC cr)
SPECIFICATIONS
Item Standard Limit

Front discbrake:
TY Pe Dual ___.
Disc outside diameterx thickness 220.0 x 3.5 mm (8.66 - 0.14in) ----

ckness Pad 4.2 mrn (0.17 in) I mm
(0.04 in)
ckness Pad 4.2 mm (0.17in) 1 mm
(0.04 in)
Master cylinder inside diameter 15.87 rnm (0.62 in) ___.
Caliper cylinder inside diameter 32.03 mm (1.26 in) ____

Brake fluid type DOT 4 ____
Rear d r u m brake:
TY Pe Leading, trailng 1 --_
Brake drum inside diameter 160 mm (6.30 in) 161 mm
I (6.34 in)
Lining thickness 4 mm (0.16 in) 1 mrn
(0.04in)
,-Shoe spring
free
length 1 68 mm (2.7 in) ____
Brake lever and brake pedal:
Brake lever free play( a t lever end) - -
2 5 mm (0.08 0.20 in) ---_
Brake lever free play (left) -
5 7 mm (0.20 -.0.28 in) ____
Brake pedal position - -
20 30 mm (0.8 1.2 in) ____
Brake pedal free play -
20 ..30 mm (0.8 1.2 in) ____
Throttle lever free play - -
3 5 mm (0.12 0.20 in) --__
-.
I Tightening torques
MAINTENANCE
SPECIFICATIONS
~~
-~
E n
SPEC p
-
Tightening torque
Part to be tightened Thread size Remarks
Nm m-kg ft4b
Engine bracket (front-upper)and frame M8 33 3.3 24
Engine bracket (front-middle) and frame M8 33 3.3 24
Engine bracket (front-upper)and engine MI0 42 4.2 30
Engine bracket (front-middle)and engine MI0 4.2 4230
Engine and frame MI0 56 40 5.6
Frame and bearing retainer (steering stem
holder bearing)
M42 40 29 4.0
Pivot shaft (right) and frame M22 130 13.0 94 4
Pivot shaft (left) and frame M22 6 0.6 4.3
Pivot shaft (left) and nut M22 130 13.0 94
--
Rear shock absorber and frame MI2 59 5.9 43
Final gear case and swingarm MI0 57 41 5.7 4
cinal gear case bearing housing and swingarm MI0 65 6.5 47 4
,la1 gear case and rear axle housing MI0 65 6.5 47 4
Swingarm and rear axle housing M12 90 9.5 65
Differential gear case and frame MI0 55 5.5 40
Front arm and frame MI0 45 4.5 32
Front shock absorber and frame M35 55 5.5 40
Front shock absorber and steering knuckle MI2 115 11.5 85
-
Steering stem, pitman arm and frame MI2 84 8.4 61
Steering stem holder and frame Use lock
M8 23 2.3 l7
washer
Steering stem and handlebar holder M8 20 2.0 14
Pitman arm and tie-rod end MI0 25 2.5 18
Tie-rod and locknut MI0 15 1.5 11
Steering knuckle and front arm MI0 48 4.8 35
Steering knuckle and tie-rod MI0 25 2.5 18
Fuel tank and fuel cock
~ M6 4 0.4 2.9
- ant
, wheel and wheel hub MI0 64 6.4 46
Front axle and wheel hub MI6 150 15.0 110
Steering knuckle andbrake caliper M8 30 3.0 22
Front brake disc and wheel hub M8 30 3.0 22 4
Rear wheel and rear wheel hub MI0 55 5.5 40
Rear wheel and brake drum MI0 55 5.5 40
Rear axle and nut MI6 150 15 110
Rear brake camshaft and camshaft lever M6 9 0.9 6.5
Swingarm and rear brake plate M8 28 2.8 20 4
Front brake pipe nut M10 19 1.9 13
Front brake hose union bolt MI0 27 2.7 19
Bleed screw M8 6 0.6 4.3
Master cylinder and handlebar M6 7 0.7 5.1
Footrest and frame MI0 55 5.5 40
~~
~~
TI )
IC-
SPEC p
-
Tightening torque
Part to be tightened Thread size . Remarks
Nm m-kg ft.lb -
Front bumper and frame M8 31 3.1 22
Rear carrier barand frame M8 35 3.5 25
Rear carrier and frame M8 35 25 3.5
Differential gearcase filler bolt MI4 23 2.3 17
Differential gear case drain bolt MI0 19 1.9 13
Universal joint yoke (differential gear) MI4 62 6.2 45 4
Ring gear M8 39 3.9 28 4
Differential gear case and bearing housing M8 25 2.5 18
Bearing housing (drive pinion gear) and differ-
M8 18 1.8 13
ential gear case
Gear motor M8 13 1.3 9.4
4WD switch MI0 19 1.9 13
Final gearcase oil filler bolt MI4 23 2.3 17
-
Final gear case oil drain bolt MI4 23 2.3 17
~ ,;aring retainer (drive pinion gear) M65 100 10.0 72
Final gear case and bearing housing MI0 40 4.0 29
Final gear case and bearing housing ’ M8 23 2.3 17 -
-
,
.
.
“
a
1 IELECTRICAL
~~ ~ ~-~
m
Item Standard Limit
Voltage: 12 v __._
Ignition system:
Ignition timing (B.T.D.C.) 12"/ 1,000 r/min ____
timing (B.T.D.C.) 28"/ 4,000 r/min Advanced ----
Advancer type Electrical type _---
30
c
.-
01
.E u
-
,s 20
.? b
e
c
g
~.~
-rn I 1 T
~~
12'/2000rpm
10 _ _ - ~ _ _ - ~
i,
,
0.
- -0
0 1 2 3 4 5 6 7 8 9 1
Engine speed (xl03r/mint
C.D.I.:
Magneto model/ manufacturer F4T4257l/MITSUBlSHI -_--
Pickup coil resistance/ color 459 -.561 !2 at 2O'C (68°F)/ Red ----
-White
Source coil resistance/ color 270 - 330 B a t 20'C (68°F)/ -_--
Brown - Green
C.D.I. unit model/ manufacturer F8T34671/MITSUBISHI ____
Ignition coil:
Model / manufacturer 2JN/YAMAHA -__-
Minimum spark gap 6 mm (0.24 in) ___-
c" Primary winding resistance -
0.18 0.28 Q at 20°C (68°F) ____
Secondary winding resistance 6.32 ..9.48 kQ a t 20'C (68°F) ----
Spark plug cap:
Type Resin type -__-
Resistance 10 kR ___-
Charging system:
Type A.C. magneto generator ----
Model /manufacturer F8T34671/MlTSUBISHI ___-
Nominal output 14 V 12 A at 3,000 r/min --_-
Stator coil resistance / color -
0.702 0.858 R a t 2O'C 168°F) / ----
White - White
Rectifier:
Model / manufacturer SH640-12/SHINDENGEN ___-
Capacity 14 A ----
~ Withstand voltage 200 v --_-
1
IIC-
MAINTENANCE SPEC
SPECIFICATIONS p
Item Limit Standard
Electric starter system:
TY Pe Bendix type ----
Starter motor:
Model / manufacturer SM-l3/MITSUBA ____
I.D. number SM-13486 ---_
output 0.7 kW ____
Armature coil resistance -
0.0249 0.0351 Q a t 20°C (68°F) ----
Brush overall length 6 mm (0.24 in) 5 mm
(0.20 in)
Spring force - -
780 1,021 g (27.5 36.0 O Z ) ----
Commutator diameter 28 mm (1.10 in) 27 mm
(1.06 in)
Mica undercut 0.7 m m (0.028 in) --_-
Starter relay:
Model / manufacturer MSSE-491/JIDECO ----
Amperage rating 100 A ____
d Coil winding resistance -
4.18 4.62 R a t 20°C (68°F) ____
Circuit breaker:
TY Pe Fuse ----
Amperage for individual circuit:
Main fuse 30Ax1 ----
Terminal fuse 10Axl -__-
Reserve 30Ax1 ----
Reserve 10Axl -_--
~~~~
.d
il EBZOlOW
HOW TO USE THE CONVERSIONTABLE/
GENERAL TORQUE SPECIFICATIONS
E8202001
1-
HOW TO USE THE CONVERSION GENERAL TORQUE
TABLE SPECIFICATIONS
All specificationdata in thismanualareThischartspecifiestorqueforstandardfas-
listed in SI and METRIC UNITS. teners with standard I.S.O. pitch
threads.
Usethistable to convert METRIC unit data Torquespecificationsforspecialcompo-
t o IMPERIAL unit data. assemblies
nents
or provided
are
each
for
chapter o f this manual. To avoid warpage,
Ex.
tighten multi-fastener assemblies in a criss-
METRIC MULTIPLIER IMPERIAL cross
fashion, in progressive stages, until
** mm x 0.03937 = **the
specified
in torque is reached. Unless
oth-
2 mm x 0.03937 = 0.08 in erwise specified, torque specifications
require clean, dry threads. Components
CONVERSION TABLE
should be a t room temperature.
METRIC TO IMPERIAL
I
Torque
:: ; 1 Metric unit
cm.kg-
1 Multiplier 1
17.233
in.lb86.794
0.0723
Imperial unit
lft.lb
ft.1 b
e.r. cm-kg 0.8679 inJb
Weight :1 1 -
2.205
10.03527
I
Ib“L
t - L
r
@
I1 mph
~~~
Speed 1 km/hr 0.6214 -

Ikm (0.6214 mi
I/
m 3.281 I I
Distance m 1.094 A: Distance between flats
cm 0.3937 B: Outside thread diameter
Il-KEmi-1
mrn /.o3g37
I - h
cc (cm3) 0.03527 oz (IMP liq.) General torque

A
Volume/
Capacity
cc (cm3)
It (liter)
It (liter)
0.06102
0.8799
0.2199
cwin
qt (IMP liq.) (nut) *
(bolt) specifications
gal (IMP liq.) -
___f____
kg’mrn 55.997 Ibh
10mm 6mm 6 0.6 4.3
Misc. kg’cm2 14.2234 psi (Ib/in*) 8mm 1 15
2 m m 1.5 11
Centigrade 9,5+32 Fahrenheit CF)
1 I
(‘C1 I I I 14mm 10mm 30 3.0 22
17 mm 12mm 55 5.5 40
‘4
19 mm 14mrn 85 8.5 61
22 mm 16 rnm 130 13.0 94
I I I___
~ ~ _ _ _ _ _ _I _ _ _~ _ _ _ _ ~~~~ I I
- --
mls
-
LUBRICATION POINTS AND LUBRICANT
TYPES SPEC p
LUBRICATION POINTS AND LUBRICANT TYPES
ENGINE
Lubrication points Lubricant type
-
Oil seal lips (all)
I I I
O-ring (all)
Bearings (all) -+a
Crank pin --a
Connecting rod (bearing) -4
. Camshaft sprocket
Balancer driven gear 4
Piston surface/piston rings --a
L
Piston pin I
-4 I
-4 -
\
,Ive stem/vaIve stem end -a
Rocker arm shaft 4 -
Rocker arm -fm -
Camshaft lobe/journal -=m
Oil pump shaft, rotor, housing -4
I
Starter idle gear 1,2
I
4 I
-
Starter wheel gear -+I
Transmission gear (wheel/pinion) -a
Axle (main/drive) 4
Shift forwguide bar . 4 -
Shift cam/shiftshaft -a
-Shift lever (select lever)
\-
eedometer
_, gear unit --.Q -
Clutch housing - - a .
Gear coupling 4
Driven cam -.QI
1
I
Crankcase mating surfaces Sealant (Quick Gasket@)

Yamaha
Bond No.1215
I
I
Middle drive axle cover
I
I Sealant (Quick Gasket@)

Yamaha
Bond No.1215
I
I
J
Starter lead grommet Sealant (Quick Gasket@)

(left side crankcase) Yamaha Bond No.1215
. -.
_I__c
1
LUBRICATION DIAGRAMS
DIAGRAMS
LUBRICATION 1
-
@ Crankshaft
@ Oil filter
@ Oil p u m p
@ Relief valve
@ Oil strainer
@ Oil delivery pipe
L-
,
@ Relief valve
LUBRICATION DIAGRAMS I
IC-
SPEC c13'
Q Oil strainer
@ Oil pump
@ Oil delivery pipe
x-
-J
- .~
1 @ Oil cooler
LUBRICATION DIAGRAMS 1-1
@Oil cooler hose
b
,-
Le.
/
1L . . - J - J -
__ -
CABLE ROUTING
CABLE ROUTING /)I
SPEC Crc IC-
0 Rear
brake
switch @ Rear
brake
switch
lead
@ Rear
brake
cable @ Indicator
light
lead
0Terminal @ Main
lead
switch
@ Front brake
hose 0 Speedometer
lead
@ 2WD/4WD select
switch @ Brake
pipe
8Fuel tank breatherhose 0 Fan
motor
@ 2WD/4WD select switch lead
@Throttle cable
@ Handlebar switch lead
ri
- 2
,*-
- --
. .-.
.
1-
Insert the breather hose (fuel tank] into the
1-
CABLE ROUTING
hole in the handlebar cover.

@I
Pass the indicator light leadsbetween the
starter knob and main switch,thenconnect
the leads on the inside of the handlebar
cover.
Pass the rear brake cable through the front
part of the cable guide and pass the speed-
ometer cable and throttle cable through the
rear part of the cable guide.
-
ri
L..
@ Headlight lead
C
I
I CABLE ROUTING
@ Starter relay
SPEC p
~~
@ Fuel tank breather hose @ Select lever control cable

@ Rectifier/regulator @ Starter cable
@ CDI unit @Carburetor breather hose
@ Carburetor overflow hose @ Rear brake breather hose
@ Carburetor drain hose @ I drive gear breather hose
Final
@ Ignition coil @ Rear shock absorber breather hose
@ F a n m o t o r c o n t r o lunit @ Battery negative lead (ground lead)
@Fan motor relay @ Starter motor lead
@ Starting circuitcut-off relay
0 Reverse relay
I
10 mm (0.4 in)
50 mrn
'r A 6-B C D-D E

I
I I 1 I
'L
I J-J 1-1 H-H
,. ..
G-G F-F K-K
1
I @Taillight lead
@I harness
Wire
@ Speedometer
@Oil
between
and
hose
cooler
cable
R Passthe startercablethroughthewireguide.
retor drain hose through themetal guide on
the swingarm.
FastentheStartermotorlead
clamp.
with a metal
Fadten the CDI magneto lead and thermo

unit lead with a metal clamp.
10 mm (0.4 in)
CABLE ROUTfNG
0Pass the speedometer
cable
tor drain hose towardthe

the engine
and
Fastenthebatterynegativelead
and
-
through
nPass the carburetor overflow hose
guide.
metal
the
the frame.
the carbure-
left side ofvehicle
the
(ground lead),
neutral switch/reverse switch lead, starter motor
Pass the carburetor overflow hose and carbu- lead, thermo unit lead and rear brake breather hose
with a plastic clamp.
Fasten the oil cooler hoses with a plastic locking
tie. The plastic locking tie should not be overtight-
ened.
Fasten the oil cooler hoses to the frame with a plas-
tic locking tie.
50 mm
1
I
' 7
I A B-B C
I
D-D
1
E
1 @
J-J 1-1 H-H G-G F-F K-K
0Selectlever
@ Gear motor
control cable
CABLE ROUTING
Pass differential
the gear
breather
hose
fan
and
r/
ID.
SPEC p
Pass the throttle cable throughthemetal guide.
motor
@ 4WD switch breather
hose through the holeright
the
in side
frame,
@ Rearbrake cable(brake lever) Fasten the fan motor breatherhoseand differential gear
@ Rearbrakecable (brake pedal) breatherhose with a plasticclip.
@ Fan motor breather hose m Pass the rearbrakecable(brake lever) throughthe metal
@ Differential gear
breather
hose
guide.
@ Gear motor lead
* ,
. ,
u
& w w a
4
B-B c-c D-D

A
- --
I @ Headlight lead
CABLE ROUTING
@ Rear brake breather hose
1-
@ Diode @ Final drive gear breather hose
@Wire harness @ Fuse lead
@ Throttle cable
0Select lever control cable
@ Main fuse
@Terminal fuse
@ Battery
@ Starter cable
@Taillight lead
*L,
A-A B-B
H Insert the wire harness T-joint into thehole in
the frame.
CABLE ROUTING
0Pass the final drive
m
DE
SPEC p
gear breather hose and
the rear brake breather hose over the air
filter
Pass the fuse lead under the battery positive case mounting bracket on the frame.
lead. Pass therearbrakebreatherhoseand the
a Pass the battery positive lead and the fuse final drive gear breather hose throughthe
lead through the holein the rear fender. metal guides on the swingarm.
a P a s s the battery negative lead through the Pass therearbrakebreatherhose through
hole in the rear fender. the metalguides on theswingarm.
' Pass theselect lever control cablebetween
the engine and the frame.
v
..--
L-L!J
k _ i
i u \
A-A
?
eB-B
CHAPTER 3.
1- E
PERIODIC INSPECTIONS AND ADJUSTMENTS
INTRODUCTION .......................................................................................... E-3
PERIODIC MAINTENANCE/LUBRfCATlON INTERVALS ........................... E-3
SEAT. CARRIERS. FENDERS AND FUEL TANK ......................................... E-4

SEAT ..................................................................................................... E-4
FRONT CARRIER. FRONT BUMPER AND FRONT FENDER ..............E-4
REAR CARRIER AND REAR FENDER .................................................. E-5
FUEL TANK .......................................................................................... E-5
ENGINE ........................................................................................................ E-6

VALVE CLEARANCE ADJUSTMENT .................................................. E-6
-
MENT CHAIN
d
TIMING ........................................................... E-7
IDLING SPEED ADJUSTMENT ........................................................... E-7
THROTLE LEVER FREE PLAY ADJUSTMENT ................................. E-8
SPEED LIMITER ADJUSTMENT ......................................................... E-9
SPARK PLUG INSPECTION ................................................................. E-9
IGNITION TIMING CHECK ................................................................. E-IO
COMPRESSION PRESSURE MEASUREMENT ................................ E-IO
ENGINE OIL LEVEL INSPECTION ..................................................... E-11
OIL TEMP WARNING LIGHT CHECK ................................................ E - I 1
ENGINE OIL REPLACEMENT ............................................................ e-12
AIR FILTER CLEANING ...................................................................... E-12
V-BELT INSPECTION ......................................................................... e-13
CHASSIS .................................................................................................... E-14

FRONT BRAKE ADJUSTMENT ......................................................... e-14
REAR BRAKE LEVER AND PEDAL ADJUSTMENT .......................... E-14
w FRONT BRAKE FLUID LEVEL INSPECTION ..................................... e-15
FRONT BRAKE PAD INSPECTION .................................................... e-16
REAR BRAKE SHOE INSPECTION .................................................... E-16
BRAKE HOSE INSPECTION ............................................................... E-16
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) .............................. E-16
SELECT LEVER CONTROL CABLEAND SHIFT ROD
ADJUSTMENT ................................................................................. F-1
FINAL GEAR OIL LEVEL INSPECTION ................................................ F-2
FINAL GEAR REPLACEMENT ............................................................. F-2
DIFFERENTIAL GEAR OIL REPLACEMENT ........................................ F-2
CONSTANT VELOCITY JOINT DUST BOOT INSPECTION ............... F-3
STEERING SYSTEM INSPECTION ...................................................... F-3
TOE-IN ADJUSTMENT ........................................................................ F-3
REAR SHOCK ABSORBER ADJUSTMENT ........................................ F-4
.
I E T q
TIRE INSPECTION ................................................................................ F-4
WHEEL INSPECTION ........................................................................... F-5
CABLE INSPECTION AND LUBRICATION .......................................... F-6
LEVERS, PEDAL, ETC . LUBRICATION ................................................ F-6
ELECTRICAL ................................................................................................. F-6

BATTERY INSPECTION ....................................................................... F-6
FUSE INSPECTION .............................................................................. F-9
HEADLIGHT BEAM ADJUSTMENT .................................................. F-10
HEADLIGHT BULB REPLACEMENT ..........................................i ....... F-10
-u
E8300003
INTRODUCTION/PERIODIC
MAINTENANCE/
LUBRICATION
INTERVALS

m]Em
INSP 0
INTRODUCTION
This chapter includes all information necessary to perform recommended inspections an d
adjustments. These preventive maintenance procedures, if followed, will ensure more re11-
able vehicle operation and a longer service life. The need for costly overhaul work will ble
greatly reduced. This information applies to vehicles already in service as well as to ne\N
vehicles that are being prepared for sale. All service technicians should be familiar withth'is
entire chapter.
E8301003
PERIODIC MAINTENANCE/LUBRICATION INTERVALS
-
-
ROUTINE
-
-
-
-
-
-
-
-
* Repair if necessary.
-
* Check bearing assemblies for looseness/darnage.
Wheelbearing'
Replace if damaged. 0 0 0 0
-
Front and rear * Check operation.
suspension' * Correct if necessary. 0 0
-
Stwring System,
-
* Check operation/replace if damaged.
Check toe-inladjust if necessary. 0 0 0 0 0
-
Check operation.
-
*
Front -le boots'
* Replace if damaged. 0 0
0 4
___
] PERIODIC
MAINTENANCE/LUBRlCATlON
INTERVALS m INSP 0
l
INITIAL EVERY
ITEM ROUTINE 1 3 6 6 1
month months months months year
* Check all chassis fittings and fasteners
FittingdFasteners.
- Correct If necessary 0 0 0 0 0
* It is recommended that these itemsbe serviced b y a Yamaha dealer.
NOTE:
Recommended brake fluid:DOT 4
(If DOT 4 is not available, DOT 3 can be used.)
Brake fluid replacement:
1.When disassembling the master cylinder or caliper cylinder, replace the brake fluid. Nor-
mally check the brake fluid leveland add fluidas required.
2.0n the inner parts of the master cylinder and caliper cylinder, replace the oil seals every
t w o years.
3.Replace the brake hoses every fouryears, or i f cracked or damaged.
,dicates a potential hazard that could result in serious injury o r death.

i-
- .-J
SEAT, CARRIERS, FENDERS AND FUEL TANK
m INSP 0
l -
I E-
I
SEAT
?{
” p
r /.9
\-” ‘ h ”/’
i / a
& &&
Q /-e- ‘ b , ,.r _
‘
~~ *
+
2
$
-A ~~ ~~~~~
Order Job narne/Part name Qty Remarks

Seat removal Remove theparts in the order below.
1 Seat 1 NOTE:
Y.- ”’
Pull up theseat lock lever, then pull up
on the rear of the seat.
For installation, reverse the removal
. procedure.
I SEAT, CARRIERS, FENDERS AND FUEL TANK m
INSP 0
l
FRONT CARRIER, FRONT BUMPER AND FRONT FENDER
Y-,
h [ 3 1Nrn (3.1m . kg, 22 f i . Ibl I
- - -
t""T
1;
~ ~~
- Job name/Part name Q'ty -- Remarks

-
Front carrier, front bumper and front Remove the parts in the order below.
fender removal
Seat Refer to "SEAT".
Terminal 1
Front carrier 1
Differential gear skid plate I
Front bumper 1
Headlight lead 2 Disconnect
Front fender 1
For installation, reversethe removal
- -
arocedure. -
1- ADJ E-
REAR CARRIER AND REAR FENDER
t t
' L Y
-- - Job name/Part name

7 --
Q'ty _. Remarks
-7
Order
__ _ _- -
Rear carrierand rear fender removal Remove theparts in the orderbelow.
Seat Refer t o "SEAT".
*-' 1 Rear carrier 1
2 Battery lead 2 Disconnect
First disconnect thenegative lead,

then
.~
~
disconnect the positive lead.
~
3 Battery holding bracket 1

4 Battery 1
5 Fuse 2
6 Plastic clamp 2
7 Lever grip I
8 Rear fender 1 I
IFor installation, reverse the removal
-- - ~
1 -
procedure. 4
-
1 SEAT, CARRIERS, FENDERS AND FUEL TANK m INSP 0
l
FUEL TANK
/sill
name/Part
Order
Jobname
>T#
1
Fuel tank removal
Front fender
Fuel hose
---
--
1
m y Remarks
Remove the partsin the order below.
Refer to "SEAT".
Refer to "FRONT CARRIER, FRONT
BUMPER AND FRONT FENDER".
-
-
NOTE:
Beforedisconnecting the fuel hose,
turn the fuel cock to "OFF".
~~~~
2 Fueltank 1 NOTE:
When installing t h e fuel tank, pass the
fuel tank breatherhosethroughthe
hole in the handlebar Drotector.
3 Plastic locking tie 2
4 Plastic band 2
5 Rubber cover 1
I I --- procedure. -
VALVE CLEARANCE ADJUSTMENT
ENGINE
mINSP 0
lp
NOTE:
Thevalveclearancemustbeadjusted
when the engineis cool to the touch.
Adjust the valve clearance when the pis-
ton is a t the Top Dead Center (T.D.C.) on
the compression stroke.
1.Remove:
Seat
Front carrier
Front fender
Fuel tank
Refer to "SEAT, CARRIERS,
FENDERS
AND FUEL TANK".
k-4
2.Remove:
Air duct @
Tappet cover (intake)@
Tappet covers (exhaust)@
3.Disconnect:
Spark plug cap @
4.Remove:
Spark plug
~~ ~~
5.Remove:
Recoil starter @
1 VALVE CLEARANCE ADJUSTMENT
6.Remove:
mINSP 0
l
Timing plug 0
7.Check:
Valve clearance
Out of specification -+Adjust.
-
Valve clearance lcold):
- -
Intake:
-
0.05 0.10 mm (0.002 0.004 in)
W
-
Exhaust:
-
0.12 0.17 mm (0.005 0.007 in)
-
**************X*******************
Checking steps:
.Turn the crankshaft counterclockwisewith
a wrench.
.Align the "I" mark @ on the rotorwith the
stationarypointer @ onthe crankcase
cover. When the "I" mark is aligned with
the stationary pointer, the piston is a t the
Top Dead Center (T.D.C.).
NOTE:
When the piston isa t the top dead center
(TDC) on the compression .stroke, there
shouldbeclearancebetween the valve
stem tips and their respective rocker arm
adjusting screws.
b
-
If there is no clearance, rotate the crank-

shaft counterclockwise one turn.
@Measure the
valve
clearance
using a
feeler gauge 0.
..................................
~~~

8.Adjust:
mINSP 0
l -
I El
I
Valve clearance
***XX*+X******tK~KYX**************
Adjustment steps:
0 Loosen the locknut0.
.Insert a feelergauge @ betweenthe
adjuster end and the valve end.
.Turn the adjuster @ clockwise or counter-
clockwise with the valve adjusting tool @
until the proper clearance is obtained.
Valve adjusting tool:

P/N. YM-08035,90890-01311
*Hold the adjuster to prevent it from mov-

ing and then tighten the locknut.
Locknut:
b%
.
14 Nm (1.4 m kg, 10 ft Ib)
~ M e a s u r the
e valve clearance.
.If theclearance is incorrect,repeatthe
above steps until the proper clearance is
obtained.
******I*X*******X*****************
9.lnstall:
All removed parts
NOTE:
Installallremovedparts in- thereverse
.- order of their disassembly. Note the follow-
ing points.
10.lnstaII:
f=a
Recoil s t a r t e r a
k l l 0 Nm (1.0m . kg, 7.2 ft . Ibjl
Spark plug [kt18Nm (1.8 m kg, 13 ft * Ib)l
I I
Tappet covers (exhaust)
+
k l l 0 Nm 11.0 m . kg, 7.2 ft Ib)l 4
Tappet cover (intake)

h [ l ONm (1.0 m . kg, 7.2 ft . lbll
NOTE:
Installtheintaketappetcoverwiththe
arrow pointing - upward.
.
1 VALVE CLEARANCE ADJUSTMENT/TIMING CHAIN
ADJUSTMENT/IDLING SPEED ADJUSTMENT
1?.Install:
m]
lNSP 0
I L 1 s >\ \ I Air duct 7 (J

NOTE:
Install the air ductso that p a r t @ aligns with
part 0.
. .. .. . . . .
1
12lnstall:
Fuel tank
Front fender
e Front carrier
Seat
Refer to "SEAT, CARRIERS, FENDERS
AND FUEL TANK".
x 4
TIMING CHAIN ADJUSTMENT

Adjustment free.
I
IDLING SPEED ADJUSTMENT
I 2 3-PG-C- 1.Start the engine and let it

several minutes.
2.Attach:
warm up for
Inductive tachometer or engine tachometer
1 I
..
L
I
i
-
I
(to the spark plug lead)
~~
3.Check:
Inductive tachometer:
P/N. YU-8036-A
Engine tachometer:
P/N. 90890-03113
I
Engine idling speed

Out of specification + Adjust.
n Engine idling speed:

.-
1,350 1,450 r/min
a
IDLING SPEED ADJUSTMENT/
THROlTLELEVERFREEPLAY ADJUSTMENT
4.Adjust:
mlNSP 0
l lx
l7‘-’
\
Engine idling speed
..................................
Adjustment steps:
*Turn in the pilot screw (iJ
until it is lightly
seated.
.Turn out the pilot screw for the specified
number of turns.
Pilot screw (turns out):

3 1/2
.Turn the throttle stop screw @ in or out

until
the
specified
idling
speed is
obtained.
I
Turn in I Idlingspeedbecomeshigher. 1
I
I Turn out I Idling speed becomes lower.
1 ~~ ~~ I ~~~~
~- ~~
I I
L-4
..................................
5.Detach:
Engine tachometer
6.Adjust:
Throttle lever free play
Refer to “THROTTLE LEVER FREE PLAY
ADJUSTMENT“.
Throttle lever freeplay:

- -
3 5 mm (0.12 0.20 in)
THROTTLE LEVER FREE PLAY

ADJUSTMENT
NOTE:
Engineidlingspeedshouldbeadjusted
‘
L properly before adjusting the throttle lever
free play.
1.Check:
Throttle lever free play8
Out of specification +Adjust.
0 ,. -
Throttle lever freeplay:
3 5 mm (0.12 0.20 in)
* 4 4
I THROlTLE LEVER FREE PLAY ADJUSTMENT
2.Remove:
l INSP 0
m
Seat
Front carrier
Front fender
Fuel tank
Refer to “SEAT, CARRIERS, FENDERS
AND FUEL TANK”.
I I 3.Adjust:
Throttle lever free play
*******************x**************
Adjustment steps:
First step:
*Pull back the adjuster cover0.
.Loosen the locknut @ on the carburetor
side.
f- _.‘ *Turn the adjuster@ in or out until the cor-
I I
rect free playis obtained.
Turning in Free play isincreased.

Turning out Free play is decreased.
*Tighten the locknut 0.

*Push in the adjuster cover 0.
NOTE:
If thefreeplaycannotbeadjusted here,
adjust it a t thethrottle fever side of the
cable.
c
Second step:
Pull back the adjuster cover0.
0 Loosen t h e locknut 0.
*Turn the adjuster @ in or out until the cor-
.“+I
rect free playis obtained.
Turning in Free play isincreased.

Turning out Free play is decreased.
-
I I
*Tighten the locknut 0.

0 Push in the adjuster cover0.
After adjusting the free play, turn the handle-

bar to the right and left t o make sure that the
engine idling speed doesnot increase.
..................................
~
THROTTLE LEVER FREE PLAY ADJUSTMENT/

SPEED LIMITER ADJUSTMENT
4.lnstall:
r l q IE
lNSP
ADJ
Fuel tank
Front fender
Front carrier
Seat
Refer
to "SEAT, CARRIERS, FENDERS
AND FUEL TANK".
SPEED LIMITER ADJUSTMENT

Thespeedlimiter keeps thecarburetor
throttle from becoming fully-opened even
w h e n the throttle lever isappliedto the
m a x i m u m position.
Screwing the
in
adjuster stops
the
engine
speed from
increasing,
'-'
1.Check:
Speed limiter length 8
Out of specification -+ Adjust.
Speed limiter length:

12 m m (0.47 in1
A
2.Adjust:
0 Speed limiter length
..................................
Speed limiter length adjustment steps:

>- @ Loosen the locknut 0.
@Turn the adjuster @ in or out until the
specified speed limiter length is obtained.
I
Speed limiter length is
Turning in decreased.
Speed limiter lengthis
Turning Out increased.
9
~ ~~ ~~
I ~~~~ ~ I
*Tighten t h e locknut.
Particularlyforabeginnerrider,the
speed limiter should be screwed in com-
pletely. Screw it out little by little as their
riding technique improves. Never remove
A
,- t h e speed limiter for a beninnina rider.
I SPEED LIMITER ADJUSTMENT/
SPARK PLUG INSPECTION [m[NSP
For proper throttle lever operation do not

0
turn out the adjuster more than 12 mm

(0.47 in]. Also, always adjust the throttle
- -
lever free playto 3 5 m m (0.12 0.20 in).
~
..................................
SPARK PLUG INSPECTION

1.Rernove:
Spark plug
2.lnspect:
Spark plug type
Incorrect + Replace.
Standard spark plug:

for USA
%-/
DP8EA-S/NGK
for Canada
DPRSEA-S/NGK
3.lnspect:
Electrode 0
Wear/damage -+ Replace.
Insulator @
Abnormal color -+ Replace.
Normal coloris a rnedium-to-light tan color.
377." 4.Clean thesparkplug with a spark plug
cleaner or wirebrush.
5.Measure:
Plug gap 8
fl
Use a wire gauge or feeler gauge.
Out of specification + Regap.
-
Spark plug gap:
-
I
- ,
'
@ 0.8 0.9 mm (0.031 0.035 in)

A
6.Tighten:
377 aa Spark plug h ( 1 8Nm (1.8 m . kg, 13 ft .Ib) I
NOTE:
Beforeinstallinga spark plug, cleanthe
gasket surface andplug surface.
IGNITION TIMING CHECK
IGNITION TIMING CHECK
1- AD J JE-
NOTE:
Engine idling speed and throttle cable free
playshouldbeadjustedproperlybefore
checking the ignition timing.
1.Attach:
Inductive tachometer or engine tachometer
Timing light
(to spark plug lead)
H Inductive tachometer:
P/N. Y U-8036-A
Engine tachometer:
P/N. 90890-031 13
Timing light:
P/N. YM-33277-A; 90890-03141
I 1
--”
2.Check:
Ignition timing
*********x************************
Checking steps:
.Warm up theengine a n d keep it at the
specified speed.
~
I I
fi Engine speed:
-
1,350 1,450 r/min
h
.Remove the recoil starter 0.
Remove the timing plug0.
oVisually check the stationary pointer @ t o
verify it is within the required firing range
@ indicated on the flywheel.
incorrect firing range -+ Check the puiser
coil assembly.
0 Install the timing plug.
0 Install the recoil starter.
Recoil starter bolt:

L
b%
I
O$( ; ! ; ; m kg, 7.2 ft Ib)
I
*******************Y~*YYYY********
I I
1 COMPRESSION PRESSURE MEASUREMENT
COMPRESSION PRESSURE
MEASUREMENT
m INSP 0
NOTE:
Insufficient
compressionpressure will
result in a loss of performance.
~ ~ ~~ ~
1.Check:
Valve clearance
Refer t o "VALVE CLEARANCE ADJUST-
MENT".
2.Start the engine a n d let it w a r m up for
several minutes.
3.Stop the engine.
--'
4.Remove:
Spark plug
- 5.Attach:
Adapter
Compression gauge @
I Compression gauge:
P/N. YU-33223,90890-03081
I
Adapter:
P/N. YU-33223-3,90890-04082
.
1 ~~ I
6.Measure:
Compression pressure
Above the maximumpressure:
Inspect the cylinder head, valve surfaces,
*3
'.J
and piston crown forcarbon deposits.
Below the minimum'pressure:
Squirt a few drops of oil into the affected
cylinder and measure again.
Refer to the table below.
Compression pressure
(with oil introduced into cylinder)
Diagnosis Reading
I~
I
~ 1 Worn or~damaged~pistons I :
I I
~
Defective ring(s1, valves,
Same as
cylinder head gasket or
without Oil
I I
piston ispossible. I
-
COMPRESSION PRESSURE MEASUREMENT/ lNSP

ENGINE OIL LEVEL INSPECTION AD J1
IIE- I
0
Compression pressure (at sea level):

Standard:
850 kPa (8.5 kg/cm2, 121 psi)
Minimum:
800 kPa (8.0 kg/cm2, 114 psi)
Maximum:
900 kPa (9.0 kg/cm2, 128 psi)
L I
*+******+*******x*****************
Measurement steps:
*Crankovertheengine with the electric
starter
(besure the batteryfully
is
charged) with the throttle wide-open until
the compressionreadingonthegauge
stabilizes.
-.e'
When cranking the engine, ground the
spark plug lead t o prevent sparking.
**XKXX****XXX***X**X*~*******~**~*
7.lnstall:
Spark plug 1b&3 Nm (1.8 m . kg, 13 ft . Ib) 1
//(.h.rY-
ENGINE OIL LEVEL INSPECTION
1.Place the machine ona level surface.
2.lnspect:
Engine oil level
[*,
Oil level shouldbe between the maximum
0and minimum@ marks.
Oil level low -+ Add oil t o the proper level.
@ _- --
@I
I I
4a Recommended oil:
Follow the left chart.
1 0" IO" 30"

50" 70" 90" 110'F
NOTE:
Recommended oil classification:
! ! I I I I I 1
i YAMA!.UBE 4 !20W40l,or SAE.20W40 i
i f : c : API Service "SE", "SF" type or equivalent
I I
j +AMALUEE 4 ( l b w 3 0 ) dr SAE ~bwm j (e.g. "SF-SE-CC", "SF-SE-SD" etc.)
t j
4 ;
:
-I
ISAE5W30
-4 i :
ygg@@gj*&F$
<*::*-,:.,-:.>::,>:>.,~,:
,. I: :*e:
&o l 0.
-
;
y ,io 200 io* &c :
'
Do not allow foreign material to enter the

crankcase.
I I
1 ENGINE OIL LEVEL INSPECTION/
OIL TEMP WARNING LIGHT CHECK
3.Start the engine and let
m lNSP
it w a r m up for
0
several minutes.
4.Stop the engine and inspect the oil level
again.
NOTE:
Wait a fewminutes until the oil settles
before inspecting theoil level.
X’.-
OIL TEMP WARNING LIGHT CHECK
----
‘4
?&&f- * [@I Lr
--/ A-
-
@ Oil temp indicator light
Oil temp warning light checking method.
Main switch “ON“. ___.________---_____

‘+.” Engine stop switch“RUN”.
I
t t
Oil temperature light does Oil temperature
not come on. light comes on.
I 1
Push starter switch with Check engineoil
transmission in “NEUTRAL“. temp.
I
f t 1 -
Oil temperature Oil temperature light Oil temp. temp.Oil i
light comes on. is low. is high. does not come on.
I
Engine oil temperature
I
i
Refer to “SIGNAL
1
4
Cool the engine oil.
and electrical circuit are SYSTEM” in CHAPTER8.
OK. Go ahead with riding.
ENGINE OILREPLACEMENT
ENGINE OIL REPLACEMENT
mE
INSP 0
1.Start the engine and let it warm up for

several minutes.
2.Stop theengine and place an oil pan
under the engine.
3.Remove:
Oil filler plug @
Drain plug (engine oil)@
Drain the crankcase of its oil.
I I
4.lf the oil filter is to be replaced during this

oil change, removethefollowing parts
a n d then reinstall them afterwards.
..................................
Replacement steps:
aRemove the oil filter cover @ and oil filter
element 0.
0 Check the O-ring 0; if they are crackedor
damaged, replace them with newones.
.Install the oil filter element and oil filter
cover.
k Bolt (oil filter cover):

10 Nm (1.0 m kg, 7.2 ft
**********X***********************
Ib)
5.lnstall:
Drain plug (engineoil) @
-
h i 2 3 N m (2.3m kg, 17 ft Ib) + I
] ENGINE
OIL
REPLACEMENT/ AIR FfLTER CLEANING
6.Fill:
mINSP Q
l
Crankcase
Refer to "ENGINE OIL LEVEL INSPEC-
TION".
Oil quantity:
hQ* Total amount:
2.6 L (2.3Imp qt, 2.7 US qt)
Periodic oil change:
1.9 L (1.7 Imp qt, 2.0 US qt)
With oil filter replacement:
2.0 L (1.8 Imp qt, 2.1 US qt)
7.lnstall:
Oil filler plug
8.Warm up the engine for a few minutes,
then stop the engine.
9.lnspect:
Engine
(for oil leaks)
L'
Oil level
AIR FILTER CLEANING
NOTE:
There is a check hose @ a t the bottom of
the air filter case. If dust and/or water cot-
' lects in this hose, clean the air filter element
and air filter case.
1.Remove:
Seat
AND FUEL TANK".
Air filter case cover @
2.Remove:
~~
Air filter element assembly0

0 Air filter element cap
Air filter element

NOTE:
When removingthe air filter element, rotate
the air filter element cap 1/4 of a turn and
remove the element.
-
AIR FILTER CLEANING
@ Air filter element cap
1- ADJ IE-
@ Air filter element
:,<{:cAuTl#@.;,;
1.1
..... ,._,,..'_, .
<.,
Never operate the engine with the air filter

element removed. This will allow unfiltered
air t o enter, causing rapid wear and possible
engine damage. Additionally, operation
without the filter element will affect carbu-
.. retor tuning with subsequent poor perfor-
mance and possible engine overheating.
3.lnspect:
Air filter element
Damaged 4 Replace.
& +p& 4.Clean:

Air filter element
****X***********X****************X
@:x
+ .).;.
: I
Cleaning steps:
.Wash the element gently, but thoroughly
in solvent.
ddb 356-Ml
Use a cleaning solvent which is designed

t o clean parts only. Never use gasoline or
low flash~point solvents as they maycause
a fire or explosion.
.Squeeze the excess solvent out o f the ele-
ment and let it dry.
t_.-
:y,"w,'c:.' :.-.,-_.<<,>*v,,,.++:*
<@@AUTjgJ&$E.$
:c .e,..<*,+..G:>,,<...*.YhO
Do n o t t w i s t owring
r out t h e element. This
could damage the foam material.
~~~~
*Apply engine oil to theelement.

*Squeeze out the excess oil.
NOTE:
The element should be wet but not drip-
ping.
********X*************************
~ ~~
,/ *", -
!I m INSP 0
l
q/a\
AIR FILTER CLEANING/V-BELT INSPECTION
I ,
I
5.1nstall:
$4 r
i ,
Air filter element

Air filter case cover
Seat
$$g -
I 0 0
NOTE:
Insert the lobes 0 on the filter element
into the receptacles0on the filtercase.
To prevent air leaks make sure that the
sealingsurface of theelementmatches
the sealing surface of thecase.
V-BELT INSPECTION
1.Remove:
Air duct assembly0
Footrest board (right)@
Crankcase cover (right)@
Refer to "PRIMARY AND SECONDARY
SHEAVES" in CHAPTER 4.
2.lnspect:
yra3
V-belt @
I CracksANear/Scaling/Chipping + Replace.
OilKrease .+ Check primary sheave and
secondary sheave.
3.Measure:
V-belt width @
>
Out of specification + Replace.
c V-belt width:
32.0 mm (1.26 in)
<Limit:> 30 mm (1.18 in)
4.Replace:
I -1.0 mm (0.04 in) I I
V-belt
I 6mm
(0.24in)
I
******Y*********f**f~**********Y**
Replacing steps:
0 (90101-06016)
@Install the bolts
into the secondary fixedsheave hold
NOTE:
Tightening the bolts (iJ will push the sec-
I \ r/- ondaryslidingsheave away, causingthe
gap between the secondary fixed and slid-
inn
- sheaves to widen.
~ R e m o v ethe V-belt (iJ from the primary
sheave and secondary sheave.
I I
b -n
V-BELT INSPECTION
olnstall theV-belt.
1- ADJ IE-
NOTE:
lnstall the V-belt so that its arrow faces the
direction shown in the illustration.
0 Remove the bolts.
*******Y*********+****************
I I
;-I
\
I
,
1 FRONT BRAKE ADJUSTMENT/
REAR BRAKE LEVER AND PEDAL ADJUSTMENT
CHASSIS
m
lNSP
l
FRONT BRAKE ADJUSTMENT
@ 1,Check:
Brake lever free play 8
>
Out o f specification +.Adjust.
Free play:
-
2 -,5 mm (0.08 0.20 in)
( a t brake lever end)
1 i
2.Adjust:
Brake lever free play
X*XX*X*+*X*****X**X**~**~*********
Adjustment steps:
! e Loosen the locknut 0.
.Turn theadjuster @ in or out until the
specified free play is obtained.
- , Turning in Free play is decreased.
~
Turning out Free play is increased.

~~
.Tighten the locknut.
;j?&@f~@&:;,
Make sure that the brake does not drag
after adjustingit.
A soft or spongy feeling in the brake lever

can indicate the presenceair ofin the brake
system.Thisairmustberemovedby
bleedingthebrake
system beforethe
machine is operated. Air in the systemwill
cause a greatly diminished braking capabil-
*i ity and
result
can i n acontrol
loss of
and an
accident. Inspectand if necessary bleed the
system.
..................................
REAR BRAKE LEVER AND PEDAL

ADJUSTMENT
Always adjust both the brake pedal and the

rearbrakeleverwheneveradjustingthe
rear brake.
I
REAR BRAKE LEVER AND PEDAL ADJUSTMENT
\ 1 I 1.Check:
mIE
ADJ
Rear brake pedal free play@

Rear brake lever freeplay a
Out of specification -+Adjust.
a:
\1
Rear brake pedal free play
-
20 30 mm (0.8 .,1.2 in)
Rear brake lever freeplay @:
..- -..
-. -
5 7 mm (0.20 0.28 in) -
I I
\,e
2.Adjust:
Free play (rear brake lever)
Free play (brake pedal)
....................................
Rear brake lever and brake pedal free play
adjustment steps:
NOTE:
Beforeadjustingthefree play, pump the
brake pedal2 t o 3 times.
.Fully loosen the brake lever cable adjuster
(drum) 0.
@Turn the rear brake pedal rod adjuster @
until the brake pedal free play is within
the specified limits.
Free play (brake pedal):

-
20 30 mm (0.8 1.2 in) -
I I @Fully
screw in the
brake
lever
cable
adjuster (handlebar) 0.
I I @Turn thebrake lever cable adjuster(drum)
0clockwise until the gap@ is within the
specified limits.
Gap 0:
Zero - 1 mrn (0.00 - 0.04 in)
- --
I REAR BRAKE LEVER AND PEDAL ADJUSTMENT/
FRONT BRAKE FLUID LEVEL INSPECTION
olnspect the freeplay(brakepedal)
m[INSP
to see
whether or notit is within the specified lim-
its. If not, perform the abovesteps again.
Free play (brake pedal):

-
20 30 mm (0.8 1.2 in) -
oLoosen the locknut (handlebar) 0.
.Turn the brake lever cable adjuster (han-
?
dlebar) 0 until the free play (brake lever)
is within the specified limits.
Free play (brake lever):
-
5 7 mm (0.20 0.28 in) -
.Tighten the locknut (handlebar)0.
After this adjustment is performed, lift the

front and rearwheels off the ground by
-4
placing a block under the engine, and spin
the rear wheels t o ensure there is no brake
drag. If any brake drag is noticed perform
the above steps again.
Y , X * ~ t * * * % % Q % X Q Y X X * % % % % * * * % ~ - ~ * * * % ~
FRONT BRAKE FLUlD LEVEL INSPECTION

1.Place the machine ona level surface.
NOTE:
When inspecting the front brake fluid level,
x-,
make sure that the top of the master cylin-
der top i s horizontal.
-
2.lnspect:
Brake fluid level
Fluid level is under "LOWER" level line 0
+ Fill up.
I I
/o o
\ l'ql Recommended brake fluid:
DOT4 I
I
k[ T I L
id
1
NOTE:
If DOT 4 is not available, DOT 3 can be
used.
-,
FRONT BRAKE FLUID LEVEL INSPECTION/FRONT BRAKE

PAD lNSPECTION/REAR BRAKE SHOE INSPECTION
$gA-#,JTiQp&.
. .
mlNSP 0
l IE-l
,-.
~ . .
Brake fluid may erode painted Surfaces or
plastic parts. Always clean up spilled fluid
immediately.
Use only the designed quality brake fluid:

otherwise, the rubber seals may deterio-
rate, causing leakage and poor brake per-
formance.
Refill with the same type of brake fluid;
mixingfluidsmayresultin a harmful
chemical reactionand lead to poor perfor-
mance.
Be careful t h a t water does not enter the
master cylinder when refilling. Water will
significantly lower the boiling point of the
._I
fluid and may result in a vapor lock.
b
FRONT BRAKE PAD INSPECTION
1.Remove:
Front wheels
2.lnspect:
Brake pad
Wear indicators @ almost touch the brake
disc --f Replace the brake pads as a set.
Refer to "FRONT AND REAR WHEELS" in
CHAPTER 7.
3.0perate the brake lever.
4.lnstall:
Front wheels
X.-/'
REAR BRAKE SHOE INSPECTION

1.Operate therear brakelever or brake
pedal.
2.lnspect:
Wear indicator @ reaches the wear limit
line @ + Replace the shoes as a set.
Refer to "REAR BRAKE" in CHAPTER 7 .
__ - -
I BRAKE HOSEINSPECTION/
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)
BRAKE HOSE INSPECTION
mlNSP 0
1.Remove:
Seat
Front carrier
Front fender
AND FUEL TANK”.
2.lnspect:
Brake hoses @
Crackslwearidamage -+ Replace.
XCheck:
Brake hose clamp
Loosen -+ Tighten.
4.Hold the machine in an upright position
and apply the frontor rear brake.
5.Check:
Brake hoses
Active the brake leverseveral times.
Fluid leakage -+ Replace the hose.
Refer to “FRONT BRAKE” in CHAPTER 7. .
6.lnstall:
Front fender
Front carrier
Seat
AND FUEL TANK“.
AIR BLEEDING (HYDRAULIC BRAKE

SYSTEM)
‘-J brake Bleed the system if

The system has been disassembled.
A brake hose or brake pipe have been
loosened or removed.
The brake fluid has beenvery low.
The brake operation has been faulty.
A loss of braking performance may occur if
the brake systemis not properly bled.
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)
1.Bleed:
mp
INSP 0
Brake system
..................................
Air bleeding steps:
a. Add the proper brake fluid to the reser-
voir.
b. Install the diaphragm. Be careful not to
spill any fluid or allow the reservoir t o
overflow.
c. Connect the clear plastic hose 0 tightly
to thecaliper bleed screw 0.
d. Place the other end of the hose into a
container.
e. Slowly applythebrakeleverseveral
times.
f. Pull the lever in and hold.it.
g. Loosenthebleedscrewand allow the
lever to travel towards itslimit.
h. Tighten the bleed screw when the lever
*-, limit has been reached, then release the
lever.
i. Repeatsteps (e) to (h) until all theair
bubbles have disappeared from the fluid.
j. Tighten the bleed screw.
Bleed screw:
b&+ 6 Nrn (0.6 rn kg, 4.3 ft ib)
NOTE:
If bleeding is difficult, it may be necessary
to let the brake fluid settle for a few hours.
Repeat thebleedingprocedurewhenthe
tinybubbles in thesystemhavedisap-
peared.
k. Add brake fluid to the proper level.
Refer to "BRAKE FLUID LEVEL INSPEC-
TION".
\--I
Check the operation of thebrakeafter

bleeding thebrake system.
..................................
A ,.A
1 SELECT LEVER CONTROL CABLE AND SHIFT ROD
ADJUSTMENT
SELECT LEVER CONTROL CABLE AND
l 1NSP 0
m
SHIFT ROD ADJUSTMENT
0NEUTRAL
@HIGH
@ LOW
@ REVERSE
@ Control cable
@ Select lever shift rod
Before moving the select lever, bring the

machine to a complete stop a n d return t h e
throttle lever to itsclosed position. Other-
wise the transmission may be damaged.
1.Adjust:
Rear brake pedal free play
Refer to “REAR BRAKE LEVER AND
PEDAL ADJUSTMENT”.
2.Adjust:
Select lever control cable
Select lever shift rod
*X*X***+l**YY*Y**Y*********~******
Select lever control cable and select lever

shift rod adjustmentsteps:
Control cable:
*Make sure the select lever is in NEUTRAL.
*Adjust the control cable so there is zero
free play in the cable. When the adjust-
ment is correct, slack in the return spring
@ w i l l be taken up.
NOTE:
In some cases it will be necessary to further
adjust
the
cable with thelocknuts @
arrangement that holds the cable to its
mount.
*When the brake begins to work ”@=20 -
-
30 mm (0.8 1.2 in)”, verify that the select
levercan be shiftedto REVERSE from
NEUTRAL and to NEUTRAL from
REVERSE.
.Before the brake begins to work “@=O -
-
20 mm (0 0.8 in)“, verify that the select
lever cannot be shifted to REVERSE from
NEUTRAL and to NEUTRAL from
REVERSE.
_.
LTGc
Ej
SELECT LEVER CONTROL CABLE AND SHIFT ROD ADJUSTMENT/
FINAL GEAR OIL LEVEL INSPECTION/ INSP 0
FINAL GEAR REPLACEMENT
- .. aCheck that locknuts 0 are tightened cor-

rectly.
a If the operation of the select lever is incor-
rect, adjust the select lever control cable
@ w i t h t h eadjuster 0.
Ic=%i Select lever shift rod:

a Make surethe select lever is in NEUTRAL.
a Loosen both locknuts0.
*Adjust the shift rod length8.
Select lever shift rod length:

274 mm (10.8 in)
.Tighten the locknuts 0.

***************Y**+***************
FINAL GEAR OIL LEVEL INSPECTION

1.Place the machine on a level place.
2.Remove:
Oil filler bolt0
3.lnspect:
Oil level
Oil level should be up to the bottom brim
@ of the hole.
I I u Oil level low -+ Add oil to the properlevel.
bq Recommended oil:
SAE80 API "GL-4" Hypoid gear oil
rni@%yi&@$2
lu-'
*.,+ :... ..,-.,->.::.>......
%.
.. e,.:+.
2. .....i
Take care not allow foreign materialto

enter thefinal gear case.
4.lnstall:
Oil filler bolt 1
1kI23 Nrn (2.3rn . kg, 17 ft * Ib)
b
FINAL GEAR REPLACEMENT
1.Place the machine on a level surface.
2.Remove:
Final gear case protector @
3.Place a receptacleunderthefinal gear
case.
b
FINAL GEARREPLACEMENT/
DlFFERENTlAL GEAR OIL REPLACEMENT
4.Remove:
m lNSP 0
l
Oil filler bolt
Drain plug ( i
J
5.Drain:
Final gear oil
6.lnstall:
Drain plug 1k.123Nm (2.3m . kg, 17 ft . Ib) I
NOTE:
Check the gasket (drain plug). If it is dam-
aged, replace it with a new one.
7.Fill:
Final gear case
.d
'9 .
0.19 L (0.17 Imp qt, 0.20 US qtl
Total amount:
0.22 L (0.20 Imp qt, 0.23 US qt)
Recommended oil:
SAE80 API "GL-4" Hypoid gear oil
@e&?d;f(&Q+
.:,
!$+ 2
"
:~!;
,~..,
' .*..;',:; #.%
I
,
...
Take care not to allow foreign

- material t o
enter the final gear case.
8.lnspect:
Oil level
Refer to "FINAL GEAR OIL LEVEL INSPEC-
TION".
9.1nstall:
./ Oil filler bolt b 1 2 3 Nm (2.3m ' kg, 17 ft . Ibl I
Final gear case protector
1&116 Nrn (1.6 m . kg, 11 ft . Ib) I
DIFFERENTIAL GEAR OIL REPLACEMENT

>dg/ 2.Place a receptacle under the differential
3!5@!$!!Y
gear case.
3.Remove:
Oil filler bolt
Drain plug @
l-&mlE
DIFFERENTIAL GEAR OIL REPLACEMENT/
CONSTANT VELOClTY JOINT DUST BOOT INSPECTION/ INSP
STEERING SYSTEMINSPECTION
4.Drain:
Differential gear oil
5.lnstall:
Drain plug h 1 1 9 Nm (1.9 m . kg, 13 f3 . Ib) 1
NOTE:
Check the gasket (drain plug). If it is dam-
aged, replace it with new one.
6.Fill:
Differential gear case
I
'Q 0.7 L (0.62 Imp qt, 0.74 US qt)
Total amount:
0.67 L (0.59 Imp qt, 0.71 US qt)
Recommended oil:
SAE 80 API "GL-4" Hypoidgear
oil
.......: ,.. ... .,

Z;;j;;CA+Jq"IQM:=
: j ,: I _ . . , _ ~ I_)
:
L-
.
,
......
,:A%... .. *.. xx_,,
Take care not t o allow foreign material to

enter the differential gear case.
7.lnstall:
oil filler bolt .
h 1 2 3 Nm (2.3 m . kg, 17 ft ib) [
CONSTANT VELOCITY JOINT DUST BOOT

INSPECTION
1.Inspect:
0 Dust boots @
Damage 4 Replace.
Refer to "DIFFERENTIAL GEAR AND CON-
STANT VELOCITY JOINT" in CHAPTER 6.
STEERING SYSTEM INSPECTION

2.Check:
Steering assembly bushings
Move the handlebarup and down, and/or
back and forth.
Excessive play 4 Replace the steering
stem bushings.
I STEERING SYSTEMINSPECTION/
TOE-IN ADJUSTMENT
3.Check:
Em [NSP
ADJ
0
Tie-rod ends
Turn the handlebar to the left and/or right
until it stops completely, then move the
handlebar fromthe
left
to
the
right
slightly.Tie-rodend 0 hasanyvertical
play --f Replace the tie-rod end(s).
+
I
,
~~ ~~ ~ ~ ~~ ~~
,
1
1
I / /
4.Raise the front end of the machine so that
there is no weightonthefrontwheels.
5.Check:
Ball joints and/or wheel bearings
Move the wheels laterallyback and forth.
Excessivefreeplay --f Replace the front
arms(upper and lower)and/orwheel

bearings.
1 I
TOE-IN ADJUSTMENT
2.Measure:
Toe-in
.
d Out of specification --f Adjust.
-
-
-
Toe-in:
5 5 mm (4.20 0.20 in) -
***************X******************
Toe-in measurement steps:

NOTE:
Before measuringthe toe-in, make sure that
the tire pressure is correct.
0 Mark both front tire tread
centers.
@Raise thefront end of the machine so that
there is no weight on the front tires.
*Face the handlebar straightahead.
I I
TOE-IN ADJUSTMENT
I 0 Measurethewldth
mEINSP 0
betweenthemarks.
t
i
a i
.Rotate the front tires 180" until the marks
are exactly opposite one another.
Measure the width between the marks.
calculate the toe-inusingtheformula
given below.
Toe-in = a-
If the toe-in is incorrect, adjust it.
1
Y**X*X******~*X~tn********~*******
3.Adjust:
Toe-in
Be sure that both tie-rods are turned the

sameamount. I f not, themachine will
drift right orleft even t h o u g h t h ehandle-
bar is positioned straight. This may lead
-J t o mishandling and an accident.
After setting the toe-in t o specification. run
the machine slowly for some distance with
both hands lightly holding the handlebar
and check that thehandlebar responds cor-
rectly. If not, turn either the right or left tie-
rod within the toe-inspecification.
*X****X********X+*****************
Adjustment steps:
Mark both tie-rodsends.
This reference point will be needed during
. adjustment.
.Loosen the locknuts(tie-rodend) 0 of
both tie-rods.
.The samenumber of turnsshouldbe
given to both the right and left tie-rods @
until the specified toe-in is ,obtained. This
is to keep the length of the rodsthe same.
.Tighten
- the rod end locknuts ofboth tierods.
lkl
I
I ...
I
Locknut (rodend):
15Nrn(1.5rn*kg,Ilf%*Ib)
NOTE:
I Adjust the rod ends so that A and 6 are

equal.
~*~~~*******Y**Y***YY*KYYXX**t*tYY
I 1
1 REAR SHOCK ABSORBER ADJUSTMENT/
TIRE INSPECTION mJ
[NSP
#
- REAR SHOCK ABSORBER ADJUSTMENT
1
1.Adjust:
a Spring preload
Turn the adjusting lever @ to soften 8or
harden @ t h e spring preload.
+
\ NOTE:
The
spring
preload of t h e rear shock
absorber can be adjusted to suit the rider's
preference,weight, andtheridingcondi-
tions.
2.Lubricate:
Adjusting lever pivot
J
-
Recommended lubricant:
I Balljoint:
Yamaha chain and cable lubeor
engine oil
Lever pivot:
Lithium soap base grease
TIRE INSPECTION
This model is equipped with low pressure

tires. It is important that they be inflated
correctlyandmaintainedattheproper
pressures.
0TIRE CHARACTERISTICS
1)Tirecharacteristicsinfluence thehan-
dling of ATV's. The t i r e s listed b e l o w
have been approved b y Yamaha Motor
L d thisLtd. for
Co.,
model. com- tireIf other
binationsare used, they canadversely
affect your machine's handling charscter-
istics
and
are
therefore
not
recom-
mended.
I*0
Front
Manufacturer
Size
DUNLOP
TIRE PRESSURE
AT25x8-12
DUNLOP
tCTl22
AT25xlO-10 KT126
1)Recommended tire pressure

Front 30 kPa (0.30kg/cm2, 4.3 psi)
Rear 27.5 kPa (0.275 kg/cm2, 4.0 psi)
TIRE INSPECTION m
INSP
PlTire pressure below theminimum specifi-

cation could cause the tire to dislodge
0
lF
from the rim under severe riding condi-
tions.
The following are minimums:
Front 27 kPa (0.27 kg/cm2, 3.9 psi)
Rear 24.5 kPa (0.245 kg/cm2, 3.5 psi)
3)Use no more than
Front 33 kPa (0.33 kg/cmz, 4.7 psi)
Rear 30.5 kPa (0.305kglcm2, 4.3 psi)
when seating the tire beads. Higher pres-
sures may cause the tire t o burst.
Inflate the tires slowly andcarefully.
Fastinflationcould cause t h et i r et o
burst.
0 MAXIMUM LOADING LIMIT

1)Vehicle load limits: 220 kg (485 Ibl*
y 4
* Total weight of t h e cargo, trailer hitch
vertical load, rider, and accessories.
2)Storage box: 2 k g (4.4 Ib)
3)Trailer hitch:
Horizontal load: 550 kg (1,212 lb)
Total weightof the trailerand cargo.
Vertical load: 15 k g (33Ib)
Vertical weighton the trailer hitch joint.
Be extracareful of t h e machinebalance
and stability when t o w i n g a trailer.
I .Measure:
Tire pressure (cold tire pressure)
NOTE:
The low-pressure tire gauge@ is included
as standard equipment.
a If dust or the like is stuck to this gauge, it
will not provide thecorrect readings.
Therefore, take two measurements of the
tire's pressure and use the second reading.
-~~ ~ ~~~~
Cold tire Front Rear

pressure
30 kPa 27.5 kPa
Standard (0.30 kg/cm2, (0.275 kg/cm2,
4.3 psi) 4.0 psi)
27 kPa 24.5 kPa
Minimum kg/cm*, (0.245 kg/crnz, (0.27
3.8 psi1 3.5 psi)
33 kPa 30.5 kPa
Maximum (0.33 kg/cm2, (0.305 kg/cmz,
4.7 psi) 4.3 psi)
-
TIRE INSPECTION/
WHEEL INSPECTION mlNSP
l
Uneven or improper tire pressure may
adversely
affect the
handling of
this
machine and maycause loss of control.
Maintain proper tirepressures.
Set tire pressures when the tires are cold.
Tirepressures m u s t be equal in b o t h
front tires and equalin b o t h rear tires.
2.lnspect:
Tire surfaces
Weaddarnage + Replace.
r---T
Tire wear limit @:
Front andrear: 3.0 mm (0.12 in)
It is dangerous to ridewith a worn-out tire.

I” Whentirewearisoutof specification,
replace thet i r e immediately.
WHEEL INSPECTION
1.lnspect:
Wheels @
Damage/bends -+ Replace.
.- NOTE:
Always balance the wheel when a tire or
wheel has been changed or replaced.
Never attempt even small repairs t o t h e

wheel.
Ride conservatively after installing a tire
t o a l l o w it t o seat itself properly on the
rim.
CABLE INSPECTIONANDLUBRICATION/
LEVERS, PEDAL, ETC. LUBRICATION m1F
lNSP
CABLE INSPECTION ANDLUBRICATION
A damaged cable sheath may cause corro-

sionandinterfere withthe cable move-
ment. An unsafeconditionmay result so
replace a damaged cable as soon as possi-
ble.
?.inspect:
Cable sheath
Damage + Replace.
2.Check:
Cable operation
Unsmooth operation -+ Lubricate or
replace.
-. Recommended'lubricant:
Yamaha chain and cable lube or
Engine oil
- - I I
NOTE:
Hold the cable end up and apply several
drops of lubricant to thecable.
3.Apply:
Lithium soap base grease
(onto end of the cable)
LEVERS, PEDAL, ETC. LUBRICATION

1.Lubricate the pivoting parts.
Recommended lubricant:
I.Ic(i Yamaha chain and cable lube
or
L-
Engine oil
- __
I BATTERY INSPECTION
E8305000
ELECTRICAL
m
INSP 0
BATTERY INSPECTION
NOTE:
Since the MF battery is a sealed type bat-
tery, it is not possible to measure the spe-
cificgravity of the electrolyte in order to
check the charge state of the battery. There-
fore the charge of the battery has to be
checked by measuring rhe voltage a t the
battery terminals.
.. .... . , .-- -,. ,

,
" ."~&
.+..A_ ,
# J ->.*.f .,[: O ~ ~ - , -
i,.%%,
. ., ..__
,__ <>
I
CHARGING METHOD
Thisis a sealed typebattery.Never
remove the sealing caps. If the sealing
caps have been removed, the balance will
not b e maintainedandbatteryperfor-
L-
mance will deteriorate.
Charging time,
chargingcurrent
and
charging voltage for the M F battery are
different from those of general type bat-
teries. The M F battery should be charged
as explained in "CHARGING METHOD". i f
the battery is overcharged, the electro-
l y t e level will dropconsiderably.There-
fore, take special care when charging the
battery.
Batteryelectrolyteisdangerous; it con-
tains sulfuric acid which is poisonous and
highly caustic.
v
Always follow these preventive measures:
+ Avoid bodily contact with electrolyte as it
can cause severeburns or permanent eye
injury.
Wear protective eye gear when handling
or working near batteries.
Antidote (EXTERNAL):
SKIN - Wash with water.
EYES - Flush with water for 15 minutes
and get immediate medical attention.
Antidote (INTERNAL):
Drink large quantities of water or milk fol-
l o w e d with milk of magnesia, beaten egg
or vegetable oil. Get immediate medical
attention.
BAlTERY INSPECTION
Batteries generate explosive hydrogengas.
mINSP 0
lp
Always follow these preventive measures:
Charge batteries in a well-ventilated area.
Keep batteries away from fire, sparks or
open flames (e.g., weldingequipment,
lighted cigarettes, etc.1
DO NOT 'SMOKE when charging or han-
dling batteries.
KEEP BATTERIES AND ELECTROLYTE OUT
OF REACH OF CHILDREN.
1.Remove:
Seat
AND FUEL TANK".
* J
2,Disconnect:
Battery leads
,,..
*.,,%,,,,~~,,.>.*- ,
,
:$$..CA$Jy$Qw
*>%A>
, .. .,_ , *.
i :I
,.,,..\
r 2 . .I . I .%
a,then
1111 111. 1.111. I
First disconnect t h e negative lead

disconnect the positive lead 0.
-
3.Remove:
Battery holding bracket
I I Battery
I I 4.Check:
I Volt meter Battery condition

..................................
Battery condition checking steps:
I
.Connect a digital voltmeter to the battery
terminals.
Tester (+) lead -+ battery (+) terminal
367-01 1
Tester (-1 lead -+ battery (-1 terminal
I I I 1
NOTE:
The charge state of an MF battery can be
checked by measuring the open-circuit volt-
age (i.e. the voltage when the positive ter-
minal is disconnected).
Open-circuit
Charging time
voltage
No charging is
12.8V or higher necessary.
1
Relationshlp between open-circuit voltage
BAlTERY INSPECTION mINSP
.Check the condition of the battery using

0
l
(VI the following charts.
;q
~
\ and charglng tlme at 2O'C ( W F )

Example:
:\-I:
0,
"i
0 *Open-circuit voltage = 12.OV

I
m 13.0 .Charging time = 6.5 hours

Y
9 11.5
*Charge condition ofthebattery = 20 -
QJ
a
30%
0 .Charging method for M F batteries
I
5 6.5 10 ....," * ,-
. Thxs vanes depending on lhe lemperalure

Charging ttme {Hours)
the SIale Of Charge
cq!iuT@t\iz'::
>..--
.I>
' , I . _,
. I .VI
~nbattery plales and the eleclro lyle level If it is impossible t o setthestandard

charging current, b e careful n o t t o o v e r -
charge.
-5 14 When charging the battery, b e s u r e t o
8 13 1Pmperai"re
remove it from the motorcycle. (If charg-
m
-
c
ing has to bedone with thebattery
2 12
r mounted on the motorcycle, be sure to
:
3
'>
11 disconnect the wire at the negative termi-
*.e:10 nal.)
0 Never remove the sealing caps of an MF
100 75 50 30 2520 0
battery.
Condltlon of charge in battery (%I
Make sure that the charging clips are in
fullcontact with the terminal and that
they are notshortedtogether. (A cor-
Chargrng Arnbtenl temperature roded clip on the charger may cause t h e
- battery to generate heat in the contact
- ,.
area. A weakclipspringmay cause
0,
-'0 IS
sparks.)
--
B
3
I,
Before removing the clips from the bat-

ez ,I
./ tery terminals, be sure to turn off t h e

~
X ' charger's power switch.

o
1
. I
The open-circuit voltage variation for t h e

I. -'I *I "5 -9 -, ,,rn.,M."",.., !
4 check M F battery, aftercharging, is s h o w n

voltage
the Open-ctrcuir
i below. As shown in the figure, the open-
circuit voltage stabilizes about 30 min-
'-4
utes after charging has been completed.
Therefore, w a i t 30 minutes after charging
is completed before measuring theopen-
circuit voltage. -
BATTERY INSPECTION
Charging method using a variable-current (voltage) typecharger
1- ADJ p
- NOTE.
Measure the open-circuit Voltage should be measured 30 mlnutes
Charger
AMP meter voltage prior to charging. afferthemachlne~**topped
-4 NOTE:
Connect a charger and Set the charglng voltage at 16 ~ 17 V (If
the setting 19 lower. charglng will be
AMP meter to the battery insufficlent. If too hlgh, the battery will
and start charging. be over-charged i
1
Make s u r e the current is
higher than thestandard - NO
charging current written
o n the battery.
-
~
By turning the charging

voltage adjust dial] set the
charging voltage a t 20 25 V. -
1
i-i I
Adjust the voltageso that
YES Monitor the amperage for
current is a t standard
charglng level.
4
-
3 5 minutes t o check if the
standard charging current is
reached.
NO
T
1
L
i
r
Set the timeraccording t o the If the current does not

charging time suitablefor the exceed standard charging
open-circuit voltage. current after 5 minutes,
Refer t o “Battery condition replace the battery.
checking steps.”
\-’
In case that charging requires more than 5 hours, it is advisableto
check the charging current after a lapse of 5 hours. If there is any
charge in the amperage, readjust the voltage to obtain the standard
charging current.
4
Measure the battery open-circuit voltageafter having left the battery
unused for more than 30 minutes.
12.8 V or more --- Charging is complete.
12.7 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery.
I
Charging method using a constant-voltage type charger
BATTERY INSPECTION m INSP 0
l
NOTE
Measure the open-circuit Voltage should be measured 30minutes
voltage prior to charging. after the machine E. stopped.
I ~-
Connect a charger and
AMP meterto the battery
a n d start charging.
A
1 1
Make sure the current is
yEH I---? higher than the standard

chargingcurrentwritten
~.--.,,
I1 on the battery.
II
1
II II
d
Charge the battery until the battery’s This type of battery charger cannot
charging voltage is 15 V. charge the MF battery.A variable
voltage charger is recommended.
NOTE:
Set the
charging
time at 20 hours
(maxtmuml.
1 Volt meter
Charger
Measure the battery open-circuit

voltage after having left the battery
unused for more than30 minutes.
12.8 V or more --- Charging is
complete.
12.7 V or less --- Recharging is
required.
Under 12.0 V --- Replace the battery.
Charging method using a constant-current type charger

This type of battery charger cannot charge the MF battery.
BATTERY INSPECTION/
FUSE INSPECTION m
INSP
ADJ E
5.lnspect:
Battery terminals
Dirty -+ Clean with a wire brush.
Poor connection -+ Correct.
NOTE:
After cleaning the terminals, apply a light
coat of grease.
6.lnstall:
Battery
Battery holding bracket
7.Connect:
Battery leads
~~,&&$$jow;:
>..-.<:, .,
,--..
. ,,. 3.: ! :: %&
First, connect the positivelead 0,
then
connect the negative lead0.
8.lnstall:
Seat
Refer to "SEAT,
CARRIERS,
FENDERS
AND FUELTANK". -
FUSE INSPECTION
.2*$
y,&&~~f@p
A?&
;:
~,~,,.,,<~~":i?..*-'.-~I--
....i:,:.r..-.~~:~l.,-.,~~-
*,~,.:-:
..._
Always turn off themainswitchwhen
"d or checking a replacing fuse.a Otherwise,
short circuit may occur.
1.Remove:
Seat
Refer to "SEAT,
CARRIERS,
FENDERS
AND FUEL TANK".
2.lnspect:
Fuses
*************X********************
Inspection steps:
*Connect the pocket tester to the fuse and
check it for continuity.
__
I FUSE INSPECTION
1- AD J
I 1
lllll,n n..d[
NOTE:
Set the tester to the
"Q x 1" position.
I
11 D n l o l l 0 Pocket tester:
P/N. YU-03112,90890-03112
If the tester indicates0 , replace the fuse.

\ y ****Y*Y*****~Y*Y******************
370-003
I I
3.Replace:
Blown fuse
***~**t*X*X*XY****X*********~*****
Replacement steps:
.Turn off the ignition.
0 Install a new fuse of the proper amperage.
.Turn on switches toverifyoperation of
the related electrical devices.
c. .If the fuseimmediately blowsagain,
check the electrical circuit.
..................................
-
I
Description Currentrating
1
1 Quantity
-
Main 30A 1
-
Terminal 1OA 1
-
Reserve 30A 1
-
Reserve 1OA 1
-
Never use a fuse with a rating other than
t h a t specified. Never use other materialsin
place of a fuse. Animproperfusemay
cause extensive damage t o the electrical
.--., system, a malfunction of the lighting a n d
ignition systems and could possibly cause
a fire.
4.lnstall:
Seat
Refer t o "SEAT, CARRIERS, FENDERS
AND FUEL TANK".
r
HEADLIGHT BEAM ADJUSTMENT/
HEADLIGHT BULB REPLACEMENT
mr---. 1 HEADLIGHT BEAM ADJUSTMENT
mJF-l
lNSP
1 1 1.Adjust:
7fiy-O C4mT
Headlight beam (vertically)
<&rm
i
Turn the adjuster @ in or out.
v
x :
' -+7 . I
ITurning in I Headlightbeamraised.
I I
I
4-( S A Y
I C < / \ h
I
I
ITurningout I Headlightbeamlowered.
I I
I
- I W'I I
HEADLIGHT BULB REPLACEMENT

1.Disconnect:
Headlight lead coupler
2.Remove:
Headlightassembly 0 ,
3.Remove:
Headlight cover @
I 1
4.Remove:
Cover 0
Bulb holder@
e Bulb
-
.
-,
NOTE:
Turn the bulb holder counterclockwise and
remove the defective bulb.
I I
Keep flammable products and your hands
a w a y f r o m t h ebulb while it is on, since it
will be hot. Do not touch the bulb until it
cools down.
1 HEADLIGHT BULB REPLACEMENT
5.lnstall:
m
INSP 0
l
Bulb (new)
Secure the new bulb with t h e headlight
unit.
-i
,
& &..,, ~ @ ~ -
I ..,: -,
, I
,,':
,,
'
Avoid touching theglass part ofthe bulb.

Keep it free from oil; otherwise, the trans-
parency of the glass, life of the bulb, and
luminous flux will be adversely affected. If
oil gets on the bulb, thoroughIy clean it
with a cloth moistened with alcoholor lac-
quer thinner.
6.lnstall:
Bulb holder
b Cover
Headlight cover
Headlight assembly
v 7.Connect:
Headlight lead couplers
\-/
AIR DUCTS. MUFFLER. EXHAUST PIPE. AND
CHAPTER 4 .
ENGINE
ENGINE REMOVAL ....................................................................................
FOOTREST BOARD (right) .............................................................

SELECT LEVER UNIT AND FOOTREST BOARD (left) ......................
HOSES AND LEADS ...........................................................................
ENGINE MOUNTING BOLTS .............................................................
CYLINDER HEAD COVER ...........................................................................

CYLINDER HEAD COVER REMOVAL .................................................
CYLINDER HEAD COVER INSPECTION .............................................
- G-4
G-4
G-4
G-5
G-5
G-6
G-7
G-7
IG
TAPPET COVER INSPECTION ............................................................ G-7

CYLINDER HEAD COVER INSTALLATION ........................................ G-7
.-. ROCKER ARMS ........................................................................................... G-8

ROCKER ARM REMOVAL ................................................................... G-8
ROCKER ARM AND CAMSHAFT INSPECTION ................................ G-8
ROCKER ARM INSTALLATION .......................................................... G-9
CAMSHAFT AND CYLINDER HEAD .......................................................... G-9

CAMSHAFT AND CYLINDER HEAD REMOVAL .............................. G-10
CAMSHAFT INSPECTION ................................................................ G-I 1
CAMSHAFT SPROCKET INSPECTION ............................................ G - I1
DECOMPRESSION SYSTEM INSPECTION ..................................... G-I1
TIMING CHAIN GUIDE INSPECTION ............................................... g-11
TIMING CHAIN TENSIONER INSPECTION ..................................... G-11
CYLINDER HEAD INSPECTION ........................................................ G-11
CAMSHAFT AND CYLINDER HEAD INSTALLATION ..................... G-12
VALVES AND VALVESPRINGS .............................................................. G-13

VALVE AND VALVE SPRING REMOVAL .........................................
\u
G-14
VALVE AND VALVE SPRING INSPECTION ..................................... g-14
VALVE AND VALVE SPRING INSTALLATION ................................ G-16
CYLINDER AND PISTON ............................................................................. H-I

PISTON REMOVAL .............................................................................. H-I
CYLINDER AND PISTON INSPECTION .............................................. H-I
PlSTON RING INSPECTION ................................................................ H-2
PISTON PIN INSPECTION ................................................................... H-3
PISTON INSTALLATION ...................................................................... H-3
CYLINDER INSTALLATION ................................................................. H-3
1 RECOIL STARTER AND CDI MAGNETO .................................................... H-4
p p q
CDI MAGNETO REMOVAL .................................................................. H-5
RECOIL STARTER DISASSEMBLY ..................................................... H-5
CDI MAGNETO INSPECTION .............................................................. H-6
STARTER PULLEY INSPECTION ......................................................... H-6
RECOIL STARTER INSPECTION ......................................................... H-6
RECOIL STARTER ASSEMBLY ........................................................... H-6
CDI MAGNETO INSTALLATION ......................................................... H-7
PRIMARY AND SECONDARY SHEAVES ................................................... H-8

PRIMARY SHEAVE ............................................................................... H-9
SECONDARY SHEAVE ........................................................................ H-9
PRIMARY AND SECONDARY SHEAVES REMOVAL ....................... H-10
SECONDARY SHEAVE DISASSEMBLY ............................................ H-IO
PRIMARY SHEAVE INSPECTION ...................................................... H-10
SECONDARY SHEAVE INSPECTION ................................................ H-IO
PRIMARY SHEAVE ASSEMBLY ........................................................ H-11
SECONDARY SHEAVE ASSEMBLY .................................................. H - I1
-d
PRIMARY AND SECONDARY SHEAVES INSTALLATION ............... H-12
CLUTCH ...................................................................................................... h-12

CLUTCH REMOVAL ........................................................................... H-13
CLUTCH INSPECTION ....................................................................... h-13
CLUTCH INSTALLATION ................................................................... H-14
CRANKCASE .............................................................................................. h-15

STARTER MOTOR, TIMING CHAIN AND OIL FILTER ..................... H-15
CRANKCASE ...................................................................................... H - I6
CRANKCASE BEARINGS ................................................................... h-16
CRANKCASE SEPARATION ................................................................. 1-1
TIMING CHAIN AND GUIDE INSPECTION .......................................... 1-1
OIL STRAINER, OIL FILTER AND OIL DELIVERY
PIPE INSPECTION ............................................................................. 1-1
.
d. CRANKCASEINSPECTION .................................................................. 1-1
BEARINGS AND OIL SEALS INSPECTION .......................................... 1-1
CRANKCASE ASSEMBLY .................................................................... 1-2
TRANSMISSION AND CRANKSHAFT ......................................................... 1-2

CRANKSHAFT REMOVAL ................................................... ;................ 1-3
SHIFT FORK INSPECTION .................................................................... 1-3
SHIFT CAM INSPECTION ..................................................................... 1-3
TRANSMISSION INSPECTION ............................................................ 1-3
CRANKSHAFT INSPECTION ................................................................ 1-4
CRANKSHAFT AND BALANCER INSTALLATION .............................. 1-4
TRANSMISSION INSTALLATION ........................................................ 1-4
OIL PUMP ...................................................................................................... 1-5

OIL PUMP INSPECTION ....................................................................... 1-7
1- IG.
MIDDLE GEAR .............................................................................................. 1-7
MIDDLE DRIVE SHAFT ......................................................................... 1-7
MIDDLE DRIVEN SHAFT ...................................................................... 1-8
MIDDLE DRIVE SHAFT REMOVAL ...................................................... 1-9
MIDDLE DRIVEN SHAFT REMOVAL .................................................... 1-9
INSPECTION ........................................................................................ 1-10
MIDDLE DRIVE AND DR.IVEN GEAR SHIM SELECTION ..................1-10
MIDDLE DRIVEN SHAFT INSTALLATION ......................................... 1-12
MIDDLE DRIVE SHAFT INSTALLATION ............................................ 1-13
GEAR LASH MEASUREMENT ........................................................... 1-13
L.'
-d
ENGINE REMOVAL W ENG %m I IG
ENGINE
ENGINE REMOVAL
AIR DUCTS, MUFFLER, EXHAUST PIPE, AND FOOTREST BOARD (right)
-
~ ~~~~ ~~~~~ ~~~~~~~ ~~~~
=I-
Order
_.
Job name/Part name
Air duct, muffler, exhaust pipe and
footrest board (right) removal
Engine oil
Q'ty Remarks
Refer to "ENGINE OIL REPLACE-

MENT" in CHAPTER 3.
Front and rear fender Refer to "SEAT, CARRIERS, FENDERS
Fuel tank I rubber cover L N D FUEL TANK" in CHAPTER 3.
Carburetor assembly Refer to "CARBURETOR" in CHAPTER 5.
1 Air duct assembly2 1
2 Guard 1
3 Muffler 1
4 Exhaust pipe / gasket 112
5 Select control cable 1
6 Brake cable 1
7 Footrest board (right) 1
For installation,reversetheremoval
- procedure.
1
SELECT LEVER UNIT AND FOOTREST BOARD (left)
ENGINE REMOVAL -
W
- - -
1;
=I -.
Job narne/Part name
_.
Select lever unit and footrest board
(left) removal
Qty Remarks
Remove the parts in the order below.
-
Cover 1
Select lever shift rod 1
Select lever unit 1
Footrest board (left) 1
Air duct assembly1 1
Front drive shaft protector 1
For installation, reversetheremoval
- - orocedure.
I . -
__
ENGINE REMOVAL r L$m - p

ENG
HOSES AND LEADS
Order
-
Job narne/Part name
--
Qty
.
Remarks
-
- --- -
Hoses and leads removal Remove the parts in the order below.
";_... I Oil cooler hose 2
2 Speedometer gear 1
3 Spark plug lead 1
4 Starter motor lead 1
5 Crankcase breather hose 1
6 Thermo unit coupler 1
7 Neutral switch lead 2
a AC magneto lead coupler 2
9 Ground lead 1 NOTE:
Afterdisconnecting the ground lead,
reinstall the bolt.
10 Metal clamp/ plastic locking tie 1/1
For installation, reverse theremoval
- - 7 - procedure. -
I ENGINE REMOVAL m ENG 4.m i
ENGINE MOUNTING BOLTS
-,-,
Order Job name/Part name Q'ty Remarks

Engine mounting boltremoval Remove the parts inthe order below.
Rear wheels Refer to "FRONT AND REAR WHEELS"
..-
in CHAPTER 7.
:
Swingarm Refer to "REAR 'SHOCK ABSORBER
AND SWINGARM" in CHAPTER 7.
1 Engine mounting bolt (front-upper) 1 ., ..........~~.~..~.,,~~,~-..~,,
$,~Q&j$!@J@5;
<..*::.: ."*::_.,. ..??Kt
,2y:,
2 Engine bracket (front-upper) 2
Install all of the bolts/nuts
3 Engine mounting bolt (front-middle) 1 and then t i g h t e n t h e m t o
4 Engine bracket (front-middle) 2 full torque specifications.
Engine mounting bolt (rear-upper) /

5 1/1 L=140 mm
nut
Engine mounting bolt (front-lower)/
6 1/1 L=,90 mm
nut
Engine mounting bolt (rear-lower) /
7 1/1 L=190 mm
nut
. *
ENGINE REMOVAL r l -% q
ENG j m
--J

8 Engine assembly 1 NOTE:
t Remove the engine assembly from the
right side of the machine. .
For installation,reverse the removal
procedure.
CYLINDER HEAD COVER
I
-
H
CYLINDER HEAD COVER
~
- I
-
.
-
- --- -
t""" - Job name/Part name
Cylinder head cover removal
Front fender
Qty
-- - Remarks
-
v
Fuel tank / rubber cover AND FUEL TANK" in CHAPTER 3.

Recoil starter to "VALVE CLEARANCE
Timing plug CE%STMENTr* in CHAPTER 3.
1 Air duct 1
2 Spark plug 1
3 Engine mounting bolt (upper) 1
4 Engine bracket (upper) 1
5 Camshaft end cover/ O-ring ?/I
6 Tappet cover (intake)/ O-ring 1/1
7 Tappet cover (exhaust)/ O-ring 2/2
8 1 Refer to "CYLINDER HEAD COVER
Cylinder head cover
REMOVAL / INSTALLATION".
9 Dowel pin 2
For installation,reversetheremoval
- 1~~
procedure.
-
CYLINDER HEAD COVER
CYLINDER HEAD COVER REMOVAL
I ENG~\*~ I Ga
1.Align:
"I" mark
(with stationary pointer)
..................................
Checking steps:
a wrench.
.Align the "I" mark @ on the rotor with the
NOTE:
When the piston is at the top dead center
(TDC) on thecompression stroke, there
shouldbeclearancebetweenthevalve
stem tips and their respective rocker arm
w
adjusting screws.
If there is no clearance, rotate the crank-
shaft counterclockwise one turn.
2.Remove:
Cylinder head cover
NOTE:
Working in a crisscross pattern, loosen
each bolt 114 of a turn. After all the bolts are
loosened, remove them.
CYLINDER HEAD COVER INSPECTION

1.lnspect:
Cylinder head cover
Crackddamage + Replace.
L
w
I
I
Q&
0
0
1
I
TAPPET COVER INSPECTION
1.lnspect:
Tappet cover (intake)0
Tappet cover (exhaust) @
O-ring @
. -
1 HEAD CYLINDER
1.Apply:
I
2.lnstall:
COVER
Sealant (Quick Gasket90

(tothematingsurfaces
-
CYLINDER HEAD COVER INSTALLATION
of thecylinder
head and cylinder head cover)
Sealant (Quick Gasketm)@

P/N. ACC-11001-05-01
Yamaha bond No. 1215":
P/N. 90890-85505
Cylinder head cover

Bolts
NOTE:
h i 1 0 Nm 11.0 m ' kg, 7.2 ft . ib) ]
Tightenthecylinder head cover bolts in

stages, using a crisscross pattern.
\.-I
.v
ROCKER ARMS
ROCKER ARMS -1 B
EiI
Order
I 1
2
3
4
5
6
7
Job name/Part name
Rocker arm removal
Cylinder head cover
Plug/O-ring
Bolt
Rocker arm shaft / O-ring
Rocker a r m
Spring
Locknut
Valve adjuster
~n
Q t y-
1/1
2
3f 2
4
4
4
4
-
-
-
Remarks
Remove theparts in the order below.
Refer to "CYLINDER HEAD COVER".
Refer to "ROCKER ARM REMOVAL/

TlNSTALLATION".
For installation, reverse t h e removal

procedure.
-
-
-
1 ~~
ROCKER ARMS
ROCKER ARM REMOVAL
~~
1- ~
~~~
1 .Remove:
Rocker arm shafts (intake and exhaust) 0
Rocker arms @
NOTE:
Use a slide hammer0to remove the rocker
arm shafts.
Slide hammer set:

P/N. YU-01083-A
Slide hammer bolt (M6):
P/N. 90890-01083
Weight:
P/N. 90890-01084
'-,
ROCKER ARM AND CAMSHAFT INSPECTION

1.lnspect:
Camshaft bushings
Damage/wear 4 Replace.
2.lnspect:
Camshaft lobes 0
Valve adjusters @ J
Blue discoloration/pitting/scratches -+
Replace.
%Inspect:
Rocker arms
Rocker arm shafts
Damage/wear -+ Replace.
***********X*****~****************
' L ~ ~ inspection steps:

.Inspect the t w o contact areas on the
rocker arms forsigns of abnormalwear.
1) Rocker arm shaft hole.
2) Camshaft lobe contactsurface.
Excessive wear 4 Replace.
I i a Inspect thesurface of the rocker arm shafts.
Blue discoloration/pitting/scratches -+
Replace/check lubrication.
@Measuretheinsidediameter 8 of the
rocker arm holes.
Out of specification -+ Replace.
I I
.~ 2 Rocker arm inside diameter:

.-
-
12.000 12.018 mm
(0.4724 0.4731 in)
4
I
w
7
1
ROCKER ARMS
.Measure the outside diameter
rocker arm shafts.
Out of specification+ Replace.
Rocker arm outside diameter:

--
11.985 11.991 mm
(0.4719 0.4721 in)
.Calculate the clearance by subtracting the

rocker arm shaftoutsidediameter
the rocker arm inside diameter.
from
Clearance greater than 0.08 mm (0.003 in)

4 Replace the defective part(s).
- @ of the
m
I
Rocker arm to shaft standard
clearance:
--
0.009 0.033 mm
(0.0004 0.0013 in)
I I
f + * * * * X * X * f X * X * X * * * X * * * f * * * ~ ~ * ~ ~ * *
x-
ROCKER A R M INSTALLATION
1.Apply:
Engine oil
(onto the rocker arm shafts)
2.lnstall:
Rocker arms T(J
Rocker arm shafts (intake and exhaust)@
NOTE:
I I w The thread hole @ of the rocker a r m shaft
must face to the outside.
Afterinstallation, make sure thatthe
thread hole @ of the rocker arm shaft is
positioned correctly, as shown in the illus-
tration.
,-.
. ..
I CAMSHAFT AND CYLINDER HEAD -1
CAMSHAFT AND CYLINDER HEAD
-
H
F Order
~'~
7
-
-
-
-
Job name/Part name
Cylinder head cover

Timing chain tensioner cap bolt
Timing chain tensioner/ gasket
Timing chain guide (exhaust)
Decompressor cam guide plate
Camshaft sprocket
Camshaft
Cylinder head
-
- Q'ty
Camshaft and cylinder head removal
Fuel tank / rubber cover
Rear fender
Air duct assembly2
Exhaust pipe / muffler
Carburetor assembly
.
1:11
1
2
1
1-
*.
Remarks
?AND FUEL TANK" in CHAPTER 3.
]Refer to "ENGINE REMOVAL".
Refer to "CARBURETOR" in CHAPTER 5.

Refer to "CYLINDER HEAD COVER".
Refer to "CAMSHAFT AND CYLINDER

HEAD REMOVAL / INSTALLATION".
'CI
-
-
-
CAMSHAFT AND
CYLINDER HEAD r y - %1 j 1 - G
ENG
I 1
L.d

8
- Cylinder headgasket 1
9 Dowel pin 2
10 Dowel pin/ gasket 1/1
11 Intake manifold/ O-ring 1/2
procedure.
1 1\ ) l
7 I
1 CAMSHAFT
AND CYLINDER HEAD ENG
CAMSHAFT AND CYLINDER HEAD
REMOVAL
1.Loosen:
Camshaft sprocket bolt @
NOTE:
Use the rotor holder @ t o hold the starter
p u I ley.
Rotor holder:
P/N. YU-01235; 90890-01235
2.Loosen:
Timing chain tensioner cap bolt
3.Remove:
Timing chain tensioner
Timing chain guide (exhaust)
Decompressor guide plate
Camshaft sprocket
i-a
NOTE:
Fasten a safety wire to the timing chain to
prevent it from falling into thecrankcase.
When removing the camshaft sprocket, it
is not necessary t o separatethe timing
chain.
4.Remove:
Cylinder head
NOTE:
Loosen the bolts and nuts in the proper
sequence.
Follow the numerical order shown in the
illustration. Loosen each bolt 1/4 of a turn
a t a time untilall of the bolts areloose.
CAMSHAFT AND CYLINDER HEAD 1- IG.
- 0 CAMSHAFT INSPECTION
lhspect:
Cam lobes
Pitting/scratches/blue
discoloration -+
Replace.
2.Measure:
Cam lobes length @ and @.
Out of specification 4 Replace.
Camshaft lobe limit:

Intake
836.37 mm (1.433 in)
B29.96 mm (1.180 in)
Exhaust:
836.52 mm (1.438 in1
@ 30.01 mm (1.181 in)
r-u
’ CAMSHAFT SPROCKET INSPECTION

1.lnspect:
Camshaft sprocket
Weaddamage --f Replace thecamshaft
sprocket and timing chain as a set.
0 1/4 of a tooth
~ , ,,,’
j I~ ‘
I -~ I1
I \;
,,\~-;:~~
:,-.,<,
,’’~
~‘x
+ , ,$;@\
+’, .,,,,~
~.
~-.x;*;
:(;,2.<:-.
!,G.
~ ,, <.,
.~:@,..%<
.-,,&yp>
,\
.i~
+.:+
2;lil , ,e=...
.%.*lll%l._ ~?;;
;.., , ; ~ ~ ~
~
@ Correct
, ~ ~ ’ ~ ~ ~
@ Roller
:
I
i
,
,
<,-,1.
~~~~
<
>; ..,,i’;.x&..
.,,I + , ;c y i ~ .A<: :
$
e&*
:
;
.
:x: @ Sprocket
I 343014
DECOMPRESSION SYSTEM INSPECTION

1.Check:
Decompression system
..................................
Checking steps:
Check while the camshaft’
sprocket
is
installed on the camshaft.
.Check that the decompressor lever pin 0
projects from the camshaft.
.Check thatthedecompressorcam @
moves smoothly.
**********+*******x**x************
. .-
-
I CAMSHAFT
AND CYLINDER HEAD 1-
TIMING CHAIN GUIDE INSPECTION
1 .Inspect:
Exhaust side timing chain guide
Weaddamage -+ Replace.
TIMING CHAIN TENSIONER INSPECTION

1 .Check:
One-way cam operation (tensioner)
Unsmooth operation -+ Replace.
~1- f I
I
CYLINDER HEAD INSPECTION
1.Eliminate:
a Carbondeposits(fromthecombustion
chambers)
Use a rounded scraper.
NOTE:
Do not use a sharpinstrument to avoid
damaging or scratching:
Spark plug threads
I I Valve seats
2.lnspect:
I Cylinder heads
Scratches/damage -+ Replace.
3.Measure:
"-- warpage head a Cylinder
Out of specification + Resurface.
Cylinder head warpage:

Less than 0.03 mm (0.002 in)
..................................
I i
Warpage measurement and resurfacement
steps:
.Place a straightedge and a feeler gauge
across the cylinder head.
*Use a feeler gauge to measure the
warpage.
*If thewarpageis out of specification,
resurface the cylinder
head.
I 1
CAMSHAFTANDCYLINDERHEAD
.Place a 400 600 grit wet sandpaper o n -
1- PI
the surface plate, and resurface the head
using a figure-eight sanding pattern.
NOTE:
To ensure an even surface rotate the cylin-
der head several times.
~~ ~~~ ~~
******************X**X************
I I CAMSHAFT AND CYLINDER HEAD

INSTALLATION
1.lnstaII:
Cylinder head
0 Bolts (M8: 1-4)
I& 129 Nrn (2.9m ' kg, 21 ft .Ibl 1

0 Nuts (M8 : 5, 6)
.
h ] 2 2 Nm (2.2 m kg, 16 ft Ib) . I
.~ ui--i I 0 Bolt (M6: 7 )
(&I10 Nrn (1.0 m . kg, 7 . 2 f t . Ibl ]
NOTE:
Tighten the bolts and nuts in the proper
sequence.
Follow the numerical order s h o w n in the
illustration, Tighten the bolts and nuts in
two stages.
2.lnstall:
Camshaft
Camshaft sprocket
***************x******************
Installation steps:
a wrench.
.Align the "I" mark @ on the rotorwith the
ggfj@$@qgj?gg4
.Zm..rS ....._
%,X< .*A A*?:.!,
Do not turn the crankshaft during the cam-

shaft installation.
, *7
!I
t CAMSHAFT
AND CYLINDER HEAD 1
-
temporarily install the camshaft sprocket
on the Camshaft. (Donot install the bolts.)
Then, install the timing chain on the cam-
shaft sprocket.
NOTE:
Make sure the small holes @ on the cam-
shaft face upward.
.- ~Alignthe notches @ on the decompressor

cams with the projections ($ on the
decompressorspring lever, theninstall
the camshaft sprocketon the camshaft.
4
*
NOTE:
Check that each part is positioned as shown
in the illustration.
@ Small holes on camshaft sprocket
@ Punch mark on decompressor spring lever
@Top front of cylinder head
I I
I
.Tighten a.
the camshaft sprocket bolts
NOTE:
Use the rotor holder @ to hold the starter
pulley.
Rotor holder:
P/N. YU-01235,90890-01235
Camshaft sprocket bolt:

b&+ 20 Nm (2.0 m kg, 14 ft Ib)
oRemove the retaining wire.

..................................
I .a"
CAMSHAFT ANDCYLINDER HEAD IENG/CI
am JG-
-
I I 3.lnstall:
Timing chain tensioner
...................................
O<<J Installation steps:
.Remove the tensioner cap bolt@, washer
@ and spring 0.
e%
.Release the timing chaintensionerone-
way cam@ and push the tensioner rod @
I 1 all the way in.
*Install t h e tensioner @ with a n e w gasket
into the cylinder.
Bolts (timing chain tensioner):

b% 10 Nm (1.0 m kg, 7.2 f t Ib)
Always use a new gasket.

.Install the spring, washer and capbolt.
r"
Cap bolt (timing chain tensioner):
b&.+ 20 N m (2.0 m kg, 14 ft Ib)
**********X***x-*******************
4.Check:
Small holes on camshaft sprocket
Rotor "I" mark
Out of alignment -+ Adjust.
..-
-
1 VALVES AND VALVE SPRINGS m

VALVES AND VALVE SPRINGS
w
~~

Valve and valvespring removal Remove the partsin the orderbelow.
Cylinder head Refer to "CYLINDER HEAD".
.-*' I Valve cotter 8 -
2 Valve spring retainer 4 -Refer t o "VALVE AND VALVE SPRING
3 Valve spring (outer) 4 REMOVAL / INSTALLATION".
4 Valve spring (inner) 4
5 Valve (inner) 2
6 Valve (exhaust) 2
7 Valve stem seal 4
8 Valve springseat 4 -
procedure.
- ^^
VALVES AND VALVE SPRINGS 1- IG-
L
sJ
VALVE AND VALVE SPRING REMOVAL
1.Check:
Valve sealing
~
Leakage at the valve seat -+ Inspect the
valve face, valve seat and valve seat
width.
Refer to “VALVE AND VALVE SPRING
INSPECTION”.
2 ..................................
Checking steps:
a Pour a clean solvent@ into the intake and
w
@y exhaust ports.
@Check that the valveseals properly.
There should be no leakage at the valve
seat 0.
w
+=/ ******************Y***************
\4.
v 1
2.Remove:
Valve cotters
NOTE:
Attach valve
a spring
compressor @
between the valve spring retainer and the
cylinder head to remove the valve cotters.
Valve spring compressor:

I I P/N. YM-04019,90890-04019
i 1 VALVE AND VALVE SPRING INSPECTION

1.Measure:
Stem-to-guide clearance
Stem-to-guide clearance = ‘
valve guide inside diameter8-
valve stem diameter@
-
Out of specification --+ Replace the valve
guide.
k Clearance (stem to guide):

Intake:
--
0.010 0.037 m m
(0.0004 0.0015 in)
slirnitz: 0.08 mm (0.003 in)
Exhaust:
- ..
0.030 0.057 m m
(0.0012 0.0022 in)
<Limit>: 0.10 rnm (0.004 in)
YllOOl
L I
__
I VALVES
VALVEAND
2.Replace:
SPRINGS 1-
Valve guide
****x****+************************
Replacement steps:
NOTE:
To ease guide removal, installation and to
maintain correct fit, heat the cylinder head
to 100°C (212'F) in an oven.
*Removethevalveguideusing a valve
guide remover 0.
.Install the new valve guide using a valve
guideremover (iJ and valveguide
installer 0.
*After installing the valve guide, bore the
valve guide usinga valve guide reamer @
to obtain proper stem-to-guideclearance.
Valve guide remover (7 mm):

PIN. YM-01225-A, 90890-01225
- Valve guide installer:
PIN. YM-04017,90890-04017
Valve guide reamer (7 mml:
P/N. YM-01227,90890-01227
NOTE:
After replacing the valve guide reface the
valve seat.
****X*+*~***+Y**Y*I********+*~***+
I I
3.lnspect:
Valve face
Pitting/wear --f Grind the face.
Valve stem end
U' Mushroom
than shape or diameter
larger
the body of the stem -+ Replace.
I I 4.Measure:
8-11- Margin thickness 8
T4
1
Margin thickness:
I U Intake:
- -
1.35 1.65 rnm (0.053 0.065 in)
<Limit>: 1.2 rnm (0.047 in)
45O
-
Exhaust:
-
1.15 1.45 mm (0.045 0.057 in)
<Limit>: 1.0 rnrn (0.039 in1
VALVES AND VALVE SPRINGS m p
5.Measure:
Runout (valve stem)
Out of specification --f Replace.
Runout limit:
0.01 rnrn (0.0004 in)
NOTE:
When installing a new
valvealways
replace the guide.
If the valveis removed or replaced always
replace the oil seal.
6.Eliminate:
Carbon deposits
(from the valve face and valve seat)
7.lnspect:
Valve seats
Pitting/wear + Reface the valve seat.
~4
8.Measure:
Valve seat width @
Out of specification 4 Reface thevalve
seat.
Valve seat width:

Intake:
-
1.0 1.2 rnm (0.039 0.047 in)
<Limit>: 1.6 mm (0.063 in)
-
Cy>
Exhaust:
-
1.0 1.2 mm (0.039 0.047 in)
<Limit>: 1.6 m m (0.063 in)
-
..................................
Measurement steps:
_i
.Apply Mechanic’s blueing dye (Dykeml 6)
to the valveface.
.. .Install the valve into the cylinder head.
._ .Press the valve through the valve guide
-. .. . ... . ..
and onto the valve seat to make a clear
- pattern.
.Measure the valve seat width. Where the
valve seat and valve face made contact,
blueing will have been removed.
.If the valve seat is too wide, too narrow,
or the seat is not centered, the valve seat
must be refaced.
* * ~ * ~ f * * C ~ f * X X ~ Q Y X + * * * * * * * ~ * * * * * * *
I I\ j l
q
1 ~ ~~~
~~ ~~ ~~ ~~~ ~~
ENG ~~ ~~ ~~~
9.Lap:
Valve face
Valve seat
NOTE:
Afterrefacingthevalveseatorreplacing
the valve and valve guide, the valve seat
and valve face should be lapped.
*****Y*********X************+*****
Lapping steps:
e3
*Apply a coarse lapping compound to the
valve face.
... .,., .. ..
:;+c&~~~~&fi-;
<.,.
~
-
Ix
%
F'
. I
I~
Do not let the compound enter the gap

between the valve stem and the guide.
. .
*Applymolybdenumdisulfideoil to the
i l
~ .. . .. .. , .
valve stem.
*Install the valve into the cylinder head.
.Turn thevalveuntilthevalve face and
.-k?
valve seat are evenly polished, then clean
off all of the compound.
NOTE:
Forbestlapping results, lightly tapthe
valve seat while rotating the valveback and
forth between yourhands.
.Apply a finelappingcompound to the
X 2 024 valve face and repeat the abovesteps.
NOTE:
Aftereverylappingoperationbesureto
clean off all of thecompoundfromthe
valve face and valve seat.
-. -J
*Apply Mechanic's blueing dye (Dykem) to
the valve face.
0 Install the valve into the cylinder
head.
.Press the valve through the valve guide
and onto the valve seat to make a clear
pattern.
*Measure the valve seat width again. Ifthe
valveseat width is out o f specification,
reface and relap the valveseat.
*************X**?+****?+************
1O.Measure:
G
-
l
Valve spring free length8
Out of specification -+Replace.
Free length (valve spring):

Inner:
40.1 mm (1.58in)
<Limit>: 38.1 mm (1.50in)
Outer:
43.8 mm (1.72 in)
<Limit>: 41.6 mm (1.64 in)
L
11.Measure:
Compressed spring force 8
@ Installed length
Compressed spring force:
Inner:
--
7.3 8.9 k g a t31.2 mm
116.1 19.2 Ib a t 1.23in)
Outer:
-
15.2 18.6 kg a t 34.2 mm
I
-
(33.5 41.0 Ib a t 1.35 in)
I
I I
12.Measure:
T 0Spring tilt 8
I L i
_.- Spring tilt limit:
Inner:
2.5"/1.7 mm (0.067 in)
Outer:
2.5"/1.9 mm 10.075 in)
a2-028 L I
I I
VALVES AND VALVE
SPRINGS
VALVE AND VALVESPRING
I= ENG %-
-
INSTALLATION
1.Apply:
Molybdenum disulfide oil
(onto the valve stem and valve stem seal)
2.lnstall:
Valve spring seats
Valve stem seals
Valves
Valve springs (inner and outer)
Valve spring retainers
NOTE:
Installthevalvesprings with the larger
pitch @ facing upwards.
@ Smaller pitch
‘v
3.lnstall:
Valve cotters
NOTE:
Install the valve cotters while compressing
the valve spring with the valve spring com-
pressor 0.
Valve spring compressor:

I I P/N. YM-04019,90890-04019
v. 1
W I
4.To secure the valve cottersonto the valve

stem, lightly tap the valve tip with a piece
of wood.
:-:*,-~w-7,<<.zL~
*-, x ,,i-(.
;+j@&&$g&ijg<;
,.vx,.<9-&+
.,..
r.*~,~~.~~~.xr~m_,~~,,xXr.inr..r
Hitting the valve tip with excessive force

could damage thevalve.
-
CYLINDER AND PISTON I ENGI\~I I H
CYLINDER AND PISTON
H
- - -
F
Order Job name/Part name
Cylinder and piston removal
Q'ty - Remarks
-
I
Cylinder head Refer to "CYLINDER HEAD";
Cylinder / O-ring 1/1 Refer to "CYLINDER INSTALLATION".
Cylinder gasket 1
Dowel pin 2
Dowel pin / gasket 1/1
Piston pin clip 2
7
Piston pin
Piston
Piston ring set
1
1
1 1 Refer to "PISTON REMOVAL /
INSTALLATION".

- I - procedure. 4
1 CYLINDER AND PISTON
PISTON REMOVAL
m
1.Remove:
Piston pin clips @
Piston pin @
Piston @
NOTE:
0 Putidentificationmarks on each piston
head for reference during reinstallation.
0 Before removing each piston pin, deburr
the clip groove and pin hole area. I f the
I I piston pin groove is deburred and the pis-
ton pin is still difficult to remove, use the
c
piston pin puller 0.
Piston pin puller:

P/N. YU-01304,90890-01304
'r"
I
w
-
U
307417
I
>..?.*
:+i. ~.
>--
i:
ri::GAIJTfOM;:
~ I
Do not use a hammer t o drive the piston

pin out.
2.Remove:
Piston rings
NOTE:
Spreadtheendgapsapartwhile a t the
same time lifting the piston ring over the
top of the piston crown, as shown in the
illustration.
CYLINDER AND PISTON INSPECTION

1.Inspect:
Cylinder and piston walls
Vertical scratches + Rebore or replace the
b 4 piston. cylinder and the
I I 1 2.Measure:
-@
leE-l Piston-to-cylinder clearance
@
*************Y*****~**~***********
Measurement steps:
1st step:
*Measure the cylinder bore "C" with a cyl-
inder bore gauge 0.
@ 40 m m (1.6 in) from the top of the cylinder
I I I
CYLINDER AND PISTON 1- p
NOTE:
B
Measurecylinderbore "C" in parallel t o
and a t right angles to the cylinder matching
surface.
Then, find the average of themeasure-
ments.
Standard
Wear limit
r I I I
I \ I I I I
Cylinder
94.97 .
95.02 rnm 95.1 mrn
bore "C" -
(3.739 3.741 in) (3.744 in)
I 1
X+Y
c= -
2
.If out of specification; rebore or replace
thecylinder,andreplacethepistonand
piston rings as a set.
-J
2nd step
.Measure piston skirt diameter "P" with a
micrometer.
@ 5.0 rnrn (0.20 in) from the piston bottom edge
Piston skirt diameter "P"
Standard
-..
94.915 94.965 mrn
(3.737 3.739 in)
.If out of specification, replace the piston

and piston rings as a set.
3rd step
@Findthe piston-to-cylinder clearance with
the following formula.
i -
d
I
Piston-to-cylinder clearance=
Cylinder bore "C" -

Piston skirt diameter "P"
1
P
Piston-to-cylinder clearance:
--
0.045 0.065 mm
(0.0018 0.0026 in)
<Limit: 0.15 mm (0.0059 in)>
f I
.If out of specification, rebore or replace
the cylinder, and replace the piston and
piston rings as a set.
..................................
I CYLINDER AND PISTON
PISTON RING INSPECTION
1-
1.Measure:
Ring side clearance
Use a feeler gauge 0.
Out of specification + Replace the piston
and rings as a set.
NOTE:
Clean carbon from the piston ring grooves
and rings before measuring t h e side clear-
ance.
x 1
Side clearance
Standard Limit
- mm
x.
k I
0.04 0.08 0.13 rnrn
ring (0.002- 0.003 in) (0.005 in)
ring
--
0.03 0.07 mm
(0.001 0.003 in)
0.13 mm
(0.005 in1
--i -
2.Position:
Piston ring
(in cylinder)
NOTE:
Insert a ring into the cylinder and push it
approximately 40 mm (1.6 in) into the cylin-
der. Push the ring with the piston crown so
that the ring will be a t a right angle to the
cylinder bore.
@ 40 mm (1.6 in)
XMeasure:
Ring end gap
Out of specification 3 Replace.
NOTE:
,-4 You cannotmeasuretheendgap on the
expander spacer of the oil control ring. If
theoilcontrolringrails show excessive
gap, replace all three rings.
End gap
- Standard Limit
--
I
TOP 0.30 0.45 mm 0.7 rnrn

(0.012 0.018 in) (0.028in)
1 1 1
ring
0.30 -
I I I I
ring (0.012- 0.018mmin)

0.45 0.8 mm
(0.031in)
0.20 - 0.70 rnm -
ring (0.008 N0.028in)
I I I I
CYLINDER AND PISTON pTqpT
PISTON PIN INSPECTION
1.lnspect:
Piston pin
Blue discoloration/grooves 4
Replace, then inspect the lubrication sys-
tem.
2.Measure:
Piston pin-to-piston clearance
..................................
Measurement steps:
*Measure the piston pin outside diameter
8.
If out of specification, replace the piston
pin.
1 Outside diameter (pistonpin):

-
21.991 22.000 m m
-
(0.8658 0.8661 in)
a Measure the piston inside diameter@.

a Calculate thepistonpin-to-pistonclear-
ance with the following formula,
I
Piston pin-to-piston clearance =
Bore size (piston pin) 8-
Outside diameter (pistonpin) 8
*If out of specification, replace the piston.
"--
1 Piston pin-to-pistonclearance:
-
0.004 0.024 mm
.
(0.00016 0.00094 in)
<Limit: 0.07 mm (0.003 in)>
..................................
1 ; PISTON
INSTALLATION
7.lnstall:
Q-2 Piston rings

(onto the piston)
NOTE:
Be sure to install the piston rings so that
the manufacturer's marks or numbers are
located on the upper sideof the rings.
Lubricate the piston and piston rings lib-
orlll\r >with o n n i n n nil
-- -
I ~ ~~~ ~ ~~~
CYLINDER AND PISTON
2.Position:
1 ENG I \ j l I
Top ring
2nd ring
Oil ring
Offset the pistonring end gapsas shown.
@ T o p ring end
@ Oil ring end (lower)
@ Oil ring end (upper)
@ 2 n d ring end
I 1
3.lnstall:
Piston 0
0 Piston pin @
0 Piston pin clips @ m

NOTE:
I
Apply engine oil onto the piston pin, pis-
ton ring and piston.
Be sure that the arrowmark 8on the pis-
I
P tonpointstotheexhaustside of the
engine.
Before installing the piston pin clip, cover
the crankcase with a clean rag to prevent
thepistonpin clip fromfallinginto the
crankcase.
~~~~ ~~~ ~~ ~
4.Lubricate:
s Piston
Piston rings
Cylinder
NOTE:
Apply a liberal coating of engine oil.
-
____
==
CYLINDER INSTALLATION
?.Install:
Cylinder
I
I
0 Nuts(M10) ~142Nm(4.2rn.kg,30ft.lb) -
0 Bolts (M6) k l l 0 Nm (1.0 m . kg, 7.2 ft .Ib) I
NOTE:
Install thecylinder with onehand while
compressing the piston ringswith the other
hand.
,-.”
.,.~~..,~... ””’:.(.: .. .. .. .
%@Au&$$&&;
i .I
,..?~..
,.i*)..%-,y<**.rn.
Be careful nottodamagethetiming
chain damper during installation.
Pass the timing chain through the timing
chain cavity.
I_
- __-
RECOIL STARTER AND CDI MAGNETO

1- jm
H

CDI magneto removal Remove the partsin the orderbelow.
-.-. Engine oil Drain
Referto "ENGINE OIL REPLACEMENT"in
CHAPTER 3.
Front fender Refer to "SEAT, CARRIERS, FENDERS
AND FUEL TANK" in CHAPTER 3.
1 Recoil starter assembly 1
. 2 Cover 1
3 Locknut 2 Loosen. 1 of 2 has LH thread
. 4 Select lever shift rod 1 Refer to "CDI MAGNETO INSTALLA-
: 5 Select lever unit 1 TION".
: 6 CDI magneto coupler 1 -
: 7 Starter pulley 1 -Refer to "CDI MAGNETO REMOVAL/
: 8 Crankcase cover (left) /gasket 1/1 INSTALLATION".
. 9 Dowel pin 2 -
I
.
.
112 Nm (1.2 m kg, 8.7 ft Ibl 1
-
- --- -
'1
e ~
Job name/Part name Q'ty

-. __ __
Remarks
- ~~~
-
I Lead holder 1
I
~ Starter coil 1
Pickup coil 1
CDI rotor 1 to "CDI MAGNETO REMOVAL/
Woodruff key 1 1-Refer
INSTALLATION".
Starter driven gear unit 1
Oil delivery housing 1
Dowel pin /gasket Y1
Circlip 2
Oil seal 2
- procedure. -
-
I E N G I \ ~ ~ IH
I
RECOILSTARTER AND CDI MAGNETO
-?-'
Order Job
name/Part
name 1 Q'ty Remarks
Recoil starter disassembly Disassemble theparts in the order
below.
P- 0 Cap 1 -
@ Starter handle 1
-Refer to "RECOIL STARTER DISAS-
@ Friction plate I
SEMBLY / ASSEMBLY".
@ Pawl spring 1
0 Drive pawl 1
@ Spring 1
0 Sheave drum 1
@ Rope 1
@ Coil spring 1 -
For assembly, reversethe disassembly
procedure.
1 RECOIL STARTER AND CDI MAGNETO
CDI MAGNETO REMOVAL
1.Remove:
Select lever unit
NOTE:
-
Makesure that theselectleveris
NEUTRAL position.
2.Remove:
Starter pulley (
NOTE:
i
j
Use the rotor holder 0to

in the
hold the starter

pulley.
Rotor holder
P/N. YU-01235,90890-01235
1 3.Remove:
, Crankcase cover (left)
Gasket
Dowel pins
NOTE:
Working in a crisscross pattern,
loosen
each bolt 1/4 of a turn. Remove them after
all of them are loosened.
4.Remove:
CDI rotor @
NOTE:
0.
Use the flywheel puller
Flywheel puller:
P/N. YU-33270,90890-01362
I I
1 RECOIL STARTER DISASSEMBLY

1.Remove:
Cap 0
I Starter handle @
NOTE:
Before untying the knot @ above the starter
handle, make a knot @ in the rope so that
the rope isnot pulled into the case.
I I
CDI MAGNETO INSPECTION
r T - 1 \j IH
ENG
1.Inspect:
Starter coil
Pickup coil
Damage t Replace.
2.lnspect:
Gear teeth (starter wheel)@
@
Gear teeth (starter clutch)
Burrs/chips/roughness/wear t Replace.
STARTER PULLEY INSPECTION
E 1.lnspect:
Starter pulley
Cracks/pitting + Deburr or replace.
RECOIL STARTER INSPECTION

1.Inspect:
Rope 0
4 Sheave drum @
Drive pawl@
Weaddamage 4 Replace.
Coil spring @
Pawl spring @
Spring @
Fatigue + Replace.
1
I I\ml
I I r
I RECOIL STARTER AND CDI MAGNETO ENG

RECOIL STARTER ASSEMBLY
I d P
1.InstaII:
Sheave drum 0
Bk.. Rope @
Pawl spring @
Drive pawl @
f?!
d p
NOTE:
Wind the rope 4-1/2 turns clockwise around
the sheave drum. Then insert the rope into
the drumslit a.
2.lnstall:
0 Starter spring @
Sheave drum assembly@

NOTE:
Mesh the spring hook0with the case slit,
then wind thespringclockwise into the
case from the larger to smaller diameter.
Mesh the sheave drum hook @ with the
spring hook 0.
, 3.lnstall:
Spring 0
Friction plate @
0 Nut
1
NOTE:
Insert the spring hooks into the pawl side
holes.
I I
4.Turn the sheave drum 3-turn clockwiseto

give preload to the spring.
RECOIL STARTER AND CDI MAGNETO 1- j
w
I 1
.
5.lnstall:
Starter handle 0
Cap @
1 .
NOTE:
Pass the rope through the case hole and
make a knot @ on the rope so that the
rope is not pulled into the case.
Untie the knot @ after making a knot @
I I
above the handle.
CDI MAGNETO INSTALLATION
1.Apply:
& Sealant (Quick Gasket@)0

(into the slit)
1
~
F
Sealant (Quick Gasket@):
P/N. ACC-11001-05-01
Yarnaha bond No. 1215@:
P/N. 90890-85505
I I
2.lnstall:
Woodruff key
CDI rotor
.
NOTE:
Before installing the rotor, clean the out-
side of the crankshaft and the insideof the
rotor.
After installing the rotor, check that the
rotor rotates smoothly. If not, reinstall the
key and rotor.
3.lnstall:
. =
Dowel pins
Gasket
Crankcase cover (left)
.u
k I l 0 Nrn (1.0 m ..kg,7.2ft. Ib) I
I NOTE:
When installing thecrankcase cover (left),
usea long rod t o hold the CDI rotor in
position from the outside. This will make
assembly easier. Be careful not to dam-
.age theoil seal.

Tighten the bolts in stages, using a CriSS-
cross pattern.
I RECOIL STARTER AND CDI MAGNETO
~ ~~ ~~~
1-
I I
4.lnstall:
Starter pulley 0
lk150 Nrn (5.0 rn . kg, 36 ft . Ibl I
NOTE:
Use a rotor holder 0to hold the starter pul-
ley.
Rotor holder
P/N. YU-01235,90890-01235
NOTE:
Before installing the starter pulley, do not
forget to install the O-ring.
~ ~~~~
'.d
5.lnstall:
Select lever unit
NOTE:
Before installing the select lever shift rod,
makesure that the select lever and shift
cam is in the NEUTRAL position.
~~ ~~
6.Adjust:
Refer to "SELECT LEVER CONTROL
CABLE AND SHIFT ROD" in CHAPTER 3.
\u
PRIMARY AND SECONDARY SHEAVES 1- ENG \j E
PRIMARY ANDSECONDARY SHEAVES
w
-
,
Order
- Job name/Part name
--
Qty
- Remarks
-
-
Primary and secondary sheave Remove the parts in the order below.
c removal
Front fender Refer t o "SEAT, CARRIERS, FEND-
Rear fender rms, FUEL TANK" in CHAPTER 3.
1 Air duct assembly 1
2 Reverse control cable 1
3 Brake pedal adjuster 1
4 Pin 1
5 Spring 1
6 Pin 1
7 Rear brake cable 1
8 Footrest board (right) 1
9 - Crankcase cover(right) ~ --1 A
PRIMARY AND SECONDARY SHEAVES -
~ ~ ~~~~
Order RemarksJob name/Part name Qty

10 Primary sheave assembly 1 -
--.11 V-belt 1 -Refer to "PRIMARY AND SECONDARY
12 Primary fixed sheave 1 SHEAVES REMOVAUlNSTALLATION".
13 Secondary sheave assembly 1 -
procedure.
PRIMARY AND
SECONDARY r p qp
SHEAVES ENG f&ii
PRIMARY SHEAVE
- Qty -
E
7
Job name/Part name Remarks
-
Primary sheave disassembly Disassemble the parts in the orderbelow
-b 0 Primary pulley sheave cap 1 -
0 Primary pulley slider 4
0 Spacer 4 -Refer to "PRIMARY SHEAVE ASSEM-
0 Primary pulley cam I BLY".
0 Primary pulleyweight 8
0 Collar 1
0 Oil seal 2
8 Bush 2
0 Primary sliding sheave 1 -
For assembly, reverse the disassembly
! d
mocedure. -
1 PRIMARY AND SECONDARY SHEAVES -1
SECONDARY SHEAVE
Order Job name/Part name Qty Remarks

-
-
- 0
@
Secondary sheave disassembly
Nut
Spring seat
1
1
1
Disassemble the parts in the order below
Compression spring 1
@
@ Spring seat ' -Refer to "SECONDARY SHEAVE DIS-
ASSEMBLY / ASSEMBLY".
@ Guide pin 4
@ Secondary sliding sheave 1
Q) O-ring 2
@ Secondary fixedsheave 1 -
procedure. I
.
PRIMARY AND SECONDARY T
SHEAVES ENG
PRIMARY AND SECONDARY SHEAVES
%j I p-
REMOVAL
1.Loosen:
Nut (secondary sheave)@
Nut (primarysheave) @
NOTE:
-
Use the sheave holder 0to hold the pri-
mary sheave.
First, loosen the nut (secondary sheave) @,
then loosen the nut (primary sheave) 0.
~~~~~~ ~~ ~
Sheave holder:
P/N. YU-01880,90890-01701
'J
SECONDARY SHEAVE DISASSEMBLY

?.Remove:
0 Nut 0
..................................
Removing steps:
.Attach the sheave fixed block @, locknut
wrench 0and sheave spring compressor
@ t o the secondary sheave assembly.
H
I
Sheave fixed block:
P/N. YM-04135, soago-04135
Locknut wrench:
P/N. 90890-01348
Sheave spring compressor:
PIN. YM-04134, soago-04134
r- I
.Place the sheave fixed block'ina vise and

I
I
I
b
I
secure it.
.Tighten the sheave springcompressor
nut @ and compress the spring.
0Loosen thenut ( ij the locknut wrench
with
0.
.Remove the nut0.
.Remove the sheave springco'mpressor
and locknut wrench.
...................................
1 I
3 PRIMARY AND SECONDARY SHEAVES 1-
ksb +
PRIMARY SHEAVE INSPECTION
1 .Inspect:
Weight outside diameter8
Out of specification -+ Replace the weight.
Weight outside diameter:

30 mm (1.18 in)
<Limit> : 29.5 mm (1.16 in)
I I
I I 2.lnspect:
Primary puller slider
Primary sliding sheave splines
Wear/cracks/damage + Replace.
Spacer
k
9@ Primary puller c a m
@@ Cracks/damage + Replace.
‘r’
I I
3.lnspect:
Primary sliding sheave
Primary fixed sheave
Cracks / damage -+ Replace.
SECONDARY SHEAVE INSPECTION

lhspect:
I
~~ ~~
.
I
Secondary fixed sheave smooth operation
Secondary sliding sheave smooth operation
I Scratcheddamage --f Replace as a set.

2.lnspect:
Torque cam groove@
’I
Wearldamage -+ Replace.
3.lnspect:
Guide pin @
Wear/darnage + Replace.
4.lnspect:
1 I
Secondary sheave spring
Damage 3 Replace.
~~~
5.Measure:
Secondary sheave spring free length@
Out of specification + Replace the sec-
ondary sheave spring.
I I
9 Free length:
125.9 mm (4.96 in)
<Limit> : 122.9 mm (4.83 in)
-
1
I
\= IH-
PRIMARY SHEAVE ASSEMBLY
ENG
1.Clean:
J Primary sliding sheave face (iJ

Primary fixed sheave face @
Collar @
Weight @
Primary sliding sheave cam face
;
-
b
NOTE:
Remove any excess grease.
2.lnstall:
Weight @
NOTE:
Apply Shell SSG-2656-2 grease (120 g) to
the whole outer surfaceof the weight and
install.
Apply SSG-2656-2 grease to the inner sur-
face o f the collar.
+-’
I I
7
3.lnstall:
a Spacer
Slider @
Cam @
Primary sliding sheave cap
[&13 Nm (0.3 rn . kg, 2.2ft . Ib) I
I I
I I SECONDARY SHEAVE ASSEMBLY
:I 1.Apply:
BEL-RAY assembly lube*
(to the secondary sliding sheave 0 inner
surface,grease nipplegroove, and oil
seals)
BEL-RAY assembly lubea
(to the bearings, oil seals and inner sur-
face of the secondary fixed sheave @)
1 1 2.lnstall:
Guide pin 0
I I
1 PRIMARY AND SECONDARY SHEAVES
3.Apply:
BEL-RAY assembly lubee
- a,
(to the guide pin sliding groove and oil
seal @
4.lnstall:
Spring seat
m)
Compression spring
Spring seat
Nut
XtXX**X+**XXXX~****X***~*****~****
Installing steps:
-- ~ A t t a c hthesheavefixedblock,locknut
wrench and sheave spring compressor to
the secondary sheave assembly.
Sheave fixed block:

P/N. YM-04135,90890-04135
- Locknut wrench:
P/N. 90890-01348
Sheave spring compressor:
P/N. YM-04134,90890-04134
.Place the sheave fixed block in a vise and

secure it.
.Tighten thesheavespringcompressor
nut 0and compress the spring.
Olnstall the nut@ and tighten it to thespec-
ified torque using the locknut wrench.
% Nut:
?-,
90 Nm (9.0 m kg, 65 ft Ib)
~ R e r n o v e t h e sheavespringcompressor,
locknut wrench, and sheave fixed block.
***********X**********************
5.lnstall:
V-belt
-
~~~~~
~~ ~ ~~ ~ ~~ ~ ~~
I ENG I%ml ~~
IH-
I

INSTALLATION
1.lnstall:
Secondary sheave assembly
V-belt
Primary sheave assembly
2.Tighten:
Nut (primary sheave) 0
k l l O 0 Nrn (10.0m . kg, 72 ft Ib)l.
Nut (secondary sheave) @
[ k l l O O Nm (10.0rn . kg, 72 ft . IbJl
NOTE:
Use the sheave holder @ to hold the pri-
mary sheave.
First, tighten the nut (primary sheave) 0,
then tighten the nut (secondary sheave)
~~
0.
~ ~~~~~ ~ ~ ~ ~
4
'd
Sheave holder:
P/N'. YU-01880,90890-01701
w
J I CLUTCH )
CLUTCH w
-
1;
I
-
~~ ~
-
c"" Job name/Part name
Clutch removal
Primary and secondarysheaves
Q'ty Remarks
Remove the partsin the orderbelow.
-
SHEAVES".
Cover 1
Clutch housing assembly 1 1
Gasket / dowel pin 1/2 -Refer to "CLUTCH REMOVAL /
One-way clutch bearing I INSTALLATION".
7 Nut 1 -
Clutch carrier assembly 1
Collar 1
- procedure.
-
-
CLUTCH I ENG I@ s jI IH-
If
- -.- w -.
F
Order
-.
Job name/Part name
Clutch housing disassembly
Q'ty
- Remarks
Disassemble the parts in the order
below.
-
Oil seal 1
Circlip 1
Bearing housing 1
Bearing retainer 1
Bearing 1
Collar / O-ring 1
Circlip 1
Bearing 1
Clutch housing 1
- --- procedure. -
1
CLUTCH REMOVAL
CLUTCH m ENG %j
1.Remove:
Clutch housing assembly
Gasket
Dowel pins
NOTE:
Working in crisscross pattern, loosen each
bolt 1/4 of a turn. Remove them after all of
them are loosened.
2.Straighten:
0.
Punched portion of the nut
3,Remove:
0 Nut 0
NOTE:
Use a clutchholding tool @ to holdthe
clutch carrier assembly.
Clutch holding tool:

P/N. YM-91042,90890-04086
CLUTCH INSPECTION
1.Inspect:
Clutch housing 0
Heat damage/wear/damage + Replace.
One-way clutch bearing @
Chafing/wear/damage -+ Replace.
NOTE:
Replace the one-way clutch assemblyand
clutch housing as a set.
Theone-wayclutchbearingmustbe
in.
installed with the flange side facing
***********Y**********************
Clutch operation:
olnstalltheone-wayclutchbearingand
clutch carrier assemblyt o the clutch hous-
ing and hold the clutch carrier assembly.
.When turning the clutchhousingclock-
wise @, the clutch housing should turn
freely.
If not, theone-wayclutchassembly is
faulty.
Replace it.
.When turning the clutch housing counter-
clockwise E!, theclutch
housing and
crankshaft should be engaged.
If not, theone-wayclutch assembly is
faulty.
Replace it.
2.lnspect:
CLUTCH T I
\j )
E
ENG
Clutch shoe
Heat damage + Replace.
3.Measure:
Clutch shoe thickness
B
I~~ ~~~~
Clutch shoe thickness:
2.0 mm (0.08 in)
Clutch shoe wear limit @:
1.5 mm (0.06 in)
~~~~
~~~ 1 I
L -'
CLUTCH INSTALLATION
1.lnstaII:
Collar
Nut 0 =
Clutch carrier assemblv
b 1 1 4 0 Nm (14.0 m . kg, 100 ft . Ibi
NOTE:
Use a clutchholding tool 0 to holdthe
clutch carrier assemblv.
P I c~~hyh~-dgi~~~~~890-04086 I
2.Lock the threads with a drift punch.
x-
3.lnstall:
One-way clutch bearing
NOTE:
Theone-way clutch
bearing should be
installed in the clutch carrier assemblywith
the mark "OUT SIDE" 8facing toward the
clutch housing.
4.lnstall:
Gasket =
Dowel pins
Clutch housing assembly'

h 1 1 0 Nm (1.0 m . kg, 7.2 ft . Ib) 1
NOTE:
Tighten the bolts in stages, using a criss-
cross'pattern.
After tightening the bolts, check that the
clutch
housing assembly rotates
smoothly.
%d
'-.
-,
CRANKCASE 1- IH-
CRANKCASE
STARTER MOTOR, TIMING CHAIN AND OIL FILTER
.
b 1 1 8 Nm (1.8 m . kg, 13 ft Ib) I
- -
Order Job name/Part name Remarks
-_Q'ty -
Starter motor, timingchain and oil Remove the parts in the order below.
filter removal
L,. i
Engine assembly Refer to "ENGINE REMOVAL".

Cylinder head cover Refer to "CYLINDER HEAD COVER".
Refer to "CAMSHAFT AND CYLINDER
Cylinder head HEAD".
Cylinder and piston Refer to "CYLINDER AND PISTON".
Refer to "RECOIL STARTER AND CDI
Recoil starter and CDI rotor
MAGNETO".
Primary and secondary sheaves
SHEAVES".
Clutch carrier assembly Refer to "CLUTCH".
1 Starter motor/ O-ring 1/1
2 Timing chain guide (intake) 1
3 Timingchain . 1
4 / O-ring
Oil filter cover 111
5 Oil filter element - 1 I -
p-
1 CRANKCASE 1-
118 Nm (1.8 rn . kg, 13 ft . Ibl I
- -
I
Y
- -. Q'ty -
6 Oil delivery pipe/ O-ring 1/2
i..I
7 Oil filler plug 1
8 Engine oil drain plug /O-ring 1
9 Compression spring 1
10 Oil strainer / oil supply pipe 1/1
11 Thermo unit / copper washer 1/1
Neutral / reverse switch /copper
12 1/1/2
washer
13 Return spring 1
14 Lever (outside) 1
15 Collar 1
16 Lever (inside) 1
17 Spring 1
18 Ball 1
- I - Drocedure.
d
CRANKCASE 1- IH.
CRANKCASE
- 1
2
Crankcase separation
Crankcase (right)
Collar / O-ring
1 -
1/1 -Refer to "CRANKCASE SE'PARATION/

3 Dowel pin 2 ASSEMBLY".
4 Crankcase (left) 1 -
For installation, reversethe removal
procedure.
il
CRANKCASE BEARINGS
CRANKCASE -
X&,
p-
~ ~~~~
Job name/Part name Remarks

-
Q'ty
1;
- -
Crankcase bearing removal Remove the partsin the order below.
Transmission and crankshaft Refer to "TRANSMISSION AND
Middle drive shaft assembly TCRANKSHAFT".
Oil pump assembly Refer to "OIL PUMP".
Oil seal 4
Bearing 10
- procedure. -
CRANKCASE
CRANKCASE SEPARATION
1- m
I
1.Separate:
Right crankcase
Left crankcase
..................................
Separation steps:
*Remove the crankcase bolts.
NOTE:
Loosen each bolt 1/4 of a turn a t a time
and after all thebolts are loosened,
i
remove them.
Loosen the bolts in numerical order (see
numbers on the illustration).
B Left crankcase
H Right crankcase
*Remove the right crankcase.
I-’
NOTE:
Insert a screwdriver or pry bar into the pry
points in the crankcase and then carefully
pry apart the crankcase halves.
.,... ,..,~..~.,~:,,,:,.~,,~:~,~~~~~~,,.~
$;;p&UTt$JW.i-
...
X ? \ _.,.
.;, ::.....,._*‘:
Use a soft hammer to tap on one side of
t h e crankcase. Tap only on reinforced por-
tions of the crankcase. Do not t a p o n t h e
crankcasemating surfaces. Work slowly
and carefully. Make sure that the crankcase
halves separate evenly.
*Remove the collar (with O-ring).
Remove the dowelpins.
..................................
---/
TIMING CHAIN AND GUIDEINSPECTION

1.lnspect:
Timing chain
Cracks/stiff -+ Replace the timing chain
and camshaft sprocketas a set.
2.lnspect:
Intake side timing chain guide
~~
I CRANKCASE 1-
OIL STRAINER, OIL FILTER AND OIL
DELIVERY PIPE INSPECTION
1.lnspect:
Oil strainer 0
Oil filter @
O-rings @
Damage 4 Replace.
2.lnspect:
.I
9 Oil delivery pipe
Crackddamage -+ Replace.
Clogged + Blow out with compressed air.
CRANKCASE INSPECTION
1.Thoroughlywashthe case halves in a
mild solvent.
2.Clean all the gasket mating surfaces and
crankcase mating surfaces thoroughly.
3.lnspect:
Crankcase
Cracks/damage 4 Replace.
Oil delivery passages
Clogged -+ Blow out with compressedair.
I
BEARINGS AND OIL SEALS INSPECTION
I 1.lnspect:
Bearing
Clean and lubricate, then rotate the inner
race with a finger.
1
I
I
\
I
~
1
I
I
Roughness 4 Replace.
2.lnspect:
Oil seals
Darnage/wear --f Replace.
__
CRANKCASE ASSEMBLY
CRANKCASE 1- p
1.Apply:
Sealant (Quick Gasket'") @
(tothemating surfaces of both case
halves)
B
I
Sealant (Quick Gasket%
P/N. ACC-11001-05-01
Yamaha bond No. 1215:
P/N. 90890-85505
2.lnstall:
Dowel pin @
3.Fit the left crankcase onto the right case.
Tap lightly on the case with a soft hammer.
, ,.._: .... . ..
.
~ ~
.;$.Q&JTifjp&;;.'
<..
-,,
~ _
;
<
;>~
,>
:;,.,<
.>-~ -",
> i *<
. %
.>
Before installing and torquing the crank:

case holdingbolts,besureto check
'i
whether the transmission is functioning
properlybymanuallyrotatingtheshift
c a m in b o t h directions.
Be sure t o install the rubber damper @ in
order t o enable proper oil flow through
the engine and avoid engine damage.
4.Tighten:
Crankcase bolts
(follow the proper tightening sequence)
r~
NOTE:
Install the clampon the bolt @, @.
-
@ @ (M6) [ k i l o Nrn (1.0 rn. kg, 7.2 ft . Ib) 1
@- @(M8)
I l& 131 Nm (3.1 rn . kg, 22 ft . Ib) I
m Right crankcase
El Left crankcase
-
M 6 x 35 mrn .@
M 6 x 40 mm 00088
M 6 x 55 mrn @@@@@@
I I
M 6 x 60 mrn 00
M 6 x 90 mm 0
M 8 x 50 mm @@I@@
5.Apply:
4-stroke engine oil
(to the crank pin, bearing and oil delivery
hole)
-
.
6.Check:
Crankshaft and transmissionoperation
Unsrnooth operation -+ Repair.
I I
.
I TRANSMISSION
CRANKSHAFT
TRANSMISSION AND CRANKSHAFT
AND
6
-
33 Nm (3.3 rn . kg, 24 ft . Ib) I
12

Transmission and crankshaft removal Remove the parts in the order below.
d
Crankcase separation Refer to "CRANKCASE".
1 Idle gear 1
2 Secondary shaft 1
3 Guide bar 1 -
4 Shift fork "R" 1
-Refer to "TRANSMISSION INSTALLA-
5 Clutch dog 2 I
TION".
6 Shift cam 1
7 Shift fork "L" 1
8 Spring /springcap 1/1
9 Middle drive shaft assembly 1
10 Drive axle assembly 1 -
11 Balancer 1 TRefer to "CRANKSHAFT REMOVAL /
12 Crankshaft 1 CRANKSHAFT AND BALANCER
13 Rubber damper 1 INSTALLATION".
procedure.
####h,, / * I, , I
-
TRANSMISSION AND CRANKSHAFT

CRANKSHAFT REMOVAL
1- p
1.Remove:
Crankshaft
Use acrankcase separating tool 0 and
slide hammer bolt 0.
4
P
Crankcase separating tool:
P/N. YU-01135-A, 90890-01135
Slide hammer bolt (MS):
P/N. YU-01083-2,90890-01085
I I
SHIFT FORK INSPECTION
1.lnspect:
Shift fork cam follower@I
Shift fork pawl @
Scoringlbendslwearldamage -+ Replace.
Zlnspect:
Guide bar
Roll the guide baron a flat surface.
Bends -+ Replace.
m 1 -
Do not attempt to straighten a bent guide

bar.
319-010
3.Check:
Shift fork movement
(on the guidebar)
Unsmooth operation -+ Replace the shift
'-_
~
fork and the guide bar.
3 1 9-011
4.lnspect:
Spring cap
Spring
. --
I TRANSMISSION AND CRANKSHAFT
SHIFT CAM INSPECTION
1-
1.lnspect:
Q
Shift cam grooves
Scratches/wear/damage -+ Replace.
~~ ~~
I
I TRANSMISSION INSPECTION
I Q 1.Measure:
Axle runout
Use a centering device and a dial gauge.
Out of specification --f Replace t h e bent
axle.
Runout limit [drive axle):

0.03 mm (0.001 in)
319-M1
Y
I I 2,inspect:
Gear teeth
Blue discoloration/pitting/wear-+
Replace.
Mated dogs
Rounded edges/cracks/rnissing portions
-+ Replace.
I ~ ~~~
I
3.Check:
Gear movement
Unsmooth -+ Repeat steps #I and #2 or
replace the defective parts.
--_-I 4.lnspect:
Circlip
Benddloosenessfdarnage -+ Replace.
. ^.
TRANSMISSIONAND CRANKSHAFT
CRANKSHAFT INSPECTION
1- I
1.Measure:
Crank width @
Out of specification -+Replace the crankshaft.
fl Crank width:
74.95 75.00 mm
(2.951 2.953 in)
-
-
cgk:z
Side clearance @ I
Out of specification --f Replace the crankshaft.
d
u 8
6 Runout 0
Big end side clearance:
-
0.35 0.65 mm (0.014 0.026 in)
<Limit: 1.0 mm (0.040 in)>
Out of specification -+Replace the crankshaft.

-
, I
fi Runoot limit:
C1: 0.03 m m (0.0072 in)
C2: 0.03 m m (0.0012 in1
..................................
E
'!;.;. Crankshaft reassembling point:
The crankshaft 0 and the crank pin @ oil
passages must be properly interconnected
with a tolerance of less than 1 mm (0.04 in).
..................................
. .,.._................:....,: ....
... .,:
z:;a&ay@.fyl$):
,. ~. ~, y-
/.. ,...:_.._.
.x__,,
<i,,,A e: G'
The buffer boss and woodruff key should

be replaced when removed from thecrank-
shaft.
._
1 TRANSMISSION
CRANKSHAFT
AND
CRANKSHAFT AND BALANCER
1-
INSTALLATION
1.InstaII:
Crankshaft
Crankshaft installer pot 0:

P/N. 90890-01274
Crankshaft installer bolt 0:
P/N. 90890-01275
Crankshaft installer set 0:
P/N. YU-90050.
Adapter #12 0:
P/N. YM-01383.90890-01383
Crank pot spacer 0:
P/N. YM-91044,90890-04081
Spacer 8:
P/N. 90890-01016
NOTE:
Hold the connecting rod a t the Top Dead
',4 Center (TDC) with one hand while turning
the nut of the installing tool with the other.
Operate the installing tool until the crank-
shaft bottoms against the bearing.
T . ,,. <,,
<.
;.<&AQy[QfVi,;.
.L
I<-,
I< ___ . -. '

I'W,$W?>X<>>.>,
Y
,%..< x I j
j.
Apply engine oil to each bearing to protect

the crankshaft against scratches andto
make installation easier.
2.lnstall:
Balancer 0
r
NOTE:
Align the punch marks @ on the drive and
driven gear.
I m
TRANSMISSION INSTALLATION
1.lnstall:
Spring cap
Spring
Shift fork "L" 0
Shift cam @
0 Clutch dog 2 @
Shift fork "R" @

Guide bar @
I I
. __
TRANSMISSION AND CRANKSHAFT 1
- D
NOTE:
Thenumberstampedintotheshiftfork
must always face towards the right side of
the crankcase. Be surethattheshiftfork
guidepin is properly seated in theshift
d r u m groove.
. 4
2.Check:
Shift operation
Unsmooth operation --f Repair.
NOTE:
Oil each gear and bearing thoroughly.
* Before assembling the crankcase, be sure
that the transmission is in neutral and that
the gears turn freely.
r A / I
\u
6 8, , 88 I, -
1 OIL PUMP
OIL P U M P 1-
i 1
\--
1~
-
I a
- - -r
3
- - -. -
Oil pump removal Remove the parts in the orderbelow.
Crankcase separation Refer to "CRANKCASE".
Circlip 1
Oil pump driven gear 1
Oil pump assembly/ gasket 111
Idle gear 1
6 Holder 1
Relief valve/ O-ring 111
Spring cap/ spring seat 1/1/1
,
- - A
procedure. -
OIL PUMP mp
li
-- -
F
-I 7
- - ~ - -
Oil pump disassembly Disassemble the parts in the order
below.
Oil strainer 1
0 Spring retainer 1
Spring 1
Relief valve 1
Rotor housing 1 1
Inner rotor 1 1
Outer rotor 1 1
Dowel pin 2
Pump cover 1
Dowel pin 2
i
Shaft
-- 1 A -
1 OIL PUMP 1-
t
. . ,
.
h i 7 Nm 10.7 m kg, 5.1 ft Ib)
a ]

@ Inner rotor 2 1
-0
@
Outer rotor 2
Rotor housing 2
1
1
procedure.
OIL PUMP j
ENG) 1-37
%jI
OIL PUMP INSPECTION
1 .Inspect:
Q@ Oil pump driven gear
@i 33)
0 Rotor housings
Rotor cover
Cracks / w e a r / Damage + Replace.
I I 2.Clean:
Oil strainer
%
3.lnspect:
Oil strainer
Damage --+ Replace.
Relief valve
Spring
Wear / damage 3 Replace.
-i
I
4.Measure:
Tip clearance@
(between the inner rotor 0and the outer
rotor 0)
4 Side clearance @
(between the outer rotor 0and the pump

housing 0)
Out of specification 4 Replacetheoil
pump.
Tip clearance 8:
0.12 mm (0.005 in)
<Limit: 0.2 mm(0.008 in)>
~.-..-
Side clearance @.
- -
0.09 0.15 mm (0.004 0.006 in)
<Limit: 0.22 mm (0.009 in)>
5.Check:
Unsmooth -+ Repeat steps #I and #3 or
replace the defective parts.
I MIDDLE GEAR
MIDDLE DRIVE S H A f l
MIDDLE GEAR -
- - -
F
-
Order Job narnejPart name
Middle driveshaft removal
-
m y Remarks
Refer to "CRANKCASE".
Refer to "TRANSMISSION AND
Shift fork
CRANKSHAFT".
1 Nut 1 Refer to "MIDDLE DRIVE SHAFT
2 Middle drive piniongear 1 rREMovAt-/ tNsrALLATm**.
Refer to "MIDDLE DRIVE AND DRIVEN
3 Shim
GEAR SHIM SELECTION".
4 Bearing retainer 2
5 Bearing housing 1
6 Drive axle assembly I I
7 Circlip 2
8 Drive gear (middle drive shaft) 1
9 Middle drive shaft 1
- - procedure.
-
MIDDLEGEAR T
ENG "*;o"s, I IT
MIDDLE DRIVEN SHAFT
.
b 1 9 7 Nm (9.7 rn kg, 70 ft . Ibl
[\I97 Nrn (9.7 rn . kg, 70 ti. 15)
-
~~~~ ~~~~~~ ~ ~ ~ ~~~~
-
F
Order
-
Job name/Part name
Middle drivenshaft assembly
Qty Remarks
Refer to "CRANKCASE". I
-
I
:i
Circlip
Bearing Refer to "MIDDLE DRIVEN SHAFT
REMOVAL/ INSTALLATION".
Universal joint 1
Universal joint yoke 1
Bearing housing / O-ring 1/1
Bearing retainer 1 '
Shim Refer to "MIDDLE DRIVE AND DRIVEN
GEAR SHIM SELECTION".
Middle drive pinion gear 1
Damper cam 1
10
11 I Spring
Gear coupling
1
1
a
I MIDDLE GEAR 1-
%
,-
h 1 9 7 N m (9.7 m . kg, 70 ft . Ib)

12 Circlip 2 -
v
13 Bearing * -Refer to "MIDDLE DRIVE SHAFT
REMOVAL/ INSTALLATION".
14 Universal joint 1
15 Universal joint yoke 1
16 Bearing retainer 1
17 Middle drivenshaft 1 -
procedure.
-
MIDDLE GEAR
MIDDLE DRIVE SHAFT REMOVAL
m-
IENG ““s, I
1.Straighten: I
Punched portion of the nut (middle drive

pinion gear)
2.Loosen:
Nut (middle drive pinion gear)0
NOTE:
Place a copper plate @ between the teethof
L .- the drive gear and the driven gear to lock
them.
3.Remove:
Nut (middle drive pinion gear)
Middle drive pinion gear
Shimls)
~ -‘
MIDDLE DRIVEN SHAFT REMOVAL
88 1.Remove:
Universal joint
***+********X**********++**********
Universal joint removal steps:

0 Remove the circlips0.
Place the U-joint in a press.
.With a suitable diameter pipe @ beneath
~
the yoke @, press the bearing @ into the
pipe as shown.
1
NOTE:
It may be necessary to lightly tap the yoke
with a punch.
0 Repeat the steps for the opposite bearing.
0 Remove theyoke.
NOTE:
with a punch.
..................................
. __
I I s-1
Y
1 * 1
MIDDLE GEAR ENG
2.Remove:
6 Nut (i
J
Washer
Universal joint yoke (rear side)
NOTE:
Use the universal joint holder@ to hold the
universal joint yoke.
I ~ ~~ I Universal joint holder:

P/N. YM-04062,90890-04062
I 1
3.Remove:
6 Bearing housing assembly 0
* * * * * * Y * X * * * ~ * * X I * * * * * * * Y * ~ * X Y X ~ X *
Bearing housing removalsteps:

*Cleantheoutside of the middledriven
shaft.
*Placethemiddledrivenshaftonto a
Y hydraulic press.
- . .. .
.>$: , ,,
;siQ&gf@&+,'"-
:,
Ij <.:< ,.
I %,.
I
, ,
1
,,
Never directly press the shaft endwith a

hydraulic press, this will result in damage
to t h e shaft thread.
Install the suitable socket@ on the shaft
end t o protect the thread from damage.
*Press the shaft end and remove the bear-
ing housing.
***XX**YY*X***********************
4.Remove:
I Bearing retainer
Bearing
*~~**XIIKYX~*****Y**************,*
0
-I Removal steps:
.Attach the folded rag0.
*Secure the bearing housingedge in the vise.
*Attach the bearing retainer wrench 0.
. .,,x>.A.p,,,<fl
Bearing retainer wrench:
P/N. YM-04128,90890-04128
$??jg&@mQ,@y:
.>><<.A:,~.v~,,-..
,,. :::.--,*. .,,"%>,

b; ,,.
,<,
The middledrivenshaftbearingretainer
hasleft-handedthreads. To loosen t h e
retainer turn it clockwise.
oRemove the bearing retainerand bearing.
X*X***f,*X*YtX*X*X*+*******t*~~*~*
1 I s-1 II-'
1
MIDDLE GEAR E N
5.Remove:
0 Nut 0
Washer
Universal joint yoke (frontside)
NOTE:
Use the universal joint holder0to hold the
universal joint yoke.
~ ~-
I 1 Universal joint holder:

P/N. YM-04062,90890-04062
I I
&Remove:
a Bearing retainer 0
a Bearing @
NOTE:
Attach the ring nut wrench0.
Ring nutwrench:
"P-'
I ~~ I P/N. YM-38404,90890-01430
I . J
<:... ..,. ,..:'..6(*..;<,.,

$':gAunQ&J:;i-i
\<...A ..
-,,i_*
,,: ,
Themiddledrivenshaftbearingretainer
has left-handedthreads. To loosen t h e
retainer turnit clockwise.
I 1
7.Remove:
a Middle driveshaft 0
(with bearing)
I I
t I 1
INSPECTION
1.lnspect:
Damper camsurfaces
Wearkscratches 4 Replace damperand
driven pinion gear as a set.
2.lnspect:
Damper spring
Damagehracks -+ Replace.
I I I
1 MIDDLE GEAR I ENG Is-1
I I 3.lnspect:
Gear teeth (drive pinion gear) 0
Gear teeth (driven pinion gear)@
Pitting/gaIIing/wear -+ Replace.
I I
4.lnspect:
O-ring
Damage + Replace.
Bearings
Pitting/damage -+ Replace.
5.Check:
U-joint movement
Roughness 4 Replace U-joint.
’4
a
MIDDLE DRIVE AND DRIVEN GEAR SHIM
SELECTION
Whenthedriveanddriven gear, bearing
housing
assembly
and/or crankcase
replaced, be sure to adjust the gear shim0.
1.Select:
~~ ‘?C
Middle drivegear shim @
I
-
I Middle drivengear shim @
..................................
Middle driveanddrivengear shim selec-
tion steps:
.Position middle drive and driven gear by
using shims @ and @ with their respec-
tive thickness calculatedfrom information
marked on crankcase, bearing housing
and drive gearend.
@ Shim thickness “ A
@Shim thickness “B”
.To find shim thickness “A” use following
formula:
~~
Middle drive pinion gear shim thickness:

“A“=@-@-@-@
- -
-
Where:
MIDDLE GEAR mI I-
@ = a numeral (usually a decimal num-
ber) on the bearing housingis either
added to or subtracted from "18.5".
@ = bearingthickness(consideredcon-
stant).
@ = thickness (considered constant).
ber) an the right crankcase specifies
1 I a thickness of "90".
Example:
1) If the bearing housingis marked "+02",
..... @ is 18.52,
2) @ is 16,
3) 0is 55.
4) If the crankcase (right) is
marked
"90.01 ",
..... @ is 90.01.
5) Therefore, the shim thickness is 0.47 rnm.
~~ ~~
, 1
A = 90.01 - 18.52 - 1 6 - 5 5
= 0.49
6) Round off hundredths digit and select

appropriate shimb).
w In theexample above, the calculated
shim thickness is 0.49 mm. Thechart
instructs you, however, to round off 9 to
I I 10.
Hundredths Round value
0,l.2 0
3,4,5,6,7 5
</
€49 10
~~ ~
,
-
Shims are supplied in the following thick-
ness.
Middle drive pinion gear shim
0.10 0.30
Thickness (mm) 0.15 0.40
- 0.20 0.50
1 1 I @&-j-j-l
I
MIDDLE GEAR ENG

.To find shim thickness "B" use the follow-
ing formula:
I
Middle drivenpinion gear shimthick-

ness:
"B"=@-@+@-@-0-0.05
Where:
ber) on the bearing housing is either
1 I
added to or subtracted from "76".
t 1 @ = a numeral (usually a decimal num-
ber)onthemiddledrivenpinion
gear is either added to or subtracted
from "59".
ber)onthemiddledrivenpinion
gear is either added to or subtracted
from "79.5".
'"i @ = a numeral (usually a decimal num-
I
1
ber) on t h e left crankcase specifies a
thickness of "94.3".
I I 6)= a numeral (usually a decimal num-
ber) on the right crankcase specifies
a thickness of "1.3".
Example:
1) If the bearing housing is marked "-15",
..... @ is 75.85.
2) If the driven piniongear is marked"+02",
..... 0is 59.02.
)=
3) If thedriven pinion gear is marked "+02",
..... @ is 79.52.
4) If the crankcase (left) is marked "94.31",
..... (8 is 94.31.
5) If the crankcase (right) is marked"1.36",
..... 0is 1.36.
1
6)Therefore, the shimthickness is 0.63 mm.
B = 75.85 - 59.02 -I-79.52 - 94.31 - 1.36 -
0.05 = 0.63
I I 7) Round off hundredths digit and select
a * appropriate shim(s1.
In theexample above, the calculated
shim thickness is 0.63 mrn. The chart
instructs you, however, to round off 3
'
))
0
sa31
I.*
sa31
I.*
0
0
0
0
0
0
@@ II 0
0
1
0
E
I
I
I
II
t o 5.
Hundredths
0, 1,z
II
II
Round value
0
1
I
I
I
I
3,4,5,6,7 5
I J
8,9 10
-
~~~~~
MtDDLE GEAR
~
I I% j l I 1- 1
ENG
ness.
Middle drive piniongear shim
0.10 0.40
0.20 0.60
0.30
*x*******************x************
MIDDLE DRIVEN SHAFT INSTALLATION

1.lnstall:
i4
Bearing retainer C
J
pq180 Nm (8.0 rn . kg, 58 ft . Ib) I
NOTE:
Attach the ring nut wrench0.
Ring nut wrench:

t ~~ ~~ ~~~ I
P/N. YM-38404,90890-01430
L
@F&gjyf#ggg$
+&.m:&fi.@ he.&&*dm
Themiddledrivenshaftbearingretainer
hasleft-handedthreads. To tightenthe
retainer turnit counterclockwise.
I I 2.lnstall:
Universal joint yoke (front side)
Washer
Nut@ 4 ~197Nrn(9.7m-kg,70ft.Ibj 1
NOTE:
Use the universal joint holder@ to hold the
yoke.
s I
w1
I' I
~ ~~~~~~
Universal joint holder:

P/N. YM-04062,90890-04062 I
I
.
1
1
I 1
MIDDLE GEAR
3.lnstall:
I
I
ENG I% ) l
Bearing retainer 0
****X*****************************
Installation steps:
@Attach the folded rag 0.
@Secure the bearing housing edge in the vise.
.Attach the bearing retainerwrench 0.
1
~~~~~~ ~
\ 7 II / \
1
p l
I- I
P/N. YM-04128,90890-04128 1 I
*Tighten the bearing retainer.
jii'",.'r..~.:.-.:,....'...,.
+ ; : .~I U:,..x
:.!%..:%.",
x:l O ~ .
~ _,,
,,__-I_ .
ZT
The middle drivenshaftbearingretainer

hasleft-handedthreads. To tightenthe
retainer turnit counterclockwise.
Bearing retainer:
110 Nm (11.0 m kg, 80 ft Ib)
'-
*Y**YX**+**K***X**XX*~************
1 1 4.lnstall:
Shims @
4 Bearing housing
NOTE:
Install the shims so that the tabs are posi-
tioned as shown in the illustration.
I I
5.lnstall:
Universal joint yoke (rear side)
Washer
Nut 0 4
l
k 197 Nm (9.7 rn . kg, 70 ft Ib) f 1
NOTE:
Use the universaljoint holder @ to hold the
yoke.
~~~ ~~ ~

PIN. YM-04062,90890-04062
- -,
MIDDLE GEAR m
ENG % j p
6.lnstall:
Universal joint
..................................
Universal joint installation steps:
olnstall the opposite yoke into the U-joint.
.Apply wheel bearing grease to the bear-
ings.
I ~ I
.Install the bearing Q onto the yoke.

;
[i;?pAGj"tGN;:
li. .,.. . ..,....,:I *, I*I
Check each bearing. The needles can easily

fall out of their races. Slide the yoke back
and forthon the bearings; the yokewill not
go all the w a y onto a hearing if a needle is
out of place.
Y .Press each bearing into the U-joint using
a suitable socket.
NOTE:
Thebearing must beinsertedfarenough
into the U-joint so that the circlip can be
installed.
.Install thecirclips @ into t h e groove of
each bearing.
**************X*******************
I ~~
I
I
MIDDLE DRIVE SHAFT INSTALLATION
1 .Tighten:
Nut (middle drive pinion gear)0 =
1k1145 N m (14.5m . kg, 105 ft . Ib)(
NOTE:
Place a copper plate @ between teethof the
drive gear and driven gearto lock them.
2.Lock the threads with a drift punch.
1 I I% j l
k
MIDDLE GEAR ENG
I
GEAR LASH MEASUREMENT
1.Measure:
Gear lash
Middle gear lash:

-
0.1 0.3 m m (0.004 - 0.012 in)
******************X***************
Measurement steps:
I I eAttach the pinion gear fix clamp @ to the
I
middledrive shaft. -
Pinion gear fix clamp:

P/N. YM-04129,90890-04129
.Attach the gear lash measurement tool@

and dial gauge 0.
Gear lash measurement tool:

P/N. YM-01231,90890-01231
'-f.
I I
@ 46 mm (1.8 in)
eMeasure the gear lash while rotating the
middle driven shaft back and forth.
NOTE:
Measure the gear lash a t 4 positions. Rotate
the middle driven gear 90" each time.
.If the gearlash is incorrect,adjustthe
gear lash by middledrivenpiniongear
shims and/or middledrivepiniongear
shim(s).
*Y***************t****************
\u
-
piTq-1 p
CHAPTER 5.
CARBURETION
CARBURETOR .............................................................................................. J-3

CARBURETOR DISASSEMBLY ........................................................... J-4
CARBURETOR INSPECTION ............................................................... J-4
CARBURETOR ASSEMBLY ................................................................. J-5
FUEL LEVEL ADJUSTMENT ............................................................... J-6
\+.
k4
CARBURETOR 1
- p
CARBURETION
CARBURETOR
r - - - - - - - - - 7
- ---r -
P=
,,
Job narne/Part name
Carburetor removal
Fuel tanwrubber cover
Q’ty
- Remarks
-
AND FUEL TANK” in CHAPTER 3.
/
Fuel hose 1
Drain hose 1
Overflow hose 1
Starter cablehtarter jet 1/1
Carburetor assembly 1
Throttle valve cover 1
Throttle cable end 1
~ Throttle cable 2 NOTE:
After removing the carburetor assem-
bly, remove t h e throttle cable.
- -L-
~
I I procedure.
7 L -L
- .
1 CARBURETOR 1-
F Order Job narne/Part name

Carburetor disassembly
Q‘ty Remarks
Disassemble the parts in the order
below.
--‘ 0 Air vent hose 2
0 Throttle stop screw 1
0 Vacuum chamber cover 1
(3 Spring 1
0 Spring seat 1
8 Jet needle set 1
0 Piston valve 1
@ Coasting enricher diaphragm 1
0 Float chamber 1
@ Float 1 Refer to “CARBURETOR ASSEMBLY”.
0 Drain screw 1
62 Needle valve set 1
C ?
- u -
CARBURETOR m
I
CARB - 1
E
- -- - -
L
Order
-- Job name/Part name
Pilot jet
Q'ty
---
1 .
Remarks
'"
Pilot screw set 1 Refer to "CARBURETOR ASSEMBLY".
Pilot airjet 1
Main jet 1
Needle jet 1 Refer to "CARBURETOR DISASSEM-
BLYfASSEMBLY".
- I - procedure. m
1 1
CARBURETOR
CARBURETOR DISASSEMBLY
t
(CARB( w1
1.Remove:
Needle jet 0
NOTE:
Remove the needle jet towards the piston
valve side.
I I
CARBURETOR INSPECTION
1.lnspect:
Carburetor body
Starter jet 0
Float chamber
Fuel passage
Contamination -+ Clean as indicated.
Fuel chamber body
Contamination -+ Clean.
I i ****+n~*XHY~***Y~*X*****X**X*****+
Cleaning steps:
o w a s h the carburetor in a petroleum based
Q-,
solvent.
(Do not use any caustic carburetor clean-
ing solution.)
0 Blow out all of the passages and jets with
compressed air.
X t f Y * X * Y Y * * * + * * * * Y + * * * * * * * ~ * Y ~ ~ Y Y f
I I
I -72.lnspect:
Float 0
Float tang @
Damage -+ Replace.
1 I
~
1 3.lnspect:
Valve seat 0
Needle valve @I
@
O-ring @
Contamination/wear/damage + Replace
as a set.
NOTE:
Always replace the needle valve and valve
I I
seat as a set.
CARBURETOR
4.lnspect:
m CARB u
Piston valve (i
J
Scratches/wear/darnage + Replace.
Rubber diaphragm @
Tears + Replace.
T
w$$@<
w
5.lnspect:
Vacuum chamber cover@
Spring @
Spring seat 0
Cracks/damage --f Replace.
6.lnspect:
Diaphragm (coasting enricher)@
Spring @
Cover @
Tears (diaphragm) /damage+ Replace.
w ~~~ ~~~~~~
7.lnspect:
Jet needle @
Needle jet @
Main jet@
Pilot air jet@
Pilot jet@
Pilot screw 8
Starter plunger 0
Bends/wear/damage + Replace.
Blockage + Blow out the jets with com-
pressed air.
1 8.Check:
CARBURETOR
I
ICARBl w11
Free movement (piston valve)

Sticks + Replace the piston valve guide
and the piston valve.
Insert the piston valve into the carburetor
body, and check for free movement.
9.Check:
Free movement (throttle valve)
Sticks 4 Replace.
CARBURETOR ASSEMBLY
+c"s ?,e.,$.:
,,:rJ""" .-,x\v
.;$j&hgJ.T&+$@$
AX* ._ _.--.
,:, , - .1..,.
.- I
Before reassembling, wash all of the parts

in a clean petroleum based solvent.
I 1 1.InstaIl:
r---. Needle jet @
NOTE:
Align the groove on the needle jet with
the projection onthe carburetor body.
Install the needle jet from the piston valve
l- side.
2.lnstall:
Pilot screw @
Pilot screw (turns out):

3 1/2
1 PI
3.Measure:
Float height8
Float height [F.H.):
14.7 m m (0.59 in)
*********X************************
Measurement and adjustmentsteps:

.Hold thecarburetor in a n upside down
position.
CARBURETOR
~~ ~~~ ~~
1-
.Measure the distance from the front mat-
p
ing surface o f the float chamber (gasket
removed) to thetop of the float.
NOTE:
The float arm should be resting on the nee-
dle valve, but not compressingit.
.If the float height is not within the specifi-
cation, inspect the valve seat and needle
va Ive.
.If either is worn, replace them both.
.If both are fine, adjust the float height by
bending the float tang 0on the float.
0 Recheck the float height.
********************Y*X,XXYX*YXYXY
FUEL LEVEL ADJUSTMENT

k-, 1.Measure:
Fuel level 8
Out of specification -+ Adjust.
B Fuel level:
-
2.0 3.0 m m (0.08 - 0.12 in)
Above the float chamber mat-
ing surface
1
****X*************************?i***
Fuel level measurement and adjustment

-I W / steps:
0 Place the machine on a level surface.
.Connect thefuellevelgauge Q tothe
drain pipe 0.
Fuel level gauge:

*-./
P/N. YM-01312-A, 90890-01312
*Loosen the drain screw0.

.Hold the gauge vertically next to the float
chamber line.
0 Measure the fuel level 8with the gauge.
.If the fuel levelis incorrect, adjust the fuel
level.
*Remove the carburetor.
.Inspect the valve seat and needle valve.
.If either is worn,replace them both.
*If both are fine, adjust the float level by
bending the float tang0slightly.
.Install the carburetor.
0 Recheck the fuel level.
*****X********+*******************
m B
CHAPTER 6.
DRIVE TRAIN
TROUBLESHOOTING ................................................................................... K-3
CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR .................... K-4

UNIVERSAL JOINTDISASSEMBLY .................................................... K-7
RING GEAR REMOVAL......................................................................... K-7
CONSTANT VELOCITY JOINT INSPECTION ...................................... K-7
DlFFERENTlAL GEAR INSPECTION..................................................... K-7
CONSTANT VELOCITY JOINT ASSEMBLY ........................................ K-8
DIFFERENTIAL GEAR ASSEMBLY ....................................................... K-8
UNIVERSAL JOINT INSTALLATION.................................................... K-8
DIFFERENTIAL GEAR LASH MEASUREMENT AND
ADJUSTMENT .................................................................................. K-9
DIFFERENTIAL GEAR OPERATION CHECK ...................................... K-10
\J
REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT ............................. K-10
REAR AXLE REMOVAL....................................................................... K-12
FINAL DRIVE GEAR DISASSEMBLY .................................................. K-12
FINAL DRIVE ROLLER BEARING REMOVAL AND REASSEMBLY ..K-12
FINAL DRIVE PINION GEAR AND RING GEAR POSITIONING ........K-13
REAR AXLE INSPECTION ................................................................... K-15
DRIVE SHAFT INSPECTION ............................................................... K-15
FINAL DRIVE GEAR INSPECTION...................................................... K-15
FINAL GEAR LASH MEASUREMENTAND ADJUSTMENT.............K-16
FINAL DRIVE GEAR ASSEMBLY .......................................................... L-I
REAR AXLE INSTALLATION ................................................................ L-I
Y d
8 8 d - - - ~~ ~
TROUBLESHOOTING I
F
DRlV
DRIVE TRAIN
TROUBLESHOOTING
The following conditions may indicate damaged shaft drive components:
Possible Causes
-
Symptoms -
l . A pronounced hesitation or "jerky" move- I A.Bearing damage.
ment during acceleration, deceleration, or
6.lmproper gear lash.
sustained speed. (Thismustnotbecon-
fused with engine surging or transmission I C.Gear tooth damage.
characteristics.)
D.Broken drive shaft.
2.A "rolling rumble"
noticeable a t low
speed; a high-pitched whine; a "clunk" I E. Brokengearteeth.
from a shaft drive component orarea.
F. Seizure due to lack of lubrication.
3.A locked-upcondition of theshaftdrive
trainmechanism,nopowertransmitted G.Small foreign objects lodged between the
from the engine to the front and/orrear moving parts.
wheel. I d
' r i
NOTE:
Areas A, B, and C above may be extremely difficult to diagnose. The symptoms are quite sub-
tle and difficult to distinguish from normal machine operating noise. If there is reason t o
believe these components are damaged, remove the components and inspect them.
~~ ~~~ ~~ ~~~
Inspection notes
1.lnvestigate any unusual noises.
***********Y****Y*****************
Thefollowing "noises" mayindicate a

mechanical defect:
a.A "rolling rumble" noise during coasting,
acceleration, ordeceleration. The noise
increases with frontand/orrearwheel
speed, but 'it does not increase with
higher engine or transmissionspeeds.
L/
Diagnosis: Possible wheelbearingdam-
age.
b.A "whining" noise that varies with accel-
eration and deceleration.
Diagnosis: Possible incorrect reassembly,
too-little gear lash.
-
I
i TROUBLESHOOTING
:$;:c&G*,&qi:<
i DRlV l
.,-..
..?,. . .
~..
%.,
Too little gear lash is extremely destructivet o

the gear teeth. If a test ride following reas-
sembly indicates this condition, stop riding
immediately to minimize gear damage.
c.A slight"thunk"evident a t low speed
operation.This
noise
must
bedistin-
guished from normal machine operation.
Diagnosis: Possible broken gear teeth.
Stop riding immediately if brokengear

teeth are suspected. This condition could
result in the shaft drive assembly locking
up, causing loss of control of the machine
and possible injuryt o t h erider.
~ * * Y * * * ~ ~ * ~ I * ~ * ~ ~ * ~ * * ~ * * * * * * * * ~ * * *
\j
2.lnspect:
Drained oil
Drained oil shows large amounts of metal
particles + Check the bearing for seizure.
NOTE:
A small amount of metal particles in the oil
is normal.
3.lnspect:
Oil leakage
******************X***************
Oil leakage inspection steps:

.Clean the entire machine thoroughly, then
dry it.
.Apply a leak-localizing compound or dry
'%I spray
drive.powder
shaft to the
@Roadtestthemachine for thedistance
necessary to locate the leak.
Leakage -+ Inspect the component hous-
ing, gasket, and/orseal for
damage.
Damage -+ Replace the component.
NOTE:
An apparent oil leak on a new or nearly
new machine may be the result of a rust-
preventative coating or excessive
seal
lubrication.
Always cleanthemachine and recheck
the suspectedlocation of an apparent
leakage.
..................................
Troubleshooting Chart
TROUBLESHOOTING 1- pG
When basic condition "a" and "b" exist, check the following points:
I q
Elevate and spin both wheels. Feel for YES Replace thewheelbearing.
wheel bearing damage. (Refer to "STEERING SYSTEM" and
. "REAR SHOCK ABSORBER AND
lNO
SWINGARM" in CHAPTER 7.)
. Check the wheel,

tightness.
hub and drumnuts for
*b
No Torque to specification.
(Refer to "FRONT AND REAR WHEELS"
bES
in CHAPTER 7.)
'
p
1
"leck the constant velocity joint.
' r bearing damage.
n
II
* YES
Feel
I
&
1
Constant velocity joint bearings and dif-
ferential gear bearings are probably not
damaged. Repeat the test or remove the
individual components.
*
I
n
Check the rear brake adjustment.
YES
'& Adjust per instructions.
(Refer t o "REAR BRAKE LEVER AND
PEDAL ADJUSTMENT" in CHAPTER 3.)
9
Check the rear axle. Feel for bearing
damage. *
No Rear axlebearings and rear drive shaft
bearings are probablynot damaged.
Repeat the test or remove the individual
kES
components.
----/
*
Remove the rear axle. Check for axle YES Replace therearaxlebearing.
bearing damage. (Refer to "REAR AXLE/FINAL DRIVE
GEAR AND DRIVE SHAFT".)
I
I
lNO
Removethedriveshaftcomponents. I
I
- -
1 CONSTANT VELOCITY JOINTS AND
DIFFERENTIAL GEAR DRlV +!*
I
I I ‘ I
CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR
- -
~~
-
F
===T
-
1;
- -
Constant velocity jointand differen- Remove the partsin the order below.
tial gear removal
_ _
Front fender Refer to “SEAT,CARRIERS,FENDERS
AND FUEL TANK” in CHAPTER 3.
Differential gear oil Drain
Steering knuckle Refer to ”STEERING SYSTEM” in
CHAPTER 7.
Engine skid plate 1
Constant velocity joint 2
Front driveshaft protector 1
6 Gear motor coupler / 4WD switch lead 1/1
Oil cooler mounting bolt 2
- Fan mounting bolt 3 i 4
- .
-
CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR I DRlV I$(=cl

.t
p
m-\
'W

7 Differential gear breatherhose 1 Disconnect
-6 Plastic clamp 1
9 Differential gear 1
Forinstallation,reversethe remov
procedure.
CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR 1-I
DRlV I ’ 1
r-----.
\
I
I
I
l
.
.
\---__I
m
+’

---.
Qty Remarks
-
-.- -
Constant velocity joint disassembly Disassemblethe
parts in
the
order
zd below.
0 Circlip 1
0 Boot band 2
0
0
Boot band
Dust boot
2
2
1 Refer to “CONSTANT VELOCITY
JOINT ASSEMBLY”.
I
0 Circlip 1
@ Double off-set joint 1
0 Snap ring 1
@ Ball bearing 1
.@ Joint shaft assembly 1
1 I -- d
procedure. -
1
I
$)=c /K
CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR DRlV
I I
Order
Job name/Part
name
-I-
Remarks
-
__ Q'ty
Differential gear disassembly Disassemble the parts in the
order
below.
'I" @IFront drive shaft 1
@ Compression spring 1
@ Circlip 2
@ Rubber boot 1
@ Circlip 2 1
8 Bearing 2 -Refer to "UNIVERSAL JOINT DISAS-
0 Universal joint 1 SEMBLY AND ASSEMBLY".
8 Universal joint yoke/O-ring 1/1
@ Gear motor/O-ring 1/1 -
@ 4WD switch 1
0 Bearing housing/O-ring 1/1
@I Input shaft 1
@I Shift fork shaft/O-ring d
?/I -
1 CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR I DRlV
*
.
Y
18 N m (1.8 m kg, 13 ft . Ib)
--i'
-
&

@ Shift fork sliding gear 1
- @
@
Shift fork
2WD/4WD shift sleeve 1
1
0 Bolt 6 NOTE:
Working
in a crisscross
pattern,
loosen each bolt 1/4 of a turn. After all
the bolts are loosened, remove them.
@ Bearing housing/O-ring 111
@ Shim (left)
@ Differential gear assembly 1
@ Ring gear 1 Refer to "DIFFERENTIAL GEAR DISAS-
SEMBLY".
@I Shim (right) Y
@ Snap ring 1
@ Drive pinion gear 1
@ Differential gear case 1
b procedure. -
CONSTANT VELOCITY JOINTS DIFFERENTIAL
AND GEAR IDRIV F
UNIVERSAL JOINT DISASSEMBLY
1.Remove:
Universal joint
..................................
Universal joint removal steps:
0 Remove the circlips0.
0 Place the U-jointin a press.
.With a suitable diameter pipe @ beneath
the yoke @, press the bearing @ into the
pipe as shown.
@--e NOTE:
with a punch.
0 Repeat the steps for the opposite bearing.
0 Remove theyoke.
NOTE:
\ d
with a punch.
..................................
2.Remove:
Universal joint yoke
Use a universal joint holder0.

P/N. YM-04062,90890-04062
L
RING GEAR REMOVAL

1.Remove:
Ring gear 0
NOTE:
The ring gear andthedifferential gear
cover should be fastened together. Do not
disassemble the differentialgear.
p&#f@jig~~
,~~~::,...~~::..;*'i.;,~~~~~:~..~~?~~-~
The differential gears are assembled intoa
proper unit at the factoryby means of spe-
cialized equipment. Do not attempt to dis-
assemble this unit. Disassembly will result
in the malfunction of the unit.
- "
1 CONSTANT VELOCITY JOINTS AND DIFFERENTIALGEAR 1-1
CONSTANT VELOCITY JOINT INSPECTION
1.lnspect:
Double off-set joint spline
Ball joint spline
Shaft spline
Weaddamage + Replace.
2.lnspect:
Dust boots
.,,;:,.,-,. ... ., . ..,*.*",:>>"<
;,P,~A'axioNI:i<r
G>
,..W<*<\>..,., ., ,x, ,I, . IxA%
Always use a new boot band.

3.lnspect:
Balls and ball races
Inner surface of double off-set joint
Pitting/wear/damage -+ Replace.
i'
DIFFERENTIAL GEAR INSPECTION

1.Inspect:
Gear teeth
Pitting/galling/wear + Replace drive pin-
ion gear and ring gear as a set.
Bearing
Pitting/damage -t Replace.
Oil seal
O-ring
Damage 3 Replace.
2.lnspect:
Drive shaft splines
Universal joints
Front drive gear splines
Wearldamage + Replace.
k ._c
Spring
Fatigue + Replace.
Move the spring up and down.
> 3.lnspect:
Front drive shaft
Bends -+ Replace.
Do not attempt t o straighten a bent shaft;

-
this mav dannerouslv weaken the shaft.
1 - .-
CONSTANT VELOCITY JOINTS AND
DIFFERENTIAL GEAR 1 - DRlV
CONSTANT VELOCITY JOINT ASSEMBLY
I I ' I
m
1.Apply:
Molybdenum disulfide grease
(into the ball joint assembly)
NOTE:
Molybdenum disulfide grease is included in
the repair kit.
2.lnstall:
0 Dust boots 0
Boot bands @ 0I =
*YX+#*Y**Y*Y***X**YK*****Y**Y*****
Installation steps:
NOTE:
The new boot bands may differ from the
original ones.
The dust boots should be fastened with
the boot bands @ a t the grooves in the
I"' joint shaft.
Apply molybdenum disulfide grease into
the dust boots.
1-(
I I
Molybdenum disulfide grease:
70 g (2.5 0 2 ) per dust boot I
I
Install the dust boots0.

Wrapthebootbandsaroundthedust
bootstwice,thenpassthebandends
through the loops8.
Tighten the boot bands by pulling the boot
band ends with pliers until the boot band
outside diameters meet specification.
Boot band 0: 69 mm (2.7 in)
Boot band0: 26.1 mm (1.0 in)
Bend the ends of the boot bands a t the
loops 8.
Securethebootbandsbyholding a
punch over the center ofthe loops 8 and
hitting the punch witha hammer. Be care-
ful not to damage the dust boots.
Cut off the excess boot band ends so that
they are the specified length.
Length from loop 8
Boot band0:
t o tab 6)
I . _ _ _-
I
_
I
Boot band0:
I
Length equal to the
width of boot band 0- I
0 Firmly bendthe ends of the boot bands over
the loops@. Secure the bootbands by bend-
ing thetabs @ over the boot band ends @.
. , *
I CONSTANT VELOCITY JOiNTS AND DIFFERENTIAL GEAR
3.Check:
m\
I
DRlV
~~
1 . 1
= Free play (thrust movement)

Excessive play ++Replace the joint assem-
bly.
~~~
DIFFERENTIAL GEAR ASSEMBLY

1.Measure:
Gear lash
Refer to "DIFFERENTIALGEAR LASH
MEASUREMENT/ADJUSTMENT".
2.lnstall:
Gear motor
Refer to "FEATURES" in CHAPTER 1.
;J
3.lnstall:
Universal joint yoke
O-ring
Washer
0 N u t 4 1h162 Nm (6.2 m . kg, 45 ft . Ib) 1
Use a universal joint holder0.

P/N. YM-04062,90890-04062
4.Check:
Differential gear operation
Unsmooth operation 4 Replace the dif-
ferential gear assembly.
Insert the double off-set joint into the dif-
ferential gear, and turn the gear back and
forth.
UNIVERSAL JOINT INSTALLATION

1.lnstall:
Universal joint
..................................
Universal joint installationsteps:
*Install the opposite yoke into the U-joint.
oApply wheel bearing grease to the bear-
mgs.
I " m
CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR
I I .Install
1
-
DRlV
I I
the bearing 0onto the yoke.

' 1
i
x
1
~
ik
1)1*A
3;y;cAuTiQN+
%
1;-
. / . .?:, .-.. ~ I
Checkeach bearing.Theneedles caneasily

fall out of their races. Slide the yoke back
and forth on the bearings; the yokewill n o t
go a l l the way onto a bearing if a needle is
~
o u t of place.
I I
.Press each bearing into the U-joint using
a suitable socket.
I
I NOTE:
The bearing must be inserted far enough
into the U-joint so t h a t the circlip canbe
l installed.
.Install the circlips @ intothegroove of
each bearing.
Y***X***************************~*
.
+
I . I
DIFFERENTIAL GEAR LASH

1.2 rnm (0.05 in) MEASUREMENT AND ADJUSTMENT
I
Differential gear lash measurement
7.Secure the gear case in a vise or another
10 rnrn
(0.39in) supporting device.
2.Remove:
Drain plug
80 mm (3.1in)
~
Gasket
I b 3.lnstall:
A bolt of the specified size @
(into thedrain plug hole)
.,,.. _,.-,.
, ..,.. -,<<"':<%.,:-,*
..
:~ ~
.+.
~&
. g ~y<<,.2*,>%..,
:$;A
,;
Q~g)~gji
',.?y.,%L.. 3,
Finger tighten the bolt until it holds the

ring gear. Otherwise, the ring-gearwill be
damaged.
4.Attach:
Gear lash measurement tool@
Dial gauge @

P/N. YM-01467.90890-01667
@ Measuring point
U -'a'-
' '. \
1 CONSTANT VELOCITY JOINTS DIFFERENTIALGEAR
AND
5.Measure:
mDRIV
Gear lash
Gently
rotate
the
gear
coupling from
engagement to engagement.
Differential gear lash:

-
0.05 0.25 mm (0.002 - 0.010 in)
NOTE:
Measurethegearlash .at fourpositions.
Rotate the shaft 90" each time.
2-i
Differential gear lash adjustment

1.Remove:
P-
Shim(s1 (left)0
Differential gear assembly @
Shim(s) (right) 0
Cr
-
2.Adjust:
Gear lash
...................................
- Gear lash adjustment steps:

the foflow-
.Select the suitable shims using
ing chart.
Too little gear lash Reduce shim thickness.
Too large gear lash Increase shim thickness.
a If it is necessary to increase by more than
0.05 mm (0.002 in):
Reduce rightshimthickness b y 0.1 mm
(0.004 in) for every 0.1 mm (0.004in) of
left shimincrease.
.If it is necessary t o reduce by more than
0.1 mrn (0.004 in):
Increase right shim thickness by 0.1 mm
(0.004 in) for every 0.1 rnm~of left shim
decreased.
, * -
CONSTANT VELOCiTY JOINTS AND DIFFERENTIAL G E A ~ DRlV

~ ~~~~~ ~
m
I I ' I
F
I Ring gear shim (left and right)
0.1 1.0
1.5 0.2
Thickness (mml 0.3 2.0
0.4 2.5
0.5
.
i-
DIFFERENTIAL GEAR OPERATION CHECK

1.Block the rear wheels, andelevatethe
front wheels by placing a suitable stand
under the frame.
2.Remove thewheel cap andcotterpin
from the axle nut (right or left).
3.Measure the starting torque of the front
wheel (i.e., differential gear preload) with
the torque wrench.
NOTE:
Repeat this step several times to obtain
an average figure.
During- this test, the other front wheelwill
turn in the opposite direction.
'x
L
Front wheel starting torque:
(differential gear preload):
New unit:
--
17 25 Nm
(1.7 2.5 m kg, 12 18 ft Ib)
Minimum:
..
10 Nm (1.0 m kg, 7.2 ft Ib)
I ~~~~~~
I
4.0ut of specification + Replace the differ-

entia1 gear assembly.
5.Within specification + Install the new cot-
ter pin and wheel cap.
-
1 REAR AXLE/FINAL DRIVE
GEAR AND DRIVE SHAFT
REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT
r-Tqq
DRlV
p-- Job name/Part name

--- -
aty
-. -
Remarks
-. -
Rear axle, final drive gear assembly Remove the parts in the order below.
and drive shaft removal
1:
Final gear oil Drain
Rear wheel/brake drurn/wheel hub Refer to "FRONT AND REAR WHEELS"
in CHAPTER 7 .
0-ring/washer 1/1
7
Rear axle
Final drive gear breather hose
Final drive gear
Coupling gear
Compression spring/washer
1
1 Disconnect
1
1
1/1
I
REMOVAUINSTAL-
Refer t o "REAR AXLE
LATION".
Drive shaft 1
8 Circlip 2
For installation,reverse the removal
4
procedure.
d
D
GI
$)=c
REAR AXLE/FINAL DRIVE GEAR AND DRIVE DRlV
SHAFT
E J S H I M W : ~]
/
asm+ /
F n d4PA v
- --- -
I-.
Final drive gear disassembly
Q'ty
-
Disassemble
below.
the
Remarks
parts in theorder
-
-' 0 Bolt 2 NOTE:

0 Bolt 6 Working in a crisscross pattern,
loosen each bolt 1/4 of a turn. After all
the bolts are loosened, remove them.
0 Bearing housing 1
0 Ring gear stopper 1
0 Ring gear stopper shim 1
8 Oil seal/bearing 1/1
0 Ring gear shim 1
@ Ring gear 1
@ Thrust washer 1
69 Bearing/oil seal 1/1 Refer to "FINAL DRIVE ROLLER BEAR-
- -- d
ING
~~~-REMOVAL AND REASSEMBLY".
~~~ ~
-
. .-
-_ ~ ~ _
1 REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT I

DRlV
Order
@
@
Job name/Part name
Bearing retainer/O-ring
Oil seal [! -
-
~~~
Remarks
~~
Refer to "FINAL DRIVE GEAR DISAS-
I
'' 0 Collar SEMBLY/ASSEMBLY".
@! Bearing
@I Final drive piniongear shim
8 Final drive piniongear
@ Bearing Refer to "FINAL DRIVE ROLLER BEAR-
ING REMOVAL/REASSEMBLY".
0 Final drive gear case/O-ring 1/1
& I I . procedure.
REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT I IDRlV I F
l IK-
I
REAR AXLE REMOVAL
1.Remove:
Rear axle 0
O-ring
Washer
........,. .
~~.,~:~~:;.,-..~,,:~,~
*@&$Jg~f$q; <,
$<:&.v...+ ..*..x.4,,.\.k::>:
Never directly tap the axle end with a
hammer, since this will result in damage
t o t h eaxle thread and spline.
Attach a suitable socket 0 on the axle
end and tap it with a soft hammer. Pull
out the rear axlet o t h eleft.
~ FINAL DRIVE GEAR DISASSEMBLY

1.Remove:
Bearing retainer (final drive pinion gear)
NOTE:
Use a bearing retainer wrench 0.

P/N. YM-04050,90890-04050
F
;&e,&$,$#@,,;
. .... ..I...*..
A .,_..
*<<*% >,is ,.<,&,,ld,.<*:%$~
The final drive shaft bearing retainer has

left-handed threads.To loosen the retainer,
turn it clockwise.
‘-”’
2.Remove:
Final drive pinion gear assembly
With a soft hammer, lightly tap on t h e
final drive pinion gear end.
$@g@#jg$;;,;
,/% *,!E>
w + . ,e
e.. I,
Removalofthefinaldrivepinion gear
should only be performed if gear replace-
ment isnecessary.
Always usenew bearings andraces.

__ .~~ ~ ~ . ~ . . ..

GEAR AND DRIVE 1-
DRlV
SHAFT
FINAL DRIVE ROLLER BEARING REMOVAL
AND REASSEMBLY
1.Remove:
Roller bearing (ring gear)0
Use a suitable press tool@ J a n appro-
and
priate support for the main housing.
Oil seal @
I I
t 1
2.Rernove:
Roller bearing (final drive pinion gear)0
% ..................................
Removal steps:
.Heat themainhousingonlyto 150°C
(302°F).
*Remove the roller bearing outer race with
an appropriately shaped punch 0.
\I a Remove the innerrace from the final drive
pinion gear.
NOTE:
The removal of the final drive pinion gear
roller bearing i s difficult and seldom neces-
sa ry.
**************I*******************
t 3.lnstall:
Roller bearing (final drive piniongear)
..................................
=
-
Installation steps:
II
I I
*Heatthemainhousingonlyto
(302'F).
.Install the roller bearing outer race using
the proper adapter.
gear.
..................................
4.lnstall:
Oil seal @ =
150°C
*Install the inner race onto the drive pinion
Roller bearing@
Use a suitable press tool 0and a press to
installtheabovecomponents into the
main housing.
I I
REAR AXLE/FINAL GEAR AND DRIVE SHAFT
DRIVE m
I
E
l
+=*
FINAL DRIVE PINION GEAR AND RING
DRlV t '
I
GEAR POSITIONING
When the final drive pinion gear, ring gear,
finalgear case and/orringgearbearing
housing are replaced, be sure to adjust the
positions of the final drive pinion gear and
ring gear using the shim(s).
Final drive piniongear shim selection

1.Select:
Final drive pinion gear shim(s)@
*
*******************X**************
Shim selection steps:

.To find the final driv.e pinion gear shim
thickness "A", use the following formula.
Finaldrivepiniongearshim
thickness:
"A" = @ - @
8= a numeral (usually a decimal num-

ber) on thefinaldrivepiniongear
eitheradded toorsubtractedfrom
"84"
0 = a numeral (usually a decimal num-
ber)onthefinalgear case either
added to or subtracted from "83"
Example:
1) If "01" is stamped on the final drive
pinion gear,
@ I + 0.01 = 84.01
= 84
2) If "50" is stampedonthefinalgear
case,
*+<
@ = 83 -+ 0.50 = 83.50 .
3 ) Therefore, "A" is 0.51. '
"A"= 84.01 - 83.50
= 0.51
4) Round off thehundredthdigitand
select the appropriateshirn(s1.
In the example above, the calculated
numberis 0.51. Thechartinstructs
you to round off 1 to 0 at the hun-
dredth place.Thus, theshimthick-
ness is 0.50 mm.
Hundredths
Rounded
value
fi-71
) 0, 1,2,3,4
5, 6,7,8,9
j REAR AXLE/FINAL DRIVE
GEAR AND DRIVE
Shims are supplied
SHAFT m
DRlV
in the following thick-
nesses.
~
Final drive piniongear shim
0.30 0.50
Thickness ( r n r n )
o.40
*****************X****************
Ring gear shim selection

1.Select:
Ring gear shim(s) @
*******************X**************
Shim selection steps:

.To find the ring gear shim thickness "B",
use the following formula.
Ring gear shim thickness:

"B"=@+@-(@+@)

ber)onthe final gear case either
added to or subtracted from 45
ber) on the outside of the ring gear
bearing housing and added to 1
ber)ontheinside of theringgear
eitheradded t o o r subtracted from
35.00
0 = bearingthickness(consideredcon-
stant)
Bearing thickness 0:
11.00 mrn
Example:
1) If "53" isstamped on thefinalgear
case,
n @ = 45 + 0.53 = 45.53
2) If"05"isstampedontheringgear
bearing housing,
@ = 1 + 0.05
= 1.05
3) If "-05" is stamped on the ring gear,
@ = 35 - 0.05
= 34.95
v 4) 0 = 11.00.
I I
- --
REAR AXLE/FINAL DRIVE
GEAR AND DRIVE SHAFTm
DRlV
I I ' J
K
5 ) Therefore, shim thickness " 5 " is 0.63.
"B"= 45.53 + 1.05 - (34.95 + 11.00)
= 46.58 - 45.95
= 0.63
6) Round off thehundredthdigitand
select the appropriate shim(s1.
In the example above, the calculated
numberis 0.63. Thechartinstructs
you to round off 3 to 5 a t the hun-
dredth place.
Thus, the shim thickness is 0.65 mm.
Hundredths Rounded value

0, 1.2 0
3.4. 5, 6.7 5
8,9 10
'b,
nesses.
Ring gear shim
0.25 0.30 0.40

Thickness ( r n r n )
0.50
..................................
Thrust washer selection
I l.Measure/select:
Ring gear thrust clearance "C"
..................................
Thrust clearance measurementsteps:
.Place four pieces of Plastigauge@ between
the originally fitted thrust washer and the
ring gear.
.Install the ring gear assembly and tighten
the bolts to specification.
i
M8 Bolts (bearing housing):
23 Nm (2.3m kg, 17 ft Ib)
M10 Bolts (bearing housing):
40 Nm (4.0 m kg, 29 f l Ib)
I I
NOTE:
-4- "C" Do not turn the drive pinion gear and ring
gear when measuring the clearance with Plas-
tigaugb.
GEAR AND SHAFT
DRIVE rTqq
.Remove the ring gear assembly.
DRIV
.Measure thethrustclearance.Calculate
the width of the flattened Plastigaugew0.
Ring gear thrust clearance:

.. -
0.1 0.2 rnm (0.004 0.008in)
.If out of specification, select the correct
washer.
Thrust washer selection steps:

.Select a suitable thrust washer using the
following chart.
Thrust washer
1.2 1.4 1.6

Thickness (mm)
1.8 2.0
I . 4
.Repeat the measurement steps until t h e

ringgearthrustclearanceis within the
specified limits.
*Y**,*XYX***YX********~****~******
s t
Ring gear stopper shim selection
-
1.Measure:
Ring gear stopper clearance"D"
Use a feeler gauge 0.
I
"0"
Out of specification+ Adjust.
- -
Ring gear stopper clearance"D":
0.30 0.60 mrn (0.012 0.024 in)
@ Ring gear
~ ~~ ~~
0 Ring gear stopper

I 1
I I
REAR AXLE/FINAL DRIVE GEAR A N D DRIVE SHAFT r T q q IK-
DRlV
Ring gear stopper clearance adjustment
1.Remove:
Ring gear @
Ring gear stopper @
Shim(s) @
@ Bearing housing
m Left-hand threads
2.Select:
Suitable shirnb)
Shim
I Thickness (mm)
I
I DelFi o.20 I
I I I
‘U
3.lnstall:
Shim(s)
Ring gear stopper (left-hand threads)
b
19 Nm 10.9 m . kg, 6.5 ft . Ib) I
Ring gear
NOTE:
Use LOCTITEe on the ring gear stopper.
4.Measure:
Ring gear stopperclearance
Out of specification + Repeat adjustment
steps.
--*
-
Ring gear stopperclearance:
.
0.30 0.60 m m (0.012 0.024 in)
REAR AXLE INSPECTION

l.lnspect:
Rear axle runout 8
Do not attempt tostraighten a bentaxle.
Rear axle runout limit:

. 1.5 mm (0.06 in)
c -c
I] REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT 1-
DRIVE SHAFT INSPECTION
1.Inspect:
Drive shaft (splines)@
Coupling gear (splines) @
FINAL DRIVE GEAR INSPECTION

1.Inspect:
Final gear case 0
Bearing housing (ring gear) @
NOTE:
When the finalgear case and/orthering
gear bearing housing are replaced, be sure
t o adjust the shim of the final drive pinion
gear and/or ring gear.
2.lnspect:
Gear teeth
Pitting/gaIIing/wear -+ Replace thedrive
pinion gear and ring gear as a set.
Oil seals
O-rings
Damage + Replace.
3Snspect:
Bearings
Damage -+ Replace.
NOTE:
Reusing roller bearings is acceptable, but
Yamaha recommends installing
new
-- ones. Do not reuse the oil seal.
When the final drive pinion gear and/or
ring gear are replaced, be sure to adjust
the shimofthe final drivepiniongear
and/or ring gear.
REAR AXLE/FINAL DRIVE
GEAR AND DRIVE r
T$)=c -
SHAFTDRlV
FINAL GEAR LASH MEASUREMENT AND
l
E
1.5 m m (0.06 in) ADJUSTMENT
Final gear lash measurement
1.Secure the gear case in a vise or another
14 m m
(0.55in) supporting device.
2.Remove:
Drain plug
100 mm (3.94 in)
Gasket
3.lnstall:
A bolt of the specified size 0
(into the drain plug hole)
~,,,~:,,.~-,~.~,~~.,~~.~,.~~~*,~,.
w,~piutr-~lu.":
'.,-,,,
. "..
i-I 1 % ,
:z
y
Finger tightentheboltuntil it holds the

ring gear. Otherwise, the ring gear will be
damaged.
4.Attach:
Gear lash measurement tool@
Dial gauge @

P/N. YM-01231,90890-01231
@ Measuring point
5.Measure:
Gear lash
Gentlyrotatethe gear coupling from
engagement to engagement.
Final gear lash:

-
0.1 0.2mm (0.004 - 0.008 in)
Ld
NOTE:
Measurethe gear lash a t four positions.
Rotate the shaft90" each time.
c 17
g REAR AXLEIFINAL DRIVE GEAR AND DRIVE SHAFT
Final gear lash adjustment
-Tj&I DRlV
1.Remove:
Bearing housing 3(J
Ring gear shim(s1 @
Ring gear 0
Thrust washer@
2.Adjust:
Gear lash
*******Y**************************
Adjustment steps:
*Select a suitable shirn(s) and thrust wash-
er(s) using the following chart.
Too little gear lash Reduce shim thickness.
u Too large gear lash Increase shim thickness.
.If increased by more than 0.2 rnm (0.008
in):
Reduce the thrust washer thicknessby 0.2
mm (0.008 in) for every 0.2 mm of ring
gear shim increase.
elf reduced by morethan 0.2 mm (0.008 in):
Increase the thrust washer thickness by
0.2 rnrn (0.008 in) for every 0.2 rnrn that
the ring gear shim is decreased.
Ring gear shim
0.25 0.30 0.40

Thickness (mm) o.50
._4
Thrust washer
1.2 1.4 1.6

**************Y****Y**************
’? .-he
REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT
FINAL DRIVE GEAR ASSEMBLY
j--Tqq
I
DRlV I ' I
m
1.lnstall:
Drive pinion gear (with shim(s) and bear-
ing)
(proper shimsize as calculated)
Bearing retainer (drive pinion gear)@
[& 1100 Nm (10.0 m ' kg, 72 ft Ib)
I I
Use a bearing retainer wrench 0.
@.A.;fl;aw;;
5<y>.: *,,;<-..:-.",,:
.,...~~.~~.~,,,..,.,,,~~
I,
. .. _..
.,...,.
Always use a n e w bearing.

The final drive shaft bearing retainer has
left-hand threads. Turn the retainer coun-
terclockwise to tinhtenit.

'"-., P/N. YM-04050,90890-04050
2.Adjust:
Final gear lash
Refer to "FINAL GEAR LASH MEASURE-
MENT AND ADJUSTMENT".
REAR AXLE INSTALLATION

1.lnstall:
Rear axle
. ..................................
-
,. "
Installation steps:
*Check if the brake shoe assembly
is
installed on the swingarm.If the brake shoe
assembly is not installed, refer to "REAR
BRAKE" for installation instructions.
I
*Check that the final gear case and rear axle
housing have been removed from the swin-
garm. If the final gear case and rear axle
housing are still installed, remove them.
*Apply sealant (Quick Gasket") to the mat-
ing surfaces of the swingarm and the final
drive gear.
i
Sealant (Quick gasket)?
P/N. ACC-11001-05-01
I I Yamaha bond No. 1215":
90890-85505
.^
, . "
GEAR AND DRIVE 1-
SHAFT DRlV
temporarily install the rear axle housing
@ and final drive gear5(J on the swingarm
0. -
The bolts and nuts 0 @ should be
temporarilytightened in the
specified
order.
.Install the rear axle@ from the left side of
the machine.
.Install the brake drum.
Axle nut:
b&.+ 150 Nm (15.0 m kg, 110 ft Ib)
Refer to "FRONT AND REAR WHEELS" in

CHAPTER 7.
*Check that the rear
axle 0 rotates
smoothly.
.Tighten the bolts and nuts @ 8 in the -
specified order.
@ Swingarm
@ Rear axle housing
r'
@ Final drive gear
@ Rear axle
0 Nut (x41
@ Bolt (x41
@ Bolt (x41
@ Bolthut (x2)
Nut 0:
b% 57 Nm (5.7 m kg, 41 f? Ib)
Bolt @, 0:
65 Nm (6.5 m kg, 47 ft Ib)
LOCTlTE@
Nut @:
90 Nm (9.0m kg, 65 ft Ib)
****Y******X*****************k$**k$*
-../
- __
pq&qpi
CHAPTER 7 .
CHASSIS
FRONT AND REAR WHEELS ...................................................................... M-3

FRONT WHEELS .................................................................................. M-3
REAR WHEELS..................................................................................... M-3
WHEEL INSPECTION ........................................................................... M-4
WHEEL HUB INSPECTION .................................................................. M-4
BRAKE DRUM INSPECTION ............................................................... M-4
BRAKE DISC INSPECTION.................................................................. M-4
WHEEL HUB/BRAKE DRUM INSTALLATION.................................... M-4
WHEEL INSTALLATION ...................................................................... M-4
FRONT BRAKE ............................................................................................. M-5

BRAKE PADS........................................................................................ M-5
BRAKE PAD REPLACEMENT.............................................................. M-6
MASTER CYLINDER ............................................................................ M-7
i_i
MASTER CYLINDER INSPECTION...................................................... M-8
MASTER CYLINDER ASSEMBLY ........................................................ M-8
MASTER CYLINDER INSTALLATION ................................................. M-8
BRAKE CALIPER................................................................................... M-9
CALIPER DISASSEMBLY ................................................................... M-10
CALIPER INSPECTION....................................................................... M-IO
CALIPER ASSEMBLY ......................................................................... M - I1
CALIPER INSTALLATION .................................................................. M-11
REAR BRAKE.............................................................................................. M-12

BRAKE SHOE PLATE INSPECTION.................................................. M-13
BRAKE SHOE INSPECTION............................................................... m-13
BRAKE DRUM INSPECTION ............................................................. M-13
REAR BRAKEASSEMBLY ................................................................. M-13
REAR BRAKE INSTALLATION .......................................................... m-14
.L.
STEERING SYSTEM .................................................................................. M-14
HANDLEBAR ...................................................................................... M-14
HANDLEBAR INSPECTION ............................................................... M-15
HANDLEBAR INSTALLATION........................................................... m-15
REAR BRAKE LEVER INSTALLATION .............................................. m-15
MASTER CYLINDER ASSEMBLY INSTALLATION .......................... M-15
STEERING STEM ............................................................................... M-16
BEARING RETAINER REMOVAL.......................................................... A-1
STEERING STEM INSPECTION ........................................................... A-1
BEARING RETAINER INSTALLATION ................................................. A-1
CABLE GUIDE 1NSTALLATION............................................................ A-1
TIE ROD AND STEERING KNUCKLE ................................................... A-1
STEERING KNUCKLEREMOVAL ......................................................... A-2
TIE ROD INSPECTION.......................................................................... A-2
I STEERING KNUCKLE INSPECTION..................................................... A-2
pi+q
BALL JOINT INSPECTION .................................................................... A-2
TIE ROD INSTALLATlON ...................................................................... A-2
FRONT ARM AND FRONT SHOCK ABSORBER ......................................... A-3

FRONT ARM REMOVAL ....................................................................... A-3
FRONT ARM INSPECTION ................................................................... A-3
FRONT SHOCK ABSORBER INSPECTION.......................................... A-3
FRONT ARM INSTALLATION .............................................................. A-4
REAR SHOCK ABSORBER AND SWINGARM ............................................. A-4

SWINGARM REMOVAL........................................................................ A-5
REAR SHOCK ABSORBER INSPECTION............................................. A-5
SWINGARM INSPECTION .................................................................... A-6
RUBBER BOOT INSPECTION............................................................... A-6
RUBBER BOOT INSTALLATION .......................................................... A-6
SWINGARM INSTALLATION............................................................... A-6
W
Le-
FRONT AND REAR WHEELS I
I
j
&6 D
CHASE
CHASSIS
FRONT ANDREAR WHEELS
FRONT WHEELS
b
-
b164 Nm (6.4 m . kg, 46 ft . Ibl

--
Qty
3
Remarks
-
--.
-. -
Front wheel removal Remove theparts in the order below.
Place the machine on a level surface.
-u
Securely support the machine so

there is n o danger of it falling over.
1 Front wheel 1 Refer to “WHEEL INSTALLATION”.
2
3
4
5
Wheel cap
Cotter pin
Axle nut
Brake caliper assembly
1
1
1
1
r Refer to “WHEEL HUB/BRAKE DRUM
INSTALLATION”.
NOTE:
Do not squeeze the brake lever when
the brake caliperis off of the brake disc
as the brake pads will be forced shut.
6 Wheel hub 1
7 Brake disc 1
~~ ~
I ~~ ~~
-
---
1
Drocedure. ~~ -
I
!
FRONT AND REAR WHEELS 1-1
REAR WHEELS
- -- -
I
_. -- -
Rear wheel removal Remove the parts in the order below.
Place the machine on a level surface,
_.
Securely support the machine so

there is no danger of it falling over.
1 Rear wheel 2 Refer to "WHEEL INSTALLATION".
2 Wheel cap 2
3
4
5
Cotter pin
Axle nut
Wheel hub
2
2
1
f Refer to "WHEEL HUB/BRAKE DRUM
INSTALLATION".
6 Brake drum 1
- ~ - - Drocedure.
~~
-
7 -
I
1
I
& DK
FRONT AND REAR WHEELS
I
~~ ~ ~~ ~
WHEEL INSPECTION
CHAS
i””;’s
1.lnspect:
Wheel
2.Measure:
Wheel runout
Overthespecified limit -+ Replace the
wheel or check the wheel bearing play0.
I .__.__
U
I B
I
3.Check:
Wheel runout limit:
Radial 0:2.0 mm (0.08 in)
Lateral 0:2.0 mrn (0.08 in) 1
I
Wheel balance
Out of balance + Adjust.
After replacing the tire, ride conservatively

to allow the tire to be properly seated in
the rim. Failure t o do so may cause an acci-
dent resultingin machine damage andpos-
Ir, sible operator injury.
I I WHEEL HUB INSPECTION

1.lnspect:
Wheel hub @
CracksMamage --f Replace. .
Splines (wheel hub) @
Wear/damage + Replace.
I I
BRAKE DRUM INSPECTION

1.lnspect:
Brake drum 0
Splines (wheel drum) @
Wearldamage + Replace.
1 FRONT AND REAR WHEELS
BRAKE DISC INSPECTiON
m
I
CHAS I 1
1.Inspect:
Brake disc
Galling/darnage 3 Replace.
2.Measure:
Brake disc deflection
Out o f specification -+ Inspect the wheel
runout.
If wheelrunoutis
within the limits,
replace the brake disc.
Brake disc maximum deflection:

0.15 mm (0.006 in)
Brake disc thickness @

-
Brake disc minimum thickness:
3 mm (0.12 in)
c-‘
< I
! WHEEL HUB/BRAKE DRUM INSTALLATION
1.lnstall:
Cotter pin @)
NOTE:
Do not loosen t h e axle nut after torquing it.
If the axle nut groove is not aligned with the
I cotter pin hole, align the groove with the
hole by tightening the axlenut.
1 1
1
2.Adjust:
Front brake lever free play
Refer to “FRONT BRAKE ADJUSTMENT“
in CHAPTER 3.
“-d
Rear brake lever and pedal freeplay

Refer to “REAR BRAKE LEVER AND
PEDAL ADJUSTMENT” in CHAPTER 3.
WHEEL INSTALLATION
1.lnstall:
Wheel
NOTE:
The arrow mark@ on the tire must point in
the direction ofrotation El of the wheel.
~ ~~
FRONT AND REAR WHEELS
2.Tighten:
Nuts (wheel) 0
-
Tapered wheel nuts @ are used for both
the front and rear wheels. Install each nut
with its TaDered side towards the wheel.
B
\d
---r
I FRONT BRAKE
FRONT BRAKE CHAS m
I I I
BRAKE PADS
--
~~ ~
-
-__-
Brake pad removal Remove the partsin the order below.
I
Front wheel Refer to "FRONT AND REAR
WHEELS".
1 Brake caliper mounting bolt 2
2 Brake pad holding bolt 2 ]Refer to "BRAKE PAD REPLACE-
]
3
4
Brake pad/pad shim
Pad spring
2/1
1
MENT".
I
I I
--- Procedure. 1
I
FRONT BRAKE pq&qpiil
$$&&j;yy&$;~
*>,..
>,?\*.,. ,,_,+.>%. %...<%
I j
Disc brake components rarely require dis-

assembly. DO NOT:
disassemblecomponentsunlessabso-
lutely necessary;
usesolvents on internalbrakecompo-
nents;
use spent brake fluid for cleaning; (use
only clean brake fluid)
allow brake fluidto come in contact with
the eyes, as this maycause eye injury;
splash brake fluid onto painted surfaces or
plastic parts, as this maycause damage;
disconnect any hydraulic connection, as
this would require the entire brake sys-
tbet e
o
m disassembled,
drained,
cleaned, properlyfilledand bled after
L-, reassem
BRAKE PAD REPLACEMENT

NOTE:
It is not necessary to disassemble the brake
caliper and brake hose to replace the brake
I
pads.
@-
1.Remove:
Brake pads
@Wear limit
NOTE:
Install a new brake pad spring when the
brake pads have to be replaced.
Replace the brake padsas a set if either is
found to be w o r n to the wear limit.
-_J'
r a
2.lnstaII:
Brake pads
Brake pad spring
..................................
Installation steps:
*Connect a suitable hose @ tightly to the
brake caliper bleed screw0. Put the other
end of this hose intoan open container.
I I
1 ~~~~
FRONT BRAKE mCHAS
.Loosen the brake caliper bleed screwand,
1
using a finger, push the caliper piston into

the brake caliper.
eTighten the brake caliper bleed screw.
Brake caliper bleed screw:

b&+ 6 Nm (0.6 m kg, 4.3 ft lb)
nx i
olnstall new brake pads, new pad shims @
and a new brake pad spring.
*Install the retaining bo-Its and brake Cali-
per.
NOTE:
The arrow mark 8 on the pad shim must
point in the direction of the disc rotation.
Brake pad holding bolt:

18 Nm (1.8 rn kg, 13 ft Ibl
Brake caliper mounting bolt:
r 30 Nm (3.0rn kg, 22 ft Ib)
**X**~C***X*********X*+XXXXX*X+XXn
3.lnspect:
Brake fluid level
Refer to "BRAKE FLUID INSPECTION" in
CHAPTER 3.
--4 4.Check:
Brake lever operation
Soft or spongy feeling + Bleed the brake
system.
Refer to "AIR BLEEDING (HYDRAULIC
BRAKE SYSTEM)" in CHAPTER 3.
FRONT BRAKE T&I@c
)
CHAS
MASTER CYLINDER

Master cylinder removal Remove the partsin the order below.
fluid Drain Brake
"-- 1 Brake lever/compression spring 1/1
2 Union bolt 1 1
*I
U1
3 Copper washer
Refer to "MASTER CYLINDER
4 Brake hose
INSTALLATION".
5 Master cylinder bracket 1
6 Master cylinder 1
I For installation, reverse the removal

Drocedure.
- -
&I
I d
FRONT BRAKE lcHASl
,%.-, &@
G
---- o
\

Master cylinder disassembly Disassemble the parts in the order
below,
- (
@
iJDust boot
Circlip
.I
I
-
-Refer to “MASTER CYLINDER
ASSEMBLY”.
@ Master cylindercup kit 1 -
procedure.
- --
-
FRONT BRAKE 1- pi
iG
~~~~~~
I
MASTER CYLINDER INSPECTION

1.lnspect:
Master cylinder
Weadscratches 4 Replace the master cyl-
inder assembly.
Master cylinder body
~
L
Brake fluid delivery passage
(master cylinder body)
Blockage -+ Blow out withcompressed
I 1 air.
2.lnspect:
Master cylinder cupkit
Scratches/wear/damage + Replaceasa
set.
I"" I
3.lnspect:
Diaphragm
4.lnspect:
Brake hose
Cracks/wear/damage + Replace.
E8702060
MASTER CYLINDER ASSEMBLY
- All internal brake components should be

cleaned andlubricated with new brake
fluid only before installation.
'q Recommended brakefluid:

DOT4
Whenever a master cylinder is disassem-

bled,replace the piston seals anddust
seals.
1.lnstall:
0
Circlip
Dust boot
=
Master cylinder cup kit
- ..
I FRONT BRAKE
MASTER CYLINDER INSTALLATION
1.Install:
Master cylinder7(J
NOTE:
Engagethereceptacleonthecollar @
-
h 1 7 Nrn (0.7 rn . kg, 5.1 ft Ib)
with the lobe on the throttle lever assem-

bly.
The "UP" mark on themastercylinder
bracket should face up:
9 I
~~~
I 1 2.lnstall:
Copper washers m
I I Brake hose
Union bolt 1&$(27 Nm (2.7 m . kg, 19 ft Ib) . I
NOTE:
Tighten the union bolt while holding the
I
U
\K
YW
60'
I
brake hose as shown.
Turn the handlebar to the left and to the
right to check that the brakehose does
not touch other parts (throttle cable, wire
harness, leads, etc.). Correct if necessary.
~~~~~ ~~ ~ ~~ ~~ ~~~~~~
Properbrake hose routing is essential t o

'.-.
insuresafemachineoperation.Refer to
"CABLE ROUTING".
3.Fill:
Reservoir tank
'q Recommended brakefluid:

DOT4
-.<_
;k
,"?
.A>
Brake fluid may damage painted surfaces

or plastic parts. Alwaysclean up spilled
brake fluid immediately.
FRONT BRAKE 1- lCn
Use onlythedesignatedqualitybrake
fluid: other brake fluids may deteriorate
therubber seals, causingleakage and
poor brake performance.
Refill with the same type of brake fluid:
mixing brake fluids may result in a harm-
fulchemicalreactionandlead topoor
brake performance.
Be careful that water does not enter the
master cylinder when refilling. Waterwill
significantly lower the boiling point of the
brake fluid and may result in vapor lock.
\L"
4.Air bleed:
Brake system
Refer to "AIR BLEEDING (HYDRAULIC
BRAKE SYSTEM)" in CHAPTER 3.
5.lnspect:
Brake fluid level
Brake fluid level is under the "LOWER"
level line -+ Fill up.
Refer to "BRAKE FLUID LEVELINSPEC-
TION" in CHAPTER 3.
I
-
- -.
I FRONT BRAKE 1
-
BRAKE CALIPER
\ _ I
.
h 1 1 8 Nm (1.8 m kg, 13 ft . Ib)
.
1%127 Nrn (2.7rn kg, 19 ft Ib)
1 I

Brake caliper removal Remove theparts in the order below.
Brake fluid Drain
v
Front wheel Refer to "FRONT AND REAR
WHEELS".
1 Union bolt 1
I
2 Copper washer 2
3 Brake hose 1 Disconnect
4 Refer to "CALIPER
Caphetaining bolt 1/1 Loosen
INSTALLATION".
5 Brake pad holding bolt 2 Loosen
6 Brake caliper mounting bolt 2
7 Brake caliper assembly 1
For instaltation, reverse the removal
procedure.
FRONT BRAKE m
&E
Ki
CHAS
b 1 6 Nm (0.6 m a kg, 4.3 ft . Ib)
Order Job name/Part name Q‘ty Remarks

Brake caliper disassembly Disassemble the parts in the order
below.
“’0 Brake pad holding bolt 2
@ Brake padlpad shim 211
@ Pad spring 1
@ Retaining bolt 1
0 Caliper bracket 1
@ Brake caliper piston I
0 Dust seal I
ASSEMBLY”.
]Refer to “CALIPER DISASSEMBLY/
8Caliper piston seal 1
@Bleed
I screw 1
For assembly, reversethe disassembly
procedure. . -
.i
:
I I 1
FRONT BRAKE
CALIPER DISASSEMBLY
rn
I
CHAS I I
1.Remove:
Brake caliper piston
6
-
Dust seal @
Caliper piston seal @
***X**XY*X*X***XX*ff***X*X********
Removal steps:
.Blow compressed air into the hose joint
_____~
~
openingtoforce out the caliperpiston
from the brake caliper body.
I +. 1
I '
Never try t o pry out t h e caliper piston.

Cover the caliper piston with arag.Be
careful not to get injured when the piston
is expelled from the master cylinder.
*Remove the caliper pistonseals.
**Y**R**~**X*~***X+***************
E8702040
CALIPER INSPECTION
II Recommended brake component
Brake
pads
replacement schedule:
1 As
required
~~
Piston seal, dust seal Every t w o years

Brake hoses Every two years
Replace when
Brake fluid brakes aredisas-
sembled.
<
-
I
All internal brake components should be
cleaned in new brake fluidonly. Do n o t use
solvents as they will cause seals t o s w e l l
and distort.
1.Inspect:
Brake caliper piston 0
Scratches/rust/wear --3 Replace the brake
caliper assembly.
Brake caliper cylinder 0
Wear/scratches + Replace the brake cali-
per assembly.
Brake caliper body @
Crackddamage -+ Replace. .
I I
FRONT BRAKE r T -&p E
CHAS
Brake fluid deliverypassage (brake caliper
body)
Blockage --f Blow out with compressed air.
Replace thecaliper piston sealand dust

seal whenever the brake caliper is disas-
sembled.
CALIPER ASSEMBLY
AI1 internal brake components should be

cleanedandlubricated with new brake
fluid only before installation.
.ti 'q Recommended brake fluid:

DOT4
Replace t h e caliper piston seal whenever

a brake caliper is disassembled.
= =
1.lnstall:
Caliper piston seal @
bb
Dust seal @
2.lnstall:
Brake caliper piston @
/
CALIPER INSTALLATION
l.lnstaI1:
Brake caliper assembly
Brake caliper bracket @
-
b 1 3 0 Nm (3.0 m . kg, 22 ft Ib) I
E
Im
I Brake hose 0
Copper washers 0 = -
Union bolt@ h 1 2 7 Nrn (2.7 rn . kg, 19 ft Ib) 1
1 .
FRONT BRAKE 1-
:,2
.,$:!>.A ejqyf&&i
:*x* ~
- *
Wheninstallingthebrakehoseonthe
brake caliper, makesurethatthebrake
pipe touches the projection 8on the brake
caliper.
-L
Proper brake hose routing is essential to
insure safe motorcycle operation. Refer t o
"CASLE ROUTING".
2.Fill:
Brake reservoir
Recommended brake fluid:

'Q DOT4
~~~
cc&jrjpp:. .:
: ,<*- ~ ,
.
1 ... -
,'4 (lil . .
Brake fluid may damage painted surfaces

orplasticparts.Alwayscleanupspilled
brake fluid immediately.
Useonlythedesignatedqualitybrake
fluid: other brake fluids may deteriorate
the rubber seals, causingleakageand
poor'brake performance.
Refill with the same type of brake fluid:
mixing brake fluids may resultin a harm-
ful chemicalreactionandlead t op o o r
brake performance.
Be careful that water does not enter the
master cylinder when refilling. Waterwill
w the ofsignificantly
pointboiling
lower the
brake fluid and may result in vapor lock.
3.Air bleed
0 Brake system
Refer to "AIR BLEEDING" in CHAPTER 3.
4.lnspect:
e Brake fluid level
Brake fluid level is underthe "LOWER"
level line -+Fill up.
Refer to "BRAKE FLUID INSPECTION" in
CHAPTER 3.
REAR BRAKE 1-I ~~~
I I
jiK
REAR BRAKE
I 1
%d
- Order -
I
-- -
--
Job name/Part name Q'ty Remarks
_. -. --. -
Rear brake removal Remove the parts in the order below.
Right rear wheel Refer to "FRONT AND REAR
..., Brake d r u m l-
WHEELS".
1 Brake pedal adjuster 1
2 Brake lever adjuster \I
3 Pin 2
4 Spring 2
5 Rear brake breatherhose Disconnect
1
6 Boltlbearing retainer 411 Refer to "REAR BRAKE INSTALLA-
7 Brake shoe assembly 1 L O Nrr.
a I
--- procedure. -
- " A
REAR BRAKE -
'4 2
Order Job name/Part name O'ty Remarks

Rear brake disassembly Disassemble the parts in the order
below.
--,aBrake shoe 2
@ Tension spring 2
@ Spring 1 -
@ BolWnut 1/1
0 Brake camshaft lever 1
@ Wear indicator plate 7 -Refer to "REAR BRAKE ASSEMBLY".
@ Brake camshaft 1
@ Washer 1
@ O-ring 2 -
@ Dust seal 1
- -_
REAR BRAKE F
BRAKE SHOE PLATE INSPECTION
&I
H A 4, - -1 (M
1.lnspect:
'
Brake shoe plate 0
Pivot pin @
Brake camshaft @
Bends/cracks/damage -+ Replace.
I W
~~
P ,
4
\
--@&
I
Dust seal @
I BRAKE SHOE INSPECTION

1.lnspect:
Brake shoes @
Brake shoe springs @
Cracks1damage --f Replace as a set.
NOTE:
Whenreplacingthebrake shoes, replace
the brake shoe springs at the same time.
I iif L 1 2.lnspect:
surface
Brake
lining
shoe
Glazed areas --f Remove.
Use coarse sandpaper.
NOTE:
Afterusingsandpaper,wipe off thepol-
ished particleswith a cloth.
3.Measure:
Brake shoe lining thickness 8
@ Measuring points
NOTE:
Replace the brake shoes as a set if either is
found to be worn to the wear limit.
y6-ax
i Brake lining thickness:

4.0 mm (0.16 in)
<Wear l i m b :
1.0 mm (0.04in)
I REAR BRAKE 1
-
1 BRAKE DRUM INSPECTION
1.Measure:
Brake drum inside diameter8
'
L
. I
2.lnspect:
Rear brake drum inside diameter:
160 m m (6.30in)
<Wear limit>:
161 mm (6.34in)
Brake drum inner surface

OiI/scratches -+ Remove.
\
I
I
I
t-- Scratches
REAR BRAKE ASSEMBLY

Use a rag soaked in lacquer
thinner or solvent.
Use an emerycloth
and evenpolishing).
Reverse the "Removal" procedure.

(light
Note the following points.
-
1.Lubricate:
Brake camshaft @)
Pivot pin @
Lithium-soap base grease

I I
-.-,,,,,
~~,<,y,<,*e,*p~" ~-7x.l,
.$:$&vTiO'N$
._...
*...:<*,. ,..,
>>%.x..,.,,.:. <.-.,: , 73:
During installation, lightly grease the brake

camshaft and the pivot pin. Wipe off t h e
excess grease.
1 2.lnstall:
Wear indicator plate0
NOTE:
When installing the wear indicator plate, fit
the projection intoa brake camshaft groove
and align the wear indicator plate with the
left end of the wear indicatorscale 0.
-
I
I I i I
REAR BRAKE lCHASl& IM

3.lnstall:
Brake camshaft lever @
Spring @
k l l 0 Nm (1.0 m . kg, 7.2 ft Ibl - I
NOTE:
When installing the brake camshaft lever,
align the punch mark 0on the brake cam-
shaft lever and brake camshaft.
4.lnstall:
Tension springs
Brake shoes
5.Check:
Brake camshaft operation
Unsmooth operation+ Repair.
i'
I BRAKE 1 REAR INSTALLATION

1.Apply:
Sealant 0
(onto the mating surfacesof swingarm)
~~
p
2.lnstall:
Sealant (Quick Gasket)?
P/N. ACC-I 1001
PjN. 90890-85505
-05-01
Yamaha bond No. 1215@:
I
Rear brake assembly
Bearing retainer
3.Apply:
h i 2 8 Nm (2.8 m - kg, 20 ft * Ib) I
L*
Yamaha brakegrease @ .
(onto the dust seal @ a n d onto the area of
the brake drum contacting t h e dust seal)
Yamaha brake grease:

I...cIL PIN. 90793-40003
7-23
il
STEERING SYSTEM
HANDLEBAR
STEERING SYSTEM -
- -
F
-f
Order Job name/Part name Q'ty 1- Remarks
__ -
Handlebar removal Remove the parts in the order below.
1 Starter knob 1 ~ Disconnect
p e f e r to "CABLE ROUT-
1
Main switch lead 1 ~ ~ I N G "in CHAPTER 2.
Indicator lightlead 4
Handlebar cover 1
Band 4
Master cylinder assembly/ bracket 1/1
4WD / 2WD select switch
Throttle lever assembly/ bracket
Collar
Rear brake lever/ bracket
1
1/1
I
1/1
1T Refer to "MASTER CYLINDER
ASSEMBLY INSTALLATION".
Refer to "REAR BRAKE LEVER

Handlebar switch 1 INSTALLATION".
Handlebar grip 2
Handlebar holder (upper) 2 Refer to "HANDLEBAR INSTALLA-
11
10
13
12 I
I A
TION".
-
- _.
STEERING SYSTEM m
I
CHAS I I
m
--
14
15
16
Handlebar
Handlebar holder (lower)
Speedometer
1
2
1
Refer to "HANDLEBAR INSTALLA-
TT,ON'f.

procedure.
1 STEERING SYSTEM
HANDLEBAR INSPECTION
1-
c
1.lnspect:
Handlebar
Bendslcracksldamage -+ Replace.
Do not attempt to straighten a bent han-

dlebar as this may dangerously weaken the
handlebar.
HANDLEBAR INSTALLATION
0 1.lnstall:
%
e Handlebar
Handlebar holders (upper andlower)
[%I20 Nrn (2.0m . kg, 14 ft * Ib) I
NOTE:
Insert the projection @ of the handlebar
holder (lower) into the steering shaft hole.
Theupperhandlebarholdershould be
installedwith the punchedmark @ for-
ward @.
~~
$;:&&@~~ ,
. ,.\,
~
First tighten the bolts 0 on the front side

of the handlebar holder, and then tighten
the bolts (5)
- on therear side.
REAR BRAKE LEVER INSTALLATION

I I 1.lnstall:
e Handlebar switch @
Rear brake lever
Lever bracket @
NOTE:
I
Install the lever bracketas shown.
@ 80 mm (3.1 in)
MASTER CYLINDER ASSEMBLY
INSTALLATION
1.lnstall:
I I
e Throttle lever assembly
I I e Collar
Master cylinder assembly
h l 7 Nm (0.7 m . kg, 5.1 ft * Ibl I
NOTE:
e Engage the indentations @ in the collar
with thelobes (8 on thethrottlelever
assembly and master cylinder.
e The "UP" mark on themastercylinder
bracket should face up.
I I
STEERING STEM
STEERING SYSTEM - (M
Order Job name/Part name Q‘ty Remarks

-
-
Steering removal Remove the parts in the order below.
Handlebar Refer to “HANDLEBAR”.
w Seat TRefer t o “SEAT, CARRIERS, FENDE iRS
Front fender AND FUEL TANK” in CHAPTER 3.
1 Lock washer 1 Refer to “CABLE GUIDE INSTALLA.
2 Cable guide 1 JTION”.
3 Steering stem bushing 2
4 Collar 2
5 Oil seal 2
6 Tie rod end nut 2
7 Tie rod 2 Disconnect
8 Steering stem nut 1
9 Pitman arm 1
10 Steering stem 1
-
7-27
il STEERING SYSTEM -
.. I

11 Oil seal 1
12 Bearing retainer 1 Refer to "BEARING RETAINER
d
REMOVAVINSTALLATION".
13 Bearing 1
14 Oil seal 1
procedure.
~
STEERING
SYSTEM
BEARING RETAINER REMOVAL
1- m
1.Remove:
Bearing retainer (steering stem)
Damper r o d holder:
P/N. 90890-01375
f 1 STEERING STEM INSPECTION

lhspect:
Steering stem
Bends + Replace.
~ ~~~~
Do not attempt to straighten a bent stem;

t h i s may dangerouslyweaken t h e stem.
'
I I
2.lnspect:
1
Oil seals 0
b Steering stem bushings @

Wearidamage + Replace.
I I
BEARING RETAINER INSTALLATION

1.lnstall:
Bearing retainer (steering stem)
-
[%I40 N m (4.0 m kg, 29 ft Ib)
-.- Damper rod holder:
P/N. 90890-01375
CABLE GUIDE INSTALLATION

1.lnstall
Cable guide
Lock washer =
h i 2 3 Nm 12.3 rn . kg, 17 ft Ib)1
2.Bend the lock washer tab along a flat side
of the bok.
NOTE:
Pass thecables and hoses through the
cable guide. Refer to "CABLE ROUTING" in
CHAPTER 2.
-. A
.
1
TIE ROD AND STEERING KNUCKLE
STEERING SYSTEM -
W
- - -
F
Order
v
_.
Job narne/Part name
Tie rod andsteering knuckle removal
Front fender
Q'ty ,-II Remarks
Remove the partsin the orderbelow.
Refer to "SEAT,CARRIERS, FENDERS
-

Front wheel / brake disc Refer to "FRONT AND REAR
WHEELS".
1 Tie rod 1 Refer to "TIE ROD INSTALLATION".
2 Brake disc guard 1
3 Brake hose holderbolt 2
4 Constant velocity joint protector 1
5 Bolt / washer I nut 1/1/1
6 Bolt / washer / nut 2/2/2
7 O-ring /washer 1/1
8 Steering knuckle
/'I Refer to "STEERING KNUCKLE
REMOVAL".
For installation. reverse the removal
- procedure.
A
STEERING SYSTEM
~~~~
STEERING KNUCKLE REMOVAL

1
I
CHAS 1 IA
1
1.Remove:
Steering knuckle @
NOTE:
Use a generalpullerto separate theball
joint 0and steering knuckle.
~
t
TIE ROD INSPECTION
1.Check:
Tie rod free playand movement
Free play -+ Replace the tie rodend.
Turns roughly -+ Replace the tie rod end.
2.lnspect:
Tie rod
Bendddamage -+ Replace.
"s
M
STEERING KNUCKLE INSPECTION
1.lnspect:
Steering knuckle
Damage/pitting -+ Replace.
2.lnspect:
I A B Front wheel bearings
I Bearings allow play in the wheel hubs or
-
the wheel turns roughly-+ Replace.
Oil seals
1I
~
I
Damage + Replace.
**Y***********X*******************
Front wheel bearing replacementsteps:

Clean the outside of the steering
.Remove the oil seals 0.
.Drive out the bearings0.
knuckle.
1 .
Eye protection is recommended

when
using striking tools.
.Remove the spacer 0.
.Apply lithium base grease to the bearings
and oil seals.
.Install the spacer to the steering knuckle.
L
l SYSTEM STEERING
.Install the new bearings.
J - G q q
NOTE:
Install the outside bearing first.
.;,:-~?#J~pJIu;::
~.~.~,.,,~~,,~.~~~..-
< < .
X...l
". ,: :,,.,.,..
A:$,%,
x <>, , . ,,.; >>$$
Do not strike the center race or balls of the

bearing. Contact should bemade only with
the outer race.
~~~ ~~ ~~ ~ ~~ ~~
olnstall a new oil seal. 1
NOTE:
Wheninstallingtheoil seals, the"seal
*
side" of the oil seal faces out.
~~
**Yl********Y**YY***YYY*YY+*************
-4
BALL JOINT INSPECTION

1.lnspect:
Ball joint
Damage/pitting 4 Replace the front arm.
Free play -+ Replace the front arm.
Turns roughly --f Replace the front arm.
TIE ROD INSTALLATION

1.lnstall:
Tie rods (left andright)
-
h 1 2 5 Nm (2.5 m kg, 18 ft Ibl 1
-F .
NOTE:
The tie rod which must be installed on t h e
right side has a white painted mark0.
2.Adjust:
Toe-in
Refer to "TOE-IN ADJUSTMENT" in
CHAPTER 3.
FRONT AND
ARMFRONT SHOCK ABSORBER r l -&- p
CHAS
SHOCK ABSORBER
FRONT ARM AND FRONT
~~~~~~
- -- -
F
I
Order Job name1Part name Q'ty Remarks

- _.- _. -
Front arm andfront shock absorber Remove the partsin the order below.
- removal
Differential gear skid plate
Front fender r
Front wheelI brake disc Refer to "FRONT AND REAR WHEELS".
1 Brake disc guard 1
2 Brake hose holding bolt I
3 Bolt 1
4 Bolt / nut 2/2
5 Front arm/ bushing 112 Refer to "FRONT ARM REMOVAU
INSTALLATION".
6 Bolt / washer / n u t 21212 ,
7 Circlip / nut 111
8 Front shock absorber 1
- IL-
I
procedure. A
-
1 FRONT ARM AND FRONT SHOCK ABSORBER
FRONT A R M REMOVAL
m
1.Check:
Front arm free play
****************x*****************
Checking steps:
*Check the front arm side play by mov-
ing it from side to side.
Ei
If side play is noticeable, check the bush-
rngs.
.Check the front a r m vertical movement
by movingit up and down.
If the vertical movementis tight or rough,
or ifthere is binding, check the bushings.
KYYXX***+Y*+****+**X***~***#******
2.Remove:
El Front arm
. ,
FRONT ARM INSPECTION
1.lnspect:
Front arm @
Bendddamage -+ Replace.
2.lnspect:
Bushings @
FRONT SHOCK ABSORBER INSPECTION

lhspect:
Shock absorber rod
Bendddamage + Replace the shock
L, absorber assembly.
Shock absorber assembly
Oil leaks -+ Replace the shock absorber
assembly.
Spring
Fatigue + Replace theshockabsorber
assembly.
FRONT ARM AND SHOCK
FRONT
ABSORBER r n B
I
CHAS I I
FRONT ARM INSTALLATION

1.lnstall:
Front arm
******************x***************
Front arm installation steps:

install the front arm (ij, bolts @ and nuts
0.
NOTE:
Lubricate the bolts @ with lithium soap
base grease.
Be sure to position the bolts so that the
bolt head faces outward.
Temporarily tighten the nuts.
olnstall the ball joint.
0 Install the bolt@, washer and nut 0.
Nut 0:
b? -
48 Nm (4.8 m kg, 35 ft Ib)
@Install the new cotter pin.

@Tighten the nuts0.
NOTE:
Beforetighteningthenuts 8,adjustthe
length @ t o 417 mm (16.4 in).
Nut 0:
b~ 45 Nm (4.5 m kg, 32 ft
YY****Y*XY+***X*****~************~
4 Ibl
”-..,
- --
1 REAR SHOCK ABSORBER AND
REAR SHOCK ABSORBER AND SWINGARM
1
SWINGARM -
I
,
- - -
I= Order
_.
Job nameIPart name
Rear shock absorber and swingarm
removal
-
Q'ty Remarks
-
i
Brake shoe assembly Refer t o "REAR BRAKE".
Final drive gear assembly Refer to "REAR AXLE/FINAL DRIVE
1 CDI unit 1
1
GEAR AND DRIVE SHAFT" in CHAP-
TER 6.
2 Lever grip 1 NOTE:

Before removing the
rear shock
absorber, turn the spring preload
adjusting lever to "H".
3 Pin /washer / clip 1/1/1
4 Nut / bolt 111
5 Rear shock absorber 1
6 Collar 2
7 Nut / bolt 212
8 - Rear axle housing- ~~
- ---
1
-
REAR SHOCK ABSORBER AND SWINGARM CHAS T & IE
r
2
a_,
P I
Order
-I
Job name/Part name

--
Q'ty
-
Remarks
-
9
-
Rear brakecable
--- -
2
10
'--'11
14
15
12
13
Rear brake breather hose
Final drive gearcase breather hose
Carburetor overflow hose
Carburetor drain hose
Metal clamp
Cover
1
1
1
1
2
2
1 Pull out of the guides on.the swing-
arm. Refer to "CABLE ROUTING" in
CHAPTER 2.
Refer to "SWINGARM INSTALLATION".
16
17
18
19
20
Locknut
pivot shaft (left)
Pivot shaft (right)
Swingarm
Rubber boot
1
1
1
1
1
1
J
Refer to "SWINGARM REMOVAU
INSTALLATION".
Refer to "RUBBER BOOT INSTALLA-

TION".
21 Collar / O-ring 2f 2
22 Oil seal 2
23 Taper roller bearing 2
- --- procedure. -
- d ,
I REAR SHOCK ABSORBER AND SWINGARM lcHAsl& I
-
SWINGARM REMOVAL
1.Inspect:
Swingarm free play
*******x**************************
Inspection steps:
.Check the tightening torque of the pivot
shafts
(swingarm)and
locknut
(pivot
shaft).
Pivot shaft (right}:

b% 130 N m (13.0 m kg, 9 4 f t Ib)
Pivot shaft (left):
6 Nm (0.6 m kg, 4.3 ft Ib)
Locknut (pivot shaft-left):
130 Nrn (13.0 m kg, 94 ft Ibl
I
~ ~~~ __ I
aCheck the swingarm side play I?% by mov-

ing it from side to side.
If side play is noticeable, check the collar,
\i
bearing and frame pivot.
.Check the swingarmverticalmovement
by moving it up and down.
If vertical movement is tight or rough, orif
there i s binding, check the bearing, collar
and frame pivot.
******************t***************
2.Remove:
Pivot shafts
Swingarm
REAR SHOCK ABSORBER INSPECTION

1.lnspect:
Shock absorber
Oil leaks --f Replace theshockabsorber
,
*e
assembly.
Shock absorber rod
Bendstdamage --f Replace the shock
absorber assembly.
Spring
Fatigue -+ Replace the shock absorber
assembly.
..
SWINGARM INSPECTION
rT-l
& IA
CHAS
1.Inspect:
Swingarm
Bends/cracks/damage --f Replace.
2.lnspect:
Pivot shafts
NOTE:
Wash the swingarm pivoting parts in a sol-
vent.
'pi I
bb\%
3.lnspect:
Taper roller bearings0
Taperrollerbearingsallowplayinthe
swingarm or the bearings t u r n roughly +
l$&@ao Replace.
Oil seals @
Collars @
O-rings @
Weaddarnage + Replace.
RUBBER BOOT INSPECTION

1 .Inspect:
Rubber boot 0
Damage + Replace.
0
I 1 RUBBER BOOT INSTALLATION

1.Apply:
E
Adhesive (for rubber)
(to the swingarm end0)
2.lnstall:
Rubber boot @
NOTE:
Be sure to position the rubber boot so that
the tang0 faces towards the left.
7 - 39
I
~
SWINGARM INSTALLATION
~~~
I I 1
1.lnstall:
Swingarm
Pivot shaft (right)( i
J
Pivot shaft (left)@
Locknut (pivot shaft-left)@
Covers @
NOTE:
~~
Finger tighten the pivot shafts and locknut;
do not torquethem a t this point.
4
2.Tighten:
Pivot shafts
*~*~****X+*Y*XX***X***************
Tightening steps:
@Tighten the pivot
shaft (right) to specifica-
I tion.
Pivot shaft (right) 0:

----I
~~
b~ -~~~~-
130 N m (13.0 m kg, 94 ft Ib)
~~~ ~~~
@Tighten the pivot shaft (left) until

~~ ~~~~
it con-
tacts the collar.
Pivot shaft (left)0:

b~ 6 N m (0.6rn kg, 4.3 ft Ib) -
.Tighten thelocknut(pivotshaft-left)to
specification.
Locknut [pivot shaft-left) 0:

b~ 130 Nm (13.0 m kg, 94 f t Ib)
********X*****~*******************
* Q,
3.lnstall:
Metal clamps
NOTE:
Seen from the rearofthevehicle, the
metalclampsshould be positioned as
shown in the illustrations.
When installing the metalclamps, be sure
that the swingarm is parallel to the vehi- 1
de.
nEngine side
m Swingarm side
- .^
*/IF
CHAPTER 8.
ELECTRICAL
ELECTRICAL COMPONENTS ...................................................................... B-3
SWITCH INSPECTION ................................................................................. B-3

SWITCH INSPECTION ......................................................................... 8-3
INSPECTING A SWITCH SHOWN IN THE MANUAL ......................... 8-3
SWITCH CONTINUITY INSPECTION .................................................. B-4
IGNITION SYSTEM ...................................................................................... B-5

CIRCUIT DIAGRAM .............................................................................. B-5
TROUBLESHOOTING .......................................................................... B-5
ELECTRIC STARTING SYSTEM ................................................................... B-7

CIRCUIT DIAGRAM .............................................................................. B-7
’
-
h
STARTING CIRCUIT OPERATION ....................................................... B-8
TROUBLESHOOTING .......................................................................... 6-8
STARTER MOTOR ..............................................................................B-10
STARTER MOTOR INSPECTION ....................................................... 6-11
STARTER MOTOR ASSEMBLY ......................................................... B - I 1
CHARGING SYSTEM ................................................................................. b-12

CIRCUIT DIAGRAM ............................................................................ B-12
TROUBLESHOOTING ........................................................................ B-12
LIGHTING SYSTEM ................................................................................... b-13

TROUBLESHOOTING ........................................................................ b-14
LIGHTING SYSTEM CHECK .............................................................. B-15
.. SIGNAL SYSTEM ....................................................................................... B-16

TROUBLESHOOTING ........................................................................ B-16
SIGNAL SYSTEM CHECK .................................................................... C-I
COOLING SYSTEM ...................................................................................... C-4

CIRCUIT DIAGRAM .............................................................................. C-4
TROUBLESHOOTING ........................................................................... C-4
2WD/4WD SELECTING SYSTEM ............................................................... C-6

CIRCUIT DIAGRAM .............................................................................. C-6
TROUBLESHOOTING .......................................................................... C-7
EBEOOOW
-
ELECTRICAL COMPONENTS /
In]
IB
ELEC
ELECTRICAL
ELECTRICAL COMPONENTS
@ Indicator light 0Battery @ Fan motor
control
unit @ 4WD swltch
@ Main@Taillight
switch @ CDI unit @ Gear motor
@ Rear
brake switch @ Starter
relay @ Rectifier/regulator @ Fan
@ Handlebar switch @ Reverse
relay @ Neutral switch @ Headlight
(left) @ Starting circuit @ Reverse switch @ Diode
cut-off
@ Ignition
coil relay @ Thermo@Terminal
unit
@ Fuses @ Fan motor relay @ Circuit
breaker (fan) @ 2WD/4WD select switch
. ,
u
1 r
-cv" .._..
1
SWITCH INSPECTION
SWITCH INSPECTION
m
U SWITCH INSPECTION
Use a pocket tester t o check the terminals
for continuity. If the continuity is faulty at
any point, replace the switch.
Pocket tester:
P/N. YU-03112.90890-03112
NOTE:
Set the pocket tester to "0" before start-
ing the test.
The pocket tester should be set to the "Q
x 1" rangewhentestingtheswitchfor
continuity.
Turn the switch on and off a f e w times
when checking it.
* ,
~-~~ ~~
1
I 1 INSPECTWIG A SWITCH SHOWN IN THE
Q MANUAL
The
terminalconnections for switches
(mainswitch, handlebar switch,
engine
stop switch, light switch, etc.) are shown in
a chart similar to the one on the left.
This chart shows the switch positions in the
columnandtheswitchleadcolorsinthe
top row.
I I For each switchposition, "M" indi-
cates the terminals with continuity.
The example chart shows that:
@Thereiscontinuitybetweenthe "Black
a n d B l a c W h i t e " leads when the switch
is set to "OFF".
*--
0There is continuity between the"Red and
Brown" leads when the switch is set to
" 0 N" .
SWITCH CONTINUITY INSPECTION
SWITCH INSPECTION Mle
lead terminals.
Refer to "SWITCH INSPECTION" and check for continuity between
Poor connection, n o continuity + Correct or replace,
Jc The coupler locations are circled.
-----___--_____
---_----------___--______
I
I _ _ _ _ _ _ _ _ - - _ _ - - _ _ - - _ _ _ _ _ _
I (BROWN)
I _ _ _ _ _ _ _ _ - - - _ - - _ _ - - _ _ _ _ _ _
li ___ \
---_
; fa;
--_ E /
A _______
@ ; rf
---___
@I j
:p
II 1 1
I
I
I
1
I
I
,
'h i ; \ ;
I
-
I
I
1
t -
,
I
t __________ J L ________-_ J
8 ,
r __________ 1
- -
1 @ Lights switch
1-
SWITCH INSPECTION
@ Engine stop switch

@ Starter switch
@ M a iI
n switch
@ 2WD/4WD select switch
@ Rear brake switch
@ 4WD switch
@ Reverse switch
@ Neutral switch
@ Fuse
'4'
'.i
E8802000
IGNITION SYSTEM
IGNITION SYSTEM m*
DI
CIRCUIT DIAGRAM
-
. ..
~~ .
. ~ .
~ ~~~
~~
~ ..
.~
-+
. .
. ..
~~ . ..
. .
~~.
.. . ~ ~~
. .
, - ~~
~~ ..
‘e
-
-7 -
-.-i-
.. - - .~
....
... 1 .
.~
1~
~~ ~ ~ ~~
~ ~ 1 -
~~ ~~ -
~- -
..- -
-
.. _ +
.--_
- - _-
- .-
-.
- - _- -.
-
--A -
~~
-
--L-
- _-
.~ . -
-
-- _- - - , ,
-
-
,-- -.
--A- -
:It :
_ _ T_ i
-
-
:d;
- -
-
zi-3:
-
~
-- -
--
11: -
--t- -
1 I nI
1 t
I EBBDlOlO
IGNlTlON SYSTEM ELEC
TROUBLESHOOTING
IF THE IGNITION SYSTEM FAILS TO OPERATE (NO SPARK OR INTERMITTENT SPARK):
Procedure
I
Check:
.Main 1.Spark plugs
spark
2.lgnition gap 7.Pickup coil resistance
3.Spark
resistance
cap
plug 8.Source
resistance
coil
4.lgnition coil
connection
9.Wiring
resistance -
system)
ignition
entire
5.Engine
(the
switchstop
NOTE: 1
Remove the following part(s) before trou- Dynamic spark tester:

P/N. YM-34487
bleshooting:
1)Seat
- Ignition checker:
P/N. 90890-06754
2)Front carrier Pocket tester:
“‘Front fender P/N. YU-03112.90890-03112
-&e the following special tool(s) for trou-
bleshooting.
i
1.Spark plug Standard spark plug:
for USA
Check the spark plug condition.
DP8EA-9/NGK
Check the spark plug type. for Canada
Check the spark plug gap. DPR8EA-S/NGK
Refer to ”SPARK PLUG INSPECTION” in
CHAPTER 3.
INCORRECT
Spark plug gap:
.
0.8 0.9 mm (0.031 - 0.035 in)
6
- 4
CoRRECT Repair or replace the spark plug.

.
L. Jr USNCDN
2.lgnition spark gap
Disconnect the spark plug cap from the
spark plug.
Connect the dynamic spark tester 0 as
shown.
@Spark plug cap
@Spark plug
0 Turn the main switch to “ON”.
Check the ignition spark gap.

.- e Crank the engine by pushing the starter MEETS SPECIFICATION
1
-
-
-
-
-
switch, and increase the spark gap until
a misfiring occurs.
Minimum spark gap:
6.0 rnm (0.24 in1
7The ignition
system is not faulty. . . ~~
~~
~~
-
for EUR/AUS
2.1gnition spark gap
Disconnect the spark plug cap from the
spark plug.
Connecttheignition
shown.
0 Spark plug cap
checker @ as
Turn the main switch to "ON".

IGNITION SYSTEM TELEC -
IIE
Check the ignition spark gap 8.

Crank the engine by pushing the starter
~
switch andincrease thespark gap untila
misfire occurs.
MEETS SPECIFICATION
Minimum spark gap:
c i
6.0 mm (0.24 in)
4
OUT OF
SPECIFICATION
OR NO SPARK
-7I
The ignition system is not faulty.
3.Spark plug cap resistance

Remove the spark plug cap.
Connect the pocket tester (SZ x I k ) to the
spark plug cap.
LJ
we36
I
OUT OF SPECIFICATION
Check that the spark plug cap has the
specified resistance.
17 Spark plug resistance:
cap - ,
- d 10 kR at 20 "C (68°F)
Replace the spark plug cap.
1
a *
MEETS
SPECIFICATION
1 EtEC 1 nI
i I
! IGNITION SYSTEM
I I I
*
a
I
4.lgnition coil resistance Tester I+)lead --f Orange lead terminal
Tester (-1 lead --f Ignition coil base
Disconnecttheignitioncoilconnector
from the wireharness.
Connect the pocket tester (Q x 1) to the
ignition coil.
I i l
I "1RI
"v * Check that the primary coilh a s the spec-
n
ified resistance.
I
11 Primary
coil resistance:
..
0.18 0.28 R at 20 'C (68'FF)
Connect the pocket tester LC2 x 1k) to the

~yignition coil.
I I
I
Tester (+) lead -+ Ignition coil base
Tester (-1 lead + Spark plug lead
& y I E
~~ ~
I (
T- 1 7 -
1
I
7
-
Check that the secondary coil has the
specified resistance.
a Secondary coil resistance:

-
6.32 9.48 kQ a t 20 "C (68°F)
OUT OF S P E C I F I C A T
Q
.-,
BOTH MEET
SPECIFICATION Replace ignition
the coil.
I
5.Engine stop switch
Refer to "SWITCH INSPECTION".
n. V
CORRECT
I
Replacehandlebar
the switch
(left).
1
I
INCORRECT
&Main switch
1
?J
* CoRRECT
Replace the main switch.
- -
sistance
coilI7.Pickup
'7'
I
'dl
I
-
.
I
n
Disconnectthe
--x
a
CDI magnetocoupler
Connect the pocket tester
the pickup coil terminal.
(Q x 100) to
Tester (+) lead -+Red terminal0

Tester (-1 lead -+ White terminal 0
Check the pickup coil for the specified

resistance.
Pickup coil resistance:

-
459 561 !2 at 20°C (68°F)
(Red -White)
a
8.Source coil resistance
.
I
MEETS
SPECIFICATION
Disconnect the source coil coupler from

the wireharness.
the source coil terminal.
(Q x 100) t o
Tester (+) lead -+ Brown terminal0

Tester (-1 lead -+ Green terminal@
Check the source coil for the specified

resistance.
I
I
IGNITION SYSTEM
OUT OF SPECIFICA;
1 Replace the pickup coil.

I
OUT OF SPECIFICA;
Mle
I
I
,
.
.
0
& -
Source coil resistance:
270 330 !2 a t 20°C (68°F)
(Brown - Green)
P
Replace the source coil.
I
I
4- MEETS
SPECIFICATION
connection
.. %Wiring POOR CONNECTIO;
0 Check the connections of the entire igni-
tion system.
. - .
~ .
:
.
Refer to "CIRCUIT DIAGRAM". Properly connect the ignition system.
I.
-
- .
. . &CORRECT
_ _ .
___ - -
--.
~
Replace the CDI unit.

1 --
-
m 7 1-
"J
'-,
- _- - ,. ..~
E
h i
ELECTRIC STARTING SYSTEM

~~~ ~~
I ELEC I [_
1 I
II] I
STARTING CIRCUIT OPERATION

0 The starting circuit on this model consists
of the starter motor, starter relay, starting
circuit cut-off relay, rear brake switch, CDI
unit and neutral switch.If the main switch is
on and the engine stop switch is in the RUN
position, the starter motor can be operated
only if:
The transmission is in neutral ( t h e neu-

tral switch is closed).
or
You pull in the rear brake lever (the rear
brake switch is ON).
1 1
Thestartingcircuitcut70ffrelayprevents
the starter from operating when the select
- - lever is in gear or in reverse and the rear
'V
brakeleverisfree. In this instance, the
startingcircuitcut-offrelayisoff so that
current cannot reach the starter motor.
I Y B r -
@ Fuse
Dl @ Battery
0Starter relay
@I Starter motor
@ Starting circuit cut-off relay
@ Start switch
@ CDI unit
@ Rear brake switch
@ Neutral switch
@ Neutral indicator light
a T O MAIN SWITCH
HFROM MAIN SWITCH
I TT b
@i"d" "1
-'
- - -
- __
€8803020
ELECTRIC STARTING SYSTEM I ELEC ID]
TROUBLESHOOTlNG
I
I
IF THE STARTER MOTOR FAILS TO OPERATE: I
I
Procedure
Check:
1.Fuse (main) 7.Engine stop switch
2.Battery 8.Neutral switch
3.Starter motor 9.Rear brake switch
4.Starting circuit cut-off relay 1O.Stat-t switch
-
5.Starter relay 11.Wiring connection
6.Main switch (the entire starting system)
NOTE:
0 Remove the following part(s) before trou- Pocket tester:
"rleshooting: P/N. YU-03112,90890-03112
A
.&eat
2)Front carrier
3)Front fender
Use the following special tool(s) for trou-
-
bleshooting.
EBB02011
1.Fuse (main)
- -
E0802012
-?J CoNTINU'N
Replace the fuse.
1
. *'
Battery
I INCORRECT
Check the battery condition.
Refer to "BAlTERY INSPECTION" in
CHAPTER 3.
Open-circuit voltage:
-+Clean the battery terminals.
12.8 V or more a t 20 "C (68 OF)
Recharge or replace the battery.
*
J.3
* CoRRECT
*
ELECTRIC STARTING SYSTEM mp
5
13.starter motor
a I
9
A wire thatis used as a jumper lead must
I
e
Connect the battery positive terminal (i J
have the equivalent capacity or more as
and starter
motor
cable @ using a
that of the battery lead, otherwise the
jumper lead @ 9.
jumper lead mayburn.
Check the operation ofthe starter motor.
This check is likely t o produce sparks, so
be sure that no flammable gas or fluid is
f
& FI
z j
l
@ in the vicinity.
L,
8 1
-
-
+-
~ ........
.LiW
v
-
- - - .0
TURNS
- .- . 0
-
I
DOES NOT TURN
Repair or replace the starter motor.

1
4.Starting circuit
cut-off
relay I I 1
Q B_ _ _ _ _ _ _ _
mi
~ ~~ ~~
le Remove the starting circuit cut-off relay~l _.___ _____

f r o m the wire harness.
e Connect the pocket tester(R x 1) and the
battery (12V) to the starting circuit cut-
off relay terminals. _ _ _ - _ _ _- --_ - - _---_I
Battery (+)terminal-+ Brown terminal@

Battery (-I terminal -+
Yellow/Black terminal@
I
I
d b I
I
Tester (+I lead -+ Brown terminal @

Tester (-) lead + Blue/White terminal@
L-'
NO CONTINUITY
for
Check the starting circuit cut-off relay
continuity.
7
G 3c.
CoNT'NUIP/
Replace the starting circuit cut-off relay.
- ~.
1 ELECTRIC STARTING SYSTEM IELEC I I
*
~ ~ ~~~ ~~
5.Starter relay
a -
Remove the starter relay from the wire
-
Q-9 R
harness.
Connect the pockettester (Q x 1) and the
battery (12 V) to the starter relay termi-
nals.
;1 $ LiW
-
. d
1
d‘ I
Battery (+) terminal -+
--
Blue/White terminal 0
Battery ( 4 terminal +
NO CONTINUITY
Red/White terminal@
L’ Tester (+) lead -+ Red terminal @
Tester (-1 lead 4Black terminal @ $7
Check the starter relay for continuity. Replace the starter relay.
I
-
Q CoNT‘NUIP/
I INCORRECT
6.Main switch
Refer to ”SWITCH INSPECTION“. 7
a CoRRECT
I
7.Engine stop switch
%i_ 3efer
to “SWITCH INSPECTION”.
Q CORRECT
Replace the handlebar switch (right).
I
8.Neutral switch
Refer to “SWITCH INSPECTION”.
Q +$
CoRRECT
Replace the neutral switch.
I
ELECTRIC STARTING SYSTEM Mle-
a
Jc
9.Rear brake switch INCORRECT

7
a CoRRECT
I
Replace the brake
rear
switch. I
I
10.Start switch INCORRECT

.
-
7
. EBB03028
v CoRRECT
Replace the handlebar switch (left).
. I .Wiring connection POOR CONNECTION
7
v
Check theconnections of theentire
starting system.
Refer to "CIRCUIT DIAGRAM".
I
Properly connect the starting system.
~ ~~~
I
I
n *I2
4 ELECTRIC
SYSTEM
STARTING -1
STARTER MOTOR
I I
- -
F Order
1
Job name/Part name
Starter motor removal
Starter motor lead
Q'ty
1
Remarks
-
Starter motor/ O-ring If1 -

Starter motor disassembly Disassemble the parts in the order
below.
Bracket 1 1
Washer kit
Bracket 2
Refer to "STARTER MOTOR ASSEM-
Shims
BLY .
~'~
'I
Brush seat Vbrush seat 2 If2
I 1
Armature coil 1
0 Yoke 1
- procedure. -
~.
ELECTRIC STARTING SYSTEM ELEC
STARTER MOTOR INSPECTION
r j q IB-
~
1.Inspect:
Commutator
~
Dirty t Clean it with #600 grit sandpaper.

2.Measure:
Commutator diameter @
Out of specification 4 Replace the starter
motor.
1
3.Measure:
Outside diameter:
28 rnrn (1.10 in)
<Wear limit:>
27 mrn (1.06 in)
Mica undercut 0
Out o f specification + Scrape the mica
using a hacksaw blade.
Mica undercut:
*-/ I
0.7 mm (0.028 in)
i
NOTE:
Scrapethemica to thepropermeasure-
ment using a hacksaw bladewhichhas
been grounded to fit the commutator.
I 4.lnspect:
I
~
Armature coil (insulation/continuity)
Defects + Replace the starter motor.
r
..................................
Armature coil inspection steps:
@Connect thepocket tester for the continu-
ity check @ and insulation check0.
0 Measure the armatureresistances.
w Armature coil resistance:

Continuity check 0:
0 R at 20 'C (68 'F)
Insulation check 0:
More than1 MR at 20 "C (68 OF)
.If the resistance is incorrect, replace the

starter motor.
..................................
1
1
ELECTRIC STARTING SYSTEM IELEC 1 - 7 1 ~~
5.Measure:
Brush length @ (each)
Out o f specification -+ Replace t h e brush.
I
Brush length:
12.5 mrn (0.49 in)
<Wear limit:>
5 mm (0.20 in)
6.Measure:
Brush spring force
Fatigue/out of specification -+ Replace as
a set.
Brush spring force:

,.
780 1,021 g (27.5,. 36.0 O Z )
7.lnspect:
Oil seal
Bushing
O-rings
r I STARTER MOTOR ASSEMBLY

1.lnstall:
~
Yoke
Brackets
*
1
NOTE:
Align the match marks8 on the yoke with
the match marks@ on the brackets.
I I
IB
.~ ~ ~
.. . ~
. .
- -.
... - .
-.
- - ..
.. .
~ ~~
.~
~~
. -
. . ..
. .
. .
...~
.~. ~~
~.... ... .~
~.
.. ..~
..-.
- -,v ...
_ _ * -
. -.-- -
-
- _ A
..- -.
___-
--J
~-~ - -
-
___- --
--I_ _
~
.-
--r i
-. -
-
___ - -
- -
-.
--$I -
-.
17-1~ -
___
+
_ , ~
__ 1 : -
--I 1 --
__ - --
-
-- -
-
q i,
I
___- -
-
-
_
-
_- - -
--
- 4 -I
---f- _
_
E0804010
CHARGING SYSTEM 1 I- I D 1
ELEC
TROUBLESHOOTING
I IF THE BATTERY IS NOT CHARGED:

I
Procedure
Check:
1.Fuse (main) $.Stator coil resistance
2.Battery 5.Wiring connections
3.Charging voltage ( t h e entire charging system)
NOTE:
Removethe
following
part(s)
before
trou-
Inductive
tachometer:
bleshooting: P/N. YU-8036-A
Engine tachometer:
1 )Seat P/N. 90890-03113
Use t h e following special tool(s) for trou- Pocket tester:
bleshooting. P/N. YU-03112,90890-03112
c A
‘4
---=v
EBB02011
1.Fuse (main) NO CONTlNUlTY
Refer to “SWITCH INSPECTION”.
€8802012
a CoNTINUIN
Replace the fuse.
I
2.Battery I
I
I I INCORRECT
I 7
Refer to “BATTERY INSPECTION” in
CHAPTER 3.
Open-circuit voltage: Clean the battery terminals.
12.8 V or moreat 20 “C (68 ‘F) Recharge or rep!ace the battery.
a
I I
CoRRECT
w
EBffl4011
13.Charging voltage
I
I
I
I I
Connect the engine tachometer to the
spark plug lead #I.
Connect the pocket tester (DC 20V) to
the battery.
..
Tester (+I lead + Battery (+) terminal

Tester (-1 lead + Battery (-) terminal
.
. i
-
- ....
- .
. ....
-
-
-
CHARGING SYSTEM m
I I I
p
I
Start the engine and accelerate to about
3,000 r/min.
M Charging voltage:
14 V at 3,000 rlmin
7
MEETS SPECIFICATION
V
NOTE:
+
Use a fully charged battery. The charging circuitis not faulty.
OUT OF
SPECIFICATION
E8804012
: 4.Stator coil resistance

Disconnectthe AC magnetocoupler
.
stator coils.
i
Tester (+) lead 4 White terminal @

Tester (-1 lead -+White terminal 0
Tester (+) lead -+ White terminal 0
+
: Tester (-1 lead t White terminal 0
: Measure the stator coilresistance.
: M Stator coil resistance:

0.70 .. 0.86 Q at 20 "C(68 O F )
a MEETS
SPECIFICATION
Replace the stator coil assembly.
I
connections
t
-
- *
r
E8804015
5.Wiring
Check theconnections
charging system.
r of theentire

l POOR CONNECTIO;
Properly connect the charging system.

I
a
IReplace the rectifier/regulator.
CoRRECT
E ~~ ~~~~~ ~~~ ~ ~ ~
I
I
. .
. .
-
-
.-
.-
~--~.-
13
L
~1
e
-
'
-
-
-
-
-
-
-
-
-
..
-
--
i
1
EEBOMIO
LIGHTING SYSTEM liqj=q le-.
I I
TROUBLESHOOTING
IF THE HEADLIGHT, TAILLIGHT AND/OR METER LGHT FAIL TO COME ON:

I
Procedure
Check:
1.Fuse (main) 4.Lights switch
3.Main switch (the entire lighting system)
NOTE:
Remove the following part(s) before trou- Pocket tester:
. bleshooting: P/N. YU-03112,90890-03112
*'Ceat
+,rant carrier
3)Front fender
bleshooting.
EEBOZOll
1.Fuse (main)
Refer to "SWITCH INSPECTION". . l
-I I -
9
CONTINUITY
L
Replace the fuse.
I
1
F"TO12
J
k,,--.Aattery
INCORRECT
Refer to "BATTERY INSPECTION" in
CHAPTER 3. 4- Clean the battery terminals.
12.8 V or more at 20 "C (68 OF) Recharge or replace the battery.
a-?4
CoRRECT
1 -E
LIGHTING SYSTEM 1-
3.Main switch
a INCORRECT

1 1
a
i
CoRRECT
J
4.Lights switch
'
7
a- CoRRECT
I
Lights switch is faulty, replace the handle-
bar switch (left).
I
'IZJWiring connection I
POOR CONNECTION
*
Check theconnections of theentire
lighting system. I
1
I
Refer tb "-WIRING DIAGRAM". I
I
Q CoRRECT
Properly connect the lighting system.
1
i Check the condition of each of t h e lighting
system's circuits.
Refer to "LIGHTING SYSTEM CHECK".
-.-*I
EBB05020
LIGHTING SYSTEM ppjpi
LIGHTING SYSTEM CHECK
l.lf the headlights fail to come
on:
i
1.Bulb and bulb socket NO CONTINUITY
7
1
Check the bulb and bulb socket for conti-
nuity.
1
~~
Replace the bulb and/or bulbsocket.

~
12.~01tage
Q CoNTINU'TY
I
I I
I
ouplers.
headlight
the
Bj
(DC 20 V) to
I
1 I
Tester {+I lead -+

Green terminal@ or Yellow terminal @
Tester ( 4 lead 4 Black terminal @
H W h e n the lights switchis on "LO".
When the lights switchis on "HI".
4
Turn the lights switch to"LO" or "HI".
Check the voltage (12V)of the "Green" 7
W
,d "Yellow" leads on the bulb socket
connector.
a MEETS
SPECIFICATION
- /III
The wiring circuit from the main switch to
the bulb socket connector is faulty, repair
This circuit is not faulty.

1
I i
LIGHTING SYSTEM I ELEC I [-I

I I
1
I
EB6UM21
2.lf the meter light failsto come on:
1.Bulb and bulb socket NO CONTINUITY
s Check the bulb and bulb socket for conti-

nuity. 1
Q CoNTINUITY
Replace the bulb and/or bulb socket.
1
2.Voltage
Connect the pocket tester (20 V) to the
bulb socket coupler.
Tester (+I lead + Blue terminal 0
Tester (-1 lead + Black terminal @
'
i '
1
a I)
Turn
the main switch
to "ON".
Turn the lights switch to"LO"or "HI".
Check the voltage ( I N ) of the"Blue"
lead on thebulb socket connector.
MEETS
SPECIFICATION
The wiring circuitfrom the main switch to

the bulb socket connector is faulty,
repair
I
This circuit is not faulty.
I
1
L,
EBB06000
SIGNAL SYSTEM
SIGNAL SYSTEM m@
. ' CIRCUIT DIAGRAM
~~
~ ..,
. .
-0.
.~
.. . ~
~~~
~. . -
. .. ~~
- ~.
. . ' b d
.~ -
.~ - -
..
..- - -
.
--~-.
-_ - ~ ~
.- - _-
--_-
.. - -
-.-*
-- -
. .~
---+
~- T
-.
- ._
-
~. t -
-
- ~- _ -~
--_ -_ --~
-_ _ -
- - _-
----
--* -
~ -I
.-
-
-
' .-
--
--I_
--* .-
--* I .~
- - _- .-
-_ _ - -~
-_ -
~
.-
31
-_ -
--I -
--J -
_-
__ __
-_--_
r -
__ t-
il EB8OM)lO
TROUBLESHOOTING
SIGNAL SYSTEM r-Tiq
ELEC ~~
~ _ _
IIF THE INDICATOR LIGHT FAILS TO COME ON: I
~~
I ~ ~~
I
Procedure
Check:
1.Fuse (main)
2.Battery
3.Main switch
4.Wiring connections
(the entire signal system)
NOTE:
Remove the following partb) before trou- Pocket tester:
P/N. YU-03112,90890-03112
bleshooting:
')Seat
-
b-dFront carrier
3)Front fender
Use the following special tool[s) for trou-
bleshooting.
-
EBB02011
1.Fuse (main)
-I I -=-l
CONTINUITY
EBmza~z
v Replace the fuse.
L-
..Battery
CHAPTER 3.
Clean the battery terminals.
12.8 V or more a t 20 "C (68 O F )
Recharge or replace the battery.
I I
a* CQRRECT
~
3.Main switch
a
*
E E I ~ O t~ O ~
4.Wiring connections
a CoRRECT
1
I1c
Check the connections of the entire sig-

nal system.
a CoRRECT
-
~~
SIGNAL SYSTEM
~
ELEC
POOR C O N N E C T I O ~
Properly connect the signal system.
I
3 Check the condition of each of the signal

system's circuits.
Refer to "SIGNAL SYSTEM CHECK".
-4
1 SIGNAL SYSTEM CHECK
SIGNAL SYSTEM M
EBB06024
l.lf the neutral indicator light fails to come
on:
NO CONTINUITY
1.Bulb and bulbsocket
Check the bulband bulb socket for conti-
nuity.
7
Q CoNTINU'TY
1
2.NeutraI switch NO CONTINUITY

3
a CoNTINU1-rf
I
I
Replace the neutral switch.
-
I
I
I1 -
~~ ~~
,Y ,.Voltage
I Connect the pocket tester (DC 20 V) to

bulbthe socket coupler.
I Tester (+) lead 4 Brown terminal @

Tester (-1 lead 3 Sky blue terminal @
0
I 1
r OUT OF SPECIFICATION
Turn the main switchto "ON".
Check the voltage (12 V).
7
i
i
h
a
-his circuit is not faulty.
MEETS
SPECIFICATION
1I I
The wiring circuit fromthe main switch to
it.
I
-1
2.lf the reverse indicator light fails to come
SIGNAL SYSTEM m i
I
m
on:
1.Bulb and bulb socket

Check the bulb and bulb
socket for conti-
- .
n u ity.
a CoNTINUI'IY
1
2.Reverse switch
Q CoNTINU1TY
Replace the reverse switch.
1
13.Reverse relay I
c I @ @
r
I
3emove the reverse relay from the wire ---_--
_ _ - ~ _ _ _ . - _
harness.
I
0 Connect the pocket tester (Q x 1) and
battery t12 VI to the reverse relay termi-
nals.
I
1
d b
@I
_____ -- _ _ _ _ _ - I
Battery (+) terminal + Brown terminal@

Battery (-1 terminal +
Green/White terminal@ CONTINUITY
I I
I
Tester (+I lead -+Green/Blue terminal @
* Tester (-1 lead --f Black terminal @ - 1
I
i Check the reverse relayfor continuity.
I I
Replace the reverse relay.
I
NO CONTINUITY
u
c 4.Voltage c -
___iConnect the pocket tester (DC 20 V) to

the bulb socket coupler.
Tester (+) lead + Brown terminal0
I
Q
Tester (-1 lead + Green/Blue terminal@
I I
,. I
.
.
.
I SIGNAL SYSTEM 1-
Turn
the
main
switch to "ON". OUT OF S P E C I F I C A T
Check the voltage (12 V).
Q MEETS
I This circuit i s not faulty.

SPECIFICATION
1 ,
I
The wiring circuit from the main switch to
the bulb socket connector i s faulty, repair
~~
I
3.lf the oil temperature warning light doesnot come on when the startswitch is pushed on,
or if the oil temperature warning light does not come on when the temperature is high
-
(more than 147.5 162.5"C (297.5 324.5"F)):-

NO CONTINUITY
-. Check the bulb and bulb socket for conti-

,nuity. 7
2.Thermo unit
a CQNT'NUlrf
-
- II I
I
-
Remove the thermounit from the !
crankcase.
Connect the pocket tester (Q x IO) to
the thermo unit 0.
Immerse the therrno unit in engine oil
0.
Measure the resistance.
1
I I
M Thermo unit resistance:

150 'C (302OF): 307 339 Q
-..
220 'C (428OFF): 209 231 !2 ~
r- I 1 -
Handlethetherrno
care.
unit with special
Neversubject it t o a strong shock or

II b b b d b d
I
I
allow it t o be dropped.Should it be
dropped, i t m u s t b ereplaced.
I-----r
BAD CONDITION
Thermo unit:
20 Nm (2.0 m kg, 14 ft Ib)
Three bond sealock@#IO
I I
JJ E L O N
Replace the thermo unit.
I
+?
SIGNALSYSTEM -.)I IC
-*
I voltage
a I
I Connect the pocket testerTDC
the bulb socket
connector.
20 V) to
I
. Tester (+I lead + Brown lead 0
Tester (-1 lead -+ Frame ground
Check the voltage (12 VI.
I ~-.-.-
-
4.Diode
0- MEETS
SPECIFICATION
+ &
-
-
,
The wiring circuit from themain switch to
Removethe diode fromthewirehar

ness.
Check for continuity as follows:
RedWhite 0- White/Blue @
-
qi
I --.----_-_-_
I----:
I $1
:r @ :..-.--...-..1-.--;
. -+ WhiteBlue @ Continuity
R e W h i t e (iJ - '
: White/Blue@+RedWhite@ continuity
-
Replace the diode.
I
.-
..
a -
e
l
CoRRECT
-
-
. - -
_.. -_
~
- --
~
I SIGNAL SYSTEM 1-
a
3c
INCORRECT
5.Sta1-t switch
Refer to "SWITCH INSPECTION". 7
a CoRRECT
Replace the handlebar switch (left).
1
Replace the fan motor control unit.
I
E0806024
4.lf the 4WD indicator light failsto come on:

P Check the bulband bulb socket for conti-
% nuity. - -
a CoNT'NUIP/
I
2.4WD switch
Q CoNT'NUITY
-7I Replace the 4WD switch.
-
13.~01tage I
I
Connect the pocket tester (DC 20 V) to
I c
I
_ _ _ - _ - _ _ _ _ _ _ _ _ _
1
bulb the lead.
socket -lDJ Br-
I Tester (+) lead 3 Brown terminal@
I Tester (-1 lead + Sky blue terminal @
( E B r
*'
,
T
L - - - - - - - -s -b-- .
- -k-S-b - -!
1 I
Turn
the
main
switch
to "ON". OUT OF S P E C I F I C A T
Check the voltage (12 VI.
a
L
MEETS
SPECIFICATION The wiring circuit from the main switch to
This circuitis not faulty.
I / 1 1 1
-
.. . .-
-- .. ..
-
COOLING SYSTEM W’I
B]
-. . .
. .
. .
. .
. .
b-
~. .
. .
. ..-
.. . -
. -
~- ”,
~ ~~
~~
--_
- +
-
~
-i 1
-~ ~
-i-
-+ -
-t
- L
-
-
I
-t -
3:
1/;1
- .-
-
-
-
_-
-
-
-
:
-
z1.z:
-J.-.
-t-
I TROUBLESHOOTING
COOLING SYSTEM 1- 1
I IF THE FAN MOTOR DOES NOT MOVE: I

Procedure
Check:
1.Fuse (main) 6.Fan motor relay
-
2.Battery 7.Thermo unit
3.Main switch 8.Wiring
connection .
4.Fan motor (the entire cooling system)
5.Circuit breaker (fan motor)
NOTE:
P/N. YU-03112,90890-03112
bleshooting.
1 )Seat
"-2)Front carrier
3)Front fender
bleshooting.
EB802011
1.Fuse (main)
E8902012
a CoNTINUITY
Replace the fuse.
I:
2.Battery
INCORRECT
'-
CHAPTER 3. 7 Clean the battery terminals.
12.8 V or more a t 20 'C (68 'F) Recharge or replace the battery.
.
a CoRRECT
INCORRECT
3.Main switch
Refer to "SWITCH
a
INSPECTION".
7
V
CORRECT
I
Replace
main
switch.
the
I
I
.. 3c.
~- ..
- -.
-
~~ ~~~
COOLING SYSTEM r ELEcn l IC
I
I4.Fan motor
I
6 II
I
I
Disconnect the fan motor coupler.
Connect the battery (12 VI as shown. I
I
Battery (+I lead -+ Blue terminal 0

Battery (-1 lead 3 Black terminal @
DOES NOT TURN
7
Check the operation of the fan motor. Replace the fan motor.
l
a TURNS
wire harness.
Replace the circuit breaker.

l
0-* MEETS
SPECIFICATION
R - 37
,-, ,#,,I-,,"# - - - -
1 +e
COOLING SYSTEM m l
6.Fan motor relay
a
Remove the fan motor relay from the __ -____
------.
-@I I
wire harness.
Connect the pocket tester (0x 1) and the
battery ('72 VI to thefan motor relay ter-
minals. ---_-___-__ _ _ _ I
Battery (+) terminal 4 Brown terminal 0

Battery ( 4terminal 9 White terminal@
Tester (+) lead --f Red/White terminal@
Tester (-1 lead 3 Blue terminal @
I I
,
1 Check the fan motor relay for continuity. I NO CONTINUITY
\ -*
a
I
1
CoNT'NU'TY
Replace the fan motor relay.
I
7.Thermo unit
-
Remove the thermo unit fromthe
crankcase.
4 Connect the pocket tester (R x IO) to
the thermo unit 0.
Immerse the thermo unit in engine oil
0.
Measure the resistance.
1
9
I
..-.~
ermo unit resistance:
Th150 "C(302
220 "C (428
307 339 Q
OF):
209 231 !2
OF):
--
1
4 b b b b b
Handle thethermounitwith special
care.
Never subject it to strong shock or
allow it t o be dropped.Should it be
dropped, it must bereplaced. BAD CONDITION
Thermo unit:
20 Nm (2.0 m kg, 14 ft Ib)
1
Three bondsealock" #IO Replace the thermo unit.
I
Q* O
TIN
::::
COOLING SYSTEM p$=q E
EB~CI~OZ~
8.Wiring connection
6 POOR CONNECTION
Check theconnections
starting system.
of theentire
1
Refer to "CIRCUIT DIAGRAM". Properly connect the cooling system.
1
a CoRRECT
Replace the fan motor control unit.
k d
n nm
- .... ..
4: 2WD/4WD SELECTING
: 2WD/4WD SELECTING SYSTEM
SYSTEM m l
. CIRCUIT DIAGRAM
~~
.. .
.~
- -.
. .
.~
~. .
. ..
~..
.. -
..
~.. .
,~ ~
. . .~~ -
.
. . -
. _.._
I~.- .
~~
.~
I~~~
~
~ *
~ L-
~-~
--__
.-
- --
. - .~.
E8803020
2WD/4WD SELECTING SYSTEM 1- (c
TROUBLESHOOTING-
II IF THE 4WD INDlCATOR LIGHT FAILS TO COME ON: I

I
~
Procedure
Check:
1.Fuse (main) 5.Gear motor
3.Main switch (the entire2WD/4WD selecting system)
4.2WD/4WD selecting switch
NOTE:
bleshooting: P/N. YU-03112,90890-03112
I -
~~
I I
1)Seat
. 2)Front carrier
"3ont fender
+Use the following special tool(s) for trou-
bleshooting.
IEBB02011
-
1.Fuse (main)
Refer to "SWITCH
INSPECTION".
E8802012
a CoNTINUITY
Replace the fuse.
I
2.Battery
INCORRECT
+-
CHAPTER 3.
Open-circuit voltage: Clean the battery terminals:
12.8 V or more at 20 'C (68 O F 1
J' Recharge or replace the battery.
3.Main switch
a CoRRECT
INCORRECT
Q 3-
CoRRECT
I
0 .I
1
5.Gear motor
a
*
4.2WD/4WD select switch

a CoRRECT
is in
Check that the shift fork sliding gear
the 2WD position.
Disconnect the gear motor coupler.
7
-6
2WD/4WD SELECTING SYSTEM
I
lELEC Ifl I
Replace the 2WD/4WD select switch.
E
I
i
-
Remove the gear motor from the differ-
2WD @
ential gear case.
Connect the battery (12 V) to the gear
,-, motor terminals.
I_ _
r 1 I I
2WD -+ 4WD:
Battery (+I terminal -+
Brown terminal I a
Battery (-1 terminal -+
Sky blue terminal0I
-
4WD -+ 2WD:
Battery (+) terminal 4
Sky blue terminal($I
Battery (-1 terminal 4
Blue/Black terminal @I
-
Make sure that the drive gear (shift fork
sliding gear) operates correctly.
I:::E: installingthedifferentialgear
case in the gear motor, refer t o CHAP-
T TER 1 "FEATURES". I
R
Replace the gear motor.

1
I
I -
II CORRECT
I I 1
v
nnection I6.Wiring I
POOR CONNECTION
Check the connections of theentire
II
2WD/4WD selecting system.
Refer t o "CIRCUIT DIAGRAM". II
-I
L
Properly connect the 2WD/4WD selecting

system.
... .... -
CHAPTER 9.
1- ID
TROUBLESHOOTING
STARTING FAILURE/HARD STARTING ...................................................... D-3

FUEL SYSTEM ...................................................................................... D-3
ELECTRICAL SYSTEM .......................................................................... D-3
COMPRESSION SYSTEM ..................................................................... 0-3
POOR IDLE SPEED PERFORMANCE ........................................................... D-3

POOR IDLE SPEED PERFORMANCE ................................................... D-3
POOR MEDIUM ANDHIGH-SPEED PERFORMANCE................................. D-3

POOR MEDIUM AND HIGH-SPEED PERFORMANCE......................... D-3
FAULTY DRIVE TRAIN ................................................................................. D-4
\v
FAULTY GEAR SHIFTING ............................................................................ D-4
HARD SHIFTING ................................................................................... D-4
SHIFT LEVER DOES NOT MOVE ......................................................... D-4
JUMPS OUT OF GEAR ......................................................................... D-4
FAULTY CLUTCH PERFORMANCE.............................................................. D-4

ENGINE OPERATES BUT MACHINE WILL NOT MOVE ..................... D-4
CLUTCH SLIPPING................................................................................ D-4
POOR STARTING PERFORMANCE ..................................................... 0-4
POOR SPEED PERFORMANCE ............................................................ D-5
OVERHEATING ............................................................................................. D-5

OVERHEATING ..................................................................................... D-5
FAULTY BRAKE ............................................................................................ D-5

POOR BRAKING EFFECT ......................................................................D-5
L-.,
SHOCK ABSORBERMALFUNCTION ..........................................................D-5

MALFUNCTION..................................................................................... D-5
UNSTABLE HANDLING................................................................................ 0-5

UNSTABLE HANDLING........................................................................ D-5
LIGHTING SYSTEM...................................................................................... D-5

HEADLIGHT DARK ................................................................................ D-5
BULB BURNTOUT ............................................................................... D-5
.
STARTING FAILURE/HARDSTARTING WSHT I p5

- TROUBLESHOOTING
NOTE:
The following troubleshooting doesnot cover all the possible causesof trouble. It should be
helpful, however, as a guide to troubleshooting. Refer to the relative procedure in this man-
ual for inwection, adiustment and replacement of parts.
STARTING FAfLURE/HARD STARTING

FUEL SYSTEM
Fuel tank
Empty Deteriorated or contaminated
fuel
filter
Clogged
fuel jetClogged
pilot
Clogged
strainer
fuel Clogged
pilot air passage
. Cloggedbreather
fuel hose Sucked-in air
' qeteriorated or contaminated fuel Deformed float
-el cock Worn needle valve
Clogged fuel hose Improperly sealed valveseat
Improperly adjusted fuel level
Improperly set pilot jet
Clogged starter jet
Starter plunger malfunction
Air filter
Clogged air filter element
ELECTRICAL SYSTEM
Spark plug Switches and wiring
Improper plug gap Faulty main switch
Worn electrodes Faulty engine stop switch
' .''ire between terminals broken Broken orshortedwiring .
w n p r o p e r h e a trange Faulty neutral switch
.* Faulty spark plug cap Faulty start switch
Ignition coil Faulty rear brake switch
Broken or shorted primary/secondary Starter motor
Faulty spark plug lead Faulty starter motor
Broken body Faulty starter relay
CDI system o Faulty starter circuit cut-off relay
0 Faulty CDI unit Faulty starter clutch
e Faulty pickup coil
0 Faulty source coil
Broken woodruff key
a- I
1 STARTING FAILURE/HARD STARTING/POORIDLE SPEED
PERFORMANCE/POOR MEDIUM AND HIGH-SPEED PERFORMANCE
COMPRESSION SYSTEM
Cylinder
cylinder
and
head Valve, camshaft
crankshaft
and
m
TRBL
SHT
9
spark
Loose plug Improperly
valve
sealed
Loose cylinder
heador
cylinder Improperly contactedvalve
and
valve seat
Broken
cylinder
head
gasket Improper
valve timing
Worn, damaged or seized cylinder Brokenvalve
spring
rings
piston
and
Piston Seized camshaft
Improperly
installed piston ring Seized
crankshaft
Worn, fatigued or broken piston ring
Seized piston ring
Seized or damaged piston
POOR IDLE SPEED PERFORMANCE

POOR IDLE SPEED PERFORMANCE
Carburetor Electrical system
Improperly returned starter plunger I Faulty spark plug
- Loose pilot jet Faulty CDI unit
-' Clogged pilot jet
, Faulty pickup coil
Clogged pilot air jet Faulty source coil
Improperly adjusted idlespeed Faulty ignition coil
(Throttle stop screw) Valve train
Improper throttle cable play Improperly adjusted valve clearance
Flooded carburetor Air filter
POOR MEDIUM AND HIGH-SPEED PERFORMANCE

POOR MEDIUM AND HIGH-SPEED PERFORMANCE
Refer to "STARTING FAILURE/HARD STARTING" and "POOR IDLE SPEED PERFORMANCE-
VALVE TRAIN".
Carburetor Air filter
Improper jet needle clip position Clogged air filter
element
Improperly adjusted fuel level
'- i
l o g g e d or loose main jet
Deteriorated or contaminated fuel
FAULTY DRIVE TRAIN m
SHT p
FAULTY DRIVE TRAIN
The following conditions may
indicate damaged shaft drive components:
Symptoms
- Possible Causes
-
-. -
l . A pronounced hesitation or "jerky" move- A.Bearing damage.
ment during acceleration, deceleration, or
sustained speed. (Thismustnot be con- BJmproper gear lash.
fused with engine surging or transmission
characteristics.) C.Gear tooth damage.
2.A "rolling rumble"
noticeable at low
speed; a high-pitchedwhine; a "clunk" D.Broken drive shaft.
f r o m a shaft drive component orarea.
3.A locked-upcondition of theshaftdrive ! E.Broken gear teeth.
mechanism,nopowertransmitted fromI
the engine to the front and/or rear wheels. F.Seizure due to lack of lubrication.
G.Smalt foreign objects lodged between the

-1 - moving parts.
4
' j r
NOTE:
Areas A, 6,and C above may be extremely difficult to diagnose. The symptoms are quite sub-
tle and difficult to distinguish from normal machine operating noise. If there is reason to
believe these components are damaged, remove the components and inspect them.
i d -
n.5
-
1 FAULTY GEAR SHlFTlNG

FAULTY
FAULTY GEAR SHIFTING/ TRBL
CLUTCH SHT
PERFORMANCE m 9
HARD SHIFTING
Refer to "CLUTCH SLlPPlNG/DRAGGING-CLUTCH DRAGGING".
SHIFT LEVER DOES NOT MOVE

Shift cam, shift fork Transmission
Groove jammed with impurities Seized transmission gear
Seized shift fork Jammed impurities
Bent shift fork guide bar Incorrectly assembled transmission
Shift guide
Broken shift guide
JUMPS OUT OF GEAR

Shift fork Shift cam
Worn shift fork improper thrust play
Worn shift cam groove
Transmission
L, Worn gear dog
FAULTY CLUTCH PERFORMANCE

ENGINE OPERATES BUT MACHINE WILL NOT MOVE
V-belt Transmission
Bent, damaged or worn V-belt Damaged
transmission
gears
V-belt slips
Primary pulley carn and primary pulley slider
Damaged or worn primary pulleycarn
Damaged or worn primary pulley slider
CLUTCH SLIPPING
Clutch spring Primary sliding sheave
Damaged, loose orwornclutch shoe Seizedprimaryslidingsheave
'-spring
Clutch shoe
Damaged or worn clutch shoe
POOR STARTING PERFORMANCE

V-belt Clutch shoe
V-belt slips Bent, damaged or worn clutch shoe
Oil or grease on the V-belt .
Primary slidingsheave
Faulty operation
Worn pin groove
Worn pin
POOR SPEED PERFORMANCE
FAULTY CLUTCH PERFORMANCE/
OVERHEATlNG/FAULTY BRAKE 1- TRBL
SHT
9
ID
V-belt Primary sliding sheave
Oil or greaseon the V-belt Worn primary sliding sheave
Primary pulley weight Secondary fixed sheave
Faulty operation Worn secondary fixedsheave
Worn primary pulley weight Secondary sliding sheave
.
Primary fixed sheave
Worn primary fixedsheave
Worn secondary sliding sheave
OVERHEATING
OVERHEATING
Ignition system Engine oil
- lmproper spark plug gap Improper oil level
nproper spark plug heat range lmproper oil viscosity
;*aulty CDI unit Inferior oil quality
Fuel system Brake
improper carburetor mainjet Brake drag
(improper setting) Oil cooling system
Improper fuel level Clogged or damaged oil cooler
Compression system
Heavy carbon build-up
FAULTY BRAKE
POOR BRAKING EFFECT
Front disc brake Rear drum brake
Vorn brake pads Worn brake shoe lining
b-tVorn disc Worn brake drum
a Air in brake fluid Oily or greasy brakeshoe lining
Leaking brake fluid Oily or greasy brake drum
Faulty master cylinderkit cup Improperly adjusted brake free play
Faulty caliper kit seal Improper brake cam lever position
0 Loose union bolt Fatiguedtdamaged return spring
0 Broken brake hose and pipe
0 Oily or greasy disc/brake pads
0 Improper brake fluid level
0.6
-, -
3
1 SHOCK ABSORBER MALFUNCTION/
UNSTABLEHANDLING/LIGHTlNG SYSTEM
SHOCK ABSORBER MALFUNCTION
ELI
TRBL
SHT
MALFUNCTION
Bent or damaged damper rod
Damaged oil seal lip
Fatigued shock absorber spring
UNSTABLE HANDLING
UNSTABLE HANDLING
Handlebar Wheels
Improperly installed or bent Deformed wheel
Steering Loose bearing
Incorrect toe-in Bent or loose wheel axle
Bent steering stem Excessive wheel runout
Improperly installed steering stem Frame
k.d Jamaged bearing or bearingrace Bent
Bent tie rods Damaged frame
Deformed steering knuckles Swingarm
Tires Worn bearing or bushing
Uneven tire pressures on both sides Bent or damaged
Incorrect tire pressure
Uneven tire wear
LIGHTING SYSTEM
ULB DARK
HEADLIGHT OUT BURNT
bulb
Improper Improper bulb
- Too many
electric
accessories
Hardcharging(brokenstatorcoiland/or
._-+:aulty rectifierhegulator)
Faulty
battery
Faultyrectifierhegulator
Improperly
grounded
Incorrect
connection Faulty and/or
main
lights
switch
Improperly
grounded Bulb life expired
Poor contacts (main or lights switch)
Bulb life expired
- -
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YAMAHA
YFM6OOFWA '18lKl
4WV4-AE1
~.-'
"J SUPPlEMENTARY
SERVC
IE MANUAl
E
FOREWORD
This Supplementary Service Manual has been prepared to introduce new service and new
data for the YFMGOOFWA '97(K). For complete information on service procedures, it is neces-
sary to use this Supplementary Service Manual together with the
following manual.
-
r
~ ~~
YFMGOOFWA '97(K) SERVICE MANUAL: 4WVZ-MEI

YFMGOOFWA '97(K)SUPPLEMENTARY SERVICE MANUAL: 4WV4-AE1
I A
---,
i/
YFMGOOFWA '97(K1
SUPPLEMENTARY
I
SERVICE MANUAL
01997 byYamaha Motor Co., Ltd.
First Edition, June 1997
All rights reserved. Any reproduction or
unauthorized use without the written
permission of Yamaha Motor Co., Ltd.
is expressly prohibited.
I
_ _ ~~~
~
E
l EBCQ1000
NOTICE
This manual was produced by the Yamaha Motor Company primarily for use by Yamaha
dealers and their qualified mechanics. It is not possible to include all the knowledge of a
mechanic in one manual, so it is assumed that anyone whouses this book to perform main-
tenance and repairs on Yamaha machine has a basic understanding of the mechanical ideas
and the procedures of machine repair. Repairs attempted by anyone without this knowledge
are likely to render the machine unsafe and unfit foruse.
Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications
and significant changes in specifications or procedures will be forwarded to a l l authorized
Yamaha dealers andwill appear in future editionsof this manual where applicable.
NOTE:
Designs and specifications are subject to change without notice.
"-/
Particularly important informationis distinguished inthis manual by the following notations.
A The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR

SAFETY IS INVOLVED!
Failure to followWARNING instructions could result insevere injury or
death to the machine operator, a bystander or a person inspecting or
repairing the machine.
~;y&@$g@jg@$ A CAUTION indicates special precautions that must be taken to avoid
L,r,,wa,,,,,,,,L.j< ,,,. +,4
.-- damage t o the machine.

NOTE: A NOTE provides key information
to make procedures easier o r clearer.
E
L -
E B O O ~ ~
HOW TO USE THIS MANUAL

MANUAL ORGANIZATION
This manual consists of chapters for the main categories of subjects. (See "Illustrated sym-
bols")
1st title 0:
This is the title of the chapter with its symbol in the upper right corner of each
page.
2nd title0:This title indicates the section of the chapter and only appears on the first pageo f
each section. It is located in the upper left corner of the page.
3rd title 0:
This title indicates a sub-section that is followed by step-by-step procedures
accompanied by corresponding illustrations.
EXPLODED DIAGRAMS
To help identify parts and clarify procedure steps, there are exploded diagramsa t the start of
each removal and disassembly section.
1. An easy-to-see exploded diagram @ is provided for removal and disassemblyjobs.
2. Numbers @ are given in the order of the jobs in the exploded diagram. A number that is
a disassembly step.
nclosed by a circle indicates
'-3. An explanationof jobs and notes is presentedin an easy-to-read wayby the use of symbol
marks @. The meanings of the symbol marks are givenon the next page.
4. A job instruction chart0accompanies the exploded diagram, providingthe order of jobs,
names of parts, notes in jobs, etc.
5. For jobs requiring more information, the step-by-step format supplements8 are given in
addition to the exploded diagram and the job instruction chart.
F
PP I I
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+
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E n
CONTENTS
SPECIFICATIONS .......................................................................................... E.5

GENERAL SPECIFICATIONS ................................................................ E-5
MAINTENANCE SPECIFICATIONS ...................................................... E-5
ENGINE ............................................................................................. E-5
ELECTRICAL ..................................................................................... E-6
CABLE ROUTING .................................................................................. E-6
PERIODIC INSPECTIONS AND ADJUSTMENTS........................................ E-7

INTRODUCTION.................................................................................... E-7
PERIODIC MAINTENANCE/LUBRICATlONINTERVALS .................... E-7
ELECTRICAL .................................................................................................. E-8

SWITCH INSPECTION .......................................................................... E-8
SWITCH CONTINUIN INSPECTION .............................................. E-8
SIGNAL SYSTEM .................................................................................. E-9
“J CIRCUIT DIAGRAM .......................................................................... E-9
SIGNAL SYSTEM CHECK ................................................................ E-9
YFMGOOFWA WIRING DIAGRAM
.x_. .
~~ ~~~ ~ ~
GENERAL
~~-~
SPECIFICATIONS
~
SPECIFICATIONS
~ ~~ ~ ~~~ ~
mF I
c -
Item Standard
-
Model code: 4WV4 : Europe
4WV5 : AUS -
Fuel:
Type Regular unleaded gasoline : Europe
Unleaded fuel only : AUS
Fuel tank capacity 19 L (16.7 Imp qt, 20 US q t )
Fuel reserve amount 3 L (2.64 Imp qt, 3.2 US qt) -
Spark plug:
Type DP8EA-9 : Except for GB
DPR8EA-9 : For GB
Manufacturer NGK
Spark plug gap -
0.8 0.9 mm (0.031 -.0.035 in) -1
’-‘
‘--I
El
MAINTENANCE
SPECIFICATIONS ELI
SPEC p
ENGINE
Item Standard Limit
~ -
-
Valve, valve seat, valve guide:
clearance
Valve
(cold) IN 0.05 0.10 mm - -___
(0.002 0.004 in) -
EX 0.12 0.17 mrn --
(0.005 0.007 in)
----
I r??
Valve dimensions:
()
k'A' 4
\) ~~~~ ji;1 -
T D '
Head Dia Face Width Seat Width Margln Thickness
"A"diameter
head IN 36.9 37.1 rnm - ____
(1.453 1.461 in) -
EX 31.9 32.1 mm - --__
'- (1.256 1.264 in) - --__
"B" face width IN 2.26 mrn (0.089 in)
EX 2.26 rnrn (0.089 in) ____
"C" seat width IN -
1.0 1.2 mm (0.039 - 0.047 in) 1.6 rnm
(0.063 in)
EX 1.0 - 1.2 rnm (0.039 - 0.047 in) 1.6 r n r n
(0.063 in)
"D" margin
thickness IN 1.35 - 1.65 mm 1.2 mm
(0.053 - 0.065 in) (0.047 in)
EX 1.15 - 1.45 rnm 1.0 rnrn
-
(0.045 0.057 in) (0.039 in)
Stem
outside
diameter IN 6.975 6.990 mm- ..__
-
(0.2746 0.2752 in)
EX 6.955 - 6.970 mm ----
(0.2738 0.2744 in)-
Guide
inside
diameter IN -
7.000 7.012 rnm _---
-
(0.2756 0.2761 in)
-
\kc
EX 7.000 7.012 rnrn ----

-
(0.2756 0.2761 in)
Stem-to-guide
clearance IN 0.010 0.037 mm- 0.08 rnm
-
(0.0004 0.0015 in) (0.003 in)
EX 0.030 0.057 mm- 0.10 mrn
-
(0.0012 0.0022 in) (0.004 in)
Stern runout limit ____ 0.01 mm
(0.0004 in)
seat Valve width IN 1.1 mm (0.043 in) ----

____
EX 1.1 m m (0.043 in) -
MAINTENANCE SPECIFICATIONS F lD
Item Standard Limit
Carburetor:
I. D. mark 4WV 00 : Except for GB ____
4WV 20 : For GB ____
# I 45 ____
Main (M.J)
air Main (M.A.J) 0.6 ____
-_._
dle Jet (J.N) 6HH23-94-3
Y-OM (#782) ____
jet Needle (N.J)
Pilot a i r jet (P.A.J.l) 0.7 ____
air Pilot (P.A.J.2) 1.O ____
utlet Pilot (P.0) 1.1 ---_
#42.5 ---_
Pilot (P.J)
Bypass 1 (B.P.1) 1.o ____
Bypass 2 (B.P.2) 0.8 ____
..__
Bypass 3 (B.P.3) 0.8
crew Pilot 2 ____
Valve seat size (VS) 2.8 ____
.__.
e-. Starter jet (G.S.1) # I 00
.__.
jet Starter (G.S.2) 2.0
Throttle
valve size (Th.V) #110 ____
height Float (F.H) 14.7 mm (0.59 in) ____
level Fuel ( F.L) - -
2 3 mm (0.08 0.12 in) ____
Engine idle speed -
1.350 1.450 r/min ____
Intake vacuum - -
38.2 40.8 kPa (290 310 mmHg, ----
~
-
11.4 12.2 inHg)
ELECTRICAL
Item Standard Limit
Horn:
Type Plane type ____
Quantity 1 _---
Model/manufacturer MF-l2/NIKKO ____
Maximum amperage 1.5 A ____
.
d
__
61
CABLE ROUTING
1-
CABLE ROUTING
@ Horn
@ Horn switch
While installing the horn, the horn and the horn

leads should not be allowed to contact theframe.
i.,
.
4
-~ ~ ~~ ~ ~~ ~~~ . . ~ ~~~. ____ ~.
EB300000
INTRODUCTION/PERIODIC
MAINTENANCE/
LUBRICATION INTERVALS 1
IE 1NSP
ADJ
0

INTRODUCTION
This chapter includes all information necessary to perform recommended inspections and
adjustments. These preventive maintenance procedures, if followed, will ensure more reli-
able vehicle operation and a longer service life. The need for costly overhaul work will be
greatly reduced. This information applies to vehicles already in service as well as to new
vehicles that are being prepared for sale. All service technicians should be familiar with this
entire chapter.
E0301000
PERIODIC MAINTENANCE/LUBRICATION INTERVALS
INITIAL EVERY
ITEM ROUTINE 1 3 6 6 1
month months months months year
Valves*
- Check
*
valve clearance.
Adjust if necessary. 0 0 0 0
Spark plug --
* Check condition.
Adjust gap and clean.
Replace if necessary
0 0 0 0 0
i d i r filter
-. Clean.
Replace ~fnecessary
Every 20-40 hours
(More often in wet or dusty areas.)
Carburetor*
- Check
. Idle
. speedlstaner operatron. l o l o l o l o
* It is recommendedthat these items be servicedby a Yarnaha dealer.

q PERIODIC MAINTENANCE/LUBRlCATlON
INTERVALS mINSP 0
l
NOTE:
Recommended brake fluid: DOT 4
(If DOT 4 is not available, DOT 3 can be used.)
Brake fluid replacement:
1.When disassembling the master cylinder or caliper cylinder, replace the brake fluid. Nor-
mally check the brake fluid leveland add fluid as required.
2.0n the inner parts of the master cylinder and caliper cylinder, replace the oil Seals every
two years.
3.Replace the brake hosesevery four years, or if cracked or damaged.
\-
-
~~~ ~~.
. ~
-./I
7
SWITCHINSPECTION LE
ELECTRICAL
SWITCH INSPECTION
SWITCH CONTINUITY INSPECTION
Refer to "SWITCH INSPECTION" and check for continuity between lead terminals.
Poor connection, no continuity-+ Correct or replace.
3t. The coupler locations are circled.
-4
I _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
-1
L _________- J c - - - - - - - - - - J L - - - - - - . - - . J
-
El 0Lights switch
SWITCH INSPECTION j ELEC l
@ Starter switch
@ Main switch
@ 2WD/4WD select switch
@ Rear brake switch
@ 4WD switch
@ Reverse switch
@ Neutral switch
Q Fuse
@ Horn switch
..-
.-
€6806000
SIGNAL SYSTEM
SIGNAL SYSTEM m'/I
IE
CIRCUIT DIAGRAM
.e 2 Z E
c o .=,
3
- L -
lng
.- E
I
, I ,
I I I
. ________--____...-----
, I ,
0 - 1
, S I
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IS I
, I O
I I I
, I I
, * I
, * a
I S 8
# I %
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8 8 -
I t '
, I O
8 , -
, c a
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0 9
, . I
, . I
, . I
.-
'
' I , *
_______..,
I
t--
2
_..._ --
..%
...~..-..,
El SIGNAL SYSTEM CHECK
SIGNAL SYSTEM 1- ELEC
1,Horn does notsound.
1.Horn switch
g
4~l
INCORRECT
Disconnect the horn switch coupler and
7
1
I
horn switch lead from wire harness.
Check for
continuity
Brown @ - Pink @
as follows:
Replace horn switch.
,-<.
Q CoRRECT
2.Voltage
@-rr
8
the horn lead.
Tester (+) lead 4 Pink lead 0
Tester (-1 lead -+ Frame ground
I
Turn the main switchto "ON".
Push the horn switch.
Check for voltage (12 V) on the "Pink"
lead a t the horn terminal.
Wiring circuit from main switch to horn
a
-'
MEETS terminal is faulty, repair.

SPECIFICATION
*
.A
SIGNAL SYSTEM T ELEC nI IE-
a
-1c
I3.Horn
1
I
I
Disconnecttheblacklead a t the horn
terminal.
Connect a jumper lead @to the horn ter-
minal and ground the jumper lead.
I ?-
I
-
B
I;
i* - 7
HORN IS SOUNDED
-
-
'-I u -
Horn is good.
I
-c
I
HORN IS NOT
SOUNDED
4.Voltage
-rV
8
the horn a t the black terminal.
Tester (+I lead -+ Brown lead @
Tester (-1 lead + Frame ground
Turn the main switchto "ON". OUT OF SPECIFICATION

-' Push the horn switch.
Check for voltage (12 V) on the "Black"
1 lead a t the horn terminal.

1 1
a
Replace horn.
MEETS
SPECIFICATION
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I
Adjust or replace horn. ~~ ~ ---1 ~~
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Yfmgoofwa '97 (K) Service Manual 01997 by Yamaha

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IA-

NOTE: A NOTE provides key information to make

a-_. ---c. Omr-

L i q q1 6-3 Illustratedsymbols @ to 0 areused to

Illustrated symbols @ to @ in the exploded

PERIODIC INSPECTION AND Qk

MACHINE IDENTIFICATION ........................................................................ 8-3

FEATURES ................................................................................................... B-3

IMPORTANT INFORMATION ...................................................................... B-6

CHECKING OF CONNECTIONS .................................................................. B-7

SPECIAL TOOLS .......................................................................................... B-7

Clutch & Engine brake

Times - with theclutchhousing,

mitted to the engine, and the engine brake

0-700 RPM 700 RPM-

I 13 Nm (1.3 m kg, 9.4 ft Ib)

A wet sump lubrication system is used.

At the "Soft" position a, thesuspension

@ Hard position ol usual Iwo step spring

Revolution and Speed Limiter

number from country to country. In such

For US and CDN

These tools are used to remove the

Valve guide reamer (7.0 rnm)

90890-01235 This tool is needed to hold thestarter

These tools are used to install the

Sheave fixed block

1 YU-01880 This tool is needed to hold the pri-

This instrument is needed for check-

Clutch holding tool

YM-91042 This tool isneeded to hold theclutch

90890-06754 This instrument is necessary for

YM-34487 This instrument is necessary for

. case mating surfaces, etc.

GENERAL SPECIFICATIONS ....................................................................... C-3

MAINTENANCE SPECIFICATIONS ............................................................. C-4

HOW TO USETHE CONVERSION TABLE ............................................... C-12

GENERAL TORQUE SPECIFICATIONS ...................................................... C-12

LUBRICATION POINTS AND LUBRICANT TYPES ................................... C-13

LUBRICATION DIAGRAMS ................................................................ :......C-13

CABLE ROUTING ....................................................................................... C-15

Out of round limit ____ 0.01 rnm

(1.183 1.187 in) - (1.180 in)

(0.251 0.263 in)

(1.185 1.187 in) (1.181 in)

(0.257 0.269 in)

EX 0.030-.0.057 rnm ' 0.10 rnrn

Valve seat width IN 1.1 rnm (0.043 in) ____

Measuring point "H" 5 mm (0.20 in) ----

Runout limit C1 0.03 mm

Final gear backlash 0.1 - 0.2 mm (0.004 - 0.008 in) ----

Crankcase tightening sequence:

Crankcase (left) Crankcase (right)

Cylinder head tightening sequence:

Middle drivengear bearing

Yoke (middle driven gear)

Middle driven gear bearing hous-

Item Standard Limit

Disc outside diameterx thickness 220.0 x 3.5 mm (8.66 - 0.14in) ----

Caliper cylinder inside diameter 32.03 mm (1.26 in) ____

Speed 1 km/hr 0.6214 -

cc (cm3) 0.03527 oz (IMP liq.) General torque

Lubrication points Lubricant type

Main switch “ON“. _.__---_