YFM7FGPW SERVICE MANUAL

Transcription

1 YFM7FGPW SRVI MNUL LIT

2 S0000 YFM7FGPW SRVI MNUL 006 by Yamaha Motor orporation, U.S.. First dition, May 006 ll rights reserved. ny reproduction or unauthorized use without the written permission of Yamaha Motor orporation, U.S.. is expressly prohibited. Printed in U.S.. LIT-66-0-

3 S0000 NOTI This manual was produced by the Yamaha Motor ompany primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha vehicle has a basic understanding of the mechanical ideas and the procedures of vehicle repair. Repairs attempted by anyone without this knowledge are likely to render the vehicle unsafe and unfit for use. This model has been designed and manufactured to perform within certain specifications in regard to performance and emissions. Proper service with the correct tools is necessary to ensure that the vehicle will operate as designed. If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives. Yamaha Motor ompany, Ltd. is continually striving to improve all its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable. NOT: _ This Service Manual contains information regarding periodic maintenance to the emission control system. Please read this material carefully. Designs and specifications are subject to change without notice. S00003 IMPORTNT INFORMTION Particularly important information is distinguished in this manual by the following notations. WRNING UTION: NOT: The Safety lert Symbol means TTNTION! OM LRT! YOUR SFTY IS INVOLVD! Failure to follow WRNING instructions could result in severe injury or death to the vehicle operator, a bystander or a person checking or repairing the vehicle. UTION indicates special precautions that must be taken to avoid damage to the vehicle. NOT provides key information to make procedures easier or clearer.

4 S00004 HOW TO US THIS MNUL MNUL ORGNIZTION This manual consists of chapters for the main categories of subjects. (See symbols ) st title : This is the title of the chapter with its symbol in the upper right corner of each page. nd title : This title indicates the section of the chapter and only appears on the first page of each section. It is located in the upper left corner of the page. 3rd title 3: This title indicates a sub-section that is followed by step-by-step procedures accompanied by corresponding illustrations. XPLODD DIGRMS To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section.. n easy-to-see exploded diagram 4 is provided for removal and disassembly jobs.. Numbers 5 are given in the order of the jobs in the exploded diagram. number that is enclosed by a circle indicates a disassembly step. 3. n explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks 6. The meanings of the symbol marks are given on the next page. 4. job instruction chart 7 accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc. 5. For jobs requiring more information, the step-by-step format supplements 8 are given in addition to the exploded diagram and the job instruction chart.

5 GN INFO HK DJ OOL DRIV L + SP D F NG FI HS TRL SHTG S00006 SYMOLS The following symbols are not relevant to every vehicle. Symbols to 0 indicate the subject of each chapter. General information Specifications 3 Periodic checks and adjustments 4 ngine 5 ooling system 6 Fuel injection system 7 Drive train 8 hassis 9 lectrical 0 Troubleshooting Symbols to H indicate the following an be serviced with engine mounted Filling fluid Lubricant D Special tool Torque F Wear limit, clearance G ngine speed H lectrical data (Ω, V, ) T R G H I J K G M L M N LS M O P LT New Symbols I to N in the exploded diagrams indicate the types of lubricants and lubrication points. I pply engine oil J pply gear oil K pply molybdenum disulfide oil L pply wheel bearing grease M pply lithium-soap-based grease N pply molybdenum disulfide grease Symbols O to P in the exploded diagrams indicate where to apply a locking agent O and when to install a new part P. O pply the locking agent (LOTIT ) P Replace

6 S00008 TL OF ONTNTS GNRL INFORMTION SPIFITIONS PRIODI HKS ND DJUSTMNTS NGIN OOLING SYSTM FUL INJTION SYSTM DRIV TRIN HSSIS LTRIL TROULSHOOTING GN INFO SP HK DJ 3 NG 4 OOL 5 FI 6 DRIV 7 HS 8 + L 9 TRL SHTG 0

7 ONTNTS HPTR GNRL INFORMTION VHIL IDNTIFITION...- VHIL IDNTIFITION NUMR...- MODL LL...- FTURS...- OUTLIN OF TH FI SYSTM...- FI SYSTM...-3 OUTLIN OF TH PS (LTRI POWR STRING) SYSTM...-4 PS (LTRI POWR STRING) SYSTM LOK DIGRM...-5 INSTRUMNT FUNTIONS...-6 IMPORTNT INFORMTION...-9 PRPRTION FOR RMOVL ND DISSSMLY...-9 RPLMNT PRTS...-9 GSKTS, OIL SLS ND O-RINGS...-9 LOK WSHRS/PLTS ND OTTR PINS...-0 RINGS ND OIL SLS...-0 IRLIPS...-0 HKING TH ONNTIONS...- SPIL TOOLS...- HPTR SPIFITIONS GNRL SPIFITIONS...- NGIN SPIFITIONS...-5 HSSIS SPIFITIONS...- LTRIL SPIFITIONS...-4 TIGHTNING TORQUS...-6 NGIN TIGHTNING TORQUS...-6 HSSIS TIGHTNING TORQUS...-9 HOW TO US TH ONVRSION TL...-

8 GNRL TIGHTNING TORQU SPIFITIONS...- LURITION POINTS ND LURINT TYPS...-3 NGIN...-3 OOLNT FLOW DIGRMS...-5 OIL FLOW DIGRMS...-6 L ROUTING...-8 HPTR 3 PRIODI HKS ND DJUSTMNTS INTRODUTION...3- PRIODI MINTNN HRT FOR TH MISSION ONTROL SYSTM...3- GNRL MINTNN ND LURITION HRT...3- NGIN SKID PLTS, ST, RRIRS ND FNDRS NGIN SKID PLTS ST ND SID PNLS FRONT RRIR ND FRONT GURD FRONT FNDRS ND FRONT GRILL RR RRIR ND RR FNDR LTRIL OMPONNTS TRY LTRIL OMPONNTS TRY / LTRIL OMPONNTS TRY /...3- FOOTRST ORDS IR FILTR S...3-5

9 NGIN DJUSTING TH VLV LRN DJUSTING TH NGIN IDLING SPD DJUSTING TH THROTTL LVR FR PLY DJUSTING TH SPD LIMITR...3- HKING TH SPRK PLUG HKING TH IGNITION TIMING MSURING TH OMPRSSION PRSSUR HKING TH NGIN OIL LVL HNGING TH NGIN OIL LNING TH IR FILTR LMNT HKING TH THROTTL ODY JOINT HKING TH FUL HOS HKING TH RTHR HOSS HKING TH OOLNT LVL HNGING TH OOLNT HKING TH OOLING SYSTM HKING TH OOLNT TMPRTUR WRNING LIGHT HKING TH V-LT HKING TH XHUST SYSTM LNING TH SPRK RRSTR HSSIS DJUSTING TH FRONT RK DJUSTING TH RR RK HKING TH RK FLUID LVL HKING TH FRONT RK PDS HKING TH RR RK PDS HKING TH RR RK HOS PROTTORS HKING TH RK HOSS LDING TH HYDRULI RK SYSTM DJUSTING TH SLT LVR ONTROL L ND SHIFT ROD HKING TH FINL GR OIL LVL HNGING TH FINL GR OIL HKING TH DIFFRNTIL GR OIL LVL HNGING TH DIFFRNTIL GR OIL HKING TH ONSTNT VLOITY JOINT DUST OOTS HKING TH STRING SYSTM DJUSTING TH TO-IN HKING TH FRONT ND RR SHOK SORRS DJUSTING TH FRONT SHOK SORRS DJUSTING TH RR SHOK SORRS HKING TH TIRS HKING TH WHLS HKING ND LURITING TH LS LURITING TH LVRS ND PDLS

10 LTRIL SYSTM HKING ND HRGING TH TTRY HKING TH FUSS DJUSTING TH HDLIGHT MS RPLING TH HDLIGHT ULS HPTR 4 NGIN NGIN RMOVL...4- IR DUTS, MUFFLR ND XHUST PIP...4- SLT LVR UNIT LDS, LS ND HOSS NGIN MOUNTING OLTS INSTLLING TH NGIN INSTLLING TH SLT LVR UNIT YLINDR HD RMOVING TH YLINDR HD...4- HKING TH MSHFT SPROKT HKING TH TPPT OVRS HKING TH TIMING HIN TNSIONR HKING TH YLINDR HD INSTLLING TH YLINDR HD ROKR RMS ND MSHFT RMOVING TH ROKR RMS ND MSHFT HKING TH MSHFT HKING TH DOMPRSSION SYSTM...4- HKING TH ROKR RMS ND ROKR RM SHFTS...4- INSTLLING TH MSHFT ND ROKR RMS...4- VLVS ND VLV SPRINGS RMOVING TH VLVS ND VLV SPRINGS HKING TH VLVS ND VLV SPRINGS INSTLLING TH VLVS ND VLV SPRINGS YLINDR ND PISTON RMOVING TH PISTON HKING TH YLINDR ND PISTON HKING TH PISTON RINGS HKING TH PISTON PIN INSTLLING TH PISTON ND YLINDR

11 MGNTO RMOVING TH MGNTO ROTOR HKING TH STTOR OIL ND RNKSHFT POSITION SNSOR HKING TH STRTR LUTH HKING TH TORQU LIMITR INSTLLING TH MGNTO ROTOR LNR GRS ND OIL PUMP GRS RMOVING TH LNR DRIVN GR ND OIL PUMP DRIVN GR HKING TH OIL PUMP DRIV HKING TH LNR DRIV INSTLLING TH LNR DRIV GR, LNR DRIVN GR, ND OIL PUMP DRIVN GR PRIMRY ND SONDRY SHVS PRIMRY SHV SONDRY SHV RMOVING TH PRIMRY ND SONDRY SHVS DISSSMLING TH SONDRY SHV HKING TH PRIMRY SHV HKING TH SONDRY SHV SSMLING TH PRIMRY SHV SSMLING TH SONDRY SHV INSTLLING TH PRIMRY ND SONDRY SHVS LUTH RMOVING TH LUTH HKING TH LUTH INSTLLING TH LUTH RNKS TIMING HIN ND OIL FILTR RNKS RNKS RINGS SPRTING TH RNKS HKING TH TIMING HIN ND GUID HKING TH RLIF VLV HKING TH RINGS HKING TH RNKS SSMLING TH RNKS INSTLLING TH SHIFT LVR

12 RNKSHFT ND OIL PUMP OIL PUMP RMOVING TH RNKSHFT HKING TH OIL PUMP HKING TH OIL STRINR HKING TH RNKSHFT SSMLING TH OIL PUMP INSTLLING TH RNKSHFT TRNSMISSION DRIV XL RMOVING TH TRNSMISSION HKING TH SHIFT FORKS HKING TH SHIFT DRUM HKING TH TRNSMISSION HKING TH SONDRY SHFT HKING TH STOPPR LVR ND STOPPR WHL SSMLING TH SHIFT FORK SSMLY INSTLLING TH TRNSMISSION MIDDL GR MIDDL DRIV SHFT MIDDL DRIVN SHFT RMOVING TH MIDDL DRIV SHFT RMOVING TH MIDDL DRIVN SHFT HKING TH PINION GRS SLTING MIDDL DRIV ND DRIVN GR SHIMS INSTLLING TH RING ND OIL SLS INSTLLING TH MIDDL DRIVN SHFT INSTLLING TH MIDDL DRIV SHFT MSURING TH MIDDL GR KLSH HPTR 5 OOLING SYSTM RDITOR...5- HKING TH RDITOR INSTLLING TH RDITOR THRMOSTT HKING TH THRMOSTT INSTLLING TH THRMOSTT WTR PUMP DISSSMLING TH WTR PUMP HKING TH WTR PUMP SSMLING TH WTR PUMP...5-0

13 HPTR 6 FUL INJTION SYSTM FUL INJTION SYSTM...6- IRUIT DIGRM U SLF-DIGNOSTI FUNTION SLF-DIGNOSTI FUNTION TL TROULSHOOTING HRT DIGNOSTI MOD TROULSHOOTING DTILS...6- HKING TH INTK IR PRSSUR SNSOR HKING TH INTK IR TMPRTUR SNSOR FUL TNK RMOVING TH FUL TNK RMOVING TH FUL PUMP HKING TH FUL PUMP ODY HKING TH ROLLOVR VLV INSTLLING TH FUL PUMP INSTLLING TH FUL HOS THROTTL ODY RMOVING TH THROTTL ODY SSMLY HKING TH FUL INJTOR HKING TH THROTTL ODY INSTLLING TH THROTTL ODY SSMLY HKING TH FUL PUMP ND PRSSUR RGULTOR OPRTION HKING ND DJUSTING TH THROTTL POSITION SNSOR HPTR 7 DRIV TRIN TROULSHOOTING...7- HKING NOISS...7- TROULSHOOTING HRT...7-3

14 FRONT ONSTNT VLOITY JOINTS ND DIFFRNTIL GR RMOVING TH DIFFRNTIL GR SSMLY HKING TH FRONT ONSTNT VLOITY JOINTS HKING TH DIFFRNTIL GRS...7- HKING TH DIFFRNTIL GR MOTOR...7- SSMLING TH FRONT ONSTNT VLOITY JOINTS...7- SSMLING TH DIFFRNTIL GRS MSURING TH DIFFRNTIL GR LSH DJUSTING TH DIFFRNTIL GR LSH HKING TH DIFFRNTIL GR OPRTION RR ONSTNT VLOITY JOINTS ND FINL DRIV GR SSMLING TH RR ONSTNT VLOITY JOINTS DISSSMLING TH FINL DRIV PINION GR SSMLY POSITIONING TH FINL DRIV PINION GR ND RING GR DJUSTING TH FINL DRIV PINION GR KLSH DJUSTING TH FINL DRIVN PINION GR KLSH MSURING TH FINL DRIVN PINION GR THRUST WSHR LRN MSURING TH WHL GR THRUST LRN HKING TH RR DRIV SHFT HKING TH FINL DRIV SSMLY MSURMNT TH FINL GR LSH DJUSTING TH FINL GR LSH SSMLING TH FINL DRIV PINION GR SSMLY SSMLING TH FINL GR S HPTR 8 HSSIS FRONT ND RR WHLS...8- FRONT WHLS...8- RR WHLS HKING TH WHLS HKING TH WHL HUS HKING TH RK DISS INSTLLING TH RK DISS INSTLLING TH WHL HUS INSTLLING TH WHLS...8-7

15 FRONT ND RR RKS FRONT RK PDS RR RK PDS RPLING TH FRONT ND RR RK PDS FRONT RK MSTR YLINDR...8- RR RK MSTR YLINDR HKING TH MSTR YLINDRS SSMLING TH FRONT ND RR RK MSTR YLINDRS INSTLLING TH FRONT RK MSTR YLINDR INSTLLING TH RR RK MSTR YLINDR...8- FRONT RK LIPRS RR RK LIPRS DISSSMLING TH FRONT ND RR RK LIPRS HKING TH FRONT ND RR RK LIPRS SSMLING TH FRONT ND RR RK LIPRS INSTLLING TH FRONT ND RR RK LIPRS STRING SYSTM HNDLR RMOVING TH HNDLR GRIPS HKING TH HNDLR INSTLLING TH HNDLR INSTLLING TH HNDLR GRIPS INSTLLING TH RR RK MSTR YLINDR INSTLLING TH FRONT RK MSTR YLINDR INSTLLING TH THROTTL LVR SSMLY STRING STM HKING TH STRING STM INSTLLING TH STRING STM INSTLLING TH PITMN RM TI-RODS ND STRING KNUKLS RMOVING TH STRING KNUKLS HKING TH TI-RODS HKING TH STRING KNUKLS INSTLLING TH TI-RODS FRONT RMS ND FRONT SHOK SORR SSMLIS RMOVING TH FRONT RMS HKING TH FRONT RMS HKING TH FRONT SHOK SORRS INSTLLING TH FRONT RMS ND FRONT SHOK SORRS RR KNUKLS ND STILIZR HKING TH RR KNUKLS HKING TH STILIZR

16 RR RMS ND RR SHOK SORR SSMLIS HKING TH RR RMS HKING TH RR SHOK SORR SSMLIS INSTLLING TH RR RMS ND RR SHOK SORR SSMLIS HPTR 9 LTRIL LTRIL OMPONNTS...9- HKING SWITH ONTINUITY HKING TH SWITHS HKING TH ULS ND UL SOKTS TYPS OF ULS HKING TH ONDITION OF TH ULS HKING TH ONDITION OF TH UL SOKTS IGNITION SYSTM IRUIT DIGRM TROULSHOOTING...9- LTRI STRTING SYSTM IRUIT DIGRM STRTING IRUIT OPRTION TROULSHOOTING STRTR MOTOR...9- HKING TH STRTR MOTOR SSMLING TH STRTR MOTOR HRGING SYSTM IRUIT DIGRM TROULSHOOTING LIGHTING SYSTM IRUIT DIGRM TROULSHOOTING HKING TH LIGHTING SYSTM SIGNLING SYSTM IRUIT DIGRM TROULSHOOTING HKING TH SIGNLING SYSTM

17 OOLING SYSTM IRUIT DIGRM TROULSHOOTING FUL PUMP SYSTM IRUIT DIGRM TROULSHOOTING WD/4WD SLTING SYSTM IRUIT DIGRM TROULSHOOTING PS (LTRI POWR STRING) SYSTM IRUIT DIGRM PS ONTROL UNIT S SLF-DIGNOSTI FUNTION PS WRNING LIGHT DURING NORML OPRTION DIGNOSTI MOD SLF-DIGNOSTI FUNTION TL (PS SYSTM) TROULSHOOTING DTILS (PS SYSTM) HKING TH PS MOTOR HKING TH PS TORQU SNSOR HPTR 0 TROULSHOOTING STRTING FILUR/HRD STRTING...0- FUL SYSTM...0- LTRIL SYSTM...0- OMPRSSION SYSTM...0- POOR IDL SPD PRFORMN...0- POOR IDL SPD PRFORMN...0- POOR MDIUM ND HIGH-SPD PRFORMN...0- POOR MDIUM ND HIGH-SPD PRFORMN...0- FULTY DRIV TRIN FULTY GR SHIFTING HRD SHIFTING SHIFT LVR DOS NOT MOV JUMPS OUT OF GR...0-4

18 FULTY LUTH PRFORMN NGIN OPRTS UT VHIL WILL NOT MOV LUTH SLIPPING POOR STRTING PRFORMN POOR SPD PRFORMN OVRHTING OVRHTING OVROOLING OOLING SYSTM FULTY RK POOR RKING FFT SHOK SORR MLFUNTION MLFUNTION UNSTL HNDLING UNSTL HNDLING LIGHTING SYSTM HDLIGHT DOS NOT OM ON UL URNT OUT...0-6

19 VHIL IDNTIFITION GN INFO S00009 GNRL INFORMTION VHIL IDNTIFITION S0000 VHIL IDNTIFITION NUMR The vehicle identification number is stamped into the front left side of the frame. S000 MODL LL The model label is affixed at the location in the illustration. This information will be needed to order spare parts. -

20 FTURS GN INFO S070 FTURS OUTLIN OF TH FI SYSTM The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective carburetor. Despite the same volume of intake air, the fuel volume requirement varies with the engine operating conditions, such as acceleration, deceleration, or operating under a heavy load. arburetors that meter the fuel through the use of jets have been provided with various auxiliary devices, so that an optimum air-fuel ratio can be achieved to accommodate the constant changes in the operating conditions of the engine. s the requirements for the engine to deliver more performance and cleaner exhaust gases increase, it becomes necessary to control the air-fuel ratio in a more precise and finely tuned manner. To accommodate this need, this model has adopted an electronically controlled fuel injection (FI) system, in place of the conventional carburetor system. This system can achieve an optimum air-fuel ratio required by the engine at all times by using a microprocessor that regulates the fuel injection volume according to the engine operating conditions detected by various sensors. The adoption of the FI system has resulted in a highly precise fuel supply, improved engine response, better fuel economy, and reduced exhaust emissions D 0 U (engine control unit) Lean angle sensor 3 Fuel injection system relay 4 ngine trouble warning light 5 Intake air pressure sensor 6 TPS (throttle position sensor) 7 Intake air temperature sensor 8 Fuel injector 9 Fuel pump 0 Speed sensor rankshaft position sensor oolant temperature sensor Spark plug D Ignition coil -

21 FTURS GN INFO FI SYSTM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at only 34 kpa (3.4 kg/cm, 46. psi). ccordingly, when the energizing signal from the U energizes the fuel injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the passage remains open. Therefore, the longer the length of time the fuel injector is energized (injection duration), the greater the volume of fuel that is supplied. onversely, the shorter the length of time the fuel injector is energized (injection duration), the lesser the volume of fuel that is supplied. The injection duration and the injection timing are controlled by the U. Signals that are input from the throttle position sensor, crankshaft position sensor, intake air pressure sensor, intake air temperature sensor, coolant temperature sensor, lean angle sensor and speed sensor enable the U to determine the injection duration. The injection timing is determined through the signals from the crankshaft position sensor. s a result, the volume of fuel that is required by the engine can be supplied at all times in accordance with the driving conditions. Illustration is for reference only. É È Ê Fuel pump Fuel injector 3 Ignition coil 4 U (engine control unit) 5 Speed sensor 6 Lean angle sensor 7 oolant temperature sensor 8 rankshaft position sensor 9 Intake air pressure sensor 0 Throttle body Throttle position sensor Intake air temperature sensor ir filter case È Fuel system É ir system Ê ontrol system - 3

22 FTURS OUTLIN OF TH PS (LTRI POWR STRING) SYSTM GN INFO Speed information from speed sensor ngine starting RPM information from U attery 4. PS control unit calculates assist power. Operates steering 5. lectricity output switched by PS control unit 3. Sends the torque sensor signal. Twists torsion bar 6. ctivates PS motor Steering stem PS control unit PS motor Torque sensor PS unit UTION: To prevent accidental damage to the PS unit, it must not be disassembled. - 4

23 FTURS PS (LTRI POWR STRING) SYSTM LOK DIGRM GN INFO PS UNIT Torque sensor PS motor Meter assembly Multifunction display Odometer/Tripmeter /Tripmeter /lock/fuel meter/gear position Indicator and warning lights PS warning/ngine trouble warning/oolant temperature warning/reverse indicator/neutral indicator/park indicator/high-range indicator/ Low-range indicator/differential lock FI and PS self-diagnostic error codes oolant temperature sensor signal rankshaft position sensor signal Speed sensor signal PS control unit ngine rpm signal U Fuel injector Fuel pump attery Intake air temperature sensor signal Throttle position sensor signal Intake air pressure sensor signal Ignition coil Lean angle sensor signal - 5

24 FTURS GN INFO INSTRUMNT FUNTIONS U79 Multifunction display LOK button RST button 3 SLT button 4 Speedometer 5 Fuel meter 6 lock/hour meter 7 Odometer/Tripmeter /Tripmeter The multifunction display is equipped with the following: a speedometer (which shows the riding speed) an odometer (which shows the total distance traveled) two tripmeters (which show the distance traveled since they were last set to zero) a clock an hour meter (which shows the total time the key has been turned to ON ) a fuel meter a self-diagnosis device Odometer and tripmeter modes Pushing the SLT button switches the display between the odometer mode ODO and the tripmeter modes and in the following order: ODO TRIP TRIP ODO To reset a tripmeter, select it by pushing the SLT button, and then push the RST button for at least three seconds. The tripmeters can be used to estimate the distance that can be traveled with a full tank of fuel. This information will enable you to plan future fuel stops. NOT: Holding in the SLT button and then turning the key to ON switches the display between mph and km/h. - 6

25 FTURS GN INFO lock mode Pushing the LOK button switches the display between the clock mode LOK and the hour meter mode HOUR in the following order: LOK HOUR LOK To set the clock. Set the display to the clock mode.. Push the SLT button and RST button together for at least three seconds. 3. When the hour digits start flashing, push the RST button to set the hours. 4. Push the SLT button, and the minute digits will start flashing. 5. Push the RST button to set the minutes. 6. Push the SLT button and then release it to start the clock. 3 Fuel meter The fuel meter indicates the amount of fuel in the fuel tank. The display segments of the fuel meter disappear from F (full) towards (empty) as the fuel level decreases. When the segment disappears and the fuel level warning indicator flashes, refuel as soon as possible. NOT: This fuel meter is equipped with a self-diagnosis system. If the electrical circuit is defective, all the display segments and fuel level warning indicator will start flashing. If this occurs, check the electrical circuit. Refer to SIGNLING SYSTM in chapter 9. Fuel level warning indicator Fuel meter 3 segment - 7

26 FTURS GN INFO Self-diagnosis device This model is equipped with a self-diagnosis device for various electrical circuits. If any of those circuits are defective, the multifunction display will indicate a two-digit error code. If the multifunction display indicates such an error code, note the code number, and check the vehicle UTION: If the multifunction display indicates an error code, the vehicle should be checked as soon as possible in order to avoid engine damage. rror code display - 8

27 IMPORTNT INFORMTION GN INFO S0003 IMPORTNT INFORMTION PRPRTION FOR RMOVL ND DISSSMLY. efore removal and disassembly remove all dirt, mud, dust and foreign material.. Use only the proper tools and cleaning equipment. Refer to SPIL TOOLS. 3. When disassembling always keep mated parts together. This includes gears, cylinders, pistons and other parts that have been mated through normal wear. Mated parts must always be reused or replaced as an assembly. 4. During disassembly, clean all of the parts and place them in trays in the order of disassembly. This will speed up assembly and allow for the correct installation of all parts. 5. Keep all parts away from any source of fire. S0004 RPLMNT PRTS. Use only genuine Yamaha parts for all replacements. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality. S0005 GSKTS, OIL SLS ND O-RINGS. When overhauling the engine, replace all gaskets, seals and O-rings. ll gasket surfaces, oil seal lips and O-rings must be cleaned.. During reassembly properly oil all mating parts and bearings, and lubricate the oil seal lips with grease. - 9

28 IMPORTNT INFORMTION GN INFO S0006 LOK WSHRS/PLTS ND OTTR PINS fter removal, replace all lock washers/plates and cotter pins. fter the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut. S0007 RINGS ND OIL SLS Install bearings and oil seals so that the manufacturer s marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if appropriate. Oil seal UTION: _ Do not spin the bearing with compressed air because this will damage the bearing surfaces. earing S0008 IRLIPS efore reassembly, check all circlips carefully and replace damaged or distorted circlips. lways replace piston pin clips after one use. When installing a circlip, make sure the sharp-edged corner is positioned opposite the thrust 3 that the circlip receives. 4 Shaft - 0

29 IMPORTNT INFORMTION GN INFO S0009 HKING TH ONNTIONS heck the leads, couplers, and connectors for stains, rust, moisture, etc.. Disconnect: lead coupler connector. heck: lead coupler connector Moisture Dry with an air blower. Rust/stains onnect and disconnect several times. 3. heck: all connections Loose connection onnect properly. NOT: _ If the pin on the terminal is flattened, bend it up. 4. onnect: lead coupler connector NOT: _ Make sure all connections are tight. 5. heck: continuity (with the pocket tester) Pocket tester nalog pocket tester YU-03- NOT: _ If there is no continuity, clean the terminals. When checking the wire harness, perform steps () to (3). s a quick remedy, use a contact revitalizer available at most part stores. -

30 SPIL TOOLS GN INFO S000 SPIL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools; this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools may differ by shape and part number from country to country. In such a case, two types are provided. When placing an order, refer to the list provided below to avoid any mistakes. For US and DN P/N. YM-, YU-, YS-, YK-, - xcept for US and DN P/N Tool No. Tool name/how to use Illustration YU Slide hammer bolt Slide hammer bolt 6 mm This tool is used to remove the rocker arm shaft. Weight YU YU This tool is used to remove the rocker arm shaft. rankcase separating tool rankcase separator YU-035- This tool is used to separate the crankcase YM YM-053- oupling gear/middle shaft tool Gear holder This tool is needed when removing or installing the coupling gear nut. Valve spring compressor attachment Valve spring compressor adapter (6 mm) This tool is needed to remove and install the valve assemblies. -

31 SPIL TOOLS GN INFO Tool No. Tool name/how to use Illustration rankshaft installer pot Installing pot Pot installer YU YU YU-90058/YU This tool is used to install the crankshaft YU rankshaft installer bolt olt This tool is used to install the crankshaft. Piston pin puller set Piston pin puller YU-0304 YU YU This tool is used to remove the piston pin. Spacer Pot spacer This tool is used to install the crankshaft. Tappet adjusting tool Valve adjuster 3 mm & 4 mm ø YM This tool is necessary for adjusting the valve clearance. - 3

32 SPIL TOOLS GN INFO Tool No. Tool name/how to use Illustration Radiator cap tester Radiator pressure tester YU YU This tool is used to check the cooling system. Locknut wrench YM-0348 This tool is needed when removing or installing the secondary sheave spring. Radiator cap tester adapter Radiator pressure tester adapter YU YU This tool is used to check the cooling system YU Flywheel puller Heavy duty puller This tool is used to remove the magneto rotor. Oil filter wrench YU-384 This tool is needed to loosen or tighten the oil filter cartridge. Ring nut wrench YM This tool is needed to removing and installing the middle driven shaft bearing retainer. - 4

33 SPIL TOOLS GN INFO Tool No. Tool name/how to use Illustration all joint remover YM YM YM-0480 These tools are used to removing or installing the ball joints. Gear lash measurement tool Middle drive gear lash tool This tool is used to measure the gear lash. all joint remover attachment set all joint adapter set These tools are used to removing or installing the ball joints. Final gear backlash band This tool is needed when measuring the final gear backlash. all joint remover short shaft set YS YM YU YU-03- These tools are used to removing or installing the ball joints. Sheave holder Primary clutch holder This tool is needed to hold the primary sheave when removing or installing the sheave nuts. Thickness gauge Narrow gauge set This tool is used to measure the valve clearance. ompression gauge ngine compression tester This tool is needed to measure engine compression. Pocket tester nalog pocket tester This instrument is needed for checking the electrical systems. - 5

34 SPIL TOOLS GN INFO Tool No. Tool name/how to use Illustration YU-034 Timing light Inductive clamp timing light This tool is necessary for checking ignition timing. Pressure gauge YU YM YU-97 This tool is used to measure fuel pressure. elt tension gauge Rear drive belt tension gauge This tool is used to measure the steering tension. Digital circuit tester Model 88 Multimeter with tachometer This tool is used to check the electrical systems. Fuel pressure adapter YM-0376 This tool is used to measure fuel pressure. Valve spring compressor YM YM YM YM This tool is used to remove or install the valve assemblies. Middle driven shaft bearing driver earing driver 40 mm This tool is used to install the water pump seal. Valve guide remover (ø6) Valve guide remover (6.0 mm) This tool is needed to remove and install the valve guides. Valve guide installer (ø6) Valve guide installer (6.0 mm) This tool is needed to install the valve guides. - 6

35 SPIL TOOLS GN INFO Tool No. Tool name/how to use Illustration YM Valve guide reamer (ø6) Valve guide reamer (6.0 mm) This tool is needed to rebore the new valve guides. Spacer (crankshaft installer) Pot spacer YM-9044 YM-9044 This tool is used to install the crankshaft. xtension This tool is used to measure engine compression. Universal clutch holder YM-904 This tool is needed to hold the clutch carrier when removing or installing the carrier nut YM YM earing retainer wrench Middle gear bearing retainer This tool is needed when removing or installing the bearing retainers. dapter (M6) dapter #3 This tool is used to install the crankshaft YM-33- Mechanical seal installer Water pump seal installer This tool is used to install the water pump seal. - 7

36 SPIL TOOLS GN INFO Tool No. Tool name/how to use Illustration Sheave spring compressor YM-0434 This tool is needed when removing or installing the secondary sheave spring. Sheave fixed block Sheave fixed bracket YM-0435 This tool is needed when removing or installing the secondary sheave spring YM Ignition checker Opama pet-4000 spark checker This instrument is necessary for checking the ignition system components. Digital tachometer YU This tool is needed for checking engine rpm. Yamaha bond No. 5 (Three bond No.5 ) This bond is used on crankcase mating surfaces, etc. - 8

37 GNRL SPIFITIONS SP S000 SPIFITIONS GNRL SPIFITIONS Item Standard 34 Model code Dimensions Overall length,065 mm (8.3 in) Overall width,80 mm (46.5 in) Overall height,40 mm (48.8 in) Seat height 905 mm (35.6 in) Wheelbase,50 mm (49. in) Minimum ground clearance 75 mm (0.8 in) Minimum turning radius 3,00 mm (6.0 in) asic weight With oil and fuel 94.0 kg (648 lb) ngine ngine type Liquid-cooled 4-stroke, SOH ylinder arrangement Forward-inclined single cylinder Displacement cm 3 (4.86 cu. in) ore stroke mm ( in) ompression ratio 9.0 : Standard compression pressure (at sea level) 450 kpa (4.50 kg/cm, 64.0 psi) Starting system lectric starter Lubrication system Wet sump Oil type or grade ngine oil F PI service S, SF, SG type or higher JSO standard M YMLU4 (0W40) or S 0W40 YMLU4 (0W30) or S 0W30 S 5W Final gear oil Differential gear oil S 80 PI GL-4 Hypoid gear oil S 80 PI GL-4 Hypoid gear oil -

38 GNRL SPIFITIONS SP Item Standard Oil quantity ngine oil Periodic oil change.00 L (.76 Imp qt,. US qt) With oil filter replacement.0 L (.85 Imp qt,. US qt) Total amount.40 L (. Imp qt,.54 US qt) Final gear oil Periodic oil change 0.0 L (0.8 Imp qt, 0. US qt) Total amount 0.5 L (0. Imp qt, 0.6 US qt) Differential gear case oil Periodic oil change 0.5 L (0.9 Imp qt, 0.3 US qt) Total amount 0.3 L (0.0 Imp qt, 0.4 US qt) Radiator capacity (including all routes).99 L (.75 Imp qt,.0 US qt) ir filter Wet type element Fuel Type Unleaded gasoline only Fuel tank capacity 0.0 L (4.40 Imp gal, 5.8 US gal) Fuel reserve amount 4.5 L (0.99 Imp gal,.9 US gal) Fuel injector Type/quantity / Manufacturer DNSO Spark plug Type/manufacturer R8/NGK Spark plug gap 0.7 ~ 0.8 mm (0.08 ~ 0.03 in) lutch type Wet, centrifugal automatic Transmission Primary reduction system V-belt Secondary reduction system Shaft drive Secondary reduction ratio 4/ 4/8 33/9 (9.544) Transmission type V-belt automatic Operation Left hand operation Single speed automatic.380 ~ : Sub transmission ratio low 3/6 (.938) high 9/5 (.60) Reverse gear 3/4 8/3 (.000) hassis Frame type Steel tube frame aster angle 5.0 amber angle 0 Kingpin angle.0 Kingpin offset 0 mm (0 in) Trail 6.0 mm (.0 in) Tread front (STD) mm (37.0 in) Tread rear (STD) 95.0 mm (37.0 in) Toe-in (with tires touching the ground) 0 ~ 0.0 mm (0 ~ 0.39 in) -

39 GNRL SPIFITIONS SP Item Standard Tire Type front Tubeless rear Tubeless Size front T5 8- rear T5 0- Manufacturer/model front DUNLOP/KT4 rear DUNLOP/KT45 Tire pressure (cold tire) Maximum load* 0.0 kg (485 lb) Off-road riding front 3 ~ 38 kpa (0.3 ~ 0.38 kg/cm, 4.6 ~ 5.5 psi) rear 7 ~ 33 kpa (0.7 ~ 0.33 kg/cm, 3.9 ~ 4.8 psi) *Load is total weight of cargo, rider, accessories, and tongue rake Front brake type Dual disc brake operation Right hand operation Rear brake type Dual disc brake operation Left hand and right foot operation Suspension Front suspension Double wishbone Rear suspension Double wishbone Shock absorber Front shock absorber oil spring/oil damper Rear shock absorber oil spring/oil damper Wheel travel Front wheel travel 80 mm (7. in) Rear wheel travel 30 mm (9. in) lectrical system Ignition system Transistorized coil ignition (digital) Generator system magneto attery type YTX0L-S attery capacity V 8.0 h ulb type Halogen bulb - 3

40 GNRL SPIFITIONS SP Item Standard ulb voltage/wattage quantity Headlight V 35.0 W/35.0 W Tail/brake light V.0/5.0 W Indicator light Neutral indicator light LD Reverse indicator light LD oolant temperature warning light LD ngine trouble warning light LD PS warning light LD Park indicator light LD On-command four-wheel drive/differential LD gear lock indicator High-range indicator light LD Low-range indicator light LD Differential gear lock indicator light LD - 4

41 NGIN SPIFITIONS SP S000 NGIN SPIFITIONS Item Standard Limit ylinder head Maximum warpage mm (0.00 in) ylinder ore ~ 0.00 mm (4.057 ~ 4.06 in) Measuring point 50.0 mm (.97 in) mm (4.089 in) Maximum taper 0.05 mm (0.00 in) Out of round 0.05 mm (0.00 in) amshaft Drive system hain drive (left) ---- amshaft lobe dimensions Intake measurement ~ mm (.7 ~.76 in) mm (.708 in) ~ mm (.455 ~.4590 in) mm (.45 in) xhaust measurement 43.9 ~ 43.9 mm (.6980 ~.709 in) mm (.694 in) ~ mm (.4570 ~.4609 in) mm (.4530 in) Maximum camshaft runout mm ( in) - 5

42 NGIN SPIFITIONS SP Item Standard Limit Timing chain Model/number of links 98XRH00/ Tensioning system utomatic ---- Rocker arm/rocker arm shaft Rocker arm inside diameter.000 ~.08 mm (0.474 ~ in) ---- Shaft outside diameter.98 ~.99 mm (0.477 ~ 0.47 in) ---- rm-to-shaft clearance ~ mm ( ~ in) ---- Rocker-arm-to-rocker-arm-shaft ~ mm ( ~ in) ---- clearance Valve, valve seat, valve guide Valve clearance intake (cold) 0.09 ~ 0.3 mm ( ~ in) ---- Valve clearance exhaust (cold) 0.6 ~ 0.0 mm ( ~ in) ---- Valve dimensions Head Diameter Face Width Seat Width Margin Thickness Valve head diameter Intake ~ 38.0 mm (.49 ~.5000 in) ---- xhaust 3.90 ~ 3.0 mm (.559 ~.638 in) ---- Valve face width Intake.6 mm ( in) ---- xhaust.6 mm ( in) ---- Valve seat width Intake.00 ~.0 mm ( ~ in).60 mm ( in) xhaust.00 ~.0 mm ( ~ in).60 mm ( in) Valve margin thickness D Intake 0.80 ~.0 mm (0.035 ~ in) ---- xhaust 0.80 ~.0 mm (0.035 ~ in) ---- Valve stem diameter Intake ~ mm (0.35 ~ in) mm (0.34 in) xhaust ~ mm (0.346 ~ 0.35 in) mm (0.335 in) Valve guide inside diameter Intake ~ 6.0 mm (0.36 ~ in) mm (0.38 in) xhaust ~ 6.0 mm (0.36 ~ in) mm (0.38 in) D - 6

43 NGIN SPIFITIONS SP Item Standard Limit Valve-stem-to-valve-guide clearance Intake 0.00 ~ mm ( ~ in) mm (0.003 in) xhaust 0.05 ~ 0.05 mm (0.000 ~ in) 0.00 mm ( in) Valve stem runout mm (0.006 in) Valve seat width Intake.00 ~.0 mm ( ~ in).60 mm ( in) xhaust.00 ~.0 mm ( ~ in).60 mm ( in) Valve spring Free length Intake mm (.53 in) mm (.45 in) xhaust mm (.53 in) mm (.45 in) Installed length (valve closed) Intake mm (.38 in) ---- xhaust mm (.38 in) ---- ompressed spring force (installed) Intake 69 ~ 99 N ---- (7.3 ~ 0.9 kgf, ~ lb) xhaust 69 ~ 99 N ---- (7.3 ~ 0.9 kgf, ~ lb) Spring tilt Intake /.70 mm (.5 /0.067 in) xhaust /.70 mm (.5 /0.067 in) Winding direction (top view) Intake lockwise ---- xhaust lockwise

44 NGIN SPIFITIONS SP Item Standard Limit Piston Piston-to-cylinder clearance ~ mm (0.00 ~ 0.00 in) 0.3 mm (0.005 in) Diameter D ~ mm (4.040 ~ in) ---- D Height H 0.0 mm (0.39 in) ---- Offset 0.50 mm (0.097 in) ---- Offset direction Intake side ---- Piston pin bore inside diameter ~ 3.05 mm ( ~ in) mm ( in) Piston pin outside diameter.99 ~ mm (0.905 ~ in).97 mm ( in) Piston-pin-to-piston-pin-bore clearance ~ 0.04 mm (0.000 ~ in) mm (0.009 in) Piston rings Top ring T H Ring type arrel ---- Dimensions ( T) mm ( in) ---- nd gap (installed) 0.0 ~ 0.35 mm (0.008 ~ 0.04 in) 0.60 mm (0.04 in) Ring side clearance ~ mm (0.00 ~ in) 0. mm ( in) nd ring T Ring type Taper ---- Dimensions ( T) mm ( in) ---- nd gap (installed) 0.75 ~ 0.90 mm (0.030 ~ in).5 mm (0.049 in) Ring side clearance ~ mm (0.00 ~ in) 0.3 mm (0.005 in) - 8

45 NGIN SPIFITIONS SP Oil ring Item Standard Limit T Dimensions ( T) mm ( in) ---- nd gap (installed) 0.0 ~ 0.70 mm (0.008 ~ 0.08 in) ---- Ring side clearance ~ 0.50 mm (0.004 ~ in) ---- rankshaft F D rank width ~ mm (.95 ~.953 in) ---- Maximum runout mm (0.00 in) ig end side clearance D ~ mm (0.038 ~ in).0 mm (0.04 in) ig end radial clearance 0.00 ~ 0.05 mm ( ~ in) ---- Small end free play F 0.6 ~ 0.40 mm ( ~ in) ---- alancer alancer drive method Gear ---- utomatic centrifugal clutch lutch shoe thickness.5 mm (0.06 in).0 mm (0.04 in) lutch-in revolution,850 ~,50 r/min ---- lutch-stall revolution 3,500 ~ 4,00 r/min ---- Transmission Maximum main axle runout mm (0.004 in) Maximum drive axle runout mm (0.004 in) Shifting mechanism Shift mechanism type Shift drum and guide bar ---- Decompression device Device type uto decomp ---- ir filter oil grade Foam air filter oil or equivalent oil ---- Throttle body Model/manufacturer quantity 44IS/MIKUNI ---- ngine idle speed,350 ~,450 r/min ---- Intake vacuum 35.0 kpa (63 mmhg, 0.3 inhg)

46 NGIN SPIFITIONS SP Item Standard Limit Fuel pump Pump type lectrical ---- Model/manufacturer 34/DNSO ---- Oil filter type artridge (paper) ---- Oil pump Oil pump type Trochoid ---- Inner-rotor-to-outer-rotor-tip clearance Less than 0. mm ( in) 0.0 mm ( in) Outer-rotor-to-oil-pump-housing clearance ~ 0.70 mm ( ~ in) 0.4 mm ( in) Oil-pump-housing-to-inner-andouter-rotor clearance 0.03 ~ 0.0 mm (0.00 ~ in) 0.7 mm ( in) Oil pressure (hot) 50.0 kpa at,600 r/min (0.50 kg/cm at ----,600 r/min, 7. psi at,600 r/min) Pressure check location ylinder head ---- ooling system Radiator core Width mm (3.39 in) ---- Height 48. mm (9.77 in) ---- Depth.0 mm (0.87 in) ---- Radiator cap opening pressure 93.3 ~.7 kpa ---- (0.933 ~.7 kg/cm, 3.7 ~ 7.45 psi) oolant reservoir capacity Up to the maximum level mark 0.7 L (0.5 Imp qt, 0.8 US qt) ---- From low to full level 0.4 L (0. Imp qt, 0.5 US qt) ---- Water pump Water pump type Single-suction centrifugal pump ---- Reduction ratio 3/3 (.03) ---- Shaft drive Middle gear backlash 0.0 ~ 0.30 mm (0.004 ~ 0.0 in) ---- Final gear backlash 0.0 ~ 0.0 mm ( ~ in) ---- Differential gear backlash 0.05 ~ 0.5 mm (0.000 ~ in)

47 NGIN SPIFITIONS SP ylinder head tightening sequence

48 HSSIS SPIFITIONS SP S0003 HSSIS SPIFITIONS Item Standard Limit Steering system Steering bearing type all and race bearing ---- Steering tension 50 N (5.0 kgf) ---- Front suspension Shock absorber travel 90.7 mm (3.57 in) ---- Spring free length 9.0 mm (.50 in) ---- Installed length 37.0 mm (9.33 in) ---- Spring rate (K) 3.00 N/mm (.35 kg/mm, 3.33 lb/in) ---- Spring stroke (K) 0 ~ 90.7 mm (0 ~ 3.57 in) ---- Optional spring available No ---- Rear suspension Shock absorber travel 09. mm (4.30 in) ---- Spring free length 34.5 mm (.38 in) ---- Installed length 7.0 mm (0.67 in) ---- Spring rate (K) N/mm (3.4 kg/mm, 9.8 lb/in) ---- Spring rate (K) N/mm (3.67 kg/mm, lb/in) ---- Spring stroke (K) 0 ~ 46.5 mm (0 ~.83 in) ---- Spring stroke (K) 46.5 ~ 09. mm (.83 ~ 4.30 in) ---- Optional spring available No ---- Front wheel Type Panel wheel ---- Rim size 6.0 T ---- Rim material luminum ---- Maximum radial wheel runout mm (0.08 in) Maximum lateral wheel runout mm (0.08 in) Rear wheel Type Panel wheel ---- Rim size 7.5 T ---- Rim material luminum ---- Maximum radial wheel runout mm (0.08 in) Maximum lateral wheel runout mm (0.08 in) -

49 HSSIS SPIFITIONS SP Item Standard Limit Front disc brake Type Dual ---- Disc outside diameter thickness mm ( in) ---- rake disc minimum thickness 3.0 mm (0. in) ---- rake disc maximum deflection 0. mm (0.004 in) ---- Pad thickness inner 4.4 mm (0.7 in).0 mm (0.04 in) Pad thickness outer 4.4 mm (0.7 in).0 mm (0.04 in) Master cylinder inside diameter.70 mm (0.50 in) ---- aliper cylinder inside diameter mm (.34 in) ---- rake fluid type DOT Rear disc brake Type Dual ---- Disc outside diameter thickness mm ( in) ---- rake disc minimum thickness 3.0 mm (0. in) ---- rake disc maximum deflection 0. mm (0.004 in) ---- Pad thickness inner 5.8 mm (0.3 in).0 mm (0.04 in) Pad thickness outer 5.8 mm (0.3 in).0 mm (0.04 in) Master cylinder inside diameter.70 mm (0.50 in) ---- aliper cylinder inside diameter mm (.34 in) ---- rake fluid type DOT rake lever and brake pedal rake pedal position 56.7 mm (.3 in) ---- rake pedal free play 0 ~ 5.0 mm (0 ~ 0.0 in) ---- Throttle lever free play 3.0 ~ 5.0 mm (0. ~ 0.0 in)

50 LTRIL SPIFITIONS SP S0004 LTRIL SPIFITIONS Item Standard Limit System voltage V ---- Ignition system Ignition timing (.T.D..) /,400 r/min ---- dvancer type Digital ---- Transistorized coil ignition rankshaft position sensor resistance/color 459 ~ 56 Ω at 0 (68 F)/ black-green/yellow U Model/manufacturer 34/MITSUISHI ---- Ignition coil Model/manufacturer JO6/DNSO ---- Minimum ignition spark gap 6.0 mm (0.4 in) ---- Primary coil resistance 3.4 ~ 4.6 Ω at 0 (68 F) ---- Secondary coil resistance 0.4 ~ 5.6 kω at 0 (68 F) ---- Spark plug cap Material Resin ---- Resistance 0.0 kω ---- magneto Model/manufacturer F4T393/MITSUISHI ---- Standard output 4.0 V 35.0 at 5,000 r/min ---- Stator coil resistance/color 0.08 ~ 0.3 Ω at 0 (68 F)/ ---- white-white Rectifier/regulator Type Semiconductor-short-circuit ---- Model/manufacturer FH0/SHINDNGN ---- No load regulated voltage (D) 4. ~ 4.8 V ---- Rectifier capacity Withstand voltage 40.0 V ---- lectric starting system Type onstant mesh ---- Starter motor Model/manufacturer SM-3/MITSU ---- Power output 0.80 kw ---- rmature coil resistance ~ Ω at 0 (68 F) ---- rush overall length.5 mm (0.49 in) 5.00 mm (0.0 in) Spring force 7.65 ~ 0.0 N ---- (780 ~,0 gf, 7.54 ~ oz) ommutator diameter 8.0 mm (.0 in) 7.0 mm (.06 in) Mica undercut 0.70 mm (0.03 in)

51 LTRIL SPIFITIONS SP Starter relay Model/manufacturer 7683-/JIDO ---- mperage rating oil winding resistance 4.8 ~ 4.6 Ω at 0 (68 F) ---- Fuel gauge Sender unit resistance (full) 9.00 ~.00 Ω ---- Sender unit resistance (empty) ~ 4.00 Ω ---- Starting circuit cut-off relay Model/manufacturer M33/MTSUSHIT ---- oil resistance 96.0 Ω ---- Radiator fan motor relay Model/manufacturer M33/MTSUSHIT ---- oil resistance 96.0 Ω ---- ircuit breaker ircuit breaker type Fuse ---- Fuses Main fuse Headlight fuse Signaling system fuse Ignition fuse uxiliary D jack fuse Fuel injection system fuse Four-wheel-drive motor fuse PS fuse Radiator fan motor fuse Spare fuse Item Standard Limit

52 TIGHTNING TORQUS SP S0005 TIGHTNING TORQUS NGIN TIGHTNING TORQUS Item Part name Thread size - 6 Q ty Tightening torque Nm m kg ft lb Remarks ylinder head (exhaust pipe) Stud bolt M ylinder head olt M M ylinder head olt M ylinder head olt M Spark plug M Oil gallery bolt Union bolt M ylinder olt M See NOT. magneto rotor Nut M alancer driven gear Nut M Use a lock washer. Thermostat cover olt M ylinder head air bleed bolt olt M Valve adjusting screw Nut M Decompression assembly olt M Timing chain guide (intake side) olt M LT Timing chain tensioner cap olt M Timing chain tensioner olt M earing retainer (camshaft) olt M LT amshaft sprocket cover olt M Tappet cover olt M amshaft sprocket olt M rankcase olt M olt M olt M ngine oil drain bolt olt M Oil filter cartridge M0 7.7 Oil filter cartridge union bolt Union bolt M Oil delivery pipe Union bolt M Oil delivery pipe Union bolt M Oil pump olt M Oil pump driven gear Nut M0. 6 Use a lock washer. earing retainer (crankcase) olt M LT xhaust pipe protector olt M Muffler and frame olt M Muffler and muffler bracket olt M xhaust pipe Nut M Water pump housing olt M oolant drain bolt olt M Water pump air bleed bolt olt M

53 TIGHTNING TORQUS SP Item Water pump outlet pipe olt M Water jacket joint olt M Timing chain guide olt M LT rankshaft end accessing screw M Timing mark accessing screw M Drive belt cover olt M earing housing (primary sheave assembly) olt M magneto/crankshaft position sensor lead holder olt M LT Starter one-way clutch Screw M LT lutch housing assembly olt M lutch carrier assembly Nut M Left-hand thread Stake. Middle drive pinion gear nut Nut M Stake. Middle driven shaft bearing housing olt M Middle drive shaft bearing retainer olt M Front drive shaft coupling gear nut (middle gear side) Nut M Middle driven shaft bearing retainer Nut M Left-hand thread Middle driven pinion gear bearing retainer Part name Thread size Nut M Left-hand thread Rear drive shaft coupling gear nut (middle gear side) Nut M LT Middle driven pinion gear bearing housing olt M Primary sheave assembly Nut M Secondary sheave spring retainer Nut M Secondary sheave assembly Nut M Shift lever assembly olt M Shift drum stopper olt M Stopper lever stopper olt M Stator coil assembly olt M LT rankshaft position sensor olt M LT oolant temperature sensor M Gear position switch olt M Reverse switch M0 7.7 Speed sensor olt M Q ty Tightening torque Nm m kg ft lb Remarks M LT LT - 7