Connect the dynamic spark tester 1 as shown. Thermo switch 1 Remove the thermo switch from the radia- tor. Place the machine on a level surface. Slide forward Headlight beam raises. Place the machine on a level surface. Camshaft lobe limit: Intake: a 35.
Cylinder head warpage: Less than 0. Front and rear fenders Fuel tank and rubber covers Muffler. Remove: Dipstick 1 Engine oil drain bolt oil tank 2 Engine oil drain bolt crankcase 3 Drain the engine oil from the oil tank and crankcase. All diagnostic and repair procedures are covered. This Manual is a must for the Do-It-Yourselfer! It is specifically written for the do-it-yourselfer as well as the experienced mechanic.
Turn the valve until the valve face and valve seat are evenly polished, then clean off all of the compound. Wiring connection the entire ignition sys-. Connect: Coolant reservoir hose 6. Maximum drive axle runout: 0. Insert the tailpipe into the muffler and align the bolt holes. Measure the starter plunger stroke distance a of the starter lever 3 fully close-to-fully open position.
Then, find the average of the measurements. Oil seal retainer Oil seal Bearing retainer Bearing For installation, reverse the removal pro- cedure. Just print it out and take it with you into the garage or workshop. Straighten the lock washer tab. Wiring connection Check the connections of the entire starting system. If the piston pin groove is deburred and the piston pin is still difficult to remove, use the piston pin puller 4. Use a feeler gauge to measure the warpage.
For installation, reverse the removal pro- cedure. Immerse the thermo switch in coolant 2. Insert a feeler gauge 2 between the adjuster end and the valve end. Other brands may be similar in function and appearance, but inferior in quality. Installed depth of bushing a: 1 mm 0. All diagnostic and repair procedures are covered.
Make sure the throttle valves operate smoothly and that the synchronization is correct. Check: Oil seals 1 Steering stem bushings 2. If out of specification, replace the piston pin. Check: Thermostat 1 Does not open at 69 ~ 73 °C 156. The coupler locations are circled.
Check: Guide bar Roll the guide bar on a flat surface. Install: Bushing 1 Oil seal 2. Drain: Coolant from the coolant reservoir 5. All diagnostic and repair procedures are covered. You can print the entire manual or any pages you want to select. Fill: Coolant reservoir with the recommended coolant to the proper level 14. Notes, cautions and warnings throughout each chapter pinpoint critical service information.
Refill with the same type of brake fluid: Mixing brake fluids may result in a harmful chemical reaction and lead to poor brake performance. Locknut Locknut Left-hand threads Adjusting rod Left footrest guard bracket Left footrest For installation, reverse the removal pro- cedure. Install: Coolant reservoir cap 15. Eliminate: Carbon deposits from the combustion chambers Use a rounded scraper. Inspect the valve seat and needle valve. Use soft metal drift punch and hammer.
Do not touch the bulb until it cools down. It is recommended that these items be serviced by a Yamaha dealer. This reference point will be needed during adjustment. Repeat the bleeding procedure when the tiny bubbles in the system have disappeared. Keep Your All-Terrain Vehicle Running Smoothly. Handlebar For installation, reverse the removal pro- cedure. Normally check the brake fluid level and add fluid as required.