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Manual Yamaha 4XE-F8197-10

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  • Yamaha 4XE-F8197-10 - page 1

    SERVICE MANUAL LIT -1 1616-12-01 4XE-F8197-10 YFM250XL(C) ...

  • Yamaha 4XE-F8197-10 - page 2

    YFM250XL SERVICE MANUAL  1998 by Yamaha Motor Corporation, U.S.A. First Edition, February1998 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. LIT-11616-12-01 ...

  • Yamaha 4XE-F8197-10 - page 3

    EB001000 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 who uses this book to perform mainte- nance and repairs on Yamaha machine has a basic understanding of the m ...

  • Yamaha 4XE-F8197-10 - page 4

    EB002000 HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual is intended as a handy, easy-to-read reference book for the mechanic. It is divided into chapters, sections and sub-sections. Comprehensive explanations of all installa- tion, removal, disassembly, assembly, repair and inspection procedures are laid out with the individual steps in seq ...

  • Yamaha 4XE-F8197-10 - page 5

    EB003000 ILLUSTRATED SYMBOLS Illustrated symbols 1 to 9 are printed on the top right of each page and indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic inspections and adjustments 4 Engine 5 Carburetion 6 Drive train 7 Chassis 8 Electrical 9 Troubleshooting Illustrated symbols 0 to F are used to identify the sp ...

  • Yamaha 4XE-F8197-10 - page 6

    CHAPTER TITLES GENERAL INFORMATION 1 SPECIFICATIONS SPEC 2 PERIODIC INSPECTION AND ADJUSTMENT 3 ENGINE OVERHAUL ENG 4 CARBURETION CARB 5 DRIVE TRAIN DRIVE 6 CHASSIS CHAS 7 ELECTRICAL ELEC 8 TROUBLESHOOTING 9 GEN INFO INSP ADJ –+ TRBL SHTG ...

  • Yamaha 4XE-F8197-10 - page 7

    CONTENTS CHAPTER 1. GENERAL INFORMATION MACHINE IDENTIFICATION ........................................................................ 1-1 VEHICLE IDENTIFICATION NUMBER .................................................. 1-1 MODEL LABEL ...................................................................................... 1-1 IMPORTANT INFORMATION ...

  • Yamaha 4XE-F8197-10 - page 8

    CHAPTER 3. PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION ........................................................................................... 3-1 PERIODIC MAINTENANCE/LUBRICATION ................................................ 3-1 FENDER AND FUEL TANK ........................................................................... 3-3 FRONT ...

  • Yamaha 4XE-F8197-10 - page 9

    ELECTRICAL ............................................................................................... 3-38 BATTERY INSPECTION ...................................................................... 3-38 FUSE INSPECTION ............................................................................. 3-41 HEADLIGHT BEAM ADJUSTMENT .................. ...

  • Yamaha 4XE-F8197-10 - page 10

    TIMING CHAIN ................................................................................... 4-30 CAM SPROCKET AND CAM DRIVE SPROCKET ............................... 4-31 TIMING CHAIN GUIDE ....................................................................... 4-31 TIMING CHAIN TENSIONER ........................................................ ...

  • Yamaha 4XE-F8197-10 - page 11

    CHAPTER 5. CARBURETION CARBURETOR .............................................................................................. 5-1 REMOVAL ............................................................................................. 5-2 DISASSEMBLY ..................................................................................... 5-2 INSPECTIO ...

  • Yamaha 4XE-F8197-10 - page 12

    CHAPTER 7. CHASSIS FRONT WHEELS AND FRONT BRAKE ....................................................... 7-1 REMOVAL ............................................................................................. 7-2 INSPECTION ......................................................................................... 7-3 INSTALLATION .................. ...

  • Yamaha 4XE-F8197-10 - page 13

    IGNITION SYSTEM ...................................................................................... 8-7 CIRCUIT DIAGRAM .............................................................................. 8-7 TROUBLESHOOTING ........................................................................... 8-8 ELECTRIC STARTING SYSTEM ....................... ...

  • Yamaha 4XE-F8197-10 - page 14

    FAULTY DRIVE TRAIN ................................................................................. 9-3 FAULTY GEAR SHIFTING ............................................................................ 9-4 HARD SHIFTING ................................................................................... 9-4 SHIFT PEDAL DOES NOT MOVE ............... ...

  • Yamaha 4XE-F8197-10 - page 15

    1 - 1 GEN INFO MACHINE IDENTIFICATION GENERAL INFORMATION MACHINE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the left side of the frame. MODEL LABEL The model label 1 is affixed to the frame. This information will be needed to order spare parts. 1 ...

  • Yamaha 4XE-F8197-10 - page 16

    1 - 2 GEN INFO IMPORTANT INFORMATION EB101000 IMPORTANT INFORMATION PREPARATION FOR REMOVAL PROCEDURES 1.Remove all dirt, mud, dust and foreign material before removal and 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 include ...

  • Yamaha 4XE-F8197-10 - page 17

    1 - 3 GEN INFO EB101030 LOCK WASHERS/PLATES AND COTTER PINS 1.Replace all lock washers/plates 1 and cot- ter pins after removal. Bend lock tabs along the bolt or nut flats after the bolt or nut has been tightened to specification. IMPORTANT INFORMATION EB101040 BEARINGS AND OIL SEALS 1.Install bearings and oil seals so that the manufacturer’s mar ...

  • Yamaha 4XE-F8197-10 - page 18

    1 - 4 GEN INFO CHECKING OF CONNECTIONS EB801000 CHECKING OF CONNECTIONS Check the connectors for stains, rust, mois- ture, etc. 1.Disconnect: ● Connector 2.Check: ● Connector Moisture → Dry each terminal with an air blower. Stains/rust → Connect and disconnect the terminals several times. 3.Check: ● Connector leads Looseness → Bend up t ...

  • Yamaha 4XE-F8197-10 - page 19

    1 - 5 GEN INFO SPECIAL TOOLS EB102001 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 by shape and part number from country to count ...

  • Yamaha 4XE-F8197-10 - page 20

    1 - 6 GEN INFO SPECIAL TOOLS 4-B Compression gauge P/N. 90890-03081 Extension P/N. 90890-04082 This gauge is used to measure the engine compression. 5 Fuel level gauge P/N. YM-01312-A P/N. 90890-01312 This gauge is used to measure the fuel level in the float chamber. FOR ENGINE SERVICE 1 Rotor holder P/N. YU-01235 P/N. 90890-01235 This tool is used ...

  • Yamaha 4XE-F8197-10 - page 21

    1 - 7 GEN INFO SPECIAL TOOLS 7-A Slide hammer set P/N. YU-01083-A These tools are used when removing the rocker arm shaft. 7-B Slide hammer bolt (M6) P/N. 90890-01083 Weight P/N. 90890-01084 These tools are used when removing the rocker arm shaft. 8 Valve spring compressor P/N. YM-04019 P/N. 90890-04019 This tool is useed to remove and install the ...

  • Yamaha 4XE-F8197-10 - page 22

    1 - 8 GEN INFO SPECIAL TOOLS 13 Sealant (Quick Gasket  ) P/N. ACC-QUICK-GS-KT YAMAHA bond No. 1215  P/N. 90890-85505 This sealant (bond) is used for crankcase mat- ing surface, etc. FOR DRIVE TRAIN SERVICE 1-A Universal joint holder P/N. YM-04062 Attachment P/N. YM-33291 These tools are used to remove and install the universal joint. 1-B Univ ...

  • Yamaha 4XE-F8197-10 - page 23

    1 - 9 GEN INFO SPECIAL TOOLS FOR CHASSIS SERVICE 1 Yamaha brake grease P/N. 90793-40003 This Yamaha brake grease is used for rear brake dust seal. FOR ELECTRICAL COMPONENTS 1-A Dynamic spark tester P/N. YM-34487 This instrument is necessary for checking the ignition system components. 1-B Ignition checker P/N. 90890-06754 This instrument is necessa ...

  • Yamaha 4XE-F8197-10 - page 24

    GEN INFO 1 - 10 1 ...

  • Yamaha 4XE-F8197-10 - page 25

    GENERAL SPECIFICATIONS SPEC 2 - 1 SPECIFICA TIONS GENERAL SPECIFICA TIONS Item Standard Model code: 4XE1 (USA) 4XE2 (CAL) 4XE3 (CDN) Dimensions: Overall length 1,940 mm (76.4 in) Overall width 1,005 mm (39.6 in) Overall height 1,118 mm (44.0 in) Seat height 780 mm (30.7 in) Wheelbase 1,170 mm (46.1 in) Minimum ground clearance 155 mm (6.1 in) Minim ...

  • Yamaha 4XE-F8197-10 - page 26

    GENERAL SPECIFICATIONS SPEC 2 - 2 Fuel: T ype Unleaded fuel Fuel tank capacity 12 L (2.64 Imp gal, 3.17 US gal) Fuel reserve amount 1.6 L (0.35 Imp gal, 0.42 US gal) Carburetor: T ype / quantity BST34/1 Manufacturer MIKUNI Spark plug: T ype DR7EA Manufacturer NGK Spark plug gap 0.6 ~ 0.7 mm (0.024 ~ 0.028 in) Clutch type W et, centrifugal automatic ...

  • Yamaha 4XE-F8197-10 - page 27

    GENERAL SPECIFICATIONS SPEC 2 - 3 T ire pressure (cold tire): Recommended front 20 kPa (0.20 kg/cm 2 , 2.9 psi) rear 25 kPa (0.25 kg/cm 2 , 3.6psi) Minimum front 17 kPa (0.17 kg/cm 2 , 2.5 psi) rear 22 kPa (0.22 kg/cm 2 , 3.2 psi) Maximum front 23 kPa (0.23 kg/cm 2 , 3.3 psi) rear 28 kPa (0.28 kg/cm 2 , 4.0 psi) Brake: Front brake type Drum brake o ...

  • Yamaha 4XE-F8197-10 - page 28

    MAINTENANCE SPECIFICATIONS SPEC 2 - 4 MAINTENANCE SPECIFICA TIONS ENGINE Item Standard Limit Cylinder head: W arp limit ---- 0.10 mm (0.004 in) Measuring point Lines indicate straight edge measurement. Cylinder: Bore size 70.97 ~ 71.02 mm (2.794 ~ 2.796 in) 71.10 mm (2.799 in) Measuring point 40 mm (1.6 in) ---- Camshaft: Drive method Chain drive ( ...

  • Yamaha 4XE-F8197-10 - page 29

    MAINTENANCE SPECIFICATIONS SPEC 2 - 5 “C” 6.572 ~ 6.692 mm (0.259 ~ 0.263 in) ---- Camshaft runout limit ---- 0.03 mm (0.0012 in) Cam chain: Cam chain type / No. of links DID25SH/104 ---- Cam chain adjustment method Automatic ---- Rocker arm / rocker arm shaft: Rocker arm inside diameter 12.000 ~ 12.018 mm (0.4724 ~ 0.4731 in) Shaft outside dia ...

  • Yamaha 4XE-F8197-10 - page 30

    MAINTENANCE SPECIFICATIONS SPEC 2 - 6 Guide inside diameter IN 6.000~ 6.012mm (0.236 ~ 0.237 in) ---- EX 6.000~ 6.012mm (0.236 ~ 0.237 in) ---- Stem-to-guide clearance IN 0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in) 0.08 mm (0.0031 in) E X 0.025 ~ 0.052 mm (0.001 ~ 0.002 in) 0.10 mm (0.0039 in) Stem runout limit ---- 0.03 mm (0.0012 in) V alve seat width ...

  • Yamaha 4XE-F8197-10 - page 31

    MAINTENANCE SPECIFICATIONS SPEC 2 - 7 Compressed pressure (installed) IN 162.8 ~ 200.1 N (16.6 ~ 20.4 kg, 36.6 ~ 45.0 lb) ---- EX 162.8 ~ 200.1 N (16.6 ~ 20.4 kg, 36.6 ~ 45.0 lb) ---- T ilt limit IN 2.5˚/1.6 mm (2.5˚/0.06 in) E X 2.5˚/1.6 mm (2.5˚/0.06 in) Direction of winding (top view) IN Clockwise ---- EX Clockwise ---- Piston: Piston to cyl ...

  • Yamaha 4XE-F8197-10 - page 32

    MAINTENANCE SPECIFICATIONS SPEC 2 - 8 Side clearance (installed) 0.03 ~ 0.07 mm (0.001 ~ 0.003 in) 0.12 mm (0.005 in) 2nd ring: T ype T aper ---- Dimensions (B × T) 1.2 × 2.8 mm (0.047 ~ 0.110 in) ---- End gap (installed) 0.15 ~ 0.30 mm (0.006 ~ 0.012 in) 0.4 mm (0.016 in) Side clearance 0.02 ~ 0.06 mm (0.0008 ~ 0.0024 in) 0.12 mm (0.005 in) Oil ...

  • Yamaha 4XE-F8197-10 - page 33

    MAINTENANCE SPECIFICATIONS SPEC 2 - 9 Clutch plate Thickness 1.45 ~ 1.75mm (0.057 ~ 0.069 in) 0.2 mm (0.008 in) Quantity 4 pcs. ---- Clutch spring Free length 35.1 mm (1.38 in) 32.9 mm (1.30 in) Quantity 4 pcs. ---- Clutch release method Outer push, cam push ---- Automatic centrifugal clutch: Clutch shoe: Thickness 2.0 mm (0.08 in) 1.5 mm (0.06 in) ...

  • Yamaha 4XE-F8197-10 - page 34

    MAINTENANCE SPECIFICATIONS SPEC 2 - 10 Lubrication system: Oil filter type Wire mesh ---- Oil pump type T rochoid type ---- T ip clearance “A” or “B” 0.15 mm (0.006 in) 0.20 mm (0.008 in) Side clearance 0.04 ~ 0.09 mm (0.002 ~ 0.004 in) 0.09 mm (0.004 in) Bypass valve setting pressure 80 ~ 120 kPa (0.8 ~ 1.2 kg/cm 2 , 11 ~ 17 psi) ---- Sha ...

  • Yamaha 4XE-F8197-10 - page 35

    MAINTENANCE SPECIFICATIONS SPEC 2 - 11 Item Standard Lubrication chart: Crankcase tightening sequence: Crankcase (left) Crankcase (right) 2 ...

  • Yamaha 4XE-F8197-10 - page 36

    MAINTENANCE SPECIFICATIONS SPEC 2 - 12 Tightening torques Part to be tightened Part name Thread size Q’ ty Tightening torque Remarks Nm m·kg ft·lb Cylinder head (oil gallery plug) Bolt M6 1 7 0.7 5.1 Cylinder head Flange bolt M8 4 22 2.2 16 E Apply oil to the washer Cylinder head and Cylinder Bolt M8 2 22 2.2 16 Cam sprocket cover Screw M6 2 7 ...

  • Yamaha 4XE-F8197-10 - page 37

    MAINTENANCE SPECIFICATIONS SPEC 2 - 13 Lock nut (clutch release adjuster) Nut M8 1 15 1.5 11 Starter clutch Bolt M8 3 30 3.0 22 LT Stake Starter motor Screw M6 2 7 0.7 5.1 Pinion gear (drive axle) Nut M16 1 60 6.0 43 Stake Bearing retainer (drive axle) Screw M8 3 25 2.5 18 LT Bearing retainer (bearing housing) Nut – 1 60 6.0 43 LT Nut – 1 60 6. ...

  • Yamaha 4XE-F8197-10 - page 38

    MAINTENANCE SPECIFICATIONS SPEC 2 - 14 CHASSIS Item Standard Limit Steering system: Steering bearing type Ball bearing ---- Front suspension: Shock absorber travel 117 mm (4.61 in) ---- Suspension spring free length 293 mm (11.54 in) ---- Spring rate (K1) 10 N/mm (1.0 kg/mm, 56 lb/in)/ 0 ~ 117 mm (0 ~ 4.61 in) ---- Optional spring No ---- Rear susp ...

  • Yamaha 4XE-F8197-10 - page 39

    MAINTENANCE SPECIFICATIONS SPEC 2 - 15 Front drum brake: T ype Leading and trailing ---- Drum inside diameter 160 mm (6.30 in) 161 mm (6.34 in) Lining thickness 4.0 mm (0.16 in) 2.0 mm (0.08 in) Shoe spring free length 71.0 mm (2.80 in) ---- Rear drum brake: T ype Leading and trailing ---- Drum inside diameter 160 mm (6.30 in) 161 mm (6.34 in) Lini ...

  • Yamaha 4XE-F8197-10 - page 40

    MAINTENANCE SPECIFICATIONS SPEC 2 - 16 Tightening torques Part to be tightened Parts name Thread size Q’ ty Tightening torque Remarks Nm m·kg ft·lb Front panel wheel and brake drum Nu t M10 × 1.25 8 55 5.5 40 Front brake drum and steering knuckle Nut M14 × 1.5 2 70 7.0 50 Front brake cam lever and cam shaft Bolt M6 × 1.0 2 9 0.9 6.5 Steering ...

  • Yamaha 4XE-F8197-10 - page 41

    MAINTENANCE SPECIFICATIONS SPEC 2 - 17 Pivot shaft and nut (right) Nut M22 × 1.5 1 130 13 94 Swingarm and final drive gear case Nut M8 × 1.25 4 48 4.8 35 LT Rear axle housing and final drive gear case Bolt M10 × 1.25 4 55 5.5 40 Rear shock absorber (upper) and frame Nut M12 × 1.25 1 50 5.0 36 Final drive gear case protector Bolt M8 × 1.25 2 17 ...

  • Yamaha 4XE-F8197-10 - page 42

    MAINTENANCE SPECIFICATIONS SPEC 2 - 18 ELECTRICAL Item Standard Limit V oltage: 12 V ---- Ignition system: Ignition timing (B.T .D.C.) 10˚/ 1,000 r/min ---- Advanced timing (B.T .D.C.) 30˚/ 6,000 r/min ---- Advancer type Electrical ---- C.D.I.: Magneto model / manufacturer F4T203/MITSUBISHI ---- Pickup coil resistance / color 189 ~ 231 Ω at 20? ...

  • Yamaha 4XE-F8197-10 - page 43

    MAINTENANCE SPECIFICATIONS SPEC 2 - 19 Withstand voltage 200 V ---- Battery: Specific Gravity 1.280 Electric starter system: T ype Constant mesh type ---- Starter motor: Model / manufacturer SM-14/MITSUBA ---- Output 0.5 kW ---- Armature coil resistance 0.004 ~ 0.005 Ω at 20˚C (68˚F) ---- Brush overall length 10 mm (0.4 in) 3.5 mm (0.14 in) Sp ...

  • Yamaha 4XE-F8197-10 - page 44

    2 - 20 SPEC HOW TO USE THE CONVERSION TABLE/ GENERAL TORQUE SPECIFICATIONS EB201000 HOW TO USE THE CONVERSION TABLE All specification data in this manual are listed in SI and METRIC UNITS. Use this table to convert METRIC unit data to IMPERIAL unit data. Ex. CONVERSION TABLE METRIC MULTIPLIER IMPERIAL ** mm × 0.03937 = ** in 2 mm × 0.03937 = 0.08 ...

  • Yamaha 4XE-F8197-10 - page 45

    2 - 21 SPEC LUBRICATION POINTS AND LUBRICANT TYPES LUBRICATION POINTS AND LUBRICANT TYPES ENGINE Lubrication points (parts name) Lubricant type Oil seal lips (all) LS O-rings (all) LS Bearings (all) E Washer (cylinder head bolt) E Crank pin E Connecting rod (big end) E Piston and piston pin E Piston and piston ring E Buffer boss E Valve stem and va ...

  • Yamaha 4XE-F8197-10 - page 46

    2 - 22 SPEC CHASSIS Lubrication points Lubricant type Oil seal lips (all)/O-rings (all) LS Steering shaft (Upper and lower with nipple bushes) LS Steering knuckle pivot LS Front lower arm (ball joint) LS Front wheel bearings B Front drum brake: Brake cam shaft Pivot pin Oil seal lips LS Rear drum brake: Brake cam shaft Pivot pin LS Dust seal (rear ...

  • Yamaha 4XE-F8197-10 - page 47

    2 - 23 SPEC LUBRICATION DIAGRAMS LUBRICATION DIAGRAMS 1 Drain plug 2 O-ring 3 Compression spring 4 Oil strainer 5 Oil pump gasket 6 Oil pump assembly 7 Oil pump driven gear 8 Oil pump drive gear 9 Camshaft 0 Crank pin A Crankshaft B Main axle C Drive axle D Oil filter 2 ...

  • Yamaha 4XE-F8197-10 - page 48

    2 - 24 SPEC LUBRICATION DIAGRAMS 1 Bypass valve 2 Oil filter 3 Oil filter cover 4 O-ring 5 Collar 6 Camshaft 7 Rocker arm 8 One way bearing (Automatic centrifugal clutch) 9 Crank pin 0 Crankshaft A Main axle B Drive axle 2 ...

  • Yamaha 4XE-F8197-10 - page 49

    2 - 25 SPEC CABLE ROUTING CABLE ROUTING 1 Rear brake lever switch lead 2 Rear brake cable 3 Cable guide 4 Front brake cable 5 Throttle cable 6 Neutral indicator light 7 Reverse indicator light 8 Handlebar switch assembly lead 9 Fuel tank breather hose 0 Headlight leads A Equalizer B Front brake breather hose Å Do not route the handlebar switch ass ...

  • Yamaha 4XE-F8197-10 - page 50

    2 - 26 SPEC CABLE ROUTING 1 Cable guide 2 Main switch 3 Fuel tank breather hose 4 Rectifier/regulator 5 CDI unit 6 Taillight 7 Final gear case breather hose 8 Carburetor overflow hose 9 Reverse switch lead 0 Neutral switch lead A Starter motor lead B Throttle cable C Rear brake cable D Rear brake breather hose E Carburetor air vent hose F CDI magne ...

  • Yamaha 4XE-F8197-10 - page 51

    2 - 27 SPEC CABLE ROUTING Î Route the carburetor overflow hose between the engine and upper rear engine mount and then between the engine and swingarm. Make sure that the hose is not pinched. ‰ Bend the cable guide after routing the cables. Ï Fasten the starter motor lead and wire har- ness to the frame with the plastic clamp. Ì Route the rear ...

  • Yamaha 4XE-F8197-10 - page 52

    2 - 28 SPEC CABLE ROUTING 1 Battery breather hose 2 Spark plug cap 3 Ignition coil 4 Starter motor lead 5 Rear brake cable 6 Rear brake breather hose Å Make sure that the battery breather hose is not kinked or bent. ı Route the rear brake cable through the cable guide on the cyl- inder. Ç Fasten the starter motor lead to the frame with the metal ...

  • Yamaha 4XE-F8197-10 - page 53

    2 - 29 SPEC CABLE ROUTING 1 Wire harness 2 Starter motor lead 3 Rear brake cable 4 Throttle cable 5 Starter relay 6 Starting circuit cut-off relay 7 Rear brake breather hose 8 Carburetor air vent hose 9 Final gear case breather hose 0 Taillight lead Å 50 mm (2.0 in) ı Route the throttle cable and rear brake cable through the cable guide. Make sur ...

  • Yamaha 4XE-F8197-10 - page 54

    2 - 30 SPEC 2 ...

  • Yamaha 4XE-F8197-10 - page 55

    INSP ADJ 3 - 1 INTRODUCTION/ PERIODIC MAINTENANCE/LUBRICATION PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjustments. These preventive maintenance procedures, if followed, will ensure more reli- able machine operation and a longer service life. In addition ...

  • Yamaha 4XE-F8197-10 - page 56

    INSP ADJ 3 - 2 *: It is recommended that these items be serviced by a Yamaha dealer. **: Lithium soap base grease. W ARNING Indicates a potential hazard that could result in serious injury or death. Steering shaft* • Lubricate every 6 months.** Fittings and Fasten- ers* • Check all chassis fittings and fasteners. • Correct if necessary. Batte ...

  • Yamaha 4XE-F8197-10 - page 57

    3 - 3 INSP ADJ FRONT FENDER FENDER AND FUEL TANK FRONT FENDER Removal 1.Place the machine on a level place. 2.Remove: ● Front carrier 1 3.Remove: ● Front bumper skid plate 1 4.Disconnect: ● Dual headlight leads 1 5.Remove: ● Front bumper 2 6.Remove: ● Front fender 1 3 ...

  • Yamaha 4XE-F8197-10 - page 58

    3 - 4 INSP ADJ FRONT FENDER Installation: Reverse the “Removal” procedures. Note the following points. 1.Install: ● Front fender 1 T R . . Bolt 2 (front fender and frame): 7 Nm (0.7 m • kg, 5.1 ft • lb) Nut 3 (front fender and fender stay): 7 Nm (0.7 m • kg, 5.1 ft • lb) 2.Install: ● Front bumper 1 T R . . Bolt (front bumper and fra ...

  • Yamaha 4XE-F8197-10 - page 59

    3 - 5 INSP ADJ REAR FENDER REAR FENDER Removal 1.Place the machine on a level place. 2.Remove: ● Rear carrier 1 2 with spacer 3.Remove: ● Seat 1 Pull up the seat lock lever 2 , then pull up the seat at the rear. 4.Disconnect: ● Battely leads (negative and positive) W ARNING Disconnect the negative lead 1 first. 5.Remove: ● Starter relay 2 ? ...

  • Yamaha 4XE-F8197-10 - page 60

    3 - 6 INSP ADJ REAR FENDER Installation Reverse the “Removal” procedure. Note the following points. 1.Install: ● Rear fender 1 T R . . Bolt 2 (rear fender and frame): 7 Nm (0.7 m • kg, 5.1ft • lb) Bolt 3 (rear fender and rear foot- rest plate): 7 Nm (0.7 m • kg, 5.1ft • lb) 2.Install: ● Battery 1 ● Battery breather hose 2 ● Batt ...

  • Yamaha 4XE-F8197-10 - page 61

    3 - 7 INSP ADJ REAR FENDER/FUEL TANK 6.Install: ● Rear carrier 1 NOTE: Do not forget to attach the spacer at the point where the carrier and bumper are connected. T R . . Bolt 2 (rear carrier and frame): 34 Nm (3.4 m • kg, 25 ft • lb) Bolt 3 (rear carrier and rear bumper): 9 Nm (0.9 m • kg, 6.5 ft • lb) FUEL TANK Removal 1.Place the machi ...

  • Yamaha 4XE-F8197-10 - page 62

    3 - 8 INSP ADJ FUEL TANK 6.Turn the fuel cock lever to “OFF” position. 7.Disconnect: ● Fuel hose 1 NOTE: Place a rug on the engine to absorb a spilt fuel. W ARNING ● Gasoline is highly flammable. ● Avoid spilling fuel on the hot engine. 8.Remove: ● Bolt 1 (with washer and collar) 9.Disconnect: ● Air duct 2 (with hoses) ● Grommet 3 ( ...

  • Yamaha 4XE-F8197-10 - page 63

    3 - 9 INSP ADJ FUEL TANK 4.Install: ● Fuel tank cover 1 ● Fuel tank cap 2 ● Rivet 3 ● Screw 4 ● Bolt 5 (with flange collar) T R . . Bolt (fuel tank cover and frame): 10 Nm (1.0 m • kg, 7.2 ft • lb) 5.Connect: ● Breather hose 1 6.Install: ● Seat Refer to the “REAR FENDER-Installation” section. 3 ...

  • Yamaha 4XE-F8197-10 - page 64

    3 - 10 INSP ADJ ENGINE VALVE CLEARANCE ADJUSTMENT NOTE: ● The valve clearance must be adjusted when the engine is cool to the touch. ● Adjust the valve clearance when the pis- ton is at the Top Dead Center (T.D.C.) on compression stroke. Removal 1.Place the machine on a level place. 2.Remove: ● Seat ● Fuel tank cover ● Fuel tank Refer to ...

  • Yamaha 4XE-F8197-10 - page 65

    3 - 11 INSP ADJ VALVE CLEARANCE ADJUSTMENT ● Align the “T” mark 1 on the flywheel with the stationary pointer 2 on the crankcase cover. When the “T” mark is aligned with the stationary pointer, the piston is at Top Dead Center (TDC). NOTE: T.D.C. on compression stroke check: ● Both rocker arms must have a valve clear- ance when the roto ...

  • Yamaha 4XE-F8197-10 - page 66

    3 - 12 INSP ADJ VALVE CLEARANCE ADJUSTMENT/ TIMING CHAIN TENSIONER ADJUSTMENT ● Once again, measure the valve clearance. ● If the clearance is incorrect, repeat above steps until the proper clearance is obtained. ********************************** Installation Reverse the “Removal” procedure. Note the following points. 1.Install: ● Tappet ...

  • Yamaha 4XE-F8197-10 - page 67

    3 - 13 INSP ADJ IDLE SPEED ADJUSTMENT 1.Place the machine on a level place. 2.Warm up engine for several minutes. 3.Adjust: ● Engine idle speed ********************************** Adjustment steps: ● Turn the pilot screw 1 clockwise until it is lightly seated. ● Loosen the pilot screw by turning it coun- terclockwise for the specified number o ...

  • Yamaha 4XE-F8197-10 - page 68

    3 - 14 INSP ADJ THROTTLE CABLE FREE PLAY ADJUSTMENT NOTE: Before adjusting the throttle cable free play, the engine idle speed should be adjusted. 1.Place the machine on a level place. 2.Check: ● Throttle cable free play a Out of specification → Adjust. Throttle cable free play: 3 ~ 5mm (0.12 ~ 0.20 in) a 3.Adjust: ● Throttle cable free play ...

  • Yamaha 4XE-F8197-10 - page 69

    3 - 15 INSP ADJ W ARNING After adjusting the free play, turn the han- dlebar to right and left, and make sure that the engine idling does not run faster. ********************************** SPEED LIMITER ADJUSTMENT The speed limiter keeps the carburetor throttle from becoming full-open even when the throttle lever is pushed to a maxi- mum. Screwing ...

  • Yamaha 4XE-F8197-10 - page 70

    3 - 16 INSP ADJ 3.Inspect: ● Spark plug type Incorrect → Replace. Standard spark plug: DR7EA (NGK) SPARK PLUG INSPECTION 4.Inspect: ● Electrode 1 Wear/Damage → Replace. ● Insulator color 2 Normal condition is a medium to light tan color. Distinctly different color → Check the engine condition. 5.Clean: ● Spark plug Clean the spark plu ...

  • Yamaha 4XE-F8197-10 - page 71

    3 - 17 INSP ADJ IGNITION TIMING CHECK NOTE: Engine idling speed and throttle cable free play should be adjusted properly before checking the ignition timing. 1.Place the machine on a level place. 2.Start the engine and let it warm up for several minutes, then stop the engine. 3.Attach: ● Inductive tachometer ● Timing light to spark plug lead. I ...

  • Yamaha 4XE-F8197-10 - page 72

    3 - 18 INSP ADJ IGNITION TIMING CHECK/ COMPRESSION PRESSURE MEASUREMENT 5.Install: ● Timing plug 6.Detach: ● Timing light ● Inductive tachometer COMPRESSION PRESSURE MEASUREMENT NOTE: ● Insufficient compression pressure will result in performance loss. ● Before measuring the compression pres- sure, the valve clearance should be adjusted. ...

  • Yamaha 4XE-F8197-10 - page 73

    3 - 19 INSP ADJ COMPRESSION PRESSURE MEASUREMENT/ ENGINE OIL LEVEL INSPECTION ● If pressure falls below the minimum level: 1) Squirt a few drops of oil into the affected cylinder. 2) Measure the compression again. ● Remove the compression gauge. ********************************** 4.Install: ● Spark plug Refer to “SPARK PLUG INSPECTION” se ...

  • Yamaha 4XE-F8197-10 - page 74

    3 - 20 INSP ADJ ENGINE OIL LEVEL INSPECTION/ ENGINE OIL REPLACEMENT ● Screw the dipstick 1 completely out, and wipe the dipstick clean, then just rest the dipstick in the hole. ● Pull up the dipstick, and inspect the oil level whether or not it is between maxi- mum 2 and minimum level 3 . ● If the level is lower, add the oil up to the proper ...

  • Yamaha 4XE-F8197-10 - page 75

    3 - 21 INSP ADJ ENGINE OIL REPLACEMENT 6.Inspect: ● O-rings 1 ● Compression spring 2 ● Oil strainer 3 ● Oil filter 4 Damage → Replace. 7.Clean: ● Compression spring 2 ● Oil strainer 3 ● Oil filter 4 ● Drain plug 5 (crankcase) ● Oil filter cover 6 Wash them with a cleaning solvent. 8.Apply: ● Engine oil (light coating) (to the ...

  • Yamaha 4XE-F8197-10 - page 76

    3 - 22 INSP ADJ ENGINE OIL REPLACEMENT 11.Install: ● Dipstick 12.Warm up the engine for 5 minutes or more, and stop it. 13.Inspect: ● Oil leaks ● Oil level 14.Inspect: ● Oil flow ********************************** Inspection steps: ● Slightly loosen the oil gallery plug 1 in the cylinder head. ● Start the engine and keep it idling until ...

  • Yamaha 4XE-F8197-10 - page 77

    3 - 23 INSP ADJ CLUTCH ADJUSTMENT/AIR FILTER CLEANING CLUTCH ADJUSTMENT Release lever free play adjustment 1.Adjust: ● Release lever free play ********************************** Adjustment steps: ● Loosen the locknut 1 . ● Slowly turn the adjuster 2 counterclock- wise until resistance is felt, then turn back it 1/8 clockwise, hold the adjuste ...

  • Yamaha 4XE-F8197-10 - page 78

    3 - 24 INSP ADJ AIR FILTER CLEANING 3.Remove: ● Air filter element 1 ● Foam cover 2 CAUTION: The engine should never be run without the air filter; excessive piston and/or cylin- der wear may result. 4.Inspect: ● Air filter element 1 ● Foam cover 2 Damage → Replace. 5.Clean: ● Air filter element Use compressed air to blow off dust from ...

  • Yamaha 4XE-F8197-10 - page 79

    3 - 25 INSP ADJ AIR FILTER CLEANING 7.Install: ● Foam cover (to air filter) 8.Install: ● Air filter assembly NOTE: Make sure its sealing surface matches the sealing surface of the case so there is no air leak. 9.Install: ● Cover (air filter case) ● Seat Refer to “REAR FENDER-Installation” sec- tion. 3 ...

  • Yamaha 4XE-F8197-10 - page 80

    3 - 26 INSP ADJ FRONT AND REAR BRAKE LINING INSPECTION/ FRONT BRAKE ADJUSTMENT CHASSIS FRONT AND REAR BRAKE LINING INSPECTION Front brake 1.Apply the front brake. 2.Inspect: ● Wear indicator 1 Indicator reaches the wear limit mark 2 → Replace brake shoes as a set. Refer to the “FRONT WHEEL AND FRONT BRAKE” section in CHAPTER 7. Rear brake 1 ...

  • Yamaha 4XE-F8197-10 - page 81

    3 - 27 INSP ADJ FRONT BRAKE ADJUSTMENT/ REAR BRAKE LEVER AND PEDAL ADJUSTMENT 2.Adjust: ● Front brake lever free play ********************************** Adjustment steps: ● Loosen the locknut 1 and turn the adjuster 2 clockwise to release the ten- sion in the front brake cable. ● Visually check the cable joint 3 in the equalizer 4 to verify i ...

  • Yamaha 4XE-F8197-10 - page 82

    3 - 28 INSP ADJ REAR BRAKE LEVER AND PEDAL ADJUSTMENT 2.Adjust: ● Brake lever free play ● Brake pedal free play ********************************** Adjustment steps: NOTE: Before adjusting the free play, pump the brake pedal 2 to 3 times. ● Fully loosen the locknut 1 (handlebar) and fully turn in the brake lever adjuster 2 . ● Fully loosen b ...

  • Yamaha 4XE-F8197-10 - page 83

    3 - 29 INSP ADJ DRIVE SELECT LEVER POSITION ADJUSTMENT/ FINAL DRIVE GEAR OIL LEVEL INSPECTION DRIVE SELECT LEVER POSITION ADJUSTMENT 1.Adjust: ● Drive select lever position ********************************** Adjustment steps: ● Place the machine on a level place. ● Shift the transmission in first gear, and move the select lever 1 to reverse p ...

  • Yamaha 4XE-F8197-10 - page 84

    3 - 30 INSP ADJ ● If the oil level is low, add the recom- mended oil up to the specified level. Refer to “FINAL DRIVE GEAR OIL REPLACE- MENT” section. ● Inspect the copper washer for damage. If damaged, replace it ● Install the copper washer and filler bolt. NOTE: ● Before installing the filler bolt, do not for- get to fit the copper wa ...

  • Yamaha 4XE-F8197-10 - page 85

    3 - 31 INSP ADJ FINAL DRIVE GEAR OIL REPLACEMENT/DRIVE SHAFT DUST BOOT INSPECTION/STEERING SYSTEM INSPECTION 7.Install: ● Filler bolt (final drive gear case) NOTE: After filling the oil, inspect the oil leaks. Recommended oil: SAE 80 API “GL-4” hypoid gear oil If desired, and SAE 80W90 hypoid gear oil may be used for all condition. Periodic o ...

  • Yamaha 4XE-F8197-10 - page 86

    3 - 32 INSP ADJ STEERING SYSTEM INSPECTION/ TOE-IN ADJUSTMENT 4.Raise the front end of the machine so that there is no weight on the front wheels. 5.Check: ● Knuckles and/or wheel bearings Move the wheels laterally back and forth. Excessive free play → Replace the follow- ing parts. 1) Wheel bearings 2) Knuckle shaft(s) 1 3) Cotter pin(s) 2 4) ...

  • Yamaha 4XE-F8197-10 - page 87

    3 - 33 INSP ADJ TOE-IN ADJUSTMENT ● If the toe-in is incorrect, adjust the toe-in. ********************************** Toe-in: 0 ~ 5 mm (0 ~ 0.2 in) 3.Adjust: ● Toe-in ********************************** Adjustment steps: ● Place a confirmation marks 1 on the both tie-rods end. ● Loosen the rod end locknuts 2 of both tie- rods. ● The same n ...

  • Yamaha 4XE-F8197-10 - page 88

    3 - 34 INSP ADJ TOE-IN ADJUSTMENT/FRONT AND REAR SHOCK ABSORBERS INSPECTION/REAR SHOCK ABSORBER ADJUSTMENT FRONT AND REAR SHOCK ABSORBERS INSPECTION 1.Place the machine on a level place. 2.Check: ● Ball joint complete 1 (front) Cracks/Damage → Replace as a set. ● Damper rod 2 (rear) Scratch/Damage → Replace as a set. ● Oil leakage 3 Exces ...

  • Yamaha 4XE-F8197-10 - page 89

    3 - 35 INSP ADJ TIRE INSPECTION TIRE INSPECTION W ARNING This model is equipped with low pressure tires. It is important that they be inflated correctly and maintained at the proper pressures. ● TIRE CHARACTERISTICS 1) Tire characteristics influence the han- dling of ATV’s. The tires listed below have been approved by Yamaha Motor Co., Ltd. for ...

  • Yamaha 4XE-F8197-10 - page 90

    3 - 36 INSP ADJ TIRE INSPECTION 1.Measure: ● Tire pressure (cold tire pressure) Out of specification → Adjust. NOTE: ● The Low-pressure tire gauge 1 is included in the standard equipment. ● If dust or the like is stuck to this gauge, it does not provide correct readings. There- fore, make two measurements on the tire pressure and get the se ...

  • Yamaha 4XE-F8197-10 - page 91

    3 - 37 INSP ADJ WHEEL INSPECTION WHEEL INSPECTION 1.Inspect: ● Wheels 1 Cracks/Bends/Damage → Replace. NOTE: Always balance the wheel when a tire or wheel has been changed or replaced. W ARNING Never attempt even small repairs to the wheel. 3 ...

  • Yamaha 4XE-F8197-10 - page 92

    3 - 38 INSP ADJ ELECTRICAL BATTERY INSPECTION W ARNING Battery electrolyte is dangerous; it contains sulfuric acid and therefore is poisonous and highly caustic. Always follow these preventive measures: ● Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury. ● Wear protective eye gear when handling or worki ...

  • Yamaha 4XE-F8197-10 - page 93

    3 - 39 INSP ADJ BATTERY INSPECTION 4.Inspect: ● Battery fluid level Battery fluid level low → Fill. Fluid level should be between upper level 1 and lower level 2 marks. CAUTION: Refill with distilled water only; tap water contains minerals harmful to a battery. 5.Inspect: ● Battery fluid specific gravity Out of specification → Charge. ***** ...

  • Yamaha 4XE-F8197-10 - page 94

    3 - 40 INSP ADJ BATTERY INSPECTION 7.Inspect: ● Battery breather hose Obstruction → Remove. Damage → Replace. 8.Install: ● Battery 1 ● Battery breather hose 2 Refer to the “CABLE ROUTING” section in CHAPTER 2. CAUTION: When installing the battery, be sure the breather hose is routed correctly. If the breather hose touches the frame or ...

  • Yamaha 4XE-F8197-10 - page 95

    3 - 41 INSP ADJ FUSE INSPECTION FUSE INSPECTION CAUTION: Don’t forget to turn off the main switch when checking or replacing the fuse. Other- wise, it may cause accidental shortcircuit- ing. W ARNING Do not use fuses of a higher amperage rat- ing than those recommended. Substitu- tion of a fuse of improper rating can cause extensive electrical sy ...

  • Yamaha 4XE-F8197-10 - page 96

    3 - 42 INSP ADJ FUSE INSPECTION/HEADLIGHT BEAM ADJUSTMENT/ HEADLIGHT BULB REPLACEMENT 4.Replace: ● Blown fuse ********************************** Blown fuse replacement steps: ● Turn off ignition and the circuit. ● Install a new fuse of proper amperage. ● Turn on the switches and see if the electri- cal device operates. ● Fuse interrupts t ...

  • Yamaha 4XE-F8197-10 - page 97

    3 - 43 INSP ADJ HEADLIGHT BULB REPLACEMENT 5.Remove: ● Bulb 1 W ARNING Keep flammable products or your hands away from the bulb while it is on, it will be hot. Do not touch the bulb until it cools down. 6.Install: ● Bulb 1 (new) NOTE: Make sure the projection 2 on the bulb is meshed with the slot 3 on the light case. CAUTION: Avoid touching gla ...

  • Yamaha 4XE-F8197-10 - page 98

    INSP ADJ 3 - 44 3 ...

  • Yamaha 4XE-F8197-10 - page 99

    4 - 1 ENG ENGINE REMOVAL ENGINE OVERHAUL ENGINE REMOVAL NOTE: ● It is not necessary to remove the engine in order to remove the following compo- nents: * Cylinder head * Cylinder * Piston * Primary and secondary clutches * Oil pump * Shift shaft * CDI Magneto ● It is necessary to remove the rear wheel drive assembly in order to remove the engin ...

  • Yamaha 4XE-F8197-10 - page 100

    4 - 2 ENG ENGINE REMOVAL ENGINE OIL 1.Drain: ● Engine oil Refer to the “ENGINE OIL REPLACE- MENT” section in CHAPTER 3. EXHAUST PIPE AND MUFFLER 1.Remove: ● Exhaust pipe 1 ● Muffler 2 CARBURETOR 1.Drain: ● Fuel (float chamber) NOTE: Place a rag under the over flow hose to absorb a spilt fuel. W ARNING Gasoline is highly flammable. Avoid ...

  • Yamaha 4XE-F8197-10 - page 101

    4 - 3 ENG ENGINE REMOVAL STARTER MOTOR 1.Disconnect: ● Starter motor lead 1 2.Remove: ● Starter motor bracket 2 ● Starter motor 3 REAR BRAKE CABLES AND FOOTREST 1.Remove: ● Adjusters 1 (brake lever and brake pedal) ● Pins 2 ● Springs 3 2.Disconnect: ● Brake cable 4 (from brake cable bracket 5 . 3.Remove: ● Footrest 1 (left) ● Shif ...

  • Yamaha 4XE-F8197-10 - page 102

    4 - 4 ENG ENGINE REMOVAL REAR WHEEL DRIVE ASSEMBLY AND SWINGARM 1.Disconnect: ● Breather hose 1 (final gear housing and rear brake drum) (from the cable guides 2 of main frame) 2.Block the front wheels, and elevate the rear wheels by placing the suitable stand under the frame. 3.Remove: ● Bolt 1 (rear shock absorber-top) 4.Remove: ● Clamps 1 ...

  • Yamaha 4XE-F8197-10 - page 103

    4 - 5 ENG ENGINE DISASSEMBLY ENGINE DISASSEMBLY CYLINDER HEAD ASSEMBLY, CYLINDER AND PISTON NOTE: With the engine mounted cylinder head assembly, cylinder and piston can be main- tained by removing the following parts. ● Fuel tank ● Exhaust pipe ● Carburetor ● Engine stays (top) 1.Remove: ● Recoil starter assembly 1 2.Remove: ● Timing p ...

  • Yamaha 4XE-F8197-10 - page 104

    4 - 6 ENG ENGINE DISASSEMBLY 5.Align: ● “T” mark on the rotor With the stationary pointer on the crank- case cover. ********************************* TDC alignment steps: ● Turn the crankshaft counterclockwise with wrench. ● Align the “T” mark 1 on the rotor with the stationary pointer 2 on the crankcase cover. When the “T” mark i ...

  • Yamaha 4XE-F8197-10 - page 105

    4 - 7 ENG ENGINE DISASSEMBLY 8.Remove: ● Bolt 1 ● Cam sprocket 2 NOTE: ● Fasten a safety wire 3 to the timing chain to prevent if from falling into the crank- case. ● When removing the cam sprocket, it is not necessary to separate the timing chain. ● Hold the starter pulley 4 by the Rotor Holder to loosen the bolt on the cam sprocket. Rot ...

  • Yamaha 4XE-F8197-10 - page 106

    4 - 8 ENG ENGINE DISASSEMBLY 11.Remove: ● Bolts 1 (cylinder) ● Cylinder 2 ● Gasket 3 (cylinder) ● Dowel pins 4 ● O-ring 5 12.Remove: ● Piston pin clip 1 ● Piston pin 2 ● Piston 3 NOTE: ● Before removing the piston pin clip, cover the crankcase with a clean rag so you will not accidentally drop the clip into the crankcase. ● Befo ...

  • Yamaha 4XE-F8197-10 - page 107

    4 - 9 ENG ENGINE DISASSEMBLY 1.Remove: ● Starter pulley 1 NOTE: Hold the starter pulley by the Rotor Holder to loosen the bolt on the starter pulley. Rotor holder: P/N. YU-01235, 90890-01235 2.Remove: ● Crankcase cover 1 3.Remove: ● Gasket 1 ● Dowel pins 2 ● Shaft 3 ● Washer 4 ● Idle gear 5 (starter) 4.Remove: ● CDI magneto 1 NOTE: ...

  • Yamaha 4XE-F8197-10 - page 108

    4 - 10 ENG ENGINE DISASSEMBLY 5.Remove: ● Woodruff key 1 ● Driven gear 2 (starter) ● Washer 3 6.Remove: ● Chain guide 1 (intake) ● Timing chain 2 MIDDLE DRIVEN PINION GEAR 1.Remove: ● Bolts 1 (bearing housing) 2.Remove: ● Bolts 1 (middle gear case cover) ● Middle gear case cover 2 3.Remove: ● Middle driven pinion gear assembly 1 ? ...

  • Yamaha 4XE-F8197-10 - page 109

    4 - 11 ENG ENGINE DISASSEMBLY PRIMARY AND SECONDARY CLUTCHES NOTE: With the engine mounted, the primary and secondary clutches can be maintained by removing the following parts: ● Starter motor ● Crankcase cover (right) 1.Remove: ● Oil filter cover 1 ● Oil filter 2 ● O-ring 3 ● Clutch cover protector 4 ● Crankcase cover 5 (right) ● ...

  • Yamaha 4XE-F8197-10 - page 110

    4 - 12 ENG ENGINE DISASSEMBLY 5.Remove: ● Lock washer 1 ● Clutch carrier assembly 2 ● Washer 3 ● Clutch housing 4 (primary) ● Washer 5 NOTE: The secondary clutch housing has two grooves 1 machined into it to permit the primary drive gear behind the primary clutch to clear the secondary clutch. Align one of these grooves with the primary g ...

  • Yamaha 4XE-F8197-10 - page 111

    4 - 13 ENG ENGINE DISASSEMBLY 9.Straighten: ● Lock washer tab 1 (clutch boss) 10.Remove: ● Nut 2 (clutch boss) NOTE: Hold the clutch boss 3 by the Rotor Holder 4 to loosen the nut. 11.Remove: ● Lock washer 1 ● Clutch boss 2 ● Friction plates 3 ● Clutch plates 4 ● Pressure plate 5 ● Washer 6 ● Clutch housing 7 OIL PUMP AND SHIFTER ...

  • Yamaha 4XE-F8197-10 - page 112

    4 - 14 ENG ENGINE DISASSEMBLY 3.Remove: ● Shift lever assembly 1 ● Washer 2 ● Return spring 3 ● Stopper lever 4 ● Washer 5 NOTE: Push the shift pawl and the stopper lever to the arrow direction and remove them from the segment. 4.Remove: ● Segment 1 (shift cam) Use the Torx  wrench to remove. NOTE: When removing the segment, the dowe ...

  • Yamaha 4XE-F8197-10 - page 113

    4 - 15 ENG ENGINE DISASSEMBLY 3.Remove: ● Lock washer 1 ● Balancer gear 2 (driven) ● Straight key 3 CRANKCASE (LEFT) 1.Remove: ● Screws (crankcase) NOTE: Working in a crisscross pattern, loosen all screws 1/4 turn each. Remove them after all are loosened. 2.Remove: ● Crankcase 1 (left) ● Dowel pins ********************************* Remo ...

  • Yamaha 4XE-F8197-10 - page 114

    4 - 16 ENG ENGINE DISASSEMBLY NOTE: Fully tighten the tool holding bolts, but make sure the tool body is parallel with the case. If necessary, one screw may be backed out slightly to level tool body. ● As pressure is applied, alternately tap on the front engine mounting boss, transmis- sion shafts and balancer shaft. CAUTION: ● Use soft hammer ...

  • Yamaha 4XE-F8197-10 - page 115

    4 - 17 ENG ENGINE DISASSEMBLY 2.Remove: ● Transmission assembly 1 (main axle and drive axle) ● Washer 2 (drive axle) 3.Remove: ● Circlip 1 4.Remove: ● Balancer drive gear 2 ● Crankshaft 3 (from right crankcase) ● Woodruff key 4 NOTE: Use a hydraulic press to remove the bal- ancer drive gear 2 from the crankshaft. CYLINDER HEAD 1.Straigh ...

  • Yamaha 4XE-F8197-10 - page 116

    4 - 18 ENG ENGINE DISASSEMBLY 4.Remove: ● Rocker arm shafts 1 ● Rocker arms (intake/exhaust) NOTE: Attach the Slide Hammer Set 2 to the rocker arm shaft, and then slide out the them. Slide hammer set: P/N. YU-01083-A Slide hammer bolt: P/N. 90890-01083 Weight: P/N. 90890-01084 VALVE NOTE: Before removing the internal parts (valve, valve spring, ...

  • Yamaha 4XE-F8197-10 - page 117

    4 - 19 ENG ENGINE DISASSEMBLY 2.Remove: ● Valve cotters 1 NOTE: Attach the Valve Spring Compressor 2 between the valve spring seat and cylinder head to remove the valve cotters. 3.Remove: ● Valve spring seat 1 (upper) ● Valve spring 2 (outer) ● Valve spring 3 (inner) ● Valve 4 ● Valve stem seal 5 ● Valve spring seat 6 (lower) NOTE: Id ...

  • Yamaha 4XE-F8197-10 - page 118

    4 - 20 ENG INSPECTION AND REPAIR INSPECTION AND REPAIR CYLINDER HEAD 1.Eliminate: ● Carbon deposit Use a rounded scraper 1 . NOTE: Do not use a sharp instrument to avoid damaging or scratching: ● Spark plug threads ● Valve seat ● Cylinder head 2.Measure: ● Cylinder head warpage Out of specification → Resurface/Replace. Cylinder head war ...

  • Yamaha 4XE-F8197-10 - page 119

    4 - 21 ENG INSPECTION AND REPAIR 3.Measure: ● Valve stem runout Out of specification → Replace. Stem runout: Less than: 0.03 mm (0.0012 in) 4.Measure: ● Valve stem clearance Out of specification → Replace either valve and/or guide. Use a Micrometer and Bore Gauge 1 . VALVE GUIDE NOTE: ● Always replace the valve guide if the valve is repla ...

  • Yamaha 4XE-F8197-10 - page 120

    4 - 22 ENG INSPECTION AND REPAIR 3.Install: ● Circlip 1 (new) ● Valve guide 2 (new) Use the Valve Guide Installer 3 with the Valve Guide Remover 4 . 4.Bore valve guide 2 to obtain proper valve stem clearance. Use the Valve Guide Reamer 5 (6.0 mm) NOTE: Reface the valve seat after installing the valve guide. V alve guide installer: P/N. YM-04065 ...

  • Yamaha 4XE-F8197-10 - page 121

    4 - 23 ENG INSPECTION AND REPAIR ● Press the valve through the valve guide and onto the valve seat to make a clear pattern. ● Remove the valve from the cylinder head. ● Measure the valve seat width a . When the valve seat and valve face make contact, bluing will be applied to the valve face. ● If the valve seat width is too wide, too nar- r ...

  • Yamaha 4XE-F8197-10 - page 122

    4 - 24 ENG INSPECTION AND REPAIR ı Valve seat is in the middle of the valve face but too narrow. Ç Valve seat is too narrow and right up near valve margin. Î Valve seat is too narrow and is located down near the bottom edge of the valve face. ********************************* Valve seat cutter set Desired result Use 45˚ cutter To achieve a uni- ...

  • Yamaha 4XE-F8197-10 - page 123

    4 - 25 ENG INSPECTION AND REPAIR ● Apply a molybdenum disulfide oil to the valve stem. ● Install the valve into the cylinder head. ● Turn the valve until the valve face and valve seat are evenly polished, then clean off all compound. NOTE: To obtain the best lapping result, lightly tap the valve seat while rotating the valve back and forth be ...

  • Yamaha 4XE-F8197-10 - page 124

    4 - 26 ENG INSPECTION AND REPAIR 2.Measure: ● Valve spring installed force Out of specification → Replace inner and outer springs as a set. a Installed length Valve spring installed force Inner spring (IN/EX) 8.4 ~ 10.2 kg (18.5 ~ 22.5 lb) at 30.5 mm (1.2 in) Outer spring (IN/EX) 16.6 ~ 20.4 kg (36.6 ~ 45.0 lb) at 32.0 mm (1.26 in) VALVE INSTAL ...

  • Yamaha 4XE-F8197-10 - page 125

    4 - 27 ENG INSPECTION AND REPAIR NOTE: All valve springs must be installed with the larger pitch a upward as shown. 1 Outer spring 2 Inner spring 4.Check: ● Valve sealing Leakage at valve seat → Reface, relap or replace valve, relap. Refer to “VALVE SEAT”. ********************************* Valve seat checking steps: ● Pour a clean solvent ...

  • Yamaha 4XE-F8197-10 - page 126

    4 - 28 ENG INSPECTION AND REPAIR 2.Inspect: ● Cam lobes Pitting/Scratches/Blue discoloration → Replace. 3.Measure: ● Cam lobes Use a Micrometer. Out of specification → Replace. Cam lobe Limit “A” Cam lobe Limit “B” Intake 36.437 mm (1.435 in) 30.031 mm (1.182 in) Exhaust 36.482 mm (1.436 in) 30.152 mm (1.187 in) ROCKER ARM AND ROCKE ...

  • Yamaha 4XE-F8197-10 - page 127

    4 - 29 ENG INSPECTION AND REPAIR ● Calculate the clearance by subtracting the rocker-arm-shaft outside diameter from the rocker-arm inside diameter. Out of specification → Replace as a set. Arm-to-shaft clearance = Rocker arm inside diameter a – Rocker arm shaft outside diameter b Arm-to-shaft clearance: 0.009 ~ 0.037 mm (0.0004 ~ 0.0013 in) ...

  • Yamaha 4XE-F8197-10 - page 128

    4 - 30 ENG INSPECTION AND REPAIR 5.Install: ● Camshaft bushing 1 NOTE: The cut-out portion 2 of the bushing must be flush with the cylinder head. CAUTION: Do not cock the bushing during installa- tion. The bushing must be perpendicular to the camshaft during installation. 6.Install: ● Retainer 1 (camshaft bushing) ● Lock washer (new) NOTE: Be ...

  • Yamaha 4XE-F8197-10 - page 129

    4 - 31 ENG INSPECTION AND REPAIR CAM SPROCKET AND CAM DRIVE SPROCKET 1.Inspect: ● Cam sprocket ● Cam drive sprocket (crank shaft) Wear/Damage → Replace cam sprocket and timing chain as a set. 1 1/4 tooth 2 Correct 3 Roller 4 Sprocket TIMING CHAIN GUIDE 1.Inspect: ● Timing chain guide 1 (exhaust) ● Timing chain guide 2 (intake) Wear/Damage ...

  • Yamaha 4XE-F8197-10 - page 130

    4 - 32 ENG INSPECTION AND REPAIR TAPPET COVER AND CAM SPROCKET COVER 1.Inspect: ● Tappet covers (intake 1 and exhaust 2 ) ● Cam sprocket cover 3 ● O-rings 4 Cracks/Damage → Replace. CYLINDER AND PISTON 1.Eliminate: ● Carbon deposits (from the piston crown and ring grooves.) 2.Inspect: ● Cylinder and piston walls Vertical scratches → R ...

  • Yamaha 4XE-F8197-10 - page 131

    4 - 33 ENG INSPECTION AND REPAIR 2nd steps ● Measure the piston skirt diameter “P” with a micrometer. b 4 mm (0.16 in) from the piston bottom edge ● If out of the specification, replace the pis- ton and piston rings as a set. 3rd steps ● Find the piston-to-cylinder clearance with following formula. ● If out of the specification, rebore ...

  • Yamaha 4XE-F8197-10 - page 132

    4 - 34 ENG INSPECTION AND REPAIR Side clearance Standard Limit Top ring 0.03 ~ 0.07 mm (0.001 ~ 0.003 in) 0.12 mm (0.005 in) 2nd ring 0.02 ~ 0.06 mm (0.0008 ~ 0.0024 in) 0.12 mm (0.005 in) 2.Position: ● Piston ring (into cylinder) NOTE: Insert the ring into the cylinder, and push it approximately 20 mm (0.8 in) into the cylin- der. Push the ring ...

  • Yamaha 4XE-F8197-10 - page 133

    4 - 35 ENG INSPECTION AND REPAIR ● Oil control ring Expander spacer of bottom ring (oil con- trol ring) is color-coded to identify sizes. Size Color Oversize 2 Blue Oversize 4 Yellow Piston pin 1.Inspect: ● Piston pin Blue discoloration/Grooves → Replace then inspect lubrication system. 2.Measure: ● Outside diameter a (piston pin) Out of sp ...

  • Yamaha 4XE-F8197-10 - page 134

    4 - 36 ENG INSPECTION AND REPAIR CRANKSHAFT 1.Measure: ● Crank width A Out of specification → Replace or repair. ● Runout c Out of specification → Replace or repair. ● Side clearance D Out of specification → Replace or repair. ● Big end radial clearance E Out of specification → Replace or repair. ● Small end free play F Out of spe ...

  • Yamaha 4XE-F8197-10 - page 135

    4 - 37 ENG INSPECTION AND REPAIR ********************************* Crankshaft reassembling point: The crankshaft 1 and the crank pin 2 oil passages must be properly interconnected with a tolerance of less than 1 mm (0.04 in). ********************************* BALANCER DRIVE GEAR AND DRIVEN GEARS 1.Inspect: ● Balancer drive gear teeth 1 ● Balanc ...

  • Yamaha 4XE-F8197-10 - page 136

    4 - 38 ENG INSPECTION AND REPAIR 3.Inspect: ● Bolts 1 (starter clutch) Loose → Replace with a new one, and calk the end of the bolt. Bolts (starter clutch): 30 Nm (3.0 m • kg, 22 ft • lb) LOCTITE  Calk the end of the bolt PRIMARY CLUTCH Clutch housing 1.Inspect: ● Clutch housing 1 (inner surface) Heat damage/Wear/Damage → Replace. ? ...

  • Yamaha 4XE-F8197-10 - page 137

    4 - 39 ENG INSPECTION AND REPAIR Clutch boss and pressure plate 1.Inspect: ● Clutch boss splines 1 ● Pressure plate splines 2 Scoring/Wear/Damage → Replace clutch boss assembly and/or pressure plate. Friction plates 1.Inspect: ● Friction plate 1 Damage/Wear → Replace friction plate as a set. 2.Measure: ● Friction plate thickness Measure ...

  • Yamaha 4XE-F8197-10 - page 138

    4 - 40 ENG INSPECTION AND REPAIR Clutch spring 1.Inspect: ● Clutch spring Wear/Damage → Replace. 2.Measure: ● Clutch spring free length a Out of specification → Replace springs as a set. Clutch release lever 1.Inspect: ● Release lever 1 ● Adjuster 2 ● O-ring 3 Cracks/Wear/Damage → Replace. Clutch spring minimum length: 32.9 mm (1.30 ...

  • Yamaha 4XE-F8197-10 - page 139

    4 - 41 ENG INSPECTION AND REPAIR TRANSMISSION AND SHIFTER Shift fork and guide bar 1.Inspect: ● Shift forks On the gear and shift cam contact sur- faces. Wear/Chafing/Bends/Damage → Replace. 2.Inspect: ● Guide bars (Roll the guide bar on a flat surface. Bends → Replace. W ARNING Do not attempt to straighten a bent guide bar. 3.Check: ● Sh ...

  • Yamaha 4XE-F8197-10 - page 140

    4 - 42 ENG INSPECTION AND REPAIR 2.Inspect: ● Gears (transmission 1 and drive pinion 2 ) ● Mating dogs Cracks/Damage/Wear → Replace. NOTE: When the drive pinion gear is replaced, be sure to adjust the drive pinion gear shim(s), refer to the “DRIVE TRAIN-MIDDLE GEAR SERVICE” section in CHAPTER 6. 3.Check: ● Gear movement (transmission) U ...

  • Yamaha 4XE-F8197-10 - page 141

    4 - 43 ENG INSPECTION AND REPAIR MIDDLE GEAR 1.Inspect: ● Middle driven pinion gear 1 ● Bearing 2 ● Middle driven shaft 3 ● Reverse gear 4 ● Bearing housing 5 Damage/Wear → Replace. 2.Check: ● Bearing movement Turns roughly → Replace. NOTE: When the driven pinion gear, reverse gear, middle driven shaft and/or bearing housing are rep ...

  • Yamaha 4XE-F8197-10 - page 142

    4 - 44 ENG INSPECTION AND REPAIR 3.Inspect: ● Crankcase Cracks/Damage → Replace. ● Oil delivery passages Clog → Blow out with compressed air. NOTE: When the crankcase is replaced, be sure to adjust the middle gear shim(s), refer to “DRIVE TRAIN-MIDDLE GEAR SERVICE” section in CHAPTER 6. RECOIL STARTER 1.Inspect: ● Drive plate 1 Cracks ...

  • Yamaha 4XE-F8197-10 - page 143

    4 - 45 ENG ENGINE ASSEMBLY AND ADJUSTMENT ENGINE ASSEMBLY AND ADJUSTMENT RECOIL STARTER 1.Install: ● Starter spring 1 NOTE: Mesh the spring hook 2 wise the case slit, then carefully wind the spring counterclock- wise, and fit the spring into the case. 2.Install: ● Plate 1 ● Starter spring case 2 NOTE: Mesh the end 3 of the sheave spring with ...

  • Yamaha 4XE-F8197-10 - page 144

    4 - 46 ENG ENGINE ASSEMBLY AND ADJUSTMENT 6.Install: ● Spring (drive pawl) 1 ● Drive pawl 2 ● Circlip 3 ● Spring 4 ● Drive plate 5 ● Bolt 6 NOTE: When installing the spring (drive pawl), align the spring end 7 with the groove a on the sheave drum. 7.Turn the sheave drum 3-turns clockwise to preload the starter spring. 8.Install: ● Sta ...

  • Yamaha 4XE-F8197-10 - page 145

    4 - 47 ENG ENGINE ASSEMBLY AND ADJUSTMENT CRANKSHAFT/BALANCER 1 Balancer driven gear 2 Bearing 3 Straight key 4 Balancer 5 Oil seal 6 Balancer drive gear 7 Woodruff key 8 Crank (right) 9 Connecting rod 0 Small end bearing A Crank pin B Crank (left) A PISTON TO CYLINDER CLEARANCE: 0.04 ~ 0.06 mm (0.0016 ~ 0.0024 in) B END GAP (INSTALLED): Top ring & ...

  • Yamaha 4XE-F8197-10 - page 146

    4 - 48 ENG ENGINE ASSEMBLY AND ADJUSTMENT TRANSMISSION 1 Bearing 2 1st wheel gear 3 5th wheel gear 4 Circlip 5 Washer 6 3rd wheel gear 7 4th wheel gear 8 2nd wheel gear 9 Drive axle 0 Bearing retainer A Main axle B 5th pinion gear C 3rd pinion gear D 4th pinion gear E 2nd pinion gear F Oil seal G Shim A DRIVE/MAIN AXLE RUNOUT: <Limit> 0.08 mm ...

  • Yamaha 4XE-F8197-10 - page 147

    4 - 49 ENG ENGINE ASSEMBLY AND ADJUSTMENT SHIFTER 1 Guide bar #1 (long) 2 Shift fork #2 3 Shift fork #3 4 Shift cam segment 5 Pin 6 Bearing 7 Shift cam 8 Guide bar #2 (short) 9 Shift fork #1 4 ...

  • Yamaha 4XE-F8197-10 - page 148

    4 - 50 ENG ENGINE ASSEMBLY AND ADJUSTMENT CRANKSHAFT, TRANSMISSION AND BALANCER SHAFT 1.Install: ● Crankshaft 1 (to right crankcase) NOTE: Hold the connecting rod at top dead center with one hand while installing the crank- shaft. 2.Install: ● Transmission assembly 1 (main axle and drive axle) 3.Install: ● Balancer shaft 1 ● Shift fork #1 2 ...

  • Yamaha 4XE-F8197-10 - page 149

    4 - 51 ENG ENGINE ASSEMBLY AND ADJUSTMENT CRANKCASE (LEFT) 1.Apply: ● Sealant 1 (to matching surfaces of both case halves) Sealant (Quick Gasket  ): ACC-QUICK-GS-KT Y amaha bond No. 1215: 90890-85505 2.Install: ● Dowel pins 2 3.Fit the left crankcase onto the right case. Tap lightly on the case with a soft ham- mer. CAUTION: Before installin ...

  • Yamaha 4XE-F8197-10 - page 150

    4 - 52 ENG ENGINE ASSEMBLY AND ADJUSTMENT Crankshaft installer set 1 : P/N. YU-90050 Buffer boss installer set 2 : P/N. 90890-04088 Adapter #11 3 : P/N. YM-33279 Spacer 4 (crankshaft): P/N. YM-90070-A, 90890-04060 2.Install: ● Balancer gear 1 (driven) ● Straight key 2 NOTE: Align the drive gear mark 3 with the driven gear mark 4 . 3.Install: ? ...

  • Yamaha 4XE-F8197-10 - page 151

    4 - 53 ENG ENGINE ASSEMBLY AND ADJUSTMENT SHIFT SHAFT/OIL PUMP 1 Adjuster 2 Spring 3 Release lever 4 Shift guides 5 Ball holder 6 Shift shaft 7 Torsion spring 8 Stopper lever 9 Return spring 0 Oil seal A Shift pedal B Oil pump assembly C Gasket 4 ...

  • Yamaha 4XE-F8197-10 - page 152

    4 - 54 ENG ENGINE ASSEMBLY AND ADJUSTMENT SHIFTER AND OIL PUMP 1.Install: ● Segment 1 ● Pin 2 (long) ● Pin 3 (short) NOTE: Install the pin 2 (long) to the match mark 4 position. 2.Install: ● Segment (shift cam) NOTE: Align the hole 1 of the shift cam with the pin 2 (long) of the segment. 3.Tighten: ● Screw 1 (segment) T R . . Screw (segme ...

  • Yamaha 4XE-F8197-10 - page 153

    4 - 55 ENG ENGINE ASSEMBLY AND ADJUSTMENT 6.Apply: ● 4-stroke engine oil (to the oil pump inner parts) 7.Install: ● Rotor housing 1 ● Outer rotor 2 ● Inner rotor 3 ● Dowel pins 4 ● Oil pump driven gear 5 ● Dowel pin 6 ● Oil pump cover 7 ● Screw 8 8.Apply: ● 4-stroke engine oil (to the oil passages in the crankcase) CAUTION: Appl ...

  • Yamaha 4XE-F8197-10 - page 154

    4 - 56 ENG ENGINE ASSEMBLY AND ADJUSTMENT CLUTCH 1 Push rod 2 Bearing 3 Bearing holder 4 Clutch boss 5 Clutch plate 6 Friction plate 7 Pressure plate 8 Washer 9 Clutch housing (secondary) 0 Clutch carrier assembly A Washer B Inner collar C One way bearing D Clutch housing (primary) A CLUTCH SPRING MINIMUM LENGTH: 0.02 mm (0.0008 in) B CLUCTH PLATE ...

  • Yamaha 4XE-F8197-10 - page 155

    4 - 57 ENG ENGINE ASSEMBLY AND ADJUSTMENT PRIMARY AND SECONDARY CLUTCHES 1.Install: ● Clutch housing 1 (secondary) ● Washer 2 2.Install: ● Friction plates 1 ● Clutch plates 2 (to clutch boss 3 ) NOTE: Install the clutch plates and friction plates alternately on the clutch boss, starting with a friction plate and ending with a friction plate ...

  • Yamaha 4XE-F8197-10 - page 156

    4 - 58 ENG ENGINE ASSEMBLY AND ADJUSTMENT NOTE: Hold the clutch boss 2 by the Rotor Holder 3 to tighten the nut. 6.Bend the lock washer tab 4 . Rotor holder: P/N. YU-01235, 90890-01235 7.Install: ● Clutch springs 1 ● Bearing holder 2 ● Bearing 3 ● Push rod 4 T R . . Bolts (clutch spring): 6 Nm (0.6 m • kg, 4.3 ft • lb) 8.Install: ● Dr ...

  • Yamaha 4XE-F8197-10 - page 157

    4 - 59 ENG ENGINE ASSEMBLY AND ADJUSTMENT 11.Install: ● Washer 1 ● Clutch housing 2 (primary) ● Washer 3 ● Clutch carrier assembly 4 NOTE: ● The secondary clutch housing has two grooves 1 machined into it permit the primary drive gear behind the primary clutch to clear the secondary clutch. ● Align one of these grooves with the pri- mar ...

  • Yamaha 4XE-F8197-10 - page 158

    4 - 60 ENG ENGINE ASSEMBLY AND ADJUSTMENT 15.Install: ● Shift guide #2 1 ● Ball holder 2 ● Shift guide #1 3 ● Spring 4 (clutch release lever) NOTE: ● The slot 5 in the shift guide #2 must engage the shift shaft projection 6 . ● The slot 7 in the shift guide #1 must engage the stopper shaft 8 . 16.Install: ● Dowel pins 1 ● Gasket 2 ? ...

  • Yamaha 4XE-F8197-10 - page 159

    4 - 61 ENG ENGINE ASSEMBLY AND ADJUSTMENT MIDDLE DRIVEN PINION GEAR 1.Install: ● Dowel pins 1 ● Shims 2 (to middle driven shaft) ● Bearing 3 ● Middle driven shaft assembly 4 NOTE: Apply the grease to the O-ring 5 . 2.Apply: ● Sealant 1 (to matching surface of middle shaft case cover) Sealant (Quick Gasket  ): P/N. ACC-QUICK-GS-KT Y ama ...

  • Yamaha 4XE-F8197-10 - page 160

    4 - 62 ENG FWD ENGINE ASSEMBLY AND ADJUSTMENT STARTER PULLEY (EXCEPT FOR USA)/CDI MAGNETO 1 Timing chain 2 Timing chain guide (intake) 3 Woodruff key 4 Washer 5 Starter driven gear 6 Starter clutch 7 Dowel pin 8 Starter clutch spring cap 9 Compression spring 0 CDI magneto A Starter idle gear B Shaft C Washer D Circlip E Stator assembly F Crankcase ...

  • Yamaha 4XE-F8197-10 - page 161

    4 - 63 ENG ENGINE ASSEMBLY AND ADJUSTMENT STARTER PULLEY (EXCEPT FOR USA) AND CDI MAGNETO 1.Inspect: ● Timing chain 1 ● Chain guide 2 (intake) NOTE: Fasten a safety wire 3 to the timing chain to prevent it from falling into the crankcase. 2.Install: ● Washer 1 ● Driven gear 2 (starter) ● Woodruff key 3 ● CDI magneto 4 NOTE: ● Clean th ...

  • Yamaha 4XE-F8197-10 - page 162

    4 - 64 ENG ENGINE ASSEMBLY AND ADJUSTMENT 5.Install: ● Starter pulley 1 NOTE: ● Hold the starter pulley by the Rotor Holder to tighten the bolt. ● Before installing the starter pulley, apply the grease to the oil seal rip 2 and O-ring 3 . T R . . Bolt (starter pulley): 50 Nm (5.0 m • kg, 36 ft • lb) Rotor holder: P/N. YU-01235, 90890-0123 ...

  • Yamaha 4XE-F8197-10 - page 163

    4 - 65 ENG ENGINE ASSEMBLY AND ADJUSTMENT CYLINDER AND CYLINDER HEAD ASSEMBLY 1 Spark plug 2 Tappet cover (intake) 3 O-ring 4 Tappet cover (exhaust) 5 Cylinder head 6 Bearing retainer 7 Lock washer 8 Cam sprocket cover 9 Oil seal 0 Cylinder A CYLINDER HEAD WARP LIMIT: 0.10 mm (0.004 in) B SPARK PLUG: C TYPE/MANUFACTURER: DR7EA/NGK D SPARK PLUG GAP: ...

  • Yamaha 4XE-F8197-10 - page 164

    4 - 66 ENG ENGINE ASSEMBLY AND ADJUSTMENT PISTON, CAMSHAFT AND TIMING CHAIN 1 Gasket 2 Timing chain tensioner 3 Gasket 4 Timing chain guide (intake) 5 Camshaft 6 Camshaft bushing 7 Cam sprocket 8 Timing chain 9 Timing chain guide (exhaust) 0 Piston ring A Piston pin clip B Piston C Piston pin 4 ...

  • Yamaha 4XE-F8197-10 - page 165

    4 - 67 ENG ENGINE ASSEMBLY AND ADJUSTMENT CYLINDER HEAD ASSEMBLY, CYLINDER AND PISTON 1.Install: ● Piston 1 ● Piston pin 2 ● Piston pin clips 3 NOTE: ● The arrow 4 on the piston must point to the front of the engine. ● Before installing the piston pin clip, cover the crankcase with a clean towel or rag so you will not accidentally drop th ...

  • Yamaha 4XE-F8197-10 - page 166

    4 - 68 ENG ENGINE ASSEMBLY AND ADJUSTMENT 5.Install: ● Cylinder 1 ● Bolts (cylinder)-temporary tighten NOTE: ● Install the cylinder with one hand while compressing the piston rings with the other hand. ● Pass the timing chain through the chain cavity. 6.Install: ● Chain guide 1 (exhaust) ● Oil seal 2 ● Dowel pins 3 ● Gasket 4 (cylin ...

  • Yamaha 4XE-F8197-10 - page 167

    4 - 69 ENG ENGINE ASSEMBLY AND ADJUSTMENT ● Turn the crankshaft counterclockwise until the TDC mark 3 is aligned with the station- ary pointer 4 on the crankcase cover. ● Place the timing chain onto the cam sprocket. ● Install the cam sprocket onto the cam- shaft, and finger tighten the sprocket bolt. NOTE: ● When installing the cam sprocke ...

  • Yamaha 4XE-F8197-10 - page 168

    4 - 70 ENG ENGINE ASSEMBLY AND ADJUSTMENT ● Insert a small screwdriver 3 into the ten- sioner body slit. While pressing the ten- sioner rod, rotate the screwdriver clockwise until it stops turning. ● While holding the screwdriver in this posi- tion, and install the tensioner assembly 2 (with the gasket) onto the cylinder, then temporary tighten ...

  • Yamaha 4XE-F8197-10 - page 169

    4 - 71 ENG ENGINE ASSEMBLY AND ADJUSTMENT 13.Install: ● Tappet cover 1 (intake) ● Tappet cover 2 (exhaust) ● Spark plug 3 T R . . Bolt (tappet cover): 10 Nm (1.0 m • kg, 7.2 ft • lb) Spark plug: 17.5 Nm (17.5 m • kg, 12.5 ft • lb) 14.Install: ● Cam sprocket cover 1 ● Carburetor joint 2 NOTE: Inspect the O-ring of the carburetor jo ...

  • Yamaha 4XE-F8197-10 - page 170

    4 - 72 ENG ENGINE ASSEMBLY AND ADJUSTMENT REMOUNTING ENGINE Reverse the “ENGINE REMOVAL” proce- dure. Note the following points. W ARNING Securely support the machine so there is no danger of it falling over. 1.Install: ● Engine assembly (from right side) 2.Install: ● Bolt 1 (engine mounting - rear lower) ● Bolt 2 (engine mounting - rear ...

  • Yamaha 4XE-F8197-10 - page 171

    4 - 73 ENG ENGINE ASSEMBLY AND ADJUSTMENT 3.Install: ● Rear wheel drive assembly and swing- arm. NOTE: ● Before installing the swingarm. Lubricate the following parts. Swingarm pivot side: 1) Bearings 1 2) Oil seals 2 3) Collars 3 4) Pivot shafts 4 Drive shaft side: 1) Drive shaft splines 5 2) Coupling gear splines 6 ● Before installing the s ...

  • Yamaha 4XE-F8197-10 - page 172

    4 - 74 ENG ENGINE ASSEMBLY AND ADJUSTMENT 7.Tighten: ● Bolt 1 (engine mounting - rear lower) ● Bolt 2 (engine mounting - rear upper) ● Bolt 3 (engine mounting - front) ● Bolts 4 (engine mounting - top) ● Pivot shafts 5 (swingarm) ● Locknut (pivot shaft - right) ● Bolt 6 (rear shock absorber - top) 8.Install: ● Pivot shaft caps T R . ...

  • Yamaha 4XE-F8197-10 - page 173

    4 - 75 ENG ENGINE ASSEMBLY AND ADJUSTMENT 11.Install: ● Spring 1 ● Footrest 2 (right) T R . . Bolt (footrest): 65 Nm (6.5 m • kg, 47 ft • lb) 12.Install: ● Front fender stay 1 ● Sift pedal 2 ● Footrest 3 (left) NOTE: The center of the shift pedal 2 should be aligned with the top of the footrest 3 . 13.Connect: ● Brake cable 1 (rear) ...

  • Yamaha 4XE-F8197-10 - page 174

    4 - 76 ENG ENGINE ASSEMBLY AND ADJUSTMENT 17.Install: ● Carburetor 1 Refer to “CARBURETOR” section in the CHAPTER 5. T R . . Hose clamp: 2 Nm (0.2 m • kg, 1.4 ft • lb) 19.Fill: ● Crankcase Refer to the “ENGINE OIL REPLACE- MENT” section in CHAPTER 3. 20.Adjust: ● Release lever free play (clutch) Refer to the "CLUTCH ADJUSTMEN ...

  • Yamaha 4XE-F8197-10 - page 175

    4 - 77 ENG ENGINE ASSEMBLY AND ADJUSTMENT 22.Install: ● Rear fender ● Rear carrier ● Front fender ● Front bumper ● Front carrier ● Fuel tank ● Seat Refer to the “FENDERS AND FUEL TANK- Installation” section in CHAPTER 3. 23.Inspect: ● Oil leakage 24.Check: ● “NEUTRAL” indicator light operation ● “REVERSE” indicator l ...

  • Yamaha 4XE-F8197-10 - page 176

    ENG 4 - 78 4 ...

  • Yamaha 4XE-F8197-10 - page 177

    FWD 5 - 1 CARB CARBURETOR CARBURETION CARBURETOR 1 Vacuum chamber cover 2 Spring 3 Jet needle set 4 Piston valve 5 Pilot air jet 6 Coasting enricher diaphragm 7 Starter plunger assembly 8 Pilot screw set 9 Pilot jet 0 Needle jet A Main jet B Needle valve set C Throttle stop screw D Float pin E Float SPECIFICATIONS ID MARK 4XE1 00 MAIN JET (M.J.) #9 ...

  • Yamaha 4XE-F8197-10 - page 178

    5 - 2 CARB REMOVAL 1.Turn the fuel cock lever to “OFF”. 2.Remove: ● Air vent hose 1 ● Overflow hose 2 ● Fuel hose 3 3.Loosen: ● Clamp screws 4 4.Remove: ● Carburetor assembly CARBURETOR 5.Remove: ● Throttle valve cover 1 6.Remove: ● Throttle cable end 1 7.Loosen: ● Throttle cable adjusting nut 1 8.Remove: ● Throttle cable 2 DI ...

  • Yamaha 4XE-F8197-10 - page 179

    5 - 3 CARB 2.Remove: ● Pilot air jet 1 CARBURETOR 3.Remove: ● Float chamber 1 ● O-ring 2 4.Remove: ● Float pin 1 ● Float 2 ● Needle valve 3 NOTE: Remove the float pin in the direction of the arrow. 5.Remove: ● Throttle stop screw 1 ● Valve seat 2 ● Main jet 3 ● Pilot jet 4 ● Pilot screw set 5 6.Remove: ● Needle jet 1 NOTE: R ...

  • Yamaha 4XE-F8197-10 - page 180

    5 - 4 CARB 7.Remove: ● Cover (coasting enricher) 1 ● Spring 2 ● Diaphragm 3 CARBURETOR 8.Remove: ● Starter plunger 1 INSPECTION 1.Inspect: ● Carburetor body ● Starter jet 1 ● Float chamber Cracks/damage → Replace. ● Fuel passage Contamination → Clean as indicated. ● Fuel chamber body Contamination → Clean. ****************** ...

  • Yamaha 4XE-F8197-10 - page 181

    5 - 5 CARB 3.Inspect: ● Float 1 ● Float tang 2 Damage → Replace. CARBURETOR 4.Inspect: ● Main jet 1 ● Needle jet 2 ● Pilot jet 3 ● Pilot air jet 4 Wear/damage → Replace. Contamination → Blow out the jets with compressed air. 5.Inspect: ● Spring 1 ● Spring seat 2 ● Jet needle set 3 ● Piston valve 4 Bends/wear/damage → Rep ...

  • Yamaha 4XE-F8197-10 - page 182

    5 - 6 CARB 8.Inspect: ● Throttle stop screw 1 ● Pilot screw 2 Contamination/wear → Replace. ● O-ring 3 Damage → Replace. CARBURETOR 9.Check: ● Free movement (piston valve) Sticks → Replace. Insert the piston valve into the carburetor body, and check for free movement. 10.Check: ● Free movement (throttle valve) Sticks → Replace. AS ...

  • Yamaha 4XE-F8197-10 - page 183

    5 - 7 CARB 3.Install: ● O-ring ● Washer ● Spring ● Pilot screw Pilot screw: 2 turns out CARBURETOR 4.Install: ● Needle valve 1 ● Float 2 ● Float pin 3 NOTE: Install the float pin in the direction of the arrow. 5.Measure: ● Float height a Out of specification → Adjust. ********************************* Measurement and adjustment st ...

  • Yamaha 4XE-F8197-10 - page 184

    5 - 8 CARB 6.Install: ● Piston valve 1 NOTE: Match the tab on the rubber diaphragm to the matching recess in the carburetor body. CARBURETOR INSTALLATION Reverse the “REMOVAL” procedure. Note the following points. 1.Install: ● Carburetor assembly T R . . Clamp screw: 2 Nm (0.2 m • kg, 1.4 ft • lb) 2.Adjust: ● Idle speed Refer to “ID ...

  • Yamaha 4XE-F8197-10 - page 185

    5 - 9 CARB FUEL LEVEL ADJUSTMENT 1.Measure: ● Fuel level a Out of specification → Adjust. ********************************* Fuel level measurement and adjustment steps: ● Place the machine on a level surface. ● Connect the fuel level gauge 1 to the drain pipe 2 . ● Loosen the drain screw 3 . ● Hold the gauge vertically next to the float ...

  • Yamaha 4XE-F8197-10 - page 186

    CARB 5 - 10 5 ...

  • Yamaha 4XE-F8197-10 - page 187

    6 - 1 DRIV MIDDLE GEAR SERVICE DRIVE TRAIN MIDDLE GEAR SERVICE MIDDLE GEAR 1 Universal joint 2 Bearing retainer 1 3 Bearing 4 Shims 5 Bearing housing 6 O-ring 7 Reverse gear securing nut 8 Bearing 9 Bearing retainer 2 0 Shims A Reverse gear B Dog clutch C Middle driven shaft D Driven pinion gear E Shims F Bearing G Shift fork 4 H Spring I Ball J Sh ...

  • Yamaha 4XE-F8197-10 - page 188

    6 - 2 DRIV MIDDLE GEAR SERVICE MIDDLE GEAR SHIMS When the crankcase assembly and/or the middle gear comp., etc. are replaced, be sure to adjust the middle gear shim(s). Refer to the “MIDDLE GEAR SHIM SELECTION” and “MIDDLE GEAR LASH ADJUSTMENT” section. 1 Drive pinion gear 2 Driven pinion gear (forward gear) 3 Reverse gear Å Drive pinion g ...

  • Yamaha 4XE-F8197-10 - page 189

    6 - 3 DRIV MIDDLE GEAR SERVICE REMOVAL NOTE: It is necessary to remove the rear wheel drive assembly and/or engine assembly in order to service the middle gear, refer to the “ENGINE OVERHAUL” section in CHAPTER 4. 1.Drain: ● Engine oil Refer to the “ENGINE OIL REPLACE- MENT” section in CHAPTER 3. 2.Remove: ● Seat ● Fuel tank ● Front ...

  • Yamaha 4XE-F8197-10 - page 190

    6 - 4 DRIV MIDDLE GEAR SERVICE 2.Remove: ● Bolts 1 (middle gear case cover) ● Middle gear case cover 2 ● Dowel pins 3.Remove: ● Middle driven shaft assembly 1 ● Bearing 2 ● Shim 3 ● Driven pinion gear 4 Middle drive axle 1.Remove: ● Nut 1 (middle drive pinion gear) ● Middle drive pinion gear 2 NOTE: ● Flatten the punched portion ...

  • Yamaha 4XE-F8197-10 - page 191

    6 - 5 DRIV MIDDLE GEAR SERVICE 3.Remove: ● Bearing retainers 1 Use a #40 Torx Driver. 4.Remove: ● Bearing 1 ● Shim 2 DISASSEMBLY Middle driven shaft 1.Remove: ● Universal joint ********************************* Removal steps: ● Remove the circlips 1 . ● Place the U-joint in a press. ● With a suitable diameter pipe beneath the yoke, pr ...

  • Yamaha 4XE-F8197-10 - page 192

    6 - 6 DRIV MIDDLE GEAR SERVICE Universal joint holder: P/N. YM-04062, 90890-04062 Attachment: P/N. YM33291, 90890-04096 3.Remove: ● Middle driven shaft 1 ● Dog clutch 2 4.Remove: ● Bearing retainer 1 NOTE: ● Use a Bearing retainer wrench 2 . ● Bearing 3 ● Shim(s) 4 5.Remove: ● Reverse gear securing nut 1 NOTE: ● The reverse gear sec ...

  • Yamaha 4XE-F8197-10 - page 193

    6 - 7 DRIV MIDDLE GEAR SERVICE 6.Remove: ● Bearing retainer 1 NOTE: ● Use a Ring nut wrench 2 . ● Bearing 3 Shift lever 1.Remove: ● Shift fork guide bar 1 ● Shift fork 2 ● Ball 3 ● Spring 4 NOTE: When removing the shift fork guide bar, the ball will fall off. Take care not lose the ball. Ring nut wrench: P/N. YM-1391, 90890-01391 2.Re ...

  • Yamaha 4XE-F8197-10 - page 194

    6 - 8 DRIV 3.Check: ● Universal joints 1 ● Yoke 2 ● Bearings 3 Wear/Cracks/Damage → Replace. 4.Inspect: ● Shift fork 4 1 On the dog clutch and shift lever contact surfaces. Wear/Chafing/Bends/Damage → Replace. ● Spring 2 Wear/Damage → Replace. ● Ball (stopper) 3 Wear/Damage/Scratches → Replace. 5.Inspect: ● Guide bar Roll the ...

  • Yamaha 4XE-F8197-10 - page 195

    6 - 9 DRIV MIDDLE GEAR SERVICE 8.Inspect: ● Bearing housing 1 Cracks/Damage → Replace bearing hous- ing assembly. ● O-ring 2 Wear/Damage → Replace. NOTE: When the bearing housing assembly is replaced, be sure to adjust the middle gear shim(s), refer to the “MIDDLE GEAR SHIM SELECTION” section. MIDDLE GEAR SHIM SELECTION Install the cran ...

  • Yamaha 4XE-F8197-10 - page 196

    6 - 10 DRIV MIDDLE GEAR SERVICE 1 Drive pinion gear 2 Driven pinion gear 3 Reverse gear 4 Middle driven shaft Shim location Å = Drive pinion gear shim ı = Driven pinion gear shim Ç = Reverse gear shim Î = Middle driven shaft shim Å = a - b ı = c - d - e - f Ç = d - g - h - i Î = j + c - e - ı - k - l - 0.25 1 Crankcase (left) 2 Drive pinio ...

  • Yamaha 4XE-F8197-10 - page 197

    6 - 11 DRIV ********************************* Middle gear shims selection steps: Shim selection Å ● When the crankcase and/or the drive pin- ion gear are replaced, be sure to adjust the drive pinion gear shim Å . ● To find drive pinion gear shim thickness “A” use following formula: a = The stamped number on the drive pin- ion gear is eith ...

  • Yamaha 4XE-F8197-10 - page 198

    6 - 12 DRIV In the example above, the calculated shim thickness is 0.57 mm. The chart instructs you, however, to round off the 7 to 5, then shim thickness is 0.55 mm. Shim selection ı ● When the crankcase and/or the driven pin- ion gear are replaced, be sure to adjust the driven pinion gear shim ı . ● To find driven pinion gear shim thickness ...

  • Yamaha 4XE-F8197-10 - page 199

    6 - 13 DRIV In the example above, the calculated shim thickness is 0.95 mm. The chart instructs you, however, to round off the 5 to 5, then shim thickness is 0.95 mm. Shim selection Ç ● When the crankcase, reverse gear and/or bearing housing are replaced, be sure to adjust the reverse gear shim Ç . ● To find reverse gear shim thickness “C? ...

  • Yamaha 4XE-F8197-10 - page 200

    6 - 14 DRIV Because shims can only be selected in 0.05 mm increments, round off hundredths digit and select appropriate shim(s). In the example above, the calculated shim thickness is 0.51 mm. The chart instructs you, however, to round off the 1 to 0, then shim thickness is 0.50 mm. Shim selection Î ● When the crankcase, driven pinion gear, reve ...

  • Yamaha 4XE-F8197-10 - page 201

    6 - 15 DRIV MIDDLE GEAR SERVICE Example: 1) If the bearing hauging is stamped “–03”. ..... j = 1 – 0.03 = 0.97 2) If the crankcase is stamped “45” ..... c = 110 + 0.45 = 110.45 3) If the pinion gear is stamped “–02” ..... k = 14.5 – 0.02 = 14.48 4) If the middle drive shaft is stamped “03” ..... l = 80.5 + 0.03 = 80.53 5) Th ...

  • Yamaha 4XE-F8197-10 - page 202

    6 - 16 DRIV MIDDLE GEAR SERVICE ASSEMBLY Reverse the “DISASSEMBLY” procedures. Note the following points. Middle driven shaft 1.Apply: ● Lithium base grease To the oil seal and O-ring. 2.Install: ● Shift lever shaft 1 ● Shift lever 2 ● Stopper shaft 3 ● Circlip 4 3.Install: ● Spring 1 (to shift fork 4) ● Ball 2 NOTE: When installi ...

  • Yamaha 4XE-F8197-10 - page 203

    6 - 17 DRIV MIDDLE GEAR SERVICE 6.Install: ● Bearing 1 (to bearing housing) ● Bearing retainer 2 NOTE: ● Use a Ring nut wrench 3 . Ring nut wrench: P/N. YM-1391, 90890-01391 7.Tighten: ● Bearing retainer T R . . Bearing retainer: 60 Nm (6.0 m • kg, 43 ft • lb) 8.Install: ● Shim(s) 1 ● Reverse gear 2 ● Reverse gear securing nut 3 N ...

  • Yamaha 4XE-F8197-10 - page 204

    6 - 18 DRIV MIDDLE GEAR SERVICE 11.Tighten: ● Bearing retainer T R . . Bearing retainer: 60 Nm (6.0 m • kg, 43 ft • lb) Use LOCTITE  12.Install: ● Middle driven shaft 1 ● Dog clutch 2 13.Install: ● U-joint 1 ● Washer 2 ● Nut 3 (U-joint) NOTE: Hold the U-joint 1 by the Universal Joint Holder 4 and Attachment 5 , and tighten the U- ...

  • Yamaha 4XE-F8197-10 - page 205

    6 - 19 DRIV MIDDLE GEAR SERVICE 14.Install ● Universal joint ********************************* Installation steps: ● Install the opposite yoke into the U-joint. ● Apply the “Wheel bearing grease” to the bearings. ● Install the bearing 1 onto the yoke. CAUTION: Check each bearing. The needles can easily fall out of their races. Slide the ...

  • Yamaha 4XE-F8197-10 - page 206

    6 - 20 DRIV MIDDLE GEAR SERVICE 3.Install: ● Middle drive axle assembly 1 Refer to the “ENGINE ASSEMBLY AND ADJUSTMENT-CRANK SHAFT, TRANS- MISSION AND BALANCER SHAFT” sec- tion in CHAPTER 4. 4.Install: ● Middle drive pinion gear 1 ● Nut 2 Use the Rotor Holder 3 to hold the clutch boss 4 . NOTE: Put the engine in 1st, and carry out the ope ...

  • Yamaha 4XE-F8197-10 - page 207

    6 - 21 DRIV MIDDLE GEAR SERVICE 2.Apply: ● Sealant 1 To the mating surface of both case halves. 3.Install: ● Dowel pins ● Middle gear case cover 2 NOTE: Before installing the middle gear case cover onto the crankcase, shift the gear into “FORWARD”. 4.Tighten: ● Bolts 3 (middle gear case) 5.Tighten: ● Bolts 1 (bearing housing) NOTE: Wh ...

  • Yamaha 4XE-F8197-10 - page 208

    6 - 22 DRIV MIDDLE GEAR SERVICE 2.Shift: ● Drive select lever For forward drive. 3.Measure: ● Gear lash Gently rotate the middle drive axle from engagement to engagement. Over specified limit → Repair. NOTE: Measure the gear lash at 4 positions. Rotate the shaft 90˚ each time. Middle driven gear lash: (using measurement tool): 0.1 ~ 0.2 mm ( ...

  • Yamaha 4XE-F8197-10 - page 209

    6 - 23 DRIV MIDDLE GEAR SERVICE 2.Install: ● Rear wheel drive assembly and swingarm Refer to “REMOUNTING ENGINE” section in the CHAPTER 4. 3.Adjust: ● Rear brake Refer to “REAR BRAKE LEVER AND PEDAL ADJUSTMENT” section in the CHAPTER 3. 4.Install: ● Rear fender ● Rear carrier ● Front fender ● Front bumper ● Front carrier ● F ...

  • Yamaha 4XE-F8197-10 - page 210

    6 - 24 DRIV FINAL DRIVE GEAR AND DRIVE SHAFT FINAL DRIVE GEAR AND DRIVE SHAFT 1 Bearing housing 2 O-ring 3 Oil seal 4 Bearing 5 Ring gear shim 6 Ring gear 7 Thrust washer 8 Bearing 9 Oil seal 0 Bearing A Drive pinion gear B Final drive gear shim C Bearing D Bearing retainer E O-ring F Oil seal G Collar H Drive shaft I Circlip J Universal joint K Be ...

  • Yamaha 4XE-F8197-10 - page 211

    6 - 25 DRIV FINAL DRIVE GEAR AND DRIVE SHAFT TROUBLESHOOTING The following conditions may indicate damage drive train components: 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 to believe these components are d ...

  • Yamaha 4XE-F8197-10 - page 212

    6 - 26 DRIV FINAL DRIVE GEAR AND DRIVE SHAFT Inspection notes 1.Investigate any unusual noises ********************************* The following “Noises” may indicate a machanical problem: ● A “rolling rumble” noise during coasting, acceleration, or deceleration. The noise increases with rear wheel speed, but it does not increase with highe ...

  • Yamaha 4XE-F8197-10 - page 213

    6 - 27 DRIV FINAL DRIVE GEAR AND DRIVE SHAFT 3.Inspect: ● Oil leakage By the following inspection steps. ********************************* Oil leakage inspection steps: ● Clean the entire machine thoroughly, then dry it. ● Apply a leak-localizing compound or dry powder spray to the shaft drive. ● Road test the machine long enough to locate ...

  • Yamaha 4XE-F8197-10 - page 214

    6 - 28 DRIV FINAL DRIVE GEAR AND DRIVE SHAFT REMOVAL W ARNING Securely support the machine so there is no danger of it falling over. 1.Drain: ● Final gear oil Refer to the “FINAL GEAR OIL REPLACE- MENT” section in CHAPTER 3. 2.Remove: ● Seat ● Rear carrier ● Rear fender Refer to the “FENDERS AND FUEL TANK- REAR FENDER” section in CH ...

  • Yamaha 4XE-F8197-10 - page 215

    6 - 29 DRIV FINAL DRIVE GEAR AND DRIVE SHAFT NOTE: ● When the final gear case until is removed from the swingarm, the drive shaft 3 may fall off. ● Be careful not to lose these parts. DISASSEMBLY 1.Remove: ● Bolts 1 (8 mm) ● Bolts 2 (10 mm) NOTE: Working in a crisscross pattern, loosen bolt 1/4 turn each. Remove them after all loos- ened. 2 ...

  • Yamaha 4XE-F8197-10 - page 216

    6 - 30 DRIV FINAL DRIVE GEAR AND DRIVE SHAFT 3.Remove: ● Bearing retainer (drive shaft - final) NOTE: Final-drive-shaft-bearing-retainer has left- hand threads. Turn retainer clockwise to loosen it. NOTE: When remounting the bearing retainer, use the Bearing Retainer Wrench 1 . Bearing retainer wrench: P/N. YM-04050, 90890-04050 4.Remove: ● Dri ...

  • Yamaha 4XE-F8197-10 - page 217

    6 - 31 DRIV FINAL DRIVE GEAR AND DRIVE SHAFT 6.Remove: ● Roller bearing 1 (drive pinion gear) ********************************* Removal steps: ● Heat the main housing only to 150˚C (302˚F). ● Remove the roller bearing outer race with an appropriately shaped punch 2 . ● Remove the inner race from the final drive shaft. NOTE: The removal of ...

  • Yamaha 4XE-F8197-10 - page 218

    6 - 32 DRIV FINAL DRIVE GEAR AND DRIVE SHAFT 4.Inspect: ● Final gear case 1 ● Bearing housing 2 (ring gear) Cracks/Damage → Replace. NOTE: When the final gear case and/or ring gear bearing housing are replaced, be sure to adjust the shim of the final drive pinion gear and/or ring gear, refer to the “FINAL DRIVE GEAR AND RING GEAR SHIM SELEC ...

  • Yamaha 4XE-F8197-10 - page 219

    6 - 33 DRIV FINAL DRIVE GEAR AND DRIVE SHAFT Example: 1) If the “+01” is stamped on the final drive pinion gear, a = 79 + 0.01 = 79.01 2) If the “50” is stamped on the final gear case, b = 78 + 0.50 = 78.50 3) Therefore, “A” is, “A” = 79.01 – 78.50 = 0.51 mm 4) Round off hundredths digit and select appropriate shim(s). In the exam ...

  • Yamaha 4XE-F8197-10 - page 220

    6 - 34 DRIV FINAL DRIVE GEAR AND DRIVE SHAFT ********************************* Shim selection steps: ● To find ring gear shim thickness “B”, use the following formula. c = The stamped number on the final gear case is either added to or subtracted from “42”. d = The stamped number on outside of ring gear bearing housing and added to “2? ...

  • Yamaha 4XE-F8197-10 - page 221

    6 - 35 DRIV FINAL DRIVE GEAR AND DRIVE SHAFT ASSEMBLY Reverse the “DISASSEMBLY” procedures. Note the following points. 1.Install: ● Roller bearing (drive pinion gear) ********************************* Installation steps: ● Heat the main housing only to 150˚C (302˚F) ● Install the roller bearing outer race using the proper adapted. ● I ...

  • Yamaha 4XE-F8197-10 - page 222

    6 - 36 DRIV FINAL DRIVE GEAR AND DRIVE SHAFT Thrust washer selection 1.Measure/Select: ● Ring gear thrust clearance “C” ********************************* Thrust clearance measurement steps: ● Place four pieces of Plastigauge  between originally fitted thrust washer and ring gear. ● Install the ring gear assembly and tighten the bolts t ...

  • Yamaha 4XE-F8197-10 - page 223

    6 - 37 DRIV FINAL DRIVE GEAR AND DRIVE SHAFT 2.Install: ● Thrust washer 1 ● Ring gear 2 ● Shim(s) 3 (proper size as calculated) ● Bearing housing 4 NOTE: ● Before installing the ring gear, apply the grease to the oil seal rips. ● Before installing the bearing housing, apply the grease to the O-ring. 3.Install: ● 10 mm bolts 1 (bearing ...

  • Yamaha 4XE-F8197-10 - page 224

    6 - 38 DRIV FINAL DRIVE GEAR AND DRIVE SHAFT 4.Attach: ● Gear lash measurement tool 1 ● Dial gauge 2 a Measuring point Gear lash measurement tool: P/N. YM-01231, 90890-01231 Dial gauge: P/N. YU-03097, 90890-03097 5.Measure: ● Gear lash Gently rotate the gear coupling from engagement to engagement. If the measured value in step 5 is different ...

  • Yamaha 4XE-F8197-10 - page 225

    6 - 39 DRIV FINAL DRIVE GEAR AND DRIVE SHAFT 3.Adjust: ● Gear lash ********************************* Gear lash adjustment steps: ● Select the suitable shims and thrust washer by the following chart. ********************************* Too-little gear lash → Reduce shim thickness. Too-large gear lash → Increase shim thickness. Ring gear shim T ...

  • Yamaha 4XE-F8197-10 - page 226

    6 - 40 DRIV FINAL DRIVE GEAR AND DRIVE SHAFT 5.Install: ● 10 mm bolts (bearing housing) ● 8 mm bolts (bearing housing) Refer to the “FINAL DRIVE GEAR AND DRIVE SHAFT – ASSEMBLY” section. 6.Measure: ● Gear lash If the gear lash is incorrect → Repeat. T R . . 10 mm Bolts (bearing housing): 40 Nm (4.0 m • kg, 29 ft • lb) 8 mm Bolts ( ...

  • Yamaha 4XE-F8197-10 - page 227

    6 - 41 DRIV FINAL DRIVE GEAR AND DRIVE SHAFT 4.Install: ● Final gear case unit 1 NOTE: Before installing the final gear case unit, apply the grease to the O-ring 2 . 5.Connect: ● Breather hose 5 (final gear case) CAUTION: Make sure the final gear case breather hose is routed correctly. 6.Install: ● Rear axle ● Final gear case protector ● ...

  • Yamaha 4XE-F8197-10 - page 228

    6 - 42 DRIV 6 ...

  • Yamaha 4XE-F8197-10 - page 229

    7 - 1 CHAS FRONT WHEELS AND FRONT BRAKE CHASSIS FRONT WHEELS AND FRONT BRAKE 1 Brake camshaft lever 2 Wear indicator plate 3 Brake shoe plate 4 Brake shoe plate seal 5 Pivot pin 6 Brake camshaft holder 7 Brake camshaft 8 Brake shoe 9 Bearing 0 Bearing spacer A Front brake drum B Oil seal C Front wheel D Collar A TIRE SIZE: AT22 × 7-10 B RIM SIZE: ...

  • Yamaha 4XE-F8197-10 - page 230

    7 - 2 CHAS FRONT WHEELS AND FRONT BRAKE REMOVAL Front wheels 1.Place the machine on a level place. 2.Loosen: ● Nuts (front wheel) Apply the parking brake 1 . 3.Elevate the front wheels by placing the suitable stand under the frame. W ARNING Securely support the machine there is no danger of falling over. 4.Remove: ● Nuts 1 (front wheel) ● Fro ...

  • Yamaha 4XE-F8197-10 - page 231

    7 - 3 CHAS FRONT WHEELS AND FRONT BRAKE 9.Remove: ● Brake camshaft lever 1 ● Wear indicator plate 2 ● Brake camshaft 3 ● Brake camshaft holder 4 ● Pivot pin 5 ● Brake shoe plate 6 INSPECTION 1.Inspect: ● Wheel Refer to the “WHEEL INSPECTION” sec- tion in CHAPTER 3. 2.Measure: ● Wheel runout Over specified limit → Replace wheel ...

  • Yamaha 4XE-F8197-10 - page 232

    7 - 4 CHAS 4.Inspect: ● Brake linings Glazed parts → Sand with coarse sandpa- per. 5.Measure: ● Brake lining thickness a Out of specification → Replace. NOTE: Replace the brake shoes as a set (with shoe springs) if either is found to be worn to the wear limit. Brake lining thickness: 4.0 mm (0.16 in) <Wear limit>: 2.0 mm (0.08 in) 6.I ...

  • Yamaha 4XE-F8197-10 - page 233

    7 - 5 CHAS 9.Inspect: ● Bearings 1 (brake drum) Bearings allow play in the brake drum or the wheel tuns roughly → Replace. ● Oil seal 2 Wear/Damage → Replace. ********************************* Wheel bearing and oil seal replacement steps: ● Clean the outside of the brake drum. ● Remove the oil seal 1 use a flat-head screw driver. NOTE: ...

  • Yamaha 4XE-F8197-10 - page 234

    7 - 6 CHAS INSTALLATION Reverse the “REMOVAL” procedure. Note the following points. 1.Lubricate: ● Oil seal lips 1 ● Bearings 2 ● Camshaft 3 ● Pivot pin 4 ● O-ring 5 CAUTION: Install the camshaft and the pivot pin lightly greased. Wipe off the excess grease. Lithium-soap base grease 2.Install: ● Pivot pin 1 ● Brake camshaft holder ...

  • Yamaha 4XE-F8197-10 - page 235

    7 - 7 CHAS 4.Install: ● Brake shoes W ARNING Do not apply grease to the brake shoe lin- ings. 5.Connect: ● Front brake breather hose ● Brake cable (to brake shoe plate) 6.Install: ● Circlip 1 ● Spring 2 ● Washer (C-type) 3 ● Spring 4 ● Pin 5 ● Adjuster 6 7.Install: ● Brake drum 1 ● Spacer collar 2 ● Plain washer 3 ● Axle n ...

  • Yamaha 4XE-F8197-10 - page 236

    7 - 8 CHAS 9.Install: ● Front wheel NOTE: Arrow mark 1 on the tire must point toward the rotating direction Å of the wheel. 10.Adjust: ● Front brake cable free play Refer to the “FRONT BRAKE ADJUST- MENT” section in CHAPTER 3. 11.Release the parking brake. T R . . Nut (front wheel): 55 Nm (5.5 m • kg, 40 ft • lb) Front brake free play: ...

  • Yamaha 4XE-F8197-10 - page 237

    7 - 9 CHAS REAR WHEELS/REAR BRAKE AND REAR AXLE 1 Rear axle 2 Bearing 3 Oil seal 4 Wheel hub 5 Axle nut A TIRE SIZE: AT22 × 10-10 B RIM SIZE: 8 × 10 C WHEEL RUNOUT LIMIT: VERTICAL: 2.0 mm (0.08 in) D TIRE WEAR LIMIT: 2.0 mm (0.08 in) E REAR AXLE RUNOUT LIMIT: 1.5 mm (0.06 in) REAR WHEELS/REAR BRAKE AND REAR AXLE 7 ...

  • Yamaha 4XE-F8197-10 - page 238

    7 - 10 CHAS REAR WHEELS/REAR BRAKE AND REAR AXLE 1 Brake drum 2 Brake shoe 3 Bearing retainer 4 Brake shoe plate seal 5 Rear brake breather hose 6 Brake shoe plate 7 Brake camshaft 8 Wear indicator plate 9 Brake camshaft lever * Yamaha brake grease A BRAKE LINING WEAR LIMIT: 2.0 mm (0.08 in) B REAR BRAKE DRUM WEAR LIMIT: 161 mm (6.34 in) 7 ...

  • Yamaha 4XE-F8197-10 - page 239

    7 - 11 CHAS REAR WHEELS/REAR BRAKE AND REAR AXLE REMOVAL 1.Place the machine on a level place. 2.Loosen: ● Nuts (rear wheel) Apply the parking brake 1 . 3.Block the front wheels, and elevate the rear wheels by placing the suitable stand under the frame. W ARNING Securely support the machine there is no danger of falling over. 4.Remove: ● Nuts 1 ...

  • Yamaha 4XE-F8197-10 - page 240

    7 - 12 CHAS REAR WHEELS/REAR BRAKE AND REAR AXLE 8.Remove: ● Adjusters 1 (brake lever and brake pedal) ● Pins ● Springs 9.Disconnect: ● Brake cable 2 ● Brake rod 3 ● Rear brake breather hose 4 10.Remove: ● Bearing retainer 1 ● Brake shoe plate assembly 2 11.Remove: ● Spring 1 ● Brake camshaft lever 2 ● Wear indicator plate 3 ? ...

  • Yamaha 4XE-F8197-10 - page 241

    7 - 13 CHAS REAR WHEELS/REAR BRAKE AND REAR AXLE INSPECTION 1.Inspect: ● Wheel Refer to the “WHEEL INSPECTION” sec- tion in CHAPTER 3. 2.Measure: ● Wheel runout ● Tire surfaces Refer to the “FRONT WHEEL AND FRONT BRAKE-INSPECTION” section. 3.Inspect: ● Wheel hub 1 Cracks/Damage → Replace. ● Splines 2 (wheel hub) Wear/Damage → ...

  • Yamaha 4XE-F8197-10 - page 242

    7 - 14 CHAS REAR WHEELS/REAR BRAKE AND REAR AXLE 8.Inspect: ● Brake drum inner surface 1 Oil/Scratches → Remove. ● Spline 2 Wear/Damage → Replace. Oil Use a rag soaked in lacquer thinner or a solvent. Scratches Use a emery cloth (lightly and evenly polishing). 9.Inspect: ● Brake shoe plate 1 Cracks/Bends/Damage → Replace. ● Dust seal ...

  • Yamaha 4XE-F8197-10 - page 243

    7 - 15 CHAS REAR WHEELS/REAR BRAKE AND REAR AXLE 13.Measure: ● Rear axle runout a Out of specification → Replace. W ARNING Do not attempt to straighten a bent axle. Rear axle runout limit: 1.5 mm (0.06 in) 14.Inspect: ● Bearing 1 (rear axle) Bearing allow play in the axle hub or the bearing turns roughly → Replace. ● Oil seal 2 Wear/Damag ...

  • Yamaha 4XE-F8197-10 - page 244

    7 - 16 CHAS REAR WHEELS/REAR BRAKE AND REAR AXLE INSTALLATION Reverse the “REMOVAL” procedures. Note the following points. 1.Lubricate: ● Oil seal lip 1 (rear axle) ● Bearings 2 (rear axle) ● Axle spline (rear axle) 2.Install: ● Rear axle 1 NOTE: Before installing the rear axle, loosen all the bolts on the final gear case 2 . Hold the r ...

  • Yamaha 4XE-F8197-10 - page 245

    7 - 17 CHAS REAR WHEELS/REAR BRAKE AND REAR AXLE 5.Install: ● Brake camshaft 1 ● Wear indicator plate 2 ● Brake camshaft lever 3 NOTE: ● When installing the wear indicator plate 2 to the brake camshaft 1 align the pro- jection a on the wear indicator plate with the slot b on the brake camshaft. ● Align the punched mark c on the brake cams ...

  • Yamaha 4XE-F8197-10 - page 246

    7 - 18 CHAS REAR WHEELS/REAR BRAKE AND REAR AXLE 8.Install: ● Brake shoes 9.Lubricate: ● Dust seal 1 (backing plate) CAUTION: Do not apply grease to the brake shoe lin- ings. ● Brake drum spline CAUTION: Do not apply grease on the axle shaft spline, or the extra grease may contami- nate the brake shoes during running. 10.Install: ● Brake dr ...

  • Yamaha 4XE-F8197-10 - page 247

    7 - 19 CHAS REAR WHEELS/REAR BRAKE AND REAR AXLE 16.Install: ● Cotter pin 1 NOTE: Do not loosen the axle nut after torque tightening. If the axle nut groove is not aligned with the cotter pin hole, align groove with the hole by tightening up on the axle nut. W ARNING Always use a new cotter pin. 17.Install: ● Rear wheel 1 (right) ● Nuts 2 NOT ...

  • Yamaha 4XE-F8197-10 - page 248

    7 - 20 CHAS STEERING SYSTEM STEERING SYSTEM 1 Handlebar holder (upper) 2 Handlebar holder (lower) 3 Steering shaft 4 Steering bearing 5 Oil seal 6 Collar 7 Cable guide 8 Lock washer 9 Rod end 0 Tie-rod A TOE-IN: 0 ~ 5 mm (0 ~ 0.39 in) 7 ...

  • Yamaha 4XE-F8197-10 - page 249

    7 - 21 CHAS STEERING SYSTEM REMOVAL Handlebar 1.Remove: ● Front carrier ● Front bumper ● Front fender Refer to “FENDERS AND FUEL TANK- FRONT FENDER-Removal” section in CHAPTER 3. 2.Disconnect: ● Main switch lead ● “NEUTRAL” indicator light leads ● “REVERSE” indicator light leads ● Handlebar switch (left) leads ● Brake sw ...

  • Yamaha 4XE-F8197-10 - page 250

    7 - 22 CHAS STEERING SYSTEM Steering shaft 1.Straighten: ● Lock washer tabs 1 2.Remove: ● Bolts 2 ● Lock washer 3 ● Cable guide 4 3.Remove: ● Clip (steering shaft) ● Nut ● Washer 4.Remove: ● Cotter pins ● Nuts ● Tie-rods 1 NOTE: When removing the rod ends from the steering shaft and knuckle arm, use a Gen- eral Bearing Puller. 5 ...

  • Yamaha 4XE-F8197-10 - page 251

    7 - 23 CHAS STEERING SYSTEM INSPECTION 1.Inspect: ● Handlebar Cracks/Bends/Damage → Replace. 2.Inspect: ● Steering shaft Bends/Damage → Replace. W ARNING Do not attempt to straighten a bent shaft; this may dangerously weaken the shaft. 3.Inspect: ● Steering bearings 1 ● Oil seals 2 Wear/Damage → Replace. 4.Inspect: ● Tie-rod 1 Bend/ ...

  • Yamaha 4XE-F8197-10 - page 252

    7 - 24 CHAS STEERING SYSTEM 6.Adjust: ● Tie-rod assembly length ********************************* Tie-rod assembly length adjustment steps: ● Loosen the locknuts. ● Adjust the tie-rod assembly length a by turning both tie-rod ends. Å Right-hand-threads ı Left-hand-threads Ç To steering shaft Î To knuckle NOTE: The threads b on both tie-ro ...

  • Yamaha 4XE-F8197-10 - page 253

    7 - 25 CHAS STEERING SYSTEM 2.Lubricate: ● Steering bearings 1 ● Oil seals 2 Lithium-soap base grease 3.Install: ● Oil seals 1 (to steering shaft) ● Collars 2 ● Steering bearings 3 NOTE: Be careful not to damage the oil seals dur- ing installation. 4.Install: ● Steering shaft 1 (with steering bearings) W ARNING Make sure the brake cable ...

  • Yamaha 4XE-F8197-10 - page 254

    7 - 26 CHAS STEERING SYSTEM 7.Install: ● Cotter pin 1 NOTE: Do not loosen the axle nut after torque tightening. If the axle nut groove is not aligned with the cotter pin hole, align groove with the hole by tightening up on the axle nut. W ARNING Always use a new cotter pin. 8.Tighten: ● Washer ● Nut ● Clip T R . . Nut (steering shaft): 30 N ...

  • Yamaha 4XE-F8197-10 - page 255

    7 - 27 CHAS STEERING SYSTEM Handlebar 1.Install: ● Handlebar holder (lower) 1 ● Handlebar 2 ● Handlebar holders (upper) 3 NOTE: The upper handlebar holder should be installed with the punched mark a forward 2 . CAUTION: Tighten the handlebar bolts so that clear- ances b are spaced evenly. T R . . Handlebar holder (upper): 20 Nm (2.0 m • kg, ...

  • Yamaha 4XE-F8197-10 - page 256

    7 - 28 CHAS FRONT SHOCK ABSORBER AND FRONT ARM FRONT SHOCK ABSORBER AND FRONT ARM 1 Front shock absorber 2 Steering knuckle 3 Lower arm 4 Bushing 7 ...

  • Yamaha 4XE-F8197-10 - page 257

    7 - 29 CHAS REMOVAL 1.Remove: ● Front carrier ● Front bumper ● Front fender Refer to the “FENDERS AND FUEL TANK- FRONT FENDER - Removal” section in CHAPTER 3. ● Front wheel ● Brake drum ● Brake shoe plate Refer to “FRONT WHEELS AND FRONT BRAKE - Removal” section. 2.Remove: ● Cotter pin 1 ● Nut 2 ● Tie-rod end 3 NOTE: When ...

  • Yamaha 4XE-F8197-10 - page 258

    7 - 30 CHAS 7.Inspect: ● Lower arms free play ********************************* Inspection steps: ● Inspect the lower arm brackets 1 of the frame. If bent, cracked or damaged, repair or replace the frame. ● Check the tightening torque of the lower arm securing nuts 2 . ● Check the lower arm side play Å by mov- ing it from side to side. If ...

  • Yamaha 4XE-F8197-10 - page 259

    7 - 31 CHAS INSPECTION 1.Inspect: ● Shock absorber Oil leaks → Replace the shock absorber assembly. ● Ball joint Cracks/Damage → Replace the shock absorber assembly. ● Spring Fatigue/Damage → Replace the shock absorber assembly. Move the spring up and down. 2.Inspect: ● Steering knuckle Cracks/Pitting/Damage → Replace. W ARNING Do n ...

  • Yamaha 4XE-F8197-10 - page 260

    7 - 32 CHAS INSTALLATION Reverse the “REMOVAL” procedures. Note the following points. 1.Lubricate: ● Bushings 1 (inner surface) 2.Tighten: ● Nut 2 (lower arm) Lithium-soap base grease T R . . Nut (lower arm): 45 Nm (4.5 m • kg, 32 ft • lb) NOTE: Be sure to position the front arm securing bolts (front 1 and rear 2 ) so that the bolt head ...

  • Yamaha 4XE-F8197-10 - page 261

    7 - 33 CHAS FRONT SHOCK ABSORBER AND FRONT ARM 5.Install: ● Cotter pin 3 NOTE: Do not loosen the axle nut after torque tightening. If the axle nut groove is not aligned with the cotter pin hole, align groove with the hole by tightening up on the axle nut. W ARNING Always use a new cotter pin. 6.Install: ● Shock absorber 4 (front) ● Flange nut ...

  • Yamaha 4XE-F8197-10 - page 262

    7 - 34 CHAS NOTE: Do not loosen the axle nut after torque tightening. If the axle nut groove is not aligned with the cotter pin hole, align groove with the hole by tightening up on the axle nut. W ARNING Always use a new cotter pin. 10.Install: ● Brake shoe plate ● Brake drum ● Front wheel Refer to the “FRONT WHEELS AND FRONT BRAKE-INSTALLA ...

  • Yamaha 4XE-F8197-10 - page 263

    7 - 35 CHAS REAR SHOCK ABSORBER AND SWINGARM 1 Rear shock absorber 2 Thrust cover 3 Locknut 4 Pivot shaft 5 Collar 6 Oil seal 7 Taper roller bearing 8 Swingarm 9 Rubber boot 0 Final gear case protector A SWINGARM FREE PLAY LIMIT: SIDE” 1.0 mm (0.04 in) REAR SHOCK ABSORBER AND SWINGARM FWD 7 ...

  • Yamaha 4XE-F8197-10 - page 264

    7 - 36 CHAS REMOVAL 1.Remove: ● Rear wheel (left) ● Wheel hub ● Rear wheel (right) ● Brake drum ● Brake shoe plate ● Rear axle Refer to the “REAR WHEEL/REAR BRAKE AND REAR AXLE - REMOVAL” section. 2.Remove: ● Final gear case protector 1 3.Remove: ● Final gear case unit 1 Refer to the “FINAL DRIVE GEAR AN DRIVE SHAFT - REMOVAL? ...

  • Yamaha 4XE-F8197-10 - page 265

    7 - 37 CHAS 5.Remove: ● Nut 1 (shock absorber - upper) ● Bolt 2 ● Shock absorber 3 REAR SHOCK ABSORBER AND SWINGARM 6.Remove: ● Spring (rear brake pedal) 1 7.Remove: ● Caps (pivot shaft) 8.Inspect: ● Swingarm free play ********************************* Free play inspection steps: ● Check the tightening torque of the pivot shafts 1 and ...

  • Yamaha 4XE-F8197-10 - page 266

    7 - 38 CHAS REAR SHOCK ABSORBER AND SWINGARM 9.Remove: ● Rear axle housing 1 10.Remove: ● Clamp 1 (rubber boot) ● Locknut (right side of pivot shaft) ● Pivot shaft (swingarm) 11.Remove: ● Swingarm 1 INSPECTION 1.Inspect: ● Shock absorber Oil leaks → Replace the shock absorber assembly. ● Shock absorber rod Bends/Damage → Replace t ...

  • Yamaha 4XE-F8197-10 - page 267

    7 - 39 CHAS REAR SHOCK ABSORBER AND SWINGARM 2.Inspect: ● Swingarm Cracks/Bends/Damage → Replace. ● Axle housing Cracks/Bends/Damage → Replace. 3.Inspect: ● Final gear case under cover Cracks/Bends/Damage → Replace. 4.Inspect: ● Pivot shaft 1 (right side) ● Pivot shaft 2 (left side) ● Spacer collar 3 Wear/Damage → Replace. 5.Ins ...

  • Yamaha 4XE-F8197-10 - page 268

    7 - 40 CHAS REAR SHOCK ABSORBER AND SWINGARM ● Remove the bearings 3 using a general bearing puller. ● Install the new bearings and oil seal by reversing the previous steps. NOTE: Use a socket 4 that matches the outside diameter of the race of the bearing and oil seal. CAUTION: Do not strike the center race 5 or balls 6 of the bearing. Contact ...

  • Yamaha 4XE-F8197-10 - page 269

    7 - 41 CHAS REAR SHOCK ABSORBER AND SWINGARM 3.Tighten: ● Pivot shafts (swingarm) ● Locknut (pivot shaft) ********************************* Pivot shaft tightening steps: ● Tighten the pivot shaft 1 (left) to specifi- cation. ● Tighten the pivot shaft 2 (right) until it contacts the collar 3 . ● Tighten the locknut 4 (right) to specifica- ...

  • Yamaha 4XE-F8197-10 - page 270

    7 - 42 CHAS REAR SHOCK ABSORBER AND SWINGARM 7.Install: ● Clip 8.Install: ● Final gear assembly 1 Refer to the “FINAL DRIVE GEAR AND DRIVE SHAFT - ASSEMBLY - INSTALLA- TION” section in CHAPTER 6. 9.Install: ● Rear axle ● Brake shoe plate ● Brake drum ● Rear wheel (right) ● Wheel hub (left) ● Rear wheel (left) Refer to the “REA ...

  • Yamaha 4XE-F8197-10 - page 271

    8 - 1 –+ ELEC ELECTRICAL COMPONENTS EB800000 ELECTRICAL ELECTRICAL COMPONENTS 1 Wire harness 2 Fuses 3 Starter relay 4 Starting circuit cut-off relay 5 Battery 6 CDI unit 7 Rectifier/regulator 8 Reverse switch 9 Neutral switch 0 Spark plug cap A Ignition coil B Main switch C Neutral indicator light D Reverse indicator light 8 ...

  • Yamaha 4XE-F8197-10 - page 272

    8 - 2 –+ ELEC SWITCH INSPECTION SWITCH INSPECTION SWITCH INSPECTION Use a pocket tester to check the terminals for continuity. If the continuity is faulty at any point, replace the switch. NOTE: ● Set the pocket tester to “0” before starting the test. ● The pocket tester should be set to the “ Ω × 1” range when testing the switch f ...

  • Yamaha 4XE-F8197-10 - page 273

    8 - 3 –+ ELEC SWITCH INSPECTION 8 ...

  • Yamaha 4XE-F8197-10 - page 274

    8 - 4 –+ ELEC SWITCH INSPECTION SWITCH CONTINUITY INSPECTION Refer to “SWITCH INSPECTION” and check for continuity between lead terminals. Poor connection, no continuity → Correct or replace. * The coupler locations are circled. 8 ...

  • Yamaha 4XE-F8197-10 - page 275

    8 - 5 –+ ELEC SWITCH INSPECTION 1 Lights switch 2 Lights switch (for New Hampshire and Maine) 3 Engine stop switch 4 Starter switch 5 Main switch 6 Rear brake lever switch 7 Rear brake lever switch (for New Hampshire and Maine) 8 Front brake lever switch (for New Hampshire and Maine) 9 Rear brake pedal switch (for New Hampshire and Maine) 0 Rever ...

  • Yamaha 4XE-F8197-10 - page 276

    8 - 6 –+ ELEC CHECKING OF BULBS (FOR HEADLIGHT) CHECKING BULBS CONDITION 1.Remove the bulb. ACHTUNG: CAUTION: Be sure to hold the socket firmly when removing the bulb. Never pull the lead. Otherwise, the lead may be pulled off the terminal in the coupler. W ARNING Keep flammable products and your hands away from the headlight bulb while it is on. ...

  • Yamaha 4XE-F8197-10 - page 277

    8 - 7 –+ ELEC IGNITION SYSTEM EB802000 IGNITION SYSTEM CIRCUIT DIAGRAM B R B / W Br B / W Br B R W / G W / R Br B O B / W B L / W B R / W O B / W Br B W / G W / R OFF ON OFF LO HI LO HI OFF ON RUN OFF R L / W B G / Y Sb L / W R / W ı Å Å (BLACK) (GLAY) (GLAY) Br Y BB (BLACK) (BLACK) Y B G Y B G Y B G Y B G Y / R Br L R / W L R / W Br Br / W WW ...

  • Yamaha 4XE-F8197-10 - page 278

    8 - 8 –+ ELEC IGNITION SYSTEM EB802010 TROUBLESHOOTING IF THE IGNITION SYSTEM FAILS TO OPERATE (NO SPARK OR INTERMITTENT SPARK): Procedure Check: 1.Spark plugs 2.Ignition spark gap 3.Spark plug cap resistance 4.Ignition coil resistance 5.Engine stop switch 6.Main switch 7.Pickup coil resistance 8.Source coil resistance 9.Wiring connection (the en ...

  • Yamaha 4XE-F8197-10 - page 279

    8 - 9 –+ ELEC IGNITION SYSTEM for EUR/AUS 2.Ignition spark gap ● Disconnect the spark plug cap from the spark plug. ● Connect the ignition checker 1 as shown. 2 Spark plug cap ● Turn the main switch to “ON”. ● Check the ignition spark gap a . ● Crank the engine by pushing the starter switch and increase the spark gap until a misfire ...

  • Yamaha 4XE-F8197-10 - page 280

    8 - 10 –+ ELEC IGNITION SYSTEM C0NTINUITY 4.Ignition coil resistance ● Disconnect the ignition coil connector from the wire harness. ● Connect the pocket tester ( Ω × 1) to the ignition coil. * Tester (+) lead → Orange lead terminal Tester (–) lead → Ignition coil base Tester (+) lead → Ignition coil base Tester (–) lead → Spar ...

  • Yamaha 4XE-F8197-10 - page 281

    8 - 11 –+ ELEC IGNITION SYSTEM C0NTINUITY 7.Pickup coil resistance ● Disconnect the CDI magneto coupler from the wire harness. ● Connect the pocket tester ( Ω × 100) to the pickup coil terminal. Tester (+) lead → White/Green terminal 1 Tester (–) lead → White/Red terminal 2 * Br W / G B W / R 2 1 MEETS SPECIFICATION ● Check the pic ...

  • Yamaha 4XE-F8197-10 - page 282

    8 - 12 –+ ELEC ELECTRIC STARTING SYSTEM EB803000 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM B R B / W Br B / W Br B R W / G W / R Br B O B / W B L / W B R / W O B / W Br B W / G W / R OFF ON OFF LO HI LO HI OFF ON RUN OFF R L / W B G / Y Sb L / W R / W ı Å Å (BLACK) (GLAY) (GLAY) Br Y BB (BLACK) (BLACK) Y B G Y B G Y B G Y B G Y / R Br L R / W L ...

  • Yamaha 4XE-F8197-10 - page 283

    8 - 13 –+ ELEC ELECTRIC STARTING SYSTEM STARTING CIRCUIT OPERATION The starting circuit on this model consists of the starter motor, starter relay, starting circuit cut-off relay, rear brake lever switch, and neutral switch. If the main switch is on position, the starter motor can be operated only if: The starting circuit cut-off relay prevents t ...

  • Yamaha 4XE-F8197-10 - page 284

    8 - 14 –+ ELEC ELECTRIC STARTING SYSTEM EB803020 TROUBLESHOOTING IF THE STARTER MOTOR FAILS TO OPERATE: Procedure Check: 1.Fuse (main) 2.Battery 3.Starter motor 4.Starting circuit cut-off relay 5.Starter relay 6.Main switch 7.Neutral switch 8.Rear brake lever switch 9.Start switch 10.Wiring connection (the entire starting system) NOTE: ● Remove ...

  • Yamaha 4XE-F8197-10 - page 285

    8 - 15 –+ ELEC ELECTRIC STARTING SYSTEM C0NTINUITY MOVES 3.Starter motor ● Connect the battery positive terminal 1 and starter motor cable 2 using a jumper lead 3 . ● Check the operation of the starter motor. * * 1 M 2 3 R L / W B W ARNING ● A wire that is used as a jumper lead must have the equivalent capacity or more as that of the batter ...

  • Yamaha 4XE-F8197-10 - page 286

    8 - 16 –+ ELEC ELECTRIC STARTING SYSTEM C0NTINUITY 5.Starter relay ● Remove the starter relay from the wire harness. ● Connect the pocket tester ( Ω × 1) and the battery (12 V) to the starter relay termi- nals. * 3 4 2 1 R B R L / W B CONTINUITY Battery (+) terminal → Blue/White terminal 1 Battery (–) terminal → Black terminal 2 Test ...

  • Yamaha 4XE-F8197-10 - page 287

    8 - 17 –+ ELEC C0NTINUITY CORRECT 8.Rear brake lever switch Refer to “SWITCH INSPECTION”. * INCORRECT Replace the rear brake lever switch. CORRECT 9.Start switch Refer to “SWITCH INSPECTION”. INCORRECT Replace the handlebar switch (left). EB803028 10.Wiring connection ● Check the connections of the entire start- ing system. Refer to “ ...

  • Yamaha 4XE-F8197-10 - page 288

    –+ ELEC 8 - 18 ELECTRIC STARTING SYSTEM STARTER MOTOR Order Job name/Part name Q’ty Remarks Starter motor removal Remove the parts in the order below. 1 Starter motor lead 1 2 Starter motor bracket 1 3 Starter motor / O-ring 1/1 Starter motor disassembly Disassemble the parts in the order below. 1 Bracket 1 1 Refer to “STARTER MOTOR ASSEM- BL ...

  • Yamaha 4XE-F8197-10 - page 289

    8 - 19 –+ ELEC ELECTRIC STARTING SYSTEM STARTER MOTOR INSPECTION 1.Inspect: ● Commutator Dirty → Clean it with #600 grit sandpaper. 2.Measure: ● Commutator diameter a Out of specification → Replace the starter motor. 3.Measure: ● Mica undercut b Out of specification → Scrape the mica using a hacksaw blade. NOTE: Scrape the mica to the ...

  • Yamaha 4XE-F8197-10 - page 290

    8 - 20 –+ ELEC ELECTRIC STARTING SYSTEM 5.Measure: ● Brush length a (each) Out of specification → Replace the brush. Brush length: 10 mm (0.39 in) <Wear limit:> 3.5 mm (0.14 in) 6.Measure: ● Brush spring force Fatigue/out of specification → Replace as a set. Brush spring force: 730 ~ 970 g (7.16 ~ 9.52 N) 7.Inspect: ● Oil seal ● ...

  • Yamaha 4XE-F8197-10 - page 291

    8 - 21 –+ ELEC CHARGING SYSTEM EB804000 CHARGING SYSTEM CIRCUIT DIAGRAM B R B / W Br B / W Br B R W / G W / R Br B B B R / W O B / W Br B W / G W / R OFF ON OFF LO HI OFF ON RUN OFF R L / W B G / Y Sb Å (BL A (GLAY) ( Y B G Y B G Y B G Y B G Y / R Br L R / W L R / W Br Br / W WW W WW W B C D I K J L EF G HH 1 2 3 4 5 6 78 Br R B B / W B / W L / ...

  • Yamaha 4XE-F8197-10 - page 292

    8 - 22 –+ ELEC CHARGING SYSTEM EB804010 TROUBLESHOOTING IF THE BATTERY IS NOT CHARGED: Procedure Check: 1.Fuse (main) 2.Battery 3.Charging voltage 4.Stator coil resistance 5.Wiring connections (the entire charging system) NOTE: ● Remove the following part(s) before trou- bleshooting: 1)Seat ● Use the following special tool(s) for trou- blesho ...

  • Yamaha 4XE-F8197-10 - page 293

    8 - 23 –+ ELEC CHARGING SYSTEM OUT OF SPECIFICATION ● Start the engine and accelerate to about 2,000 r/min. Charging voltage: 14 to 15 V at 2,000 r/min NOTE: Use a fully charged battery. MEETS SPECIFICATION The charging circuit is not faulty. EB804012 MEETS SPECIFICATION 4.Stator coil resistance ● Disconnect the AC magneto coupler from the wi ...

  • Yamaha 4XE-F8197-10 - page 294

    8 - 24 –+ ELEC LIGHTING SYSTEM EB805000 LIGHTING SYSTEM CIRCUIT DIAGRAM B R B / W Br B / W Br B R W / G W / R Br B O B / W B L / W B R / W O B / W Br B W / G W / R OFF ON OFF LO HI LO HI OFF ON RUN OFF R L / W B G / Y Sb L / W R / W ı Å Å (BLACK) (GLAY) (GLAY) Br Y BB (BLACK) (BLACK) Y B G Y B G Y B G Y B G Y / R Br L R / W L R / W Br Br / W W ...

  • Yamaha 4XE-F8197-10 - page 295

    8 - 25 –+ ELEC LIGHTING SYSTEM EB805010 TROUBLESHOOTING IF THE HEADLIGHT AND/OR TAILLIGHT FAIL TO COME ON: Procedure Check: 1.Fuse (main) 2.Battery 3.Main switch 4.Lights switch 5.Wiring connections (the entire lighting system) NOTE: ● Remove the following part(s) before trou- bleshooting: 1)Seat 2)Front carrier 3)Front fender ● Use the follo ...

  • Yamaha 4XE-F8197-10 - page 296

    8 - 26 –+ ELEC LIGHTING SYSTEM C0NTINUITY CORRECT 3.Main switch Refer to “SWITCH INSPECTION”. * INCORRECT Replace the main switch. CORRECT 4.Lights switch Refer to “SWITCH INSPECTION”. Lights switch is faulty, replace the handle- bar switch (left). EB805013 CORRECT 5.Wiring connection ● Check the connections of the entire light- ing sys ...

  • Yamaha 4XE-F8197-10 - page 297

    8 - 27 –+ ELEC LIGHTING SYSTEM EB805020 LIGHTING SYSTEM CHECK 1.If the headlights fail to come on: CONTINUITY 1.Bulb and bulb socket ● Check the bulb and bulb socket for conti- nuity. NO CONTINUITY Replace the bulb and/or bulb socket. 2.Voltage ● Connect the pocket tester (DC 20 V) to the headlight couplers. Tester (+) lead → Green terminal ...

  • Yamaha 4XE-F8197-10 - page 298

    8 - 28 –+ ELEC LIGHTING SYSTEM 2.If the taillight fails to come on: CONTINUITY 1.Bulb and bulb socket ● Check the bulb and bulb socket for conti- nuity. NO CONTINUITY Replace the bulb and/or bulb socket. 2.Voltage ● Connect the pocket tester (DC 20 V) to the taillight leads. Tester (+) lead → Blue terminal 1 Tester (–) lead → Black term ...

  • Yamaha 4XE-F8197-10 - page 299

    8 - 29 –+ ELEC SIGNAL SYSTEM EB806000 SIGNAL SYSTEM CIRCUIT DIAGRAM B R B / W Br B / W Br B R W / G W / R Br B O B / W B L / W B R / W O B / W Br B W / G W / R OFF ON OFF LO HI LO HI OFF ON RUN OFF R L / W B G / Y Sb L / W R / W ı Å Å (BLACK) (GLAY) (GLAY) Br Y BB (BLACK) (BLACK) Y B G Y B G Y B G Y B G Y / R Br L R / W L R / W Br Br / W WW W ...

  • Yamaha 4XE-F8197-10 - page 300

    8 - 30 –+ ELEC SIGNAL SYSTEM EB806010 TROUBLESHOOTING IF THE INDICATOR LIGHT AND/OR BRAKE LIGHT FAILS TO COME ON: Procedure Check: 1.Fuse (main) 2.Battery 3.Main switch 4.Wiring connections (the entire signal system) NOTE: ● Remove the following part(s) before trou- bleshooting: 1)Seat 2)Front carrier 3)Front fender ● Use the following specia ...

  • Yamaha 4XE-F8197-10 - page 301

    8 - 31 –+ ELEC SIGNAL SYSTEM C0NTINUITY CORRECT 3.Main switch Refer to “SWITCH INSPECTION”. * INCORRECT Replace the main switch. EB806011 CORRECT 4.Wiring connections ● Check the connections of the entire sig- nal system. Refer to “CIRCUIT DIAGRAM”. Check the condition of each of the signal system’s circuits. Refer to “SIGNAL SYSTEM ...

  • Yamaha 4XE-F8197-10 - page 302

    8 - 32 –+ ELEC SIGNAL SYSTEM SIGNAL SYSTEM CHECK EB806024 1.If the neutral indicator light fails to come on: CONTINUITY 1.Bulb and bulb socket ● Check the bulb and bulb socket for conti- nuity. NO CONTINUITY Replace the bulb and/or bulb socket. CONTINUITY 2.Neutral switch Refer to “SWITCH INSPECTION”. NO CONTINUITY Replace the neutral switc ...

  • Yamaha 4XE-F8197-10 - page 303

    8 - 33 –+ ELEC SIGNAL SYSTEM 2.If the reverse indicator light fails to come on: CONTINUITY 1.Bulb and bulb socket ● Check the bulb and bulb socket for conti- nuity. NO CONTINUITY Replace the bulb and/or bulb socket. CONTINUITY 2.Reverse switch Refer to “SWITCH INSPECTION”. NO CONTINUITY Replace the reverse switch. 3.Voltage ● Connect the ...

  • Yamaha 4XE-F8197-10 - page 304

    8 - 34 –+ ELEC SIGNAL SYSTEM 3.If the brake light fails to come on: (for New Hampshire and Maine) CONTINUITY 1.Bulb and bulb socket ● Check the bulb and bulb socket for conti- nuity. NO CONTINUITY Replace the bulb and/or bulb socket. CONTINUITY 2.Brake switch Refer to “SWITCH INSPECTION”. NO CONDITION Replace the brake switches. CONTINUITY ...

  • Yamaha 4XE-F8197-10 - page 305

    TRBL SHTG 9 - 1 STARTING FAILURE/HARD STARTING TROUBLESHOOTING NOTE: The following troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to troubleshooting. Refer to the relative procedure in this man- ual for inspection, adjustment and replacement of parts. STARTING FAILURE/HARD STARTING FUEL ...

  • Yamaha 4XE-F8197-10 - page 306

    TRBL SHTG 9 - 2 STARTING FAILURE/HARD STARTING/POOR IDLE SPEED PERFORMANCE/POOR MEDIUM AND HIGH-SPEED PERFORMANCE COMPRESSION SYSTEM Cylinder and cylinder head ● Loose spark plug ● Loose cylinder head or cylinder ● Broken cylinder head gasket ● Worn, damaged or seized cylinder Piston and piston rings ● Improperly installed piston ring ● ...

  • Yamaha 4XE-F8197-10 - page 307

    9 - 3 TRBL SHTG FAULTY DRIVE TRAIN FAULTY DRIVE TRAIN The following conditions may indicate damaged shaft drive components: 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 to believe these components are damaged ...

  • Yamaha 4XE-F8197-10 - page 308

    TRBL SHTG 9 - 4 F AUL TY GEAR SHIFTING/ FAULTY CLUTCH PERFORMANCE FAULTY GEAR SHIFTING HARD SHIFTING Refer to “CLUTCH SLIPPING/DRAGGING-CLUTCH DRAGGING”. SHIFT PEDAL DOES NOT MOVE Shift shaft ● Bent shift shaft Shift cam, shift fork ● Groove jammed with impurities ● Seized shift fork ● Bent shift fork guide bar Transmission ● Seized t ...

  • Yamaha 4XE-F8197-10 - page 309

    TRBL SHTG 9 - 5 FAULTY CLUTCH PERFORMANCE/ OVERHEATING/FAULTY BRAKE OVERHEATING OVERHEATING Ignition system ● Improper spark plug gap ● Improper spark plug heat range ● Faulty CDI unit Fuel system ● Improper carburetor main jet (improper setting) ● Improper fuel level ● Clogged air filter element Compression system ● Heavy carbon buil ...

  • Yamaha 4XE-F8197-10 - page 310

    TRBL SHTG 9 - 6 UNSTABLE HANDLING SHOCK ABSORBER MALFUNCTION/ UNSTABLE HANDLING/LIGHTING SYSTEM UNSTABLE HANDLING Handlebar ● Improperly installed or bent Steering ● Incorrect toe-in ● Bent steering shaft ● Improperly installed steering shaft ● Damaged bearing or bearing race ● Bent tie rods ● Deformed steering knuckles Tires ● Unev ...

  • Yamaha 4XE-F8197-10 - page 311

    YFM250XL WIRING DIAGRAM 1 Main switch 2 Battery 3 Fuse 4 Starter relay 5 Starter motor 6 Rectifier / regulator 7 CDI magneto 8 CDI unit 9 Ignition coil 0 Spark plug A Starting circuit cut-off relay B Rear brake lever switch C Tail light D Handlebar switch E Engine stop switch F Starter switch G Lights switch H Headlight I Neutral indicator light J ...

  • Yamaha 4XE-F8197-10 - page 312

    PRINTED IN U.S.A. Y AMAHA MOT OR CO., L TD. 2500 SHINGAI IWATA SHIZUOKA JAPAN ...

  • Yamaha 4XE-F8197-10 - page 313

    SUPPLEMENT AR Y SERVICE MANUAL LIT -1 1616-14-17 4XE-F8197-1 1 YFM250XN ...

  • Yamaha 4XE-F8197-10 - page 314

    YFM250XN SUPPLEMENTARY SERVICE MANUAL  2000 by Yamaha Motor Corporation, U.S.A. First Edition, April 2000 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. LIT-11616-14-17 FOREWORD This Supplementary Service Manual has been prepa ...

  • Yamaha 4XE-F8197-10 - page 315

    EB001000 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 who uses this book to perform maintenance and repairs on Yamaha machine has a basic understanding of the mec ...

  • Yamaha 4XE-F8197-10 - page 316

    EB002000 HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual is intended as a handy, easy-to-read reference book for the mechanic. It is divided into chapters, sections and sub-sections. Comprehensive explanations of all installation, removal, dis- assembly, assembly, repair and inspection procedures are laid out with the individual steps in seq ...

  • Yamaha 4XE-F8197-10 - page 317

    EB003000 ILLUSTRATED SYMBOLS Illustrated symbols 1 to 9 are printed on the top right of each page and indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic inspections and adjustments 4 Engine 5 Carburetion 6 Drive train 7 Chassis 8 Electrical 9 Troubleshooting Illustrated symbols 0 to F are used to identify the sp ...

  • Yamaha 4XE-F8197-10 - page 318

    CONTENTS GENERAL INFORMATION .............................................................................. 1 MACHINE IDENTIFICATION ................................................................... 1 VEHICLE IDENTIFICATION NUMBER ............................................ 1 MODEL LABEL .......................................................... ...

  • Yamaha 4XE-F8197-10 - page 319

    ELECTRICAL ................................................................................................. 40 ELECTRICAL COMPONENTS .............................................................. 40 IGNITION SYSTEM ............................................................................... 41 CIRCUIT DIAGRAM ................................... ...

  • Yamaha 4XE-F8197-10 - page 320

    – 1 – GEN INFO MACHINE IDENTIFICATION GENERAL INFORMATION MACHINE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the left side of the frame. MODEL LABEL The model label 1 is affixed to the frame. This information will be needed to order spare parts. ...

  • Yamaha 4XE-F8197-10 - page 321

    – 2 – SPEC SPECIFICA TIONS GENERAL SPECIFICA TIONS Item Standard Model code: 4XEA (USA) Dimensions: Ov erall length 1,940 mm (76.4 in) Ov erall width 1,005 mm (39.6 in) Ov erall height 1,118 mm (44.0 in) Seat height 780 mm (30.7 in) Wheelbase 1,170 mm (46.1 in) Minimum ground clear ance 150 mm (5.9 in) Minimum turning radius 2,900 mm (114 in) B ...

  • Yamaha 4XE-F8197-10 - page 322

    – 3 – SPEC MAINTENANCE SPECIFICA TIONS ENGINE Item Standard Limit Shifter : Shifter type Shift drum and guide bar ---- Guide bar bending limit ---- 0.8 mm (0.032 in) Carburetor: I. D . mark 4XEA 12 ---- Main jet (M.J) #95 ---- Main air jet (M.A.J) 0.7 ---- Jet needle (J.N) 5CE35-2 ---- Needle jet (N.J) P-2M (#823) ---- Pilot air jet (P .A.J .1) ...

  • Yamaha 4XE-F8197-10 - page 323

    – 4 – SPEC CHASSIS Item Standard Limit Rear suspension: Shock absorber tr av el 85 mm (3.35 in) ---- Suspension spring free length 268 mm (10.55 in) ---- Fitting length 244 mm (9.61 in) ---- Spring rate 3 9 N/mm (3.9 kg/mm, 222.69 lb/in)/ 0 ~ 85 mm (0 ~ 3.35 in) ---- Optional spring No ---- F ront wheel: T ype Disc wheel ---- Rim size 10 × 6.0 ...

  • Yamaha 4XE-F8197-10 - page 324

    – 5 – SPEC Tightening torques P ar t to be tightened P ar ts name Thread size Q’ty Tightening torque Remar ks Nm m·kg ft·lb Front panel wheel and wheel hub N u t M10 × 1.25 8 55 5.5 40 Wheel hub and steering knuckle Nut M14 × 1.5 2 70 7.0 50 Steering knuckle and brake caliper Bolt M8 × 1.25 4 30 3.0 22 Brake disc and wheel hub Bolt M8 × ...

  • Yamaha 4XE-F8197-10 - page 325

    – 6 – SPEC ELECTRICAL Item Standard Limit C.D.I.: Magneto model/manuf acturer F4T259/MITSUBISHI ---- Pickup coil resistance/color 189 ~ 231 Ω at 20˚C (68˚F)/ White/Green – White/Red ---- Charging/rotor rotation direction detection coil resistance/color 270 ~ 330 Ω at 20˚C (68˚F)/ Red/White/Blue ---- C .D .I. unit model/manuf acturer F ...

  • Yamaha 4XE-F8197-10 - page 326

    – 7 – SPEC CABLE ROUTING CABLE ROUTING 1 Rear brake lever switch lead 2 Rear brake cable 3 Cable guide 4 Front brake hose 5 Throttle cable 6 Neutral indicator light 7 Reverse indicator light 8 Handlebar switch assembly lead 9 Fuel tank breather hose 0 Headlight leads Å Do not route the handlebar switch assembly lead through the lower bracket c ...

  • Yamaha 4XE-F8197-10 - page 327

    – 8 – SPEC CABLE ROUTING 1 Cable guide 2 Main switch 3 Fuel tank breather hose 4 Taillight 5 Final gear case breather hose 6 Carburetor overflow hose 7 Reverse switch lead 8 Neutral switch lead 9 Starter motor lead 0 Throttle cable A Rear brake cable B Rear brake breather hose C Carburetor air vent hose D CDI magneto lead Å Route the main swit ...

  • Yamaha 4XE-F8197-10 - page 328

    – 9 – SPEC CABLE ROUTING Ç Make sure that the starter motor lead is not slacked. Î Fasten the starter motor lead and wire harness to the frame with the plastic band. ‰ Fasten the starter motor lead and wire harness to the frame with the plastic clamp. Ï Route the starter motor lead, wire harness, and battery - lead through the hole in the ...

  • Yamaha 4XE-F8197-10 - page 329

    – 10 – SPEC Ò Fasten the starter motor lead and wire harness to the frame with the plastic clamp. ˜ Route the rear brake cable and rear brake breather hose through the cable guide. ˆ Fasten the rear brake cable and rear brake breather hose to the swingarm with the plastic clips. Ø Route the rear brake breather hose through the cable guide. ...

  • Yamaha 4XE-F8197-10 - page 330

    – 11 – SPEC CABLE ROUTING 1 Battery breather hose 2 Spark plug cap 3 Ignition coil 4 Starter motor lead 5 Rear brake cable 6 Rear brake breather hose Å Make sure that the battery breather hose is not kinked or bent. ı Route the rear brake cable through the cable guide on the cyl- inder. Ç Fasten the starter motor lead to the frame with the p ...

  • Yamaha 4XE-F8197-10 - page 331

    – 12 – SPEC CABLE ROUTING 1 Wire harness 2 Starter motor lead 3 Rear brake cable 4 Throttle cable 5 Starter relay 6 Rectifier/regulator 7 CDI unit 8 Starting circuit cut-off relay 9 Rear brake breather hose 0 Carburetor air vent hose A Final gear case breather hose B Taillight lead Å Fasten the wire harness to the frame with the plastic clamps ...

  • Yamaha 4XE-F8197-10 - page 332

    – 13 – SPEC CABLE ROUTING Ï Fasten the battery breather hose to the rear fender with the plastic clamp and then insert the clamp into the hole in the rear fender. Ì Fasten the battery + lead and starter motor lead to the rear fender with the plastic clamps. Ó Install the starter circuit cut-off relay onto the tab with its terminal side facin ...

  • Yamaha 4XE-F8197-10 - page 333

    – 14 – INSP ADJ INTRODUCTION/ PERIODIC MAINTENANCE/LUBRICATION PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjust- ments. These preventive maintenance procedures, if followed, will ensure more reliable machine operation and a longer service life. In add ...

  • Yamaha 4XE-F8197-10 - page 334

    – 15 – INSP ADJ PERIODIC MAINTENANCE/LUBRICATION *: It is recommended that these items be serviced by a Yamaha dealer. **: Lithium soap base grease. W ARNING Indicates a potential hazard that could result in serious injury or death. Steering shaft* • Lubricate every 6 months.** Fittings and Fasteners* • Check all chassis fittings and fasten ...

  • Yamaha 4XE-F8197-10 - page 335

    – 16 – INSP ADJ SPARK ARRESTER CLEANING ENGINE SPARK ARRESTER CLEANING 1.Clean: ● Spark arrester ********************************************* Cleaning steps: W ARNING ● Select a well-ventilated area free of com- bustible materials. ● Always let the exhaust system cool before performing this operation. ● Remove the purging bolt 1 . ● ...

  • Yamaha 4XE-F8197-10 - page 336

    – 17 – INSP ADJ FRONT BRAKE FLUID LEVEL INSPECTION/ FRONT BRAKE PAD INSPECTION CHASSIS FRONT BRAKE FLUID LEVEL INSPECTION 1.Place the machine on a level surface. N OTE: When inspecting the front brake fluid level, make sure that the top of the master cylinder top is horizontal. 2.Inspect: ● Brake fluid level Fluid level is under “LOWER” l ...

  • Yamaha 4XE-F8197-10 - page 337

    – 18 – INSP ADJ BRAKE HOSE INSPECTION/ AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) BRAKE HOSE INSPECTION 1.Remove: ● Front carrier ● Front fender Refer to “FENDER AND FUEL TANK”. 2.Inspect: ● Brake hoses 1 Cracks/wear/damage → Replace. 3.Check: ● Brake hose clamp Loosen → Tighten. 4.Hold the machine in an upright position and apply th ...

  • Yamaha 4XE-F8197-10 - page 338

    – 19 – INSP ADJ AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) 1.Bleed: ● Brake system ********************************************* Air bleeding steps: a. Add the proper brake fluid to the reservoir. b. Install the diaphragm. Be careful not to spill any fluid or allow the reservoir to overflow. c. Connect the clear plastic hose 1 tightly to the calip ...

  • Yamaha 4XE-F8197-10 - page 339

    – 20 – CHAS FRONT WHEEL CHASSIS FRONT WHEEL 1 Wheel cap 2 Cotter pin 3 Axle nut 4 Plain washer 5 Wheel nut 6 Front wheel 7 Spacer 8 Oil seal 9 Bearing 0 Front wheel hub A Bearing spacer TIRE AIR PRESSURE Cold Tire Pressure Front Rear Standard 20 kPa (0.20 kg/cm 2 , 2.9 psi) 25 kPa (0.25 kg/cm 2 , 3.6 psi) Minimum 17 kPa (0.17 kg/cm 2 , 2.5 psi) ...

  • Yamaha 4XE-F8197-10 - page 340

    – 21 – CHAS REMOVAL 1.Place the machine on a level surface. 2.Loosen: ● Nuts (front wheel) Apply the front brake. 3.Block the rear wheels, and elevate the front wheels by placing the suitable stand under the frame. 4.Remove: ● Nuts 1 (front wheel) ● Front wheel 2 5.Remove: ● Wheel cap ● Cotter pin 1 ● Axle nut 2 ● Plain washer 3 1 ...

  • Yamaha 4XE-F8197-10 - page 341

    – 22 – CHAS FRONT WHEEL 8.Remove: ● Front brake disc 1 1 INSPECTION 1.Inspect: ● Wheel hub 1 Cracks/damage → Replace. ...

  • Yamaha 4XE-F8197-10 - page 342

    – 23 – CHAS FRONT BRAKE FRONT BRAKE 1 Brake master cylinder reservoir cap 2 Brake master cylinder reservoir diaphragm holder 3 Brake master cylinder reservoir diaphragm 4 Brake master cylinder 5 Brake master cylinder kit 6 Copper washer 7 Union bolt 8 Brake hose 9 Brake pipe 0 Brake disc A Caliper bleed screw B Retaining bolt C Brake caliper D ...

  • Yamaha 4XE-F8197-10 - page 343

    – 24 – CHAS FRONT BRAKE CAUTION: Disc brake components rarely require dis- assembly. DO NOT: ● Disassemble components unless abso- lutely necessary. ● Use solvents on internal brake compo- nents. ● Use contaminated brake fluid for clean- ing. Use only clean brake fluid. ● Allow brake fluid to come in contact with the eyes, otherwise eye ...

  • Yamaha 4XE-F8197-10 - page 344

    – 25 – CHAS FRONT BRAKE 5.Remove: ● Brake pads 1 (with pad shim 2 ) ● Pad spring 3 N OTE: ● When pad replacement is required, also replace the pad spring and shim. ● Replace the pads as a set if either is found to be worn to the wear limit a . Wear limit a : 1.0 mm (0.04 in) 1 2 3 6.Install: ● Pad shim (onto inside brake pad) ● Pad ...

  • Yamaha 4XE-F8197-10 - page 345

    – 26 – CHAS FRONT BRAKE 7.Install: ● Retaining bolts ● Front brake caliper 8.Install: ● Front wheel 9.Inspect: ● Brake fluid level Refer to “FRONT BRAKE FLUID LEVEL INSPECTION”. a “LOWER” level line T R . . Retaining bolt: 18 Nm (1.8 m • kg, 13 ft • lb) Bolt (front brake caliper): 30 Nm (3.0 m • kg, 22 ft • lb) UP LOWER ...

  • Yamaha 4XE-F8197-10 - page 346

    – 27 – CHAS FRONT BRAKE 4.Remove: ● Union bolt 1 ● Copper washers 2 ● Brake hose 3 N OTE: Place the open end of the hose into a con- tainer and pump the oil fluid out carefully. 5.Remove: ● Caliper body 1 ● Caliper bracket 2 N OTE: Before removing the caliper body from the bracket, disconnect the dust boot from the guide shaft on the ...

  • Yamaha 4XE-F8197-10 - page 347

    – 28 – CHAS FRONT BRAKE 1.Remove: ● Brake lever 1 ● Union bolt 2 ● Copper washers 3 ● Brake hose 4 N OTE: Hold a container under the master cylinder and under the hose end to collect remaining brake fluid. 2.Remove: ● Brake master cylinder reservoir cap 1 ● Brake master cylinder reservoir diaphragm holder ● Brake master cylinder r ...

  • Yamaha 4XE-F8197-10 - page 348

    – 29 – CHAS FRONT BRAKE 1.Inspect: ● Caliper piston 1 Scratches/rust/wear → Replace caliper assembly. ● Caliper cylinder 2 Wear/scratches → Replace caliper assem- bly. ● Caliper body 3 Cracks/damage → Replace. ● Oil delivery passage (caliper body) Blow out with compressed air. W ARNING Replace the piston seal whenever the cali- pe ...

  • Yamaha 4XE-F8197-10 - page 349

    – 30 – CHAS FRONT BRAKE 6.Measure: ● Brake pads (thickness) a Out of specification → Replace. N OTE: ● When pad replacement is required, also replace the pad spring and shims. ● Replace the pads as a set if either is found to be worn to the wear limit a . Wear limit a : 1.0 mm (0.04 in) 7.Inspect: ● Brake disc Galling/damage → Repla ...

  • Yamaha 4XE-F8197-10 - page 350

    – 31 – CHAS FRONT BRAKE N OTE: Tighten the bolts (brake disc) in stage using a crisscross pattern. T R . . Bolt (brake disc): 16 Nm (1.6 m • kg, 12 ft • lb) CALIPER ASSEMBLY W ARNING ● All internal parts should be cleaned in new brake fluid only. ● Internal parts should be lubricated with brake fluid when installed. ● Replace the pist ...

  • Yamaha 4XE-F8197-10 - page 351

    – 32 – CHAS FRONT BRAKE 3.Install: ● Brake caliper 1 (temporarily) ● Copper washers 2 ● Brake hose 3 ● Union bolt 4 CAUTION: When installing the brake hose on the cali- per, make sure that the brake pipe touches the projection a on the brake caliper. W ARNING ● Proper hose routing is essential to insure safe machine operation. Refer t ...

  • Yamaha 4XE-F8197-10 - page 352

    – 33 – CHAS FRONT BRAKE 6.Fill: ● Reservoir tank N OTE: If DOT 4 is not available, 3 can be used. CAUTION: Brake fluid may erode painted surfaces or plastic parts. Always clean up spilled fluid immediately. W ARNING ● Use only the designated quality brake fluid: otherwise, the rubber seals may deteriorate, causing leakage and poor brake per ...

  • Yamaha 4XE-F8197-10 - page 353

    – 34 – CHAS FRONT BRAKE MASTER CYLINDER ASSEMBLY W ARNING ● All internal parts should be cleaned in new brake fluid only. ● Internal parts should be lubricated with brake fluid when installed. ● Replace the piston seals and dust seals whenever a brake master cylinder is dis- assembled. Recommended brake fluid: DOT 4 1.Install: ● Brake m ...

  • Yamaha 4XE-F8197-10 - page 354

    – 35 – CHAS FRONT BRAKE 3.Install: ● Copper washers ● Brake hose ● Union bolt N OTE: ● Tighten the union bolt while holding the brake hose as shown. ● Check that the brake hose does not touch other parts (throttle cable, wire harness, leads, etc.) by turning the handlebar left and right, and correct if necessary. W ARNING ● Proper h ...

  • Yamaha 4XE-F8197-10 - page 355

    – 36 – CHAS FRONT BRAKE ● Refill with the same type of brake fluid: mixing fluids may result in a harmful chemical reaction and lead to poor per- formance. ● Be careful that water does not enter the master cylinder when refilling. Water will significantly lower the boiling point of the fluid and may result in vapor lock. 6.Air bleed: ● Br ...

  • Yamaha 4XE-F8197-10 - page 356

    – 37 – CHAS REAR WHEELS/REAR BRAKE AND REAR AXLE 1 Rear axle 2 Bearing 3 Oil seal 4 Wheel hub 5 Axle nut A TIRE SIZE: AT22 × 10-10 B TIRE WEAR LIMIT: 2.0 mm (0.08 in) C RIM SIZE: 8 × 10AT D RIM RUNOUT LIMIT: Radial: 2 mm (0.08 in) Lateral: 2 mm (0.08 in) E REAR AXLE RUNOUT LIMIT: 1.5 mm (0.06 in) FWD REAR WHEELS/REAR BRAKE AND REAR AXLE ...

  • Yamaha 4XE-F8197-10 - page 357

    – 38 – CHAS FRONT SHOCK ABSORBER AND FRONT ARM FRONT SHOCK ABSORBER AND FRONT ARM 1 Front shock absorber 2 Steering knuckle 3 Lower arm 4 Bushing FWD ...

  • Yamaha 4XE-F8197-10 - page 358

    – 39 – CHAS REAR SHOCK ABSORBER AND SWINGARM REAR SHOCK ABSORBER AND SWINGARM 1 Rear shock absorber 2 Thrust cover 3 Locknut 4 Pivot shaft 5 Collar 6 Oil seal 7 Taper roller bearing 8 Swingarm 9 Rubber boot 0 Final gear case protector A SWINGARM FREE PLAY LIMIT: End: 1.0 mm (0.04 in) Side: 1.0 mm (0.04 in) FWD ...

  • Yamaha 4XE-F8197-10 - page 359

    – 40 – –+ ELEC ELECTRICAL COMPONENTS EB800000 ELECTRICAL ELECTRICAL COMPONENTS 1 Reverse indicator light 2 Neutral indicator light 3 Main switch 4 Rear brake lever switch 5 Handlebar switch 6 Fuses 7 Starter relay 8 Rectifier/regulator 9 CDI unit 0 Taillight A Battery B Starting circuit cut-off relay C Reverse switch D Neutral switch E Headli ...

  • Yamaha 4XE-F8197-10 - page 360

    – 41 – –+ ELEC IGNITION SYSTEM EB802000 IGNITION SYSTEM CIRCUIT DIAGRAM B R B / W Br B / W Br B R OFF ON 3 Br Br RR L / WL / B 4 5 6 7 R R B B B B B L / W L / W R R R G / Y Sb L / W R / B (BLACK) (BLACK) (BLACK) (BLACK) 0 A 8 B G / Y Sb O O F CB G / Y B D E OFF LO HI I J L L L OFF RUN G OFF PUSH H R / W B K G Y G Y B B B GY B YG B YG K G Y B ...

  • Yamaha 4XE-F8197-10 - page 361

    – 42 – –+ ELEC IGNITION SYSTEM EB802010 TROUBLESHOOTING IF THE IGNITION SYSTEM FAILS TO OPERATE (NO SPARK OR INTERMITTENT SPARK): Procedure Check: 1.Fuse 2.Battery 3.Spark plug 4.Ignition spark gap 5.Spark plug cap resistance 6.Ignition coil resistance 7.Engine stop switch 8.Main switch 9.Pickup coil resistance 10. Charging/rotor rotation dir ...

  • Yamaha 4XE-F8197-10 - page 362

    – 43 – –+ ELEC IGNITION SYSTEM C0NTINUITY CORRECT Spark plug gap: 0.6 ~ 0.7 mm (0.024 ~ 0.028 in) * INCORRECT Repair or replace the spark plug. OUT OF SPECIFICATION OR NO SPARK 4.Ignition spark gap ● Disconnect the spark plug cap from the spark plug. ● Connect the dynamic spark tester 1 as shown. 2 Spark plug cap 3 Spark plug ● Turn the ...

  • Yamaha 4XE-F8197-10 - page 363

    – 44 – –+ ELEC IGNITION SYSTEM C0NTINUITY 6.Ignition coil resistance ● Disconnect the ignition coil connector from the wire harness. ● Connect the pocket tester ( Ω × 1) to the ignition coil. * Tester (+) lead → Orange lead terminal Tester (–) lead → Ignition coil base Tester (+) lead → Ignition coil base Tester (–) lead → ...

  • Yamaha 4XE-F8197-10 - page 364

    – 45 – –+ ELEC IGNITION SYSTEM C0NTINUITY 9.Pickup coil resistance ● Disconnect the CDI magneto coupler from the wire harness. ● Connect the pocket tester ( Ω × 100) to the pickup coil terminal. Tester (+) lead → White/Green terminal 1 Tester (–) lead → White/Red terminal 2 * MEETS SPECIFICATION ● Check the pickup coil for the ...

  • Yamaha 4XE-F8197-10 - page 365

    – 46 – –+ ELEC IGNITION SYSTEM C0NTINUITY CORRECT 11. Wiring connection ● Check the connections of the entire ignition system. Refer to “CIRCUIT DIAGRAM”. Replace the CDI unit. * POOR CONNECTION Properly connect the ignition system. ...

  • Yamaha 4XE-F8197-10 - page 366

    – 47 – –+ ELEC ELECTRIC STARTING SYSTEM EB803000 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM B R B / W Br B / W Br B R OFF ON 3 Br Br RR L / WL / B 4 5 6 7 R R B B B B B L / W L / W R R R G / Y Sb L / W R / B (BLACK) (BLACK) (BLACK) (BLACK) 0 A 8 B G / Y Sb O O F CB G / Y B D E OFF LO HI I J L L L OFF RUN G OFF PUSH H R / W B K G Y G Y B B B GY ...

  • Yamaha 4XE-F8197-10 - page 367

    – 48 – –+ ELEC ELECTRIC STARTING SYSTEM STARTING CIRCUIT OPERATION The starting circuit on this model consists of the starter motor, starter relay, starting circuit cut-off relay, rear brake lever switch, and neu- tral switch. If the main switch is on and engine stop switch is in the RUN position, the starter motor can be operated only if: Th ...

  • Yamaha 4XE-F8197-10 - page 368

    – 49 – –+ ELEC ELECTRIC STARTING SYSTEM EB803020 TROUBLESHOOTING IF THE STARTER MOTOR FAILS TO OPERATE: Procedure Check: 1.Fuse 2.Battery 3.Starter motor 4.Starting circuit cut-off relay 5.Starter relay 6.Main switch 7.Engine stop switch 8.Neutral switch 9.Rear brake lever switch 10. Start switch 11. Wiring connection (the entire starting sys ...

  • Yamaha 4XE-F8197-10 - page 369

    – 50 – –+ ELEC ELECTRIC STARTING SYSTEM C0NTINUITY MOVES 3.Starter motor ● Connect the battery positive terminal 1 and starter motor lead 2 using a jumper lead 3 . ● Check the operation of the starter motor. * * 1 M 2 3 R L / W L / B R W ARNING ● A wire that is used as a jumper lead must have the equivalent capacity or more as that of t ...

  • Yamaha 4XE-F8197-10 - page 370

    – 51 – –+ ELEC ELECTRIC STARTING SYSTEM C0NTINUITY 5.Starter relay ● Remove the starter relay from the wire har- ness. ● Connect the pocket tester ( Ω × 1) and the battery (12 V) to the starter relay terminals. * 3 4 2 1 R B RR L / W L / B CONTINUITY Battery (+) terminal → Blue/White terminal 1 Battery (–) terminal → Blue/Black t ...

  • Yamaha 4XE-F8197-10 - page 371

    – 52 – –+ ELEC ELECTRIC STARTING SYSTEM C0NTINUITY CORRECT 9.Rear brake lever switch Refer to “SWITCH INSPECTION”. * INCORRECT Replace the rear brake lever switch. CORRECT 10.Start switch Refer to “SWITCH INSPECTION”. INCORRECT Replace the handlebar switch (left). EB803028 11.Wiring connection ● Check the connections of the entire s ...

  • Yamaha 4XE-F8197-10 - page 372

    PRINTED IN U.S.A. Y AMAHA MO T OR CO. , L TD . 2500 SHINGAI IW A T A SHIZUOKA JAP AN ...

  • Yamaha 4XE-F8197-10 - page 373

    B R B / W Br B / W Br B R OFF ON 3 Br Br RR L / WL / B 4 5 6 7 R R B B B B B L / W L / W R R R G / Y Sb L / W R / B (BLACK) (BLACK) (BLACK) (BLACK) 0 A 8 B G / Y Sb O O F CB G / Y B D E OFF LO HI I J L L L OFF RUN G OFF PUSH H R / W B K G Y G Y B B B GY B YG B YG K G Y B B GY Sb G / LR / W R / W Br Br Sb G / L G / L G / L Sb G / L G / L Sb Br Br L ...

  • Yamaha 4XE-F8197-10 - page 374

    YFM250XP SUPPLEMENTARY SERVICE MANUAL LIT-11616-15-03 4XE-F8197-12 ...

  • Yamaha 4XE-F8197-10 - page 375

    FOREWORD This Supplementary Service Manual has been prepared to introd uce new service and new data for the YFM250XP. For complete information on service procedures, it is necessary to use this Supple- mentary Service Manual together with the following manual. YFM250XL(C) SERVICE MANUAL: LIT-11616-12-01 (4XE-F8197-1 0) YFM250XN SUPPLEMENTARY SERVIC ...

  • Yamaha 4XE-F8197-10 - page 376

    EB001000 NOTICE This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not po ssible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to pe rform maintenance and repairs on Yamaha machine has a basic understanding o f the ...

  • Yamaha 4XE-F8197-10 - page 377

    HOW TO USE THIS MANUAL CONSTRUCTION OF THIS MANUAL This manual consists of chapters for the main ca tegories of subjects. (See “Illustrated symb ols”) 1st title 1 : This is a chapter with its symbol on the upper right o f each page. 2nd title 2 : This title appears on the upper of each page on the left of the chapter sym- bol. (For the chapter ...

  • Yamaha 4XE-F8197-10 - page 378

    EB003000 ILLUSTRATED SYMBOLS Illustrated symbols 1 to 9 are pr inted on the top right of each page and indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic checks and ad justments 4 Engine 5 Carburetion 6 Drive train 7 Chassis 8 Electrical 9 Troubleshooting Illustrated symbols 0 to F are used to identify the speci ...

  • Yamaha 4XE-F8197-10 - page 379

    CONTENTS SPECIFICATIONS ........................................ ................................................... 1 GENERAL SPECIFICATIONS .............. ................................................... 1 MAINTENANCE SPECIFICATION ........................................................... 2 ENGINE ............................................ ...

  • Yamaha 4XE-F8197-10 - page 380

    – 1 – SPEC GENERAL SPECIFICATIONS SPECIFICA TIONS GENERAL SPECIFICATIONS Item Standard Model code: 4XEE (USA) Brake: F ront brak e type Dual disc brake operation Right hand operation Rear brak e type Drum brake (fully sealed) operat ion Left hand and right foot operation Electrical: Ignition system DC.C.D.I. Generator system A.C. magneto Batter ...

  • Yamaha 4XE-F8197-10 - page 381

    – 2 – SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Cylinder head: W ar p limit ---- 0.03 mm (0.001 in) Measuring point Lines indicate straightedge measurement. Piston: Piston to cylinder clearance 0.04 ~ 0.06 mm (0.0016 ~ 0.0024 in) 0.15 mm (0.0059 in) Piston siz e “ D ” 70.92 ~ 70.97 mm (2.792 ~ 2.7 ...

  • Yamaha 4XE-F8197-10 - page 382

    – 3 – SPEC MAINTENANCE SPECIFICATIONS CHASSIS Tightening torques ELECTRICAL Item Standard Limit Rear suspension: Shoc k absorber tra vel 85 mm (3.35 in) ---- Suspension spring free length 268 mm (10.55 in) ---- Fitting length 244 mm (9.61 in) ---- S p r in g r a t e 39 N/mm (3.9 kg/mm, 222.69 lb /in)/0 ~ 85 mm (0 ~ 3.35 in) ---- Optional spring ...

  • Yamaha 4XE-F8197-10 - page 383

    – 4 – SPEC CABLE ROUTING 1 Rear brake lever switch lead 2 Rear brake cable 3 Cable guide 4 Front brake ho se 5 Front brake light switch lead 6 Throttle cable 7 Neutral indicator light 8 Reverse indicator light 9 Fuel tank breath er hose 0 Handlebar switch assembly lead A Headlight leads È Do not rou te the han dlebar switch assembly lead throu ...

  • Yamaha 4XE-F8197-10 - page 384

    – 5 – SPEC 1 Cable guide 2 Main switch 3 Fuel tank breath er hose 4 Carburetor overflow ho se 5 Reverse switch lead 6 Neutral switch lead 7 Starter moto r lead 8 Throttle cable 9 Rear brake cable È Route the main switch lead and indicator light lead to the side of the cable guide. É Insert the carbur etor air vent hose, rear br ake breather h ...

  • Yamaha 4XE-F8197-10 - page 385

    – 6 – SPEC 1 Tail/brake light 2 Final gear case breather hose 3 Front brake light switch lead 4 Carburetor air vent hose 5 Rear brake breath er hose 6 Rear brake cable 7 CDI magneto lead È Make sure that the star ter motor lead has no slack. É Fasten the star ter motor lead and wire har ness to the frame with the plasti c band. Ê Fasten the ...

  • Yamaha 4XE-F8197-10 - page 386

    – 7 – SPEC Í Fasten the t ail/brake light lead to the sto rage box with the plastic clamp. Î Fasten the starte r motor lead and wire harnes s to the frame with the plastic clamp. Ï Route the rear brake cable and re ar brake breather hose thr ough the cable guide. Ð Route the rear brake breather h ose through the cable guide. Ñ Route the fi ...

  • Yamaha 4XE-F8197-10 - page 387

    – 8 – SPEC 1 Battery breat her hose 2 Rear brake cable 3 Spark plug cap 4 Ignition coil 5 Ignition coil lead 6 Starter moto r lead 7 Rear brake light switch 8 Rear brake breath er hose È Make sure that the batt ery breather hose is not kinked or bent. É Route the re ar brake cable t hrough the cable guide on th e cylinder. Ê Fasten the sta r ...

  • Yamaha 4XE-F8197-10 - page 388

    – 9 – SPEC 1 Rectifier/regulator 2 CDI unit 3 Starting circuit cut- off relay lead 4 Starter relay lead 5 Starter moto r lead 6 Starting circuit cut- off relay 7 Starter relay 8 Rear brake breath er hose 9 Carburetor air vent hose 0 Final gear case breather hose È Fasten the battery + lead and starte r motor lead to the rear fende r with the p ...

  • Yamaha 4XE-F8197-10 - page 389

    – 10 – SPEC Í Make sure that the grommet is installed with the mark facing forward. Î 5 mm (0.2 in) CABLE ROUTING ...

  • Yamaha 4XE-F8197-10 - page 390

    – 11 – SPEC 1 Rear brake cable 2 Throttle cable 3 Wire harness 4 Starter moto r lead 5 Tail/brake light lead È Route the throt tle cable and rear brake cable through th e cable guide. Make sure that the throttle cab le is routed to the insi de of the re ar brake cable. É Fasten the wire harne ss to the frame with the plastic clamps. Ê Make s ...

  • Yamaha 4XE-F8197-10 - page 391

    – 12 – CHK ADJ INTRODUCTION/PERIODIC MAINTENANCE/ LUBRICATION INTERVALS EB300000 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all info rmation necessary to perform recommen ded inspections and adjust- ments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and a longer servi ...

  • Yamaha 4XE-F8197-10 - page 392

    – 13 – CHK ADJ PERIODIC MAINTENANCE/LUBRICATION INTERVALS * It is recommended that these items be serviced by a Yamaha d ealer. ** Lithium-soap-based grease NOTE: ● Recommended brake fluid: DOT 4 ● Brake fluid replacement: 1.When disassembling the master cylinder or caliper, replace the brake fluid. Normally check the brake fluid level and ...

  • Yamaha 4XE-F8197-10 - page 393

    – 14 – CHK ADJ ADJUSTING THE FRONT BRAKE/ ADJUSTING THE REAR BRAKE LIGHT SWITCH CHASSIS ADJUSTING THE FRONT BRAKE 1.Check: ● Brake lever free play a Out of specification → Bleed the front bra ke system. Refer to “ AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) ” . (Manual No.: 4XE-F8197-11) ADJUSTING THE REAR BRAKE LIGHT SWITCH NOTE: The rear br ...

  • Yamaha 4XE-F8197-10 - page 394

    – 15 – – + ELEC CHECKING THE SWITCH ELECTRICAL CHECKING THE SWITCH CHECKING THE SWITCH Use a pocket tester to che ck the terminals for continuity. If the continuity is faulty at any point, replace the switch. N OTE: ● Set the pocket tester to “ 0 ” before starting the test. ● The pocket tester should be set to the “ Ω × 1 ” ran ...

  • Yamaha 4XE-F8197-10 - page 395

    – 16 – – + ELEC SIGNAL SYSTEM EB806000 SIGNAL SYSTEM CIRCUIT DIAGRAM W / L B B B W / GW / L O W / R RR / B Br Sb Br G / L Sb G / L G / L G / L R / W R / W Sb G / L Br Br G / L Sb W / R W / G W R W / L W / R W / G R / B R / B Sb R W W W W W R W / GR W / RW / L RW / G W / LW / R W WW W WW 1 ON OFF R Br RB r (GRA Y) Br R (GRA Y) 3 4 L / W L / W ...

  • Yamaha 4XE-F8197-10 - page 396

    – 17 – – + ELEC SIGNAL SYSTEM CHECKING THE SIGNAL SYSTEM 1.If the tail/brake light fails to come on: CONTINUITY 1.Bulb and bulb so cket ● Check the bulb and bulb socket for continu- ity. NO CONTINUITY Replace the bulb and/or bulb socke t. CONTINUITY 2.Brake light switches Refer to “ CHECKING THE SWITCH ” . NO CONTINUITY Replace the brak ...

  • Yamaha 4XE-F8197-10 - page 397

    Y AMAHA MO T OR CO. , L TD . 2500 SHINGAI IW A T A SHIZUOKA JAP AN PRINTED IN U.S.A. ...

  • Yamaha 4XE-F8197-10 - page 398

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Manufacturer Yamaha Category Motorcycle

Documents that we receive from a manufacturer of a Yamaha 4XE-F8197-10 can be divided into several groups. They are, among others:
- Yamaha technical drawings
- 4XE-F8197-10 manuals
- Yamaha product data sheets
- information booklets
- or energy labels Yamaha 4XE-F8197-10
All of them are important, but the most important information from the point of view of use of the device are in the user manual Yamaha 4XE-F8197-10.

A group of documents referred to as user manuals is also divided into more specific types, such as: Installation manuals Yamaha 4XE-F8197-10, service manual, brief instructions and user manuals Yamaha 4XE-F8197-10. Depending on your needs, you should look for the document you need. In our website you can view the most popular manual of the product Yamaha 4XE-F8197-10.

Similar manuals

A complete manual for the device Yamaha 4XE-F8197-10, how should it look like?
A manual, also referred to as a user manual, or simply "instructions" is a technical document designed to assist in the use Yamaha 4XE-F8197-10 by users. Manuals are usually written by a technical writer, but in a language understandable to all users of Yamaha 4XE-F8197-10.

A complete Yamaha manual, should contain several basic components. Some of them are less important, such as: cover / title page or copyright page. However, the remaining part should provide us with information that is important from the point of view of the user.

1. Preface and tips on how to use the manual Yamaha 4XE-F8197-10 - At the beginning of each manual we should find clues about how to use the guidelines. It should include information about the location of the Contents of the Yamaha 4XE-F8197-10, FAQ or common problems, i.e. places that are most often searched by users in each manual
2. Contents - index of all tips concerning the Yamaha 4XE-F8197-10, that we can find in the current document
3. Tips how to use the basic functions of the device Yamaha 4XE-F8197-10 - which should help us in our first steps of using Yamaha 4XE-F8197-10
4. Troubleshooting - systematic sequence of activities that will help us diagnose and subsequently solve the most important problems with Yamaha 4XE-F8197-10
5. FAQ - Frequently Asked Questions
6. Contact detailsInformation about where to look for contact to the manufacturer/service of Yamaha 4XE-F8197-10 in a specific country, if it was not possible to solve the problem on our own.

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