RESEÑAS DE TESIS
NACIONAL DEL SUR
Whichever comes first INITIAL EVERY month 1 3 6 6 12 km (mi) 320 (200) 1,300 (800) 2,500 (1,600) 2,500 (1,600) 5,000 (3,200) hours 20 80 160 160 320 Valves* • Check valve clearance.
• Adjust if necessary.
Spark plug*
• Check condition. • Adjust gap and clean. • Replace if necessary.
Carburetor* • Check and adjust idle speed/starter operation. • Adjust if necessary.
Cylinder head cover breather system*
• Check breather hose for cracks or damage. • Replace if necessary.
Exhaust system*
• Check leakage. • Tighten if necessary.
General maintenance and lubrication chart ITEM ROUTINE Whichever comes first INITIAL EVERY month 1 3 6 6 12 km (mi) 320 (200) 1,300 (800) 2,500 (1,600) 2,500 (1,600) 5,000 (3,200) hours 20 80 160 160 320 Engine oil • Replace (Warm engine before draining).
Engine oil filter element • Clean. Engine oil strainer • Clean.
Final gear oil • Check oil level/oil leakage. • Replace every 12 months. Differential gear oil
Air filter element • Clean.
• Replace if necessary.
Every 20–40 hours (More often in wet or dusty areas.) Front brake* • Check operation/fluid leakage/see NOTE page 8-5.
• Correct if necessary. Rear brake* • Check operation.
• Adjust if necessary. Clutch* • Check operation.
• Adjust if necessary. Reverse lock release
cable*
• Check operation. • Adjust if necessary.
Wheels* • Check balance/damage/runout. • Repair if necessary.
Wheel bearings* • Check bearing assemblies for looseness/damage. • Replace if damaged.
Front and rear suspension* • Check operation. • Correct if necessary. Steering system* • Check operation. • Replace if damaged. • Check toe-in. • Adjust if necessary.
NOTE:
● Recommended brake fluid: DOT 4
● Brake fluid replacement:
• When disassembling the master cylinder or cali- per, replace the brake fluid. Normally check the brake fluid level and add fluid as required. • On the inner parts of the master cylinder and cal-
iper, replace the oil seals every two years. • Replace the brake hoses every four years, or if
cracked or damaged.
WARNING
_Indicates a potential hazard that could result in serious injury or death.
Axle boots* • Check operation. • Replace if damaged.
Fittings and fasteners* • Check all chassis fittings and fasteners. • Correct if necessary.
Lights and switches* • Check operation. • Adjust headlight beams. ITEM ROUTINE Whichever comes first INITIAL EVERY month 1 3 6 6 12 km (mi) 320 (200) 1,300 (800) 2,500 (1,600) 2,500 (1,600) 5,000 (3,200) hours 20 80 160 160 320
Engine oil and oil filter element
The engine oil level should be checked before each ride. In addition, the oil must be changed and the oil filter element cleaned at the inter- vals specified in the periodic maintenance and lubrication chart.
To check the engine oil level
1. Place the ATV on a level surface.
2. Warm up the engine for several minutes, and then turn it off.
3. Wait a few minutes until the oil level set- tles before checking.
4. Remove the engine oil filler cap, and then wipe the dipstick off with a clean rag. In- sert the dipstick in the filler hole (without screwing it in), and then remove it again to check the oil level.
1. Engine oil filler cap
1. Dipstick 2. Maximum level mark 3. Minimum level mark
NOTE:
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The oil level should be between the minimum and maximum level marks.
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5. If the engine oil is at or below the mini- mum level mark, add sufficient oil of the recommended type to raise it to the cor- rect level.
CAUTION:
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Be sure no foreign material enters the crankcase.
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6. Insert the dipstick into the oil filler hole, and then tighten the engine oil filler cap.
To change the engine oil (with or without oil filter element cleaning)
1. Place the ATV on a level surface.
2. Warm up the engine for several minutes, and then turn it off.
3. Place a container under the engine to collect the used oil.
4. Remove the engine oil filler cap, and then remove the engine oil drain bolt to drain the oil from the crankcase.
CAUTION:
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When removing the engine oil drain bolt, the compression spring, oil strainer and O-ring will fall out. Take care not to lose these parts.
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NOTE:
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Skip steps 5–9 if the oil filter element is not be- ing cleaned.
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5. Remove the oil filter cover by removing the bolts, and then remove the oil filter el- ement.
1. Oil filter cover 2. Oil filter cover bolt (× 3)
6. Clean the oil strainer and oil filter element with solvent.
7. Check the O-ring for damage and re- place it if necessary.
1. O-ring 2. Oil filter element 8. Install the oil filter element and O-ring.
NOTE:
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Make sure the O-ring is seated properly.
9. Install the oil filter cover by installing the bolts, and then tighten them to the speci- fied torque.
10. Install the oil strainer, compression spring, O-ring and engine oil drain bolt. Tighten the engine oil drain bolt to the specified torque.
CAUTION:
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Before installing the engine oil drain bolt, be sure to install the O-ring, compression spring and oil strainer.
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11. Add the specified amount of the recom- mended engine oil, and then install and tighten the engine oil filler cap.
Tightening torque: Oil filter cover bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Tightening torque: Engine oil drain bolt:
Recommended oil: See page 10-2. Oil quantity:
Without oil filter element replacement: 2.90 L (2.55 Imp qt, 3.07 US qt) With oil filter element replacement:
CAUTION:
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● In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemical additives. Do not use oils with a diesel specification of “CD” or oils of a high- er quality than specified. In addition, do not use oils labeled “ENERGY CONSERVING II” or higher.
● Make sure that no foreign material en- ters the crankcase.
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12. Start the engine, and then let it idle for several minutes while checking it for oil leakage. If oil is leaking, immediately turn the engine off and check for the cause. 13. Turn the engine off, and then check the
EBU11453
Final gear oil
Checking the final gear oil
1. Place the ATV on a level surface.
2. Remove the oil filler bolt, and then check the oil level in the final gear case.
NOTE:
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The oil level should be at the brim of the filler hole.
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3. If the oil is below the brim of the filler hole, add sufficient oil of the recommended type to raise it to the correct level.
CAUTION:
_
Be sure no foreign material enters the final gear case.
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1. Final gear oil 2. Correct oil level 3. Final gear oil filler bolt
4. Install the oil filler bolt, and then tighten it to the specified torque.
Tightening torque: Final gear oil filler bolt:
Replacing the final gear oil
1. Remove the final gear case cover by re- moving the bolts.
1. Final gear case cover 2. Bolt (× 2)
2. Place the ATV on a level surface.
3. Place a container under the final gear case to collect the used oil.
4. Remove the oil filler bolt and the drain bolt to drain the oil.
1. Final gear oil drain bolt
5. Install the drain bolt, and then tighten it to the specified torque.
Tightening torque:
Final gear oil drain bolt: 23 Nm (2.3 m·kgf, 17 ft·lbf)
6. Add the recommended final gear oil to the brim of the filler hole.
CAUTION:
_
Be sure no foreign material enters the final gear case.
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7. Install the oil filler bolt, and then tighten it to the specified torque.
8. Check for oil leakage. If oil leakage is Recommended oil:
SAE 80 API GL-4 Hypoid gear oil Oil quantity:
0.23 L (0.20 Imp qt, 0.24 US qt)
Tightening torque: Final gear oil filler bolt:
23 Nm (2.3 m·kgf, 17 ft·lbf)
Tightening torque:
Final gear case cover bolt: 17 Nm (1.7 m·kgf, 13 ft·lbf)
Differential gear oil
Checking the differential gear oil
1. Place the ATV on a level surface.
2. Remove the differential gear oil filler bolt and check the oil level. It should be up to the brim of the filler hole. If the level is low, add sufficient oil of the recommend- ed type to raise it to the specified level.
CAUTION:
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Be sure no foreign material enters the dif- ferential gear case.
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1. Differential gear oil filler bolt 2. Correct oil level
3. Differential gear oil
3. Install the differential gear oil filler bolt, and then tighten it to the specified torque. Tightening torque:
Differential gear oil filler bolt: 23 Nm (2.3 m·kgf, 17 ft·lbf)
Replacing the differential gear oil
1. Place the ATV on a level surface.
2. Place a container under the differential gear case to collect the used oil.
3. Remove the differential gear oil filler bolt and differential gear oil drain bolt to drain the oil.
1. Differential gear oil drain bolt
4. Install the differential gear oil drain bolt and tighten it to the specified torque.
5. Fill the differential gear case with the rec- ommended oil.
CAUTION:
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Be sure no foreign material enters the dif- ferential gear case.
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Tightening torque:
Differential gear oil drain bolt: 10 Nm (1.0 m·kgf, 7 ft·lbf)
Recommended oil:
SAE 80 API GL-4 Hypoid gear oil Oil quantity:
6. Install the differential gear oil filler bolt, and then tighten it to the specified torque.
7. Check for oil leakage. If oil leakage is found, check for the cause.
Axle boots
Check the protective boots for holes or tears. If any damage is found, have them replaced by a Yamaha dealer.
1. Axle boot (× 2)
1. Axle boot (× 2) Tightening torque:
Differential gear oil filler bolt: 23 Nm (2.3 m·kgf, 17 ft·lbf)
EBU11820
Spark plug inspection
The spark plug is an important engine compo- nent and is easy to inspect. The condition of the spark plug can indicate the condition of the engine.
For example, a very white center electrode porcelain color could indicate an intake air leak or carburetion problem for that cylinder. Do not attempt to diagnose such problems yourself.
Instead, take the ATV to a Yamaha dealer. You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode. If electrode erosion becomes ex- cessive, you should replace the spark plug with one of the proper type.
Before installing the spark plug, measure the electrode gap with a wire thickness gauge and adjust it to specification.
a. Spark plug gap
When installing the spark plug, always clean the gasket surface and its mating surface. Wipe off any grime from the threads and tight- en it to the specified torque.
Standard spark plug: DR8EA (NGK)
Spark plug gap:
Air filter element cleaning NOTE:
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There is a check hose at the bottom of the air filter case. If dust or water collects in this hose, empty the hose and clean the air filter element and air filter case.
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1. Check hose
1. Remove the seat. (See page 4-15 for seat removal and installation proce- dures.)
2. Remove the air filter case cover by un- hooking the holders.
1. Air filter case cover 2. Holder (× 3) 3. Pull the air filter element out.
4. Remove the foam cover from the air filter element.
1. Air filter element 2. Foam cover
5. Wash the foam cover gently but thor- oughly in water or solvent.
6. Squeeze the excess water or solvent out of the foam cover and let it dry.
CAUTION:
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● Do not twist the foam cover when squeezing it.
● Do not apply oil to the foam cover.
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WARNING
POTENTIAL HAZARD
Using low flash point solvents or gaso- line to clean the foam cover.
WHAT CAN HAPPEN
Low flash point solvents or gasoline can catch fire or explode.
HOW TO AVOID THE HAZARD
Use parts cleaning solvent to clean the foam cover.
7. Tap the element lightly to remove most of the dust and dirt. Blow out the remaining dirt with compressed air as shown. If the air filter element is damaged, replace it.
NOTE:
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Check the foam cover for damage and re- place it if necessary.
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8. Install the foam cover onto the air filter el- ement.
9. Install the air filter element.
10. Install the air filter case cover by fasten- ing the holders.
11. Install the seat.
NOTE:
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The air filter element should be cleaned every 20–40 hours. It should be cleaned more often if the ATV is operated in extremely dusty ar- eas. Each time air filter element maintenance is performed, check the air inlet to the air filter case for obstructions. Check the air filter ele- ment rubber joint to the carburetor and mani- fold fittings for an airtight seal. Tighten all fittings securely to avoid the possibility of unfil- tered air entering the engine.
CAUTION:
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Never operate the engine with the air filter element removed. This will allow unfiltered air to enter, causing rapid engine wear and possible engine damage. Additionally, op- eration without the air filter element will af- fect carburetor jetting with subsequent poor performance and possible engine overheating.
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EBU00754
Spark arrester cleaning
Select a well-ventilated area free of combusti- ble materials and make sure the exhaust pipe and muffler are cool.
1. Remove the purging bolt.
1. Purging bolt
2. Start the engine and rev it up approxi- mately twenty times while momentarily creating exhaust system back pressure by blocking the end of the muffler with a shop towel.
Carburetor adjustment
The carburetor is a vital part of the engine and requires very sophisticated adjustment. Most adjusting should be left to a Yamaha dealer who has the professional knowledge and ex- perience to do so. However, the idling speed may be performed by the owner as a part of the usual maintenance routine.
CAUTION:
The carburetor was set at the Yamaha fac- tory after many tests. If the settings are disturbed by someone without sufficient technical knowledge, poor engine perfor- mance and damage may result.
WARNING
POTENTIAL HAZARD
Improperly purging the exhaust system. Hot exhaust system.
WHAT CAN HAPPEN