Yamaha Wolverine 2wd 4wd Atv Service Repair Pdf Manual 2003 2009

How to use this Service Manual In the bookmarks to the left you will find different segments of this manual:

Service Manual This is the standard manual for this vehicle. Use this segment as your major point of reference and information.

Supplementary Service Manual (if available) These segments are updates and additions to the standard service manual. They are added as needed when certain changes are made to the model. Be sure to check these for additional information that may be lacking from the regular service manual.

YFM350FXN SUPPLEMENTARY SERVICE MANUAL LIT-11616-14-02

4KB-28197-24

FOREWORD This Supplementary Service Manual has been prepared to introduce new service and new data for the YFM350FXN. For complete information on service procedures, it is necessary to use this Supplementary Service Manual together with the following manual.

YFM350FXG SERVICE MANUAL: LIT-11616-09-58 (4KB-28197-20) YFM350FXH SUPPLEMENTARY SERVICE MANUAL: LIT-11616-09-95 (4KB-28197-21) YFM350FXLC (for California) SUPPLEMENTARY SERVICE MANUAL: LIT-11616-12-03 (4KB-28197-22) YFM350FXN/YFM350FXMC SUPPLEMENTARY SERVICE MANUAL: LIT-11616-13-05 (4KB-28197-23)

YFM350FXN SUPPLEMENTARY SERVICE MANUAL ï›™ 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-11616-14-02

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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 mechanical ideas and the procedures of machine repair. Repairs attempted by anyone without this knowledge are likely to render the machine unsafe and unfit for use.

Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable.

NOTE: Designs and specifications are subject to change without notice.

IMPORTANT INFORMATION Particularly important information is distinguished in this manual by the following notations.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

WARNING

CAUTION: NOTE:

Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander or a person inspecting or repairing the machine.

A CAUTION indicates special precautions that must be taken to avoid damage to the machine.

A NOTE provides key information to make procedures easier or clearer.

HOW TO USE THIS MANUAL CONSTRUCTION OF THIS MANUAL This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”) 1st title 1:

This is a chapter with its symbol on the upper right of each page.

2nd title 2:

This title appears on the upper of each page on the left of the chapter symbol. (For the chapter “Periodic inspection and adjustment” the 3rd title appears.)

3rd title 3:

This is a final title.

MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspections.

A set of particularly important procedure 4 is placed between a line of asterisks “*” with each procedure preceded by “●”.

IMPORTANT FEATURES ● Data and a special tool are framed in a box preceded by a relevant symbol 5. ● An encircled numeral 6 indicates a part name, and an encircled alphabetical letter data or an alignment mark 7, the others being indicated by an alphabetical letter in a box 8. ● A condition of a faulty component will precede an arrow symbol 9 and the course of action will follow it.

EXPLODED DIAGRAM Each chapter provides exploded diagrams before each disassembly section for ease in identifying correct disassembly and assembly procedures.

1

ILLUSTRATED SYMBOLS (Refer to the illustration)

2

GEN INFO

SPEC

3

Illustrated symbols 1 to 9 are designed as thumb tabs to indicate the chapter’s number and content.

4

INSP ADJ

1 General information 2 Specifications 3 Periodic inspection and adjustment 4 Engine 5 Carburetion 6 Drive train 7 Chassis 8 Electrical 9 Troubleshooting

ENG

5

6

DRIV

CARB 7

8

CHAS

ELEC

–

+

0

Illustrated symbols 0 to F are used to identify the specifications appearing in the text.

A

B

0 Filling fluid A Lubricant B Special tool C Tightening D Wear limit, clearance E Engine speed F Ω, V, A

C

D

9

TRBL SHTG

T.

R.

E

F

G

H

G

E J

M

K B

L M

LS

M

Illustrated symbols G to N in the exploded diagram indicate grade of lubricant and location of lubrication point.

I

N

LT

New

G Apply engine oil H Apply gear oil I Apply molybdenum disulfide oil J Apply wheel bearing grease K Apply lightweight lithium-soap base grease L Apply molybdenum disulfide grease M Apply locking agent (LOCTITE) N Use new one

CONTENTS GENERAL INFORMATION............................................................................... 1 MACHINE IDENTIFICATION..................................................................... 1 ENGINE SERIAL NUMBER .................................................................. 1 MODEL LABEL ..................................................................................... 1 SPECIFICATIONS ............................................................................................ 2 GENERAL SPECIFICATIONS................................................................... 2 MAINTENANCE SPECIFICATIONS.......................................................... 2 ENGINE................................................................................................. 2 CHASSIS............................................................................................... 4 ELECTRICAL ........................................................................................ 4 PERIODIC INSPECTIONS AND ADJUSTMENTS ........................................... 5 INTRODUCTION ....................................................................................... 5 PERIODIC MAINTENANCE/LUBRICATION ............................................. 5 ENGINE OVERHAUL........................................................................................ 7 ENGINE ASSEMBLY AND ADJUSTMENT............................................... 7 VALVE, CAMSHAFT AND ROCKER ARM ........................................... 7 CHASSIS........................................................................................................... 8 STEERING SYSTEM................................................................................. 8 INSTALLATION..................................................................................... 9

MACHINE IDENTIFICATION

GEN INFO

GENERAL INFORMATION MACHINE IDENTIFICATION ENGINE SERIAL NUMBER The engine serial number 1 is stamped into the right side of the engine.

MODEL LABEL The model label 1 is affixed to the frame. This information will be needed to order spare parts.

–1–

GENERAL SPECIFICATIONS/ MAINTENANCE SPECIFICATIONS

SPEC

SPECIFICATIONS GENERAL SPECIFICATIONS Model

YFM350FX

Model code:

4KBM (for USA) 4KBN (for CDN) 4KBP (for Europe)

MAINTENANCE SPECIFICATIONS ENGINE Model

YFM350FX

Rocker arm/rocker arm shaft: Bearing inside diameter <Limit> Shaft outside diameter <Limit> Arm-to-shaft clearance <Limit> Piston: Piston to cylinder clearance <Limit> Piston size “D”

11.980 ~ 11.998 mm (0.4717 ~ 0.4724 in) <12.058 mm (0.4747 in)> 11.961 ~ 11.971 mm (0.4709 ~ 0.4713 in) <11.931 mm (0.4697 in)> 0.009 ~ 0.037 mm (0.0004 ~ 0.0015 in) <0.08 mm (0.0031 in)> 0.04 ~ 0.06 mm (0.0016 ~ 0.0024 in) <0.15 mm (0.0059 in)> 82.92 ~ 82.97 mm (3.265 ~ 3.267 in)

H D

Measuring point “H” Oversize Oversize Piston off-set Piston off-set direction Piston pin bore inside diameter Piston pin outside diameter

2nd 4th

5.5 mm (0.217 in) 83.5 mm (3.287 in) 84 mm (3.307 in) 0.5 mm (0.02 in) Inside 19.004 ~ 19.015 mm (0.7482 ~ 0.7486 in) 18.991 ~ 19.000 mm (0.7477 ~ 0.7480 in)

–2–

MAINTENANCE SPECIFICATIONS Model

YFM350FX

Carburetor: I. D. mark Main jet Main air jet Jet needle Needle jet Pilot air jet Pilot air jet Pilot outlet Pilot jet Bypass 1 Bypass 2 Bypass 3 Valve seat size Starter jet Starter jet Throttle valve size Float height Fuel level Engine idle speed Intake vacuum Lubrication system: Oil filter type Oil pump type Tip clearance <Limit> Side clearance Bypass valve setting pressure Relief valve operating pressure Oil pressure (hot) Pressure check location

SPEC

(M.J) (M.A.J) (J.N) (N.J) (P.A.J.1) (P.A.J.2) (P.O) (P.J) (B.P.1) (B.P.2) (B.P.3) (V.S) (G.S.1) (G.S.2) (Th.V) (F.H) (F.L)

4KBM 22 (for USA) 4KBN 13 (for CDN and Europe) #141.3 0.8 5H65-3 P-0M (#823) #80 1.3 0.85 #42.5 0.8 0.8 0.8 2.0 #45 0.7 #130 12 ~ 14 mm (0.47 ~ 0.55 in) 2.0 ~ 3.0 mm (0.08 ~ 0.12 in) Above the float chamber mating surface 1,450 ~ 1,550 r/min 33.3 kPa (250 mmHg, 9.8 inHg) Wire mesh type Trochoid type 0.15 mm (0.006 in) <0.2 mm (0.008 in)> 0.04 ~ 0.09 mm (0.002 ~ 0.004 in) 40 ~ 80 kPa (0.4 ~ 0.8 kg/cm2, 5.66 ~ 11.31 psi) 60 kPa (0.6 kg/cm2, 8.56 psi) 8 kPa (0.08 kg/cm2, 1.16 psi) at 1,500 r/min Cylinder head

–3–

MAINTENANCE SPECIFICATIONS

SPEC

CHASSIS Model Front wheel: Type Rim size Rim material Rim runout limit Rear wheel: Type Rim size Rim material Rim runout limit

YFM350FX

Radial Lateral

Panel wheel 12 × 6.0AT Steel 2 mm (0.08 in) 2 mm (0.08 in)

Radial Lateral

Panel wheel 12 × 8.0AT Steel 2 mm (0.08 in) 2 mm (0.08 in)

ELECTRICAL Model Ignition coil: Model/manufacturer Minimum spark gap Primary winding resistance Secondary winding resistance

YFM350FX F6T535/MITSUBISHI 6 mm (0.24 in) 0.36 ~ 0.48 Ω at 20 ˚C (68 ˚F) 5.44 ~ 7.36 kΩ at 20 ˚C (68 ˚F)

–4–

INTRODUCTION/ PERIODIC MAINTENANCE/LUBRICATION

INSP ADJ

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 reliable machine operation and a longer service life. In addition, the need for costly overhaul work will be greatly reduced. This information applies to machines already in service as well as new machines that are being prepared for sale. All service technicians should be familiar with this entire chapter.

PERIODIC MAINTENANCE/LUBRICATION ITEM

INITIAL

ROUTINE

Valves*

• Check valve clearance.

• Adjust if necessary.

Spark plug

• Check condition.

• Adjust gap and clean.

• Replace if necessary.

Air filter

• Clean.

• Replace if necessary.

Carburetor*

• Check idle speed/starter operation.

• Adjust if necessary.

Every 20 ~ 40 hours (More often in wet or dusty areas.)

Cylinderhead cover • Check breather hose for cracks or damage.

• Replace if necessary. breather system* Exhaust system*

• Check leakage.

• Retighten if necessary.

• Replace gasket if necessary.

Spark arrester

• Clean

Fuel line*

• Check fuel hose for cracks or damage.

• Replace if necessary.

Engine oil

• Replace (Warm engine before draining).

Engine oil filter

• Replace.

Engine oil strainer

• Clean.

Final gear oil

• Check oil level/oil leakage.

• Replace every 12 months.

Differential gear oil

EVERY

1 month 3 months 6 months 6 months

Brakes*

• Check operation/fluid leakage/See NOTE. • Correct if necessary.

Clutch*

• Check operation.

• Adjust if necessary.

Reverse release cable*

• Check operation.

• Adjust if necessary.

Wheels*

• Check balance/damage/runout.

• Replace if necessary.

Wheel bearings*

• Check bearing assembly for looseness/ damage.

• Replace if damaged.

Steering system*

• Check operation.

• Replace if damaged.

• Check toe-in.

• Adjust if necessary.

Drive shaft universal joint*

• Lubricate every 6 months.**

–5–

1 year

PERIODIC MAINTENANCE/LUBRICATION ITEM

INSP ADJ

INITIAL

ROUTINE

EVERY

1 month 3 months 6 months 6 months

Front axle boots*

• Replace if damaged.

Fittings and fasteners*

• Check all chassis fittings and fasteners.

• Correct if necessary.

Battery*

• Check specific gravity.

• Check that the breather hose is positioned properly.

• Correct if necessary.

* It is recommended that these items be serviced by a Yamaha dealer. ** Lithium-soap-based grease

NOTE: Recommended brake fluid: DOT 4 (If DOT 4 is not available, DOT 3 can be used.)

WARNING Indicates a potential hazard that could result in serious injury or death.

–6–

1 year

ENGINE ASSEMBLY AND ADJUSTMENT

ENG

ENGINE OVERHAUL ENGINE ASSEMBLY AND ADJUSTMENT VALVE, CAMSHAFT AND ROCKER ARM 1 Locknut (valve adjusting) 2 Adjuster (valve adjusting) 3 Wave washer 4 Rocker arm 5 Rocker arm shaft 6 O-ring 7 Valve cotter

8 Valve spring retainer 9 Oil seal 0 Valve spring A Valve spring seat B Valve C Bearing retainer D Lock washer

VALVE CLEARANCE (COLD): Intake: 0.06 ~ 0.10 mm (0.002 ~ 0.004 in) A Exhaust: 0.16 ~ 0.20 mm (0.006 ~ 0.008 in) VALVE SPRING TILT LIMIT: Inner spring: B 2.5˚ or 1.6 mm (0.06 in) Outer spring: 2.5˚ or 1.6 mm (0.06 in) C

VALVE SPRING LENGTH LIMIT (FREE): Inner spring: 37.9 mm (1.49 in) Outer spring: 37.9 mm (1.49 in)

D

FW

–7–

E Bearing F Camshaft G Bearing H Circlip I Valve guide

D

STEM RUNOUT LIMIT: 0.02 mm (0.0008 in)

E

VALVE SEAT WIDTH LIMIT: 1.8 mm (0.07 in)

STEERING SYSTEM

CHAS

CHASSIS STEERING SYSTEM 1 Steering shaft bushing 2 Oil seal 3 Steering shaft 4 Oil seal 5 Bearing 6 Spacer 7 Steering knuckle 8 Tie-rod end

9 Tie-rod 0 Bearing retainer A Collar

A

D

FW

–8–

TOE-IN: 0 ~ 5 mm (0 ~ 0.20 in)

STEERING SYSTEM

CHAS

INSTALLATION 1.Adjust: ● Tie-rod assembly length

********************************************* Adjustment steps: ● Loosen the locknuts. ● Adjust tie-rod assembly length a by turning both tie-rod ends.

Tie-rod assembly length a : 361 mm (14.2 in) Å Right-hand-threads ı Left-hand-threads Ç To steering shaft Î To knuckle NOTE: The threads b on both tie-rod ends must be of the same length. ●

Tighten the locknuts.

T.

Locknut (tie-rod): 30 Nm (3.0 m • kg, 22 ft • lb)

R.

*********************************************

2.Install: Tie-rods (left and right)

●

NOTE: The tie-rod which must be installed on the out side has grooves 1.

Nuts (tie-rod end): T.

25 Nm (2.5 m • kg, 18 ft • lb)

R.

WARNING Always use a new cotter pin.

–9–

YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U.S.A.

YFM350FXP SUPPLEMENTARY SERVICE MANUAL LIT-11616-15-07

4KB-28197-25

FOREWORD This Supplementary Service Manual has been prepared to introduce new service and new data for the YFM350FXP. For complete information on service procedures, it is necessary to use this Supplementary Service Manual together with the following manual.

YFM350FXG SERVICE MANUAL: LIT-11616-09-58 (4KB-28197-20) YFM350FXH SUPPLEMENTARY SERVICE MANUAL: LIT-11616-09-95 (4KB-28197-21) YFM350FXLC (for California) SUPPLEMENTARY SERVICE MANUAL: LIT-11616-12-03 (4KB-28197-22) YFM350FXN/YFM350FXMC SUPPLEMENTARY SERVICE MANUAL: LIT-11616-13-05 (4KB-28197-23) YFM350FXN SUPPLEMENTARY SERVICE MANUAL: LIT-11616-14-02 (4KB-28197-24)

YFM350FXP SUPPLEMENTARY SERVICE MANUAL ï&#x203A;&#x2122; 2001 by Yamaha Motor Corporation, U.S.A. First Edition, May 2001 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-11616-15-07

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 mechanical ideas and the procedures of machine repair. Repairs attempted by anyone without this knowledge are likely to render the machine unsafe and unfit for use.

Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable.

NOTE: Designs and specifications are subject to change without notice.

IMPORTANT INFORMATION Particularly important information is distinguished in this manual by the following notations.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

WARNING

CAUTION: NOTE:

Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander or a person inspecting or repairing the machine.

A CAUTION indicates special precautions that must be taken to avoid damage to the machine.

A NOTE provides key information to make procedures easier or clearer.

HOW TO USE THIS MANUAL CONSTRUCTION OF THIS MANUAL This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”) 1st title 1:

This is a chapter with its symbol on the upper right of each page.

2nd title 2:

This title appears on the upper of each page on the left of the chapter symbol. (For the chapter “Periodic inspection and adjustment” the 3rd title appears.)

3rd title 3:

This is a final title.

MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspections.

A set of particularly important procedure 4 is placed between a line of asterisks “*” with each procedure preceded by “●”.

IMPORTANT FEATURES ● Data and a special tool are framed in a box preceded by a relevant symbol 5. ● An encircled numeral 6 indicates a part name, and an encircled alphabetical letter data or an alignment mark 7, the others being indicated by an alphabetical letter in a box 8. ● A condition of a faulty component will precede an arrow symbol 9 and the course of action will follow it.

EXPLODED DIAGRAM Each chapter provides exploded diagrams before each disassembly section for ease in identifying correct disassembly and assembly procedures.

1

EB003000

2

GEN INFO

ILLUSTRATED SYMBOLS Illustrated symbols 1 to 9 are printed on the top right of each page and indicate the subject of each chapter.

SPEC

3

4

CHK ADJ

1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Carburetion 6 Drive train 7 Chassis 8 Electrical 9 Troubleshooting

ENG

5

6

CARB

DRIV

7

8

CHAS

–

ELEC

+

0

Illustrated symbols 0 to F are used to identify the specifications appearing in the text.

A

B

0 Filling fluid A Lubricant B Special tool C Torque D Wear limit, clearance E Engine speed F Ω, V, A

C

D

9

TRBL SHTG

T.

R.

E

F

G

H

G

E J

K B

M

L

M M

LS

N

Illustrated symbols G to M in the exploded diagrams indicate the types of lubricants and lubrication points.

I

S

O

LT

New

G Apply engine oil H Apply gear oil I Apply molybdenum disulfide oil J Apply wheel bearing grease K Apply lightweight lithium soap base grease L Apply molybdenum disulfide grease M Apply silicon grease

Illustrated symbols N to O in the exploded diagrams indicate where to apply a locking agent N and when to install a new part O. N Apply the locking agent (LOCTITE) O Replace

CONTENTS SPECIFICATIONS ........................................................................................... 1 GENERAL SPECIFICATIONS ................................................................. 1 MAINTENANCE SPECIFICATIONS ........................................................ 2 CHASSIS............................................................................................... 2 ELECTRICAL ....................................................................................... 2 CABLE ROUTING .................................................................................... 3 PERIODIC CHECKS AND ADJUSTMENTS ................................................... 8 CHASSIS .................................................................................................. 8 ADJUSTING THE FRONT BRAKE ....................................................... 8 ADJUSTING THE REAR BRAKE LIGHT SWITCH .............................. 8 ELECTRICAL ................................................................................................... 9 CHECKING THE SWITCH ....................................................................... 9 CHECKING THE SWITCH ................................................................... 9 CHECKING A SWITCH SHOWN IN THE MANUAL ............................ 9 IGNITION SYSTEM ................................................................................ 10 CIRCUIT DIAGRAM ........................................................................... 10 TROUBLESHOOTING ....................................................................... 11 SIGNAL SYSTEM ................................................................................... 16 CIRCUIT DIAGRAM ........................................................................... 16 CHECKING THE SIGNAL SYSTEM .................................................. 17 YFM350FXP WIRING DIAGRAM

GENERAL SPECIFICATIONS

SPEC

SPECIFICATIONS GENERAL SPECIFICATIONS Model Model code: Basic weight: With oil and full fuel tank Maximum load-except motorcycle Spark plug: Type Manufacturer Spark plug gap Electrical: Ignition system Generator system Battery capacity Battery type Bulb wattage × quantity: Headlight Tail/brake light Indicator light NEUTRAL REVERSE OIL TEMPERATURE

YFM350FXP 4KBR (USA) 234.5 kg (517 lb) 180 kg (397 lb) DR8EA NGK 0.6 ~ 0.7 mm (0.024 ~ 0.028 in) C.D.I. A.C. magneto 12 V 12AH GM12CZ-4A-2 12 V 30 W/30 W × 2 12 V 21 W/5 W × 1 12 V 3.4 W × 1 12 V 3.4 W × 1 12 V 3.4 W × 1

–1–

MAINTENANCE SPECIFICATIONS

SPEC

MAINTENANCE SPECIFICATIONS CHASSIS Model Front brake lever: Brake lever free play (at brake lever end)

YFM350FXP 0 mm (0 in)

ELECTRICAL Model DC. C.D.I.: Magneto model/manufacturer Pickup coil resistance/color Rotor rotation direction detection coil resistance/color C.D.I. unit model/manufacturer Ignition coil: Model/manufacturer Minimum spark gap Primary winding resistance Secondary winding resistance Charging system: Type Model/manufacturer Nominal output Charging coil resistance/color Rectifier/regulator: Regulator type Model/manufacturer No load regulated voltage Rectifier capacity Withstand voltage

YFM350FXP F4T423/MITSUBISHI 459 ~ 561 Ω at 20 °C (68 °F)/(White/GreenWhite/Red) 0.104 ~ 0.127 Ω at 20 °C (68 °F)/(RedWhite/Blue) F8T38674/MITSUBISHI 2JN/YAMAHA 6 mm (0.24 in) 0.18 ~ 0.28 Ω at 20 °C (68 °F) 6.32 ~ 9.48 kΩ at 20 °C (68 °F) A.C. magneto generator F4T423/MITSUBISHI 14 V 12 A at 3,000 r/min 0.70 ~ 0.86 Ω at 20 °C (68 °F)/(White-White) Semi conductor-short circuit SH640-11/SHINDENGEN 14.1 ~ 14.9 V 14 A 200 V

–2–

CABLE ROUTING

SPEC

CABLE ROUTING 1 Rear brake switch 2 Rear brake cable 3 Parking brake cable 4 Front brake hose 5 Front brake light switch 6 Throttle cable 7 Band 8 Reverse control knob 9 Main switch 0 Parking brake switch A Handlebar switch

È Pass the throttle cable, the rear brake cable, the parking brake cable and the reverse control cable through the wire guide located at the rear. É Pass the brake hose through the wire guide located at the front. Ê Pass the throttle cable inside the handlebar protector rib.

–3–

Ë Insert the fuel tank breather hose into the hole of the handlebar protector. Ì Connect the indicator light leads inside the handlebar protector, then pass it between the reverse control knob bracket and the main switch.

CABLE ROUTING 1 Throttle cable 2 Front brake hose 3 Front brake light switch 4 Reverse control cable 5 Rear brake cable 6 Parking brake cable 7 Main switch lead 8 Indicator light lead 9 Handlebar switch lead 0 Rear brake switch lead A Parking brake switch lead B Band

SPEC

C Brake pipe 1 D Breather hose E Brake pipe 2 È Pass the reverse control cable in front of the rear brake cable and the parking brake cable. É Pass the rear brake cable and the parking brake cable in front of the throttle cable. Ê Pass brake pipe 2 in front of brake pipe 1.

–4–

CABLE ROUTING 1 Fuel hose 2 Rectifier/regulator 3 CDI unit 4 Starter relay 5 Battery positive lead 6 Tail/brake light lead 7 Breather hose (rear gear housing) 8 Battery breather hose 9 Carburetor overflow hose 0 Damper plate A Clamp B Rear brake light switch lead

C Starter motor lead È Fasten the starter motor lead, marking sure that it is not slack. É Fasten the wire harness to the frame. Ê Pass the battery breather hose through the wire guide. Ë Pass the carburetor overflow hose through the cross pipe frame.

–5–

SPEC

Ì Pass the carburetor air vent hose through the guide hole in the damper plate. Make sure that the spacers on the hose engage with the damper plate. Í Pass the front axle gear case breather hose and the rear gear housing breather hose through the guide hole in the damper plate.

CABLE ROUTING

SPEC

Ñ Pass the reverse control cable between the frame bracket and the engine. Ò Pass the wire harness and the breather hose through the wire guide.

Î Fasten the thermo switch lead and the neutral switch lead to the frame with the band. Ï Pass the parking brake cable through the wire guide. Ð Make sure that the reverse control cable and the parking brake cable do not touch each other.

–6–

CABLE ROUTING 1 Battery negative lead 2 Rear brake cable 3 Reverse control cable 4 Parking brake cable 5 Spark plug lead 6 Rear brake light switch 7 Rear brake hose

SPEC

È Fasten the rear brake light switch lead to the frame. É Align the edge of the rear brake cable protector spring with the tip of the rear fender. Ê Adjust the length of the protruding edge of the reverse control cable to the specified length.

Make sure that it is not slack.

–7–

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL

• Thank you very much for reading the preview of the manual.

• You can download the complete manual from: www.heydownloads.com by clicking the link below

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL