Target Audience:
DIY owners, home mechanics, professional service technicians, workshops seeking comprehensive repair information.
Value Proposition:
Enables users to save money on repairs by performing their own maintenance and troubleshooting, provides immediate access to critical service information.
Information Source:
Represents factory-level information, same as used by authorized service centers.
Accessibility:
Instant download, accessible on multiple devices (computer, iPad), no shipping fees.
Completeness:
Highly detailed, comprehensive guide for repair, service, restoration, maintenance, rebuilding, and diagnosing.
Engine System:
Complete engine overhaul, repair, diagnostics, including: cylinder, piston, crankshaft, conrod (connecting rod), camshaft, valves, valve clearance, ignition system, starting system, lubrication system, cooling system (radiator, coolant, fluid), fuel system (EFI/PGM-FI, fuel pump, fuel tank, carburettor/carburettor components like main jet, pilot jet, slow jet, mixture screw), exhaust system, muffler.
Drivetrain System:
Includes: transmission, drive shaft, drive train, primary reduction gear, reverse gear, gearshift mechanism, clutch (including clutch components), axle, suspension (front forks, rear swingarm, struts, bogey), wheels, tires.
Electrical System:
Covers: ignition, starter, battery, charging system, stator, rectifier, regulator, switches, lights, electronic components, error codes, troubleshooting no spark.
Chassis And Body:
Includes: frame, panels, body, plastic components, fenders, seat, steering, handle bars, front and rear sections, hull.
Braking System:
Covers: brakes, brake rotors, brake pads, hydraulic systems.
Maintenance Procedures:
Routine maintenance schedules, oil changes, coolant flushes, lubrication, filter replacement, spark plug replacement, battery maintenance, tire pressure checks, brake inspection.
Repair Procedures:
Step-by-step repair instructions for all major components, including engine rebuilds, transmission overhauls, suspension repairs, electrical system fixes, brake system servicing.
Troubleshooting:
Detailed troubleshooting guides for common problems, error code interpretation, diagnosing ignition issues, fuel system problems, starting problems, no spark conditions, and other performance issues.
Technical Specifications:
Provides torque specifications, fluid capacities, fluid types and viscosities, compression ratios, engine dimensions (bore, stroke, displacement), electrical component specifications, tire sizes, wheel specifications.
Performance Enhancement:
Includes information relevant to performance tuning and modifications, such as carburettor adjustments, jetting information, and general engine tuning principles.
Diagnostic Capabilities:
Advanced diagnostics for engine, electrical, and drivetrain systems, including the ability to interpret error codes and identify root causes of malfunctions.
Rebuild Instructions:
Comprehensive instructions for complete engine and transmission rebuilds, component replacements, and major overhauls.
Diagrams And Schematics:
Illustrated diagrams, exploded views, component breakdowns, wiring schematics, and system diagrams to aid in identification and repair.
Diy Support:
Designed for both professional technicians and DIY enthusiasts, providing clear, step-by-step instructions for a wide range of maintenance and repair tasks.
Factory Level Information:
This manual is stated to be the same as used by professional technicians and workshops, implying factory-level accuracy and detail.
Engine Type:
Liquid-cooled, 4-stroke, DOHC, 4-valve
Displacement:
686 cc (41.8 cu. in.)
Bore X Stroke:
100.0 mm x 84.0 mm (3.94 in x 3.31 in)
Horsepower:
Approx. 45.3 HP @ 5,500 RPM (Manufacturer Spec - varies slightly)
Torque:
Approx. 50.1 lb-ft @ 4,000 RPM (Manufacturer Spec - varies slightly)
Fuel Delivery:
Electronic Fuel Injection (EFI) / PGM-FI
Carburetor Information:
While EFI is standard, manual covers carburetor principles/adjustments for troubleshooting and older models/conversions if applicable.
Fuel Type:
Unleaded gasoline, minimum 87 octane
Fuel Tank Capacity:
7.9 gallons (30 Liters)
Engine Oil Change:
Every 100 hours or 6 months, whichever comes first (check manual for specific usage conditions).
Air Filter Cleaning:
Every 50 hours, clean and oil; replace every 100 hours or as needed.
Spark Plug Replacement:
Every 100 hours or annually.
Valve Clearance Check:
Every 200 hours or annually.
Engine Oil Type:
Yamalube 4 (or equivalent) SAE 10W-40 API SG or higher
Engine Oil Capacity:
2.50 L (2.64 US qt) without filter change; 2.70 L (2.85 US qt) with filter change
Coolant Type:
Permanent type antifreeze coolant (ethylene glycol based), 50/50 mix with distilled water
Transmission Oil Type:
Yamalube Gear Oil 80W-90 (API GL-4)
Transmission Oil Capacity:
0.60 L (0.63 US qt)
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid
Cvt Belt Wear:
CVT belts can wear prematurely under heavy use, leading to slipping or reduced performance. Regular inspection and replacement are recommended.
Overheating:
Some units may experience overheating in extreme conditions or if the cooling system is not properly maintained. Ensure radiator is clean and coolant levels are correct.
Electrical Gremlins:
Occasional reports of minor electrical issues, often related to grounds or corrosion in connectors. The manual's troubleshooting section is invaluable here.