Engine Mechanical:
Engine disassembly, assembly, inspection, torque specifications, cylinder head, valve train, piston, connecting rod, crankshaft, camshaft, timing.
Cooling System:
Radiator, fan, water pump, thermostat, coolant specifications and flushing procedures.
Fuel System Efi:
Fuel pump, injectors, fuel pressure regulator, throttle body, ECM (Engine Control Module) diagnostics, sensor data interpretation, fuel filter replacement.
Fuel System Carbureted:
Carburetor identification, disassembly, cleaning, reassembly, jetting specifications, float bowl adjustment, fuel lines, fuel tank maintenance.
Ignition System:
Ignition coil, spark plug specifications, CDI (Capacitor Discharge Ignition) unit, timing procedures (if applicable).
Electrical System Charging:
Stator, rectifier/regulator, battery specifications, charging system testing.
Electrical System Starting:
Starter motor, starter solenoid, battery testing.
Electrical System Lighting:
Headlights, taillights, brake lights, indicator lights, wiring diagrams.
Electrical System Instruments:
Speedometer, odometer, fuel gauge, indicator lights, diagnostic port (if applicable).
Chassis Frame:
Frame inspection, alignment checks, component mounting points.
Suspension Front:
A-arms, shocks, springs, bearings, seals, alignment adjustments, rebuild procedures.
Steering System:
Handlebars, steering stem, tie rods, steering knuckles, universal joints, power steering (if equipped), adjustments and rebuilds.
Braking System Front:
Brake calipers, brake pads, brake discs, brake lines, master cylinder, bleeding procedures, maintenance.
Wheels And Tires:
Tire pressure recommendations, wheel bearing inspection and replacement, lug nut torque specifications.
Drivetrain Transmission:
Ultramatic® automatic transmission operation, maintenance, fluid type and level checks, seal replacement.
Drivetrain Final Drive:
Front differential, rear differential, driveshafts, U-joints, oil specifications, seal replacement, maintenance.
Drivetrain Cv Joints:
CV boot inspection and replacement, CV joint maintenance.
Suspension Rear:
Swingarm, shock absorber, linkages, bearings, seals, rebuild procedures.
Braking System Rear:
Brake caliper, brake pads, brake disc, brake lines, master cylinder, parking brake mechanism, bleeding procedures, maintenance.
Maintenance Schedule:
Detailed recommended service intervals for oil changes, filter replacements, fluid checks, spark plug replacement, air filter cleaning/replacement, and valve adjustments.
Troubleshooting Guides:
Systematic diagnostic procedures for common and uncommon issues, symptom-based troubleshooting, fault code interpretation (if applicable).
Repair Procedures:
Step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation for all major systems.
Adjustment Procedures:
Carburetor idle speed and mixture, throttle cable, brake levers, parking brake, suspension settings.
Diagnostic Tests:
Electrical component testing, fuel system pressure testing, compression testing, ignition system testing.
Depth:
Comprehensive, suitable for professional technicians and advanced DIY enthusiasts. Covers everything from basic checks to full engine and transmission rebuilds.
Engine Oil Change:
Every 1,000 km or 6 months, whichever comes first (refer to manual for specific conditions).
Air Filter Cleaning:
Every 500 km or 3 months; replace every 2 years or 1,000 km (depending on usage and conditions).
Spark Plug Replacement:
Every 5,000 km or 2 years.
Valve Clearance Check:
Every 5,000 km or 2 years.
Engine Oil Type:
Yamalube 4 (or equivalent SAE 10W-30 API SG or higher)
Engine Oil Capacity:
Approx. 2.3 US qt (2.2 L) without filter change; 2.4 US qt (2.3 L) with filter change.
Coolant Type:
Ethylene glycol based antifreeze (Yamaha Super Coolant or equivalent)
Brake Fluid Type:
SAE J1703 or FMVSS No. 116 DOT 3
Differential Oil Type:
Yamalube Gear Oil (or equivalent SAE 80 API GL-4)
Differential Oil Capacity Front:
Approx. 0.35 US qt (0.33 L)
Differential Oil Capacity Rear:
Approx. 0.66 US qt (0.62 L)
Common Wear Items:
Drive belts (Ultramatic®), brake pads, wheel bearings, ball joints, tie rod ends due to typical off-road usage.
Efi Specific Issues:
Potential for fuel injector clogging or fuel pump issues if fuel quality is poor or maintenance is neglected.
Cooling System Maintenance:
Regular coolant flushes and inspection for leaks are crucial to prevent overheating.