Use only genuine Yamaha parts for all replacements. Use oil and grease recom- mended by Yamaha for all lubrication jobs. Other brands may be similar in func- tion and appearance, but inferior in qual- ity.
Bend lock tabs along the bolt or nut flats after the bolt or nut has been tightened to specification. Disconnect: Connector 2. 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 country. Valve spring compressor Valve guide remover and installer 6mm 0. YM These tools are used to remove and install the universal joint. Page 24 INFO 1 - Page Chapter 2. Cylinder: Bore size Position the 2 Rear brake cable switch assembly lead through plastic band with its tab fac- 3 Cable guide the lower bracket cable guide. Make sure that the throttle cable is routed to the 4 Throttle cable inside of the rear brake cable.
Page 54 SPEC 2 - Page Chapter 3. These preventive maintenance procedures, if followed, will ensure more reli- able machine operation and a longer service life. In addition, the need for costly overhaul work will be greatly reduced.
It is recommended that these items be serviced by a Yamaha dealer. Place the machine on a level place. 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 - Note the following points. Install: Front fender 1 Bolt 2 front fender and frame : 7 Nm 0. Install: Front bumper 1 Bolt front bumper and frame 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. Install: Rear fender 1 Bolt 2 rear fender and frame : 7 Nm 0. Install: Rear carrier 1 Bolt 2 rear carrier and frame : 34 Nm 3.
Avoid spilling fuel on the hot engine. Remove: Bolt 1 with washer and collar 9. Connect: Breather hose 1 6. Adjust the valve clearance when the pis- ton is at the Top Dead Center T. Removal 1. NOTE: T. If the clearance is incorrect, repeat above steps until proper clearance obtained. Warm up engine for several minutes. Loosen the pilot screw by turning it coun- terclockwise for the specified number of turns. Insulator color 2 Normal condition is a medium to light tan color.
Start the engine and let it warm up for several minutes, then stop the engine. Install: Timing plug 6. Before measuring the compression pres- sure, the valve clearance should be adjusted.
Compression pressure with oil introduced into cylinder Reading Diagnosis Higher than with- Worn or damaged cyl- out oil Pull up the dipstick, and inspect the oil level whether or not it is between maxi- mum 2 and minimum level 3.
Clean: Compression spring 2 Oil strainer 3 Oil filter 4 Drain plug 5 crankcase Oil filter cover 6 Wash them with a cleaning solvent. Install: Dipstick Warm up the engine for 5 minutes or more, and stop it. Inspect: Oil leaks Oil level Start the engine and keep it idling until oil begins to seep from the oil gallery plug. Clean: Air filter element Use compressed air to blow off dust from 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. Apply the front brake. Visually check the cable joint 3 in the equalizer 4 to verify it is horizontal.
Fully loosen the locknut 1 handlebar and fully turn in the brake lever adjuster Fully loosen brake lever cable adjuster 3 and brake pedal adjuster 4.
Shift the transmission in first gear, and move the select lever 1 to reverse posi- tion. Inspect the copper washer for damage. If damaged, replace it Install the copper washer and filler bolt.
Periodic oil change: 0. Raise the front end of the machine so that there is no weight on the front wheels. Loosen the rod end locknuts 2 of both tie- rods.
The tires listed below have been approved by Yamaha Motor Co. NOTE: Low-pressure tire gauge 1 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 second reading. NOTE: Always balance the wheel when a tire or wheel has been changed or replaced. Always follow these preventive measures: Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury.
If the breather hose touches the frame or exits in such a way as to cause battery electrolyte or gas to exit onto the frame, structual and Other- wise, it may cause accidental shortcircuit- ing. Substitu- tion of a fuse of improper rating can cause extensive electrical system damage and possible fire. Install a new fuse of proper amperage.
Turn on the switches and see if the electri- cal device operates. Do not touch the bulb until it cools down. Page 98 INSP 3 - Page Chapter 4. Disconnect: Starter motor lead 1 2. Remove: Adjusters 1 brake lever and brake pedal Pins 2 Springs 3 2.
Disconnect: Brake cable 4 from brake cable bracket 5. Remove: Footrest 1 left Shift pedal 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. Fuel tank Exhaust pipe Carburetor Engine stays top 1. Remove: Recoil starter assembly 1 2. Remove: Timing plug 1 Drive select lever assembly 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. 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.
YU, 2. Remove: Crankcase cover 1 3. Remove: Woodruff key 1 Driven gear 2 starter Washer 3 6. 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 Dowel pins 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 gear 2 before removing the primary clutch assembly. Straighten: Lock washer tab 1 clutch boss YU, 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.
Remove them after all are loosened. 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.
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.
YM, 3. Remove: Valve spring seat 1 upper Valve spring 2 outer Valve spring 3 inner Valve 4 Valve stem seal Eliminate: Carbon deposit Use a rounded scraper 1. Cylinder head warp: Less than 0.
Stem runout: Less than: 0. YMA, Valve guide remover 6. YMA, 4. Bore valve guide 2 to obtain proper valve stem clearance. 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.
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 between your hand.
Measure: Cam lobes Use a Micrometer. Arm-to-shaft clearance: 0. The bushing must be perpendicular to the camshaft during installation. Eliminate: Carbon deposits from the piston crown and ring grooves. Crank width: Bolts starter clutch : 30 Nm 3. Friction plates 1. Measure: Friction plate thickness Measure at all four points.
Clutch spring minimum length: Inspect: Shift forks On the gear and shift cam contact sur- faces. Inspect: Guide bars Roll the guide bar on a flat surface. Inspect: Drive plate 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.
Turn the sheave drum 3-turns clockwise to preload the starter spring. Install: Crankshaft 1 to right crankcase NOTE: Hold the connecting rod at top dead center with one hand while installing the crank- shaft. Install: Transmission assembly 1 main axle and drive axle 3.
Install: Balancer shaft 1 Shift fork 1 Install: Dowel pins 2 3. Fit the left crankcase onto the right case. Tap lightly on the case with a soft ham- mer. YMA, 2. Apply: 4-stroke engine oil to the oil pump inner parts 7. 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.
YU, 6. Bend the lock washer tab 4. 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- mary gear 2 before installing the primary clutch housing.
The slot 7 in the shift guide 1 must engage the stopper shaft 8. Install: Case cover 1 middle driven shaft Bolt middle shaft case cover : 10 Nm 1. Inspect: Timing chain 1 Chain guide 2 intake Chain guide intake : 8 Nm 0. Install: Starter pulley 1 Bolt starter pulley : 50 Nm 5. YU, Before installing the starter pulley, apply the grease to the oil seal rip 2 and O-ring 4 - Before installing the piston pin clip, cover the crankcase with a clean towel or rag so you will not accidentally drop the pin clip and material into the crankcase.
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. Place the timing chain onto the cam sprocket. Install the cam sprocket onto the cam- shaft, and finger tighten the sprocket bolt. While pressing the ten- sioner rod, rotate 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 the tensioner assembly holding bolts 4.
Install: Cam sprocket cover 1 Carburetor joint Install: Engine assembly from right side 2. Install: Rear wheel drive assembly and swing- arm. NOTE: Before installing the swingarm. Lubricate the following parts.
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 Bolt engine mounting - rear lower Install: Spring 1 Footrest 2 right Bolt footrest : 65 Nm 6.
Hose clamp: 2 Nm 0. Inspect: Oil leakage Page 4 - Page Chapter 5. Remove: Air vent hose 1 Overflow hose 2 Fuel hose 3 3. Loosen: Clamp screws 4 4. Remove: Carburetor assembly 5. Remove: Throttle valve cover 1 6. Remove: Throttle cable end 1 7. Loosen: Throttle cable adjusting nut 1 8. Remove: Pilot air jet 1 3. Remove: Float chamber 1 O-ring 2 4. Remove: Cover coasting enricher 1 Spring 2 Diaphragm 3 8. Inspect: Spring 1 Spring seat 2 Jet needle set 3 Piston valve Insert the piston valve into the carburetor body, and check for free movement.
Float height F. Install: Carburetor assembly Clamp screw: 2 Nm 0. Fuel level: 1. Connect the fuel level gauge 1 to the drain pipe 2. Page CARB 5 - Page Chapter 6. Remove: Bolts 1 middle gear case cover Middle gear case cover 2 Dowel pins 3. Remove: Bearing retainers 1 Use a 40 Torx Driver. Place the U-joint in a press. With a suitable diameter pipe beneath the yoke, press the bearing into the pipe as shown. Remove: Middle driven shaft 1 Dog clutch 2 4. Bearing retainer wrench 32 mm 1.
YM, Bearing 3 Shift lever 1. Inspect: Shift fork 4 1 On the dog clutch and shift lever contact surfaces. The chart instructs you, however, to round off the 7 to 5, then shim thickness is 0. The chart instructs you, however, to round off the 5 to 5, then shim thickness is 0. Hundredths Round value 0, 1 2, 3 4, 5, 6 7, 8 In the example above, the calculated shim thickness is 0. Middle driven shaft 1. Apply: Lithium base grease To the oil seal and O-ring.
Install: Shift lever shaft 1 Shift lever 2 Stopper shaft 3 Circlip 4 3. YM, 7. Tighten: Bearing retainer Bearing retainer: 60 Nm 6. Install: Shim s 1 Reverse gear Install: Middle driven shaft 1 Dog clutch 2 Install the bearing 1 onto the yoke.
The needles can easily fall out of their races. Install: Middle drive pinion gear 1 Nut 2 Nut middle drive pinion gear : 60 Nm 6. Apply: Sealant 1 To the mating surface of both case halves. Shift: Drive select lever For forward drive. Measure: Gear lash Gently rotate the middle drive axle from engagement to engagement. Middle driven gear lash: using measurement tool : 0. Bearing damage. The noise increases with rear wheel speed, but it does not increase with higher engine or transmission speeds.
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