LIT-11616-19-13

1S3-28197-10

YFM700RV

SERVICE MANUAL

EBS00001

YFM700RV

SERVICE MANUAL

©2005 by Yamaha Motor Corporation, U.S.A.

First Edition, May 2005

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-11616-19-13

EBS00002

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 vehicle has a basic understanding of the mechanical ideas and the procedures of vehicle

repair. Repairs attempted by anyone without this knowledge are likely to render the vehicle unsafe

and unfit for use.

Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and sig-

nificant 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.

EBS00003

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!

Failure to follow WARNING instructions could result in severe injury or death to

the vehicle operator, a bystander or a person checking or repairing the vehicle.

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

to the vehicle.

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

WARNING

CAUTION:

NOTE:

EBS00004

HOW TO USE THIS MANUAL

MANUAL ORGANIZATION

This manual consists of chapters for the main categories of subjects. (See “symbols”)

1st title 1: This is the title of the chapter with its symbol in the upper right corner of each page.

2nd title 2: This title indicates the section of the chapter and only appears on the first page of each

section. It is located in the upper left corner of the page.

3rd title 3: This title indicates a sub-section that is followed by step-by-step procedures accompa-

nied by corresponding illustrations.

EXPLODED DIAGRAMS

To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each

removal and disassembly section.

1. An easy-to-see exploded diagram 4 is provided for removal and disassembly jobs.

2. Numbers 5 are given in the order of the jobs in the exploded diagram. A number that is enclosed

by a circle indicates a disassembly step.

3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks

6. The meanings of the symbol marks are given on the next page.

4. A job instruction chart 7 accompanies the exploded diagram, providing the order of jobs, names

of parts, notes in jobs, etc.

5. For jobs requiring more information, the step-by-step format supplements 8 are given in addition

to the exploded diagram and the job instruction chart.

EBS00006

SYMBOLS

The following symbols are not relevant to

every vehicle.

Symbols 1 to 9 indicate the subject of each

chapter.

1 General information

2 Specifications

3 Periodic checks and adjustments

4 Engine

5 Cooling system

6 Fuel injection system

7 Chassis

8 Electrical

9 Troubleshooting

Symbols 0 to G indicate the following.

0 Serviceable with engine mounted

A Filling fluid

B Lubricant

C Special tool

D Tightening torque

E Wear limit, clearance

F Engine speed

G Electrical data (Ω, V, A)

Symbols H to M in the exploded diagrams

indicate the types of lubricants and lubrication

points.

H Apply engine oil

I Apply gear oil

J Apply molybdenum disulfide oil

K Apply wheel bearing grease

L Apply lithium-soap-based grease

M Apply molybdenum disulfide grease

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

1

2

3

4

5

6

7

8

9

0

A

B

C

D

E

F

G

H

I

J

K

L

M

N

O

GEN

INFO

SPEC

CHK

ADJ

ENG

COOL

FI

CHAS

–

+

ELEC

TRBL

SHTG

T R

.

.

E

G

M

B

LS

M

LT

New

EBS00008 TABLE OF CONTENTS

GENERAL INFORMATION

GEN

INFO 1

SPECIFICATIONS

SPEC 2

PERIODIC CHECKS AND

ADJUSTMENTS

CHK

ADJ 3

ENGINE

ENG 4

COOLING SYSTEM

COOL 5

FUEL INJECTION SYSTEM

FI

6

CHASSIS

CHAS 7

ELECTRICAL

ELEC 8

TROUBLESHOOTING

TRBL

SHTG 9

–

+

CONTENTS

CHAPTER 1

GENERAL INFORMATION

VEHICLE IDENTIFICATION............................................................................1-1

VEHICLE IDENTIFICATION NUMBER.....................................................1-1

MODEL LABEL..........................................................................................1-1

FEATURES......................................................................................................1-2

OUTLINE OF THE FI SYSTEM.................................................................1-2

FI SYSTEM................................................................................................1-3

SELF-ADJUSTING PARKING BRAKE MECHANISM...............................1-4

IMPORTANT INFORMATION .........................................................................1-7

PREPARATION FOR REMOVAL AND DISASSEMBLY...........................1-7

REPLACEMENT PARTS...........................................................................1-7

GASKETS, OIL SEALS AND O-RINGS ....................................................1-7

LOCK WASHERS/PLATES AND COTTER PINS.....................................1-8

BEARINGS AND OIL SEALS....................................................................1-8

CIRCLIPS..................................................................................................1-8

CHECKING THE CONNECTIONS............................................................1-9

SPECIAL TOOLS ..........................................................................................1-10

CHAPTER 2

SPECIFICATIONS

GENERAL SPECIFICATIONS ........................................................................2-1

ENGINE SPECIFICATIONS ............................................................................2-4

CHASSIS SPECIFICATIONS........................................................................2-12

ELECTRICAL SPECIFICATIONS .................................................................2-14

TIGHTENING TORQUES ..............................................................................2-16

ENGINE TIGHTENING TORQUES ........................................................2-16

CHASSIS TIGHTENING TORQUES ......................................................2-19

HOW TO USE THE CONVERSION TABLE..................................................2-22

GENERAL TIGHTENING TORQUE SPECIFICATIONS...............................2-22

LUBRICATION POINTS AND LUBRICANT TYPES ....................................2-23

ENGINE...................................................................................................2-23

COOLANT FLOW DIAGRAMS .....................................................................2-24

OIL FLOW DIAGRAMS.................................................................................2-28

CABLE ROUTING .........................................................................................2-33

CHAPTER 3

PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION..............................................................................................3-1

PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL

SYSTEM .........................................................................................................3-1

GENERAL MAINTENANCE AND LUBRICATION CHART............................3-2

SEAT, FENDERS AND FUEL TANK ..............................................................3-3

REMOVING THE FUEL TANK..................................................................3-9

REMOVING THE FUEL PUMP .................................................................3-9

INSTALLING THE FUEL PUMP..............................................................3-10

INSTALLING THE FUEL HOSE..............................................................3-10

ENGINE .........................................................................................................3-11

ADJUSTING THE VALVE CLEARANCE ................................................3-11

ADJUSTING THE ENGINE IDLING SPEED...........................................3-13

ADJUSTING THE THROTTLE LEVER FREE PLAY ..............................3-14

ADJUSTING THE SPEED LIMITER........................................................3-15

CHECKING THE SPARK PLUG .............................................................3-16

CHECKING THE IGNITION TIMING.......................................................3-17

MEASURING THE COMPRESSION PRESSURE..................................3-18

CHECKING THE ENGINE OIL LEVEL....................................................3-20

CHANGING THE ENGINE OIL ...............................................................3-22

ADJUSTING THE CLUTCH CABLE........................................................3-25

CLEANING THE AIR FILTER ELEMENT................................................3-25

CHECKING THE THROTTLE BODY JOINT...........................................3-27

CHECKING THE FUEL HOSE................................................................3-28

CHECKING THE BREATHER HOSES ...................................................3-28

CHECKING THE COOLANT LEVEL.......................................................3-29

CHANGING THE COOLANT...................................................................3-29

CHECKING THE COOLING SYSTEM....................................................3-32

CHECKING THE COOLANT TEMPERATURE WARNING LIGHT.........3-33

CHECKING THE EXHAUST SYSTEM....................................................3-34

CLEANING THE SPARK ARRESTER ....................................................3-34

CHASSIS .......................................................................................................3-36

ADJUSTING THE FRONT BRAKE .........................................................3-36

ADJUSTING THE REAR BRAKE............................................................3-36

ADJUSTING THE PARKING BRAKE......................................................3-37

CHECKING THE BRAKE FLUID LEVEL.................................................3-38

CHECKING THE FRONT BRAKE PADS................................................3-39

CHECKING THE REAR BRAKE PADS ..................................................3-39

ADJUSTING THE REAR BRAKE LIGHT SWITCH .................................3-40

CHECKING THE BRAKE HOSES...........................................................3-40

BLEEDING THE HYDRAULIC BRAKE SYSTEM ...................................3-41

ADJUSTING THE SHIFT PEDAL............................................................3-43

ADJUSTING THE REVERSE CONTROL CABLE ..................................3-43

ADJUSTING THE DRIVE CHAIN SLACK...............................................3-44

CHECKING THE STEERING SYSTEM ..................................................3-46

ADJUSTING THE TOE-IN.......................................................................3-46

CHECKING THE FRONT AND REAR SHOCK ABSORBERS ...............3-48

ADJUSTING THE FRONT SHOCK ABSORBERS .................................3-48

ADJUSTING THE REAR SHOCK ABSORBER ......................................3-49

CHECKING THE TIRES..........................................................................3-52

CHECKING THE WHEELS .....................................................................3-54

CHECKING AND LUBRICATING THE CABLES ....................................3-54

LUBRICATING THE LEVERS AND PEDALS .........................................3-55

ELECTRICAL SYSTEM.................................................................................3-56

CHECKING AND CHARGING THE BATTERY.......................................3-56

CHECKING THE FUSES ........................................................................3-62

ADJUSTING THE HEADLIGHT BEAMS.................................................3-64

REPLACING A HEADLIGHT BULB ........................................................3-64

CHAPTER 4

ENGINE

ENGINE REMOVAL ........................................................................................4-1

MUFFLER AND EXHAUST PIPES ...........................................................4-1

INSTALLING THE EXHAUST PIPES AND MUFFLER .............................4-2

OIL TANK ..................................................................................................4-3

LEADS, CABLES AND HOSES ................................................................4-4

ENGINE MOUNTING BOLTS ...................................................................4-6

INSTALLING THE ENGINE.......................................................................4-8

CYLINDER HEAD............................................................................................4-9

REMOVING THE CYLINDER HEAD.......................................................4-11

CHECKING THE CYLINDER HEAD .......................................................4-12

CHECKING THE TAPPET COVERS AND CAMSHAFT SPROCKET

COVER...................................................................................................4-13

CHECKING THE TIMING CHAIN TENSIONER......................................4-13

CHECKING THE CAMSHAFT SPROCKET............................................4-13

INSTALLING THE CYLINDER HEAD .....................................................4-13

ROCKER ARMS AND CAMSHAFT..............................................................4-17

REMOVING THE ROCKER ARMS AND CAMSHAFT............................4-19

CHECKING THE CAMSHAFT.................................................................4-19

CHECKING THE DECOMPRESSION SYSTEM.....................................4-20

CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS ........4-21

INSTALLING THE CAMSHAFT AND ROCKER ARMS ..........................4-22

VALVES AND VALVE SPRINGS..................................................................4-24

REMOVING THE VALVES AND VALVE SPRINGS ...............................4-25

CHECKING THE VALVES AND VALVE SPRINGS................................4-26

INSTALLING THE VALVES AND VALVE SPRINGS..............................4-31

CYLINDER AND PISTON..............................................................................4-33

REMOVING THE PISTON ......................................................................4-34

CHECKING THE CYLINDER AND PISTON ...........................................4-34

CHECKING THE PISTON RINGS...........................................................4-36

CHECKING THE PISTON PIN................................................................4-37

INSTALLING THE PISTON AND CYLINDER .........................................4-38

A.C. MAGNETO.............................................................................................4-41

REMOVING THE A.C. MAGNETO ROTOR............................................4-43

CHECKING THE STATOR COIL

AND CRANKSHAFT POSITION SENSOR ............................................4-43

CHECKING THE STARTER CLUTCH....................................................4-44

CHECKING THE TORQUE LIMITER......................................................4-45

INSTALLING THE A.C. MAGNETO ROTOR ..........................................4-45

CLUTCH ........................................................................................................4-47

REMOVING THE CLUTCH .....................................................................4-51

REMOVING THE PRIMARY DRIVE GEAR

AND BALANCER DRIVEN GEAR..........................................................4-52

CHECKING THE FRICTION PLATES.....................................................4-52

CHECKING THE CLUTCH PLATES.......................................................4-53

CHECKING THE CLUTCH SPRINGS.....................................................4-53

CHECKING THE CLUTCH HOUSING ....................................................4-54

CHECKING THE CLUTCH BOSS...........................................................4-54

CHECKING THE PRESSURE PLATE ....................................................4-54

CHECKING THE PULL LEVER SHAFT AND PULL ROD ......................4-54

CHECKING THE PRIMARY DRIVE GEARS ..........................................4-55

CHECKING THE BALANCER DRIVE GEARS .......................................4-55

INSTALLING THE PRIMARY DRIVE GEAR

AND BALANCER DRIVEN GEARS .......................................................4-55

INSTALLING THE CLUTCH....................................................................4-56

OIL PUMP......................................................................................................4-59

CHECKING THE OIL PUMP ...................................................................4-61

ASSEMBLING THE OIL PUMP...............................................................4-62

SHIFT SHAFT................................................................................................4-63

CHECKING THE SHIFT SHAFT .............................................................4-65

CHECKING THE STOPPER LEVER ......................................................4-65

CHECKING THE SHIFT GUIDE..............................................................4-65

CHECKING THE SHIFT DRUM SEGMENT ...........................................4-65

INSTALLING THE SHIFT LEVER ...........................................................4-65

INSTALLING THE SHIFT SHAFT ...........................................................4-66

CRANKCASE ................................................................................................4-67

CRANKCASE BEARINGS.......................................................................4-69

SEPARATING THE CRANKCASE..........................................................4-70

CHECKING THE OIL STRAINER ...........................................................4-70

CHECKING THE TIMING CHAIN AND GUIDE.......................................4-71

CHECKING THE BEARINGS AND OIL SEALS......................................4-71

CHECKING THE CRANKCASE..............................................................4-71

ASSEMBLING THE CRANKCASE..........................................................4-72

CRANKSHAFT ..............................................................................................4-74

CRANKSHAFT AND BALANCER ...........................................................4-74

REMOVING THE CRANKSHAFT ...........................................................4-75

CHECKING THE CRANKSHAFT............................................................4-75

INSTALLING THE CRANKSHAFT..........................................................4-76

TRANSMISSION............................................................................................4-77

MAIN AXLE .............................................................................................4-79

DRIVE AXLE ...........................................................................................4-80

COUNTER AXLE.....................................................................................4-82

CHECKING THE SHIFT FORKS.............................................................4-83

CHECKING THE SHIFT DRUM ASSEMBLY..........................................4-83

CHECKING THE TRANSMISSION.........................................................4-83

ASSEMBLING THE MAIN AXLE AND DRIVE AXLE..............................4-84

INSTALLING THE TRANSMISSION.......................................................4-85

CHAPTER 5

COOLING SYSTEM

RADIATOR ......................................................................................................5-1

CHECKING THE RADIATOR....................................................................5-3

INSTALLING THE RADIATOR..................................................................5-4

THERMOSTAT ................................................................................................5-5

CHECKING THE THERMOSTAT..............................................................5-6

INSTALLING THE THERMOSTAT............................................................5-6

WATER PUMP.................................................................................................5-7

DISASSEMBLING THE WATER PUMP....................................................5-9

CHECKING THE WATER PUMP..............................................................5-9

ASSEMBLING THE WATER PUMP........................................................5-10

CHAPTER 6

FUEL INJECTION SYSTEM

FUEL INJECTION SYSTEM............................................................................6-1

CIRCUIT DIAGRAM ..................................................................................6-2

ECU’S SELF-DIAGNOSTIC FUNCTION...................................................6-4

SELF-DIAGNOSTIC FUNCTION TABLE..................................................6-5

TROUBLESHOOTING CHART.................................................................6-6

DIAGNOSTIC MODE ................................................................................6-7

TROUBLESHOOTING DETAILS ............................................................6-11

CHECKING THE SPEED SENSOR........................................................6-25

CHECKING THE INTAKE AIR PRESSURE SENSOR ...........................6-26

CHECKING THE INTAKE AIR TEMPERATURE SENSOR ....................6-27

THROTTLE BODY.........................................................................................6-28

CHECKING THE INJECTOR ..................................................................6-31

CHECKING THE THROTTLE BODY ......................................................6-31

INSTALLING THE THROTTLE BODY ASSEMBLY................................6-31

CHECKING THE FUEL PUMP

AND PRESSURE REGULATOR OPERATION......................................6-32

CHECKING AND ADJUSTING THE THROTTLE POSITION

SENSOR ................................................................................................6-33

CHAPTER 7

CHASSIS

FRONT AND REAR WHEELS ........................................................................7-1

FRONT WHEELS......................................................................................7-1

REAR WHEELS ........................................................................................7-3

CHECKING THE WHEELS .......................................................................7-4

CHECKING THE WHEEL HUBS...............................................................7-4

CHECKING THE BRAKE DISCS ..............................................................7-5

INSTALLING THE FRONT WHEEL HUB BEARINGS..............................7-6

INSTALLING THE FRONT BRAKE DISCS...............................................7-6

INSTALLING THE FRONT WHEELS........................................................7-6

INSTALLING THE FRONT WHEEL HUBS ...............................................7-7

INSTALLING THE REAR WHEEL HUBS..................................................7-7

REAR AXLE AND REAR AXLE HUB.............................................................7-8

REMOVING THE REAR BRAKE CALIPER ............................................7-10

REMOVING THE REAR AXLE................................................................7-10

CHECKING THE REAR AXLE ................................................................7-11

CHECKING THE DRIVEN SPROCKET..................................................7-11

CHECKING THE BRAKE DISC...............................................................7-12

INSTALLING THE DRIVEN SPROCKET................................................7-12

INSTALLING THE REAR AXLE ..............................................................7-12

FRONT AND REAR BRAKES.......................................................................7-14

FRONT BRAKE PADS ............................................................................7-14

REAR BRAKE PADS...............................................................................7-15

REPLACING THE FRONT BRAKE PADS ..............................................7-16

REPLACING THE REAR BRAKE PADS.................................................7-18

FRONT BRAKE MASTER CYLINDER....................................................7-20

REAR BRAKE MASTER CYLINDER ......................................................7-22

REMOVING THE FRONT BRAKE LIGHT SWITCH ...............................7-25

CHECKING THE MASTER CYLINDERS................................................7-25

ASSEMBLING THE FRONT BRAKE MASTER CYLINDER ...................7-26

ASSEMBLING THE REAR BRAKE MASTER CYLINDER......................7-26

INSTALLING THE FRONT BRAKE MASTER CYLINDER......................7-27

INSTALLING THE REAR BRAKE MASTER CYLINDER........................7-29

FRONT BRAKE CALIPERS ....................................................................7-31

REAR BRAKE CALIPER.........................................................................7-33

REMOVING THE REAR BRAKE CALIPER ............................................7-36

DISASSEMBLING THE FRONT BRAKE CALIPERS..............................7-36

DISASSEMBLING THE REAR BRAKE CALIPER ..................................7-37

CHECKING THE FRONT AND REAR BRAKE CALIPERS ....................7-37

ASSEMBLING THE FRONT BRAKE CALIPERS....................................7-38

ASSEMBLING THE REAR BRAKE CALIPER ........................................7-39

INSTALLING THE FRONT BRAKE CALIPERS......................................7-40

INSTALLING THE REAR BRAKE CALIPER...........................................7-41

STEERING SYSTEM.....................................................................................7-44

HANDLEBAR...........................................................................................7-44

REMOVING THE FRONT BRAKE LIGHT SWITCH

AND CLUTCH SWITCH .........................................................................7-46

REMOVING THE HANDLEBAR GRIPS..................................................7-46

CHECKING THE HANDLEBAR ..............................................................7-46

INSTALLING THE HANDLEBAR ............................................................7-47

INSTALLING THE HANDLEBAR GRIPS ................................................7-47

INSTALLING THE CLUTCH LEVER.......................................................7-48

INSTALLING THE BRAKE MASTER CYLINDER...................................7-48

STEERING STEM ...................................................................................7-49

REMOVING THE BEARING RETAINER ................................................7-51

CHECKING THE STEERING STEM.......................................................7-51

INSTALLING THE BEARING RETAINER...............................................7-51

INSTALLING THE LOCK WASHER........................................................7-51

INSTALLING THE PITMAN ARM............................................................7-52

TIE-RODS AND STEERING KNUCKLES...............................................7-53

REMOVING THE STEERING KNUCKLES.............................................7-54

CHECKING THE TIE-RODS ...................................................................7-54

CHECKING THE STEERING KNUCKLES..............................................7-54

INSTALLING THE TIE-RODS .................................................................7-54

FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES.............7-55

REMOVING THE FRONT ARMS............................................................7-57

CHECKING THE FRONT ARMS.............................................................7-57

CHECKING THE FRONT SHOCK ABSORBER ASSEMBLIES .............7-57

CHECKING THE BALL JOINTS..............................................................7-58

INSTALLING THE FRONT ARMS...........................................................7-59

REAR SHOCK ABSORBER AND RELAY ARM ..........................................7-60

HANDLING THE REAR SHOCK ABSORBER AND GAS CYLINDER....7-62

DISPOSING OF A REAR SHOCK ABSORBER

AND GAS CYLINDER ............................................................................7-62

REMOVING THE REAR SHOCK ABSORBER.......................................7-63

CHECKING THE REAR SHOCK ABSORBER........................................7-63

CHECKING THE RELAY ARM AND CONNECTING ARM.....................7-63

INSTALLING THE RELAY ARM AND CONNECTING ARM...................7-64

INSTALLING THE REAR SHOCK ABSORBER......................................7-64

SWINGARM AND DRIVE CHAIN..................................................................7-65

REMOVING THE SWINGARM................................................................7-67

CHECKING THE SWINGARM ................................................................7-67

CHECKING THE DRIVE CHAIN .............................................................7-68

INSTALLING THE SWINGARM ..............................................................7-70

INSTALLING THE DRIVE SPROCKET...................................................7-70

CHAPTER 8

ELECTRICAL

ELECTRICAL COMPONENTS........................................................................8-1

CHECKING SWITCH CONTINUITY................................................................8-2

CHECKING THE SWITCHES..........................................................................8-3

CHECKING THE BULBS AND BULB SOCKETS ..........................................8-5

TYPES OF BULBS....................................................................................8-5

CHECKING THE CONDITION OF THE BULBS .......................................8-5

CHECKING THE CONDITION OF THE BULB SOCKETS .......................8-7

IGNITION SYSTEM .........................................................................................8-8

CIRCUIT DIAGRAM ..................................................................................8-8

TROUBLESHOOTING ..............................................................................8-9

ELECTRIC STARTING SYSTEM..................................................................8-14

CIRCUIT DIAGRAM ................................................................................8-14

STARTING CIRCUIT CUT-OFF SYSTEM OPERATION ........................8-15

TROUBLESHOOTING ............................................................................8-16

STARTER MOTOR........................................................................................8-20

CHECKING THE STARTER MOTOR .....................................................8-22

ASSEMBLING THE STARTER MOTOR.................................................8-23

CHARGING SYSTEM....................................................................................8-25

CIRCUIT DIAGRAM ................................................................................8-25

TROUBLESHOOTING ............................................................................8-26

LIGHTING SYSTEM ......................................................................................8-28

CIRCUIT DIAGRAM ................................................................................8-28

TROUBLESHOOTING ............................................................................8-29

CHECKING THE LIGHTING SYSTEM....................................................8-30

SIGNALING SYSTEM ...................................................................................8-33

CIRCUIT DIAGRAM ................................................................................8-33

TROUBLESHOOTING ............................................................................8-34

CHECKING THE SIGNALING SYSTEM.................................................8-35

COOLING SYSTEM.......................................................................................8-42

CIRCUIT DIAGRAM ................................................................................8-42

TROUBLESHOOTING ............................................................................8-43

CHAPTER 9

TROUBLESHOOTING

STARTING FAILURE/HARD STARTING .......................................................9-1

FUEL SYSTEM..........................................................................................9-1

ELECTRICAL SYSTEM.............................................................................9-1

COMPRESSION SYSTEM........................................................................9-1

POOR IDLE SPEED PERFORMANCE...........................................................9-2

POOR IDLE SPEED PERFORMANCE.....................................................9-2

POOR MEDIUM AND HIGH-SPEED PERFORMANCE..................................9-2

POOR MEDIUM AND HIGH-SPEED PERFORMANCE ...........................9-2

FAULTY GEAR SHIFTING..............................................................................9-2

HARD SHIFTING.......................................................................................9-2

SHIFT PEDAL DOES NOT MOVE............................................................9-2

JUMPS OUT GEAR...................................................................................9-2

CLUTCH SLIPPING/DRAGGING....................................................................9-3

CLUTCH SLIPPING ..................................................................................9-3

CLUTCH DRAGGING ...............................................................................9-3

OVERHEATING...............................................................................................9-3

OVERHEATING ........................................................................................9-3

OVERCOOLING ..............................................................................................9-3

COOLING SYSTEM ..................................................................................9-3