Therefore, wait 30 minutes after charging is completed before measuring the open-circuit volt- age. If the charging voltage is lower, charging will be insufficient, if it is higher, the battery will be over-charged. Is the standard standard charging amperage. If the amperage does not Set the timer to the charging exceed the standard charging time determined by the open- amperage after 5 minutes, circuit voltage.
If the required charging time exceeds 5 hours, it is advisable to check the charging amperage after 5 hours. If there is any change in the amperage, readjust the voltage to obtain the standard charging amperage. Leave the battery unused for more than 30 minutes before measuring its open-circuit voltage. Under Connect a charger and ammeter to the battery and start charging. Charge the battery until the charging voltage reaches 15 V. This type of battery charger cannot charge an MF battery.
A variable- NOTE: voltage charger is recommended. Set the charging time to a maxi- mum of 20 hours. Leave the battery unused for more than Ammeter 30 minutes before measuring its open-cir- Voltmeter cuit voltage. First, connect the positive battery lead 1, and then the negative battery lead 2. Recommended lubricant Dielectric grease. Connect the pocket tester to the fuse and check the continuity. Install a new fuse of the correct amperage. Set on the switches to verify if the electrical circuit is operational.
If the fuse immediately blows again, check the electrical circuit. Never use a fuse with an amperage rating other than that specified. Improvising or using a fuse with the wrong amperage rat- ing may cause extensive damage to the electrical system, cause the lighting and ignition systems to malfunction and could possibly cause a fire.
Turn the adjusting screw 1 in direction a a b or b. Headlight beam is Direction b lowered. Unhook the headlight bulb holder, and then remove the defective bulb. Keep flammable products and your hands away from the bulb while it is on, as it will be hot.
Do not touch the bulb until it cools down. Avoid touching the glass part of the bulb. Keep it free from oil; otherwise, the trans- parency of the glass, life of the bulb, and luminous flux will be adversely affected. If oil gets on the bulb, thoroughly clean it with a cloth moistened with alcohol or lac- quer thinner. For installation, reverse the removal pro- cedure. Remove the engine from the left side of the vehicle. New 10 Nm 1. New 20 Nm 2.
To prevent the timing chain from falling into the crankcase, fasten it with a wire. After 1 5 all of the bolts are fully loosened, remove 3 them.
Maximum cylinder head warpage 0. Place a straightedge 1 and a thickness gauge 2 across the cylinder head. Measure the warpage. If the limit is exceeded, resurface the cylin- 2 der head as follows. To ensure an even surface, rotate the cylinder head several times. Tighten the cylinder head bolts in the proper tightening sequence as shown and torque them in two stages. Install the decompressor assembly onto the camshaft, and then finger tighten the decompressor assembly bolts 1.
Install the timing chain 2 onto the camshaft c sprocket 3, then the camshaft sprocket onto the camshaft, and then finger tighten 2 the camshaft sprocket bolts 4. When installing the camshaft sprocket, keep the timing chain as tense as possible on the exhaust side.
Do not turn the crankshaft when installing the camshaft to avoid damage or improper valve timing. Remove the wire from the timing chain. Remove the timing chain tensioner cap bolt 3 2 New 1, copper washer 2 and spring 3. Release the timing chain tensioner one-way cam 4 and push the timing chain tensioner rod 5 all the way into the timing chain ten- sioner housing. Install the timing chain tensioner and gasket 6 onto the cylinder. Timing chain tensioner bolt 4 10 Nm 1. NOTE: Install the gasket with its beaded side facing the timing chain tensioner end.
Install the spring and timing chain tensioner cap bolt. Timing chain tensioner cap bolt 20 Nm 2. Repeat steps 4 to 7 , if necessary. Be sure to tighten the camshaft sprocket bolts to the specified torque to avoid the possibility of the bolts coming loose and damaging the engine.
Camshaft lobe dimensions Intake a Camshaft runout limit 0. Check the decompression system with the 2 camshaft sprocket installed on the decom- pressor lever and pin installed in the cam- shaft. Check that the decompressor lever pin 1 projects from the camshaft. Check that the decompressor cam 2 moves smoothly. Rocker arm inside diameter Rocker arm shaft outside diame- ter Calculate the clearance by subtracting the rocker arm shaft outside diameter from the rocker arm inside diameter. Rocker-arm-to-rocker-arm-shaft clearance 0.
Recommended lubricant Engine oil. Install the decompressor lever pin 1 and decompressor lever 2 in the camshaft 3 as 2 shown in the illustration. Slide hammer bolt Slide hammer bolt 6 mm YU Before removing the internal parts of the cylin- der head e. Pour a clean solvent a into the intake and exhaust ports. Check that the valve seals properly. There should be no leakage at the valve seat 1.
Attach a valve spring compressor 1 and attachment 2 between the valve spring retainer and the cylinder head to remove the valve cotters.
Valve spring compressor , YM Valve spring compressor attach- ment Valve spring compressor adapter 26 mm YM Identify the position of each part very carefully so that it can be reinstalled in its original place. Stem-to-guide clearance Intake 0. Remove the valve guide using a valve guide remover 1. Install the new valve guide using a valve guide remover 1 and valve guide installer 2.
Valve guide position a After installing the valve guide, bore the valve guide using a valve guide reamer 3 to obtain proper stem-to-guide clearance. Margin thickness 0. Valve seat width 1. Install the valve into the cylinder head. Press the valve through the valve guide and onto the valve seat to make a clear pattern.
Measure the valve seat width. Where the valve seat and valve face made contact, blueing will have been removed. If the valve seat is too wide, too narrow, or the seat is not centered, the valve seat must be refaced. After refacing the valve seat or replacing the valve and valve guide, the valve seat and valve face should be lapped. Apply a coarse lapping compound to the valve face. Do not let the compound enter the gap between the valve stem and the valve guide.
Apply molybdenum disulfide oil to the valve stem. Turn the valve until the valve face and valve seat are evenly polished, then clean off all of the compound. For best lapping results, lightly tap the valve seat while rotating the valve back and forth between your hands.
Apply a fine lapping compound to the valve face and repeat the above steps. After every lapping operation be sure to clean off all of the compound from the valve face and valve seat. Measure the valve seat width again. If the valve seat width is out of specification, reface and relap the valve seat.
Valve spring free length Compressed spring force Spring tilt limit 2. Recommended lubricant Molybdenum disulfide oil. Install the valve springs with the larger pitch a facing upwards. Install the valve cotters while compressing the valve spring with the valve spring compressor 1 and attachment 2. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a piece of wood.
Hitting the valve tip with excessive force could damage the valve. If both areas are deburred and the piston pin is still difficult to remove, remove it with the piston pin puller set 4. Piston pin puller set Piston pin puller YU Spread the end gaps apart while at the same time lifting the piston ring over the top of the piston crown, as shown in the illustration.
Then, find the average of the measurements. Cylinder bore If out of specification, replace the cylinder, and the piston and piston rings as a set. If out of specification, replace the piston and piston rings as a set. Calculate the piston-to-cylinder clearance with the following formula. Piston-to-cylinder clearance 0.
Before measuring the piston ring side clear- ance, eliminate any carbon deposits from the piston ring grooves and piston rings. Piston ring side clearance Top ring 0. Piston pin outside diameter Piston pin bore inside diameter Piston-pin-to-piston clearance 0. New 5 R. Engine oil Drain. Coolant Drain. After all of the bolts are fully loosened, remove them.
Sheave holder Primary clutch holder YSA. The arrow mark on the starter clutch must face inward, away from the AC magneto rotor. Starter clutch bolt 30 Nm 3. Install the starter wheel gear to the starter clutch, and hold the starter clutch. If not, the starter clutch is faulty. Replace it. NOTE: Do not disassemble the torque limiter. Stator coil bolt 7 Nm 0. If not, reinstall the key and rotor. While holding the AC magneto rotor 2 with the sheave holder 3, tighten the AC magneto rotor nut.
Tighten the AC magneto cover bolts in stages, using a crisscross pattern. Straighten the lock washer tabs. Bend the lock washer tabs along the bal- ancer driven gear nut and oil pump driven gear nut. E Nm Attach the sheave fixed block 2, locknut wrench 3 and sheave spring compressor 4 to the secondary sheave assembly.
Place the sheave fixed block in a vise and secure it. Tighten the sheave spring compressor nut 5 and compress the spring.
Loosen the nut 1 with the locknut wrench 3. Remove the nut 1. Remove the sheave spring compressor and locknut wrench. Weight outside diameter 30 mm 1. Free length Attach the sheave fixed block, locknut wrench and sheave spring compressor to the secondary sheave. Tighten the sheave spring compressor nut 1 and compress the spring.
Install the nut 2 and tighten it to the speci- fied torque using the locknut wrench. Nut 90 Nm 9. Remove the sheave spring compressor, locknut wrench, and sheave fixed block. Remove them after all of them are loosened. To loosen the clutch car- rier assembly nut turn it clockwise. Install the one-way clutch bearing and clutch carrier assembly to the clutch hous- ing and hold the clutch carrier assembly.
If not, the one-way clutch assembly is faulty. Clutch shoe thickness 1. To tighten the clutch car- rier assembly nut turn it counterclockwise. LS 8 New New 10 Nm 1. New LS. Remove the lead holders and crankcase bolts. Remove the right crankcase.
Tap only on reinforced portions of the crankcase. Do not tap on the crank- case mating surfaces. Work slowly and carefully. Make sure that the crankcase halves separate evenly. Remove the dowel pins. Thoroughly wash the case halves in a mild solvent. Clean all the gasket mating surfaces and crankcase mating surfaces thoroughly. NOTE: Apply two coats of sealant to the area a shown in the illustration. Fit the right crankcase onto the left crank- case.
Tap lightly on the case with a soft hammer. Before installing and torquing the crank- case holding bolts, be sure to check whether the transmission is functioning properly by manually rotating the shift drum in both directions. Inner-rotor-to-outer-rotor-tip clearance Less than 0. Big end side clearance 0. Runout limit 0. When installing the oil pump shaft 4 align the pin 5 with the groove a in the inner rotor 3.
Hold the connecting rod at the Top Dead Cen- ter TDC with one hand while turning the nut of the installing tool with the other. Operate the installing tool until the crankshaft bottoms against the bearing. Apply engine oil to each bearing to protect the crankshaft against scratches and to make installation easier.
Crankcase Separate. Pull out the guide bar from the left crank- case. Push down on the drive shaft, and then slide the shift fork assembly to remove the shift fork cam followers. Remove the shift drum. Remove the shift fork assembly. Secure the middle drive shaft in the vise with a clean rag. Clean the outside of the bearing housing assembly. Place the bearing housing assembly onto a hydraulic press. Press the middle driven pinion gear end and remove the bearing housing.
Attach the folded rag 1. Secure the bearing housing edge in the vise. Attach the bearing retainer wrench 2. Bearing retainer wrench Middle gear bearing retainer YM The middle driven pinion gear bearing retainer has left-handed threads. To loosen the retainer, turn it clockwise. Remove the bearing retainer and bearing. Ring nut wrench 1 , YM The middle driven shaft bearing retainer has left-handed threads. To loosen the retainer turn it clockwise.
Position middle drive and driven gear by using shims 1 and 2 with their respective thickness calculated from information marked on crankcase, bearing housing and drive gear end. In the example above, the calculated shim thickness is 1. The chart instructs you, however, to round off 0 to 0. Hundredths Round value 0, 1, 2 0 3, 4, 5, 6, 7 5 8, 9 Therefore, be sure to measure distance f to select the correct mid- dle driven pinion gear shim thickness.
In the example above, the calculated shim thickness is 0. The chart instructs you, however, to round off 2 j to 0. Ring nut wrench , YM To tighten the retainer turn it counterclockwise.
Secure the bearing housing edge in the vise with a clean rag. Tighten the bearing retainer. Bearing retainer Nm Install the shim s so that the tabs are posi- tioned as shown in the illustration. Installed depth of middle driven 2 gear a 1 NOTE: Secure the middle drive shaft in the vise with a clean rag.
Middle gear lash 0. Temporarily install the left crankcase. Wrap a rag 1 around a screwdriver 2, and then insert it into the installation hole a of 4 the left crankcase speed sensor to hold the middle driven gear.
Attach the final gear backlash band 3 and dial gauge 4. Final gear backlash band b Measure the gear lash while rotating the middle driven shaft back and forth.
Measure the gear lash at 4 positions. Apply compressed air to the rear of the radi- ator. Radiator cap opening pressure Install the radiator cap tester 1 and radiator cap tester adapter 2 to the radiator cap 3. Radiator cap tester Radiator pressure tester YU Radiator cap tester adapter Radiator pressure tester adapter YU Apply the specified pressure for ten sec- onds and make sure there is no drop in pressure.
Suspend the thermostat in a container filled with water. Slowly heat the water. Place a thermometer in the water. If the accuracy of the thermostat is in doubt, replace it. A faulty thermostat could cause seri- ous overheating or overcooling.
Install the thermostat with its breather hole a LS facing up. Tap out the water pump seal from the inside of the AC magneto cover 2. Tap out the bearing and oil seal from the out- side of the AC magneto cover 3. Installed depth of oil seal a 8. Never lubricate the water pump seal sur- face with oil or grease. Install the water pump seal with the special tools.
Mechanical seal installer 3 Water pump seal installer YMA Middle driven shaft bearing driver 4 Bearing driver 40 mm YM Make sure the rubber damper and rubber damper holder are flush with the impeller.
If this function detects a malfunction in the system, it immediately operates the engine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.
Once a malfunction has been detected, a fault code is stored in the memory of the ECU. Once a fault code has been displayed, it remains stored in the memory of the ECU until it is deleted. Lean angle sensor Crankshaft position sensor open or short-circuit Lean angle sensor ECU internal malfunction latch up detected memory check error.
When an abnormal signal is received from a sensor, the ECU processes the specified values that are programmed for each sensor in order to provide the engine with alternate operating instructions that enable the engine to continue to operate or stop operating, depending on the conditions. Intake air pressure sensor Intake air pressure sensor: open or short circuit 13 Able Able open or short circuit detected. Intake air pressure sensor Intake air pressure sensor: hose system malfunction 14 Able Able hose line clogged or detached hose.
Throttle position sensor open Throttle position sensor: open or short circuit 15 Able Able or short circuit detected. Able Able Coolant temperature sensor: open or short circuit 21 Coolant temperature sensor Able Able detected. Intake air temperature sen- Intake air temperature sensor: open or short circuit 22 Able Able sor open or short circuit detected. Lean angle sensor latch up 30 The vehicle has overturned.
Unable Unable detected Malfunction detected in the primary wire of ignition 33 Ignition coil faulty ignition Unable Unable coil.
Unable Unable Lean angle sensor open or 41 Lean angle sensor: open or short circuit detected. Unable Unable short circuit No normal signals are received from the speed sen- 42 Speed sensor Able Able sor. Vehicle system power supply 46 Power supply is not normal. When this malfunction is ECU internal malfunction 50 detected in the ECU, the fault code number might not Unable Unable memory check error appear on the meter.
The engine trouble warning light comes on. The engine trouble warning light does not come on. Check the fault code number displayed on the meter. Check the operation of following sensors and actua- tors in the diagnostic mode. D Throttle position sensor throttle angle Identify the system with the malfunction. D Fuel injector. Identify the probable cause of the malfunction. OK NG.
Check and repair the probable cause of malfunction. Engine malfunction Defective sensor or actuator Fault code No. YES Fault code No. Check and repair. Check and repair the Check and repair the Monitor the operation of inner parts of engine. Check the engine condition.
Perform ECU reinstatement action. The malfunction history must be erased in the diagnostic mode. Setting the diagnostic mode 1. Disconnect the wire harness coupler from the fuel pump. Verify the operation of the sensor or actua- tor. NOTE: To perform a reliable diagnosis, make sure to turn off the power supply before every check and then start right from the beginning.
D03 short circuit detected. D03 hose. D01 circuit detected. D08 cuit detected. D07 the speed sensor. Faulty ECU memory. The program and data are not 50 — fault code number might not appear properly written on or read from the internal memory. Pressure difference Displays the intake air pressure.
If the display value changes, the performance is OK. Intake air temperature Displays the intake air temperature. Compare the actually measured D05 intake air temperature with the meter.
Coolant temperature Displays the coolant temperature. Compare the actually measured cool- D06 ant temperature with the meter. The D07 number is cumulative and does not reset each time the wheel is stopped. If the bat- tery voltage is lower, perform recharg- ing.
Neutral switch Shift the transmission. When all code num- bers are shown, the display repeats the same pro- cess. Diagnos- tic code Item Actuation Checking method No. Actuates the ignition coil five times in one-second intervals. Check the spark five times. Actuates the injector five times in one-second inter- Check the operating sound of the D36 Injector vals. Actuates the fuel pump relay five times in one-sec- ond intervals. The engine trouble warning light also flashes five Check the operating sound of the fuel D50 Fuel pump relay times.
Actuates the radiator fan motor relay and illuminates the engine trouble warning light five cycles 5 sec- Check the operating sound of the D51 Radiator fan motor relay onds per cycle—2 seconds ON, 3 seconds OFF. ON 2 seconds, OFF 3 seconds.
Check and service the items or components that are the probable cause of the malfunction following the order given. Fault code No. Diagnostic code No. Cranking the position sensor. Code No. Turning the tion sensor. If there is a malfunction, repair it and connect the coupler securely. Turning the ture sensor. Raise the vehicle upright. Turning the 2 Installed condition of the lean Check for looseness or pinching. Turning the Code No. D60 main switch to 1. Check the faulty cylinder.
Join our Forum! Sign in with Facebook. Sign in with Twitter. Sign in with Google. Sign in with Microsoft. Share More sharing options Followers 0. Timberwolf stator wiring help By 3wheelerwarrior , June 10, yamaha timberwolf and 2 more Tagged with: yamaha timberwolf wiring help. Manufacturer Logos. 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.
A job instruction chart 7 accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc. 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.
Symbols 1 to 0 indicate the subject of each chapter. This information will be needed to order spare parts. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective carburetor.
Despite the same volume of intake air, the fuel volume requirement varies with the engine operating conditions, such as acceleration, deceleration, or operating under a heavy load. Carburetors that meter the fuel through the use of jets have been provided with various auxiliary devices, so that an optimum air-fuel ratio can be achieved to accommodate the constant changes in the operating con- ditions of the engine.
As the requirements for the engine to deliver more performance and cleaner exhaust gases increase, it becomes necessary to control the air-fuel ratio in a more precise and finely tuned man- ner. To accommodate this need, this model has adopted an electronically controlled fuel injection FI system, in place of the conventional carburetor system.
This system can achieve an optimum air-fuel ratio required by the engine at all times by using a microprocessor that regulates the fuel injection volume according to the engine operating conditions detected by various sensors.
The adoption of the FI system has resulted in a highly precise fuel supply, improved engine response, better fuel economy, and reduced exhaust emissions. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at only kPa 3.
Accord- ingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the passage remains open.
Therefore, the longer the length of time the fuel injector is energized injection duration , the greater the volume of fuel that is supplied. Conversely, the shorter the length of time the fuel injector is energized injection duration , the lesser the volume of fuel that is supplied.
The injection duration and the injection timing are controlled by the ECU. Signals that are input from the throttle position sensor, crankshaft position sensor, intake air pressure sensor, intake air tem- perature sensor, coolant temperature sensor, lean angle sensor and speed sensor enable the ECU to determine the injection duration. The injection timing is determined through the signals from the crankshaft position sensor.
As a result, the volume of fuel that is required by the engine can be sup- plied at all times in accordance with the driving conditions. Illustration is for reference only.
EPS control unit calculates assist power 5. Electricity output switched by EPS control unit 6. Activates EPS motor 3. Sends the torque sensor signal 1. Operates steering 2. The tripme- ters can be used to estimate the distance that can be traveled with a full tank of fuel. This information will enable you to plan future fuel stops.
Set the display to the clock mode. Fuel meter The fuel meter indicates the amount of fuel in the fuel tank. NOTE: This fuel meter is equipped with a self-diagno- sis system.
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