2024 Yamaha YZ65 Service & Repair Manual

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@YAMAHA SERVICEMANUAL BASICINFORMATION LIT-11616-MC-BOYOA-28197-10

IMPORTANT ThismanualwasproducedbytheYamahaMotorCompany,Ltd.primarilyforusebyYamahadealers andtheirqualifiedmechanics. Thismanualcontainsonlybasicinstructionsthatmustbeobservedduringservicing.Refertotheapplicableservicemanualfordetailedinformationonchecking,adjustment,andreplacement. TIP. Designsandspecificationsaresubjecttochangewithoutnotice. IMPORTANTMANUALINFORMATION Particularlyimportantinformationisdistinguishedinthismanualbythefollowingnotations. Thisisthesafetyalertsymbol.Itisusedtoalertyoutopotentialpersonal aNinjuryhazards.Obeyallsafetymessagesthatfollowthissymboltoavoid possibleinjuryordeath. AWARNINGindicatesahazardoussituationwhich,ifnotavoided,could AWARNINGresultindeathorseriousinjury. ANOTICEindicatesspecialprecautionsthatmustbetakentoavoid NOTICEdamagetothevehicleorotherproperty. TIPATIPprovideskeyinformationtomakeprocedureseasierorclearer. BASICINFORMATION SERVICEMANUAL ©2017byYamahaMotorCorporation,U.S.A. Firstedition,January2017 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. P/NLIT-11616-MC-BO

SYMBOLS Thefollowingsymbolsareusedinthismanualforeasierunderstanding. TIP. Thefollowingsymbolsarenotrelevanttoeveryvehicle. SYMBOLDEFINITIONSYMBOLDEFINITION oy)Serviceablewithenginemounted4Molybdenumdisulfideoil Na)Fillingfluid4Gearoil emg||Lubricant|Brakefluid 4) VedSpecialtool=@BBy|Wheelbearinggrease Tighteningtorque ay Lithium-soap-basedgrease Wearlimit,clearance =@M Molybdenumdisulfidegrease Enginespeed =asPq Siliconegrease Electricaldata Applylockingagent(LOCTITE®). Engineoil Replacethepartwithanewone.

CONTENTS IMPORTANTINFORMATION........scssesssesssssseseeesses PREPARATIONFORREMOVALANDDISASSEI REPLACEMENTPARTS........c-seceesee0e GASKETS,OILSEALSANDO-RINGS . LOCKWASHERS/PLATESANDCOTTERPINS BEARINGSANDOILSEALS CIRCLIPS......ssesseesseeseesseene REASSEMBLYOFPARTSUSINGLOCKINGAGENT(LOCTITE®) RUBBERPARTS VMYUMMAaAaUS BASICSERVICEINFORMATION QUICKFASTENERS.. ELECTRICALSYSTE GENERALTIGHTENINGTORQUESPECIFICATIONS ADJUSTINGTHEWHEELSTATICBALANCE CHECKINGTHESWITCHES........0.0eceseesee CHECKINGTHEBULBSANDBULBSOCKETS CHECKINGANDCHARGINGTHEBATTERY... arene : VNOCCHBAAWYH TROUBLESHOOTING. GENERALINFORMATION TROUBLESHOOTINGOFENGINE(faultcodenotdetected). TROUBLESHOOTINGOFCLUTCH TROUBLESHOOTINGOFTRANSM TROUBLESHOOTINGOFCOOLINGSYSTE! TROUBLESHOOTINGOFBRAKE............04+5 TROUBLESHOOTINGATABSWARNINGLIGHT. TROUBLESHOOTINGOFSUSPENSION............ TROUBLESHOOTINGOFSTEERING/HANDLING TROUBLESHOOTINGOFCHARGINGSYSTEM TROUBLESHOOTINGOFLIGHTINGSYSTEM.. TROUBLESHOOTINGOFSIGNALINGSYSTEM..

IMPORTANTINFORMATION IMPORTANTINFORMATION PREPARATIONFORREMOVALAND DISASSEMBLY 1.Beforeremovalanddisassembly,removeall dirt,mud,dustandforeignmaterial. 2.Useonlythepropertoolsandcleaningequip- ment. Refer to“SPECIALTOOLS’intheapplicable servicemanual. 3.Whendisassembling,alwayskeepmated partstogether.Thisincludesgears,cylinders, pistonsandotherpartsthathavebeen“mated”throughnormalwear.Matedpartsmust alwaysbereusedorreplacedasanassembly. 4.Duringdisassembly,cleanallofthepartsand placethemintraysintheorderofdisassembly.Thiswillspeedupassemblyandallowfor thecorrectinstallationofallparts. 5.Keepallpartsawayfromanysourceoffire. REPLACEMENTPARTS UseonlygenuineYamahapartsforallreplace- ments.Useoilandgreaserecommendedby Yamahaforalllubricationjobs.Otherbrands maybesimilarinfunctionandappearance,but inferiorinquality. GASKETS,OILSEALSANDO-RINGS 1.Whenoverhaulingtheengine,replaceall gaskets,sealsandO-rings.Allgasketsurfac- es,oilseallipsandO-ringsmustbecleaned. 2.Duringreassembly,properlyoilallmating partsandbearingsandlubricatetheoilseal lipswithgrease. 1.Oil 2.Lip 3.Spring 4.Grease LOCKWASHERS/PLATESANDCOTTER PINS Afterremoval,replacealllockwashers/plates “4”andcotterpins.Aftertheboltornuthasbeen tightenedtospecification,bendthelocktabs alongaflatoftheboltornut.

IMPORTANTINFORMATION BEARINGSANDOILSEALS Installbearings“1”andoilseals“2”sothatthe manufacturermarksornumbersarevisible. Wheninstallingoilseals,lubricatetheoilseal lipswithalightcoatoflithium-soap-based grease.Oilbearingsliberallywheninstalling,if appropriate. ecatsoo0 NOTICE Donotspinthebearingwithcompressedair becausethiswilldamagethebearingsurfac- es. CIRCLIPS Beforereassembly,checkallcirclipscarefully andreplacedamagedordistortedcirclips.Al- waysreplacepistonpinclipsafteroneuse. Wheninstallingacirclip“1”,makesurethe sharp-edgedcorner“2”ispositionedopposite thethrust“3”thatthecirclipreceives. 1 =e LIME REASSEMBLYOFPARTSUSINGLOCKING AGENT(LOCTITE®) Beforereassemblingscrews,bolts,andnuts,or otherparts,usinglockingagent(LOCTITE®), removealltheoldlockingagent,andthenapply newlockingagentandreassembletheparts.Al- so,aspecifiedamountoftimeisrequiredforthe lockingagenttocure. RUBBERPARTS Checkrubberpartsfordeteriorationduringin- spection.Someoftherubberpartsaresensitive togasoline,flammableoil,grease,etc.Donotallowanyitemsotherthanthespecifiedoneto contacttheparts.

BASICSERVICEINFORMATION BASICSERVICEINFORMATION QUICKFASTENERS Rivettype 1.Remove: *Quickfastener TIP. Toremovethequickfastener,pushitspinwitha screwdriver,thenpullthefastenerout. WH ; LL Cn 1&r &Il 2.Install: *Quickfastener TIP Toinstallthequickfastener,pushitspinsothat itprotrudesfromthefastenerhead,theninsert thefastenerintothepart tobesecuredandpush thepin“a”inwithascrewdriver.Makesurethat thepinisflushwiththefastener’shead. Ty *9a*|=] a a Screwtype1 1.Remove: *Quickfastener TIP. Toremovethequickfastener,loosenthescrew withascrewdriver,thenpullthefastenerout. 2.Install: *Quickfastener TIP. Toinstallthequickfastener,insertthefastener intotheparttobesecuredandtightenthescrew.

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2024 Yamaha YZ65 Service & Repair Manual

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