1986 Yamaha Moto-4 60 (4-Zinger) Service & Repair Manual

_YAMAHA LIT -11616-04-87 1HN-28197-10

NOTICE This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to put an entire mechanic's education into one manual, so it is assumed that persons using this book to perform maintenance and repairs on Yamaha motor- cycles have a basic understanding of the mechanical concepts and procedures inherent in motorcycle repair technology. Without such knowledge, attempted repairs or service to this model may render it unfit to use and/or unsafe. Yamaha Motor Company, Ltd. is continually striving to improve all models manufactured by Yamaha. Modifications and significant changes in specifications or procedures will be forwarded to all Authorized Yamaha dealers and will, where applicable, appear in future editions of this manual. TECHNICAL PUBLICATIONS SERVICE DIVISION MOTORCYCLE OPERATIONS YAMAHA MOTOR CO., LTD HOW TO USE THIS MANUAL PARTICULARLY IMPORTANT INFORMATION This material is distinguished by the following notation. NOTE: WARNING: A NOTE provides key information to make procedures easier or clearer. A CAUTION indicates special procedures that must be followed to avoid damage to the motorcycle. A WARNING indicates special procedures that must be followed to avoid injury to a motorcycle operator or person inspecting or repairing the motorcycle. MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations. In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol, e.g., -Bearings Pitting/ Damage--+ Replace. EXPLODED DIAGRAM Each chapter provides exploded diagrams before each disassembly section for ease in identifying correct disassembly and assembly procedures.

CD ® I=I~I l~g~1 §tl ® ® IENGI~I lcooy ~I @ ® ~ARBI.I ~HASI~I (j) ® IELEel §I ~pp~6"1 ® ~ @ ~ QD ~ @ ~ @ [0J (3) ~ @ 1 @ 1 @ 1 m m a @ @ ® ~~ ~sn ~ @ A B ILLUSTRATED SYMBOLS (Refer to the illustration) Illustrated symbols CD to ® are designed as thumb tabs to indicate the chapter's number and content. CD General information (2) Periodic inspection and adjustment @ Engine @ Cooling system @ Carburetion ® Chassis (J) Electrical @ Appendices Illustrated symbols ® to @ are used to identify the specifications appearing in the text. ® Filling fluid ® Lubricant @ Tightening © Wear limit, clearance @ Engine speed @O,V,A Illustrated symbols @ to @ in the exploded diagram indicate grade of lubricant and location of lubrication point. ® Apply engine oil ® Apply gear oil @ Apply molybdenum disulfide oil @ Apply wheel bearing grease @l Apply lightweight lithium-soap base grease @ Apply molybdenum disulfide grease @ Apply locking agent (LOCTITE®)

INDEX GENERAL INFORMATION fItti; GEN INFO

____________________ I~~~I~I CHAPTER 1. GENERAL INFORMATION MACHINE IDENTIFICATION . ...................................... 1-1 VEHICLE IDENTIFICATION NUMBER .............................. 1-1 ENGINE SERIAL NUMBER ....................................... 1-1 IMPORTANT INFORMATION . ..................................... 1-2 ALL REPLACEMENT PARTS ..................................... 1-2 GASKETS, OIL SEALS, AND O-RINGS ............................ 1-2 LOCK WASHERS/PLATES AND COTTER PINS .................... 1-2 BEARINGS AND OIL SEALS ..................................... 1-2 CIRCLIPS ...................................................... 1-3 SPECIAL TOOLS .................................................. 1-3 FOR TUNE-UP .................................................. 1-3 FOR ENGINE SERVICE .......................................... 1-3 FOR CHASSIS SERViCE ......................................... 1-5 FOR ELECTRICAL COMPONENTS ................................ 1-5

I ~~ IAI MACHINE IDENTIFICATION 1-1 GENERAL INFORMATION MACHINE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER The vehicle identification number CD is stamped into the left side of the frame. NOTE: ________________________ _ The vehicle identification number is used to identify your machine and may be used to register your machine with the licensing outhority in your state. Starting Serial Number: JY41HNOO*GCOOO101 ENGINE SERIAL NUMBER The engine serial number CD is stamped into the left side of the engine. NOTE: ______________________ __ The first three digits of these numbers are for model identifications; the remaining digits are the unit production number. Starting Serial Number: 1HN-000101 NOTE: ________________________ _ Designs and specifications are subject to change without notice.

IMPORTANT INFORMATION I,~~ Icteal IMPORTANT INFORMATION 300-000 ALL REPLACEMENTS PARTS 1. We recommend to use Yamaha genuine parts for all replacements. Use oil and/or grease recommended by Yamaha for assembly and adjustment. GASKETS, OIL SEALS, AND a-RINGS 1. All gaskets, seals, and a-rings should be replaced when an engine is overhauled. All gasket surfaces, oil seal lips, and a-rings must be cleaned. 2. Properly oil all mating parts and bearings dur- ing reassembly. Apply grease to the oil seal lips. LOCK WASHERS/PLATES AND COTTER PINS 1. All lock washers/plates CD and cotter pins must be replaced when they are removed. Lock tab(s) should be bent along the bolt or nut flat(s) after the bolt or nut has been properly tightened. BEARINGS AND OIL SEALS 1. Install the bearing(s) CD and oil seal(s) CV with their manufacturer's marks or numbers facing outward. (In other words, the stamped letters must be on the side exposed to view.) When installing oil seal(s), apply a light coating of light-weight lithium base grease to the seallip(s). Oil the bearings liberally when 300 OO? installing. 300-003 Do not use compressed air to spin the bearings dry. This causes damage to the bearing surfaces. 1-2

I,~~~ I AI SPECIAL TOOLS 1-3 CIRCLIPS 1. All circlips should be inspected carefully before reassembly. Always replace piston pin clips after one use. Replace distorted circlips. When installing a circlip CD, make sure that the sharp-edged corner (2) is positioned op- posite to the thrust ® it receives. See the sectional view. @ Shaft SPECIAL TOOLS The proper special tools are necessary for com- plete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvis- ed techniques. FOR TUNE-UP 1. Inductive Tachometer P/ N YU-08036 This tool is needed for detecting engine rpm. FOR ENGINE SERVICE 1. Dial Gauge P/ N YU-03097 2. Universal Puller P/ N YU-33270 This tool is used to remove the crankshaft from the crankcase.

SPECIAL TOOLS I ~~ I ~I 3. Crankshaft Installation Set ............ CD PIN YU-90050 Adapter # 3 ......................... <bl PIN YU-90063 These tools are used to install the crankshaft. 4. Flywheel Puller PIN YM-01189 This tool is used to remove the flywheel magneto. 5. Flywheel Holding Tool PIN YU-01235 Use this tool to hold the flywheel magneto while removing or tightening the flywheel magneto securing nut. 6. Hexagon Wrench (25MM) PIN YM-01306 Use this tool to loosen or tighten the middle- driven-shaft-bearing retainer nut. 1-4

II~~ 1cJe81 SPECIAL TOOLS 'II __ -~I L-. -- __ II I 1-5 FOR CHASSIS SERVICE 1. Hexagon Wrench (22M) PIN YM-01307 Use this tool to loosen or tighten the final- drive-shaft-bearing retainer nut. 2. Ring Nut Wrench PIN YU-33975 Use this wrench to tighten or loosen the ring nut on the rear axle. FOR ELECTRICAL COMPONENTS 1. Coil Tester PIN YU-33261 This instrument is necessary for checking the ig- nition system components. 2. Pocket Tester PIN YU-03112 This instrument is invaluable for checking the electrical system.

1986 Yamaha Moto-4 60 (4-Zinger) Service & Repair Manual

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