Service manual

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SERVICE MANUAL

YFM250RX

4D3-28197-10LIT-11616-21-22

2008

Summary of content (311 pages)

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2008 SERVICE MANUAL YFM250RX LIT-11616-21-22 4D3-28197-10
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EBS00001 YFM250RX SERVICE MANUAL © 2007 by Yamaha Motor Corporation, U.S.A. First Edition, July 2007 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.
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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 machine has a basic understanding of the mechanical ideas and the procedures of machine repair. Repairs attempted by anyone without this knowledge are likely to render the machine unsafe and unfit for use.
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EBS00004 HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual consists of chapters for the main categories of subjects. (See “symbols”) 1st title : This is the title of the chapter with its symbol in the upper right corner of each page. 2nd title : 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.
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EBS00006 SYMBOLS The following symbols are not relevant to every machine. Symbols to indicate the subject of each chapter.
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EBS00008 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS ENGINE CARBURETOR CHASSIS ELECTRICAL TROUBLESHOOTING GEN INFO 1 SPEC 2 CHK ADJ 3 ENG 4 CARB 5 CHAS 6 ELEC 7 TRBL SHTG 8
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CHAPTER 1 GENERAL INFORMATION MACHINE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 VEHICLE IDENTIFICATION NUMBER. . . . . . . . . . . . . . . . . . . . . . . . 1-1 MODEL LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 IMPORTANT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 PREPARATION FOR REMOVAL AND DISASSEMBLY . . . . . . . . . . 1-2 REPLACEMENT PARTS . . . . . . . . . . . . . . . .
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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. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 SEAT, FRONT FENDER AND HEADLIGHTS . . . . . . . . .
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CHECKING AND LUBRICATING THE CABLES . . . . . . . . . . . . . . . . 3-43 LUBRICATING THE LEVERS AND PEDALS . . . . . . . . . . . . . . . . . . . 3-44 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45 CHECKING AND CHARGING THE BATTERY . . . . . . . . . . . . . . . . . 3-45 CHECKING THE FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52 ADJUSTING THE HEADLIGHT BEAM . . . . . . . . . . . . . . . . . . . . . . . .
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CHECKING THE CLUTCH PLATES . . . . . . . . . . . . . . . . . . . . . . . . . 4-44 CHECKING THE CLUTCH SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . 4-45 CHECKING THE CLUTCH HOUSING . . . . . . . . . . . . . . . . . . . . . . . . 4-45 CHECKING THE CLUTCH BOSS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45 CHECKING THE PRESSURE PLATE . . . . . . . . . . . . . . . . . . . . . . . . 4-45 CHECKING THE CLUTCH PUSH RODS . . . . . . . . . . . . . . . . . . . . . .
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CHAPTER 5 CARBURETOR CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 CHECKING THE CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 ASSEMBLING THE CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 INSTALLING THE CARBURETOR JOINT . . . . . . . . . . . . . . . . . . . . . 5-7 INSTALLING THE CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 CHAPTER 6 CHASSIS FRONT AND REAR WHEELS . . . . . . . . . . .
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ASSEMBLING THE REAR BRAKE CALIPER . . . . . . . . . . . . . . . . . . 6-36 INSTALLING THE FRONT BRAKE CALIPERS . . . . . . . . . . . . . . . . . 6-38 INSTALLING THE REAR BRAKE CALIPER . . . . . . . . . . . . . . . . . . . 6-40 STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42 HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42 REMOVING THE CLUTCH SWITCH . . . . . . . . . . . . . . . . . . . . . . . . .
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CHECKING THE BULBS AND BULB SOCKETS . . . . . . . . . . . . . . . . . . 7-5 TYPES OF BULBS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 CHECKING THE CONDITION OF THE BULBS . . . . . . . . . . . . . . . . . 7-5 CHECKING THE CONDITION OF THE BULB SOCKETS . . . . . . . . 7-7 IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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CLUTCH SLIPPING/DRAGGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 CLUTCH SLIPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 CLUTCH DRAGGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 OVERHEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 OVERHEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 FAULTY BRAKE . . . . . . . . .
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MACHINE IDENTIFICATION GEN INFO EBS00009 GENERAL INFORMATION MACHINE IDENTIFICATION EBS00010 VEHICLE IDENTIFICATION NUMBER The vehicle identification number stamped into the left side of the frame. is EBS00011 MODEL LABEL The model label is affixed to the air filter case cover. This information will be needed to order spare parts.
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IMPORTANT INFORMATION GEN INFO EBS00013 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 equipment. Refer to “SPECIAL TOOLS”. 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.
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IMPORTANT INFORMATION GEN INFO EBS00017 BEARINGS AND OIL SEALS Install bearings and oil seals so that the manufacturer’s 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. Oil seal CAUTION: Do not spin the bearing with compressed air because this will damage the bearing surfaces.
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IMPORTANT INFORMATION GEN INFO EBS00019 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: • lead • coupler • connector 2. Check: • lead • coupler • connector Moisture → Dry with an air blower. Rust /stains → Connect and disconnect several times. 3. Check: • all connections Loose connection → Connect properly. NOTE: If the pin on the terminal is flattened, bend it up. 4.
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SPECIAL TOOLS GEN INFO EBS00021 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. 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. In such a case, two types are provided. When placing an order, refer to the list provided below to avoid any mistakes. For US and CAN P/N.
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SPECIAL TOOLS Tool No. Adapter 90890-01383 YU-90062 Tool name/Function GEN INFO Illustration Adapter (M10) Adapter #2 This tool is used to install the crankshaft. Spacer 90890-01288 This tool is used to install the crankshaft. Piston pin puller set Piston pin puller YU-01304 90890-01304 YU-01304 This tool is used to remove the piston pin. Tappet adjusting tool Six piece tappet set 90890-01311 YM-A5970 This tool is necessary for adjusting the valve clearance.
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SPECIAL TOOLS Tool No. Tool name/Function Compression gauge Engine compression tester 90890-03081 YU-33223 This tool is needed to measure the engine compression. Extension 90890-04082 This tool is needed to measure engine compression. Pocket tester Analog pocket tester 90890-03112 YU-03112-C This instrument is needed for checking the electrical system. Timing light Inductive clamp timing light 90890-03141 YU-03141 This tool is necessary for checking ignition timing.
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SPECIAL TOOLS Tool No. Tool name/Function Valve guide installer (φ6) Valve guide installer (6.0 mm) 90890-04065 YM-04065-A This tool is needed to install the valve guides. Valve guide reamer (φ6) Valve guide reamer (6.0 mm) 90890-04066 YM-04066 This tool is needed to rebore the new valve guides. Valve lapper Valve lapping tool 90890-04101 YM-A8998 This tool is needed to remove and install the valve lifters. PTT wrench 46 90890-06588 This tool is needed to loosen or tighten the rear axle nut.
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GENERAL SPECIFICATIONS SPEC EBS01001 SPECIFICATIONS GENERAL SPECIFICATIONS Item Model code Dimensions Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius Basic weight With oil and full fuel tank Engine Engine type Cylinder arrangement Displacement Bore × stroke Compression ratio Engine idle speed Intake vacuum Oil temperature Standard compression pressure (at sea level) Starting system Lubrication system Oil type or grade Engine oil Oil capa
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GENERAL SPECIFICATIONS Item Fuel Type Fuel tank capacity Fuel reserve amount Carburetor Type/quantity Manufacturer Spark plug Type/manufacturer Spark plug gap Clutch type Transmission Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Transmission type Operation Gear ratio 1st gear 2nd gear 3rd gear 4th gear 5th gear Chassis Frame type Caster angle Camber angle Kingpin angle Trail Tread (STD) front rear Toe-in (with tires touching the ground) Tire Type Siz
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GENERAL SPECIFICATIONS Item Brake Front brake Rear brake Suspension Front suspension Rear suspension Shock absorber Front shock absorber Rear shock absorber Wheel travel Front wheel travel Rear wheel travel Electrical Ignition system Generator system Battery type Battery capacity Headlight type Bulb voltage/wattage × quantity Headlight Tail/brake light Indicator lights Neutral SPEC Standard type operation type operation Dual disc brake Right hand operation Single disc brake Right foot operation Double wi
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ENGINE SPECIFICATIONS SPEC EBS01002 ENGINE SPECIFICATIONS Item Standard Cylinder head Volume Warp limit 20.50 ~ 21.50 cm3 (1.25 ~ 1.31 cu.in) ••• Cylinder Bore size Chain drive (Right) “A” “B” Exhaust ••• 0.05 mm (0.0020 in) 74.000 ~ 74.016 mm (2.9134 ~ 2.9140 in) 74.100 mm (2.9173 in) Camshaft Drive method Camshaft lobe dimensions Intake Limit “A” “B” Camshaft runout limit Timing chain Timing chain type/No.
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ENGINE SPECIFICATIONS Item Valve, valve seat, valve guide Valve clearance (cold) IN EX Valve dimensions Head Diameter “A” head diameter “B” face width “C” seat width “D” margin thickness Stem outside diameter Guide inside diameter Stem-to-guide clearance Standard Limit ••• ••• 0.05 ~ 0.10 mm (0.0020 ~ 0.0039 in) 0.10 ~ 0.15 mm (0.0039 ~ 0.0059 in) Face Width Seat Width Margin Thickness IN EX IN EX IN 33.90 ~ 34.10 mm (1.3346 ~ 1.3425 in) 28.40 ~ 28.60 mm (1.1181 ~ 1.1260 in) 2.26 mm (0.
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ENGINE SPECIFICATIONS Item Valve spring Inner spring Free length Installed length (valve closed) Spring rate K1 K2 K1 K2 Compressed spring force (installed) Standard Direction of winding (top view) Outer spring Free length Installed length (valve closed) Spring rate K1 Spring rate K2 Spring rate K1 Spring rate K2 Compressed spring force (installed) Limit IN 36.17 mm (1.42 in) EX 36.17 mm (1.42 in) IN EX IN IN EX EX 30.50 mm (1.20 in) 30.50 mm (1.20 in) 14.70 N/mm (1.50 kg/mm, 83.94 lb/in) 19.
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ENGINE SPECIFICATIONS Item Tilt limit Direction of winding (top view) SPEC Standard IN ••• EX ••• IN EX Clockwise Clockwise Piston Piston to cylinder clearance Limit 2.5°/1.60 mm (2.5°/0.063 in) 2.5°/1.60 mm (2.5°/0.063 in) ••• ••• Piston size “D” 0.15 mm (0.006 in) 73.983 ~ 73.998 mm (2.9127 ~ 2.9133 in) • • • Measuring point “H” Piston off set Offset direction Piston pin bore inside diameter 5.0 mm (0.20 in) 0.25 mm (0.0098 in) Intake side 17.002 ~ 17.013 mm (0.6694 ~ 0.
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ENGINE SPECIFICATIONS Item SPEC Standard Limit Piston rings Top ring Type Dimensions (B × T) End gap (installed) Barrel 0.90 × 2.75 mm (0.035 × 0.108 in) 0.19 ~ 0.31 mm (0.007 ~ 0.012 in) Side clearance 0.030 ~ 0.065 mm (0.0012 ~ 0.0026 in) ••• ••• 0.56 mm (0.022 in) 0.115 mm (0.0045 in) 2nd ring Type Dimensions (B × T) End gap (installed) Taper 0.80 × 2.80 mm (0.031 × 0.110 in) 0.30 ~ 0.45 mm (0.012 ~ 0.018 in) Side clearance 0.020 ~ 0.055 mm (0.0008 ~ 0.0022 in) ••• ••• 0.80 mm (0.
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ENGINE SPECIFICATIONS Item Balancer Balancer drive method Clutch Friction plate 1 (inside dia.: 104.5 ~ 105.5 mm) Thickness SPEC Standard Limit Gear ••• 2.9 ~ 3.1 mm (0.114 ~ 0.122 in) 2.8 mm (0.110 in) ••• Quantity Friction plate 2 (inside dia.: 104.5 ~ 105.5 mm) Thickness 4 Quantity Clutch plate Thickness Quantity Max. warpage 2 1.5 ~ 1.7 mm (0.059 ~ 0.067 in) 5 ••• ••• ••• 0.2 mm (0.0079 in) Clutch spring Free length 47.8 mm (1.
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ENGINE SPECIFICATIONS Item Carburetor I. D. mark Main jet (M.J) Main air jet (M.A.J) Jet needle (J.N) Needle jet (N.J) Pilot air jet 1 (P.A.J.1) Pilot air jet 2 (P.A.J.2) Pilot outlet (P.O) Pilot jet (P.J) Bypass 1 (B.P.1) Bypass 2 (B.P.2) Bypass 3 (B.P.3) Valve seat size (V.S) Starter jet 1 (G.S.1) Starter jet 2 (G.S.2) Throttle valve size (THV) Float height (F.H) Oil filter type Oil pump Oil pump type Inner-rotor-to-outer-rotor-tip clearance SPEC Standard 4D31 00 #133.8 #140 5DH66-1 P-0M #85 #170 ø0.
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CHASSIS SPECIFICATIONS SPEC EBS01003 CHASSIS SPECIFICATIONS Item Front suspension Shock absorber travel Spring free length Spring rate Spring stroke Optional spring Rear suspension Shock absorber assembly travel Spring free length Spring rate Stroke Optional spring Swingarm Free play limit radial axial Standard Limit 90.7 mm (3.57 in) 248.5 mm (9.78 in) 23.0 N/mm (2.34 kg/mm, 131.26 lb/in) 0.0 ~ 90.7 mm (0.0 ~ 3.57 in) No ••• ••• ••• ••• ••• 87.0 mm (3.43 in) 240.5 mm (9.47 in) 54.0 N/mm (5.
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CHASSIS SPECIFICATIONS Item Front disc brake Type Disc outside diameter × thickness SPEC Standard Dual 161.0 × 3.5 mm (6.34 × 0.14 in) Brake disk maximum deflection Pad thickness inner 4.4 mm (0.17 in) Pad thickness outer 4.5 mm (0.18 in) Master cylinder inside diameter Caliper cylinder inside diameter Brake fluid type Rear disc brake Type Disc outside diameter × thickness 12.7 mm (0.50 in) 27 mm (1.06 in) DOT 4 Single 200.0 × 4.0 mm (7.87 × 0.16 in) Limit ••• 3.0 mm (0.12 in) 0.15 mm (0.006 in) 1.
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ELECTRICAL SPECIFICATIONS SPEC EBS01004 ELECTRICAL SPECIFICATIONS Item Standard Voltage Ignition system Ignition timing (B.T.D.C.) Advanced timing (B.T.D.C.
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ELECTRICAL SPECIFICATIONS Item Starter relay Model/manufacturer Amperage rating Coil winding resistance Headlight relay Headlight relay Model/manufacturer Coil resistance Circuit breaker Type Amperage for individual circuit Fuse Reserve SPEC Standard Limit A4616-051/JIDECO 180 A 4.18 ~ 4.62 Ω ••• ••• ••• G8HN-1C4T-DJ-Y52/OMRON 94.5 Ω ~ 115.
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TIGHTENING TORQUES SPEC EBS01005 TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Tightening torque Part name Thread size Q’ty Bolt M8 4 Cylinder head Camshaft lock plate Cylinder head side cover (1 and 2) Cylinder head side cover 3 Cylinder head breather plate Spark plug Cylinder head stud bolt Oil gallery bolt Carburetor joint Plate, 2 Cylinder Left crankcase cover Pickup coil rotor Balancer weight gear Bolt Bolt Bolt Bolt Bolt — Stud bolt Bolt Bolt Bolt Bolt Bolt Bolt Nut M8 M6 M55 M6 M6 M12 M8 M
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TIGHTENING TORQUES Part to be tightened Clutch boss nut Clutch spring Push lever adjusting screw locknut Push lever shaft Chain case cover Drive sprocket nut Stopper lever Shift pedal Neutral switch Starter motor Stator coil Pickup coil Part name Thread size Q’ty Nut M16 Screw Nut Bolt Bolt Nut Bolt Bolt — Bolt Bolt Bolt SPEC Tightening torque 1 Nm 75 m•kg 7.5 ft•lb 55 M6 M6 M8 M10 M18 5 1 1 2 1 8 8 12 10 110 0.8 0.8 1.2 1.0 11.0 5.9 5.9 8.9 7.
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TIGHTENING TORQUES SPEC EBS01006 CHASSIS TIGHTENING TORQUES Part to be tightened Thread size Tightening torque Engine upper stay and frame Engine upper stay and engine Engine lower stay and engine Engine and frame Engine lower stay and frame Swingarm pivot shaft and frame Rear shock absorber and frame Rear shock absorber locknut Rear axle pinch bolt Front shock absorber and frame Front shock absorber and lower front arm Upper front arm and frame Lower front arm and frame Steering stem and frame Steeri
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TIGHTENING TORQUES Part to be tightened Thread size Tightening torque Front brake master cylinder and brake lever Throttle assembly and handlebar Front brake master cylinder and brake hose Brake hose joint and frame Bleed screw Front brake pad retaining bolt Front brake caliper and brake hose Rear brake caliper retaining bolt Parking brake case and caliper Rear axle ring nut Rear axle ring nut set bolt Rear brake pad retaining bolt M6 M5 M10 M6 M8 M10 M10 M8 M8 M33 M6 M8 Nm 6 4 27 10 5 17 27 17 22 140
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HOW TO USE THE CONVERSION TABLE/ GENERAL TIGHTENING TORQUE SPECIFICATIONS SPEC EBS00022 EBS00023 HOW TO USE THE CONVERSION TABLE GENERAL TIGHTENING TORQUE SPECIFICATIONS All specification data in this manual are listed in SI and METRIC UNITS. Use this table to convert METRIC unit data to IMPERIAL unit data. Ex. This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch.
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LUBRICATION POINTS AND LUBRICANT TYPES SPEC EBS00024 LUBRICATION POINTS AND LUBRICANT TYPES ENGINE Lubrication point Lubricant Oil seal lips O-rings Bearings Cylinder head bolts (bearing surface of bolts) Cylinder head bolts (thread part) Cylinder body surface Crankshaft journals Connecting rod small end and big end Piston pin Piston surface Boss periphery Valve stems (intake and exhaust) Valve stem ends (intake and exhaust) Rocker arm shafts (intake and exhaust) Camshaft Valve rocker arms Oil pump rot
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LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Crankcase mating surfaces AC magneto lead grommet (AC magneto cover) 2-21 SPEC Lubricant Sealant (Three Bond No.1215®) Yamaha bond No.1215 Sealant (Three Bond No.1215®) Yamaha bond No.
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OIL FLOW DIAGRAMS EBS00026 OIL FLOW DIAGRAMS Camshaft Oil filter element Oil pump Oil strainer Oil filter Oil cooler Pin, with hole Cylinder head Oil pump Drive axle Main axle Crank shaft Cam shaft Oil strainer Oil pan 2-22 SPEC
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OIL FLOW DIAGRAMS Camshaft Drive axle Main axle Push lever shaft Oil pump assembly Oil strainer Crankshaft assembly Oil filter element 2-23 SPEC
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OIL FLOW DIAGRAMS Oil cooler Oil hose 1 Oil hose 2 2-24 SPEC
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CABLE ROUTING EBS00028 CABLE ROUTING Front brake hose Front brake light switch lead Throttle cable Plastic band Clutch cable Parking brake cable Clutch switch lead Handlebar switch lead 2-25 SPEC
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CABLE ROUTING Clamp the front brake light switch lead at the bends of handlebar. Route the front brake hose and throttle cable through the guide of the handlebar protector. Route the throttle cable under the front brake hose. Route the clutch cable and parking brake cable through the guide of the handlebar protector. Route the clutch cable in front of the parking brake cable. 2-26 SPEC Clamp the clutch switch lead and handlebar switch lead at the bends of handlebar.
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CABLE ROUTING Indicator light lead Main switch lead Coupler joint Front brake light switch lead Front brake hose 2 Oil cooler hose 1, 2 Exhaust pipe Engine bracket Rear brake light switch lead Parking brake cable Battery negative lead A Carburetor warmer lead Air vent hose Air filter case breather hose Throttle cable Front brake hose 1 Clutch cable Main harness Clamp Frame complete Rear brake reservoir hose Carburetor overflow hose SPEC Neutral switch lead Rear brake reservoir cover A F H H F A-A
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CABLE ROUTING To the front panel To the front fender To the handlebar To the right headlight Make sure to route the oil cooler hoses 1and 2 through the guide wire. Install the front brake hose 2, making sure to face the white paint mark forward. Route the oil cooler hose 1 and 2 between the exhaust pipe and the engine bracket. A SPEC Route the battery negative lead behind the clutch cable holder. Route the air vent hose through the bracket.
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CABLE ROUTING Route the parking brake cable and the clutch cable under the cross pipe and right of the steering column as shown in the illustration. Route the rear brake light switch lead, neutral switch lead, air vent hose, carburetor overflow hose and parking brake cable through the bracket. Route the rear brake light switch lead under the bracket. Route the rear brake light switch lead between the bracket and rear brake reservoir tank.
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CABLE ROUTING SPEC Rear brake reservoir Rear brake light switch Clip Rear brake reservoir hose Rear brake master cylinder Parking brake cable Rear brake hose Rear brake caliper D-D C-C E C D E C D 2-30
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CABLE ROUTING Make sure that the end of the clip is facing downward. Set the rear brake reservoir hose with the positioning yellow paint mark pointing down. Install the rear brake hose in the direction shown in the illustration. Insert the rear brake hose until it contacts the projection. Make sure that the end of the clip is facing outward. D-D SPEC Install the rear brake reservoir hose, making sure to face the white paint mark outward.
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CABLE ROUTING Clutch switch lead Handlebar switch lead Bolt Main harness Air vent hose Clamp Battery negative lead AC magneto lead Carburetor overflow hose Starter motor lead B-B Neutral switch lead Ignition coil spark plug lead Ignition coil Drain hose Frame complete Damper plate Seat pad Cover Rear brake light switch lead Carburetor warmer lead SPEC Air filter case breather hose Air filter joint Air filter case G-G B D G M B I I G E N E N L C D M C L D-D I-I N-N L-L C-C E-E 2-32 M-
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CABLE ROUTING To the front fender Route the wire harness above the guide for the damper plate. Fix point for wire harness Clamp near the hook of the air filter. Clamp near the edge of the air filter case. Route the drain hose in front of the left oil cooler hose. Clamp on top of the frame bracket. To the left headlight Route the clamp through the damper plate hole. B-B SPEC Route the carburetor overflow hose as shown in the illustration. Fasten the clamp with the engine.
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CABLE ROUTING Indicator light Coupler joint Main switch lead Front brake light switch lead Throttle cable Regulator Flange bolt Headlight lead Indicator light lead Clutch cable Parking brake cable SPEC N Rear brake reservoir Rear brake light switch lead Air vent hose Battery negative lead Carburetor warmer lead Starter motor lead Clutch switch lead Handlebar switch lead Main harness Frame complete Clamp K-K J-J K K J J 2-34
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CABLE ROUTING To the handlebar Route the air vent hose through the bracket. Route the battery negative lead behind the clutch cable holder. Fix point for wire harness Insert the air vent hose into the fender. Route the clutch switch lead and handlebar switch lead on the box shaped part. Connect the clutch switch lead and handlebar switch lead on top of the front fender. Route the wire harness from the front. N Install the indicator light as shown in the illustration.
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CABLE ROUTING SPEC N Route the cables and leads through the guide of the front fender. Route the leads behind the clutch and parking brake cable.
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CABLE ROUTING CDI unit Band Battery Starter relay lead Starter relay Taillight lead Battery negative lead AC magneto coupler Starter motor lead Headlight relay Neutral relay SPEC Damper CDI unit lead Relay lead B A A J J B A-A 2-37
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CABLE ROUTING Route the starter relay lead under the starter motor lead. Clamp the taillight lead. Do not clamp. When clamping the wire harness, make sure that the insulator lock is behind the clamp. After connecting the battery negative lead, push the sag in the box. SPEC After connecting the taillight lead and each electric part, the length between the air filter and AC magneto coupler should be 185 mm (7.28 in) on straight line. There is no particular order in placing each lead.
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INTRODUCTION/PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM EBS00029 CHK ADJ PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable machine operation and a longer service life. The need for costly overhaul work will be greatly reduced.
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CHK ADJ GENERAL MAINTENANCE AND LUBRICATION CHART GENERAL MAINTENANCE AND LUBRICATION CHART INITIAL NO. 1 2 3 * * ITEM CHECK OR MAINTENANCE JOB Whichever comes first month 1 3 6 6 12 km (mi) 320 (200) 1300 (800) 2500 (1600) 2500 (1600) 5000 (3200) hours 20 80 160 160 320 Every 20 ~ 40 hours (more often in wet or dusty areas) Air filter element • Clean and replace if necessary. Clutch • Check operation and adjust if necessary.
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GENERAL MAINTENANCE AND LUBRICATION CHART CHK ADJ NOTE: • The air filter needs more frequent service if you are riding in unusually wet or dusty areas. • Hydraulic brake service • Regularly check and, if necessary, correct the brake fluid level. • Every two years replace the internal components of the brake master cylinders and calipers, and change the brake fluid. • Replace the brake hoses every four years and if cracked or damaged.
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SEAT, FENDERS AND FUEL TANK CHK ADJ EBS00033 SEAT, FENDERS AND FUEL TANK SEAT, FRONT FENDER AND HEADLIGHTS 7 Nm (0.7 m•kg, 5.2 ft•Ib) 7 Nm (0.7 m•kg, 5.2 ft•Ib) Order 7 Nm (0.7 m•kg, 5.2 ft•Ib) 1 Job/Part Removing the seat, front fender and headlights Seat 2 3 4 5 6 7 8 9 Indicator light coupler Front panel Plate Main switch coupler Front fender Headlight coupler Left headlight Right headlight Q’ty 7 Nm (0.7 m•kg, 5.2 ft•Ib) Remarks Remove the parts in the order listed.
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CHK ADJ SEAT, FENDERS AND FUEL TANK EBS00034 FOOT PROTECTORS AND ENGINE SKID PLATE T. R. 17 Nm (1.7 m•kg, 13 ft•Ib) 2 17 Nm (1.7 m•kg, 13 ft•Ib) T. R. T. R. 17 Nm (1.7 m•kg, 13 ft•Ib) T. R. 17 Nm (1.7 m•kg, 13 ft•Ib) 3 1 T. R. 7 Nm (0.7 m•kg, 5.2 ft•Ib) Order 1 2 3 Job/Part Removing the foot protectors and engine skid plate Left foot protector Right foot protector Engine skid plate Q’ty Remarks Remove the parts in the order listed.
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SEAT, FENDERS AND FUEL TANK CHK ADJ REAR FENDER AND AIR FILLTER CASE 7 Nm (0.7 m•kg, 5.2 ft•Ib) 7 Nm (0.7 m•kg, 5.2 ft•Ib) 7 Nm (0.7 m•kg, 5.2 ft•Ib) 7 Nm (0.7 m•kg, 5.2 ft•Ib) Order 1 2 3 Job/Part Removing the rear fender and air fillter case Seat/front fender Q’ty Remarks Remove the parts in the order listed. Refer to “SEAT, FENDERS AND FUEL TANK”. Rear fender Battery cover Battery lead 1 1 2 CAUTION: First disconnect the negative lead, then disconnect the positive lead.
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SEAT, FENDERS AND FUEL TANK 7 Nm (0.7 m•kg, 5.2 ft•Ib) CHK ADJ 7 Nm (0.7 m•kg, 5.2 ft•Ib) 7 Nm (0.7 m•kg, 5.2 ft•Ib) 7 Nm (0.7 m•kg, 5.2 ft•Ib) Order 10 Job/Part Air filter case Q’ty 1 Remarks For installation, reverse the removal procedure.
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CHK ADJ SEAT, FENDERS AND FUEL TANK EBS00042 FUEL TANK 7 Nm (0.7 m•kg, 5.2 ft•Ib) . 2 3 4 1 Order Job/Part Removing the fuel tank Seat/front fender Q’ty 1 Fuel hose (fuel cock side) 1 2 Fuel tank 1 3 4 Clamp Fuel tank shield 1 1 Remarks Remove the parts in the order listed. Refer to “SEAT, FENDERS AND FUEL TANK”. NOTE: Before disconnecting the fuel hose, turn the fuel cock to “OFF”.
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ADJUSTING THE VALVE CLEARANCE CHK ADJ EAS00048 ENGINE ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: • Valve clearance adjustment should be made on a cold engine, at room temperature. • When the valve clearance is to be measured or adjusted, the piston must be at the Top Dead Center (TDC) on the compression stroke. 1. Remove: • seat • front fender • fuel tank Refer to “SEAT, FENDERS AND FUEL TANK”. 2.
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ADJUSTING THE VALVE CLEARANCE CHK ADJ a. Turn the crankshaft counterclockwise. b. When the piston is at the Top Dead Center (TDC) on the compression stroke, align the “I” mark on the AC magneto rotor with the stationary pointer on the crankcase cover. NOTE: Top dead center (TDC) is a point where the mark on the AC magneto rotor and the pointer on the crankcase cover match, plus at the same time, the punch mark in the camshaft sprocket and the pointer on the cylinder head match. c.
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ADJUSTING THE VALVE CLEARANCE/ ADJUSTING THE ENGINE IDLING SPEED CHK ADJ d. Measure the valve clearance again. e. If the valve clearance is still out of specification, repeat all of the valve clearance adjustment steps until the specified clearance is obtained. 6. Install: • all removed parts NOTE: For installation, reverse the removal procedure. EBS00051 ADJUSTING THE ENGINE IDLING SPEED 1. Start the engine and let it warm up for several minutes. 2.
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ADJUSTING THE ENGINE IDLING SPEED/ ADJUSTING THE THROTTLE LEVER FREE PLAY CHK ADJ 4. Adjust: • engine idling speed a. Turn the throttle stop screw in direction or until the specified idling speed is obtained. b a Direction Direction Idling speed becomes higher. Idling speed becomes lower. 5. Remove: • fuel tank NOTE: Slide the fuel tank. 6. Detach: • digital tachometer 7. Adjust: • throttle lever free play Refer to “ADJUSTING THE THROTTLE LEVER FREE PLAY”. Throttle lever free play 2 ~ 4 mm (0.08 ~ 0.
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ADJUSTING THE THROTTLE LEVER FREE PLAY/ ADJUSTING THE SPEED LIMITER 2. Adjust: • throttle lever free play b First step: a. Slide back the rubber cover . b. Loosen the locknut on the carburetor side. c. Turn the adjusting nut in direction or until the correct free play is obtained. a 1 2 CHK ADJ 3 Direction Direction Free play is increased. Free play is decreased. d. Tighten the locknut. e. Slide the rubber cover to its original position.
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ADJUSTING THE SPEED LIMITER 1 a CHK ADJ 1. Measure: • Speed limiter length Out of specification → Adjust. 2 Speed limiter length Less than 12 mm (0.47 in) b 2. Adjust: • speed limiter length c a. Loosen the locknut . b. Turn the adjusting screw in or out until the specified speed limiter length is obtained. Direction Direction Speed limiter length is decreased. Speed limiter length is increased. c. Tighten the locknut.
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CHECKING THE SPARK PLUG CHK ADJ EBS00057 CHECKING THE SPARK PLUG 1. Disconnect: • spark plug cap 2. Remove: • spark plug 3. Check: • spark plug type Incorrect → Change. Standard spark plug NGK/DR7EA 4. Check: • electrode Wear/damage → Replace. • insulator Abnormal color → Replace. Normal color is a medium-to-light tan color. 5. Clean: • spark plug (with a spark plug cleaner or wire brush) 6. Measure: • spark plug gap Use a wire gauge or thickness gauge. Out of specification → Regap. Spark plug gap 0.
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CHECKING THE IGNITION TIMING CHK ADJ EBS00058 CHECKING THE IGNITION TIMING NOTE: Engine idling speed and throttle cable free play should be adjusted properly before checking the ignition timing. 1. Attach: • digital tachometer Digital tachometer 90890-06760, YU-39951-B • timing light (onto the ignition coil spark plug lead) Timing light 90890-03141 Inductive clamp timing light YU-03141 2. Check: • ignition timing 1 a. Warm up the engine and keep it at the specified speed.
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MEASURING THE COMPRESSION PRESSURE CHK ADJ MEASURING THE COMPRESSION PRESSURE The following procedure applies to the cylinder. NOTE: Insufficient compression pressure will result in a loss of performance. 1. Measure: • Valve clearance Out of specification → Adjust. Refer to “ADJUSTING THE VALVE CLEARANCE” 2. Start the engine, warm it up for several minutes, and then turn it off. 3. Disconnect: • Spark plug cap 4.
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MEASURING THE COMPRESSION PRESSURE CHK ADJ 6. Measure: • Compression pressure Out of specification → Refer to steps (c) and (d). Compression pressure (standard) 1,100 kPa/720 r/min (11.2 kgf/cm2, 160 psi/720 r/min) Compression pressure (maximum) 1,300 kPa/720 r/min (13.3 kgf/cm2, 189 psi /720 r/min) Compression pressure (minimum) 900 kPa/720 r/min (9.2 kgf/cm2, 131 psi /720 r/min) a. Set the main switch to “ON”. b.
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MEASURING THE COMPRESSION PRESSURE/ CHECKING THE ENGINE OIL LEVEL CHK ADJ 7. Install: • Spark plug Spark plug 18 Nm (1.8 m•kg, 13 ft•lb) 8. Connect: • Spark plug cap EBS01101 CHECKING THE ENGINE OIL LEVEL 1. Place the machine on a level surface. 2. Start the engine, warm it up several minutes, and then turn it off. 3. Check: • engine oil level Oil level should be between the minimum level mark and the maximum level mark . Low oil level → Add oil to the proper level.
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CHECKING THE ENGINE OIL LEVEL/ CHANGING THE ENGINE OIL CHK ADJ 4. Start the engine, warm it up for several minutes, and then turn it off. 5. Check: • engine oil level NOTE: Before checking the engine oil level, wait a few minutes until the oil has settled. EBS00067 CHANGING THE ENGINE OIL 1. Place the machine on a level surface. 2. Start the engine, warm it up for several minutes, and then turn it off. 3. Place a container under the engine oil drain bolt. 4.
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CHANGING THE ENGINE OIL CHK ADJ 8. Install: • engine oil drain bolt gasket • engine oil drain bolt 2 Engine oil drain bolt 20 Nm (2.0 m•kg, 15 ft•lb) 3 • oil filter element drain bolt 3 Oil filter element drain bolt 10 Nm (1.0 m•kg, 7.4 ft•lb) 9. Fill: • crankcase (with the specified amount of the recommended engine oil) Periodic oil replacement 1.25 L (1.10 Imp qt, 1.32 US qt) With oil filter element replacement 1.35 L (1.19 Imp qt, 1.43 US qt) Engine oil quantity Total amount 1.60 L (1.41 Imp qt, 1.
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CHANGING THE ENGINE OIL/ ADJUSTING THE CLUTCH CABLE CHK ADJ 14.Check: • engine oil pressure a. Slightly loosen the oil gallery bolt . b. Start the engine and keep it idling until engine oil starts to seep from the oil gallery bolt. If no engine oil comes out after one minute, turn the engine off so that it will not seize. c. Check the engine oil passages, the oil filter element and the oil pump for damage or leakage. Refer to “OIL PUMP AND BLANCER WEIGHT GEAR” in chapter 4. d.
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ADJUSTING THE CLUTCH CABLE/ CLEANING THE AIR FILTER ELEMENT CHK ADJ EBS00073 CLEANING THE AIR FILTER ELEMENT NOTE: There is a check hose at the bottom of the air filter case. If dust and/or water collects in this hose, clean the air filter element and air filter case. 1 1. Remove: • seat Refer to “SEAT, FENDERS AND FUEL TANK”. 2. Remove: • air filter case cover 1 2 3.
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CLEANING THE AIR FILTER ELEMENT CHK ADJ 5. Clean: • air filter element a. Wash the element gently, but thoroughly in solvent. WARNING Use a cleaning solvent which is designed to clean parts only. Never use gasoline or low flash point solvents as they may cause a fire or explosion. b. Squeeze the excess solvent out of the element and let it dry. CAUTION: Do not twist or wring out the element. This could damage the foam material. c.
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CLEANING THE AIR FILTER ELEMENT/ CLEANING THE SPARK ARRESTER CHK ADJ CLEANING THE SPARK ARRESTER 1. Clean: • Spark arrester 1 2 1 WARNING • Select a well-ventilated area free of combustible materials. • Always let the exhaust system cool before performing this operation. • Do not start the engine when removing the tailpipe from the muffler. a. Remove the bolts . b. Remove the tailpipe from the muffler. c.
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ADJUSTING THE FRONT BRAKE/ADJUSTING THE BRAKE LEVER/ADJUSTING THE REAR BRAKE CHK ADJ EBS00080 CHASSIS a ADJUSTING THE FRONT BRAKE 1. Measure: • brake lever free play Out of specification → Bleed the front brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM”. Brake lever free play (at the end of the brake lever) 0 mm (0 in) 1 ADJUSTING THE BRAKE LEVER (For adjustment type model) 1. Adjust: • brake lever position 2 b a a a. While pushing the brake lever forward, loosen the locknut . b.
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ADJUSTING THE REAR BRAKE/ ADJUSTING THE PARKING BRAKE CHK ADJ 2. Adjust: • rear brake pedal height a. Loosen the locknut . b. Turn the adjusting bolt until the brake pedal height is within the specified limits. c. Tighten the locknut. NOTE: When adjusting the brake pedal height make sure the locknut-to-adjusting bolt clearance does not exceed 2.2 ~ 3.2 mm (0.09 ~ 0.13 in).
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ADJUSTING THE PARKING BRAKE/ CHECKING THE BRAKE FLUID LEVEL CHK ADJ 2. Adjust: • parking brake cable end length a. Loosen the locknut and adjusting bolt . b. Slide back the rubber cover . c. Loosen the locknut . d. Turn the adjusting nut in direction or until the specified brake cable end length is obtained. e. Tighten the locknut. f. Slowly turn the adjusting bolt clockwise until resistance is felt. g. Turn it 1/8 counterclockwise. h. Tighten the locknut . 16 Nm (1.6 m•kg, 11 ft•lb) i.
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CHECKING THE BRAKE FLUID LEVEL/ CHECKING THE FRONT BRAKE PADS CHK ADJ 2. Check: • brake fluid level Below the minimum level mark → Add the recommended brake fluid to the proper level. Recommended brake fluid DOT 4 Front brake Rear brake WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • Refill with the same type of brake fluid that is already in the system.
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CHECKING THE FRONT BRAKE PADS/ CHECKING THE REAR BRAKE PADS CHK ADJ 2. Check: • brake pads Wear indicator groove almost disappeared → Replace the brake pads as a set. Refer to “FRONT AND REAR BRAKES” in chapter 6. Brake pad wear limit 1.5 mm (0.06 in) 3. Operate the brake lever. 4. Install: • front wheels Refer to “FRONT AND REAR WHEELS” in chapter 6. EBS00089 CHECKING THE REAR BRAKE PADS 1. Check: • brake pads Wear indicators almost touch the brake disc → Replace the brake pads as a set.
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ADJUSTING THE REAR BRAKE LIGHT SWITCH/ CHECKING THE BRAKE HOSES CHK ADJ ADJUSTING THE REAR BRAKE LIGHT SWITCH NOTE: • The rear brake light switch is operated by movement of the brake pedal. • The rear brake light switch is properly adjusted when the brake light comes on just before the braking effect starts. 1. Check: • rear brake light operation timing Incorrect → Adjust. 2. Adjust: • rear brake light operation timing a.
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CHECKING THE BRAKE HOSES/ BLEEDING THE HYDRAULIC BRAKE SYSTEM CHK ADJ 2. Check: • front brake hoses • front brake pipe • rear brake hose Cracks/wear/damage → Replace. 3. Check: • brake hose clamps Loosen → Tighten. 4. Hold the machine in an upright position and apply the front or rear brake. 5. Check: • brake hoses Apply the brake lever or brake pedal several times. Fluid leakage → Replace the hoses or pipe. Refer to “FRONT AND REAR BRAKES” in chapter 6. 6.
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BLEEDING THE HYDRAULIC BRAKE SYSTEM CHK ADJ NOTE: • Be careful not to spill any brake fluid or allow the brake master cylinder reservoir or brake fluid reservoir to overflow. • When bleeding the hydraulic brake system, make sure there is always enough brake fluid before applying the brake. Ignoring this precaution could allow air to enter the hydraulic brake system, considerably lengthening the bleeding procedure.
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BLEEDING THE HYDRAULIC BRAKE SYSTEM/ ADJUSTING THE SHIFT PEDAL CHK ADJ j. Tighten the bleed screw to specification. 5 Nm (0.5 m•kg, 3.7 ft•lb) k. Fill the brake fluid reservoir to the proper level with the recommended brake fluid. Refer to “CHECKING THE BRAKE FLUID LEVEL”. WARNING After bleeding the hydraulic brake system, check the brake operation. EBS00098 ADJUSTING THE SHIFT PEDAL 1. Measure: • shift pedal height Out of specification → Adjust. Shift pedal height 15.2 mm (0.60 in) 2.
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ADJUSTING THE DRIVE CHAIN SLACK CHK ADJ ADJUSTING THE DRIVE CHAIN SLACK NOTE: • Measure the drive chain slack halfway between the drive axle and the rear axle. • When checking and adjusting the drive chain slack, there should be no weight on the vehicle and all tires must be touching the ground. CAUTION: A drive chain that is too tight will overload the engine and other vital parts, and one that is too loose can skip and damage the swingarm or cause an accident.
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ADJUSTING THE DRIVE CHAIN SLACK/ CHECKING THE STEERING SYSTEM CHK ADJ CAUTION: Excessive chain slack will overload the engine and other vital parts; keep the slack within the specified limits. 1 2 5 6 e. If the chain slack cannot be adjusted, replace the sprockets and drive chain as a set. f. Tighten the rear axle pinch bolts . 3 4 7 8 21 Nm (2.1 m•kg, 15 ft•lb) NOTE: • Tighten the rear axle pinch bolts in the proper sequence as shown.
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ADJUSTING THE TOE-IN CHK ADJ EBS00108 ADJUSTING THE TOE-IN 1. Place the machine on a level surface. 2. Measure: • toe-in Out of specification → Adjust. Toe-in 9 ~ 19 mm (0.35 ~ 0.75 in) NOTE: Before measuring the toe-in, make sure that the tire pressure is correct. a. b. c. d. Mark both front tire tread centers. Face the handlebar straight ahead. Measure the width between the marks. Rotate the front tires 180° until the marks are exactly opposite one another. e. Measure the width between the marks. f.
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ADJUSTING THE TOE-IN/CHECKING THE FRONT AND REAR SHOCK ABSORBERS CHK ADJ a. Mark both tie-rods ends. This reference point will be needed during adjustment. b. Loosen the locknuts (tie-rod end) of both tie-rods. c. The same number of turns should be given to both the right and left tie-rods until the specified toe-in is obtained. This is to keep the length of the rods the same. d. Tighten the rod end locknuts of both tie15 Nm (1.5 m•kg, 11 ft•lb) rods. NOTE: Adjust the rod ends so that A and B are equal.
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ADJUSTING THE FRONT SHOCK ABSORBERS CHK ADJ EBS00111 ADJUSTING THE FRONT SHOCK ABSORBERS WARNING Always adjust the spring preload of both front shock absorbers to the same setting. Uneven adjustment can result in poor handling and loss of stability. 1. Adjust: • spring preload a. Turn the adjusting ring in direction with the spanner wrench . 1 2 3 4 5 Direction Direction Spring preload is increased (suspension is harder). Spring preload is decreased (suspension is softer).
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ADJUSTING THE REAR SHOCK ABSORBER CHK ADJ EBS00111 ADJUSTING THE REAR SHOCK ABSORBER 1. Adjust: • spring preload a. Elevate the rear wheels by placing a suitable stand under the frame. b. Loosen the locknut . c. Turn the adjusting nut in direction or . Direction Direction Spring preload is increased (suspension is harder). Spring preload is decreased (suspension is softer). Adjusting length Standard: 230 mm (9.06 in) Minimum: 222 mm (8.74 in) Maximum: 234 mm (9.
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CHECKING THE TIRES CHK ADJ EBS00114 CHECKING THE TIRES WARNING This model is equipped with low pressure tires. It is important that they be inflated correctly and maintained at the proper pressures. • TIRE CHARACTERISTICS 1) Tire characteristics influence the handling of ATVs. The tires listed below have been approved by Yamaha Motor Co., Ltd. for this model. If other tire combinations are used, they can adversely affect your machine’s handling characteristics and are therefore not recommended.
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CHECKING THE TIRES CHK ADJ 1. Measure: • tire pressure Out of specification → Adjust. NOTE: • The low-pressure tire gauge is included as standard equipment. • If dust or the like is stuck to this gauge, it will not provide the correct readings. Therefore, take two measurements of the tire’s pressure and use the second reading. Cold tire pressure Standard Minimum Maximum Front/Rear 27.5 kPa (0.28 kg/cm2, 4.0 psi) 24.5 kPa (0.25 kg/cm2, 3.6 psi) 30.5 kPa (0.31 kg/cm2, 4.
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CHECKING THE WHEELS/CHECKING AND LUBRICATING THE CABLES CHK ADJ EBS00116 CHECKING THE WHEELS 1. Check: • wheel Damage/bends → Replace. NOTE: Always balance the wheel when a tire or wheel has been changed or replaced. WARNING • Never attempt even small repairs to the wheel. • Ride conservatively after installing a tire to allow it to seat itself properly on the rim. EBS00117 CHECKING AND LUBRICATING THE CABLES WARNING A damaged cable sheath may cause corrosion and interfere with the cable movement.
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LUBRICATING THE LEVERS AND PEDALS CHK ADJ EBS00118 LUBRICATING THE LEVERS AND PEDALS Lubricate the pivoting point and metal-to-metal moving parts of the levers and pedal.
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CHECKING AND CHARGING THE BATTERY CHK ADJ EBS00120 ELECTRICAL SYSTEM CHECKING AND CHARGING THE BATTERY WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: • Wear protective eye gear when handling or working near batteries. • Charge batteries in a well-ventilated area. • Keep batteries away from fire, sparks or open flames (e.g., welding equipment, lighted cigarettes).
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CHECKING AND CHARGING THE BATTERY CHK ADJ NOTE: Since MF batteries are sealed, it is not possible to check the charge state of the battery by measuring the specific gravity of the electrolyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals. 1. Remove: • seat • battery cover Refer to “SEAT, FENDERS AND FUEL TANK”. 2.
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CHECKING AND CHARGING THE BATTERY CHK ADJ Example c. Open-circuit voltage = 12.0 V d. Charging time = 6.5 hours e. Charge of the battery = 20 ~ 30% 14 13 12 11 10 5. Charge: • battery (refer to the appropriate charging method illustration) Ambient temperature 20°C (68°F) WARNING Do not quick charge a battery. 0 10 20 30 40 50 60 Time (minutes) Check the open-circuit voltage.
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CHECKING AND CHARGING THE BATTERY CHK ADJ • As shown in the following illustration, the open-circuit voltage of an MF battery stabilizes about 30 minutes after charging has been completed. Therefore, wait 30 minutes after charging is completed before measuring the open-circuit voltage.
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CHK ADJ CHECKING AND CHARGING THE BATTERY Charging method using a variable-current (voltage) charger Charger Ammeter Measure the open-circuit voltage prior to charging. Connect a charger and ammeter to the battery and start charging. YES Is the amperage higher than the standard charging amperage written on the battery? Leave the battery unused for more than 30 minutes before measuring its open-circuit voltage. Set the charging voltage to 16 ~ 17 V.
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CHECKING AND CHARGING THE BATTERY CHK ADJ Charging method using a constant voltage charger Measure the open-circuit voltage prior to charging. Leave the battery unused for more than 30 minutes before measuring its open-circuit voltage. Connect a charger and ammeter to the battery and start charging. Is the amperage higher than the standard charging amperage written on the battery? Charge the battery until the charging voltage reaches 15 V. This type of battery charger cannot charge an MF battery.
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CHECKING AND CHARGING THE BATTERY CHK ADJ 6. Install: • battery 7. Connect: • battery leads (to the battery terminals) CAUTION: First, connect the positive battery lead and then the negative battery lead . , 8. Check: • battery terminals Dirt → Clean with a wire brush. Loose connection → Connect properly. 9. Lubricate: • battery terminals Recommended lubricant Dielectric grease 10.Install: • battery cover • seat Refer to “SEAT, FENDERS AND FUEL TANK”.
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CHECKING THE FUSES CHK ADJ EBS00121 CHECKING THE FUSES The following procedure applies to all of the fuses. CAUTION: To avoid a short circuit, always set the main switch to “OFF” when checking or replacing a fuse. 1. Remove: • seat • battery cover Refer to “SEAT, FENDERS AND FUEL TANK”. 2. Check: • fuse a. Connect the pocket tester to the fuse and check the continuity. NOTE: Set the pocket tester selector to “Ω × 1”. Pocket tester 90890-03112 Analog pocket tester YU-03112-C b.
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CHK ADJ CHECKING THE FUSES/ ADJUSTING THE HEADLIGHT BEAM Items Amperage rating Q’ty Main 15 A 1 Reserve 15 A 1 WARNING Never use a fuse with an amperage rating other than that specified. Improvising or using a fuse with the wrong amperage rating may cause extensive damage to the electrical system, cause the lighting and ignition systems to malfunction and could possibly cause a fire. 4. Install: • battery cover • seat Refer to “SEAT, FENDERS AND FUEL TANK”.
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REPLACING A HEADLIGHT BULB CHK ADJ EBS00124 REPLACING A HEADLIGHT BULB 1. Remove: • headlight Refer to “SEAT, FENDERS AND FUEL TANK”. 2. Disconnect: • headlight lead coupler 3. Remove: • headlight bulb holder cover 4. Remove: • bulb holder • bulb NOTE: Push the headlight bulb holder inward, turn it counterclockwise and remove the defective bulb. WARNING Keep flammable products and your hands away from the bulb while it is on. since it will be hot. Do not touch the bulb until it cools down. 5.
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REPLACING A HEADLIGHT BULB CHK ADJ 6. Install: • bulb holder • headlight bulb holder cover NOTE: After installing the bulb holder cover, make sure that the “TOP” mark is in the position shown. 7. Connect: • headlight lead coupler 8. Install: • headlight Refer to “SEAT, FENDERS AND FUEL TANK”.
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ENGINE REMOVAL ENG ENGINE ENGINE REMOVAL MUFFLER AND EXHAUST PIPE 1 34 Nm (3.4 m•kg, 25 ft•lb) 2 3 4 20 Nm (2.0 m•kg, 15 ft•lb) 5 8 Nm (0.8 m•kg, 5.9 ft•lb) 18 Nm (1.8 m•kg, 13 ft•lb) Order 1 2 3 4 5 6 Job/Parts to remove Removing the muffler and exhaust pipe Seat/front panel/fender Q’ty Clamp Muffler Gasket Exhaust pipe EXhaust pipe protector Gasket 1 1 1 1 1 1 Remarks Remove the parts in the order listed. Refer to “SEAT, FENDERS AND FUEL TANK” in chapter 3.
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ENGINE REMOVAL ENG INSTALLING THE EXHAUST PIPE AND MUFFLER 1. Install: • gasket (to muffler) Installed depth of gasket 3.5 mm (0.14 in) 2. Install: • exhaust pipe protector 3. Tighten: • exhaust pipe protector screws Screw 8 Nm (0.8 m•kg, 5.9 ft•lb) LOCTITE® 4. Install: • gasket • exhaust pipe 5. Tighten: • nuts (exhaust pipe) Exhaust pipe nut 18 Nm (1.8 m•kg, 13 ft•lb) 6.
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ENGINE REMOVAL ENG LEADS, CABLES AND HOSES 7 6 9 8 1 2 3 10 Nm (1.0 m•kg, 7.4 ft•lb) 5 Order 1 2 3 4 5 6 7 8 Job/Parts to remove Removing the leads, cables and hoses Engine oil Oil cooler hose 1, 2 Carburetor Drive sprocket/drive chain Q’ty 4 Remarks Remove the parts in the order listed. Drain. Refer to “CLUTCH”. Refer to “CARBURETOR” in chapter 5. Refer to “REAR SHOCK ABSORBER, SWINGARM AND DRIVE CHAIN” in chapter 6.
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ENGINE REMOVAL ENG 7 6 9 8 1 2 3 10 Nm (1.0 m•kg, 7.4 ft•lb) 5 Order 9 Job/Parts to remove Neutral switch connector 4 Q’ty Remarks 1 Disconnect. For installation, reverse the removal procedure.
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ENGINE REMOVAL ENG ENGINE MOUNTING BOLTS 33 Nm (3.3 m•kg, 24 ft•lb) 40 Nm (4.0 m•kg, 30 ft•lb) 66 Nm (6.6 m•kg, 49 ft•lb) 33 Nm (3.3 m•kg, 24 ft•lb) 66 Nm (6.6 m•kg, 49 ft•lb) 40 Nm (4.0 m•kg, 30 ft•lb) 33 Nm (3.
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ENGINE REMOVAL ENG INSTALLING THE ENGINE 1. Install: • Engine mounting bolt (rear lower side) • Engine mounting bolt (rear upper side) • Engine bracket bolts (upper side) • Engine mounting bolt (upper side) • Engine brackets (front side) • Engine mounting bolt (front side) NOTE: • The direction of the bolt insertion is made from the right side of the body. • Do not fully tighten the bolts and nuts. 2. Install: • Crankcase bolt 3.
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CYLINDER HEAD ENG CYLINDER HEAD 10 Nm (1.0 m•kg, 7.4 ft•lb) 60 Nm (6.0 m•kg, 44 ft•lb) 10 Nm (1.0 m•kg, 7.4 ft•lb) 18 Nm (1.8 m•kg, 13 ft•lb) 24 Nm (2.4 m•kg, 18 ft•lb) 18 Nm (1.8 m•kg, 13 ft•lb) 10 Nm (1.0 m•kg, 7.4 ft•lb) 20 Nm (2.
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CYLINDER HEAD ENG 10 Nm (1.0 m•kg, 7.4 ft•lb) 60 Nm (6.0 m•kg, 44 ft•lb) 10 Nm (1.0 m•kg, 7.4 ft•lb) 18 Nm (1.8 m•kg, 13 ft•lb) 24 Nm (2.4 m•kg, 18 ft•lb) 18 Nm (1.8 m•kg, 13 ft•lb) 10 Nm (1.0 m•kg, 7.4 ft•lb) 20 Nm (2.0 m•kg, 15 ft•lb) Order 9 10 11 12 13 14 15 16 Job/Parts to remove Cap bolt Timing chain tensioner/gasket Breather pipe 2 Camshaft sprocket/dowel pin Cylinder head Timing chain guide Dowel pin Cylinder head gasket Q’ty Remarks 1 Loosen.
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CYLINDER HEAD ENG REMOVING THE CYLINDER HEAD 1. Align: • “I” mark on the Pickup coil rotor (with the stationary pointer on the crankcase cover) a. Turn the Pickup coil rotor counterclockwise. b. When the piston is at TDC on the compression stroke, align the “I” mark on the camshaft sprocket with the mark on the cylinder head. 2. Loosen: • Camshaft sprocket bolt 3.
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CYLINDER HEAD ENG CHECKING THE CYLINDER HEAD 1. Eliminate: • Combustion chamber carbon deposits (with a rounded scraper) NOTE: Do not use a sharp instrument to avoid damaging or scratching: • Spark plug bore threads • Valve seats 2. Check: • Cylinder head Damage/scratches → Replace. 3. Measure: • Cylinder head warpage Out of specification → Resurface the cylinder head. Warpage limit 0.05 mm (0.0020 in) a. Place a straightedge and a thickness gauge across the cylinder head. b. Measure the warpage. c.
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CYLINDER HEAD ENG CHECKING THE TIMING CHAIN GUIDES The following procedure applies to the camshaft sprockets and timing chain guides. 1. Check: • Timing chain Damage/stiffness → Replace the timing chain and camshaft sprocket and crankshaft sprocket as a set. 2. Check: • Camshaft sprocket More than 1/4 tooth wear → Replace the timing chain and camshaft sprocket and crankshaft sprocket as a set. 1/4 tooth Correct Timing chain Camshaft sprocket 3.
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CYLINDER HEAD ENG b. Remove the screwdriver and slowly release the timing chain tensioner rod. c. Make sure that the timing chain tensioner rod comes out of the timing chain tensioner housing smoothly. If there is rough movement, replace the timing chain tensioner. 3. Check: • Cap bolt • Copper washer • Spring • One-way cam • Timing chain tensioner rod Damage/wear → Replace the defective part(s). INSTALLING THE CYLINDER HEAD 1. Install: • Cylinder head gasket • Dowel pins 2.
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ENG CYLINDER HEAD a. Turn the Pickup coil rotor counterclockwise. b. Align the “I” mark on the Pickup coil rotor with the stationary pointer on the crankcase cover. c. Remove the wire from the timing chain. d. Install the timing chain onto the camshaft sprocket, and then install the camshaft sprocket onto the camshaft. NOTE: • When installing the camshaft sprocket, be sure to keep the timing chain as tight as possible on the exhaust side.
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CYLINDER HEAD ENG 6. Turn: • Crankshaft (several turns counterclockwise) 7. Check: • “I” mark Align the “I” mark on the pickup coil rotor with the stationary pointer on the crankcase cover. • “I” mark Align the “I” mark on the camshaft sprocket with the stationary pointer on the cylinder head. Out of alignment → Correct. Refer to the installation steps above. 8. Tighten: • Camshaft sprocket bolt Camshaft sprocket bolt 60 Nm (6.
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ROCKER ARM, CAMSHAFT ENG ROCKER ARM, CAMSHAFT Order 1 2 3 4 5 6 7 Job/Parts to remove Q’ty Remarks Removing the rocker arms and camRemove the parts in the order listed. shaft Cylinder head Refer to “CYLINDER HEAD”. Lock plate 1 Locknut/valve clearance adjusting 2/2 screw Camshaft 1 Intake rocker arm shaft 1 Intake rocker arm 1 Exhaust rocker arm shaft 1 Exhaust rocker arm 1 For installation, reverse the removal procedure.
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ROCKER ARM, CAMSHAFT ENG REMOVING THE ROCKER ARMS AND CAMSHAFT 1. Loosen: • Locknut • Valve clearance adjusting screw 2. Remove: • Stopper plate 3. Remove: • Camshaft • Bearing NOTE: Screw 10 mm (0.396 in) bolt into the threaded end of the camshaft and then pull out the camshaft. 4. Remove: • Intake rocker arm shaft • Exhaust rocker arm shaft • Intake rocker arm • Exhaust rocker arm NOTE: Remove the rocker arm shafts with the slide hammer bolt and weight .
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ROCKER ARM, CAMSHAFT ENG CHECKING THE CAMSHAFT 1. Check: • Bearing Damage/wear → Replace. 2. Check: • Camshaft lobes Blue discoloration/pitting/scratches Replace the camshaft. → 3. Measure: • Camshaft lobe dimensions and Out of specification → Replace the camshaft. Camshaft lobe dimension Intake A 36.890 ~ 36.990 mm (1.4524 ~ 1.4563 in) Limit 36.790 mm (1.4484 in) Intake B 30.111 ~ 30.211 mm (1.1855 ~ 1.1894 in) Limit 30.011 mm (1.1815 in) Exhaust A 36.891 ~ 36.991 mm (1.4524 ~ 1.4563 in) Limit 36.
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ROCKER ARM, CAMSHAFT ENG CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS The following procedure applies to all of the rocker arms and rocker arm shafts. 1. Check: • Rocker arms • Valve clearance adjusting screws Damage/wear → Replace. 2. Check: • Rocker arm shaft Blue discoloration/excessive wear/pitting/ scratches → Replace or check the lubrication system. 3. Measure: • Rocker arm inside diameter Out of specification → Replace. Rocker arm inside diameter 12.000 ~ 12.018 mm (0.4724 ~ 0.4731 in) Limit 12.
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ROCKER ARM, CAMSHAFT ENG INSTALLING THE CAMSHAFT AND ROCKER ARMS 1. Lubricate: • Camshaft Recommended lubricant Camshaft Molybdenum disulfide oil Camshaft bearing Engine oil 2. Lubricate: • Rocker arm • Rocker arm shaft Recommended lubricant Rocker arm Molybdenum disulfide oil Rocker arm shaft Engine oil 3. Install: • Exhaust rocker arm • Exhaust rocker arm shaft NOTE: Make sure the exhaust rocker arm shaft is completely pushed into the cylinder head. 4.
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ROCKER ARM, CAMSHAFT ENG 5. Install: • Camshaft NOTE: Screw a 10 mm bolt into the threaded end of the camshaft and then install the camshaft. 6. Install: • Lock plate 7. Tighten: • Lock plate bolts Lock plate bolt 8 Nm (0.8 m•kg, 5.
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VALVES AND VALVE SPRINGS ENG VALVES AND VALVE SPRINGS Order 1 2 3 4 5 6 7 8 9 Job/Parts to remove Removing the valves and valve springs Cylinder head Rocker arm Camshaft Valve cotter Valve spring retainer Outer valve spring Inner valve spring Intake valve Exhaust valve Valve stem seal Valve spring seat Valve guide Q’ty Remarks Remove the parts in the order listed. Refer to “CYLINDER HEAD”. Refer to “ROCKER ARM, CAMSHAFT”. 4 2 2 2 1 1 2 2 2 For installation, reverse the removal procedure.
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VALVES AND VALVE SPRINGS ENG REMOVING THE VALVES The following procedure applies to all of the valves and related components. NOTE: Before removing the internal parts of the cylinder head (e.g., valves, valve springs, valve seats), make sure the valves properly seal. 1. Check: • Valve sealing Leakage at the valve seat → Check the valve face, valve seat, and valve seat width. Refer to “CHECKING THE VALVE SEATS”. a. Pour a clean solvent into the intake and exhaust ports. b.
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VALVES AND VALVE SPRINGS ENG 3. Remove: • Upper spring seat • Inner valve spring • Outer valve spring • Valve • Lower spring seat • Valve stem seal NOTE: Identify the position of each part very carefully so that it can be reinstalled in its original place. CHECKING THE VALVES AND VALVE GUIDES The following procedure applies to all of the valves and valve guides. 1. Measure: • Valve-stem-to-valve-guide clearance Out of specification → Replace the valve guide.
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VALVES AND VALVE SPRINGS ENG 2. Replace: • Valve guide NOTE: To ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100°C (212°F) in an oven. a. Remove the valve guide with the valve guide remover . b. Install the new valve guide with the valve guide installer and valve guide remover . c. After installing the valve guide, bore the valve guide with the valve guide reamer to obtain the proper valve-stem-to-valveguide clearance.
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VALVES AND VALVE SPRINGS ENG 5. Measure: • Valve margin thickness D Out of specification → Replace the valve. Valve margin thickness Valve margin thickness D (intake) 0.80 ~ 1.20 mm (0.0315 ~ 0.0472 in) Valve margin thickness D (exhaust) 0.80 ~ 1.20 mm (0.0315 ~ 0.0472 in) 6. Measure: • Valve stem runout Out of specification → Replace the valve. NOTE: • When installing a new valve, always replace the valve guide. • If the valve is removed or replaced, always replace the oil seal. Valve stem runout 0.
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VALVES AND VALVE SPRINGS ENG 3. Measure: • Valve seat width Out of specification → Replace the cylinder head. Valve seat width Valve seat width C (intake) 0.90 ~ 1.10 mm (0.0354 ~ 0.0433 in) Valve seat width C (exhaust) 0.90 ~ 1.10 mm (0.0354 ~ 0.0433 in) a. Apply Mechanic’s blueing dye (Dykem) onto the valve face. b. Install the valve into the cylinder head. c. Press the valve through the valve guide and onto the valve seat to make a clear impression. d. Measure the valve seat width.
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VALVES AND VALVE SPRINGS ENG a. Apply a coarse lapping compound valve face. to the CAUTION: Do not let the lapping compound enter the gap between the valve stem and the valve guide. b. Apply molybdenum disulfide oil onto the valve stem. c. Install the valve into the cylinder head. d. Turn the valve until the valve face and valve seat are evenly polished, then clean off all of the lapping compound.
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VALVES AND VALVE SPRINGS ENG CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs. 1. Measure: • Valve spring free length Out of specification → Replace the valve spring. Inner spring Free length (intake) 36.17 mm (1.42 in) Free length (exhaust) 36.17 mm (1.42 in) Outer spring Free length (intake) 36.63 mm (1.44 in) Free length (exhaust) 36.63 mm (1.44 in) 2. Measure: • Compressed valve spring force Out of specification → Replace the valve spring.
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VALVES AND VALVE SPRINGS ENG 3. Measure: • Valve spring tilt Out of specification → Replace the valve spring. Inner spring Spring tilt (intake) 2.5°/1.60 mm (2.5°/0.063 in) Spring tilt (exhaust) 2.5°/1.60 mm (2.5°/0.063 in) Outer spring Spring tilt (intake) 2.5°/1.60 mm (2.5°/0.063 in) Spring tilt (exhaust) 2.5°/1.60 mm (2.5°/0.063 in) INSTALLING THE VALVES The following procedure applies to all of the valves and related components. 1. Deburr: • Valve stem end (with an oil stone) 2.
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VALVES AND VALVE SPRINGS ENG 4. Install: • Valve cotters NOTE: Install the valve cotters by compressing the valve spring with the valve spring compressor and the valve spring compressor attachment . Valve spring compressor 90890-04019, YM-04019 Valve spring compressor attachment 90890-01243 Valve spring compressor adapter (26 mm) YM-01253-1 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a softface hammer.
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CYLINDER AND PISTON ENG CYLINDER AND PISTON 10 Nm (1.0 m•kg, 7.4 ft•lb) 17 Nm (1.7 m•kg, 13 ft•lb) Order 1 2 3 4 5 6 7 8 Job/Parts to remove Removing the cylinder and piston Cylinder head Oil delivery pipe Cylinder Dowel pin Cylinder gasket Piston pin clip Piston pin Piston Piston ring set Q’ty Remarks Remove the parts in the order listed. Refer to “CYLINDER HEAD”. 1 1 2 1 2 1 1 1 For installation, reverse the removal procedure.
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CYLINDER AND PISTON ENG + REMOVING THE PISTON 1. Remove: • Piston pin clips • Piston pin • Piston NOTE: • Before removing the piston pin clip, cover the crankcase opening with a clean rag to prevent the piston pin clip from falling into the crankcase. • Before removing each piston pin, deburr the clip groove and pin hole area. If the piston pin groove is deburred and the piston pin is still difficult to remove, use the piston pin puller .
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CYLINDER AND PISTON ENG a. Measure cylinder bore “C” with the cylinder bore gauge. NOTE: Measure cylinder bore “C” by taking side-toside and front-to-back measurements of the cylinder. Then, find the average of the measurements. Bore “C” 74.000 ~ 74.016 mm (2.9134 ~ 2.9140 in) Wear limit 74.100 mm (2.9173 in) “C” = maximum of D1 ~ D6 b. If out of specification, rebore or replace the cylinder, and replace the piston and piston rings as a set. c. Measure piston skirt diameter D with the micrometer.
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CYLINDER AND PISTON ENG Piston-to-cylinder clearance 0.010 ~ 0.025 mm (0.0004 ~ 0.0010 in) Limit 0.15 mm (0.006 in) f. If out of specification, rebore or replace the cylinder, and replace the piston and piston rings as a set. CHECKING THE PISTON RINGS 1. Measure: • Piston ring side clearance Out of specification → Replace the piston and piston rings as a set. NOTE: Before measuring the piston ring side clearance, eliminate any carbon deposits from the piston ring grooves and piston rings.
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CYLINDER AND PISTON ENG 2. Install: • Piston ring (into the cylinder) NOTE: Level the piston ring into the cylinder with the piston crown. 40 mm (1.476 in) 3. Measure: • Piston ring end gap Out of specification → Replace the piston ring. NOTE: The oil ring expander spacer’s end gap cannot be measured. If the oil ring rail’s gap is excessive, replace all three piston rings. Piston ring Top ring End gap (installed) 0.19 ~ 0.31 mm (0.007 ~ 0.012 in) Limit 0.56 mm (0.022 in) 2nd ring End gap (installed) 0.
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CYLINDER AND PISTON ENG CHECKING THE PISTON PIN 1. Check: • Piston pin Blue discoloration/grooves → Replace the piston pin and then check the lubrication system. 2. Measure: • Piston pin outside diameter Out of specification → Replace the piston pin. Piston pin outside diameter 16.991 ~ 17.000 mm (0.6689 ~ 0.6693 in) Limit 16.971 mm (0.6681 in) 3. Measure: • Piston pin bore diameter Out of specification → Replace the piston. Piston pin bore inside diameter 17.002 ~ 17.013 mm (0.6694 ~ 0.
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CYLINDER AND PISTON ENG INSTALLING THE PISTON AND CYLINDER 1. Install: • Lower oil ring rail • Oil ring expander • Upper oil ring rail • 2nd ring • Top ring NOTE: Be sure to install the piston rings so that the “T” marks or numbers face up. 2. Install: • Piston • Piston pin • Piston pin clips NOTE: • Apply engine oil the piston pin. • Make sure the dot on the piston points towards the exhaust side of the cylinder.
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CYLINDER AND PISTON ENG 5. Offset: • Piston ring end gaps Top ring Upper oil ring rail Oil ring expander Lower oil ring rail 2nd ring 20 mm 6. Install: • Cylinder NOTE: • While compressing the piston rings with one hand, install the cylinder with the other hand. • Pass the timing chain and timing chain guide (exhaust side) through the timing chain cavity. 7. Tighten: • Cylinder bolts Cylinder bolt 10 Nm (1.0 m•kg, 7.
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CLUTCH ENG CLUTCH 73 Nm (7.3 m•kg, 54 ft•lb) 20 Nm (2.0 m•kg, 15 ft•lb) 10 Nm (1.0 m•kg, 7.4 ft•lb) 10 Nm (1.0 m•kg, 7.4 ft•lb) Order 1 2 3 4 5 6 7 8 9 Job/Parts to remove Removing the clutch cover Engine oil Cotter pin/Washer Clevis pin Brake pedal/Footrest Oil delivery pipe Oil cooler hose O-ring Right crankcase cover Dowel pin Crankcase cover gasket Q’ty Remarks Remove the parts in the order listed. Drain. 1/1 1 1/1 1 2 2 1 2 1 For installation, reverse the removal procedure.
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CLUTCH ENG 8 Nm (0.8 m•kg, 5.9 ft•lb) 75 Nm (7.5 m•kg, 55 ft•lb) 80 Nm (8.0 m•kg, 59 ft•lb) Order 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Job/Parts to remove Removing the clutch Clutch spring Pressure plate Primary drive gear nut Friction plate Clutch plate Clutch boss nut Clutch boss Thrust washer Clutch housing Claw washer Primary drive gear Locknut/Washer Push rod1 Push plate Q’ty 5 1 1 6 5 1 1 1 1 1 1 1/1 1 1 4-40 Remarks Remove the parts in the order listed.
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CLUTCH ENG 8 Nm (0.8 m•kg, 5.9 ft•lb) 75 Nm (7.5 m•kg, 55 ft•lb) 80 Nm (8.0 m•kg, 59 ft•lb) Order 15 Job/Parts to remove Push rod 2/Ball Q’ty 1/1 Remarks For installation, reverse the removal procedure.
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CLUTCH Order 1 2 3 4 5 6 7 Job/Parts to remove Removing the push lever shaft Shift pedal Left crankcase cover Clutch assembly Clutch cable Bolt Push lever shaft Torsion spring Circlip Oil seal Bearing Q’ty ENG Remarks Remove the parts in the order listed. Refer to “SHIFT SHAFT”. Refer to “PICK UP COIL ROTOR AND STARTER CLUTCH”. 1 1 1 1 1 1 1 For installation, reverse the removal procedure.
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CLUTCH ENG REMOVING THE CLUTCH 1. Remove: • Bolt • Clutch spring NOTE: Loosen the bolts in stages and in a crisscross pattern. 2. Straighten the lock washer tab. 3. Loosen: • Primary drive gear nut • Clutch boss nut NOTE: • Place the aluminum plate between clutch housing and primary drive gear , and then loosen the primary drive gear nut . • While holding the clutch boss with the universal clutch holder , loosen the clutch boss nut . Universal clutch holder 90890-04086, YM-91042 4.
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CLUTCH ENG CHECKING THE FRICTION PLATES The following procedure applies to all of the friction plates. 1. Check: • Friction plate Damage/wear → Replace the friction plate. 2. Measure: • Friction plate thickness Out of specification → Replace the friction plate. NOTE: Measure the friction plate at four places. Friction plate thickness 2.9 ~ 3.1 mm (0.114 ~ 0.122 in) Wear limit 2.8 mm (0.110 in) CHECKING THE CLUTCH PLATES The following procedure applies to all of the clutch plates. 1.
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CLUTCH ENG CHECKING THE CLUTCH SPRINGS The following procedure applies to all of the clutch springs. 1. Check: • Clutch spring Damage → Replace the clutch spring. 2. Measure: • Clutch spring free length Out of specification → Replace the clutch spring. Clutch spring free length 47.80 mm (1.88 in) Minimum length 46.50 mm (1.83 in) CHECKING THE CLUTCH HOUSING 1. Check: • Clutch housing dogs Damage/pitting/wear → Deburr the clutch housing dogs or replace the clutch housing.
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CLUTCH ENG CHECKING THE CLUTCH PUSH RODS 1. Check: • Push lever shaft • Push rod 2 • Ball Cracks/damage/wear → Replace defective part(s). the CHECKING THE PRIMARY DRIVE GEAR 1. Check: • Primary drive gear Damage/wear → Replace the primary drive and primary driven gears as a set. Excessive noise during operation → Replace the primary drive and primary driven gears as a set. 2.
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CLUTCH ENG 3. Tighten: • Clutch boss nut • Primary drive gear nut Clutch boss nut 75 Nm (7.5 m•kg, 55 ft•lb) Primary drive gear nut 80 Nm (8.0 m•kg, 59 ft•lb) NOTE: • While holding the clutch boss with the universal clutch holder , tighten the clutch boss nut. • Place the aluminum plate between primary drive gear and clutch housing , and then tighten the primary drive gear nut. Universal clutch holder 90890-04086, YM-91042 4. Bend the lock washer tab along a flat side of the nut. 5.
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CLUTCH ENG 7. Install: • Bearing • Oil seal • Circlip • Torsion spring • Push lever shaft • Bolt • Clutch cable NOTE: After installing the clutch cable, bend the push lever shaft tab along a flat side of the nut. 8. Install: • Push rod 2 • Ball • Push rod 1 • Push plate • Washer • Locknut • Pressure plate • Clutch spring • Bolt 9. Tighten: • Clutch spring bolt • Locknut Clutch spring bolt 8 Nm (0.8 m•kg, 5.9 ft•lb) Locknut 8 Nm (0.8 m•kg, 5.
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ENG CLUTCH 11.Adjust: • Push lever position a. Loosen the locknut . b. Turn the adjusting screw in or out until the marks are aligned. c. Hold the adjusting screw to prevent it from moving and then tighten the locknut to specification. 8 Nm (0.8 m•kg, 5.9 ft•lb) CAUTION: Do not overtighten the locknut since this will remove the free play between both push rods. 12.Check: • Clutch cable free play Refer to “ADJUSTING THE CLUTCH CABLE FREE PLAY” in chapter 3. Clutch lever free play 5 ~ 10 mm (0.20 ~ 0.
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OIL PUMP AND BLANCER WEIGHT GEAR ENG OIL PUMP AND BLANCER WEIGHT GEAR 6 Nm (0.6 m•kg, 4.4 ft•lb) 55 Nm (5.
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OIL PUMP AND BLANCER WEIGHT GEAR ENG 6 Nm (0.6 m•kg, 4.4 ft•lb) 55 Nm (5.5 m•kg, 41 ft•lb) Order 14 15 16 Job/Parts to remove Balancer drive gear Oil strainer Spacer Q’ty 1 1 1 Remarks For installation, reverse the removal procedure.
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OIL PUMP AND BLANCER WEIGHT GEAR ENG 7 Nm (0.7 m•kg, 5.0 ft•lb) Order Job/Parts to remove Disassembling the oil pump Oil pump housing Dowel pin Outer rotor Inner rotor Dowel pin Shaft Oil pump cover Q’ty Remarks Remove the parts in the order listed. 1 2 1 1 1 1 1 For assembly, reverse the disassembly procedure.
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OIL PUMP AND BLANCER WEIGHT GEAR ENG REMOVING THE BALANCER WEIGHT GEAR AND OIL PUMP 1. Straighten the lock washer tab. 2. Remove: • Balancer weight gear nut • Lock washer • Balancer weight gear NOTE: Place the aluminum plate between balancer drive gear and balancer weight gear , and then loosen the balancer weight gear nut . 3. Remove: • Oil pump assembly CHECKING THE OIL PUMP 1. Check: • Oil pump driven gear • Oil pump housing • Oil pump cover Cracks/damage/wear → Replace the defective part(s). 2.
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OIL PUMP AND BLANCER WEIGHT GEAR ENG Inner-rotor-to-outer-rotor-tip clearance 0.150 mm (0.0059 in) Limit 0.23 mm (0.0091 in) Outer-rotor-to-oil-pump-housing clearance 0.100 ~ 0.151 mm (0.0039 ~ 0.0059 in) Limit 0.22 mm (0.0087 in) Oil-pump-housing-to-inner-andouter-rotor clearance 0.04 ~ 0.09 mm (0.0016 ~ 0.0035 in) Limit 0.16 mm (0.0063 in) 3. Check: • Oil pump operation Rough movement → Repeat steps (1) and (2) or replace the defective part(s). CHECKING THE BALANCER WEIGHT GEAR 1.
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OIL PUMP AND BLANCER WEIGHT GEAR ENG ASSENBLING THE BALANCER DRIVE GEAR 1. Assemble: • Dowel pin • Compression spring NOTE: Install the dowel pins and compression springs alternately as shown as. 2. Assemble: • Buffer boss INSTALLING THE OIL PUMP 1. Install: • Gasket • Oil pump 2. Tighten: • Oil pump bolts Oil pump bolt 6 Nm (0.6 m•kg, 4.4 ft•lb) LOCTITE® CAUTION: After tightening the bolts, make sure the oil pump turns smoothly.
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OIL PUMP AND BLANCER WEIGHT GEAR ENG INSTALLING THE BALANCER WEIGHT GEAR 1. Install: • Balancer weight gear • Lock washer • Balancer weight gear nut 2. Tighten: • Balancer weight gear nut Balancer weight gear nut 55 Nm (5.5 m•kg, 41 ft•lb) NOTE: • Align the punch mark in the balancer drive gear with the punch mark in the balancer weight gear. • Place the aluminum plate between balancer drive gear and balancer weight gear , and then tighten the balancer weight gear nut . 3.
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SHIFT SHAFT ENG SHIFT SHAFT 10 Nm (1.0 m•kg, 7.4 ft•lb) 10 Nm (1.0 m•kg, 7.4 ft•lb) Order 1 2 3 4 Job/Parts to remove Removing the shift shaft and stopper lever Right crankcase cover Clutch Shift pedal Shift shaft assembly Stopper lever Torsion spring Q’ty Remarks Remove the parts in the order listed. Refer to “CLUTCH”. 1 1 1 1 For installation, reverse the removal procedure.
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SHIFT SHAFT ENG CHECKING THE SHIFT SHAFT 1. Check: • Shift shaft • Shift lever Bends/damage/wear → Replace. • Shift lever spring Damage/wear → Replace. CHECKING THE STOPPER LEVER 1. Check: • Stopper lever Bends/damage → Replace. Roller turns roughly → Replace the stopper lever. • Torsion spring Damage/wear → Replace. INSTALLING THE SHIFT SHAFT 1. Install: • Stopper lever NOTE: • Hook the ends of the stopper lever spring onto the stopper lever and the crankcase boss.
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SHIFT SHAFT ENG 4. Check: • When the gear position is in Neutral, check the length ( , ) between the tip of the and dowel pin are equal. shift lever If not → Replace the shift shaft. 5. Install: • Shift pedal 6. Tighten: • Shift pedal bolt Shift pedal bolt 10 Nm (1.0 m•kg, 7.4 ft•lb) 7. Adjust: • Shift pedal height Refer to “ADJUSTING THE SHIFT PEDAL” in chapter 3.
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PICKUP COIL ROTOR AND STARTER CLUTCH ENG PICKUP COIL ROTOR AND STARTER CLUTCH 7 Nm (0.7 m•kg, 5.2 ft•lb) 10 Nm (1.0 m•kg, 7.4 ft•lb) 10 Nm (1.0 m•kg, 7.4 ft•lb) 30 Nm (3.0 m•kg, 22 ft•lb) 10 Nm (1.0 m•kg, 7.4 ft•lb) 60 Nm (6.0 m•kg, 44 ft•lb) Order 1 2 3 4 5 6 7 8 9 10 11 Job/Parts to remove Removing the pickup coil rotor and starter clutch Engine oil Shift pedal Drive sprocket cover Q’ty Remarks Remove the parts in the order listed.
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PICKUP COIL ROTOR AND STARTER CLUTCH ENG 7 Nm (0.7 m•kg, 5.2 ft•lb) 10 Nm (1.0 m•kg, 7.4 ft•lb) 10 Nm (1.0 m•kg, 7.4 ft•lb) 30 Nm (3.0 m•kg, 22 ft•lb) 60 Nm (6.0 m•kg, 44 ft•lb) Order 12 13 14 Job/Parts to remove Bearing Washer Starter clutch assembly Q’ty 1 1 1 10 Nm (1.0 m•kg, 7.4 ft•lb) Remarks For installation, reverse the removal procedure.
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PICKUP COIL ROTOR AND STARTER CLUTCH ENG REMOVING THE PICKUPCOIL ROTOR 1. Remove: • Pickup coil rotor bolt • Washer NOTE: • Loosen the pickup coil rotor bolt while holding the rotor with a sheave holder . • Do not allow the sheave holder to touch the projection on the rotor . Sheave holder 90890-01701 Primary clutch holder YS-01880-A 2. Remove: • Pickup coil rotor NOTE: Remove the rotor using flywheel puller Flywheel puller 90890-01362 Heavy duty puller YU-33270-B Bolt (M8 × 80 mm) 90890-01359 3.
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PICKUP COIL ROTOR AND STARTER CLUTCH ENG CHECKING THE STARTER CLUTCH 1. Check: • Starter clutch rollers Damage/wear → Replace the starter clutch. 2. Check: • Starter idle gear • Starter wheel gear • Starter clutch gear Burrs/chips/roughness/wear → Replace the defective part(s). 3. Check: • Starter clutch gear’s contacting surfaces Damage/pitting/wear → Replace the starter clutch gear. 4. Check: • Starter clutch operation a.
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PICKUP COIL ROTOR AND STARTER CLUTCH ENG INSTALLING THE PICKUP COIL ROTOR 1. Install: • Washer • Bearing • Starter wheel gear • Starter idle gear 2 2. Install: • Woodruff key • Pickup coil rotor • Washer • Pickup coil rotor bolt NOTE: • Clean the tapered portion of the crankshaft and the rotor hub. • When installing the rotor, make sure the woodruff key is properly seated in the key way of the crankshaft. 3. Tighten: • Pickup coil rotor bolt Pickup coil rotor bolt 60 Nm (6.
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PICKUP COIL ROTOR AND STARTER CLUTCH ENG 4. Install: • Stater coil • Pickup coil 5. Tighten: • Stater coil bolts • Pickup coil bolts • Left crankcase cover bolt Stater coil bolt 10 Nm (1.0 m•kg, 7.4 ft•lb) LOCTITE® Pickup coil bolt 10 Nm (1.0 m•kg, 7.4 ft•lb) LOCTITE® Left crankcase cover bolt 7 Nm (0.7 m•kg, 5.2 ft•lb) LOCTITE® 6. Install: • Dowel pin • Crankcase cover gasket 7. Install: • Left crankcase cover 8.
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ENG CRANKCASE CRANKCASE 8 Nm (0.8 m•kg, 5.9 ft•lb) 1 2 4 5 3 7 6 5 10 Nm (1.0 m•kg, 7.4 ft•lb) 20 Nm (2.0 m•kg, 15 ft•lb) Order Job/Parts to remove Separating the crankcase Engine Cylinder head Cylinder Clutch Oil pump Q’ty Balancer weight gear Shift shaft Pickup coil rotor 1 2 3 4 5 6 Timing chain guide (intake side) Timing chain Crankshaft sprocket Right crankcase Dowel pin Left crankcase Remarks Remove the parts in the order listed. Refer to “ENGINE REMOVAL”. Refer to “CYLINDER HEAD”.
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ENG CRANKCASE 8 Nm (0.8 m•kg, 5.9 ft•lb) 1 2 4 5 3 7 6 5 10 Nm (1.0 m•kg, 7.4 ft•lb) 20 Nm (2.0 m•kg, 14.8 ft•lb) Order 7 Job/Parts to remove Spacer Q’ty 1 Remarks For installation, reverse the removal procedure.
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CRANKCASE ENG 2 2 2 2 2 2 1 2 2 1 Order 1 2 Job/Parts to remove Removing the bearing Crankshaft assembly Main axle assembly/drive axle assembly Oil seal Bearing Q’ty Remarks Remove the parts in the order listed. Refer to “CRANKSHAFT ASSEMBLY”. Refer to “TRANSMISSION”. 2 8 For installation, reverse the removal procedure.
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CRANKCASE ENG DISASSEMBLING THE CRANKCASE 1. Remove: • Timing chain guide (intake side) • Timing chain • Crankshaft sprocket 2. Remove: • Neutral switch • Crankcase bolts M6 × 70 mm ~ • Copper washers • Crankcase bolts M6 × 60 mm , • Crankcase bolts M6 × 55 mm ~ • Crankcase bolts M6 × 45 mm ~ NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 3.
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CRANKCASE ENG CHECKING THE CRANKCASE 1. Thoroughly wash the crankcase halves in a mild solvent. 2. Thoroughly clean all the gasket surfaces and crankcase mating surfaces. 3. Check: • Crankcase Cracks/damage → Replace. • Oil delivery passages Obstruction → Blow out with compressed air. ASSEMBLING THE CRANKCASE 1. Apply: • Yamaha bond No.1215 (Three Bond No.1215®) (onto the crankcase mating surfaces) Yamaha bond No.1215 (Three Bond No.
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CRANKCASE ENG 4. Install: • Crankcase bolts M6 × 70 mm • Copper washers to ~ . • Crankcase bolts M6 × 60 mm • Crankcase bolts M6 × 55 mm • Crankcase bolts M6 × 45 mm 5. Tighten: • Crankcase bolts ~ ~ , ~ ~ Crankcase bolt 10 Nm (1.0 m•kg, 7.4 ft•lb) NOTE: Tighten each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. 6. Install: • Neutral switch 7. Install: • Crankshaft sprocket • Timing chain guide (intake side) • Timing chain 8.
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CRANKSHAFT ASSEMBLY ENG CRANKSHAFT ASSEMBLY 3 2 4 5 1 Order 1 2 3 4 5 Job/Parts to remove Removing the crankshaft assembly Crankcase Balancer weight Crankshaft assembly Dowel pin Plunger seal Bearing Q’ty Remarks Remove the parts in the order listed. Refer to “CRANKCASE”. 1 1 1 1 1 For installation, reverse the removal procedure.
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CRANKSHAFT ASSEMBLY ENG REMOVING THE CRANKSHAFT ASSEMBLY 1. Remove: • Balancer weight • Crankshaft assembly NOTE: • Remove the crankshaft assembly with the crankcase separating tool . • Make sure the crankcase separating tool is centered over the crankshaft assembly. Crankcase separating tool 90890-01135 Crankcase separator YU-01135-B REMOVING THE PLUNGER SEAL 1.
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CRANKSHAFT ASSEMBLY ENG 2. Measure: • Big end side clearance Out of specification → Replace the big end bearing, crankshaft pin, or connecting rod. Big end side clearance D 0.350 ~ 0.650 mm (0.0138 ~ 0.0256 in) 3. Measure: • Crankshaft width Out of specification → Replace the crankshaft. Width A 69.25 ~ 69.30 mm (2.726 ~ 2.728 in) 4. Check: • Crankshaft sprocket Damage/wear → Replace the crankshaft. • Bearing Cracks/damage/wear → Replace the crankshaft. 5.
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CRANKSHAFT ASSEMBLY ENG 3. Check: • Timing chain guide (intake side) Damage/wear → Replace the timing chain guide (intake side) INSTALLING THE PLUNGER SEAL 1. Install: • Compression spring • Plunger seal • Dowel pin Check the plunger seal smooth operation pushing the plunger seal by your finger. INSTALLING THE CRANKSHAFT ASSEMBLY 1. Install: • Crankshaft assembly NOTE: Install the crankshaft assembly with the crankshaft installer pot , crankshaft installer bolt , adapter and spacer .
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CRANKSHAFT ASSEMBLY ENG CAUTION: To avoid scratching the crankshaft and to ease the installation procedure, lubricate the oil seal lips with lithium-soap-based grease and each bearing with engine oil. NOTE: Hold the connecting rod at top dead center (TDC) with one hand while turning the nut of the crankshaft installer bolt with the other. Turn the crankshaft installer bolt until the crankshaft assembly bottoms against the bearing. 2. Install: • Balancer weight To the right crank case.
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TRANSMISSION ENG TRANSMISSION 7 3 4 5 6 1 2 Order 1 2 3 4 5 6 7 Job/Parts to remove Removing the transmission, shift drum assembly, and shift forks Crankcase Shift fork guide bar Shift drum assembly Shift fork-3 (R) Shift fork-2 (C) Shift fork-1 (L) Main axle assembly Drive axle assembly Q’ty Remarks Remove the parts in the order listed. Separate. Refer to “CRANKCASE”. 1 1 1 1 1 1 1 For installation, reverse the removal procedure.
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ENG TRANSMISSION 6 7 5 8 4 3 9 2 10 1 11 12 13 14 15 Order 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Job/Parts to remove Disassembling the transmission 2nd pinion gear 5th pinion gear 3rd pinion gear Circlip/washer 4th pinion gear Main axle Plain washer 1st wheel gear 4th wheel gear Circlip/washer 3rd wheel gear/collar Claw washer 1 Claw washer 2 5th wheel gear Circlip/washer 2nd wheel gear Q’ty 1 1 1 1/1 1 1 1 1 1 1/1 1/1 1 1 1 1/1 1 4-78 16 Remarks Remove the parts in the order listed.
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ENG TRANSMISSION 6 7 5 8 4 3 9 2 10 1 11 12 13 14 15 Order 17 Job/Parts to remove Drive axle Q’ty 1 16 Remarks For installation, reverse the removal procedure.
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TRANSMISSION ENG REMOVING THE TRANSMISSION 1. Remove: • Shift fork guide bar • Shift drum assembly • Shift fork 3 (R) • Shift fork 2 (C) • Shift fork 1 (L) 2. Remove: • Transmission CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks. 1. Check: • Shift fork movement (along the shift fork guide bar) Rough movement → Replace the shift forks and shift fork guide bar as a set.
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TRANSMISSION ENG CHECKING THE SHIFT DRUM ASSEMBLY 1. Check: • Shift drum groove Damage/scratches/wear → Replace the shift drum assembly. • Shift drum segment Damage/wear → Replace the shift drum assembly. • Shift drum bearing Damage/pitting → Replace the shift drum assembly. CHECKING THE TRANSMISSION 1. Measure: • Main axle runout (with a centering device and dial gauge) Out of specification → Replace the main axle. Main axle runout limit 0.06 mm (0.0024 in) 2.
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TRANSMISSION ENG 4. Check: • Transmission gear engagement (each pinion gear to its respective wheel gear) Incorrect → Reassemble the transmission axle assemblies. NOTE: When reassembling the main axle, press the 2nd pinion gear onto it as shown. 102.2 ~ 102.4 mm (4.02 ~ 4.03 in) 5. Check: • Transmission gear movement Rough movement → Replace the defective part(s). 6. Check: • Circlips Bends/damage/looseness → Replace. INSTALLING THE SHIFT FORKS AND SHIFT DRUM ASSEMBLY 1.
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CARBURETOR EBS00141 CARB CARBURETOR CARBURETOR 2 Nm (0.2 m•kg, 1.5 ft•lb) 1 3.5 Nm (0.4 m•kg, 2.6 ft•lb) 2 3 4 5 3.5 Nm (0.4 m•kg, 2.6 ft•lb) Order 1 2 3 4 5 6 7 8 9 Job/Part Removing a carburetor Seat/front fender/rear fender/air filter case Carburetor warmer coupler Air vent hose Fuel hose (carburetor side) Throttle cable cover Throttle cable Clamp Clamp Carburetor Carburetor joint Q’ty 1 1 1 1 1 1 2 1 1 Remarks Remove the parts in the order listed.
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CARBURETOR CARB EBS00144 Order Job/Part Disassembling the carburetor Drain hose Throttle stop screw Cover Diaphragm spring Piston valve Jet needle Cover Spring Coasting enricher diaphragm Coasting enricher jet (P. A. J. 2) Starter plunger Carburetor warmer positive lead Carburetor warmer Carburetor warmer negative lead Float chamber Float pin Q’ty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 5-2 Remarks Remove the parts in the order listed.
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CARBURETOR Order Job/Part Float Needle valve seat set Main jet Needle jet holder Needle jet Pilot jet Starter jet Q’ty 1 1 1 1 1 1 1 CARB Remarks For assembly, reverse the disassembly procedure.
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CARBURETOR CARB EBS00148 CHECKING THE CARBURETOR 1. Check: • carburetor body • float chamber Cracks/damage → Replace. • fuel passage Contamination → Clean as indicated. • fuel chamber body Contamination → Clean. a. Wash the carburetor in a petroleum based solvent. Do not use any caustic carburetor cleaning solution. b. Blow out all of the passages and jets with compressed air. 2. Check: • float • float tang Damage → Replace. 3. Check: • valve seat • needle valve Contamination → Clean.
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CARBURETOR CARB 5. Check: • piston valve movement Sticks → Replace. Insert the piston valve into the carburetor body, and check for free movement. 6. Check: • throttle valve movement Sticks → Replace. 7. Check: • cover • diaphragm spring Cracks/damage → Replace. 8. Check: • coasting enricher diaphragm • spring Cracks/damage → Replace. 9. Check: • jet needle Bends/wear/damage → Replace. • clip groove Free play/wear → Replace. 10.
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CARBURETOR CARB 11.Check: • starter plunger • starter plunger spring Bends/cracks/damage → Replace. EBS00150 ASSEMBLING THE CARBURETOR CAUTION: Before reassembling, wash all of the parts in a clean petroleum based solvent. 1. Measure: • float height Out of specification → Adjust. Float height (F.H) 13.0 mm (0.51 in) a. Hold the carburetor in an upside down position. b. Measure the distance from the front mating surface of the float chamber (gasket removed) to the top of the float.
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CARBURETOR CARB INSTALLING THE CARBURETOR JOINT 1. Install: • clamp NOTE: Align the projection on the carburetor joint with the slot in the clamp. 2. Install: • carburetor joint NOTE: Align the projection on the cylinder head with the slot in the carburetor joint. INSTALLING THE CARBURETOR 1. Install: • carburetor NOTE: Align the projection on the carburetor with the slot in the carburetor joint. 2. Install: • throttle cable • throttle cable cover 3.
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FRONT AND REAR WHEELS EBS00378 CHAS CHASSIS FRONT AND REAR WHEELS FRONT WHEELS 28 Nm (2.8 m•kg, 21 ft•lb) 70 Nm (7.0 m•kg, 52 ft•lb) 28 Nm (2.8 m•kg, 21 ft•lb) 45 Nm (4.5 m•kg, 33 ft•lb) Order Job/Part Removing the front wheels Q’ty Remarks Remove the parts in the order listed. The following procedure applies to both of the front wheels. Place the machine on a level surface. WARNING Securely support the machine so there is no danger of it falling over.
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FRONT AND REAR WHEELS CHAS 1 28 Nm (2.8 m•kg, 21 ft•lb) 70 Nm (7.0 m•kg, 52 ft•lb) 2 3 28 Nm (2.8 m•kg, 21 ft•lb) 4 45 Nm (4.5 m•kg, 33 ft•lb) Order 5 Job/Part Brake caliper assembly Q’ty Remarks 1 NOTE: Do not squeeze the brake lever when the brake caliper is off of the brake discs as the brake pads will be forced shut. 6 Wheel hub 1 7 Brake disc 1 6-2 Refer to “INSTALLING THE WHEEL HUB BEARINGS”. Rear to “INSTALLING FRONT BRAKE DISCS”. For installation, reverse the removal procedure.
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FRONT AND REAR WHEELS CHAS REAR WHEELS 120 Nm (12.0 m•kg, 89 ft•lb) 45 Nm (4.5 m•kg, 33 ft•lb) Order Job/Part Removing the rear wheels Q’ty Remarks Remove the parts in the order listed. Place the machine on a level surface. WARNING Securely support the machine so there is no danger of it falling over. 1 2 3 4 Rear wheel Cotter pin Axle nut Wheel hub 2 2 2 2 Refer to “INSTALLING THE WHEEL HUBS”. For installation, reverse the removal procedure.
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FRONT AND REAR WHEELS CHAS EBS00383 CHECKING THE WHEELS 1. Check: • wheels 2. Measure: • wheel runout Over the specified limit → Replace the wheel or check the wheel bearing play . Wheel runout limit Radial : 2.0 mm (0.08 in) Lateral : 2.0 mm (0.08 in) 3. Check: • wheel balance Out of balance → Adjust. WARNING After replacing the tire, ride conservatively to allow the tire to be properly seated in the rim. Failure to do so may cause an accident resulting in machine damage and possible operator injury.
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FRONT AND REAR WHEELS CHAS 2. Check: • wheel bearings Wheel hub play/wheel turns roughly → Replace. a. Clean wheel hub exterior. b. Drive bearing out by pushing spacer aside and tapping around perimeter of bearing inner race. Use soft metal drift punch and “floats” between hammer. The spacer bearings. Remove both bearings as described. WARNING Eye protection is recommended when using striking tools. c. To install the wheel bearings, reverse the above sequence.
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FRONT AND REAR WHEELS CHAS INSTALLING THE FRONT WHEEL HUB BEARINGS 1. Install: • bearings NOTE: Face the oil seal side of the bearing inward. INSTALLING THE FRONT BRAKE DISCS 1. Install: • brake discs NOTE: Install the brake disc with its spot-faced side facing the bolt heads. EBS00392 INSTALLING THE FRONT WHEELS 1. Install: • brake disc guards (outer) NOTE: Install the brake disc guard (outer) with punched burrs on the wheel hub side. 2.
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FRONT AND REAR WHEELS CHAS EBS00390 INSTALLING THE WHEEL HUBS 1. Install: • front axle nuts Front axle nut 70 Nm (7.0 m•kg, 52 ft•lb) • rear axle nuts Rear axle nut 120 Nm (12.0 m•kg, 89 ft•lb) • cotter pins NOTE: • Do not loosen the axle nut after torquing it. If the axle nut groove is not aligned with the cotter pin hole, align the groove with the hole by tightening the axle nut. • Bend the longer cotter pin up.
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REAR AXLE AND REAR AXLE HUB CHAS EBS00382 REAR AXLE AND REAR AXLE HUB 34 Nm (3.4 m•kg, 25 ft•lb) 7 Nm (0.7 m•kg, 5.2 ft•lb) 28 Nm (2.8 m•kg, 21 ft•lb) 55 Nm (5.5 m•kg, 41 ft•lb) 140 Nm (14.0 m•kg, 103 ft•lb) Order 1 2 3 4 Job/Part Q’ty Remarks Removing the rear axle and rear axle Remove the parts in the order listed. hub Rear wheels/rear wheel hubs Refer to “FRONT AND REAR WHEELS”. Bolt 2 Refer to “REMOVING THE REAR Nut 1 AXLE” and “INSTALLING THE REAR AXLE”.
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REAR AXLE AND REAR AXLE HUB CHAS 34 Nm (3.4 m•kg, 25 ft•lb) 7 Nm (0.7 m•kg, 5.2 ft•lb) 28 Nm (2.8 m•kg, 21 ft•lb) 55 Nm (5.5 m•kg, 41 ft•lb) 140 Nm (14.0 m•kg, 103 ft•lb) Order 5 6 7 8 9 10 11 12 13 14 Job/Part Brake disc/brake disc bracket Rear axle Driven sprocket/sprocket bracket Circlip Brake caliper bracket Collar Rear axle hub Bearing/oil seal Spacer Dust cover Q’ty Remarks 1/1 1 Refer to “REMOVING THE REAR AXLE”. 1/1 Refer to “INSTALLING THE DRIVEN SPROCKET”.
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REAR AXLE AND REAR AXLE HUB CHAS EBS00393 REMOVING THE REAR AXLE 1. Place the machine on a level surface. 2. Loosen: • bolts 3. Remove: • nut NOTE: • Apply the brake pedal so that the rear axle does not turn, when loosening the nut. • Use the PTT wrench 46 or axle nut wrench (46 mm) . PTT wrench 46 90890-06588 Axle nut wrench (46 mm) YM-37134 4. Elevate the rear wheels by placing the suitable stand under the frame. 5. Remove: • rear wheels • wheel hubs • nuts • washers 6.
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REAR AXLE AND REAR AXLE HUB CHAS EBS00395 CHECKING THE REAR AXLE 1. Check: • rear axle runout Out of specification → Replace. WARNING Do not attempt to straighten a bent axle. Rear axle runout limit 1.5 mm (0.06 in) CHECKING THE DRIVEN SPROCKET 1. Check: • driven sprocket Refer to “REAR SHOCK ABSORBER, SWINGARM AND DRIVE CHAIN”. CHECKING THE BRAKE DISC 1. Check: • brake disc Refer to “FRONT AND REAR WHEELS”. INSTALLING THE DRIVEN SPROCKET 1.
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REAR AXLE AND REAR AXLE HUB CHAS 2. Tighten: • nut a. Tighten the nut with PTT wrench 46 or rear axle nut wrench to specification while holding the rear axle. 140 Nm (14.0 m•kg, 103 ft•lb) PTT wrench 46 90890-06588 Axle nut wrench (46 mm) YM-37134 b. Tighten bolts . 7 Nm (0.7 m•kg, 5.
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FRONT AND REAR BRAKES CHAS EBS00400 FRONT AND REAR BRAKES FRONT BRAKE PADS 2.5 Nm (0.25 m•kg, 1.8 ft•lb) 17 Nm (1.7 m•kg, 13 ft•lb) 28 Nm (2.8 m•kg, 21 ft•lb) Order 1 2 3 4 Job/Part Removing the front brake pads Front wheel Bolt Brake pad retaining bolt Brake pad Brake pad spring Q’ty 1 1 2 1 Remarks Remove the parts in the order listed. The following procedure applies to both of the front brake calipers. Refer to “FRONT AND REAR WHEELS”. Refer to “REPLACING THE FRONT BRAKE PADS”.
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FRONT AND REAR BRAKES CHAS EBS00401 REAR BRAKE PADS 17 Nm (1.7 m•kg, 13 ft•lb) 34 Nm (3.4 m•kg, 25 ft•lb) Order 1 2 3 4 Job/Part Removing the rear brake pads Brake pad retaining bolt Lock washer Brake pad Brake pad spring Q’ty 2 1 2 1 Remarks Remove the parts in the order listed. Refer to “REPLACING THE REAR BRAKE PADS”. For installation, reverse the removal procedure.
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FRONT AND REAR BRAKES CHAS EBS00402 CAUTION: Disc brake components rarely require disassembly.
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CHAS FRONT AND REAR BRAKES 2. Install: • brake pads • brake pad spring NOTE: Always install new brake pads and brake pad spring as a set. a. Connect a suitable hose tightly to the brake caliper bleed screw . Put the other end of this hose into an open container. b. Loosen the brake caliper bleed screw and, using a finger, push the caliper piston into the brake caliper. c. Tighten the brake caliper bleed screw. 5 Nm (0.5 m•kg, 3.7 ft•lb) d. Install new brake pads and a new brake pad spring. 3.
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FRONT AND REAR BRAKES CHAS EBS00405 REPLACING THE REAR BRAKE PADS NOTE: It is not necessary to disassemble the brake caliper and brake hose to replace the brake pads. 1. Remove: • brake pads wear limit NOTE: Replace the brake pads as a set if either is found to be worn to the wear limit. 2. Install: • brake pads • brake pad spring NOTE: Always install new brake pads and brake pad spring as a set. a. Connect a suitable hose tightly to the brake caliper bleed screw .
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FRONT AND REAR BRAKES CHAS 5. Check: • brake lever or brake pedal operation Soft or spongy feeling → Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3.
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FRONT AND REAR BRAKES CHAS EBS00407 FRONT BRAKE MASTER CYLINDER 7 Nm (0.7 m•kg, 5.2 ft•lb) 6 Nm (0.6 m•kg, 4.4 ft•lb) 27 Nm (2.
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FRONT AND REAR BRAKES CHAS EBS00409 Order Job/Part Disassembling the front brake master cylinder Dust boot Circlip Brake master cylinder kit Q’ty 1 1 1 Remarks Remove the parts in the order listed. Refer to “ASSEMBLING THE FRONT BRAKE MASTER CYLINDER”. For assembly, reverse the disassembly procedure.
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FRONT AND REAR BRAKES CHAS EBS00410 REAR BRAKE MASTER CYLINDER 7 Nm (0.7 m•kg, 5.2 ft•lb) 31 Nm (3.1 m•kg, 23 ft•lb) 20 Nm (2.0 m•kg, 15 ft•lb) 73 Nm (7.3 m•kg, 54 ft•lb) Order Job/Part Removing the rear brake master cylinder Right foot protector Q’ty Refer to “SEAT, FENDERS AND FUEL TANK” in chapter 3. Drain. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. Brake fluid 1 2 3 4 5 6 Remarks Remove the parts in the order listed.
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FRONT AND REAR BRAKES CHAS 7 Nm (0.7 m•kg, 5.2 ft•lb) 31 Nm (3.1 m•kg, 23 ft•lb) 20 Nm (2.0 m•kg, 15 ft•lb) 73 Nm (7.3 m•kg, 54 ft•lb) Order 7 8 9 10 11 12 13 Job/Part Union bolt Copper washer Brake hose Brake master cylinder Rear brake light switch Right footrest Brake pedal/spring Q’ty Remarks 1 Refer to “INSTALLING 2 THE REAR BRAKE 1 Disconnect. MASTER CYLINDER”. 1 1 1 1/1 For installation, reverse the removal procedure.
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FRONT AND REAR BRAKES CHAS EBS00411 17 Nm (1.7 m•kg, 13 ft•lb) Order Job/Part Disassembling the rear brake master cylinder Hose joint Brake master cylinder kit Brake master cylinder Q’ty 1 1 1 6-23 Remarks Remove the parts in the order listed. Refer to “ASSEMBLING THE REAR BRAKE MASTER CYLINDER”. For assembly, reverse the disassembly procedure.
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FRONT AND REAR BRAKES CHAS EBS00413 CHECKING THE MASTER CYLINDERS 1. Check: • brake master cylinder Wear/scratches → Replace the brake master cylinder assembly. • brake master cylinder body Cracks/damage → Replace. • brake fluid delivery passage (brake master cylinder body) Blockage → Blow out with compressed air. Front Rear 2. Check: • brake master cylinder kit Scratches/wear/damage → Replace as a set. Front Rear 3.
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FRONT AND REAR BRAKES CHAS EBS00415 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER WARNING • All internal brake components should be cleaned and lubricated with new brake fluid only before installation. Recommended brake fluid DOT 4 • Whenever a master cylinder is disassembled, replace the piston seals and dust seals. EBS00416 ASSEMBLING THE REAR BRAKE MASTER CYLINDER WARNING • All internal brake components should be cleaned and lubricated with new brake fluid only before installation.
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FRONT AND REAR BRAKES CHAS 2. Tighten: • nut Nut 17 Nm (1.7 m•kg, 13 ft•lb) EBS00418 INSTALLING THE FRONT BRAKE MASTER CYLINDER 1. Install: • brake master cylinder Brake master cylinder holder bolt 7 Nm (0.7 m•kg, 5.1 ft•lb) NOTE: • The “UP” mark on the brake master cylinder bracket should face up. • Install the brake master cylinder so that the gaps between the brake master cylinder and the brake master cylinder bracket are equal. 2.
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FRONT AND REAR BRAKES CHAS 3. Fill: • brake fluid reservoir Recommended brake fluid DOT 4 CAUTION: Brake fluid may damage painted surfaces or plastic parts. Always clean up spilled brake fluid immediately. WARNING • Use only the designated quality brake fluid: other brake fluids may deteriorate the rubber seals, causing leakage and poor brake performance. • Refill with the same type of brake fluid: mixing brake fluids may result in a harmful reaction and lead to poor brake performance.
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FRONT AND REAR BRAKES CHAS EBS00419 INSTALLING THE REAR BRAKE MASTER CYLINDER 1. Install: • copper washers • brake hose • union bolt Union bolt 31 Nm (3.1 m•kg, 23 ft•lb) CAUTION: When installing the brake hose onto the brake master cylinder, make sure the brake pipe touches the projection as shown. WARNING Proper brake hose routing is essential to insure safe machine operation. Refer to “CABLE ROUTING” in chapter 2. 2.
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FRONT AND REAR BRAKES CHAS WARNING • Use only the designated quality brake fluid: other brake fluids may deteriorate the rubber seals, causing leakage and poor brake performance. • Refill with the same type of brake fluid: mixing brake fluids may result in a harmful chemical reaction and lead to poor brake performance. • Be careful that water does not enter the brake master cylinder when refilling. Water will significantly lower the boiling point of the brake fluid and may result in vapor lock. 4.
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FRONT AND REAR BRAKES CHAS EBS00421 FRONT BRAKE CALIPERS 17 Nm (1.7 m•kg, 13 ft•lb) 2.5 Nm (0.25 m•kg, 1.8 ft•lb) 28 Nm (2.8 m•kg, 21 ft•lb) 27 Nm (2.7 m•kg, 20 ft•lb) Order Job/Part Removing the front brake calipers Q’ty Brake fluid 1 2 3 4 5 6 Front wheel Union bolt Copper washer Brake hose Bolt Brake pad retaining bolt Brake caliper assembly 1 2 1 1 2 1 Remarks Remove the parts in the order listed. The following procedure applies to both of the front brake calipers. Drain.
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FRONT AND REAR BRAKES CHAS EBS00423 5 Nm (0.5 m•kg, 3.7 ft•lb) 17 Nm (1.7 m•kg, 13 ft•lb) 2.5 Nm (0.25 m•kg, 1.8 ft•lb) Order Job/Part Disassembling the front brake calipers Q’ty Remarks Remove the parts in the order listed. The following procedure applies to both of the front brake calipers.
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FRONT AND REAR BRAKES CHAS EBS00424 REAR BRAKE CALIPER 31 Nm (3.1 m•kg, 23 ft•lb) 34 Nm (3.4 m•kg, 25 ft•lb) Order Job/Part Removing the rear brake caliper Brake fluid Q’ty 1 Parking brake cable 1 2 3 4 5 Union bolt Copper washer Brake hose Brake caliper assembly 1 2 1 1 Remarks Remove the parts in the order listed. Drain. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. Disconnect. Refer to “REMOVING THE PARKING BRAKE CABLE”. Disconnect.
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FRONT AND REAR BRAKES CHAS EBS00425 17 Nm (1.7 m•kg, 13 ft•lb) 5 Nm (0.5 m•kg, 3.7 ft•lb) 17 Nm (1.7 m•kg, 13 ft•lb) 15 Nm (1.5 m•kg, 11 ft•lb) Order Job/Part Q’ty Remarks Disassembling the rear brake caliper Remove the parts in the order listed.
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FRONT AND REAR BRAKES CHAS REMOVING THE PARKING BRAKE CABLE 1. Loosen: • nut • adjusting bolt 2. Disconnect: • parking brake cable (from parking brake lever) 3. Disconnect: • parking brake cable (from rear brake) EBS00427 DISASSEMBLING THE FRONT AND REAR BRAKE CALIPERS 1. Remove: • brake caliper piston • caliper dust seal • caliper piston seal Front Rear a. Blow compressed air into the hose joint opening to force out the caliper piston from the brake caliper body.
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FRONT AND REAR BRAKES CHAS EBS00429 CHECKING THE FRONT AND REAR BRAKE CALIPERS Recommended brake component replacement schedule Brake pads As required Piston seals, dust Every two years seals Brake hoses Every four years Replace when Brake fluid brakes are disassembled. WARNING All internal brake components should be cleaned in new brake fluid only. Do not use solvents as they will cause seals to swell and distort. 1.
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FRONT AND REAR BRAKES CHAS EBS00431 ASSEMBLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the front brake calipers. WARNING • All internal brake components should be cleaned and lubricated with new brake fluid only before installation. Recommended brake fluid DOT 4 • Replace the caliper piston seal whenever a brake caliper is disassembled. 1. Install: • caliper piston seal • caliper dust seal 2.
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FRONT AND REAR BRAKES CHAS 2. Install: • brake caliper piston 3. Install: • lock washer • brake pad retaining bolts Brake pad retaining bolt 17 Nm (1.7 m•kg, 13 ft•lb) 4. Bend the lock washer tabs along a flat side of the bolts. 5. Install: • parking brake arm 6. Measure: • parking brake arm to parking brake bracket distance Out of specification → Adjust. Parking brake arm to parking brake bracket distance 73.3 mm (2.
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FRONT AND REAR BRAKES CHAS EBS00434 INSTALLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the front brake calipers. 1. Install: • brake caliper assembly • brake caliper mounting bolts Brake caliper mounting bolt 28 Nm (2.8 m•kg, 21 ft•lb) • brake hose • copper washers • union bolt Union bolt 27 Nm (2.7 m•kg, 20 ft•lb) CAUTION: When installing the brake hose on the brake caliper, make sure that the brake pipe touches the projection on the brake caliper.
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FRONT AND REAR BRAKES CHAS WARNING • Use only the designated quality brake fluid: other brake fluids may deteriorate the rubber seals, causing leakage and poor brake performance. • Refill with the same type of brake fluid: mixing brake fluids may result in a harmful chemical reaction and lead to poor brake performance. • Be careful that water does not enter the master cylinder when refilling. Water will significantly lower the boiling point of the brake fluid and may result in vapor lock. 3.
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FRONT AND REAR BRAKES CHAS EBS00436 INSTALLING THE REAR BRAKE CALIPER 1. Install: • brake caliper assembly • brake caliper mounting bolts Brake caliper mounting bolt 34 Nm (3.4 m•kg, 25 ft•lb) • brake hose • copper washers • union bolt Union bolt 31 Nm (3.1 m•kg, 23 ft•lb) CAUTION: When installing the brake hose on the brake caliper, make sure that the brake pipe touches the projection on the brake caliper. WARNING Proper brake hose routing is essential to insure safe machine operation.
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FRONT AND REAR BRAKES CHAS WARNING • Use only the designated quality brake fluid: other brake fluids may deteriorate the rubber seals, causing leakage and poor brake performance. • Refill with the same type of brake fluid: mixing brake fluids may result in a harmful chemical reaction and lead to poor brake performance. • Be careful that water does not enter the master cylinder when refilling. Water will significantly lower the boiling point of the brake fluid and may result in vapor lock. 3.
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STEERING SYSTEM CHAS EBS00444 STEERING SYSTEM HANDLEBAR 7 Nm (0.7 m•kg, 5.2 ft•lb) 20 Nm (2.0 m•kg, 15 ft•lb) 4 Nm (0.4 m•kg, 3.0 ft•lb) 4 Nm (0.4 m•kg, 3.0 ft•lb) 7 Nm (0.7 m•kg, 5.2 ft•lb) Order 1 2 3 4 5 6 7 Job/Part Removing the handlebar Handlebar protecter Band Front brake light switch Brake master cylinder/bracket Throttle lever assembly/bracket Spacer Clutch switch 8 9 10 Parking brake lever Clutch lever/bracket Handlebar switch Q’ty Remarks Remove the parts in the order listed.
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STEERING SYSTEM CHAS 7 Nm (0.7 m•kg, 5.2 ft•lb) 20 Nm (2.0 m•kg, 15 ft•lb) 4 Nm (0.4 m•kg, 3.0 ft•lb) 4 Nm (0.4 m•kg, 3.0 ft•lb) 7 Nm (0.7 m•kg, 5.2 ft•lb) Order Job/Part 11 Handlebar grip 12 13 Handlebar holder Handlebar Q’ty Remarks 2 Refer to “REMOVING THE HANDLEBAR GRIPS” and “INSTALLING THE HANDLEBAR GRIPS”. 2 Refer to “INSTALLING THE 1 HANDLEBAR”. For installation, reverse the removal procedure.
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STEERING SYSTEM CHAS EBS00446 REMOVING THE CLUTCH SWITCH 1. Remove: • clutch switch NOTE: Push the fastener when removing the clutch switch out of the clutch lever holder. EBS00447 REMOVING THE HANDLEBAR GRIPS 1. Remove: • handlebar grips NOTE: Blow compressed air between the handlebar and handlebar grip, and gradually push the grip off the handlebar. EBS00448 CHECKING THE HANDLEBAR 1. Check: • handlebar Bends/cracks/damage → Replace.
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STEERING SYSTEM CHAS EBS00449 INSTALLING THE HANDLEBAR 1. Install: • handlebar • handlebar holders Handleber holder 20 Nm (2.0 m•kg, 15 ft•lb) NOTE: • Install the handlebar horizontally shown in the illustration. • The upper handlebar holder should be forward installed with the punched mark . CAUTION: First tighten the bolt on the front side of the handlebar holder, and then tighten the bolt on the rear side. EBS00450 INSTALLING THE HANDLEBAR GRIPS 1.
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STEERING SYSTEM CHAS EBS00452 INSTALLING THE CLUTCH LEVER 1. Install: • handlebar switch • clutch lever • clutch lever bracket NOTE: • Install the clutch lever bracket as shown. • Install the clutch lever at 10 degrees angle as shown. 53 ~ 54 mm (2.09 ~ 2.13 in) EBS00453 INSTALLING THE BRAKE MASTER CYLINDER 1. Install: • throttle lever assembly • spacer • brake master cylinder Brake master cylinder bracket 7 Nm (0.7 m•kg, 5.
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STEERING SYSTEM CHAS EBS00454 STEERING STEM 23 Nm (2.3 m•kg, 17 ft•lb) 25 Nm (2.5 m•kg, 18 ft•lb) 35 Nm (3.5 m•kg, 26 ft•lb) Order Job/Part Removing the steering stem Front fender Q’ty 1 Lock washer 1 2 3 4 5 6 7 Bracket Steering stem bushing Spacer Oil seal Steering stem Bushing 1 2 2 2 1 2 6-47 Remarks Remove the parts in the order listed. Refer to “SEAT, FENDERS AND FUEL TANK” in chapter 3. Refer to “INSTALLING THE LOCK WASHER”.
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STEERING SYSTEM CHAS EBS00456 CHECKING THE STEERING STEM 1. Check: • steering stem Bends/damage → Replace. WARNING Do not attempt to straighten a bent stem; this may dangerously weaken the stem. 2. Check: • oil seals • steering stem bushings Wear/damage → Replace. 3. Check • O-rings • bushings Wear/damage → Replace. INSTALLING THE STEERING STEM 1. Install: • steering stem NOTE: Pass the throttle cable through the cable guide. Refer to “CABLE ROUTING” in chapter 2.
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STEERING SYSTEM CHAS EBS00460 TIE-RODS AND STEERING KNUCKLES 31 Nm (3.1 m•kg, 23 ft•lb) 45 Nm (4.5 m•kg, 33 ft•lb) 25 Nm (2.5 m•kg, 18 ft•lb) 45 Nm (4.5 m•kg, 33 ft•lb) 25 Nm (2.5 m•kg, 18 ft•lb) 48 Nm (4.8 m•kg, 35 ft•lb) 25 Nm (2.
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STEERING SYSTEM CHAS EBS00461 REMOVING THE STEERING KNUCKLES 1. Remove: • steering knuckles NOTE: Use a general puller to separate the ball joint and steering knuckle. EBS00462 CHECKING THE TIE-RODS 1. Check: • tie-rod free play and movement Free play → Replace the tie-rod end. Turns roughly → Replace the tie-rod end. 2. Check: • tie-rods Bends/damage → Replace. EBS00464 CHECKING THE STEERING KNUCKLES 1. Check: • steering knuckles Damage/pitting → Replace. EBS00465 INSTALLING THE TIE-RODS 1.
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FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES CHAS EBS00468 FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES 45 Nm (4.5 m•kg, 33 ft•lb) 31 Nm (3.1 m•kg, 23 ft•lb) 48 Nm (4.8 m•kg, 35 ft•lb) 45 Nm (4.5 m•kg, 33 ft•lb) 48 Nm (4.8 m•kg, 35 ft•lb) 25 Nm (2.
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FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES CHAS 45 Nm (4.5 m•kg, 33 ft•lb) 31 Nm (3.1 m•kg, 23 ft•lb) 48 Nm (4.8 m•kg, 35 ft•lb) 45 Nm (4.5 m•kg, 33 ft•lb) 48 Nm (4.8 m•kg, 35 ft•lb) 25 Nm (2.5 m•kg, 18 ft•lb) Order 8 9 10 11 Job/Part Dust cover Spacer Spacer Bushing Q’ty 6 1 2 6 25 Nm (2.5 m•kg, 18 ft•lb) Remarks For installation, reverse the removal procedure.
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FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES CHAS EBS00469 REMOVING THE FRONT ARMS 1. Check: • front arm free play a. Check the front arm side play by moving it from side to side. If side play is noticeable, check the bushings. b. Check the front arm vertical movement by moving it up and down. If the vertical movement is tight or rough, or if there is binding, check the bushings. 2. Remove: • front arm EBS00470 CHECKING THE FRONT ARMS 1. Check: • front arms Bends/damage → Replace. 2.
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FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES CHAS EBS00472 CHECKING THE BALL JOINTS The following procedure applies to both of the front arm ball joints. 1. Check: • ball joint Damage/pitting → Replace the front arm. Free play → Replace the front arm. Turns roughly → Replace the front arm. EBS00473 INSTALLING THE FRONT ARMS The following procedure applies to both of the front arms. 1. Install: • upper front arm • lower front arm Front arm (upper, lower) 45 Nm (4.
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REAR SHOCK ABSORBER, SWINGARM AND DRIVE CHAIN CHAS REAR SHOCK ABSORBER, SWINGARM AND DRIVE CHAIN 55 Nm (5.5 m•kg, 41 ft•lb) 23 Nm (2.3 m•kg, 17 ft•lb) 100 Nm (10.0 m•kg, 74 ft•lb) 110 Nm (11.0 m•kg, 81 ft•lb) 55 Nm (5.5 m•kg, 41 ft•lb) Order Job/Part Removing the rear shock absorber, swingarm and drive chain Seat/rear fender/air filter case Q’ty Refer to “SEAT, FENDERS AND FUEL TANK” in chapter 3. Refer to “REAR AXLE AND REAR AXLE HUB”.
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REAR SHOCK ABSORBER, SWINGARM AND DRIVE CHAIN CHAS 55 Nm (5.5 m•kg, 41 ft•lb) 23 Nm (2.3 m•kg, 17 ft•lb) 100 Nm (10.0 m•kg, 74 ft•lb) 110 Nm (11.0 m•kg, 81 ft•lb) 55 Nm (5.5 m•kg, 41 ft•lb) Order 9 10 11 12 13 14 15 16 17 Job/Part Drive chain guide 2 Drive chain guide 3 Nut Lock washer Drive sprocket Drive chain Dust cover/oil seal Spacer Bearing Q’ty 1 1 1 1 1 1 2/2 1 2 6-56 Remarks Refer to “INSTALLING THE DRIVE SPROCKET”. Refer to “INSTALLING THE SWINGARM”.
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REAR SHOCK ABSORBER, SWINGARM AND DRIVE CHAIN CHAS HANDLING THE REAR SHOCK ABSORBER WARNING This rear shock absorber contains highly compressed nitrogen gas. Before handling the rear shock absorber read and make sure you understand the following information. The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling of the rear shock absorber. • Do not tamper or attempt to open the rear shock absorber.
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REAR SHOCK ABSORBER, SWINGARM AND DRIVE CHAIN CHAS EBS00487 REMOVING THE REAR SHOCK ABSORBER 1. Remove: • rear shock absorber lower bolt • rear shock absorber upper bolt NOTE: While removing the rear shock absorber lower bolt, hold the swingarm so that it does not drop down. EBS00488 CHECKING THE REAR SHOCK ABSORBER 1. Check: • shock absorber Gas leaks/oil leaks → Replace the rear shock absorber assembly. • shock absorber rod Bends/damage → Replace the rear shock absorber assembly.
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REAR SHOCK ABSORBER, SWINGARM AND DRIVE CHAIN CHAS Swingarm free play limit (at the end of the swingarm) 1.0 mm (0.04 in) b. Check the swingarm side play by moving it from side to side. If side play is noticeable, check the spacer, bearings and frame pivot. c. Check the swingarm vertical movement by moving it up and down. If vertical movement is tight or rough, or if there is binding, check the spacer, bearings and frame pivot. 2.
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REAR SHOCK ABSORBER, SWINGARM AND DRIVE CHAIN CHAS 4. Check: • oil seals Damage/wear → Replace. • bearings Damage/pitting → Replace. EBS00496 CHECKING THE DRIVE CHAIN 1. Measure: • 15-link section of the drive chain Out of specification → Replace the drive chain. 15-link drive chain section limit (maximum) 239.3 mm (9.42 in) NOTE: • While measuring the 15-link section, push down on the drive chain to increase its tension. • Measure the length between drive chain roller and as shown.
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REAR SHOCK ABSORBER, SWINGARM AND DRIVE CHAIN CHAS 3. Clean: • drive chain a. Wipe the drive chain with a clean cloth. b. Put the drive chain in kerosene and remove any remaining dirt. c. Remove the drive chain from the kerosene and completely dry it. CAUTION: This machine has a drive chain with small rubber O-rings between the drive chain side plates. Never use high-pressure water or air, steam, gasoline, certain solvents (e.g., benzine), or a coarse brush to clean the drive chain.
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REAR SHOCK ABSORBER, SWINGARM AND DRIVE CHAIN CHAS 6. Check: • drive sprocket • driven sprocket More than 1/4 tooth wear → Replace the drive chain sprockets as a set. Bent teeth → Replace the drive chain sprockets as a set. Correct Drive chain roller Drive chain sprocket EBS00497 INSTALLING THE SWINGARM 1. Install: • bearings • spacer NOTE: • Inject the bearing with the character stamp turned outward. Apply the lithium-soap-based grease to inside.
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ELECTRICAL COMPONENTS EBS00500 ELEC ELECTRICAL ELECTRICAL COMPONENTS Main switch Front brake light switch Clutch switch Handlebar switch CDI unit Starter relay Fuse Battery Tail/brake light Headlight relay Starting circuit cut-off relay Thermo switch Carburetor warmer Starter motor 7-1 Pickup coil/stator assembly Neutral switch Rear brake light switch Ignition coil Spark plug Headlight Rectifier/regulator Neutral indicator light
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CHECKING SWITCH CONTINUITY ELEC EBS01028 CHECKING SWITCH CONTINUITY Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. CAUTION: Never insert the tester probes into the coupler terminal slots . Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.
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CHECKING THE SWITCHES ELEC EBS01029 CHECKING THE SWITCHES Check each switch for damage or wear, proper connections, and also for continuity between the terminals. Refer to “CHECKING SWITCH CONTINUITY”. Damage/wear → Repair or replace. Improperly connected → Properly connect. Incorrect continuity reading → Replace the switch.
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CHECKING THE SWITCHES Light switch Engine stop switch Start switch Main switch Front brake light switch Clutch switch Fuse Neutral switch Rear brake light switch 7-4 ELEC
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CHECKING THE BULBS AND BULB SOCKETS ELEC EBS01030 CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage or wear, proper connections, and also for continuity between the terminals. Damage/wear → Repair or replace the bulb, bulb socket or both. Improperly connected → Properly connect. No continuity → Repair or replace the bulb, bulb socket or both. TYPES OF BULBS The bulbs used on this machine are shown in the illustration on the left.
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CHECKING THE BULBS AND BULB SOCKETS ELEC WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. CAUTION: • Be sure to hold the socket firmly when removing the bulb. Never pull the lead, otherwise it may be pulled out of the terminal in the coupler.
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CHECKING THE BULBS AND BULB SOCKETS ELEC CHECKING THE CONDITION OF THE BULB SOCKETS The following procedure applies to all of the bulb sockets. 1. Check: • bulb socket (for continuity) (with the pocket tester) No continuity → Replace Pocket tester 90890-03112 Analog pocket tester YU-03112-C NOTE: Check each bulb socket for continuity in the same manner as described in the bulb section; however, note the following. a. Install a good bulb into the bulb socket. b.
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7-8 B G Y B G Y Y B R/B L Br R/W L R/B L/B Br W W W W R W W W W/L W/R L Y G B Y Y G B B G Y L Y B G Y OFF ON ON OFF Br Y G B R R/B W G Y B OFF PUSH R Br B W L/B B Br R R W W W W B R R B B R R B R R B Y L Y R Br L/B Y/B R R Y/B L/B Y Br Br Y B/Y Y/B Sb R/B Y Br R/B Sb Y/B B/Y R/B W/L W/R Br Sb B W W W Sb Sb Br B/Y B B B O B A # B B B W W B R/B W W/R W/L O Sb Br B BY O BY A # BY BY BY Br B/Y B WIRE HARNESS SUB-WIRE HARNE
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IGNITION SYSTEM ELEC EBS01044 EBS01045 TROUBLESHOOTING 2. Battery • Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. The ignition system fails to operate (no spark or intermittent spark). Check: 1. fuse 2. battery 3. spark plug 4. ignition spark gap 5. ignition coil resistance 6. main switch 7. engine stop switch 8. pickup coil resistance 9. wiring connections (of the entire ignition system) Minimum open-circuit voltage 12.
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IGNITION SYSTEM EBS01034 ELEC EAS00745 4. Ignition spark gap 5. Spark plug cap resistance The following procedure applies to all of the spark plugs. • Disconnect the spark plug cap from the spark plug. • Connect the ignition checker and spark plug cap as shown. • Set the main switch to “ON”. • Measure the ignition spark gap . • Crank the engine by pushing the starter switch and gradually increase the spark gap until a misfire occurs. The following procedure applies to all of the spark plug caps.
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ELEC IGNITION SYSTEM EBS01038 EBS01041 6. Ignition coil resistance 7. Main switch • Disconnect the ignition coil coupler from the ignition coil. • Connect the pocket tester (Ω × 1) to the ignition coil as shown. • Check the main switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the main switch OK? NO YES Positive tester probe → orange lead terminal Negative tester probe → ignition coil base Replace the main switch. EBS01042 8.
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IGNITION SYSTEM EBS01047 10. Wiring • Check the entire ignition system’s wiring. Refer to “CIRCUIT DIAGRAM”. • Is the ignition system’s wiring properly connected and without defects? YES Replace unit. the CDI NO Properly connect or repair the ignition system’s wiring.
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7-13 G Y B Y ࡯ B G Y B R/B L Br R/W L R/B L/B Br W W W W R W W W W/L W/R L Y G B Y Y G B B G Y L Y B G Y OFF ON OFF ON Br R/B Y G B R ࡯ W G Y B OFF PUSH R Br B W L/B B Br R R W W W W B R R B B R R B R R B Y L Y R Br L/B Y/B R R Y/B L/B Y Br Br Y B/Y Y/B Sb R/B Y Br R/B Sb Y/B B/Y R/B W/L W/R Br Sb B W W W Sb Sb Br B/Y B B B O B A B B B W W B R/B W W/R W/L O Sb Br B BY O BY BY A BY BY Br B/Y B WIRE HARNESS SUB-WIRE HARNES
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ELECTRIC STARTING SYSTEM ELEC EBS00508 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION The starting circuit on this model consists of the starter motor, starter relay, clutch switch, and neutral switch. If the main switch is on and the engine stop switch is in the RUN position, the starter motor can be operated only if: M The transmission is in neutral (the neutral switch is closed) or You pull in the clutch lever (the clutch switch is closed).
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ELECTRIC STARTING SYSTEM ELEC EBS01044 EBS01050 TROUBLESHOOTING 2. Battery • Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. The starter motor fails to turn. Check: 1. fuse 2. battery 3. starter motor 4. starting circuit cut-off relay 5. starting circuit cut-off relay (diode) 6. starter relay 7. main switch 8. engine stop switch 9. neutral switch 10.clutch switch 11.start switch 12.
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ELECTRIC STARTING SYSTEM EBS01052 ELEC EBS01053 4. Starting circuit cut-off relay 5. Starting circuit cut-off relay (diode) • Remove the starting circuit cut-off relay from the wire harness. • Connect the pocket tester (Ω × 1) and battery (12 V) to the starting circuit cut-off relay as shown. • Remove the starting circuit cut-off relay from the wire harness. • Connect the pocket tester (Ω × 1) to the starting circuit cut-off relay as shown.
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ELECTRIC STARTING SYSTEM EBS01054 ELEC EBS01042 6. Starter relay 8. Engine stop switch • Disconnect the starter relay coupler from the wire harness. • Connect the pocket tester (Ω × 1) and battery (12 V) to the starter relay as shown. • Check the engine stop switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the engine stop switch OK? YES Positive battery terminal → blue/black Negative battery terminal → yellow/black NO Replace the handlebar switch.
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ELECTRIC STARTING SYSTEM EBS01059 12. Wiring • Check the entire starting system’s wiring. Refer to “CIRCUIT DIAGRAM”. • Is the starting system’s wiring properly connected and without defects? YES The starting system circuit is OK. NO Properly connect or repair the starting system’s wiring.
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STARTER MOTOR ELEC EBS01061 STARTER MOTOR 10 Nm (1.0 m•kg, 7.4 ft•lb) 7 Nm (0.7 m•kg, 5.2 ft•lb) 10 Nm (1.0 m•kg, 7.4 ft•lb) Order 1 2 3 Job/Part Removing the starter motor Exhaust pipe Idle gear cover and idle gear Clutch cable holder Starter motor lead Starter motor Q’ty 1 1 1 Remarks Remove the parts in the order listed. Refer to “ENGINE REMOVAL” in chapter 4. Disconnect. For installation, reverse the removal procedure.
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STARTER MOTOR ELEC EBS01062 Order Job/Part Disassembling the starter motor Front bracket Tang washer Plate washer Circlip Rear bracket/Brush Armature assembly Starter motor yoke Brush/spring Q’ty 1 1 1 1 1/1 1 1 2/2 Remarks Remove the parts in the order listed. Refer to “ASSEMBLING THE STARTER MOTOR”. For assembly, reverse the disassembly procedure.
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STARTER MOTOR ELEC EBS01064 CHECKING THE STARTER MOTOR 1. Check: • commutator Dirt → Clean with 600-grit sandpaper. 2. Measure: • commutator diameter Out of specification → Replace the starter motor. Commutator wear limit 21 mm (0.83 in) 3. Measure: • mica undercut Out of specification → Scrape the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commutator. Mica undercut 1.5 mm (0.
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STARTER MOTOR ELEC b. If any resistance is out of specification, replace the starter motor. 5. Measure: • brush length Out of specification → Replace the brushes as a set. Brush length wear limit 3.5 mm (0.14 in) 6. Measure: • brush spring force Out of specification → Replace the brush springs as a set. Brush spring force 5.52 ~ 8.28 N (563 ~ 844 gf, 19.85 ~ 29.78 oz) 7. Check: • gear teeth Damage/wear → Replace the gear. 8.
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STARTER MOTOR ELEC EBS00515 ASSEMBLING THE STARTER MOTOR 1. Install: • brush spring • brush 2 2 1 2. Install: • armature coil 1 3. Install • O-rings 1 to starter motor yoke . 2 b 4. Install • Starter motor yoke NOTE: Align the match marks a on the starter motor york with the match marks on the rear bracket. 1 b 5. Install • Tang washer • Plate washer • Front bracket NOTE: Align the match marks a 1 york with the match marks 3 2 7-23 on the starter motor on the front bracket.
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ELEC CHARGING SYSTEM EBS00516 CHARGING SYSTEM L/B B B R R Br R R W W W W W W Stator coil Rectifier/regulator Battery positive lead Battery Fuse Ground W W W W W/L W/R R W W/L W/R ON OFF R Br B W R Br W W W W B R R B R R R Y/B R R Y/B L/B CIRCUIT DIAGRAM 7-24
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CHARGING SYSTEM ELEC EBS01044 EBS01065 TROUBLESHOOTING 2. Battery • Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. The battery is not being charged. Check: 1. fuse 2. battery 3. charging voltage 4. stator coil resistance 5. wiring connections (of the entire charging system) Minimum open-circuit voltage 12.8 V or more at 20°C (68°F) • Is the battery OK? YES NOTE: • Before troubleshooting, remove the following part(s): 1. seat 2. front panel 3.
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ELEC CHARGING SYSTEM EBS01066 EBS01100 3. Charging voltage 4. Stator coil resistance • Connect the engine tachometer to on to the ignition coil. • Connect the pocket tester (DC 20 V) to the battery as shown. • Disconnect the AC magneto coupler from the wire harness. • Connect the pocket tester (Ω × 1) to the charging coils.
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7-27 G Y B Y ࡯ B G Y B R/B L Br R/W L R/B L/B Br W W W W R W W W W/L W/R L Y G B Y Y G B B G Y L Y B G Y OFF ON OFF ON Br R/B Y G B R ࡯ W G Y B OFF PUSH R Br B W L/B B Br R R W W W W B R R B B R R B R R B Y L Y R Br L/B Y/B R R Y/B L/B Y Br Br Y B/Y Y/B Sb R/B Y Br R/B Sb Y/B B/Y R/B W/L W/R Br Sb B W W W Sb Sb Br B/Y B B B O B A B B B W W B R/B W W/R W/L O Sb Br B BY O BY BY A BY BY Br B/Y B WIRE HARNESS SUB-WIRE HARNES
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ELEC LIGHTING SYSTEM EBS01067 EAS00776 TROUBLESHOOTING 2. Stator coil resistance • Disconnect the AC magneto coupler from the wire harness. • Connect the pocket tester (Ω × 1) to the charging coils. Any of the following fail to light: headlight, tail/brake light. Check: 1. light switch 2. Stator coil resistance 3. wiring connections (of the entire lighting system) NOTE: • Before troubleshooting, remove the following part(s): 1. seat 2. front panel 3. front fender 4. rear fender 5.
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LIGHTING SYSTEM ELEC EBS01069 3. Wiring 2. Voltage • Check the entire lighting system’s wiring. Refer to “CIRCUIT DIAGRAM”. • Is the lighting system’s wiring properly connected and without defects? • Connect the pocket tester (AC 20 V) to the headlight couplers as shown. Headlight coupler (wire harness side) NO YES Check the condition of each of the lighting system’s circuits. Refer to “CHECKING THE LIGHTING SYSTEM”.
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LIGHTING SYSTEM 2. The tail/brake light fails to come on. ELEC 3. Voltage 1. Tail/brake light bulb and bulb socket (4D31) • Connect the pocket tester (AC 20 V) to the tail/brake light coupler as shown. • Check the tail/brake light bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS”.
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7-31 G Y B Y ࡯ B G Y B R/B L Br R/W L R/B L/B Br W W W W R W W W W/L W/R L Y G B Y Y G B B G Y L Y B G Y OFF ON OFF ON Br R/B Y G B R ࡯ W G Y B OFF PUSH R Br B W L/B B Br R R W W W W B R R B B R R B R R B Y L Y R Br L/B Y/B R R Y/B L/B Y Br Br Y B/Y Y/B Sb R/B Y Br R/B Sb Y/B B/Y R/B W/L W/R Br Sb B W W W Sb Sb Br B/Y B B B O B A B B B W W B R/B W W/R W/L O Sb Br B BY O BY BY A BY BY Br B/Y B WIRE HARNESS SUB-WIRE HARNES
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SIGNAL SYSTEM EBS01073 ELEC EBS01044 TROUBLESHOOTING 2. Battery • Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Any of the following fail to light: brake light or an indicator light. Check: 1. fuse 2. battery 3. main switch 4. wiring connections (of the entire signaling system) NOTE: • Before troubleshooting, remove the following part(s): 1. seat 2. front fender • Troubleshoot with the following special tool(s). Minimum open-circuit voltage 12.
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SIGNAL SYSTEM EBS01075 3. Brake light switches CHECKING THE SIGNALING SYSTEM • Check the brake light switches for continuity. Refer to “CHECKING THE SWITCHES”. • Is the brake light switch OK? EBS01076 1. The tail/brake light fails to come on. 1. Tail/brake light bulb and bulb socket (4D31) NO YES • Check the tail/brake light bulb and bulb socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS”. • Are the tail/brake light bulb and bulb socket OK? Replace the brake light switch. 4.
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SIGNAL SYSTEM EBS01077 3. Voltage 2. The neutral indicator light fails to come on. • Connect the pocket tester (DC 20 V) to the indicator light coupler (wire harness side) as shown. 1. Neutral indicator light bulb and socket • Check the neutral indicator light bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS”.
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SIGNAL SYSTEM EBS01083 ELEC 2. Carburetor warmer 3. The carburetor heater fails to come on. • Remove the carburetor heating element from the carburetor. • Connect the pocket tester (Ω × 1) to the carburetor heating element. 1. Thermo switch • Disconnect the thermo switch from the wireharness. • Connect the pocket tester (Ω × 1) to the thermo switch lead.
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STARTING FAILURE/HARD STARTING TRBL SHTG EBS00537 TROUBLESHOOTING NOTE: The following troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to troubleshooting. Refer to the relative procedure in this manual for check, adjustment and replacement of parts.
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STARTING FAILURE/HARD STARTING/POOR IDLE SPEED PERFORMANCE/POOR MEDIUM AND HIGH-SPEED PERFORMANCE COMPRESSION SYSTEM Cylinder and cylinder head • Loose spark plug • Loose cylinder head or cylinder • Broken cylinder head gasket • Broken cylinder gasket • Worn, damaged or seized cylinder Valve and camshaft • Improperly sealed valve • Improperly contacted valve and valve seat • Improper valve timing • Broken valve spring • Seized camshaft TRBL SHTG Piston and piston rings • Improperly installed piston ring •
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FAULTY GEAR SHIFTING/ CLUTCH SLIPPING/DRAGGING TRBL SHTG EBS00541 FAULTY GEAR SHIFTING HARD SHIFTING Refer to “CLUTCH DRAGGING”.
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OVERHEATING/ FAULTY BRAKE / SHOCK ABSORBER MALFUNCTION EBS00547 OVERHEATING OVERHEATING Ignition system • Improper spark plug gap • Improper spark plug heat range • Faulty CDI unit Fuel system • Improper carburetor main jet (improper setting) • Improper fuel level • Clogged air filter element Compression system • Heavy carbon deposit Engine oil • Improper oil level • Improper oil viscosity • Inferior oil quality Brake • Brake drag EBS00550 FAULTY BRAKE POOR BRAKING EFFECT Disc brake • Worn brake pads •
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UNSTABLE HANDLING/ LIGHTING SYSTEM TRBL SHTG EBS00552 UNSTABLE HANDLING UNSTABLE HANDLING Handlebar • Improperly installed or bent Steering • Incorrect toe-in • Bent steering stem • Improperly installed steering stem • Damaged bearing or bearing race • Bent tie-rods • Deformed steering knuckles Tires • Uneven tire pressures on both sides • Incorrect tire pressure • Uneven tire wear Wheels • Deformed wheel • Loose bearing • Bent or loose wheel axle • Excessive wheel runout Frame • Bent • Damaged frame Sw
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YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U.S.A.
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YFM250RX WIRING DIAGRAM Pickup coil Stator coil Rectifier/regulator Main switch Battery positive lead Battery Fuse Starter relay Starter motor CDI unit Ignition coil Spark plug Starting circuit cut-off relay Clutch switch Thermo switch Carburetor warmer Neutral indicator light Neutral switch Rear brake light switch Front brake light switch Tail/brake light Handlebar switch Light switch Engine stop switch Start switch Headlight relay Headlight Ground COLOR CODE B . . . . . . . Black Br . . . . . .