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Yamaha 2003 YFZ450S, Service Manual

The Yamaha 2003 YFZ450S Service Manual is an essential resource for owners of this high-performance ATV. Available for free download at manualshive.com, this comprehensive manual provides step-by-step instructions, diagrams, and troubleshooting tips to ensure optimal performance and maintenance. Get the most out of your Yamaha with this user-friendly manual!

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CHAS

EBS00421

FRONT BRAKE CALIPERS

1

2

6

3

5

T

 

R

.

.

27 Nm (2.7 m 

•

 

kg, 19 ft

 

•

 

Ib)

New

T

 

R

.

.

18 Nm (1.8 m 

•

 

kg, 13 ft

 

•

 

Ib)

LT

4

T

 

R

.

.

28 Nm (2.8 m 

•

 

kg, 20 ft

 

•

 

Ib)

Order

Job/Part

Q’ty

Remarks

Removing the front brake calipers

Remove the parts in the order listed.
The following procedure applies to both
of the front brake calipers.

Brake caliper

Drain.

Front wheel

Refer to “FRONT AND REAR WHEELS”.

1

Union bolt

1

Refer to “INSTALLING
THE FRONT BRAKE
CALIPERS”.

2

Copper washer

2

3

Brake hose

1

Disconnect.

4

Brake pad retaining bolt

2

Loosen.

5

Brake caliper mounting bolt

2

6

Brake caliper assembly

1

For installation, reverse the removal pro-
cedure.

FRONT AND REAR BRAKES

Summary of Contents for 2003 YFZ450S

Page 1: ...YFZ450S5TG2 AE1 SERVICE MANUAL ...

Page 2: ......

Page 3: ...YFZ450S SERVICE MANUAL 2003 by Yamaha Motor Co Ltd First Edition April 2003 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited ...

Page 4: ...tions and sig nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable NOTE _ Designs and specifications are subject to change without notice EBS00003 IMPORTANT INFORMATION Particularly important information is distinguished in this manual by the following notations The Safety Alert Symbol...

Page 5: ...parts and clarify procedure steps there are exploded diagrams at the start of each removal and disassembly section 1 An easy to see exploded diagram 4 is provided for removal and disassembly jobs 2 Numbers 5 are given in the order of the jobs in the exploded diagram A number that is enclosed by a circle indicates a disassembly step 3 An explanation of jobs and notes is presented in an easy to read...

Page 6: ...r limit clearance F Engine speed G Electrical data Ω V A Symbols H to N in the exploded diagrams indicate the types of lubricants and lubrication points H Apply engine oil I Apply gear oil J Apply molybdenum disulfide oil K Apply wheel bearing grease L Apply lithium soap based grease M Apply molybdenum disulfide grease Symbols N to O in the exploded diagrams indicate where to apply a locking agent...

Page 7: ... CONTENTS GENERAL INFORMATION GEN INFO 1 SPECIFICATIONS SPEC 2 PERIODIC CHECKS AND ADJUSTMENTS CHK ADJ 3 ENGINE ENG 4 COOLING SYSTEM COOL 5 CARBURETOR CARB 6 CHASSIS CHAS 7 ELECTRICAL ELEC 8 TROUBLESHOOTING TRBL SHTG 9 ...

Page 8: ......

Page 9: ...GEN INFO 1 ...

Page 10: ...ATION NUMBER 1 1 MODEL LABEL 1 1 IMPORTANT INFORMATION 1 2 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 2 REPLACEMENT PARTS 1 2 GASKETS OIL SEALS AND O RINGS 1 2 LOCK WASHERS PLATES AND COTTER PINS 1 3 BEARINGS AND OIL SEALS 1 3 CIRCLIPS 1 3 CHECKING THE CONNECTIONS 1 4 SPECIAL TOOLS 1 5 ...

Page 11: ...GEN INFO ...

Page 12: ...NE IDENTIFICATION EBS00010 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the left side of the frame 1 EBS00011 MODEL LABEL The model label 1 is affixed to the air filter case cover This information will be needed to order spare parts 1 ...

Page 13: ...all of the parts and place them in trays in the order of dis assembly This will speed up assembly and allow for the correct installation of all parts 5 Keep all parts away from any source of fire EBS00014 REPLACEMENT PARTS 1 Use only genuine Yamaha parts for all replacements Use oil and grease recom mended by Yamaha for all lubrication jobs Other brands may be similar in function and appearance bu...

Page 14: ...sible When installing oil seals lubricate the oil seal lips with a light coat of lithium soap based grease Oil bearings liberally when installing if appro priate 1 Oil seal CAUTION _ Do not spin the bearing with compressed air because this will damage the bearing surfaces 1 Bearing EBS00018 CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlips Always rep...

Page 15: ...t sev eral times 3 Check all connections Loose connection Connect properly NOTE _ If the pin 1 on the terminal is flattened bend it up 4 Connect lead coupler connector NOTE _ Make sure all connections are tight 5 Check continuity with the pocket tester NOTE _ If there is no continuity clean the terminals When checking the wire harness perform steps 1 to 3 As a quick remedy use a contact revitalize...

Page 16: ...CC Except for US and CDN P N 90890 Tool No Tool name Function Illustration 90890 01135 YU 01135 A Crankcase separating tool This tool is used to separate the crank case Pot 90890 01274 Bolt 90890 01275 Crankshaft installer pot Crankshaft installer bolt These tools are used to install the crank shaft YU 90050 Crankshaft installer set These tools are used to install the crank shaft Adapter 90890 012...

Page 17: ...4 YM 01474 Ball joint remover installer set These tools are used to removing or installing the ball joints 90890 01480 YM 01480 Ball joint remover installer attachment set These tools are used to removing or installing the ball joints 90890 01701 YS 01880 A Sheave holder This tool is needed to hold the A C mag neto rotor when loosen or tighten the A C magneto rotor nut 90890 03112 YU 03112 C Pocke...

Page 18: ... This tool is needed to remove and install the valve guides 90890 04098 YM 04098 90890 04117 YM 04117 Valve guide installer ø 5 Valve guide installer ø 4 5 This tool is needed to install the valve guides 90890 04099 YM 04099 90890 04118 YM 04118 Valve guide reamer ø 5 Valve guide reamer ø 4 5 This tool is needed to rebore the new valve guides 90890 04101 Valve lapper This tool is needed to remove ...

Page 19: ... instrument is necessary for checking the ignition system components YM 34487 Dynamic spark tester This instrument is necessary for checking the ignition system components Bond 90890 85505 Sealant ACC 11001 05 01 Yamaha bond No 1215 Sealant Quick Gasket This sealant bond is used on crankcase mating surfaces etc Tool No Tool name Function Illustration ...

Page 20: ......

Page 21: ...SPEC 2 ...

Page 22: ...ICAL SPECIFICATIONS 2 14 TIGHTENING TORQUES 2 16 ENGINE TIGHTENING TORQUES 2 16 CHASSIS TIGHTENING TORQUES 2 19 HOW TO USE THE CONVERSION TABLE 2 21 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 21 LUBRICATION POINTS AND LUBRICANT TYPES 2 22 ENGINE 2 22 COOLANT FLOW DIAGRAMS 2 24 OIL FLOW DIAGRAMS 2 26 CABLE ROUTING 2 28 ...

Page 23: ...SPEC ...

Page 24: ...m turning radius 3 500 mm 137 8 in Basic weight With oil and full fuel tank 169 kg 373 lb Engine Engine type Liquid cooled 4 stroke DOHC Cylinder arrangement Forward inclined single cylinder Displacement 439 cm3 26 79 cu in Bore stroke 95 0 62 0 mm 3 74 2 44 in Compression ratio 11 9 1 Starting system Electric starter Lubrication system Dry sump Oil type or grade Engine oil For CDN API service SE ...

Page 25: ...g Type manufacturer CR8E NGK Spark plug gap 0 7 0 8 mm 0 028 0 031 in Clutch type Wet multiple disc Transmission Primary reduction system Spur gear Primary reduction ratio 62 22 2 818 Secondary reduction system Chain drive Secondary reduction ratio 38 14 2 714 Transmission type Constant mesh 5 speed Operation Left foot operation Gear ratio 1st gear 29 12 2 416 2nd gear 27 14 1 928 3rd gear 25 16 1...

Page 26: ...disc brake operation Right foot operation Suspension Front suspension Double wishbone Rear suspension Swingarm link suspension Shock absorber Front shock absorber Coil spring gas oil damper Rear shock absorber Coil spring gas oil damper Wheel travel Front wheel travel 230 mm 9 06 in Rear wheel travel 256 mm 10 08 in Electrical Ignition system DC C D I Generator system A C magneto Battery type GT7B...

Page 27: ...m 0 8648 0 8654 in Camshaft journal to camshaft cap clearance 0 020 0 054 mm 0 0008 0 0021 in 0 080 mm 0 0032 in Camshaft lobe dimensions Intake A 31 200 31 300 mm 1 2283 1 2323 in 31 100 mm 1 2244 in B 22 550 22 650 mm 0 8878 0 8917 in 22 450 mm 0 8839 in Exhaust A 30 950 31 050 mm 1 2185 1 2224 in 30 850 mm 1 2146 in B 22 494 22 594 mm 0 8856 0 8895 in 22 394 mm 0 8817 in Camshaft runout limit 0...

Page 28: ... 033 in EX 1 0 mm 0 0394 in 0 85 mm 0 033 in Stem outside diameter IN 4 475 4 490 mm 0 1762 0 1768 in 4 445 mm 0 175 in EX 4 965 4 980 mm 0 1955 0 1961 in 4 935 mm 0 194 in Guide inside diameter IN 4 500 4 512 mm 0 1772 0 1776 in 4 550 mm 0 179 in EX 5 000 5 012 mm 0 1969 0 1973 in 5 050 mm 0 199 in Stem to guide clearance IN 0 010 0 037 mm 0 0004 0 0015 in 0 080 mm 0 003 in EX 0 020 0 047 mm 0 00...

Page 29: ... 5 0 065 in Direction of winding top view IN Clockwise EX Clockwise Piston Piston to cylinder clearance 0 040 0 065 mm 0 0016 0 0026 in 0 10 mm 0 004 in Piston size D 94 945 94 960 mm 3 7380 3 7386 in Measuring point H 10 mm 0 39 in Piston off set 1 0 mm 0 0394 in Offset direction Intake side Piston pin bore inside diameter 20 004 20 015 mm 0 7876 0 7880 in 20 045 mm 0 789 in Piston pin outside di...

Page 30: ... 0 50 mm 0 014 0 020 in 0 85 mm 0 034 in Side clearance 0 020 0 055 mm 0 0008 0 0022 in 0 12 mm 0 0047 in Oil ring Dimensions B T 2 0 2 9 mm 0 079 0 114 in End gap installed 0 20 0 50 mm 0 008 0 020 in Crankshaft Crank width A 61 95 62 00 mm 2 439 2 441 in Runout limit C1 0 03 mm 0 0012 in 0 05 mm 0 002 in C2 0 03 mm 0 0012 in 0 05 mm 0 002 in Big end side clearance D 0 15 0 45 mm 0 0059 0 0177 in...

Page 31: ...spring Free length 51 8 mm 2 04 in 50 0 mm 1 97 in Quantity 6 Clutch housing thrust clearance 0 10 0 35 mm 0 0039 0 0138 in Clutch housing radial clearance 0 010 0 044 mm 0 0004 0 0017 in Clutch release method Inner push cam push Push rod 2 bending limit 0 1 mm 0 004 in Transmission Main axle deflection limit 0 08 mm 0 0031 in Drive axle deflection limit 0 08 mm 0 0031 in Shifter Shifter type Shif...

Page 32: ...il pump Oil pump type Trochoid Inner rotor to outer rotor tip clear ance 0 07 0 12 mm 0 0028 0 0047 in 0 20 mm 0 0079 in Outer rotor to oil pump housing clearance 0 09 0 17 mm 0 0035 0 0067 in 0 24 mm 0 0094 in Bypass valve setting pressure 40 0 80 0 kPa 300 602 mmHg 11 8 23 7 inHg Cooling system Radiator core Width 300 mm 11 8 in Height 188 mm 7 4 in Depth 24 mm 0 94 in Radiator cap opening press...

Page 33: ...rication chart Oil tank Camshaft Valve lifter Piston Piston pin Crank pin Oil filter Cylinder head Transmission gears Main axle Drive axle Check ball Oil pump rotor 1 Oil pump rotor 2 Oil strainer Oil pan Pressure feed Splashed scavenge ...

Page 34: ...2 11 SPEC ENGINE SPECIFICATIONS Cylinder head tightening sequence ...

Page 35: ...rber travel 116 0 4 57 in Spring free length 259 mm 10 20 in Spring fitting length 244 mm 9 61 in Spring rate K1 46 0 N mm 4 69 kg mm 263 lb in Stroke K1 0 116 0 mm 0 4 57 in Optional spring No Swingarm Free play limit end 1 mm 0 04 in side 1 mm 0 04 in Front wheel Type Panel wheel Rim size 10 5 5 AT Rim material Aluminum Rim runout limit radial 2 0 mm 0 08 in lateral 2 0 mm 0 08 in Rear wheel Typ...

Page 36: ...iameter thickness 200 0 3 6 mm 7 87 0 14 in Pad thickness inner 4 5 mm 0 18 in 1 0 mm 0 04 in Pad thickness outer 4 5 mm 0 18 in 1 0 mm 0 04 in Master cylinder inside diameter 12 7 mm 0 50 in Caliper cylinder inside diameter 33 96 mm 1 34 in Brake fluid type DOT 4 Brake lever and brake pedal Brake pedal position 11 7 mm 0 46 in Parking brake cable end length 56 60 mm 2 20 2 36 in Clutch lever free...

Page 37: ...nufacturer F5TG MORIC Nominal output 14 V 120 W at 5 000 r min Lighting coil resistance color 0 224 0 336 Ω at 20 C 68 F yellow ground Charging coil resistance color 0 288 0 432 Ω at 20 C 68 F white ground Rectifier regulator Type Semi conductor short circuit Model manufacturer SH712AB SHINDENGEN No load regulated voltage DC 14 1 14 9 V AC 13 0 14 0 V Rectifier capacity DC 8 0 A AC 12 0 A Electric...

Page 38: ...Model manufacturer 5GH NIPPON THERMOSTAT Opening temperature 95 101 C 203 0 213 8 F Closing temperature 89 95 C 192 2 203 0 F Thermo switch 2 Model manufacturer 5LP NIPPON THERMOSTAT Opening temperature 117 123 C 242 6 253 4 F Closing temperature 112 118 C 233 6 244 4 F Circuit breaker Type Fuse Amperage for individual circuit Fuse 15 A 1 Reserve 15 A 1 Item Standard Limit ...

Page 39: ...19 1 9 13 Engine oil drain bolt engine Bolt M10 1 20 2 0 14 Oil pump Bolt M6 3 10 1 0 7 2 Oil pump housing cover Screw M4 1 2 0 2 1 4 Engine oil drain bolt oil filter Bolt M6 1 10 1 0 7 2 Oil filter cover Bolt M6 2 10 1 0 7 2 Oil delivery pipe 1 Union bolt M10 1 20 2 0 14 Union bolt M8 2 18 1 8 13 Oil delivery pipe 2 Bolt M6 1 10 1 0 7 2 Oil pipe 1 and crankcase cover Bolt M6 1 8 0 8 8 Oil pipe 2 ...

Page 40: ...e a lock washer Drive sprocket Nut M20 1 75 7 5 54 Use a lock washer Drive axle oil seal retainer Bolt M6 2 10 1 0 7 2 LT Torque limiter cover Bolt M6 2 10 1 0 7 2 A C magneto cover Bolt M6 9 10 1 0 7 2 A C magneto rotor Nut M12 1 65 6 5 47 Stator coil Bolt M5 2 7 0 7 5 1 A C magneto lead holder Bolt M5 2 7 0 7 5 1 Pickup coil Bolt M6 2 10 1 0 7 2 Starter clutch Bolt M6 6 16 1 6 11 LT Shift drum s...

Page 41: ...er tightening sequence and then tighten the cylinder head bolts further in two steps of 90 to reach the specified angle of 180 in the proper tightening sequence Thermo switch 2 M18 1 28 2 8 20 Starter motor Bolt M6 2 10 1 0 7 2 Starter motor lead Nut M6 1 7 0 7 5 1 Bush holder assembly and rear bracket nut Nut M6 1 7 0 7 5 1 Part to be tightened Part name Thread size Q ty Tightening torque Remarks...

Page 42: ...locknut M50 30 3 0 22 Upper front arm and frame M10 38 3 8 27 Lower front arm and frame M10 55 5 5 40 Steering stem pitman arm and frame M14 180 18 130 Steering stem bushing and frame M8 23 2 3 17 Use a lock washer Steering stem and handlebar holder M8 23 2 3 17 Tie rod end and locknut M10 15 1 5 11 Steering knuckle and front wheel hub M14 70 7 0 50 Steering knuckle and front arm upper and lower M...

Page 43: ...id reservoir cover and bracket M6 11 1 1 8 Rear brake fluid reservoir and bracket M6 4 0 4 2 9 Front bumper and frame M8 31 3 1 22 Front fender and frame M6 7 0 7 5 1 Side cover and frame M6 7 0 7 5 1 Side cover rear fender and frame M6 7 0 7 5 1 Rear fender and frame M6 7 0 7 5 1 Rear fender stay and rear fender M6 7 0 7 5 1 Front fender stay and front fender M6 7 0 7 5 1 Rear carrier bar and fra...

Page 44: ...nless otherwise specified tightening torque specifications require clean dry threads Com ponents should be at room temperature A Distance between flats B Outside thread diameter Ex METRIC MULTIPLIER IMPERIAL mm 0 03937 in 2 mm 0 03937 0 08 in METRIC TO IMPERIAL Torque Metric unit Multiplier Imperial unit m kg m kg cm kg cm kg 7 233 86 794 0 0723 0 8679 ft lb in lb ft lb in lb Weight kg g 2 205 0 0...

Page 45: ...p E Auto decompression lever E Water pump impeller shaft E Oil pump rotors inner and outer and oil pump housing E Oil pump drive gear E Connecting rod bearing E Torque limiter E Starter idle gear inner surface and shaft E Starter clutch inner surface E Primary driven gear E Push rod 1 2 and ball E Push lever shaft E Push rod bearing and plane washer E Transmission gears wheel and pinion M Shift fo...

Page 46: ...mating surfaces Sealant Quick Gasket Yamaha bond No 1215 Cylinder head and cylinder head cover mating surfaces Sealant Quick Gasket Yamaha bond No 1215 AC magneto lead grommet AC magneto cover Sealant Quick Gasket Yamaha bond No 1215 Lubrication point Lubricant ...

Page 47: ...LANT FLOW DIAGRAMS 1 Radiator inlet hose 2 Radiator 3 Radiator fan 4 Radiator outlet hose 5 Water pump inlet pipe 6 Water pump 7 Thermo switch 1 8 Thermo switch 2 9 Cylinder head water jacket 7 8 1 2 3 4 5 6 9 Î Ê È É Ê Ë Í Ì A B C D D C A B D D ...

Page 48: ...e until the end of the hose reaches the middle of the blue paint mark on the pipe Ì Align the white paint mark on the radiator inlet hose with the projection on the radiator pipe Í Install the radiator inlet hose onto the radiator pipe until the end of the hose contacts the projection of the pipe Î Install the radiator inlet hose onto the outlet pipe of the cylinder head water jacket until the end...

Page 49: ...0026 OIL FLOW DIAGRAMS 1 Intake camshaft 2 Exhaust camshaft 3 Oil filter element 4 Oil tank 5 Oil pipe 1 6 Oil pipe 2 7 Main axle 8 Drive axle 9 Oil delivery pipe 1 0 Oil pump A Oil strainer B C B A A B B C C C 1 9 8 7 6 5 3 0 3 4 2 A ...

Page 50: ...2 27 SPEC OIL FLOW DIAGRAMS 1 Camshaft 2 Oil filter element 3 Crankshaft 4 Main axle 5 Drive axle 6 Oil delivery pipe 2 7 Connecting rod 7 1 2 3 4 5 6 ...

Page 51: ...BS00028 CABLE ROUTING 1 Parking brake cable 2 Clutch cable 3 Clutch switch lead 4 Handlebar switch lead 5 Front brake light switch lead 6 Throttle switch lead 7 Front brake hose 8 Throttle cable 2 1 3 4 5 6 7 8 É È Ê Ë 6 Ì A A ...

Page 52: ...astic band É Fasten the front brake light switch lead and throttle switch lead to the handlebar with the plastic band Ê Less than 10 mm 0 39 in Ë Make sure that there is no slack in the throttle switch lead Ì Fasten the throttle switch lead to the handlebar with the plastic band 2 1 3 4 5 6 7 8 É È Ê Ë 6 Ì A A ...

Page 53: ...6 Parking brake cable 7 Clutch switch lead 8 Handlebar switch lead 9 Radiator fan breather hose 0 Thermo switch 2 lead A Headlight coupler left B C D I unit leads C Rectifier regulator coupler D Brake pipe E Rectifier regulator F C D I unit G Diode 1 H Diode 2 I Thermo switch 1 lead J Headlight coupler right K Main switch coupler ...

Page 54: ...the order listed Ê Pass the throttle cable through the steering stem cable guide Ë 30 50 mm 1 18 1 97 in Ì Fasten the front brake light switch lead throttle switch lead clutch switch lead and handlebar switch lead with the plastic band and then place the end of the band under the fuel tank cover Í Pass the radiator fan breather hose through the hose guide Î Fasten the radiator fan breather hose cl...

Page 55: ...ndlebar switch and fasten the center of the cover with the plastic band Ð Pass the clutch cable and parking brake cable through the cable guide in this order Ñ Fasten the radiator fan breather hose with the holder on the radiator grill Ò Install the brake hose cover so that the slits in the cover fit over the brake hose grommet ...

Page 56: ...ankcase breather hose B Battery negative lead C Starter motor lead D Neutral switch lead E A C magneto lead F Oil tank breather hose G Neutral switch coupler H A C magneto coupler I Front brake hose J Throttle cable K Parking brake cable L Clutch cable M Indicator leads N Cylinder head breather hose A Ë Ï È É Ê Ì Í Î Ñ Ð Ó Ô Õ Ö Ø N E D D E G H F E D C B A 0 9 8 7 6 5 2 1 3 4 Û Ú Ù Ü L K J I M 7 5...

Page 57: ...ten the wire harness throttle position sensor lead and carburetor switch lead with the plastic band Make sure that there is no slack in the throttle position sensor lead and carburetor switch lead along the frame as shown Î Install the cylinder head breather hose with the paint mark facing to the left Ï More than 15 mm 0 59 in Ð Fasten the wire harness with the plastic band on the white tape and t...

Page 58: ...ll the crankcase breather hose with the paint mark facing outward Ô Fasten the neutral switch lead with the lead holder Õ Fasten the neutral switch lead with the clamp Ö Fasten the A C magneto lead with the lead holder Fasten the neutral switch lead and A C mag neto lead with the plastic band Face the end of the plastic band inward on top of the frame Ø Pass the neutral switch lead and A C magneto...

Page 59: ...nt of the handle bar cover Û Route the clutch cable and parking brake cable in front of the handlebar cover Ü When installing the fuel tank cover do not pinch the clutch cable parking brake cable clutch switch lead or handlebar switch lead A Ë Ï È É Ê Ì Í Î Ñ Ð Ó Ô Õ Ö Ø N E D D E G H F E D C B A 0 9 8 7 6 5 2 1 3 4 Û Ú Ù Ü L K J I M 7 5 Ò 7 0 9 G G G G C C B B E E A D D C C B B F F E E F F D D G ...

Page 60: ...A Battery negative lead B Starter motor lead È When installing the rear fender make sure that the rear fender does not overlap or pinch the cyl inder head breather hose coolant reservoir hose or wire harness É Install the air filter case breather hose with the paint mark facing outward Ê Install the cylinder head breather hose with the paint mark facing outward A C C D D E E G G A E E B B C C D D ...

Page 61: ...es not hang from the rear fender Ï Pass the carburetor drain hose and carburetor air vent hoses through the hose guide on the engine from the left side of the machine in the order listed Do not pinch the hoses Ð Route the negative battery lead to the outside of the carburetor air vent hose and to the inside of the carburetor drain hose Ñ Route the carburetor drain hose between the rear shock absor...

Page 62: ...Route the carburetor drain hose between the frame and connecting arm and let it hang freely under the vehicle A C C D D E E G G A E E B B C C D D F F G G F F 9 0 A A B 8 5 3 6 7 5 4 3 2 1 8 4 7 A B 7 È É Ê Ë Í Î Ð Ï Ñ Ò 9 5 1 Ì ...

Page 63: ...rake cable È Fasten the coolant reservoir hose with a clamp so that it is not pinched É Route the thermo switch 1 lead under the frame Ê Fasten the thermo switch 1 lead with a plastic band between the diode 1 and the diode 2 and then face the end of the band inward Ë Pass the parking brake cable through the cable guide A A A A C B B C A A 1 4 7 3 7 6 5 4 3 2 1 7 È É Ê Ë ...

Page 64: ...ke light switch 4 Rear brake light switch lead È Install the lead protector of the rear brake light switch lead between the clamps É Face the rear brake light switch lead holder inward and then fasten the lead with the holder C C C C A A B B 1 2 3 È 4 É 4 2 1 2 1 C C B B A A ...

Page 65: ...linder head breather hose A Carburetor switch lead B Throttle position sensor lead C Wire harness D Headlight lead left E C D I unit È Route the wire harness on top of the frame É Route the headlight lead right over the frame and connect After connecting the lead to the headlight place the headlight coupler behind the headlight toward the center of the vehicle A A B B B B A A E 2 3 4 5 6 7 8 9 Î 0...

Page 66: ...lead over the cylinder head breather hose Ð To carburetor Ñ Fasten the wire harness with the holder on the shield under the fuel tank Ò Route the headlight lead left over the frame and connect After connecting the lead to the headlight place the headlight coupler behind the headlight toward the center of the vehicle Ó When installing the left side cover do not pinch the wire harness A A B B B B A ...

Page 67: ...eather hose 0 Wire harness È Pass the coolant reservoir hose through the hose guide É Route the earth lead and wire harness under the battery bracket Ê Connect the tail brake light lead between the coolant reservoir and the rear fender Ë Pass the wire harness through the notch in the rear fender Be sure that the rear fender and air filter case do not pinch the wire harness È É Ê Ë Ì 7 8 0 9 8 6 5 ...

Page 68: ...NG Ì Fasten the coolant reservoir hose and the cylin der head breather hose to the frame with the plastic beaded tie at its loosest position so that the hoses are not pinched È É Ê Ë Ì 7 8 0 9 8 6 5 4 3 2 1 B 7 7 A A B A A ...

Page 69: ......

Page 70: ...CHK ADJ 3 ...

Page 71: ...ANK 3 7 ENGINE 3 8 ADJUSTING THE VALVE CLEARANCE 3 8 ADJUSTING THE ENGINE IDLING SPEED 3 13 ADJUSTING THE THROTTLE LEVER FREE PLAY 3 14 ADJUSTING THE SPEED LIMITER 3 16 CHECKING THE SPARK PLUG 3 17 CHECKING THE IGNITION TIMING 3 18 CHECKING THE ENGINE OIL LEVEL 3 19 CHANGING THE ENGINE OIL 3 21 ADJUSTING THE CLUTCH CABLE 3 24 CLEANING THE AIR FILTER ELEMENT 3 26 CHECKING THE COOLANT LEVEL 3 28 CHA...

Page 72: ...KE SYSTEM 3 39 ADJUSTING THE SHIFT PEDAL 3 41 ADJUSTING THE DRIVE CHAIN SLACK 3 42 CHECKING THE STEERING SYSTEM 3 43 ADJUSTING THE TOE IN 3 44 CHECKING THE FRONT AND REAR SHOCK ABSORBERS 3 45 ADJUSTING THE FRONT SHOCK ABSORBERS 3 46 ADJUSTING THE REAR SHOCK ABSORBER 3 48 CHECKING THE TIRES 3 52 CHECKING THE WHEELS 3 54 CHECKING AND LUBRICATING THE CABLES 3 54 LUBRICATING THE LEVERS AND PEDALS 3 55...

Page 73: ...ery 20 40 hours More often in wet or dusty areas Carburetor Check starter choke operation Adjust engine idling speed Crankcase breather system Check breather hose for cracks or damage Replace if necessary Exhaust system Check for leakage Tighten if necessary Replace gasket if necessary Fuel line Check fuel hose for cracks or damage Replace if necessary Engine oil Replace Warm engine before drainin...

Page 74: ...ck the brake fluid level and add fluid as required 2 On the inner parts of the master cylinder and caliper cylinder replace the oil seals every two years 3 Replace the brake hoses every four years or if cracked or damaged WARNING _ Indicates a potential hazard that could result in serious injury or death Fittings and fasten ers Check all chassis fittings and fasteners Correct if necessary Lights a...

Page 75: ...Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib Order Job Part Q ty Remarks Removing the seat fuel tank cover and side covers Remove the parts in the order listed 1 Seat 1 NOTE _ Pull back the seat lock lever than pull up on the rear of the seat 2 Fuel tank cover 1 3 Left side cover 1 4 Right side cover 1 For installation reverse the removal pro cedure ...

Page 76: ... R 16 Nm 1 6 m kg 11 ft Ib T R 16 Nm 1 6 m kg 11 ft Ib T R 13 Nm 1 3 m kg 9 4 ft Ib T R 16 Nm 1 6 m kg 11 ft Ib LT 6 Order Job Part Q ty Remarks Removing the foot protectors and engine skid plate Remove the parts in the order listed 1 Left foot protector 1 2 Right foot protector 1 3 Engine skid plate 1 For installation reverse the removal pro cedure ...

Page 77: ... m kg 5 1 ft Ib Order Job Part Q ty Remarks Removing the headlight and front fender Remove the parts in the order listed Seat fuel tank cover side covers left and right Refer to SEAT FENDERS AND FUEL TANK 1 Headlight coupler 2 Disconnect 2 Left headlight 1 3 Right headlight 1 4 Main switch coupler 1 Disconnect 5 Indicator light coupler 1 Disconnect 6 Front fender 1 For installation reverse the rem...

Page 78: ... Remarks Removing the rear fender Remove the parts in the order listed Seat fuel tank cover side covers left and right Refer to SEAT FENDERS AND FUEL TANK 1 Battery lead 2 CAUTION _ First disconnect the negative lead then disconnect the positive lead 2 Battery holding bracket 1 3 Battery 1 4 Air filter case breather hose 1 Disconnect 5 Clamp 1 Loosen 6 Air filter case 1 7 Rear fender 1 For install...

Page 79: ...ted Seat fuel tank cover side covers left and right Refer to SEAT FENDERS AND FUEL TANK 1 Fuel hose fuel cock side 1 NOTE _ Before disconnecting the fuel hose turn the fuel cock to OFF 2 Fuel tank 1 NOTE _ When installing the fuel tank pass the fuel tank breather hose through the hole in the handlebar cover 3 Fuel tank shield 1 For installation reverse the removal pro cedure ...

Page 80: ... Top Dead Center TDC on the compression stroke 1 Remove seat fuel tank cover side covers left and right fuel tank Refer to SEAT FENDERS AND FUEL TANK 2 Remove ignition coil 1 oil tank breather hose 2 cylinder head breather hose 3 spark plug cylinder head cover 4 3 4 2 1 3 Remove timing mark accessing screw 1 crankshaft end accessing screw 2 4 Measure valve clearance Out of specification Adjust Val...

Page 81: ...unch mark d on the intake camshaft sprocket must align with the cylinder head mating surface as shown in the illustration The Top Dead Center TDC on the com pression stroke can be found when the cam shaft lobes are turned away from each other c Measure the valve clearance with a thick ness gauge 1 NOTE _ If the valve clearance is incorrect record the measured reading a b EX IN 5 Remove intake cams...

Page 82: ...lve pad from the follow ing table NOTE _ The thickness a of each valve pad is marked in hundredths of millimeters on the side that touches the valve lifter Since valve pads of various sizes are origi nally installed the valve pad number must be rounded in order to reach the closest equiva lent to the original c Round off the original valve pad number according to the following table Valve lapper 9...

Page 83: ...disulfide oil Lubricate the valve lifter with engine oil The valve lifter must turn smoothly when rotated by hand Install the valve lifter and the valve pad in the correct place f Install the exhaust and intake camshafts timing chain and the camshaft caps NOTE _ Refer to INSTALLING THE CAMSHAFTS CAMSHAFTS in chapter 4 Lubricate the camshaft bearings camshaft lobes and camshaft journals First insta...

Page 84: ...0 1 26 1 30 235 240 1 31 1 35 240 MEASURED CLEARANCE INSTALLED PAD NUMBER 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0 00 0 04 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 0 05 0 09 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 0 10 0 14 120 125 130 135 140 145 ...

Page 85: ...G SPEED 1 Start the engine and let it warm up for sev eral minutes 2 Remove seat fuel tank cover side covers left and right fuel tank NOTE Slide the fuel tank Refer to SEAT FENDERS AND FUEL TANK 3 Attach digital tachometer onto the ignition coil 4 Install fuel tank Refer to SEAT FENDERS AND FUEL TANK 5 Measure engine idling speed Out of specification Adjust Engine idling speed 1 750 1 850 r min ...

Page 86: ...achometer 9 Install fuel tank side covers left and right fuel tank cover seat Refer to SEAT FENDERS AND FUEL TANK 10 Adjust throttle lever free play Refer to ADJUSTING THE THROTTLE LEVER FREE PLAY Direction a Idling speed becomes higher Direction b Idling speed becomes lower Throttle lever free play 2 4 mm 0 08 0 16 in a b 1 EBS00052 ADJUSTING THE THROTTLE LEVER FREE PLAY NOTE _ Engine idling spee...

Page 87: ...inal posi tion NOTE _ If the free play cannot be adjusted here adjust it at the throttle lever side of the cable Direction a Free play is increased Direction b Free play is decreased 2 3 b a 1 Second step f Slide back the rubber cover 4 g Loosen the locknut 5 h Turn the adjusting bolt 6 in direction c or d until the correct free play is obtained i Tighten the locknut j Slide the rubber cover to it...

Page 88: ...sting screw 2 in or out until the specified speed limiter length is obtained c Tighten the locknut WARNING _ Particularly for a beginner rider the speed limiter should be screwed in com pletely Screw it out little by little as their riding technique improves Never remove the speed limiter for a beginning rider For proper throttle lever operation do not turn out the adjusting screw more than 12 mm ...

Page 89: ...park plug CR8E NGK 5 Check electrode 1 Wear damage Replace insulator 2 Abnormal color Replace Normal color is a medium to light tan color 6 Clean spark plug with a spark plug cleaner or wire brush 7 Measure spark plug gap a Use a wire gauge or thickness gauge Out of specification Regap 8 Tighten spark plug NOTE _ Before installing a spark plug clean the gasket surface and plug surface Spark plug g...

Page 90: ... TIMING NOTE _ Engine idling speed and throttle cable free play should be adjusted properly before checking the ignition timing 1 Remove seat fuel tank cover side covers left and right fuel tank NOTE Slide the fuel tank Refer to SEAT FENDERS AND FUEL TANK 2 Attach digital tachometer timing light onto the ignition coil 3 Install fuel tank Refer to SEAT FENDERS AND FUEL TANK Timing light P N YM 3327...

Page 91: ...he fuel tank 6 Detach timing light engine tachometer 7 Install fuel tank side covers left and right fuel tank cover seat Refer to SEAT FENDERS AND FUEL TANK EBS01101 CHECKING THE ENGINE OIL LEVEL 1 Place the machine on a level surface 2 Start the engine warm it up until the engine oil has reached a normal temperature of 40 C 104 F let it continue to idle for ten seconds and then turn the engine of...

Page 92: ... clutch slippage Therefore do not add any chemical additives or use engine oils with a grade of CD c or higher and do not use oils labeled ENERGY CON SERVING II d or higher Do not add any chemical additives Engine oil also lubricates the clutch and additives could cause clutch slippage Do not allow foreign material to enter the crankcase È For CDN É For Europe Oceania 4 Start the engine warm it up...

Page 93: ...l min utes and then turn it off 3 Place a container under the engine oil drain bolt 4 Remove engine oil filler cap 1 dipstick 2 2 1 5 Remove engine oil drain bolt oil tank 1 along with the washer 1 6 Remove engine oil drain bolt crankcase 1 along with the gasket 1 7 Remove oil filter element drain bolt 1 8 Drain engine oil completely from the oil tank and the crank case 1 ...

Page 94: ...ter element cover 10 Check engine oil drain bolt gasket Damage Replace 11 Install engine oil drain bolt crankcase along with the gasket engine oil drain bolt oil tank along with the washer oil filter element drain bolt 12 Fill oil tank with the specified amount of the recom mended engine oil crankcase with the specified amount of the recom mended engine oil T R Oil filter element cover bolt 10 Nm ...

Page 95: ...1 95 L 1 72 Imp qt 2 06 US qt Quantity in oil tank 1 55 L 1 36 Imp qt 1 64 US qt Quantity in crankcase 0 40 L 0 35 Imp qt 0 42 US qt Periodic oil replacement Total amount 1 75 L 1 54 Imp qt 1 85 US qt Quantity in oil tank 1 55 L 1 36 Imp qt 1 64 US qt Quantity in crankcase 0 20 L 0 18 Imp qt 0 21 US qt With oil filter element replace ment Total amount 1 85 L 1 63 Imp qt 1 96 US qt Quantity in oil ...

Page 96: ...he engine oil passages the oil filter element and the oil pump for damage or leakage Refer to OIL PUMP in chapter 4 d Start the engine after solving the problem s and check the engine oil pressure again e Tighten the oil gallery bolt to specification 18 Install engine skid plate Refer to SEAT FENDERS AND FUEL TANK T R Oil gallery bolt 10 Nm 1 0 m kg 7 2 ft lb 1 EBS00070 ADJUSTING THE CLUTCH CABLE ...

Page 97: ...able use the adjusting nut on the engine side Direction a Clutch cable free play is increased Direction b Clutch cable free play is decreased a b 1 Engine side a Slide back the rubber cover 2 b Loosen the locknut 3 c Turn the adjusting nut 4 in direction c or d until the specified clutch cable free play is obtained d Tighten the locknut e Slide the rubber cover to its original posi tion Direction ...

Page 98: ...s in this hose clean the air filter element and air fil ter case 1 Remove seat Refer to SEAT FENDERS AND FUEL TANK 1 2 Remove air filter case cover 1 1 3 Remove wing bolt 1 air filter element 2 air filter element frame 3 CAUTION _ The engine should never be run without the air filter excessive piston and or cylinder wear may result 4 Check air filter element Damage Replace 2 1 3 2 ...

Page 99: ... CAUTION _ Do not twist or wring out the element This could damage the foam material c Apply engine oil to the element d Squeeze out the excess oil NOTE _ The element should be wet but not dripping 6 Install air filter element frame 7 Apply Lithium soap based grease On the matching surface a on air filter ele ment 8 Install air filter element wing bolt NOTE _ Make sure its sealing surface matches ...

Page 100: ... check and if necessary correct the antifreeze concentration of the coolant Use only distilled water However soft water may be used if distilled water is not available 4 Start the engine warm it up for several min utes and then turn it off 5 Check coolant level NOTE _ Before checking the coolant level wait a few minutes until the coolant has settled b a EBS00075 CHANGING THE COOLANT 1 Remove seat ...

Page 101: ...njury When the engine has cooled open the radiator cap as follows Place a thick rag or a towel over the radia tor cap and slowly turn the radiator cap counterclockwise toward the detent to allow any residual pressure to escape When the hissing sound has stopped press down on the radiator cap and turn it counterclockwise to remove 1 8 Remove coolant drain bolt 1 along with the copper washer 9 Drain...

Page 102: ... Adding water instead of coolant lowers the antifreeze content of the coolant If water is used instead of coolant check and if necessary correct the antifreeze concentration of the coolant Use only distilled water However if dis tilled water is not available soft water may be used If coolant comes into contact with painted surfaces immediately wash them with water Do not mix different types of ant...

Page 103: ...l coolant reservoir cap 16 Start the engine warm it up for several min utes and then stop it 17 Check coolant level Refer to CHECKING THE COOLANT LEVEL NOTE _ Before checking the coolant level wait a few minutes until the coolant has settled 18 Install right side cover fuel tank cover seat Refer to SEAT FENDERS AND FUEL TANK a ...

Page 104: ...tch ON and the engine stop switch to RUN Coolant temperature warning light does not come on Coolant temperature warning light comes on Push start switch with transmission in neutral Coolant temperature warning light comes on momentarily Coolant temperature warning light does not come on Check the electrical circuit Refer to SIGNAL SYSTEM in chapter 8 Coolant temperature and electrical circuit are ...

Page 105: ...n a ADJUSTING THE BRAKE LEVER 1 Adjust brake lever position a a While pushing the brake lever forward loosen the locknut 1 b While pushing the brake lever forward turn the adjusting bolt 2 in direction b or c until the brake lever is in the desired posi tion c Tighten the locknut CAUTION Be sure to tighten the locknut as failing to do so will cause poor brake performance 2 1 a b c EBS00085 ADJUSTI...

Page 106: ...re the locknut to adjusting bolt clearance a does not exceed 2 2 3 2 mm 0 09 0 13 in WARNING _ After this adjustment is performed lift the front and rear wheels off the ground by placing a block under the engine and spin the rear wheels to ensure there is no brake drag If any brake drag is noticed perform the above steps again 2 1 a ADJUSTING THE PARKING BRAKE 1 Check parking brake cable end lengt...

Page 107: ...ance is felt g Turn it 1 8 counterclockwise h Tighten the locknut 1 i Slide the rubber cover to its original posi tion WARNING After this adjustment is performed lift the rear wheels off the ground by placing a block under the engine and spin the rear wheels to ensure there is no brake drag If any brake drag is noticed perform the above steps again T R Locknut 16 Nm 1 6 m kg 11 ft lb 1 2 4 5 a b 3...

Page 108: ...may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock CAUTION _ Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately NOTE _ In order to ensu...

Page 109: ... BRAKES in chapter 7 3 Operate the brake lever 4 Install front wheels Refer to FRONT AND REAR WHEELS in chapter 7 Brake pad wear limit a 1 0 mm 0 04 in EBS00089 CHECKING THE REAR BRAKE PADS 1 Check brake pads Wear indicator 1 almost touch the brake disc Replace the brake pads as a set Refer to FRONT AND REAR BRAKES in chapter 7 2 Operate the brake pedal Brake pad wear limit a 1 0 mm 0 04 in ...

Page 110: ...Check rear brake light operation timing Incorrect Adjust 2 Adjust rear brake light operation timing a Hold the main body 1 of the rear brake light switch so that it does not rotate and turn the adjusting nut 2 in direction a or b until the rear brake light comes on at the proper time Direction a Brake light comes on sooner Direction b Brake light comes on later 1 2 a b EBS00092 CHECKING THE BRAKE ...

Page 111: ...ses Apply the brake lever or brake pedal sev eral times Fluid leakage Replace the hoses Refer to FRONT AND REAR BRAKES in chapter 7 6 Install front fender side covers left and right fuel tank cover seat Refer to SEAT FENDERS AND FUEL TANK 1 1 1 2 EBS00094 BLEEDING THE HYDRAULIC BRAKE SYSTEM WARNING _ Bleed the hydraulic brake system when ever the system is disassembled a brake hose is loosened dis...

Page 112: ...in the hose have disappeared 1 Bleed hydraulic brake system a Fill the brake fluid reservoir to the proper level with the recommended brake fluid b Install the diaphragm brake master cylinder reservoir or brake fluid reservoir c Connect a clear plastic hose 1 tightly to the bleed screw 2 È Front É Rear d Place the other end of the hose into a con tainer e Slowly apply the brake lever or brake peda...

Page 113: ...nded brake fluid Refer to CHECKING THE BRAKE FLUID LEVEL WARNING _ After bleeding the hydraulic brake system check the brake operation T R Bleed screw 6 Nm 0 6 m kg 4 3 ft lb EBS00098 ADJUSTING THE SHIFT PEDAL 1 Measure shift pedal height a Out of specification Adjust Shift pedal height 25 mm 0 98 in a 2 Adjust shift pedal position a Loosen the bolt 1 b Remove the shift pedal 2 c Install the shift...

Page 114: ...he speci fied limits 1 Elevate the rear wheels by placing the suit able stand under the frame 2 Measure drive chain slack a Out of specification Adjust Drive chain slack 25 35 mm 0 98 1 38 in a 3 Adjust drive chain slack a Loosen the hub nuts 1 b Loosen the locknuts 2 c Turn both adjusting bolts 3 in direction a or b until the specified drive chain slack is obtained NOTE To maintain the proper axl...

Page 115: ...BS00106 CHECKING THE STEERING SYSTEM 1 Place the machine on a level surface 2 Check steering assembly bushings Move the handlebar up and down and or back and forth Excessive play Replace the steering stem bushings 3 Check tie rod ends Turn the handlebar to the left and right until it stops completely and then move the han dlebar slightly in the opposite direction Tie rod end s 1 have vertical play...

Page 116: ...ly opposite one another f Measure the width É between the marks g Calculate the toe in using the formula given below h If the toe in is incorrect adjust it Ê Forward 3 Adjust toe in WARNING _ Be sure that both tie rods are turned the same amount If not the machine will drift right or left even though the handlebar is positioned straight This may lead to mis handling and an accident After setting t...

Page 117: ... machine on a level surface 2 Check damper rod 1 Bends damage Replace the front rear shock absorber assembly oil leakage Excessive oil leakage Replace the front rear shock absorber assembly gas cylinder Damage gas leaks the front rear shock absorber assembly spring Fatigue the front rear shock absorber assembly Refer to FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES and REAR SHOCK ABSORBER AND REL...

Page 118: ...ing 2 in direction a or b NOTE _ Be sure to remove all dirt and mud from around the locknut and adjusting ring before adjustment The length of the spring installed changes 1 5 mm 0 06 in per turn of the adjuster CAUTION _ Never attempt to turn the adjusting ring beyond the maximum or minimum setting d Tighten the locknut 1 with a steering nut wrench 3 NOTE Set the torque wrench at a right angle to...

Page 119: ... 0 m kg 22 ft lb 2 Adjust rebound damping force a Turn the adjusting screw 1 in direction a or b CAUTION _ Do not force the adjuster past the minimum or maximum extent of adjustment The adjuster may be damaged Direction a Rebound damping force is increased Direction b Rebound damping force is decreased From the fully turned in position Standard 12 clicks out Minimum 22 clicks out Maximum 1 click o...

Page 120: ...aximum extent of adjustment The adjuster may be damaged Direction a Compression damping force is increased Direction b Compression damping force is decreased From the fully turned in position Standard 11 clicks out Minimum 22 clicks out Maximum 1 click out 1 b a EBS00111 ADJUSTING THE REAR SHOCK ABSORBER 1 Remove seat Refer to SEAT FENDERS AND FUEL TANK 2 Loosen the clamp screw 1 and then dis conn...

Page 121: ...om around the locknut and adjusting ring before adjustment The length of the spring installed changes 1 5 mm 0 06 in per turn of the adjuster CAUTION _ Never attempt to turn the adjusting ring beyond the maximum or minimum setting d Tighten the locknut 1 with a steering nut wrench 3 NOTE Set the torque wrench at a right angle to the steering nut wrench Direction a Spring preload is increased suspe...

Page 122: ...rebound damping force a Turn the adjusting screw 1 in direction a or b NOTE Make sure that the position indicator marks c are aligned when the shock absorber is set to the standard setting CAUTION _ Do not force the adjuster past the minimum or maximum extent of adjustment The adjuster may be damaged Direction a Rebound damping force is increased Direction b Rebound damping force is decreased Mini...

Page 123: ...ting CAUTION _ Do not force the adjuster past the minimum or maximum extent of adjustment The adjuster may be damaged 8 Install seat Refer to SEAT FENDERS AND FUEL TANK Direction a Compression damping force is increased Direction b Compression damping force is decreased Minimum soft Adjusting screw fully turned out Standard Adjusting screw 1 3 4 turns out from the fully turned in position Maximum ...

Page 124: ... psi Rear 35 kPa 0 35 kg cm2 5 0 psi 2 Tire pressure below the minimum speci fication could cause the tire to dislodge from the rim under severe riding condi tions The following are minimums Front 27 kPa 0 27 kg cm2 3 9 psi Rear 32 kPa 0 32 kg cm2 4 5 psi 3 Use no more than Front 250 kPa 2 5 kg cm2 36 psi Rear 250 kPa 2 5 kg cm2 36 psi when seating the tire beads Higher pressures may cause the tir...

Page 125: ...e and may cause loss of control Maintain proper tire pressures Set tire pressures when the tires are cold Tire pressures must be equal in both front tires and equal in both rear tires 2 Check tire surfaces Wear damage Replace WARNING _ It is dangerous to ride with a worn out tire When tire wear is out of specification replace the tire immediately Cold tire pressure Front Rear Standard 30 kPa 0 30 ...

Page 126: ...self properly on the rim EBS00117 CHECKING AND LUBRICATING THE CABLES WARNING _ A damaged cable sheath may cause corro sion and interfere with the cable move ment An unsafe condition may result so replace a damaged cable as soon as possi ble 1 Check cable sheath Damage Replace 2 Check cable operation Unsmooth operation Lubricate or replace NOTE _ Hold the cable end up and apply several drops of lu...

Page 127: ...J LUBRICATING THE LEVERS AND PEDALS EBS00118 LUBRICATING THE LEVERS AND PEDALS Lubricate the pivoting point and metal to metal moving parts of the levers and pedals Recommended lubricant Lithium soap based grease ...

Page 128: ...r permanent eye injury FIRST AID IN CASE OF BODILY CONTACT EXTERNAL Skin Wash with water Eyes Flush with water for 15 minutes and get immediate medical attention INTERNAL Drink large quantities of water or milk fol lowed with milk of magnesia beaten egg or vegetable oil Get immediate medical attention CAUTION _ This is a sealed battery Never remove the sealing caps because the balance between cell...

Page 129: ...t the battery terminals 1 Remove seat Refer to SEAT FENDERS AND FUEL TANK 2 Disconnect battery leads from the battery terminals CAUTION _ First disconnect the negative battery lead 1 and then the positive battery lead 2 3 Remove battery holding bracket Refer to SEAT FENDERS AND FUEL TANK 4 Remove battery 5 Check battery charge a Connect a pocket tester to the battery termi nals Positive tester pro...

Page 130: ... method illustration WARNING _ Do not quick charge a battery CAUTION _ Never remove the MF battery sealing caps Do not use a high rate battery charger since it forces a high amperage current into the battery quickly and can cause battery overheating and battery plate damage If it is impossible to regulate the charging current on the battery charger be careful not to overcharge the battery When cha...

Page 131: ...ad clip may generate heat in the contact area and a weak clip spring may cause sparks If the battery becomes hot to the touch at any time during the charging process disconnect the battery charger and let the battery cool before reconnecting it Hot batteries can explode As shown in the following illustration the open circuit voltage of an MF battery sta bilizes about 30 minutes after charging has ...

Page 132: ...HARGING THE BATTERY If the amperage does not exceed the standard charging amperage after 5 minutes replace the battery If the required charging time exceeds 5 hours it is advisable to check the charging amperage after 5 hours If there is any change in the amperage readjust the voltage to obtain the standard charging amperage Leave the battery unused for more than 30 minutes before measuring its op...

Page 133: ... the battery Charge the battery until the charging voltage reaches 15 V This type of battery charger cannot charge an MF battery A variable volt age charger is recommended Leave the battery unused for more than 30 minutes before measuring its open cir cuit voltage 12 8 V Charging is complete 12 0 12 7 V Recharging is required Under 12 0 V Replace the battery Constant amperage chargers are not suit...

Page 134: ... battery leads to the battery terminals CAUTION _ First connect the positive battery lead 1 and then the negative battery lead 2 10 Check battery terminals Dirt Clean with a wire brush Loose connection Connect properly 11 Lubricate battery terminals 12 Install seat Refer to SEAT FENDERS AND FUEL TANK Recommended lubricant Dielectric grease 1 2 ...

Page 135: ...UEL 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 b If the pocket tester indicates replace the fuse 3 Replace blown fuse a Set the main switch to OFF b Install a new fuse of the correct amperage c Set on the switches to verify if the electrical circuit is operational d If the fuse immediately blows again check the el...

Page 136: ...age to the electrical system cause the lighting and ignition systems to malfunction and could possibly cause a fire 4 Install seat Refer to SEAT FENDERS AND FUEL TANK Items Amperage rating Q ty Main 15 A 1 Reserve 15 A 1 EBS00122 ADJUSTING THE HEADLIGHT BEAM 1 Adjust headlight beam vertically a Turn the adjusting bolt 1 in direction a or b Direction a Headlight beam is raised Direction b Headlight...

Page 137: ... 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 Install bulb Secure the new bulb with the headlight unit CAUTION _ Avoid touching the glass part of the bulb Keep it free from oil otherwise the trans parency of the glass life of the bulb and luminous flux will be adversely ...

Page 138: ...nstall bulb holder headlight bulb holder cover 1 NOTE After installing the bulb holder cover make sure that the TOP mark a is in the position shown 7 Connect headlight lead coupler 2 8 Install headlight Refer to SEAT FENDERS AND FUEL TANK 2 1 a ...

Page 139: ...ENG 4 ...

Page 140: ...CHECKING THE CYLINDER HEAD 4 20 CHECKING THE OIL DELIVERY PIPE 4 21 CHECKING THE TIMING CHAIN GUIDE 4 21 INSTALLING THE CYLINDER HEAD 4 21 VALVES AND VALVE SPRINGS 4 24 REMOVING THE VALVES AND VALVE SPRINGS 4 26 CHECKING THE VALVES AND VALVE SPRINGS 4 27 CHECKING THE VALVE LIFTERS 4 32 INSTALLING THE VALVES AND VALVE SPRINGS 4 32 CYLINDER AND PISTON 4 34 REMOVING THE PISTON 4 35 CHECKING THE CYLIN...

Page 141: ...ING THE BALANCER 4 56 INSTALLING THE BALANCER DRIVE GEAR AND BALANCER DRIVEN GEAR 4 57 OIL PUMP 4 58 CHECKING THE OIL PUMP 4 60 SHIFT SHAFT 4 61 CHECKING THE SHIFT SHAFT 4 63 CHECKING THE STOPPER LEVER 4 63 CHECKING THE SHIFT GUIDE AND SHIFT LEVER 4 63 CHECKING THE SHIFT DRUM SEGMENT 4 63 INSTALLING THE SHIFT LEVER 4 63 INSTALLING THE SHIFT SHAFT 4 64 CRANKCASE 4 65 OIL SEAL AND BEARING 4 67 SEPAR...

Page 142: ...MISSION 4 75 MAIN AXLE 4 76 DRIVE AXLE 4 77 CHECKING THE SHIFT FORKS 4 78 CHECKING THE SHIFT DRUM 4 78 CHECKING THE TRANSMISSION 4 78 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 4 79 INSTALLING THE TRANSMISSION 4 80 ...

Page 143: ...ENG ...

Page 144: ...New 3 6 Order Job Part Q ty Remarks Removing the muffler and exhaust pipe Remove the parts in the order listed Seat fuel tank cover side covers left and right Refer to SEAT FENDERS AND FUEL TANK in chapter 3 Fuel tank Right foot protector engine skid plate 1 Clamp 1 Loosen Refer to INSTALLING THE EXHAUST PIPE AND MUFFLER 2 Muffler 1 3 Muffler protector 1 4 Gasket 1 5 Exhaust pipe 1 6 Exhaust pipe ...

Page 145: ... exhaust pipe protector screws NOTE Tighten the screws to the specified torque in the proper tightening sequence as shown 3 Install exhaust pipe 1 nut exhaust pipe 2 bolt exhaust pipe 3 NOTE First temporarily tighten the nut exhaust pipe then tighten the bolt exhaust pipe 20 Nm 2 0 m kg 14 ft lb After that retighten the nut exhaust pipe 13 Nm 1 3 m kg 9 4 ft lb and then the bolt exhaust pipe 24 Nm...

Page 146: ... ENG 4 Install clamp NOTE Slide the clamp onto the end of the muffler and insert the projection a of the clamp into a slot b in the muffler Tighten the clamp after installing the muffler a b ENGINE REMOVAL ...

Page 147: ...y Remarks Removing the leads cables and hoses Remove the parts in the order listed Engine oil Drain Coolant Drain Radiator outlet hose water pump inlet pipe Refer to WATER PUMP in chapter 5 Carburetor Refer to CARBURETOR in chapter 6 Drive sprocket drive chain Refer to SWINGARM AND DRIVE CHAIN in chapter 7 1 Ignition coil 1 2 Cylinder head breather hose 1 3 Oil tank breather hose 1 4 Radiator inle...

Page 148: ...5 8 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib Order Job Part Q ty Remarks 6 Starter motor lead 1 Disconnect 7 Battery negative lead 1 Disconnect 8 Clutch cable 1 9 Parking brake cable 1 10 Oil pipe 1 1 11 A C magneto coupler 2 Disconnect 12 Plastic band 2 13 Oil pipe 2 1 14 Neutral switch lead 1 Disconnect For installation reverse the removal pro cedure ...

Page 149: ...rks Removing the engine mounting bolts Remove the parts in the order listed 1 Engine lower bracket bolt 4 CAUTION _ Install all of the bolts nuts and then tighten them to full torque specifica tions 2 Engine mounting bolt middle nut 1 1 3 Engine lower bracket right 1 4 Engine lower bracket left 1 5 Engine mounting bolt lower nut 1 1 6 Engine upper bracket bolt 2 7 Engine stay bolt washer 2 2 8 Eng...

Page 150: ... ft lb T R 33 Nm 3 3 m kg 24 ft Ib T R 66 Nm 6 6 m kg 48 ft Ib T R 38 Nm 3 8 m kg 27 ft Ib T R 38 Nm 3 8 m kg 27 ft Ib T R 66 Nm 6 6 m kg 48 ft Ib Order Job Part Q ty Remarks 13 Engine assembly 1 NOTE _ Remove the engine assembly from the right side of the machine For installation reverse the removal pro cedure ENGINE REMOVAL ...

Page 151: ...t engine mounting bolt middle nut 9 engine lower bracket bolts 0 NOTE _ Do not fully tighten the bolts and nuts 2 Tighten pivot shaft nut 1 engine mounting bolt upper 3 engine stay bolts 5 engine upper bracket bolts 6 engine mounting bolt lower nut 7 engine mounting bolt middle nut 9 engine lower bracket bolts 0 6 4 5 2 3 1 7 9 8 0 T R 100 Nm 10 0 m kg 72 ft lb T R 40 Nm 4 0 m kg 29 ft lb T R 33 N...

Page 152: ...k cover side covers left and right Refer to SEAT FENDERS AND FUEL TANK in chapter 3 1 Spark plug 1 2 Engine upper bracket right 1 3 Engine upper bracket left 1 4 Engine stay 1 5 Cylinder head breather hose 1 6 Oil tank breather hose 1 7 Cylinder head cover 1 8 Cylinder head cover gasket 1 9 Timing chain guide top side 1 For installation reverse the removal pro cedure ...

Page 153: ...in the order listed 1 Tensioner cap bolt 1 Refer to REMOVING THE CAM SHAFTS and INSTALLING THE CAM SHAFTS 2 Timing chain tensioner 1 3 Gasket 1 4 Exhaust camshaft cap 1 5 Clip 1 6 Exhaust camshaft 1 7 Intake camshaft cap 1 8 Clip 1 9 Intake camshaft 1 For installation reverse the removal pro cedure ...

Page 154: ...C the punch mark c on the exhaust camshaft sprocket and the punch mark d on the intake camshaft sprocket must align with the cylinder head mating surface as shown in the illustration The Top Dead Center TDC on the compres sion stroke can be found when the camshaft lobes are turned away from each other 1 2 a b 3 Loosen tensioner cap bolt 1 4 Remove timing chain tensioner 2 5 Remove camshaft cap bol...

Page 155: ...t 2 Measure camshaft lobe dimensions a and b Out of specification Replace the cam shaft Camshaft lobe dimensions Intake a 31 200 31 300 mm 1 2283 1 2323 in Limit 31 100 mm 1 2244 in b 22 550 22 650 mm 0 8878 0 8917 in Limit 22 450 mm 0 8839 in Exhaust a 30 950 31 050 mm 1 2185 1 2224 in Limit 30 850 mm 1 2146 in b 22 494 22 594 mm 0 8856 0 8895 in Limit 22 394 mm 0 8817 in 3 Measure camshaft runou...

Page 156: ...ttern working from the inner caps out Do not turn the camshaft when measuring the camshaft journal to camshaft cap clear ance with the Plastigauge d Remove the camshaft caps and then mea sure the width of the Plastigauge 1 Camshaft journal to camshaft cap clearance 0 020 0 054 mm 0 0008 0 0021 in Limit 0 080 mm 0 0032 in T R Camshaft cap bolt 10 Nm 1 0 m kg 7 2 ft lb 5 Measure camshaft journal dia...

Page 157: ...n as a set a 1 4 of a tooth b Correct 1 Roller 2 Sprocket EBS00225 CHECKING THE DECOMPRESSION SYSTEM 1 Check decompression system a Check that the decompressor lever pin 1 projects from the camshaft b Check that the decompressor cam 2 moves smoothly EBS00226 CHECKING THE TIMING CHAIN GUIDE 1 Check timing chain guide top side Wear damage Replace ...

Page 158: ... INSTALLING THE CAMSHAFTS 1 Install exhaust camshaft 1 intake camshaft 2 a Turn the crankshaft counterclockwise until the I mark a on the rotor is aligned with the stationary pointer b on the A C mag neto cover b Fit the timing chain 3 onto both camshaft sprockets and install the camshafts on the cylinder head NOTE The camshafts should be installed onto the cylinder head so that the exhaust camsha...

Page 159: ...ain tensioner a While lightly pressing the timing chain ten sioner rod by hand turn the tensioner rod fully clockwise with a thin screwdriver 1 b With the timing chain tensioner rod turned all the way into the timing chain tensioner housing with the thin screwdriver still installed install the gasket and the timing chain tensioner 2 onto the cylinder block NOTE _ The UP mark a on the timing chain ...

Page 160: ...djust Refer to INSTALLING THE CAMSHAFTS 6 Measure valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEARANCE in chapter 3 T R Tensioner cap bolt 7 Nm 0 7 m kg 5 1 ft lb 7 Install timing chain guide top side cylinder head cover gasket cylinder head cover NOTE Apply Sealant Quick Gasket or Yamaha bond No 1215 1 onto the mating surfaces of the cylinder head cover and cylinder ...

Page 161: ...EAT FENDERS AND FUEL TANK in chapter 3 Muffler and exhaust pipe Refer to MUFFLER AND EXHAUST PIPE Radiator inlet hose parking brake and clutch cable holder Refer to LEADS CABLES AND HOSES Parking brake holder Carburetor Refer to CARBURETOR in chapter 6 Camshafts Refer to CAMSHAFTS 1 Radiator inlet hose 1 2 Cylinder head water jacket 1 3 Oil delivery pipe 1 1 Refer to INSTALLING THE CYLINDER HEAD ...

Page 162: ...proper tightening sequence and then tighten the cylinder head bolts further in two steps of 90 to reach the specified angle of 180 in the proper tightening sequence Order Job Part Q ty Remarks 4 Cylinder head 1 Refer to REMOVING THE CYLINDER HEAD and INSTALLING THE CYLIN DER HEAD 5 Cylinder head gasket 1 6 Dowel pin 2 7 Timing chain guide exhaust side 1 For installation reverse the removal pro ced...

Page 163: ...o avoid damag ing or scratching spark plug bore threads valve seats 2 Check cylinder head Damage scratches Replace cylinder head water jacket Mineral deposits rust Eliminate 3 Measure cylinder head warpage Out of specification Resurface the cylin der head a Place a straightedge 1 and a thickness gauge 2 across the cylinder head b Measure the warpage c If the limit is exceeded resurface the cylin d...

Page 164: ...elivery pipe 1 Cracks damage Replace Clogged Blow out with compressed air CHECKING THE TIMING CHAIN GUIDE 1 Check timing chain guide exhaust side Wear damage Replace INSTALLING THE CYLINDER HEAD 1 Install timing chain guide exhaust side gasket dowel pins 2 Install cylinder head NOTE Pass the timing chain through the timing chain cavity New ...

Page 165: ...nkcase b Apply molybdenum disulfide grease on the threads and contact surfaces of the bolts and on both contact surfaces of the wash ers c Install the washers and bolts d Tighten the bolts to the specified torque in two or three steps in the proper tightening sequence as shown e Remove the bolts f Again apply molybdenum disulfide grease on the threads and contact surfaces of the bolts and on both ...

Page 166: ...two steps to reach the specified angle of 180 in the proper tightening sequence as shown 4 Install cylinder head nuts T R Cylinder head bolts Final Specified angle 180 1 2 180 T R 10 Nm 1 0 m kg 7 2 ft lb 5 Install copper washers oil delivery pipe 1 1 union bolts M8 2 union bolt M10 3 2 1 2 3 New T R 18 Nm 1 8 m kg 13 ft lb T R 20 Nm 2 0 m kg 14 ft lb ...

Page 167: ...d valve springs Remove the parts in the order listed Cylinder head Refer to CYLINDER HEAD 1 Valve lifter 5 Refer to REMOVING THE VALVES AND VALVE SPRINGS and INSTALLING THE VALVES AND VALVE SPRINGS 2 Adjusting pad 5 3 Valve cotter 10 4 Upper valve spring seat 5 5 Exhaust valve spring 2 red 6 Intake valve spring 3 blue ...

Page 168: ...tem seal 5 Refer to REMOVING THE VALVES AND VALVE SPRINGS and INSTALLING THE VALVES AND VALVE SPRINGS 8 Lower valve spring seat 5 9 Exhaust valve 2 10 Intake valve 1 1 76 3 mm 3 00 in 11 Intake valve 2 2 77 2 mm 3 04 in For installation reverse the removal pro cedure ...

Page 169: ...sition of each valve lifter and valve pad so that they can be reinstalled in their original place 2 Check valve sealing Leakage at the valve seat Check the valve face valve seat and valve seat width Refer to CHECKING THE VALVES AND VALVE SPRINGS a Pour a clean solvent a into the intake and exhaust ports b Check that the valve seals properly There should be no leakage at the valve seat 1 3 Remove v...

Page 170: ...dentify the position of each part very carefully so that it can be reinstalled in its original place EBS00240 CHECKING THE VALVES AND VALVE SPRINGS 1 Measure stem to guide clearance Out of specification Replace the valve guide Stem to guide clearance valve guide inside diameter a valve stem diameter b Stem to guide clearance Intake 0 010 0 037 mm 0 0004 0 0015 in Limit 0 080 mm 0 003 in Exhaust 0 ...

Page 171: ...he valve guide using a valve guide reamer 3 to obtain proper stem to guide clearance NOTE _ After replacing the valve guide reface the valve seat 3 Check valve face Pitting wear Grind the face valve stem end Mushroom shape or diameter larger than the body of the stem Replace Valve guide remover Intake ø 4 5 P N YM 04116 90890 04116 Exhaust ø 5 P N YM 04097 90890 04097 Valve guide installer Intake ...

Page 172: ...eal 6 Eliminate carbon deposits from the valve face and valve seat 7 Check valve seats Pitting wear Reface the valve seat Margin thickness Intake 1 0 mm 0 0394 in Limit 0 85 mm 0 033 in Exhaust 1 0 mm 0 0394 in Limit 0 85 mm 0 033 in Valve stem runout 0 01 mm 0 0004 in 8 Measure valve seat width a Out of specification Reface the valve seat Valve seat width Intake 0 9 1 1 mm 0 0354 0 0433 in Limit ...

Page 173: ...valve and valve guide the valve seat and valve face should be lapped a Apply a coarse lapping compound to the valve face CAUTION _ Do not let the compound enter the gap between the valve stem and the valve guide b Apply molybdenum disulfide oil to 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...

Page 174: ...and relap the valve seat 10 Measure valve spring free length a Out of specification Replace Valve spring free length Intake 37 03 mm 1 46 in Limit 35 17 mm 1 38 in Exhaust 37 68 mm 1 48 in Limit 35 79 mm 1 41 in 11 Measure compressed valve spring force a Out of specification Replace b Installed length Compressed valve spring force installed Intake 111 3 127 9 N at 27 87 mm 11 35 13 04 kg at 27 87 ...

Page 175: ...re applies to all of the valve lifters 1 Check valve lifter Damage scratches Replace the valve lift ers and cylinder head EBS00241 INSTALLING THE VALVES AND VALVE SPRINGS 1 Apply molybdenum disulfide oil onto the valve stem and valve stem seal 2 Install valves lower valve spring seats valve stem seals valve springs upper valve spring seats NOTE _ Install the valve springs with the larger pitch a f...

Page 176: ...e of wood CAUTION _ Hitting the valve tip with excessive force could damage the valve 5 Install valve pads valve lifters NOTE Lubricate the valve lifters with engine oil and valve pads with molybdenum disulfide oil The valve lifters must move smoothly when rotated with a finger Each valve lifter and valve pad must be rein stalled in its original position Valve spring compressor P N YM 04019 90890 ...

Page 177: ...e order listed Cylinder head Refer to CYLINDER HEAD 1 Cylinder 1 Refer to INSTALLING THE CYLINDER 2 Cylinder gasket 1 3 Dowel pin 2 4 Dowel pin O ring 1 1 5 Piston pin clip 2 Refer to REMOVING THE PISTON and INSTALLING THE PISTON 6 Piston pin 1 7 Piston 1 8 Top ring 1 9 2nd ring 1 10 Oil ring 1 For installation reverse the removal pro cedure ...

Page 178: ...lt to remove use the piston pin puller 4 CAUTION _ Do not use a hammer to drive the piston pin out 2 Remove piston rings NOTE _ Spread the end gaps apart while at the same time lifting the piston ring over the top of the piston crown as shown in the illustration Piston pin puller P N YU 01304 90890 01304 EBS00248 CHECKING THE CYLINDER AND PISTON 1 Check piston wall cylinder wall Vertical scratches...

Page 179: ... mm 0 39 in from the bottom edge of the pis ton d If out of specification replace the piston and piston rings as a set e Calculate the piston to cylinder clearance with the following formula Cylinder bore C 95 00 95 01 mm 3 7402 3 7406 in Taper limit T 0 05 mm 0 002 in Out of round R 0 05 mm 0 002 in C Maximum D T Maximum D1 or D2 Maximum D5 or D6 R Maximum D1 D3 or D5 Minimum D2 D4 or D6 Piston s...

Page 180: ...piston rings as a set NOTE _ Before measuring the piston ring side clear ance eliminate any carbon deposits from the piston ring grooves and piston rings Piston ring side clearance Top ring 0 030 0 065 mm 0 0012 0 0026 in Limit 0 12 mm 0 0047 in 2nd ring 0 020 0 055 mm 0 0008 0 0022 in Limit 0 12 mm 0 0047 in 2 Install piston ring into the cylinder NOTE _ Level the piston ring into the cylinder wi...

Page 181: ...l ring rail s gap is exces sive replace all three piston rings Piston ring end gap Top ring 0 20 0 30 mm 0 008 0 012 in Limit 0 55 mm 0 022 in 2nd ring 0 35 0 50 mm 0 014 0 020 in Limit 0 85 mm 0 034 in Oil ring 0 20 0 50 mm 0 008 0 020 in EBS00251 CHECKING THE PISTON PIN 1 Check piston pin Blue discoloration grooves Replace the piston pin and then check the lubrication system ...

Page 182: ... mm 0 7870 0 7874 in Limit 19 971 mm 0 786 in Piston pin bore inside diameter 20 004 20 015 mm 0 7876 0 7880 in Limit 20 045 mm 0 789 in 4 Calculate piston pin to piston pin bore clearance Out of specification Replace the piston pin and piston as a set Piston pin to piston pin bore clearance Piston pin bore diameter b Piston pin outside diameter a Piston pin to piston clearance 0 004 0 024 mm 0 00...

Page 183: ...piston ring end gaps as shown a Top ring end b 2nd ring end c Oil ring end upper d Oil ring e Oil ring end lower a b c e d 90 45 45 3 Install piston 1 piston pin 2 piston pin clips 3 NOTE _ Apply engine oil onto the piston pin piston rings and piston Be sure that the punch mark a on the piston points to the exhaust side of the engine Before installing the piston pin clips cover the crankcase with ...

Page 184: ...HE CYLINDER 1 Install cylinder gasket 1 dowel pins O ring cylinder 2 bolts NOTE _ Install the cylinder with one hand while com pressing the piston rings with the other hand CAUTION _ Be careful not to damage the timing chain damper during installation Pass the timing chain through the timing chain cavity New T R 10 Nm 1 0 m kg 7 2 ft lb ...

Page 185: ...6 5 Order Job Part Q ty Remarks Removing the A C magneto Remove the parts in the order listed Engine oil Drain Front fender Refer to SEAT FENDERS AND FUEL TANK in chapter 3 1 A C magneto coupler 2 Disconnect 2 Crankcase breather hose 1 3 Torque limiter cover 1 Refer to REMOV ING THE A C MAG NETO ROTOR and INSTALLING THE A C MAGNETO ROTOR 4 Torque limiter 1 NOTE Do not disassem ble 5 A C magneto co...

Page 186: ...8 7 9 6 15 6 12 11 10 16 14 2 13 4 3 1 5 New New New LS E 6 5 Order Job Part Q ty Remarks 9 Stator coil 1 10 Starter idle gear 1 11 Bearing 2 12 Starter idle gear shaft 1 13 A C magneto rotor 1 Refer to REMOVING THE A C MAG NETO ROTOR and INSTALLING THE A C MAGNETO ROTOR 14 Starter clutch 1 15 Woodruff key 1 16 Starter wheel gear 1 For installation reverse the removal pro cedure ...

Page 187: ...r nut 1 washer NOTE _ While holding the A C magneto rotor 2 with the sheave holder 3 loosen the rotor nut Do not allow the sheave holder to touch the projection 4 on the rotor Sheave holder P N YS 01880 A 90890 01701 3 4 1 2 3 Remove A C magneto rotor 1 NOTE _ Use the rotor puller 2 Rotor puller P N YM 04142 90890 04142 1 2 EBS00262 CHECKING THE STATOR COIL AND PICKUP COIL 1 Check stator coil pick...

Page 188: ...counter clockwise È the starter clutch and the wheel gear should be engaged If not the starter clutch is faulty Replace it c When turning the starter wheel gear clock wise É the starter wheel gear should turn freely If not the starter clutch is faulty Replace it T R Starter clutch bolt 16 Nm 1 6 m kg 11 ft lb LOCTITE 1 2 LT È É 2 Check starter idle gear teeth 1 starter wheel gear teeth 2 Burrs cli...

Page 189: ...he slot b in the A C magneto cover a b 1 2 Apply sealant Quick Gasket or Yamaha bond No 1215 1 into the slit Sealant Quick Gasket P N ACC 11001 05 01 Yamaha bond No 1215 P N 90890 85505 1 3 Install woodruff key A C magneto rotor NOTE _ Before installing the rotor clean the outside of the crankshaft and the inside of the rotor After installing the rotor check that the rotor rotates smoothly If not ...

Page 190: ...or Sheave holder P N YS 01880 A 90890 01701 3 4 1 2 T R 65 Nm 6 5 m kg 47 ft lb 5 Install gasket A C magneto cover A C magneto lead holder 1 neutral switch lead holder 2 bolts NOTE _ Tighten the A C magneto cover bolts in stages using a crisscross pattern 1 2 New T R 10 Nm 1 0 m kg 7 2 ft lb 6 Install torque limiter cover 1 NOTE Install the torque limiter cover with the projec tion a facing up 1 a...

Page 191: ...order listed Engine oil Drain Clutch cable Refer to LEADS CABLES AND HOSES 1 Clutch cover 1 Refer to REMOVING THE CLUTCH and INSTALLING THE CLUTCH 2 Gasket 1 3 Dowel pin 2 4 Clutch spring 6 Refer to INSTALLING THE CLUTCH 5 Pressure plate 1 6 Push rod 1 1 7 Circlip 1 8 Plain washer 1 9 Bearing 1 10 Ball 1 ...

Page 192: ...te 7 14 Friction plate 2 1 15 Spring washer 1 16 Seat plate 1 17 Lock washer 1 Refer to REMOVING THE CLUTCH and INSTALLING THE CLUTCH 18 Clutch boss 1 19 Thrust washer 1 20 Clutch housing 1 21 Push lever shaft 1 Refer to INSTALLING THE CLUTCH 22 Circlip washer 1 1 23 Push lever 1 For installation reverse the removal pro cedure ...

Page 193: ...s nut Universal clutch holder P N YM 91042 90890 04086 EBS00300 CHECKING THE FRICTION PLATES The following procedure applies to all of the friction plates 1 Check friction plate 1 friction plate 2 Damage wear Replace the friction plates as a set 2 Measure friction plate 1 thickness friction plate 2 thickness Out of specification Replace the friction plates as a set NOTE _ Measure the friction plat...

Page 194: ...EBS00302 CHECKING THE CLUTCH SPRINGS The following procedure applies to all of the clutch springs 1 Check clutch spring Damage Replace the clutch springs as a set 2 Measure clutch spring free length a Out of specification Replace the clutch springs as a set Clutch spring free length 51 8 mm 2 04 in Limit 50 0 mm 1 97 in EBS00303 CHECKING THE CLUTCH HOUSING 1 Check clutch housing dogs Damage pittin...

Page 195: ...ge Replace CHECKING THE PUSH RODS 1 Check push rod 1 1 bearing 2 plain washer 3 push rod 2 4 ball 5 Wear damage cracks bend Replace the defective part s CHECKING THE PUSH LEVER 1 Check push lever 1 push lever shaft 2 Damage wear Replace 2 1 EBS00307 CHECKING THE PRIMARY DRIVEN GEAR 1 Check primary driven gear Damage wear Replace the primary drive gear and clutch housing as a set Excessive noise du...

Page 196: ...the oil pump drive gear teeth and oil pump driven gear teeth mesh cor rectly b a 3 Tighten thrust washer clutch boss lock washer clutch boss nut 1 NOTE _ While holding the clutch boss 2 with the uni versal clutch holder 3 tighten the clutch boss nut 4 Bend the lock washer tab along a flat side of the nut Universal clutch holder P N YM 91042 90890 04086 New T R 75 Nm 7 5 m kg 54 ft lb 5 Install clu...

Page 197: ...h cable length a Out of specification Adjust NOTE _ Push the push lever in direction b and check the cable length a 9 Adjust clutch cable length a Remove the circlip and washer b Remove the push lever c Install the push lever so that the clutch cable length is within specification d Install the washer and a new circlip Clutch cable length 38 0 45 2 mm 1 50 1 78 in 1 a b ...

Page 198: ...er 5 A C magneto rotor Refer to A C MAGNETO 1 Primary drive gear nut 1 Refer to REMOVING THE BALANCER DRIVE GEAR AND BALANCER DRIVEN GEAR and INSTALLING THE BALANCER DRIVE GEAR AND BAL ANCER DRIVEN GEAR 2 Balancer driven gear nut 1 3 Lock washer 1 4 Primary drive gear 1 5 Balancer drive gear 1 6 Lock washer 1 7 Balancer driven gear 1 8 Balancer 1 For installation reverse the removal pro cedure ...

Page 199: ...E Place an aluminum plate a between the teeth of the balancer drive gear 3 and driven gear 4 3 Remove balancer drive gear balancer driven gear CHECKING THE PRIMARY DRIVE GEAR BALANCER DRIVE GEAR AND BALANCER DRIVEN GEAR 1 Check primary drive gear 1 balancer drive gear 2 balancer driven gear 3 Wear damage Replace CHECKING THE BALANCER 1 Check balancer Cracks damage Replace ...

Page 200: ...ark a on the balancer drive gear with the punch mark b on the bal ancer driven gear Align the punch mark c on the balancer drive gear with the shorter spline d on the crankshaft 3 Install lock washer 1 balancer driven gear nut 2 primary drive gear 3 primary drive gear nut 4 NOTE Install the primary drive gear with its stepped side b facing the engine Place an aluminum plate a between the teeth of ...

Page 201: ...ing the oil pump Remove the parts in the order listed Clutch housing Refer to CLUTCH Right crankcase cover Refer to WATER PUMP in chapter 5 1 Circlip 1 2 Washer 1 3 Oil pump drive gear 1 4 Oil pump assembly 1 5 Dowel pin 1 6 Outer rotor 2 1 7 Circlip 1 8 Inner rotor 2 1 ...

Page 202: ... Order Job Part Q ty Remarks 9 Pin 1 10 Oil pump housing cover 1 11 Outer rotor 1 1 12 Inner rotor 1 1 13 Pin 1 14 Washer 1 15 Oil pump driven gear 1 16 Oil pump housing 1 For installation reverse the removal pro cedure ...

Page 203: ...e a outer rotor to oil pump housing clearance b Out of specification Replace the oil pump 1 inner rotor 2 outer rotor 3 oil pump housing Inner rotor to outer rotor tip clearance 0 07 0 12 mm 0 0028 0 0047 in Limit 0 20 mm 0 0079 in Outer rotor to oil pump housing clearance 0 09 0 17 mm 0 0035 0 0067 in Limit 0 24 mm 0 0094 in 3 Check oil pump operation Unsmooth Repeat steps 1 and 2 or replace the ...

Page 204: ...order listed Clutch Refer to CLUTCH Oil pump drive gear Refer to OIL PUMP 1 Shift pedal 1 Refer to INSTALLING THE SHIFT SHAFT 2 Shift shaft 1 3 Shift shaft spring washer 1 1 4 Roller 1 Refer to INSTALLING THE SHIFT LEVER 5 Shift guide 1 6 Shift lever assembly 1 7 Pawl holder 1 8 Pawl 2 9 Pawl pin 2 10 Spring 2 ...

Page 205: ...4 62 ENG SHIFT SHAFT Order Job Part Q ty Remarks 11 Stopper lever 1 Refer to INSTALLING THE SHIFT LEVER 12 Stopper lever spring 1 13 Shift drum segment 1 For installation reverse the removal pro cedure ...

Page 206: ...stopper lever stopper spring 2 Damage wear Replace EBS00359 CHECKING THE SHIFT GUIDE AND SHIFT LEVER 1 Check shift guide 1 pawl holder 2 pawls 3 pawl pins 4 springs 5 Wear cracks damage Replace CHECKING THE SHIFT DRUM SEGMENT 1 Check shift drum segment Damage wear Replace INSTALLING THE SHIFT LEVER 1 Install shift drum segment 1 shift drum segment bolt NOTE Align the notch a on the shift drum segm...

Page 207: ...ever assembly 1 shift guide 2 NOTE The shift lever assembly is installed at the same time as the shift guide 1 2 T R 10 Nm 1 0 m kg 7 2 ft lb INSTALLING THE SHIFT SHAFT 1 Install roller 1 shift shaft spring shift shaft 2 NOTE Install the end of the shift shaft spring onto the shift shaft spring stopper 3 Install the end of the shift shaft lever onto the roller 1 2 Install shift pedal 3 Adjust shif...

Page 208: ... REMOVAL Camshafts Refer to CAMSHAFTS Cylinder head Refer to CYLINDER HEAD A C magneto Refer to A C MAGNETO Clutch Refer to CLUTCH Balancer Refer to BALANCER Oil pump Refer to OIL PUMP Shift drum segment Refer to SHIFT SHAFT Starter motor Refer to STARTER MOTOR in chapter 8 1 Timing chain guide intake side 1 2 Timing chain 1 3 Neutral switch 1 4 Hose guide 1 ...

Page 209: ... Q ty Remarks 5 Circlip spacer 1 1 6 Oil delivery pipe 2 1 7 Right crankcase 1 Refer to SEPARATING THE CRANK CASE 8 Left crankcase 1 9 Dowel pin O ring 1 1 10 Dowel pin 2 11 Oil stainer 1 For installation reverse the removal pro cedure ...

Page 210: ... Q ty Remarks Removing the crankcase bearings Remove the parts in the order listed Crankshaft Refer to CRANKSHAFT Transmission Refer to TRANSMISSION 1 Oil seal holder 1 2 Oil seal 3 3 Bearing retainer 13 4 Bearing 10 For installation reverse the removal pro cedure ...

Page 211: ...TE _ Insert a screwdriver or pry bar into the pry points in the crankcase and then carefully pry apart the crankcase halves CAUTION _ Use a soft hammer to tap on one side of the crankcase Tap only on reinforced portions of the crankcase Do not tap on the crank case mating surfaces Work slowly and carefully Make sure that the crankcase halves separate evenly c Remove the dowel pins and O ring EBS00...

Page 212: ...in guide intake side Wear damage Replace EBS00339 CHECKING THE BEARINGS AND OIL SEALS 1 Check bearings Clean and lubricate then rotate the inner race with a finger Roughness Replace 2 Check oil seals Damage wear Replace EBS00338 CHECKING THE CRANKCASE 1 Thoroughly wash the case halves in a mild solvent 2 Clean all the gasket mating surfaces and crankcase mating surfaces thoroughly 3 Check crankcas...

Page 213: ...ose flatten the edge a of each screw into the depres sion b using a punch etc Be careful not to damage the hole for the screwdriver in the screw head È Right crankcase É Left crankcase È New T R 10 Nm 1 0 m kg 7 2 ft lb T R 12 Nm 1 2 m kg 8 7 ft lb a b 2 1 É T R 12 Nm 1 2 m kg 8 7 ft lb 2 Apply sealant Quick Gasket or Yamaha bond No 1215 1 to the mating surfaces of both case halves 3 Install dowel...

Page 214: ...is functioning properly by manually rotating the shift drum in both directions 5 Install hose guide 1 crankcase bolts 6 Tighten crankcase bolts follow the proper tightening sequence NOTE _ Tighten the bolts in stages using a crisscross pattern 7 Apply 4 stroke engine oil to the crankshaft pin bearing and oil deliv ery hole 8 Check crankshaft and transmission operation Unsmooth operation Repair 1 T...

Page 215: ...emarks Removing the crankshaft Remove the parts in the order listed Crankcase Separate Refer to CRANKCASE 1 Crankshaft 1 Refer to REMOVING THE CRANK SHAFT and INSTALLING THE CRANK SHAFT For installation reverse the removal pro cedure CRANKSHAFT ...

Page 216: ...learance d Out of specification Replace the crank shaft 2 Measure runout c Out of specification Replace the crank shaft a The crankshaft 1 and the crankshaft pin 2 oil passages must be properly intercon nected with a tolerance of less than 1 mm 0 04 in Big end side clearance 0 15 0 45 mm 0 0059 0 0177 in Limit 0 50 mm 0 0197 in Runout limit C1 0 05 mm 0 002 in C2 0 05 mm 0 002 in d C1 C2 2 1 CRANK...

Page 217: ...stalling tool until the crankshaft bottoms against the bearing CAUTION _ Apply engine oil to each bearing to protect the crankshaft against scratches and to make installation easier Crankshaft installer pot 2 P N 90890 01274 Crankshaft installer bolt 3 P N 90890 01275 Crankshaft installer set P N YU 90050 Adapter 4 P N YM 90063 90890 01278 Spacer crankshaft installer 5 P N YM 91044 90890 04081 CRA...

Page 218: ...ing the transmission Remove the parts in the order listed Crankcase Separate Refer to CRANKCASE 1 Shift fork C 1 Refer to INSTALLING THE TRANSMIS SION 2 Shift fork R 1 3 Shift fork L 1 4 Shift drum 1 5 Main axle assembly 1 6 Spacer 1 7 Drive axle assembly 1 For installation reverse the removal pro cedure ...

Page 219: ...arts in the order listed 1 2nd pinion gear 1 Refer to ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 2 4th pinion gear 1 3 3rd pinion gear 1 4 Circlip 1 Refer to ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 5 Toothed washer 1 6 5th pinion gear 1 7 Main axle 1st pinion gear 1 For assembly reverse the disassembly procedure ...

Page 220: ... Crankcase Refer to CRANKCASE 1 1st wheel gear 1 2 5th wheel gear 1 3 Circlip 2 Refer to ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 4 Toothed washer 2 5 3rd wheel gear 1 6 Toothed spacer 1 7 Toothed lock washer 1 8 Toothed washer retainer 1 9 4th wheel gear 1 0 2nd wheel gear 1 A Drive axle 1 For assembly reverse the disassembly procedure ...

Page 221: ...ace the shift forks EBS00351 CHECKING THE SHIFT DRUM 1 Check shift drum grooves Scratches wear damage Replace EBS00354 CHECKING THE TRANSMISSION 1 Measure main axle runout with a centering device and dial gauge 1 Out of specification Replace the main axle 2 Check transmission gears Blue discoloration pitting wear Replace the defective gear s transmission gear dogs Cracks damage rounded edges Repla...

Page 222: ...rclips Bends damage looseness Replace EBS00355 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 1 Install toothed washer 1 circlip 2 NOTE _ Be sure the circlip shape edged corner a is positioned opposite side to the toothed washer and gear Be sure the circlip end b is positioned at axle spline groove c New 2 Install 2nd pinion gear 1 NOTE _ Press the 2nd pinion gear into the main axle 2 as shown in the ill...

Page 223: ...ed marks on the shift forks should face towards the right side of the engine and be in the following sequence R C L Be sure that the shift fork cam follower is properly seated in the shift drum groove 2 Check shift operation Unsmooth operation Repair NOTE _ Oil each gear and bearing thoroughly Before assembling the crankcase be sure that the transmission is in neutral and that the gears turn freel...

Page 224: ...COOL 5 ...

Page 225: ...COOL CHAPTER 5 COOLING SYSTEM RADIATOR 5 1 CHECKING THE RADIATOR 5 3 INSTALLING THE RADIATOR 5 4 WATER PUMP 5 5 CHECKING THE WATER PUMP 5 7 ...

Page 226: ...COOL ...

Page 227: ...arks Removing the radiator Remove the parts in the order listed Seat fuel tank cover side covers left and right front fender Refer to SEAT FENDERS AND FUEL TANK in chapter 3 Coolant Drain 1 Plastic band 1 2 Radiator fan coupler 1 Disconnect 3 Thermo switch 1 coupler 1 Disconnect 4 Thermo switch 1 1 5 Thermo switch 2 coupler 1 Disconnect 6 Thermo switch 2 1 7 Radiator fan breather hose 1 8 Coolant ...

Page 228: ... Ib T R 28 Nm 2 8 m kg 20 ft Ib T R 28 Nm 2 8 m kg 20 ft Ib New New T R 7 Nm 0 7 m kg 5 1 ft Ib 2 Order Job Part Q ty Remarks 11 Radiator 1 12 Radiator grill 1 13 Radiator fan 1 14 Coolant reservoir breather hose 1 15 Coolant reservoir cap 1 16 Coolant reservoir 1 For installation reverse the removal pro cedure ...

Page 229: ... Below the specified pressure Replace the radiator cap a Install the radiator cap tester 1 and radiator cap tester adapter 2 to the radiator cap 3 b Apply the specified pressure for ten sec onds and make sure there is no drop in pressure 4 Check radiator fan Damage Replace Malfunction Check and repair Refer to COOLING SYSTEM in chapter 8 Radiator cap opening pressure 107 9 137 3 kPa 1 079 1 373 kg...

Page 230: ...OR EBS00128 INSTALLING THE RADIATOR 1 Fill cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT in chapter 3 2 Check cooling system Leaks Repair or replace any faulty part ...

Page 231: ...Drain Exhaust pipe Refer to ENGINE REMOVAL in chapter 4 Rear brake light switch footrest right Refer to FRONT AND REAR BRAKES in chapter 7 Clutch cover Refer to CLUTCH in chapter 4 1 Radiator outlet hose 1 2 Water pump inlet pipe 1 3 Water pump housing 1 4 Oil filter element cover 1 5 Oil filter element 1 6 Parking brake holder 1 7 Oil delivery pipe 1 1 ...

Page 232: ...MP Order Job Part Q ty Remarks 8 Oil hose 1 1 9 Right crankcase cover 1 10 Gasket 1 11 Impeller 1 12 Washer 1 13 Impeller shaft 1 14 Oil seal 1 15 Bearing 1 16 Oil seal 1 For installation reverse the removal pro cedure ...

Page 233: ...P EBS00139 CHECKING THE WATER PUMP 1 Check water pump housing 1 impeller 2 impeller shaft 3 Cracks damage wear Replace 2 Check oil seal water pump inlet pipe Cracks damage wear Replace bearing Rough movement Replace New ...

Page 234: ......

Page 235: ...CARB 6 ...

Page 236: ...EMBLING THE CARBURETOR 6 5 CHECKING THE CARBURETOR 6 5 ASSEMBLING THE CARBURETOR 6 7 ADJUSTING THE ACCELERATOR PUMP TIMING 6 8 INSTALLING THE CARBURETOR JOINT 6 8 INSTALLING THE CARBURETOR 6 9 CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR 6 9 ...

Page 237: ...CARB ...

Page 238: ...e order listed Seat fuel tank cover side covers left and right Refer to SEAT FENDERS AND FUEL TANK in chapter 3 1 Throttle position sensor coupler 1 Disconnect 2 Carburetor switch coupler 1 Disconnect 3 Fuel hose carburetor side 1 4 Throttle cable cover 1 5 Throttle cable 1 6 Clamp 1 Loosen Refer to INSTALLING THE CARBURETOR JOINT and INSTALL ING THE CARBURE TOR 7 Clamp 2 Loosen 8 Carburetor 1 9 C...

Page 239: ...uretor Remove the parts in the order listed 1 Drain hose 1 2 Air vent hose 2 3 Throttle position sensor 1 4 Cover 1 5 Carburetor switch throttle stop screw assembly 1 6 Starter plunger 1 7 Carburetor top cover 1 8 Screw throttle shaft 1 9 Throttle valve 1 0 Throttle valve plate 1 ...

Page 240: ...b Part Q ty Remarks A Needle holder 1 B Jet needle 1 C Cover spring 1 1 D Pilot air diaphragm 1 E Cover spring 1 1 F Accelerator pump diaphragm 1 G Float chamber 1 H Accelerator jet 1 I Float pin 1 J Float 1 CARBURETOR ...

Page 241: ...6 4 CARB Order Job Part Q ty Remarks K Needle valve 1 L Main jet 1 M Needle jet 1 N Spacer 1 O Pilot jet 1 P Starter jet 1 Q Pilot air jet 1 For assembly reverse the disassembly procedure CARBURETOR ...

Page 242: ...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 1 float tang 2 Damage Replace 3 Check valve seat needle valve 1 Contamination C...

Page 243: ...clip groove Free play wear Replace clip position Standard clip position No 4 groove 7 Check main jet 1 pilot jet 2 needle jet 3 starter jet 4 pilot air jet 5 accelerator jet 6 Bends wear damage Replace Blockage Blow out the jets with com pressed air 8 Check throttle valve movement 1 Sticks Replace the throttle valve guide and the throttle valve Insert the throttle valve into the carburetor body an...

Page 244: ...t a Out of specification Adjust a Hold the carburetor in an upside down posi tion b Measure the distance from the front mating surface of the float chamber gasket removed to the top of the float NOTE _ The float arm should be resting on the needle valve but not compressing it c If the float height is not within the specifica tion check the valve seat and needle valve d If either is worn replace th...

Page 245: ...sting screw 3 b Check that the link lever 4 has free play b by pushing lightly on it c Gradually turn out the adjusting screw while moving the link lever until the lever has no free play Throttle valve height 3 40 mm 0 134 in b 4 3 INSTALLING THE CARBURETOR JOINT 1 Install clamp NOTE Align the projection a on the carburetor joint with the slot b in the clamp b a b a 2 Install carburetor joint NOTE...

Page 246: ...E IDLING SPEED in chapter 3 EAS00502 CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR NOTE _ Before adjusting the throttle position sensor the engine idling speed should be properly adjusted b a d c 1 Check throttle position sensor a Turn the main switch to ON b Connect the pocket tester 20 V DC to the throttle position sensor c Check the throttle position sensor input volt age Out of specifica...

Page 247: ...onnect the pocket tester 20 V DC to the throttle position sensor d Check the throttle position sensor output voltage Out of specification Adjust or replace NOTE _ When checking the throttle position sensor it must be connected to the throttle position sen sor coupler on the wire harness 3 Tighten throttle position sensor screw Tester positive lead yellow 3 Tester negative lead black 2 Throttle pos...

Page 248: ...CHAS 7 ...

Page 249: ...FRONT BRAKE PADS 7 13 REAR BRAKE PADS 7 14 REPLACING THE FRONT BRAKE PADS 7 15 REPLACING THE REAR BRAKE PADS 7 17 FRONT BRAKE MASTER CYLINDER 7 19 REAR BRAKE MASTER CYLINDER 7 21 CHECKING THE MASTER CYLINDERS 7 24 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER 7 25 ASSEMBLING THE REAR BRAKE MASTER CYLINDER 7 25 INSTALLING THE FRONT BRAKE MASTER CYLINDER 7 26 INSTALLING THE REAR BRAKE MASTER CYLINDER 7...

Page 250: ...IE RODS 7 51 FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES 7 52 REMOVING THE FRONT ARMS 7 54 CHECKING THE FRONT ARMS 7 54 HANDLING THE FRONT SHOCK ABSORBER AND GAS CYLINDER 7 54 DISPOSING OF A FRONT SHOCK ABSORBER AND GAS CYLINDER 7 55 CHECKING THE FRONT SHOCK ABSORBERS 7 55 CHECKING THE BALL JOINTS 7 56 INSTALLING THE FRONT ARMS 7 57 REAR SHOCK ABSORBER AND RELAY ARM 7 58 HANDLING THE REAR SHOCK...

Page 251: ...e 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 1 Cotter pin 1 Refer to INSTALLING THE WHEEL HUBS 2 Axle nut 1 3 Front wheel 1 Refer to INSTALLING THE FRONT WHEELS 4 Brake disc guard outer 1 ...

Page 252: ...e caliper assembly 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 For installation reverse the removal pro cedure FRONT AND REAR WHEELS ...

Page 253: ...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 Rear wheel 2 2 Cotter pin 2 Refer to INSTALLING THE WHEEL HUBS 3 Axle nut 2 4 Wheel hub 2 For installation reverse the removal pro cedure FRONT AND REAR WHEELS ...

Page 254: ...cing 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 Wheel runout limit Radial 2 2 0 mm 0 08 in Lateral 3 2 0 mm 0 08 in EBS00385 CHECKING THE WHEEL HUBS 1 Check wheel hubs 1 Cracks damage Replace splines wheel hub 2 Wear damage Replace the wheel hub È Front É Rear È É FR...

Page 255: ...he wheel bearings reverse the above sequence Use a socket that matches outside diameter of bearing outer race to drive in bearing CAUTION _ Do not strike the center race or balls of the bearing Contact should be made only with the outer race 1 EBS00389 CHECKING THE BRAKE DISCS 1 Check brake discs Galling damage Replace 2 Measure brake disc deflection Out of specification Check the wheel runout bra...

Page 256: ...ake 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 1 NOTE _ Install the brake disc guard outer with punched burrs 2 on the wheel hub side 2 Install wheels NOTE _ The arrow mark 1 on the must point in the direction of rotation È of the wheel FRONT AND REAR WHEELS ...

Page 257: ...le nuts 1 cotter pins 2 NOTE _ Do not loosen the axle nut after torquing it If the axle nut groove is not aligned with the cot ter pin hole align the groove with the hole by tightening the axle nut T R 70 Nm 7 0 m kg 50 ft lb T R 120 Nm 12 0 m kg 85 ft lb New FRONT AND REAR WHEELS ...

Page 258: ...r listed Rear wheels rear wheel hubs Refer to FRONT AND REAR WHEELS 1 Bolt 2 Refer to REMOVING THE REAR AXLE and INSTALLING THE REAR AXLE 2 Nut 1 3 Conical spring washer 1 4 Locknut 2 5 Adjusting bolt 2 6 Brake caliper 1 NOTE _ Do not apply the brake pedal and do not use the parking brake when the brake caliper is off of the brake disc as the brake pad will be force shut ...

Page 259: ... Rear axle 1 9 Circlip 1 10 Driven sprocket sprocket bracket 1 1 Refer to INSTALLING THE DRIVEN SPROCKET 11 Brake caliper bracket 1 12 Rear axle hub 1 13 Spacer bearing oil seal 1 2 2 Refer to INSTALLING THE FRONT WHEEL HUB BEARINGS For installation reverse the removal pro cedure REAR AXLE AND REAR AXLE HUB ...

Page 260: ...l so that the rear axle does not turn when loosening the nut Use the PTT wrench 46 or axle nut wrench 46 mm 2 4 Elevate the rear wheels by placing the suit able stand under the frame 5 Remove rear wheels wheel hubs nuts washers PTT wrench 46 P N 90890 06588 Axle nut wrench 46 mm P N YM 37134 1 6 Loosen rear axle hub nuts 1 1 7 Loosen locknuts 1 adjusting bolts 2 2 1 ...

Page 261: ... tap it with a soft hammer then pull out the rear axle to the right 9 Remove circlip driven sprocket bracket EBS00395 CHECKING THE REAR AXLE 1 Check rear axle runout a Out of specification Replace WARNING _ Do not attempt to straighten a bent axle CHECKING THE DRIVEN SPROCKET 1 Check driven sprocket Refer to SWINGARM AND DRIVE CHAIN Rear axle runout limit 1 5 mm 0 06 in CHECKING THE BRAKE DISC 1 C...

Page 262: ...all conical spring washer 1 NOTE Install the conical spring washer with the con vex side of the washer facing outward as shown 1 2 Tighten nut 1 a Tighten the nut with PTT wrench 46 or rear axle nut wrench 2 to specification while holding the rear axle b Tighten bolts 3 PTT wrench 46 P N 90890 06588 Axle nut wrench 46 mm P N YM 37134 T R Nut 100 Nm 10 0 m kg 72 ft lb LOCTITE T R Bolt 7 Nm 0 7 m kg...

Page 263: ... Removing the front brake pads Remove the parts in the order listed The following procedure applies to both of the front brake calipers Front wheel Refer to FRONT AND REAR WHEELS 1 Brake pad retaining bolt 2 Refer to REPLACING THE FRONT BRAKE PADS 2 Brake pad 2 3 Brake pad spring 1 For installation reverse the removal pro cedure FRONT AND REAR BRAKES ...

Page 264: ...b Part Q ty Remarks Removing the rear brake pads Remove the parts in the order listed 1 Brake caliper mounting bolt 2 Refer to REPLACING THE REAR BRAKE PADS 2 Brake pad retaining bolt 2 3 Lock washer 1 4 Brake pad pad shim 2 1 5 Brake pad spring 1 For installation reverse the removal pro cedure FRONT AND REAR BRAKES ...

Page 265: ...aces or plastic parts as this may cause dam age disconnect any hydraulic connection as this would require the entire brake sys tem to be disassembled drained cleaned properly filled and bled after reassembly EBS00404 REPLACING THE FRONT BRAKE PADS The following procedure applies to both of the front brake calipers NOTE _ It is not necessary to disassemble the brake calipers and brake hoses to repl...

Page 266: ...iper c Tighten the brake caliper bleed screw d Install new brake pads and a new brake pad spring e Install the retaining bolts and brake caliper 3 Check brake fluid level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 4 Check brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 T R Brake caliper bleed screw 6 Nm 0 6 m k...

Page 267: ...r bleed screw 2 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 d Install a new brake pad spring new pad shim 3 and new brake pads NOTE The pad shim must be installed toward the piston The arrow mark a on the pad shim must point in the direction of ...

Page 268: ... the bolts 3 Check brake fluid level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 4 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 FRONT AND REAR BRAKES ...

Page 269: ...luid Drain 1 Brake fluid reservoir cap 1 2 Brake fluid reservoir diaphragm 1 3 Front brake light switch 1 4 Brake lever 1 5 Union bolt 1 Refer to INSTALLING THE FRONT BRAKE MASTER CYLINDER 6 Copper washer 2 7 Brake hose 1 Disconnect 8 Brake master cylinder bracket 1 9 Brake master cylinder 1 For installation reverse the removal pro cedure FRONT AND REAR BRAKES ...

Page 270: ...embling the front brake mas ter cylinder Remove the parts in the order listed 1 Dust boot 1 Refer to ASSEMBLING THE FRONT BRAKE MASTER CYLINDER 2 Circlip 1 3 Brake master cylinder kit 1 For assembly reverse the disassembly procedure FRONT AND REAR BRAKES ...

Page 271: ...ts in the order listed Right foot protector Refer to SEAT FENDERS AND FUEL TANK in chapter 3 Brake fluid Drain 1 Brake fluid reservoir cover 1 2 Brake fluid reservoir cap 1 3 Brake fluid reservoir diaphragm holder 1 4 Brake fluid reservoir diaphragm 1 5 Brake fluid reservoir 1 6 Brake fluid reservoir hose 1 FRONT AND REAR BRAKES ...

Page 272: ...to INSTALLING THE REAR BRAKE MAS TER CYLINDER 8 Copper washer 2 9 Brake hose 1 Disconnect 10 Brake master cylinder 1 11 Rear brake light switch 1 12 Right footrest 1 13 Brake pedal spring 1 1 For installation reverse the removal pro cedure FRONT AND REAR BRAKES ...

Page 273: ...g the rear brake mas ter cylinder Remove the parts in the order listed 1 Hose joint 1 2 Brake master cylinder kit 1 Refer to ASSEMBLING THE REAR BRAKE MASTER CYLINDER 3 Brake master cylinder 1 For assembly reverse the disassembly procedure FRONT AND REAR BRAKES ...

Page 274: ...e brake master cylinder body Blockage Blow out with compressed air È Front É Rear È É 2 Check brake master cylinder kit Scratches wear damage Replace as a set È Front É Rear É È 3 Check front brake master cylinder reservoir 1 front brake master cylinder reservoir dia phragm 2 Cracks damage Replace 4 Check rear brake fluid reservoir 1 rear brake fluid reservoir diaphragm 2 Cracks damage Replace FRO...

Page 275: ... BRAKE MASTER CYLINDER WARNING _ All internal brake components should be cleaned and lubricated with new brake fluid only before installation Whenever a master cylinder is disassem bled replace the piston seals and dust seals 1 Install brake master cylinder kit nut 1 joint 2 NOTE _ Turn the adjusting bolt 3 until the clearance a is within the specified limits when install the joint 2 2 Tighten nut...

Page 276: ...NOTE _ Tighten the union bolt while holding the brake hose as shown Turn the handlebar to the left and to the right to check that the brake hose does not touch other parts throttle cable wire harness leads etc Correct if necessary WARNING _ Proper brake hose routing is essential to insure safe machine operation Refer to CABLE ROUTING in chapter 2 3 Fill brake fluid reservoir CAUTION _ Brake fluid ...

Page 277: ... bleed brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 5 Check brake fluid level Brake fluid level is under the LOWER level line Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 EBS00419 INSTALLING THE REAR BRAKE MASTER CYLINDER 1 Install copper washers brake hose 1 union bolt 2 CAUTION _ When installing the brake hose ...

Page 278: ...Refill with the same type of brake fluid mixing brake fluids may result in a harm ful 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 Air bleed brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 5 C...

Page 279: ...s in the order listed The following procedure applies to both of the front brake calipers Brake caliper Drain Front wheel Refer to FRONT AND REAR WHEELS 1 Union bolt 1 Refer to INSTALLING THE FRONT BRAKE CALIPERS 2 Copper washer 2 3 Brake hose 1 Disconnect 4 Brake pad retaining bolt 2 Loosen 5 Brake caliper mounting bolt 2 6 Brake caliper assembly 1 For installation reverse the removal pro cedure ...

Page 280: ...er listed The following procedure applies to both of the front brake calipers 1 Brake pad retaining bolt 2 2 Brake pad 2 3 Brake pad spring 1 4 Caliper bracket 1 5 Caliper piston 2 Refer to DISASSEMBLING THE FRONT AND REAR BRAKE CALI PERS and ASSEMBLING THE FRONT BRAKE CALIPERS 6 Dust seal 2 7 Caliper piston seal 2 8 Bleed screw 1 For assembly reverse the disassembly procedure FRONT AND REAR BRAKE...

Page 281: ...sted Brake fluid Drain 1 Parking brake cable 1 Disconnect Refer to REMOVING THE PARKING BRAKE CABLE 2 Union bolt 2 Refer to INSTALLING THE REAR BRAKE CALI PER 3 Copper washer 2 4 Brake hose 1 Disconnect 5 Brake caliper mounting bolt 2 6 Brake caliper assembly 1 For installation reverse the removal pro cedure FRONT AND REAR BRAKES ...

Page 282: ... rear brake cali per Remove the parts in the order listed 1 Adjusting bolt 1 2 Locknut 1 3 Parking brake arm 1 4 Parking brake case mounting bolt 2 5 Parking brake case bracket 1 6 Parking brake case 1 7 Gasket 1 8 Spring 1 9 Nut 1 0 Bearing 1 FRONT AND REAR BRAKES ...

Page 283: ...rake pad spring 1 E Retaining bolt 1 F Caliper bracket 1 G Brake caliper piston 1 Refer to DISASSEMBLING THE FRONT AND REAR BRAKE CALI PERS and ASSEMBLING THE REAR BRAKE CALIPER H Dust seal 1 I Caliper piston seal 1 J O ring 1 K Bleed screw 1 For assembly reverse the disassembly procedure FRONT AND REAR BRAKES ...

Page 284: ...IPERS 1 Remove brake caliper pistons dust seals 1 caliper piston seals 2 È Front É Rear a Blow compressed air into the hose joint opening to force out the caliper piston from the brake caliper body WARNING _ Never try to pry out the caliper piston Cover the caliper piston with a rag Be careful not to get injured when the piston is expelled from the caliper cylinder b Remove the caliper piston seal...

Page 285: ...Brake hoses Every four years Brake fluid Replace when brakes are disassembled 1 Check brake caliper pistons 1 Scratches rust wear Replace the brake caliper assembly brake caliper cylinders 2 Wear scratches Replace the brake cali per assembly brake caliper body 3 Cracks damage Replace brake fluid delivery passage brake caliper body Blockage Blow out with compressed air WARNING _ Replace the caliper...

Page 286: ... is disassembled 1 Install caliper piston seals 1 dust seals 2 Recommended brake fluid DOT 4 1 2 New New New New 2 Install brake caliper pistons 1 1 EBS00432 ASSEMBLING THE REAR BRAKE CALIPER WARNING _ All internal brake components should be cleaned and lubricated with new brake fluid only before installation Replace the caliper piston seal whenever a brake caliper is disassembled 1 Install O ring...

Page 287: ... the bearing race tab 1 with parking brake case slit 1 6 Install parking brake arm 1 NOTE Align the center of the parking brake arm with a adjuster nut corner a and position the park ing brake arm as shown 7 Measure parking brake arm to parking brake bracket distance b Out of specification Adjust Parking brake arm to parking brake bracket distance 58 mm 2 28 in 1 b a FRONT AND REAR BRAKES ...

Page 288: ...rvoir 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 harm ful chemical reaction and lead to poor brake per...

Page 289: ...R 1 Install brake caliper assembly brake caliper mounting bolts 1 brake hose 2 copper washers 3 union bolt 4 CAUTION _ When installing the brake hose on the brake caliper make sure that the brake pipe touches the projection a on the brake caliper WARNING _ Proper brake hose routing is essential to insure safe machine operation Refer to CABLE ROUTING in chapter 2 2 Fill brake reservoir Recommended ...

Page 290: ... 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 Air bleed brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 4 Check brake fluid level Brake fluid level is below the LOWER level line Add the recommended brake fluid to the...

Page 291: ...bar Remove the parts in the order listed 1 Handlebar cover 1 2 Plastic band 4 3 Front brake light switch 1 Refer to REMOVING THE FRONT BRAKE LIGHT SWITCH AND CLUTCH SWITCH 4 Brake master cylinder bracket 1 1 Refer to INSTALLING THE BRAKE MASTER CYLINDER 5 Throttle lever assembly bracket 1 1 6 Spacer 1 7 Clutch switch 1 Refer to REMOVING THE FRONT BRAKE LIGHT SWITCH AND CLUTCH SWITCH 8 Parking brak...

Page 292: ...R 7 Nm 0 7 m kg 5 1 ft Ib 2 4 T R 4 Nm 0 4 m kg 2 9 ft Ib T R 4 Nm 0 4 m kg 2 9 ft Ib Order Job Part Q ty Remarks 11 Handlebar grip 2 Refer to REMOVING THE HANDLEBAR GRIPS and INSTALLING THE HAN DLEBAR GRIPS 12 Handlebar holder 2 Refer to INSTALLING THE HANDLE BAR 13 Handlebar 1 For installation reverse the removal pro cedure ...

Page 293: ...r Push the fastener when removing the clutch switch out of the clutch lever holder EBS00447 REMOVING THE HANDLEBAR GRIPS 1 Remove handlebar grips 1 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 1 Bends cracks damage Replace WARNING _ Do not attempt to straighten a bent handle bar a...

Page 294: ...ark 1 forward 2 CAUTION _ First tighten the bolt 3 on the front side of the handlebar holder and then tighten the bolt 4 on the rear side T R 23 Nm 2 3 m kg 17 ft lb EBS00450 INSTALLING THE HANDLEBAR GRIPS 1 Install handlebar grips 1 NOTE _ Before applying the adhesive wipe off grease or oil on the handlebar surface a with a lacquer thinner Install the handlebar grips to the handlebar so that the ...

Page 295: ...69 mm 2 68 2 72 in a 1 2 EBS00453 INSTALLING THE BRAKE MASTER CYLINDER 1 Install throttle lever assembly spacer brake master cylinder NOTE _ Engage the indentations a in the spacer with the lobes b on the throttle lever assem bly and brake master cylinder The UP mark on the brake master cylinder bracket should face up a b T R 7 Nm 0 7 m kg 5 1 ft lb STEERING SYSTEM ...

Page 296: ...he order listed Fuel tank cover side covers left and right fuel tank front fender Refer to SEAT FENDERS AND FUEL TANK in chapter 3 1 Pitman arm 1 Refer to INSTALLING THE PITMAN ARM 2 Lock washer 1 Refer to INSTALLING THE LOCK WASHER 3 Steering stem bushing 2 4 Spacer 2 5 Oil seal 2 6 Steering stem 1 7 Oil seal 1 8 Oil seal 1 ...

Page 297: ... CHAS STEERING SYSTEM Order Job Part Q ty Remarks 9 Bearing retainer 1 Refer to REMOVING THE BEARING RETAINER and INSTALLING THE BEARING RETAINER 10 Bearing 1 For installation reverse the removal pro cedure ...

Page 298: ... attempt to straighten a bent stem this may dangerously weaken the stem 2 Check oil seals 1 steering stem bushings 2 Wear damage Replace New EBS00457 INSTALLING THE BEARING RETAINER 1 Install bearing retainer Damper rod holder 30 mm P N YM 01327 90890 01327 T R 65 Nm 6 5 m kg 47 ft lb INSTALLING THE STEERING STEM 1 Install steering stem NOTE _ Pass the throttle cable through the cable guide Refer ...

Page 299: ... Bend the lock washer tab along a flat side of the bolt New New T R 23 Nm 2 3 m kg 17 ft lb INSTALLING THE PITMAN ARM 1 Install washer nut pitman arm NOTE _ Make sure that the threads of the steering stem washers nuts and the installation sur faces of the pitman arm are free of grease and oil ...

Page 300: ...es to both of the tie rods and steering knuckles Front wheel brake disc Refer to FRONT AND REAR WHEELS Front brake caliper Refer to FRONT AND REAR BRAKES 1 Brake disc guard inner 1 2 Tie rod 2 Refer to INSTALLING THE TIE RODS 3 Pitman arm 1 4 Front bumper 1 5 Lower front arm 1 6 Upper front arm 1 7 Steering knuckle 1 Refer to REMOVING THE STEERING KNUCKLES For installation reverse the removal pro ...

Page 301: ...ovement 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 Install tie rods left and right NOTE _ The tie rod side which must be installed on the outside has grooves 1 2 Adjust toe in Refer to ADJUSTING THE TOE IN in ...

Page 302: ...shock absorber assemblies Remove the parts in the order listed The following procedure applies to both of the front arms and front shock absorber assemblies Front wheel brake disc Refer to FRONT AND REAR WHEELS Front brake caliper Refer to FRONT AND REAR BRAKES 1 Front bumper 1 2 Brake disc guard inner 1 3 Nut 1 4 Tie rod 1 Disconnect 5 Nut 1 6 Nut 1 7 Nut washer bolt 1 1 1 ...

Page 303: ...MS and INSTALLING THE FRONT ARMS 9 Lower front arm 1 10 Nut bolt 1 1 11 Upper front arm 1 12 Nut bolt 1 1 13 Front shock absorber bushing 1 1 14 Steering knuckle 1 15 Dust cover 6 16 Spacer 1 17 Spacer 2 18 Bushing 6 19 Circlip 1 20 Rubber boot boot retaining ring 1 1 21 Ball joint 1 For installation reverse the removal pro cedure ...

Page 304: ...s 2 Wear damage Replace 1 1 2 2 HANDLING THE FRONT SHOCK ABSORBER AND GAS CYLINDER WARNING _ This front shock absorber and gas cylinder contain highly compressed nitrogen gas Before handling the front shock absorber or gas cylinder 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 impr...

Page 305: ...e gas valve needle with a suitable tool as shown until all of the gas is released the hissing has stopped WARNING _ Wear eye protection to prevent eye damage from released gas or metal chips EBS00488 CHECKING THE FRONT SHOCK ABSORBERS The following procedure applies to both of the front shock absorber assemblies 1 Check shock absorber Oil leaks Replace the front shock absorber assembly shock absor...

Page 306: ...ball joint a Clean the outside of the lower front arm b Remove the circlip 1 boot retaining ring 2 and rubber boot 3 Use the ball joint remover and installer set c Install the body 4 long bolt 5 base 6 and attachment 7 onto ball joint d Hold the body 4 in place while turning in the long bolt 5 to remove the ball joint 0 from the lower front arm A e Remove the ball joint remover installer Ball join...

Page 307: ...e aligned with the projection on the head of the ball joint B g Remove the ball joint remover installer h Install a new circlip NOTE _ Always use a new ball joint set EBS00473 INSTALLING THE FRONT ARMS The following procedure applies to both of the front arms 1 Install upper front arm 1 lower front arm 2 NOTE _ Be sure to position the bolts upper and lower so that the bolt head faces forward Apply...

Page 308: ... LS LS New New New LS LS Order Job Part Q ty Remarks Removing the rear shock absorber and relay arm Remove the parts in the order listed Seat left foot protector Refer to SEAT FENDERS AND FUEL TANK in chapter 3 Muffler exhaust pipe Refer to ENGINE REMOVAL in chapter 4 Rear axle hub Refer to REAR AXLE AND REAR AXLE HUB 1 Self locking nut bolt 1 1 2 Self locking nut bolt 1 1 3 Connecting arm 1 4 Bea...

Page 309: ...S LS Order Job Part Q ty Remarks 6 Bolt washer 1 1 Refer to REMOVING THE REAR SHOCK ABSORBER and INSTALL ING THE REAR SHOCK ABSORBER 7 Self locking nut bolt washer 1 1 2 8 Rear shock absorber 1 9 Dust seal bearing spacer 2 1 1 10 Self locking nut bolt 1 1 11 Relay arm 1 12 Spacer bearing oil seal 1 1 2 Refer to INSTALLING THE RELAY ARM AND CONNECTING ARM 13 Spacer bearing oil seal 1 1 2 14 Spacer ...

Page 310: ...r or gas cylinder Do not subject the rear shock absorber or gas cylinder to an open flame or any other source of high heat High heat can cause an explosion due to excessive gas pressure Do not deform or damage the rear shock absorber or gas cylinder in any way If the rear shock absorber gas cylinder or both are damaged damping performance will suffer EBS00486 DISPOSING OF A REAR SHOCK ABSORBER AND...

Page 311: ...KING THE REAR SHOCK ABSORBER 1 Check shock absorber Oil leaks Replace the rear shock absorber assembly shock absorber rod Bends damage Replace the rear shock absorber assembly spring Fatigue Replace the rear shock absorber assembly Move the spring up and down gas cylinder Damage gas leaks Replace the rear shock absorber assembly EBS00489 CHECKING THE RELAY ARM AND CONNECTING ARM 1 Check relay arm ...

Page 312: ...he rear shock absorber lift up the swingarm Make sure that the blunt edged corner a of the washer is facing outward Make sure that the sharp edged corner b of the washer is facing outward Install the cotter pin and bend the ends as shown È Rear shock absorber upper side Rear shock absorber lower side Installed depth of bearing a 4 mm 0 16 in Installed depth of bearing a 6 5 mm 0 26 in Installed de...

Page 313: ...and drive chain Remove the parts in the order listed Rear axle hub Refer to REAR AXLE AND REAR AXLE HUB Rear shock absorber Refer to REAR SHOCK ABSORBER AND RELAY ARM 1 Drive chain guard 1 2 Rear brake disc guard 1 3 Pivot shaft nut washer 1 1 4 Pivot shaft 1 5 Swingarm 1 6 Drive chain guide 1 1 7 Drive sprocket cover 1 ...

Page 314: ...chain guide 2 1 Refer to INSTALLING THE DRIVE SPROCKET 9 Nut 1 10 Lock washer 1 11 Drive sprocket 1 12 Drive chain 1 Refer to INSTALLING THE SWING ARM 13 Dust cover washer bearing 2 2 2 14 Spacer 2 15 Oil seal 2 16 Bushing 2 For installation reverse the removal pro cedure ...

Page 315: ...e swingarm side play È by moving it from side to side If side play is noticeable check the spacers bearings bushings and frame pivot c Check the swingarm vertical movement É by moving it up and down If vertical movement is tight or rough or if there is binding check the spacers bear ings bushings and frame pivot 2 Remove pivot shaft nut washer pivot shaft swingarm T R Pivot shaft nut 100 Nm 10 0 m...

Page 316: ... the axle on a flat surface Bends Replace WARNING _ Do not attempt to straighten a bent pivot shaft 3 Clean pivot shaft spacer bearings bushings 4 Check oil seals Damage wear Replace bearings bushings Damage pitting Replace Recommended cleaning solvent Kerosene ...

Page 317: ...ain 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 1 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 High pressure methods could force dirt or water into the dri...

Page 318: ...lace the drive chain sprockets as a set Bent teeth Replace the drive chain sprockets as a set b Correct 1 Drive chain roller 2 Drive chain sprocket Recommended lubricant Engine oil or chain lubricant suitable for O ring chains EBS00497 INSTALLING THE SWINGARM 1 Install bearings 1 bushings 2 to swingarm spacer 3 NOTE _ Apply the lithium soap based grease on the bushing when installing Installed dep...

Page 319: ...S SWINGARM AND DRIVE CHAIN EBS00498 INSTALLING THE DRIVE SPROCKET 1 Install drive sprocket 1 lock washer 2 nut 3 2 Bend the lock washer tab along a flat side of the nut 2 1 New 3 New T R 75 Nm 7 5 m kg 54 ft lb ...

Page 320: ......

Page 321: ...ELEC 8 ...

Page 322: ... CHECKING THE THROTTLE OVERRIDE SYSTEM 8 14 ELECTRIC STARTING SYSTEM 8 16 CIRCUIT DIAGRAM 8 16 STARTING CIRCUIT CUT OFF SYSTEM OPERATION 8 17 TROUBLESHOOTING 8 18 STARTER MOTOR 8 22 CHECKING THE STARTER MOTOR 8 24 ASSEMBLING THE STARTER MOTOR 8 25 CHARGING SYSTEM 8 26 CIRCUIT DIAGRAM 8 26 TROUBLESHOOTING 8 27 LIGHTING SYSTEM 8 29 CIRCUIT DIAGRAM 8 29 TROUBLESHOOTING 8 30 CHECKING THE LIGHTING SYST...

Page 323: ... ELEC ...

Page 324: ...tch 7 Fuse 8 Starter relay 9 Starting circuit cut off relay 0 Tail brake light A Battery B Ignition coil C Spark plug D Throttle position sensor E Carburetor switch F Thermo switch 2 G Pickup coil stator assembly H Neutral switch I Rear brake light switch J Radiator fan K Circuit breaker fan motor L Rectifier regulator M C D I unit N Headlight O Diode 2 P Diode 1 Q Thermo switch 1 ...

Page 325: ...itch back and forth between the switch positions a few times The terminal connections for switches e g main switch engine stop switch are shown in an illustration similar to the one on the left The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row in the switch illustration NOTE _ indicates a continuity of electricity between switch terminals...

Page 326: ...CHES Check each switch for damage or wear proper connections and also for continuity between the ter minals Refer to CHECKING SWITCH CONTINUITY Damage wear Repair or replace Improperly connected Properly connect Incorrect continuity reading Replace the switch ...

Page 327: ...CKING THE SWITCHES 1 Light switch 2 Engine stop switch 3 Start switch 4 Main switch 5 Front brake light switch 6 Throttle switch 7 Clutch switch 8 Carburetor switch 9 Fuse 0 Neutral switch A Rear brake light switch ...

Page 328: ...illustration on the left Bulbs a and b are used for the headlights and usually use a bulb holder that must be detached before removing the bulb The majority of these types of bulbs can be removed from their respective socket by turning them counterclockwise Bulbs c is used for turn signal and tail brake lights and can be removed from the socket by pushing and turning the bulb counterclockwise Bulb...

Page 329: ...lb and the luminous flux will be adversely affected If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 2 Check bulb for continuity with the pocket tester No continuity Replace NOTE _ Before checking for continuity set the pocket tester to 0 and to the Ω 1 range a Connect the positive tester probe to termi nal 1 and the negative tester probe...

Page 330: ...ulb 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 Connect the pocket tester probes to the respective leads of the bulb socket c Check the bulb socket for continuity If any of the readings indicate no continuity replace the bulb socket Pocket tester P N YU 03112 C 90890 03112 CHECKING THE BULBS AND B...

Page 331: ...F PUSH L B Y G B Y R L B Y G L B L B Y G Y R L B R B Br R B Br 15A L B R Y B Y B B Y R B Sb B B L L Y Y O O B B L Y B B L B Y W B W R R B Sb R R R R Y B Y B L B L B B B B B B Y B R B B Y Sb Y B L B L B Br L Br L W L R B W L Br Sb B W L Sb Sb Sb L B W L B O W B W BLACK BLACK O B BLACK GRAY GRAY R B B L R L Y Y B Sb Br R B W L Sb Sb W L Br Br R W R W Y B Y B B L B L L L B 1 2 4 7 6 8 M K J N 9 0 A 5...

Page 332: ...p the engine if the carburetor or throttle cable malfunctions during operation The throttle switch is open when the switch is pushed The carburetor switch is open when the switch is not pushed When both the throttle switch and carbure tor switch are open the throttle override system operates and the engine stops 1 Battery 2 Fuse 3 Main switch 4 Engine stop switch 5 C D I unit 6 A C magneto 7 Ignit...

Page 333: ...ynamic spark tester P N YM 34487 Ignition checker 90890 06754 Pocket tester P N YU 03112 C 90890 03112 1 Fuse Check the fuse for continuity Refer to CHECKING THE SWITCHES Is the fuse OK Replace the fuse 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C 68 F Is the battery OK Clean the battery ter...

Page 334: ...gap until a misfire occurs Minimum ignition spark gap 6 mm 0 24 in Is there a spark and is the spark gap within specification The ignition system is OK 4 Ignition spark gap Disconnect the ignition coil from the spark plug Connect the ignition checker 1 as shown 2 Ignition coil Set the main switch to ON Measure the ignition spark gap a Crank the engine by pushing the start switch and gradually incr...

Page 335: ... coil terminal 2 Measure the secondary coil resistance Secondary coil resistance 4 56 6 84 kΩ at 20 C 68 F Is the ignition coil OK Replace the ignition coil 1 2 1 2 6 Main switch Check the main switch for continuity Refer to CHECKING THE SWITCHES Is the main switch OK Replace the main switch 7 Engine stop switch Check the engine stop switch for continu ity Refer to CHECKING THE SWITCHES Is the eng...

Page 336: ... white terminal 1 Negative tester probe red terminal 2 Measure the pickup coil resistance Pickup coil resistance 248 372 Ω at 20 C 68 F Is the pickup coil OK Replace the pickup coil stator assembly W R 2 1 11 Wiring Check the entire ignition system s wiring Refer to CIRCUIT DIAGRAM Is the ignition system s wiring properly connected and without defects Replace the C D I unit Properly connect or rep...

Page 337: ...ottle switch 1 a Press the throttle lever so that the throttle lever arm 2 does not contact the throttle switch and then use a screwdriver to hold the throttle lever arm away from the switch b Release the throttle lever so that the throttle switch is pushed and check that the throttle override system operates and the engine stops Engine stops Throttle switch is O K Engine does not stop Check the e...

Page 338: ...8 15 ELEC IGNITION SYSTEM 4 Install throttle lever cover ...

Page 339: ...H L B Y G B Y R L B Y G L B L B Y G Y R L B R B Br R B Br 15A L B R Y B Y B B Y R B Sb B B L L Y Y O O B B L Y B B L B Y W B W R R B Sb R R R R Y B Y B L B L B B B B B B Y B R B B Y Sb Y B L B L B W L R B W L Br Sb B W L Sb Sb Sb L B W L B O W B W BLACK BLACK O B BLACK GRAY GRAY R B B L R L Y Y B Sb Br R B W L Sb Sb W L Br Br R W R W Y B Y B B L B L L L B 1 2 4 7 6 8 M K J N 9 0 A 5 V U T S O P Q ...

Page 340: ... switch is on and the engine stop switch is in the RUN position the starter motor can be operated only if 1 Battery 2 Fuse 3 Main switch 4 Engine stop switch 5 Starting circuit cutoff relay 6 Clutch switch 7 Neutral switch 8 Start switch 9 Starter relay 0 Starter motor The transmission is in neutral the neutral switch is closed or You pull in the clutch lever the clutch switch is closed 1 0 9 2 4 ...

Page 341: ...tester P N YU 03112 C 90890 03112 1 Fuse Check the fuse for continuity Refer to CHECKING THE SWITCHES Is the fuse OK Replace the fuse 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C 68 F Is the battery OK Clean the battery terminals Recharge or replace the battery 3 Starter motor Connect the po...

Page 342: ...and yellow black Replace the starting circuit cut off relay B Y Sb R B Y B 1 4 2 3 5 Starting circuit cut off relay diode 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 Measure the starting circuit cut off relay for continuity as follows Positive tester probe sky blue 1 Negative tester probe red black 2 C...

Page 343: ...n switch Check the main switch for continuity Refer to CHECKING THE SWITCHES Is the main switch OK Replace the main switch R B R Y B L B 1 2 4 3 8 Engine stop switch Check the engine stop switch for continu ity Refer to CHECKING THE SWITCHES Is the engine stop switch OK Replace the handle bar switch 9 Neutral switch Check the neutral switch for continuity Refer to CHECKING THE SWITCHES Is the neut...

Page 344: ... YES NO 12 Wiring Check the entire starting system s wiring Refer to CIRCUIT DIAGRAM Is the starting system s wiring properly connected and without defects The starting system circuit is OK Properly connect or repair the starting system s wiring ...

Page 345: ...R 20 Nm 2 0 m kg 14 ft Ib 1 T R 10 Nm 1 0 m kg 7 2 ft Ib Order Job Part Q ty Remarks Removing the starter motor Remove the parts in the order listed Exhaust pipe Refer to ENGINE REMOVAL in chapter 4 1 Parking brake cable holder 1 2 Oil delivery pipe 1 1 3 Starter motor lead 1 Disconnect 4 Starter motor 1 For installation reverse the removal pro cedure ...

Page 346: ...emarks Disassembling the starter motor Remove the parts in the order listed 1 Front bracket 1 Refer to ASSEMBLING THE STARTER MOTOR 2 O ring 1 3 Shim 1 4 Lock washer 1 5 Rear bracket 1 6 O ring 1 7 Shim 1 8 Brush holder assembly 1 9 Armature assembly 1 0 Starter motor yoke 1 For assembly reverse the disassembly procedure ...

Page 347: ...he mica of the commutator must be undercut to ensure proper operation of the commutator Commutator wear limit 27 mm 1 06 in Mica undercut 0 7 mm 0 03 in 4 Measure armature assembly resistances commutator and insulation Out of specification Replace the starter motor a Measure the armature assembly resis tances with the pocket tester b If any resistance is out of specification replace the starter mo...

Page 348: ...ear 8 Check bushing bearing oil seal Damage wear Replace the defective part s Brush length wear limit 3 5 mm 0 14 in Brush spring force 7 16 9 52 N 730 971 gf 25 77 34 27 oz EBS00515 ASSEMBLING THE STARTER MOTOR 1 Install brush seat 1 NOTE _ Align the projection a on the rear bracket with the slot b in the yoke 2 Install yoke bracket NOTE _ Align the match mark a on the yoke with the match mark b ...

Page 349: ...Br Y B Y L Y L B L Y B B Y R W W B R Y R B B Y G G Y B Y G B BLACK BLACK G Y B Y G B B Y G OFF LO HI OFF RUN R Br Br L Y R BrR B OFF PUSH L B Y G B Y R L B Y G L B L B Y G Y R L B R B Br R B Br 15A L B R Y B R R R R Y B Y B L B L B B B B B B Y B R B B Y Sb Y B L B L B W L B W L L B W L 1 2 4 7 6 8 M J N 5 V U T S O P Q R S R Br Br L Br L R W Br R R ON OFF Br L 3 R Br R 1 A C magneto 2 Rectifier re...

Page 350: ...ender Troubleshoot with the following special tool s EBS01043 YES NO EBS01044 YES NO The battery is not being charged Pocket tester P N YU 03112 C 90890 03112 1 Fuse Check the fuse for continuity Refer to CHECKING THE SWITCHES Is the fuse OK Replace the fuse 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or m...

Page 351: ...ged Is the charging voltage within specifica tion The charging circuit is OK 4 Charging coil resistance Disconnect the A C magneto coupler from the wire harness Connect the pocket tester Ω 1 to the charging coils Positive tester probe white 1 Negative tester probe ground 2 Measure the charging coil resistance Charging coil resistance 0 288 0 432 Ω at 20 C 68 F Replace the pickup coil stator assemb...

Page 352: ...Y R W W B R Y R B B Y G G Y B Y G B BLACK BLACK G Y B Y G B B Y G OFF LO HI OFF RUN Br Br L Y R BrR B OFF PUSH L B Y G B Y R L B Y G L B L B Y G Y R L B R B Br R B Br 15A L B R Y B Y B R B R R R R Y B Y B L B L B B B B B B Y B R B B Y Sb Y B L B L B W L R B W L B W L L B W L 1 2 4 7 6 8 M K J N 9 0 5 V U T S O P Q R S ON OFF R Br L R 3 R Br Br L Br L R W Br R R Br 1 A C magneto 2 Rectifier regulat...

Page 353: ...ght head light tail brake light Pocket tester P N YU 03112 C 90890 03112 1 Light switch Check the light switch for continuity Refer to CHECKING THE SWITCHES Is the light switch OK Replace the handle bar switch 2 Lighting coil resistance Disconnect the A C magneto coupler from the wire harness Connect the pocket tester Ω 1 to the lighting coil terminals as shown Positive tester probe yellow 1 Negat...

Page 354: ...ket for continuity Refer to CHECKING THE BULBS AND BULB SOCKETS Are the headlight bulb and socket OK Replace the head light bulb socket or both 2 Voltage Connect the pocket tester AC 20 V to the headlight couplers as shown È When the light switch is set to LO É When the light switch is set to HI Headlight coupler wire harness side Headlight Positive tester probe yellow 1 or green 2 Negative tester...

Page 355: ...tail brake light bulb socket or both 2 Voltage Connect the pocket tester AC 20 V to the tail brake light coupler as shown Tail brake light coupler wire harness side Tail brake light Positive tester probe blue 1 Negative tester probe black 2 Set the main switch to ON Start the engine Measure the voltage AC 12 V of blue 1 on the tail brake light coupler wire har ness side Is the voltage within speci...

Page 356: ...B Br R B Br 15A L B R Y B Y B B Y R B Sb B B L L Y Y O O B B L Y B B L B Y W B W R R B Sb R R R R Y B Y B L B B B B B B L B Y B R B B Y Sb Y B L B L B W L R B W L Br Sb B W L Sb Sb Sb L B W L B O W B W BLACK BLACK O B BLACK GRAY GRAY R B B L R L Y Y B Sb Br R B W L Sb Sb W L Br Br R W R W Y B Y B B L B L L L B 1 2 4 7 6 8 M K J N 9 0 A 5 V U T S O P Q R S L G H I B C D F Br L Br L GRAY GRAY R Br B...

Page 357: ... to CHECKING THE SWITCHES Is the fuse OK Replace the fuse 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C 68 F Is the battery OK Clean the battery terminals Recharge or replace the bat tery 3 Main switch Check the main switch for continuity Refer to CHECKING THE SWITCHES Is the main switch OK R...

Page 358: ... brake light switch 3 Voltage Connect the pocket tester DC 20 V to the tail brake light coupler wire harness side as shown Positive tester probe yellow 1 Negative tester probe black 2 Set the main switch to ON Pull in the brake lever or push down on the brake pedal Measure the voltage DC 12 V of yellow 1 on the tail brake light coupler wire har ness side Is the voltage within specification This ci...

Page 359: ...ster DC 20 V to the indicator light coupler wire harness side as shown Positive tester probe brown 1 Negative tester probe sky blue 2 Set the main switch to ON Measure the voltage DC 12 V Is the voltage within specification This circuit is OK The wiring circuit from the main switch to the indicator light coupler is faulty and must be repaired 1 Coolant temperature warning light bulb and socket Che...

Page 360: ... 1 Less than 120 3 C 248 5 4 F NO 2 More than 120 3 C 248 5 4 F YES 3 More than 115 3 C 239 5 4 F YES 4 Less than 115 3 C 239 5 4 F NO Steps 1 2 Heating phase Steps 3 4 Cooling phase È The thermo switch circuit is open and the cool ant temperature warning light is off É The thermo switch circuit is closed and the coolant temperature warning light is on WARNING _ Handle the thermo switch with speci...

Page 361: ...ty repair it 4 Diode Remove the diode from the coupler Connect the pocket tester Ω 1 to the diode terminals as shown Check the diode for continuity as follows Positive tester probe blue black 1 Negative tester probe white blue 2 Continuity Positive tester probe white blue 2 Negative tester probe blue black 1 No continuity NOTE When you switch the tester s positive and negative probes the readings ...

Page 362: ...Br BrR B OFF PUSH L B Y G B Y R L B Y G L B L B Y G Y R L B R B Br R B Br 15A L B R Y B Y BB Y R B Sb B B B Y W B W R R B Sb R R R R Y B Y B L B L B B B B B B Y B R B B Y Sb Y B L B L B W L R B W L Br Sb B W L Sb Sb Sb L B W L BLACK R B B L R L Y Y B Sb Br R BW L Sb Sb W L Br Br R W R W L L B 2 4 7 6 8 M K J N 9 0 A 5 Q R S L G H I F R ON OFF Br L Br L 3 3 Main switch 4 Battery 5 Fuse G Circuit br...

Page 363: ...3 YES NO EBS01044 YES NO EBS01041 YES NO The radiator fan motor fails to turn Pocket tester P N YU 03112 C 90890 03112 1 Fuse Check the fuse for continuity Refer to CHECKING THE SWITCHES Are the fuse OK Replace the fuse 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C 68 F Is the battery OK Clea...

Page 364: ...tance Zero Ω at 20 C 68 F Replace the circuit breaker 6 Thermo switch 1 Remove the thermo switch 1 from the radi ator Connect the pocket tester Ω 1 to the thermo switch 1 1 as shown Immerse the thermo switch 1 in a con tainer filled with coolant 2 Place a thermometer 3 in the coolant Slowly heat the coolant then let it cool down to the specified temperature Check the thermo switch 1 for continuity...

Page 365: ...ircuit is open and the radia tor fan is off É The thermo switch circuit is closed and the radiator fan is on Does the thermo switch 1 operate properly as described above Replace the thermo switch 1 7 Wiring Check the entire cooling system s wiring Refer to CIRCUIT DIAGRAM Is the cooling system s wiring properly connected and without defects This circuit is OK Properly connect or repair the cooling...

Page 366: ...TRBL SHTG 9 ...

Page 367: ...ANCE 9 2 FAULTY GEAR SHIFTING 9 3 HARD SHIFTING 9 3 SHIFT PEDAL DOES NOT MOVE 9 3 JUMPS OUT GEAR 9 3 CLUTCH SLIPPING DRAGGING 9 3 CLUTCH SLIPPING 9 3 CLUTCH DRAGGING 9 3 OVERHEATING 9 4 OVERHEATING 9 4 FAULTY BRAKE 9 4 POOR BRAKING EFFECT 9 4 SHOCK ABSORBER MALFUNCTION 9 4 MALFUNCTION 9 4 UNSTABLE HANDLING 9 5 UNSTABLE HANDLING 9 5 LIGHTING SYSTEM 9 5 HEADLIGHT DOES NOT COME ON 9 5 TAIL BRAKE LIGH...

Page 368: ...TRBL SHTG ...

Page 369: ... Improperly adjusted fuel level Improperly set pilot jet Clogged starter jet Choke valve malfunction Air filter Clogged air filter element ELECTRICAL SYSTEM Spark plug Improper plug gap Worn electrodes Wire between terminals broken Improper heat range Ignition coil Broken or shorted primary secondary Faulty ignition coil lead Broken body C D I system Faulty C D I unit Faulty pickup coil Faulty lig...

Page 370: ...arance Improperly adjusted valve timing EBS00538 POOR IDLE SPEED PERFORMANCE POOR IDLE SPEED PERFORMANCE Carburetor Improperly returned choke Loose or clogged pilot jet Loose or clogged pilot air jet Improperly adjusted idle speed throttle stop screw Improper throttle cable play Flooded carburetor Intake manifold Loosen carburetor joint Electrical system Faulty battery Faulty C D I unit Faulty pic...

Page 371: ...lever position Improperly returned stopper lever Shift forks Worn shift fork Shift drum Improper thrust play Worn shift drum groove Transmission Worn gear dog EBS00545 CLUTCH SLIPPING DRAGGING CLUTCH SLIPPING Clutch Loose clutch spring Fatigued clutch spring Worn friction plate Worn clutch plate Incorrectly assembled clutch Engine oil Low oil level Improper quality low viscosity Deterioration CLUT...

Page 372: ... Inferior oil quality Brake Brake drag Cooling system Low coolant level Clogged or damaged radiator Damaged or faulty water pump Faulty fan motor Faulty thermo switch EBS00550 FAULTY BRAKE POOR BRAKING EFFECT Disc brake Worn brake pads Worn disc Air in brake fluid Leaking brake fluid Faulty master cylinder kit cup Faulty caliper kit seal Loose union bolt Broken brake hose and pipe Oily or greasy d...

Page 373: ...ccessories Hard charging broken stator coil and or faulty rectifier regulator Incorrect connection Improperly grounded Poor contacts main or light switch Bulb life expired TAIL BRAKE LIGHT DOES NOT LIGHT Wrong tail brake light bulb Too many electrical accessories Hard charging broken stator coil and or faulty rectifier regulator Incorrect connection Improperly grounded Poor contacts main or light ...

Page 374: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN ...

Page 375: ... Sb W L Br Br Br L Br L R W R W Y B Y B B L B L L L B R 1 2 3 4 7 6 8 M K J N 9 0 A 5 V U T S O P Q R S L G H I B C D F E 1 A C magneto 2 Rectifier regulator 3 Main switch 4 Battery 5 Fuse 6 Starter relay 7 Starter motor 8 Diode 1 9 Starting circuit cut off relay 0 Clutch switch A C D I unit B Ignition coil C Spark plug D Throttle position sensor E Throttle switch F Carburetor switch G Circuit bre...

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