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Yamaha 2008 Raptor 250, Service Manual

The Yamaha 2008 Raptor 250 Service Manual is a comprehensive guide for maintaining and repairing your ATV. This manual offers detailed instructions, diagrams, and troubleshooting tips, ensuring a seamless user experience. Download this invaluable resource for free from our website and maximize your Raptor's performance.

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ENG

4-68

Order

Job/Parts to remove

Q’ty

Remarks

Removing the bearing

Remove the parts in the order listed.

Crankshaft assembly

Refer to “CRANKSHAFT ASSEMBLY”.

Main axle assembly/drive axle assem-
bly

Refer to “TRANSMISSION”.

1

Oil seal

2

2

Bearing

8

For installation, reverse the removal 
procedure.

2

2

2

2

1

2

2

2

1

2

CRANKCASE

Summary of Contents for 2008 Raptor 250

Page 1: ...SERVICE MANUAL YFM250RX 4D3 28197 10 LIT 11616 21 22 2008 ...

Page 2: ...ha Motor Corporation U S A First Edition July 2007 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in U S A LIT 11616 21 22 EBS00001 ...

Page 3: ...ations 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 4: ...y 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 is provided for removal and disassembly jobs 2 Numbers 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 w...

Page 5: ...g fluid Lubricant Special tool Torque Wear limit clearance Engine speed Electrical data Ω V A Symbols to in the exploded diagrams indicate the types of lubricants and lubrication points Apply engine oil Apply gear oil Apply molybdenum disulfide oil Apply brake fluid Apply wheel bearing grease Apply lithium soap based grease Apply molybdenum disulfide grease Apply silicone grease Symbols to in the ...

Page 6: ......

Page 7: ...08 TABLE OF CONTENTS GENERAL INFORMATION GEN INFO 1 SPECIFICATIONS SPEC 2 PERIODIC CHECKS AND ADJUSTMENTS CHK ADJ 3 ENGINE ENG 4 CARBURETOR CARB 5 CHASSIS CHAS 6 ELECTRICAL ELEC 7 TROUBLESHOOTING TRBL SHTG 8 ...

Page 8: ... AND OIL SEALS 1 3 CIRCLIPS 1 3 CHECKING THE CONNECTIONS 1 4 SPECIAL TOOLS 1 5 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS 2 1 ENGINE SPECIFICATIONS 2 4 CHASSIS SPECIFICATIONS 2 11 ELECTRICAL SPECIFICATIONS 2 13 TIGHTENING TORQUES 2 15 ENGINE TIGHTENING TORQUES 2 15 CHASSIS TIGHTENING TORQUES 2 17 HOW TO USE THE CONVERSION TABLE 2 19 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 19 LUBRICATION PO...

Page 9: ...3 19 CHANGING THE ENGINE OIL 3 20 ADJUSTING THE CLUTCH CABLE 3 22 CLEANING THE AIR FILTER ELEMENT 3 23 CLEANING THE SPARK ARRESTER 3 25 CHASSIS 3 26 ADJUSTING THE FRONT BRAKE 3 26 ADJUSTING THE BRAKE LEVER For adjustment type model 3 26 ADJUSTING THE REAR BRAKE 3 26 ADJUSTING THE PARKING BRAKE 3 27 CHECKING THE BRAKE FLUID LEVEL 3 28 CHECKING THE FRONT BRAKE PADS 3 29 CHECKING THE REAR BRAKE PADS ...

Page 10: ...N GUIDES 4 11 CHECKING THE TIMING CHAIN TENSIONERS 4 11 INSTALLING THE CYLINDER HEAD 4 12 ROCKER ARM CAMSHAFT 4 15 REMOVING THE ROCKER ARMS AND CAMSHAFT 4 16 CHECKING THE CAMSHAFT 4 17 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS 4 18 INSTALLING THE CAMSHAFT AND ROCKER ARMS 4 19 VALVES AND VALVE SPRINGS 4 21 REMOVING THE VALVES 4 22 CHECKING THE VALVES AND VALVE GUIDES 4 23 CHECKING THE VALVE SE...

Page 11: ...ER LEVER 4 58 INSTALLING THE SHIFT SHAFT 4 58 PICKUP COIL ROTOR AND STARTER CLUTCH 4 60 REMOVING THE PICKUPCOIL ROTOR 4 62 CHECKING THE STARTER CLUTCH 4 63 INSTALLING THE PICKUP COIL ROTOR 4 64 CRANKCASE 4 66 DISASSEMBLING THE CRANKCASE 4 69 CHECKING THE CRANKCASE 4 70 ASSEMBLING THE CRANKCASE 4 70 CRANKSHAFT ASSEMBLY 4 72 REMOVING THE CRANKSHAFT ASSEMBLY 4 73 REMOVING THE PLUNGER SEAL 4 73 CHECKI...

Page 12: ... SPROCKET 6 11 CHECKING THE BRAKE DISC 6 11 INSTALLING THE DRIVEN SPROCKET 6 11 INSTALLING THE REAR AXLE 6 11 FRONT AND REAR BRAKES 6 13 FRONT BRAKE PADS 6 13 REAR BRAKE PADS 6 14 REPLACING THE FRONT BRAKE PADS 6 15 REPLACING THE REAR BRAKE PADS 6 17 FRONT BRAKE MASTER CYLINDER 6 19 REAR BRAKE MASTER CYLINDER 6 21 CHECKING THE MASTER CYLINDERS 6 24 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER 6 25 A...

Page 13: ...CKLES 6 50 CHECKING THE TIE RODS 6 50 CHECKING THE STEERING KNUCKLES 6 50 INSTALLING THE TIE RODS 6 50 FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES 6 51 REMOVING THE FRONT ARMS 6 53 CHECKING THE FRONT ARMS 6 53 CHECKING THE FRONT SHOCK ABSORBERS 6 53 CHECKING THE BALL JOINTS 6 54 INSTALLING THE FRONT ARMS 6 54 REAR SHOCK ABSORBER SWINGARM AND DRIVE CHAIN 6 55 HANDLING THE REAR SHOCK ABSORBER 6 5...

Page 14: ...GING SYSTEM 7 24 CIRCUIT DIAGRAM 7 24 TROUBLESHOOTING 7 25 LIGHTING SYSTEM 7 27 CIRCUIT DIAGRAM 7 27 TROUBLESHOOTING 7 28 CHECKING THE LIGHTING SYSTEM 7 29 SIGNAL SYSTEM 7 31 CIRCUIT DIAGRAM 7 31 TROUBLESHOOTING 7 32 CHECKING THE SIGNALING SYSTEM 7 33 CHAPTER 8 TROUBLESHOOTING STARTING FAILURE HARD STARTING 8 1 FUEL SYSTEM 8 1 ELECTRICAL SYSTEM 8 1 COMPRESSION SYSTEM 8 2 POOR IDLE SPEED PERFORMANC...

Page 15: ...VERHEATING 8 4 FAULTY BRAKE 8 4 POOR BRAKING EFFECT 8 4 SHOCK ABSORBER MALFUNCTION 8 4 MALFUNCTION 8 4 UNSTABLE HANDLING 8 5 UNSTABLE HANDLING 8 5 LIGHTING SYSTEM 8 5 HEADLIGHT DOES NOT COME ON 8 5 TAIL BRAKE LIGHT DOES NOT LIGHT 8 5 BULB BURNT OUT 8 5 TAIL BRAKE LIGHT BULB BURNT OUT 8 5 ...

Page 16: ...BS00010 VEHICLE IDENTIFICATION NUMBER The vehicle identification number is stamped into the left side of the frame EBS00011 MODEL LABEL The model label is affixed to the air filter case cover This information will be needed to order spare parts MACHINE IDENTIFICATION ...

Page 17: ...t 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 but inferior in quality EBS00015 GASKETS OIL SEALS AND O RINGS 1 When overhauling the engine replace all gaskets seals and O...

Page 18: ...rally when installing if appro priate Oil seal CAUTION Do not spin the bearing with compressed air because this will damage the bearing surfaces Bearing EBS00018 CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlips Always replace piston pin clips after one use When installing a circlip make sure the sharp edged corner is positioned opposite the thrust t...

Page 19: ...ctions Loose connection Connect properly NOTE NOTE If the pin on the terminal is flattened bend it up 4 Connect lead coupler connector NOTE NOTE Make sure all connections are tight 5 Check continuity with the pocket tester NOTE 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 revitalizer available at most part st...

Page 20: ... N 90890 Tool No Tool name Function Illustration 90890 01083 YU 01083 1 Slide hummer bolt Slide hummer bolt 6 mm This tool is used to remove the rocker arm shaft 90890 01084 YU 01083 3 Weight This tool is used to remove the rocker arm shaft 90890 01135 YU 01135 B Crankcase separating tool Crankcase separator This tool is used to separate the crankcase 90890 01268 YU 01268 Ring nut wrench Spanner w...

Page 21: ...Six piece tappet set This tool is necessary for adjusting the valve clearance 90890 01362 YU 33270 B Flywheel puller Heavy duty puller This tool is used to remove the AC magneto rotor 90890 01359 Bolt M8 80 mm This tool is used to remove the AC magneto rotor 90890 01701 YS 01880 A Sheave holder Primary clutch holder This tool is needed to hold the AC magneto rotor when loosen or tighten the AC mag...

Page 22: ...ng light This tool is necessary for checking ignition timing Compressor 90890 04019 YM 04019 Valve spring compressor This tool is needed to remove and install the valve assemblies 90890 01243 YM 01253 1 Valve spring compressor attachment Valve spring compressor adapter 26 mm This tool is needed to remove and install the valve assemblies 90890 04086 YM 91042 Universal clutch holder This tool is nee...

Page 23: ...needed to remove and install the valve lifters 90890 06588 PTT wrench 46 This tool is needed to loosen or tighten the rear axle nut YM 37134 Axle nut wrench 46 mm This tool is needed to loosen or tighten the rear axle nut 90890 06754 YM 34487 Ignition checker Opama pet 4000 spark checker This instrument is necessary for checking the ignition system components 90890 06760 YU 39951 B Digital tachome...

Page 24: ...r Displacement 249 cm3 15 19 cu in Bore stroke 74 0 58 0 mm 2 91 2 28 in Compression ratio 9 5 1 Engine idle speed 1 500 1 600 r min Intake vacuum 34 kPa 255 mmHg 10 0 inHg Oil temperature 55 65 C Standard compression pressure at sea level 1 100 kPa 11 2 kg cm2 160 psi 720 r min Starting system Electric starter Lubrication system Wet sump Oil type or grade Engine oil YAMALUBE4 SAE 5W 30 or SAE 10W...

Page 25: ...nstant mesh 5 speed Operation Left foot operation Gear ratio 1st gear 37 13 2 846 2nd gear 33 18 1 833 3rd gear 29 21 1 381 4th gear 27 24 1 125 5th gear 28 29 0 966 Chassis Frame type Steel tube frame Caster angle 6 Camber angle 1 5 Kingpin angle 14 8 Trail 23 0 mm 0 91 in Tread STD front 826 mm 32 52 in rear 824 mm 32 44 in Toe in with tires touching the ground 9 19 mm 0 35 0 75 in Tire Type Tub...

Page 26: ... spring oil damper Rear shock absorber Coil spring gas oil damper Wheel travel Front wheel travel 190 mm 7 48 in Rear wheel travel 200 mm 7 87 in Electrical Ignition system DC CDI Generator system AC magneto Battery type YTZ7S Battery capacity 12 V 6 0 Ah Headlight type Krypton bulb Bulb voltage wattage quantity Headlight 12 V 30 W 30 W 2 Tail brake light 12 V 5 W 21 W 1 4D31 12 V 0 5 W 3 9 W 1 4D...

Page 27: ...in 30 011 mm 1 1815 in Exhaust A 36 891 36 991 mm 1 4524 1 4563 in 36 791 mm 1 4485 in B 30 092 30 192 mm 1 1847 1 1887 in 29 992 mm 1 1808 in Camshaft runout limit 0 03 mm 0 0012 in Timing chain Timing chain type No of links DID SCR 0404 SV 104 Timing chain adjustment method Automatic Rocker arm rocker arm shaft Rocker arm inside diameter 12 000 12 018 mm 0 4724 0 4731 in 12 036 mm 0 4739 in Rock...

Page 28: ...5 0 0472 in EX 0 80 1 20 mm 0 0315 0 0472 in Stem outside diameter IN 5 975 5 990 mm 0 2352 0 2358 in 5 945 mm 0 234 in EX 5 960 5 975 mm 0 2346 0 2352 in 5 930 mm 0 233 in Guide inside diameter IN 6 000 6 012 mm 0 2362 0 2367 in 6 050 mm 0 238 in EX 6 000 6 012 mm 0 2362 0 2367 in 6 050 mm 0 238 in Stem to guide clearance IN 0 010 0 037 mm 0 0004 0 0015 in 0 080 mm 0 003 in EX 0 025 0 052 mm 0 00...

Page 29: ... kg 16 86 20 62 lb Tilt limit IN 2 5 1 60 mm 2 5 0 063 in EX 2 5 1 60 mm 2 5 0 063 in Direction of winding top view IN Counter clockwise EX Counter clockwise Outer spring Free length IN 36 63 mm 1 44 in 34 80 mm 1 37 in EX 36 63 mm 1 44 in 34 80 mm 1 37 in Installed length valve closed IN 32 00 mm 1 26 in EX 32 00 mm 1 26 in Spring rate K1 IN 30 90 N mm 3 15 kg mm 176 44 lb in Spring rate K2 IN 40...

Page 30: ... 006 in Piston size D 73 983 73 998 mm 2 9127 2 9133 in Measuring point H 5 0 mm 0 20 in Piston off set 0 25 mm 0 0098 in Offset direction Intake side Piston pin bore inside diameter 17 002 17 013 mm 0 6694 0 6698 in 17 043 mm 0 6710 in Piston pin outside diameter 16 991 17 000 mm 0 6689 0 6693 in 16 971 mm 0 6681 in Piston pin to piston pin bore clearance 0 002 0 022 mm 0 0001 0 0009 in 0 072 mm ...

Page 31: ... in End gap installed 0 30 0 45 mm 0 012 0 018 in 0 80 mm 0 032 in Side clearance 0 020 0 055 mm 0 0008 0 0022 in 0 115 mm 0 0045 in Oil ring Dimensions B T 1 50 2 60 mm 0 059 0 102 in End gap installed 0 10 0 35 mm 0 004 0 014 in Crankshaft Crank width A 69 25 69 30 mm 2 726 2 728 in Runout limit C1 0 03 mm 0 0012 in C2 0 03 mm 0 0012 in Big end side clearance D 0 350 0 650 mm 0 0138 0 0256 in 0 ...

Page 32: ...0 067 in Quantity 5 Max warpage 0 2 mm 0 0079 in Clutch spring Free length 47 8 mm 1 88 in 45 4 mm 1 79 in Quantity 5 Clutch release method Inner push cam push Push rod 2 bending limit 0 1 mm 0 004 in Transmission Main axle runout limit 0 06 mm 0 0024 in Drive axle runout limit 0 06 mm 0 0024 in Main axle assembly width 102 2 102 4 mm 4 02 4 03 in Shifter Shifter type Shift drum and guide bar Max ...

Page 33: ...G S 1 55 Starter jet 2 G S 2 0 5 Throttle valve size THV 100 Float height F H 13 0 mm 0 51 in Oil filter type Wire mesh Oil pump Oil pump type Trochoid Inner rotor to outer rotor tip clearance 0 15 mm 0 0059 in 0 23 mm 0 0091 in Outer rotor to oil pump housing clearance 0 100 0 151 mm 0 0039 0 0059 in 0 22 mm 0 0087 in Oil pump housing to inner and outer rotor clearance 0 04 0 09 mm 0 0016 0 0035 ...

Page 34: ...18 lb in Stroke 0 87 0 mm 0 3 43 in Optional spring No Swingarm Free play limit radial 1 0 mm 0 04 in axial 1 0 mm 0 04 in Rear axle Rear axle runout 1 5 mm 0 06 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 Type Panel wheel Rim size 9 8 5 AT Rim material Aluminum Rim runout limit radial 2 0 mm 0 08...

Page 35: ... 0 16 in 3 5 mm 0 14 in Brake disk maximum deflection 0 15 mm 0 006 in Pad thickness inner 4 2 mm 0 17 in 1 0 mm 0 04 in Pad thickness outer 4 2 mm 0 17 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 Lever and pedal Brake lever free play 0 mm 0 in Brake pedal position top of the brake pedal to top of the fr...

Page 36: ...ng system Type AC magneto Model manufacturer F5XT YAMAHA Nominal output 14 V 190 W at 5 000 r min Charging coil resistance color 0 688 1 032 Ω at 20 C 68 F white white Rectifier regulator Type Semi conductor short circuit Model manufacturer SH640E 11 SHINDENGEN No load regulated voltage DC 14 1 14 9 V Rectifier capacity DC 14 0 A Withstand voltage 200 0 V Battery Specific gravity 1 310 Electric st...

Page 37: ...ECO Amperage rating 180 A Coil winding resistance 4 18 4 62 Ω Headlight relay Headlight relay Model manufacturer G8HN 1C4T DJ Y52 OMRON Coil resistance 94 5 Ω 115 5 Ω Circuit breaker Type Fuse Amperage for individual circuit Fuse 15 A 1 Reserve 15 A 1 ELECTRICAL SPECIFICATIONS ...

Page 38: ...Nut M6 2 14 1 4 10 Camshaft sprocket Bolt M10 1 60 6 0 44 Timing chain tensioner Bolt M6 2 10 1 0 7 4 Timing chain tensioner cap bolt Bolt M6 1 8 0 8 5 9 Timing chain guide intake side Bolt M6 2 8 0 8 5 9 Oil filter element cover Bolt M6 3 10 1 0 7 4 Oil delivery pipe Union bolt M10 1 20 2 0 15 Oil delivery pipe and cylinder Union bolt M8 1 17 1 7 13 Oil pump assembly Screw M6 3 6 0 6 4 4 Carburet...

Page 39: ...Use a lock washer Clutch spring Screw M6 5 8 0 8 5 9 Push lever adjusting screw locknut Nut M6 1 8 0 8 5 9 Push lever shaft Bolt M8 1 12 1 2 8 9 Chain case cover Bolt M10 2 10 1 0 7 4 Drive sprocket nut Nut M18 1 110 11 0 81 Use a lock washer Stopper lever Bolt M6 1 10 1 0 7 4 Shift pedal Bolt M6 1 10 1 0 7 4 Neutral switch M10 1 20 2 0 15 Starter motor Bolt M6 2 10 1 0 7 4 Stator coil Bolt M6 3 1...

Page 40: ...lock washer Steering stem and handlebar holder M8 20 2 0 15 Tie rod end and locknut M10 15 1 5 11 Steering knuckle and front wheel hub M14 70 7 0 52 Steering knuckle and front arm upper and lower M10 25 2 5 18 Steering knuckle and tie rod ball joint M10 25 2 5 18 Steering stem and tie rod ball joint M10 25 2 5 18 Fuel tank and fuel cock M6 4 0 4 3 0 Fuel tank and frame M6 7 0 7 5 2 Front wheel and...

Page 41: ...31 3 1 23 Parking brake adjusting bolt and locknut M8 15 1 5 11 Rear brake disc and brake disc bracket M8 28 2 8 21 Rear brake fluid reservoir cover and bracket M6 7 0 7 5 2 Front bumper and frame M8 31 3 1 23 Front fender stay and frame M6 7 0 7 5 2 Side cover and frame M6 7 0 7 5 2 Rear fender and frame M6 7 0 7 5 2 Rear fender air filter case and frame M6 7 0 7 5 2 Rear fender and rear fender s...

Page 42: ...n dry threads Com ponents should be at room temperature A Distance between flats B Outside thread diameter METRIC MULTIPLIER IMPERIAL mm 0 03937 in 2 mm 0 03937 0 08 in METRIC TO IMPERIAL Metric unit Multiplier Imperial unit Torque 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 03527 lb oz Speed km hr 0 6214 mph Distance km m m cm mm 0 6214 3 281 1 094...

Page 43: ...ry Valve stems intake and exhaust Valve stem ends intake and exhaust Rocker arm shafts intake and exhaust Camshaft Valve rocker arms Oil pump rotors inner and outer and oil pump housing and shaft Starter idler gears 1 Starter idler gears 2 Starter wheel gear Push rods Clutch housing primary driven gear Push lever shaft Push rod ball Drive axle Main axle Transmission gears inside and end Shift fork...

Page 44: ...ion point Lubricant Crankcase mating surfaces Sealant Three Bond No 1215 Yamaha bond No 1215 AC magneto lead grommet AC magneto cover Sealant Three Bond No 1215 Yamaha bond No 1215 LUBRICATION POINTS AND LUBRICANT TYPES ...

Page 45: ...00026 OIL FLOW DIAGRAMS Camshaft Oil filter element Oil pump Oil strainer Oil cooler Drive axle Main axle Pin with hole Crank shaft Oil pump Oil strainer Cylinder head Cam shaft Oil pan Oil filter OIL FLOW DIAGRAMS ...

Page 46: ...SPEC 2 23 Camshaft Drive axle Main axle Push lever shaft Oil pump assembly Oil strainer Crankshaft assembly Oil filter element OIL FLOW DIAGRAMS ...

Page 47: ...SPEC 2 24 Oil cooler Oil hose 1 Oil hose 2 OIL FLOW DIAGRAMS ...

Page 48: ...SPEC 2 25 EBS00028 CABLE ROUTING Front brake hose Front brake light switch lead Throttle cable Plastic band Clutch cable Parking brake cable Clutch switch lead Handlebar switch lead CABLE ROUTING ...

Page 49: ...he guide of the handlebar protector Route the throttle cable under the front brake hose Route the clutch cable and parking brake cable through the guide of the handlebar protector Route the clutch cable in front of the parking brake cable Clamp the clutch switch lead and handlebar switch lead at the bends of handlebar CABLE ROUTING ...

Page 50: ...cket Rear brake light switch lead Parking brake cable Battery negative lead Carburetor warmer lead Air vent hose Air filter case breather hose Throttle cable Front brake hose 1 Clutch cable Main harness Clamp Frame complete Rear brake reservoir hose Carburetor overflow hose Neutral switch lead Rear brake reservoir cover H H H H F A A F A A CABLE ROUTING ...

Page 51: ...ooler hose 1 and 2 between the exhaust pipe and the engine bracket Route the battery negative lead behind the clutch cable holder Route the air vent hose through the bracket Make sure that the white paint mark on the air filter case breather hose Make sure that the clip end is facing the left side of the vehicle Route the throttle cable under the cross pipe and left of the steering column as shown...

Page 52: ... lead neutral switch lead air vent hose carburetor overflow hose and parking brake cable through the bracket Route the rear brake light switch lead under the bracket Route the rear brake light switch lead between the bracket and rear brake reservoir tank Route the neutral switch lead and rear brake light switch lead as shown in the illustration H H H H F A A F A A CABLE ROUTING ...

Page 53: ...SPEC 2 30 Rear brake reservoir Rear brake light switch Clip Rear brake reservoir hose Rear brake master cylinder Parking brake cable Rear brake hose Rear brake caliper E E D D C C D D C C CABLE ROUTING ...

Page 54: ...e rear brake hose until it contacts the pro jection Make sure that the end of the clip is facing out ward Install the rear brake reservoir hose making sure to face the white paint mark outward Insert the rear brake reservoir hose until it contacts the projection When installing the rear brake hose make sure that the metal part on the rear brake Inlet hose is touching the stopper of the rear calipe...

Page 55: ...ow hose Starter motor lead Neutral switch lead Ignition coil spark plug lead Ignition coil Drain hose Frame complete Damper plate Seat pad Cover Rear brake light switch lead Carburetor warmer lead Air filter case breather hose Air filter joint Air filter case D M D L L M M E E B B C C D D G G N N I I M E E B N L L N I I B G G C C CABLE ROUTING ...

Page 56: ...t oil cooler hose Clamp on top of the frame bracket To the left headlight Route the clamp through the damper plate hole Route the carburetor overflow hose as shown in the illustration Fasten the clamp with the engine Route the leads on the upper inside of the cover Place the couplers on the inside of the cover Route the clamp through the frame bracket D M D L L M M E E B B C C D D G G N N I I M E ...

Page 57: ...ange bolt Headlight lead Indicator light lead Clutch cable Parking brake cable Rear brake reservoir Rear brake light switch lead Air vent hose Battery negative lead Carburetor warmer lead Starter motor lead Clutch switch lead Handlebar switch lead Main harness Frame complete Clamp N N J J K K J J K K CABLE ROUTING ...

Page 58: ...adlight lead under the frame To the front fender To the front panel To the handlebar Route the air vent hose through the bracket Route the battery negative lead behind the clutch cable holder Fix point for wire harness Insert the air vent hose into the fender Route the clutch switch lead and handlebar switch lead on the box shaped part Connect the clutch switch lead and handlebar switch lead on to...

Page 59: ...SPEC 2 36 Route the cables and leads through the guide of the front fender Route the leads behind the clutch and parking brake cable CABLE ROUTING N N J J K K J J K K ...

Page 60: ...nit Band Battery Starter relay lead Starter relay Taillight lead Battery negative lead AC magneto coupler Starter motor lead Headlight relay Neutral relay Damper CDI unit lead Relay lead CABLE ROUTING J A A B A A J B ...

Page 61: ...ry negative lead push the sag in the box After connecting the taillight lead and each electric part the length between the air filter and AC mag neto coupler should be 185 mm 7 28 in on straight line There is no particular order in placing each lead Insert each relay all the way into the rib on the air filter side Insert the starter relay all the way into the rib on the air filter side J A A B A A...

Page 62: ...sed for a long period of time the month main tenance intervals should be followed Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools data and technical skills NO ITEM CHECK OR MAINTENANCE JOB Whichever comes first INITIAL EVERY month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 1 Fuel line Check fuel hoses f...

Page 63: ...ricate with lithium soap based grease 11 Upper and lower arm pivots Lubricate with lithium soap based grease 12 Drive chain Check chain slack and adjust if necessary Check rear wheel alignment and correct if necessary Clean and lubricate 13 Drive chain rollers Check for wear and replace if necessary 14 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 15 Shock absor...

Page 64: ...d if necessary correct the brake fluid level Every two years replace the internal components of the brake master cylinders and calipers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged WARNING Indicates a potential hazard that could result in serious injury or death GENERAL MAINTENANCE AND LUBRICATION CHART ...

Page 65: ...ack the seat lock lever than pull up on the rear of the seat 2 Indicator light coupler 1 Disconnect 3 Front panel 1 4 Plate 1 5 Main switch coupler 1 Disconnect 6 Front fender 1 7 Headlight coupler 2 Disconnect 8 Left headlight 1 9 Right headlight 1 For installation reverse the removal procedure 7 Nm 0 7 m kg 5 2 ft Ib 7 Nm 0 7 m kg 5 2 ft Ib 7 Nm 0 7 m kg 5 2 ft Ib 7 Nm 0 7 m kg 5 2 ft Ib SEAT FE...

Page 66: ...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 procedure 2 1 3 T R T R T R T R T R 17 Nm 1 7 m kg 13 ft Ib 7 Nm 0 7 m kg 5 2 ft Ib 17 Nm 1 7 m kg 13 ft Ib 17 Nm 1 7 m kg 13 ft Ib 17 Nm 1 7 m kg 13 ft Ib SEAT FENDERS AND FUEL TANK ...

Page 67: ...AND FUEL TANK 1 Rear fender 1 2 Battery cover 1 3 Battery lead 2 CAUTION First disconnect the negative lead then disconnect the positive lead 4 Battery 1 5 Relay 2 6 CDI unit 1 7 Tail brake light lead 1 Disconnect 8 Air filter case breather hose 1 Disconnect 9 Clamp 1 Loosen 7 Nm 0 7 m kg 5 2 ft Ib 7 Nm 0 7 m kg 5 2 ft Ib 7 Nm 0 7 m kg 5 2 ft Ib 7 Nm 0 7 m kg 5 2 ft Ib SEAT FENDERS AND FUEL TANK ...

Page 68: ...der Job Part Q ty Remarks 10 Air filter case 1 For installation reverse the removal procedure 7 Nm 0 7 m kg 5 2 ft Ib 7 Nm 0 7 m kg 5 2 ft Ib 7 Nm 0 7 m kg 5 2 ft Ib 7 Nm 0 7 m kg 5 2 ft Ib SEAT FENDERS AND FUEL TANK ...

Page 69: ...ANK 1 Fuel hose fuel cock side 1 NOTE NOTE Before disconnecting the fuel hose turn the fuel cock to OFF 2 Fuel tank 1 NOTE NOTE When installing the fuel tank pass the fuel tank breather hose through the hole in the handlebar protector 3 Clamp 1 4 Fuel tank shield 1 For installation reverse the removal procedure 2 1 3 4 7 Nm 0 7 m kg 5 2 ft Ib SEAT FENDERS AND FUEL TANK ...

Page 70: ...the Top Dead Center TDC on the compression stroke 1 Remove seat front fender fuel tank Refer to SEAT FENDERS AND FUEL TANK 2 Remove spark plug cap spark plug cylinder head side cover 1 cylinder head side cover 2 3 Remove timing mark accessing screw crankshaft end accessing screw 4 Measure valve clearance Out of specification Adjust 1 2 1 2 Valve clearance cold Intake valve 0 05 0 10 mm 0 0020 0 00...

Page 71: ...t and the pointer on the cylinder head match c Measure the valve clearance with a thick ness gauge Out of specification Adjust 5 Adjust valve clearance a Loosen the locknut b Insert a thickness gauge between the end of the adjusting screw and the valve stem c Turn the adjusting screw until the speci fied valve clearance is obtained Hold the adjusting screw to prevent it from moving and tighten the...

Page 72: ...NOTE NOTE For installation reverse the removal proce dure EBS00051 ADJUSTING THE ENGINE IDLING SPEED 1 Start the engine and let it warm up for sev eral minutes 2 Attach digital tachometer onto the ignition coil spark plug lead 3 Measure engine idling speed Out of specification Adjust Digital tachometer 90890 06760 YU 39951 B Engine idling speed 1 500 1 600 r min ADJUSTING THE VALVE CLEARANCE ADJUS...

Page 73: ...E LEVER FREE PLAY EBS00052 ADJUSTING THE THROTTLE LEVER FREE PLAY NOTE NOTE Engine idling speed should be adjusted prop erly before adjusting the throttle lever free play 1 Measure throttle lever free play Out of specification Adjust a b Direction Idling speed becomes higher Direction Idling speed becomes lower Throttle lever free play 2 4 mm 0 08 0 16 in a Throttle lever free play 2 4 mm 0 08 0 1...

Page 74: ...rect free play is obtained i Tighten the locknut j Slide the rubber cover to its original posi tion WARNING After adjusting the free play turn the han dlebar to the right and left to make sure that the engine idling speed does not increase EBS00053 ADJUSTING THE SPEED LIMITER The speed limiter keeps the carburetor throttle from becoming fully opened even when the throttle lever is applied to the m...

Page 75: ...ter should be screwed in completely 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 0 47 in Also always adjust the throt tle lever free play to 2 4 mm 0 08 0 16 in 1 2 b c a Speed limiter length Less than 12 mm 0 47 in Direction Speed limiter...

Page 76: ...ium to light tan color 5 Clean spark plug with a spark plug cleaner or wire brush 6 Measure spark plug gap Use a wire gauge or thickness gauge Out of specification Regap 7 Install spark plug NOTE NOTE Before installing a spark plug clean the gasket surface and plug surface 8 Install spark plug cap Standard spark plug NGK DR7EA Spark plug gap 0 6 0 7 mm 0 024 0 028 in Spark plug 18 Nm 1 8 m kg 13 f...

Page 77: ... keep it at the specified speed b Remove the timing mark accessing screw c Visually check the stationary pointer to verify it is within the required firing range indicated on the AC magneto rotor Incorrect firing range Check the pickup coil assembly d Install the timing mark accessing screw 3 Detach timing light digital tachometer Digital tachometer 90890 06760 YU 39951 B Timing light 90890 03141 ...

Page 78: ...EAR ANCE 2 Start the engine warm it up for several min utes and then turn it off 3 Disconnect Spark plug cap 4 Remove Spark plug ECA13340 CAUTION Before removing the spark plug use com pressed air to blow away any dirt accumu lated in the spark plug wells to prevent it from falling into the cylinder 5 Install Compression gauge Extension 2 1 Compression gauge 90890 03081 Engine compression tester Y...

Page 79: ...d If the compression pressure is below the minimum specification pour a teaspoonful of engine oil into the spark plug bore and measure again Refer to the following table Compression pressure standard 1 100 kPa 720 r min 11 2 kgf cm2 160 psi 720 r min Compression pressure maximum 1 300 kPa 720 r min 13 3 kgf cm2 189 psi 720 r min Compression pressure minimum 900 kPa 720 r min 9 2 kgf cm2 131 psi 72...

Page 80: ...ait a few minutes until the oil settles before checking the oil level Do not screw the dipstick in when check ing the oil level CAUTION 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 Spark plug 18 Nm 1 8 m kg 13 ft lb 1 1 a b Recommended engine oil type YAMALUBE 4 SAE 5W 30 or SA...

Page 81: ...turn it off 3 Place a container under the engine oil drain bolt 4 Remove dipstick oil filter element drain bolt 5 Remove engine oil drain bolt along with the washer 6 Drain engine oil completely from the crankcase 7 If the oil filter element is also to be replaced perform the following procedure a Remove the oil filter element cover and oil filter element b Install new O rings c Install the new oi...

Page 82: ...n utes and then turn it off 12 Check engine for engine oil leaks 13 Check engine oil level Refer to CHECKING THE ENGINE OIL LEVEL 2 3 3 Engine oil drain bolt 20 Nm 2 0 m kg 15 ft lb Oil filter element drain bolt 10 Nm 1 0 m kg 7 4 ft lb Periodic oil replacement 1 25 L 1 10 Imp qt 1 32 US qt With oil filter element replacement 1 35 L 1 19 Imp qt 1 43 US qt Engine oil quantity Total amount 1 60 L 1 ...

Page 83: ...e engine oil pressure again e Tighten the oil gallery bolt to specification EBS00070 ADJUSTING THE CLUTCH CABLE 1 Check clutch lever free play Out of specification Adjust 2 Adjust clutch release lever free play a Slide back the lever cover b Loosen the locknut c Turn the adjusting bolt in direction or until the specified clutch cable free play is obtained d Tighten the locknut e Slide the rubber c...

Page 84: ...ent and air fil ter case 1 Remove seat Refer to SEAT FENDERS AND FUEL TANK 2 Remove air filter case cover 3 Remove wing bolt air filter element air filter element frame 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 1 1 1 2 2 3 ADJUSTING THE CLUTCH CABLE CLEANING THE AIR FILTER ELEMENT ...

Page 85: ...amage the foam material c Apply Yamaha foam air filter oil or other quality foam air filter oil not spray type d Squeeze out the excess oil NOTE 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 on air filter ele ment 8 Install air filter element wing bolt NOTE NOTE Make sure its sealing surface matches the ...

Page 86: ...pipe from the muffler a Remove the bolts b Remove the tailpipe from the muffler c Tap the tailpipe lightly with a soft face ham mer or suitable tool then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe and the inner contact surfaces of the muffler d Insert the tailpipe and gasket into the muffler e Install the bolts and tighten it 2 1 1 1 2 CLEANING T...

Page 87: ...ile pushing the brake lever forward turn the adjusting bolt in direction or 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 EBS00085 ADJUSTING THE REAR BRAKE 1 Measure rear brake pedal height Out of specification Adjust a Brake lever free play at the end of the brake lever 0 mm 0 in...

Page 88: ...t 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 ADJUSTING THE PARKING BRAKE 1 Check parking brake cable end length Out of specification Adjust 1 2 a Parking brake cable end ...

Page 89: ...ide 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 EBS00087 CHECKING THE BRAKE FLUID LEVEL 1 Place the machine on a level surface NOTE NOTE When checking the brake fluid le...

Page 90: ...n 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 NOTE In order to ensure a correct reading of the brake fluid level make sure that the top of the br...

Page 91: ...ont wheels Refer to FRONT AND REAR WHEELS in chapter 6 EBS00089 CHECKING THE REAR BRAKE PADS 1 Check brake pads Wear indicators almost touch the brake disc Replace the brake pads as a set Refer to FRONT AND REAR BRAKES in chapter 6 2 Operate the brake pedal Brake pad wear limit 1 5 mm 0 06 in Brake pad wear limit 1 0 mm 0 04 in CHECKING THE FRONT BRAKE PADS CHECKING THE REAR BRAKE PADS ...

Page 92: ...ion timing Incorrect Adjust 2 Adjust rear brake light operation timing a Hold the main body of the rear brake light switch so that it does not rotate and turn the adjusting nut in direction or until the rear brake light comes on at the proper time EBS00092 CHECKING THE BRAKE HOSES 1 Remove seat front fender Refer to SEAT FENDERS AND FUEL TANK Direction Brake light comes on sooner Direction Brake l...

Page 93: ...ake pedal several times Fluid leakage Replace the hoses or pipe Refer to FRONT AND REAR BRAKES in chapter 6 6 Install front fender seat Refer to SEAT FENDERS AND FUEL TANK EBS00094 BLEEDING THE HYDRAULIC BRAKE SYSTEM WARNING Bleed the hydraulic brake system when ever the system is disassembled a brake hose is loosened disconnected or replaced the brake fluid level is very low brake operation is fa...

Page 94: ...uid reservoir to the proper level with the recommended brake fluid b Install the diaphragm brake master cylin der reservoir or brake fluid reservoir c Connect a clear plastic hose tightly to the bleed screw Front Rear d Place the other end of the hose into a con tainer e Slowly apply the brake lever or brake pedal several times f Fully squeeze the brake lever or fully depress the brake pedal and h...

Page 95: ... THE SHIFT PEDAL 1 Measure shift pedal height Out of specification Adjust 2 Adjust shift pedal position a Remove the drive sprocket cover Refer to REAR SHOCK ABSORBER SWINGARM AND DRIVE CHAIN in chap ter 6 b Remove the bolt c Remove the shift pedal d Install the shift pedal at the correct height e Tighten the bolt to specification 5 Nm 0 5 m kg 3 7 ft lb Shift pedal height 15 2 mm 0 60 in 10 Nm 1 ...

Page 96: ... cause an accident Therefore keep the drive chain slack within the speci fied limits 1 Measure drive chain slack Out of specification Adjust 2 Adjust drive chain slack NOTE NOTE The drive chain slack is adjusted by the rota tion of the rear axle hub a Loosen the rear axle pinch bolts b Insert a rod of a diameter of 8 mm 0 31 in and length of 10 cm 4 in in the hole of rear axle hub c Shift the tran...

Page 97: ... 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 have vertical play Replace the tie rod end s 4 Raise the front end of the machine so that there is no w...

Page 98: ...arks f Calculate the toe in using the formula given below g If the toe in is incorrect adjust it 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 the toe in to specification run the machine slowly for some dist...

Page 99: ...rod Bends damage Replace the front rear shock absorber assembly oil leakage Excessive oil leakage Replace the front rear shock absorber assembly cylinder Damage 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 SWINGARM AND DRIVE CHAIN in chapter 6 3 Check operation Pump the s...

Page 100: ...dling and loss of stability 1 Adjust spring preload a Turn the adjusting ring in direction or with the spanner wrench 1 2 3 4 5 Direction Spring preload is increased suspension is harder Direction Spring preload is decreased suspension is softer Standard position 2 Minimum position 1 Maximum position 5 Ring nut wrench 90890 01268 Spanner wrench YU 01268 ADJUSTING THE FRONT SHOCK ABSORBERS ...

Page 101: ...he spring installed changes 1 0 mm 0 04 in per turn of the adjuster CAUTION Never attempt to turn the adjusting ring beyond the maximum or minimum setting d Tighten the locknut NOTE NOTE Always tighten the locknut against the adjust ing nut then torque it to specification Direction Spring preload is increased suspension is harder Direction Spring preload is decreased suspension is softer Adjusting...

Page 102: ...kPa 0 28 kg cm2 4 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 24 5 kPa 0 25 kg cm2 3 6 psi Rear 24 5 kPa 0 25 kg cm2 3 6 psi 3 Use no more than Front 250 kPa 2 6 kg cm2 36 psi Rear 250 kPa 2 6 kg cm2 36 psi when seating the tire beads Higher pressures may cause the tire to burs...

Page 103: ...dling of this machine 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 Sta...

Page 104: ...NG THE CABLES WARNING A damaged cable sheath may cause corro sion and interfere with the cable movement An unsafe condition may result so replace a damaged cable as soon as possible 1 Check cable sheath Damage Replace 2 Check cable operation Unsmooth operation Lubricate or replace NOTE NOTE Hold the cable end up and apply several drops of lubricant to the cable 3 Apply Lithium soap based grease on...

Page 105: ...EVERS AND PEDALS Lubricate the pivoting point and metal to metal moving parts of the levers and pedal Recommended lubricants Brake lever Silicone grease Clutch lever and brake pedal Lithium soap based grease LUBRICATING THE LEVERS AND PEDALS ...

Page 106: ...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 cells ...

Page 107: ...nnect a pocket tester to the battery ter minals NOTE NOTE The charge state of an MF battery can be checked by measuring its open circuit voltage i e the voltage when the positive terminal is disconnected No charging is necessary when the open cir cuit voltage equals or exceeds 12 8 V b Check the charge of the battery as shown in the charts and the following example Positive tester probe positive b...

Page 108: ...chance of sparks do not plug in the battery charger until the bat tery charger leads are connected to the battery Before removing the battery charger lead clips from the battery terminals be sure to turn off the battery charger Make sure the battery charger lead clips are in full contact with the battery terminal and that they are not shorted A corroded battery charger lead clip may generate heat ...

Page 109: ...ustration the open circuit voltage of an MF battery sta bilizes about 30 minutes after charging has been completed Therefore wait 30 minutes after charging is completed before measuring the open circuit voltage CHECKING AND CHARGING THE BATTERY ...

Page 110: ...rd charg ing amperage after 5 min utes replace the battery Set the timer to the charging time determined by the open circuit voltage Refer to CHECKING AND CHARGING 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 batter...

Page 111: ... of battery charger cannot charge an MF battery A variable voltage charger is recommended Set the charging time to a maxi mum of 20 hours Constant amperage chargers are not suitable for charging MF batteries Leave the battery unused for more than 30 minutes before measuring its open circuit voltage 12 8 V Charging is complete 12 0 12 7 V Recharging is required Under 12 0 V Replace the battery Is t...

Page 112: ...tive battery lead and then the negative battery lead 8 Check battery terminals Dirt Clean with a wire brush Loose connection Connect properly 9 Lubricate battery terminals 10 Install battery cover seat Refer to SEAT FENDERS AND FUEL TANK Recommended lubricant Dielectric grease CHECKING AND CHARGING THE BATTERY ...

Page 113: ...a Connect the pocket tester to the fuse and check the continuity NOTE 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 electrical circuit Po...

Page 114: ...and ignition systems to malfunction and could possibly cause a fire 4 Install battery cover seat Refer to SEAT FENDERS AND FUEL TANK EBS00122 ADJUSTING THE HEADLIGHT BEAM 1 Adjust headlight beam vertically a Turn the adjusting bolt in direction or Items Amperage rating Q ty Main 15 A 1 Reserve 15 A 1 Direction Headlight beam is raised Direction Headlight beam is lowered CHECKING THE FUSES ADJUSTIN...

Page 115: ...b 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 affected If oil gets on the b...

Page 116: ...light bulb holder cover NOTE NOTE After installing the bulb holder cover make sure that the TOP mark is in the position shown 7 Connect headlight lead coupler 8 Install headlight Refer to SEAT FENDERS AND FUEL TANK REPLACING A HEADLIGHT BULB ...

Page 117: ... the parts in the order listed Seat front panel fender Refer to SEAT FENDERS AND FUEL TANK in chapter 3 1 Clamp 1 Loosen 2 Muffler 1 3 Gasket 1 4 Exhaust pipe 1 5 EXhaust pipe protector 1 6 Gasket 1 For installation reverse the removal procedure 34 Nm 3 4 m kg 25 ft lb 20 Nm 2 0 m kg 15 ft lb 8 Nm 0 8 m kg 5 9 ft lb 18 Nm 1 8 m kg 13 ft lb ENGINE REMOVAL ...

Page 118: ...sket exhaust pipe 5 Tighten nuts exhaust pipe 6 Install clamp NOTE NOTE Slide the clamp onto the end of the muffler and insert the projection of the clamp into a slot in the muffler Tighten the clamp after installing the muffler Installed depth of gasket 3 5 mm 0 14 in Screw 8 Nm 0 8 m kg 5 9 ft lb LOCTITE Exhaust pipe nut 18 Nm 1 8 m kg 13 ft lb ENGINE REMOVAL ...

Page 119: ...CARBURETOR in chapter 5 Drive sprocket drive chain Refer to REAR SHOCK ABSORBER SWINGARM AND DRIVE CHAIN in chapter 6 1 Ignition coil spark plug lead 1 2 Air filter case breather hose 1 3 Starter motor lead 1 Disconnect 4 Battery negative lead 1 Disconnect 5 Clutch cable 1 6 Plastic band 1 Disconnect 7 Parking brake cable 1 8 AC magneto coupler 2 Disconnect 6 7 3 1 2 9 8 4 5 10 Nm 1 0 m kg 7 4 ft ...

Page 120: ...ENG 4 4 Order Job Parts to remove Q ty Remarks 9 Neutral switch connector 1 Disconnect For installation reverse the removal procedure 6 7 3 1 2 9 8 4 5 10 Nm 1 0 m kg 7 4 ft lb ENGINE REMOVAL ...

Page 121: ...bracket left and right 2 4 Engine mounting bolt upper 1 5 Engine bracket upper 1 6 Engine mounting bolt rear upper 1 7 Engine mounting bolt rear lower 1 8 Engine assembly 1 For installation reverse the removal procedure 66 Nm 6 6 m kg 49 ft lb 33 Nm 3 3 m kg 24 ft lb 33 Nm 3 3 m kg 24 ft lb 66 Nm 6 6 m kg 49 ft lb 33 Nm 3 3 m kg 24 ft lb 40 Nm 4 0 m kg 30 ft lb 40 Nm 4 0 m kg 30 ft lb ENGINE REMOV...

Page 122: ...bracket bolts upper side Engine mounting nut rear lower side Engine mounting nut rear upper side Engine mounting nut upper side Engine mounting nut front side Engine bracket bolts front side Crankcase nut 40 Nm 4 0 m Engine bracket bolt upper side 33 Nm 3 3 m kg 24 ft lb Engine mounting nut rear lower side 66 Nm 6 6 m kg 49 ft lb Engine mounting nut rear upper side 66 Nm 6 6 m kg 49 ft lb Engine m...

Page 123: ...D HOSES Engine bracket upper side Refer to ENGINE MOUNTING BOLTS 1 Spark plug 1 2 Cylinder head cover 1 O ring 1 1 3 Cylinder head cover 2 O ring 1 1 4 Cylinder head cover 3 O ring 1 1 5 Breather pipe 1 Gasket 1 1 6 Crankshaft end accessing screw O ring 1 1 7 Timing mark accessing screw O ring 1 1 8 Camshaft sprocket bolt 1 Loosen 20 Nm 2 0 m kg 15 ft lb 60 Nm 6 0 m kg 44 ft lb 10 Nm 1 0 m kg 7 4 ...

Page 124: ...el pin 1 1 13 Cylinder head 1 14 Timing chain guide 1 15 Dowel pin 2 16 Cylinder head gasket 1 For installation reverse the removal procedure 20 Nm 2 0 m kg 15 ft lb 60 Nm 6 0 m kg 44 ft lb 10 Nm 1 0 m kg 7 4 ft lb 10 Nm 1 0 m kg 7 4 ft lb 18 Nm 1 8 m kg 13 ft lb 24 Nm 2 4 m kg 18 ft lb 18 Nm 1 8 m kg 13 ft lb 10 Nm 1 0 m kg 7 4 ft lb CYLINDER HEAD ...

Page 125: ...compres sion stroke align the I mark on the camshaft sprocket with the mark on the cylinder head 2 Loosen Camshaft sprocket bolt 3 Remove Timing chain tensioner cap Timing chain tensioner along with the gasket Camshaft sprocket bolt Breather plate 2 Camshaft sprocket Timing chain NOTE NOTE To prevent the timing chain from falling into the crankcase fasten it with a wire 4 Remove Cylinder head CYLI...

Page 126: ...der head warpage Out of specification Resurface the cylin der head a Place a straightedge and a thickness gauge across the cylinder head b Measure the warpage c If the limit is exceeded resurface the cylin der head as follows d Place a 400 600 grit wet sandpaper on the surface plate and resurface the cylinder head using a figure eight sanding pattern NOTE NOTE To ensure an even surface rotate the ...

Page 127: ...t sprocket and crankshaft sprocket as a set 1 4 tooth Correct Timing chain Camshaft sprocket 3 Check Timing chain guide exhaust side CHECKING THE TIMING CHAIN TENSIONERS 1 Check Timing chain tensioner Cracks damage Replace 2 Check One way cam operation Rough movement Replace the timing chain tensioner housing a Lightly press the timing chain tensioner rod into the timing chain tensioner housing by...

Page 128: ...ective part s INSTALLING THE CYLINDER HEAD 1 Install Cylinder head gasket Dowel pins 2 Install Cylinder head Copper washers Cylinder head bolts 3 Tighten Cylinder head bolts NOTE NOTE Apply oil to the bearing surface of upper cyl inder head bolt Further apply molybdenum disulfide grease to thread part Tighten the cylinder head bolts in the proper tightening sequence as shown 4 Install Camshaft spr...

Page 129: ... timing e Align the I mark on the camshaft sprocket with the stationary pointer on the cylinder head f While holding the camshaft temporarily tighten the camshaft sprocket bolts 5 Install Timing chain tensioner a While lightly pressing the timing chain ten sioner rod by hand turn the tensioner rod fully clockwise with a thin screwdriver b With the timing chain tensioner rod turned all the way into...

Page 130: ...er on the cylin der head Out of alignment Correct Refer to the installation steps above 8 Tighten Camshaft sprocket bolt CAUTION Be sure to tighten the camshaft sprocket bolts to the specified torque to avoid the possibility of the bolts coming loose and damaging the engine 9 Measure Valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEAR ANCE in chapter 3 Camshaft sprocket ...

Page 131: ...ve the parts in the order listed Cylinder head Refer to CYLINDER HEAD 1 Lock plate 1 2 Locknut valve clearance adjusting screw 2 2 3 Camshaft 1 4 Intake rocker arm shaft 1 5 Intake rocker arm 1 6 Exhaust rocker arm shaft 1 7 Exhaust rocker arm 1 For installation reverse the removal procedure ROCKER ARM CAMSHAFT ...

Page 132: ...0 396 in bolt into the threaded end of the camshaft and then pull out the camshaft 4 Remove Intake rocker arm shaft Exhaust rocker arm shaft Intake rocker arm Exhaust rocker arm NOTE NOTE Remove the rocker arm shafts with the slide hammer bolt and weight Slide hammer bolt 90890 01083 Slide hammer bolt 6 mm YU 01083 1 Weight 90890 01084 YU 01083 3 ROCKER ARM CAMSHAFT ...

Page 133: ...place the cam shaft 4 Check Camshaft oil passage Obstruction Blow out with compressed air Camshaft lobe dimension Intake A 36 890 36 990 mm 1 4524 1 4563 in Limit 36 790 mm 1 4484 in Intake B 30 111 30 211 mm 1 1855 1 1894 in Limit 30 011 mm 1 1815 in Exhaust A 36 891 36 991 mm 1 4524 1 4563 in Limit 36 791 mm 1 4485 in Exhaust B 30 092 30 192 mm 1 1847 1 1887 in Limit 29 992 mm 1 1808 in ROCKER A...

Page 134: ...on Replace 4 Measure Rocker arm shaft outside diameter Out of specification Replace 5 Calculate Rocker arm to rocker arm shaft clearance NOTE NOTE Calculate the clearance by subtracting the rocker arm shaft outside diameter from the rocker arm inside diameter Out of specification Replace the defec tive part s Rocker arm inside diameter 12 000 12 018 mm 0 4724 0 4731 in Limit 12 036 mm 0 4739 in Ro...

Page 135: ... arm Intake rocker arm shaft NOTE NOTE Insert a cylinder head bolt 226 mm into the hole in the cylinder head and the intake rocker arm shaft as shown Install the intake rocker arm shaft so that groove is horizontal and aligning the notch of the pointed end with the hole in the cyl inder head Recommended lubricant Camshaft Molybdenum disulfide oil Camshaft bearing Engine oil Recommended lubricant R...

Page 136: ...Camshaft NOTE NOTE Screw a 10 mm bolt into the threaded end of the camshaft and then install the camshaft 6 Install Lock plate 7 Tighten Lock plate bolts Lock plate bolt 8 Nm 0 8 m kg 5 9 ft lb LOCTITE ROCKER ARM CAMSHAFT ...

Page 137: ...sted Cylinder head Refer to CYLINDER HEAD Rocker arm Camshaft 1 Valve cotter 4 2 Valve spring retainer 2 3 Outer valve spring 2 4 Inner valve spring 2 5 Intake valve 1 6 Exhaust valve 1 7 Valve stem seal 2 8 Valve spring seat 2 9 Valve guide 2 For installation reverse the removal procedure VALVES AND VALVE SPRINGS Refer to ROCKER ARM CAMSHAFT ...

Page 138: ...alve seat width Refer to CHECKING THE VALVE SEATS a Pour a clean solvent into the intake and exhaust ports b Check that the valves properly seal NOTE NOTE There should be no leakage at the valve seat 2 Remove Valve cotters NOTE NOTE Remove the valve cotters by compressing the valve spring with the valve spring compressor and the valve spring compressor attachment Valve spring compressor 90890 0401...

Page 139: ...ure applies to all of the valves and valve guides 1 Measure Valve stem to valve guide clearance Out of specification Replace the valve guide Valve stem to valve guide clearance Valve guide inside diameter Valve stem diameter Valve stem to valve guide clearance Valve stem to valve guide clearance intake 0 010 0 037 mm 0 0004 0 0015 in Limit 0 080 mm 0 003 in Valve stem to valve guide clearance exha...

Page 140: ...eamer to obtain the proper valve stem to valve guide clearance NOTE NOTE After replacing the valve guide reface the valve seat 3 Eliminate Carbon deposits from the valve face and valve seat 4 Check Valve face Pitting wear Grind the valve face Valve stem end Mushroom shape or diameter larger than the body of the valve stem Replace the valve Valve guide remover ø6 90890 04064 Valve guide remover 6 0...

Page 141: ...ed always replace the oil seal CHECKING THE VALVE SEATS The following procedure applies to all of the valves and valve seats 1 Eliminate Carbon deposits from the valve face and valve seat 2 Check Valve seat Pitting wear Replace the cylinder head Valve margin thickness Valve margin thickness D intake 0 80 1 20 mm 0 0315 0 0472 in Valve margin thickness D exhaust 0 80 1 20 mm 0 0315 0 0472 in Valve ...

Page 142: ...the valve seat width NOTE NOTE Where the valve seat and valve face contacted one another the blueing will have been removed 4 Lap Valve face Valve seat NOTE NOTE After replacing the cylinder head or replacing the valve and valve guide the valve seat and valve face should be lapped Valve seat width Valve seat width C intake 0 90 1 10 mm 0 0354 0 0433 in Valve seat width C exhaust 0 90 1 10 mm 0 035...

Page 143: ...ightly tap the valve seat while rotating the valve back and forth between your hands e Apply a fine lapping compound to the valve face and repeat the above steps f After every lapping procedure be sure to clean off all of the lapping compound from the valve face and valve seat g Apply Mechanic s blueing dye Dykem onto the valve face h Install the valve into the cylinder head i Press the valve thro...

Page 144: ...intake 36 63 mm 1 44 in Free length exhaust 36 63 mm 1 44 in Inner spring Installed compression spring force intake 75 00 91 70 N 7 65 9 35 kg 16 86 20 62 lb Installed compression spring force exhaust 75 00 91 70 N 7 65 9 35 kg 16 86 20 62 lb Installed length intake 30 50 mm 1 20 in Installed length exhaust 30 50 mm 1 20 in Outer spring Installed compression spring force intake 128 50 157 90 N 13 ...

Page 145: ...Install Valve spring seat Valve stem seal Valve Inner valve spring Outer valve spring Upper spring seat into the cylinder head NOTE NOTE Install the valve springs with the larger pitch facing up Larger pitch Smaller pitch Inner spring Spring tilt intake 2 5 1 60 mm 2 5 0 063 in Spring tilt exhaust 2 5 1 60 mm 2 5 0 063 in Outer spring Spring tilt intake 2 5 1 60 mm 2 5 0 063 in Spring tilt exhaust...

Page 146: ...mpressor attachment 5 To secure the valve cotters onto the valve stem lightly tap the valve tip with a soft face hammer CAUTION Hitting the valve tip with excessive force could damage the valve Valve spring compressor 90890 04019 YM 04019 Valve spring compressor attachment 90890 01243 Valve spring compressor adapter 26 mm YM 01253 1 VALVES AND VALVE SPRINGS ...

Page 147: ...parts in the order listed Cylinder head Refer to CYLINDER HEAD 1 Oil delivery pipe 1 2 Cylinder 1 3 Dowel pin 2 4 Cylinder gasket 1 5 Piston pin clip 2 6 Piston pin 1 7 Piston 1 8 Piston ring set 1 For installation reverse the removal procedure 10 Nm 1 0 m kg 7 4 ft lb 17 Nm 1 7 m kg 13 ft lb CYLINDER AND PISTON ...

Page 148: ... still difficult to remove use the piston pin puller CAUTION Do not use a hammer to drive the piston pin out 2 Remove Top ring 2nd ring Oil ring NOTE NOTE When removing a piston ring open the end gap with your fingers and lift the other side of the ring over the piston crown CHECKING THE CYLINDER AND PISTON 1 Check Piston wall Cylinder wall Vertical scratches Rebore or replace the cylinder and rep...

Page 149: ...ings as a set c Measure piston skirt diameter D with the micrometer 5 mm 0 20 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 Bore C 74 000 74 016 mm 2 9134 2 9140 in Wear limit 74 100 mm 2 9173 in C maximum of D1 D6 Piston size diameter D Standard 73 983 73 998 mm ...

Page 150: ...gs as a set NOTE NOTE Before measuring the piston ring side clear ance eliminate any carbon deposits from the piston ring grooves and piston rings Piston to cylinder clearance 0 010 0 025 mm 0 0004 0 0010 in Limit 0 15 mm 0 006 in Piston ring Top ring Ring side clearance 0 030 0 065 mm 0 0012 0 0026 in Limit 0 115 mm 0 0045 in 2nd ring Ring side clearance 0 020 0 055 mm 0 0008 0 0022 in Limit 0 11...

Page 151: ...he piston ring NOTE NOTE The oil ring expander spacer s end gap cannot be measured If the oil ring rail s gap is exces sive replace all three piston rings Piston ring Top ring End gap installed 0 19 0 31 mm 0 007 0 012 in Limit 0 56 mm 0 022 in 2nd ring End gap installed 0 30 0 45 mm 0 012 0 018 in Limit 0 80 mm 0 032 in Oil ring End gap installed 0 10 0 35 mm 0 004 0 014 in CYLINDER AND PISTON ...

Page 152: ...alculate Piston pin to piston pin bore clearance Out of specification Replace the piston pin and piston as a set Piston pin outside diameter 16 991 17 000 mm 0 6689 0 6693 in Limit 16 971 mm 0 6681 in Piston pin bore inside diameter 17 002 17 013 mm 0 6694 0 6698 in Limit 17 043 mm 0 6710 in Piston pin to piston pin bore clearance Piston pin bore diameter Piston pin outside diameter Piston pin to ...

Page 153: ...iston pin clips NOTE NOTE Apply engine oil the piston pin Make sure the dot on the piston points towards the exhaust side of the cylinder Before installing the piston pin clip cover the crankcase opening with a clean rag to pre vent the clip from falling into the crankcase 3 Install O ring Cylinder gasket Dowel pins 4 Lubricate Piston Piston rings Cylinder with the recommended lubricant New Recomm...

Page 154: ...2nd ring 20 mm 6 Install Cylinder NOTE NOTE While compressing the piston rings with one hand install the cylinder with the other hand Pass the timing chain and timing chain guide exhaust side through the timing chain cavity 7 Tighten Cylinder bolts Cylinder bolt 10 Nm 1 0 m kg 7 4 ft lb CYLINDER AND PISTON ...

Page 155: ...1 Cotter pin Washer 1 1 2 Clevis pin 1 3 Brake pedal Footrest 1 1 4 Oil delivery pipe 1 5 Oil cooler hose 2 6 O ring 2 7 Right crankcase cover 1 8 Dowel pin 2 9 Crankcase cover gasket 1 For installation reverse the removal procedure 73 Nm 7 3 m kg 54 ft lb 10 Nm 1 0 m kg 7 4 ft lb 10 Nm 1 0 m kg 7 4 ft lb 20 Nm 2 0 m kg 15 ft lb CLUTCH ...

Page 156: ... Pressure plate 1 3 Primary drive gear nut 1 4 Friction plate 6 5 Clutch plate 5 6 Clutch boss nut 1 7 Clutch boss 1 8 Thrust washer 1 9 Clutch housing 1 10 Claw washer 1 11 Primary drive gear 1 12 Locknut Washer 1 1 13 Push rod1 1 14 Push plate 1 80 Nm 8 0 m kg 59 ft lb 8 Nm 0 8 m kg 5 9 ft lb 75 Nm 7 5 m kg 55 ft lb CLUTCH ...

Page 157: ...ENG 4 41 Order Job Parts to remove Q ty Remarks 15 Push rod 2 Ball 1 1 For installation reverse the removal procedure 80 Nm 8 0 m kg 59 ft lb 8 Nm 0 8 m kg 5 9 ft lb 75 Nm 7 5 m kg 55 ft lb CLUTCH ...

Page 158: ...s in the order listed Shift pedal Refer to SHIFT SHAFT Left crankcase cover Refer to PICK UP COIL ROTOR AND STARTER CLUTCH Clutch assembly 1 Clutch cable 1 2 Bolt 1 3 Push lever shaft 1 4 Torsion spring 1 5 Circlip 1 6 Oil seal 1 7 Bearing 1 For installation reverse the removal procedure CLUTCH ...

Page 159: ...TE Place the aluminum plate between clutch housing and primary drive gear and then loosen the primary drive gear nut While holding the clutch boss with the univer sal clutch holder loosen the clutch boss nut 4 Remove Clutch boss nut Lock washer Clutch boss Thrust washer Clutch housing 5 Remove Primary drive gear nut Lock washer Claw washer Primary drive gear Universal clutch holder 90890 04086 YM ...

Page 160: ...tion plate NOTE NOTE Measure the friction plate at four places CHECKING THE CLUTCH PLATES The following procedure applies to all of the clutch plates 1 Check Clutch plate Damage Replace the clutch plate 2 Measure Clutch plate warpage with a surface plate and thickness gauge Out of specification Replace the clutch plate Friction plate thickness 2 9 3 1 mm 0 114 0 122 in Wear limit 2 8 mm 0 110 in W...

Page 161: ...Damage pitting wear Deburr the clutch housing dogs or replace the clutch housing NOTE NOTE Pitting on the clutch housing dogs will cause erratic clutch operation CHECKING THE CLUTCH BOSS 1 Check Clutch boss splines Damage pitting wear Replace the clutch boss NOTE NOTE Pitting on the clutch boss splines will cause erratic clutch operation CHECKING THE PRESSURE PLATE 1 Check Pressure plate Cracks da...

Page 162: ...on Replace the primary drive and primary driven gears as a set 2 Check Primary drive gear to primary driven gear free play Free play exists Replace the primary drive and primary driven gears as a set INSTALLING THE CLUTCH 1 Install Primary drive gear Claw washer Lock washer Primary drive gear nut 2 Install Clutch housing Thrust washer Clutch boss Lock washer Clutch boss nut NOTE NOTE Make sure the...

Page 163: ...gear nut 4 Bend the lock washer tab along a flat side of the nut 5 Lubricate Friction plates Clutch plates with the recommended lubricant 6 Install Friction plates 6 piece Clutch plates 5 piece NOTE NOTE First install a friction plate and then alternate between a clutch plate and a friction plate Clutch boss nut 75 Nm 7 5 m kg 55 ft lb Primary drive gear nut 80 Nm 8 0 m kg 59 ft lb Universal clutc...

Page 164: ... rod 1 Push plate Washer Locknut Pressure plate Clutch spring Bolt 9 Tighten Clutch spring bolt Locknut NOTE NOTE Tighten the clutch spring bolts in stages and in a crisscross pattern 10 Check Push lever position Push lever mark and crankcase mark not aligned Correct NOTE NOTE Push the push lever in direction and make sure the marks are aligned Clutch spring bolt 8 Nm 0 8 m kg 5 9 ft lb Locknut 8 ...

Page 165: ...UTCH CABLE FREE PLAY in chapter 3 13 Install Spacer Dowel pin Crankcase cover gasket 14 Install Right crankcase cover 15 Install Crankcase cover bolts M6 50 mm Copper washers to Crankcase cover bolts M6 40 mm Crankcase cover bolts M6 25 mm Oil filter element cover bolt M6 70 mm 16 Tighten Crankcase cover bolts Oil filter element cover bolt NOTE NOTE Tighten the bolts in stages using a crisscross p...

Page 166: ...kcase cover Refer to CLUTCH Clutch Primary drive gear 1 Balancer weight gear nut 1 2 Lock washer 1 3 Buffer boss 1 4 Balancer weight gear 1 5 Absorber plate 1 6 Compression spring 6 7 Dowel pin 3 8 Straight key 1 9 Spacer 1 10 Circlip 1 11 Oil pump driven gear 1 12 Oil pump assembly 1 13 Gasket 1 6 Nm 0 6 m kg 4 4 ft lb 55 Nm 5 5 m kg 41 ft lb OIL PUMP AND BLANCER WEIGHT GEAR ...

Page 167: ... Job Parts to remove Q ty Remarks 14 Balancer drive gear 1 15 Oil strainer 1 16 Spacer 1 For installation reverse the removal procedure 6 Nm 0 6 m kg 4 4 ft lb 55 Nm 5 5 m kg 41 ft lb OIL PUMP AND BLANCER WEIGHT GEAR ...

Page 168: ...mbling the oil pump Remove the parts in the order listed Oil pump housing 1 Dowel pin 2 Outer rotor 1 Inner rotor 1 Dowel pin 1 Shaft 1 Oil pump cover 1 For assembly reverse the disassembly procedure 7 Nm 0 7 m kg 5 0 ft lb OIL PUMP AND BLANCER WEIGHT GEAR ...

Page 169: ...sen the balancer weight gear nut 3 Remove Oil pump assembly CHECKING THE OIL PUMP 1 Check Oil pump driven gear Oil pump housing Oil pump cover Cracks damage wear Replace the defective part s 2 Measure Inner rotor to outer rotor tip clearance Outer rotor to oil pump housing clearance Oil pump housing to inner rotor and outer rotor clearance Out of specification Replace the oil pump Inner rotor Oute...

Page 170: ...s Compression spring Dowel pin Cracks damage wear Replace Inner rotor to outer rotor tip clearance 0 150 mm 0 0059 in Limit 0 23 mm 0 0091 in Outer rotor to oil pump housing clearance 0 100 0 151 mm 0 0039 0 0059 in Limit 0 22 mm 0 0087 in Oil pump housing to inner and outer rotor clearance 0 04 0 09 mm 0 0016 0 0035 in Limit 0 16 mm 0 0063 in OIL PUMP AND BLANCER WEIGHT GEAR ...

Page 171: ...dowel pins and compression springs alternately as shown as 2 Assemble Buffer boss INSTALLING THE OIL PUMP 1 Install Gasket Oil pump 2 Tighten Oil pump bolts CAUTION After tightening the bolts make sure the oil pump turns smoothly Oil pump bolt 6 Nm 0 6 m kg 4 4 ft lb LOCTITE OIL PUMP AND BLANCER WEIGHT GEAR ...

Page 172: ... Align the punch mark in the balancer drive gear with the punch mark in the balancer weight gear Place the aluminum plate between bal ancer drive gear and balancer weight gear and then tighten the balancer weight gear nut 3 Bend the lock washer tab along a flat side of the nut Balancer weight gear nut 55 Nm 5 5 m kg 41 ft lb OIL PUMP AND BLANCER WEIGHT GEAR ...

Page 173: ...and stopper lever Remove the parts in the order listed Right crankcase cover Refer to CLUTCH Clutch 1 Shift pedal 1 2 Shift shaft assembly 1 3 Stopper lever 1 4 Torsion spring 1 For installation reverse the removal procedure 10 Nm 1 0 m kg 7 4 ft lb 10 Nm 1 0 m kg 7 4 ft lb SHIFT SHAFT ...

Page 174: ...er Torsion spring Damage wear Replace INSTALLING THE SHIFT SHAFT 1 Install Stopper lever NOTE NOTE Hook the ends of the stopper lever spring onto the stopper lever and the crankcase boss Mesh the stopper lever with the shift drum segment assembly 2 Tighten Stopper lever bolt 3 Install Shift shaft NOTE NOTE Install the shift shaft by aligning the shift shaft spring with the stopper Stopper lever bo...

Page 175: ...h between the tip of the shift lever and dowel pin are equal If not Replace the shift shaft 5 Install Shift pedal 6 Tighten Shift pedal bolt 7 Adjust Shift pedal height Refer to ADJUSTING THE SHIFT PEDAL in chapter 3 Shift pedal bolt 10 Nm 1 0 m kg 7 4 ft lb SHIFT SHAFT ...

Page 176: ...er 6 1 Starter idle gear cover O ring 1 1 2 Starter idler gear 1 shaft 1 1 3 Pickup coil rotor lead coupler 2 Disconnect 4 Left crankcase cover 1 5 Dowel pin 2 6 Crank case cover gasket 1 7 Stator coil assembly pickup coil 1 1 8 Starter idler gear 2 shaft 1 1 9 Pickup coil rotor 1 10 Woodruff key 1 11 Starter wheel gear 1 30 Nm 3 0 m kg 22 ft lb 10 Nm 1 0 m kg 7 4 ft lb 10 Nm 1 0 m kg 7 4 ft lb 60...

Page 177: ...asher 1 14 Starter clutch assembly 1 For installation reverse the removal procedure 30 Nm 3 0 m kg 22 ft lb 10 Nm 1 0 m kg 7 4 ft lb 10 Nm 1 0 m kg 7 4 ft lb 60 Nm 6 0 m kg 44 ft lb 10 Nm 1 0 m kg 7 4 ft lb 7 Nm 0 7 m kg 5 2 ft lb PICKUP COIL ROTOR AND STARTER CLUTCH ...

Page 178: ...eave holder to touch the projection on the rotor 2 Remove Pickup coil rotor NOTE NOTE Remove the rotor using flywheel puller 3 Remove Woodruff key 4 Remove Starter idle gear 2 Starter wheel gear Bearing Washer Sheave holder 90890 01701 Primary clutch holder YS 01880 A Flywheel puller 90890 01362 Heavy duty puller YU 33270 B Bolt M8 80 mm 90890 01359 PICKUP COIL ROTOR AND STARTER CLUTCH ...

Page 179: ...ar 4 Check Starter clutch operation a Install the starter wheel gear onto the starter clutch and hold the starter clutch b When turning the starter wheel gear clock wise the starter clutch and the starter wheel gear should engage otherwise the starter clutch is faulty and must be replaced c When turning the starter wheel gear coun terclockwise it should turn freely other wise the starter clutch is...

Page 180: ...r hub When installing the rotor make sure the woo druff key is properly seated in the key way of the crankshaft 3 Tighten Pickup coil rotor bolt NOTE NOTE Tighten the pickup coil rotor bolt while holding the rotor with a sheave holder Do not allow the sheave holder to touch the projection on the rotor Pickup coil rotor bolt 60 Nm 6 0 m kg 44 ft lb Sheave holder 90890 01701 Primary clutch holder YS...

Page 181: ...kcase cover bolts NOTE NOTE Tighten the bolts in stages and in a crisscross pattern as shown 10 Install Starter idle gear 1 Shaft 11 Install O ring Starter idle gear cover 12 Tighten Starter idle gear cover bolt Stater coil bolt 10 Nm 1 0 m kg 7 4 ft lb LOCTITE Pickup coil bolt 10 Nm 1 0 m kg 7 4 ft lb LOCTITE Left crankcase cover bolt 7 Nm 0 7 m kg 5 2 ft lb LOCTITE Crankcase cover bolt 10 Nm 1 0...

Page 182: ...TON Clutch Refer to CLUTCH Oil pump Refer to OIL PUMP AND BLANCER WEIGHT GEAR Balancer weight gear Shift shaft Refer to SHIFT SHAFT Pickup coil rotor Refer to PICKUP COIL ROTOR AND STARTER CLUTCH 1 Timing chain guide intake side 1 2 Timing chain 1 3 Crankshaft sprocket 1 4 Right crankcase 1 5 Dowel pin 2 6 Left crankcase 1 1 2 3 4 5 5 6 7 8 Nm 0 8 m kg 5 9 ft lb 20 Nm 2 0 m kg 15 ft lb 10 Nm 1 0 m...

Page 183: ...G 4 67 Order Job Parts to remove Q ty Remarks 7 Spacer 1 For installation reverse the removal procedure 1 2 3 4 5 5 6 7 8 Nm 0 8 m kg 5 9 ft lb 20 Nm 2 0 m kg 14 8 ft lb 10 Nm 1 0 m kg 7 4 ft lb CRANKCASE ...

Page 184: ...he bearing Remove the parts in the order listed Crankshaft assembly Refer to CRANKSHAFT ASSEMBLY Main axle assembly drive axle assem bly Refer to TRANSMISSION 1 Oil seal 2 2 Bearing 8 For installation reverse the removal procedure 2 2 2 2 1 2 2 2 1 2 CRANKCASE ...

Page 185: ...nd in a crisscross pattern After all of the bolts are fully loosened remove them 3 Turn Shift drum segment NOTE NOTE Turn the shift drum segment to the position shown in the illustration In this position the shift drum segment s teeth will not contact the crankcase during crankcase separation 4 Remove Right crankcase CAUTION First check that the shift drum segment s teeth and the drive axle circli...

Page 186: ...Obstruction Blow out with compressed air ASSEMBLING THE CRANKCASE 1 Apply Yamaha bond No 1215 Three Bond No 1215 onto the crankcase mating surfaces NOTE NOTE Do not allow any sealant to come into contact with the oil gallery 2 Install Dowel pins 3 Install Right crankcase onto the left crankcase NOTE NOTE Tap lightly on the right crankcase with a soft face hammer Yamaha bond No 1215 Three Bond No 1...

Page 187: ...in a crisscross pattern 6 Install Neutral switch 7 Install Crankshaft sprocket Timing chain guide intake side Timing chain 8 Tighten Timing chain guide intake side bolt 9 Apply Engine oil onto the crankshaft pins bearings and oil delivery holes 10 Check Crankshaft and transmission operation Rough movement Repair Crankcase bolt 10 Nm 1 0 m kg 7 4 ft lb Timing chain guide intake side bolt 8 Nm 0 8 m...

Page 188: ...rks Removing the crankshaft assembly Remove the parts in the order listed Crankcase Refer to CRANKCASE 1 Balancer weight 1 2 Crankshaft assembly 1 3 Dowel pin 1 4 Plunger seal 1 5 Bearing 1 For installation reverse the removal procedure 3 4 2 5 1 CRANKSHAFT ASSEMBLY ...

Page 189: ... PLUNGER SEAL 1 Remove Dowel pin Plunger seal Compression spring Remove the plunger seal and compression spring push the plunger seal lightly and remove the dowel pin CHECKING THE CRANKSHAFT AND CONNECTING ROD 1 Measure Crankshaft runout Out of specification Replace the crank shaft bearing or both NOTE NOTE Turn the crankshaft slowly Crankcase separating tool 90890 01135 Crankcase separator YU 011...

Page 190: ...air CHECKING THE TIMING CHAIN CRANKSHAFT SPROCKET AND TIMING CHAIN GUIDE The following procedure applies to all of the camshaft sprockets and timing chain guides 1 Check Timing chain Damage stiffness Replace the timing chain and camshaft sprocket and crank shaft sprocket as a set 2 Check Crankshaft sprocket More than 1 4 tooth wear Replace the timing chain and camshaft sprocket and crankshaft spro...

Page 191: ...n pushing the plunger seal by your finger INSTALLING THE CRANKSHAFT ASSEMBLY 1 Install Crankshaft assembly NOTE NOTE Install the crankshaft assembly with the crank shaft installer pot crankshaft installer bolt adapter and spacer Crankshaft installer pot 90890 01274 Installing pot YU 90058 Crankshaft installer bolt 90890 01275 Bolt YU 90060 Spacer 90890 01288 Adapter M10 90890 01383 Adapter 2 YU 90...

Page 192: ... grease and each bearing with engine oil NOTE NOTE Hold the connecting rod at top dead center TDC with one hand while turning the nut of the crankshaft installer bolt with the other Turn the crankshaft installer bolt until the crankshaft assembly bottoms against the bearing 2 Install Balancer weight To the right crank case CRANKSHAFT ASSEMBLY ...

Page 193: ...shift forks Remove the parts in the order listed Crankcase Separate Refer to CRANKCASE 1 Shift fork guide bar 1 2 Shift drum assembly 1 3 Shift fork 3 R 1 4 Shift fork 2 C 1 5 Shift fork 1 L 1 6 Main axle assembly 1 7 Drive axle assembly 1 For installation reverse the removal procedure 1 3 4 5 2 6 7 TRANSMISSION ...

Page 194: ...inion gear 1 3 3rd pinion gear 1 4 Circlip washer 1 1 5 4th pinion gear 1 6 Main axle 1 7 Plain washer 1 8 1st wheel gear 1 9 4th wheel gear 1 10 Circlip washer 1 1 11 3rd wheel gear collar 1 1 12 Claw washer 1 1 13 Claw washer 2 1 14 5th wheel gear 1 15 Circlip washer 1 1 16 2nd wheel gear 1 7 8 9 10 11 12 13 14 15 1 2 5 4 3 6 16 TRANSMISSION ...

Page 195: ...ENG 4 79 Order Job Parts to remove Q ty Remarks 17 Drive axle 1 For installation reverse the removal procedure 7 8 9 10 11 12 13 14 15 1 2 5 4 3 6 16 TRANSMISSION ...

Page 196: ...e shift fork guide bar Rough movement Replace the shift forks and shift fork guide bar as a set Shift fork 3 R Shift fork 2 C Shift fork 1 L Shift fork guide bar Shift drum assembly Shift fork cam follower 2 Check Shift fork cam follower Shift fork pawl Bends damage scoring wear Replace the shift fork 3 Check Shift fork guide bar Roll the shift fork guide bar on a flat sur face Bends Replace WARNI...

Page 197: ...Measure Main axle runout with a centering device and dial gauge Out of specification Replace the main axle 2 Measure Drive axle runout with a centering device and dial gauge Out of specification Replace the drive axle 3 Check Transmission gears Blue discoloration pitting wear Replace the defective gear s Transmission gear dogs Cracks damage rounded edges Replace the defective gear s Main axle runo...

Page 198: ...NSTALLING THE SHIFT FORKS AND SHIFT DRUM ASSEMBLY 1 Install Transmission Shift fork 1 L Shift fork 2 C Shift fork 3 R Shift drum assembly Shift fork guide bar Spacer Right crankcase NOTE NOTE The embossed marks on the shift forks should face towards the left side of the engine and be in the following sequence L C R The grooved side of the shift fork guide bar should face towards the right side of ...

Page 199: ...chapter 3 1 Carburetor warmer coupler 1 Disconnect 2 Air vent hose 1 Disconnect 3 Fuel hose carburetor side 1 4 Throttle cable cover 1 5 Throttle cable 1 6 Clamp 1 Loosen 7 Clamp 2 Loosen 8 Carburetor 1 9 Carburetor joint 1 For installation reverse the removal procedure 2 Nm 0 2 m kg 1 5 ft lb 3 5 Nm 0 4 m kg 2 6 ft lb 3 5 Nm 0 4 m kg 2 6 ft lb Refer to INSTALLING THE CARBURETOR JOINT and INSTALL ...

Page 200: ...Drain hose 1 Throttle stop screw 1 Cover 1 Diaphragm spring 1 Piston valve 1 Jet needle 1 Cover 1 Spring 1 Coasting enricher diaphragm 1 Coasting enricher jet P A J 2 1 Starter plunger 1 Carburetor warmer positive lead 1 Carburetor warmer 1 Carburetor warmer negative lead 1 Float chamber 1 Float pin 1 CARBURETOR ...

Page 201: ...CARB 5 3 Order Job Part Q ty Remarks Float 1 Needle valve seat set 1 Main jet 1 Needle jet holder 1 Needle jet 1 Pilot jet 1 Starter jet 1 For assembly reverse the disassembly procedure CARBURETOR ...

Page 202: ...based solvent Do not use any caustic carburetor cleaning solution b Blow out all of the passages and jets with compressed air 2 Check float float tang Damage Replace 3 Check valve seat needle valve Contamination Clean Wear damage Replace as a set NOTE NOTE Always replace the valve seat needle valve and O ring as a set 4 Check piston valve Scratches wear damage Replace piston valve diaphragm Cracks...

Page 203: ... Check cover diaphragm spring Cracks damage Replace 8 Check coasting enricher diaphragm spring Cracks damage Replace 9 Check jet needle Bends wear damage Replace clip groove Free play wear Replace 10 Check main jet pilot jet needle jet needle jet holder starter jet coasting enricher jet P A J 2 Bends wear damage Replace Blockage Blow out the jets with com pressed air CARBURETOR ...

Page 204: ...ure the distance from the front mating surface of the float chamber gasket removed to the top of the float NOTE 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 the valve seat needle valve and O ring as a set e If both are fine adjust the float hei...

Page 205: ... head with the slot in the carburetor joint INSTALLING THE CARBURETOR 1 Install carburetor NOTE NOTE Align the projection on the carburetor with the slot in the carburetor joint 2 Install throttle cable throttle cable cover 3 Adjust throttle lever free play Refer to ADJUSTING THE THROTTLE LEVER FREE PLAY in chapter 3 4 Adjust engine idling speed Refer to ADJUSTING THE ENGINE IDLING SPEED in chapte...

Page 206: ...f 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 2 Axle nut 1 3 Front wheel 1 4 Brake disc guard outer 1 28 Nm 2 8 m kg 21 ft lb 28 Nm 2 8 m kg 21 ft lb 70 Nm 7 0 m kg 52 ft lb 45 Nm 4 5 m kg 33 ft lb Refer to INSTALLING THE WHEEL HUBS Refer to INSTALLING THE FRONT WHEELS FRONT AND REAR WHEELS ...

Page 207: ...per is off of the brake discs as the brake pads will be forced shut 6 Wheel hub 1 Refer to INSTALLING THE WHEEL HUB BEARINGS 7 Brake disc 1 Rear to INSTALLING FRONT BRAKE DISCS For installation reverse the removal procedure 28 Nm 2 8 m kg 21 ft lb 28 Nm 2 8 m kg 21 ft lb 70 Nm 7 0 m kg 52 ft lb 45 Nm 4 5 m kg 33 ft lb FRONT AND REAR WHEELS ...

Page 208: ...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 3 Axle nut 2 4 Wheel hub 2 For installation reverse the removal procedure 45 Nm 4 5 m kg 33 ft lb 120 Nm 12 0 m kg 89 ft lb Refer to INSTALLING THE WHEEL HUBS FRONT AND REAR WHEELS ...

Page 209: ... replacing the tire ride conservatively to allow the tire to be properly seated in the rim Failure to do so may cause an accident resulting in machine damage and possible operator injury EBS00385 CHECKING THE WHEEL HUBS 1 Check wheel hubs Cracks damage Replace splines wheel hub Wear damage Replace the wheel hub Front Rear Wheel runout limit Radial 2 0 mm 0 08 in Lateral 2 0 mm 0 08 in FRONT AND RE...

Page 210: ...heel 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 EBS00389 CHECKING THE BRAKE DISCS 1 Check brake discs Galling damage Replace 2 Measure brake disc deflection Out of specification Replace brake disc thickness Out o...

Page 211: ...ake discs NOTE NOTE Install the brake disc with its spot faced side facing the bolt heads EBS00392 INSTALLING THE FRONT WHEELS 1 Install brake disc guards outer NOTE NOTE Install the brake disc guard outer with punched burrs on the wheel hub side 2 Install wheels NOTE NOTE The arrow mark on the must point in the direction of rotation of the wheel FRONT AND REAR WHEELS ...

Page 212: ... 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 Bend the longer cotter pin up Front axle nut 70 Nm 7 0 m kg 52 ft lb Rear axle nut 120 Nm 12 0 m kg 89 ft lb FRONT AND REAR WHEELS ...

Page 213: ... 2 Nut 1 3 Conical spring washer 1 4 Brake caliper 1 NOTE NOTE Do not apply the brake pedal and do not use the parking brake when the brake cal iper is off of the brake disc as the brake pad will be force shut 34 Nm 3 4 m kg 25 ft lb 7 Nm 0 7 m kg 5 2 ft lb 28 Nm 2 8 m kg 21 ft lb 55 Nm 5 5 m kg 41 ft lb 140 Nm 14 0 m kg 103 ft lb Refer to REMOVING THE REAR AXLE and INSTALLING THE REAR AXLE REAR A...

Page 214: ... Refer to INSTALLING THE DRIVEN SPROCKET 8 Circlip 1 9 Brake caliper bracket 1 10 Collar 1 11 Rear axle hub 1 12 Bearing oil seal 2 2 13 Spacer 1 14 Dust cover 1 For installation reverse the removal procedure 34 Nm 3 4 m kg 25 ft lb 7 Nm 0 7 m kg 5 2 ft lb 28 Nm 2 8 m kg 21 ft lb 55 Nm 5 5 m kg 41 ft lb 140 Nm 14 0 m kg 103 ft lb REAR AXLE AND REAR AXLE HUB ...

Page 215: ... Elevate the rear wheels by placing the suit able stand under the frame 5 Remove rear wheels wheel hubs nuts washers 6 Remove rear axle CAUTION Never directly tap the axle end with a ham mer since this will result in damage to the axle thread and spline Attach a suitable socket on the axle end and tap it with a soft hammer then pull out the rear axle to the right PTT wrench 46 90890 06588 Axle nut...

Page 216: ...CHECKING THE BRAKE DISC 1 Check brake disc Refer to FRONT AND REAR WHEELS INSTALLING THE DRIVEN SPROCKET 1 Install driven sprocket NOTE NOTE Make sure that the blunt edged corner of the driven sprocket is facing outward EBS00397 INSTALLING THE REAR AXLE 1 Install conical spring washer NOTE NOTE Install the conical spring washer with the con vex side of the washer facing inward as shown Rear axle r...

Page 217: ...t with PTT wrench 46 or rear axle nut wrench to specification while holding the rear axle b Tighten bolts 140 Nm 14 0 m kg 103 ft lb PTT wrench 46 90890 06588 Axle nut wrench 46 mm YM 37134 7 Nm 0 7 m kg 5 2 ft lb REAR AXLE AND REAR AXLE HUB ...

Page 218: ...llowing procedure applies to both of the front brake calipers Front wheel Refer to FRONT AND REAR WHEELS 1 Bolt 1 2 Brake pad retaining bolt 1 3 Brake pad 2 4 Brake pad spring 1 For installation reverse the removal procedure 2 5 Nm 0 25 m kg 1 8 ft lb 17 Nm 1 7 m kg 13 ft lb 28 Nm 2 8 m kg 21 ft lb Refer to REPLACING THE FRONT BRAKE PADS FRONT AND REAR BRAKES ...

Page 219: ...brake pads Remove the parts in the order listed 1 Brake pad retaining bolt 2 2 Lock washer 1 3 Brake pad 2 4 Brake pad spring 1 For installation reverse the removal procedure 34 Nm 3 4 m kg 25 ft lb 17 Nm 1 7 m kg 13 ft lb FRONT AND REAR BRAKES Refer to REPLACING THE REAR BRAKE PADS ...

Page 220: ...es or plastic parts as this may cause dam age disconnect any hydraulic connection as this would require the entire brake system 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 NOTE It is not necessary to disassemble the brake calipers and brake hoses to repl...

Page 221: ... brake caliper bleed screw d Install new brake pads and a new brake pad spring 3 Install brake pad retaining bolt bolt 4 Install brake caliper brake caliper mounting bolts 5 Check brake fluid level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 6 Check brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 5 Nm 0 5 m kg 3...

Page 222: ...aliper bleed screw Put the other end of this hose into an open container b Loosen the brake caliper bleed screw and using a finger push the caliper piston into the brake caliper c Tighten the brake caliper bleed screw d Install a new brake pad spring and new brake pads 3 Install brake pad retaining bolts Bend the lock washer tabs along a flat side of the bolts brake caliper brake caliper mounting ...

Page 223: ...CHAS 6 18 5 Check brake lever or brake pedal operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 FRONT AND REAR BRAKES ...

Page 224: ...ervoir cap 1 2 Brake fluid reservoir diaphragm plate 1 3 Brake fluid reservoir diaphragm 1 4 Front brake light switch 1 5 Brake lever 1 6 Union bolt 1 7 Copper washer 2 8 Brake hose 1 Disconnect 9 Brake master cylinder bracket 1 10 Brake master cylinder 1 For installation reverse the removal procedure 7 Nm 0 7 m kg 5 2 ft lb 6 Nm 0 6 m kg 4 4 ft lb 27 Nm 2 7 m kg 20 ft lb Refer to INSTALLING THE F...

Page 225: ...sassembling the front brake master cylinder Remove the parts in the order listed Dust boot 1 Circlip 1 Brake master cylinder kit 1 For assembly reverse the disassembly procedure Refer to ASSEMBLING THE FRONT BRAKE MASTER CYLINDER FRONT AND REAR BRAKES ...

Page 226: ...NK in chapter 3 Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 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 7 Nm 0 7 m kg 5 2 ft lb 31 Nm 3 1 m kg 23 ft lb 20 Nm 2 0 m kg 15 ft lb 73 Nm 7 3 m kg 54 ft lb FRONT AND REAR...

Page 227: ...master cylinder 1 11 Rear brake light switch 1 12 Right footrest 1 13 Brake pedal spring 1 1 For installation reverse the removal procedure 7 Nm 0 7 m kg 5 2 ft lb 31 Nm 3 1 m kg 23 ft lb 20 Nm 2 0 m kg 15 ft lb 73 Nm 7 3 m kg 54 ft lb Refer to INSTALLING THE REAR BRAKE MASTER CYLINDER FRONT AND REAR BRAKES ...

Page 228: ...r brake master cylinder Remove the parts in the order listed Hose joint 1 Brake master cylinder kit 1 Brake master cylinder 1 For assembly reverse the disassembly procedure 17 Nm 1 7 m kg 13 ft lb Refer to ASSEMBLING THE REAR BRAKE MASTER CYLINDER FRONT AND REAR BRAKES ...

Page 229: ...very passage brake master cylinder body Blockage Blow out with compressed air Front Rear 2 Check brake master cylinder kit Scratches wear damage Replace as a set Front Rear 3 Check front brake master cylinder reservoir front brake master cylinder reservoir dia phragm Cracks damage Replace 4 Check rear brake fluid reservoir rear brake fluid reservoir diaphragm Cracks damage Replace FRONT AND REAR B...

Page 230: ... 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 joint NOTE NOTE Turn the adjusting bolt until the clearance is within the specified limits when install the joint Recommended brake flui...

Page 231: ...opper washers brake hose union bolt NOTE 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 Nut 17 Nm 1 7 ...

Page 232: ...s may result in a harm ful reaction and lead to poor brake perfor mance 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 Check brake fluid level Brake fluid level is under the LOWER level l...

Page 233: ...e hose routing is essential to insure safe machine operation Refer to CABLE ROUTING in chapter 2 2 Install brake fluid reservoir hose NOTE NOTE Install the brake fluid reservoir hose with the white paint mark facing up as shown 3 Fill brake fluid reservoir CAUTION Brake fluid may damage painted surfaces or plastic parts Always clean up spilled brake fluid immediately Union bolt 31 Nm 3 1 m kg 23 f...

Page 234: ...r 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 Check brake fluid level Brake fluid level is under the LOWER level line Add the recommended brake fluid to the proper le...

Page 235: ...BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 Front wheel Refer to FRONT AND REAR WHEELS 1 Union bolt 1 2 Copper washer 2 3 Brake hose 1 Disconnect 4 Bolt 1 5 Brake pad retaining bolt 2 Loosen 6 Brake caliper assembly 1 For installation reverse the removal procedure 2 5 Nm 0 25 m kg 1 8 ft lb 17 Nm 1 7 m kg 13 ft lb 28 Nm 2 8 m kg 21 ft lb 27 Nm 2 7 m kg 20 ft lb Refer to INSTALLING THE FRONT B...

Page 236: ...s Bolt 1 Brake pad retaining bolt 1 Brake pad 2 Brake pad spring 1 Caliper bracket 1 Caliper piston 1 Dust seal 1 Caliper piston seal 1 Bleed screw 1 For assembly reverse the disassembly procedure 5 Nm 0 5 m kg 3 7 ft lb 17 Nm 1 7 m kg 13 ft lb 2 5 Nm 0 25 m kg 1 8 ft lb Refer to DISASSEMBLING THE FRONT AND REAR BRAKE CALIPERS and ASSEMBLING THE FRONT BRAKE CALIPERS FRONT AND REAR BRAKES ...

Page 237: ...DING THE HYDRAULIC BRAKE SYSTEM in chapter 3 1 Parking brake cable 1 Disconnect Refer to REMOVING THE PARKING BRAKE CABLE 2 Union bolt 1 3 Copper washer 2 4 Brake hose 1 Disconnect 5 Brake caliper assembly 1 For installation reverse the removal procedure 31 Nm 3 1 m kg 23 ft lb 34 Nm 3 4 m kg 25 ft lb Refer to INSTALLING THE REAR BRAKE CALIPER FRONT AND REAR BRAKES ...

Page 238: ...her 1 Brake pad 2 Brake pad spring 1 Retaining bolt 1 Caliper bracket 1 Brake caliper piston 1 Dust seal 1 Caliper piston seal 1 Bleed screw 1 For assembly reverse the disassembly procedure 17 Nm 1 7 m kg 13 ft lb 5 Nm 0 5 m kg 3 7 ft lb 17 Nm 1 7 m kg 13 ft lb 15 Nm 1 5 m kg 11 ft lb FRONT AND REAR BRAKES Refer to DISASSEMBLING THE FRONT AND REAR BRAKE CALIPERS and ASSEMBLING THE REAR BRAKE CALIP...

Page 239: ...AKE CALIPERS 1 Remove brake caliper piston caliper dust seal caliper piston seal Front Rear a Blow compressed air into the hose joint opening to force out the caliper piston from the brake caliper body 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 se...

Page 240: ...cylinder Wear scratches Replace the brake cali per assembly brake caliper body Cracks damage Replace brake fluid delivery passage brake caliper body Blockage Blow out with compressed air WARNING Replace the caliper piston seal and dust seal whenever the brake caliper is disas sembled Front Rear Recommended brake component replacement schedule Brake pads As required Piston seals dust seals Every tw...

Page 241: ... a brake caliper is disassembled 1 Install caliper piston seal caliper dust seal 2 Install brake caliper piston 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 caliper piston seal caliper dust seal ...

Page 242: ...ock washer tabs along a flat side of the bolts 5 Install parking brake arm 6 Measure parking brake arm to parking brake bracket distance Out of specification Adjust Brake pad retaining bolt 17 Nm 1 7 m kg 13 ft lb Parking brake arm to parking brake bracket distance 73 3 mm 2 89 in FRONT AND REAR BRAKES ...

Page 243: ...e caliper make sure that the brake pipe touches the projection on the brake caliper WARNING Proper brake hose routing is essential to insure safe machine operation Refer to CABLE ROUTING in chapter 2 2 Fill brake reservoir CAUTION Brake fluid may damage painted surfaces or plastic parts Always clean up spilled brake fluid immediately Brake caliper mounting bolt 28 Nm 2 8 m kg 21 ft lb Union bolt 2...

Page 244: ...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 proper level...

Page 245: ...ipe touches the projection on the brake cali per WARNING Proper brake hose routing is essential to insure safe machine operation Refer to CABLE ROUTING in chapter 2 2 Fill brake reservoir CAUTION Brake fluid may damage painted surfaces or plastic parts Always clean up spilled brake fluid immediately Brake caliper mounting bolt 34 Nm 3 4 m kg 25 ft lb Union bolt 31 Nm 3 1 m kg 23 ft lb Recommended ...

Page 246: ...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 proper level Refer to CHECKING THE BRAKE FLUID LEVEL in c...

Page 247: ...linder bracket 1 1 5 Throttle lever assembly bracket 1 1 6 Spacer 1 7 Clutch switch 1 Refer to REMOVING THE CLUTCH SWITCH 8 Parking brake lever 1 9 Clutch lever bracket 1 1 10 Handlebar switch 1 4 Nm 0 4 m kg 3 0 ft lb 7 Nm 0 7 m kg 5 2 ft lb 20 Nm 2 0 m kg 15 ft lb 4 Nm 0 4 m kg 3 0 ft lb 7 Nm 0 7 m kg 5 2 ft lb STEERING SYSTEM Refer to INSTALLING THE BRAKE MASTER CYLINDER Refer to INSTALLING THE...

Page 248: ...RIPS and INSTALLING THE HANDLEBAR GRIPS 12 Handlebar holder 2 13 Handlebar 1 For installation reverse the removal procedure 4 Nm 0 4 m kg 3 0 ft lb 7 Nm 0 7 m kg 5 2 ft lb 20 Nm 2 0 m kg 15 ft lb 4 Nm 0 4 m kg 3 0 ft lb 7 Nm 0 7 m kg 5 2 ft lb STEERING SYSTEM Refer to INSTALLING THE HANDLEBAR ...

Page 249: ...47 REMOVING THE HANDLEBAR GRIPS 1 Remove handlebar grips NOTE NOTE Blow compressed air between the handlebar and handlebar grip and gradually push the grip off the handlebar EBS00448 CHECKING THE HANDLEBAR 1 Check handlebar Bends cracks damage Replace WARNING Do not attempt to straighten a bent handle bar as this may dangerously weaken the handlebar STEERING SYSTEM ...

Page 250: ...hten the bolt on the front side of the handlebar holder and then tighten the bolt on the rear side EBS00450 INSTALLING THE HANDLEBAR GRIPS 1 Install handlebar grips NOTE NOTE Before applying the adhesive wipe off grease or oil on the handlebar surface with a lac quer thinner Install the handlebar grips so that the L arrow on the left grip and R arrow on the right grip are placed vertically Handleb...

Page 251: ...09 2 13 in EBS00453 INSTALLING THE BRAKE MASTER CYLINDER 1 Install throttle lever assembly spacer brake master cylinder NOTE NOTE Engage the indentations in the spacer with the lobes on the throttle lever assembly and brake master cylinder The UP mark on the brake master cylinder bracket should face up Install the brake lever at 10 degrees angle as shown Brake master cylinder bracket 7 Nm 0 7 m kg...

Page 252: ...the order listed Front fender Refer to SEAT FENDERS AND FUEL TANK in chapter 3 1 Lock washer 1 Refer to INSTALLING THE LOCK WASHER 2 Bracket 1 3 Steering stem bushing 2 4 Spacer 2 5 Oil seal 2 6 Steering stem 1 7 Bushing 2 23 Nm 2 3 m kg 17 ft lb 25 Nm 2 5 m kg 18 ft lb 35 Nm 3 5 m kg 26 ft lb STEERING SYSTEM ...

Page 253: ...ering stem bushings Wear damage Replace 3 Check O rings bushings Wear damage Replace INSTALLING THE STEERING STEM 1 Install steering stem NOTE NOTE Pass the throttle cable through the cable guide Refer to CABLE ROUTING in chapter 2 EBS00459 INSTALLING THE LOCK WASHER 1 Install lock washer bolts 2 Bend the lock washer tab along a flat side of the bolt Bolt 23 Nm 2 3 m kg 17 ft lb STEERING SYSTEM ...

Page 254: ...EAR WHEELS Front brake caliper Refer to FRONT AND REAR BRAKES 1 Brake disc guard inner 1 2 Tie rod 1 Refer to INSTALLING THE TIE RODS 3 Front bumper 1 4 Lower front arm 1 5 Upper front arm 1 6 Steering knuckle 1 Refer to REMOVING THE STEERING KNUCKLES For installation reverse the removal procedure 31 Nm 3 1 m kg 23 ft lb 45 Nm 4 5 m kg 33 ft lb 25 Nm 2 5 m kg 18 ft lb 45 Nm 4 5 m kg 33 ft lb 25 Nm...

Page 255: ...ce 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 NOTE The tie rod side which must be installed on the outside has grooves 2 Adjust toe in Refer to ADJUSTING THE TOE IN in chapter 3 Ball joint n...

Page 256: ...efer 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 Tie rod 1 Disconnect 4 Lower front arm 1 5 Upper front arm 1 6 Front shock absorber 1 7 Steering knuckle 1 31 Nm 3 1 m kg 23 ft lb 45 Nm 4 5 m kg 33 ft lb 45 Nm 4 5 m kg 33 ft lb 25 Nm 2 5 m kg 18 ft lb 25 Nm 2 5 m kg 18 ft lb 48 Nm 4 8 m kg 35 ft lb 48 Nm 4 8 m kg 35 ft l...

Page 257: ...2 11 Bushing 6 For installation reverse the removal procedure 31 Nm 3 1 m kg 23 ft lb 45 Nm 4 5 m kg 33 ft lb 45 Nm 4 5 m kg 33 ft lb 25 Nm 2 5 m kg 18 ft lb 25 Nm 2 5 m kg 18 ft lb 48 Nm 4 8 m kg 35 ft lb 48 Nm 4 8 m kg 35 ft lb FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES ...

Page 258: ...2 Remove front arm EBS00470 CHECKING THE FRONT ARMS 1 Check front arms Bends damage Replace 2 Check bushings Wear damage Replace 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 absorber rod Bends damage Replace the front shock absorber assembly...

Page 259: ...ns roughly Replace the front arm EBS00473 INSTALLING THE FRONT ARMS The following procedure applies to both of the front arms 1 Install upper front arm lower front arm NOTE NOTE Be sure to position the bolts upper and lower so that the bolt head faces forward Apply lithium soap based grease to the grease nipple Front arm upper lower 45 Nm 4 5 m kg 33 ft lb FRONT ARMS AND FRONT SHOCK ABSORBER ASSEM...

Page 260: ...EAT FENDERS AND FUEL TANK in chapter 3 Rear axle hub Refer to REAR AXLE AND REAR AXLE HUB 1 Plate 1 2 Swingarm end cover 1 3 Rear shock absorber 1 4 Pivot shaft nut washer 1 1 5 Pivot shaft 1 6 Swingarm 1 7 Drive chain guide 1 1 8 Drive sprocket cover 1 23 Nm 2 3 m kg 17 ft lb 55 Nm 5 5 m kg 41 ft lb 100 Nm 10 0 m kg 74 ft lb 110 Nm 11 0 m kg 81 ft lb 55 Nm 5 5 m kg 41 ft lb REAR SHOCK ABSORBER SW...

Page 261: ...ain 1 15 Dust cover oil seal 2 2 16 Spacer 1 17 Bearing 2 For installation reverse the removal procedure 23 Nm 2 3 m kg 17 ft lb 55 Nm 5 5 m kg 41 ft lb 100 Nm 10 0 m kg 74 ft lb 110 Nm 11 0 m kg 81 ft lb 55 Nm 5 5 m kg 41 ft lb REAR SHOCK ABSORBER SWINGARM AND DRIVE CHAIN Refer to INSTALLING THE SWINGARM Refer to INSTALLING THE DRIVE SPROCKET ...

Page 262: ...rear shock absorber 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 in any way If the rear shock absorber is damaged damping perfor mance will suffer DISPOSING OF A REAR SHOCK ABSORBER Gas pressure must be released before dispos ing of a rear shock absorber To release the gas pressure d...

Page 263: ...eplace 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 EBS00493 NOTE NOTE Before removing the drive chain and the sprockets measure the drive chain slack and a 15 link section of the drive chain EBS00494 REMOVING THE SWINGARM 1 Check swingarm free play a Che...

Page 264: ...k the spacer bearings and frame pivot 2 Remove pivot shaft nut washer pivot shaft swingarm EBS00495 CHECKING THE SWINGARM 1 Check swingarm Bends cracks damage Replace 2 Check pivot shaft Roll the axle on a flat surface Bends Replace WARNING Do not attempt to straighten a bent pivot shaft 3 Clean pivot shaft spacer bearings Swingarm free play limit at the end of the swingarm 1 0 mm 0 04 in Recommen...

Page 265: ...drive chain NOTE NOTE While measuring the 15 link section push down on the drive chain to increase its ten sion Measure the length between drive chain roller and as shown Perform this measurement at two or three dif ferent places 2 Check drive chain Stiffness Clean and lubricate or replace 15 link drive chain section limit maximum 239 3 mm 9 42 in REAR SHOCK ABSORBER SWINGARM AND DRIVE CHAIN ...

Page 266: ...ressure methods could force dirt or water into the drive chain s internal parts and solvents will deteriorate the O rings A coarse brush can also damage the O rings Therefore use only kerosene to clean the drive chain Don t soak the drive chain in kerosene for more than ten minutes Kerosene will dam age the O rings 4 Check O rings Damage Replace the drive chain drive chain rollers Damage wear Repl...

Page 267: ...rings spacer NOTE NOTE Inject the bearing with the character stamp turned outward Apply the lithium soap based grease to inside Apply the lithium soap based grease on the spacer when installing EBS00498 INSTALLING THE DRIVE SPROCKET 1 Install drive sprocket lock washer nut 2 Bend the lock washer tab along a flat side of the nut Installed depth of bearing 1 2 mm 0 04 0 08 in Drive sprocket nut 110 ...

Page 268: ...tch CDI unit Starter relay Fuse Battery Tail brake light Headlight relay Starting circuit cut off relay Thermo switch Carburetor warmer Starter motor Pickup coil stator assembly Neutral switch Rear brake light switch Ignition coil Spark plug Headlight Rectifier regulator Neutral indicator light ELECTRICAL COMPONENTS ...

Page 269: ... 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 are shown in the far left column and the switch lead colors are shown in the top row in the switch illustration NOTE NOTE indicates a continuity of electricity between switch terminals i e a closed circuit at the...

Page 270: ... 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 CHECKING THE SWITCHES ...

Page 271: ...ELEC 7 4 Light switch Engine stop switch Start switch Main switch Front brake light switch Clutch switch Fuse Neutral switch Rear brake light switch CHECKING THE SWITCHES ...

Page 272: ...ne are shown in the illustration on the left Bulb is used for the headlight and can be pulled out by turning counterclockwise while pushing the bulb holder and remov ing After this you can remove the bulb Bulb is used for tail brake lights and can be removed from the socket by pushing and turning the bulb counterclockwise Bulb is used for indicator lights and can be removed from their respective s...

Page 273: ...ly 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 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 and the negative tester probe to ter minal and check the continuity ...

Page 274: ...ket 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 90890 03112 Analog pocket tester YU 03112 C CHECKING THE B...

Page 275: ...W W W L Y B G Y R B B W W O W L W R W Br Sb Br Sb Y Br Y Br SUB WIRE HARNESS A WIRE HARNESS R B W W W W R W L W W W W W W B R R B W W W B B R Br B R R R R R R Y B L B B B Y B B Y R B Sb BY B Br Br Br Sb BY BY BY BY B B B B Sb Y L Y Y Br L B R B Br B Y L B G L Y Y G Y G Y B B W R W L Pickup coil Stator coil Main switch Battery positive lead Battery Fuse CDI unit Ignition coil Spark plug Engine stop...

Page 276: ...se OK YES NO Replace the fuse Ignition checker 90890 06754 Opama pet 4000 spark checker YM 34487 Pocket tester 90890 03112 Analog pocket tester YU 03112 C 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 YES NO Clean the battery terminals Recharge or replace the battery 3 ...

Page 277: ...ase the spark 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 NO YES The ignition system is OK 1 a 2 5 Spark plug cap resistance The following procedure applies to all of the spark plug caps Remove the spark plug cap from the spark plug lead Connect the pocket tester Ω 1k to the spark plug cap as shown Measure the spark ...

Page 278: ...2 9 48 kΩ at 20 C 68 F Is the ignition coil OK YES NO Replace the ignition coil 7 Main switch Check the main switch for continuity Refer to CHECKING THE SWITCHES Is the main switch OK YES NO Replace the main switch 8 Engine stop switch Check the engine stop switch for continuity Refer to CHECKING THE SWITCHES Is the engine stop switch OK YES NO Replace the handle bar switch 9 Pickup coil resistanc...

Page 279: ...k the entire ignition system s wiring Refer to CIRCUIT DIAGRAM Is the ignition system s wiring properly con nected and without defects YES NO Replace the CDI unit Properly connect or repair the ignition system s wiring IGNITION SYSTEM ...

Page 280: ... O W L W R W Br Sb Br Sb Y Br Y Br SUB WIRE HARNESS A WIRE HARNESS R B W W W W R W L W W W W W W R Br B R R R R O O B R W R W L R B W W W B B R R Y B L B B B Y B B Y R B Sb BY B Br Br Sb BY BY BY BY B B B Sb Br B Y L Y Y Br L B R B Br B Y L B G L Y Y G Y G Y B B Main switch Battery positive lead Battery Fuse Starter relay Starter motor Starting circuit cut off relay Clutch switch Neutral switch En...

Page 281: ...h is on and the engine stop switch is in the RUN position the starter motor can be operated only if Battery Fuse Main switch Engine stop switch Starting circuit cut off relay Clutch switch Neutral switch Start switch Starter relay Starter motor M The transmission is in neutral the neutral switch is closed or You pull in the clutch lever the clutch switch is closed ELECTRIC STARTING SYSTEM ...

Page 282: ...K YES NO Replace the fuse The starter motor fails to turn Pocket tester 90890 03112 YU 03112 C 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 YES NO Clean the battery terminals Recharge or replace the battery 3 Starter motor Connect the positive battery terminal and star...

Page 283: ...NO Replace the starting circuit cut off relay 5 Starting circuit cut off relay diode Remove the starting circuit cut off relay from the wire harness Connect the pocket tester Ω 1 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 Negative tester probe red black Continuity Positive tester probe red black...

Page 284: ...ING THE SWITCHES Is the main switch OK YES NO Replace the main switch R B R R Y B L B 8 Engine stop switch Check the engine stop switch for continuity Refer to CHECKING THE SWITCHES Is the engine stop switch OK YES NO Replace the handle bar switch 9 Neutral switch Check the neutral switch for continuity Refer to CHECKING THE SWITCHES Is the neutral switch OK YES NO Replace the neutral switch 10 Cl...

Page 285: ...e starting system s wiring Refer to CIRCUIT DIAGRAM Is the starting system s wiring properly con nected and without defects YES NO The starting system circuit is OK Properly connect or repair the starting system s wiring ELECTRIC STARTING SYSTEM ...

Page 286: ... the order listed Exhaust pipe Idle gear cover and idle gear Refer to ENGINE REMOVAL in chapter 4 1 Clutch cable holder 1 2 Starter motor lead 1 Disconnect 3 Starter motor 1 For installation reverse the removal procedure 7 Nm 0 7 m kg 5 2 ft lb 10 Nm 1 0 m kg 7 4 ft lb 10 Nm 1 0 m kg 7 4 ft lb STARTER MOTOR ...

Page 287: ...otor Remove the parts in the order listed Front bracket 1 Tang washer 1 Plate washer 1 Circlip 1 Rear bracket Brush 1 1 Armature assembly 1 Starter motor yoke 1 Brush spring 2 2 For assembly reverse the disassembly procedure STARTER MOTOR Refer to ASSEMBLING THE STARTER MOTOR ...

Page 288: ...or NOTE NOTE The mica of the commutator must be undercut to ensure proper operation of the commutator 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 Commutator wear limit 21 mm 0 83 in Mica undercut 1 5 mm 0 06 in Pocket tester 90890 03112 Analog pocket tester YU 03...

Page 289: ...e brushes as a set 6 Measure brush spring force Out of specification Replace the brush springs as a set 7 Check gear teeth Damage wear Replace the gear 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 5 52 8 28 N 563 844 gf 19 85 29 78 oz STARTER MOTOR ...

Page 290: ... motor yoke 4 Install Starter motor yoke NOTE NOTE Align the match marks on the starter motor york with the match marks on the rear bracket 5 Install Tang washer Plate washer Front bracket NOTE NOTE Align the match marks on the starter motor york with the match marks on the front bracket 2 1 2 1 1 2 1 a b 1 2 3 a b STARTER MOTOR ...

Page 291: ...SYSTEM CIRCUIT DIAGRAM R Br R Br ON OFF R R L B Y B W W W W R W L W R W W W R B W W W W R W L W W W W W W B R R B R R R R R R Br Y B L B B B Stator coil Rectifier regulator Battery positive lead Battery Fuse Ground CHARGING SYSTEM ...

Page 292: ... following special tool s EBS01043 EBS01044 1 Fuse Check the fuse for continuity Refer to CHECKING THE SWITCHES Is the fuse OK YES NO Replace the fuse The battery is not being charged Pocket tester 90890 03112 Analog pocket tester YU 03112 C 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 ...

Page 293: ...OK 4 Stator coil resistance Disconnect the AC magneto coupler from the wire harness Connect the pocket tester Ω 1 to the charging coils Tester lead White terminal Tester lead White terminal Tester lead White terminal Tester lead White terminal Tester lead White terminal Tester lead White terminal Measure the stator coil resistance Charging coil resistance 0 688 1 032 Ω at 20 C 68 F YES NO Replace ...

Page 294: ... B G Y R B B W W O W L W R W Br Sb Br Sb Y Br Y Br SUB WIRE HARNESS A WIRE HARNESS R B W W W W R W L W W W W W W B R W W W B R Br B R R R R R R Br BY BY BY BY B B B B O O W R W L R B B Y B L B B B Y B B Y R B Sb BY B Br Sb Sb Br Br Y L Y Y Br L B R B B Y L B G L Y Y G Y G Y B B Stator coil Rectifier regulator Main switch Battery positive lead Battery Fuse Tail brake light Light switch Headlight re...

Page 295: ...ght switch OK YES NO Replace the handle bar switch Any of the following fail to light head light tail brake light Pocket tester 90890 03112 Analog pocket tester YU 03112 C 2 Stator coil resistance Disconnect the AC magneto coupler from the wire harness Connect the pocket tester Ω 1 to the charging coils Tester lead White terminal Tester lead White terminal Tester lead White terminal Tester lead Wh...

Page 296: ...tinuity Refer to CHECKING THE BULBS AND BULB SOCKETS Are the headlight bulb and socket OK YES NO Replace the head light bulb socket or both 2 Voltage Connect the pocket tester AC 20 V to the headlight couplers as shown When the light switch is set to LO When the light switch is set to HI Headlight coupler wire harness side Headlight Positive tester probe yellow or green Negative tester probe black...

Page 297: ...he jumper leads are connected to the terminals the tail brake light should illu minate Positive battery terminal blue Negative battery terminal black Is the tail brake light OK YES NO Replace the tail brake light 3 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 Negative tester...

Page 298: ...B B W W O W L W R W Br Sb Br Sb Y Br Y Br SUB WIRE HARNESS A WIRE HARNESS R B W W W R Br B R R R R R O O W R W L R B W W W B B R Y B L B Y B B Y R B Sb BY B Br Br Br Sb BY BY BY BY B B B B Sb Y L Y Y Br W R W L W W W W W W B R B B L B R B Br B Y L B G L Y Y G Y G Y B B Main switch Battery positive lead Battery Fuse Neutral indicator light Neutral switch Rear brake light switch Front brake light sw...

Page 299: ...U 03112 C 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 YES NO Clean the battery terminals Recharge or replace the battery 3 Main switch Check the main switch for continuity Refer to CHECKING THE SWITCHES Is the main switch OK YES NO Replace the main switch 4 Wiring Che...

Page 300: ...ositive battery terminal yellow Negative battery terminal black Is the tail brake light OK YES NO Replace the tail brake light 3 Brake light switches Check the brake light switches for continuity Refer to CHECKING THE SWITCHES Is the brake light switch OK YES NO Replace the brake light switch 4 Voltage Connect the pocket tester DC 20 V to the tail brake light coupler wire harness side as shown Pos...

Page 301: ... switch Check the neutral switch for continuity Refer to CHECKING THE SWITCHES Is the neutral switch OK YES NO Replace the neutral switch 3 Voltage Connect the pocket tester DC 20 V to the indicator light coupler wire harness side as shown Positive tester probe brown Negative tester probe sky blue Set the main switch to ON Measure the voltage DC 12 V Is the voltage within specification YES NO This...

Page 302: ...itch operated properly YES NO Replace the thermo switch OFF ON 11 C 3 C 51 8 F 5 4 F 16 C 3 C 60 8 F 5 4 F 2 Carburetor warmer Remove the carburetor heating element from the carburetor Connect the pocket tester Ω 1 to the car buretor heating element Tester positive probe heating element Tester negative probe heating element body Measure the carburetor heating element resistance Carburetor heating ...

Page 303: ...uel 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 CDI system Faulty CDI unit Faulty pickup coil Faulty lighting coil Faulty charging...

Page 304: ...ORMANCE 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 CDI unit Faulty pickup coil Faulty ignition coil Valve train Improperly adjusted valve clearance Air filter Clogged ai...

Page 305: ...er 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 CLUTCH DRAGGING Clutch Warped pressure plate Uneve...

Page 306: ...l viscosity Inferior oil quality Brake Brake drag 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 disc brake pads Improper brake fluid level EBS00551 SHOCK ABSORBER MALFUNCTION MALFUNCTION Bent or damaged damper rod ...

Page 307: ...ator 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 switch Burnt out tail brake light ...

Page 308: ......

Page 309: ......

Page 310: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U S A ...

Page 311: ...Thermo switch Carburetor warmer Neutral indicator light Neutral switch Rear brake light switch Front brake light switch Tail brake light Handlebar switch Light switch Engine stop switch Start switch Headlight relay Headlight Ground COLOR CODE B Black Br Brown G Green L Blue O Orange R Red Sb Sky blue W White Y Yellow B Y Black Yellow L B Blue Black R B Red Black R W Red White W L White Blue W R Wh...

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