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Yamaha 2011 WR250FA, Owner'S Service Manual

The Yamaha 2011 WR250FA Owner's Service Manual is a comprehensive guide that provides detailed instructions and information on maintaining and servicing your Yamaha WR250FA motorcycle. This essential manual can be easily downloaded for free from manualshive.com, ensuring you have all the necessary information at your fingertips.

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2-14

TIGHTENING TORQUES

TIGHTENING TORQUES

ENGINE

△

- marked portion shall be checked for torque tightening after break-in.

Part to be tightened

Thread size

Q'ty

Tightening torque

Nm

m•kg

ft•lb

Spark plug

M10S × 1.0

1

13

1.3

9.4

Camshaft cap

M6 × 1.0

10

10

1.0

7.2

Cylinder head blind plug screw

M12 × 1.0

1

28

2.8

20

Cylinder head (stud bolt)

M6 × 1.0

2

7

0.7

5.1

Cylinder head (stud bolt)

M8 × 1.25

1

15

1.5

11

Cylinder head (bolt)

M9 × 1.25

4

38

3.8

27

Cylinder head (nut)

M6 × 1.0

2

10

1.0

7.2

Cylinder head cover

M6 × 1.0

2

10

1.0

7.2

Cylinder

M6 × 1.0

1

10

1.0

7.2

Balancer weight

M6 × 1.0

2

10

1.0

7.2

Balancer shaft driven gear

M14 × 1.0

1

50

5.0

36

Timing chain guide (intake side)

M6 × 1.0

2

10

1.0

7.2

Timing chain tensioner

M6 × 1.0

2

10

1.0

7.2

Timing chain tensioner cap bolt

M6 × 1.0

1

7

0.7

5.1

Impeller

M8 × 1.25

1

14

1.4

10

Radiator hose clamp

M6 × 1.0

10

2

0.2

1.4

Coolant drain bolt

M6 × 1.0

1

10

1.0

7.2

Water pump housing

M6 × 1.0

4

10

1.0

7.2

Radiator stay

M6 × 1.0

6

10

1.0

7.2

Radiator

M6 × 1.0

4

10

1.0

7.2

Radiator pipe

M6 × 1.0

1

10

1.0

7.2

Oil pump cover

M4 × 0.7

1

1.7

0.17

1.2

Oil pump

M6 × 1.0

3

10

1.0

7.2

Oil filter element drain bolt

M6 × 1.0

1

10

1.0

7.2

Oil filter element cover

M6 × 1.0

2

10

1.0

7.2

Oil strainer (crankcase)

M6 × 1.0

2

10

1.0

7.2

Oil delivery pipe 1 (M10)

M10 × 1.25

1

20

2.0

14

Oil delivery pipe 1 (M8)

M8 × 1.25

2

18

1.8

13

△

Oil hose

M6 × 1.0

2

8

0.8

5.8

Oil hose clamp

—

2

2

0.2

1.4

Oil strainer (oil tank)

M6 × 1.0

1

9

0.9

6.5

Oil tank drain bolt

M8 × 1.25

1

18

1.8

13

Oil tank (upper)

M6 × 1.0

1

7

0.7

5.1

Oil tank and frame

M6 × 1.0

3

9

0.9

6.5

Summary of Contents for 2011 WR250FA

Page 1: ...LIT 11626 24 20 1HC 28199 10 OWNER S SERVICE MANUAL WR250FA Read this manual carefully before operating this vehicle 2011 ...

Page 2: ...Read this manual carefully before operating this vehicle This manual should stay with this vehicle if it is sold ...

Page 3: ... by Yamaha Motor Corporation U S A 1st Edition May 2010 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in Japan P N LIT 11626 24 20 ...

Page 4: ...roduct information available at the time of printing there may be minor discrepancies between your machine and this manual If you have any questions concerning this manual please con sult your Yamaha dealer PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MACHINE DO NOT ATTEMPT TO OP ERATE THIS MACHINE UNTIL YOU HAVE ATTAINED A SATISFACTORY KNOWL EDGE OF ITS CONTROLS AND OPER...

Page 5: ...oline on the en gine or exhaust system Never refuel in the vi cinity of an open flame or while smoking GASOLINE CAN CAUSE INJURY If you should swallow some gasoline inhale excess gasoline vapors or allow any gasoline to get into your eyes contact a doctor imme diately If any gasoline spills onto your skin or clothing immediately wash skin areas with soap and water and change your clothes ONLY OPER...

Page 6: ...YAMAHA MOTOR CORPORATION U S A WR MOTORCYCLE LIMITED WARRANTY ...

Page 7: ...wn to find the required fore edge symbol mark and go to a page for required item and description MANUAL FORMAT All of the procedures in this manual are organized in a sequential step by step format The informa tion has been complied to provide the mechanic with an easy to read handy reference that contains comprehensive explanations of all disassembly repair assembly and inspection operations In t...

Page 8: ...iagram 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 way by the use of symbol marks 3 The meanings of the symbol marks are given on the next page 4 A job instruction chart 4 accompanies the exploded diagram providing the order of jobs names of parts notes in jobs etc 5 For jobs requiring more information the st...

Page 9: ...c cur rent A Illustrated symbols 8 to 13 in the exploded diagrams indicate grade of lubricant and loca tion of lubrication point 8 Apply engine oil 9 Apply molybdenum disulfide oil 10 Apply brake fluid 11 Apply lightweight lithium soap base grease 12 Apply molybdenum disulfide grease 13 Apply silicone grease Illustrated symbols 14 to 15 in the exploded diagrams indicate where to apply a locking ag...

Page 10: ...MEMO ...

Page 11: ...TABLE OF CONTENTS GENERAL INFORMATION 1 SPECIFICATIONS 2 REGULAR INSPECTION AND ADJUSTMENTS 3 TUNING 4 ENGINE 5 CHASSIS 6 ELECTRICAL 7 ...

Page 12: ...ORMATION 1 5 CHECKING OF CONNECTION 1 7 SPECIAL TOOLS 1 8 CONTROL FUNCTIONS 1 12 MULTI FUNCTION DISPLAY 1 15 STARTING AND BREAK IN 1 22 TORQUE CHECK POINTS 1 25 CLEANING AND STORAGE 1 26 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS 2 1 MAINTENANCE SPECIFICATIONS 2 4 TIGHTENING TORQUES 2 14 LUBRICATION DIAGRAMS 2 22 CABLE ROUTING DIAGRAM 2 26 ...

Page 13: ... CHASSIS 3 27 ELECTRICAL 3 45 CHAPTER 4 TUNING CHASSIS 4 1 CHAPTER 5 ENGINE RADIATOR 5 1 CARBURETOR 5 5 AIR INDUCTION SYSTEM 5 16 CAMSHAFTS 5 18 CYLINDER HEAD 5 26 VALVES AND VALVE SPRINGS 5 30 CYLINDER AND PISTON 5 37 CLUTCH 5 42 OIL FILTER ELEMENT AND WATER PUMP 5 49 BALANCER 5 55 OIL PUMP 5 58 KICK SHAFT AND SHIFT SHAFT 5 63 AC MAGNETO AND STARTER CLUTCH 5 69 ENGINE REMOVAL 5 76 CRANKCASE AND C...

Page 14: ...RK 6 24 HANDLEBAR 6 35 STEERING 6 42 SWINGARM 6 48 REAR SHOCK ABSORBER 6 55 CHAPTER 7 ELECTRICAL ELECTRICAL COMPONENTS AND WIRING DIAGRAM 7 1 IGNITION SYSTEM 7 3 ELECTRIC STARTING SYSTEM 7 7 CHARGING SYSTEM 7 15 THROTTLE POSITION SENSOR SYSTEM 7 17 LIGHTING SYSTEM 7 21 SIGNALING SYSTEM 7 23 ...

Page 15: ...1 1 LOCATION OF IMPORTANT LABELS GENERAL INFORMATION LOCATION OF IMPORTANT LABELS Please read the following important labels carefully before operating this vehicle 1 ...

Page 16: ...ever 3 Engine stop switch 4 Multi function display 5 Main switch 6 Start switch 7 Front brake lever 8 Throttle grip 9 Radiator cap 10 Fuel tank cap 11 Taillight 12 Kickstarter crank 13 Fuel tank 14 Headlight 15 Radiator 16 Coolant drain bolt 17 Rear brake pedal 18 Valve joint 19 Fuel cock 20 Cold starter knob 21 Air cleaner 22 Catch tank 23 Drive chain 24 Oil level check window 25 Shift pedal 26 F...

Page 17: ...ehicle identification number 1 is stamped on the right of the steering head pipe ENGINE SERIAL NUMBER The engine serial number 1 is stamped into the elevated part of the right side of the engine MODEL LABEL The model label 1 is affixed to the frame un der the rider s seat This information will be needed to order spare parts VEHICLE EMISSION CONTROL INFORMATION LABEL The Vehicle Emission Control In...

Page 18: ...wing out and is installed to the fuel tank breather hose In this installation make sure the arrow fac es the fuel tank and also downward SPARK PLUG WRENCH This spark plug wrench 1 is used to remove and install the spark plug NIPPLE WRENCH This nipple wrench 1 is used to tighten the spoke ...

Page 19: ...replaced 4 During the machine disassembly clean all parts and place them in trays in the order of disassembly This will speed up assembly time and help assure that all parts are cor rectly reinstalled 5 Keep away from fire ALL REPLACEMENT PARTS 1 We recommend to use Yamaha genuine parts for all replacements Use oil and or grease recommended by Yamaha for as sembly and adjustment GASKETS OIL SEALS ...

Page 20: ...ightweight lithium base grease to the seal lip s Oil the bear ings liberally when installing Do not use compressed air to spin the bear ings dry This causes damage to the bearing surfaces CIRCLIPS 1 All circlips should be inspected carefully be fore reassembly Always replace piston pin clips after one use Replace distorted cir clips When installing a circlip 1 make sure that the sharp edged corner...

Page 21: ...eck that it will not come off 5 If the terminal comes off bend up the pin 1 and reinsert the terminal into the connector 6 Connect Connector The two connectors click together 7 Check for continuity with a tester If there in no continuity clean the terminals Be sure to perform the steps 1 to 7 listed above when checking the wire harness For a field remedy use a contact revitalizer available on the ...

Page 22: ...r ACC For others use part number starting with 90890 Tool name Part number How to use Illustration Crankcase separating tool YU 1135 A 90890 01135 These tool is used to remove the crankshaft from either case Dial gauge and stand YU 3097 90890 01252 Stand YU 1256 These tools are used to check each part for runout or bent Crankshaft installing tool Crankshaft installing pot YU 90050 90890 01274 Cran...

Page 23: ...ring nut to speci fication Damper rod holder YM 01494 90890 01494 Use this tool to remove and install the damper rod Fork seal driver YM A0948 90890 01502 This tool is used when install the fork oil seal Spoke nipple wrench YM 01521 90890 01521 This tool is used to tighten the spoke Sheave holder YS 1880 A 90890 01701 This tool is used for when loosening or tightening the flywheel magneto securing...

Page 24: ...ld the clutch when removing or in stalling the clutch boss secur ing nut Valve guide remover Intake 4 0 mm 0 16 in Exhaust 4 5 mm 0 18 in YM 4111 90890 04111 YM 4116 90890 04116 This tool is needed to remove and install the valve guide Valve guide installer Intake 4 0 mm 0 16 in Exhaust 4 5 mm 0 18 in YM 4112 90890 04112 YM 4117 90890 04117 This tool is needed to install the valve guide Valve guid...

Page 25: ...r 90890 06754 This instrument is necessary for checking the ignition sys tem components Vacuum pressure pump gauge set YB 35956 A 90890 06756 This tool is used to check the air induction system YAMAHA Bond No 1215 ThreeBond No 1215 90890 85505 This sealant Bond is used for crankcase mating surface etc Tool name Part number How to use Illustration ...

Page 26: ...shows a lack of the battery voltage Recharge the battery ENGINE STOP SWITCH The engine stop switch 1 is located on the left handlebar Continue pushing the engine stop switch till the engine comes to a stop START SWITCH The start switch 1 is located on the right han dlebar Push this switch to crank the engine with the starter CLUTCH LEVER The clutch lever 1 is located on the left han dlebar it dise...

Page 27: ...ebar Pull it toward the handlebar to acti vate the front brake REAR BRAKE PEDAL The rear brake pedal 1 is located on the right side of the machine Press down on the brake pedal to activate the rear brake FUEL COCK The fuel cock supplies fuel from the tank to car buretor and also filters the fuel The fuel cock has the three positions OFF With the lever in this position fuel will not flow Always ret...

Page 28: ... cir cuit HOT STARTER LEVER The hot starter lever 1 is used when starting a warm engine Use the hot starter lever when starting the engine again immediately after it was stopped the engine is still warm Pulling the hot starter lever injects secondary air to thin the air fuel mixture temporarily allowing the engine to be started more easily SIDESTAND This sidestand 1 is used to support only the mac...

Page 29: ...orrection which shows the tire diametrical difference in percentage as the tripmeter travel distance is corrected DESCRIPTION Operation buttons 1 Select button SLCT 1 2 Select button SLCT 2 3 Reset button RST Screen display 4 Tripmeter indicator 5 Tripmeter indicator 6 Timer indicator 7 Clock Timer 8 Speedometer Current speed Average speed 9 Tripmeter 10 Average speed indicator The operation butto...

Page 30: ... course condition If the outer diameter of a tire varies with tire wear or tire pressure it can be corrected in the following manner The initial value is preset with approximately 700 mm as 100 If the outer diameter of a tire is larger than the initial value Provide a larger set value If the outer diameter of a tire is smaller than the initial value Provide a smaller set value 1 Compute the differ...

Page 31: ...CE MODE forces the digits for tripmeter A TRIP A in BASIC MODE to be reset Changeover from BASIC MODE to RACE MODE 1 Push the SLCT1 button and SLCT2 but ton for 2 seconds or more at the same time to change over to RACE MODE Changeover to RACE MODE will put manual start measurement on standby causing and the average speed display to flash For manual start refer to Putting measure ment on standby in...

Page 32: ...ton 3 When stopping timer measurement pushing the SLCT1 button and SLCT2 button at the same time If the machine is run while timer measurement is not made no change will occur to the digit in tripmeter A TRIP A 4 To resume the measurement again push the SLCT1 button and SLCT2 button at the same time Auto start 1 Check that changeover has been made to RACE MODE Refer to Changeover from BASIC MODE t...

Page 33: ...A display and the average speed display by pushing the RST button for 2 seconds or more If reset the travel distance display and average speed display will go on flashing for four seconds Resetting average speed AVS tripmeter A TRIP A and timer 1 Check that the timer is not in operation If the timer is in operation stop it by pushing the SLCT1 button and SLCT2 button at the same time 2 Reset all m...

Page 34: ...time and enter tire diameter correction mode Changeover to tire correction mode will cause the timer display to change and show the dia metric digit of the tire 2 Change the digits of the travel distance by pushing the SLCT1 button plus or SLCT2 button minus A long push on the button will fast forward the change in digits Change in the digits of the travel distance will be accompanied by the chang...

Page 35: ...1 21 MULTI FUNCTION DISPLAY FUNCTION DIAGRAM The following diagram illustrates the multi function display regarding the direction and operation con dition involved in each of its functions ...

Page 36: ...engine cannot be kick started when the throttle is open because the kickstarter may kick back Also if the throttle is open the air fuel mixture may be too lean for the engine to start Before starting the machine perform the checks in the pre operation check list AIR FILTER MAINTENANCE According to CLEANING THE AIR FILTER ELEMENT section in the CHAPTER 3 apply the foam air filter oil or its equival...

Page 37: ...tarter lever all the way out and while holding the lever kick the kickstarter crank 10 to 20 times to clear the engine Then restart the engine Refer to Restarting an en gine after a fall Observe the following break in procedures during initial operation to ensure optimum performance and avoid engine damage BREAK IN PROCEDURES 1 Before starting the engine fill the fuel tank with the fuel 2 Perform ...

Page 38: ...hine throughout its entire operat ing range Restart the machine and operate it for about 10 to 15 more minutes After the break in or before each ride you must check the entire machine for loose fit tings and fasteners as per TORQUE CHECK POINTS Tighten all such fasteners as required ...

Page 39: ...ink type Assembly of links Link to frame Link to rear shock absorber Link to swingarm Installation of rear shock absorber Rear shock absorber to frame Installation of swingarm Tightening of pivot shaft Wheel Installation of wheel Front Tightening of wheel axle Tightening of axle holder Rear Tightening of wheel axle Wheel to rear wheel sprocket Brake Front Brake caliper to front fork Brake disc to ...

Page 40: ...ith a vinyl upholstery clean er to keep the cover pliable and glossy 8 Automotive wax may be applied to all paint ed or chromed surfaces Avoid combination cleaner waxes as they may contain abra sives 9 After completing the above start the engine and allow it to idle for several minutes STORAGE If your machine is to be stored for 60 days or more some preventive measures must be tak en to avoid dete...

Page 41: ...1 480 mm 58 27 in 1 485 mm 58 46 in Minimum ground clearance 365 mm 14 37 in Weight USA CDN AUS NZ ZA EUROPE With oil and fuel 114 kg 251 lb 116 kg 256 lb 117 kg 258 lb Engine Engine type Liquid cooled 4 stroke DOHC Cylinder arrangement Single cylinder forward inclined Displacement 250 cm3 8 80 Imp oz 8 45 US oz Bore stroke 77 0 53 6 mm 3 03 2 11 in Compression ratio 12 5 1 Starting system Kick an...

Page 42: ...US gal Carburetor Type FCR MX37 Manufacturer KEIHIN Spark plug Type manufacturer CR9E NGK resistance type Gap 0 7 0 8 mm 0 028 0 031 in Clutch type Wet multiple disc Transmission USA CDN ZA AUS NZ EUROPE Primary reduction system Gear Primary reduction ratio 57 17 3 353 Secondary reduction system Chain drive Secondary reduction ratio 50 13 3 846 47 14 3 357 Transmission type Constant mesh 5 speed O...

Page 43: ...disc brake Operation Right foot operation Suspension Front suspension Telescopic fork Rear suspension Swingarm link type monocross suspension Shock absorber Front shock absorber Coil spring oil damper Rear shock absorber Coil spring gas oil damper Wheel travel Front wheel travel 300 mm 11 8 in Rear wheel travel 310 mm 12 2 in Electrical Ignition system CDI Generator system AC magneto Battery type ...

Page 44: ...diameter 22 000 22 021 mm 0 8661 0 8670 in Camshaft outside diameter 21 959 21 972 mm 0 8645 0 8650 in Shaft to cap clearance 0 028 0 062 mm 0 0011 0 0024 in 0 08 mm 0 003 in Cam dimensions Intake A 29 65 29 75 mm 1 1673 1 1713 in 29 55 mm 1 1634 in Intake B 22 45 22 55 mm 0 8839 0 8878 in 22 35 mm 0 8799 in Exhaust A 30 399 30 499 mm 1 1968 1 2007 in 30 299 mm 1 1929 in Exhaust B 22 45 22 55 mm 0...

Page 45: ...9016 0 9094 in A head diameter EX 24 4 24 6 mm 0 9606 0 9685 in B face width IN 2 26 mm 0 089 in B face width EX 2 26 mm 0 089 in C seat width IN 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in C seat width EX 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in D margin thickness IN 0 8 mm 0 0315 in D margin thickness EX 0 7 mm 0 0276 in Stem outside diameter IN 3 975 3 990 mm 0 1565 0 1571 in 3 945 mm 0 15...

Page 46: ...t width EX 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in Valve spring Free length IN 36 58 mm 1 44 in 35 58 mm 1 40 in Free length EX 37 54 mm 1 48 in 36 54 mm 1 44 in Set length valve closed IN 29 13 mm 1 15 in Set length valve closed EX 29 30 mm 1 15 in Compressed force installed IN 103 118 N at 29 13 mm 10 50 12 09 kg at 29 13 mm 23 15 26 66 lb at 1 15 in Compressed force installed EX 126 144 N ...

Page 47: ...000 mm 0 6296 0 6299 in 15 971 mm 0 6288 in Piston rings Top ring Type Barrel Dimensions B T 0 90 2 75 mm 0 04 0 11 in End gap installed 0 15 0 25 mm 0 006 0 010 in 0 50 mm 0 020 in Side clearance installed 0 030 0 065 mm 0 0012 0 0026 in 0 12 mm 0 005 in 2nd ring Type Taper Dimensions B T 0 80 2 75 mm 0 03 0 11 in End gap installed 0 30 0 45 mm 0 012 0 018 in 0 80 mm 0 031 in Side clearance 0 020...

Page 48: ...m 0 114 0 122 in 2 7 mm 0 106 in Quantity 9 Clutch plate thickness 1 1 1 3 mm 0 043 0 051 in Quantity 8 Warp limit 0 1 mm 0 004 in Clutch spring free length 37 0 mm 1 46 in 36 0 mm 1 42 in Quantity 5 Clutch housing thrust clearance 0 10 0 35 mm 0 0039 0 0138 in Clutch housing radial clearance 0 010 0 044 mm 0 0004 0 0017 in Clutch release method Inner push cam push Shifter Shifter type Cam drum an...

Page 49: ... 36 7 kPa 235 275 mmHg 9 25 10 83 inHg Hot starter lever free play 3 6 mm 0 12 0 24 in Lubrication system Oil filter type Paper type Oil pump type Trochoid type Tip clearance 0 12 mm or less 0 0047 in or less 0 20 mm 0 008 in Side clearance 0 09 0 17 mm 0 0035 0 0067 in 0 24 mm 0 009 in Housing and rotor clearance 0 03 0 10 mm 0 0012 0 0039 in 0 17 mm 0 0067 in Cooling Radiator core size Width 120...

Page 50: ...ter tube with inner tube and damper rod fully com pressed without spring 95 150 mm 3 74 5 91 in Oil grade Suspension oil S1 Inner tube outer diameter 48 mm 1 89 in Front fork top end 5 mm 0 20 in Rear suspension USA CDN AUS NZ ZA EUROPE Shock absorber travel 130 mm 5 12 in Spring free length 260 mm 10 24 in Fitting length 249 mm 9 80 in 245 0 mm 9 65 in 248 5 mm 9 78 in Preload length Min Max 1 5 ...

Page 51: ... Chain length 15 links 239 3 mm 9 42 in Front disc brake Disc outside dia Thickness 250 3 0 mm 9 84 0 12 in 250 2 5 mm 9 84 0 10 in Pad thickness 4 4 mm 0 17 in 1 0 mm 0 04 in Master cylinder inside dia 11 0 mm 0 433 in Caliper cylinder inside dia 27 0 mm 1 063 in 2 Brake fluid type DOT 4 Rear disc brake Disc outside dia Thickness 245 4 0 mm 9 65 0 16 in 245 3 5 mm 9 65 0 14 in Deflection limit 0 ...

Page 52: ...A 5UM F1 YA MAHA 5UM L1 YA MAHA Ignition coil Model manufacturer 5UL 10 DENSO Minimum spark gap 6 mm 0 24 in Primary coil resistance 0 08 0 10 Ωat 20 C 68 F Secondary coil resistance 4 6 6 8 kΩat 20 C 68 F Charging system System type AC magneto Model stator manufacturer 5UM 30 YAMAHA Normal output 14 V 120 W at 5 000 r min Charging coil resistance color 0 288 0 432 Ω at 20 C 68 F White Ground Ligh...

Page 53: ...uantity 2 pcs Spring force 3 92 5 88 N 400 600 g 14 1 21 2 oz Commutator diameter 17 6 mm 0 69 in 16 6 mm 0 65 in Mica undercut depth 1 5 mm 0 06 in Starter relay Model manufacturer RC19 042 MITSUBA Amperage rating 180 A Coil winding resistance 4 2 4 6 Ω at 20 C 68 F Starting circuit cut off relay Model manufacturer ACM33221 M38 MATSUSHITA Coil winding resistance 75 69 92 51 Ω at 20 C 68 F Fuse am...

Page 54: ...6 1 0 2 10 1 0 7 2 Timing chain tensioner M6 1 0 2 10 1 0 7 2 Timing chain tensioner cap bolt M6 1 0 1 7 0 7 5 1 Impeller M8 1 25 1 14 1 4 10 Radiator hose clamp M6 1 0 10 2 0 2 1 4 Coolant drain bolt M6 1 0 1 10 1 0 7 2 Water pump housing M6 1 0 4 10 1 0 7 2 Radiator stay M6 1 0 6 10 1 0 7 2 Radiator M6 1 0 4 10 1 0 7 2 Radiator pipe M6 1 0 1 10 1 0 7 2 Oil pump cover M4 0 7 1 1 7 0 17 1 2 Oil pu...

Page 55: ...5 0 8 6 5 0 5 3 6 Air induction pipe M6 1 0 1 10 1 0 7 2 Air induction pipe clamp M6 1 0 1 4 0 4 2 9 Air cut off valve assembly and bracket M6 1 0 2 10 1 0 7 2 Bracket air cut off valve and frame M6 1 0 2 7 0 7 5 1 Crankcase M6 1 0 11 12 1 2 8 7 Crankcase bearing stopper M6 1 0 11 10 1 0 7 2 Crankcase bearing stopper crankshaft M6 1 0 4 14 1 4 10 Left crankcase cover M6 1 0 8 10 1 0 7 2 Idle gear ...

Page 56: ...bar lower holder and upper bracket M10 1 25 2 34 3 4 24 Steering stem and steering ring nut M28 1 0 1 Refer to TIP Front fork and front fork cap bolt M51 1 5 2 30 3 0 22 Front fork and base valve M30 1 0 2 55 5 5 40 Front fork cap bolt and damper rod M12 1 25 2 29 2 9 21 Front fork bleed screw and front fork cap bolt M5 0 8 2 1 0 1 0 7 Front fork and front fork protector M6 1 0 6 7 0 7 5 1 Front f...

Page 57: ... 5 1 125 12 5 90 Nipple spoke 72 3 0 3 2 2 Rear wheel sprocket M8 1 25 6 50 5 0 36 Rear brake disc cover M6 1 0 2 10 1 0 7 2 Rear brake caliper protector M6 1 0 2 7 0 7 5 1 Drive chain puller adjust bolt and locknut M8 1 25 2 19 1 9 13 Engine mounting Engine and engine bracket front M10 1 25 1 53 5 3 38 Engine and frame lower M10 1 25 1 53 5 3 38 Upper engine bracket and frame M8 1 25 4 34 3 4 24 ...

Page 58: ... 6 4 3 Front fender M6 1 0 4 7 0 7 5 1 Rear fender front M6 1 0 2 7 0 7 5 1 Rear fender rear M6 1 0 2 11 1 1 8 0 Side cover M6 1 0 2 7 0 7 5 1 Seat M8 1 25 2 22 2 2 16 Multi function display bracket and upper bracket M6 1 0 2 7 0 7 5 1 Multi function display M5 0 8 2 4 0 4 2 9 Plate 1 and front fork protector M5 0 8 2 4 0 4 2 9 Plate 2 and front fork protector 2 0 5 0 05 0 36 Speed sensor lead hol...

Page 59: ... be tightened Thread size Q ty Tightening torque Nm m kg ft lb Stator M5 0 8 2 7 0 7 5 1 Holder AC magneto lead M5 0 8 2 7 0 7 5 1 Rotor M12 1 25 1 Refer to TIP Neutral switch M5 0 8 2 4 0 4 2 9 Starter motor M6 1 0 2 10 1 0 7 2 Starter relay terminal M6 1 0 2 4 0 4 2 9 Negative lead and cylinder head M6 1 0 1 10 1 0 7 2 Pickup coil M6 1 0 2 10 1 0 7 2 ...

Page 60: ...warpage tighten multi fastener assemblies in a crisscross fash ion in progressive stages until full torque is reached Unless otherwise specified torque specifications call for clean dry threads Com ponents should be at room temperature A Distance between flats B Outside thread diameter A Nut B Bolt TORQUE SPECIFICA TION Nm m kg ft lb 10 mm 6 mm 6 0 6 4 3 12 mm 8 mm 15 1 5 11 14 mm 10 mm 30 3 0 22 ...

Page 61: ...imeter 10 2 meter Length kg kilogram 103 gram Weight N Newton 1 kg m sec2 Force Nm Newton meter N m Torque m kg Meter kilogram m kg Torque Pa Pascal N m2 Pressure N mm Newton per millimeter N mm Spring rate L Liter Volume or capacity cm3 Cubic centimeter Volume or capacity r min Revolution per minute Engine speed ...

Page 62: ...2 22 LUBRICATION DIAGRAMS LUBRICATION DIAGRAMS ...

Page 63: ...2 23 LUBRICATION DIAGRAMS 1 Oil filter element 2 Oil pump 3 Drive axle 4 Main axle 5 Intake camshaft 6 Exhaust camshaft 7 Oil tank 8 Oil delivery pipe A To oil tank ...

Page 64: ...2 24 LUBRICATION DIAGRAMS ...

Page 65: ...2 25 LUBRICATION DIAGRAMS 1 Crankshaft 2 Oil filter element 3 Oil tank 4 Oil hose A From oil pump ...

Page 66: ...2 26 CABLE ROUTING DIAGRAM CABLE ROUTING DIAGRAM ...

Page 67: ...ose and catch tank breath er hose between the connecting rod and cross tube frame F Fasten the neutral switch lead and oil hose together with the plastic locking ties and cut off the tie ends G Fasten the neutral switch lead and AC magneto lead onto the frame Locate the clamp end facing toward the outside of the frame and tie end facing toward the rear of the frame H Pass the clutch cable through ...

Page 68: ...2 28 CABLE ROUTING DIAGRAM ...

Page 69: ... A Cross the pull and push throttle cables B Fasten the catch tank hose and air induc tion hose air cut off valve rear of cylinder head onto the frame Locate the clamp end facing toward the lower side of the frame and cut off the tie end C Fasten the catch tank breather hose and carburetor breather hoses together D Pass the carburetor breather hose of the throttle cable cover through the hose hold...

Page 70: ...2 30 CABLE ROUTING DIAGRAM ...

Page 71: ...n directs as shown and lightly touches the projection on the brake caliper B Pass the brake hose into the brake hose holders C If the brake hose contacts the spring rear shock absorber correct its twist D Install the brake hose so that its pipe por tion directs as shown and lightly touches the projection on the brake master cylinder ...

Page 72: ...2 32 CABLE ROUTING DIAGRAM ...

Page 73: ... of the frame with the tie end facing downward G Fasten the three CDI unit leads and tail light lead to the rear frame Locate the clamp end facing toward the upper side of the frame and cut off the tie end H Connect the negative battery lead to the battery negative terminal I Connect the negative battery lead to the wire harness J Fasten the wire harness to the rear frame Locate the clamp end faci...

Page 74: ...2 34 CABLE ROUTING DIAGRAM ...

Page 75: ...D Secure the coupler by inserting it into the multi function display bracket E Pass the throttle cables clutch cable and hot starter cable between the upper brack et and multi function display bracket F Fasten the multi function display leads to the bracket Cut off the tie end G Secure the coupler by pushing it into the hole in the multi function display bracket H Secure the wire harness clip by p...

Page 76: ... fuel hoses for cracks or dam age Replace if necessary 2 Spark plug Check condition Adjust gap and clean 3 Valve clearance Check and adjust valve clearance when engine is cold 4 Air filter element Clean with solvent and apply foam air filter oil or equivalent oil Replace if necessary 5 Breather system Check ventilation hose for cracks or damage and drain any deposits Replace if necessary 6 Carbure...

Page 77: ...rake fluid every 1 year Every 1 year 5 Rear brake Check operation fluid level and for fluid leakage Replace brake pads if necessary Replace brake fluid every 1 year Every 1 year 6 Brake hoses Check for cracks or damage Replace Every 4 years 7 Wheels Check runout spoke tightness and for damage Tighten spokes if necessary 8 Tires Check tread depth and for damage Replace if necessary Check air pressu...

Page 78: ...se grease lightly 14 Brake pedal pivot shafts Apply lithium soap based grease all purpose grease lightly 15 Sidestand pivot Check operation Apply lithium soap based grease all purpose grease lightly 16 Front fork Check operation and for oil leakage Replace if necessary 17 Shock absorber assem bly Check operation and for oil leakage Replace if necessary 18 Rear suspension link piv ots Apply molybde...

Page 79: ... which the machine runs e g rain dirt etc Therefore earlier inspection is required by reference to the list below Item After break in Every race Every third or 500 km Every fifth or 1 000 km As re quired Remarks ENGINE OIL Replace VALVES Check the valve clearanc es The engine must be cold Inspect Check the valve seats and valve stems for wear Replace VALVE SPRINGS Inspect Check the free length and...

Page 80: ...Replace Inspect wear CLUTCH Inspect and adjust Inspect housing friction plate clutch plate and spring Replace TRANSMISSION Inspect Replace bearing SHIFT FORK SHIFT CAM GUIDE BAR Inspect Inspect wear ROTOR NUT Retighten MUFFLER Inspect and retighten Clean Replace CRANK Inspect and clean CARBURETOR Inspect adjust and clean SPARK PLUG Inspect and clean Replace Item After break in Every race Every thi...

Page 81: ...APTER 1 AIR FILTER Clean and lubricate Use foam air filter oil or equiva lent oil Replace OIL FILTER Replace ENGINE GUARD Replace Breakage FRAME Clean and inspect FUEL TANK COCK Clean and inspect BRAKES Adjust lever position and pedal height Lubricate pivot point Check brake disc surface Check fluid level and leak age Retighten brake disc bolts caliper bolts master cylin der bolts and union bolts ...

Page 82: ...pect SWINGARM Inspect lube and retighten Molybdenum disulfide grease RELAY ARM CONNECT ING ROD Inspect lube and retighten Molybdenum disulfide grease SIDESTAND Lubricate Lithium base grease STEERING HEAD Inspect free play and re tighten Clean and lube Lithium base grease Replace bearing TIRE WHEELS Inspect air pressure wheel run out tire wear and spoke looseness Retighten sprocket bolt Inspect bea...

Page 83: ... THROTTLE CONTROL CABLE Check routing and con nection Lubricate Yamaha cable lube or SAE 10W 40 motor oil HOT STARTER CLUTCH LEVER Inspect free play Item After break in Every race Every third or 500 km Every fifth or 1 000 km As re quired Remarks ...

Page 84: ...ain slack and alignment Check that the drive chain is lubricated properly P 3 32 34 Wheels Check for excessive wear and tire pressure Check for loose spokes and have no excessive play P 3 39 40 Steering Check that the handlebar can be turned smoothly and have no excessive play P 3 40 41 Front forks and rear shock absorber Check that they operate smoothly and there is no oil leakage P 3 35 39 Cable...

Page 85: ...t name Q ty Remarks Turn the fuel cock to OFF Disconnect the fuel hose 1 Seat 1 2 Air scoop left and right 2 3 Bolt fuel tank 2 4 Fuel tank 1 5 Left side cover 1 Open the air filter case cover 6 Right side cover 1 Refer to removal section 7 Headlight coupler 1 8 Headlight 1 ...

Page 86: ...3 11 ENGINE REMOVING THE SIDE COVER 1 Remove Bolt side cover Right side cover 1 Draw the side cover backward to remove it be cause its claw a is inserted in the air filter case ...

Page 87: ...Q ty Remarks Right side cover Refer to REMOVING THE SEAT FUEL TANK AND SIDE COVERS section 1 Bolt silencer clamp 1 Only loosening 2 Bolt silencer front 1 3 Bolt silencer rear 1 4 Collar 1 5 Silencer 1 6 Silencer clamp 1 7 Nut exhaust pipe 2 8 Exhaust pipe 1 9 Gasket 2 ...

Page 88: ...radia tor are hot Scalding hot fluid and steam may be blown out under pressure which could cause serious injury When the en gine has cooled place a thick towel over the radiator cap slowly rotate the cap counter clockwise to the detent This procedure al lows any residual pressure to escape When the hissing sound has stopped press down on the cap while turning counterclockwise and remove it Hard wa...

Page 89: ...than one type of ethylene glycol antifreeze containing corrosion in hibitors for aluminum engine Do not use water containing impurities or oil Handling notes of coolant The coolant is harmful so it should be handled with special care When coolant splashes to your eye Thoroughly wash your eye with water and see your doctor When coolant splashes to your clothes Quickly wash it away with water and th...

Page 90: ... COOLING SYSTEM 1 Inspect Coolant level 2 Attach Radiator cap tester 1 and adapter 2 3 Apply the specified pressure Do not apply pressure more than specified pressure Radiator should be filled fully 4 Inspect Pressure Impossible to maintain the specified pres sure for 10 seconds Repair Radiator 1 Radiator hose joint 2 Coolant leakage Repair or replace Radiator hose 3 Swelling Replace Radiator cap ...

Page 91: ...ttle grip free play a Out of specification Adjust 2 Adjust Throttle grip free play Throttle grip free play adjustment steps a Slide the adjuster cover b Loosen the locknut 1 c Turn the adjuster 2 until the specified free play is obtained d Tighten the locknut Before adjusting the throttle cable free play the engine idle speed should be adjusted After adjusting the throttle cable free play start th...

Page 92: ... b Turn the adjuster 2 until free play a is within the specified limits c Tighten the locknut After adjustment check proper operation of hot starter CLEANING THE AIR FILTER ELEMENT Proper air filter maintenance is the biggest key to preventing premature engine wear and dam age Never run the engine without the air filter el ement in place this would allow dirt and dust to enter the engine and cause...

Page 93: ...eplace 6 Apply Foam air filter oil or equivalent oil to the ele ment Squeeze out the excess oil Element should be wet but not dripping Wipe off the oil left on the element surface us ing a clean dry cloth Excess oil in the ele ment may adversely affect engine starting 7 Install Filter guide 1 Align the projection a on filter guide with the hole b in air filter element Apply the lithium soap base g...

Page 94: ...not allow foreign materials to enter the crankcase 4 Install Oil tank cap 5 Start the engine and let it warm up for sever al minutes 6 Turn off the engine and inspect the oil level once again Wait a few minutes until the oil settles before in specting the oil level CHANGING THE ENGINE OIL 1 Start the engine and warm it up for several minutes and then turn off the engine and wait for five minute 2 ...

Page 95: ...the oil filter element cover 1 and oil filter element 2 b Check the O rings 3 if cracked or dam aged replace them with a new one c Install the oil filter element and oil filter ele ment cover 8 Install O ring 1 Oil strainer 2 Oil hose Bolt oil hose Oil hose clamp 9 Install Copper washer Oil filter element cover 10 Nm 1 0 m kg 7 2 ft lb Oil strainer 9 Nm 0 9 m kg 6 5 ft lb Bolt oil hose 8 Nm 0 8 m ...

Page 96: ...e engine and thoroughly warm it up 2 Adjust Engine idling speed Adjustment steps a Turn the throttle stop screw 1 until the specified engine idling speed Using a digital engine tachometer for idle speed adjustment detect the engine idling speed by bringing the sensing element c of the engine tachometer close to the ignition coil 2 Oil filter element drain bolt 10 Nm 1 0 m kg 7 2 ft lb Crankcase oi...

Page 97: ... valve clearance 1 Remove Seat Fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section 2 Drain Coolant Refer to CHANGING THE COOLANT sec tion 3 Remove Right radiator Refer to RADIATOR section in the CHAP TER 5 Carburetor Refer to CARBURETOR section in the CHAPTER 5 Spark plug Upper engine bracket Cylinder head cover Refer to CAMSHAFTS section in the CHAPTER 5 4 Remove Timing mark accessing screw...

Page 98: ...r to CAMSHAFTS section in the CHAPTER 5 b Remove the valve lifters 1 and the pads 2 Place a rag in the timing chain space to pre vent pads from falling into the crankcase Identity each valve lifter and pad position very carefully so that they can be reinstalled in their original place c Select the proper pad using the pad select ing table The thickness a of each pad is indicated in hundredths of m...

Page 99: ...pad number only as a guide when verifying the valve clearance adjustment f Install the new pads 3 and the valve lifters 4 Apply the engine oil on the valve lifters Apply the molybdenum disulfide oil on the valve stem ends Valve lifter must turn smoothly when rotated with a finger Be careful to reinstall valve lifters and pads in their original place g Install the camshafts exhaust and intake Refer...

Page 100: ...230 235 240 1 21 1 25 230 235 240 1 26 1 30 235 240 1 31 1 35 240 MEASURED CLEARANCE INSTALLED PAD NUMBER 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0 00 0 04 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 0 05 0 09 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 22...

Page 101: ...the spark arrester out of the silencer Gasket spark arrester 4 4 Clean Spark arrester Tap the spark arrester lightly then use a wire brush to remove any carbon deposits 5 Install Gasket spark arrester Spark arrester Insert the spark arrester into the silencer and align the bolt holes Gasket tail pipe Bolt spark arrester 6 Install Silencer cap First tighten the two screws a located horizon tally ap...

Page 102: ...l sever al times f Pull the lever in or push down on the pedal Hold the lever or pedal in position g Loosen the bleed screw and allow the lever or pedal to travel towards its limit h Tighten the bleed screw when the lever or pedal limit has been reached then release the lever or pedal i Repeat steps e to h until of the air bub bles have been removed from the system If bleeding is difficult it may ...

Page 103: ...height a Out of specification Adjust 2 Adjust Brake pedal height Pedal height adjustment steps a Loosen the locknut 1 b Turn the adjusting nut 2 until the pedal height a is within specified height c Tighten the locknut Adjust the pedal height between the maxi mum A and the minimum B as shown In this adjustment the bolt 3 end b should protrude out of the threaded por tion 4 but not be less than 2 m...

Page 104: ...d brake pads 4 e Connect the transparent hose 5 to the bleed screw 6 and place the suitable con tainer under its end f Loosen the bleed screw and push the brake caliper piston in Do not reuse the drained brake fluid g Tighten the bleed screw h Install the brake pads 7 and pad pin Install the brake pads with their projections a into the brake caliper recesses b Temporarily tighten the pad pin at th...

Page 105: ...n CHECKING AND REPLACING THE REAR BRAKE PADS 1 Inspect Brake pad thickness a Out of specification Replace as a set 2 Replace Brake pad Brake pad replacement steps a Remove the protector 1 and pad pin plug 2 b Loosen the pad pin 3 c Remove the rear wheel 4 and brake caliper 5 Refer to FRONT WHEEL AND REAR WHEEL section in the CHAPTER 6 Bolt brake caliper 23 Nm 2 3 m kg 17 ft lb Pad pin 18 Nm 1 8 m ...

Page 106: ...per recesses b Temporarily tighten the pad pin at this point i Install the brake caliper 12 and rear wheel 13 Refer to FRONT WHEEL AND REAR WHEEL section in the CHAPTER 6 j Tighten the pad pin 14 k Install the pad pin plug 15 and protector 16 3 Inspect Brake fluid level Refer to CHECKING THE BRAKE FLUID LEVEL section 4 Check Brake pedal operation A softy or spongy feeling Bleed brake sys tem Refer...

Page 107: ... enter master cylinder when refill ing Clean up spilled fluid immediately to avoid erosion of painted surfaces or plastic parts a Lower level A Front B Rear CHECKING THE SPROCKET 1 Inspect Sprocket teeth a Excessive wear Replace Replace the drive sprocket rear wheel sprock et and drive chain as a set CHECKING THE DRIVE CHAIN 1 Measure Drive chain length 15 links a Out of specification Replace Whil...

Page 108: ...in Roller 2 Side plate 3 Damage wear Replace the drive chain 5 Check Drive chain stiffness a Clean and oil the drive chain and hold as il lustrated Stiff Replace the drive chain 6 Install Chain joint 1 O ring 2 Drive chain 3 Link plate 4 When installing the drive chain apply the lithi um soap base grease on the chain joint and O rings 7 Install Link plate Press the link plate onto the chain joint ...

Page 109: ...ach adjuster exactly the same amount to maintain correct axle alignment There are marks a on each side of the drive chain puller alignment NOTICE Improper drive chain slack will overload the engine as well as other vital parts of the motorcycle and can lead to chain slippage or break age To prevent this from occurring keep the drive chain slack within the specified limits Turn the adjuster so that...

Page 110: ... FORK INTERNAL PRESSURE If the front fork initial movement feels stiff dur ing a run relieve the front fork internal pres sure 1 Elevate the front wheel by placing a suitable stand under the engine 2 Remove the air bleed screw 1 and release the internal pressure from the front fork 3 Install Air bleed screw ADJUSTING THE FRONT FORK REBOUND DAMPING FORCE 1 Adjust Rebound damping force By turning th...

Page 111: ...clicks from the fully turned in position Do not force the adjuster past the minimum or maximum extent of adjustment The ad juster may be damaged Always adjust each front fork to the same setting Uneven adjustment can cause poor handling and loss of stability 3 Install Rubber cap CHECKING THE REAR SHOCK ABSORBER 1 Inspect Swingarm smooth action Abnormal noise unsmooth action Grease the pivoting poi...

Page 112: ...ring installed changes 1 5 mm 0 06 in per turn of the adjuster Never attempt to turn the adjuster beyond the maximum or minimum setting e Tighten the locknut 5 Install Rear frame upper Rear frame lower Standard fitting length I D MARK Q TY Length Yellow 1 249 mm 9 80 in 245 0 mm 9 65 in 248 5 mm 9 78 in For AUS NZ and ZA For EUROPE Stiffer Increase the spring preload Turn the adjuster 2 in Softer ...

Page 113: ...ic number of clicks from the fully turned in position Which align the punch mark a on the adjuster with the punch mark b on the high compression damping adjuster Do not force the adjuster past the minimum or maximum extent of adjustment The ad juster may be damaged Stiffer a Increase the rebound damp ing force Turn the adjuster 1 in Softer b Decrease the rebound damp ing force Turn the adjuster 1 ...

Page 114: ...sure is low A tilted tire valve stem indicates that the tire slips off its position on the rim If the tire valve stem is found tilted the tire is considered to be slipping off its position Cor rect the tire position CHECKING AND TIGHTENING THE SPOKES The following procedure applies to all of the spokes 1 Check Spokes Bend damage Replace Loose spoke Retighten Tap the spokes with a screwdriver A tig...

Page 115: ...g over 2 Check Steering stem Grasp the bottom of the forks and gently rock the fork assembly back and forth Free play Adjust steering head 3 Check Steering smooth action Turn the handlebar lock to lock Unsmooth action Adjust steering ring nut 4 Adjust Steering ring nut Steering ring nut adjustment steps a Remove the headlight b Remove the handlebar and upper bracket c Loosen the steering ring nut ...

Page 116: ...acing downward The handlebar upper holder should be in stalled with the punched mark a forward Install the handlebar so that the marks b are in place on both sides Install the handlebar so that the projection c of the handlebar upper holder is positioned at the mark on the handlebar as shown Insert the end of the fuel breather hose 13 into the hole in the steering stem First tighten the bolts on t...

Page 117: ...3 42 CHASSIS ...

Page 118: ...3 43 CHASSIS LUBRICATION ...

Page 119: ...Throttle to handlebar contact 6 Drive chain 7 Tube guide cable winding portion 8 Throttle cable end 9 Clutch cable end 10 Hot starter cable end A Use Yamaha cable lube or equivalent on these areas B Use SAE 10W 40 motor oil or suitable chain lubricants C Lubricate the following areas with high quality lightweight lithium soap base grease Wipe off any excess grease and avoid get ting grease on the ...

Page 120: ...a spark plug cleaner if necessary 5 Tighten Spark plug Before installing a spark plug clean the gas ket surface and plug surface Finger tighten a the spark plug before torqu ing to specification b CHECKING THE IGNITION TIMING 1 Remove Timing mark accessing screw 1 2 Attach Timing light Digital tachometer To the ignition coil lead orange lead 1 3 Adjust Engine idling speed Refer to ADJUSTING THE EN...

Page 121: ... fol lowed with milk of magnesia beaten egg or vegetable oil Get immediate medical at tention Charging time charging amperage and charging voltage for an MF battery are dif ferent from those of conventional batteries The MF battery should be charged as ex plained in the charging method illustra tions If the battery is overcharged the electrolyte level will drop considerably Therefore take special ...

Page 122: ...rheating and battery plate dam age If it is impossible to regulate the charging current on the battery charger be careful not to overcharge the battery When charging a battery be sure to re move it from the machine If charging has to be done with the battery mounted on the machine disconnect the negative battery lead from the battery terminal To reduce the chance of sparks do not plug in the batte...

Page 123: ...3 48 ELECTRICAL Charging method using a variable voltage charger ...

Page 124: ...3 49 ELECTRICAL Charging method using a constant voltage charger ...

Page 125: ...tester selector to Ω 1 2 Reserve fuse c If the pocket tester indicates replace the fuse 3 Replace Blown fuse Replacement steps 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 Never use a fuse with an amperage rating other than that sp...

Page 126: ...the glass part of the head light bulb to keep it free form oil otherwise the transparency of the glass the life of the bulb and the luminous flux will be adversely affected If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 6 Install Headlight bulb holder 7 Install Headlight bulb holder cover 8 Install Headlight Refer to SEAT FUEL TANK AND ...

Page 127: ...an develop its maximum revolutions toward the end of the straight line with care taken to avoid the en gine over revving Riding technique varies from rider to rider and the performance of a machine also vary from machine to machine Therefore do not imitate other rider s settings from the beginning but choose your own setting according to the level of your riding technique DRIVE AND REAR WHEEL SPRO...

Page 128: ...n incre ments or decrements Too low oil level causes the front fork to produce a noise at full rebound or the rider to feel some pres sure on his hands or body Alternatively too high oil level will develop unexpectedly early oil lock with the consequent shorter front fork travel and deteriorated perfor mance and characteristics Therefore ad just the front fork within the specified range A Air spri...

Page 129: ...gaps 2 Use of stiff spring Change the rebound damping Turn in one or two clicks Change the compression damping Turn out one or two clicks Generally a stiff spring gives a stiff riding feel ing Rebound damping tends to become weak er resulting in lack of a sense of contact with the road surface or in a vibrating handlebar FRONT FORK SETTING PARTS Adjustment washer 1 Front fork spring 2 The I D mark...

Page 130: ...e spring Therefore be sure to make reevalua tion If the standard figure cannot be achieved by adjusting the spring adjuster and changing the spring set length replace the spring with an optional one and make readjustment SETTING OF SPRING AFTER REPLACEMENT After replacement be sure to adjust the spring to the set length sunken length 90 100 mm 3 5 3 9 in and set it 1 Use of soft spring Set the sof...

Page 131: ... 488 5 mm 19 23 in TYPE SPRING RATE SPRING PART NUMBER 22212 I D MARK Q TY SOFT 4 3 5UN 00 Brown 1 4 5 5UN 10 Green 1 4 7 5UN 20 Red 1 4 9 5UN 30 Black 1 5 1 5UN 40 Blue 1 STD 5 3 5UN 50 Yellow 1 5 5 5UN 60 Pink 1 STIFF 5 7 5UN 70 White 1 SPRING PART NUMBER 22212 Maximum Minimum 5UN 00 5UN 10 5UN 20 5UN 30 Position in which the spring is turned in 20 mm 0 79 in from its free length Position in whi...

Page 132: ...amping Turn adjuster clockwise about 2 clicks to in crease damping Oil level oil amount Increase oil level by about 5 10 mm 0 2 0 4 in Spring Replace with stiff spring Stiff toward stroke end Oil level oil amount Decrease oil level by about 5 mm 0 2 in Soft toward stroke end bottoming out Oil level oil amount Increase oil level by about 5 mm 0 2 in Stiff initial move ment Compression damping Turn ...

Page 133: ...eavy and dragging Rebound damping Turn adjuster counterclockwise about 2 clicks to decrease damping Spring Replace with soft spring Poor road gripping Rebound damping Turn adjuster counterclockwise about 2 clicks to decrease damping Low compression damping Turn adjuster clockwise about 1 clicks to in crease damping High compression damping Turn adjuster clockwise about 1 6 turn to in crease dampin...

Page 134: ...ake inspection adjustment disas sembly or reassembly only by reference to this manual It may lead to servicing trouble and mechanical damage RADIATOR REMOVING THE RADIATOR Order Part name Q ty Remarks Drain the coolant Refer to CHANGING THE COOL ANT section in the CHAPTER 3 Seat fuel tank and left side cover Refer to SEAT FUEL TANK AND SIDE COVERS section in the CHAPTER 3 1 Radiator guard 2 2 Radi...

Page 135: ...ose 3 1 6 Radiator pipe 2 1 7 Radiator hose 5 1 8 Catch tank hose 1 9 Right radiator 1 10 Radiator hose 2 1 11 Radiator hose 4 1 12 Radiator pipe 1 1 13 Catch tank breather hose 1 14 Catch tank 1 Order Part name Q ty Remarks 5 ...

Page 136: ...n the cap while turning counter clockwise and remove it CHECKING THE RADIATOR 1 Inspect Radiator core 1 Obstruction Blow out with compressed air through rear of the radiator Bent fin Repair replace INSTALLING THE RADIATOR 1 Install O ring 1 Radiator pipe 1 2 Bolt radiator pipe 3 Apply the lithium soap base grease on the O ring 2 Install Catch tank hose 1 Radiator hose 2 2 Radiator hose 3 3 Radiato...

Page 137: ...portion a and then the outer one b onto the radiator 7 Install Catch tank 1 Bolt catch tank 2 Bolt catch tank 3 Catch tank hose 4 Catch tank breather hose 5 Refer to CABLE ROUTING DIAGRAM section in the CHAPTER 2 Bolt left radiator 10 Nm 1 0 m kg 7 2 ft lb Radiator hose 1 2 Nm 0 2 m kg 1 4 ft lb Radiator hose clamp 2 Nm 0 2 m kg 1 4 ft lb Bolt catch tank 7 Nm 0 7 m kg 5 1 ft lb Bolt catch tank 16 ...

Page 138: ... 2 Throttle position sensor lead coupler 1 3 Throttle cable cover 1 4 Throttle cable 2 5 Clamp air filter joint 1 Loosen the screw air filter joint 6 Clamp carburetor joint 1 Loosen the screws carburetor joint 7 Hot starter plunger 1 8 Carburetor assembly 1 9 Carburetor joint 1 4 Nm 0 4 m kg 2 9 ft lb 2 Nm 0 2 m kg 1 4 ft lb 11 Nm 1 1 m kg 8 0 ft lb 4 Nm 0 4 m kg 2 9 ft lb 10 Nm 1 0 m kg 7 2 ft lb...

Page 139: ...2 Valve lever housing cover 1 3 Screw throttle shaft 1 4 Throttle valve 1 5 Needle holder 1 6 Jet needle 1 7 Accelerator pump cover 1 8 Spring 1 9 Diaphragm accelerator pump 1 10 Air cut valve cover 1 11 Spring air cut valve 1 12 Diaphragm air cut valve 1 13 Float chamber 1 14 Leak jet 1 15 Float pin 1 ...

Page 140: ... jet 1 19 Needle jet 1 20 Spacer 1 21 Pilot jet 1 22 Starter jet 1 23 Push rod 1 Pull the push rod 24 Throttle shaft assembly 1 25 Push rod link lever assembly 1 26 Main air jet 1 27 Pilot air jet 1 28 Cold starter plunger 1 Order Part name Q ty Remarks ...

Page 141: ...ressed air Never use a wire 2 Inspect Main jet 1 Pilot jet 2 Needle jet 3 Starter jet 4 Pilot air jet 5 Leak jet 6 Main air jet 7 Damage Replace Contamination Clean Use a petroleum based solvent for cleaning Blow out all passages and jets with com pressed air Never use a wire CHECKING THE NEEDLE VALVE 1 Inspect Needle valve 1 Valve seat 2 Grooved wear a Replace Dust b Clean Filter c Clogged Clean ...

Page 142: ...h in the needle valve resulting in an in correct measurement b Measure the distance between the mating surface of the float chamber and top of the float using a vernier calipers The float arm should be resting on the needle valve but not compressing the needle valve c If the float height is not within specification inspect the valve seat and needle valve d If either is worn replace them both e If ...

Page 143: ...haft 1 Spring 2 Lever 1 3 Spring 1 4 Lever 2 5 Spring 2 6 Dirt Clean CHECKING THE AIR CUT VALVE 1 Inspect Diaphragm air cut valve 1 Spring air cut valve 2 Air cut valve cover 3 O ring 4 Tears diaphragm damage Replace ASSEMBLING THE CARBURETOR 1 Install Cold starter plunger 1 2 Install Pilot air jet 1 Main air jet 2 3 Install Spring 1 1 Lever 1 2 To lever 2 3 Make sure the spring 1 fits on the stop...

Page 144: ...b of the throttle shaft pulley 8 Install Throttle shaft assembly 1 Washer metal 2 Washer resin 3 Valve lever 4 Apply the fluorochemical grease on the bear ings Fit the projection a on the throttle shaft as sembly into the slot b in the throttle position sensor Make sure the stopper c of the spring fits into the recess in the carburetor Turn the throttle shaft assembly left while holding down the l...

Page 145: ...oat pin 3 After installing the needle valve to the float in stall them to the carburetor Check the float for smooth movement 12 Install O ring Leak jet 1 Float chamber 2 Bolt float chamber 3 Cable holder throttle stop screw cable 4 Hose holder carburetor breather hose 5 13 Install Diaphragm air cut valve 1 Spring air cut valve 2 O ring 3 Air cut valve cover 4 Holder cylinder head breather hose 5 S...

Page 146: ...e 1 Collar 2 Spring 3 Needle holder 4 Throttle valve plate 5 To throttle valve 6 16 Install Throttle valve assembly 1 Screw throttle shaft 2 Install the valve lever rollers 3 into the slits a of the throttle valve 17 Install O ring 1 Valve lever housing cover 2 Bolt valve lever housing cover 3 18 Install Carburetor breather hose 1 Install the carburetor breather hoses to the car buretor so that th...

Page 147: ...p adjusting screw 3 b Check that the link lever 4 has free play b by pushing lightly on it c Gradually turn out the adjusting screw while moving the link lever until it has no more free play INSTALLING THE CARBURETOR 1 Install Carburetor joint 1 2 Install Carburetor 1 Install the projection a between the carburetor joint slots 3 Install Hot starter plunger 1 Throttle valve height 0 8 mm 0 031 in C...

Page 148: ...ble cover 1 Bolt throttle cable cover 2 8 Install Throttle position sensor lead coupler 1 Clamp 2 Refer to CABLE ROUTING DIAGRAM section in the CHAPTER 2 9 Install Clamp 1 Refer to CABLE ROUTING DIAGRAM section in the CHAPTER 2 Bolt carburetor joint 3 Nm 0 3 m kg 2 2 ft lb Bolt air filter joint 3 Nm 0 3 m kg 2 2 ft lb Throttle cable pull 4 Nm 0 4 m kg 2 9 ft lb Throttle cable return 11 Nm 1 1 m kg...

Page 149: ... 2 Air cut off valve assembly 1 3 Air induction hose air cut off valve front of cylinder head 1 4 Air induction pipe 1 5 Gasket 1 6 Air induction hose air cut off valve rear of cylinder head 1 7 Air induction hose air cut off valve air filter case 1 7 Nm 0 7 m kg 5 1 ft lb 10 Nm 1 0 m kg 7 2 ft lb 4 Nm 0 4 m kg 2 9 ft lb ...

Page 150: ...se of the vacuum pressure pump gauge set 1 When using vacuum on the pipe c take care not to exceed the specified value a From air filter b To cylinder head exhaust port c From cylinder head intake port A Check for induction from air filter B Check for prevention of backflow into air filter C Check for prevention of afterburn When throttle is closed at sudden deceleration a to b Air passes b to a A...

Page 151: ... Refer to REMOVING THE SEAT FUEL TANK AND SIDE COVERS section in the CHAPTER 3 Air cut off valve assembly Refer to AIR INDUCTION SYSTEM section 1 Spark plug 1 2 Cylinder head breather hose 1 3 Bolt cylinder head cover 2 4 Cylinder head cover 1 5 Cylinder head cover gasket 1 6 Timing chain guide top side 1 ...

Page 152: ...shaft end accessing screw 1 Refer to removal section 3 Timing chain tensioner cap bolt 1 Refer to removal section 4 Timing chain tensioner 1 Refer to removal section 5 Camshaft cap 2 Refer to removal section 6 Clip 2 Refer to removal section 7 Exhaust camshaft 1 Refer to removal section 8 Intake camshaft 1 Refer to removal section ...

Page 153: ...he punch mark c on the ex haust camshaft and the punch mark d on the intake camshaft must align with the cylinder head surface as shown in the illustration 3 Remove Timing chain tensioner cap bolt 1 Timing chain tensioner 2 Gasket 4 Remove Bolt camshaft cap 1 Camshaft cap 2 Clip Remove the bolts camshaft cap in a criss cross pattern working from the outside in The bolts camshaft cap must be remove...

Page 154: ... clip dowel pins and camshaft caps Tighten the bolts camshaft cap in a criss cross pattern from innermost to outer caps Do not turn the camshaft when measuring clearance with the Plastigauge Cam lobes length Intake a 29 65 29 75 mm 1 1673 1 1713 in Limit 29 55 mm 1 1634 in Intake b 22 45 22 55 mm 0 8839 0 8878 in Limit 22 35 mm 0 8799 in Exhaust a 30 399 30 499 mm 1 1968 1 2007 in Limit 30 299 mm ...

Page 155: ...SION SYSTEM 1 Check Decompression system Checking steps a Check that the decompression mechanism cam 1 moves smoothly b Check that the decompression mechanism cam lever pin 2 projects from the camshaft CHECKING THE TIMING CHAIN TENSIONER 1 Check While pressing the tensioner rod lightly with fingers use a thin screwdriver 1 and wind the tensioner rod up fully clockwise When releasing the screwdrive...

Page 156: ...on the exhaust camshaft and the punch mark d on the intake camshaft must align with the cylinder head surface as shown in the illustration Do not turn the crankshaft during the cam shaft installation Damage or improper valve timing will result d Install the clips camshaft caps 4 and bolts camshaft cap 5 Before installing the clips cover the cylinder head with a clean rag to prevent the clips from ...

Page 157: ...cap bolt 5 to the specified torque 3 Turn Crankshaft Counterclockwise several turns 4 Check Rotor T D C mark Align with the crankcase align mark Camshaft match marks Align with the cylinder head surface Out of alignment Adjust 5 Install Timing mark accessing screw 1 Crankshaft end accessing screw 2 6 Install Timing chain guide top side 1 Cylinder head cover gasket 2 Cylinder head cover 3 Bolt cyli...

Page 158: ...5 25 CAMSHAFTS 7 Install Cylinder head breather hose Spark plug Spark plug 13 Nm 1 3 m kg 9 4 ft lb ...

Page 159: ...haust pipe and silencer Refer to REMOVING THE EX HAUST PIPE AND SILENCER sec tion in the CHAPTER 3 Radiator hose 1 Disconnect at cylinder head side Carburetor Refer to CARBURETOR section Air cut off valve assembly Refer to AIR INDUCTION SYSTEM section Camshaft Refer to CAMSHAFTS section Upper engine bracket Refer to ENGINE REMOVAL sec tion 1 Radiator pipe 1 2 Oil delivery pipe 1 3 Nut 2 ...

Page 160: ...5 27 CYLINDER HEAD 4 Bolt L 135 mm 5 31 in 2 5 Bolt L 145 mm 5 71 in 2 6 Cylinder head 1 7 Timing chain guide exhaust side 1 Order Part name Q ty Remarks ...

Page 161: ...e a 400 600 grit wet sandpaper on the surface plate and resurface the head using a figure eight sanding pattern To ensure an even surface rotate the cylinder head several times INSTALLING THE CYLINDER HEAD 1 Install Dowel pin 1 Cylinder head gasket 2 Timing chain guide exhaust side 3 Cylinder head 4 While pulling up the timing chain install the tim ing chain guide exhaust side and cylinder head 2 ...

Page 162: ... tighten the union bolts temporarily Then retighten them with the width a across flats of the oil delivery pipe held tight with a spanner 4 Install Radiator pipe 1 Bolt radiator pipe 2 Union bolt M8 18 Nm 1 8 m kg 13 ft lb Union bolt M10 20 Nm 2 0 m kg 14 ft lb Bolt radiator pipe 10 Nm 1 0 m kg 7 2 ft lb ...

Page 163: ...me Q ty Remarks Cylinder head Refer to CYLINDER HEAD section 1 Valve lifter 5 Refer to removal section 2 Adjusting pad 5 Refer to removal section 3 Valve cotter 10 Refer to removal section 4 Valve spring retainer 5 5 Valve spring 5 6 Valve stem seal 5 7 Valve spring seat 5 8 Exhaust valve 2 9 Intake valve 3 ...

Page 164: ... b Check that the valve seals properly There should be no leakage at the valve seat 2 3 Remove Valve cotter Attach a valve spring compressor 1 between the valve spring retainer and the cylinder head to remove the valve cotters CHECKING THE VALVE 1 Measure Stem to guide clearance Out of specification Replace the valve guide Valve spring compressor YM 4019 90890 04019 Stem to guide clearance valve g...

Page 165: ...ce the valve seat 3 Inspect Valve face Pitting wear Grind the face Valve stem end Mushroom shape or diameter larger than the body of the stem Replace 4 Measure Margin thickness a Out of specification Replace Valve guide installation height a Intake 11 8 12 2 mm 0 46 0 48 in Exhaust 11 3 11 7mm 0 44 0 46 in Valve guide remover Intake 4 0 mm 0 16 in YM 4111 90890 04111 Exhaust 4 5 mm 0 18 in YM 4116...

Page 166: ...tern d Measure the valve seat width Where the valve seat and valve face made contact blueing will have been removed e If the valve seat is too wide too narrow or the seat is not centered the valve seat must be refaced 9 Lap Valve face Valve seat This model uses titanium intake and ex haust valves Titanium valves that have been used to lap the valve seats must not be used Always replace lapped valv...

Page 167: ...f the compound from the valve face and valve seat f Apply Mechanic s blueing dye Dykem to the valve face g Install the valve into the cylinder head h Press the valve through the valve guide and onto the valve seat to make a clear pattern i Measure the valve seat width again If the valve seat width is out of specification reface and relap the valve seat CHECKING THE VALVE SPRINGS 1 Measure Valve sp...

Page 168: ...m seal 3 Valve spring 4 Valve spring retainer 5 To cylinder head Make sure that each valve is installed in its original place also referring to the painted color as follows Intake middle a Orange Intake right left b Green Exhaust c Purple Install the valve springs with the larger pitch d facing upward e Smaller pitch 3 Install Valve cotter While compressing the valve spring with a valve spring com...

Page 169: ...ting the valve tip with excessive force could damage the valve 5 Install Adjusting pad 1 Valve lifter 2 Apply the molybdenum disulfide oil on the valve stem end Apply the engine oil on the valve lifters Valve lifter must turn smoothly when rotated with a finger Be careful to reinstall valve lifters and pads in their original place ...

Page 170: ...STON Order Part name Q ty Remarks Cylinder head Refer to CYLINDER HEAD section 1 Bolt cylinder 1 2 Cylinder 1 3 Piston pin clip 2 Refer to removal section 4 Piston pin 1 Refer to removal section 5 Piston 1 Refer to removal section 6 Piston ring set 1 Refer to removal section ...

Page 171: ...same time lifting the piston ring over the top of the pis ton crown as shown in the illustration CHECKING THE CYLINDER AND PISTON 1 Inspect Cylinder and piston walls Vertical scratches Replace cylinder and piston 2 Measure Piston to cylinder clearance Measurement steps a Measure the cylinder bore C with a cylin der bore gauge Measure the cylinder bore C in parallel to and at right angles to the cr...

Page 172: ...ng into the cylinder and push it ap proximately 10 mm 0 39 in into the cylinder Push the ring with the piston crown so that the ring will be at a right angle to the cylinder bore a 10 mm 0 39 in 3 Measure Ring end gap Out of specification Replace You cannot measure the end gap on the ex pander spacer of the oil control ring If the oil control ring rails show excessive gap replace all three rings P...

Page 173: ...g Onto the piston Be sure to install the piston rings so that the manufacturer s marks or numbers are located on the upper side of the rings Lubricate the piston and piston rings liberally with engine oil 2 Position Top ring 2nd ring Oil ring Offset the piston ring end gaps as shown a Top ring end b 2nd ring end c Oil ring end upper d Oil ring e Oil ring end lower 3 Install Piston 1 Piston pin 2 P...

Page 174: ...heir ends fac ing downward INSTALLING THE CYLINDER 1 Lubricate Piston Piston ring Cylinder Apply a liberal coating of engine oil 2 Install Dowel pin 1 O ring 2 Apply the lithium soap base grease on the O ring 3 Install Cylinder gasket 1 Cylinder 2 Install the cylinder with one hand while com pressing the piston rings with the other hand Pass the timing chain 3 through the tim ing chain cavity Be c...

Page 175: ... Refer to CHANGING THE ENGINE OIL section in the CHAPTER 3 Brake pedal Refer to ENGINE REMOVAL sec tion Clutch cable Disconnect at engine side 1 Clutch cover 1 2 Clutch spring 5 3 Pressure plate 1 4 Push rod 1 1 5 Circlip 1 6 Washer 1 7 Bearing 1 8 Ball 1 9 Push rod 2 1 10 Friction plate 9 ...

Page 176: ...ing 1 13 Seat plate 1 14 Nut clutch boss 1 Refer to removal section 15 Lock washer 1 Refer to removal section 16 Clutch boss 1 Refer to removal section 17 Thrust washer 1 18 Primary driven gear 1 19 Push lever shaft 1 Order Part name Q ty Remarks ...

Page 177: ...CKING THE PRIMARY DRIVEN GEAR 1 Check Circumferential play Free play exists Replace Gear teeth a Wear damage Replace CHECKING THE CLUTCH SPRINGS 1 Measure Clutch spring free length a Out of specification Replace springs as a set CHECKING THE FRICTION PLATES 1 Measure Friction plate thickness Out of specification Replace friction plate as a set Measure at all four points Clutch holding tool YM 9104...

Page 178: ...G THE PUSH ROD 1 Inspect Push rod 1 1 Bearing 2 Washer 3 Push rod 2 4 Ball 5 Wear damage bend Replace INSTALLING THE PUSH LEVER SHAFT 1 Install Push lever shaft 1 Bolt push lever shaft 2 Apply the lithium soap base grease on the oil seal lip Apply the engine oil on the push lever shaft Fit the seat plate 3 in the groove a of the push lever shaft and tighten the bolt seat plate Warp limit 0 1 mm 0 ...

Page 179: ...he step b Install the cushion spring with the paint c facing out 5 Install Friction plate 1 1 Clutch plate 1 2 Friction plate 2 3 Clutch plate 2 4 Install the clutch plates and friction plates al ternately on the clutch boss starting with a friction plate and ending with a friction plate Use the friction plates 1 for the first and final while paying attention to the difference in sur face pattern ...

Page 180: ...er 7 Install Push rod 2 1 Ball 2 Push rod 1 3 Apply the engine oil on the push rod 1 2 and ball 8 Install Pressure plate 1 9 Install Clutch spring 1 Bolt clutch spring 2 Tighten the bolts in stage using a crisscross pattern 10 Install Dowel pin 1 Gasket clutch cover 2 Bolt clutch spring 10 Nm 1 0 m kg 7 2 ft lb ...

Page 181: ...5 48 CLUTCH 11 Install Clutch cover 1 Bolt clutch cover Tighten the bolts in stage using a crisscross pattern Bolt clutch cover 10 Nm 1 0 m kg 7 2 ft lb ...

Page 182: ... THE ENGINE OIL section in the CHAPTER 3 Drain the coolant Refer to CHANGING THE COOL ANT section in the CHAPTER 3 Radiator hose 3 Disconnect at water pump side Exhaust pipe Refer to EXHAUST PIPE AND SI LENCER section in the CHAPTER 3 Brake pedal Refer to ENGINE REMOVAL sec tion Engine guard 1 Oil filter element cover 1 2 Oil filter element 1 3 Water pump housing 1 4 Oil delivery pipe 1 ...

Page 183: ...tarter crank 1 7 Right crankcase cover 1 8 Impeller 1 Refer to removal section 9 Washer 1 Refer to removal section 10 Impeller shaft 1 Refer to removal section 11 Oil seal 2 Refer to removal section 12 Bearing 1 Refer to removal section Order Part name Q ty Remarks ...

Page 184: ...disassemble the water pump unless there is an abnormality such as excessive change in coolant level discolor ation of coolant or milky transmission oil 1 Remove Bearing 1 2 Remove Oil seal 1 CHECKING THE OIL DELIVERY PIPE 1 Inspect Oil delivery pipe 1 Bend damage Replace Clogged Blow CHECKING THE IMPELLER SHAFT 1 Inspect Impeller shaft 1 Bend wear damage Replace Fur deposits Clean CHECKING THE IMP...

Page 185: ...acing the right crankcase cover 2 2 Install Bearing 1 Install the bearing by pressing its outer race parallel INSTALLING THE IMPELLER SHAFT 1 Install Impeller shaft 1 Washer 2 Impeller 3 Take care so that the oil seal lip is not dam aged or the spring does not slip off its posi tion When installing the impeller shaft apply the lithium soap base grease on the oil seal lip and impeller shaft And ins...

Page 186: ... primary drive gear 4 Tighten the bolts in stage using a crisscross pattern INSTALLING THE KICKSTARTER CRANK 1 Install Kickstarter crank 1 Washer Bolt kickstarter crank Install so that there is a clearance a of 13 mm 0 51 in or more between the kickstarter and frame and that the kickstarter does not contact the crankcase cover when it is pulled 2 Install Oil hose 1 Bolt oil hose 2 Bolt right crank...

Page 187: ...1 Install Dowel pin 1 O ring 2 Apply the lithium soap base grease on the O ring 2 Install Water pump housing 1 Bolt water pump housing 2 INSTALLING THE OIL FILTER ELEMENT 1 Install Oil filter element 1 O ring 2 Oil filter element cover 3 Bolt oil filter element cover Apply the lithium soap base grease on the O ring Union bolt M8 18 Nm 1 8 m kg 13 ft lb Union bolt M10 20 Nm 2 0 m kg 14 ft lb Bolt w...

Page 188: ...ER ELEMENT AND WATER PUMP section Stator Refer to AC MAGNETO AND STARTER CLUTCH section 1 Nut primary drive gear 1 Refer to removal section 2 Nut balancer shaft driven gear 1 Refer to removal section 3 Lock washer 1 4 Primary drive gear 1 5 Balancer shaft drive gear 1 6 Lock washer 1 7 Balancer shaft driven gear 1 8 Balancer shaft 1 Refer to removal section ...

Page 189: ...the centers of the crank shaft and balancer shaft CHECKING THE PRIMARY DRIVE GEAR BALANCER SHAFT DRIVE GEAR AND BALANCER SHAFT DRIVEN GEAR 1 Inspect Primary drive gear 1 Balancer shaft drive gear 2 Balancer shaft driven gear 3 Wear damage Replace CHECKING THE BALANCER SHAFT 1 Inspect Balancer shaft Cracks damage Replace INSTALLING THE BALANCER 1 Install Balancer shaft 1 Apply the engine oil on the...

Page 190: ...n the balancer shaft driven gear 2 Align the punched mark c on the balancer shaft drive gear with the lower spline d on the crankshaft end 4 Install Lock washer 1 Nut balancer shaft driven gear 2 Primary drive gear 3 Lock washer 4 Nut primary drive gear 5 Install the primary drive gear with its stepped side a facing the engine Place an aluminum plate b between the teeth of the balancer shaft drive...

Page 191: ... gear Refer to CLUTCH section Right crankcase cover Refer to OIL FILTER ELEMENT AND WATER PUMP section 1 Circlip 1 2 Washer 1 3 Oil pump drive gear 1 4 Oil pump assembly 1 5 Outer rotor 2 1 6 Circlip 1 7 Inner rotor 2 1 8 Dowel pin 1 9 Oil pump cover 1 10 Outer rotor 1 1 11 Inner rotor 1 1 ...

Page 192: ...5 59 OIL PUMP 12 Dowel pin 1 13 Washer 1 14 Oil pump drive shaft 1 15 Rotor housing 1 Order Part name Q ty Remarks ...

Page 193: ...G THE OIL TANK Order Part name Q ty Remarks Drain the engine oil Refer to CHANGING THE ENGINE OIL section in the CHAPTER 3 1 Oil hose 2 1 2 Oil hose 1 1 3 Dowel pin 2 4 Oil tank breather hose 1 5 Oil tank 1 6 Oil strainer 1 ...

Page 194: ...t of specification Replace the oil pump assembly 3 Check Unsmooth Repeat steps 1 and 2 or re place the defective parts INSTALLING THE OIL PUMP 1 Install Oil pump drive shaft 1 Washer 2 Dowel pin 3 Inner rotor 1 4 Apply the engine oil on the oil pump drive shaft and inner rotor 1 Fit the dowel pin into the groove in the inner rotor 1 Tip clearance a 0 12 mm or less 0 0047 in or less Limit 0 20 mm 0...

Page 195: ...ner rotor 2 4 Install Outer rotor 2 1 Dowel pin 2 Oil pump assembly 3 Bolt oil pump assembly L 25 mm 0 94 in 4 Bolt oil pump assembly L 30 mm 1 18 in 5 Apply the engine oil on the outer rotor 2 5 Install Oil pump drive gear 1 Washer 2 Circlip 3 Apply the engine oil on the oil pump drive gear inner circumference Screw oil pump cover 1 7 Nm 0 17 m kg 1 2 ft lb Bolt oil pump assembly 10 Nm 1 0 m kg 7...

Page 196: ...rder Part name Q ty Remarks Oil pump Refer to OIL PUMP section 1 Kick idle gear 1 2 Kick shaft assembly 1 Refer to removal section 3 Spring guide 1 4 Torsion spring 1 5 Ratchet wheel 1 6 Kick gear 1 7 Kick shaft 1 8 Washer 1 9 Shift pedal 1 10 Shift shaft 1 11 Collar 1 12 Torsion spring 1 13 Roller 1 ...

Page 197: ...r to removal section 15 Shift lever assembly 1 Refer to removal section 16 Shift lever 1 17 Pawl 2 18 Pawl pin 2 19 Spring 2 20 Bolt stopper lever 1 21 Stopper lever 1 22 Torsion spring 1 23 Segment 1 Refer to removal section Order Part name Q ty Remarks ...

Page 198: ...THE SEGMENT 1 Remove Bolt segment 1 Segment 2 Turn the segment counterclockwise until it stops and loosen the bolt If the segment gets an impact it may be damaged Take care not to give an impact to the segment when removing the bolt CHECKING THE KICK SHAFT AND RATCHET WHEEL 1 Check Ratchet wheel 1 smooth movement Unsmooth movement Replace Kick shaft 2 Wear damage Replace Spring 3 Broken Replace CH...

Page 199: ... damage Replace Torsion spring 2 Broken Replace INSTALLING THE SEGMENT 1 Install Segment 1 Bolt segment Align the notch a on the segment with the pin b on the shift cam If the segment gets an impact it may be damaged Take care not to give an impact to the segment when tightening the bolt INSTALLING THE STOPPER LEVER 1 Install Torsion spring 1 Stopper lever 2 Bolt stopper lever 3 Align the stopper ...

Page 200: ... shaft 4 Install Bolt shift guide 1 INSTALLING THE SHIFT SHAFT 1 Install Roller 1 Collar 2 Torsion spring 3 Shift shaft 4 Apply the engine oil on the roller and shift shaft 2 Install Shift pedal Refer to AC MAGNETO AND STARTER CLUTCH section INSTALLING THE KICK SHAFT ASSEMBLY 1 Install Kick gear 1 Washer 2 Circlip 3 Ratchet wheel 4 Spring 5 Washer 6 Circlip 7 To kick shaft 8 Apply the molybdenum d...

Page 201: ...e grease on the contacting surfaces of the kick shaft stop per a and kick shaft ratchet wheel guide 3 Apply the engine oil on the kick shaft Slide the kick shaft assembly into the crank case and make sure the kick shaft stopper a fits into the kick shaft ratchet wheel guide 5 Hook Torsion spring 1 Turn the torsion spring clockwise and hook into the proper hole a in the crankcase INSTALLING THE KIC...

Page 202: ...HANGING THE ENGINE OIL section in the CHAPTER 3 Seat and fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section in the CHAPTER 3 Disconnect the AC magneto lead 1 Shift pedal 1 2 Cover torque limiter 1 3 Torque limiter 1 Do not disassemble 4 Crankcase cover left 1 5 Gasket 1 6 Dowel pin 2 7 Nut rotor 1 Refer to TIP 8 Rotor 1 Refer to removal section 9 Woodruff key 1 ...

Page 203: ...d retighten the rotor nut to 65 Nm 6 5 m kg 47 ft lb 10 Starter clutch drive gear 1 11 Starter clutch assembly cover 1 12 Starter clutch 1 Refer to removal section 13 Bearing 1 14 Washer 1 15 Idle gear plate 1 16 Idle gear 1 17 Holder 1 18 Pickup coil 1 19 Stator 1 Order Part name Q ty Remarks ...

Page 204: ...as sembly cover by prying it gently to void damage to the cover 2 Remove Starter clutch 1 Using a thin screwdriver or the like remove the plate a while prying it upward little by little REMOVING THE AC MAGNETO 1 Inspect Rotor inner surface a Stator outer surface b Damage Inspect the crankshaft runout and crankshaft bearing If necessary replace AC magneto and or stator CHECKING THE WOODRUFF KEY 1 I...

Page 205: ...hen turning the starter clutch drive gear clockwise A it should turn freely If the starter clutch drive gear does not turn freely the starter clutch is faulty and must be re placed CHECKING THE TORQUE LIMITER 1 Check Torque limiter Damage wear Replace INSTALLING THE AC MAGNETO AND STARTER CLUTCH 1 Install Stator 1 Bolt stator 2 Pickup coil 3 Bolt pickup coil 4 2 Install Holder 1 Bolt 2 Pass the pi...

Page 206: ...er clutch drive gear inner circumference 6 Install Starter clutch 1 To rotor 2 Install the starter clutch with its plate side up ward While installing the starter clutch push in the projections a one by one on the clutch cir cumference Push in the starter clutch until it hits the rotor 7 Install Starter clutch assembly cover 1 To rotor 2 Install the starter clutch assembly cover by fit ting its pa...

Page 207: ...Use the sheave holder 2 Tighten the rotor nut to 65 Nm 6 5 m kg 47 ft lb loosen and retighten the rotor nut to 65 Nm 6 5 m kg 47 ft lb 10 Install Dowel pin Gasket crankcase cover left Crankcase cover left 1 Bolt crankcase cover left 2 Bolt crankcase cover left 3 Tighten the bolts in stage using a crisscross pattern 11 Install Washer 1 Torque limiter 2 Washer 3 Apply the engine oil to the shaft and...

Page 208: ...ark a facing upward 13 Connect AC magneto lead Refer to CABLE ROUTING DIAGRAM section in the CHAPTER 2 14 Install Shift pedal 1 Bolt shift pedal 2 When installing the shift pedal onto the shift shaft be sure that the center of the shift pedal is about 1 4 mm 0 06 in a above the top of the footrest Bolt 10 Nm 1 0 m kg 7 2 ft lb Bolt shift pedal 12 Nm 1 2 m kg 8 7 ft lb ...

Page 209: ... CHANGING THE ENGINE OIL section in the CHAPTER 3 Seat and fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section in the CHAPTER 3 Carburetor Refer to CARBURETOR section Exhaust pipe and silencer Refer to EXHAUST PIPE AND SI LENCER section in the CHAPTER 3 Air cut off valve assembly Refer to AIR INDUCTION SYSTEM section Clutch cable Disconnect at the engine side Radiator Refer to RADIATOR secti...

Page 210: ...Ignition coil Disconnect the AC magneto lead Negative battery lead Disconnect at the engine side 1 Engine guard 1 2 Neutral switch 1 3 Drive chain sprocket cover 1 4 Nut drive sprocket 1 Refer to removal section 5 Lock washer 1 Refer to removal section 6 Drive sprocket 1 Refer to removal section 7 Clip 1 8 Bolt brake pedal 1 9 Brake pedal 1 10 Upper engine bracket 2 Order Part name Q ty Remarks ...

Page 211: ...5 78 ENGINE REMOVAL 11 Lower engine bracket 2 12 Engine mounting bolt 3 13 Pivot shaft 1 Refer to removal section 14 Engine 1 Refer to removal section Order Part name Q ty Remarks ...

Page 212: ...e insert a shaft of similar diameter into the other side of the swingarm to support it 2 Remove Engine 1 From right side Make sure that the couplers hoses and cables are disconnected INSTALLING THE ENGINE 1 Install Engine 1 Install the engine from right side Pivot shaft 2 Engine mounting bolt lower 3 Lower engine bracket 4 Bolt lower engine bracket 5 Patch 6 Engine mounting bolt front 7 Upper engi...

Page 213: ...the bolt O rings and brake pedal bracket INSTALLING THE DRIVE SPROCKET 1 Install Drive sprocket 1 Drive chain 2 Install the drive sprocket together with the drive chain 2 Install Lock washer 1 Nut drive sprocket 2 Tighten the nut while applying the rear brake 3 Bend the lock washer tab to lock the nut 4 Install Drive chain sprocket guide 1 Drive chain sprocket cover 2 Engine mounting bolt upper 55...

Page 214: ... INSTALLING THE NEUTRAL SWITCH 1 Install Spring 1 Pin 2 O ring 3 Neutral switch 4 Screw neutral switch 5 Apply the lithium soap base grease on the O ring Bolt drive chain sprocket cover 7 Nm 0 7 m kg 5 1 ft lb Screw neutral switch 4 Nm 0 4 m kg 2 9 ft lb ...

Page 215: ... CYLINDER AND PISTON section Kick shaft assembly Refer to KICK SHAFT AND SHIFT SHAFT section Segment Refer to KICK SHAFT AND SHIFT SHAFT section Stator Refer to AC MAGNETO AND STARTER CLUTCH section Balancer shaft Refer to BALANCER section 1 Timing chain guide intake side 1 2 Timing chain 1 3 Oil delivery pipe 2 1 4 Bolt L 45 mm 1 77 in 5 Refer to removal section ...

Page 216: ...76 in 3 Refer to removal section 7 Hose guide 1 Refer to removal section 8 Clutch cable holder 1 Refer to removal section 9 Right crankcase 1 Refer to removal section 10 Left crankcase 1 Refer to removal section 11 Oil strainer 1 12 Crankshaft 1 Refer to removal section Order Part name Q ty Remarks ...

Page 217: ...CRANKCASE BEARING Order Part name Q ty Remarks Transmission Refer to TRANSMISSION SHIFT CAM AND SHIFT FORK section Shift cam and shift fork Refer to TRANSMISSION SHIFT CAM AND SHIFT FORK section 1 Oil seal 2 2 Bearing 10 Refer to removal section ...

Page 218: ...engine mounting boss using a soft hammer and leave the crankshaft and transmission with the left crankcase Use soft hammer to tap on the case half Tap only on reinforced portions of case Do not tap on gasket mating surface Work slowly and carefully Make sure the case halves separate evenly If the cases do not separate check for a remaining case bolt or fitting Do not force c Remove the dowel pins ...

Page 219: ...g Rotate inner race with a finger Rough spot seizure Replace 3 Inspect Oil seal Damage Replace CHECKING THE CRANKSHAFT 1 Measure Runout limit a Small end free play limit b Connecting rod big end side clearance c Crank width d Out of specification Replace Use the dial gauge and a thickness gauge Dial gauge and stand YU 3097 90890 01252 Standard Limit Runout lim it 0 03 mm 0 0012 in 0 05 mm 0 002 in...

Page 220: ... dam age the screwdriver receiving hole in the screw head INSTALLING THE CRANKSHAFT 1 Install Crankshaft 1 Use the crankshaft installing tool 2 3 4 and 5 Hold the connecting rod at top dead center with one hand while turning the nut of the in stalling tool with the other Operate the install ing tool until the crankshaft bottoms against the bearing Before installing the crankshaft clean the contact...

Page 221: ...ng the sealant 5 Install Dowel pin 1 O ring 2 Right crankcase To left crankcase Apply the lithium soap base grease on the O ring Fit the right crankcase onto the left crankcase Tap lightly on the case with soft hammer When installing the crankcase the connecting rod should be positioned at TDC top dead center 6 Tighten Hose guide 1 Clutch cable holder 2 Bolt crankcase 3 Bolt oil strainer 10 Nm 1 0...

Page 222: ...grease on the Or ings 8 Install Timing chain 1 Timing chain guide intake side 2 Bolt timing chain guide 3 9 Remove Sealant Forced out on the cylinder mating surface 10 Apply Engine oil To the crank pin bearing and oil delivery hole 11 Check Crankshaft and transmission operation Unsmooth operation Repair Bolt oil delivery pipe 2 10 Nm 1 0 m kg 7 2 ft lb Bolt timing chain guide 10 Nm 1 0 m kg 7 2 ft...

Page 223: ...s Engine Refer to ENGINE REMOVAL sec tion Separate the crankcase Refer to CRANKCASE AND CRANKSHAFT section 1 Main axle 1 Refer to removal section 2 Drive axle 1 Refer to removal section 3 Shift cam 1 Refer to removal section 4 Shift fork 3 1 Refer to removal section 5 Shift fork 2 1 Refer to removal section 6 Shift fork 1 1 Refer to removal section 7 Collar 1 ...

Page 224: ... forks Remove the main axle drive axle shift cam and shift fork all together by tapping lightly on the transmission drive axle with a soft ham mer CHECKING THE GEARS 1 Inspect Matching dog a Gear teeth b Shift fork groove c Wear damage Replace 2 Inspect O ring 1 Damage Replace 3 Check Gears movement Unsmooth movement Repair or replace CHECKING THE BEARING 1 Inspect Bearing 1 Rotate inner race with...

Page 225: ...on gear 17T 2 Collar 3 4th pinion gear 21T 4 2nd pinion gear 16T 5 To main axle 6 Apply the molybdenum disulfide oil on the inner and end surface of the idler gear and on the in ner surface of the sliding gear then install 2 Install 2nd wheel gear 28T 1 4th wheel gear 23T 2 3rd wheel gear 23T 3 5th wheel gear 17T 4 1st wheel gear 31T 5 O ring 6 To drive axle 7 Apply the molybdenum disulfide oil on...

Page 226: ... the lithium soap base grease on the oil seal lip When installing the collar into the crankcase pay careful attention to the crankcase oil seal lip 5 Install Shift fork 1 L 1 Shift fork 2 C 2 Shift fork 3 R 3 Shift cam 4 To main axle and drive axle Apply the engine oil on the shift fork grooves Mesh the shift fork 1 L with the 4th wheel gear 5 and 3 R with the 5th wheel gear 7 on the drive axle Me...

Page 227: ...ISSION SHIFT CAM AND SHIFT FORK 6 Install Transmission assembly 1 To left crankcase 2 Apply the engine oil on the bearings and guide bars 7 Check Shifter operation Transmission operation Unsmooth operation Repair ...

Page 228: ...ment disas sembly or reassembly only by reference to this manual It may lead to servicing trouble and mechanical damage FRONT WHEEL AND REAR WHEEL REMOVING THE FRONT WHEEL Order Part name Q ty Remarks Hold the machine by placing the suit able stand under the engine Refer to HANDLING NOTE 1 Bolt axle holder 4 Only loosening 2 Nut front wheel axle 1 3 Front wheel axle 1 4 Front wheel 1 5 Speed senso...

Page 229: ...HEEL AND REAR WHEEL 7 Oil seal 1 8 Bearing 2 Refer to removal section 9 Brake disc 1 Order Part name Q ty Remarks 21 Nm 2 1 m kg 15 ft lb 21 Nm 2 1 m kg 15 ft lb 12 Nm 1 2 m kg 8 7 ft lb 90 Nm 9 0 m kg 65 ft lb 6 ...

Page 230: ...o HANDLING NOTE 1 Nut rear wheel axle 1 2 Rear wheel axle 1 3 Drive chain puller 2 4 Rear wheel 1 Refer to removal section 5 Collar 2 6 Rear wheel sprocket 1 7 Oil seal 2 8 Circlip 1 9 Bearing 2 Refer to removal section 10 Brake disc 1 125 Nm 12 5 m kg 90 ft lb 14 Nm 1 4 m kg 10 ft lb 19 Nm 1 9 m kg 13 ft lb 19 Nm 1 9 m kg 13 ft lb 50 Nm 5 0 m kg 36 ft lb ...

Page 231: ...ING THE WHEEL 1 Measure Wheel runout Out of limit Repair replace 2 Inspect Bearing Rotate inner race with a finger Rough spot seizure Replace Replace the bearings oil seal and wheel collar as a set CHECKING THE WHEEL AXLE 1 Measure Wheel axle bends Out of specification Replace Use the dial gauge 1 The bending value is shown by one half of the dial gauge reading Do not attempt to straighten a bent ...

Page 232: ...ing and oil seal lip when installing Use a socket that matches the outside diam eter of the race of the bearing Left side of bearing shall be installed first Install the oil seal with its manufacture s marks or numbers facing outward Do not strike the inner race of the bearing Contact should be made only with the outer race 2 Install Brake disc 1 Bolt brake disc 2 Tighten the bolts in stage using ...

Page 233: ...Wheel Install the brake disc 1 between the brake pads 2 correctly Make sure that the projections a in the speed sensor fits over the stopper b on the front fork inner tube 6 Install Wheel axle 1 Apply the lithium soap base grease on the wheel axle 7 Install Nut wheel axle 1 8 Tighten Bolt axle holder 1 Before tightening the bolt fit the wheel axle to the axle holder by stroking the front fork seve...

Page 234: ...aring shall be installed first Install the oil seal with its manufacture s marks or numbers facing outward Do not strike the inner race of the bearing Contact should be made only with the outer race 2 Install Brake disc 1 Bolt brake disc 2 Tighten the bolts in stage using a crisscross pattern 3 Install Rear wheel sprocket 1 Bolt rear wheel sprocket 2 Washer rear wheel sprocket 3 Nut rear wheel spr...

Page 235: ...ectly 6 Install Drive chain 1 Push the wheel 2 forward and install the drive chain 7 Install Left drive chain puller 1 Wheel axle 2 Install the left drive chain puller and insert the wheel axle from left side Apply the lithium soap base grease on the wheel axle 8 Install Right drive chain puller 1 Washer 2 Nut wheel axle 3 Temporarily tighten the nut wheel axle at this point ...

Page 236: ...ust Drive chain slack a Refer to ADJUSTING THE DRIVE CHAIN SLACK section in the CHAPTER 3 10 Tighten Nut wheel axle 1 Locknut 2 Drive chain slack 48 58 mm 1 9 2 3 in Nut wheel axle 125 Nm 12 5 m kg 90 ft lb Locknut 19 Nm 1 9 m kg 13 ft lb ...

Page 237: ...gine Refer to HANDLING NOTE Drain the brake fluid Refer to removal section 1 Brake hose holder protector 2 2 Brake hose holder brake caliper 1 3 Union bolt 2 4 Brake hose 1 5 Pad pin plug 1 Remove when loosening the pad pin 6 Pad pin 1 Loosen when disassembling the brake caliper 7 Brake caliper 1 8 Brake lever 1 9 Brake master cylinder bracket 1 10 Brake master cylinder 1 ...

Page 238: ...ine Refer to HANDLING NOTE Rear wheel Refer to FRONT WHEEL AND REAR WHEEL section Drain the brake fluid Refer to removal section 1 Brake pedal 1 2 Brake master cylinder 1 3 Brake hose holder 2 4 Union bolt 2 5 Brake hose 1 6 Pad pin plug 1 Remove when loosening the pad pin 7 Pad pin 1 Loosen when disassembling the brake caliper 8 Brake caliper 1 ...

Page 239: ...Order Part name Q ty Remarks A Front B Rear A B 1 Pad pin 1 1 2 Brake pad 2 2 3 Pad support 1 1 4 Brake caliper piston 2 1 Refer to removal section 5 Brake caliper piston dust seal 2 1 Refer to removal section 6 Brake caliper piston seal 2 1 Refer to removal section ...

Page 240: ...KE MASTER CYLINDER Order Part name Q ty Remarks A Front B Rear 1 Brake master cylinder cap 1 2 Diaphragm 1 3 Reservoir float 1 4 Brake master cylinder boot 1 5 Circlip 1 Use a long nose circlip pliers 6 Washer 1 7 Push rod 1 8 Brake master cylinder kit 1 ...

Page 241: ...while pulling the lever in or pushing down on the pedal Do not reuse the drained brake fluid Brake fluid may erode painted surfaces or plastic parts Always clean up spilled fluid immediately REMOVING THE BRAKE CALIPER PISTON 1 Remove Brake caliper piston Use compressed air and proceed carefully Cover piston with rag and use extreme caution when expelling piston from cylin der Never attempt to pry ...

Page 242: ... the brake caliper piston seals and brake caliper piston dust seals whenever a caliper is disassembled A Front B Rear CHECKING THE BRAKE MASTER CYLINDER 1 Inspect Brake master cylinder inner surface a Wear scratches Replace master cylinder assembly Stains Clean Use only new brake fluid A Front B Rear 2 Inspect Diaphragm 1 Crack damage Replace A Front B Rear 3 Inspect front brake only Reservoir flo...

Page 243: ...only Internal parts should be lubricated with brake fluid when installed Replace the brake caliper piston seals and brake caliper piston dust seals whenever a caliper is disassembled INSTALLING THE BRAKE CALIPER PISTON 1 Clean Brake caliper Brake caliper piston seal Brake caliper piston dust seal Brake caliper piston Clean them with brake fluid 2 Install Brake caliper piston seal 1 Brake caliper p...

Page 244: ...Front B Rear INSTALLING THE FRONT BRAKE CALIPER 1 Install Pad support 1 Brake pad 2 Pad pin 3 Install the brake pads with their projections a into the brake caliper recesses b Temporarily tighten the pad pin at this point 2 Install Brake caliper 1 Bolt brake caliper 2 3 Tighten Pad pin 3 4 Install Pad pin plug 4 Bolt brake caliper 23 Nm 2 3 m kg 17 ft lb Pad pin 18 Nm 1 8 m kg 13 ft lb Pad pin plu...

Page 245: ...Pad pin 3 5 Install Pad pin plug 4 INSTALLING THE BRAKE MASTER CYLINDER KIT 1 Clean Brake master cylinder Brake master cylinder kit Clean them with brake fluid 2 Install Brake master cylinder cup primary 1 Brake master cylinder cup secondary 2 To brake master cylinder piston 3 Apply the brake fluid on the brake master cylin der cup After installing cylinder cup should be in stalled as shown direct...

Page 246: ...t B Rear INSTALLING THE FRONT BRAKE MASTER CYLINDER 1 Install Brake master cylinder 1 Brake master cylinder bracket 2 Bolt brake master cylinder bracket 3 Install the bracket so that the arrow mark a face upward First tighten the bolts on the upper side of the brake master cylinder bracket and then tight en the bolts on the lower side 2 Install Brake lever 1 Bolt brake lever 2 Nut brake lever 3 Ap...

Page 247: ...linder 2 Install Brake master cylinder 1 Bolt brake master cylinder 2 3 Install Spring 1 Brake pedal 2 O ring 3 Bolt brake pedal 4 Clip 5 Apply the lithium soap base grease on the bolt O ring and brake pedal bracket 4 Install Pin 1 Washer 2 Cotter pin 3 After installing check the brake pedal height Refer to ADJUSTING THE REAR BRAKE section in the CHAPTER 3 Union bolt 30 Nm 3 0 m kg 22 ft lb Bolt b...

Page 248: ...l Brake hose holder 1 Bolt brake hose holder 2 3 Install Brake hose holder 1 Nut brake hose holder 2 Align the top a of the brake hose holder with the paint b of the brake hose 4 Pass the brake hose through the front brake hose guides 1 5 Install Copper washer 1 Brake hose 2 Union bolt 3 Always use new copper washers Union bolt 30 Nm 3 0 m kg 22 ft lb Bolt brake hose holder 10 Nm 1 0 m kg 7 2 ft l...

Page 249: ...rew brake hose holder 2 After installing the brake hose holders make sure the brake hose does not contact the spring rear shock absorber If it does correct its twist FILLING THE BRAKE FLUID 1 Fill Brake fluid Until the fluid level reaches LOWER level line a Use only the designated quality brake flu id otherwise the rubber seals may deterio rate causing leakage and poor brake per formance Refill wi...

Page 250: ...luid level Fluid at lower level Fill up Refer to CHECKING THE BRAKE FLUID LEVEL section in the CHAPTER 3 4 Install Reservoir float front brake Diaphragm Brake master cylinder cap 1 Screw bolt brake master cylinder cap 2 After installation while pulling the brake le ver in or pushing down on the brake pedal check whether there is any brake fluid leak ing where the union bolts are installed re spect...

Page 251: ...fer to HANDLING NOTE Front wheel Refer to FRONT WHEEL AND REAR WHEEL section Front brake caliper Refer to FRONT BRAKE AND REAR BRAKE section Headlight Handlebar Refer to HANDLEBAR section 1 Protector 1 2 Pinch bolt upper bracket 2 Only loosening 3 Cap bolt 1 Loosen when disassembling the front fork 4 Pinch bolt lower bracket 2 Only loosening 5 Front fork 1 ...

Page 252: ... spring 1 Drain the fork oil 3 Dust seal 1 Refer to removal section 4 Stopper ring 1 Refer to removal section 5 Inner tube 1 Refer to removal section 6 Outer tube 1 7 Piston metal 1 8 Slide metal 1 9 Oil seal washer 1 10 Oil seal 1 11 Spring guide 1 12 Base valve 1 Refer to removal section 13 Damper rod 1 Refer to removal section ...

Page 253: ...ront fork is disas sembled and reassembled Before removing the cap bolts or front forks be sure to extract the air from the air chamber completely REMOVING THE FRONT FORK CAP BOLT 1 Remove Front fork cap bolt 1 From the outer tube Before removing the front fork from the ma chine loosen the front fork cap bolt 2 Remove Front fork cap bolt 1 Hold the locknut 2 and remove the front fork cap bolt REMO...

Page 254: ...ront fork is disassembled and reassembled CHECKING THE BASE VALVE 1 Inspect Valve assembly 1 Wear damage Replace O ring 2 Damage Replace CHECKING THE FORK SPRING 1 Measure Fork spring free length a Out of specification Replace CHECKING THE INNER TUBE 1 Inspect Inner tube surface a Score marks Repair or replace Use 1 000 grit wet sandpaper Damaged oil lock piece Replace Inner tube bends Out of spec...

Page 255: ...RONT FORK 1 Wash the all parts in a clean solvent 2 Install Damper rod 1 To inner tube 2 To install the damper rod into the inner tube hold the inner tube aslant If the inner tube is held vertically the damper rod may fall into it damaging the valve inside 3 Install Copper washer 1 O ring 2 Base valve 3 To inner tube 4 4 Tighten Base valve 1 Use a damper rod holder 2 to lock the damp er rod 3 Appl...

Page 256: ...il seal 3 Oil seal washer 4 Slide metal 5 To inner tube 6 Apply the fork oil on the inner tube When installing the oil seal use vinyl seat a with fork oil applied to protect the oil seal lip Install the oil seal with its manufacture s marks or number facing the axle holder side Install the oil seal washer with its projections b facing upward 7 Install Piston metal 1 Install the piston metal onto t...

Page 257: ... Fit the stopper ring correctly in the groove in the outer tube 12 Install Dust seal 1 Apply the lithium soap base grease on the inner tube 13 Check Inner tube smooth movement Tightness binding rough spots Repeat the steps 2 to 12 14 Compress the front fork fully 15 Fill Front fork oil Until outer tube top surface with recom mended fork oil 1 Fork seal driver YM A0948 90890 01502 Fork seal driver ...

Page 258: ...bbles have been removed from the front fork and the oil has dispense evenly in system before set ting recommended oil level Fill with the fork oil up to the top end of the outer tube or the fork oil will not spread over to every part of the front forks thus making it impossible to obtain the correct level Be sure to fill with the fork oil up to the top of the outer tube and bleed the front forks 2...

Page 259: ... rod 3 pulled up After installing the fork spring hold the damp er rod end so that it will not go down 24 Install Spring seat 1 Front fork cap bolt 2 Fully finger tighten the front fork cap bolt onto the damper rod 25 Tighten Front fork cap bolt locknut 1 Hold the locknut 2 and tighten the front fork cap bolt with specified torque 26 Install Front fork cap bolt 1 To outer tube Temporarily tighten ...

Page 260: ...Pinch bolt lower bracket 2 Tighten the lower bracket to specified torque If torqued too much it may cause the front fork to malfunction 5 Install Speed sensor lead 1 Plate 1 2 Bolt plate 1 3 To right protector 4 Install the speed sensor lead so that its paint a directs as shown and align the bottom b of the plate 1 with the same paint Front fork cap bolt 30 Nm 3 0 m kg 22 ft lb Front fork top end ...

Page 261: ... 4 Install the plate 2 in the direction as shown 7 Install Protector 1 Bolt protector 2 8 Adjust Rebound damping force Turn in the damping adjuster 1 finger tight and then turn out to the originally set position Screw plate 2 0 5 Nm 0 05 m kg 0 36 ft lb Bolt protector 7 Nm 0 7 m kg 5 1 ft lb ...

Page 262: ...lutch lever holder 1 Disconnect the clutch switch lead 5 Engine stop switch 1 Disconnect the engine stop switch lead 6 Brake master cylinder 1 Refer to removal section 7 Start switch 1 Disconnect the start switch lead 8 Throttle cable cap 1 9 Throttle cable 1 pulled 1 Disconnect at the throttle side 10 Throttle cable 2 pushed 1 Disconnect at the throttle side 11 Right grip 1 Refer to removal secti...

Page 263: ...6 36 HANDLEBAR 13 Left grip 1 Refer to removal section 14 Handlebar upper holder 2 15 Handlebar 1 16 Handlebar lower holder 2 Order Part name Q ty Remarks ...

Page 264: ...BAR 1 Inspect Handlebar 1 Bends cracks damage Replace Do not attempt to straighten a bent handle bar as this may dangerously weaken the handlebar INSTALLING THE HANDLEBAR 1 Install Handlebar lower holder 1 Washer 2 Nut handlebar lower holder 3 Install the handlebar lower holder with its side having the greater distance a from the mounting bolt center facing forward Apply the lithium soap base grea...

Page 265: ...he handlebar as shown First tighten the bolts on the front side of the handlebar upper holder and then tighten the bolts on the rear side 3 Tighten Nut handlebar lower holder 1 4 Install Left grip 1 Apply the adhesive to the handlebar 2 Before applying the adhesive wipe off grease or oil on the handlebar surface a with a lac quer thinner Install the left grip to the handlebar so that the line b be...

Page 266: ...s shown 6 Install Grip cap cover 1 Throttle grip 2 Apply the lithium soap base grease on the throttle grip sliding surface 7 Install Throttle cables 1 To tube guide 2 Apply the lithium soap base grease on the throttle cable end and tube guide cable winding portion 8 Install Throttle cable cap 1 Screw throttle cable cap 2 After tightening the screws check that the throttle grip 3 moves smoothly If ...

Page 267: ...he upper side of the brake master cylinder bracket and then tight en the bolt on the lower side 11 Install Engine stop switch 1 Clutch lever holder 2 Bolt clutch lever holder 3 Hot starter lever holder 4 Bolt hot starter lever holder 5 Clamp 6 The engine stop switch clutch lever holder and clamp should be installed according to the dimensions shown Pass the engine stop switch lead in the middle of...

Page 268: ...m soap base grease on the clutch cable end and hot starter cable end 13 Adjust Clutch lever free play Refer to ADJUSTING THE CLUTCH CA BLE FREE PLAY section in the CHAPTER 3 Hot starter lever free play Refer to ADJUSTING THE HOT STARTER LEVER FREE PLAY section in the CHAP TER 3 ...

Page 269: ... lb Loosen it one turn Retighten it 7 Nm 0 7 m kg 5 1 ft lb Hold the machine by placing the suit able stand under the engine Refer to HANDLING NOTE Headlight Handlebar Refer to HANDLEBAR section Front brake hose guide Front fender 1 Multi function display 1 2 Multi function display bracket 1 3 Main switch 1 Disconnect the main switch lead ...

Page 270: ... FRONT FORK section 6 Upper bracket 1 7 Steering ring nut 1 Refer to removal section 8 Lower bracket 1 9 Bearing race cover 1 10 Upper bearing 1 11 Lower bearing 1 Refer to removal section 12 Bearing race 2 Refer to removal section Order Part name Q ty Remarks ...

Page 271: ...BEARING RACE 1 Remove Bearing race 1 Remove the bearing race using long rod 2 and the hammer CHECKING THE STEERING STEM 1 Inspect Steering stem 1 Bend damage Replace CHECKING THE BEARING AND BEARING RACE 1 Wash the bearings and bearing races with a solvent 2 Inspect Bearing 1 Bearing race Pitting damage Replace bearings and bearing races as a set Install the bearing in the bearing races Spin the b...

Page 272: ...ium soap base grease on the bearing the portion a and thread of the steer ing stem 4 Install Steering ring nut 1 Tighten the steering ring nut using the steer ing nut wrench 2 Refer to CHECKING AND ADJUSTING THE STEERING HEAD section in the CHAPTER 3 5 Check the steering stem by turning it lock to lock If there is any binding remove the steering stem assembly and inspect the steering bearings 6 In...

Page 273: ...Washer 1 Steering stem nut 2 10 After tightening the nut check the steering for smooth movement If not adjust the steering by loosening the steering ring nut little by little 11 Adjust Front fork top end a 12 Tighten Pinch bolt upper bracket 1 Pinch bolt lower bracket 2 Tighten the lower bracket to specified torque If torqued too much it may cause the front fork to malfunction Nut front reflector ...

Page 274: ...ction display bracket and upper bracket 14 Install Holder 1 Clamp 2 Install so that the marking a on the speed sensor lead aligns with the holder edge Fasten the speed sensor lead to the holder with the clamp Multi function display bracket 7 Nm 0 7 m kg 5 1 ft lb Multi function display 4 Nm 0 4 m kg 2 9 ft lb Holder 13 Nm 1 3 m kg 9 4 ft lb Clamp 7 Nm 0 7 m kg 5 1 ft lb ...

Page 275: ...LING NOTE Brake hose holder Refer to FRONT BRAKE AND REAR BRAKE section Rear brake caliper Refer to FRONT BRAKE AND REAR BRAKE section Bolt brake pedal Shift the brake pedal backward Drive chain 1 Drive chain support 1 2 Lower chain tensioner 1 3 Bolt rear shock absorber relay arm 1 Hold the swingarm 4 Bolt connecting rod 1 5 Pivot shaft 1 6 Swingarm 1 ...

Page 276: ...EMBLING THE SWINGARM Order Part name Q ty Remarks 1 Cap 2 Refer to removal section 2 Relay arm 1 3 Connecting rod 1 4 Collar 2 5 Oil seal 2 6 Thrust bearing 2 7 Bushing 2 8 Oil seal 8 9 Bearing 10 Refer to removal section ...

Page 277: ... CHECKING THE SWINGARM 1 Inspect Bearing 1 Bushing 2 Free play exists unsmooth revolution rust Replace bearing and bushing as a set 2 Inspect Oil seal 3 Damage Replace CHECKING THE RELAY ARM 1 Inspect Bearing 1 Collar 2 Free play exists unsmooth revolution rust Replace bearing and collar as a set 2 Inspect Oil seal 3 Damage Replace CHECKING THE CONNECTING ROD 1 Inspect Bearing 1 Collar 2 Free play...

Page 278: ...e bearing when installing Install the bearing by pressing it on the side having the manufacture s marks or numbers Apply the molybdenum disulfide grease on the washer 3 Install Bearing 1 Oil seal 2 To connecting rod Apply the molybdenum disulfide grease on the bearing when installing Install the bearing by pressing it on the side having the manufacture s marks or numbers INSTALLING THE SWINGARM 1 ...

Page 279: ...and oil seal lips 4 Install Connecting rod 1 Bolt connecting rod 2 Washer 3 Nut connecting rod 4 To relay arm 5 Apply the molybdenum disulfide grease on the bolt 5 Install Relay arm 1 Bolt relay arm 2 Washer 3 Nut relay arm 4 To swingarm Apply the molybdenum disulfide grease on the bolt circumference and threaded portion Do not tighten the nut yet 6 Install Swingarm 1 Pivot shaft 2 Apply the molyb...

Page 280: ...he molybdenum disulfide grease on the bolt Do not tighten the nut yet 9 Install Bolt rear shock absorber relay arm 1 Nut rear shock absorber relay arm 2 Apply the molybdenum disulfide grease on the bolt 10 Tighten Nut connecting rod 1 11 Tighten Nut relay arm 1 12 Install Cap 1 Install the right cap with its mark a facing for ward Nut rear shock absorber relay arm 53 Nm 5 3 m kg 38 ft lb Nut conne...

Page 281: ...Install Drive chain support 1 Drive chain support cover 2 Bolt drive chain support L 50 mm 1 97 in 3 Nut drive chain support 4 Bolt drive chain support cover L 10 mm 0 39 in 5 Nut lower chain tensioner 16 Nm 1 6 m kg 11 ft lb Nut drive chain support 7 Nm 0 7 m kg 5 1 ft lb Bolt drive chain support cover 7 Nm 0 7 m kg 5 1 ft lb ...

Page 282: ...DE COVERS section in the CHAPTER 3 Silencer Refer to REMOVING THE EX HAUST PIPE AND SILENCER sec tion in the CHAPTER 3 Drain the coolant Refer to CHANGING THE COOL ANT section in the CHAPTER 3 Catch tank breather hose Disconnect at the catch tank side Catch tank hose Disconnect at the catch tank side Air induction hose air cut off valve air filter case Disconnect at the air filter case side Cylind...

Page 283: ...starter relay side 1 Locking tie 4 2 Taillight coupler 1 3 CDI unit coupler 3 4 Plastic band 1 5 Clamp air filter joint 1 Only loosening 6 Rear frame 1 7 Bolt rear shock absorber relay arm 1 Hold the swingarm 8 Bolt rear shock absorber frame 1 9 Rear shock absorber 1 10 Locknut 1 Only loosening 11 Adjuster 1 Only loosening 12 Lower spring guide 1 Order Part name Q ty Remarks ...

Page 284: ...6 57 REAR SHOCK ABSORBER 13 Upper spring guide 1 14 Spring rear shock absorber 1 15 Bearing 2 Refer to removal section Order Part name Q ty Remarks ...

Page 285: ...k will impair the damping performance or cause a malfunction Take care not to scratch the contact sur face of the piston rod with the cylinder or oil could leak out Never attempt to remove the plug at the bottom of the nitrogen gas tank It is very dangerous to remove the plug When scrapping the rear shock absorb er follow the instructions on disposal NOTES ON DISPOSAL YAMAHA DEALERS ONLY Before di...

Page 286: ...ooth revolution rust Replace INSTALLING THE BEARING 1 Install Upper bearing 1 Install the bearing parallel until the stopper ring groove appears by pressing its outer race Do not apply the grease on the bearing out er race because it will wear the rear shock absorber surface on which the bearing is press fitted 2 Install Stopper ring upper bearing 1 After installing the stopper ring push back the ...

Page 287: ...R SPRING PRELOAD section in the CHAPTER 3 4 Tighten Locknut 1 INSTALLING THE REAR SHOCK ABSORBER 1 Install Dust seal 1 O ring 2 Collar 3 Apply the molybdenum disulfide grease on the dust seal lips and collars Apply the lithium soap base grease on the O rings 2 Install Bushing 1 Collar 2 Dust seal 3 Apply the molybdenum disulfide grease on the bearing and dust seal lips Install the dust seals with ...

Page 288: ... arm 2 Apply the molybdenum disulfide grease on the bolt 6 Install Rear frame 1 Bolt rear frame upper 2 Bolt rear frame lower 3 7 Tighten Screw air filter joint 1 8 Install Plastic band Taillight coupler Locking tie Nut rear shock absorber frame 56 Nm 5 6 m kg 40 ft lb Nut rear shock absorber relay arm 53 Nm 5 3 m kg 38 ft lb Bolt rear frame upper 38 Nm 3 8 m kg 27 ft lb Bolt rear frame lower 32 N...

Page 289: ...ly or reassembly only by reference to this manual It may lead to servicing trouble and mechanical damage ELECTRICAL COMPONENTS AND WIRING DIAGRAM ELECTRICAL COMPONENTS 1 Headlight 2 Multi function display 3 Engine stop switch 4 Clutch switch 5 Diode 6 Starter relay diode 7 Throttle position sensor 8 Starter relay 9 Fuse 10 Starting circuit cut off relay 11 CDI unit 12 Taillight 13 Neutral switch 1...

Page 290: ...t 12 Taillight 13 Neutral switch 14 Starter motor 15 AC magneto 16 Rectifier regulator 17 Ignition coil 18 Spark plug 19 Start switch 20 Main switch 21 Speed sensor 22 Battery 1 For USA CDN and EUROPE 2 For AUS NZ and ZA COLOR CODE B Black Br Brown Ch Chocolate Dg Dark green G Green Gy Gray L Blue O Orange R Red Sb Sky blue W White Y Yellow B L Black Blue B W Black White L B Blue Black L R Blue Re...

Page 291: ...Use the following special tools in this inspection 1 Check fuse No good Replace fuse and check wire harness OK 2 Check battery No good Recharge or replace OK Spark gap test Spark 3 Clean or replace spark plug No spark Check entire ignition system for connec tion couplers leads and ignition coil No good Repair or replace OK Check engine stop switch No good Replace OK Check main switch No good Repla...

Page 292: ...N COIL CONNECTION 1 Check Couplers and leads connection Rust dust looseness short circuit Repair or replace Ignition coil and spark plug as they are fitted Push in the ignition coil until it closely con tacts the spark plug hole in the cylinder head cover CHECKING THE ENGINE STOP SWITCH 1 Inspect Engine stop switch conduction Not conductive while it is pushed Replace Conductive while it is freed R...

Page 293: ...TION COIL 1 Remove the ignition coil cap 2 Inspect Primary coil resistance Out of specification Replace 3 Inspect Secondary coil resistance Out of specification Replace Tester lead Red lead 1 Tester lead Brown lead 2 Result Conductive while the main switch is moved to ON Battery lead Red Black lead 1 Battery lead Black lead 2 Tester lead Orange lead 1 Tester lead Black lead 2 Primary coil re sista...

Page 294: ...n Not conductive while it is in neutral Replace Conductive while it is engaged Replace Set the tester selection position to Ω 1 CHECKING THE CDI UNIT Check all electrical components If no fault is found replace the CDI unit Then check the electrical components again Tester lead Red lead 1 Tester lead White lead 2 Pickup coil resis tance Tester selector position 248 372 Ω at 20 C 68 F Ω 100 Tester ...

Page 295: ...ents the starter motor from operating when neither of these conditions has been met In this instance the starting circuit cut off relay is open so cur rent cannot reach the starter motor When at least one of the above conditions has been met the starting circuit cut off relay is closed and the engine can be started by pressing the start switch WHEN THE TRANSMISSION IS IN NEUTRAL WHEN THE CLUTCH LE...

Page 296: ...12 V battery in this inspection Use the following special tools in this inspection 1 Check fuse No good Replace fuse and check wire harness OK 2 Check battery No good Recharge or replace OK Check each coupler and wire connec tion No good Repair or replace OK 3 Check main switch No good Replace OK Check starter motor operation No good Repair or replace OK Check starting circuit cut off relay No goo...

Page 297: ...it cut off relay 2 Inspect Starting circuit cut off relay conduction Use 12 V battery Not conductive while the battery is connected Replace Conductive while the battery is not connected Replace Set the tester selection position to Ω 1 CHECKING THE STARTER RELAY 1 Remove Starter relay 2 Inspect Starter relay conduction Use 12 V battery Not conductive while the battery is connected Replace Conductiv...

Page 298: ...onductive while it is pushed Replace Conductive while it is freed Replace Set the tester selection position to Ω 1 2 Inspect Rubber part a Tears damage Replace Tester lead Black lead 1 Tester lead Black lead 2 Result Conductive while the clutch lever is pulled Tester Blue Red termi nal 1 Tester Sky blue terminal 2 Continuous Tester Blue Red termi nal 1 Tester Blue Yellow ter minal 3 Continuous Tes...

Page 299: ...7 11 ELECTRIC STARTING SYSTEM REMOVING THE STARTER MOTOR Order Part name Q ty Remarks Exhaust pipe Refer to EXHAUST PIPE AND SI LENCER section in the CHAPTER 3 1 Starter motor 1 ...

Page 300: ...SSEMBLING THE STARTER MOTOR Order Part name Q ty Remarks 1 Starter motor front cover 1 2 Washer starter motor front cover 1 3 Gasket 2 4 Starter motor yoke 1 5 Armature assembly 1 6 Starter motor rear cover 1 7 Brush 2 8 Brush spring 2 ...

Page 301: ...uta tor and insulation Out of specification Replace the starter motor a Measure the armature assembly resistanc es with the pocket tester b If any resistance is out of specification re place the starter motor 5 Measure Brush length a Out of specification Replace the brushes as a set 6 Measure Brush spring force Out of specification Replace the brush springs as a set Min commutator diameter 16 6 mm...

Page 302: ...th its groove a facing front cover Align the match mark b on the starter motor yoke with the match mark c on the starter motor rear cover 4 Install Gasket 1 Circlip Plain washer 2 Washer starter motor front cover 3 Starter motor front cover 4 For installation align the projections on the washer with the slots in the front cover Align the match mark a on the starter motor yoke with the match mark b...

Page 303: ...move the following parts before inspection 1 Seat 2 Fuel tank Use the following special tools in this inspection 1 Check fuse No good Replace fuse and check wire harness OK 2 Check battery No good Recharge or replace OK Check each coupler and wire connec tion No good Repair or replace OK Check charging voltage OK Charging system is good No good Check AC magneto Charging coil No good Replace OK Rep...

Page 304: ... Out of specification If no failure is found in checking the source coil resistance replace the rectifier regulator 3 Inspect Charging coil resistance Out of specification Replace Tester lead Red lead 1 Tester lead Black lead 2 Charging voltage Tester selector position 14 0 15 0 V at 5 000 r min DCV 20 Tester lead White lead 1 Tester lead Ground 2 Charging coil re sistance Tester selector position...

Page 305: ...he following inspection steps Use the following special tools in this inspection Check entire ignition system for connec tion No good Repair or replace OK Check throttle position sensor Throttle position sensor coil No good Replace OK Check CDI unit Throttle position sen sor input voltage No good Replace Pocket tester YU 3112 C 90890 03112 ...

Page 306: ...e 2 Loosen Throttle stop screw 1 Turn out the throttle stop screw until the throttle shaft is in the full close position 3 Inspect Throttle position sensor coil variable resis tance Check that the resistance in increased as the throttle grip is moved from the full close position to the full open position Out of specification Replace Tester lead Blue lead 1 Tester lead Black lead 2 Throttle positio...

Page 307: ...SPEED section in the CHAPTER 3 7 Insert the thin electric conductors 2 lead into the throttle position sensor coupler 1 as shown and connect the tester to them Do not insert the electric conductors more than required because it may reduce the waterproof function of the coupler Make sure that a short circuit does not de velop between the terminals because it may cause damage to electrical compo nen...

Page 308: ...rew throttle position sensor us ing the T25 bit 14 Install the carburetor CHECKING THE THROTTLE POSITION SENSOR INPUT VOLTAGE 1 Disconnect the throttle position sensor cou pler 2 Start the engine 3 Inspect Throttle position sensor input voltage Out of specification Replace the CDI unit Tester lead Blue lead 1 Tester lead Black Blue lead 2 Throttle position sensor input voltage Tester selector posi...

Page 309: ...following special tools in this inspection Check the bulb and bulb socket No good Replace the bulb and or bulb socket OK Check the taillight LEDs No good Replace the taillight assembly OK Check the AC magneto Lighting coil No good Replace OK Check the entire lighting system proper for connections Improperly connected Repair or replace OK Check the rectifier regulator Out put voltage No good Replac...

Page 310: ...able gas or fluid is in the vicinity CHECKING THE AC MAGNETO 1 Inspect Lighting coil resistance Out of specification Replace CHECKING THE RECTIFIER REGUALATOR 1 Connect the battery leads 2 Start the engine 3 Turn on the headlight and taillight by turning on the light switch 4 Inspect Out put voltage Out of specification Replace rectifier regu lator Battery terminal Blue lead 2 Battery terminal Bla...

Page 311: ...s before inspection 1 Headlight Use the following special tools in this inspection 1 Check battery No good Recharge or replace OK Check each coupler and wire connec tion No good Repair or replace OK Check multi function display Input volt age No good Replace wire harness OK Check multi function display Output voltage No good Replace multi function display OK Check speed sensor No good Replace Pock...

Page 312: ...fication Replace multi function display Make sure that a short circuit does not de velop between the terminals because it may cause damage to electrical components CHECKING THE SPEED SENSOR OUTPUT VOLTAGE 1 Insert the thin electric conductors 1 lead into the speed sensor coupler 2 as shown and connect the tester to them Do not insert the electric conductors more than required because it may reduce...

Page 313: ...e Output voltage not correct Replace the speed sensor Measurement steps a Elevate the front wheel and slowly rotate it b Measure the voltage DCV of white lead and black lead With each full rotation of the front wheel the voltage reading should cycle from 0 6 V to 4 8 V to 0 6 V to 4 8 V ...

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Page 316: ...PRINTED IN JAPAN 2010 05 0 3 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN ...

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