Yamaha 2013 WR205F Owner'S Service Manual Download | Manualshive

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SPECIAL TOOLS

SPECIAL TOOLS

The proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool will
help prevent damage caused by the use of improper tools or improvised techniques. The shape and part number used for
the special tool differ by country, so two types are provided. Refer to the list provided to avoid errors when placing an order.

• For U.S.A. and Canada, use part number starting with "YM-", "YU-" or "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
Crankshaft installing bolt
YU-90050, 90890-01275
Spacer (crankshaft installer)
YU-91044, 90890-04081
Adapter (M12)
YU-90063, 90890-01278

These tools are used to install the
crankshaft.

Piston pin puller set
YU-1304, 90890-01304

This tool is used to remove the pis-
ton pin.

Radiator cap tester
YU-24460-01, 90890-01325
Radiator cap tester adapter
YU-33984, 90890-01352

These tools are used for checking
the cooling system.

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Summary of Contents for 2013 WR205F

Page 1: ...O Il convient de lire attentivement ce manuel avant la première utilisation du véhicule Read this manual carefully before operating this vehicle Bitte lesen Sie diese Bedienungsanleitung sorgfältig durch bevor Sie das Fahrzeug in Betrieb nehmen Leggere attentamente questo manuale prima di utilizzare questo veicolo Lea atentamente este manual antes de utilizar el vehículo 2013 ...

Page 2: ...vente de ce dernier Bitte lesen Sie diese Bedienungsanleitung sorgfältig durch bevor Sie das Fahrzeug in Betrieb nehmen Diese Bedienungsanleitung muss wenn das Fahrzeug verkauft wird beim Fahrzeug verbleiben Leggere attentamente questo manuale prima di utilizzare il veicolo Questo manuale dovrebbe accompa gnare il veicolo se viene venduto Lea atentamente este manual antes de utilizar el vehículo E...

Page 3: ...WR250F D 2013 2013 1HC 28199 52 E0 1HC 28199 52 E0 OWNER S SERVICE MANUAL OWNER S SERVICE MANUAL Read this manual carefully before operating this vehicle Read this manual carefully before operating this vehicle ...

Page 4: ......

Page 5: ...S SERVICE MANUAL 2012 by Yamaha Motor Co Ltd 1st Edition April 2012 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan ...

Page 6: ...achine is designed for off road use only It is illegal for this machine to be operated on any public street road or highway Off road use on public lands may be illegal Please check local regulations before riding Except for Canada THIS MACHINE IS DESIGNED STRICTLY FOR COMPETITION USE ONLY ON A CLOSED COURSE It is illegal for this machine to be operated on any public street road or highway Off road...

Page 7: ... of the manual Look over the general layout of the book be fore finding then required chapter and item Bend the book at its edge as shown to find the required fore edge symbol mark and go to a page for required item and de scription MANUAL FORMAT All of the procedures in this manual are organized in a sequential step by step format The information has been complied to provide the me chanic with an...

Page 8: ...informa tion the step by step format sup plements 5 are given in addition to the exploded diagram and job instruction chart ILLUSTRATED SYMBOLS Refer to the illustration Illustrated symbols 1 to 7 are used to identify the specifications appear ing in the text 1 With engine mounted 2 Filling fluid 3 Lubricant 4 Special tool 5 Tightening 6 Specified value Service limit 7 Resistance Ω Voltage V Elect...

Page 9: ...TABLE OF CONTENTS GENERAL INFORMATION 1 SPECIFICATIONS 2 REGULAR INSPECTION AND ADJUSTMENTS 3 TUNING 4 ENGINE 5 CHASSIS 6 ELECTRICAL 7 ...

Page 10: ...RE OPERATION INSPECTION AND MAINTENANCE 3 7 ENGINE 3 8 CHASSIS 3 19 ELECTRICAL 3 29 CHAPTER 4 TUNING ENGINE Except for Canada 4 1 CHASSIS 4 5 CHAPTER 5 ENGINE RADIATOR 5 1 CARBURETOR 5 4 AIR INDICTOIN SYSTEM 5 12 CAMSHAFTS 5 14 CYLINDER HEAD 5 19 VALVES AND VALVE SPRINGS 5 21 CYLINDER AND PISTON 5 25 CLUTCH 5 29 OIL FILTER ELEMENT AND WATER PUMP 5 34 BALANCER 5 39 OIL PUMP 5 41 KICK SHAFT AND SHIF...

Page 11: ...ON OF IMPORTANT LABELS GENERAL INFORMATION LOCATION OF IMPORTANT LABELS Please read the following important labels carefully before operating this vehicle CANADA Essence super sans plomb seulement 3FB 2415E 12 1 ...

Page 12: ...1 2 LOCATION OF IMPORTANT LABELS EUROPE ...

Page 13: ...1 3 LOCATION OF IMPORTANT LABELS AUS NZ ZA ...

Page 14: ...ains high pressure nitrogen gas Mishandling can cause explosion Do not incinerate puncture or open Turn off the main switch after riding to avoid draining the battery Use unleaded gasoline only Measure tire pressure when tires are cold Adjust tire pressure Improper tire pressure can cause loss of control Loss of control can result in severe injury or death ...

Page 15: ...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 16: ... as required by feder al law state law and Environment Canada A Left B Right INCLUDED PARTS VALVE JOINT This valve joint 1 prevents fuel from flowing out and is installed to the fuel tank breather hose In this installation make sure the arrow faces 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 wrenc...

Page 17: ...ring s 1 and oil seal s 2 with their manufactur er s marks or numbers facing out ward In other words the stamped letters must be on the side exposed to view When in stalling oil seal s apply a light coating of lightweight lithium base grease to the seal lip s Oil the bearings liberally when installing Do not use compressed air to spin the bearings dry This causes dam age to the bearing surfaces CI...

Page 18: ... 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 Crankshaft installing bolt YU 90050 90890 01275 Spacer crankshaft installer YU...

Page 19: ...iver 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 nut Pocket tester YU 3112 C 90890 03112 Use this tool to inspect the coil resis tance output voltage and amper age Tool name Par...

Page 20: ...oss securing 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 guide reamer Intake 4 0 mm 0 16 in Exhaust 4 5 mm 0 18 in YM...

Page 21: ...ed to remove the fly wheel magneto Dynamic spark tester YM 34487 Ignition checker 90890 06754 This instrument is necessary for checking the ignition system compo nents Vacuum pressure pump gauge set YB 35956 A 90890 06756 This tool is used to check the air in duction system YAMAHA Bond No 1215 Three Bond No 1215 90890 85505 This sealant Bond is used for crankcase mating surface etc Tool name Part ...

Page 22: ...ft pedal 1 on the left side of the engine KICKSTARTER CRANK Rotate the kickstarter crank 1 away from the engine Push the starter down lightly with your foot until the gears engage then kick smoothly and forcefully to start the engine This model has a primary kickstarter crank so the engine can be started in any gear if the clutch is disengaged In normal practices however shift to neutral before st...

Page 23: ...time that has been accumulated since the start of timer measurement Tripmeter which shows the accu mulated travel distance in timer measurement Change tripmeter digits capable of change to any given ones 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 Speedome...

Page 24: ... for 2 seconds or more at the same time to change over to BASIC MODE RACE MODE Putting measurement on standby Starting measurement consists of the following two starts either of which can be selected Manual start Starting measurement by the rider himself operating the button A long push on the SLCT2 button will put measurement on standby Auto start Starting timer measurement automat ically on dete...

Page 25: ...1 button and SLCT2 but ton at the same time 2 Reset tripmeter A TRIP A dis play by pushing the RST button for 2 seconds or more If reset and travel distance dis play will go on flashing for four sec onds Resetting tripmeter A TRIP A and timer 1 Check that the timer is not in op eration If the timer is in operation stop it by pushing the SLCT1 button and SLCT2 button at the same time 2 Reset all me...

Page 26: ... on the button changes the operation in both arrowed directions Meter function Function that can be performed whether the time is or is not in operation Extent to which the meter can operate Clock BASIC MODE Tripmeter ODO TRIP A TRIP B ODO Speedometer for U K MPH km h MPH Putting measurement on standby Manual start Auto start RACE MODE Timer in operation Reset TRIP A Correct TRIP A Measurement sta...

Page 27: ...the button changes the operation in the ar rowed direction D A long push on the button changes the operation in both arrowed directions E Meter function F Function that can be performed whether the time is or is not in operation G Extent to which the meter can operate 1 BASIC MODE 2 Clock 3 Trip meter 4 Speedometer for U K 5 RACE MODE 6 Putting measurement on stand by 7 Manual start 8 Auto start 9...

Page 28: ... starting STARTING A COLD ENGINE This model is equipped with an igni tion circuit cut off system The engine can be started under the following conditions When the transmission is in neutral When the clutch is disengaged with the transmission in any position However it is recommended to shift into neutral before starting the en gine 1 Inspect the coolant level 2 Turn the fuel cock to ON 3 Push on t...

Page 29: ...ate the machine in the lower gears at moderate throttle open ings for five to eight minutes 5 Check how the engine runs when the machine is ridden with the throttle 1 4 to 1 2 open low to me dium speed for about one hour 6 Restart the engine and check the operation of the machine through out its entire operating range Re start the machine and operate it for about 10 to 15 more minutes After the br...

Page 30: ...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 31: ...ith a vinyl uphol stery cleaner to keep the cover pliable and glossy 8 Automotive wax may be applied to all painted or chromed surfac es 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 mea sures must be taken to avoid dete...

Page 32: ...115 kg 254 lb 116 kg 256 lb 117 kg 258 lb Engine Engine type Liquid cooled 4 stroke DOHC Cylinder arrangement Single cylinder 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 and electric starter Lubrication system Dry sump Oil type or grade Engine oil Recommended brand YAMALUBE SAE 10W 30 SAE 10W 40 SAE 10W 50 SAE 15W ...

Page 33: ... 5 speed Operation Left foot operation Gear ratio 1st 2 385 31 13 2nd 1 750 28 16 3rd 1 353 23 17 4th 1 095 23 21 5th 0 895 17 19 Chassis USA CDN ZA AUS NZ EUROPE Frame type Semi double cra dle Caster angle 27 0 26 6 26 5 Trail 115 mm 4 53 in 114 mm 4 49 in 113 mm 4 45 in Tire Type With tube Size front 80 100 21 51M For USA CDN and ZA 90 90 21 M C 54M M S For EUROPE AUS and NZ Size rear 100 100 18...

Page 34: ...capacity 12V 6 AH Specific gravity 1 310 Headlight type Quartz bulb halogen Bulb wattage quantity Headlight 12 V 35 36 5 W 1 Taillight 12 V 1 6 0 3 W 1 Item Standard Limit Cylinder head Warp limit 0 05 mm 0 002 in Cylinder Bore size 77 00 77 01 mm 3 0315 3 0319 in Out of round limit 0 05 mm 0 002 in Camshaft Drive method Chain drive Left Camshaft cap inside diameter 22 000 22 021 mm 0 8661 0 8670 ...

Page 35: ...n Timing chain type No of links 92RH2010 114M 114 Timing chain adjustment method Automatic Valve valve seat valve guide Valve clearance cold IN 0 10 0 15 mm 0 0039 0 0059 in EX 0 17 0 22 mm 0 0067 0 0087 in Valve dimensions A head diameter IN 22 9 23 1 mm 0 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...

Page 36: ... in Stem to guide clearance EX 0 025 0 052 mm 0 0010 0 0020 in 0 10 mm 0 004 in Stem runout limit 0 01 mm 0 0004 in Valve seat width IN 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in Valve seat 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...

Page 37: ...Piston pin bore inside diameter 16 002 16 013 mm 0 6300 0 6304 in 16 043 mm 0 6316 in Piston pin outside diameter 15 991 16 000 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 ...

Page 38: ...0 08 in Clutch Friction plate thickness 2 9 3 1 mm 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 Inn...

Page 39: ...nHg 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 2 mm 4 73 in Height 240 mm 9 45 in...

Page 40: ...p 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 0mm 9 65 in 248 5mm 9 78 in Preload length Min Max 1 5 22 mm 0 06 0 87 in Spring rate STD K 52 0 N mm 5 30 kg mm 296 8 lb in Optional spring Yes Enclosed gas pressure 1 000 kPa 10 kg cm2 142 psi Swingarm Swingarm free play limit End 1...

Page 41: ...4 mm 0 25 in 1 0 mm 0 04 in Master cylinder inside dia 11 0 mm 0 433 in Caliper cylinder inside dia 25 4 mm 1 000 in 1 Brake fluid type DOT 4 Brake lever and brake pedal Brake lever position 95 mm 3 74 in Brake pedal height vertical height above footrest top 10 mm 0 39 in Clutch lever free play lever end 8 13 mm 0 31 0 51 in Throttle grip free play 3 5 mm 0 12 0 20 in Item Standard Limit Item Stan...

Page 42: ...A Electric starting system Type Constant mesh Starter motor Model manufacturer 5UM01 YAMAHA Operation voltage 12 V Output 0 35 kW Armature coil resistance 0 0189 0 0231 Ω at 20 C 68 F Brush overall length 7 mm 0 28 in 3 5 mm 0 14 in Brush quantity 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 rel...

Page 43: ...b Radiator hose clamp M6 10 2 Nm 0 2 m kg 1 4 ft lb Coolant drain bolt M6 1 10 Nm 1 0 m kg 7 2 ft lb Copper washer Water pump housing M6 4 10 Nm 1 0 m kg 7 2 ft lb Radiator stay M6 6 10 Nm 1 0 m kg 7 2 ft lb Radiator M6 4 10 Nm 1 0 m kg 7 2 ft lb Radiator pipe M6 1 10 Nm 1 0 m kg 7 2 ft lb Oil pump cover M4 1 1 7 Nm 0 17 m kg 1 2 ft lb Oil pump M6 3 10 Nm 1 0 m kg 7 2 ft lb Oil filter element drai...

Page 44: ... 10 Nm 1 0 m kg 7 2 ft lb Crankcase bearing stopper crankshaft M6 4 14 Nm 1 4 m kg 10 ft lb Stake Left crankcase cover M6 8 10 Nm 1 0 m kg 7 2 ft lb Idle gear cover starter motor M6 3 10 Nm 1 0 m kg 7 2 ft lb Idle gear plate M6 2 10 Nm 1 0 m kg 7 2 ft lb Right crankcase cover M6 6 10 Nm 1 0 m kg 7 2 ft lb Clutch cover M6 7 10 Nm 1 0 m kg 7 2 ft lb Crankcase oil drain bolt M10 1 20 Nm 2 0 m kg 14 f...

Page 45: ... 9 Nm 0 9 m kg 6 5 ft lb Brake lever mounting bolt M6 1 6 Nm 0 6 m kg 4 3 ft lb Brake lever mounting nut M6 1 6 Nm 0 6 m kg 4 3 ft lb Brake lever position locknut M6 1 5 Nm 0 5 m kg 3 6 ft lb Front brake hose guide and front brake hose guide bracket M5 1 4 Nm 0 4 m kg 2 9 ft lb Front brake hose guide and lower bracket M6 1 4 Nm 0 4 m kg 2 9 ft lb Clutch lever holder M5 2 4 Nm 0 4 m kg 2 9 ft lb Cl...

Page 46: ...4 1 70 Nm 7 0 m kg 50 ft lb Relay arm and connecting rod M14 1 80 Nm 8 0 m kg 58 ft lb Connecting rod and frame M14 1 80 Nm 8 0 m kg 58 ft lb Rear shock absorber and frame M10 1 56 Nm 5 6 m kg 40 ft lb Rear shock absorber and relay arm M10 1 53 Nm 5 3 m kg 38 ft lb Rear frame upper M8 1 38 Nm 3 8 m kg 27 ft lb Rear frame lower M8 2 32 Nm 3 2 m kg 23 ft lb Swingarm and brake hose holder M5 4 3 Nm 0...

Page 47: ...adlight body and headlight unit 2 1 Nm 0 1 m kg 0 7 ft lb Headlight M6 2 7 Nm 0 7 m kg 5 1 ft lb Taillight 3 1 Nm 0 1 m kg 0 7 ft lb Taillight lead clamp and rear fender 3 0 5 Nm 0 05 m kg 0 36 ft lb Catch tank upper M6 1 16 Nm 1 6 m kg 11 ft lb Catch tank lower M6 1 7 Nm 0 7 m kg 5 1 ft lb Footrest bracket and frame M10 4 55 Nm 5 5 m kg 40 ft lb TORX Sidestand M10 1 25 Nm 2 5 m kg 18 ft lb Front ...

Page 48: ...nts should be at room temperature A Distance between flats B Outside thread diameter DEFINITION OF UNITS A Nut B Bolt TORQUE SPECIFI CATION 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 17 mm 12 mm 55 5 5 40 19 mm 14 mm 85 8 5 61 22 mm 16 mm 130 13 94 Unit Read Definition Measure mm millimeter 10 3 meter Length cm centimeter 10 2 meter Length kg kilogram 103 gram We...

Page 49: ...2 18 TIGHTENING TORQUES ...

Page 50: ...2 19 LUBRICATION DIAGRAMS 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 51: ...2 20 LUBRICATION DIAGRAMS 1 Crankshaft 2 Oil filter element 3 Oil tank 4 Oil hose A From oil pump ...

Page 52: ...head breather hose 8 Throttle position sensor lead 9 Neutral switch lead 10 Oil hose 11 Clutch cable 12 Starter motor lead 13 Cable guide 14 Negative battery lead 15 AC magneto lead 16 Brake hose 17 Rectifier regulator lead 18 Carburetor breather hose 19 Carburetor overflow hose 20 Catch tank breather hose 21 Hot starter cable protector 22 Rubber cap ...

Page 53: ...d 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 the cable guide I Fasten the starter motor lead AC magneto lead and neutral switch lead onto the frame Lo cate the clamp end facing to ward the rear of the frame and cut off the tie end J Fasten the clutch cable starter motor l...

Page 54: ...e A Cross the pull and push throttle cables B Fasten the catch tank hose and air induction 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 55: ... directs as shown and lightly touches the projec tion 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 portion directs as shown and lightly touches the projec tion on the brake master cylin der ...

Page 56: ...2 25 CABLE ROUTING DIAGRAM 1 Clamp 2 Positive battery lead 3 Battery 4 Negative battery lead 5 Taillight coupler 6 CDI unit coupler 6 pin 7 CDI unit coupler 3 pin 8 CDI unit coupler 6 pin ...

Page 57: ...ds and taillight 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 ter minal I Connect the negative battery lead to the wire harness J Fasten the wire harness to the rear frame Locate the clamp end facing toward the upper side of the frame and the tie end to ward the inside of th...

Page 58: ...ain switch coupler 7 Wire harness 8 Headlight coupler 9 Hot starter cable 10 Multi function display bracket 11 Main switch 12 Upper bracket 13 Clutch switch coupler 14 Engine stop switch coupler 15 Multi function display coupler 16 Start switch coupler 17 Speed sensor coupler 18 Speed sensor lead ...

Page 59: ...n 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 pushing it into the hole in the multi function display bracket on the inside I Fasten the wire harness to the multi function display bracket Cut off the tie end J Fasten the main switc...

Page 60: ... line Check fuel hoses for cracks or damage Replace if necessary 2 Spark plug Check condition Adjust gap and clean 3 Valve clearance Check and adjust valve clearance when en gine 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 necessar...

Page 61: ...r Every 1 year 6 Brake hoses Check for cracks or damage Replace Every 4 years 7 Wheels Check runout spoke tightness and for dam age Tighten spokes if necessary 8 Tires Check tread depth and for damage Replace if necessary Check air pressure Correct if necessary 9 Wheel bearings Check bearings for smooth operation Replace if necessary 10 Swingarm pivot bearings Check bearing assemblies for loosenes...

Page 62: ...t in which the machine runs e g rain dirt etc Therefore earlier inspection is required by reference to the list below 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 assembly Check operation and for oil leakage Replace if necessary 18 Rear suspension link pivots Ap...

Page 63: ...are also replaced at the same time PISTON RING Inspect Check ring end gap Replace PISTON PIN Inspect Replace CYLINDER HEAD Inspect carbon deposits and eliminate them Inspect and clean Change gasket CYLINDER Inspect and clean Inspect score marks Replace Inspect wear CLUTCH Inspect and adjust Inspect housing friction plate clutch plate and spring Replace TRANSMISSION Inspect Replace bearing SHIFT FO...

Page 64: ...AND BOLTS Retighten Refer to STARTING AND BREAK IN section in the CHAPTER 1 AIR FILTER Clean and lubricate Use foam air filter oil or equivalent 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 leakage Retighten brak...

Page 65: ...ct lube and retighten Molybdenum disulfide grease SIDESTAND Lubricate Lithium base grease STEERING HEAD Inspect free play and retighten Clean and lube Lithium base grease Replace bearing TIRE WHEELS Inspect air pressure wheel run out tire wear and spoke loose ness Retighten sprocket bolt Inspect bearings Replace bearings Lubricate Lithium base grease THROTTLE CONTROL CABLE Check routing and connec...

Page 66: ...chain slack and alignment Check that the drive chain is lubricated properly P 3 22 23 Wheels Check for excessive wear and tire pressure Check for loose spokes and have no excessive play P 3 26 27 Steering Check that the handlebar can be turned smoothly and have no ex cessive play P 3 27 Front forks and rear shock absorber Check that they operate smoothly and there is no oil leakage P 3 23 26 Cable...

Page 67: ... 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 68: ...3 9 ENGINE REMOVING THE SIDE COVER 1 Remove Bolt side cover Right side cover 1 Draw the side cover backward to re move it because its claw a is insert ed in the air filter case ...

Page 69: ...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 70: ...s harmful to the engine parts You may use distilled water if you can t get soft water 1 Place the machine on a level place and hold it in an upright po sition 2 Remove Radiator cap 3 Check Coolant level a Coolant level low Add coolant 1 Radiator CHANGING THE COOLANT Do not remove the radiator cap when the engine is hot Take care so that coolant does not splash on painted surfaces If it splashes wa...

Page 71: ...ci fied pressure for 10 seconds Replace CHECKING THE COOLING SYSTEM 1 Inspect Coolant level 2 Attach Radiator cap tester 1 and adapt er 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 speci fied pressure for 10 seconds Repair Radiator 1 Radiator hose joint 2 Coolant leakage Repair or r...

Page 72: ...TARTER LEVER FREE PLAY 1 Check Hot starter lever free play a Out of specification Adjust 2 Adjust Hot starter lever free play Hot starter lever free play adjust ment steps a Loosen the locknut 1 b Turn the adjuster 2 until free play a is within the specified lim its c Tighten the locknut After adjustment check proper oper ation of hot starter CLEANING THE AIR FILTER ELEMENT Proper air filter maint...

Page 73: ...ble stand under the engine 3 Inspect Oil level Oil should be up to the full level in the check window 1 Level check window is not full Add 0 2 L 0 18 Imp qt 0 21 US qt of oil Engine oil also lubricates the clutch and the wrong oil types or additives could cause clutch slippage Therefore do not add any chemical additives or use en gine oils with a grade of CD or higher and do not use oils la beled ...

Page 74: ...king steps a Slightly loosen the oil pressure check bolt 1 b Start the engine and keep it idling until oil starts to seep from the oil pressure check bolt If no oil comes out after one minute turn the engine off so it will not seize c Check oil passages and oil pump for damage or leakage d Start the engine after solving the problem s and recheck the oil pressure e Tighten the oil pressure check bo...

Page 75: ...ve clearance should be ad justed when the engine is cool to the touch The piston must be at Top Dead Center T D C on compression stroke to check or adjust the valve clearance 1 Remove Seat Fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section 2 Drain Coolant Refer to CHANGING THE COOLANT section 3 Remove Right radiator Right to RADIATOR section in the CHAPTER 5 Carburetor Refer to CARBURETOR s...

Page 76: ...150 Pads can only be selected in 0 05 mm increments e Locate the rounded off value and the measured valve clearance in the chart PAD SELECTION TA BLE The field where these two coordinates intersect shows the new pad number to use Use the new pad number only as a guide when verifying the valve clear ance adjustment f Install the new pads 3 and the valve lifters 4 Apply the engine oil on the valve l...

Page 77: ...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 78: ...m Reservoir float front brake Protector rear brake 2 Bleed Brake fluid Air bleeding steps a Add proper brake fluid to the res ervoir b Install the diaphragm Be careful not to spill any fluid or allow the reservoir to overflow c Connect the clear plastic tube 2 tightly to the caliper bleed screw 1 A Front B Rear d Place the other end of the tube into a container e Slowly apply the brake lever or pe...

Page 79: ...ighten the locknut Adjust the pedal height between the maximum A and the mini mum B as shown In this ad justment the bolt 3 end b should protrude out of the threaded portion 4 but not be less than 2 mm 0 08 in c away from the brake pedal 5 After the pedal height adjust ment make sure that the rear brake does not drag CHECKING AND REPLACING THE FRONT BRAKE PADS 1 Inspect Brake pad thickness a Out o...

Page 80: ...ake 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 d Remove the pad pin 6 and brake pads 7 e Connect the transparent hose 8 to the bleed screw 9 and place the suitable con...

Page 81: ...not enter master cylinder when refilling Clean up spilled fluid immediate ly 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 sprocket and drive chain as a set CHECKING THE DRIVE CHAIN 1 Measure Drive chain length 15 links a Out of specification Replace Wh...

Page 82: ... chain slack with the rear wheel in this tight chain position 3 Adjust Drive chain slack Drive chain slack adjustment steps a Loosen the axle nut 1 and lock nuts 2 b Adjust the drive chain slack by turning the adjusters 3 c Turn each adjuster exactly the same amount to maintain correct axle alignment There are marks a on each side of the drive chain puller alignment NOTICE Im proper drive chain sl...

Page 83: ...STING THE FRONT FORK COMPRESSION DAMPING FORCE 1 Remove Rubber cap 2 Adjust Compression damping force By turning the adjuster 1 STANDARD POSITION This is the position which is back by the specific number of clicks from the fully turned in position Do not force the adjuster past the minimum or maximum extent of adjustment The adjuster may be damaged Always adjust each front fork to the same setting...

Page 84: ...djuster past the minimum or maximum extent of adjustment The adjuster may be damaged ADJUSTING THE REAR SHOCK ABSORBER LOW COMPRESSION DAMPING FORCE 1 Adjust Low compression damping force By turning the adjuster 1 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 pre load Turn the adjuster...

Page 85: ...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 Correct 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 screw driver A tig...

Page 86: ...er tightening g Check the steering stem by turn ing it lock to lock If there is any binding remove the steering stem assembly and inspect the steer ing bearings h Install the washer 5 collar 6 upper bracket 7 washer 8 steering stem nut 9 handlebar 10 handlebar upper holder 11 and headlight 12 Install the collar 6 with the larger inside diameter facing downward The handlebar upper holder should be ...

Page 87: ...vot 5 Throttle to handlebar contact 6 Drive chain 7 Tube guide cable winding por tion 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 lith ium soap base grease Wipe off any excess grease and avoid getting grease ...

Page 88: ...ighly caustic sulfuric acid There fore always follow these preven tive measures Wear protective eye gear when handling or working near batter ies Charge batteries in a well venti lated area Keep batteries away from fire sparks or open flames e g welding equipment lighted ciga rettes DO NOT SMOKE when charging or handling batteries KEEP BATTERIES AND ELEC TROLYTE OUT OF REACH OF CHILDREN Avoid bodi...

Page 89: ...since it forces a high amperage current into the bat tery quickly and can cause bat tery overheating and battery plate damage If it is impossible to regulate the charging current on the battery charger be careful not to over charge the battery When charging a battery be sure to remove it from the machine If charging has to be done with the battery mounted on the machine disconnect the negative bat...

Page 90: ...3 31 ELECTRICAL Charging method using a variable voltage charger ...

Page 91: ...3 32 ELECTRICAL Charging method using a constant voltage charger ...

Page 92: ...age rating other than that specified Im provising or using a fuse with the wrong amperage rating may cause extensive damage to the electrical system cause the starting and ig nition systems to malfunction and could possibly cause a fire 4 Install Fuse cover Seat REPLACING THE HEADLIGHT BULBS 1 Remove Headlight Refer to REMOVING THE SEAT FUEL TANK AND SIDE COV ERS section 2 Remove Headlight bulb ho...

Page 93: ...ht Refer to REMOVING THE SEAT FUEL TANK AND SIDE COV ERS section ADJUSTING THE HEADLIGHT BEAMS 1 Adjust Headlight beam vertically Adjusting steps a Turn the adjusting screw 1 in di rection a or b Headlight 7 Nm 0 7 m kg 5 1 ft lb Direction a Headlight beam is raised Direction b Headlight beam is lowered ...

Page 94: ...When the engine is stopped or when riding at no load do not open and close the throttle un necessarily Otherwise too much fuel may be discharged starting may become difficult or the engine may not run well After installing the carburetor check that the throttle operates correctly and opens and closes smoothly ATMOSPHERIC CONDITIONS AND CARBURETOR SETTINGS The air density i e concentration of oxyge...

Page 95: ...he throttle is 1 8 to 1 4 open A Idle B Fully open RELATIONSHIP WITH THROTTLE OPENING The flow of the fuel through the car buretor main system is controlled by the main jet and then it is further reg ulated by the area between the main nozzle and the jet needle The fuel flow relates to the diameter of the straight portion of the jet needle with the throttle 1 8 to 1 4 open and relates to the clip ...

Page 96: ...number 14948 Rich 50 4MX 07 48 4MX 06 STD 45 4MX 05 STD 42 4MX 04 Lean 40 4MX 03 Jet needle Size Part number 14916 Rich GDEPN 5UM BN GDEPP 5UM BP GDEPQ 5UM B1 GDEPR 5UM BR GDEPS 5UM BS GDEPT 5UM BT Lean GDEPU 5UM BU Rich GDEMP 5UM VP GDEMQ 5UM V1 GDEMR 5UM VR GDEMS 5UM VS GDEMT 5UM VT GDEMU 5UM VU Lean GDEMV 5UM VV Leak jet Size Part number 1494F Rich 60 4JT 11 STD 70 4JT 15 80 4JT 19 90 4JT 23 10...

Page 97: ...bered from the top Check that the accelerator pump operates smoothly except for rich mixture symp tom Rich mixture Raise jet needle clip position 1 groove up 1 4 3 4 throttle Hard breathing Lack of speed Lower jet needle clip position 1 groove down 1 4 1 2 throttle Slow speed pick up Poor acceleration Raise jet needle clip position 1 groove up Closed to 1 4 throttle Hard breathing Speed down Use j...

Page 98: ...ould be higher to prevent a flat tire FRONT FORK SETTING The front fork setting should be made depending on the rider s feeling of an actual run and the circuit conditions The front fork setting includes the fol lowing three factors 1 Setting of air spring characteris tics Change the fork oil level 2 Setting of spring preload Change the spring Install the adjustment washer 3 Setting of damping for...

Page 99: ...gaps 2 Use of stiff spring Change the rebound damping Turn in one or two clicks Change the compression damp ing Turn out one or two clicks Generally a stiff spring gives a stiff riding feeling Rebound damping tends to become weaker resulting in lack of a sense of contact with the road surface or in a vibrating handle bar FRONT FORK SETTING PARTS Adjustment washer 1 Front fork spring 2 The I D mark...

Page 100: ...less re bound damping to compensate for its less spring load Run with the rebound damping adjuster one or two clicks on the softer side and readjust it to suit your preference 2 Use of stiff spring Set the soft spring for more re bound damping to compensate for its greater spring load Run with the rebound damping adjust er one or two clicks on the stiffer side and readjust it to suit your preferen...

Page 101: ...n the CHAPTER 3 SPRING PART NUM BER 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 which the spring is turned in 1 5 mm 0 06 in from its free length 5UN 40 5UN 50 5UN 60 5UN 70 Position in which the spring is turned in 22 mm 0 87 in from its free length ...

Page 102: ...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 103: ...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 104: ...y 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 CHECKING THE COOLANT sec tion in the CHAPTER 3 Seat fuel tank and left side cover Refer to REMOVING THE SEAT FUEL TANK AND SIDE COVERS section in the CHAPTER 3 1 Radiator guard 2 2 Radiator hose clamp 10 Only ...

Page 105: ...5 2 RADIATOR 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 106: ...on the O ring 2 Install Catch tank hose 1 Radiator hose 2 2 Radiator hose 3 3 Radiator pipe 2 4 Radiator hose 5 5 Radiator hose 4 6 To right radiator 7 3 Install Right radiator 1 Bolt right radiator 2 Radiator hose 5 3 Refer to CABLE ROUTING DIA GRAM section in the CHAPTER 2 4 Install Left radiator 1 Bolt left radiator 2 Radiator hose 1 3 Refer to CABLE ROUTING DIA GRAM section in the CHAPTER 2 5 ...

Page 107: ...Clamp 2 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 ...

Page 108: ...ottle 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 Pilot screw For EUROPE 1 Refer to removal section 16 Float pin 1 17 Float 1 18 Needle valve 1 ...

Page 109: ...e jet 1 21 Spacer 1 22 Pilot jet 1 23 Starter jet 1 24 Push rod 1 Pull the push rod 25 Throttle shaft assembly 1 26 Push rod link lever assembly 1 27 Main air jet 1 28 Pilot air jet 1 29 Cold starter plunger 1 Order Part name Q ty Remarks ...

Page 110: ...NEEDLE VALVE 1 Inspect Needle valve 1 Valve seat 2 Grooved wear a Replace Dust b Clean Filter c Clogged Clean CHECKING THE THROTTLE VALVE 1 Check Free movement Stick Repair or replace Insert the throttle valve 1 into the carburetor body and check for free movement CHECKING THE JET NEEDLE 1 Inspect Jet needle 1 Bends wear Replace Clip groove Free play exists wear Replace MEASURING AND ADJUSTING THE...

Page 111: ... 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 Re place 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 stopper a of the lever 2 4 I...

Page 112: ...t pin 3 After installing the needle valve to the float install them to the carbure tor Check the float for smooth move ment 12 Install For EUROPE Pilot screw 1 Spring 2 Washer 3 O ring 4 Note the following installation points a Turn in the pilot screw until it is lightly seated b Turn out the pilot screw by the number of turns recorded before removing 13 Install O ring Leak jet 1 Float chamber 2 B...

Page 113: ...ith the same outer di ameter as the specified value a Fully turn in the accelerator pump 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 carbure...

Page 114: ...CHAPTER 3 7 Install Throttle cable cover 1 Bolt throttle cable cover 2 8 Install Throttle position sensor lead cou pler 1 Clamp 2 Refer to CABLE ROUTING DIA GRAM section in the CHAPTER 2 9 Install Clamp 1 Refer to CABLE ROUTING DIA GRAM section in the CHAPTER 2 Bolt throttle cable cov er 4 Nm 0 4 m kg 2 9 ft lb ...

Page 115: ...2 Air cut off valve assembly 1 3 Air induction hose air cut off valve front of cyl inder head 1 4 Air induction pipe 1 5 Gasket 1 6 Air induction hose air cut off valve rear of cylin der 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 116: ... 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 back flow into air filter C Check for prevention of after burn When throttle is closed at sudden deceleration a to b Air passes b to a A...

Page 117: ... 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 118: ...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 119: ... cap 2 Clip Remove the bolts camshaft cap in a crisscross pattern working from the outside in The bolts camshaft cap must be removed evenly to prevent dam age to the cylinder head cam shafts or camshaft caps 5 Remove Exhaust camshaft 1 Intake camshaft 2 Attach a wire 3 to the timing chain to prevent it from falling into the crank case CHECKING THE CAMSHAFT 1 Inspect Cam lobe Pitting scratches blue...

Page 120: ... decompression mechanism cam lever pin 2 proj ects 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 ten sioner rod up fully clockwise When releasing the screwdriver by pressing lightly with fingers make sure that the tensioner rod will come out smoothly If not replace the tensioner as sembly IN...

Page 121: ...use a thin screwdriver and wind the tension er rod up fully clockwise b With the rod fully wound and the chain tensioner UP mark a fac ing upward install the gasket 1 and the timing chain tensioner 2 and tighten the bolt 3 to the specified torque c Release the screwdriver check the tensioner rod to come out and tighten the gasket 4 and the cap bolt 5 to the specified torque 3 Turn Crankshaft Count...

Page 122: ...ST PIPE AND SILENCER section 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 section 1 Radiator pipe 1 2 Oil delivery pipe 1 3 Nut 2 4 Bolt L 135 mm 5 31 in 2 5 Bolt L 145 mm 5 71 in 2 6 Cylinder h...

Page 123: ...YLINDER 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 in stall the timing chain guide exhaust side and cylinder head 2 Install Washer 1 Cable guide 2 Bolts L 145 mm 5 71 in 3 Bolts L 135 mm 5 31 in 4 Nuts 5 Apply the molybdenum disulfide grease on the thread and contact surface of the bolts Follow the numerical...

Page 124: ...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 125: ...ve the valve guide using a valve guide remover 1 b Install the new valve guide using a valve guide remover 1 and valve guide installer 2 c After installing the valve guide bore the valve guide using a valve guide reamer 3 to obtain proper stem to guide clearance After replacing the valve guide reface the valve seat Valve spring compres sor YM 4019 90890 04019 Valve spring compressor adapter 19 5 m...

Page 126: ...valves that have been used to lap the valve seats must not be used Always replace lapped valves with new valves When replacing the cylinder head replace the valves without lapping the valve seats and valve faces When replacing the valves or valve guides use new valves to lap the valve seats and then replace them with new valves Lapping steps a Apply a coarse lapping compound to the valve face Do n...

Page 127: ...with the larger pitch d facing upward e Smaller pitch 3 Install Valve cotter Install the valve cotters by compress ing the valve spring with the valve spring compressor 1 and the valve spring compressor attachment 2 4 To secure the valve cotters onto the valve stem lightly tap the valve tip with a piece of wood Hitting the valve tip with excessive force could damage the valve 5 Install Adjusting p...

Page 128: ...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 129: ...n from the piston bottom edge d If out of specification replace the piston and piston rings as a set e Calculate the piston to cylinder clearance with following formula f If out of specification replace the cylinder and replace the piston and piston rings as set CHECKING THE PISTON RING 1 Measure Ring side clearance Use a feeler gauge 1 Out of specification Replace the piston and rings as a set Cl...

Page 130: ... 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 Piston pin clip 3 Apply engine oil onto the piston pin and piston Be sure that the arrow mark a on the piston points to the exhaust side of t...

Page 131: ... the lithium soap base grease on the O ring 3 Install Cylinder gasket 1 Cylinder 2 Install the cylinder with one hand while compressing the piston rings with the other hand Pass the timing chain 3 through the timing chain cavity Be careful not to damage the tim ing chain guide 4 during instal lation 4 Install Bolt cylinder 5 Bolt cylinder 10 Nm 1 0 m kg 7 2 ft lb ...

Page 132: ...NE OIL section in the CHAPTER 3 Brake pedal Refer to ENGINE REMOVAL section 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 11 Clutch plate 8 12 Cushion spring 1 13 Seat plate 1 ...

Page 133: ...t 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 134: ...asure at all four points CHECKING THE CLUTCH PLATES 1 Measure Clutch plate warpage Out of specification Replace clutch plate as a set Use a surface plate 1 and thick ness gauge 2 CHECKING THE PUSH LEVER SHAFT 1 Inspect Push lever shaft 1 Wear damage Replace CHECKING 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...

Page 135: ...ion plates alternately 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 surface pattern Apply the engine oil on the friction plates and clutch plates Unlike the clutch plate 2 the clutch plate 1 has no surface gloss Use the clutch plate 1 for the first while paying attent...

Page 136: ...5 33 CLUTCH 10 Install Dowel pin 1 Gasket clutch cover 2 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 137: ... Refer to CHANGING THE COOLANT sec tion in the CHAPTER 3 Radiator hose 3 Disconnect at water pump side Exhaust pipe Refer to REMOVING THE EXHAUST PIPE AND SILENCER section in the CHAPTER 3 Brake pedal Refer to ENGINE REMOVAL section Engine guard 1 Oil filter element cover 1 2 Oil filter element 1 3 Water pump housing 1 4 Oil delivery pipe 1 5 Bolt oil hose 1 6 Kickstarter crank 1 7 Right crankcase...

Page 138: ...TER ELEMENT AND WATER PUMP 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 139: ... damage Replace CHECKING THE BEARING 1 Inspect Bearing Rotate inner race with a finger Rough spot seizure Replace CHECKING THE OIL SEAL 1 Inspect Oil seal 1 Wear damage Replace INSTALLING THE OIL SEAL 1 Install Oil seal 1 Apply the lithium soap base grease on the oil seal lip Install the oil seal with its manufac ture s marks or numbers facing the right crankcase cover 2 2 Install Bearing 1 Instal...

Page 140: ... frame and that the kickstarter does not contact the crankcase cover when it is pulled 2 Install Oil hose 1 Bolt oil hose 2 3 Install Copper washer 1 Oil delivery pipe 2 Union bolt M8 3 Union bolt M10 4 First tighten the union bolts temporar ily Then retighten them with the width a across flats of the oil delivery pipe held tight with a spanner INSTALLING THE WATER PUMP HOUSING 1 Install Dowel pin...

Page 141: ...MP 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 Bolt oil filter element cover 10 Nm 1 0 m kg 7 2 ft lb ...

Page 142: ...R ELEMENT AND WA TER 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 143: ...n the center a of the balancer shaft weight along the line connect ing the centers of the crankshaft and balancer shaft 2 Install Balancer shaft driven gear 1 Install the balancer shaft driven gear onto the balancer shaft while aligning the punch mark a on the balancer shaft driven gear with the lower spline b on the balancer shaft end 3 Install Balancer shaft drive gear 1 Align the punched mark a...

Page 144: ...rankcase cover Refer to OIL FILTER ELEMENT AND WA TER 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 12 Dowel pin 1 13 Washer 1 14 Oil pump drive shaft 1 15 Rotor housing 1 ...

Page 145: ...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 146: ...otor 1 1 Apply the engine oil on the outer rotor 1 3 Install Oil pump cover 1 Screw oil pump cover 2 Dowel pin 3 Inner rotor 2 4 Circlip 5 Apply the engine oil on the inner ro tor 2 Fit the dowel pin into the groove in the inner 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...

Page 147: ...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 14 Shift guide 1 Refer to removal section 15 Shift lever assembly 1 Refer to removal section 16 Shift lever 1 ...

Page 148: ...5 45 KICK SHAFT AND SHIFT SHAFT 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 149: ... move ment Unsmooth movement Replace Kick shaft 2 Wear damage Replace Spring 3 Broken Replace CHECKING THE KICK GEAR KICK IDLE GEAR AND RATCHET WHEEL 1 Inspect Kick gear 1 Kick idle gear 2 Ratchet wheel 3 Gear teeth a Ratchet teeth b Wear damage Replace CHECKING THE SHIFT SHAFT 1 Inspect Shift shaft 1 Bend damage Replace Spring 2 Broken Replace CHECKING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY 1 I...

Page 150: ...r 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 disulfide oil on the inner circumferences of the kick gear and ratchet wheel Align the p...

Page 151: ...Slide the kick shaft assembly into the crankcase 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 KICK IDLE GEAR 1 Install Kick idle gear 1 Washer 2 Circlip 3 Apply the engine oil on the kick idle gear inner circumference Install the kick idle...

Page 152: ...APTER 3 Seat and fuel tank Refer to REMOVING THE 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 10 Starter clutch drive gear 1 11 Starter clutch assembl...

Page 153: ...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 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 154: ...TCH 1 Check Starter clutch Damage wear Replace 2 Check Idle gear Starter clutch drive gear Pitting burrs chips roughness wear Replace the defective parts 3 Check Starter clutch operation a Install the starter clutch drive gear 1 onto the starter clutch 2 and hold the starter clutch b When turning the starter clutch drive gear counterclockwise B the starter clutch and the starter clutch drive gear ...

Page 155: ...rd While installing the starter clutch push in the projections a one by one on the clutch circumference 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 fitting its pawls a into the groove b in the rotor 8 Install Woodruff key 1 Rotor 2 Degrease the contact surfaces of the tapered portions of the cr...

Page 156: ... the lithium soap base grease on the O ring Install the cover idle gear 1 with its mark a facing upward 13 Connect AC magneto lead Refer to CABLE ROUTING DIA GRAM 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 foot rest Bolt crankcase ...

Page 157: ...D SIDE COVERS section in the CHAPTER 3 Carburetor Refer to CARBURETOR section Exhaust pipe and silencer Refer to REMOVING THE EXHAUST PIPE AND SILENCER 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 section Shift pedal Refer to AC MAGNETO AND STARTER CLUTCH section Cylinder head breathe...

Page 158: ...r 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 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 159: ...et 4 Bolt lower engine bracket 5 Patch 6 Engine mounting bolt front 7 Upper engine bracket 8 Bolt upper engine bracket 9 Engine mounting bolt upper 10 Lower engine guard 11 Bolt lower engine guard 12 Apply the molybdenum disulfide grease on the pivot shaft Install the patch with the claw a facing outside the chassis INSTALLING THE BRAKE PEDAL 1 Install Spring 1 Brake pedal 2 O ring 3 Bolt brake pe...

Page 160: ...sprocket guide 1 Drive chain sprocket cover 2 Bolt drive chain sprocket cover 3 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 Nut drive sprocket 75 Nm 7 5 m kg 54 ft lb Bolt drive chain sprock et 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 161: ...ment 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 5 Bolt L 55 mm 2 17 in 1 Refer to removal section 6 Bolt L 70 mm 2 76 in 3 Refer to removal section 7 Hose guide 1 Refer to remova...

Page 162: ...9 CRANKCASE AND CRANKSHAFT 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 163: ...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 164: ...kshaft 1 Use the crankcase separating tool 2 Do not use a hammer to drive out the crankshaft REMOVING THE CRANKCASE BEARING 1 Remove Bearing 1 Remove the bearing from the crankcase by pressing its inner race Do not use the removed bearing CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDE 1 Inspect Timing chain Cracks stiff Replace the timing chain and camshaft sprocket as a set 2 Inspect Timing cha...

Page 165: ... center with one hand while turning the nut of the installing tool with the other Operate the installing tool un til the crankshaft bottoms against the bearing Before installing the crankshaft clean the contacting surface of crankcase Do not use a hammer to drive in the crankshaft A For USA and CDN B Except for USA and CDN 2 Check Shifter operation Transmission operation Unsmooth operation Repair ...

Page 166: ...crankcase tightening bolts in stage using a crisscross pat tern 7 Install Oil delivery pipe 2 1 O ring 2 Bolt oil delivery pipe 2 3 Apply the lithium soap base grease on the Orings 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 ...

Page 167: ...s Engine Refer to ENGINE REMOVAL section Separate the crankcase Refer to CRANKCASE AND CRANK SHAFT 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 168: ...Replace CHECKING THE SHIFT FORK SHIFT CAM AND SEGMENT 1 Inspect Shift fork 1 Wear damage scratches Re place 2 Inspect Shift cam 1 Segment 2 Wear damage Replace 3 Check Shift fork movement Unsmooth operation Replace shift fork For a malfunctioning shift fork re place not only the shift fork itself but the two gears each adjacent to the shift fork INSTALLING THE TRANSMISSION 1 Install 5th pinion gea...

Page 169: ...case 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 Mesh the shift fork 2 C with the 3rd pinion gear 6 on the main ax le 6 Install Transmission a...

Page 170: ...nly 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 suitable 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 sensor 1 6 Collar 1 7 Oil seal 1 8 Bear...

Page 171: ... 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 6 ...

Page 172: ...rake disc deflection only rear brake disc Use the dial gauge 1 Out of specification Inspect wheel runout If wheel runout is in good condi tion replace the brake disc 2 Measure Brake disc thickness a Out of limit Replace INSTALLING THE FRONT WHEEL 1 Install Bearing left 1 Spacer 2 Bearing right 3 Oil seal 4 Apply the lithium soap base grease on the bearing and oil seal lip when installing Use a soc...

Page 173: ... 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 strok ing the front fork several times with the front brake applied INSTALLING THE REAR WHEEL 1 Install Bearing right 1 Circlip 2 Spacer 3 Bearing left 4 Oil seal 5 Apply the lithium soap base grease on the bearing and oil seal lip when installing Install the ...

Page 174: ...he 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 9 Adjust Drive chain slack a Refer to ADJUSTING THE DRIVE ...

Page 175: ...ine 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 cali per 7 Brake caliper 1 8 Brake lever 1 9 Brake master cylinder bracket 1 10 Brake master cylinder 1 ...

Page 176: ...ne 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 cali per 8 Brake caliper 1 ...

Page 177: ...rder 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 178: ...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 179: ...tion when expelling piston from cylinder Never attempt to pry out piston Caliper piston removal steps a Insert a piece of rag into the brake caliper to lock one brake caliper b Carefully force the piston out of the brake caliper cylinder with compressed air A Front B Rear REMOVING THE BRAKE CALIPER PISTON SEAL KIT 1 Remove Brake caliper piston dust seal 1 Brake caliper piston seal 2 Remove the bra...

Page 180: ...rnal parts should be lubricat ed with brake fluid when in stalled 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 piston d...

Page 181: ...ter cylinder kit Clean them with brake fluid 2 Install Brake master cylinder cup prima ry 1 Brake master cylinder cup sec ondary 2 To brake master cylinder piston 3 Apply the brake fluid on the brake master cylinder cup After installing cylinder cup should be installed as shown di rection Wrong installation cause improper brake performance A Front B Rear 3 Install Spring 1 To brake master cylinder...

Page 182: ... washer 1 Brake hose 2 Union bolt 3 Always use new copper washers Install the brake hose so that its pipe portion a directs as shown and lightly touches the projection b on the brake master cylinder 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 ...

Page 183: ...all the brake hose so that it contacts the brake master cylinder projection a and that its bent portion b faces downward INSTALLING THE REAR BRAKE HOSE 1 Install Copper washer 1 Brake hose 2 Union bolt 3 Always use new copper washers Install the brake hose so that its pipe portion a directs as shown and lightly touches the projection b on the brake caliper 2 Install Brake hose holder 1 Screw brake...

Page 184: ...an up spilled fluid immediately A Front B Rear 2 Air bleed Brake system Refer to BLEEDING THE HY DRAULIC BRAKE SYSTEM sec tion in the CHAPTER 3 3 Inspect Brake fluid 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 cylin der cap 2 After installation...

Page 185: ...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 186: ... 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 187: ... front fork cap bolt REMOVING THE INNER TUBE 1 Remove Dust seal 1 Stopper ring 2 Using slotted head screwdriver Take care not to scratch the inner tube 2 Remove Inner tube 1 Oil seal removal steps a Push in slowly a the inner tube just before it bottoms out and then pull it back quickly b b Repeat this step until the inner tube can be pulled out from the outer tube REMOVING THE DAMPER ROD 1 Remove...

Page 188: ...tube is held ver tically 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 damper rod 3 Apply the LOCTITE on the base valve thread 5 Install Spring guide 1 Locknut 2 To damper rod 3 Install the spring guide with its smaller dia end a facing down ward With its thread ...

Page 189: ...y 15 Fill Front fork oil Until outer tube top surface with recommended fork oil 1 Be sure to use recommended fork oil If other oils are used they may have an excessively ad verse effect on the front fork per formance Never allow foreign materials to enter the front fork 16 After filling pump the damper rod 1 slowly up and down more than 10 times to distribute the fork oil 17 Fill Front fork oil Un...

Page 190: ...Loosen Rebound damping adjuster 1 Loosen the rebound damping ad juster finger tight Record the set position of the ad juster the amount of turning out the fully turned in position 23 Install Push rod 1 Fork spring 2 Install the fork spring with the damper rod 3 pulled up After installing the fork spring hold the damper rod end so that it will not go down 24 Install Spring seat 1 Front fork cap bol...

Page 191: ...nsor lead so that its paint a directs as shown and align the bottom b of the plate 1 with the same paint 6 Install Speed sensor lead 1 Plate 2 2 Screw plate 2 3 To right protector 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 fin ger tight and then turn out to the orig inally set position Front f...

Page 192: ... 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 section 12 Tube guide 1 13 Left grip 1 Refer to removal secti...

Page 193: ...holder Installing the handlebar lower hold er in the reverse direction allows the front to rear offset amount of the handlebar position to be changed Do not tighten the nut yet 2 Install Handlebar 1 Handlebar upper holder 2 Bolt handlebar upper holder 3 The handlebar upper holder should be installed with the punched mark a forward Install the handlebar so that the marks b are in place on both side...

Page 194: ...oothly If it does not retighten the bolts for adjustment 9 Install Grip cap cover 1 Cover throttle cable cap 2 10 Install Start switch 1 Brake master cylinder 2 Brake master cylinder bracket 3 Bolt brake master cylinder brack et 4 Clamp 5 The start switch and brake master cylinder bracket should be installed according to the dimensions shown Install the bracket so that the arrow mark a faces upwar...

Page 195: ...e of the clutch lever hold er 12 Install Clutch cable 1 Hot starter cable 2 Apply the lithium soap base grease on the clutch cable end and hot start er cable end 13 Adjust Clutch lever free play Refer to ADJUSTING THE CLUTCH LEVER FREE PLAY section in the CHAPTER 3 Hot starter lever free play Refer to ADJUSTING THE HOT STARTER LEVER FREE PLAY section in the CHAPTER 3 ...

Page 196: ...the machine by placing the suitable 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 4 Steering stem nut 1 5 Front fork 2 Refer to FRONT FORK section 6 Upper bracket 1 7 Steering ring nut 1 Refer to removal sec...

Page 197: ...6 28 STEERING 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 198: ...ngs hang up or are not smooth in their operation in the bearing races replace bearings and bearing races as a set INSTALLING THE LOWER BRACKET 1 Install Lower bearing 1 Apply the lithium soap base grease on the dust seal lip and bearing inner circumference 2 Install Bearing race Upper bearing 1 Bearing race cover 2 Apply the lithium soap base grease on the bearing and bearing race cov er lip 3 Ins...

Page 199: ...et 2 Tighten the lower bracket to speci fied torque If torqued too much it may cause the front fork to mal function 13 Install Multi function display bracket 1 Multi function display 2 Pass the throttle cables 3 clutch ca ble 4 and hot starter cable 5 be tween the multi function display bracket and upper bracket 14 Install Holder 1 Clamp 2 Install so that the marking a on the speed sensor lead ali...

Page 200: ...ING 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 201: ...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 202: ... 1 Collar 2 Free play exists unsmooth revolu tion rust Replace bearing and collar as a set 2 Inspect Oil seal 3 Damage Replace INSTALLING THE BEARING AND OIL SEAL 1 Install Bearing 1 Oil seal 2 To swingarm Apply the molybdenum disulfide grease on the bearing when install ing Install the bearing by pressing it on the side having the manufacture s marks or numbers First install the outer and then th...

Page 203: ... 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 molybdenum disulfide grease on the pivot shaft Insert the pivot shaft from right side 7 Check Swingarm side play a Free play exists Replace thrust bearing Swinga...

Page 204: ...r chain tensioner 5 14 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 connecting rod 80 Nm 8 0 m kg 58 ft lb Nut relay arm 70 Nm 7 0 m kg 50 ft lb Nut lower chain tension er 16 Nm 1 6 m kg 11 ft lb Nut drive chain sup port 7 Nm 0 7 m kg 5 1 ft lb Bolt drive chain sup...

Page 205: ...section in the CHAPTER 3 Drain the coolant Refer to CHANGING THE COOLANT sec tion 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 Cylinder head breather hose Disconnect at the air filter case side Battery Refer to CHECKING AND CHA...

Page 206: ...ear 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 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 207: ...n disposal NOTES ON DISPOSAL YAMAHA DEALERS ONLY Before disposing the rear shock ab sorber be sure to extract the nitrogen gas from valve 1 Wear eye protec tion to prevent eye damage from es caping gas and or metal chips To dispose of a damaged or worn out rear shock absorber take the unit to your Yamaha dealer for this disposal procedure REMOVING THE BEARING 1 Remove Stopper ring upper bearing 1 ...

Page 208: ...eal lips and col lars 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 their lips facing inward 3 Install Rear shock absorber 4 Install Bolt rear shock absorber frame 1 Washer 2 Nut rear shock absorber frame 3 Apply the molybdenum disulfide grease on the bol...

Page 209: ...6 40 REAR SHOCK ABSORBER 7 Tighten Screw air filter joint 1 8 Install Plastic band Taillight coupler Locking tie Screw air filter joint 3 Nm 0 3 m kg 2 2 ft lb ...

Page 210: ...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 211: ... 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 Red...

Page 212: ...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 connection couplers leads and ignition coil No good Repair or replace OK Check engine stop switch No good Replace OK Check main switch No good Replac...

Page 213: ... it is freed Re place Set the tester selection position to Ω 1 2 Inspect Rubber part a Tears damage Replace CHECKING THE MAIN SWITCH 1 Inspect Main switch conduction Not conductive while the main switch is moved to ON Replace Conductive while the main switch is moved to OFF Replace Set the tester selection position to Ω 1 2 Inspect Main switch indicator light Use 12 V battery Indicator light does ...

Page 214: ...sed The clutch lever is pulled to the han dlebar the clutch switch is closed The starting circuit cut off relay pre vents the starter motor from operating when neither of these conditions has been met In this instance the start ing circuit cut off relay is open so cur rent cannot reach the starter motor When at least one of the above con ditions has been met the starting cir cuit cut off relay is ...

Page 215: ...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 connection 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 good...

Page 216: ...attery is connected Replace Conductive while the battery is not connected Replace Set the tester selection position to Ω 1 CHECKING THE CLUTCH SWITCH 1 Inspect Clutch switch conduction Not conductive while it is pulled Re place Conductive while it is freed Re place Set the tester selection position to Ω 1 CHECKING THE DIODE 1 Remove the diode from wire har ness 2 Inspect Diode continuity Use pocke...

Page 217: ... conduction Not conductive while it is pushed Replace Conductive while it is freed Re place 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 start switch is pushed ...

Page 218: ...7 9 ELECTRIC STARTING SYSTEM REMOVING THE STARTER MOTOR Order Part name Q ty Remarks Exhaust pipe Refer to REMOVING THE EXHAUST PIPE AND SILENCER section in the CHAPTER 3 1 Starter motor 1 ...

Page 219: ...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 220: ...e brushes as a set 6 Measure Brush spring force Out of specification Replace the brush springs as a set ASSEMBLING THE STARTER MOTOR 1 Install Brush spring 1 Brush 2 2 Install Armature assembly 1 Install while holding down the brush using a thin screw driver Be careful not to damage the brush during installation 3 Install Gasket 1 Starter motor yoke 2 Install the starter motor yoke with its groove...

Page 221: ...n the projec tions 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 on the starter motor front cover 5 Install Gasket Bolt 1 O ring 2 Apply the lithium soap base grease on the O ring ...

Page 222: ...emove 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 connection 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 223: ...t of specification If no failure is found in checking the source coil resistance replace the rectifi er regulator 3 Inspect Charging coil resistance Out of specification Replace Tester lead Red lead 1 Tester lead Black lead 2 Charging voltage Tester se lector posi tion 14 0 15 0 V at 5 000 r min DCV 20 Tester lead White lead 1 Tester lead Ground 2 Charging coil resis tance Tester se lector posi ti...

Page 224: ...the following inspection steps Use the following special tools in this inspection Check entire ignition system for connection No good Repair or replace OK Check throttle position sensor Throttle position sensor coil No good Replace OK Check CDI unit Throttle position sensor input voltage No good Replace Pocket tester YU 3112 C 90890 03112 ...

Page 225: ...tion sensor using the T25 bit 3 Replace Throttle position sensor 4 Install Throttle position sensor 1 Screw throttle position sensor 2 Align the slot a in the throttle posi tion sensor with the projection b on the carburetor Temporarily tighten the screw throttle position sensor 5 Install Carburetor Throttle position sensor coupler 6 Adjust Engine idling speed Refer to ADJUSTING THE EN GINE IDLING...

Page 226: ...11 Stop the engine 12 Remove the carburetor 13 Tighten Screw throttle position sensor 1 Tighten the screw throttle position sensor using the T25 bit 14 Install the carburetor CHECKING THE THROTTLE POSITION SENSOR INPUT VOLTAGE 1 Disconnect the throttle position sensor coupler 2 Start the engine 3 Inspect Throttle position sensor input volt age Out of specification Replace the CDI unit Throttle po ...

Page 227: ...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 con nections Improperly connected Repair or replace OK Check the rectifier regulator Out put voltage No good Repla...

Page 228: ...le gas or fluid is in the vicinity CHECKING THE AC MAGNETO 1 Inspect Lighting coil resistance Out of specification Replace CHECKING THE RECTIFIER REGULATOR 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 regulator Battery terminal Blue lead 2 Battery terminal Black l...

Page 229: ...ts 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 connection No good Repair or replace OK Check multi function display Input voltage 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 Pocke...

Page 230: ...D SENSOR OUTPUT VOLTAGE 1 Insert the thin electric conductors 1 lead into the speed sensor coupler 2 as shown and con nect the tester to them Do not insert the electric conduc tors more than required because it may reduce the waterproof function of the coupler Make sure that a short circuit does not develop between the terminals because it may cause damage to electrical compo nents 2 Set the main ...

Page 231: ......

Page 232: ...PRINTED IN JAPAN E PRINTED ON RECYCLED PAPER ...

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