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Yamaha RAPTOR YFM125RA Service Manual Download Page 292

TROUBLESHOOTING

8-1

EAS28451

TROUBLESHOOTING

EAS28460

GENERAL INFORMATION

TIP

The following guide for troubleshooting does 
not cover all the possible causes of trouble. It 
should be helpful, however, as a guide to basic 
troubleshooting. Refer to the relative proce-
dure in this manual for checks, adjustments, 
and replacement of parts.

EAS28470

STARTING FAILURES

Engine

1. Cylinder and cylinder head

• Loose spark plug
• Loose cylinder head or cylinder
• Damaged cylinder head gasket
• Damaged cylinder gasket
• Worn or damaged cylinder
• Incorrect valve clearance
• Improperly sealed valve
• Incorrect valve-to-valve-seat contact
• Incorrect valve timing
• Faulty valve spring
• Seized valve

2. Piston and piston ring

• Improperly installed piston ring
• Damaged, worn or fatigued piston ring
• Seized piston ring
• Seized or damaged piston

3. Air filter

• Improperly installed air filter
• Clogged air filter element

4. Crankcase and crankshaft

• Improperly assembled crankcase
• Seized crankshaft

Fuel system

1. Fuel tank

• Empty fuel tank
• Clogged fuel strainer
• Clogged fuel tank breather hose
• Deteriorated or contaminated fuel

2. Fuel cock

• Clogged or damaged fuel hose

3. Carburetor

• Deteriorated or contaminated fuel
• Clogged pilot jet
• Clogged pilot air passage
• Sucked-in air

• Damaged float
• Worn needle valve
• Improperly installed needle valve seat
• Incorrect fuel level
• Improperly installed pilot jet
• Clogged starter jet
• Faulty starter plunger

Electrical system

1. Battery

• Discharged battery
• Faulty battery

2. Fuse

• Blown, damaged or incorrect fuse
• Improperly installed fuse

3. Spark plug

• Incorrect spark plug gap
• Incorrect spark plug heat range
• Fouled spark plug
• Worn or damaged electrode
• Worn or damaged insulator
• Faulty spark plug cap

4. Ignition coil

• Cracked or broken ignition coil body
• Broken or shorted primary or secondary 

coils

• Faulty spark plug lead

5. Ignition system

• Faulty CDI unit
• Faulty pickup coil
• Faulty stator coil
• Broken generator rotor woodruff key

6. Switches and wiring

• Faulty main switch
• Faulty engine stop switch
• Broken or shorted wiring
• Faulty neutral switch
• Faulty start switch
• Faulty clutch switch
• Improperly grounded circuit
• Loose connections

7. Starting system

• Faulty starter motor
• Faulty starter relay
• Faulty starting circuit cut-off relay
• Faulty starter clutch

EAS28490

INCORRECT ENGINE IDLING SPEED

Engine

1. Cylinder and cylinder head

• Incorrect valve clearance
• Damaged valve train components

Summary of Contents for RAPTOR YFM125RA

Page 1: ...SERVICE MANUAL YFM125RA 2011 2PA 28197 10 LIT 11616 24 36 ...

Page 2: ...by Yamaha Motor Corporation U S A First edition May 2010 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in U S A P N LIT 11616 24 36 ...

Page 3: ...th the most satisfaction from his vehicle and to conform to federal environmental quality objectives Yamaha Motor Company Ltd is continually striving to improve all of its models Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha deal ers and will appear in future editions of this manual where applicable TIP This Service Manual contains...

Page 4: ...h page Sub section titles 2 appear in smaller print than the section title To help identify parts and clarify procedure steps there are exploded diagrams 3 at the start of each removal and disassembly section Numbers 4 are given in the order of the jobs in the exploded diagram A number indicates a dis assembly step Symbols 5 indicate parts to be lubricated or replaced Refer to SYMBOLS A job instru...

Page 5: ...ITION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque Lithium soap based grease Wear limit clearance Molybdenum disulfide grease Engine speed Silicone grease Electrical data Apply locking agent LOC TITE Engine oil Replace the part with a new one G M BF B T R LS M S LT E New ...

Page 6: ......

Page 7: ...1 2 3 4 5 6 7 8 EAS20110 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING ...

Page 8: ......

Page 9: ...MPORTANT INFORMATION 1 2 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 2 REPLACEMENT PARTS 1 2 GASKETS OIL SEALS AND O RINGS 1 2 LOCK WASHERS PLATES AND COTTER PINS 1 2 BEARINGS AND OIL SEALS 1 3 CIRCLIPS 1 3 BASIC SERVICE INFORMATION 1 4 QUICK FASTENERS 1 4 ELECTRICAL SYSTEM 1 5 SPECIAL TOOLS 1 9 ...

Page 10: ...S20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the left side of the frame EAS20150 MODEL LABEL The model label 1 is affixed to the air filter case cover This information will be needed to order spare parts ...

Page 11: ...correct installation of all parts 5 Keep all parts away from any source of fire EAS20200 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace ments Use oil and grease recommended by Yamaha for all lubrication jobs Other brands may be similar in function and appearance but inferior in quality EAS20210 GASKETS OIL SEALS AND O RINGS 1 When overhauling the engine replace all gaskets seals a...

Page 12: ...ed grease Oil bearings liberally when installing if appropriate ECA13300 Do not spin the bearing with compressed air because this will damage the bearing surfaces EAS20240 CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlips Always replace piston pin clips after one use When installing a circlip 1 make sure the sharp edged corner 2 is positioned opposit...

Page 13: ...ner push its pin so that it protrudes from the fastener head then insert the fastener into the part to be secured and push the pin a in with a screwdriver Make sure that the pin is flush with the fastener s head Screw type 1 Remove Quick fastener TIP To remove the quick fastener loosen the screw with a screwdriver then pull the fastener out 2 Install Quick fastener TIP To install the quick fastene...

Page 14: ...P If a battery lead is difficult to disconnect due to rust on the battery terminal remove the rust using hot water ECA16760 Be sure to connect the battery leads to the correct battery terminals Reversing the battery lead connections could damage the electrical components ECA16771 When connecting the battery leads to the battery be sure to connect the positive bat tery lead first then the negative ...

Page 15: ...ly 5 seconds before turning the main switch back to ON Checking the electrical system TIP Before checking the electrical system make sure that the battery voltage is at least 12 V ECA14371 Never insert the tester probes into the cou pler terminal slots Always insert the probes from the opposite end a of the coupler taking care not to loosen or dam age the leads ECA16640 For waterproof couplers nev...

Page 16: ...connector do not pull the leads Hold both sections of the connector securely and then disconnect the connector 2 Check Lead Coupler Connector Moisture Dry with an air blower Rust stains Connect and disconnect several times 3 Check All connections Loose connection Connect properly TIP If the pin 1 on the terminal is flattened bend it up After disassembling and assembling a cou pler pull on the lead...

Page 17: ...h the pocket tester TIP If there is no continuity clean the terminals When checking the wire harness perform steps 1 to 3 As a quick remedy use a contact revitalizer available at most part stores Pocket tester 90890 03112 Analog pocket tester YU 03112 C ...

Page 18: ...differ depending on the country When placing an order refer to the list provided below to avoid any mistakes TIP 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 Tool No Illustration Reference pages Slide hammer bolt 90890 01083 Slide hammer bolt 6 mm YU 01083 1 5 14 5 16 Weight 90890 01084 YU 01083 3 5 14 Crankcase separating...

Page 19: ...ankshaft installer bolt 90890 01275 Bolt YU 90060 5 65 Adapter M12 90890 01278 Adapter 3 YU 90063 5 65 Spacer crankshaft installer 90890 04081 Pot spacer YM 91044 5 65 Piston pin puller set 90890 01304 Piston pin puller YU 01304 5 27 Tool name Tool No Illustration Reference pages YM 91044 ...

Page 20: ... clutch holder YS 01880 A 5 50 5 51 5 52 Thickness gauge 90890 03180 Feeler gauge set YU 26900 9 3 5 5 36 Digital circuit tester 90890 03174 Model 88 Multimeter with tachometer YU A1927 5 56 Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 8 7 31 7 32 7 33 7 37 7 38 7 39 7 40 7 41 7 42 Carburetor angle driver 90890 03158 3 7 Tool name Tool No Illustration Reference pages ...

Page 21: ...24 Fuel level gauge 90890 01312 YM 01312 A 6 10 Universal clutch holder 90890 04086 YM 91042 5 35 5 38 Valve guide remover ø5 90890 04097 Valve guide remover 5 0 mm YM 04097 5 21 Valve guide installer ø5 90890 04098 Valve guide installer 5 0 mm YM 04098 5 21 Valve guide reamer ø5 90890 04099 Valve guide reamer 5 0 mm YM 04099 5 21 Tool name Tool No Illustration Reference pages ...

Page 22: ... mm 90890 01498 Rear axle nut wrench 46 mm YM 37134 4 14 4 15 Ignition checker 90890 06754 Opama pet 4000 spark checker YM 34487 7 39 Digital tachometer 90890 06760 YU 39951 B 3 6 7 41 Yamaha bond No 1215 Three bond No 1215 90890 85505 5 52 5 61 5 62 Tool name Tool No Illustration Reference pages ...

Page 23: ...IONS 2 11 TIGHTENING TORQUES 2 13 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 13 ENGINE TIGHTENING TORQUES 2 14 CHASSIS TIGHTENING TORQUES 2 16 LUBRICATION POINTS AND LUBRICANT TYPES 2 20 ENGINE 2 20 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 21 ENGINE OIL LUBRICATION CHART 2 21 LUBRICATION DIAGRAMS 2 23 CABLE ROUTING 2 27 ...

Page 24: ...c starter Lubrication system Wet sump Engine oil Recommended brand YAMALUBE Type SAE 5W 30 10W 30 10W 40 15W 40 20W 40 or 20W 50 Recommended engine oil grade API service SG type or higher JASO standard MA Engine oil quantity Periodic oil change 1 25 L 1 32 US qt 1 10 Imp qt Total amount 1 50 L 1 59 US qt 1 32 Imp qt Oil filter Oil filter type Centrifugal Air filter Air filter element Wet element A...

Page 25: ...m 31 14 in Tread front STD 841 0 mm 33 11 in Toe in with tire touching the ground 8 0 18 0 mm 0 31 0 71 in Front tire Type Tubeless Size AT19 6 10 Manufacturer model MAXXIS M957Y Wear limit 3 0 mm 0 12 in Rear tire Type Tubeless Size AT18 9 8 Manufacturer model MAXXIS M940 Wear limit 3 0 mm 0 12 in Tire air pressure measured on cold tires Maximum loading limit 100 0 kg 220 lb Recommended Front 25 ...

Page 26: ...g gas oil damper Wheel travel 200 mm 7 9 in Electrical system Ignition system CDI Charging system AC magneto Battery Model YTZ7S Voltage capacity 12 V 6 0 Ah Manufacturer GS YUASA Ten hour rate amperage 0 6 A Headlight Bulb type Halogen bulb Bulb voltage wattage quantity Headlight 12 V 35 0 36 5 W 1 Tail brake light 12 V 5 0 21 0 W 1 Neutral indicator light 12 V 1 7 W 1 ...

Page 27: ...3 in Limit 21 165 mm 0 8333 in Exhaust A 25 841 25 941 mm 1 0174 1 0213 in Limit 25 811 mm 1 0162 in Exhaust B 20 997 21 097 mm 0 8267 0 8306 in Limit 20 967 mm 0 8255 in Camshaft runout limit 0 030 mm 0 0012 in Timing chain Model number of links 92RH2005 90M 90 Tensioning system Automatic Rocker arm rocker arm shaft Rocker arm inside diameter 10 000 10 015 mm 0 3937 0 3943 in Limit 10 030 mm 0 39...

Page 28: ...m 0 0315 0 0472 in Valve stem diameter intake 4 975 4 990 mm 0 1959 0 1965 in Limit 4 950 mm 0 1949 in Valve stem diameter exhaust 4 960 4 975 mm 0 1953 0 1959 in Limit 4 935 mm 0 1943 in Valve guide inside diameter intake 5 000 5 012 mm 0 1969 0 1973 in Limit 5 042 mm 0 1985 in Valve guide inside diameter exhaust 5 000 5 012 mm 0 1969 0 1973 in Limit 5 042 mm 0 1985 in Valve stem to valve guide c...

Page 29: ...ing tilt exhaust 2 5 2 1 mm 0 08 in Winding direction intake Clockwise Winding direction exhaust Clockwise Piston Piston to cylinder clearance 0 019 0 035 mm 0 0007 0 0014 in Limit 0 15 mm 0 006 in Diameter D 53 997 54 029 mm 2 1259 2 1271 in Height H 4 5 mm 0 18 in Offset 0 50 mm 0 0197 in Offset direction Intake side Piston pin bore inside diameter 15 002 15 013 mm 0 5906 0 5911 in Limit 15 043 ...

Page 30: ...m 0 0059 0 0177 in Limit 0 50 mm 0 0197 in Big end radial clearance E 0 010 0 021 mm 0 0004 0 0008 in Balancer Balancer drive method Gear Clutch Friction plate thickness 3 00 mm 0 12 in Wear limit 2 80 mm 0 11 in Plate quantity 4 pcs Clutch plate thickness 1 60 mm 0 06 in Plate quantity 3 pcs Clutch plate warpage limit 0 05 mm 0 0020 in Clutch spring free length 31 7 mm 1 25 in Limit 30 1 mm 1 19 ...

Page 31: ... 2 AUS NZL Valve seat size 2 Starter jet 1 67 5 Starter jet 2 0 5 Throttle valve size 100 Float height 13 0 mm 0 51 in Fuel level above the float chamber mating sur face 4 0 5 0 mm 0 16 0 20 in Idling condition Engine idling speed 1550 1650 r min CO 3 5 4 5 Oil temperature 55 0 65 0 C 131 00 149 00 F Oil pump Oil pump type Trochoid Inner rotor to outer rotor tip clearance Less than 0 15 mm 0 0059 ...

Page 32: ... Minimum 234 0 mm 9 21 in Standard 230 0 mm 9 06 in Maximum 222 0 mm 8 74 in Rear axle Rear axle runout limit 1 5 mm 0 06 in Swingarm Swingarm end free play limit radial 1 0 mm 0 04 in Swingarm end free play limit axial 1 0 mm 0 04 in Front wheel Wheel type Panel wheel Rim size 10 5 0AT Rim material Steel Radial wheel runout limit 2 0 mm 0 08 in Lateral wheel runout limit 2 0 mm 0 08 in Rear wheel...

Page 33: ...n Brake disc deflection limit 0 15 mm 0 006 in Brake pad lining thickness inner 4 5 mm 0 18 in Limit 1 0 mm 0 04 in Brake pad lining thickness outer 4 5 mm 0 18 in Limit 1 0 mm 0 04 in Master cylinder inside diameter 12 7 mm 0 50 in Caliper cylinder inside diameter 33 96 mm 1 34 in Recommended fluid DOT 4 Lever and pedal Brake lever free play 0 mm 0 in Brake pedal height 6 9 mm 0 27 in Parking bra...

Page 34: ...andard output 14 0 V 8 2 A 5000 r min Stator coil resistance 0 64 0 96 Ω W W Rectifier regulator Regulator type Semi conductor short circuit No load regulated voltage 14 2 15 2 V Rectifier capacity 16 0 A Withstand voltage 200 0 V Battery Specific gravity 1 31 Electric starting system System type Constant mesh Starter motor Power output 0 40 kW Armature coil resistance 0 0171 0 0209 Ω Brush overal...

Page 35: ...ELECTRICAL SPECIFICATIONS 2 12 Carburetor warmer Resistance 5 6 8 4 Ω at 25 C 77 F Circuit breaker Circuit breaker type Fuse Fuse Fuse 15 0 A Reserve 15 0 A ...

Page 36: ...l To avoid warpage tighten multi fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specifications require clean dry threads Com ponents should be at room temperature A Distance between flats B Outside thread diameter A nut B bolt General tightening torques Nm m kgf ft lbf 10 mm 6 mm 6 0 6...

Page 37: ...gf 7 2 ft lbf Timing chain tensioner cap bolt M6 1 8 Nm 0 8 m kgf 5 8 ft lbf Timing chain tensioner bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Oil pump assembly screw M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Oil pump housing screw M5 1 5 Nm 0 5 m kgf 3 6 ft lbf Engine oil drain bolt M12 1 20 Nm 2 0 m kgf 14 ft lbf Intake manifold bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Carburetor joint clamp bolt intake manifold sid...

Page 38: ...ear holder screw M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Starter motor bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Starter clutch bolt M8 3 30 Nm 3 0 m kgf 22 ft lbf Stake Primary drive gear nut M12 1 70 Nm 7 0 m kgf 51 ft lbf Clutch spring bolt M5 4 6 Nm 0 6 m kgf 4 3 ft lbf Clutch boss nut M12 1 60 Nm 6 0 m kgf 43 ft lbf Short clutch push rod locknut M6 1 8 Nm 0 8 m kgf 5 8 ft lbf Bearing retainer screw M6 2 7 ...

Page 39: ...IP Front shock absorber assembly and frame nut M10 2 48 Nm 4 8 m kgf 35 ft lbf Front shock absorber assembly and front lower arm nut M10 2 48 Nm 4 8 m kgf 35 ft lbf Front upper arm and frame nut M10 2 45 Nm 4 5 m kgf 33 ft lbf Front lower arm and frame nut M10 4 45 Nm 4 5 m kgf 33 ft lbf Steering stem and frame nut M10 1 35 Nm 3 5 m kgf 25 ft lbf Steering stem bushing and frame bolt M8 2 23 Nm 2 3...

Page 40: ...f 4 3 ft lbf Front brake master cylinder and brake hose union bolt M10 1 27 Nm 2 7 m kgf 20 ft lbf Brake hose joint and frame bolt M6 1 10 Nm 1 0 m kgf 7 2 ft lbf Front brake hose holder and upper front arm bolt M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Bleed screw M8 3 6 Nm 0 6 m kgf 4 3 ft lbf Front brake pad retaining bolt M10 2 17 Nm 1 7 m kgf 12 ft lbf Front brake caliper and brake hose union bolt M10 2...

Page 41: ...or screw M5 6 6 Nm 0 6 m kgf 4 3 ft lbf Foot protector stay and frame bolt M8 2 17 Nm 1 7 m kgf 12 ft lbf Foot protector stay and footrest nut M8 4 17 Nm 1 7 m kgf 12 ft lbf Battery cover air filter case and frame bolt M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Air filter case and frame bolt M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Headlight and front fender stay bolt M5 2 1 3 Nm 0 13 m kgf 0 94 ft lbf Tail brake light...

Page 42: ...TIGHTENING TORQUES 2 19 ...

Page 43: ...accessing screw O ring Crankshaft end accessing screw O ring Engine oil filler cap O ring Starter clutch idle gear shaft inner surface Starter clutch gear inner surface and boss Starter clutch gear boss Starter motor O ring Clutch push lever Primary driven gear inner surface Short clutch push rod Long clutch push rod ends and ball Main axle and pinion gears Drive axle and wheel gears Shift drum Sh...

Page 44: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 21 EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART ...

Page 45: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 22 1 Oil pan 2 Oil strainer 3 Oil pump 4 Rotary filter 5 Cylinder head 6 Camshaft 7 Crankshaft 8 Drive axle 9 Main axle ...

Page 46: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 23 EAS20410 LUBRICATION DIAGRAMS ...

Page 47: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 24 1 Camshaft 2 Rotary filter 3 Oil pump 4 Oil strainer 5 Push lever shaft ...

Page 48: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 25 ...

Page 49: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 26 1 Camshaft 2 Rotary filter 3 Crankshaft 4 Main axle 5 Drive axle ...

Page 50: ...CABLE ROUTING 2 27 EAS20430 CABLE ROUTING Handlebar top view ...

Page 51: ...handlebar protec tor Pass the throttle cable behind the brake hose B Clamp the front brake light switch lead at the bends of handlebar C Pass the clutch cable and parking brake cable through the guide of the handlebar protector Pass the clutch cable in front of the parking brake cable D Clamp the clutch switch lead and handle bar switch lead at the bends of handlebar ...

Page 52: ...CABLE ROUTING 2 29 Frame right side view ...

Page 53: ... the air vent hose between the brack ets F Pass the throttle cable under the cross pipe and left of the steering column as shown in the illustration G Pass the parking brake cable and the clutch cable under the cross pipe and right of the steering column as shown in the illustration H The clamp position should be at the center between the engine mounting brackets I Pass the rear brake light switch...

Page 54: ...CABLE ROUTING 2 31 Rear brake right side view ...

Page 55: ...all the rear brake hose in the direction shown in the illustration D Insert the rear brake hose until it contacts the projection E Install the rear brake reservoir hose in the direction shown in the illustration F Install the rear brake reservoir hose mak ing sure to face the white paint mark out ward G Make sure that the end of the clip is facing outward H Insert the rear brake reservoir hose unt...

Page 56: ...CABLE ROUTING 2 33 Frame left side view ...

Page 57: ...stay 18 Frame 19 Damper plate A The target of the screw protrusion is 12 mm 0 47 in B Install the adjusting nut so that the spheri cal side faces to the front of the vehicle C Insert the bottom hole of the rectifier regu lator into the boss of the headlight stay D To the front fender E Pass the rectifier regulator lead outside of the vehicle F Pass the wire harness above the guide for the damper p...

Page 58: ...CABLE ROUTING 2 35 Rear frame left side view ...

Page 59: ...ront fender B Fix point for wire harness C Clamp near the hook of the air filter D Clamp near the edge of the air filter case E Pass the AC magneto lead through the guide of the drive sprocket cover F Clamp the starter motor lead at the center hole of the engine mounting bracket G Clamp the starter motor lead at the hole on the engine side of the engine mounting bracket H Pass the clamp through th...

Page 60: ...CABLE ROUTING 2 37 Front fender top view ...

Page 61: ...ss the headlight lead and main switch lead through the guide of the front fender It is allowable if the open wired lead is posi tioned on the guide or clamp D Pass the front brake light switch lead and throttle cable through the guide E Insert the air vent hose into the front fender F Pass the clutch switch lead handlebar switch lead parking brake cable and clutch cable through the guide of the fr...

Page 62: ...CABLE ROUTING 2 39 Frame top view ...

Page 63: ...tor warmer lead 12 Starter motor lead 13 Clutch switch lead 14 Handlebar switch lead 15 Rectifier regulator lead 16 Headlight stay 17 Band 18 CDI unit 19 Headlight relay 20 Starting circuit cut off relay 21 Wire harness 22 Frame 23 Clamp A To the front fender B To the front panel C To the handlebar D Route the air vent hose between the brack ets E Fix point for wire harness F Insert into the headl...

Page 64: ...CABLE ROUTING 2 41 Air filter case top view ...

Page 65: ...ht lead B Do not clamp C Set the insulator lock on the wire harness behind the fixed point D Pass the starter relay lead under the starter motor lead E After connecting the wire harness and each electric part the length between the air filter and AC magneto coupler should be 185 mm 7 28 in on straight line F ø20 G After connecting the battery negative lead push the sag in the box H Insert the star...

Page 66: ...CABLE ROUTING 2 43 ...

Page 67: ... HOSES 3 13 CHECKING THE REAR BRAKE HOSE 3 14 ADJUSTING THE PARKING BRAKE 3 14 CHECKING THE WHEELS 3 15 CHECKING THE TIRES 3 15 CHECKING THE WHEEL HUB BEARINGS 3 17 CHECKING AND LUBRICATING THE SWINGARM PIVOTS 3 17 LUBRICATING THE UPPER AND LOWER ARM PIVOTS 3 17 ADJUSTING THE DRIVE CHAIN SLACK 3 17 LUBRICATING THE DRIVE CHAIN 3 18 CHECKING THE DRIVE CHAIN ROLLERS 3 18 CHECKING THE CHASSIS FASTENER...

Page 68: ...REPLACING THE HEADLIGHT BULB 3 25 ADJUSTING THE HEADLIGHT BEAM 3 26 ...

Page 69: ......

Page 70: ...r keep in mind that if the ATV isn t used for a long period of time the month maintenance intervals should be followed Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools data and technical skills NO ITEM CHECK OR MAINTENANCE JOB Whichever comes first INITIAL EVERY month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 1...

Page 71: ... limit 5 Brake hoses Check for cracks or other damage and replace if neces sary Replace Every 4 years 6 Parking brake Check operation and adjust if necessary 7 Wheels Check runout and for damage and replace if necessary 8 Tires Check tread depth and for damage and replace if neces sary Check air pressure and balance and correct if necessary 9 Wheel hub bearings Check for looseness or damage and re...

Page 72: ...Replace the brake hoses every four years and if cracked or damaged 2 1 Throttle lever hous ing and cable Check operation and correct if necessary Check throttle cable free play and adjust if necessary Lubricate throttle lever housing and cable 2 2 Front and rear brake switches Check operation and correct if necessary 2 3 Lights and switches Check operation and correct if necessary Adjust headlight...

Page 73: ...nder 3 Check Spark plug type Incorrect Change 4 Check Electrode 1 Damage wear Replace the spark plug Insulator 2 Abnormal color Replace the spark plug Normal color is medium to light tan 5 Clean Spark plug with a spark plug cleaner or wire brush 6 Measure Spark plug gap a with a wire thickness gauge Out of specification Regap 7 Install Spark plug TIP Before installing the spark plug clean the spar...

Page 74: ...b When the piston is at TDC on the compres sion stroke align the mark a on the gen erator rotor with the stationary pointer b on the generator rotor cover c Align the mark c on the camshaft sprocket with the stationary pointer d on the cylin der head d Measure the valve clearance with a thick ness gauge 1 Out of specification Adjust 4 Adjust Valve clearance a Loosen the locknut 1 b Insert a thickn...

Page 75: ... operation Unsmooth operation Sticks Replace Refer to CHECKING THE CARBURE TOR on page 6 6 EAS20620 ADJUSTING THE ENGINE IDLING SPEED TIP Prior to adjusting the engine idling speed the carburetor should be adjusted properly the air filter element should be clean and the engine should have adequate compression 1 Start the engine and let it warm up for sev eral minutes 2 Attach Digital tachometer on...

Page 76: ...ks damage Replace Loose connection Connect properly ECA14920 Make sure the crankcase breather hose is routed correctly EAS21081 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the exhaust pipe and gaskets 1 Check Exhaust pipe 1 Muffler 2 Cracks damage Replace Gaskets 3 Exhaust gas leaks Replace 2 Check Tightening torque Carburetor angle driver 90890 03158 Standard pilot screw...

Page 77: ...t face hammer or suitable tool then use a wire brush to remove any carbon deposits from the spark arrester portion a of the tailpipe and the inner contact surfaces of the muf fler d Insert the tailpipe and gasket 3 into the muffler and align the bolt holes e Insert the bolts and tighten it EAS20941 CLEANING THE AIR FILTER ELEMENT TIP On the bottom of the air filter case is a check hose 1 If dust o...

Page 78: ...as gasoline to clean the air filter element Such solvents may cause a fire or an explo sion TIP After cleaning gently squeeze the air filter ele ment to remove the excess solvent ECA13430 Do not twist the air filter element when squeezing it 5 Check Air filter element Damage Replace 6 Apply the recommended oil to the entire surface of the air filter element and squeeze out the excess oil The air f...

Page 79: ...not working properly Check the brake system Refer to FRONT BRAKE on page 4 17 and REAR BRAKE on page 4 30 TIP Drive on the road operate the front and rear brakes separately and check to see if the brakes are operating properly EAS21170 ADJUSTING THE FRONT DISC BRAKE 1 Check Brake lever free play a Out of specification Bleed the front brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on pag...

Page 80: ...brake system a Fill the brake fluid reservoir to the proper level with the recommended brake fluid b Install the diaphragm brake master cylin der reservoir or brake fluid reservoir c Connect a clear plastic hose 1 tightly to the bleed screw 2 d Place the other end of the hose into a con tainer e Slowly apply the brake lever or brake pedal several times f Fully pull the brake lever or fully press d...

Page 81: ...ion leading to poor brake perfor mance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately TIP In order to ensure a correct reading of the brake fluid l...

Page 82: ... wheels to ensure there is no brake drag If any brake drag is noticed perform the above steps again 3 Adjust Rear brake light switch Refer to ADJUSTING THE REAR BRAKE LIGHT SWITCH on page 3 25 EAS21260 CHECKING THE REAR BRAKE PADS The following procedure applies to all of the brake pads 1 Operate the brake 2 Check Rear brake pad Wear indicators a almost touch the brake disc Replace the brake pads ...

Page 83: ...e fluid leakage Replace the dam aged hose Refer to REAR BRAKE on page 4 30 EAS29210 ADJUSTING THE PARKING BRAKE 1 Check Parking brake cable end length a Out of specification Adjust 2 Adjust Parking brake cable end length a Loosen the locknut 1 and adjusting bolt 2 b Slide back the rubber cover 3 c Loosen the locknut 4 d Turn the adjusting nut 5 in direction a or b until the specified brake cable e...

Page 84: ...NG THE TIRES WARNING EWA14940 This model is equipped with low pressure tires It is important that they be inflated correctly and maintained at the proper pressures Tire characteristics WARNING EWA14950 Tire characteristics influence the handling of vehicles The tires listed below have been approved by Yamaha Motor Co Ltd for this model If other tire combinations are used they can adversely affect ...

Page 85: ...ssure and use the second reading WARNING EWA14980 Uneven or improper tire pressure may adversely affect the handling of this vehicle and may cause loss of control Maintain proper tire pressures Set tire pressures when the tires are cold Tire pressures must be equal in both front tires and equal in both rear tires 2 Check Tire surfaces Wear damage Replace WARNING EWA13190 It is dangerous to ride wi...

Page 86: ... touching the ground 1 Check Drive chain slack a Out of specification Adjust 2 Adjust Drive chain slack TIP The drive chain slack is adjusted by the rota tion of the rear axle hub a Place the vehicle on a level surface b Loosen the rear axle pinch bolts 1 c Insert a rod of a diameter of 8 mm 0 31 in and length of 10 cm 4 in 2 in the hole 3 of rear axle hub 4 d Shift the transmission into the neutr...

Page 87: ...KING THE FRONT SHOCK ABSORBER ASSEMBLIES The following procedure applies to both of the front shock absorber assemblies 1 Place the vehicle on a level surface 2 Check Front shock absorber assembly Front shock absorber rod Spring Refer to CHECKING THE FRONT SHOCK ABSORBER ASSEMBLIES on page 4 51 3 Check Operation Pump the front shock absorber assembly up and down several times Unsmooth operation Re...

Page 88: ...3 Never attempt to turn the adjusting nut beyond the maximum or minimum setting a Elevate the rear wheels by placing a suit able stand under the frame b Loosen the locknut 1 c Turn the adjusting nut 2 in direction a or b TIP Be sure to remove all dirt and mud from around the locknut and adjusting nut before adjustment d Tighten the locknut TIP Always tighten the locknut against the adjust ing nut ...

Page 89: ...ds 4 Raise the front end of the vehicle so that there is no weight on the front wheels 5 Check Ball joints and wheel bearings Move the wheels laterally back and forth Excessive free play Replace the front arms upper and lower and or wheel bearings EAS29290 ADJUSTING THE TOE IN 1 Place the vehicle on a level surface 2 Measure Toe in Out of specification Adjust TIP Before measuring the toe in make s...

Page 90: ...e locknuts tie rod end 1 of both tie rods c The same number of turns should be given to both the right and left tie rods 2 until the specified toe in is obtained This is to keep the length of the rods the same d Tighten the rod end locknuts of both tie rods TIP Adjust the tie rod ends so that A and B are equal EAS2PA1311 CHECKING THE ENGINE MOUNT 1 Check Engine brackets Frame Cracks damage Replace...

Page 91: ...aterials to enter the crankcase 4 Check the engine oil level again EAS20801 CHANGING THE ENGINE OIL 1 Place the vehicle on a level surface 2 Remove Engine skid plate 3 Start the engine warm it up for several minutes and then turn it off 4 Place a container under the engine oil drain bolt 5 Remove Dipstick 1 along with the O ring Engine oil drain bolt 2 along with the gasket 6 Drain Engine oil comp...

Page 92: ...s to all of the inner and outer cables WARNING EWA13270 Damaged outer cable may cause the cable to corrode and interfere with its movement Replace damaged outer cable and inner cables as soon as possible 1 Check Outer cable Damage Replace 2 Check Cable operation Rough movement Lubricate or replace TIP Hold the cable end up and apply several drops of lubricant to the cable 3 Apply Lithium soap base...

Page 93: ...2 c Turn the adjusting bolt 3 in direction a or b until the specified throttle cable free play is obtained d Tighten the locknut e Slide the rubber cover to its original posi tion WARNING EWA12930 After adjusting the throttle cable free play start the engine and turn the handlebar to the right or left to ensure that this does not cause the engine idling speed to change EAS29170 ADJUSTING THE SPEED...

Page 94: ...erated by movement of the brake pedal The rear brake light switch is stepped on by 6 15 mm 0 24 0 59 in adjusted when the brake light comes on 1 Check Rear brake light operation timing Incorrect Adjust 2 Adjust Rear brake light operation timing a Hold the main body 1 of the rear brake light switch so that it does not rotate and turn the adjusting nut 2 in direction a or b until the rear brake ligh...

Page 95: ...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 5 Install Headlight bulb holder Headlight bulb holder cover 1 TIP Install the headlight bulb holder by pushing it in and turning it clockwise After installing the headlight bulb holder cover ...

Page 96: ...PERIODIC MAINTENANCE 3 27 ...

Page 97: ... 4 14 CHECKING THE REAR AXLE 4 14 CHECKING THE REAR AXLE HUB 4 15 CHECKING THE REAR WHEEL SPROCKET 4 15 CHECKING THE SPROCKET BRACKET 4 15 INSTALLING THE REAR WHEEL HUB BEARINGS 4 15 INSTALLING THE REAR WHEEL SPROCKET 4 15 INSTALLING THE REAR AXLE 4 15 FRONT BRAKE 4 17 INTRODUCTION 4 22 CHECKING THE FRONT BRAKE DISCS 4 22 REPLACING THE FRONT BRAKE PADS 4 23 REMOVING THE FRONT BRAKE CALIPERS 4 24 D...

Page 98: ...47 INSTALLING THE LOCK WASHER 4 47 TIE RODS AND STEERING KNUCKLES 4 48 REMOVING THE STEERING KNUCKLES 4 49 CHECKING THE TIE RODS 4 49 CHECKING THE STEERING KNUCKLES 4 49 INSTALLING THE TIE RODS 4 49 FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES 4 50 REMOVING THE FRONT ARMS 4 51 CHECKING THE FRONT ARMS 4 51 REMOVING THE FRONT SHOCK ABSORBER ASSEMBLY 4 51 CHECKING THE FRONT SHOCK ABSORBER ASSEMBLIE...

Page 99: ...DRIVE 4 58 REMOVING THE DRIVE CHAIN 4 59 CHECKING THE DRIVE CHAIN 4 59 CHECKING THE DRIVE SPROCKET 4 60 CHECKING THE REAR WHEEL SPROCKET 4 60 CHECKING THE SPROCKET BRACKET 4 60 INSTALLING THE DRIVE CHAIN 4 60 ...

Page 100: ...the rear of the seat 2 Front panel 1 3 Main switch coupler 1 Disconnect 4 Wire harness clamp 1 5 Fuel tank cap 1 6 Front side reflector 2 CAN 7 Front side reflector bracket 2 CAN 8 Front fender 1 9 Headlight connector 3 Disconnect 10 Headlight 1 11 Rectifier regulator 1 12 Headlight relay 1 13 Starting circuit cut off relay 1 14 CDI unit 1 For installation reverse the removal proce dure ...

Page 101: ...IS 4 2 Removing the foot protectors and engine skid plate Order Job Parts to remove Q ty Remarks 1 Left foot protector 1 2 Right foot protector 1 3 Engine skid plate 1 For installation reverse the removal proce dure ...

Page 102: ...L CHASSIS on page 4 1 1 Rear fender 1 2 Battery cover 1 3 Negative battery lead 1 4 Positive battery lead 1 5 Battery 1 6 Tail brake light lead 3 Disconnect 7 Crankcase breather hose 1 Disconnect 8 Clamp 1 Loosen 9 Air filter case cover 1 10 Air filter element 1 11 Air filter element frame 1 12 Tail brake light 1 13 Washer 2 USA AUS NZL ...

Page 103: ...ar fender and air filter case Order Job Parts to remove Q ty Remarks 14 License bracket 1 CAN 15 Rear reflector 1 CAN 16 Air filter case 1 17 Left side cover 1 18 Rear side reflector 2 CAN For installation reverse the removal proce dure ...

Page 104: ...h the bulb by pulling it out b Pull the panel downward and then remove the panel by pulling it as shown EAS2PA1402 INSTALLING THE FRONT PANEL 1 Install Front panel a Place the panel in its original position and then install the socket 1 together with the bulb by pushing it in ECA2PA1401 When installing the panel be sure not to pinch the cables or wires 2 Install Quick fasteners ...

Page 105: ...move Q ty Remarks The following procedure applies to both of the front wheels 1 Cotter pin 1 2 Axle nut 1 3 Front wheel 1 4 Brake disc guard outer 1 5 Brake caliper assembly 1 6 Wheel hub 1 7 Collar 1 8 Oil seal 2 9 Bearing 2 10 Spacer 1 11 Brake disc 1 For installation reverse the removal proce dure ...

Page 106: ...CKING THE TIRES on page 3 15 and CHECKING THE WHEELS on page 3 15 2 Measure Radial wheel runout 1 Lateral wheel runout 2 Over the specified limit Replace the wheel or check the wheel bearing play 3 3 Check Wheel balance Out of balance Adjust WARNING EWA15000 After replacing the tire ride conservatively to allow the tire to be properly seated in the rim Failure to do so may cause an accident result...

Page 107: ... race to drive in bearing ECA2PA1402 Do not strike the center race or balls of the bearing Contact should be made only with the outer race EAS29400 INSTALLING THE FRONT WHEEL HUB BEARINGS 1 Install Bearings 1 TIP Face the oil seal side of the bearing inward EAS29410 INSTALLING THE FRONT WHEEL HUBS The following procedure applies to both of the front hubs 1 Install Front wheel hub Washer Front axle...

Page 108: ...T WHEEL 4 9 EAS29420 INSTALLING THE FRONT WHEELS The following procedure applies to both of the front wheels 1 Install Brake disc guard outer 2 Install Front wheel Front wheel nut 45 Nm 4 5 m kgf 33 ft lbf ...

Page 109: ...EAR WHEEL 4 10 EAS22020 REAR WHEEL Removing the rear wheel Order Job Parts to remove Q ty Remarks 1 Rear wheel 2 2 Cotter pin 2 3 Axle nut 2 4 Wheel hub 2 For installation reverse the removal proce dure ...

Page 110: ...e specified limit Replace 3 Check Wheel balance Out of balance Adjust EAS29440 CHECKING THE REAR WHEEL HUBS The following procedure applies to both of the rear wheel hubs 1 Check Wheel hub 1 Cracks damage Replace Spline wheel hub 2 Wear damage Replace EAS29450 INSTALLING THE REAR WHEEL HUBS The following procedure applies to both of the rear wheel hubs 1 Install Rear wheel hub Washer Rear axle nut...

Page 111: ...page 4 10 1 Rear axle ring nut set bolt 2 2 Rear axle ring nut 1 3 Conical spring washer 1 4 Brake caliper 1 TIP Do not apply the brake pedal and do not use the parking brake when the brake caliper is off of the brake disc as the brake pads will be force shut 5 Brake disc brake disc bracket 1 1 6 Rear axle 1 7 Rear wheel sprocket sprocket bracket 1 1 8 Circlip 1 9 Brake caliper bracket 1 10 Collar...

Page 112: ... axle and rear axle hub Order Job Parts to remove Q ty Remarks 11 Rear axle pinch bolt 4 Loosen Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 17 12 Rear axle hub 1 13 Bearing oil seal 2 2 14 Spacer 1 For installation reverse the removal proce dure ...

Page 113: ...eels Wheel hubs Rear axle ring nut Conical spring washer 6 Remove Rear axle 1 with rear wheel sprocket ECA16180 Never directly tap the axle end with a hammer since this will result in damage to the axle thread and spline Attach a suitable socket on the axle end and tap it with a soft hammer then pull out the rear axle to the left EAS29500 CHECKING THE REAR AXLE 1 Check Rear axle runout a Out of sp...

Page 114: ...edged corner a of the rear wheel sprocket is facing outward EAS29530 INSTALLING THE REAR AXLE 1 Install Conical spring washer 1 Rear axle ring nut TIP Install the conical spring washer with the con vex side of the washer facing inward as shown 2 Tighten Rear axle ring nut 1 Rear axle ring nut set bolts 2 TIP Apply the brake pedal so that the rear axle does not turn when tightening the nut Use the ...

Page 115: ...REAR AXLE AND REAR AXLE HUB 4 16 ...

Page 116: ...Job Parts to remove Q ty Remarks The following procedure applies to both of the front brake calipers Front wheel Refer to FRONT WHEEL on page 4 6 1 Brake pad retaining bolt 2 2 Brake pad 2 3 Brake pad spring 1 4 Brake pad shim 1 For installation reverse the removal proce dure ...

Page 117: ...1 1 Front brake light switch connector 2 Disconnect 2 Brake fluid reservoir cap 1 3 Brake fluid reservoir diaphragm plate 1 4 Brake fluid reservoir diaphragm 1 5 Front brake light switch 1 6 Brake lever 1 7 Union bolt 1 8 Copper washer 2 9 Brake hose 1 Disconnect 10 Brake master cylinder bracket 1 11 Brake master cylinder 1 For installation reverse the removal proce dure ...

Page 118: ...T BRAKE 4 19 Disassembling the front brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 2 Brake master cylinder body 1 For assembly reverse the disassembly pro cedure ...

Page 119: ...rocedure applies to both of the front brake calipers Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 11 Front wheel Refer to FRONT WHEEL on page 4 6 1 Union bolt 1 2 Copper washer 2 3 Brake hose 1 Disconnect 4 Brake caliper assembly 1 For installation reverse the removal proce dure ...

Page 120: ...he front brake calipers 1 Brake pad retaining bolt 2 2 Brake pad 2 3 Brake pad spring 1 4 Brake pad shim 1 5 Dust plug 1 6 Slide pin bolt 1 7 Boot 1 8 Brake caliper bracket 1 9 Boot 1 10 Brake caliper piston 1 11 Brake caliper piston dust seal 1 12 Brake caliper piston seal 1 13 Bleed screw 1 For assembly reverse the disassembly pro cedure ...

Page 121: ...22240 CHECKING THE FRONT BRAKE DISCS The following procedure applies to both brake discs 1 Remove Front wheel Refer to REMOVING THE FRONT WHEELS on page 4 7 2 Check Brake disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc a Remove the brake disc with wheel hub b Hold the dial gauge at a right angle against th...

Page 122: ... the brake pad Brake pad spring TIP Always install new brake pads brake pad shim and brake pad spring as a set a Connect a clear plastic hose 1 tightly to the bleed screw 2 Put the other end of the hose into an open container b Loosen the bleed screw and push the brake caliper piston into the brake caliper with your finger c Tighten the bleed screw d Install the brake pads brake pad shim and brake...

Page 123: ...n Brake caliper piston dust seal 1 Brake caliper piston seal 2 a Blow compressed air into the brake hose joint opening a to force out the piston from the brake caliper WARNING EWA13550 Cover the brake caliper piston with a rag Be careful not to get injured when the pis ton is expelled from the brake caliper Never try to pry out the brake caliper pis ton b Remove the brake caliper piston dust seal ...

Page 124: ...ents should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake components as they will cause the brake caliper piston dust seal and brake caliper piston seal to swell and distort Whenever a brake caliper is disassem bled replace the brake caliper piston dust seal and brake caliper piston seal 1 Install Brake caliper piston seal 1 Brake caliper piston dust ...

Page 125: ...ling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 5 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 11 6 Check Brake fluid level Below...

Page 126: ...rake hose Cracks damage wear Replace EAS22520 ASSEMBLING THE FRONT BRAKE MAS TER CYLINDER WARNING EWA13520 Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake components EAS22530 INSTALLING THE FRONT BRAKE MASTER CYLINDER 1 Install Brake master cylinder 1 TIP Install the brake master cylinder holder ...

Page 127: ...nd poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake perfor mance When refilling be careful that water does not enter the brake master cylinder reser voir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock ECA13540 Brake fluid m...

Page 128: ...FRONT BRAKE 4 29 6 Check Brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 11 ...

Page 129: ... EAS22550 REAR BRAKE Removing the rear brake pads Order Job Parts to remove Q ty Remarks 1 Brake pad retaining bolt 2 2 Lock washer 1 3 Brake pad 2 4 Brake pad spring 1 For installation reverse the removal proce dure ...

Page 130: ...e 3 11 1 Brake fluid reservoir cover 1 2 Brake fluid reservoir cap 1 3 Brake fluid reservoir diaphragm holder 1 4 Brake fluid reservoir diaphragm 1 5 Brake fluid reservoir 1 6 Brake fluid reservoir hose 1 7 Union bolt 1 8 Copper washer 2 9 Brake hose 1 Disconnect 10 Brake master cylinder 1 11 Rear brake light switch 1 Disconnect 12 Right footrest 1 13 Brake pedal spring 1 1 For installation revers...

Page 131: ... 4 32 Disassembling the rear brake master cylinder Order Job Parts to remove Q ty Remarks 1 Pin 1 2 Joint 1 3 Brake master cylinder kit 1 4 Brake master cylinder 1 For assembly reverse the disassembly pro cedure ...

Page 132: ...o remove Q ty Remarks Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 11 1 Parking brake cable 1 Disconnect 2 Union bolt 1 3 Copper washer 2 4 Brake hose 1 Disconnect 5 Brake caliper assembly 1 For installation reverse the removal proce dure ...

Page 133: ...g bolt 1 4 Parking brake arm 1 5 Brake pad retaining bolt 2 6 Lock washer 1 7 Brake pad 2 8 Brake pad spring 1 9 Slide pin bolt 1 10 Brake caliper bracket 1 11 Boot 2 12 Boot 1 13 Brake caliper piston 1 14 Brake caliper piston dust seal 1 15 Brake caliper piston seal 1 16 Bleed screw 1 For assembly reverse the disassembly pro cedure ...

Page 134: ...t of specification Correct the brake disc deflection or replace the brake disc Refer to CHECKING THE FRONT BRAKE DISCS on page 4 22 4 Measure Brake disc thickness Measure the brake disc thickness at a few different locations Out of specification Replace Refer to CHECKING THE FRONT BRAKE DISCS on page 4 22 5 Adjust Brake disc deflection Refer to CHECKING THE FRONT BRAKE DISCS on page 4 22 6 Install...

Page 135: ...7 Check Brake pedal operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 11 EAS22590 REMOVING THE REAR BRAKE CALIPER TIP Before disassembling the brake caliper drain the brake fluid from the entire brake system 1 Remove Union bolt 1 Copper washers 2 Brake hose 3 Brake caliper bolts 4 TIP Put the end of the brake hose into a container and pu...

Page 136: ... Blow out with compressed air WARNING EWA13611 Whenever a brake caliper is disassembled replace the brake caliper piston dust seal and brake caliper piston seal 2 Check Brake caliper bracket 1 Cracks damage Replace the brake caliper assembly EAS22661 ASSEMBLING THE REAR BRAKE CALIPER WARNING EWA13621 Before installation all internal brake com ponents should be cleaned and lubricated with clean or ...

Page 137: ...safe vehicle operation Refer to CABLE ROUTING on page 2 27 ECA2PA1404 When installing the brake hose onto the brake caliper 1 make sure the brake pipe touches the projection a on the brake cal iper 2 Remove Brake caliper 3 Install Brake pads Brake pad spring Lock washer Brake pad retaining bolts Brake caliper Brake caliper bolts Refer to REPLACING THE REAR BRAKE PADS on page 4 35 Recommended fluid...

Page 138: ...rake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 11 6 Check Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 12 7 Check Brake pedal operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 11 EAS22700 REMOVING THE REAR BRAKE M...

Page 139: ...components 1 Install Brake master cylinder kit Nut 1 Joint 2 TIP Turn the adjusting bolt 3 until the clearance a is within the specified limits when install the joint 2 EAS22740 INSTALLING THE REAR BRAKE MASTER CYLINDER 1 Install Copper washers Brake hoses 1 Union bolt 2 WARNING EWA13530 Proper brake hose routing is essential to insure safe vehicle operation Refer to CABLE ROUTING on page 2 27 ECA...

Page 140: ...ling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 4 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 11 5 Check Brake fluid level Below...

Page 141: ...1 2 Band 3 3 Front brake light switch 1 4 Brake master cylinder bracket 1 1 5 Throttle lever assembly bracket 1 1 6 Spacer 1 7 Clutch switch 1 8 Parking brake lever 1 9 Clutch lever bracket 1 1 10 Handlebar switch 1 11 Handlebar grip 2 12 Handlebar holder 2 13 Handlebar 1 For installation reverse the removal proce dure ...

Page 142: ...k Handlebar 1 Bends cracks damage Replace WARNING EWA13690 Do not attempt to straighten a bent handle bar as this may dangerously weaken it EAS22911 INSTALLING THE HANDLEBAR 1 Install Handlebar Handlebar holders TIP Install the handlebar horizontally shown in the illustration The handlebar holder should be installed with the punched mark 1 forward 2 ECA2PA1403 First tighten the bolts 3 on the fron...

Page 143: ...nder TIP Engage the indentations a in the spacer with the lobes b on the throttle lever assem bly and brake master cylinder The UP mark on the brake master cylinder bracket should face up Install the brake lever 1 at 10 degrees angle as shown 5 Install Clutch switch Front brake light switch 6 Adjust Clutch cable free play Refer to ADJUSTING THE CLUTCH CABLE FREE PLAY on page 3 10 7 Adjust Throttle...

Page 144: ...HANDLEBAR 4 45 Throttle cable free play 2 0 4 0 mm 0 08 0 16 in ...

Page 145: ...teering stem Order Job Parts to remove Q ty Remarks Front fender Refer to GENERAL CHASSIS on page 4 1 1 Lock washer 1 2 Bracket 1 3 Steering stem bushing 2 4 Spacer 2 5 Oil seal 2 6 Steering stem 1 7 Bushing 2 For installation reverse the removal proce dure ...

Page 146: ... Wear damage Replace 3 Check O rings 1 Bushings 2 Wear damage Replace EAS2PA1405 INSTALLING THE STEERING STEM 1 Install Steering stem TIP Pass the throttle cable through the cable guide Refer to CABLE ROUTING on page 2 27 EAS29580 INSTALLING THE LOCK WASHER 1 Install Lock washer 1 Steering stem bushing bolts 2 Bend the lock washer tabs along a flat side of the bolts New New Steering stem bushing b...

Page 147: ... to remove Q ty Remarks The following procedure applies to both of the tie rods and steering knuckles Front wheel Refer to FRONT WHEEL on page 4 6 Front brake caliper Brake disc Refer to FRONT BRAKE on page 4 17 1 Brake disc guard inner 1 2 Tie rod 1 3 Front bumper 1 4 Steering knuckle 1 For installation reverse the removal proce dure ...

Page 148: ... free play and movement Free play Replace the tie rod end Turns roughly Replace the tie rod end 2 Check Tie rod Bends damage Replace EAS29690 CHECKING THE STEERING KNUCKLES The following procedure applies to both of the steering knuckles 1 Check Steering knuckle Damage pitting Replace EAS29700 INSTALLING THE TIE RODS The following procedure applies to both of the tie rods 1 Install Tie rod TIP Ins...

Page 149: ...of the front upper arms front lower arms and front shock absorber assemblies Front wheel Refer to FRONT WHEEL on page 4 6 Front brake caliper Brake disc Refer to FRONT BRAKE on page 4 17 Steering knuckle Refer to TIE RODS AND STEERING KNUCKLES on page 4 48 1 Front lower arm 1 2 Brake hose holder 1 3 Front upper arm 1 4 Front shock absorber assembly 1 5 Dust cover 6 6 Spacer 1 7 Spacer 2 8 Bushing ...

Page 150: ...AS2PA1406 REMOVING THE FRONT SHOCK ABSORBER ASSEMBLY 1 Place the vehicle on a level surface WARNING EWA2PA1402 Securely support the vehicle so that there is no danger of it falling over TIP Place the vehicle on a suitable stand so that the front wheel is elevated 2 Remove Front wheel Refer to FRONT WHEEL on page 4 6 Front shock absorber assembly lower bolt Front shock absorber assembly upper bolt ...

Page 151: ... 2 Front shock absorber assembly a Install the front upper arm 1 and front lower arm 2 TIP Be sure to position the front upper and lower arm bolts so that the bolt heads face forward Temporarily tighten the front upper and lower arm nuts b Install the front shock absorber assembly c Install the steering knuckle d Install the new cotter pins e Tighten the front upper and lower arm nuts to specifica...

Page 152: ...CK ABSORBER ASSEMBLY Removing the rear shock absorber assembly Order Job Parts to remove Q ty Remarks Seat Rear fender Air filter case Refer to GENERAL CHASSIS on page 4 1 1 Rear shock absorber assembly 1 For installation reverse the removal proce dure ...

Page 153: ...rear shock absorber at a point 15 20 mm 0 59 0 79 in from its end as shown WARNING EWA13760 Wear eye protection to prevent eye damage from released gas or metal chips EAS23210 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1 Place the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over TIP Place the vehicle on a suitable stand so that t...

Page 154: ...LE AND REAR AXLE HUB on page 4 12 Rear shock absorber assembly Refer to REAR SHOCK ABSORBER ASSEMBLY on page 4 53 1 Plate 1 2 Swingarm end cover 1 3 Pivot shaft nut washer 1 1 4 Pivot shaft 1 5 Swingarm 1 6 Drive chain guide 1 1 7 Dust cover oil seal 2 2 8 Spacer 1 9 Bearing 2 For installation reverse the removal proce dure ...

Page 155: ...rings d Measure the swingarm end free play radial B by moving the swingarm up and down e If swingarm vertical movement is not smooth or if there is binding check the spacers and bearings 3 Remove Pivot shaft nut Washer Pivot shaft Swingarm EAS23361 CHECKING THE SWINGARM 1 Check Swingarm Bends cracks damage Replace 2 Check Pivot shaft Roll the pivot shaft on a flat surface Bends Replace WARNING EWA...

Page 156: ...k absorber assembly Rear axle hub Rear axle Rear wheel Refer to REAR WHEEL on page 4 10 REAR SHOCK ABSORBER ASSEM BLY on page 4 53 and REAR AXLE AND REAR AXLE HUB on page 4 12 5 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 17 Recommended lubricant Lithium soap based grease Installed depth of bearing a 1 2 mm 0 04 0 08 in Pivot shaft nut 100 Nm 10 m kgf 72 ft lbf Driv...

Page 157: ... drive chain Order Job Parts to remove Q ty Remarks Swingarm Refer to SWINGARM on page 4 55 1 Drive sprocket cover 1 2 Drive chain guide 1 3 Drive sprocket lock plate 1 4 Drive sprocket 1 5 Drive chain 1 For installation reverse the removal proce dure ...

Page 158: ... inner sides length b between pin outer sides 2 TIP When measuring a 15 link section of the drive chain make sure that the drive chain is taut Perform this procedure 2 3 times at a differ ent location each time 2 Clean Drive chain a Wipe the drive chain with a clean cloth b Put the drive chain in kerosene and remove any remaining dirt c Remove the drive chain from the kerosene and completely dry i...

Page 159: ...30 CHECKING THE SPROCKET BRACKET Refer to CHECKING THE SPROCKET BRACKET on page 4 15 EAS23500 INSTALLING THE DRIVE CHAIN 1 Lubricate Drive chain 2 Install Drive chain Drive sprocket Drive sprocket lock plate Drive sprocket bolts TIP While applying the rear brake tighten the drive sprocket bolt 3 Install Swingarm Refer to SWINGARM on page 4 55 4 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE...

Page 160: ...0 A drive chain that is too tight will overload the engine and other vital parts and one that is too loose can skip and damage the swingarm or cause an accident Therefore keep the drive chain slack within the speci fied limits ...

Page 161: ... REMOVING THE VALVES 5 19 CHECKING THE VALVES AND VALVE GUIDES 5 19 CHECKING THE VALVE SEATS 5 21 CHECKING THE VALVE SPRINGS 5 23 INSTALLING THE VALVES 5 24 CYLINDER AND PISTON 5 26 REMOVING THE PISTON 5 27 CHECKING THE TIMING CHAIN GUIDE 5 27 CHECKING THE CYLINDER AND PISTON 5 27 CHECKING THE PISTON RINGS 5 28 CHECKING THE PISTON PIN 5 29 INSTALLING THE PISTON AND CYLINDER 5 30 CLUTCH 5 31 REMOVI...

Page 162: ...R 5 54 CHECKING THE STARTER MOTOR 5 56 ASSEMBLING THE STARTER MOTOR 5 57 CRANKCASE 5 58 DISASSEMBLING THE CRANKCASE 5 61 CHECKING THE CRANKCASE 5 61 CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDE 5 61 CHECKING THE BEARINGS 5 61 ASSEMBLING THE CRANKCASE 5 61 CRANKSHAFT ASSEMBLY 5 63 REMOVING THE CRANKSHAFT AND BALANCER 5 64 CHECKING THE CRANKSHAFT AND CONNECTING ROD 5 64 CHECKING THE BALANCER 5 6...

Page 163: ......

Page 164: ...he exhaust pipe and muffler Order Job Parts to remove Q ty Remarks 1 Muffler clamp 1 Loosen 2 Muffler 1 3 Muffler gasket 1 4 Spark arrester 1 5 Gasket 1 6 Exhaust pipe 1 7 EXhaust pipe protector 1 8 Gasket 1 For installation reverse the removal proce dure ...

Page 165: ...to CARBURETOR on page 6 3 Drive sprocket Refer to CHAIN DRIVE on page 4 58 1 Spark plug cap 1 Disconnect 2 Crankcase breather hose 1 Disconnect 3 Battery negative lead 1 Disconnect 4 Starter motor lead 1 Disconnect 5 Starter motor lead guard 1 6 Clutch cable 1 Disconnect 7 AC magneto coupler 2 Disconnect For assembly reverse the removal proce dure ...

Page 166: ... Q ty Remarks 1 Engine mounting bolt front 1 2 Engine bracket left and right 2 3 Engine mounting bolt upper 1 4 Engine bracket upper 1 5 Engine mounting bolt rear upper 1 6 Engine mounting bolt rear lower 1 7 Engine 1 For installation reverse the removal proce dure ...

Page 167: ...per side 4 Engine mounting nut front side 7 Engine bracket bolts front side EAS2PA1001 INSTALLING THE MUFFLER AND EXHAUST PIPE 1 Install Exhaust pipe protector 1 Exhaust pipe protector screws 2 to exhaust pipe 2 Install Gasket Exhaust pipe 1 Exhaust pipe bolts 2 Engine bracket bolt upper side 33 Nm 3 3 m kgf 24 ft lbf Engine mounting nut rear lower side 44 Nm 4 4 m kgf 32 ft lbf Engine mounting nu...

Page 168: ...fler clamp TIP Slide the clamp onto the end of the muffler and insert the projection a of the clamp into a slot b in the muffler Tighten the clamp after installing the muffler Installed depth of gasket a 3 5 mm 0 14 in Spark arrester bolt 11 Nm 1 1 m kgf 8 0 ft lbf Muffler clamp bolt 20 Nm 2 0 m kgf 14 ft lbf New New ...

Page 169: ...NGINE REMOVAL on page 5 1 Fuel tank Refer to FUEL TANK on page 6 1 Carburetor Refer to CARBURETOR on page 6 3 1 Engine bracket upper 1 2 Spark plug 1 3 Camshaft sprocket cover 1 4 Intake tappet cover 1 5 Exhaust tappet cover 1 6 Timing chain tensioner cap bolt 1 7 Timing chain tensioner assembly 1 8 Timing chain tensioner gasket 1 9 Camshaft sprocket 1 10 Cylinder head 1 ...

Page 170: ...7 Yamaha bond No 1215 Three bond No 1215 Removing the cylinder head Order Job Parts to remove Q ty Remarks 11 Plate 1 12 Gasket 1 13 Cylinder head gasket 1 14 Dowel pin 2 For installation reverse the removal proce dure ...

Page 171: ... Loosen Timing chain tensioner cap bolt 4 Remove Timing chain tensioner along with the gasket Camshaft sprocket Timing chain TIP To prevent the timing chain from falling into the crankcase fasten it with a wire 5 Remove Cylinder head TIP Loosen the bolts in the proper sequence as shown Loosen each nut 1 2 of a turn at a time After all of the bolts are fully loosened remove them EAS24160 CHECKING T...

Page 172: ...CHECKING THE CAMSHAFT SPROCKET 1 Check Camshaft sprocket More than 1 4 tooth wear a Replace the camshaft sprocket and the timing chain as a set EAS24200 CHECKING THE TIMING CHAIN TEN SIONER 1 Check Timing chain tensioner Cracks damage rough movement Replace 2 Check One way cam operation Rough movement Replace the timing chain tensioner assembly a Lightly press the timing chain tensioner rod into t...

Page 173: ... cylinder head bolts in the proper tightening sequence as shown and torque them in two stages 4 Fill Cylinder head Engine oil 5 ml or more into the space a TIP Be sure to add engine oil every time the cylin der head is removed 5 Install Camshaft sprocket 1 Timing chain 2 a Turn the crankshaft counterclockwise b Align the I mark a on the generator rotor with the stationary pointer b on the gener at...

Page 174: ...in screwdriver 1 TIP Make sure that the tensioner rod has been fully set clockwise b Install the gasket and the timing chain ten sioner 2 onto the cylinder WARNING EWA2PA1501 Always use a new gasket c Turn the timing chain tensioner rod coun terclockwise with a thin screwdriver 1 make sure it releases and then tighten the cap bolt to specification 7 Turn Crankshaft several turns counterclockwise 8...

Page 175: ...ing the engine 10 Measure Valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEARANCE on page 3 4 11 Install Gasket Plate 1 TIP Make sure the projection a of the gasket face toward the upper side of the vehicle Make sure that the blunt edged corner b of the plate is facing upward Camshaft sprocket bolt 26 Nm 2 6 m kgf 19 ft lbf Plate bolt 10 Nm 1 0 m kgf 7 2 ft lbf New ...

Page 176: ...page 5 6 1 Locknut valve clearance adjusting screw 2 2 Loosen 2 Camshaft retainer 1 3 Camshaft 1 4 Camshaft bushing 1 5 Camshaft bearing 2 6 Intake rocker arm shaft 1 7 Intake rocker arm 1 8 Exhaust rocker arm shaft 1 9 Exhaust rocker arm 1 For installation reverse the removal proce dure New LT E E E E E 1 1 1 1 2 8 6 9 7 3 5 5 T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf 10 Nm 1 0 ...

Page 177: ...er arm shaft Intake rocker arm Exhaust rocker arm shaft Exhaust rocker arm TIP Remove the rocker arm shafts with the slide hammer bolt 1 and weight 2 EAS23840 CHECKING THE CAMSHAFT 1 Check Camshaft bushings Damage wear Replace 2 Check Camshaft lobes Blue discoloration pitting scratches Replace the camshaft 3 Measure Camshaft lobe dimensions a and b Out of specification Replace the cam shaft Slide ...

Page 178: ...or check the lubri cation system 3 Check Camshaft lobe Excessive wear Replace the camshaft 4 Measure Rocker arm inside diameter a Out of specification Replace Camshaft lobe dimensions Intake A 25 881 25 981 mm 1 0189 1 0229 in Limit 25 851 mm 1 0178 in Intake B 21 194 21 294 mm 0 8344 0 8383 in Limit 21 165 mm 0 8333 in Exhaust A 25 841 25 941 mm 1 0174 1 0213 in Limit 25 811 mm 1 0162 in Exhaust ...

Page 179: ... 3 Intake rocker arm shaft 4 ECA2PA1502 Install the rocker arm shafts so that the threaded side faces outward TIP Use a slide hammer bolt 5 to install the rocker arm shaft 3 Lubricate Camshaft Camshaft bearings Rocker arm shaft outside diam eter 9 981 9 991 mm 0 3930 0 3933 in Limit 9 950 mm 0 3917 in Rocker arm to rocker arm shaft clearance 0 009 0 034 mm 0 0004 0 0013 in Limit 0 08 mm 0 0031 in ...

Page 180: ... 17 4 Install Camshaft 1 TIP Screw 8 mm 0 31 in bolt 2 into the threaded end of the camshaft and then install the cam shaft 5 Install Camshaft retainer 1 Camshaft retainer bolt 10 Nm 1 0 m kgf 7 2 ft lbf LOCTITE ...

Page 181: ... remove Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 5 6 Rocker arm camshaft Refer to CAMSHAFT on page 5 13 1 Valve cotter 4 2 Valve spring retainer 2 3 Valve spring 2 4 Intake valve 1 5 Exhaust valve 1 6 Valve stem seal 2 7 Valve spring seat 2 8 Valve guide 2 For installation reverse the removal proce dure ...

Page 182: ...cotters 1 TIP Remove the valve cotters by compressing the valve spring with the valve spring compressor and valve spring compressor attachment 2 3 Remove Valve spring retainer 1 Valve spring 2 Valve 3 Valve stem seal 4 Valve spring seat 5 TIP Identify the position of each part very carefully so that it can be reinstalled in its original place EAS24290 CHECKING THE VALVES AND VALVE GUIDES The follo...

Page 183: ...guide installer 2 and valve guide remover 1 c After installing the valve guide bore the valve guide with the valve guide reamer 3 to obtain the proper valve stem to valve guide clearance TIP After replacing the valve guide reface the valve seat Valve stem to valve guide clear ance Valve stem to valve guide clear ance intake 0 010 0 037 mm 0 0004 0 0015 in Limit 0 080 mm 0 0032 in Valve stem to val...

Page 184: ...es to all of the valves and valve seats 1 Eliminate Carbon deposits from the valve face and valve seat 2 Check Valve seat Pitting wear Replace the cylinder head 3 Measure Valve seat width a Out of specification Replace the cylin der head Valve guide remover ø5 90890 04097 Valve guide remover 5 0 mm YM 04097 Valve guide installer ø5 90890 04098 Valve guide installer 5 0 mm YM 04098 Valve guide ream...

Page 185: ... a to the valve face ECA13790 Do not let the lapping compound enter the gap between the valve stem and the valve guide b Apply engine oil onto the valve stem c Install the valve into the cylinder head d Turn the valve until the valve face and valve seat are evenly polished then clean off all of the lapping compound TIP For the best lapping results lightly tap the valve seat while rotating the valv...

Page 186: ...Compressed valve spring force a Out of specification Replace the valve spring 3 Measure Valve spring tilt a Out of specification Replace the valve spring Valve spring free length Free length intake 47 06 mm 1 85 in Limit 44 71 mm 1 76 in Free length exhaust 47 06 mm 1 85 in Limit 44 71 mm 1 76 in Installed compression spring force intake 160 00 184 00 N 16 32 18 76 kgf 35 97 41 36 lbf Installed co...

Page 187: ...alve spring retainer 5 into the cylinder head TIP Install the valve springs with the larger pitch a facing up Install the valve spring with its painted end facing up 4 Install Valve cotters 1 TIP Install the valve cotters by compressing the valve spring with the valve spring compressor and the valve spring compressor attachment 2 Recommended lubricant Engine oil New b Smaller pitch Valve spring co...

Page 188: ...ALVES AND VALVE SPRINGS 5 25 5 To secure the valve cotters onto the valve stem lightly tap the valve tip with a soft face hammer ECA13800 Hitting the valve tip with excessive force could damage the valve ...

Page 189: ...b Parts to remove Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 5 6 1 Timing chain guide exhaust side 1 2 Cylinder 1 3 Cylinder gasket 1 4 Dowel pin 2 5 Piston pin clip 2 6 Piston pin 1 7 Piston 1 8 Top ring 1 9 2nd ring 1 10 Oil ring 1 For installation reverse the removal proce dure ...

Page 190: ...ing open the end gap with your fingers and lift the other side of the ring over the piston crown EAS2PA1503 CHECKING THE TIMING CHAIN GUIDE 1 Check Timing chain guide exhaust side Damage wear Replace EAS24400 CHECKING THE CYLINDER AND PISTON 1 Check Piston wall Cylinder wall Vertical scratches Rebore or replace the cylinder and replace the piston and piston rings as a set 2 Measure Piston to cylin...

Page 191: ...measuring the piston ring side clear ance eliminate any carbon deposits from the piston ring grooves and piston rings 2 Install Piston rings into the cylinder TIP Level the piston ring into the cylinder with the piston crown 3 Measure Piston ring end gap Out of specification Replace the piston ring a 40 mm 1 57 in from the top of the cylinder Piston Diameter D 53 997 54 029 mm 2 1259 2 1271 in a 4...

Page 192: ...pin bore clearance Out of specification Replace the piston pin and piston as a set Piston ring Top ring End gap installed 0 15 0 30 mm 0 006 0 012 in Limit 0 40 mm 0 0157 in 2nd ring End gap installed 0 30 0 45 mm 0 012 0 018 in Limit 0 55 mm 0 0217 in Oil ring End gap installed 0 20 0 70 mm 0 008 0 028 in a 40 mm 1 57 in Piston pin outside diameter 14 991 15 000 mm 0 5902 0 5906 in Limit 14 971 m...

Page 193: ...ver the crankcase opening with a clean rag to pre vent the clip from falling into the crankcase 3 Install O ring Dowel pins Cylinder gasket 4 Lubricate Piston Piston rings Cylinder with the recommended lubricant 5 Offset Piston ring end gaps 6 Install O ring to the cylinder Cylinder 1 TIP While compressing the piston rings with one hand install the cylinder with the other hand Pass the timing chai...

Page 194: ...remove Q ty Remarks Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 22 Starter motor Refer to ELECTRIC STARTER on page 5 54 1 Battery negative lead 1 Disconnect 2 Clutch cover 1 3 Clutch cover gasket 1 4 Dowel pin 2 For installation reverse the removal proce dure ...

Page 195: ... ty Remarks 1 Clutch spring 4 2 Pressure plate 1 3 Locknut Washer 1 1 4 Short clutch push rod 1 5 Clutch push rod holder 1 6 Ball 1 7 Friction plate 4 8 Clutch plate 3 9 Primary drive gear nut 1 10 Washer 1 11 Clutch boss nut 1 12 Lock washer 1 13 Clutch boss 1 ...

Page 196: ... 33 Removing the clutch Order Job Parts to remove Q ty Remarks 14 Thrust washer 1 15 Clutch housing 1 16 Plate washer 1 17 Primary drive gear 1 18 Straight key 1 For installation reverse the removal proce dure ...

Page 197: ...rts to remove Q ty Remarks Clutch cable Refer to ENGINE REMOVAL on page 5 1 Short clutch push rod Refer to CLUTCH on page 5 31 1 Clutch push lever 1 2 Clutch push lever spring 1 3 Circlip 1 4 Oil seal 1 For installation reverse the removal proce dure ...

Page 198: ...the uni versal clutch holder 3 loosen the clutch boss nut EAS25100 CHECKING THE FRICTION PLATES The following procedure applies to all of the friction plates 1 Check Friction plate Damage wear Replace the friction plates as a set 2 Measure Friction plate thickness Out of specification Replace the fric tion plates as a set TIP Measure the friction plate at four places EAS25111 CHECKING THE CLUTCH P...

Page 199: ... THE CLUTCH HOUSING 1 Check Clutch housing dogs Damage pitting wear Deburr the clutch housing dogs or replace the clutch hous ing TIP Pitting on the clutch housing dogs will cause erratic clutch operation EAS25160 CHECKING THE CLUTCH BOSS 1 Check Clutch boss splines Damage pitting wear Replace the clutch boss TIP Pitting on the clutch boss splines will cause erratic clutch operation EAS25170 CHECK...

Page 200: ...o primary driven gear free play Free play exists Replace the primary drive and primary driven gears as a set EAS25260 INSTALLING THE CLUTCH 1 Install Clutch push lever spring 1 Clutch push lever 2 TIP Install the clutch push lever spring as shown 2 Install Straight key Primary drive gear 1 Washer Primary drive gear nut temporarily tighten TIP Install the primary drive gear with its cham fered side...

Page 201: ... crisscross pattern 10 Adjust Clutch mechanism free play a Check that projection a on the clutch push lever 1 aligns with concave b on the crankcase by pushing the clutch push lever manually in direction c until it stops b If projection a is not aligned with concave b align them as follows Loosen the locknut 2 With the clutch push lever fully pushed in direction c turn the short clutch push rod 3 ...

Page 202: ...end of the bat tery negative lead terminal and the contour of the clutch cover should be 3 mm 0 12 in or less The angle of battery negative lead bend b to inside should be 30 degrees angle or less The lead should not be bent outward 13 Adjust Clutch cable free play Refer to ADJUSTING THE CLUTCH CABLE FREE PLAY on page 3 10 Short clutch push rod locknut 8 Nm 0 8 m kgf 5 8 ft lbf Clutch cover bolt 1...

Page 203: ...b Parts to remove Q ty Remarks Clutch housing Primary drive gear Refer to CLUTCH on page 5 31 1 Rotary filter 1 2 Oil pump drive gear 1 3 Oil pump assembly oil pump driven gear 1 4 Oil pump gasket 1 5 Oil strainer 1 For installation reverse the removal proce dure ...

Page 204: ...arts to remove Q ty Remarks 1 Circlip 1 2 Washer 1 3 Conical spring washer 1 4 Oil pump driven gear 1 5 Pin 1 6 Washer 1 7 Oil pump housing cover 1 8 Pin 1 9 Oil pump shaft 1 10 Oil pump inner rotor 1 11 Oil pump outer rotor 1 12 Oil pump housing 1 13 Dowel pin 2 For assembly reverse the disassembly pro cedure ...

Page 205: ... and 2 or replace the oil pump assembly EAS29010 CHECKING THE ROTARY FILTER 1 Check Rotary filter Cracks damage wear Replace Contaminants Clean with engine oil EAS25000 ASSEMBLING THE OIL PUMP 1 Lubricate Oil pump inner rotor Oil pump outer rotor Oil pump shaft with the recommended lubricant Inner rotor to outer rotor tip clearance Less than 0 15 mm 0 0059 in Limit 0 23 mm 0 0091 in Outer rotor to...

Page 206: ...mp driven gear Install the spring washer as shown in the illustration 4 Check Oil pump operation Refer to CHECKING THE OIL PUMP on page 5 42 EAS25030 INSTALLING THE OIL PUMP 1 Install Oil pump gasket 1 Oil pump assembly ECA27S1019 After tightening the screws make sure the oil pump turns smoothly TIP Install the oil pump gasket as shown in the illustration 2 Install Rotary filter 1 TIP Align the pr...

Page 207: ...OIL PUMP 5 44 ...

Page 208: ...s Right footrest Refer to REAR BRAKE on page 4 30 Clutch assembly Refer to CLUTCH on page 5 31 1 Shift pedal 1 2 Shift shaft 1 3 Circlip 1 4 Shift shaft spring 1 5 Shift shaft spring stopper 1 6 Stopper lever 1 7 Stopper lever spring 1 8 Shift drum segment 1 9 Dowel pin 2 For installation reverse the removal proce dure ...

Page 209: ...hift drum segment Damage wear Replace the shift drum segment EAS25451 INSTALLING THE SHIFT SHAFT 1 Install Stopper lever 1 Stopper lever spring 2 TIP Hook the ends of the stopper lever spring onto the stopper lever and the crankcase boss 3 Install the stopper lever spring as shown in the illustration Mesh the stopper lever with the shift drum segment assembly 2 Install Shift shaft spring stopper 1...

Page 210: ...Shift pedal 1 TIP Lubricate the oil seal lips with lithium soap based grease Install the shift pedal as shown in the illustra tion For the installation heights of the shift pedal height b from the center of the shift pedal to footrest top face a should be 20 7 mm 0 81 in Shift pedal bolt 10 Nm 1 0 m kgf 7 2 ft lbf New ...

Page 211: ...ks Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 22 Left side cover Refer to GENERAL CHASSIS on page 4 1 Drive sprocket cover Refer to CHAIN DRIVE on page 4 58 1 AC magneto coupler pickup coil coupler 1 1 Disconnect 2 Neutral switch lead 1 Disconnect 3 Generator rotor cover 1 4 Timing mark accessing screw 1 5 Crankshaft end accessing screw 1 6 Generator rotor cover gasket 1 7 Dowel p...

Page 212: ...embly Removing the generator and starter clutch Order Job Parts to remove Q ty Remarks 11 Generator rotor 1 12 Starter clutch assembly 1 13 Starter clutch gear 1 14 Washer 1 15 Woodruff key 1 16 Starter clutch idle gear holder 1 17 Starter clutch idle gear 1 18 Starter clutch idle gear shaft 1 For installation reverse the removal proce dure ...

Page 213: ...kshaft place an appropriate sized socket between the flywheel puller set s center bolt and the crankshaft TIP Remove the generator rotor using flywheel puller 2 Make sure the flywheel puller is centered over the generator rotor 4 Remove Starter clutch idle gear holder Starter clutch idle gear Starter clutch idle gear shaft EAS2PA1506 REMOVING THE STARTER CLUTCH 1 Remove Starter clutch TIP While ho...

Page 214: ...generator rotor 2 b When turning the starter clutch gear clock wise A the starter clutch and the starter clutch gear should engage otherwise the starter clutch is faulty and must be replaced c When turning the starter clutch gear coun terclockwise B it should turn freely other wise the starter clutch is faulty and must be replaced 5 Check Starter clutch idle gear shaft Damage fatigue wear Replace ...

Page 215: ...ghten Generator rotor nut 1 TIP Tighten the generator rotor nut 1 while holding the generator rotor 2 with sheave holder 3 Do not allow the sheave holder to touch the projection the generator rotor 4 Apply Sealant onto the stator coil lead grommet 1 TIP Install the grommet within 30 minutes after application of sealant Wipe off any excess sealant Starter clutch idle gear shaft press fit height a 1...

Page 216: ...equence as shown 7 Install Neutral switch lead 1 TIP Route the neutral switch lead as shown in the illustration and then apply sealant Three bond 7738 to affix the lead to the generator rotor cover at the locations a Stator coil bolt 10 Nm 1 0 m kgf 7 2 ft lbf LOCTITE Stator coil lead holder screw 7 Nm 0 7 m kgf 5 1 ft lbf Pickup coil bolt 10 Nm 1 0 m kgf 7 2 ft lbf LOCTITE Generator rotor cover b...

Page 217: ...IC STARTER 5 54 EAS24780 ELECTRIC STARTER Removing the starter motor Order Job Parts to remove Q ty Remarks 1 Starter motor lead 1 Disconnect 2 Starter motor 1 For installation reverse the removal proce dure ...

Page 218: ...sembly Disassembling the starter motor Order Job Parts to remove Q ty Remarks 1 Starter motor front cover 1 2 Lock washer 1 3 Shim 1 4 Circlip 1 5 Starter motor rear cover 1 6 Brush set 1 7 Armature assembly 1 8 Starter motor yoke 1 For assembly reverse the disassembly pro cedure ...

Page 219: ...or 4 Measure Armature assembly resistances commu tator and insulation Out of specification Replace the starter motor a Measure the armature assembly resis tances with the digital circuit tester b If any resistance is out of specification replace the starter motor 5 Measure Brush length a Out of specification Replace the brushes as a set Limit 21 0 mm 0 83 in Mica undercut depth 1 50 mm 0 06 in Dig...

Page 220: ...er motor EAS24800 ASSEMBLING THE STARTER MOTOR 1 Install Lock washer 1 TIP Align the tabs a on the lock washer with the slots b in the starter motor front cover 2 Install Starter motor yoke 1 Starter motor front cover 2 Starter motor rear cover 3 TIP Align the match marks a on the starter motor yoke with the match marks b on the starter motor front and rear covers Brush spring force 5 52 8 28 N 56...

Page 221: ...NDER AND PISTON on page 5 26 Generator rotor Starter clutch idle gear Refer to GENERATOR AND STARTER CLUTCH on page 5 48 Starter motor Refer to ELECTRIC STARTER on page 5 54 Clutch Primary drive gear Refer to CLUTCH on page 5 31 Oil pump Refer to OIL PUMP on page 5 40 Shift shaft Shift drum segment Refer to SHIFT SHAFT on page 5 45 1 Timing chain guide intake side 1 2 Timing chain 1 3 Neutral swit...

Page 222: ...nd No 1215 Three bond No 1215 Separating the crankcase Order Job Parts to remove Q ty Remarks 5 Right crankcase 1 6 Left crankcase 1 7 Dowel pin 2 For installation reverse the removal proce dure 10 Nm 1 0 m kgf 7 2 ft Ibf T R ...

Page 223: ...er Job Parts to remove Q ty Remarks Crankshaft Balancer shaft Refer to CRANKSHAFT ASSEMBLY on page 5 63 Transmission Refer to TRANSMISSION on page 5 66 1 Oil seal 1 2 Bearing retainer 1 3 Bearing 7 For installation reverse the removal proce dure ...

Page 224: ...bstruction Blow out with compressed air EAS2PA1511 CHECKING THE TIMING CHAIN AND TIM ING CHAIN GUIDE 1 Check Timing chain Damage stiffness Replace the timing chain and camshaft sprocket as a set 2 Check Timing chain guide intake side Damage wear Replace EAS2PA1512 CHECKING THE BEARINGS 1 Check Bearings Clean and lubricate the bearings then rotate the inner race with your finger Rough movement Repl...

Page 225: ...in stages and in the proper sequence as shown M6 45 mm bolts 1 4 7 9 11 13 M6 30 mm bolts 5 6 M6 55 mm bolts 10 7 Apply Engine oil onto the connecting rod big end bearing and crankshaft bearings 8 Check Crankshaft and transmission operation Rough movement Repair Yamaha bond No 1215 Three bond No 1215 90890 85505 Crankcase bolt 10 Nm 1 0 m kgf 7 2 ft lbf A Left crankcase B Right crankcase ...

Page 226: ...S25970 CRANKSHAFT ASSEMBLY Removing the crankshaft and balancer Order Job Parts to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 58 1 Balancer 1 2 Crankshaft 1 For installation reverse the removal proce dure ...

Page 227: ...eplace the crank shaft bearing or both TIP Turn the crankshaft slowly 2 Measure Big end side clearance Out of specification Replace the big end bearing crankshaft pin or connect ing rod 3 Measure Crankshaft width Out of specification Replace the crank shaft 4 Check Crankshaft sprocket Damage wear Replace the crankshaft Bearing Cracks damage wear Replace the crankshaft 5 Check Crankshaft journal Sc...

Page 228: ... the oil seal lips with lithium soap based grease and each bearing with engine oil TIP Hold the connecting rod at top dead center TDC with one hand while turning the nut of the crankshaft installer bolt with the other Turn the crankshaft installer bolt until the crankshaft assembly bottoms against the bearing EAS26220 INSTALLING THE BALANCER 1 Install Balancer 1 TIP Align the punch mark a on the b...

Page 229: ...ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 58 1 Long shift fork guide bar 1 2 Short shift fork guide bar 1 3 Shift fork R 1 4 Shift fork L 1 5 Shift fork C 1 6 Shift drum 1 7 Main axle assembly 1 8 Long clutch push rod 1 9 Collar 1 10 Drive axle assembly 1 11 Washer 1 For installation reverse the removal proce dure ...

Page 230: ...the main axle Order Job Parts to remove Q ty Remarks 1 5th pinion gear 1 2 2nd pinion gear 1 3 3rd pinion gear 1 4 Circlip 1 5 Washer 1 6 4th pinion gear 1 7 Main axle 1st pinion gear 1 For assembly reverse the disassembly pro cedure ...

Page 231: ...le Order Job Parts to remove Q ty Remarks 1 5th wheel gear 1 2 2nd wheel gear 1 3 Circlip 1 4 Washer 1 5 1st wheel gear 1 6 4th wheel gear 1 7 Circlip 1 8 Washer 1 9 3rd wheel gear 1 10 Drive axle 1 For assembly reverse the disassembly pro cedure ...

Page 232: ...ck Shift fork guide bar Roll the shift fork guide bar on a flat sur face Bends Replace WARNING EWA12840 Do not attempt to straighten a bent shift fork guide bar 3 Check Shift fork movement along the shift fork guide bar Rough movement Replace the shift forks and shift fork guide bar as a set EAS26270 CHECKING THE SHIFT DRUM 1 Check Shift drum groove Damage scratches wear Replace the shift drum ass...

Page 233: ... s EAS27S1023 CHECKING THE LONG CLUTCH PUSH ROD 1 Check Long clutch push rod Cracks damage wear Replace the long clutch push rod 2 Measure Long clutch push rod bending limit Out of specification Replace the long clutch push rod EAS29020 ASSEMBLING THE MAIN AXLE AND DRIVE AXEL 1 Install Washer 1 Circlip 2 TIP Be sure the circlip sharp edged corner a is positioned opposite side to the washer and gea...

Page 234: ...ar 6 Long shift fork guide bar 7 TIP The embossed marks on the shift forks should face towards the right side of the engine and be in the following sequence R C L 2 Check Transmission Rough movement Repair TIP Apply engine oil to each gear shaft and bearing thoroughly Before assembling the crankcase make sure that the transmission is in neutral and that the gears turn freely ...

Page 235: ... FUEL TANK 6 2 CHECKING THE FUEL COCK 6 2 CARBURETOR 6 3 CHECKING THE CARBURETOR 6 6 CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD 6 7 ASSEMBLING THE CARBURETOR 6 8 INSTALLING THE CARBURETOR 6 9 MEASURING AND ADJUSTING THE FUEL LEVEL 6 9 ...

Page 236: ... remove Q ty Remarks Seat Refer to GENERAL CHASSIS on page 4 1 Front fender Refer to GENERAL CHASSIS on page 4 1 1 Fuel hose fuel cock side 1 Disconnect 2 Fuel tank 1 3 Fuel cock 1 4 Drain hose 1 Disconnect 5 Fuel tank shield 1 For installation reverse the removal proce dure ...

Page 237: ...from the fuel tank be careful when removing the fuel hoses since there may be fuel remain ing in it TIP Before removing the hoses place a few rags in the area under where it will be removed 3 Remove Fuel tank EAS26650 CHECKING THE FUEL COCK 1 Check Fuel cock Cracks damage wear Replace 2 Check Fuel cock strainer 1 Obstruction clean Blow out the jets with compressed air Damage Replace the fuel cock ...

Page 238: ...1 Rear fender Refer to GENERAL CHASSIS on page 4 1 Air filter case Refer to GENERAL CHASSIS on page 4 1 1 Carburetor warmer coupler 1 Disconnect 2 Air vent hose 1 Disconnect 3 Fuel hose carburetor side 1 Disconnect 4 Throttle cable cover 1 5 Throttle cable 1 Disconnect 6 Clamp 2 Loosen 7 Carburetor 1 8 Carburetor joint 1 9 Intake manifold 1 For installation reverse the removal proce dure ...

Page 239: ... Piston valve 1 6 Ring 1 7 Piston valve diaphragm 1 8 Jet needle set 1 9 Diaphragm cover 1 10 Diaphragm spring 1 11 Coasting enricher diaphragm 1 12 Coasting enricher jet P A J 2 1 13 Starter plunger set 1 14 Carburetor warmer positive lead 1 15 Carburetor warmer 1 16 Carburetor warmer negative lead 1 17 Float chamber 1 18 Float pin 1 19 Float 1 20 Needle valve set 1 ...

Page 240: ...2 Needle jet holder 1 23 Needle jet 1 24 Pilot jet 1 25 Starter jet 1 26 Pilot screw set 1 AUS NZL TIP Before disassembling the carburetor make sure to note the number of times the pilot screw is turned out from the seated position to its set position For assembly reverse the disassembly pro cedure ...

Page 241: ...h compressed air 3 Check Float chamber body Dirt Clean 4 Check Float 1 Float tang 2 Damage Replace 5 Check Needle valve seat 1 Needle valve 2 Contamination Clean Damage obstruction wear Replace the needle valve needle valve seat and O ring as a set 6 Check Piston valve 1 Damage scratches wear Replace Piston valve diaphragm 2 Cracks tears Replace 7 Check Diaphragm cover 1 Piston valve spring 2 Crac...

Page 242: ...iston valve into the carburetor body and move it up and down Tightness Replace the piston valve Throttle valve movement Sticks Replace the carburetor 12 Check Starter plunger 1 Starter plunger spring 2 Bends cracks damage Replace 13 Check Air vent hose joint Cracks damage Replace 14 Check Air vent hoses Fuel hose Drain hose Cracks damage wear Replace Obstruction Clean Blow out the hoses with compr...

Page 243: ... resting on the needle valve but not compressing it c If the float height is not within the specifica tion check the valve seat and needle valve d If either is worn replace the valve seat needle valve and O ring as a set e If both are fine adjust the float height by bending the float tang 1 on the float f Recheck the float height 4 Install Float chamber O ring 5 Install Pilot screw 1 AUS NZL TIP B...

Page 244: ...nstall Carburetor TIP Align the projection a on the carburetor with the slot b in the carburetor joint 4 Install Throttle cable O ring Throttle cable cover 5 Adjust Engine idling speed Refer to ADJUSTING THE ENGINE IDLING SPEED on page 3 6 6 Adjust Throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY on page 3 24 EAS26910 MEASURING AND ADJUSTING THE FUEL LEVEL 1 Measure Fuel le...

Page 245: ...the fuel level a 2 Adjust Fuel level a Remove the carburetor b Check the needle valve seat and needle valve c If either is worn replace the valve seat needle valve and O ring as a set d If both are fine adjust the float level by slightly bending the float tang 1 e Install the carburetor f Measure the fuel level again g Repeat steps a to f until the fuel level is within specification Fuel level gau...

Page 246: ...CARBURETOR 6 11 ...

Page 247: ...BLESHOOTING 7 21 CARBURETOR HEATING SYSTEM 7 23 CIRCUIT DIAGRAM 7 23 TROUBLESHOOTING 7 25 ELECTRICAL COMPONENTS 7 27 CHECKING THE SWITCHES 7 29 CHECKING THE BULBS AND BULB SOCKETS 7 32 CHECKING THE FUSES 7 33 CHECKING AND CHARGING THE BATTERY 7 33 CHECKING THE RELAYS 7 37 CHECKING THE DIODE 7 38 CHECKING THE SPARK PLUG CAP 7 38 CHECKING THE IGNITION COIL 7 38 CHECKING THE PICKUP COIL 7 39 CHECKING...

Page 248: ...IGNITION SYSTEM 7 1 EAS27090 IGNITION SYSTEM EAS27100 CIRCUIT DIAGRAM ...

Page 249: ...IGNITION SYSTEM 7 2 1 Pickup coil 4 Main switch 5 Battery 8 Fuse 9 CDI unit 10 Ignition coil 11 Spark plug 22 Left handlebar switch 24 Engine stop switch ...

Page 250: ...E BATTERY on page 7 33 Clean the battery terminals Recharge or replace the battery 3 Check the spark plug Refer to CHECKING THE SPARK PLUG on page 3 4 Re gap or replace the spark plug 4 Check the ignition spark gap Refer to CHECKING THE IGNI TION COIL on page 7 38 Ignition system is OK 5 Check the spark plug cap Refer to CHECKING THE SPARK PLUG CAP on page 7 38 Replace the spark plug cap 6 Check t...

Page 251: ...ge 7 29 Replace the main switch 9 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 7 29 Replace the left handlebar switch 10 Check the entire ignition system s wiring Refer to CIRCUIT DIAGRAM on page 7 1 Properly connect or repair the ignition system s wiring Replace the CDI unit ...

Page 252: ...ELECTRIC STARTING SYSTEM 7 5 EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM ...

Page 253: ...G SYSTEM 7 6 4 Main switch 5 Battery 6 Starter relay 7 Starter motor 8 Fuse 12 Diode 1 14 Clutch switch 15 Starting circuit cut off relay 22 Left handlebar switch 24 Engine stop switch 25 Start switch 28 Neutral switch ...

Page 254: ...al the neutral switch is closed The clutch lever is pulled to the handlebar the clutch switch is closed The starting circuit cut off relay prevents the starter motor from operating when neither of these con ditions has been met In this instance the starting circuit cut off relay is open so current cannot reach the starter motor When at least one of the above conditions has been met the starting ci...

Page 255: ...RANSMISSION IS IN NEU TRAL b WHEN THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 1 Battery 2 Fuse 3 Main switch 4 Engine stop switch 5 Starting circuit cut off relay 6 Clutch switch 7 Neutral switch 8 Start switch 9 Starter relay 10 Starter motor ...

Page 256: ...e or replace the battery 3 Check the starter motor operation Refer to CHECKING THE STARTER MOTOR OPERATION on page 7 40 Starter motor is OK Perform the elec tric starting system troubleshooting starting with step 5 4 Check the starter motor Refer to CHECKING THE STARTER MOTOR on page 5 56 Repair or replace the starter motor 5 Check the starting circuit cut off relay Refer to CHECKING THE RELAYS on...

Page 257: ...k the neutral switch Refer to CHECKING THE SWITCHES on page 7 29 Replace the neutral switch 11 Check the clutch switch Refer to CHECKING THE SWITCHES on page 7 29 Replace the clutch switch 12 Check the start switch Refer to CHECKING THE SWITCHES on page 7 29 Replace the left handlebar switch 13 Check the entire starting system s wiring Refer to CIRCUIT DIAGRAM on page 7 5 Properly connect or repai...

Page 258: ...CHARGING SYSTEM 7 11 EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM ...

Page 259: ...CHARGING SYSTEM 7 12 2 Stator coil 3 Rectifier regulator 5 Battery 8 Fuse ...

Page 260: ...ry Refer to CHECKING AND CHARGING THE BATTERY on page 7 33 Clean the battery terminals Recharge or replace the battery 3 Check the stator coil Refer to CHECKING THE STATOR COIL on page 7 40 Replace the pickup coil stator coil assembly 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 7 40 Replace the rectifier regulator 5 Check the entire charging system s wiring R...

Page 261: ...CHARGING SYSTEM 7 14 ...

Page 262: ...LIGHTING SYSTEM 7 15 EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM ...

Page 263: ...LIGHTING SYSTEM 7 16 4 Main switch 5 Battery 8 Fuse 21 Tail brake light 22 Left handlebar switch 23 Dimmer switch 26 Headlight relay 27 Headlight ...

Page 264: ...Replace the bulb s and bulb socket s 2 Check the fuse Refer to CHECKING THE FUSES on page 7 33 Replace the fuse 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 7 33 Clean the battery terminals Recharge or replace the battery 4 Check the main switch Refer to CHECKING THE SWITCHES on page 7 29 Replace the main switch 5 Check the dimmer switch Refer to CHECKING THE SWITCHES on ...

Page 265: ...LIGHTING SYSTEM 7 18 NG OK 7 Check the entire lighting system s wiring Refer to CIRCUIT DIAGRAM on page 7 15 Properly connect or repair the lighting system s wiring This circuit is OK ...

Page 266: ...SIGNALING SYSTEM 7 19 EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM ...

Page 267: ...SIGNALING SYSTEM 7 20 4 Main switch 5 Battery 8 Fuse 13 Neutral indicator light 19 Rear brake light switch 20 Front brake light switch 21 Tail brake light 28 Neutral switch ...

Page 268: ...ttery Refer to CHECKING AND CHARGING THE BATTERY on page 7 33 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 7 29 Replace the main switch 4 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 7 19 Properly connect or repair the signal ing system s wiring This circuit is OK 1 Check the tail brake lig...

Page 269: ... circuit is OK 1 Check the neutral indicator light bulb and socket Refer to CHECKING THE BULBS AND BULB SOCKETS on page 7 32 Replace the neutral indicator light bulb socket or both 2 Check the neutral switch Refer to CHECKING THE SWITCHES on page 7 29 Replace the neutral switch 3 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 7 19 Properly connect or repair the signal ...

Page 270: ...CARBURETOR HEATING SYSTEM 7 23 EAS27490 CARBURETOR HEATING SYSTEM EAS27500 CIRCUIT DIAGRAM ...

Page 271: ...CARBURETOR HEATING SYSTEM 7 24 4 Main switch 5 Battery 8 Fuse 17 Thermo switch 18 Carburetor warmer ...

Page 272: ... THE BATTERY on page 7 33 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 7 29 Replace the main switch 4 Check the thermo switch Refer to CHECKING THE THERMO SWITCH on page 7 41 Replace the thermo switch 5 Check the carburetor warmer Refer to CHECKING THE CAR BURETOR WARMER on page 7 41 Replace the carburetor warmer 6 Check...

Page 273: ...CARBURETOR HEATING SYSTEM 7 26 ...

Page 274: ...ELECTRICAL COMPONENTS 7 27 EAS27973 ELECTRICAL COMPONENTS ...

Page 275: ... 6 Fuse 7 Battery 8 Tail brake light 9 Thermo switch 10 Carburetor warmer 11 Spark plug 12 Pickup coil stator assembly 13 Neutral switch 14 Rear brake light switch 15 Starter motor 16 Rectifier regulator 17 Starting circuit cut off relay 18 Headlight relay 19 CDI unit 20 Headlight 21 Neutral indicator light 22 Ignition coil ...

Page 276: ...ELECTRICAL COMPONENTS 7 29 EAS27981 CHECKING THE SWITCHES ...

Page 277: ...ELECTRICAL COMPONENTS 7 30 1 Light switch 2 Engine stop switch 3 Start switch 4 Front brake light switch 5 Main switch 6 Clutch switch 7 Fuse 8 Neutral switch 9 Rear brake light switch ...

Page 278: ... back and forth between the switch positions a few times The switches and their terminal connections are illustrated as in the following example of the main switch The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row The continuity i e a closed circuit between switch terminals at a given switch position is indicated by There is continuity be...

Page 279: ...THE HEADLIGHT BULB on page 3 25 WARNING EWA13320 Since the headlight bulb gets extremely hot keep flammable products and your hands away from the bulb until it has cooled down ECA14380 Be sure to hold the socket firmly when removing the bulb Never pull the lead otherwise it may be pulled out of the ter minal in the coupler Avoid touching the glass part of the head light bulb to keep it free from o...

Page 280: ...TIP Set the pocket tester selector to Ω 1 b If the pocket tester indicates replace the fuse 3 Replace Blown fuse a Set the main switch to OFF b Install a new fuse of the correct amperage rating c Set on the switches to verify if the electrical circuit is operational d If the fuse immediately blows again check the electrical circuit WARNING EWA13310 Never use a fuse with an amperage rating other th...

Page 281: ...ing to the appropriate charging method If the bat tery is overcharged the electrolyte level will drop considerably Therefore take special care when charging the battery TIP Since VRLA Valve Regulated Lead Acid bat teries are sealed it is not possible to check the charge state of the battery by measuring the specific gravity of the electrolyte Therefore the charge of the battery has to be checked b...

Page 282: ...ded battery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks If the battery becomes hot to the touch at any time during the charging process disconnect the battery charger and let the battery cool before reconnecting it Hot batteries can explode As shown in the following illustration the open circuit voltage of a VRLA Valve Regulated Lead Acid battery...

Page 283: ...g TIP Voltage should be measured 30 minutes after the engine is stopped b Connect a charger and ammeter to the bat tery and start charging c Make sure that the current is higher than the standard charging current written on the battery TIP If the current is lower than the standard charg ing current written on the battery this type of battery charger cannot charge the VRLA Valve Regulated Lead Acid...

Page 284: ... circuit cut off relay Headlight relay Recommended lubricant Dielectric grease Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Relay operation Continuity No continuity between 3 to 4 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe...

Page 285: ... cap as shown c Measure the spark plug cap resistance EAS28090 CHECKING THE IGNITION COIL 1 Check Primary coil resistance Out of specification Replace a Disconnect the ignition coil connector from the ignition coil terminal b Connect the pocket tester Ω 1 to the ignition coil as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C No continuity Positive tester probe Black Yellow 1 Negat...

Page 286: ...d gradually increase the spark gap until a misfire occurs EAS28110 CHECKING THE PICKUP COIL 1 Disconnect Pickup coil coupler from the wire harness 2 Check Pickup coil resistance Out of specification Replace the pickup coil stator coil assembly a Connect the pocket tester Ω 100 to the pickup coil terminal as shown Secondary coil resistance 6 32 9 48 kΩ Pocket tester 90890 03112 Analog pocket tester...

Page 287: ...ly to produce sparks therefore make sure no flammable gas or fluid is in the vicinity b Check the starter motor operation EAS28150 CHECKING THE STATOR COIL 1 Disconnect Stator coil coupler from the wire harness 2 Check Stator coil resistance Out of specification Replace the pickup coil stator coil assembly a Connect the pocket tester Ω 1 to the stator coil coupler as shown b Measure the stator coi...

Page 288: ...ermo switch continuity Out of specification Replace the thermo switch Step 1 and 2 Heating phase Step 3 and 4 Cooling phase 3 Install Thermo switch EAS28310 CHECKING THE CARBURETOR WARMER 1 Check Carburetor warmer resistance Out of specification Replace Digital tachometer 90890 06760 YU 39951 B Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe Red 1 Negative tester pr...

Page 289: ...et tester Ω 1 to the carburetor warmer as shown c Measure the carburetor warmer resistance Carburetor warmer resistance 5 6 8 4 Ω at 25 C 77 F Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe Carburetor warmer terminal 1 Negative tester probe Carburetor warmer body 2 ...

Page 290: ...ELECTRICAL COMPONENTS 7 43 ...

Page 291: ...8 1 INCORRECT ENGINE IDLING SPEED 8 1 POOR MEDIUM AND HIGH SPEED PERFORMANCE 8 2 FAULTY GEAR SHIFTING 8 2 SHIFT PEDAL DOES NOT MOVE 8 2 JUMPS OUT OF GEAR 8 2 FAULTY CLUTCH 8 2 OVERHEATING 8 3 POOR BRAKING PERFORMANCE 8 3 UNSTABLE HANDLING 8 3 FAULTY LIGHTING OR SIGNALING SYSTEM 8 3 ...

Page 292: ... Fuel cock Clogged or damaged fuel hose 3 Carburetor Deteriorated or contaminated fuel Clogged pilot jet Clogged pilot air passage Sucked in air Damaged float Worn needle valve Improperly installed needle valve seat Incorrect fuel level Improperly installed pilot jet Clogged starter jet Faulty starter plunger Electrical system 1 Battery Discharged battery Faulty battery 2 Fuse Blown damaged or inc...

Page 293: ... 1 Engine 1 Air filter Clogged air filter element Fuel system 1 Carburetor Faulty diaphragm Incorrect fuel level Loose or clogged main jet EAS28530 FAULTY GEAR SHIFTING Shifting is difficult Refer to Clutch drags EAS28540 SHIFT PEDAL DOES NOT MOVE Shift shaft Improperly adjusted shift rod Bent shift shaft Shift drum and shift forks Foreign object in a shift drum groove Seized shift fork Bent shift...

Page 294: ... pad Incorrect brake fluid level EAS28670 UNSTABLE HANDLING 1 Handlebar Bent or improperly installed handlebar 2 Steering components Incorrect toe in Improperly installed steering stem Bent tie rods Bent steering stem Damaged bushing Deformed steering knuckles 3 Front shock absorber assembly ies Faulty front shock absorber spring Leaking oil 4 Swingarm Worn bearing or bushing Bent or damaged swing...

Page 295: ...tail brake light bulb Too many electrical accessories Incorrect connection Burnt out tail brake light bulb Tail brake light bulb burnt out Wrong tail brake light bulb Faulty battery Incorrectly adjusted rear brake light switch Tail brake light bulb life expired ...

Page 296: ...rcuit cut off relay 16 Diode 2 17 Thermo switch 18 Carburetor warmer 19 Rear brake light switch 20 Front brake light switch 21 Tail brake light 22 Left handlebar switch 23 Dimmer switch 24 Engine stop switch 25 Start switch 26 Headlight relay 27 Headlight 28 Neutral switch EAS28750 COLOR CODE B Black Br Brown G Green L Blue O Orange R Red Sb Sky blue W White Y Yellow B R Black Red B Y Black Yellow...

Page 297: ......

Page 298: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN ...

Page 299: ...WIRING DIAGRAM YFM125RA ...

Page 300: ...WIRING DIAGRAM YFM125RA ...

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