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Yamaha WR125R 2009, Service Manual

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Yamaha WR125R 2009 Service Manual Download Page 151

REAR BRAKE

4-38

b. Remove the brake caliper piston dust seal 

and brake caliper piston seal.

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EAS22640

CHECKING THE REAR BRAKE CALIPER

1. Check:

• Brake caliper piston “1”

Rust/scratches/wear 

→

 Replace the brake 

caliper piston.

• Brake caliper cylinder “2”

Scratches/wear 

→

 Replace the brake caliper 

assembly.

• Brake caliper body “3”

Cracks/damage 

→

 Replace the brake caliper 

assembly.

• Brake fluid delivery passages

(brake caliper body)
Obstruction 

→

 Blow out with compressed air.

WARNING

EWA22B1007

Whenever a brake caliper is disassembled, 
replace the brake caliper piston dust seal 
and brake caliper piston seal.

2. Check:

• Rear brake caliper bracket

Cracks/damage 

→

 Replace.

EAS22650

ASSEMBLING THE REAR BRAKE CALIPER

WARNING

EWA22B1008

• Before installation, all internal brake com-

ponents should be cleaned and lubricated 
with clean or new brake fluid.

• Never use solvents on internal brake com-

ponents as they will cause the brake caliper 
piston dust seal and brake caliper piston 
seal to swell and distort.

• Whenever a brake caliper is disassembled, 

replace the brake caliper piston dust seal 
and brake caliper piston seal.

EAS22670

INSTALLING THE REAR BRAKE CALIPER

1. Install:

• Rear brake caliper “1” (temporarily)

• Copper washers 
• Rear brake hose “2”
• Brake hose union bolt “3”

WARNING

EWA13530

Proper brake hose routing is essential to in-
sure safe vehicle operation. Refer to “CABLE 
ROUTING” on page 2-35.

NOTICE

ECA14170

When installing the brake hose onto the 
brake caliper “1”, make sure the brake pipe 
“a” touches the projection “b” on the brake 
caliper.

2. Remove:

• Brake caliper

Recommended brake component replace-

ment schedule

Brake pads

If necessary

Piston seal

Every two years

Piston dust seal

Every two years

Brake hoses

Every four years

Brake fluid

Every two years and 
whenever the brake 
is disassembled

1

3

2

 

Recommended fluid

DOT 4

T

 

R

.

.

 

Brake hose union bolt

30 Nm (3.0 m·kgf, 22 ft·lbf)

New

1

3

2

b

a

Summary of Contents for WR125R 2009

Page 1: ...2009 SERVICE MANUAL WR125R WR125X 22B F8197 E0 ...

Page 2: ...R125R WR125X 2009 SERVICE MANUAL 2008 by MBK Industrie First edition December 2008 All rights reserved Any reproduction or unauthorized use without the written permission of MBK Industrie is expressly prohibited ...

Page 3: ... changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable TIP Designs and specifications are subject to change without notice EAS20081 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following notations This is the safety alert symbol It is use...

Page 4: ...ub 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 disas sembly step Symbols 5 indicate parts to be lubricated or replaced Refer to SYMBOLS A job instruction ch...

Page 5: ...T R 1 2 3 4 5 6 7 8 1 Serviceable with engine mounted 2 Filling fluid 3 Lubricant 4 Special tool 5 Tightening torque 6 Wear limit clearance 7 Engine speed 8 Electrical data 9 Engine oil 10 Gear oil 11 Molybdenum disulfide oil 12 Brake fluid 13 Wheel bearing grease 14 Lithium soap based grease 15 Molybdenum disulfide grease 16 Silicone grease 17 Locking agent LOCTITE 18 Replace the part with a new ...

Page 6: ......

Page 7: ...EAS20110 TABLE OF CONTENTS GENERAL INFORMATION 1 SPECIFICATIONS 2 PERIODIC CHECKS AND ADJUSTMENTS 3 CHASSIS 4 ENGINE 5 COOLING SYSTEM 6 FUEL SYSTEM 7 ELECTRICAL SYSTEM 8 TROUBLESHOOTING 9 ...

Page 8: ......

Page 9: ... OF THE FI SYSTEM 1 2 FI SYSTEM 1 3 INSTRUMENT FUNCTIONS 1 4 IMPORTANT INFORMATION 1 6 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 6 REPLACEMENT PARTS 1 6 GASKETS OIL SEALS AND O RINGS 1 6 LOCK WASHERS PLATES AND COTTER PINS 1 6 BEARINGS AND OIL SEALS 1 7 CIRCLIPS 1 7 CHECKING THE CONNECTIONS 1 8 SPECIAL TOOLS 1 9 ...

Page 10: ...HICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe EAS20150 MODEL LABEL The model label 1 is affixed to the frame under the seat This information will be needed to order spare parts 1 1 ...

Page 11: ...the en gine As the requirements for the engine to deliver more performance and cleaner exhaust gases increase it becomes necessary to control the air fuel ratio in a more precise and finely tuned manner To accom modate this need this model has adopted an electronically controlled fuel injection FI system in place of the conventional carburetor system This system can achieve an optimum air fuel rat...

Page 12: ...ration and the injection timing are controlled by the ECU Signals that are input from the throttle position sensor crankshaft position sensor intake air pressure sensor intake air temperature sensor lean angle sensor and coolant temperature sensor enable the ECU to determine the injection duration The injection timing is determined through the signals from the crankshaft position sensor As a resul...

Page 13: ...lowing order ODO TRIP 1 TRIP 2 ODO When approximately 1 6 L 0 42 US gal 0 35 Imp gal of fuel remains in the fuel tank the odometer display will automatically change to the fuel reserve tripmeter mode F TRIP and start counting the distance traveled from that point and the last segment of the fuel meter will start flashing In that case pushing the RE SET SELECT button switches the display be tween t...

Page 14: ...e indicator still flashes after the rest procedure has been completed repeat the reset procedure completely Fuel meter The fuel meter indicates the amount of fuel in the fuel tank The display segments of the fuel meter disappear towards E Empty as the fuel level decreases When the last fuel meter segment starts flashing refuel as soon as possible 1 Fuel meter 1 ...

Page 15: ...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 16: ...ease Oil bearings liberally when installing if appropriate NOTICE ECA13300 Do not spin the bearing with compressed air because this will damage the bearing surfac es EAS20240 CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlips Al ways replace piston pin clips after one use When installing a circlip 1 make sure the sharp edged corner 2 is positioned opp...

Page 17: ...ral times 3 Check All connections Loose connection Connect properly TIP If the pin 1 on the terminal is flattened bend it up 4 Connect Lead Coupler Connector TIP Make sure all connections are tight 5 Check Continuity with 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 m...

Page 18: ...elow 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 Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 8 5 36 8 63 8 64 8 65 8 67 8 68 8 69 8 70 8 71 8 72 8 73 8 74 8 75 8 76 8 77 Thickness gauge 90890 03180 Feeler gauge set YU 26900 9 3 4 5 43 Tappet ad...

Page 19: ...U A9472 3 22 4 58 Spoke nipple wrench 8 9 90890 01522 YM 01522 3 25 Spoke nipple wrench 10 11 90890 01523 YM 01523 3 25 Damper rod holder 90890 01460 4 51 4 52 T handle 90890 01326 T handle 3 8 drive 60 cm long YM 01326 4 51 4 52 Fork seal driver weight 90890 01367 Replacement hammer YM A9409 7 4 52 4 53 Tool name Tool No Illustration Reference pages YM A9409 7 YM A5142 4 ...

Page 20: ...or attachment 90890 04108 Valve spring compressor adapter 22 mm YM 04108 5 18 5 23 Valve guide remover ø4 5 90890 04116 Valve guide remover 4 5 mm YM 04116 5 19 Valve guide installer ø4 5 90890 04117 Valve guide installer 4 5 mm YM 04117 5 19 Valve guide reamer ø4 5 90890 04118 Valve guide reamer 4 5 mm YM 04118 5 19 Piston pin puller set 90890 01304 Piston pin puller YU 01304 5 25 Tool name Tool ...

Page 21: ...er 90890 01362 Heavy duty puller YU 33270 B 5 31 Universal clutch holder 90890 04086 YM 91042 5 42 5 45 Crankcase separating tool 90890 01135 Crankcase separator YU 01135 B 5 63 Crankshaft installer pot 90890 01274 Installing pot YU 90058 5 64 Tool name Tool No Illustration Reference pages YU 90058 YU 90059 ...

Page 22: ...U 90063 5 64 Spacer crankshaft installer 90890 04081 Pot spacer YM 91044 5 64 Radiator cap tester 90890 01325 Radiator pressure tester YU 24460 01 6 3 Radiator cap tester adapter 90890 01352 Radiator pressure tester adapter YU 33984 6 3 Tool name Tool No Illustration Reference pages YM 91044 YU 24460 01 YU 33984 ...

Page 23: ... driver 40 mm YM 04058 6 8 Pressure gauge 90890 03153 YU 03153 7 3 Fuel pressure adapter 90890 03186 7 3 Ignition checker 90890 06754 Opama pet 4000 spark checker YM 34487 8 71 Digital circuit tester 90890 03174 Model 88 Multimeter with tachometer YU A1927 8 75 Tool name Tool No Illustration Reference pages ø10 ø30 ...

Page 24: ...SPECIAL TOOLS 1 15 ...

Page 25: ...TORQUES 2 15 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 15 ENGINE TIGHTENING TORQUES 2 16 CHASSIS TIGHTENING TORQUES 2 19 LUBRICATION POINTS AND LUBRICANT TYPES 2 23 ENGINE 2 23 CHASSIS 2 25 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 27 ENGINE OIL LUBRICATION CHART 2 27 LUBRICATION DIAGRAMS 2 29 COOLING SYSTEM DIAGRAMS 2 33 CABLE ROUTING 2 35 ...

Page 26: ...verall width 835 mm 32 9 in Overall height WR125R 1285 mm 50 6 in WR125X 1260 mm 49 6 in Seat height WR125R 930 mm 36 6 in WR125X 920 mm 36 2 in Wheelbase 1430 mm 56 3 in Ground clearance WR125R 265 mm 10 43 in WR125X 255 mm 10 04 in Minimum turning radius 2200 mm 86 6 in Weight With oil and fuel WR125R 133 0 kg 293 lb WR125X 137 0 kg 302 lb Maximum load 185 kg 408 lb ...

Page 27: ...uantity Total amount 1 15 L 1 22 US qt 1 01 Imp qt Without oil filter element replacement 0 95 L 1 00 US qt 0 84 Imp qt With oil filter element replacement 1 00 L 1 06 US qt 0 88 Imp qt Oil filter Oil filter type Paper Oil pump Oil pump type Trochoid Inner rotor to outer rotor tip clearance Less than 0 150 mm 0 0059 in Limit 0 23 mm 0 0091 in Outer rotor to oil pump housing clearance 0 130 0 180 m...

Page 28: ...CR8E Spark plug gap 0 7 0 8 mm 0 028 0 031 in Cylinder head Volume 9 90 10 50 cm 0 60 0 64 cu in Warpage limit 0 03 mm 0 0012 in Camshaft Drive system Chain drive left Camshaft lobe dimensions Intake A 30 225 30 325 mm 1 1900 1 1939 in Limit 30 125 mm 1 1860 in Intake B 25 127 25 227 mm 0 9893 0 9932 in Limit 25 027 mm 0 9853 in Exhaust A 30 232 30 332 mm 1 1902 1 1942 in Limit 30 132 mm 1 1863 in...

Page 29: ...B intake 1 538 2 138 mm 0 0606 0 0842 in Valve face width B exhaust 1 538 2 138 mm 0 0606 0 0842 in Valve seat width C intake 0 90 1 10 mm 0 0354 0 0433 in Limit 1 6 mm 0 06 in Valve seat width C exhaust 0 90 1 10 mm 0 0354 0 0433 in Limit 1 6 mm 0 06 in Valve margin thickness D intake 0 50 0 90 mm 0 0197 0 0354 in Valve margin thickness D exhaust 0 50 0 90 mm 0 0197 0 0354 in Valve stem diameter ...

Page 30: ...0 kgf mm 134 41 lb in Spring rate K2 intake 36 58 N mm 3 73 kgf mm 208 87 lb in Spring rate K1 exhaust 23 54 N mm 2 40 kgf mm 134 41 lb in Spring rate K2 exhaust 36 58 N mm 3 73 kgf mm 208 87 lb in Installed compression spring force intake 140 00 162 00 N 14 28 16 52 kgf 31 47 36 42 lbf Installed compression spring force exhaust 140 00 162 00 N 14 28 16 52 kgf 31 47 36 42 lbf Spring tilt intake 2 ...

Page 31: ... Dimensions B T 0 80 1 90 mm 0 03 0 07 in End gap installed 0 10 0 25 mm 0 0039 0 0098 in Limit 0 50 mm 0 0197 in Ring side clearance 0 030 0 065 mm 0 0012 0 0026 in Limit 0 100 mm 0 0039 in 2nd ring Ring type Taper Dimensions B T 0 80 2 10 mm 0 03 0 08 in End gap installed 0 10 0 25 mm 0 0039 0 0098 in Limit 0 60 mm 0 0236 in Ring side clearance 0 020 0 055 mm 0 0008 0 0022 in Limit 0 100 mm 0 00...

Page 32: ...Friction plate 2 thickness 2 90 3 10 mm 0 114 0 122 in Wear limit 2 80 mm 0 1102 in Plate quantity 1 pc Clutch plate thickness 1 45 1 75 mm 0 057 0 069 in Plate quantity 4 pcs Warpage limit 0 20 mm 0 0079 in Clutch spring free length 38 71 mm 1 52 in Minimum length 36 77 mm 1 45 in Spring quantity 4 pcs Long clutch push rod bending limit 0 500 mm 0 0197 in Transmission Transmission type Constant m...

Page 33: ... 36 3 psi Fuel injector Model quantity 1100 87K00 1 Manufacturer AISAN Throttle body Type quantity SE AC28 2 1 Manufacturer MIKUNI ID mark 5D71 00 Fuel injection sensor Crankshaft position sensor resistance 248 372 Ω at 20 C 68 F Intake air pressure sensor output voltage 4 70 5 20 V Intake air temperature sensor resistance 5 7 6 3 kΩ at 0 C 32 F Coolant temperature sensor resistance 2 32 2 59 kΩ a...

Page 34: ...wheel Wheel type Spoke wheel Rim size WR125R 18 1 85 WR125X 17 3 5 Rim material WR125R Steel WR125X Aluminum Wheel travel 230 0 mm 9 06 in Radial wheel runout limit 1 0 mm 0 04 in Lateral wheel runout limit 0 5 mm 0 02 in Wheel axle bending limit 0 25 mm 0 01 in Front tire Type With tube Size WR125R 80 90 21 M C 48P WR125R 80 90 21 M C 48S WR125R 80 90 21 M C 48R WR125X 110 70 17 M C 54H Manufactu...

Page 35: ...m 0 0059 in Brake pad lining thickness inner 5 0 mm 0 20 in Limit 1 0 mm 0 04 in Brake pad lining thickness outer 5 0 mm 0 20 in Limit 1 0 mm 0 04 in Master cylinder inside diameter 13 00 mm 0 51 in Caliper cylinder inside diameter 27 00 mm 2 1 06 in 2 Recommended fluid DOT 4 Rear brake Type Single disc brake Operation Right foot operation Brake pedal position 12 0 mm 0 47 in Rear disc brake Disc ...

Page 36: ...ivalent Quantity WR125R 560 0 cm 18 93 US oz 19 75 Imp oz WR125X 610 0 cm 20 62 US oz 21 51 Imp oz Level WR125R 165 0 mm 6 50 in WR125X 145 0 mm 5 71 in Rear suspension Type Swingarm monocross Spring shock absorber type WR125R Coil spring gas oil damper WR125X Coil spring oil damper Rear shock absorber assembly travel 74 0 mm 2 91 in Spring free length 224 0 mm 8 82 in Installed length 203 0 mm 7 ...

Page 37: ...n Resistance 5 0 kΩ AC magneto Model manufacturer F22B YAMAHA Standard output 14 0 V 20 8 A at 5000 r min Standard output 14 0 V 160 W at 5000 r min Stator coil resistance 0 448 0 672 Ω at 20 C 68 F Rectifier regulator Regulator type Semi conductor short circuit Model manufacturer SH629A 12 SHINDENGEN Regulated voltage DC 14 1 14 9 V Rectifier capacity DC 10 0 A Withstand voltage 200 0 V Battery M...

Page 38: ... diameter 17 6 mm 0 69 in Limit 16 6 mm 0 65 in Mica undercut depth 1 35 mm 0 05 in Starter relay Model manufacturer 5TN OMRON Amperage 50 0 A Coil resistance 54 66 Ω Horn Horn type Plane Quantity 1 pc Model manufacturer HF 12 NIKKO Maximum amperage 3 0 A Coil resistance 1 06 1 11 Ω at 20 C 68 F Turn signal relay Model manufacturer FE218BH DENSO Relay type Full transistor Built in self canceling d...

Page 39: ...Model manufacturer SSW6101 PANASONIC Running rpm 4800 r min Fan motor relay Model manufacturer ACM33211 M05 MATSUSHITA Coil resistance 96 0 Ω Fuses Main fuse 20 0 A Headlight fuse 15 0 A Signaling system fuse 7 5 A Ignition fuse 7 5 A Radiator fan fuse 5 0 A Spare fuse 20 0 A Spare fuse 15 0 A Spare fuse 7 5 A Spare fuse 5 0 A ...

Page 40: ... To avoid warpage tight en multi fastener assemblies in a crisscross pat tern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specifications re quire clean dry threads Components 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 ...

Page 41: ...r bolt M6 3 7 Nm 0 7 m kgf 5 1 ft lbf Radiator cap lock bolt M3 1 1 Nm 0 1 m kgf 0 7 ft lbf Radiator fan bolt M6 2 8 Nm 0 8 m kgf 5 8 ft lbf Radiator bracket bolt M8 2 16 Nm 1 6 m kgf 11 ft lbf Coolant reservoir bolt M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Clutch cable guide bolt M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Water pump assembly bolt M6 3 10 Nm 1 0 m kgf 7 2 ft lbf Water pump housing cover bolt M6 4 10 Nm...

Page 42: ...lutch spring bolt M6 4 12 Nm 1 2 m kgf 8 7 ft lbf Short clutch push rod locknut M6 1 8 Nm 0 8 m kgf 5 8 ft lbf Clutch boss nut M14 1 70 Nm 7 0 m kgf 50 ft lbf Clutch cable locknut M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Crankcase bearing retainer bolt M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Shift drum segment screw M6 1 12 Nm 1 2 m kgf 8 7 ft lbf Stopper lever bolt M6 1 10 Nm 1 0 m kgf 7 2 ft lbf Stator coil bolt M...

Page 43: ...nerator cover tightening sequence Clutch cover tightening sequence Crankcase tightening sequence 1 6 7 8 9 5 4 3 11 2 10 8 1 7 3 13 2 12 6 9 5 11 10 4 A 1 7 11 12 3 14 4 5 6 8 9 10 16 15 B 2 13 A Left crankcase B Right crankcase ...

Page 44: ...Relay arm and swingarm nut M12 1 59 Nm 5 9 m kgf 43 ft lbf Relay arm and connecting rod nut M12 1 59 Nm 5 9 m kgf 43 ft lbf Connecting rod and frame nut M12 1 59 Nm 5 9 m kgf 43 ft lbf Drive chain guard bolt M6 3 7 Nm 0 7 m kgf 5 1 ft lbf Drive chain guide bolt M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Upper bracket pinch bolt M8 4 23 Nm 2 3 m kgf 17 ft lbf Lower bracket pinch bolt M8 4 22 Nm 2 2 m kgf 16 ft...

Page 45: ...brake light assembly cover bolt M6 6 7 Nm 0 7 m kgf 5 1 ft lbf Tail brake light assembly bolt M6 4 7 Nm 0 7 m kgf 5 1 ft lbf License plate bracket nut M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Rear left and right turn signal light nut M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Battery cover bolt M6 3 7 Nm 0 7 m kgf 5 1 ft lbf Battery box bolt M6 4 7 Nm 0 7 m kgf 5 1 ft lbf Battery bracket bolt M6 1 10 Nm 1 0 m kgf 7 2 f...

Page 46: ...Nm 1 7 m kgf 12 ft lbf Rear brake light switch M10 1 24 Nm 2 4 m kgf 17 ft lbf Rear brake hose union bolt M10 1 30 Nm 3 0 m kgf 22 ft lbf Brake fluid reservoir bolt M6 1 4 Nm 0 4 m kgf 2 9 ft lbf Brake fluid reservoir bracket bolt M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Rear brake hose holder bolt M8 1 22 Nm 2 2 m kgf 16 ft lbf Sidestand nut M10 1 55 Nm 5 5 m kgf 40 ft lbf Sidestand switch bolt M5 2 4 Nm 0...

Page 47: ...front wheel axle from the right side of the vehicle and tighten it to 58 Nm 5 8 m kgf 42 ft lbf 2 Tighten each bolt to 9 Nm 0 9 m kgf 6 5 ft lbf in the order of pinch bolt 2 pinch bolt 1 pinch bolt 2 or pinch bolt 1 pinch bolt 2 pinch bolt 1 1 A B 1 A WR125R B WR125X 1 2 ...

Page 48: ...cker arm inner surface Decompression lever pivoting point Engine oil drain plug O ring Oil pump driven gear shaft Oil filter cover O ring Intake manifold O ring Fuel injector O ring Timing mark accessing screw O ring Crankshaft end accessing screw O ring Engine oil filler cap O ring Starter clutch gear thrust surfaces and washer Starter clutch rollers and starter clutch gear boss Starter motor O r...

Page 49: ...ars Shift drum assembly Shift forks and shift fork guide bar Shift shaft Crankshaft position sensor stator coil lead grommet Yamaha bond No 1215 Three Bond No 1215 Crankcase mating surfaces Yamaha bond No 1215 Three Bond No 1215 Timing chain tensioner bolt threads Yamaha bond No 1215 Three Bond No 1215 Lubrication point Lubricant E E E E E E ...

Page 50: ...nd bearing cover lip Oil seal lips front wheel and speed sensor Front wheel axle Rear wheel oil seal lips Rear wheel axle Tube guide throttle grip inner surface and throttle cable end Clutch lever pivoting point Clutch cable end Sidestand pivoting point and metal to metal moving parts Sidestand spring hooks Brake pedal pivoting point and metal to metal moving parts Brake pedal spring hooks Passeng...

Page 51: ...LUBRICATION POINTS AND LUBRICANT TYPES 2 26 ...

Page 52: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 27 EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 1 6 5 2 4 3 ...

Page 53: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 28 1 Oil pump 2 Oil filter element 3 Crankshaft 4 Camshaft 5 Main axle 6 Drive axle ...

Page 54: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 29 EAS20410 LUBRICATION DIAGRAMS A 1 4 5 6 7 2 3 ...

Page 55: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 30 1 Clutch push lever 2 Main axle 3 Drive axle 4 Crankshaft 5 Oil filter 6 Oil pump assembly 7 Oil strainer A To cylinder head ...

Page 56: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 31 1 3 2 4 ...

Page 57: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 32 1 Camshaft 2 Crankshaft 3 Main axle 4 Drive axle ...

Page 58: ...COOLING SYSTEM DIAGRAMS 2 33 EAS20420 COOLING SYSTEM DIAGRAMS 9 1 2 6 7 8 3 5 4 ...

Page 59: ...SYSTEM DIAGRAMS 2 34 1 Radiator cap 2 Water pump breather hose 3 Coolant reservoir hose 4 Coolant reservoir breather hose 5 Coolant reservoir 6 Water pump 7 Radiator outlet hose 8 Radiator 9 Radiator inlet hose ...

Page 60: ...CABLE ROUTING 2 35 EAS20430 CABLE ROUTING D D C C B B A A C C A A A A D D B B C B A D D E F G B H 1 1 3 4 4 2 3 4 5 5 6 9 8 9 7 6 7 8 8 7 4 5 6 7 8 12 13 14 15 15 10 10 11 ...

Page 61: ...ead left handlebar switch lead clutch switch lead front brake light switch lead and throttle cable between the meter assembly and the upper bracket D Fasten the left handlebar switch lead and clutch switch lead with the plastic bands at the bend in the handlebar E Fasten the wire harness at the white tape with a plastic locking tie F Route the wire harness to the rear of the front brake light swit...

Page 62: ...CABLE ROUTING 2 37 C C B B E E D D A F F G G A G G F F E E B B C C D D 1 1 6 1 1 1 1 2 2 3 3 4 5 6 7 8 9 10 11 12 18 13 15 14 16 17 1 5 5 19 18 12 17 18 18 A B C 20 22 21 21 21 ...

Page 63: ... Negative battery lead 13 Fuse box 14 Coupler starter relay to fuse box 15 Starter relay 16 Positive battery lead 17 Starter relay lead 18 Ground lead 19 Fuse box lead 20 Battery box 21 Starter motor lead 22 Horn leads A Fasten the starter relay lead at the white tape with a plastic locking tie B Fasten the positive battery lead at the white tape with a plastic locking tie C Position the coupler s...

Page 64: ...CABLE ROUTING 2 39 D D D D B C C B A A E D D C C B B A A E B F A E C D 1 2 1 1 1 5 7 6 4 3 8 8 7 5 4 3 ...

Page 65: ... tape with a plastic locking tie C Fasten the rear left turn signal light lead rear right turn signal light lead license plate light lead and tail brake light lead with a plastic locking tie D Fasten the rear left turn signal light lead rear right turn signal light lead and license plate light lead with a plastic locking tie E Route the battery breather hose between the crankcase and the swingarm ...

Page 66: ...CABLE ROUTING 2 41 A A B B C C A A B B A B C E D 1 2 3 4 5 6 7 8 9 12 10 11 14 13 ...

Page 67: ...lead right handlebar switch lead main switch lead and front brake light switch lead at the white tape on each lead with a plastic locking tie B Fasten the radiator fan motor coupler to the engine bracket front left upper with a plastic locking tie C Fasten the wire harness at the split in the harness to the engine bracket front left upper with a plastic locking tie D Route the clutch cable under t...

Page 68: ...CABLE ROUTING 2 43 B B C C A A A B B C C A A B C C 1 2 3 4 3 4 5 6 7 8 9 10 11 ...

Page 69: ...rator cover 11 Drive sprocket cover A Fasten the neutral switch lead crankshaft position sensor stator coil lead sidestand switch lead and ground lead with a plastic locking tie B Fasten the sidestand switch lead with the holder on the drive sprocket cover C Fasten the sidestand switch lead at the white tape to the frame with plastic locking tie D Route the neutral switch lead between the generato...

Page 70: ...CABLE ROUTING 2 45 B B A A C C D D B B C C C A A D D C A B B 2 1 2 3 4 5 6 7 6 8 9 10 6 8 9 10 11 12 13 14 15 4 5 16 2 6 17 ...

Page 71: ...lead 11 Throttle body sensor assembly lead 12 Fuel pump lead 13 FID fast idle solenoid lead 14 Fuel injector lead 15 Couplers left handlebar switch right handlebar switch main switch and front brake light switch 16 Battery 17 Starter motor coupler A Route the clutch cable between the radiator and frame and pass the cable through the cable guide B Fasten the wire harness at the white tape with a pl...

Page 72: ...CABLE ROUTING 2 47 A A C C B B A A B C C B A B E C D 1 2 3 4 5 7 8 9 6 5 6 17 18 12 13 14 14 19 15 16 10 11 ...

Page 73: ...l coupler 18 Self diagnosis signal lead 19 Tail brake light lead license plate light lead rear left turn signal light lead and rear right turn signal light lead A Fasten the rear brake light switch coupler and the leads that branch off from the wire harness with a plastic locking tie B Route the leads that branch off from the wire harness along the frame and then fasten them with a plastic locking...

Page 74: ...CABLE ROUTING 2 49 B B F F G G C C D D E E A A B WR125R WR125X C D E B C D E G G F F 1 2 1 1 1 1 1 1 3 1 1 1 3 3 3 5 4 2 5 B C A ...

Page 75: ...CABLE ROUTING 2 50 1 Front brake hose 2 Front brake hose guide 3 Front fork protector 4 Front fork protector guide 5 Front brake hose holders A 4 6 B White paint mark C Yellow paint mark ...

Page 76: ...CABLE ROUTING 2 51 G G H H A F F B B C C D D E E A G H G H C B C D D E E B WR125R WR125X 1 1 1 5 1 1 1 1 2 1 3 1 1 4 4 4 B A B A ...

Page 77: ...CABLE ROUTING 2 52 1 Speed sensor lead 2 Front fork protector 3 Front fork protector guide 4 Speed sensor lead holder 5 Front mudguard A White paint mark B Yellow paint mark ...

Page 78: ...CABLE ROUTING 2 53 ...

Page 79: ...ER HEAD BREATHER HOSE 3 13 CHECKING THE EXHAUST SYSTEM 3 14 CHECKING THE COOLANT LEVEL 3 14 CHECKING THE COOLING SYSTEM 3 14 CHANGING THE COOLANT 3 15 CHASSIS 3 17 ADJUSTING THE REAR DISC BRAKE 3 17 CHECKING THE BRAKE FLUID LEVEL 3 17 CHECKING THE FRONT BRAKE PADS 3 18 CHECKING THE REAR BRAKE PADS 3 18 CHECKING THE FRONT BRAKE HOSE 3 18 CHECKING THE REAR BRAKE HOSE 3 19 BLEEDING THE HYDRAULIC BRAK...

Page 80: ...ELECTRICAL SYSTEM 3 27 CHECKING AND CHARGING THE BATTERY 3 27 CHECKING THE FUSES 3 27 REPLACING THE HEADLIGHT BULB 3 27 ADJUSTING THE HEADLIGHT BEAM 3 27 ...

Page 81: ......

Page 82: ... if a kilometer based maintenance or for the UK a mileage based maintenance is performed instead From 30000 km 17500 mi repeat the maintenance intervals starting from 6000 km 3500 mi 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 ODOMETER READING ANNUAL CHECK 1000 km 600 mi 6000 km 3500 m...

Page 83: ... 16 Clutch lever pivot shaft Lubricate with lithium soap based grease 17 Sidestand Check operation Lubricate 18 Sidestand switch Check operation 19 Front fork Check operation and for oil leakage 20 Shock absorber assembly Check operation and shock absorber for oil leakage 21 Rear suspension relay arm and connecting arm pivoting points Check operation Lubricate with lithium soap based grease 22 Eng...

Page 84: ...re frequent service if you are riding in unusually wet or dusty areas Hydraulic brake service Regularly check and if necessary correct the brake fluid level Every two years change the brake fluid Replace the brake hoses every four years and if cracked or damaged ...

Page 85: ... CYLINDER HEAD on page 5 7 4 Remove Timing mark accessing screw 1 Crankshaft end accessing screw 2 5 Measure Valve clearance Out of specification Adjust a Turn the crankshaft counterclockwise b Align the TDC mark a on the generator rotor with the stationary pointer b on the genera tor cover c Check that the cam lobes are positioned as shown in the illustration d Measure the valve clearance with a ...

Page 86: ...nsity level to standard and then adjust the exhaust gas volume 1 Remove Seat Refer to GENERAL CHASSIS on page 4 1 2 Set the main switch to OFF 3 Disconnect Self diagnosis signal coupler 1 4 Connect FI diagnostic tool 2 5 While pressing the MODE button 1 turn the main switch to ON TIP DIAG appears on the LCD 2 of the FI diag nostic tool POWER LED Green 3 comes on 6 Press the UP button 4 to select t...

Page 87: ...IS on page 4 1 EAS20610 ADJUSTING THE ENGINE IDLING SPEED TIP Prior to adjusting the engine idling speed the air filter element should be clean and the engine should have adequate compression 1 Start the engine and let it warm up for several minutes 2 Connect Digital tachometer onto the spark plug lead 3 Check Engine idling speed Out of specification Adjust 4 Adjust Engine idling speed a Turn the ...

Page 88: ... original position 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 EAS20690 CHECKING THE SPARK PLUG 1 Disconnect Spark plug cap 2 Remove Spark plug NOTICE ECA13330 Before removing the spark plug blow away any dirt accumulated in the spark plug well with co...

Page 89: ...iming check the wiring connections of the entire ignition system Make sure all connections are tight and free of corrosion 1 Remove Timing mark accessing screw 1 2 Connect Timing light 1 Digital tachometer 3 Check Ignition timing a Start the engine warm it up for several min utes and then let it run at the specified en gine idling speed b Check that the stationary pointer a on the generator cover ...

Page 90: ...t the main switch to ON b With the throttle wide open crank the engine until the reading on the compression gauge stabilizes c If the compression pressure is above the maximum specification check the cylinder head valve surfaces and piston crown for carbon deposits Carbon deposits Eliminate d If the compression pressure is below the min imum specification pour a teaspoonful of en gine oil into the...

Page 91: ...clutch slippage Therefore do not add any chemical additives or use engine oils with a grade of CD c or higher and do not use oils labeled ENERGY CONSERVING II d Do not allow foreign materials to enter the crankcase 4 Start the engine warm it up for several min utes and then turn it off 5 Check the engine oil level again TIP Before checking the engine oil level wait a few minutes until the oil has ...

Page 92: ...or engine oil leaks 12 Check Engine oil level Refer to CHECKING THE ENGINE OIL LEVEL on page 3 10 13 Check Engine oil pressure a Slightly loosen the oil check bolt 1 b Start the engine and keep it idling until engine oil starts to seep from the oil check bolt If no engine oil comes out after one minute turn the engine off so that it will not seize c Check the engine oil passages the oil filter ele...

Page 93: ...btained on the handlebar end of the cable use the adjusting nut on the engine end Engine end a Loosen the locknut 1 b Turn the adjusting nut 2 in direction a or b until the specified clutch cable free play is ob tained c Tighten the locknut EAS20921 CLEANING THE AIR FILTER ELEMENT TIP There is a check hose 1 at the bottom of the air filter case If dust and or water collects in this hose clean the ...

Page 94: ...lter element will also affect throttle body tuning leading to poor engine performance and possible overheating TIP Make sure the air filter element is properly in stalled in the air filter case 6 Install Seat bracket Seat Refer to GENERAL CHASSIS on page 4 1 EAS22B1003 CHECKING THE THROTTLE BODY JOINT AND AIR FILTER CASE JOINT 1 Check Throttle body joint 1 Air filter case joint 2 Cracks damage Rep...

Page 95: ...ontent of the coolant If water is used instead of coolant check and if nec essary correct the antifreeze concentra tion of the coolant Use only distilled water However if dis tilled water is not available soft water may be used 3 Start the engine warm it up for several min utes and then turn it off 4 Check Coolant level TIP Before checking the coolant level wait a few minutes until it settles EAS2...

Page 96: ...nd turn it counterclockwise to re move 3 Remove Coolant drain bolt 1 along with the copper washer 4 Drain Coolant from the engine and radiator 5 Remove Coolant reservoir cap 1 Coolant reservoir 2 6 Drain Coolant from the coolant reservoir 7 Install Coolant reservoir 8 Install Coolant drain bolt along with the copper washer 9 Fill Cooling system with the specified amount of the recom mended coolant...

Page 97: ... water may be used If coolant comes into contact with painted surfaces immediately wash them with wa ter Do not mix different types of antifreeze 10 Install Radiator cap 1 Radiator cap lock bolt 2 TIP Install the radiator cap so that the lock bolt faces forward as shown in the illustration 11 Fill Coolant reservoir with the recommended coolant to the maxi mum level mark a 12 Install Coolant reserv...

Page 98: ...fore the vehicle is operated the air must be removed by bleeding the brake system Air in the brake system will consid erably reduce braking performance NOTICE ECA13510 After adjusting the brake pedal position make sure there is no brake drag EAS21240 CHECKING THE BRAKE FLUID LEVEL 1 Stand the vehicle on a level surface TIP Place the vehicle on a suitable stand Make sure the vehicle is upright 2 Ch...

Page 99: ...linder reservoir and brake fluid reservoir are horizontal EAS21250 CHECKING THE FRONT BRAKE PADS The following procedure applies to all of the brake pads 1 Operate the brake 2 Check Front brake pad Brake pad wear limit a Out of specification Replace the brake pads as a set Refer to FRONT BRAKE on page 4 19 EAS21260 CHECKING THE REAR BRAKE PADS The following procedure applies to all of the brake pa...

Page 100: ...he hydraulic brake system make sure there is always enough brake fluid before applying the brake Ignoring this pre caution could allow air to enter the hydraulic brake system considerably lengthening the bleeding procedure If bleeding is difficult it may be necessary to let the brake fluid settle for a few hours Repeat the bleeding procedure when the tiny bubbles in the hose have disappeared 1 Rem...

Page 101: ...ad the engine and other vital parts and one that is too loose can skip and damage the swing arm or cause an accident Therefore keep the drive chain slack within the specified lim its 1 Stand 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 the rear wheel is elevated 2 Move th...

Page 102: ...on the drive chain since they may contain solvents that could damage the O rings EAS21510 CHECKING AND ADJUSTING THE STEERING HEAD 1 Stand 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 the front wheel is elevated 2 Check Steering head Grasp the bottom of the front fork leg...

Page 103: ...ke sure the lock washer tabs a sit correctly in the ring nut slots b 5 Install Upper bracket Refer to STEERING HEAD on page 4 55 EAS21530 CHECKING THE FRONT FORK 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Check Inner tube Damage scratches Replace Oil seal Oil leakage Replace 3 Hold the vehicle upright and app...

Page 104: ...essure Out of specification Regulate WARNING EWA13180 The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature The tire pressure and the suspension must be adjusted according to the total weight including cargo rider passenger and ac cessories and the anticipated riding speed Operation of an overloaded vehicle could cause tire damage an ac...

Page 105: ... Motor Co Ltd for this model The front and rear tires should always be by the same manufacturer and of the same design No guarantee con cerning handling characteristics can be giv en if a tire combination other than one approved by Yamaha is used on this vehicle Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198 lb Front 200 kPa 2 00 kgf cm 29 psi Rear 200 kPa 2 00 kgf cm 29 ...

Page 106: ...l has been changed or re placed always balance the wheel EAS21680 CHECKING AND TIGHTENING THE SPOKES The following procedure applies to all of the spokes 1 Check Spoke Bends damage Replace Loose Tighten Tap the spokes with a screwdriver TIP A tight spoke will emit a clear ringing tone a loose spoke will sound flat 2 Tighten Spoke with a spoke nipple wrench 1 WR125X WR125R TIP Be sure to tighten th...

Page 107: ... metal moving parts of the lever EAS22B1036 LUBRICATING THE BRAKE LEVER Lubricate the pivoting point and metal to metal moving parts of the lever EAS21710 LUBRICATING THE BRAKE PEDAL Lubricate the pivoting point and metal to metal moving parts of the pedal EAS21720 LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal to metal moving parts of the sidestand EAS21740 LUBRICATING THE REAR ...

Page 108: ...way from the bulb until it has cooled down 5 Install Headlight bulb Secure the new headlight bulb with the head light bulb holder NOTICE ECA13690 Avoid touching the glass part of the head light bulb to keep it free from oil otherwise the transparency of the glass the life of the bulb and the luminous flux will be adversely affected If the headlight bulb gets soiled thoroughly clean it with a cloth...

Page 109: ...ELECTRICAL SYSTEM 3 28 1 a b ...

Page 110: ...ELECTRICAL SYSTEM 3 29 ...

Page 111: ...4 REMOVING THE FRONT BRAKE CALIPER 4 25 DISASSEMBLING THE FRONT BRAKE CALIPER 4 25 CHECKING THE FRONT BRAKE CALIPER 4 25 ASSEMBLING THE FRONT BRAKE CALIPER 4 26 INSTALLING THE FRONT BRAKE CALIPER 4 26 REMOVING THE FRONT BRAKE MASTER CYLINDER 4 27 CHECKING THE FRONT BRAKE MASTER CYLINDER 4 27 INSTALLING THE FRONT BRAKE MASTER CYLINDER 4 27 REAR BRAKE 4 30 INTRODUCTION 4 36 CHECKING THE REAR BRAKE D...

Page 112: ... REAR SHOCK ABSORBER ASSEMBLY 4 60 HANDLING THE REAR SHOCK ABSORBER ASSEMBLY WR125R 4 61 DISPOSING OF A REAR SHOCK ABSORBER ASSEMBLY WR125R 4 61 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4 61 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 4 61 CHECKING THE CONNECTING ROD AND RELAY ARMS 4 61 INSTALLING THE RELAY ARMS AND CONNECTING ROD 4 61 SWINGARM 4 63 REMOVING THE SWINGARM 4 65 CHECKING THE SWINGARM ...

Page 113: ......

Page 114: ...r 1 5 Fuel tank cap 1 6 Fuel tank cover assembly 1 7 Side panel plate 2 WR125X 8 Side panel 2 For installation reverse the removal proce dure 2 1 4 7 8 8 7 2 6 3 5 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R ...

Page 115: ...g the fuel tank cover Order Job Parts to remove Q ty Remarks 1 Fuel tank top cover 1 2 Fuel overflow hose 1 3 Fuel tank front side cover 2 4 Fuel tank rear side cover 2 For assembly reverse the disassembly pro cedure 1 4 4 2 3 3 3 3 3 ...

Page 116: ...er 1 2 Negative battery lead 1 Disconnect 3 Positive battery lead 1 Disconnect 4 Battery band 1 5 Battery breather hose 1 Disconnect 6 Battery 1 7 Fuse box 1 8 Starter relay 1 9 Battery box 1 10 Battery bracket 1 For installation reverse the removal proce dure 1 4 8 7 2 6 5 3 9 4 10 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R ...

Page 117: ...ilter element 1 3 Air filter case seal 2 4 Rear mudguard 1 5 Air filter case joint clamp screw 1 Loosen 6 Air filter case 1 7 Cylinder head breather hose 1 Disconnect 8 Air induction system hose air filter case to reed valve assembly 1 Disconnect 9 Air filter case silencer hose 1 For installation reverse the removal proce dure 1 4 2 5 3 3 7 9 8 6 1 Nm 0 1 m kgf 0 7 ft Ibf T R 10 Nm 1 0 m kgf 7 2 f...

Page 118: ...IR FILTER CASE 1 Install Air filter case joint clamp TIP Align the projection a on the air filter case with the slot b in the air filter case joint clamp 2 Install Air filter case TIP Temporarily tighten the air filter case bolts 3 Tighten Air filter case joint clamp screw 4 Tighten Air filter case bolts TIP Tighten the air filter case bolts in the proper tight ening sequence as shown a 1 a b T R ...

Page 119: ...emove Q ty Remarks 1 Front wheel axle pinch bolt 2 Loosen 2 Front wheel axle 1 3 Front wheel 1 4 Collar 1 5 Speed sensor 1 6 Front brake disc 1 For installation reverse the removal proce dure 3 2 1 9 Nm 0 9 m kgf 6 5 ft Ibf T R 13 Nm 1 3 m kgf 9 4 ft Ibf T R 58 Nm 5 8 m kgf 42 ft Ibf T R LS LT LS 6 4 6 5 ...

Page 120: ...caliper 1 2 Front wheel axle pinch bolt 2 Loosen 3 Front wheel axle 1 4 Front wheel 1 5 Speed sensor 1 6 Front brake disc 1 For installation reverse the removal proce dure LS LS LT 6 1 3 6 5 4 2 LT 9 Nm 0 9 m kgf 6 5 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R 58 Nm 5 8 m kgf 42 ft Ibf T R ...

Page 121: ...FRONT WHEEL 4 8 Disassembling the front wheel WR125R Order Job Parts to remove Q ty Remarks 1 Oil seal 1 2 Bearing 2 3 Spacer 1 For assembly reverse the disassembly pro cedure LS 1 2 2 3 New ...

Page 122: ...RONT WHEEL 4 9 Disassembling the front wheel WR125X Order Job Parts to remove Q ty Remarks 1 Collar 1 2 Oil seal 1 3 Bearing 2 4 Spacer 1 For assembly reverse the disassembly pro cedure LS 1 2 3 4 3 New ...

Page 123: ...ub b Remove the oil seal 1 with a flat head screwdriver TIP To prevent damaging the wheel place a rag 2 between the screwdriver and the wheel surface c Remove the wheel bearings 3 with a gener al bearing puller EAS21930 CHECKING THE FRONT WHEEL 1 Check Wheel axle Roll the wheel axle on a flat surface Bends Replace WARNING EWA13460 Do not attempt to straighten a bent wheel ax le 2 Check Tire Front ...

Page 124: ...the diameter of the wheel bearing outer race and oil seal EAS21990 INSTALLING THE FRONT WHEEL DISC 1 Install Front brake disc TIP Be sure to install the front brake disc with the arrow mark a on the disc facing out Tighten the brake disc bolts in stages and in a crisscross pattern 2 Check Front brake disc Refer to CHECKING THE FRONT BRAKE DISC on page 4 23 3 Lubricate Front wheel axle Oil seal lip...

Page 125: ...ube 7 Tighten Front wheel axle Front wheel axle pinch bolts WARNING EWA22B1004 Make sure the speed sensor lead is routed properly NOTICE ECA22B1023 Before tightening the wheel axle push down hard on the handlebar several times and check if the front fork rebounds smoothly a Insert the front wheel axle from the right side of the vehicle and tighten it to specification b Tighten each bolt to specifi...

Page 126: ...heel axle nut 1 6 Rear wheel axle 1 7 Drive chain alignment plate 2 8 Rear wheel 1 9 Collar with dust cover 1 10 Collar with dust cover 1 11 Brake caliper 1 12 Chain puller 2 13 Rear wheel sprocket 1 14 Rear brake disc 1 WR125R 1 2 2 3 3 4 4 12 12 7 7 6 3 5 14 11 10 6 6 6 15 8 9 13 LS LT 7 Nm 0 7 m kgf 5 1 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 16 Nm 1 6 m kgf 11 ft Ibf T R 16 Nm 1 6 m kgf 11 f...

Page 127: ...ear brake disc and rear wheel sprocket Order Job Parts to remove Q ty Remarks 1 2 2 3 3 4 4 12 12 7 7 6 3 5 14 11 10 6 6 6 15 8 9 13 LS LT 7 Nm 0 7 m kgf 5 1 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 16 Nm 1 6 m kgf 11 ft Ibf T R 16 Nm 1 6 m kgf 11 ft Ibf T R 35 Nm 3 5 m kgf 25 ft Ibf T R 90 Nm 9 0 m kgf 65 ft Ibf T R ...

Page 128: ...REAR WHEEL 4 15 Disassembling the rear wheel WR125R Order Job Parts to remove Q ty Remarks 1 Oil seal 2 2 Bearing 2 3 Spacer 1 For assembly reverse the disassembly pro cedure 1 2 1 2 3 LS LS New New ...

Page 129: ...REAR WHEEL 4 16 Disassembling the rear wheel WR125X Order Job Parts to remove Q ty Remarks 1 Oil seal 2 2 Bearing 3 3 Spacer 1 For assembly reverse the disassembly pro cedure 1 2 1 2 3 LS LS New New ...

Page 130: ...ASSEMBLING THE FRONT WHEEL on page 4 10 EAS22100 CHECKING THE REAR WHEEL 1 Check Rear wheel axle Rear wheel Wheel bearings Oil seals Refer to CHECKING THE FRONT WHEEL on page 4 10 2 Check Tire Rear wheel Damage wear Replace Refer to CHECKING THE TIRES on page 3 23 and CHECKING THE WHEELS on page 3 25 3 Check Spokes Refer to CHECKING THE FRONT WHEEL on page 4 10 4 Measure Radial wheel runout Latera...

Page 131: ...brake disc bolts in stages and in a crisscross pattern 2 Check Rear brake disc Refer to CHECKING THE REAR BRAKE DISC on page 4 36 3 Lubricate Rear wheel axle Oil seal lips 4 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 20 NOTICE ECA13550 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 sw...

Page 132: ...marks 1 Front brake caliper bolt 2 2 Front brake caliper 1 3 Brake pad pin 1 4 Front brake pad 2 5 Brake pad spring 1 6 Brake pad support 1 For installation reverse the removal proce dure LT LT 1 2 3 1 4 5 6 LT LT 6 Nm 0 6 m kgf 4 3 ft Ibf T R 18 Nm 1 8 m kgf 13 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R ...

Page 133: ... Brake master cylinder reservoir cap 1 3 Brake master cylinder reservoir diaphragm 1 4 Front brake light switch 1 5 Brake lever 1 6 Brake hose union bolt 1 7 Copper washer 2 8 Front brake hose 1 9 Front brake master cylinder holder 1 10 Front brake master cylinder 1 For installation reverse the removal proce dure 5 4 7 9 10 6 1 2 3 8 9 Nm 0 9 m kgf 6 5 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R New ...

Page 134: ...Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 19 1 Brake hose union bolt 1 2 Copper washer 2 3 Front brake hose 1 4 Front brake caliper bolt 2 5 Front brake caliper 1 For installation reverse the removal proce dure 4 5 2 1 3 4 LT LT 30 Nm 3 0 m kgf 22 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R New LT ...

Page 135: ...ad spring 1 4 Brake pad support 1 5 Front brake caliper bracket 1 6 Brake caliper piston 2 7 Brake caliper piston dust seal 2 8 Brake caliper piston seal 2 9 Bleed screw 1 10 Brake caliper body 1 For assembly reverse the disassembly pro cedure S BF 8 10 1 9 2 3 4 New 7 6 New 5 6 Nm 0 6 m kgf 4 3 ft Ibf T R 18 Nm 1 8 m kgf 13 ft Ibf T R LT S ...

Page 136: ... 6 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 Place the vehicle on a suitable stand so that the front wheel is elevated b Before measuring the front brake disc deflec tion turn the handlebar to the left or right to ensure that the front wheel is stationary c Remove the brake caliper d ...

Page 137: ...upport TIP Always install new brake pads a new brake pad spring and a new brake pad support 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 pistons into the brake caliper with your fingers c Tighten the bleed screw d Install new brake pads a new brake pad spring and a new...

Page 138: ...ston dust seals 2 Brake caliper piston seals 3 a Blow compressed air into the brake hose joint opening a to force out the pistons from the brake caliper WARNING EWA13560 Cover the brake caliper pistons with a rag Be careful not to get injured when the pis tons are expelled from the brake caliper Never try to pry out the brake caliper pis tons b Remove the brake caliper piston dust seals and brake ...

Page 139: ...the brake caliper piston dust seals and brake caliper piston seals EAS22420 INSTALLING THE FRONT BRAKE CALIPER 1 Install Front brake caliper 1 temporarily Copper washers Front brake hose 2 Brake hose union bolt 3 WARNING EWA13530 Proper brake hose routing is essential to in sure safe vehicle operation Refer to CABLE ROUTING on page 2 35 NOTICE ECA14170 When installing the brake hose onto the brake...

Page 140: ...ling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 19 EAS22490 REMOVING THE FRONT BRAKE MASTER CYLINDER TIP Before removing the front brake master cylinder drain the brake fluid from the entire brake sys tem 1 Remove Front brake light switch TIP The front brake light switch is a screw type switch Unscrew the switch to remove it from the brake master cylinder 2 Remo...

Page 141: ...13540 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and 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 performance When refilling be careful that water does not enter the brake master cylinder reser voi...

Page 142: ...FRONT BRAKE 4 29 Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 19 ...

Page 143: ... remove Q ty Remarks Rear wheel Refer to REAR WHEEL on page 4 13 1 Brake pad clip 1 2 Brake pad pin 1 3 Rear brake pad 2 4 Brake pad spring 1 5 Brake pad support 1 For installation reverse the removal proce dure 1 2 4 3 3 5 6 Nm 0 6 m kgf 4 3 ft Ibf T R 13 Nm 1 3 m kgf 9 4 ft Ibf T R ...

Page 144: ...e fluid reservoir cap 1 4 Brake fluid reservoir diaphragm holder 1 5 Brake fluid reservoir diaphragm 1 6 Brake fluid reservoir 1 7 Brake fluid reservoir hose 1 8 Right passenger footrest assembly 1 9 Rear brake light switch coupler 1 Disconnect 10 Rear brake light switch 1 11 Copper washer 2 12 Rear brake hose 1 1 3 4 5 6 7 13 12 11 10 8 9 2 New New 10 Nm 1 0 m kgf 7 2 ft Ibf T R 4 Nm 0 4 m kgf 2 ...

Page 145: ...val proce dure Removing the rear brake master cylinder Order Job Parts to remove Q ty Remarks 1 3 4 5 6 7 13 12 11 10 8 9 2 New New 10 Nm 1 0 m kgf 7 2 ft Ibf T R 4 Nm 0 4 m kgf 2 9 ft Ibf T R 20 Nm 2 0 m kgf 14 ft Ibf T R 22 Nm 2 2 m kgf 16 ft Ibf T R 24 Nm 2 4 m kgf 17 ft Ibf T R ...

Page 146: ...brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake hose joint 1 2 Brake master cylinder kit 1 3 Brake master cylinder body 1 For assembly reverse the disassembly pro cedure 1 3 2 New New New S 17 Nm 1 7 m kgf 12 ft Ibf T R ...

Page 147: ...fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 19 Rear wheel Refer to REAR WHEEL on page 4 13 1 Rear brake hose union bolt 1 2 Copper washer 2 3 Rear brake hose 1 4 Rear brake caliper 1 For installation reverse the removal proce dure 2 1 3 4 New 30 Nm 3 0 m kgf 22 ft Ibf T R ...

Page 148: ...4 Brake pad spring 1 5 Brake pad support 1 6 Rear brake caliper bracket 1 7 Brake caliper piston 1 8 Brake caliper piston dust seal 1 9 Brake caliper piston seal 1 10 Bleed screw 1 11 Brake caliper body 1 For assembly reverse the disassembly pro cedure 4 8 7 5 6 3 2 1 10 11 9 S S S New New BF 6 Nm 0 6 m kgf 4 3 ft Ibf T R 13 Nm 1 3 m kgf 9 4 ft Ibf T R ...

Page 149: ... 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 Refer to CHECKING THE FRONT BRAKE DISC on page 4 23 4 Measure Brake disc thickness Measure the brake disc thickness at a few dif ferent locations Out of specification Replace Refer to CHECKING THE FRONT BRAKE DISC on page 4 23 5 Adjust Brake di...

Page 150: ...he brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 19 EAS22590 REMOVING THE REAR BRAKE CALIPER TIP Before disassembling the brake caliper drain the brake fluid from the entire brake system 1 Remove Brake hose union bolt Copper washers Rear brake hose TIP Put the end of the brake hose into a container and pump out the brake fluid carefully EAS22600 DISASSEMBLING THE REAR BRAKE ...

Page 151: ...se solvents on internal brake com ponents as they will cause the brake caliper piston dust seal and brake caliper piston seal to swell and distort Whenever a brake caliper is disassembled replace the brake caliper piston dust seal and brake caliper piston seal EAS22670 INSTALLING THE REAR BRAKE CALIPER 1 Install Rear brake caliper 1 temporarily Copper washers Rear brake hose 2 Brake hose union bol...

Page 152: ... fluid immediately 5 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 19 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 17 7 Check Brake pedal operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 19 EAS22...

Page 153: ...ill 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 performance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock NOTICE ECA13540 Brake fluid may damage painted surfaces and pla...

Page 154: ... Throttle cable 1 Disconnect 8 Throttle grip 1 9 Clutch switch coupler 1 Disconnect 10 Left handlebar switch 1 11 Handlebar grip 1 12 Clutch cable 1 Disconnect 13 Clutch switch 1 14 Clutch lever 1 15 Clutch lever holder 1 16 Upper handlebar holder 2 1 14 11 12 16 17 10 10 3 4 6 5 7 18 18 8 1 9 2 2 13 15 6 LS LS LS 16 LS 9 Nm 0 9 m kgf 6 5 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 34 Nm 3 4 m kgf 24...

Page 155: ... proce dure Removing the handlebar Order Job Parts to remove Q ty Remarks 1 14 11 12 16 17 10 10 3 4 6 5 7 18 18 8 1 9 2 2 13 15 6 LS LS LS 16 LS 9 Nm 0 9 m kgf 6 5 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 34 Nm 3 4 m kgf 24 ft Ibf T R 9 Nm 0 9 m kgf 6 5 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R ...

Page 156: ...pport the vehicle so that there is no danger of it falling over 2 Install Lower handlebar holders Washers Lower handlebar holder nuts TIP Temporarily tighten the nuts 3 Install Handlebar 1 Upper handlebar holders 2 NOTICE ECA22B1027 First tighten the front bolt on each handle bar holder then the rear bolt Turn the handlebar all the way to the left and right If there is any contact with the fuel ta...

Page 157: ...ith a clean rag WARNING EWA13700 Do not touch the handlebar grip until the rub ber adhesive has fully dried 9 Install Left handlebar switch 1 TIP Align the projection a on the left handlebar switch with the hole b in the handlebar 10 Install Throttle grip 1 Throttle cable 2 Right handlebar switch 3 TIP Be sure to position the washer between the throttle grip and the right handlebar switch Lubricat...

Page 158: ...the punch mark b on the handlebar First tighten the front bolt then the rear bolt 12 Adjust Clutch cable free play Refer to ADJUSTING THE CLUTCH CABLE FREE PLAY on page 3 12 13 Adjust Throttle cable free play Refer to ADJUSTING THE THROTTLE CA BLE FREE PLAY on page 3 6 T R Front brake master cylinder hold er bolt 9 Nm 0 9 m kgf 6 5 ft lbf Clutch lever free play 10 0 15 0 mm 0 39 0 59 in Throttle c...

Page 159: ... on page 4 19 1 Front fork protector 2 2 Brake hose guide 1 3 Brake hose holder 2 4 Front fork protector guide 2 5 Speed sensor lead holder 2 6 Upper bracket pinch bolt 2 Loosen 7 Front fork cap bolt 1 Loosen 8 Lower bracket pinch bolt 2 Loosen 9 Front fork leg 1 For installation reverse the removal proce dure 1 1 4 5 5 3 4 2 8 8 6 6 7 9 23 Nm 2 3 m kgf 17 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R...

Page 160: ... holder 2 3 Brake hose guide 1 4 Speed sensor lead holder 1 5 Upper bracket pinch bolt 2 Loosen 6 Front fork cap bolt 1 Loosen 7 Lower bracket pinch bolt 2 Loosen 8 Front fork leg 1 For installation reverse the removal proce dure 5 5 8 2 1 3 4 7 7 6 4 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 20 Nm 2 0 m kgf 14 ft Ibf T...

Page 161: ...1 3 Spring seat 2 4 Spacer 1 5 Fork spring 1 6 Dust seal 1 7 Oil seal clip 1 8 Damper rod bolt 1 9 Copper washer 1 10 Damper rod 1 11 Rebound spring 1 12 Inner tube 1 13 Oil seal 1 14 Washer 1 15 Outer tube bushing 1 16 Oil flow stopper 1 6 16 7 13 14 15 18 9 8 2 1 10 11 12 17 3 4 3 5 20 Nm 2 0 m kgf 14 ft Ibf T R 28 Nm 2 8 m kgf 20 ft Ibf T R New New New New New New LS LT ...

Page 162: ...For assembly reverse the disassembly pro cedure Disassembling the front fork legs Order Job Parts to remove Q ty Remarks 6 16 7 13 14 15 18 9 8 2 1 10 11 12 17 3 4 3 5 20 Nm 2 0 m kgf 14 ft Ibf T R 28 Nm 2 8 m kgf 20 ft Ibf T R New New New New New New LS LT ...

Page 163: ... support the front fork leg 3 Remove Front fork leg EAS22980 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Drain Fork oil TIP Stroke the inner tube several times while drain ing the fork oil 2 Remove Dust seal 1 Oil seal clip 2 with a flat head screwdriver NOTICE ECA14180 Do not scratch the inner tube TIP Do not remove the fork leg protector fro...

Page 164: ...Do not attempt to straighten a bent inner tube as this may dangerously weaken it 2 Measure Spring free length a Out of specification Replace 3 Check Damper rod Damage wear Replace Obstruction Blow out all of the oil passag es with compressed air Oil flow stopper Damage Replace NOTICE ECA22B1024 When disassembling and assembling the front fork leg do not allow any foreign mate rial to enter the fro...

Page 165: ...Install the rebound spring 3 with its smaller di ameter end a facing up 2 Lubricate Inner tube outer surface 3 Tighten Damper rod bolt 1 TIP While holding the damper rod with the damper rod holder 2 and T handle 3 tighten the damper rod bolt 4 Install Outer tube bushing 1 Washer 2 with the fork seal driver weight 3 and fork seal driver attachment 4 Recommended oil Fork oil 10W or equivalent New 4 ...

Page 166: ...s into the outer tube groove 7 Install Dust seal 1 with the fork seal driver 2 8 Fill Front fork leg with the specified amount of the recom mended fork oil 9 Measure Front fork leg oil level a from the top of the inner tube with the outer tube fully compressed and without the fork spring Out of specification Correct TIP While filling the front fork leg keep it upright After filling slowly pump the...

Page 167: ...Make sure the inner tube is flush with the top of the upper bracket 2 Tighten Lower bracket pinch bolts 1 Cap bolt 2 Upper bracket pinch bolts 3 WARNING EWA22B1018 Make sure the brake hose is routed properly TIP Tighten the lower bracket pinch bolts to specifi cation twice each time in the order of lower pinch bolt upper pinch bolt Do not loosen the bolts after tightening them to specification T R...

Page 168: ...Disconnect 4 Auxiliary light coupler 1 Disconnect 5 Plastic locking tie 1 6 Headlight bracket cover 1 7 Meter assembly coupler 1 Disconnect 8 Front turn signal light coupler 2 Disconnect 9 Speed sensor lead coupler 1 Disconnect 10 Turn signal light 2 11 Meter assembly 1 12 Front fender 1 13 Speed sensor lead holder 1 9 6 12 14 10 8 8 1 10 13 11 2 3 3 4 4 4 7 3 16 15 15 4 5 7 Nm 0 7 m kgf 5 1 ft Ib...

Page 169: ...the removal proce dure Removing the headlight assembly and meter assembly Order Job Parts to remove Q ty Remarks 9 6 12 14 10 8 8 1 10 13 11 2 3 3 4 4 4 7 3 16 15 15 4 5 7 Nm 0 7 m kgf 5 1 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R ...

Page 170: ...7 Rubber washer 1 8 Lower ring nut 1 9 Lower bracket 1 10 Bearing cover 1 11 Upper bearing inner race 1 12 Upper bearing 1 13 Lower bearing 1 14 Upper bearing outer race 1 15 Lower bearing outer race 1 For installation reverse the removal proce dure LS LS 1st 38 Nm 3 8 m kgf 27 ft lbf 2nd 4 Nm 0 4 m kgf 2 9 ft lbf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 140 Nm 14 0 m kgf 100 ft lbf T R 2 3 4 5 6 7 8 10...

Page 171: ...Bearing races a Remove the bearing races from the steering head pipe with a long rod 1 and hammer b Remove the bearing race from the lower bracket with a floor chisel 2 and hammer c Install new bearing races NOTICE ECA14270 If the bearing race is not installed properly the steering head pipe could be damaged TIP Always replace the bearings and bearing races as a set 4 Check Upper bracket Lower bra...

Page 172: ...on page 3 21 3 Install Upper bracket Steering stem nut TIP Temporarily tighten the steering stem nut 4 Install Front fork legs Refer to FRONT FORK on page 4 46 TIP Temporarily tighten the upper and lower bracket pinch bolts 5 Tighten Steering stem nut T R Steering stem nut 140 Nm 14 0 m kgf 100 ft lbf ...

Page 173: ...1 1 2 Rear shock absorber assembly lower nut bolt 1 1 3 Rear shock absorber assembly upper nut bolt 1 1 4 Rear shock absorber assembly 1 5 Connecting rod rear nut bolt 1 1 6 Connecting rod 1 7 Spacer 2 8 Oil seal 4 9 Bushing 2 10 Relay arm nut bolt 1 1 11 Relay arm 2 For installation reverse the removal proce dure 8 5 5 8 8 2 2 10 10 11 11 4 3 3 1 1 6 9 9 7 7 LS LS LS LS New New New 59 Nm 5 9 m kg...

Page 174: ... To release the gas pressure drill a 2 3 mm 0 08 0 12 in hole through the 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 EAS23230 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no dan...

Page 175: ...o the connecting rod 3 Install Relay arms 1 TIP Be sure to face the L mark a on both of the re lay arms to the left Recommended lubricant Lithium soap based grease Installed depth a 0 mm 0 in 2 Connecting rod A Left side B Right side a a 1 2 1 1 1 a a A B a 1 ...

Page 176: ...er assembly Relay arm Refer to REAR SHOCK ABSORBER AS SEMBLY on page 4 60 1 Rear brake hose holder 2 2 Rear mudguard 1 3 Pivot shaft nut 1 4 Pivot shaft 1 5 Swingarm 1 6 Drive chain guide 1 7 Dust cover 2 8 Bushing 2 9 Bushing 1 10 Spacer 1 11 Oil seal 2 11 11 2 3 1 8 7 12 10 7 9 8 6 5 4 LS LS LS LS LS LS New New 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 80 Nm 8 0 m kgf 58 ft Ibf...

Page 177: ...n reverse the removal proce dure Removing the swingarm Order Job Parts to remove Q ty Remarks 11 11 2 3 1 8 7 12 10 7 9 8 6 5 4 LS LS LS LS LS LS New New 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 80 Nm 8 0 m kgf 58 ft Ibf T R ...

Page 178: ...rm vertical movement is not smooth or if there is binding check the bushings and dust covers EAS23360 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 EWA13770 Do not attempt to straighten a bent pivot shaft 3 Wash Pivot shaft Dust covers Bushings 4 Check Dust covers Bushings Damage wear Replace EAS2...

Page 179: ...rive chain that is too tight will overload the engine and other vital parts and one that is too loose can skip and damage the swing arm or cause an accident Therefore keep the drive chain slack within the specified lim its 2 Swingarm A Left side B Right side Drive chain slack 40 0 50 0 mm 1 57 1 97 in 1 1 2 a a A B ...

Page 180: ...rks Swingarm Refer to SWINGARM on page 4 63 1 Drive sprocket cover 1 2 Drive sprocket retainer 1 3 Drive sprocket 1 4 Drive chain 1 5 Spacer 2 6 Bush 2 7 Chain tensioner 2 For installation reverse the removal proce dure 1 5 6 7 4 3 2 LS LS 10 Nm 1 0 m kgf 7 2 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R ...

Page 181: ...5 link section of the drive chain make sure that the drive chain is taut Perform this procedure 2 3 times at a different location each time 2 Check Drive chain Stiffness Clean and lubricate or replace 3 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 it NOTICE E...

Page 182: ...EPLACING THE REAR WHEEL SPROCKET on page 4 17 EAS28800 INSTALLING THE DRIVE CHAIN 1 Lubricate Drive chain 2 Install Drive sprocket cover 1 TIP Be sure not to pinch the neutral switch lead when installing the drive sprocket cover Pass the sidestand switch lead 2 through the groove a in the drive sprocket cover 3 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 20 Recommen...

Page 183: ...t is too tight will overload the engine and other vital parts and one that is too loose can skip and damage the swing arm or cause an accident Therefore keep the drive chain slack within the specified lim its Drive chain slack 40 0 50 0 mm 1 57 1 97 in ...

Page 184: ...CHAIN DRIVE 4 71 ...

Page 185: ...ARMS AND ROCKER ARM SHAFTS 5 15 INSTALLING THE CAMSHAFT AND ROCKER ARMS 5 16 VALVES AND VALVE SPRINGS 5 17 REMOVING THE VALVES 5 18 CHECKING THE VALVES AND VALVE GUIDES 5 18 CHECKING THE VALVE SEATS 5 20 CHECKING THE VALVE SPRINGS 5 21 INSTALLING THE VALVES 5 22 CYLINDER AND PISTON 5 24 REMOVING THE PISTON 5 25 CHECKING THE CYLINDER AND PISTON 5 25 CHECKING THE PISTON RINGS 5 26 CHECKING THE PISTO...

Page 186: ...HIFT SHAFT 5 51 CHECKING THE SHIFT SHAFT 5 52 CHECKING THE STOPPER LEVER 5 52 INSTALLING THE SHIFT SHAFT 5 52 BALANCER GEARS 5 53 REMOVING THE PRIMARY DRIVE GEAR AND BALANCER GEARS 5 54 CHECKING THE BALANCER GEARS AND PRIMARY DRIVE GEAR 5 54 INSTALLING THE PRIMARY DRIVE GEAR AND BALANCER GEARS 5 54 CRANKCASE 5 56 SEPARATING THE CRANKCASE 5 59 CHECKING THE CRANKCASE 5 59 CHECKING THE TIMING CHAIN A...

Page 187: ...THE SHIFT FORKS 5 68 CHECKING THE SHIFT DRUM ASSEMBLY 5 68 CHECKING THE TRANSMISSION 5 68 CHECKING THE LONG CLUTCH PUSH ROD 5 69 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 5 69 INSTALLING THE SHIFT FORKS AND SHIFT DRUM ASSEMBLY 5 69 ...

Page 188: ...er Refer to GENERAL CHASSIS on page 4 1 1 Air induction system hose reed valve assembly to exhaust pipe 1 Disconnect 2 Muffler clamp bolt 1 Loosen 3 Muffler 1 4 Gasket 1 5 Exhaust pipe 1 6 Gasket 1 For installation reverse the removal proce dure 6 2 1 5 4 3 New New 18 Nm 1 8 m kgf 13 ft Ibf T R 20 Nm 2 0 m kgf 14 ft Ibf T R 27 Nm 2 7 m kgf 19 ft Ibf T R ...

Page 189: ... Radiator hoses Radiator bracket Refer to RADIATOR on page 6 1 Coolant temperature sensor Refer to THERMOSTAT on page 6 4 Cylinder head breather hose Refer to WATER PUMP on page 6 6 Air induction system reed valve assembly Refer to AIR INDUCTION SYSTEM on page 7 9 Drive sprocket cover Drive sprocket Refer to CHAIN DRIVE on page 4 67 1 Spark plug cap 1 Disconnect 2 Starter motor lead 1 Disconnect 3...

Page 190: ...2 12 Ignition coil 1 13 Shift pedal 1 14 Plastic locking tie 1 15 Rider footrest sidestand bracket assembly 1 16 Rider footrest brake pedal bracket assembly 1 For installation reverse the removal proce dure Disconnecting the leads and couplers Order Job Parts to remove Q ty Remarks 1 3 4 5 2 6 3 16 7 15 13 11 11 10 10 12 9 14 8 LT 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 10 Nm 1...

Page 191: ... 2 6 Engine rear bracket 1 7 Engine front upper mounting bolt nut 1 1 8 Engine front upper bracket bolt 4 9 Engine front upper bracket 2 10 Engine rear lower mounting bolt nut 1 1 11 Engine 1 For installation reverse the removal proce dure 1 1 8 8 8 7 6 4 2 3 3 11 2 10 10 5 5 4 9 7 9 33 Nm 3 3 m kgf 24 ft Ibf T R 46 Nm 4 6 m kgf 33 ft Ibf T R 46 Nm 4 6 m kgf 33 ft Ibf T R 67 Nm 6 7 m kgf 48 ft Ibf...

Page 192: ... careful not to pull on or damage the wire harness and bat tery breather hose with the engine TIP Do not fully tighten the nuts and bolts 2 Tighten Engine rear lower mounting nut 3 Engine front upper bracket bolts 5 Engine front upper mounting nut 7 Engine rear bracket bolts 9 Engine rear upper mounting nut 11 Engine front lower bracket nuts 14 Engine front lower mounting nut 16 EAS22B1040 INSTALL...

Page 193: ... EAS22B1028 INSTALLING THE MUFFLER AND EXHAUST PIPE 1 Install Gaskets Exhaust pipe Muffler clamp Muffler TIP Do not fully tighten the nuts and bolts 2 Tighten Exhaust pipe nuts 1 Muffler bolts 2 Muffler clamp bolt 3 Brake pedal position 12 0 mm 0 47 in T R Shift pedal bolt 16 Nm 1 6 m kgf 11 ft lbf LOCTITE T R Exhaust pipe nut 20 Nm 2 0 m kgf 14 ft lbf T R Muffler bolt 27 Nm 2 7 m kgf 19 ft lbf a ...

Page 194: ...E BODY on page 7 5 Radiator Refer to RADIATOR on page 6 1 Thermostat Coolant temperature sensor Refer to THERMOSTAT on page 6 4 Water pump Refer to WATER PUMP on page 6 6 1 Spark plug cap 1 Disconnect 2 Spark plug 1 3 Crankshaft end accessing screw 1 4 Timing mark accessing screw 1 New New New New New New E E 4 12 11 14 15 16 15 13 6 7 1 2 4 4 10 9 8 5 4 3 5 E LS M LS 10 Nm 1 0 m kgf 7 2 ft Ibf T ...

Page 195: ... 1 15 Dowel pin 2 16 Timing chain guide exhaust side 1 For installation reverse the removal proce dure Removing the cylinder head Order Job Parts to remove Q ty Remarks New New New New New New E E 4 12 11 14 15 16 15 13 6 7 1 2 4 4 10 9 8 5 4 3 5 E LS M LS 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ...

Page 196: ...ench 2 loosen the camshaft sprocket bolt 3 Remove Camshaft sprocket TIP To prevent the timing chain from falling into the crankcase fasten it with a wire 1 4 Remove Cylinder head TIP Loosen the bolts in the proper sequence as shown Loosen each bolt 1 2 of a turn at a time After all of the bolts are fully loosened remove them Remove the cylinder head from the right side of the vehicle EAS24160 CHEC...

Page 197: ...te the cylinder head several times EAS22B1004 CHECKING THE CAMSHAFT SPROCKET AND TIMING CHAIN GUIDE 1 Check Camshaft sprocket More than 1 4 tooth wear a Replace the camshaft sprocket timing chain and crank shaft as a set 2 Check Timing chain guide exhaust side Damage wear Replace EAS24200 CHECKING THE TIMING CHAIN TENSIONER 1 Check Timing chain tensioner Cracks damage rough movement Re place a Rem...

Page 198: ... decompression cam 2 projects from the camshaft exhaust cam as shown in the illustration A d Move the decompression lever 1 in the di rection of the arrow shown and check that the decompression cam does not project from the camshaft exhaust cam as shown in the illustration B EAS24230 INSTALLING THE CYLINDER HEAD 1 Install Cylinder head TIP Pass the timing chain through the timing chain cavity 2 Ti...

Page 199: ...ding the camshaft temporarily tight en the camshaft sprocket bolt f Remove the wire from the timing chain 4 Install Timing chain tensioner gasket Timing chain tensioner a Remove the timing chain tensioner cap b While lightly pressing the timing chain ten sioner rod by hand turn it clockwise with a thin screwdriver 1 until it stops c Install the gasket and the timing chain ten sioner 2 onto the cyl...

Page 200: ...nter d on the cylinder head Out of alignment Correct Refer to the installation steps above 7 Tighten Camshaft sprocket bolt NOTICE ECA22B1010 Be sure to tighten the camshaft sprocket bolt to the specified torque to avoid the possibil ity of the bolt coming loose and damaging the engine 8 Measure Valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEAR ANCE on page 3 4 T R Cam...

Page 201: ...LINDER HEAD on page 5 7 1 Locknut 4 2 Adjusting screw 4 3 Camshaft retainer 1 4 Rocker arm shaft 2 5 Intake rocker arm 1 6 Exhaust rocker arm 1 7 Camshaft 1 For installation reverse the removal proce dure M M M 1 1 2 2 4 4 7 3 1 1 2 2 5 E E E 6 M 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R ...

Page 202: ...n excessive wear pit ting scratches Replace or check the lubri cation system 3 Measure Rocker arm inside diameter a Out of specification Replace 4 Measure Rocker arm shaft outside diameter a Out of specification Replace Camshaft lobe dimensions Intake A 30 225 30 325 mm 1 1900 1 1939 in Limit 30 125 mm 1 1860 in Intake B 25 127 25 227 mm 0 9893 0 9932 in Limit 25 027 mm 0 9853 in Exhaust A 30 232 ...

Page 203: ...jections a and hole b are positioned as shown in the illustra tion 4 Install Rocker arms Rocker arm shafts 1 TIP Make sure that the cutout a in each rocker arm shaft is facing downward as shown in the illustration Make sure the rocker arm shafts intake and exhaust are completely pushed into the cylin der head Rocker arm to rocker arm shaft clearance 0 009 0 034 mm 0 0004 0 0013 in Limit 0 074 mm 0...

Page 204: ...to CYLINDER HEAD on page 5 7 Rocker arms Camshaft Refer to CAMSHAFT on page 5 14 1 Valve cotter 8 2 Upper spring seat 4 3 Valve spring 4 4 Intake valve 2 5 Exhaust valve 2 6 Valve stem seal 4 7 Lower spring seat 4 8 Valve guide 4 For installation reverse the removal proce dure New New New New M M M M M M M 1 2 3 6 7 8 1 2 3 6 7 8 1 2 3 6 7 8 1 2 3 6 7 8 5 5 4 4 ...

Page 205: ...tters 1 TIP Remove the valve cotters by compressing the valve spring with the valve spring compressor and the valve spring compressor attachment 2 3 Remove Upper spring seat 1 Valve spring 2 Valve 3 Valve stem seal 4 Lower 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 followi...

Page 206: ...em to valve guide clearance TIP After replacing the valve guide reface the valve seat 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 valve guide clear ance exhaust 0 025 0 052 mm 0 0010 0 0020 in Limit 0 100 mm 0 0039 in Valve guide position intake 17 0 17 4 mm 0 669 0 685 in Valve guide position exhaust 14 0 14 4 mm 0 551 0 567 i...

Page 207: ...d 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 C a Out of specification Replace the cylinder head a Apply Mechanic s blueing dye Dykem b onto the valve face b Install the valve into the cylinder head c Press the valve through the valve guide and onto the valve seat to make a clear imp...

Page 208: ...g results lightly tap the valve seat while rotating the valve back and forth be tween your hands e Apply a fine lapping compound to the valve face and repeat the above steps f After every lapping procedure be sure to clean off all of the lapping compound from the valve face and valve seat g Apply Mechanic s blueing dye Dykem b to the valve face h Install the valve into the cylinder head i Press th...

Page 209: ... the recommended lubricant 3 Install Lower spring seat 1 Valve stem seal 2 Free length intake 41 71 mm 1 64 in Limit 39 62 mm 1 56 in Free length exhaust 41 71 mm 1 64 in Limit 39 62 mm 1 56 in Installed compression spring force intake 140 00 162 00 N 14 28 16 52 kgf 31 47 36 42 lbf Installed compression spring force exhaust 140 00 162 00 N 14 28 16 52 kgf 31 47 36 42 lbf Installed length intake 3...

Page 210: ...ve cotters by compressing the valve spring with the valve spring compressor and the valve spring compressor attachment 2 5 To secure the valve cotters onto the valve stem lightly tap the valve tip with a soft face hammer NOTICE ECA13800 Hitting the valve tip with excessive force could damage the valve b Smaller pitch Valve spring compressor 90890 04019 YM 04019 Valve spring compressor attach ment ...

Page 211: ... ty Remarks Cylinder head Refer to CYLINDER HEAD on page 5 7 1 Cylinder 1 2 Cylinder gasket 1 3 Dowel pin 2 4 Piston pin clip 2 5 Piston pin 1 6 Piston 1 7 Top ring 1 8 2nd ring 1 9 Oil ring 1 For installation reverse the removal proce dure E E E E New New New New 6 5 4 7 8 4 2 3 1 3 9 7 Nm 0 7 m kgf 5 1 ft Ibf T R ...

Page 212: ... 2 Remove Top ring 2nd ring Oil ring TIP When removing a piston ring open the end gap with your fingers and lift the other side of the ring over the piston crown EAS24390 CHECKING THE CYLINDER AND PISTON 1 Check Piston wall Cylinder wall Vertical scratches Replace the cylinder and replace the piston and piston rings as a set 2 Measure Piston to cylinder clearance a Measure cylinder bore C with the...

Page 213: ...he piston ring side clearance eliminate any carbon deposits from the piston ring grooves and piston rings 2 Install Piston ring into the cylinder TIP Level the piston ring into the cylinder with the piston crown C maximum of D1 D2 T maximum of D1 or D2 maximum of D5 or D6 R maximum of D1 D3 or D5 minimum of D2 D4 or D6 b 5 0 mm 0 20 in from the bottom edge of the piston Piston Diameter D 51 962 51...

Page 214: ...set EAS24450 INSTALLING THE PISTON AND CYLINDER 1 Install Top ring 1 2nd ring 2 Oil ring expander 3 Lower oil ring rail 4 Upper oil ring rail 5 TIP Be sure to install the piston rings so that the manufacturer marks or numbers face up Piston ring Top ring End gap installed 0 10 0 25 mm 0 0039 0 0098 in Limit 0 50 mm 0 0197 in 2nd ring End gap installed 0 10 0 25 mm 0 0039 0 0098 in Limit 0 60 mm 0 ...

Page 215: ...kcase 3 Lubricate Piston Piston rings Cylinder with the recommended lubricant 4 Offset Piston ring end gaps 5 Install Dowel pins Cylinder gasket Cylinder 1 TIP While compressing the piston rings with one hand install the cylinder with the other hand Pass the timing chain and timing chain guide intake side through the timing chain cavity Recommended lubricant Engine oil New 3 2 1 a New a Top ring b...

Page 216: ...oupler 1 Disconnect 2 Crankshaft position sensor coupler 1 Disconnect 3 Neutral switch lead connector 1 Disconnect 4 Generator cover 1 5 Generator cover gasket 1 6 Dowel pin 2 7 Crankshaft position sensor 1 8 Stator coil 1 9 Generator rotor 1 10 Woodruff key 1 11 Starter clutch gear 1 12 Bearing 1 3 E LS LS E LT LT E E E 18 9 12 13 3 New New 15 11 17 16 14 10 3 7 8 5 6 6 4 7 2 1 LT 10 Nm 1 0 m kgf...

Page 217: ...For installation reverse the removal proce dure Removing the generator and starter clutch Order Job Parts to remove Q ty Remarks 3 E LS LS E LT LT E E E 18 9 12 13 3 New New 15 11 17 16 14 10 3 7 8 5 6 6 4 7 2 1 LT 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 14 Nm 1 4 m kgf 10 ft Ibf T R 70 Nm 7 0 m kgf 50 ft Ibf T R ...

Page 218: ...eel puller 2 Woodruff key NOTICE ECA13880 To protect the end of the crankshaft place an appropriate sized socket between the fly wheel puller set center bolt and the crank shaft TIP Make sure the flywheel puller is centered over the generator rotor EAS24560 REMOVING THE STARTER CLUTCH 1 Remove Starter clutch bolts 1 TIP While holding the generator rotor 2 with the sheave holder 3 remove the starte...

Page 219: ...g the starter clutch gear counter clockwise B it should turn freely otherwise the starter clutch is faulty and must be re placed EAS24600 INSTALLING THE STARTER CLUTCH 1 Install Starter clutch assembly Starter clutch bolts 1 TIP While holding the generator rotor 2 with the sheave holder 3 tighten the starter clutch bolts Do not allow the sheave holder to touch the projections on the generator roto...

Page 220: ... generator rotor 3 Apply Sealant to the crankshaft position sensor stator as sembly lead grommet 4 Install Generator cover TIP Tighten the generator cover bolts in the proper tightening sequence as shown Sheave holder 90890 01701 Primary clutch holder YS 01880 A Yamaha bond No 1215 90890 85505 Three Bond No 1215 T R Generator cover bolt 10 Nm 1 0 m kgf 7 2 ft lbf 1 3 2 1 6 7 8 9 5 4 3 11 2 10 ...

Page 221: ...AS24780 ELECTRIC STARTER Removing the starter motor Order Job Parts to remove Q ty Remarks 1 Starter motor 1 2 Starter motor lead 1 Disconnect For installation reverse the removal proce dure 1 2 10 Nm 1 0 m kgf 7 2 ft Ibf T R ...

Page 222: ...Order Job Parts to remove Q ty Remarks 1 O ring 1 2 Starter motor yoke 1 3 O ring 1 4 Armature assembly 1 5 Starter motor front cover brush holder set 1 6 Brush 2 7 Brush spring 2 For assembly reverse the disassembly pro cedure New New LS 4 2 5 1 6 7 7 6 3 ...

Page 223: ...ommutator and insulation Out of specification Replace the starter motor a Measure the armature assembly resistances with the pocket tester b If any resistance is out of specification re place the starter motor 5 Measure Brush length a Out of specification Replace the starter motor front cover brush holder set 6 Measure Brush spring force Out of specification Replace the brush springs as a set Limi...

Page 224: ...ng Oil seal Damage wear Replace the starter motor front cover brush holder set EAS24800 ASSEMBLING THE STARTER MOTOR 1 Install Starter motor front cover brush holder set 1 Starter motor yoke 2 TIP Align the marks a on the starter motor yoke and starter motor front cover brush holder set 2 a 1 ...

Page 225: ... 1 Clutch cable 1 Disconnect 2 Oil filter element cover 1 3 Oil filter element 1 4 Clutch cover 1 5 Clutch cover gasket 1 6 Dowel pin 2 7 Oil seal 1 For installation reverse the removal proce dure 1 LS New 7 New New LS 4 6 6 5 2 6 4 3 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R ...

Page 226: ...n plate 1 1 8 Clutch plate 4 9 Friction plate 3 3 Green paint mark 10 Friction plate 2 1 11 Clutch damper spring 1 12 Clutch damper spring seat 1 13 Clutch boss nut 1 14 Lock washer 1 15 Clutch boss 1 16 Thrust washer 1 17 Clutch housing 1 New E E 10 4 4 8 9 9 8 8 9 8 7 E 6 4 5 3 2 1 11 12 13 14 15 16 17 18 8 Nm 0 8 m kgf 5 8 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 70 Nm 7 0 m kgf 50 ft Ibf T R ...

Page 227: ...ion reverse the removal proce dure Removing the clutch Order Job Parts to remove Q ty Remarks New E E 10 4 4 8 9 9 8 8 9 8 7 E 6 4 5 3 2 1 11 12 13 14 15 16 17 18 8 Nm 0 8 m kgf 5 8 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 70 Nm 7 0 m kgf 50 ft Ibf T R ...

Page 228: ... Job Parts to remove Q ty Remarks Exhaust pipe Refer to ENGINE REMOVAL on page 5 1 1 Clutch push lever 1 2 Clutch push lever spring 1 3 Circlip 1 4 Oil seal 1 5 Bearing 1 For installation reverse the removal proce dure New New LS E E 1 2 3 4 5 ...

Page 229: ...s to all of the fric tion plates 1 Check Friction plate Damage wear Replace the friction plates as a set 2 Measure Friction plate thickness Out of specification Replace the friction plates as a set TIP Measure the friction plate at four places Universal clutch holder 90890 04086 YM 91042 3 1 2 Friction plate 1 thickness 2 90 3 10 mm 0 114 0 122 in Wear limit 2 80 mm 0 110 in Friction plate 2 thick...

Page 230: ... Replace the clutch springs as a set EAS25150 CHECKING THE CLUTCH HOUSING 1 Check Clutch housing dogs 1 Damage pitting wear Deburr the clutch housing dogs or replace the clutch housing TIP Pitting on the clutch housing dogs will cause er ratic clutch operation 2 Check Bearing Damage wear Replace the bearing and clutch housing EAS25160 CHECKING THE CLUTCH BOSS 1 Check Clutch boss splines Damage pit...

Page 231: ...er to BALANCER GEARS on page 5 53 EAS25210 CHECKING THE PRIMARY DRIVEN GEAR 1 Check Primary driven gear 1 Damage wear Replace the primary drive gear and clutch housing as a set Excessive noise during operation Replace the primary drive gear and clutch housing as a set EAS25240 INSTALLING THE CLUTCH 1 Install Conical spring washer 1 TIP Install the conical spring washer as shown in the illustration...

Page 232: ... and then alternate between a clutch plate and a friction plate 8 Install Pressure plate Clutch springs Clutch spring bolts 1 TIP Tighten the clutch spring bolts in stages and in a crisscross pattern 9 Adjust Clutch mechanism free play a Check that the projection a on the clutch push lever 1 aligns with the mark b shown on the crankcase in the illustration by pushing the clutch push lever manually...

Page 233: ... locknut to specification 10 Install Oil seal 1 11 Install Clutch cover TIP Tighten the clutch cover bolts in the proper tight ening sequence as shown 12 Adjust Clutch cable free play Refer to ADJUSTING THE CLUTCH CABLE FREE PLAY on page 3 12 T R Short clutch push rod locknut 8 Nm 0 8 m kgf 5 8 ft lbf Installed depth a 1 4 1 9 mm 0 055 0 075 in T R Clutch cover bolt 10 Nm 1 0 m kgf 7 2 ft lbf 2 3 ...

Page 234: ...ks Clutch housing Refer to CLUTCH on page 5 38 Balancer drive gear Refer to BALANCER GEARS on page 5 53 1 Oil baffle plate 1 2 Oil pump assembly 1 3 Oil pump drive gear 1 For installation reverse the removal proce dure LT LT 2 3 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 4 Nm 0 4 m kgf 2 9 ft Ibf T R ...

Page 235: ...pump Order Job Parts to remove Q ty Remarks 1 Oil pump housing cover 1 2 Pin 1 3 Oil pump driven gear 1 4 Oil pump inner rotor 1 5 Oil pump outer rotor 1 6 Oil pump housing 1 For assembly reverse the disassembly pro cedure 1 5 2 4 6 3 E E ...

Page 236: ...LING THE OIL PUMP 1 Lubricate Oil pump inner rotor Oil pump outer rotor Oil pump driven gear with the recommended lubricant 2 Install Oil pump outer rotor Oil pump inner rotor 1 Oil pump driven gear Pin 2 TIP When installing the inner rotor align the pin 2 in the oil pump shaft with the groove a in the in ner rotor 1 Inner rotor 2 Outer rotor 3 Oil pump housing Inner rotor to outer rotor tip clear...

Page 237: ...er to CHECKING THE OIL PUMP on page 5 49 EAS25020 INSTALLING THE OIL PUMP 1 Install Oil pump assembly NOTICE ECA22B1011 After tightening the screws make sure the oil pump turns smoothly T R Oil pump assembly screw 4 Nm 0 4 m kgf 2 9 ft lbf 2 a 1 ...

Page 238: ... Clutch housing Refer to CLUTCH on page 5 38 Shift pedal Refer to ENGINE REMOVAL on page 5 1 1 Pin 1 2 Shift shaft 1 3 Circlip 1 4 Shift shaft spring 1 5 Stopper lever 1 6 Stopper lever spring 1 7 Oil seal 1 For installation reverse the removal proce dure LT 5 1 3 6 7 4 2 New New New E LS 10 Nm 1 0 m kgf 7 2 ft Ibf T R ...

Page 239: ...EAS25450 INSTALLING THE SHIFT SHAFT 1 Install Oil seal 1 to the left crankcase 2 2 Install Stopper lever 1 Stopper lever spring 2 TIP Install the stopper lever spring as shown in the illustration Hook the ends of the stopper lever spring onto the stopper lever and the crankcase boss 3 Mesh the stopper lever with the shift drum seg ment assembly 3 Install Shift shaft 1 TIP Hook the end of the shift...

Page 240: ... to CLUTCH on page 5 38 1 Primary drive gear nut 1 2 Balancer driven gear nut 1 3 Washer 1 4 Primary drive gear 1 5 Balancer drive gear 1 6 Straight key 1 7 Lock washer 1 8 Balancer driven gear 1 9 Straight key 1 10 Spacer 1 For installation reverse the removal proce dure 1 3 4 5 6 9 7 8 2 10 New 60 Nm 6 0 m kgf 43 ft Ibf T R 50 Nm 5 0 m kgf 36 ft Ibf T R ...

Page 241: ...rimary drive gear Refer to CHECKING THE PRIMARY DRIVE GEAR on page 5 44 EAS22B1011 INSTALLING THE PRIMARY DRIVE GEAR AND BALANCER GEARS 1 Install Balancer driven gear 1 Lock washer Balancer drive gear 2 Primary drive gear Washer 3 Balancer driven gear nut Primary drive gear nut TIP Align the punch mark a in the balancer drive gear 2 with the punch mark b in the balancer driven gear 1 Be sure to in...

Page 242: ... 5 55 Place an aluminum plate b between the bal ancer drive gear 3 and the balancer driven gear 4 and then tighten the primary drive gear nut 3 Bend the lock washer tab along a flat side of the nut a 4 1 3 3 1 2 b 4 ...

Page 243: ... shaft Refer to SHIFT SHAFT on page 5 51 Starter motor Refer to ELECTRIC STARTER on page 5 34 Balancer gears Refer to BALANCER GEARS on page 5 53 Generator rotor Refer to GENERATOR AND STARTER CLUTCH on page 5 29 1 Timing chain guide intake side 1 2 Timing chain guard 1 3 Timing chain 1 4 Engine oil drain plug 1 8 9 8 New New New New 1 3 2 4 5 6 7 11 11 10 12 LS 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 N...

Page 244: ...1 For installation reverse the removal proce dure Separating the crankcase Order Job Parts to remove Q ty Remarks 8 9 8 New New New New 1 3 2 4 5 6 7 11 11 10 12 LS 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 20 Nm 2 0 m kgf 14 ft Ibf T R 32 Nm 3 2 m kgf 23 ft Ibf T R ...

Page 245: ...move Q ty Remarks Crankshaft Balancer Refer to CRANKSHAFT on page 5 62 Transmission Refer to TRANSMISSION on page 5 65 1 Oil seal 1 2 Bearing retainer 1 3 Bearing 7 For installation reverse the removal proce dure LT E E E 2 1 3 3 3 3 3 3 3 LS 7 Nm 0 7 m kgf 5 1 ft Ibf T R ...

Page 246: ... make sure the crankcase halves sepa rate evenly EAS25580 CHECKING THE CRANKCASE 1 Thoroughly wash the crankcase halves in a mild solvent 2 Thoroughly clean all the gasket surfaces and crankcase mating surfaces 3 Check Crankcase Cracks damage Replace Oil delivery passages Obstruction Blow out with compressed air EAS22B1013 CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDE 1 Check Timing chain Damag...

Page 247: ...ny sealant to come into contact with the oil gallery 3 Install Right crankcase onto the left crankcase TIP Turn the shift drum segment 1 to the position shown in the illustration In this position the shift drum segment teeth will not contact the crankcase during crankcase installation Tap lightly on the right crankcase with a soft face hammer 4 Install Crankcase bolts TIP Tighten each bolt 1 4 of ...

Page 248: ...CRANKCASE 5 61 A Left crankcase B Right crankcase A 1 7 11 12 3 14 2 13 4 5 6 8 9 10 16 15 B ...

Page 249: ...KSHAFT Removing the crankshaft and balancer Order Job Parts to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 56 1 Balancer 1 2 Crankshaft 1 For installation reverse the removal proce dure New New 1 2 LS LS E E ...

Page 250: ...ance Out of specification Replace the crank shaft 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 crank shaft 5 Check Crankshaft journal Scratches wear Replace the crankshaft Crankshaft journal oil passage Obstruction Blow out with compressed air EAS22B1019 INSTALLING THE C...

Page 251: ...g 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 bot toms against the bearing Crankshaft installer pot 90890 01274 Installing pot YU 90058 Crankshaft installer bolt 90890 01275 Bolt YU 90060 Adapter M12 90890 01278 Adapter 3 YU 90063 Spacer crankshaft installer 90890 04081 Pot sp...

Page 252: ...ve Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 56 1 Shift fork guide bar 1 2 Spring 2 3 Shift drum assembly 1 4 Shift fork R 1 5 Shift fork C 1 6 Shift fork L 1 7 Drive axle assembly 1 8 Main axle assembly 1 9 Long clutch push rod 1 For installation reverse the removal proce dure E 7 8 9 2 1 2 3 4 5 6 E E E E ...

Page 253: ...r Job Parts to remove Q ty Remarks 1 2nd pinion gear 1 2 6th pinion gear 1 3 3rd 4th pinion gear 1 4 Circlip 1 5 Toothed washer 1 6 5th pinion gear 1 7 Main axle 1st pinion gear 1 For assembly reverse the disassembly pro cedure E E E 2 1 4 5 3 6 7 New ...

Page 254: ...ar 1 4 Washer 1 5 1st wheel gear 1 6 Spacer 1 7 5th wheel gear 1 8 Circlip 1 9 Toothed washer 1 10 4th wheel gear 1 11 3rd wheel gear 1 12 Drive axle 1 For assembly reverse the disassembly pro cedure 2 1 9 10 7 5 6 11 8 4 12 3 New 2 1 9 10 7 5 6 11 8 4 12 3 New 2 1 9 10 7 5 6 11 8 4 12 3 New 2 1 9 10 7 5 6 11 8 4 12 3 New E E E E ...

Page 255: ...place the shift forks and shift fork guide bar as a set EAS26270 CHECKING THE SHIFT DRUM ASSEMBLY 1 Check Shift drum groove Damage scratches wear Replace the shift drum assembly Shift drum segment 1 Damage wear Replace the shift drum as sembly Shift drum bearing 2 Damage pitting Replace the shift drum as sembly EAS26290 CHECKING THE TRANSMISSION 1 Measure Main axle runout with a centering device a...

Page 256: ...ch push rod bending limit Out of specification Replace the long clutch push rod EAS29020 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 1 Install Toothed washer 1 Circlip 2 TIP Be sure to install the circlip so that its sharp edge a is facing away from the toothed wash er and gear Be sure the circlip ends b are positioned at the axle spline groove c 2 Install 2nd pinion gear 1 TIP Press the 2nd pinion ge...

Page 257: ... 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 and bearing thor oughly Before assembling the crankcase make sure that the transmission is in neutral and that the gears turn freely 1 2 3 5 4 ...

Page 258: ...TRANSMISSION 5 71 ...

Page 259: ...DIATOR 6 3 INSTALLING THE RADIATOR 6 3 THERMOSTAT 6 4 CHECKING THE THERMOSTAT 6 5 INSTALLING THE THERMOSTAT 6 5 WATER PUMP 6 6 DISASSEMBLING THE WATER PUMP 6 8 CHECKING THE WATER PUMP 6 8 ASSEMBLING THE WATER PUMP 6 8 INSTALLING THE WATER PUMP 6 9 ...

Page 260: ...rvoir hose 1 3 Coolant reservoir cap 1 4 Coolant reservoir 1 5 Water pump breather hose 1 6 Radiator outlet hose 1 7 Radiator inlet hose 1 8 Radiator cap 1 9 Radiator cover 1 10 Clutch cable guide 1 11 Radiator fan coupler 1 Disconnect 12 Radiator 1 3 1 4 5 2 6 8 14 13 11 12 9 7 10 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T...

Page 261: ...val proce dure Removing the radiator Order Job Parts to remove Q ty Remarks 3 1 4 5 2 6 8 14 13 11 12 9 7 10 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R 16 Nm 1 6 m kgf 11 ft Ibf T R 16 Nm 1 6 m kgf 11 ft Ibf T R ...

Page 262: ...sure there is no drop in pressure 4 Check Radiator fan Damage Replace Malfunction Check and repair Refer to COOLING SYSTEM on page 8 25 EAS26400 INSTALLING THE RADIATOR 1 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 15 2 Check Cooling system Leaks Repair or replace all faulty parts 3 Measure Radiator cap opening pressure Below th...

Page 263: ...NT on page 3 15 Fuel tank cover assembly Refer to GENERAL CHASSIS on page 4 1 1 Coolant temperature sensor coupler 1 Disconnect 2 Coolant temperature sensor 1 3 Thermostat cover 1 4 Thermostat 1 5 Radiator inlet hose 1 For installation reverse the removal proce dure 1 3 4 5 2 New 10 Nm 1 0 m kgf 7 2 ft Ibf T R 18 Nm 1 8 m kgf 13 ft Ibf T R ...

Page 264: ...AS26480 INSTALLING THE THERMOSTAT 1 Install Thermostat TIP Install the thermostat with its breather hole a facing up 2 Install Copper washer Coolant temperature sensor NOTICE ECA22B1012 Use extreme care when handling the coolant temperature sensor Replace any part that was dropped or subjected to a strong im pact 3 Fill Cooling system with the specified amount of the recom mended coolant Refer to ...

Page 265: ...to CHANGING THE COOLANT on page 3 15 Fuel tank cover assembly Refer to GENERAL CHASSIS on page 4 1 1 Radiator outlet hose 1 2 Water pump breather hose 1 3 Cylinder head breather hose 1 Disconnect 4 Water pump assembly 1 For installation reverse the removal proce dure 1 3 2 4 LS LS New New 10 Nm 1 0 m kgf 7 2 ft Ibf T R ...

Page 266: ...ousing cover gasket 1 3 Impeller shaft retainer 1 4 Impeller shaft 1 5 Water pump housing plate 1 6 Water pump housing gasket 1 7 Water pump seal 1 8 Bearing 1 9 Water pump housing 1 For assembly reverse the disassembly pro cedure LT New New New LS 1 2 9 7 4 8 3 5 6 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R ...

Page 267: ...ASSEMBLING THE WATER PUMP 1 Install Water pump seal 1 into the water pump housing 2 NOTICE ECA14080 Never lubricate the water pump seal surface with oil or grease TIP Install the water pump seal with the special tools to the specified depth as shown in the illustra tion 2 Lubricate Water pump seal lip 3 Install Water pump housing gasket 1 Water pump housing plate 2 Impeller shaft 2 1 2 1 New Mecha...

Page 268: ...all Water pump assembly 1 O rings 2 TIP Align the projection a on the impeller shaft with the slit b on the camshaft sprocket bolt Lubricate the O rings with a thin coat of lithium soap based grease 2 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 15 3 Check Cooling system Leaks Repair or replace all faulty parts 4 Measure Radiator...

Page 269: ... BODY 7 2 INSTALLING THE FUEL PUMP 7 2 INSTALLING THE FUEL TANK 7 3 CHECKING THE FUEL PRESSURE 7 3 THROTTLE BODY 7 5 REMOVING THE THROTTLE BODY 7 7 CHECKING THE FUEL INJECTOR 7 7 CHECKING THE THROTTLE BODY 7 7 INSTALLING THE THROTTLE BODY 7 7 AIR INDUCTION SYSTEM 7 9 CHECKING THE AIR INDUCTION SYSTEM 7 12 ...

Page 270: ... 1 Disconnect 2 Fuel hose 1 3 Fuel tank 1 4 Fuel tank rear bracket 1 5 Fuel tank front bracket 1 6 Fuel pump bracket 1 7 Fuel pump 1 8 Fuel pump gasket 1 For installation reverse the removal proce dure 2 6 6 7 8 4 3 5 1 New 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 4 Nm 0 4 m kgf 2 9 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R LT ...

Page 271: ...Remove Fuel tank TIP Do not set the fuel tank down on the installation surface of the fuel pump Be sure to lean the fuel tank in an upright position EAS26640 REMOVING THE FUEL PUMP 1 Remove Fuel pump NOTICE ECA14720 Do not drop the fuel pump or give it a strong shock Do not touch the base section of the fuel sender EAS26670 CHECKING THE FUEL PUMP BODY 1 Check Fuel pump body Obstruction Clean Crack...

Page 272: ...ntil a distinct click is heard To install the fuel hose onto the fuel pump or fuel injector slide the fuel hose connector cov er 3 on the end of the hose in the direction of the arrow shown EAS27010 CHECKING THE FUEL PRESSURE 1 Check Fuel pressure a Disconnect the fuel hose 1 from the fuel pump WARNING EWA22B1009 Cover fuel hose connections with a cloth when disconnecting them Residual pres sure i...

Page 273: ...FUEL TANK 7 4 d Start the engine e Measure the fuel pressure Out of specification Replace the fuel pump Output pressure 250 0 kPa 2 50 kgf cm 36 3 psi 3 2 1 ...

Page 274: ...connect 3 Fuel injector 1 4 Fuel injector gasket 1 5 Throttle body sensor assembly coupler 1 Disconnect 6 Throttle cable 1 Disconnect 7 Throttle body joint clamp screw 2 Loosen 8 Throttle body cover 1 WR125R 9 Throttle body 1 NOTICE ECA22B1013 The throttle body should not be disas sembled 10 Throttle body joint 1 E 5 7 7 10 11 9 6 8 4 3 1 2 LS New New 10 Nm 1 0 m kgf 7 2 ft Ibf T R 2 Nm 0 2 m kgf ...

Page 275: ...everse the removal proce dure Removing the throttle body Order Job Parts to remove Q ty Remarks E 5 7 7 10 11 9 6 8 4 3 1 2 LS New New 10 Nm 1 0 m kgf 7 2 ft Ibf T R 2 Nm 0 2 m kgf 1 4 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R LT ...

Page 276: ...ent Do not use any caustic carburetor cleaning solution b Blow out all of the passages with compressed air EAS22B1022 INSTALLING THE THROTTLE BODY 1 Install Throttle body joint clamps TIP Align the projections a on the throttle body joint with the slot b in each throttle body joint clamp 2 Install Throttle body joint TIP Align the projection a on the throttle body joint with the slot b in the inta...

Page 277: ...THROTTLE BODY 7 8 ...

Page 278: ...AIR INDUCTION SYSTEM 7 9 EAS27040 AIR INDUCTION SYSTEM 2 1 3 ...

Page 279: ...AIR INDUCTION SYSTEM 7 10 1 Air induction system hose air filter case to reed valve assembly 2 Air induction system reed valve assembly 3 Air induction system hose reed valve assembly to exhaust pipe ...

Page 280: ...arts to remove Q ty Remarks 1 Air induction system hose reed valve assembly to exhaust pipe 1 2 Air induction system reed valve assembly 1 3 Air induction system hose air filter case to reed valve assembly 1 For installation reverse the removal proce dure 3 2 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R ...

Page 281: ...operly Cracks damage Replace 2 Check Air induction system reed valve assembly Cracks damage Replace 3 Check Air induction system reed valve assembly op eration a Blow air into the pipe 1 of the air induction system reed valve assembly and check that it comes out from the pipe 2 b Blow air into the pipe 2 of the air induction system reed valve assembly and check that it does not come out from the p...

Page 282: ...AIR INDUCTION SYSTEM 7 13 ...

Page 283: ... 8 13 LIGHTING SYSTEM 8 15 CIRCUIT DIAGRAM 8 15 TROUBLESHOOTING 8 17 SIGNALING SYSTEM 8 19 CIRCUIT DIAGRAM 8 19 TROUBLESHOOTING 8 21 COOLING SYSTEM 8 25 CIRCUIT DIAGRAM 8 25 TROUBLESHOOTING 8 27 FUEL INJECTION SYSTEM 8 29 CIRCUIT DIAGRAM 8 29 ECU SELF DIAGNOSTIC FUNCTION 8 31 SELF DIAGNOSTIC FUNCTION TABLE 8 32 TROUBLESHOOTING METHOD 8 34 DIAGNOSTIC MODE 8 34 TROUBLESHOOTING DETAILS 8 42 FUEL PUMP...

Page 284: ...ION COIL 8 70 CHECKING THE IGNITION SPARK GAP 8 70 CHECKING THE CRANKSHAFT POSITION SENSOR 8 71 CHECKING THE LEAN ANGLE SENSOR 8 71 CHECKING THE STARTER MOTOR OPERATION 8 72 CHECKING THE STATOR COIL 8 72 CHECKING THE RECTIFIER REGULATOR 8 72 CHECKING THE HORN 8 73 CHECKING THE FUEL SENDER 8 73 CHECKING THE SPEED SENSOR 8 74 CHECKING THE RADIATOR FAN MOTOR 8 74 CHECKING THE COOLANT TEMPERATURE SENS...

Page 285: ......

Page 286: ... R G B Y Y L R B Y L B R Y L G R Gy B Sb Y B R W O W G Y Br B Br Y G B R B L B L B R B OFF ON PASS A A A WIRE HARNESS CLUTCH SWITCH SUB LEAD R Gy B W W W W W W W R B R W O Br Br L R Y Br L R B Dg Ch Y Br L R W R R Gy R Gy R R R B P W P W Gy B Gy B Br W Br W Y Y G R O B Y R O O B R W R L G R Gy B Gy B Gy R Y G Y G G W Gy R R L Y Br L L B B R B Br Br W Br W Br B R B R W L W R W Sb W P B Ch Dg G Y G ...

Page 287: ...YSTEM 8 2 1 Crankshaft position sensor 3 Main switch 5 Main fuse 6 Battery 14 Engine stop switch 20 Lean angle sensor 22 ECU engine control unit 23 Ignition coil 24 Spark plug 60 Ignition fuse 63 Sidestand switch ...

Page 288: ... or replace the battery 3 Check the spark plug Refer to CHECKING THE SPARK PLUG on page 3 7 Re gap or replace the spark plug 4 Check the ignition spark gap Refer to CHECKING THE IGNI TION SPARK GAP on page 8 70 Ignition system is OK 5 Check the spark plug cap Refer to CHECKING THE SPARK PLUG CAP on page 8 69 Replace the spark plug cap 6 Check the ignition coil Refer to CHECKING THE IGNI TION COIL ...

Page 289: ...ndlebar switch 10 Check the sidestand switch Refer to CHECKING THE SWITCHES on page 8 61 Replace the sidestand switch 11 Check the lean angle sensor Refer to CHECKING THE SWITCHES on page 8 61 Replace the lean angle sensor 12 Check the entire ignition system wiring Refer to CIRCUIT DIAGRAM on page 8 1 Properly connect or repair the ignition sys tem wiring Replace the ECU ...

Page 290: ...Y R G B Y Y L R B Y L B R Y L G R Gy B Sb Y B R W O W G Y Br B Br Y G B R B L B L B R B R B L B OFF ON PASS A A A WIRE HARNESS CLUTCH SWITCH SUB LEAD R Gy B W W W W W W W R B R W O Br Br L R Y Br L R B Dg Ch Y Br L R W R R Gy R Gy R R R B P W P W Gy B Gy B Br W Br W Y Y G R O B Y R O O B R W R L G R Gy B Gy B Gy R Y G Y G G W Gy R R L Y Br L L B B R B Br Br W Br W Br B R B R W L W R W Sb W P B Ch ...

Page 291: ...M 8 6 3 Main switch 5 Main fuse 6 Battery 7 Starter motor 8 Starter relay 9 Starting circuit cut off relay 10 Diode 11 Neutral switch 13 Start switch 14 Engine stop switch 60 Ignition fuse 62 Clutch switch 63 Sidestand switch ...

Page 292: ... prevents the starter motor from operating when neither of these condi tions 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 circuit cut off relay is closed and the engine can be started by pressing the start switch 1 2 3 12 6 5 4 13 a b 7 8 10 11 9 a WHEN THE TRAN...

Page 293: ...tery terminals Recharge or replace the battery 3 Check the starter motor operation Refer to CHECKING THE START ER MOTOR OPERATION on page 8 72 Starter motor is OK Perform the electric starting system troubleshooting starting with step 5 4 Check the starter motor Refer to CHECKING THE START ER MOTOR on page 5 36 Repair or replace the starter motor 5 Check the starting circuit cut off re lay Refer t...

Page 294: ...THE SWITCHES on page 8 61 Replace the neutral switch 11 Check the sidestand switch Refer to CHECKING THE SWITCHES on page 8 61 Replace the sidestand switch 12 Check the clutch switch Refer to CHECKING THE SWITCHES on page 8 61 Replace the clutch switch 13 Check the start switch Refer to CHECKING THE SWITCHES on page 8 61 The start switch is faulty Replace the right handlebar switch 14 Check the en...

Page 295: ...ELECTRIC STARTING SYSTEM 8 10 ...

Page 296: ...ED L B Br L L Y RED R L B Br L L Y R W W W R B R L B R W R W R W L W B L W B R B R W L B R B Sb W OFF ON 2 4 5 1 3 6 7 8 9 10 11 12 13 14 58 59 60 61 62 63 R Gy B W W W W W W W R B Br Br L R Y Br L R B Br L R W R R R R L Y Br L L B B R B Br B R B R W L W R W Sb W R Y R Y R B R R R W R L B L B L W L B B B R R L B R W R B R R W L B R B R B Sb W A A R B L B L B L B R B R B ...

Page 297: ...CHARGING SYSTEM 8 12 2 AC magneto 4 Rectifier regulator 5 Main fuse 6 Battery ...

Page 298: ...THE BATTERY on page 8 65 Refill battery fluid Clean the battery terminals Recharge or replace the battery 3 Check the stator coil Refer to CHECKING THE STATOR COIL on page 8 72 Replace the crankshaft position sen sor stator assembly 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 8 72 Replace the rectifier regulator 5 Check the entire charging system wiring Refer...

Page 299: ...CHARGING SYSTEM 8 14 ...

Page 300: ... Y L R B Y L B R Y L G R Gy B Sb Y B R W O W G Y Br B Br Y G B R B L B L B R B R B L B OFF ON PASS A A A WIRE HARNESS CLUTCH SWITCH SUB LEAD R Gy B W W W W W W W R B R W O Br Br L R Y Br L R B Dg Ch Y Br L R W R R Gy R Gy R R R B P W P W Gy B Gy B Br W Br W Y Y G R O B Y R O O B R W R L G R Gy B Gy B Gy R Y G Y G G W Gy R R L Y Br L L B B R B Br Br W Br W Br B R B R W L W R W Sb W P B Ch Dg G Y G ...

Page 301: ... 22 ECU engine control unit 33 License plate light 34 Tail brake light 41 Headlight relay 43 Pass switch 44 Dimmer switch 47 Headlight 48 Auxiliary light 51 Meter light 53 High beam indicator light 58 Signaling system fuse 59 Headlight fuse 60 Ignition fuse ...

Page 302: ... and sig naling system Refer to CHECKING THE FUS ES on page 8 65 Replace the fuse s 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 65 Refill battery fluid Clean the battery terminals Recharge or replace the battery 4 Check the main switch Refer to CHECKING THE SWITCHES on page 8 61 Replace the main switch 5 Check the dimmer switch Refer to CHECKING THE SWITCHES on page 8 ...

Page 303: ...LIGHTING SYSTEM 8 18 NG OK 8 Check the entire lighting system wiring Refer to CIRCUIT DIAGRAM on page 8 15 Properly connect or repair the lighting sys tem wiring Replace the ECU or meter assembly ...

Page 304: ...Y Y L R B Y L B R Y L G R Gy B Sb Y B R W O W G Y Br B Br Y G B R B L B L B R B R B L B OFF ON PASS A A A WIRE HARNESS CLUTCH SWITCH SUB LEAD R Gy B W W W W W W W R B R W O Br Br L R Y Br L R B Dg Ch Y Br L R W R R Gy R Gy R R R B P W P W Gy B Gy B Br W Br W Y Y G R O B Y R O O B R W R L G R Gy B Gy B Gy R Y G Y G G W Gy R R L Y Br L L B B R B Br Br W Br W Br B R B R W L W R W Sb W P B Ch Dg G Y G...

Page 305: ...ght switch 34 Tail brake light 35 Rear right turn signal light 36 Rear left turn signal light 37 Front right turn signal light 38 Front left turn signal light 39 Turn signal relay 40 Horn 45 Horn switch 46 Turn signal switch 50 Multi function meter 54 Turn signal indicator light 55 Neutral indicator light 57 Speed sensor 58 Signaling system fuse 60 Ignition fuse ...

Page 306: ...gnaling sys tem Refer to CHECKING THE FUS ES on page 8 65 Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 65 Refill battery fluid Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 61 Replace the main switch 4 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on pag...

Page 307: ...Refer to CHECKING THE BULBS AND BULB SOCKETS on page 8 64 Replace the tail brake light bulb socket or both 2 Check the front brake light switch Refer to CHECKING THE SWITCHES on page 8 61 Replace the front brake light switch 3 Check the rear brake light switch Refer to CHECKING THE SWITCHES on page 8 61 Replace the rear brake light switch 4 Check the entire signaling system wiring Refer to CIRCUIT...

Page 308: ...er to CIRCUIT DIAGRAM on page 8 19 Properly connect or repair the signaling system wiring Replace the meter assembly 1 Check the neutral switch Refer to CHECKING THE SWITCHES on page 8 61 Replace the neutral switch 2 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 8 19 Properly connect or repair the signaling system wiring Replace the meter assembly 1 Check the fuel sende...

Page 309: ... 1 Check the speed sensor Refer to CHECKING THE SPEED SENSOR on page 8 74 Replace the speed sensor 2 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 8 19 Properly connect or repair the signaling system wiring Replace the ECU or meter assembly ...

Page 310: ...Y L R B Y L B R Y L G R Gy B Sb Y B R W O W G Y Br B Br Y G B R B L B L B R B R B L B OFF ON PASS A A A WIRE HARNESS CLUTCH SWITCH SUB LEAD R Gy B W W W W W W W R B R W O Br Br L R Y Br L R B Dg Ch Y Br L R W R R Gy R Gy R R R B P W P W Gy B Gy B Br W Br W Y Y G R O B Y R O O B R W R L G R Gy B Gy B Gy R Y G Y G G W Gy R R L Y Br L L B B R B Br Br W Br W Br B R B R W L W R W Sb W P B Ch Dg G Y G Y...

Page 311: ... 5 Main fuse 6 Battery 19 Coolant temperature sensor 22 ECU engine control unit 29 Radiator fan motor relay 30 Radiator fan motor 52 Coolant temperature warning light 58 Signaling system fuse 60 Ignition fuse 61 Radiator fan motor fuse ...

Page 312: ...Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 61 Replace the main switch 4 Check the radiator fan motor Refer to CHECKING THE RADIA TOR FAN MOTOR on page 8 74 Replace the radiator fan motor 5 Check the radiator fan motor relay Refer to CHECKING THE RE LAYS on page 8 67 Replace the radiator fan motor relay 6 Check the co...

Page 313: ...COOLING SYSTEM 8 28 ...

Page 314: ... G B Y Y L R B Y L B R Y L G R Gy B Sb Y B R W O W G Y Br B Br Y G B R B L B L B R B R B L B OFF ON PASS A A A WIRE HARNESS CLUTCH SWITCH SUB LEAD R Gy B W W W W W W W R B R W O Br Br L R Y Br L R B Dg Ch Y Br L R W R R Gy R Gy R R R B P W P W Gy B Gy B Br W Br W Y Y G R O B Y R O O B R W R L G R Gy B Gy B Gy R Y G Y G G W Gy R R L Y Br L L B B R B Br Br W Br W Br B R B R W L W R W Sb W P B Ch Dg ...

Page 315: ...e sensor 18 Throttle position sensor 19 Coolant temperature sensor 20 Lean angle sensor 21 Self diagnosis signal coupler 22 ECU engine control unit 23 Ignition coil 25 FID fast idle solenoid 26 Fuel injector 27 Fuel pump 29 Radiator fan motor relay 41 Headlight relay 56 Engine trouble warning light 57 Speed sensor 59 Headlight fuse 60 Ignition fuse 63 Sidestand switch ...

Page 316: ... engine trouble warning light flashes when the start switch is being pushed to start the engine If a malfunction is detected in the system by the self diagnostic function the ECU provides an appro priate substitute characteristic operation and alerts the rider of the detected malfunction by illuminat ing the engine trouble warning light After the engine has been stopped the lowest fault code numbe...

Page 317: ...ceived from a sensor the ECU processes the specified values that are programmed for each sensor in order to provide the engine with alternate operating instructions that enable the engine to continue to operate or stop operating depending on the conditions Warning light indica tion ECU operation Fuel injection opera tion Vehicle operation Flashing Warning provided when unable to start engine Opera...

Page 318: ...U lead broken or discon nected A break or disconnection of the blue yellow lead of the ECU is de tected Unable Unable 21 Coolant temperature sensor open or short circuit Coolant temperature sensor open or short circuit detected Able Able 22 Intake air tempera ture sensor open or short circuit Intake air temperature sensor open or short circuit detected Able Able 30 Lean angle sensor latch up detec...

Page 319: ... Check the operation of the following sensors and actuators in the Diagnostic mode Refer to Sensor operation table and Actuator op eration table If a malfunction is detected in the sensors or actuators repair or replace all faulty parts If no malfunction is detected in the sensors and actuators check and repair the inner parts of the engine EAS27431 DIAGNOSTIC MODE It is possible to monitor the se...

Page 320: ...coupler 1 and then connect the FI diagnostic tool 2 as shown 3 Set the main switch to ON and start the engine TIP The coolant temperature and engine speed appear on the LCD of the FI diagnostic tool The POWER LED green comes on If a malfunction is detected in the system the WARNING LED orange comes on 4 Turn the engine off TIP If a malfunction is detected in the system the fault code appears on th...

Page 321: ... Select the diagnostic code number corresponding to the fault code number by pressing the UP and DOWN buttons TIP The diagnostic code number appears on the LCD D01 D70 To decrease the selected diagnostic code number press the DOWN button Press the DOWN but ton for 1 second or longer to automatically decrease the diagnostic code numbers To increase the selected diagnostic code number press the UP b...

Page 322: ...improp erly installed throttle body sensor assembly Intake air system malfunc tion correct pressure is not supplied to throttle body sensor assembly Intake air pressure sensor hole is clogged Malfunction in ECU Improperly installed throttle body sensor assembly D03 15 Throttle position sensor open or short circuit detect ed Malfunction in wire harness ECU coupler Malfunction in throttle body senso...

Page 323: ...function in ignition coil connectors Open circuit in wire harness Malfunction in ignition coil Malfunction in ECU Malfunction in a component of ignition sys tem Improperly installed ignition coil D30 39 Fuel injector open or short circuit detected Malfunction in wire harness ECU coupler Malfunction in fuel injector coupler Open or short circuit in wire harness Defective fuel injector Malfunction i...

Page 324: ...te the throttle while pushing the start switch If the display value changes the performance is OK D05 Intake air temperature Displays the intake air tem perature Compare the actually mea sured intake air tempera ture with the FI diagnostic tool display value D06 Coolant temperature Displays the coolant temper ature Compare the actually mea sured coolant temperature with the FI diagnostic tool disp...

Page 325: ...he de tected code numbers When all code numbers are shown the display repeats the same process D62 Malfunction history code erasure No history 00 History exists Up to 16 fault codes To erase the history press the MODE button of the FI diagnostic tool D70 Control number 00 254 Diag nostic code No Item Actuation Checking method D30 Ignition coil When the MODE button is pressed the ignition coil is a...

Page 326: ...ve times at five second intervals 2 seconds on 3 seconds off and the WARNING LED on the FI diagnostic tool the high beam indicator light and the headlight come on each time the relay is actuated Check the operating sound of the headlight relay five times D54 FID fast idle solenoid When the MODE button is pressed the FID fast idle so lenoid is actuated five times at one second intervals and the WAR...

Page 327: ...ry is insufficiently charged Malfunction in wire harness ECU coupler Malfunction in FI diagnostic tool coupler Open or short circuit in wire harness Malfunction in the FI diagnostic tool Malfunction in the ECU Fault code No 12 Symptom No normal signals are received from the crankshaft posi tion sensor Diagnostic code No Order Item components and probable cause Check or maintenance job Reinstatemen...

Page 328: ...ler If there is a malfunction repair it and connect the coupler se curely Set the main switch to ON 2 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between throttle body sensor assembly coupler and ECU coupler gray red gray red pink white pink white gray black gray black 3 Defective throttle body sensor assem bly intake air pressure sensor Execute the...

Page 329: ... method 1 Connections Throttle body sensor assembly cou pler Wire harness ECU coupler Check the coupler for any pins that may have pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely Start the en gine and let it run at idle 2 Defective throttle body sensor assem bly intake air pressure sensor Execute the diagnostic mode Code N...

Page 330: ...arness Repair or replace if there is an open or short circuit Between throttle body sensor assembly coupler and ECU coupler gray red gray red gray black gray black yellow yellow 3 Throttle position sensor lead wire open circuit output voltage check Check for open circuit and re place the throttle body gray red gray black Open circuit item Output voltage Ground wire open circuit 5 V Output wire ope...

Page 331: ...dle and then race it Fault code No 19 Symptom A break or disconnection of the blue yellow lead of the ECU is detected Diagnostic code No D20 Sidestand switch Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connections Wire harness ECU coupler Execute the diagnostic mode Code No D20 Check the coupler for any pins that may have pulled out Check the locking co...

Page 332: ...oolant temperature sensor coupler Wire harness ECU coupler Check the coupler for any pins that may have pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect it securely 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between coolant temperature sensor coupler and ECU cou pler gray black gray black green...

Page 333: ...f the couplers If there is a malfunction repair it and connect the coupler se curely Set the main switch to ON 2 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between throttle body sensor assembly coupler and ECU coupler brown white brown white gray black gray black 3 Defective throttle body sensor assem bly intake air temperature sensor Execute the d...

Page 334: ...owever the engine cannot be restarted unless the main switch is first set to OFF 2 Installed condition of the lean angle sensor Check for looseness or pinching 3 Connections Lean angle sensor coupler Wire harness ECU coupler Check the coupler for any pins that may have pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely 4 Defe...

Page 335: ...he connector and coupler If there is a malfunction repair it and connect the coupler se curely Start the en gine and let it run at idle 2 Open circuit in wire harness Repair or replace if there is an open circuit Between ignition coil connector and ECU coupler orange orange Between ignition coil connector and engine stop switch coupler red white red white Between engine stop switch coupler and ECU...

Page 336: ...tion of the couplers If there is a malfunction repair it and connect the coupler se curely Start the en gine 2 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between fuel injector coupler and ECU coupler orange black orange black Between fuel injection coupler and engine stop switch coupler red white red white Between engine stop switch coupler and ECU...

Page 337: ...ins that may have pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely Set the main switch to ON 2 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between lean angle sensor coupler and ECU coupler gray red gray red yellow green yellow green gray black gray black 3 Defective lean angl...

Page 338: ...in wire harness Repair or replace if there is an open or short circuit Between speed sensor coupler and ECU coupler gray gray gray black gray black gray red gray red 3 Defective speed sensor Execute the diagnostic mode Code No D07 Replace if defective Refer to CHECKING THE SPEED SENSOR on page 8 74 Fault code No 44 Symptom Error is detected while reading from or writing on EE PROM Diagnostic code ...

Page 339: ... if defective Refer to CHECKING THE RECTIFIER REGULATOR on page 8 72 4 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between battery and main fuse terminal red red Between main fuse terminal and main switch coupler red red Between main switch coupler and fuse box terminal ignition fuse brown blue brown blue Between fuse box terminal ig nition fuse and...

Page 340: ...Y Y L R B Y L B R Y L G R Gy B Sb Y B R W O W G Y Br B Br Y G B R B L B L B R B R B L B OFF ON PASS A A A WIRE HARNESS CLUTCH SWITCH SUB LEAD R Gy B W W W W W W W R B R W O Br Br L R Y Br L R B Dg Ch Y Br L R W R R Gy R Gy R R R B P W P W Gy B Gy B Br W Br W Y Y G R O B Y R O O B R W R L G R Gy B Gy B Gy R Y G Y G G W Gy R R L Y Br L L B B R B Br Br W Br W Br B R B R W L W R W Sb W P B Ch Dg G Y G...

Page 341: ...FUEL PUMP SYSTEM 8 56 3 Main switch 5 Main fuse 6 Battery 14 Engine stop switch 22 ECU engine control unit 27 Fuel pump 60 Ignition fuse ...

Page 342: ...65 Refill battery fluid Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 61 Replace the main switch 4 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 8 61 The engine stop switch is faulty Replace the right handlebar switch 5 Check the fuel pump operation Refer to CHECKING THE FUEL PRESSURE on page 7 3 R...

Page 343: ...FUEL PUMP SYSTEM 8 58 ...

Page 344: ...ELECTRICAL COMPONENTS 8 59 EAS27972 ELECTRICAL COMPONENTS 1 2 3 4 5 6 8 10 11 12 13 14 15 16 17 18 19 7 9 20 21 22 23 24 25 ...

Page 345: ... sensor intake air temperature sensor throttle position sensor 9 FID fast idle solenoid 10 Lean angle sensor 11 ECU engine control unit 12 Turn signal relay 13 Rectifier regulator 14 Headlight relay 15 Radiator fan motor relay 16 Starting circuit cut off relay 17 Rear brake light switch 18 Sidestand switch 19 Neutral switch 20 Crankshaft position sensor 21 Radiator fan 22 Speed sensor 23 Horn 24 B...

Page 346: ... 61 EAS27980 CHECKING THE SWITCHES R B L B B L W Dg Ch Br W P B G Y L B Y R Y Y B G Dg Ch Br W R Y P L B PASS OFF ON R R L B L B Br L Sb W Br L L Y L Y RED Br Y G B B BLUE B B R W R W R W R W L W B 1 10 9 7 6 8 5 4 3 2 11 12 ...

Page 347: ...62 1 Clutch switch 2 Pass switch 3 Dimmer switch 4 Horn switch 5 Turn signal switch 6 Rear brake light switch 7 Sidestand switch 8 Neutral switch 9 Front brake light switch 10 Main switch 11 Engine stop switch 12 Start switch ...

Page 348: ...and to the Ω 1 range When checking for continuity switch 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 give...

Page 349: ... 1 Remove Bulb WARNING EWA22B1003 Since the headlight bulbs get extremely hot keep flammable products and your hands away from them until they have cooled down NOTICE ECA22B1015 Be sure to hold the socket firmly when re moving the bulb Never pull the lead other wise it may be pulled out of the terminal in the coupler Avoid touching the glass part of a headlight bulb to keep it free from oil otherw...

Page 350: ... 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 than that specified Improvising or us ing a fuse with the wrong amperage rating may cause extensive damage to the electri cal system cause the lighting and ign...

Page 351: ...tery 6 Check Specific gravity Less than 1 280 Recharge the battery 7 Charge Battery WARNING EWA13300 Do not quick charge a battery NOTICE ECA13620 Loosen the battery sealing caps Make sure the battery breather hose and battery vent are free of obstructions To ensure maximum performance always charge a new battery before using it Do not use a high rate battery charger They force a high amperage cur...

Page 352: ...CE ECA22B1018 When checking the battery make sure the battery breather hose is properly installed and routed correctly If the battery breather hose is positioned so as to allow electrolyte or hydrogen gas from the battery to contact the frame the vehicle and its finish may be damaged Refer to CABLE ROUTING on page 2 35 10 Install Battery 11 Check Battery terminals Dirt Clean with a wire brush Loos...

Page 353: ...robe Result Continuity between 3 and 4 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 1 Positive battery terminal R R W R B L B 2 1 4 3 1 3 2 4 R B L B R W L W R Y L B R Y W B 1 2 3 4 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 1 Positive batt...

Page 354: ...als as shown c Check the diode for continuity d Check the diode for no continuity EAS28060 CHECKING THE SPARK PLUG CAP 1 Check Spark plug cap resistance Out of specification Replace Turn signal relay output voltage DC 12 V Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe brown white 1 Negative tester probe ground Br W Br 1 Br W Br 1 Pocket tester 90890 03112 Analog p...

Page 355: ...the spark plug cap from the igni tion coil b Connect the pocket tester Ω 1k to the ig nition coil as shown c Measure the secondary coil resistance EAS28930 CHECKING THE IGNITION SPARK GAP 1 Check Ignition spark gap Out of specification Perform the ignition system troubleshooting starting with step 5 Resistance 5 0 kΩ Pocket tester 90890 03112 Analog pocket tester YU 03112 C Primary coil resistance...

Page 356: ... the pocket tester Ω 100 to the crankshaft position sensor coupler as shown b Measure the crankshaft position sensor re sistance EAS28130 CHECKING THE LEAN ANGLE SENSOR 1 Remove Lean angle sensor 2 Check Lean angle sensor output voltage Out of specification Replace a Connect the lean angle sensor to the wire harness b Connect the pocket tester DC 20 V to the lean angle sensor coupler as shown Mini...

Page 357: ...erefore 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 crank shaft position sensor stator assembly a Connect the pocket tester Ω 1 to the stator coil coupler as shown b Measure the stator coil resistance...

Page 358: ...place a Connect a battery 12 V to the horn b Turn the adjusting screw in direction a or b until the specified horn sound is obtained EAS28230 CHECKING THE FUEL SENDER 1 Disconnect Fuel pump coupler Fuel hose from the fuel pump 2 Remove Fuel tank 3 Remove Fuel pump assembly from the fuel tank 4 Check Fuel sender resistance Out of specification Replace the fuel pump assembly Charging voltage 14 V at...

Page 359: ... should cycle from 0 6 V to 4 8 V to 0 6 V to 4 8 V EAS28250 CHECKING THE RADIATOR FAN MOTOR 1 Check Radiator fan motor Faulty rough movement Replace a Disconnect the radiator fan motor coupler from the wire harness b Connect the battery DC 12 V as shown Sender unit resistance full 19 0 21 0 Ω at 20 C 68 F Sender unit resistance empty 137 0 143 0 Ω at 20 C 68 F Pocket tester 90890 03112 Analog poc...

Page 360: ... THE THROTTLE BODY SENSOR ASSEMBLY WARNING EWA22B1002 Do not remove the throttle body sensor as sembly Handle the throttle body sensor assembly with special care Never subject the throttle body sensor as sembly to strong shocks If the throttle body sensor assembly is dropped replace it Throttle position sensor 1 Check Throttle position sensor a Connect the digital circuit tester to the termi nals ...

Page 361: ...Intake air temperature sensor resistance Out of specification Replace the throttle body a Connect the pocket tester Ω 1k to the throttle body sensor assembly coupler as shown b Measure the intake air temperature sensor resistance Positive tester probe yellow terminal 3 Negative tester probe gray black terminal 2 Throttle position sensor output voltage closed position 0 63 0 73 V Intake air pressur...

Page 362: ...specification Replace the throttle body a Connect the pocket tester Ω 10 to the ter minals of the FID fast idle solenoid b Measure the FID fast idle solenoid resis tance FID fast idle solenoid resistance 31 5 38 5 Ω Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe red black terminal 1 Negative tester probe yellow red terminal 2 R B 1 2 ...

Page 363: ...DLING SPEED 9 1 POOR MEDIUM AND HIGH SPEED PERFORMANCE 9 2 FAULTY GEAR SHIFTING 9 2 SHIFT PEDAL DOES NOT MOVE 9 2 JUMPS OUT OF GEAR 9 2 FAULTY CLUTCH 9 2 OVERHEATING 9 2 OVERCOOLING 9 3 POOR BRAKING PERFORMANCE 9 3 FAULTY FRONT FORK LEGS 9 3 UNSTABLE HANDLING 9 3 FAULTY LIGHTING OR SIGNALING SYSTEM 9 4 ...

Page 364: ...l pump Faulty fuel pump 3 Throttle body Deteriorated or contaminated fuel Sucked in air Electrical system 1 Battery Discharged battery Faulty battery 2 Fuse s 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 Crack...

Page 365: ...gn object in a shift drum groove Seized shift fork Bent shift fork guide bar Transmission Seized transmission gear Foreign object between transmission gears Improperly assembled transmission EAS28550 JUMPS OUT OF GEAR Shift shaft Incorrect shift pedal position Improperly returned stopper lever Shift forks Worn shift fork Shift drum Incorrect axial play Worn shift drum groove Transmission Worn gear...

Page 366: ...ase on the brake pad Incorrect brake fluid level EAS28660 FAULTY FRONT FORK LEGS Leaking oil Bent damaged or rusty inner tube Cracked or damaged outer tube Improperly installed oil seal Damaged oil seal lip Incorrect oil level high Loose damper rod bolt Damaged damper rod bolt copper washer Cracked or damaged cap bolt O ring Malfunction Bent or damaged inner tube Bent or damaged outer tube Damaged...

Page 367: ... accessories Incorrect connection Burnt out tail brake light bulb Tail brake light bulb burnt out Wrong tail brake light bulb Faulty battery Tail brake light bulb life expired Turn signal does not come on Faulty turn signal switch Faulty turn signal relay Burnt out turn signal bulb Incorrect connection Damaged or faulty wire harness Improperly grounded circuit Faulty battery Blown damaged or incor...

Page 368: ... signal light 39 Turn signal relay 40 Horn 41 Headlight relay 42 Left handlebar switch 43 Pass switch 44 Dimmer switch 45 Horn switch 46 Turn signal switch 47 Headlight 48 Auxiliary light 49 Meter assembly 50 Multi function meter 51 Meter light 52 Coolant temperature warning light 53 High beam indicator light 54 Turn signal indicator light 55 Neutral indicator light 56 Engine trouble warning light...

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Page 371: ... O W B Y L Gy Dg Y Sb W Sb Ch G W L B R B Sb W R B Y R G B Y Y L R B Y L B R Y L G R Gy B Sb Y B R W O W G Y Br B Br Y G B R B L B L B R B OFF ON PASS A WIRE HARNESS CLUTCH SWITCH SUB LEAD R Gy B W W W W W W W R B R W O Br Br L R Y Br L R B Dg Ch Y Br L R W R R Gy R Gy R R R B P W P W Gy B Gy B Br W Br W Y Y G R O B Y R O O B R W R L G R Gy B Gy B Gy R Y G Y G G W Gy R R L Y Br L L B B R B Br Br W...

Page 372: ...WR125R WR125X 2009 DIAGRAMA ELÉCTRICO BLACK BLACK BLACK GREEN GREEN BLACK BLACK GREEN GREEN RED RED BLACK OFF ON PASS A A A WIRE HARNESS CLUTCH SWITCH SUB LEAD 2 4 5 1 3 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 ...

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