Yamaha XG250 Service Manual Download | Manualshive

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TROUBLESHOOTING

8-1

EAS28450

TROUBLESHOOTING

EAS28460

GENERAL INFORMATION

NOTE:

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

ment of parts.

EAS28470

STARTING FAILURES
Engine

1. Cylinder(s) and cylinder head(s)

●

Loose spark plug

●

Loose cylinder head or cylinder

●

Damaged cylinder head gasket

●

Damaged cylinder gasket

●

Worn or damaged cylinder

●

Incorrect valve clearance

●

Improperly sealed valve

●

Incorrect valve-to-valve-seat contact

●

Incorrect valve timing

●

Faulty valve spring

●

Seized valve

2. Piston(s) and piston ring(s)

●

Improperly installed piston ring

●

Damaged, worn or fatigued piston ring

●

Seized piston ring

●

Seized or damaged piston

3. Air filter

●

Improperly installed air filter

●

Clogged air filter element

4. Crankcase and crankshaft

●

Improperly assembled crankcase

●

Seized crankshaft

Fuel system

1. Fuel tank

●

Empty fuel tank

●

Clogged fuel filter

●

Clogged fuel strainer

●

Clogged fuel tank drain hose

●

Clogged rollover valve

●

Clogged rollover valve hose

●

Deteriorated or contaminated fuel

2. Fuel pump

●

Faulty fuel pump

●

Faulty fuel pump relay

3. Fuel cock

●

Clogged or damaged fuel hose

4. Carburetor(s)

●

Deteriorated or contaminated fuel

●

Clogged pilot jet

●

Clogged pilot air passage

●

Sucked-in air

●

Damaged float

●

Worn needle valve

●

Improperly installed needle valve seat

●

Incorrect fuel level

●

Improperly installed pilot jet

●

Clogged starter jet

●

Faulty starter plunger

●

Improperly adjusted starter cable

Electrical system

1. Battery

●

Discharged battery

●

Faulty battery

2. Fuse(s)

●

Blown, damaged or incorrect fuse

●

Improperly installed fuse

3. Spark plug(s)

●

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(s)

●

Cracked or broken ignition coil body

●

Broken or shorted primary or secondary coils

●

Faulty spark plug lead

5. Ignition system

●

Faulty ignitor unit

●

Faulty pickup coil

●

Broken generator rotor woodruff key

6. Switches and wiring

●

Faulty main switch

●

Faulty engine stop switch

●

Broken or shorted wiring

●

Faulty neutral switch

●

Faulty start switch

●

Faulty sidestand switch

●

Faulty clutch switch

●

Improperly grounded circuit

●

Loose connections

7. Starting system

●

Faulty starter motor

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Summary of Contents for XG250

Page 1: ...SERVICE MANUAL XG250 4D6 28197 E0 ...

Page 2: ...ended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives Yamaha Motor Company Ltd is continually striving to improve all of its models Modifications and sig nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable ...

Page 3: ...Pressure plate 1 3 Primary drive gear nut 1 4 Friction plate 6 5 Clutch plate 5 6 Cushion spring 1 7 Seat plate 1 8 Clutch boss nut 1 9 Clutch boss 1 10 Thrust washer 1 11 Clutch housing 1 12 Claw washer 1 13 Primary driven gear 1 14 Locknut Washer 1 1 15 Push rod1 1 16 Push plate 1 17 Push rod 2 Ball 1 1 3 1 2 4 5 6 7 8 9 10 11 12 13 14 16 15 17 CLUTCH 5 32 2 Straighten the lock washer tab 3 Loos...

Page 4: ...5 16 LT New 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 Wheel bearing grease 13 Lithium soap based grease 14 Molybdenum disulfide grease 15 Apply locking agent LOCTITE 16 Replace the part ...

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

Page 6: ...MODEL LABEL 1 1 ENGINE SERIAL NUMBER 1 1 IMPORTANT INFORMATION 1 2 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 2 REPLACEMENT PARTS 1 2 GASKETS OIL SEALS AND O RINGS 1 2 LOCK WASHERS PLATES AND COTTER PINS 1 2 BEARINGS AND OIL SEALS 1 2 CIRCLIPS 1 3 CHECKING THE CONNECTIONS 1 4 SPECIAL TOOLS 1 5 ...

Page 7: ...er 1 is stamped into the right side of the steering head pipe MODEL LABEL The model label 1 is affixed to the frame This information will be needed to order spare parts ENGINE SERIAL NUMBER The engine serial number 1 is stamped into the elevated part of the right rear section of the en gine 1 1 1 ...

Page 8: ...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 GASKETS OIL SEALS AND O RINGS 1 When overhauling the engine replace all gaskets seals and O rings All gasket sur faces oil seal lips and O rings must be cleaned 2 During reassembly properly oil all mating parts and beari...

Page 9: ...damage the bearing surfac es 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 opposite the thrust 3 that the circlip receives ...

Page 10: ...mes 3 Check All connections Loose connection Connect properly NOTE If the pin 1 on the terminal is flattened bend it up 4 Connect Lead Coupler Connector NOTE Make sure all connections are tight 5 Check Continuity with the pocket tester NOTE If there is no continuity clean the terminals When checking the wire harness perform steps 1 to 3 As a quick remedy use a contact revitalizer available at most...

Page 11: ...hen placing an order refer to the list provided below to avoid any mistakes NOTE For U S A and Canada use part number starting with YM YU or ACC For others use part number starting with 90890 Tool name Tool No Illustration Reference pages Slide hammer bolt 90890 01083 Slide hammer bolt 6 mm YU 01083 1 5 13 Weight 90890 01084 YU 01083 3 5 13 Crankcase separating tool 90890 01135 Crankcase separator...

Page 12: ... 01268 Spanner wrench YU 01268 4 50 Crankshaft installer pot 90890 01274 Installing pot YU 90058 5 61 Crankshaft installer bolt 90890 01275 Bolt YU 90060 5 61 Spacer 90890 01288 5 61 Adapter M10 90890 01383 Adapter 2 YU 90062 5 61 Tool name Tool No Illustration Reference pages YU 90058 YU 90059 ...

Page 13: ...t adjusting tool 90890 01311 Valve adjuster 3 mm 4 mm YM 08035 A 3 4 Flywheel puller 90890 01362 Heavy duty puller YU 33270 B 5 51 Fork seal driver weight 90890 01367 Replacement hammer YM A9409 7 4 45 4 46 Fork seal driver attachment ø35 90890 01369 Replacement 35 mm YM A9409 5 4 45 4 46 Tool name Tool No Illustration Reference pages YM 01300 YM A9409 7 YM A5142 4 ...

Page 14: ... 90890 03081 Engine compression tester YU 33223 3 9 Extension 90890 04082 3 9 Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 4 7 35 7 36 7 37 7 41 7 42 7 43 7 44 7 45 7 47 Pocket tester 90890 03132 3 4 Digital circuit tester 90890 03174 Model 88 Multimeter with tachometer YU A1927 5 47 Valve guide remover ø6 90890 04064 Valve guide remover 6 0 mm YM 04064 A 5 20 Tool name Tool No Illu...

Page 15: ...ø6 90890 04066 Valve guide reamer 6 0 mm YM 04066 5 20 Universal clutch holder 90890 04086 YM 91042 5 33 5 35 Valve lapper 90890 04101 Valve lapping tool YM A8998 5 21 Ignition checker 90890 06754 Opama pet 4000 spark checker YM 34487 7 44 Digital tachometer 90890 06760 3 4 Tool name Tool No Illustration Reference pages ...

Page 16: ...TIONS 2 12 TIGHTENING TORQUES 2 14 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 14 ENGINE TIGHTENING TORQUES 2 14 CHASSIS TIGHTENING TORQUES 2 16 LUBRICATION POINTS AND LUBRICANT TYPES 2 19 ENGINE 2 19 CHASSIS 2 20 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 21 ENGINE OIL LUBRICATION CHART 2 21 LUBRICATION DIAGRAMS 2 23 CABLE ROUTING 2 25 ...

Page 17: ... Overall length 2010 mm 79 1 in Overall width 800 mm 31 5 in Overall height 1145 mm 45 1 in Seat height 790 mm 31 1 in Wheelbase 1330 mm 52 4 in Ground clearance 280 mm 11 02 in Minimum turning radius 1900 mm 74 8 in Weight With oil and fuel 120 0 kg 265 lb Maximum load 180 kg 397 lb ...

Page 18: ...or SAE20W50 Recommended engine oil grade API service SE SF SG type or higher Engine oil quantity Total amount 1 40 L 1 48 US qt 1 23 Imp qt Without oil filter element replacement 1 20 L 1 27 US qt 1 06 Imp qt With oil filter element replacement 1 30 L 1 37 US qt 1 14 Imp qt Oil filter type Wire mesh Oil pump Oil pump type Trochoid Inner rotor to outer rotor tip clearance 0 150 mm 0 0059 in Limit 0...

Page 19: ...nks DID SCR 0404 SDH 104 Tensioning system Automatic Rocker arm rocker arm shaft Rocker arm inside diameter 12 000 12 018 mm 0 4724 0 4731 in Limit 12 036 mm 0 4739 in Rocker arm shaft outside diameter 11 981 11 991 mm 0 4717 0 4721 in Limit 11 950 mm 0 4705 in Rocker arm to rocker arm shaft clearance 0 009 0 037 mm 0 0004 0 0015 in Valve valve seat valve guide Valve clearance cold Intake 0 05 0 1...

Page 20: ...lve guide clearance exhaust 0 025 0 052 mm 0 0010 0 0020 in Limit 0 100 mm 0 0039 in Valve stem runout 0 030 mm 0 0012 in Cylinder head valve seat width intake 0 90 1 10 mm 0 0354 0 0433 in Limit 1 7 mm 0 07 in Cylinder head valve seat width exhaust 0 90 1 10 mm 0 0354 0 0433 in Limit 1 7 mm 0 07 in Valve spring Inner spring Free length intake 36 17 mm 1 42 in Limit 34 47 mm 1 36 in Free length ex...

Page 21: ...rate K2 intake 40 80 N mm 232 97 lb in 4 16 kgf mm Spring rate K1 exhaust 30 90 N mm 176 44 lb in 3 15 kgf mm Spring rate K2 exhaust 40 80 N mm 232 97 lb in 4 16 kgf mm Installed compression spring force intake 128 50 157 90 N 28 89 35 50 lb 13 10 16 10 kgf Installed compression spring force exhaust 128 50 157 90 N 28 89 35 50 lb 13 10 16 10 kgf Spring tilt intake 2 5 1 6 mm Spring tilt exhaust 2 ...

Page 22: ...iston pin bore clearance 0 002 0 022 mm 0 0001 0 0009 in Limit 0 073 mm 0 0029 in Piston ring Top ring Ring type Barrel Dimensions B T 0 90 2 75 mm 0 04 0 11 in End gap installed 0 19 0 31 mm 0 0075 0 0122 in Limit 0 60 mm 0 0236 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 80 mm 0 03 0 11 in End gap installed 0 30 0...

Page 23: ...n Clutch spring free length 40 10 mm 1 58 in Minimum length 38 10 mm 1 50 in Spring quantity 5 pcs Clutch housing thrust clearance 0 100 0 350 mm 0 0039 0 0138 in Clutch housing radial clearance 0 010 0 044 mm 0 0004 0 0017 in Push rod bending limit 0 500 mm 0 0197 in Transmission Transmission type Constant mesh 5 speed Primary reduction system Spur gear Primary reduction ratio 74 24 3 083 Seconda...

Page 24: ...ir jet 1 20 Jet needle 5A12 3 Needle jet E1 Pilot air jet 1 0 90 Pilot outlet 0 8 x 1 2 Pilot jet 34 Bypass 1 0 8 Bypass 2 0 8 Bypass 3 0 8 Pilot screw turns out 1 1 4 Valve seat size 1 8 Starter jet 1 0 50 Starter jet 2 90 Throttle valve size 33 Float height 10 5 mm 0 41 in Idling condition Engine idling speed 1300 1500 r min CO 0 5 1 5 Intake vacuum 29 0 37 0 kPa 8 6 10 9 inHg 218 278 mmHg Oil t...

Page 25: ...ONE TW201 Wear limit front 0 8 mm 0 03 in Rear tire Type With tube Size 120 90 16M C 63P Manufacturer model BRIDGESTONE TW202 Wear limit rear 0 8 mm 0 03 in Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198 lb Front 125 kPa 18 psi 1 25 kgf cm2 1 25 bar Rear 150 kPa 22 psi 1 50 kgf cm2 1 50 bar Loading condition 90 180 kg 198 397 lb Front 150 kPa 22 psi 1 50 kgf cm2 1 50 bar ...

Page 26: ... to lock angle right 48 0 Front suspension Type Telescopic fork Spring shock absorber type Coil spring oil damper Front fork travel 180 0 mm 7 09 in Fork spring free length 478 0 mm 18 82 in Limit 468 4 mm 18 44 in Spring rate K1 3 80 N mm 21 70 lb in 0 39 kgf mm Spring rate K2 4 60 N mm 26 27 lb in 0 47 kgf mm Spring stroke K1 0 0 114 0 mm 0 00 4 49 in Spring stroke K2 114 0 180 0 mm 4 49 7 09 in...

Page 27: ...CHASSIS SPECIFICATIONS 2 11 Drive chain Type manufacturer 428V DAIDO Link quantity 124 Drive chain slack 40 0 45 0 mm 1 57 1 77 in 15 link length limit 191 5 mm 7 54 in ...

Page 28: ...l manufacturer F5XT YAMAHA Standard output 14 0 V190 W5000 r min Stator coil resistance 0 56 0 84 Ω Rectifier regulator Regulator type Semi conductor short circuit Model manufacturer SH629A 12 SHINDENGEN No load regulated voltage 14 1 14 9 V Rectifier capacity 10 0 A Withstand voltage 200 0 V Battery Model YTZ7S Voltage capacity 12 V 6 0 Ah Specific gravity 1 310 Manufacturer YUASA Ten hour rate a...

Page 29: ...m 0 83 in Mica undercut depth 1 50 mm 0 06 in Starter relay Model manufacturer 2768096 A JIDECO Amperage 180 0 A Horn Horn type Plane Quantity 1 pcs Model manufacturer HF 12 NIKKO Maximum amperage 3 0 A Coil resistance 1 01 1 11 Ω Performance 108 116 dB 2m Turn signal relay Relay type Full transistor Model manufacturer FE218BH DENSO Built in self canceling device No Turn signal blinking frequency ...

Page 30: ...15 1 5 11 14 mm 10 mm 30 3 0 22 17 mm 12 mm 55 5 5 40 19 mm 14 mm 85 8 5 61 22 mm 16 mm 130 13 0 94 Item Thread size Q ty Tightening torque Remarks Cylinder head upper M8 4 22 Nm 2 2 m kg 16 ft lb Cylinder head M8 2 20 Nm 2 0 m kg 14 ft lb Camshaft lock plate M6 2 8 Nm 0 8 m kg 5 8 ft lb Cylinder head side cover 1 and 2 M55 1 1 18 Nm 1 8 m kg 13 ft lb Cylinder head side cover 3 M6 2 10 Nm 1 0 m kg...

Page 31: ...t crankcase cover M6 14 10 Nm 1 0 m kg 7 2 ft lb Crankcase M6 12 10 Nm 1 0 m kg 7 2 ft lb Oil drain bolt M12 1 20 Nm 2 0 m kg 14 ft lb Ground lead clutch cable holder M6 1 10 Nm 1 0 m kg 7 2 ft lb Neutral switch lead clamp M6 1 7 Nm 0 7 m kg 5 1 ft lb Starter idle gear cover M6 3 8 Nm 0 8 m kg 5 8 ft lb Starter clutch M8 3 30 Nm 3 0 m kg 22 ft lb Primary drive gear nut M16 1 80 Nm 8 0 m kg 58 ft l...

Page 32: ...2 72 Nm 7 2 m kg 52 ft lb Down tube and frame rear under M10 1 72 Nm 7 2 m kg 52 ft lb Down tube and engine M10 2 72 Nm 7 2 m kg 52 ft lb Chain tensioner M8 2 23 Nm 2 3 m kg 17 ft lb Helmet holder M6 1 7 Nm 0 7 m kg 5 1 ft lb Grab bar M8 4 32 Nm 3 2 m kg 23 ft lb Seat M6 2 7 Nm 0 7 m kg 5 1 ft lb Flap guard M6 2 7 Nm 0 7 m kg 5 1 ft lb Horn M6 1 10 Nm 1 0 m kg 7 2 ft lb Tool box M6 2 7 Nm 0 7 m kg...

Page 33: ...ylinder M6 2 13 Nm 1 3 m kg 9 4 ft lb Rear footrest bracket M8 4 23 Nm 2 3 m kg 17 ft lb Rear footrest bolt M8 2 23 Nm 2 3 m kg 17 ft lb Front footrest cover bolt M6 2 10 Nm 1 0 m kg 7 2 ft lb Brake pedal M10 1 30 Nm 3 0 m kg 22 ft lb Rear brake caliper cover M6 2 7 Nm 0 7 m kg 5 1 ft lb Chain support M6 2 7 Nm 0 7 m kg 5 1 ft lb Seal guard M5 3 5 Nm 0 5 m kg 3 6 ft lb Front fork cap bolt M30 1 23...

Page 34: ... Nm 1 0 m kg 7 2 ft lb Shift arm and engine M6 1 10 Nm 1 0 m kg 7 2 ft lb Handle crown and inner tube M8 2 23 Nm 2 3 m kg 17 ft lb Headlight M6 2 9 Nm 0 9 m kg 6 5 ft lb Front fork leg cable guide M5 1 0 7 Nm 0 07 m kg 0 5 ft lb Front brake hose and meter cable M4 1 0 5 Nm 0 05 m kg 0 4 ft lb Grab bar M6 4 10 Nm 1 0 m kg 7 2 ft lb Battry leads 2 2 Nm 0 2 m kg 1 5 ft lb Master cylinder cap front an...

Page 35: ...n surfaces Valve stems intake and exhaust Valve stem ends intake and exhaust Rocker arm shafts intake and exhaust Camshaft Valve rocker arms Starter idler gears 1 Starter idler gears 2 Starter wheel gear Push rods Clutch housing Push lever shaft Push rod ball Drive axle main axle Transmission gear Shift fork guide bar Shift drum Shift shaft Shift shaft pawl Crankcase matting surface Yamaha bond No...

Page 36: ...ever bolt and pivoting point and metal moving point Silicon grease Rear master cylinder push rod Silicon grease Brake caliper and brake caliper bolt Silicon grease Clutch lever pivoting point and metal moving point Pivot shaft Swingarm bush collar and oil seal lip Relay arm bush collar bearing and oil seal lip Relay arm connecting rod shaft outside Rear wheel axle Sidestand switch and link point F...

Page 37: ...N SYSTEM CHART AND DIAGRAMS 2 21 LUBRICATION SYSTEM CHART AND DIAGRAMS ENGINE OIL LUBRICATION CHART Drive axle Main axle Pin with hole Crank shaft Oil filter Oil pump Oil strainer Cylinder head Cam shaft Oil pan ...

Page 38: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 22 1 Camshaft 2 Oil filter element 3 Oil check window 4 Oil pump assembly 5 Oil strainer ...

Page 39: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 23 LUBRICATION DIAGRAMS ...

Page 40: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 24 1 Camshaft 2 Drive axle 3 Main axle 4 Push lever shaft 5 Oil pump assembly 6 Oil strainer 7 Crankshaft assembly 8 Oil filter element ...

Page 41: ...CABLE ROUTING 2 25 CABLE ROUTING ...

Page 42: ... light right lead meter lead and headlight relay with a clamp at the place around the frame gusset end Cut the end of the clamp with facing it to the grommmet side I Do not project from the side cover out side J Route the throttle cable upon the breather hose K Route the throttle cable to the upper side of the breather hose Fasten the clutch cable starter motor lead and carburetor warmer lead with...

Page 43: ...CABLE ROUTING 2 27 ...

Page 44: ...he meter lead and the headlight lead together at the center of the located point and cut off the end of it And make sure to fasten the T stud of the stay AA Cut the end of the bundle less than 2 mm AB Route the turn signal light right lead handlebar switch right lead front brake switch lead and meter lead to the upper side of the meter lead and the head light relay AC To cover AD To meter and head...

Page 45: ...CABLE ROUTING 2 29 ...

Page 46: ... to the body M Fasten the left handlebar switch lead clutch switch lead front left turn signal light lead and main switch lead with a clamp Face the open side downward N Fasten the front brake hose and speed ometer cable with a cable guide O Fit the projection of the cable guide to the hole of the front fork P Pass the front brake hose and speedom eter cable through the cable guide Pos sible to us...

Page 47: ...CABLE ROUTING 2 31 ...

Page 48: ...and turn the edge behind the cross tube D Make sure that the clip end faces to the front side E Fasten the thermo switch lead rectifier regulator lead and regulator ground lead with a clamp F Make sure that the clip end faces to the upper side G Make sure to fasten the wire harness with the T stud H Route the cutch cable between the throt tle cable decelerator and throttle cable accelerator I Thro...

Page 49: ...CABLE ROUTING 2 33 ...

Page 50: ...to use synthetic deter gent or water as lubricant during assem bling the front brake hose C Route the front turn signal light right lead behind the front brake hose and throttle cable and above the meter lead and headlight lead D Fasten the front brake hose and speed ometer cable with a cable guide After pushing the front brake hose into the guide route the speedometer cable to the guide Possible ...

Page 51: ...4 CHASSIS 3 15 ADJUSTING THE FRONT DISC BRAKE 3 15 ADJUSTING THE REAR DISC BRAKE 3 15 CHECKING THE BRAKE FLUID LEVEL 3 16 CHECKING THE FRONT BRAKE PADS 3 16 CHECKING THE REAR BRAKE PADS 3 17 CHECKING THE FRONT BRAKE HOSE 3 17 CHECKING THE REAR BRAKE HOSE 3 17 ADJUSTING THE REAR BRAKE LIGHT SWITCH 3 17 BLEEDING THE HYDRAULIC BRAKE SYSTEM 3 18 ADJUSTING THE DRIVE CHAIN SLACK 3 19 LUBRICATING THE DRI...

Page 52: ...R READING 1000 km ANNUAL CHECK 1 10 20 30 40 1 Fuel line Check fuel hoses for cracks or damage 2 Spark plug Check condition Clean and regap Replace 3 Valves Check valve clearance Adjust 4 Air filter element Replace 5 Clutch Check operation Adjust 6 Front brake Check operation fluid level and vehicle for fluid leakage Replace brake pads Whenever worn to the limit 7 Rear brake Check operation fluid ...

Page 53: ...bolts and screws are properly tightened 16 Sidestand Check operation Lubricate 17 Sidestand switch Check operation 18 Front fork Check operation and for oil leakage 19 Shock absorber assembly Check operation and shock absorber for oil leak age 20 Rear suspension relay arm and con necting arm pivot ing points Check operation Lubricate with molybdenum disulfide grease 21 Carburetor Check starter cho...

Page 54: ... cap Spark plug Cylinder head side cover1 1 Cylinder head side cover2 2 Cylinder head side cover3 Refer to CYLINDER HEAD on page 5 5 2 Remove Straight screw plug 1 Center cap 2 3 Measure Valve clearance Out of specification Adjust a Turn the crankshaft counterclockwise b When the piston is at TDC on the compres sion stroke align the punch mark a in the camshaft sprocket with the stationary b on th...

Page 55: ... cover left and right Seat side cover left and right Refer to GENERAL CHASSIS on page 4 1 EAS20580 CHECKING THE EXHAUST GAS When the air induction system is not operat ing 1 Stand the vehicle on a level surface NOTE Place the vehicle on a suitable stand Make sure the vehicle is upright Measure the exhaust gas at idle when the air induction system is not operating 2 Install Temperature probe tester...

Page 56: ...shown in the illustration Be sure to set the heat resistant rubber tube so that exhaust gas does not leak out 7 Measure CO density Out of specification Adjust Within specification Measure the exhaust gas when the air induction system is operat ing Refer to CHECKING THE EXHAUST GAS on page 3 6 8 Adjust CO density Turn the pilot screw to adjust the CO density level to specification 9 If the specifie...

Page 57: ...ling prove 2 NOTE Since it is necessary to insert the sampling probe 600 mm into the exhaust pipe be sure to use a heat resistant rubber tube as shown in the illustration Be sure to set the heat resistant rubber tube so that exhaust gas does not leak out 6 Measure CO density Out of specification Check the air induc tion system Refer to AIR INDUCTION SYSTEM on page 6 9 7 After checking the air indu...

Page 58: ...spec ified engine idling speed is obtained 5 Adjust Throttle cable free play Refer to ADJUSTING THE THROTTLE CA BLE FREE PLAY on page 3 7 EAS20640 ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE Prior to adjusting the throttle cable free play the engine idling speed should be adjusted properly 1 Check Throttle cable free play a Out of specification Adjust 2 Adjust Throttle cable free play Pocket teste...

Page 59: ...e 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 CAUTION ECA13330 Before removing the spark plug blow away any dirt accumulated in the spark plug well with compressed air to prevent it from falling into the cylinder 3 Check Spark plug type Incorrect Change 4 Check Electrode 1 Damage wear Replace the spark ...

Page 60: ...pression pressure Out of specification Refer to steps c and d a Set the main switch to ON b With the throttle wide open crank the engine until the reading on the compression gauge stabilizes WARNING EWA12960 To prevent sparking ground the spark plug lead before cranking the engine c If the compression pressure is above the maximum specification check the cylinder head valve surfaces and piston cro...

Page 61: ...grade of CD a or higher and do not use oils labeled ENERGY CON SERVING II b 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 NOTE Before checking the engine oil level wait a few minutes until the oil has settled EAS20810 CHANGING THE ENGINE OIL 1 Start the engine warm it up for several m...

Page 62: ...l 9 Install Engine oil filler bolt 10 Start the engine warm it up for several min utes and then turn it off 11 Check Engine for 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 gallery bolt 1 b Start the engine and keep it idling until en gine oil starts to seep from the oil gallery bolt If no engi...

Page 63: ...h cable free play is obtained c Tighten the locknut 1 NOTE If the specified clutch cable free play cannot be obtained on the handlebar side of the cable use the adjusting nut on the clutch cable side Clutch cable side a Loosen the locknut 3 b Turn the adjusting nut 4 in direction a or b until the specified clutch cable free play is obtained c Tighten the locknuts 3 EAS20960 REPLACING THE AIR FILTE...

Page 64: ...e sealing sur faces are aligned to prevent any air leaks 5 Install Seat Refer to GENERAL CHASSIS on page 4 1 EAS20990 CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD 1 Remove Left side cover Right side cover Seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 6 1 2 Check Carburetor joint 1 Intake manifold 2 Cracks damage Replace Refer to CARBURETOR on page 6 3 3 Instal...

Page 65: ...reather hose is routed correctly EAS21080 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the ex haust pipes and gaskets 1 Check Exhaust pipe Muffler Exhaust pipe joint Cracks damage Replace Gasket Exhaust gas leaks Replace 2 Check Tightening torque 1 1 Exhaust pipe nut 1 18 Nm 1 8 m kg 13 ft lb Exhaust pipe and muffler bolt 2 20 Nm 2 0 m kg 14 ft lb Muffler and muffler brack...

Page 66: ... the brake system will consid erably reduce braking performance CAUTION ECA13490 After adjusting the brake lever position make sure there is no brake drag EAS21200 ADJUSTING THE REAR DISC BRAKE 1 Check Brake pedal position distance a from the top of the rider footrest to the top of the brake pedal Out of specification Adjust 2 Adjust Brake pedal position a Loosen the locknut 1 b Turn the adjusting...

Page 67: ...ber 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 flu ids may result in a harmful chemical reac tion 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 v...

Page 68: ...E 1 Check Brake hose 1 Cracks damage wear Replace 2 Check Brake hose clamp Loose Connection Tighten the clamp bolt 3 Hold the vehicle upright and apply the front brake several times 4 Check Brake hose Brake fluid leakage Replace the damaged hose Refer to REAR BRAKE on page 4 26 EAS21330 ADJUSTING THE REAR BRAKE LIGHT SWITCH NOTE The rear brake light switch is operated by move ment of the brake ped...

Page 69: ...luid reservoir to the proper lev el with the recommended brake fluid b Install the diaphragm brake master cylinder reservoir or brake fluid reservoir c Connect a clear plastic hose 1 tightly to the bleed screw 2 d Place the other end of the hose into a con tainer e Slowly apply the brake several times f Fully pull the brake lever or fully press down the brake pedal and hold it in position g Loosen...

Page 70: ... wheel several times and find the tightest position of drive chain 3 Check Drive chain slack a Out of specification Adjust NOTE Measure the drive chain 1 slack at the point that drive chain touch to the seal guard 2 4 Adjust Drive chain slack a Loosen the wheel axle nut 1 b Turn the drive chain adjusting plate 2 in di rection a or b until the specified drive chain slack is obtained NOTE To maintai...

Page 71: ...o that there is no danger of it falling over NOTE 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 legs and gently rock the front fork Blinding looseness Adjust the steering head 3 Remove Steering stem nut Upper bracket Refer to STEERING HEAD on page 4 48 4 Adjust Steering head a Remove the lock washer 1 the upper ri...

Page 72: ...pport 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 apply the front brake 4 Check Front fork operation Push down hard on the handlebar several times and check if the front fork rebounds smoothly Rough movement Repair Refer to FRONT FORK on page 4 41 EAS21650 CHECKING THE TIRES The fo...

Page 73: ...turer 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 WARNING EWA13210 New tires have a relatively low grip on the road surface until they have been slightly worn Therefore approximately 100 km should be traveled at normal speed before any high speed riding is done NOTE For tires ...

Page 74: ...nds damage Replace Loose Tighten Tap the spokes with a screwdriver NOTE A tight spoke will emit a clear ringing tone a loose spoke will sound flat 2 Tighten Spoke with a spoke wrench 1 NOTE Be sure to tighten the spokes before and after break in EAS21690 CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the in ner and outer cables WARNING EWA13270 Damaged outer cable ma...

Page 75: ...al 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 SUSPENSION Lubricate the pivoting point and metal to metal moving parts of the rear suspension Recommended lubricant Engine oil or a suitable cable lu bricant Recommended lubricant Lithium soap based grease Recommended lubricant...

Page 76: ...hands away from the bulb until it has cooled down 6 Install Headlight bulb Secure the new headlight bulb with the head light bulb holder CAUTION 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...

Page 77: ...ELECTRICAL SYSTEM 3 26 Direction a Headlight beam is raised Direction b Headlight beam is lowered a b 1 ...

Page 78: ...CALIPER 4 20 DISASSEMBLING THE FRONT BRAKE CALIPER 4 20 CHECKING THE FRONT BRAKE CALIPERS 4 20 ASSEMBLING THE FRONT BRAKE CALIPER 4 21 INSTALLING THE FRONT BRAKE CALIPER 4 21 REMOVING THE FRONT BRAKE MASTER CYLINDER 4 22 CHECKING THE FRONT BRAKE MASTER CYLINDER 4 23 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER 4 23 INSTALLING THE FRONT BRAKE MASTER CYLINDER 4 24 REAR BRAKE 4 26 INTRODUCTION 4 31 CHE...

Page 79: ... 4 51 REAR SHOCK ABSORBER ASSEMBLY 4 52 HANDLING THE REAR SHOCK ABSORBER 4 53 DISPOSING OF A REAR SHOCK ABSORBER 4 53 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4 53 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 4 54 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4 54 SWINGARM 4 55 REMOVING THE SWINGARM 4 56 CHECKING THE SWINGARM 4 56 INSTALLING THE SWINGARM 4 57 CHAIN DRIVE 4 58 REMOVING THE DRIVE CHAIN ...

Page 80: ...SSIS Removing the seat side cover Order Job Parts to remove Q ty Remarks 1 Seat 1 2 Side cover left right 1 1 3 Fuel tank side cover left right 1 1 4 Tool box cover left right 1 1 For installation reverse the removal proce dure 1 3 3 2 2 4 4 ...

Page 81: ...iscs Order Job Parts to remove Q ty Remarks 1 Speedometer cable 1 2 Washer Front wheel axle nut 1 1 3 Front wheel axle 1 4 Front wheel assembly 1 5 Speedometer gear unit 1 6 Collar Spacer 1 1 7 Front brake disc 1 For installation reverse the removal proce dure 1 2 3 4 5 6 7 ...

Page 82: ...FRONT WHEEL 4 3 Disassembling the front wheel 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 1 2 3 2 ...

Page 83: ...ll 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 wheel Damage wear Replace Refer to CHECKING THE TIRES on page 3 21 and CHECKING THE WHEELS on page 3 23 3 Check Spokes Bends damage Replace Loose Tighten Tap the spokes with a screwdriver NOTE A tight spoke will emit a clear ringing tone a loose spoke will sound fla...

Page 84: ...wheel bearings 3 with a gener al bearing pulle 4 EAS21940 CHECKING THE SPEEDOMETER GEAR UNIT 1 Check Speedometer clutch Bends damage wear Replace 2 Check Speedometer drive gear Speedometer driven gear Damage wear Replace EAS21960 ASSEMBLING THE FRONT WHEEL 1 Install Wheel bearings Oil seals a Install the new wheel bearings and oil seals in the reverse order of disassembly CAUTION ECA4D602 Do not c...

Page 85: ...eel b When the front wheel stops put an X1 mark at the bottom of the wheel c Turn the front wheel 90 so that the X1 mark is positioned as shown d Release the front wheel e When the wheel stops put an X2 mark at the bottom of the wheel f Repeat steps d through f several times until all the marks come to rest at the same spot g The spot where all the marks come to rest is the front wheel s heavy spo...

Page 86: ...l Speedometer gear unit NOTE Make sure the speedometer gear unit and the wheel hub are installed with the two projections a meshed into the two slots b respectively 3 Install Front wheel assembly Front wheel axle Speedometer cable NOTE Make sure the slot 1 in the speedometer gear unit fits over the stopper 2 on the outer tube 4 Tighten Front wheel axle nut 1 WARNING EWA13680 Make sure the brake ho...

Page 87: ...FRONT WHEEL 4 8 down hard on the handlebar s several times and check if the front fork rebounds smooth ly ...

Page 88: ...e Q ty Remarks 1 Rear wheel axle nut Washer 1 1 2 Left drive chain puller 1 3 Rear wheel axle Washer 1 1 4 Right drive chain puller 1 5 Drive chain 1 6 Rear wheel assembly 1 7 Spacer 1 8 Collar 1 9 Rear wheel sprocket 1 For installation reverse the removal proce dure 1 2 3 4 5 6 7 8 9 ...

Page 89: ...REAR WHEEL 4 10 Disassembling the rear wheel Order Job Parts to remove Q ty Remarks 1 Brake disc 1 2 Oil seal 2 3 Bearing 3 4 Spacer 1 For assembly reverse the disassembly pro cedure 2 3 1 4 3 2 ...

Page 90: ...eel bearings Oil seals Refer to CHECKING THE FRONT WHEEL on page 4 4 2 Check Tire Rear wheel Damage wear Replace Refer to CHECKING THE TIRES on page 3 21 and CHECKING THE WHEELS on page 3 23 3 Check Spokes Refer to CHECKING THE FRONT WHEEL on page 4 4 4 Measure Radial wheel runout Lateral wheel runout Refer to CHECKING THE FRONT WHEEL on page 4 4 EAS22080 DISASSEMBLING THE REAR WHEEL 1 Remove Oil ...

Page 91: ...the rear wheel static balance with the brake disc and rear wheel drive hub installed 1 Adjust Rear wheel static balance Refer to ADJUSTING THE FRONT WHEEL STATIC BALANCE on page 4 6 EAS22160 INSTALLING THE REAR WHEEL DISC 1 Lubricate Rear wheel axle Wheel bearings Oil seal lips 2 Install Collar Spacer Rear wheel Washer Right drive chain puller 1 Wheel axle Left drive chain puller Washer Wheel axle...

Page 92: ...ront brake pads Order Job Parts to remove Q ty Remarks 1 Front brake caliper bolt 1 Lower side only 2 Front brake caliper 1 Slide the brake caliper upward 3 Front brake pad 2 4 Brake pad shim 1 5 Brake pad spring 2 For installation reverse the removal proce dure 1 2 3 4 5 5 ...

Page 93: ... SYSTEM on page 3 18 1 Right rear view mirror 1 2 Front brake lever Compression spring 1 1 3 Front brake light switch connector 1 Disconnect 4 Union bolt 1 5 Copper washers 2 6 Front brake hose 1 7 Brake master cylinder reservoir cap 1 8 Front brake master cylinder holder 1 9 Front brake master cylinder 1 For installation reverse the removal proce dure 1 2 3 4 5 6 7 8 9 2 ...

Page 94: ...15 Disassembling the front brake master cylinder Order Job Parts to remove Q ty Remarks 1 Master cylinder boot 1 2 Circlip 1 3 Master cylinder kit 1 4 Spring 1 For assembly reverse the disassembly pro cedure 1 2 3 4 ...

Page 95: ...remove Q ty Remarks Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 18 1 Union bolt 1 2 Copper washers 2 3 Front brake hose 1 4 Brake caliper bolt 2 5 Front brake caliper assembly 1 6 Brake caliper bracket 1 For installation reverse the removal proce dure 1 2 3 4 5 6 ...

Page 96: ...Disassembling the front brake calipers Order Job Parts to remove Q ty Remarks 1 Brake caliper piston 2 2 Dust seal 2 3 Brake caliper piston seal 2 4 Bleed screw 1 For assembly reverse the disassembly pro cedure 4 2 3 1 ...

Page 97: ...d get immediate medical attention EAS22230 CHECKING THE FRONT BRAKE DISC 1 Remove Front wheel Refer to FRONT WHEEL on page 4 2 2 Check Brake disc Damage galling Replace 3 Measure Brake disc deflection a 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 ...

Page 98: ...sem ble the brake caliper 1 Measure Brake pad wear limit a Out of specification Replace the brake pads as a set 2 Install Brake pad spring Brake pad shims onto the brake pads Brake pads NOTE Always install new brake pads brake pad shims and a brake pad spring as a set a Connect a clear plastic hose 1 tightly to the bleed screw 2 Put the other end of the hose into an open container b Loosen the ble...

Page 99: ...ke hose NOTE Put the end of the brake hose into a container and pump out the brake fluid carefully EAS22320 DISASSEMBLING THE FRONT BRAKE CALIPER 1 Remove Brake caliper pistons Dust seals 1 Brake caliper piston seals 2 a Blow compressed air into the brake hose joint opening a to force out the pistons from the brake caliper WARNING EWA13550 Cover the brake caliper piston with a rag Be careful not t...

Page 100: ...ARNING EWA13620 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 piston seals to swell and distort Whenever a brake caliper is disassem bled replace the brake caliper piston seals EAS22420 INSTALLING THE FRONT BRAKE CALIPER 1 Install Brake caliper piston seals 1 ...

Page 101: ...rake 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 CAUTION ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 6 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3...

Page 102: ...r 1 Damage scratches wear Replace Brake fluid delivery passages 2 brake master cylinder body Obstruction Blow out with compressed air 2 Check Brake master cylinder kit 1 Brake master cylinder cup 2 Damage scratches wear Replace 3 Check Brake master cylinder reservoir cap 1 Brake master cylinder reservoir diaphragm holder Brake master cylinder reservoir diaphragm Damage wear Replace 4 Check Brake h...

Page 103: ...he handlebar to the left and right to make sure the brake hose does not touch oth er parts e g wire harness cables leads Correct if necessary 3 Fill Brake master cylinder reservoir with the specified amount of the recom mended brake fluid WARNING EWA13540 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refi...

Page 104: ...leed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 18 5 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 16 6 Check Brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 18 a ...

Page 105: ... Apply silicone grease Removing the rear brake pads Order Job Parts to remove Q ty Remarks 1 Rear brake caliper cover 1 2 Brake caliper bolt 2 3 Rear brake pad 2 4 Brake pad shim 1 For installation reverse the removal proce dure 1 2 3 4 ...

Page 106: ...y Remarks Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 18 1 Union bolt 1 2 Copper washers 2 3 Rear brake hose 1 4 Cotter pin 1 5 Washer 1 6 Clevis pin 1 7 Master cylinder cap assembly 1 8 Rear brake master cylinder 1 For installation reverse the removal proce dure 1 2 3 4 5 6 7 8 ...

Page 107: ...licone grease Disassembling the rear brake master cylinder Order Job Parts to remove Q ty Remarks 1 Master cylinder boot 1 2 Circlip 1 3 Master cylinder kit 1 4 Spring 1 For assembly reverse the disassembly pro cedure 4 3 2 1 ...

Page 108: ... on page 4 9 Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 18 1 Rear brake caliper cover 1 2 Rear brake hose assembly Joint 1 1 3 Copper washer 1 4 Brake caliper bolt 2 5 Brake pad 2 6 Brake pad shim 1 7 Rear brake caliper 1 8 Brake caliper bracket 1 For installation reverse the removal proce dure 1 2 3 4 5 6 7 8 ...

Page 109: ...Disassembling the rear brake calipers Order Job Parts to remove Q ty Remarks 1 Brake caliper piston 1 2 Dust seal 1 3 Brake caliper piston seal 1 4 Bleed screw 1 For assembly reverse the disassembly pro cedure 1 3 2 4 ...

Page 110: ...4 9 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 18 4 Measure Brake disc thickness Measure the brake disc thickness at a few different locations Out of specification Replace Refer to CHECKING THE FRONT BRAKE DISC on page 4 18 5 Adjust Brake ...

Page 111: ...rk a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 16 5 Check Brake pedal operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 18 EAS22590 REMOVING THE REAR BRAKE CALIPER NOTE Before disassembling the brake caliper drain the brake fluid from the entire brake system 1 Remove Rear brake ...

Page 112: ...lace the brake caliper piston seals 2 Check Brake caliper brackets Cracks damage Replace EAS22650 ASSEMBLING THE REAR BRAKE CALIPER WARNING EWA13620 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 piston seals to swell and distort Whenever a brake caliper is dis...

Page 113: ...uid 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 flu ids may result in a harmful chemical reac tion leading to poor brake performance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling po...

Page 114: ...G THE REAR BRAKE MASTER CYLINDER NOTE Before removing the rear brake master cylinder drain the brake fluid from the entire brake sys tem 1 Remove Union bolt Copper washers Rear brake hose NOTE To collect any remaining brake fluid place a container under the master cylinder and the end of the brake hose 2 Remove Master cylinder boots 1 Circlip 2 Master cylinder kit 3 Spring 4 EAS22710 CHECKING THE ...

Page 115: ...NG THE REAR BRAKE MASTER CYLINDER 1 Install Brake master cylinder kit 1 Adjusting rod 2 Circlip 3 Dust boots 4 To the brake master cylinder 5 2 Install Rear brake master cylinder 1 Brake master cylinder bolt 2 3 Install Copper washers Brake hoses Union bolt WARNING EWA13530 Proper brake hose routing is essential to in sure safe vehicle operation Refer to CABLE ROUTING on page 2 25 CAUTION ECA14160...

Page 116: ... brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock CAUTION ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 5 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 18 6 Check Brake fluid level Below the minimum level mark a Add the rec...

Page 117: ...linder holder 1 4 Master cylinder assembly 1 5 Holder 1 6 Right handlebar switch 1 7 Throttle cable housing 1 8 Throttle cable 1 9 Throttle grip 1 10 Clutch cable 1 11 Clutch switch 1 12 Bracket 1 13 Clutch lever holder 1 14 Left handlebar switch 1 15 Handlebar grip 1 16 Handlebar upper holder 2 17 Handlebar 1 For installation reverse the removal proce dure 1 2 3 4 5 6 7 7 8 9 16 17 11 10 12 13 14...

Page 118: ...EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Install Handlebar 1 Handlebar upper holders 2 CAUTION ECA14250 First tighten the bolts on the front side of the handlebar holder and then on the rear side Turn the handlebar all the way to the left and right If there is any contact with the fuel tank adjust the handlebar position NOTE Align the match mark a on th...

Page 119: ...hesive has fully dried 6 Install Left handlebar switch 1 NOTE Align the groove on the handlebar switch with the punch mark a in the handlebar 7 Install Clutch lever holder 1 Clutch cable NOTE Align the groove on the clutch lever holder with the punch mark a in the handlebar 8 Connect Clutch switch coupler NOTE Lubricate the end of the clutch cable with a thin coat of lithium soap based grease 9 Ad...

Page 120: ... ty Remarks Front wheel Refer to FRONT WHEEL on page 4 2 1 Brake hose holder 1 2 Cable holder 1 3 Front fender 1 4 Front brake caliper 1 5 Upper bracket pinch bolt 4 Loosen 6 Cap bolt 2 Loosen 7 Pinch bolt 4 Loosen 8 Front fork 2 For installation reverse the removal proce dure 1 2 3 4 5 6 7 8 ...

Page 121: ... 4 Fork spring seat 1 5 Fork spring 1 6 Dust seal 1 7 Oil seal clip 1 8 Damper rod bolt 1 9 Inner tube 1 10 Oil lock piece 1 11 Rebound spring 1 12 Damper rod 1 13 Oil seal 1 14 Outer tube bushing 1 15 Inner tube bushing 1 16 Outer tube 1 For assembly reverse the disassembly pro cedure 1 2 3 4 5 12 11 9 10 6 7 13 14 15 16 8 ...

Page 122: ...ork leg 3 Remove Front fork leg EAS22990 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Remove Fork spring seat Fork spring 2 Drain Fork oil 3 Remove Dust seals Oil seal clip 1 with a flat head screwdriver 2 CAUTION ECA14180 Do not scratch the inner tube 4 Remove Damper rod bolt 1 Damper rod NOTE While holding the damper rod with the damper rod h...

Page 123: ...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 lock piece Damage Replace CAUTION ECA14200 The front fork leg has a built in damper ad justing rod and a very sophisticated inter nal construction which are particularly sensitive to foreign m...

Page 124: ... s outer surface 3 Tighten Damper rod bolt 1 Washer NOTE While holding the damper rod with the damper rod holder 3 and T handle 4 tighten the damper rod bolt 4 Install Oil seal 1 with the fork seal driver and adapter CAUTION ECA14220 Make sure the numbered side of the oil seal faces up NOTE Before installing the oil seal lubricate its lips with lithium soap base grease Lubricate the outer surface ...

Page 125: ...weight 7 Fill Front fork leg with the specified amount of the recom mended fork oil NOTE While filling the front fork leg keep it upright After filling slowly pump the front fork leg up and down to distribute the fork oil 8 Install Fork spring 1 Fork seal driver weight 90890 01367 Replacement hammer YM A9409 7 Fork seal driver attachment ø35 90890 01369 Replacement 35 mm YM A9409 5 342 034 2 1 New...

Page 126: ... both of the front fork legs 1 Install Front fork leg Temporarily tighten the upper and lower bracket pinch bolts NOTE Make sure the inner fork tube is flush with the top of the upper bracket 2 Tighten Lower bracket pinch bolt 1 Cap bolt 2 Upper bracket pinch bolt 3 WARNING EWA13680 Make sure the brake hoses are routed prop erly Lower bracket pinch bolt 23 Nm 2 3 m kg 17 ft lb New 5 3 1 2 4 T R Ca...

Page 127: ...TANK on page 6 1 Handlebar Refer to HANDLEBAR on page 4 38 1 Headlight body 1 2 Headlight coupler 1 Disconnect 3 Tool box 1 1 4 Front turn signal leads 2 2 5 Front turn signal light assembly left right 1 1 6 Meter lead coupler 2 7 Speedometer cable 1 8 Meter 1 9 Stay 1 For installation reverse the removal proce dure 1 2 3 4 5 5 6 7 8 9 4 ...

Page 128: ... 4 38 Headlight Meter 1 Cable guide 1 2 Cap 1 3 Steering stem nut 1 4 Main switch coupler Upper bracket 1 1 5 Lock washer 1 6 Upper ring nut 1 7 Rubber washer 1 8 Lower ring nut 1 9 Ball race cover 1 10 Lower bracket 1 11 Washer 1 12 Bearing bearing race 1 1 13 Bearing bearing race 1 1 For installation reverse the removal proce dure 1 2 3 4 4 5 6 7 8 9 10 11 12 13 ...

Page 129: ...AS23130 CHECKING THE STEERING HEAD 1 Wash Bearings Bearing races 2 Check Bearings 1 Bearing races 2 Damage pitting Replace 3 Replace Bearings Bearing races a Remove the bearing races 1 from the steer ing head pipe with a long rod 2 and ham mer b Remove the bearing race 3 from the lower bracket with a floor chisel 4 and hammer c Install a new bearing races CAUTION ECA14270 If the bearing race is no...

Page 130: ... on page 3 20 3 Install Upper bracket Steering stem nut NOTE Temporarily tighten the steering stem nut 4 Install Front fork legs Refer to FRONT FORK on page 4 41 NOTE Temporarily tighten the upper and lower bracket pinch bolts 5 Tighten Steering stem nut Upper bracket pinch bolts Lower bracket pinch bolts Refer to FRONT FORK on page 4 41 Recommended lubricant Lithium soap based grease Steering ste...

Page 131: ...y Order Job Parts to remove Q ty Remarks Seat Refer to GENERAL CHASSIS on page 4 1 Battery Refer to CHECKING AND CHARGING THE BATTERY on page 7 38 1 Connecting rod 2 2 Relay arm 1 3 Rear shock absorber assembly 1 4 Collars 3 5 Oil seals 8 For installation reverse the removal proce dure 3 4 4 5 1 5 5 4 5 1 5 4 4 2 ...

Page 132: ...ed before dis posing of a rear shock absorber To release the gas pressure drill a 2 3mm hole through the rear shock absorber at a point 15 20 mm 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 th...

Page 133: ...3310 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1 Lubricate Spacers Bearings 2 Install Rear shock absorber assembly NOTE When installing the rear shock absorber as sembly lift up the swingarm Install the connecting arm front bolt from the right 3 Tighten Rear shock absorber assembly upper nut 1 Rear shock absorber assembly lower nut Connecting rod lower nut 2 Recommended lubricant Molybdenum disu...

Page 134: ...RGING THE BATTERY on page 7 38 Rear shock absorber assembly Refer to REAR SHOCK ABSORBER ASSEMBLY on page 4 52 Rear wheel Refer to REAR WHEEL on page 4 9 Rear brake caliper Refer to REAR BRAKE on page 4 26 1 Pivot shaft 1 2 Swingarm 1 3 Seal guard 1 4 Drive chain case 1 5 Dust cover collar 2 2 6 Spacer 1 For installation reverse the removal proce dure 1 2 4 3 5 6 5 5 ...

Page 135: ...ft nut b Measure the swingarm side play A by mov ing the swingarm from side to side c If the swingarm side play is out of specifica tion check the spacers bearings washers and dust covers d Check the swingarm vertical movement B by moving the swingarm up and down If swingarm vertical movement is not smooth or if there is binding check the spacers bearings washers and dust covers 4 Remove Connectin...

Page 136: ...ighten Relay arm to frame nut Connecting rod nut NOTE Install the connecting rod front bolt from the right 5 Install Rear shock absorber assembly Rear wheel Refer to REAR SHOCK ABSORBER AS SEMBLY on page 4 52 and REAR WHEEL on page 4 9 6 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 19 Recommended cleaning solvent Kerosene Recommended lubricant Molybdenum disulfide gr...

Page 137: ...to remove Q ty Remarks Swingarm Refer to SWINGARM on page 4 55 1 Drive sprocket cover 1 Disconnect 2 Nut 1 3 Lock washer 1 Straighten the lock washer tab 4 Drive sprocket 1 Loosen the rear wheel sprocket nut 5 Drive chain 1 For installation reverse the removal proce dure 1 4 3 2 5 ...

Page 138: ...M on page 4 55 EAS23440 CHECKING THE DRIVE CHAIN 1 Measure 15 link section a of the drive chain Out of specification Replace the drive chain drive sprocket and rear wheel sprock et as a set a Measure the length of 15 links on the inner side b and outer side c of the pin and cal culate the length between pin centers b Length a between pin centers inner di mension b outer dimension c 2 c 15 Link sec...

Page 139: ...herwise the O rings can be damaged 4 Check O rings 1 Damage Replace the drive chain Drive chain rollers 2 Damage wear Replace the drive chain Drive chain side plates 3 Damage wear Replace the drive chain Cracks Replace the drive chain and make sure the battery breather hose is properly routed away from the drive chain and below the swingarm 5 Lubricate Drive chain EAS23460 CHECKING THE DRIVE SPROC...

Page 140: ...Bend the lock washer tab 2 along a flat side of the nut 5 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 19 CAUTION 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 swing arm or cause an accident Therefore keep the drive chain slack within the specified lim its Recommended lubrican...

Page 141: ...ING THE VALVES 5 23 CYLINDER AND PISTON 5 25 REMOVING THE PISTON 5 26 CHECKING THE CYLINDER AND PISTON 5 26 CHECKING THE PISTON RINGS 5 27 CHECKING THE PISTON PIN 5 28 INSTALLING THE PISTON AND CYLINDER 5 28 CLUTCH 5 30 REMOVING THE CLUTCH 5 33 CHECKING THE FRICTION PLATES 5 33 CHECKING THE CLUTCH PLATES 5 34 CHECKING THE CLUTCH SPRINGS 5 34 CHECKING THE CLUTCH HOUSING 5 34 CHECKING THE CLUTCH BOS...

Page 142: ...RANKCASE 5 56 CHECKING THE CRANKCASE 5 56 ASSEMBLING THE CRANKCASE 5 56 CRANKSHAFT ASSEMBLY 5 58 REMOVING THE CRANKSHAFT ASSEMBLY 5 59 REMOVING THE PLUNGER SEAL 5 59 CHECKING THE CRANKSHAFT AND CONNECTING ROD 5 59 CHECKING THE TIMING CHAIN CRANKSHAFT SPROCKET AND TIM ING CHAIN GUIDE 5 60 INSTALLING THE PLUNGER SEAL 5 60 INSTALLING THE CRANKSHAFT ASSEMBLY 5 60 TRANSMISSION 5 62 REMOVING THE TRANSMI...

Page 143: ...ng the exhaust pipe Order Job Parts to remove Q ty Remarks Seat Refer to GENERAL CHASSIS on page 4 1 1 Muffler 1 Loosen the clamp screw and then remove from exhaust pipe 2 Gasket 1 3 Exhaust pipe 1 For installation reverse the removal proce dure 1 2 3 ...

Page 144: ... induction system hose 1 Disconnect 3 Starter motor lead 1 4 Ground lead 1 5 Clutch cable 1 6 Pickup coil rotor lead coupler 2 Disconnect 7 Spark plug cap 1 Disconnect 8 Drive sprocket cover 1 Disconnect 9 Shift pedal 1 10 Neutral switch lead 1 11 Nut 1 12 Lock washer 1 Straighten the lock washer tab 13 Drive sprocket 1 Loosen the rear wheel sprocket nut 14 Drive chain 1 For installation reverse t...

Page 145: ... bracket left right 1 1 2 Engine mounting bolt rear upper side 1 3 Down tube bolts 2 4 Engine mounting bolt rear side 1 5 Engine mounting bolt rear lower side 1 6 Engine mounting bolts front upper side 1 7 Engine mounting bolt front lower side 1 8 Down tube 1 9 Engine 1 For installation reverse the removal proce dure 1 1 2 3 4 5 6 7 8 9 ...

Page 146: ... arm NOTE Align the punch mark a in the shift shaft with the punch mark b in the shift arm 4 Install Shift arm position NOTE Loosen lock nut 1 and then turn shift rod 2 so that the height difference b between footrest 3 and the shift pedal is between 28 34 mm 5 Install Locknut Shift arm bolt 1 2 3 4 5 6 7 Engine mounting nuts front upper side 72 Nm 7 2 m kg 52 ft lb Engine mounting nut front lower...

Page 147: ...age 5 1 Engine bracket left right 1 Spark plug 1 2 Cylinder head cover1 O ring 1 1 3 Cylinder head cover2 O ring 1 1 4 Cylinder head cover3 O ring 1 1 5 Breather pipe1 Gasket 1 1 6 Center cap O ring 1 1 7 Straight screw plug O ring 1 1 8 Camshaft sprocket bolt 1 Loosen 9 Cap bolt 1 Loosen 10 Timing chain tensioner gasket 1 1 11 Breather pipe2 1 12 Camshaft sprocket dowelpin 1 1 13 Cylinder head 1 ...

Page 148: ...iming chain guide 1 16 Dowel pin 2 17 Cylinder head gasket 1 For installation reverse the removal proce dure Removing the cylinder head Order Job Parts to remove Q ty Remarks 1 3 2 4 4 5 6 7 8 10 11 12 13 14 15 16 17 9 LS LS ...

Page 149: ... head 2 Loosen Camshaft sprocket bolt 1 3 Remove Timing chain tensioner cap Timing chain tensioner 1 along with the gasket Camshaft sprocket bolt Breather plate 2 Camshaft sprocket Timing chain NOTE To prevent the timing chain from falling into the crankcase fasten it with a wire 4 Remove Cylinder head 1 EAS24160 CHECKING THE CYLINDER HEAD 1 Eliminate Combustion chamber carbon deposits with a roun...

Page 150: ...rocket and crankshaft sprocket as a set 2 Check Camshaft sprocket More than 1 4 tooth wear a Replace the timing chain and camshaft sprocket and crankshaft sprocket as a set 3 Check Timing chain guide exhaust side EAS24190 CHECKING THE TIMING CHAIN TENSIONERS 1 Check Timing chain tensioner Cracks damage Replace 2 Check One way cam operation Rough movement Replace the timing chain tensioner housing ...

Page 151: ...erclockwise b Align the I mark a on the Pickup coil rotor with the stationary pointer b on the crank case cover c Remove the wire from the timing chain d Install the timing chain onto the camshaft sprocket and then install the camshaft sprocket onto the camshaft NOTE When installing the camshaft sprocket be sure to keep the timing chain as tight as pos sible on the exhaust side Align the pin e on ...

Page 152: ...onto the body cylinder c Tighten the timing chain tensioner bolts 3 to the specified torque d Remove the screwdriver make sure that the timing chain tensioner rod releases and then tighten the cap bolt 4 to the specified torque 6 Turn Crankshaft several turns counterclockwise 7 Check I mark a Align the I mark on the pickup coil rotor with the stationary pointer b on the crankcase cover I mark c Al...

Page 153: ...sprocket bolts to the specified torque to avoid the possibility of the bolts coming loose and damaging the engine 9 Measure Valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEAR ANCE on page 3 3 Camshaft sprocket bolt 60 Nm 6 0 m kg 44 ft lb T R ...

Page 154: ...move Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 5 5 1 Stopper plate 1 2 Locknut valve clearance adjusting screw 2 2 3 Camshaft 1 4 Intake rocker arm shaft 1 5 Intake rocker arm 1 6 Exhaust rocker arm shaft 1 7 Exhaust rocker arm 1 For installation reverse the removal proce dure 1 2 3 4 5 2 6 7 LS LS ...

Page 155: ...3840 CHECKING THE CAMSHAFT 1 Check Bearing Damage wear Replace 2 Check Camshaft lobes Blue discoloration pitting scratches Re place the camshaft 3 Measure Camshaft lobe dimensions a and b Out of specification Replace the camshaft Slide hammer bolt 90890 01083 Slide hammer bolt 6 mm YU 01083 1 Weight 90890 01084 YU 01083 3 1 2 3 1 2 3 Camshaft lobe dimension limit Intake A 36 520 36 620 mm 1 4378 1...

Page 156: ... screws 2 Damage wear Replace 2 Check Rocker arm shaft Blue discoloration excessive wear pitting scratches Replace or check the lubrica tion system 3 Measure Rocker arm inside diameter a Out of specification Replace 4 Measure Rocker arm shaft outside diameter a Out of specification Replace Rocker arm inside diameter 12 000 12 018 mm 0 4724 0 4731 in Limit 12 036 mm 0 4739 in Rocker arm shaft outsi...

Page 157: ...pletely pushed into the cylinder head 4 Install Intake rocker arm Intake rocker arm shaft NOTE Insert a cylinder head bolt 226 mm 1 into the hole in the cylinder head and the intake rocker arm shaft as shown Install the intake rocker arm shaft so that groove a is horizontal and aligning the notch of the pointed end b with the hole in the cyl inder head 5 Install Camshaft 1 NOTE Screw a 10 mm bolt ...

Page 158: ...ROCKER ARM CAMSHAFT 5 16 6 Install Lock plate Lock plate bolt Lock plate bolt 8 Nm 0 8 m kg 5 8 ft lb 1 T R ...

Page 159: ...efer to CYLINDER HEAD on page 5 5 Rocker arm Refer to ROCKER ARM CAMSHAFT on page 5 12 Camshaft 1 Valve cotter 4 2 Valve spring retainer 2 3 Outer valve spring 2 4 Inner valve spring 2 5 Intake valve 1 6 Exhaust valve 1 7 Valve stem seal 2 8 Valve spring seat 2 9 Valve guide 2 For installation reverse the removal proce dure 1 2 3 4 5 6 7 8 9 9 8 1 2 3 4 7 ...

Page 160: ...at 1 2 Remove Valve cotters 1 NOTE 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 Inner valve spring 2 Outer valve spring 3 Valve 4 Lower spring seat 5 Valve stem seal 6 NOTE Identify the position of each part very carefully so that it can be reinstalled in its original place EAS242...

Page 161: ...er installing the valve guide bore the valve guide with the valve guide reamer 3 to ob tain the proper valve stem to valve guide clearance NOTE After replacing the valve guide reface the valve seat Valve stem to valve guide clearance Valve guide inside diameter a Valve stem diameter b Valve stem to valve guide clear ance Valve stem to valve guide clear ance intake 0 010 0 037 mm 0 0004 0 0015 in L...

Page 162: ...eats 1 Eliminate Carbon deposits from the valve face and valve seat 2 Check Valve seat Pitting wear Replace the cylinder head 3 Measure Valve seat width a Out of specification Replace the cylinder head a Apply Mechanic s blueing dye Dykem b onto the valve face Valve guide remover ø6 90890 04064 Valve guide remover 6 0 mm YM 04064 A Valve guide installer ø6 90890 04065 Valve guide installer 6 0 mm ...

Page 163: ...t let the lapping compound enter the gap between the valve stem and the valve guide b Apply molybdenum disulfide oil onto the valve stem c Install the valve into the cylinder head d Turn the valve until the valve face and valve seat are evenly polished then clean off all of the lapping compound NOTE For the best lapping results lightly tap the valve seat while rotating the valve back and forth be ...

Page 164: ...ion Replace the valve spring Inner spring Free length intake 36 17 mm 1 42 in Free length exhaust 36 17 mm 1 42 in Outer spring Free length intake 36 63 mm 1 44 in Free length exhaust 36 63 mm 1 44 in c a Compressed valve spring force b Installed length Inner spring Installed compression spring force intake 75 00 91 70 N 16 86 20 61 lb 7 65 9 35 kgf Installed compression spring force exhaust 75 00...

Page 165: ...e valve springs with the larger pitch a facing up 4 Install Valve cotters 1 NOTE Install the valve cotters by compressing the valve spring with the valve spring compressor and the valve spring compressor attachment 2 Inner spring Spring tilt intake 2 5 1 6 mm Spring tilt exhaust 2 5 1 6 mm Outer spring Spring tilt intake 2 5 1 6 mm Spring tilt exhaust 2 5 1 6 mm Recommended lubricant Molybdenum di...

Page 166: ...ND VALVE SPRINGS 5 24 5 To secure the valve cotters 1 onto the valve stem lightly tap the valve tip with a soft face hammer CAUTION ECA13800 Hitting the valve tip with excessive force could damage the valve 1 2 ...

Page 167: ...rder Job Parts to remove Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 5 5 1 Oil delivery pipe 1 2 Cylinder 1 3 Dowel pin 2 4 Cylinder gasket 1 5 Piston pin clip 2 6 Piston pin 1 7 Piston 1 8 Piston ring set 1 For installation reverse the removal proce dure 2 3 4 5 5 6 7 8 1 LS ...

Page 168: ... CHECKING THE CYLINDER AND PISTON 1 Check Piston wall Cylinder wall Vertical scratches Rebore or replace the cylinder and replace the piston and piston rings as a set 2 Measure Piston to cylinder clearance a Measure cylinder bore C with the cylinder bore gauge NOTE Measure cylinder bore C by taking side to side and front to back measurements of the cylinder Then find the average of the measurement...

Page 169: ...to the cylinder NOTE Level the piston ring into the cylinder with the piston crown 3 Measure Piston ring end gap Out of specification Replace the piston ring NOTE The oil ring expander spacer s end gap cannot be measured If the oil ring rail s gap is exces sive replace all three piston rings b 11 mm 1 in from the bottom edge of the piston Piston size diameter D Standard 73 960 73 975 mm 2 9118 2 9...

Page 170: ...il ring expander 2 Upper oil ring rail 3 2nd ring 4 Top ring 5 NOTE Be sure to install the piston rings so that the T marks or numbers face up Piston ring Top ring End gap installed 0 19 0 31 mm 0 0075 0 0122 in Limit 0 60 mm 0 0236 in 2nd ring End gap installed 0 30 0 45 mm 0 0118 0 0177 in Limit 0 60 mm 0 0236 in Oil ring End gap installed 0 10 0 35 mm 0 0039 0 0138 in Piston pin outside diamete...

Page 171: ...3 Install O ring Cylinder gasket Dowel pins 4 Lubricate Piston Piston rings Cylinder with the recommended lubricant 5 Offset Piston ring end gaps 6 Install Cylinder NOTE While compressing the piston rings with one hand install the cylinder with the other hand Pass the timing chain and timing chain guide exhaust side through the timing chain cavity T 1 2 3 4 5 New 1 2 3 a New New Recommended lubric...

Page 172: ...o remove Q ty Remarks Engine oil Refer to CHANGING THE ENGINE OIL on page 3 10 1 Cotter pin Washer 1 1 2 Clevis pin 1 3 Brake pedal 1 4 Oil delivery pipe 1 5 Right crankcase cover 1 6 Dowel pin 2 7 Gasket 1 For installation reverse the removal proce dure 1 2 3 4 5 6 6 7 LS ...

Page 173: ...on plate 6 5 Clutch plate 5 6 Cushion spring 1 7 Seat plate 1 8 Clutch boss nut 1 9 Clutch boss 1 10 Thrust washer 1 11 Clutch housing 1 12 Claw washer 1 13 Primary driven gear 1 14 Locknut Washer 1 1 15 Push rod1 1 16 Push plate 1 17 Push rod 2 Ball 1 1 For installation reverse the removal proce dure 3 1 2 4 5 6 7 8 9 10 11 12 13 14 16 15 17 ...

Page 174: ...e Q ty Remarks Shift pedal Refer to ENGINE REMOVAL on page 5 1 Left crankcase cover Clutch assembly 1 Clutch cable 1 2 Bolt 1 3 Push lever shaft 1 4 Torsion spring 1 5 Circlip 1 6 Oil seal 1 7 Bearing 1 For installation reverse the removal proce dure 5 6 3 4 7 2 1 LS ...

Page 175: ...While holding the clutch boss with the univer sal clutch holder 4 loosen the clutch boss nut 5 4 Remove Clutch boss nut 1 Lock washer 2 Clutch boss 3 Thrust washer 4 Clutch housing 5 5 Remove Primary drive gear nut 1 Lock washer 2 Claw washer 3 Primary drive gear 4 EAS25100 CHECKING THE FRICTION PLATES The following procedure applies to all of the fric tion plates 1 Check Friction plate Damage wea...

Page 176: ...lace the clutch spring 2 Measure Clutch spring free length a Out of specification Replace the clutch spring EAS25150 CHECKING THE CLUTCH HOUSING 1 Check Clutch housing dogs 1 Damage pitting wear Deburr the clutch housing dogs or replace the clutch housing NOTE Pitting on the clutch housing dogs will cause er ratic clutch operation EAS25160 CHECKING THE CLUTCH BOSS 1 Check Clutch boss splines Damag...

Page 177: ...rimary drive and primary driven gears as a set EAS25260 INSTALLING THE CLUTCH 1 Install Primary drive gear Claw washer Lock washer Primary drive gear nut 2 Install Clutch housing Thrust washer Clutch boss Lock washer 1 Clutch boss nut NOTE Make sure the teeth on the lock washer are cor rectly aligned with the grooves on the clutch boss 3 Tighten Clutch boss nut Primary drive gear nut NOTE While ho...

Page 178: ...spring Push lever shaft Bolt Clutch cable NOTE After installing the clutch cable bend the push lever shaft tab along a flat side of the nut 8 Install Push rod 2 Ball Push rod 1 Push plate Washer Washer Locknut Pressure plate Clutch spring 1 Bolt 2 NOTE Tighten the clutch spring bolts in stages and in a crisscross pattern 9 Check Push lever position Push lever mark a and crankcase mark b not aligne...

Page 179: ...prevent it from moving and then tighten the locknut to spec ification CAUTION ECA13820 Do not overtighten the locknut since this will remove the free play between both push rods 11 Check Clutch cable free play Refer to ADJUSTING THE CLUTCH CA BLE FREE PLAY on page 3 12 Locknut 8 Nm 0 8 m kg 5 8 ft lb Clutch lever free play 10 0 15 0 mm 0 39 0 59 in a b c T R 1 2 ...

Page 180: ...r to CLUTCH on page 5 30 Clutch Primary drive gear 1 Balancer weight gear nut 1 2 Lock washer 1 3 Buffer boss 1 4 Balancer weight gear 1 5 Absorber plate 1 6 Compression spring 6 7 Dowel pin 3 8 Straight key 1 9 Spacer 1 10 Circlip 1 11 Oil pump driven gear 1 12 Oil pump assembly 1 13 Gasket 1 14 Straight key 1 15 Balancer drive gear 1 16 Oil strainer 1 1 2 3 4 5 6 7 8 9 14 15 16 10 11 13 12 ...

Page 181: ...PUMP AND BLANCER WEIGHT GEAR 5 39 For installation reverse the removal proce dure Removing the oil pump and balancer weight gear Order Job Parts to remove Q ty Remarks 1 2 3 4 5 6 7 8 9 14 15 16 10 11 13 12 ...

Page 182: ...Disassembling the oil pump Order Job Parts to remove Q ty Remarks 1 Oil pump housing 1 2 Dowel pin 2 3 Outer rotor 1 4 Inner rotor 1 5 Dowel pin 1 6 Shaft 1 7 Oil pump cover 1 For assembly reverse the disassembly pro cedure 7 6 4 5 2 1 3 2 ...

Page 183: ... clearance a Outer rotor to oil pump housing clearance b Oil pump housing to inner rotor and out er rotor clearance c Out of specification Replace the oil pump 3 Check Oil pump operation Rough movement Repeat steps 1 and 2 or replace the defective part s EAS4D602 CHECKING THE BALANCER WEIGHT GEAR 1 Check Balancer weight gear Buffer boss Compression spring Dowel pin Cracks damage wear Replace 1 2 3...

Page 184: ...w mark on the oil pump with the ar row mark on the crankcase EAS4D604 INSTALLING THE BALANCER WEIGHT GEAR 1 Remove Balancer weight gear Lock washer Balancer weight gear nut NOTE Align the punch mark a in the balancer drive gear with the punch mark b in the balancer weightn gear Place the aluminum plate c between balanc er drive gear 2 and balancer weight gear 3 and then tighten the balancer weight...

Page 185: ... the shift shaft and stopper lever Order Job Parts to remove Q ty Remarks Right crankcase cover Refer to CLUTCH on page 5 30 Clutch 1 Shift shaft assembly 1 2 Stopper lever 1 3 Torsion spring 1 For installation reverse the removal proce dure 1 2 3 ...

Page 186: ...s roughly Replace the stopper lever EAS25450 INSTALLING THE SHIFT SHAFT 1 Install Stopper lever 1 NOTE Hook the ends of the stopper lever spring onto the stopper lever and the crankcase boss Mesh the stopper lever with the shift drum segment assembly 2 Tighten Stopper lever bolt 3 Install Shift shaft 1 NOTE Install the shift shaft 1 by aligning the shift shaft spring 2 with the stopper 3 1 2 Stopp...

Page 187: ...ts to remove Q ty Remarks Fuel tank Refer to FUEL TANK on page 6 1 Battery negative lead Refer to CHECKING AND CHARGING THE BATTERY on page 7 38 Carburetor Refer to CARBURETOR on page 6 3 1 Starter motor lead 1 2 Starter motor assembly 1 For installation reverse the removal proce dure 1 2 ...

Page 188: ... Job Parts to remove Q ty Remarks 1 Front bracket 1 2 O ring 1 3 Tang washer Plate washer 1 1 4 Rear bracket 1 5 O ring 1 6 Armature coil 1 7 Stator assembly 2 8 O ring 1 9 Brush brush spring 2 2 For assembly reverse the disassembly pro cedure 8 5 7 1 2 4 6 9 3 ...

Page 189: ... assembly resistances com mutator 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 brushes as a set 6 Measure Brush spring force Out of specification Replace the brush Limit 21 0 mm 0 83 in M...

Page 190: ...Install O rings 1 To stator assembly 2 4 Install Stator assembly 1 NOTE Align the match marks a on the starter assem bly with the match marks b on the rear bracket 5 Install Tang washer 1 Plate washer 2 Front bracket 3 NOTE Align the match marks a on the starter assem bly with the match marks b on the front bracket Brush spring force 5 52 8 28 N 19 87 29 80 oz 563 844 gf 2 1 2 1 New 1 2 1 a b 1 2 ...

Page 191: ...efer to ENGINE REMOVAL on page 5 1 Drive sprocket cover 1 Starter idle gear cover O ring 1 1 2 Starter idler gear 1 shaft 1 1 3 Pickup coil rotor lead coupler 2 Disconnect 4 Left crankcase cover 1 5 Dowel pin 2 6 Crank case cover gasket 1 7 Stator coil assembly pickup coil 1 1 8 Starter idler gear 2 shaft 1 1 9 Pickup coil rotor 1 10 Woodruff key 1 11 Starter wheel gear 1 12 Bearing 1 13 Washer 1 ...

Page 192: ... COIL ROTOR AND STARTER CLUTCH 5 50 For installation reverse the removal proce dure Removing the pickup coil rotor and starter clutch Order Job Parts to remove Q ty Remarks 1 1 2 3 4 5 6 7 8 9 12 13 11 10 14 ...

Page 193: ...NOTE Remove the rotor using flywheel puller 2 3 Remove Woodruff key 1 4 Remove Starter idle gear 2 1 Starter wheel gear 2 Bearing 3 Washer 4 EAS24570 CHECKING THE STARTER CLUTCH 1 Check Starter clutch rollers Damage wear Replace the starter clutch 2 Check Starter idle gear 1 Starter wheel gear 2 Starter clutch gear 3 Burrs chips roughness wear Replace the defective part s Sheave holder 90890 01701...

Page 194: ...placed 5 Check Shaft Damage fatigue wear Replace the defec tive part s EAS24540 INSTALLING THE PICKUP COIL ROTOR 1 Install Washer 1 Bearing 2 Starter wheel gear 3 Starter idle gear 2 4 2 Install Woodruff key 1 Pickup coil rotor 2 Washer 3 Pickup coil rotor bolt 4 NOTE Clean the tapered portion of the crankshaft and the rotor hub When installing the rotor make sure the woo druff key is properly sea...

Page 195: ... as shown 7 Install Starter idle gear 1 Shaft 8 Install O ring Starter idle gear cover Stater coil bolt 7 Nm 0 7 m kg 5 1 ft lb LOCTITE Pickup coil bolt 7 Nm 0 7 m kg 5 1 ft lb LOCTITE Crank case cover bolt M6 30mm 1 5 10 Nm 1 0 m kg 7 2 ft lb M6 45mm 6 10 Nm 1 0 m kg 7 2 ft lb M6 40mm 7 9 10 Nm 1 0 m kg 7 2 ft lb 1 2 a T R 1 2 New T R Starter idle gear cover bolt 8 Nm 0 8 m kg 5 8 ft lb 1 2 3 4 5...

Page 196: ... 25 Clutch Refer to CLUTCH on page 5 30 Oil pump Refer to OIL PUMP AND BLANCER WEIGHT GEAR on page 5 38 Balancer weight gear Shift shaft Refer to SHIFT SHAFT on page 5 43 Pickup coil rotor Refer to PICKUP COIL ROTOR AND STARTER CLUTCH on page 5 49 1 Timing chain guide intake side 1 2 Timing chain 1 3 Crankshaft sprocket 1 4 Right crankcase 1 5 Dowel pin 2 6 Left crankcase 1 For installation revers...

Page 197: ... Q ty Remarks Crankshaft assembly Refer to CRANKSHAFT ASSEMBLY on page 5 58 Main axle assembly drive axle assembly Refer to TRANSMISSION on page 5 62 1 Bearing retainer 1 2 Oil seal 2 3 Bearing 7 For installation reverse the removal proce dure 3 3 1 3 3 2 3 3 3 2 ...

Page 198: ...n the shift drum segment s teeth will not contact the crank case during crankcase separation 4 Remove Right crankcase CAUTION ECA13910 First check that the shift drum segment s teeth and the drive axle circlip are properly positioned then remove the right crank case Do not damage the crankcase mating sur faces EAS25580 CHECKING THE CRANKCASE 1 Thoroughly wash the crankcase halves in a mild solvent...

Page 199: ...ase bolt M6 40mm 9 12 NOTE Tighten each bolt 1 4 of a turn at a time in stag es and in a crisscross pattern 5 Install Neutral switch 13 6 Install Crankshaft sprocket 1 Timing chain guide intake side 2 Timing chain 3 7 Apply Engine oil onto the crankshaft pins bearings and oil de livery holes 8 Check Crankshaft and transmission operation Rough movement Repair Crankcase bolts 1 12 10 Nm 1 0 m kg 7 2...

Page 200: ...emoving the crankshaft assembly Order Job Parts to remove Q ty Remarks Crankcase Refer to CRANKCASE on page 5 54 1 Balancer weight 1 2 Crankshaft assembly 1 3 Dowel pin 1 4 Plunger seal 1 5 Bearing 1 For installation reverse the removal proce dure 3 4 2 5 1 ...

Page 201: ...HAFT AND CONNECTING ROD 1 Measure Crankshaft runout Out of specification Replace the crank shaft bearing or both NOTE Turn the crankshaft slowly 2 Measure Big end side clearance Out of specification Replace the big end bearing crankshaft pin or connecting rod 3 Measure Crankshaft width Out of specification Replace the crank shaft 4 Check Crankshaft sprocket Damage wear Replace the crankshaft Beari...

Page 202: ...1 4 tooth wear a Replace the timing chain and camshaft sprocket and crankshaft sprocket as a set 3 Check Timing chain guide intake side EAS4D607 INSTALLING THE PLUNGER SEAL 1 Install Compression spring 1 Plunger seal 2 Dowel pin 3 Check the plunger seal smooth operation pushing the plunger seal by your finger EAS26210 INSTALLING THE CRANKSHAFT ASSEMBLY 1 Install Crankshaft assembly 1 NOTE Install ...

Page 203: ...d 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 as sembly bottoms against the bearing 2 Install Balancer weight To the right crank case Crankshaft installer pot 90890 01274 Installing pot YU 90058 Crankshaft installer bolt 90890 01275 Bolt YU 90060 Spacer 90890 01288 Adapter M10 908...

Page 204: ... Job Parts to remove Q ty Remarks Crankcase Separate Refer to CRANKSHAFT ASSEMBLY on page 5 58 1 Shift fork guide bar 1 2 Shift drum assembly 1 3 Shift fork 3 R 1 4 Shift fork 2 C 1 5 Shift fork 1 L 1 6 Main axle assembly 1 7 Drive axle assembly 1 For installation reverse the removal proce dure 1 3 4 5 2 6 7 ...

Page 205: ...ion gear 1 3 3rd pinion gear 1 4 Main axle 1 5 Circlip washer 1 1 6 1st wheel gear 1 7 Dog clutch 1 8 Circlip washer 1 1 9 3rd wheel gear 1 10 4th wheel gear 1 11 5th wheel gear 1 12 Circlip washer 1 1 13 2nd wheel gear 1 14 Drive axle 1 For installation reverse the removal proce dure 5 6 7 8 9 10 11 12 13 1 2 3 4 14 ...

Page 206: ...Shift fork pawl 2 Bends damage scoring wear Replace the shift fork 3 Check Shift fork guide bar Roll the shift fork guide bar on a flat surface Bends Replace WARNING EWA12840 Do not attempt to straighten a bent shift fork guide bar EAS26270 CHECKING THE SHIFT DRUM ASSEMBLY 1 Check Shift drum groove 1 Damage scratches wear Replace the shift drum assembly Shift drum segment 2 Damage wear Replace the...

Page 207: ...efective gear s Transmission gear dogs Cracks damage rounded edges Replace the defective gear s 4 Check Transmission gear engagement each pinion gear to its respective wheel gear Incorrect Reassemble the transmission axle assemblies NOTE When reassembling the main axle press the 2nd pinion gear 1 onto it 2 as shown 5 Check Transmission gear movement Rough movement Replace the defective part s 6 Ch...

Page 208: ...rankcase NOTE The embossed marks a on the shift forks should face towards the left side of the engine and be in the following sequence L C R The grooved side of the shift fork guide bar should face towards the right side of the en gine 2 Check Shift cam operation Unsmoothy operation Repair NOTE Check the transmission and shift forks for smooth operation by turning the shift cam with your hand 1 2 ...

Page 209: ...FUEL SYSTEM FUEL TANK 6 1 CHECKING THE FUEL COCK 6 2 CARBURETOR 6 3 CHECKING THE CARBURETOR 6 5 ASSEMBLING THE CARBURETOR 6 6 INSTALLING THE CARBURETOR 6 7 AIR INDUCTION SYSTEM 6 9 CHECKING THE AIR INDUCTION SYSTEM 6 12 ...

Page 210: ... the fuel tank Order Job Parts to remove Q ty Remarks Seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank side cover left right 1 Fuel tank 1 Check that the fuel cock lever is positioned to OFF For installation reverse the removal proce dure 1 ...

Page 211: ... out the jets with compressed air Damage Replace 3 Check Fuel cock operation NOTE After installing the fuel cock check its operation a Check that the fuel cock lever is positioned to OFF b Place a container under the end of the fuel hose c Check the fuel cock 1 operation Fuel flows Fuel cock is OK Fuel does not flow Replace the fuel cock 1 1 ...

Page 212: ... FUEL TANK on page 6 1 Battery 1 Throttle cable 1 throttle cable 2 1 1 2 Starter plunger 1 3 Carburetor warmer lead coupler 1 Disconnect 4 Fuel hose 1 Disconnect 5 Carburetor joint clamp screw 1 Loosen 6 Air filter clamp screw 1 Loosen 7 Air filter case bolt 3 Remove 8 Carburetor assembly 1 9 Air vent hose 3 For installation reverse the removal proce dure 1 2 3 4 5 6 7 7 8 9 9 9 ...

Page 213: ...ng 1 6 Coasting enricher diaphragm 1 7 Carburetor warmer positive lead 1 8 Carburetor warmer 1 9 Carburetor warmer negative lead 1 10 Pilot screw set 1 11 Float chamber Gasket 1 1 12 Float pin 1 13 Float 1 14 Needle valve seat set 1 15 Main jet 1 16 Pilot jet 1 17 Main nozzle 1 For assembly reverse the disassembly pro cedure 2 3 6 5 4 10 12 11 13 1615 17 1 14 9 8 7 ...

Page 214: ... Float Damage Replace 5 Check Needle valve seat 1 Needle valve 2 Damage obstruction wear Replace the needle valve needle valve seat and O ring as a set 6 Check O ring 3 Damage wear Replace the needle valve needle valve seat and O ring as a set 7 Check Piston valve 1 Damage scratches wear Replace Piston valve diaphragm 2 Cracks tears Replace 8 Check Cover 1 Diaphram spring 2 Cracks damage Replace 9...

Page 215: ...0 ASSEMBLING THE CARBURETOR CAUTION ECA14110 Before assembling the carburetor wash all of the parts in a petroleum based sol vent Always use a new gasket 1 Install Main nozzle 1 Pilot jet 2 2 Install Main jet 1 Needle valve seat 2 NOTE Install the screw a securely 3 Install Needle valve 1 Float 2 Float pin 3 NOTE Install the float pin from the side opposite the ar row 4 Check Float height a Hold t...

Page 216: ...8 Install Coasting enricher diaphram Cover 1 Hoser 2 Stopper 3 EAS26890 INSTALLING THE CARBURETOR 1 Adjust Engine idling speed Refer to ADJUSTING THE ENGINE IDLING SPEED on page 3 6 2 Adjust Throttle cable free play Refer to ADJUSTING THE THROTTLE CA BLE FREE PLAY on page 3 7 Float height 10 5 mm 0 41 in Pilot screw turns out 1 1 4 a 1 1 New Engine idling speed 1300 1500 r min Throttle cable free ...

Page 217: ...CARBURETOR 6 8 ...

Page 218: ...AIR INDUCTION SYSTEM 6 9 EAS27040 AIR INDUCTION SYSTEM ...

Page 219: ...INDUCTION SYSTEM 6 10 1 Air induction system pipe 2 Air induction system hose air cut off valve cylinder head 3 Air induction system hose carburetor joint air cut off valve 4 Air cut off valve 5 Air cleaner ...

Page 220: ...ff valve Order Job Parts to remove Q ty Remarks 1 Air induction system hose air cut off valve cylinder head 1 2 Air induction system hose carburetor joint air cut off valve 1 3 Air cut off valve 1 For installation reverse the removal proce dure 1 2 3 ...

Page 221: ...haust port The required temperature for burning the un burned exhaust gases is approximately 600 to 700 C Air cut off valve The air cut off valve is controlled by the intake gas pressure Ordinarily the air cut off valve opens to allow the air to flow during idle and closes to cut off the flow when the vehicle is be ing driven 1 Check Hoses Loose connections Connect properly Cracks damage Replace P...

Page 222: ...AIR INDUCTION SYSTEM 6 13 ...

Page 223: ...BLESHOOTING 7 21 CARBURETOR HEATING SYSTEM 7 25 CIRCUIT DIAGRAM 7 25 TROUBLESHOOTING 7 27 ELECTRICAL COMPONENTS 7 29 CHECKING THE SWITCHES 7 33 CHECKING THE BULBS AND BULB SOCKETS 7 36 CHECKING THE FUSE 7 37 CHECKING AND CHARGING THE BATTERY 7 38 CHECKING THE RELAYS 7 41 CHECKING THE TURN SIGNAL RELAY 7 41 CHECKING THE DIODE 7 42 CHECKING THE SPARK PLUG CAP 7 43 CHECKING THE IGNITION COIL 7 43 CHE...

Page 224: ...Br W Y L G P Dg Ch B Br W Y L B G P Ch B Br W G W B G Y Ch Ch Ch Y G B Y B G B B B B B Y L B L Y B L Y G Y G Y G Y Br B B B B Br Br Br G Y Sb B W Br Br Br Br W Br W Br B W B B B W L B L B L B L W L W B W Br Sb B B L W L B L W Br L W L B L B L W O B B R L W B L Y R B W R W L W W W O W W W R B L Y B R L W L L Y W B W R O R B W W W W W W W L W R W R W W W R W W W W W W W L W R L B L Y Br R R Br L L Y...

Page 225: ...ckup coil rotor 5 Engine stop switch 7 CDI unit 8 Ignition coil 9 Diode 11 Sidestand switch 12 Starting circuit cut off relay 28 Neutral switch lead 29 Neutral switch 38 Main fuse 39 Battery positive lead 41 Battery 42 Battery negative lead ...

Page 226: ...er to CHECKING THE SPARK PLUG on page 3 8 NG Re gap or replace the spark plug OK 4 Check the spark plug cap Refer to CHECKING THE SPARK PLUG CAP on page 7 43 NG Replace the spark plug cap OK 5 Check the ignition coil Refer to CHECKING THE IGNI TION COIL on page 7 43 NG Replace the ignition coil OK 6 Check the pickup coil Refer to CHECKING THE PICKUP COIL on page 7 44 NG Replace the pickup coil OK ...

Page 227: ...e the sidestand switch OK 12 Check the starting circuit cut off relay Refer to CHECKING THE RELAYS on page 7 41 NG Replace the starting circuit cut off relay OK 13 Check the diode Refer to CHECKING THE DIODE on page 7 42 NG Replace the diode OK 14 Check the entire ignition system s wir ing Refer to CIRCUIT DIAGRAM on page 7 1 NG Properly connect or repair the ignition system s wiring OK Replace th...

Page 228: ... B P L B Br W Y L G P Dg Ch B Br W Y L B G P Ch B Br W G W B G Y Ch Ch Ch Y G B Y B G B B B B B Y L B L Y B L Y G Y G Y G Y Br B B B B Br Br Br G Y Sb B W Br Br Br Br W Br W Br B W B B B W L B L B L B L W L W B W Br Sb B B L W L B L W Br L W L B L B L W O B B R L W B L Y R B W R W L W W W O W W W R B L Y B R L W L L Y W B W R O R B W W W W W W W L W R W R W W W R W W W W W W W L W R L B L Y Br R R...

Page 229: ...witch 6 Start switch 7 CDI unit 9 Diode 10 Clutch switch 11 Sidestand switch 12 Starting circuit cut off relay 28 Neutral switch lead 29 Neutral switch 37 Starter relay 38 Main fuse 39 Battery positive lead 40 Starter motor 41 Battery 42 Battery negative lead ...

Page 230: ...d The clutch lever is pulled to the handlebar the clutch switch is closed and the sidestand is up the sidestand switch is closed The starting circuit cut off relay 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...

Page 231: ...L b WHEN THE SIDESTAND IS UP AND THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 1 Battery 2 Main fuse 3 Main switch 4 Engine stop switch 5 Starting circuit cut off relay 6 Clutch switch 7 Sidestand switch 8 Neutral switch 9 Start switch 10 Starter relay 11 Starter motor ...

Page 232: ... MOTOR on page 5 47 NG Repair or replace the starter motor OK 4 Check the starting circuit cut off relay Refer to CHECKING THE RELAYS on page 7 41 NG Replace the starting circuit cut off relay OK 5 Check the starter relay Refer to CHECKING THE RELAYS on page 7 41 NG Replace the starter relay OK 6 Check the main switch Refer to CHECKING THE SWITCHES on page 7 33 NG Replace the main switch OK 7 Chec...

Page 233: ...e the clutch switch OK 11 Check the start switch Refer to CHECKING THE SWITCHES on page 7 33 NG Replace the right handlebar switch OK 12 Check the entire starting system s wiring Refer to CIRCUIT DIAGRAM on page 7 5 NG Properly connect or repair the starting system s wiring OK The starting system circuit is OK ...

Page 234: ... Br L Y R L B B B Br B Y B Y B Y B Y B Y R R R B B B B B B B B B R R Br Br R W R W Br R W W B R L Br P Br L B Br W B L B W B P L B Br Br L Y R B W R W L R B W W W W W W W L W R W R W W W R W W W W W W W L W R L B L Y Br R R Br L L Y L B B B R R B B W R W L W R R R Br R W B L W R W R W L W B B W R W B B B ...

Page 235: ...CHARGING SYSTEM 7 12 2 Pickup coil rotor 3 Rectifier regulator 38 Main fuse 39 Battery positive lead 41 Battery 42 Battery negative lead ...

Page 236: ... ING THE BATTERY on page 7 38 NG Clean the battery terminals Recharge or replace the battery OK 3 Check the stator coil Refer to CHECKING THE STATOR COIL on page 7 44 NG Replace the stator assembly OK 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 7 45 NG Replace the rectifier regulator OK 5 Check the entire charging system s wiring Refer to CIRCUIT DIAGRAM on p...

Page 237: ...CHARGING SYSTEM 7 14 ...

Page 238: ...Br W Y L G P Dg Ch B Br W Y L B G P Ch B Br W G W B G Y Ch Ch Ch Y G B Y B G B B B B B Y L B L Y B L Y G Y G Y G Y Br B B B B Br Br Br G Y Sb B W Br Br Br Br W Br W Br B W B B B W L B L B L B L W L W B W Br Sb B B L W L B L W Br L W L B L B L W O B B R L W B L Y R B W R W L W W W O W W W R B L Y B R L W L L Y W B W R O R B W W W W W W W L W R W R W W W R W W W W W W W L W R L B L Y Br R R Br L L Y...

Page 239: ...in switch 2 Pickup coil rotor 7 CDI unit 15 Tail brake light 17 Headlight relay 21 Dimmer switch 27 Headlight 32 Meter light 35 High beam indicator light 38 Main fuse 39 Battery positive lead 41 Battery 42 Battery negative lead ...

Page 240: ... to CHECKING THE FUSE on page 7 37 NG Replace the fuse OK 3 Check the battery Refer to CHECKING AND CHARG ING THE BATTERY on page 7 38 NG Clean the battery terminals Recharge or replace the battery OK 4 Check the main switch Refer to CHECKING THE SWITCHES on page 7 33 NG Replace the main switch OK 5 Check the dimmer switch Refer to CHECKING THE SWITCHES on page 7 33 NG The dimmer switch is faulty ...

Page 241: ...LIGHTING SYSTEM 7 18 ...

Page 242: ... Br W Y L G P Dg Ch B Br W Y L B G P Ch B Br W G W B G Y Ch Ch Ch Y G B Y B G B B B B B Y L B L Y B L Y G Y G Y G Y Br B B B B Br Br Br G Y Sb B W Br Br Br Br W Br W Br B W B B B W L B L B L B L W L W B W Br Sb B B L W L B L W Br L W L B L B L W O B B R L W B L Y R B W R W L W W W O W W W R B L Y B R L W L L Y W B W R O R B W W W W W W W L W R W R W W W R W W W W W W W L W R L B L Y Br R R Br L L ...

Page 243: ... Horn 20 Turn switch 22 Horn switch 23 Rear right turn signal light 24 Rear left turn signal light 25 Front right turn signal light 26 Front left turn signal light 28 Neutral switch lead 29 Neutral switch 33 Neutral indicator light 34 Turn signal indicator light 38 Main fuse 39 Battery positive lead 41 Battery 42 Battery negative lead ...

Page 244: ...ATTERY on page 7 38 NG Clean the battery terminals Recharge or replace the battery OK 3 Check the main switch Refer to CHECKING THE SWITCHES on page 7 33 NG Replace the main switch OK 4 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 7 19 NG Properly connect or repair the signaling sys tem s wiring OK This circuit is OK 1 Check the horn switch Refer to CHECKING THE SWIT...

Page 245: ...GRAM on page 7 19 NG Properly connect or repair the signaling sys tem s wiring OK This circuit is OK 1 Check the turn signal indicator light bulb and socket Refer to CHECKING THE BULBS AND BULB SOCKETS on page 7 36 NG Replace the turn signal indicator light bulb socket or both OK 2 Check the turn signal switch Refer to CHECKING THE SWITCHES on page 7 33 NG Replace the left handlebar switch OK 3 Ch...

Page 246: ... SOCKETS on page 7 36 NG Replace the neutral indicator light bulb socket or both OK 2 Check the neutral switch Refer to CHECKING THE SWITCHES on page 7 33 NG Replace the neutral switch OK 3 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 7 19 NG Properly connect or repair the signaling sys tem s wiring OK This circuit is OK ...

Page 247: ...SIGNALING SYSTEM 7 24 ...

Page 248: ...FF ON Br Br L Y R L B B B Br B Y B Y B Y B Y B Y R R R B B B B B B B B B R R Br Br R W R W Br R W W B R L Br P Br L B Br W B P B W W W W W W W L W R W R W W W R W W W W W W W L W R L B L Y Br R R Br L L Y L B B B R R B B W R W L W R R R Br R W B L W R W R W L W B B W R W B B B B B B B Y B B Y CAB HEATER MAIN HARNESS ...

Page 249: ...CARBURETOR HEATING SYSTEM 7 26 1 Main switch 38 Main fuse 39 Battery positive lead 41 Battery 42 Battery negative lead 43 Thermo switch 44 Carburetor warmer ...

Page 250: ...HARG ING THE BATTERY on page 7 38 NG Clean the battery terminals Recharge or replace the battery OK 3 Check the main switch Refer to CHECKING THE SWITCHES on page 7 33 NG Replace the main switch OK 4 Check the thermo switch Refer to CHECKING THE THERMO SWITCH on page 7 46 NG Replace the thermo switch OK 5 Check the carburetor warmer Refer to CHECKING THE CARBU RETOR WARMER on page 7 47 NG Replace ...

Page 251: ...CARBURETOR HEATING SYSTEM 7 28 ...

Page 252: ...ELECTRICAL COMPONENTS 7 29 EAS27970 ELECTRICAL COMPONENTS 1 2 3 4 5 6 8 7 9 ...

Page 253: ...ELECTRICAL COMPONENTS 7 30 1 Main switch 2 Starter relay 3 Battery 4 Rectifier regurator 5 Sidestand switch 6 Rear brake light switch 7 Starting circuit cut off relay 8 Headlight relay 9 Wire harness ...

Page 254: ...ELECTRICAL COMPONENTS 7 31 10 11 12 14 13 ...

Page 255: ...ELECTRICAL COMPONENTS 7 32 10 Horn 11 CDI unit 12 Thermo switch 13 Neutral switch 14 Ignition coil ...

Page 256: ...33 EAS27980 CHECKING THE SWITCHES G Y Br B B B B L W L B OFF LOCK ON R Br L L Y L B R OFF RUN OFF ON L W R W R W L W B B W R W B B B B W L B Sb B B Br G Y Br Br N R L PUSH HI LO OFF Y L G P Dg Ch B Br W Y L B G P Ch B Br W G W ...

Page 257: ...TS 7 34 1 Main switch 5 Engine stop switch 6 Start switch 10 Clutch switch 11 Sidestand switch 13 Rear brake light switch 14 Front brake light switch 20 Turn signal switch 21 Dimmer switch 22 Horn switch 29 Neutral switch ...

Page 258: ...between the switch positions a few times The terminal connections for switches e g main switch engine stop switch are shown in an illustra tion similar to the one on the left The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row in the switch illustration NOTE indicates a continuity of electricity between switch terminals i e a closed circuit...

Page 259: ...ollowing procedure applies to all of the bulbs 1 Remove Bulb WARNING EWA13320 Since the headlight bulb gets extremely hot keep flammable products and your hands away from the bulb until it has cooled down CAUTION ECA14380 Be sure to hold the socket firmly when re moving the bulb Never pull the lead oth erwise it may be pulled out of the terminal in the coupler Avoid touching the glass part of the ...

Page 260: ...ight Refer to GENERAL CHASSIS on page 4 1 2 Check Fuse a Connect the pocket tester to the fuse and check the continuity NOTE Set the pocket tester selector to Ω 1 b If the pocket tester indicates replace the fuse 3 Replace Blown fuse a Set the main switch to OFF b Install a new fuse of the correct amperage rating c Set on the switches to verify if the electrical circuit is operational d If the fus...

Page 261: ...g time charging amperage and charging voltage for an MF battery are dif ferent from those of conventional batter ies The MF battery should be charged as explained in the charging method illustra tions If the battery is overcharged the electrolyte level will drop considerably Therefore take special care when charg ing the battery NOTE Since MF batteries are sealed it is not possible to check the ch...

Page 262: ...the battery charger Make sure the battery charger lead clips are in full contact with the battery terminal and that they are not shorted A corroded battery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks If the battery becomes hot to the touch at any time during the charging process dis connect the battery charger and let the battery cool before reco...

Page 263: ...er a Measure the open circuit voltage prior to charging NOTE Voltage should be measured 30 minutes after the machine is stopped b Connect a charger and AMP meter to the battery and start charging c Make sure that the current is higher than the standard charging current written on the bat tery NOTE If the current is lower than the standard charging current written on the battery This type of bat te...

Page 264: ...ecification The wiring circuit from the main switch to the turn signal relay cou pler is faulty and must be repaired Recommended lubricant Dielectric grease Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity No continuity Between 3 to 4 3 4 2 1 L W B W Sb Br L W B W Br S...

Page 265: ... a Disconnect the diode from the wire harness b Connect the pocket tester Ω 1 to the di ode coupler as shown c Check the diode for continuity Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe brown 1 Negative tester probe ground Turn signal relay input voltage DC 12 V Pocket tester 90890 03112 Analog pocket tester YU 03112 C Negative tester probe brown white 1 Positiv...

Page 266: ...n coil connectors from the ignition coil terminals b Connect the pocket tester Ω 1 to the igni tion coil as shown c Measure the primary coil resistance 2 Check Secondary coil resistance Out of specification Replace a Disconnect the spark plug cap from the igni tion coil b Connect the pocket tester Ω 1k to the ig nition coil as shown Resistance 10 0 kΩ Pocket tester 90890 03112 Analog pocket tester...

Page 267: ...ness 2 Check Pickup coil resistance Out of specification Replace a Connect the pocket tester Ω 100 to the pickup coil terminal as shown b Measure the pickup coil resistance EAS28150 CHECKING THE STATOR COIL 1 Disconnect Stator coil coupler from the wire harness 2 Check Stator coil resistance Out of specification Replace the stator coil Minimum ignition spark gap 6 mm 0 24 in 1 Ignition checker opa...

Page 268: ...HORN 1 Check Horn resistance Out of specification Replace a Disconnect the horn leads from the horn ter minals b Connect the pocket tester Ω 1 to the horn terminals Stator coil resistance 0 56 0 84 Ω Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe White 1 Negative tester probe White 2 Positive tester probe White 1 Negative tester probe White 3 Positive tester probe ...

Page 269: ...f specification Replace the thermo switch Step 1 and 2 Heating phase Step 3 and 4 Cooling phase a Connect the pocket tester Ω 1 to the ther mo switch 1 coupler as shown b Immerse the thermo switch in a container filled with coolant 2 c Place a thermometer 3 in the coolant d Slowly heat the coolant then let it cool down to the specified temperature e Check the thermo switch for continuity Positive ...

Page 270: ...Replace a Remove the carburetor warmer leads from the carburetor b Connect the pocket tester Ω 1 to the car buretor warmer as shown c Measure the carburetor warmer resistance Resistance 4 7 9 5 Ω Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe Carburetor warmer terminal 1 Negative tester probe Carburetor warmer body 2 ...

Page 271: ...CORRECT ENGINE IDLING SPEED 8 2 POOR MEDIUM AND HIGH SPEED PERFORMANCE 8 2 FAULTY GEAR SHIFTING 8 2 SHIFT PEDAL DOES NOT MOVE 8 2 JUMPS OUT OF GEAR 8 2 FAULTY CLUTCH 8 2 OVERHEATING 8 3 POOR BRAKING PERFORMANCE 8 3 FAULTY FRONT FORK LEGS 8 3 UNSTABLE HANDLING 8 3 FAULTY LIGHTING OR SIGNALING SYSTEM 8 4 ...

Page 272: ...in hose Clogged rollover valve Clogged rollover valve hose Deteriorated or contaminated fuel 2 Fuel pump Faulty fuel pump Faulty fuel pump relay 3 Fuel cock Clogged or damaged fuel hose 4 Carburetor s Deteriorated or contaminated fuel Clogged pilot jet Clogged pilot air passage Sucked in air Damaged float Worn needle valve Improperly installed needle valve seat Incorrect fuel level Improperly inst...

Page 273: ... unit Faulty pickup coil Broken generator rotor woodruff key EAS28510 POOR MEDIUM AND HIGH SPEED PERFORMANCE Refer to STARTING FAILURES on page 8 1 Engine 1 Air filter Clogged air filter element Fuel system 1 Carburetor s Faulty diaphragm Incorrect fuel level Loose or clogged main jet 2 Fuel pump Faulty fuel pump EAS28530 FAULTY GEAR SHIFTING Shifting is difficult Refer to Clutch drags EAS28540 SH...

Page 274: ... or grease 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 assembly bolt Damaged damper rod assembly bolt copper washer Cracked or damaged cap bolt O ring Malfunction Bent or damaged inner tube Bent or d...

Page 275: ...cal accessories Incorrect connection Burnt out tail brake light bulb Tail brake light bulb burnt out Wrong tail brake light bulb Faulty battery Incorrectly adjusted rear brake light switch Tail brake light bulb life expired 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 ground...

Page 276: ...indicator light 34 Turn signal indicator light 35 High beam indicator light 36 Diode relay unit 37 Starter relay 38 Main fuse 39 Battery positive lead 40 Starter motor 41 Battery 42 Battery negative lead 43 Thermo switch 44 Carburetor warmer EAS28750 COLOR CODE B Black Br Brown Ch Chocolate Dg Dark green G Green Gy Gray L Blue O Orange P Pink R Red Sb Sky blue W White Y Yellow B G Black Green B L ...

Page 277: ... G Y G Y Br B B B B Br Br Br G Y Sb B W Br Br Br Br W Br W Br B W B B B W L B L B L B L W L W B W Br Sb B B L W L B L W Br L W L B L B L W O B B R L W B L Y R B W R W L W W W O W W W R B L Y B R L W L L Y W B W R O R B W W W W W W W L W R W R W W W R W W W W W W W L W R L B L Y Br R R Br L L Y L B B B B B R R B B W R W L W R R R Br R W B L W R W R W L W B B W R W B Br Br G W G W G W B B B B B B Y ...

Page 278: ...AGRAM XG250 2005 SCHÉMA DE CÂBLAGE XG250 2005 SCHALTPLAN SCHEMA ELETTRICO XG250 2005 DIAGRAMA ELÉCTRICO DE LA XG250 2005 OFF LOCK ON 20A OFF RUN OFF ON N R L PUSH HI LO OFF B B B B B R R B Br Br B B CAB HEATER MAIN HARNESS ...

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