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Yamaha YFM660RN, Service Manual

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Yamaha YFM660RN Service Manual Download Page 212

5 - 32

ENG

CYLINDER AND PISTON

CYLINDER AND PISTON

Order

Job name/Part name

Q’ty

Remarks

Removing the cylinder and piston

Remove the parts in the order below.

Water jacket inlet housing

Refer to “WATER PUMP” in CHAPTER 6.

Cylinder head

Refer to “CAMSHAFT AND CYLINDER 
HEAD”.

1

Cable guide

1

2

Cylinder/O-ring

1/1

Refer to “INSTALLING THE CYLINDER”.

3

Cylinder gasket

1

4

Dowel pin

2

5

Piston pin clip

2

Refer to “REMOVING/INSTALLING THE 
PISTON”.

6

Piston pin

1

7

Piston

1

8

Piston ring set

1

For installation, reverse the removal pro-
cedure.

Summary of Contents for YFM660RN

Page 1: ...YFM660RN YFM660RNC SERVICEMANUAL LIT 11616 14 21 5LP 28197 E0 ...

Page 2: ...fications 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 NOTE Designs and specifications are subject to change without notice IMPORTANT INFORMATION Particularly important information is distinguished in this manual by the following notations The Safety Alert Symbol means ...

Page 3: ...ntify parts and clarify procedure steps there are exploded diagrams at the start of each removal and disassembly section 1 An easy to see exploded diagram 4 is provided for removal and disassembly jobs 2 Numbers 5 are given in the order of the jobs in the exploded diagram A number that is enclosed by a circle indicates a disassembly step 3 An explanation of jobs and notes is presented in an easy t...

Page 4: ...Torque E Wear limit clearance F Engine speed G Ω V A Illustrated symbols H to N in the exploded diagrams indicate the types of lubricants and lubrication points H Apply engine oil I Apply gear oil J Apply molybdenum disulfide oil K Apply wheel bearing grease L Apply lightweight lithium soap base grease M Apply molybdenum disulfide grease N Apply silicon grease Illustrated symbols O to P in the exp...

Page 5: ...ENTS GENERAL INFORMATION GEN INFO 1 SPECIFICATIONS SPEC 2 PERIODIC CHECKS AND ADJUSTMENTS CHK ADJ 3 CHASSIS CHAS 4 ENGINE ENG 5 COOLING SYSTEM COOL 6 CARBURETION CARB 7 ELECTRICAL ELEC 8 TROUBLESHOOTING TRBL SHTG 9 ...

Page 6: ...HERS PLATES AND COTTER PINS 1 3 BEARINGS AND OIL SEALS 1 3 CIRCLIPS 1 3 CHECKING OF CONNECTIONS 1 4 SPECIAL TOOLS 1 5 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS 2 1 MAINTENANCE SPECIFICATIONS 2 4 ENGINE 2 4 CHASSIS 2 14 ELECTRICAL 2 18 HOW TO USE THE CONVERSION TABLE 2 20 GENERAL TORQUE SPECIFICATIONS 2 20 LUBRICATION POINTS AND LUBRICANT TYPES 2 21 ENGINE 2 21 COOLANT FLOW DIAGRAMS 2 22 OIL ...

Page 7: ...URE 3 18 CHECKING THE ENGINE OIL LEVEL 3 19 CHANGING THE ENGINE OIL 3 20 ADJUSTING THE CLUTCH CABLE 3 23 CLEANING THE AIR FILTER 3 24 CHECKING THE COOLANT LEVEL 3 27 CHANGING THE COOLANT 3 27 CHECKING THE COOLANT TEMPERATURE WARNING LIGHT 3 31 CLEANING THE SPARK ARRESTER 3 31 CHASSIS 3 33 ADJUSTING THE FRONT BRAKE 3 33 ADJUSTING THE REAR BRAKE 3 33 ADJUSTING THE PARKING BRAKE 3 34 CHECKING THE BRA...

Page 8: ...REAR AXLE 4 9 CHECKING THE WHEEL 4 10 CHECKING THE WHEEL HUB 4 10 CHECKING THE REAR AXLE 4 10 CHECKING THE HUB 4 11 CHECKING THE BRAKE DISC 4 11 INSTALLING THE NUTS REAR AXLE 4 11 INSTALLING THE WHEEL HUB 4 12 INSTALLING THE WHEEL 4 12 FRONT AND REAR BRAKES 4 13 FRONT BRAKE PADS 4 13 REAR BRAKE PADS 4 14 REPLACING THE FRONT BRAKE PAD 4 15 REPLACING THE REAR BRAKE PAD 4 17 FRONT BRAKE MASTER CYLIND...

Page 9: ...G THE LOCK WASHER 4 47 TIE ROD AND STEERING KNUCKLE 4 48 REMOVING THE STEERING KNUCKLE 4 49 CHECKING THE TIE ROD 4 49 CHECKING THE STEERING KNUCKLE 4 49 INSTALLING THE TIE ROD 4 49 FRONT ARMS AND FRONT SHOCK ABSORBERS 4 50 REMOVING THE FRONT ARM 4 52 CHECKING THE FRONT ARM 4 52 CHECKING THE FRONT SHOCK ABSORBER 4 52 CHECKING THE BALL JOINT 4 53 INSTALLING THE FRONT ARM 4 54 REAR SHOCK ABSORBER AND...

Page 10: ... CHECKING THE CAMSHAFT SPROCKET 5 19 CHECKING THE DECOMPRESSION SYSTEM 5 19 CHECKING THE TIMING CHAIN GUIDE 5 20 CHECKING THE TIMING CHAIN TENSIONER 5 20 CHECKING THE CYLINDER HEAD 5 20 INSTALLING THE CAMSHAFT AND CYLINDER HEAD 5 21 VALVES AND VALVE SPRINGS 5 24 REMOVING THE VALVE AND VALVE SPRING 5 25 CHECKING THE VALVE AND VALVE SPRING 5 26 INSTALLING THE VALVE AND VALVE SPRING 5 30 CYLINDER AND...

Page 11: ...INSTALLING THE CLUTCH 5 52 OIL PUMP 5 54 CHECKING THE OIL PUMP 5 56 ASSEMBLING THE OIL PUMP 5 56 SHIFT SHAFT 5 57 CHECKING THE SHIFT SHAFT 5 59 CHECKING THE STOPPER LEVER 5 59 CHECKING THE SHIFT GUIDE AND SHIFT LEVER 5 59 CHECKING THE SEGMENT 5 59 INSTALLING THE SHIFT LEVER 5 59 INSTALLING THE STOPPER LEVER 5 60 INSTALLING THE SHIFT SHAFT 5 61 CRANKCASE 5 62 TIMING CHAIN AND SPEED SENSOR ROTOR 5 6...

Page 12: ... 6 COOLING SYSTEM RADIATOR 6 1 CHECKING THE RADIATOR 6 3 INSTALLING THE RADIATOR 6 4 THERMOSTAT 6 5 CHECKING THE THERMOSTAT 6 7 ASSEMBLING THE THERMOSTAT 6 7 WATER PUMP 6 8 DISASSEMBLING THE WATER PUMP 6 11 CHECKING THE WATER PUMP 6 11 ASSEMBLING THE WATER PUMP 6 12 CHAPTER 7 CARBURETION CARBURETORS 7 1 DISASSEMBLING THE CARBURETOR 7 5 CHECKING THE CARBURETOR 7 5 ASSEMBLING THE CARBURETOR 7 7 ADJU...

Page 13: ...6 ELECTRIC STARTING SYSTEM 8 11 CIRCUIT DIAGRAM 8 11 STARTING CIRCUIT OPERATION 8 12 TROUBLESHOOTING 8 13 STARTER MOTOR 8 16 CHECKING THE STARTER MOTOR 8 17 ASSEMBLING THE STARTER MOTOR 8 18 CHARGING SYSTEM 8 19 CIRCUIT DIAGRAM 8 19 TROUBLESHOOTING 8 20 LIGHTING SYSTEM 8 22 CIRCUIT DIAGRAM 8 22 TROUBLESHOOTING 8 23 CHECKING THE LIGHTING SYSTEM 8 25 SIGNAL SYSTEM 8 27 CIRCUIT DIAGRAM 8 27 TROUBLESH...

Page 14: ... HIGH SPEED PERFORMANCE 9 2 FAULTY GEAR SHIFTING 9 3 HARD SHIFTING 9 3 SHIFT PEDAL DOES NOT MOVE 9 3 JUMP OUT GEAR 9 3 CLUTCH SLIPPING DRAGGING 9 3 CLUTCH SLIPPING 9 3 CLUTCH DRAGGING 9 3 OVERHEATING 9 4 OVERHEATING 9 4 OVER COOLING 9 4 COOLING SYSTEM 9 4 FAULTY BRAKE 9 4 POOR BRAKING EFFECT 9 4 SHOCK ABSORBER MALFUNCTION 9 5 MALFUNCTION 9 5 UNSTABLE HANDLING 9 5 UNSTABLE HANDLING 9 5 LIGHTING SYS...

Page 15: ...N MACHINE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the left side of the frame MODEL LABEL The model label 1 is affixed to the air filter case cover This information will be needed to order spare parts ...

Page 16: ...arts and place them in trays in the order of disas sembly This will speed up assembly and allow for the correct installation of all parts 5 Keep all parts away from any source of fire EB101010 REPLACEMENT PARTS 1 Use only genuine Yamaha parts for all replacements Use oil and grease recom mended by Yamaha for all lubrication jobs Other brands may be similar in function and appearance but inferior i...

Page 17: ...oil seals apply a light coat ing of lightweight lithium base grease to the seal lips Oil bearings liberally when install ing if appropriate 1 Oil seal CAUTION Do not use compressed air to spin the bearings dry This will damage the bearing surfaces 1 Bearing EB101050 CIRCLIPS 1 Check all circlips carefully before reassem bly Always replace piston pin clips after one use Replace distorted circlips W...

Page 18: ...terminals several times 3 Check Connector leads Looseness Bend up the pin 1 and con nect the terminals 4 Connect Connector terminals NOTE The two terminals click together 5 Check Continuity using a pocket tester NOTE If there is no continuity clean the terminals When checking the wire harness be sure to perform steps 1 to 3 As a quick remedy use a contact revitalizer available at most part stores ...

Page 19: ... US and CDN P N 90890 Tool No Tool name How to use Illustration Bolt 90890 01083 Weight 90890 01084 Set YU 01083 A Slide hammer bolt M6 weight set These tools are used to remove the rocker arm shaft 90890 01135 YU 01135 A Crankcase separating tool This tool is used to separate the crank case Pot 90890 01274 Bolt 90890 01275 Crankshaft installer pot Crankshaft installer bolt These tools are used to...

Page 20: ...mber 90890 01325 YU 24460 01 Radiator cap tester This tool is used to check the cooling sys tem 90890 01352 YU 33984 Adapter This tool is used to check the cooling sys tem 90890 01327 YM 01327 Damper rod holder 30 mm This tool is needed to loosen and tighten the steering stem bearing retainer 90890 01362 YU 33270 Flywheel puller These tools are needed to remove the rotor 90890 01419 YM 37132 Axle ...

Page 21: ...ed to hold the AC mag neto rotor when removing or installing the AC magneto rotor bolts Set 90890 03081 YU 33223 Adapter 90890 04082 YU 33223 3 Compression gauge set Adapter These tools are needed to measure engine compression 90890 03112 YU 03112 Pocket tester This instrument is needed for checking the electrical system 90890 03141 YM 33277 A Timing light This tool is necessary for checking ignit...

Page 22: ...the valve guide 90890 04066 YM 04066 Valve guide reamer ø 6 This tool is needed to rebore the new valve guide 90890 04086 YM 91042 Clutch holding tool This tool is needed to hold the clutch car rier when removing or installing the carrier nut 90890 06754 Ignition checker This instrument is necessary for checking the ignition system components YM 34487 Dynamic spark tester This instrument is necess...

Page 23: ... 3 31 in Compression ratio 9 2 1 Standard compression pressure at sea level 1 250 kPa 12 5 kg cm2 181 psi Starting system Electric starter Lubrication system Dry sump Oil type or grade Engine oil API service SE SF SG type or higher Oil capacity Engine oil Periodic oil change 1 9 L 1 67 lmp qt 2 01 US qt With oil filter replacement 1 95 L 1 72 lmp qt 2 06 US qt Total amount 2 3 L 2 02 lmp qt 2 43 U...

Page 24: ...ward 1 speed reverse Operation Left foot operation Gear ratio 1st gear 34 14 2 428 2nd gear 29 19 1 526 3rd gear 26 21 1 238 4th gear 22 21 1 047 5th gear 19 21 0 904 Reverse gear 28 23 23 16 1 750 Chassis Frame type Steel tube frame Caster angle 8 Camber angle 1 Kingpin angle 14 5 Kingpin offset 5 mm 0 20 in Trail 47 mm 1 85 in Tread STD front 925 mm 36 42 in rear 840 mm 33 07 in Toe in 0 10 mm 0...

Page 25: ...nsion Swingarm link suspension Shock absorber Front shock absorber Coil spring oil damper Rear shock absorber Coil spring gas oil damper Wheel travel Front wheel travel 230 mm 9 06 in Rear wheel travel 220 mm 8 66 in Electrical Ignition system DC C D I Generator system A C magneto Battery type YTX14 BS Battery capacity 12 V 12 Ah Headlight type Krypton bulb Bulb voltage wattage quantity Headlight ...

Page 26: ... 000 23 021 mm 0 9055 0 9063 in Camshaft journal diameter 22 967 22 980 mm 0 9042 0 9047 in Camshaft journal to camshaft cap clearance 0 020 0 054 mm 0 0008 0 0021 in Cam dimensions Intake A 35 69 35 79 mm 1 4051 1 4091 in 35 59 mm 1 4012 in B 30 15 30 25 mm 1 1870 1 1909 in 30 05 mm 1 1831 in C 5 74 mm 0 2260 in Exhaust A 36 50 36 60 mm 1 437 1 441 in 36 40 mm 1 4331 in B 30 15 30 25 mm 1 187 1 1...

Page 27: ... 1 1850 in EX 31 9 32 1 mm 1 2559 1 2638 in B face width IN 2 25 mm 0 0886 in EX 2 26 mm 0 0890 in C seat width IN 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in EX 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in D margin thickness IN 0 85 1 15 mm 0 0335 0 0453 in EX 0 85 1 15 mm 0 0335 0 0453 in Stem outside diameter IN 5 975 5 990 mm 0 2352 0 2358 in 5 945 mm 0 2341 in EX 5 960 5 975 mm 0 2346 0 2352...

Page 28: ...433 in 1 6 mm 0 0630 in Valve spring Free length IN 35 95 mm 1 42 in 34 15 mm 1 34 in EX 37 75 mm 1 49 in 35 86 mm 1 41 in Set length valve closed IN 27 2 mm 1 07 in EX 30 7 mm 1 21 in Compressed pressure installed IN 149 173 N 15 19 17 64 kg 33 50 38 89 lb EX 165 191 N 16 83 19 49 kg 37 09 42 94 lb Tilt limit IN 2 5 1 6 mm 2 5 0 06 in EX 2 5 1 6 mm 2 5 0 06 in Direction of winding top view IN Clo...

Page 29: ...in Piston rings Top ring Type Barrel Dimensions B T 1 2 3 8 mm 0 0472 0 1496 in End gap installed 0 30 0 45 mm 0 0118 0 0177 in 0 70 mm 0 0276 in Side clearance installed 0 04 0 08 mm 0 0016 0 0031 in 0 13 mm 0 0051 in 2nd ring Type Taper Dimensions B T 1 2 4 0 mm 0 0472 0 1575 in End gap installed 0 30 0 45 mm 0 0118 0 0177 in 0 80 mm 0 0315 in Side clearance 0 03 0 07 mm 0 0012 0 0028 in 0 13 mm...

Page 30: ... Balancer Balancer drive method Gear Clutch Friction plate 1 Thickness 2 74 2 86 mm 0 108 0 113 in 2 6 mm 0 102 in Quantity 6 Friction plate 2 Thickness 2 94 3 06 mm 0 116 0 120 in 2 8 mm 0 110 in Quantity 2 Clutch plate Thickness 1 1 1 3 mm 0 043 0 051 in Quantity 7 Max warpage 0 2 mm 0 008 in Clutch spring Free length 42 8 mm 1 69 in 40 7 mm 1 60 in Quantity 5 Min length 40 8 mm 1 61 in Clutch r...

Page 31: ... 1 0 Carburetor 2 0 9 Pilot jet P J 22 5 Bypass 1 B P 1 0 8 Bypass 2 B P 2 0 8 Valve seat size V S 2 0 Starter jet G S 1 95 Starter jet G S 2 0 5 Throttle valve size Th V 80 Float height F H 13 mm 0 51 in Fuel level F L 3 4 mm 0 12 0 16 in Engine idle speed 1 450 1 550 r min Intake vacuum 32 0 33 3 kPa 240 250 mmHg 9 45 9 83 inHg Oil pump Oil filter type Paper Oil pump type Trochoid Tip clearance ...

Page 32: ...25 kPa 0 95 1 25 kg cm2 13 8 18 1 psi Radiator capacity 0 55 L 0 48 Imp qt 0 58 US qt Coolant reservoir Capacity 0 29 L 0 26 Imp qt 0 31 US qt From low to full level 0 165 L 0 15 Imp qt 0 17 US qt Water pump Type Single suction centrifugal pump Reduction ratio 33 34 0 971 Lubrication chart Item Standard Limit MAINTENANCE SPECIFICATIONS ...

Page 33: ...2 11 SPEC Cylinder head tightening sequence Item Standard Limit MAINTENANCE SPECIFICATIONS ...

Page 34: ...ker arm shaft Bolt M6 2 10 1 0 7 2 Valve adjusting screw Nut M6 5 14 1 4 10 Radiator Bolt M6 2 7 0 7 5 1 Coolant drain bolt M6 1 10 1 0 7 2 Engine oil drain bolt oil tank M10 1 25 2 5 18 Engine oil drain bolt engine M14 1 30 3 0 22 Oil filter bolt Union bolt M20 1 63 6 3 45 E Oil filter cartridge M20 1 17 1 7 12 Oil delivery pipe 1 Union bolt M10 2 20 2 0 14 Oil delivery pipe 2 Union bolt M8 2 18 ...

Page 35: ...gment Bolt M8 1 30 3 0 22 Shift guide Bolt M6 2 10 1 0 7 2 LT Stopper lever Bolt M6 1 10 1 0 7 2 Reverse shift lever Bolt M6 1 13 1 3 9 4 Shift arm Bolt M6 1 10 1 0 7 2 Shift pedal adjusting rod Nut M6 1 8 0 8 5 8 Left hand threads Nut M6 1 8 0 8 5 8 Stator assembly Bolt M5 3 7 0 7 5 1 LT Pick up coil Bolt M5 2 7 0 7 5 1 LT AC magneto lead holder Bolt M6 2 10 1 0 7 2 LT Ignition coil Bolt M6 2 7 0...

Page 36: ... suspension Shock absorber travel 100 mm 3 94 in Spring free length 273 mm 10 75 in Spring fitting length 253 mm 9 96 in Spring rate K1 55 N mm 5 61 kg mm 314 05 lb in Stroke K1 0 100 mm 0 3 94 in Optional spring No Swingarm Free play limit end 1 mm 0 04 in side 1 mm 0 04 in Front wheel Type Panel wheel Rim size 10 5 5 AT Rim material Aluminum Rim runout limit radial 2 mm 0 08 in lateral 2 mm 0 08...

Page 37: ...sc brake Type Single Disc outside diameter thickness 220 0 3 6 mm 8 66 0 14 in Pad thickness inner 4 5 mm 0 18 in 1 mm 0 04 in Pad thickness outer 4 5 mm 0 18 in 1 mm 0 04 in Master cylinder inside diameter 12 7 mm 0 50 in Caliper cylinder inside diameter 33 96 mm 1 34 in Brake fluid type DOT 4 Brake lever and brake pedal Brake lever free play at lever end 0 mm 0 in Brake pedal position 4 mm 0 16 ...

Page 38: ... 3 8 27 Front arm lower and frame M10 32 3 2 23 Brake hose holder and front arm upper M6 7 0 7 5 1 Steering stem pitman arm and frame M14 110 11 80 Steering stem bushing and frame M8 23 2 3 17 Use a lock washer Steering stem and handlebar holder M8 23 2 3 17 Tie rod end and locknut M10 15 1 5 11 Steering knuckle and front wheel hub M14 70 7 0 50 Steering knuckle and front arm upper and lower M10 2...

Page 39: ...adjusting bolt and locknut M8 16 1 6 11 Rear brake disc and brake disc bracket M8 28 2 8 20 Rear brake fluid reservoir cover and bracket M6 4 0 4 2 9 Rear brake fluid reservoir and bracket M6 4 0 4 2 9 Brake hose holder and swingarm M6 7 0 7 5 1 Front bumper and frame M8 31 3 1 22 Front fender bracket and frame M8 16 1 6 11 Rear carrier bar and frame M8 23 2 3 17 Footrest and frame M10 65 6 5 48 F...

Page 40: ...6 32 9 48 kΩ at 20 C 68 F Spark plug cap Type Resin type Resistance 10 kΩ Charging system Type A C magneto generator Model manufacturer F4T260 MITSUBISHI Nominal output 14 V 16 A at 5 000 r min Charging coil resistance color 0 43 0 65 Ω at 20 C 68 F White White Rectifier Type Semi conductor short circuit Model manufacturer SH640E 11 SHINDENGEN No load voltage DC 14 1 14 9 V Capacity 14 A Withstand...

Page 41: ...ance 4 18 4 62 Ω at 20 C 68 F Thermostat switch Thermostat switch 1 Model manufacturer 5GH NIPPON THERMOSTAT Thermostat switch 2 Model manufacturer 5LP NIPPON THERMOSTAT Circuit breaker Type Fuse Amperage for individual circuit Fuse 20 A 1 Reserve 20 A 1 Item Standard Limit MAINTENANCE SPECIFICATIONS ...

Page 42: ...s should be at room temperature A Distance between flats B Outside thread diameter METRIC MULTIPLIER IMPERIAL mm 0 03937 in 2 mm 0 03937 0 08 in METRIC TO IMPERIAL Metric unit Multiplier Imperial unit Torque m kg m kg cm kg cm kg 7 233 86 794 0 0723 0 8679 ft lb in lb ft lb in lb Weight kg g 2 205 0 03527 lb oz Speed km hr 0 6214 mph Distance km m m cm mm 0 6214 3 281 1 094 0 3937 0 03937 mi ft yd...

Page 43: ...ocker arm M Camshaft lobe journal M Oil pump shaft rotor housing E Oil filter O ring E Starter idle gear shaft E Transmission gear wheel pinion M Axle main drive M Shift fork guide bar E Shift drum shift shaft shift cam stopper ball E Shift lever shift guide LS Crankcase mating surfaces Sealant Quick Gasket Yamaha bond No 1215 Cylinder head and cylinder head cover mating surfaces Sealant Quick Gas...

Page 44: ...S 1 Radiator 2 Radiator fan 3 Radiator outlet hose 4 Water pump inlet hose 5 Water pump 6 Water jacket outlet pipe 7 Thermostat inlet hose 8 Thermostat 9 Radiator inlet hose 0 Thermo switch 2 A Thermo switch 1 COOLANT FLOW DIAGRAMS ...

Page 45: ...2 23 SPEC OIL FLOW DIAGRAMS 1 Oil tank 2 Oil pipe 2 3 Oil pipe 1 OIL FLOW DIAGRAMS ...

Page 46: ...2 24 SPEC 1 Oil delivery pipe 2 2 Oil delivery pipe 1 3 Oil filter 4 Crankshaft 5 Oil pump OIL FLOW DIAGRAMS ...

Page 47: ...2 25 SPEC 1 Oil pipe 2 2 Drive axle 3 Main axle 4 Engine oil drain bolt engine 5 Oil pipe 1 6 Oil strainer 7 Shift drum OIL FLOW DIAGRAMS ...

Page 48: ...2 26 SPEC 1 Oil delivery pipe 2 2 Oil filter cartridge 3 Oil pump rotor 1 4 Oil pump rotor 2 5 Oil pipe 1 6 Main axle OIL FLOW DIAGRAMS ...

Page 49: ...e 4 Throttle cable 5 Front brake hose 6 Front brake switch 7 Park switch È Fasten the handlebar switch lead park switch lead and clutch switch lead to the handlebar with the plastic band É Fasten the front brake switch lead to the handle bar with the plastic band CABLE ROUTING ...

Page 50: ...ead A Headlight lead coupler left B Brake pipe C Headlight lead coupler right D Radiator fan breather hose E Headlight lead right È Pass the throttle cable through the cable guide É Pass the clutch cable parking brake cable and starter cable through the cable guide Ê Fasten the left and right headlight lead radiator fan lead and thermo switch 1 lead to the frame with the plastic band CABLE ROUTING...

Page 51: ...Coolant reservoir hose 9 Starter cable È Put the wire harness and coolant reservoir hose with the plastic holder É Fasten the wire harness AC magneto lead speed sensor lead negative battery lead and rear brake switch lead with the plastic band Ê 70 mm 2 76 in Ë 25 35 mm 0 98 1 38 in Ì 60 mm 2 36 in Í 0 5 mm 0 0 20 in Î 80 90 mm 3 15 3 54 in CABLE ROUTING ...

Page 52: ...ervoir tank breather hose 4 Rectifier regulator 5 CDI unit 6 Negative battery lead 7 AC magneto lead 8 Wire harness 9 Starter motor lead 0 Tail brake light lead A Rectifier regulator lead È Pass the negative battery lead between the wire harness and frame CABLE ROUTING ...

Page 53: ...1 SPEC 1 Radiator fan breather hose 2 Reverse control cable 3 Parking brake cable 4 Clutch cable È Fasten the reverse control cable to the frame with the plastic band É 15 25 mm 0 59 0 98 in CABLE ROUTING ...

Page 54: ...brake hose 2 Parking brake cable 3 Negative battery lead 4 AC magneto lead 5 Crankcase breather hose 6 Carburetor drain hose 7 Rear brake switch 8 Speed sensor 9 Speed sensor lead 0 Rear brake switch lead CABLE ROUTING ...

Page 55: ...adiator fan breather hose 4 Thermo switch 2 lead 5 Carburetor breather hose 6 Headlight lead left 7 Wire harness 8 Coolant reservoir hose È Fasten the fan motor lead headlight lead right and thermo switch 1 lead to the frame with the plastic band CABLE ROUTING ...

Page 56: ...ervoir breather hose 4 Negative battery lead 5 Coolant reservoir hose 6 Starter motor lead 7 Wire harness 8 Rectifier regulator lead È Fasten the wire harness with the plastic clamp É Fasten the starter motor lead and starter relay lead with the plastic clamp CABLE ROUTING ...

Page 57: ... necessary Air filter See page 3 24 Clean Replace if necessary Every 20 40 hours More often in wet or dusty areas Carburetor See page 3 11 Check and adjust idle speed starter operation Adjust if necessary Crankcase breather system Check breather hose for cracks or damage Replace if necessary Exhaust system Check for leakage Retighten if necessary Replace gasket if necessary Spark arrester See page...

Page 58: ...r caliper cylinder replace the brake fluid Normally check the brake fluid level and add fluid as required 2 On the inner parts of the master cylinder and caliper cylinder replace the oil seals every two years 3 Replace the brake hoses every four years or if cracked or damaged WARNING Indicates a potential hazard that could result in serious injury or death ...

Page 59: ...rt name Q ty Remarks Removing the seat front panel foot rest guard and engine skid plate Remove the parts in the order below 1 Seat 1 NOTE Pull back the seat lock lever than pull up on the rear of the seat 2 Front panel 1 3 Left footrest guard 1 4 Right footrest guard 1 5 Engine skid plate 1 For installation reverse the removal pro cedure ...

Page 60: ... the headlight and front fender Remove the parts in the order below Seat and front panel Refer to SEAT FRONT PANEL FOOT REST GUARDS AND ENGINE SKID PLATE 1 Headlight coupler 2 Disconnect 2 Left headlight 1 3 Right headlight 1 4 Fuel tank top panel 1 5 Front fender 1 For installation reverse the removal pro cedure ...

Page 61: ...order below Seat Refer to SEAT FRONT PANEL FOOT REST GUARDS AND ENGINE SKID PLATE Front fender Refer to HEADLIGHTS AND FRONT FENDER 1 Battery holding bracket 1 2 Battery lead 2 Disconnect CAUTION First disconnect the negative lead then disconnect the positive lead 3 Battery 1 4 Rear fender 1 For installation reverse the removal pro cedure ...

Page 62: ...and front panel Refer to SEAT FRONT PANEL FOOT REST GUARDS AND ENGINE SKID PLATE Front fender Refer to HEADLIGHTS AND FRONT FENDER 1 Fuel hose 1 NOTE Before disconnecting the fuel hose turn the fuel cock to OFF 2 Fuel tank 1 NOTE When installing the fuel tank pass the fuel tank breather hose through the hole in the handlebar protector 3 Plastic band 2 ...

Page 63: ...3 7 CHK ADJ SEAT FENDERS AND FUEL TANK Order Job name Part name Q ty Remarks 4 Rubber cover 1 1 5 Rubber cover 2 1 6 Hose holder 2 For installation reverse the removal pro cedure ...

Page 64: ...uch Adjust the valve clearance when the piston is at the Top Dead Center T D C on the com pression stroke 1 Remove Seat Front fender Fuel tank Refer to SEAT FENDERS AND FUEL TANK 2 Remove Tappet cover intake 1 Tappet covers exhaust 2 3 Disconnect Spark plug cap 3 4 Remove Spark plug 5 Remove Crankshaft end accessing screw 1 Timing mark accessing screw 2 ...

Page 65: ... with the station ary pointer the piston is at the Top Dead Center T D C NOTE When the piston is at the Top Dead Center T D C on the compression stroke there should be clearance between the valve stem tips and their respective rocker arm adjusting screws If there is no clearance rotate the crankshaft counterclockwise one turn Valve clearance cold Intake 0 10 0 15 mm 0 0039 0 0059 in Exhaust 0 15 0...

Page 66: ...t it from moving and then tighten the locknut Measure the valve clearance If the clearance is incorrect repeat the above steps until the proper clearance is obtained Tappet adjusting tool P N YM 08035 90890 01311 T R Locknut 14 Nm 1 4 m kg 10 ft lb 8 Install All removed parts NOTE Install all removed parts in the reverse order of their disassembly Note the following points 9 Install Spark plug Tap...

Page 67: ...Front fender Seat Refer to SEAT FENDERS AND FUEL TANK ADJUSTING THE TIMING CHAIN Adjustment free ADJUSTING THE IDLING SPEED 1 Start the engine and let it warm up for sev eral minutes 2 Attach Tachometer to the spark plug lead 3 Check Engine idling speed Out of specification Adjust Engine idling speed 1 450 1 550 r min ...

Page 68: ...h Tachometer 6 Adjust Throttle lever free play Refer to ADJUSTING THE THROTTLE LEVER FREE PLAY Turning in Idling speed becomes higher Turning out Idling speed becomes lower ADJUSTING THE THROTTLE LEVER FREE PLAY NOTE Engine idling speed should be adjusted prop erly before adjusting the throttle lever free play 1 Check Throttle lever free play a Out of specification Adjust Throttle lever free play ...

Page 69: ...annot be adjusted here adjust it at the throttle lever side of the cable Second step Pull back the adjuster cover 4 Loosen the locknut 5 Turn the adjuster 6 in or out until the correct free play is obtained Tighten the locknut 5 Push in the adjuster cover 4 WARNING After adjusting the free play turn the handle bar to the right and left to make sure that the engine idling speed does not increase Tu...

Page 70: ... length adjustment steps Loosen the locknut 1 Turn the adjuster 2 in or out until the speci fied speed limiter length is obtained Tighten the locknut WARNING Particularly for a beginner rider the speed limiter should be screwed in com pletely Screw it out little by little as their riding technique improves Never remove the speed limiter for a beginning rider For proper throttle lever operation do ...

Page 71: ... If the distance is out of specification adjust it as described below È Fully closed position É Fully open position Pull back the boot 4 Loosen the locknut 5 Turn the adjuster 6 in or out until the correct distance is obtained Tighten the locknut 5 Push in the boot 4 Connect the starter cable WARNING After adjusting the cable turn the handle bar to right to left and make sure that the engine idlin...

Page 72: ... color Replace Normal color is a medium to light tan color 4 Clean the spark plug with a spark plug cleaner or wire brush 5 Measure Plug gap a Use a wire gauge or feeler gauge Out of specification Regap 6 Tighten Spark plug NOTE Before installing a spark plug clean the gasket surface and plug surface Spark plug gap 0 8 0 9 mm 0 031 0 035 in T R 18 Nm 1 8 m kg 13 ft lb CHECKING THE SPARK PLUG ...

Page 73: ...ing light P N YM 33277 A 90890 03141 2 Check Ignition timing Checking steps Warm up the engine and keep it at the speci fied speed Remove the timing mark accessing screw 1 Visually check the stationary pointer 2 to verify it is within the required firing range 3 indicated on the flywheel Incorrect firing range Check the pulser coil assembly Install the timing mark accessing screw 3 Detach Timing l...

Page 74: ...er Compression gauge 1 Compression gauge P N YU 33223 90890 03081 Adapter P N YU 33223 3 90890 04082 6 Measure Compression pressure Above the maximum pressure Inspect the cylinder head valve surfaces and piston crown for carbon deposits Below the minimum pressure Squirt a few drops of oil into the affected cyl inder and measure again Refer to the table below Compression pressure with oil introduce...

Page 75: ...level Standard 1 250 kPa 12 5 kg cm2 181 psi Minimum 1 050 kPa 10 5 kg cm2 149 psi Maximum 1 350 kPa 13 5 kg cm2 192 psi T R 18 Nm 1 8 m kg 13 ft lb CHECKING THE ENGINE OIL LEVEL 1 Place the machine on a level surface 2 Start the engine warm it up until the engine oil has reached a normal temperature of 60 C 140 F let it continue to idle for ten seconds and then turn the engine off NOTE To achieve...

Page 76: ...SF SE CC SF SE SD etc CAUTION Do not add any chemical additives Engine oil also lubricates the clutch and additives could cause clutch slippage Do not allow foreign material to enter the crankcase 4 Start the engine and let it warm up for sev eral minutes 5 Stop the engine and inspect the oil level again NOTE Wait a few minutes until the oil settles before inspecting the oil level Recommended oil ...

Page 77: ...f the oil filter cartridge is also to be replaced perform the following procedure Replacement steps Remove the oil filter cartridge 1 with an oil filter wrench 2 Apply a thin coat of engine oil to the O ring 3 of the new oil filter cartridge CAUTION Make sure that the O ring 3 is properly seated in the groove of the oil filter car tridge Oil filter wrench P N YM 01469 90890 01469 ...

Page 78: ... Stop the engine and then pour in the remainder of the specified amount CAUTION When starting the engine make sure the dipstick is securely fitted into the oil tank 8 Install Dipstick 9 Warm up the engine for a few minutes then stop the engine 10 Check Engine for engine oil leaks Oil level Refer to CHECKING THE ENGINE OIL LEVEL T R Oil filter cartridge 17 Nm 1 7 m kg 12 ft lb Quantity Total amount...

Page 79: ...eck the engine oil passages the oil filter cartridge and the oil pump for damage or leakage Refer to OIL PUMP in CHAPTER 5 Start the engine after solving the problem s and check the engine oil pressure again Tighten the oil gallery bolt to specification 12 Install Engine skid plate Refer to SEAT FENDERS AND FUEL TANK T R Oil gallery bolt 7 Nm 0 7 m kg 5 1 ft lb ADJUSTING THE CLUTCH CABLE 1 Check C...

Page 80: ...free play cannot be obtained on it use the adjusting bolt 3 Turn the adjusting bolt 3 until the clutch lever free play is within the specified limits Tighten the locknut 2 Pull the rubber cover 1 in Clutch lever free play at the clutch lever end 5 10 mm 0 20 0 39 in CLEANING THE AIR FILTER NOTE There is a check hose 1 at the bottom of the air filter case If dust and or water collects in this hose ...

Page 81: ... causing rapid wear and possible engine damage Additionally operation without the filter element will affect carbure tor tuning with subsequent poor perfor mance and possible engine overheating 5 Check Air filter element Damaged Replace 6 Clean Air filter element Cleaning steps Wash the element gently but thoroughly in solvent WARNING Use a cleaning solvent which is designed to clean parts only Ne...

Page 82: ...E The element should be wet but not dripping 7 Install Air filter element Air filter case cover NOTE Insert the lobes 1 on the filter element into the receptacles 2 on the filter case To prevent air leaks make sure that the seal ing surface of the element matches the seal ing surface of the case 8 Connect Crankcase breather hose 1 9 Install Seat Refer to SEAT FENDERS AND FUEL TANK ...

Page 83: ... instead of coolant check and if necessary correct the antifreeze concentration of the coolant Use only distilled water However soft water may be used if distilled water is not available 3 Start the engine warm it up for several min utes and then turn it off 4 Check Coolant level NOTE Before inspecting the coolant level wait a few minutes until the coolant has settled CHANGING THE COOLANT 1 Remove...

Page 84: ... engine has cooled open the radiator cap as follows Place a thick rag or a towel over the radia tor cap and slowly turn the radiator cap counterclockwise toward the detent to allow any residual pressure to escape When the hissing sound has stopped turn the radiator cap counterclockwise while pressing down on it and then remove it 7 Remove Coolant drain bolt 1 along with the copper washer 8 Drain C...

Page 85: ...Adding water instead of coolant lowers the antifreeze content of the coolant If water is used instead of coolant check and if necessary correct the antifreeze concentration of the coolant Use only distilled water However soft water may be used if distilled water is not available If coolant comes into contact with painted surfaces immediately wash them with water Do not mix different types of antif...

Page 86: ...4 Install Coolant reservoir cap 15 Start the engine warm it up for several min utes and then turn it off 16 Check Coolant level Refer to CHECKING THE COOLANT LEVEL NOTE Before inspecting the coolant level wait a few minutes until the coolant has settled 17 Install Front panel Refer to SEAT FENDERS AND FUEL TANK ...

Page 87: ... warning light CLEANING THE SPARK ARRESTER 1 Clean Spark arrester Cleaning steps WARNING Select a well ventilated area free of com bustible materials Always let the exhaust system cool before performing this operation Do not start the engine when removing the tailpipe from the muffler Remove the bolt 1 Remove the tailpipe 2 by pulling it out of the muffler ...

Page 88: ...he muffler Insert the tailpipe into the muffler and align the bolt holes Insert the bolt and tighten it Remove the purging bolt 3 Start the engine and rev it up approximately twenty times while momentarily creating exhaust system back pressure by blocking the end of the muffler with a shop towel Stop the engine and allow the exhaust pipe to cool Install the purging bolt 3 and tighten it CLEANING T...

Page 89: ... 0 in ADJUSTING THE REAR BRAKE 1 Check Rear brake pedal height a Out of specification Adjust 2 Adjust Rear brake pedal height Adjustment steps Loosen the locknut 1 Turn the adjusting bolt 2 until the brake pedal height is within the specified limits Tighten the locknut 1 NOTE When adjusting the brake pedal height make sure the locknut to adjusting bolt clearance a does not exceed 2 2 3 2 mm 0 09 0...

Page 90: ...68 mm 2 5 2 7 in 2 Adjust Parking brake cable end length Adjustment steps Loosen the locknut 1 and adjusting bolt 2 Pull the rubber cover 3 off Loosen the locknut 4 Turn the adjuster 5 in or out until the speci fied brake cable end length is obtained Tighten the locknut 4 Slowly turn the adjusting bolt 2 clockwise until resistance is felt Turn it 1 8 counterclockwise Tighten the locknut 1 Check th...

Page 91: ...luid level Fluid level is below the LOWER level line 1 Add the recommended brake fluid to the proper level È Front brake É Rear brake CAUTION Brake fluid may erode painted surfaces or plastic parts Always clean up spilled fluid immediately WARNING Use only the designated quality brake fluid Otherwise the rubber seals may deteriorate causing leakage and poor brake performance Refill with the same t...

Page 92: ...ver 4 Install Front wheels Brake pad wear limit a 1 mm 0 04 in CHECKING THE REAR BRAKE PAD 1 Check Brake pad Wear indicators 1 almost in contact with the brake disc Replace the brake pads as a set Refer to FRONT AND REAR BRAKES in CHAPTER 4 2 Operate the brake pedal Brake pad wear limit a 1 mm 0 04 in ADJUSTING THE REAR BRAKE LIGHT SWITCH NOTE The rear brake light switch is operated by movement of...

Page 93: ...ake light comes on at the proper time Direction a Brake light comes on sooner Direction b Brake light comes on later CHECKING THE BRAKE HOSE 1 Remove Seat Front fender Refer to SEAT FENDERS AND FUEL TANK 2 Check Front brake hoses 1 Rear brake hoses 2 Cracks wear damage Replace 3 Check Brake hose clamp Loosen Tighten 4 Hold the machine in an upright position and apply the front or rear brake 5 Chec...

Page 94: ...leeding steps a Add the proper brake fluid to the reservoir b Install the diaphragm Be careful not to spill any fluid or allow the reservoir to overflow c Connect the clear plastic hose 1 tightly to the caliper bleed screw 2 È Front É Rear d Place the other end of the hose into a con tainer e Slowly apply the brake lever or pedal sev eral times f Pull the lever in or push down on the pedal and hol...

Page 95: ... bleeding the brake system T R Bleed screw 6 Nm 0 6 m kg 4 3 ft lb ADJUSTING THE SHIFT PEDAL 1 Check Shift pedal height a Out of specification Adjust Shift pedal height 22 mm 0 89 in 2 Adjust Shift pedal height Adjustment steps Loosen the locknuts 1 Turn the adjusting rod 2 in direction a or b until the specified shift pedal position obtained Tighten the locknuts Direction a Shift pedal position i...

Page 96: ...shift lever 6 when make this adjustment so that it does not move Tighten the locknut 3 Pull the boots 1 and 2 in ADJUSTING THE DRIVE CHAIN SLACK NOTE The drive chain slack must be checked at the tightest point on the chain CAUTION A drive chain that is too tight will overload the engine and other vital parts and one that is too loose can skip and damage the swingarm or cause an accident Therefore ...

Page 97: ...xle alignment adjust both sides evenly There are marks c on each side of hub CAUTION Excessive chain slack will overload the engine and other vital parts keep the slack within the specified limits If the chain slack cannot be adjusted replace the sprockets and drive chain as a set Tighten the hub nuts and locknuts NOTE The chain should be cleaned and lubricated after every use of the machine Direc...

Page 98: ...ight until it stops completely then move the han dlebar from the left to the right slightly Tie rod end has any vertical play Replace the tie rod end s 4 Raise the front end of the machine so that there is no weight on the front wheels 5 Check Ball joints and or wheel bearings Move the wheels laterally back and forth Excessive free play Replace the front arms upper and lower and or wheel bear ings...

Page 99: ...he marks Calculate the toe in using the formula given below If the toe in is incorrect adjust it Ê Forward 3 Adjust Toe in WARNING Be sure that both tie rods are turned the same amount If not the machine will drift right or left even though the handlebar is positioned straight This may lead to mis handling and an accident After setting the toe in to specification run the machine slowly for some di...

Page 100: ...TE Adjust the rod ends so that A and B are equal T R Locknut rod end 15 Nm 1 5 m kg 11 ft lb ADJUSTING THE FRONT SHOCK ABSORBER WARNING Always adjust both front shock absorber spring preload to the same setting Uneven adjustment can cause poor handling and loss of stability 1 Adjust Spring preload Turn the adjuster 1 in direction a or b Direction a Spring preload is increased suspension is harder ...

Page 101: ...ring installed changes 1 5 mm 0 06 in per turn of the adjuster CAUTION Never attempt to turn the adjusting ring beyond the maximum or minimum setting Tighten the locknut 1 NOTE Always tighten the locknut against the adjust ing ring then torque it to specification Direction a Spring preload is increased suspension is harder Direction b Spring preload is decreased suspension is softer Adjusting leng...

Page 102: ...tion b Rebound damping force is decreased From the fully turned in position Standard 10 clicks out Minimum 20 clicks out Maximum 3 clicks out 3 Adjust Compression damping force Adjustment steps Turn the adjusting screw 1 in direction a or b Direction a Compression damping force is increased Direction b Compression damping force is decreased From the fully turned out position Standard 7 clicks in M...

Page 103: ...fect your machine s handling characteristics and are therefore not recommended TIRE PRESSURE 1 Recommended tire pressure Front 27 5 kPa 0 275 kg cm2 4 0 psi Rear 27 5 kPa 0 275 kg cm2 4 0 psi 2 Tire pressure below the minimum specifi cation could cause the tire to dislodge from the rim under severe riding condi tions The following are minimums Front 24 5 kPa 0 245 kg cm2 3 5 psi Rear 24 5 kPa 0 24...

Page 104: ...re take two measurements of the tire s pressure and use the second reading WARNING Uneven or improper tire pressure may adversely affect the handling of this machine and may cause loss of control Maintain proper tire pressures Set tire pressures when the tires are cold Tire pressures must be equal in both front tires and equal in both rear tires Cold tire pressure Front Rear Standard 27 5 kPa 0 27...

Page 105: ...12 in CHECKING THE WHEEL 1 Check Wheels 1 Damage bends Replace NOTE Always balance the wheel when a tire or wheel has been changed or replaced WARNING Never attempt even small repairs to the wheel Ride conservatively after installing a tire to allow it to seat itself properly on the rim CHECKING AND LUBRICATING THE CABLE WARNING A damaged cable sheath may cause corro sion and interfere with the ca...

Page 106: ...smooth operation Lubricate or replace NOTE Hold the cable end up and apply several drops of lubricant to the cable 3 Apply Lithium soap base grease onto end of the cable Recommended lubricant Yamaha chain and cable lube or Engine oil LUBRICATING THE LEVERS AND PEDAL 1 Lubricate the pivoting parts Recommended lubricant Lithium soap base grease ...

Page 107: ...ttery are different from those of general type bat teries The MF battery should be charged as explained in CHARGING METHOD If the battery is overcharged the electrolyte level will drop considerably Therefore take special care when charging the bat tery WARNING Battery electrolyte is dangerous it con tains sulfuric acid which is poisonous and highly caustic Always follow these preventive measures A...

Page 108: ...tery holding bracket Refer to SEAT FENDERS AND FUEL TANK 2 Disconnect Battery leads CAUTION First disconnect the negative lead 1 then disconnect the positive lead 2 3 Remove Battery 4 Check Battery condition Battery condition checking steps Connect a digital voltmeter to the battery ter minals NOTE The charge state of an MF battery can be checked by measuring the open circuit voltage i e the volta...

Page 109: ... Never remove the sealing caps of an MF battery Make sure that the charging clips are in full contact with the terminal and that they are not shorted together A corroded clip on the charger may cause the battery to generate heat in the contact area A weak clip spring may cause sparks Before removing the clips from the bat tery terminals be sure to turn off the charger s power switch The open circu...

Page 110: ...3 54 CHK ADJ CHECKING THE BATTERY Charging method using a variable voltage charger ...

Page 111: ...3 55 CHK ADJ CHECKING THE BATTERY Charging method using a constant voltage charger ...

Page 112: ...ry leads CAUTION First connect the positive lead 1 then connect the negative lead 2 8 Install Battery holding bracket Seat Refer to SEAT FENDERS AND FUEL TANK CHECKING THE FUSE CAUTION Always turn off the main switch when checking or replacing a fuse Otherwise a short circuit may occur 1 Remove Seat Refer to SEAT FENDERS AND FUEL TANK 2 Check Fuse Checking steps Connect the pocket tester to the fu...

Page 113: ...operation of the related electrical devices If the fuse immediately blows again check the electrical circuit WARNING Never use a fuse with a rating other than that specified Never use other materials in place of a fuse An improper fuse may cause extensive damage to the electrical system a malfunction of the lighting and ignition systems and could possibly cause a fire 4 Install Seat Refer to SEAT ...

Page 114: ...n the screw 1 Slide the headlight lens unit under Tighten the screw 1 Slide forward Headlight beam raises Slide backward Headlight beam low ers REPLACING THE HEADLIGHT BULB 1 Remove Headlight Refer to SEAT FENDERS AND FUEL TANK 2 Remove Cover 1 Headlight unit 2 Case 3 NOTE Pull outward on the rear of the headlight unit 2 and then pull out ward on the front ...

Page 115: ...touch the bulb until it cools down 4 Install Bulb Secure the new bulb with the headlight unit CAUTION Avoid touching the glass part of the bulb Keep it free from oil otherwise the trans parency of the glass life of the bulb and luminous flux will be adversely affected If oil gets on the bulb thoroughly clean it with a cloth moistened with alcohol or lac quer thinner 5 Install Bulb holder Cover Cov...

Page 116: ...a level surface WARNING Securely support the machine so there is no danger of it falling over 1 Cotter pin 1 Refer to INSTALLING THE WHEEL HUB 2 Axle nut 1 3 Front wheel 1 Refer to INSTALLING THE WHEEL 4 Brake disc guard outer 1 5 Brake caliper assembly 1 NOTE Do not apply the brake lever after the brake calipers have been removed other wise the brake pads will be forced shut ...

Page 117: ...4 2 CHAS FRONT WHEELS Order Job name Part name Q ty Remarks 6 Wheel hub 1 7 Brake disc 1 For installation reverse the removal pro cedure ...

Page 118: ...eel balance Out of balance Adjust Wheel runout limit Radial 2 2 0 mm 0 08 in Lateral 3 2 0 mm 0 08 in WARNING After replacing the tire ride conservatively to allow the tire to be properly seated in the rim Failure to do so may cause an accident resulting in machine damage and possible operator injury CHECKING THE WHEEL HUB 1 Check Wheel hub 1 Cracks damage Replace ...

Page 119: ...ction is recommended when using striking tools To install the wheel bearings reverse the above sequence Use a socket that matches outside diameter of bearing outer race to drive in bearing CAUTION Do not strike the center race or balls of the bearing Contact should be made only with the outer race CHECKING THE BRAKE DISC 1 Check Brake disc Galling damage Replace 2 Measure Brake disc deflection Out...

Page 120: ...ned with the cot ter pin hole align the groove with the hole by tightening the axle nut T R 70 Nm 7 0 m kg 50 ft lb New INSTALLING THE WHEEL 1 Install Brake disc guard outer 1 NOTE Install the brake disc guard outer with punched burrs 2 on the wheel hub side 2 Install Wheel NOTE The arrow mark 1 on the tire must point in the direction of rotation È of the wheel ...

Page 121: ...he rear wheel Remove the parts in the order below Place the machine on a level surface WARNING Securely support the machine so there is no danger of it falling over 1 Rear wheel 2 Refer to INSTALLING THE WHEEL 2 Cotter pin 2 Refer to INSTALLING THE WHEEL HUB 3 Axle nut 2 4 Wheel hub 2 For installation reverse the removal pro cedure ...

Page 122: ... Remove the parts in the order below 1 Nut 2 Refer to INSTALLING THE NUTS REAR AXLE 2 Locknut 2 Refer to REMOVING THE REAR AXLE 3 Adjusting bolt 2 4 Rear axle 1 5 Brake caliper 1 NOTE Do not apply the brake pedal and do not use the parking brake when the brake caliper is off of the brake disc as the brake pad will be force shut ...

Page 123: ...4 8 CHAS REAR WHEELS WHEEL AXLE AND HUB Order Job name Part name Q ty Remarks 6 Brake disc 1 7 Driven sprocket 1 8 Brake caliper bracket 1 9 Hub 1 For installation reverse the removal pro cedure ...

Page 124: ...pply the brake pedal so that the rear axle does not turn when loosening the nuts Use a axle nut wrench 50 mm 2 Axle nut wrench 50 mm P N YM 37132 90890 01419 3 Elevate the rear wheels by placing the suit able stand under the frame 4 Remove Rear wheels Wheel hubs Nuts rear axle 5 Loosen Hub nuts 1 6 Loosen Locknuts 1 Adjusting bolts 2 ...

Page 125: ...on the axle end and tap it with a soft hammer Pull out the rear axle to the right CHECKING THE WHEEL Refer to FRONT WHEELS CHECKING THE WHEEL HUB 1 Check Wheel hub 1 Cracks damage Replace Splines wheel hub 2 Wear damage Replace the wheel hub CHECKING THE REAR AXLE 1 Check Rear axle runout a Out of specification Replace WARNING Do not attempt to straighten a bent axle Rear axle runout limit 1 5 mm ...

Page 126: ...ide nut with rear axle nut wrench to specification while holding the rear axle Hold the inside nut 1 and tighten the outside nut 2 with rear axle nut wrench to specifica tion Draw the line a on inside and outside nut Hold the outside nut 2 and tighten back the inside nut 1 with rear axle nut wrench to specification Measure the distance b between lines If distance b is less than 15 mm 0 59 in retig...

Page 127: ...4 12 CHAS REAR WHEELS WHEEL AXLE AND HUB INSTALLING THE WHEEL HUB Refer to FRONT WHEELS INSTALLING THE WHEEL 1 Install Wheel NOTE The wording on the tire SIDE FACING OUT WARDS 1 must be facing outwards ...

Page 128: ...rt name Q ty Remarks Removing the front brake pad Remove the parts in the order below Front wheel wheel hub Refer to FRONT WHEELS 1 Brake pad holding bolt 2 Refer to REPLACING THE FRONT BRAKE PAD 2 Brake pad pad shim 2 1 3 Brake pad spring 1 For installation reverse the removal pro cedure ...

Page 129: ...ing rear brake pad Remove the parts in the order below 1 Brake caliper mounting bolt 1 Refer to REPLACING THE REAR BRAKE PAD 2 Brake caliper mounting bolt 1 3 Brake pad holding bolt 2 4 Lock washer 1 5 Brake pad pad shim 2 1 6 Brake pad spring 1 For installation reverse the removal pro cedure ...

Page 130: ...aces or plastic parts as this may cause damage disconnect any hydraulic connection as this would require the entire brake sys tem to be disassembled drained cleaned properly filled and bled after reassembly REPLACING THE FRONT BRAKE PAD NOTE It is not necessary to disassemble the brake caliper and brake hose to replace the brake pads 1 Remove Brake pads a Wear limit NOTE Replace the brake pads as ...

Page 131: ...pad shim 3 and a new brake pad spring Install the holding bolts and brake caliper NOTE The arrow mark a on the pad shim must point in the direction of the disc rotation T R Brake caliper bleed screw 6 Nm 0 6 m kg 4 3 ft lb T R Brake pad holding bolt 18 Nm 1 8 m kg 13 ft lb Brake caliper mounting bolt 28 Nm 2 8 m kg 20 ft lb 3 Check Brake fluid level Refer to CHECKING THE BRAKE FLUID LEVEL in CHAPT...

Page 132: ...brake pad spring as a set Installation steps Connect a suitable hose 1 tightly to the brake caliper bleed screw 2 Put the other end of this hose into an open container Loosen the brake caliper bleed screw and using a finger push the caliper piston into the brake caliper Tighten the brake caliper bleed screw Install new brake pads new pad shim 3 and a new brake pad spring Install a new lock washer ...

Page 133: ...olding bolt 18 Nm 1 8 m kg 13 ft lb Brake caliper mounting bolt 28 Nm 2 8 m kg 20 ft lb 3 Check Brake fluid level Refer to CHECKING THE BRAKE FLUID LEVEL in CHAPTER 3 4 Check Brake pedal operation Soft or spongy feeling Bleed the rear brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in CHAPTER 3 ...

Page 134: ...ts in the order below Brake fluid Drain 1 Brake fluid reservoir cap 1 2 Brake fluid reservoir diaphragm 1 3 Front brake switch 1 4 Brake lever 1 5 Union bolt 1 Refer to INSTALLING THE FRONT BRAKE MASTER CYLINDER 6 Copper washer 2 7 Brake hose 1 8 Brake master cylinder bracket 1 9 Brake master cylinder 1 For installation reverse the removal pro cedure ...

Page 135: ... ty Remarks Disassembling the front brake mas ter cylinder Remove the parts in the order below 1 Dust boot 1 Refer to ASSEMBLING THE FRONT AND REAR BRAKE MASTER CYLIN DER 2 Circlip 1 3 Brake master cylinder kit 1 For assembly reverse the disassembly procedure ...

Page 136: ...the parts in the order below Right footrest guard Refer to SEAT FENDERS AND FUEL TANK in CHAPTER 3 Brake fluid Drain 1 Brake fluid reservoir cover 1 2 Brake fluid reservoir cap 1 3 Brake fluid reservoir diaphragm holder 1 4 Brake fluid reservoir diaphragm 1 5 Brake fluid reservoir 1 6 Brake fluid reservoir hose 1 7 Right footrest guard bracket 1 ...

Page 137: ...EAR BRAKES Order Job name Part name Q ty Remarks 8 Union bolt 1 Refer to INSTALLING THE REAR BRAKE MASTER CYLINDER 9 Copper washer 2 10 Brake hose 1 11 Brake master cylinder 1 For installation reverse the removal pro cedure ...

Page 138: ...arks Disassembling the rear brake mas ter cylinder Remove the parts in the order below 1 Hose joint 1 2 Brake master cylinder kit 1 Refer to ASSEMBLING THE FRONT AND REAR BRAKE MASTER CYLIN DER 3 Brake master cylinder 1 For assembly reverse the disassembly procedure ...

Page 139: ... delivery passage brake master cylinder body Blockage Blow out with compressed air È Front É Rear È É 2 Check Brake master cylinder kit Scratches wear damage Replace as a set È Front É Rear É È 3 Check Front brake master cylinder reservoir 1 Front brake master cylinder reservoir dia phragm 2 Cracks damage Replace 4 Check Rear brake fluid reservoir 1 Rear brake fluid reservoir diaphragm 2 Cracks da...

Page 140: ...STER CYLINDER 1 Install Brake master cylinder 1 NOTE The UP mark on the brake master cylinder bracket should face up T R 7 Nm 0 7 m kg 5 1 ft lb 2 Install Copper washers Brake hose Union bolt NOTE Tighten the union bolt while holding the brake hose as shown Turn the handlebar to the left and to the right to check that the brake hose does not touch other parts throttle cable wire harness leads etc ...

Page 141: ...Mixing brake fluids may result in a harm ful chemical reaction and lead to poor brake performance Be careful that water does not enter the brake master cylinder when refilling Water will significantly lower the boiling point of the brake fluid and may result in vapor lock Recommended brake fluid DOT 4 4 Air bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in CHAPTER 3 5 Check Brake ...

Page 142: ... damage painted surfaces or plastic parts Always clean up spilled brake fluid immediately WARNING Use only the designated quality brake fluid Other brake fluids may deteriorate the rubber seals causing leakage and poor brake performance Refill with the same type of brake fluid Mixing brake fluids may result in a harm ful chemical reaction and lead to poor brake performance Be careful that water do...

Page 143: ...EEDING THE HYDRAULIC BRAKE SYSTEM in CHAPTER 3 4 Check Brake fluid level Brake fluid level is below the LOWER level line Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL in CHAPTER 3 FRONT AND REAR BRAKES ...

Page 144: ... the order below Brake fluid Drain Front wheel Refer to FRONT WHEELS 1 Union bolt 1 Refer to INSTALLING THE FRONT BRAKE CAL IPER 2 Copper washer 2 3 Brake hose 1 Disconnect 4 Cap retaining bolt 1 1 Loosen 5 Brake pad holding bolt 2 Loosen 6 Brake caliper mounting bolt 2 7 Brake caliper assembly 1 For installation reverse the removal pro cedure ...

Page 145: ...er below 1 Brake pad holding bolt 2 2 Brake pad pad shim 2 1 3 Brake pad spring 1 4 Retaining bolt 1 5 Caliper bracket 1 6 Brake caliper piston 1 Refer to DISASSEMBLING THE FRONT AND REAR BRAKE CALIPER ASSEM BLING THE FRONT BRAKE CALIPER 7 Dust seal 1 8 Caliper piston seal 1 9 Bleed screw 1 For assembly reverse the disassembly procedure ...

Page 146: ...ve the parts in the order below Brake fluid Drain 1 Parking brake cable 1 Disconnect 2 Union bolt 1 Refer to INSTALLING THE REAR BRAKE CALI PER 3 Copper washer 2 4 Brake hose 1 Disconnect 5 Brake caliper mounting bolt 1 6 Brake caliper mounting bolt 1 7 Brake caliper assembly 1 For installation reverse the removal pro cedure ...

Page 147: ... brake caliper Remove the parts in the order below 1 Adjusting bolt 1 2 Locknut 1 3 Parking brake lever 1 4 Parking brake case mounting bolt 2 5 Parking brake case 1 6 Gasket 1 7 Spring 1 8 Nut 1 9 Bearing 1 Refer to ASSEMBLING THE REAR BRAKE CALIPER 0 Brake pad holding bolt 2 A Lock washer 1 ...

Page 148: ... 2 1 C Brake pad spring 1 D Retaining bolt 1 E Caliper bracket 1 F Brake caliper piston 1 Refer to DISASSEMBLING THE FRONT AND REAR BRAKE CALIPER ASSEM BLING THE REAR BRAKE CALIPER G Dust seal 1 H Caliper piston seal 1 I O ring 1 J Bleed screw 1 For assembly reverse the disassembly procedure ...

Page 149: ...caliper piston with a rag Be careful not to get injured when the piston is expelled from the master cylinder Remove the caliper piston seals EB702040 CHECKING THE FRONT AND REAR BRAKE CALIPER WARNING All internal brake components should be cleaned in new brake fluid only Do not use solvents as they will cause seals to swell and distort Recommended brake component replacement schedule Brake pads As...

Page 150: ...kage Blow out with compressed air WARNING Replace the caliper piston seal and dust seal whenever the brake caliper is disas sembled È Front É Rear È É ASSEMBLING THE FRONT BRAKE CALIPER WARNING All internal brake components should be cleaned and lubricated with new brake fluid only before installation Replace the caliper piston seal whenever a brake caliper is disassembled 1 Install Caliper piston...

Page 151: ...the caliper piston seal whenever a brake caliper is disassembled 1 Install O ring 1 Caliper piston seal 2 Dust seal 3 Recommended brake fluid DOT 4 New New New 2 Install Brake caliper piston 1 3 Install Lock washer 1 Brake pad holding bolts 2 4 Bend the lock washer tabs along a flat side of the bolts New T R 18 Nm 1 8 m kg 13 ft lb 5 Mesh the bearing race tab 1 with parking brake case slit ...

Page 152: ... plastic parts Always clean up spilled brake fluid immediately WARNING Use only the designated quality brake fluid Other brake fluids may deteriorate the rubber seals causing leakage and poor brake performance Refill with the same type of brake fluid Mixing brake fluids may result in a harm ful chemical reaction and lead to poor brake performance Be careful that water does not enter the master cyl...

Page 153: ...shers 3 Union bolt 4 CAUTION When installing the brake hose on the brake caliper make sure that the brake pipe touches the projection a on the brake caliper WARNING Proper brake hose routing is essential to insure safe motorcycle operation Refer to CABLE ROUTING 2 Fill Brake reservoir CAUTION Brake fluid may damage painted surfaces or plastic parts Always clean up spilled brake fluid immediately R...

Page 154: ...oes not enter the master cylinder when refilling Water will significantly lower the boiling point of the brake fluid and may result in vapor lock 3 Air bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in CHAPTER 3 4 Check Brake fluid level Brake fluid level is below the LOWER level line Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL in CH...

Page 155: ...ch 1 Refer to REMOVING THE FRONT BRAKE SWITCH PARK SWITCH AND CLUTCH SWITCH 4 Brake master cylinder bracket 1 1 Refer to INSTALLING THE BRAKE MASTER CYLINDER 5 Throttle lever assembly bracket 1 1 6 Collar 1 7 Park switch 1 Refer to REMOVING THE FRONT BRAKE SWITCH PARK SWITCH AND CLUTCH SWITCH 8 Clutch switch 1 9 Clutch lever bracket 1 1 Refer to INSTALLING THE CLUTCH LEVER 10 Handlebar switch 1 ...

Page 156: ...e Part name Q ty Remarks 11 Handlebar grip 2 Refer to REMOVING INSTALLING THE HANDLEBAR GRIP 12 Handlebar cover bracket 2 Refer to INSTALLING THE HANDLE BAR 13 Handlebar holder 2 14 Handlebar 1 For installation reverse the removal pro cedure ...

Page 157: ...er Push the fastener when removing the park switch and clutch switch out of the clutch lever holder REMOVING THE HANDLEBAR GRIP 1 Remove Handlebar grips 1 NOTE Blow compressed air between the handlebar and handlebar grip and gradually push the grip off the handlebar CHECKING THE HANDLEBAR 1 Check Handlebar 1 Bends cracks damage Replace WARNING Do not attempt to straighten a bent handle bar as this...

Page 158: ... tighten the bolts 4 on the rear side T R 23 Nm 2 3 m kg 17 ft lb INSTALLING THE HANDLEBAR GRIP 1 Install Handlebar grips 1 NOTE Before applying the adhesive wipe off grease or oil on the handlebar surface a with a lacquer thinner Install the handlebar grips to the handlebar so that the line b between the two arrow marks faces straight upward INSTALLING THE CLUTCH LEVER 1 Install Handlebar switch ...

Page 159: ...ever assembly Collar Brake master cylinder NOTE Engage the indentations a in the collar with the lobes b on the throttle lever assembly and brake master cylinder The UP mark on the brake master cylinder bracket should face up T R 7 Nm 0 7 m kg 5 1 ft lb STEERING SYSTEM ...

Page 160: ...stem Remove the parts in the order below Front fender Refer to SEAT FENDERS AND FUEL TANK in CHAPTER 3 Fuel tank Handlebar Refer to HANDLEBAR 1 Pitman arm 1 2 Lock washer 1 Refer to INSTALLING THE LOCK WASHER 3 Steering stem bushing 2 4 Collar 2 5 Oil seal 2 6 Steering stem 1 7 Oil seal 1 8 Oil seal 1 ...

Page 161: ...4 46 CHAS STEERING SYSTEM Order Job name Part name Q ty Remarks 9 Bearing retainer 1 Refer to REMOVING INSTALLING THE BEARING RETAINER 10 Bearing 1 For installation reverse the removal pro cedure ...

Page 162: ...attempt to straighten a bent stem this may dangerously weaken the stem 2 Check Oil seals 1 Steering stem bushings 2 Wear damage Replace New INSTALLING THE BEARING RETAINER 1 Install Bearing retainer steering stem Damper rod holder P N YM 01327 90890 01327 T R 40 Nm 4 0 m kg 29 ft lb INSTALLING THE LOCK WASHER 1 Install Lock washer 2 Bend the lock washer tab along a flat side of the bolt New T R 23...

Page 163: ...le Remove the parts in the order below Front wheel brake disc Refer to FRONT WHEELS 1 Tie rod 2 Refer to INSTALLING THE TIE ROD 2 Pitman arm 1 3 Brake disc guard inner 1 4 Front bumper 1 5 Front arm lower 1 6 Front arm upper 1 7 Steering knuckle 1 Refer to REMOVING THE STEERING KNUCKLE For installation reverse the removal pro cedure ...

Page 164: ... movement Free play Replace the tie rod end Turns roughly Replace the tie rod end 2 Check Tie rod Bends damage Replace CHECKING THE STEERING KNUCKLE 1 Check Steering knuckle Damage pitting Replace INSTALLING THE TIE ROD 1 Install Tie rods left and right NOTE The tie rod which must be installed on the out side has grooves 1 T R 25 Nm 2 5 m kg 18 ft lb 2 Adjust Toe in Refer to ADJUSTING THE TOE IN i...

Page 165: ...front arm and front shock absorber Remove the parts in the order below Front wheel brake disc Refer to FRONT WHEELS 1 Front bumper 1 2 Brake disc guard inner 1 3 Nut 1 4 Tie rod 1 Disconnect 5 Nut 1 6 Nut 1 7 Nut bolt 1 1 8 Nut bolt 2 2 Refer to REMOVING INSTALLING THE FRONT ARMS 9 Front arm lower 1 10 Nut bolt 1 1 11 Front arm upper 1 ...

Page 166: ...r Job name Part name Q ty Remarks 12 Nut bolt 1 1 13 Front shock absorber collar 1 1 14 Steering knuckle 1 15 Dust cover 6 16 Collar 1 17 Collar 2 18 Bushing 6 19 Circlip 1 20 Rubber boot 1 21 Ball joint 1 For installation reverse the removal pro cedure ...

Page 167: ...p and down If the vertical movement is tight or rough or if there is binding check the bushings 2 Remove Front arms CHECKING THE FRONT ARM 1 Check Front arms 1 Bends damage Replace 2 Check Bushings 2 Wear damage Replace CHECKING THE FRONT SHOCK ABSORBER 1 Check Shock absorber rod Bends damage Replace the shock absorber assembly Shock absorber assembly Oil leaks Replace the shock absorber assembly ...

Page 168: ...an the outside of the front lower arm Remove the circlip 1 and rubber boot 2 Use the ball joint remover and installer set Install the body 3 long bolt 4 base 5 and attachment 6 onto ball joint Hold the body 3 in place while turning in the long bolt 4 to remove the ball joint 9 from the front lower arm 0 Remove the ball joint remover installer Ball joint remover installer set P N YM 01474 90890 014...

Page 169: ... the head of the ball joint A Remove the ball joint remover installer Apply lithium soap base grease to the new ball joint A Install a new rubber boot and new circlip NOTE Always use a new ball joint set INSTALLING THE FRONT ARM 1 Install Front upper arm 1 Front lower arm 2 NOTE Be sure to position the bolts upper and lower so that the bolt head faces outward T R 38 Nm 3 8 m kg 27 ft lb T R 32 Nm ...

Page 170: ...nd relay arm Remove the parts in the order below Rear wheels and hub Refer to REAR WHEELS WHEEL AXLE AND HUB 1 Metal screw clamp 2 2 Self locking nut bolt 1 1 Refer to REMOVING THE REAR SHOCK ABSORBER 3 Self locking nut bolt 1 1 4 Self locking nut bolt 1 1 5 Self locking nut bolt 1 1 6 Rear shock absorber 1 7 Collar oil seal 2 2 8 Collar oil seal 2 2 ...

Page 171: ...cking nut bolt 1 1 10 Relay arm 1 11 Spacer oil seal bushing 1 2 2 Refer to INSTALLING THE RELAY ARM AND CONNECTING ARM 12 Connecting arm 1 13 Dust cover 4 14 Spacer 1 15 Spacer 1 16 Bushing 4 Refer to INSTALLING THE RELAY ARM AND CONNECTING ARM For installation reverse the removal pro cedure ...

Page 172: ...r or gas cylinder Do not subject the rear shock absorber or gas cylinder to an open flame or any other source of high heat High heat can cause an explosion due to excessive gas pressure Do not deform or damage the rear shock absorber or gas cylinder in any way If the rear shock absorber gas cylinder or both are damaged damping performance will suffer DISPOSING OF A REAR SHOCK ABSORBER AND GAS CYLI...

Page 173: ...OCK ABSORBER 1 Check Shock absorber Oil leaks Replace the rear shock absorber assembly Shock absorber rod Bends damage Replace the rear shock absorber assembly Spring Fatigue Replace the rear shock absorber assembly Move the spring up and down Gas cylinder Damage gas leaks Replace the rear shock absorber assembly CHECKING THE RELAY ARM AND CONNECTING ARM 1 Check Relay arm Connecting arm Damage wea...

Page 174: ...ng when installing Installed depth of bushing a 1 mm 0 04 in 2 Install Bushing 1 Oil seal 2 to relay arm NOTE Apply the lithium soap base grease on the bushing when installing Installed depth of bushing a 6 5 mm 0 26 in New INSTALLING THE REAR SHOCK ABSORBER 1 Install Connecting arm Relay arm Rear shock absorber NOTE When installing the rear shock absorber lift up the swingarm ...

Page 175: ...ls and hub Refer to REAR WHEELS WHEEL AXLE AND HUB Rear shock absorber Refer to REAR SHOCK ABSORBER AND RELAY ARM Left footrest and left footrest guard bracket Refer to ENGINE REMOVAL in CHAP TER 5 1 Adjusting bolt nut 2 2 2 Swingarm skid plate 1 3 Drive chain guide 1 4 Pivot shaft nut washer 1 1 5 Pivot shaft 1 6 Swingarm 1 Refer to REMOVING THE SWINGARM 7 Drive sprocket cover 1 ...

Page 176: ...LING THE DRIVE SPROCKET 9 Lock washer 1 10 Drive sprocket 1 11 Drive chain 1 12 Collar 1 13 Spacer 1 14 Oil seal 1 15 Bearing 1 16 Dust cover oil seal washer 1 1 1 17 Spacer 1 18 Oil seal 2 19 Bushing 2 Refer to INSTALLING THE SWING ARM 20 Bearing 2 For installation reverse the removal pro cedure ...

Page 177: ... the swingarm side play È by moving it from side to side If side play is noticeable check the collar spacers bearings bushings and frame pivot Check the swingarm vertical movement É by moving it up and down If vertical movement is tight or rough or if there is binding check the collar spacers bearings bushings and frame pivot 2 Remove Pivot shaft nut Pivot shaft Swingarm T R Pivot shaft nut 95 Nm ...

Page 178: ...rings Bushings Damage pitting Replace Recommended cleaning solvent Kerosine CHECKING THE DRIVE CHAIN 1 Measure Ten link section a of the drive chain Out of specification Replace the drive chain NOTE While measuring the ten link section push down on the drive chain to increase its ten sion Measure the length between drive chain roller 1 and A as shown Perform this measurement at two or three differ...

Page 179: ...ween the drive chain side plates Never use high pressure water or air steam gasoline certain solvents e g benzine or a coarse brush to clean the drive chain High pressure methods could force dirt or water into the drive chain s internals and solvents will deterio rate the O rings A coarse brush can also damage the O rings Therefore use only kerosine to clean the drive chain 4 Check O rings 1 Damag...

Page 180: ...ets as a set b Correct 1 Drive chain roller 2 Drive chain sprocket INSTALLING THE SWINGARM 1 Install Bearings 1 Bushings 2 to swingarm NOTE Apply the lithium soap base grease on the bearing and bushing when installing Installed depth of bearing Left a 0 mm 0 in Right b 4 mm 0 16 in Installed depth of bushing c 8 mm 0 31 in INSTALLING THE DRIVE SPROCKET 1 Install Drive sprocket 1 Lock washer 2 Nut ...

Page 181: ...moving the muffler and exhaust pipes Remove the parts in the order below Seat left footrest guard engine Refer to SEAT FENDERS AND FUEL TANK in CHAPTER 3 Skid plate Front and rear fenders Fuel tank and rubber covers 1 Muffler 1 2 Exhaust pipe 1 1 3 Exhaust pipe 2 1 For installation reverse the removal pro cedure ...

Page 182: ...name Part name Q ty Remarks Removing the left footrest Remove the parts in the order below 1 Locknut 1 2 Locknut 1 Left hand threads 3 Adjusting rod 1 4 Left footrest guard bracket 1 5 Left footrest 1 For installation reverse the removal pro cedure ...

Page 183: ...rain Water jacket outlet pipe Refer to THERMOSTAT in CHAPTER 6 Radiator outlet hose Refer to WATER PUMP in CHAPTER 6 Carburetors Refer to CARBURETORS in CHAPTER 7 Rear shock absorber and connecting arm Refer to REAR SHOCK ABSORBER AND RELAY ARM in CHAPTER 4 Drive sprocket and swingarm Refer to SWINGARM AND DRIVE CHAIN in CHAPTER 4 1 Spark plug cap 1 2 Starter motor lead 1 3 Band 1 ...

Page 184: ... 6 Neutral switch lead reverse switch lead 1 1 7 Ground lead 1 8 Clutch cable 1 9 Parking brake cable 1 10 Reverse control cable 1 11 Oil pipe 2 1 Disconnect 12 Oil pipe 1 1 Disconnect 13 Oil tank breather hose 1 Disconnect 14 Crankcase breather hose 1 Disconnect For installation reverse the removal pro cedure ...

Page 185: ...e bracket bolt upper 4 CAUTION Install all of the bolts nuts and then tighten them to full torque specifica tions Refer to INSTALLING THE ENGINE 3 Engine bracket upper 1 4 Engine mounting bolt middle nut 1 1 5 Engine mounting bolt lower nut 1 1 6 Engine bracket middle left 1 7 Engine bracket middle right 1 8 Engine bracket bolt lower 4 9 Engine bracket lower left 1 10 Engine bracket lower right 1 ...

Page 186: ...5 6 ENG ENGINE REMOVAL Order Job name Part name Q ty Remarks 11 Engine assembly 1 NOTE Remove the engine assembly from the left side of the machine For installation reverse the removal pro cedure ...

Page 187: ... fully tighten the bolts and nuts 2 Install Swingarm Pivot shaft nut 9 NOTE Do not fully tighten the pivot shaft nut 3 Tighten Engine bracket bolt lower 2 Engine bracket bolt upper 7 Engine mounting bolt lower nut 4 Engine mounting bolt middle nut 5 Engine mounting bolt upper nut 8 Pivot shaft nut 9 T R 56 Nm 5 6 m kg 40 ft lb T R 33 Nm 3 3 m kg 24 ft lb T R 56 Nm 5 6 m kg 40 ft lb T R 56 Nm 5 6 m...

Page 188: ...he parts in the order below Seat front fender Refer to SEAT FENDERS AND FUEL TANK in CHAPTER 3 Fuel tank rubber cover 2 1 Engine mounting bolt nut 1 1 2 Engine bracket front upper 1 3 Oil tank breather hose 1 4 Union bolt 2 5 Copper washer 4 6 Oil delivery pipe 1 1 7 Spark plug 1 8 Tappet cover intake 1 9 Tappet cover exhaust 2 ...

Page 189: ... 9 ENG CYLINDER HEAD COVER Order Job name Part name Q ty Remarks 10 Cylinder head cover 1 Refer to REMOVING INSTALLING CYL INDER HEAD COVER 11 Dowel pin 2 For installation reverse the removal pro cedure ...

Page 190: ...D C NOTE When the piston is at the top dead center T D C on the compression stroke there should be clearance between the valve stem tips and their respective rocker arm adjusting screws If there is no clearance rotate the crankshaft counterclockwise one turn 2 Remove Cylinder head cover NOTE Loosen each bolt 1 4 of a turn at a time in stages and in a crisscross pattern After all the bolts are loos...

Page 191: ... 1 to the mating surfaces of the cylinder head and cylinder head cover 2 Install Cylinder head cover Cable guides 1 Washers 2 Bolts 3 Bolt 25 mm 4 Bolt 40 mm 5 Bolt 55 mm 6 Bolt 115 mm 7 Bolt 130 mm NOTE Tighten the cylinder head cover bolts in stages using a crisscross pattern Sealant Quick Gasket 1 P N ACC 11001 05 01 Yamaha bond No 1215 P N 90890 85505 T R 10 Nm 1 0 m kg 7 2 ft lb ...

Page 192: ...parts in the order below Cylinder head cover Refer to CYLINDER HEAD COVER 1 Plug O ring 1 1 2 Bolt 2 3 Rocker arm shaft 2 O ring 1 1 Refer to REMOVING INSTALLING THE ROCKER ARM 4 Rocker arm 3 1 5 Rocker arm shaft 3 O ring 1 1 6 Rocker arm 4 1 7 Rocker arm shaft 1 O ring 1 1 8 Rocker arm 1 1 9 Rocker arm 2 1 ...

Page 193: ...5 13 ENG ROCKER ARMS Order Job name Part name Q ty Remarks 10 Spring 4 11 Locknut 5 12 Valve adjuster 5 For installation reverse the removal pro cedure ...

Page 194: ... 2 Blue discoloration pitting scratches Replace 2 Check Rocker arms Rocker arm shafts Damage wear Replace Checking steps Check the two contact areas on the rocker arms for signs of abnormal wear 1 Rocker arm shaft hole 2 Camshaft lobe contact surface Excessive wear Replace Check the surface of the rocker arm shafts Blue discoloration pitting scratches Replace check lubrication Measure the inside d...

Page 195: ...he defective part s Rocker arm outside diameter 11 976 11 991 mm 0 4715 0 4721 in Rocker arm to shaft standard clearance 0 009 0 042 mm 0 0004 0 0017 in INSTALLING THE ROCKER ARM 1 Apply Engine oil onto the rocker arm shafts 2 Install Rocker arms 1 Rocker arm shafts 2 NOTE The thread hole a of the rocker arm shaft must face to the outside After installation make sure that the thread hole a of the ...

Page 196: ...R 3 Fuel tank rubber covers Carburetors Refer to CARBURETORS in CHAPTER 7 Water jacket outlet pipe Refer to THERMOSTAT in CHAPTER 6 Muffler exhaust pipe Refer to ENGINE REMOVAL Cylinder head cover Refer to CYLINDER HEAD COVER 1 Timing chain tensioner cap bolt 1 Refer to REMOVING INSTALLING THE CAMSHAFT AND CYLINDER HEAD 2 Timing chain tensioner gasket 1 1 3 Timing chain guide exhaust 1 4 Decompres...

Page 197: ...rder Job name Part name Q ty Remarks 6 Camshaft 1 Refer to CAMSHAFT AND CYLINDER HEAD 7 Cylinder head 1 8 Cylinder head gasket 1 9 Dowel pin 2 10 Carburetor joint 1 1 11 Carburetor joint 2 1 For installation reverse the removal pro cedure ...

Page 198: ...ompressor cam guide plates Camshaft sprocket NOTE Fasten a safety wire to the timing chain to prevent it from falling into the crankcase When removing the camshaft sprocket it is not necessary to separate the timing chain 4 Remove Cylinder head NOTE Loosen the bolts in the proper sequence Follow the numerical order shown in the illus tration Loosen each bolt 1 4 of a turn at a time until all of th...

Page 199: ... mm 1 4331 in b 30 05 mm 1 1831 in CHECKING THE CAMSHAFT SPROCKET 1 Check Camshaft sprocket Wear damage Replace the camshaft sprocket and timing chain as a set a 1 4 of a tooth b Correct 1 Timing chain 2 Sprocket CHECKING THE DECOMPRESSION SYS TEM 1 Check Decompression system Checking steps Check while the camshaft sprocket is installed on the camshaft Check that the decompressor lever pin 1 proje...

Page 200: ...ensioner Unsmooth operation Replace CHECKING THE CYLINDER HEAD 1 Eliminate Carbon deposits from the combustion chambers Use a rounded scraper NOTE Do not use a sharp instrument to avoid damag ing or scratching Spark plug threads Valve seats 2 Check Cylinder head Scratches damage Replace the cylinder head cover and cylinder head as a set Cylinder head water jacket Mineral deposits rust Eliminate ...

Page 201: ...d Place a 400 600 grit wet sandpaper on the surface plate and resurface the head using a figure eight sanding pattern NOTE To ensure an even surface rotate the cylinder head several times Cylinder head warpage Less than 0 05 mm 0 002 in INSTALLING THE CAMSHAFT AND CYLIN DER HEAD 1 Install Cylinder head Bolts M9 1 6 Bolt M6 7 NOTE Tighten the bolts in the proper sequence Follow the numerical order ...

Page 202: ...t during the cam shaft installation Temporarily install the camshaft sprocket on the camshaft Do not install the bolts Then install the timing chain on the camshaft sprocket NOTE Make sure the small holes 3 on the camshaft face upward Align the notches 4 on the decompressor cams with the projections 5 on the decom pressor spring lever then install the cam shaft sprocket on the camshaft NOTE Check ...

Page 203: ...cap bolt 1 washer 2 and spring 3 Release the timing chain tensioner one way cam 4 and push the tensioner rod 5 all the way in Install the tensioner 6 with a new gasket into the cylinder WARNING Always use a new gasket Install the spring washer and timing chain tensioner cap bolt 4 Check Small holes on camshaft sprocket Rotor I mark Out of alignment Adjust T R Bolts timing chain tensioner 10 Nm 1 0...

Page 204: ...arts in the order below Cylinder head Refer to CAMSHAFT AND CYLINDER HEAD 1 Valve cotter 10 Refer to REMOVING INSTALLING THE VALVE AND VALVE SPRING 2 Valve spring retainer 5 3 Intake valve spring 3 4 Exhaust valve spring 2 5 Intake valve 3 6 Exhaust valve 2 7 Valve stem seal 5 8 Valve spring seat 5 For installation reverse the removal pro cedure ...

Page 205: ...Checking steps Pour a clean solvent 1 into the intake and exhaust ports Check that the valve seals properly There should be no leakage at the valve seat 2 2 Remove Valve cotters NOTE Attach a valve spring compressor 1 and attachment 2 between the valve spring retainer and the cylinder head to remove the valve cotters Valve spring compressor P N YM 04019 90890 04019 Valve spring compressor attachme...

Page 206: ...acement steps NOTE To ease guide removal installation and to maintain correct fit heat the cylinder head to 100 C 212 F in an oven Remove the valve guide using a valve guide remover 1 Install the new valve guide using a valve guide remover 1 and valve guide installer 2 After installing the valve guide bore the valve guide using a valve guide reamer 3 to obtain proper stem to guide clearance NOTE A...

Page 207: ...e Margin thickness Intake 0 85 1 15 mm 0 0335 0 0453 in Exhaust 0 85 1 15 mm 0 0335 0 0453 in 5 Measure Runout valve stem Out of specification Replace NOTE When installing a new valve always replace the guide If the valve is removed or replaced always replace the oil seal 6 Eliminate Carbon deposits from the valve face and valve seat 7 Check Valve seats Pitting wear Reface the valve seat Runout li...

Page 208: ...l have been removed If the valve seat is too wide too narrow or the seat is not centered the valve seat must be refaced Valve seat width Intake 0 9 1 1 mm 0 0354 0 0433 in Limit 1 6 mm 0 0630 in Exhaust 0 9 1 1 mm 0 0354 0 0433 in Limit 1 6 mm 0 0630 in 9 Lap Valve face Valve seat NOTE After refacing the valve seat or replacing the valve and valve guide the valve seat and valve face should be lapp...

Page 209: ...r every lapping operation be sure to clean off all of the compound from the valve face and valve seat Apply Mechanic s blueing dye Dykem to the valve face Install the valve into the cylinder head Press the valve through the valve guide and onto the valve seat to make a clear pattern Measure the valve seat width again If the valve seat width is out of specification reface and relap the valve seat 1...

Page 210: ...9 49 kg 37 09 42 94 lb at 1 21 in 12 Measure Spring tilt a Out of specification Replace Spring tilt limit Inner 2 5 1 6 mm 0 06 in Outer 2 5 1 6 mm 0 06 in INSTALLING THE VALVE AND VALVE SPRING 1 Apply Molybdenum disulfide oil onto the valve stem and valve stem seal 2 Install Valve spring seats Valve stem seals Valves Valve springs Valve spring retainers NOTE Install the valve springs with the lar...

Page 211: ...g with the valve spring compressor 1 and attachment 2 Valve spring compressor P N YM 04019 90890 04019 Valve spring compressor attachment P N 90890 01243 4 To secure the valve cotters onto the valve stem lightly tap the valve tip with a piece of wood CAUTION Hitting the valve tip with excessive force could damage the valve ...

Page 212: ... jacket inlet housing Refer to WATER PUMP in CHAPTER 6 Cylinder head Refer to CAMSHAFT AND CYLINDER HEAD 1 Cable guide 1 2 Cylinder O ring 1 1 Refer to INSTALLING THE CYLINDER 3 Cylinder gasket 1 4 Dowel pin 2 5 Piston pin clip 2 Refer to REMOVING INSTALLING THE PISTON 6 Piston pin 1 7 Piston 1 8 Piston ring set 1 For installation reverse the removal pro cedure ...

Page 213: ...ller 4 CAUTION Do not use a hammer to drive the piston pin out 2 Remove Piston rings NOTE Spread the end gaps apart while at the same time lifting the piston ring over the top of the piston crown as shown in the illustration Piston pin puller P N YU 01304 90890 01304 CHECKING THE CYLINDER AND PISTON 1 Check Cylinder and piston walls Vertical scratches Rebore or replace the cylinder and the piston ...

Page 214: ... edge If out of specification replace the piston and piston rings as a set 3rd step Find the piston to cylinder clearance with the following formula If out of specification rebore or replace the cylinder and replace the piston and piston rings as a set Standard Wear limit Cylinder bore C 100 005 100 045 mm 3 9372 3 9388 in 100 100 mm 3 9404 in C Piston skirt diameter P Standard 99 945 99 995 mm 3 ...

Page 215: ...iston ring in cylinder NOTE Insert a ring into the cylinder and push it approximately 50 mm 2 0 in into the cylinder Push the ring with the piston crown so that the ring will be at a right angle to the cylinder bore a 50 mm 2 0 in 3 Measure Ring end gap Out of specification Replace NOTE You cannot measure the end gap on the expander spacer of the oil control ring If the oil control ring rails show...

Page 216: ... formula If out of specification replace the piston INSTALLING THE PISTON 1 Install Piston rings onto the piston NOTE Be sure to install the piston rings so that the manufacturer s marks or numbers are located on the upper side of the rings Lubricate the piston and piston rings liberally with engine oil Outside diameter piston pin 21 991 22 000 mm 0 8658 0 8661 in Piston pin bore inside diameter 2...

Page 217: ...Before installing the piston pin clip cover the crankcase with a clean rag to prevent the piston pin clip from falling into the crankcase 4 Lubricate Piston Piston rings Cylinder NOTE Apply a liberal coating of engine oil New INSTALLING THE CYLINDER 1 Install Cylinder O ring Bolts M10 Bolts M6 NOTE Install the cylinder with one hand while com pressing the piston rings with the other hand CAUTION B...

Page 218: ... in the order below Engine oil Drain Shift pedal link Disconnect 1 Oil pipe 1 1 Disconnect 2 AC magneto coupler 2 3 Starter idle gear cover gasket 1 1 4 Dowel pin 1 5 Starter idle gear 1 1 6 Starter idle gear 1 shaft 1 7 Bearing 1 8 AC magneto cover gasket 1 1 Refer to REMOVING INSTALLING THE AC MAGNETO ROTOR ...

Page 219: ...er 1 11 Pickup coil 1 12 Stator assembly 1 13 Starter idle gear 2 1 14 Starter idle gear 2 shaft 1 15 Bearing 1 16 AC magneto rotor 1 Refer to REMOVING INSTALLING THE AC MAGNETO ROTOR 17 Starter wheel gear 1 18 Woodruff key 1 19 Bearing washer 1 1 For installation reverse the removal pro cedure ...

Page 220: ... 2 Remove AC magneto rotor nut 1 Washer NOTE While holding the AC magneto rotor 2 with the sheave holder 3 loosen the generator rotor nut Do not allow the sheave holder to touch the projection 4 on the rotor Sheave holder P N YS 01880 90890 01701 3 Remove AC magneto rotor 1 NOTE Use the flywheel puller 2 Flywheel puller P N YU 33270 90890 01362 CHECKING THE COIL 1 Check Stator assembly Pickup coil...

Page 221: ...h When turning the starter wheel gear counter clockwise È the starter clutch and the wheel gear should be engaged If not the starter clutch is faulty Replace it When turning the starter wheel gear clock wise É the starter wheel gear should turn freely If not the starter clutch is faulty Replace it T R Bolts starter clutch 16 Nm 1 6 m kg 11 ft lb LOCTITE 2 Check Gear teeth starter idle 1 Gear teeth...

Page 222: ...g the rotor check that the rotor rotates smoothly If not reinstall the key and rotor 3 Tighten AC magneto rotor nut 1 NOTE While holding the AC magneto rotor 2 with the sheave holder 3 tighten the generator rotor nut Do not allow the sheave holder to touch the projection 4 on the rotor Sheave holder P N YS 01880 90890 01701 T R 150 Nm 15 0 m kg 110 ft lb 4 Install AC magneto cover Oil pipe holder ...

Page 223: ...low Engine assembly Refer to ENGINE REMOVAL 1 Oil filter bolt 1 2 Union bolt 2 3 Copper washer 4 4 Oil delivery pipe 1 1 5 Union bolt 2 6 Copper washer 4 7 Oil delivery pipe 2 1 8 Clutch cover 1 Refer to REMOVING INSTALLING THE CLUTCH 9 Clutch cover gasket 1 10 Dowel pin 2 For installation reverse the removal pro cedure ...

Page 224: ...Q ty Remarks Removing the pull lever shaft Remove the parts in the order below 1 Circlip 1 2 Pull lever 1 3 Pull lever spring 1 4 Bolt 1 5 Pull lever shaft 1 6 Oil seal 1 7 Bearing 1 8 Bearing 1 For installation reverse the removal pro cedure ...

Page 225: ...ow 1 Clutch spring 5 Refer to INSTALLING THE CLUTCH 2 Pressure plate 1 3 Pull rod 1 4 Bearing 1 5 Friction plate 2 2 Inside diameter 116 mm 4 57 in 6 Clutch plate 7 7 Friction plate 1 6 Inside diameter 112 mm 4 41 in 8 Cushion spring 1 9 Lock washer 1 Refer to REMOVING INSTALLING THE CLUTCH 10 Clutch boss 1 ...

Page 226: ...H 13 Lock washer 1 Refer to REMOVING INSTALLING THE PRIMARY DRIVE GEAR AND BAL ANCER DRIVEN GEAR 14 Balancer driven gear 1 15 Straight key 1 16 Lock washer 1 17 Primary drive gear 1 18 Balancer drive gear 1 19 Spring 16 20 Dowel pin 16 21 Plate 1 22 Straight key 1 23 Washer 1 For installation reverse the removal pro cedure ...

Page 227: ...tab 3 Loosen Clutch boss nut 1 NOTE While holding the clutch boss 2 with the clutch holding tool 3 loosen the clutch boss nut Clutch holding tool P N YM 91042 90890 04086 REMOVING THE PRIMARY DRIVE GEAR AND BALANCER DRIVEN GEAR 1 Straighten the lock washer tabs 2 Loosen Primary drive gear nut 1 Balancer driven gear nut 2 NOTE Place an aluminum plate 3 between the teeth of the balancer drive gear 4...

Page 228: ...plate at four places Friction plate 1 thickness 2 74 2 86 mm 0 108 0 113 in Limit 2 6 mm 0 102 in Friction plate 2 thickness 2 94 3 06 mm 0 116 0 120 in Limit 2 8 mm 0 110 in CHECKING THE CLUTCH PLATE The following procedure applies to all of the clutch plates 1 Check Clutch plate Damage Replace the clutch plates as a set 2 Measure Clutch plate warpage with a surface plate and thickness gauge 1 Ou...

Page 229: ... 8 mm 1 69 in Limit 40 7 mm 1 60 in CHECKING THE CLUTCH HOUSING 1 Check Clutch housing dogs Damage pitting wear Deburr the clutch housing dogs or replace the clutch housing NOTE Pitting on the clutch housing dogs will cause erratic clutch operation CHECKING THE CLUTCH BOSS 1 Check Clutch boss splines Damage pitting wear Replace the clutch boss NOTE Pitting on the clutch boss splines will cause err...

Page 230: ... Primary drive gear 1 Primary driven gear 2 Damage wear Replace the primary drive gear and clutch housing as a set Excessive noise during operation Replace the primary drive gear and clutch housing as a set CHECKING THE BALANCER DRIVE 1 Check Balancer drive gear 1 Balancer driven gear 2 Damage wear Replace the balancer drive gear and balancer driven gear as a set Excessive noise during operation R...

Page 231: ...h mark a on the balancer driven gear with the punch mark b on the primary drive gear 3 Tighten Balancer driven gear nut 1 Primary drive gear nut 2 NOTE Place an aluminum plate 3 between the teeth of the balancer drive gear 4 and bal ancer driven gear 5 Apply the molybdenum disulfide grease to the thread of axles and nuts 4 Bend the lock washer tabs along the bal ancer driven gear nut 5 Bend the lo...

Page 232: ...l pump driven gear teeth mesh cor rectly 2 Tighten Clutch boss nut 1 NOTE While holding the clutch boss 2 with the clutch holding tool 3 tighten the clutch boss nut 3 Bend the lock washer tab along a flat side of the nut Clutch holding tool P N YM 91042 90890 04086 T R 90 Nm 9 0 m kg 65 ft lb 4 Install Pressure plate 1 NOTE Align the punch mark a on the pressure plate with the punch mark b on the ...

Page 233: ...esh the pull lever shaft with the pull rod teeth to ensure that the mark a on pull lever 1 is at the closest position to stationary pointer b onto the clutch cover when the clutch is engaged 7 Install Clutch cable holder 1 Bolts 2 Bolt 25 mm 3 Bolt 30 mm 4 Bolt 35 mm 5 Bolt 50 mm NOTE Tighten the bolts in stages using a crisscross pattern T R 10 Nm 1 0 m kg 7 2 ft lb ...

Page 234: ... name Part name Q ty Remarks Removing the oil pump Remove the parts in the order below Clutch Refer to CLUTCH 1 Circlip 1 2 Oil pump driven gear 1 3 Oil pump 1 4 Oil pump gasket 1 5 O ring 2 For installation reverse the removal pro cedure ...

Page 235: ...housing 1 oil seal 1 1 2 Oil pump outer rotor 1 1 3 Dowel pin 1 4 Oil pump inner rotor 1 1 5 Oil pump housing cover oil seal 1 1 6 Dowel pin 2 7 Oil pump shaft 1 8 Dowel pin 1 9 Oil pump inner rotor 2 1 Refer to ASSEMBLING THE OIL PUMP 0 Oil pump outer rotor 2 1 A Oil pump housing 2 1 For assembly reverse the disassembly procedure ...

Page 236: ...e outer rotor 2 and the pump housing 3 Out of specification Replace the oil pump Tip clearance a 0 12 mm 0 005 in Limit 0 2 mm 0 008 in Side clearance b 0 03 0 08 mm 0 001 0 003 in 3 Check Oil pump operation Unsmooth Repeat steps 1 and 2 or replace the defective parts ASSEMBLING THE OIL PUMP 1 Install Oil pump inner rotor 2 Oil pump outer rotor 2 NOTE Align the match mark a on the inner rotor 2 wi...

Page 237: ...g the shift shaft Remove the parts in the order below Clutch Refer to CLUTCH 1 Shift arm 1 Refer to INSTALLING THE SHIFT SHAFT 2 Shift shaft 1 3 Shift shaft spring 1 4 Collar 1 5 Roller 1 6 Stopper lever 1 Refer to INSTALLING THE STOPPER LEVER 7 Stopper lever spring 1 8 Roller 1 ...

Page 238: ...FT Order Job name Part name Q ty Remarks 9 Shift guide 1 Refer to INSTALLING THE SHIFT LEVER 10 Shift lever 1 11 Pawl 2 12 Pawl pin 2 13 Spring 2 14 Segment 1 15 Oil seal 1 For installation reverse the removal pro cedure ...

Page 239: ...er turns roughly Replace the stopper lever Stopper spring 2 Damage Replace CHECKING THE SHIFT GUIDE AND SHIFT LEVER 1 Check Shift guide 1 Shift lever 2 Pawl 3 Pawl pin 4 Spring 5 Damage wear Replace CHECKING THE SEGMENT 1 Check Segment Damage wear Replace INSTALLING THE SHIFT LEVER 1 Install Segment 1 Segment bolt NOTE Align the notch a on the segment with the pin b on the shift cam T R 30 Nm 3 0 ...

Page 240: ...y 1 Shift guide 2 NOTE The shift lever assembly is installed at the same time as the shift guide INSTALLING THE STOPPER LEVER 1 Install Roller Stopper lever spring 1 Stopper lever 2 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 ...

Page 241: ...ing Shift shaft 2 NOTE Install the end of the shift shaft spring onto the shift shaft spring stopper 3 Install the end of the shift shaft lever onto the roller 1 2 Install Shift arm 1 Bolt 2 NOTE Be sure to install the shaft arm so that position a is horizontal T R 10 Nm 1 0 m kg 7 2 ft lb ...

Page 242: ...ly Refer to ENGINE REMOVAL Cylinder head cover Refer to CYLINDER HEAD COVER Cylinder head Refer to CAMSHAFT AND CYLINDER HEAD Cylinder and piston Refer to CYLINDER AND PISTON AC rotor Refer to AC MAGNETO Clutch balancer drive gear and bal ancer driven gear Refer to CLUTCH Oil pump Refer to OIL PUMP Shift shaft and shift drum segment Refer to SHIFT SHAFT 1 Timing chain guide intake 1 2 Timing chain...

Page 243: ...ty Remarks 3 Reverse shift lever 1 4 Reverse shift lever spring 1 5 Circlip 1 6 Neutral switch 1 7 Reverse switch 1 8 Oil pipe joint 1 9 Circlip 1 10 Wave washer 1 11 Speed sensor rotor 1 12 Circlip 1 For installation reverse the removal pro cedure ...

Page 244: ...emarks Separating the crankcase Remove the parts in the order below 1 Right crankcase 1 Refer to CRANKCASE 2 Dowel pin 2 3 Dowel pin O ring 1 1 4 Left crankcase 1 5 Oil strainer 1 6 Cover 1 7 Oil strainer gasket 1 For installation reverse the removal pro cedure ...

Page 245: ... Removing the crankcase bearing Remove the parts in the order below Crankshaft and balancer Refer to CRANKSHAFT AND BAL ANCER Transmission Refer to TRANSMISSION 1 Oil seal retainer 1 2 Oil seal 3 3 Bearing retainer 3 4 Bearing 8 For installation reverse the removal pro cedure ...

Page 246: ...ON Use a soft hammer to tap on one side of the crankcase Tap only on reinforced portions of the crankcase Do not tap on the crank case mating surfaces Work slowly and carefully Make sure that the crankcase halves separate evenly Remove the dowel pins and O ring È É CHECKING THE TIMING CHAIN AND GUIDE 1 Check Timing chain Cracks stiff Replace the timing chain and camshaft sprocket as a set 2 Check ...

Page 247: ...damage Replace Oil delivery passages Clogged Blow out with compressed air CHECKING THE BEARINGS 1 Check Bearing Clean and lubricate then rotate the inner race with a finger Roughness Replace ASSEMBLING THE CRANKCASE 1 Apply Sealant Quick Gasket 1 to the mating surfaces of both case halves 2 Install Dowel pin 2 O ring 3 Sealant Quick Gasket P N ACC 11001 05 01 Yamaha bond No 1215 P N 90890 85505 Ne...

Page 248: ... cam in both directions 4 Install Lead guides 1 Hose guide 2 Crankcase bolts 5 Tighten Crankcase bolts follow the proper tightening sequence È Right crankcase É Left crankcase 3 Bolt 30 mm 4 Bolt 45 mm 5 Bolt 60 mm 6 Bolt 65 mm 7 Bolt 80 mm NOTE Tighten the bolts in stages using a crisscross pattern È É T R 10 Nm 1 0 m kg 7 2 ft lb 6 Apply 4 stroke engine oil to the crank pin bearing and oil deliv...

Page 249: ... Job name Part name Q ty Remarks Removing the crankshaft and bal ancer Remove the parts in the order below Crankcase Separate Refer to CRANKCASE 1 Balancer 1 2 Crankshaft 1 Refer to REMOVING INSTALLING THE CRANKSHAFT For installation reverse the removal pro cedure ...

Page 250: ...place the crank shaft Runout C Out of specification Replace the crank shaft Crankshaft reassembling point The crankshaft 1 and the crank pin 2 oil pas sages must be properly interconnected with a tolerance of less than 1 mm 0 04 in CAUTION The buffer boss and woodruff key should be replaced when removed from the crank shaft Crank width 74 95 75 00 mm 2 9508 2 9528 in Big end side clearance 0 32 0 ...

Page 251: ... installing tool until the crankshaft bottoms against the bearing CAUTION Apply engine oil to each bearing to protect the crankshaft against scratches and to make installation easier Crankshaft installer pot 1 P N 90890 01274 Crankshaft installer bolt 2 P N 90890 01275 Crankshaft installer set 3 P N YU 90050 Adapter 4 P N YM 90069 90890 04059 Spacer crankshaft installer 5 P N YM 91044 90890 04081 ...

Page 252: ... parts in the order below Crankcase Separate Refer to CRANKCASE 1 Shift fork guide bar short 1 Refer to INSTALLING THE TRANSMIS SION 2 Shift fork C 1 3 Shift fork guide bar long 1 4 Shift fork R 1 5 Shift fork L 1 6 Shift drum 1 7 Reverse shift shaft 1 8 Main axle assembly 1 9 Spacer O ring 1 1 10 Drive axle 1 ...

Page 253: ...5 73 ENG TRANSMISSION Order Job name Part name Q ty Remarks 11 Counter axle 1 12 Counter gear 1 For installation reverse the removal pro cedure ...

Page 254: ...main axle Remove the parts in the order below 1 Reverse pinion gear 1 2 4th pinion gear 1 3 2nd 3rd pinion gear 1 4 Circlip 1 Refer to ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 5 Toothed washer 1 6 5th pinion gear 1 7 Main axle 1st pinion gear 1 For assembly reverse the disassembly procedure ...

Page 255: ... drive axle Remove the parts in the order below 1 Washer 1 2 1st wheel gear 1 3 5th wheel gear 1 4 Circlip 3 Refer to ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 5 Toothed washer 3 6 3rd wheel gear 1 7 Toothed collar 2 8 Toothed lock washer 1 9 Toothed lock washer retainer 1 0 2nd wheel gear 1 ...

Page 256: ...5 76 ENG TRANSMISSION Order Job name Part name Q ty Remarks A 4th wheel gear 1 B Reverse wheel gear 1 C Collar 1 D Drive axle 1 For assembly reverse the disassembly procedure ...

Page 257: ...ot attempt to straighten a bent guide bar 3 Check Shift fork movement on the guide bar Unsmooth operation Replace the shift fork and the guide bar as a set CHECKING THE SHIFT DRUM 1 Check Shift cam grooves Scratches wear damage Replace CHECKING THE TRANSMISSION 1 Measure Main axle runout with a centering device and dial gauge 1 Out of specification Replace the main axle Maximum main axle runout 0 ...

Page 258: ... defective gear s 4 Check Transmission gear engagement each pinion gear to its respective wheel gear Incorrect Reassemble the transmission axle assemblies 5 Check Transmission gear movement Rough movement Replace the defective part s 6 Check Circlips Bends damage looseness Replace ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 1 Install Toothed washer 1 Circlip 2 NOTE Be sure the circlip shap edged corne...

Page 259: ... Shift fork L 2 Shift fork R 3 Shift fork guide bar long 4 Shift fork C 5 Shift fork guide bar short 6 NOTE The embossed marks on the shift forks should face towards the right side of the engine and be in the following sequence R C L 2 Check Transmission Rough movement Repair NOTE Oil each gear and bearing thoroughly Before assembling the crankcase be sure that the transmission is in neutral and t...

Page 260: ...er Refer to SEAT FENDERS AND FUEL TANK in CHAPTER 3 Coolant Drain 1 Radiator fan coupler 1 Disconnect 2 Thermo switch coupler 1 Disconnect 3 Coolant reservoir hose 1 4 Radiator fan breather hose 1 Disconnect 5 Radiator outlet hose 1 Disconnect 6 Radiator inlet hose 1 Disconnect 7 Radiator 1 8 Radiator fan 1 9 Thermo switch 1 1 10 Coolant reservoir breather hose 1 ...

Page 261: ...6 2 COOL RADIATOR Order Job name Part name Q ty Remarks 11 Coolant reservoir 1 12 Coolant reservoir cap 1 For installation reverse the removal pro cedure ...

Page 262: ...pressure Below the specified pressure Replace the radiator cap Measurement steps Install the radiator cap tester 1 and adapter 2 onto the radiator cap 3 Apply the specified pressure for ten seconds and make sure that there is no drop in pres sure 4 Check Radiator fan Damage Replace Malfunction Check and repair Refer to COOLING SYSTEM in CHAPTER 9 Radiator cap opening pressure 95 125 kPa 0 95 1 25 ...

Page 263: ...DIATOR INSTALLING THE RADIATOR 1 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT in CHAPTER 3 2 Check Cooling system Leaks Repair or replace any faulty part ...

Page 264: ...ow Front panel and front fender Refer to SEAT FENDERS AND FUEL TANK in CHAPTER 3 Coolant Drain Radiator Refer to RADIATOR 1 Radiator inlet hose 1 2 Front fender bracket 1 3 Thermostat inlet hose 1 4 Water jacket outlet pipe 1 5 O ring 1 6 Thermostat assembly 1 7 Thermo switch 2 1 For installation reverse the removal pro cedure ...

Page 265: ...rt name Q ty Remarks Disassembling the thermostat Remove the parts in the order listed 1 Thermostat cover 1 Refer to ASSEMBLING THE THERMO STAT 2 O ring 1 3 Thermostat 1 4 Thermostat housing 1 For assembly reverse the disassembly procedure ...

Page 266: ...ntainer È Fully closed É Fully open OTE If the accuracy of the thermostat is in doubt replace it A faulty thermostat could cause seri ous overheating or overcooling 2 Check Thermostat housing cover Thermostat housing Cracks damage Replace ASSEMBLING THE THERMOSTAT 1 Install Thermostat 1 Thermostat housing cover OTE Install the thermostat with its breather hole a toward the projection b 2 Fill Cool...

Page 267: ...arks Removing the water pump Remove the parts in the order below Coolant Drain 1 Radiator outlet hose 1 Disconnect 2 Water pump outlet hose 1 3 Water pump assembly 1 4 O ring 1 5 Water jacket inlet housing 1 6 O ring 1 For installation reverse the removal pro cedure ...

Page 268: ...ssembling the water pump Remove the parts in the order below 1 Water pump housing cover 1 2 O ring 1 3 Circlip 1 4 Impeller shaft gear 1 5 Pin 1 6 Circlip 1 7 Impeller 1 Refer to DISASSEMBLING ASSEM BLING THE THERMOSTAT 8 Impeller shaft 1 9 Rubber damper holder 1 ...

Page 269: ... Order Job name Part name Q ty Remarks 0 Rubber damper 1 Refer to DISASSEMBLING ASSEM BLING THE THERMOSTAT A Water pump seal 1 B Oil seal 1 C Bearing 1 D Water pump housing 1 For assembly reverse the disassembly procedure ...

Page 270: ...h the impeller 3 Remove Water pump seal 1 OTE Tap out the water pump seal from the inside of the water pump housing 2 Water pump housing 4 Remove Oil seal 1 Bearing 2 OTE Tap out the bearing and oil seal from the out side of the water pump housing 3 Water pump housing CHECKING THE WATER PUMP 1 Check Water pump housing cover 1 Water pump housing 2 Impeller 3 Impeller shaft 4 Rubber damper 5 Rubber ...

Page 271: ...al with a socket 3 that matches its outside diameter 2 Install Water pump seal 1 into the water pump housing 2 CAUTION Never lubricate the water pump seal sur face with oil or grease OTE Install the water pump seal with the special tools È Push down Mechanical seal installer 3 P N YM 33221 90890 04078 Middle driven shaft bearing driver 4 P N YM 04058 1 90890 04058 New New 3 Install Rubber damper 1...

Page 272: ...ure Impeller shaft tilt Out of specification Repeat steps 3 and 4 CAUTION Make sure that the rubber damper and rub ber damper holder are bottom with the impeller 1 Straightedge 2 Impeller Max impeller shaft tilt 0 15 mm 0 006 in ...

Page 273: ...l tank rubber cover 2 Refer to SEAT FENDERS AND FUEL TANK in CHAPTER 3 1 Air vent hose 2 2 Float chamber breather hose 1 3 Starter cable starter plunger 1 1 4 Throttle valve cover 1 5 Throttle cable end 1 6 Throttle cable 1 7 Clamp screw air filter case 2 Loosen 8 Clamp screw carburetor joint 2 Loosen 9 Carburetors 1 For installation reverse the removal pro cedure ...

Page 274: ...Q ty Remarks Separating the carburetors Remove the parts in the order below 1 Drain hose 2 2 Plate 1 3 Connecting bolt spacer 2 2 4 Spring 1 5 Hose joint 1 6 Pipe 1 7 Carburetor 2 1 8 Carburetor 1 1 For installation reverse the separating procedure ...

Page 275: ... carburetor Remove the parts in the order below 1 Throttle stop screw 1 2 Vacuum chamber cover 1 3 Spring 1 4 Jet needle holder 1 5 Spring 1 6 Jet needle set 1 7 Piston valve 1 8 Float chamber 1 9 Drain screw 1 0 Float 1 Refer to ASSEMBLING THE CARBURE TOR A Needle valve set 1 ...

Page 276: ...EMBLING THE CARBURETOR OTE Before disassembling the carburetor make sure to note the number of times the pilot screw is turned out from the seated position to its set position D Main jet 1 E Needle jet 1 Refer to ASSEMBLING THE CARBURE TOR F Starter jet 1 G Pilot air jet 1 For assembly reverse the disassembly procedure ...

Page 277: ...acks damage Replace Fuel passage Contamination Clean as indicated Fuel chamber body Contamination Clean Cleaning steps Wash the carburetor in a petroleum based solvent Do not use any caustic carburetor cleaning solution Blow out all of the passages and jets with compressed air 2 Check Float 1 Float tang 2 Damage Replace 3 Check Valve seat 1 Needle valve 2 O ring 3 Contamination wear damage Replace...

Page 278: ...ain jet 2 Needle jet 3 Pilot air jet 4 Pilot jet 5 Pilot screw 6 Starter jet 7 Starter plunger 8 Bends wear damage Replace Blockage Blow out the jets with compressed air 7 Check Free movement piston valve Sticks Replace the piston valve guide and the piston valve Insert the piston valve into the carburetor body and check for free movement 8 Check Free movement throttle valve Sticks Replace ...

Page 279: ...of specification Adjust Measurement and adjustment steps Hold the carburetor in an upside down position Measure the distance from the front mating surface of the float chamber gasket removed to the top of the float OTE The float arm should be resting on the needle valve but not compressing it If the float height is not within the specification inspect the valve seat and needle valve If either is w...

Page 280: ...E FUEL LEVEL 1 Measure Fuel level a Out of specification Adjust Fuel level 3 4 mm 0 12 0 16 in Below the float chamber mating surface Fuel level measurement and adjustment steps Place the machine on a level surface Connect the fuel level gauge 1 to the drain pipe 2 Loosen the drain screw 3 Hold the gauge vertically next to the float chamber line Measure the fuel level a with the gauge If the fuel ...

Page 281: ... Remove the carburetor Inspect the valve seat and needle valve If either is worn replace them both If both are fine adjust the float level by bending the float tang 4 slightly Install the carburetor Recheck the fuel level ...

Page 282: ...tor light 4 Circuit breaker fan 5 Park switch 6 Clutch switch 7 Handlebar switch left 8 Fuse 9 Starter relay 0 Tail brake light A Rectifier regulator B CDI unit C Battery D Neutral switch E Reverse switch F Speed sensor G Rear brake switch H Ignition coil I Headlight J Thermo switch 1 K Fan L Thermo switch 2 M Diode ...

Page 283: ...ch on and off a few times when checking it Pocket tester P N YU 03112 90890 03112 CHECKING A SWITCH SHOWN IN THE MANUAL The terminal connections for switches main switch handlebar switch engine stop switch light switch etc are shown in a chart similar to the one on the left This chart shows the switch positions in the column and the switch lead colors in the top row For each switch position indica...

Page 284: ...CHECKING THE SWITCH CHECKING THE SWITCH CONTINUITY Refer to CHECKING THE SWITCH and check for continuity between lead terminals Poor connection no continuity Correct or replace The coupler locations are circled ...

Page 285: ...4 ELEC CHECKING THE SWITCH 1 Lights switch 2 Engine stop switch 3 Start switch 4 Main switch 5 Front brake switch 6 Clutch switch 7 Park switch 8 Fuse 9 Reverse switch 0 Neutral switch A Rear brake switch ...

Page 286: ...8 5 ELEC IGNITION SYSTEM EB802000 IGNITION SYSTEM CIRCUIT DIAGRAM 1 AC magneto 3 Main switch 4 Battery 5 Fuse 0 CDI unit A Ignition coil B Spark plug P Engine stop switch ...

Page 287: ...ooting 1 Seat 2 Front fender Use the following special tool s for trouble shooting Dynamic spark tester P N YM 34487 Ignition checker P N 90890 06754 Pocket tester P N YU 03112 90890 03112 EB802011 CONTINUITY 1 Fuse Refer to CHECKING THE SWITCH NO CONTINUITY Replace the fuse EB802012 CORRECT 2 Battery Check the battery condition Refer to CHECKING THE BATTERY in CHAPTER 3 Open circuit voltage 12 8 ...

Page 288: ...tarter switch and increase the spark gap until a misfiring occurs Minimum spark gap 6 0 mm 0 24 in MEETS SPECIFICATION The ignition system is not faulty For Europe OUT OF SPECIFICATION OR NO SPARK 4 Ignition spark gap Disconnect the spark plug cap from the spark plug Connect the ignition checker 1 as shown 2 Spark plug cap Turn the main switch to ON Check the ignition spark gap a Crank the engine ...

Page 289: ...ance Spark plug cap resistance 10 kΩ at 20 C 68 F OUT OF SPECIFICATION Replace the spark plug cap 6 Ignition coil resistance Disconnect the ignition coil connector from the wire harness Connect the pocket tester Ω 1 to the ignition coil Tester lead Orange lead terminal Tester lead Ignition coil base Check that the primary coil has the speci fied resistance Primary coil resistance 0 18 0 28 Ω at 20...

Page 290: ...HE SWITCH INCORRECT Replace the handlebar switch left CORRECT 8 Main switch Refer to CHECKING THE SWITCH INCORRECT Replace the main switch 9 Pickup coil resistance Disconnect the AC magneto coupler from the wire harness Connect the pocket tester Ω 100 to the pickup coil terminal Tester lead White Red terminal 1 Tester lead White Green terminal 2 MEETS SPECIFICATION Check the pickup coil for the sp...

Page 291: ...er lead Red terminal 1 Tester lead White Blue terminal 2 Check the charging rotor rotation direction detection coil for the specified resistance Rotor rotation direction detec tion coil resistance 0 069 0 085 Ω at 20 C 68 F Red White Blue OUT OF SPECIFICATION Replace the pickup coil stator assembly CORRECT 11 Wiring connection Check the connections of the entire ignition system Refer to CIRCUIT DI...

Page 292: ...TARTING SYSTEM EB803000 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM 3 Main switch 4 Battery 5 Fuse 6 Starter relay 7 Starter motor 8 Clutch switch 9 Park switch 0 CDI unit J Neutral switch P Engine stop switch Q Start switch ...

Page 293: ...ain switch is on and the engine stop switch is in the RUN position the starter motor can be operated only if 1 Fuse 2 Battery 3 Starter relay 4 Starter motor 5 Start switch 6 CDI unit 7 Engine stop switch 8 Neutral switch 9 Clutch switch È TO MAIN SWITCH É FROM MAIN SWITCH The transmission is in neutral the neutral switch is closed or You pull in the clutch lever the clutch switch is closed ...

Page 294: ... Remove the following part s before trouble shooting 1 Seat 2 Front fender 3 Rear fender 4 Exhaust pipe Use the following special tool s for trouble shooting Pocket tester P N YU 03112 90890 03112 EB802011 CONTINUITY 1 Fuse Refer to CHECKING THE SWITCH NO CONTINUITY Replace the fuse EB802012 CORRECT 2 Battery Check the battery condition Refer to CHECKING THE BATTERY in CHAPTER 3 Open circuit volta...

Page 295: ...ce sparks so be sure that no flammable gas or fluid is in the vicinity DOES NOT TURN Repair or replace the starter motor 4 Starter relay Remove the starter relay from the wire har ness Connect the pocket tester Ω 1 and the battery 12 V to the starter relay terminals CONTINUITY Battery terminal Yellow Black terminal 1 Battery terminal Blue Black terminal 2 Tester lead Red terminal 3 Tester lead Bla...

Page 296: ...HE SWITCH INCORRECT Replace the handlebar switch left CORRECT 8 Neutral switch Refer to CHECKING THE SWITCH INCORRECT Replace the neutral switch CORRECT 9 Clutch switch Refer to CHECKING THE SWITCH INCORRECT Replace the clutch switch EB803028 10 Wiring connection Check the connections of the entire starting system Refer to CIRCUIT DIAGRAM POOR CONNECTION Properly connect the starting system ...

Page 297: ...EMOVAL 1 Parking brake cable 1 Disconnect 2 Starter motor lead 1 3 Starter motor O ring 1 1 Disassembling the starter motor Remove the parts in the order below 1 Starter motor drive gear 1 2 Bracket 1 1 Refer to ASSEMBLING THE STARTER MOTOR 3 Washer kit 4 Bracket 2 1 5 Shims 6 Brush seat 1 brush seat 2 1 1 7 Armature coil 1 8 Yoke 1 For assembly reverse the disassembly procedure ...

Page 298: ...a hacksaw blade which has been grounded to fit the commutator Outside diameter 28 mm 1 10 in Wear limit 27 mm 1 06 in Mica undercut 0 7 mm 0 03 in 4 Check Armature coil insulation continuity Defects Replace the starter motor Armature coil checking steps Connect the pocket tester for the continuity check 1 and insulation check 2 Measure the armature resistances If the resistance is incorrect replac...

Page 299: ...force Fatigue out of specification Replace as a set Brush spring force 7 65 10 01 Nm 27 5 36 0 oz 7 Check Oil seal Bushing O rings Wear damage Replace ASSEMBLING THE STARTER MOTOR 1 Install Brush seat 1 OTE Align the projection a on the brush seat with the slot b on the housing 2 Install Yoke Brackets OTE Align the match marks a on the yoke with the match marks b on the brackets ...

Page 300: ...8 19 ELEC CHARGING SYSTEM EB804000 CHARGING SYSTEM CIRCUIT DIAGRAM 1 AC magneto 2 Rectifier regulator 4 Battery 5 Fuse ...

Page 301: ...g Pocket tester P N YU 03112 90890 03112 EB802011 CONTINUITY 1 Fuse Refer to CHECKING THE SWITCH NO CONTINUITY Replace the fuse EB802012 CORRECT 2 Battery Check the battery condition Refer to CHECKING THE BATTERY in CHAPTER 3 Open circuit voltage 12 8 V or more at 20 C 68 F INCORRECT Clean the battery terminals Recharge or replace the battery EB804011 3 Charging voltage Connect the tachometer to t...

Page 302: ...the charging coils Tester lead White terminal 1 Tester lead White terminal 2 Tester lead White terminal 1 Tester lead White terminal 3 Tester lead White terminal 2 Tester lead White terminal 3 Measure the stator coil resistance Charging coil resistance 0 43 0 65 Ω at 20 C 68 F OUT OF SPECIFICATION Replace the pickup coil stator assembly EB804015 CORRECT 5 Wiring connections Check the connections o...

Page 303: ...8 22 ELEC LIGHTING SYSTEM EB805000 LIGHTING SYSTEM CIRCUIT DIAGRAM 3 Main switch 4 Battery 5 Fuse O Lights switch R Headlight S Tail brake light ...

Page 304: ...rt s before trouble shooting 1 Seat 2 Front fender Use the following special tool s for trouble shooting Pocket tester P N YU 03112 90890 03112 EB802011 CONTINUITY 1 Fuse Refer to CHECKING THE SWITCH NO CONTINUITY Replace the fuse EB802012 CORRECT 2 Battery Check the battery condition Refer to CHECKING THE BATTERY in CHAPTER 3 Open circuit voltage 12 8 V or more at 20 C 68 F INCORRECT Clean the ba...

Page 305: ... CHECKING THE SWITCH INCORRECT Lights switch is faulty replace the handlebar switch left EB805013 CORRECT 5 Wiring connection Check the connections of the entire lighting system Refer to WIRING DIAGRAM Check the condition of each of the lighting system s circuits Refer to CHECKING THE LIGHTING SYS TEM POOR CONNECTION Properly connect the lighting system ...

Page 306: ...o the headlight couplers Tester lead Green terminal 1 or Yellow terminal 2 Tester lead Black terminal 3 È When the lights switch is on LO É When the lights switch is on HI È É MEETS SPECIFICATION Turn the main switch to ON Turn the lights switch to LO or HI Check the voltage 12 V of the Green and Yellow leads on the bulb socket con nector This circuit is not faulty OUT OF SPECIFICATION The wiring ...

Page 307: ... Voltage Connect the pocket tester 20 V to the bulb socket coupler Tester lead Blue terminal 1 Tester lead Black terminal 2 MEETS SPECIFICATION Turn the main switch to ON Turn the lights switch to LO or HI Check the voltage 12 V of the Blue lead on the bulb socket connector This circuit is not faulty OUT OF SPECIFICATION The wiring circuit from the main switch to the bulb socket connector is fault...

Page 308: ...ttery 5 Fuse 0 CDI unit C Speed sensor G Coolant temperature warning light H Reverse indicator light I Neutral indicator light J Neutral switch K Reverse switch L Diode M Thermo switch 2 P Engine stop switch Q Start switch S Tail brake light T Rear brake switch U Front brake switch ...

Page 309: ...rouble shooting 1 Seat 2 Front fender 3 Rear fender Use the following special tool s for trouble shooting Pocket tester P N YU 03112 90890 03112 EB802011 CONTINUITY 1 Fuse Refer to CHECKING THE SWITCH NO CONTINUITY Replace the fuse EB802012 CORRECT 2 Battery Check the battery condition Refer to CHECKING THE BATTERY in CHAPTER 3 Open circuit voltage 12 8 V or more at 20 C 68 F INCORRECT Clean the b...

Page 310: ...RRECT Replace the main switch EB806011 CORRECT 4 Wiring connections Check the connections of the entire signal system Refer to CIRCUIT DIAGRAM Check the condition of each of the signal sys tem s circuits Refer to CHECKING THE SIGNAL SYS TEM POOR CONNECTION Properly connect the signal system ...

Page 311: ...G THE SWITCH NO CONTINUITY Replace the brake switch 3 Voltage Connect the pocket tester DC 20V to the bulb socket coupler Tester lead Yellow terminal 1 Tester lead Black terminal 2 MEETS SPECIFICATION Turn the main switch to ON Turn the lights switch to LO or HI Check the voltage 12 V of the Yellow lead on the bulb socket connector This circuit is not faulty OUT OF SPECIFICATION The wiring circuit...

Page 312: ... 2 Neutral switch Refer to CHECKING THE SWITCH NO CONTINUITY Replace the neutral switch 3 Voltage Connect the pocket tester DC 20V to the bulb socket coupler Tester lead Brown terminal 1 Tester lead Sky blue terminal 2 MEETS SPECIFICATION Turn the main switch to ON Check the voltage 12 V This circuit is not faulty OUT OF SPECIFICATION The wiring circuit from the main switch to the bulb socket conn...

Page 313: ...verse switch Refer to CHECKING THE SWITCH NO CONTINUITY Replace the reverse switch 3 Voltage Connect the pocket tester DC 20V to the bulb socket coupler Tester lead Brown terminal 1 Tester lead Green Blue terminal 2 MEETS SPECIFICATION Turn the main switch to ON Check the voltage 12 V This circuit is not faulty OUT OF SPECIFICATION The wiring circuit from the main switch to the bulb socket connect...

Page 314: ... to the thermo switch 1 Immerse the thermo switch in coolant 2 Check the thermo switch for continuity While heating the coolant use a thermome ter 3 to record the temperatures Test step Water temperature Good condition Thermo switch 1 0 115 3 C 32 239 5 4 F 2 More than 120 3 C 248 5 4 F 3 120 3 to 115 3 C 248 5 4 to 239 5 4 F 4 Less than 115 3 C 239 5 4 F Tests 1 2 Heat up tests Tests 3 4 Cool dow...

Page 315: ...o the bulb socket connector is faulty repair it CORRECT 4 Diode Remove the diode from the coupler Connect the pocket tester Ω 1 to the diode terminals as shown Check the diode for continuity as follows Tester positive probe Blue Black 1 Tester negative probe White Blue 2 Continu ity Tester positive probe White Blue 2 Tester negative probe Blue Black 1 No conti nuity OTE When you switch the tester ...

Page 316: ...8 35 ELEC SIGNAL SYSTEM C0NTINUITY CORRECT 5 Start switch Refer to CHECKING THE SWITCH This circuit is not faulty INCORRECT Replace the handlebar switch left ...

Page 317: ...8 36 ELEC COOLING SYSTEM COOLING SYSTEM CIRCUIT DIAGRAM 3 Main switch 4 Battery 5 Fuse D Circuit breaker fan motor E Thermo switch 1 F Fan motor ...

Page 318: ...ont fender Use the following special tool s for trouble shooting Pocket tester P N YU 03112 90890 03112 EB802011 CONTINUITY 1 Fuse Refer to CHECKING THE SWITCH NO CONTINUITY Replace the fuse EB802012 CORRECT 2 Battery Check the battery condition Refer to CHECKING THE BATTERY in CHAPTER 3 Open circuit voltage 12 8 V or more at 20 C 68 F INCORRECT Clean the battery terminals Recharge or replace the ...

Page 319: ... Battery lead Black terminal 2 Check the operation of the fan motor DOES NOT TURN Replace the fan motor MEETS SPECIFICATION 5 Circuit breaker fan motor Remove the circuit breaker from the wire harness Connect the pocket tester Ω 1 to the cir cuit breaker Circuit breaker resistance Zero Ω at 20 C 68 F OUT OF SPECIFICATION Replace the circuit breaker ...

Page 320: ...Test step Water temperature Good condition Thermo switch 1 0 92 3 C 32 197 6 5 4 F 2 More than 98 3 C 208 4 5 4 F 3 98 3 to 92 3 C 208 4 5 4 to 197 6 5 4 F 4 Less than 92 3 C 197 6 5 4 F Tests 1 2 Heat up tests Tests 3 4 Cool down tests Continuity No continuity T R Thermo switch 28 Nm 2 8 m kg 20 ft lb Three bond sealock 10 WARNING Handle the thermo switch with special care Never subject it to a s...

Page 321: ...LING SYSTEM C0NTINUITY EB803028 CORRECT 7 Wiring connection Check the connections of the entire starting system Refer to CIRCUIT DIAGRAM This circuit is not faulty POOR CONNECTION Properly connect the cooling system ...

Page 322: ...mproper heat range Faulty spark plug cap Ignition coil Broken or shorted primary secondary Faulty spark plug lead Broken body CDI system Faulty CDI unit Faulty pickup coil Broken woodruff key Carburetor Deteriorated or contaminated fuel Clogged pilot jet Clogged pilot air passage Sucked in air Deformed float Worn needle valve Improperly sealed valve seat Improperly adjusted fuel level Improperly s...

Page 323: ...rankshaft Valve train Improperly adjusted valve clearance Improperly adjusted valve timing POOR IDLE SPEED PERFORMANCE POOR IDLE SPEED PERFORMANCE Carburetor Improperly returned starter plunger Loose pilot jet Clogged pilot jet Clogged pilot air jet Improperly adjusted idle speed Throttle stop screw Improper throttle cable play Flooded carburetor Electrical system Faulty spark plug Faulty CDI unit...

Page 324: ...mproperly returned stopper lever Shift fork Worn shift fork Shift drum Improper thrust play Worn shift drum groove Transmission Worn gear dog CLUTCH SLIPPING DRAGGING CLUTCH SLIPPING Clutch Loose clutch spring Fatigued clutch spring Worn friction plate Worn clutch plate Incorrectly assembled clutch Engine oil Low oil level Improper quality low viscosity Deterioration CLUTCH DRAGGING Clutch Warped ...

Page 325: ...Improper oil level Improper oil viscosity Inferior oil quality Brake Brake drag Cooling system Low coolant level Clogged or damaged radiator Damaged or faulty water pump Thermostat stays closed OVER COOLING COOLING SYSTEM Thermostat Thermostat stays open FAULTY BRAKE POOR BRAKING EFFECT Disc brake Worn brake pads Worn disc Air in brake fluid Leaking brake fluid Faulty master cylinder kit cup Fault...

Page 326: ... Tires Uneven tire pressures on both sides Incorrect tire pressure Uneven tire wear Wheels Deformed wheel Loose bearing Bent or loose wheel axle Excessive wheel runout Frame Bent Damaged frame Swingarm Worn bearing or bushing Bent or damaged LIGHTING SYSTEM HEADLIGHT DARK Improper bulb Too many electric accessories Hard charging broken charging coil and or faulty rectifier regulator Incorrect conn...

Page 327: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U S A ...

Page 328: ... Thermo switch 2 N Handlebar switch left O Lights switch P Engine stop switch Q Start switch R Headlight S Tail brake light T Rear brake switch U Front brake switch COLOR CODE B Black Br Brown G Green L Blue O Orange P Pink R Red Sb Sky blue W White Y Yellow B W Black White B Y Black Yellow Br L Brown Blue Br R Brown Red Br W Brown White G L Green Blue G W Green White G Y Green Yellow L B Blue Bla...

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