Yamaha YP250R 2005 Service Manual Download Page 168

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CHAS

FRONT FORK

EAS06490

REMOVING THE FRONT FORK LEGS

The following procedure applies to both of the
front fork legs.
1. Stand the vehicle on a level surface.

WARNING

Securely support the vehicle so that there
is no danger of it falling over.

NOTE:

Place the vehicle on a suitable stand so that
the front wheel is elevated.

2. Remove:

• clip

3. Loosen:

• lower bracket pinch bolts

WARNING

Support the front fork leg while loosening
the lower bracket pinch bolts.

4. Remove:

• front fork leg

EAS06520

DISASSEMBLING THE FRONT FORK LEGS

The following procedure applies to both of the
front fork legs.
1. Remove:

• rubber cap
• circlip

• front fork cap

• O-ring
• fork spring

NOTE:

Push the front fork cap in the direction of the
arrow shown in the illustration to remove the
circlip.

Summary of Contents for YP250R 2005

Page 1: ...YP250R SERVICE MANUAL 2005 1C0 F8197 E0 ...

Page 2: ...2005 SERVICE MANUAL 2007 by Yamaha Motor España S A First edition February 2007 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor España S A is expressly prohibited ...

Page 3: ...odels Modifications and sig nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable NOTE _ Designs and specifications are subject to change without notice EAS00005 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following The Safety A...

Page 4: ...of each page except in Chapter 3 PERIODIC CHECKS AND ADJUSTMENTS where the sub section title s appears 3 Sub section titles appear in smaller print than the section title 4 To help identify parts and clarify procedure steps there are exploded diagrams at the start of each removal and disassembly section 5 Numbers are given in the order of the jobs in the exploded diagram A circled number indicates...

Page 5: ... B Lubricant C Special tool D Tightening torque E Wear limit clearance F Engine speed G Electrical data Symbols H to M in the exploded diagrams indicate the types of lubricants and lubrication points H Engine oil I Gear oil J Molybdenum disulfide oil K Wheel bearing grease L Lithium soap based grease M Molybdenum disulfide grease Symbols N to O in the exploded diagrams indicate the following N App...

Page 6: ...NTENTS 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 CARBURETOR CARB 7 ELECTRICAL SYSTEM ELEC 8 TROUBLESHOOTING TRBL SHTG 9 ...

Page 7: ...ODEL LABEL 1 1 MULTI FUNCTION DISPLAY 1 2 IMPORTANT INFORMATION 1 5 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 5 REPLACEMENT PARTS 1 5 GASKETS OIL SEALS AND O RINGS 1 5 LOCK WASHERS PLATES AND COTTER PINS 1 6 BEARINGS AND OIL SEALS 1 6 CIRCLIPS 1 6 CHECKING THE CONNECTIONS 1 7 SPECIAL TOOLS 1 8 ...

Page 8: ...ATION EAS00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the frame 1 EAS00018 MODEL LABEL The model label 1 is affixed underneath the seat This information will be needed when ordering spare parts 1 IDENTIFICATION ...

Page 9: ...which comes on when the engine oil should be changed NOTE For the UK the distance traveled is dis played in miles and the temperature reading is displayed in F For other countries the distance traveled is displayed in kilometers and the temperature reading is displayed in C 1 Total 2 Trip 1 3 Trip 2 4 Trip Fuel Odometer and tripmeter modes Pushing the MODE button switches the dis play between the ...

Page 10: ...select it by pushing the MODE button and then push the SET but ton for at least one second If you do not reset the fuel reserve tripmeter manually it will reset itself automatically and the display will return to the prior mode after refueling and traveling 5 km Trip Fuel Trip 1 Trip 2 Total Trip fuel Clock mode To set the clock 1 When the display is in the Total mode push the SET button for at le...

Page 11: ... After changing the engine oil reset the indicator as follows 1 Oil change indicator OIL To reset the oil change indicator 1 Set the main switch to ON while holding the MODE and SET buttons pushed for two to five seconds 2 Release the buttons and the oil change indicator will go off NOTE The oil change indicator will come on at the initial 1000 km and every 3000 km thereafter If the engine oil is ...

Page 12: ... all of the parts and place them in trays in the order of dis assembly This will speed up assembly and allow for the correct installation of all parts 5 Keep all parts away from any source of fire EAS00021 REPLACEMENT PARTS 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...

Page 13: ...sible When installing oil seals lubricate the oil seal lips with a light coat of lithium soap based grease Oil bearings liberally when installing if appro priate 1 Oil seal CAUTION _ Do not spin the bearing with compressed air because this will damage the bearing surfaces 2 Bearing EAS00025 CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlips Always rep...

Page 14: ...disconnect sev eral times 3 Check all connections Loose connection Connect properly NOTE _ If the pin 1 on the terminal is flattened bend it up 4 Connect lead coupler connector NOTE _ Make sure all connections are tight 5 Check continuity with the pocket tester NOTE _ If there is no continuity clean the terminals When checking the wire harness perform steps 1 to 3 As a quick remedy use a contact r...

Page 15: ...tion Illustration 90890 01083 90890 01084 Slide hammer bolt Weight These tools are used to remove or install the rocker arm shafts 90890 01135 Crankshaft separating tool This tool is used to remove the crank shaft 90890 01235 Rotor holding tool This tool is used to hold the primary fixed sheave 90890 01274 Crankshaft installer pot This tool is used to install the crankshaft 90890 01275 Crankshaft ...

Page 16: ... to remove or install the clutch carrier nut 90890 01362 Flywheel puller This tool is used to remove the generator rotor 90890 01367 Fork seal driver weight This tool is used to install the oil seal dust seal and the outer tube bushing of a front fork leg 90890 01370 Fork seal driver attachment ø36 This tool is used to install the oil seal and the outer tube bushing of the front fork leg 90890 013...

Page 17: ...nstall the crankshaft 90890 01701 Sheave holder This tool is used to hold the generator rotor clutch housing and clutch carrier 90890 03081 Compression gauge This tool is used to measure the engine compression 90890 03112 Pocket tester This tool is used to check the electrical system 90890 03134 Exhaust attachment This tool is used to measure the CO den sity 90890 03141 Timing light This tool is u...

Page 18: ...e valve guides 90890 04065 Valve guide installer ø6 This tool is used to install the valve guides 90890 04066 Valve guide reamer ø6 This tool is used to rebore the new valve guides 90890 04081 Spacer crankshaft installer This tool is used to install the crankshaft 90890 04108 Valve spring compressor attachment This tool is used to remove or install the valve assemblies 90890 04132 Mechanical seal ...

Page 19: ...890 06756 Vacuum pressure pump gauge set This tool is used to check the air cut off valve 90890 11098 Fuel sender removal tool This tool are used to remove the fuel sender 90890 85505 Yamaha bond No 1215 This bond is used to seal two mating sur faces e g crankcase mating surfaces Tool No Tool name Function Illustration ...

Page 20: ...VERSION TABLE 2 18 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 18 TIGHTENING TORQUES 2 19 ENGINE TIGHTENING TORQUES 2 19 CHASSIS TIGHTENING TORQUES 2 21 LUBRICATION POINTS AND LUBRICANT TYPES 2 23 ENGINE LUBRICATION POINTS AND LUBRICANT TYPES 2 23 CHASSIS LUBRICATION POINTS AND LUBRICANT TYPES 2 24 COOLING SYSTEM DIAGRAMS 2 25 CABLE ROUTING 2 26 ...

Page 21: ... 790 mm 31 1 in Overall height 1 380 mm 54 3 in Seat height 775 mm 30 5 in Wheelbase 1 545 mm 60 8 in Minimum ground clearance 113 mm 4 45 in Minimum turning radius 3 600 mm 143 7 in Weight Wet with oil and a full fuel tank 176 kg 388 lb Maximum load total of cargo rider passen ger and accessories 180 kg 397 lb GENERAL SPECIFICATIONS ...

Page 22: ...ecommended fuel Regular unleaded gasoline only Fuel tank capacity Total including reserve 13 0 L 2 86 Imp gal 3 43 US gal Fuel reserve amount 2 0 L 0 44 Imp gal 0 53 US gal Engine oil Lubrication system Wet sump Recommended oil type SAE10W30 SAE10W40 SAE15W40 SAE20W40 or SAE20W50 Recommended engine oil grade API service SG type or higher JASO standard MA Quantity Total amount 1 40 L 1 23 Imp qt 1 ...

Page 23: ...ity 0 70 L 0 62 Imp qt 0 74 US qt Radiator capacity 0 34 L 0 30 Imp qt 0 36 US qt Radiator core Width 229 0 mm 9 02 in Height 111 5 mm 4 39 in Depth 33 0 mm 1 30 in Coolant reservoir capacity up to the maximum level mark 0 26 L 0 23 Imp qt 0 28 US qt Water pump Water pump type Single suction centrifugal pump Reduction ratio 37 22 25 37 1 136 Impeller shaft tilt limit 0 15 mm 0 0059 in Coolant temp...

Page 24: ...mm 1 4550 in Measurement B 30 091 30 191 mm 1 1847 1 1886 in 29 194 mm 1 1494 in Maximum camshaft runout 0 030 mm 0 0012 in Timing chain Model number of links DID SC A 0404A SV 104 Tensioning system Automatic Rocker arms rocker arm shafts Rocker arm inside diameter 12 000 12 018 mm 0 4724 0 4731 in 12 030 mm 0 4736 in Rocker arm shaft outside diameter 11 981 11 991 mm 0 4717 0 4721 in 11 950 mm 0 ...

Page 25: ...4 0 0433 in 1 6 mm 0 06 in Valve margin thickness D Intake 0 80 1 20 mm 0 0315 0 0472 in 0 5 mm 0 02 in Exhaust 0 80 1 20 mm 0 0315 0 0472 in 0 5 mm 0 02 in Valve stem diameter Intake 5 975 5 990 mm 0 2352 0 2358 in 5 940 mm 0 2339 in Exhaust 5 960 5 975 mm 0 2346 0 2352 in 5 920 mm 0 2331 in Valve guide inside diameter Intake 6 000 6 012 mm 0 2362 0 2367 in 6 050 mm 0 2382 in Exhaust 6 000 6 012 ...

Page 26: ...nstalled length valve closed Intake 30 10 mm 1 19 in Exhaust 30 10 mm 1 19 in Spring rate intake K1 10 29 N mm 1 05 kgf mm 58 75 lb in Spring rate intake K2 13 37 N mm 1 36 kgf mm 76 34 lb in Spring rate exhaust K1 10 29 N mm 1 05 kgf mm 58 75 lb in Spring rate exhaust K2 13 37 N mm 1 36 kgf mm 76 34 lb in Compression spring force installed Intake 76 88 N 7 80 9 00 kgf 17 20 19 85 lbf Exhaust 76 8...

Page 27: ...31 66 N mm 3 23 kgf mm 180 78 lb in Spring rate exhaust K1 23 18 N mm 2 36 kgf mm 132 36 lb in Spring rate exhaust K2 31 66 N mm 3 23 kgf mm 180 78 lb in Compression spring force installed Intake 115 133 N 11 73 13 56 kgf 25 85 29 90 lbf Exhaust 115 133 N 11 73 13 56 kgf 25 85 29 90 lbf Spring tilt Intake 2 5 1 6 mm 2 5 0 063 in Exhaust 2 5 1 6 mm 2 5 0 063 in Winding direction Intake Clockwise Ex...

Page 28: ...0 6689 0 6693 in 16 971 mm 0 6681 in Piston pin to piston pin bore clear ance 0 004 0 024 mm 0 0002 0 0009 in 0 074 mm 0 0029 in Piston rings Top ring Ring type Barrel Dimensions B T 1 00 2 60 mm 0 04 0 10 in End gap installed 0 15 0 30 mm 0 0059 0 0118 in 0 45 mm 0 0177 in Ring side clearance 0 040 0 080 mm 0 0016 0 0031 in 0 120 mm 0 0047 in 2nd ring Ring type Taper Dimensions B T 1 00 2 90 mm 0...

Page 29: ...0 08 in Clutch shoe spring free length 31 3 mm 1 23 in Clutch housing inside diameter 145 0 mm 5 71 in 145 5 mm 5 73 in Compression spring free length 102 4 mm 4 03 in 90 0 mm 3 54 in Primary sheave weight outside diam eter 20 0 mm 0 79 in 19 5 mm 0 77 in Clutch in revolution 2 250 2 850 r min Clutch stall revolution 3 700 4 700 r min V belt V belt width 23 0 mm 0 91 in 21 0 mm 0 83 in Transmissio...

Page 30: ...0 Jet needle N425 DVD00 Needle jet 2 6 Pilot air jet 1 125 Pilot outlet 0 85 Pilot jet 35 Bypass 1 0 7 Bypass 2 0 7 Bypass 3 0 7 Bypass 4 0 7 Pilot screw turns out 2 Valve seat size 1 6 Starter jet 1 38 Throttle valve size 10 Float height 17 5 mm 0 69 in Idling condition Engine idling speed 1 550 1 650 r min CO density when air induction sys tem is operating 4 0 CO density when air induction sys t...

Page 31: ...l runout 0 5 mm 0 02 in Wheel axle bending limit 0 03 mm 0 0012 in Rear wheel Wheel type Cast wheel Rim Size 14 MT3 75 Material Aluminum Wheel travel 83 0 mm 3 27 in Wheel runout Maximum radial wheel runout 1 0 mm 0 04 in Maximum lateral wheel runout 0 5 mm 0 02 in Front tire Tire type Tubeless Size 120 70 15 M C 56S or 56P Manufacturer model MICHELIN GOLD STANDARD PIRELLI GTS23 Tire pressure cold...

Page 32: ...Brake pad lining thickness inner 4 5 mm 0 18 in 0 5 mm 0 02 in Brake pad lining thickness outer 4 5 mm 0 18 in 0 5 mm 0 02 in Master cylinder inside diameter 12 70 mm 0 50 in Caliper cylinder inside diameter 25 00 mm 1 and 28 00 mm 1 0 98 in 1 and 1 10 in 1 Rear brake Brake type Single disc brake Operation Left hand operation Recommended fluid DOT 4 Brake disc Diameter thickness 240 0 5 0 mm 9 45 ...

Page 33: ... 921 in Spring rate K1 8 00 N mm 0 82 kgf mm 45 68 lb in Spring rate K2 13 60 N mm 1 39 kgf mm 77 65 lb in Spring stroke K1 0 80 0 mm 0 3 15 in Spring stroke K2 80 0 110 0 mm 3 15 4 33 in Inner tube outer diameter 36 0 mm 1 42 in Inner tube bending limit 0 2 mm 0 008 in Optional spring available No Fork oil Recommended oil Fork oil 15W or equivalent Quantity each front fork leg 195 0 cm3 6 86 Imp ...

Page 34: ... 42 in Installed length 249 mm 9 80 in Spring rate K1 8 00 N mm 0 82 kgf mm 45 68 lb in Spring rate K2 13 70 N mm 1 40 kgf mm 78 23 lb in Spring rate K3 20 30 N mm 2 07 kgf mm 115 91 lb in Spring stroke K1 0 42 0 mm 0 1 65 in Spring stroke K2 42 0 72 5 mm 1 65 2 85 in Spring stroke K3 72 5 95 0 mm 2 85 3 74 in Optional spring available No Spring preload adjusting positions Minimum 1 Standard 1 Max...

Page 35: ... system System type AC magneto Model manufacturer 5425 H Mitsuba Standard output 14 0 V 235 W at 5 000 r min Stator coil resistance 0 385 0 415 Ω at 20 C 68 F Rectifier regulator Regulator type Semi conductor short circuit Model manufacturer SH678 11 SHINDENGEN No load regulated voltage 14 1 14 9 V Rectifier capacity 22 0 A Withstand voltage 200 0 V Battery Model YTX9 BS Voltage capacity 12 V 8 0 ...

Page 36: ... F Commutator diameter 28 0 mm 1 10 in 27 0 mm 1 06 in Mica undercut depth 0 7 mm 0 028 in Starter relay Model manufacturer MS5F 631 JIDECO Amperage 180 0 A Coil resistance 4 18 4 62 Ω at 20 C 68 F Horn Horn type Plane Quantity 1 pc Model manufacturer YF 12 NIKKO Maximum amperage 3 0 A Performance 105 113 dB 2 m Coil resistance 1 15 1 25 Ω at 20 C 68 F Turn signal hazard relay Relay type Full tran...

Page 37: ...M33211 M05 Coil resistance 96 Ω at 20 C 68 F Coolant temperature sensor Model manufacturer C40 1734 PRICOL Resistance at 80 C 176 F 69 0 Ω Resistance at 100 C 212 F 37 2 Ω Speed sensor Output voltage When sensor is on DC 4 8 V or more When sensor is off DC 0 6 V or less Fuses Main fuse 30 0 A Headlight fuse 15 0 A Signaling system fuse 15 0 A Ignition fuse 5 0 A Radiator fan motor fuse 10 0 A CDI ...

Page 38: ...fied tightening torque specifications require clean dry threads Com ponents should be at room temperature A Distance between flats B Outside thread diameter Ex METRIC MULTIPLIER IMPERIAL mm 0 03937 in 2 mm 0 03937 0 08 in METRIC TO IMPERIAL Tighten ing torque Metric unit Multiplier Imperial unit 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 o...

Page 39: ... intake side Bolt M6 1 10 1 0 7 2 Water pump housing cover Bolt M6 2 10 1 0 7 2 Water pump housing Bolt M6 2 10 1 0 7 2 Coolant drain bolt Bolt M6 1 10 1 0 7 2 Water pump outlet pipe Bolt M6 2 7 0 7 5 1 Thermostat cover Bolt M6 2 10 1 0 7 2 Oil pump assembly Bolt M6 2 7 0 7 5 1 Oil strainer cover M35 1 32 3 2 23 Intake manifold Bolt M6 2 10 1 0 7 2 Carburetor clamp screw Screw M6 1 2 0 2 1 4 Throt...

Page 40: ...up coil Bolt M5 2 7 0 7 5 1 LT Starter motor Bolt M6 2 10 1 0 7 2 Coolant temperature sensor Pt 1 8 1 8 0 8 5 8 LT Air filter case mounting bolt Bolt M6 2 9 0 9 6 5 Exhaust pipe nut Nut M8 2 20 2 0 14 Muffler mounting bolt Bolt M12 3 65 6 5 47 Muffler joint bolt Bolt M8 1 14 1 4 10 Coolant reservoir Bolt M6 2 7 0 7 5 1 Radiator Bolt M6 2 10 1 0 7 2 Thermo switch auto choke M18 1 30 3 0 22 Thermo s...

Page 41: ... 43 Front wheel axle pinch bolt M6 9 0 9 6 5 Rear wheel axle nut M14 135 13 5 98 Front brake caliper and outer tube M8 23 2 3 17 Brake pad pin M8 12 1 2 8 7 Brake caliper retaining nut M8 22 2 2 16 Brake caliper housing bolt M10 45 4 5 32 Front brake disc and wheel hub M6 12 1 2 8 7 LT Rear brake disc and wheel hub M8 23 2 3 17 LT Brake hose union bolt M10 23 2 3 17 Bleed screw front brake caliper...

Page 42: ...all the lock washer 5 Hold the lower and center ring nuts and then tighten the upper ring nut 75 Nm 7 5 m kg 54 ft lb with a torque wrench and the steering nut wrench Rear brake master cylinder and holder M6 7 0 7 5 1 Rear brake master cylinder and brake lever M6 10 1 0 7 2 Grip end M16 26 2 6 19 Front cowling inner panel and frame M6 7 0 7 5 1 Radiator cover and frame M6 7 0 7 5 1 Rear side cover...

Page 43: ... Valve stems intake and exhaust M Valve stem ends intake and exhaust M Valve stem seals M Rocker arm shafts E Rocker arm inner surface M Oil pump assembly shaft E Oil pump assembly gasket LS Oil pump rotors inner and outer E Starter clutch idle gear thrust surfaces E Starter clutch idle gear shaft E Starter clutch gear thrust surfaces E Starter clutch gear inner surface E Main axle thrust surfaces...

Page 44: ...r LS Throttle cable end LS Handlebar grip inner surface Rubber adhesive Throttle grip inner surface and throttle cables LS Seat hinge pin LS Seat damper LS Front wheel oil seal lip LS Speed sensor oil seal lip LS Sidestand pivoting point and metal to metal moving parts LS Centerstand shaft pivoting point and metal to metal moving parts LS Centerstand stopper pivoting point LS Centerstand and sides...

Page 45: ...oolant reservoir hose 4 Coolant reservoir 5 Thermostat inlet hose 6 Thermostat outlet hose 7 Water pump 8 Radiator inlet outlet pipe 9 Radiator inlet hose 0 Radiator outlet hose A Radiator cap B Water pump inlet hose È 3 4 mm 0 12 0 16 in A B B A 1 2 3 4 5 6 7 8 8 9 0 A B 6 8 8 9 0 1 2 3 A 6 È È ...

Page 46: ...turn signal light coupler right 8 Front brake light switch lead 9 Throttle cable decelerator cable 0 Throttle cable accelerator cable È Connect the air temperature sensor coupler and then place the air temperature sensor in the steering head pipe É Connect the meter assembly coupler and then install the rubber cover Ê Apply grease to the throttle cable ends and rub ber covers A C C B C C A B 1 0 2...

Page 47: ...er connecting the throttle cables check the operation of the throttle grip and make sure that it returns to its home position easily after being released A C C B C C A B 1 0 2 0 9 0 9 2 0 9 7 6 2 4 5 1 3 1 8 9 8 7 6 5 4 3 È Ë Ê Ê É ...

Page 48: ...tor relay A Speed sensor lead B Radiator filler hose C Radiator fan motor coupler D Fuel pump coupler E Thermo switch radiator fan motor F Thermo switch auto choke G Coolant reservoir hose H Fuel pump I Fuel hose fuel tank to fuel pump J Fuel hose fuel pump to carburetor K Ground lead L Fuel sender lead K Ñ Ò Ó Ô Õ È Ö L M N O P 1 1 O P 3 Q 1 2 3 4 5 6 8 9 0 A C D G H I J 7 É Ì Ê Ï Î Ð A B A B È E...

Page 49: ...tle slack in the speed sensor lead since the front fork moves 10 mm 0 040 in vertically Ê Fasten the front brake hose and speed sensor lead with a holder making sure to fasten the front brake hose at the white tape Ë 15 mm 0 60 in Ì To horn and rectifier regulator Í Connect each thermo switch connectors radia tor fan motor to the switch terminals of the same color K Ñ Ò Ó Ô Õ È Ö L M N O P 1 1 O P...

Page 50: ...ie Ñ Fasten the wire harness rear brake pipe starter motor lead and sidestand switch lead with a plastic locking tie Ò Fasten the wire harness and starter motor lead to the frame with a plastic locking tie Ó Fasten the rear brake pipe with a plastic locking tie Ô Fasten the wire harness relay leads headlight relay radiator fan motor relay fuel pump relay and starting circuit cut off relay starter ...

Page 51: ...tion the tie between the blue tape sections of the wire harness and to fasten the tie around the lead protectors not the leads them selves Fasten the speed sensor lead with a plastic lock ing tie making sure to install the tie around the protective sleeve of the lead not the lead itself and then connect the speed sensor coupler Ø Cover the anti theft alarm LED connector OPTION and auxiliary DC jac...

Page 52: ... 9 Coolant reservoir hose È Route the license plate light lead as shown in the illustration É Fasten the wire harness tail brake light lead and license plate light lead with a plastic locking tie Ê Fasten the wire harness with the holder Ë Fasten the wire harness starter motor lead pickup coil stator assembly lead with to the frame with a plastic locking tie 1 È É A 2 3 4 6 5 6 7 8 9 Ê Ë Ì A Í ...

Page 53: ... wire harness starter motor lead rear brake pipe pickup coil stator assembly lead to the frame with a plastic locking tie Í Connect each ignition coil connectors to the coil terminals of the same color 1 È É A 2 3 4 6 5 6 7 8 9 Ê Ë Ì A Í ...

Page 54: ... switch lead B Fuel hose fuel pump to carburetor C Fuel tank overflow hose È Pass the battery lead through the opening in the battery box É Route the horn lead to the rear of the frame Ê Fasten the seat lock cable and throttle cables to the frame with a plastic locking tie Ë Fasten the seat lock cable throttle cables and sidestand switch lead to the frame with a plastic locking tie 1 È É Ê 2 3 4 5...

Page 55: ...5 SPEC CABLE ROUTING Ì Fasten the sidestand switch lead to the frame with a plastic locking tie Í Pass the fuel tank overflow hose through the hole in the under cover 1 È É Ê 2 3 4 5 6 7 8 9 0 C A B Ë Ì Í ...

Page 56: ... OPTION 9 Anti theft alarm OPTION È Fasten the seat lock cable and throttle cables with a plastic locking tie making sure to fasten the throttle cables at the mark É Pass the seat lock cable through the frame tube Ê Route the carburetor overflow hose to the out side of the water pump Ë Fasten the anti theft alarm lead OPTION and tail brake light assembly lead left to the frame with a plastic locki...

Page 57: ...E ROUTING Ì Fasten the tail brake light assembly lead left to the frame with a plastic locking tie Í Fasten the anti theft coupler OPTION to the frame with a plastic locking tie 1 2 6 5 4 7 8 9 Ì Ë Í 3 3 4 Ê È É A A ...

Page 58: ...e 6 CDI unit 7 Starter relay 8 Ground coupler 9 Headlight assembly coupler 0 Rectifier regulator A Horn B Speed sensor coupler C Main switch coupler D Turn signal relay E Seat lock cable È To wire harness É Pass the speed sensor lead through the hole in the inner fender É È E D C B A 9 8 7 6 5 4 3 2 1 0 ...

Page 59: ...hose 0 Auto choke unit lead A Air induction system vacuum hose B Fuel sender lead È Fasten the sidestand switch lead to the frame cross member with a plastic locking tie É Route the fuel hose fuel tank to fuel pump and fuel hose fuel pump to carburetor over the fuel sender lead Ê After connecting the pickup coil stator assembly coupler slide the boot over the couplers as shown the illustration Í Ë...

Page 60: ... making sure to align the white tape on the starter motor lead with the holder Ì Pass the auto choke unit lead and air induction system vacuum hose with a plastic locking tie Í Fasten the grommet on the fuel hose fuel pump to carburetor with the holder Í Ë Ê É Ì A 0 9 8 7 6 5 4 3 2 1 È B ...

Page 61: ...AND ADJUSTING THE EXHAUST GAS AT IDLE 3 13 ADJUSTING THE THROTTLE CABLE FREE PLAY 3 15 CHECKING THE SPARK PLUG 3 16 CHECKING THE IGNITION TIMING 3 17 MEASURING THE COMPRESSION PRESSURE 3 19 CHECKING THE ENGINE OIL LEVEL 3 21 CHANGING THE ENGINE OIL 3 22 CHANGING THE FINAL TRANSMISSION OIL 3 24 REPLACING THE AIR FILTER ELEMENT 3 25 CLEANING THE V BELT CASE AIR FILTER ELEMENT 3 26 CHECKING THE FUEL ...

Page 62: ... THE STEERING HEAD 3 37 CHECKING THE FRONT FORK 3 39 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLIES 3 40 CHECKING THE TIRES 3 40 CHECKING THE WHEELS 3 43 CHECKING AND LUBRICATING THE CABLES 3 44 LUBRICATING THE SIDESTAND 3 44 LUBRICATING THE CENTERSTAND 3 44 ELECTRICAL SYSTEM 3 45 CHECKING AND CHARGING THE BATTERY 3 45 CHECKING THE FUSES 3 51 REPLACING THE HEADLIGHT BULBS 3 53 ADJUSTING THE HEADLIGH...

Page 63: ... JOB ODOMETER READING 1000 Km ANNUAL CHECK 1 10 20 30 40 1 Fuel line Check fuel and vacuum hoses for cracks or dam age 2 Spark plug Check condition Clean and regap Replace 3 Valves Check valve clearance Adjust 4 Air filter element Replace 5 V belt case air fil ter elements Clean Replace 6 Front brake Check operation fluid level and vehicle for fluid leakage Replace brake pads Whenever worn to the ...

Page 64: ...dling speed 19 Engine oil Change When the oil change indicator light comes on every 3000 km Check oil level and vehicle for oil leakage Every 3000 km 20 Engine oil strainer Clean 21 Cooling system Check coolant level and vehicle for coolant leak age Change Every 3 years 22 Final transmission oil Check vehicle for oil leakage Change 23 V belt Replace Every 20000 km 24 Front and rear brake switches ...

Page 65: ...7 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib 4 Order Job Part Q ty Remarks Removing the seat and side covers Remove the parts in the order listed 1 Seat 1 2 Storage box 1 3 Grab bar 2 4 Rear cover 1 5 Tail brake light assembly coupler left and right 2 Disconnect 6 Rear side cover left and right 2 7 Tail brake light assembly left and right 2 8 License plate light coupler 1 Disconnect 9 Mudguard 1 For instal...

Page 66: ...Removing the footrest board Remove the parts in the order listed 1 Center panel 1 left and right 2 2 Protector left and right 2 3 Center panel 2 left and right 2 4 Footrest board mat left and right 2 5 Front panel left and right 2 6 Fuel tank cap 1 7 Seat damper 1 8 Footrest board 1 9 Fuel tank overflow hose 1 10 Under cover 1 For installation reverse the removal pro cedure ...

Page 67: ...ignal light assembly 1 2 Front turn signal light coupler 2 Disconnect 3 Windshield 1 4 Rearview mirror left and right 2 5 Handlebar upper cover right switch coupler 1 Disconnect 6 Handlebar upper cover left switch cou pler 1 Disconnect 7 Handlebar upper cover with meter assembly 1 8 Meter assembly coupler 1 Disconnect 9 Handlebar lower cover 1 For installation reverse the removal pro cedure ...

Page 68: ... 7 m kg 5 1 ft Ib Order Job Part Q ty Remarks Removing the storage compartment Remove the parts in the order listed 1 Upper panel 1 2 Headlight assembly coupler 1 Disconnect 3 Front cowling 1 4 Battery cover 1 5 Storage compartment 1 For installation reverse the removal pro cedure ...

Page 69: ...marks Removing the air filter case assem bly Remove the parts in the order listed Storage box Refer to COVERS AND PANELS 1 Cylinder head breather hose 1 2 Air induction system hose air filter case to air cut off valve assembly 1 3 Air filter case assembly 1 For installation reverse the removal pro cedure ...

Page 70: ...on a cold engine at room temperature When the valve clearance is to be measured or adjusted the piston must be at top dead center TDC on the compression stroke 1 Remove storage box footrest board Refer to COVERS AND PANELS 2 Remove V belt case air filter cover 1 3 Remove spark plug tappet covers intake and exhaust 1 camshaft sprocket cover 2 1 2 1 4 Remove timing mark accessing plug 1 1 ...

Page 71: ... at TDC on the compres sion stroke align the I mark a on the camshaft sprocket with the stationary pointer b on the cylinder head c Align the I mark c on the generator rotor with the stationary pointer d on the genera tor cover d Measure the valve clearance with a thick ness gauge 1 Out of specification Adjust Valve clearance cold Intake valve 0 08 0 12 mm 0 0031 0 0047 in Exhaust valve 0 16 0 20 ...

Page 72: ...arance is still out of specifica tion repeat all of the valve clearance adjust ment steps until the specified clearance is obtained 7 Install timing mark accessing plug 8 Install camshaft sprocket cover O rings tappet covers intake and exhaust spark plug 9 Install V belt case air filter cover 10 Install footrest board storage box Refer to COVERS AND PANELS Direction a Valve clearance is increased ...

Page 73: ...utes 3 Connect engine tachometer to the spark plug lead 4 Check engine idling speed Out of specification Adjust 5 Adjust engine idling speed a Turn the pilot screw 1 in or out until it is lightly seated b Turn the pilot screw out the specified num ber of turns c Turn the throttle stop screw 2 in direction a or b until the specified engine idling speed is obtained Engine idling speed 1 550 1 650 r ...

Page 74: ...induction system is operating 1 Stand the vehicle on a level surface NOTE Place the vehicle on a suitable stand Make sure that the vehicle is upright 2 Remove storage box Refer to COVERS AND PANELS 3 Remove exhaust pipe bolt 1 1 4 Connect temperature probe tester 1 to the engine oil drain bolt engine tachometer to the spark plug lead exhaust attachment 2 to the exhaust pipe 5 Start the engine and ...

Page 75: ...ion system Refer to AIR INDUCTION SYSTEM in chapter 7 CO density when air induction system is operating 4 0 Reference value CHECKING AND ADJUSTING THE EXHAUST GAS AT IDLE Check the exhaust gas at idle when the air induction system is not operating 1 Stand the vehicle on a level surface NOTE Place the vehicle on a suitable stand Make sure that the vehicle is upright The air filter element should be...

Page 76: ...on NOTE Crimp the hose a running from the lead valve to the air cut off valve to prevent the air cut off valve from operating Be sure not to damage the hose while crimping it 6 Start the engine and warm it up until the specified oil temperature is reached 7 Measure engine idling speed Out of specification Adjust Refer to ADJUSTING THE ENGINE IDLING SPEED 8 Connect CO tester 1 to the exhaust attach...

Page 77: ... by adjust ing the pilot screw overhaul the carburetor and check the air filter If there are no problems found with the carbu retor or air filter replace the muffler assembly 11 Install footrest board Refer to COVERS AND PANELS CO density when air induction system is not operating 6 0 Pilot screw 2 turns out 1 EAS00058 ADJUSTING THE THROTTLE CABLE FREE PLAY 1 Check throttle cable free play a Out o...

Page 78: ... cable free play start the engine and turn the handlebar to the right or left to ensure that this does not cause the engine idling speed to change 3 Install front turn signal light assembly Refer to COVERS AND PANELS Direction a Throttle cable free play is increased Direction b Throttle cable free play is decreased 2 3 1 a b EAS00060 CHECKING THE SPARK PLUG 1 Remove storage box Refer to COVERS AND...

Page 79: ...cation Regap 8 Install spark plug NOTE Before installing the spark plug clean the spark plug and gasket surface 9 Connect spark plug cap 10 Install storage box Refer to COVERS AND PANELS EAS00064 CHECKING THE IGNITION TIMING NOTE Prior to checking the ignition timing check the wiring connections of the entire ignition sys tem Make sure that all connections are tight and free of corrosion 1 Stand t...

Page 80: ...he engine warm it up for several min utes and then let it run at the specified engine idling speed b Check that the stationary pointer a on the generator cover is within the firing range b on the generator rotor Incorrect firing range Check the ignition system NOTE The ignition timing is not adjustable 6 Install timing mark accessing plug 7 Install storage box Refer to COVERS AND PANELS Engine idl...

Page 81: ... valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEARANCE 3 Start the engine warm it up for several min utes and then turn it off 4 Disconnect spark plug cap 5 Remove spark plug CAUTION Before removing the spark plug use com pressed air to blow away any dirt accumu lated in the spark plug well to prevent it from falling into the cylinder 6 Install compression gauge 1 Comp...

Page 82: ...surfaces and piston crown for carbon deposits Carbon deposits Eliminate d If the compression pressure is below the minimum specification pour a teaspoonful of engine oil into the spark plug bore and measure again Refer to the following table Compression pressure at sea level Minimum 1 120 kPa 11 2 kg cm2 159 3 psi Standard 1 400 kPa 14 0 kg cm2 199 1 psi Maximum 1 570 kPa 15 7 kg cm2 223 3 psi Com...

Page 83: ... Wipe the dipstick 1 clean insert it into the oil filler hole without screwing it in and then remove it to check the oil level The engine oil level should be between the minimum level mark a and maximum level mark b Below the minimum level mark Add the recommended engine oil to the proper level NOTE Before checking the engine oil level wait a few minutes until the oil has settled Do not screw the ...

Page 84: ...AND PANELS 2 Start the engine warm it up for several min utes and then turn it off 3 Place a container under the engine oil drain bolt 4 Remove engine oil filler cap 1 engine oil drain bolt 2 along with the gasket 5 Drain engine oil completely from the crankcase 6 If the oil strainer is also to be cleaned per form the following procedure a Remove the oil strainer cover 1 and oil strainer 2 b Insta...

Page 85: ...check bolt 1 b Start the engine and keep it idling until engine oil starts to seep from the oil check bolt If no engine oil comes out after one minute turn the engine off so that it will not seize c Check the engine oil passages the oil filter element and the oil pump for damage or leakage Refer to OIL PUMP in chapter 5 d Start the engine after solving the problem s and check the engine oil pressu...

Page 86: ...ge indicator must be reset as soon as possible so that it comes on for the next periodic maintenance and lubrication interval 16 Install footrest board storage box Refer to COVERS AND PANELS CHANGING THE FINAL TRANSMISSION OIL 1 Stand the vehicle on a level surface NOTE Place the vehicle on a centerstand Make sure that the vehicle is upright 2 Start the engine warm it up for several min utes and t...

Page 87: ...al min utes and then turn it off 10 Check transmission case for transmission oil leaks Recommended oil SAE 10W30 type SE motor oil Oil quantity 0 25 L 0 22 Imp qt 0 26 US qt T R 22 Nm 2 2 m kg 16 ft lb EAS00089 REPLACING THE AIR FILTER ELEMENT NOTE On the bottom of the air filter case is a check hoses If dust or water or both collects in this hose remove the clamp from it and then remove the plug ...

Page 88: ...ate the engine without the air fil ter element installed Unfiltered air will cause rapid wear of engine parts and may damage the engine Operating the engine without the air filter element will also affect the carburetor tuning leading to poor engine performance and possible overheat ing EAS00091 CLEANING THE V BELT CASE AIR FILTER ELEMENT 1 Remove center panel 1 left Refer to COVERS AND PANELS 2 R...

Page 89: ...V belt case air filter cover 6 Install center panel 1 left Refer to COVERS AND PANELS EAS00096 CHECKING THE FUEL AND VACUUM HOSES 1 Remove storage box Refer to COVERS AND PANELS 2 Check fuel hose fuel tnak to fuel pump 1 fuel hose fuel pump to carburetor 2 air induction system vacuum hose 3 Cracks damage Replace Loose connection Connect properly 3 Install storage box Refer to COVERS AND PANELS 1 3...

Page 90: ...e routed correctly 3 Install storage box Refer to COVERS AND PANELS 1 2 EAS00100 CHECKING THE EXHAUST SYSTEM 1 Remove center panel 1 right Refer to COVERS AND PANELS 2 Check exhaust pipe 1 muffler 2 Cracks damage Replace gaskets Exhaust gas leaks Replace 3 Check tightening torque 4 Install center panel 1 right Refer to COVERS AND PANELS T R Exhaust pipe nut 3 20 Nm 2 0 m kg 14 ft lb Muffler joint ...

Page 91: ...lant to the proper level CAUTION 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 if dis tilled water is not available soft water may be used 3 Start the engine warm it up for several min utes and then turn it off 4 Check coolan...

Page 92: ...7 thermostat outlet hose 8 thermostat inlet hose 9 Cracks damage Replace 3 Install storage box footrest board Refer to COVERS AND PANELS 4 5 1 3 2 6 7 9 8 EAS00105 CHANGING THE COOLANT 1 Remove battery cover center panel 1 right footrest board mat right storage box Refer to COVERS AND PANELS 2 Remove coolant reservoir cap 1 3 Disconnect coolant reservoir hose 2 4 Drain coolant completely from the ...

Page 93: ...s 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 to allow any residual pressure to escape When the hissing sound has stopped remove the cap 1 6 Remove coolant drain bolt 1 along with the copper washer 7 Drain coolant completely from the engine and radiator 8 Install copper washer coolant drain bolt 9 Con...

Page 94: ... for aluminum engines Mixing ratio 1 1 antifreeze water Quantity Radiator and engine capacity 0 70 L 0 62 Imp qt 0 74 US qt Coolant reservoir capacity 0 26 L 0 23 Imp qt 0 28 US qt Up to the maximum level mark 1 Handling notes for coolant Coolant is potentially harmful and should be handled with special care WARNING If coolant splashes in your eyes thor oughly wash them with water and consult a do...

Page 95: ...mediately wash them with water Do not mix different types of antifreeze 11 Install radiator cap 12 Fill coolant reservoir with the recommended coolant to the maxi mum level mark a 13 Tighten air bleed bolt coolant 14 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 checking ...

Page 96: ...d poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock CAUTION Brake fluid may damage pain...

Page 97: ...Refer to REPLACING THE REAR BRAKE PADS in chapter 4 È Front brake É Rear brake EAS01320 CHECKING THE FRONT AND REAR BRAKE HOSES The following procedure applies to all of the brake hoses and brake hose clamps 1 Check brake hoses 1 Cracks damage wear Replace È Front brake É Rear brake 2 Check brake hose clamps Loose Tighten the clamp bolt 3 Hold the vehicle upright and apply the brake several times ...

Page 98: ...aution could allow air to enter the hydraulic brake system considerably length ening the bleeding procedure If bleeding is difficult it may be necessary to let the brake fluid settle for a few hours Repeat the bleeding procedure when the tiny bubbles in the hose have disappeared 1 Bleed hydraulic brake system a Fill the brake master cylinder reservoir to the proper level with the recommended brake...

Page 99: ...oir to the proper level with the recommended brake fluid Refer to CHECKING THE BRAKE FLUID LEVEL WARNING After bleeding the hydraulic brake system check the brake operation T R Bleed screw front brake caliper 6 Nm 0 6 m kg 4 3 ft lb Bleed screw rear brake caliper 6 Nm 0 6 m kg 4 3 ft lb EAS01480 CHECKING AND ADJUSTING THE STEERING HEAD 1 Stand the vehicle on a level surface WARNING Securely suppor...

Page 100: ...ench at a right angle to the steering nut wrench c Loosen the lower ring nut 4 1 4 of turn and then tighten it to specification with a steer ing nut wrench WARNING Do not overtighten the lower ring nut d Check the steering head for looseness or binding by turning the front fork all the way in both directions If any binding is felt remove the lower bracket and check the upper and lower bearings Ref...

Page 101: ...nuts with a steering nut wrench and tighten the upper ring nut with a steering nut wrench 5 Install handlebar lower holder Refer to STEERING HEAD in chapter 4 EAS01510 CHECKING THE FRONT FORK 1 Stand the vehicle on a level surface WARNING Securely support the vehicle so that there is no danger of it falling over 2 Check inner tube Damage scratches Replace oil seal Oil leakage Replace 3 Hold the ve...

Page 102: ...esult in poor handling and loss of stability Spring preload CAUTION Never go beyond the maximum or mini mum adjustment positions 1 Adjust spring preload a Turn the adjusting ring 1 in direction a or b Align the desired position on the adjusting ring with the stopper 2 Direction a Spring preload is increased suspension is harder Direction b Spring preload is decreased suspension is softer Adjusting...

Page 103: ...VERLOAD THE VEHICLE Total weight of rider passenger cargo and accessories WARNING It is dangerous to ride with a worn out tire When the tire tread reaches the wear limit replace the tire immediately Basic weight with oil and a full fuel tank 176 kg 388 lb Maximum load 180 kg 397 lb Cold tire pressure Front Rear Up to 90 kg 198 lb load 190 kPa 1 90kgf cm2 28 psi 220 kPa 2 20kgf cm2 32 psi 90 kg 198...

Page 104: ...e tube as soon as possible with a good quality replacement È Tire É Wheel After extensive tests the tires listed below have been approved by Yamaha Motor España S A Ltd for this model The front and rear tires should always be by the same manufacturer and of the same design No guarantee concerning handling characteristics can be given if a tire combination other than one approved by Yamaha is used ...

Page 105: ...fore any high speed riding is done NOTE For tires with a rotation direction mark 1 Install the tire with the mark pointing in the direction of the wheel rotation EAS01680 CHECKING THE WHEELS The following procedure applies to both of the wheels 1 Check wheel Damage out of round Replace WARNING Never attempt to make any repairs to the wheel NOTE After a tire or wheel has been changed or replaced al...

Page 106: ...r cable Damage Replace 2 Check cable operation Rough movement Lubricate NOTE Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suitable lubricating device Recommended lubricant Engine oil or a suitable cable lubricant EAS01720 LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal to metal moving parts of the sidestand Recommended lubricant Lithi...

Page 107: ...yte as it can cause severe burns or permanent eye injury FIRST AID IN CASE OF BODILY CONTACT EXTERNAL Skin Wash with water Eyes Flush with water for 15 minutes and get immediate medical attention INTERNAL Drink large quantities of water or milk fol lowed with milk of magnesia beaten egg or vegetable oil Get immediate medical attention CAUTION This is a sealed battery Never remove the sealing caps ...

Page 108: ...1 3 Disconnect battery leads from the battery terminals CAUTION CAUTION First disconnect the negative battery lead 1 and then the positive battery lead 2 4 Remove battery 5 Check battery charge a Connect a pocket tester to the battery termi nals NOTE NOTE The charge state of an MF battery can be checked by measuring its open circuit volt age i e the voltage when the positive termi nal is disconnec...

Page 109: ...ttery mounted on the vehicle disconnect the negative battery lead from the battery terminal To reduce the chance of sparks do not plug in the battery charger until the bat tery charger leads are connected to the battery Before removing the battery charger lead clips from the battery terminals be sure to turn off the battery charger Make sure the battery charger lead clips are in full contact with ...

Page 110: ...ct the battery charger and let the battery cool before reconnecting it Hot batteries can explode As shown in the following illustration the open circuit voltage of an MF battery sta bilizes about 30 minutes after charging has been completed Therefore wait 30 minutes after charging is completed before measuring the open circuit volt age ...

Page 111: ...it voltage 12 8 V Charging is complete 12 0 12 7 V Recharging is required Under 12 0 V Replace the battery Charger Ammeter Set the charging voltage to 16 17 V If the charging voltage is lower charging will be insufficient if it is higher the battery will be over charged NOTE Monitor the amperage for 3 5 minutes Is the standard charg ing amperage exceeded YES Set the timer to the charging time dete...

Page 112: ...measuring its open circuit voltage NOTE YES NO Charge the battery until the charging voltage reaches 15 V Set the charging time to a maxi mum of 20 hours NOTE This type of battery charger cannot charge an MF battery A variable volt age charger is recommended Constant amperage chargers are not suitable for charging MF batteries CAUTION Leave the battery unused for more than 30 minutes before measur...

Page 113: ...th a wire brush Loose connection Connect properly 10 Lubricate battery terminals 11 Install battery bracket 12 Install battery cover Refer to COVERS AND PANELS Recommended lubricant Dielectric grease 2 1 T R 23 Nm 2 3 m kg 17 ft lb EAS01810 CHECKING THE FUSES The following procedure applies to all of the fuses CAUTION To avoid a short circuit always set the main switch to OFF when checking or repl...

Page 114: ...main switch to OFF b Install a new fuse of the correct amperage rating c Set on the switches to verify if the electrical circuit is operational d If the fuse immediately blows again check the electrical circuit Pocket tester 90890 03112 Fuses Amperage rating Q ty Main 30 A 1 Headlight 15 A 1 Signaling system 15 A 1 Radiator fan motor 10 A 1 Ignition 5 A 1 CDI unit 5 A 1 Backup meter assembly 5 A 1...

Page 115: ...ion and could possibly cause a fire 4 Install upper panel Refer to COVERS AND PANELS EAS01830 REPLACING THE HEADLIGHT BULBS The following procedure applies to both of the headlight bulbs 1 Remove upper panel Refer to COVERS AND PANELS 2 Disconnect headlight coupler 1 3 Remove headlight bulb cover 2 4 Detach headlight bulb holder 1 5 Remove headlight bulb WARNING Since the headlight bulb gets extre...

Page 116: ... and the luminous flux will be adversely affected If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 7 Attach headlight bulb holder 8 Install headlight bulb cover 9 Connect headlight coupler 10 Install upper panel Refer to COVERS AND PANELS New EAS01860 ADJUSTING THE HEADLIGHT BEAM 1 Adjust headlight beam vertically a Turn the adjusting scr...

Page 117: ...RAKE MASTER CYLINDER 4 25 DISASSEMBLING THE REAR BRAKE MASTER CYLINDER 4 25 CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS 4 26 ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER 4 27 ASSEMBLING AND INSTALLING THE REAR BRAKE MASTER CYLINDER 4 29 FRONT BRAKE CALIPER 4 33 REAR BRAKE CALIPER 4 36 DISASSEMBLING THE FRONT BRAKE CALIPER 4 38 DISASSEMBLING THE REAR BRAKE CALIPER 4 39 CHECKING ...

Page 118: ...G HEAD 4 67 INSTALLING THE STEERING HEAD 4 68 REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM 4 69 REMOVING THE REAR SHOCK ABSORBER ASSEMBLIES 4 71 CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES 4 71 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLIES 4 72 REMOVING THE SWINGARM 4 72 CHECKING THE SWINGARM 4 73 INSTALLING THE SWINGARM 4 73 ...

Page 119: ... Job Part Q ty Remarks Removing the front wheel and brake disc Remove the parts in the order listed 1 Front wheel axle pinch bolt 2 Loosen Refer to REMOVING THE FRONT WHEEL and INSTALLING THE FRONT WHEEL 2 Front wheel axle 1 3 Front wheel 1 4 Speed sensor 1 5 Spacer 1 6 Front brake disc 1 For installation reverse the removal pro cedure FRONT WHEEL AND BRAKE DISC ...

Page 120: ...RONT WHEEL AND BRAKE DISC EAS05130 Order Job Part Q ty Remarks Disassembling the front wheel Remove the parts in the order listed 1 Oil seal 1 2 Bearing 2 3 Collar 1 For assembly reverse the disassembly procedure ...

Page 121: ... a suitable stand so that the front wheel is elevated 3 Remove front wheel speed sensor spacer NOTE NOTE Do not squeeze the front brake lever when removing the front wheel EAS05250 CHECKING THE FRONT WHEEL 1 Check wheel axle Roll the wheel axle on a flat surface Bends Replace WARNING Do not attempt to straighten a bent wheel axle 2 Check tire front wheel Damage wear Replace Refer to CHECKING THE T...

Page 122: ...l seal a Clean the outside of the front wheel hub b Remove the oil seal 1 with a flat head screwdriver NOTE To prevent damaging the wheel place a rag 2 between the screwdriver and the wheel sur face c Remove the wheel bearings 3 with a gen eral bearing puller d Install the new wheel bearings and oil seal in the reverse order of disassembly CAUTION Do not contact the wheel bearing inner race 4 or b...

Page 123: ...ection turn the handlebar to the left or right to ensure that the front wheel is sta tionary c Remove the brake caliper d Hold the dial gauge at a right angle against the brake disc surface e Measure the deflection 1 5 mm 0 059 in below the edge of the brake disc Brake disc deflection limit maxi mum Front 0 10 mm 0 0039 in Rear 0 15 mm 0 0059 in 3 Measure brake disc thickness Measure the brake dis...

Page 124: ...cification repeat the adjustment steps until the brake disc deflection is within specification f If the brake disc deflection cannot be brought within specification replace the brake disc T R Brake disc bolt 12 Nm 1 2 m kg 8 7 ft lb LOCTITE EAS05480 ADJUSTING THE FRONT WHEEL STATIC BALANCE NOTE After replacing the tire wheel or both the front wheel static balance should be adjusted Adjust the fron...

Page 125: ... the marks come to rest is the front wheel s heavy spot X 3 Adjust front wheel static balance a Install a balancing weight 1 onto the rim exactly opposite the heavy spot X NOTE Start with the lightest weight b Turn the front wheel 90 so that the heavy spot is positioned as shown c If the heavy spot does not stay in that posi tion install a heavier weight d Repeat steps b and c until the front whee...

Page 126: ...peed sensor When installing the speed sensor make sure that the projection on the wheel hub does not damage the lip of the speed sensor oil seal Make sure that the slot c in the speed sen sor fits over the stopper d on the outer tube 3 Tighten front wheel axle front wheel axle pinch bolts WARNING Make sure the brake hose is routed prop erly CAUTION Before tightening the wheel axle push down hard o...

Page 127: ...ear wheel and brake disc Remove the parts in the order listed NOTE Place the vehicle on a suitable stand so that the rear wheel is elevated Muffler Refer to ENGINE REMOVAL in chapter 5 Swingarm Refer to REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM 1 Air filter case mounting bolt 2 Refer to INSTALLING THE REAR WHEEL 2 Rear fender 1 3 Rear wheel 1 Refer to REMOVING THE REAR WHEEL 4 Spacer 1 ...

Page 128: ...S REAR WHEEL AND BRAKE DISC 1 2 3 6 5 4 LS LT 4 T R 9 Nm 0 9 m kg 6 5 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib Order Job Part Q ty Remarks 5 Washer 1 6 Rear brake disc 1 For installation reverse the removal pro cedure ...

Page 129: ...el is elevated 2 Remove brake caliper rear wheel axle nut swingarm Refer to REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM NOTE Do not squeeze the rear brake lever when removing the rear brake caliper 3 Remove rear wheel EAS05650 CHECKING THE REAR WHEEL 1 Check tire rear wheel Damage wear Replace Refer to CHECKING THE TIRES and CHECKING THE WHEELS in chapter 3 2 Measure radial wheel runout lateral wh...

Page 130: ...just the rear wheel static balance with the brake disc installed 1 Adjust rear wheel static balance Refer to ADJUSTING THE FRONT WHEEL STATIC BALANCE INSTALLING THE REAR WHEEL 1 Install rear fender air filter case mounting bolts NOTE Place the rear fender between the air filter case and the crankcase and then install the air filter case mounting bolts T R 9 Nm 0 9 m kg 6 5 ft lb ...

Page 131: ... 1 2 m kg 8 7 ft Ib New Order Job Part Q ty Remarks Removing the front brake pads Remove the parts in the order listed 1 Holder 1 2 Front brake caliper bolt 2 Refer to REPLACING THE FRONT BRAKE PADS 3 Front brake caliper 1 4 Brake pad clip 1 5 Brake pad pin 1 6 Brake pad 2 7 Brake pad spring 1 8 Brake pad support 1 For installation reverse the removal pro cedure ...

Page 132: ...grease Order Job Part Q ty Remarks Removing the rear brake pads Remove the parts in the order listed Muffler Refer to ENGINE REMOVAL in chapter 5 1 Rear brake caliper retaining bolt 2 Refer to REPLACING THE REAR BRAKE PADS 2 Rear brake caliper 1 3 Brake pad 2 4 Brake pad shim 4 5 Brake caliper bracket 1 6 Brake pad support 2 For installation reverse the removal pro cedure ...

Page 133: ... brake fluid for cleaning brake components Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately Avoid brake fluid coming into contact with the eyes as it can cause serious injury FIRST AID FOR BRAKE FLUID ENTERING THE EYES Flush with water for 15 minutes and get immediate medical attention EAS05820 REPLACING THE FRONT BRAKE PADS NOTE...

Page 134: ...ct a clear plastic hose 1 tightly to the bleed screw 2 Put the other end of the hose into an open container b Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger c Tighten the bleed screw d Install the new brake pads new brake pad spring and new brake pad support NOTE The arrow mark a on the brake pad spring must point in the direction of disc rotation...

Page 135: ... to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 a EAS05830 REPLACING THE REAR BRAKE PADS NOTE When replacing the brake pads it is not neces sary to disconnect the brake hose or disas semble the brake caliper 1 Remove brake caliper retaining bolts 1 brake caliper 2 brake pads along with the brake pad shims brake caliper bracket 3 brake pad supports 2 Measure brake pad wear limit a Out of speci...

Page 136: ...finger c Tighten the bleed screw d Install new brake pad shims onto each new brake pads e Install new brake pad supports and new brake pads 4 Install brake caliper bolts brake caliper retaining bolts 5 Check brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 6 Check brake lever operation Soft or ...

Page 137: ...ks Removing the front brake master cylinder Remove the parts in the order listed Handlebar lower cover Refer to COVERS AND PANELS in chapter 3 Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 1 Brake master cylinder reservoir cap 1 2 Brake master cylinder reservoir dia phragm holder 1 3 Brake master cylinder reservoir dia phragm 1 4 Front brake light switch connector 2 D...

Page 138: ... Refer to DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER and ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLIN DER 6 Copper washer 2 7 Front brake hose 1 8 Front brake master cylinder holder 1 Refer to ASSEMBLING AND INSTALL ING THE FRONT BRAKE MASTER CYLINDER 9 Brake master cylinder assembly 1 10 Front brake lever 1 11 Front brake light switch 1 For installation reverse the removal pro cedure...

Page 139: ... Q ty Remarks Disassembling the front brake mas ter cylinder Remove the parts in the order listed 1 Brake master cylinder kit 1 Refer to ASSEMBLING AND INSTALL ING THE FRONT BRAKE MASTER CYL INDER 2 Brake master cylinder body 1 For assembly reverse the disassembly procedure ...

Page 140: ...b Part Q ty Remarks Removing the rear brake master cyl inder Remove the parts in the order listed Handlebar lower cover Refer to COVERS AND PANELS in chapter 3 Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 1 Brake master cylinder reservoir cap 1 2 Brake master cylinder reservoir dia phragm holder 1 3 Brake master cylinder reservoir dia phragm 1 4 Rear brake lever 1 ...

Page 141: ...or 2 Disconnect 6 Brake hose union bolt 1 Refer to DISASSEMBLING THE REAR BRAKE MASTER CYLINDER and ASSEMBLING AND INSTALLING THE REAR BRAKE MASTER CYLINDER 7 Copper washer 2 8 Rear brake hose 1 9 Rear brake master cylinder holder 1 Refer to ASSEMBLING AND INSTALL ING THE REAR BRAKE MASTER CYL INDER 10 Brake master cylinder assembly 1 11 Rear brake light switch 1 For installation reverse the remov...

Page 142: ... Part Q ty Remarks Disassembling the rear brake mas ter cylinder Remove the parts in the order listed 1 Brake master cylinder kit 1 Refer to ASSEMBLING AND INSTALL ING THE REAR BRAKE MASTER CYL INDER 2 Brake master cylinder body 1 For assembly reverse the disassembly procedure ...

Page 143: ... To collect any remaining brake fluid place a container under the master cylinder and the end of the brake hose 2 1 3 EAS05890 DISASSEMBLING THE REAR BRAKE MASTER CYLINDER NOTE Before disassembling the rear brake master cylinder drain the brake fluid from the entire brake system 1 Remove brake hose union bolt 1 copper washers 2 brake hose 3 NOTE To collect any remaining brake fluid place a contain...

Page 144: ... Replace brake fluid delivery passages brake master cylinder body Obstruction Blow out with compressed air È Front É Rear 1 1 È É 2 Check brake master cylinder kit 1 Damage scratches wear Replace 1 3 Check brake master cylinder reservoir cap 1 Cracks damage Replace brake master cylinder reservoir diaphragm holder 2 brake master cylinder diaphragm 3 Damage wear Replace 4 Check brake hoses Cracks da...

Page 145: ...solvents on internal brake components Recommended brake fluid DOT 4 1 Install brake master cylinder kit 1 NOTE Install the spring with its smaller diameter end towards the circlip and dust boot New 2 Install brake master cylinder 1 brake master cylinder holder NOTE Align the projection a on the brake master cylinder with the hole b in the handlebar First tighten the front bolt then the rear bolt 1...

Page 146: ...s Correct if necessary 4 Fill brake master cylinder reservoir with the specified amount of the recom mended brake fluid WARNING Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction...

Page 147: ...he recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 7 Check brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 a EAS06001 ASSEMBLING AND INSTALLING THE REAR BRAKE MASTER CYLINDER WARNING Before installation all internal brake com ponents should be cleaned and lubricated with c...

Page 148: ...lt 1 a b T R 7 Nm 0 7 m kg 5 1 ft lb 3 Install copper washers 1 brake hose 2 brake hose union bolt 3 WARNING Proper brake hose routing is essential to insure safe vehicle operation Refer to CABLE ROUTING in chapter 2 CAUTION When installing the brake hose onto the brake master cylinder make sure the brake pipe touches the projection a on the brake master cylinder NOTE Turn the handlebar to the lef...

Page 149: ...ading to poor brake performance When refilling be careful that water does not enter the brake master cylinder reser voir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock CAUTION Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 5 Bleed brake system Refer to BLEEDING THE HYDRAULIC BRAKE...

Page 150: ...4 32 CHAS FRONT AND REAR BRAKES 7 Check brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 ...

Page 151: ...nt brake caliper Remove the parts in the order listed Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 1 Holder 1 2 Brake hose union bolt 1 Refer to DISASSEMBLING THE FRONT BRAKE CALIPER and ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPER 3 Copper washer 2 4 Front brake hose 1 5 Front brake caliper bolt 2 6 Front brake caliper 1 For installation reverse the removal pro...

Page 152: ...e pad clip 1 2 Brake pad pin 1 3 Brake pad 2 Refer to ASSEMBLING AND INSTALL ING THE FRONT BRAKE CALIPER 4 Brake pad support 1 5 Brake pad spring 1 6 Brake caliper bracket 1 Refer to DISASSEMBLING THE FRONT BRAKE CALIPER and ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPER 7 Brake caliper housing 1 8 Brake caliper piston 2 9 Brake caliper dust seal 2 0 Brake caliper piston seal 2 ...

Page 153: ...4 35 CHAS FRONT AND REAR BRAKES Apply silicone grease Apply brake fluid Order Job Part Q ty Remarks A Bleed screw cap 1 1 B Brake caliper body 1 For assembly reverse the disassembly procedure ...

Page 154: ...iper Remove the parts in the order listed Muffler Refer to ENGINE REMOVAL in chapter5 Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 1 Brake hose holder 1 Refer to DISASSEMBLING THE REAR BRAKE CALIPER and ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER 2 Brake hose union bolt 1 3 Copper washer 2 4 Rear brake hose 1 5 Rear brake caliper bolt 3 6 Rear brake caliper 1 Fo...

Page 155: ... listed 1 Rear brake caliper retaining bolt 2 Refer to ASSEMBLING AND INSTALL ING THE REAR BRAKE CALIPER 2 Brake caliper bracket 1 3 Brake pad 2 4 Brake pad shim 4 5 Brake pad support 2 6 Brake caliper piston 2 Refer to DISASSEMBLING THE REAR BRAKE CALIPER and ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER 7 Brake caliper dust seal 2 8 Brake caliper piston seal 2 9 Bleed screw cap 1 1 0 Brake ca...

Page 156: ...ump out the brake fluid carefully 3 1 2 4 5 2 Remove brake caliper bracket 1 brake caliper housing 2 2 1 3 Remove brake caliper pistons 1 brake caliper dust seals and piston seals 2 a Blow compressed air into the brake hose joint opening a to force out the pistons from the brake caliper WARNING Cover the brake caliper pistons with a rag Be careful not to get injured when the pistons are expelled f...

Page 157: ... of the brake hose into a container and pump out the brake fluid carefully 2 Remove brake caliper pistons 1 brake caliper dust seals and piston seals 2 a Blow compressed air into the brake hose joint opening a to force out the pistons from the brake caliper WARNING Cover the brake caliper pistons with a rag Be careful not to get injured when the pistons are expelled from the brake cali per Never t...

Page 158: ...the brake cali per assembly brake fluid delivery passages brake caliper body Obstruction Blow out with compressed air WARNING Whenever a brake caliper is disassembled replace the brake caliper piston seals È Front É Rear 2 Check brake caliper bracket Cracks damage Replace Recommended brake component replacement schedule Brake pads If necessary Dust seals Piston seals Every two years Brake hose Eve...

Page 159: ... seals and piston seals 1 Install brake caliper dust seals and piston seals 1 brake calliper pistons 2 2 Install brake caliper housing brake caliper bracket Recommended brake fluid DOT 4 2 1 1 New New New T R 45 Nm 4 5 m kg 32 ft lb 3 Install brake caliper 1 temporarily copper washers 2 brake hose 3 brake hose union bolt 4 WARNING Proper brake hose routing is essential to insure safe vehicle opera...

Page 160: ...e performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake master cylinder reser voir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock CAUTION Brake fluid may damage pain...

Page 161: ...pter 3 a EAS06351 ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER WARNING Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake components Whenever a brake caliper is disassem bled replace the brake caliper dust seals and piston seals 1 Install brake caliper dust seals and piston seals 1 brake callipe...

Page 162: ...e operation Refer to CABLE ROUTING in chapter 2 CAUTION When installing the brake hose onto the brake caliper make sure the brake pipe touches the projection a on the brake cali per 4 Remove brake caliper 5 Install brake pad shims brake pads Refer to REPLACING THE REAR BRAKE PADS 6 Install brake caliper brake caliper retaining bolts New T R 23 Nm 2 3 m kg 17 ft lb T R 27 Nm 2 7 m kg 19 ft lb ...

Page 163: ...ading to poor brake performance When refilling be careful that water does not enter the brake master cylinder reser voir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock CAUTION Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 8 Bleed brake system Refer to BLEEDING THE HYDRAULIC BRAKE...

Page 164: ...4 46 CHAS FRONT AND REAR BRAKES 10 Check brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 ...

Page 165: ...lowing procedure applies to both of the front fork legs Front cowling Refer to COVERS AND PANELS in chapter 3 Front wheel Refer to FRONT WHEEL AND BRAKE DISC 1 Front brake caliper 1 Refer to REMOVING THE FRONT FORK LEGS 2 Front fender 1 3 Clip 1 Refer to REMOVING THE FRONT FORK LEGS and INSTALLING THE FRONT FORK LEGS 4 Lower bracket pinch bolt 2 5 Front fork leg 1 For installation reverse the remo...

Page 166: ...d The following procedure applies to both of the front fork legs 1 Rubber cap 1 Refer to DISASSEMBLING THE FRONT FORK LEGS and ASSEM BLING THE FRONT FORK LEGS 2 Circlip 1 3 Front fork cap 1 4 O ring 1 5 Fork spring 1 6 Dust seal 1 7 Oil seal clip 1 8 Damper rod bolt 1 9 Copper washer 1 0 Damper rod 1 A Rebound spring 1 ...

Page 167: ...s B Inner tube 1 Refer to DISASSEMBLING THE FRONT FORK LEGS and ASSEM BLING THE FRONT FORK LEGS C Inner tube bushing 1 D Oil flow stopper 1 E Oil seal 1 F Washer 1 G Outer tube bushing 1 H Outer tube 1 For assembly reverse the disassembly procedure ...

Page 168: ...nd so that the front wheel is elevated 2 Remove clip 1 3 Loosen lower bracket pinch bolts 2 WARNING Support the front fork leg while loosening the lower bracket pinch bolts 4 Remove front fork leg 1 2 EAS06520 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Remove rubber cap circlip 1 front fork cap 2 O ring fork spring NOTE Push the front fork ca...

Page 169: ...Remove dust seal 1 oil seal clip 2 with a flat head screwdriver CAUTION Do not scratch the inner tube 1 2 4 Remove damper rod bolt 1 damper rod rebound spring NOTE Hold the damper rod with the damper rod holder 2 and T handle 3 then loosen the damper rod bolt Damper rod holder 90890 01294 T handle 90890 01326 ...

Page 170: ... or bush ing must be replaced Avoid bottoming the inner tube into the outer tube during the above procedure as the oil flow stopper will be damaged EAS06560 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Check inner tube 1 outer tube 2 Bends damage scratches Replace WARNING Do not attempt to straighten a bent inner tube as this may dangerously weaken ...

Page 171: ... fork 1 2 EAS06590 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs WARNING Make sure the oil levels in both front fork legs are equal Uneven oil levels can result in poor han dling and a loss of stability NOTE When assembling the front fork leg be sure to replace the following parts outer tube bushing inner tube bushing oil seal dust seal O ring clip B...

Page 172: ... it protrudes from the bottom of the inner tube Be careful not to damage the inner tube 2 Lubricate inner tube s outer surface Recommended lubricant Fork oil 15 W or equivalent 2 1 3 3 Install inner tube bushing 1 inner tube 2 into outer tube 3 oil flow stopper 4 3 4 2 1 New New 4 Install copper washer 1 damper rod bolt 2 2 1 New New ...

Page 173: ...then tighten the damper rod bolt T R Damper rod bolt 28 Nm 2 8 m kg 20 ft lb Damper rod holder 90890 01294 T handle 90890 01326 6 Install outer tube bushing 1 washer 2 with the fork seal driver weight 3 and fork seal driver attachment 4 Fork seal driver weight 90890 01367 Fork seal driver attachment ø36 90890 01370 New ...

Page 174: ...ate the outer surface of the inner tube with fork oil Before installing the oil seal cover the top of the front fork leg with a plastic bag to protect the oil seal during installation Fork seal driver weight 90890 01367 Fork seal driver attachment ø36 90890 01370 New 8 Install oil seal clip 1 NOTE Adjust the oil seal clip so that it fits into the outer tube s groove 9 Install dust seal 1 with the ...

Page 175: ...l 15 W or equivalent Front fork leg oil level a from the top of the inner tube with the inner tube fully compressed and without the fork spring 105 0 mm 4 13 in 11 Install fork spring 1 NOTE Install the spring with the smaller pitch a fac ing up 12 Install O ring to front fork cap front fork cap circlip NOTE Before installing the cap lubricate its O ring with grease Insert the front fork cap into ...

Page 176: ...he following procedure applies to both of the front fork legs 1 Install front fork leg 1 lower bracket pinch bolts 2 NOTE Pull up the inner tube until it stops and then tighten the lower bracket pinch bolts 2 Install clip 3 2 3 New T R 22 Nm 2 2 m kg 16 ft lb New ...

Page 177: ...ebar lower cover Refer to COVERS AND PANELS in chapter 3 1 Grip end 2 2 Front brake light switch connector 2 Disconnect 3 Front brake master cylinder holder 1 Refer to INSTALLING THE HANDLE BAR 4 Front brake master cylinder 1 5 Throttle cable housing 2 Refer to REMOVING THE HANDLEBAR and INSTALLING THE HAN DLEBAR 6 Throttle cable 2 Disconnect 7 Throttle grip 1 8 Rear brake light switch connector 2...

Page 178: ...m 2 3 m kg 17 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 26 Nm 2 6 m kg 19 ft Ib LS 6 LS Order Job Part Q ty Remarks 11 Handlebar grip 1 Refer to REMOVING THE HANDLE BAR and INSTALLING THE HANDLE BAR 12 Upper handlebar holder 2 Refer to INSTALLING THE HANDLE BAR 13 Handlebar 1 For installation reverse the removal pro cedure ...

Page 179: ...ck the rubber cover 4 1 2 3 1 4 3 Remove handlebar grip 1 NOTE Blow compressed air between the handlebar and the handlebar grip and gradually push the grip off the handlebar EAS06680 CHECKING THE HANDLEBAR 1 Check handlebar 1 Bends cracks damage Replace WARNING Do not attempt to straighten a bent handle bar as this may dangerously weaken it EAS06700 INSTALLING THE HANDLEBAR 1 Stand the vehicle on ...

Page 180: ...handlebar grip a Apply a thin coat of rubber adhesive onto the left end of the handlebar b Slide the handlebar grip over the left end of the handlebar c Wipe off any excess rubber adhesive with a clean rag WARNING Do not touch the handlebar grip until the rubber adhesive has fully dried 1 2 b T R 23 Nm 2 3 m kg 17 ft lb 4 Install rear brake master cylinder 1 rear brake master cylinder holder NOTE ...

Page 181: ...sure to slide the throttle cable rubber cover to its original position 3 1 2 3 a b 6 Install front brake master cylinder 1 front brake master cylinder holder NOTE Align the projection a on the brake master cylinder with the hole b in the handlebar First tighten the front bolt then the rear bolt 7 Adjust throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY in chapter 3 Throttle ...

Page 182: ...g the lower bracket Remove the parts in the order listed Handlebar lower cover Refer to COVERS AND PANELS in chapter 3 Front fork Refer to FRONT WHEEL AND BRAKE DISC Handlebar Refer to HANDLEBAR 1 Air temperature sensor 1 2 Steering stem nut 1 3 Lower handlebar holder 1 Refer to REMOVING THE LOWER BRACKET and INSTALLING THE STEERING HEAD 4 Woodruff key 1 5 Upper ring nut 1 6 Lock washer 1 7 Center...

Page 183: ... Nm 12 0 m kg 85 ft Ib Order Job Part Q ty Remarks 11 Upper bearing cover 1 12 Upper bearing inner race 1 Refer to INSTALLING THE STEERING HEAD 13 Upper bearing 1 14 Lower bearing 1 15 Lower bearing outer race 1 16 Dust seal 1 17 Lower bearing inner race 1 Refer to INSTALLING THE STEERING HEAD 18 Upper bearing outer race 1 For installation reverse the removal pro cedure ...

Page 184: ...over 2 Remove lower handlebar holder 1 woodruff key 2 1 2 3 Remove upper ring nut 1 with the steering nut wrench 2 lock washer center ring nut rubber washer Steering nut wrench 90890 01403 2 1 4 Remove lower ring nut 1 with the steering nut wrench 2 lower bracket WARNING Securely support the lower bracket so that there is no danger of it falling Steering nut wrench 90890 01403 ...

Page 185: ...long rod 1 and a hammer b Remove the bearing race from the lower bracket with a floor chisel 2 and a hammer c Install a new rubber seal and new bearing races CAUTION If the bearing race is not installed properly the steering head pipe could be damaged NOTE Always replace the bearings and bearing races as a set Whenever the steering head is disassem bled replace the dust seal 4 Check lower handleba...

Page 186: ... directions for the upper bearing Recommended lubricant Lithium soap based grease 3 Install lower ring nut 1 rubber washer center ring nut 2 lock washer 3 upper ring nut 4 Refer to CHECKING AND ADJUSTING THE STEERING HEAD in chapter 3 4 Install woodruff key 1 lower handlebar holder 2 steering stem nut NOTE Align the woodruff key with the groove a in the lower handlebar holder 2 1 a T R 120 Nm 12 0...

Page 187: ...t Ib T R 18 Nm 1 8 m kg 13 ft Ib Order Job Part Q ty Remarks Removing the rear shock absorber assemblies and swingarm Remove the parts in the order listed Mudguard assembly Refer to COVERS AND PANELS in chapter 3 Muffler Refer to ENGINE REMOVAL in chapter 5 1 Rear wheel axle nut 1 Refer to REMOVING THE SWING ARM and INSTALLING THE SWING ARM 2 Brake hose holder 1 3 Rear brake caliper 1 4 Rear shock...

Page 188: ...5 m kg 98 ft lb T R 16 Nm 1 6 m kg 11 ft Ib T R 59 Nm 5 9 m kg 43 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 18 Nm 1 8 m kg 13 ft Ib Order Job Part Q ty Remarks 5 Rear fender bracket 1 Refer to REMOVING THE SWING ARM and INSTALLING THE SWING ARM 6 Swingarm 1 7 Spacer 1 8 Collar 1 9 Oil seal 1 10 Oil seal 1 11 Circlip 1 12 Bearing 1 For installation reverse the removal pro cedure ...

Page 189: ...nterstand so that the rear wheel is elevated 2 Remove rear shock absorber lower bolts 1 rear shock absorber upper bolts 2 1 2 2 1 EAS06960 CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES 1 Check rear shock absorber rod Bends damage Replace the rear shock absorber assembly rear shock absorber Oil leaks Replace the rear shock absorber assembly spring Damage wear Replace the rear shock absorber assembly ...

Page 190: ...0 REMOVING THE SWINGARM 1 Stand the vehicle on a level surface WARNING Securely support the vehicle so that there is no danger of it falling over NOTE Place the vehicle on a centerstand so that the rear wheel is elevated 2 Remove rear wheel axle nut 1 brake hose holder 2 rear brake caliper 3 rear shock absorber lower bolt right 4 rear fender bracket 5 NOTE Do not squeeze the rear brake lever when ...

Page 191: ...bricate bearings oil seal lips drive axle Recommended lubricant Lithium soap based grease 2 Install swingarm 1 rear fender bracket 2 rear fender bracket lower bolt rear shock absorber lower bolt right 3 rear brake caliper 4 brake hose holder 5 rear wheel axle nut 6 T R 59 Nm 5 9 m kg 43 ft lb T R 16 Nm 1 6 m kg 11 ft lb T R 18 Nm 1 8 m kg 13 ft lb T R 40 Nm 4 0 m kg 29 ft lb T R 7 Nm 0 7 m kg 5 1 ...

Page 192: ...EMOVING THE ROCKER ARMS AND CAMSHAFT 5 14 CHECKING THE CAMSHAFT 5 14 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS 5 15 INSTALLING THE CAMSHAFT AND ROCKER ARMS 5 17 VALVES AND VALVE SPRINGS 5 19 REMOVING THE VALVES 5 20 CHECKING THE VALVES AND VALVE GUIDES 5 21 CHECKING THE VALVE SEATS 5 23 CHECKING THE VALVE SPRINGS 5 25 INSTALLING THE VALVES 5 26 CYLINDER AND PISTON 5 29 REMOVING THE PISTON 5 3...

Page 193: ... GENERATOR COVER AND STATOR COIL 5 49 STARTER CLUTCH 5 51 REMOVING THE GENERATOR 5 52 REMOVING THE STARTER CLUTCH 5 53 CHECKING THE STARTER CLUTCH 5 53 INSTALLING THE STARTER CLUTCH 5 54 INSTALLING THE GENERATOR 5 54 OIL PUMP 5 56 CHECKING THE OIL PUMP 5 58 ASSEMBLING THE OIL PUMP 5 59 INSTALLING THE OIL PUMP ASSEMBLY 5 59 TRANSMISSION 5 60 REMOVING THE TRANSMISSION 5 62 CHECKING THE TRANSMISSION ...

Page 194: ...and muffler Remove the parts in the order listed Seat rear side covers footrest board air filter case assembly Refer to COVERS AND PANELS and AIR FILTER CASE in chapter 3 Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 Air cut off valve Refer to AIR INDUCTION SYSTEM in chapter 7 Carburetor Refer to CARBURETOR in chapter 7 Starter motor Refer to STARTER MOTOR in chapter 8 1 Spark plug cap ...

Page 195: ... 14 Nm 1 4 m kg 10 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib Order Job Part Q ty Remarks 4 Thermostat outlet hose 1 Disconnect 5 Water pump inlet hose 1 6 Muffler 1 7 Gasket 1 8 Exhaust pipe 1 9 Gasket 1 10 Brake hose holder 1 11 Rear brake caliper 1 For installation reverse the removal pro cedure ...

Page 196: ... 5 9 m kg 43 ft Ib Order Job Part Q ty Remarks Removing the engine Remove the parts in the order listed NOTE Place a suitable stand under the engine 1 Rear shock absorber 2 Refer to INSTALLING THE ENGINE 2 Engine mounting nut washer bolt 1 2 1 3 Engine bracket rod bolt washer 2 4 4 Engine bracket rod 2 5 Spacer 1 6 Engine 1 7 Engine bracket nut bolt 2 2 8 Engine bracket 1 For installation reverse ...

Page 197: ...ine bracket rods 2 NOTE Engine bracket bolts and rod bolts should be temporarily tightened 2 Install engine 3 Tighten engine bracket rod bolts 3 engine mounting nut 4 engine bracket nuts 5 5 4 2 2 5 1 3 T R 64 Nm 6 4 m kg 46 ft lb T R 32 Nm 3 2 m kg 23 ft lb T R 59 Nm 5 9 m kg 43 ft lb ...

Page 198: ... 5 8 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib Order Job Part Q ty Remarks Removing the cylinder head Remove the parts in the order listed Engine Refer to ENGINE REMOVAL 1 Coolant temperature sensor 1 2 Intake manifold 1 3 V belt case air filter cover 1 4 Timing m...

Page 199: ...R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib Order Job Part Q ty Remarks 9 Timing chain tensioner 1 Refer to REMOVING THE CYLINDER HEAD and INSTALLING THE CYLIN DER HEAD 10 Timing chain tensioner gasket 1 11 Camshaft sprocket plate 1 12 Camshaft sprocket 1 13 Cylinder head 1...

Page 200: ... camshaft sprocket with the alignment mark d on the cylinder head 3 Remove camshaft sprocket bolt 1 timing chain tensioner along with the gasket camshaft sprocket plate 2 camshaft sprocket 3 timing chain 4 NOTE To prevent the timing chain from falling into the crankcase fasten it with a wire While holding the primary sheave nut with a wrench remove the camshaft sprocket bolt 1 4 Remove cylinder he...

Page 201: ...al deposits rust Eliminate 3 Measure cylinder head warpage Out of specification Resurface the cylin der head a Place a straightedge and a thickness gauge across the cylinder head b Measure the warpage c If the limit is exceeded resurface the cylin der head as follows d Place a 400 600 grit wet sandpaper on the surface plate and resurface the cylinder head using a figure eight sanding pattern NOTE ...

Page 202: ...00210 CHECKING THE TIMING CHAIN TENSIONER 1 Check timing chain tensioner Cracks damage Replace 2 Check one way cam operation Rough movement Replace the timing chain tensioner housing 3 Check cap bolt spring one way cam timing chain tensioner rod Damage wear Replace the defective part s INSTALLING THE CYLINDER HEAD 1 Install dowel pins cylinder head gasket 2 Install cylinder head NOTE Pass the timi...

Page 203: ...nera tor cover c Align the I mark c on the camshaft sprocket with the stationary pointer d on the cylinder head d Place the timing chain onto the camshaft sprocket and then install the camshaft sprocket onto the camshaft NOTE When installing the camshaft sprocket be sure to keep the timing chain as tight as pos sible on the exhaust side Align the pin e on the camshaft with the slot in the camshaft...

Page 204: ...e cylinder d Install the spring 2 and cap bolt 1 7 Turn crankshaft turn the primary sheave nut on the left side of the crankshaft several turns counter clockwise several times 8 Check I mark Align the I mark a on the generator rotor with the stationary pointer b on the genera tor cover I mark Align the I mark c on the camshaft sprocket with the stationary pointer d on the cylinder head Out of alig...

Page 205: ...e to tighten the camshaft sprocket bolt to the specified torque to avoid the possibility of the bolt coming loose and damaging the engine 10 Measure valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEARANCE in chapter 3 T R 60 Nm 6 0 m kg 43 ft lb ...

Page 206: ...ng the camshaft and rocker arms Remove the parts in the order listed Cylinder head Refer to CYLINDER HEAD 1 Locknut 2 Loosen Refer to REMOVING THE ROCKER ARMS AND CAM SHAFT and INSTALLING THE CAMSHAFT AND ROCKER ARMS 2 Adjusting screw 2 Loosen 3 Lock plate 1 4 Camshaft retainer 1 5 Camshaft 1 6 Intake rocker arm shaft 1 7 Exhaust rocker arm shaft 1 8 Rocker arm 2 For installation reverse the remov...

Page 207: ...a 10 mm bolt 2 into the threaded end of the camshaft and then pull the camshaft out 4 Remove intake rocker arm shaft exhaust rocker arm shaft rocker arms NOTE Remove the rocker arm shafts with the slide hammer bolt 1 and weight 2 Slide hammer bolt 90890 01083 Weight 90890 01084 EAS00205 CHECKING THE CAMSHAFT 1 Check camshaft lobes Blue discoloration pitting scratches Replace the camshaft ...

Page 208: ...627 in Limit 36 956 mm 1 4550 in b 30 091 30 191 mm 1 1847 1 1886 in Limit 29 194 mm 1 1494 in 3 Check camshaft oil passage Obstruction Blow out with compressed air EAS00206 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS The following procedure applies to all of the rocker arms and rocker arm shafts 1 Check rocker arm camshaft lobe contact surface 1 adjusting screw surface 2 Damage wear Replace 2 ...

Page 209: ...specification Replace 5 Calculate rocker arm to rocker arm shaft clearance Above 0 080 mm 0 0031 in Replace the defective part s NOTE Calculate the clearance by subtracting the rocker arm shaft outside diameter from the rocker arm inside diameter Rocker arm shaft outside diame ter 11 981 11 991 mm 0 4717 0 4721 in Limit 11 950 mm 0 4705 in Rocker arm to rocker arm shaft clearance 0 009 0 037 mm 0 ...

Page 210: ...bricant Molybdenum disulfide oil 3 Install exhaust rocker arm exhaust rocker arm shaft 1 NOTE Make sure the exhaust rocker arm shaft is completely pushed into the cylinder head 4 Install intake rocker arm intake rocker arm shaft 1 NOTE Insert a guide shaft 8 mm 2 into the stud bolt hole in the cylinder head and install the intake rocker arm shaft as shown CAUTION Make sure the threaded part of the...

Page 211: ... AND ROCKER ARMS 5 Install camshaft 1 6 Install camshaft retainer 1 lock plate 2 camshaft retainer bolts 3 NOTE Bend the lock plate tab along a flat side of the camshaft retainer bolts 3 New T R 8 Nm 0 8 m kg 5 8 ft lb ...

Page 212: ...arts in the order listed Cylinder head Refer to CYLINDER HEAD Rocker arms and camshaft Refer to CAMSHAFT AND ROCKER ARMS 1 Valve cotter 4 Refer to REMOVING THE VALVES and INSTALLING THE VALVES 2 Upper spring seat 2 3 Outer valve spring 2 4 Inner valve spring 2 5 Intake valve 1 6 Exhaust valve 1 7 Valve stem seal 2 8 Lower spring seat 2 9 Valve guide 2 For installation reverse the removal pro cedur...

Page 213: ...e at the valve seat Check the valve face valve seat and valve seat width Refer to CHECKING THE VALVE SEATS a Pour a clean solvent into the intake and exhaust ports a b Check that the valves properly seal NOTE There should be no leakage at the valve seat 1 2 Remove valve cotters 1 NOTE Remove the valve cotters by compressing the valve spring with the valve spring compressor and the valve spring com...

Page 214: ...e EAS00239 CHECKING THE VALVES AND VALVE GUIDES The following procedure applies to all of the valves and valve guides 1 Measure valve stem to valve guide clearance Out of specification Replace the valve guide Valve stem to valve guide clearance Valve guide inside diameter a Valve stem diameter b Valve stem to valve guide clear ance Intake 0 010 0 037 mm 0 0004 0 0015 in Limit 0 080 mm 0 0031 in Ex...

Page 215: ...ver 1 c After installing the valve guide bore the valve guide with the valve guide reamer 3 to obtain the proper valve stem to valve guide clearance NOTE After replacing the valve guide reface the valve seat 3 Eliminate carbon deposits from the valve face and valve seat 4 Check valve face Pitting wear Grind the valve face valve stem end Mushroom shape or diameter larger than the body of the valve ...

Page 216: ...2 in Limit 0 5 mm 0 02 in 6 Measure valve stem runout Out of specification Replace the valve NOTE When installing a new valve always replace the valve guide If the valve is removed or replaced always replace the oil seal Valve stem runout 0 010 mm 0 0004 in EAS00240 CHECKING THE VALVE SEATS The following procedure applies to all of the valves and valve seats 1 Eliminate carbon deposits from the va...

Page 217: ... Measure the valve seat width NOTE Where the valve seat and valve face contacted one another the blueing will have been removed 4 Lap valve face valve seat NOTE After replacing the cylinder head or replacing the valve and valve guide the valve seat and valve face should be lapped a Apply a coarse lapping compound a to the valve face CAUTION Do not let the lapping compound enter the gap between the...

Page 218: ...ng compound from the valve face and valve seat g Apply Mechanic s blueing dye Dykem b to the valve face h Install the valve into the cylinder head i Press the valve through the valve guide and onto the valve seat to make a clear impres sion j Measure the valve seat width again If the valve seat width is out of specification reface and lap the valve seat EAS00241 CHECKING THE VALVE SPRINGS The foll...

Page 219: ... 19 in Intake and exhaust outer valve spring 115 133 N 11 73 13 56 kg 25 85 29 90 lb at 31 60 mm 1 24 in 3 Measure valve spring tilt a Out of specification Replace the valve spring Valve spring tilt limit Intake and exhaust inner valve spring 2 5 1 7 mm 0 067 in Intake and exhaust outer valve spring 2 5 1 6 mm 0 063 in EAS00245 INSTALLING THE VALVES The following procedure applies to all of the va...

Page 220: ... valve 3 inner valve spring 4 outer valve spring 5 upper spring seat 6 NOTE Install the valve spring with the larger pitch a facing up b Smaller pitch New 4 Install valve cotters 1 NOTE Install the valve cotters by compressing the valve spring with the valve spring compressor and the valve spring compressor attachment 2 Valve spring compressor 90890 04019 Valve spring compressor attachment 90890 0...

Page 221: ...8 ENG VALVES AND VALVE SPRINGS 5 To secure the valve cotters onto the valve stem lightly tap the valve tip with a soft face hammer CAUTION Hitting the valve tip with excessive force could damage the valve ...

Page 222: ...arts in the order listed Cylinder head Refer to CYLINDER HEAD 1 Water pump outlet pipe 1 2 Timing chain guide exhaust side 1 3 Cylinder 1 4 Cylinder gasket 1 Refer to INSTALLING THE PISTON AND CYLINDER 5 Dowel pin 2 6 Piston pin clip 2 Refer to REMOVING THE PISTON and INSTALLING THE PISTON AND CYLINDER 7 Piston pin 1 8 Piston 1 9 Top ring 1 10 2nd ring 1 11 Oil ring 1 For installation reverse the ...

Page 223: ...urr the piston pin clip groove and the piston pin bore area If both areas are deburred and the pis ton pin is still difficult to remove remove it with the piston pin puller set 4 Piston pin puller set 90890 01304 2 Remove top ring 2nd ring oil ring NOTE When removing a piston ring open the end gap with your fingers and lift the other side of the ring over the piston crown EAS00259 CHECKING THE CYL...

Page 224: ...5 mm 0 20 in from the bottom edge of the pis ton d If out of specification replace the piston and piston rings as a set e Calculate the piston to cylinder clearance with the following formula Cylinder bore C 69 000 69 005 mm 2 7165 2 7167 in Taper limit T 0 050 mm 0 0020 in Out of round R 0 030 mm 0 0012 in C maximum of D1 D2 T maximum of D1 or D2 maximum of D5 or D6 R maximum of D1 D3 or D5 mini ...

Page 225: ...iston and piston rings as a set NOTE Before measuring the piston ring side clear ance eliminate any carbon deposits from the piston ring grooves and piston rings Piston ring side clearance Top ring 0 040 0 080 mm 0 0016 0 0031 in Limit 0 120 mm 0 0047 in 2nd ring 0 030 0 070 mm 0 0012 0 0028 in Limit 0 120 mm 0 0047 in 2 Install piston ring into the cylinder NOTE Level the piston ring into the cyl...

Page 226: ...g 0 15 0 30 mm 0 0059 0 0118 in Limit 0 45 mm 0 0177 in 2nd ring 0 30 0 45 mm 0 0118 0 0177 in Limit 0 70 mm 0 0276 in Oil ring 0 20 0 70 mm 0 0079 0 0276 in EAS00266 CHECKING THE PISTON PIN 1 Check piston pin Blue discoloration grooves Replace the piston pin and then check the lubrication system 2 Measure piston pin outside diameter a Out of specification Replace the piston pin Piston pin outside...

Page 227: ...6699 in Limit 17 045 mm 0 6711 in Piston pin to piston pin bore clearance Piston pin bore diameter in the piston Piston pin outside diameter Piston pin to piston pin bore clearance 0 004 0 024 mm 0 0002 0 0009 in Limit 0 074 mm 0 0029 in EAS00267 INSTALLING THE PISTON AND CYLINDER 1 Install top ring 1 2nd ring 2 upper oil ring rail 3 oil ring expander 4 lower oil ring rail 5 NOTE Be sure to instal...

Page 228: ... crankcase 3 Install dowel pins cylinder gasket 4 Lubricate piston piston rings cylinder with the recommended lubricant Recommended lubricant Engine oil New New 5 Offset piston ring end gaps a Top ring b Upper oil ring rail c Oil ring expander d Lower oil ring rail e 2nd ring f 20 mm 0 79 in È Intake side 120 120 120 e È b c d f f a 6 Install cylinder NOTE While compressing the piston rings with o...

Page 229: ...Order Job Part Q ty Remarks Removing the V belt case cover Remove the parts in the order listed Center panel 1 left air filter case assembly Refer to COVERS AND PANELS in chapter 3 1 V belt case air filter cover 1 2 V belt case air filter element 1 3 V belt case cover 1 4 V belt case 1 5 V belt case gasket 1 6 Dowel pin 2 For installation reverse the removal pro cedure ...

Page 230: ...ing the V belt primary sheave and secondary sheave Remove the parts in the order listed 1 Primary sheave nut washer 1 1 Refer to REMOVING THE PRIMARY SHEAVE and INSTALLING THE SEC ONDARY SHEAVE V BELT AND PRI MARY SHEAVE 2 Primary fixed sheave 1 3 Secondary sheave bracket 1 4 Secondary sheave nut 1 Refer to REMOVING THE SECOND ARY SHEAVE AND V BELT and INSTALLING THE SECONDARY SHEAVE V BELT AND PR...

Page 231: ...m kg 58 ft Ib T T R 60 Nm 6 0 m kg 43 ft Ib T R 3 Nm 0 3 m kg 2 2 ft Ib T R 22 Nm 2 2 m kg 16 ft Ib Apply Shell BT grease 3 YAMAHA grease G 90793 40016 Order Job Part Q ty Remarks 11 Primary sheave cap 1 12 Cam 1 13 Weight 8 14 Slider 4 15 Spacer 4 For installation reverse the removal pro cedure ...

Page 232: ...ob Part Q ty Remarks Disassembling the secondary sheave Remove the parts in the order listed 1 Clutch carrier nut 1 2 Clutch carrier 1 3 Clutch carrier plate 1 4 Clutch shoe spring 3 5 Compression spring 1 6 Spring seat 1 7 Guide pin 4 8 Secondary sliding sheave 1 9 O ring 2 0 Oil seal 2 A Secondary fixed sheave 1 For assembly reverse the disassembly procedure ...

Page 233: ... fully loosened remove them 2 Remove primary sheave nut 1 washer primary fixed sheave 2 NOTE While holding the primary fixed sheave with the rotor holding tool 3 loosen the primary sheave nut Rotor holding tool 90890 01235 EAS00318 REMOVING THE SECONDARY SHEAVE AND V BELT 1 Remove secondary sheave nut 1 collar clutch housing 2 NOTE While holding the clutch housing with the sheave holder 3 loosen t...

Page 234: ...0890 01701 Locknut wrench 90890 01348 1 3 2 3 Remove secondary sheave assembly 1 V belt 2 NOTE Remove the V belt and secondary sheave assembly from the primary sheave side 2 1 EAS00319 DISASSEMBLING THE SECONDARY SHEAVE 1 Remove clutch carrier nut 1 NOTE While compressing the compression spring with the clutch spring holder 2 and clutch spring holder arm 3 remove the clutch carrier nut Clutch spri...

Page 235: ...RIMARY SHEAVE WEIGHTS The following procedure applies to all of the primary sheave weights 1 Check primary sheave weight Cracks damage wear Replace 2 Measure primary sheave weight outside diameter Out of specification Replace Primary sheave weight outside diameter 20 0 mm 0 79 in Limit 19 5 mm 0 77 in EAS00322 CHECKING THE SECONDARY SHEAVE 1 Check secondary fixed sheave secondary sliding sheave Cr...

Page 236: ...ession spring free length 102 4 mm 4 03 in Limit 90 0 mm 3 54 in CHECKING THE CLUTCH SHOES The following procedure applies to all of the clutch shoes 1 Check clutch shoe Damage wear Replace the clutch shoes and springs as a set Glazed areas Sand with coarse sandpa per NOTE After sanding the glazed areas clean the clutch with a cloth 2 Measure clutch shoe thickness Out of specification Replace the ...

Page 237: ...eave weights 4 primary sliding sheave cam face 5 2 Install primary sheave weights 1 spacer 2 NOTE Before installing the primary sheave weights lubricate the inside and outside of each weight with Shell BT grease 3 Recommended lubricant Shell BT grease 3 3 Install spacers 1 sliders 2 cam 3 primary sheave cap T R 3 Nm 0 3 m kg 2 2 ft lb ...

Page 238: ...ant Recommended lubricant BEL RAY assembly lube New 2 Install oil seals secondary sliding sheave 1 NOTE Install the secondary sliding sheave onto the secondary fixed sheave 2 with the oil seal guide 3 Oil seal guide ø41 90890 01396 3 1 2 New 3 Install guide pins 1 4 Lubricate guide pin grooves 2 O rings 3 with the recommended lubricant Recommended lubricant BEL RAY assembly lube 2 1 New 3 New ...

Page 239: ... nut Clutch spring holder 90890 01337 Clutch spring holder arm 90890 01464 EAS00325 INSTALLING THE SECONDARY SHEAVE V BELT AND PRIMARY SHEAVE 1 Install V belt 1 secondary sheave assembly 2 CAUTION Do not allow grease to contact the V belt or secondary sheave assembly NOTE Install the V belt with the printed arrow mark on the V belt facing in the direction shown in the illustration Install the V be...

Page 240: ...h carrier nut with the locknut wrench 3 Sheave holder 90890 01701 Locknut wrench 90890 01348 1 3 2 T R 90 Nm 9 0 m kg 65 ft lb 3 Install clutch housing 1 collar secondary sheave nut 2 NOTE While holding the clutch housing with the sheave holder 3 tighten the secondary sheave nut Sheave holder 90890 01701 T R 60 Nm 6 0 m kg 43 ft lb ...

Page 241: ...ake sure the V belt is tight While holding the primary fixed sheave with the rotor holding tool tighten the primary sheave nut 5 Install secondary sheave bracket 6 Install dowel pins V belt case gasket V belt case NOTE Make sure that the V belt case gasket lip fits properly around the V belt case Tighten the V belt case bolts in stages and in a crisscross pattern Rotor holding tool 90890 01235 T R...

Page 242: ...ks Removing the generator cover and stator coil Remove the parts in the order listed Storage box center panel 1 Refer to COVERS AND PANELS in chapter 3 Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Muffler exhaust pipe Refer to ENGINE REMOVAL Air cut off valve assembly Refer to AIR INDUCTION SYSTEM in chapter 7 1 Pickup coil stator assembly coupler 1 1 Disconnect 2 Generator cover...

Page 243: ...D GENERATOR LT New 1 5 6 3 4 2 4 New LT LT T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib LS New Order Job Part Q ty Remarks 6 Stator coil 1 For installation reverse the removal pro cedure ...

Page 244: ...he starter clutch Remove the parts in the order listed 1 Generator rotor 1 Refer to REMOVING THE GENERA TOR REMOVING THE STARTER CLUTCH INSTALLING THE STARTER CLUTCH and INSTALLING THE GENERATOR 2 Starter clutch 1 3 Woodruff key 1 4 Starter clutch gear 1 5 Circlip 1 6 Washer 1 7 Starter clutch idle gear shaft 1 8 Starter clutch idle gear 1 For installation reverse the removal pro cedure ...

Page 245: ... generator rotor 2 with the sheave holder 3 loosen the generator rotor nut Do not allow the sheave holder to touch the projection on the generator rotor Sheave holder 90890 01701 1 2 3 3 Remove generator rotor 1 with the flywheel puller 2 woodruff key CAUTION To protect the end of the crankshaft place an appropriate sized socket between the flywheel puller set s center bolt and the crankshaft NOTE...

Page 246: ...le gear starter clutch gear Burrs chips roughness wear Replace the defective part s 3 Check starter clutch gear s contacting surfaces Damage pitting wear Replace the starter clutch gear 4 Check starter clutch operation a Install the starter clutch gear 1 onto the starter clutch 2 and hold the starter clutch b When turning the starter clutch gear clock wise È the starter clutch and the starter clut...

Page 247: ...ING THE GENERATOR 1 Install starter clutch gear woodruff key generator rotor washer generator rotor nut NOTE Clean the tapered portion of the crankshaft and the generator rotor hub When installing the generator rotor make sure the woodruff key is properly seated in the keyway of the crankshaft 2 Tighten generator rotor nut 1 NOTE While holding the generator rotor 2 with the sheave holder 3 tighten...

Page 248: ...5 55 ENG 3 Apply sealant onto the pickup coil stator assembly lead grommet Yamaha bond No 1215 90890 85505 STARTER CLUTCH AND GENERATOR ...

Page 249: ...ob Part Q ty Remarks Removing the oil pump assembly Remove the parts in the order listed Starter clutch gear Refer to STARTER CLUTCH AND GEN ERATOR 1 Oil baffle plate 1 2 Circlip 1 3 Washer 1 4 Oil pump driven gear 1 5 Pin 1 6 Oil pump assembly 1 7 Oil pump gasket 1 8 Oil pump housing cover 1 9 Pin 1 10 Oil pump shaft 1 11 Oil pump inner rotor 1 ...

Page 250: ... 11 10 13 5 6 1 7 12 New LT E T R 7 Nm 0 7 m kg 5 1 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib LS 2 3 4 New Order Job Part Q ty Remarks 12 Oil pump outer rotor 1 13 Oil pump housing 1 For installation reverse the removal pro cedure ...

Page 251: ... outer rotor clearance Ê Out of specification Replace the oil pump assembly 1 Inner rotor 2 Outer rotor 3 Oil pump housing Inner rotor to outer rotor tip clearance Less than 0 15 mm 0 0059 in Limit 0 23 mm 0 0091 in Outer rotor to oil pump housing clearance 0 013 0 036 mm 0 0005 0 0014 in Limit 0 106 mm 0 0042 in Oil pump housing to inner rotor and outer rotor clearance 0 04 0 09 mm 0 0016 0 0035 ...

Page 252: ...NOTE When installing the pin align the pin with the groove a in the inner rotor 3 Check oil pump operation Refer to CHECKING THE OIL PUMP Recommended lubricant Engine oil 1 2 a EAS00376 INSTALLING THE OIL PUMP ASSEMBLY 1 Install oil pump gasket oil pump assembly CAUTION After tightening the bolts make sure the oil pump turns smoothly New T R 7 Nm 0 7 m kg 5 1 ft lb ...

Page 253: ...s in the order listed Final transmission oil Drain Refer to CHANGING THE FINAL TRANSMISSION OIL in chapter 3 Rear wheel Refer to REAR WHEEL AND BRAKE DISC in chapter 4 Secondary sheave assembly Refer to BELT DRIVE 1 Transmission case cover 1 2 Transmission case cover gasket 1 3 Dowel pin 2 4 Primary drive gear 1 5 Washer 1 6 Washer 1 7 1st wheel gear 1 ...

Page 254: ...T R 16 Nm 1 6 m kg 11 ft Ib LS LS È É Order Job Part Q ty Remarks 8 Conical spring washer 1 9 Drive axle 1 10 Main axle 1 11 Conical spring washer 1 12 Primary driven gear 1 13 Washer 1 For installation reverse the removal pro cedure ...

Page 255: ... are fully loosened removed them EAS00425 CHECKING THE TRANSMISSION 1 Check transmission gears Blue discoloration pitting wear Replace the defective gear s transmission gear dogs Cracks damage rounded edges Replace the defective gear s 2 Check transmission gear movement Rough movement Replace the defective part s 3 Check circlips Bends damage looseness Replace TRANSMISSION ...

Page 256: ...he crankshaft Remove the parts in the order listed Water pump assembly Refer to WATER PUMP in chapter 6 Engine Refer to ENGINE Cylinder head Refer to CYLINDER HEAD Piston Refer to CYLINDER AND PISTON Secondary sheave assembly Refer to BELT DRIVE Starter clutch gear Refer to STARTER CLUTCH AND GEN ERATOR Oil pump assembly Refer to OIL PUMP Transmission Refer to TRANSMISSION 1 Timing chain guide ret...

Page 257: ... New New LS E T R 22 Nm 2 2 m kg 16 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib Order Job Part Q ty Remarks 5 Crankshaft assembly 1 6 Timing chain 1 7 Left crankcase 1 8 Oil seal 1 For installation reverse the removal pro cedure ...

Page 258: ...crankcase 1 NOTE Remove the right crankcase with the crank case separating tool 2 Make sure that the crankcase separating tool is centered over the crankshaft assembly Crankcase separating tool 90890 01135 EAS00389 REMOVING THE CRANKSHAFT ASSEMBLY 1 Remove timing chain NOTE Before removing the crankshaft remove the timing chain from the crankshaft sprocket The crankshaft cannot be removed if the t...

Page 259: ...separating tool is centered over the crankshaft CAUTION Do not tap on the crankshaft Crankcase separating tool 90890 01135 EAS00207 CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDE 1 Check timing chain Damage stiffness Replace the timing chain and camshaft sprocket as a set 2 Check timing chain guide intake side Damage wear Replace the defective part s ...

Page 260: ...sure big end side clearance Out of specification Replace the crank shaft Big end side clearance 0 350 0 850 mm 0 0138 0 0335 in 3 Measure crankshaft width Out of specification Replace the crank shaft Crankshaft width 59 75 59 80 mm 2 352 2 354 in 4 Check crankshaft sprocket 1 Damage wear Replace the crankshaft bearing 2 Cracks damage wear Replace the crank shaft oil pump drive gear 3 Damage wear R...

Page 261: ...ivery passages Obstruction Blow out with compressed air EAS00401 CHECKING THE BEARINGS 1 Check bearings Clean and lubricate the bearings and then rotate the inner race with your finger Rough movement Replace EAS00408 INSTALLING THE CRANKSHAFT 1 Lubricate oil seals bearings oil pump drive gear 2 Install timing chain 1 NOTE Install the timing chain so it is not visible through the opening a in the l...

Page 262: ...g the crankshaft and to ease the installation procedure lubricate the oil seal lips with lithium soap based grease and each bearing with engine oil NOTE Hold the connecting rod at top dead center TDC with one hand while turning the nut of the crankshaft installer bolt with the other Turn the crankshaft installer bolt until the crankshaft assembly bottoms against the bearing Crankshaft installer po...

Page 263: ...t onto the crankcase mating surfaces NOTE Do not allow any sealant to come into contact with the oil gallery Yamaha bond No 1215 90890 85505 3 Install water pump assembly crankcase bolts NOTE Tighten the crankcase bolts in stages and in a crisscross pattern M6 100 mm 3 94 in bolts 1 M6 70 mm 2 76 in bolts 2 1 2 1 1 2 1 2 T R 10 Nm 1 0 m kg 7 2 ft lb ...

Page 264: ...THE RADIATOR 6 3 INSTALLING THE RADIATOR 6 3 THERMOSTAT 6 4 CHECKING THE THERMOSTAT 6 5 INSTALLING THE THERMOSTAT 6 5 WATER PUMP 6 6 DISASSEMBLING THE WATER PUMP 6 8 CHECKING THE WATER PUMP 6 9 ASSEMBLING THE WATER PUMP 6 9 INSTALLING THE WATER PUMP 6 11 ...

Page 265: ...ks Removing the radiator Remove the parts in the order listed Storage compartment footrest board under cover Refer to COVERS AND PANELS in chapter 3 Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 1 Radiator cap 1 2 Coolant reservoir hose 1 3 Coolant reservoir 1 4 Radiator filler hose 1 5 Radiator outlet hose 1 6 Radiator inlet hose 1 7 Radiator inlet outlet pipe 1 8 Radiator fan motor co...

Page 266: ... Ib T R 30 Nm 3 0 m kg 22 ft Ib Order Job Part Q ty Remarks 9 Thermo switch connector auto choke 2 Disconnect White 10 Thermo switch connector radiator fan motor 2 Disconnect Green 11 Radiator 1 12 Radiator fan motor 1 13 Thermo switch auto choke 1 White 14 Thermo switch radiator fan motor 1 Green For installation reverse the removal pro cedure ...

Page 267: ...or inlet hose radiator outlet hose radiator filler hose coolant reservoir hose radiator inlet outlet pipe Cracks damage Replace 3 Check radiator fan motor Damage Replace Malfunction Check and repair Refer to COOLING SYSTEM in chapter 8 EAS00456 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 cool...

Page 268: ... thermostat Remove the parts in the order listed Rear side cover left and right Refer to COVERS AND PANELS in chapter 3 Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 1 Thermostat inlet hose 1 Disconnect 2 Thermostat outlet hose 1 3 Thermostat cover 1 4 Thermostat 1 For installation reverse the removal pro cedure ...

Page 269: ...rmostat 2 Container 3 Thermometer 4 Water È Fully closed É Fully open NOTE _ If the accuracy of the thermostat is in doubt replace it A faulty thermostat could cause seri ous overheating or overcooling 2 Check thermostat cover Cracks damage Replace 3 Check thermostat inlet hose thermostat outlet hose Cracks damage Replace EAS00467 INSTALLING THE THERMOSTAT 1 Fill cooling system with the specified ...

Page 270: ...Order Job Part Q ty Remarks Removing the water pump Remove the parts in the order listed NOTE It is not necessary to remove the water pump unless the coolant level is extremely low or the coolant contains engine oil Center panel 2 left Refer to COVERS AND PANELS in chapter 3 Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 Generator rotor Refer to STARTER CLUTCH AND GEN ERATOR in chapter 5...

Page 271: ...g 7 2 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib Order Job Part Q ty Remarks 1 Oil baffle plate 1 2 Impeller shaft gear 1 3 Dowel pin Washer 1 1 4 Shaft 1 5 Water pump inlet hose 1 6 Water pump outlet pipe 1 7 Water pump housing cover 1 8 Water pump housing gasket 1 9 Water pump housing 1 10 Impeller shaft 1 For installation reverse the removal pro cedure ...

Page 272: ...r with a thin flathead screwdriver NOTE Do not scratch the impeller shaft 2 Remove water pump seal 1 NOTE Remove the water pump seal from the inside of the water pump housing 1 3 Remove oil seal 1 bearing 2 with a thin flathead screwdriver NOTE Remove the oil seal and bearing from the out side of the water pump housing 2 1 ...

Page 273: ...gear Pitting wear Replace 4 Check water pump inlet hose water pump outlet pipe Cracks damage wear Replace EAS00475 ASSEMBLING THE WATER PUMP 1 Install oil seal 1 into the water pump housing NOTE Before installing the oil seal apply tap water or coolant onto its outer surface Install the oil seal with a socket that matches its outside diameter Installed depth of oil seal a 8 1 8 7 mm 0 32 0 34 in 1...

Page 274: ...driven shaft bearing driver 3 Before installing the water pump seal apply Yamaha bond No 1215 4 to the water pump housing 5 È Push down Mechanical seal installer 90890 04132 Middle driven shaft bearing driver 90890 04058 Yamaha bond No 1215 90890 85505 New 3 Install rubber damper 1 rubber damper holder 2 NOTE Before installing the rubber damper apply tap water or coolant onto its outer surface New...

Page 275: ...peller 1 Straightedge 2 Impeller Impeller shaft tilt limit 0 15 mm 0 0059 in 5 Install impeller shaft 1 circlip 2 NOTE After installation check that the impeller shaft rotates smoothly 6 Install water pump housing cover New T R 10 Nm 1 0 m kg 7 2 ft lb INSTALLING THE WATER PUMP 1 Install shaft 1 NOTE Align the projection a on the shaft 1 with the slot b in the impeller shaft ...

Page 276: ...stall water pump 3 Fill cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT in chapter 3 4 Check cooling system Leaks Repair or replace any faulty part T R 10 Nm 1 0 m kg 7 2 ft lb ...

Page 277: ...G THE CARBURETOR 7 5 ASSEMBLING THE CARBURETOR 7 6 INSTALLING THE CARBURETOR 7 7 CHECKING THE AUTO CHOKE UNIT 7 8 AIR INDUCTION SYSTEM 7 10 CHECKING THE AIR INDUCTION SYSTEM 7 11 FUEL TANK 7 12 REMOVING THE FUEL SENDER 7 14 CHECKING THE FUEL PUMP 7 14 INSTALLING THE FUEL SENDER 7 15 ...

Page 278: ...ts in the order listed Storage box footrest board Refer to COVERS AND PANELS in chapter 3 Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 1 Auto choke unit coupler 1 Disconnect 2 Carburetor inlet hose 1 Disconnect 3 Thermostat inlet hose 1 Disconnect 4 Fuel hose fuel pump to carburetor 1 Disconnect 5 Throttle cable 2 Disconnect 6 Air filter case clamp screw 1 Loosen 7 Carburetor clamp scr...

Page 279: ... 3 4 5 6 8 7 T R 2 Nm 0 2 m kg 1 4 ft Ib T R 2 Nm 0 2 m kg 1 4 ft Ib T R 11 Nm 1 1 m kg 8 0 ft Ib Order Job Part Q ty Remarks 8 Carburetor 1 Refer to INSTALLING THE CARBURE TOR For installation reverse the removal pro cedure ...

Page 280: ...emarks Disassembling the carburetor Remove the parts in the order listed 1 Coolant hose joint 1 2 Auto choke unit 1 3 Pilot screw 1 4 Vacuum chamber cover 1 5 Piston valve spring 1 6 Piston valve 1 7 Jet needle 1 8 Coasting enricher assembly 1 9 Float chamber 1 0 Float pin 1 A Float 1 B Needle valve 1 C Main jet 1 ...

Page 281: ...ew New New 4 6 5 7 E F D C 8 1 A 0 3 B 9 G 2 H New 4 4 Order Job Part Q ty Remarks D Needle jet holder 1 E Needle jet 1 F Pilot jet 1 G Accelerator pump assembly 1 H Fuel drain screw 1 For assembly reverse the disassembly procedure ...

Page 282: ...uction Clean a Wash the carburetor in a petroleum based solvent Do not use any caustic carburetor cleaning solution b Blow out all of the passages and jets with compressed air 3 Check float chamber body Dirt Clean 4 Check float Damage Replace 5 Check needle valve Damage obstruction wear Replace 6 Check piston valve Damage scratches wear Replace piston valve diaphragm coasting enricher diaphragm Cr...

Page 283: ...body and move it up and down Tightness Replace the piston valve 10 Check fuel hoses Cracks damage wear Replace Obstruction Clean Blow out the hoses with compressed air 3 1 4 2 5 6 EAS00487 ASSEMBLING THE CARBURETOR CAUTION Before assembling the carburetor wash all of the parts in a petroleum based sol vent Always use a new gasket 1 Measure float height a Out of specification Adjust a Hold the carb...

Page 284: ...t is fine adjust the float height by bending the float tang 1 on the float f Recheck the float height 2 Install float 1 needle valve 2 float pin 3 NOTE Install the float pin in the direction of the arrow 3 Install float chamber rubber gasket float chamber pilot air screw 4 Install accelerator pump assembly 5 Install coasting enricher assembly Pilot air screw 2 turns out 3 2 1 New EAS00492 INSTALLI...

Page 285: ...rottle grip 4 0 6 0 mm 0 16 0 24 in EAS00503 CHECKING THE AUTO CHOKE UNIT NOTE When checking the auto choke unit the ambi ent temperature must be lower than 45 C 113 F 1 Remove carburetor 2 Check auto choke unit a Connect a 3 3 mm 0 13 in hose 2 to the starter air passage 1 and blow into the hose NOTE When the starter plunger is open air should come out of the other side of the starter air passage...

Page 286: ...lead to a 12 0 V battery for five minutes b Connect a 3 3 mm 0 13 in hose 4 to the starter air passage 3 and blow into the hose Positive battery lead yellow 1 Negative battery lead green black 2 Starter plunger opens Replace the auto choke unit Starter plunger closes Auto choke unit is OK ...

Page 287: ...der listed Seat right center panel 2 under cover Refer to COVERS AND PANELS in chapter 3 1 Air induction system vacuum hose 1 2 Air induction system hose to air cut off valve assembly 1 3 Air induction system hose air cut off valve assembly to cylinder head 1 4 Air induction system pipe air cut off valve assembly to cylinder head 1 5 Air cut off valve bracket 1 6 Air cut off valve assembly 1 For i...

Page 288: ...s from the pipe air cut off valve assembly to cylinder head b Install a vacuum pressure pump to the air cut off valve 1 and apply negative pressure to the valve c Blow air through the end of the air induction system hose to air cut off valve assembly and check that air does not flow and out through the pipe air cut off valve assembly to cylinder head Air cut off valve opens Perform step b Air cut ...

Page 289: ...k Remove the parts in the order listed Storage box under cover Refer to COVERS AND PANELS in chapter 3 1 Fuel pump coupler 1 Disconnect 2 Fuel hose holder 1 3 Fuel hose fuel tank to fuel pump 1 4 Fuel hose fuel pump to carburetor 1 Disconnect 5 Fuel pump 1 6 Fuel sender coupler 1 Disconnect 7 Fuel tank lower cover 1 8 Fuel tank 1 9 Fuel pipe 1 FUEL TANK ...

Page 290: ... m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib 7 6 9 5 1 4 3 10 LS Order Job Part Q ty Remarks 10 Fuel sender 1 Refer to REMOVING THE FUEL SENDER and INSTALLING THE FUEL SENDER For installation reverse the removal pro cedure FUEL TANK ...

Page 291: ... the fuel hose fuel pump to car buretor fuel hose 2 from the carburetor b Place a container under the end of the fuel hose c Turn the main switch to ON and check if fuel flows from the fuel hose 2 d Turn the main switch to OFF and check if the fuel stops flowing from the fuel hose 2 Fuel flows Fuel pump is OK Fuel does not flow Replace the fuel pump Fuel stops flowing Fuel pump is OK Fuel flows Re...

Page 292: ...l fuel sender 1 NOTE Install the fuel sender using the fuel sender removal tool Lubricate the gasket with lithium soap based grease Position the fuel sender coupler a as shown in the illustration Fuel sender removal tool 90890 11098 a 1 FUEL TANK ...

Page 293: ...ELECTRIC STARTING SYSTEM 8 12 CIRCUIT DIAGRAM 8 12 STARTING CIRCUIT CUT OFF SYSTEM OPERATION 8 13 TROUBLESHOOTING 8 14 STARTER MOTOR 8 17 CHECKING THE STARTER MOTOR 8 19 ASSEMBLING THE STARTER MOTOR 8 20 CHARGING SYSTEM 8 21 CIRCUIT DIAGRAM 8 21 TROUBLESHOOTING 8 22 LIGHTING SYSTEM 8 24 CIRCUIT DIAGRAM 8 24 TROUBLESHOOTING 8 25 CHECKING THE LIGHTING SYSTEM 8 27 SIGNALING SYSTEM 8 30 CIRCUIT DIAGRA...

Page 294: ...YSTEM 8 51 CIRCUIT DIAGRAM 8 51 TROUBLESHOOTING 8 52 IMMOBILIZER SYSTEM 8 55 SYSTEM DIAGRAM 8 55 CIRCUIT DIAGRAM 8 56 GENERAL INFORMATION 8 57 KEY CODE REGISTRATION 8 58 SELF DIAGNOSIS MALFUNCTION CODES 8 61 TROUBLESHOOTING 8 62 CHECKING THE IMMOBILIZER SYSTEM 8 63 PART REPLACEMENT KEY REGISTRATION REQUIREMENTS 8 65 ...

Page 295: ... Starter relay 8 Main fuse 9 Coolant temperature sensor 0 Pickup coil stator assembly A Spark plug cap B Ignition coil C Sidestand switch D Radiator fan motor E Horn F Rectifier regulator G Starting circuit cut off relay H Fuel pump relay I Radiator fan motor relay J Headlight relay K Wire harness 2 E G 9 K F 0 A B C D 7 8 6 3 5 4 1 J I H ELECTRICAL COMPONENTS ...

Page 296: ...et tester to 0 and to the Ω 1 range When checking for continuity switch back and forth between the switch positions a few times The terminal connections for switches e g main switch are shown in an illustration simi lar to the one on the left The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row in the switch illustration NOTE _ indicates a c...

Page 297: ...d Properly connect Incorrect continuity reading Replace the switch OFF ON Br R R Br 8 B B BLUE 7 L W W Y W Y L W Br W L W W Y B B B Br W Br W BLACK 5 4 R Y G L B Y Br G B Br B BLACK P B RED B G B Br R Y L B Br B Y G P 1 9 2 3 G Y G Y Br Br 6 0 L B Y G R Y P B Br B Br G B 1 Dimmer pass switch 2 Horn switch 3 Turn signal switch 4 Start switch 5 Hazard switch 6 Front brake light switch 7 Sidestand sw...

Page 298: ...cket or both TYPES OF BULBS The bulbs used on this vehicle are shown in the illustration on the left Bulbs a and b are used for the headlights and usually use a bulb holder that must be detached before removing the bulb The majority of these types of bulbs can be removed from their respective socket by turning them counterclockwise Bulb c is used for turn signal and tail brake lights and can be re...

Page 299: ...ther wise the transparency of the glass the life of the bulb and the luminous flux will be adversely affected If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 2 Check bulb for continuity with the pocket tester No continuity Replace NOTE _ Before checking for continuity set the pocket tester to 0 and to the Ω 1 range a Connect the positive...

Page 300: ...er No continuity Replace NOTE _ Check each bulb socket for continuity in the same manner as described in the bulb section however note the following a Install a good bulb into the bulb socket b Connect the pocket tester probes to the respective leads of the bulb socket c Check the bulb socket for continuity If any of the readings indicate no continuity replace the bulb socket Pocket tester 90890 0...

Page 301: ... Y L B W B L Y Br G Br G B B Gy Gy B Gy R R B L R W L R B P G R G L R B L G L W R G B BLACK R Y B R Y B R Br L R Br B R W W W G L Y B Dg Sb G R Gy B O W B Br G Gy R Br G Gy Br Ch R L Br G B Y L G B Y L B B Br Br Dg G Y B Br Ch G Y B R Y G L B Y P Br G B L B R Y Br B Y G B Br W B Br Ch Dg Br B G B R L B R B L BLACK L W W Y Br W L W W Y B Br W L W B B B B BLUE L Y B BLUE G B L W Sb O W B Br W BLACK ...

Page 302: ...6754 Pocket tester 90890 03112 1 Main ignition and CDI unit fuses Check the main ignition and CDI unit fuses for continuity Refer to CHECKING THE FUSES in chapter 3 Are the main ignition and CDI unit fuses OK Replace the fuse s 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C 68 F Is the battery...

Page 303: ... the start switch and gradually increase the spark gap until a misfire occurs Minimum ignition spark gap 6 mm 0 24 in Is there a spark and is the spark gap within specification The ignition system is OK 5 Spark plug cap resistance Remove the spark plug cap from the spark plug lead Connect the pocket tester Ω 1k range to the spark plug cap as shown Measure the spark plug cap resistance Spark plug c...

Page 304: ...ive tester probe spark plug lead 2 Measure the secondary coil resistance Secondary coil resistance 1 89 2 31 kΩ at 25 C 77 F Is the ignition coil OK Replace the ignition coil 1k 1 2 7 Pickup coil resistance Disconnect the pickup coil coupler from the wire harness Connect the pocket tester Ω 100 to the pickup coil terminal as shown Positive tester probe brown 1 Negative tester probe red 2 Measure t...

Page 305: ...inuity Refer to CHECKING THE SWITCHES Is the sidestand switch OK Replace the side stand switch 10 Wiring Check the entire ignition system wiring Refer to CIRCUIT DIAGRAM Is the ignition system wiring properly con nected and without defects Replace the CDI unit Properly connect or repair the ignition system wiring ...

Page 306: ...Gy R R B L R W L R B P G R G L R B L G L W R G B BLACK R Y B R Y B R Br L R Br B R W W W G L Y B Dg Sb G R Gy B O W B Br G Gy R Br G Gy Br Ch R L Br G B Y L G B Y L B B Br Br Dg G Y B Br Ch G Y B R Y G L B Y P Br G B L B R Y Br B Y G B Br W B Br Ch Dg Br B G B R L B R B L BLACK L W W Y Br W L W W Y B Br W L W B B B B BLUE L Y B BLUE G B L W Sb O W B Br W BLACK Ch B BLACK Dg B GREEN Br G B Br B BLA...

Page 307: ...g conditions are met A brake lever is pulled to the handlebar the brake light switch is closed and the side stand is up the sidestand switch is closed 1 Battery 2 Main fuse 3 Main switch 4 Ignition fuse 5 Starting circuit cut off relay 6 Sidestand switch 7 Signaling system fuse 8 Front brake light switch 9 Rear brake light switch 0 Start switch A Diode B Starter relay C Starter motor ...

Page 308: ...naling system fuses Check the main ignition and signaling system fuses for continuity Refer to CHECKING THE FUSES in chapter 3 Are the main ignition and signaling sys tem fuses OK Replace the fuse s 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C 68 F Is the battery OK Clean the battery termina...

Page 309: ...tarting circuit cut off relay have continuity between green yellow and green black Replace the starting circuit cut off relay 5 Starter relay Remove the starter relay Connect the pocket tester Ω 1 and bat tery 12 V to the starter relay terminal as shown Positive battery terminal green black 1 Negative battery terminal blue white 2 Positive tester probe red 3 Negative tester probe black 4 Does the ...

Page 310: ...h Check the sidestand switch for continuity Refer to CHECKING THE SWITCHES Is the sidestand switch OK Replace the side stand switch 9 Start switch Check the start switch for continuity Refer to CHECKING THE SWITCHES Is the start switch OK Replace the start switch 10 Wiring Check the entire starting system wiring Refer to CIRCUIT DIAGRAM Is the starting system wiring properly con nected and without...

Page 311: ... T R 7 Nm 0 7 m kg 5 1 ft Ib T R 5 Nm 0 5 m kg 3 6 ft Ib Order Job Part Q ty Remarks Removing the starter motor Remove the parts in the order listed Air filter case assembly Refer to AIR FILTER CASE in chapter 3 1 Starter motor lead 1 Disconnect 2 Ground lead 1 Disconnect 3 Starter motor 1 For installation reverse the removal pro cedure ...

Page 312: ...ob Part Q ty Remarks Disassembling the starter motor Remove the parts in the order listed 1 Starter motor front cover 1 Refer to ASSEMBLING THE STARTER MOTOR 2 O ring 1 3 Shim 4 Lock washer 1 5 Oil seal 1 6 Bearing 1 7 Starter motor yoke 1 8 Armature assembly 1 9 O ring 1 0 Shim A Brush holder set 1 B Starter motor rear cover 1 C Bushing 1 For assembly reverse the disassembly procedure ...

Page 313: ...tor NOTE The mica of the commutator must be undercut to ensure proper operation of the commutator 4 Measure armature assembly resistances commuta tor and insulation Out of specification Replace the starter motor a Measure the armature assembly resis tances with the pocket tester b If any resistance is out of specification replace the starter motor Commutator wear limit 27 mm 1 06 in Mica undercut ...

Page 314: ...h spring force 7 65 10 01 N 780 1 021 gf 27 5 36 0 oz 8 Check bearing 1 oil seal 2 bushing 3 Damage wear Replace the defective part s EAS00772 ASSEMBLING THE STARTER MOTOR 1 Install starter motor rear cover 1 armature assembly starter motor yoke 2 starter motor front cover 3 NOTE To prevent damaging the brushes during installation push down on the brush springs Align the alignment marks a on the s...

Page 315: ... G B L W G B R B G Y L Y B L Y L W L W B R R G R L R W Y B W L W R Br R R R R W W W B B L W R G B BLACK R Y B R Y B R Br L R Br B R W W W L W W Y Br W L W W Y B Br W L W B B B B BLUE L Y B BLUE G B L W R B L Y G B G Y BLUE B L B BLACK L B BLACK 1 2 3 å 4 5 6 7 8 9 A B C D E F N G M H L 1 AC magneto 3 Rectifier regulator A Ground lead B Battery C Main fuse ...

Page 316: ...ot with the following special tool s EAS00738 YES NO EAS00739 YES NO The battery is not being charged Pocket tester 90890 03112 1 Main fuse Check the main fuse for continuity Refer to CHECKING THE FUSES in chapter 3 Is the main fuse OK Replace the fuse 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at...

Page 317: ... The charging circuit is OK 4 Stator coil resistance Disconnect the stator coil coupler from the wire harness Connect the pocket tester Ω 1 to the stator coil as shown Positive tester probe red 1 Negative tester probe red 2 Positive tester probe red 1 Negative tester probe red 3 Measure the stator coil resistances Stator coil resistance 0 385 0 415 Ω at 20 C 68 F Is the stator coil OK Replace the ...

Page 318: ... R B L G L W R G B BLACK R Y B R Y B R Br L R Br B R W W W G L Y B Dg Sb G R Gy B O W B Br G Gy R Br G Gy Br Ch R L Br G B Y L G B Y L B B Br Br Dg G Y B Br Ch G Y B R Y G L B Y P Br G B L B R Y Br B Y G B Br W B Br Ch Dg Br B G B R L B R B L BLACK L W W Y Br W L W W Y B Br W L W B B B B BLUE L Y B BLUE G B L W Sb O W B Br W BLACK Ch B BLACK Dg B GREEN Br G B Br B BLACK P B RED B G B Br R Y L B Br...

Page 319: ...s or meter light Pocket tester 90890 03112 1 Main headlight signaling system and CDI unit fuses Check the main headlight signal system and CDI unit fuses for continuity Refer to CHECKING THE FUSES in chapter 3 Are the main headlight signal system and CDI unit fuses OK Replace the fuse s 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum ope...

Page 320: ...relay for continuity Positive battery terminal white black 1 Negative battery terminal blue yellow 2 Positive tester probe red yellow 3 Negative tester probe blue black 4 Does the headlight relay have continuity between red yellow and blue black Replace the head light relay 7 Wiring Check the entire lighting system wiring Refer to CIRCUIT DIAGRAM Is the lighting system wiring properly con nected a...

Page 321: ...witch is set to Headlight Positive tester probe yellow 1 or green 2 Negative tester probe black 3 Headlight coupler G L Y B Br G B Y É DC 20V È 1 3 2 High beam indicator light Positive tester probe yellow 4 Negative tester probe black 5 Meter assembly coupler Set the main switch to ON Start the engine Set the dimmer pass switch to or Measure the voltage DC 12 V of yellow 1 green 2 on the headlight...

Page 322: ...ake light bulbs and sock ets for continuity Refer to CHECKING THE BULBS AND BULB SOCKETS Are the tail brake light bulbs and sockets OK Replace the tail brake light bulb socket or both 1 G L Y B Dg Sb G R O W B Br G Br G Gy Br Ch R L 2 Gy R Gy B 2 Voltage Connect the pocket tester DC 20 V to the tail brake light assembly coupler wire har ness side as shown È Tail brake light left É Tail brake light...

Page 323: ...the voltage within specification This circuit is OK The wiring circuit from the main switch to the headlight assembly coupler is faulty and must be repaired Br G B Y DC 20V 2 1 G L Y B 1 License plate light bulb and socket Check the license plate light bulb and socket for continuity Refer to CHECKING THE BULBS AND BULB SOCKETS Are the license plate light bulb and socket OK Replace the license plat...

Page 324: ...Y G L L G Y Y B GREEN GREEN WHITE WHITE BLACK W L W R Br R R R R W W W B B R Y L B W B L Y Br G Br G B B Gy Gy B Gy R R B L R W L R B P G R G L R B L G L W R G B BLACK R Y B R Y B R Br L R Br B R W W W G L Y B Dg Sb G R Gy B O W B Br G Gy R Br G Gy Br Ch R L Br G B Y L G B Y L B B Br Br Dg G Y B Br Ch G Y B R Y G L B Y P Br G B L B R Y Br B Y G B Br W B Br Ch Dg Br B G B R L B R B L BLACK L W W Y ...

Page 325: ...elay Horn c Horn switch d Turn signal switch f Rear turn signal light right g Tail brake light i Rear turn signal light left j Front turn signal light right k Front turn signal light left p Coolant temperature sensor r Coolant temperature gauge s Fuel level gauge t Speedometer u Multifunction meter w Fuel level warning light y Left turn signal indicator light z Right turn signal indicator light Ai...

Page 326: ...te Pocket tester 90890 03112 1 Main signaling system and backup fuses Check the main signaling system and backup fuses for continuity Refer to CHECKING THE FUSES in chapter 3 Are the main signaling system and backup fuses OK Replace the fuse s 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C 68 ...

Page 327: ...minal as shown Tester positive probe brown 1 Tester negative probe ground Set the main switch to ON Measure the voltage 12 V of brown at the horn terminal Is the voltage within specification The wiring circuit from the main switch to the horn connector is faulty and must be repaired 3 Horn Disconnect the pink connector at the horn terminal Connect a jumper lead 1 to the horn ter minal and ground t...

Page 328: ... brake light switch es 3 Voltage Connect the pocket tester DC 20 V to the tail brake light assembly coupler wire har ness side as shown È Tail brake light left É Tail brake light right Positive tester probe green yellow 1 Negative tester probe black 2 Set the main switch to ON Pull in the brake levers Measure the voltage DC 12 V of green yellow 1 on the tail brake light assembly coupler wire harne...

Page 329: ...tch OK Replace the hazard switch 4 Voltage Connect the pocket tester DC 20 V to the turn signal hazard relay coupler as shown Turn signal function Positive tester probe brown 1 Negative tester probe ground Hazard function Positive tester probe red blue 2 Negative tester probe ground Turn signal function Set the main switch to ON Measure the voltage DC 12 V on brown 1 at the turn signal hazard rela...

Page 330: ...r probe ground Turn signal function Set the main switch to ON Set the turn signal switch to Measure the voltage DC 12 V on choco late 1 at the turn signal hazard relay cou pler Set the turn signal switch to Measure the voltage DC 12 V on dark green 2 at the turn signal hazard relay coupler Hazard function Set the main switch to ON Set the hazard switch to Measure the voltage DC 12 V on choco late ...

Page 331: ...reen 2 Negative tester probe ground 1 2 Br B Ch B Dg B Dg B È 1 2 Br W G Y B Br Ch G Y B Br W G Y B Br Dg G Y B É 2 1 G L Y B Dg Sb G R O W Br G Br G Gy Br Ch R L B Gy B Gy R Ê Set the main switch to ON Set the turn signal switch to or Measure the voltage DC 12 V of the chocolate 1 or dark green 2 at the turn signal light assembly coupler wire har ness side or meter assembly coupler Is the voltage...

Page 332: ...th each full rotation of the front wheel the voltage reading should cycle from 0 6 V to 4 8 V to 0 6 V to 4 8 V Does the voltage reading cycle correctly Replace the speed sensor 2 1 Gy Gy B Gy R R B L 2 Voltage Connect the pocket tester DC 20 V to the meter assembly coupler as shown Positive tester probe gray 1 Negative tester probe black 2 Set the main switch to ON Measure the voltage DC 5 V of g...

Page 333: ...mpty position of the float É Ω 10 87 103 Ω Is the fuel sender OK Replace the fuel sender Sb O W 2 1 È É 2 Voltage Connect the pocket tester DC 20 V to the meter assembly coupler as shown Positive tester probe brown 1 Negative tester probe black 2 Set the main switch to ON Measure the voltage DC 12 V of brown 1 and black 2 at the meter assembly coupler Is the voltage within specification Replace th...

Page 334: ...8 31 kΩ at 30 C 86 F Is the air temperature sensor OK Replace the air tem perature sensor Br G Br G B B 1 2 2 Voltage Connect the pocket tester DC 20 V to the meter assembly coupler as shown Positive tester probe brown 1 Negative tester probe black 2 Set the main switch to ON Measure the voltage DC 12 V of brown 1 and black 2 at the meter assembly coupler Is the voltage within specification Replac...

Page 335: ...rmometer 3 in the coolant Slowly heat the coolant and then let it cool to the specified temperature indicated in the table Check the coolant temperature sensor for continuity at the temperatures indicated below Coolant temperature sensor resistance 80 C 176 F 69 0 Ω 100 C 212 F 37 2 Ω WARNING _ Handle the coolant temperature sensor with special care Never subject the coolant temperature sensor to ...

Page 336: ...e tester probe black 2 Set the main switch to ON Measure the voltage DC 12 V of brown 1 and black 2 at the meter assembly coupler Is the voltage within specification Replace the meter assembly The wiring circuit from the main switch to the meter assem bly coupler is faulty and must be repaired 1 G L Y B B Dg Sb G R O W Br G Br G Gy Br Ch R L 2 Gy B Gy R ...

Page 337: ... Br G Br G B B Gy Gy B Gy R R B L R W L R B P G R G L R B L G L W R G B BLACK R Y B R Y B R Br L R Br B R W W W G L Y B Dg Sb G R Gy B O W B Br G Gy R Br G Gy Br Ch R L Br G B Y L G B Y L B B Br Br Dg G Y B Br Ch G Y B R Y G L B Y P Br G B L B R Y Br B Y G B Br W B Br Ch Dg Br B G B R L B R B L BLACK L W W Y Br W L W W Y B Br W L W B B B B BLUE L Y B BLUE G B L W Sb O W B Br W BLACK Ch B BLACK Dg ...

Page 338: ...O The radiator fan motor fails to turn Pocket tester 90890 03112 1 Main ignition and radiator fan motor fuses Check the main ignition and radiator fan motor fuses for continuity Refer to CHECKING THE FUSES in chapter 3 Are the main ignition and radiator fan motor fuses OK Replace the fuse s 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum...

Page 339: ... faulty and must be replaced 5 Radiator fan motor relay Remove the radiator fan motor relay Connect the pocket tester Ω 1 and bat tery 12 V to the radiator fan motor terminal as shown Check the radiator fan motor relay of conti nuity Positive battery terminal red black 1 Negative battery terminal pink green 2 Positive tester probe red white 3 Negative tester probe blue 4 Does the radiator fan moto...

Page 340: ... 5 4 F NO 2 More than 105 3 C 221 5 4 F YES 3 More than 98 3 C 208 4 5 4 F YES 4 Less than 98 3 C 208 4 5 4 F NO Steps 1 and 2 Heating phase Steps 3 and 4 Cooling phase WARNING Handle the thermo switch with special care Never subject the thermo switch to strong shocks If the thermo switch is dropped replace it T R thermo switch radiator fan motor 30 Nm 3 0 m kg 22 ft lb È The thermo switch circuit...

Page 341: ... R W W W B B R Y L B W B L Y Br G Br G B B Gy Gy B Gy R R B L R W L R B P G R G L R B L G L W R G B BLACK R Y B R Y B R Br L R Br B R W W W G L Y B Dg Sb G R Gy B O W B Br G Gy R Br G Gy Br Ch R L Br G B Y L G B Y L B B Br Br Dg G Y B Br Ch G Y B R Y G L B Y P Br G B L B R Y Br B Y G B Br W B Br Ch Dg Br B G B R L B R B L BLACK L W W Y Br W L W W Y B Br W L W B B B B BLUE L Y B BLUE G B L W Sb O W...

Page 342: ...ION The fuel pump circuit consists of the fuel pump relay fuel pump and CDI unit The CDI unit includes the control unit for the fuel pump 1 Battery 2 Main fuse 3 Main switch 4 Ignition fuse 5 CDI unit 6 CDI unit fuse 7 Fuel pump relay 8 Fuel pump 1 2 3 4 5 6 7 8 ...

Page 343: ...l pump fails to operate Pocket tester 90890 03112 1 Main ignition and CDI unit fuses Check the main ignition and CDI unit fuses for continuity Refer to CHECKING THE FUSES in chapter 3 Are the main ignition and CDI unit fuses OK Replace the fuse s 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C ...

Page 344: ...een 2 Positive tester probe red green 3 Negative tester probe blue 4 Does the fuel pump relay have continuity between red green and blue Replace the fuel pump relay 5 Fuel pump operation Check the fuel pump operation Refer to CHECKING THE FUEL PUMP in chapter 7 Is the fuel pump OK Replace the fuel pump 6 Wiring Check the entire fuel pump system wiring Refer to CIRCUIT DIAGRAM Is the fuel pump syst...

Page 345: ... R R W W W B B R Y L B W B L Y Br G Br G B B Gy Gy B Gy R R B L R W L R B P G R G L R B L G L W R G B BLACK R Y B R Y B R Br L R Br B R W W W G L Y B Dg Sb G R Gy B O W B Br G Gy R Br G Gy Br Ch R L Br G B Y L G B Y L B B Br Br Dg G Y B Br Ch G Y B R Y G L B Y P Br G B L B R Y Br B Y G B Br W B Br Ch Dg Br B G B R L B R B L BLACK L W W Y Br W L W W Y B Br W L W B B B B BLUE L Y B BLUE G B L W Sb O...

Page 346: ...00749 YES NO The auto choke system fails to operate Pocket tester 90890 03112 1 Main and ignition fuses Check the main and ignition fuses for con tinuity Refer to CHECKING THE FUSES in chapter 3 Are the main and ignition fuses OK Replace the fuse s 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 ...

Page 347: ...ted in the table Test step Coolant temperature Continu ity Thermo switch 1 Less than 47 3 C 116 6 5 4 F NO 2 More than 47 3 C 116 6 5 4 F YES 3 More than 42 3 C 107 6 5 4 F YES 4 Less than 42 3 C 107 6 5 4 F NO Steps 1 and 2 Heating phase Steps 3 and 4 Cooling phase WARNING Handle the thermo switch with special care Never subject the thermo switch to strong shocks If the thermo switch is dropped r...

Page 348: ... positive probe green black 1 Tester negative probe yellow 2 Measure the auto choke unit resistance Auto choke resistance 30 Ω at 20 C 68 F Is the auto choke OK Replace the auto choke unit 6 Wiring Check the entire auto choke system wir ing Refer to CIRCUIT DIAGRAM Is the auto choke system wiring properly connected and without defects Replace the CDI unit Properly connect or repair the auto choke ...

Page 349: ...3 Immobilizer system indicator light Br L R G R L R B G W G L G W R R R R R Main switch Ignition fuse immobilizer antenna Backup fuse Meter assembly Immobilizer system indi cator light Main fuse Battery R Red Br L Brown Blue G L Green Blue G W Green White R B Red Black R G Red Green R L Red Blue CDI unit CDI unit fuse ...

Page 350: ... B Gy Gy B Gy R R B L R W L R B P G R G L R B L G L W R G B BLACK R Y B R Y B R Br L R Br B R W W W G L Y B Dg Sb G R Gy B O W B Br G Gy R Br G Gy Br Ch R L Br G B Y L G B Y L B B Br Br Dg G Y B Br Ch G Y B R Y G L B Y P Br G B L B R Y Br B Y G B Br W B Br Ch Dg Br B G B R L B R B L BLACK L W W Y Br W L W W Y B Br W L W B B B B BLUE L Y B BLUE G B L W Sb O W B Br W BLACK Ch B BLACK Dg B GREEN Br G...

Page 351: ...the keys at purchase is not necessary 1 Code re registering key red bow 2 Standard keys black bow CAUTION DO NOT LOSE THE CODE RE REGISTERING KEY If the code re registering key is lost reg istering new codes in the standard keys is impossible The standard keys can still be used to start the vehicle however if code re registering is required i e if a new standard key is made or all keys are lost th...

Page 352: ...standard keys Refer to Standard key registration Standard key registration A standard key should be registered or the other standard keys should be re registered when a reg istered standard key has been lost The standard keys must be re registered when the CDI unit has been replaced and the code re registering key has been re registered NOTE Do not start the engine with a standard key that has not...

Page 353: ...to OFF and then remove the key within 3 seconds 6 Within 5 seconds and using the code re registering key turn the main switch to ON to OFF and then remove the key within 3 seconds NOTE When the indicator light goes off registration is complete NOTE Don t make this registration procedure by standard key for virgin CDI unit If main switch is turned ON with a standard key and CDI unit is virgin then ...

Page 354: ...tion erases the stored standard key codes from memory therefore the lost standard key is disabled Standard key code voiding method If the immobilizer system indicator light stops flashing 5 seconds after the first standard key is registered the second standard key cannot be registered less than 3 0 s less than 10 0 s less than 3 0 s Code re regis tering key Remaining standard key Registration mode...

Page 355: ... Keep magnets metal objects and other immo bilizer system keys away from the keys and antenna Noise interference Check for the possible cause of the interference Main switch and immobilizer antenna Disconnected leads Check the leads Flash pattern 3 Engine cannot start Codes transmitted between the key and CDI unit do not match Others Signal received from other transponder failed to recognize code ...

Page 356: ...uity Refer to CHECKING THE FUSES in chapter 3 Are the main ignition CDI unit and backup fuses OK Replace the fuse s 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C 68 F Is the battery OK Clean the battery terminals Recharge or replace the battery 3 Main switch Check the main switch for continui...

Page 357: ...pler as shown Positive tester probe red blue 1 Negative tester probe black 2 Turn the main switch to ON Measure the voltage DC 12 V at the meter assembly coupler wire harness side Is the voltage within specification Replace the meter assembly The wiring circuit from the main switch to the meter assem bly coupler is faulty and must be repaired 1 G L Y B Dg Sb G R O W B Br G Br G Gy Br Ch R L Gy R G...

Page 358: ...n switch to ON with the code re registering key and check the immobilizer system indicator light Malfunction Second standard key transpon der is defective Correct Re register the stan dard key Malfunc tion Replace the standard key Check the immobilizer system indica tor light is flashing Flashing Determine the malfunction code according to the flash pattern and check the corresponding part Refer t...

Page 359: ...it s Parts to be replaced Required key registration Main switch Standard key CDI unit Accessory lock 2 and key immobilizer antenna Standard key is lost New standard key All keys have been lost including code re reg istering key 1 Code re registering key and standard keys CDI unit is defective Code re registering key and standard keys immobilizer antenna is defective Code re registering key and sta...

Page 360: ...M AND HIGH SPEED PERFORMANCE 9 3 ENGINE 9 3 FUEL SYSTEM 9 3 FAULTY CLUTCH 9 3 ENGINE OPERATES BUT VEHICLE WILL NOT MOVE 9 3 CLUTCH SLIPS 9 3 POOR STARTING PERFORMANCE 9 3 POOR SPEED PERFORMANCE 9 3 OVERHEATING 9 4 ENGINE 9 4 COOLING SYSTEM 9 4 FUEL SYSTEM 9 4 CHASSIS 9 4 ELECTRICAL SYSTEMS 9 4 OVERCOOLING 9 4 COOLING SYSTEM 9 4 POOR BRAKING PERFORMANCE 9 4 FAULTY FRONT FORK LEGS 9 5 LEAKING OIL 9 ...

Page 361: ...NOT COME ON 9 5 HEADLIGHT BULB BURNT OUT 9 5 TAIL BRAKE LIGHT DOES NOT COME ON 9 5 TAIL BRAKE LIGHT BULB BURNT OUT 9 5 TURN SIGNAL DOES NOT COME ON 9 5 TURN SIGNAL FLASHES SLOWLY 9 5 TURN SIGNAL REMAINS LIT 9 5 TURN SIGNAL FLASHES QUICKLY 9 5 HORN DOES NOT SOUND 9 5 ...

Page 362: ...ed valve Piston and piston ring s Improperly installed piston ring Damaged worn or fatigued piston ring Seized piston ring Seized or damaged piston Air filter Improperly installed air filter Clogged air filter element Crankcase and crankshaft Improperly assembled crankcase Seized crankshaft FUEL SYSTEM Fuel tank Empty fuel tank Clogged fuel tank cap breather hole Deteriorated or contaminated fuel ...

Page 363: ...ty start switch Faulty sidestand switch Improperly grounded circuit Loose connections Starting system Faulty starter motor Faulty starter relay Faulty starting circuit cut off relay Faulty starter clutch EAS00847 INCORRECT ENGINE IDLING SPEED ENGINE Cylinder and cylinder head Incorrect valve clearance Damaged valve train components Air filter Clogged air filter element FUEL SYSTEM Carburetor Loose...

Page 364: ...worn primary pulley slider Clutch spring s Damaged clutch spring Transmission gear s Damaged transmission gear CLUTCH SLIPS Clutch shoe spring s Damaged loose or worn clutch shoe spring Clutch shoe s Damaged or worn clutch shoe Primary sliding sheave Seized primary sliding sheave POOR STARTING PERFORMANCE V belt V belt slips Oil or grease on the V belt Primary sliding sheave Faulty operation Worn ...

Page 365: ...se Damaged pipe Improperly connected pipe FUEL SYSTEM Carburetor Incorrect main jet setting Incorrect fuel level Damaged or loose carburetor joint Air filter Clogged air filter element CHASSIS Brake s Dragging brake ELECTRICAL SYSTEMS Spark plug Incorrect spark plug gap Incorrect spark plug heat range Ignition system Faulty CDI unit EAS00856 OVERCOOLING COOLING SYSTEM Thermostat Thermostat stays o...

Page 366: ...ircuit Faulty main switch Faulty dimmer pass switch Headlight bulb life expired TAIL BRAKE LIGHT DOES NOT COME ON Wrong tail brake light bulb Too many electrical accessories Incorrect connection Burnt out tail brake light bulb TAIL BRAKE LIGHT BULB BURNT OUT Wrong tail brake light bulb Faulty battery Incorrectly adjusted front and rear brake light switch Tail brake light bulb life expired TURN SIG...

Page 367: ... light h Tail brake light assembly left i Rear turn signal light left j Front turn signal light right k Front turn signal light left l License plate light m Headlight assembly n Headlight o Auxiliary light p Coolant temperature sensor q Meter assembly r Coolant temperature gauge s Fuel level gauge t Speedometer u Multifunction meter v Meter light w Fuel level warning light x High beam indicator li...

Page 368: ...YAMAHA MOTOR ESPAÑA S A ...

Page 369: ...Y R B L W B B W G W G W R R G R L R W Y G L L G Y Y B GREEN GREEN WHITE WHITE BLACK W L W R Br R R R R W W W B B R Y L B W B L Y Br G Br G B B Gy Gy B Gy R R B L R W L R B P G R G L R B L G L W R G B BLACK R Y B R Y B R Br L R Br B R W W W G L Y B Dg Sb G R Gy B O W B Br G Gy R Br G Gy Br Ch R L Br G B Y L G B Y L B B Br Br Dg G Y B Br Ch G Y B R Y G L B Y P Br G B L B R Y Br B Y G B Br W B Br Ch ...

Page 370: ... SCHEMA ELETTRICO YP250R 2005 DIAGRAMA ELÉCTRICO OFF ON GREEN GREEN WHITE WHITE BLACK BLACK BLACK BLUE BLUE BLACK BLACK GREEN BLACK RED BLUE BLACK BLACK GREEN 1 2 3 6 7 A B C D E F N G M H I J K S T U Y W Z _ b c d e g f h i g j k l m o o n n q r s t u v w x y z 0 8 9 å L a 4 5 Q R P V X p O ...

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Yamaha YP250R 2005, Service Manual

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