Yamaha XVS250 2001 Service Manual Download

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Summary of Contents for XVS250 2001

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Page 3: ...VS250 SERVICE MANUAL 2000 by Yamaha Motor Co Ltd First edition September 2000 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited ...

Page 4: ...ll its models Modifications and signifi cant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable Designs and specifications are subject to change without notice IMPORTANT INFORMATION Particularly important information is distinguished in this manual by the following notations The Safety Alert ...

Page 5: ...hecks and Adjustments where the sub section title s appears In Chapter 3 Periodic checks and Adjustments the sub section title appears at the top of each page instead of the section title 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 ...

Page 6: ...eshooting Symbols 9 to 16 indicate the following 9 Serviceable with engine mounted 10 Filling fluid 11 Lubricant 12 Special tool 13 Tightening torque 14 Wear limit clearance 15 Engine speed 16 Electrical data Symbols 17 to 22 in the exploded diagrams indi cate the types of lubricants and lubrication points 17 Engine oil 18 Gear oil 19 Molybdenum disulfide oil 20 Wheel bearing grease 21 Lithium soa...

Page 7: ... ADJ GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE CARBURETOR ELECTRICAL SYSTEM TROUBLESHOOTING GEN INFO 1 SPEC 2 3 CHAS 4 ENG 5 CARB 6 ELEC 7 TRBL SHTG 8 EAS00011 INDEX ...

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Page 10: ...TIFICATION NUMBER 1 1 MODEL CODE 1 1 IMPORTANT INFORMATION 1 2 PREPARATION FOR REMOVAL PROCEDURES 1 2 REPLACEMENT PARTS 1 2 GASKETS OIL SEALS AND O RINGS 1 2 LOCK WASHER PLATE AND COTTER PINS 1 3 BEARINGS AND OIL SEALS 1 3 CIRCLIPS 1 3 CHECKING THE CONNECTIONS 1 4 SPECIAL TOOLS 1 5 ...

Page 11: ...GEN INFO ...

Page 12: ...ION MOTORCYCLE IDENTIFICATION EB10010 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head MODEL CODE The model code label 1 is affixed to the frame This information will be needed to order spare parts ...

Page 13: ...sassembly clean all of the parts and place them in trays in the order of disassembly This will speed up assembly and allow for the correct installation of all parts 5 Keep all parts away from any source of fire EB101010 REPLACEMENT PARTS 1 Use only genuine Yamaha parts for all re placements Use oil and grease recom mended by Yamaha for all lubrication jobs Other brands may be similar in function a...

Page 14: ...rs are vis ible When installing oil seals apply a light coating of lightweight lithium base grease to the seal lips Oil bearings liberally when installing if appropriate 1 Oil seal Do not use compressed air to spin the bear ings dry This will damage the bearing sur faces 1 Bearing EB101050 CIRCLIPS 1 Check all circlips carefully before reassemb ly Always replace piston pin clips after one use Repl...

Page 15: ...ns Connect and disconnect sev eral times 3 Check all connections Loose connection Connect properly If the pin 1 on the terminal is flattened bend it up 4 Connect lead coupler connector Make sure that all connections are tight 5 Check continuity with the pocket tester Pocket tester 90890 03112 If there is no continuity clean the terminals When checking the wire harness perform steps 1 to 3 As a qui...

Page 16: ...ocker arm shaft Valve adjusting tool 90890 01311 Tappet adjusting tool This tool is used to adjust the valve CLEARANCE T handle 90890 01326 Damper rod holder 90890 01365 T handle Damper rod holder 22 mm These tools are needed to loosen and tighten the damper rod holding bolt 90890 01304 Piston pin puller set This tool is used to remove the piston pin 90890 01312 Fuel level gauge This gauge is used...

Page 17: ... remove and install the valve assemblies 90890 04097 Valve guide remover 5 0 mm This tool is needed to remove the valve guide 90890 04098 Valve guide installer 5 0 mm This tool is needed to install the valve guides properly 90890 04099 Valve guide reamer 5 0 mm This tool is needed to rebore the new valve guide 90890 03141 Timing light This tool is necessary for checloing ignition timing 90890 0311...

Page 18: ... 06754 Ignition checker This instrument is necessary for checking the ignition system components 90890 03081 Compression gauge set These tools are needed to measure engine compression 90890 85505 Yamaha bond No 1215 This sealant bond is used for crankcase mat ing surfaces etc ...

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Page 21: ...ELECTRICAL SPECIFICATONS 2 12 GENERAL TORQUE SPECIFICATIONS 2 14 CONVERSION TABLE 2 14 MAINTENANCE SPECIFICATIONS 2 15 ENGINE 2 15 CHASSIS 2 18 LUBRICATIONS POINTS AND LUBRICANT TYPES 2 20 ENGINE 2 20 CHASSIS 2 21 ENGINE OIL LUBRICATION CHART SPECIFICATIONS 2 22 ENGINE OIL FLOW DIAGRAMS 2 23 CABLE ROUTING 2 26 ...

Page 22: ...SPEC ...

Page 23: ...Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius 2 320 mm 910 mm 1 075 mm 670 mm 1 530 mm 150 mm 2 900 mm Weight Wet with oil and a full fuel tank Dry with out oil and fuel Maximum load total of cargo rider passenger and accessaries 159 kg 147 kg 180 kg ...

Page 24: ...only Regular unleaded gasoline 11 L 3 4 L DDD DDD DDD Engine oil Lubrication system Recommended oil Quantity Total amount Without oil filter cartridge replacement With oil filter cartridge replacement Oil pressure hot Relief valve opening pressure Wet sump SAE20W40SE or SAE10W30SE 1 75 L 1 4 L 1 6 L 50 kPa at 1 300 r min 0 5 kg cm2 at 1 300 r min 450 550 kPa 4 5 5 5 kg cm2 DDD DDD DDD DDD DDD DDD ...

Page 25: ... inside diameter Camshaft journal diameter Camshaft journal to camshaftcap clearance Camshaft lobe dimensions Intake Measurement A Measurement B Measurement C Exhaust Measurement A Measurement B Measurement C Max camshaft runout Chain drive left and right 22 000 22 021 mm 21 96 21 98 mm 0 020 0 061 mm 26 190 mm 1 21 045 mm 2 21 087 mm 5 19 mm 26 190 mm 1 21 087 mm 2 21 045 mm 5 19 mm 26 15 mm 21 0...

Page 26: ...s 0 08 0 12 mm 0 10 0 14 mm Valve head diameter A Intake Exhaust Valve face width B Intake Exhaust Valve seat width C Intake Exhaust Valve margin thickness D Intake Exhaust Valve stem diameter Intake Exhaust Valve guide inside diameter Intake Exhaust Valve stem to valve guide clearance Intake Exhaust Valve stem runout Valve seat width Intake Exhaust 25 9 26 1 mm 21 9 22 1 mm 1 4 3 2 mm 1 7 2 8 mm ...

Page 27: ...st Spring tilt Intake Exhaust Winding direction top view Intake Exhaust 29 75 mm 29 75 mm 25 7 mm 25 7 mm 71 7 79 3 N 71 7 7 93 kg 71 7 79 3 N 71 7 79 3 kg DDD DDD Clockwise Clockwise 28 75 mm 28 75 mm DDD DDD DDD DDD 2 5_ 1 7 mm 2 5_ 1 7 mm DDD DDD Cylinders Cylinder arrangement Bore stroke Compression ratio Bore Air coded 4 stroke 49 66 mm 10 0 1 48 99 49 03 mm DDD DDD DDD 49 1 mm ...

Page 28: ...Top ring Ring type Dimensions B T End gap installed Ring side clearance 2nd ring Ring type Dimensions B T End gap installed Ring side clearance Oil ring Dimensions B T End gap installed 0 02 0 03 mm 48 965 49 005 mm 6 mm 13 002 13 013 mm 0 5 mm Intake side 12 996 13 000 mm 0 002 0 017 mm Barrel 1 0 2 0 mm 0 15 0 30 mm 0 02 0 06 mm Taper 1 0 2 0 mm 0 15 0 30 mm 0 02 0 06 mm 2 0 2 2 mm 0 3 0 9 mm 0 ...

Page 29: ...0 40 1 05 mm 0 020 0 048 mm 0 03 mm Clutch Clutch type Clutch release method Clutch release method operation Operation Clutch cable free play at the end of the clutch lever Friction plates Thickness Plate quantity Clutch plates Thickness Plate quantity Max warpage Clutch springs Free length Spring quantity Wet multiple disc Inner push cam push Cable operation Left hand operation 5 10 mm 2 9 3 1 mm...

Page 30: ...0 08 mm 0 08 mm Shifting mechanism Shift mechanism type Max shift fork guide bar bending installed shift rod length Shift drum and guide bar 276 8 mm 0 025 mm Air filter type Dry element Carburetors Model manufacturer quantity Throttle cable free play at the flange of the throttle grip ID mark Main jet Main air jet Jet needle Needle jet Pilot air jet Pilot outlet Pilot jet Bypass 1 Bypass 2 Bypass...

Page 31: ...el 15 M C MT 3 00 Steel 70 mm DDD DDD DDD DDD DDD DDD 2 0 mm 2 0 mm Front tire Tire type Size Model manufacturer Tire pressure cold 0 90 kg 90 180 kg High speed riding Min tire tread depth Tube 80 100 18 47P CHENG SHIN C 916 INOUE MARBELLA NF27 175 kPa 1 75 kg cm2 1 75 bar 225 kPa 2 25 kg cm2 2 25 bar 225 kPa 2 25 kg cm2 2 25 bar DDD DDD DDD DDD DDD DDD DDD 1 6 mm Rear tire Tire type Size Model ma...

Page 32: ...nsion type Front fork type Front fork travel Spring Free length Spacer length Installed length Spring rate K1 Spring stroke K1 Optional spring available Fork oil Recommended oil Quantity each front fork leg Level from the top of the innertube with the inner tube fullycompressed and without the fork spring Telescopic fork Coil spring oil damper 140 mm 304 4 mm 180 mm 299 4 mm 5 2 N mm 0 52 kg mm 0 ...

Page 33: ...TIONS SPEC Item Standard Limit Swingarm Free play at the end of the swingarm Radial Axial 1 0 mm 1 0 mm Drive chain Model manufacturer Link quantity Drive chain slack Maximum ten link section 428 V DID 146 30 40 mm 129 5 mm ...

Page 34: ...sensor standard resistance 4 0 6 0 kΩ DDD Charging system System type Model manufacturer Nominal output Stater coil resistance color AC magneto TLMX21 DENSO 14 V 23 A at 5000 r min 0 224 0 336 Ω at 20_C W W DDD DDD DDD DDD Voltage regulator Regulator type Model manufacturer No load regulated voltage Semiconductor short circuit SH650D 11 SHINDENGEN 14 1 14 9 V DDD DDD DDD Rectifier Model Rectifier ...

Page 35: ...m 21 mm Starter relay Model manufacturer Amperage Coil resistance MS5F 561 JIDENCO 180 A 4 18 4 62 Ω Horn Horn type Model manufacturer quantity Max amperage Plain YF 12 NIKKO 1 3 A Flasher relay Relay type Model manufacturer Self cancelling device built in Turn signal blinking frequency Wattage Full transistor FE246BH DENSO No 75 95 cycles min 21 W 2 3 4 W Thermo switch Model manufacturer 4TR NIPP...

Page 36: ...10 mm 30 3 0 19 mm 14 mm 85 8 5 22 mm 16 mm 130 13 0 17 mm 12 mm 55 5 5 A Nut B Bolt General torque specifications Nm mDkg EAS00028 CONVERSION TABLE All specification data in this manual are listed in SI and METRIC UNITS Use this table to convert METRIC unit data to IMPERIAL unit data Ex CONVERSION TABLE EB202001 METRIC MULTIPLIER IMP mm x 0 03937 in 2 mm x 0 03937 0 08 in METRIC TO IMP Known Mult...

Page 37: ... pipe and muffler Exhaust pipe cover Muffler mount Crankcase Generator cover Crankcase cover Clutch cover Clutch cable holder and clutch cover Left crankcase straight plug Oil check plug Nozzle One way clutch Primary drive gear Clutch boss Clutch spring Push lever adjusting screw lock nut Bolt Bolt Bolt Bolt Bolt Stud bolt Bolt Screw Nut Bolt Bolt Bolt Bolt Bolt Bolt Nut Screw Screw Screw Bolt Bol...

Page 38: ...arter motor Air induction case cover Air induction case and bracket Air induction case and frame Air filter case and bracket Air cutoff valve and bracket Pipe and cylinder head Screw Nut Screw Bolt Nut Screw Screw Bolt Screw Nut Bolt Bolt Bolt Clamp M8 M16 M5 M6 M8 M10 M6 M5 M6 M5 M6 M6 M6 M5 M6 1 1 1 1 2 1 3 2 2 4 3 2 3 3 2 12 60 3 8 8 10 20 7 5 10 1 3 5 5 5 3 8 2 1 2 6 0 0 38 0 8 1 0 2 0 0 7 0 5...

Page 39: ...2 17 MAINTENANCE SPECIFICATIONS SPEC Cylinder head tightening sequence Crankcase tightening sequence ...

Page 40: ... and stay front upper Engine and frame front lower Engine and stay rear upper Engine and frame rear lower Ignition coil and frame Horn Muffler stay and frame Licence bracket and rear fender Taillight and rear fender Rear fender Rear turn signal light and rear fender Rear fender and wire harness holder Rectifier regulator and battery box Starter relay and battery positive lead Starter relay and wir...

Page 41: ...bleed screw Brake hose union bolt Rear wheel sprocket Chain puller lock nut Sidestand bolt and nut Footrest assembly mounting Rear footrest bracket and frame Sidestand switch Sidestand switch panel and frame M6 M8 M5 M12 M6 M8 M16 M14 M10 M8 M7 M10 M10 M8 M10 M10 M8 M5 M6 7 23 4 3 7 20 59 104 40 23 6 30 40 16 40 40 26 4 7 0 7 2 3 0 4 0 3 0 7 2 0 5 9 10 4 4 0 2 3 0 6 3 0 4 0 1 6 4 0 4 0 2 6 0 4 0 7...

Page 42: ...aft journal big end Piston surface Piston pin Camshaft cam lobe journal Rocker arm shaft Valve stem IN EX Valve stem end IN EX Timing chain drive gear shafts sprockets Oil pump rotor inner outer housing Starter idle gear Starter idle gear shaft Push rod 1 2 Transmission gear wheel pinion Shift cam Shift fork guide bar Shift shaft assembly Push rod ball Push lever assembly Crankcase mating surface ...

Page 43: ... seal lip right left Rear wheel oil seal lip Clutch hub fitting area Rear brake pedal shaft Shift pedal shaft Sidestand bolt sidestand sliding surface Tube guide throttle grip inner surface Brake lever pivot bolt contact surface Clutch lever pivot bolt contact surface Speedometer gear unit Rear brake camshaft journal Rear brake shoe plate anchor pin Swingarm pivot bearing inner surface Swingarm pi...

Page 44: ...Splashed Crankshaft Drive axle Main axle 2 Cam shaft 1 Cam shaft Bypass valve Oil filter Relief valve Oil pump Oil pan ENGINE OIL LUBRICATION CHART SPECIFICATIONS SPEC ENGINE OIL LUBRICATION CHART SPECIFICATIONS Item Standard Lubrication chart ...

Page 45: ...2 23 ENGINE OIL FLOW DIAGRAMS SPEC EB205000 ENGINE OIL FLOW DIAGRAMS ...

Page 46: ...2 24 ENGINE OIL FLOW DIAGRAMS SPEC ...

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Page 48: ... brake switch lead 11 Vacuum hose 12 Air induction system assembly A Clamp the vacuum hose Avoid the bold section B To the carburetor joint C Connect the ignition coil lead orange lead upper red lead lower D Route the right handlebar switches lead and front brake switch lead through the hole of frame from inside to out side E Clamp the rear brake switch lead F To the cylinder head 2 G Clamp H To t...

Page 49: ... Carburetor heater lead 17 Carburetor heater ground lead 18 Flasher relay 19 Headlight relay 20 Carburetor heater relay 21 Thermo switch lead 22 Thermo switch 23 Horn lead 24 Horn 25 Ignition coil lead 26 Ignition coil 2 27 Left side cover 28 Wire harness 29 Throttle cable 30 Ground connection lead 31 Battery negative lead 32 Alarm lead 33 Starter motor lead 34 A C magneto lead 35 Vacuum hose 36 R...

Page 50: ...p end to inward D Route the speedometer cable speedometer leads and fuel tank breather hose through the hole of fuel tank E Clamp the white tape section of wireharness F Clamp the wireharness and leads backward of 3 coulers G Clamp the wireharness back ward of branch H Clamp end faces to bottom CABLE ROUTING SPEC O Connect the ignition coil leads gray lead upper red lead lower P Clamp the wireharn...

Page 51: ...harness B To the engine C Through the fuel tank breather hose between wireharness and leads D To the fuel tank E Bend the tip of cramp to backward F Clamp the wireharness battery negative leads starter motor lead alarm lead A C magneto lead and sidestand lead Clamp end faces to inward CABLE ROUTING SPEC 1 Throttle cable 2 Brake hose 3 Speedometer cable 4 Fuel tank breather hose 5 Battery negative ...

Page 52: ... lead and high tension code 2 O Do not slack the leads this area CABLE ROUTING SPEC P Clamp the wireharness left handlebar switches lead clutch switch lead right handlebar switches lead front brake switch lead throttle cable starter cable and thermo switch lead Q Put the alarm coupler to this area surrourded by inner panel R Bend over the alarm lead and cramped it with wireharness S To starter mot...

Page 53: ...15 Igniter unit lead CABLE ROUTING SPEC 16 Carburetor heater lead 17 Throttle position sensor lead 18 Ignition coil 1 lead 19 Horn lead 20 Thermo switch lead 21 Ignition coil 2 lead 22 Main switch lead 23 White tape for fix the position 24 Main switch 25 Front brake switch lead A Route the front brake switch lead through the hole of frame from inside to outside B Clamp the white tape section of wi...

Page 54: ...d of head pipe and outside of throttle cables 1 Throttle cables 2 Brake hose 3 Right handlebar switches 4 Front brake switch lead 5 Clutch switch lead 6 Left handlebar switch lead 7 Starter cable 8 Clutch cable 9 Headlight lead CABLE ROUTING SPEC ...

Page 55: ... 10 Hose 3 11 Hose 4 12 Air induction case 13 Air induction case cover CABLE ROUTING SPEC A White paint mark of hose faces to the top B Aligh the white paint mark of hose and arrow mark of nozzle C Clamp the vacuum hose 2 Avoid connecting the bold section D Clamp the vacuum hose 2 E White paint mark of hose faces to the top ...

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Page 58: ...20 CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD 3 21 CHECKING THE FUEL HOSES 3 22 CHECKING THE CRANKCASE BREATHER HOSE 3 22 CHECKING THE EXHAUST SYSTEM 3 23 CHASSIS 3 24 ADJUSTING THE FRONT BRAKE 3 24 ADJUSTING THE REAR BRAKE 3 24 CHECKING THE BRAKE FLUID LEVEL 3 26 CHECKING THE BRAKE PADS 3 27 CHECKING THE BRAKE SHOES 3 27 ADJUSTING THE REAR BRAKE LIGHT SWITCH 3 27 CHECKING THE BRAKE HOSE 3 ...

Page 59: ...D PEDALS 3 39 LUBRICATING THE SIDESTAND 3 39 LUBRICATING THE REAR SUSPENSION 3 39 ELECTRICAL SYSTEM 3 40 CHECKING AND CHARGING THE BATTERY 3 40 CHECKING THE FUSES 3 46 REPLACING THE HEADLIGHT BULB 3 47 ADJUSTING THE HEADLIGHT BEAM 3 48 ...

Page 60: ...r element Clean 5 Air filter element Replace 6 Clutch Check operation Adjust 7 Front brake Check operation fluid level and vehicle for fluid leakage 7 Front brake Replace brake pads Whenever worn to the limit 8 Rear brake Check operation and adjust brake pedal freeplay 8 Rear brake Replace brake shoes Whenever worn to the limit 9 Brake hose Check for cracks or damage 9 Brake hose Replace Every 4 y...

Page 61: ...eck the air cut valve and reed valve for damage D Replace the entire air induction system necessary 27 Lights signals and switches D Check operation D Adjust headlight beam D The air filter needs more frequent service if you are reding in unusually wet or dusty areas D Hydraulic brake service SRegularly check and if necessary correct the brake fluid level SEvery two years replace the internal comp...

Page 62: ...and passenger seats Passenger seat Seat bracket Rider s seat 1 1 1 Remove the parts in the order listed For installation reverse the removal procedure 7 Nm 0 7 mSkg 5 1 ftSlb 20 Nm 2 0 mSkg 14 ftSlb RIDER AND PASSENGER SEATS CHK ADJ RIDER AND PASSENGER SEATS ...

Page 63: ...e Speedometer cable Speedometer lead coupler Fuel tank Air filter 1 1 1 1 1 1 1 1 Remove the parts in the order listed Refer to RIDER AND PASSENGER SEATS Set the fuel cock to ON or RES before disconnecting the fuel hose Disconnect For installation reverse the removal procedure NOTE 7 Nm 0 7 mSkg 23 Nm 2 3 mSkg FUEL TANK AND AIR FILTER CHK ADJ FUEL TANK AND AIR FILTER ...

Page 64: ...enter in with a screwdriver then pull the fastener out INSTALLATION 1 Install SIgnitor plate To install the quick fastener push its pin so that it protrudes from the fastener head then insert the fastener into the cowling and push the pin a in with a screwdriver Make sure that the pin is flush with the fastener s head ...

Page 65: ...be measured or adjusted the piston must be at top dead center TDC on the compression stroke 1 Remove rider and passenger seats Refer to RIDER AND PASSENGER SEATS fuel tank Refer to FUEL TANK AND AIR FILTER air filter assembly 1 Refer to FUEL TANK AND AIR FILTER 2 Disconnect spark plug caps 3 Remove spark plugs 4 Remove damper 1 frame cover 2 silencer assembly 3 5 Remove cylinder head side covers 1...

Page 66: ... 1 7 Remove Scamshaft sprocket cover front cylinder 1 Scamshaft sprocket cover rear cylinder 8 Remove Stiming plug 1 Sstraight plug 2 9 Measure Svalve clearance Out of specification Adjust Valve clearance cold Intake valve 0 08 X 0 12 mm Exhaust valve 0 10 X 0 14 mm ...

Page 67: ... stationary pointer e on the genera tor cover A Front cylinder T mark d Measure the valve clearance with a thick ness gauge 1 e Turn the crankshaft counterclockwise 300 and then align the I mark d on the genera tor rotor with the stationary pointer e on the generator cover B Rear cylinder I mark f Measure the valve clearance with a thick ness gauge 1 10 Adjust valve clearance a Loosen the locknut ...

Page 68: ...ll removed parts in the reverse order of their disassembly Note the following points Scamshaft sprocket covers Stappet covers Sspark plugs EAS00054 ADJUSTING THE ENGINE IDLING SPEED Prior to adjusting the engine idling speed the air filter should be clean and the engine should have adequate compression 1 Start the engine and let it warm up for several minutes 2 Install Sengine tachometer to the sp...

Page 69: ...t screw 2 5 8 turns out c Turn the throttle stop screw 1 in direction a or b until the specified engine idling speed is obtained Direction Engine idling speed is increased Direction Engine idling speed is decreased 5 Adjust Sthrottle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY Throttle cable free play at the flange of the throttle grip 3 X 5 mm ...

Page 70: ...ut 1 b Turn the adjusting nut 2 in direction a or b until the specified throttle cable free play is obtained Direction Throttle cable free play is increased Direction Throttle cable free play is decreased c Tighten the locknuts 1 If the specified throttle cable free play cannot be obtained on the carburetor side of the cable use the adjusting nut on the handlebar side Handlebar side a Loosen the l...

Page 71: ...g Before removing the spark plug blow away any dirt accumulated in the spark plug well with compressed air to prevent it from fal ling into the cylinder 3 Check Sspark plug type Incorrect Change Spark plug type manufacturer CR6HSA NGK U20FSR U DENSO 4 Check Selectrode 1 Damage wear Replace the spark plug Sinsulator 2 Abnormal color Replace the spark plug Normal color is a medium to light tan color...

Page 72: ...3 13 CHECKING THE SPARK PLUGS CHK ADJ 13 Nm 1 3 mSkg NOTE 7 Install Sspark plug Before installing the spark plug clean the spark plug and gasket surface 8 Connect Sspark plug cap ...

Page 73: ...t 1 Sengine tachometer 2 to the spark plug lead of cyl 1 Timing light 90890 03141 Engine tachometer 90890 03113 3 Check Signition timing a Start the engine warm it up for several min utes and then let it run at the specified en gine idling speed Engine idling speed 1 200 X 1 400 r min b Check that the mark a on the generator ro tor is within the firing range b on the genera tor cover Incorrect fir...

Page 74: ...it up for several min utes and then turn it off 3 Disconnect Sspark plug cap 4 Remove Sspark plug Before removing the spark plugs use com pressed air to blow away any dirt accumu lated in the spark plug wells to prevent it from falling into the cylinders 5 Install Scompression gauge 1 Compression gauge set 90890 03081 6 Measure Scompression pressure Above the maximum pressure Inspect the cylinder ...

Page 75: ...r Compression pressure at sea level Compression pressure at sea level Standard 1 100 kPa 11 kg cm2 11 bar Minimum 1 000 kPa 10 kg cm2 10 bar Maximum 1 200 kPa 12 kg cm2 12 bar a Turn the main switch to ON b With the throttle wide open crank the engine until the reading on the compression gauge stabilizes To prevent sparking ground all spark plug leads before cranking the engine The difference in c...

Page 76: ...d engine oil Refer to the chart for the engine oil grade which is best suited for certain atmospheric temperatures API standard SE or higher grade ACEA standard G4 or G5 SEngine oil also lubricates the clutch and the wrong oil types or additives could cause clutch slippage Therefore do not add any chemical additives or use engine oils with a grade of CD a or higher and do not use oils labeled ENER...

Page 77: ... Drain Sengine oil completely from the crankcase 5 If the oil filter element is also to be replaced perform the following procedure a Remove the oil filter element cover 1 and oil filter element 2 b Check the O ring 3 and replace it if it is cracked or damaged c Install the new oil filter element and the oil fil ter element cover Oil filter element cover bolt 10 Nm 1 0 mSkg 6 Check Sengine oil dra...

Page 78: ...DJUSTING THE CLUTCH CABLE FREE PLAY 1 Check Sclutch cable free play a Out of specification Adjust Clutch cable free play at the end of the clutch lever 5 X 10 mm 2 Adjust Sclutch cable free play Handlebar side a Loosen the locknut 1 b Turn the adjusting bolt 2 in direction a or b until the specified clutch cable free play is ob tained Direction Clutch cable free play is increased Direction Clutch ...

Page 79: ...h cable free play is increased Direction Clutch cable free play is decreased c Tighten the locknut 1 CLEANING THE AIR FILTER ELEMENT 1 Remove Sair filter case assembly 1 Sair filter case cover Sair filter element 1 2 Clean Sair filter element Apply compressed air to the inner surface of the air filter element 3 Check Sair filter element Damage Replace 4 Install Sair filter element Sair filter case...

Page 80: ...e without the air filter element will also affect the carburetor tuning leading to poor en gine performance and possible overheat ing When installing the air filter element into the air filter case cover be sure their sealing surfaces are aligned to prevent any air leaks EAS00094 CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD 1 Remove Sfuel tank Ssilencer 2 Check Scarburetor joint 1 Cracks dama...

Page 81: ...hose 2 Cracks damage Replace Damage dirt Replace SDrain and flush the fuel tank if abrasive dam age to any components of the fuel line is evi dent 3 Install Ssilencer Sfuel tank EAS00098 CHECKING THE CRANKCASE BREATHER HOSE 1 Remove Sfuel tank Ssilencer 2 Check Scrankcase breather hose 1 Cracks damage Replace Loose connection Connect properly Make sure that the crankcase breather hose is routed co...

Page 82: ...st pipe muffler and gaskets 1 Check Sexhaust pipe 1 Smuffler 2 Cracks damage Replace Sgaskets 3 New Exhaust gas leaks Replace 2 Check Stightening torque Exhaust pipe nut 4 10 Nm 1 0 mSkg Exhaust pipe and muffler bolt 5 10 Nm 1 0 mSkg Muffler and muffler bracket bolt 6 25 Nm 2 5 mSkg Front exhaust pipe and muffler 7 12 Nm 1 2 mSkg ...

Page 83: ...Tighten the locknut A soft or spongy feeling in the brake lever can indicate the presence of air in the brake system Before the vehicle is operated the air must be removed by bleeding the brake system Air in the brake system will consid erably reduce braking performance and could result in loss of control and possibly an accident Therefore check and if neces sary bleed the brake system After adjus...

Page 84: ...Locknut 10 Nm 1 0 mSkg 3 Check Sbrake pedal free play a Out of specification Adjust Brake pedal free play 20 X 30 mm 4 Adjust Sbrake pedal free play a Turn the adjusting nut 1 in direction a or b until the specified brake pedal free play is ob tained Direction Brake pedal free play is increased Direction Brake pedal free play is decreased After adjusting the brake pedal position and free play make...

Page 85: ... cause the rubber seals to deteriorate causing leakage and poor brake performance SRefill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake perfor mance SWhen refilling be careful that water does not enter the reservoir Water will signifi cantly lower the boiling point of the brake fluid and could cau...

Page 86: ...place the brake shoes as a set Refer to REAR WHEEL in chapter 6 EAS00128 ADJUSTING THE REAR BRAKE LIGHT SWITCH The rear brake light switch is operated by move ment of the brake pedal The rear brake light switch is properly adjusted when the brake light comes on just before the braking effect starts 1 Check Srear brake light operation timing Incorrect Adjust 2 Adjust Srear brake light operation tim...

Page 87: ...draulic brake system whenev er SThe system was disassembled SA brake hose was loosened or removed SThe brake fluid level is very low SBrake operation is faulty SBe careful not to spill any brake fluid or allow the brake master cylinder reservoir to over flow SWhen bleeding the hydraulic brake system make sure that there is always enough brake fluid before applying the brake Ignoring this precautio...

Page 88: ... times f Fully squeeze the brake lever without releas ing it g Loosen the bleed screw This will release the tension and cause the brake lever to contact the throttle grip h Tighten the bleed screw and then release the brake lever i Repeat steps e to h until all of the air bubbles have disappeared from the brake fluid in the plastic hose j Tighten the bleed screw to specification Bleed screw 6 Nm 0...

Page 89: ... shift pedal position Direction shift pedal is raised Direction shift pedal is lowered EAS00141 ADJUSTING THE DRIVE CHAIN SLACK The drive chain slack must be checked at the tightest point on the chain A drive chain that is too tight will overload the engine and other vital parts and one that is too loose can skip and damage the swin garm or cause an accident Therefore keep the drive chain slack wi...

Page 90: ...3 b Turn the chain puller nut 2 in direction a or b until the specified drive chain slack is ob tained Direction Drive chain is tightened Direction Drive chain is loosened To maintain the proper wheel alignment adjust both sides evenly c Tighten the wheel axle nut Wheel axle nut 104 Nm 10 4 m kg Do not loosen the wheel axle nut after tight ening it to the specified torque If the groove in the whee...

Page 91: ...erefore use only kerosine to clean the drive chain Wipe the drive chain dry and thoroughly lubricate it with engine oil or chain lubricant that is suitable for O ring chains Do not use any other lubricants on the drive chain since they may contain solvents that could damage the O rings Recommended lubricant Engine oil or chain lubricant suitable for O ring chains EAS00146 CHECKING AND ADJUSTING TH...

Page 92: ...que wrench at a right angle to the ring nut wrench Ring nut wrench 90890 01043 Lower ring nut initial tightening torque 52 Nm 5 2 m kg c Loosen the lower ring nut 4 completely then tighten it to specification Do not overtighten the lower ring nut Lower ring nut final tightening torque 18 Nm 1 8 m kg d Check the steering head for looseness or binding by turning the front fork all the way in both di...

Page 93: ...e sure that the lock washer tabs a sit cor rectly in the ring nut slots b 5 Install upper bracket steering stem nut upper bracket pinch bolt EAS00149 CHECKING THE FRONT FORK 1 Stand the motorcycle on a level surface Securely support the motorcycle 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 motorcycle upright and...

Page 94: ...ring preload Never go beyond the maximum or minimum adjustment positions 1 Adjust spring preload Adjust the spring preload with the special wrench and extension bar included in the own er s tool kit a Turn the adjusting ring 1 in direction a or b Direction Spring preload is increased suspension is harder Direction Spring preload is decreased suspension is softer Adjusting positions Standard 2 Mini...

Page 95: ...speed Operation of an overloaded motorcycle could cause tire damage an accident or an injury NEVER OVERLOAD THE MOTORCYCLE Basic weight with oil and a full fuel tank 159 kg Maximum load 180 kg Cold tire pressure Front tire Rear tire Up to 90 kg load 175 kPa 1 75 kgf cm2 200 kPa 2 00 kgf cm2 90 kg maximum load 225 kPa 2 25 kgf cm2 225 kPa 2 25 kgf cm2 High speed riding 225 kPa 2 25 kgf cm2 225 kPa ...

Page 96: ... is not recom mended If it is absolutely necessary to do so use great care and replace the tube as soon as possible with a good quality re placement Tube wheel Tube tire only Tubeless wheel Tube or tubeless tire After extensive tests the tires listed below have been approved by Yamaha Motor Co Ltd for this model The front and rear tires should always be by the same manufactur er and of the same de...

Page 97: ...speed riding is done For tires with a direction of rotation mark 1 Install the tire with the mark pointing in the direction of wheel rotation Align the mark 2 with the valve installation point EAS00169 CHECKING AND TIGHTENING THE SPOKES The following procedure applies to all of the spokes 1 Check spoke 1 Bends damage Replace Loose Tighten Tap the spokes with a screwdriver A tight spoke will emit a...

Page 98: ...Lubricate Recommended lubricant Engine oil or a suitable cable lubricant Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suit able lubing device EAS00171 LUBRICATING THE LEVERS AND PEDALS Lubricate the pivoting point and metal to metal moving parts of the levers and pedals Recommended lubricant Lithium soap base grease EAS00172 LUBRICATING THE SIDESTAND ...

Page 99: ...electrolyte 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 atten tion This is a sealed battery Never remove the sealing caps...

Page 100: ...over 3 2 Disconnect battery leads from the battery terminals First disconnect the negative lead 1 then the positive lead 2 3 Remove battery 3 4 Check battery charge a Connect a pocket tester to the battery termi nals Tester positive lead battery positive terminal Tester negative lead battery negative terminal The charge state of a MF battery can be checked by measuring its open circuit voltage i e...

Page 101: ...ne with the battery mounted on the motorcycle disconnect the negative lead from the battery terminal DTo reduce the chance of sparks do not plug in the battery charger until the battery charger leads are connected to the battery DBefore removing the battery charger lead clips from the battery terminals be sure to turn off the battery charger DMake sure that the battery charger lead clips are in fu...

Page 102: ...g cur rent after 5 min utes replace the battery In case that charging requires more than 5 hours it is advisable to check the charging current after a lapse of 5 hours If there is any charge in the amperage readjust the voltage to obtain the standard charging current Measure the battery open circuit voltage after having left the battery unused for more than 30 minutes 12 8 V or more Charging is co...

Page 103: ...r cannot charge the MF battery A variable volt age charger is recommended Measure the battery open circuit voltage after having left the battery unused for more than 30 minutes 12 8 V or more Charging is com plete 12 7 V or less Recharging is re quired Under 12 0 V Replace the battery NOTE Set the charging time at 20 hours maxi mum YES NO Charging method using a constant current type charger This ...

Page 104: ...yte or hydrogen gas from the bat tery to contact the frame the motorcycle and its finish may be damaged Make sure that the battery breather hose is properly routed away from the drive chain and from below the swingarm 8 Connect battery leads to the battery terminals First connect the positive lead 1 then the negative lead 2 9 Check battery terminals Dirt Clean with a wire brush Loose connection Co...

Page 105: ... continuity Set the pocket tester selector to Ω 1 Pocket tester 90890 03112 b If the pocket tester indicates replace the fuse 3 Replace blown fuse a Turn off the ignition b Install a new fuse of the correct amperage rating c Turn on the switches to verify if the electrical circuit is operational d If the fuse immediately blows again check the electrical circuit Fuses Amperage rating Quantity Main ...

Page 106: ...ighting and ignition systems to malfunction and could possibly cause a fire 4 Install left side cover EAS00182 REPLACING THE HEADLIGHT BULB 1 Disconnect connector 1 2 Remove headlight bulb cover 2 3 Remove headlight bulb holder 1 4 Remove headlight bulb 2 Since the headlight bulb gets extremely hot keep flammable products and your hands away from the bulb until it has cooled down 5 Install headlig...

Page 107: ...oughly clean it with a cloth moistened with alcohol or lacquer thinner 6 Install headlight bulb holder 7 Install headlight bulb cover 8 Connect leads EAS00184 ADJUSTING THE HEADLIGHT BEAM 1 Adjust headlight beam vertically a Turn the adjusting screw 1 in direction a or b Direction Headlight beam is raised Direction Headlight beam is lowered 2 Adjust headlight beam horizontally a Turn the adjusting...

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Page 109: ...WHEEL 4 19 ADJUSTING THE REAR WHEEL STATIC BALANCE 4 19 FRONT AND REAR BRAKES 4 20 FRONT BRAKE PADS 4 20 REPLACING THE FRONT BRAKE PADS 4 22 FRONT BRAKE MASTER CYLINDER 4 24 REMOVING THE FRONT BRAKE MASTER CYLINDER 4 26 CHECKING THE FRONT BRAKE MASTER CYLINDERS 4 27 INSTALLING THE FRONT BRAKE MASTER CYLINDER 4 28 FRONT BRAKE CALIPER 4 30 DISASSEMBLING THE FRONT BRAKE CALIPER 4 32 CHECKING THE FRON...

Page 110: ...INGARM 4 57 REAR SHOCK ABSORBER ASSEMBLY 4 57 SWINGARM 4 58 HANDLING THE REAR SHOCK ABSORBER 4 59 REMOVING THE REAR SHOCK ABSORBER ASSEMBLIES 4 60 REMOVING THE DRIVE CHAIN 4 60 REMOVING THE SWINGARM 4 61 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 4 62 CHECKING THE SWINGARM 4 62 CHECKING THE DRIVE CHAIN 4 64 INSTALLING THE SWINGARM 4 66 INSTALLING THE DRIVE CHAIN 4 67 ...

Page 111: ... the order listed Place the motorcycle on a suitable stand so that the front wheel is elevated Securely support the motorcycle so there is no danger of it falling over For installation reverse the removal procedure NOTE Refer to REMOVING INSTALLING THE FRONT WHEEL Refer to INSTALLING THE FRONT WHEEL WARNING 20 Nm 2 0 m kg 40 Nm 4 0 m kg 59 Nm 5 9 m kg 23 Nm 2 3 m kg FRONT WHEEL AND BRAKE DISC CHAS...

Page 112: ...Order Job Part Q ty Remarks Disassembling the front wheel Oil seal Speedometer clutch retainer Speedometer clutch Bearing Collar 2 1 1 2 1 Disassemble the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 4 5 ...

Page 113: ...emove brake caliper 1 Do not squeeze the brake lever when removing the brake caliper 3 Remove pinch bolt front wheel axle 2 front wheel axle 3 4 Elevate front wheel Place the motorcycle on a suitable stand so that the front wheel is elevated EAS00526 CHECKING THE FRONT WHEEL 1 Check wheel axle Roll the wheel axle on a flat surface Bends Replace Do not attempt to straighten a bent wheel axle 2 Chec...

Page 114: ...ut 1 front wheel lateral runout 2 Over the specified limits Replace Front wheel radial runout limit 2 0 mm Front wheel lateral runout limit 2 0 mm 6 Check collars Damage wear Replace New tires have a relatively low grip on the road surface until they have been slightly worn Therefore approximately 100 km should be traveled at normal speed before any highspeed riding is done 7 Check wheel bearings ...

Page 115: ...ring center race 4 or balls 5 Contact should be made only with the outer race 6 Use a socket 3 that matches the diameter of the wheel bearing outer race and oil seal EAS00531 CHECKING THE BRAKE DISC 1 Check brake disc Damage galling Replace 2 Measure brake disc deflection 1 Out of specification Correct the brake disc deflection or replace the brake disc Brake disc deflection limit maximum Front 0 ...

Page 116: ...on Replace Brake disc thickness limit minimum Front 4 5 mm 4 Adjust brake disc deflection a Remove the brake disc b Rotate the brake disc by one bolt hole c Install the brake disc Tighten the brake disc bolts in stages and in a crisscross pattern Brake disc bolt 23 Nm 2 3 m kg LOCTITE d Measure the brake disc deflection e If out of specification repeat the adjustment steps until the brake disc def...

Page 117: ...arings oil seal lips speedometer drive gear speedometer driven gear Recommended lubricant Lithium soap base grease 2 Install speedometer gear unit Make sure that the speedometer gear unit and the wheel hub are installed with the two projec tions meshed into the two slots respectively 3 Install front wheel assembly Make sure that the slot b in the speedometer gear unit fits over the stopper c on th...

Page 118: ...4 0 m kg WARNING CAUTION 4 Tighten wheel axle 1 wheel axle pinch bolt 2 brake caliper bolts 3 Make sure that the brake cable is routed properly Before tightening the wheel axle nut push down hard on the handlebar several times and check if the front fork rebounds smooth ly ...

Page 119: ... the front wheel 90_ so that the X1 mark is positioned as shown d Release the front wheel e When the wheel stops put an X2 mark at the bottom of the wheel f Repeat steps b through d several times until all the marks come to rest at the same spot g The spot where all the marks come to rest is the front wheel s heavy spot X 3 Adjust Dfront wheel static balance a Install a balancing weight 1 onto the...

Page 120: ...EL AND BRAKE DISC CHAS 4 Check front wheel static balance a Turn the front wheel and make sure that it stays at each position shown b If the front wheel does not remain stationary at all of the positions rebalance it ...

Page 121: ...t washer Chain puller Rear wheel assembly 1 1 1 1 1 1 1 2 2 2 2 1 Remove the parts in the order listed Place the motorcycle on a suitable stand so that the rear wheel is elevant For installation reverse the removal procedure NOTE 23 Nm 2 3 m kg 16 Nm 1 6 m kg 104 Nm 10 4 m kg 16 Nm 1 6 m kg REAR WHEEL AND REAR BRAKE CHAS REAR WHEEL AND REAR BRAKE REAR WHEEL ...

Page 122: ...rocket Shoe plate Sprocket Collar Oil seal Bearing Rear wheel drive hub Rear wheel drive hub damper Rear wheel 1 1 1 1 1 1 4 1 Remove the parts in the order listed For installation reverse the removal procedure 40 Nm 4 0 m kg REAR WHEEL AND REAR BRAKE CHAS REAR BRAKE AND REAR WHEEL SPROCKET ...

Page 123: ... 13 REAR WHEEL AND REAR BRAKE CHAS Order Job Part Q ty Remarks Disassembling the rear wheel Bearing Spacer 2 1 Disassemble the parts in the order listed For assembly reverse the disassembly procedure 1 2 ...

Page 124: ...e shoe plate Brake shoe Tension spring Camshaft lever Indicator plate Camshaft Brake shoe plate 2 2 1 1 1 1 Disassemble the parts in the order listed For assembly reverse the disassembly procedure Refer to REMOVING THE REAR WHEEL ASSEMBLING THE BRAKE SHOE PLATE 1 2 3 4 5 6 9 Nm 0 9 m kg ...

Page 125: ...ing over Place the motorcycle on a suitable stand so that the rear wheel is elevated 2 Remove tension bar 1 3 Remove wheel axle 2 rear wheel Push the rear wheel forward and remove the drive chain from the rear wheel sprocket 4 Remove brake shoe plate 5 Remove brake shoes 1 brake camshaft lever 2 Mark the position on the brake camshaft lever where it is aligned with the punch mark in the brake cams...

Page 126: ... REAR WHEEL DRIVE HUB 1 Check rear wheel drive hub 1 Cracks damage Replace rear wheel drive hub dampers 2 Damage wear Replace EAS00568 CHECKING AND REPLACING THE REAR WHEEL SPROCKET 1 Check rear wheel sprocket More than 1 4 tooth a wear Replace the rear wheel sprocket Bent teeth Replace the rear wheel sprock et b Correct 1 Drive chain roller 2 Rear wheel sprocket 2 Replace rear wheel sprocket a Re...

Page 127: ...Glazed areas Repair Sand the glazed areas with course sandpa per After sanding the glazed areas clean the brake shoe with a cloth 2 Measure brake shoe lining thickness a Out of specification Replace Brake shoe lining thickness limit minimum 2 mm Do not allow oil or grease to contact the brake shoes Replace the brake shoes as a set if either is worn to the wear limit 3 Measure brake drum inside dia...

Page 128: ...cratches with an emery cloth 5 Check brake camshaft Damage wear Replace EAS00570 ASSEMBLING THE BRAKE SHOE PLATE 1 Install brake camshaft 1 spring brake shoe wear indicator 2 a Install the camshaft lever so its punch mark c is positioned as shown b Align the projection a on the brake shoe wear indicator with the notch b in the brake shoe camshaft c Check that the brake shoes are properly positione...

Page 129: ... chain slack 30 40 mm Refer to ADJUSTING THE DRIVE CHAIN SLACK in chapter 3 3 Tighten wheel axle nut Make sure that the brake hose is routed properly EAS00575 ADJUSTING THE REAR WHEEL STATIC BALANCE After replacing the tire wheel or both the rear wheel static balance should be adjusted Adjust the rear wheel static balance with the brake disc and rear wheel drive hub installed 1 Adjust rear wheel s...

Page 130: ...ds Retaining bolt Brake caliper Brake pad Pad spring 2 1 2 3 Remove the parts in the order listed For installation reverse the removal procedure Refer to REPLACING THE FRONT BRAKE PADS 40 Nm 4 0 m kg FRONT AND REAR BRAKES CHAS FRONT AND REAR BRAKES FRONT BRAKE PADS ...

Page 131: ... must be disassembled drained cleaned properly filled and bled after reas sembly Never use solvents on internal brake com ponents Use only clean or new brake fluid for clean ing brake components Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt fluid immediately Avoid brake fluid coming into contact with the eyes as it can cause serious injury First aid ...

Page 132: ...ing thickness a Out of specification Replace the brake pads as a set Brake pad wear limit 0 8 mm 5 Install brake pad spring brake pads Always install new brake pads and a new brake pad spring as a set a Connect a clear plastic hose 1 tightly to the bleed screw 2 Put the other end of the hose into an open container b Loosen the bleed screw and push the brake caliper pistons into the brake caliper w...

Page 133: ...rake pads Remove any excess grease 7 Install brake caliper retaining bolt 8 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 9 Check brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 ...

Page 134: ...r Brake lever compression spring Front brake switch Union bolt Copper washer Brake hose Master cylinder bracket Master cylinder 1 1 1 1 1 2 1 1 1 Remove the parts in the order listed Drain For installation reverse the removal procedure 7 Nm 0 7 m kg 30 Nm 3 0 m kg FRONT AND REAR BRAKES CHAS FRONT BRAKE MASTER CYLINDER ...

Page 135: ... Remarks Disassembling the front brake master cylinder Dust boot Circlip Master cylinder cup Spring 1 1 1 1 Remove the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 4 FRONT AND REAR BRAKES CHAS ...

Page 136: ...r drain the brake fluid from the entire brake system 1 Remove rear view mirror right brake lever compression spring brake switch 1 2 Remove union bolt 2 copper washers brake hose 3 To collect any remaining brake fluid place a container under the master cylinder and the end of the brake hose 3 Remove master cylinder bracket master cylinder ...

Page 137: ...master cylinder 1 Damage scratches wear Replace brake fluid delivery passages 2 brake master cylinder body Obstruction Blow out with compressed air 2 Check brake master cylinder kit 1 Damage scratches wear Replace 3 Check brake fluid reservoir 1 Cracks damage Replace brake fluid reservoir diaphragm 2 Cracks damage Replace 4 Check brake hoses 1 Cracks damage wear Replace ...

Page 138: ...ark facing up Align the end of the brake master cylinder hold er with the punch mark a on the handlebar First tighten the upper bolt then the lower bolt 2 Install copper washers New 1 brake hose 2 union bolt 3 Proper brake hose routing is essential to in sure safe motorcycle operation Refer to CABLE ROUTING While holding the brake hose tighten the union bolt as shown Turn the handlebar to the left...

Page 139: ...ter the reservoir Water will signifi cantly lower the boiling point of the brake fluid and could cause vapor lock Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 4 Bleed brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 5 Check brake fluid level Below the minimum level mark a Add the recommended brake fluid ...

Page 140: ...ion bolt Copper washer Brake hose Retaining bolt Brake caliper assembly 1 1 2 1 2 1 Remove the parts in the order listed Drain For installation reverse the removal procedure Refer to REMOVING INSTALLING THE FRONT BRAKE CALIPER 30 Nm 3 0 m kg 40 Nm 4 0 m kg FRONT AND REAR BRAKES CHAS EAS00612 FRONT BRAKE CALIPER ...

Page 141: ...ke caliper Pad spring Brake caliper piston Dust seal Caliper piston seal Bleed screw 1 2 2 2 1 Remove the parts in the order listed For assembly reverse the disassembly procedure Refer to REMOVING THE FRONT BRAKE CALIPERS 1 2 3 4 5 6 Nm 0 6 m kg FRONT AND REAR BRAKES CHAS ...

Page 142: ...f the brake hose into a container and pump out the brake fluid carefully 2 Remove brake caliper pistons 1 brake caliper piston seals 2 a Blow compressed air into the brake hose joint opening to force out the pistons from the brake caliper Cover the brake caliper pistons with a rag Be careful not to get injured when the pis tons are expelled from the brake caliper Never try to pry out the brake cal...

Page 143: ...r the brake is disas sembled 1 Check brake caliper pistons 1 Rust scratches wear Replace the brake caliper Piston assembly brake caliper cylinders 2 Scratches wear Replace the brake cali per brake calipers 3 Cracks damage Replace brake fluid delivery passages brake caliper body Obstruction Blow out with compressed air Whenever a brake caliper is disassembled replace the brake caliper piston seals ...

Page 144: ...istort Whenever a brake caliper is disassembled replace the brake caliper piston seals Recommended brake fluid DOT 4 1 Install brake caliper 1 temporarily copper washers New 2 brake hose 3 union bolt 4 Proper brake hose routing is essential to in sure safe motorcycle operation Refer to CABLE ROUTING When installing the brake hose onto the brake caliper 1 make sure that the brake pipe a touches the...

Page 145: ...e perfor mance When refilling be careful that water does not enter the reservoir Water will signifi cantly lower the boiling point of the brake fluid and could cause vapor lock Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 4 Bleed brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 5 Check brake fluid level ...

Page 146: ...pper bracket pinch bolt Cap bolt Lower bracket pinch bolt Front fork 1 1 1 2 2 2 2 2 Remove the parts in the order listed Refer to FRONT WHEEL AND BRAKE DISC Loosen Loosen Loosen Loosen For installation reverse the removal procedure 7 Nm 0 7 m kg 40 Nm 4 0 m kg 7 Nm 0 7 m kg 20 Nm 2 0 m kg 30 Nm 3 0 m kg 23 Nm 2 3 m kg 7 Nm 0 7 m kg FRONT FORK CHAS EAS00646 FRONT FORK ...

Page 147: ...ing seat Fork spring Dust seal Oil seal clip Damper rod bolt Copper washer Damper rod rebound spring Oil seal 1 1 1 1 1 1 1 1 1 1 1 1 Disassemble the parts in the order listed Refer to DISASSEMBLING ASSEM BLING THE FRONT FORK LEGS 1 2 3 4 5 9 6 7 8 10 11 23 Nm 2 3 m kg 30 Nm 3 0 m kg FRONT FORK CHAS ...

Page 148: ...cer Outer tube bushing Inner tube inner tube bushing Oil lock piece Outer tube 1 1 1 1 1 1 For assembly reverse the disassembly procedure Refer to DISASSEMBLING ASSEM BLING THE FRONT FORK LEGS 12 13 14 15 16 23 Nm 2 3 m kg 30 Nm 3 0 m kg FRONT FORK CHAS ...

Page 149: ...e stand so that the front wheel is elevated 2 Loosen cap bolt 1 upper bracket pinch bolt 2 lower bracket pinch bolt 3 front turn signal pinch bolt 4 Before loosening the upper and lower bracket pinch bolts support the front fork leg 3 Remove front fork leg DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Remove cap bolt O ring spacer 1 spring seat ...

Page 150: ...01326 5 Remove damper rod inner tube a Hold the front fork leg horizontally b Securely clamp the brake caliper bracket in a vise with soft jaws c Separate the inner tube from the outer tube by pulling the inner tube forcefully but care fully Excessive force will damage the oil seal and bushing A damaged oil seal or bush ing must be replaced Avoid bottoming the inner tube into the outer tube during...

Page 151: ...ng free length limit 299 4 mm 3 Check damper rod 1 Damage wear Replace Obstruction Blow out all of the oil pas sages with compressed air oil lock piece 2 Damage Replace When disassembling and assembling the front fork leg do not allow any foreign ma terial to enter the front fork 4 Check cap bolt O ring Damage wear Replace EAS00659 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to ...

Page 152: ... slide slowly down the inner tube until it protrudes from the bot tom of the inner tube Be careful not to dam age the inner tube 2 Lubricate inner tube s outer surface Recommended lubricant Fork oil 10 W or equivalent 3 Tighten damper rod bolt 1 While holding the damper rod with the damper rod holder 1 and T handle 2 tighten the damper rod bolt Damper rod holder 90890 01365 T handle 90890 01326 4 ...

Page 153: ...tube Before installing the oil seal cover the top of the front fork leg with a plastic bag 2 to protect the oil seal during installation 6 Install oil seal clip 1 Adjust the oil seal clip so that it fits into the outer tube s groove 7 Install dust seal 1 with the fork seal driver weight Fork seal driver weight 90890 01367 Adapter 90890 01369 8 Fill front fork leg with the specified amount of the r...

Page 154: ...t fork leg keep it upright After filling slowly pump the front fork leg up and down to distribute the fork oil Be sure to stroke the inner tube slowly be cause the fork oil may spurt out 9 Install spring 1 spring seat 2 spacer 3 cap bolt 4 Install the spring with the smaller pitch facing up Before installing the cap bolt apply grease onto the O ring Temporarily tighten the cap bolt ...

Page 155: ...pplies to both of the front fork legs 1 Install front fork leg Temporarily tighten the upper and lower bracket pinch bolts Make sure that the inner fork tube is flush with the top of the handlebar holder 2 Tighten lower bracket pinch bolt 1 upper bracket pinch bolt 2 cap bolt 3 front turn signal pinch bolt 4 Make sure that the brake hoses are routed properly ...

Page 156: ...mbly Clutch switch lead Starter cable Left handlebar switch Grip left Master cylinder bracket 4 2 1 1 1 1 1 1 1 Remove the parts in the order listed Stand the motorcycle on a level surface Securely support the motorcycle so that there is no danger of it falling over WARNING 7 Nm 0 7 m kg 32 Nm 3 2 m kg 23 Nm 2 3 m kg HANDLEBAR CHAS HANDLEBAR ...

Page 157: ...ylinder assembly Right handlebar switch Throttle cable Throttle grip assembly Handlebar holder upper Handlebar Cable guide Handlebar holder lower 1 1 2 1 2 1 1 1 For installation reverse the removal procedure 7 Nm 0 7 m kg 32 Nm 3 2 m kg 23 Nm 2 3 m kg HANDLEBAR CHAS ...

Page 158: ...witch 2 throttle grip 3 3 Remove clutch lever assembly handlebar grip left 1 Blow compressed air between the handlebar and the handlebar grip and gradually push the grip off the handlebar EAS00668 CHECKING THE HANDLEBAR 1 Stand the motorcycle on a level surface Securely support the motorcycle so that there is no danger of it falling over 2 Check handlebar 1 Bends cracks damage Replace Do not attem...

Page 159: ...G THE HANDLEBAR 1 Stand the motorcycle on a level surface Securely support the motorcycle so that there is no danger of it falling over 2 Install handlebar 1 upper handlebar holders 2 First tighten the bolts on the front side of the handlebar holder then on the rear side Turn the handlebar all the way to the left and right If there is any contact with the fuel tank adjust the handlebar position Th...

Page 160: ...ent surface 4 Install Dmaster cylinder Refer to FRONT AND REAR BRAKES 5 Install Dclutch lever holder 1 Align the slit in the clutch lever holder with the punch mark a in the handlebar 6 Install Dclutch cable 7 Connect Dclutch switch Apply a thin coat of lithium soap base grease onto the end of the clutch cable 8 Install Dleft handlebar switch Align the clutch lever assembly matching face with the ...

Page 161: ...ING THE CLUTCH CABLE FREE PLAY in chapter 3 Clutch cable free play at the end of the clutch lever 5 10 mm 10 Adjust throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY in chapter 3 Throttle cable free play at the flange of the throttle grip 3 5 mm ...

Page 162: ...ke hose holder Upper bracket Lock washer Upper ring nut 1 1 1 1 1 1 1 1 Remove the parts in the order listed Stand the motorcycle on a level surface Securely support the motorcycle so that there is no danger of it falling over Refer to FRONT FORK Refer to HANDLEBAR Disconnect WARNING 110 Nm 11 0 m kg 2nd 52 Nm 5 2 m kg 18 Nm 1 8 m kg 1st 8 Nm 0 8 m kg 7 Nm 0 7 m kg STEERING HEAD CHAS STEERING HEAD...

Page 163: ...earing cover Lower bracket Bearing upper Rubber seal Bearing lower 1 1 1 1 1 1 1 For installaiton reverse the removal procedure Refer to REMOVING THE LOWER BRACKET INSTALLING THE STEERING HEAD 110 Nm 11 0 m kg 2nd 52 Nm 5 2 m kg 18 Nm 1 8 m kg 1st 8 Nm 0 8 m kg 7 Nm 0 7 m kg STEERING HEAD CHAS ...

Page 164: ...lower ring nut with the exhaust and steering nut wrench then remove the upper ring nut with the ring nut wrench Exhaust and steering nut wrench 90890 01268 Ring nut wrench 90890 01403 Securely support the lower bracket so that there is no danger of it falling EAS00681 CHECKING THE STEERING HEAD 1 Wash bearings bearing races Recommended cleaning solvent Kerosine 2 Check bearings 1 bearing races 2 D...

Page 165: ...aged Always replace the bearings and bearing races as a set Whenever the steering head is disassembled replace the rubber seal 4 Check upper bracket lower bracket along with the steering stem Bends cracks damage Replace EAS00683 INSTALLING THE STEERING HEAD 1 lubricate upper bearing lower bearing bearing races Recommended lubricant Lithium soap base grease 2 Install lower ring nut 1 rubber washer ...

Page 166: ...4 56 STEERING HEAD CHAS NOTE NOTE Temporarily tighten the steering stem nut 4 Install front fork legs Refer to FRONT FORK Temporarily tighten the upper and lower bracket pinch bolts ...

Page 167: ...ock absorber assembly 2 Remove the parts in the order listed Stand the motorcycle on a level surface For installation reverse the removal procedure 23 Nm 2 3 m kg 23 Nm 2 3 m kg REAR SHOCK ABSORBER AND SWINGARM CHAS EAS00685 REAR SHOCK ABSORBER AND SWINGARM REAR SHOCK ABSORBER ASSEMBLY ...

Page 168: ...ver Chain case Drive chain Nut washer Pivot shaft Cover Coller Oil seal Bush 1 1 1 1 1 1 2 2 2 2 Remove the parts in order listed Refer to REAR WHEEL AND REAR BRAKE Refer to REMOVING INSTALLING THE REAR SHOCK ABSORBER For installation reverse the removal procedure 46 Nm 4 6 m kg 7 Nm 0 7 m kg REAR SHOCK ABSORBER AND SWINGARM CHAS SWINGARM ...

Page 169: ...not be held responsi ble for property damage or personal injury that may result from improper handling of the rear shock absorber Do not tamper or attempt to open the rear shock absorber Do not subject the rear shock absorber to an open flame or any other source of high heat High heat can cause an explosion due to excessive gas pressure Do not deform or damage the rear shock absorber in any way If...

Page 170: ...of it falling over Place the motorcycle on a suitable stand so that the rear wheel is elevated 2 Remove rear shock absorber left and right EAS00706 REMOVING THE DRIVE CHAIN 1 Stand the motorcycle on a level surface Securely support the motorcycle so that there is no danger of it falling over Place the motorcycle on a suitable stand so that the rear wheel is elevated 2 Remove chain cover 1 chain ca...

Page 171: ...swingarm so that it does not drop down 3 Check swingarm side play A swingarm vertical movement B a Check the tightening torque of the pivot shaft nut Pivot shaft nut 46 Nm 4 6 m kg b Check the swingarm side play A by moving the swingarm from side to side c If the swingarm side play is out of specifica tion check the spacers bearings washers and dust covers Swingarm side play at the end of the swin...

Page 172: ...rber assembly spring Damage wear Replace the rear shock ab sorber assembly bushings Damage wear Replace dust seals Damage wear Replace bolts Bends damage wear Replace EAS00707 CHECKING THE SWINGARM 1 Check swingarm Bends cracks damage Replace 2 Check pivot shaft Roll the pivot shaft on a flat surface Bends Replace Do not attempt to straighten a bent pivot shaft 3 Wash pivot shaft dust covers colla...

Page 173: ...4 63 REAR SHOCK ABSORBER AND SWINGARM CHAS 4 Check dust covers 1 spacer 2 oil seals 3 Damage wear Replace bearings Damage pitting Replace ...

Page 174: ... 129 5 mm While measuring the ten link section push down on the drive chain to increase its tension Measure the length between drive chain roller 1 and 11 as shown Perform this measurement at two or three dif ferent places 2 Check drive chain Stiffness Clean and lubricate or replace 3 Clean drive chain a Wipe the drive chain with a clean cloth b Put the drive chain in kerosine and remove any remai...

Page 175: ...rush can also damage the O rings Therefore use only kerosine to clean the drive chain Don t soak drive drain in kerosine more them ten minutes O ring is damage by kero sine 4 Check O rings 1 Damage Replace the drive chain drive chain rollers 2 Damage wear Replace the drive chain drive chain side plates 3 Cracks damage wear Replace the drive chain 5 Lubricate drive chain Recommended lubricant Engin...

Page 176: ...0711 INSTALLING THE SWINGARM 1 Lubricate bearings spacers dust covers pivot shaft Recommended lubricant Molybdenum disulfide grease 2 Install rear shock absorber assembly rear wheel Refer to INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY and REAR WHEEL ...

Page 177: ...al switch Face the terminal cover to right under side then as semble the chain cover without the both leads being caught 3 Install rear wheel Refer to INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY and REAR WHEEL 4 Adjust drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK in chapter 3 Drive chain slack 30 40 mm A drive chain that is too tight will overload the engine and other vital parts and...

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Page 180: ... SHAFTS 5 17 INSTALLING THE CAMSHAFT AND ROCKER ARMS 5 18 VALVES AND VALVE SPRINGS 5 20 REMOVING THE VALVES 5 21 CHECKING THE VALVES AND VALVE GUIDES 5 21 CHECKING THE VALVE SEATS 5 23 CHECKING THE VALVE SPRINGS 5 25 INSTALLING THE VALVES 5 25 CYLILNDERS AND PISTONS 5 27 REMOVING THE PISTONS 5 28 CHECKING THE CYLINDERS AND PISTONS 5 28 CHECKING THE PISTON RINGS 5 30 CHECKING THE PISTON PINS 5 31 I...

Page 181: ...TOPPER LEVER 5 54 CHECKING THE SHIFT SHAFT 5 56 CHECKING THE SHIFT LEVER 5 56 INSTALLILNG THE SHIFT SHAFT 5 56 CRANKSHAFT AND CONNECTING RODS 5 57 CRANKSHAFT ASSEMBLY 5 57 CRANKSHAFT AND CONNECTING RODS 5 59 DISASSEMBLING THE CRANKCASE 5 60 CHECKING THE CRANKSHAFT AND CONNECTING ROD 5 61 CHECKING THE BEARINGS AND OIL SEALS 5 62 CHECKING THE TIMING CHAIN CAMSHAFT SPROCKET AND TIMING CHAIN GUIDES 5 ...

Page 182: ...rder listed Stand the motorcycle on a level surface Securely support the motorcycles so there is no danger of it falling over Refer to RIDER AND PASSENGER SEATS in chapter 3 Refer to FUEL TANK in chapter 3 Refer to CARBURETOR in chapter 5 WARNING 7 Nm 0 7 m kg 7 Nm 0 7 m kg 60 Nm 6 0 m kg 10 Nm 1 0 m kg 12 Nm 1 2 m kg 25 Nm 2 5 m kg 10 Nm 1 0 m kg ENGINE REMOVAL ENG ENGINE ENGINE REMOVAL DRIVE SPR...

Page 183: ...ake switch lead Footrest brake pedal Drive chain case Chain cover Sprocket holder Drive sprocket 1 1 1 1 1 1 1 Disconnect For installation reverse the removal procedure 7 Nm 0 7 m kg 7 Nm 0 7 m kg 60 Nm 6 0 m kg 10 Nm 1 0 m kg 12 Nm 1 2 m kg 25 Nm 2 5 m kg 10 Nm 1 0 m kg ...

Page 184: ...al and clutch cable Battery negative lead Pickup coil coupler A C magneto coupler Plug code Starter motor lead Clutch cable 1 1 1 2 1 1 Remove the parts in the order listed For installation reverse the removal procedure ENGINE REMOVAL ENG LEADS SHIFT PEDAL AND CLUTCH CABLE ...

Page 185: ...nt upper Engine stay front under Engine stay rear upper 2 1 1 1 1 1 2 Remove the parts in the order listed Place a suitable stand under the frame and engine Refer to INSTALLING THE ENGINE For installation reverse the removal procedure NOTE 35 Nm 3 5 m kg 35 Nm 3 5 m kg 35 Nm 3 5 m kg 35 Nm 3 5 m kg 35 Nm 3 5 m kg ENGINE REMOVAL ENG EAS00191 ENGINE ...

Page 186: ... order self locking nut 8 bolt front upper 4 engine bracket bolts 9 3 Install chain cover Connecting the neutral switch lead starter motor and A C generator leads should be through under the neutral switch Face the terminal cover to right under side then assemble the chain cover without the both leads being caught 4 Install shift arm 1 Align the punch mark a in the shift shaft with the slot in the...

Page 187: ...ner Camshaft sprocket Bracket Cylinder head Dowel pin Head gasket 1 2 1 1 1 1 1 1 2 1 Remove the parts in the order listed Refer to ENGINE REMOVAL For installation reverse the removal procedure 22 Nm 2 2 m kg 12 Nm 1 2 m kg 10 Nm 1 0 m kg 10 Nm 1 0 m kg 8 Nm 0 8 m kg 10 Nm 1 0 m kg 26 Nm 2 6 m kg 12 Nm 1 2 m kg CYLINDER HEADS ENG CYLINDER HEADS FRONT CYLINDER HEAD ...

Page 188: ... Chain tensioner Camshaft sprocket Bracket Cylinder head Dowel pin Head gasket 1 1 1 1 1 2 1 Remove the parts in the order listed For installation reverse the removal procedure 22 Nm 2 2 m kg 12 Nm 1 2 m kg 26 Nm 2 6 m kg 12 Nm 1 2 m kg 10 Nm 1 0 m kg 8 Nm 0 8 m kg CYLINDER HEADS ENG REAR CYLINDER HEAD ...

Page 189: ...ar piston is at TDC on the compression stroke c Check that the front piston is at TDC in the compression stroke d The front piston is at TDC on the compres sion stroke when there is clearance at both of the rocker arms If there is no clearance then turn the crankshaft counterclockwise one full turn e When to T mark is aligned with the station ary pointer the alignment mark c on the camshaft sprock...

Page 190: ... When removing the rear cylinder head repeat the front cylinder head removal procedures However note the following points 1 Align D I mark with the stationary pointer Removal steps DTurn the crankshaft counterclockwise 300_ DAlign the I mark a with the stationary pointer b on the crankcase cover left when the rear piston is at TDC on the compression stroke DWhen the I mark is aligned with the stat...

Page 191: ...nder head Damage scratches Replace 3 Measure cylinder head warpage Out of specification Resurface the cylin der head Cylinder head warpage Less than 0 03 mm a Place a straightedge 1 and a thickness gauge 2 across the cylinder head b Measure the warpage c If the limited is exceeded resurface the cylin der head as follows d Place 400 600 grit wet sandpaper on the surface plate and resurface the cyli...

Page 192: ...in tensioner rod wind it clockwise with a thin screwdriver 1 until it stops b Remove the screwdriver and slowly release the timing chain tensioner rod c Make sure that the timing chain tensioner rod comes out of the timing chain tensioner housing smoothly If there is rough move ment replace the timing chain tensioner INSTALLING THE CYLINDER HEADS Front cylinder 1 Install dowel pins gasket New 2 In...

Page 193: ...k from the intake side of the timing chain e Insert your finger into the hole and timing chain tensioner hole and push the timing chain guide inward f While pushing the timing chain guide be sure that the timing mark c and the station ary pointer d are properly aligned at TDC 5 Install timing chain tensioner gasket a Lightly press the timing chain tensioner rod into the timing chain tensioner hous...

Page 194: ...ket 1 bolt camshaft sprocket 2 Be sure the projection on the camshaft sprock et plate is aligned with the hole in the sprocket Use the sheave holder to hold the rotor Sheave holder 90890 01701 7 Check alignment marks If the marks do not align Adjust 8 Measure valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEAR ANCE in chapter 3 Rear cylinder head When installing the rear...

Page 195: ...the camshaft sprocket with the timing mark c facing out d Turn the camshaft just enough to remove any slack from the intake side of the timing chain e Insert your finger into the hole and timing chain tensioner hole and push the timing chain guide inward f While pushing the timing chain guide be sure that the timing mark c and the station ary pointer d are properly aligned at TDC ...

Page 196: ...ut Valve adjusting screw Camshaft 1 1 2 2 2 2 1 Remove the parts in the order listed Refer to CYLINDER HEAD Refer to REMOVING INSTALLING THE ROCKER ARM AND CAMSHAFT For installation reverse the removal procedure Refer to REMOVING INSTALLING THE ROCKER ARM AND CAMSHAFT 7 Nm 0 7 m kg 7 Nm 0 7 m kg 12 Nm 1 2 m kg ROCKER ARMS AND CAMSHAFT ENG ROCKER ARMS AND CAMSHAFT ...

Page 197: ...ove camshaft bushing 1 camshaft 2 Screw a 8 mm bolt 3 into the threaded end of the camshaft and then pull out the camshaft EAS00205 CHECKING THE CAMSHAFT 1 Check camshaft bushings Damage wear Replace 2 Check camshaft lobes Blue discoloration pitting scratches Re place the camshaft 3 Measure camshaft lobe dimensions a and b Out of specification Replace the cam shaft Camshaft lobe dimension limit In...

Page 198: ...r pit ting scratches Replace or check the lu brication system 4 Measure rocker arm inside diameter a Out of specification Replace Rocker arm inside diameter 10 000 10 015 mm Limit 10 035 mm 5 Measure rocker arm shaft outside diameter b Out of specification Replace Rocker arm shaft outside diameter 9 981 9 991 mm Limit 9 961 mm 6 Calculate rocker arm to rocker arm shaft clearance Calculate the clea...

Page 199: ...ed lubricant Camshaft Bushing Molybdenum disulfide oil 2 Install camshaft 1 camshaft bushing 2 Make sure that the No 1 camshaft 3 is installed in the front cylinder head and the No 2 camshaft 4 is installed in the rear cylinder head 3 Install stopper plate 1 4 Lubricate rocker arm shafts Recommended lubricant Molybdenum disulfide oil ...

Page 200: ...5 19 ROCKER ARMS AND CAMSHAFT ENG NOTE 5 Install rocker arms 1 rocker arm shafts 2 Make sure that the rocker arm shafts is com pletely pushed into the cylinder head ...

Page 201: ...ner Valve spring Valve intake Valve exhaust Valve stem seal Valve spring seat 4 2 2 1 1 2 2 Remove the parts in the order listed Refer to CYLINDER HEADS Refer to ROCKER ARMS AND CAMSHAFTS Refer to REMOVING INSTALLING THE VALVES For installation reverse the removal procedure Refer to INSTALLING THE VALVES VALVES AND VALVE SPRINGS ENG VALVES AND VALVE SPRINGS ...

Page 202: ...dth Refer to CHECKING THE VALVE SEATS a Pour a clean solvent 1 into the intake and exhaust ports b Check that the valves properly seal There should be no leakage at the valve seat 2 2 Remove valve cotters Remove the valve cotters by compressing the valve spring with the valve spring compressor 1 Valve spring compressor 90890 04019 EAS00239 CHECKING THE VALVES AND VALVE GUIDES The following procedu...

Page 203: ... remover 1 b Install the new valve guide with a valve guide installer 2 and valve guide remover 1 c After installing the valve guide bore the valve guide with a valve guide reamer 3 to obtain the proper valve stem to valve guide clearance After replacing the valve guide reface the valve seat Valve guide remover 5 0 mm 90890 04097 Valve guide installer 5 0 mm 90890 04098 3 Eliminate Dcarbon deposit...

Page 204: ...procedure applies to all of the valves and valve seats 1 Eliminate carbon deposits from the valve face and valve seat 2 Check valve seat Pitting wear Replace the cylinder head 3 Measure valve seat width a Out of specification Replace the cylinder head Valve seat width Intake 0 9 1 1 mm Limit 1 6 mm Exhaust 0 9 1 1 mm Limit 1 6 mm a Apply Mechanic s blueing dye Dykem b onto the valve face b Install...

Page 205: ... seat are evenly polished then clean off all of the lapping compound For the best lapping results lightly tap the valve seat while rotating the valve back and forth be tween your hand e Apply a fine lapping compound to the valve face and repeat the above steps f After every lapping procedure be sure to clean off all of the lapping compound from the valve face and valve seat g Apply Mechanic s blue...

Page 206: ... Compressed spring force Intake and exhaust spring 71 7 79 3 N at 25 7 mm 3 Measure Dvalve spring tilt c Out of specification Replace the valve spring Spring tilt limit Intake and exhaust valve spring 2 5_ 1 7 mm EAS00245 INSTALLING THE VALVES The following procedure applies to all of the valves and related components 1 Deburr Dvalve stem end with an oil stone 2 Lubricate Dvalve stem Doil seal New...

Page 207: ...itch 4 Install valve cotters Install the valve cotters by compressing the valve spring with the valve spring compressor 1 Valve spring compressor 90890 04019 5 To secure the valve cotters onto the valve stem lightly tap the valve tip with a soft face hammer Hitting the valve tip with excessive force could damage the valve ...

Page 208: ... 2 3 4 5 6 7 8 9 Removing the cylinders and pistons Cylinder heads Timing chain guide Cylinder O ring Dowel pin Cylinder gasket Piston pin clip Piston pin Piston Piston ring set 1 1 1 2 1 2 1 1 1 Refer to INSTALLING THE PISTONS AND CYLINDERS Refer to REMOVING INSTALLING THE CYLINDERS AND PISTONS CYLINDERS AND PISTONS ENG CYLINDERS AND PISTONS ...

Page 209: ...own Before removing the piston pin deburr the pis ton pin clip s groove and the piston s pin bore area If both areas are deburred and the piston 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 When removing a piston ring open the end gap with your fingers and lift the other side of the ring over the p...

Page 210: ...ecification rebore or replace the cylinder and replace the piston and piston rings as a set c Measure piston skirt diameter P with the micrometer b 3 mm from the bottom edge of the piston Piston size P Standard 48 965 49 005 mm 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 Piston to cylinder clearance ...

Page 211: ...Limit 0 12 mm 2nd ring 0 02 0 06 mm Limit 0 12 mm 2 Install piston ring into the cylinder Using the piston crown pash the ring into the cyl inder so that the ring will be at a right angle to the cylinder bore a 20 mm from the top of the cylinder 3 Measure piston ring end gap Out of specification Replace the piston ring The oil ring expander spacer s end gap cannot be measured If the oil ring rail ...

Page 212: ...ut of specification Replace the piston Piston pin bore inside diameter 13 002 13 013 mm 4 Calculate piston pin to piston clearance Out of specification Replace the piston pin Piston pin to piston clearance Piston pin bore size b Piston pin outside diameter a Piston pin to piston clearance 0 002 0 017 mm EB404701 INSTALLING THE PISTONS AND CYLINDERS The following procedure applies to all of the pis...

Page 213: ... a clean rag to prevent the clip from falling into the crankcase 3 Install gasket New dowel pins O ring New 4 Lubricate piston piston rings cylinder with the recommended lubricant Recommended lubricant Engine oil 5 Offset piston ring end gaps a Top ring b Lower oil ring rail c Upper oil ring rail d 2nd ring 6 Install cylinder 1 While compressing the piston rings with one hand install the cylinder ...

Page 214: ...Dowel pin Gasket Stator coil Pickup coil 1 2 1 1 1 Remove the parts in the order listed Refer to CHANGING THE ENGINE OIL in chapter 3 For installation reverse the removal procedure Refer to ENGINE REMOVAL 7 Nm 0 7 m kg 5 Nm 0 5 m kg 10 Nm 1 0 m kg 10 Nm 1 0 m kg 10 Nm 1 0 m kg GENERATOR AND STARTER CLUTCH ENG GENERATOR AND STARTER CLUTCH STATOR COIL AND PICKUP COIL ...

Page 215: ...ter clutch Generator rotor Starter clutch assembly Starter clutch drive gear Idler gear Idler gear shaft 1 1 1 1 1 Remove the parts in the order listed For installation reverse the removal procedure 80 Nm 8 0 m kg GENERATOR AND STARTER CLUTCH ENG GENERATOR ROTOR AND STARTER CLUTCH ...

Page 216: ... loosen the generator rotor nut Do not allow the sheave holder to touch the projection on the generator rotor Sheave holder 90890 01701 4 Remove generator rotor 1 with the flywheel puller set 2 woodruff key To protect the end of the crankshaft place an appropriate sized socket between the fly wheel puller set s center bolt and the crank shaft Make sure that the flywheel puller is centered over the...

Page 217: ...ion a Install the starter clutch drive gear 1 onto the starter clutch 2 and hold the starter clutch b When turning the starter clutch drive gear clockwise A the starter clutch and the start er clutch drive gear should engage If the starter clutch drive gear and starter clutch do not engage the starter clutch is faulty and must be replaced c When turning the starter clutch drive gear counterclockwi...

Page 218: ... key is properly seated in the key way of the crankshaft 2 Tighten generator rotor nut 1 While holding the generator rotor 2 with the sheave holder 3 tighten the generator rotor nut Do not allow the sheave holder to touch the projection on the generator rotor Sheave holder 90890 01701 3 Apply sealant onto stater coil assembly lead grommet Yamaha bond No 1215 90890 85505 4 Install stator coil gener...

Page 219: ...er cover O ring 1 1 Remove the parts in the order listed Stand the motorcycle on a level surface Securely support the motorcycle so there is no danger of it falling over Drain Refer to CHANGING THE ENGINE OIL in chapter 3 WARNING 10 Nm 1 0 m kg Refer to ENGINE REMOVAL 10 Nm 1 0 m kg CLUTCH ENG CLUTCH CLUTCH COVER ...

Page 220: ...5 39 CLUTCH ENG Order Job Part Q ty Remarks 3 4 5 6 Oil filter Clutch cover Dowel pin Clutch cover gasket 1 1 2 1 For installation reverse the removal procedure 10 Nm 1 0 m kg 10 Nm 1 0 m kg ...

Page 221: ... Pressure plate Push plate 1 Friction plate Clutch plate Push rod short Ball Push rod long Clutch boss nut Lock washer Clutch boss Holding plate Clutch housing Nut Lock washer 1 1 5 4 1 1 1 1 1 1 1 1 1 1 Remove the parts in the order listed 80 Nm 8 0 m kg 75 Nm 7 5 m kg 8 Nm 0 8 m kg CLUTCH ENG CLUTCH ...

Page 222: ...41 Order Job Part Q ty Remarks 15 16 17 18 Washer Primary drive gear Spacer Key 1 1 1 1 For installation reverse the removal procedure 80 Nm 8 0 m kg 80 Nm 8 0 m kg 75 Nm 7 5 m kg 8 Nm 0 8 m kg CLUTCH ENG ...

Page 223: ...Remarks 1 2 3 4 5 Removing the push lever shaft Push lever Spring Circlip Oil seal Bearing 1 1 1 1 1 Remove the parts in the order listed For installation reverse the removal procedure 8 Nm 0 8 m kg CLUTCH ENG PUSH LEVER SHAFT ...

Page 224: ... Universal clutch holder 90890 04086 3 Remove clutch boss nut 1 lock washer 2 clutch boss 3 EAS00279 REMOVING THE PRIMARY DRIVE GEAR 1 Straighten the lock washer tab 2 Remove primary drive gear nut 1 lock washer 2 While holding the generator rotor with the sheave holder loosen the primary drive gear nut Do not allow the sheave holder to touch the projection on the generator rotor Sheave holder 908...

Page 225: ...ce the friction plates as a set Measure the friction plate at four places Friction plate thickness 2 9 3 1 mm Limit 2 5 mm EAS00281 CHECKING THE CLUTCH PLATES The following procedure applies to all of the clutch plates 1 Check clutch plate Damage Replace the clutch plates as a set 2 Measure clutch plate warpage with a surface plate and thickness gauge 1 Out of specification Replace the clutch plat...

Page 226: ...ch springs as a set Clutch spring free length 34 6 mm Limit 33 6 mm EAS00284 CHECKING THE CLUTCH HOUSING 1 Check clutch housing dogs Damage pitting wear Deburr the clutch housing dogs or replace the clutch housing Pitting on the clutch housing dogs will cause er ratic clutch operation EAS00285 CHECKING THE CLUTCH BOSS 1 Check clutch boss splines Damage pitting wear Replace the clutch boss Pitting ...

Page 227: ...g limit Out of specification Replace the long clutch push rod Long clutch push rod bending limit 0 5 mm EAS00292 CHECKING THE PRIMARY DRIVE GEAR 1 Check primary drive gear 1 primary driven gear 2 Damage wear Replace the primary drive and primary driven gears as a set Excessive noise during operation Re place the primary drive and primary driven gears as a set 2 Check primary drive gear to primary ...

Page 228: ...STALLING THE CLUTCH 1 Install clutch housing 1 thrust washer 2 clutch boss 3 lock washer clutch boss nut Make sure that the teeth on the lock washer are correctly aligned with the grooves on the clutch boss 2 Tighten clutch boss nut 1 While holding the clutch boss with the universal clutch holder tighten the clutch boss nut Universal clutch holder 90890 04086 3 Bend the lock washer tab along a fla...

Page 229: ...tch push rod ball 7 Install short clutch push rod 1 O ring 2 New push plate 3 washer 4 nut 5 8 Install pressure plate 1 clutch springs 2 clutch spring bolts 3 Align the punch mark a in the clutch boss with the punch mark b in the pressure place Tighten the clutch spring bolts in stages and in a crisscross pattern 9 Check push lever position Push lever mark a and crankcase mark b not aligned Correc...

Page 230: ...are aligned c Hold the adjusting screw to prevent it from moving and then tighten the locknut to speci fication Do not overtighten the locknut since this will remove the free play between both push rods Push lever lock nut 8Nm 0 8m kg 11 Install clutch cover 1 clutch cover gasket New Tighten the clutch cover bolts in stages and in a crisscross pattern ...

Page 231: ...er Clutch Circlip Washer Oil pump drive gear O ring Oil pump 1 2 1 2 1 Remove the parts in the order listed Drain Refer to REMOVING THE CLUTCH COVER Refer to REMOVING THE CLUTCH For installation reverse the removal procedure 7 Nm 0 7 m kg 7 Nm 0 7 m kg 7 Nm 0 7 m kg OIL PUMP ENG OIL PUMP ...

Page 232: ... Disassembling the oil pump Oil pump cover Inner rotor Outer rotor Dowel pin Dowel pin Oil pump driven gear Housing 1 1 1 2 1 1 1 Disassemble the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 4 5 6 7 7 Nm 0 7 m kg ...

Page 233: ...ut of specification Replace the oil pump 1 Inner rotor 2 Outer rotor 3 Oil pump housing Inner rotor to outer rotor tip clearance 0 15 mm Limit 0 2 mm Outer rotor to oil pump housing clearance 0 03 0 09 mm Limit 0 15 mm Oil pump housing to inner rotor and outer rotor clearance 0 03 0 09 mm Limit 0 15 mm 3 Check oil pump operation Unsmooth Repeat steps 1 and 2 or re place the defective part s EAS003...

Page 234: ...ump housing 7 screw When installing the inner rotor align the pin 3 in the oil pump shaft with the groove a on the in ner rotor 4 3 Check oil pump operation Refer to CHECKING THE OIL PUMP EAS00376 INSTALLING THE OIL PUMP 1 Install O ring New oil pump 1 oil pump drive gear 2 circlip 3 New After tightening the bolts make sure that the oil pump turns smoothly ...

Page 235: ...ne oil Clutch cover Clutch Oil pump drive gear Circlip Shift lever Spring Shift lever arm Shift shaft 1 1 1 1 1 Remove the parts in the order listed Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Refer to OIL PUMP Refer to CLUTCH SHIFT SHAFT ENG SHIFT SHAFT SHIFT SHAFT AND STOPPER LEVER ...

Page 236: ...5 55 SHIFT SHAFT ENG Order Job Part Q ty Remarks 6 7 Shift cam stopper lever Collar 1 1 For installation reverse the removal procedure ...

Page 237: ... shift le ver EB408410 CHECKING THE SHIFT LEVER 1 Check shift lever 1 Bends damage wear Replace shift lever spring 2 Damage wear Replace INSTALLING THE SHIFT SHAFT 1 Install stopper lever 1 stopper lever spring 2 shift shaft lever 3 Hook the ends of the stopper lever spring onto the stopper lever and the crankcase boss Mesh the stopper lever with the shift drum seg ment assembly ...

Page 238: ...iming chain guide Timing chain holder Timing chain 2 1 2 Remove the parts in the order listed Refer to ENGINE REMOVAL Refer to CYLINDER HEADS Refer to CYLINDER AND PISTONS Refer to CLUTCH Refer to GENERATOR AND STARTER CLUTCH Refer to SHIFT SHAFT Refer to OIL PUMP Refer to CLUTCH 32 Nm 3 2 m kg 10 Nm 1 0 m kg 10 Nm 1 0 m kg CRANKSHAFT AND CONNECTING RODS ENG CRANKSHAFT AND CONNECTING RODS CRANKSHA...

Page 239: ...b Part Q ty Remarks 4 5 6 7 8 9 10 11 Timing chain drive gear Crankcase right Dowel pin Crankshaft assembly Plug Oil seal Spring Oil strainer 1 1 2 1 1 1 1 1 For installation reverse the removal procedure 32 Nm 3 2 m kg 10 Nm 1 0 m kg 10 Nm 1 0 m kg ...

Page 240: ...rankshaft and connecting rods Timing chain drive gear Bearing Crank Washer Crank pin Connecting rod 2 2 2 3 1 2 Remove the parts in the order listed For installation reverse the removal procedure CRANKSHAFT AND CONNECTING RODS ENG CRANKSHAFT AND CONNECTING RODS ...

Page 241: ...rews in decreasing numerical or der refer to the numbers in the illustration The numbers embossed on the crankcase in dicate the crankcase tightening sequence 2 Remove right crankcase For this removal slits a in the crankcase can be use as shown Use a soft hammer to tap on one side of the crankcase Tap only on reinforced portions of the crankcase Do not tap on the crank case mating surfaces Work s...

Page 242: ...ance Out of specification Replace the big end bearing crankshaft pin or connecting rod Big end side clearance 0 40 1 05 mm 3 Measure crankshaft width Out of specification Replace the crank shaft Crankshaft width 67 95 68 00 mm 4 Check crankshaft sprocket 1 Damage wear Replace the crankshaft bearing 2 Cracks damage wear Replace the crankshaft 5 Check crankshaft journal Scratches wear Replace the cr...

Page 243: ...CHECKING THE TIMING CHAIN CAMSHAFT SPROCKET AND TIMING CHAIN GUIDES 1 Check timing chain Damage stiffness Replace the timing chain and camshaft sprocket as a set 2 Check camshaft sprocket More than 1 4 tooth a wear Replace the camshaft sprocket and the timing chain as a set a 1 4 tooth b Correct 1 Timing chain roller 2 Camshaft sprocket 3 Check timing chain guide exhaust side timing chain guide in...

Page 244: ... lips and apply en gine oil onto each bearing EAS00418 ASSEMBLING THE CRANKCASE 1 Thoroughly clean all the gasket mating sur faces and crankcase mating surfaces 2 Apply sealant onto the crankcase mating surfaces Yamaha bond No 1215 90890 85505 Do not allow any sealant to come into contact with the oil gallery a 3 Install dowel pins 1 4 Tighten crankcase screws Tighten the screws in decreasing nume...

Page 245: ...th Shift drum Shift fork 2 2 center Shift fork 3 3 right Shift fork 1 1 left Main axle assembly Drive axle assembly 1 1 1 1 1 1 1 1 Remove the parts in the order listed Refer to CRANKCASE AND CRANKSHAFT For installation reverse the removal procedure Refer to INSTALLING THE TRANSMISSION SHIFT FORK AND SHIFT DRUM ASSEMBLY Refer to REMOVING THE TRANSMISSION TRANSMISSION TRANSMISSION SHIFT DRUM ASSEMB...

Page 246: ...heel gear Forth wheel gear Third wheel gear Fifth wheel gear Second wheel gear Drive axle Second pinion gear Fifth pinion gear Third pinion gear Forth pinion gear Main axle Collar 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Disassemble the parts in the order listed For assembly reverse the removal procedure 1 2 3 4 5 6 7 8 9 11 12 13 14 15 ...

Page 247: ...ds damage scoring wear Replace the shift fork 2 Check shift fork guide bar Roll the shift fork guide bar on a flat surface Bends Replace Do not attempt to straighten a bent shift fork guide bar 3 Check shift fork movement on the shift fork guide bar Rough movement Replace the shift forks and shift fork guide bar as a set EAS00422 CHECKING THE SHIFT DRUM ASSEMBLY 1 Check shift drum grooves Damage s...

Page 248: ... axle runout limit 0 08 mm 3 Check transmission gears Blue discoloration pitting wear Replace the defective gear s transmission gear dogs Cracks damage rounded edges Replace the defective gear s 4 Check transmission gear engagement each pinion gear to its respective wheel gear Incorrect Reassemble the transmission axle assemblies When reassembling the main axle press the 2nd pinion gear 1 onto it ...

Page 249: ...r the clutch side shift fork 3 3 center 3 face the 3 side for the magneto side shift drum 4 shift fork guide bar 1 5 long shift fork guide bar 2 6 short Install the shift forks with the embossed mark to the right and in sequence 1 2 3 beginning from the right 2 Check shift drum operation Unsmoothy operation Repair Check the transmission and shift forks for smooth operation by turning the shift dru...

Page 250: ......

Page 251: ...NG THE FUEL LEVEL 6 7 CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR 6 9 FUEL PUMP 6 12 CHECKING THE FUEL PUMP 6 12 DISASSEMBLING THE FUEL PUMP 6 12 ASSEMBLING THE FUEL PUMP 6 13 AIR INDUCTION SYSTEM 6 14 AIR INDUCTION SYSTEM DIAGRAMS 6 16 AIR INDUCTION ASSEMBLY 6 17 CHECKING THE AIR INDUCTION SYSTEM 6 19 INSTALLING THE AIR INDUCTION SYSTEM 6 20 ...

Page 252: ...CARB ...

Page 253: ...arburetor heater ground lead Carburetor heater lead Throttle position sensor lead Carburetor Starter cable Throttle cable 1 1 1 1 3 1 1 1 1 Remove the parts in the order listed Loosen Disconnect Disconnect Disconnect For installation reverse the removal procedure 10 Nm 1 0 m kg Refer to FUEL TANK AND AIR FILTER in chapter 3 CARBURETOR CARB CARBURETOR CARBURETOR ...

Page 254: ...Needle valve Main jet Main jet holder Pilot screw Starter plunger Pilot air screw Heater Pilot jet 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Disassemble the parts in the order listed Before disassembling the carburetor make sure to note the number of times the pilot screw is turned out from the seated position to its set position NOTE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 CARBURETOR CARB ...

Page 255: ...6 3 CARBURETOR CARB Order Job Part Q ty Remarks Throttle stop screw Throttle position sensor 1 1 For assembly reverse the disassembly procedure 16 17 ...

Page 256: ...er jet housing Cracks damage Replace 2 Check fuel passages Obstruction Clean a Wash the carburetor in a petroleumbased 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 1 needle valve seat 2 O ring 3 Damage obstruction wear Replace the needle...

Page 257: ...pilot screw 5 Bends damage wear Replace Obstruction Clean Blow out the jets with compressed air 9 Check piston valve movement Insert the piston valve into the carburetor body and move it up and down Tightness Replace the piston valve 10 Check fuel feed pipes hose joint Cracks damage Replace Obstruction Clean Blow out the pipes with compressed air 11 Check fuel feed hoses fuel hoses Cracks damage w...

Page 258: ...out from the seated position to its set position Before assembling the carburetors wash all of the parts in a petroleum based sol vent Always use a new gasket 1 Install main jet holder 1 main jet 2 pilot jet 3 2 Install needle valve seat 3 Install needle valve float 1 float pin 2 4 Install float chamber pilot screw piston valve piston valve spring vacuum chamber cover ...

Page 259: ...JUSTING THE FUEL LEVEL 1 Measure fuel level a Out of specification Adjust Fuel level above the line on the float chamber b 3 4 mm a Stand the motorcycle on a level surface b Place the motorcycle on a suitable stand to ensure that the motorcycle is standing straight up c Install the fuel level gauge 1 to the fuel drain pipe 2 Fuel level gauge 90890 01312 d Loosen the fuel drain screw 3 e Hold the f...

Page 260: ...eedle valve seat and needle valve c If either is worn replace them as a set d If both are fine adjust the float level by slight ly bending the float tang 1 e Install the carburetor assembly f Measure the fuel level again g Repeat steps a to f until the fuel level is within specification ...

Page 261: ...nce Out of specification Replace the throttle position sensor Maximum throttle position sensor resistance 4 0 X 6 0 kΩ at 20_C blue black d Connect the pocket tester Ω 1k to the throttle position sensor Positive tester probe yellow terminal 3 Negative tester probe black terminal 2 e While slowly opening the throttle check that the throttle position sensor resistance is with in the specified range ...

Page 262: ...nsor resistance 4 0 X 6 0 kΩ at 20_C blue black e Connect the pocket tester Ω 1k to the throttle position sensor coupler Positive tester probe yellow terminal Negative tester probe black terminal f While slowly opening the throttle check that the throttle position sensor resistance is with in the specified range The resistance does not change or it changes abruptly Replace the throttle position se...

Page 263: ...aximum resistance 0 13 0 15 Example If the maximum resistance 5 kΩ then the throttle position sensor s maximum resistance when the throttle is fully closed should be 5 kΩ 0 13 0 15 650 750 Ω Lift the carburetor assembly slightly out of the intake manifolds Loosen the throttle position sensor screws 4 Connect the pocket tester Ω 100 to the throttle position sensor Positive tester probe yellow termi...

Page 264: ...switch to ON e Push the START switch f Check the fuel flows out from the fuel hose end If fuel does not flow Clean or replace the fuel pump DISASSEMBLING THE FUEL PUMP Turn the fuel cock ON or RES 1 Remove fuel hoses pulser hose fuel pump 2 Remove fuel pump cover 1 diaphragm 2 fuel pump body 3 gasket 4 fuel pump cover 5 3 Check fuel pump body 1 Obstruction Clean Cracks damage Replace fuel pump as ...

Page 265: ...eck diaphragms and gaskets Turn fatigue cracks Replace fuel pump assembly 5 Check valves 1 Cracks damage Replace fuel pump as sembly ASSEMBLING THE FUEL PUMP Reverse the disassembly procedure Be sure to connect the hoses correctly ...

Page 266: ...6 14 To exhaust port of front cylinder head AIR INDUCTION SYSTEM CARB 1 Air cutoff valve 2 Reed valve 3 Air cleaner 4 Carburetor joint 5 Vacuum pulse 6 Exhaust port EAS00507 AIR INDUCTION SYSTEM ...

Page 267: ...6 15 A From air cleaner B To reed valve AIR INDUCTION SYSTEM CARB EAS00508 ...

Page 268: ...r cleaner assembly 3 Air cutoff valve 4 Carbretor joint 5 Exhaust port of front cylinder 6 Exhaust port of rear cylinder A From the front cylinder B From the rear cylinder C To the front exhaust pipe D To the rear exhaust pipe AIR INDUCTION SYSTEM CARB EAS00509 AIR INDUCTION SYSTEM DIAGRAMS ...

Page 269: ...lve to front cylinder head hose Air cutoff valve to rear cylinder head hose Air induction assembly 1 1 1 1 Remove the parts in the order listed Refer to Rear wheel in chapter 4 For installation reverse the removal procedure 5 Nm 0 5 m kg 5 Nm 0 5 m kg 5 Nm 0 5 m kg AIR INDUCTION SYSTEM CARB AIR INDUCTION ASSEMBLY ...

Page 270: ...t Vacuum hose Air cutoff valve to front cylinder head hose Air cutoff valve to rear cylinder head hose Air cutoff valve Air cleaner assembly 1 1 1 1 1 1 1 Remove the parts in the order listed For installation reverse the removal procedure 1 2 3 4 5 6 7 5 Nm 0 5 m kg 4 Nm 0 4 m kg 5 Nm 0 5 m kg AIR INDUCTION SYSTEM CARB ...

Page 271: ...Connect properly Cracks damage Replace pipes 2 Cracks damage Replace 2 Check air filter element 1 Damage Replace 3 Clean air filter element Apply compressed air to the inner surface of the air filter element 4 Check fiber reed 1 fiber reed stopper reed valve seat Cracks damage Replace the reed valve ...

Page 272: ...Replace the reed valve Maximum fiber reed bending 0 4 mm 0 016 in 1 Surface plate 6 Check air cutoff valve Cracks damage Replace INSTALLING THE AIR INDUCTION SYSTEM 1 Install air filter element 2 Install reed valves 1 reed valve stoppers 2 reed valve base 3 3 Install reed valve cover ...

Page 273: ...0 5 m kg 4 Nm 0 4 m kg NOTE 5 Nm 0 5 m kg 4 Install air cleaner assembly 1 5 Install air cut off valve assembly 1 6 Install vacuum hose 1 hoses 2 Fuse the white paint mark of hoses 2 as shown 7 Install bracket nut air induction case cover ...

Page 274: ......

Page 275: ......

Page 276: ...SYSTEM 7 13 CIRCUIT DIAGRAM 7 13 STARTING CIRCUIT OPERATION 7 14 TROUBLESHOOTING 7 15 STARTER MOTOR 7 19 CHECKING THE STARTER MOTOR 7 20 ASSEMBLING THE STARTER MOTOR 7 21 CHARGING SYSTEM 7 23 CIRCUIT DIAGRAM 7 23 TROUBLESHOOTING 7 24 LIGHTING SYSTEM 7 26 CIRCUIT DIAGRAM 7 26 TROUBLESHOOTING 7 27 CHECKING THE LIGHTING SYSTEM 7 28 SIGNALING SYSTEM 7 31 CIRCUIT DIAGRAM 7 31 TROUBLESHOOTING 7 33 CHECK...

Page 277: ...ELEC ...

Page 278: ... coil 4 Front brake light switch 5 Clutch switch 6 Carb heater relay 7 Flasher relay 8 Rectifier regulator 9 Fuse 10 Starter relay 11 Side stand switch 12 Neutral switch 13 Battery 14 Igniter unit 15 Rear brake light switch 16 Horn EB800000 ELECTRICAL ELECTRICAL COMPONENTS ...

Page 279: ...ecking for continuity switch back and forth between the switch positions a few times The terminal connections for switches e g main switch engine stop switch are shown in an illustration similar to the one on the left The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row in the switch illustration indicates a continuity of electricity between...

Page 280: ...heck each switch for damage or wear proper connections and also for continuity between the termi nals Refer to CHECKING SWITCH CONTINUITY Damage wear Repair or replace the switch Improperly connected Properly connect Incorrect continuity reading Replace the switch ...

Page 281: ...tart switch 11 Rear brake switch 12 Neutral switch 13 Sidestand switch 14 Fuses 1 Clutch switch 2 Pass switch 3 Horn switch 4 Dimmer switch 5 Turn switch 6 Front brake switch 7 Main switch 8 Lights switch CHECKING THE SWITCHES ELEC ...

Page 282: ...own in the illustration on the left Bulbs A and B are used for headlights and usually use a bulb holder which must be de tached before removing the bulb The majority of these bulbs can be removed from their re spective socket by turning them counterclock wise Bulb C is used for turn signal and tail brake lights and can be removed from the socket by pushing and turning the bulb counterclock wise Bu...

Page 283: ...ife of the bulb and the luminous flux will be adverse ly affected If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 2 Check bult for continuity with the pocket tester No continuity Replace Pocket tester 90890 03112 Before checking for continuity set the pocket tester to 0 and to the Ω 1 range a Connect the tester positive probe to terminal...

Page 284: ... tester No continuity Replace Pocket tester 90890 03112 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 re spective leads of the bulb socket c Check the bulb socket for continuity If any of the readings indicate no continuity replace the bulb soc...

Page 285: ... 6 Battery 8 Fuse ignition 9 Relay unit 11 Sidestand switch 13 Ignitor 14 Ignition coil 1 15 Ignition coil 2 16 Spark plug 17 Pickup coil 18 Neutral switch 26 Engine stop switch IGNITION SYSTEM ELEC IGNITION SYSTEM CIRCUIT DIAGRAM ...

Page 286: ... NOTE YES NO Replace the fuse s 1 Main and ignition fuses DCheck the main and ignition fuses for conti nuity Refer to CHECKING THE FUSES in chap ter 3 DAre the main and ignition fuses OK EAS00737 EAS00739 TROUBLESHOOTING The ignition system fails to operate no spark or intermittent spark Check 1 main and ignition fuses 2 battery 3 spark plugs 4 ignition spark gap 5 spark plug cap resistance 6 igni...

Page 287: ...the spark plug DConnect the pocket tester Ω 1k to the spark plug cap as shown DMeasure the spark plug cap resistance Spark plug cap resistance 10 kΩ at 20_C DIs the spark plug cap OK YES Replace the spark plug cap NO EAS00747 Tester positive probe spark plug lead Tester negative probe Orange gray lead 1 1 2 a 2 6 Ignition coil resistance The following procedure applies to all of the ignition coils...

Page 288: ...p coil resistance EAS00749 DCheck the main switch for continuity Refer to CHECKING THE SWITCHES DIs the main switch OK YES Replace the main switch NO 8 Main switch EAS00750 DCheck the engine stop switch for continuity Refer to CHECKING THE SWITCHES DIs the engine stop switch OK YES Replace the right handlebar switch NO 9 Engine stop switch EAS00751 DCheck the neutral switch for continuity Refer to...

Page 289: ...r repair the ignition system s wiring NO Replace the ignitor unit EAS00760 Tester positive probe blue green Tester negative probe blue yellow Tester positive probe blue yellow Tester negative probe blue green Continuity No continuity 1 2 2 1 YES Replace the starting circuit cut off relay NO NOTE When you switch the and leads of the digital pocket tester the readings in the above chart will be reve...

Page 290: ... Starter relay 6 Battery 7 Starter motor 8 Fuse ignition 9 Relay unit 10 Clutch switch 11 Sidestand switch 18 Neutral switch 26 Engine stop switch 27 Start switch ELECTRIC STARTING SYSTEM ELEC ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM ...

Page 291: ...closed The starting circuit cut off relay prevents the starter from operating when neither of these conditions have been met In this instance the starting circuit cut off relay is open so current cannot reach the starter motor When at least one of the above conditions have been met however the starting circuit cut off relay is closed and the engine can be started by pressing the starter switch WHE...

Page 292: ...able gas or fluid is in the vicinity DDoes the starter motor turn WARNING NOTE YES NO Replace the fuse s 1 Main and ignition fuses DCheck the main and ignition fuses for conti nuity Refer to CHECKING THE FUSES in chap ter 3 DAre the main and ignition fuses OK EAS00757 EAS00739 TROUBLESHOOTING The starter motor fails to turn Check 1 main and ignition fuses 2 battery 3 starter motor 4 relay unit sta...

Page 293: ...When you switch the and leads of the digital pocket tester the readings in the above chart will be reversed Are the tester readings correct Tester positive probe blue yellow Tester negative probe light green 3 1 No continuity 5 Relay unit Diode Disconnect the relay unit Diode from the coupler Connect the pocket tester Ω 1 to the starting circuit cutoff relay terminals as shown Measure the relay un...

Page 294: ...NG THE SWITCHES Is the sidestand switch OK YES Replace the side stand switch NO 10 Sidestand switch EAS00763 Check the clutch switch for continuity Refer to CHECKING THE SWITCHES Is the clutch switch OK YES Replace the clutch switch NO 11 Clutch switch 1 Tester positive probe red Tester negative probe black 3 4 Does the starter relay have continuity be tween red and black EAS00749 Check the main s...

Page 295: ... the starting system s wiring 12 Start switch Check the start switch for continuity Refer to CHECKING THE SWITCHES Is the start switch OK 13 Wiring Check the entire starting system s wiring Refer to CIRCUIT DIAGRAM Is the starting system s wiring properly con nected and without defects ELECTRIC STARTING SYSTEM ELEC EAS00764 ...

Page 296: ...r Oil seal Bearing Armature assembly O ring Brush holder brush Starter motor rear cover Starter motor yoke 1 1 1 1 1 1 1 1 1 1 1 1 1 Remove the parts in the order listed For installation reverse the removal procedure Disassembly the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 4 5 6 7 8 9 5 Nm 0 5 m kg ELECTRIC STARTING SYSTEM ELEC STARTER MOTOR ...

Page 297: ...saw blade which has been grounded to fit the commuta tor Mica undercut 1 5 mm The mica must be undercut to ensure proper op eration of the commutator 4 Measure Darmature assembly resistances commuta tor and insulation Out of specification Replace the starter motor a Measure the armature assembly resis tances with the pocket tester Pocket tester 90890 03112 Armature assembly Armature coil resistanc...

Page 298: ...ure brush spring force free length a Out of specification Replace the brush springs as a set Brush spring force 5 52 X 8 28 N 563 X 844 gf 7 Check gear teeth Damage wear Replace the gear 8 Check oil seal Damage wear Replace the defective part s EAS00772 ASSEMBLING THE STARTER MOTOR 1 Install brush commutator 1 2 Install starter motor yoke 1 ...

Page 299: ...7 22 ELECTRIC STARTING SYSTEM ELEC NOTE 3 Install Starter motor front cover 1 Align the match marks a on the rear cover with the match marks b on the front cover ...

Page 300: ...7 23 1 A C magneto 2 Rectifier regulator 4 Fuse main 6 Battery CHARGING SYSTEM ELEC CHARGING SYSTEM CIRCUIT DIAGRAM ...

Page 301: ... terminal Tester negative probe battery negative terminal DStart the engine and let it run at approximate ly 5 000 r min DMeasure the charging voltage NOTE YES NO Replace the fuse 1 Main fuse DCheck the main fuse for continuity Refer to CHECKING THE FUSES in chap ter 3 DIs the main fuse OK EAS00774 EAS00739 TROUBLESHOOTING The battery is not being charged Check 1 main fuses 2 battery 3 charging vo...

Page 302: ...K YES Replace the stator coil assembly NO Tester positive probe white Tester negative probe white 1 2 DMeasure the stator coil assembly resis tances Tester positive probe white Tester negative probe white 1 3 5 Wiring NO Replace the rectifi er regulator YES EAS00779 DCheck the wiring connections of the entire charging system Refer to CIRCUIT DIAGRAM DIs the charging system s wiring properly con ne...

Page 303: ...er switch 36 Headlight 37 Auxiliary light 42 Fuse headlight 46 Tail brake light 3 Main switch 4 Fuse main 6 Battery 22 High beam indicator light 24 Meter light 28 Light switch LIGHTING SYSTEM ELEC LIGHTING SYSTEM CIRCUIT DIAGRAM ...

Page 304: ...n chapter 3 DIs the battery OK NO EAS00783 4 Lights switch DCheck the lights switch for continuity Refer to CHECKING THE SWITCHES DIs the lights switch OK YES The lights switch is faulty Replace the right handlebar switch NOTE EAS00781 EAS00739 TROUBLESHOOTING Any of the following fail to light headlight high beam indicator light taillight auxilia ry light or meter light Check 1 main and headlight...

Page 305: ...of each of the lighting system s circuits Refer to CHECKING THE LIGHTING SYS TEM Check the headlight bulb and socket for con tinuity Refer to CHECKING THE BULBS AND BULB SOCKETS Are the headlight bulb and socket OK YES Replace the head light bulb socket or both NO 1 Headlight bulb and socket 2 Voltage Connect the pocket tester DC 20 V to the headlight and high beam indicator light cou plers as sho...

Page 306: ...must be repaired NO YES 2 Voltage Connect the pocket tester 20 V to the meter assembly coupler wire harness side as shown Tester positive probe blue Tester negative probe black 1 2 This circuit is OK Replace the tail brake light bulb sock et or both NO YES The wiring circuit from the main switch to the meter assem bly coupler is faulty and must be re paired NO This circuit is OK EAS00790 3 A tail ...

Page 307: ...05413 4 The auxiliary light fails to come on 1 Auxiliary light bulb and socket Check the auxiliary light bulb and socket for continuity Refer to CHECKING THE BULBS AND BULB SOCKETS Are the auxiliary light bulb and socket OK YES 2 Voltage Connect the pocket tester DC 20 V to the auxiliary light couplers wire harness side as shown Tester positive probe blue red Tester negative probe black 1 2 YES Th...

Page 308: ...7 31 SIGNALING SYSTEM ELEC SIGNALING SYSTEM CIRCUIT DIAGRAM ...

Page 309: ...indicator light 23 Turn signal indicator light 32 Horn switch 33 Turn signal switch 34 Horn 35 Flasher relay 38 Front turn signal light left 39 Front turn signal light right 40 Rear turn signal light left 41 Rear turn signal light right 43 Fuse signal 44 Rear stop switch 45 Front stop switch 46 Tail brake light ...

Page 310: ...795 4 Wiring DCheck the entire signaling system s wiring Refer to CIRCUIT DIAGRAM DIs the signaling system s wiring properly con nected and without defects YES Properly connect or repair the signaling system s wring Check the condition of each of the signal ing system s circuits Refer to CHECKING THE SIGNALING SYSTEM NOTE EB806010 EAS00739 TROUBLESHOOTING DAny of the following fail to light turn s...

Page 311: ...ead Set the main switch to ON Does the horn sound NO 4 Voltage Connect the pocket tester DC 20 V to the horn connecter at the pink terminal as shown Tester positive probe pink Tester negative probe ground 1 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 connecter is faulty and ...

Page 312: ...THE SWITCHES Is the brake light switch OK YES 2 YES The wiring circuit from the main switch to the tail brake light coupler is faulty and must bne repaired NO This circuit is OK Set the main switch to ON Pull in the brake lever or push down on the brake pedal Measure the voltage 12 V of yellow at the tail brake light coupler wire harness side Is the voltage within specification Replace the turn si...

Page 313: ...e harness side Is the voltage within specification 1 4 Voltage Connect the tester DC 20 V to the flasher relay coupler wire harness side as shown The flasher relay is faulty and must be re placed NO YES 1 Set the main switch to ON Set the turn signal switch to or Measure the voltage 12 V of brown white at the flasher relay coupler wire harness side Is the voltage within specification Tester positi...

Page 314: ... switch to ON Set the turn signal switch to or Measure the voltage 12 V of chocolate or dark green at the turn signal light connec tor wire harness side Is the voltage within specification 1 2 Replace the neutral switch NO 2 Neutral switch Check the neutral switch for continuity Refer to CHECKING THE SWITCHES Is the neutral switch OK YES 3 Voltage Connect the pocket tester DC 20 V to the meter ass...

Page 315: ... 48 Thermo switch 49 Carburetor heater 50 Carburetor heater ground 51 Carburetor heater relay 3 Main switch 4 Fuse main 6 Battery 8 Fuse ignition 13 Ignitor unit CARBURETOR HEATER SYSTEM ELEC CARBURETOR HEATER SYSTEM CIRCUIT DIAGRAM ...

Page 316: ...own Yellow terminal Tester lead Black Yellow terminal 1 2 CARBURETOR HEATER SYSTEM ELEC NOTE YES NO Replace the fuse s 1 Main and carburetor heater fuses DCheck the main and carburetor heater fuses for continuity Refer to CHECKING THE FUSES in chap ter 3 DAre the main and carburetor heater fuses OK EAS00781 TROUBLESHOOTING The carburetor heater fails to operate Check 1 main and carburetor heater f...

Page 317: ...witch 12 4_C Thermoswitch 23 3_C 5 Carburetor heater DRemove the carburetor heater from the car buretor body DConnect the pocket tester to the carburetor heater Tester lead Heater terminal Tester lead Heater body 1 2 YES Replace the carbure tor heater NO 6 Wiring DCheck the entire carburetor heater system s wiring Refer to CIRCUIT DIAGRAM DIs the carburetor heater system s wiring properly connecte...

Page 318: ...tor light in the speedometer comes on for 1 4 seconds then goes off However if there is a malfunction it comes on for 1 4 seconds goes off and then begins flashing However it is on while the engine is running Display condition code Item Condition Response When engine is stationary When engine is running Throttle position sensor TPS Disconnected Short circuit Locked Enables the motorcycle to run so...

Page 319: ...OK YES Replace the throttle position sensor Replace the ignitor unit EB812401 SELF DIAGNOSIS ELEC NOTE 12 Throttle position sensor 13 Ignitor unit EAS00835 TROUBLESHOOTING The engine warning light starts to display the self diagnosis sequence Check 1 throttle position sensor Before troubleshooting remove the following part s 1 rider seat and passenger seat 2 fuel tank 3 air filter assembly 4 silen...

Page 320: ...1 Wire harness Check the wire harness for continuity Refer to CIRCUIT DIAGRAM Is the wire harness OK Replace the speed meter SELF DIAGNOSIS ELEC NOTE 13 Ignitor unit 19 Meter 2 Speed sensor 5JX2 CIRCUIT DIAGRAM The speed sensor into the speedometer ...

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Page 323: ...EAR 8 2 FAULTY CLUTCH 8 3 CLUTCH SLIPS 8 3 CLUTCH DRAGS 8 3 OVERHEATING 8 3 ENGINE 8 3 FUEL SYSTEM 8 3 CHASSIS 8 3 ELECTRICAL SYSTEMS 8 3 POOR BRAKING PERFORMANCE 8 4 FAULTY FRONT LEGS 8 4 LEAKING OIL 8 4 MALFUNCTION 8 4 UNSTABLE HANDLING 8 4 FAULTY LIGHTNING AND SIGNALING SYSTEMS 8 5 HEADLIGHT DOES NOT LIGHT 8 5 HEADLIGHT BULB BURNT OUT 8 5 TAIL BRAKE LIGHT DOES NOT LIGHT 8 5 TAIL BRAKE LIGHT BUL...

Page 324: ...TRBL SHTG ...

Page 325: ...r all the possible causes of trouble It should be helpful however as a guide to basic troubleshooting Refer to the relative procedure in this manual for checks adjustments and replacement of parts STARTING PROBLEMS ENGINE Cylinders and cylinder heads Loose spark plug Loose cylinder head Damaged cylinder head gasket Worn or damaged cylinder Incorrect valve clearance Incorrectly sealed valve Incorre...

Page 326: ...ansmission Worn gear dog EAS00846 INCORRECT ENGINE IDLING SPEED ENGINE Cylinders and cylinder heads Incorrect valve clearance Damaged valve train components Air filter Clogged air filter element FUEL SYSTEM Carburetor Faulty starter plunger Loose or clogged pilot jet Loose or clogged pilot air jet Damaged or loose carburetor joint Incorrectly adjusted engine idling speed throttle stop screw Incorr...

Page 327: ... gap Incorrect spark plug heat range Ignition system Faulty CDI unit EAS00851 FAULTY CLUTCH CLUTCH SLIPS Clutch Incorrectly assembled clutch Incorrectly adjusted clutch cable Loose or fatigued clutch spring Worn friction plate Worn clutch plate Engine oil Incorrect oil level Incorrect oil viscosity low Deteriorated oil EAS00854 OVERHEATING ENGINE Cylinder heads and pistons Heavy carbon buildup Eng...

Page 328: ...ut Frame Bent frame Damaged steering head pipe Incorrectly installed bearing race EAS00859 POOR BRAKING PERFORMANCE Front brake Worn brake pad Worn brake disc Air in hydraulic brake system Leaking brake fluid Faulty brake caliper piston seal Loose union bolt Damaged brake hose Oil or grease on the brake disc Oil or grease on the brake pad Incorrect brake fluid level EAS00861 FAULTY FRONT FORK LEGS...

Page 329: ...es Hard charging Incorrect connection Incorrectly grounded circuit Poor contacts main or light switch Burnt out headlight bulb HEADLIGHT BULB BURNT OUT Wrong headlight bulb Faulty battery Faulty rectifier regulator Incorrectly grounded circuit Faulty main switch Faulty light switch Headlight bulb life expired TAIL BRAKE LIGHT DOES NOT LIGHT Wrong tail brake light bulb Too may electrical accessorie...

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Page 331: ...iliary light 38 Front turn signal light left 39 Front turn signal light right 40 Rear turn signal light left 41 Rear turn signal light right 42 Fuse headlight 43 Fuse signal 44 Rear stop switch 45 Front stop switch 46 Tail brake light 47 Fuse carburetor heater 48 Thermo switch 49 Carburetor heater 50 Carburetor heater ground 51 Carburetor heater relay 52 Alarm option COLOR CODE B Black Br Brown Ch...

Page 332: ...36 Headlight 37 Front turn signal light left 38 Front turn signal light right 39 Rear turn signal light left 40 Rear turn signal light right 41 Fuse headlight 42 Fuse signal 43 Rear stop switch 44 Front stop switch 45 Tail brake light 46 Fuse carburetor heater 47 Thermo switch 48 Carburetor heater 49 Carburetor heater ground 50 Carburetor heater relay COLOR CODE B Black Br Brown Ch Chocolate Dg Da...

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Yamaha XVS250 2001, Service Manual

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