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2-13

TIGHTENING TORQUES

Throttle cable adjust bolt and locknut

M6 × 0.75

1

4

0.4

2.9

Throttle cable (pull)

M6 × 1.0

1

4

0.4

2.9

Throttle cable (return)

M12 × 1.0

1

11

1.1

8.0

Throttle cable cover

M5 × 0.8

2

4

0.4

2.9

Hot starter plunger

M12 × 1.0

1

2

0.2

1.4

Hot starter cable adjust bolt and locknut

M6 × 0.75

1

4

0.4

2.9

△

Air filter case

M6 × 1.0

2

8

0.8

5.8

Air filter joint and air filter case

M5 × 0.8

1

4

0.4

2.9

Exhaust pipe

M8 × 1.25

2

20

2.0

14

△

Exhaust pipe protector

M6 × 1.0

3

10

1.0

7.2

△

Silencer

M8 × 1.25

2

30

3.0

22

Silencer clamp

M8 × 1.25

1

16

1.6

11

Spark arrester

M5 × 0.8

4

7

0.7

5.1

Silencer cap

M5 × 0.8

6

5

0.5

3.6

Air induction pipe

M6 × 1.0

1

10

1.0

7.2

Air induction pipe clamp

M6 × 1.0

1

4

0.4

2.9

Air cut-off valve assembly and bracket

M6 × 1.0

2

10

1.0

7.2

Bracket (air cut-off valve) and frame

M6 × 1.0

2

7

0.7

5.1

Crankcase

M6 × 1.0

11

12

1.2

8.7

Crankcase bearing stopper

M6 × 1.0

11

10

1.0

7.2

Crankcase bearing stopper (crankshaft)

M6 × 1.0

4

14

1.4

10

Left crankcase cover

M6 × 1.0

8

10

1.0

7.2

Idle gear cover (starter motor)

M6 × 1.0

3

10

1.0

7.2

Idle gear plate

M6 × 1.0

2

10

1.0

7.2

Right crankcase cover

M6 × 1.0

6

10

1.0

7.2

Clutch cover

M6 × 1.0

7

10

1.0

7.2

Crankcase oil drain bolt

M10 × 1.25

1

20

2.0

14

△

Crankshaft end accessing screw

M32 × 1.5

1

—

—

—

△

Timing mark accessing screw

M14 × 1.5

1

—

—

—

Drive chain sprocket cover

M6 × 1.0

2

8

0.8

5.8

Kick shaft ratchet wheel guide

M6 × 1.0

2

12

1.2

8.7

Kickstarter crank

M8 × 1.25

1

33

3.3

24

Primary drive gear

M18 × 1.0

1

75

7.5

54

Clutch spring

M6 × 1.0

5

10

1.0

7.2

Clutch boss

M16 × 1.0

1

60

6.0

43

Clutch cable locknut

M8 × 1.25

2

7

0.7

5.1

Push lever shaft

M6 × 1.0

1

10

1.0

7.2

Drive sprocket

M18 × 1.0

1

75

7.5

54

Drive axle oil seal stopper

M6 × 1.0

2

10

1.0

7.2

Segment

M8 × 1.25

1

30

3.0

22

Shift guide

M6 × 1.0

2

10

1.0

7.2

Stopper lever

M6 × 1.0

1

10

1.0

7.2

Shift pedal

M6 × 1.0

1

12

1.2

8.7

Part to be tightened

Thread size

Q'ty

Tightening torque

Nm

m•kg

ft•lb

Содержание WR250F(Y) 2009

Страница 1: ...R250F Y 2009 2009 5UM 28199 56 E0 5UM 28199 56 E0 OWNER S SERVICE MANUAL OWNER S SERVICE MANUAL Read this manual carefully before operating this vehicle Read this manual carefully before operating thi...

Страница 2: ......

Страница 3: ...SERVICE MANUAL 2008 by Yamaha Motor Co Ltd 1st Edition July 2008 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited P...

Страница 4: ...chine is designed for off road use only It is illegal for this machine to be operated on any public street road or highway Off road use on public lands may be illegal Please check local regulations be...

Страница 5: ...seven chapters General Information Specifications Regular inspec tion and adjustments Tuning Engine Chassis and Electri cal 2 The table of contents is at the be ginning of the manual Look over the gen...

Страница 6: ...informa tion the step by step format sup plements 5 are given in addition to the exploded diagram and job instruction chart ILLUSTRATED SYMBOLS Refer to the illustration Illustrated symbols 1 to 7 are...

Страница 7: ...TABLE OF CONTENTS GENERAL INFORMATION 1 SPECIFICATIONS 2 REGULAR INSPECTION AND ADJUSTMENTS 3 TUNING 4 ENGINE 5 CHASSIS 6 ELECTRICAL 7...

Страница 8: ...TION AND MAINTENANCE 3 7 ENGINE 3 8 CHASSIS 3 19 ELECTRICAL 3 29 CHAPTER 4 TUNING ENGINE Except for Canada 4 1 CHASSIS 4 5 CHAPTER 5 ENGINE RADIATOR 5 1 CARBURETOR 5 4 AIR INDICTOIN SYSTEM 5 12 CAMSHA...

Страница 9: ...tarter lever 3 Engine stop switch 4 Multi function display 5 Main switch 6 Start switch 7 Front brake lever 8 Throttle grip 9 Radiator cap 10 Fuel tank cap 11 Taillight 12 Kickstarter crank 13 Fuel ta...

Страница 10: ...e fuel tank and also downward SPARK PLUG WRENCH This spark plug wrench 1 is used to remove and install the spark plug NIPPLE WRENCH This nipple wrench 1 is used to tighten the spoke JET NEEDLE PULL UP...

Страница 11: ...mped letters must be on the side exposed to view When in stalling oil seal s apply a light coating of lightweight lithium base grease to the seal lip s Oil the bearings liberally when installing Do no...

Страница 12: ...How to use Illustration Crankcase separating tool YU 1135 A 90890 01135 These tool is used to remove the crankshaft from either case Dial gauge and stand YU 3097 90890 01252 Stand YU 1256 These tools...

Страница 13: ...ver YM A0948 90890 01502 This tool is used when install the fork oil seal Spoke nipple wrench YM 01521 90890 01521 This tool is used to tighten the spoke Sheave holder YS 1880 A 90890 01701 This tool...

Страница 14: ...4 0 mm 0 16 in Exhaust 4 5 mm 0 18 in YM 4111 90890 04111 YM 4116 90890 04116 This tool is needed to remove and install the valve guide Valve guide installer Intake 4 0 mm 0 16 in Exhaust 4 5 mm 0 18...

Страница 15: ...or checking the ignition system compo nents Vacuum pressure pump gauge set YB 35956 A 90890 06756 This tool is used to check the air in duction system YAMAHA Bond No 1215 ThreeB ond No 1215 90890 8550...

Страница 16: ...t pedal 1 on the left side of the engine KICKSTARTER CRANK Rotate the kickstarter crank 1 away from the engine Push the starter down lightly with your foot until the gears engage then kick smoothly an...

Страница 17: ...ime that has been accumulated since the start of timer measurement Tripmeter which shows the accu mulated travel distance in timer measurement Change tripmeter digits capable of change to any given on...

Страница 18: ...for 2 seconds or more at the same time to change over to BASIC MODE RACE MODE Putting measurement on standby Starting measurement consists of the following two starts either of which can be selected M...

Страница 19: ...button and SLCT2 but ton at the same time 2 Reset tripmeter A TRIP A dis play by pushing the RST button for 2 seconds or more If reset and travel distance dis play will go on flashing for four sec on...

Страница 20: ...on the button changes the operation in both arrowed directions Meter function Function that can be performed whether the time is or is not in operation Extent to which the meter can operate Clock BASI...

Страница 21: ...he button changes the operation in the ar rowed direction D A long push on the button changes the operation in both arrowed directions E Meter function F Function that can be performed whether the tim...

Страница 22: ...starting STARTING A COLD ENGINE This model is equipped with an igni tion circuit cut off system The engine can be started under the following conditions When the transmission is in neutral When the cl...

Страница 23: ...te the machine in the lower gears at moderate throttle open ings for five to eight minutes 5 Check how the engine runs when the machine is ridden with the throttle 1 4 to 1 2 open low to me dium speed...

Страница 24: ...nk type Assembly of links Link to frame Link to rear shock absorber Link to swingarm Installation of rear shock absorber Rear shock absorber to frame Installation of swingarm Tightening of pivot shaft...

Страница 25: ...in with a paper towel and lubri cate the chain to prevent rust 7 Clean the seat with a vinyl uphol stery cleaner to keep the cover pliable and glossy 8 Automotive wax may be applied to all painted or...

Страница 26: ...round clearance 365 mm 14 37 in 370 mm 14 57 in 375 mm 14 76 in Dry weight Without oil and fuel 106 0 kg 233 7 lb Engine Engine type Liquid cooled 4 stroke DOHC Cylinder arrangement Single cylinder fo...

Страница 27: ...0 028 0 031 in Clutch type Wet multiple disc Transmission USA CDN ZA AUS NZ EUROPE Primary reduction system Gear Primary reduction ratio 57 17 3 353 Secondary reduction system Chain drive Secondary r...

Страница 28: ...wheel travel 310 mm 12 2 in Electrical Ignition system CDI Generator system AC magneto Battery type YTZ7S F Battery voltage capacity 12V 6 AH Specific gravity 1 310 Headlight type Quartz bulb halogen...

Страница 29: ...35 mm 0 8799 in Camshaft runout limit 0 03 mm 0 0012 in Timing chain Timing chain type No of links 92RH2010 114M 114 Timing chain adjustment method Automatic Valve valve seat valve guide Valve clearan...

Страница 30: ...0 in 4 050 mm 0 1594 in Guide inside diameter EX 4 500 4 512 mm 0 1772 0 1776 in 4 550 mm 0 1791 in Stem to guide clearance IN 0 010 0 037 mm 0 0004 0 0015 in 0 08 mm 0 003 in Stem to guide clearance...

Страница 31: ...Piston Piston to cylinder clearance 0 030 0 055 mm 0 0012 0 0022 in 0 1 mm 0 004 in Piston size D 76 955 76 970 mm 3 0297 3 0303 in Measuring point H 8 mm 0 31 in Piston off set 0 5 mm 0 020 in IN si...

Страница 32: ...mm 0 0012 in 0 05 mm 0 002 in Big end side clearance D 0 15 0 45 mm 0 0059 0 0177 in 0 50 mm 0 02 in Small end free play F 0 4 1 0 mm 0 02 0 04 in 2 0 mm 0 08 in Clutch Friction plate thickness 2 9 3...

Страница 33: ...31 in Engine idle speed 1 750 1 950 r min Intake vacuum 31 3 36 7 kPa 235 275 mmHg 9 25 10 83 inHg Hot starter lever free play 3 6 mm 0 12 0 24 in Lubrication system Oil filter type Paper type Oil pum...

Страница 34: ...nner tube outer diameter 48 mm 1 89 in Front fork top end 5 mm 0 20 in Rear suspension USA CDN AUS NZ ZA EUROPE Shock absorber travel 130 mm 5 12 in Spring free length 260 mm 10 24 in Fitting length 2...

Страница 35: ...mm 0 25 in 1 0 mm 0 04 in Master cylinder inside dia 11 0 mm 0 433 in Caliper cylinder inside dia 25 4 mm 1 000 in 1 Brake fluid type DOT 4 Brake lever and brake pedal Brake lever position 95 mm 3 74...

Страница 36: ...A Electric starting system Type Constant mesh Starter motor Model manufacturer 5UM01 YAMAHA Operation voltage 12 V Output 0 35 kW Armature coil resistance 0 0189 0 0231 at 20 C 68 F Brush overall leng...

Страница 37: ...n tensioner cap bolt M6 1 0 1 7 0 7 5 1 Impeller M8 1 25 1 14 1 4 10 Radiator hose clamp M6 1 0 10 2 0 2 1 4 Coolant drain bolt M6 1 0 1 10 1 0 7 2 Water pump housing M6 1 0 4 10 1 0 7 2 Radiator stay...

Страница 38: ...7 Crankcase bearing stopper M6 1 0 11 10 1 0 7 2 Crankcase bearing stopper crankshaft M6 1 0 4 14 1 4 10 Left crankcase cover M6 1 0 8 10 1 0 7 2 Idle gear cover starter motor M6 1 0 3 10 1 0 7 2 Idl...

Страница 39: ...lever mounting nut M6 1 0 1 6 0 6 4 3 Brake lever position locknut M6 1 0 1 5 0 5 3 6 Front brake hose guide and front brake hose guide bracket M5 0 8 1 4 0 4 2 9 Front brake hose guide and lower bra...

Страница 40: ...32 3 2 23 Swingarm and brake hose holder M5 0 8 4 3 0 3 2 2 Swingarm and patch M4 0 7 4 2 0 2 1 4 Upper drive chain tensioner M8 1 25 1 16 1 6 11 Lower drive chain tensioner M8 1 25 1 16 1 6 11 Drive...

Страница 41: ...0 1 0 7 Taillight lead clamp and rear fender 3 0 5 0 05 0 36 Catch tank upper M6 1 0 1 16 1 6 11 Catch tank lower M6 1 0 1 7 0 7 5 1 Footrest bracket and frame M10 1 25 4 55 5 5 40 Sidestand M10 1 25...

Страница 42: ...s should be at room temperature A Distance between flats B Outside thread diameter DEFINITION OF UNITS A Nut B Bolt TORQUE SPECIFI CATION Nm m kg ft lb 10 mm 6 mm 6 0 6 4 3 12 mm 8 mm 15 1 5 11 14 mm...

Страница 43: ......

Страница 44: ...2 18 LUBRICATION DIAGRAMS LUBRICATION DIAGRAMS 1 Oil filter element 2 Oil pump 3 Drive axle 4 Main axle 5 Intake camshaft 6 Exhaust camshaft 7 Oil tank 8 Oil delivery pipe A To oil tank...

Страница 45: ...2 19 LUBRICATION DIAGRAMS 1 Crankshaft 2 Oil filter element 3 Oil tank 4 Oil hose A From oil pump...

Страница 46: ...ead breather hose 8 Throttle position sensor lead 9 Neutral switch lead 10 Oil hose 11 Clutch cable 12 Starter motor lead 13 Cable guide 14 Negative battery lead 15 AC magneto lead 16 Brake hose 17 Re...

Страница 47: ...onto the frame Locate the clamp end facing toward the outside of the frame and tie end facing toward the rear of the frame H Pass the clutch cable through the cable guide I Fasten the starter motor le...

Страница 48: ...A Cross the pull and push throttle cables B Fasten the catch tank hose and air induction hose air cut off valve rear of cylinder head onto the frame Locate the clamp end facing toward the lower side...

Страница 49: ...directs as shown and lightly touches the projec tion on the brake caliper B Pass the brake hose into the brake hose holders C If the brake hose contacts the spring rear shock absorber correct its twis...

Страница 50: ...2 24 CABLE ROUTING DIAGRAM 1 Clamp 2 Positive battery lead 3 Battery 4 Negative battery lead 5 Taillight coupler 6 CDI unit coupler 6 pin 7 CDI unit coupler 3 pin 8 CDI unit coupler 6 pin...

Страница 51: ...s and taillight lead to the rear frame Locate the clamp end facing toward the upper side of the frame and cut off the tie end H Connect the negative battery lead to the battery negative ter minal I Co...

Страница 52: ...in switch coupler 7 Wire harness 8 Headlight coupler 9 Hot starter cable 10 Multi function display bracket 11 Main switch 12 Upper bracket 13 Clutch switch coupler 14 Engine stop switch coupler 15 Mul...

Страница 53: ...display bracket F Fasten the multi function display leads to the bracket Cut off the tie end G Secure the coupler by pushing it into the hole in the multi function display bracket H Secure the wire h...

Страница 54: ...line Check fuel hoses for cracks or damage Replace if necessary 2 Spark plug Check condition Adjust gap and clean 3 Valve clearance Check and adjust valve clearance when en gine is cold 4 Air filter e...

Страница 55: ...Every 1 year 6 Brake hoses Check for cracks or damage Replace Every 4 years 7 Wheels Check runout spoke tightness and for dam age Tighten spokes if necessary 8 Tires Check tread depth and for damage...

Страница 56: ...eck operation Apply lithium soap based grease all purpose grease lightly 16 Front fork Check operation and for oil leakage Replace if necessary 17 Shock absorber assembly Check operation and for oil l...

Страница 57: ...RING Inspect Check ring end gap Replace PISTON PIN Inspect Replace CYLINDER HEAD Inspect carbon deposits and eliminate them Inspect and clean Change gasket CYLINDER Inspect and clean Inspect score mar...

Страница 58: ...ND BOLTS Retighten Refer to STARTING AND BREAK IN section in the CHAPTER 1 AIR FILTER Clean and lubricate Use foam air filter oil or equivalent oil Replace OIL FILTER Replace ENGINE GUARD Replace Brea...

Страница 59: ...t lube and retighten Molybdenum disulfide grease SIDESTAND Lubricate Lithium base grease STEERING HEAD Inspect free play and retighten Clean and lube Lithium base grease Replace bearing TIRE WHEELS In...

Страница 60: ...hain slack and alignment Check that the drive chain is lubricated properly P 3 22 23 Wheels Check for excessive wear and tire pressure Check for loose spokes and have no excessive play P 3 26 27 Steer...

Страница 61: ...name Q ty Remarks Turn the fuel cock to OFF Disconnect the fuel hose 1 Seat 1 2 Air scoop left and right 2 3 Bolt fuel tank 2 4 Fuel tank 1 5 Left side cover 1 Open the air filter case cover 6 Right s...

Страница 62: ...3 9 ENGINE REMOVING THE SIDE COVER 1 Remove Bolt side cover Right side cover 1 Draw the side cover backward to re move it because its claw a is insert ed in the air filter case...

Страница 63: ...ty Remarks Right side cover Refer to REMOVING THE SEAT FUEL TANK AND SIDE COVERS section 1 Bolt silencer clamp 1 Only loosening 2 Bolt silencer front 1 3 Bolt silencer rear 1 4 Collar 1 5 Silencer 1...

Страница 64: ...harmful to the engine parts You may use distilled water if you can t get soft water 1 Place the machine on a level place and hold it in an upright po sition 2 Remove Radiator cap 3 Check Coolant leve...

Страница 65: ...i fied pressure for 10 seconds Replace CHECKING THE COOLING SYSTEM 1 Inspect Coolant level 2 Attach Radiator cap tester 1 and adapt er 2 3 Apply the specified pressure Do not apply pressure more than...

Страница 66: ...NG THE HOT STARTER LEVER FREE PLAY 1 Check Hot starter lever free play a Out of specification Adjust 2 Adjust Hot starter lever free play Hot starter lever free play adjust ment steps a Loosen the loc...

Страница 67: ...L 1 Start the engine warm it up for several minutes and then turn off the engine and wait for five min utes 2 Place the machine on a level place and hold it up on upright po sition by placing the suit...

Страница 68: ...2 b Check the O rings 3 if cracked or damaged replace them with a new one c Install the oil filter element and oil filter element cover 8 Install O ring 1 Oil strainer 2 Oil hose Bolt oil hose Oil hos...

Страница 69: ...ct the en gine idling speed by bringing the sensing element c of the engine ta chometer close to the ignition coil 2 ADJUSTING THE VALVE CLEARANCE This section is intended for those who have basic kno...

Страница 70: ...table The thickness a of each pad is indi cated in hundredths of millimeters on the pad upper surface d Round off the last digit of the in stalled pad number to the nearest increment EXAMPLE Installed...

Страница 71: ...3 18 ENGINE INTAKE EXHAUST...

Страница 72: ...Reservoir float front brake Protector rear brake 2 Bleed Brake fluid Air bleeding steps a Add proper brake fluid to the res ervoir b Install the diaphragm Be careful not to spill any fluid or allow t...

Страница 73: ...ghten the locknut Adjust the pedal height between the maximum A and the mini mum B as shown In this ad justment the bolt 3 end b should protrude out of the threaded portion 4 but not be less than 2 mm...

Страница 74: ...ke pad thickness a Out of specification Replace as a set 2 Replace Brake pad Brake pad replacement steps a Remove the protector 1 and pad pin plug 2 b Loosen the pad pin 3 c Remove the rear wheel 4 an...

Страница 75: ...ot enter master cylinder when refilling Clean up spilled fluid immediate ly to avoid erosion of painted surfaces or plastic parts a Lower level A Front B Rear CHECKING THE SPROCKET 1 Inspect Sprocket...

Страница 76: ...chain slack with the rear wheel in this tight chain position 3 Adjust Drive chain slack Drive chain slack adjustment steps a Loosen the axle nut 1 and lock nuts 2 b Adjust the drive chain slack by tur...

Страница 77: ...TING THE FRONT FORK COMPRESSION DAMPING FORCE 1 Remove Rubber cap 2 Adjust Compression damping force By turning the adjuster 1 STANDARD POSITION This is the position which is back by the specific numb...

Страница 78: ...ster past the minimum or maximum extent of adjustment The adjuster may be damaged ADJUSTING THE REAR SHOCK ABSORBER LOW COMPRESSION DAMPING FORCE 1 Adjust Low compression damping force By turning the...

Страница 79: ...is low A tilted tire valve stem indicates that the tire slips off its position on the rim If the tire valve stem is found tilted the tire is considered to be slipping off its position Correct the tire...

Страница 80: ...r tightening g Check the steering stem by turn ing it lock to lock If there is any binding remove the steering stem assembly and inspect the steer ing bearings h Install the washer 5 collar 6 upper br...

Страница 81: ...ot 5 Throttle to handlebar contact 6 Drive chain 7 Tube guide cable winding por tion 8 Throttle cable end 9 Clutch cable end 10 Hot starter cable end A Use Yamaha cable lube or equivalent on these are...

Страница 82: ...ghly caustic sulfuric acid There fore always follow these preven tive measures Wear protective eye gear when handling or working near batter ies Charge batteries in a well venti lated area Keep batter...

Страница 83: ...ince it forces a high amperage current into the bat tery quickly and can cause bat tery overheating and battery plate damage If it is impossible to regulate the charging current on the battery charger...

Страница 84: ...3 31 ELECTRICAL Charging method using a variable voltage charger...

Страница 85: ...3 32 ELECTRICAL Charging method using a constant voltage charger...

Страница 86: ...e rating other than that specified Im provising or using a fuse with the wrong amperage rating may cause extensive damage to the electrical system cause the starting and ig nition systems to malfuncti...

Страница 87: ...t Refer to REMOVING THE SEAT FUEL TANK AND SIDE COV ERS section ADJUSTING THE HEADLIGHT BEAMS 1 Adjust Headlight beam vertically Adjusting steps a Turn the adjusting screw 1 in di rection a or b Headl...

Страница 88: ...hen the engine is stopped or when riding at no load do not open and close the throttle un necessarily Otherwise too much fuel may be discharged starting may become difficult or the engine may not run...

Страница 89: ...e throttle is 1 8 to 1 4 open A Idle B Fully open RELATIONSHIP WITH THROTTLE OPENING The flow of the fuel through the car buretor main system is controlled by the main jet and then it is further reg u...

Страница 90: ...4MX 39 Lean 158 4MX 89 Pilot jet Size Part number 14948 Rich 50 4MX 07 48 4MX 06 STD 45 4MX 05 STD 42 4MX 04 Lean 40 4MX 03 Jet needle Size Part number 14916 Rich GDEPN 5UM BN GDEPP 5UM BP GDEPQ 5UM B...

Страница 91: ...ered from the top Check that the accelerator pump operates smoothly except for rich mixture symp tom Rich mixture Raise jet needle clip position 1 groove up 1 4 3 4 throttle Hard breathing Lack of spe...

Страница 92: ...uld be higher to prevent a flat tire FRONT FORK SETTING The front fork setting should be made depending on the rider s feeling of an actual run and the circuit conditions The front fork setting includ...

Страница 93: ...aps 2 Use of stiff spring Change the rebound damping Turn in one or two clicks Change the compression damp ing Turn out one or two clicks Generally a stiff spring gives a stiff riding feeling Rebound...

Страница 94: ...our preference 2 Use of stiff spring Set the soft spring for more re bound damping to compensate for its greater spring load Run with the rebound damping adjust er one or two clicks on the stiffer sid...

Страница 95: ...mping Turn adjuster clockwise about 2 clicks to in crease damping Oil level oil amount Increase oil level by about 5 10 mm 0 2 0 4 in Spring Replace with stiff spring Stiff toward stroke end Oil level...

Страница 96: ...avy and dragging Rebound damping Turn adjuster counterclockwise about 2 clicks to decrease damping Spring Replace with soft spring Poor road gripping Rebound damping Turn adjuster counterclockwise abo...

Страница 97: ...or reassembly only by reference to this manual It may lead to servicing trouble and mechanical damage RADIATOR REMOVING THE RADIATOR Order Part name Q ty Remarks Drain the coolant Refer to CHECKING TH...

Страница 98: ...5 2 RADIATOR 8 Catch tank hose 1 9 Right radiator 1 10 Radiator hose 2 1 11 Radiator hose 4 1 12 Radiator pipe 1 1 13 Catch tank breather hose 1 14 Catch tank 1 Order Part name Q ty Remarks...

Страница 99: ...n the O ring 2 Install Catch tank hose 1 Radiator hose 2 2 Radiator hose 3 3 Radiator pipe 2 4 Radiator hose 5 5 Radiator hose 4 6 To right radiator 7 3 Install Right radiator 1 Bolt right radiator 2...

Страница 100: ...lamp 2 2 Throttle position sensor lead coupler 1 3 Throttle cable cover 1 4 Throttle cable 2 5 Clamp air filter joint 1 Loosen the screw air filter joint 6 Clamp carburetor joint 1 Loosen the screws c...

Страница 101: ...ttle shaft 1 4 Throttle valve 1 5 Needle holder 1 6 Jet needle 1 7 Accelerator pump cover 1 8 Spring 1 9 Diaphragm accelerator pump 1 10 Air cut valve cover 1 11 Spring air cut valve 1 12 Diaphragm ai...

Страница 102: ...jet 1 21 Spacer 1 22 Pilot jet 1 23 Starter jet 1 24 Push rod 1 Pull the push rod 25 Throttle shaft assembly 1 26 Push rod link lever assembly 1 27 Main air jet 1 28 Pilot air jet 1 29 Cold starter p...

Страница 103: ...EEDLE VALVE 1 Inspect Needle valve 1 Valve seat 2 Grooved wear a Replace Dust b Clean Filter c Clogged Clean CHECKING THE THROTTLE VALVE 1 Check Free movement Stick Repair or replace Insert the thrott...

Страница 104: ...ean CHECKING THE AIR CUT VALVE 1 Inspect Diaphragm air cut valve 1 Spring air cut valve 2 Air cut valve cover 3 O ring 4 Tears diaphragm damage Re place ASSEMBLING THE CARBURETOR 1 Install Cold starte...

Страница 105: ...to the float install them to the carbure tor Check the float for smooth move ment 12 Install For EUROPE Pilot screw 1 Spring 2 Washer 3 O ring 4 Note the following installation points a Turn in the p...

Страница 106: ...th the same outer di ameter as the specified value a Fully turn in the accelerator pump adjusting screw 3 b Check that the link lever 4 has free play b by pushing lightly on it c Gradually turn out th...

Страница 107: ...CHAPTER 3 7 Install Throttle cable cover 1 Bolt throttle cable cover 2 8 Install Throttle position sensor lead cou pler 1 Clamp 2 Refer to CABLE ROUTING DIA GRAM section in the CHAPTER 2 9 Install Cla...

Страница 108: ...Air cut off valve assembly 1 3 Air induction hose air cut off valve front of cyl inder head 1 4 Air induction pipe 1 5 Gasket 1 6 Air induction hose air cut off valve rear of cylin der head 1 7 Air i...

Страница 109: ...of the vacuum pressure pump gauge set 1 When using vacuum on the pipe c take care not to exceed the specified value a From air filter b To cylinder head exhaust port c From cylinder head intake port A...

Страница 110: ...Refer to REMOVING THE SEAT FUEL TANK AND SIDE COVERS section in the CHAPTER 3 Air cut off valve assembly Refer to AIR INDUCTION SYSTEM section 1 Spark plug 1 2 Cylinder head breather hose 1 3 Bolt cyl...

Страница 111: ...haft end accessing screw 1 Refer to removal section 3 Timing chain tensioner cap bolt 1 Refer to removal section 4 Timing chain tensioner 1 Refer to removal section 5 Camshaft cap 2 Refer to removal s...

Страница 112: ...cap 2 Clip Remove the bolts camshaft cap in a crisscross pattern working from the outside in The bolts camshaft cap must be removed evenly to prevent dam age to the cylinder head cam shafts or camshaf...

Страница 113: ...decompression mechanism cam lever pin 2 projects from the camshaft CHECKING THE TIMING CHAIN TENSIONER 1 Check While pressing the tensioner rod lightly with fingers use a thin screwdriver 1 and wind...

Страница 114: ...se a thin screwdriver and wind the tension er rod up fully clockwise b With the rod fully wound and the chain tensioner UP mark a fac ing upward install the gasket 1 and the timing chain tensioner 2 a...

Страница 115: ...T PIPE AND SILENCER section in the CHAPTER 3 Radiator hose 1 Disconnect at cylinder head side Carburetor Refer to CARBURETOR section Air cut off valve assembly Refer to AIR INDUCTION SYSTEM section Ca...

Страница 116: ...several times INSTALLING THE CYLINDER HEAD 1 Install Dowel pin 1 Cylinder head gasket 2 Timing chain guide exhaust side 3 Cylinder head 4 While pulling up the timing chain in stall the timing chain g...

Страница 117: ...e Q ty Remarks Cylinder head Refer to CYLINDER HEAD section 1 Valve lifter 5 Refer to removal section 2 Adjusting pad 5 Refer to removal section 3 Valve cotter 10 Refer to removal section 4 Valve spri...

Страница 118: ...to 100 C 212 F a Remove the valve guide using a valve guide remover 1 b Install the new valve guide using a valve guide remover 1 and valve guide installer 2 c After installing the valve guide bore t...

Страница 119: ...e face should be lapped Lapping steps a Apply a coarse lapping compound to the valve face Do not let the compound enter the gap between the valve stem and the guide b Apply molybdenum disulfide oil to...

Страница 120: ...g upward e Smaller pitch 3 Install Valve cotter While compressing the valve spring with a valve spring compressor 1 in stall the valve cotters 4 To secure the valve cotters onto the valve stem lightly...

Страница 121: ...TON Order Part name Q ty Remarks Cylinder head Refer to CYLINDER HEAD section 1 Bolt cylinder 1 2 Cylinder 1 3 Piston pin clip 2 Refer to removal section 4 Piston pin 1 Refer to removal section 5 Pist...

Страница 122: ...from the piston bottom edge d If out of specification replace the piston and piston rings as a set e Calculate the piston to cylinder clearance with following formula f If out of specification replac...

Страница 123: ...Lubricate the piston and piston rings liberally with engine oil 2 Position Top ring 2nd ring Oil ring Offset the piston ring end gaps as shown a Top ring end b 2nd ring end c Oil ring end upper d Oil...

Страница 124: ...the lithium soap base grease on the O ring 3 Install Cylinder gasket 1 Cylinder 2 Install the cylinder with one hand while compressing the piston rings with the other hand Pass the timing chain 3 thro...

Страница 125: ...E OIL section in the CHAPTER 3 Brake pedal Refer to ENGINE REMOVAL section Clutch cable Disconnect at engine side 1 Clutch cover 1 2 Clutch spring 5 3 Pressure plate 1 4 Push rod 1 1 5 Circlip 1 6 Was...

Страница 126: ...clutch boss 1 Refer to removal section 15 Lock washer 1 Refer to removal section 16 Clutch boss 1 Refer to removal section 17 Thrust washer 1 18 Primary driven gear 1 19 Push lever shaft 1 Order Part...

Страница 127: ...sure at all four points CHECKING THE CLUTCH PLATES 1 Measure Clutch plate warpage Out of specification Replace clutch plate as a set Use a surface plate 1 and thick ness gauge 2 CHECKING THE PUSH LEVE...

Страница 128: ...on plates alternately on the clutch boss starting with a friction plate and ending with a friction plate Use the friction plates 1 for the first and final while paying attention to the difference in s...

Страница 129: ...5 33 CLUTCH 10 Install Dowel pin 1 Gasket clutch cover 2 11 Install Clutch cover 1 Bolt clutch cover Tighten the bolts in stage using a crisscross pattern Bolt clutch cover 10 Nm 1 0 m kg 7 2 ft lb...

Страница 130: ...Refer to CHANGING THE COOLANT sec tion in the CHAPTER 3 Radiator hose 3 Disconnect at water pump side Exhaust pipe Refer to REMOVING THE EXHAUST PIPE AND SILENCER section in the CHAPTER 3 Brake pedal...

Страница 131: ...ER ELEMENT AND WATER PUMP 9 Washer 1 Refer to removal section 10 Impeller shaft 1 Refer to removal section 11 Oil seal 2 Refer to removal section 12 Bearing 1 Refer to removal section Order Part name...

Страница 132: ...damage Replace CHECKING THE BEARING 1 Inspect Bearing Rotate inner race with a finger Rough spot seizure Replace CHECKING THE OIL SEAL 1 Inspect Oil seal 1 Wear damage Replace INSTALLING THE OIL SEAL...

Страница 133: ...act the crankcase cover when it is pulled 2 Install Oil hose 1 Bolt oil hose 2 3 Install Copper washer 1 Oil delivery pipe 2 Union bolt M8 3 Union bolt M10 4 INSTALLING THE WATER PUMP HOUSING 1 Instal...

Страница 134: ...ELEMENT AND WA TER PUMP section Stator Refer to AC MAGNETO AND STARTER CLUTCH section 1 Nut primary drive gear 1 Refer to removal section 2 Nut balancer shaft driven gear 1 Refer to removal section 3...

Страница 135: ...the center a of the balancer shaft weight along the line connect ing the centers of the crankshaft and balancer shaft 2 Install Balancer shaft driven gear 1 Install the balancer shaft driven gear ont...

Страница 136: ...ankcase cover Refer to OIL FILTER ELEMENT AND WA TER PUMP section 1 Circlip 1 2 Washer 1 3 Oil pump drive gear 1 4 Oil pump assembly 1 5 Outer rotor 2 1 6 Circlip 1 7 Inner rotor 2 1 8 Dowel pin 1 9 O...

Страница 137: ...THE OIL TANK Order Part name Q ty Remarks Drain the engine oil Refer to CHANGING THE ENGINE OIL section in the CHAPTER 3 1 Oil hose 2 1 2 Oil hose 1 1 3 Dowel pin 2 4 Oil tank breather hose 1 5 Oil t...

Страница 138: ...tor 1 1 Apply the engine oil on the outer rotor 1 3 Install Oil pump cover 1 Screw oil pump cover 2 Dowel pin 3 Inner rotor 2 4 Circlip 5 Apply the engine oil on the inner ro tor 2 Fit the dowel pin i...

Страница 139: ...ection 1 Kick idle gear 1 2 Kick shaft assembly 1 Refer to removal section 3 Spring guide 1 4 Torsion spring 1 5 Ratchet wheel 1 6 Kick gear 1 7 Kick shaft 1 8 Washer 1 9 Shift pedal 1 10 Shift shaft...

Страница 140: ...5 44 KICK SHAFT AND SHIFT SHAFT 17 Pawl 2 18 Pawl pin 2 19 Spring 2 20 Bolt stopper lever 1 21 Stopper lever 1 22 Torsion spring 1 23 Segment 1 Refer to removal section Order Part name Q ty Remarks...

Страница 141: ...move ment Unsmooth movement Replace Kick shaft 2 Wear damage Replace Spring 3 Broken Replace CHECKING THE KICK GEAR KICK IDLE GEAR AND RATCHET WHEEL 1 Inspect Kick gear 1 Kick idle gear 2 Ratchet whee...

Страница 142: ...2 Torsion spring 3 Shift shaft 4 Apply the engine oil on the roller and shift shaft 2 Install Shift pedal Refer to AC MAGNETO AND STARTER CLUTCH section INSTALLING THE KICK SHAFT ASSEMBLY 1 Install K...

Страница 143: ...lide the kick shaft assembly into the crankcase and make sure the kick shaft stopper a fits into the kick shaft ratchet wheel guide 5 Hook Torsion spring 1 Turn the torsion spring clockwise and hook i...

Страница 144: ...PTER 3 Seat and fuel tank Refer to REMOVING THE SEAT FUEL TANK AND SIDE COVERS section in the CHAPTER 3 Disconnect the AC magneto lead 1 Shift pedal 1 2 Cover torque limiter 1 3 Torque limiter 1 Do no...

Страница 145: ...5 Nm 6 5 m kg 47 ft lb loosen and retighten the rotor nut to 65 Nm 6 5 m kg 47 ft lb 12 Starter clutch 1 Refer to removal section 13 Bearing 1 14 Washer 1 15 Idle gear plate 1 16 Idle gear 1 17 Holder...

Страница 146: ...CH 1 Check Starter clutch Damage wear Replace 2 Check Idle gear Starter clutch drive gear Pitting burrs chips roughness wear Replace the defective parts 3 Check Starter clutch operation a Install the...

Страница 147: ...d While installing the starter clutch push in the projections a one by one on the clutch circumference Push in the starter clutch until it hits the rotor 7 Install Starter clutch assembly cover 1 To r...

Страница 148: ...the lithium soap base grease on the O ring Install the cover idle gear 1 with its mark a facing upward 13 Connect AC magneto lead Refer to CABLE ROUTING DIA GRAM section in the CHAPTER 2 14 Install Sh...

Страница 149: ...SIDE COVERS section in the CHAPTER 3 Carburetor Refer to CARBURETOR section Exhaust pipe and silencer Refer to REMOVING THE EXHAUST PIPE AND SILENCER section in the CHAPTER 3 Air cut off valve assemb...

Страница 150: ...1 4 Nut drive sprocket 1 Refer to removal section 5 Lock washer 1 Refer to removal section 6 Drive sprocket 1 Refer to removal section 7 Clip 1 8 Bolt brake pedal 1 9 Brake pedal 1 10 Upper engine br...

Страница 151: ...t 4 Bolt lower engine bracket 5 Patch 6 Engine mounting bolt front 7 Upper engine bracket 8 Bolt upper engine bracket 9 Engine mounting bolt upper 10 Lower engine guard 11 Bolt lower engine guard 12 A...

Страница 152: ...rocket guide 1 Drive chain sprocket cover 2 Screw drive chain sprocket cov er 3 INSTALLING THE NEUTRAL SWITCH 1 Install Spring 1 Pin 2 O ring 3 Neutral switch 4 Screw neutral switch 5 Apply the lithiu...

Страница 153: ...ent Refer to KICK SHAFT AND SHIFT SHAFT section Stator Refer to AC MAGNETO AND STARTER CLUTCH section Balancer shaft Refer to BALANCER section 1 Timing chain guide intake side 1 2 Timing chain 1 3 Oil...

Страница 154: ...CRANKCASE AND CRANKSHAFT 9 Right crankcase 1 Refer to removal section 10 Left crankcase 1 Refer to removal section 11 Oil strainer 1 12 Crankshaft 1 Refer to removal section Order Part name Q ty Rema...

Страница 155: ...RANKCASE BEARING Order Part name Q ty Remarks Transmission Refer to TRANSMISSION SHIFT CAM AND SHIFT FORK section Shift cam and shift fork Refer to TRANSMISSION SHIFT CAM AND SHIFT FORK section 1 Oil...

Страница 156: ...haft 1 Use the crankcase separating tool 2 Do not use a hammer to drive out the crankshaft REMOVING THE CRANKCASE BEARING 1 Remove Bearing 1 Remove the bearing from the crankcase by pressing its inner...

Страница 157: ...center with one hand while turning the nut of the installing tool with the other Operate the installing tool un til the crankshaft bottoms against the bearing Before installing the crankshaft clean th...

Страница 158: ...rankcase tightening bolts in stage using a crisscross pat tern 7 Install Oil delivery pipe 2 1 O ring 2 Bolt oil delivery pipe 2 3 Apply the lithium soap base grease on the Orings 8 Install Timing cha...

Страница 159: ...Engine Refer to ENGINE REMOVAL section Separate the crankcase Refer to CRANKCASE AND CRANK SHAFT section 1 Main axle 1 Refer to removal section 2 Drive axle 1 Refer to removal section 3 Shift cam 1 R...

Страница 160: ...eplace CHECKING THE SHIFT FORK SHIFT CAM AND SEGMENT 1 Inspect Shift fork 1 Wear damage scratches Re place 2 Inspect Shift cam 1 Segment 2 Wear damage Replace 3 Check Shift fork movement Unsmooth oper...

Страница 161: ...careful attention to the crankcase oil seal lip 5 Install Shift fork 1 L 1 Shift fork 2 C 2 Shift fork 3 R 3 Shift cam 4 To main axle and drive axle Apply the molybdenum disulfide oil on the shift fo...

Страница 162: ...ly by reference to this manual It may lead to servicing trouble and mechanical damage FRONT WHEEL AND REAR WHEEL REMOVING THE FRONT WHEEL Order Part name Q ty Remarks Hold the machine by placing the s...

Страница 163: ...HANDLING NOTE 1 Nut rear wheel axle 1 2 Rear wheel axle 1 3 Drive chain puller 2 4 Rear wheel 1 Refer to removal section 5 Collar 2 6 Rear wheel sprocket 1 7 Oil seal 2 8 Circlip 1 9 Bearing 2 Refer t...

Страница 164: ...ake disc deflection only rear brake disc Use the dial gauge 1 Out of specification Inspect wheel runout If wheel runout is in good condi tion replace the brake disc 2 Measure Brake disc thickness a Ou...

Страница 165: ...the wheel axle 7 Install Nut wheel axle 1 8 Tighten Bolt axle holder 1 Before tightening the bolt fit the wheel axle to the axle holder by strok ing the front fork several times with the front brake a...

Страница 166: ...e wheel 2 forward and install the drive chain 7 Install Left drive chain puller 1 Wheel axle 2 Install the left drive chain puller and insert the wheel axle from left side Apply the lithium soap base...

Страница 167: ...ne Refer to HANDLING NOTE Drain the brake fluid Refer to removal section 1 Brake hose holder protector 2 2 Brake hose holder brake caliper 1 3 Union bolt 2 4 Brake hose 1 5 Pad pin plug 1 Remove when...

Страница 168: ...e Refer to HANDLING NOTE Rear wheel Refer to FRONT WHEEL AND REAR WHEEL section Drain the brake fluid Refer to removal section 1 Brake pedal 1 2 Brake master cylinder 1 3 Brake hose holder 2 4 Union b...

Страница 169: ...der Part name Q ty Remarks A Front B Rear A B 1 Pad pin 1 1 2 Brake pad 2 2 3 Pad support 1 1 4 Brake caliper piston 2 1 Refer to removal section 5 Brake caliper piston dust seal 2 1 Refer to removal...

Страница 170: ...E MASTER CYLINDER Order Part name Q ty Remarks A Front B Rear 1 Brake master cylinder cap 1 2 Diaphragm 1 3 Reservoir float 1 4 Brake master cylinder boot 1 5 Circlip 1 Use a long nose circlip pliers...

Страница 171: ...ion when expelling piston from cylinder Never attempt to pry out piston Caliper piston removal steps a Insert a piece of rag into the brake caliper to lock one brake caliper b Carefully force the pist...

Страница 172: ...nal parts should be lubricat ed with brake fluid when in stalled Replace the brake caliper piston seals and brake caliper piston dust seals whenever a caliper is disassembled INSTALLING THE BRAKE CALI...

Страница 173: ...er cylinder kit Clean them with brake fluid 2 Install Brake master cylinder cup prima ry 1 Brake master cylinder cup sec ondary 2 To brake master cylinder piston 3 Apply the brake fluid on the brake m...

Страница 174: ...washer 1 Brake hose 2 Union bolt 3 Always use new copper washers Install the brake hose so that its pipe portion a directs as shown and lightly touches the projection b on the brake master cylinder 2...

Страница 175: ...ll the brake hose so that it contacts the brake master cylinder projection a and that its bent portion b faces downward INSTALLING THE REAR BRAKE HOSE 1 Install Copper washer 1 Brake hose 2 Union bolt...

Страница 176: ...n up spilled fluid immediately A Front B Rear 2 Air bleed Brake system Refer to BLEEDING THE HY DRAULIC BRAKE SYSTEM sec tion in the CHAPTER 3 3 Inspect Brake fluid level Fluid at lower level Fill up...

Страница 177: ...HANDLING NOTE Front wheel Refer to FRONT WHEEL AND REAR WHEEL section Front brake caliper Refer to FRONT BRAKE AND REAR BRAKE section Headlight Handlebar Refer to HANDLEBAR section 1 Protector 1 2 Pi...

Страница 178: ...spring 1 Drain the fork oil 3 Dust seal 1 Refer to removal section 4 Stopper ring 1 Refer to removal section 5 Inner tube 1 Refer to removal section 6 Outer tube 1 7 Piston metal 1 8 Slide metal 1 9 O...

Страница 179: ...front fork cap bolt REMOVING THE INNER TUBE 1 Remove Dust seal 1 Stopper ring 2 Using slotted head screwdriver Take care not to scratch the inner tube 2 Remove Inner tube 1 Oil seal removal steps a Pu...

Страница 180: ...ube is held ver tically the damper rod may fall into it damaging the valve inside 3 Install Copper washer 1 O ring 2 Base valve 3 To inner tube 4 4 Tighten Base valve 1 Use a damper rod holder 2 to lo...

Страница 181: ...15 Fill Front fork oil Until outer tube top surface with recommended fork oil 1 Be sure to use recommended fork oil If other oils are used they may have an excessively ad verse effect on the front fo...

Страница 182: ...oosen Rebound damping adjuster 1 Loosen the rebound damping ad juster finger tight Record the set position of the ad juster the amount of turning out the fully turned in position 23 Install Push rod 1...

Страница 183: ...sor lead so that its paint a directs as shown and align the bottom b of the plate 1 with the same paint 6 Install Speed sensor lead 1 Plate 2 2 Screw plate 2 3 To right protector 4 Install the plate 2...

Страница 184: ...Engine stop switch 1 Disconnect the engine stop switch lead 6 Brake master cylinder 1 Refer to removal section 7 Start switch 1 Disconnect the start switch lead 8 Throttle cable cap 1 9 Throttle cable...

Страница 185: ...older Installing the handlebar lower hold er in the reverse direction allows the front to rear offset amount of the handlebar position to be changed Do not tighten the nut yet 2 Install Handlebar 1 Ha...

Страница 186: ...othly If it does not retighten the bolts for adjustment 9 Install Grip cap cover 1 Cover throttle cable cap 2 10 Install Start switch 1 Brake master cylinder 2 Brake master cylinder bracket 3 Bolt bra...

Страница 187: ...of the clutch lever hold er 12 Install Clutch cable 1 Hot starter cable 2 Apply the lithium soap base grease on the clutch cable end and hot start er cable end 13 Adjust Clutch lever free play Refer...

Страница 188: ...placing the suitable stand under the engine Refer to HANDLING NOTE Headlight Handlebar Refer to HANDLEBAR section Front brake hose guide Front fender 1 Multi function display 1 2 Multi function displa...

Страница 189: ...6 28 STEERING 9 Bearing race cover 1 10 Upper bearing 1 11 Lower bearing 1 Refer to removal section 12 Bearing race 2 Refer to removal section Order Part name Q ty Remarks...

Страница 190: ...place bear ings and bearing races as a set Install the bearing in the bearing races Spin the bearings by hand If the bearings hang up or are not smooth in their operation in the bearing races replace...

Страница 191: ...by lit tle 11 Adjust Front fork top end a 12 Tighten Pinch bolt upper bracket 1 Pinch bolt lower bracket 2 Tighten the lower bracket to speci fied torque If torqued too much it may cause the front for...

Страница 192: ...NG NOTE Brake hose holder Refer to FRONT BRAKE AND REAR BRAKE section Rear brake caliper Refer to FRONT BRAKE AND REAR BRAKE section Bolt brake pedal Shift the brake pedal backward Drive chain 1 Drive...

Страница 193: ...MBLING THE SWINGARM Order Part name Q ty Remarks 1 Cap 2 Refer to removal section 2 Relay arm 1 3 Connecting rod 1 4 Collar 2 5 Oil seal 2 6 Thrust bearing 2 7 Bushing 2 8 Oil seal 8 9 Bearing 10 Refe...

Страница 194: ...1 Collar 2 Free play exists unsmooth revolu tion rust Replace bearing and collar as a set 2 Inspect Oil seal 3 Damage Replace INSTALLING THE BEARING AND OIL SEAL 1 Install Bearing 1 Oil seal 2 To swin...

Страница 195: ...bolt 5 Install Relay arm 1 Bolt relay arm 2 Washer 3 Nut relay arm 4 To swingarm Apply the molybdenum disulfide grease on the bolt circumference and threaded portion Do not tighten the nut yet 6 Insta...

Страница 196: ...chain tensioner 5 14 Install Drive chain support 1 Drive chain support cover 2 Bolt drive chain support L 50 mm 1 97 in 3 Nut drive chain support 4 Bolt drive chain support cover L 10 mm 0 39 in 5 Nu...

Страница 197: ...ection in the CHAPTER 3 Drain the coolant Refer to CHANGING THE COOLANT sec tion in the CHAPTER 3 Catch tank breather hose Disconnect at the catch tank side Catch tank hose Disconnect at the catch tan...

Страница 198: ...ar frame 1 7 Bolt rear shock absorber relay arm 1 Hold the swingarm 8 Bolt rear shock absorber frame 1 9 Rear shock absorber 1 10 Locknut 1 Only loosening 11 Adjuster 1 Only loosening 12 Lower spring...

Страница 199: ...disposal NOTES ON DISPOSAL YAMAHA DEALERS ONLY Before disposing the rear shock ab sorber be sure to extract the nitrogen gas from valve 1 Wear eye protec tion to prevent eye damage from es caping gas...

Страница 200: ...al lips and col lars Apply the lithium soap base grease on the O rings 2 Install Bushing 1 Collar 2 Dust seal 3 Apply the molybdenum disulfide grease on the bearing and dust seal lips Install the dust...

Страница 201: ...6 40 REAR SHOCK ABSORBER 7 Tighten Screw air filter joint 1 8 Install Plastic band Taillight coupler Locking tie Screw air filter joint 3 Nm 0 3 m kg 2 2 ft lb...

Страница 202: ...y or reassembly only by reference to this manual It may lead to servicing trouble and mechanical damage ELECTRICAL COMPONENTS AND WIRING DIAGRAM ELECTRICAL COMPONENTS 1 Headlight 2 Multi function disp...

Страница 203: ...12 Taillight 13 Neutral switch 14 Starter motor 15 AC magneto 16 Rectifier regulator 17 Ignition coil 18 Spark plug 19 Start switch 20 Main switch 21 Speed sensor 22 Battery 1 For USA CDN and EUROPE 2...

Страница 204: ...se the following special tools in this inspection 1 Check fuse No good Replace fuse and check wire harness OK 2 Check battery No good Recharge or replace OK Spark gap test Spark 3 Clean or replace spa...

Страница 205: ...ile it is freed Re place Set the tester selection position to 1 2 Inspect Rubber part a Tears damage Replace CHECKING THE MAIN SWITCH 1 Inspect Main switch conduction Not conductive while the main swi...

Страница 206: ...sed The clutch lever is pulled to the han dlebar the clutch switch is closed The starting circuit cut off relay pre vents the starter motor from operating when neither of these conditions has been met...

Страница 207: ...2 V battery in this inspection Use the following special tools in this inspection 1 Check fuse No good Replace fuse and check wire harness OK 2 Check battery No good Recharge or replace OK Check each...

Страница 208: ...battery is connected Replace Conductive while the battery is not connected Replace Set the tester selection position to 1 CHECKING THE CLUTCH SWITCH 1 Inspect Clutch switch conduction Not conductive w...

Страница 209: ...conduction Not conductive while it is pushed Replace Conductive while it is freed Re place Set the tester selection position to 1 2 Inspect Rubber part a Tears damage Replace Tester lead Black lead 1...

Страница 210: ...7 9 ELECTRIC STARTING SYSTEM REMOVING THE STARTER MOTOR Order Part name Q ty Remarks Exhaust pipe Refer to REMOVING THE EXHAUST PIPE AND SILENCER section in the CHAPTER 3 1 Starter motor 1...

Страница 211: ...SEMBLING THE STARTER MOTOR Order Part name Q ty Remarks 1 Starter motor front cover 1 2 Washer starter motor front cover 1 3 Gasket 2 4 Starter motor yoke 1 5 Armature assembly 1 6 Starter motor rear...

Страница 212: ...e brushes as a set 6 Measure Brush spring force Out of specification Replace the brush springs as a set ASSEMBLING THE STARTER MOTOR 1 Install Brush spring 1 Brush 2 2 Install Armature assembly 1 Inst...

Страница 213: ...the projec tions on the washer with the slots in the front cover Align the match mark a on the starter motor yoke with the match mark b on the starter motor front cover 5 Install Gasket Bolt 1 O ring...

Страница 214: ...move the following parts before inspection 1 Seat 2 Fuel tank Use the following special tools in this inspection 1 Check fuse No good Replace fuse and check wire harness OK 2 Check battery No good Rec...

Страница 215: ...ut of specification If no failure is found in checking the source coil resistance replace the rectifi er regulator 3 Inspect Charging coil resistance Out of specification Replace Tester lead Red lead...

Страница 216: ...he following inspection steps Use the following special tools in this inspection Check entire ignition system for connection No good Repair or replace OK Check throttle position sensor Throttle positi...

Страница 217: ...tion sensor using the T25 bit 3 Replace Throttle position sensor 4 Install Throttle position sensor 1 Screw throttle position sensor 2 Align the slot a in the throttle posi tion sensor with the projec...

Страница 218: ...1 Stop the engine 12 Remove the carburetor 13 Tighten Screw throttle position sensor 1 Tighten the screw throttle position sensor using the T25 bit 14 Install the carburetor CHECKING THE THROTTLE POSI...

Страница 219: ...ollowing special tools in this inspection Check the bulb and bulb socket No good Replace the bulb and or bulb socket OK Check the taillight LEDs No good Replace the taillight assembly OK Check the AC...

Страница 220: ...ble gas or fluid is in the vicinity CHECKING THE AC MAGNETO 1 Inspect Lighting coil resistance Out of specification Replace CHECKING THE RECTIFIER REGULATOR 1 Connect the battery leads 2 Start the eng...

Страница 221: ...s before inspection 1 Headlight Use the following special tools in this inspection 1 Check battery No good Recharge or replace OK Check each coupler and wire connection No good Repair or replace OK Ch...

Страница 222: ...SENSOR OUTPUT VOLTAGE 1 Insert the thin electric conductors 1 lead into the speed sensor coupler 2 as shown and con nect the tester to them Do not insert the electric conduc tors more than required b...

Страница 223: ......

Страница 224: ...PRINTED IN JAPAN E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN...

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