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6-12

FRONT BRAKE AND REAR BRAKE

•

Pad pin plug "4"

INSTALLING THE REAR BRAKE
CALIPER

1. Install:

•

Pad support "1"

•

Brake pad "2"

•

Pad pin "3"

•

Install the brake pads with their pro-
jections "a" into the brake caliper re-
cesses "b".

•

Temporarily tighten the pad pin at
this point.

2. Install:

•

Brake disc cover "1"

•

Bolt (brake disc cover) "2"

3. Install:

•

Brake caliper "1"

•

Rear wheel "2"
Refer to "FRONT WHEEL AND
REAR WHEEL" section.

4. Tighten:

•

Pad pin "3"

5. Install:

•

Pad pin plug "4"

INSTALLING THE BRAKE
MASTER CYLINDER KIT

1. Clean:

•

Brake master cylinder

•

Brake master 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
master cylinder cup.

After installing, cylinder cup
should be installed as shown di-
rection. Wrong installation cause
improper brake performance.

A. Front
B. Rear

3. Install:

•

Spring "1"
To brake master cylinder piston
"2".

Install the spring at the smaller dia.
side.

A. Front
B. Rear

4. Install:

•

Brake master cylinder kit "1"

•

Washer (front brake) "2"

•

Push rod (rear brake) "2"

•

Circlip "3"

•

Brake master cylinder boot "4"
To brake master cylinder.

•

Apply the brake fluid on the brake
master cylinder kit.

•

Apply the silicone grease on the tip
of the push rod.

•

When installing the circlip, use a
long nose circlip pliers.

A. Front
B. Rear

INSTALLING THE FRONT BRAKE
MASTER CYLINDER

1. Install:

•

Brake master cylinder "1"

•

Brake master cylinder bracket "2"

•

Bolt (brake master cylinder brack-
et) "3"

•

Install the bracket so that the arrow
mark "a" face upward.

•

First tighten the bolts on the upper
side of the brake master cylinder
bracket, and then tighten the bolts
on the lower side.

Pad pin plug:

3 Nm (0.3 m•kg, 2.2
ft•lb)

Bolt (brake disc cover):

10 Nm (1.0 m•kg, 7.2
ft•lb)

Pad pin:

18 Nm (1.8 m•kg, 13
ft•lb)

Pad pin plug:

3 Nm (0.3 m•kg, 2.2
ft•lb)

Bolt (brake master cylin-
der bracket):

9 Nm (0.9 m•kg, 6.5
ft•lb)

ProCarManuals.com

Содержание WR450FX

Страница 1: ...2008 5TJ 28199 71 WR450F X 2008 5TJ 28199 71 WR450F X WR450F X 2008 OWNER S SERVICE MANUAL MANUEL D ATELIER DU PROPRIETAIRE ProCarManuals com...

Страница 2: ...ProCarManuals com...

Страница 3: ...MANUAL 2007 by Yamaha Motor Co Ltd 1st Edition June 2007 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in...

Страница 4: ...ck local regulations before riding 1 THIS MACHINE IS TO BE OP ERATED BY AN EXPERI ENCED RIDER ONLY Do not attempt to operate this machine at maximum power until you are totally familiar with its chara...

Страница 5: ...IS MANUAL FINDING THE REQUIRED PAGE 1 This manual consists of seven chapters General Information Specifications Regular inspec tion and adjustments Tuning Engine Chassis and Electri cal 2 The table of...

Страница 6: ...ion 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 used to...

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

Страница 8: ...TUNING ENGINE 4 1 CHASSIS 4 5 CHAPTER 5 ENGINE RADIATOR 5 1 CARBURETOR 5 4 AIR INDICTOIN SYSTEM 5 11 CAMSHAFTS 5 13 CYLINDER HEAD 5 18 VALVES AND VALVE SPRINGS 5 21 CYLINDER AND PISTON 5 25 CLUTCH 5...

Страница 9: ...er 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 tank 1...

Страница 10: ...H 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 TOOL The jet needle pull up tool 1 is used to...

Страница 11: ...thium base grease to the seal lip s Oil the bearings liberally when installing Do not use compressed air to spin the bearings dry This causes dam age to the bearing surfaces CIRCLIPS 1 All circlips sh...

Страница 12: ...Illustration Dial gauge and stand YU 3097 90890 01252 Stand YU 1256 These tools are used to check each part for runout or bent Crankshaft installing tool Crankshaft installing pot YU 90050 90890 0127...

Страница 13: ...used for when loosening or tightening the flywheel magneto securing nut Pocket tester YU 3112 C 90890 03112 Use this tool to inspect the coil resis tance output voltage and amper age Timing light YM...

Страница 14: ...ntake 4 5 mm 0 18 in Exhaust 5 0 mm 0 20 in YM 4117 90890 04117 YM 4098 90890 04098 This tool is needed to install the valve guide Valve guide reamer Intake 4 5 mm 0 18 in Exhaust 5 0 mm 0 20 in YM 41...

Страница 15: ...essure pump gauge set YB 35956 A 90890 06756 This tool is used to check the air in duction system Digital tachometer YU 39951 B 90890 06760 This tool is needed for observing en gine rpm YAMAHA Bond No...

Страница 16: ...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 and forcefu...

Страница 17: ...ed travel distance in timer measurement Change tripmeter digits capable of change to any given ones DESCRIPTION Operation buttons 1 Select button SLCT 1 2 Select button SLCT 2 3 Reset button RST Scree...

Страница 18: ...ther of which can be selected Manual start Starting measurement by the rider himself operating the button A long push on the SLCT2 button will put measurement on standby Auto start Starting timer meas...

Страница 19: ...ay by pushing the RST button for 2 seconds or more If reset and travel distance dis play will go on flashing for four sec onds Resetting tripmeter A TRIP A and timer 1 Check that the timer is not in o...

Страница 20: ...tton 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 BASIC MODE Tr...

Страница 21: ...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 time is or i...

Страница 22: ...position However it is recommended to shift into neutral before starting the en gine 1 Inspect the coolant level 2 Turn the fuel cock to ON 3 Push on the main switch to ON 4 Shift the transmission in...

Страница 23: ...e through out its entire operating range Re start the machine and operate it for about 10 to 15 more minutes The machine will now be ready to race After the break in or before each race you must check...

Страница 24: ...ssembly 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 Wheel In...

Страница 25: ...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 chromed s...

Страница 26: ...in 370 mm 14 57 in Dry weight Without oil and fuel 112 5 kg 248 0 lb Engine Engine type Liquid cooled 4 stroke DOHC Cylinder arrangement Single cylinder forward inclined Displacement 449 cm3 15 8 Imp...

Страница 27: ...manufacturer CR8E NGK resistance type Gap 0 7 0 8 mm 0 028 0 031 in Clutch type Wet multiple disc Transmission Primary reduction system Gear Primary reduction ratio 61 23 2 652 Secondary reduction sys...

Страница 28: ...il damper Rear shock absorber Coil spring gas oil damper Wheel travel Front wheel travel 300 mm 11 8 in Rear wheel travel 305 mm 12 0 in Electrical Ignition system CDI Generator system AC magneto Batt...

Страница 29: ...39 0 8878 in 22 350 mm 0 8799 in Exhaust A 30 200 30 300 mm 1 1890 1 1929 in 30 100 mm 1 1850 in Exhaust B 22 450 22 550 mm 0 8839 0 8878 in 22 350 mm 0 8799 in Camshaft runout limit 0 03 mm 0 0012 in...

Страница 30: ...tem outside diameter IN 4 475 4 490 mm 0 1762 0 1768 in 4 445 mm 0 1750 in Stem outside diameter EX 4 965 4 980 mm 0 1955 0 1961 in 4 935 mm 0 1943 in Guide inside diameter IN 4 500 4 512 mm 0 1772 0...

Страница 31: ...5 kg at 28 38 mm 27 67 31 85 lb at 1 12 in Tilt limit IN 2 5 1 7 mm 2 5 0 067 in Tilt limit EX 2 5 1 6 mm 2 5 0 063 in Direction of winding top view IN Clockwise Direction of winding top view EX Clock...

Страница 32: ...in 0 85 mm 0 033 in Side clearance 0 020 0 055 mm 0 0008 0 0022 in 0 12 mm 0 005 in Oil ring Dimensions B T 2 0 2 9 mm 0 08 0 11 in End gap installed 0 2 0 5 mm 0 01 0 02 in Crankshaft Crank width A...

Страница 33: ...clearance 0 010 0 044 mm 0 0004 0 0017 in Clutch release method Inner push cam push Shifter Shifter type Cam drum and guide bar Guide bar bending limit 0 05 mm 0 002 in Kickstarter Type Ratchet type C...

Страница 34: ...ndard Limit Steering system Steering bearing type Taper roller bearing Front suspension CDN AUS NZ ZA Front fork travel 300 mm 11 8 in Fork spring free length 460 mm 18 1 in 455 mm 17 9 in Spring rate...

Страница 35: ...84 0 10 in Pad thickness 4 4 mm 0 17 in 1 0 mm 0 04 in Master cylinder inside dia 11 0 mm 0 433 in Caliper cylinder inside dia 27 0 mm 1 063 in 2 Brake fluid type DOT 4 Rear disc brake Disc outside d...

Страница 36: ...e color 0 224 0 336 at 20 C 68 F Yellow Ground Rectifier regulator Regulator type Semiconductor short circuit Model manufacturer SH770AA SHINDENGEN Regulated voltage AC 12 5 13 5 V Regulated voltage D...

Страница 37: ...15 1 5 11 Cylinder head bolt M10 1 25 4 Refer to NOTE 1 Cylinder head bolt M6 1 0 2 10 1 0 7 2 Cylinder head cover M6 1 0 2 10 1 0 7 2 Cylinder M6 1 0 1 10 1 0 7 2 Timing chain tensioner M6 1 0 2 10 1...

Страница 38: ...7 10 1 0 7 2 Crankcase cover right M6 1 0 8 10 1 0 7 2 Crankcase cover right M6 1 0 2 12 1 2 8 7 Crankcase cover left M6 1 0 8 10 1 0 7 2 Idle gear cover starter motor M6 1 0 2 10 1 0 7 2 Crankcase M6...

Страница 39: ...ork and protector M6 1 0 6 7 0 7 5 1 Front fork protector and brake hose holder M6 1 0 2 7 0 7 5 1 Throttle cable cap M5 0 8 2 4 0 4 2 9 Clutch lever holder mounting M5 0 8 2 4 0 4 2 9 Clutch lever mo...

Страница 40: ...3 38 Engine guard M6 1 0 3 7 0 7 5 1 Regulator mounting M6 1 0 2 7 0 7 5 1 Pivot shaft and nut M16 1 5 1 85 8 5 61 Relay arm and swingarm M14 1 5 1 70 7 0 50 Relay arm and connecting rod M14 1 5 1 80...

Страница 41: ...ate 2 and protector 2 0 5 0 05 0 36 Speed sensor lead holder and under bracket M6 1 0 1 13 1 3 9 4 Headlight body and headlight unit 2 1 0 1 0 7 Headlight mounting left and right M6 1 0 2 7 0 7 5 1 Ta...

Страница 42: ...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 10 mm 30...

Страница 43: ...2 18 TIGHTENING TORQUES ProCarManuals com...

Страница 44: ...2 19 LUBRICATION DIAGRAMS LUBRICATION DIAGRAMS 1 Oil filter element 2 Oil pump 3 Drive axle 4 Main axle 5 Crankshaft 6 Connecting rod A From cylinder B To oil tank ProCarManuals com...

Страница 45: ...2 20 LUBRICATION DIAGRAMS 1 Intake camshaft 2 Exhaust camshaft A To main axle B From oil pump ProCarManuals com...

Страница 46: ...lead 11 AC magneto lead 12 Brake hose 13 Rectifier regulator lead 14 Carburetor breather hose 15 Carburetor overflow hose 16 Catch tank breather hose A Insert the end of the fuel tank breather hose in...

Страница 47: ...necting rod and cross tube frame G Pass the neutral switch lead on the inside of the engine bracket H Fasten the neutral switch lead and AC magneto lead onto the frame Locate the clamp end facing towa...

Страница 48: ...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 of the fr...

Страница 49: ...s 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 twist D Insta...

Страница 50: ...de Locate the clamp end facing to ward the upper side of the frame with the tie end cut off on the in side of the frame B Fasten the wire harness to the upper engine bracket left side Locate the clamp...

Страница 51: ...mp end facing toward the upper side of the frame and the tie end to ward the inside of the frame Clamp the wire harness at the marking K Pass the wire harness starter relay lead starting circuit cut o...

Страница 52: ...coupler 14 Engine stop switch coupler 15 Multi function display coupler 16 Start switch coupler 17 Speed sensor coupler 18 Speed sensor lead A Fasten the start switch lead to the handlebar with the pl...

Страница 53: ...by pushing it into the hole in the multi function display bracket H Secure the wire harness clip by pushing it into the hole in the multi function display bracket on the inside I Fasten the main swit...

Страница 54: ...Replace VALVES Check the valve clearances The engine must be cold Inspect Check the valve seats and valve stems for wear Replace VALVE SPRINGS Inspect Check the free length and the tilt Replace VALVE...

Страница 55: ...UG Inspect and clean Replace DRIVE CHAIN Use chain lube Lubricate slack alignment Chain slack 48 58 mm 1 9 2 3 in Replace COOLING SYSTEM Check coolant level and leakage Check radiator cap operation Re...

Страница 56: ...AND DUST SEAL Clean and lube Lithium base grease PROTECTOR GUIDE Replace REAR SHOCK ABSORBER Inspect and adjust Lube After rain ride Molybdenum disulfide grease Retighten DRIVE CHAIN GUIDE AND ROLLER...

Страница 57: ...bearings Lubricate Lithium base grease THROTTLE CONTROL CABLE Check routing and connection Lubricate Yamaha cable lube or SAE 10W 30 motor oil HOT STARTER CLUTCH LEVER Inspect free play BATTERY Check...

Страница 58: ...nd alignment Check that the drive chain is lubricated properly P 3 20 21 Wheels Check for excessive wear and tire pressure Check for loose spokes and have no excessive play P 3 24 Steering Check that...

Страница 59: ...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 side cover...

Страница 60: ...3 7 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 ProCarManuals com...

Страница 61: ...ght side cover Refer to 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 6 Silencer clamp 1 7 Nut ex...

Страница 62: ...e machine on a level place and hold it in an upright po sition 2 Remove Radiator cap 3 Check Coolant level a Coolant level low Add coolant 1 Radiator CHANGING THE COOLANT Do not remove the radiator ca...

Страница 63: ...re Do not apply pressure more than specified pressure Radiator should be filled fully 4 Inspect Pressure Impossible to maintain the speci fied pressure for 10 seconds Repair Radiator Radiator hose joi...

Страница 64: ...ee play adjust ment steps a Loosen the locknut 1 b Turn the adjuster 2 until free play a is within the specified lim its c Tighten the locknut After adjustment check proper oper ation of hot starter C...

Страница 65: ...gh speed operation The heated oil could spurt out causing danger Wait until the oil cools down to approximately 70 C 158 F 2 Idle the engine more than 3 min utes while keeping the machine upright Then...

Страница 66: ...r element 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 5 Install Gaskets Oil filter drain bolt Drain bolt rig...

Страница 67: ...djust Checking steps a Turn the crankshaft counterclock wise with a wrench b Align the T D C mark a on the rotor with the align mark b on the crankcase cover when piston is at T D C on compression str...

Страница 68: ...fide oil on the valve stem ends Valve lifter must turn smoothly when rotated with a finger Be careful to reinstall valve lifters and pads in their original place g Install the camshafts exhaust and in...

Страница 69: ...3 16 ENGINE INTAKE EXHAUST ProCarManuals com...

Страница 70: ...s a Add proper brake fluid to the res ervoir b Install the diaphragm Be careful not to spill any fluid or allow the reservoir to overflow c Connect the clear plastic tube 2 tightly to the caliper blee...

Страница 71: ...08 in c away from the brake pedal 5 After the pedal height adjust ment make sure that the rear brake does not drag CHECKING AND REPLACING THE FRONT BRAKE PADS 1 Inspect Brake pad thickness a Out of sp...

Страница 72: ...ransparent hose 8 to the bleed screw 9 and place the suitable container under its end f Loosen the bleed screw and push the brake caliper piston in Do not reuse the drained brake flu id g Tighten the...

Страница 73: ...ocket teeth a Excessive wear Replace Replace the drive sprocket rear wheel sprocket and drive chain as a set CHECKING THE DRIVE CHAIN 1 Measure Drive chain length 15 links a Out of specification Repla...

Страница 74: ...on each side of the drive chain puller alignment Turn the adjuster so that the drive chain is in line with the sprocket as viewed from the rear Too small drive chain slack will overload the engine and...

Страница 75: ...rmal noise unsmooth action Grease the pivoting points or repair the pivoting points Damage oil leakage Replace ADJUSTING THE REAR SHOCK ABSORBER SPRING PRELOAD 1 Elevate the rear wheel by placing the...

Страница 76: ...he position which is back by the specific number of turns from the fully turned in position Which align the punch mark a on the adjuster with the punch mark b on the adjuster body Do not force the adj...

Страница 77: ...to lock Unsmooth action Adjust steer ing ring nut 4 Adjust Steering ring nut Steering ring nut adjustment steps a Remove the headlight b Remove the handlebar and upper bracket c Loosen the steering ri...

Страница 78: ...uel breather hose 12 into the hole in the steer ing stem First tighten the bolts on the front side of the handlebar upper holder and then tighten the bolts on the rear side Steering stem nut 145 Nm 14...

Страница 79: ...ttle 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 areas B Use...

Страница 80: ...protective eye gear when handling or working near batter ies Charge batteries in a well venti lated area Keep batteries away from fire sparks or open flames e g welding equipment lighted ciga rettes...

Страница 81: ...ry overheating and battery plate damage If it is impossible to regulate the charging current on the battery charger be careful not to over charge the battery When charging a battery be sure to remove...

Страница 82: ...3 29 ELECTRICAL Charging method using a variable voltage charger ProCarManuals com...

Страница 83: ...3 30 ELECTRICAL Charging method using a constant voltage charger ProCarManuals com...

Страница 84: ...rating may cause extensive damage to the electrical system cause the starting and ig nition systems to malfunction and could possibly cause a fire 4 Install Fuse cover Seat REPLACING THE HEADLIGHT BUL...

Страница 85: ...STING THE HEADLIGHT BEAMS 1 Adjust Headlight beam vertically Adjusting steps a Turn the adjusting screw 1 in di rection a or b Direction a Headlight beam is raised Direction b Headlight beam is lowere...

Страница 86: ...topped 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 well After installi...

Страница 87: ...of the straight portion adjusts the air fuel mixture when the 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 syst...

Страница 88: ...55 4MX 09 52 4MX 08 50 4MX 07 48 4MX 06 STD Lean 45 4MX 05 Jet needle Size Part number 14916 Rich GDDUM 5TJ 9M GDDUN 5TJ 9N GDDUP 5TJ 9P GDDUQ 5TJ 91 GDDUR 5TJ 9R GDDUS 5TJ 9S Lean GDDUT 5TJ 9T Rich...

Страница 89: ...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 speed Lower jet needl...

Страница 90: ...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 includes the fol lowing...

Страница 91: ...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 damping t...

Страница 92: ...with the rebound damping adjuster one or two clicks on the softer side and readjust it to suit your preference 2 Use of stiff spring Set the soft spring for more re bound damping to compensate for it...

Страница 93: ...n 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 oil amou...

Страница 94: ...agging Rebound damping Turn adjuster counterclockwise about 2 clicks to decrease damping Spring Replace with soft spring Poor road gripping Rebound damping Turn adjuster counterclockwise about 2 click...

Страница 95: ...eft side cover Refer to SEAT FUEL TANK AND SIDE COVERS section in the CHAPTER 3 Exhaust pipe Refer to EXHAUST PIPE AND SILENCER section in the CHAPTER 3 1 Radiator guard 2 2 Radiator hose clamp 8 3 Ri...

Страница 96: ...5 2 RADIATOR 11 Pipe 1 O ring 1 1 12 Catch tank breather hose 1 13 Catch tank 1 Order Part name Q ty Remarks ProCarManuals com...

Страница 97: ...1 Install Pipe 1 1 Radiator hose 1 2 Pipe 2 3 Radiator hose 3 4 Radiator hose 4 5 2 Install Radiator hose 2 1 Left radiator 2 3 Install Catch tank hose 1 Right radiator 2 Refer to CABLE ROUTING DIA G...

Страница 98: ...e 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 carburetor joint...

Страница 99: ...Screw throttle 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 D...

Страница 100: ...20 Spacer 1 21 Pilot jet 1 22 Starter jet 1 23 Push rod 1 Pull the push rod 24 Throttle shaft assembly 1 25 Push rod link lever assembly 1 26 Pilot air jet 1 27 Cold starter plunger 1 Order Part name...

Страница 101: ...1 Bends wear Replace Clip groove Free play exists wear Replace MEASURING AND ADJUSTING THE FLOAT HEIGHT 1 Measure Float height a Out of specification Adjust Measurement and adjustment steps a Hold th...

Страница 102: ...e lever 2 4 Install Spring 2 1 To lever 2 2 5 Install Push rod link lever assembly 1 Make sure the stopper a of the spring 2 fits into the recess b in the carburetor 6 Install Washer 1 Circlip 2 7 Ins...

Страница 103: ...e holder drain hose 5 Screw accelerator pump cover 6 Install the diaphragm accelerator pump with its mark a facing the spring 15 Install Jet needle 1 Collar 2 Spring 3 Needle holder 4 Throttle valve p...

Страница 104: ...en Bolt carburetor joint 1 Bolt air filter joint 2 5 Install Throttle cable pull 1 Throttle cable return 2 6 Adjust Throttle grip free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY section in t...

Страница 105: ...e Q ty Remarks 1 Bracket 1 2 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...

Страница 106: ...cuum 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 Check fo...

Страница 107: ...IDE COVERS section in the CHAPTER 3 Air cut off valve assembly Refer to AIR INDUCTION SYSTEM section Engine upper bracket right Refer to ENGINE REMOVAL section Engine upper bracket left 1 Spark plug 1...

Страница 108: ...3 Timing chain tensioner cap bolt 1 Refer to removal section 4 Timing chain tensioner 1 Refer to removal section 5 Gasket 1 Refer to removal section 6 Bolt camshaft cap 10 Refer to removal section 7...

Страница 109: ...ttern working from the outside in The bolts camshaft cap must be removed evenly to prevent dam age to the cylinder head cam shafts or camshaft caps 5 Remove Exhaust camshaft 1 Intake camshaft 2 Attach...

Страница 110: ...the tensioner rod lightly with fingers use a thin screwdriver 1 and wind the ten sioner rod up fully clockwise When releasing the screwdriver by pressing lightly with fingers make sure that the tensio...

Страница 111: ...tensioner Installation steps a While pressing the tensioner rod lightly with fingers use a thin screwdriver and wind the tension er rod up fully clockwise b With the rod fully wound and the chain ten...

Страница 112: ...ngle 180 in the proper tightening sequence Order Part name Q ty Remarks Seat and fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section in the CHAPTER 3 Exhaust pipe and silencer Refer to EXHAUST P...

Страница 113: ...the rotation angle procedure to ob tain uniform tightening torque a Wash the threads and contact surfaces of the bolts the contact surfaces of the plain washers the contact surface of the cylinder hea...

Страница 114: ...5 20 CYLINDER HEAD 3 Install Bolt cylinder head 1 Bolt cylinder head 10 Nm 1 0 m kg 7 2 ft lb ProCarManuals com...

Страница 115: ...marks 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 spring retain...

Страница 116: ...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 the valve...

Страница 117: ...nd the guide b Apply molybdenum disulfide oil to the valve stem c Install the valve into the cylinder head d Turn the valve until the valve face and valve seat are evenly pol ished then clean off all...

Страница 118: ...d e Smaller pitch 3 Install Valve cotters 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 tap t...

Страница 119: ...ty Remarks Cylinder head Refer to CYLINDER HEAD section 1 Bolt cylinder 1 2 Cylinder 1 3 Gasket 1 4 Dowel pin 2 5 Piston pin clip 2 Refer to removal section 6 Piston pin 1 Refer to removal section 7 P...

Страница 120: ...m 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 replace the cylinder and rep...

Страница 121: ...ring e Oil ring end lower 3 Install Piston 1 Piston pin 2 Piston pin clip 3 Apply engine oil onto the piston pin and piston Be sure that the arrow mark a on the piston points to the exhaust side of th...

Страница 122: ...L section in the CHAPTER 3 Brake pedal Refer to ENGINE REMOVAL section Clutch cable Disconnect at engine side 1 Clutch cover 1 2 Gasket 1 3 Dowel pin 2 4 Clutch spring 6 5 Pressure plate 1 6 Push rod...

Страница 123: ...oss 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 name Q t...

Страница 124: ...r 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 LEVER SHAFT 1 Inspe...

Страница 125: ...n the friction plates and clutch plates Check the clutch plate for thickness and install 4 thicker ones a on the engine side and 3 thinner ones b on the outside 5 Install Bearing 1 Washer 2 Circlip 3...

Страница 126: ...on Exhaust pipe Refer to EXHAUST PIPE AND SILENCER section Brake pedal Refer to ENGINE REMOVAL section Clutch cover Refer to CLUTCH section 1 Oil filter element cover 1 2 Oil filter element 1 3 Coolan...

Страница 127: ...emoval section 14 Oil seal 1 1 Refer to removal section 15 Oil seal 2 1 Refer to removal section 16 Bearing 1 Refer to removal section Order Part name Q ty Remarks 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m...

Страница 128: ...mage Replace INSTALLING THE OIL SEAL 1 Install Oil seal 1 Apply the lithium soap base grease on the oil seal lip Install the oil seal with its manufac ture s marks or numbers facing the right crankcas...

Страница 129: ...NSTALLING THE WATER PUMP HOUSING 1 Install Dowel pin 1 O ring 2 Apply the lithium soap base grease on the O ring 2 Install Water pump housing 1 Bolt water pump housing 2 Washer 3 Coolant drain bolt 4...

Страница 130: ...section Stator Refer to CDI MAGNETO section 1 Nut balancer 1 Refer to removal section 2 Nut primary drive gear 1 Refer to removal section 3 Nut balancer shaft driven gear 1 Refer to removal section 4...

Страница 131: ...stall Balancer shaft driven gear 1 Align the punched mark a on the balancer shaft drive gear with the punched mark b on the balancer shaft driven gear Install the balancer shaft driven gear and cranks...

Страница 132: ...ght crankcase 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 Dowel pin 2 6 Outer rotor 2 1 7 Circlip 1 8 Inner rotor 2...

Страница 133: ...5 39 OIL PUMP 15 Oil pump drive shaft 1 16 Rotor housing 1 Order Part name Q ty Remarks ProCarManuals com...

Страница 134: ...r rotor 1 2 Install Outer rotor 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 oil pu...

Страница 135: ...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 1 11 Coll...

Страница 136: ...K 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 ProCarManu...

Страница 137: ...GEAR KICK IDLE GEAR AND RATCHET WHEEL 1 Inspect Kick gear 1 Kick idle gear 2 Ratchet wheel 3 Gear teeth a Ratchet teeth b Wear damage Replace CHECKING THE SHIFT SHAFT 1 Inspect Shift shaft 1 Bend dam...

Страница 138: ...shaft 8 Apply the molybdenum disulfide oil on the inner circumferences of the kick gear and ratchet wheel Align the punch mark a on the ratchet wheel with the punch mark b on the kick shaft 2 Install...

Страница 139: ...HAFT INSTALLING THE KICK IDLE GEAR 1 Install Kick idle gear 1 Washer 2 Circlip 3 Apply the engine oil on the kick idle gear inner circumference Install the kick idle gear with its de pressed side a to...

Страница 140: ...in the CHAPTER 3 Seat and fuel tank Refer to 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 not...

Страница 141: ...oosen and retighten the rotor nut to 65 Nm 6 5 m kg 47 ft lb 13 Starter clutch assembly cover 1 Refer to removal section 14 Starter clutch 1 Refer to removal section 15 Starter clutch drive gear 1 16...

Страница 142: ...3 Check Starter clutch operation 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 counterclockwise B the sta...

Страница 143: ...a is in parallel with the crankshaft center line b When installing the rotor align the keyway c of the rotor with the woodruff key 6 Install Washer rotor Nut rotor 1 Use the sheave holder 2 Tighten th...

Страница 144: ...IA GRAM section in the CHAPTER 2 12 Install Shift pedal 1 Bolt shift pedal When installing the shift pedal onto the shift shaft be sure that the center of the shift pedal is about 5 1 mm 0 2 in a abov...

Страница 145: ...r Refer to RADIATOR section Exhaust pipe and silencer Refer to EXHAUST PIPE AND SILENCER section in the CHAPTER 3 Air cut off valve assembly Refer to AIR INDUCTION SYSTEM section Clutch cable and guid...

Страница 146: ...eutral switch 1 3 Drive chain sprocket cover 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 brak...

Страница 147: ...lower 3 Lower engine bracket 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 Apply the molybdenum d...

Страница 148: ...the nut 4 Install Drive chain sprocket guide Drive chain sprocket cover 1 Screw drive chain sprocket cov er 2 INSTALLING THE NEUTRAL SWITCH 1 Install Spring 1 Pin 2 O ring 3 Neutral switch 4 Screw ne...

Страница 149: ...SHAFT section Segment Refer to KICK SHAFT AND SHIFT SHAFT section Stator Refer to AC MAGNETO AND STARTER CLUTCH section 1 Timing chain guide intake side 1 2 Timing chain 1 3 Bolt L 50 mm 1 97 in 7 Re...

Страница 150: ...SE AND CRANKSHAFT 9 Left crankcase 1 Refer to removal section 10 Oil strainer 1 11 Balancer shaft 1 Refer to removal section 12 Crankshaft 1 Refer to removal section Order Part name Q ty Remarks ProCa...

Страница 151: ...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 seal 3 2...

Страница 152: ...force c Remove the dowel pins and O ring REMOVING THE BALANCER SHAFT 1 Remove Balancer shaft 1 Remove the balancer shaft with its flat side a facing the crankshaft REMOVING THE CRANKSHAFT 1 Remove Cr...

Страница 153: ...Before installing the crankshaft clean the contacting surface of crankcase Do not use a hammer to drive in the crankshaft A For USA and CDN B Except for USA and CDN 2 Check Shifter operation Transmiss...

Страница 154: ...e holder 2 Bolt clutch cable holder Bolt crankcase Tighten the crankcase tightening bolts in stage using a crisscross pat tern 7 Install Timing chain Timing chain guide intake side Bolt timing chain g...

Страница 155: ...efer 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 Refer to r...

Страница 156: ...IFT 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 operation Replace shift fork For a ma...

Страница 157: ...rk 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 fork grooves Apply engine oil to the shift cam groove bearing contact...

Страница 158: ...able stand under the engine Refer to HANDLING NOTE 1 Bolt axle holder 4 Only loosening 2 Nut front wheel axle 1 3 Front wheel axle 1 4 Front wheel 1 5 Speed sensor 1 6 Collar 1 7 Oil seal 1 8 Bearing...

Страница 159: ...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 to removal...

Страница 160: ...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 Out of limit Replace I...

Страница 161: ...el 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 applied INSTALLING THE REAR WHEEL...

Страница 162: ...d 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 grease on the wheel...

Страница 163: ...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 loosening...

Страница 164: ...o 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 bolt 2 5 B...

Страница 165: ...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 section 6...

Страница 166: ...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 6 Washer...

Страница 167: ...Insert a piece of rag into the brake caliper to lock one brake caliper b Carefully force the piston out of the brake caliper cylinder with compressed air A Front B Rear REMOVING THE BRAKE CALIPER PIST...

Страница 168: ...seal Brake caliper piston Clean them with brake fluid 2 Install Brake caliper piston seal 1 Brake caliper piston dust seal 2 Always use new brake caliper pis ton seals and brake caliper piston dust se...

Страница 169: ...roper brake performance A Front B Rear 3 Install Spring 1 To brake master cylinder piston 2 Install the spring at the smaller dia side A Front B Rear 4 Install Brake master cylinder kit 1 Washer front...

Страница 170: ...se grease on the bolt O ring and brake pedal bracket 4 Install Pin 1 Washer 2 Cotter pin 3 After installing check the brake pedal height Refer to ADJUSTING THE REAR BRAKE section in the CHAP TER 3 INS...

Страница 171: ...rear shock absorber If it does correct its twist FILLING THE BRAKE FLUID 1 Fill Brake fluid Until the fluid level reaches LOWER level line a Use only the designated quality brake fluid otherwise the r...

Страница 172: ...ke master cylin der cap 2 After installation while pulling the brake lever in or pushing down on the brake pedal check whether there is any brake fluid leaking where the union bolts are installed resp...

Страница 173: ...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 Pinch bolt...

Страница 174: ...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 Oil seal w...

Страница 175: ...the inner tube 2 Remove Inner tube 1 Oil seal removal steps a Push in slowly a the inner tube just before it bottoms out and then pull it back quickly b b Repeat this step until the inner tube can be...

Страница 176: ...en Base valve 1 Use a damper rod holder 2 to lock the damper rod 3 Apply the LOCTITE on the base valve thread 5 Install Spring guide 1 Locknut 2 To damper rod 3 Install the spring guide with its small...

Страница 177: ...urface with recom mended fork oil once more 18 After filling pump the outer tube 1 slowly up and down about 200 mm 7 9 in stroke to distrib ute the fork oil once more Be careful not to excessive full...

Страница 178: ...hat it will not go down 24 Install Spring seat 1 Front fork cap bolt 2 Fully finger tighten the front fork cap bolt onto the damper rod 25 Tighten Front fork cap bolt locknut 1 Hold the locknut 2 and...

Страница 179: ...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 in the direction as shown 7 Install Protector 1 Bolt protector 2 8 Adjust...

Страница 180: ...op 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 1 pulled...

Страница 181: ...lebar 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 Handlebar upper holder 2 Bo...

Страница 182: ...ke master cylinder 2 Brake master cylinder bracket 3 Bolt brake master cylinder brack et 4 Clamp 5 The start switch and brake master cylinder bracket should be installed according to the dimensions sh...

Страница 183: ...cable end and hot start er cable end 13 Adjust Clutch lever free play Refer to ADJUSTING THE CLUTCH CABLE FREE PLAY section in the CHAPTER 3 Hot starter lever free play Refer to ADJUSTING THE HOT STA...

Страница 184: ...he 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 display bracket...

Страница 185: ...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 ProCarManuals com...

Страница 186: ...bearings by hand If the bearings hang up or are not smooth in their operation in the bearing races replace bearings and bearing races as a set INSTALLING THE LOWER BRACKET 1 Install Lower bearing 1 A...

Страница 187: ...to speci fied torque If torqued too much it may cause the front fork to mal function 13 Install Multi function display bracket 1 Multi function display 2 Pass the throttle cables 3 clutch ca ble 4 and...

Страница 188: ...rake 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 chain su...

Страница 189: ...E 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 Refer to remo...

Страница 190: ...amage Replace INSTALLING THE BEARING AND OIL SEAL 1 Install Bearing 1 Oil seal 2 To swingarm Apply the molybdenum disulfide grease on the bearing when install ing Install the bearing by pressing it on...

Страница 191: ...disulfide grease on the bolt circumference and threaded portion Do not tighten the nut yet 6 Install Swingarm 1 Pivot shaft 2 Apply the molybdenum disulfide grease on the pivot shaft Insert the pivot...

Страница 192: ...ain 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 Nut r...

Страница 193: ...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 tank side Air induction hose air cut...

Страница 194: ...ar 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 guide 1 13 Upper spr...

Страница 195: ...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 and or metal chips To dispose of a damaged or worn out rear shock absorbe...

Страница 196: ...ly the molybdenum disulfide grease on the bearing and dust seal lips Install the dust seals with their lips facing outward 3 Install Rear shock absorber 4 Install Bolt rear shock absorber frame 1 Wash...

Страница 197: ...6 40 REAR SHOCK ABSORBER 8 Install Plastic band Taillight coupler Locking tie ProCarManuals com...

Страница 198: ...3 Engine stop switch 4 Clutch switch 5 Diode 6 Starter relay diode 7 Throttle position sensor 8 Starter relay 9 Fuse 10 Starting circuit cut off relay 11 CDI unit 12 Taillight 13 Neutral switch 14 St...

Страница 199: ...11 CDI unit 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 COLOR CODE B...

Страница 200: ...llowing 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 spark plug N...

Страница 201: ...KING THE MAIN SWITCH 1 Inspect Main switch conduction Not conductive while the main switch is moved to ON Replace Conductive while the main switch is moved to OFF Replace Set the tester selection posi...

Страница 202: ...tral the neutral switch is closed 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...

Страница 203: ...ry 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 coupler a...

Страница 204: ...1 Inspect Clutch switch conduction Not conductive while it is pulled Re place Conductive while it is freed Re place Set the tester selection position to 1 CHECKING THE DIODE 1 Remove the diode from w...

Страница 205: ...7 8 ELECTRIC STARTING SYSTEM 2 Inspect Rubber part a Tears damage Replace ProCarManuals com...

Страница 206: ...7 9 ELECTRIC STARTING SYSTEM REMOVING THE STARTER MOTOR Order Part name Q ty Remarks Exhaust pipe Refer to EXHAUST PIPE AND SILENCER section in the CHAPTER 3 1 Starter motor 1 ProCarManuals com...

Страница 207: ...MOTOR Order Part name Q ty Remarks 1 Starter motor front cover 1 2 Washer starter motor front cover 1 3 Washer 1 4 Circlip 1 5 O ring 1 6 Starter motor yoke 1 7 Armature assembly 1 8 Starter motor rea...

Страница 208: ...ASSEMBLING THE STARTER MOTOR 1 Install Brush spring 1 Brush 2 2 Install Armature assembly 1 Install while holding down the brush using a thin screw driver Be careful not to damage the brush during ins...

Страница 209: ...7 12 ELECTRIC STARTING SYSTEM 5 Install Bolt 1 O ring 2 Apply the lithium soap base grease on the O ring ProCarManuals com...

Страница 210: ...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 Recharge or...

Страница 211: ...cification 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 1 Tester...

Страница 212: ...ing 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 position sensor...

Страница 213: ...the throttle posi tion sensor with the projection b on the carburetor Temporarily tighten the screw throttle position sensor 5 Install Carburetor Throttle position sensor coupler 6 Adjust Engine idli...

Страница 214: ...all the carburetor CHECKING THE THROTTLE POSITION SENSOR INPUT VOLTAGE 1 Disconnect the throttle position sensor coupler 2 Start the engine 3 Inspect Throttle position sensor input volt age Out of spe...

Страница 215: ...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 magneto L...

Страница 216: ...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 engine 3 Tu...

Страница 217: ...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 Check multi...

Страница 218: ...UTPUT 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 because it...

Страница 219: ...ProCarManuals com...

Страница 220: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2007 07 0 9 1 CR E OSM Cover4_CDN_E fm Page 1 Friday June 29 2007 5 35 PM ProCarManuals com...

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