4D3 28197 10 2008 Yamaha Raptor 250 Sevice Manual

User Manual: 2008 Yamaha Raptor 250 Sevice Manual

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TABLE OF CONTENTS

SERVICE MANUAL

YFM250RX

4D3-28197-10LIT-11616-21-22

2008

YFM250RX

SERVICE MANUAL

Corporation, U.S.A.

First Edition, July 2007

Any reproduction or unauthorized use

without the written permission of

Yamaha Motor Corporation, U.S.A.

is expressly prohibited.

Printed in U.S.A

LIT-11616-21-22

EBS00001

EBS00002

NOTICE

This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and

their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man-

ual, so it is assumed that anyone who uses this book to perform maintenance and repairs on

Yamaha machine has a basic understanding of the mechanical ideas and the procedures of

machine repair. Repairs attempted by anyone without this knowledge are likely to render the

machine unsafe and unfit for use.

Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and sig-

nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers

and will appear in future editions of this manual where applicable.

TE:

Designs and specifications are subject to change without notice.

EBS00003

IMPORTANT INFORMATION

Particularly important information is distinguished in this manual by the following notations.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR

SAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death

to the machine operator, a bystander or a person checking or repairing the

machine.

A CAUTION indicates special precautions that must be taken to avoid dam-

age to the machine.

A NOTE provides key information to make procedures easier or clearer.

WARNING

CAUTION:

NOTE:

EBS00004

HOW TO USE THIS MANUAL

MANUAL ORGANIZATION

This manual consists of chapters for the main categories of subjects. (See “symbols”)

1st title : This is the title of the chapter with its symbol in the upper right corner of each page.

2nd title : This title indicates the section of the chapter and only appears on the first page of each

section. It is located in the upper left corner of the page.

3rd title : This title indicates a sub-section that is followed by step-by-step procedures accompa-

nied by corresponding illustrations.

EXPLODED DIAGRAMS

To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each

removal and disassembly section.

1. An easy-to-see exploded diagram is provided for removal and disassembly jobs.

2. Numbers are given in the order of the jobs in the exploded diagram. A number that is enclosed

by a circle indicates a disassembly step.

3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks

. The meanings of the symbol marks are given on the next page.

4. A job instruction chart accompanies the exploded diagram, providing the order of jobs, names

of parts, notes in jobs, etc.

5. For jobs requiring more information, the step-by-step format supplements are given in addition

to the exploded diagram and the job instruction chart.

GEN

INFO

CHAS

EBS00006

SYMBOLS

The following symbols are not relevant to every

machine.

Symbols to indicate the subject of each

chapter.

General information

Specifications

Periodic checks and adjustments

Engine

Carburetor

Chassis

Electrical

Troubleshooting

Symbols to indicate the following

Serviceable with engine mounted

Filling fluid

Lubricant

Special tool

Torque

Wear limit, clearance

Engine speed

Electrical data (Ω, V, A)

Symbols to in the exploded diagrams

indicate the types of lubricants and lubrication

points.

Apply engine oil

Apply gear oil

Apply molybdenum disulfide oil

Apply brake fluid

Apply wheel bearing grease

Apply lithium-soap-based grease

Apply molybdenum disulfide grease

Apply silicone grease

Symbols to in the exploded diagrams

indicate where to apply a locking agent and

when to install a new part .

Apply the locking agent (LOCTITE®)

Replace

EBS00008 TABLE OF CONTENTS

GENERAL INFORMATION GEN

INFO 1

SPECIFICATIONS SPEC 2

PERIODIC CHECKS AND

ADJUSTMENTS CHK

ADJ 3

ENGINE ENG 4

CARBURETOR CARB 5

CHASSIS CHAS 6

ELECTRICAL ELEC 7

TROUBLESHOOTING TRBL

SHTG 8

CHAPTER 1

GENERAL INFORMATION

MACHINE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

VEHICLE IDENTIFICATION NUMBER. . . . . . . . . . . . . . . . . . . . . . . . 1-1

MODEL LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

IMPORTANT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

PREPARATION FOR REMOVAL AND DISASSEMBLY . . . . . . . . . . 1-2

REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

GASKETS, OIL SEALS AND O-RINGS . . . . . . . . . . . . . . . . . . . . . . . 1-2

LOCK WASHERS/PLATES AND COTTER PINS . . . . . . . . . . . . . . . 1-2

BEARINGS AND OIL SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

CIRCLIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

CHECKING THE CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

CHAPTER 2

SPECIFICATIONS

GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

ENGINE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

CHASSIS SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

ELECTRICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

TIGHTENING TORQUES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

ENGINE TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

CHASSIS TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

HOW TO USE THE CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . 2-19

GENERAL TIGHTENING TORQUE SPECIFICATIONS . . . . . . . . . . . . . 2-19

LUBRICATION POINTS AND LUBRICANT TYPES . . . . . . . . . . . . . . . . 2-20

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

OIL FLOW DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

CHAPTER 3

PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL

SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

GENERAL MAINTENANCE AND LUBRICATION CHART . . . . . . . . . . 3-2

SEAT, FENDERS AND FUEL TANK. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

SEAT, FRONT FENDER AND HEADLIGHTS . . . . . . . . . . . . . . . . . . 3-4

FOOT PROTECTORS AND ENGINE SKID PLATE . . . . . . . . . . . . . . 3-5

REAR FENDER AND AIR FILLTER CASE. . . . . . . . . . . . . . . . . . . . . 3-6

FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

ADJUSTING THE VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . 3-9

ADJUSTING THE ENGINE IDLING SPEED. . . . . . . . . . . . . . . . . . . . 3-11

ADJUSTING THE THROTTLE LEVER FREE PLAY . . . . . . . . . . . . . 3-12

ADJUSTING THE SPEED LIMITER . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

CHECKING THE SPARK PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

CHECKING THE IGNITION TIMING . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

MEASURING THE COMPRESSION PRESSURE . . . . . . . . . . . . . . . 3-17

CHECKING THE ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . 3-19

CHANGING THE ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

ADJUSTING THE CLUTCH CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

CLEANING THE AIR FILTER ELEMENT . . . . . . . . . . . . . . . . . . . . . . 3-23

CLEANING THE SPARK ARRESTER . . . . . . . . . . . . . . . . . . . . . . . . 3-25

CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

ADJUSTING THE FRONT BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

ADJUSTING THE BRAKE LEVER (For adjustment type model) . . . . 3-26

ADJUSTING THE REAR BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

ADJUSTING THE PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

CHECKING THE BRAKE FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . 3-28

CHECKING THE FRONT BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . 3-29

CHECKING THE REAR BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . 3-30

ADJUSTING THE REAR BRAKE LIGHT SWITCH. . . . . . . . . . . . . . . 3-31

CHECKING THE BRAKE HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

BLEEDING THE HYDRAULIC BRAKE SYSTEM . . . . . . . . . . . . . . . . 3-32

ADJUSTING THE SHIFT PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34

ADJUSTING THE DRIVE CHAIN SLACK. . . . . . . . . . . . . . . . . . . . . . 3-35

CHECKING THE STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 3-36

ADJUSTING THE TOE-IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37

CHECKING THE FRONT AND REAR SHOCK ABSORBERS. . . . . . 3-38

ADJUSTING THE FRONT SHOCK ABSORBERS . . . . . . . . . . . . . . . 3-39

ADJUSTING THE REAR SHOCK ABSORBER . . . . . . . . . . . . . . . . . 3-40

CHECKING THE TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41

CHECKING THE WHEELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43

CHECKING AND LUBRICATING THE CABLES . . . . . . . . . . . . . . . . 3-43

LUBRICATING THE LEVERS AND PEDALS. . . . . . . . . . . . . . . . . . . 3-44

ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45

CHECKING AND CHARGING THE BATTERY . . . . . . . . . . . . . . . . . 3-45

CHECKING THE FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52

ADJUSTING THE HEADLIGHT BEAM. . . . . . . . . . . . . . . . . . . . . . . . 3-53

REPLACING A HEADLIGHT BULB . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54

CHAPTER 4

ENGINE

ENGINE REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

MUFFLER AND EXHAUST PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

INSTALLING THE EXHAUST PIPE AND MUFFLER . . . . . . . . . . . . . 4-2

LEADS, CABLES AND HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

ENGINE MOUNTING BOLTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

INSTALLING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

REMOVING THE CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

CHECKING THE CYLINDER HEAD. . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

CHECKING THE TIMING CHAIN GUIDES . . . . . . . . . . . . . . . . . . . . 4-11

CHECKING THE TIMING CHAIN TENSIONERS. . . . . . . . . . . . . . . . 4-11

INSTALLING THE CYLINDER HEAD. . . . . . . . . . . . . . . . . . . . . . . . . 4-12

ROCKER ARM, CAMSHAFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

REMOVING THE ROCKER ARMS AND CAMSHAFT . . . . . . . . . . . . 4-16

CHECKING THE CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

CHECKING THE ROCKER ARMS AND ROCKER ARM

SHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

INSTALLING THE CAMSHAFT AND ROCKER ARMS . . . . . . . . . . . 4-19

VALVES AND VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

REMOVING THE VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

CHECKING THE VALVES AND VALVE GUIDES . . . . . . . . . . . . . . . 4-23

CHECKING THE VALVE SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

CHECKING THE VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28

INSTALLING THE VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29

CYLINDER AND PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31

REMOVING THE PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32

CHECKING THE CYLINDER AND PISTON. . . . . . . . . . . . . . . . . . . . 4-32

CHECKING THE PISTON RINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34

CHECKING THE PISTON PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36

INSTALLING THE PISTON AND CYLINDER. . . . . . . . . . . . . . . . . . . 4-37

CLUTCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39

REMOVING THE CLUTCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43

CHECKING THE FRICTION PLATES . . . . . . . . . . . . . . . . . . . . . . . . 4-44

CHECKING THE CLUTCH PLATES . . . . . . . . . . . . . . . . . . . . . . . . . 4-44

CHECKING THE CLUTCH SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . 4-45

CHECKING THE CLUTCH HOUSING . . . . . . . . . . . . . . . . . . . . . . . . 4-45

CHECKING THE CLUTCH BOSS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45

CHECKING THE PRESSURE PLATE . . . . . . . . . . . . . . . . . . . . . . . . 4-45

CHECKING THE CLUTCH PUSH RODS . . . . . . . . . . . . . . . . . . . . . . 4-46

CHECKING THE PRIMARY DRIVE GEAR . . . . . . . . . . . . . . . . . . . . 4-46

INSTALLING THE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46

OIL PUMP AND BLANCER WEIGHT GEAR . . . . . . . . . . . . . . . . . . . . . 4-50

REMOVING THE BALANCER WEIGHT GEAR AND OIL PUMP. . . . 4-53

CHECKING THE OIL PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-53

CHECKING THE BALANCER WEIGHT GEAR . . . . . . . . . . . . . . . . . 4-54

ASSENBLING THE BALANCER DRIVE GEAR . . . . . . . . . . . . . . . . . 4-55

INSTALLING THE OIL PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55

INSTALLING THE BALANCER WEIGHT GEAR . . . . . . . . . . . . . . . . 4-56

SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57

CHECKING THE SHIFT SHAFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58

CHECKING THE STOPPER LEVER . . . . . . . . . . . . . . . . . . . . . . . . . 4-58

INSTALLING THE SHIFT SHAFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58

PICKUP COIL ROTOR AND STARTER CLUTCH . . . . . . . . . . . . . . . . . 4-60

REMOVING THE PICKUPCOIL ROTOR . . . . . . . . . . . . . . . . . . . . . . 4-62

CHECKING THE STARTER CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . 4-63

INSTALLING THE PICKUP COIL ROTOR . . . . . . . . . . . . . . . . . . . . . 4-64

CRANKCASE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66

DISASSEMBLING THE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . 4-69

CHECKING THE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-70

ASSEMBLING THE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-70

CRANKSHAFT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-72

REMOVING THE CRANKSHAFT ASSEMBLY. . . . . . . . . . . . . . . . . . 4-73

REMOVING THE PLUNGER SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . 4-73

CHECKING THE CRANKSHAFT AND CONNECTING ROD. . . . . . . 4-73

CHECKING THE TIMING CHAIN, CRANKSHAFT SPROCKET

AND TIMING CHAIN GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74

INSTALLING THE PLUNGER SEAL . . . . . . . . . . . . . . . . . . . . . . . . . 4-75

INSTALLING THE CRANKSHAFT ASSEMBLY . . . . . . . . . . . . . . . . . 4-75

TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-77

REMOVING THE TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . 4-80

CHECKING THE SHIFT FORKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-80

CHECKING THE SHIFT DRUM ASSEMBLY . . . . . . . . . . . . . . . . . . . 4-81

CHECKING THE TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-81

INSTALLING THE SHIFT FORKS AND SHIFT DRUM

ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-82

CHAPTER 5

CARBURETOR

CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

CHECKING THE CARBURETOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

ASSEMBLING THE CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

INSTALLING THE CARBURETOR JOINT . . . . . . . . . . . . . . . . . . . . . 5-7

INSTALLING THE CARBURETOR. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

CHAPTER 6

CHASSIS

FRONT AND REAR WHEELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

FRONT WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

REAR WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

CHECKING THE WHEELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

CHECKING THE WHEEL HUBS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

CHECKING THE BRAKE DISCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

INSTALLING THE FRONT WHEEL HUB BEARINGS . . . . . . . . . . . . 6-6

INSTALLING THE FRONT BRAKE DISCS . . . . . . . . . . . . . . . . . . . . 6-6

INSTALLING THE FRONT WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

INSTALLING THE WHEEL HUBS . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

REAR AXLE AND REAR AXLE HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

REMOVING THE REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

CHECKING THE REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

CHECKING THE DRIVEN SPROCKET . . . . . . . . . . . . . . . . . . . . . . . 6-11

CHECKING THE BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

INSTALLING THE DRIVEN SPROCKET . . . . . . . . . . . . . . . . . . . . . . 6-11

INSTALLING THE REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

FRONT AND REAR BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13

FRONT BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13

REAR BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

REPLACING THE FRONT BRAKE PADS . . . . . . . . . . . . . . . . . . . . . 6-15

REPLACING THE REAR BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . 6-17

FRONT BRAKE MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . 6-19

REAR BRAKE MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . 6-21

CHECKING THE MASTER CYLINDERS . . . . . . . . . . . . . . . . . . . . . . 6-24

ASSEMBLING THE FRONT BRAKE MASTER CYLINDER . . . . . . . 6-25

ASSEMBLING THE REAR BRAKE MASTER CYLINDER . . . . . . . . 6-25

INSTALLING THE FRONT BRAKE MASTER CYLINDER . . . . . . . . . 6-26

INSTALLING THE REAR BRAKE MASTER CYLINDER . . . . . . . . . . 6-28

FRONT BRAKE CALIPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30

REAR BRAKE CALIPER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32

REMOVING THE PARKING BRAKE CABLE . . . . . . . . . . . . . . . . . . . 6-34

DISASSEMBLING THE FRONT AND REAR BRAKE CALIPERS . . . 6-34

CHECKING THE FRONT AND REAR BRAKE CALIPERS . . . . . . . . 6-35

ASSEMBLING THE FRONT BRAKE CALIPERS . . . . . . . . . . . . . . . . 6-36

ASSEMBLING THE REAR BRAKE CALIPER . . . . . . . . . . . . . . . . . . 6-36

INSTALLING THE FRONT BRAKE CALIPERS . . . . . . . . . . . . . . . . . 6-38

INSTALLING THE REAR BRAKE CALIPER . . . . . . . . . . . . . . . . . . . 6-40

STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42

HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42

REMOVING THE CLUTCH SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . 6-44

REMOVING THE HANDLEBAR GRIPS . . . . . . . . . . . . . . . . . . . . . . 6-44

CHECKING THE HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44

INSTALLING THE HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45

INSTALLING THE HANDLEBAR GRIPS . . . . . . . . . . . . . . . . . . . . . . 6-45

INSTALLING THE CLUTCH LEVER. . . . . . . . . . . . . . . . . . . . . . . . . . 6-46

INSTALLING THE BRAKE MASTER CYLINDER . . . . . . . . . . . . . . . 6-46

STEERING STEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47

CHECKING THE STEERING STEM. . . . . . . . . . . . . . . . . . . . . . . . . . 6-48

INSTALLING THE STEERING STEM. . . . . . . . . . . . . . . . . . . . . . . . . 6-48

INSTALLING THE LOCK WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48

TIE-RODS AND STEERING KNUCKLES. . . . . . . . . . . . . . . . . . . . . . 6-49

REMOVING THE STEERING KNUCKLES. . . . . . . . . . . . . . . . . . . . . 6-50

CHECKING THE TIE-RODS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50

CHECKING THE STEERING KNUCKLES . . . . . . . . . . . . . . . . . . . . . 6-50

INSTALLING THE TIE-RODS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50

FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES . . . . 6-51

REMOVING THE FRONT ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-53

CHECKING THE FRONT ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-53

CHECKING THE FRONT SHOCK ABSORBERS . . . . . . . . . . . . . . . 6-53

CHECKING THE BALL JOINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54

INSTALLING THE FRONT ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54

REAR SHOCK ABSORBER, SWINGARM AND DRIVE CHAIN . . . . . . 6-55

HANDLING THE REAR SHOCK ABSORBER . . . . . . . . . . . . . . . . . . 6-57

DISPOSING OF A REAR SHOCK ABSORBER . . . . . . . . . . . . . . . . . 6-57

REMOVING THE REAR SHOCK ABSORBER. . . . . . . . . . . . . . . . . . 6-58

CHECKING THE REAR SHOCK ABSORBER . . . . . . . . . . . . . . . . . . 6-58

REMOVING THE SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-58

CHECKING THE SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-59

CHECKING THE DRIVE CHAIN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-60

INSTALLING THE SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-62

INSTALLING THE DRIVE SPROCKET . . . . . . . . . . . . . . . . . . . . . . . 6-62

CHAPTER 7

ELECTRICAL

ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

CHECKING SWITCH CONTINUITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

CHECKING THE SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

CHECKING THE BULBS AND BULB SOCKETS. . . . . . . . . . . . . . . . . . 7-5

TYPES OF BULBS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

CHECKING THE CONDITION OF THE BULBS. . . . . . . . . . . . . . . . . 7-5

CHECKING THE CONDITION OF THE BULB SOCKETS . . . . . . . . 7-7

IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

ELECTRIC STARTING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

STARTING CIRCUIT CUT-OFF SYSTEM OPERATION . . . . . . . . . . 7-14

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15

STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19

CHECKING THE STARTER MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . 7-21

ASSEMBLING THE STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . 7-23

CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24

CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25

LIGHTING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27

CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28

CHECKING THE LIGHTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 7-29

SIGNAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31

CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32

CHECKING THE SIGNALING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . 7-33

CHAPTER 8

TROUBLESHOOTING

STARTING FAILURE/HARD STARTING . . . . . . . . . . . . . . . . . . . . . . . . 8-1

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

COMPRESSION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

POOR IDLE SPEED PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

POOR IDLE SPEED PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . 8-2

POOR MEDIUM AND HIGH-SPEED PERFORMANCE . . . . . . . . . . . . . 8-2

POOR MEDIUM AND HIGH-SPEED PERFORMANCE . . . . . . . . . . . 8-2

FAULTY GEAR SHIFTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

HARD SHIFTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

SHIFT PEDAL DOES NOT MOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

JUMPS OUT GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

CLUTCH SLIPPING/DRAGGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

CLUTCH SLIPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

CLUTCH DRAGGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

OVERHEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

OVERHEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

FAULTY BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

POOR BRAKING EFFECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

SHOCK ABSORBER MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

UNSTABLE HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

UNSTABLE HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

LIGHTING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

HEADLIGHT DOES NOT COME ON . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

TAIL/BRAKE LIGHT DOES NOT LIGHT . . . . . . . . . . . . . . . . . . . . . . 8-5

BULB BURNT OUT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

TAIL/BRAKE LIGHT BULB BURNT OUT . . . . . . . . . . . . . . . . . . . . . 8-5

GEN

INFO

1-1

EBS00009

GENERAL INFORMATION

MACHINE IDENTIFICATION

EBS00010

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number is

stamped into the left side of the frame.

EBS00011

MODEL LABEL

The model label is affixed to the air filter

case cover. This information will be needed to

order spare parts.

MACHINE IDENTIFICATION

GEN

INFO

1-2

EBS00013

IMPORTANT INFORMATION

PREPARATION FOR REMOVAL AND

DISASSEMBLY

1. Before removal and disassembly remove all

dirt, mud, dust and foreign material.

2. Use only the proper tools and cleaning

equipment.

Refer to “SPECIAL TOOLS”.

3. When disassembling always keep mated

parts together. This includes gears, cylin-

ders, pistons and other parts that have

been “mated” through normal wear. Mated

parts must always be reused or replaced as

an assembly.

4. During disassembly, clean all of the parts

and place them in trays in the order of dis-

assembly. This will speed up assembly and

allow for the correct installation of all parts.

5. Keep all parts away from any source of fire.

EBS00014

REPLACEMENT PARTS

1. Use only genuine Yamaha parts for all

replacements. Use oil and grease recom-

mended by Yamaha for all lubrication jobs.

Other brands may be similar in function and

appearance, but inferior in quality.

EBS00015

GASKETS, OIL SEALS AND O-RINGS

1. When overhauling the engine, replace all

gaskets, seals and O-rings. All gasket sur-

faces, oil seal lips and O-rings must be

cleaned.

2. During reassembly properly oil all mating

parts and bearings, and lubricate the oil

seal lips with grease.

EBS00016

LOCK WASHERS/PLATES AND COTTER

PINS

After removal, replace all lock washers/plates

and cotter pins. After the bolt or nut has

been tightened to specification, bend the lock

tabs along a flat of the bolt or nut.

IMPORTANT INFORMATION

GEN

INFO

1-3

EBS00017

BEARINGS AND OIL SEALS

Install bearings and oil seals so that the manu-

facturer’s marks or numbers are visible. When

installing oil seals, lubricate the oil seal lips

with a light coat of lithium-soap-based grease.

Oil bearings liberally when installing, if appro-

priate.

Oil seal

CAUTION:

Do not spin the bearing with compressed

air because this will damage the bearing

surfaces.

Bearing

EBS00018

CIRCLIPS

Before reassembly, check all circlips carefully

and replace damaged or distorted circlips.

Always replace piston pin clips after one use.

When installing a circlip , make sure the

sharp-edged corner is positioned opposite

the thrust that the circlip receives.

Shaft

IMPORTANT INFORMATION

GEN

INFO

1-4

EBS00019

CHECKING THE CONNECTIONS

Check the leads, couplers, and connectors for

stains, rust, moisture, etc.

1. Disconnect:

• lead

• coupler

• connector

2. Check:

• lead

• coupler

• connector

Moisture → Dry with an air blower.

Rust /stains → Connect and disconnect

several times.

3. Check:

• all connections

Loose connection → Connect properly.

TE:N

TE:

If the pin on the terminal is flattened, bend it

up.

4. Connect:

• lead

• coupler

• connector

TE:N

TE:

Make sure all connections are tight.

5. Check:

• continuity (with the pocket tester)

TE:N

TE:

• If there is no continuity, clean the terminals.

• When checking the wire harness, perform

steps (1) to (3).

• As a quick remedy, use a contact revitalizer

available at most part stores.

Pocket tester

YU-03112-C

Analog pocket tester

YU-03112-C

IMPORTANT INFORMATION

GEN

INFO

1-5

EBS00021

SPECIAL TOOLS

The following special tools are necessary for complete and accurate tune-up and assembly. Use

only the appropriate special tools; this will help prevent damage caused by the use of inappropriate

tools or improvised techniques. Special tools may differ by shape and part number from country to

country. In such a case, two types are provided.

When placing an order, refer to the list provided below to avoid any mistakes.

For US and CAN

P/N. YM-, YU-, YS-, YK-, ACC-

Except for US and CAN

P/N. 90890

Tool No. Tool name/Function Illustration

90890-01083

YU-01083-1

Slide hummer bolt

Slide hummer bolt 6 mm

This tool is used to remove the rocker arm

shaft.

90890-01084

YU-01083-3

Weight

This tool is used to remove the rocker arm

shaft.

90890-01135

YU-01135-B

Crankcase separating tool

Crankcase separator

This tool is used to separate the crankcase.

90890-01268

YU-01268

Ring nut wrench

Spanner wrench

This tool is used to adjusting the front shock

absorbers.

90890-01274

YU-90058

Crankshaft installer pot

Installing pot

These tools are used to install the crankshaft.

90890-01275

YU-90060

Crankshaft installer bolt

Bolt

This tool is used to install the crankshaft.

YU-01083-3

YU-90058/YU-90059

SPECIAL TOOLS

GEN

INFO

1-6

Tool No. Tool name/Function Illustration

Adapter

90890-01383

YU-90062

Adapter (M10)

Adapter #2

This tool is used to install the crankshaft.

90890-01288

Spacer

This tool is used to install the crankshaft.

90890-01304

YU-01304

Piston pin puller set

Piston pin puller

This tool is used to remove the piston pin.

90890-01311

YM-A5970

Tappet adjusting tool

Six piece tappet set

This tool is necessary for adjusting the valve

clearance.

90890-01362

YU-33270-B

Flywheel puller

Heavy duty puller

This tool is used to remove the AC magneto

rotor.

90890-01359

Bolt (M8 × 80 mm)

This tool is used to remove the AC magneto

rotor.

90890-01701

YS-01880-A

Sheave holder

Primary clutch holder

This tool is needed to hold the AC magneto

rotor when loosen or tighten the AC magneto

rotor nut.

90890-03079

YM-34483

Thickness gauge

Narrow gauge set

This tool is used to measure the valve clear-

ance and spark plug gap.

YU-01304

SPECIAL TOOLS

GEN

INFO

1-7

Tool No. Tool name/Function Illustration

90890-03081

YU-33223

Compression gauge

Engine compression tester

This tool is needed to measure the engine

compression.

90890-04082

Extension

This tool is needed to measure engine com-

pression.

90890-03112

YU-03112-C

Pocket tester

Analog pocket tester

This instrument is needed for checking the

electrical system.

90890-03141

YU-03141

Timing light

Inductive clamp timing light

This tool is necessary for checking ignition

timing.

Compressor

90890-04019

YM-04019

Valve spring compressor

This tool is needed to remove and install the

valve assemblies.

90890-01243

YM-01253-1

Valve spring compressor attachment

Valve spring compressor adapter (26 mm)

This tool is needed to remove and install the

valve assemblies.

90890-04086

YM-91042

Universal clutch holder

This tool is needed to hold the clutch carrier

when removing or installing the carrier nut.

90890-04064

YM-04064-A

Valve guide remover (φ6)

Valve guide remover (6.0 mm)

This tool is needed to remove and install the

valve guides.

SPECIAL TOOLS

GEN

INFO

1-8

Tool No. Tool name/Function Illustration

90890-04065

YM-04065-A

Valve guide installer (φ6)

Valve guide installer (6.0 mm)

This tool is needed to install the valve guides.

90890-04066

YM-04066

Valve guide reamer (φ6)

Valve guide reamer (6.0 mm)

This tool is needed to rebore the new valve

guides.

90890-04101

YM-A8998

Valve lapper

Valve lapping tool

This tool is needed to remove and install the

valve lifters.

90890-06588

PTT wrench 46

This tool is needed to loosen or tighten the

rear axle nut.

YM-37134

Axle nut wrench (46 mm)

This tool is needed to loosen or tighten the

rear axle nut.

90890-06754

YM-34487

Ignition checker

Opama pet-4000 spark checker

This instrument is necessary for checking the

ignition system components.

90890-06760

YU-39951-B

Digital tachometer

This tool is needed for observing engine rpm.

90890-85505

Yamaha bond No. 1215

(Three Bond No. 1215®)

This bond is used on crankcase mating sur-

faces, etc.

SPECIAL TOOLS

SPEC

2-1

EBS01001

SPECIFICATIONS

GENERAL SPECIFICATIONS

Item Standard

Model code 4D31

4D35

4D39

Dimensions

Overall length 1,625 mm (64.0 in)

Overall width 1,070 mm (42.1 in)

Overall height 1,040 mm (40.9 in)

Seat height 730 mm (28.7 in)

Wheelbase 1,110 mm (43.7 in)

Minimum ground clearance 100 mm (3.94 in)

Minimum turning radius 2,900 mm (114.2 in)

Basic weight

With oil and full fuel tank 150 kg (331 lb)

Engine

Engine type Air-cooled 4-stroke, SOHC

Cylinder arrangement Forward-inclined single cylinder

Displacement 249 cm3 (15.19 cu in)

Bore × stroke 74.0 × 58.0 mm (2.91 × 2.28 in)

Compression ratio 9.5 : 1

Engine idle speed 1,500 ~ 1,600 r/min

Intake vacuum 34 kPa (255 mmHg, 10.0 inHg)

Oil temperature 55 ~ 65 °C

Standard compression pressure (at sea level) 1,100 kPa (11.2 kg/cm2, 160 psi)/720 r/min

Starting system Electric starter

Lubrication system Wet sump

Oil type or grade

Engine oil YAMALUBE4, SAE 5W-30 or SAE 10W-30 or

SAE 20W-40

API service, SG type or higher, JASO standard

Oil capacity

Engine oil

Periodic oil change 1.25 L (1.10 Imp qt, 1.32 US qt)

With oil filter replacement 1.35 L (1.19 Imp qt, 1.43 US qt)

Total amount 1.60 L (1.41 Imp qt, 1.69 US qt)

Air filter Wet type element

GENERAL SPECIFICATIONS

SPEC

2-2

Item Standard

Fuel

Type Unleaded gasoline only

Fuel tank capacity 9.0 L (1.97 Imp gal, 2.37 US gal)

Fuel reserve amount 1.0 L (0.22 Imp gal, 0.26 US gal)

Carburetor

Type/quantity BSR29 × 1

Manufacturer MIKUNI

Spark plug

Type/manufacturer DR7EA/NGK

Spark plug gap 0.6 ~ 0.7 mm (0.024 ~ 0.028 in)

Clutch type Wet, multiple-disc

Transmission

Primary reduction system Spur gear

Primary reduction ratio 76/22 (3.455)

Secondary reduction system Chain drive

Secondary reduction ratio 38/14 (2.714)

Transmission type Constant mesh, 5-speed

Operation Left foot operation

Gear ratio

1st gear 37/13 (2.846)

2nd gear 33/18 (1.833)

3rd gear 29/21 (1.381)

4th gear 27/24 (1.125)

5th gear 28/29 (0.966)

Chassis

Frame type Steel tube frame

Caster angle 6°

Camber angle –1.5°

Kingpin angle 14.8°

Trail 23.0 mm (0.91 in)

Tread (STD) front 826 mm (32.52 in)

rear 824 mm (32.44 in)

Toe-in (with tires touching the ground) 9 ~ 19 mm (0.35 ~ 0.75 in)

Tire

Type Tubeless

Size front AT20 × 7-10

rear AT19 × 10-9

Manufacturer front DUNLOP

rear DUNLOP

Type front KT201

rear KT205A

Tire pressure (cold tire)

Maximum load* 100 kg (220 lb)

Off-road riding front 27.5 kPa (0.28 kg/cm2, 4.0 psi)

rear 27.5 kPa (0.28 kg/cm2, 4.0 psi)

*Load in total weight of cargo, rider and

accessories

GENERAL SPECIFICATIONS

SPEC

2-3

Item Standard

Brake

Front brake type Dual disc brake

operation Right hand operation

Rear brake type Single disc brake

operation Right foot operation

Suspension

Front suspension Double wishbone

Rear suspension Swingarm

Shock absorber

Front shock absorber Coil spring/oil damper

Rear shock absorber Coil spring/gas-oil damper

Wheel travel

Front wheel travel 190 mm (7.48 in)

Rear wheel travel 200 mm (7.87 in)

Electrical

Ignition system DC-CDI

Generator system AC magneto

Battery type YTZ7S

Battery capacity 12 V 6.0 Ah

Headlight type Krypton bulb

Bulb voltage/wattage × quantity

Headlight 12 V 30 W/30 W × 2

Tail/brake light 12 V 5 W/21 W × 1 (4D31)

12 V 0.5 W/3.9 W × 1 (4D35, 4D39)

Indicator lights

Neutral 12 V 1.7 W × 1

GENERAL SPECIFICATIONS

SPEC

2-4

EBS01002

ENGINE SPECIFICATIONS

Item Standard Limit

Cylinder head

Volume 20.50 ~ 21.50 cm3 (1.25 ~ 1.31 cu.in) • • •

Warp limit • • •0.05 mm

(0.0020 in)

Cylinder

Bore size 74.000 ~ 74.016 mm (2.9134 ~ 2.9140 in) 74.100 mm

(2.9173 in)

Camshaft

Drive method Chain drive (Right) • • •

Camshaft lobe dimensions

Intake “A” 36.890 ~ 36.990 mm (1.4524 ~ 1.4563 in) 36.790 mm

(1.4484 in)

“B” 30.111 ~ 30.211 mm (1.1855 ~ 1.1894 in) 30.011 mm

(1.1815 in)

Exhaust “A” 36.891 ~ 36.991 mm (1.4524 ~ 1.4563 in) 36.791 mm

(1.4485 in)

“B” 30.092 ~ 30.192 mm (1.1847 ~ 1.1887 in) 29.992 mm

(1.1808 in)

Camshaft runout limit • • •0.03 mm

(0.0012 in)

Timing chain

Timing chain type/No. of links DID SCR-0404 SV/104 • • •

Timing chain adjustment method Automatic • • •

Rocker arm/rocker arm shaft

Rocker arm inside diameter 12.000 ~ 12.018 mm (0.4724 ~ 0.4731 in) 12.036 mm

(0.4739 in)

Rocker arm shaft outside diameter 11.981 ~ 11.991 mm (0.4717 ~ 0.4721 in) 11.950 mm

(0.4705 in)

Rocker-arm-to-rocker-arm-shaft

clearance 0.009 ~ 0.037 mm (0.0004 ~ 0.0015 in) • • •

ENGINE SPECIFICATIONS

SPEC

2-5

Item Standard Limit

Valve, valve seat, valve guide

Valve clearance (cold) IN 0.05 ~ 0.10 mm (0.0020 ~ 0.0039 in) • • •

EX 0.10 ~ 0.15 mm (0.0039 ~ 0.0059 in) • • •

Valve dimensions

“A” head diameter IN 33.90 ~ 34.10 mm (1.3346 ~ 1.3425 in) • • •

EX 28.40 ~ 28.60 mm (1.1181 ~ 1.1260 in) • • •

“B” face width IN 2.26 mm (0.0890 in) • • •

EX 2.26 mm (0.0890 in) • • •

“C” seat width IN 0.90 ~ 1.10 mm (0.0354 ~ 0.0433 in) 1.6 mm

(0.06 in)

EX 0.90 ~ 1.10 mm (0.0354 ~ 0.0433 in) 1.6 mm

(0.06 in)

“D” margin thickness IN 0.80 ~ 1.20 mm (0.0315 ~ 0.0472 in) • • •

EX 0.80 ~ 1.20 mm (0.0315 ~ 0.0472 in) • • •

Stem outside diameter IN 5.975 ~ 5.990 mm (0.2352 ~ 0.2358 in) 5.945 mm

(0.234 in)

EX 5.960 ~ 5.975 mm (0.2346 ~ 0.2352 in) 5.930 mm

(0.233 in)

Guide inside diameter IN 6.000 ~ 6.012 mm (0.2362 ~ 0.2367 in) 6.050 mm

(0.238 in)

EX 6.000 ~ 6.012 mm (0.2362 ~ 0.2367 in) 6.050 mm

(0.238 in)

Stem-to-guide clearance IN 0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in) 0.080 mm

(0.003 in)

EX 0.025 ~ 0.052 mm (0.0010 ~ 0.0020 in) 0.100 mm

(0.004 in)

Valve stem runout • • •0.01 mm

(0.0004 in)

Valve seat width IN 0.90 ~ 1.10 mm (0.0354 ~ 0.0433 in) 1.6 mm

(0.06 in)

EX 0.90 ~ 1.10 mm (0.0354 ~ 0.0433 in) 1.6 mm

(0.06 in)

Head Diameter Face Width Seat Width Margin Thickness

ENGINE SPECIFICATIONS

SPEC

2-6

Item Standard Limit

Valve spring

Inner spring

Free length IN 36.17 mm (1.42 in) 34.36 mm

(1.35 in)

EX 36.17 mm (1.42 in) 34.36 mm

(1.35 in)

Installed length

(valve closed) IN 30.50 mm (1.20 in) • • •

EX 30.50 mm (1.20 in) • • •

Spring rate K1 IN 14.70 N/mm (1.50 kg/mm, 83.94 lb/in) • • •

K2 IN 19.00 N/mm (1.94 kg/mm, 108.49 lb/in) • • •

K1 EX 14.70 N/mm (1.50 kg/mm, 83.94 lb/in) • • •

K2 EX 19.00 N/mm (1.94 kg/mm, 108.49 lb/in) • • •

Compressed spring force

(installed) IN 75.00 ~ 91.70 N

(7.65 ~ 9.35 kg, 16.86 ~ 20.62 lb) • • •

EX 75.00 ~ 91.70 N

(7.65 ~ 9.35 kg, 16.86 ~ 20.62 lb) • • •

Tilt limit IN • • • 2.5°/1.60 mm

(2.5°/0.063 in)

EX • • • 2.5°/1.60 mm

(2.5°/0.063 in)

Direction of winding

(top view) IN Counter clockwise • • •

EX Counter clockwise • • •

Outer spring

Free length IN 36.63 mm (1.44 in) 34.80 mm

(1.37 in)

EX 36.63 mm (1.44 in) 34.80 mm

(1.37 in)

Installed length

(valve closed) IN 32.00 mm (1.26 in) • • •

EX 32.00 mm (1.26 in) • • •

Spring rate K1 IN 30.90 N/mm (3.15 kg/mm, 176.44 lb/in) • • •

Spring rate K2 IN 40.80 N/mm (4.16 kg/mm, 232.97 lb/in) • • •

Spring rate K1 EX 30.90 N/mm (3.15 kg/mm, 176.44 lb/in) • • •

Spring rate K2 EX 40.80 N/mm (4.16 kg/mm, 232.97 lb/in) • • •

Compressed spring force

(installed) IN 128.50 ~ 157.90 N

(13.10 ~ 16.10 kg, 28.89 ~ 35.50 lb) • • •

EX 128.50 ~ 157.90 N

(13.10 ~ 16.10 kg, 28.89 ~ 35.50 lb) • • •

ENGINE SPECIFICATIONS

SPEC

2-7

Item Standard Limit

Tilt limit IN • • • 2.5°/1.60 mm

(2.5°/0.063 in)

EX • • • 2.5°/1.60 mm

(2.5°/0.063 in)

Direction of winding

(top view) IN Clockwise • • •

EX Clockwise • • •

Piston

Piston to cylinder clearance 0.010 ~ 0.025 mm (0.0004 ~ 0.0010 in) 0.15 mm

(0.006 in)

Piston size “D” 73.983 ~ 73.998 mm (2.9127 ~ 2.9133 in) • • •

Measuring point “H” 5.0 mm (0.20 in) • • •

Piston off set 0.25 mm (0.0098 in) • • •

Offset direction Intake side • • •

Piston pin bore inside diameter 17.002 ~ 17.013 mm (0.6694 ~ 0.6698 in) 17.043 mm

(0.6710 in)

Piston pin outside diameter 16.991 ~ 17.000 mm (0.6689 ~ 0.6693 in) 16.971 mm

(0.6681 in)

Piston-pin-to-piston-pin-bore

clearance 0.002 ~ 0.022 mm (0.0001 ~ 0.0009 in) 0.072 mm

(0.0028 in)

ENGINE SPECIFICATIONS

SPEC

2-8

Item Standard Limit

Piston rings

Top ring

Type Barrel • • •

Dimensions (B × T) 0.90 × 2.75 mm (0.035 × 0.108 in) • • •

End gap (installed) 0.19 ~ 0.31 mm (0.007 ~ 0.012 in) 0.56 mm

(0.022 in)

Side clearance 0.030 ~ 0.065 mm (0.0012 ~ 0.0026 in) 0.115 mm

(0.0045 in)

2nd ring

Type Taper • • •

Dimensions (B × T) 0.80 × 2.80 mm (0.031 × 0.110 in) • • •

End gap (installed) 0.30 ~ 0.45 mm (0.012 ~ 0.018 in) 0.80 mm

(0.032 in)

Side clearance 0.020 ~ 0.055 mm (0.0008 ~ 0.0022 in) 0.115 mm

(0.0045 in)

Oil ring

Dimensions (B × T) 1.50 × 2.60 mm (0.059 × 0.102 in) • • •

End gap (installed) 0.10 ~ 0.35 mm (0.004 ~ 0.014 in) • • •

Crankshaft

Crank width “A” 69.25 ~ 69.30 mm (2.726 ~ 2.728 in) • • •

Runout limit C1 • • •0.03 mm

(0.0012 in)

C2 • • •0.03 mm

(0.0012 in)

Big end side clearance “D” 0.350 ~ 0.650 mm (0.0138 ~ 0.0256 in) 0.50 mm

(0.0197 in)

Big end radial clearance “E” 0.010 ~ 0.025 mm (0.0004 ~ 0.0010 in) • • •

ENGINE SPECIFICATIONS

SPEC

2-9

Item Standard Limit

Balancer

Balancer drive method Gear • • •

Clutch

Friction plate 1 (inside dia.: 104.5 ~

105.5 mm)

Thickness 2.9 ~ 3.1 mm (0.114 ~ 0.122 in) 2.8 mm

(0.110 in)

Quantity 4 • • •

Friction plate 2 (inside dia.: 104.5 ~

105.5 mm)

Thickness 2.9 ~ 3.1 mm (0.114 ~ 0.122 in) 2.8 mm

(0.110 in)

Quantity 2 • • •

Clutch plate

Thickness 1.5 ~ 1.7 mm (0.059 ~ 0.067 in) • • •

Quantity 5 • • •

Max. warpage • • • 0.2 mm

(0.0079 in)

Clutch spring

Free length 47.8 mm (1.88 in) 45.4 mm

(1.79 in)

Quantity 5 • • •

Clutch release method Inner push, cam push • • •

Push rod 2 bending limit • • • 0.1 mm

(0.004 in)

Transmission

Main axle runout limit • • •0.06 mm

(0.0024 in)

Drive axle runout limit • • •0.06 mm

(0.0024 in)

Main axle assembly width 102.2 ~ 102.4 mm (4.02 ~ 4.03 in) • • •

Shifter

Shifter type Shift drum and guide bar • • •

Max. shift fork guide bar bending • • •0.05 mm

(0.002 in)

Air filter oil grade Foam air filter oil or equivalent oil • • •

ENGINE SPECIFICATIONS

SPEC

2-10

Item Standard Limit

Carburetor

I. D. mark 4D31 00 • • •

Main jet (M.J) #133.8 • • •

Main air jet (M.A.J) #140 • • •

Jet needle (J.N) 5DH66-1 • • •

Needle jet (N.J) P-0M • • •

Pilot air jet 1 (P.A.J.1) #85 • • •

Pilot air jet 2 (P.A.J.2) #170 • • •

Pilot outlet (P.O) ø0.9 • • •

Pilot jet (P.J) #25 • • •

Bypass 1 (B.P.1) ø0.8 • • •

Bypass 2 (B.P.2) ø0.8 • • •

Bypass 3 (B.P.3) ø0.8 • • •

Valve seat size (V.S) ø2.0 • • •

Starter jet 1 (G.S.1) #55 • • •

Starter jet 2 (G.S.2) #0.5 • • •

Throttle valve size (THV) #100 • • •

Float height (F.H) 13.0 mm (0.51 in) • • •

Oil filter type Wire mesh • • •

Oil pump

Oil pump type Trochoid • • •

Inner-rotor-to-outer-rotor-tip clearance 0.15 mm (0.0059 in) 0.23 mm

(0.0091 in)

Outer-rotor-to-oil-pump-housing

clearance 0.100 ~ 0.151 mm (0.0039 ~ 0.0059 in) 0.22 mm

(0.0087 in)

Oil-pump-housing-to-inner-and-outer-

rotor clearance 0.04 ~ 0.09 mm (0.0016 ~ 0.0035 in) 0.16 mm

(0.0063 in)

Oil pressure (hot) 3.0 kPa, 0.03 kg/cm2, 0.44 psi/1550 r/min • • •

Pressure check location HEAD CYLINDER • • •

ENGINE SPECIFICATIONS

SPEC

2-11

EBS01003

CHASSIS SPECIFICATIONS

Item Standard Limit

Front suspension

Shock absorber travel 90.7 mm (3.57 in) • • •

Spring free length 248.5 mm (9.78 in) • • •

Spring rate 23.0 N/mm (2.34 kg/mm, 131.26 lb/in) • • •

Spring stroke 0.0 ~ 90.7 mm (0.0 ~ 3.57 in) • • •

Optional spring No • • •

Rear suspension

Shock absorber assembly travel 87.0 mm (3.43 in) • • •

Spring free length 240.5 mm (9.47 in) • • •

Spring rate 54.0 N/mm (5.50 kg/mm, 308.18 lb/in) • • •

Stroke 0 ~ 87.0 mm (0 ~ 3.43 in) • • •

Optional spring No • • •

Swingarm

Free play limit radial • • • 1.0 mm

(0.04 in)

axial • • • 1.0 mm

(0.04 in)

Rear axle

Rear axle runout • • • 1.5 mm

(0.06 in)

Front wheel

Type Panel wheel • • •

Rim size 10 × 5.5 AT • • •

Rim material Aluminum • • •

Rim runout limit radial • • • 2.0 mm

(0.08 in)

lateral • • • 2.0 mm

(0.08 in)

Rear wheel

Type Panel wheel • • •

Rim size 9 × 8.5 AT • • •

Rim material Aluminum • • •

Rim runout limit radial • • • 2.0 mm

(0.08 in)

lateral • • • 2.0 mm

(0.08 in)

Drive chain

Type/manufacturer 520V/DAIDO • • •

Link quantity 91 • • •

Drive chain slack 45.0 ~ 55.0 mm (1.77 ~ 2.17 in) • • •

Maximum 15-links section 239.3 mm (9.42 in) • • •

CHASSIS SPECIFICATIONS

SPEC

2-12

Item Standard Limit

Front disc brake

Type Dual • • •

Disc outside diameter × thickness 161.0 × 3.5 mm (6.34 × 0.14 in) 3.0 mm

(0.12 in)

Brake disk maximum deflection 0.15 mm

(0.006 in)

Pad thickness inner 4.4 mm (0.17 in) 1.5 mm

(0.06 in)

Pad thickness outer 4.5 mm (0.18 in) 1.5 mm

(0.06 in)

Master cylinder inside diameter 12.7 mm (0.50 in) • • •

Caliper cylinder inside diameter 27 mm (1.06 in) • • •

Brake fluid type DOT 4 • • •

Rear disc brake

Type Single • • •

Disc outside diameter × thickness 200.0 × 4.0 mm (7.87 × 0.16 in) 3.5 mm

(0.14 in)

Brake disk maximum deflection 0.15 mm

(0.006 in)

Pad thickness inner 4.2 mm (0.17 in) 1.0 mm

(0.04 in)

Pad thickness outer 4.2 mm (0.17 in) 1.0 mm

(0.04 in)

Master cylinder inside diameter 12.7 mm (0.50 in) • • •

Caliper cylinder inside diameter 33.96 mm (1.34 in) • • •

Brake fluid type DOT 4 • • •

Lever and pedal

Brake lever free play 0 mm (0 in) • • •

Brake pedal position (top of the brake

pedal to top of the frame) 40.0 mm (1.57 in) • • •

Parking brake cable end length 64 ~ 68 mm (2.52 ~ 2.68 in) • • •

Clutch lever free play (lever end) 5 ~ 10 mm (0.20 ~ 0.39 in) • • •

Throttle lever free play 2 ~ 4 mm (0.08 ~ 0.16 in) • • •

Speed limiter length Less than 12 mm (0.47 in) • • •

Shift pedal height 15.2 mm (0.60 in) • • •

CHASSIS SPECIFICATIONS

SPEC

2-13

EBS01004

ELECTRICAL SPECIFICATIONS

Item Standard Limit

Voltage 12 V • • •

Ignition system

Ignition timing (B.T.D.C.) 10.0°/1,550 r/min • • •

Advanced timing (B.T.D.C.) 24.4°/5,000 r/min

Advancer type Digital type • • •

CDI

CDI unit model/manufacturer 4D3/YAMAHA • • •

Pickup coil resistance/color 248 ~ 372 Ω at 20°C (68°F) red–white • • •

Ignition coil

Model/manufacturer 2JN/YAMAHA • • •

Minimum ignition spark gap 6.0 mm (0.24 in) • • •

Primary winding resistance 0.18 ~ 0.28 Ω at 20°C (68°F) • • •

Secondary winding resistance 6.32 ~ 9.48 kΩ at 20°C (68°F) • • •

Spark plug cap

Material Resin

Resistance 10.0 kΩ

Charging system

Type AC magneto • • •

Model/manufacturer F5XT/YAMAHA • • •

Nominal output 14 V 190 W at 5,000 r/min • • •

Charging coil resistance/color 0.688 ~ 1.032 Ω at 20°C (68°F)

white–white • • •

Rectifier/regulator

Type Semi conductor-short circuit • • •

Model/manufacturer SH640E-11/SHINDENGEN • • •

No load regulated voltage (DC) 14.1 ~ 14.9 V • • •

Rectifier capacity (DC) 14.0 A • • •

Withstand voltage 200.0 V

Battery

Specific gravity 1.310

Electric starter system

Type Constant mesh type • • •

Starter motor

Model/manufacturer 4D3/YAMAHA • • •

Output 0.40 kW • • •

Armature coil resistance 0.013 ~ 0.015 Ω at 20°C (68°F) • • •

Brush overall length 10.0 mm (0.39 in) 3.5 mm

(0.14 in)

Spring force 5.52 ~ 8.28 N

(563 ~ 844 gf, 19.85 ~ 29.78 oz) • • •

Commutator diameter 22.0 mm (0.87 in) 21.0 mm

(0.83 in)

Mica undercut 1.5 mm (0.06 in) • • •

ELECTRICAL SPECIFICATIONS

SPEC

2-14

Item Standard Limit

Starter relay

Model/manufacturer A4616-051/JIDECO • • •

Amperage rating 180 A • • •

Coil winding resistance 4.18 ~ 4.62 Ω• • •

Headlight relay

Model/manufacturer G8HN-1C4T-DJ-Y52/OMRON • • •

Coil resistance 94.5 Ω ~ 115.5 Ω• • •

Circuit breaker

Type Fuse • • •

Amperage for individual circuit

Fuse 15 A × 1•

• •

Reserve 15 A × 1•

• •

ELECTRICAL SPECIFICATIONS

SPEC

2-15

EBS01005

TIGHTENING TORQUES

ENGINE TIGHTENING TORQUES

Part to be tightened Part

name Thread

size Q’ty Tightening torque Remarks

Nm m•kg ft•lb

Cylinder head (upper) Bolt M8 4 24 2.4 18

See NOTE *1

Cylinder head Bolt M8 2 20 2.0 15

Camshaft lock plate Bolt M6 2 8 0.8 5.9

Cylinder head side cover (1 and 2) Bolt M55 2 18 1.8 13

Cylinder head side cover 3 Bolt M6 2 10 1.0 7.4

Cylinder head breather plate Bolt M6 2 10 1.0 7.4

Spark plug — M12 1 18 1.8 13

Cylinder head stud bolt Stud bolt M8 2 15 1.5 11

Oil gallery bolt Bolt M6 1 7 0.7 5.2

Carburetor joint Bolt M6 2 10 1.0 7.4

Plate, 2 Bolt M6 2 12 1.2 8.9

Cylinder Bolt M6 2 10 1.0 7.4

Left crankcase cover Bolt M6 9 10 1.0 7.4

Pickup coil rotor Bolt M10 1 60 6.0 44

Balancer weight gear Nut M12 1 55 5.5 41 Use a lock

washer.

Valve clearance adjusting locknut Nut M6 2 14 1.4 10

Camshaft sprocket Bolt M10 1 60 6.0 44

Timing chain tensioner Bolt M6 2 10 1.0 7.4

Timing chain tensioner cap bolt Bolt M6 1 8 0.8 5.9

Timing chain guide (intake side) Bolt M6 2 8 0.8 5.9

Oil filter element cover Bolt M6 3 10 1.0 7.4

Oil delivery pipe Union

bolt M10 1 20 2.0 15

Oil delivery pipe and cylinder Union

bolt M8 1 17 1.7 13

Oil pump assembly Screw M6 3 6 0.6 4.4

Carburetor joint clamp screw (front) Screw M4 2 4 0.4 3.0

Carburetor joint clamp screw (rear) Screw M4 1 4 0.4 3.0

Exhaust pipe nut Nut M8 2 18 1.8 13

Muffler joint Bolt M8 1 20 2.0 15

Muffler Bolt M8 2 34 3.4 25

Left crankcase cover Bolt M5 1 7 0.7 5.2

Right crankcase cover Bolt M6 13 10 1.0 7.4

Crankcase Bolt M6 12 10 1.0 7.4

Oil drain bolt Bolt M12 1 20 2.0 15

Ground lead, clutch cable holder Bolt M6 1 10 1.0 7.4

Neutral switch lead clamp Bolt M6 1 10 1.0 7.4

Starter idle gear cover Bolt M6 3 10 1.0 7.4

Starter clutch Bolt M8 3 30 3.0 22

Primary drive gear nut Nut M16 1 80 8.0 59 Use a lock

washer.

TIGHTENING TORQUES

SPEC

2-16

TE:

*1: Apply oil to the bearing surface of (upper) cylinder head bolt.

Further, apply molybdenum disulfide grease to thread part.

Part to be tightened Part

name Thread

size Q’ty Tightening torque Remarks

Nm m•kg ft•lb

Clutch boss nut Nut M16 1 75 7.5 55 Use a lock

washer.

Clutch spring Screw M6 5 8 0.8 5.9

Push lever adjusting screw locknut Nut M6 1 8 0.8 5.9

Push lever shaft Bolt M8 1 12 1.2 8.9

Chain case cover Bolt M10 2 10 1.0 7.4

Drive sprocket nut Nut M18 1 110 11.0 81 Use a lock

washer.

Stopper lever Bolt M6 1 10 1.0 7.4

Shift pedal Bolt M6 1 10 1.0 7.4

Neutral switch — M10 1 20 2.0 15

Starter motor Bolt M6 2 10 1.0 7.4

Stator coil Bolt M6 3 10 1.0 7.4

Pickup coil Bolt M6 2 10 1.0 7.4

TIGHTENING TORQUES

SPEC

2-17

EBS01006

CHASSIS TIGHTENING TORQUES

Part to be tightened Thread size Tightening torque Remarks

Nm m•kg ft•lb

Engine upper stay and frame M8 33 3.3 24

Engine upper stay and engine M10 66 6.6 49

Engine lower stay and engine M10 40 4.0 30

Engine and frame M10 66 6.6 49

Engine lower stay and frame M8 33 3.3 24

Swingarm pivot shaft and frame M14 100 10 74

Rear shock absorber and frame M12 55 5.5 41

Rear shock absorber locknut M20 42 4.2 31

Rear axle pinch bolt M8 21 2.1 15

Front shock absorber and frame M10 48 4.8 35

Front shock absorber and lower front arm M10 48 4.8 35

Upper front arm and frame M10 45 4.5 33

Lower front arm and frame M10 45 4.5 33

Steering stem and frame M10 35 3.5 26

Steering stem bushing and frame M8 23 2.3 17 Use a lock

washer.

Steering stem and handlebar holder M8 20 2.0 15

Tie-rod end and locknut M10 15 1.5 11

Steering knuckle and front wheel hub M14 70 7.0 52

Steering knuckle and front arm (upper and

lower) M10 25 2.5 18

Steering knuckle and tie-rod ball joint M10 25 2.5 18

Steering stem and tie-rod ball joint M10 25 2.5 18

Fuel tank and fuel cock M6 4 0.4 3.0

Fuel tank and frame M6 7 0.7 5.2

Front wheel and front wheel hub M10 45 4.5 33

Steering knuckle and front brake caliper bracket M8 28 2.8 21

Front brake disc and front wheel hub M8 28 2.8 21

Rear axle and rear wheel hub M14 120 12 89

Rear brake caliper and brake caliper bracket M8 34 3.4 25

Rear wheel and rear wheel hub M10 45 4.5 33

Driven sprocket and sprocket bracket M10 55 5.5 41

Front brake pipe nut M10 19 1.9 14

Front brake master cylinder and handlebar M6 7 0.7 5.2

Clutch lever holder and handlebar M5 4 0.4 3.0

Parking brake assembly and clutch lever holder M6 7 0.7 5.2

TIGHTENING TORQUES

SPEC

2-18

Part to be tightened Thread size Tightening torque Remarks

Nm m•kg ft•lb

Front brake master cylinder and brake lever M6 6 0.6 4.4

Throttle assembly and handlebar M5 4 0.4 3.0

Front brake master cylinder and brake hose M10 27 2.7 20

Brake hose joint and frame M6 10 1.0 7.4

Bleed screw M8 5 0.5 3.7

Front brake pad retaining bolt M10 17 1.7 13

Front brake caliper and brake hose M10 27 2.7 20

Rear brake caliper retaining bolt M8 17 1.7 13

Parking brake case and caliper M8 22 2.2 16

Rear axle ring nut M33 140 14 103

Rear axle ring nut set bolt M6 7 0.7 5.2

Rear brake pad retaining bolt M8 17 1.7 13 Use a lock

washer.

Rear brake caliper and brake hose M10 31 3.1 23

Rear brake master cylinder and frame M8 20 2.0 15

Rear brake master cylinder and brake hose M10 31 3.1 23

Parking brake adjusting bolt and locknut M8 15 1.5 11

Rear brake disc and brake disc bracket M8 28 2.8 21

Rear brake fluid reservoir, cover and bracket M6 7 0.7 5.2

Front bumper and frame M8 31 3.1 23

Front fender stay and frame M6 7 0.7 5.2

Side cover and frame M6 7 0.7 5.2

Rear fender and frame M6 7 0.7 5.2

Rear fender, air filter case and frame M6 7 0.7 5.2

Rear fender and rear fender stay M6 7 0.7 5.2

Front fender stay and front fender M6 7 0.7 5.2

Rear carrier bar and frame M8 31 3.1 23

Footrest and frame M10 73 7.3 54

Foot protector stay foot protector M6 7 0.7 5.2

Foot protector stay foot protector M5 6 0.6 4.4

Foot protector stay and frame M8 17 1.7 13

Foot protector stay and footrest M8 17 1.7 13

Battery cover, air filter case and frame M6 7 0.7 5.2

Headlight and frame M6 7 0.7 5.2

Tail/brake light bracket and air filter case M6 4 0.4 3.0

Drive chain guide roller and frame M8 23 2.3 17

Engine skid plate and frame M6 7 0.7 5.2

TIGHTENING TORQUES

SPEC

2-19

EBS00022

HOW TO USE THE CONVERSION

TABLE

All specification data in this manual are listed

in SI and METRIC UNITS.

Use this table to convert METRIC unit data to

IMPERIAL unit data.

Ex.

CONVERSION TABLE

EBS00023

GENERAL TIGHTENING TORQUE

SPECIFICATIONS

This chart specifies tightening torques for

standard fasteners with a standard ISO thread

pitch. Tightening torque specifications for spe-

cial components or assemblies are provided

for each chapter of this manual. To avoid

warpage, tighten multi-fastener assemblies in

a crisscross pattern and progressive stages

until the specified tightening torque is reached.

Unless otherwise specified, tightening torque

specifications require clean, dry threads. Com-

ponents should be at room temperature.

A: Distance between flats

B: Outside thread diameter

METRIC MULTIPLIER IMPERIAL

** mm ×0.03937 = ** in

2 mm ×0.03937 = 0.08 in

METRIC TO IMPERIAL

Metric unit Multiplier Imperial unit

Torque

m•kg

cm•kg

7.233

86.794

0.0723

0.8679

ft•lb

in•lb

ft•lb

in•lb

Weight kg

g2.205

0.03527 lb

Speed km/hr 0.6214 mph

Distance

0.6214

3.281

1.094

0.3937

0.03937

Volume /

Capacity

cc (cm3)

lt (liter)

0.03527

0.06102

0.8799

0.2199

oz (IMP liq.)

cu•in

qt (IMP liq.)

gal (IMP liq.)

Misc.

kg/mm

kg/cm2

Centigrade

(°C)

55.997

14.2234

9/5+32

lb/in

psi (lb/in2)

Fahrenheit

(°F)

(nut) B

(bolt)

General tightening

torques

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 3.0 22

17 mm 12 mm 55 5.5 40

19 mm 14 mm 85 8.5 61

22 mm 16 mm 130 13.0 94

HOW TO USE THE CONVERSION TABLE/

GENERAL TIGHTENING TORQUE SPECIFICATIONS

SPEC

2-20

EBS00024

LUBRICATION POINTS AND LUBRICANT TYPES

ENGINE

Lubrication point Lubricant

Oil seal lips

O-rings

Bearings

Cylinder head bolts (bearing surface of bolts)

Cylinder head bolts (thread part)

Cylinder body surface

Crankshaft journals

Connecting rod small end and big end

Piston pin

Piston surface

Boss periphery

Valve stems (intake and exhaust)

Valve stem ends (intake and exhaust)

Rocker arm shafts (intake and exhaust)

Camshaft

Valve rocker arms

Oil pump rotors (inner and outer) and oil pump housing and shaft

Starter idler gears 1

Starter idler gears 2

Starter wheel gear

Push rods

Clutch housing (primary driven gear)

Push lever shaft

Push rod ball

Drive axle

Main axle

Transmission gears (inside and end)

Shift fork guide bar

Shift drum

Shift shaft

LUBRICATION POINTS AND LUBRICANT TYPES

SPEC

2-21

Lubrication point Lubricant

Crankcase mating surfaces

Sealant

(Three Bond No.1215®)

Yamaha bond

No.1215

AC magneto lead grommet (AC magneto cover)

Sealant

(Three Bond No.1215®)

Yamaha bond

No.1215

LUBRICATION POINTS AND LUBRICANT TYPES

SPEC

2-22

EBS00026

OIL FLOW DIAGRAMS

Camshaft

Oil filter element

Oil pump

Oil strainer

Oil cooler

Drive axle Main axle

Pin,

with hole

Crank

shaft

Oil pump

Oil strainer

Cylinder

head

Cam shaft

Oil pan

Oil filter

OIL FLOW DIAGRAMS

SPEC

2-23

Camshaft

Drive axle

Main axle

Push lever shaft

Oil pump assembly

Oil strainer

Crankshaft assembly

Oil filter element

OIL FLOW DIAGRAMS

SPEC

2-24

Oil cooler

Oil hose 1

Oil hose 2

OIL FLOW DIAGRAMS

SPEC

2-25

EBS00028

CABLE ROUTING

Front brake hose

Front brake light switch lead

Throttle cable

Plastic band

Clutch cable

Parking brake cable

Clutch switch lead

Handlebar switch lead

CABLE ROUTING

SPEC

2-26

Clamp the front brake light switch lead at the

bends of handlebar.

Route the front brake hose and throttle cable

through the guide of the handlebar protector.

Route the throttle cable under the front brake

hose.

Route the clutch cable and parking brake cable

through the guide of the handlebar protector.

Route the clutch cable in front of the parking brake

cable.

Clamp the clutch switch lead and handlebar switch

lead at the bends of handlebar.

CABLE ROUTING

SPEC

2-27

Indicator light lead

Main switch lead

Coupler joint

Front brake light switch lead

Front brake hose 2

Oil cooler hose 1, 2

Exhaust pipe

Engine bracket

Rear brake light switch lead

Parking brake cable

Battery negative lead

Carburetor warmer lead

Air vent hose

Air filter case breather hose

Throttle cable

Front brake hose 1

Clutch cable

Main harness

Clamp

Frame complete

Rear brake reservoir hose

Carburetor overflow hose

Neutral switch lead

Rear brake reservoir cover

H-H

A-A

CABLE ROUTING

SPEC

2-28

To the front panel

To the front fender

To the handlebar

To the right headlight

Make sure to route the oil cooler hoses 1and 2

through the guide wire.

Install the front brake hose 2, making sure to face

the white paint mark forward.

Route the oil cooler hose 1 and 2 between the

exhaust pipe and the engine bracket.

Route the battery negative lead behind the clutch

cable holder.

Route the air vent hose through the bracket.

Make sure that the white paint mark on the air filter

case breather hose

Make sure that the clip end is facing the left side of

the vehicle.

Route the throttle cable under the cross pipe and

left of the steering column as shown in the illustra-

tion.

CABLE ROUTING

H-H

A-A

SPEC

2-29

Route the parking brake cable and the clutch cable

under the cross pipe and right of the steering col-

umn as shown in the illustration.

Route the rear brake light switch lead, neutral

switch lead, air vent hose, carburetor overflow

hose and parking brake cable through the bracket.

Route the rear brake light switch lead under the

bracket.

Route the rear brake light switch lead between the

bracket and rear brake reservoir tank.

Route the neutral switch lead and rear brake light

switch lead as shown in the illustration.

H-H

A-A

CABLE ROUTING

SPEC

2-30

Rear brake reservoir

Rear brake light switch

Clip

Rear brake reservoir hose

Rear brake master cylinder

Parking brake cable

Rear brake hose

Rear brake caliper

D-D C-C

CABLE ROUTING

SPEC

2-31

Make sure that the end of the clip is facing down-

ward.

Set the rear brake reservoir hose with the position-

ing yellow paint mark pointing down.

Install the rear brake hose in the direction shown in

the illustration.

Insert the rear brake hose until it contacts the pro-

jection.

Make sure that the end of the clip is facing out-

ward.

Install the rear brake reservoir hose, making sure

to face the white paint mark outward.

Insert the rear brake reservoir hose until it contacts

the projection.

When installing the rear brake hose, make sure

that the metal part on the rear brake Inlet hose is

touching the stopper of the rear caliper.

D-D C-C

CABLE ROUTING

SPEC

2-32

Clutch switch lead

Handlebar switch lead

Bolt

Main harness

Air vent hose

Clamp

Battery negative lead

AC magneto lead

Carburetor overflow hose

Starter motor lead

Neutral switch lead

Ignition coil spark plug lead

Ignition coil

Drain hose

Frame complete

Damper plate

Seat pad

Cover

Rear brake light switch lead

Carburetor warmer lead

Air filter case breather hose

Air filter joint

Air filter case

L-L M-M

E-E

B-B

C-C

D-D

G-G

N-N

I-I

CABLE ROUTING

SPEC

2-33

To the front fender

Route the wire harness above the guide for the

damper plate.

Fix point for wire harness

Clamp near the hook of the air filter.

Clamp near the edge of the air filter case.

Route the drain hose in front of the left oil cooler

hose.

Clamp on top of the frame bracket.

To the left headlight

Route the clamp through the damper plate hole.

Route the carburetor overflow hose as shown in

the illustration.

Fasten the clamp with the engine.

Route the leads on the upper inside of the cover.

Place the couplers on the inside of the cover.

Route the clamp through the frame bracket.

L-L M-M

E-E

B-B

C-C

D-D

G-G

N-N

I-I

CABLE ROUTING

SPEC

2-34

Indicator light

Coupler joint

Main switch lead

Front brake light switch lead

Throttle cable

Regulator

Flange bolt

Headlight lead

Indicator light lead

Clutch cable

Parking brake cable

Rear brake reservoir

Rear brake light switch lead

Air vent hose

Battery negative lead

Carburetor warmer lead

Starter motor lead

Clutch switch lead

Handlebar switch lead

Main harness

Frame complete

Clamp

J-J

K-K

CABLE ROUTING

SPEC

2-35

Install the indicator light as shown in the illustra-

tion.

Place the coupler joint above the front fender.

Route the front brake light switch lead and throttle

cable through the guide.

Connect the main switch lead on top of the front

fender.

Route both leads from the front.

Route the headlight lead under the frame.

To the front fender

To the front panel

To the handlebar

Route the air vent hose through the bracket.

Route the battery negative lead behind the clutch

cable holder.

Fix point for wire harness

Insert the air vent hose into the fender.

Route the clutch switch lead and handlebar switch

lead on the box shaped part.

Connect the clutch switch lead and handlebar

switch lead on top of the front fender.

Route the wire harness from the front.

J-J

K-K

CABLE ROUTING

SPEC

2-36

Route the cables and leads through the guide of

the front fender.

Route the leads behind the clutch and parking

brake cable.

CABLE ROUTING

J-J

K-K

SPEC

2-37

CDI unit

Band

Battery

Starter relay lead

Starter relay

Taillight lead

Battery negative lead

AC magneto coupler

Starter motor lead

Headlight relay

Neutral relay

Damper

CDI unit lead

Relay lead

CABLE ROUTING

A-A

SPEC

2-38

Route the starter relay lead under the starter

motor lead.

Clamp the taillight lead.

Do not clamp.

When clamping the wire harness, make sure that

the insulator lock is behind the clamp.

After connecting the battery negative lead, push

the sag in the box.

After connecting the taillight lead and each electric

part, the length between the air filter and AC mag-

neto coupler should be 185 mm (7.28 in) on

straight line.

There is no particular order in placing each lead.

Insert each relay all the way into the rib on the air

filter side.

Insert the starter relay all the way into the rib on

the air filter side.

A-A

CABLE ROUTING

CHK

ADJ

3-1

EBS00029 PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION

This chapter includes all information necessary to perform recommended checks and adjustments.

These preventive maintenance procedures, if followed, will ensure more reliable machine operation

and a longer service life. The need for costly overhaul work will be greatly reduced. This information

applies to machines already in service as well as to new machines that are being prepared for sale.

All service technicians should be familiar with this entire chapter.

PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL

SYSTEM

TE:

• For ATVs not equipped with an odometer or an hour meter, follow the month maintenance inter-

vals.

• For ATVs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance

intervals. However, keep in mind that if the ATV isn’t used for a long period of time, the month main-

tenance intervals should be followed.

• Items marked with an asterisk should be performed by a Yamaha dealer as they require special

tools, data and technical skills.

NO. ITEM CHECK OR MAINTENANCE

JOB

Whichever

comes

first

INITIAL EVERY

month136612

(mi)

320

(200)

1300

(800)

2500

(1600)

2500

(1600)

5000

(3200)

hours 20 80 160 160 320

1 * Fuel line • Check fuel hoses for cracks or other damage, and replace

if necessary. √√√

2 Spark plug • Check condition and clean, regap, or replace if necessary. √√√√√

3 * Valves • Check valve clearance and adjust if necessary. √√√√

4 * Carburetor • Check starter (choke) operation and correct if necessary.

• Check engine idling speed and adjust if necessary. √√√√

Crankcase breather

system

• Check breather hose for cracks or other damage, and

replace if necessary. √√√

6 * Exhaust system

• Check for leakage and replace gasket(s) if necessary.

• Check for looseness and tighten all screw clamps and

joints if necessary.

√√√

7 Spark arrester • Clean. √√√

INTRODUCTION/PERIODIC MAINTENANCE

CHART FOR THE EMISSION CONTROL SYSTEM

CHK

ADJ

3-2

GENERAL MAINTENANCE AND LUBRICATION CHART

NO. ITEM CHECK OR MAINTENANCE

JOB

Whichever

comes

first

INITIAL EVERY

month136612

(mi)

320

(200)

1300

(800)

2500

(1600)

2500

(1600)

5000

(3200)

hours 20 80 160 160 320

1 Air filter element • Clean and replace if necessary. Every 20 ~ 40 hours (more often in wet or dusty

areas)

2*Clutch • Check operation and adjust if necessary. √√√√

3 * Front brake

• Check operation and correct if necessary.

• Check fluid level and ATV for fluid leakage, and correct if

necessary.

√√√√√

• Replace brake pads. Whenever worn to the limit

4 * Rear brake

• Check operation and correct if necessary.

• Check fluid level and ATV for fluid leakage, and correct if

necessary.

√√√√√

• Replace brake pads. Whenever worn to the limit

5 * Brake hoses

• Check for cracks or other damage, and replace if neces-

sary. √√√√

• Replace. Every 4 years

6 * Parking brake • Check operation and adjust if necessary. √√√√√

7 * Wheels • Check runout and for damage, and replace if necessary. √√√√

8*Tires

• Check tread depth and for damage, and replace if neces-

sary.

• Check air pressure and balance, and correct if necessary.

√√√√

9 * Wheel hub bearings • Check for looseness or damage, and replace if necessary. √√√√

10 * Swingarm pivots

• Check operation and for excessive play, and replace bear-

ings if necessary.

• Lubricate with lithium-soap-based grease.

√√√

11 * Upper and lower arm

pivots • Lubricate with lithium-soap-based grease. √√√

12 Drive chain

• Check chain slack and adjust if necessary.

• Check rear wheel alignment and correct if necessary.

• Clean and lubricate.

√√√√√

13 * Drive chain rollers • Check for wear and replace if necessary. √√√

14 * Chassis fasteners • Make sure that all nuts, bolts, and screws are properly

tightened. √√√√√

15 * Shock absorber assem-

blies

• Check operation and correct if necessary.

• Check for oil leakage and replace if necessary. √√√

16 *

Rear suspension relay

arm and connecting

arm pivoting points

• Check operation and correct if necessary.

• Lubricate with lithium-soap-based grease. √√√√

17 * Steering shaft • Lubricate with lithium-soap-based grease. √√√

18 * Steering system • Check operation and repair or replace if damaged.

• Check toe-in and adjust if necessary. √√√√√

19 * Engine mount • Check for cracks or other damage, and replace if neces-

sary. √√√

20 Engine oil • Change.

• Check ATV for oil leakage, and correct if necessary. √√√√

21 Engine oil filter element • Clean or replace if necessary. √√√

22 * Moving parts and

cables • Lubricate. √√√√

23 * Throttle lever housing

and cable

• Check operation and correct if necessary.

• Check throttle cable free play and adjust if necessary.

• Lubricate throttle lever housing and cable.

√√√√√

24 * Front and rear brake

switches • Check operation and correct if necessary. √√√√√

25 * Lights and switches • Check operation and correct if necessary.

• Adjust headlight beams. √√√√√

GENERAL MAINTENANCE AND LUBRICATION CHART

CHK

ADJ

3-3

TE:

• The air filter needs more frequent service if you are riding in unusually wet or dusty areas.

• Hydraulic brake service

• Regularly check and, if necessary, correct the brake fluid level.

• Every two years replace the internal components of the brake master cylinders and calipers, and

change the brake fluid.

• Replace the brake hoses every four years and if cracked or damaged.

WARNING

Indicates a potential hazard that could result in serious injury or death.

GENERAL MAINTENANCE AND LUBRICATION CHART

CHK

ADJ

3-4

EBS00033

SEAT, FENDERS AND FUEL TANK

SEAT, FRONT FENDER AND HEADLIGHTS

Order Job/Part Q’ty Remarks

Removing the seat, front fender and

headlights Remove the parts in the order listed.

1 Seat 1 N

TE:N

TE:

Pull back the seat lock lever, than pull up

on the rear of the seat.

2 Indicator light coupler 1 Disconnect.

3 Front panel 1

4Plate 1

5 Main switch coupler 1 Disconnect.

6 Front fender 1

7 Headlight coupler 2 Disconnect.

8 Left headlight 1

9 Right headlight 1

For installation, reverse the removal

procedure.

7 Nm (0.7 m•kg, 5.2 ft•Ib)

7 Nm (0.7 m•kg, 5.2 ft•Ib) 7 Nm (0.7 m•kg, 5.2 ft•Ib) 7 Nm (0.7 m•kg, 5.2 ft•Ib)

SEAT, FENDERS AND FUEL TANK

CHK

ADJ

3-5

EBS00034

FOOT PROTECTORS AND ENGINE SKID PLATE

Order Job/Part Q’ty Remarks

Removing the foot protectors and

engine skid plate Remove the parts in the order listed.

1 Left foot protector 1

2 Right foot protector 1

3 Engine skid plate 1

For installation, reverse the removal

procedure.

17 Nm (1.7 m•kg, 13 ft•Ib)

7 Nm (0.7 m•kg, 5.2 ft•Ib)

17 Nm (1.7 m•kg, 13 ft•Ib) 17 Nm (1.7 m•kg, 13 ft•Ib)

17 Nm (1.7 m•kg, 13 ft•Ib)

SEAT, FENDERS AND FUEL TANK

CHK

ADJ

3-6

REAR FENDER AND AIR FILLTER CASE

Order Job/Part Q’ty Remarks

Removing the rear fender and air

fillter case Remove the parts in the order listed.

Seat/front fender Refer to “SEAT, FENDERS AND FUEL

TANK”.

1 Rear fender 1

2 Battery cover 1

3 Battery lead 2 CAUTION:

First disconnect the negative lead,

then disconnect the positive lead.

4 Battery 1

5Relay 2

6 CDI unit 1

7 Tail/brake light lead 1 Disconnect.

8 Air filter case breather hose 1 Disconnect.

9 Clamp 1 Loosen.

7 Nm (0.7 m•kg, 5.2 ft•Ib) 7 Nm (0.7 m•kg, 5.2 ft•Ib)

7 Nm (0.7 m•kg, 5.2 ft•Ib)

SEAT, FENDERS AND FUEL TANK

CHK

ADJ

3-7

Order Job/Part Q’ty Remarks

10 Air filter case 1

For installation, reverse the removal

procedure.

7 Nm (0.7 m•kg, 5.2 ft•Ib) 7 Nm (0.7 m•kg, 5.2 ft•Ib)

7 Nm (0.7 m•kg, 5.2 ft•Ib)

SEAT, FENDERS AND FUEL TANK

CHK

ADJ

3-8

EBS00042

FUEL TANK

Order Job/Part Q’ty Remarks

Removing the fuel tank Remove the parts in the order listed.

Seat/front fender Refer to “SEAT, FENDERS AND FUEL

TANK”.

1 Fuel hose (fuel cock side) 1 N

TE:N

TE:

Before disconnecting the fuel hose, turn

the fuel cock to “OFF”.

2 Fuel tank 1 N

TE:N

TE:

When installing the fuel tank, pass the fuel

tank breather hose through the hole in the

handlebar protector.

3Clamp 1

4 Fuel tank shield 1

For installation, reverse the removal

procedure.

7 Nm (0.7 m•kg, 5.2 ft•Ib)

SEAT, FENDERS AND FUEL TANK

CHK

ADJ

3-9

EAS00048

ENGINE

ADJUSTING THE VALVE CLEARANCE

The following procedure applies to all of the

valves.

TE:N

TE:

• Valve clearance adjustment should be made

on a cold engine, at room temperature.

• When the valve clearance is to be measured

or adjusted, the piston must be at the Top

Dead Center (TDC) on the compression

stroke.

1. Remove:

• seat

• front fender

• fuel tank

Refer to “SEAT, FENDERS AND FUEL

TANK”.

2. Remove:

• spark plug cap

• spark plug

• cylinder head side cover 1

• cylinder head side cover 2

3. Remove:

• timing mark accessing screw

• crankshaft end accessing screw

4. Measure:

• valve clearance

Out of specification → Adjust.

Valve clearance (cold)

Intake valve

0.05 ~ 0.10 mm

(0.0020 ~ 0.0039 in)

Exhaust valve

0.10 ~ 0.15 mm

(0.0039 ~ 0.0059 in)

ADJUSTING THE VALVE CLEARANCE

CHK

ADJ

3-10

a. Turn the crankshaft counterclockwise.

b. When the piston is at the Top Dead Center

(TDC) on the compression stroke, align the

“I” mark on the AC magneto rotor with

the stationary pointer on the crankcase

cover.

TE:N

TE:

Top dead center (TDC) is a point where the

mark on the AC magneto rotor and the pointer

on the crankcase cover match, plus at the

same time, the punch mark in the camshaft

sprocket and the pointer on the cylinder head

match.

c. Measure the valve clearance with a thick-

ness gauge .

Out of specification → Adjust.

5. Adjust:

• valve clearance

a. Loosen the locknut .

b. Insert a thickness gauge between the end

of the adjusting screw and the valve stem.

c. Turn the adjusting screw until the speci-

fied valve clearance is obtained.

• Hold the adjusting screw to prevent it from

moving and tighten the locknut to specifica-

tion.

Thickness gauge

90890-03079

Narrow gauge set

YM-34483

Tappet adjusting tool

90890-01311

Six piece tappet set

YM-A5970

14 Nm (1.4 m•kg, 10 ft•lb)

ADJUSTING THE VALVE CLEARANCE

CHK

ADJ

3-11

d. Measure the valve clearance again.

e. If the valve clearance is still out of specifica-

tion, repeat all of the valve clearance

adjustment steps until the specified clear-

ance is obtained.

6. Install:

• all removed parts

TE:N

TE:

For installation, reverse the removal proce-

dure.

EBS00051

ADJUSTING THE ENGINE IDLING SPEED

1. Start the engine and let it warm up for sev-

eral minutes.

2. Attach:

• digital tachometer

(onto the ignition coil spark plug lead)

3. Measure:

• engine idling speed

Out of specification → Adjust.

Digital tachometer

90890-06760, YU-39951-B

Engine idling speed

1,500 ~ 1,600 r/min

ADJUSTING THE VALVE CLEARANCE/

ADJUSTING THE ENGINE IDLING SPEED

CHK

ADJ

3-12

4. Adjust:

• engine idling speed

a. Turn the throttle stop screw in direction

or until the specified idling speed is

obtained.

5. Remove:

• fuel tank

TE:N

TE:

Slide the fuel tank.

6. Detach:

• digital tachometer

7. Adjust:

• throttle lever free play

Refer to “ADJUSTING THE THROTTLE

LEVER FREE PLAY”.

EBS00052

ADJUSTING THE THROTTLE LEVER FREE

PLAY

TE:N

TE:

Engine idling speed should be adjusted prop-

erly before adjusting the throttle lever free play.

1. Measure:

• throttle lever free play

Out of specification → Adjust.

ab Direction Idling speed becomes

higher.

Direction Idling speed becomes

lower.

Throttle lever free play

2 ~ 4 mm (0.08 ~ 0.16 in)

Throttle lever free play

2 ~ 4 mm (0.08 ~ 0.16 in)

ADJUSTING THE ENGINE IDLING SPEED/

ADJUSTING THE THROTTLE LEVER FREE PLAY

CHK

ADJ

3-13

2. Adjust:

• throttle lever free play

First step:

a. Slide back the rubber cover .

b. Loosen the locknut on the carburetor

side.

c. Turn the adjusting nut in direction or

until the correct free play is obtained.

d. Tighten the locknut.

e. Slide the rubber cover to its original posi-

tion.

TE:N

TE:

If the free play cannot be adjusted here, adjust

it at the throttle lever side of the cable.

Second step:

f. Slide back the rubber cover .

g. Loosen the locknut .

h. Turn the adjusting bolt in direction or

until the correct free play is obtained.

i. Tighten the locknut.

j. Slide the rubber cover to its original posi-

tion.

WARNING

After adjusting the free play, turn the han-

dlebar to the right and left to make sure

that the engine idling speed does not

increase.

EBS00053

ADJUSTING THE SPEED LIMITER

The speed limiter keeps the carburetor throttle

from becoming fully-opened even when the

throttle lever is applied to the maximum posi-

tion. Screwing in the adjusting screw stops the

engine speed from increasing.

Direction Free play is increased.

Direction Free play is decreased.

Direction Free play is increased.

Direction Free play is decreased.

ADJUSTING THE THROTTLE LEVER FREE PLAY/

ADJUSTING THE SPEED LIMITER

CHK

ADJ

3-14

1. Measure:

• Speed limiter length

Out of specification → Adjust.

2. Adjust:

• speed limiter length

a. Loosen the locknut .

b. Turn the adjusting screw in or out until

the specified speed limiter length is

obtained.

c. Tighten the locknut.

WARNING

• Particularly for a beginner rider, the speed

limiter should be screwed in completely.

Screw it out little by little as their riding

technique improves. Never remove the

speed limiter for a beginning rider.

• For proper throttle lever operation do not

turn out the adjusting screw more than 12

mm (0.47 in). Also, always adjust the throt-

tle lever free play to 2 ~ 4 mm (0.08 ~ 0.16

in).

1 2

Speed limiter length

Less than 12 mm (0.47 in)

Direction Speed limiter length is

decreased.

Direction Speed limiter length is

increased.

ADJUSTING THE SPEED LIMITER

CHK

ADJ

3-15

EBS00057

CHECKING THE SPARK PLUG

1. Disconnect:

• spark plug cap

2. Remove:

• spark plug

3. Check:

• spark plug type

Incorrect → Change.

4. Check:

• electrode

Wear/damage → Replace.

• insulator

Abnormal color → Replace.

Normal color is a medium-to-light tan color.

5. Clean:

• spark plug

(with a spark plug cleaner or wire brush)

6. Measure:

• spark plug gap

Use a wire gauge or thickness gauge.

Out of specification → Regap.

7. Install:

• spark plug

TE:N

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Before installing a spark plug, clean the gasket

surface and plug surface.

8. Install:

• spark plug cap

Standard spark plug

NGK/DR7EA

Spark plug gap

0.6 ~ 0.7 mm (0.024 ~ 0.028 in)

Spark plug

18 Nm (1.8 m•kg, 13 ft•lb)

CHECKING THE SPARK PLUG

CHK

ADJ

3-16

EBS00058

CHECKING THE IGNITION TIMING

TE:N

TE:

Engine idling speed and throttle cable free play

should be adjusted properly before checking

the ignition timing.

1. Attach:

• digital tachometer

• timing light

(onto the ignition coil spark plug lead)

2. Check:

• ignition timing

a. Warm up the engine and keep it at the

specified speed.

b. Remove the timing mark accessing screw

c. Visually check the stationary pointer to

verify it is within the required firing range

indicated on the AC magneto rotor.

Incorrect firing range → Check the pickup

coil assembly.

d. Install the timing mark accessing screw.

3. Detach:

• timing light

• digital tachometer

Digital tachometer

90890-06760, YU-39951-B

Timing light

90890-03141

Inductive clamp timing light

YU-03141

Engine speed

1,500 ~ 1,600 r/min

CHECKING THE IGNITION TIMING

CHK

ADJ

3-17

MEASURING THE COMPRESSION

PRESSURE

The following procedure applies to the cylinder.

TE:N

TE:

Insufficient compression pressure will result in

a loss of performance.

1. Measure:

• Valve clearance

Out of specification → Adjust.

Refer to “ADJUSTING THE VALVE CLEAR-

ANCE”

2. Start the engine, warm it up for several min-

utes, and then turn it off.

3. Disconnect:

• Spark plug cap

4. Remove:

• Spark plug

ECA13340

CAUTION:

Before removing the spark plug, use com-

pressed air to blow away any dirt accumu-

lated in the spark plug wells to prevent it

from falling into the cylinder.

5. Install:

• Compression gauge

• Extension

Compression gauge

90890-03081

Engine compression tester

YU-33223

Extension

90890-04082

MEASURING THE COMPRESSION PRESSURE

CHK

ADJ

3-18

6. Measure:

• Compression pressure

Out of specification → Refer to steps (c)

and (d).

a. Set the main switch to “ON”.

b. With the throttle wide open, crank the

engine until the reading on the compres-

sion gauge stabilizes.

WARNING

To prevent sparking, ground the spark plug

lead before cranking the engine.

c. If the compression pressure is above the

maximum specification, check the cylinder

head, valve surfaces and piston crown for

carbon deposits.

Carbon deposits → Eliminate.

d. If the compression pressure is below the

minimum specification, pour a teaspoonful

of engine oil into the spark plug bore and

measure again.

Refer to the following table.

Compression pressure (standard)

1,100 kPa/720 r/min

(11.2 kgf/cm2, 160 psi/720 r/min)

Compression pressure

(maximum)

1,300 kPa/720 r/min

(13.3 kgf/cm2, 189 psi/720 r/min)

Compression pressure (minimum)

900 kPa/720 r/min

(9.2 kgf/cm2, 131 psi /720 r/min)

Compression pressure

(with oil applied into the cylinder)

Reading Diagnosis

Higher than without

oil Piston ring(s) wear or

damage → Repair.

Same as without oil

Piston, valves, cylin-

der head gasket or

piston possibly

defective → Repair.

MEASURING THE COMPRESSION PRESSURE

CHK

ADJ

3-19

7. Install:

• Spark plug

8. Connect:

• Spark plug cap

EBS01101

CHECKING THE ENGINE OIL LEVEL

1. Place the machine on a level surface.

2. Start the engine, warm it up several min-

utes, and then turn it off.

3. Check:

• engine oil level

Oil level should be between the minimum

level mark and the maximum level mark

Low oil level → Add oil to the proper level.

TE:N

TE:

• Wait a few minutes until the oil settles before

checking the oil level.

• Do not screw the dipstick in when check-

ing the oil level.

CAUTION:

• Do not add any chemical additives.

Engine oil also lubricates the clutch and

additives could cause clutch slippage.

• Do not allow foreign material to enter the

crankcase.

Spark plug

18 Nm (1.8 m•kg, 13 ft•lb)

Recommended engine oil type

YAMALUBE 4, SAE 5W-30 or

SAE 10W-30 or SAE 20W-40

Recommended engine oil grade

API service SG type or higher

JASO standard MA

MEASURING THE COMPRESSION PRESSURE/

CHECKING THE ENGINE OIL LEVEL

CHK

ADJ

3-20

4. Start the engine, warm it up for several min-

utes, and then turn it off.

5. Check:

• engine oil level

TE:N

TE:

Before checking the engine oil level, wait a few

minutes until the oil has settled.

EBS00067

CHANGING THE ENGINE OIL

1. Place the machine on a level surface.

2. Start the engine, warm it up for several min-

utes, and then turn it off.

3. Place a container under the engine oil drain

bolt.

4. Remove:

• dipstick

• oil filter element drain bolt

5. Remove:

• engine oil drain bolt

(along with the washer)

6. Drain:

• engine oil

(completely from the crankcase)

7. If the oil filter element is also to be

replaced, perform the following procedure.

a. Remove the oil filter element cover and

oil filter element .

b. Install new O-rings .

c. Install the new oil filter element and the oil

filter element cover.

10 Nm (1.0 m•kg, 7.4 ft•lb)

CHECKING THE ENGINE OIL LEVEL/

CHANGING THE ENGINE OIL

CHK

ADJ

3-21

8. Install:

• engine oil drain bolt gasket

• engine oil drain bolt

• oil filter element drain bolt

9. Fill:

• crankcase

(with the specified amount of the recom-

mended engine oil)

10.Install:

• dipstick

11.Start the engine, warm it up for several min-

utes, and then turn it off.

12.Check:

• engine

(for engine oil leaks)

13.Check:

• engine oil level

Refer to “CHECKING THE ENGINE OIL

LEVEL”.

Engine oil drain bolt

20 Nm (2.0 m•kg, 15 ft•lb)

Oil filter element drain bolt

10 Nm (1.0 m•kg, 7.4 ft•lb)

Periodic oil replacement

1.25 L (1.10 Imp qt, 1.32 US qt)

With oil filter element replacement

1.35 L (1.19 Imp qt, 1.43 US qt)

Engine oil quantity

Total amount

1.60 L (1.41 Imp qt, 1.69 US qt)

CHANGING THE ENGINE OIL

CHK

ADJ

3-22

14.Check:

• engine oil pressure

a. Slightly loosen the oil gallery bolt .

b. Start the engine and keep it idling until

engine oil starts to seep from the oil gallery

bolt. If no engine oil comes out after one

minute, turn the engine off so that it will not

seize.

c. Check the engine oil passages, the oil filter

element and the oil pump for damage or

leakage. Refer to “OIL PUMP AND

BLANCER WEIGHT GEAR” in chapter 4.

d. Start the engine after solving the prob-

lem(s) and check the engine oil pressure

again.

e. Tighten the oil gallery bolt to specification.

EBS00070

ADJUSTING THE CLUTCH CABLE

1. Check:

• clutch lever free play

Out of specification → Adjust.

2. Adjust:

• clutch release lever free play

a. Slide back the lever cover .

b. Loosen the locknut .

c. Turn the adjusting bolt in direction or

until the specified clutch cable free play

is obtained.

d. Tighten the locknut.

e. Slide the rubber cover to its original posi-

tion.

7 Nm (0.7 m•kg, 5.2 ft•lb)

Clutch lever free play

(at the clutch lever end)

5 ~ 10 mm (0.20 ~ 0.39 in)

Direction Clutch cable free play is

increased.

Direction Clutch cable free play is

decreased.

CHANGING THE ENGINE OIL/

ADJUSTING THE CLUTCH CABLE

CHK

ADJ

3-23

EBS00073

CLEANING THE AIR FILTER ELEMENT

TE:N

TE:

There is a check hose at the bottom of the

air filter case. If dust and/or water collects in

this hose, clean the air filter element and air fil-

ter case.

1. Remove:

• seat

Refer to “SEAT, FENDERS AND FUEL

TANK”.

2. Remove:

• air filter case cover

3. Remove:

• wing bolt

• air filter element

• air filter element frame

CAUTION:

The engine should never be run without the

air filter; excessive piston and / or cylinder

wear may result.

4. Check:

• air filter element

Damage → Replace.

ADJUSTING THE CLUTCH CABLE/

CLEANING THE AIR FILTER ELEMENT

CHK

ADJ

3-24

5. Clean:

• air filter element

a. Wash the element gently, but thoroughly in

solvent.

WARNING

Use a cleaning solvent which is designed

to clean parts only. Never use gasoline or

low flash point solvents as they may cause

a fire or explosion.

b. Squeeze the excess solvent out of the ele-

ment and let it dry.

CAUTION:

Do not twist or wring out the element. This

could damage the foam material.

c. Apply Yamaha foam air filter oil or other

quality foam air filter oil (not spray type).

d. Squeeze out the excess oil.

TE:N

TE:

The element should be wet but not dripping.

6. Install:

• air filter element frame

7. Apply:

• Lithium-soap-based grease

On the matching surface on air filter ele-

ment.

8. Install:

• air filter element

• wing bolt

TE:N

TE:

Make sure its sealing surface matches the

sealing surface of the case so there is no air

leak.

9. Install:

• air filter case cover

10.Install:

• seat

Refer to “SEAT, FENDERS AND FUEL

TANK”.

CLEANING THE AIR FILTER ELEMENT

CHK

ADJ

3-25

CLEANING THE SPARK ARRESTER

1. Clean:

• Spark arrester

WARNING

• Select a well-ventilated area free of com-

bustible materials.

• Always let the exhaust system cool before

performing this operation.

• Do not start the engine when removing the

tailpipe from the muffler.

a. Remove the bolts .

b. Remove the tailpipe from the muffler.

c. Tap the tailpipe lightly with a soft-face ham-

mer or suitable tool, then use a wire brush

to remove any carbon deposits from the

spark arrester portion of the tailpipe and the

inner contact surfaces of the muffler.

d. Insert the tailpipe and gasket into the

muffler.

e. Install the bolts and tighten it.

CLEANING THE AIR FILTER ELEMENT/

CLEANING THE SPARK ARRESTER

CHK

ADJ

3-26

EBS00080

CHASSIS

ADJUSTING THE FRONT BRAKE

1. Measure:

• brake lever free play

Out of specification → Bleed the front brake

system.

Refer to “BLEEDING THE HYDRAULIC

BRAKE SYSTEM”.

ADJUSTING THE BRAKE LEVER

(For adjustment type model)

1. Adjust:

• brake lever position

a. While pushing the brake lever forward,

loosen the locknut .

b. While pushing the brake lever forward, turn

the adjusting bolt in direction or

until the brake lever is in the desired posi-

tion.

c. Tighten the locknut.

CAUTION:

Be sure to tighten the locknut, as failing to

do so will cause poor brake performance.

EBS00085

ADJUSTING THE REAR BRAKE

1. Measure:

• rear brake pedal height

Out of specification → Adjust.

Brake lever free play

(at the end of the brake lever)

0 mm (0 in)

Rear brake pedal height

40.0 mm (1.57 in)

ADJUSTING THE FRONT BRAKE/ADJUSTING THE

BRAKE LEVER/ADJUSTING THE REAR BRAKE

CHK

ADJ

3-27

2. Adjust:

• rear brake pedal height

a. Loosen the locknut .

b. Turn the adjusting bolt until the brake

pedal height is within the specified limits.

c. Tighten the locknut.

TE:N

TE:

When adjusting the brake pedal height make

sure the locknut-to-adjusting bolt clearance

does not exceed 2.2 ~ 3.2 mm (0.09 ~ 0.13 in).

WARNING

After this adjustment is performed, lift the

front and rear wheels off the ground by

placing a block under the engine, and spin

the rear wheels to ensure there is no brake

drag. If any brake drag is noticed, perform

the above steps again.

ADJUSTING THE PARKING BRAKE

1. Check:

• parking brake cable end length

Out of specification → Adjust.

Parking brake cable end length

64 ~ 68 mm (2.52 ~ 2.68 in)

ADJUSTING THE REAR BRAKE/

ADJUSTING THE PARKING BRAKE

CHK

ADJ

3-28

2. Adjust:

• parking brake cable end length

a. Loosen the locknut and adjusting bolt

b. Slide back the rubber cover .

c. Loosen the locknut .

d. Turn the adjusting nut in direction or

until the specified brake cable end

length is obtained.

e. Tighten the locknut.

f. Slowly turn the adjusting bolt clockwise until

resistance is felt.

g. Turn it 1/8 counterclockwise.

h. Tighten the locknut .

i. Slide the rubber cover to its original posi-

tion.

WARNING

After this adjustment is performed, lift the

rear wheels off the ground by placing a

block under the engine, and spin the rear

wheels to ensure there is no brake drag. If

any brake drag is noticed perform the

above steps again.

EBS00087

CHECKING THE BRAKE FLUID LEVEL

1. Place the machine on a level surface.

TE:N

TE:

When checking the brake fluid level, make sure

that the top of the brake master cylinder reser-

voir or brake fluid reservoir is horizontal.

16 Nm (1.6 m•kg, 11 ft•lb)

ADJUSTING THE PARKING BRAKE/

CHECKING THE BRAKE FLUID LEVEL

CHK

ADJ

3-29

2. Check:

• brake fluid level

Below the minimum level mark → Add

the recommended brake fluid to the proper

level.

Front brake

Rear brake

WARNING

• Use only the designated brake fluid.

Other brake fluids may cause the rubber

seals to deteriorate, causing leakage and

poor brake performance.

• Refill with the same type of brake fluid that

is already in the system. Mixing brake flu-

ids may result in a harmful chemical reac-

tion, leading to poor brake performance.

• When refilling, be careful that water does

not enter the brake fluid reservoir. Water

will significantly lower the boiling point of

the brake fluid and could cause vapor

lock.

CAUTION:

Brake fluid may damage painted surfaces

and plastic parts. Therefore, always clean

up any spilt brake fluid immediately.

TE:N

TE:

In order to ensure a correct reading of the

brake fluid level, make sure that the top of the

brake master cylinder reservoir or brake fluid

reservoir is horizontal.

EBS00088

CHECKING THE FRONT BRAKE PADS

1. Remove:

• front wheels

Refer to “FRONT AND REAR WHEELS” in

chapter 6.

Recommended brake fluid

DOT 4

CHECKING THE BRAKE FLUID LEVEL/

CHECKING THE FRONT BRAKE PADS

CHK

ADJ

3-30

2. Check:

• brake pads

Wear indicator groove almost disappeared

→ Replace the brake pads as a set.

Refer to “FRONT AND REAR BRAKES” in

chapter 6.

3. Operate the brake lever.

4. Install:

• front wheels

Refer to “FRONT AND REAR WHEELS” in

chapter 6.

EBS00089

CHECKING THE REAR BRAKE PADS

1. Check:

• brake pads

Wear indicators almost touch the brake disc

→ Replace the brake pads as a set.

Refer to “FRONT AND REAR BRAKES” in

chapter 6.

2. Operate the brake pedal.

Brake pad wear limit

1.5 mm (0.06 in)

Brake pad wear limit

1.0 mm (0.04 in)

CHECKING THE FRONT BRAKE PADS/

CHECKING THE REAR BRAKE PADS

CHK

ADJ

3-31

ADJUSTING THE REAR BRAKE LIGHT

SWITCH

TE:N

TE:

• The rear brake light switch is operated by

movement of the brake pedal.

• The rear brake light switch is properly

adjusted when the brake light comes on just

before the braking effect starts.

1. Check:

• rear brake light operation timing

Incorrect → Adjust.

2. Adjust:

• rear brake light operation timing

a. Hold the main body of the rear brake

light switch so that it does not rotate and

turn the adjusting nut in direction or

until the rear brake light comes on at the

proper time.

EBS00092

CHECKING THE BRAKE HOSES

1. Remove:

• seat

• front fender

Refer to “SEAT, FENDERS AND FUEL

TANK”.

Direction Brake light comes on

sooner.

Direction Brake light comes on

later.

ADJUSTING THE REAR BRAKE LIGHT SWITCH/

CHECKING THE BRAKE HOSES

CHK

ADJ

3-32

2. Check:

• front brake hoses

• front brake pipe

• rear brake hose

Cracks/wear/damage → Replace.

3. Check:

• brake hose clamps

Loosen → Tighten.

4. Hold the machine in an upright position and

apply the front or rear brake.

5. Check:

•brake hoses

Apply the brake lever or brake pedal several

times.

Fluid leakage → Replace the hoses or pipe.

Refer to “FRONT AND REAR BRAKES” in

chapter 6.

6. Install:

• front fender

• seat

Refer to “SEAT, FENDERS AND FUEL

TANK”.

EBS00094

BLEEDING THE HYDRAULIC BRAKE

SYSTEM

WARNING

Bleed the hydraulic brake system when-

ever:

• the system is disassembled.

• a brake hose is loosened, disconnected or

replaced.

• the brake fluid level is very low.

• brake operation is faulty.

CHECKING THE BRAKE HOSES/

BLEEDING THE HYDRAULIC BRAKE SYSTEM

CHK

ADJ

3-33

TE:N

TE:

• Be careful not to spill any brake fluid or allow

the brake master cylinder reservoir or brake

fluid reservoir to overflow.

• When bleeding the hydraulic brake system,

make sure there is always enough brake fluid

before applying the brake. Ignoring this pre-

caution could allow air to enter the hydraulic

brake system, considerably lengthening the

bleeding procedure.

• If bleeding is difficult, it may be necessary to

let the brake fluid settle for a few hours.

Repeat the bleeding procedure when the tiny

bubbles in the hose have disappeared.

1. Bleed:

• hydraulic brake system

a. Fill the brake fluid reservoir to the proper

level with the recommended brake fluid.

b. Install the diaphragm (brake master cylin-

der reservoir or brake fluid reservoir).

c. Connect a clear plastic hose tightly to

the bleed screw .

Front

Rear

d. Place the other end of the hose into a con-

tainer.

e. Slowly apply the brake lever or brake pedal

several times.

f. Fully squeeze the brake lever or fully

depress the brake pedal and hold it in posi-

tion.

g. Loosen the bleed screw.

TE:N

TE:

Loosening the bleed screw will release the

pressure and cause the brake lever to contact

the grip or the brake pedal to fully extend.

h. Tighten the bleed screw and then release

the brake lever or brake pedal.

i. Repeat steps (e) to (h) until all of the air

bubbles have disappeared from the brake

fluid in the plastic hose.

BLEEDING THE HYDRAULIC BRAKE SYSTEM

CHK

ADJ

3-34

j. Tighten the bleed screw to specification.

k. Fill the brake fluid reservoir to the proper

level with the recommended brake fluid.

Refer to “CHECKING THE BRAKE FLUID

LEVEL”.

WARNING

After bleeding the hydraulic brake system,

check the brake operation.

EBS00098

ADJUSTING THE SHIFT PEDAL

1. Measure:

• shift pedal height

Out of specification → Adjust.

2. Adjust:

• shift pedal position

a. Remove the drive sprocket cover .

Refer to “REAR SHOCK ABSORBER,

SWINGARM AND DRIVE CHAIN” in chap-

ter 6.

b. Remove the bolt .

c. Remove the shift pedal .

d. Install the shift pedal at the correct height.

e. Tighten the bolt to specification.

5 Nm (0.5 m•kg, 3.7 ft•lb)

Shift pedal height

15.2 mm (0.60 in)

10 Nm (1.0 m•kg, 7.4 ft•lb)

BLEEDING THE HYDRAULIC BRAKE SYSTEM/

ADJUSTING THE SHIFT PEDAL

CHK

ADJ

3-35

ADJUSTING THE DRIVE CHAIN SLACK

TE:N

TE:

• Measure the drive chain slack halfway

between the drive axle and the rear axle.

• When checking and adjusting the drive chain

slack, there should be no weight on the vehi-

cle and all tires must be touching the ground.

CAUTION:

A drive chain that is too tight will overload

the engine and other vital parts, and one

that is too loose can skip and damage the

swingarm or cause an accident. Therefore,

keep the drive chain slack within the speci-

fied limits.

1. Measure:

• drive chain slack

Out of specification → Adjust.

2. Adjust:

• drive chain slack

TE:N

TE:

The drive chain slack is adjusted by the rota-

tion of the rear axle hub.

a. Loosen the rear axle pinch bolts .

b. Insert a rod of a diameter of 8 mm (0.31 in)

and length of 10 cm (4 in) in the hole

of rear axle hub .

c. Shift the transmission into the neutral posi-

tion.

d. To loosen the drive chain, push the vehicle

forward and to tighten the drive chain, pull

the vehicle backward.

Drive chain slack

45 ~ 55 mm (1.77 ~ 2.17 in)

ADJUSTING THE DRIVE CHAIN SLACK

CHK

ADJ

3-36

CAUTION:

Excessive chain slack will overload the

engine and other vital parts; keep the slack

within the specified limits.

e. If the chain slack cannot be adjusted,

replace the sprockets and drive chain as a

set.

f. Tighten the rear axle pinch bolts .

TE:N

TE:

• Tighten the rear axle pinch bolts in the

proper sequence as shown.

• The chain should be cleaned and lubricated

after every use of the vehicle.

EBS00106

CHECKING THE STEERING SYSTEM

1. Place the machine on a level surface.

2. Check:

• steering assembly bushings

Move the handlebar up and down, and/or

back and forth.

Excessive play → Replace the steering

stem bushings.

3. Check:

• tie-rod ends

Turn the handlebar to the left and right until

it stops completely, and then move the han-

dlebar slightly in the opposite direction.

Tie-rod end(s) have vertical play →

Replace the tie-rod end(s).

4. Raise the front end of the machine so that

there is no weight on the front wheels.

5. Check:

• ball joints and/or wheel bearings

Move the wheels laterally back and forth.

Excessive free play → Replace the front

arms (upper and lower) and/or wheel bear-

ings.

12 34

56 78

21 Nm (2.1 m•kg, 15 ft•lb)

ADJUSTING THE DRIVE CHAIN SLACK/

CHECKING THE STEERING SYSTEM

CHK

ADJ

3-37

EBS00108

ADJUSTING THE TOE-IN

1. Place the machine on a level surface.

2. Measure:

• toe-in

Out of specification → Adjust.

TE:N

TE:

Before measuring the toe-in, make sure that

the tire pressure is correct.

a. Mark both front tire tread centers.

b. Face the handlebar straight ahead.

c. Measure the width between the marks.

d. Rotate the front tires 180° until the marks

are exactly opposite one another.

e. Measure the width between the marks.

f. Calculate the toe-in using the formula given

below.

g. If the toe-in is incorrect, adjust it.

Forward

3. Adjust:

• toe-in

WARNING

• Be sure that both tie-rods are turned the

same amount. If not, the machine will drift

right or left even though the handlebar is

positioned straight. This may lead to mis-

handling and an accident.

• After setting the toe-in to specification,

run the machine slowly for some distance

with both hands lightly holding the han-

dlebar and check that the handlebar

responds correctly. If not, turn either the

right or left tie-rod within the toe-in speci-

fication.

Toe-in

9 ~ 19 mm (0.35 ~ 0.75 in)

Toe-in = –

ADJUSTING THE TOE-IN

CHK

ADJ

3-38

a. Mark both tie-rods ends.

This reference point will be needed during

adjustment.

b. Loosen the locknuts (tie-rod end) of both

tie-rods.

c. The same number of turns should be given

to both the right and left tie-rods until the

specified toe-in is obtained. This is to keep

the length of the rods the same.

d. Tighten the rod end locknuts of both tie-

rods.

TE:N

TE:

Adjust the rod ends so that A and B are equal.

EBS00109

CHECKING THE FRONT AND REAR SHOCK

ABSORBERS

1. Place the machine on a level surface.

2. Check:

• damper rod

Bends/damage → Replace the front/rear

shock absorber assembly.

• oil leakage

Excessive oil leakage → Replace the front/

rear shock absorber assembly.

• cylinder

Damage → the front/rear shock absorber

assembly.

•spring

Fatigue → the front/rear shock absorber

assembly.

Refer to “FRONT ARMS AND FRONT

SHOCK ABSORBER ASSEMBLIES” and

“REAR SHOCK ABSORBER, SWINGARM

AND DRIVE CHAIN” in chapter 6.

3. Check:

• operation

Pump the shock absorbers up and down for

several times.

Unsmooth operation → Replace the front/

rear shock absorber assembly.

Refer to “ADJUSTING THE FRONT

SHOCK ABSORBERS” and “ADJUSTING

THE REAR SHOCK ABSORBER”.

Front shock absorber

Rear shock absorber

15 Nm (1.5 m•kg, 11 ft•lb)

ADJUSTING THE TOE-IN/CHECKING THE FRONT AND

REAR SHOCK ABSORBERS

CHK

ADJ

3-39

EBS00111

ADJUSTING THE FRONT SHOCK

ABSORBERS

WARNING

Always adjust the spring preload of both

front shock absorbers to the same setting.

Uneven adjustment can result in poor han-

dling and loss of stability.

1. Adjust:

• spring preload

a. Turn the adjusting ring in direction or

with the spanner wrench .

12345Direction Spring preload is

increased (suspension is

harder).

Direction Spring preload is

decreased (suspension is

softer).

Standard position: 2

Minimum position: 1

Maximum position: 5

Ring nut wrench

90890-01268

Spanner wrench

YU-01268

ADJUSTING THE FRONT SHOCK ABSORBERS

CHK

ADJ

3-40

EBS00111

ADJUSTING THE REAR SHOCK

ABSORBER

1. Adjust:

• spring preload

a. Elevate the rear wheels by placing a suit-

able stand under the frame.

b. Loosen the locknut .

c. Turn the adjusting nut in direction or

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• Be sure to remove all dirt and mud from

around the locknut and adjusting nut before

adjustment.

• The length of the spring (installed) changes

1.0 mm (0.04 in) per turn of the adjuster.

CAUTION:

Never attempt to turn the adjusting ring

beyond the maximum or minimum setting.

d. Tighten the locknut.

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Always tighten the locknut against the adjust-

ing nut, then torque it to specification.

Direction Spring preload is

increased (suspension is

harder).

Direction Spring preload is

decreased (suspension is

softer).

Adjusting length

Standard: 230 mm (9.06 in)

Minimum: 222 mm (8.74 in)

Maximum: 234 mm (9.21 in)

42 Nm (4.2 m•kg, 31 ft•lb)

ADJUSTING THE REAR SHOCK ABSORBER

CHK

ADJ

3-41

EBS00114

CHECKING THE TIRES

WARNING

This model is equipped with low pressure

tires. It is important that they be inflated

correctly and maintained at the proper

pressures.

• TIRE CHARACTERISTICS

1) Tire characteristics influence the han-

dling of ATVs. The tires listed below

have been approved by Yamaha Motor

Co., Ltd. for this model. If other tire com-

binations are used, they can adversely

affect your machine’s handling charac-

teristics and are therefore not recom-

mended.

• TIRE PRESSURE

1) Recommended tire pressure

Front 27.5 kPa (0.28 kg/cm2, 4.0 psi)

Rear 27.5 kPa (0.28 kg/cm2, 4.0 psi)

2) Tire pressure below the minimum speci-

fication could cause the tire to dislodge

from the rim under severe riding condi-

tions.

The following are minimums:

Front 24.5 kPa (0.25 kg/cm2, 3.6 psi)

Rear 24.5 kPa (0.25 kg/cm2, 3.6 psi)

3) Use no more than

Front 250 kPa (2.6 kg/cm2, 36 psi)

Rear 250 kPa (2.6 kg/cm2, 36 psi)

when seating the tire beads. Higher

pressures may cause the tire to burst.

Inflate the tires slowly and carefully.

Fast inflation could cause the tire to

burst.

• MAXIMUM LOADING LIMIT

1) Vehicle load limits: 100 kg (220 lb)

*Total weight of the cargo, rider, and

accessories.

Be extra careful of the machine balance

and stability when towing a trailer.

Manufacturer Size Type

Front DUNLOP AT20 ×

7-10 KT201

Rear DUNLOP AT19 ×

10-9 KT205A

CHECKING THE TIRES

CHK

ADJ

3-42

1. Measure:

• tire pressure

Out of specification → Adjust.

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• The low-pressure tire gauge is included as

standard equipment.

• If dust or the like is stuck to this gauge, it will

not provide the correct readings. Therefore,

take two measurements of the tire’s pressure

and use the second reading.

WARNING

Uneven or improper tire pressure may

adversely affect the handling of this

machine and may cause loss of control.

• Maintain proper tire pressures.

• Set tire pressures when the tires are cold.

• Tire pressures must be equal in both front

tires and equal in both rear tires.

2. Check:

• tire surfaces

Wear/damage → Replace.

WARNING

It is dangerous to ride with a worn-out tire.

When tire wear is out of specification,

replace the tire immediately.

Cold tire

pressure Front/Rear

Standard 27.5 kPa

(0.28 kg/cm2, 4.0 psi)

Minimum 24.5 kPa

(0.25 kg/cm2, 3.6 psi)

Maximum 30.5 kPa

(0.31 kg/cm2, 4.4 psi)

Tire wear limit

Front and rear: 3.0 mm (0.12 in)

CHECKING THE TIRES

CHK

ADJ

3-43

EBS00116

CHECKING THE WHEELS

1. Check:

• wheel

Damage/bends → Replace.

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Always balance the wheel when a tire or wheel

has been changed or replaced.

WARNING

• Never attempt even small repairs to the

wheel.

• Ride conservatively after installing a tire

to allow it to seat itself properly on the rim.

EBS00117

CHECKING AND LUBRICATING THE

CABLES

WARNING

A damaged cable sheath may cause corro-

sion and interfere with the cable movement.

An unsafe condition may result so replace

a damaged cable as soon as possible.

1. Check:

• cable sheath

Damage → Replace.

2. Check:

• cable operation

Unsmooth operation → Lubricate or

replace.

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Hold the cable end up and apply several drops

of lubricant to the cable.

3. Apply:

• Lithium-soap-based grease

(onto end of the cable)

Recommended lubricant

Yamaha chain and cable lube or

engine oil

CHECKING THE WHEELS/CHECKING AND

LUBRICATING THE CABLES

CHK

ADJ

3-44

EBS00118

LUBRICATING THE LEVERS AND PEDALS

Lubricate the pivoting point and metal-to-metal

moving parts of the levers and pedal.

Recommended lubricants

Brake lever

Silicone grease

Clutch lever and brake pedal

Lithium-soap-based grease

LUBRICATING THE LEVERS AND PEDALS

CHK

ADJ

3-45

EBS00120

ELECTRICAL SYSTEM

CHECKING AND CHARGING THE BATTERY

WARNING

Batteries generate explosive hydrogen gas

and contain electrolyte which is made of

poisonous and highly caustic sulfuric acid.

Therefore, always follow these preventive

measures:

• Wear protective eye gear when handling

or working near batteries.

• Charge batteries in a well-ventilated area.

• Keep batteries away from fire, sparks or

open flames (e.g., welding equipment,

lighted cigarettes).

• DO NOT SMOKE when charging or han-

dling batteries.

• KEEP BATTERIES AND ELECTROLYTE

OUT OF REACH OF CHILDREN.

• Avoid bodily contact with electrolyte as it

can cause severe burns or permanent eye

injury.

FIRST AID IN CASE OF BODILY CONTACT:

EXTERNAL

• Skin — Wash with water.

• Eyes — Flush with water for 15 minutes

and get immediate medical attention.

INTERNAL

• Drink large quantities of water or milk fol-

lowed with milk of magnesia, beaten egg

or vegetable oil. Get immediate medical

attention.

CAUTION:

• This is a sealed battery. Never remove the

sealing caps because the balance

between cells will not be maintained and

battery performance will deteriorate.

• Charging time, charging amperage and

charging voltage for an MF battery are dif-

ferent from those of conventional batter-

ies. The MF battery should be charged as

explained in the charging method illustra-

tions. If the battery is overcharged, the

electrolyte level will drop considerably.

Therefore, take special care when charg-

ing the battery.

CHECKING AND CHARGING THE BATTERY

CHK

ADJ

3-46

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Since MF batteries are sealed, it is not possi-

ble to check the charge state of the battery by

measuring the specific gravity of the electro-

lyte. Therefore, the charge of the battery has to

be checked by measuring the voltage at the

battery terminals.

1. Remove:

• seat

• battery cover

Refer to “SEAT, FENDERS AND FUEL

TANK”.

2. Disconnect:

• battery leads

(from the battery terminals)

CAUTION:

First, disconnect the negative battery lead

, and then the positive battery lead .

3. Remove:

• battery

4. Check:

• battery charge

a. Connect a pocket tester to the battery ter-

minals.

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• The charge state of an MF battery can be

checked by measuring its open-circuit voltage

(i.e., the voltage when the positive terminal is

disconnected).

• No charging is necessary when the open-cir-

cuit voltage equals or exceeds 12.8 V.

b. Check the charge of the battery, as shown

in the charts and the following example.

Positive tester probe →

positive battery terminal

Negative tester probe →

negative battery terminal

Relationship between the open-circuit voltage

and the charging time at 20 °C (68 °F)

Charging time (hours)

These values vary with the temperature, the condition of

the battery plates, and the electrolyte level.

Open-circuit voltage (V)

CHECKING AND CHARGING THE BATTERY

CHK

ADJ

3-47

Example

c. Open-circuit voltage = 12.0 V

d. Charging time = 6.5 hours

e. Charge of the battery = 20 ~ 30%

5. Charge:

• battery

(refer to the appropriate charging method

illustration)

WARNING

Do not quick charge a battery.

CAUTION:

• Never remove the MF battery sealing caps.

• Do not use a high-rate battery charger

since it forces a high-amperage current

into the battery quickly and can cause bat-

tery overheating and battery plate dam-

age.

• If it is impossible to regulate the charging

current on the battery charger, be careful

not to overcharge the battery.

• When charging a battery, be sure to

remove it from the machine. (If charging

has to be done with the battery mounted

on the machine, disconnect the negative

battery lead from the battery terminal.)

• To reduce the chance of sparks, do not

plug in the battery charger until the bat-

tery charger leads are connected to the

battery.

• Before removing the battery charger lead

clips from the battery terminals, be sure to

turn off the battery charger.

• Make sure the battery charger lead clips

are in full contact with the battery terminal

and that they are not shorted. A corroded

battery charger lead clip may generate

heat in the contact area and a weak clip

spring may cause sparks.

• If the battery becomes hot to the touch at

any time during the charging process, dis-

connect the battery charger and let the

battery cool before reconnecting it. Hot

batteries can explode!

Charging

Open-circuit voltage (V)

Ambient temperature

20°C (68°F)

Check the open-circuit

voltage.

Time (minutes)

6020 5040

10030

Ambient

temperature

20°C (68°F)

Charging condition of the battery (%)

Open-circuit voltage (V)

100 75 50 30 25 20 0

CHECKING AND CHARGING THE BATTERY

CHK

ADJ

3-48

• As shown in the following illustration, the

open-circuit voltage of an MF battery sta-

bilizes about 30 minutes after charging

has been completed. Therefore, wait 30

minutes after charging is completed

before measuring the open-circuit voltage.

CHECKING AND CHARGING THE BATTERY

CHK

ADJ

3-49

Charging method using a variable-current (voltage) charger

Measure the open-circuit

voltage prior to charging.

Connect a charger and

ammeter to the battery

and start charging.

Is the amperage higher

than the standard charg-

ing amperage written on

the battery?

Leave the battery unused for

more than 30 minutes before

measuring its open-circuit voltage.

Adjust the voltage to obtain

the standard charging amper-

age.

Monitor the amperage for 3 ~ 5

minutes. Is the standard charg-

ing amperage exceeded?

Adjust the charging voltage

to 20 ~ 25 V.

If the amperage does not

exceed the standard charg-

ing amperage after 5 min-

utes, replace the battery.

Set the timer to the charging

time determined by the open-

circuit voltage.

Refer to “CHECKING AND

CHARGING THE BATTERY”.

If the required charging time exceeds 5 hours, it is advisable to

check the charging amperage after 5 hours. If there is any change in

the amperage, readjust the voltage to obtain the standard charging

amperage.

Leave the battery unused for more than 30 minutes before measur-

ing its open-circuit voltage.

12.8 V → Charging is complete.

12.0 ~ 12.7 V → Recharging is required.

Under 12.0 V → Replace the battery.

Charger Ammeter

Set the charging voltage to 16 ~

17 V. (If the charging voltage is

lower, charging will be insufficient,

if it is higher, the battery will be

over-charged.)

YES

CHECKING AND CHARGING THE BATTERY

CHK

ADJ

3-50

Charging method using a constant voltage charger

Measure the open-circuit

voltage prior to charging.

Connect a charger and

ammeter to the battery

and start charging.

Charge the battery until the charging

voltage reaches 15 V.

Leave the battery unused for more

than 30 minutes before measuring

its open-circuit voltage.

This type of battery charger cannot

charge an MF battery. A variable-

voltage charger is recommended.

Set the charging time to a maxi-

mum of 20 hours.

Constant amperage chargers are not

suitable for charging MF batteries.

Leave the battery unused for more than 30

minutes before measuring its open-circuit

voltage.

12.8 V → Charging is complete.

12.0 ~ 12.7 V → Recharging is required.

Under 12.0 V → Replace the battery.

Is the amperage higher

than the standard charg-

ing amperage written on

the battery?

Charger

Ammeter

Voltmeter

CHECKING AND CHARGING THE BATTERY

CHK

ADJ

3-51

6. Install:

• battery

7. Connect:

• battery leads

(to the battery terminals)

CAUTION:

First, connect the positive battery lead ,

and then the negative battery lead .

8. Check:

• battery terminals

Dirt → Clean with a wire brush.

Loose connection → Connect properly.

9. Lubricate:

• battery terminals

10.Install:

• battery cover

• seat

Refer to “SEAT, FENDERS AND FUEL

TANK”.

Recommended lubricant

Dielectric grease

CHECKING AND CHARGING THE BATTERY

CHK

ADJ

3-52

EBS00121

CHECKING THE FUSES

The following procedure applies to all of the

fuses.

CAUTION:

To avoid a short circuit, always set the main

switch to “OFF” when checking or replac-

ing a fuse.

1. Remove:

• seat

• battery cover

Refer to “SEAT, FENDERS AND FUEL

TANK”.

2. Check:

•fuse

a. Connect the pocket tester to the fuse and

check the continuity.

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Set the pocket tester selector to “Ω × 1”.

b. If the pocket tester indicates “•”, replace the

fuse.

3. Replace:

• blown fuse

a. Set the main switch to “OFF”.

b. Install a new fuse of the correct amperage.

c. Set on the switches to verify if the electrical

circuit is operational.

d. If the fuse immediately blows again, check

the electrical circuit.

Pocket tester

90890-03112

Analog pocket tester

YU-03112-C

CHECKING THE FUSES

CHK

ADJ

3-53

WARNING

Never use a fuse with an amperage rating

other than that specified. Improvising or

using a fuse with the wrong amperage rat-

ing may cause extensive damage to the

electrical system, cause the lighting and

ignition systems to malfunction and could

possibly cause a fire.

4. Install:

• battery cover

• seat

Refer to “SEAT, FENDERS AND FUEL

TANK”.

EBS00122

ADJUSTING THE HEADLIGHT BEAM

1. Adjust:

• headlight beam (vertically)

a. Turn the adjusting bolt in direction or

Items Amperage

rating Q’ty

Main 15 A 1

Reserve 15 A 1

Direction Headlight beam is

raised.

Direction Headlight beam is

lowered.

CHECKING THE FUSES/

ADJUSTING THE HEADLIGHT BEAM

CHK

ADJ

3-54

EBS00124

REPLACING A HEADLIGHT BULB

1. Remove:

• headlight

Refer to “SEAT, FENDERS AND FUEL

TANK”.

2. Disconnect:

• headlight lead coupler

3. Remove:

• headlight bulb holder cover

4. Remove:

• bulb holder

•bulb

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Push the headlight bulb holder inward, turn it

counterclockwise and remove the defective

bulb.

WARNING

Keep flammable products and your hands

away from the bulb while it is on. since it

will be hot. Do not touch the bulb until it

cools down.

5. Install:

•bulb

Secure the new bulb with the headlight unit.

CAUTION:

Avoid touching the glass part of the bulb.

Keep it free from oil; otherwise, the trans-

parency of the glass, life of the bulb, and

luminous flux will be adversely affected. If

oil gets on the bulb, thoroughly clean it

with a cloth moistened with alcohol or lac-

quer thinner.

REPLACING A HEADLIGHT BULB

CHK

ADJ

3-55

6. Install:

• bulb holder

• headlight bulb holder cover

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After installing the bulb holder cover, make

sure that the “TOP” mark is in the position

shown.

7. Connect:

• headlight lead coupler

8. Install:

• headlight

Refer to “SEAT, FENDERS AND FUEL

TANK”.

REPLACING A HEADLIGHT BULB

ENG

4-1

ENGINE

ENGINE REMOVAL

MUFFLER AND EXHAUST PIPE

Order Job/Parts to remove Q’ty Remarks

Removing the muffler and exhaust

pipe Remove the parts in the order listed.

Seat/front panel/fender Refer to “SEAT, FENDERS AND FUEL

TANK” in chapter 3.

1 Clamp 1 Loosen

2 Muffler 1

3Gasket 1

4 Exhaust pipe 1

5 EXhaust pipe protector 1

6Gasket 1

For installation, reverse the removal

procedure.

34 Nm (3.4 m•kg, 25 ft•lb)

20 Nm (2.0 m•kg, 15 ft•lb)

8 Nm (0.8 m•kg, 5.9 ft•lb)

18 Nm (1.8 m•kg, 13 ft•lb)

ENGINE REMOVAL

ENG

4-2

INSTALLING THE EXHAUST PIPE AND

MUFFLER

1. Install:

• gasket

(to muffler)

2. Install:

• exhaust pipe protector

3. Tighten:

• exhaust pipe protector screws

4. Install:

• gasket

• exhaust pipe

5. Tighten:

• nuts (exhaust pipe)

6. Install:

•clamp

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Slide the clamp onto the end of the muffler and

insert the projection of the clamp into a slot

in the muffler. Tighten the clamp after

installing the muffler.

Installed depth of gasket

3.5 mm (0.14 in)

Screw

8 Nm (0.8 m•kg, 5.9 ft•lb)

LOCTITE®

Exhaust pipe nut

18 Nm (1.8 m•kg, 13 ft•lb)

ENGINE REMOVAL

ENG

4-3

LEADS, CABLES AND HOSES

Order Job/Parts to remove Q’ty Remarks

Removing the leads, cables and

hoses Remove the parts in the order listed.

Engine oil Drain.

Oil cooler hose 1, 2 Refer to “CLUTCH”.

Carburetor Refer to “CARBURETOR” in chapter 5.

Drive sprocket/drive chain Refer to “REAR SHOCK ABSORBER,

SWINGARM AND DRIVE CHAIN” in

chapter 6.

1 Ignition coil spark plug lead 1

2 Air filter case breather hose 1

3 Starter motor lead 1 Disconnect.

4 Battery negative lead 1 Disconnect.

5Clutch cable 1

6 Plastic band 1 Disconnect.

7 Parking brake cable 1

8 AC magneto coupler 2 Disconnect.

10 Nm (1.0 m•kg, 7.4 ft•lb)

ENGINE REMOVAL

ENG

4-4

Order Job/Parts to remove Q’ty Remarks

9 Neutral switch connector 1 Disconnect.

For installation, reverse the removal

procedure.

10 Nm (1.0 m•kg, 7.4 ft•lb)

ENGINE REMOVAL

ENG

4-5

ENGINE MOUNTING BOLTS

Order Job/Parts to remove Q’ty Remarks

Removing the engine mounting

bolts Remove the parts in the order listed.

1 Crankcase bolt 1

2 Engine mounting bolt (front) 1

3 Engine bracket (left and right) 2

4 Engine mounting bolt (upper) 1

5 Engine bracket (upper) 1

6 Engine mounting bolt (rear upper) 1

7 Engine mounting bolt (rear lower) 1

8 Engine assembly 1

For installation, reverse the removal

procedure.

66 Nm (6.6 m•kg, 49 ft•lb)

33 Nm (3.3 m•kg, 24 ft•lb)

66 Nm (6.6 m•kg, 49 ft•lb)

33 Nm (3.3 m•kg, 24 ft•lb)

40 Nm (4.0 m•kg, 30 ft•lb)

ENGINE REMOVAL

ENG

4-6

INSTALLING THE ENGINE

1. Install:

• Engine mounting bolt (rear lower side)

• Engine mounting bolt (rear upper side)

• Engine bracket bolts (upper side)

• Engine mounting bolt (upper side)

• Engine brackets (front side)

• Engine mounting bolt (front side)

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• The direction of the bolt insertion is made

from the right side of the body.

• Do not fully tighten the bolts and nuts.

2. Install:

• Crankcase bolt

3. Tighten:

• Engine bracket bolts (upper side)

• Engine mounting nut (rear lower side)

• Engine mounting nut (rear upper side)

• Engine mounting nut (upper side)

• Engine mounting nut (front side)

• Engine bracket bolts (front side)

• Crankcase nut

40 Nm (4.0 m

Engine bracket bolt (upper side)

33 Nm (3.3 m•kg, 24 ft•lb)

Engine mounting nut (rear lower

side)

66 Nm (6.6 m•kg, 49 ft•lb)

Engine mounting nut (rear upper

side)

66 Nm (6.6 m•kg, 49 ft•lb)

Engine mounting nut (upper side)

66 Nm (6.6 m•kg, 49 ft•lb)

Engine mounting nut (front lower

side)

40 Nm (4.0 m•kg, 30 ft•lb)

Engine bracket bolt (M8)

33 Nm (3.3 m•kg, 24 ft•lb)

Crankcase nut

40 Nm (4.0 m•kg, 30 ft•lb)

ENGINE REMOVAL

ENG

4-7

CYLINDER HEAD

Order Job/Parts to remove Q’ty Remarks

Removing the cylinder head

Seat/front fender/fuel tank/fuel tank

shield Refer to “SEAT, FENDERS AND FUEL

TANK” in chapter 3.

Muffler and exhaust pipe Refer to “MUFFLER AND EXHAUST

PIPE”.

Carburetor Refer to “CARBURETOR” in chapter 5.

Ignition coil spark plug lead Refer to “LEADS, CABLES AND HOSES”.

Engine bracket (upper side) Refer to “ENGINE MOUNTING BOLTS”.

1 Spark plug 1

2 Cylinder head cover 1/O-ring 1/1

3 Cylinder head cover 2/O-ring 1/1

4 Cylinder head cover 3/O-ring 1/1

5 Breather pipe 1/Gasket 1/1

6 Crankshaft end accessing screw/

O-ring 1/1

7 Timing mark accessing screw/O-ring 1/1

8 Camshaft sprocket bolt 1 Loosen.

20 Nm (2.0 m•kg, 15 ft•lb)

60 Nm (6.0 m•kg, 44 ft•lb)

10 Nm (1.0 m•kg, 7.4 ft•lb)

18 Nm (1.8 m•kg, 13 ft•lb)

24 Nm (2.4 m•kg, 18 ft•lb)

18 Nm (1.8 m•kg, 13 ft•lb)

10 Nm (1.0 m•kg, 7.4 ft•lb)

CYLINDER HEAD

ENG

4-8

Order Job/Parts to remove Q’ty Remarks

9 Cap bolt 1 Loosen.

10 Timing chain tensioner/gasket 1/1

11 Breather pipe 2 1

12 Camshaft sprocket/dowel pin 1/1

13 Cylinder head 1

14 Timing chain guide 1

15 Dowel pin 2

16 Cylinder head gasket 1

For installation, reverse the removal

procedure.

20 Nm (2.0 m•kg, 15 ft•lb)

60 Nm (6.0 m•kg, 44 ft•lb)

10 Nm (1.0 m•kg, 7.4 ft•lb)

18 Nm (1.8 m•kg, 13 ft•lb)

24 Nm (2.4 m•kg, 18 ft•lb)

18 Nm (1.8 m•kg, 13 ft•lb)

10 Nm (1.0 m•kg, 7.4 ft•lb)

CYLINDER HEAD

ENG

4-9

REMOVING THE CYLINDER HEAD

1. Align:

• “I” mark on the Pickup coil rotor

(with the stationary pointer on the crank-

case cover)

a. Turn the Pickup coil rotor counterclockwise.

b. When the piston is at TDC on the compres-

sion stroke, align the “I” mark on the

camshaft sprocket with the mark on the

cylinder head.

2. Loosen:

• Camshaft sprocket bolt

3. Remove:

• Timing chain tensioner cap

• Timing chain tensioner

(along with the gasket)

• Camshaft sprocket bolt

• Breather plate 2

• Camshaft sprocket

• Timing chain

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To prevent the timing chain from falling into the

crankcase, fasten it with a wire.

4. Remove:

• Cylinder head

CYLINDER HEAD

ENG

4-10

CHECKING THE CYLINDER HEAD

1. Eliminate:

• Combustion chamber carbon deposits

(with a rounded scraper)

TE:

Do not use a sharp instrument to avoid damag-

ing or scratching:

• Spark plug bore threads

• Valve seats

2. Check:

• Cylinder head

Damage/scratches → Replace.

3. Measure:

• Cylinder head warpage

Out of specification → Resurface the cylin-

der head.

a. Place a straightedge and a thickness

gauge across the cylinder head.

b. Measure the warpage.

c. If the limit is exceeded, resurface the cylin-

der head as follows.

d. Place a 400–600 grit wet sandpaper on the

surface plate and resurface the cylinder

head using a figure-eight sanding pattern.

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To ensure an even surface, rotate the cylinder

head several times.

Warpage limit

0.05 mm (0.0020 in)

CYLINDER HEAD

ENG

4-11

CHECKING THE TIMING CHAIN GUIDES

The following procedure applies to the cam-

shaft sprockets and timing chain guides.

1. Check:

• Timing chain

Damage/stiffness → Replace the timing

chain and camshaft sprocket and crank-

shaft sprocket as a set.

2. Check:

• Camshaft sprocket

More than 1/4 tooth wear → Replace

the timing chain and camshaft sprocket and

crankshaft sprocket as a set.

1/4 tooth

Correct

Timing chain

Camshaft sprocket

3. Check:

• Timing chain guide (exhaust side)

CHECKING THE TIMING CHAIN

TENSIONERS

1. Check:

• Timing chain tensioner

Cracks/damage → Replace.

2. Check:

• One-way cam operation

Rough movement → Replace the timing

chain tensioner housing.

a. Lightly press the timing chain tensioner rod

into the timing chain tensioner housing by

hand.

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While pressing the timing chain tensioner rod,

wind it clockwise with a thin screwdriver

until it stops.

CYLINDER HEAD

ENG

4-12

b. Remove the screwdriver and slowly release

the timing chain tensioner rod.

c. Make sure that the timing chain tensioner

rod comes out of the timing chain tensioner

housing smoothly. If there is rough move-

ment, replace the timing chain tensioner.

3. Check:

• Cap bolt

• Copper washer

•Spring

•One-way cam

• Timing chain tensioner rod

Damage/wear → Replace the defective

part(s).

INSTALLING THE CYLINDER HEAD

1. Install:

• Cylinder head gasket

• Dowel pins

2. Install:

• Cylinder head

• Copper washers

• Cylinder head bolts

3. Tighten:

• Cylinder head bolts

TE:N

TE:

• Apply oil to the bearing surface of (upper) cyl-

inder head bolt.

Further, apply molybdenum disulfide grease

to thread part.

• Tighten the cylinder head bolts in the proper

tightening sequence as shown.

4. Install:

• Camshaft sprocket

• Dowel pin

• Timing chain

Cylinder head bolt 226 mm (8.90 in)

24 Nm (2.4 m•kg, 18 ft•lb)

Cylinder head bolt 45 mm (1.77 in)

20 Nm (2.0 m•kg, 15 ft•lb)

CYLINDER HEAD

ENG

4-13

a. Turn the Pickup coil rotor counterclockwise.

b. Align the “I” mark on the Pickup coil rotor

with the stationary pointer on the crank-

case cover.

c. Remove the wire from the timing chain.

d. Install the timing chain onto the camshaft

sprocket, and then install the camshaft

sprocket onto the camshaft.

TE:N

TE:

• When installing the camshaft sprocket, be

sure to keep the timing chain as tight as pos-

sible on the exhaust side.

• Align the pin on the camshaft with the slot

in the camshaft sprocket.

CAUTION:

Do not turn the crankshaft when installing

the camshaft(s) to avoid damage or

improper valve timing.

e. Align the “I” mark on the camshaft

sprocket with the stationary pointer on

the cylinder head.

f. While holding the camshaft, temporarily

tighten the camshaft sprocket bolts.

5. Install:

• Timing chain tensioner

a. While lightly pressing the timing chain ten-

sioner rod by hand, turn the tensioner rod

fully clockwise with a thin screwdriver .

b. With the timing chain tensioner rod turned

all the way into the timing chain tensioner

housing (with the thin screwdriver still

installed), install the new gasket and the

timing chain tensioner onto the body cyl-

inder.

c. Tighten the timing chain tensioner bolts

to the specified torque.

d. Remove the screwdriver, make sure that

the timing chain tensioner rod releases, and

then tighten the cap bolt to the specified

torque.

10 Nm (1.0 m•kg, 7.4 ft•lb)

CYLINDER HEAD

ENG

4-14

6. Turn:

• Crankshaft

(several turns counterclockwise)

7. Check:

• “I” mark

Align the “I” mark on the pickup coil rotor

with the stationary pointer on the crank-

case cover.

• “I” mark

Align the “I” mark on the camshaft sprocket

with the stationary pointer on the cylin-

der head.

Out of alignment → Correct.

Refer to the installation steps above.

8. Tighten:

• Camshaft sprocket bolt

CAUTION:

Be sure to tighten the camshaft sprocket

bolts to the specified torque to avoid the

possibility of the bolts coming loose and

damaging the engine.

9. Measure:

• Valve clearance

Out of specification → Adjust.

Refer to “ADJUSTING THE VALVE CLEAR-

ANCE” in chapter 3.

Camshaft sprocket bolt

60 Nm (6.0 m•kg, 44 ft•lb)

CYLINDER HEAD

ENG

4-15

ROCKER ARM, CAMSHAFT

Order Job/Parts to remove Q’ty Remarks

Removing the rocker arms and cam-

shaft Remove the parts in the order listed.

Cylinder head Refer to “CYLINDER HEAD”.

1 Lock plate 1

2 Locknut/valve clearance adjusting

screw 2/2

3Camshaft 1

4 Intake rocker arm shaft 1

5 Intake rocker arm 1

6 Exhaust rocker arm shaft 1

7 Exhaust rocker arm 1

For installation, reverse the removal

procedure.

ROCKER ARM, CAMSHAFT

ENG

4-16

REMOVING THE ROCKER ARMS AND

CAMSHAFT

1. Loosen:

• Locknut

• Valve clearance adjusting screw

2. Remove:

• Stopper plate

3. Remove:

• Camshaft

• Bearing

TE:N

TE:

Screw 10 mm (0.396 in) bolt into the

threaded end of the camshaft and then pull out

the camshaft.

4. Remove:

• Intake rocker arm shaft

• Exhaust rocker arm shaft

• Intake rocker arm

• Exhaust rocker arm

TE:N

TE:

Remove the rocker arm shafts with the slide

hammer bolt and weight .

Slide hammer bolt

90890-01083

Slide hammer bolt 6 mm

YU-01083-1

Weight

90890-01084, YU-01083-3

ROCKER ARM, CAMSHAFT

ENG

4-17

CHECKING THE CAMSHAFT

1. Check:

• Bearing

Damage/wear → Replace.

2. Check:

• Camshaft lobes

Blue discoloration/pitting/scratches →

Replace the camshaft.

3. Measure:

• Camshaft lobe dimensions and

Out of specification → Replace the cam-

shaft.

4. Check:

• Camshaft oil passage

Obstruction → Blow out with compressed

air.

Camshaft lobe dimension

Intake A

36.890 ~ 36.990 mm

(1.4524 ~ 1.4563 in)

Limit

36.790 mm (1.4484 in)

Intake B

30.111 ~ 30.211 mm

(1.1855 ~ 1.1894 in)

Limit

30.011 mm (1.1815 in)

Exhaust A

36.891 ~ 36.991 mm

(1.4524 ~ 1.4563 in)

Limit

36.791 mm (1.4485 in)

Exhaust B

30.092 ~ 30.192 mm

(1.1847 ~ 1.1887 in)

Limit

29.992 mm (1.1808 in)

ROCKER ARM, CAMSHAFT

ENG

4-18

CHECKING THE ROCKER ARMS AND

ROCKER ARM SHAFTS

The following procedure applies to all of the

rocker arms and rocker arm shafts.

1. Check:

• Rocker arms

• Valve clearance adjusting screws

Damage/wear → Replace.

2. Check:

• Rocker arm shaft

Blue discoloration/excessive wear/pitting/

scratches → Replace or check the lubrica-

tion system.

3. Measure:

• Rocker arm inside diameter

Out of specification → Replace.

4. Measure:

• Rocker arm shaft outside diameter

Out of specification → Replace.

5. Calculate:

• Rocker-arm-to-rocker-arm-shaft clearance

TE:N

TE:

Calculate the clearance by subtracting the

rocker arm shaft outside diameter from the

rocker arm inside diameter.

Out of specification → Replace the defec-

tive part(s).

Rocker arm inside diameter

12.000 ~ 12.018 mm

(0.4724 ~ 0.4731 in)

Limit

12.036 mm (0.4739 in)

Rocker arm shaft outside diameter

11.981 ~ 11.991 mm

(0.4717 ~ 0.4721 in)

Limit

11.950 mm (0.4705 in)

Rocker-arm-to-rocker-arm-shaft

clearance

0.009 ~ 0.037 mm

(0.0004 ~ 0.0015 in)

ROCKER ARM, CAMSHAFT

ENG

4-19

INSTALLING THE CAMSHAFT AND

ROCKER ARMS

1. Lubricate:

•Camshaft

2. Lubricate:

• Rocker arm

• Rocker arm shaft

3. Install:

• Exhaust rocker arm

• Exhaust rocker arm shaft

TE:N

TE:

Make sure the exhaust rocker arm shaft is

completely pushed into the cylinder head.

4. Install:

• Intake rocker arm

• Intake rocker arm shaft

TE:N

TE:

• Insert a cylinder head bolt (226 mm) into

the hole in the cylinder head and the intake

rocker arm shaft as shown.

• Install the intake rocker arm shaft so that

groove is horizontal and aligning the notch

of the pointed end with the hole in the cyl-

inder head.

Recommended lubricant

Camshaft

Molybdenum disulfide oil

Camshaft bearing

Engine oil

Recommended lubricant

Rocker arm

Molybdenum disulfide oil

Rocker arm shaft

Engine oil

ROCKER ARM, CAMSHAFT

ENG

4-20

5. Install:

• Camshaft

TE:N

TE:

Screw a 10 mm bolt into the threaded end of

the camshaft and then install the camshaft.

6. Install:

• Lock plate

7. Tighten:

• Lock plate bolts

Lock plate bolt

8 Nm (0.8 m•kg, 5.9 ft•lb)

LOCTITE®

ROCKER ARM, CAMSHAFT

ENG

4-21

VALVES AND VALVE SPRINGS

Order Job/Parts to remove Q’ty Remarks

Removing the valves and valve

springs Remove the parts in the order listed.

Cylinder head Refer to “CYLINDER HEAD”.

Rocker arm

Camshaft

1 Valve cotter 4

2 Valve spring retainer 2

3 Outer valve spring 2

4 Inner valve spring 2

5 Intake valve 1

6 Exhaust valve 1

7 Valve stem seal 2

8 Valve spring seat 2

9 Valve guide 2

For installation, reverse the removal

procedure.

VALVES AND VALVE SPRINGS

Refer to “ROCKER ARM, CAMSHAFT”.

ENG

4-22

REMOVING THE VALVES

The following procedure applies to all of the

valves and related components.

TE:N

TE:

Before removing the internal parts of the cylin-

der head (e.g., valves, valve springs, valve

seats), make sure the valves properly seal.

1. Check:

• Valve sealing

Leakage at the valve seat → Check the

valve face, valve seat, and valve seat width.

Refer to “CHECKING THE VALVE SEATS”.

a. Pour a clean solvent into the intake and

exhaust ports.

b. Check that the valves properly seal.

TE:N

TE:

There should be no leakage at the valve seat

2. Remove:

• Valve cotters

TE:N

TE:

Remove the valve cotters by compressing the

valve spring with the valve spring compressor

and the valve spring compressor attachment

Valve spring compressor

90890-04019

YM-04019

Valve spring compressor

attachment

90890-01243

Valve spring compressor adapter

(26 mm)

YM-01253-1

VALVES AND VALVE SPRINGS

ENG

4-23

3. Remove:

• Upper spring seat

• Inner valve spring

• Outer valve spring

•Valve

• Lower spring seat

• Valve stem seal

TE:N

TE:

Identify the position of each part very carefully

so that it can be reinstalled in its original place.

CHECKING THE VALVES AND VALVE

GUIDES

The following procedure applies to all of the

valves and valve guides.

1. Measure:

• Valve-stem-to-valve-guide clearance

Out of specification → Replace the valve

guide.

Valve-stem-to-valve-guide clearance =

Valve guide inside diameter -

Valve stem diameter

Valve-stem-to-valve-guide

clearance

Valve-stem-to-valve-guide

clearance (intake)

0.010 ~ 0.037 mm

(0.0004 ~ 0.0015 in)

Limit

0.080 mm (0.003 in)

Valve-stem-to-valve-guide

clearance (exhaust)

0.025 ~ 0.052 mm

(0.0010 ~ 0.0020 in)

Limit

0.100 mm (0.004 in)

VALVES AND VALVE SPRINGS

ENG

4-24

2. Replace:

• Valve guide

TE:N

TE:

To ease valve guide removal and installation,

and to maintain the correct fit, heat the cylinder

head to 100°C (212°F) in an oven.

a. Remove the valve guide with the valve

guide remover .

b. Install the new valve guide with the valve

guide installer and valve guide remover

c. After installing the valve guide, bore the

valve guide with the valve guide reamer

to obtain the proper valve-stem-to-valve-

guide clearance.

TE:N

TE:

After replacing the valve guide, reface the

valve seat.

3. Eliminate:

• Carbon deposits

(from the valve face and valve seat)

4. Check:

•Valve face

Pitting/wear → Grind the valve face.

• Valve stem end

Mushroom shape or diameter larger than

the body of the valve stem → Replace the

valve.

Valve guide remover (ø6)

90890-04064

Valve guide remover (6.0 mm)

YM-04064-A

Valve guide installer (ø6)

90890-04065

Valve guide installer (6.0 mm)

YM-04065-A

Valve guide reamer (ø6)

90890-04066

Valve guide reamer (6.0 mm)

YM-04066

VALVES AND VALVE SPRINGS

ENG

4-25

5. Measure:

• Valve margin thickness D

Out of specification → Replace the valve.

6. Measure:

• Valve stem runout

Out of specification → Replace the valve.

TE:N

TE:

• When installing a new valve, always replace

the valve guide.

• If the valve is removed or replaced, always

replace the oil seal.

CHECKING THE VALVE SEATS

The following procedure applies to all of the

valves and valve seats.

1. Eliminate:

• Carbon deposits

(from the valve face and valve seat)

2. Check:

• Valve seat

Pitting/wear → Replace the cylinder head.

Valve margin thickness

Valve margin thickness D (intake)

0.80 ~ 1.20 mm

(0.0315 ~ 0.0472 in)

Valve margin thickness D

(exhaust)

0.80 ~ 1.20 mm

(0.0315 ~ 0.0472 in)

Valve stem runout

0.01 mm (0.0004 in)

VALVES AND VALVE SPRINGS

ENG

4-26

3. Measure:

• Valve seat width

Out of specification → Replace the cylinder

head.

a. Apply Mechanic’s blueing dye (Dykem)

onto the valve face.

b. Install the valve into the cylinder head.

c. Press the valve through the valve guide and

onto the valve seat to make a clear impres-

sion.

d. Measure the valve seat width.

TE:N

TE:

Where the valve seat and valve face contacted

one another, the blueing will have been

removed.

4. Lap:

•Valve face

• Valve seat

TE:N

TE:

After replacing the cylinder head or replacing

the valve and valve guide, the valve seat and

valve face should be lapped.

Valve seat width

Valve seat width C (intake)

0.90 ~ 1.10 mm

(0.0354 ~ 0.0433 in)

Valve seat width C (exhaust)

0.90 ~ 1.10 mm

(0.0354 ~ 0.0433 in)

Valve lapper

90890-04101

Valve lapping tool

YM-A8998

VALVES AND VALVE SPRINGS

ENG

4-27

a. Apply a coarse lapping compound to the

valve face.

CAUTION:

Do not let the lapping compound enter the

gap between the valve stem and the valve

guide.

b. Apply molybdenum disulfide oil onto the

valve stem.

c. Install the valve into the cylinder head.

d. Turn the valve until the valve face and valve

seat are evenly polished, then clean off all

of the lapping compound.

TE:N

TE:

For the best lapping results, lightly tap the

valve seat while rotating the valve back and

forth between your hands.

e. Apply a fine lapping compound to the valve

face and repeat the above steps.

f. After every lapping procedure, be sure to

clean off all of the lapping compound from

the valve face and valve seat.

g. Apply Mechanic’s blueing dye (Dykem)

onto the valve face.

h. Install the valve into the cylinder head.

i. Press the valve through the valve guide and

onto the valve seat to make a clear impres-

sion.

j. Measure the valve seat width again. If

the valve seat width is out of specification,

reface and lap the valve seat.

VALVES AND VALVE SPRINGS

ENG

4-28

CHECKING THE VALVE SPRINGS

The following procedure applies to all of the

valve springs.

1. Measure:

• Valve spring free length

Out of specification → Replace the valve

spring.

2. Measure:

• Compressed valve spring force

Out of specification → Replace the valve

spring.

Compressed valve spring force

Installed length

Inner spring

Free length (intake)

36.17 mm (1.42 in)

Free length (exhaust)

36.17 mm (1.42 in)

Outer spring

Free length (intake)

36.63 mm (1.44 in)

Free length (exhaust)

36.63 mm (1.44 in)

Inner spring

Installed compression spring

force (intake)

75.00 ~ 91.70 N (7.65 ~

9.35 kg) (16.86 ~ 20.62 lb)

Installed compression spring

force (exhaust)

75.00 ~ 91.70 N (7.65 ~

9.35 kg) (16.86 ~ 20.62 lb)

Installed length (intake)

30.50 mm (1.20 in)

Installed length (exhaust)

30.50 mm (1.20 in)

Outer spring

Installed compression spring

force (intake)

128.50 ~ 157.90 N (13.10 ~

16.10 kg) (28.89 ~ 35.50 lb)

Installed compression spring

force (exhaust)

128.50 ~ 157.90 N (13.10 ~

16.10 kg) (28.89 ~ 35.50 lb)

Installed length (intake)

32.00 mm (1.26 in)

Installed length (exhaust)

32.00 mm (1.26 in)

VALVES AND VALVE SPRINGS

ENG

4-29

3. Measure:

• Valve spring tilt

Out of specification → Replace the valve

spring.

INSTALLING THE VALVES

The following procedure applies to all of the

valves and related components.

1. Deburr:

• Valve stem end

(with an oil stone)

2. Lubricate:

• Valve stem

• Valve stem seal

(with the recommended lubricant)

3. Install:

• Valve spring seat

• Valve stem seal

•Valve

• Inner valve spring

• Outer valve spring

• Upper spring seat

(into the cylinder head)

TE:N

TE:

Install the valve springs with the larger pitch

facing up.

Larger pitch

Smaller pitch

Inner spring

Spring tilt (intake)

2.5°/1.60 mm (2.5°/0.063 in)

Spring tilt (exhaust)

2.5°/1.60 mm (2.5°/0.063 in)

Outer spring

Spring tilt (intake)

2.5°/1.60 mm (2.5°/0.063 in)

Spring tilt (exhaust)

2.5°/1.60 mm (2.5°/0.063 in)

Recommended lubricant

Molybdenum disulfide oil

VALVES AND VALVE SPRINGS

ENG

4-30

4. Install:

• Valve cotters

TE:N

TE:

Install the valve cotters by compressing the

valve spring with the valve spring compressor

and the valve spring compressor attachment

5. To secure the valve cotters onto the valve

stem, lightly tap the valve tip with a soft-

face hammer.

CAUTION:

Hitting the valve tip with excessive force

could damage the valve.

Valve spring compressor

90890-04019, YM-04019

Valve spring compressor

attachment

90890-01243

Valve spring compressor adapter

(26 mm)

YM-01253-1

VALVES AND VALVE SPRINGS

ENG

4-31

CYLINDER AND PISTON

Order Job/Parts to remove Q’ty Remarks

Removing the cylinder and piston Remove the parts in the order listed.

Cylinder head Refer to “CYLINDER HEAD”.

1 Oil delivery pipe 1

2Cylinder 1

3 Dowel pin 2

4 Cylinder gasket 1

5 Piston pin clip 2

6 Piston pin 1

7Piston 1

8 Piston ring set 1

For installation, reverse the removal

procedure.

10 Nm (1.0 m•kg, 7.4 ft•lb)

17 Nm (1.7 m•kg, 13 ft•lb)

CYLINDER AND PISTON

ENG

4-32

+REMOVING THE PISTON

1. Remove:

• Piston pin clips

• Piston pin

•Piston

TE:N

TE:

• Before removing the piston pin clip, cover the

crankcase opening with a clean rag to pre-

vent the piston pin clip from falling into the

crankcase.

• Before removing each piston pin, deburr the

clip groove and pin hole area. If the piston pin

groove is deburred and the piston pin is still

difficult to remove, use the piston pin puller

CAUTION:

Do not use a hammer to drive the piston

pin out.

2. Remove:

• Top ring

• 2nd ring

•Oil ring

TE:N

TE:

When removing a piston ring, open the end

gap with your fingers and lift the other side of

the ring over the piston crown.

CHECKING THE CYLINDER AND PISTON

1. Check:

•Piston wall

• Cylinder wall

Vertical scratches → Rebore or replace the

cylinder, and replace the piston and piston

rings as a set.

2. Measure:

• Piston-to-cylinder clearance

Piston pin puller set

90890-01304

Piston pin puller

YU-01304

CYLINDER AND PISTON

ENG

4-33

a. Measure cylinder bore “C” with the cylinder

bore gauge.

TE:N

TE:

Measure cylinder bore “C” by taking side-to-

side and front-to-back measurements of the

cylinder. Then, find the average of the mea-

surements.

b. If out of specification, rebore or replace the

cylinder, and replace the piston and piston

rings as a set.

c. Measure piston skirt diameter D with the

micrometer.

5 mm (0.20 in) from the bottom edge of the pis-

ton

d. If out of specification, replace the piston

and piston rings as a set.

e. Calculate the piston-to-cylinder clearance

with the following formula.

Bore “C”

74.000 ~ 74.016 mm

(2.9134 ~ 2.9140 in)

Wear limit

74.100 mm (2.9173 in)

“C” = maximum of D1 ~ D6

Piston size diameter “D”

Standard

73.983 ~ 73.998 mm

(2.9127 ~ 2.9133 in)

Piston-to-cylinder clearance =

Cylinder bore “C” -

Piston skirt diameter “D”

CYLINDER AND PISTON

ENG

4-34

f. If out of specification, rebore or replace the

cylinder, and replace the piston and piston

rings as a set.

CHECKING THE PISTON RINGS

1. Measure:

• Piston ring side clearance

Out of specification → Replace the piston

and piston rings as a set.

TE:N

TE:

Before measuring the piston ring side clear-

ance, eliminate any carbon deposits from the

piston ring grooves and piston rings.

Piston-to-cylinder clearance

0.010 ~ 0.025 mm

(0.0004 ~ 0.0010 in)

Limit

0.15 mm (0.006 in)

Piston ring

Top ring

Ring side clearance

0.030 ~ 0.065 mm

(0.0012 ~ 0.0026 in)

Limit

0.115 mm (0.0045 in)

2nd ring

Ring side clearance

0.020 ~ 0.055 mm

(0.0008 ~ 0.0022 in)

Limit

0.115 mm (0.0045 in)

CYLINDER AND PISTON

ENG

4-35

2. Install:

•Piston ring

(into the cylinder)

TE:N

TE:

Level the piston ring into the cylinder with the

piston crown.

40 mm (1.476 in)

3. Measure:

• Piston ring end gap

Out of specification → Replace the piston

ring.

TE:N

TE:

The oil ring expander spacer’s end gap cannot

be measured. If the oil ring rail’s gap is exces-

sive, replace all three piston rings.

Piston ring

Top ring

End gap (installed)

0.19 ~ 0.31 mm

(0.007 ~ 0.012 in)

Limit

0.56 mm (0.022 in)

2nd ring

End gap (installed)

0.30 ~ 0.45 mm

(0.012 ~ 0.018 in)

Limit

0.80 mm (0.032 in)

Oil ring

End gap (installed)

0.10 ~ 0.35 mm

(0.004 ~ 0.014 in)

CYLINDER AND PISTON

ENG

4-36

CHECKING THE PISTON PIN

1. Check:

• Piston pin

Blue discoloration/grooves → Replace the

piston pin and then check the lubrication

system.

2. Measure:

• Piston pin outside diameter

Out of specification → Replace the piston

pin.

3. Measure:

• Piston pin bore diameter

Out of specification → Replace the piston.

4. Calculate:

• Piston-pin-to-piston-pin-bore clearance

Out of specification → Replace the piston

pin and piston as a set.

Piston pin outside diameter

16.991 ~ 17.000 mm

(0.6689 ~ 0.6693 in)

Limit

16.971 mm (0.6681 in)

Piston pin bore inside diameter

17.002 ~ 17.013 mm

(0.6694 ~ 0.6698 in)

Limit

17.043 mm (0.6710 in)

Piston-pin-to-piston-pin-bore clearance =

Piston pin bore diameter -

Piston pin outside diameter

Piston-pin-to-piston-pin-bore

clearance

0.002 ~ 0.022 mm

(0.0001 ~ 0.0009 in)

Limit

0.072 mm (0.0028 in)

CYLINDER AND PISTON

ENG

4-37

INSTALLING THE PISTON AND CYLINDER

1. Install:

• Lower oil ring rail

• Oil ring expander

• Upper oil ring rail

• 2nd ring

• Top ring

TE:N

TE:

Be sure to install the piston rings so that the

“T” marks or numbers face up.

2. Install:

•Piston

• Piston pin

• Piston pin clips

TE:N

TE:

• Apply engine oil the piston pin.

• Make sure the dot on the piston points

towards the exhaust side of the cylinder.

• Before installing the piston pin clip, cover the

crankcase opening with a clean rag to pre-

vent the clip from falling into the crankcase.

3. Install:

• O-ring

• Cylinder gasket

• Dowel pins

4. Lubricate:

•Piston

•Piston rings

• Cylinder

(with the recommended lubricant)

New

Recommended lubricant

Engine oil

CYLINDER AND PISTON

ENG

4-38

5. Offset:

• Piston ring end gaps

Top ring

Upper oil ring rail

Oil ring expander

Lower oil ring rail

2nd ring

20 mm

6. Install:

• Cylinder

TE:N

TE:

• While compressing the piston rings with one

hand, install the cylinder with the other hand.

• Pass the timing chain and timing chain guide

(exhaust side) through the timing chain cavity.

7. Tighten:

• Cylinder bolts

Cylinder bolt

10 Nm (1.0 m•kg, 7.4 ft•lb)

CYLINDER AND PISTON

ENG

4-39

CLUTCH

Order Job/Parts to remove Q’ty Remarks

Removing the clutch cover Remove the parts in the order listed.

Engine oil Drain.

1 Cotter pin/Washer 1/1

2Clevis pin 1

3 Brake pedal/Footrest 1/1

4 Oil delivery pipe 1

5 Oil cooler hose 2

6O-ring 2

7 Right crankcase cover 1

8 Dowel pin 2

9 Crankcase cover gasket 1

For installation, reverse the removal

procedure.

73 Nm (7.3 m•kg, 54 ft•lb)

10 Nm (1.0 m•kg, 7.4 ft•lb)

20 Nm (2.0 m•kg, 15 ft•lb)

CLUTCH

ENG

4-40

Order Job/Parts to remove Q’ty Remarks

Removing the clutch Remove the parts in the order listed.

1 Clutch spring 5

2 Pressure plate 1

3 Primary drive gear nut 1

4 Friction plate 6

5 Clutch plate 5

6 Clutch boss nut 1

7Clutch boss 1

8 Thrust washer 1

9 Clutch housing 1

10 Claw washer 1

11 Primary drive gear 1

12 Locknut/Washer 1/1

13 Push rod1 1

14 Push plate 1

80 Nm (8.0 m•kg, 59 ft•lb)

8 Nm (0.8 m•kg, 5.9 ft•lb)

75 Nm (7.5 m•kg, 55 ft•lb)

CLUTCH

ENG

4-41

Order Job/Parts to remove Q’ty Remarks

15 Push rod 2/Ball 1/1 For installation, reverse the removal

procedure.

80 Nm (8.0 m•kg, 59 ft•lb)

8 Nm (0.8 m•kg, 5.9 ft•lb)

75 Nm (7.5 m•kg, 55 ft•lb)

CLUTCH

ENG

4-42

Order Job/Parts to remove Q’ty Remarks

Removing the push lever shaft Remove the parts in the order listed.

Shift pedal Refer to “SHIFT SHAFT”.

Left crankcase cover Refer to “PICK UP COIL ROTOR AND

STARTER CLUTCH”.

Clutch assembly

1Clutch cable 1

2Bolt 1

3 Push lever shaft 1

4 Torsion spring 1

5Circlip 1

6 Oil seal 1

7 Bearing 1

For installation, reverse the removal

procedure.

CLUTCH

ENG

4-43

REMOVING THE CLUTCH

1. Remove:

•Bolt

• Clutch spring

TE:N

TE:

Loosen the bolts in stages and in a crisscross

pattern.

2. Straighten the lock washer tab.

3. Loosen:

• Primary drive gear nut

• Clutch boss nut

TE:N

TE:

• Place the aluminum plate between clutch

housing and primary drive gear , and

then loosen the primary drive gear nut .

• While holding the clutch boss with the univer-

sal clutch holder , loosen the clutch boss

nut .

4. Remove:

• Clutch boss nut

• Lock washer

• Clutch boss

• Thrust washer

• Clutch housing

5. Remove:

• Primary drive gear nut

• Lock washer

• Claw washer

• Primary drive gear

Universal clutch holder

90890-04086, YM-91042

CLUTCH

ENG

4-44

CHECKING THE FRICTION PLATES

The following procedure applies to all of the

friction plates.

1. Check:

• Friction plate

Damage/wear → Replace the friction plate.

2. Measure:

• Friction plate thickness

Out of specification → Replace the friction

plate.

TE:N

TE:

Measure the friction plate at four places.

CHECKING THE CLUTCH PLATES

The following procedure applies to all of the

clutch plates.

1. Check:

• Clutch plate

Damage → Replace the clutch plate.

2. Measure:

• Clutch plate warpage

(with a surface plate and thickness gauge

)

Out of specification → Replace the clutch

plate.

Friction plate thickness

2.9 ~ 3.1 mm (0.114 ~ 0.122 in)

Wear limit

2.8 mm (0.110 in)

Warpage limit

0.2 mm (0.0079 in)

CLUTCH

ENG

4-45

CHECKING THE CLUTCH SPRINGS

The following procedure applies to all of the

clutch springs.

1. Check:

•Clutch spring

Damage → Replace the clutch spring.

2. Measure:

• Clutch spring free length

Out of specification → Replace the clutch

spring.

CHECKING THE CLUTCH HOUSING

1. Check:

• Clutch housing dogs

Damage/pitting/wear → Deburr the clutch

housing dogs or replace the clutch housing.

TE:N

TE:

Pitting on the clutch housing dogs will cause

erratic clutch operation.

CHECKING THE CLUTCH BOSS

1. Check:

• Clutch boss splines

Damage/pitting/wear → Replace the clutch

boss.

TE:N

TE:

Pitting on the clutch boss splines will cause

erratic clutch operation.

CHECKING THE PRESSURE PLATE

1. Check:

• Pressure plate

Cracks/damage → Replace.

Clutch spring free length

47.80 mm (1.88 in)

Minimum length

46.50 mm (1.83 in)

CLUTCH

ENG

4-46

CHECKING THE CLUTCH PUSH RODS

1. Check:

• Push lever shaft

• Push rod 2

• Ball

Cracks/damage/wear → Replace the

defective part(s).

CHECKING THE PRIMARY DRIVE GEAR

1. Check:

• Primary drive gear

Damage/wear → Replace the primary drive

and primary driven gears as a set.

Excessive noise during operation →

Replace the primary drive and primary

driven gears as a set.

2. Check:

• Primary-drive-gear-to-primary-driven-gear

free play

Free play exists → Replace the primary

drive and primary driven gears as a set.

INSTALLING THE CLUTCH

1. Install:

• Primary drive gear

• Claw washer

• Lock washer

• Primary drive gear nut

2. Install:

• Clutch housing

• Thrust washer

• Clutch boss

• Lock washer

• Clutch boss nut

TE:N

TE:

Make sure the teeth on the lock washer are

correctly aligned with the grooves on the clutch

boss.

CLUTCH

ENG

4-47

3. Tighten:

• Clutch boss nut

• Primary drive gear nut

TE:N

TE:

• While holding the clutch boss with the univer-

sal clutch holder , tighten the clutch boss

nut.

• Place the aluminum plate between pri-

mary drive gear and clutch housing ,

and then tighten the primary drive gear nut.

4. Bend the lock washer tab along a flat side

of the nut.

5. Lubricate:

• Friction plates

• Clutch plates

(with the recommended lubricant)

)

6. Install:

• Friction plates (6 piece)

• Clutch plates (5 piece)

TE:N

TE:

First, install a friction plate and then alternate

between a clutch plate and a friction plate.

Clutch boss nut

75 Nm (7.5 m•kg, 55 ft•lb)

Primary drive gear nut

80 Nm (8.0 m•kg, 59 ft•lb)

Universal clutch holder

90890-04086, YM-91042

Recommended lubricant

Engine oil

CLUTCH

ENG

4-48

7. Install:

• Bearing

•Oil seal

•Circlip

• Torsion spring

• Push lever shaft

•Bolt

•Clutch cable

TE:N

TE:

After installing the clutch cable, bend the push

lever shaft tab along a flat side of the nut.

8. Install:

• Push rod 2

•Ball

• Push rod 1

• Push plate

• Washer

• Locknut

• Pressure plate

• Clutch spring

•Bolt

9. Tighten:

• Clutch spring bolt

• Locknut

TE:N

TE:

Tighten the clutch spring bolts in stages and in

a crisscross pattern.

10.Check:

• Push lever position

Push lever mark and crankcase mark

not aligned → Correct.

TE:N

TE:

Push the push lever in direction and make

sure the marks are aligned.

Clutch spring bolt

8 Nm (0.8 m•kg, 5.9 ft•lb)

Locknut

8 Nm (0.8 m•kg, 5.9 ft•lb)

CLUTCH

ENG

4-49

11.Adjust:

• Push lever position

a. Loosen the locknut .

b. Turn the adjusting screw in or out until

the marks are aligned.

c. Hold the adjusting screw to prevent it from

moving and then tighten the locknut to

specification.

CAUTION:

Do not overtighten the locknut since this

will remove the free play between both

push rods.

12.Check:

• Clutch cable free play

Refer to “ADJUSTING THE CLUTCH

CABLE FREE PLAY” in chapter 3.

13.Install:

•Spacer

• Dowel pin

• Crankcase cover gasket

14.Install:

• Right crankcase cover

15.Install:

• Crankcase cover bolts M6 × 50 mm ,

• Copper washers to ,

• Crankcase cover bolts M6 × 40 mm ~

• Crankcase cover bolts M6 × 25 mm ~

• Oil filter element cover bolt M6 × 70 mm

16.Tighten:

• Crankcase cover bolts ~

• Oil filter element cover bolt

TE:N

TE:

Tighten the bolts in stages, using a crisscross

pattern.

8 Nm (0.8 m•kg, 5.9 ft•lb)

Clutch lever free play

5 ~ 10 mm (0.20 ~ 0.39 in)

Crankcase cover bolt

10 Nm (1.0 m•kg, 7.4 ft•lb)

Oil filter element cover bolt

10 Nm (1.0 m•kg, 7.4 ft•lb)

CLUTCH

ENG

4-50

OIL PUMP AND BLANCER WEIGHT GEAR

Order Job/Parts to remove Q’ty Remarks

Removing the oil pump and bal-

ancer weight gear Remove the parts in the order listed.

Right crankcase cover Refer to “CLUTCH”.

Clutch

Primary drive gear

1 Balancer weight gear nut 1

2 Lock washer 1

3 Buffer boss 1

4 Balancer weight gear 1

5 Absorber plate 1

6 Compression spring 6

7 Dowel pin 3

8 Straight key 1

9 Spacer 1

10 Circlip 1

11 Oil pump driven gear 1

12 Oil pump assembly 1

13 Gasket 1

6 Nm (0.6 m•kg, 4.4 ft•lb)

55 Nm (5.5 m•kg, 41 ft•lb)

OIL PUMP AND BLANCER WEIGHT GEAR

ENG

4-51

Order Job/Parts to remove Q’ty Remarks

14 Balancer drive gear 1

15 Oil strainer 1

16 Spacer 1

For installation, reverse the removal

procedure.

6 Nm (0.6 m•kg, 4.4 ft•lb)

55 Nm (5.5 m•kg, 41 ft•lb)

OIL PUMP AND BLANCER WEIGHT GEAR

ENG

4-52

Order Job/Parts to remove Q’ty Remarks

Disassembling the oil pump Remove the parts in the order listed.

Oil pump housing 1

Dowel pin 2

Outer rotor 1

Inner rotor 1

Dowel pin 1

Shaft 1

Oil pump cover 1

For assembly, reverse the disassembly

procedure.

7 Nm (0.7 m•kg, 5.0 ft•lb)

OIL PUMP AND BLANCER WEIGHT GEAR

ENG

4-53

REMOVING THE BALANCER WEIGHT

GEAR AND OIL PUMP

1. Straighten the lock washer tab.

2. Remove:

• Balancer weight gear nut

• Lock washer

• Balancer weight gear

TE:N

TE:

Place the aluminum plate between balancer

drive gear and balancer weight gear ,

and then loosen the balancer weight gear nut

3. Remove:

• Oil pump assembly

CHECKING THE OIL PUMP

1. Check:

• Oil pump driven gear

• Oil pump housing

• Oil pump cover

Cracks/damage/wear → Replace the

defective part(s).

2. Measure:

• Inner-rotor-to-outer-rotor-tip clearance

• Outer-rotor-to-oil-pump-housing clearance

• Oil-pump-housing-to-inner-rotor-and-outer-

rotor clearance

Out of specification → Replace the oil

pump.

Inner rotor

Outer rotor

Oil pump housing

OIL PUMP AND BLANCER WEIGHT GEAR

ENG

4-54

3. Check:

• Oil pump operation

Rough movement → Repeat steps (1) and

(2) or replace the defective part(s).

CHECKING THE BALANCER WEIGHT

GEAR

1. Check:

• Balancer weight gear

• Buffer boss

• Compression spring

• Dowel pin

• Cracks/damage/wear → Replace.

Inner-rotor-to-outer-rotor-tip

clearance

0.150 mm (0.0059 in)

Limit

0.23 mm (0.0091 in)

Outer-rotor-to-oil-pump-housing

clearance

0.100 ~ 0.151 mm

(0.0039 ~ 0.0059 in)

Limit

0.22 mm (0.0087 in)

Oil-pump-housing-to-inner-and-

outer-rotor clearance

0.04 ~ 0.09 mm

(0.0016 ~ 0.0035 in)

Limit

0.16 mm (0.0063 in)

OIL PUMP AND BLANCER WEIGHT GEAR

ENG

4-55

ASSENBLING THE BALANCER DRIVE

GEAR

1. Assemble:

• Dowel pin

• Compression spring

TE:N

TE:

Install the dowel pins and compression springs

alternately as shown as.

2. Assemble:

• Buffer boss

INSTALLING THE OIL PUMP

1. Install:

•Gasket

• Oil pump

2. Tighten:

• Oil pump bolts

CAUTION:

After tightening the bolts, make sure the oil

pump turns smoothly.

Oil pump bolt

6 Nm (0.6 m•kg, 4.4 ft•lb)

LOCTITE®

OIL PUMP AND BLANCER WEIGHT GEAR

ENG

4-56

INSTALLING THE BALANCER WEIGHT

GEAR

1. Install:

• Balancer weight gear

• Lock washer

• Balancer weight gear nut

2. Tighten:

• Balancer weight gear nut

TE:N

TE:

• Align the punch mark in the balancer drive

gear with the punch mark in the balancer

weight gear.

• Place the aluminum plate between bal-

ancer drive gear and balancer weight gear

, and then tighten the balancer weight gear

nut .

3. Bend the lock washer tab along a flat side

of the nut.

Balancer weight gear nut

55 Nm (5.5 m•kg, 41 ft•lb)

OIL PUMP AND BLANCER WEIGHT GEAR

ENG

4-57

SHIFT SHAFT

Order Job/Parts to remove Q’ty Remarks

Removing the shift shaft and

stopper lever Remove the parts in the order listed.

Right crankcase cover Refer to “CLUTCH”.

Clutch

1 Shift pedal 1

2 Shift shaft assembly 1

3 Stopper lever 1

4 Torsion spring 1

For installation, reverse the removal

procedure.

10 Nm (1.0 m•kg, 7.4 ft•lb)

SHIFT SHAFT

ENG

4-58

CHECKING THE SHIFT SHAFT

1. Check:

• Shift shaft

• Shift lever

Bends/damage/wear → Replace.

• Shift lever spring

Damage/wear → Replace.

CHECKING THE STOPPER LEVER

1. Check:

• Stopper lever

Bends/damage → Replace.

Roller turns roughly → Replace the stopper

lever.

• Torsion spring

Damage/wear → Replace.

INSTALLING THE SHIFT SHAFT

1. Install:

• Stopper lever

TE:N

TE:

• Hook the ends of the stopper lever spring

onto the stopper lever and the crankcase

boss.

• Mesh the stopper lever with the shift drum

segment assembly.

2. Tighten:

• Stopper lever bolt

3. Install:

• Shift shaft

TE:N

TE:

Install the shift shaft by aligning the shift

shaft spring with the stopper .

Stopper lever bolt

10 Nm (1.0 m•kg, 7.4 ft•lb)

LOCTITE®

SHIFT SHAFT

ENG

4-59

4. Check:

• When the gear position is in Neutral, check

the length ( , ) between the tip of the

shift lever and dowel pin are equal.

If not → Replace the shift shaft.

5. Install:

• Shift pedal

6. Tighten:

• Shift pedal bolt

7. Adjust:

• Shift pedal height

Refer to “ADJUSTING THE SHIFT PEDAL”

in chapter 3.

Shift pedal bolt

10 Nm (1.0 m•kg, 7.4 ft•lb)

SHIFT SHAFT

ENG

4-60

PICKUP COIL ROTOR AND STARTER CLUTCH

Order Job/Parts to remove Q’ty Remarks

Removing the pickup coil rotor and

starter clutch Remove the parts in the order listed.

Engine oil Drain.

Shift pedal Refer to “SHIFT SHAFT”.

Drive sprocket cover Refer to “REAR SHOCK ABSORBER,

SWINGARM AND DRIVE CHAIN” in

chapter 6.

1 Starter idle gear cover/O-ring 1/1

2 Starter idler gear 1/shaft 1/1

3 Pickup coil rotor lead coupler 2 Disconnect.

4 Left crankcase cover 1

5 Dowel pin 2

6 Crank case cover gasket 1

7 Stator coil assembly/pickup coil 1/1

8 Starter idler gear 2/shaft 1/1

9 Pickup coil rotor 1

10 Woodruff key 1

11 Starter wheel gear 1

30 Nm (3.0 m•kg, 22 ft•lb)

10 Nm (1.0 m•kg, 7.4 ft•lb)

60 Nm (6.0 m•kg, 44 ft•lb) 10 Nm (1.0 m•kg, 7.4 ft•lb)

7 Nm (0.7 m•kg, 5.2 ft•lb)

PICKUP COIL ROTOR AND STARTER CLUTCH

ENG

4-61

Order Job/Parts to remove Q’ty Remarks

12 Bearing 1

13 Washer 1

14 Starter clutch assembly 1

For installation, reverse the removal

procedure.

30 Nm (3.0 m•kg, 22 ft•lb)

10 Nm (1.0 m•kg, 7.4 ft•lb)

60 Nm (6.0 m•kg, 44 ft•lb) 10 Nm (1.0 m•kg, 7.4 ft•lb)

7 Nm (0.7 m•kg, 5.2 ft•lb)

PICKUP COIL ROTOR AND STARTER CLUTCH

ENG

4-62

REMOVING THE PICKUPCOIL ROTOR

1. Remove:

• Pickup coil rotor bolt

• Washer

TE:N

TE:

• Loosen the pickup coil rotor bolt while

holding the rotor with a sheave holder .

• Do not allow the sheave holder to touch the

projection on the rotor .

2. Remove:

• Pickup coil rotor

TE:N

TE:

Remove the rotor using flywheel puller .

3. Remove:

• Woodruff key

4. Remove:

• Starter idle gear 2

• Starter wheel gear

• Bearing

• Washer

Sheave holder

90890-01701

Primary clutch holder

YS-01880-A

Flywheel puller

90890-01362

Heavy duty puller

YU-33270-B

Bolt (M8 × 80 mm)

90890-01359

PICKUP COIL ROTOR AND STARTER CLUTCH

ENG

4-63

CHECKING THE STARTER CLUTCH

1. Check:

• Starter clutch rollers

Damage/wear → Replace the starter

clutch.

2. Check:

• Starter idle gear

• Starter wheel gear

• Starter clutch gear

Burrs/chips/roughness/wear → Replace

the defective part(s).

3. Check:

• Starter clutch gear’s contacting surfaces

Damage/pitting/wear → Replace the

starter clutch gear.

4. Check:

• Starter clutch operation

a. Install the starter wheel gear onto the

starter clutch and hold the starter clutch.

b. When turning the starter wheel gear clock-

wise , the starter clutch and the starter

wheel gear should engage, otherwise the

starter clutch is faulty and must be

replaced.

c. When turning the starter wheel gear coun-

terclockwise , it should turn freely, other-

wise the starter clutch is faulty and must be

replaced.

5. Check:

•Shaft

Damage/fatigue/wear → Replace the

defective part(s).

PICKUP COIL ROTOR AND STARTER CLUTCH

ENG

4-64

INSTALLING THE PICKUP COIL ROTOR

1. Install:

• Washer

• Bearing

• Starter wheel gear

• Starter idle gear 2

2. Install:

• Woodruff key

• Pickup coil rotor

• Washer

• Pickup coil rotor bolt

TE:N

TE:

• Clean the tapered portion of the crankshaft

and the rotor hub.

• When installing the rotor, make sure the woo-

druff key is properly seated in the key way of

the crankshaft.

3. Tighten:

• Pickup coil rotor bolt

TE:N

TE:

• Tighten the pickup coil rotor bolt while

holding the rotor with a sheave holder .

• Do not allow the sheave holder to touch the

projection on the rotor .

Pickup coil rotor bolt

60 Nm (6.0 m•kg, 44 ft•lb)

Sheave holder

90890-01701

Primary clutch holder

YS-01880-A

PICKUP COIL ROTOR AND STARTER CLUTCH

ENG

4-65

4. Install:

• Stater coil

• Pickup coil

5. Tighten:

• Stater coil bolts

• Pickup coil bolts

• Left crankcase cover bolt

6. Install:

• Dowel pin

• Crankcase cover gasket

7. Install:

• Left crankcase cover

8. Install:

• Crankcase cover bolts M6 × 30 mm ~

• Crankcase cover bolt M6 × 45 mm

• Crankcase cover bolts M6 × 40 mm ~

9. Tighten:

• Crankcase cover bolts ~

TE:N

TE:

Tighten the bolts in stages and in a crisscross

pattern as shown.

10.Install:

• Starter idle gear 1

•Shaft

11.Install:

• O-ring

• Starter idle gear cover

12.Tighten:

• Starter idle gear cover bolt

Stater coil bolt

10 Nm (1.0 m•kg, 7.4 ft•lb)

LOCTITE®

Pickup coil bolt

10 Nm (1.0 m•kg, 7.4 ft•lb)

LOCTITE®

Left crankcase cover bolt

7 Nm (0.7 m•kg, 5.2 ft•lb)

LOCTITE®

Crankcase cover bolt

10 Nm (1.0 m•kg, 7.2 ft•lb)

Starter idle gear cover bolt

10 Nm (1.0 m•kg, 7.4 ft•lb)

PICKUP COIL ROTOR AND STARTER CLUTCH

ENG

4-66

CRANKCASE

Order Job/Parts to remove Q’ty Remarks

Separating the crankcase Remove the parts in the order listed.

Engine Refer to “ENGINE REMOVAL”.

Cylinder head Refer to “CYLINDER HEAD”.

Cylinder Refer to “CYLINDER AND PISTON”.

Clutch Refer to “CLUTCH”.

Oil pump Refer to “OIL PUMP AND BLANCER

WEIGHT GEAR”.

Balancer weight gear

Shift shaft Refer to “SHIFT SHAFT”.

Pickup coil rotor Refer to “PICKUP COIL ROTOR AND

STARTER CLUTCH”.

1 Timing chain guide (intake side) 1

2 Timing chain 1

3 Crankshaft sprocket 1

4 Right crankcase 1

5 Dowel pin 2

6 Left crankcase 1

8 Nm (0.8 m•kg, 5.9 ft•lb)

20 Nm (2.0 m•kg, 15 ft•lb)

10 Nm (1.0 m•kg, 7.4 ft•lb)

CRANKCASE

ENG

4-67

Order Job/Parts to remove Q’ty Remarks

7 Spacer 1

For installation, reverse the removal

procedure.

8 Nm (0.8 m•kg, 5.9 ft•lb)

20 Nm (2.0 m•kg, 14.8 ft•lb)

10 Nm (1.0 m•kg, 7.4 ft•lb)

CRANKCASE

ENG

4-68

Order Job/Parts to remove Q’ty Remarks

Removing the bearing Remove the parts in the order listed.

Crankshaft assembly Refer to “CRANKSHAFT ASSEMBLY”.

Main axle assembly/drive axle assem-

bly Refer to “TRANSMISSION”.

1 Oil seal 2

2 Bearing 8

For installation, reverse the removal

procedure.

CRANKCASE

ENG

4-69

DISASSEMBLING THE CRANKCASE

1. Remove:

• Timing chain guide (intake side)

• Timing chain

• Crankshaft sprocket

2. Remove:

• Neutral switch

• Crankcase bolts M6 × 70 mm ~

• Copper washers

• Crankcase bolts M6 × 60 mm ,

• Crankcase bolts M6 × 55 mm ~

• Crankcase bolts M6 × 45 mm ~

TE:N

TE:

Loosen each bolt 1/4 of a turn at a time, in

stages and in a crisscross pattern. After all of

the bolts are fully loosened, remove them.

3. Turn:

• Shift drum segment

TE:N

TE:

Turn the shift drum segment to the position

shown in the illustration. In this position, the

shift drum segment’s teeth will not contact the

crankcase during crankcase separation.

4. Remove:

• Right crankcase

CAUTION:

• First check that the shift drum segment’s

teeth and the drive axle circlip are prop-

erly positioned, then remove the right

crankcase.

• Do not damage the crankcase mating sur-

faces.

CRANKCASE

ENG

4-70

CHECKING THE CRANKCASE

1. Thoroughly wash the crankcase halves in a

mild solvent.

2. Thoroughly clean all the gasket surfaces

and crankcase mating surfaces.

3. Check:

•Crankcase

Cracks/damage → Replace.

• Oil delivery passages

Obstruction → Blow out with compressed

air.

ASSEMBLING THE CRANKCASE

1. Apply:

• Yamaha bond No.1215 (Three Bond

No.1215®)

(onto the crankcase mating surfaces)

TE:N

TE:

Do not allow any sealant to come into contact

with the oil gallery.

2. Install:

• Dowel pins

3. Install:

• Right crankcase

(onto the left crankcase)

TE:N

TE:

Tap lightly on the right crankcase with a soft-

face hammer.

Yamaha bond No.1215

(Three Bond No.1215®)

90890-85505

CRANKCASE

ENG

4-71

4. Install:

• Crankcase bolts M6 × 70 mm ~

• Copper washers to ~ .

• Crankcase bolts M6 × 60 mm ,

• Crankcase bolts M6 × 55 mm ~

• Crankcase bolts M6 × 45 mm ~

5. Tighten:

• Crankcase bolts ~

TE:N

TE:

Tighten each bolt 1/4 of a turn at a time, in

stages and in a crisscross pattern.

6. Install:

• Neutral switch

7. Install:

• Crankshaft sprocket

• Timing chain guide (intake side)

• Timing chain

8. Tighten:

• Timing chain guide (intake side) bolt

9. Apply:

• Engine oil

(onto the crankshaft pins bearings and oil

delivery holes)

10.Check:

• Crankshaft and transmission operation

Rough movement → Repair.

Crankcase bolt

10 Nm (1.0 m•kg, 7.4 ft•lb)

Timing chain guide (intake side)

bolt

8 Nm (0.8 m•kg, 5.9 ft•lb)

LOCTITE®

CRANKCASE

ENG

4-72

CRANKSHAFT ASSEMBLY

Order Job/Parts to remove Q’ty Remarks

Removing the crankshaft assembly Remove the parts in the order listed.

Crankcase Refer to “CRANKCASE”.

1 Balancer weight 1

2 Crankshaft assembly 1

3 Dowel pin 1

4 Plunger seal 1

5 Bearing 1

For installation, reverse the removal

procedure.

CRANKSHAFT ASSEMBLY

ENG

4-73

REMOVING THE CRANKSHAFT ASSEMBLY

1. Remove:

• Balancer weight

• Crankshaft assembly

TE:N

TE:

• Remove the crankshaft assembly with the

crankcase separating tool .

• Make sure the crankcase separating tool is

centered over the crankshaft assembly.

REMOVING THE PLUNGER SEAL

1. Remove:

• Dowel pin

• Plunger seal

• Compression spring

Remove the plunger seal and compression

spring, push the plunger seal lightly and

remove the dowel pin.

CHECKING THE CRANKSHAFT AND

CONNECTING ROD

1. Measure:

• Crankshaft runout

Out of specification → Replace the crank-

shaft, bearing or both.

TE:N

TE:

Turn the crankshaft slowly.

Crankcase separating tool

90890-01135

Crankcase separator

YU-01135-B

Runout limit C

0.03 mm (0.0012 in)

CRANKSHAFT ASSEMBLY

ENG

4-74

2. Measure:

• Big end side clearance

Out of specification → Replace the big end

bearing, crankshaft pin, or connecting rod.

3. Measure:

• Crankshaft width

Out of specification → Replace the crank-

shaft.

4. Check:

• Crankshaft sprocket

Damage/wear → Replace the crankshaft.

• Bearing

Cracks/damage/wear → Replace the

crankshaft.

5. Check:

• Crankshaft journal oil passage

Obstruction → Blow out with compressed

air.

CHECKING THE TIMING CHAIN,

CRANKSHAFT SPROCKET AND TIMING

CHAIN GUIDE

The following procedure applies to all of the

camshaft sprockets and timing chain guides.

1. Check:

• Timing chain

Damage/stiffness → Replace the timing

chain and camshaft sprocket and crank-

shaft sprocket as a set.

2. Check:

• Crankshaft sprocket

More than 1/4 tooth wear → Replace

the timing chain and camshaft sprocket and

crankshaft sprocket as a set.

1/4 tooth

Correct

Timing chain roller

Crankshaft sprocket

Big end side clearance D

0.350 ~ 0.650 mm

(0.0138 ~ 0.0256 in)

Width A

69.25 ~ 69.30 mm

(2.726 ~ 2.728 in)

CRANKSHAFT ASSEMBLY

ENG

4-75

3. Check:

• Timing chain guide (intake side)

Damage/wear → Replace the timing chain

guide (intake side)

INSTALLING THE PLUNGER SEAL

1. Install:

• Compression spring

• Plunger seal

• Dowel pin

Check the plunger seal smooth operation

pushing the plunger seal by your finger.

INSTALLING THE CRANKSHAFT

ASSEMBLY

1. Install:

• Crankshaft assembly

TE:N

TE:

Install the crankshaft assembly with the crank-

shaft installer pot , crankshaft installer bolt

, adapter and spacer .

Crankshaft installer pot

90890-01274

Installing pot

YU-90058

Crankshaft installer bolt

90890-01275

Bolt

YU-90060

Spacer

90890-01288

Adapter (M10)

90890-01383

Adapter #2

YU-90062

CRANKSHAFT ASSEMBLY

ENG

4-76

CAUTION:

To avoid scratching the crankshaft and to

ease the installation procedure, lubricate

the oil seal lips with lithium-soap-based

grease and each bearing with engine oil.

TE:N

TE:

Hold the connecting rod at top dead center

(TDC) with one hand while turning the nut of

the crankshaft installer bolt with the other. Turn

the crankshaft installer bolt until the crankshaft

assembly bottoms against the bearing.

2. Install:

• Balancer weight

To the right crank case.

CRANKSHAFT ASSEMBLY

ENG

4-77

TRANSMISSION

Order Job/Parts to remove Q’ty Remarks

Removing the transmission, shift

drum assembly, and shift forks Remove the parts in the order listed.

Crankcase Separate.

Refer to “CRANKCASE”.

1 Shift fork guide bar 1

2 Shift drum assembly 1

3 Shift fork-3 (R) 1

4 Shift fork-2 (C) 1

5 Shift fork-1 (L) 1

6 Main axle assembly 1

7 Drive axle assembly 1

For installation, reverse the removal

procedure.

TRANSMISSION

ENG

4-78

Order Job/Parts to remove Q’ty Remarks

Disassembling the transmission Remove the parts in the order listed.

1 2nd pinion gear 1

2 5th pinion gear 1

3 3rd pinion gear 1

4 Circlip/washer 1/1

5 4th pinion gear 1

6 Main axle 1

7 Plain washer 1

8 1st wheel gear 1

9 4th wheel gear 1

10 Circlip/washer 1/1

11 3rd wheel gear/collar 1/1

12 Claw washer 1 1

13 Claw washer 2 1

14 5th wheel gear 1

15 Circlip/washer 1/1

16 2nd wheel gear 1

12 13 14

TRANSMISSION

ENG

4-79

Order Job/Parts to remove Q’ty Remarks

17 Drive axle 1

For installation, reverse the removal

procedure.

12 13 14

TRANSMISSION

ENG

4-80

REMOVING THE TRANSMISSION

1. Remove:

• Shift fork guide bar

• Shift drum assembly

• Shift fork 3 (R)

• Shift fork 2 (C)

• Shift fork 1 (L)

2. Remove:

• Transmission

CHECKING THE SHIFT FORKS

The following procedure applies to all of the

shift forks.

1. Check:

• Shift fork movement

(along the shift fork guide bar)

Rough movement → Replace the shift forks

and shift fork guide bar as a set.

Shift fork 3 (R)

Shift fork 2 (C)

Shift fork 1 (L)

Shift fork guide bar

Shift drum assembly

Shift fork cam follower

2. Check:

• Shift fork cam follower

• Shift fork pawl

Bends/damage/scoring/wear → Replace

the shift fork.

3. Check:

• Shift fork guide bar

Roll the shift fork guide bar on a flat sur-

face.

Bends → Replace.

WARNING

Do not attempt to straighten a bent shift

fork guide bar.

TRANSMISSION

ENG

4-81

CHECKING THE SHIFT DRUM ASSEMBLY

1. Check:

• Shift drum groove

Damage/scratches/wear → Replace the

shift drum assembly.

• Shift drum segment

Damage/wear → Replace the shift drum

assembly.

• Shift drum bearing

Damage/pitting → Replace the shift drum

assembly.

CHECKING THE TRANSMISSION

1. Measure:

• Main axle runout

(with a centering device and dial gauge)

Out of specification → Replace the main

axle.

2. Measure:

• Drive axle runout

(with a centering device and dial gauge)

Out of specification → Replace the drive

axle.

3. Check:

• Transmission gears

Blue discoloration/pitting/wear → Replace

the defective gear(s).

• Transmission gear dogs

Cracks/damage/rounded edges →

Replace the defective gear(s).

Main axle runout limit

0.06 mm (0.0024 in)

Drive axle runout limit

0.06 mm (0.0024 in)

TRANSMISSION

ENG

4-82

4. Check:

• Transmission gear engagement

(each pinion gear to its respective wheel

gear)

Incorrect → Reassemble the transmission

axle assemblies.

TE:N

TE:

When reassembling the main axle, press the

2nd pinion gear onto it as shown.

102.2 ~ 102.4 mm (4.02 ~ 4.03 in)

5. Check:

• Transmission gear movement

Rough movement → Replace the defective

part(s).

6. Check:

•Circlips

Bends/damage/looseness → Replace.

INSTALLING THE SHIFT FORKS AND SHIFT

DRUM ASSEMBLY

1. Install:

• Transmission

• Shift fork 1 (L)

• Shift fork 2 (C)

• Shift fork 3 (R)

• Shift drum assembly

• Shift fork guide bar

•Spacer

• Right crankcase

TE:N

TE:

• The embossed marks on the shift forks

should face towards the left side of the engine

and be in the following sequence: “L”, “C”, “R”.

• The grooved side of the shift fork guide bar

should face towards the right side of the

engine.

2. Check:

• Shift cam operation

Unsmoothy operation → Repair.

TE:N

TE:

Check the transmission and shift forks for

smooth operation by turning the shift cam with

your hand.

TRANSMISSION

CARB

5-1

EBS00141 CARBURETOR

CARBURETOR

Order Job/Part Q’ty Remarks

Removing a carburetor Remove the parts in the order listed.

Seat/front fender/rear fender/air filter

case Refer to “SEAT, FENDERS AND FUEL

TANK” in chapter 3.

1 Carburetor warmer coupler 1 Disconnect.

2 Air vent hose 1 Disconnect.

3 Fuel hose (carburetor side) 1

4 Throttle cable cover 1

5 Throttle cable 1

6 Clamp 1 Loosen.

7 Clamp 2 Loosen.

8Carburetor 1

9 Carburetor joint 1

For installation, reverse the removal

procedure.

2 Nm (0.2 m•kg, 1.5 ft•lb)

3.5 Nm (0.4 m•kg, 2.6 ft•lb)

Refer to “INSTALLING

THE CARBURETOR

JOINT” and “INSTALL-

ING THE CARBURE-

TOR”.

CARBURETOR

CARB

5-2

EBS00144

Order Job/Part Q’ty Remarks

Disassembling the carburetor Remove the parts in the order listed.

Drain hose 1

Throttle stop screw 1

Cover 1

Diaphragm spring 1

Piston valve 1

Jet needle 1

Cover 1

Spring 1

Coasting enricher diaphragm 1

Coasting enricher jet (P. A. J. 2) 1

Starter plunger 1

Carburetor warmer positive lead 1

Carburetor warmer 1

Carburetor warmer negative lead 1

Float chamber 1

Float pin 1

CARBURETOR

CARB

5-3

Order Job/Part Q’ty Remarks

Float 1

Needle valve seat set 1

Main jet 1

Needle jet holder 1

Needle jet 1

Pilot jet 1

Starter jet 1

For assembly, reverse the disassembly

procedure.

CARBURETOR

CARB

5-4

EBS00148

CHECKING THE CARBURETOR

1. Check:

• carburetor body

• float chamber

Cracks/damage → Replace.

• fuel passage

Contamination → Clean as indicated.

• fuel chamber body

Contamination → Clean.

a. Wash the carburetor in a petroleum based

solvent. Do not use any caustic carburetor

cleaning solution.

b. Blow out all of the passages and jets with

compressed air.

2. Check:

• float

• float tang

Damage → Replace.

3. Check:

• valve seat

• needle valve

Contamination → Clean.

Wear/damage → Replace as a set.

TE:N

TE:

Always replace the valve seat, needle valve

and O-ring as a set.

4. Check:

• piston valve

Scratches/wear/damage → Replace.

• piston valve diaphragm

Cracks/tears → Replace.

CARBURETOR

CARB

5-5

5. Check:

• piston valve movement

Sticks → Replace.

Insert the piston valve into the carburetor

body, and check for free movement.

6. Check:

• throttle valve movement

Sticks → Replace.

7. Check:

•cover

• diaphragm spring

Cracks/damage → Replace.

8. Check:

• coasting enricher diaphragm

• spring

Cracks/damage → Replace.

9. Check:

• jet needle

Bends/wear/damage → Replace.

• clip groove

Free play/wear → Replace.

10.Check:

• main jet

• pilot jet

• needle jet

• needle jet holder

• starter jet

• coasting enricher jet (P. A. J. 2)

Bends/wear/damage → Replace.

Blockage → Blow out the jets with com-

pressed air.

CARBURETOR

CARB

5-6

11.Check:

• starter plunger

• starter plunger spring

Bends/cracks/damage → Replace.

EBS00150

ASSEMBLING THE CARBURETOR

CAUTION:

Before reassembling, wash all of the parts

in a clean petroleum based solvent.

1. Measure:

• float height

Out of specification → Adjust.

a. Hold the carburetor in an upside down posi-

tion.

b. Measure the distance from the front mating

surface of the float chamber (gasket

removed) to the top of the float.

TE:N

TE:

The float arm should be resting on the needle

valve, but not compressing it.

c. If the float height is not within the specifica-

tion, check the valve seat and needle valve.

d. If either is worn, replace the valve seat,

needle valve and O-ring as a set.

e. If both are fine, adjust the float height by

bending the float tang on the float.

f. Recheck the float height.

Float height (F.H)

13.0 mm (0.51 in)

CARBURETOR

CARB

5-7

INSTALLING THE CARBURETOR JOINT

1. Install:

•clamp

TE:N

TE:

Align the projection on the carburetor joint

with the slot in the clamp.

2. Install:

• carburetor joint

TE:N

TE:

Align the projection on the cylinder head

with the slot in the carburetor joint.

INSTALLING THE CARBURETOR

1. Install:

•carburetor

TE:N

TE:

Align the projection on the carburetor with

the slot in the carburetor joint.

2. Install:

• throttle cable

• throttle cable cover

3. Adjust:

• throttle lever free play

Refer to “ADJUSTING THE THROTTLE

LEVER FREE PLAY” in chapter 3.

4. Adjust:

• engine idling speed

Refer to “ADJUSTING THE ENGINE

IDLING SPEED” in chapter 3.

CARBURETOR

CHAS

6-1

EBS00378 CHASSIS

FRONT AND REAR WHEELS

FRONT WHEELS

Order Job/Part Q’ty Remarks

Removing the front wheels Remove the parts in the order listed.

The following procedure applies to both of

the front wheels.

Place the machine on a level surface.

WARNING

Securely support the machine so there

is no danger of it falling over.

1 Cotter pin 1

2Axle nut 1

3 Front wheel 1

4 Brake disc guard (outer) 1

28 Nm (2.8 m•kg, 21 ft•lb)

70 Nm (7.0 m•kg, 52 ft•lb)

45 Nm (4.5 m•kg, 33 ft•lb)

Refer to “INSTALLING THE WHEEL

HUBS”.

Refer to “INSTALLING THE FRONT

WHEELS”.

FRONT AND REAR WHEELS

CHAS

6-2

Order Job/Part Q’ty Remarks

5 Brake caliper assembly 1 N

TE:N

TE:

Do not squeeze the brake lever when the

brake caliper is off of the brake discs as

the brake pads will be forced shut.

6 Wheel hub 1 Refer to “INSTALLING THE WHEEL HUB

BEARINGS”.

7 Brake disc 1 Rear to “INSTALLING FRONT BRAKE

DISCS”.

For installation, reverse the removal

procedure.

28 Nm (2.8 m•kg, 21 ft•lb)

70 Nm (7.0 m•kg, 52 ft•lb)

45 Nm (4.5 m•kg, 33 ft•lb)

FRONT AND REAR WHEELS

CHAS

6-3

REAR WHEELS

Order Job/Part Q’ty Remarks

Removing the rear wheels Remove the parts in the order listed.

Place the machine on a level surface.

WARNING

Securely support the machine so there

is no danger of it falling over.

1 Rear wheel 2

2 Cotter pin 2

3Axle nut 2

4 Wheel hub 2

For installation, reverse the removal

procedure.

45 Nm (4.5 m•kg, 33 ft•lb)

120 Nm (12.0 m•kg, 89 ft•lb)

Refer to “INSTALLING THE WHEEL

HUBS”.

FRONT AND REAR WHEELS

CHAS

6-4

EBS00383

CHECKING THE WHEELS

1. Check:

• wheels

2. Measure:

• wheel runout

Over the specified limit → Replace the

wheel or check the wheel bearing play .

3. Check:

• wheel balance

Out of balance → Adjust.

WARNING

After replacing the tire, ride conservatively

to allow the tire to be properly seated in the

rim. Failure to do so may cause an accident

resulting in machine damage and possible

operator injury.

EBS00385

CHECKING THE WHEEL HUBS

1. Check:

• wheel hubs

Cracks/damage → Replace.

• splines (wheel hub)

Wear/damage → Replace the wheel hub.

Front

Rear

Wheel runout limit

Radial : 2.0 mm (0.08 in)

Lateral : 2.0 mm (0.08 in)

FRONT AND REAR WHEELS

CHAS

6-5

2. Check:

• wheel bearings

Wheel hub play/wheel turns roughly →

Replace.

a. Clean wheel hub exterior.

b. Drive bearing out by pushing spacer aside

and tapping around perimeter of bearing

inner race. Use soft metal drift punch and

hammer. The spacer “floats” between

bearings. Remove both bearings as

described.

WARNING

Eye protection is recommended when

using striking tools.

c. To install the wheel bearings, reverse the

above sequence. Use a socket that

matches outside diameter of bearing outer

race to drive in bearing.

CAUTION:

Do not strike the center race or balls of the

bearing. Contact should be made only with

the outer race.

EBS00389

CHECKING THE BRAKE DISCS

1. Check:

• brake discs

Galling/damage → Replace.

2. Measure:

• brake disc deflection

Out of specification → Replace.

• brake disc thickness

Out of specification → Replace.

Brake disc maximum deflection

Front: 0.15 mm (0.006 in)

Rear: 0.15 mm (0.006 in)

Brake disc minimum thickness

Front: 3 mm (0.12 in)

Rear: 3.5 mm (0.14 in)

FRONT AND REAR WHEELS

CHAS

6-6

INSTALLING THE FRONT WHEEL HUB

BEARINGS

1. Install:

• bearings

TE:N

TE:

Face the oil seal side of the bearing inward.

INSTALLING THE FRONT BRAKE DISCS

1. Install:

•brake discs

TE:N

TE:

Install the brake disc with its spot-faced side

facing the bolt heads.

EBS00392

INSTALLING THE FRONT WHEELS

1. Install:

• brake disc guards (outer)

TE:N

TE:

Install the brake disc guard (outer) with

punched burrs on the wheel hub side.

2. Install:

• wheels

TE:N

TE:

The arrow mark on the must point in the

direction of rotation of the wheel.

FRONT AND REAR WHEELS

CHAS

6-7

EBS00390

INSTALLING THE WHEEL HUBS

1. Install:

• front axle nuts

• rear axle nuts

• cotter pins

TE:N

TE:

• Do not loosen the axle nut after torquing it. If

the axle nut groove is not aligned with the cot-

ter pin hole, align the groove with the hole by

tightening the axle nut.

• Bend the longer cotter pin up.

Front axle nut

70 Nm (7.0 m•kg, 52 ft•lb)

Rear axle nut

120 Nm (12.0 m•kg, 89 ft•lb)

FRONT AND REAR WHEELS

CHAS

6-8

EBS00382

REAR AXLE AND REAR AXLE HUB

Order Job/Part Q’ty Remarks

Removing the rear axle and rear axle

hub Remove the parts in the order listed.

Rear wheels/rear wheel hubs Refer to “FRONT AND REAR WHEELS”.

1Bolt 2

2Nut 1

3 Conical spring washer 1

4 Brake caliper 1 N

TE:N

TE:

Do not apply the brake pedal and do not

use the parking brake when the brake cal-

iper is off of the brake disc as the brake

pad will be force shut.

34 Nm (3.4 m•kg, 25 ft•lb)

7 Nm (0.7 m•kg, 5.2 ft•lb)

28 Nm (2.8 m•kg, 21 ft•lb)

55 Nm (5.5 m•kg, 41 ft•lb)

140 Nm (14.0 m•kg, 103 ft•lb)

Refer to “REMOVING THE REAR

AXLE” and “INSTALLING THE REAR

AXLE”.

REAR AXLE AND REAR AXLE HUB

CHAS

6-9

Order Job/Part Q’ty Remarks

5 Brake disc/brake disc bracket 1/1

6 Rear axle 1 Refer to “REMOVING THE REAR AXLE”.

7 Driven sprocket/sprocket bracket 1/1 Refer to “INSTALLING THE DRIVEN

SPROCKET”.

8Circlip 1

9 Brake caliper bracket 1

10 Collar 1

11 Rear axle hub 1

12 Bearing/oil seal 2/2

13 Spacer 1

14 Dust cover 1

For installation, reverse the removal

procedure.

34 Nm (3.4 m•kg, 25 ft•lb)

7 Nm (0.7 m•kg, 5.2 ft•lb)

28 Nm (2.8 m•kg, 21 ft•lb)

55 Nm (5.5 m•kg, 41 ft•lb)

140 Nm (14.0 m•kg, 103 ft•lb)

REAR AXLE AND REAR AXLE HUB

CHAS

6-10

EBS00393

REMOVING THE REAR AXLE

1. Place the machine on a level surface.

2. Loosen:

• bolts

3. Remove:

•nut

TE:N

TE:

• Apply the brake pedal so that the rear axle

does not turn, when loosening the nut.

• Use the PTT wrench 46 or axle nut wrench

(46 mm) .

4. Elevate the rear wheels by placing the suit-

able stand under the frame.

5. Remove:

• rear wheels

• wheel hubs

•nuts

• washers

6. Remove:

• rear axle

CAUTION:

• Never directly tap the axle end with a ham-

mer, since this will result in damage to the

axle thread and spline.

• Attach a suitable socket on the axle

end and tap it with a soft hammer, then

pull out the rear axle to the right.

PTT wrench 46

90890-06588

Axle nut wrench (46 mm)

YM-37134

REAR AXLE AND REAR AXLE HUB

CHAS

6-11

EBS00395

CHECKING THE REAR AXLE

1. Check:

• rear axle runout

Out of specification → Replace.

WARNING

Do not attempt to straighten a bent axle.

CHECKING THE DRIVEN SPROCKET

1. Check:

• driven sprocket

Refer to “REAR SHOCK ABSORBER,

SWINGARM AND DRIVE CHAIN”.

CHECKING THE BRAKE DISC

1. Check:

•brake disc

Refer to “FRONT AND REAR WHEELS”.

INSTALLING THE DRIVEN SPROCKET

1. Install:

• driven sprocket

TE:N

TE:

Make sure that the blunt-edged corner of

the driven sprocket is facing outward.

EBS00397

INSTALLING THE REAR AXLE

1. Install:

• conical spring washer

TE:N

TE:

Install the conical spring washer with the con-

vex side of the washer facing inward as shown.

Rear axle runout limit

1.5 mm (0.06 in)

REAR AXLE AND REAR AXLE HUB

CHAS

6-12

2. Tighten:

•nut

a. Tighten the nut with PTT wrench 46 or rear

axle nut wrench to specification while

holding the rear axle.

b. Tighten bolts .

140 Nm (14.0 m•kg, 103 ft•lb)

PTT wrench 46

90890-06588

Axle nut wrench (46 mm)

YM-37134

7 Nm (0.7 m•kg, 5.2 ft•lb)

REAR AXLE AND REAR AXLE HUB

CHAS

6-13

EBS00400

FRONT AND REAR BRAKES

FRONT BRAKE PADS

Order Job/Part Q’ty Remarks

Removing the front brake pads Remove the parts in the order listed.

The following procedure applies to both of

the front brake calipers.

Front wheel Refer to “FRONT AND REAR WHEELS”.

1Bolt 1

2 Brake pad retaining bolt 1

3 Brake pad 2

4 Brake pad spring 1

For installation, reverse the removal

procedure.

2.5 Nm (0.25 m•kg, 1.8 ft•lb) 17 Nm (1.7 m•kg, 13 ft•lb)

28 Nm (2.8 m•kg, 21 ft•lb)

Refer to “REPLACING THE FRONT

BRAKE PADS”.

FRONT AND REAR BRAKES

CHAS

6-14

EBS00401

REAR BRAKE PADS

Order Job/Part Q’ty Remarks

Removing the rear brake pads Remove the parts in the order listed.

1 Brake pad retaining bolt 2

2 Lock washer 1

3 Brake pad 2

4 Brake pad spring 1

For installation, reverse the removal

procedure.

34 Nm (3.4 m•kg, 25 ft•lb)

17 Nm (1.7 m•kg, 13 ft•lb)

FRONT AND REAR BRAKES

Refer to “REPLACING THE REAR

BRAKE PADS”.

CHAS

6-15

EBS00402

CAUTION:

Disc brake components rarely require dis-

assembly.

DO NOT:

• disassemble components unless abso-

lutely necessary;

• use solvents on internal brake compo-

nents;

• use spent brake fluid for cleaning; (use

only clean brake fluid)

• allow brake fluid to come in contact with

the eyes, as this may cause eye injury;

• splash brake fluid onto painted surfaces

or plastic parts, as this may cause dam-

age;

• disconnect any hydraulic connection, as

this would require the entire brake system

to be disassembled, drained, cleaned,

properly filled and bled after reassembly.

EBS00404

REPLACING THE FRONT BRAKE PADS

The following procedure applies to both of the

front brake calipers.

TE:N

TE:

It is not necessary to disassemble the brake

calipers and brake hoses to replace the brake

pads.

1. Remove:

• brake pads

Wear limit

TE:N

TE:

Replace the brake pads as a set if either is

found to be worn to the wear limit.

FRONT AND REAR BRAKES

CHAS

6-16

2. Install:

• brake pads

• brake pad spring

TE:N

TE:

Always install new brake pads and brake pad

spring as a set.

a. Connect a suitable hose tightly to the

brake caliper bleed screw . Put the other

end of this hose into an open container.

b. Loosen the brake caliper bleed screw and,

using a finger, push the caliper piston into

the brake caliper.

c. Tighten the brake caliper bleed screw.

d. Install new brake pads and a new brake

pad spring.

3. Install:

• brake pad retaining bolt

• bolt

4. Install:

• brake caliper

• brake caliper mounting bolts

5. Check:

• brake fluid level

Refer to “CHECKING THE BRAKE FLUID

LEVEL” in chapter 3.

6. Check:

• brake lever operation

Soft or spongy feeling → Bleed the brake

system.

Refer to “BLEEDING THE HYDRAULIC

BRAKE SYSTEM” in chapter 3.

5 Nm (0.5 m•kg, 3.7 ft•lb)

Brake pad retaining bolt

17 Nm (1.7 m•kg, 13 ft•lb)

Bolt

3 Nm (0.3 m•kg, 2 ft•lb)

Brake caliper mounting bolt

28 Nm (2.8 m•kg, 21 ft•lb)

FRONT AND REAR BRAKES

CHAS

6-17

EBS00405

REPLACING THE REAR BRAKE PADS

TE:N

TE:

It is not necessary to disassemble the brake

caliper and brake hose to replace the brake

pads.

1. Remove:

• brake pads

wear limit

TE:N

TE:

Replace the brake pads as a set if either is

found to be worn to the wear limit.

2. Install:

• brake pads

• brake pad spring

TE:N

TE:

Always install new brake pads and brake pad

spring as a set.

a. Connect a suitable hose tightly to the

brake caliper bleed screw . Put the other

end of this hose into an open container.

b. Loosen the brake caliper bleed screw and,

using a finger, push the caliper piston into

the brake caliper.

c. Tighten the brake caliper bleed screw.

d. Install a new brake pad spring and new

brake pads.

3. Install:

• brake pad retaining bolts

(Bend the lock washer tabs along a flat side

of the bolts)

• brake caliper

• brake caliper mounting bolts

4. Check:

• brake fluid level

Refer to “CHECKING THE BRAKE FLUID

LEVEL” in chapter 3.

5 Nm (0.5 m•kg, 3.7 ft•lb)

Brake pad retaining bolt

17 Nm (1.7 m•kg, 13 ft•lb)

Brake caliper mounting bolt

34 Nm (3.4 m•kg, 25 ft•lb)

FRONT AND REAR BRAKES

CHAS

6-18

5. Check:

• brake lever or brake pedal operation

Soft or spongy feeling → Bleed the brake

system.

Refer to “BLEEDING THE HYDRAULIC

BRAKE SYSTEM” in chapter 3.

FRONT AND REAR BRAKES

CHAS

6-19

EBS00407

FRONT BRAKE MASTER CYLINDER

Order Job/Part Q’ty Remarks

Removing the front brake master

cylinder Remove the parts in the order listed.

Brake fluid Drain.

Refer to “BLEEDING THE HYDRAULIC

BRAKE SYSTEM” in chapter 3.

1 Brake fluid reservoir cap 1

2 Brake fluid reservoir diaphragm plate 1

3 Brake fluid reservoir diaphragm 1

4 Front brake light switch 1

5Brake lever 1

6 Union bolt 1

7 Copper washer 2

8 Brake hose 1 Disconnect.

9 Brake master cylinder bracket 1

10 Brake master cylinder 1

For installation, reverse the removal

procedure.

7 Nm (0.7 m•kg, 5.2 ft•lb)

6 Nm (0.6 m•kg, 4.4 ft•lb)

27 Nm (2.7 m•kg, 20 ft•lb)

Refer to “INSTALLING

THE FRONT BRAKE

MASTER CYLINDER”.

FRONT AND REAR BRAKES

CHAS

6-20

EBS00409

Order Job/Part Q’ty Remarks

Disassembling the front brake

master cylinder Remove the parts in the order listed.

Dust boot 1

Circlip 1

Brake master cylinder kit 1

For assembly, reverse the disassembly

procedure.

Refer to “ASSEMBLING THE FRONT

BRAKE MASTER CYLINDER”.

FRONT AND REAR BRAKES

CHAS

6-21

EBS00410

REAR BRAKE MASTER CYLINDER

Order Job/Part Q’ty Remarks

Removing the rear brake master

cylinder Remove the parts in the order listed.

Right foot protector Refer to “SEAT, FENDERS AND FUEL

TANK” in chapter 3.

Brake fluid Drain.

Refer to “BLEEDING THE HYDRAULIC

BRAKE SYSTEM” in chapter 3.

1 Brake fluid reservoir cover 1

2 Brake fluid reservoir cap 1

3 Brake fluid reservoir diaphragm holder 1

4 Brake fluid reservoir diaphragm 1

5 Brake fluid reservoir 1

6 Brake fluid reservoir hose 1

7 Nm (0.7 m•kg, 5.2 ft•lb)

31 Nm (3.1 m•kg, 23 ft•lb)

20 Nm (2.0 m•kg, 15 ft•lb)

73 Nm (7.3 m•kg, 54 ft•lb)

FRONT AND REAR BRAKES

CHAS

6-22

Order Job/Part Q’ty Remarks

7 Union bolt 1

8 Copper washer 2

9 Brake hose 1 Disconnect.

10 Brake master cylinder 1

11 Rear brake light switch 1

12 Right footrest 1

13 Brake pedal/spring 1/1

For installation, reverse the removal

procedure.

7 Nm (0.7 m•kg, 5.2 ft•lb)

31 Nm (3.1 m•kg, 23 ft•lb)

20 Nm (2.0 m•kg, 15 ft•lb)

73 Nm (7.3 m•kg, 54 ft•lb)

Refer to “INSTALLING

THE REAR BRAKE

MASTER CYLINDER”.

FRONT AND REAR BRAKES

CHAS

6-23

EBS00411

Order Job/Part Q’ty Remarks

Disassembling the rear brake

master cylinder Remove the parts in the order listed.

Hose joint 1

Brake master cylinder kit 1

Brake master cylinder 1

For assembly, reverse the disassembly

procedure.

17 Nm (1.7 m•kg, 13 ft•lb)

Refer to “ASSEMBLING THE REAR

BRAKE MASTER CYLINDER”.

FRONT AND REAR BRAKES

CHAS

6-24

EBS00413

CHECKING THE MASTER CYLINDERS

1. Check:

• brake master cylinder

Wear/scratches → Replace the brake mas-

ter cylinder assembly.

• brake master cylinder body

Cracks/damage → Replace.

• brake fluid delivery passage

(brake master cylinder body)

Blockage → Blow out with compressed air.

Front

Rear

2. Check:

• brake master cylinder kit

Scratches/wear/damage → Replace as a

set.

Front

Rear

3. Check:

• front brake master cylinder reservoir

• front brake master cylinder reservoir dia-

phragm

Cracks/damage → Replace.

4. Check:

• rear brake fluid reservoir

• rear brake fluid reservoir diaphragm

Cracks/damage → Replace.

FRONT AND REAR BRAKES

CHAS

6-25

EBS00415

ASSEMBLING THE FRONT BRAKE

MASTER CYLINDER

WARNING

• All internal brake components should be

cleaned and lubricated with new brake

fluid only before installation.

• Whenever a master cylinder is disassem-

bled, replace the piston seals and dust

seals.

EBS00416

ASSEMBLING THE REAR BRAKE MASTER

CYLINDER

WARNING

• All internal brake components should be

cleaned and lubricated with new brake

fluid only before installation.

• Whenever a master cylinder is disassem-

bled, replace the piston seals and dust

seals.

1. Install:

• brake master cylinder kit

•nut

•joint

TE:N

TE:

Turn the adjusting bolt until the clearance

is within the specified limits when install the

joint .

Recommended brake fluid

DOT 4

Recommended brake fluid

DOT 4

Clearance

2.2 ~ 3.2 mm (0.09 ~ 0.13 in)

FRONT AND REAR BRAKES

CHAS

6-26

2. Tighten:

•nut

EBS00418

INSTALLING THE FRONT BRAKE MASTER

CYLINDER

1. Install:

• brake master cylinder

TE:N

TE:

• The “UP” mark on the brake master cylinder

bracket should face up.

• Install the brake master cylinder so that the

gaps between the brake master cylinder and

the brake master cylinder bracket are equal.

2. Install:

• copper washers

•brake hose

• union bolt

TE:N

TE:

• Tighten the union bolt while holding the brake

hose as shown.

• Turn the handlebar to the left and to the right

to check that the brake hose does not touch

other parts (throttle cable, wire harness,

leads, etc.). Correct if necessary.

WARNING

Proper brake hose routing is essential to

insure safe machine operation. Refer to

“CABLE ROUTING” in chapter 2.

Nut

17 Nm (1.7 m•kg, 13 ft•lb)

Brake master cylinder holder bolt

7 Nm (0.7 m•kg, 5.1 ft•lb)

Union bolt

27 Nm (2.7 m•kg, 20 ft•lb)

FRONT AND REAR BRAKES

CHAS

6-27

3. Fill:

• brake fluid reservoir

CAUTION:

Brake fluid may damage painted surfaces

or plastic parts. Always clean up spilled

brake fluid immediately.

WARNING

• Use only the designated quality brake

fluid: other brake fluids may deteriorate

the rubber seals, causing leakage and

poor brake performance.

• Refill with the same type of brake fluid:

mixing brake fluids may result in a harm-

ful reaction and lead to poor brake perfor-

mance.

• Be careful that water does not enter the

brake master cylinder when refilling.

Water will significantly lower the boiling

point of the brake fluid and may result in

vapor lock.

4. Air bleed:

• brake system

Refer to “BLEEDING THE HYDRAULIC

BRAKE SYSTEM” in chapter 3.

5. Check:

• brake fluid level

Brake fluid level is under the “LOWER” level

line → Add the recommended brake fluid to

the proper level.

Refer to “CHECKING THE BRAKE FLUID

LEVEL” in chapter 3.

Recommended brake fluid

DOT 4

FRONT AND REAR BRAKES

CHAS

6-28

EBS00419

INSTALLING THE REAR BRAKE MASTER

CYLINDER

1. Install:

• copper washers

•brake hose

• union bolt

CAUTION:

When installing the brake hose onto the

brake master cylinder, make sure the brake

pipe touches the projection as

shown.

WARNING

Proper brake hose routing is essential to

insure safe machine operation. Refer to

“CABLE ROUTING” in chapter 2.

2. Install:

• brake fluid reservoir hose

TE:N

TE:

Install the brake fluid reservoir hose with the

white paint mark facing up as shown.

3. Fill:

• brake fluid reservoir

CAUTION:

Brake fluid may damage painted surfaces

or plastic parts. Always clean up spilled

brake fluid immediately.

Union bolt

31 Nm (3.1 m•kg, 23 ft•lb)

Recommended brake fluid

DOT 4

FRONT AND REAR BRAKES

CHAS

6-29

WARNING

• Use only the designated quality brake

fluid: other brake fluids may deteriorate

the rubber seals, causing leakage and

poor brake performance.

• Refill with the same type of brake fluid:

mixing brake fluids may result in a harm-

ful chemical reaction and lead to poor

brake performance.

• Be careful that water does not enter the

brake master cylinder when refilling.

Water will significantly lower the boiling

point of the brake fluid and may result in

vapor lock.

4. Air bleed:

• brake system

Refer to “BLEEDING THE HYDRAULIC

BRAKE SYSTEM” in chapter 3.

5. Check:

• brake fluid level

Brake fluid level is under the “LOWER” level

line → Add the recommended brake fluid to

the proper level.

Refer to “CHECKING THE BRAKE FLUID

LEVEL” in chapter 3.

FRONT AND REAR BRAKES

CHAS

6-30

EBS00421

FRONT BRAKE CALIPERS

Order Job/Part Q’ty Remarks

Removing the front brake calipers Remove the parts in the order listed.

The following procedure applies to both of

the front brake calipers.

Brake fluid Drain.

Refer to “BLEEDING THE HYDRAULIC

BRAKE SYSTEM” in chapter 3.

Front wheel Refer to “FRONT AND REAR WHEELS”.

1 Union bolt 1

2 Copper washer 2

3 Brake hose 1 Disconnect.

4Bolt 1

5 Brake pad retaining bolt 2 Loosen.

6 Brake caliper assembly 1

For installation, reverse the removal

procedure.

2.5 Nm (0.25 m•kg, 1.8 ft•lb) 17 Nm (1.7 m•kg, 13 ft•lb)

28 Nm (2.8 m•kg, 21 ft•lb)

27 Nm (2.7 m•kg, 20 ft•lb)

Refer to “INSTALLING

THE FRONT BRAKE

CALIPERS”.

FRONT AND REAR BRAKES

CHAS

6-31

EBS00423

Order Job/Part Q’ty Remarks

Disassembling the front brake

calipers Remove the parts in the order listed.

The following procedure applies to both of

the front brake calipers.

Bolt 1

Brake pad retaining bolt 1

Brake pad 2

Brake pad spring 1

Caliper bracket 1

Caliper piston 1

Dust seal 1

Caliper piston seal 1

Bleed screw 1

For assembly, reverse the disassembly

procedure.

5 Nm (0.5 m•kg, 3.7 ft•lb)

17 Nm (1.7 m•kg, 13 ft•lb)

2.5 Nm (0.25 m•kg, 1.8 ft•lb)

Refer to “DISASSEMBLING THE

FRONT AND REAR BRAKE CALIPERS”

and “ASSEMBLING THE FRONT

BRAKE CALIPERS”.

FRONT AND REAR BRAKES

CHAS

6-32

EBS00424

REAR BRAKE CALIPER

Order Job/Part Q’ty Remarks

Removing the rear brake caliper Remove the parts in the order listed.

Brake fluid Drain.

Refer to “BLEEDING THE HYDRAULIC

BRAKE SYSTEM” in chapter 3.

1 Parking brake cable 1 Disconnect.

Refer to “REMOVING THE PARKING

BRAKE CABLE”.

2 Union bolt 1

3 Copper washer 2

4 Brake hose 1 Disconnect.

5 Brake caliper assembly 1

For installation, reverse the removal

procedure.

31 Nm (3.1 m•kg, 23 ft•lb)

34 Nm (3.4 m•kg, 25 ft•lb)

Refer to “INSTALLING

THE REAR BRAKE

CALIPER”.

FRONT AND REAR BRAKES

CHAS

6-33

EBS00425

Order Job/Part Q’ty Remarks

Disassembling the rear brake caliper Remove the parts in the order listed.

Adjusting bolt 1

Locknut 1

Parking brake arm 1

Brake pad retain bolt 2

Lock washer 1

Brake pad 2

Brake pad spring 1

Retaining bolt 1

Caliper bracket 1

Brake caliper piston 1

Dust seal 1

Caliper piston seal 1

Bleed screw 1

For assembly, reverse the disassembly

procedure.

17 Nm (1.7 m•kg, 13 ft•lb)

5 Nm (0.5 m•kg, 3.7 ft•lb)

17 Nm (1.7 m•kg, 13 ft•lb)

15 Nm (1.5 m•kg, 11 ft•lb)

FRONT AND REAR BRAKES

Refer to “DISASSEMBLING THE

FRONT AND REAR BRAKE

CALIPERS” and “ASSEMBLING THE

REAR BRAKE CALIPER”.

CHAS

6-34

REMOVING THE PARKING BRAKE CABLE

1. Loosen:

•nut

• adjusting bolt

2. Disconnect:

• parking brake cable

(from parking brake lever)

3. Disconnect:

• parking brake cable

(from rear brake)

EBS00427

DISASSEMBLING THE FRONT AND REAR

BRAKE CALIPERS

1. Remove:

• brake caliper piston

• caliper dust seal

• caliper piston seal

Front

Rear

a. Blow compressed air into the hose joint

opening to force out the caliper piston from

the brake caliper body.

WARNING

• Never try to pry out the caliper piston.

• Cover the caliper piston with a rag. Be

careful not to get injured when the piston

is expelled from the caliper cylinder.

b. Remove the caliper piston seal.

FRONT AND REAR BRAKES

CHAS

6-35

EBS00429

CHECKING THE FRONT AND REAR BRAKE

CALIPERS

WARNING

All internal brake components should be

cleaned in new brake fluid only. Do not use

solvents as they will cause seals to swell

and distort.

1. Check:

• brake caliper piston

Scratches/rust/wear → Replace the brake

caliper assembly.

• brake caliper cylinder

Wear/scratches → Replace the brake cali-

per assembly.

• brake caliper body

Cracks/damage → Replace.

• brake fluid delivery passage

(brake caliper body)

Blockage → Blow out with compressed air.

WARNING

Replace the caliper piston seal and dust

seal whenever the brake caliper is disas-

sembled.

Front

Rear

Recommended brake component

replacement schedule

Brake pads As required

Piston seals, dust

seals Every two years

Brake hoses Every four years

Brake fluid Replace when

brakes are

disassembled.

FRONT AND REAR BRAKES

CHAS

6-36

EBS00431

ASSEMBLING THE FRONT BRAKE

CALIPERS

The following procedure applies to both of the

front brake calipers.

WARNING

• All internal brake components should be

cleaned and lubricated with new brake

fluid only before installation.

• Replace the caliper piston seal whenever

a brake caliper is disassembled.

1. Install:

• caliper piston seal

• caliper dust seal

2. Install:

• brake caliper piston

EBS00432

ASSEMBLING THE REAR BRAKE CALIPER

WARNING

• All internal brake components should be

cleaned and lubricated with new brake

fluid only before installation.

• Replace the caliper piston seal whenever

a brake caliper is disassembled.

1. Install:

• O-ring

• caliper piston seal

• caliper dust seal

Recommended brake fluid

DOT 4

Recommended brake fluid

DOT 4

FRONT AND REAR BRAKES

CHAS

6-37

2. Install:

• brake caliper piston

3. Install:

• lock washer

• brake pad retaining bolts

4. Bend the lock washer tabs along a flat side

of the bolts.

5. Install:

• parking brake arm

6. Measure:

• parking brake arm to parking brake bracket

distance

Out of specification → Adjust.

Brake pad retaining bolt

17 Nm (1.7 m•kg, 13 ft•lb)

Parking brake arm to parking

brake bracket distance

73.3 mm (2.89 in)

FRONT AND REAR BRAKES

CHAS

6-38

EBS00434

INSTALLING THE FRONT BRAKE

CALIPERS

The following procedure applies to both of the

front brake calipers.

1. Install:

• brake caliper assembly

• brake caliper mounting bolts

•brake hose

• copper washers

• union bolt

CAUTION:

When installing the brake hose on the

brake caliper, make sure that the brake pipe

touches the projection on the brake

caliper.

WARNING

Proper brake hose routing is essential to

insure safe machine operation. Refer to

“CABLE ROUTING” in chapter 2.

2. Fill:

•brake reservoir

CAUTION:

Brake fluid may damage painted surfaces

or plastic parts. Always clean up spilled

brake fluid immediately.

Brake caliper mounting bolt

28 Nm (2.8 m•kg, 21 ft•lb)

Union bolt

27 Nm (2.7 m•kg, 20 ft•lb)

Recommended brake fluid

DOT 4

FRONT AND REAR BRAKES

CHAS

6-39

WARNING

• Use only the designated quality brake

fluid: other brake fluids may deteriorate

the rubber seals, causing leakage and

poor brake performance.

• Refill with the same type of brake fluid:

mixing brake fluids may result in a harm-

ful chemical reaction and lead to poor

brake performance.

• Be careful that water does not enter the

master cylinder when refilling. Water will

significantly lower the boiling point of the

brake fluid and may result in vapor lock.

3. Air bleed:

• brake system

Refer to “BLEEDING THE HYDRAULIC

BRAKE SYSTEM” in chapter 3.

4. Check:

• brake fluid level

Brake fluid level is below the “LOWER” level

line → Add the recommended brake fluid to

the proper level.

Refer to “CHECKING THE BRAKE FLUID

LEVEL” in chapter 3.

FRONT AND REAR BRAKES

CHAS

6-40

EBS00436

INSTALLING THE REAR BRAKE CALIPER

1. Install:

• brake caliper assembly

• brake caliper mounting bolts

•brake hose

• copper washers

• union bolt

CAUTION:

When installing the brake hose on the

brake caliper, make sure that the brake pipe

touches the projection on the brake cali-

per.

WARNING

Proper brake hose routing is essential to

insure safe machine operation. Refer to

“CABLE ROUTING” in chapter 2.

2. Fill:

•brake reservoir

CAUTION:

Brake fluid may damage painted surfaces

or plastic parts. Always clean up spilled

brake fluid immediately.

Brake caliper mounting bolt

34 Nm (3.4 m•kg, 25 ft•lb)

Union bolt

31 Nm (3.1 m•kg, 23 ft•lb)

Recommended brake fluid

DOT 4

FRONT AND REAR BRAKES

CHAS

6-41

WARNING

• Use only the designated quality brake

fluid: other brake fluids may deteriorate

the rubber seals, causing leakage and

poor brake performance.

• Refill with the same type of brake fluid:

mixing brake fluids may result in a harm-

ful chemical reaction and lead to poor

brake performance.

• Be careful that water does not enter the

master cylinder when refilling. Water will

significantly lower the boiling point of the

brake fluid and may result in vapor lock.

3. Air bleed:

• brake system

Refer to “BLEEDING THE HYDRAULIC

BRAKE SYSTEM” in chapter 3.

4. Check:

• brake fluid level

Brake fluid level is below the “LOWER” level

line → Add the recommended brake fluid to

the proper level.

Refer to “CHECKING THE BRAKE FLUID

LEVEL” in chapter 3.

5. Adjust:

• parking brake cable end length

Refer to “ADJUSTING THE PARKING

BRAKE” in chapter 3.

FRONT AND REAR BRAKES

CHAS

6-42

EBS00444

STEERING SYSTEM

HANDLEBAR

Order Job/Part Q’ty Remarks

Removing the handlebar Remove the parts in the order listed.

1 Handlebar protecter 1

2 Band 3

3 Front brake light switch 1

4 Brake master cylinder/bracket 1/1

5 Throttle lever assembly/bracket 1/1

6 Spacer 1

7 Clutch switch 1 Refer to “REMOVING THE CLUTCH

SWITCH”.

8 Parking brake lever 1

9 Clutch lever/bracket 1/1

10 Handlebar switch 1

4 Nm (0.4 m•kg, 3.0 ft•lb)

7 Nm (0.7 m•kg, 5.2 ft•lb)

20 Nm (2.0 m•kg, 15 ft•lb)

4 Nm (0.4 m•kg, 3.0 ft•lb)

7 Nm (0.7 m•kg, 5.2 ft•lb)

STEERING SYSTEM

Refer to “INSTALLING THE BRAKE

MASTER CYLINDER”.

Refer to “INSTALLING THE CLUTCH

LEVER”.

CHAS

6-43

Order Job/Part Q’ty Remarks

11 Handlebar grip 2 Refer to “REMOVING THE HANDLEBAR

GRIPS” and “INSTALLING THE

HANDLEBAR GRIPS”.

12 Handlebar holder 2

13 Handlebar 1

For installation, reverse the removal

procedure.

4 Nm (0.4 m•kg, 3.0 ft•lb)

7 Nm (0.7 m•kg, 5.2 ft•lb)

20 Nm (2.0 m•kg, 15 ft•lb)

4 Nm (0.4 m•kg, 3.0 ft•lb)

7 Nm (0.7 m•kg, 5.2 ft•lb)

STEERING SYSTEM

Refer to “INSTALLING THE

HANDLEBAR”.

CHAS

6-44

EBS00446

REMOVING THE CLUTCH SWITCH

1. Remove:

• clutch switch

TE:N

TE:

Push the fastener when removing the clutch

switch out of the clutch lever holder.

EBS00447

REMOVING THE HANDLEBAR GRIPS

1. Remove:

• handlebar grips

TE:N

TE:

Blow compressed air between the handlebar

and handlebar grip, and gradually push the

grip off the handlebar.

EBS00448

CHECKING THE HANDLEBAR

1. Check:

• handlebar

Bends/cracks/damage → Replace.

WARNING

Do not attempt to straighten a bent handle-

bar as this may dangerously weaken the

handlebar.

STEERING SYSTEM

CHAS

6-45

EBS00449

INSTALLING THE HANDLEBAR

1. Install:

• handlebar

• handlebar holders

TE:N

TE:

• Install the handlebar horizontally shown in the

illustration.

• The upper handlebar holder should be

installed with the punched mark forward

CAUTION:

First tighten the bolt on the front side of

the handlebar holder, and then tighten the

bolt on the rear side.

EBS00450

INSTALLING THE HANDLEBAR GRIPS

1. Install:

• handlebar grips

TE:N

TE:

• Before applying the adhesive, wipe off grease

or oil on the handlebar surface with a lac-

quer thinner.

• Install the handlebar grips so that the “L”

arrow on the left grip and “R” arrow on the

right grip are placed vertically.

Handleber holder

20 Nm (2.0 m•kg, 15 ft•lb)

STEERING SYSTEM

CHAS

6-46

EBS00452

INSTALLING THE CLUTCH LEVER

1. Install:

• handlebar switch

•clutch lever

• clutch lever bracket

TE:N

TE:

• Install the clutch lever bracket as shown.

• Install the clutch lever at 10 degrees angle

as shown.

53 ~ 54 mm (2.09 ~ 2.13 in)

EBS00453

INSTALLING THE BRAKE MASTER

CYLINDER

1. Install:

• throttle lever assembly

• spacer

• brake master cylinder

TE:N

TE:

• Engage the indentations in the spacer with

the lobes on the throttle lever assembly

and brake master cylinder.

• The “UP” mark on the brake master cylinder

bracket should face up.

• Install the brake lever at 10 degrees angle

as shown.

Brake master cylinder bracket

7 Nm (0.7 m•kg, 5.2 ft•lb)

STEERING SYSTEM

CHAS

6-47

EBS00454

STEERING STEM

Order Job/Part Q’ty Remarks

Removing the steering stem Remove the parts in the order listed.

Front fender Refer to “SEAT, FENDERS AND FUEL

TANK” in chapter 3.

1 Lock washer 1 Refer to “INSTALLING THE LOCK

WASHER”.

2 Bracket 1

3 Steering stem bushing 2

4 Spacer 2

5 Oil seal 2

6 Steering stem 1

7 Bushing 2

23 Nm (2.3 m•kg, 17 ft•lb)

25 Nm (2.5 m•kg, 18 ft•lb)

35 Nm (3.5 m•kg, 26 ft•lb)

STEERING SYSTEM

CHAS

6-48

EBS00456

CHECKING THE STEERING STEM

1. Check:

• steering stem

Bends/damage → Replace.

WARNING

Do not attempt to straighten a bent stem;

this may dangerously weaken the stem.

2. Check:

• oil seals

• steering stem bushings

Wear/damage → Replace.

3. Check

• O-rings

• bushings

Wear/damage → Replace.

INSTALLING THE STEERING STEM

1. Install:

• steering stem

TE:N

TE:

Pass the throttle cable through the cable guide.

Refer to “CABLE ROUTING” in chapter 2.

EBS00459

INSTALLING THE LOCK WASHER

1. Install:

• lock washer

• bolts

2. Bend the lock washer tab along a flat side

of the bolt.

Bolt

23 Nm (2.3 m•kg, 17 ft•lb)

STEERING SYSTEM

CHAS

6-49

EBS00460

TIE-RODS AND STEERING KNUCKLES

Order Job/Part Q’ty Remarks

Removing the tie-rods and steering

knuckles Remove the parts in the order listed.

The following procedure applies to both of

the tie-rods and steering knuckles.

Front wheel/brake disc Refer to “FRONT AND REAR WHEELS”.

Front brake caliper Refer to “FRONT AND REAR BRAKES”.

1 Brake disc guard (inner) 1

2 Tie-rod 1 Refer to “INSTALLING THE TIE-RODS”.

3 Front bumper 1

4 Lower front arm 1

5 Upper front arm 1

6 Steering knuckle 1 Refer to “REMOVING THE STEERING

KNUCKLES”.

For installation, reverse the removal

procedure.

31 Nm (3.1 m•kg, 23 ft•lb) 45 Nm (4.5 m•kg, 33 ft•lb)

25 Nm (2.5 m•kg, 18 ft•lb)

45 Nm (4.5 m•kg, 33 ft•lb)

25 Nm (2.5 m•kg, 18 ft•lb)

48 Nm (4.8 m•kg, 35 ft•lb)

STEERING SYSTEM

CHAS

6-50

EBS00461

REMOVING THE STEERING KNUCKLES

1. Remove:

• steering knuckles

TE:N

TE:

Use a general puller to separate the ball joint

and steering knuckle.

EBS00462

CHECKING THE TIE-RODS

1. Check:

• tie-rod free play and movement

Free play → Replace the tie-rod end.

Turns roughly → Replace the tie-rod end.

2. Check:

• tie-rods

Bends/damage → Replace.

EBS00464

CHECKING THE STEERING KNUCKLES

1. Check:

• steering knuckles

Damage/pitting → Replace.

EBS00465

INSTALLING THE TIE-RODS

1. Install:

• tie-rods (left and right)

TE:N

TE:

The tie-rod side which must be installed on the

outside has grooves .

2. Adjust:

• toe-in

Refer to “ADJUSTING THE TOE-IN” in

chapter 3.

Ball joint nut

25 Nm (2.5 m•kg, 18 ft•lb)

STEERING SYSTEM

CHAS

6-51

EBS00468

FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES

Order Job/Part Q’ty Remarks

Removing the front arms and front

shock absorber assemblies Remove the parts in the order listed.

The following procedure applies to both of

the front arms and front shock absorber

assemblies.

Front wheel/brake disc Refer to “FRONT AND REAR WHEELS”.

Front brake caliper Refer to “FRONT AND REAR BRAKES”.

1 Front bumper 1

2 Brake disc guard (inner) 1

3 Tie-rod 1 Disconnect.

4Lower front arm 1

5 Upper front arm 1

6 Front shock absorber 1

7 Steering knuckle 1

31 Nm (3.1 m•kg, 23 ft•lb) 45 Nm (4.5 m•kg, 33 ft•lb)

45 Nm (4.5 m•kg, 33 ft•lb)

25 Nm (2.5 m•kg, 18 ft•lb) 25 Nm (2.5 m•kg, 18 ft•lb)

48 Nm (4.8 m•kg, 35 ft•lb)

FRONT ARMS AND FRONT SHOCK ABSORBER

ASSEMBLIES

Refer to “REMOVING THE FRONT ARMS”

and “INSTALLING THE FRONT ARMS”.

CHAS

6-52

Order Job/Part Q’ty Remarks

8Dust cover 6

9 Spacer 1

10 Spacer 2

11 Bushing 6

For installation, reverse the removal

procedure.

31 Nm (3.1 m•kg, 23 ft•lb) 45 Nm (4.5 m•kg, 33 ft•lb)

45 Nm (4.5 m•kg, 33 ft•lb)

25 Nm (2.5 m•kg, 18 ft•lb) 25 Nm (2.5 m•kg, 18 ft•lb)

48 Nm (4.8 m•kg, 35 ft•lb)

FRONT ARMS AND FRONT SHOCK ABSORBER

ASSEMBLIES

CHAS

6-53

EBS00469

REMOVING THE FRONT ARMS

1. Check:

• front arm free play

a. Check the front arm side play by moving

it from side to side.

If side play is noticeable, check the bush-

ings.

b. Check the front arm vertical movement

by moving it up and down.

If the vertical movement is tight or rough, or

if there is binding, check the bushings.

2. Remove:

• front arm

EBS00470

CHECKING THE FRONT ARMS

1. Check:

• front arms

Bends/damage → Replace.

2. Check:

• bushings

Wear/damage → Replace.

EBS00488

CHECKING THE FRONT SHOCK

ABSORBERS

The following procedure applies to both of the

front shock absorber assemblies.

1. Check:

• shock absorber

Oil leaks → Replace the front shock

absorber assembly.

• shock absorber rod

Bends/damage → Replace the front shock

absorber assembly.

•spring

Fatigue → Replace the front shock

absorber assembly.

Move the spring up and down.

FRONT ARMS AND FRONT SHOCK ABSORBER

ASSEMBLIES

CHAS

6-54

EBS00472

CHECKING THE BALL JOINTS

The following procedure applies to both of the

front arm ball joints.

1. Check:

• ball joint

Damage/pitting → Replace the front arm.

Free play → Replace the front arm.

Turns roughly → Replace the front arm.

EBS00473

INSTALLING THE FRONT ARMS

The following procedure applies to both of the

front arms.

1. Install:

• upper front arm

• lower front arm

TE:N

TE:

• Be sure to position the bolts (upper and

lower) so that the bolt head faces forward.

• Apply lithium-soap-based grease to the

grease nipple .

Front arm (upper, lower)

45 Nm (4.5 m•kg, 33 ft•lb)

FRONT ARMS AND FRONT SHOCK ABSORBER

ASSEMBLIES

CHAS

6-55

REAR SHOCK ABSORBER, SWINGARM AND DRIVE CHAIN

Order Job/Part Q’ty Remarks

Removing the rear shock absorber,

swingarm and drive chain Remove the parts in the order listed.

Seat/rear fender/air filter case Refer to “SEAT, FENDERS AND FUEL

TANK” in chapter 3.

Rear axle hub Refer to “REAR AXLE AND REAR AXLE

HUB”.

1Plate 1

2 Swingarm end cover 1

3 Rear shock absorber 1

4 Pivot shaft nut/washer 1/1

5 Pivot shaft 1

6 Swingarm 1

7 Drive chain guide 1 1

8 Drive sprocket cover 1

23 Nm (2.3 m•kg, 17 ft•lb) 55 Nm (5.5 m•kg, 41 ft•lb)

100 Nm (10.0 m•kg, 74 ft•lb)

110 Nm (11.0 m•kg, 81 ft•lb)

55 Nm (5.5 m•kg, 41 ft•lb)

REAR SHOCK ABSORBER, SWINGARM AND

DRIVE CHAIN

CHAS

6-56

Order Job/Part Q’ty Remarks

9Drive chain guide 2 1

10 Drive chain guide 3 1

11 Nut 1

12 Lock washer 1

13 Drive sprocket 1

14 Drive chain 1

15 Dust cover/oil seal 2/2

16 Spacer 1

17 Bearing 2

For installation, reverse the removal

procedure.

23 Nm (2.3 m•kg, 17 ft•lb) 55 Nm (5.5 m•kg, 41 ft•lb)

100 Nm (10.0 m•kg, 74 ft•lb)

110 Nm (11.0 m•kg, 81 ft•lb)

55 Nm (5.5 m•kg, 41 ft•lb)

REAR SHOCK ABSORBER, SWINGARM AND

DRIVE CHAIN

Refer to “INSTALLING THE

SWINGARM”.

Refer to “INSTALLING THE DRIVE

SPROCKET”.

CHAS

6-57

HANDLING THE REAR SHOCK ABSORBER

WARNING

This rear shock absorber contains highly

compressed nitrogen gas. Before handling

the rear shock absorber read and make

sure you understand the following informa-

tion. The manufacturer cannot be held

responsible for property damage or per-

sonal injury that may result from improper

handling of the rear shock absorber.

• Do not tamper or attempt to open the rear

shock absorber.

• Do not subject the rear shock absorber to

an open flame or any other source of high

heat. High heat can cause an explosion

due to excessive gas pressure.

• Do not deform or damage the rear shock

absorber in any way. If the rear shock

absorber is damaged, damping perfor-

mance will suffer.

DISPOSING OF A REAR SHOCK

ABSORBER

Gas pressure must be released before dispos-

ing of a rear shock absorber. To release the

gas pressure, drill a 2 ~ 3 mm (0.08 ~ 0.12 in)

hole through the rear shock absorber at point

15 ~ 20 mm (0.59 ~ 0.79 in) from its end as

shown.

WARNING

Wear eye protection to prevent eye damage

from released gas or metal chips.

REAR SHOCK ABSORBER, SWINGARM AND

DRIVE CHAIN

CHAS

6-58

EBS00487

REMOVING THE REAR SHOCK ABSORBER

1. Remove:

• rear shock absorber lower bolt

• rear shock absorber upper bolt

TE:N

TE:

While removing the rear shock absorber lower

bolt, hold the swingarm so that it does not drop

down.

EBS00488

CHECKING THE REAR SHOCK ABSORBER

1. Check:

• shock absorber

Gas leaks/oil leaks → Replace the rear

shock absorber assembly.

• shock absorber rod

Bends/damage → Replace the rear shock

absorber assembly.

•spring

Fatigue → Replace the rear shock absorber

assembly.

Move the spring up and down.

EBS00493

TE:N

TE:

Before removing the drive chain and the

sprockets, measure the drive chain slack and a

15-link section of the drive chain.

EBS00494

REMOVING THE SWINGARM

1. Check:

• swingarm free play

a. Check the tightening torque of the pivot

shaft nut. 100 Nm (10.0 m•kg, 74 ft•lb)

REAR SHOCK ABSORBER, SWINGARM AND

DRIVE CHAIN

CHAS

6-59

b. Check the swingarm side play by mov-

ing it from side to side.

If side play is noticeable, check the spacer,

bearings and frame pivot.

c. Check the swingarm vertical movement

by moving it up and down.

If vertical movement is tight or rough, or if

there is binding, check the spacer, bearings

and frame pivot.

2. Remove:

• pivot shaft nut

• washer

• pivot shaft

• swingarm

EBS00495

CHECKING THE SWINGARM

1. Check:

• swingarm

Bends/cracks/damage → Replace.

2. Check:

• pivot shaft

Roll the axle on a flat surface.

Bends → Replace.

WARNING

Do not attempt to straighten a bent pivot

shaft.

3. Clean:

• pivot shaft

• spacer

• bearings

Swingarm free play limit

(at the end of the swingarm)

1.0 mm (0.04 in)

Recommended cleaning solvent

Kerosene

REAR SHOCK ABSORBER, SWINGARM AND

DRIVE CHAIN

CHAS

6-60

4. Check:

• oil seals

Damage/wear → Replace.

• bearings

Damage/pitting → Replace.

EBS00496

CHECKING THE DRIVE CHAIN

1. Measure:

• 15-link section of the drive chain

Out of specification → Replace the drive

chain.

TE:N

TE:

• While measuring the 15-link section, push

down on the drive chain to increase its ten-

sion.

• Measure the length between drive chain roller

and as shown.

• Perform this measurement at two or three dif-

ferent places.

2. Check:

•drive chain

Stiffness → Clean and lubricate or replace.

15-link drive chain section limit

(maximum)

239.3 mm (9.42 in)

REAR SHOCK ABSORBER, SWINGARM AND

DRIVE CHAIN

CHAS

6-61

3. Clean:

•drive chain

a. Wipe the drive chain with a clean cloth.

b. Put the drive chain in kerosene and remove

any remaining dirt.

c. Remove the drive chain from the kerosene

and completely dry it.

CAUTION:

This machine has a drive chain with small

rubber O-rings between the drive chain

side plates. Never use high-pressure water

or air, steam, gasoline, certain solvents

(e.g., benzine), or a coarse brush to clean

the drive chain. High-pressure methods

could force dirt or water into the drive

chain’s internal parts, and solvents will

deteriorate the O-rings. A coarse brush can

also damage the O-rings. Therefore, use

only kerosene to clean the drive chain.

Don’t soak the drive chain in kerosene for

more than ten minutes. Kerosene will dam-

age the O-rings.

4. Check:

• O-rings

Damage → Replace the drive chain.

• drive chain rollers

Damage/wear → Replace the drive chain.

• drive chain side plates

Cracks/damage/wear → Replace the drive

chain.

5. Lubricate:

•drive chain

Recommended lubricant

Engine oil or chain lubricant

suitable for O-ring chains

REAR SHOCK ABSORBER, SWINGARM AND

DRIVE CHAIN

CHAS

6-62

6. Check:

• drive sprocket

• driven sprocket

More than 1/4 tooth wear → Replace

the drive chain sprockets as a set.

Bent teeth → Replace the drive chain

sprockets as a set.

Correct

Drive chain roller

Drive chain sprocket

EBS00497

INSTALLING THE SWINGARM

1. Install:

• bearings

• spacer

TE:N

TE:

• Inject the bearing with the character stamp

turned outward. Apply the lithium-soap-based

grease to inside.

• Apply the lithium-soap-based grease on the

spacer when installing.

EBS00498

INSTALLING THE DRIVE SPROCKET

1. Install:

• drive sprocket

• lock washer

•nut

2. Bend the lock washer tab along a flat side

of the nut.

Installed depth of bearing

1 ~ 2 mm (0.04 ~ 0.08 in)

Drive sprocket nut

110 Nm (11.0 m•kg, 81 ft•lb)

REAR SHOCK ABSORBER, SWINGARM AND

DRIVE CHAIN

ELEC

7-1

EBS00500 ELECTRICAL

ELECTRICAL COMPONENTS

Main switch

Front brake light switch

Clutch switch

Handlebar switch

CDI unit

Starter relay

Fuse

Battery

Tail/brake light

Headlight relay

Starting circuit cut-off

relay

Thermo switch

Carburetor warmer

Starter motor

Pickup coil/stator

assembly

Neutral switch

Rear brake light switch

Ignition coil

Spark plug

Headlight

Rectifier/regulator

Neutral indicator light

ELECTRICAL COMPONENTS

ELEC

7-2

EBS01028

CHECKING SWITCH CONTINUITY

Check each switch for continuity with the

pocket tester. If the continuity reading is incor-

rect, check the wiring connections and if nec-

essary, replace the switch.

CAUTION:

Never insert the tester probes into the cou-

pler terminal slots . Always insert the

probes from the opposite end of the cou-

pler, taking care not to loosen or damage

the leads.

TE:N

TE:

• Before checking for continuity, set the pocket

tester to “0” and to the “Ω × 1” range.

• When checking for continuity, switch back and

forth between the switch positions a few

times.

The terminal connections for switches (e.g.,

main switch, engine stop switch) are shown in

an illustration similar to the one on the left.

The switch positions are shown in the far

left column and the switch lead colors are

shown in the top row in the switch illustration.

TE:N

TE:

“ ” indicates a continuity of electricity

between switch terminals (i.e., a closed circuit

at the respective switch position).

The example illustration on the left shows

that:

There is continuity between the switch termi-

nals for the red and brown switch leads and

between the switch terminals for the red/white

and brown/blue switch leads when the switch

is set to “ON”.

Pocket tester

90890-03112

Analog pocket tester

YU-03112-C

CHECKING SWITCH CONTINUITY

ELEC

7-3

EBS01029

CHECKING THE SWITCHES

Check each switch for damage or wear, proper connections, and also for continuity between the ter-

minals. Refer to “CHECKING SWITCH CONTINUITY”.

Damage/wear → Repair or replace.

Improperly connected → Properly connect.

Incorrect continuity reading → Replace the switch.

CHECKING THE SWITCHES

ELEC

7-4

Light switch

Engine stop switch

Start switch

Main switch

Front brake light switch

Clutch switch

Fuse

Neutral switch

Rear brake light switch

CHECKING THE SWITCHES

ELEC

7-5

EBS01030

CHECKING THE BULBS AND

BULB SOCKETS

Check each bulb and bulb socket for damage

or wear, proper connections, and also for conti-

nuity between the terminals.

Damage/wear → Repair or replace the

bulb, bulb socket or both.

Improperly connected → Properly connect.

No continuity → Repair or replace the bulb,

bulb socket or both.

TYPES OF BULBS

The bulbs used on this machine are shown in

the illustration on the left.

• Bulb is used for the headlight and can

be pulled out by turning counterclockwise

while pushing the bulb holder and remov-

ing.

After this, you can remove the bulb.

• Bulb is used for tail/ brake lights and can

be removed from the socket by pushing and

turning the bulb counterclockwise.

• Bulb is used for indicator lights and can

be removed from their respective socket by

carefully pulling them out.

CHECKING THE CONDITION OF THE

BULBS

The following procedure applies to all of the

bulbs.

1. Remove:

•bulb

CHECKING THE BULBS AND BULB SOCKETS

ELEC

7-6

WARNING

Since the headlight bulb gets extremely

hot, keep flammable products and your

hands away from the bulb until it has

cooled down.

CAUTION:

• Be sure to hold the socket firmly when

removing the bulb. Never pull the lead,

otherwise it may be pulled out of the ter-

minal in the coupler.

• Avoid touching the glass part of the head-

light bulb to keep it free from oil, other-

wise the transparency of the glass, the life

of the bulb, and the luminous flux will be

adversely affected. If the headlight bulb

gets soiled, thoroughly clean it with a

cloth moistened with alcohol or lacquer

thinner.

2. Check:

• bulb (for continuity)

(with the pocket tester)

No continuity → Replace.

TE:N

TE:

Before checking for continuity, set the pocket

tester to “0” and to the “Ω × 1” range.

a. Connect the positive tester probe to termi-

nal and the negative tester probe to ter-

minal , and check the continuity.

b. Connect the positive tester probe to termi-

nal and the negative tester probe to ter-

minal , and check the continuity.

c. If either of the readings indicate no continu-

ity, replace the bulb.

Pocket tester

90890-03112, YU-03112-C

CHECKING THE BULBS AND BULB SOCKETS

ELEC

7-7

CHECKING THE CONDITION OF THE BULB

SOCKETS

The following procedure applies to all of the

bulb sockets.

1. Check:

• bulb socket (for continuity)

(with the pocket tester)

No continuity → Replace

TE:N

TE:

Check each bulb socket for continuity in the

same manner as described in the bulb section;

however, note the following.

a. Install a good bulb into the bulb socket.

b. Connect the pocket tester probes to the

respective leads of the bulb socket.

c. Check the bulb socket for continuity. If any

of the readings indicate no continuity,

replace the bulb socket.

Pocket tester

90890-03112

Analog pocket tester

YU-03112-C

CHECKING THE BULBS AND BULB SOCKETS

ELEC

7-8

EBS00503

IGNITION SYSTEM

CIRCUIT DIAGRAM

B/Y

RBrRBr

OFF

PUSH

R/B

R/W

R/B

L/B

L/BY/B

B/Y

Y/BB/Y

R/B

W/L W/R

BGY

R/B

BWW

W/LW/R

Br Sb BrSbYBr Y Br

SUB-WIRE HARNESS

WIRE HARNESS

W/R

W/L

R/B

WWW

Br B

Y/B

L/B

Y/B B/Y

R/B Sb

Sb BY

L/B

R/B

GYGY

W/R

W/L

Pickup coil

Stator coil

Main switch

Battery positive lead

Battery

Fuse

CDI unit

Ignition coil

Spark plug

Engine stop switch

Ground

IGNITION SYSTEM

ELEC

7-9

EBS01045

TROUBLESHOOTING

Check:

1. fuse

2. battery

3. spark plug

4. ignition spark gap

5. ignition coil resistance

6. main switch

7. engine stop switch

8. pickup coil resistance

9. wiring connections (of the entire ignition

system)

TE:N

TE:

• Before troubleshooting, remove the following

part(s):

1. seat

2. front panel

3. front fender

4. rear fender

5. side cover

• Troubleshoot with the following special

tool(s).

EBS01043

EBS01044

EBS01032

The ignition system fails to operate (no

spark or intermittent spark).

1. Fuse

• Check the fuse for continuity.

Refer to “CHECKING THE SWITCHES”.

• Is the fuse OK?

YES NO

Replace the fuse.

Ignition checker

90890-06754

Opama pet-4000 spark checker

YM-34487

Pocket tester

90890-03112

Analog pocket tester

YU-03112-C

2. Battery

• Check the condition of the battery.

Refer to “CHECKING AND CHARGING

THE BATTERY” in chapter 3.

Minimum open-circuit voltage

12.8 V or more at 20°C (68°F)

• Is the battery OK?

YES NO

• Clean the battery

terminals.

• Recharge or replace

the battery.

3. Spark plug

• Check the condition of the spark plug.

• Check the spark plug type.

• Measure the spark plug gap.

Refer to “CHECKING THE SPARK PLUG”

in chapter 3.

Standard spark plug

DR7EA (NGK)

Spark plug gap

0.6 ~ 0.7 mm (0.024 ~ 0.028 in)

• Is the spark plug in good condition, is it of

the correct type, and is its gap within speci-

fication?

YES NO

Re-gap or replace

the spark plug.

IGNITION SYSTEM

ELEC

7-10

EBS01034 EAS00745

4. Ignition spark gap

The following procedure applies to all of the

spark plugs.

• Disconnect the spark plug cap from the

spark plug.

• Connect the ignition checker and spark

plug cap as shown.

• Set the main switch to “ON”.

• Measure the ignition spark gap .

• Crank the engine by pushing the starter

switch and gradually increase the spark gap

until a misfire occurs.

Minimum ignition spark gap

6 mm (0.24 in)

• Is there a spark and is the spark gap within

specification?

NO YES

The ignition system

is OK.

5. Spark plug cap resistance

The following procedure applies to all of the

spark plug caps.

• Remove the spark plug cap from the spark

plug lead.

• Connect the pocket tester (Ω × 1k) to the

spark plug cap as shown.

• Measure the spark plug cap resistance.

Spark plug cap resistance

10 kΩ at 20°C (68°F)

• Is the spark plug cap OK?

YES NO

Replace the spark

plug cap.

IGNITION SYSTEM

ELEC

7-11

EBS01038 EBS01041

EBS01042

EBS01040

6. Ignition coil resistance

• Disconnect the ignition coil coupler from the

ignition coil.

• Connect the pocket tester (Ω × 1) to the

ignition coil as shown.

Positive tester probe →

orange lead terminal

Negative tester probe →

ignition coil base

• Measure the primary coil resistance.

Primary coil resistance

0.18 ~ 0.28 Ω at 20°C (68°F)

• Connect the pocket tester (Ω × 1k) to the

ignition coil as shown.

Positive tester probe →

high tension code

Negative tester probe →

orange lead terminal

• Measure the secondary coil resistance.

Secondary coil resistance

6.32 ~ 9.48 kΩ at 20°C (68°F)

• Is the ignition coil OK?

YES NO

Replace the ignition

coil.

7. Main switch

• Check the main switch for continuity.

Refer to “CHECKING THE SWITCHES”.

• Is the main switch OK?

YES NO

Replace the main

switch.

8. Engine stop switch

• Check the engine stop switch for continuity.

Refer to “CHECKING THE SWITCHES”.

• Is the engine stop switch OK?

YES NO

Replace the handle-

bar switch.

9. Pickup coil resistance

• Disconnect the pickup coil coupler from the

wire harness.

• Connect the pocket tester (Ω × 100) to the

pickup coil terminal as shown.

Positive tester probe → red terminal

Negative tester probe → white terminal

• Measure the pickup coil resistance.

Pickup coil resistance

248 ~ 372 Ω at 20°C (68°F)

• Is the pickup coil OK?

YES NO

Replace the pickup

coil/stator assembly.

(BLACK)

IGNITION SYSTEM

ELEC

7-12

EBS01047

10. Wiring

• Check the entire ignition system’s wiring.

Refer to “CIRCUIT DIAGRAM”.

• Is the ignition system’s wiring properly con-

nected and without defects?

YES NO

Replace the CDI

unit. Properly connect or

repair the ignition

system’s wiring.

IGNITION SYSTEM

ELEC

7-13

EBS00506

ELECTRIC STARTING SYSTEM

CIRCUIT DIAGRAM

B/Y

RBrRBr

OFF

PUSH

R/B

R/W

R/B

L/B

࡯

L/BY/B

B/Y

Y/BB/Y

R/B

W/L W/R

BGY

R/B

BWW

W/LW/R

Br Sb BrSbYBr Y Br

SUB-WIRE HARNESS

WIRE HARNESS

R࡯B

WWW

W/R

W/L

Br B

W/R

W/L

R/B

WWW

Y/B

L/B

Y/B B/Y

R/B Sb

Sb BY

L/B

R/B

GYGY

Main switch

Battery positive lead

Battery

Fuse

Starter relay

Starter motor

Starting circuit cut-off relay

Clutch switch

Neutral switch

Engine stop switch

Start switch

Ground

ELECTRIC STARTING SYSTEM

ELEC

7-14

EBS00508

STARTING CIRCUIT CUT-OFF SYSTEM

OPERATION

The starting circuit on this model consists of

the starter motor, starter relay, clutch switch,

and neutral switch. If the main switch is on and

the engine stop switch is in the RUN position,

the starter motor can be operated only if:

Battery

Fuse

Main switch

Engine stop switch

Starting circuit cut-off relay

Clutch switch

Neutral switch

Start switch

Starter relay

Starter motor

The transmission is in neutral (the neutral

switch is closed) or

You pull in the clutch lever (the clutch

switch is closed).

ELECTRIC STARTING SYSTEM

ELEC

7-15

EBS01050

TROUBLESHOOTING

Check:

1. fuse

2. battery

3. starter motor

4. starting circuit cut-off relay

5. starting circuit cut-off relay (diode)

6. starter relay

7. main switch

8. engine stop switch

9. neutral switch

10.clutch switch

11.start switch

12.wiring connections

(of the entire starting system)

TE:N

TE:

• Before troubleshooting, remove the following

part(s):

1. seat

2. front panel

3. front fender

4. rear fender

5. side cover

• Troubleshoot with the following special

tool(s).

EBS01043

EBS01044

EBS01051

1. Fuse

• Check the fuse for continuity.

Refer to “CHECKING THE SWITCHES”.

• Is the fuse OK?

YES NO

Replace the fuse.

The starter motor fails to turn.

Pocket tester

90890-03112, YU-03112-C

2. Battery

• Check the condition of the battery.

Refer to “CHECKING AND CHARGING

THE BATTERY” in chapter 3.

Minimum open-circuit voltage

12.8 V or more at 20°C (68°F)

• Is the battery OK?

YES NO

• Clean the battery

terminals.

• Recharge or replace

the battery.

3. Starter motor

• Connect the positive battery terminal

and starter motor lead with a jumper

lead .

WARNING

• A wire that is used as a jumper lead

must have at least the same capacity or

more as that of the battery lead, other-

wise the jumper lead may burn.

• This check is likely to produce sparks,

therefore make sure nothing flammable

is in the vicinity.

• Does the starter motor turn?

YES NO

Repair or replace

the starter motor.

ELECTRIC STARTING SYSTEM

ELEC

7-16

EBS01052 EBS01053

4. Starting circuit cut-off relay

• Remove the starting circuit cut-off relay

from the wire harness.

• Connect the pocket tester (Ω × 1) and bat-

tery (12 V) to the starting circuit cut-off relay

as shown.

Positive battery terminal → red/black

Negative battery terminal →

sky blue or black/yellow

Positive tester probe → red/black

Negative tester probe → yellow/black

• Does the starting circuit cut-off relay have

continuity between red/black and yellow/

black?

YES NO

Replace the starting

circuit cut-off relay.

5. Starting circuit cut-off relay (diode)

• Remove the starting circuit cut-off relay

from the wire harness.

• Connect the pocket tester (Ω × 1) to the

starting circuit cut-off relay as shown.

• Measure the starting circuit cut-off relay for

continuity as follows.

Positive tester probe →

sky blue

Negative tester probe →

red/black

Continuity

Positive tester probe →

red/black

Negative tester probe →

sky blue

continuity

TE:N

TE:

When you switch the tester’s positive and

negative probes, the readings in the above

chart will be reversed.

• Are the testing readings correct?

YES NO

Replace the starting

circuit cut-off relay.

ELECTRIC STARTING SYSTEM

ELEC

7-17

EBS01054

EBS01041

EBS01042

EBS01046

EBS01056

EBS01057

6. Starter relay

• Disconnect the starter relay coupler from

the wire harness.

• Connect the pocket tester (Ω × 1) and bat-

tery (12 V) to the starter relay as shown.

Positive battery terminal → blue/black

Negative battery terminal →

yellow/black

Positive tester probe → red

Negative tester probe → black

• Does the starter relay have continuity

between red and black?

YES NO

Replace the starter

relay.

7. Main switch

• Check the main switch for continuity.

Refer to “CHECKING THE SWITCHES”.

• Is the main switch OK?

YES NO

Replace the main

switch.

Y/BL/B

8. Engine stop switch

• Check the engine stop switch for continuity.

Refer to “CHECKING THE SWITCHES”.

• Is the engine stop switch OK?

YES NO

Replace the handle-

bar switch.

9. Neutral switch

• Check the neutral switch for continuity.

Refer to “CHECKING THE SWITCHES”.

• Is the neutral switch OK?

YES NO

Replace the neutral

switch.

10.Clutch switch

• Check the clutch switch for continuity.

Refer to “CHECKING THE SWITCHES”.

• Is the clutch switch OK?

YES NO

Replace the clutch

switch.

11.Start switch

• Check the start switch for continuity.

Refer to “CHECKING THE SWITCHES”.

• Is the start switch OK?

YES NO

Replace the handle-

bar switch.

ELECTRIC STARTING SYSTEM

ELEC

7-18

EBS01059

12. Wiring

• Check the entire starting system’s wiring.

Refer to “CIRCUIT DIAGRAM”.

• Is the starting system’s wiring properly con-

nected and without defects?

YES NO

The starting system

circuit is OK. Properly connect or

repair the starting

system’s wiring.

ELECTRIC STARTING SYSTEM

ELEC

7-19

EBS01061

STARTER MOTOR

Order Job/Part Q’ty Remarks

Removing the starter motor Remove the parts in the order listed.

Exhaust pipe

Idle gear cover and idle gear Refer to “ENGINE REMOVAL” in chapter

1 Clutch cable holder 1

2 Starter motor lead 1 Disconnect.

3 Starter motor 1

For installation, reverse the removal

procedure.

7 Nm (0.7 m•kg, 5.2 ft•lb)

10 Nm (1.0 m•kg, 7.4 ft•lb)

STARTER MOTOR

ELEC

7-20

EBS01062

Order Job/Part Q’ty Remarks

Disassembling the starter motor Remove the parts in the order listed.

Front bracket 1

Tang washer 1

Plate washer 1

Circlip 1

Rear bracket/Brush 1/1

Armature assembly 1

Starter motor yoke 1

Brush/spring 2/2

For assembly, reverse the disassembly

procedure.

STARTER MOTOR

Refer to “ASSEMBLING THE STARTER

MOTOR”.

ELEC

7-21

EBS01064

CHECKING THE STARTER MOTOR

1. Check:

•commutator

Dirt → Clean with 600-grit sandpaper.

2. Measure:

• commutator diameter

Out of specification → Replace the starter

motor.

3. Measure:

• mica undercut

Out of specification → Scrape the mica to

the proper measurement with a hacksaw

blade that has been grounded to fit the

commutator.

TE:N

TE:

The mica of the commutator must be undercut

to ensure proper operation of the commutator.

4. Measure:

• armature assembly resistances

(commutator and insulation)

Out of specification → Replace the starter

motor.

a. Measure the armature assembly resis-

tances with the pocket tester.

Commutator wear limit

21 mm (0.83 in)

Mica undercut

1.5 mm (0.06 in)

Pocket tester

90890-03112

Analog pocket tester

YU-03112-C

Armature coil

Commutator resistance

0.013 ~ 0.015 Ω at 20°C (68°F)

Insulation resistance

Above 1 MΩ at 20°C (68°F)

STARTER MOTOR

ELEC

7-22

b. If any resistance is out of specification,

replace the starter motor.

5. Measure:

• brush length

Out of specification → Replace the brushes

as a set.

6. Measure:

• brush spring force

Out of specification → Replace the brush

springs as a set.

7. Check:

• gear teeth

Damage/wear → Replace the gear.

8. Check:

• bushing

• bearing

• oil seal

Damage/wear → Replace the defective

part(s).

Brush length wear limit

3.5 mm (0.14 in)

Brush spring force

5.52 ~ 8.28 N

(563 ~ 844 gf, 19.85 ~ 29.78 oz)

STARTER MOTOR

ELEC

7-23

EBS00515

ASSEMBLING THE STARTER MOTOR

1. Install:

• brush spring

•brush

2. Install:

• armature coil

3. Install

• O-rings to starter motor yoke .

4. Install

• Starter motor yoke

TE:N

TE:

Align the match marks on the starter motor

york with the match marks on the rear

bracket.

5. Install

• Tang washer

• Plate washer

• Front bracket

TE:N

TE:

Align the match marks on the starter motor

york with the match marks on the front bracket.

STARTER MOTOR

ELEC

7-24

EBS00516

CHARGING SYSTEM

CIRCUIT DIAGRAM

RBrRBr

OFF RR

L/BY/B

W/L W/R

WWW

W/R

W/L

Y/B

L/B

Stator coil

Rectifier/regulator

Battery positive lead

Battery

Fuse

Ground

CHARGING SYSTEM

ELEC

7-25

EBS01065

TROUBLESHOOTING

Check:

1. fuse

2. battery

3. charging voltage

4. stator coil resistance

5. wiring connections

(of the entire charging system)

TE:N

TE:

• Before troubleshooting, remove the following

part(s):

1. seat

2. front panel

3. front fender

4. rear fender

5. side cover

• Troubleshoot with the following special

tool(s).

EBS01043

EBS01044

1. Fuse

• Check the fuse for continuity.

Refer to “CHECKING THE SWITCHES”.

• Is the fuse OK?

YES NO

Replace the fuse.

The battery is not being charged.

Pocket tester

90890-03112

Analog pocket tester

YU-03112-C

2. Battery

• Check the condition of the battery.

Refer to “CHECKING AND CHARGING

THE BATTERY” in chapter 3.

Minimum open-circuit voltage

12.8 V or more at 20°C (68°F)

• Is the battery OK?

YES NO

• Clean the battery

terminals.

• Recharge or replace

the battery.

CHARGING SYSTEM

ELEC

7-26

EBS01066 EBS01100

3. Charging voltage

• Connect the engine tachometer to on to the

ignition coil.

• Connect the pocket tester (DC 20 V) to the

battery as shown.

Positive tester probe →

positive battery terminal

Negative tester probe →

negative battery terminal

• Start the engine and let it run at approxi-

mately 5,000 r/min.

• Measure the charging voltage.

Charging voltage

14 V at 5,000 r/min

TE:N

TE:

Make sure the battery is fully charged.

• Is the charging voltage within specification?

NO YES

The charging circuit

is OK.

4. Stator coil resistance

• Disconnect the AC magneto coupler from

the wire harness.

• Connect the pocket tester (Ω × 1) to the

charging coils.

Tester (+) lead → White terminal

Tester (–) lead → White terminal

Tester (+) lead → White terminal

Tester (–) lead → White terminal

Tester (+) lead → White terminal

Tester (–) lead → White terminal

• Measure the stator coil resistance.

Charging coil resistance:

0.688 ~ 1.032 Ω at 20°C (68°F)

YES NO

Replace the pickup

coil/stator assembly.

5. Wiring

• Check the entire charging system’s wiring.

Refer to “CIRCUIT DIAGRAM”.

• Is the charging system’s wiring properly

connected and without defects?

YES NO

Replace the rectifier/

regulator. Replace the diode

and properly con-

nect or repair the

charging system’s

wiring.

CHARGING SYSTEM

ELEC

7-27

EBS00518

LIGHTING SYSTEM

CIRCUIT DIAGRAM

B/Y

RBrRBr

OFF

PUSH

R/B

R/W

R/B

L/B

࡯

L/BY/B

B/Y

Y/BB/Y

R/B

W/L W/R

BGY

R/B

BWW

W/LW/R

Br Sb BrSbYBr Y Br

SUB-WIRE HARNESS

WIRE HARNESS

R࡯B

WWW

W/R

W/L

WWW

Br B

W/R

W/L

R/B

Y/B

L/B

Y/B B/Y

R/B Sb

L/B

R/B

GYGY

Stator coil

Rectifier/regulator

Main switch

Battery positive lead

Battery

Fuse

Tail/brake light

Light switch

Headlight relay

Headlight

Ground

LIGHTING SYSTEM

ELEC

7-28

EBS01067

TROUBLESHOOTING

Check:

1. light switch

2. Stator coil resistance

3. wiring connections

(of the entire lighting system)

TE:N

TE:

• Before troubleshooting, remove the following

part(s):

1. seat

2. front panel

3. front fender

4. rear fender

5. side cover

• Troubleshoot with the following special

tool(s).

EAS00783

EAS00776

1. Light switch

• Check the light switch for continuity.

Refer to “CHECKING THE SWITCHES”.

• Is the light switch OK?

YES NO

Replace the handle-

bar switch.

Any of the following fail to light: head-

light, tail/brake light.

Pocket tester

90890-03112

Analog pocket tester

YU-03112-C

2. Stator coil resistance

• Disconnect the AC magneto coupler from

the wire harness.

• Connect the pocket tester (Ω × 1) to the

charging coils.

Tester (+) lead → White terminal

Tester (–) lead → White terminal

Tester (+) lead → White terminal

Tester (–) lead → White terminal

Tester (+) lead → White terminal

Tester (–) lead → White terminal

• Measure the stator coil resistance.

Charging coil resistance:

0.688 ~ 1.032 Ω at 20°C (68°F)

YES NO

Replace the pickup

coil/stator assembly.

LIGHTING SYSTEM

ELEC

7-29

EBS01069

EBS01070

CHECKING THE LIGHTING SYSTEM

1. The headlights fail to come on.

3. Wiring

• Check the entire lighting system’s wiring.

Refer to “CIRCUIT DIAGRAM”.

• Is the lighting system’s wiring properly con-

nected and without defects?

YES NO

Check the condition

of each of the light-

ing system’s circuits.

Refer to “CHECK-

ING THE LIGHT-

ING SYSTEM”.

Properly connect or

repair the lighting

system’s wiring.

1. Headlight bulb and socket

• Check the headlight bulb and socket for

continuity.

Refer to “CHECKING THE BULBS AND

BULB SOCKETS”.

• Are the headlight bulb and socket OK?

YES NO

Replace the head-

light bulb, socket or

both.

2. Voltage

• Connect the pocket tester (AC 20 V) to the

headlight couplers as shown.

When the light switch is set to “LO”

When the light switch is set to “HI”

Headlight coupler (wire harness side)

Headlight

Positive tester probe →

yellow or green

Negative tester probe → black

• Set the main switch to “ON”.

• Start the engine.

• Set the light switch to “LO” or “HI”.

• Measure the voltage (AC 12 V) of yellow

or green on the headlight coupler (wire

harness side).

• Is the voltage within specification?

YES NO

This circuit is OK. Replace the rectifier/

regulator.

LIGHTING SYSTEM

ELEC

7-30

2. The tail/brake light fails to come on.

1. Tail/brake light bulb and bulb socket

(4D31)

• Check the tail/brake light bulb and socket

for continuity.

Refer to “CHECKING THE BULBS AND

BULB SOCKETS”.

• Are the tail/brake light bulb and socket OK?

YES NO

Replace the tail/brake

light bulb, socket or

both.

2. Tail/brake light (4D35, 4D39)

• Disconnect the tail/brake light coupler.

• Connect the battery (12 V) to the tail/brake

light coupler terminals as shown.

• When the jumper leads are connected to

the terminals, the tail/brake light should illu-

minate.

Positive battery terminal → blue

Negative battery terminal → black

• Is the tail/brake light OK?

YES NO

Replace the tail/

brake light.

3. Voltage

• Connect the pocket tester (AC 20 V) to the

tail/brake light coupler as shown.

Tail/brake light coupler (wire harness side)

Tail/brake light

Positive tester probe → blue

Negative tester probe → black

• Set the main switch to “ON”.

• Start the engine.

• Measure the voltage (AC 12 V) of blue

on the tail/brake light coupler (wire harness

side).

• Is the voltage within specification?

YES NO

This circuit is OK. Replace the rectifier/

regulator.

LIGHTING SYSTEM

ELEC

7-31

EBS00521

SIGNAL SYSTEM

CIRCUIT DIAGRAM

B/Y

RBrRBr

OFF

PUSH

R/B

R/W

R/B

L/B

࡯

L/BY/B

B/Y

Y/BB/Y

R/B

W/L W/R

BGY

R/B

BWW

W/LW/R

Br Sb BrSbYBr Y Br

SUB-WIRE HARNESS

WIRE HARNESS

R࡯B

WWW

Br B

W/R

W/L

R/B

WWW

Y/B

L/B

Y/B B/Y

R/B Sb

Sb BY

W/R

W/L

L/B

R/B

GYGY

Main switch

Battery positive lead

Battery

Fuse

Neutral indicator light

Neutral switch

Rear brake light switch

Front brake light switch

Tail/brake light

Ground

SIGNAL SYSTEM

ELEC

7-32

EBS01073

TROUBLESHOOTING

Check:

1. fuse

2. battery

3. main switch

4. wiring connections

(of the entire signaling system)

TE:N

TE:

• Before troubleshooting, remove the following

part(s):

1. seat

2. front fender

• Troubleshoot with the following special

tool(s).

EBS01043

EBS01044

EBS01041

EBS01074

Any of the following fail to light: brake

light or an indicator light.

1. Fuse

• Check the fuse for continuity.

Refer to “CHECKING THE SWITCHES”.

• Is the fuse OK?

YES NO

Replace the fuse.

Pocket tester

90890-03112

Analog pocket tester

YU-03112-C

2. Battery

• Check the condition of the battery.

Refer to “CHECKING AND CHARGING

THE BATTERY” in chapter 3.

Minimum open-circuit voltage

12.8 V or more at 20°C (68°F)

• Is the battery OK?

YES NO

• Clean the battery

terminals.

• Recharge or replace

the battery.

3. Main switch

• Check the main switch for continuity.

Refer to “CHECKING THE SWITCHES”.

• Is the main switch OK?

YES NO

Replace the main

switch.

4. Wiring

• Check the entire signal system’s wiring.

Refer to “CIRCUIT DIAGRAM”.

• Is the signaling system’s wiring properly

connected and without defects?

YES NO

Check the condition

of each of the signal-

ing system’s circuits.

Refer to “CHECK-

ING THE SIGNAL-

ING SYSTEM”.

Properly connect or

repair the signaling

system’s wiring.

SIGNAL SYSTEM

ELEC

7-33

EBS01075

CHECKING THE SIGNALING SYSTEM

EBS01076

1. The tail/brake light fails to come on.

1. Tail/brake light bulb and bulb socket

(4D31)

• Check the tail/brake light bulb and bulb

socket for continuity.

Refer to “CHECKING THE BULBS AND

BULB SOCKETS”.

• Are the tail/brake light bulb and bulb socket

OK?

YES NO

Replace the tail/

brake light bulb, bulb

socket or both.

2. Tail/brake light (4D35, 4D39)

• Disconnect the tail/brake light coupler.

• Connect the battery (12 V) to the tail/brake

light coupler terminals as shown.

• When the jumper leads are connected to

the terminals, the tail/brake light should illu-

minate.

Positive battery terminal → yellow

Negative battery terminal → black

• Is the tail/brake light OK?

YES NO

Replace the tail/

brake light.

3. Brake light switches

• Check the brake light switches for continuity.

Refer to “CHECKING THE SWITCHES”.

• Is the brake light switch OK?

YES NO

Replace the brake

light switch.

4. Voltage

• Connect the pocket tester (DC 20 V) to the

tail/brake light coupler (wire harness side)

as shown.

Positive tester probe → yellow

Negative tester probe → black

• Set the main switch to “ON”.

• Pull in the brake lever or push down on the

brake pedal.

• Measure the voltage (DC 12 V) of yellow

on the tail/brake light coupler (wire harness

side).

• Is the voltage within specification?

YES NO

This circuit is OK. The wiring circuit

from the main switch

to the tail/brake light

coupler is faulty and

must be repaired.

SIGNAL SYSTEM

ELEC

7-34

EBS01077

2. The neutral indicator light fails to come on.

1. Neutral indicator light bulb and socket

• Check the neutral indicator light bulb and

socket for continuity.

Refer to “CHECKING THE BULBS AND

BULB SOCKETS”.

• Are the neutral indicator light bulb and

socket OK?

YES NO

Replace the neutral

indicator light bulb,

socket or both.

2. Neutral switch

• Check the neutral switch for continuity.

Refer to “CHECKING THE SWITCHES”.

• Is the neutral switch OK?

YES NO

Replace the neutral

switch.

3. Voltage

• Connect the pocket tester (DC 20 V) to the

indicator light coupler (wire harness side)

as shown.

Positive tester probe → brown

Negative tester probe → sky blue

• Set the main switch to “ON”.

• Measure the voltage (DC 12 V).

• Is the voltage within specification?

YES NO

This circuit is OK. The wiring circuit

from the main switch

to the indicator light

coupler is faulty and

must be repaired.

Br Sb BrSb

SIGNAL SYSTEM

ELEC

7-35

EBS01083

3. The carburetor heater fails to come on.

1. Thermo switch

• Disconnect the thermo switch from the wire-

harness.

• Connect the pocket tester (Ω × 1) to the

thermo switch lead.

Tester positive probe → black

Tester negative probe → black

• Check the thermo switch for continuity at

the temperatures indicated below.

COOL DOWN

HEAT UP

• Does the thermo switch operated properly?

YES NO

Replace the thermo

switch.

OFF

11°C±3°C

(51.8°F±5.4°F) 16°C±3°C

(60.8°F±5.4°F)

2. Carburetor warmer

• Remove the carburetor heating element

from the carburetor.

• Connect the pocket tester (Ω × 1) to the car-

buretor heating element.

Tester positive probe →

heating element

Tester negative probe →

heating element body

• Measure the carburetor heating element

resistance.

Carburetor heating element resis-

tance:

6 ~ 12 Ω (20°C)

• Is the carburetor heating element OK?

YES NO

This circuit is OK. Replace the carbu-

retor warmer ele-

ment.

SIGNAL SYSTEM

TRBL

SHTG

8-1

EBS00537

TROUBLESHOOTING

TE:

The following troubleshooting does not cover all the possible causes of trouble. It should be helpful,

however, as a guide to troubleshooting. Refer to the relative procedure in this manual for check,

adjustment and replacement of parts.

STARTING FAILURE/HARD STARTING

FUEL SYSTEM

Fuel tank

•Empty

• Clogged fuel strainer

• Clogged fuel tank breather hose

• Deteriorated or contaminated fuel

Fuel cock

• Clogged fuel hose

Carburetor

• Deteriorated or contaminated fuel

• Clogged pilot jet

• Clogged pilot air passage

• Sucked-in air

• Deformed float

• Worn needle valve

• Improperly sealed valve seat

• Improperly adjusted fuel level

• Improperly set pilot jet

• Clogged starter jet

• Choke valve malfunction

Air filter

• Clogged air filter element

ELECTRICAL SYSTEM

Spark plug

• Improper plug gap

• Worn electrodes

• Wire between terminals broken

• Improper heat range

Ignition coil

• Broken or shorted primary/secondary

• Faulty ignition coil lead

• Broken body

CDI system

• Faulty CDI unit

• Faulty pickup coil

• Faulty lighting coil

• Faulty charging coil

• Broken woodruff key

Switches and wiring

• Faulty main switch

• Faulty engine stop switch

• Broken or shorted wiring

• Faulty neutral switch

• Faulty start switch

• Faulty clutch switch

• Faulty throttle switch

• Faulty carburetor switch

• Loose connections

Starter motor

• Faulty starter motor

• Faulty starter relay

• Faulty starting circuit cut-off relay

• Faulty starter clutch

• Faulty torque limiter

Battery

• Faulty battery

• Discharged battery

STARTING FAILURE/HARD STARTING

TRBL

SHTG

8-2

COMPRESSION SYSTEM

Cylinder and cylinder head

• Loose spark plug

• Loose cylinder head or cylinder

• Broken cylinder head gasket

• Broken cylinder gasket

• Worn, damaged or seized cylinder

Valve and camshaft

• Improperly sealed valve

• Improperly contacted valve and valve seat

• Improper valve timing

• Broken valve spring

• Seized camshaft

Piston and piston rings

• Improperly installed piston ring

• Worn, fatigued or broken piston ring

• Seized piston ring

• Seized or damaged piston

Crankcase and crankshaft

• Improperly seated crankcase

• Seized crankshaft

Valve train

• Improperly adjusted valve clearance

• Improperly adjusted valve timing

EBS00538

POOR IDLE SPEED PERFORMANCE

Carburetor

• Improperly returned choke

• Loose or clogged pilot jet

• Loose or clogged pilot air jet

• Improperly adjusted idle speed

(throttle stop screw)

• Improper throttle cable play

• Flooded carburetor

Intake manifold

• Loosen carburetor joint

Electrical system

• Faulty battery

• Faulty CDI unit

• Faulty pickup coil

• Faulty ignition coil

Valve train

• Improperly adjusted valve clearance

Air filter

• Clogged air filter element

• Loosen air filter joint

EBS00539

POOR MEDIUM AND HIGH-SPEED PERFORMANCE

Refer to “STARTING FAILURE/HARD STARTING” and “POOR IDLE SPEED PERFORMANCE—

Valve train”.

Carburetor

• Improper jet needle clip position

• Improperly adjusted fuel level

• Clogged or loose main jet

• Deteriorated or contaminated fuel

Air filter

• Clogged air filter element

STARTING FAILURE/HARD STARTING/POOR IDLE SPEED

PERFORMANCE/POOR MEDIUM AND HIGH-SPEED PERFORMANCE

TRBL

SHTG

8-3

EBS00541

FAULTY GEAR SHIFTING

HARD SHIFTING

Refer to “CLUTCH DRAGGING”.

SHIFT PEDAL DOES NOT MOVE

Shift shaft

• Bent shift shaft

Shift drum and shift forks

• Groove jammed with impurities

• Seized shift fork

• Bent shift fork guide bar

Transmission

• Seized transmission gear

• Jammed impurities

• Incorrectly assembled transmission

Shift guide

• Broken shift guide

JUMPS OUT GEAR

Shift shaft

• Improperly adjusted shift lever position

• Improperly returned stopper lever

Shift forks

• Worn shift fork

Shift drum

• Improper thrust play

• Worn shift drum groove

Transmission

• Worn gear dog

EBS00545

CLUTCH SLIPPING/DRAGGING

CLUTCH SLIPPING

Clutch

• Loose clutch spring

• Fatigued clutch spring

• Worn friction plate

• Worn clutch plate

• Incorrectly assembled clutch

Engine oil

•Low oil level

• Improper quality (low viscosity)

• Deterioration

CLUTCH DRAGGING

Clutch

• Warped pressure plate

• Unevenly tensioned clutch springs

• Loose clutch boss nut

• Burnt primary driven gear bushing

• Bent clutch plate

• Swollen friction plate

• Broken clutch boss

Engine oil

• High oil level

• Improper quality (high viscosity)

• Deterioration

FAULTY GEAR SHIFTING/

CLUTCH SLIPPING/DRAGGING

TRBL

SHTG

8-4

EBS00547

OVERHEATING

Ignition system

• Improper spark plug gap

• Improper spark plug heat range

• Faulty CDI unit

Fuel system

• Improper carburetor main jet

(improper setting)

• Improper fuel level

• Clogged air filter element

Compression system

• Heavy carbon deposit

Engine oil

• Improper oil level

• Improper oil viscosity

• Inferior oil quality

Brake

•Brake drag

EBS00550

FAULTY BRAKE

POOR BRAKING EFFECT

Disc brake

• Worn brake pads

• Worn disc

• Air in brake fluid

• Leaking brake fluid

• Faulty master cylinder kit cup

• Faulty caliper kit seal

• Loose union bolt

• Broken brake hose and pipe

• Oily or greasy disc/brake pads

• Improper brake fluid level

EBS00551

SHOCK ABSORBER MALFUNCTION

MALFUNCTION

• Bent or damaged damper rod

• Damaged oil seal lip

• Fatigued shock absorber spring

• Leaking oil or gas

OVERHEATING/FAULTY BRAKE/

SHOCK ABSORBER MALFUNCTION

TRBL

SHTG

8-5

EBS00552

UNSTABLE HANDLING

Handlebar

• Improperly installed or bent

Steering

• Incorrect toe-in

• Bent steering stem

• Improperly installed steering stem

• Damaged bearing or bearing race

• Bent tie-rods

• Deformed steering knuckles

Tires

• Uneven tire pressures on both sides

• Incorrect tire pressure

• Uneven tire wear

Wheels

• Deformed wheel

• Loose bearing

• Bent or loose wheel axle

• Excessive wheel runout

Frame

• Bent

• Damaged frame

Swingarm

• Worn bearing or bushing

• Bent or damaged

EBS00553

LIGHTING SYSTEM

HEADLIGHT DOES NOT COME ON

• Improper bulb

• Too many electric accessories

• Hard charging (broken stator coil and/or

faulty rectifier/regulator)

• Incorrect connection

• Improperly grounded

• Poor contacts (main or light switch)

• Bulb life expired

TAIL/BRAKE LIGHT DOES NOT LIGHT

• Wrong tail/brake light bulb

• Too many electrical accessories

• Hard charging (broken stator coil and/or

faulty rectifier/regulator)

• Incorrect connection

• Improperly grounded

• Poor contacts (main or light switch)

• Burnt-out tail/brake light bulb

BULB BURNT OUT

• Improper bulb

• Faulty battery

• Faulty rectifier/regulator

• Improperly grounded

• Faulty main and/or light switch

• Bulb life expired

TAIL/BRAKE LIGHT BULB BURNT OUT

• Wrong tail/brake light bulb

• Faulty battery

• Faulty rectifier/regulator

• Improperly grounded

• Faulty main and/or light switch

• Incorrectly adjusted rear brake light switch

• Tail/brake light bulb life expired

UNSTABLE HANDLING/

LIGHTING SYSTEM

YAMAHA MOTOR CO., LTD.

2500 SHINGAI IWATA SHIZUOKA JAPAN

PRINTED IN U.S.A.

YFM250RX WIRING DIAGRAM Pickup coil

Stator coil

Rectifier/regulator

Main switch

Battery positive lead

Battery

Fuse

Starter relay

Starter motor

CDI unit

Ignition coil

Spark plug

Starting circuit cut-off relay

Clutch switch

Thermo switch

Carburetor warmer

Neutral indicator light

Neutral switch

Rear brake light switch

Front brake light switch

Tail/brake light

Handlebar switch

Light switch

Engine stop switch

Start switch

Headlight relay

Headlight

Ground

COLOR CODE

B. . . . . . .Black

Br . . . . . .Brown

G . . . . . .Green

L . . . . . . .Blue

O . . . . . .Orange

R. . . . . . .Red

Sb . . . . . Sky blue

W . . . . . White

Y . . . . . . Yellow

B/Y . . . . Black/Yellow

L/B . . . . Blue/Black

R/B . . . . Red/Black

R/W . . . . Red/White

W/L . . . . White/Blue

W/R . . . . White/Red

Y/B. . . . . Yellow/Black

4D3 28197 10 2008 Yamaha Raptor 250 Sevice Manual

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