2005 YP250R SERVICE MANUAL 1C0-F8197-E0
EAS00000 YP250R 2005 SERVICE MANUAL ©2007 by Yamaha Motor España, S.A. First edition, February 2007 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor España, S.A. is expressly prohibited.
EAS00002 NOTICE This manual was produced by the Yamaha Motor España S.A. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
EAS00007 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. 1 The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each page indicate the current chapter. Refer to “SYMBOLS”. 2 Each chapter is divided into sections.
1 EAS00008 2 GEN INFO SYMBOLS The following symbols are not relevant to every vehicle. Symbols 1 to 9 indicate the subject of each chapter. SPEC 3 4 CHK ADJ 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Chassis 5 Engine 6 Cooling system 7 Carburetor 8 Electrical system 9 Troubleshooting CHAS 5 6 ENG COOL 7 8 – ELEC CARB 9 Symbols 0 to G indicate the following.
EAS00010 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM CARBURETOR GEN INFO 1 SPEC 2 CHK ADJ 3 CHAS 4 ENG 5 COOL 6 CARB 7 – ELECTRICAL SYSTEM TROUBLESHOOTING + ELEC 8 TRBL SHTG 9
GEN INFO CHAPTER 1 GENERAL INFORMATION IDENTIFICATION ............................................................................................ 1-1 VEHICLE IDENTIFICATION NUMBER .....................................................1-1 MODEL LABEL.......................................................................................... 1-1 MULTI-FUNCTION DISPLAY..........................................................................1-2 IMPORTANT INFORMATION ..............................................
IDENTIFICATION GEN INFO EAS00015 GENERAL INFORMATION IDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 stamped into the frame. is 1 EAS00018 MODEL LABEL The model label 1 is affixed underneath the seat. This information will be needed when ordering spare parts.
MULTI-FUNCTION DISPLAY GEN INFO MULTI-FUNCTION DISPLAY The multi-function display is equipped with the following: • an odometer (which shows the total distance traveled) • two tripmeters (which show the distance traveled since they were last set to zero, the time passed since the tripmeters were set to zero, and the average speed traveled during this time) 1 “MODE” button 2 Multi-function display 3 “SET” button • a fuel reserve tripmeter (which shows the distance traveled since the fuel level warning lig
MULTI-FUNCTION DISPLAY GEN INFO Pushing the “SET” button when in the tripmeter mode switches the display between the different tripmeter functions in the following order: Distance → Time → Average speed → Distance If the fuel level warning light comes on, the display will automatically change to the fuel reserve tripmeter mode “Trip/fuel” and start counting the distance traveled from that point.
MULTI-FUNCTION DISPLAY GEN INFO Ambient temperature display This display shows the ambient temperature from -30 °C to 50 °C. The frost warning indicator “*” automatically comes on if the temperature is lower than 3 °C. 1 Frost warning indicator 2 Negative symbol 3 Ambient temperature Oil change indicator “OIL” The engine oil should be changed when this indicator comes on. The indicator stays on until it is reset. After changing the engine oil, reset the indicator as follows.
IMPORTANT INFORMATION GEN INFO EAS00020 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, cylinders, pistons and other parts that have been “mated” through normal wear. Mated parts must always be reused or replaced as an assembly. 4.
IMPORTANT INFORMATION GEN INFO EAS00023 LOCK WASHERS/PLATES AND COTTER PINS After removal, replace all lock washers/plates 1 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. EAS00024 BEARINGS AND OIL SEALS Install bearings and oil seals so that the manufacturer’s marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease.
CHECKING THE CONNECTIONS GEN INFO EAS00026 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. NOTE: If the pin 1 on the terminal is flattened, bend it up. _ 4.
SPECIAL TOOLS GEN INFO EAS00027 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes. Tool No.
SPECIAL TOOLS Tool No. Tool name/Function Tappet adjusting tool 90890-01311 This tool is used to adjust valve clearance. T-handle 90890-01326 This tool is used to hold the damper rod when removing or installing the damper rod. Clutch spring holder 90890-01337 This tool is used to disassembly and assembly the secondary sheave. Locknut wrench 90890-01348 This tool is used to remove or install the clutch carrier nut. Flywheel puller 90890-01362 This tool is used to remove the generator rotor.
SPECIAL TOOLS Tool No. Tool name/Function Steering nut wrench 90890-01403 This tool is used to loosen or tighten the steering ring nuts. Clutch spring holder arm 90890-01464 This tool is used to disassembly and assembly the secondary sheave. Adapter (M14) 90890-01478 This tool is used to install the crankshaft. Sheave holder 90890-01701 This tool is used to hold the generator rotor, clutch housing, and clutch carrier. Compression gauge 90890-03081 This tool is used to measure the engine compression.
SPECIAL TOOLS Tool No. Tool name/Function Valve spring compressor 90890-04019 This tool is used to remove or install the valve assemblies. Middle driven shaft bearing driver 90890-04058 This tool is used to install the water pump seal. Valve guide remover (ø6) 90890-04064 This tool is used to remove or install the valve guides. Valve guide installer (ø6) 90890-04065 This tool is used to install the valve guides. Valve guide reamer (ø6) 90890-04066 This tool is used to rebore the new valve guides.
SPECIAL TOOLS Tool No. Tool name/Function Ignition checker 90890-06754 This tool is used to check the ignition system components. Vacuum/pressure pump gauge set 90890-06756 This tool is used to check the air cut-off valve. Fuel sender removal tool 90890-11098 This tool are used to remove the fuel sender. Yamaha bond No. 1215 90890-85505 This bond is used to seal two mating surfaces (e.g., crankcase mating surfaces).
SPEC CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS ........................................................................ 2-1 ENGINE SPECIFICATIONS ............................................................................2-2 CHASSIS SPECIFICATIONS ........................................................................2-11 ELECTRICAL SPECIFICATIONS .................................................................2-15 CONVERSION TABLE ...................................................................
GENERAL SPECIFICATIONS SPEC SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Model code Dimensions Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius Weight Wet (with oil and a full fuel tank) Maximum load (total of cargo, rider, passenger, and accessories) 1C01 2,210 mm (87.0 in) 790 mm (31.1 in) 1,380 mm (54.3 in) 775 mm (30.5 in) 1,545 mm (60.8 in) 113 mm (4.45 in) 3,600 mm (143.
ENGINE SPECIFICATIONS SPEC ENGINE SPECIFICATIONS Item Engine Engine type Displacement Cylinder arrangement Bore × stroke Compression ratio Standard compression pressure (at sea level) Starting system Fuel Recommended fuel Fuel tank capacity Total (including reserve) Fuel reserve amount Engine oil Lubrication system Recommended oil type Recommended engine oil grade Quantity Total amount Periodic oil change Oil temperature Final transmission oil Type Oil quantity Standard Limit Liquid cooled 4-stroke, SO
ENGINE SPECIFICATIONS Item Oil pump Oil pump type Inner-rotor-to-outer-rotor-tip clearance Outer-rotor-to-oil-pump-housing clearance Oil-pump-housing-to-inner-andouter-rotor clearance Cooling system Radiator and engine capacity Radiator capacity Radiator core Width Height Depth Coolant reservoir capacity (up to the maximum level mark) Water pump Water pump type Reduction ratio Impeller shaft tilt limit Coolant temperature Spark plug Manufacturer/model × quantity Spark plug gap Cylinder head Maximum warpage
ENGINE SPECIFICATIONS Item Standard Camshaft Drive system Intake camshaft lobe dimensions Chain drive (left) SPEC Limit ---- A B Measurement A 37.051 ~ 37.151 mm (1.4587 ~ 1.4626 in) 36.956 mm (1.4550 in) 30.074 ~ 30.174 mm (1.1840 ~ 1.1880 in) 29.973 mm (1.
ENGINE SPECIFICATIONS Item SPEC Standard Valves, valve seats, valve guides Valve clearance (cold) Intake Exhaust Valve dimensions Limit 0.08 ~ 0.12 mm (0.0031 ~ 0.0047 in) 0.16 ~ 0.20 mm (0.0063 ~ 0.
ENGINE SPECIFICATIONS Item SPEC Standard Limit Valve stem runout ---- 0.010 mm (0.0004 in) Cylinder head valve seat width Intake 0.90 ~ 1.10 mm (0.0354 ~ 0.0433 in) 1.6 mm (0.06 in) 1.6 mm (0.06 in) Exhaust Valve springs Inner spring Free length Intake Exhaust Installed length (valve closed) Intake Exhaust Spring rate - intake (K1) Spring rate - intake (K2) Spring rate - exhaust (K1) Spring rate - exhaust (K2) Compression spring force (installed) Intake Exhaust 0.90 ~ 1.10 mm (0.0354 ~ 0.
ENGINE SPECIFICATIONS Item Winding direction (top view) Intake Exhaust Outer spring Free length Intake Exhaust Installed length (valve closed) Intake Exhaust Spring rate - intake (K1) Spring rate - intake (K2) Spring rate - exhaust (K1) Spring rate - exhaust (K2) Compression spring force (installed) Intake Exhaust Standard Counterclockwise Counterclockwise 36.93 mm (1.45 in) 36.93 mm (1.45 in) ------- 35.00 mm (1.38 in) 35.00 mm (1.38 in) ------------------- 115 ~ 133 N (11.73 ~ 13.56 kgf, 25.85 ~ 29.
ENGINE SPECIFICATIONS Item SPEC Standard Piston Piston-to-cylinder clearance Limit 0.020 ~ 0.040 mm (0.0008 ~ 0.0016 in) 0.15 mm (0.0059 in) 68.965 ~ 68.980 mm (2.7152 ~ 2.7157 in) ---- Diameter D H D Height H Piston pin bore (in the piston) Diameter 5.0 mm (0.20 in) ---- 17.004 ~ 17.015 mm (0.6694 ~ 0.6699 in) 17.045 mm (0.6711 in) 0.50 mm (0.0197 in) ---Intake side ---- Offset Offset direction Piston pin Outside diameter Piston-pin-to-piston-pin-bore clearance Piston rings Top ring 16.
ENGINE SPECIFICATIONS Item SPEC Standard Limit Oil ring B T Dimensions (B × T) End gap (installed) Ring side clearance Crankshaft C 1.50 × 2.50 mm (0.06 × 0.10 in) 0.20 ~ 0.70 mm (0.0079 ~ 0.0276 in) 0.060 ~ 0.150 mm (0.0024 ~ 0.0059 in) ---------- C E D A Width A Maximum runout C Big end side clearance D Big end radial clearance E Automatic centrifugal clutch Clutch type Clutch shoe thickness 59.75 ~ 59.80 mm (2.352 ~ 2.354 in) ---0.350 ~ 0.850 mm (0.0138 ~ 0.0335 in) 0.010 ~ 0.025 mm (0.
ENGINE SPECIFICATIONS Item Air filter Air filter element Fuel pump Pump type Model/manufacturer Output pressure Carburetor Type × quantity Manufacturer ID mark Main jet Main air jet Jet needle Needle jet Pilot air jet 1 Pilot outlet Pilot jet Bypass 1 Bypass 2 Bypass 3 Bypass 4 Pilot screw turns out Valve seat size Starter jet 1 Throttle valve size Float height Idling condition Engine idling speed CO density (when air induction system is operating) CO density (when air induction system is not operating) Thr
CHASSIS SPECIFICATIONS SPEC CHASSIS SPECIFICATIONS Item Frame Frame type Caster angle Trail Front wheel Wheel type Rim Size Material Wheel travel Wheel runout Maximum radial wheel runout Maximum lateral wheel runout Wheel axle bending limit Rear wheel Wheel type Rim Size Material Wheel travel Wheel runout Maximum radial wheel runout Maximum lateral wheel runout Front tire Tire type Size Manufacturer/model Tire pressure (cold) 0 ~ 90 kg (0 ~ 198 lb) 90 ~ 235 kg (198 ~ 518 lb) Maximum tire tread depth Stan
CHASSIS SPECIFICATIONS Item Rear tire Tire type Size Manufacturer/model Tire pressure (cold) 0 ~ 90 kg (0 ~ 198 lb) 90 ~ 180 kg (198 ~ 397 lb) Maximum tire tread depth Front brake Brake type Operation Recommended fluid Brake disc Diameter × thickness Minimum thickness Standard Tubeless 140/70-14 M/C 68S or 68P MICHELIN/GOLD STANDARD PIRELLI/GTS24 220 kPa (2.20 kgf/cm2, 32 psi) 250 kPa (2.50 kgf/cm2, 36 psi) ---- Single disc brake Right hand operation DOT 4 267.0 × 5.0 mm (10.51 × 0.
CHASSIS SPECIFICATIONS Item Steering Steering bearing type Center to lock angle (left) Center to lock angle (right) Front suspension Suspension type Front fork type Front fork travel Spring Free length SPEC Standard Limit Angular bearing 62.0° 62.0° ---------- Telescopic fork Coil spring/oil damper 110.0 mm (4.33 in) ---------- 308.0 mm (12.126 in) Installed length Spring rate (K1) Spring rate (K2) Spring stroke (K1) Spring stroke (K2) Inner tube outer diameter Inner tube bending limit 277.
CHASSIS SPECIFICATIONS Item Rear suspension Suspension type Rear shock absorber type Rear shock absorber assembly travel Spring Free length Installed length Spring rate (K1) Spring rate (K2) Spring rate (K3) Spring stroke (K1) Spring stroke (K2) Spring stroke (K3) Optional spring available Spring preload adjusting positions Minimum Standard Maximum SPEC Standard Unit swing Coil spring/oil damper 95.0 mm (3.74 in) 270.1 mm (10.63 in) 249 mm (9.80 in) 8.00 N/mm (0.82 kgf/mm, 45.68 lb/in) 13.70 N/mm (1.
ELECTRICAL SPECIFICATIONS SPEC ELECTRICAL SPECIFICATIONS Item System voltage Ignition system Ignition system type Ignition timing (B.T.D.C.
ELECTRICAL SPECIFICATIONS Item Indicator light Meter lighting Turn signal indicator light High beam indicator light Fuel level warning light Immobilizer system indicator light Electric starting system System type Starter motor Model/manufacturer Power output Brush Overall length Spring force Armature coil resistance Commutator diameter Mica undercut (depth) Starter relay Model/manufacturer Amperage Coil resistance Horn Horn type Quantity Model/manufacturer Maximum amperage Performance Coil resistance Turn s
ELECTRICAL SPECIFICATIONS Item Starting circuit cut-off relay Model/manufacturer Coil resistance Headlight relay Model/manufacturer Coil resistance Fuel pump relay Model/manufacturer Coil resistance Radiator fan motor relay Model/manufacturer Coil resistance Coolant temperature sensor Model/manufacturer Resistance at 80 °C (176 °F) Resistance at 100 °C (212 °F) Speed sensor Output voltage When sensor is on When sensor is off Fuses Main fuse Headlight fuse Signaling system fuse Ignition fuse Radiator fan mot
CONVERSION TABLE/ GENERAL TIGHTENING TORQUE SPECIFICATIONS SPEC EAS00028 EAS00029 CONVERSION TABLE GENERAL TIGHTENING TORQUE SPECIFICATIONS 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. METRIC MULTIPLIER IMPERIAL ** mm × 0.03937 = ** in 2 mm × 0.03937 = 0.08 in CONVERSION TABLE METRIC TO IMPERIAL Metric unit m·kg Tightening torque m·kg cm·kg cm·kg Weight kg g Multiplier Imperial unit 7.
TIGHTENING TORQUES SPEC TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Item Part name Thread Q’ty size Tightening torque Nm m · kg ft · lb Oil check bolt Exhaust pipe stud bolt Air induction system pipe stud bolt Spark plug Camshaft sprocket cover Cylinder head and cylinder Cylinder head and cylinder Bolt Bolt Bolt — Bolt Nut Bolt M6 M8 M6 M12 M6 M8 M6 1 2 2 1 2 4 2 7 13 10 18 10 22 10 0.7 1.3 1.0 1.8 1.0 2.2 1.0 5.1 9.4 7.2 13 7.2 16 7.
TIGHTENING TORQUES Item Timing mark accessing plug Starter clutch Secondary sheave Primary sheave cap Primary sheave Clutch carrier Secondary sheave bracket Stator coil Pickup coil Starter motor Coolant temperature sensor Air filter case mounting bolt Exhaust pipe nut Muffler mounting bolt Muffler joint bolt Coolant reservoir Radiator Thermo switch (auto choke) Thermo switch (radiator fan motor) Part name — Bolt Nut Screw Nut Nut Bolt Bolt Bolt Bolt — Bolt Nut Bolt Bolt Bolt Bolt — — SPEC Thread Q’ty siz
TIGHTENING TORQUES SPEC CHASSIS TIGHTENING TORQUES Item Thread size Frame and engine bracket Frame and engine bracket rod Engine bracket, engine bracket rod and engine Frame and sidestand bolt Frame and sidestand nut Passenger footrest and frame Grab bar and frame Fuel tank and frame Sidestand switch Battery bracket and frame Seat lock cable bracket and frame Swingarm and engine Rear brake hose holder and frame Rear shock absorber and engine Rear shock absorber and swingarm Rear shock absorber and frame
TIGHTENING TORQUES Item Thread size Rear brake master cylinder and holder Rear brake master cylinder and brake lever Grip end Front cowling inner panel and frame Radiator cover and frame Rear side cover (left and right) and frame Mudguard and frame Footrest board and frame Storage compartment and frame M6 M6 M16 M6 M6 M6 M6 M6 M6 SPEC Tightening torque Nm m · kg ft · lb 7 10 26 7 7 7 7 7 7 0.7 1.0 2.6 0.7 0.7 0.7 0.7 0.7 0.7 Remarks 5.1 7.2 19 5.1 5.1 5.1 5.1 5.1 5.1 NOTE: 1.
LUBRICATION POINTS AND LUBRICANT TYPES SPEC EAS00031 LUBRICATION POINTS AND LUBRICANT TYPES ENGINE LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Oil seal lips Lubricant LS Bearings E O-rings LS Cylinder head nut mounting surface E Crankshaft pin E Connecting rod big end thrust surface E Rotary filter inner surface E Oil pump drive gear inner surface E Timing chain sprocket inner surface E Piston pin E Piston, ring grooves, and piston rings E Cylinder inner surface E Cam
LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point SPEC Lubricant Yamaha bond No.
COOLING SYSTEM DIAGRAMS SPEC COOLING SYSTEM DIAGRAMS 1 Radiator filler hose 2 Radiator 3 Coolant reservoir hose 4 Coolant reservoir 5 Thermostat inlet hose 6 Thermostat outlet hose 7 Water pump 8 Radiator inlet/outlet pipe 9 Radiator inlet hose 0 Radiator outlet hose A Radiator cap B Water pump inlet hose È 3 ~ 4 mm (0.12 ~ 0.
CABLE ROUTING SPEC EAS00035 CABLE ROUTING 1 Front brake hose 2 Rear brake hose 3 Rear brake light switch lead 4 Front turn signal light coupler (left) 5 Handlebar upper cover left switches coupler 6 Handlebar upper cover right switches coupler 7 Front turn signal light coupler (right) 8 Front brake light switch lead 9 Throttle cable (decelerator cable) 1 0 Throttle cable (accelerator cable) È Connect the air temperature sensor coupler, and then place the air temperature sensor in the steering head pipe
CABLE ROUTING Ë After connecting the throttle cables, check the operation of the throttle grip and make sure that it returns to its home position easily after being released.
CABLE ROUTING 1 Wire harness 2 Rear brake hose 3 Front brake hose 4 Turn signal relay 5 Fuse box 6 Seat lock cable 7 Headlight assembly coupler 8 Starter motor lead 9 Headlight relay 0 Radiator fan motor relay A Speed sensor lead B Radiator filler hose C Radiator fan motor coupler D Fuel pump coupler E Thermo switch (radiator fan motor) F Thermo switch (auto choke) G Coolant reservoir hose H Fuel pump I Fuel hose (fuel tank to fuel pump) J Fuel hose (fuel pump to carburetor) K Ground lead L Fuel sender lea
CABLE ROUTING É Be sure to leave a little slack in the speed sensor lead since the front fork moves 10 mm (0.040 in) vertically. Ê Fasten the front brake hose and speed sensor lead with a holder, making sure to fasten the front brake hose at the white tape. Ë 15 mm (0.60 in) Ì To horn, and rectifier/regulator Í Connect each thermo switch connectors (radiator fan motor) to the switch terminals of the same color.
CABLE ROUTING Ò Fasten the wire harness and starter motor lead to the frame with a plastic locking tie. Ó Fasten the rear brake pipe with a plastic locking tie. Ô Fasten the wire harness, relay leads (headlight relay, radiator fan motor relay, fuel pump relay and starting circuit cut-off relay), starter motor lead and radiator filler hose with a plastic locking tie. Î Connect each thermo switch connectors (auto choke) to the switch terminals of the same color.
CABLE ROUTING × Fasten the speed sensor lead with a plastic locking tie, making sure to install the tie around the protective sleeve of the lead, not the lead itself, and then connect the speed sensor coupler Ø Cover the anti-theft alarm LED connector (OPTION) and auxiliary DC jack fuse connector (OPTION) with the protector. Õ Fasten the wire harness, rear brake pipe, starter motor lead and speed sensor lead to the frame with a plastic locking tie, making sure to fasten the wire harness at the tape.
CABLE ROUTING SPEC È Route the license plate light lead as shown in the illustration. É Fasten the wire harness, tail/brake light lead and license plate light lead with a plastic locking tie. Ê Fasten the wire harness with the holder Ë Fasten the wire harness, starter motor lead, pickup coil/stator assembly lead with to the frame with a plastic locking tie.
CABLE ROUTING SPEC Ì Fasten the wire harness, starter motor lead, rear brake pipe, pickup coil/stator assembly lead to the frame with a plastic locking tie. Í Connect each ignition coil connectors to the coil terminals of the same color.
CABLE ROUTING 1 Headlight assembly coupler 2 Seat lock cable 3 Starter motor lead 4 Starter relay 5 Positive battery lead 6 Front brake hose 7 Rear brake hose 8 Battery 9 Throttle cables 0 Horn lead A Sidestand switch lead SPEC B Fuel hose (fuel pump to carburetor) C Fuel tank overflow hose È Pass the battery lead through the opening in the battery box. É Route the horn lead to the rear of the frame. Ê Fasten the seat lock cable and throttle cables to the frame with a plastic locking tie.
CABLE ROUTING SPEC Ì Fasten the sidestand switch lead to the frame with a plastic locking tie. Í Pass the fuel tank overflow hose through the hole in the under cover.
CABLE ROUTING SPEC È Fasten the seat lock cable and throttle cables with a plastic locking tie, making sure to fasten the throttle cables at the mark É Pass the seat lock cable through the frame tube. Ê Route the carburetor overflow hose to the outside of the water pump. Ë Fasten the anti-theft alarm lead (OPTION) and tail/brake light assembly lead (left) to the frame with a plastic locking tie.
CABLE ROUTING SPEC Ì Fasten the tail/brake light assembly lead (left) to the frame with a plastic locking tie. Í Fasten the anti-theft coupler (OPTION) to the frame with a plastic locking tie.
CABLE ROUTING 1 Fuse box 2 Wire harness 3 Rear brake hose 4 Throttle cables 5 Front brake hose 6 CDI unit 7 Starter relay 8 Ground coupler 9 Headlight assembly coupler 0 Rectifier/regulator A Horn SPEC B Speed sensor coupler C Main switch coupler D Turn signal relay E Seat lock cable È To wire harness É Pass the speed sensor lead through the hole in the inner fender.
SPEC CABLE ROUTING 1 Fuel hose (fuel tank to fuel pump) 2 Fuel hose (fuel pump to carburetor) 3 Sidestand switch coupler 4 Starter motor lead 5 Starter motor 6 Ground lead 7 Seat lock cable 8 Throttle cables 9 Carburetor overflow hose 0 Auto choke unit lead A Air induction system vacuum hose B Fuel sender lead È Fasten the sidestand switch lead to the frame cross member with a plastic locking tie.
SPEC CABLE ROUTING Ë Fasten the starter motor lead and ground lead with the holder, making sure to align the white tape on the starter motor lead with the holder. Ì Pass the auto choke unit lead and air induction system vacuum hose with a plastic locking tie. Í Fasten the grommet on the fuel hose (fuel pump to carburetor) with the holder.
CHK ADJ CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION.............................................................................................. 3-1 PERIODIC MAINTENANCE AND LUBRICATION CHART ............................ 3-1 COVERS AND PANELS.................................................................................. 3-3 SEAT AND SIDE COVERS ....................................................................... 3-3 FOOTREST BOARD ...........................................................
CHK ADJ CHASSIS ....................................................................................................... 3-34 CHECKING THE BRAKE FLUID LEVEL................................................. 3-34 CHECKING THE FRONT AND REAR BRAKE PADS ............................ 3-35 CHECKING THE FRONT AND REAR BRAKE HOSES.......................... 3-35 BLEEDING THE HYDRAULIC BRAKE SYSTEM ................................... 3-36 CHECKING AND ADJUSTING THE STEERING HEAD .........................
INTRODUCTION/ PERIODIC MAINTENANCE AND LUBRICATION CHART CHK ADJ EAS00036 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer service life and reduce the need for costly overhaul work. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale.
CHK ADJ PERIODIC MAINTENANCE AND LUBRICATION CHART No ITEM CHECK OR MAINTENANCE JOB ODOMETER READING (× 1000 Km) 1 10 20 30 40 ANNUAL CHECK √ √ 15 * Sidestand switch • Check operation. √ √ √ √ 16 * Front fork • Check operation and for oil leakage. √ √ √ √ • Check operation and shock absorbers for oil leakage. √ √ √ √ √ √ √ √ 17 * Shock absorber assemblies 18 * Carburetor 19 Engine oil √ • Adjust engine idling speed. √ • Change.
COVERS AND PANELS CHK ADJ EAS00038 COVERS AND PANELS SEAT AND SIDE COVERS 8 1 3 7 Nm (0.7 m • kg, 5.1 ft • Ib) R. R. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) T. T. T. 23 Nm (2.3 m • kg, 17 ft • Ib) 7 9 5 4 2 6 T. R. 23 Nm (2.3 m • kg, 17 ft • Ib) T. R. 3 7 Nm (0.7 m • kg, 5.1 ft • Ib) 5 7 6 (4) T. R. Order 1 2 3 4 5 6 7 8 9 7 Nm (0.7 m • kg, 5.1 ft • Ib) Job/Part Q’ty Remarks Removing the seat and side covers Remove the parts in the order listed.
CHK ADJ COVERS AND PANELS EAS00040 FOOTREST BOARD 1 T. R. 4 7 Nm (0.7 m • kg, 5.1 ft • Ib) 6 9 3 2 8 5 LS 1 8 7 4 3 2 5 T. R. 7 Nm (0.7 m • kg, 5.
COVERS AND PANELS CHK ADJ EAS00042 HANDLEBAR COVERS 4 4 3 7 (5) 9 5 8 6 (4) 1 2 2 Order 1 2 3 4 5 6 7 8 9 Job/Part Removing the handlebar covers Front turn signal light assembly Front turn signal light coupler Windshield Rearview mirror (left and right) Handlebar upper cover right switch coupler Handlebar upper cover left switch coupler Handlebar upper cover (with meter assembly) Meter assembly coupler Handlebar lower cover Q’ty Remarks Remove the parts in the order listed.
COVERS AND PANELS CHK ADJ EAS00043 STORAGE COMPARTMENT T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 1 5 4 2 3 Order 1 2 3 4 5 Job/Part Removing the storage compartment Upper panel Headlight assembly coupler Front cowling Battery cover Storage compartment Q’ty 1 1 1 1 1 Remarks Remove the parts in the order listed. Disconnect. For installation, reverse the removal procedure.
CHK ADJ AIR FILTER CASE AIR FILTER CASE 2 1 (6) 3 (3) T. R. Order 1 2 3 9 Nm (0.9 m • kg, 6.5 ft • Ib) Job/Part Removing the air filter case assembly Storage box Cylinder head breather hose Air induction system hose (air filter case to air cut-off valve assembly) Air filter case assembly Q’ty Remarks Remove the parts in the order listed. Refer to “COVERS AND PANELS”. 1 1 1 For installation, reverse the removal procedure.
ADJUSTING THE VALVE CLEARANCE CHK ADJ EAS00049 ENGINE ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: • 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 top dead center (TDC) on the compression stroke. 1. Remove: • storage box • footrest board Refer to “COVERS AND PANELS”. 2. Remove: • V-belt case air filter cover 1 3.
ADJUSTING THE VALVE CLEARANCE CHK ADJ 5. Measure: • valve clearance Out of specification → Adjust. Valve clearance (cold) Intake valve 0.08 ~ 0.12 mm (0.0031 ~ 0.0047 in) Exhaust valve 0.16 ~ 0.20 mm (0.0063 ~ 0.0079 in) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the primary sheave nut on the left side of the crankshaft counterclockwise to turn the crankshaft. b.
ADJUSTING THE VALVE CLEARANCE CHK ADJ 6. Adjust: • valve clearance ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Loosen the locknut 1. b. Insert a thickness gauge between the end of the adjusting screw and the valve tip. c. Turn the adjusting screw 2 in direction a or b until the specified valve clearance is obtained. Direction a Valve clearance is increased. Direction b Valve clearance is decreased. Tappet adjusting tool 90890-01311 d.
ADJUSTING THE ENGINE IDLING SPEED CHK ADJ EAS00054 ADJUSTING THE ENGINE IDLING SPEED NOTE: Prior to adjusting the engine idling speed, the air filter element should be cleaned, and the engine should have adequate compression. 1. Remove: • storage box Refer to “COVERS AND PANELS”. 2. Start the engine and warm it up for several minutes. 3. Connect: • engine tachometer (to the spark plug lead) 4. Check: • engine idling speed Out of specification → Adjust. Engine idling speed 1,550 ~ 1,650 r/min 2 a 5.
ADJUSTING THE ENGINE IDLING SPEED/ CHECKING THE EXHAUST GAS AT IDLE CHK ADJ 6. Adjust: • throttle cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY”. Throttle cable free play (at the flange of the throttle grip) 4.0 ~ 6.0 mm (0.16 ~ 0.24 in) CHECKING THE EXHAUST GAS AT IDLE Check the exhaust gas at idle when the air induction system is operating. 1. Stand the vehicle on a level surface. NOTE: • Place the vehicle on a suitable stand. • Make sure that the vehicle is upright. 2.
CHECKING THE EXHAUST GAS AT IDLE/CHECKING AND ADJUSTING THE EXHAUST GAS AT IDLE CHK ADJ 6. Measure: • engine idling speed Out of specification → Adjust. Refer to “ADJUSTING THE IDLING SPEED”. ENGINE Engine idling speed 1,550 ~ 1,650 r/min 7. Connect: • CO tester 1 (to the exhaust attachment) 8. Measure: • CO density Out of specification → Check air induction system. Refer to “AIR INDUCTION SYSTEM” in chapter 7. CO density (when air induction system is operating) 4.
CHECKING AND ADJUSTING THE EXHAUST GAS AT IDLE CHK ADJ 4. Connect: • temperature probe tester 1 (to the engine oil drain bolt) • engine tachometer (to the spark plug lead) • exhaust attachment 2 (to the exhaust pipe) Exhaust attachment 90890-03134 2 5. Stop air induction system operation. NOTE: Crimp the hose a running from the lead valve to the air cut-off valve to prevent the air cut-off valve from operating. Be sure not to damage the hose while crimping it. a 6.
CHECKING AND ADJUSTING THE EXHAUST GAS AT IDLE/ADJUSTING THE THROTTLE CABLE FREE PLAY CHK ADJ 9. Measure: • CO density Out of specification → Adjust. Within specification → Checking the air induction system. Refer to “AIR INDUCTION SYSTEM” in chapter 7. CO density (when air induction system is not operating) 6.0% 10.Adjust: • pilot screw 1 Pilot screw 2 turns out 1 If the CO density cannot be adjusted by adjusting the pilot screw, overhaul the carburetor and check the air filter.
ADJUSTING THE THROTTLE CABLE FREE PLAY/ CHECKING THE SPARK PLUG 2 1 a CHK ADJ 2. Remove: • front turn signal light assembly Refer to “COVERS AND PANELS”. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ b 3 a. Slide back the rubber cover 1. b. Loosen the locknut 2. c. Turn the adjusting nut 3 in direction a or b until the specified throttle cable free play is obtained. Direction a Throttle cable free play is increased. Direction b Throttle cable free play is decreased. d. Tighten the locknut. e.
CHECKING THE SPARK PLUG/ CHECKING THE IGNITION TIMING CHK ADJ 4. Check: • spark plug type Incorrect → Change. Spark plug type (manufacturer) DR8EA (NGK) 5. Check: • electrode 1 Damage/wear → Replace the spark plug. • insulator 2 Abnormal color → Replace the spark plug. Normal color is medium-to-light tan. 6. Clean: • spark plug (with a spark plug cleaner or wire brush) 7. Measure: • spark plug gap a (with a wire thickness gauge) Out of specification → Regap. Spark plug gap 0.6 ~ 0.7 mm (0.024 ~ 0.
CHECKING THE IGNITION TIMING 1 CHK ADJ 2. Remove: • storage box Refer to “COVERS AND PANELS”. 3. Remove: • timing mark accessing plug 1 4. Connect: • timing light 1 • engine tachometer (to the spark plug lead) Timing light 90890-03141 5. Check: • ignition timing ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Start the engine, warm it up for several minutes, and then let it run at the specified engine idling speed. Engine idling speed 1,550 ~ 1,650 r/min b.
MEASURING THE COMPRESSION PRESSURE CHK ADJ EAS00067 MEASURING THE COMPRESSION PRESSURE NOTE: Insufficient compression pressure will result in a loss of performance. 1. Remove: • storage box Refer to “COVERS AND PANELS”. 2. Measure: • valve clearance Out of specification → Adjust. Refer to “ADJUSTING THE VALVE CLEARANCE”. 3. Start the engine, warm it up for several minutes, and then turn it off. 4. Disconnect: • spark plug cap 5.
MEASURING THE COMPRESSION PRESSURE CHK ADJ 7. Measure: • compression pressure Out of specification → Refer to steps (c) and (d). Compression pressure (at sea level) Minimum 1,120 kPa (11.2 kg/cm2, 159.3 psi) Standard 1,400 kPa (14.0 kg/cm2, 199.1 psi) Maximum 1,570 kPa (15.7 kg/cm2, 223.3 psi) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Set the main switch to “ON”. b. With the throttle wide open, crank the engine until the reading on the compression gauge stabilizes.
MEASURING THE COMPRESSION PRESSURE/ CHECKING THE ENGINE OIL LEVEL CHK ADJ T. 8. Install: 18 Nm (1.8 m · kg, 13 ft · lb) • spark plug 9. Connect: • spark plug cap 10.Install: • storage box Refer to “COVERS AND PANELS”. R. EAS00070 CHECKING THE ENGINE OIL LEVEL 1. Stand the vehicle on a level surface. NOTE: • Place the vehicle on a centerstand. • Make sure that the vehicle is upright. 2. Start the engine, warm it up for several minutes, and then turn it off. 3.
CHECKING THE ENGINE OIL LEVEL/ CHANGING THE ENGINE OIL CHK ADJ 4. Start the engine, warm it up for several minutes, and then turn it off. 5. Check the engine oil level again. NOTE: Before checking the engine oil level, wait a few minutes until the oil has settled. EAS00076 CHANGING THE ENGINE OIL 1. Remove: • storage box • footrest board Refer to “COVERS AND PANELS”. 2. Start the engine, warm it up for several minutes, and then turn it off. 3. Place a container under the engine oil drain bolt. 4.
CHANGING THE ENGINE OIL CHK ADJ 8. Install: • engine oil drain bolt (along with the gasket) T. R. 20 Nm (2.0 m · kg, 14 ft · lb) 9. Fill: • crankcase (with the specified amount of the recommended engine oil) Quantity Total amount 1.40 L (1.23 Imp qt, 1.48 US qt) Periodic oil change 1.20 L (1.06 Imp qt, 1.27 US qt) 10.Install: • engine oil filler cap 11.Start the engine, warm it up for several minutes, and then turn it off. 12.Check: • engine (for engine oil leaks) 13.
CHANGING THE ENGINE OIL/ CHANGING THE FINAL TRANSMISSION OIL CHK ADJ 15.Reset: • oil change indicator ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Set the main switch to “ON” while holding the “MODE” and “SET” buttons pushed for two to five seconds. b. Release the buttons and the oil change indicator will go off. NOTE: If the engine oil is changed before the oil change indicator comes on (i.e.
CHANGING THE FINAL TRANSMISSION OIL/ REPLACING THE AIR FILTER ELEMENT CHK ADJ 6. Install: • final transmission oil drain bolt T. R. 22 Nm (2.2 m · kg, 16 ft · lb) 7. Fill: • transmission case (with the specified amount of the recommended transmission oil) Recommended oil SAE 10W30 type SE motor oil Oil quantity 0.25 L (0.22 Imp qt, 0.26 US qt) 8. • • 9. Install: final transmission oil filler cap O-ring Start the engine, warm it up for several minutes, and then turn it off. 10.
REPLACING THE AIR FILTER ELEMENT/ CLEANING THE V-BELT CASE AIR FILTER ELEMENT CHK ADJ 2. Check: • air filter element Damage → Replace. NOTE: • Replace the air filter element every 20,000 km of operation. • The air filter needs more frequent service if you are riding in unusually wet or dusty areas. 3. Install: • air filter element • air filter case cover CAUTION: Never operate the engine without the air filter element installed.
CLEANING THE V-BELT CASE AIR FILTER ELEMENT/ CHECKING THE FUEL AND VACUUM HOSES/ CHECKING THE BREATHER HOSES CHK ADJ 4. Check: • V-belt case air filter element Damage → Replace. CAUTION: Since the V-belt case air filter element is a dry type, do not let grease or water contact it. 5. • 6. • Install: V-belt case air filter cover Install: center panel 1 (left) Refer to “COVERS AND PANELS”. EAS00096 1 3 2 CHECKING THE FUEL AND VACUUM HOSES 1. Remove: • storage box Refer to “COVERS AND PANELS”. 2.
CHECKING THE BREATHER HOSES/ CHECKING THE EXHAUST SYSTEM 1 CHK ADJ 2. Check: • cylinder head breather hose 1 • transmission case breather hose 2 Cracks/damage → Replace. Loose connection → Connect properly. CAUTION: Make sure the cylinder head breather hose and transmission case breather hose are routed correctly. 2 3. Install: • storage box Refer to “COVERS AND PANELS”. EAS00100 CHECKING THE EXHAUST SYSTEM 1. Remove: • center panel 1 (right) Refer to “COVERS AND PANELS”. 2.
CHECKING THE COOLANT LEVEL/ CHECKING THE COOLING SYSTEM CHK ADJ EAS00103 CHECKING THE COOLANT LEVEL 1. Stand the vehicle on a level surface. NOTE: • Place the vehicle on a centerstand. • Make sure that the vehicle is upright. 2. Check: • coolant level The coolant level should be between the maximum level mark a and minimum level mark b. Below the minimum level mark → Add the recommended coolant to the proper level. CAUTION: • Adding water instead of coolant lowers the antifreeze content of the coolant.
CHECKING THE COOLING SYSTEM/ CHANGING THE COOLANT CHK ADJ 2. • • • • • • • • • 6 1 5 3 Check: radiator 1 radiator outlet hose 2 radiator inlet hose 3 radiator inlet/outlet pipe 4 water pump inlet hose 5 radiator filler hose 6 thermostat cover 7 thermostat outlet hose 8 thermostat inlet hose 9 Cracks/damage → Replace. 3. Install: • storage box • footrest board Refer to “COVERS AND PANELS”. 4 2 9 8 7 EAS00105 1 2 CHANGING THE COOLANT 1.
CHANGING THE COOLANT CHK ADJ 5. Remove: • radiator cap 1 WARNING A hot radiator is under pressure. Therefore, do not remove the radiator cap when the engine is hot. Scalding hot fluid and steam may be blown out, which could cause serious injury. When the engine has cooled, open the radiator cap as follows: Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap counterclockwise to allow any residual pressure to escape. When the hissing sound has stopped, remove the cap.
CHANGING THE COOLANT CHK ADJ 10.Fill: • cooling system (with the specified amount of the recommended coolant to the specified level) Recommended antifreeze High-quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines Mixing ratio 1:1 (antifreeze:water) Quantity Radiator and engine capacity 0.70 L (0.62 Imp qt, 0.74 US qt) Coolant reservoir capacity 0.26 L (0.23 Imp qt, 0.28 US qt) Up to the maximum level mark 1 NOTE: The specified amount of coolant is a standard amount.
CHANGING THE COOLANT CHK ADJ CAUTION: • Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant check, and if necessary, correct the antifreeze concentration of the coolant. • Use only distilled water. However, if distilled water is not available, soft water may be used. • If coolant comes into contact with painted surfaces, immediately wash them with water. • Do not mix different types of antifreeze. 11.Install: • radiator cap a 12.
CHECKING THE BRAKE FLUID LEVEL CHK ADJ EAS01160 CHASSIS CHECKING THE BRAKE FLUID LEVEL 1. Stand the vehicle on a level surface. NOTE: • Place the vehicle on the centerstand. • Make sure the vehicle is upright. 2. Check: • brake fluid level Below the minimum level mark a → Add the recommended brake fluid to the proper level. È a Recommended brake fluid DOT 4 È Front brake É Rear brake É WARNING a • Use only the designated brake fluid.
CHECKING THE FRONT AND REAR BRAKE PADS/ CHECKING THE FRONT AND REAR BRAKE HOSES CHK ADJ EAS01220 È a CHECKING THE FRONT AND REAR BRAKE PADS The following procedure applies to all of the brake pads. 1. Operate the brake. 2. Check: • front brake pad Wear limit a reached → Replace the brake pads as a set. É Brake pad lining thickness limit 0.5 mm (0.02 in) Refer to “REPLACING THE FRONT BRAKE PADS” in chapter 4. • rear brake pad Wear limit a reached → Replace the brake pads as a set.
BLEEDING THE HYDRAULIC BRAKE SYSTEM CHK ADJ EAS01350 BLEEDING THE HYDRAULIC BRAKE SYSTEM WARNING Bleed the hydraulic brake system whenever: • the system is disassembled. • a brake hose is loosened, disconnected or replaced. • the brake fluid level is very low. • brake operation is faulty. NOTE: • Be careful not to spill any brake fluid or allow the brake master cylinder reservoir to overflow.
BLEEDING THE HYDRAULIC BRAKE SYSTEM/ CHECKING AND ADJUSTING THE STEERING HEAD CHK ADJ g. Loosen the bleed screw. NOTE: Loosening the bleed screw will release the pressure and cause the brake lever to contact the handlebar. h. Tighten the bleed screw and then release the brake lever. i. Repeat steps (e) to (h) until all of the air bubbles have disappeared from the brake fluid in the plastic hose. j. Tighten the bleed screw to specification. T. R. Bleed screw (front brake caliper) 6 Nm (0.6 m · kg, 4.
CHECKING AND ADJUSTING THE STEERING HEAD CHK ADJ 3. Remove: • handlebar lower holder Refer to “STEERING HEAD” in chapter 4. 4. Adjust: • steering head ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the upper ring nut 1, lock washer 2, the center ring nut 3 and the rubber washer. b. Loosen the lower ring nut 4 and then tighten it to specification with the steering nut wrench 5. NOTE: • Be sure to install all the ring nuts with the broad side of the inner tapered section facing down.
CHECKING AND ADJUSTING THE STEERING HEAD/ CHECKING THE FRONT FORK CHK ADJ g. Finger tighten the center ring nut, then align the slots of both ring nuts. If necessary, hold the lower ring nut and tighten the center ring nut until their slots are aligned. NOTE: When aligning the slots, align them by turning the center ring nut in the tightening direction. h. Install the lock washer 2. NOTE: Make sure the lock washer tabs a sit correctly in the ring nut slots b. i.
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLIES/CHECKING THE TIRES CHK ADJ EAS01600 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLIES The following procedure applies to both of the rear shock absorber assemblies. WARNING • Securely support the vehicle so that there is no danger of it falling over. • Always adjust both rear shock absorber assemblies evenly. Uneven adjustment can result in poor handling and loss of stability. Spring preload CAUTION: Never go beyond the maximum or minimum adjustment positions. 1.
CHECKING THE TIRES CHK ADJ WARNING • The tire pressure should only be checked and regulated when the tire temperature is at ambient air temperature. • The tire pressure and the suspension must be adjusted according to the total weight (including cargo, rider, passenger and accessories) and the anticipated riding speed. • Operation of an overloaded vehicle could cause tire damage, an accident or an injury. NEVER OVERLOAD THE VEHICLE.
CHECKING THE TIRES CHK ADJ WARNING È É • Do not use a tubeless tire on a wheel designed only for tube tires to avoid tire failure and personal injury from sudden deflation. • When using tube tires, be sure to install the correct tube. • Always replace a new tube tire and a new tube as a set. • To avoid pinching the tube, make sure the wheel rim band and tube are centered in the wheel groove. • Patching a punctured tube is not recommended.
CHECKING THE TIRES/ CHECKING THE WHEELS CHK ADJ WARNING New tires have a relatively low grip on the road surface until they have been slightly worn. Therefore, approximately 100 km should be traveled at normal speed before any high-speed riding is done. NOTE: For tires with a rotation direction mark 1: Install the tire with the mark pointing in the direction of the wheel rotation. EAS01680 CHECKING THE WHEELS The following procedure applies to both of the wheels. 1.
CHECKING AND LUBRICATING THE CABLES/ LUBRICATING THE SIDESTAND/ LUBRICATING THE CENTERSTAND CHK ADJ EAS01700 CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the inner and outer cables. WARNING Damaged outer cable may cause the cable to corrode and interfere with its movement. Replace damaged outer cable and inner cable as soon as possible. 1. Check: • outer cable Damage → Replace. 2. Check: • cable operation Rough movement → Lubricate.
CHECKING AND CHARGING THE BATTERY CHK ADJ EAS01790 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).
CHECKING AND CHARGING THE BATTERY CHK ADJ NOTE: Since MF batteries are sealed, it is not possible to check the charge state of the battery by measuring the specific gravity of the electrolyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals. NOTE: 1. Remove: • battery cover Refer to “COVERS AND PANELS”. 2. Remove: • battery bracket 1 1 2 3.
CHECKING AND CHARGING THE BATTERY Open-circuit voltage (V) Relationship between the open-circuit voltage and the charging time at 20 °C. CHK ADJ b. Check the charge of the battery, as shown in the charts and the following example. Example c. Open-circuit voltage = 12.0 V d. Charging time = 6.5 hours e. Charge of the battery = 20 ~ 30% ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Charging time (hours) These values vary with the temperature, the condition of the battery plates, and the electrolyte level.
CHECKING AND CHARGING THE BATTERY CHK ADJ • If the battery becomes hot to the touch at any time during the charging process, disconnect the battery charger and let the battery cool before reconnecting it. Hot batteries can explode! • As shown in the following illustration, the open-circuit voltage of an MF battery stabilizes 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 Charging method using a variable-current (voltage) charger Charger Ammeter Measure the open-circuit voltage prior to charging. NOTE: Leave the battery unused for more than 30 minutes before measuring its open-circuit voltage. Connect a charger and ammeter to the battery and start charging. NOTE: 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.
CHECKING AND CHARGING THE BATTERY CHK ADJ Charging method using a constant voltage charger Measure the open-circuit voltage prior to charging. NOTE: Leave the battery unused for more than 30 minutes before measuring its open-circuit voltage. Connect a charger and ammeter to the battery and start charging. Is the amperage higher than the standard charging amperage written on the battery? YES NO Charge the battery until the charging voltage reaches 15 V.
CHECKING AND CHARGING THE BATTERY/ CHECKING THE FUSES 1 7. • 8. • 2 CHK ADJ Install: battery Connect: battery leads (to the battery terminals) CAUTION: First, connect the positive battery lead 1, and then the negative battery lead 2. 9. Check: • battery terminals Dirt → Clean with a wire brush. Loose connection → Connect properly. 10.Lubricate: • battery terminals Recommended lubricant Dielectric grease 11.Install: • battery bracket T. R. 23 Nm (2.3 m · kg, 17 ft · lb) 12.
CHECKING THE FUSES CHK ADJ 2. Check: • fuse ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester to the fuse and check the continuity. NOTE: Set the pocket tester selector to “Ω × 1”. Pocket tester 90890-03112 b. If the pocket tester indicates “∞”, replace the fuse. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Replace: • blown fuse ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Set the main switch to “OFF”. b. Install a new fuse of the correct amperage rating. c.
CHECKING THE FUSES/ REPLACING THE HEADLIGHT BULBS CHK ADJ WARNING Never use a fuse with an amperage rating other than that specified. Improvising or using a fuse with the wrong amperage rating may cause extensive damage to the electrical system, cause the lighting and ignition systems to malfunction and could possibly cause a fire. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Install: • upper panel Refer to “COVERS AND PANELS”.
REPLACING THE HEADLIGHT BULBS/ ADJUSTING THE HEADLIGHT BEAM CHK ADJ 6. Install: • headlight bulb New Secure the new headlight bulb with the headlight bulb holder. CAUTION: Avoid touching the glass part of the headlight bulb to keep it free from oil, otherwise 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. 7. Attach: • headlight bulb holder 8.
CHAS CHAPTER 4 CHASSIS FRONT WHEEL AND BRAKE DISC............................................................... 4-1 REMOVING THE FRONT WHEEL............................................................ 4-3 CHECKING THE FRONT WHEEL ............................................................ 4-3 CHECKING THE BRAKE DISC.................................................................4-5 ADJUSTING THE FRONT WHEEL STATIC BALANCE ........................... 4-6 INSTALLING THE FRONT WHEEL ........................
CHAS INSTALLING THE HANDLEBAR ............................................................ 4-61 STEERING HEAD.......................................................................................... 4-64 LOWER BRACKET ................................................................................. 4-64 REMOVING THE LOWER BRACKET.....................................................4-66 CHECKING THE STEERING HEAD .......................................................4-67 INSTALLING THE STEERING HEAD ......
FRONT WHEEL AND BRAKE DISC CHAS EAS05130 CHASSIS FRONT WHEEL AND BRAKE DISC T. R. 9 Nm (0.9 m • kg, 6.5 ft • Ib) 1 LS 4 (5) 2 LT 6 5 R. 59 Nm (5.9 m • kg, 43 ft • Ib) T. R. 12 Nm (1.2 m • kg, 8.7 ft • Ib) Order 1 2 3 4 5 6 T. 3 Job/Part Removing the front wheel and brake disc Front wheel axle pinch bolt Front wheel axle Front wheel Speed sensor Spacer Front brake disc Q’ty 2 1 1 1 1 1 Remarks Remove the parts in the order listed. Loosen.
FRONT WHEEL AND BRAKE DISC CHAS EAS05130 Order 1 2 3 Job/Part Disassembling the front wheel Oil seal Bearing Collar Q’ty Remarks Remove the parts in the order listed. 1 2 1 For assembly, reverse the disassembly procedure.
FRONT WHEEL AND BRAKE DISC CHAS EAS05200 REMOVING THE FRONT WHEEL 1. Stand the vehicle on a level surface. WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Elevate: • front wheel NOTE: Place the vehicle on a suitable stand so that the front wheel is elevated. 3. • • • Remove: front wheel speed sensor spacer NOTE: Do not squeeze the front brake lever when removing the front wheel. NOTE: EAS05250 CHECKING THE FRONT WHEEL 1.
FRONT WHEEL AND BRAKE DISC CHAS 3. Measure: • radial wheel runout 1 • lateral wheel runout 2 Over the specified limits → Replace. Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in) 4. Check: • wheel bearings Front wheel turns roughly or is loose → Replace the wheel bearings. • oil seal Damage/wear → Replace. 5. Replace: • wheel bearings New • oil seal New ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Clean the outside of the front wheel hub. b.
FRONT WHEEL AND BRAKE DISC CHAS EAS05280 CHECKING THE BRAKE DISC 1. Check: • brake disc Damage/galling → Replace. 2. Measure: • brake disc deflection Out of specification → Correct the brake disc deflection or replace the brake disc. Brake disc deflection limit (maximum) Front: 0.10 mm (0.0039 in) Rear: 0.15 mm (0.0059 in) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Place the vehicle on a suitable stand so that the front wheel is elevated. b.
FRONT WHEEL AND BRAKE DISC CHAS 4. Adjust: • brake disc deflection ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the brake disc. b. Rotate the brake disc by one bolt hole. c. Install the brake disc. NOTE: • Install the brake disc with the recessed bolt holes facing outward. (For front brake disc) • Tighten the brake disc bolts in stages and in a crisscross pattern. T. R. Brake disc bolt 12 Nm (1.2 m · kg, 8.7 ft · lb) LOCTITE® d. Measure the brake disc deflection. e.
FRONT WHEEL AND BRAKE DISC CHAS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Spin the front wheel. b. When the front wheel stops, put an “X1” mark at the bottom of the wheel. c. Turn the front wheel 90° so that the “X1” mark is positioned as shown. d. Release the front wheel. e. When the wheel stops, put an “X2” mark at the bottom of the wheel. f. Repeat steps (d) through (f) several times until all the marks come to rest at the same spot. g.
FRONT WHEEL AND BRAKE DISC CHAS EAS05420 INSTALLING THE FRONT WHEEL 1. Lubricate: • oil seal lips • speed sensor Recommended lubricant Lithium-soap-based grease 2. • • • a Install: spacer speed sensor front wheel NOTE: • Make sure that the speed sensor and the wheel hub are installed with the projection a of the wheel hub inserted in a slot b of the speed sensor. • When installing the speed sensor, make sure that the projection on the wheel hub does not damage the lip of the speed sensor oil seal.
CHAS REAR WHEEL AND BRAKE DISC EAS05520 REAR WHEEL AND BRAKE DISC 1 T. R. 9 Nm (0.9 m • kg, 6.5 ft • Ib) LS 5 4 LT (4) 2 3 6 T. R. Order Job/Part Removing the rear wheel and brake disc Q’ty 23 Nm (2.3 m • kg, 17 ft • Ib) Remarks Remove the parts in the order listed. NOTE: Place the vehicle on a suitable stand so that the rear wheel is elevated. Muffler Swingarm 1 2 3 Air filter case mounting bolt Rear fender Rear wheel 2 1 1 4 Spacer 1 4-9 Refer to “ENGINE REMOVAL” in chapter 5.
CHAS REAR WHEEL AND BRAKE DISC 1 T. R. 9 Nm (0.9 m • kg, 6.5 ft • Ib) LS 5 4 LT (4) 2 3 6 T. R. Order 5 6 Job/Part Washer Rear brake disc Q’ty 1 1 23 Nm (2.3 m • kg, 17 ft • Ib) Remarks For installation, reverse the removal procedure.
REAR WHEEL AND BRAKE DISC CHAS REMOVING THE REAR WHEEL 1. Stand the vehicle on a level surface. WARNING Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a centerstand so that the rear wheel is elevated. 2. • • • Remove: brake caliper rear wheel axle nut swingarm Refer to “REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM”. NOTE: Do not squeeze the rear brake lever when removing the rear brake caliper. 3.
REAR WHEEL AND BRAKE DISC CHAS EAS05750 ADJUSTING THE REAR WHEEL STATIC BALANCE NOTE: • After replacing the tire, wheel or both, the rear wheel static balance should be adjusted. • Adjust the rear wheel static balance with the brake disc installed. 1. Adjust: • rear wheel static balance Refer to “ADJUSTING THE WHEEL STATIC BALANCE”. FRONT INSTALLING THE REAR WHEEL 1. Install: • rear fender • air filter case mounting bolts T. R. 9 Nm (0.9 m · kg, 6.
FRONT AND REAR BRAKES CHAS EAS05770 FRONT AND REAR BRAKES FRONT BRAKE PADS 1 T. R. 23 Nm (2.3 m • kg, 17 ft • Ib) T. R. 6 Nm (0.6 m • kg, 4.3 ft • Ib) 2 New 4 8 5 6 7 6 3 T. R. Order 1 2 3 4 5 6 7 8 12 Nm (1.2 m • kg, 8.7 ft • Ib) Job/Part Removing the front brake pads Holder Front brake caliper bolt Front brake caliper Brake pad clip Brake pad pin Brake pad Brake pad spring Brake pad support Q’ty 1 2 1 1 1 2 1 1 Remarks Remove the parts in the order listed.
CHAS FRONT AND REAR BRAKES EAS05780 REAR BRAKE PADS T. R. 4 6 Nm (0.6 m • kg, 4.3 ft • Ib) 3 5 6 2 6 1 4 T. R. 27 Nm (2.7 m • kg, 19 ft • Ib) * Apply silicone grease. T. R. 40 Nm (4.0 m • kg, 29 ft • Ib) Order Job/Part Removing the rear brake pads Muffler Q’ty 1 2 3 4 5 6 Rear brake caliper retaining bolt Rear brake caliper Brake pad Brake pad shim Brake caliper bracket Brake pad support 2 1 2 4 1 2 Remarks Remove the parts in the order listed. Refer to “ENGINE REMOVAL” in chapter 5.
FRONT AND REAR BRAKES CHAS EAS00579 CAUTION: _ Disc brake components rarely require disassembly. Therefore, always follow these preventive measures: • Never disassemble brake components unless absolutely necessary. • If any connection on the hydraulic brake system is disconnected, the entire brake system must be disassembled, drained, cleaned, properly filled, and bled after reassembly. • Never use solvents on internal brake components. • Use only clean or new brake fluid for cleaning brake components.
FRONT AND REAR BRAKES CHAS 2. Measure: • brake pad wear limit a Out of specifications → Replace the brake pads as a set. a 1 Brake pad wear limit 0.5 mm (0.02 in) 3. • • • 2 Install: brake pad support brake pad spring brake pads NOTE: Always install new brake pads, brake pad spring, and brake pad support as a set. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect a clear plastic hose 1 tightly to the bleed screw 2. Put the other end of the hose into an open container. b.
FRONT AND REAR BRAKES a CHAS 5. Check: • brake fluid level Below the minimum level mark a → Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” in chapter 3. 6. Check: • brake lever operation Soft or spongy feeling → Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. EAS05830 REPLACING THE REAR BRAKE PADS NOTE: When replacing the brake pads, it is not necessary to disconnect the brake hose or disassemble the brake caliper. 1.
FRONT AND REAR BRAKES CHAS 3. Install: • brake pad supports • brake pads (along with the brake pad shims) 2 1 NOTE: Always install new brake pads, brake pad shims, and a brake pad supports as a set. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect a clear plastic hose 1 tightly to the bleed screw 2. Put the other end of the hose into an open container. b. Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger. c. Tighten the bleed screw. T. Bleed screw 6 Nm (0.
CHAS FRONT AND REAR BRAKES EAS05840 FRONT BRAKE MASTER CYLINDER 1 T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 2 3 10 8 9 11 T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) 7 6 New 5 T. R. Order Job/Part Removing the front brake master cylinder Handlebar lower cover 4 23 Nm (2.3 m • kg, 17 ft • Ib) Q’ty Refer to “COVERS AND PANELS” in chapter 3. Drain. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3.
CHAS FRONT AND REAR BRAKES 1 T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 2 3 10 8 9 11 T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) 7 6 New 5 T. R. Order 5 6 7 Job/Part Brake hose union bolt Copper washer Front brake hose 4 23 Nm (2.
FRONT AND REAR BRAKES CHAS 1 New 2 ** Apply brake fluid Order 1 Job/Part Disassembling the front brake master cylinder Brake master cylinder kit 2 Brake master cylinder body Q’ty 1 Remarks Remove the parts in the order listed. Refer to “ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER”. 1 For assembly, reverse the disassembly procedure.
CHAS FRONT AND REAR BRAKES EAS05860 REAR BRAKE MASTER CYLINDER T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 1 2 9 3 10 5 New 7 11 8 New 7 4 6 T. R. T. R. Order 1 2 3 4 10 Nm (1.0 m • kg, 7.2 ft • Ib) 23 Nm (2.3 m • kg, 17 ft • Ib) Job/Part Q’ty Remarks Removing the rear brake master cylRemove the parts in the order listed. inder Handlebar lower cover Refer to “COVERS AND PANELS” in chapter 3. Brake fluid Drain. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3.
CHAS FRONT AND REAR BRAKES T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 1 2 9 3 10 5 New 7 11 8 New 7 4 6 T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) T. R. 23 Nm (2.3 m • kg, 17 ft • Ib) Order 5 6 7 8 Job/Part Rear brake light switch connector Brake hose union bolt Copper washer Rear brake hose 9 10 Rear brake master cylinder holder Brake master cylinder assembly 11 Rear brake light switch Q’ty Remarks 2 Disconnect.
FRONT AND REAR BRAKES CHAS EAS05870 2 1 New ** Apply brake fluid Order 1 Job/Part Disassembling the rear brake master cylinder Brake master cylinder kit 2 Brake master cylinder body Q’ty 1 Remarks Remove the parts in the order listed. Refer to “ASSEMBLING AND INSTALLING THE REAR BRAKE MASTER CYLINDER”. 1 For assembly, reverse the disassembly procedure.
FRONT AND REAR BRAKES CHAS EAS05880 DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER NOTE: Before disassembling the front brake master cylinder, drain the brake fluid from the entire brake system. 3 1. • • • Remove: brake hose union bolt 1 copper washers 2 brake hose 3 NOTE: To collect any remaining brake fluid, place a container under the master cylinder and the end of the brake hose.
FRONT AND REAR BRAKES È EAS05920 É 1 CHAS 1 CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS The following procedure applies to both of the brake master cylinders. 1. Check: • brake master cylinder 1 Damage/scratches/wear → Replace. • brake fluid delivery passages (brake master cylinder body) Obstruction → Blow out with compressed air. È Front É Rear 1 2. Check: • brake master cylinder kit 1 Damage/scratches/wear → Replace. 3.
FRONT AND REAR BRAKES CHAS EAS06000 ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER WARNING • Before installation, all internal brake components should be cleaned and lubricated with clean or new brake fluid. • Never use solvents on internal brake components. Recommended brake fluid DOT 4 1. Install: • brake master cylinder kit 1 New NOTE: Install the spring with its smaller diameter end towards the circlip and dust boot. 1 2.
FRONT AND REAR BRAKES 2 a 3. • • • CHAS Install: copper washers 1 New brake hose 2 brake hose union bolt 3 T. R. 23 Nm (2.3 m · kg, 17 ft · lb) WARNING New 1 3 Proper brake hose routing is essential to insure safe vehicle operation. Refer to “CABLE ROUTING” in chapter 2. CAUTION: When installing the brake hose onto the brake master cylinder, make sure the brake pipe touches the projection a on the brake master cylinder.
FRONT AND REAR BRAKES CHAS CAUTION: Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. a 5. Bleed: • brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. 6. Check: • brake fluid level Below the minimum level mark a → Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” in chapter 3. 7. Check: • brake lever operation Soft or spongy feeling → Bleed the brake system.
FRONT AND REAR BRAKES CHAS 1. Install: • brake master cylinder kit 1 New NOTE: Install the spring with its smaller diameter end towards the circlip and dust boot. 2. Install: • brake master cylinder 1 • brake master cylinder holder 1 T. R. b a NOTE: • Align the projection a on the brake master cylinder with the hole b in the handlebar. • First tighten the front bolt, then the rear bolt. 3. • • • a Install: copper washers 1 New brake hose 2 brake hose union bolt 3 T. R. 1 New 2 3 7 Nm (0.
FRONT AND REAR BRAKES CHAS 4. Fill: • brake master cylinder reservoir (with the specified amount of the recommended brake fluid) Recommended brake fluid DOT 4 WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance.
FRONT AND REAR BRAKES CHAS 7. Check: • brake lever operation Soft or spongy feeling → Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3.
FRONT AND REAR BRAKES CHAS EAS06120 FRONT BRAKE CALIPER T. R. 4 6 Nm (0.6 m • kg, 4.3 ft • Ib) 6 1 2 3 New 5 T. R. 23 Nm (2.3 m • kg, 17 ft • Ib) T. R. Order 1 2 3 4 5 6 Job/Part Removing the front brake caliper Brake fluid Holder Brake hose union bolt Copper washer Front brake hose Front brake caliper bolt Front brake caliper Q’ty 1 1 2 1 2 1 23 Nm (2.3 m • kg, 17 ft • Ib) Remarks Remove the parts in the order listed. Drain. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3.
FRONT AND REAR BRAKES * CHAS Apply silicone grease ** Apply brake fluid Order 1 2 3 4 5 6 7 8 9 0 Job/Part Disassembling the front brake caliper Brake pad clip Brake pad pin Brake pad Brake pad support Brake pad spring Brake caliper bracket Brake caliper housing Brake caliper piston Brake caliper dust seal Brake caliper piston seal Q’ty 1 1 2 1 1 1 1 2 2 2 4 - 34 Remarks Remove the parts in the order listed. Refer to “ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPER”.
FRONT AND REAR BRAKES * CHAS Apply silicone grease ** Apply brake fluid Order A B Job/Part Bleed screw/cap Brake caliper body Q’ty 1/1 1 Remarks For assembly, reverse the disassembly procedure.
FRONT AND REAR BRAKES CHAS EAS06160 REAR BRAKE CALIPER T. R. 23 Nm (2.3 m • kg, 17 ft • Ib) T. R. 6 Nm (0.6 m • kg, 4.3 ft • Ib) 4 1 2 6 T. 3 New R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 5 T. R. Order Job/Part Removing the rear brake caliper Muffler Q’ty Brake fluid 1 2 3 4 5 6 Brake hose holder Brake hose union bolt Copper washer Rear brake hose Rear brake caliper bolt Rear brake caliper 1 1 2 1 3 1 40 Nm (4.0 m • kg, 29 ft • Ib) Remarks Remove the parts in the order listed.
FRONT AND REAR BRAKES CHAS 2 T. R. 6 Nm (0.6 m • kg, 4.3 ft • Ib) 9 0 6 7 New 8 New 1 1 5 T. 4 R. 27 Nm (2.
FRONT AND REAR BRAKES CHAS EAS06190 4 3 DISASSEMBLING THE FRONT BRAKE CALIPER NOTE: Before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1 2 5 1. • • • • • Remove: brake hose union bolt 1 copper washers 2 brake hose 3 brake caliper bolts 4 brake caliper 5 NOTE: Put the end of the brake hose into a container and pump out the brake fluid carefully. 1 2. Remove: • brake caliper bracket 1 • brake caliper housing 2 2 3.
FRONT AND REAR BRAKES CHAS EAS00627 DISASSEMBLING THE REAR BRAKE CALIPER NOTE: Before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1. • • • • • Remove: brake hose union bolt 1 copper washers 2 brake hose 3 brake caliper retaining bolts brake caliper NOTE: Put the end of the brake hose into a container and pump out the brake fluid carefully. 2. Remove: • brake caliper pistons 1 • brake caliper dust seals and piston seals 2 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a.
FRONT AND REAR BRAKES CHAS EAS06330 CHECKING THE FRONT AND REAR BRAKE CALIPERS Recommended brake component replacement schedule È 2 1 É Brake pads If necessary Dust seals, Piston seals Every two years Brake hose Every four years Brake fluid Every two years and whenever the brake is disassembled 3 1. Check: • brake caliper pistons 1 Rust/scratches/wear → Replace the brake caliper pistons. • brake caliper cylinders 2 Scratches/wear → Replace the brake caliper assembly.
FRONT AND REAR BRAKES CHAS EAS06350 ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPER WARNING • Before installation, all internal brake components should be cleaned and lubricated with clean or new brake fluid. • Never use solvents on internal brake components as they will cause the piston seals to swell and distort. • Whenever a brake caliper is disassembled, replace the brake caliper dust seals and piston seals. New 1 Recommended brake fluid DOT 4 2 1 New 1.
FRONT AND REAR BRAKES CHAS 4. • 5. • • • Remove: brake caliper Install: brake pad support brake pad spring brake pads Refer to “REPLACING BRAKE PADS”. 6. Install: • brake caliper • brake caliper bolts THE FRONT T. R. 23 Nm (2.3 m · kg, 17 ft · lb) 7. Fill: • brake master cylinder reservoir (with the specified amount of the recommended brake fluid) Recommended brake fluid DOT 4 WARNING • Use only the designated brake fluid.
FRONT AND REAR BRAKES a CHAS 9. Check: • brake fluid level Below the minimum level mark a → Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” in chapter 3. 10.Check: • brake lever operation Soft or spongy feeling → Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3.
FRONT AND REAR BRAKES CHAS 3. Install: • brake caliper 1 (temporarily) • copper washers 2 New • brake hose 3 • brake hose union bolt 4 T. R. 23 Nm (2.3 m · kg, 17 ft · lb) WARNING Proper brake hose routing is essential to insure safe vehicle operation. Refer to “CABLE ROUTING” in chapter 2. CAUTION: When installing the brake hose onto the brake caliper, make sure the brake pipe touches the projection a on the brake caliper. 4. • 5.
FRONT AND REAR BRAKES CHAS 7. Fill: • brake master cylinder reservoir (with the specified amount of the recommended brake fluid) Recommended brake fluid DOT 4 WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance.
FRONT AND REAR BRAKES CHAS 10.Check: • brake lever operation Soft or spongy feeling → Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3.
FRONT FORK CHAS EAS06460 FRONT FORK New 3 T. R. 22 Nm (2.2 m • kg, 16 ft • Ib) 4 T. R. 23 Nm (2.3 m • kg, 17 ft • Ib) 1 2 5 Order Job/Part Removing the front fork legs Q’ty Front cowling Front wheel 1 Front brake caliper 1 2 3 4 5 Front fender Clip Lower bracket pinch bolt Front fork leg 1 1 2 1 4 - 47 Remarks Remove the parts in the order listed. The following procedure applies to both of the front fork legs. Refer to “COVERS AND PANELS” in chapter 3.
FRONT FORK Order 1 2 3 4 5 6 7 8 9 0 A Job/Part Disassembling the front fork legs Rubber cap Circlip Front fork cap O-ring Fork spring Dust seal Oil seal clip Damper rod bolt Copper washer Damper rod Rebound spring Q’ty 1 1 1 1 1 1 1 1 1 1 1 4 - 48 CHAS Remarks Remove the parts in the order listed. The following procedure applies to both of the front fork legs. Refer to “DISASSEMBLING THE FRONT FORK LEGS” and “ASSEMBLING THE FRONT FORK LEGS”.
FRONT FORK Order B C D E F G H Job/Part Inner tube Inner tube bushing Oil flow stopper Oil seal Washer Outer tube bushing Outer tube Q’ty 1 1 1 1 1 1 1 CHAS Remarks Refer to “DISASSEMBLING THE FRONT FORK LEGS” and “ASSEMBLING THE FRONT FORK LEGS”. For assembly, reverse the disassembly procedure.
FRONT FORK CHAS EAS06490 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the vehicle on a level surface. WARNING Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the front wheel is elevated. 2. • 3. • 1 2 Remove: clip 1 Loosen: lower bracket pinch bolts 2 WARNING Support the front fork leg while loosening the lower bracket pinch bolts. 4.
FRONT FORK CHAS 2. Drain: • fork oil NOTE: Stroke the inner tube several times while draining the fork oil. 1 3. Remove: • dust seal 1 • oil seal clip 2 (with a flat-head screwdriver) CAUTION: 2 Do not scratch the inner tube. 4. • • • Remove: damper rod bolt 1 damper rod rebound spring NOTE: Hold the damper rod with the damper rod holder 2 and T-handle 3, then loosen the damper rod bolt.
FRONT FORK CHAS 5. Remove: • inner tube ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Hold the front fork leg horizontally. b. Securely clamp the brake caliper bracket in a vise with soft jaws. c. Separate the inner tube from the outer tube by pulling the inner tube forcefully but carefully. CAUTION: • Excessive force will damage the oil seal and bushing. A damaged oil seal or bushing must be replaced.
FRONT FORK 1 2 CHAS 3. Check: • damper rod 1 Damage/wear → Replace. Obstruction → Blow out all of the oil passages with compressed air. • oil flow stopper 2 Damage → Replace. CAUTION: When disassembling and assembling the front fork leg, do not allow any foreign material to enter the front fork. EAS06590 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. WARNING • Make sure the oil levels in both front fork legs are equal.
FRONT FORK 2 1 CHAS 1. Install: • damper rod 1 • rebound spring 2 3 CAUTION: Allow the damper rod to slide slowly down the inner tube 3 until it protrudes from the bottom of the inner tube. Be careful not to damage the inner tube. 2. Lubricate: • inner tube’s outer surface Recommended lubricant Fork oil 15 W or equivalent 2 4 3. Install: • inner tube bushing 1 New • inner tube 2 (into outer tube 3) • oil flow stopper 4 1 New 3 4.
FRONT FORK CHAS 5. Tighten: • damper rod bolt 1 T. Damper rod bolt 28 Nm (2.8 m · kg, 20 ft · lb) R. NOTE: Hold the damper rod with the damper rod holder 2 and T-handle 3, then tighten the damper rod bolt. Damper rod holder 90890-01294 T-handle 90890-01326 6.
FRONT FORK CHAS 7. Install: • oil seal 1 New (with the fork seal driver weight 2 and fork seal driver attachment 3) CAUTION: Make sure the numbered side of the oil seal faces up. Fork seal driver weight 90890-01367 Fork seal driver attachment (ø36) 90890-01370 NOTE: • Before installing the oil seal, lubricate its lips with lithium-soap-based grease. • Lubricate the outer surface of the inner tube with fork oil.
FRONT FORK CHAS 10.Fill: • front fork leg (with the specified amount of the recommended fork oil) Quantity (each front fork leg) 195.0 cm3 (6.86 Imp oz, 6.59 US oz) Recommended oil Fork oil 15 W or equivalent Front fork leg oil level a (from the top of the inner tube, with the inner tube fully compressed and without the fork spring) 105.0 mm (4.13 in) NOTE: • While filling the front fork leg, keep it upright. • After filling, slowly pump the front fork leg up and down to distribute the fork oil. 11.
FRONT FORK CHAS EAS06630 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Install: • front fork leg 1 • lower bracket pinch bolts 2 T. R. 22 Nm (2.2 m · kg, 16 ft · lb) NOTE: Pull up the inner tube until it stops, and then tighten the lower bracket pinch bolts. 2.
CHAS HANDLEBAR EAS06640 HANDLEBAR T. R. 23 Nm (2.3 m • kg, 17 ft • Ib) T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) T. 7 Nm (0.7 m • kg, 5.1 ft • Ib) R. T. 26 Nm (2.6 m • kg, 19 ft • Ib) R. 7 5 12 9 1 3 LS 13 5 11 6 LS 1 6 2 10 4 8 T. R. 26 Nm (2.
CHAS HANDLEBAR T. R. 23 Nm (2.3 m • kg, 17 ft • Ib) T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) T. 7 Nm (0.7 m • kg, 5.1 ft • Ib) R. T. 26 Nm (2.6 m • kg, 19 ft • Ib) R. 7 5 12 9 1 3 LS 13 5 11 6 LS 1 6 2 10 8 T. R. 26 Nm (2.6 m • kg, 19 ft • Ib) Order 11 12 13 4 Job/Part Handlebar grip Upper handlebar holder Handlebar Q’ty Remarks 1 Refer to “REMOVING THE HANDLEBAR” and “INSTALLING THE HANDLEBAR”. 2 Refer to “INSTALLING THE HANDLEBAR”.
HANDLEBAR CHAS EAS06660 REMOVING THE HANDLEBAR 1. Stand the vehicle on a level surface. WARNING Securely support the vehicle so that there is no danger of it falling over. 1 4 3 2 2. • • • Remove: throttle cable housings 1 throttle cables 2 throttle grip 3 NOTE: While removing the throttle cable housing, pull back the rubber cover 4. 1 3. Remove: • handlebar grip 1 NOTE: Blow compressed air between the handlebar and the handlebar grip, and gradually push the grip off the handlebar.
HANDLEBAR 1 2 CHAS 2. Install: • handlebar 1 • upper handlebar holders 2 T. b R. 23 Nm (2.3 m · kg, 17 ft · lb) CAUTION: First, tighten the bolt on the front side of the handlebar holders, and then on the rear side. NOTE: • The upper handlebar holders should be installed with the arrow marks a facing forward È. • Align the match mark b on the handlebar with the upper surface of the lower handlebar holder. 3. Install: • handlebar grip ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a.
HANDLEBAR 3 a 1 b 2 3 1 5 • • • Install: throttle grip 1 throttle cables 2 throttle cable housings 3 NOTE: • Lubricate the inside of the throttle grip with a thin coat of lithium-soap-based grease and install it onto the handlebar. • Align the projection a on the throttle cable housing with the hole b in the handlebar. • Be sure to slide the throttle cable rubber cover to its original position. 6. Install: • front brake master cylinder 1 • front brake master cylinder holder T. R.
CHAS STEERING HEAD EAS06750 STEERING HEAD LOWER BRACKET T. R. 120 Nm (12.0 m • kg, 85 ft • Ib) 1 2 3 T. R. 75 Nm (7.5 m • kg, 54 ft • Ib) T. R. 1st 38 Nm (3.8 m • kg, 27 ft • Ib) 2nd 22 Nm (2.
CHAS STEERING HEAD T. R. 120 Nm (12.0 m • kg, 85 ft • Ib) 1 2 3 T. R. 75 Nm (7.5 m • kg, 54 ft • Ib) T. R. 1st 38 Nm (3.8 m • kg, 27 ft • Ib) 2nd 22 Nm (2.
STEERING HEAD CHAS EAS06780 REMOVING THE LOWER BRACKET 1. Stand the vehicle on a level surface. WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: • lower handlebar holder 1 • woodruff key 2 1 2 3. Remove: • upper ring nut 1 (with the steering nut wrench 2) • lock washer • center ring nut • rubber washer 2 Steering nut wrench 90890-01403 1 4.
STEERING HEAD CHAS EAS06810 CHECKING THE STEERING HEAD 1. Wash: • bearings • bearing races Recommended cleaning solvent Kerosene 2. Check: • bearings • bearing races Damage/pitting → Replace. 3. Replace: • bearings • bearing races ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the bearing races from the steering head pipe with a long rod 1 and a hammer. b. Remove the bearing race from the lower bracket with a floor chisel 2 and a hammer. c. Install a new rubber seal and new bearing races.
STEERING HEAD CHAS EAS06840 INSTALLING THE STEERING HEAD 1. Lubricate: • upper bearing • lower bearing • bearing races Recommended lubricant Lithium-soap-based grease 2. Install: • upper bearing WARNING When installing the upper bearing, do not mistake the up and down directions for the upper bearing. 2 3. • • • • • Install: lower ring nut 1 rubber washer center ring nut 2 lock washer 3 upper ring nut 4 Refer to “CHECKING AND ADJUSTING THE STEERING HEAD” in chapter 3. 4.
REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM CHAS EAS06850 REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM T. 59 Nm (5.9 m • kg, 43 ft • Ib) R. LS 8 3 2 10 T. R. 4 7 Nm (0.7 m • kg, 5.1 ft • Ib) New LS 12 6 5 New 11 4 New 9 T. R. T. R. R. R. Job/Part Removing the rear shock absorber assemblies and swingarm Mudguard assembly Q’ty Muffler 1 2 3 4 Rear wheel axle nut Brake hose holder Rear brake caliper Rear shock absorber assembly 135 Nm (13.5 m • kg, 98 ft • lb) T. T.
REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM 59 Nm (5.9 m • kg, 43 ft • Ib) T. R. LS 8 3 2 10 T. R. 4 CHAS 7 Nm (0.7 m • kg, 5.1 ft • Ib) New LS 12 6 5 New 11 4 New 9 T. R. T. Spacer Collar Oil seal Oil seal Circlip Bearing R. Job/Part Rear fender bracket Swingarm 135 Nm (13.5 m • kg, 98 ft • lb) T. R. 7 8 9 10 11 12 R. T. Order 5 6 32 Nm (3.2 m • kg, 23 ft • Ib) Q’ty 1 1 LS 16 Nm (1.6 m • kg, 11 ft • Ib) T. R. 18 Nm (1.8 m • kg, 13 ft • Ib) 7 1 40 Nm (4.
REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM CHAS EAS06930 REMOVING THE REAR SHOCK ABSORBER ASSEMBLIES 1. Stand the vehicle on a level surface. WARNING Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a centerstand so that the rear wheel is elevated. 2 2 1 1 2. Remove: • rear shock absorber lower bolts 1 • rear shock absorber upper bolts 2 EAS06960 CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES 1.
REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM CHAS EAS06990 1 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLIES 1. Install: • rear shock absorber upper nuts 1 1 T. R. 32 Nm (3.2 m · kg, 23 ft · lb) • rear shock absorber lower bolts 2 2 T. 2 R. 18 Nm (1.8 m · kg, 13 ft · lb) EAS07030 REMOVING THE SWINGARM 1. Stand the vehicle on a level surface. WARNING Securely support the vehicle so that there is no danger of it falling over.
REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM CHAS EAS07070 CHECKING THE SWINGARM 1. Check: • swingarm Bends/cracks/damage → Replace. 2 2. • • • • 3 4 3 Check: spacer 1 collar 2 oil seals 3 bearing 4 Damage/wear → Replace. 1 EAS07120 INSTALLING THE SWINGARM 1. Lubricate: • bearings • oil seal lips • drive axle Recommended lubricant Lithium-soap-based grease 2. Install: • swingarm 1 4 2 T. R. 59 Nm (5.9 m · kg, 43 ft · lb) • rear fender bracket 2 • rear fender bracket lower bolt 5 T. R.
ENG CHAPTER 5 ENGINE ENGINE REMOVAL ........................................................................................5-1 LEADS, HOSES, EXHAUST PIPE AND MUFFLER .................................5-1 ENGINE..................................................................................................... 5-3 INSTALLING THE ENGINE....................................................................... 5-4 CYLINDER HEAD......................................................................................
ENG BELT DRIVE.................................................................................................. 5-36 V-BELT CASE COVER ...........................................................................5-36 V-BELT, PRIMARY SHEAVE AND SECONDARY SHEAVE .................. 5-37 SECONDARY SHEAVE ..........................................................................5-39 REMOVING THE PRIMARY SHEAVE....................................................5-40 REMOVING THE SECONDARY SHEAVE AND V-BELT .......
ENGINE REMOVAL ENG EAS00188 ENGINE ENGINE REMOVAL LEADS, HOSES, EXHAUST PIPE AND MUFFLER 11 10 5 2 4 10 3 T. R. 40 Nm (4.0 m • kg, 29 ft • Ib) 6 T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 8 T. R. 65 Nm (6.5 m • kg, 47 ft • Ib) New 9 1 7 New T. R. T. R.
ENGINE REMOVAL ENG 11 10 5 2 10 4 3 T. R. 40 Nm (4.0 m • kg, 29 ft • Ib) 6 T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 8 T. R. 65 Nm (6.5 m • kg, 47 ft • Ib) New 9 1 7 New T. R. T. R. Order 4 5 6 7 8 9 10 11 Job/Part Thermostat outlet hose Water pump inlet hose Muffler Gasket Exhaust pipe Gasket Brake hose holder Rear brake caliper 20 Nm (2.0 m • kg, 14 ft • Ib) 14 Nm (1.4 m • kg, 10 ft • Ib) Q’ty Remarks 1 Disconnect. 1 1 1 1 1 1 1 For installation, reverse the removal procedure.
ENGINE REMOVAL ENG EAS00191 ENGINE 7 8 T. R. 32 Nm (3.2 m • kg, 23 ft • Ib) T. R. 59 Nm (5.9 m • kg, 43 ft • Ib) 7 T. R. 18 Nm (1.8 m • kg, 13 ft • Ib) 1 7 1 LS 2 3 3 T. R. 32 Nm (3.2 m • kg, 23 ft • Ib) 2 4 5 6 Q’ty R. 64 Nm (6.4 m • kg, 46 ft • Ib) T. R. Job/Part Removing the engine T. 3 Order 5 64 Nm (6.4 m • kg, 46 ft • Ib) Remarks Remove the parts in the order listed. NOTE: Place a suitable stand under the engine.
ENGINE REMOVAL ENG EAS00192 1 5 INSTALLING THE ENGINE 1. Install: • engine bracket 1 • engine bracket rods 2 5 4 2 NOTE: Engine bracket bolts and rod bolts should be temporarily tightened. 2 3 2. • 3. • Install: engine Tighten: engine bracket rod bolts 3 T. R. 64 Nm (6.4 m · kg, 46 ft · lb) • engine mounting nut 4 T. R. 32 Nm (3.2 m · kg, 23 ft · lb) • engine bracket nuts 5 T. R. 5-4 59 Nm (5.
ENG CYLINDER HEAD EAS00221 CYLINDER HEAD T. R. 18 Nm (1.8 m • kg, 13 ft • Ib) T. R. 8 Nm (0.8 m • kg, 5.8 ft • Ib) T. R. 22 Nm (2.2 m kg, 16 ft Ib) • • R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) T. R. 2 T. R. 8 Nm (0.8 m • kg, 5.8 ft • Ib) New T. LT LT 10 Nm (1.0 m • kg, 7.2 ft • Ib) 1 LS 4 R. LS T. New 13 8 10 Nm (1.0 m • kg, 7.2 ft • Ib) T. R. 60 Nm (6.0 m • kg, 43 ft • Ib) New 5 12 T. R. E 11 8 Nm (0.8 m • kg, 5.8 ft • Ib) 8 New New 6 7 LS New 9 New LS T. R.
ENG CYLINDER HEAD T. R. 18 Nm (1.8 m • kg, 13 ft • Ib) T. R. 8 Nm (0.8 m • kg, 5.8 ft • Ib) T. R. 22 Nm (2.2 m kg, 16 ft Ib) • • R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) T. R. 2 T. R. 8 Nm (0.8 m • kg, 5.8 ft • Ib) New T. LT LT 10 Nm (1.0 m • kg, 7.2 ft • Ib) 1 LS 4 R. LS T. New 13 8 10 Nm (1.0 m • kg, 7.2 ft • Ib) T. R. 60 Nm (6.0 m • kg, 43 ft • Ib) New 5 12 T. R. E 11 8 Nm (0.8 m • kg, 5.8 ft • Ib) 8 New New 6 7 LS New 9 New LS T. R. 10 Nm (1.0 m • kg, 7.
CYLINDER HEAD ENG EAS00225 REMOVING THE CYLINDER HEAD 1. Remove: • camshaft sprocket cover • V-belt case air filter cover 2. Align: • “I” mark a on the generator rotor (with the stationary pointer b on the generator cover) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the primary sheave nut on the left side of the crankshaft counterclockwise to turn the crankshaft. b.
CYLINDER HEAD ENG EAS00229 CHECKING THE CYLINDER HEAD 1. Eliminate: • combustion chamber carbon deposits (with a rounded scraper) NOTE: Do not use a sharp instrument to avoid damaging or scratching: • spark plug bore threads • valve seats 2. Check: • cylinder head Damage/scratches → Replace. • cylinder head water jacket Mineral deposits/rust → Eliminate. 3. Measure: • cylinder head warpage Out of specification → Resurface the cylinder head. Maximum cylinder head warpage 0.05 mm (0.
CYLINDER HEAD ENG EAS00207 CHECKING THE CAMSHAFT SPROCKET 1. Check: • camshaft sprocket More than 1/4 tooth wear a → Replace the camshaft sprocket and the timing chain as a set. a 1/4 tooth b Correct 1 Timing chain roller 2 Camshaft sprocket EAS00210 CHECKING THE TIMING CHAIN TENSIONER 1. Check: • timing chain tensioner Cracks/damage → Replace. 2. Check: • one-way cam operation Rough movement → Replace the timing chain tensioner housing. 3.
CYLINDER HEAD ENG 3. Tighten: • cylinder head nuts 1 T. R. 22 Nm (2.2 m · kg, 16 ft · lb) • cylinder head bolts 2 T. R. 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: • Apply engine oil to the threads of the cylinder head nuts. • Tighten the cylinder head nuts and bolts in the proper tightening sequence as shown and torque them in two stages. 4. Install: • camshaft sprocket 1 • timing chain 2 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a.
CYLINDER HEAD 5. • • • ENG Install: camshaft sprocket plate 1 washer 2 camshaft sprocket bolt 3 6. Install: • timing chain tensioner ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the cap bolt 1 and spring 2. b. Release the timing chain tensioner one-way cam 3 and push the timing chain tensioner rod 4 all the way into the timing chain tensioner housing. c. Install the timing chain tensioner and gasket 5 onto the cylinder. T. Timing chain tensioner bolt 10 Nm (1.0 m · kg, 7.2 ft · lb) R. d.
CYLINDER HEAD ENG 9. Tighten: • camshaft sprocket bolt T. R. 60 Nm (6.0 m · kg, 43 ft · lb) CAUTION: Be sure to tighten the camshaft sprocket bolt to the specified torque to avoid the possibility of the bolt coming loose and damaging the engine. 10.Measure: • valve clearance Out of specification → Adjust. Refer to “ADJUSTING THE CLEARANCE” in chapter 3.
CAMSHAFT AND ROCKER ARMS ENG EAS00195 CAMSHAFT AND ROCKER ARMS T. R. 1 2 14 Nm (1.4 m • kg, 10 ft • Ib) 8 T. R. 5 8 Nm (0.8 m • kg, 5.8 ft • Ib) 4 8 7 3 6 New 2 1 T. R. Order 1 2 3 4 5 6 7 8 14 Nm (1.4 m • kg, 10 ft • Ib) Job/Part Removing the camshaft and rocker arms Cylinder head Locknut Adjusting screw Lock plate Camshaft retainer Camshaft Intake rocker arm shaft Exhaust rocker arm shaft Rocker arm Q’ty 2 2 1 1 1 1 1 2 Remarks Remove the parts in the order listed.
CAMSHAFT AND ROCKER ARMS ENG EAS00202 REMOVING THE ROCKER ARMS AND CAMSHAFT 1. Straighten the lock plate tabs a. 2. Remove: • lock plate 1 • camshaft retainer 2 3. Remove: • camshaft 1 NOTE: Screw a 10 mm bolt 2 into the threaded end of the camshaft, and then pull the camshaft out. 4. • • • Remove: intake rocker arm shaft exhaust rocker arm shaft rocker arms NOTE: Remove the rocker arm shafts with the slide hammer bolt 1 and weight 2.
CAMSHAFT AND ROCKER ARMS ENG 2. Measure: • camshaft lobe dimensions a and b Out of specification → Replace the camshaft. Camshaft lobe dimensions Intake a 37.051 ~ 37.151 mm (1.4587 ~ 1.4626 in) : 36.956 mm (1.4550 in) b 30.074 ~ 30.174 mm (1.1840 ~ 1.1880 in) : 29.973 mm (1.1800 in) Exhaust a 37.053 ~ 37.153 mm (1.4588 ~ 1.4627 in) : 36.956 mm (1.4550 in) b 30.091 ~ 30.191 mm (1.1847 ~ 1.1886 in) : 29.194 mm (1.1494 in) 3.
CAMSHAFT AND ROCKER ARMS ENG 3. Measure: • rocker arm inside diameter Out of specification → Replace. Rocker arm inside diameter 12.000 ~ 12.018 mm (0.4724 ~ 0.4731 in) : 12.030 mm (0.4736 in) 4. Measure: • rocker arm shaft outside diameter Out of specification → Replace. Rocker arm shaft outside diameter 11.981 ~ 11.991 mm (0.4717 ~ 0.4721 in) : 11.950 mm (0.4705 in) 5. Calculate: • rocker-arm-to-rocker-arm-shaft clearance Above 0.080 mm (0.0031 in) → Replace the defective part(s).
CAMSHAFT AND ROCKER ARMS ENG EAS00220 INSTALLING THE CAMSHAFT AND ROCKER ARMS 1. Lubricate: • camshaft Recommended lubricant Camshaft Molybdenum disulfide oil Camshaft bearing Engine oil 2. Lubricate: • rocker arms Recommended lubricant Molybdenum disulfide oil 3. Install: • exhaust rocker arm • exhaust rocker arm shaft 1 NOTE: Make sure the exhaust rocker arm shaft is completely pushed into the cylinder head. 4.
CAMSHAFT AND ROCKER ARMS ENG 5. Install: • camshaft 1 6. • • • Install: camshaft retainer 1 lock plate 2 New camshaft retainer bolts 3 T. R. 8 Nm (0.8 m · kg, 5.8 ft · lb) NOTE: Bend the lock plate tab along a flat side of the camshaft retainer bolts 3.
ENG VALVES AND VALVE SPRINGS EAS00236 VALVES AND VALVE SPRINGS 7 New M 8 1 New 9 2 4 3 6 5 M New 9 8 7 New M 3 Order 1 2 3 4 5 6 7 8 9 Job/Part Removing the valves and valve springs Cylinder head Rocker arms and camshaft Valve cotter Upper spring seat Outer valve spring Inner valve spring Intake valve Exhaust valve Valve stem seal Lower spring seat Valve guide Q’ty 4 2 1 Remarks Remove the parts in the order listed. Refer to “CYLINDER HEAD”. Refer to “CAMSHAFT AND ROCKER ARMS”.
VALVES AND VALVE SPRINGS ENG EAS00237 REMOVING THE VALVES The following procedure applies to all of the valves and related components. NOTE: Before removing the internal parts of the cylinder 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.
VALVES AND VALVE SPRINGS 3. • • • • • • ENG Remove: upper spring seat 1 outer valve spring 2 inner valve spring 3 valve 4 valve stem seal 5 lower spring seat 6 NOTE: Identify the position of each part very carefully so that they can be reinstalled in their original place. EAS00239 CHECKING THE VALVES AND VALVE GUIDES The following procedure applies to all of the valves and valve guides. 1. Measure: • valve-stem-to-valve-guide clearance Out of specification → Replace the valve guide.
VALVES AND VALVE SPRINGS ENG 2. Replace: • valve guide NOTE: 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 1. b. Install the new valve guide with the valve guide installer 2 and valve guide remover 1. c.
VALVES AND VALVE SPRINGS ENG 5. Measure: • valve margin thickness a Out of specification → Replace the valve. Valve margin thickness Intake 0.80 ~ 1.20 mm (0.0315 ~ 0.0472 in) 0.5 mm (0.02 in) Exhaust 0.80 ~ 1.20 mm (0.0315 ~ 0.0472 in) 0.5 mm (0.02 in) 6. Measure: • valve stem runout Out of specification → Replace the valve. NOTE: • When installing a new valve, always replace the valve guide. • If the valve is removed or replaced, always replace the oil seal. Valve stem runout 0.
VALVES AND VALVE SPRINGS ENG 2. Check: • valve seat Pitting/wear → Replace the cylinder head. 3. Measure: • valve seat width a Out of specification → Replace the cylinder head. Valve seat width Intake 0.90 ~ 1.10 mm (0.0354 ~ 0.0433 in) : 1.6 mm (0.06 in) Exhaust 0.90 ~ 1.10 mm (0.0354 ~ 0.0433 in) : 1.6 mm (0.06 in) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Apply Mechanic’s blueing dye (Dykem) b to the valve face. b. Install the valve into the cylinder head. c.
VALVES AND VALVE SPRINGS ENG b. Apply molybdenum disulfide oil to the valve stem. c. Install the valve into the cylinder head. d. Turn the valve until the valve face and valve seat are evenly polished, and then clean off all of the lapping compound. NOTE: 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.
VALVES AND VALVE SPRINGS ENG 2. Measure: • compressed valve spring force a Out of specification → Replace the valve spring. b Installed length Compressed valve spring force (installed) Intake and exhaust inner valve spring 76 ~ 88 N (7.80 ~ 9.00 kg, 17.20 ~ 19.85 lb) at 30.10 mm (1.19 in) Intake and exhaust outer valve spring 115 ~ 133 N (11.73 ~ 13.56 kg, 25.85 ~ 29.90 lb) at 31.60 mm (1.24 in) 3. Measure: • valve spring tilt a Out of specification → Replace the valve spring.
VALVES AND VALVE SPRINGS ENG 2. Lubricate: • valve stem 1 • valve stem seal 2 (with the recommended lubricant) Recommended lubricant Molybdenum disulfide oil 3. • • • • • • Install: lower spring seat 1 valve stem seal 2 New valve 3 inner valve spring 4 outer valve spring 5 upper spring seat 6 NOTE: Install the valve spring with the larger pitch a facing up. b Smaller pitch 4.
VALVES AND VALVE SPRINGS ENG 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.
CYLINDER AND PISTON ENG EAS00251 CYLINDER AND PISTON 3 6 New 4 New 5 E New 9 1 10 11 2 LS 8 7 6 New New LS T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) Order 1 2 3 4 5 6 7 8 9 10 11 E E Job/Part Removing the cylinder and piston Cylinder head Water pump outlet pipe Timing chain guide (exhaust side) Cylinder Cylinder gasket Dowel pin Piston pin clip Piston pin Piston Top ring 2nd ring Oil ring Q’ty 1 1 1 1 2 2 1 1 1 1 1 Remarks Remove the parts in the order listed. Refer to “CYLINDER HEAD”.
CYLINDER AND PISTON ENG EAS00253 REMOVING THE PISTON 1. Remove: • piston pin clips 1 • piston pin 2 • piston 3 CAUTION: Do not use a hammer to drive the piston pin out. NOTE: • Before removing the piston pin clip, cover the crankcase opening with a clean rag to prevent the piston pin clip from falling into the crankcase. • Before removing the piston pin, deburr the piston pin clip groove and the piston pin bore area.
CYLINDER AND PISTON ENG 2. Measure: • piston-to-cylinder clearance ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Measure cylinder bore “C” with the cylinder bore gauge. NOTE: Measure cylinder bore “C” by taking side-toside and front-to-back measurements of the cylinder. Then, find the average of the measurements. Cylinder bore “C” 69.000 ~ 69.005 mm (2.7165 ~ 2.7167 in) Taper limit “T” 0.050 mm (0.0020 in) Out of round “R” 0.030 mm (0.
CYLINDER AND PISTON ENG f. If out of specification, rebore or replace the cylinder, and replace the piston and piston rings as a set. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS00264 CHECKING THE PISTON RINGS 1. Measure: • piston ring side clearance Out of specification → Replace the piston and piston rings as a set. NOTE: Before measuring the piston ring side clearance, eliminate any carbon deposits from the piston ring grooves and piston rings. Piston ring side clearance Top ring 0.040 ~ 0.080 mm (0.
CYLINDER AND PISTON ENG 3. Measure: • piston ring end gap Out of specification → Replace the piston ring. NOTE: The end gap of the oil ring expander spacer cannot be measured. If the oil ring rail gap is excessive, replace all three piston rings. Piston ring end gap Top ring 0.15 ~ 0.30 mm (0.0059 ~ 0.0118 in) : 0.45 mm (0.0177 in) 2nd ring 0.30 ~ 0.45 mm (0.0118 ~ 0.0177 in) : 0.70 mm (0.0276 in) Oil ring 0.20 ~ 0.70 mm (0.0079 ~ 0.0276 in) EAS00266 CHECKING THE PISTON PIN 1.
CYLINDER AND PISTON ENG 3. Measure: • piston pin bore diameter b (in the piston) Out of specification → Replace the piston pin. Piston pin bore diameter 17.004 ~ 17.015 mm (0.6694 ~ 0.6699 in) : 17.045 mm (0.6711 in) 4. Calculate: • piston-pin-to-piston-pin-bore clearance Out of specification → Replace the piston pin. Piston-pin-to-piston-pin-bore clearance = Piston pin bore diameter (in the piston) – Piston pin outside diameter Piston-pin-to-piston-pin-bore clearance 0.004 ~ 0.024 mm (0.0002 ~ 0.
CYLINDER AND PISTON 2. • • • ENG Install: piston 1 piston pin 2 piston pin clips 3 New NOTE: • Apply engine oil to the piston pin. • Make sure the arrow mark a 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 prevent the clip from falling into the crankcase. 3. • • 4.
ENG BELT DRIVE EAS00316 BELT DRIVE V-BELT CASE COVER 6 6 T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) New 5 4 New T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) 3 T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) New 2 1 Order 1 2 3 4 5 6 Job/Part Removing the V-belt case cover Center panel 1 (left)/air filter case assembly V-belt case air filter cover V-belt case air filter element V-belt case cover V-belt case V-belt case gasket Dowel pin Q’ty Remarks Remove the parts in the order listed.
BELT DRIVE ENG V-BELT, PRIMARY SHEAVE AND SECONDARY SHEAVE * Apply Shell BT grease 3® (YAMAHA grease G 90793-40016) 8 LS 6 New 7 E LS 15 5 4 10 11 14 12 1 2 3 13 New LS T R. 9 . New 80 Nm (8.0 m • kg, 58 ft • Ib) T. R. R. R. Order T. T. 3 Nm (0.3 m • kg, 2.2 ft • Ib) 22 Nm (2.
BELT DRIVE ENG * Apply Shell BT grease 3® (YAMAHA grease G 90793-40016) 8 LS 6 New 7 E LS 15 5 4 10 11 14 12 1 2 3 13 New LS T R. 9 . New 80 Nm (8.0 m • kg, 58 ft • Ib) T. R. Job/Part Primary sheave cap Cam Weight Slider Spacer R. R. Order 11 12 13 14 15 T. T. 3 Nm (0.3 m • kg, 2.2 ft • Ib) 22 Nm (2.2 m • kg, 16 ft • Ib) LS Q’ty 1 1 8 4 4 60 Nm (6.0 m • kg, 43 ft • Ib) Remarks For installation, reverse the removal procedure.
BELT DRIVE ENG SECONDARY SHEAVE ** Apply BEL-RAY assembly lube® 6 5 New 4 New 2 1 A 7 7 New 3 4 New New 0 Order 1 2 3 4 5 6 7 8 9 0 A 7 Job/Part Disassembling the secondary sheave Clutch carrier nut Clutch carrier Clutch carrier plate Clutch shoe spring Compression spring Spring seat Guide pin Secondary sliding sheave O-ring Oil seal Secondary fixed sheave R. 7 T. 8 90 Nm (9.0 m • kg, 65 ft • Ib) 0 New 9 New Q’ty Remarks Remove the parts in the order listed.
BELT DRIVE ENG EAS00317 REMOVING THE PRIMARY SHEAVE 1. Remove: • V-belt case air filter cover • V-belt case cover • V-belt case NOTE: Loosen each V-belt case 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. 2. • • • Remove: primary sheave nut 1 washer primary fixed sheave 2 NOTE: While holding the primary fixed sheave with the rotor holding tool 3, loosen the primary sheave nut.
BELT DRIVE 2 ENG 2. Loosen: • clutch carrier nut 1 CAUTION: Do not remove the clutch carrier nut at this stage. 3 1 NOTE: While holding the clutch carrier with the sheave holder 2, loosen the clutch carrier nut one full turn with the locknut wrench 3. Sheave holder 90890-01701 Locknut wrench 90890-01348 3. Remove: • secondary sheave assembly 1 • V-belt 2 NOTE: Remove the V-belt and secondary sheave assembly from the primary sheave side. 2 1 EAS00319 DISASSEMBLING THE SECONDARY SHEAVE 1.
BELT DRIVE ENG EAS00320 CHECKING THE V-BELT 1. Check: • V-belt 1 Cracks/damage/wear → Replace. Grease/oil → Clean the primary and secondary sheaves. 2. Measure: • V-belt width 2 Out of specification → Replace. V-belt width 23.0 mm (0.91 in) : 21.0 mm (0.83 in) EAS00321 CHECKING THE PRIMARY SHEAVE WEIGHTS The following procedure applies to all of the primary sheave weights. 1. Check: • primary sheave weight Cracks/damage/wear → Replace. 2.
BELT DRIVE ENG 2. Check: • torque cam groove 1 Damage/wear → Replace the secondary fixed and sliding sheaves as a set. 3. Check: • guide pin 2 Damage/wear → Replace the secondary fixed and sliding sheaves as a set. 4. Check: • compression spring free length Out of specification → Replace the spring. Compression spring free length 102.4 mm (4.03 in) : 90.0 mm (3.54 in) CHECKING THE CLUTCH SHOES The following procedure applies to all of the clutch shoes. 1.
BELT DRIVE ENG EAS00323 ASSEMBLING THE PRIMARY SHEAVE 1. Clean: • primary fixed sheave 1 • primary sliding sheave 2 • spacer 3 • primary sheave weights 4 • primary sliding sheave cam face 5 2. Install: • primary sheave weights 1 • spacer 2 NOTE: Before installing the primary sheave weights, lubricate the inside and outside of each weight with Shell BT grease 3®. Recommended lubricant Shell BT grease 3® 3. • • • • Install: spacers 1 sliders 2 cam 3 primary sheave cap T. R. 5 - 44 3 Nm (0.
BELT DRIVE ENG EAS00324 ASSEMBLING THE SECONDARY SHEAVE 1. Lubricate: • secondary fixed sheave’s inner surface 1 • secondary sliding sheave’s inner surface 2 • oil seals New (with the recommended lubricant) Recommended lubricant BEL-RAY assembly lube® 2. Install: • oil seals New • secondary sliding sheave 1 3 NOTE: Install the secondary sliding sheave onto the secondary fixed sheave 2 with the oil seal guide 3. 1 2 Oil seal guide (ø41) 90890-01396 New 3 1 3. • 4.
BELT DRIVE 5. • • • • ENG Install: spring seat compression spring clutch carrier 1 clutch carrier nut 2 NOTE: While compressing the compression spring with the clutch spring holder 3 and clutch spring holder arm 4, install the clutch carrier nut. Clutch spring holder 90890-01337 Clutch spring holder arm 90890-01464 EAS00325 INSTALLING THE SECONDARY SHEAVE, V-BELT, AND PRIMARY SHEAVE 1.
BELT DRIVE 2 2. Install: • clutch carrier nut 1 T. R. 3 1 ENG 90 Nm (9.0 m · kg, 65 ft · lb) NOTE: While holding the clutch carrier with the sheave holder 2, tighten the clutch carrier nut with the locknut wrench 3. Sheave holder 90890-01701 Locknut wrench 90890-01348 3. • • • Install: clutch housing 1 collar secondary sheave nut 2 T. R. 60 Nm (6.0 m · kg, 43 ft · lb) NOTE: While holding the clutch housing with the sheave holder 3, tighten the secondary sheave nut.
BELT DRIVE 4. • • • • ENG Install: V-belt primary fixed sheave 1 washer primary sheave nut 2 T. R. 80 Nm (8.0 m · kg, 58 ft · lb) NOTE: • Install the V-belt onto the primary sheave (when the pulley is at its widest position) and onto the secondary sheave (when the pulley is at its narrowest position), and make sure the V-belt is tight. • While holding the primary fixed sheave with the rotor holding tool, tighten the primary sheave nut. Rotor holding tool 90890-01235 5.
STARTER CLUTCH AND GENERATOR ENG EAS00341 STARTER CLUTCH AND GENERATOR GENERATOR COVER AND STATOR COIL T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 1 LT LT 5 New LS 4 LT T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) 2 6 New New 3 4 T. R. Order Job/Part Removing the generator cover and stator coil Storage box/center panel 1 10 Nm (1.0 m • kg, 7.
STARTER CLUTCH AND GENERATOR ENG T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 1 LT LT 5 New LS 4 LT T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) 2 6 New New 3 4 T. R. Order 6 Job/Part Stator coil 10 Nm (1.0 m • kg, 7.2 ft • Ib) Q’ty 1 Remarks For installation, reverse the removal procedure.
ENG STARTER CLUTCH AND GENERATOR EAS00342 STARTER CLUTCH 4 3 2 E 1 LT E 8 E 7 6 LT 1 2 3 4 Job/Part Removing the starter clutch Generator rotor Starter clutch Woodruff key Starter clutch gear 5 6 7 8 Circlip Washer Starter clutch idle gear shaft Starter clutch idle gear Q’ty 1 1 1 1 T R. R. 30 Nm (3.0 m • kg, 22 ft • Ib) . T. Order 5 New 80 Nm (8.0 m • kg, 58 ft • Ib) Remarks Remove the parts in the order listed.
STARTER CLUTCH AND GENERATOR ENG EAS00347 REMOVING THE GENERATOR 1. Remove: • generator cover NOTE: 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. 2. Remove: • generator rotor nut 1 • washer 1 2 3 NOTE: • While holding the generator rotor 2 with the sheave holder 3, loosen the generator rotor nut. • Do not allow the sheave holder to touch the projection on the generator rotor. Sheave holder 90890-01701 3.
STARTER CLUTCH AND GENERATOR ENG EAS00344 REMOVING THE STARTER CLUTCH 1. Remove: • starter clutch bolts 1 NOTE: • While holding the generator rotor 2 with the sheave holder 3, remove the starter clutch bolts. • Do not allow the sheave holder to touch the projection on the generator rotor. Sheave holder 90890-01701 EAS00351 1 CHECKING THE STARTER CLUTCH 1. Check: • starter clutch rollers 1 Damage/wear → Replace. 2.
STARTER CLUTCH AND GENERATOR ENG EAS00355 INSTALLING THE STARTER CLUTCH 1. Install: • starter clutch bolts 1 LT T. R. 30 Nm (3.0 m · kg, 22 ft · lb) NOTE: • While holding the generator rotor 2 with the sheave holder 3, tighten the starter clutch bolts. • Do not allow the sheave holder to touch the projection on the generator rotor. Sheave holder 90890-01701 EAS00354 INSTALLING THE GENERATOR 1.
STARTER CLUTCH AND GENERATOR ENG 3. Apply: • sealant (onto the pickup coil/stator assembly lead grommet) Yamaha bond No.
ENG OIL PUMP EAS00357 OIL PUMP 7 New LS 6 8 10 12 11 13 9 4 3 2 New 1 5 E T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) LT T. R. Order 1 2 3 4 5 6 7 8 9 10 11 Job/Part Removing the oil pump assembly Starter clutch gear Oil baffle plate Circlip Washer Oil pump driven gear Pin Oil pump assembly Oil pump gasket Oil pump housing cover Pin Oil pump shaft Oil pump inner rotor Q’ty 1 1 1 1 1 1 1 1 1 1 1 5 - 56 12 Nm (1.2 m • kg, 8.7 ft • Ib) Remarks Remove the parts in the order listed.
ENG OIL PUMP 7 New LS 6 8 10 12 11 13 9 4 3 2 New 1 5 E T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) LT T. R. Order 12 13 Job/Part Oil pump outer rotor Oil pump housing Q’ty 1 1 12 Nm (1.2 m • kg, 8.7 ft • Ib) Remarks For installation, reverse the removal procedure.
OIL PUMP ENG EAS00364 CHECKING THE OIL PUMP 1. Check: • oil pump drive gear • oil pump driven gear • oil pump housing • oil pump housing cover Cracks/damage/wear → Replace the defective part(s). 2. Measure: • inner-rotor-to-outer-rotor-tip clearance È • outer-rotor-to-oil-pump-housing clearance É • oil-pump-housing-to-inner-rotor-and-outerrotor clearance Ê Out of specification → Replace the oil pump assembly.
OIL PUMP ENG EAS00375 ASSEMBLING THE OIL PUMP 1. Lubricate: • inner rotor • outer rotor • oil pump shaft (with the recommended lubricant) Recommended lubricant Engine oil 2 1 a 2. Install: • oil pump shaft 1 • pin 2 NOTE: When installing the pin, align the pin with the groove a in the inner rotor. 3. Check: • oil pump operation Refer to “CHECKING THE OIL PUMP”. EAS00376 INSTALLING THE OIL PUMP ASSEMBLY 1. Install: • oil pump gasket New • oil pump assembly T. R. 7 Nm (0.7 m · kg, 5.
ENG TRANSMISSION TRANSMISSION LS New 3 È É T. R. 16 Nm (1.6 m • kg, 11 ft • Ib) LS New Order Job/Part Removing the transmission Final transmission oil Q’ty Rear wheel 1 2 3 4 5 6 7 Secondary sheave assembly Transmission case cover Transmission case cover gasket Dowel pin Primary drive gear Washer Washer 1st wheel gear 1 1 2 1 1 1 1 5 - 60 Remarks Remove the parts in the order listed. Drain. Refer to “CHANGING THE FINAL TRANSMISSION OIL” in chapter 3.
ENG TRANSMISSION LS New 3 È É T. R. 16 Nm (1.6 m • kg, 11 ft • Ib) LS New Order 8 9 10 11 12 13 Job/Part Conical spring washer Drive axle Main axle Conical spring washer Primary driven gear Washer Q’ty 1 1 1 1 1 1 Remarks For installation, reverse the removal procedure.
TRANSMISSION ENG REMOVING THE TRANSMISSION 1. Remove: • transmission case cover NOTE: 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, removed them. EAS00425 CHECKING THE TRANSMISSION 1. Check: • transmission gears Blue discoloration/pitting/wear → Replace the defective gear(s). • transmission gear dogs Cracks/damage/rounded edges → Replace the defective gear(s). 2.
CRANKSHAFT ENG EAS00381 CRANKSHAFT CRANKSHAFT ASSEMBLY 3 4 E 5 T. 7 R. 22 Nm (2.2 m • kg, 16 ft • Ib) 4 New E New 2 8 T. R. 32 Nm (3.2 m • kg, 23 ft • Ib) 1 New 6 LS T. R. New 10 Nm (1.0 m • kg, 7.2 ft • Ib) T. R. 20 Nm (2.0 m • kg, 14 ft • Ib) T. R.
CRANKSHAFT ENG 3 4 E 5 T. 7 R. 22 Nm (2.2 m • kg, 16 ft • Ib) 4 New E New 2 8 T. R. 32 Nm (3.2 m • kg, 23 ft • Ib) 1 New 6 LS T. R. New 10 Nm (1.0 m • kg, 7.2 ft • Ib) T. R. 20 Nm (2.0 m • kg, 14 ft • Ib) T. R. Order 5 6 7 8 Job/Part Crankshaft assembly Timing chain Left crankcase Oil seal Q’ty 1 1 1 1 10 Nm (1.0 m • kg, 7.2 ft • Ib) Remarks For installation, reverse the removal procedure.
CRANKSHAFT 1 EAS00385 1 1 1 1 1 ENG DISASSEMBLING THE CRANKCASE 1. Remove: • crankcase bolts 1 NOTE: 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. 1 2. Remove: • right crankcase 1 NOTE: • Remove the right crankcase with the crankcase separating tool 2. • Make sure that the crankcase separating tool is centered over the crankshaft assembly.
CRANKSHAFT ENG 2. Remove: • crankshaft assembly 1 NOTE: • Remove the crankshaft assembly with the crankcase separating tool 2. • Make sure that the crankcase separating tool is centered over the crankshaft. CAUTION: Do not tap on the crankshaft. Crankcase separating tool 90890-01135 EAS00207 CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDE 1. Check: • timing chain Damage/stiffness → Replace the timing chain and camshaft sprocket as a set. 2.
CRANKSHAFT ENG EAS00394 CHECKING THE CRANKSHAFT AND CONNECTING ROD 1. Measure: • crankshaft runout Out of specification → Replace the crankshaft. NOTE: Turn the crankshaft slowly. Crankshaft runout 0.030 mm (0.0012 in) 2. Measure: • big end side clearance Out of specification → Replace the crankshaft. Big end side clearance 0.350 ~ 0.850 mm (0.0138 ~ 0.0335 in) 3. Measure: • crankshaft width Out of specification → Replace the crankshaft. Crankshaft width 59.75 ~ 59.80 mm (2.352 ~ 2.354 in) 4.
CRANKSHAFT ENG 5. Check: • crankshaft journal oil passage Obstruction → Blow out with compressed air. EAS00399 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. EAS00401 CHECKING THE BEARINGS 1.
CRANKSHAFT 2 ENG 3. Install: • crankshaft assembly 1 • left crankcase 2 6 1 5 3 4 NOTE: • Install the crankshaft assembly with the crankshaft installer pot 3, crankshaft installer bolt 4, adapter 5, and spacer 6. • After installing the crankcase, make sure that timing chain is securely meshed with the crankshaft sprocket.
CRANKSHAFT ENG EAS00418 ASSEMBLING THE CRANKCASE 1. Thoroughly clean all the gasket mating surfaces and crankcase mating surfaces. 2. Apply: • sealant (onto the crankcase mating surfaces) Yamaha bond No. 1215 90890-85505 NOTE: Do not allow any sealant to come into contact with the oil gallery. 1 2 3. Install: • water pump assembly • crankcase bolts T. R. NOTE: Tighten the crankcase bolts in stages and in a crisscross pattern. 1 2 1 10 Nm (1.0 m · kg, 7.2 ft · lb) 2 1 • M6 × 100 mm (3.
COOL CHAPTER 6 COOLING SYSTEM RADIATOR ...................................................................................................... 6-1 CHECKING THE RADIATOR.................................................................... 6-3 INSTALLING THE RADIATOR..................................................................6-3 THERMOSTAT ................................................................................................6-4 CHECKING THE THERMOSTAT.............................................
RADIATOR COOL EAS00454 COOLING SYSTEM RADIATOR T. 6 Nm (0.6 m • kg, 4.3 ft • Ib) R. 2 3 1 4 T. R. 30 Nm (3.0 m • kg, 22 ft • Ib) 13 9 10 14 (3) New 11 6 7 New T. R. 30 Nm (3.0 m • kg, 22 ft • Ib) T. R. 10 Nm (1.0 m • kg, 7.
RADIATOR COOL T. 6 Nm (0.6 m • kg, 4.3 ft • Ib) R. 2 3 1 4 T. R. 30 Nm (3.0 m • kg, 22 ft • Ib) 13 9 10 14 (3) New 11 6 7 New T. R. 30 Nm (3.0 m • kg, 22 ft • Ib) T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) (3) 8 12 Order 9 Job/Part Thermo switch connector (auto choke) 10 Thermo switch connector (radiator fan motor) Radiator Radiator fan motor Thermo switch (auto choke) Thermo switch (radiator fan motor) 11 12 13 14 5 Q’ty Remarks 2 Disconnect. White. 2 Disconnect. Green. 1 1 1 White.
RADIATOR COOL EAS00455 CHECKING THE RADIATOR 1. Check: • radiator fins Obstruction → Clean. Apply compressed air to the rear of the radiator. Damage → Repair or replace. NOTE: Straighten any flattened fins with a thin, flathead screwdriver. _ 2. • • • • • Check: radiator inlet hose radiator outlet hose radiator filler hose coolant reservoir hose radiator inlet/outlet pipe Cracks/damage → Replace. 3. Check: • radiator fan motor Damage → Replace. Malfunction → Check and repair.
THERMOSTAT COOL EAS00460 THERMOSTAT T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) 1 New 3 1 4 2 Order Job/Part Removing the thermostat Rear side cover (left and right) Q’ty Coolant 1 2 3 4 Thermostat inlet hose Thermostat outlet hose Thermostat cover Thermostat 1 1 1 1 Remarks Remove the parts in the order listed. Refer to “COVERS AND PANELS” in chapter 3. Drain. Refer to “CHANGING THE COOLANT” in chapter 3. Disconnect. For installation, reverse the removal procedure.
THERMOSTAT COOL EAS00462 CHECKING THE THERMOSTAT 1. Check: • thermostat 1 Does not open at 80.5 ~ 83.5 °C (176.9 ~ 182.3 °F) → Replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Suspend the thermostat in a container filled with water. b. Slowly heat the water. c. Place a thermometer in the water. d. While stirring the water, observe the thermostat and thermometer’s indicated temperature.
WATER PUMP COOL WATER PUMP T. R. 12 Nm (1.2 m • kg, 8.7 ft • Ib) 4 3 LS 2 New New 1 LS 9 6 LT New LS T. R. T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib) 7 8 New 10 5 New T. R. Order Job/Part Removing the water pump Q’ty 10 Nm (1.0 m • kg, 7.2 ft • Ib) Remarks Remove the parts in the order listed. NOTE: It is not necessary to remove the water pump unless the coolant level is extremely low or the coolant contains engine oil.
WATER PUMP COOL T. R. 12 Nm (1.2 m • kg, 8.7 ft • Ib) 4 3 LS 2 New New 1 LS 9 6 LT New LS T. R. T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib) 7 8 New 10 5 New T. R. Order 1 2 3 4 5 6 7 8 9 10 Job/Part Oil baffle plate Impeller shaft gear Dowel pin/Washer Shaft Water pump inlet hose Water pump outlet pipe Water pump housing cover Water pump housing gasket Water pump housing Impeller shaft Q’ty 1 1 1/1 1 1 1 1 1 1 1 10 Nm (1.0 m • kg, 7.
WATER PUMP COOL EAS00471 DISASSEMBLING THE WATER PUMP 1. Remove: • rubber damper holder 1 • rubber damper 2 (from the impeller with a thin, flathead screwdriver) NOTE: Do not scratch the impeller shaft. 2. Remove: • water pump seal 1 NOTE: Remove the water pump seal from the inside of the water pump housing. 1 3. Remove: • oil seal 1 • bearing 2 (with a thin, flathead screwdriver) 2 NOTE: Remove the oil seal and bearing from the outside of the water pump housing.
WATER PUMP COOL EAS00474 CHECKING THE WATER PUMP 1. Check: • water pump housing cover • water pump housing • impeller shaft Cracks/damage/wear → Replace. 2. Check: • bearing Rough movement → Replace. 3. Check: • impeller shaft gear Pitting/wear → Replace. 4. Check: • water pump inlet hose • water pump outlet pipe Cracks/damage/wear → Replace. EAS00475 ASSEMBLING THE WATER PUMP 1.
WATER PUMP COOL 2. Install: • water pump seal 1 New CAUTION: Never lubricate the water pump seal surface with oil or grease. NOTE: • Install the water pump seal with the mechanical seal installer 2 and middle driven shaft bearing driver 3. • Before installing the water pump seal, apply Yamaha bond No.1215 4 to the water pump housing 5. Mechanical seal installer 90890-04132 Middle driven shaft bearing driver 90890-04058 Yamaha bond No.1215 90890-85505 È Push down. 3.
WATER PUMP COOL 4. Measure: • impeller shaft tilt Out of specification → Repeat steps (3) and (4). CAUTION: Make sure the rubber damper and rubber damper holder are flush with the impeller. Impeller shaft tilt limit 0.15 mm (0.0059 in) 1 Straightedge 2 Impeller 5. Install: • impeller shaft 1 • circlip 2 New NOTE: After installation, check that the impeller shaft rotates smoothly. 6. Install: • water pump housing cover T. R. 10 Nm (1.0 m · kg, 7.2 ft · lb) INSTALLING THE WATER PUMP 1.
WATER PUMP COOL 2. Install: • water pump T. R. 10 Nm (1.0 m · kg, 7.2 ft · lb) 3. Fill: • cooling system (with the specified amount of the recommended coolant) Refer to “CHANGING THE COOLANT” in chapter 3. 4. Check: • cooling system Leaks → Repair or replace any faulty part.
CARB CHAPTER 7 CARBURETOR CARBURETOR................................................................................................7-1 DISASSEMBLING THE CARBURETOR................................................... 7-5 CHECKING THE CARBURETOR ............................................................. 7-5 ASSEMBLING THE CARBURETOR.........................................................7-6 INSTALLING THE CARBURETOR ...........................................................
CARBURETOR CARB CARBURETOR CARBURETOR T. R. 11 Nm (1.1 m • kg, 8.0 ft • Ib) T. R. T. R. 2 Nm (0.2 m • kg, 1.4 ft • Ib) 2 Nm (0.2 m • kg, 1.
CARBURETOR CARB T. R. 11 Nm (1.1 m • kg, 8.0 ft • Ib) T. R. T. R. 2 Nm (0.2 m • kg, 1.4 ft • Ib) 2 Nm (0.2 m • kg, 1.4 ft • Ib) 6 4 8 5 7 3 2 1 Order 8 Job/Part Carburetor Q’ty Remarks 1 Refer to “INSTALLING THE CARBURETOR” For installation, reverse the removal procedure.
CARBURETOR CARB EAS00483 (4) 4 5 7 6 8 New 1 New E F D C B 0 2 3 New New A G New 9 (4) H New Order 1 2 3 4 5 6 7 8 9 0 A B C Job/Part Disassembling the carburetor Coolant hose joint Auto choke unit Pilot screw Vacuum chamber cover Piston valve spring Piston valve Jet needle Coasting enricher assembly Float chamber Float pin Float Needle valve Main jet Q’ty 1 1 1 1 1 1 1 1 1 1 1 1 1 7-3 Remarks Remove the parts in the order listed.
CARBURETOR (4) CARB 4 5 7 6 8 New New E F D C 1 B 0 2 3 New New A G New 9 (4) H New Order D E F G H Job/Part Needle jet holder Needle jet Pilot jet Accelerator pump assembly Fuel drain screw Q’ty 1 1 1 1 1 Remarks For assembly, reverse the disassembly procedure.
CARBURETOR 1 CARB DISASSEMBLING THE CARBURETOR 1. Remove: • float pin 1 • needle valve 2 • float 3 2 3 NOTE: Remove the float pin in the direction of the arrow. EAS00485 CHECKING THE CARBURETOR 1. Check: • carburetor body • float chamber • jet housing Cracks/damage → Replace. 2. Check: • fuel passages Obstruction → Clean. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Wash the carburetor in a petroleum-based solvent. Do not use any caustic carburetor cleaning solution. b.
CARBURETOR 1 8. • • • • • • Check: jet needle 1 main jet 2 needle jet holder 3 pilot jet 4 pilot screw 5 needle jet 6 Bends/damage/wear → Replace. Obstruction → Clean. Blow out the jets with compressed air. 9. Check: • piston valve movement Insert the piston valve into the carburetor body and move it up and down. Tightness → Replace the piston valve. 10.Check: • fuel hoses Cracks/damage/wear → Replace. Obstruction → Clean. Blow out the hoses with compressed air.
CARBURETOR CARB b. Measure the distance from the front mating surface of the float chamber (gasket removed) to the top of the float. NOTE: The float arm should be resting on the needle valve, but not compressing it. _ c. If the float height is not within the specification, check the needle valve. d. If it is worn, replace it. e. If it is fine, adjust the float height by bending the float tang 1 on the float. f. Recheck the float height. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2.
CARBURETOR CARB 2. Adjust: • engine idling speed Engine idling speed 1,550 ~ 1,650 r/min Refer to “ADJUSTING THE IDLING SPEED” in chapter 3. 3. Adjust: • throttle cable free play ENGINE Throttle cable free play (at the flange of the throttle grip) 4.0 ~ 6.0 mm (0.16 ~ 0.24 in) Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY” in chapter 3. EAS00503 CHECKING THE AUTO CHOKE UNIT NOTE: When checking the auto choke unit, the ambient temperature must be lower than 45 °C (113 °F). 1. Remove: • carburetor 2.
CARBURETOR CARB 3. Check: • auto choke unit (with battery) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the auto choke unit lead to a 12.0 V battery for five minutes. Positive battery lead → yellow 1 Negative battery lead → green/black 2 b. Connect a 3.3 mm (0.13 in) hose 4 to the starter air passage 3 and blow into the hose. Starter plunger opens Replace the auto choke unit. Starter plunger closes Auto choke unit is OK.
AIR INDUCTION SYSTEM CARB AIR INDUCTION SYSTEM 2 1 T. R. 5 3 10 Nm (1.0 m • kg, 7.2 ft • Ib) 6 4 1 2 3 4 5 6 R. R. Order T. T. 10 Nm (1.0 m • kg, 7.2 ft • Ib) New 12 Nm (1.2 m • kg, 8.
AIR INDUCTION SYSTEM CARB EAS00510 CHECKING THE AIR INDUCTION SYSTEM 1. Check: • hoses Loose connection → Connect properly. Cracks/damage → Replace. • pipe Cracks/damage → Replace. 2. Check: • air cut-off valve Cracks/damage → Replace. 3. Check: • air cut-off valve operation Does not operate → Replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a.
FUEL TANK CARB FUEL TANK 5 4 3 1 2 6 9 10 New LS T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 8 7 T. R. Order 1 2 3 4 5 6 7 8 9 Job/Part Removing the fuel tank Storage box/under cover Fuel pump coupler Fuel hose holder Fuel hose (fuel tank to fuel pump) Fuel hose (fuel pump to carburetor) Fuel pump Fuel sender coupler Fuel tank lower cover Fuel tank Fuel pipe Q’ty 1 1 1 1 1 1 1 1 1 7 - 12 7 Nm (0.7 m • kg, 5.1 ft • Ib) Remarks Remove the parts in the order listed.
FUEL TANK 5 CARB 4 3 1 2 6 9 10 New LS T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 8 7 T. R. Order 10 Job/Part Fuel sender 7 Nm (0.7 m • kg, 5.1 ft • Ib) Q’ty Remarks 1 Refer to “REMOVING THE FUEL SENDER” and “INSTALLING THE FUEL SENDER”. For installation, reverse the removal procedure.
FUEL TANK 2 1 CARB REMOVING THE FUEL SENDER 1. Remove: • fuel sender 1 NOTE: Remove the fuel sender using the fuel sender removal tool 2. Fuel sender removal tool 90890-11098 EAS00504 CHECKING THE FUEL PUMP 1. Check: • fuel pump 1 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the fuel hose (fuel pump to carburetor fuel hose) 2 from the carburetor. b. Place a container under the end of the fuel hose. c. Turn the main switch to “ON” and check if fuel flows from the fuel hose 2. Fuel flows.
FUEL TANK 1 a CARB INSTALLING THE FUEL SENDER 1. Install: • fuel sender 1 NOTE: • Install the fuel sender using the fuel sender removal tool. • Lubricate the gasket with lithium-soap-based grease. • Position the fuel sender coupler a as shown in the illustration.
ELEC CHAPTER 8 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS........................................................................ 8-1 CHECKING SWITCH CONTINUITY................................................................8-2 CHECKING THE SWITCHES..........................................................................8-3 CHECKING THE BULBS AND BULB SOCKETS .......................................... 8-4 TYPES OF BULBS ....................................................................................
ELEC FUEL PUMP SYSTEM...................................................................................8-47 CIRCUIT DIAGRAM ................................................................................ 8-47 FUEL PUMP CIRCUIT OPERATION ......................................................8-48 TROUBLESHOOTING ............................................................................8-49 AUTO CHOKE SYSTEM ...............................................................................
ELECTRICAL COMPONENTS ELEC – + EAS07290 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS 1 CDI unit 2 Turn signal relay 3 immobilizer antenna 4 Main switch 5 Air temperature sensor 6 Battery 7 Starter relay 8 Main fuse 9 Coolant temperature sensor 0 Pickup coil/stator assembly A Spark plug cap B Ignition coil C Sidestand switch D Radiator fan motor E Horn F Rectifier/regulator G Starting circuit cut-off relay H Fuel pump relay I Radiator fan motor relay J Headlight relay K Wire harness 2 5 4 1 6 3 7 J 8
CHECKING SWITCH CONTINUITY ELEC – + EAS00730 CHECKING SWITCH CONTINUITY Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. CAUTION: _ Never insert the tester probes into the coupler terminal slots a. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.
CHECKING THE SWITCHES – ELEC + EAS00731 CHECKING THE SWITCHES Check each switch for damage or wear, proper connections, and also for continuity between the terminals. Refer to “CHECKING SWITCH CONTINUITY”. Damage/wear → Repair or replace. Improperly connected → Properly connect. Incorrect continuity reading → Replace the switch.
CHECKING THE BULBS AND BULB SOCKETS ELEC – + EAS00733 CHECKING THE BULBS AND BULB SOCKETS NOTE: Do not check any of the lights that use LEDs. Check each bulb and bulb socket for damage or wear, proper connections, and also for continuity 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.
CHECKING THE BULBS AND BULB SOCKETS ELEC – + CHECKING THE CONDITION OF THE BULBS The following procedure applies to all of the bulbs. 1. Remove: • bulb 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 terminal in the coupler.
CHECKING THE BULBS AND BULB SOCKETS ELEC – + 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. Pocket tester 90890-03112 NOTE: Check each bulb socket for continuity in the same manner as described in the bulb section; however, note the following. _ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Install a good bulb into the bulb socket. b.
Br W/L W/R 8-7 Gy Gy/B Gy/R L B R Gy B W/R W W/L W W R Br R Br/L ~ q R/Y B 1 R/Y R 2 R/L W W W G/L OFF ON 6 B R/L Gy B B Br/G Br/G Gy/R Gy/B Br/G Br/G Gy/B Gy/R G/L B Dg Y u s Br/L Br/L R Br/L B B R 5 4 G/R B Gy/B Gy Br R/L Sb O/W Br/G Br/G Ch Gy/R Br/L R R/L R/G R W W B 3 W 2 Pickup coil 4 CDI unit fuse 6 Main switch r 7 Ignition | fuse A Ground lead t B Battery C Main fuse G Sidestand switch S CDI unit T Ignition coil U Spark plug } R
IGNITION SYSTEM EAS00736 ELEC – + EAS00739 TROUBLESHOOTING 2. Battery The ignition system fails to operate (no spark or intermittent spark). • Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: 1. main, ignition, and CDI unit fuses 2. battery 3. spark plug 4. ignition spark gap 5. spark plug cap resistance 6. ignition coil resistance 7. pickup coil resistance 8. main switch 9. sidestand switch 10.
IGNITION SYSTEM EAS00742 ELEC – + EAS00744 4. Ignition spark gap 5. Spark plug cap resistance • Disconnect the spark plug cap from the spark plug. • Connect the ignition checker 1 as shown. • Remove the spark plug cap from the spark plug lead. • Connect the pocket tester (“Ω × 1k” range) to the spark plug cap as shown. • Measure the spark plug cap resistance. 2 Spark plug cap • Set the main switch to “ON”. • Measure the ignition spark gap a.
ELEC IGNITION SYSTEM EAS00746 – + EAS00748 6. Ignition coil resistance 7. Pickup coil resistance • Disconnect the ignition coil connectors from the ignition coil terminals. • Connect the pocket tester (Ω × 1) to the ignition coil as shown. Positive tester probe → orange Negative tester probe → black • Disconnect the pickup coil coupler from the wire harness. • Connect the pocket tester (Ω × 100) to the pickup coil terminal as shown.
IGNITION SYSTEM EAS00752 9. Sidestand switch • Check the sidestand switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the sidestand switch OK? YES NO Replace the stand switch. side- EAS00754 10.Wiring • Check the entire ignition system wiring. Refer to “CIRCUIT DIAGRAM”. • Is the ignition system wiring properly connected and without defects? YES Replace the CDI unit. NO Properly connect or repair the ignition system wiring.
Br W/L W/R 8 - 12 Gy B B Br/G Br/G Gy/R Gy/B } R W | Gy Br/G Br/G Gy/B Gy/R Gy/B Gy/R L B R W/R W W/L W W R/L W W W B Br/L B Br/L Br/L R Br/L B R 5 4 G/R B Gy/B Gy Br R/L Sb O/W Br/G Br/G Ch Gy/R t u r s G/L OFF ON R R/L R/G W W W R/L R 3 B 6 G/L B Dg Y R Br R Br/L ~ q B Gy R/Y B 1 2 R/Y R å R R WW Br R/Y R/W R/B Sb A B G/R yz{ vwx 0 9 8 7 R R p Br B O/W B B Dg Ch Y B L/Y Br G B Y G B G L Y B G G B B
ELECTRIC STARTING SYSTEM ELEC – + EAS00756 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the main switch is set to “ON” (switch is closed), the starter motor can only operate if the following conditions are met: • A brake lever is pulled to the handlebar (the brake light switch is closed) and the sidestand is up (the sidestand switch is closed).
ELECTRIC STARTING SYSTEM EAS00757 ELEC – + EAS00739 TROUBLESHOOTING 2. Battery The starter motor fails to turn. • Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: 1. main, ignition, and signaling system fuses 2. battery 3. starter motor 4. starting circuit cut-off relay 5. starter relay 6. main switch 7. brake light switch (front and rear) 8. sidestand switch 9. start switch 10.
ELECTRIC STARTING SYSTEM EAS00759 ELEC – + EAS00761 5. Starter relay 4. Starting circuit cut-off relay • Remove the starter relay. • Connect the pocket tester (Ω × 1) and battery (12 V) to the starter relay terminal as shown. • Remove the starting circuit cut-off relay. • Connect the pocket tester (Ω × 1) and battery (12 V) to the starting circuit cut-off relay terminals as shown.
ELECTRIC STARTING SYSTEM EAS00751 ELEC – + EAS00766 10.Wiring 7. Brake light switch (front and rear) • Check the entire starting system wiring. Refer to “CIRCUIT DIAGRAM”. • Is the starting system wiring properly connected and without defects? • Check the brake light switches for continuity. Refer to “CHECKING THE SWITCHES”. • Is each brake light switch OK? NO YES YES Replace the brake light switch(es). The starting system circuit is OK. EAS00752 8.
ELEC ELECTRIC STARTING SYSTEM – + STARTER MOTOR T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 1 T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) 2 A 3 B 7 C 8 0 9 New 3 4 6 1 New LS 5 New New 2 New New T. R. Order 1 2 3 Job/Part Removing the starter motor Air filter case assembly Starter motor lead Ground lead Starter motor Q’ty 1 1 1 5 Nm (0.5 m • kg, 3.6 ft • Ib) Remarks Remove the parts in the order listed. Refer to “AIR FILTER CASE” in chapter 3. Disconnect. Disconnect.
ELEC ELECTRIC STARTING SYSTEM – + T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 1 T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) 2 A 3 B 7 C 8 0 9 New 3 4 6 1 New LS 5 New New 2 New New T. R. Order 1 2 3 4 5 6 7 8 9 0 A B C Job/Part Disassembling the starter motor Starter motor front cover O-ring Shim Lock washer Oil seal Bearing Starter motor yoke Armature assembly O-ring Shim Brush holder set Starter motor rear cover Bushing Q’ty 1 1 * 1 1 1 1 1 1 * 1 1 1 5 Nm (0.5 m • kg, 3.
ELECTRIC STARTING SYSTEM ELEC – + EAS00770 CHECKING THE STARTER MOTOR 1. Check: • commutator Dirt → Clean with 600 grit sandpaper. 2. Measure: • commutator diameter a Out of specification → Replace the starter motor. Commutator wear limit 27 mm (1.06 in) 3. Measure: • mica undercut a Out of specification → Scrape the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commutator. Mica undercut 0.7 mm (0.
ELECTRIC STARTING SYSTEM ELEC – + 5. Measure: • brush length a Out of specification → Replace the brushes as a set. Brush length wear limit 4.0 mm (0.16 in) 6. Measure: • brush spring force Out of specification → Replace the brush springs as a set. Brush spring force 7.65 ~ 10.01 N (780 ~ 1,021 gf, 27.5 ~ 36.0 oz) 7. Check: • gear teeth Damage/wear → Replace the gear. 8. • • • Check: bearing 1 oil seal 2 bushing 3 Damage/wear → Replace the defective part(s). EAS00772 ASSEMBLING THE STARTER MOTOR 1.
R Br W W/L W/R R/Y B B 1 2 R/Y R 1 AC magneto 3 Rectifier/regulator A Ground lead B Battery C Main fuse å R R WW 8 - 21 R Br R Br/L ~ W W/L W W W/R W W W OFF ON 6 B R/L W W W Br/L R R/L R/G R B 3 Br/L R Br/L B 5 4 R 9 8 7 R R R/Y R/W R/B A B B B G B B L/Y B (BLUE) (BLUE) R R L/W G/B L/W G/B L/W Br/W L/W W/Y B B W/Y L/W W/Y B L/W L/W G/Y L B H B/L B N (BLACK) (BLACK) L/Y R/B ELEC B L/W Br/W G/B F M L/W G/B (BLACK) L
CHARGING SYSTEM EAS00774 ELEC – + EAS00739 TROUBLESHOOTING 2. Battery The battery is not being charged. • Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: 1. main fuse 2. battery 3. charging voltage 4. stator coil resistance 5. wiring connections (of the entire charging system) Minimum open-circuit voltage 12.8 V or more at 20 °C (68 °F) • Is the battery OK? YES NOTE: • Before troubleshooting, remove the following part(s): 1. upper panel 2.
CHARGING SYSTEM EAS00775 ELEC – + EAS00776 3. Charging voltage 4. Stator coil resistance • Connect the pocket tester (DC 20 V) to the battery as shown. Positive tester probe → positive battery terminal Negative tester probe → negative battery terminal • Disconnect the stator coil coupler from the wire harness. • Connect the pocket tester (Ω × 1) to the stator coil as shown.
Br W/L W/R 8 - 24 Gy B B Br/G Br/G Gy/R Gy/B } R W | Gy/R R Br/G Br/G Gy/B Gy/R Gy Gy/B L B Gy B W/R W W/L W W R/L W W W B R/L Br/L B Br/L Br/L R Br/L B R 5 4 G/R B Gy/B Gy Br R/L Sb O/W Br/G Br/G Ch Gy/R t u r s G/L OFF ON R R/L R/G R W W B 3 W 6 G/L B Dg Y R Br R Br/L ~ q R/Y B 1 2 R/Y R å R R WW Br R/Y R/W R/B Sb A B G/R yz{ vwx 0 9 8 7 R R p Br B O/W B B Dg Ch Y B L/Y Br G B Y G B G L Y B G G B B
LIGHTING SYSTEM EAS00781 ELEC – + EAS00739 TROUBLESHOOTING 2. Battery Any of the following fail to light: headlights, high beam indicator light, taillight, license plate light, auxiliary lights or meter light. • 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) Check: 1. main, headlight, signaling system, and CDI unit fuses 2. battery 3. main switch 4. dimmer/pass switch 5. sidestand switch 6.
LIGHTING SYSTEM EAS00752 ELEC – + EAS00787 5. Sidestand switch 7. Wiring • Check the sidestand switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the sidestand switch OK? YES • Check the entire lighting system wiring. Refer to “CIRCUIT DIAGRAM”. • Is the lighting system wiring properly connected and without defects? NO YES Replace the stand switch. side- 6. Headlight relay • Remove the headlight relay.
ELEC LIGHTING SYSTEM EAS00788 CHECKING THE LIGHTING SYSTEM 1. The headlights and the high beam indicator light fail to come on. – + High beam indicator light Positive tester probe → yellow 4 Negative tester probe → black 5 Meter assembly coupler 1. Headlight bulb and socket • Check the headlight bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS”.
ELEC LIGHTING SYSTEM EAS00789 – + 2. Voltage 2. The meter light fails to come on. • Connect the pocket tester (DC 20 V) to the tail/brake light assembly coupler (wire harness side) as shown. 1. Voltage • Connect the pocket tester (DC 20 V) to the meter assembly coupler as shown.
ELEC LIGHTING SYSTEM – EAS00791 EAS00792 4. The auxiliary lights fail to come on. 5. The license plate light fails to come on. 1. Auxiliary light bulb and socket 1. License plate light bulb and socket • Check the license plate light bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS”. • Are the license plate light bulb and socket OK? • Check the auxiliary light bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS”.
Br W/L W/R 8 - 30 Gy B B Br/G Br/G Gy/R Gy/B } R W | Gy/R R Br/G Br/G Gy/B Gy/R Gy Gy/B L B Gy B W/R W W/L W W R/L W W W B R/L Br/L B Br/L Br/L R Br/L B R 5 4 G/R B Gy/B Gy Br R/L Sb O/W Br/G Br/G Ch Gy/R t u r s G/L OFF ON R R/L R/G R W W B 3 W 6 G/L B Dg Y R Br R Br/L ~ q R/Y B 1 2 R/Y R å R R WW Br R/Y R/W R/B Sb A B G/R yz{ vwx 0 9 8 7 R R p Br B O/W B B Dg Ch Y B L/Y Br G B Y G B G L Y B G G B B
SIGNALING SYSTEM 5 Backup fuse (meter assembly) 6 Main switch 0 Signaling system fuse A Ground lead B Battery C Main fuse K Fuel sender N Hazard switch Z Rear brake light switch [ Front brake light switch \ Turn signal/hazard relay ] Horn c Horn switch d Turn signal switch f Rear turn signal light (right) g Tail/brake light i Rear turn signal light (left) j Front turn signal light (right) k Front turn signal light (left) p Coolant temperature sensor r Coolant temperature gauge s Fuel level gauge t Speedomet
SIGNALING SYSTEM EAS00794 ELEC – + EAS00739 TROUBLESHOOTING 2. Battery • Any of the following fail to light: turn signal light, brake light or an indicator light. • The horn fails to sound. • The fuel level gauge fails to operate. • The speedometer fails operate. • The ambient temperature display fails to operate. • The coolant temperature gauge (meter assembly) fails to indicate. • Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3.
SIGNALING SYSTEM EAS00796 ELEC – 3. Horn CHECKING THE SIGNALING SYSTEM 1. The horn fails to sound. • Disconnect the pink connector at the horn terminal. • Connect a jumper lead 1 to the horn terminal and ground the jumper lead. • Set the main switch to “ON”. • Does the horn sound? 1. Horn switch • Check the horn switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the horn switch OK? NO YES Replace switch. the horn 2.
SIGNALING SYSTEM EAS00797 + • Connect the pocket tester (DC 20 V) to the tail/brake light assembly coupler (wire harness side) as shown. 1. Tail/brake light bulbs and sockets • Check the tail/brake light bulbs and sockets for continuity. • Are the tail/brake light bulbs and sockets OK? NO È Tail/brake light (left) É Tail/brake light (right) Positive tester probe → green/yellow 1 Negative tester probe → black 2 È É Replace the tail/ brake light bulb, socket or both. 2.
SIGNALING SYSTEM EAS00799 3. The turn signal light, turn signal indicator light or both fail to blink. YES – + 4. Voltage • Connect the pocket tester (DC 20 V) to the turn signal/hazard relay coupler as shown. 1. Turn signal light bulbs and sockets • Check the turn signal light bulbs and sockets for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS”.
SIGNALING SYSTEM 5. Voltage • Connect the pocket tester (DC 20 V) to the turn signal/hazard relay coupler as shown. Turn signal function Left turn signal light Positive tester probe → chocolate 1 Negative tester probe → ground Right turn signal light Positive tester probe → dark green 2 Negative tester probe → ground ELEC – + Hazard function • Set the main switch to “ON”. • Set the hazard switch to “ ”. • Measure the voltage (DC 12 V) on chocolate 1 at the turn signal/hazard relay coupler.
SIGNALING SYSTEM 6. Voltage È Front turn signal light (left and right) É Tail/brake light (left and right) Ê Meter assembly Right turn signal light Positive tester probe → dark green 2 Negative tester probe → ground È 1 Br Ch B B YES Replace the meter assembly. 2 Dg Dg B B É 1 B G/Y B G/Y W Br W Br 2 Ch Br Dg Br B G/Y B G/Y Ê 2 – + • Set the main switch to “ON”. • Set the turn signal switch to “ ” or “ ”.
SIGNALING SYSTEM EAS00806 ELEC – + 2. Voltage 4. The speedometer fails to operate. • Connect the pocket tester (DC 20 V) to the meter assembly coupler as shown. 1. Speed sensor • Connect the pocket tester (DC 20 V) to the speed sensor coupler (wire harness side) as shown.
SIGNALING SYSTEM EAS00804 ELEC – + 2. Voltage 5. The fuel level gauge fails to operate. • Connect the pocket tester (DC 20 V) to the meter assembly coupler as shown. 1. Fuel sender • Remove the fuel sender from the fuel tank. • Connect the pocket tester to the fuel sender coupler as shown.
SIGNALING SYSTEM EAS00804 ELEC – + 2. Voltage 6. The ambient temperature display fails to operate. • Connect the pocket tester (DC 20 V) to the meter assembly coupler as shown. 1. Air temperature sensor • Connect the pocket tester (Ω × 1k) to the air temperature sensor coupler as shown.
SIGNALING SYSTEM ELEC – + 7. Coolant temperature gauge fails to operate. EAS00812 1. Coolant temperature sensor • Remove the coolant temperature sensor from the cylinder head. • Connect the pocket tester (Ω × 10k) to the coolant temperature sensor 1 as shown. • Immerse the coolant temperature sensor in a container filled with coolant 2. NOTE: Make sure the coolant temperature sensor terminals do not get wet. _ • Place a thermometer 3 in the coolant.
SIGNALING SYSTEM 2. Voltage • Connect the pocket tester (DC 20 V) to the meter assembly coupler as shown. Positive tester probe → brown 1 Negative tester probe → black 2 G/L B Dg Y Sb O/W Br/G Br/G Ch Gy/R G/R B Gy/B Gy Br R/L 2 1 • Set the main switch to “ON”. • Measure the voltage (DC 12 V) of brown 1 and black 2 at the meter assembly coupler. • Is the voltage within specification? YES Replace the meter assembly.
Br W/L W/R 8 - 43 Gy B B Br/G Br/G Gy/R Gy/B } R W | Gy/R R Br/G Br/G Gy/B Gy/R Gy Gy/B L B Gy B W/R W W/L W W R/L W W W B R/L Br/L B Br/L Br/L R Br/L B R 5 4 G/R B Gy/B Gy Br R/L Sb O/W Br/G Br/G Ch Gy/R t u r s G/L OFF ON R R/L R/G R W W B 3 W 6 G/L B Dg Y R Br R Br/L ~ q R/Y B 1 2 R/Y R å R R WW Br R/Y R/W R/B Sb A B G/R yz{ vwx 0 9 8 7 R R p Br B O/W B B Dg Ch Y B L/Y Br G B Y G B G L Y B G G B B
COOLING SYSTEM EAS00808 ELEC – + EAS00739 TROUBLESHOOTING 2. Battery The radiator fan motor fails to turn. • Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: 1. main, ignition, and radiator fan motor fuses 2. battery 3. main switch 4. radiator fan motor 5. radiator fan motor relay 6. thermo switch (radiator fan motor) 7. wiring connections (the entire cooling system) Minimum open-circuit voltage 12.
COOLING SYSTEM EAS00809 ELEC – + 5. Radiator fan motor relay 4. Radiator fan motor • Disconnect the radiator fan motor coupler from the wire harness. • Connect the battery (DC 12 V) as shown. Positive battery lead → red 1 Negative battery lead → black 2 • Remove the radiator fan motor relay. • Connect the pocket tester (Ω × 1) and battery (12 V) to the radiator fan motor terminal as shown. • Check the radiator fan motor relay of continuity.
COOLING SYSTEM ELEC – + EAS00811 WARNING 6. Thermo switch (radiator fan motor) • Remove the thermo switch (radiator fan motor) from the radiator. • Connect the pocket tester (Ω × 1) to the thermo switch 1 as shown. • Immerse the thermo switch in a container filled with coolant 2. • Handle the thermo switch with special care. • Never subject the thermo switch to strong shocks. If the thermo switch is dropped, replace it. Test step Coolant temperature Thermo switch R.
Br W/L W/R 8 - 47 Gy Gy/R R Gy/R Gy Gy/B L B Gy B W/R W W/L W W R/L W W W B R/L G/L OFF ON B B Br/G Br/G Br/G Br/G Gy/B u s Br/L Br/L R Br/L B B R 5 4 G/R B Gy/B Gy Br R/L Sb O/W Br/G Br/G Ch Gy/R Br/L R R/L R/G R W W B 3 W 6 G/L B Dg Y R Br R Br/L ~ q R/Y B 1 R/Y R 2 4 CDI unit fuse r 6 Main|switch 7 Ignition fuse t A Ground lead B Battery C Main fuse I Fuel pump relay J Fuel pump S CDI unit Gy/R Gy/B } R W å R R WW Br R/Y R/W R/
FUEL PUMP SYSTEM ELEC EB808010 FUEL PUMP CIRCUIT OPERATION The fuel pump circuit consists of the fuel pump relay, fuel pump, and CDI unit. The CDI unit includes the control unit for the fuel pump.
FUEL PUMP SYSTEM EAS00816 ELEC – + EAS00739 TROUBLESHOOTING 2. Battery The fuel pump fails to operate. • Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: 1. main, ignition, and CDI unit fuses 2. battery 3. main switch 4. fuel pump relay 5. fuel pump operation 6. wiring connections (the entire fuel system) Minimum open-circuit voltage 12.
FUEL PUMP SYSTEM EAS00759 ELEC – + EAS00817 4. Fuel pump relay 5. Fuel pump operation • Remove the fuel pump relay. • Connect the pocket tester (Ω × 1) and battery (12 V) to the fuel pump relay terminals as shown. • Check the fuel pump relay for continuity. • Check the fuel pump operation. Refer to “CHECKING THE FUEL PUMP” in chapter 7. • Is the fuel pump OK? NO YES Positive battery terminal → red/black 1 Negative battery terminal → blue/green 2 Replace pump.
Br W/L W/R 8 - 51 Gy Gy/R R Gy/B Gy/R Gy Gy/B L B Gy B W/R W W/L W W R/L W W W B R/L Br/L Br/L Br/L R Br/L B B R 5 4 Sb O/W Br/G Br/G Ch Gy/R G/L OFF ON R R/L R/G R W W B 3 W 6 G/L B Dg Y R Br R Br/L ~ q R/Y B 1 R/Y R 2 Br R/Y R/W R/B Sb A vwx 0 9 8 7 R R Br B B B Br/G Br/G Br/G Br/G G/R B Gy/B Gy Br R/L B G/R r s 6 Main|switch 7 Ignition fuse t u yz{ A Ground lead B Battery C Main fuse p Q Auto choke unit R Thermo switch (auto
AUTO CHOKE SYSTEM EAS00821 ELEC – + EAS00739 TROUBLESHOOTING 2. Battery The auto choke system fails to operate. • Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: 1. main and ignition fuses 2. battery 3. main switch 4. thermo switch (auto choke) 5. auto choke unit 6. CDI unit 7. wiring connections (of the entire carburetor heating system) Minimum open-circuit voltage 12.
AUTO CHOKE SYSTEM 4. Thermo switch (auto choke) È The thermo switch circuit is open and the auto choke is off. É The thermo switch circuit is closed and the auto choke is on. Continuity 1 Less than 47 ± 3 °C (116.6 ± 5.4 °F) NO 2 More than 47 ± 3 °C (116.6 ± 5.4 °F) YES 3 More than 42 ± 3 °C (107.6 ± 5.4 °F) YES Less than 42 ± 3 °C (107.6 ± 5.4 °F) NO 4 Thermo switch (auto choke) 30 Nm (3.0 m · kg, 22 ft · lb) R. • Place a thermometer 3 in the coolant.
AUTO CHOKE SYSTEM EAS00825 5. Auto choke unit • Remove the auto choke unit coupler from the wire harness. • Connect the pocket tester (Ω × 10) to the auto choke unit coupler as shown. Tester positive probe → green/black 1 Tester negative probe → yellow 2 • Measure the auto choke unit resistance. Auto choke resistance 30 Ω at 20 °C (68 °F) • Is the auto choke OK? YES NO Replace the choke unit. auto EAS00826 6. Wiring • Check the entire auto choke system wiring. Refer to “CIRCUIT DIAGRAM”.
IMMOBILIZER SYSTEM ELEC – IMMOBILIZER SYSTEM SYSTEM DIAGRAM 2 3 1 1 CDI unit 2 Main switch and immobilizer antenna 3 Immobilizer system indicator light Main switch Br/L R..... Br/L . . . G/L . . . G/W . . . R/B . . . R/G . . . R/L. . . .
Br W/L W/R 8 - 56 Gy B B Br/G Br/G Gy/R Gy/B } R W | Gy Br/G Br/G Gy/B Gy/R Gy/B Gy/R B R L W/R W W/L W W R/L W W W B R/L Br/L B Br/L Br/L R Br/L B R 5 4 G/R B Gy/B Gy Br R/L Sb O/W Br/G Br/G Ch Gy/R t u r s G/L OFF ON R R/L R/G R W W B 3 W 6 G/L B Dg Y R Br R Br/L ~ q B Gy R/Y B 1 2 R/Y R å R R WW Br R/Y R/W R/B Sb A B G/R yz{ vwx 0 9 8 7 R R p Br B O/W B B Dg Ch Y B L/Y Br G B Y G B G L Y B G G B B
IMMOBILIZER SYSTEM ELEC – + GENERAL INFORMATION This vehicle is equipped with an immobilizer system to help prevent theft by registering codes in standard keys.
IMMOBILIZER SYSTEM ELEC – + KEY CODE REGISTRATION Code registration of the code re-registering key or standard keys may be required when CDI is replaced or a standard key is lost. NOTE: Each standard key is registered during production, therefore, registering the keys at purchase is not necessary. Code re-registering key registration: When the CDI unit is replaced, the code re-registering key must be re-registered. To register a code re-registering key: 1.
IMMOBILIZER SYSTEM ELEC – + 2. Using the code re-registering key, turn the main switch to “ON”, then to “OFF”, and then remove the key within 3 seconds. NOTE: All existing standard key codes will be erased from the memory when the key registration mode is activated. When the key registration mode is activated, the immobilizer system indicator light is ON for 2 seconds, then will be OFF. 3.
IMMOBILIZER SYSTEM ELEC – + Voiding a standard key code: If a registered standard key has been lost and you want to disable its use, register a new standard key or re-register the other standard key. For registration of a standard key, refer to “Standard key registration:”. Standard key registration erases the stored standard key codes from memory, therefore, the lost standard key is disabled. Main switch Standard key code voiding method ON less than 3.0 s less than 10.0 s less than 3.
IMMOBILIZER SYSTEM ELEC – + SELF-DIAGNOSIS MALFUNCTION CODES When a system malfunction occurs, the malfunction code number is signaled by the immobilizer system indicator light flash patterns. Malfunction code Immobilizer system condition Symptom Engine cannot start. CDI unit is not receving any valid transponder code. Malfunctioning part Action Key Key malfunction Replace the standard key. CDI unit CDI unit malfunction Replace the CDI unit.
IMMOBILIZER SYSTEM EAS00794 ELEC – + EAS00739 TROUBLESHOOTING 2. Battery When the main switch is turned “ON”, the immobilizer system indicator light does not come on or flash. • Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: 1. main, ignition, CDI unit, and backup fuses 2. battery 3. main switch 4. wiring connections (of the entire immobilizer system) Minimum open-circuit voltage 12.
IMMOBILIZER SYSTEM EAS00788 CHECKING THE IMMOBILIZER SYSTEM 1. The immobilizer system indicator light does not come on. 1. Voltage • Connect the pocket tester (DC 20 V) to the meter assembly coupler as shown. G/L B Dg Y Sb O/W Br/G Br/G Ch Gy/R G/R B Gy/B Gy Br R/L 2 1 Positive tester probe → red/blue 1 Negative tester probe → black 2 • Turn the main switch to “ON”. • Measure the voltage (DC 12 V) at the meter assembly coupler (wire harness side).
IMMOBILIZER SYSTEM ELEC – + 2. When the main switch is turned to “ON”, the immobilizer system indicator light flashes. • Check if a metal object or other immobilizer system keys are placed near the immobilizer antenna. If so, remove the objects or keys, and then check the condition again. Turn the main switch to “ON” with another registered standard key and check the immobilizer system indicator light. The indicator light goes on for about 2 seconds, then goes off.
IMMOBILIZER SYSTEM ELEC – + PART REPLACEMENT KEY REGISTRATION REQUIREMENTS Parts to be replaced Main switch immobilizer antenna Standard key Standard key is lost All keys have been lost (including code re-registering key) CDI unit Required key registration Accessory lock*2 and key New standard key Code re-registering key and standard keys *1 CDI unit is defective Code re-registering key and standard keys immobilizer antenna is defective Code re-registering key and standard keys Main switch
TRBL SHTG CHAPTER 9 TROUBLESHOOTING STARTING FAILURE/HARD STARTING .......................................................9-1 ENGINE..................................................................................................... 9-1 FUEL SYSTEM.......................................................................................... 9-1 ELECTRICAL SYSTEMS ..........................................................................9-2 INCORRECT ENGINE IDLING SPEED..........................................
TRBL SHTG FAULTY LIGHTING OR SIGNALING SYSTEM..............................................9-5 HEADLIGHT DOES NOT COME ON ........................................................9-5 HEADLIGHT BULB BURNT OUT.............................................................. 9-5 TAIL/BRAKE LIGHT DOES NOT COME ON ............................................9-5 TAIL/BRAKE LIGHT BULB BURNT OUT.................................................. 9-5 TURN SIGNAL DOES NOT COME ON ..........................................
STARTING FAILURE/HARD STARTING TRBL SHTG EAS00845 TROUBLESHOOTING NOTE: The following guide for troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this manual for checks, adjustments, and replacement of parts.
STARTING FAILURE/HARD STARTING/ INCORRECT ENGINE IDLING SPEED ELECTRICAL SYSTEMS Battery • Discharged battery • Faulty battery Fuse(s) • Blown, damaged or incorrect fuse • Improperly installed fuse Spark plug • Incorrect spark plug gap • Incorrect spark plug heat range • Fouled spark plug • Worn or damaged electrode • Worn or damaged insulator • Faulty spark plug cap Ignition coil • Cracked or broken ignition coil body • Broken or shorted primary or secondary coils • Faulty spark plug lead TRBL SHTG Ignit
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE/ FAULTY CLUTCH TRBL SHTG EAS00849 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE Refer to “STARTING FAILURE/HARD STARTING”.
OVERHEATING/OVERCOOLING/ POOR BRAKING PERFORMANCE TRBL SHTG EAS00855 OVERHEATING FUEL SYSTEM Carburetor • Incorrect main jet setting • Incorrect fuel level • Damaged or loose carburetor joint Air filter • Clogged air filter element CHASSIS Brake(s) • Dragging brake ELECTRICAL SYSTEMS Spark plug • Incorrect spark plug gap • Incorrect spark plug heat range Ignition system • Faulty CDI unit ENGINE Clogged coolant passages • Cylinder head and piston • Heavy carbon buildup Engine oil • Incorrect oil level •
FAULTY FRONT FORK LEGS/ FAULTY LIGHTING OR SIGNALING SYSTEM TRBL SHTG EAS00860 FAULTY FRONT FORK LEGS MALFUNCTION • Bent or damaged inner tube • Bent or damaged outer tube • Damaged fork spring • Worn or damaged outer tube bushing • Bent or damaged damper rod • Incorrect oil viscosity • Incorrect oil level LEAKING OIL • Bent, damaged or rusty inner tube • Cracked or damaged outer tube • Improperly installed oil seal • Damaged oil seal lip • Incorrect oil level (high) • Loose damper rod assembly bolt • D
YP250R 2005 WIRING DIAGRAM 1 AC magneto 2 Pickup coil 3 Rectifier/regulator 4 CDI unit fuse 5 Backup fuse (meter assembly) 6 Main switch 7 Ignition fuse 8 Radiator fan motor fuse 9 Headlight fuse 0 Signaling system fuse A Ground lead B Battery C Main fuse D Starter relay E Starter motor F Diode G Sidestand switch H Starting circuit cut-off relay I Fuel pump relay J Fuel pump K Fuel sender L Handlebar upper cover right switches M Start switch N Hazard switch O Anti-theft alarm (OPTION) P Anti-theft alarm LED
YAMAHA MOTOR ESPAÑA, S.A.
YP250R 2005 WIRING DIAGRAM WW R R W R W/L W/R Br YP250R 2005 SCHALTPLAN YP250R 2005 SCHÉMA DE CÂBLAGE 2 W/R R/G W/L W W 1 R L/Y G/Y R/B G/B W W W R 3 W R/Y B B L R/B R/B R/B R/G G/B B R W W W H ~ R R O R/G (BLUE) B R/Y YP250R 2005 DIAGRAMA ELÉCTRICO YP250R 2005 SCHEMA ELETTRICO W/R W/L L/G R/L Dg R/G R L/W G/B R/L G/B L F L/W B B G/W G/W Sb B/Y B R 6 B L B E B OFF ON L/G Sb O/W R B O G/B L/W B P/W L/Y G/B D 5 B P/W L/G G/Y (BLACK)
YP250R 2005 WIRING DIAGRAM YP250R 2005 SCHALTPLAN YP250R 2005 SCHÉMA DE CÂBLAGE YP250R 2005 SCHEMA ELETTRICO YP250R 2005 DIAGRAMA ELÉCTRICO 2 1 (BLUE) 3 (GREEN) H T I U (BLACK) ~ C B 4 å O (BLACK) D 5 F K J 6 E OFF ON S Q V (BLACK) (BLACK) A 7 W L 8 (BLACK) (BLACK) G (BLUE) M (BLUE) N (WHITE) P R 9 (GREEN) (WHITE) X (GREEN) Y 0 ] _ [ a } (RED) q b (BLACK) c d \ | r s vwx t u yz{ h m p (BLACK) n n o o l k e (GREEN) j i g f g Z
