2008 SERVICE MANUAL XT250X XT250XC LIT-11616-21-52 3C5-28197-10
EAS20050 XT250X XT250XC SERVICE MANUAL ©2008 by Yamaha Motor Corporation, U.S.A. First edition, August 2007 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A.
EAS20070 NOTICE This manual was produced by the Yamaha Motor Company, Ltd. 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.
EAS20090 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. ● The manual is divided into chapters and each chapter is divided into sections. The current section title is shown at the top of each page “1”. ● Sub-section titles appear in smaller print than the section title “2”.
EAS20100 SYMBOLS The following symbols are used in this manual for easier understanding. NOTE: The following symbols are not relevant to every vehicle. 2 3 4 5 6 7 8 T. 1 R. 9 10 E 11 G 12 M 13 BF 14 B 15 LS 16 M 17 S 18 LT New 1. Serviceable with engine mounted 2. Filling fluid 3. Lubricant 4. Special tool 5. Tightening torque 6. Wear limit, clearance 7. Engine speed 8. Electrical data 9. Engine oil 10. Gear oil 11. Molybdenum-disulfide oil 12. Brake fluid 13.
EAS20110 TABLE OF CONTENTS GENERAL INFORMATION 1 SPECIFICATIONS 2 PERIODIC CHECKS AND ADJUSTMENTS 3 CHASSIS 4 ENGINE 5 FUEL SYSTEM 6 ELECTRICAL SYSTEM 7 TROUBLESHOOTING 8
GENERAL INFORMATION IDENTIFICATION ...........................................................................................1-1 VEHICLE IDENTIFICATION NUMBER....................................................1-1 MODEL LABEL ........................................................................................1-1 IMPORTANT INFORMATION ........................................................................1-2 PREPARATION FOR REMOVAL AND DISASSEMBLY .........................1-2 REPLACEMENT PARTS ........
IDENTIFICATION EAS20130 IDENTIFICATION EAS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the right side of the steering head pipe. 1 EAS20150 MODEL LABEL The model label “1” is affixed to the frame. This information will be needed to order spare parts.
IMPORTANT INFORMATION EAS20180 IMPORTANT INFORMATION EAS20190 PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Before removal and disassembly, remove all dirt, mud, dust and foreign material. EAS20210 GASKETS, OIL SEALS AND O-RINGS 1. When overhauling the engine, replace all gaskets, seals and O-rings. All gasket surfaces, oil seal lips and O-rings must be cleaned. 2. During reassembly, properly oil all mating parts and bearings and lubricate the oil seal lips with grease. 2.
IMPORTANT INFORMATION ECA13300 CAUTION: Do not spin the bearing with compressed air because this will damage the bearing surfaces. EAS20240 CIRCLIPS Before reassembly, check all circlips carefully and replace damaged or distorted circlips. Always replace piston pin clips after one use. When installing a circlip “1”, make sure the sharp-edged corner “2” is positioned opposite the thrust “3” that the circlip receives.
CHECKING THE CONNECTIONS EAS20250 CHECKING THE CONNECTIONS Pocket tester 90890-03132 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. NOTE: ● If there is no continuity, clean the terminals. ● When checking the wire harness, perform steps (1) to (3).
SPECIAL TOOLS EAS20260 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. NOTE: For U.S.A. and Canada, use part number starting with “YM-”, “YU-”, or “ACC-”.
SPECIAL TOOLS Tool name/Tool No.
SPECIAL TOOLS Tool name/Tool No. Illustration Reference pages Fork seal driver attachment (ø35) 90890-01369 Replacement 35 mm YM-A9409-5 4-44 Slide hammer bolt 90890-01083 Slide hammer bolt 6 mm YU-01083-1 5-14 Weight 90890-01084 YU-01083-3 5-14 YU-01083-3 Valve spring compressor 90890-04019 YM-04019 5-18, 5-23 Valve guide remover (ø6) 90890-04064 Valve guide remover (6.0 mm) YM-04064-A 5-20 Valve guide installer (ø6) 90890-04065 Valve guide installer (6.
SPECIAL TOOLS Tool name/Tool No. Illustration Reference pages Universal clutch holder 90890-04086 YM-91042 5-33, 5-35 Sheave holder 90890-01701 Primary clutch holder YS-01880-A 5-47, 5-48 Flywheel puller 90890-01362 Heavy duty puller YU-33270-B 5-47 Yamaha bond No. 1215 (Three Bond No.
SPECIAL TOOLS Tool name/Tool No.
SPECIFICATIONS GENERAL SPECIFICATIONS .......................................................................2-1 ENGINE SPECIFICATIONS...........................................................................2-2 CHASSIS SPECIFICATIONS.........................................................................2-9 1 ELECTRICAL SPECIFICATIONS..................................................................2-11 TIGHTENING TORQUES...............................................................................
GENERAL SPECIFICATIONS EAS20280 GENERAL SPECIFICATIONS Model Model 3C58 (U49) 3C59 (CAL) Dimensions Overall length Overall width Overall height Seat height Wheelbase Ground clearance Minimum turning radius 2150 mm (84.6 in) 805 mm (31.7 in) 1160 mm (45.7 in) 810 mm (31.9 in) 1360 mm (53.5 in) 285 mm (11.22 in) 1900 mm (74.8 in) Weight With oil and fuel Maximum load 132.0 kg (291 lb) 160.
ENGINE SPECIFICATIONS EAS20290 ENGINE SPECIFICATIONS Engine Engine type Displacement Cylinder arrangement Bore × stroke Compression ratio Starting system Air cooled 4-stroke, SOHC 249.0 cm3 Forward-inclined single cylinder 74.0 × 58.0 mm (2.91 × 2.28 in) 9.50 :1 Electric starter Fuel Recommended fuel Fuel tank capacity Unleaded gasoline only 9.1 L (2.40 US gal) (2.00 Imp.gal) (CAL) 9.8 L (2.59 US gal) (2.16 Imp.gal) (U49) 1.9 L (0.50 US gal) (0.42 Imp.
ENGINE SPECIFICATIONS Camshaft lobe dimensions Intake A Limit Intake B Limit Exhaust A Limit Exhaust B Limit 36.520–36.620 mm (1.4378–1.4417 in) 36.460 mm (1.4354 in) 30.201–30.301 mm (1.1890–1.1930 in) 30.151 mm (1.1870 in) 36.564–36.664 mm (1.4395–1.4435 in) 36.514 mm (1.4376 in) 30.216–30.316 mm (1.1896–1.1935 in) 30.166 mm (1.1876 in) A B Camshaft runout limit 0.030 mm (0.
ENGINE SPECIFICATIONS C Valve margin thickness D (intake) Valve margin thickness D (exhaust) 0.80–1.20 mm (0.0315–0.0472 in) 0.80–1.20 mm (0.0315–0.0472 in) D Valve stem diameter (intake) Limit Valve stem diameter (exhaust) Limit Valve guide inside diameter (intake) Limit Valve guide inside diameter (exhaust) Limit Valve-stem-to-valve-guide clearance (intake) Limit Valve-stem-to-valve-guide clearance (exhaust) Limit Valve stem runout 5.975–5.990 mm (0.2352–0.2358 in) 5.950 mm (0.2343 in) 5.960–5.
ENGINE SPECIFICATIONS Winding direction (intake) Winding direction (exhaust) Outer spring Free length (intake) Limit Free length (exhaust) Limit Installed length (intake) Installed length (exhaust) Spring rate K1 (intake) Spring rate K2 (intake) Spring rate K1 (exhaust) Spring rate K2 (exhaust) Installed compression spring force (intake) Counter clockwise Counter clockwise Spring tilt (intake) Spring tilt (exhaust) 36.63 mm (1.44 in) 34.63 mm (1.36 in) 36.63 mm (1.44 in) 34.63 mm (1.36 in) 32.00 mm (1.
ENGINE SPECIFICATIONS H D Offset Offset direction Piston pin bore inside diameter Limit Piston pin outside diameter Limit Piston-pin-to-piston-pin-bore clearance 0.50 mm (0.0197 in) Intake side 16.002–16.013 mm (0.6300–0.6304 in) 16.043 mm (0.6316 in) 15.991–16.000 mm (0.6296–0.6299 in) 15.971 mm (0.6288 in) 0.002–0.022 mm (0.0001–0.0009 in) Piston ring Top ring Ring type Dimensions (B × T) Barrel 0.90 × 2.75 mm (0.04 × 0.
ENGINE SPECIFICATIONS Crankshaft Width A Runout limit C Big end side clearance D C 69.25–69.30 mm (2.726–2.728 in) 0.030 mm (0.0012 in) 0.350–0.850 mm (0.0138–0.
ENGINE SPECIFICATIONS Air filter Air filter element Oil-coated paper element Carburetor Type × quantity Manufacturer ID mark MV33 x 1 TEIKEI 3C58 00 (U49) 3C59 00 (CAL) #135 1.20 5A21-1 2.585 0.90 0.8x1.2 #34 0.8 0.8 0.8 0.8 2–1/2 0.50 #90 #78 33 11.9 mm (0.
CHASSIS SPECIFICATIONS EAS20300 CHASSIS SPECIFICATIONS Chassis Frame type Caster angle Trail Semi double cradle 26.42 ° 106.0 mm (4.17 in) Front wheel Wheel type Rim size Rim material Wheel travel Radial wheel runout limit Lateral wheel runout limit Wheel axle bending limit Spoke wheel 21x1.60 Aluminum 225.0 mm (8.86 in) 2.0 mm (0.08 in) 2.0 mm (0.08 in) 0.25 mm (0.
CHASSIS SPECIFICATIONS Brake disc deflection limit Brake pad lining thickness (inner) Limit Brake pad lining thickness (outer) Limit Master cylinder inside diameter Caliper cylinder inside diameter Caliper cylinder inside diameter Recommended fluid 0.15 mm (0.0059 in) 5.3 mm (0.21 in) 0.8 mm (0.03 in) 5.3 mm (0.21 in) 0.8 mm (0.03 in) 11.00 mm (0.43 in) 26.99 mm (1.06 in) 22.22 mm (0.
ELECTRICAL SPECIFICATIONS EAS20310 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system Advancer type Ignition timing (B.T.D.C.) CDI Digital 10.0 °/1400 r/min CDI Magneto model/manufacturer Pickup coil resistance CDI unit model/manufacturer F5XT/YAMAHA 248–372 Ω (Red–white) 3C5/YAMAHA Ignition coil Model/manufacturer Minimum ignition spark gap Primary coil resistance Secondary coil resistance 2JN/YAMAHA 6.0 mm (0.24 in) 0.18–0.28 Ω 6.32–9.
ELECTRICAL SPECIFICATIONS Electric starting system System type Constant mesh Starter motor Model/manufacturer Power output Armature coil resistance Brush overall length Limit Brush spring force Commutator diameter Limit Mica undercut (depth) 3C5/YAMAHA 0.40 kW 0.0126–0.0154 Ω 10.0 mm (0.39 in) 3.50 mm (0.14 in) 5.52–8.28 N (19.87–29.80 oz) (563–844 gf) 22.0 mm (0.87 in) 21.0 mm (0.83 in) 1.50 mm (0.06 in) Starter relay Model/manufacturer Amperage Coil resistance 2768096-A/JIDECO 180.0 A 4.18–4.
TIGHTENING TORQUES EAS20320 TIGHTENING TORQUES EAS20330 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided for each chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached.
TIGHTENING TORQUES Item Threa Q’ty d size Tightening torque Remarks Breather plate bolt M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb) Spark plug M12 1 18 Nm (1.8 m•kg, 13 ft•lb) Exhaust pipe stud bolt M8 2 15 Nm (1.5 m•kg, 11 ft•lb) Oil check bolt M6 1 7 Nm (0.7 m•kg, 5.1 ft•lb) Generator rotor bolt M10 1 60 Nm (6.0 m•kg, 43 ft•lb) Balancer driven gear nut M12 1 55 Nm (5.5 m•kg, 40 ft•lb) Locknut (valve clearance adjusting screw) M6 2 14 Nm (1.
TIGHTENING TORQUES Item Threa Q’ty d size Tightening torque Remarks lock washer use Clutch boss nut M16 1 75 Nm (7.5 m•kg, 54 ft•lb) Clutch spring bolt M6 5 8 Nm (0.8 m•kg, 5.8 ft•lb) Lock nut (Push lever adjusting screw) M6 1 8 Nm (0.8 m•kg, 5.8 ft•lb) Push lever holding bolt M8 1 12 Nm (1.2 m•kg, 8.7 ft•lb) Drive sprocket nut M18 1 110 Nm (11.0 m•kg, 80 ft\•lb) Stopper lever bolt M6 1 10 Nm (1.0 m•kg, 7.2 ft•lb) Neutral switch M10 1 20 Nm (2.
TIGHTENING TORQUES Item Threa Q’ty d size Tightening torque Relay arm nut (frame side) M12 2 50 Nm (5.0 m•kg, 36 ft•lb) Steering stem nut M22 1 110 Nm (11.0 m•kg, 80 ft•lb) Lower ring nut M22 1 – Fuel tank bolt M6 3 7 Nm (0.7 m•kg, 5.1 ft•lb) Brake hose union bolt M10 3 30 Nm (3.0 m•kg, 22 ft•lb) Brake hose holding bolt M6 1 7 Nm (0.7 m•kg, 5.1 ft•lb) Front brake hose holding bolt (holder and lower bracket) M6 1 10 Nm (1.0 m•kg, 7.
TIGHTENING TORQUES Item Threa Q’ty d size Tightening torque Rear brake disc bolt M8 3 28 Nm (2.8 m•kg, 21 ft•lb) Front brake master cylinder holder bolt M6 2 7 Nm (0.7 m•kg, 5.1 ft•lb) Front brake lever nut M6 1 7 Nm (0.7 m•kg, 5.1 ft•lb) Rear brake hose joint (caliper side) M10 1 26 Nm (2.6 m•kg, 19 ft•lb) Rear brake hose joint (hose side) M10 1 14 Nm (1.4 m•kg, 10 ft•lb) Rear brake pad support bolt M10 2 17 Nm (1.
LUBRICATION POINTS AND LUBRICANT TYPES EAS20360 LUBRICATION POINTS AND LUBRICANT TYPES EAS20370 ENGINE Lubrication point Lubricant Oil seal lips LS All O-rings LS All bearing retainers E Seat surface of cylinder head bolt (226 mm) E Threaded portion of cylinder head bolt (226 mm) M Cylinder inner surface E Crankshaft pin surface E Thrust end surface of connecting rod big end E Piston pin surface E Piston surface E Buffer boss surface E Valve stem (intake/exhaust) M Valve stem end
LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Ball surface (clutch push rod) Lubricant LS Main axle assembly M Drive axle assembly M Shift fork guide bar E Shift drum assembly E Shift shaft assembly E Shift pedal (bolt mount inner surface) LS Crankcase mating surface Yamaha bond No. 1215 (Three Bond No. 1215®) Threaded portion of starter motor bolt Yamaha bond No. 1215 (Three Bond No.
LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Clutch lever cable mount LS Clutch lever bolt shaft LS Clutch lever moving parts LS Pivot shaft surface M Swing arm bushing, spacer, and oil seal lip M Relay arm bushing, spacer, and oil seal lip M Relay arm bolt shaft (on the frame and connecting arm) M Relay arm bolt shaft M Connecting arm bolt shaft M Lower bolt shaft of rear shock absorber assembly M Rear wheel axle surface LS Sidestand switch end and contact LS
LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 1 2 3 4 5 2 8 10 4 6 7 9 1 5 11 2-21
LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Camshaft 2. Oil filter element 3. Oil level check window 4. Oil pump assembly 5. Oil strainer 6. Drive axle 7. Main axle 8. Plunger pin 9. Crankshaft 10. Cylinder head 11.
LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20410 LUBRICATION DIAGRAMS 4 1 2 3 8 5 6 2 7 2-23
LUBRICATION SYSTEM CHART AND DIAGRAMS 1. 2. 3. 4. 5. 6. 7. 8.
CABLE ROUTING EAS20430 CABLE ROUTING AA 10 AB 16 17 AC I H AM AN 1 21 C A 2 AN E B A B C G F F D G 4 J K 3 L 5 6 M 7 N O C Z A Y D B E E F 15 X 13 AL 14 13 AJ P W AI 8 AD 12 V U S 10 R 11 T 22 9 Q 20 AK 13 AE AF 3 AH AG 3 8 19 AF 19 16 2-25 18
CABLE ROUTING R. Pass the negative battery lead behind the wire harness. Also, pass the battery lead from the battery/electric parts box through the inside of the vehicle. S. Gray tape (headlight relay lead) T. Install diode 3 in front of the headlight relay. U. Clamp the rear brake light switch lead using clamps. Face the clamp opening inwards . V. Pass the rear brake light switch lead along the frame, and install the rear brake light switch. W.
CABLE ROUTING A E F 2 G 3 F D C B B N 4 D G 1 5 H L A K G I H 6 7 E 8 M 9 J C V 10 11 20 V 17 16 15 14 13 12 22 S O T 21 U O 19 18 6 P Q R P 6 Q 7 2-27
CABLE ROUTING O. Secure two carburetor air vent hoses, carburetor fuel drain hose, and negative battery lead using clamp. Face the clamp holders on the left of the vehicle. P. Pass the speed sensor lead between each hose and the crankcase. Q. Secure two carburetor air vent hoses, carburetor fuel drain hose, and neutral switch lead using clamp. R. Secure the neutral switch lead using clamp. S.
CABLE ROUTING D C 1 2 16 6 5 A N N 15 15 4 3 6 5 B K 16 B 7 J 3 I B 8 9 M E 15 M F 4 10 F E 3 16 11 14 J A 12 5 13 1 H 6 C D 17 G E L F 2-29 F 4
CABLE ROUTING 1. Clutch cable 2. Front brake hose 3. Front brake light switch lead 4. Right handlebar switch lead 5. Throttle cable (decelerator cable) 6. Throttle cable (accelerator cable) 7. Carburetor warmer lead 8. Starter motor lead 9. Rear brake light switch lead 10. Negative battery lead 11. Tail/brake light lead/ 12. Rear turn signal light leads 13. Thermo switch 14. Rectifier/regulator lead 15. Clutch switch lead 16. Left handlebar switch lead 17. Rectifier/regulator A.
CABLE ROUTING 1 2 4 A 3 B 8 I 7 A C A H 5 F G 6 D E L K M J 2-31
CABLE ROUTING 1. 2. 3. 4. 5. 6. 7. 8. Throttle cable (accelerator cable) Throttle cable (decelerator cable) Meter assembly leads Clutch cable Left front turn signal light lead Main switch lead Right front turn signal light lead Front brake hose A. Route the meter assembly leads, and main switch leads from the top of the guide to the backward of vehicle. B. To the meter assembly. C. Install the left front turn signal light lead to the cap. D.
CABLE ROUTING G 2 M 1 K N A J B C C 2 G B D E F A 3 L E 3 D G 4 H 2-33 I
CABLE ROUTING 1. 2. 3. 4. Fuel tank Roll over valve Canister Canister breather hose A. Face the end of clip toward the vehicle. B. Install the hose to fuel tank by facing the white paint mark left side of the vehicle. C. Pass through the hose in the space of the tool box. D. Install the hose to the roll over valve and canister. E. Install the hose to the carburetor and canister. F. Pass through the hose to the guide. G. The clip may be installed, which ever direction end of the clip. H.
CABLE ROUTING 2-35
PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE...........................................................................3-1 INTRODUCTION......................................................................................3-1 Periodic maintenance chart for the emission control system ...................3-1 General maintenance and lubrication chart..............................................3-2 ENGINE ...................................................................................................
PERIODIC MAINTENANCE EAS20450 PERIODIC MAINTENANCE EAS20460 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.
PERIODIC MAINTENANCE INITIAL No . ITEM ROUTINE 600 mi (1000 km) or 1 month ODOMETER READINGS 4000 mi (6000 km) or 6 months 7000 mi (11000 km) or 12 months 10000 mi (16000 km) or 18 months 13000 mi (21000 km) or 24 months 16000 mi (26000 km) or 30 months ● Check the air cut-off valve, Air induction sys9 * tem reed valve, and hose for damage. ● Replace any damaged parts. √ √ * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
PERIODIC MAINTENANCE INITIAL No . ITEM ROUTINE 600 mi (1000 km) or 1 month ODOMETER READINGS 4000 mi (6000 km) or 6 months 7000 mi (11000 km) or 12 months 10000 mi (16000 km) or 18 months 13000 mi (21000 km) or 24 months 16000 mi (26000 km) or 30 months ● Check chain slack, align- ment and condition. 10 Drive chain ● Adjust and lubricate chain Every 300 mi (500 km) and after washing the motorcycle or riding in the rain with a special O-ring chain lubricant thoroughly.
PERIODIC MAINTENANCE INITIAL No . 27 * ITEM Lights, signals and switches ROUTINE ● Check operation. ● Adjust headlight beam. ODOMETER READINGS 600 mi (1000 km) or 1 month 4000 mi (6000 km) or 6 months 7000 mi (11000 km) or 12 months 10000 mi (16000 km) or 18 months 13000 mi (21000 km) or 24 months 16000 mi (26000 km) or 30 months √ √ √ √ √ √ * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
ENGINE EAS20471 ENGINE Valve clearance (cold) Intake 0.05–0.10 mm (0.0020–0.0039 in) Exhaust 0.10–0.15 mm (0.0039–0.0059 in) EAS20520 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. a.
ENGINE 8. Install: ● Spark plug ● Spark plug cap ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 6. Adjust: ● Valve clearance T. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ R. a. Loosen the locknut “1” b. Insert special thickness gauge “2” between the adjusting screw and the valve stem end. c. Using tappet adjusting tool “3”, turn the adjusting screw “4” in direction “a” or “b” to adjust the valve clearance. 9.
ENGINE 2. Start the engine and let it warm up until it reaches specified oil temperature. 5. Adjust: ● Throttle cable play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY” on page 3-9. Oil temperature 95.0–105.0 °C (203.00–221.00 °F) Throttle cable free play 3.0–5.0 mm (0.12–0.20 in) 3. Check: ● Engine idling speed Out of specification → Adjust.
ENGINE 4. Check: ● Electrode “1” Damage/wear → Replace the spark plug. ● Insulator “2” Abnormal color → Replace the spark plug. Normal color is medium-to-light tan. 5. Clean: ● Spark plug (with a spark plug cleaner or wire brush) 6. Measure: ● Spark plug gap “a” (with a wire thickness gauge) Out of specification → Regap. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Handlebar side a. Loosen the locknut “1”. b. Adjust the play of throttle cable by turning the adjusting nut “2” in direction “a” or “b”.
ENGINE 2. Connect: ● Timing light “1” ● Digital tachometer NOTE: The ignition timing is not adjustable. Timing light 90890-03141 Inductive clamp timing light YU-03141 Digital tachometer 90890-06760 YU-39951-B ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Remove: ● Digital tachometer ● Timing light 5. Install: ● Timing mark accessing screw EAS20710 MEASURING THE COMPRESSION PRESSURE The following procedure applies to all of the cylinders.
ENGINE Compression pressure (with oil applied into the cylinder) Compression gauge 90890-03081 Engine compression tester YU-33223 Reading Diagnosis Higher than without oil Piston ring(s) wear or damage → Repair. Same as without oil Piston, valves, cylinder head gasket or piston possibly defective → Repair. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 7. Install: ● Spark plug T. 6. Measure: ● Compression pressure Out of specification → Refer to steps (c) and (d). Spark plug 18 Nm (1.8 m•kg, 13 ft•lb) R. 8.
ENGINE 3. Remove: ● Engine oil filler cap “1” ● Engine oil drain bolt “2” (along with the gasket) ● Oil filter element drain bolt “3” Type YAMALUBE 4, SAE10W30 or SAE20W40 Recommended engine oil grade API service SG type or higher, JASO standard MA ACEA standard G4 or G5 ECA13360 CAUTION: ● Engine oil also lubricates the clutch and the wrong oil types or additives could cause clutch slippage.
ENGINE ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 6. Check: ● Engine oil drain bolt gasket ● Oil filter element drain bolt gasket Damage → Replace. 7. Install: ● Engine oil drain bolt ● Oil filter element drain bolt (along with the gasket) T. R. b. Start the engine and keep it idling until engine oil starts to seep from the oil check bolt. If no engine oil comes out after one minute, turn the engine off so that it will not seize. c.
ENGINE ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ NOTE: Clutch lever side a. Slide rubber cover “1” from the clutch lever. b. Loosen the locknut “2”. c. Fully tighten the adjusting bolt “3”. d. Tighten the locknut “2”. e. Slide and return rubber cover “1” to original position. Check the air filter check hose locating at the bottom of air filter case. If a foreign material such as dust and water is found, replace the air filter element. Also, clean the air filter case and air filter check hose. 2.
ENGINE NOTE: Make sure that the air filter element is installed securely in the air filter case to prevent any air leaks. 1 6. Install: ● Seat Refer to “GENERAL CHASSIS” on page 4-1. EAS20990 CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD 1. Remove: ● Fuel tank Refer to “FUEL TANK” on page 6-1. 2. Check: ● Carburetor joint “1” ● Intake manifold “2” Cracks/damage → Replace. Refer to “CARBURETOR” on page 6-3. 3. Install: ● Left fuel tank side cover Refer to “GENERAL CHASSIS” on page 4-1.
ENGINE Exhaust gas leaks → Replace. 2. Check: Tightening torque ● Exhaust pipe nut “3” ● Exhaust pipe joint bolt “4” ● Muffler bolt “5” T. R. Exhaust pipe nut 18 Nm (1.8 m•kg, 13 ft•lb) Exhaust pipe joint bolt 20 Nm (2.0 m•kg, 15 ft•lb) Muffler bolt 42 Nm (4.
CHASSIS erably reduce braking performance. EAS21140 CHASSIS ECA13490 CAUTION: EAS21170 ADJUSTING THE FRONT DISC BRAKE 1. Check: ● Brake lever free play “a” Out of specification → Adjust. After adjusting the brake lever position, make sure there is no brake drag. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ a EAS21200 ADJUSTING THE REAR DISC BRAKE 1. Check: ● Brake pedal position (Height “b” from footrest position “a” to brake pedal top position) Out of specification → Adjust. Brake pedal position 20.0 mm (0.
CHASSIS c. Tighten the locknut “1” to specification. A T. Locknut 17 Nm (1.7 m•kg, 12.5 ft•lb) R. EWA5UXB005 WARNING a A soft or spongy feeling in the brake pedal can indicate the presence of air in the brake system. Before the vehicle is operated, the air must be removed by bleeding the brake system. Air in the brake system will considerably reduce braking performance and could result in loss of control and possibly an accident. Therefore, check and, if necessary, bleed the brake system.
CHASSIS Loose connection → Tighten the clamp bolt. 3. Hold the vehicle upright and apply the front brake several times. 4. Check: ● Front brake hose Brake fluid leakage → Replace the damaged hose. Refer to “FRONT BRAKE” on page 4-12. 2. Check: ● Front brake pad Wear indicator grooves “a” almost disappeared → Replace the brake pads as a set. Refer to “FRONT BRAKE” on page 4-12. EAS21290 CHECKING THE REAR BRAKE HOSE 1. Check: ● Front brake hose “1” Cracks/damage/wear → Replace.
CHASSIS screw “2”, and place an oil pan under the plastic hose end. Direction “a” Brake light comes on sooner. Direction “b” Brake light comes on later. A 2 1 1 a b 2 B 2 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 1 EAS21350 BLEEDING THE HYDRAULIC BRAKE SYSTEM EWA13100 WARNING A. Front B. Rear 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. 1.
CHASSIS check the brake operation. ● Drive chain slack ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Loosen the wheel axle nut “1”. b. Turn the drive chain adjusting plate “2” in direction “a” or “b” until the specified drive chain slack is obtained. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS21420 ADJUSTING THE DRIVE CHAIN SLACK NOTE: Direction “a” Drive chain is tightened. Direction “b” Drive chain is loosened. The drive chain slack must be checked at the tightest point on the chain.
CHASSIS Recommended lubricant Engine oil or chain lubricant suitable for O-ring chains EAS21510 CHECKING AND ADJUSTING THE STEERING HEAD 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. Steering nut wrench 90890-01403 Spanner wrench YU-33975 NOTE: Place the vehicle on a suitable stand so that the front wheel is elevated. T. 2.
CHASSIS EAS21590 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. Spring preload ECA13590 CAUTION: Never go beyond the maximum or minimum adjustment positions. 1. Adjust: ● Spring preload ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Install: ● Upper bracket Refer to “STEERING HEAD” on page 4-47. NOTE: Adjust the spring preload by removing the rear shock absorber. EAS21530 CHECKING THE FRONT FORK 1.
CHASSIS speed. Spring length “c” Standard 197.0 mm Minimum (hard) 187.0 mm Maximum (soft) 207.0 mm ● Operation of an overloaded vehicle could cause tire damage, an accident or an injury. NEVER OVERLOAD THE VEHICLE. Tire air pressure (measured on cold tires) Loading condition 0–90 kg (0–198 lb) Front 125 kPa (18 psi) (1.25 kgf/cm2) Rear 150 kPa (22 psi) (1.50 kgf/cm2) Loading condition 90 kg–Maximum load Front 150 kPa (22 psi) (1.50 kgf/cm2) Rear 175 kPa (25 psi) (1.
CHASSIS Front tire Size 2.75-21 45P Manufacturer/model CHENG SHIN/C-6006 Manufacturer/model DUNLOP/D605F Wear limit (front) 0.8 mm (0.03 in) Wear limit (rear) 0.8 mm (0.03 in) EWA14080 WARNING ● 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 a tube tire, be sure to install the correct tube. ● Always replace a new tube tire and a new tube as a set.
CHASSIS EAS21680 EAS21690 CHECKING AND TIGHTENING THE SPOKES The following procedure applies to all of the spokes. 1. Check: ● Spoke Bends/damage → Replace. Loose → Tighten. Tap the spokes with a screwdriver. CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the inner and outer cables. EWA13270 WARNING Damaged outer cable may cause the cable to corrode and interfere with its movement. Replace damaged outer cable and inner cables as soon as possible. 1.
ELECTRICAL SYSTEM EAS21750 ELECTRICAL SYSTEM EAS21760 CHECKING AND CHARGING THE BATTERY Refer to “ELECTRICAL COMPONENTS” on page 7-29. EAS21770 1 CHECKING THE FUSES Refer to “ELECTRICAL COMPONENTS” on page 7-29. EWA13320 EAS21780 WARNING REPLACING THE HEADLIGHT BULB 1. Remove: ● Headlight cowling “1” Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. 5.
ELECTRICAL SYSTEM a b ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3-27
CHASSIS GENERAL CHASSIS .....................................................................................4-1 FRONT WHEEL .............................................................................................4-2 REMOVING THE FRONT WHEEL ..........................................................4-4 CHECKING THE FRONT WHEEL ...........................................................4-4 DISASSEMBLING THE FRONT WHEEL.................................................4-4 ASSEMBLING THE FRONT WHEEL.......
CHECKING THE HANDLEBAR ...............................................................4-36 INSTALLING THE HANDLEBAR .............................................................4-36 FRONT FORK ................................................................................................4-39 REMOVING THE FRONT FORK LEGS...................................................4-42 DISASSEMBLING THE FRONT FORK LEGS.........................................4-42 CHECKING THE FRONT FORK LEGS ..........................
GENERAL CHASSIS EAS21830 GENERAL CHASSIS Removing the cowling T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 1 3 8 T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 5 7 2 T. R. 4 6 R. R. 1 2 3 4 5 6 7 8 7 Nm (0.7 m • kg, 5.1 ft • Ib) T. T. Order 9 Nm (0.9 m • kg, 6.5 ft • Ib) Job/Parts to remove 4 Nm (0.4 m • kg, 2.
FRONT WHEEL EAS21870 FRONT WHEEL Removing the front wheel and brake disc 2 4 1 3 T. R. 85 Nm (8.5 m • kg, 62 ft • Ib) 5 4 (6) R. Order T. LT Job/Parts to remove 10 Nm (1.0 m • kg, 7.2 ft • Ib) Q’ty Remarks NOTE: Use a suitable stand to raise the front wheel off the ground. 1 2 3 4 5 Front wheel axle nut Front wheel axle Front wheel assembly Collar/dust seal Front brake disc 1 1 1 2/2 1 For installation, reverse the removal procedure.
FRONT WHEEL Disassembling the front wheel New 1 2 3 2 1 New Order 1 2 3 Job/Parts to remove Q’ty Oil seal Wheel bearing Spacer Remarks 2 2 1 For assembly, reverse the disassembly procedure.
FRONT WHEEL Over the specified limits → Replace. EAS21890 REMOVING THE FRONT WHEEL 1. Stand the vehicle on a level surface. Radial wheel runout limit 2.0 mm (0.08 in) Lateral wheel runout limit 2.0 mm (0.08 in) EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Elevate: ● Front wheel b NOTE: a Place the vehicle on a suitable stand so that the front wheel is elevated. EAS21930 CHECKING THE FRONT WHEEL 1.
FRONT WHEEL 2 4 3 2 1 1 c. Remove the wheel bearings with a general bearing puller. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS21970 ADJUSTING THE FRONT WHEEL STATIC BALANCE NOTE: ● After replacing the tire, wheel or both, the front wheel static balance should be adjusted. ● Adjust the front wheel static balance with the brake disc installed. 1. Remove: ● Balancing weight(s) 2.
FRONT WHEEL ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Check: ● Front wheel static balance ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the front wheel and make sure it stays at each position shown. f. Repeat steps (d) through (f) several times until all the marks come to rest at the same spot. g. The spot where all the marks come to rest is the front wheel’s heavy spot “X”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Adjust: ● Front wheel static balance b.
FRONT WHEEL T. Front axle nut 85 Nm (8.5 m•kg, 62 ft•lb) R. EWA13500 WARNING Make sure the brake hose is routed properly. ECA14140 CAUTION: Before tightening the wheel axle nut, push down hard on the handlebar(s) several times and check if the front fork rebounds smoothly.
REAR WHEEL EAS22020 REAR WHEEL Removing the rear wheel, brake disc and rear wheel sprocket T. 3 R. 33 Nm (3.3 m • kg, 24 ft • Ib) 4 9 (3) 6 8 LT T. R. 28 Nm (2.8 m • kg, 21 ft • Ib) 10 (6) 3 7 2 5 T. R. 85 Nm (8.5 m • kg, 62 ft • Ib) 1 R. Order T. LT 4 Nm (0.4 m • kg, 2.9 ft • Ib) Job/Parts to remove Q’ty Remarks NOTE: Use a suitable stand to raise the rear wheel off the ground.
REAR WHEEL Disassembling the rear wheel 1 New 2 3 Order 1 2 3 2 New 1 Job/Parts to remove Q’ty Oil seal Wheel bearing Spacer Remarks 2 3 1 For installation, reverse the removal procedure.
REAR WHEEL Refer to “CHECKING THE TIRES” on page 3-23 and “CHECKING THE WHEELS” on page 3-24. 3. Check: ● Spokes Bends/damage → Replace. Loose → Tighten. Refer to “CHECKING THE FRONT WHEEL” on page 4-4. 4. Measure: ● Radial rear wheel runout ● Lateral rear wheel runout Refer to “CHECKING THE FRONT WHEEL” on page 4-4. EAS22040 REMOVING THE REAR WHEEL (DISC) 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over.
REAR WHEEL T. R. Rear wheel sprocket self-locking nut 33 Nm (3.3 m•kg, 29 ft•lb) Recommended lubricant Lithium-soap-based grease 3. Adjust: ● Drive chain slack Refer to “ADJUSTING THE DRIVE CHAIN SLACK” on page 3-20. NOTE: Tighten the self-locking nuts in stages and in a crisscross pattern. Drive chain slack 40.0–45.0 mm (1.57–1.77 in) 4. Tighten: ● Rear wheel axle nut T. R. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS22140 ASSEMBLING THE REAR WHEEL 1.
FRONT BRAKE EAS22210 FRONT BRAKE Removing the front brake pads T. R. 6 Nm (0.6 m • kg, 4.3 ft • Ib) 2 4 5 1 3 S T. R. 32 Nm (3.2 m • kg, 23 ft • Ib) 5 Order 1 Job/Parts to remove Q’ty Front brake caliper support bolt 1 Remarks NOTE: Remove the lower parts only. NOTE: 2 Front brake caliper assembly 1 3 4 5 Front brake pad Brake pad shim Brake pad spring 2 1 2 Lift and remove the front brake caliper assembly. For installation, reverse the removal procedure.
FRONT BRAKE Removing the front brake master cylinder T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 7 1 10 8 9 11 S 2 S 3 5 New S 6 T. 4 R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) T. R. 30 Nm (3.0 m • kg, 22 ft • Ib) Order Job/Parts to remove Q’ty Drain the brake fluid 1 2 3 4 5 6 7 8 9 10 11 Remarks Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-19.
FRONT BRAKE Disassembling the front brake master cylinder BF New 1 Order 1 Job/Parts to remove Q’ty Master cylinder kit Remarks 1 For assembly, reverse the disassembly procedure.
FRONT BRAKE Removing the front brake calipers T. 32 Nm (3.2 m • kg, 23 ft • Ib) R. T. R. 40 Nm (4.0 m • kg, 29 ft • Ib) S S 9 4 8 3 5 1 4 7 2 New 8 T. R. 6 T. R. Order Job/Parts to remove 32 Nm (3.2 m • kg, 23 ft • Ib) Q’ty Remarks Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-19. Drain the brake fluid 1 2 3 4 5 6 7 8 9 30 Nm (3.
FRONT BRAKE Disassembling the front brake calipers T. R. 6 Nm (0.6 m • kg, 4.3 ft • Ib) 4 S New 3 2 New 1 BF Order 1 2 3 4 Job/Parts to remove Q’ty Brake caliper piston Brake caliper piston seal Brake caliper dust seal Bleed screw Remarks 2 2 2 1 For assembly, reverse the disassembly procedure.
FRONT BRAKE EAS22220 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ INTRODUCTION a. Place the vehicle on a suitable stand so that the front wheel is elevated. b. Before measuring the front brake disc deflection, turn the handlebar to the left or right to ensure that the front wheel is stationary. c. Remove the brake caliper. d. Hold the dial gauge at a right angle against the brake disc surface. e. Measure the deflection at the point 13 mm (front brake) or 14 mm (rear brake) below the edge of brake disc.
FRONT BRAKE LT T. R. 2. Install: ● Brake pad shims (onto the inner brake pads) ● Front brake pads ● Brake pad spring Brake disc bolt 10 Nm (1.0 m•kg, 7.2 ft•lb) Apply locking agent (LOCTITE®) NOTE: Always install new brake pads, brake pad shims, and a brake pad spring as a set. d. Measure the brake disc deflection. e. If out of specification, repeat the adjustment steps until the brake disc deflection is within specification. f.
FRONT BRAKE EAS22320 Front brake caliper support bolt Silicone grease DISASSEMBLING THE FRONT BRAKE CALIPER 1. Remove: ● Brake caliper pistons “1” ● Brake caliper piston seals “2” ● Brake caliper dust seals “3” ECA14150 CAUTION: ● Do not allow grease to contact the brake pads. ● Remove any excess grease. 2 4. Install: ● Front brake caliper 3 T. Brake caliper support bolt 32 Nm (3.2 m•kg, 24 ft•lb) 1 R. 5.
FRONT BRAKE Copper washers New Front brake hose ● Union bolt 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. ● Brake caliper body “3” Cracks/damage → Replace the brake caliper assembly. ● Brake fluid delivery passages (brake caliper body) Obstruction → Blow out with compressed air. ● ● T. Front brake caliper bracket bolt 40 Nm (4.0 m•kg, 29 ft•lb) Union bolt 30 Nm (3.
FRONT BRAKE 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. ● When refilling, be careful that water does not enter the brake fluid reservoir. Water will significantly lower the boiling point of the brake fluid and could cause vapor lock.
FRONT BRAKE ● Front brake hose Cracks/damage/wear → Replace. EAS22530 INSTALLING THE FRONT BRAKE MASTER CYLINDER 1. Install: ● Front brake master cylinder “1” EAS22520 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER EWA13520 WARNING T. R. ● Before installation, all internal brake components should be cleaned and lubricated with clean or new brake fluid. ● Never use solvents on internal brake components. Front brake master cylinder holder bolt 7 Nm (0.7 m•kg, 5.
FRONT BRAKE 1 New a 15 25˚ 3 2 6. Check: ● Brake lever operation Soft or spongy feeling → Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-19. 3. Fill: ● Brake master cylinder reservoir (with the specified amount of the recommended brake fluid) Recommended fluid DOT 4 EWA13540 WARNING ● Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.
REAR BRAKE EAS22550 REAR BRAKE Removing the rear brake pads T. R. 3 6 Nm (0.6 m • kg, 4.3 ft • Ib) 6 5 S 1 2 5 2 S R. 17 Nm (1.7 m • kg, 12 ft • Ib) T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) Order 1 2 3 4 5 6 T. 4 Job/Parts to remove Q’ty Rear wheel Rear brake caliper cover Brake pad support bolt Rear brake pad Rear brake caliper bracket Brake pad spring Rear brake caliper assembly Remarks Refer to “REAR WHEEL” on page 4-8. 1 2 2 1 2 1 For installation, reverse the removal procedure.
REAR BRAKE Removing the rear brake master cylinder T. R. 13 Nm (1.3 m • kg, 9.4 ft • Ib) T. R. New 2 30 Nm (3.0 m • kg, 22 ft • Ib) 1 3 5 6 7 T. R. 13 Nm (1.3 m • kg, 9.4 ft • Ib) 8 New 4 Order Job/Parts to remove Q’ty Drain the brake fluid 1 2 3 4 5 6 7 8 Remarks Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-19.
REAR BRAKE Disassembling the rear brake master cylinder BF S New 1 T. R. Order 1 Job/Parts to remove 17 Nm (1.7 m • kg, 12 ft • Ib) Q’ty Master cylinder kit Remarks 1 For assembly, reverse the disassembly procedure.
REAR BRAKE Removing the rear brake calipers T. R. 26 Nm (2.6 m • kg, 19 ft • Ib) T. R. 14 Nm (1.4 m • kg, 10 ft • Ib) 9 6 2 8 3 4 New 1 S 8 5 7 5 S T. R. 17 Nm (1.7 m • kg, 12 ft • Ib) T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) Order Job/Parts to remove Q’ty Drain the brake fluid 1 2 3 4 5 6 7 8 9 Remarks Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-19. Refer to “REAR WHEEL” on page 4-8.
REAR BRAKE Disassembling the rear brake calipers 4 1 2 New T. R. 6 Nm (0.6 m • kg, 4.3 ft • Ib) 3 New Order 1 2 3 4 Job/Parts to remove Q’ty Brake caliper piston Brake caliper piston seal Brake caliper dust seal Bleed screw Remarks 1 2 2 1 For assembly, reverse the disassembly procedure.
REAR BRAKE EAS22560 Brake disc thickness limit 4.0 mm (0.16 in) INTRODUCTION EWA14100 WARNING 5. Adjust: ● Brake disc deflection Refer to “CHECKING THE FRONT BRAKE DISC” on page 4-17. T. R. Disc brake components rarely require disassembly. Therefore, always follow these preventive measures: ● Never disassemble brake components unless absolutely necessary.
REAR BRAKE 5. Check: ● Brake fluid level Below minimum level mark “a” → Add the recommended brake fluid to proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 3-17. Brake pad support bolt Silicone grease ECA14150 CAUTION: ● Do not allow grease to contact the brake pads. ● Remove any excess grease. 3. Install: ● Rear brake pad ● Brake pad spring ● Rear brake caliper bracket a NOTE: Always install new brake pads, brake pad shims, and a brake pad spring as a set.
REAR BRAKE ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Blow compressed air into the brake hose joint opening “a” to force out the piston from the brake caliper. 3 EWA13560 WARNING ● Cover the brake caliper pistons with a rag. Be careful not to get injured when the pistons are expelled from the brake caliper. ● Never try to pry out the brake caliper pistons. 2 1 EWA13610 WARNING Whenever a brake caliper is disassembled, replace the brake caliper piston seals. 2.
REAR BRAKE T. R. brake performance. 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. ● When refilling, be careful that water does not enter the brake fluid reservoir. Water will significantly lower the boiling point of the brake fluid and could cause vapor lock. Brake hose joint (caliper side) 26 Nm (2.6 m•kg, 19 ft•lb) Brake hose joint (hose side) 14 Nm (1.
REAR BRAKE container under the master cylinder and the end of the brake hose. Cylinder cup installer 90890-01996 EAS22710 CHECKING THE REAR BRAKE MASTER CYLINDER 1. Check: ● Rear brake master cylinder “1” Damage/scratches/wear → Replace. ● Brake fluid delivery passages “2” (brake master cylinder body) Obstruction → Blow out with compressed air. 1 2. Assemble: ● Spring“1” ● Master cylinder piston “2” ● Adjusting rod “3” ● Circlip“4” New ● Dust boot“5” 2 2.
REAR BRAKE a 5. Check: ● Brake lever operation Soft or spongy feeling → Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-19. 2. Add the recommended brake fluid to the proper level. ● Brake master cylinder reservoir Recommended fluid DOT 4 EWA13090 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.
HANDLEBAR EAS22840 HANDLEBAR Removing the handlebar T. 8 R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 6 5 R. 6 T. 1 23 Nm (2.
HANDLEBAR EAS22860 EAS22921 REMOVING THE HANDLEBARS 1. Stand the vehicle on a level surface. INSTALLING THE HANDLEBAR 1. Stand the vehicle on a level surface. EWA13120 EWA13120 WARNING WARNING Securely support the vehicle so that there is no danger of it falling over. Securely support the vehicle so that there is no danger of it falling over. 2. Remove: ● Front brake light switch ● Clutch switch 2. Install: ● Handlebar “1” ● Upper handlebar holders “2” NOTE: T.
HANDLEBAR c. Clean the excessive rubber adhesive with a clean cloth. rubber adhesive ● Slightly coat the end of slot cable and inside of throttle grip with Yamaha Grease B. Then, mount the throttle grip onto the handlebar. EWA13700 WARNING Do not touch the handlebar grip until the rubber adhesive has fully dried. 3 1. Install: ● Left handlebar switch “1” 2 a b 1 NOTE: ● Align tab “a” of special washer with slot “b” of left handlebar switch.
HANDLEBAR 1 a 2 6. Adjust: ● Clutch cable free play Refer to “ADJUSTING THE CLUTCH CABLE FREE PLAY” on page 3-12. Clutch lever free play 10.0–15.0 mm (0.39–0.59 in) 7. Adjust: ● Throttle cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY” on page 3-7 Throttle cable free play 3.0–5.0 mm (0.12–0.
FRONT FORK EAS22950 FRONT FORK Removing the front fork legs T. R. 23 Nm (2.3 m • kg, 17 ft • Ib) T. R. 23 Nm (2.3 m • kg, 17 ft • Ib) 4 6 5 8 3 7 T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 1 2 T. R. 23 Nm (2.3 m • kg, 17 ft • Ib) T. R. T. R. Order 1 2 3 4 5 6 7 8 40 Nm (4.0 m • kg, 29 ft • Ib) 7 Nm (0.7 m • kg, 5.
FRONT FORK Disassembling the front fork legs T. 1 New 2 R. 23 Nm (2.3 m • kg, 17 ft • Ib) 3 16 15 14 New 6 7 New 11 12 New 13 4 5 17 18 20 10 New 19 T. New 9 R.
FRONT FORK Disassembling the front fork legs T. 1 New 2 R. 23 Nm (2.3 m • kg, 17 ft • Ib) 3 16 15 14 New 6 7 New 11 12 New 13 4 5 17 18 20 10 New 19 T. New 9 R. LT Order Job/Parts to remove 18 Nm (1.8 m • kg, 13 ft • Ib) 8 Q’ty Remarks For assembly, reverse the disassembly procedure.
FRONT FORK EAS22970 EAS22980 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the vehicle on a level surface. DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Drain: ● Fork oil EWA13120 WARNING NOTE: Securely support the vehicle so that there is no danger of it falling over. Stroke the outer tube several times while draining the fork oil.
FRONT FORK EWA13650 WARNING Do not attempt to straighten a bent inner tube as this may dangerously weaken it. 2. Measure: ● Spring free length “a” Out of specification → Replace. Fork spring free length 482.0 mm (18.98 in) Limit 472.3 mm (18.59 in) 4. Remove: ● Inner tube ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Hold the front fork leg horizontally. b. Securely clamp the brake caliper bracket in a vise with soft jaws. c.
FRONT FORK NOTE: Damper rod holder 90890-01460 T-handle 90890-01326 T-handle 3/8" drive 60 cm long YM-01326 ● When assembling the front fork leg, be sure to replace the following parts: ● Inner tube bushing ● Outer tube bushing ● Oil seal ● Dust seal ● Before assembling the front fork leg, make sure all of the components are clean. 1. Install: ● Inner tube bushing “1” New ● Damper rod “2” ● Rebound spring ● Spring “3” ● Spacer “4” ● Oil flow stopper “5” EC3C51002 CAUTION: 4.
FRONT FORK ● Lubricate the outer surface of the inner tube with fork oil. ● Before installing the oil seal, cover the top of the front fork leg with a plastic bag to protect the oil seal during installation. 8. Fill: ● Front fork leg (with the specified amount of the recommended fork oil) Quantity 385.0 cm3 (13.02 US oz) (13.58 Imp.oz) Recommended oil Yamaha fork oil 15WT Level 125.0 mm (4.92 in) At position “a” from the inner tube top end when the inner tube is fully compressed in the outer tube 6.
FRONT FORK EAS23050 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Install: ● Dust boot ● Clamp screw (temporarily) 2. Install: ● Front fork leg Temporarily tighten the upper and lower bracket pinch bolts. 1 NOTE: 2 The inner tube top face must match the upper bracket top face. 3 4.
STEERING HEAD EAS23090 STEERING HEAD Removing the head light unit, meter assembly and front fender T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) T. R. 3 Nm (0.3 m • kg, 2.2 ft • Ib) 3 5 4 2 7 1 4 5 6 9 (4) T. R. 8 7 Nm (0.7 m • kg, 5.1 ft • Ib) 11 T. R. 2 Nm (0.2 m • kg, 1.4 ft • Ib) 10 (4) T. R. T. R. T. R. Order Job/Parts to remove 10 Nm (1.0 m • kg, 7.2 ft • Ib) 7 Nm (0.7 m • kg, 5.
STEERING HEAD Removing the lower bracket T. R. 110 Nm (11 m • kg, 80 ft • Ib) 2 3 4 1 5 6 7 9 10 11 13 8 13 38 Nm (3.8 m • kg, 28 ft • Ib) Return fully 2nd 4 Nm (0.4 m • kg, 2.9 ft • Ib) 1st 1 2 3 4 5 6 7 8 9 10 11 12 13 R Order T.
STEERING HEAD b. Remove the bearing from the lower bracket with a floor chisel “2” and hammer. c. Install new bearing races. EAS23110 REMOVING THE LOWER BRACKET 1. Stand the vehicle on a level surface. EWA13120 ECA14270 WARNING CAUTION: Securely support the vehicle so that there is no danger of it falling over. If the bearing race is not installed properly, the steering head pipe could be damaged. 2.
STEERING HEAD ● ● Upper ring nut “3” Lock washer “4” Refer to “CHECKING AND ADJUSTING THE STEERING HEAD” on page 3-21. NOTE: Portion “a” having the large tapered area must face downward when the lower ring nut is mounted. a 4 3 2 1 3. Install: ● Upper bracket ● Steering stem nut NOTE: Temporarily tighten the steering stem nut. 4. Install: ● Front fork legs Refer to “FRONT FORK” on page 4-39. NOTE: Temporarily tighten the lower bracket pinch bolts. 5. Tighten: ● Steering stem nut T.
REAR SHOCK ABSORBER ASSEMBLY EAS23160 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly T. M R. 50 Nm (5.0 m • kg, 36 ft • Ib) M M 3 1 T. R. 7 7 T. R. 50 Nm (5.0 m • kg, 36 ft • Ib) 9 5 M 6 7 4 2 8 7 7 7 M M T. R. Job/Parts to remove Q’ty 59 Nm (5.9 m • kg, 43 ft • Ib) Remarks Refer to “GENERAL CHASSIS” on page 4-1. Rear left side cover/rear right side cover 1 2 3 4 5 6 7 8 9 1 9 9 M Order 40 Nm (4.
REAR SHOCK ABSORBER ASSEMBLY EAS23180 HANDLING THE REAR SHOCK ABSORBER NOTE: Place the vehicle on a suitable stand so that the rear wheel is elevated. EWA13740 WARNING This rear shock absorber contains highly compressed nitrogen gas. Before handling the rear shock absorber, read and make sure you understand the following information. The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling of the rear shock absorber.
REAR SHOCK ABSORBER ASSEMBLY Installed depth “a” 4.5 mm Installed depth “b” 3 mm Installed depth “c” 4 mm 3 2 1 b c 3 a b 3 EAS23310 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1. Install: ● Rear shock absorber assembly NOTE: Install the rear shock absorber by facing its valve backward. 2. Tighten: ● Rear shock absorber assembly upper nut T. R. ● Rear shock absorber assembly upper nut 50 Nm (5.0 m•kg, 36 ft•lb) Relay arm nut (frame side) T. Relay-arm nut (frame side) 50 Nm (5.
SWINGARM EAS23330 SWINGARM Removing the swingarm T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) T. R. 3 1 M 7 Nm (0.7 m • kg, 5.1 ft • Ib) 4 LT 11 6 M 9 12 7 M M 10 9 8 12 5 11 M 7 2 T. R. Order 80 Nm (8.0 m • kg, 58 ft • Ib) Job/Parts to remove Q’ty Rear wheel Refer to “REAR WHEEL” on page 4-8. Refer to “REAR SHOCK ABSORBER ASSEMBLY” on page 4-51.
SWINGARM EAS23350 EAS23360 REMOVING THE SWINGARM 1. Stand the vehicle on a level surface. CHECKING THE SWINGARM 1. Check: ● Swingarm Bends/cracks/damage → Replace. 2. Check: ● Pivot shaft Roll the pivot shaft on a flat surface. Bends → Replace. EWA13120 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 rear wheel is elevated. EWA13770 WARNING 2.
SWINGARM ● ● Oil seal “2” Spacer “3” (to the swingarm “4”) Installed depth “a” 3 mm 2 a 2 1 3 4 a 3. Install: ● Rear shock absorber assembly ● Rear wheel Refer to “REAR SHOCK ABSORBER ASSEMBLY” on page 4-51 and “REAR WHEEL” on page 4-8. 4. Adjust: ● Drive chain slack Refer to “ADJUSTING THE DRIVE CHAIN SLACK” on page 3-20. Drive chain slack 40.0–45.0 mm (1.57–1.
CHAIN DRIVE EAS23400 CHAIN DRIVE Removing the drive chain 5 4 T. R. 110 Nm (11 m • kg, 80 ft • Ib) 1 New 3 2 T. R. Order 1 2 3 4 5 Job/Parts to remove Q’ty Swingarm Drive sprocket cover Drive sprocket nut Lock washer Drive sprocket Drive chain 10 Nm (1.0 m • kg, 7.2 ft • Ib) Remarks Refer to “SWINGARM” on page 4-54. 1 1 1 1 1 For installation, reverse the removal procedure.
CHAIN DRIVE EAS23420 REMOVING THE DRIVE CHAIN 1. Stand the vehicle on a level surface. EWA13120 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 rear wheel is elevated. 2. Remove: ● Drive sprocket nut “1” ● Lock washer “2” b. Calculate the length “c” of the 15-link section, push down on the drive chain to increase its tension.
CHAIN DRIVE 5. Lubricate: ● Drive chain b. Put the drive chain in kerosene and remove any remaining dirt. c. Remove the drive chain from the kerosene and completely dry it. Recommended lubricant Engine oil or chain lubricant suitable for O-ring chains EC3C51003 CAUTION: This vehicle has a drive chain with small rubber O-rings “1” between the drive chain side plates. Steam cleaning, high-pressure washing, certain solvents, and the use of a coarse brush can damage these O-rings.
CHAIN DRIVE NOTE: ● Tighten the drive sprocket nut by applying the rear drive. ● Be sure to bend the lock washer tab along to the nut side face. 2 1 5. Adjust: ● Drive chain slack Refer to “ADJUSTING THE DRIVE CHAIN SLACK” on page 3-20 Drive chain slack 40.0–45.0 mm (1.57–1.77 in) ECA13550 CAUTION: A drive chain that is too tight will overload the engine and other vital parts, and one that is too loose can skip and damage the swingarm or cause an accident.
ENGINE ENGINE REMOVAL .......................................................................................5-1 INSTALLING THE ENGINE .....................................................................5-4 INSTALLING THE SHIFT PEDAL ............................................................5-4 CYLINDER HEAD ..........................................................................................5-6 REMOVING THE CYLINDER HEAD .......................................................
OIL PUMP AND BALANCER GEAR .............................................................5-38 REMOVING THE BALANCER GEAR ......................................................5-40 CHECKING THE OIL PUMP ....................................................................5-40 CHECKING THE OIL STRAINER ............................................................5-40 ASSEMBLING THE OIL PUMP................................................................5-41 INSTALL THE OIL PUMP AND BALANCER GEAR ................
ENGINE REMOVAL EAS23710 ENGINE REMOVAL Removing the exhaust pipe T. R. 42 Nm (4.2 m • kg, 30 ft • Ib) 1 New 3 New T. R. 20 Nm (2.0 m • kg, 15 ft • Ib) 2 T. R. 42 Nm (4.2 m • kg, 30 ft • Ib) T. R. Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page 4-1. Rear right side cover 1 2 3 18 Nm (1.8 m • kg, 13 ft • Ib) Muffler Exhaust pipe Exhaust pipe gasket 1 1 1 For installation, reverse the removal procedure.
ENGINE REMOVAL Removing the shift pedal assembly and leads and hoses T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) 3 5 1 2 4 6 T. 10 Nm (1.0 m • kg, 7.2 ft • Ib) R. 8 T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) 7 T. R.
ENGINE REMOVAL Removing the engine T. R. T. R. 44 Nm (4.4 m • kg, 32 ft • Ib) 60 Nm (6.0 m • kg, 43 ft • Ib) 3 T. R. 60 Nm (6.0 m • kg, 43 ft • Ib) 4 2 12 1 2 11 10 7 9 T. R. 60 Nm (6.0 m • kg, 43 ft • Ib) Order 8 5 6 Job/Parts to remove Q’ty Remarks NOTE: Use an appropriate vehicle stand and support the engine securely. Refer to “CHANGING THE ENGINE OIL” on page 3-11.
ENGINE REMOVAL EAS23720 ● Down tube nut (front) T. INSTALLING THE ENGINE 1.
ENGINE REMOVAL in). When this adjustment is complete, tighten the locknut “1”. T. Locknut 10 Nm (1.0 m•kg, 7.2 ft•lb) R.
CYLINDER HEAD EAS24100 CYLINDER HEAD Removing the cylinder head T. R. T. R. 60 Nm (6.0 m • kg, 43 ft • Ib) 15 T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) T. R. 4 12 10 Nm (1.0 m • kg, 7.2 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib) TLTL New T. R. 6 5 New 18 Nm (1.8 m • kg, 13 ft • Ib) T. R. 9 T. R. New 10 Nm (1.0 m • kg, 7.2 ft • Ib) 22 Nm (2.2 m • kg, 16 ft • Ib) T. R. 13 14 8 Nm (0.8 m • kg, 5.8 ft • Ib) 7 T. 18 Nm (1.8 m • kg, 13 ft • Ib) R. New New New 18 (4) T. 20 Nm (2.
CYLINDER HEAD Removing the cylinder head T. R. T. R. 60 Nm (6.0 m • kg, 43 ft • Ib) 15 T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) T. R. 4 12 10 Nm (1.0 m • kg, 7.2 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib) TLTL New T. R. 6 5 New 18 Nm (1.8 m • kg, 13 ft • Ib) T. R. 9 T. R. New 10 Nm (1.0 m • kg, 7.2 ft • Ib) 22 Nm (2.2 m • kg, 16 ft • Ib) T. R. 13 14 8 Nm (0.8 m • kg, 5.8 ft • Ib) 7 T. 18 Nm (1.8 m • kg, 13 ft • Ib) R. New New New 18 (4) T. 20 Nm (2.
CYLINDER HEAD EAS24130 REMOVING THE CYLINDER HEAD 1. Disconnect: ● Wire harness ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Loosen: ● Camshaft sprocket bolt NOTE: Disconnect the wire harness from the T-stud of vehicle frame. NOTE: Tighten the generator rotor bolts but loosen the camshaft sprocket bolts using a wrench. 2. Align: ● Mark “a” of the camshaft sprocket (with mark “b” of the cylinder head) 4.
CYLINDER HEAD head several times. 4 1 6 2 2 1 5 3 EAS24160 CHECKING THE CYLINDER HEAD 1. Eliminate: ● Combustion chamber carbon deposits (with a rounded scraper) e. When the cylinder head warpage is out of specification after resurfacing, replace the cylinder head.
CYLINDER HEAD ● Tighten the cylinder head bolts in two stages in the correct sequence as shown. 2. Check: ● Timing chain guide (exhaust side) Crack/wear → Replace. EAS24200 CHECKING THE TIMING CHAIN TENSIONER 1. Check: ● Timing chain tensioner Cracks/damage/rough movement → Replace. 3 1 5 6 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 2 a. Lightly press the timing chain tensioner rod into the timing chain tensioner housing by hand. 4 2.
CYLINDER HEAD d. While holding the camshafts, temporarily tighten the camshaft sprocket bolts. e. Remove the wire from the timing chain. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Tighten: ● Camshaft sprocket bolts ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ T. 3. Install: ● Timing chain tensioner Camshaft sprocket bolt 60 Nm (6.0 m•kg, 43 ft•lb) R. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ ECA13750 a.
CYLINDER HEAD 7. Measure: ● Bulb clearance Out of specification → Adjust. Refer to “ADJUSTING THE VALVE CLEARANCE” on page 3-5.
CAMSHAFT EAS3C51006 CAMSHAFT REMOVING THE ROCKER ARMS AND CAMSHAFT Order 1 2 3 4 5 6 7 Job/Part Q’ty Cylinder head Camshaft retainer Camshaft Intake rocker arm shaft Rocker arm Exhaust rocker arm shaft Locknut Valve clearance adjusting screws Remarks Refer to “CYLINDER HEAD” on page 5-6. 1 1 1 2 1 2 2 For installation, reverse the removal procedure.
CAMSHAFT EAS23770 REMOVING THE ROCKER ARMS AND CAMSHAFT 1. Loosen: ● Locknuts “1” ● Valve clearance adjusting screws “2” 2. Remove: ● Camshaft retainer “3” EAS23840 CHECKING THE CAMSHAFT 1. Check: ● Camshaft lobes Blue discoloration/pitting/scratches → Replace the camshaft. 2. Measure: ● Camshaft lobe dimensions “a” and “b” Out of specification → Replace the camshaft. 3. Remove: ● Camshaft “1” Camshaft lobe dimension limit Intake A 36.520–36.620 mm (1.4378–1.4417 in) Limit 36.460 mm (1.
CAMSHAFT Rocker arm shaft outside diameter 11.981–11.991 mm (0.4717–0.4721 in) Limit 11.950 mm (0.4705 in) 3. Check: ● Camshaft oil passage Obstruction → Blow out with compressed air. EAS23880 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS The following procedure applies to all of the rocker arms and rocker arm shafts. 1. Check: ● Rocker arm Damage/wear → Replace. 2. Check: ● Rocker arm shaft Blue discoloration/excessive wear/pitting/ scratches → Replace or check the lubrication system. 3.
CAMSHAFT NOTE: Assemble the camshaft by inserting the 10-mm bolt into the camshaft hole and tightening it. 3. Install: ● Intake rocker arm ● Intake rocker arm shaft NOTE: ● Insert cylinder head bolt “1” (226-mm long) into the cylinder head bolt hole. ● Keep slot “a” of intake rocker arm shaft in horizontal direction, align slot “b” of the shaft end with the cylinder head bolt hole, and assemble the camshaft. 1 b a 4.
VALVES AND VALVE SPRINGS EAS24270 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order 1 2 3 4 5 6 7 8 9 Job/Parts to remove Q’ty Cylinder head Rocker arm/Camshaft Valve cotter Valve spring retainer Outer valve spring Inner valve spring Intake valve Exhaust valve Valve stem seal Valve spring seat Valve guide Remarks Refer to “CYLINDER HEAD” on page 5-6. Refer to “CAMSHAFT” on page 5-13. 4 2 2 2 1 1 2 2 2 For installation, reverse the removal procedure.
VALVES AND VALVE SPRINGS EAS24280 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” on page 5-20. 3.
VALVES AND VALVE SPRINGS Valve-stem-to-valve-guide clearance Valve-stem-to-valve-guide clearance (intake) 0.010–0.037 mm (0.0004–0.0015 in) Limit 0.080 mm (0.0032 in) Valve-stem-to-valve-guide clearance (exhaust) 0.025–0.052 mm (0.0010–0.0020 in) Limit 0.100 mm (0.0039 in) b. Install the new valve guide with the valve guide installer “2” and valve guide remover “1”. c.
VALVES AND VALVE SPRINGS Valve stem runout Valve stem runout 0.030 mm (0.0012 in) Valve guide remover (ø6) 90890-04064 Valve guide remover (6.0 mm) YM-04064-A Valve guide installer (ø6) 90890-04065 Valve guide installer (6.0 mm) YM-04065-A Valve guide reamer (ø6) 90890-04066 Valve guide reamer (6.0 mm) YM-04066 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS24300 3. Eliminate: ● Carbon deposits (from the valve face and valve seat) 4. Check: ● Valve face Pitting/wear → Grind the valve face.
VALVES AND VALVE SPRINGS seat are evenly polished, then clean off all of the lapping compound. NOTE: For the best lapping results, lightly tap the valve seat while turning the valve back and forth between your hands. e. Apply a fine lapping compound to the valve face and repeat the above steps. f. After every lapping procedure, be sure to clean off all of the lapping compound from the valve face and valve seat. g. Apply Mechanic’s blueing dye (Dykem) “b” onto the valve face. b.
VALVES AND VALVE SPRINGS Inner spring Installed compression spring force (intake) 75.00–91.70 N (16.86–20.61 lbf) (7.65–9.35 kgf) Installed length (intake) 30.50 mm (1.20 in) Installed compression spring force (exhaust) 75.00–91.70 N (16.86–20.61 lbf) (7.65–9.35 kgf) Installed length (exhaust) 30.50 mm (1.20 in) Outer spring Installed compression spring force (intake) 128.50–157.90 N (28.89–35.50 lbf) (13.10–16.10 kgf) Installed length (intake) 32.00 mm (1.
VALVES AND VALVE SPRINGS EAS24340 INSTALLING THE VALVES The following procedure applies to all of the valves and related components. 1. Deburr: ● Valve stem end (with an oil stone) 2. Lubricate: ● Valve stem “1” ● Valve stem seal “2” (with the recommended lubricant) a. Larger pitch b. Smaller pitch Recommended lubricant Molybdenum disulfide oil 4. Install: ● Valve cotters “1” NOTE: Install the valve cotters by compressing the valve spring with the valve spring compressor “2”.
VALVES AND VALVE SPRINGS 5-24
CYLINDER AND PISTON EAS24350 CYLINDER AND PISTON Removing the cylinder and piston T. R. 20 Nm (2.0 m • kg, 15 ft • Ib) T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) New 4 E 8 1 9 10 12 11 New T. R. 17 Nm (1.
CYLINDER AND PISTON Vertical scratches → Rebore or replace the cylinder, and replace the piston and piston rings as a set. 2. Measure: ● Piston-to-cylinder clearance EAS24380 REMOVING THE PISTON 1. Remove: ● Piston pin clips “1” ● Piston pin “2” ● Piston “3” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ ECA13810 a. Measure cylinder bore “C” with the cylinder bore gauge. CAUTION: Do not use a hammer to drive the piston pin out.
CYLINDER AND PISTON Piston ring side clearance Top ring Ring side clearance 0.030–0.065 mm (0.0012–0.0026 in) Limit 0.115 mm (0.0045 in) 2nd ring Ring side clearance 0.020–0.055 mm (0.0008–0.0022 in) Limit 0.115 mm (0.0045 in) a. Piston skirt diameter b. 11 mm (0.43 in) from the bottom edge of the piston Diameter D 73.983–73.998 mm (2.9127–2.9133 in) d. If out of specification, replace the piston and piston rings as a set. e. Calculate the piston-to-cylinder clearance with the following formula.
CYLINDER AND PISTON Piston ring end gap Top ring End gap (installed) 0.19–0.31 mm (0.0075–0.0122 in) Limit 0.60 mm (0.0236 in) 2nd ring End gap (installed) 0.30–0.45 mm (0.0118–0.0177 in) Limit 0.60 mm (0.0236 in) Oil ring End gap (installed) 0.10–0.35 mm (0.0039–0.0138 in) 4. Calculate: ● Piston-pin-to-piston-pin-bore clearance Out of specification → Replace the piston pin and piston as a set. EAS24440 CHECKING THE PISTON PIN 1.
CYLINDER AND PISTON ● 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. (exhaust side) through the timing chain cavity. 3. Lubricate: ● Piston ● Piston rings ● Cylinder (with the recommended lubricant) Recommended lubricant Engine oil 4. Offset: ● Piston ring end gaps a. Top ring b. Upper oil ring rail c. Oil ring expander d.
CLUTCH EAS25061 CLUTCH Removing the clutch cover New 1 T. R. 20 Nm (2.0 m • kg, 15 ft • Ib) 2 New New 8 9 T. R. 30 Nm (3.0 m • kg, 22 ft • Ib) 5 New T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) 8 7 New T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) 6 4 New 3 T. R. T. R. Order 10 Nm (1.0 m • kg, 7.2 ft • Ib) Job/Parts to remove 10 Nm (1.0 m • kg, 7.2 ft • Ib) Q’ty Refer to “CHANGING THE ENGINE OIL” on page 3-11. Refer to “ENGINE REMOVAL” on page 5-1.
CLUTCH Removing the clutch T. R. 8 Nm (0.8 m • kg, 5.8 ft • Ib) 14 3 4 2 7 8 12 1 (5) 16 13 New 6 17 18 15 5 11 9 19 10 New T. R. 75 Nm (7.5 m • kg, 54 ft • Ib) E T. R.
CLUTCH Removing the push lever shaft T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 3 2 1 4 E New 7 6 5 New E T. R. Order Job/Parts to remove 12 Nm (1.2 m • kg, 8.7 ft • Ib) Q’ty Air cut-off valve Generator rotor cover 1 2 3 4 5 6 7 Remarks Refer to “AIR INDUCTION SYSTEM” on page 6-9. Refer to “GENERATOR AND STARTER CLUTCH” on page 5-45. Clutch cable Ignition coil Push lever shaft Push lever spring Circlip Oil seal Bearing 1 1 1 1 1 1 1 For installation, reverse the removal procedure.
CLUTCH EAS25070 NOTE: REMOVING THE CLUTCH 1. Straighten the lock washer tab. 2. Loosen: ● Primary drive gear nut “1” Measure the friction plate at four places. Friction plate thickness 2.70–2.90 mm (0.106–0.114 in) Wear limit 2.60 mm (0.1024 in) NOTE: Insert aluminum plate “a” between primary drive gear “2” and primary driven gear “3”, and loosen the primary drive gear nut. EAS25110 CHECKING THE CLUTCH PLATES The following procedure applies to all of the clutch plates. 1.
CLUTCH ● Clutch spring free length “a” Out of specification → Replace the clutch springs as a set. Clutch spring free length 40.10 mm (1.58 in) Limit 38.10 mm (1.50 in) EAS25170 CHECKING THE PRESSURE PLATE 1. Check: ● Pressure plate Cracks/damage → Replace. EAS25190 CHECKING THE CLUTCH PUSH RODS 1. Check: ● Clutch push rod ● Adjusting screw ● Ball Cracks/damage/wear → Replace the defective part(s). 2. Measure: ● Push rod bending limit Out of specification → Replace.
CLUTCH Clutch housing “2” Thrust washer ● Clutch boss “3” ● Lock washer “4” New ● Claw washer “5” ● Lock washer “6” New ● 1 3 ● 2 NOTE: ● Assemble the primary drive gear by facing its flat face “a” toward the crankcase. ● Align lock washer projection “b” with the clutch boss slit during assembling. ● Align lock washer projection “c” with the claw washer slit during assembling. 1 Primary drive gear nut 80 Nm (8.0 m•kg, 58 ft•lb) R. 5 T. New 6 4.
CLUTCH 10.Adjust: ● Push lever position 1 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 2 a. Loosen the locknut “1”. b. Turn the adjusting screw “2” in or out until the marks are aligned. c. Hold the adjusting screw to prevent it from moving and then tighten the locknut to specification. ECA13820 CAUTION: 8. Install: ● Pressure plate ● Adjusting screw ● Pressure plate ● Clutch springs Do not overtighten the locknut since this will remove the free play between both push rods. NOTE: T.
CLUTCH 5 4 4 6 2 2 2 1 2 2 2 3 2 2 12.Adjust: ● Clutch cable free play Refer to “ADJUSTING THE CLUTCH CABLE FREE PLAY” on page 3-12.
OIL PUMP AND BALANCER GEAR EAS3C51007 OIL PUMP AND BALANCER GEAR Removing oil pump and balancer gear 14 15 LT New 13 8 T. R. 6 Nm (0.6 m • kg, 4.3 ft • Ib) 12 11 T. R. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 5 4 7 6 3 New 10 Order 9 55 Nm (5.
OIL PUMP AND BALANCER GEAR Disassembling the oil pump Order 1 2 3 4 5 6 7 Job/Part Q’ty Oil pump cover Dowel pin Oil pump shaft Dowel pin Inner rotor Outer rotor Oil pump housing Remarks 1 1 1 2 1 1 1 For assembly, reverse the disassembly procedure.
OIL PUMP AND BALANCER GEAR EAS3C51008 Inner-rotor-to-outer-rotor-tip clearance 0.150 mm (0.0059 in) Limit 0.200 mm (0.0079 in) Outer-rotor-to-oil-pump-housing clearance 0.100–0.151 mm (0.0039–0.0059 in) Limit 0.221 mm (0.0087 in) Oil-pump-housing-to-inner-and-outer-rotor clearance 0.04–0.09 mm (0.0016–0.0035 in) Limit 0.16 mm (0.0063 in) REMOVING THE BALANCER GEAR 1. Straighten the lock washer tab. 2.
OIL PUMP AND BALANCER GEAR arrow direction as shown. EAS25000 ASSEMBLING THE OIL PUMP 1. Lubricate: ● Inner rotor ● Outer rotor ● Oil pump shaft (with the recommended lubricant) Recommended lubricant Engine oil 2. Install: ● Oil pump housing “1” ● Dowel pin ● Outer rotor “2” ● Inner rotor “3” 2. Install: ● Balancer drive gear NOTE: Direct the balancer drive gear mark outward of the vehicle during assembling.
OIL PUMP AND BALANCER GEAR ● Assemble the dowel pin on the spring as shown. a b 2 3 4 1 9. Be sure to bend the lock washer tab along to the nut side face. 6. Install: ● Balancer driven gear “1” ● Lock washer New ● Balancer driven gear nut NOTE: Align mark “a” of the balancer drive gear with mark “b” of the balancer driven gear. 7. Tighten: ● Primary drive gear nut Refer to “CLUTCH” on page 5-30. 8. Tighten: ● Balancer driven gear nut “1” T. Balancer driven gear nut 55 Nm (5.5 m•kg, 40 ft•lb) R.
SHIFT SHAFT EAS25410 SHIFT SHAFT Removing the shift shaft and stopper lever 1 E 3 2 T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) LT Order 1 2 3 Job/Parts to remove Q’ty Shift pedal assembly Clutch housing Shift shaft assembly Stopper lever Stopper lever spring Remarks Refer to “ENGINE REMOVAL” on page 5-1. Refer to “CLUTCH” on page 5-30. 1 1 1 For installation, reverse the removal procedure.
SHIFT SHAFT EAS25420 CHECKING THE SHIFT SHAFT 1. Check: ● Shift shaft ● Shift lever Bends/damage/wear → Replace. ● Shift lever spring Damage/wear → Replace. 3 2 1 EAS25430 CHECKING THE STOPPER LEVER 1. Check: ● Stopper lever Bends/damage → Replace. Roller turns roughly → Replace the stopper lever. EAS25450 INSTALLING THE SHIFT SHAFT 1. Install: ● Stopper lever “1” ● Stopper lever spring T. R. Stopper lever bolt 10 Nm (1.
GENERATOR AND STARTER CLUTCH EAS3C51010 GENERATOR AND STARTER CLUTCH Removing the generator rotor and starter clutch 1 T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) T. 12 7 Nm (0.7 m • kg, 5.1 ft • Ib) R. E LT LT 10 E 3 T. R. 6 New 10 Nm (1.0 m • kg, 7.2 ft • Ib) 9 (3) 4 LT 5 8 (5) 7 14 New E (3) 13 (3) LT 15 (3) T. R. 30 Nm (3.0 m • kg, 22 ft • Ib) 11 T. R. R. R. 60 Nm (6.
GENERATOR AND STARTER CLUTCH Removing the generator rotor and starter clutch 1 T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) T. 12 7 Nm (0.7 m • kg, 5.1 ft • Ib) R. E LT LT 10 E 3 T. R. 6 New 10 Nm (1.0 m • kg, 7.2 ft • Ib) 9 (3) 4 LT 5 8 (5) 7 14 New E (3) 13 (3) LT 15 (3) T. R. 30 Nm (3.0 m • kg, 22 ft • Ib) 11 T. R. R. R. 14 15 60 Nm (6.0 m • kg, 43 ft • Ib) Job/Parts to remove Q’ty Bearing Starter clutch New 10 Nm (1.0 m • kg, 7.2 ft • Ib) T. T.
GENERATOR AND STARTER CLUTCH EAS24490 REMOVING THE GENERATOR 1. Remove: ● Generator rotor bolt “1” ● Washer 1 2 NOTE: ● While holding the generator rotor “2” with the sheave holder “3”, loosen the generator rotor bolt. ● Do not allow the sheave holder to touch the projection on the generator rotor. EAS24560 REMOVING THE STARTER CLUTCH 1.
GENERATOR AND STARTER CLUTCH ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Install the starter clutch gear “1” onto the starter clutch and hold the starter clutch. b. When turning the starter clutch gear clockwise “A”, the starter clutch and the starter clutch gear should engage, otherwise the starter clutch is faulty and must be replaced. c. When turning the starter clutch drive gear counterclockwise “B”, it should turn freely, otherwise the starter clutch is faulty and must be replaced.
GENERATOR AND STARTER CLUTCH T. Generator rotor cover bolt 10 Nm (1.0 m•kg, 7.2 ft•lb) R. NOTE: Tighten the bolts diagonally.
ELECTRIC STARTER EAS24780 ELECTRIC STARTER Removing the starter motor T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) 1 T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 2 3 T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) Order 1 2 3 Job/Parts to remove Q’ty Carburetor Exhaust pipe Clutch cable holder Starter motor lead Starter motor Remarks Refer to “CARBURETOR” on page 6-3. Refer to “ENGINE REMOVAL” on page 5-1. 1 1 1 Disconnect. For installation, reverse the removal procedure.
ELECTRIC STARTER Disassembling the starter motor 6 7 New 5 6 4 7 3 New 2 New 1 Order 1 2 3 4 5 6 7 Job/Parts to remove New Q’ty Starter motor front cover Lock washer Armature assembly Starter motor yoke Starter motor rear cover Brush Brush spring Remarks 1 1 1 1 1 2 2 For assembly, reverse the disassembly procedure.
ELECTRIC STARTER with the pocket tester. EAS24790 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. Pocket tester 90890-03132 Armature coil Commutator resistance “1” 0.0126–0.0154 Ω at 20°C (68°F) Insulation resistance “2” Above 1 MΩ at 20°C (68°F) Limit 21.0 mm (0.83 in) b. If any resistance is out of specification, replace the starter motor. 3.
ELECTRIC STARTER Gear teeth Damage/wear → Replace the gear. 8. Check: ● Bearing ● Oil seal Damage/wear → Replace the defective part(s). ● EAS24800 ASSEMBLING THE STARTER MOTOR 1. Install: ● Lock washer “1” NOTE: Align the tab “a” on the brush seat with the slot “b” in the starter motor rear cover. b a 1 2.
CRANKCASE EAS25540 CRANKCASE Separating the crankcase New 6 New T. R. T. R. 8 Nm (0.8 m • kg, 5.8 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib) 5 1 LT 8 2 LT 3 9 10 4 New 9 7 New T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) T. R. Order Job/Parts to remove Q’ty Engine Remarks Refer to “ENGINE REMOVAL” on page 5-1. Refer to “CYLINDER AND PISTON” on page 5-25. Refer to “OIL PUMP AND BALANCER GEAR” on page 5-38. Refer to “SHIFT SHAFT” on page 5-43.
CRANKCASE Removing the Bearing 3 3 E T. R. LT LT 1 3 10 Nm (1.0 m • kg, 7.2 ft • Ib) E 3 3 3 E 2 New 3 E E 2 New Order Job/Parts to remove Q’ty Refer to “CRANKSHAFT ASSEMBLY” on page 5-58. Refer to “TRANSMISSION” on page 5-61. Crankshaft assembly 1 2 3 Remarks Main axle assembly/Drive axle assembly Bearing retainer Oil seal Bearing 1 2 7 For installation, reverse the removal procedure.
CRANKCASE Crack/stiffness → Replace the camshaft sprocket, timing chain, and crankshaft sprocket as a set. 2. Check: ● Crankshaft sprocket Refer to “CYLINDER HEAD” on page 5-6. 3. Check: ● Timing chain guide (intake side) Damage/wear → Replace. EAS25570 DISASSEMBLING THE CRANKCASE 1. Remove: ● Crankcase bolts NOTE: Loosen each bolt 1/4 of a turn at a time, in two stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2.
CRANKCASE crankcase during its assembling. the bolts diagonally in two (2) stages, with 1/4 turn each. ● Tighten M6 × 70 mm bolt (with gasket)“1” ● M6 × 60 mm bolt “2” ● M6 × 55 mm bolt “3” ● M6 × 45 mm bolt “4” ● 4. Install: ● Crankshaft sprocket “1” NOTE: Assemble the crankshaft sprocket by facing its chamfered side “a” toward the crankcase.
CRANKSHAFT ASSEMBLY EAS3C51013 CRANKSHAFT ASSEMBLY Crankshaft assembly and balancer 3 2 4 E 5 1 Order 1 2 3 4 5 Job/Part Q’ty Separate the crank case. Balancer Crankshaft assembly Dowel pin Plunger pin Bearing Remarks Refer to “CRANKCASE” on page 5-54. 1 1 1 1 1 For installation, reverse the removal procedure.
CRANKSHAFT ASSEMBLY EAS26000 Runout limit C 0.030 mm (0.0012 in) REMOVING THE CRANKSHAFT ASSEMBLY 1. Remove: ● Crankshaft assembly “1” NOTE: Remove the crankshaft assembly using crankshaft separating tool “2”. Crankcase separating tool 90890-01135 Crankcase separator YU-01135-B 2. Measure: ● Big end side clearance Out of specification → Replace the crankshaft assembly. Big end side clearance D 0.350–0.850 mm (0.0138–0.0335 in) 3.
CRANKSHAFT ASSEMBLY 2. Install: ● Crankshaft assembly “1” NOTE: Install the crankshaft assembly using spacer “2”, adapter (M10) “3”, crankshaft installer “4”, and crankshaft installer bolt “5”.
TRANSMISSION EAS26241 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order 1 2 3 4 5 6 7 Job/Parts to remove Q’ty Crankcase separation Shift fork guide bar Shift drum assembly Shift fork-R Shift fork-C Shift fork-L Main axle assembly Drive axle assembly Remarks Refer to “CRANKCASE” on page 5-54. 1 1 1 1 1 1 1 For installation, reverse the removal procedure.
TRANSMISSION Disassembling the transmission Order 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Job/Parts to remove Q’ty 2nd pinion gear 5th pinion gear 3rd/4th pinion gear Main axle/1st pinion gear Circlip 1st wheel gear Dog clutch Circlip Lock washer 3rd wheel gear 4th wheel gear 5th wheel gear Circlip Lock washer 2nd wheel gear Drive axle Remarks 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 For assembly, reverse the disassembly procedure.
TRANSMISSION EAS26260 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks. 1. Check: ● Shift fork cam follower “1” ● Shift fork pawl “2” Bends/damage/scoring/wear → Replace the shift fork. EAS26290 CHECKING THE TRANSMISSION 1. Measure: ● Main axle runout (with a centering device and dial gauge “1”) Out of specification → Replace the main axle. Main axle runout limit 0.08 mm (0.0032 in) 2. Check: ● Shift fork guide bar Roll the shift fork guide bar on a flat surface.
TRANSMISSION 3. Check: ● Transmission gears Blue discoloration/pitting/wear → Replace the defective gear(s). ● Transmission gear dogs Cracks/damage/wear → Replace the defective gear(s). 4. Check: ● Transmission gear engagement (each pinion gear to its respective wheel gear) Incorrect → Reassemble the transmission axle assemblies. NOTE: When reassembling the main axle “1”, press the 2nd pinion gear “2” onto it as shown. 2. Check: ● Transmission Rough movement → Repair.
FUEL SYSTEM FUEL TANK ...................................................................................................6-1 CHECKING THE FUEL COCK.................................................................6-2 CARBURETOR ..............................................................................................6-3 CHECKING THE CARBURETOR ............................................................6-6 ASSEMBLING THE CARBURETOR........................................................
FUEL TANK EAS26620 FUEL TANK Removing the fuel tank 2 T. R. T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 7 Nm (0.7 m • kg, 5.1 ft • Ib) 1 3 T. R. Order 1 2 3 Job/Parts to remove Q’ty Left fuel tank side cover/right fuel tank side cover Fuel hose Fuel tank Fuel cock 1 1 1 7 Nm (0.7 m • kg, 5.1 ft • Ib) Remarks Refer to “GENERAL CHASSIS” on page 4-1. Disconnect. For installation, reverse the removal procedure.
FUEL TANK EAS26650 CHECKING THE FUEL COCK 1. Check: ● Fuel cock Cracks/damage/wear → Replace. 2. Check: ● Fuel cock strainer “1” Obstruction → clean. Blow out the jets with compressed air. Damage → Replace.
CARBURETOR EAS26720 CARBURETOR Removing the carburetor T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 8 8 LT LT 7 Nm (0.7 m • kg, 5.1 ft • Ib) T. R. 1 7 3 4 6 10 9 2 5 11 Order Job/Parts to remove Q’ty Fuel tank Remarks Refer to “FUEL TANK” on page 6-1. Refer to “AIR INDUCTION SYSTEM” on page 6-9.
CARBURETOR Disassembling the carburetor 4 5 6 2 3 7 10 9 8 1 13 22 21 23 20 19 17 18 16 15 New 14 11 12 Order 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Job/Parts to remove Q’ty Throttle stop screw Vacuum chamber cover Piston valve spring Jet needle holder Spring Jet needle kit Piston valve Coasting enricher cover Coasting enricher spring Coasting enricher diaphragm Carburetor warmer lead Carburetor warmer Pilot screw set Float chamber Float chamber rubber gasket Float pin Float Needl
CARBURETOR Disassembling the carburetor 4 5 6 2 3 7 10 9 8 1 13 22 21 23 20 19 17 18 16 15 New 14 11 12 Order 21 22 23 Job/Parts to remove Q’ty Main jet holder Needle jet Pilot jet Remarks 1 1 1 For assembly, reverse the disassembly procedure.
CARBURETOR Cracks/tears → Replace. EAS26760 CHECKING THE CARBURETOR 1. Check: ● Carburetor body ● Float chamber ● Jet housing Cracks/damage → Replace. 2. Check: ● Fuel passages Obstruction → Clean. 2 1 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Wash and clean the carburetor with a kerosene. Never use a poor volatile carburetor cleaner. b. Clean all carburetor passages by air blow. 7. Check: ● Vacuum chamber cover ● Piston valve spring Cracks/damage → Replace. 8.
CARBURETOR Cracks/damage → Replace. 13.Check: ● Carburetor air vent hose ● Carburetor fuel drain hose ● Fuel hoses Cracks/damage/wear → Replace. Obstruction → Clean. Blow out the hoses with compressed air. ber matching face to the float top face. Float height 11.9 mm (0.47 in) a EAS26800 ASSEMBLING THE CARBURETOR ECA14110 CAUTION: ● Before assembling the carburetor, wash all of the parts in a petroleum-based solvent. ● Always use a new gasket. NOTE: 1.
CARBURETOR Clip position Standard clip position 3 levels 1 2 3 4 5 1 EAS26890 INSTALLING THE CARBURETOR 1. Adjust: ● Engine idling speed Refer to “ADJUSTING THE ENGINE IDLING SPEED” on page 3-8. Engine idling speed 1300–1500 r/min 2. Adjust: ● Throttle cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY” on page 3-9. Throttle cable free play 3.0–5.0 mm (0.12–0.
AIR INDUCTION SYSTEM EAS27040 AIR INDUCTION SYSTEM 1 6 2 4 3 5 6-9 7
AIR INDUCTION SYSTEM 1. Cylinder head 2. Air induction system pipe 3. Air induction system hose (from the air cut-off valve to the cylinder head) 4. Air induction system vacuum hose 5. Air cut-off valve 6. Air induction system hose (from the air filter to the air cut-off valve) 7.
AIR INDUCTION SYSTEM Removing the air cut-off valve and hose 4 3 1 T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 2 Order 1 2 3 4 Job/Part Q’ty Fuel tank Air induction system vacuum hose Air induction system hose (from the air cut-off valve to the cylinder head) Air cut-off valve Air induction system hose (from the air filter to the air cut-off valve) Remarks Refer to “FUEL TANK” on page 6-1. 1 1 1 1 For installation, reverse the removal procedure.
AIR INDUCTION SYSTEM Cracks/damage → Replace the reed valve. EAS27060 CHECKING THE AIR INDUCTION SYSTEM Air induction The air induction system burns unburned exhaust gases by injecting fresh air (secondary air) into the exhaust port, reducing the emission of carbon monoxide. When there is negative pressure at the exhaust port, the reed valve opens, allowing secondary air to flow into the exhaust port. The required temperature for burning the unburned exhaust gases is approximately 600 to 700°C.
AIR INDUCTION SYSTEM 6-13
ELECTRICAL SYSTEM IGNITION SYSTEM ........................................................................................7-1 CIRCUIT DIAGRAM .................................................................................7-1 TROUBLESHOOTING .............................................................................7-3 ELECTRIC STARTING SYSTEM...................................................................7-5 CIRCUIT DIAGRAM .............................................................................
W W W W W W W R (BLACK) W/L W/R (BLACK) 2 1 B B B W R R R W W W B B B B % 7-1 B B B B P Dg $ Y Dg Ch L/B Ch Br/W B B/Y B/Y B/Y Br R/W Br (BLACK) R R Br R/W B 3 B/Y B 4 7 5B R R R R W W B/Y Br 6 W/L W/R W W W 20A R/W Br P B .
IGNITION SYSTEM 1. Pickup coil 2. A.C. magneto 4. Fuse 6. Battery 9. Main switch 10. Right handlebar switch 11. Engine stop switch 13. Diode 15. Sidestand switch 16. Starting circuit cut-off relay 17. Diode 3 18. Neutral switch 19. C.D.I. unit 20. Ignition coil 21.
IGNITION SYSTEM EAS27130 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). NOTE: Before troubleshooting, remove the following part(s): 1.Seat 2.Rear side cover 3.Tool box 4.Fuel tank 5.Carburetor assembly 6.Starter (choke) knob 1. Check the fuse. Refer to “CHECKING THE FUSE” on page 7-37. NG→ Replace the fuse(s). OK↓ 2. Check the battery. Refer to “CHECKING AND CHARGING THE BATTERY” on page 7-37. NG→ ● Clean the battery terminals. or replace the battery.
IGNITION SYSTEM 10.Check the sidestand switch. Refer to “CHECKING THE SWITCHES” on page 7-33. NG→ Replace the sidestand switch. NG→ Replace the clutch switch. NG→ Properly connect or repair the ignition system's wiring. OK↓ 11.Check the clutch switch. Refer to “CHECKING THE SWITCHES” on page 7-33. OK↓ 12.Checking the entire ignition system’s wiring. Refer to “CIRCUIT DIAGRAM” on page 7-1. OK↓ Replace the C.D.I. unit.
W W W W W W W R (BLACK) W/L W/R (BLACK) 2 1 B B B W R R R W W W B B B B % 7-5 B B B B P Dg $ Y Dg Ch L/B Ch Br/W B B/Y B/Y B/Y Br R/W Br (BLACK) R R Br R/W B 3 B/Y B 4 7 5B R R R R W W B/Y Br 6 W/L W/R W W W 20A R/W Br P B .
ELECTRIC STARTING SYSTEM 4. Fuse 5. Starter relay 6. Battery 7. Starter motor 8. Diode 1 9. Main switch 10. Right handlebar switch 11. Engine stop switch 12. Start switch 13. Diode 2 14. Clutch switch 15. Sidestand switch 16. Starting circuit cut-off relay 17. Diode 3 18.
ELECTRIC STARTING SYSTEM EAS27180 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: ● The transmission is in neutral (the neutral switch is closed). ● The clutch lever is pulled to the handlebar (the clutch switch is closed) and the sidestand is up (the sidestand switch is closed).
ELECTRIC STARTING SYSTEM a. WHEN THE TRANSMISSION IS IN NEUTRAL b. WHEN THE SIDESTAND IS UP AND THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 1. Battery 2. Fuse 3. Main switch 4. Diode2 5. Clutch switch 6. Sidestand switch 7. Engine stop switch 8. Neutral switch 9. Diode3 10. Starting circuit cut-off relay 11. Start switch 12. Diode1 13. Starter relay 14.
ELECTRIC STARTING SYSTEM EAS27190 TROUBLESHOOTING The starter motor fails to turn. NOTE: Before troubleshooting, remove the following part(s): 1.Seat 2.Rear side cover 3.Tool box 4.Fuel tank 5.Carburetor assembly 1. Check the fuse. Refer to “CHECKING THE FUSE” on page 7-37. NG→ Replace the fuse(s). OK↓ 2. Check the battery. Refer to “CHECKING AND CHARGING THE BATTERY” on page 7-37. NG→ ● Clean the battery terminals. or replace the battery. ● Recharge OK↓ 3. Check the starter motor.
ELECTRIC STARTING SYSTEM 10.Check the engine stop switch. Refer to “CHECKING THE SWITCHES” on page 7-33. NG→ Replace the right handlebar switch. NG→ Replace the neutral switch. NG→ Replace the sidestand switch. NG→ Replace the clutch switch. NG→ Poor conducting of engine stop switch. Replace the right handlebar switch. NG→ Properly connect or repair the starting system’s wiring OK↓ 11.Check the neutral switch. Refer to “CHECKING THE SWITCHES” on page 7-33. OK↓ 12.Check the sidestand switch.
W W W W W W W R (BLACK) W/L W/R (BLACK) 2 1 7-11 B B B W R R R W W W B B % B B B B P Dg $ L/B Ch Br/W B B/Y B/Y B/Y Br R/W Br (BLACK) R R Br R/W B 3 B/Y B 4 7 B R B 5B R R R W W B/Y Br 6 W/L W/R W W W 20A R/W Br P B .
CHARGING SYSTEM 2. 3. 4. 6. A.C.
CHARGING SYSTEM EAS27220 TROUBLESHOOTING The battery is not being charged. NOTE: Before troubleshooting, remove the following part(s): 1.Seat 2.Rear side cover 3.Fuel tank 4.Carburetor assembly 1. Check the fuse. Refer to “CHECKING THE FUSE” on page 7-37. NG→ Replace the fuse. OK↓ 2. Check the battery. Refer to “CHECKING AND CHARGING THE BATTERY” on page 7-37. NG→ ● Clean the battery terminals. or replace the battery. ● Recharge OK↓ 3. Check the stator coil.
CHARGING SYSTEM 7-14
W W W W W W W R (BLACK) W/L W/R (BLACK) 2 1 B B B W R R R W W W B B B B % 7-15 B B B B P Dg $ Y Dg Ch L/B Ch Br/W B B/Y B/Y B/Y Br R/W Br (BLACK) R R Br R/W B 3 B/Y B 4 7 5B R R R R W W B/Y Br 6 W/L W/R W W W 20A R/W Br P B .
LIGHTING SYSTEM 4. Fuse 6. Battery 9. Main switch 19. C. D. I. unit 22. Meter assembly 26. High beam indicator light 29. Tail/brake light 31. Front turn signal light (right) 32. Front turn signal light (left) 34. Headlight 38. Headlight relay 40. Left handlebar switch 42.
LIGHTING SYSTEM EAS27260 TROUBLESHOOTING Any of the following fail to light: headlight, high beam indicator light, taillight, license light or meter light. NOTE: Before troubleshooting, remove the following part(s): 1.Seat 2.Rear side cover 3.Tool box 1. Check the each bulbs and bulb sockets condition. Refer to “CHECKING THE BULBS NG→ Replace the bulb(s), bulb socket(s) or both. NG→ Replace the fuse(s). AND BULB SOCKETS” on page 7-36. OK↓ 2. Check the fuse. Refer to “CHECKING THE FUSE” on page 7-37.
LIGHTING SYSTEM 7-18
W W W W W W W R (BLACK) W/L W/R (BLACK) 2 1 B B B W R R R W W W B B B B % 7-19 B B B B P Dg $ Y Dg Ch L/B Ch Br/W B B/Y B/Y B/Y Br R/W Br (BLACK) R R Br R/W B 3 B/Y B 4 7 5B R R R R W W B/Y Br 6 W/L W/R W W W 20A R/W Br P B .
SIGNALING SYSTEM 4. Fuse 6. Battery 9. Main switch 18. Neutral switch 19. C. D. I. unit 22. Meter assembly 23. Neutral indicator light 24. Multi-function display 25. Speedometer 27. Turn signal indicator light 28. Speed sensor 29. Tail/brake light 30. Rear turn signal light (right) 31. Front turn signal light (right) 32. Front turn signal light (left) 33. Rear turn signal light (left) 35. Rear brake light switch 36. Front brake light switch 37. Turn signal relay 39. Horn 40. Left handlebar switch 41.
SIGNALING SYSTEM EAS27290 TROUBLESHOOTING ● Any of the following fail to light: turn signal light, brake light or an indicator light. ● The horn fails to sound. ● The speedometer fails to operate. NOTE: Before troubleshooting, remove the following part(s): 1.Seat 2.Rear side cover 3.Tool box 1. Check the fuse. Refer to “CHECKING THE FUSE” on page 7-37. NG→ Replace the fuse(s). OK↓ 2. Check the battery. Refer to “CHECKING AND CHARGING THE BATTERY” on page 7-37. NG→ ● Clean the battery terminals.
SIGNALING SYSTEM The tail/brake light fails to come on. 1. Check the tail/brake light bulb and socket. Refer to “CHECKING THE BULBS NG→ Replace the tail/brake light bulb, socket or both. NG→ Replace the front brake light switch. NG→ Replace the rear brake light switch. NG→ Properly connect or repair the signaling system’s wiring. AND BULB SOCKETS” on page 7-36. OK↓ 2. Check the front brake light switch. Refer to “CHECKING THE SWITCHES” on page 7-33. OK↓ 3. Check the rear brake light switch.
SIGNALING SYSTEM The neutral indicator light fails to come. 1. Check the neutral switch. Refer to “CHECKING THE SWITCHES” on page 7-33. NG→ Replace the neutral switch. NG→ Properly connect or repair the signaling system’s wiring. NG→ Replace the speed sensor. NG→ Properly connect or repair the signaling system’s wiring. OK↓ 2. Check the entire signaling system’s wiring. Refer to “CIRCUIT DIAGRAM” on page 7-19. OK↓ This circuit is OK. The speedometer fails to operate. 1. Check the speed sensor.
SIGNALING SYSTEM 7-24
W W W W W W W R (BLACK) W/L W/R (BLACK) 2 1 B B 7-25 W R R R W W W B B B B % B B B B P Dg $ Y Dg Ch L/B Ch Br/W B B/Y B/Y B/Y Br R/W Br (BLACK) R R Br R/W B 3 B/Y B 4 7 5B R R R R W W B/Y Br B 6 W/L W/R W W W 20A R/W Br P B .
CARBURETOR HEATING SYSTEM 4. Fuse 6. Battery 9. Main switch 44. Thermo switch 45.
CARBURETOR HEATING SYSTEM EAS27510 TROUBLESHOOTING The carburetor warmer system fails to operate. NOTE: Before troubleshooting, remove the following part(s): 1.Seat 2.Rear side cover 3.Tool box 4.Fuel tank 5.Carburetor assembly 6.Rectifier/regulator 1. Check the fuse. Refer to “CHECKING THE FUSE” on page 7-37. NG→ Replace the fuse(s). OK↓ 2. Check the battery. Refer to “CHECKING AND CHARGING THE BATTERY” on page 7-37. NG→ ● Clean the battery terminals. ● Recharge or replace the battery. OK↓ 3.
CARBURETOR HEATING SYSTEM 7-28
ELECTRICAL COMPONENTS EAS27971 ELECTRICAL COMPONENTS EAS3C51017 4 3 7 2 1 5 6 8 13 12 9 11 10 7-29
ELECTRICAL COMPONENTS 1. Main switch 2. Diode1 3. Diode3 4. Diode2 5. Fuse 6. Starter relay 7. Battery 8. Rectifier/regulator 9. Sidestand switch 10. Rear brake light switch 11. Headlight relay 12. Starting circuit cut-off relay 13.
ELECTRICAL COMPONENTS 2 3 1 4 8 9 7 5 6 7-31
ELECTRICAL COMPONENTS 1. 2. 3. 4. 5. 6. 7. 8. 9.
ELECTRICAL COMPONENTS EAS27980 CHECKING THE SWITCHES 6 1 2 7 3 8 9 4 10 Sb Sb 5 Sb 11 B 7-33 B
ELECTRICAL COMPONENTS 1. Horn switch 2. Dimmer switch 3. Turn signal switch 4. Clutch switch 5. Sidestand switch 6. Main switch 7. Engine stop switch 8. Start switch 9. Front brake light switch 10. Neutral switch 11.
ELECTRICAL COMPONENTS 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. ECA14370 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. Pocket tester 90890-03132 NOTE: checking for continuity, set the pocket tester to “0” and to the “Ω × 1” range.
ELECTRICAL COMPONENTS EAS27990 ● CHECKING THE BULBS AND BULB SOCKETS 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. Types of bulbs The bulbs used on this vehicle are shown in the illustration on the left.
ELECTRICAL COMPONENTS 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. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Replace: ● Blown fuse ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Set the main switch to “OFF”. b. Install a new fuse of the correct amperage rating. c. Set on the switches to verify if the electrical circuit is operational. d.
ELECTRICAL COMPONENTS OUT OF REACH OF CHILDREN. bodily contact with electrolyte as it can cause severe burns or permanent eye injury. FIRST AID IN CASE OF BODILY CONTACT: EXTERNAL ● Skin — Wash with water. ● Eyes — Flush with water for 15 minutes and get immediate medical attention. INTERNAL ● Drink large quantities of water or milk followed with milk of magnesia, beaten egg or vegetable oil. Get immediate medical attention. 2 ● Avoid 3 1 3. Remove: ● Battery 4.
ELECTRICAL COMPONENTS voltage adjust dial at 20–24 V and monitor the amperage for 3–5 minutes to check the battery. the battery quickly and can cause battery overheating and battery plate damage. ● If it is impossible to regulate the charging current on the battery charger, be careful not to overcharge the battery. ● Remove the battery when charging it. (If charging has to be done with the battery mounted on the vehicle, disconnect the negative lead from the battery terminal.
ELECTRICAL COMPONENTS 1. Disconnect the relay from the wire harness. 2. Connect the pocket tester (Ω × 1) and battery (12 V) to the relay terminal as shown. Check the relay operation. Out of specification → Replace. Starter relay ter leaving the battery unused for more than 30 minutes. 12.8 V or more --- Charging is complete. 12.7 V or less --- Recharging is required. Under 12.0 V --- Replace the battery. 3 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 6. Install: ● Battery 7.
ELECTRICAL COMPONENTS Headlight relay 3 4 2 1. 2. 3. 4. + 1 b. Turn the main switch “ON”. c. Measure the input voltage of the turn signal light and hazard relay. Positive battery terminal Negative battery terminal Positive tester probe Negative tester probe ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Check: ● Turn signal light and hazard relay output voltage Out of specification → Replace the turn signal light and hazard relay.
ELECTRICAL COMPONENTS B ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3 EAS28050 CHECKING THE DIODE 1. Check: ● Diode2 ● Diode3 Out of specification → Replace. 4 Pocket tester 90890-03132 A. Diode2 B. Diode3 NOTE: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ The following lists the specifications if you use the pocket tester (90890-03132). a. Disconnect the diode from the wire harness. b. Connect the pocket tester (Ω × 1) to the diode coupler as shown. c. Check the diode for continuity. d.
ELECTRICAL COMPONENTS EAS28090 CHECKING THE IGNITION COIL 1. Check: ● Primary coil resistance Out of specification → Replace. Positive tester probe High tension code “1” Negative tester probe Orange “2” Primary coil resistance 0.18–0.27 Ω ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the ignition coil connectors from the wire harness. b. Connect the pocket tester (Ω × 1) to the ignition coil as shown. Pocket tester 90890-03132 c. Measure the secondary coil resistance.
ELECTRICAL COMPONENTS 2 1 b. Measure the pickup coil resistance. 2. Spark plug cap c. Turn the main switch “ON” and set the engine stop switch to the “ . d. Measure ignition spark gap “a”. e. Press start switch “ ” to crank the engine, and gradually increase the spark plug gap until the engine misfires. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS28150 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS28110 CHECKING THE PICKUP COIL 1. Disconnect: ● Pickup coil coupler (from the wire harness) 2.
ELECTRICAL COMPONENTS ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS28180 CHECKING THE HORN 1. Check: ● Horn resistance Out of specification → Replace. 1 2 Horn resistance 1.01–1.11 Ω at 20°C (68°F) 3 b. Measure the stator coil resistance. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS28170 CHECKING THE RECTIFIER/REGULATOR 1. Check: ● Rectifier/regulator input voltage Out of specification → Replace the rectifier/ regulator. a. Disconnect the horn leads from the horn terminals. b.
ELECTRICAL COMPONENTS EAS28270 a CHECKING THE THERMO SWITCH 1. Remove: ● Thermo switch (from the thermostat housing) b EWA13830 WARNING ● Handle the thermo switch with special care. subject the thermo switch to strong shocks. If the thermo switch is dropped, replace it. ● Never ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS28240 CHECKING THE SPEED SENSOR 1. Disconnect: ● Speed sensor coupler 2. Check: ● Speed sensor resistance Out of specification → Replace. 2.
ELECTRICAL COMPONENTS ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ A. When the water temperature increases B. When the water temperature decreases e. Check the thermo switch for continuity. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS28310 CHECKING THE CARBURETOR WARMER 1. Check: ● Carburetor warmer element resistance Out of specification → Replace. Carburetor warmer resistance 4.7–9.5 Ω 20°C (68°F) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the carburetor warmer leads from the carburetor. b.
TROUBLESHOOTING TROUBLESHOOTING ...................................................................................8-1 GENERAL INFORMATION ......................................................................8-1 STARTING FAILURES.............................................................................8-1 INCORRECT ENGINE IDLING SPEED ...................................................8-1 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE..........................8-2 FAULTY GEAR SHIFTING............................
TROUBLESHOOTING Deteriorated or contaminated fuel Clogged pilot jet ● Clogged pilot air passage ● Sucked-in air ● Damaged float ● Worn needle valve ● Improperly installed needle valve seat ● Incorrect fuel level ● Improperly installed pilot jet ● Clogged starter jet ● Faulty starter plunger ● Improperly adjusted starter cable Electrical system 1. Battery ● Discharged battery ● Faulty battery 2. Fuse(s) ● Blown, damaged or incorrect fuse ● Improperly installed fuse 3.
TROUBLESHOOTING Incorrect valve clearance ● Damaged valve train components 2. Air filter ● Clogged air filter element Fuel system 1. Carburetor(s) ● Faulty starter plunger ● Loose or clogged pilot jet ● Loose or clogged pilot air jet ● Damaged or loose carburetor joint ● Improperly synchronized carburetors ● Improperly adjusted engine idling speed (throttle stop screw) ● Improper throttle cable free play ● Flooded carburetor ● Faulty air induction system Electrical system 1.
TROUBLESHOOTING Incorrect oil level Incorrect oil viscosity (high) ● Deteriorated oil ● Cracked or damaged cap bolt O-ring 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 ● ● EAS28590 OVERHEATING Engine 1. Cylinder head(s) and piston(s) ● Heavy carbon buildup 2.
TROUBLESHOOTING ● Incorrect connection grounded circuit ● Poor contacts (main or light switch) ● Burnt-out headlight bulb Headlight bulb burnt out ● Wrong headlight bulb ● Faulty battery ● Faulty rectifier/regulator ● Improperly grounded circuit ● Faulty main switch ● Faulty light switch ● Headlight bulb life expired Tail/brake light does not come on ● Wrong tail/brake light bulb ● Too many electrical accessories ● Incorrect connection ● Burnt-out tail/brake light bulb Tail/brake light bulb burnt out ● Wro
EAS28740 EAS28750 WIRING DIAGRAM COLOR CODE XT250X/XT250XC 2008 B Black 1.Pickup coil 2.A.C. magneto 3.Rectifier/regulator 4.Fuse 5.Starter relay 6.Battery 7.Starter motor 8.Diode 1 9.Main switch 10.Right handlebar switch 11.Engine stop switch 12.Start switch 13.Diode 2 14.Clutch switch 15.Sidestand switch 16.Starting circuit cut-off relay 17.Diode 3 18.Neutral switch 19.C. D. I. unit 20.Ignition coil 21.Spark plug 22.Meter assembly 23.Neutral indicator light 24.Multi-function display 25.
YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U.S.A.
W W W W W W W R (BLACK) W/L W/R (BLACK) 2 1 B B W R R R W W W B B B B % B B B B P Dg $ Y Dg Ch L/B Ch Br/W B B/Y B/Y B/Y Br R/W Br (BLACK) R R Br R/W B 3 B/Y B 4 7 5B R R R R W W B/Y Br B 6 W/L W/R W W W R/W Br P B .
(BLACK) (BLACK) A A (BLACK) OFF PUSH (BLACK) ON OFF LOCK 2008 XT250X/XT250XC WIRING DIAGRAM (RED) HI LO (RED) OFF RUN L N R (BLACK) (BLACK) (GRAY) (BLACK) (BLACK) (GRAY) OFF ON C C C (BLACK) (BROWN) (BROWN) B B (BLACK) (BLACK) (BLACK) (GRAY) (BLACK) TAIL LIGHT (BLACK) MAIN HARNESS MAIN HARNESS SPEED SENSOR C (GRAY) MAIN HARNESS CARB.
