YFZ450S SERVICE MANUAL LIT-11616-17-11 5TG-28197-10
EBS00001 YFZ450S SERVICE MANUAL ©2003 by Yamaha Motor Corporation, U.S.A. First Edition, May 2003 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.
EBS00002 NOTICE This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha machine has a basic understanding of the mechanical ideas and the procedures of machine repair. Repairs attempted by anyone without this knowledge are likely to render the machine unsafe and unfit for use.
EBS00004 HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual consists of chapters for the main categories of subjects. (See “symbols”) 1st title 1: This is the title of the chapter with its symbol in the upper right corner of each page. 2nd title 2: This title indicates the section of the chapter and only appears on the first page of each section. It is located in the upper left corner of the page.
1 EBS00006 2 GEN INFO SYMBOLS The following symbols are not relevant to every machine. Symbols 1 to 9 indicate the subject of each chapter.
EBS00008 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS ENGINE COOLING SYSTEM CARBURETOR CHASSIS GEN INFO 1 SPEC 2 CHK ADJ 3 ENG 4 COOL 5 CARB 6 CHAS 7 – ELECTRICAL TROUBLESHOOTING + ELEC 8 TRBL SHTG 9
CHAPTER 1 GENERAL INFORMATION MACHINE IDENTIFICATION...........................................................................1-1 VEHICLE IDENTIFICATION NUMBER .....................................................1-1 MODEL LABEL.......................................................................................... 1-1 IMPORTANT INFORMATION ......................................................................... 1-2 PREPARATION FOR REMOVAL AND DISASSEMBLY...........................
CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION.............................................................................................. 3-1 PERIODIC MAINTENANCE/LUBRICATION .................................................. 3-1 SEAT, FENDERS AND FUEL TANK .............................................................. 3-3 SEAT, FUEL TANK COVER AND SIDE COVERS ...................................3-3 FOOT PROTECTORS AND ENGINE SKID PLATE .................................
CHECKING THE WHEELS ..................................................................... 3-55 CHECKING AND LUBRICATING THE CABLES .................................... 3-55 LUBRICATING THE LEVERS AND PEDALS .........................................3-56 ELECTRICAL SYSTEM................................................................................. 3-57 CHECKING AND CHARGING THE BATTERY....................................... 3-57 CHECKING THE FUSES ..........................................................
CYLINDER AND PISTON.............................................................................. 4-34 REMOVING THE PISTON ...................................................................... 4-35 CHECKING THE CYLINDER AND PISTON ...........................................4-35 CHECKING THE PISTON RINGS........................................................... 4-37 CHECKING THE PISTON PIN ................................................................4-38 INSTALLING THE PISTON ...........................
CRANKCASE ................................................................................................4-65 OIL SEAL AND BEARING....................................................................... 4-67 SEPARATING THE CRANKCASE.......................................................... 4-68 CHECKING THE OIL STRAINER AND OIL DELIVERY PIPE 2 ............. 4-68 CHECKING THE TIMING CHAIN AND GUIDE....................................... 4-69 CHECKING THE BEARINGS AND OIL SEALS................................
CHAPTER 7 CHASSIS FRONT AND REAR WHEELS ........................................................................ 7-1 FRONT WHEELS ......................................................................................7-1 REAR WHEELS ........................................................................................7-3 CHECKING THE WHEELS ....................................................................... 7-4 CHECKING THE WHEEL HUBS...............................................................
INSTALLING THE HANDLEBAR ............................................................ 7-44 INSTALLING THE HANDLEBAR GRIPS ................................................ 7-44 INSTALLING THE CLUTCH LEVER .......................................................7-45 INSTALLING THE BRAKE MASTER CYLINDER ................................... 7-45 STEERING STEM ...................................................................................7-46 REMOVING THE BEARING RETAINER ......................................
CHAPTER 8 ELECTRICAL ELECTRICAL COMPONENTS........................................................................ 8-1 CHECKING SWITCH CONTINUITY................................................................8-2 CHECKING THE SWITCHES..........................................................................8-4 CHECKING THE BULBS AND BULB SOCKETS .......................................... 8-6 TYPES OF BULBS ....................................................................................
CHAPTER 9 TROUBLESHOOTING STARTING FAILURE/HARD STARTING .......................................................9-1 FUEL SYSTEM.......................................................................................... 9-1 ELECTRICAL SYSTEM.............................................................................9-1 COMPRESSION SYSTEM........................................................................ 9-2 POOR IDLE SPEED PERFORMANCE ...........................................................
MACHINE IDENTIFICATION GEN INFO EBS00009 GENERAL INFORMATION MACHINE IDENTIFICATION EBS00010 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 stamped into the left side of the frame. is 1 EBS00011 MODEL LABEL The model label 1 is affixed to the air filter case cover. This information will be needed to order spare parts.
IMPORTANT INFORMATION GEN INFO EBS00013 IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Before removal and disassembly remove all dirt, mud, dust and foreign material. 2. Use only the proper tools and cleaning equipment. Refer to “SPECIAL TOOLS”. 3. When disassembling always keep mated parts together. This includes gears, cylinders, pistons and other parts that have been “mated” through normal wear. Mated parts must always be reused or replaced as an assembly. 4.
IMPORTANT INFORMATION GEN INFO EBS00016 LOCK WASHERS/PLATES AND COTTER PINS After removal, replace all lock washers/plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut. EBS00017 BEARINGS AND OIL SEALS Install bearings and oil seals so that the manufacturer’s marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease.
IMPORTANT INFORMATION GEN INFO EBS00019 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: • lead • coupler • connector 2. Check: • lead • coupler • connector Moisture → Dry with an air blower. Rust/stains → Connect and disconnect several times. 3. Check: • all connections Loose connection → Connect properly. NOTE: If the pin 1 on the terminal is flattened, bend it up. _ 4.
SPECIAL TOOLS GEN INFO EBS00021 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools; this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools may differ by shape and part number from country to country. In such a case, two types are provided. When placing an order, refer to the list provided below to avoid any mistakes. For US and CDN P/N.
SPECIAL TOOLS Tool No. Tool name/Function Radiator cap tester adapter 90890-01352 YU-33984 This tool is used to check the cooling system. Damper rod holder (30 mm) 90890-01327 YM-01327 This tool is needed to loosen and tighten the steering stem bearing retainer. Steering nut wrench 90890-01443 YU-33975 This tool is needed to loosen and tighten the front shock absorber and rear shock absorber locknuts.
SPECIAL TOOLS Tool No. Compressor 90890-04019 YM-04019 Attachment 90890-04114 YM-04114 Tool name/Function Valve spring compressor Valve spring compressor attachment This tool is needed to remove and install the valve assemblies. Universal clutch holder 90890-04086 YM-91042 90890-04097 YM-04097 90890-04116 YM-04116 90890-04098 YM-04098 90890-04117 YM-04117 90890-04099 YM-04099 90890-04118 YM-04118 This tool is needed to hold the clutch carrier when removing or installing the carrier nut.
SPECIAL TOOLS Tool No. Tool name/Function Axle nut wrench (46 mm) YM-37134 This tool is needed to loosen or tighten the rear axle nut. Ignition checker 90890-06754 This instrument is necessary for checking the ignition system components. Dynamic spark tester YM-34487 This instrument is necessary for checking the ignition system components. Bond 90890-85505 Sealant ACC-11001-05-01 Yamaha bond No. 1215 Sealant (Quick Gasket®) This sealant (bond) is used on crankcase mating surfaces, etc.
GENERAL SPECIFICATIONS SPEC EBS01001 SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Model code Dimensions Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius Basic weight With oil and full fuel tank Engine Engine type Cylinder arrangement Displacement Bore × stroke Compression ratio Starting system Lubrication system Oil type or grade Engine oil 5TG1 1,840 mm (72.4 in) 1,170 mm (46.1 in) 1,090 mm (42.9 in) 800 mm (31.
GENERAL SPECIFICATIONS Item Carburetor Type/quantity Manufacturer Spark plug Type/manufacturer Spark plug gap Clutch type Transmission Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Transmission type Operation Gear ratio 1st gear 2nd gear 3rd gear 4th gear 5th gear Chassis Frame type Caster angle Camber angle Kingpin angle Kingpin offset Trail Tread (STD) front rear Toe-in (with tires touching the ground) Tire Type Size front rear Manufacturer front re
GENERAL SPECIFICATIONS Item Brake Front brake Rear brake Suspension Front suspension Rear suspension Shock absorber Front shock absorber Rear shock absorber Wheel travel Front wheel travel Rear wheel travel Electrical Ignition system Generator system Battery type Battery capacity Headlight type Bulb voltage/wattage × quantity Headlight Tail/brake light Indicator and warning lights Neutral Coolant temperature SPEC Standard type operation type operation Dual disc brake Right hand operation Single disc brak
ENGINE SPECIFICATIONS SPEC EBS01002 ENGINE SPECIFICATIONS Item Standard Cylinder head Warp limit ---- Cylinder Bore size Camshaft Drive method Camshaft cap inside diameter Camshaft journal diameter Camshaft-journal-to-camshaft-cap clearance Camshaft lobe dimensions Limit 0.05 mm (0.002 in) 95.00 ~ 95.01 mm (3.7402 ~ 3.7406 in) ---- Chain drive (Left) 22.000 ~ 22.021 mm (0.8661 ~ 0.8670 in) ---21.967 ~ 21.980 mm (0.8648 ~ 0.8654 in) ---0.020 ~ 0.054 mm (0.0008 ~ 0.0021 in) 0.080 mm (0.
ENGINE SPECIFICATIONS Item SPEC Standard Valve, valve seat, valve guide Valve clearance (cold) IN EX Valve dimensions Limit 0.10 ~ 0.15 mm (0.0039 ~ 0.0059 in) 0.20 ~ 0.25 mm (0.0079 ~ 0.0098 in) B ------- C D A Head Diameter “A” head diameter “B” face width “C” seat width “D” margin thickness Stem outside diameter Guide inside diameter Face Width Margin Thickness IN EX IN EX IN 26.9 ~ 27.1 mm (1.0591 ~ 1.0669 in) 27.9 ~ 28.1 mm (1.0984 ~ 1.1063 in) 2.26 mm (0.0890 in) 2.26 mm (0.
ENGINE SPECIFICATIONS Item Valve spring Free length Standard IN 37.03 mm (1.46 in) EX 37.68 mm (1.48 in) Set length (valve closed) IN EX Compressed pressure (installed) IN 27.87 mm (1.10 in) 27.38 mm (1.08 in) IN 111.3 ~ 127.9 N (11.35 ~ 13.04 kg, 25.02 ~ 28.75 lb) 127.4 ~ 146.4 N (12.99 ~ 14.93 kg, 28.64 ~ 32.91 lb) ---- EX ---- IN EX Clockwise Clockwise EX Tilt limit Direction of winding (top view) SPEC Piston Piston to cylinder clearance Limit 35.17 mm (1.38 in) 35.79 mm (1.
ENGINE SPECIFICATIONS Item SPEC Standard Limit Piston rings Top ring B T Type Dimensions (B × T) Barrel 1.2 × 3.5 mm (0.047 × 0.138 in) End gap (installed) 0.20 ~ 0.30 mm (0.008 ~ 0.012 in) Side clearance 0.030 ~ 0.065 mm (0.0012 ~ 0.0026 in) ------0.55 mm (0.022 in) 0.12 mm (0.0047 in) 2nd ring B T Type Dimensions (B × T) End gap (installed) Taper 1.00 × 3.35 mm (0.039 × 0.132 in) 0.35 ~ 0.50 mm (0.014 ~ 0.020 in) Side clearance 0.020 ~ 0.055 mm (0.0008 ~ 0.0022 in) ------0.85 mm (0.
ENGINE SPECIFICATIONS Item Balancer Balancer drive method Clutch Friction plate 1 (inside dia.: 120 mm) Thickness Quantity Friction plate 2 (inside dia.: 128 mm) Thickness SPEC Standard Gear 2.9 ~ 3.1 mm (0.114 ~ 0.122 in) 7 2.9 ~ 3.1 mm (0.114 ~ 0.122 in) ---- 2.8 mm (0.110 in) ---2.8 mm (0.110 in) ---- Quantity Clutch plate Thickness Quantity Max. warpage 1.5 ~ 1.7 mm (0.059 ~ 0.067 in) 7 ---- ------0.2 mm (0.0079 in) Clutch spring Free length 51.8 mm (2.04 in) 50.0 mm (1.
ENGINE SPECIFICATIONS Item Carburetor I. D. mark Main jet Main air jet Jet needle/clip position Cutaway Pilot air jet Pilot outlet Pilot jet Bypass 1 Valve seat size Starter jet Float height Engine idle speed Intake vacuum Standard (M.J) (M.A.J) (J.N) (C.A) (P.A.J.1) (P.O) (P.J) (B.P.1) (V.S) (G.S.1) (F.
ENGINE SPECIFICATIONS SPEC Lubrication chart Oil tank Pressure feed Splashed scavenge Camshaft Valve lifter Cylinder head Piston Transmission gears Piston pin Main axle Oil filter Crank pin Drive axle Check ball Oil pump rotor 1 Oil pump rotor 2 Oil strainer Oil pan 2 - 10
ENGINE SPECIFICATIONS Cylinder head tightening sequence 2 - 11 SPEC
CHASSIS SPECIFICATIONS SPEC EBS01003 CHASSIS SPECIFICATIONS Item Steering system Steering bearing type Front suspension Shock absorber travel Fork spring free length Spring fitting length Spring rate (K1) Spring rate (K2) Optional spring Rear suspension Shock absorber travel Spring free length Spring fitting length Spring rate (K1) Stroke (K1) Optional spring Swingarm Free play limit Front wheel Type Rim size Rim material Rim runout limit Rear wheel Type Rim size Rim material Rim runout limit Drive ch
CHASSIS SPECIFICATIONS Item Front disc brake Type Disc outside diameter × thickness Pad thickness inner Pad thickness outer Master cylinder inside diameter Caliper cylinder inside diameter Brake fluid type Rear disc brake Type Disc outside diameter × thickness Pad thickness inner Pad thickness outer Master cylinder inside diameter Caliper cylinder inside diameter Brake fluid type Brake lever and brake pedal Brake pedal position Parking brake cable end length Clutch lever free play (lever end) Throttle lever
ELECTRICAL SPECIFICATIONS SPEC EBS01004 ELECTRICAL SPECIFICATIONS Item Standard Voltage Ignition system Ignition timing (B.T.D.C.) Advancer type C.D.I. C.D.I.
ELECTRICAL SPECIFICATIONS Item Starter relay Model/manufacturer Amperage rating Coil winding resistance Thermo switch Thermo switch 1 Model/manufacturer Opening temperature Closing temperature Thermo switch 2 Model/manufacturer Opening temperature Closing temperature Circuit breaker Type Amperage for individual circuit Fuse Reserve Standard SPEC Limit 2768079-A/JIDECO 180 A 4.18 ~ 4.62 Ω ---------- 5GH/NIPPON THERMOSTAT 95 ~ 101 °C (203.0 ~ 213.8 °F) 89 ~ 95 °C (192.2 ~ 203.
TIGHTENING TORQUES SPEC EBS01005 TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Part to be tightened Part name Thread Q’ty size Spark plug Cylinder head cover Camshaft cap Cylinder head blind plug screw Timing chain tensioner Timing chain tensioner cap Timing chain guide (intake) Cylinder head (exhaust pipe) Cylinder head (timing chain side) Cylinder head — M10S 1 Bolt M6 2 Bolt M6 10 Screw M12 1 Bolt M6 2 Bolt M6 1 Bolt M6 2 Stud bolt M8 1 Stud bolt M6 2 Bolt M10 4 Nut M6 2 Parking brake cable and clu
TIGHTENING TORQUES Part to be tightened Part name Thread Q’ty size SPEC Tightening torque Nm m · kg ft · lb Cylinder head water jacket Water pump housing cover Coolant reservoir Clutch cover Clutch spring Clutch boss Bolt Bolt Bolt Bolt Bolt Nut M6 M6 M6 M6 M6 M20 1 4 2 7 6 1 10 10 7 10 8 75 1.0 1.0 0.7 1.0 0.8 7.5 7.2 7.2 5.1 7.
TIGHTENING TORQUES Part to be tightened Part name Thermo switch 2 Starter motor Starter motor lead Bush holder assembly and rear bracket nut — Bolt Nut Nut Thread Q’ty size M18 M6 M6 M6 1 2 1 1 SPEC Tightening torque Nm m · kg ft · lb 28 10 7 7 2.8 1.0 0.7 0.7 Remarks 20 7.2 5.1 5.1 NOTE: *1: Tighten the cylinder head bolts to 30 Nm (3.0 m · kg, 22 ft · lb) in the proper tightening sequence, remove and retighten the cylinder head bolts to 20 Nm (2.
TIGHTENING TORQUES SPEC EBS01006 CHASSIS TIGHTENING TORQUES Part to be tightened Thread size Tightening torque Nm m · kg ft · lb Engine stay and frame Engine stay and engine upper bracket Engine upper bracket and engine Engine lower bracket and engine Engine and frame Engine lower bracket and frame Swingarm pivot shaft, engine, and frame Rear shock absorber and frame Rear shock absorber locknut Relay arm and swingarm Connecting arm and frame Relay arm and rear shock absorber Relay arm and connecting a
TIGHTENING TORQUES Part to be tightened Thread size Tightening torque Nm m · kg ft · lb Front brake master cylinder and brake lever Front brake master cylinder and brake hose Brake hose joint and frame Bleed screw Front brake pad retaining bolt Front brake caliper and brake hose Rear brake caliper retaining bolt Parking brake case bracket and parking brake case Rear axle ring nut Rear axle ring nut set bolt Rear brake pad retaining bolt M36 M6 M8 100 7 18 10.0 0.7 1.8 72 5.
HOW TO USE THE CONVERSION TABLE/ GENERAL TIGHTENING TORQUE SPECIFICATIONS SPEC EBS00022 EBS00023 HOW TO USE THE CONVERSION TABLE GENERAL TIGHTENING TORQUE SPECIFICATIONS All specification data in this manual are listed in SI and METRIC UNITS. Use this table to convert METRIC unit data to IMPERIAL unit data. This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch.
LUBRICATION POINTS AND LUBRICANT TYPES SPEC EBS00024 LUBRICATION POINTS AND LUBRICANT TYPES ENGINE Lubrication point Lubricant Oil seal lips LS O-rings LS Bearings E Crankshaft pins E Valve stems (intake and exhaust) M Valve stem ends (intake and exhaust) M Valve lifters (intake and exhaust) E Camshafts (intake and exhaust) M Camshaft cap bolt E Cylinder head bolt M Piston surfaces E Piston pins M Auto decomp E Auto decompression lever E Water pump impeller shaft E Oil pum
LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point SPEC Lubricant Crankcase mating surfaces Sealant (Quick Gasket®) Yamaha bond No.1215 Cylinder head and cylinder head cover mating surfaces Sealant (Quick Gasket®) Yamaha bond No.1215 AC magneto lead grommet (AC magneto cover) Sealant (Quick Gasket®) Yamaha bond No.
SPEC COOLANT FLOW DIAGRAMS EBS00025 COOLANT FLOW DIAGRAMS 1 Radiator inlet hose 2 Radiator 3 Radiator fan 4 Radiator outlet hose 5 Water pump inlet pipe 6 Water pump 7 Thermo switch 1 8 Thermo switch 2 9 Cylinder head water jacket 7 8 A Ì Í B A 1 B D 2 C Ê 4 Ë D 3 È C É 5 Ê Î 6 D-D 2 - 24 9
SPEC COOLANT FLOW DIAGRAMS È Install the radiator outlet hose with the white paint mark parallel to the ground as shown. É Install the radiator outlet hose completely on the radiator pipe until the hose contacts the flange of the pipe. Ê 30 mm (1.18 in) Ë Install the radiator outlet hose onto the water pump inlet pipe until the end of the hose reaches the middle of the blue paint mark on the pipe. Ì Align the white paint mark on the radiator inlet hose with the projection on the radiator pipe.
OIL FLOW DIAGRAMS SPEC EBS00026 OIL FLOW DIAGRAMS 1 Intake camshaft 2 Exhaust camshaft 3 Oil filter element 4 Oil tank 5 Oil pipe 1 6 Oil pipe 2 7 Main axle 8 Drive axle 9 Oil delivery pipe 1 0 Oil pump A Oil strainer A 1 2 A 9 4 3 3 B C B C 8 B-B 7 6 5 A 0 C-C 2 - 26
SPEC OIL FLOW DIAGRAMS 1 Camshaft 2 Oil filter element 3 Crankshaft 4 Main axle 5 Drive axle 6 Oil delivery pipe 2 7 Connecting rod 1 7 2 3 4 5 6 2 - 27
CABLE ROUTING EBS00028 CABLE ROUTING 1 Parking brake cable 2 Clutch cable 3 Clutch switch lead 4 Handlebar switch lead 5 Front brake light switch lead 6 Throttle switch lead 7 Front brake hose 8 Throttle cable 1 4 2 3 5 6 7 É È A Ê Ì A 2 - 28 6Ë 8 SPEC
CABLE ROUTING SPEC È Fasten the clutch switch lead and handlebar switch lead to the handlebar with the plastic band. É Fasten the front brake light switch lead and throttle switch lead to the handlebar with the plastic band. Ê Less than 10 mm (0.39 in) Ë Make sure that there is no slack in the throttle switch lead. Ì Fasten the throttle switch lead to the handlebar with the plastic band.
CABLE ROUTING 1 Throttle cable 2 Front brake hose 3 Front brake light switch lead 4 Throttle switch lead 5 Clutch cable 6 Parking brake cable 7 Clutch switch lead 8 Handlebar switch lead 9 Radiator fan breather hose 0 Thermo switch 2 lead A Headlight coupler (left) B C.D.I. unit leads C Rectifier/regulator coupler D Brake pipe E Rectifier/regulator F C.D.I.
CABLE ROUTING È Pass the throttle cable through the cable guide. É Pass the throttle cable, leads (front brake light switch, throttle switch, clutch switch, and handlebar switch), parking brake cable, and clutch cable through the cable guide in the order listed. Ê Pass the throttle cable through the steering stem cable guide. Ë 30 ~ 50 mm (1.18 ~ 1.
CABLE ROUTING Ï Slide the rubber cover over the couplers (front brake light switch, throttle switch, clutch switch, and handlebar switch) and fasten the center of the cover with the plastic band. Ð Pass the clutch cable and parking brake cable through the cable guide in this order. Ñ Fasten the radiator fan breather hose with the holder on the radiator grill. Ò Install the brake hose cover so that the slits in the cover fit over the brake hose grommet.
CABLE ROUTING 1 Indicator coupler 2 Radiator fan motor coupler 3 Thermo switch 2 4 Fuel tank breather hose 5 Radiator fan motor lead 6 Radiator fan breather hose 7 Wire harness 8 Fuel hose 9 Throttle position sensor lead 0 Carburetor switch lead A Crankcase breather hose B Battery negative lead C Starter motor lead D Neutral switch lead E A.C. magneto lead F Oil tank breather hose G Neutral switch coupler H A.C.
CABLE ROUTING SPEC Í Fasten the wire harness, throttle position sensor lead, and carburetor switch lead with the plastic band. Make sure that there is no slack in the throttle position sensor lead and carburetor switch lead along the frame as shown. Î Install the cylinder head breather hose with the paint mark facing to the left. Ï More than 15 mm (0.59 in) Ð Fasten the wire harness with the plastic band on the white tape and then face the end of the plastic band inward.
CABLE ROUTING SPEC Ô Fasten the neutral switch lead with the lead holder. Õ Fasten the neutral switch lead with the clamp. Ö Fasten the A.C. magneto lead with the lead holder. × Fasten the neutral switch lead and A.C. magneto lead with the plastic band. Face the end of the plastic band inward on top of the frame. Ø Pass the neutral switch lead and A.C. magneto lead through the guide on the fender stay.
CABLE ROUTING SPEC Ù When installing the fuel tank cover, do not pinch the front brake hose, throttle cable, front brake light switch lead, or throttle switch lead. Ú Route the front brake hose in front of the handlebar cover. Û Route the clutch cable and parking brake cable in front of the handlebar cover. Ü When installing the fuel tank cover, do not pinch the clutch cable, parking brake cable, clutch switch lead, or handlebar switch lead.
CABLE ROUTING 1 Wire harness 2 Air filter case breather hose 3 Cylinder head breather hose 4 Coolant reservoir breather hose 5 Coolant reservoir hose 6 Tail/brake light 7 Tail/brake light lead 8 Crankcase breather hose 9 Carburetor drain hose 0 Carburetor air vent hose A Battery negative lead SPEC B Starter motor lead È When installing the rear fender, make sure that the rear fender does not overlap or pinch the cylinder head breather hose, coolant reservoir hose, or wire harness.
CABLE ROUTING SPEC Ï Pass the carburetor drain hose and carburetor air vent hoses through the hose guide on the engine from the left side of the machine in the order listed. Do not pinch the hoses. Ð Route the negative battery lead to the outside of the carburetor air vent hose and to the inside of the carburetor drain hose. Ñ Route the carburetor drain hose between the rear shock absorber and swingarm, and then under the frame. Ë Install the coolant reservoir breather hose without twisting the hose.
CABLE ROUTING SPEC Ò Route the carburetor drain hose between the frame and connecting arm and let it hang freely under the vehicle.
SPEC CABLE ROUTING 1 Rear brake light switch lead 2 Throttle cable 3 Clutch cable 4 Coolant reservoir hose 5 Oil tank breather hose 6 Thermo switch 1 lead 7 Parking brake cable È Fasten the coolant reservoir hose with a clamp so that it is not pinched. É Route the thermo switch 1 lead under the frame. Ê Fasten the thermo switch 1 lead with a plastic band between the diode 1 and the diode 2 and then face the end of the band inward. Ë Pass the parking brake cable through the cable guide.
CABLE ROUTING 1 Rear brake hose 2 Parking brake cable 3 Rear brake light switch 4 Rear brake light switch lead 2 1 SPEC È Install the lead protector of the rear brake light switch lead between the clamps. É Face the rear brake light switch lead holder inward and then fasten the lead with the holder.
SPEC CABLE ROUTING 1 Rectifier/regulator 2 Headlight lead (right) 3 Main switch lead 4 Thermo switch 1 lead 5 Coolant reservoir hose 6 Oil tank breather hose 7 Throttle cable 8 Ignition coil lead 9 Rear brake light switch lead 0 Cylinder head breather hose A Carburetor switch lead B Throttle position sensor lead C Wire harness D Headlight lead (left) E C.D.I. unit È Route the wire harness on top of the frame. É Route the headlight lead (right) over the frame and connect.
SPEC CABLE ROUTING Ê Route the main switch lead under the frame and connect. Ë To thermo switch 1 Ì To main switch Í To radiator Î Route the rear brake light switch lead over the throttle cable. Ï Route the rear brake light switch lead and ignition coil lead over the cylinder head breather hose. Ð To carburetor Ñ Fasten the wire harness with the holder on the shield under the fuel tank. Ò Route the headlight lead (left) over the frame and connect.
CABLE ROUTING 1 Starter relay 2 Battery positive lead 3 Tail/brake light lead 4 Starter motor lead 5 Starting circuit cut-off relay 6 Earth lead 7 Battery negative lead 8 Coolant reservoir hose 9 Cylinder head breather hose 0 Wire harness SPEC È Pass the coolant reservoir hose through the hose guide. É Route the earth lead and wire harness under the battery bracket. Ê Connect the tail/brake light lead between the coolant reservoir and the rear fender.
CABLE ROUTING SPEC Ì Fasten the coolant reservoir hose and the cylinder head breather hose to the frame with the plastic beaded tie at its loosest position so that the hoses are not pinched.
INTRODUCTION/ PERIODIC MAINTENANCE/LUBRICATION CHK ADJ EBS00029 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable machine operation and a longer service life. The need for costly overhaul work will be greatly reduced. This information applies to machines already in service as well as to new machines that are being prepared for sale.
PERIODIC MAINTENANCE/LUBRICATION CHK ADJ INITIAL ITEM ROUTINE 1 month Rear arm pivot* • Lubricate every 6 months with lithium-soap-based grease. Fittings and fasteners* • Check all chassis fittings and fasteners. • Correct if necessary. Lights and switches* • Check operation. • Adjust headlight beams. * 3 months EVERY 6 months 6 months 1 year Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
SEAT, FENDERS AND FUEL TANK CHK ADJ EBS00033 SEAT, FENDERS AND FUEL TANK SEAT, FUEL TANK COVER AND SIDE COVERS 2 T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 4 1 3 T. R. Order 1 Job/Part Removing the seat, fuel tank cover and side covers Seat Q’ty 1 7 Nm (0.7 m • kg, 5.1 ft • Ib) Remarks Remove the parts in the order listed. NOTE: Pull back the seat lock lever, than pull up on the rear of the seat.
SEAT, FENDERS AND FUEL TANK CHK ADJ EBS00034 FOOT PROTECTORS AND ENGINE SKID PLATE T. R. 16 Nm (1.6 m • kg, 11 ft • Ib) T. R. T. R. 13 Nm (1.3 m • kg, 9.4 ft • Ib) 13 Nm (1.3 m • kg, 9.4 ft • Ib) 2 1 3 T. R. 16 Nm (1.6 m • kg, 11 ft • Ib) 16 Nm (1.6 m • kg, 11 ft • Ib) T. R. T. R. Order 1 2 3 7 Nm (0.7 m • kg, 5.
CHK ADJ SEAT, FENDERS AND FUEL TANK EBS00036 HEADLIGHTS AND FRONT FENDER 4 5 6 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. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 3 1 1 2 R. R. 1 2 3 4 5 6 T. T. Order 7 Nm (0.7 m • kg, 5.1 ft • Ib) 7 Nm (0.7 m • kg, 5.1 ft • Ib) Job/Part Q’ty Remarks Removing the headlight and front Remove the parts in the order listed. fender Seat/fuel tank cover/side covers (left Refer to “SEAT, FENDERS AND FUEL and right) TANK”.
CHK ADJ SEAT, FENDERS AND FUEL TANK EBS00039 REAR 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) 2 T. 1 R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 1 3 5 6 T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 7 T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 4 Order 1 Job/Part Q’ty Remarks Removing the rear fender Remove the parts in the order listed. Seat/fuel tank cover/side covers (left Refer to “SEAT, FENDERS AND FUEL and right) TANK”.
SEAT, FENDERS AND FUEL TANK CHK ADJ EBS00042 FUEL TANK T. 7 Nm (0.7 m • kg, 5.1 ft • Ib) R. 3 2 1 Order 1 Job/Part Q’ty Remarks Removing the fuel tank Remove the parts in the order listed. Seat/fuel tank cover/side covers (left Refer to “SEAT, FENDERS AND FUEL and right) TANK”. Fuel hose (fuel cock side) 1 NOTE: Before disconnecting the fuel hose, turn the fuel cock to “OFF”.
ADJUSTING THE VALVE CLEARANCE CHK ADJ EAS00048 ENGINE ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: • Valve clearance adjustment should be made on a cold engine, at room temperature. • When the valve clearance is to be measured or adjusted, the piston must be at the Top Dead Center (TDC) on the compression stroke. _ 1. • • • • 3 2. • • • • • 4 2 Remove: seat fuel tank cover side covers (left and right) fuel tank Refer to “SEAT, FENDERS AND FUEL TANK”.
ADJUSTING THE VALVE CLEARANCE CHK ADJ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the crankshaft counterclockwise. b. When the piston is at the Top Dead Center (TDC) on the compression stroke, align the “I” mark a on the A.C. magneto rotor with the stationary pointer b on the A.C. magneto cover.
ADJUSTING THE VALVE CLEARANCE CHK ADJ 6. Adjust: • valve clearance ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the valve lifter 1 and the valve pad 2 with a valve lapper 3. Valve lapper 90890-04101 NOTE: • Cover the timing chain opening with a rag to prevent the valve pad from falling into the crankcase. • Make a note of the position of each valve lifter 1 and valve pad 2 so that they can be installed in the correct place. _ b. Select the proper valve pad from the following table.
ADJUSTING THE VALVE CLEARANCE CHK ADJ EXAMPLE: Original valve pad number = 148 {thickness = 1.48 mm (0.058 in)} Rounded value = 150 d. Locate the rounded number of the original valve pad and the measured valve clearance in the valve pad selection table. The point where the column and row intersect is the new valve pad number. NOTE: The new valve pad number is only an approximation. The valve clearance must be measured again and the above steps should be repeated if the measurement is still incorrect.
ADJUSTING THE VALVE CLEARANCE CHK ADJ INTAKE MEASURED CLEARANCE 0.00 ~ 0.04 0.05 ~ 0.09 0.10 ~ 0.15 0.16 ~ 0.20 0.21 ~ 0.25 0.26 ~ 0.30 0.31 ~ 0.35 0.36 ~ 0.40 0.41 ~ 0.45 0.46 ~ 0.50 0.51 ~ 0.55 0.56 ~ 0.60 0.61 ~ 0.65 0.66 ~ 0.70 0.71 ~ 0.75 0.76 ~ 0.80 0.81 ~ 0.85 0.86 ~ 0.90 0.91 ~ 0.95 0.96 ~ 1.00 1.01 ~ 1.05 1.06 ~ 1.10 1.11 ~ 1.15 1.16 ~ 1.20 1.21 ~ 1.25 1.26 ~ 1.30 1.31 ~ 1.
ADJUSTING THE VALVE CLEARANCE/ ADJUSTING THE ENGINE IDLING SPEED CHK ADJ 7. Install: • all removed parts NOTE: For installation, reverse the removal procedure. _ EBS00051 ADJUSTING THE ENGINE IDLING SPEED 1. Start the engine and let it warm up for several minutes. 2. Remove: • seat • fuel tank cover • side covers (left and right) • fuel tank NOTE: Slide the fuel tank. 3. • 4. • 5. • Refer to “SEAT, FENDERS AND FUEL TANK”.
ADJUSTING THE ENGINE IDLING SPEED/ ADJUSTING THE THROTTLE LEVER FREE PLAY a 1 b CHK ADJ 6. Adjust: • engine idling speed ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the throttle stop screw 1 in direction a or b until the specified idling speed is obtained. Direction a Idling speed becomes higher. Direction b Idling speed becomes lower. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 7. Remove: • fuel tank NOTE: Slide the fuel tank. 8. • 9.
ADJUSTING THE THROTTLE LEVER FREE PLAY CHK ADJ 1. Measure: • throttle lever free play a Out of specification → Adjust. Throttle lever free play 2 ~ 4 mm (0.08 ~ 0.16 in) 2. Adjust: • throttle lever free play b a 2 3 1 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ First step: a. Slide back the rubber cover 1. b. Loosen the locknut 2 on the carburetor side. c. Turn the adjusting nut 3 in direction a or b until the correct free play is obtained. Direction a Free play is increased.
ADJUSTING THE SPEED LIMITER CHK ADJ EBS00053 ADJUSTING THE SPEED LIMITER The speed limiter keeps the carburetor throttle from becoming fully-opened even when the throttle lever is applied to the maximum position. Screwing in the adjusting screw stops the engine speed from increasing. a 1 2 1. Measure: • speed limiter length a Out of specification → Adjust. Speed limiter length Less than 12 mm (0.47 in) 2. Adjust: • speed limiter length ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Loosen the locknut 1. b.
CHECKING THE SPARK PLUG CHK ADJ EBS00057 CHECKING THE SPARK PLUG 1. Remove: • seat • fuel tank cover • side covers (left and right) • fuel tank NOTE: Slide the fuel tank. 2. • 3. • 4. • Remove: ignition coil Remove: spark plug Check: spark plug type Incorrect → Change. Standard spark plug CR8E/NGK 5. Check: • electrode 1 Wear/damage → Replace. • insulator 2 Abnormal color → Replace. Normal color is a medium-to-light tan color. 6. Clean: • spark plug (with a spark plug cleaner or wire brush) 7.
CHECKING THE SPARK PLUG/ CHECKING THE IGNITION TIMING 9. • • • • • CHK ADJ Install: ignition coil fuel tank side covers (left and right) fuel tank cover seat Refer to “SEAT, FENDERS AND FUEL TANK”. EBS00058 CHECKING THE IGNITION TIMING NOTE: Engine idling speed and throttle cable free play should be adjusted properly before checking the ignition timing. _ 1. • • • • Remove: seat fuel tank cover side covers (left and right) fuel tank NOTE: Slide the fuel tank. Refer to “SEAT, FENDERS AND FUEL TANK”.
CHECKING THE IGNITION TIMING/ CHECKING THE ENGINE OIL LEVEL CHK ADJ 4. Check: • ignition timing 1 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Warm up the engine and keep it at the specified speed. Engine speed 1,750 ~ 1,850 r/min a b b. Remove the timing mark accessing screw 1. c. Visually check the stationary pointer a to verify it is within the required firing range b indicated on the A.C. magneto rotor. Incorrect firing range → Check the pulser coil assembly. d. Install the timing mark accessing screw.
CHECKING THE ENGINE OIL LEVEL 1 b a CHK ADJ 3. Check: • engine oil level Oil level should be between the minimum level mark a and the maximum level mark b. Low oil level → Add oil to the proper level. NOTE: • Wait a few minutes until the oil settles before checking the oil level. • Do not screw the dipstick 1 in when checking the oil level. _ Recommended oil Follow the chart on the left. NOTE: Recommended oil classification: API Service “SE”, “SF”, “SG” type or equivalent (e.g.
CHANGING THE ENGINE OIL CHK ADJ EBS00067 CHANGING THE ENGINE OIL 1. Remove: • engine skid plate Refer to “SEAT, FENDERS AND FUEL TANK”. 2. Start the engine, warm it up for several minutes, and then turn it off. 3. Place a container under the engine oil drain bolt. 4. Remove: • engine oil filler cap 1 • dipstick 2 2 1 5. Remove: • engine oil drain bolt (oil tank) 1 (along with the washer) 1 6. Remove: • engine oil drain bolt (crankcase) 1 (along with the gasket) 1 7. • 8.
CHANGING THE ENGINE OIL CHK ADJ 9. If the oil filter element is also to be replaced, perform the following procedure. 3 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 1 2 a. Remove the oil filter element cover 1 and oil filter element 2. b. Check the O-rings 3 and replace them if they are cracked or damaged. c. Install the new oil filter element and the oil filter element cover. T. Oil filter element cover bolt 10 Nm (1.0 m · kg, 7.2 ft · lb) R. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 10.
CHANGING THE ENGINE OIL SPCBXFF CHK ADJ Overhaul Total amount 1.95 L (1.72 Imp qt, 2.06 US qt) Quantity in oil tank 1.55 L (1.36 Imp qt, 1.64 US qt) Quantity in crankcase 0.40 L (0.35 Imp qt, 0.42 US qt) Periodic oil replacement Total amount 1.75 L (1.54 Imp qt, 1.85 US qt) Quantity in oil tank 1.55 L (1.36 Imp qt, 1.64 US qt) Quantity in crankcase 0.20 L (0.18 Imp qt, 0.21 US qt) With oil filter element replacement Total amount 1.85 L (1.63 Imp qt, 1.96 US qt) Quantity in oil tank 1.55 L (1.36 Imp qt, 1.
CHANGING THE ENGINE OIL/ ADJUSTING THE CLUTCH CABLE CHK ADJ 17.Check: • engine oil pressure ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 1 a. Slightly loosen the oil gallery bolt 1. b. Start the engine and keep it idling until engine oil starts to seep from the oil gallery bolt. If no engine oil comes out after one minute, turn the engine off so that it will not seize. c. Check the engine oil passages, the oil filter element and the oil pump for damage or leakage. Refer to “OIL PUMP” in chapter 4. d.
ADJUSTING THE CLUTCH CABLE CHK ADJ 2. Adjust: • clutch release lever free play ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a b 1 Handlebar side a. Turn the adjusting nut 1 in direction a or b until the specified clutch cable free play is obtained. Direction a Clutch cable free play is increased. Direction b Clutch cable free play is decreased. NOTE: If the specified clutch cable free play cannot be obtained on the handlebar side of the cable, use the adjusting nut on the engine side.
CLEANING THE AIR FILTER ELEMENT CHK ADJ EBS00073 CLEANING THE AIR FILTER ELEMENT NOTE: There is a check hose 1 at the bottom of the air filter case. If dust and/or water collects in this hose, clean the air filter element and air filter case. _ 1 1. Remove: • seat Refer to “SEAT, FENDERS AND FUEL TANK”. 2. Remove: • air filter case cover 1 1 2 1 3.
CLEANING THE AIR FILTER ELEMENT CHK ADJ 5. Clean: • air filter element ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Wash the element gently, but thoroughly in solvent. WARNING _ Use a cleaning solvent which is designed to clean parts only. Never use gasoline or low flash point solvents as they may cause a fire or explosion. b. Squeeze the excess solvent out of the element and let it dry. CAUTION: _ Do not twist or wring out the element. This could damage the foam material. c. Apply engine oil to the element. d.
CHECKING THE COOLANT LEVEL/ CHANGING THE COOLANT CHK ADJ EBS00076 b a CHECKING THE COOLANT LEVEL 1. Place the machine on a level surface. 2. Check: • coolant level The coolant level should be between the minimum level mark a and maximum level mark b. Below the minimum level mark → Add the recommended coolant to the proper level. CAUTION: _ • Adding water instead of coolant lowers the antifreeze content of the coolant.
CHANGING THE COOLANT CHK ADJ 5. Install: • coolant reservoir • coolant reservoir bolts T. R. 7 Nm (0.7 m · kg, 5.1 ft · lb) 6. Connect: • coolant reservoir breather hose 7. Remove: • radiator cap 1 1 1 WARNING _ A hot radiator is under pressure. Therefore, do not remove the radiator cap when the engine is hot. Scalding hot fluid and steam may be blown out, which could cause serious injury.
CHANGING THE COOLANT CHK ADJ 12.Fill: • cooling system (with the specified amount of the recommended coolant) Recommended antifreeze High-quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines Mixing ratio 1:1 (antifreeze:water) Quantity Total amount 1.3 L (1.14 Imp qt, 1.37 US qt) Coolant reservoir capacity 0.29 L (0.26 Imp qt, 0.31 US qt) Handling notes for coolant Coolant is potentially harmful and should be handled with special care.
CHANGING THE COOLANT a CHK ADJ 14.Fill: • coolant reservoir (with the recommended coolant to the maximum level mark a) 15.Install: • coolant reservoir cap 16.Start the engine, warm it up for several minutes, and then stop it. 17.Check: • coolant level Refer to “CHECKING THE COOLANT LEVEL”. NOTE: Before checking the coolant level, wait a few minutes until the coolant has settled. _ 18.Install: • right side cover • fuel tank cover • seat Refer to “SEAT, FENDERS AND FUEL TANK”.
CHECKING THE COOLANT TEMPERATURE WARNING LIGHT CHK ADJ EBS00077 CHECKING THE COOLANT TEMPERATURE WARNING LIGHT 1 Coolant temperature warning light 1 Coolant temperature warning light checking method Turn the main switch “ON” and the engine stop switch to “RUN”. Coolant temperature warning light does not come on. Coolant temperature warning light comes on. Push start switch with transmission in “neutral”. Coolant temperature warning light comes on momentarily.
CLEANING THE SPARK ARRESTER CHK ADJ CLEANING THE SPARK ARRESTER 1. Clean: • Spark arrester ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ WARNING • Select a well-ventilated area free of combustible materials. • Always let the exhaust system cool before performing this operation. • Do not start the engine when removing the tailpipe from the muffler. a. Remove the bolt 1. b. Remove the tailpipe 2 by pulling it out of the muffler. c.
ADJUSTING THE FRONT BRAKE/ADJUSTING THE BRAKE LEVER/ADJUSTING THE REAR BRAKE CHK ADJ EBS00080 CHASSIS a ADJUSTING THE FRONT BRAKE 1. Measure: • brake lever free play a Out of specification → Bleed the front brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM”. Brake lever free play (at the end of the brake lever) 0 mm (0 in) 12 ADJUSTING THE BRAKE LEVER 1. Adjust: • brake lever position a b c a ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. While pushing the brake lever forward, loosen the locknut 1.
ADJUSTING THE REAR BRAKE/ ADJUSTING THE PARKING BRAKE CHK ADJ 2. Adjust: • rear brake pedal height a 2 1 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Loosen the locknut 1. b. Turn the adjusting bolt 2 until the brake pedal height is within the specified limits. c. Tighten the locknut. NOTE: When adjusting the brake pedal height make sure the locknut-to-adjusting bolt clearance a does not exceed 2.2 ~ 3.2 mm (0.09 ~ 0.13 in).
ADJUSTING THE PARKING BRAKE/ CHECKING THE BRAKE FLUID LEVEL CHK ADJ 2. Adjust: • parking brake cable end length ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. b. c. d. 1 2 e. f. 3 a g. h. Loosen the locknut 1 and adjusting bolt 2. Slide back the rubber cover 3. Loosen the locknut 4. Turn the adjusting nut 5 in direction a or b until the specified brake cable end length is obtained. Tighten the locknut. Slowly turn the adjusting bolt clockwise until resistance is felt. Turn it 1/8 counterclockwise.
CHECKING THE BRAKE FLUID LEVEL/ CHECKING THE FRONT BRAKE PADS CHK ADJ 2. Check: • brake fluid level Below the minimum level mark 1 → Add the recommended brake fluid to the proper level. È Recommended brake fluid DOT 4 È Front brake É Rear brake É WARNING _ 1 • 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.
CHECKING THE FRONT BRAKE PADS/ CHECKING THE REAR BRAKE PADS CHK ADJ 2. Check: • brake pads Wear indicators 1 almost touch the brake disc → Replace the brake pads as a set. Refer to “FRONT AND REAR BRAKES” in chapter 7. Brake pad wear limit a 1.0 mm (0.04 in) 3. Operate the brake lever. 4. Install: • front wheels Refer to “FRONT AND REAR WHEELS” in chapter 7. EBS00089 CHECKING THE REAR BRAKE PADS 1. Check: • brake pads Wear indicator 1 almost touch the brake disc → Replace the brake pads as a set.
ADJUSTING THE REAR BRAKE LIGHT SWITCH/ CHECKING THE BRAKE HOSES CHK ADJ ADJUSTING THE REAR BRAKE LIGHT SWITCH NOTE: • The rear brake light switch is operated by movement of the brake pedal. • The rear brake light switch is properly adjusted when the brake light comes on just before the braking effect starts. 1. Check: • rear brake light operation timing Incorrect → Adjust. 2. Adjust: • rear brake light operation timing 1 2 a b ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a.
CHECKING THE BRAKE HOSES/ BLEEDING THE HYDRAULIC BRAKE SYSTEM 1 1 1 2 CHK ADJ 2. Check: • front brake hoses 1 • rear brake hose 2 Cracks/wear/damage → Replace. 3. Check: • brake hose clamps Loosen → Tighten. 4. Hold the machine in an upright position and apply the front or rear brake. 5. Check: • brake hoses Apply the brake lever or brake pedal several times. Fluid leakage → Replace the hoses. Refer to “FRONT AND REAR BRAKES” in chapter 7. 6.
BLEEDING THE HYDRAULIC BRAKE SYSTEM CHK ADJ NOTE: • Be careful not to spill any brake fluid or allow the brake master cylinder reservoir or brake fluid reservoir to overflow. • When bleeding the hydraulic brake system, make sure there is always enough brake fluid before applying the brake. Ignoring this precaution could allow air to enter the hydraulic brake system, considerably lengthening the bleeding procedure.
BLEEDING THE HYDRAULIC BRAKE SYSTEM/ ADJUSTING THE SHIFT PEDAL CHK ADJ i. Repeat steps (e) to (h) until all of the air bubbles have disappeared from the brake fluid in the plastic hose. j. Tighten the bleed screw to specification. T. Bleed screw 6 Nm (0.6 m · kg, 4.3 ft · lb) R. k. Fill the brake fluid reservoir to the proper level with the recommended brake fluid. Refer to “CHECKING THE BRAKE FLUID LEVEL”. WARNING _ After bleeding the hydraulic brake system, check the brake operation.
ADJUSTING THE DRIVE CHAIN SLACK CHK ADJ ADJUSTING THE DRIVE CHAIN SLACK NOTE: Measure the drive chain slack halfway between the drive axle and the rear axle. CAUTION: A drive chain that is too tight will overload the engine and other vital parts, and one that is too loose can skip and damage the swingarm or cause an accident. Therefore, keep the drive chain slack within the specified limits. 1. Elevate the rear wheels by placing the suitable stand under the frame. 2.
ADJUSTING THE DRIVE CHAIN SLACK/ CHECKING THE STEERING SYSTEM CHK ADJ CAUTION: Excessive chain slack will overload the engine and other vital parts; keep the slack within the specified limits. d. If the chain slack cannot be adjusted, replace the sprockets and drive chain as a set. e. Tighten the hub nuts and locknuts. T. R. Hub nut 85 Nm (8.5 m · kg, 61 ft · lb) Locknut (chain puller) 16 Nm (1.6 m · kg, 11 ft · lb) NOTE: The chain should be cleaned and lubricated after every use of the machine.
ADJUSTING THE TOE-IN CHK ADJ EBS00108 ADJUSTING THE TOE-IN 1. Place the machine on a level surface. 2. Measure: • toe-in Out of specification → Adjust. Toe-in 2 ~ 12 mm (0.08 ~ 0.47 in) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ NOTE: Before measuring the toe-in, make sure that the tire pressure is correct. _ a. Mark both front tire tread centers. b. Raise the front end of the machine so that there is no weight on the front tires. c. Face the handlebar straight ahead. d. Measure the width È between the marks. e.
ADJUSTING THE TOE-IN/CHECKING THE FRONT AND REAR SHOCK ABSORBERS CHK ADJ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 1 a. Mark both tie-rods ends. This reference point will be needed during adjustment. b. Loosen the locknuts (tie-rod end) 1 of both tie-rods. c. The same number of turns should be given to both the right and left tie-rods 2 until the specified toe-in is obtained. This is to keep the length of the rods the same. d. Tighten the rod end locknuts of both tierods. 1 2 T. Locknut (rod end) 15 Nm (1.
ADJUSTING THE FRONT SHOCK ABSORBERS CHK ADJ EBS00111 ADJUSTING THE FRONT SHOCK ABSORBERS WARNING _ Always adjust the spring preload, rebound damping force and compression damping force of both front shock absorbers to the same setting. Uneven adjustment can result in poor handling and loss of stability. 1 2 a b 1. Adjust: • spring preload ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Elevate the front wheels by placing a suitable stand under the frame. b. Loosen the locknut 1. c.
ADJUSTING THE FRONT SHOCK ABSORBERS CHK ADJ Steering nut wrench P/N. YU-33975, 90890-01443 T. Locknut 30 Nm (3.0 m · kg, 22 ft · lb) R. NOTE: Always tighten the locknut against the adjusting ring, then torque it to specification. _ ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Adjust: • rebound damping force ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjusting screw 1 in direction a or b. b 1 a Direction a Rebound damping force is increased. Direction b Rebound damping force is decreased.
ADJUSTING THE FRONT SHOCK ABSORBERS/ ADJUSTING THE REAR SHOCK ABSORBER CHK ADJ 3. Adjust: • compression damping force ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a b a. Turn the adjusting screw 1 in direction a or b. 1 Direction a Compression damping force is increased. Direction b Compression damping force is decreased. From the fully turned-in position Standard: 11 clicks out Minimum: 22 clicks out Maximum: 1 click out CAUTION: _ Do not force the adjuster past the minimum or maximum extent of adjustment.
ADJUSTING THE REAR SHOCK ABSORBER CHK ADJ 3. Disconnect the air filter case breather hose 1, and then remove the air filter case 2 with the air intake duct. 2 1 1 2 a b 4. Adjust: • spring preload ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Elevate the rear wheels by placing a suitable stand under the frame. b. Loosen the locknut 1. c. Turn the adjusting ring 2 in direction a or b. Direction a Spring preload is increased (suspension is harder).
ADJUSTING THE REAR SHOCK ABSORBER CHK ADJ Steering nut wrench P/N. YU-33975, 90890-01443 T. Locknut 45 Nm (4.5 m · kg, 32 ft · lb) R. NOTE: Always tighten the locknut against the adjusting ring, then torque it to specification. _ ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Install: • air filter case with air intake duct b a NOTE: Align the projection a on the carburetor with the slot b in the air intake duct. _ 6. Adjust: • rebound damping force 1 c b a 1 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a.
ADJUSTING THE REAR SHOCK ABSORBER CHK ADJ 7. Adjust: • compression damping force ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjusting screw 1 in direction a or b. a 1 b 1 c Direction a Compression damping force is increased. Direction b Compression damping force is decreased.
CHECKING THE TIRES CHK ADJ EBS00114 CHECKING THE TIRES WARNING _ This model is equipped with low pressure tires. It is important that they be inflated correctly and maintained at the proper pressures. • TIRE CHARACTERISTICS 1) Tire characteristics influence the handling of ATVs. The tires listed below have been approved by Yamaha Motor Co., Ltd. for this model. If other tire combinations are used, they can adversely affect your machine’s handling characteristics and are therefore not recommended.
CHECKING THE TIRES CHK ADJ 1. Measure: • tire pressure Out of specification → Adjust. NOTE: • The low-pressure tire gauge 1 is included as standard equipment. • If dust or the like is stuck to this gauge, it will not provide the correct readings. Therefore, take two measurements of the tire’s pressure and use the second reading. _ Cold tire pressure Front Rear Standard 30 kPa 35 kPa (0.30 kg/cm2, (0.35 kg/cm2, 4.4 psi) 5.0 psi) Minimum 32 kPa 27 kPa (0.27 kg/cm2, (0.32 kg/cm2, 3.9 psi) 4.
CHECKING THE WHEELS/CHECKING AND LUBRICATING THE CABLES CHK ADJ EBS00116 CHECKING THE WHEELS 1. Check: • wheel 1 Damage/bends → Replace. NOTE: Always balance the wheel when a tire or wheel has been changed or replaced. _ WARNING _ • Never attempt even small repairs to the wheel. • Ride conservatively after installing a tire to allow it to seat itself properly on the rim.
LUBRICATING THE LEVERS AND PEDALS CHK ADJ EBS00118 LUBRICATING THE LEVERS AND PEDALS Lubricate the pivoting point and metal-to-metal moving parts of the levers and pedals.
CHECKING AND CHARGING THE BATTERY CHK ADJ EBS00120 ELECTRICAL SYSTEM CHECKING AND CHARGING THE BATTERY WARNING _ Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: • Wear protective eye gear when handling or working near batteries. • Charge batteries in a well-ventilated area. • Keep batteries away from fire, sparks or open flames (e.g., welding equipment, lighted cigarettes).
CHECKING AND CHARGING THE BATTERY CHK ADJ NOTE: Since MF batteries are sealed, it is not possible to check the charge state of the battery by measuring the specific gravity of the electrolyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals. _ 1. Remove: • seat Refer to “SEAT, FENDERS AND FUEL TANK”. 2.
CHECKING AND CHARGING THE BATTERY CHK ADJ NOTE: • The charge state of an MF battery can be checked by measuring its open-circuit voltage (i.e., the voltage when the positive terminal is disconnected). • No charging is necessary when the open-circuit voltage equals or exceeds 12.8 V. _ b. Check the charge of the battery, as shown in the charts and the following example. Example c. Open-circuit voltage = 12.0 V d. Charging time = 6.5 hours e.
CHECKING AND CHARGING THE BATTERY CHK ADJ • Before removing the battery charger lead clips from the battery terminals, be sure to turn off the battery charger. • Make sure the battery charger lead clips are in full contact with the battery terminal and that they are not shorted. A corroded battery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks.
CHK ADJ CHECKING AND CHARGING THE BATTERY Charging method using a variable-current (voltage) charger Measure the open-circuit voltage prior to charging. Connect a charger and ammeter to the battery and start charging. YES Is the amperage higher than the standard charging amperage written on the battery? NOTE: Leave the battery unused for more than 30 minutes before measuring its open-circuit voltage. NOTE: Set the charging voltage to 16 ~ 17 V.
CHECKING AND CHARGING THE BATTERY CHK ADJ Charging method using a constant voltage charger Measure the open-circuit voltage prior to charging. NOTE: Leave the battery unused for more than 30 minutes before measuring its open-circuit voltage. Connect a charger and ammeter to the battery and start charging. Is the amperage higher than the standard charging amperage written on the battery? Charge the battery until the charging voltage reaches 15 V.
CHECKING AND CHARGING THE BATTERY 7. • 8. • CHK ADJ Install: battery Install: battery holding bracket Refer to “SEAT, FENDERS AND FUEL TANK”. 9. Connect: • battery leads (to the battery terminals) 1 CAUTION: _ First, connect the positive battery lead 1, and then the negative battery lead 2. 2 10.Check: • battery terminals Dirt → Clean with a wire brush. Loose connection → Connect properly. 11.Lubricate: • battery terminals Recommended lubricant Dielectric grease 12.
CHECKING THE FUSES CHK ADJ EBS00121 CHECKING THE FUSES The following procedure applies to all of the fuses. CAUTION: _ To avoid a short circuit, always set the main switch to “OFF” when checking or replacing a fuse. 1. Remove: • seat Refer to “SEAT, FENDERS AND FUEL TANK”. 2. Check: • fuse ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester to the fuse and check the continuity. NOTE: Set the pocket tester selector to “Ω × 1”. _ Pocket tester P/N. YU-03112-C, 90890-03112 b.
CHECKING THE FUSES/ ADJUSTING THE HEADLIGHT BEAM CHK ADJ Items Amperage rating Q’ty Main 15 A 1 Reserve 15 A 1 WARNING _ Never use a fuse with an amperage rating other than that specified. Improvising or using a fuse with the wrong amperage rating may cause extensive damage to the electrical system, cause the lighting and ignition systems to malfunction and could possibly cause a fire. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Install: • seat Refer to “SEAT, FENDERS AND FUEL TANK”.
REPLACING A HEADLIGHT BULB CHK ADJ EBS00124 REPLACING A HEADLIGHT BULB 1. Remove: • headlight Refer to “SEAT, FENDERS AND FUEL TANK”. 2. • 3. • 1 Disconnect: headlight lead coupler 1 Remove: headlight bulb holder cover 2 2 4. Remove: • bulb holder 1 • bulb NOTE: Push the headlight bulb holder inward, turn it counterclockwise and remove the defective bulb. _ 1 WARNING _ Keep flammable products and your hands away from the bulb while it is on. since it will be hot.
REPLACING A HEADLIGHT BULB CHK ADJ 6. Install: • bulb holder • headlight bulb holder cover 1 a 2 1 NOTE: After installing the bulb holder cover, make sure that the “TOP” mark a is in the position shown. 7. • 8. • 3 - 67 Connect: headlight lead coupler 2 Install: headlight Refer to “SEAT, FENDERS AND FUEL TANK”.
ENGINE REMOVAL ENG EBS00198 ENGINE ENGINE REMOVAL MUFFLER AND EXHAUST PIPE T. R. 34 Nm (3.4 m • kg, 24 ft • Ib) 2 1 7 New 4 New LT 3 T. 20 Nm (2.0 m • kg, 14 ft • Ib) R. 6 5 T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) LT T. R. 13 Nm (1.3 m • kg, 9.4 ft • Ib) T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) T. R. Order 1 2 3 4 5 6 7 24 Nm (2.4 m • kg, 17 ft • Ib) Job/Part Q’ty Remarks Removing the muffler and exhaust Remove the parts in the order listed.
ENGINE REMOVAL c 1 ENG INSTALLING THE EXHAUST PIPE AND MUFFLER 1. Install: • gasket 1 New (to muffler) b a NOTE: Install the gasket with the chamfer a, located on an inner rim of the gasket, and the chamfer b, located on an outer rim of the gasket, as shown. Installed depth of gasket c 1 ~ 1.5 mm (0.04 ~ 0.06 in) 2. Install: • exhaust pipe protector • exhaust pipe protector screws LT 3 T. 1 R. LT Screw 7 Nm (0.7 m · kg, 5.
ENGINE REMOVAL ENG 4. Install: • clamp a NOTE: Slide the clamp onto the end of the muffler and insert the projection a of the clamp into a slot b in the muffler. Tighten the clamp after installing the muffler.
ENGINE REMOVAL ENG EBS00204 LEADS, CABLES AND HOSES T. R. T. R. 8 Nm (0.8 m • kg, 5.8 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib) 9 T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) 1 2 6 3 7 10 8 New 5 LS 4 New LS 13 11 12 14 T. R. Order 1 2 3 4 5 8 Nm (0.8 m • kg, 5.8 ft • Ib) Job/Part Q’ty Remarks Removing the leads, cables and Remove the parts in the order listed. hoses Engine oil Drain. Coolant Drain. Radiator outlet hose/water pump inlet Refer to “WATER PUMP” in chapter 5.
ENGINE REMOVAL T. R. T. R. 8 Nm (0.8 m • kg, 5.8 ft • Ib) ENG 10 Nm (1.0 m • kg, 7.2 ft • Ib) 9 T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) 1 2 6 3 7 10 8 New 5 LS 4 New LS 13 11 12 14 T. R. Order 6 7 8 9 10 11 12 13 14 Job/Part Starter motor lead Battery negative lead Clutch cable Parking brake cable Oil pipe 1 A.C. magneto coupler Plastic band Oil pipe 2 Neutral switch lead Q’ty 1 1 1 1 1 2 2 1 1 4-5 8 Nm (0.8 m • kg, 5.8 ft • Ib) Remarks Disconnect. Disconnect. Disconnect.
ENGINE REMOVAL ENG EBS00205 ENGINE MOUNTING BOLTS 7 T. 33 Nm (3.3 m • kg, 24 ft • Ib) R. T. R. 26 Nm (2.6 m • kg, 19 ft • Ib) 12 11 8 T. R. 100 Nm (10.0 m • kg, 72 ft • lb) 5 6 10 9 T. R. 40 Nm (4.0 m • kg, 29 ft • Ib) 12 2 T. 1 R. 13 T. R. 5 2 T. R. 3 1 T. R. 1 2 3 4 5 6 7 8 9 10 11 12 38 Nm (3.8 m • kg, 27 ft • Ib) 4 66 Nm (6.6 m • kg, 48 ft • Ib) Order 66 Nm (6.6 m • kg, 48 ft • Ib) 38 Nm (3.
ENGINE REMOVAL 7 T. 33 Nm (3.3 m • kg, 24 ft • Ib) R. T. R. 26 Nm (2.6 m • kg, 19 ft • Ib) ENG 12 11 8 T. R. 100 Nm (10.0 m • kg, 72 ft • lb) 5 6 10 9 T. R. 40 Nm (4.0 m • kg, 29 ft • Ib) 12 2 T. 1 R. 13 T. R. 5 38 Nm (3.8 m • kg, 27 ft • Ib) 4 2 T. R. 66 Nm (6.6 m • kg, 48 ft • Ib) 3 1 T. R. Order 13 66 Nm (6.6 m • kg, 48 ft • Ib) 38 Nm (3.8 m • kg, 27 ft • Ib) Job/Part Engine assembly Q’ty Remarks 1 NOTE: Remove the engine assembly from the right side of the machine.
ENGINE REMOVAL ENG EBS00206 6 45 2 INSTALLING THE ENGINE 1. Install: • pivot shaft/nut/washer 1 • engine upper bracket (left) 2 • engine upper bracket (right) • engine mounting bolt (upper) 3 • engine stay 4 • engine stay bolts/washers 5 • engine upper bracket bolts 6 • engine mounting bolt (lower)/nut 7 • engine lower bracket (left) 8 • engine lower bracket (right) • engine mounting bolt (middle)/nut 9 • engine lower bracket bolts 0 3 1 0 89 NOTE: Do not fully tighten the bolts and nuts. 7 _ 2.
CAMSHAFTS ENG EBS00208 CAMSHAFTS CYLINDER HEAD COVER Order 1 2 3 4 5 6 7 8 9 Job/Part Q’ty Remarks Removing the cylinder head cover Remove the parts in the order listed. Seat/fuel tank cover/side covers (left Refer to “SEAT, FENDERS AND FUEL and right) TANK” in chapter 3.
CAMSHAFTS ENG CAMSHAFTS Order 1 2 3 4 5 6 7 8 9 Job/Part Removing the camshafts Tensioner cap bolt Timing chain tensioner Gasket Exhaust camshaft cap Clip Exhaust camshaft Intake camshaft cap Clip Intake camshaft Q’ty 1 1 1 1 1 1 1 1 1 Remarks Remove the parts in the order listed. Refer to “REMOVING THE CAMSHAFTS” and “INSTALLING THE CAMSHAFTS”. For installation, reverse the removal procedure.
CAMSHAFTS ENG REMOVING THE CAMSHAFTS 1. Remove: • timing mark accessing screw 1 • crankshaft end accessing screw 2 2. Align: • “I” mark on the A.C. magneto rotor (with stationary pointer on the A.C. magneto cover) 1 2 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ b a a. Turn the crankshaft counterclockwise. b. When the piston is at the Top Dead Center (TDC) on the compression stroke, align the “I” mark a on the A.C. magneto rotor with the stationary pointer b on the A.C. magneto cover.
CAMSHAFTS 1 2 6. • • • ENG Remove: exhaust camshaft 1 intake camshaft 2 clips NOTE: To prevent the timing chain from falling into the crankcase, fasten it with a wire 3. 3 CHECKING THE CAMSHAFTS 1. Check: • camshaft lobes Pitting/scratches/blue discoloration → Replace the camshaft. 2. Measure: • camshaft lobe dimensions a and b Out of specification → Replace the camshaft. Camshaft lobe dimensions Intake a 31.200 ~ 31.300 mm (1.2283 ~ 1.2323 in) : 31.100 mm (1.2244 in) b 22.550 ~ 22.650 mm (0.
CAMSHAFTS ENG 4. Measure: • camshaft-journal-to-camshaft-cap clearance Out of specification → Measure the camshaft journal diameter. Camshaft-journal-to-camshaft-cap clearance 0.020 ~ 0.054 mm (0.0008 ~ 0.0021 in) : 0.080 mm (0.0032 in) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Install the camshaft into the cylinder head (without the camshaft caps). b. Position a strip of Plastigauge® 1 onto the camshaft journal as shown. c. Install the circlip and camshaft caps.
CAMSHAFTS ENG EBS00224 CHECKING THE CAMSHAFT SPROCKETS 1. Check: • camshaft sprockets Wear/damage → Replace the camshaft sprockets and timing chain as a set. a 1/4 of a tooth b Correct 1 Roller 2 Sprocket EBS00225 CHECKING THE DECOMPRESSION SYSTEM 1. Check: • decompression system ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Check that the decompressor lever pin 1 projects from the camshaft. b. Check that the decompressor cam 2 moves smoothly.
CAMSHAFTS ENG EBS00228 CHECKING THE TIMING CHAIN TENSIONER 1. Check: • chain tensioner rod Damage/wear → Replace. 2. Check: • timing chain tensioner play ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. While pressing the tensioner rod lightly with fingers, use a thin screwdriver 1 and wind the tensioner rod up fully clockwise. b. When releasing the screwdriver by pressing lightly with fingers, make sure that the tensioner rod will come out smoothly. c. If not, replace the tensioner assembly.
CAMSHAFTS 1 2 2. • • • • ENG Install: clips intake camshaft cap 1 exhaust camshaft cap 2 camshaft cap bolts T. R. 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: Tighten the camshaft cap bolts in stages and in a crisscross pattern, working from the inner caps out. CAUTION: The camshaft cap bolts must be tightened evenly or damage to the cylinder head, camshaft caps, and camshafts will result. 3. Install: • timing chain tensioner ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a.
CAMSHAFTS ENG d. Remove the screwdriver, mark sure that the timing chain tensioner rod releases, and then tighten the cap bolt to the specified torque. T. Tensioner cap bolt 7 Nm (0.7 m · kg, 5.1 ft · lb) R. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Turn: • crankshaft (counterclockwise several turns) 5. Check: • A.C. magneto rotor “I” mark Align with the A.C. magneto cover stationary pointer. • camshaft sprocket punch marks Align with the cylinder head mating surface. Out of alignment → Adjust.
CYLINDER HEAD ENG CYLINDER HEAD Order 1 2 3 Job/Part Q’ty Remarks Removing the cylinder head Remove the parts in the order listed. Seat/fuel tank cover/side covers (left Refer to “SEAT, FENDERS AND FUEL and right)/fuel tank TANK” in chapter 3. Muffler and exhaust pipe Refer to “MUFFLER AND EXHAUST PIPE”. Radiator inlet hose/parking brake and Refer to “LEADS, CABLES AND clutch cable holder HOSES”. Parking brake holder Carburetor Refer to “CARBURETOR” in chapter 6. Camshafts Refer to “CAMSHAFTS”.
CYLINDER HEAD Order 4 5 6 7 Job/Part Cylinder head Cylinder head gasket Dowel pin Timing chain guide (exhaust side) ENG Q’ty Remarks 1 Refer to “REMOVING THE CYLINDER HEAD” and “INSTALLING THE CYLINDER HEAD”. 1 2 1 For installation, reverse the removal procedure. NOTE: *1: Tighten the cylinder head bolts to 30 Nm (3.0 m · kg, 22 ft · lb) in the proper tightening sequence, remove and retighten the cylinder head bolts to 20 Nm (2.
CYLINDER HEAD ENG REMOVING THE CYLINDER HEAD 1. Remove: • cylinder head NOTE: • Loosen the bolts in the proper sequence. • Follow the numerical order shown in the illustration. Loosen each bolt 1/4 of a turn at a time until all of the bolts are loose. EBS00230 CHECKING THE CYLINDER HEAD 1. Eliminate: • combustion chamber carbon deposits (with a rounded scraper) NOTE: Do not use a sharp instrument to avoid damaging or scratching: • spark plug bore threads • valve seats _ 2.
CYLINDER HEAD ENG NOTE: To ensure an even surface, rotate the cylinder head several times. _ ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ CHECKING THE OIL DELIVERY PIPE 1. Check: • oil delivery pipe 1 Cracks/damage → Replace. Clogged → Blow out with compressed air. CHECKING THE TIMING CHAIN GUIDE 1. Check: • timing chain guide (exhaust side) Wear/damage → Replace. INSTALLING THE CYLINDER HEAD 1. Install: • timing chain guide (exhaust side) • gasket New • dowel pins 2.
CYLINDER HEAD 3. • • • Install: washers bolts 1: bolts 2: ENG = 159 mm (6.26 in) = 149 mm (5.87 in) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ NOTE: Tighten the bolts to the specified torque in two or three steps in the proper tightening sequence as shown. a. Wash the threads and contact surfaces of the bolts, the contact surfaces of the washers, the contact surface of the cylinder head, and the threads of the crankcase. b.
CYLINDER HEAD ENG h. Put a mark on the corner 1 of the cylinder head bolt and the cylinder head 2 as shown. 1 NOTE: Tighten the bolts 90° in each of the two steps to reach the specified angle of 180° in the proper tightening sequence as shown. 2 T. R. Cylinder head bolts Final Specified angle 180° ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Install: • cylinder head nuts T. R. 10 Nm (1.0 m · kg, 7.2 ft · lb) 180˚ 5. • • • 2 1 Install: copper washers New oil delivery pipe 1 1 union bolts (M8) 2 T. R.
VALVES AND VALVE SPRINGS ENG EBS00234 VALVES AND VALVE SPRINGS Order 1 2 3 4 5 6 Job/Part Removing the valves and valve springs Cylinder head Valve lifter Adjusting pad Valve cotter Upper valve spring seat Exhaust valve spring Intake valve spring Q’ty Remarks Remove the parts in the order listed. Refer to “CYLINDER HEAD”. 5 5 10 5 2 3 4 - 24 red blue Refer to “REMOVING THE VALVES AND VALVE SPRINGS” and “INSTALLING THE VALVES AND VALVE SPRINGS”.
VALVES AND VALVE SPRINGS Order 7 8 9 10 11 Job/Part Stem seal Lower valve spring seat Exhaust valve Intake valve 1 Intake valve 2 Q’ty 5 5 2 1 2 4 - 25 ENG Remarks Refer to “REMOVING THE VALVES AND VALVE SPRINGS” and “INSTALLING THE VALVES AND VALVE SPRINGS”. = 76.3 mm (3.00 in) = 77.2 mm (3.04 in) For installation, reverse the removal procedure.
VALVES AND VALVE SPRINGS ENG EBS00238 REMOVING THE VALVES AND VALVE SPRINGS 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. Remove: • valve lifter 1 • valve pad 2 NOTE: Make a note of the position of each valve lifter and valve pad so that they can be reinstalled in their original place. 2.
VALVES AND VALVE SPRINGS ENG Valve spring compressor P/N. YM-04019, 90890-04019 Valve spring compressor attachment P/N. YM-04114, 90890-04114 4. • • • • • Remove: upper valve spring seat 1 valve spring 2 valve stem seal 3 lower valve spring seat 4 valve 5 NOTE: Identify the position of each part very carefully so that it can be reinstalled in its original place. EBS00240 CHECKING THE VALVES AND VALVE SPRINGS 1.
VALVES AND VALVE SPRINGS ENG 2. Replace: • valve guide ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ NOTE: To ease guide removal, installation and to maintain correct fit, heat the cylinder head to 100 °C (212 °F) in an oven. _ a. Remove the valve guide using a valve guide remover 1. b. Install the new valve guide using a valve guide remover 1 and valve guide installer 2. c. After installing the valve guide, bore the valve guide using a valve guide reamer 3 to obtain proper stem-to-guide clearance.
VALVES AND VALVE SPRINGS ENG 4. Measure: • margin thickness a Out of specification → Replace. Margin thickness Intake 1.0 mm (0.0394 in) : 0.85 mm (0.033 in) Exhaust 1.0 mm (0.0394 in) : 0.85 mm (0.033 in) 5. Measure: • valve stem runout Out of specification → Replace. Valve stem runout 0.01 mm (0.0004 in) NOTE: • When installing a new valve always replace the guide. • If the valve is removed or replaced always replace the oil seal. _ 6.
VALVES AND VALVE SPRINGS ENG ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Apply Mechanic’s blueing dye (Dykem) b to the valve face. b. Install the valve into the cylinder head. c. Press the valve through the valve guide and onto the valve seat to make a clear pattern. d. Measure the valve seat width. Where the valve seat and valve face made contact, blueing will have been removed. e. If the valve seat is too wide, too narrow, or the seat is not centered, the valve seat must be refaced.
VALVES AND VALVE SPRINGS ENG f. Apply Mechanic’s blueing dye (Dykem) to the valve face. g. Install the valve into the cylinder head. h. Press the valve through the valve guide and onto the valve seat to make a clear pattern. i. Measure the valve seat width again. If the valve seat width is out of specification, reface and relap the valve seat. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 10.Measure: • valve spring free length a Out of specification → Replace. Valve spring free length Intake 37.03 mm (1.
VALVES AND VALVE SPRINGS ENG 12.Measure: • valve spring tilt a Out of specification → Replace. Valve spring tilt limit Intake 2.5°/1.61 mm (0.063 in) Exhaust 2.5°/1.65 mm (0.065 in) EAS00242 CHECKING THE VALVE LIFTERS The following procedure applies to all of the valve lifters. 1. Check: • valve lifter Damage/scratches → Replace the valve lifters and cylinder head. EBS00241 INSTALLING THE VALVES AND VALVE SPRINGS 1. Apply: • molybdenum disulfide oil (onto the valve stem and valve stem seal) 2.
VALVES AND VALVE SPRINGS ENG 3. Install: • valve cotters NOTE: Install the valve cotters while compressing the valve spring with the valve spring compressor 1 and attachment 2. _ Valve spring compressor P/N. YM-04019, 90890-04019 Valve spring compressor attachment P/N. YM-04114, 90890-04114 4. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a piece of wood. CAUTION: _ Hitting the valve tip with excessive force could damage the valve. 5.
CYLINDER AND PISTON ENG EBS00245 CYLINDER AND PISTON Order 1 2 3 4 5 6 7 8 9 10 Job/Part Removing the cylinder and piston Cylinder head Cylinder Cylinder gasket Dowel pin Dowel pin/O-ring Piston pin clip Piston pin Piston Top ring 2nd ring Oil ring Q’ty 1 1 2 1/1 2 1 1 1 1 1 Remarks Remove the parts in the order listed. Refer to “CYLINDER HEAD”. Refer to “INSTALLING THE CYLINDER”. Refer to “REMOVING THE PISTON” and “INSTALLING THE PISTON”. For installation, reverse the removal procedure.
CYLINDER AND PISTON ENG EBS00247 REMOVING THE PISTON 1. Remove: • piston pin clips 1 • piston pin 2 • piston 3 NOTE: Before removing each piston pin, deburr the clip groove and pin hole area. If the piston pin groove is deburred and the piston pin is still difficult to remove, use the piston pin puller 4. _ Piston pin puller P/N. YU-01304, 90890-01304 CAUTION: _ Do not use a hammer to drive the piston pin out. 2.
ENG CYLINDER AND PISTON 2. Measure: • piston-to-cylinder clearance ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Measure the cylinder bore “C” with a cylinder bore gauge. NOTE: Measure the cylinder bore “C” in parallel to and right angles to the crankshaft. Then, find the average of the measurements. _ Cylinder bore “C” 95.00 ~ 95.01 mm (3.7402 ~ 3.7406 in) Taper limit “T” 0.05 mm (0.002 in) Out of round “R” 0.05 mm (0.
CYLINDER AND PISTON ENG f. If out of specification, replace the cylinder, and the piston and piston rings as a set. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EBS00250 CHECKING THE PISTON RINGS 1. Measure: • piston ring side clearance Out of specification → Replace the piston and piston rings as a set. NOTE: Before measuring the piston ring side clearance, eliminate any carbon deposits from the piston ring grooves and piston rings. _ Piston ring side clearance Top ring 0.030 ~ 0.065 mm (0.0012 ~ 0.
CYLINDER AND PISTON ENG 3. Measure: • piston ring end gap Out of specification → Replace the piston ring. NOTE: The oil ring expander spacer’s end gap cannot be measured. If the oil ring rail’s gap is excessive, replace all three piston rings. _ Piston ring end gap Top ring 0.20 ~ 0.30 mm (0.008 ~ 0.012 in) : 0.55 mm (0.022 in) 2nd ring 0.35 ~ 0.50 mm (0.014 ~ 0.020 in) : 0.85 mm (0.034 in) Oil ring 0.20 ~ 0.50 mm (0.008 ~ 0.020 in) EBS00251 CHECKING THE PISTON PIN 1.
CYLINDER AND PISTON ENG 2. Measure: • piston pin outside diameter a Out of specification → Replace the piston pin. Piston pin outside diameter 19.991 ~ 20.000 mm (0.7870 ~ 0.7874 in) : 19.971 mm (0.786 in) 3. Measure: • piston pin bore inside diameter Out of specification → Replace the piston. Piston pin bore inside diameter 20.004 ~ 20.015 mm (0.7876 ~ 0.7880 in) : 20.045 mm (0.789 in) 4.
CYLINDER AND PISTON ENG EBS00252 INSTALLING THE PISTON 1. Install: • piston rings (onto the piston) NOTE: • Be sure to install the piston rings so that the manufacturer’s marks or numbers are located on the upper side of the rings. • Lubricate the piston and piston rings liberally with engine oil. _ 2. • • • ad 90˚ 45˚ 45˚ c be Position: top ring 2nd ring oil ring Offset the piston ring end gaps as shown. a Top ring end b 2nd ring end c Oil ring end (upper) d Oil ring e Oil ring end (lower) 3.
CYLINDER AND PISTON 4. • • • ENG Lubricate: piston piston rings cylinder NOTE: Apply a liberal coating of engine oil. _ EBS00253 T. INSTALLING THE CYLINDER 1. Install: • cylinder gasket 1 New • dowel pins • O-ring • cylinder 2 10 Nm (1.0 m · kg, 7.2 ft · lb) • bolts R. NOTE: Install the cylinder with one hand while compressing the piston rings with the other hand. _ CAUTION: _ • Be careful not to damage the timing chain damper during installation.
ENG A.C. MAGNETO EBS00256 A.C. MAGNETO T. 6 15 R. 16 Nm (1.6 m • kg, 11 ft • Ib) E 12 10 E 11 LT 13 T. 7 Nm (0.7 m • kg, 5.1 ft • Ib) R. (6) 6 16 LS 9 14 2 R. 7 T. New 65 Nm (6.5 m • kg, 47 ft • Ib) LS E New LS 8 3 4 (5) New 1 T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) New 5 T. R. Order Job/Part Removing the A.C. magneto Engine oil Front fender 1 2 3 4 A.C. magneto coupler Crankcase breather hose Torque limiter cover Torque limiter 5 6 7 8 A.C.
ENG A.C. MAGNETO T. 6 15 R. 16 Nm (1.6 m • kg, 11 ft • Ib) E 12 10 E 11 LT 13 T. 7 Nm (0.7 m • kg, 5.1 ft • Ib) R. (6) 6 16 LS 9 14 2 R. 7 T. New 65 Nm (6.5 m • kg, 47 ft • Ib) LS E New LS 8 3 4 (5) New 1 T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) New 5 T. R. Order 9 10 11 12 13 14 15 16 Job/Part Stator coil Starter idle gear Bearing Starter idle gear shaft A.C. magneto rotor Starter clutch Woodruff key Starter wheel gear 10 Nm (1.0 m • kg, 7.
A.C. MAGNETO ENG EBS00259 REMOVING THE A.C. MAGNETO ROTOR 1. Remove: • A.C. magneto cover NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. _ 2. Remove: • A.C. magneto rotor nut 1 • washer 3 NOTE: • While holding the A.C. magneto rotor 2 with the sheave holder 3, loosen the rotor nut. • Do not allow the sheave holder to touch the projection 4 on the rotor. _ 4 1 2 Sheave holder P/N.
A.C. MAGNETO ENG EBS00263 1 LT 2 CHECKING THE STARTER CLUTCH 1. Check: • starter one-way clutch 1 Cracks/damage → Replace. • bolts 2 Loose → Replace with a new one, and clinch the end of the bolt. T. R. É Starter clutch bolt 16 Nm (1.6 m · kg, 11 ft · lb) LOCTITE® ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Install the starter wheel gear to the starter clutch, and hold the starter clutch. b. When turning the starter wheel gear counter clockwise È, the starter clutch and the wheel gear should be engaged.
A.C. MAGNETO ENG CHECKING THE TORQUE LIMITER 1. Check: • torque limiter Damage/wear → Replace. EBS00268 1 a b 1 INSTALLING THE A.C. MAGNETO ROTOR 1. Install: • stator coil 1 • pickup coil NOTE: Align the projection a on the stator coil with the slot b in the A.C. magneto cover. _ 2. Apply: • sealant (Quick Gasket®) or Yamaha bond No. 1215 1 (into the slit) Sealant (Quick Gasket®) P/N. ACC-11001-05-01 Yamaha bond No. 1215 P/N. 90890-85505 3. Install: • woodruff key • A.C.
A.C. MAGNETO ENG 4. Tighten: • A.C. magneto rotor nut 1 3 T. R. 65 Nm (6.5 m · kg, 47 ft · lb) NOTE: • While holding the A.C. magneto rotor 2 with the sheave holder 3, tighten the A.C. magneto rotor nut. • Do not allow the sheave holder to touch the projection 4 on the rotor. _ 4 1 2 Sheave holder P/N. YS-01880-A, 90890-01701 Install: gasket New A.C. magneto cover A.C. magneto lead holder 1 neutral switch lead holder 2 10 Nm (1.0 m · kg, 7.2 ft · lb) bolts T. R. 2 5.
CLUTCH ENG EBS00291 CLUTCH Order Job/Part Removing the clutch Engine oil Clutch cable Q’ty 1 Clutch cover 1 2 3 4 5 6 7 8 9 10 Gasket Dowel pin Clutch spring Pressure plate Push rod 1 Circlip Plain washer Bearing Ball 1 2 6 1 1 1 1 1 1 4 - 48 Remarks Remove the parts in the order listed. Drain. Refer to “LEADS, CABLES AND HOSES”. Refer to “REMOVING THE CLUTCH” and “INSTALLING THE CLUTCH”. Refer to “INSTALLING THE CLUTCH”.
CLUTCH Order 11 12 13 14 15 16 17 18 19 20 21 22 23 Job/Part Push rod 2 Friction plate 1 Clutch plate Friction plate 2 Spring washer Seat plate Lock washer Clutch boss Thrust washer Clutch housing Push lever shaft Circlip/washer Push lever ENG Q’ty Remarks 1 7 7 Refer to “INSTALLING THE CLUTCH”. 1 1 1 1 1 Refer to “REMOVING THE CLUTCH” and “INSTALLING THE CLUTCH”. 1 1 1 Refer to “INSTALLING THE CLUTCH”. 1/1 1 For installation, reverse the removal procedure.
CLUTCH ENG EBS00297 REMOVING THE CLUTCH 1. Remove: • clutch cover 1 NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. _ 2. Straighten the lock washer tab. 3. Loosen: • clutch boss nut 1 NOTE: While holding the clutch boss 2 with the universal clutch holder 3, loosen the clutch boss nut. _ Universal clutch holder P/N.
CLUTCH ENG EBS00301 CHECKING THE CLUTCH PLATES The following procedure applies to all of the clutch plates. 1. Check: • clutch plate Damage → Replace the clutch plates as a set. 2. Measure: • clutch plate warpage (with a surface plate and thickness gauge 1) Out of specification → Replace the clutch plates as a set. Clutch plate warpage 0.2 mm (0.0079 in) EBS00302 CHECKING THE CLUTCH SPRINGS The following procedure applies to all of the clutch springs. 1.
CLUTCH ENG EBS00304 CHECKING THE CLUTCH BOSS 1. Check: • clutch boss splines Damage/pitting/wear → Replace the clutch boss. NOTE: Pitting on the clutch boss splines will cause erratic clutch operation. _ EBS00305 CHECKING THE PRESSURE PLATE 1. Check: • pressure plate Cracks/damage → Replace. CHECKING THE PUSH RODS 1. Check: • push rod 1 1 • bearing 2 • plain washer 3 • push rod 2 4 • ball 5 Wear/damage/cracks/bend → Replace the defective part(s). CHECKING THE PUSH LEVER 1.
CLUTCH ENG EBS00311 b a INSTALLING THE CLUTCH 1. Install: • push lever NOTE: Align the punch mark a on the push lever with the punch mark b on the push lever shaft. _ 2. Install: • clutch housing NOTE: • Make sure that the primary driven gear teeth and primary drive gear teeth mesh correctly. • Make sure that the oil pump drive gear teeth and oil pump driven gear teeth mesh correctly. _ 3. • • • • Tighten: thrust washer clutch boss lock washer New clutch boss nut 1 T. R. 75 Nm (7.
CLUTCH ENG 6. Install: • clutch cover 1 T. R. 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: Tighten the bolts in stages, using a crisscross pattern. _ 1 a 7. • 8. • Install: clutch cable 1 Check: clutch cable length a Out of specification → Adjust. NOTE: Push the push lever in direction b and check the cable length a. _ b Clutch cable length 38.0 ~ 45.2 mm (1.50 ~ 1.78 in) 9. Adjust: • clutch cable length ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the circlip and washer. b. Remove the push lever. c.
BALANCER ENG BALANCER Order 1 2 Job/Part Removing the balancer Clutch housing Right crankcase cover A.C. magneto rotor Primary drive gear nut Balancer driven gear nut 3 4 5 6 7 8 Lock washer Primary drive gear Balancer drive gear Lock washer Balancer driven gear Balancer Q’ty 1 1 Remarks Remove the parts in the order listed. Refer to “CLUTCH”. Refer to “WATER PUMP” in chapter 5. Refer to “A.C. MAGNETO”.
BALANCER ENG REMOVING THE BALANCER DRIVE GEAR AND BALANCER DRIVEN GEAR 1. Straighten the lock washer tab. 2. Loosen: • primary drive gear nut 1 • balancer driven gear nut 2 NOTE: Place an aluminum plate a between the teeth of the balancer drive gear 3 and driven gear 4. 3. Remove: • balancer drive gear • balancer driven gear CHECKING THE PRIMARY DRIVE GEAR, BALANCER DRIVE GEAR AND BALANCER DRIVEN GEAR 1. Check: • primary drive gear 1 • balancer drive gear 2 • balancer driven gear 3 Wear/damage → Replace.
BALANCER ENG INSTALLING THE BALANCER DRIVE GEAR AND BALANCER DRIVEN GEAR 1. Install: • balancer driven gear 1 NOTE: Install the balancer driven gear onto the balancer while aligning the punch mark a on the balancer driven gear with the shorter spline b on the balancer end. 2. Install: • balancer drive gear 1 NOTE: • Align the punch mark a on the balancer drive gear with the punch mark b on the balancer driven gear.
OIL PUMP ENG EBS00315 OIL PUMP Order 1 2 3 4 5 6 7 8 Job/Part Removing the oil pump Clutch housing Right crankcase cover Circlip Washer Oil pump drive gear Oil pump assembly Dowel pin Outer rotor 2 Circlip Inner rotor 2 Q’ty 1 1 1 1 1 1 1 1 4 - 58 Remarks Remove the parts in the order listed. Refer to “CLUTCH”. Refer to “WATER PUMP” in chapter 5.
OIL PUMP Order 9 10 11 12 13 14 15 16 Job/Part Pin Oil pump housing cover Outer rotor 1 Inner rotor 1 Pin Washer Oil pump driven gear Oil pump housing Q’ty 1 1 1 1 1 1 1 1 ENG Remarks For installation, reverse the removal procedure.
OIL PUMP ENG EBS00317 CHECKING THE OIL PUMP 1. Check: • oil pump drive gear • oil pump driven gear • oil pump housing • oil pump housing cover Cracks/wear/damage → Replace. 2. Measure: • inner-rotor-to-outer-rotor-tip clearance a • outer-rotor-to-oil-pump-housing clearance b Out of specification → Replace the oil pump. 1 inner rotor 2 outer rotor 3 oil pump housing Inner-rotor-to-outer-rotor-tip clearance 0.07 ~ 0.12 mm (0.0028 ~ 0.0047 in) : 0.20 mm (0.
SHIFT SHAFT ENG SHIFT SHAFT Order 1 2 3 4 5 6 7 8 9 10 Job/Part Removing the shift shaft Clutch Oil pump drive gear Shift pedal Shift shaft Shift shaft spring/washer Roller Shift guide Shift lever assembly Pawl holder Pawl Pawl pin Spring Q’ty 1 1 1/1 1 1 1 1 2 2 2 4 - 61 Remarks Remove the parts in the order listed. Refer to “CLUTCH”. Refer to “OIL PUMP”. Refer to “INSTALLING THE SHIFT SHAFT”. Refer to “INSTALLING THE SHIFT LEVER”.
SHIFT SHAFT Order 11 12 13 Job/Part Stopper lever Stopper lever spring Shift drum segment Q’ty 1 1 1 ENG Remarks Refer to “INSTALLING THE SHIFT LEVER”. For installation, reverse the removal procedure.
SHIFT SHAFT ENG EBS01018 1 CHECKING THE SHIFT SHAFT 1. Check: • shift shaft 1 Bends/damage/wear → Replace. • shift shaft spring 2 Damage/wear → Replace. 2 EBS01019 CHECKING THE STOPPER LEVER 1. Check: • stopper lever 1 Bends/damage → Replace. Roller turns roughly → Replace the stopper lever. • stopper spring 2 Damage/wear → Replace. EBS00359 CHECKING THE SHIFT GUIDE AND SHIFT LEVER 1. Check: • shift guide 1 • pawl holder 2 • pawls 3 • pawl pins 4 • springs 5 Wear/cracks/damage → Replace.
SHIFT SHAFT 1 2. Install: • stopper lever spring 1 • stopper lever 2 T. R. 2 ENG 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: Align the stopper lever roller with a slot on the shift drum segment. Install: springs 1 pawl pins 2 pawls 3 shift guide 4 10 Nm (1.0 m · kg, 7.2 ft · lb) (to the pawl holder) T. R. 3. • • • • T. 4. Install: • shift lever assembly 1 • shift guide 2 10 Nm (1.0 m · kg, 7.2 ft · lb) R. NOTE: The shift lever assembly is installed at the same time as the shift guide.
CRANKCASE ENG EBS00320 CRANKCASE Order 1 2 3 4 Job/Part Separating the crankcase Engine assembly Camshafts Cylinder head A.C. magneto Clutch Balancer Oil pump Shift drum segment Starter motor Timing chain guide (intake side) Timing chain Neutral switch Hose guide Q’ty 1 1 1 1 4 - 65 Remarks Remove the parts in the order listed. Refer to “ENGINE REMOVAL”. Refer to “CAMSHAFTS”. Refer to “CYLINDER HEAD”. Refer to “A.C. MAGNETO”. Refer to “CLUTCH”. Refer to “BALANCER”. Refer to “OIL PUMP”.
CRANKCASE Order 5 6 7 8 9 10 11 Job/Part Circlip/spacer Oil delivery pipe 2 Right crankcase Left crankcase Dowel pin/O-ring Dowel pin Oil stainer Q’ty 1/1 1 1 1 1/1 2 1 ENG Remarks Refer to “SEPARATING THE CRANKCASE”. For installation, reverse the removal procedure.
CRANKCASE ENG EBS00321 OIL SEAL AND BEARING Order 1 2 3 4 Job/Part Removing the crankcase bearings Crankshaft Transmission Oil seal holder Oil seal Bearing retainer Bearing Q’ty Remarks Remove the parts in the order listed. Refer to “CRANKSHAFT”. Refer to “TRANSMISSION”. 1 3 13 10 For installation, reverse the removal procedure.
CRANKCASE ENG EBS00332 SEPARATING THE CRANKCASE 1. Separate: • right crankcase • left crankcase ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the crankcase bolts. NOTE: • Loosen each bolt 1/4 of a turn at a time and after all the bolts are loosened, remove them. • Loosen the bolts in stages, using a crisscross pattern. _ Left crankcase b. Remove the right crankcase. NOTE: Insert a screwdriver or pry bar into the pry points in the crankcase and then carefully pry apart the crankcase halves.
CRANKCASE ENG 2. Check: • oil delivery pipe 2 Cracks/damage → Replace. • oil delivery pipe holes 1 Clogged → Blow out with compressed air. EBS00335 CHECKING THE TIMING CHAIN AND GUIDE 1. Check: • timing chain Cracks/stiffness → Replace the timing chain and camshaft as a set. 2. Check: • timing chain guide (intake side) Wear/damage → Replace. EBS00339 CHECKING THE BEARINGS AND OIL SEALS 1. Check: • bearings Clean and lubricate, then rotate the inner race with a finger. Roughness → Replace. 2.
CRANKCASE ENG EBS00342 È ASSEMBLING THE CRANKCASE 1. Install: • bearing New • bearing retainer • bolt (bearing retainer) T. R. 10 Nm (1.0 m · kg, 7.2 ft · lb) • screw [bearing retainer (crankshaft)] 1 T. R. 12 Nm (1.2 m · kg, 8.7 ft · lb) • screw [bearing retainer (drive axle)] 2 T. R. É 2 1 a b 12 Nm (1.2 m · kg, 8.7 ft · lb) NOTE: • Install the bearing by pressing its outer race evenly.
CRANKCASE ENG 4. Fit the right crankcase onto the left crankcase. Tap lightly on the case with a soft hammer. CAUTION: _ Before installing and torquing the crankcase holding bolts, be sure to check whether the transmission is functioning properly by manually rotating the shift drum in both directions. 1 5. • • 6. • Install: hose guide 1 crankcase bolts Tighten: crankcase bolts (follow the proper tightening sequence) T. R. 12 Nm (1.2 m · kg, 8.
CRANKSHAFT ENG CRANKSHAFT 1 Order 1 Job/Part Removing the crankshaft Crankcase Crankshaft Q’ty 1 4 - 72 Remarks Remove the parts in the order listed. Separate. Refer to “CRANKCASE”. Refer to “REMOVING THE CRANKSHAFT” and “INSTALLING THE CRANKSHAFT”. For installation, reverse the removal procedure.
CRANKSHAFT ENG EBS00337 1 REMOVING THE CRANKSHAFT 1. Remove: • crankshaft 1 Use a crankcase separating tool 2. 2 Crankcase separating tool P/N. YU-01135-A, 90890-01135 EBS00360 CHECKING THE CRANKSHAFT 1. Measure: • side clearance d Out of specification → Replace the crankshaft. d C1 Big end side clearance 0.15 ~ 0.45 mm (0.0059 ~ 0.0177 in) : 0.50 mm (0.0197 in) C2 2. Measure: • runout c Out of specification → Replace the crankshaft. Runout limit C1: 0.05 mm (0.002 in) C2: 0.05 mm (0.
CRANKSHAFT ENG INSTALLING THE CRANKSHAFT 1. Install: • crankshaft 1 Crankshaft installer pot 2 P/N. 90890-01274 Crankshaft installer bolt 3 P/N. 90890-01275 Crankshaft installer set P/N. YU-90050 Adapter 4 P/N. YM-90063, 90890-01278 Spacer (crankshaft installer) 5 P/N. YM-91044, 90890-04081 NOTE: Hold the connecting rod at the Top Dead Center (TDC) with one hand while turning the nut of the installing tool with the other. Operate the installing tool until the crankshaft bottoms against the bearing.
TRANSMISSION ENG EBS00345 TRANSMISSION 7 6 E 2 3 E E 4 1 E 5 E Order 1 2 3 4 5 6 7 Job/Part Removing the transmission Crankcase Shift fork “C” Shift fork “R” Shift fork “L” Shift drum Main axle assembly Spacer Drive axle assembly Q’ty 1 1 1 1 1 1 1 E Remarks Remove the parts in the order listed. Separate. Refer to “CRANKCASE”. Refer to “INSTALLING THE TRANSMISSION”. For installation, reverse the removal procedure.
TRANSMISSION ENG EBS00347 MAIN AXLE Order 1 Job/Part Disassembling the main axle 2nd pinion gear 2 3 4 5 6 7 4th pinion gear 3rd pinion gear Circlip Toothed washer 5th pinion gear Main axle/1st pinion gear Q’ty 1 1 1 1 1 1 1 Remarks Remove the parts in the order listed. Refer to “ASSEMBLING THE MAIN AXLE AND DRIVE AXLE”. Refer to “ASSEMBLING THE MAIN AXLE AND DRIVE AXLE”. For assembly, reverse the disassembly procedure.
TRANSMISSION ENG EBS00348 DRIVE AXLE Order 1 2 3 4 5 6 7 8 9 0 A Job/Part Disassembling the drive axle Crankcase 1st wheel gear 5th wheel gear Circlip Toothed washer 3rd wheel gear Toothed spacer Toothed lock washer Toothed washer retainer 4th wheel gear 2nd wheel gear Drive axle Q’ty 1 1 2 2 1 1 1 1 1 1 1 Remarks Remove the parts in the order listed. Refer to “CRANKCASE”. Refer to “ASSEMBLING THE MAIN AXLE AND DRIVE AXLE”. For assembly, reverse the disassembly procedure.
TRANSMISSION ENG EBS00350 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. 2. Check: • shift fork movement Rough movement → Replace the shift forks. EBS00351 CHECKING THE SHIFT DRUM 1. Check: • shift drum grooves Scratches/wear/damage → Replace. EBS00354 CHECKING THE TRANSMISSION 1.
TRANSMISSION ENG 3. Check: • transmission gear engagement (each pinion gear to its respective wheel gear) Incorrect → Reassemble the transmission axle assemblies. 4. Check: • transmission gear movement Rough movement → Replace the defective part(s). 5. Check: • circlips Bends/damage/looseness → Replace. EBS00355 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 1.
TRANSMISSION ENG EBS00356 3 1 4 2 INSTALLING THE TRANSMISSION 1. Install: • shift fork “L” 1 (to drive axle) • shift fork “C” 2 (to main axle) • shift fork “R” 3 (to drive axle) • shift drum 4 • transmission assembly NOTE: The embossed marks on the shift forks should face towards the right side of the engine and be in the following sequence: “R”, “C”, “L”. Be sure that the shift fork cam follower is properly seated in the shift drum groove. _ 2. Check: • shift operation Unsmooth operation → Repair.
COOL RADIATOR EBS00125 COOLING SYSTEM RADIATOR T. R. T. R. T. R. 28 Nm (2.8 m • kg, 20 ft • Ib) 9 Nm (0.9 m • kg, 6.5 ft • Ib) 7 Nm (0.7 m • kg, 5.1 ft • Ib) 15 (2) 7 9 16 13 8 2 14 34 New 11 (2) 1 12 5 6 10 New T. R. 28 Nm (2.8 m • kg, 20 ft • Ib) T. R. Order 1 2 3 4 5 6 7 8 9 10 7 Nm (0.7 m • kg, 5.1 ft • Ib) Job/Part Q’ty Remarks Removing the radiator Remove the parts in the order listed.
COOL RADIATOR T. R. T. R. T. R. 28 Nm (2.8 m • kg, 20 ft • Ib) 9 Nm (0.9 m • kg, 6.5 ft • Ib) 7 Nm (0.7 m • kg, 5.1 ft • Ib) 15 (2) 7 9 16 13 8 2 14 34 New 11 (2) 1 12 5 6 10 New T. R. 28 Nm (2.8 m • kg, 20 ft • Ib) T. R. Order 11 12 13 14 15 16 Job/Part Radiator Radiator grill Radiator fan Coolant reservoir breather hose Coolant reservoir cap Coolant reservoir Q’ty 1 1 1 1 1 1 7 Nm (0.7 m • kg, 5.1 ft • Ib) Remarks For installation, reverse the removal procedure.
RADIATOR COOL EBS00127 CHECKING THE RADIATOR 1. Check: • radiator fins Obstruction → Clean. Apply compressed air to the rear of the radiator. Damage → Repair or replace. NOTE: Straighten any flattened fins with a thin, flathead screwdriver. _ 2. Check: • radiator hoses Cracks/damage → Replace. 3. Measure: • radiator cap opening pressure Below the specified pressure → Replace the radiator cap. Radiator cap opening pressure 107.9 ~ 137.3 kPa (1.079 ~ 1.373 kg/cm2, 15.35 ~ 19.
RADIATOR COOL EBS00128 INSTALLING THE RADIATOR 1. Fill: • cooling system (with the specified amount of the recommended coolant) Refer to “CHANGING THE COOLANT” in chapter 3. 2. Check: • cooling system Leaks → Repair or replace any faulty part.
WATER PUMP COOL EBS00134 WATER PUMP Order Job/Part Removing the water pump Engine oil Coolant Exhaust pipe Q’ty Rear brake light switch/footrest (right) 1 2 3 4 5 6 7 Clutch cover Radiator outlet hose Water pump inlet pipe Water pump housing Oil filter element cover Oil filter element Parking brake holder Oil delivery pipe 1 1 1 1 1 1 1 1 5-5 Remarks Remove the parts in the order listed. Drain. Drain. Refer to “ENGINE REMOVAL” in chapter 4. Refer to “FRONT AND REAR BRAKES” in chapter 7.
WATER PUMP Order 8 9 10 11 12 13 14 15 16 Job/Part Oil hose 1 Right crankcase cover Gasket Impeller Washer Impeller shaft Oil seal Bearing Oil seal Q’ty 1 1 1 1 1 1 1 1 1 COOL Remarks For installation, reverse the removal procedure.
WATER PUMP COOL EBS00139 CHECKING THE WATER PUMP 1. Check: • water pump housing 1 • impeller 2 • impeller shaft 3 Cracks/damage/wear → Replace. 2. Check: • oil seal New • water pump inlet pipe Cracks/damage/wear → Replace. • bearing Rough movement → Replace.
CARB CARBURETOR EBS00141 CARBURETOR CARBURETOR T. R. T. R. 4 Nm (0.4 m • kg, 2.9 ft • Ib) 4 Nm (0.4 m • kg, 2.9 ft • Ib) 5 T. R. New 3 Nm (0.3 m • kg, 2.2 ft • Ib) 8 2 4 6 New 1 3 7 T. R. Order 1 2 3 4 5 6 7 8 9 3 Nm (0.3 m • kg, 2.2 ft • Ib) 7 9 Job/Part Q’ty Remarks Removing a carburetor Remove the parts in the order listed. Seat/fuel tank cover/side covers (left Refer to “SEAT, FENDERS AND FUEL and right) TANK” in chapter 3. Throttle position sensor coupler 1 Disconnect.
CARBURETOR CARB EBS00144 Order 1 2 3 4 5 6 7 8 9 0 Job/Part Disassembling the carburetor Drain hose Air vent hose Throttle position sensor Cover Carburetor switch/throttle stop screw assembly Starter plunger Carburetor top cover Screw (throttle shaft) Throttle valve Throttle valve plate Q’ty 1 2 1 1 1 1 1 1 1 1 6-2 Remarks Remove the parts in the order listed.
CARBURETOR Order A B C D E F G H I J Job/Part Needle holder Jet needle Cover/spring Pilot air diaphragm Cover/spring Accelerator pump diaphragm Float chamber Accelerator jet Float pin Float Q’ty 1 1 1/1 1 1/1 1 1 1 1 1 6-3 CARB Remarks
CARBURETOR Order K L M N O P Q Job/Part Needle valve Main jet Needle jet Spacer Pilot jet Starter jet Pilot air jet Q’ty 1 1 1 1 1 1 1 CARB Remarks For assembly, reverse the disassembly procedure.
CARBURETOR CARB EBS00146 DISASSEMBLING THE CARBURETOR NOTE: Before disassembling the carburetor, make sure to note the number of times the pilot screw is turned out from the seated position to its set position. _ EBS00148 CHECKING THE CARBURETOR 1. Check: • carburetor body • float chamber Cracks/damage → Replace. • fuel passage Contamination → Clean as indicated. • fuel chamber body Contamination → Clean. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Wash the carburetor in a petroleum based solvent.
CARBURETOR 2 3 4. Check: • throttle valve 1 • throttle valve plate 2 Scratches/wear/damage → Replace. 1 5. • • • 3 1 CARB Check: accelerator pump diaphragm 1 pilot jet diaphragm 2 spring 3 2 6. Check: • jet needle 1 Bends/wear/damage → Replace. • clip groove Free play/wear → Replace. • clip position Standard clip position No.4 groove 7. • • • • • • Check: main jet 1 pilot jet 2 needle jet 3 starter jet 4 pilot air jet 5 accelerator jet 6 Bends/wear/damage → Replace.
CARBURETOR CARB EBS00150 ASSEMBLING THE CARBURETOR CAUTION: _ Before reassembling, wash all of the parts in a clean petroleum based solvent. 1. Install: • pilot screw 1 1 NOTE: Before assembling the carburetor, make sure to turn out the pilot screw the same number of times, as noted before disassembly, from the seated position to the set position. _ 2. Measure: • float height a Out of specification → Adjust. a Float height (F.H) 8.0 mm (0.31 in) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a.
CARBURETOR CARB ADJUSTING THE ACCELERATOR PUMP TIMING 1. Adjust: • accelerator pump timing ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ NOTE: Insert a rod 1 with an outer diameter equal to the specified throttle valve height a under the throttle valve plate 2 to achieve the specified value. Throttle valve height 3.40 mm (0.134 in) b a. Fully turn in the accelerator pump adjusting screw 3. b. Check that the link lever 4 has free play b by pushing lightly on it. c.
CARBURETOR a d CARB INSTALLING THE CARBURETOR 1. Install: • carburetor c NOTE: Align the projection a on the carburetor with the slot b in the carburetor joint, and then align the projection c on the carburetor with the slot d in the air intake duct. b 2. • • 3. • Install: throttle cable throttle cable cover Adjust: throttle lever free play Refer to “ADJUSTING THE THROTTLE LEVER FREE PLAY” in chapter 3. 4. Adjust: • engine idling speed Refer to “ADJUSTING THE ENGINE IDLING SPEED” in chapter 3.
CARBURETOR 2. Adjust: • throttle position sensor angle a 1 b CARB ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Loosen the throttle position sensor screw 1. b. Turn the throttle position sensor in direction a or b until the specified throttle position sensor output voltage is indicated on the pocket tester. c. Connect the pocket tester (20 V DC) to the throttle position sensor. Tester positive lead → yellow 3 Tester negative lead → black 2 d. Check the throttle position sensor output voltage.
FRONT AND REAR WHEELS CHAS EBS00378 CHASSIS FRONT AND REAR WHEELS FRONT WHEELS Order Job/Part Removing the front wheels Q’ty Remarks Remove the parts in the order listed. The following procedure applies to both of the front wheels. Place the machine on a level surface. WARNING _ Securely support the machine so there is no danger of it falling over. 1 2 3 4 Cotter pin Axle nut Front wheel Brake disc guard (outer) 1 1 1 1 7-1 Refer to “INSTALLING THE WHEEL HUBS”.
FRONT AND REAR WHEELS Order 5 Job/Part Brake caliper assembly CHAS Q’ty Remarks 1 NOTE: Do not squeeze the brake lever when the brake caliper is off of the brake discs as the brake pads will be forced shut. _ 6 7 Wheel hub Brake disc 1 1 For installation, reverse the removal procedure.
FRONT AND REAR WHEELS CHAS REAR WHEELS Order Job/Part Removing the rear wheels Q’ty Remarks Remove the parts in the order listed. Place the machine on a level surface. WARNING _ Securely support the machine so there is no danger of it falling over. 1 2 3 4 Rear wheel Cotter pin Axle nut Wheel hub 2 2 2 2 Refer to “INSTALLING THE WHEEL HUBS”. For installation, reverse the removal procedure.
FRONT AND REAR WHEELS CHAS EBS00383 CHECKING THE WHEELS 1. Check: • wheels 2. Measure: • wheel runout Over the specified limit → Replace the wheel or check the wheel bearing play 1. Wheel runout limit Radial 2: 2.0 mm (0.08 in) Lateral 3: 2.0 mm (0.08 in) 3. Check: • wheel balance Out of balance → Adjust. WARNING _ After replacing the tire, ride conservatively to allow the tire to be properly seated in the rim.
FRONT AND REAR WHEELS CHAS 2. Check: • wheel bearings Wheel hub play/wheel turns roughly → Replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Clean wheel hub exterior. b. Drive bearing out by pushing spacer aside and tapping around perimeter of bearing inner race. Use soft metal drift punch and hammer. The spacer 1 “floats” between bearings. Remove both bearings as described. 1 WARNING _ Eye protection is recommended when using striking tools. c. To install the wheel bearings, reverse the above sequence.
FRONT AND REAR WHEELS CHAS INSTALLING THE FRONT WHEEL HUB BEARINGS 1. Install: • bearings 1 NOTE: Face the oil seal side of the bearing inward. INSTALLING THE FRONT BRAKE DISCS 1. Install: • brake discs NOTE: Install the brake disc with its spot-faced side facing the bolt heads. EBS00392 INSTALLING THE FRONT WHEELS 1. Install: • brake disc guards (outer) 1 NOTE: Install the brake disc guard (outer) with punched burrs 2 on the wheel hub side. _ 2.
FRONT AND REAR WHEELS CHAS EBS00390 INSTALLING THE WHEEL HUBS 1. Install: • front axle nuts 1 T. R. 70 Nm (7.0 m · kg, 50 ft · lb) • rear axle nuts 1 T. R. 120 Nm (12.0 m · kg, 85 ft · lb) • cotter pins 2 New NOTE: Do not loosen the axle nut after torquing it. If the axle nut groove is not aligned with the cotter pin hole, align the groove with the hole by tightening the axle nut.
REAR AXLE AND REAR AXLE HUB CHAS EBS00382 REAR AXLE AND REAR AXLE HUB Order 1 2 3 4 5 6 Job/Part Q’ty Remarks Removing the rear axle and rear axle Remove the parts in the order listed. hub Rear wheels/rear wheel hubs Refer to “FRONT AND REAR WHEELS”. Bolt 2 Nut 1 Refer to “REMOVING THE REAR Conical spring washer 1 AXLE” and “INSTALLING THE REAR AXLE”.
REAR AXLE AND REAR AXLE HUB Order 7 8 9 10 11 12 13 Job/Part Brake disc/brake disc bracket Rear axle Circlip Driven sprocket/sprocket bracket Brake caliper bracket Rear axle hub Spacer/bearing/oil seal CHAS Q’ty Remarks 1/1 Refer to “REMOVING THE REAR 1 AXLE”. 1 1/1 Refer to “INSTALLING THE DRIVEN SPROCKET”. 1 1 1/2/2 Refer to “INSTALLING THE FRONT WHEEL HUB BEARINGS”. For installation, reverse the removal procedure.
REAR AXLE AND REAR AXLE HUB CHAS EBS00393 1 REMOVING THE REAR AXLE 1. Place the machine on a level surface. 2. Remove: • bolts 3. Loosen: • nut 1 NOTE: • Apply the brake pedal so that the rear axle does not turn, when loosening the nut. • Use the PTT wrench 46 or axle nut wrench (46 mm) 2. _ PTT wrench 46 P/N. 90890-06588 Axle nut wrench (46 mm) P/N. YM-37134 4. Elevate the rear wheels by placing the suitable stand under the frame. 5. Remove: • rear wheels • wheel hubs • nuts • washers 6.
REAR AXLE AND REAR AXLE HUB CHAS 8. Remove: • rear axle 1 (with driven sprocket) CAUTION: _ • Never directly tap the axle end with a hammer, since this will result in damage to the axle thread and spline. • Attach a suitable socket 2 on the axle end and tap it with a soft hammer, then pull out the rear axle to the right. 9. Remove: • circlip • driven sprocket bracket EBS00395 CHECKING THE REAR AXLE 1. Check: • rear axle runout a Out of specification → Replace.
REAR AXLE AND REAR AXLE HUB CHAS INSTALLING THE DRIVEN SPROCKET 1. Install: • driven sprocket a NOTE: Make sure that the blunt-edged corner a of the driven sprocket is facing outward. EBS00397 INSTALLING THE REAR AXLE 1. Install: • conical spring washer 1 1 NOTE: Install the conical spring washer with the convex side of the washer facing outward as shown. 2. Tighten: • nut 1 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a.
FRONT AND REAR BRAKES CHAS EBS00400 FRONT AND REAR BRAKES FRONT BRAKE PADS T. R. 18 Nm (1.8 m • kg, 13 ft • Ib) LT 1 3 2 T. R. 28 Nm (2.8 m • kg, 20 ft • Ib) Order 1 2 3 Job/Part Removing the front brake pads Front wheel Brake pad retaining bolt Brake pad Brake pad spring Q’ty 2 2 1 Remarks Remove the parts in the order listed. The following procedure applies to both of the front brake calipers. Refer to “FRONT AND REAR WHEELS”. Refer to “REPLACING THE FRONT BRAKE PADS”.
CHAS FRONT AND REAR BRAKES EBS00401 REAR BRAKE PADS 4 5 2 New 3 1 T. R. 18 Nm (1.8 m • kg, 13 ft • Ib) 1 T. R. Order 31 Nm (3.1 m • kg, 22 ft • Ib) Q’ty 1 Job/Part Removing the rear brake pads Brake caliper mounting bolt 2 3 4 5 Brake pad retaining bolt Lock washer Brake pad/pad shim Brake pad spring 2 1 2/1 1 2 Remarks Remove the parts in the order listed. Refer to “REPLACING THE REAR BRAKE PADS”. For installation, reverse the removal procedure.
FRONT AND REAR BRAKES CHAS EBS00402 CAUTION: _ Disc brake components rarely require disassembly.
FRONT AND REAR BRAKES CHAS 2. Install: • brake pads • brake pad spring NOTE: Always install new brake pads and brake pad spring as a set. _ 2 1 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect a suitable hose 1 tightly to the brake caliper bleed screw 2. Put the other end of this hose into an open container. b. Loosen the brake caliper bleed screw and, using a finger, push the caliper piston into the brake caliper. c. Tighten the brake caliper bleed screw. T. Brake caliper bleed screw 6 Nm (0.6 m · kg, 4.
FRONT AND REAR BRAKES CHAS EBS00405 REPLACING THE REAR BRAKE PADS NOTE: It is not necessary to disassemble the brake caliper and brake hose to replace the brake pads. _ 1. Remove: • brake pads a wear limit NOTE: Replace the brake pads as a set if either is found to be worn to the wear limit. _ 2. Install: • brake pads • brake pad spring NOTE: Always install new brake pads, brake pad shim and brake pad spring as a set. _ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a.
FRONT AND REAR BRAKES CHAS f. Bend the lock washer tabs along a flat side of the bolts. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Check: • brake fluid level Refer to “CHECKING THE BRAKE FLUID LEVEL” in chapter 3. 4. Check: • brake lever or brake pedal operation Soft or spongy feeling → Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3.
FRONT AND REAR BRAKES CHAS EBS00407 FRONT BRAKE MASTER CYLINDER Order 1 2 3 4 5 6 7 8 9 Job/Part Removing the front brake master cylinder Brake fluid Brake fluid reservoir cap Brake fluid reservoir diaphragm Front brake light switch Brake lever Union bolt Copper washer Brake hose Brake master cylinder bracket Brake master cylinder Q’ty Remarks Remove the parts in the order listed. Drain. 1 1 1 1 1 2 1 1 1 Disconnect. Refer to “INSTALLING THE FRONT BRAKE MASTER CYLINDER”.
FRONT AND REAR BRAKES CHAS EBS00409 Order 1 2 3 Job/Part Disassembling the front brake master cylinder Dust boot Circlip Brake master cylinder kit Q’ty 1 1 1 Remarks Remove the parts in the order listed. Refer to “ASSEMBLING THE FRONT BRAKE MASTER CYLINDER”. For assembly, reverse the disassembly procedure.
FRONT AND REAR BRAKES CHAS EBS00410 REAR BRAKE MASTER CYLINDER Order 1 2 3 4 5 6 Job/Part Q’ty Remarks Removing the rear brake master cylRemove the parts in the order listed. inder Right foot protector Refer to “SEAT, FENDERS AND FUEL TANK” in chapter 3. Brake fluid Drain.
FRONT AND REAR BRAKES Order 7 8 9 10 11 12 13 Job/Part Union bolt Copper washer Brake hose Brake master cylinder Rear brake light switch Right footrest Brake pedal/spring CHAS Q’ty Remarks 1 Refer to “INSTALLING 2 THE REAR BRAKE MAS1 Disconnect. TER CYLINDER”. 1 1 1 1/1 For installation, reverse the removal procedure.
FRONT AND REAR BRAKES CHAS EBS00411 Order 1 2 3 Job/Part Disassembling the rear brake master cylinder Hose joint Brake master cylinder kit Brake master cylinder Q’ty 1 1 1 7 - 23 Remarks Remove the parts in the order listed. Refer to “ASSEMBLING THE REAR BRAKE MASTER CYLINDER”. For assembly, reverse the disassembly procedure.
FRONT AND REAR BRAKES È EBS00413 CHECKING THE MASTER CYLINDERS 1. Check: • brake master cylinder 1 Wear/scratches → Replace the brake master cylinder assembly. • brake master cylinder body Cracks/damage → Replace. • brake fluid delivery passage (brake master cylinder body) Blockage → Blow out with compressed air. É È CHAS È Front É Rear É 2. Check: • brake master cylinder kit Scratches/wear/damage → Replace as a set. È Front É Rear 3.
FRONT AND REAR BRAKES CHAS EBS00415 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER WARNING _ • All internal brake components should be cleaned and lubricated with new brake fluid only before installation. Recommended brake fluid DOT 4 • Whenever a master cylinder is disassembled, replace the piston seals and dust seals. EBS00416 ASSEMBLING THE REAR BRAKE MASTER CYLINDER WARNING _ • All internal brake components should be cleaned and lubricated with new brake fluid only before installation.
FRONT AND REAR BRAKES CHAS EBS00418 INSTALLING THE FRONT BRAKE MASTER CYLINDER 1. Install: • brake master cylinder 1 T. R. 7 Nm (0.7 m · kg, 5.1 ft · lb) NOTE: • The “UP” mark on the brake master cylinder bracket should face up. • Install the brake master cylinder so that the gaps between the brake master cylinder and the brake master cylinder bracket are equal. _ Install: copper washers New brake hose 27 Nm (2.7 m · kg, 19 ft · lb) union bolt T. R. 2.
FRONT AND REAR BRAKES CHAS WARNING _ • Use only the designated quality brake fluid: other brake fluids may deteriorate the rubber seals, causing leakage and poor brake performance. • Refill with the same type of brake fluid: mixing brake fluids may result in a harmful reaction and lead to poor brake performance. • Be careful that water does not enter the brake master cylinder when refilling. Water will significantly lower the boiling point of the brake fluid and may result in vapor lock. 4.
FRONT AND REAR BRAKES 35˚ 1 a CHAS 2. Install: • brake fluid reservoir hose 1 NOTE: Install the brake fluid reservoir hose with the white paint mark a facing up as shown. 3. Fill: • brake fluid reservoir Recommended brake fluid DOT 4 CAUTION: _ Brake fluid may damage painted surfaces or plastic parts. Always clean up spilled brake fluid immediately. WARNING _ • Use only the designated quality brake fluid: other brake fluids may deteriorate the rubber seals, causing leakage and poor brake performance.
FRONT AND REAR BRAKES CHAS EBS00421 FRONT BRAKE CALIPERS T. R. 18 Nm (1.8 m • kg, 13 ft • Ib) LT 4 6 5 3 T. R. 28 Nm (2.8 m • kg, 20 ft • Ib) 2 New 1 T. R. Order 1 2 3 4 5 6 27 Nm (2.7 m • kg, 19 ft • Ib) Job/Part Removing the front brake calipers Brake caliper Front wheel Union bolt Copper washer Brake hose Brake pad retaining bolt Brake caliper mounting bolt Brake caliper assembly Q’ty 1 2 1 2 2 1 Remarks Remove the parts in the order listed.
CHAS FRONT AND REAR BRAKES EBS00423 3 T. R. T. R. 6 Nm (0.6 m • kg, 4.3 ft • Ib) 18 Nm (1.8 m • kg, 13 ft • Ib) 8 New 7 2 6 1 5 4 LT New LS Order Job/Part Disassembling the front brake calipers Q’ty Remarks Remove the parts in the order listed. The following procedure applies to both of the front brake calipers.
FRONT AND REAR BRAKES CHAS EBS00424 REAR BRAKE CALIPER Order 1 Job/Part Removing the rear brake caliper Brake fluid Parking brake cable 2 3 4 5 6 Union bolt Copper washer Brake hose Brake caliper mounting bolt Brake caliper assembly Q’ty 1 2 2 1 2 1 Remarks Remove the parts in the order listed. Drain. Disconnect. Refer to “REMOVING THE PARKING BRAKE CABLE”. Disconnect. Refer to “INSTALLING THE REAR BRAKE CALIPER”. For installation, reverse the removal procedure.
FRONT AND REAR BRAKES CHAS EBS00425 Order 1 2 3 4 5 6 7 8 9 0 Job/Part Disassembling the rear brake caliper Adjusting bolt Locknut Parking brake arm Parking brake case mounting bolt Parking brake case bracket Parking brake case Gasket Spring Nut Bearing Q’ty 1 1 1 2 1 1 1 1 1 1 7 - 32 Remarks Remove the parts in the order listed.
FRONT AND REAR BRAKES Order A B C D E F G H I J K Job/Part Brake pad holding bolt Lock washer Brake pad/pad shim Brake pad spring Retaining bolt Caliper bracket Brake caliper piston Dust seal Caliper piston seal O-ring Bleed screw Q’ty 2 1 2/1 1 1 1 1 1 1 1 1 CHAS Remarks Refer to “DISASSEMBLING THE FRONT AND REAR BRAKE CALIPERS” and “ASSEMBLING THE REAR BRAKE CALIPER”. For assembly, reverse the disassembly procedure.
FRONT AND REAR BRAKES CHAS REMOVING THE PARKING BRAKE CABLE 1. Loosen: • nut • adjusting bolt 2. Disconnect: • parking brake cable (from parking brake lever) 3. Disconnect: • parking brake cable (from rear brake) È EBS00427 1 2 DISASSEMBLING THE FRONT AND REAR BRAKE CALIPERS 1. Remove: • brake caliper pistons • dust seals 1 • caliper piston seals 2 È Front É Rear ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ É a.
FRONT AND REAR BRAKES CHAS EBS00429 CHECKING THE FRONT AND REAR BRAKE CALIPERS Recommended brake component replacement schedule Brake pads As required Piston seals, dust seals Every two years Brake hoses Every four years Brake fluid Replace when brakes are disassembled. WARNING _ All internal brake components should be cleaned in new brake fluid only. Do not use solvents as they will cause seals to swell and distort. È 2 1 2 1 É 3 1.
FRONT AND REAR BRAKES CHAS EBS00431 ASSEMBLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the front brake calipers. WARNING _ • All internal brake components should be cleaned and lubricated with new brake fluid only before installation. Recommended brake fluid DOT 4 2 New 1 New • Replace the caliper piston seal whenever a brake caliper is disassembled. 1. Install: • caliper piston seals 1 New • dust seals 2 New 2.
FRONT AND REAR BRAKES CHAS 2. Install: • brake caliper piston 1 3. Install: • lock washer 1 New • brake pad holding bolts 2 T. R. 18 Nm (1.8 m · kg, 13 ft · lb) 4. Bend the lock washer tabs along a flat side of the bolts. 5. Mesh the bearing race tab 1 with parking brake case slit. 1 6. Install: • parking brake arm 1 1 b a NOTE: Align the center of the parking brake arm with a adjuster nut corner a and position the parking brake arm as shown. 7.
FRONT AND REAR BRAKES CHAS EBS00434 1 a b 2 3 New R. 1 T. 4 INSTALLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the front brake calipers. 1. Install: • brake caliper assembly • brake caliper mounting bolts 1 28 Nm (2.8 m · kg, 20 ft · lb) T. • brake hose 2 • copper washers 3 New 27 Nm (2.7 m · kg, 19 ft · lb) • union bolt 4 R.
FRONT AND REAR BRAKES CHAS 3. Air bleed: • brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. 4. Check: • brake fluid level Brake fluid level is below the “LOWER” level line → Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” in chapter 3. EBS00436 2 a INSTALLING THE REAR BRAKE CALIPER 1. Install: • brake caliper assembly • brake caliper mounting bolts 1 1 T. R. 31 Nm (3.
FRONT AND REAR BRAKES CHAS CAUTION: _ Brake fluid may damage painted surfaces or plastic parts. Always clean up spilled brake fluid immediately. WARNING _ • Use only the designated quality brake fluid: other brake fluids may deteriorate the rubber seals, causing leakage and poor brake performance. • Refill with the same type of brake fluid: mixing brake fluids may result in a harmful chemical reaction and lead to poor brake performance.
CHAS STEERING SYSTEM EBS00444 STEERING SYSTEM HANDLEBAR T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) T. R. 23 Nm (2.3 m • kg, 17 ft • Ib) 8 9 4 3 7 1 9 5 T. R. 4 Nm (0.4 m • kg, 2.9 ft • Ib) 11 12 12 10 2 13 4 5 T. R. T. R.
CHAS STEERING SYSTEM T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) T. R. 23 Nm (2.3 m • kg, 17 ft • Ib) 8 4 3 7 9 1 9 5 T. R. 4 Nm (0.4 m • kg, 2.9 ft • Ib) 11 12 12 10 2 13 4 5 T. R. T. R. 12 13 Job/Part Handlebar grip Handlebar holder Handlebar 11 2 2 Order 11 6 4 Nm (0.4 m • kg, 2.9 ft • Ib) 7 Nm (0.7 m • kg, 5.1 ft • Ib) Q’ty Remarks 2 Refer to “REMOVING THE HANDLEBAR GRIPS” and “INSTALLING THE HANDLEBAR GRIPS”. 2 Refer to “INSTALLING THE HANDLEBAR”.
STEERING SYSTEM CHAS EBS00446 REMOVING THE FRONT BRAKE LIGHT SWITCH AND CLUTCH SWITCH 1. Remove: • front brake light switch 1 • clutch switch NOTE: • Push the fastener when removing the front brake light switch out of the brake master cylinder. • Push the fastener when removing the clutch switch out of the clutch lever holder. _ EBS00447 REMOVING THE HANDLEBAR GRIPS 1.
STEERING SYSTEM CHAS EBS00449 INSTALLING THE HANDLEBAR 1. Install: • handlebar • handlebar holders T. R. 23 Nm (2.3 m · kg, 17 ft · lb) NOTE: • Install the handlebar within 3.3° from the horizontal line shown in the illustration. • The upper handlebar holder should be installed with the punched mark 1 forward 2. _ CAUTION: _ First tighten the bolt 3 on the front side of the handlebar holder, and then tighten the bolt 4 on the rear side. EBS00450 INSTALLING THE HANDLEBAR GRIPS 1.
STEERING SYSTEM CHAS EBS00452 1 2 INSTALLING THE CLUTCH LEVER 1. Install: • handlebar switch 1 • clutch lever • clutch lever bracket 2 NOTE: Install the clutch lever bracket as shown. _ a a 68 ~ 69 mm (2.68 ~ 2.72 in) EBS00453 a INSTALLING THE BRAKE MASTER CYLINDER 1. Install: • throttle lever assembly • spacer • brake master cylinder T. R. b 7 Nm (0.7 m · kg, 5.1 ft · lb) NOTE: • Engage the indentations a in the spacer with the lobes b on the throttle lever assembly and brake master cylinder.
STEERING SYSTEM CHAS EBS00454 STEERING STEM Order 1 2 3 4 5 6 7 8 Job/Part Q’ty Remarks Removing the steering stem Remove the parts in the order listed. Fuel tank cover/side covers (left and Refer to “SEAT, FENDERS AND FUEL right)/fuel tank/front fender TANK” in chapter 3. Pitman arm 1 Refer to “INSTALLING THE PITMAN ARM”. Lock washer 1 Refer to “INSTALLING THE LOCK WASHER”.
STEERING SYSTEM Order 9 10 Job/Part Bearing retainer Bearing CHAS Q’ty Remarks 1 Refer to “REMOVING THE BEARING RETAINER” and “INSTALLING THE BEARING RETAINER”. 1 For installation, reverse the removal procedure.
STEERING SYSTEM CHAS EBS00455 REMOVING THE BEARING RETAINER 1. Remove: • bearing retainer Damper rod holder (30 mm) P/N. YM-01327, 90890-01327 EBS00456 CHECKING THE STEERING STEM 1. Check: • steering stem Bends → Replace. WARNING _ Do not attempt to straighten a bent stem; this may dangerously weaken the stem. 2. Check: • oil seals 1 New • steering stem bushings 2 Wear/damage → Replace. EBS00457 INSTALLING THE BEARING RETAINER 1. Install: • bearing retainer T. R. 65 Nm (6.
STEERING SYSTEM CHAS EBS00459 T. INSTALLING THE LOCK WASHER 1. Install: • lock washer New 23 Nm (2.3 m · kg, 17 ft · lb) • bolts 2. Bend the lock washer tab along a flat side of the bolt. R. New INSTALLING THE PITMAN ARM 1. Install: • washer • nut • pitman arm NOTE: Make sure that the threads of the steering stem, washers, nuts, and the installation surfaces of the pitman arm are free of grease and oil.
STEERING SYSTEM CHAS EBS00460 TIE-RODS AND STEERING KNUCKLES Order 1 2 3 4 5 6 7 Job/Part Removing the tie-rods and steering knuckles Front wheel/brake disc Front brake caliper Brake disc guard (inner) Tie-rod Pitman arm Front bumper Lower front arm Upper front arm Steering knuckle Q’ty Remarks Remove the parts in the order listed. The following procedure applies to both of the tie-rods and steering knuckles. Refer to “FRONT AND REAR WHEELS”. Refer to “FRONT AND REAR BRAKES”.
STEERING SYSTEM CHAS EBS00461 REMOVING THE STEERING KNUCKLES 1. Remove: • steering knuckles 1 NOTE: Use a general puller to separate the ball joint 2 and steering knuckle. _ EBS00462 CHECKING THE TIE-RODS 1. Check: • tie-rod free play and movement Free play → Replace the tie-rod end. Turns roughly → Replace the tie-rod end. 2. Check: • tie-rods Bends/damage → Replace. EBS00464 CHECKING THE STEERING KNUCKLES 1. Check: • steering knuckles Damage/pitting → Replace. EBS00465 INSTALLING THE TIE-RODS 1.
FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES CHAS EBS00468 FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES Order 1 2 3 4 5 6 7 Job/Part Removing the front arms and front shock absorber assemblies Front wheel/brake disc Front brake caliper Front bumper Brake disc guard (inner) Nut Tie-rod Nut Nut Nut/washer/bolt Q’ty Remarks Remove the parts in the order listed. The following procedure applies to both of the front arms and front shock absorber assemblies. Refer to “FRONT AND REAR WHEELS”.
FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES Order 8 9 10 11 12 13 14 15 16 17 18 19 20 21 Job/Part Nut/bolt Lower front arm Nut/bolt Upper front arm Nut/bolt Front shock absorber/bushing Steering knuckle Dust cover Spacer Spacer Bushing Circlip Rubber boot/boot retaining ring Ball joint Q’ty 2/2 1 1/1 1 1/1 1/1 1 6 1 2 6 1 1/1 1 CHAS Remarks Refer to “REMOVING THE FRONT ARMS” and “INSTALLING THE FRONT ARMS”. For installation, reverse the removal procedure.
FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES CHAS EBS00469 REMOVING THE FRONT ARMS 1. Check: • front arm free play ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Check the front arm side play È by moving it from side to side. If side play is noticeable, check the bushings. b. Check the front arm vertical movement É by moving it up and down. If the vertical movement is tight or rough, or if there is binding, check the bushings. È È ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2.
FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES CHAS • Do not deform or damage the front shock absorber or gas cylinder in any way. If the front shock absorber, gas cylinder or both are damaged, damping performance will suffer. EBS00486 DISPOSING OF A FRONT SHOCK ABSORBER AND GAS CYLINDER Gas pressure must be released before disposing of a front shock absorber and gas cylinder.
FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES CHAS EBS00472 CHECKING THE BALL JOINTS The following procedure applies to both of the front arm ball joints. 1. Check: • ball joint (upper front arm) Damage/pitting → Replace the upper front arm. Free play → Replace the front arm. Turns roughly → Replace the upper front arm. 2. Check: • ball joint (lower front arm) Damage/pitting → Replace the ball joint. Free play → Replace the ball joint. Turns roughly → Replace the ball joint.
FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES CHAS f. Attach the assembled ball joint remover/ installer, new ball joint (with rubber boot and retaining ring) B, installer spacer 8 and installer washer 9 to the lower front arm A. NOTE: • Do not tap or damage the top of the ball joint. • Installer spacer 8 must be aligned with the projection on the head of the ball joint B. _ g. Remove the ball joint remover/installer. h. Install a new circlip. NOTE: Always use a new ball joint set.
CHAS REAR SHOCK ABSORBER AND RELAY ARM EBS00484 REAR SHOCK ABSORBER AND RELAY ARM T. 7 R. 80 Nm (8.0 m • kg, 58 ft • Ib) T. 7 R. 55 Nm (5.5 m • kg, 40 ft • Ib) LS New 9 1 8 9 LS New 10 1 6 10 New 5 4 4 LS 3 LS New New 12 2 New LS LS New 12 T. R. 55 Nm (5.
CHAS REAR SHOCK ABSORBER AND RELAY ARM T. 7 R. 80 Nm (8.0 m • kg, 58 ft • Ib) T. 7 R. 55 Nm (5.5 m • kg, 40 ft • Ib) LS New 9 1 8 9 LS New 10 1 6 10 New 5 4 4 LS 3 LS New New 12 2 New LS LS New 12 T. R. 55 Nm (5.
REAR SHOCK ABSORBER AND RELAY ARM CHAS EBS00485 HANDLING THE REAR SHOCK ABSORBER AND GAS CYLINDER WARNING _ This rear shock absorber and gas cylinder contain highly compressed nitrogen gas. Before handling the rear shock absorber or gas cylinder, 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 and gas cylinder.
REAR SHOCK ABSORBER AND RELAY ARM CHAS EBS00487 REMOVING THE REAR SHOCK ABSORBER 1. Remove: • relay arm-to-rear shock absorber lower bolt • rear shock absorber upper bolt NOTE: While removing the relay arm-to-rear shock absorber lower bolt, hold the swingarm so that it does not drop down. _ EBS00488 CHECKING THE REAR SHOCK ABSORBER 1. Check: • shock absorber Oil leaks → Replace the rear shock absorber assembly. • shock absorber rod Bends/damage → Replace the rear shock absorber assembly.
REAR SHOCK ABSORBER AND RELAY ARM CHAS EBS00490 1 1 INSTALLING THE RELAY ARM AND CONNECTING ARM 1. Install: • bearing 1 (to connecting arm) Installed depth of bearing a 4 mm (0.16 in) a a 2. Install: • bearings 1 to 3 (to relay arm) a Installed depth of bearing a 6.5 mm (0.26 in) Installed depth of bearing b 5.0 mm (0.20 in) Installed depth of bearing c 6.0 mm (0.24 in) 1 2 2 b b 3 EBS00491 c INSTALLING THE REAR SHOCK ABSORBER 1.
SWINGARM AND DRIVE CHAIN CHAS EBS00492 SWINGARM AND DRIVE CHAIN Order Job/Part Removing the swingarm and drive chain Rear axle hub Q’ty Refer to “REAR AXLE AND REAR AXLE HUB”. Refer to “REAR SHOCK ABSORBER AND RELAY ARM”. Rear shock absorber 1 2 3 4 5 6 7 Drive chain guard Rear brake disc guard Pivot shaft nut/washer Pivot shaft Swingarm Drive chain guide 1 Drive sprocket cover Remarks Remove the parts in the order listed.
SWINGARM AND DRIVE CHAIN Order 8 9 10 11 12 13 14 15 16 Job/Part Drive chain guide 2 Nut Lock washer Drive sprocket Drive chain Dust cover/washer/bearing Spacer Oil seal Bushing Q’ty 1 1 1 1 1 2/2/2 2 2 2 CHAS Remarks Refer to “INSTALLING THE DRIVE SPROCKET”. Refer to “INSTALLING THE SWINGARM”. For installation, reverse the removal procedure.
SWINGARM AND DRIVE CHAIN CHAS EBS00493 NOTE: Before removing the drive chain and the sprockets, measure the drive chain slack and a 15-link section of the drive chain. EBS00494 REMOVING THE SWINGARM 1. Check: • swingarm free play É ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Check the tightening torque of the pivot shaft nut. È T. Pivot shaft nut 100 Nm (10.0 m · kg, 72 ft · lb) R. b. Check the swingarm side play È by moving it from side to side.
SWINGARM AND DRIVE CHAIN CHAS 2. Check: • pivot shaft Roll the axle on a flat surface. Bends → Replace. WARNING _ Do not attempt to straighten a bent pivot shaft. 3. • • • • Clean: pivot shaft spacer bearings bushings Recommended cleaning solvent Kerosene 4. Check: • oil seals Damage/wear → Replace. • bearings • bushings Damage/pitting → Replace.
SWINGARM AND DRIVE CHAIN CHAS EBS00496 CHECKING THE DRIVE CHAIN 1. Measure: • 15-link section a of the drive chain Out of specification → Replace the drive chain. 15-link drive chain section limit (maximum) 240.5 mm (9.47 in) NOTE: • While measuring the 15-link section, push down on the drive chain to increase its tension. • Measure the length between drive chain roller 1 and F as shown. • Perform this measurement at two or three different places. _ 2.
SWINGARM AND DRIVE CHAIN CHAS 4. Check: • O-rings 1 Damage → Replace the drive chain. • drive chain rollers 2 Damage/wear → Replace the drive chain. • drive chain side plates 3 Cracks/damage/wear → Replace the drive chain. 5. Lubricate: • drive chain Recommended lubricant Engine oil or chain lubricant suitable for O-ring chains 6. Check: • drive sprocket • driven sprocket More than 1/4 tooth a wear → Replace the drive chain sprockets as a set. Bent teeth → Replace the drive chain sprockets as a set.
SWINGARM AND DRIVE CHAIN CHAS EBS00498 New 2 1 T. INSTALLING THE DRIVE SPROCKET 1. Install: • drive sprocket 1 • lock washer 2 New 75 Nm (7.5 m · kg, 54 ft · lb) • nut 3 2. Bend the lock washer tab along a flat side of the nut. R.
ELECTRICAL COMPONENTS ELEC – + EBS00500 ELECTRICAL ELECTRICAL COMPONENTS 1 Main switch 2 Throttle switch 3 Front brake light switch 4 Indicator light 5 Clutch switch 6 Handlebar switch 7 Fuse 8 Starter relay 9 Starting circuit cut-off relay 0 Tail/brake light A Battery B Ignition coil C Spark plug D Throttle position sensor E Carburetor switch F Thermo switch 2 G Pickup coil/stator assembly H Neutral switch I Rear brake light switch J Radiator fan K Circuit breaker (fan motor) L Rectifier/regulator
CHECKING SWITCH CONTINUITY ELEC – + EBS01028 CHECKING SWITCH CONTINUITY Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. CAUTION: _ Never insert the tester probes into the coupler terminal slots 1. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads. Pocket tester P/N.
CHECKING SWITCH CONTINUITY 8-3 ELEC – +
CHECKING THE SWITCHES ELEC – + EBS01029 CHECKING THE SWITCHES Check each switch for damage or wear, proper connections, and also for continuity between the terminals. Refer to “CHECKING SWITCH CONTINUITY”. Damage/wear → Repair or replace. Improperly connected → Properly connect. Incorrect continuity reading → Replace the switch.
CHECKING THE SWITCHES 1 Light switch 2 Engine stop switch 3 Start switch 4 Main switch 5 Front brake light switch 6 Throttle switch 7 Clutch switch 8 Carburetor switch 9 Fuse 0 Neutral switch A Rear brake light switch 8-5 ELEC – +
CHECKING THE BULBS AND BULB SOCKETS ELEC – + EBS01030 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 machine are shown in the illustration on the left.
CHECKING THE BULBS AND BULB SOCKETS ELEC – + WARNING _ Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. CAUTION: _ • Be sure to hold the socket firmly when removing the bulb. Never pull the lead, otherwise it may be pulled out of the terminal in the coupler.
CHECKING THE BULBS AND BULB SOCKETS ELEC – + CHECKING THE CONDITION OF THE BULB SOCKETS The following procedure applies to all of the bulb sockets. 1. Check: • bulb socket (for continuity) (with the pocket tester) No continuity → Replace. Pocket tester P/N. YU-03112-C, 90890-03112 NOTE: Check each bulb socket for continuity in the same manner as described in the bulb section; however, note the following. _ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Install a good bulb into the bulb socket. b.
8-9 Y Y Br (BLACK) (BLACK) Y Br B B Y L Y Br 1 B B U W Y Y/R W/B V (BLACK) (BLACK) Br W R R W B L B B G Y B (BLACK) B (BLACK) (BLACK) G Y (BLACK) B S Y G B Y G OFF PUSH L/B B R 6 5 (BROWN) W/L B Br R/B (BLACK) R/B Br L Y Y/R B G L/B 7 B R 15A (BLACK) Y/R Y L L/B G B (GRAY) (GRAY) B R Br R Br/L B B 4B R R Br R/W Br/L R R R Br/L BrR/B Br R B B Y G L Y G OFF RUN Q R B Y G S Y/R OFF ON 3 Y R Y/R R B W 2 W/B B W/B Y/R L/B N
IGNITION SYSTEM 3 4 6 5 7 8 0 – + THROTTLE OVERRIDE SYSTEM (T.O.R.S.) OPERATION This model is equipped with a throttle override system as a safety device that operates according to the positions of the throttle switch and carburetor switch and stops the flow of electricity from the C.D.I. unit to the ignition coil to stop the engine if the carburetor or throttle cable malfunctions during operation.
IGNITION SYSTEM EBS01045 ELEC – + EBS01044 TROUBLESHOOTING 2. Battery The ignition system fails to operate (no spark or intermittent spark). • Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: 1. fuse 2. battery 3. spark plug 4. ignition spark gap 5. ignition coil resistance 6. main switch 7. engine stop switch 8. throttle switch 9. carburetor switch 10.pickup coil resistance 11.
ELEC IGNITION SYSTEM EBS01034 – + EBS01038 4. Ignition spark gap 5. Ignition coil resistance • Disconnect the ignition coil from the spark plug. • Connect the dynamic spark tester 1 as shown. 2 Ignition coil • Set the main switch to “ON”. • Measure the ignition spark gap a. • Crank the engine by pushing the start switch and gradually increase the spark gap until a misfire occurs. • Disconnect the ignition coil coupler from the ignition coil.
EBS01041 – ELEC IGNITION SYSTEM + EBS01040 10.Pickup coil resistance 6. Main switch • Disconnect the pickup coil coupler from the wire harness. • Connect the pocket tester (Ω × 100) to the pickup coil terminal as shown. • Check the main switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the main switch OK? NO YES Replace switch. the Positive tester probe → white terminal 1 Negative tester probe → red terminal 2 main EBS01042 7.
IGNITION SYSTEM ELEC – + CHECKING THE THROTTLE OVERRIDE SYSTEM WARNING • Make sure that the parking brake is applied. • Make sure that the transmission is in neutral. NOTE: Make sure that the throttle lever moves smoothly. 1. • • • Remove: throttle lever cover throttle position sensor carburetor switch/throttle stop screw assembly cover Refer to “CARBURETOR” in chapter 6. 2. Start the engine. 3. Check: • throttle switch 1 1 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a.
IGNITION SYSTEM ELEC – + 5. Install: • throttle lever cover • carburetor switch/throttle stop screw assembly cover • throttle position sensor Refer to “CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR” in chapter 6.
8 - 16 Y B G Y B (BLACK) B (BLACK) (BLACK) B (BLACK) Y G S B B Y G OFF PUSH L/B B R 6 5 (BROWN) W/L B Br R/B (BLACK) R/B Br L Y Y/R B G L/B 7 B R 15A (BLACK) Y/R Y L L/B G B (GRAY) (GRAY) B R Br R Br/L B B 4B R R Br R/W Br/L R R R Br/L BrR/B Br R G Y B Y G L Y G OFF RUN Q R B Y G S Y/R OFF ON 3 R Y/R R Y W/B B 2 B W W/B Y/R B B L Y L Y OFF LO HI O P W/B Y/R W R L/B N B W/L W/L M L/B Y/B R Y/B L/B L/B Y/B 8 W/L L/B (BLACK
ELECTRIC STARTING SYSTEM ELEC – + EBS00508 9 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION The starting circuit on this model consists of the starter motor, starter relay, clutch switch, and neutral switch. If the main switch is on and the engine stop switch is in the RUN position, the starter motor can be operated only if: 2 • The transmission is in neutral (the neutral switch is closed) or • You pull in the clutch lever (the clutch switch is closed).
ELECTRIC STARTING SYSTEM EBS01050 ELEC – + EBS01044 TROUBLESHOOTING 2. Battery The starter motor fails to turn. • Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: 1. fuse 2. battery 3. starter motor 4. starting circuit cut-off relay 5. starting circuit cut-off relay (diode) 6. starter relay 7. main switch 8. engine stop switch 9. neutral switch 10.clutch switch 11.start switch 12.
ELEC ELECTRIC STARTING SYSTEM EBS01052 – + EBS01053 4. Starting circuit cut-off relay 5. Starting circuit cut-off relay (diode) • Remove the starting circuit cut-off relay from the wire harness. • Connect the pocket tester (Ω × 1) and battery (12 V) to the starting circuit cut-off relay as shown.
ELECTRIC STARTING SYSTEM EBS01054 ELEC – + EBS01042 8. Engine stop switch 6. Starter relay • Check the engine stop switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the engine stop switch OK? • Disconnect the starter relay coupler from the wire harness. • Connect the pocket tester (Ω × 1) and battery (12 V) to the starter relay as shown. Positive battery terminal → blue/black 1 Negative battery terminal → yellow/black 2 YES NO Replace the handlebar switch.
ELECTRIC STARTING SYSTEM EBS01059 12.Wiring • Check the entire starting system’s wiring. Refer to “CIRCUIT DIAGRAM”. • Is the starting system’s wiring properly connected and without defects? YES The starting system circuit is OK. NO Properly connect or repair the starting system’s wiring.
ELEC STARTER MOTOR – + EBS01061 STARTER MOTOR T. R. 20 Nm (2.0 m • kg, 14 ft • Ib) New T. R. 18 Nm (1.8 m • kg, 13 ft • Ib) New 2 T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) New 1 3 4 T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) T. R. Order 1 2 3 4 Job/Part Removing the starter motor Exhaust pipe Parking brake cable holder Oil delivery pipe 1 Starter motor lead Starter motor Q’ty 1 1 1 1 10 Nm (1.0 m • kg, 7.2 ft • Ib) Remarks Remove the parts in the order listed.
STARTER MOTOR ELEC – + EBS01062 5 T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 7 8 6 New 0 9 3 New 4 LS New 2 1 New Order 1 2 3 4 5 6 7 8 9 0 Job/Part Disassembling the starter motor Front bracket O-ring Shim Lock washer Rear bracket O-ring Shim Brush holder assembly Armature assembly Starter motor yoke Q’ty 1 1 1 1 1 1 1 1 1 1 Remarks Remove the parts in the order listed. Refer to “ASSEMBLING THE STARTER MOTOR”. For assembly, reverse the disassembly procedure.
STARTER MOTOR ELEC – + EBS01064 CHECKING THE STARTER MOTOR 1. Check: • commutator Dirt → Clean with 600-grit sandpaper. 2. Measure: • commutator diameter a Out of specification → Replace the starter motor. Commutator wear limit 27 mm (1.06 in) 3. Measure: • mica undercut a Out of specification → Scrape the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commutator. Mica undercut 0.7 mm (0.
STARTER MOTOR ELEC – + 5. Measure: • brush length a Out of specification → Replace the brushes as a set. Brush length wear limit 3.5 mm (0.14 in) 6. Measure: • brush spring force Out of specification → Replace the brush springs as a set. Brush spring force 7.16 ~ 9.52 N (730 ~ 971 gf, 25.77 ~ 34.27 oz) 7. Check: • gear teeth Damage/wear → Replace the gear. 8. Check: • bushing • bearing • oil seal Damage/wear → Replace the defective part(s). EBS00515 1 a ASSEMBLING THE STARTER MOTOR 1.
ELEC CHARGING SYSTEM – + EBS00516 CHARGING SYSTEM CIRCUIT DIAGRAM W R R W W R (BLACK) (BLACK) Y/R W/B W Y 1 W/B Y/R W/B Y/R R 2 R B W W/B B Y R Y/R R R R R B 5 15A 4B R Y/B L/B Y/B B 6 L/B B B B B/Y Y/B Sb R/B 7 (BLACK) Y/B R R 3 8 Br R/W Br/L R R Br R Br/L (GRAY) (GRAY) OFF ON L/B Y/B L/B Br Br V Br B B B B (BLACK) (BLACK) Y Y Br (BLACK) (BLACK) BrR/B Y/R Q OFF LO HI J M OFF PUSH Y/R Y L L/B G B L Y Y/R B G L/B R/B Br Br R/B (BLACK) (BLAC
CHARGING SYSTEM EBS01065 ELEC – + EBS01044 TROUBLESHOOTING 2. Battery The battery is not being charged. • Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: 1. fuse 2. battery 3. charging voltage 4. charging coil resistance 5. wiring connections (of the entire charging system) Minimum open-circuit voltage 12.8 V or more at 20 °C (68 °F) • Is the battery OK? YES NOTE: • Before troubleshooting, remove the following part(s): 1. seat 2.
ELEC CHARGING SYSTEM EBS01066 – + EBS01100 4. Charging coil resistance 3. Charging voltage • Disconnect the A.C. magneto coupler from the wire harness. • Connect the pocket tester (Ω × 1) to the charging coils. • Connect the engine tachometer to on to the ignition coil. • Connect the pocket tester (DC 20 V) to the battery as shown.
ELEC LIGHTING SYSTEM – + EBS00518 LIGHTING SYSTEM CIRCUIT DIAGRAM W R R W W R (BLACK) (BLACK) Y/R W/B W Y 1 W/B Y/R W/B Y/R R 2 R B W W/B B Y R Y/R R R R R B 5 15A 4B R Y/B L/B Y/B B 6 L/B B Y/B B B B/Y Y/B Sb R/B 7 (BLACK) 9 Y/B R R/B R 3 8 Br R/W Br/L R R Br R Br/L (GRAY) (GRAY) OFF ON L/B Y/B L/B Br/L Br L/B O Br V BrR/B Y/R Br B B B B (BLACK) (BLACK) Y Q P U OFF LO HI Y Br (BLACK) (BLACK) J K M Y/R Y L L/B G B OFF PUSH L Y Y/R B G
ELEC LIGHTING SYSTEM EBS01067 – + EAS00776 TROUBLESHOOTING 2. Lighting coil resistance Any of the following fail to light: headlight, tail/brake light. • Disconnect the A.C. magneto coupler from the wire harness. • Connect the pocket tester (Ω × 1) to the lighting coil terminals as shown. Check: 1. light switch 2. lighting coil resistance 3.
ELEC LIGHTING SYSTEM EBS01069 – + 2. Voltage 3. Wiring • Check the entire lighting system’s wiring. Refer to “CIRCUIT DIAGRAM”. • Is the lighting system’s wiring properly connected and without defects? NO YES Check the condition of each of the lighting system’s circuits. Refer to “CHECKING THE LIGHTING SYSTEM”. Properly connect or repair the lighting system’s wiring. • Connect the pocket tester (AC 20 V) to the headlight couplers as shown.
LIGHTING SYSTEM 2. The tail/brake light fails to come on. 1. Tail/brake light bulb and socket • Check the tail/brake light bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS”. • Are the tail/brake light bulb and socket OK? NO YES Replace the tail/ brake light bulb, socket or both. 2. Voltage • Connect the pocket tester (AC 20 V) to the tail/brake light coupler as shown.
8 - 33 B G Y B (BLACK) B (BLACK) (BLACK) B (BLACK) Y G S B B Y G OFF PUSH L/B (GRAY) Br R/W Br/L R R R Br/L G Y B Y G L Y G OFF RUN Q R BrR/B Br B Y G S OFF LO HI Y/R OFF ON 3 R R B W Y R Y/R 2 W/B B W/B Y/R B B Y L Y Br O P W/B Y/R W R B B R 6 5 (BROWN) W/L B Br R/B (BLACK) R/B Br L Y Y/R B G L/B 7 B R 15A (BLACK) Y/R Y L L/B G B (GRAY) R Br R Br/L B B 4B R R L/B N B W/L W/L M L/B Y/B R Y/B L/B W/L L/B L/B Y/B R/B R/B Br
SIGNAL SYSTEM EBS01073 – ELEC + EBS01044 TROUBLESHOOTING 2. Battery Any of the following fail to light: brake light or an indicator light. • Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: 1. fuse 2. battery 3. main switch 4. wiring connections (of the entire signaling system) Minimum open-circuit voltage 12.8 V or more at 20 °C (68 °F) • Is the battery OK? NO YES NOTE: • Before troubleshooting, remove the following part(s): 1. seat 2.
SIGNAL SYSTEM EBS01075 – + 3. Voltage CHECKING THE SIGNALING SYSTEM EBS01076 • Connect the pocket tester (DC 20 V) to the tail/brake light coupler (wire harness side) as shown. 1. The tail/brake light fails to come on. 1. Tail/brake light bulb and bulb socket • Check the tail/brake light bulb and bulb socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS”.
SIGNAL SYSTEM ELEC – + EBS01083 2. Neutral switch 3. The coolant temperature warning light does not come on when the start switch is pushed on, or if the coolant temperature warning light does not come on when the temperature is high (more than 117 ~ 123 °C (242.6 ~ 253.4 °F)). • Check the neutral switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the neutral switch OK? NO YES Replace the neutral switch. 1. Coolant temperature warning light bulb and socket 3.
2. Thermo switch 2 • Remove the thermo switch 2 from the radiator. • Connect the pocket tester (Ω × 1) to the thermo switch 2 1 as shown. • Immerse the thermo switch 2 in a container filled with coolant 2. • Place a thermometer 3 in the coolant. • Slowly heat the coolant, then let it cool down to the specified temperature. • Check the thermo switch 2 for continuity at the temperatures indicated below. Test step Coolant temperature Continuity Thermo switch NO 2 More than 120 ± 3 °C (248 ± 5.
SIGNAL SYSTEM ELEC – + 3. Voltage • Connect the pocket tester (DC 20 V) to the indicator light connector (wire harness side) as shown. 1 L/B Positive tester probe → red/black 1 Negative tester probe → white/blue 2 W/L 2 NOTE: When you switch the tester’s positive and negative probes, the readings in the above chart will be reversed. • Is the diode OK? YES • Set the main switch to “ON”. • Measure the voltage (12 V) of red/black 1 and brown 2 at the indicator light coupler.
COOLING SYSTEM – ELEC + EBS00532 COOLING SYSTEM CIRCUIT DIAGRAM W/B Y/R R 2 B W B Y Y/R Y/B Y L R B/L R/B Sb R R (BLACK) R R ( R B 5 15A 4B B 6 R Y/B L/B W/B W R Y/B L/B B/Y B A R/B Y/B B/Y B B B/Y Y/B Sb R/B 7 0 (BLACK) Sb 9 Y/B R R/B R Sb B 3 8 Br R/W Br/L R R Br R Br/L (GRAY) (GRAY) OFF ON L/B B Y/B L/B Br Br/L (BLACK) Br/L F G L/B BrR/B Q M Y/R Y L L/B G B OFF PUSH R/B Br (GR J K L Y Y/R B G L/B L/B (BLACK) R/W B/L Sb Br W/L Br W/L (GR
COOLING SYSTEM EBS01085 – ELEC + EBS01044 TROUBLESHOOTING 2. Battery The radiator fan motor fails to turn. • Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: 1. fuse 2. battery 3. main switch 4. radiator fan motor 5. circuit breaker (fan motor) 6. thermo switch 1 7. wiring connections (the entire cooling system) Minimum open-circuit voltage 12.
COOLING SYSTEM EBS01086 ELEC – + EBS01088 4. Radiator fan motor 6. Thermo switch 1 • Disconnect the radiator fan motor coupler from the wire harness. • Connect the battery (DC 12 V) as shown. • Remove the thermo switch 1 from the radiator. • Connect the pocket tester (Ω × 1) to the thermo switch 1 1 as shown. • Immerse the thermo switch 1 in a container filled with coolant 2. • Place a thermometer 3 in the coolant. • Slowly heat the coolant, then let it cool down to the specified temperature.
COOLING SYSTEM WARNING _ • Handle the thermo switch with special care. • Never subject the thermo switch to strong shocks. If the thermo switch is dropped, replace it. T. Thermo switch 28 Nm (2.8 m · kg, 20 ft · lb) R. È The thermo switch circuit is open and the radiator fan is off. É The thermo switch circuit is closed and the radiator fan is on. É È 92 ± 3 ˚C (197.6 ± 5.4 ˚F) 98 ± 3 ˚C (208.4 ± 5.
STARTING FAILURE/HARD STARTING TRBL SHTG EBS00537 TROUBLESHOOTING NOTE: The following troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to troubleshooting. Refer to the relative procedure in this manual for check, adjustment and replacement of parts.
STARTING FAILURE/HARD STARTING/POOR IDLE SPEED PERFORMANCE/POOR MEDIUM AND HIGH-SPEED PERFORMANCE COMPRESSION SYSTEM Cylinder and cylinder head • Loose spark plug • Loose cylinder head or cylinder • Broken cylinder head gasket • Broken cylinder gasket • Worn, damaged or seized cylinder Valve and camshaft • Improperly sealed valve • Improperly contacted valve and valve seat • Improper valve timing • Broken valve spring • Seized camshaft TRBL SHTG Piston and piston rings • Improperly installed piston ring •
FAULTY GEAR SHIFTING/ CLUTCH SLIPPING/DRAGGING TRBL SHTG EBS00541 FAULTY GEAR SHIFTING HARD SHIFTING Refer to “CLUTCH DRAGGING”.
OVERHEATING/FAULTY BRAKE/ SHOCK ABSORBER MALFUNCTION TRBL SHTG EBS00547 OVERHEATING OVERHEATING Ignition system • Improper spark plug gap • Improper spark plug heat range • Faulty C.D.I.
UNSTABLE HANDLING/ LIGHTING SYSTEM TRBL SHTG EBS00552 UNSTABLE HANDLING UNSTABLE HANDLING Handlebar • Improperly installed or bent Steering • Incorrect toe-in • Bent steering stem • Improperly installed steering stem • Damaged bearing or bearing race • Bent tie-rods • Deformed steering knuckles Tires • Uneven tire pressures on both sides • Incorrect tire pressure • Uneven tire wear Wheels • Deformed wheel • Loose bearing • Bent or loose wheel axle • Excessive wheel runout Frame • Bent • Damaged frame Sw
YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U.S.A.
YFZ450S WIRING DIAGRAM W R R W W R (BLACK) (BLACK) Y/R W/B W Y 1 W/B Y/R W/B Y/R R 2 W/B B Y R Y/R O W B W/B Y/B Y L R B/L R/B Sb R B W R (BLACK) R R (BLACK) O B R (BLACK) B 5 15A 4B B 6 R Y/B L/B W/B W R O C B/Y Y/B B/Y B A R/B B B B/Y Y/B Sb R/B 7 (BLACK) Y/B 0 L Y B/L Y/B Sb 9 R/B R L Y B/L Sb 3 8 Br R/W Br/L R R Br R Br/L (GRAY) (GRAY) L/B L Y B D (GRAY) Y L B/L B OFF ON B B Y/B L/B R O B (GRAY) Y/B L/B Br Br/L (BLACK) Br/L Y/B Y/B
