Raptor 125 - Maul Tech ATV

Transcription

2011
SERVICE MANUAL
YFM125RA
LIT-11616-24-36
2PA-28197-10
EAS20050
YFM125RA
SERVICE MANUAL
©2010 by Yamaha Motor Corporation, U.S.A.
First edition, May 2010
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.
P/N LIT-11616-24-36
EAS20071
IMPORTANT
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one
manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha
vehicles should have a basic understanding of mechanics and the techniques to repair these types
of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to
render the vehicle unsafe and unfit for use.
This model has been designed and manufactured to perform within certain specifications in regard
to performance and emissions. Proper service with the correct tools is necessary to ensure that the
vehicle will operate as designed. If there is any question about a service procedure, it is imperative
that you contact a Yamaha dealer for any service information changes that apply to this model. This
policy is intended to provide the customer with the most satisfaction from his vehicle and to conform
to federal environmental quality objectives.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and
significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable.
TIP
• This Service Manual contains information regarding periodic maintenance to the emission control
system. Please read this material carefully.
• Designs and specifications are subject to change without notice.
EAS20081
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following notations.
This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol
to avoid possible injury or death.
WARNING
NOTICE
TIP
A WARNING indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
A NOTICE indicates special precautions that must be taken to avoid
damage to the vehicle or other property.
A TIP provides key information to make procedures easier or clearer.
EAS20091
HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are
laid out with the individual steps in sequential order.
• The manual is divided into chapters and each chapter is divided into sections. The current section
title “1” is shown at the top of each page.
• Sub-section titles “2” appear in smaller print than the section title.
• To help identify parts and clarify procedure steps, there are exploded diagrams “3” at the start of
each removal and disassembly section.
• Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a disassembly step.
• Symbols “5” indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
• A job instruction chart “6” accompanies the exploded diagram, providing the order of jobs, names
of parts, notes in jobs, etc.
• Jobs “7” requiring more information (such as special tools and technical data) are described
sequentially.
EAS30370
SYMBOLS
The following symbols are used in this manual for easier understanding.
TIP
The following symbols are not relevant to every vehicle.
SYMBOL
DEFINITION
Serviceable with engine
mounted
SYMBOL
DEFINITION
Gear oil
G
Filling fluid
Molybdenum disulfide oil
M
Lubricant
Brake fluid
BF
B
Wheel bearing grease
Tightening torque
LS
Lithium-soap-based grease
Wear limit, clearance
M
Molybdenum disulfide grease
Engine speed
S
Silicone grease
LT
Apply locking agent (LOCTITE®).
T.
Special tool
R.
Electrical data
Engine oil
E
New
Replace the part with a new
one.
EAS20110
TABLE OF CONTENTS
GENERAL INFORMATION
1
SPECIFICATIONS
2
PERIODIC CHECKS AND ADJUSTMENTS
3
CHASSIS
4
ENGINE
5
FUEL SYSTEM
6
ELECTRICAL SYSTEM
7
TROUBLESHOOTING
8
GENERAL INFORMATION
IDENTIFICATION ..........................................................................................1-1
VEHICLE IDENTIFICATION NUMBER...................................................1-1
MODEL LABEL .......................................................................................1-1
IMPORTANT INFORMATION .......................................................................1-2
PREPARATION FOR REMOVAL AND DISASSEMBLY..........................1-2
REPLACEMENT PARTS.........................................................................1-2
GASKETS, OIL SEALS AND O-RINGS..................................................1-2
LOCK WASHERS/PLATES AND COTTER PINS ...................................1-2
BEARINGS AND OIL SEALS .................................................................1-3
CIRCLIPS ...............................................................................................1-3
BASIC SERVICE INFORMATION.................................................................1-4
QUICK FASTENERS ..............................................................................1-4
ELECTRICAL SYSTEM ..........................................................................1-5
SPECIAL TOOLS..........................................................................................1-9
1
IDENTIFICATION
EAS20130
IDENTIFICATION
EAS20140
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number “1” is
stamped into the left side of the frame.
EAS20150
MODEL LABEL
The model label “1” is affixed to the air filter
case cover. This information will be needed to
order spare parts.
1-1
IMPORTANT INFORMATION
EAS20180
EAS20190
PREPARATION FOR REMOVAL AND DISASSEMBLY
1. Before removal and disassembly, remove
all dirt, mud, dust and foreign material.
EAS20210
GASKETS, OIL SEALS AND O-RINGS
1. When overhauling the engine, replace all
gaskets, seals and O-rings. All gasket surfaces, oil seal lips and O-rings must be
cleaned.
2. During reassembly, properly oil all mating
parts and bearings and lubricate the oil
seal lips with grease.
2. Use only the proper tools and cleaning
equipment.
Refer to “SPECIAL TOOLS” on page 1-9.
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.
1.
2.
3.
4.
Oil
Lip
Spring
Grease
EAS20220
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.
4. During disassembly, clean all of the parts
and place them in trays in the order of disassembly. This will speed up assembly and
allow for the correct installation of all parts.
5. Keep all parts away from any source of fire.
EAS20200
REPLACEMENT PARTS
Use only genuine Yamaha parts for all replacements. Use oil and grease recommended by
Yamaha for all lubrication jobs. Other brands
may be similar in function and appearance, but
inferior in quality.
1-2
EAS20231
BEARINGS AND OIL SEALS
Install bearings “1” and oil seals “2” so that the
manufacturer marks or numbers are visible.
When installing oil seals, lubricate the oil seal
lips with a light coat of lithium-soap-based
grease. Oil bearings liberally when installing, if
appropriate.
ECA13300
Do not spin the bearing with compressed
air because this will damage the bearing
surfaces.
EAS20240
CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips.
Always replace piston pin clips after one use.
When installing a circlip “1”, make sure the
sharp-edged corner “2” is positioned opposite
the thrust “3” that the circlip receives.
1-3
BASIC SERVICE INFORMATION
EAS30380
EAS30390
QUICK FASTENERS
Rivet type
1. Remove:
• Quick fastener
TIP
Screw type
1. Remove:
• Quick fastener
To remove the quick fastener, push its pin with
a screwdriver, then pull the fastener out.
TIP
To remove the quick fastener, loosen the screw
with a screwdriver, then pull the fastener out.
2. Install:
• Quick fastener
TIP
2. Install:
• Quick fastener
To install the quick fastener, insert the fastener
into the part to be secured and tighten the
screw “a”.
TIP
To install the quick fastener, push its pin so that
it protrudes from the fastener head, then insert
the fastener into the part to be secured and
push the pin “a” in with a screwdriver. Make
sure that the pin is flush with the fastener’s
head.
1-4
EAS30402
ECA16760
ELECTRICAL SYSTEM
Be sure to connect the battery leads to the
correct battery terminals. Reversing the
battery lead connections could damage the
electrical components.
Electrical parts handling
ECA16600
Never disconnect a battery lead while the
engine is running; otherwise, the electrical
components could be damaged.
ECA16771
When connecting the battery leads to the
battery, be sure to connect the positive battery lead first, then the negative battery
lead. If the negative battery lead is connected first and a tool or similar item contacts the vehicle while the positive battery
lead is being connected, a spark could be
generated, which is extremely dangerous.
ECA16751
When disconnecting the battery leads from
the battery, be sure to disconnect the negative battery lead first, then the positive battery lead. If the positive battery lead is
disconnected first and a tool or similar item
contacts the vehicle, a spark could be generated, which is extremely dangerous.
ECA16610
TIP
Turn the main switch to “OFF” before disconnecting or connecting an electrical
component.
If a battery lead is difficult to disconnect due to
rust on the battery terminal, remove the rust
using hot water.
1-5
Checking the electrical system
ECA16620
TIP
Handle electrical components with special
care, and do not subject them to strong
shocks.
Before checking the electrical system, make
sure that the battery voltage is at least 12 V.
ECA14371
ECA16630
Never insert the tester probes into the coupler terminal slots. Always insert the
probes from the opposite end “a” of the
coupler, taking care not to loosen or damage the leads.
Electrical components are very sensitive to
and can be damaged by static electricity.
Therefore, never touch the terminals and be
sure to keep the contacts clean.
a
TIP
ECA16640
When resetting the CDI Unit by turning the
main switch to “OFF”, be sure to wait approximately 5 seconds before turning the main
switch back to “ON”.
For waterproof couplers, never insert the
tester probes directly into the coupler.
When performing any checks using a
waterproof coupler, use the specified test
harness or a suitable commercially available test harness.
1-6
Checking the connections
Check the leads, couplers, and connectors for
stains, rust, moisture, etc.
1. Disconnect:
• Lead
• Coupler
• Connector
ECA16780
• When disconnecting a coupler, release
the coupler lock, hold both sections of
the coupler securely, and then disconnect
the coupler.
• There are many types of coupler locks;
therefore, be sure to check the type of
coupler lock before disconnecting the
coupler.
3. Check:
• All connections
Loose connection → Connect properly.
TIP
• If the pin “1” on the terminal is flattened,
bend it up.
• After disassembling and assembling a coupler, pull on the leads to make sure that they
are installed securely.
1
ECA16790
When disconnecting a connector, do not
pull the leads. Hold both sections of the
connector securely, and then disconnect
the connector.
4. Connect:
• Lead
• Coupler
• Connector
TIP
2. Check:
• Lead
• Coupler
• Connector
Moisture → Dry with an air blower.
Rust/stains → Connect and disconnect
several times.
• When connecting a coupler or connector,
push both sections of the coupler or connector together until they are connected
securely.
• Make sure all connections are tight.
1-7
5. Check:
• Continuity
(with the pocket tester)
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
TIP
• If there is no continuity, clean the terminals.
• When checking the wire harness, perform
steps (1) to (3).
• As a quick remedy, use a contact revitalizer
available at most part stores.
1-8
SPECIAL TOOLS
EAS20260
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use
only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the
country.
When placing an order, refer to the list provided below to avoid any mistakes.
TIP
• For U.S.A. and Canada, use part number starting with “YM-”, “YU-”, or “ACC-”.
• For others, use part number starting with “90890-”.
Tool name/Tool No.
Illustration
Slide hammer bolt
90890-01083
Slide hammer bolt 6 mm
YU-01083-1
Reference
pages
5-14, 5-16
Weight
90890-01084
YU-01083-3
5-14
Crankcase separating tool
90890-01135
Crankcase separator
YU-01135-B
5-64
Ring nut wrench
90890-01268
Spanner wrench
YU-01268
3-18
1-9
SPECIAL TOOLS
Tool name/Tool No.
Illustration
Crankshaft installer pot
90890-01274
Installing pot
YU-90058
Reference
pages
5-65
Crankshaft installer bolt
90890-01275
Bolt
YU-90060
5-65
Adapter (M12)
90890-01278
Adapter #3
YU-90063
5-65
Spacer (crankshaft installer)
90890-04081
Pot spacer
YM-91044
5-65
YM-91044
Piston pin puller set
90890-01304
Piston pin puller
YU-01304
5-27
1-10
SPECIAL TOOLS
Tool name/Tool No.
Illustration
Tappet adjusting tool
90890-01311
Six piece tappet set
YM-A5970
Reference
pages
3-6
Flywheel puller
90890-01362
Heavy duty puller
YU-33270-B
5-50
Sheave holder
90890-01701
Primary clutch holder
YS-01880-A
5-50, 5-51, 5-52
Thickness gauge
90890-03180
Feeler gauge set
YU-26900-9
3-5, 5-36
Digital circuit tester
90890-03174
Model 88 Multimeter with tachometer
YU-A1927
5-56
Pocket tester
90890-03112
YU-03112-C
1-8, 7-31, 7-32,
7-33, 7-37, 738, 7-39, 7-40,
7-41, 7-42
Carburetor angle driver
90890-03158
3-7
1-11
SPECIAL TOOLS
Tool name/Tool No.
Illustration
Valve spring compressor
90890-04019
YM-04019
Reference
pages
5-19, 5-24
Valve spring compressor attachment
90890-04114
Valve spring compressor adapter 19.5 mm
YM-04114
5-19, 5-24
Fuel level gauge
90890-01312
YM-01312-A
6-10
Universal clutch holder
90890-04086
YM-91042
5-35, 5-38
Valve guide remover (ø5)
90890-04097
Valve guide remover (5.0 mm)
YM-04097
5-21
Valve guide installer (ø5)
90890-04098
Valve guide installer (5.0 mm)
YM-04098
5-21
Valve guide reamer (ø5)
90890-04099
Valve guide reamer (5.0 mm)
YM-04099
5-21
1-12
SPECIAL TOOLS
Tool name/Tool No.
Illustration
Valve lapper
90890-04101
Valve lapping tool
YM-A8998
Reference
pages
5-22
Axle nut wrench (46 mm)
90890-01498
Rear axle nut wrench 46 mm
YM-37134
4-14, 4-15
Ignition checker
90890-06754
Opama pet-4000 spark checker
YM-34487
7-39
Digital tachometer
90890-06760
YU-39951-B
3-6, 7-41
Yamaha bond No. 1215
(Three bond No.1215®)
90890-85505
5-52, 5-61, 5-62
1-13
SPECIFICATIONS
GENERAL SPECIFICATIONS ......................................................................2-1
ENGINE SPECIFICATIONS..........................................................................2-4
CHASSIS SPECIFICATIONS........................................................................2-9
ELECTRICAL SPECIFICATIONS...............................................................2-11
TIGHTENING TORQUES............................................................................2-13
GENERAL TIGHTENING TORQUE SPECIFICATIONS.......................2-13
ENGINE TIGHTENING TORQUES ......................................................2-14
CHASSIS TIGHTENING TORQUES ....................................................2-16
LUBRICATION POINTS AND LUBRICANT TYPES ..................................2-20
ENGINE ................................................................................................2-20
LUBRICATION SYSTEM CHART AND DIAGRAMS .................................2-21
ENGINE OIL LUBRICATION CHART ...................................................2-21
LUBRICATION DIAGRAMS ..................................................................2-23
CABLE ROUTING ......................................................................................2-27
2
GENERAL SPECIFICATIONS
EAS29110
Model
Model
2PA1 (USA)
2PA2 (CAN)
2PA3 (AUS, NZL)
Dimensions
Overall length
Overall width
Overall height
Seat height
Wheelbase
Ground clearance
Minimum turning radius
1610 mm (63.4 in)
1018 mm (40.1 in)
1010 mm (39.8 in)
715 mm (28.1 in)
1110 mm (43.7 in)
85 mm (3.3 in)
2900 mm (114 in)
Weight
With oil and fuel
136.0 kg (300 lb)
Engine
Engine type
Cylinder arrangement
Displacement
Bore × stroke
Compression ratio
Starting system
Lubrication system
Air cooled 4-stroke, SOHC
Forward-inclined single cylinder
124 cm³
54.0 × 54.0 mm (2.13 × 2.13 in)
10.0 : 1
Electric starter
Wet sump
Engine oil
Recommended brand
Type
YAMALUBE
SAE 5W-30, 10W-30, 10W-40, 15W-40, 20W40 or 20W-50
API service SG type or higher, JASO standard
MA
Recommended engine oil grade
Engine oil quantity
Periodic oil change
Total amount
1.25 L (1.32 US qt, 1.10 Imp.qt)
1.50 L (1.59 US qt, 1.32 Imp.qt)
Oil filter
Oil filter type
Centrifugal
Air filter
Air filter element
Air filter oil grade
Wet element
Yamaha foam air filter oil or equivalent oil
Fuel
Recommended fuel
Unleaded gasoline only (USA, AUS, NZL)
Regular unleaded gasoline only (CAN)
9.0 L (2.38 US gal, 1.98 Imp.gal)
1.0 L (0.26 US gal, 0.22 Imp.gal)
Fuel tank capacity
Fuel reserve amount
Carburetor
Type × quantity
BSR29 × 1
Spark plug
Manufacturer/model
Spark plug gap
NGK/CR6HSA
0.6–0.7 mm (0.024–0.028 in)
2-1
Clutch
Type
Wet, multiple-disc
Transmission
Primary reduction system
Primary reduction ratio
Secondary reduction system
Secondary reduction ratio
Transmission type
Operation
1st
2nd
3rd
4th
5th
Helical gear
68/20 (3.400)
Chain drive
48/14 (3.429)
Constant mesh 5-speed
Left foot operation
37/14 (2.643)
32/18 (1.778)
25/19 (1.316)
23/22 (1.045)
21/24 (0.875)
Chassis
Frame type
Caster angle
Camber angle
Kingpin angle
Trail
Tread rear (STD)
Tread front (STD)
Toe-in (with tire touching the ground)
Steel tube frame
6°
-1.5°
14.8°
23.0 mm (0.91 in)
791.0 mm (31.14 in)
841.0 mm (33.11 in)
8.0–18.0 mm (0.31–0.71 in)
Front tire
Type
Size
Manufacturer/model
Wear limit
Tubeless
AT19 × 6-10
MAXXIS/M957Y
3.0 mm (0.12 in)
Rear tire
Type
Size
Manufacturer/model
Wear limit
Tubeless
AT18 × 9-8
MAXXIS/M940
3.0 mm (0.12 in)
Tire air pressure (measured on cold tires)
Maximum loading limit
Recommended
Front
Rear
Minimum
Front
Rear
100.0 kg (220 lb)
25.0 kPa (0.25 kgf/cm², 3.6 psi)
30.0 kPa (0.30 kgf/cm², 4.4 psi)
22.0 kPa (0.22 kgf/cm², 3.2 psi)
27.0 kPa (0.27 kgf/cm², 4.0 psi)
Front brake
Type
Operation
Dual disc brake
Right hand operation
Rear brake
Type
Operation
Single disc brake
Right foot operation
Front suspension
Type
Double wishbone
2-2
Spring/shock absorber type
Wheel travel
Coil spring/oil damper
190 mm (7.5 in)
Rear suspension
Type
Spring/shock absorber type
Wheel travel
Swingarm
Coil spring/gas-oil damper
200 mm (7.9 in)
Electrical system
Ignition system
Charging system
CDI
AC magneto
Battery
Model
Voltage, capacity
Manufacturer
Ten hour rate amperage
YTZ7S
12 V, 6.0 Ah
GS YUASA
0.6 A
Headlight
Bulb type
Bulb voltage, wattage × quantity
Headlight
Tail/brake light
Neutral indicator light
Halogen bulb
12 V, 35.0/36.5 W × 1
12 V, 5.0/21.0 W × 1
12 V, 1.7 W × 1
2-3
ENGINE SPECIFICATIONS
EAS29120
Cylinder head
Volume
Warpage limit
15.20–15.60 cm³ (0.93–0.95 cu.in)
0.03 mm (0.0012 in)
Cylinder
Bore
Wear limit
54.024–54.056 mm (2.1269–2.1282 in)
54.156 mm (2.1321 in)
Camshaft
Drive system
Camshaft lobe dimensions
Intake A
Limit
Intake B
Limit
Exhaust A
Limit
Exhaust B
Limit
Chain drive (left)
25.881–25.981 mm (1.0189–1.0229 in)
25.851 mm (1.0178 in)
21.194–21.294 mm (0.8344–0.8383 in)
21.165 mm (0.8333 in)
25.841–25.941 mm (1.0174–1.0213 in)
25.811 mm (1.0162 in)
20.997–21.097 mm (0.8267–0.8306 in)
20.967 mm (0.8255 in)
Camshaft runout limit
0.030 mm (0.0012 in)
Timing chain
Model/number of links
Tensioning system
92RH2005-90M/90
Automatic
Rocker arm/rocker arm shaft
Rocker arm inside diameter
Limit
Rocker arm shaft outside diameter
Limit
Rocker-arm-to-rocker-arm-shaft clearance
Limit
10.000–10.015 mm (0.3937–0.3943 in)
10.030 mm (0.3949 in)
9.981–9.991 mm (0.3930–0.3933 in)
9.950 mm (0.3917 in)
0.009–0.034 mm (0.0004–0.0013 in)
0.08 mm (0.0031 in)
2-4
Valve, valve seat, valve guide
Valve clearance (cold)
Intake
Exhaust
Valve dimensions
Valve head diameter A (intake)
Valve head diameter A (exhaust)
0.08–0.12 mm (0.0032–0.0047 in)
0.10–0.14 mm (0.0039–0.0055 in)
25.90–26.10 mm (1.0197–1.0276 in)
21.90–22.10 mm (0.8622–0.8701 in)
Valve face width B (intake)
Valve face width B (exhaust)
1.10–3.00 mm (0.0433–0.1181 in)
1.70–2.80 mm (0.0669–0.1102 in)
Valve seat width C (intake)
Limit
Valve seat width C (exhaust)
Limit
0.90–1.10 mm (0.0354–0.0433 in)
1.60 mm (0.06 in)
0.90–1.10 mm (0.0354–0.0433 in)
1.60 mm (0.06 in)
Valve margin thickness D (intake)
Valve margin thickness D (exhaust)
0.40–0.80 mm (0.0157–0.0315 in)
0.80–1.20 mm (0.0315–0.0472 in)
Valve stem diameter (intake)
Limit
Valve stem diameter (exhaust)
Limit
Valve guide inside diameter (intake)
Limit
Valve guide inside diameter (exhaust)
Limit
Valve-stem-to-valve-guide clearance (intake)
Limit
Valve-stem-to-valve-guide
clearance
(exhaust)
Limit
Valve stem runout limit
Cylinder head valve seat width (intake)
Limit
Cylinder head valve seat width (exhaust)
Limit
4.975–4.990 mm (0.1959–0.1965 in)
4.950 mm (0.1949 in)
4.960–4.975 mm (0.1953–0.1959 in)
4.935 mm (0.1943 in)
5.000–5.012 mm (0.1969–0.1973 in)
5.042 mm (0.1985 in)
5.000–5.012 mm (0.1969–0.1973 in)
5.042 mm (0.1985 in)
0.010–0.037 mm (0.0004–0.0015 in)
0.080 mm (0.0032 in)
Valve spring
Free length (intake)
Limit
0.025–0.052 mm (0.0010–0.0020 in)
0.100 mm (0.0039 in)
0.010 mm (0.0004 in)
0.90–1.10 mm (0.0354–0.0433 in)
1.60 mm (0.06 in)
0.90–1.10 mm (0.0354–0.0433 in)
1.60 mm (0.06 in)
47.06 mm (1.85 in)
44.71 mm (1.76 in)
2-5
Free length (exhaust)
Limit
Installed length (intake)
Installed length (exhaust)
Spring rate K1 (intake)
Spring rate K2 (intake)
Spring rate K1 (exhaust)
Spring rate K2 (exhaust)
Installed compression spring force (intake)
Spring tilt (intake)
Spring tilt (exhaust)
47.06 mm (1.85 in)
44.71 mm (1.76 in)
25.60 mm (1.01 in)
25.60 mm (1.01 in)
8.01 N/mm (0.82 kgf/mm, 45.74 lbf/in)
9.33 N/mm (0.95 kgf/mm, 53.27 lbf/in)
8.01 N/mm (0.82 kgf/mm, 45.74 lbf/in)
9.33 N/mm (0.95 kgf/mm, 53.27 lbf/in)
160.00–184.00 N (16.32–18.76 kgf, 35.97–
41.36 lbf)
160.00–184.00 N (16.32–18.76 kgf, 35.97–
41.36 lbf)
2.5°/2.1 mm (0.08 in)
2.5°/2.1 mm (0.08 in)
Winding direction (intake)
Winding direction (exhaust)
Clockwise
Clockwise
Installed compression spring force (exhaust)
Piston
Piston-to-cylinder clearance
Limit
Diameter D
Height H
0.019–0.035 mm (0.0007–0.0014 in)
0.15 mm (0.006 in)
53.997–54.029 mm (2.1259–2.1271 in)
4.5 mm (0.18 in)
Offset
Offset direction
Piston pin bore inside diameter
Limit
Piston pin outside diameter
Limit
Piston-pin-to-piston-pin-bore clearance
Limit
0.50 mm (0.0197 in)
Intake side
15.002–15.013 mm (0.5906–0.5911 in)
15.043 mm (0.5922 in)
14.991–15.000 mm (0.5902–0.5906 in)
14.971 mm (0.5894 in)
0.002–0.022 mm (0.0001–0.0009 in)
0.072 mm (0.0028 in)
Piston ring
Top ring
Ring type
Dimensions (B × T)
Barrel
1.00 × 2.10 mm (0.04 × 0.08 in)
End gap (installed)
Limit
Ring side clearance
Limit
0.15–0.30 mm (0.006–0.012 in)
0.40 mm (0.0157 in)
0.035–0.070 mm (0.0014–0.0028 in)
0.120 mm (0.0047 in)
2-6
2nd ring
Ring type
Dimensions (B × T)
Taper
1.00 × 2.10 mm (0.04 × 0.08 in)
End gap (installed)
Limit
Ring side clearance
Limit
Oil ring
Dimensions (B × T)
0.30–0.45 mm (0.012–0.018 in)
0.55 mm (0.0217 in)
0.020–0.060 mm (0.0008–0.0024 in)
0.120 mm (0.0047 in)
2.00 × 2.25 mm (0.08 × 0.09 in)
End gap (installed)
0.20–0.70 mm (0.008–0.028 in)
Crankshaft
Width A
Runout limit C
Big end side clearance D
Limit
Big end radial clearance E
46.95–47.00 mm (1.848–1.850 in)
0.030 mm (0.0012 in)
0.15–0.45 mm (0.0059–0.0177 in)
0.50 mm (0.0197 in)
0.010–0.021 mm (0.0004–0.0008 in)
Balancer
Balancer drive method
Gear
Clutch
Friction plate thickness
Wear limit
Plate quantity
Clutch plate thickness
Plate quantity
Clutch plate warpage limit
Clutch spring free length
Limit
Spring quantity
Clutch release method
Push rod bending limit
3.00 mm (0.12 in)
2.80 mm (0.11 in)
4 pcs
1.60 mm (0.06 in)
3 pcs
0.05 mm (0.0020 in)
31.7 mm (1.25 in)
30.1 mm (1.19 in)
4 pcs
Inner push, cam push
0.5 mm (0.02 in)
Transmission
Main axle runout limit
Drive axle runout limit
Main axle assembly width
0.03 mm (0.0012 in)
0.03 mm (0.0012 in)
83.25–83.45 mm (3.278–3.285 in)
2-7
Shifting mechanism
Shift mechanism type
Shift fork thickness
Shift drum and guide bar
4.76–4.89 mm (0.1874–0.1925 in)
Carburetor
ID mark
Main jet
Main air jet
Jet needle
Needle jet
Pilot air jet 1
Pilot air jet 2
Pilot outlet
Pilot jet
Bypass 1
Bypass 2
Bypass 3
Standard pilot screw turns out
Valve seat size
Starter jet 1
Starter jet 2
Throttle valve size
Float height
Fuel level (above the float chamber mating surface)
Idling condition
Engine idling speed
CO%
Oil temperature
2PA1 00 (USA, CAN)
2PA1 10 (AUS, NZL)
#123.8
#110
5DH54-1 (USA, CAN)
5DH72-2 (AUS, NZL)
P-0M (922)
#85
#170
0.9
#22.5
0.8
0.8
0.8
2–1/2 (AUS, NZL)
2
#67.5
0.5
#100
13.0 mm (0.51 in)
4.0–5.0 mm (0.16–0.20 in)
1550–1650 r/min
3.5–4.5%
55.0–65.0 °C (131.00–149.00 °F)
Oil pump
Oil pump type
Inner-rotor-to-outer-rotor-tip clearance
Limit
Outer-rotor-to-oil-pump-housing clearance
Limit
Oil-pump-housing-to-inner-and-outer-rotor
clearance
Limit
Trochoid
Less than 0.15 mm (0.0059 in)
0.23 mm (0.0091 in)
0.130–0.193 mm (0.0051–0.0076 in)
0.263 mm (0.0104 in)
0.060–0.100 mm (0.0024–0.0039 in)
0.15 mm (0.0059 in)
2-8
CHASSIS SPECIFICATIONS
EAS29130
Front suspension
Shock absorber travel
Spring free length
Spring rate K1
Spring stroke K1
Optional spring available
Spring preload adjusting positions
Minimum
Standard
Maximum
90.7 mm (3.57 in)
248.5 mm (9.78 in)
23.00 N/mm (2.35 kgf/mm, 131.33 lbf/in)
0.0–90.7 mm (0.00–3.57 in)
No
1
2
5
Rear suspension
Rear shock absorber assembly travel
Spring free length
Installed length
Spring rate K1
Spring stroke K1
Optional spring available
Enclosed gas/air pressure (STD)
Minimum
Standard
Maximum
87.0 mm (3.43 in)
240.5 mm (9.47 in)
230.0 mm (9.06 in)
54.00 N/mm (5.51 kgf/mm, 308.34 lbf/in)
0.0–87.0 mm (0.00–3.43 in)
No
2500 kPa (25.0 kgf/cm², 355.6 psi)
234.0 mm (9.21 in)
230.0 mm (9.06 in)
222.0 mm (8.74 in)
Rear axle
Rear axle runout limit
1.5 mm (0.06 in)
Swingarm
Swingarm end free play limit (radial)
Swingarm end free play limit (axial)
1.0 mm (0.04 in)
1.0 mm (0.04 in)
Front wheel
Wheel type
Rim size
Rim material
Radial wheel runout limit
Lateral wheel runout limit
Panel wheel
10 × 5.0AT
Steel
2.0 mm (0.08 in)
2.0 mm (0.08 in)
Rear wheel
Wheel type
Rim size
Rim material
Panel wheel
8 × 7.0AT
Steel
2.0 mm (0.08 in)
2.0 mm (0.08 in)
Drive chain
Type/manufacturer
Link quantity
Drive chain slack
15-link length limit
428V/DAIDO
114
45.0–55.0 mm (1.77–2.17 in)
191.5 mm (7.54 in)
Front brake
Type
Disc outside diameter × thickness
Brake disc thickness limit
Brake disc deflection limit
Dual disc brake
161.0 × 3.5 mm (6.34 × 0.14 in)
3.0 mm (0.12 in)
0.15 mm (0.006 in)
2-9
Brake pad lining thickness (inner)
Limit
Brake pad lining thickness (outer)
Limit
Master cylinder inside diameter
Caliper cylinder inside diameter
Recommended fluid
4.5 mm (0.18 in)
1.0 mm (0.04 in)
4.5 mm (0.18 in)
1.0 mm (0.04 in)
12.7 mm (0.50 in)
32.03 mm (1.26 in)
DOT 4
Rear brake
Type
Disc outside diameter × thickness
Brake pad lining thickness (inner)
Limit
Brake pad lining thickness (outer)
Limit
Master cylinder inside diameter
Caliper cylinder inside diameter
Recommended fluid
Single disc brake
200.0 × 4.0 mm (7.87 × 0.16 in)
3.5 mm (0.14 in)
0.15 mm (0.006 in)
4.5 mm (0.18 in)
1.0 mm (0.04 in)
4.5 mm (0.18 in)
1.0 mm (0.04 in)
12.7 mm (0.50 in)
33.96 mm (1.34 in)
DOT 4
Lever and pedal
Brake lever free play
Brake pedal height
Parking brake cable end length
Clutch cable free play
Throttle cable free play
Speed limiter length
Shift pedal height
0 mm (0 in)
6.9 mm (0.27 in)
64.0–68.0 mm (2.52–2.68 in)
5.0–10.0 mm (0.20–0.39 in)
2.0–4.0 mm (0.08–0.16 in)
Less than 12 mm (0.47 in)
20.7 mm (0.81 in)
2-10
ELECTRICAL SPECIFICATIONS
EAS29140
System voltage
System voltage
12 V
Ignition system
Ignition timing (B.T.D.C.)
Advanced timing (B.T.D.C.)
Advancer type
7.0°/1600 r/min
32.5°/9400 r/min
Digital
CDI
Pickup coil resistance
CDI unit model/manufacturer
248.0–372.0 Ω (R–W)
2PA-0/MORIC
Ignition coil
Minimum ignition spark gap
Primary coil resistance
Secondary coil resistance
6.0 mm (0.24 in)
0.18–0.28 Ω
6.32–9.48 kΩ
Spark plug cap
Material
Resistance
Resin
7.5–12.5 kΩ
AC magneto
Standard output
Stator coil resistance
14.0 V, 8.2 A @ 5000 r/min
0.64–0.96 Ω (W–W)
Rectifier/regulator
Regulator type
No load regulated voltage
Rectifier capacity
Withstand voltage
Semi conductor-short circuit
14.2–15.2 V
16.0 A
200.0 V
Battery
Specific gravity
1.31
Electric starting system
System type
Constant mesh
Starter motor
Power output
Armature coil resistance
Brush overall length
Limit
Brush spring force
Commutator diameter
Limit
Mica undercut (depth)
0.40 kW
0.0171–0.0209 Ω
10.0 mm (0.39 in)
3.50 mm (0.14 in)
5.52–8.28 N (563–844 gf, 19.87–29.80 oz)
22.0 mm (0.87 in)
21.0 mm (0.83 in)
1.50 mm (0.06 in)
Starter relay
Amperage
Coil resistance
180.0 A
4.18–4.62 Ω
Headlight relay
Coil resistance
94.5–115.5 Ω
2-11
Carburetor warmer
Resistance
5.6–8.4 Ω at 25 °C (77 °F)
Circuit breaker
Circuit breaker type
Fuse
Fuse
Fuse
Reserve
15.0 A
15.0 A
2-12
TIGHTENING TORQUES
EAS20320
TIGHTENING TORQUES
EAS20331
GENERAL TIGHTENING TORQUE SPECIFICATIONS
This chart specifies tightening torques for standard fasteners with a standard ISO thread
pitch. Tightening torque specifications for special components or assemblies are provided
for each chapter of this manual. To avoid
warpage, tighten multi-fastener assemblies in
a crisscross pattern and progressive stages
until the specified tightening torque is reached.
Unless otherwise specified, tightening torque
specifications require clean, dry threads. Components should be at room temperature.
A. Distance between flats
B. Outside thread diameter
A (nut) B (bolt)
10 mm
12 mm
14 mm
17 mm
19 mm
22 mm
6 mm
8 mm
10 mm
12 mm
14 mm
16 mm
General tightening
torques
Nm
m·kgf
ft·lbf
6
0.6
4.3
15
1.5
11
30
3.0
22
55
5.5
40
85
8.5
61
130
13.0
94
2-13
TIGHTENING TORQUES
EAS20340
ENGINE TIGHTENING TORQUES
Item
Cylinder head bolt
Thread
Q’ty
size
M8
4
Tightening torque
22 Nm (2.2 m·kgf, 16 ft·lbf)
Remarks
See TIP
E
See TIP
E
Cylinder head bolt
M6
2
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil check bolt
Spark plug
Camshaft sprocket cover bolt
Tappet cover (intake and exhaust
side)
Generator rotor nut
Timing chain guide bolt (intake
side)
Valve adjusting screw locknut
(intake and exhaust side)
Camshaft sprocket bolt
Camshaft retainer bolt
Timing chain tensioner cap bolt
Timing chain tensioner bolt
Oil pump assembly screw
Oil pump housing screw
Engine oil drain bolt
Intake manifold bolt
Carburetor joint clamp bolt (intake
manifold side)
Carburetor joint clamp bolt (carburetor side)
Air filter case joint clamp bolt
Exhaust pipe bolt
Muffler joint bolt
Muffler bolt
Spark arrester bolt
Cylinder head plate bolt
M6
M10
M6
1
1
2
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
13 Nm (1.3 m·kgf, 9.4 ft·lbf)
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
M45
2
18 Nm (1.8 m·kgf, 13 ft·lbf)
M12
1
70 Nm (7.0 m·kgf, 51 ft·lbf)
M6
1
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
M5
2
8 Nm (0.8 m·kgf, 5.8 ft·lbf)
M8
M6
M6
M6
M6
M5
M12
M6
1
1
1
2
2
1
1
2
26 Nm (2.6 m·kgf, 19 ft·lbf)
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
8 Nm (0.8 m·kgf, 5.8 ft·lbf)
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
5 Nm (0.5 m·kgf, 3.6 ft·lbf)
20 Nm (2.0 m·kgf, 14 ft·lbf)
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
M5
1
4.5 Nm (0.45 m·kgf, 3.3 ft·lbf)
M4
1
3.5 Nm (0.35 m·kgf, 2.5 ft·lbf)
M4
M6
M8
M8
M6
M6
1
2
1
2
3
2
3.5 Nm (0.35 m·kgf, 2.5 ft·lbf)
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
20 Nm (2.0 m·kgf, 14 ft·lbf)
34 Nm (3.4 m·kgf, 25 ft·lbf)
11 Nm (1.1 m·kgf, 8.0 ft·lbf)
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Crankcase
M6
10
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Generator rotor cover bolt
M6
7
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
2-14
Yamaha
bond
No.1215
(Three
bond
No.1215®)
LT
LT
Yamaha
bond
No.1215
(Three
bond
No.1215®)
TIGHTENING TORQUES
Item
Drive sprocket cover bolt
Clutch cover bolt
Stator coil lead holder screw
Timing mark accessing screw
Crankshaft end accessing screw
Starter motor lead screw
Starter clutch idle gear holder
screw
Starter motor bolt
Starter clutch bolt
Primary drive gear nut
Clutch spring bolt
Clutch boss nut
Short clutch push rod locknut
Bearing retainer screw
Drive sprocket bolt
Shift pedal bolt
Shift drum segment screw
Stopper lever bolt
Pickup coil bolt
Neutral switch
Neutral switch lead screw
Stator coil bolt
Thread
Q’ty
size
M6
2
M6
9
M6
1
M14
1
M32
1
M5
1
Tightening torque
Remarks
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
3.5 Nm (0.35 m·kgf, 2.5 ft·lbf)
M6
2
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
M6
M8
M12
M5
M12
M6
M6
M5
M6
M6
M6
M6
M10
M4
M6
2
3
1
4
1
1
2
2
1
1
1
2
1
1
3
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
30 Nm (3.0 m·kgf, 22 ft·lbf)
70 Nm (7.0 m·kgf, 51 ft·lbf)
6 Nm (0.6 m·kgf, 4.3 ft·lbf)
60 Nm (6.0 m·kgf, 43 ft·lbf)
8 Nm (0.8 m·kgf, 5.8 ft·lbf)
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
6 Nm (0.6 m·kgf, 4.3 ft·lbf)
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
12 Nm (1.2 m·kgf, 8.7 ft·lbf)
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
9 Nm (0.9 m·kgf, 6.5 ft·lbf)
1.3 Nm (0.13 m·kgf, 0.94 ft·lbf)
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Stake
LT
LT
LT
LT
LT
TIP
Cylinder head bolt
1. Apply Yamaha bond No.1215 (Three bond No.1215®) to the threads of the cylinder head bolts
“5”, “6”.
2. Lubricate the contact surfaces of the cylinder head bolts and on both contact surfaces of washers with engine oil.
3. Tightening the cylinder head bolts in the proper sequence as shown.
2-15
TIGHTENING TORQUES
EAS20350
CHASSIS TIGHTENING TORQUES
Item
Engine bracket (upper side) and
frame bolt
Engine bracket (upper side) and
engine nut
Engine bracket (front side) and
engine nut
Engine and frame nut
Engine bracket (front side) and
frame bolt
Swingarm pivot shaft and frame
nut
Swingarm and drive chain guide
bolt
Rear shock absorber assembly
and frame nut
Rear shock absorber and swingarm nut
locknut
Rear axle pinch bolt
Front shock absorber assembly
and frame nut
and front lower arm nut
Front upper arm and frame nut
Front lower arm and frame nut
Steering stem and frame nut
Steering stem bushing and frame
bolt
Steering stem and handlebar
holder bolt
Tie-rod end and locknut
Steering knuckle and front wheel
hub nut
Steering knuckle and front arm
nut (upper and lower)
Steering knuckle and tie-rod ball
joint nut
Steering stem and tie-rod ball
joint nut
Fuel tank and fuel cock screw
Fuel tank and frame bolt
Front wheel and front wheel hub
nut
Thread
Q’ty
size
Tightening torque
M8
2
33 Nm (3.3 m·kgf, 24 ft·lbf)
M8
1
40 Nm (4.0 m·kgf, 29 ft·lbf)
M8
1
40 Nm (4.0 m·kgf, 29 ft·lbf)
M8
2
44 Nm (4.4 m·kgf, 32 ft·lbf)
M8
4
33 Nm (3.3 m·kgf, 24 ft·lbf)
M14
1
100 Nm (10 m·kgf, 72 ft·lbf)
M6
1
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
M12
1
55 Nm (5.5 m·kgf, 40 ft·lbf)
M12
1
55 Nm (5.5 m·kgf, 40 ft·lbf)
M20
1
42 Nm (4.2 m·kgf, 30 ft·lbf)
M8
4
21 Nm (2.1 m·kgf, 15 ft·lbf)
M10
2
48 Nm (4.8 m·kgf, 35 ft·lbf)
M10
2
48 Nm (4.8 m·kgf, 35 ft·lbf)
M10
M10
M10
2
4
1
45 Nm (4.5 m·kgf, 33 ft·lbf)
45 Nm (4.5 m·kgf, 33 ft·lbf)
35 Nm (3.5 m·kgf, 25 ft·lbf)
M8
2
23 Nm (2.3 m·kgf, 17 ft·lbf)
M8
4
20 Nm (2.0 m·kgf, 14 ft·lbf)
M10
4
15 Nm (1.5 m·kgf, 11 ft·lbf)
M14
2
70 Nm (7.0 m·kgf, 51 ft·lbf)
M10
4
25 Nm (2.5 m·kgf, 18 ft·lbf)
M10
2
25 Nm (2.5 m·kgf, 18 ft·lbf)
M10
2
25 Nm (2.5 m·kgf, 18 ft·lbf)
M6
M6
2
4
4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
M10
8
45 Nm (4.5 m·kgf, 33 ft·lbf)
2-16
Remarks
See TIP
Use a lock
washer.
TIGHTENING TORQUES
Item
Steering knuckle and front brake
caliper bracket bolt
Front brake disc and front wheel
hub bolt
Rear axle and rear wheel hub nut
Rear brake caliper and brake caliper bracket bolt
Rear wheel and rear wheel hub
nut
Driven sprocket and sprocket
bracket nut
Front brake pipe nut
Front brake master cylinder and
bracket bolt
Clutch and parking brake lever
assembly and bracket bolt
Parking brake lever holder and
clutch lever holder bolt
Throttle lever assembly and handlebar screw
brake lever bolt
brake hose union bolt
Brake hose joint and frame bolt
Front brake hose holder and
upper front arm bolt
Bleed screw
Front brake pad retaining bolt
Front brake caliper and brake
hose union bolt
Rear brake caliper retaining bolt
Rear axle ring nut
Rear axle ring nut set bolt
Rear brake pad retaining bolt
Rear brake caliper and brake
hose union bolt
Rear brake master cylinder and
frame bolt
Rear brake master cylinder and
brake hose union bolt
Parking brake adjusting bolt and
locknut
Rear brake disc and brake disc
bracket bolt
Thread
Q’ty
size
Tightening torque
M8
4
28 Nm (2.8 m·kgf, 20 ft·lbf)
M8
8
28 Nm (2.8 m·kgf, 20 ft·lbf)
M14
2
120 Nm (12 m·kgf, 87 ft·lbf)
M8
2
34 Nm (3.4 m·kgf, 25 ft·lbf)
M10
8
45 Nm (4.5 m·kgf, 33 ft·lbf)
M10
4
55 Nm (5.5 m·kgf, 40 ft·lbf)
M10
2
19 Nm (1.9 m·kgf, 14 ft·lbf)
M6
2
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
M5
2
4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
M6
2
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
M5
2
4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
M6
1
6 Nm (0.6 m·kgf, 4.3 ft·lbf)
M10
1
27 Nm (2.7 m·kgf, 20 ft·lbf)
M6
1
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
M6
2
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
M8
M10
3
2
6 Nm (0.6 m·kgf, 4.3 ft·lbf)
17 Nm (1.7 m·kgf, 12 ft·lbf)
M10
2
27 Nm (2.7 m·kgf, 20 ft·lbf)
M8
M33
M6
1
1
2
17 Nm (1.7 m·kgf, 12 ft·lbf)
140 Nm (14 m·kgf, 100 ft·lbf)
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
M8
2
17 Nm (1.7 m·kgf, 12 ft·lbf)
M10
1
31 Nm (3.1 m·kgf, 22 ft·lbf)
M8
2
20 Nm (2.0 m·kgf, 14 ft·lbf)
M10
1
31 Nm (3.1 m·kgf, 22 ft·lbf)
M8
1
16 Nm (1.6 m·kgf, 12 ft·lbf)
M8
4
28 Nm (2.8 m·kgf, 20 ft·lbf)
2-17
Remarks
LT
LT
LT
Use a lock
washer.
LT
TIGHTENING TORQUES
Item
Rear brake fluid reservoir, cover
and frame bolt
Front bumper and frame bolt
Front fender stay and frame bolt
Side cover and frame bolt
Rear fender and frame bolt
Rear fender and air filter case and
frame bolt
Rear fender stay and rear fender
bolt
Front fender stay and front fender
bolt
Rear carrier bar and frame bolt
Footrest and frame bolt
Foot protector stay and foot protector nut
Foot protector stay and foot protector screw
Foot protector stay and frame bolt
Foot protector stay and footrest
nut
Battery cover, air filter case and
frame bolt
Air filter case and frame bolt
Headlight and front fender stay
bolt
Tail/brake light bracket and air filter case nut
Rectifier/regulator and front
fender stay bolt
Main switch nut
Ignition coil and frame bolt
Drive chain guide roller and frame
bolt
Engine skid plate and frame bolt
Swingarm end cover plate bolt
Front side reflector nut (CAN)
Front side reflector bracket bolt
(CAN)
Rear reflector (CAN)
Thread
Q’ty
size
Tightening torque
M6
1
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
M8
M6
M6
M6
4
4
4
2
31 Nm (3.1 m·kgf, 22 ft·lbf)
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
M6
3
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
M6
2
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
M6
4
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
M8
M10
4
4
34 Nm (3.4 m·kgf, 25 ft·lbf)
73 Nm (7.3 m·kgf, 53 ft·lbf)
M6
2
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
M5
6
6 Nm (0.6 m·kgf, 4.3 ft·lbf)
M8
2
17 Nm (1.7 m·kgf, 12 ft·lbf)
M8
4
17 Nm (1.7 m·kgf, 12 ft·lbf)
M6
2
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
M6
2
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
M5
2
1.3 Nm (0.13 m·kgf, 0.94 ft·lbf)
M6
2
4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
M6
1
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
M22
M6
1
2
1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
M8
1
23 Nm (2.3 m·kgf, 17 ft·lbf)
M6
M6
M5
4
4
2
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
9 Nm (0.9 m·kgf, 6.5 ft·lbf)
3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
M6
2
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
M5
1
3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
TIP
Tightening the rear axle pinch bolts in the proper sequence as shown.
2-18
Remarks
TIGHTENING TORQUES
2-19
LUBRICATION POINTS AND LUBRICANT TYPES
EAS20360
LUBRICATION POINTS AND LUBRICANT TYPES
EAS20370
ENGINE
Lubrication point
Oil seal lips
Lubricant
LS
Bearings
Cylinder head bolt seats and washers
E
E
Camshaft sprocket cover O-ring
LS
Tappet cover O-rings
LS
Connecting rod big end thrust surface
Piston pin
Cylinder inner surface, piston ring grooves, and piston rings
Crankshaft end (clutch side)
Camshaft lobes
E
E
E
E
M
Valve stems, valve guides, and valve stem seals
Valve stem ends
Rocker arm shafts outer surface
E
E
E
Rocker arm inner surface
M
Timing mark accessing screw O-ring
LS
Crankshaft end accessing screw O-ring
LS
Engine oil filler cap O-ring
LS
Starter clutch idle gear shaft inner surface
Starter clutch gear inner surface and boss
Starter clutch gear boss
E
E
E
Starter motor O-ring
LS
Clutch push lever
Primary driven gear inner surface
Short clutch push rod
Long clutch push rod ends and ball
Main axle and pinion gears
Drive axle and wheel gears
Shift drum
Shift forks and shift fork guide bars
E
E
E
E
M
M
E
E
Yamaha bond
No.1215 (Three Bond
No.1215®)
Yamaha bond
No.1215 (Three Bond
No.1215®)
Yamaha bond
No.1215 (Three Bond
No.1215®)
Three Bond 7738
Crankcase mating surface
Stator coil lead grommet
Cylinder head bolt (M6) thread
Neutral switch lead
2-20
LUBRICATION SYSTEM CHART AND DIAGRAMS
EAS20390
EAS20400
ENGINE OIL LUBRICATION CHART
2-21
1.
2.
3.
4.
5.
6.
7.
8.
9.
Oil pan
Oil strainer
Oil pump
Rotary filter
Cylinder head
Camshaft
Crankshaft
Drive axle
Main axle
2-22
EAS20410
LUBRICATION DIAGRAMS
2-23
1.
2.
3.
4.
5.
Camshaft
Rotary filter
Oil pump
Oil strainer
Push lever shaft
2-24
2-25
1.
2.
3.
4.
5.
Camshaft
Rotary filter
Crankshaft
Main axle
Drive axle
2-26
CABLE ROUTING
EAS20430
CABLE ROUTING
Handlebar (top view)
2-27
CABLE ROUTING
1.
2.
3.
4.
5.
Brake hose
Throttle cable
Plastic band
Parking brake cable
Clutch cable
A. Pass the brake hose and throttle cable
through the guide of the handlebar protector. Pass the throttle cable behind the
brake hose.
B. Clamp the front brake light switch lead at
the bends of handlebar.
C. Pass the clutch cable and parking brake
cable through the guide of the handlebar
protector. Pass the clutch cable in front of
the parking brake cable.
D. Clamp the clutch switch lead and handlebar switch lead at the bends of handlebar.
2-28
CABLE ROUTING
Frame (right side view)
2-29
CABLE ROUTING
1. Neutral indicator light lead
2. Front brake light switch lead
3. Main switch lead
4. Headlight lead
5. Brake hose
6. Starter motor lead
7. Battery negative lead
8. Parking brake cable
9. Rear brake light switch lead
10.Carburetor warmer lead
11.Air vent hose
12.Crankcase breather hose
13.Spark plug lead
14.Ignition coil
15.Throttle cable
16.Clutch cable
17.Wire harness
18.Clamp
19.Frame
20.Brake fluid reservoir hose
21.Carburetor overflow hose
22.Brake fluid reservoir cover
A.
B.
C.
D.
E.
F.
G.
H.
I.
J.
K.
L.
M.
To the front panel
To the handlebar
To the front fender
Route the starter motor lead between the
engine mounting brackets.
Route the air vent hose between the brackets.
Pass the throttle cable under the cross pipe
and left of the steering column as shown in
the illustration.
Pass the parking brake cable and the
clutch cable under the cross pipe and right
of the steering column as shown in the
illustration.
The clamp position should be at the center
between the engine mounting brackets.
Pass the rear brake light switch lead under
the engine mounting bracket on the right of
the vehicle.
Pass the rear brake light switch lead, air
vent hose, carburetor overflow hose, and
starter motor lead through the engine
mounting brackets.
Insert the clamp into the center hole of the
engine mounting bracket.
Pass the rear brake light switch lead next to
the rear brake reservoir cover.
Pass the battery negative lead on the top
of the engine mounting bracket.
2-30
CABLE ROUTING
Rear brake (right side view)
2-31
CABLE ROUTING
1. Rear brake reservoir
2. Rear brake light switch
3. Clip
4. Rear brake reservoir hose
5. Rear brake master cylinder
7. Parking brake cable adjusting nut
8. Brake hose
9. Rear brake caliper
10.Swingarm
A. Make sure that the end of the clip is facing
downward.
B. Set the rear brake reservoir hose with the
positioning yellow paint mark pointing
down.
C. Install the rear brake hose in the direction
shown in the illustration.
D. Insert the rear brake hose until it contacts
the projection.
E. Install the rear brake reservoir hose in the
direction shown in the illustration.
F. Install the rear brake reservoir hose, making sure to face the white paint mark outward.
G. Make sure that the end of the clip is facing
outward.
H. Insert the rear brake reservoir hose until it
contacts the projection.
I. When installing the rear brake hose, make
sure that the metal part on the rear brake
hose is touching the stopper of the rear
caliper.
J. 64–68 mm (2.52–2.68 in)
2-32
CABLE ROUTING
Frame (left side view)
2-33
CABLE ROUTING
1. Spring
2. Adjusting screw
3. Washer
4. Adjusting nut
5. Rectifier/regulator
6. Clutch switch lead
7. Handlebar switch lead
8. Rectifier/regulator lead
9. Wire harness
10.Neutral switch lead
11.Drain hose
12.Clamp
13.Screw
14.Collar
15.Headlight
16.Spring nut
17.Headlight stay
18.Frame
19.Damper plate
A. The target of the screw protrusion is 12
mm (0.47 in).
B. Install the adjusting nut so that the spherical side faces to the front of the vehicle.
C. Insert the bottom hole of the rectifier/regulator into the boss of the headlight stay.
D. To the front fender
E. Pass the rectifier/regulator lead outside of
the vehicle.
F. Pass the wire harness above the guide for
the damper plate.
G. Clamp on top of the frame bracket.
H. Pass the clamp through the damper plate
hole.
2-34
CABLE ROUTING
Rear frame (left side view)
2-35
CABLE ROUTING
1. Air vent hose
2. Clamp
3. Starter motor lead
4. AC magneto lead
5. Carburetor overflow hose
6. Frame
7. Seat pad
8. Wire harness
10.Rear brake light switch lead
12.Side cover
13.Crankcase breather hose
14.Air filter joint
15.Engine mounting bracket
A.
B.
C.
D.
E.
F.
G.
H.
I.
J.
To the front fender
Fix point for wire harness
Clamp near the hook of the air filter.
Clamp near the edge of the air filter case.
Pass the AC magneto lead through the
guide of the drive sprocket cover.
Clamp the starter motor lead at the center
hole of the engine mounting bracket.
Clamp the starter motor lead at the hole on
the engine side of the engine mounting
bracket.
Pass the clamp through the frame bracket.
Place the couplers on the inside of the side
cover.
Route the leads on the upper inside of the
side cover
2-36
CABLE ROUTING
Front fender (top view)
2-37
CABLE ROUTING
1. Neutral indicator light
2. Main switch lead coupler
3. Main switch lead
4. Headlight lead
5. Main switch
7. Throttle cable
8. Air vent hose
9. Clutch switch lead
10.Handlebar switch lead
11.Parking brake cable
12.Clutch cable
13.Front fender
14.Clamp
15.Rectifier/regulator lead
A. Install the indicator light as shown in the
illustration.
B. Connect the main switch lead coupler on
the front fender.
C. Pass the headlight lead and main switch
lead through the guide of the front fender. It
is allowable if the open-wired lead is positioned on the guide or clamp.
D. Pass the front brake light switch lead and
throttle cable through the guide.
E. Insert the air vent hose into the front
fender.
F. Pass the clutch switch lead, handlebar
switch lead, parking brake cable, and
clutch cable through the guide of the front
fender. Pass the clutch switch lead and
handlebar switch lead behind the clutch
cable and parking brake cable.
G. Pass the clutch switch lead and handlebar
switch lead through the guide of the front
fender and then connect them on the front
fender.
2-38
CABLE ROUTING
Frame (top view)
2-39
CABLE ROUTING
1. Main switch lead
2. Headlight lead
3. Neutral indicator light lead
5. Clutch cable
7. Throttle cable
8. Brake fluid reservoir
9. Rear brake light switch lead
10.Air vent hose
12.Starter motor lead
13.Clutch switch lead
14.Handlebar switch lead
15.Rectifier/regulator lead
16.Headlight stay
17.Band
18.CDI unit
19.Headlight relay
20.Starting circuit cut-off relay
21.Wire harness
22.Frame
23.Clamp
A.
B.
C.
D.
To the front fender
To the front panel
To the handlebar
Route the air vent hose between the brackets.
E. Fix point for wire harness
F. Insert into the headlight stay until the position shown in the illustration.
2-40
CABLE ROUTING
Air filter case (top view)
2-41
CABLE ROUTING
1. Tool kit
2. Air filter case
3. Tail/brake light
4. Tail/brake light lead
5. Battery
6. Starter relay lead
7. Starter relay
8. Battery positive lead
10.AC magneto coupler
11.Starter motor lead
A. Clamp the tail/brake light lead.
B. Do not clamp.
C. Set the insulator lock on the wire harness
behind the fixed point.
D. Pass the starter relay lead under the
starter motor lead.
E. After connecting the wire harness and
each electric part, the length between the
air filter and AC magneto coupler should
be 185 mm (7.28 in) on straight line.
F. ø20
G. After connecting the battery negative lead,
push the sag in the box.
H. Insert the starter relay all the way into the
rib on the air filter side.
2-42
CABLE ROUTING
2-43
PERIODIC CHECKS AND ADJUSTMENTS
PERIODIC MAINTENANCE .........................................................................3-1
INTRODUCTION ....................................................................................3-1
PERIODIC MAINTENANCE CHART FOR THE EMISSION
CONTROL SYSTEM...............................................................................3-1
GENERAL MAINTENANCE AND LUBRICATION CHART .....................3-2
CHECKING THE FUEL LINE .................................................................3-4
CHECKING THE SPARK PLUG .............................................................3-4
ADJUSTING THE VALVE CLEARANCE ................................................3-4
CHECKING THE STARTER (CHOKE) OPERATION .............................3-6
ADJUSTING THE ENGINE IDLING SPEED ..........................................3-6
CHECKING THE CRANKCASE BREATHER HOSE ..............................3-7
CHECKING THE EXHAUST SYSTEM ...................................................3-7
CLEANING THE SPARK ARRESTER ....................................................3-8
CLEANING THE AIR FILTER ELEMENT ...............................................3-8
ADJUSTING THE CLUTCH CABLE FREE PLAY ................................3-10
CHECKING THE BRAKE OPERATION................................................3-10
ADJUSTING THE FRONT DISC BRAKE .............................................3-10
BLEEDING THE HYDRAULIC BRAKE SYSTEM .................................3-11
CHECKING THE BRAKE FLUID LEVEL ..............................................3-12
CHECKING THE FRONT BRAKE PADS..............................................3-12
ADJUSTING THE BRAKE PEDAL .......................................................3-13
CHECKING THE REAR BRAKE PADS ................................................3-13
CHECKING THE FRONT BRAKE HOSES...........................................3-13
CHECKING THE REAR BRAKE HOSE ...............................................3-14
ADJUSTING THE PARKING BRAKE ...................................................3-14
CHECKING THE WHEELS ..................................................................3-15
CHECKING THE TIRES .......................................................................3-15
CHECKING THE WHEEL HUB BEARINGS.........................................3-17
CHECKING AND LUBRICATING THE SWINGARM PIVOTS ..............3-17
LUBRICATING THE UPPER AND LOWER ARM PIVOTS ...................3-17
ADJUSTING THE DRIVE CHAIN SLACK ............................................3-17
LUBRICATING THE DRIVE CHAIN......................................................3-18
CHECKING THE DRIVE CHAIN ROLLERS.........................................3-18
CHECKING THE CHASSIS FASTENERS............................................3-18
CHECKING THE FRONT SHOCK ABSORBER ASSEMBLIES...........3-18
ADJUSTING THE FRONT SHOCK ABSORBER ASSEMBLIES .........3-18
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY .................3-19
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY................3-19
LUBRICATING THE STEERING SHAFT..............................................3-20
CHECKING THE STEERING SYSTEM ...............................................3-20
ADJUSTING THE TOE-IN ....................................................................3-20
CHECKING THE ENGINE MOUNT......................................................3-21
CHECKING THE ENGINE OIL LEVEL .................................................3-21
CHANGING THE ENGINE OIL.............................................................3-22
CHECKING AND LUBRICATING THE CABLES ..................................3-23
LUBRICATING THE LEVERS...............................................................3-23
LUBRICATING THE PEDAL .................................................................3-23
ADJUSTING THE THROTTLE CABLE FREE PLAY ............................3-24
ADJUSTING THE SPEED LIMITER .....................................................3-24
ADJUSTING THE REAR BRAKE LIGHT SWITCH ..............................3-25
3
REPLACING THE HEADLIGHT BULB .................................................3-25
ADJUSTING THE HEADLIGHT BEAM ................................................3-26
PERIODIC MAINTENANCE
EAS20450
EAS20460
INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments.
If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a
longer service life and reduce the need for costly overhaul work. This information applies to vehicles
already in service as well as to new vehicles that are being prepared for sale. All service technicians
should be familiar with this entire chapter.
EAS2PA1301
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM
TIP
• For ATVs not equipped with an odometer or an hour meter, follow the month maintenance intervals.
• For ATVs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance
intervals. However, keep in mind that if the ATV isn’t used for a long period of time, the month
maintenance intervals should be followed.
• Items marked with an asterisk should be performed by a Yamaha dealer as they require special
tools, data and technical skills.
INITIAL
EVERY
month
1
3
6
6
12
km
(mi)
320
(200)
1300
(800)
2500
(1600)
2500
(1600)
5000
(3200)
hours
20
80
160
160
320
√
√
√
√
√
√
√
√
√
√
√
√
• Check breather hose for cracks or other damage, and
replace if necessary.
√
√
√
6 * Exhaust system
• Check for leakage and replace gasket(s) if necessary.
• Check for looseness and tighten all screw clamps and
joints if necessary.
√
√
√
7
• Clean.
√
√
√
NO.
ITEM
CHECK OR MAINTENANCE
JOB
Whichever
comes first
1 * Fuel line
• Check fuel hoses for cracks or other damage, and replace
if necessary.
2
• Check condition and clean, regap, or replace if necessary.
√
3 * Valves
• Check valve clearance and adjust if necessary.
√
4 * Carburetor
• Check starter (choke) operation and correct if necessary.
• Check engine idling speed and adjust if necessary.
5 *
Spark plug
Crankcase breather
system
Spark arrester
3-1
√
√
EAS2PA1302
GENERAL MAINTENANCE AND LUBRICATION CHART
TIP
• For ATVs not equipped with an odometer or an hour meter, follow the month maintenance intervals.
• For ATVs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance
intervals. However, keep in mind that if the ATV isn’t used for a long period of time, the month
maintenance intervals should be followed.
• Items marked with an asterisk should be performed by a Yamaha dealer as they require special
tools, data and technical skills.
INITIAL
NO.
ITEM
Whichever
comes first
JOB
1
3
6
6
12
km
(mi)
320
(200)
1300
(800)
2500
(1600)
2500
(1600)
5000
(3200)
20
80
160
160
320
hours
1
Air filter element
• Clean and replace if necessary.
Every 20–40 hours (more often in wet or
dusty areas)
2 * Clutch
• Check operation and adjust if necessary.
√
3 * Front brake
• Check operation and correct if necessary.
• Check fluid level and ATV for fluid leakage, and correct if
necessary.
√
• Replace brake pads.
4 * Rear brake
√
√
√
√
√
√
√
Whenever worn to the limit
• Check fluid level and ATV for fluid leakage, and correct if
necessary.
√
• Replace brake pads.
5 * Brake hoses
EVERY
month
√
√
√
√
Whenever worn to the limit
• Check for cracks or other damage, and replace if necessary.
√
• Replace.
√
√
√
Every 4 years
6 * Parking brake
• Check operation and adjust if necessary.
√
√
√
√
7 * Wheels
• Check runout and for damage, and replace if necessary.
√
√
√
√
8 * Tires
• Check tread depth and for damage, and replace if necessary.
• Check air pressure and balance, and correct if necessary.
√
√
√
√
9 * Wheel hub bearings
• Check for looseness or damage, and replace if necessary.
√
√
√
√
1
* Swingarm pivots
0
• Check operation and for excessive play, and replace
bearings if necessary.
• Lubricate with lithium-soap-based grease.
√
√
√
1
Upper and lower arm
*
1
pivots
√
√
√
1
2
• Check chain slack and adjust if necessary.
• Check rear wheel alignment and correct if necessary.
• Clean and lubricate.
√
√
√
√
√
√
√
√
√
Drive chain
√
√
√
1
* Drive chain rollers
3
• Check for wear and replace if necessary.
1
* Chassis fasteners
4
• Make sure that all nuts, bolts, and screws are properly
tightened.
Shock absorber
1
*
assemblies
5
• Check for oil leakage and replace if necessary.
√
√
√
1
* Steering shaft
6
√
√
√
1
* Steering system
7
• Check operation and repair or replace if damaged.
• Check toe-in and adjust if necessary.
√
√
√
1
* Engine mount
8
• Check for cracks or other damage, and replace if necessary.
√
√
√
1
9
• Change.
• Check ATV for oil leakage, and correct if necessary.
√
√
√
√
√
√
Engine oil
Moving parts and
2
*
cables
0
√
√
√
√
√
√
• Lubricate.
3-2
INITIAL
NO.
ITEM
JOB
Whichever
comes first
EVERY
month
1
3
6
6
12
km
(mi)
320
(200)
1300
(800)
2500
(1600)
2500
(1600)
5000
(3200)
hours
20
80
160
160
320
Throttle lever hous2
*
ing and cable
1
• Check throttle cable free play and adjust if necessary.
• Lubricate throttle lever housing and cable.
√
√
√
√
√
Front and rear brake
2
*
switches
2
√
√
√
√
√
2
* Lights and switches
3
• Adjust headlight beam.
√
√
√
√
√
TIP
• Some maintenance items need more frequent service if you are riding in unusually wet, dusty,
sandy or muddy areas, or at full-throttle.
• Hydraulic brake service
• Regularly check and, if necessary, correct the brake fluid level.
• Every two years replace the internal components of the brake master cylinders and calipers, and
change the brake fluid.
• Replace the brake hoses every four years and if cracked or damaged.
3-3
EAS21030
CHECKING THE FUEL LINE
The following procedure applies to all of the
fuel and breather hoses.
1. Check:
• Fuel hose “1”
• Fuel tank breather hose “2”
Cracks/damage → Replace.
ECA14940
5. Clean:
• Spark plug
(with a spark plug cleaner or wire brush)
6. Measure:
• Spark plug gap “a”
(with a wire thickness gauge)
Out of specification → Regap.
Make sure the fuel tank breather hose is
routed correctly.
Spark plug gap
0.6–0.7 mm (0.024–0.028 in)
EAS20690
CHECKING THE SPARK PLUG
1. Disconnect:
• Spark plug cap
2. Remove:
• Spark plug
ECA13330
7. Install:
• Spark plug
Before removing the spark plug, blow away
any dirt accumulated in the spark plug well
with compressed air to prevent it from falling into the cylinder.
Spark plug
13 Nm (1.3 m·kgf, 9.4 ft·lbf)
3. Check:
• Spark plug type
Incorrect → Change.
TIP
Before installing the spark plug, clean the
spark plug and gasket surface.
Manufacturer/model
NGK/CR6HSA
8. Connect:
• Spark plug cap
4. Check:
• Electrode “1”
Damage/wear → Replace the spark plug.
• Insulator “2”
Abnormal color → Replace the spark
plug.
Normal color is medium-to-light tan.
EAS20520
ADJUSTING THE VALVE CLEARANCE
valves.
TIP
• Valve clearance adjustment should be made
on a cold engine, at room temperature.
3-4
• When the valve clearance is to be measured
or adjusted, the piston must be at top dead
center (TDC) on the compression stroke.
1. Remove:
• Spark plug cap
• Spark plug
• Intake tappet cover “1”
• Exhaust tappet cover “2”
• Camshaft sprocket cover “3”
c. Align the mark “c” on the camshaft sprocket
with the stationary pointer “d” on the cylinder head.
2. Remove:
• Timing mark accessing screw “1”
• Crankshaft end accessing screw “2”
d. Measure the valve clearance with a thickness gauge “1”.
Out of specification → Adjust.
Thickness gauge
90890-03180
Feeler gauge set
YU-26900-9
3. Measure:
• Valve clearance
Valve clearance (cold)
Intake
0.08–0.12 mm (0.0032–0.0047
in)
Exhaust
0.10–0.14 mm (0.0039–0.0055
in)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
4. Adjust:
• Valve clearance
a. Turn the crankshaft counterclockwise.
b. When the piston is at TDC on the compression stroke, align the mark “a” on the generator rotor with the stationary pointer “b”
on the generator rotor cover.
a. Loosen the locknut “1”.
b. Insert a thickness gauge “2” between the
end of the adjusting screw and the valve
tip.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
3-5
5. Install:
• All removed parts
TIP
For installation, reverse the removal procedure.
EAS2PA1304
CHECKING THE STARTER (CHOKE) OPERATION
1. Check:
• Starter (choke) operation
Unsmooth operation/Sticks → Replace.
Refer to “CHECKING THE CARBURETOR” on page 6-6.
c. Turn the adjusting screw “3” in direction “a”
or “b” until the specified valve clearance is
obtained.
EAS20620
Direction “a”
Valve clearance is increased.
Direction “b”
Valve clearance is decreased.
ADJUSTING THE ENGINE IDLING SPEED
TIP
Prior to adjusting the engine idling speed, the
carburetor should be adjusted properly, the air
filter element should be clean, and the engine
should have adequate compression.
Tappet adjusting tool
90890-01311
Six piece tappet set
YM-A5970
1. Start the engine and let it warm up for several minutes.
2. Attach:
• Digital tachometer
(onto the ignition coil spark plug lead)
• Hold the adjusting screw to prevent it
from moving and tighten the locknut to
specification.
Digital tachometer
90890-06760
YU-39951-B
Locknut
8 Nm (0.8 m·kgf, 5.8 ft·lbf)
d. Measure the valve clearance again.
e. If the valve clearance is still out of specification, repeat all of the valve clearance
adjustment steps until the specified clearance is obtained.
3. Measure:
• Engine idling speed
Engine idling speed
1550–1650 r/min
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3-6
4. Adjust:
2.0–4.0 mm (0.08–0.16 in)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the pilot screw “1” in until it is lightly
seated. (AUS, NZL)
b. Turn the pilot screw out the specified number of turns. (AUS, NZL)
EAS2PA1303
CHECKING THE CRANKCASE BREATHER
HOSE
1. Check:
• Crankcase breather hose “1”
Carburetor angle driver
90890-03158
ECA14920
2–1/2 (AUS, NZL)
Make sure the crankcase breather hose is
routed correctly.
c. Turn the throttle stop screw “1” in direction
“a” or “b” until the specified idling speed is
obtained.
EAS21081
CHECKING THE EXHAUST SYSTEM
exhaust pipe and gaskets.
1. Check:
• Exhaust pipe “1”
• Muffler “2”
• Gaskets “3”
Exhaust gas leaks → Replace.
2. Check:
• Tightening torque
Direction “a”
Engine idling speed is increased.
Direction “b”
Engine idling speed is decreased.
Exhaust pipe nut
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Muffler joint bolt
20 Nm (2.0 m·kgf, 14 ft·lbf)
Muffler bolt
34 Nm (3.4 m·kgf, 25 ft·lbf)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Detach:
• Digital tachometer
6. Adjust:
• Throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY” on page 3-24.
3-7
d. Insert the tailpipe and gasket “3” into the
muffler and align the bolt holes.
EAS28970
CLEANING THE SPARK ARRESTER
1. Clean:
• Spark arrester
e. Insert the bolts and tighten it.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
EWA14680
Spark arrester bolt
11 Nm (1.1 m·kgf, 8.0 ft·lbf)
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.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS20941
CLEANING THE AIR FILTER ELEMENT
TIP
On the bottom of the air filter case is a check
hose “1”. If dust or water or both collects in this
hose, clean the air filter element and air filter
case.
a. Remove the bolts “1”.
b. Remove the tailpipe “2” by pulling it out of
the muffler.
c. Tap the tailpipe “2” lightly with a soft-face
hammer or suitable tool, then use a wire
brush to remove any carbon deposits from
the spark arrester portion “a” of the tailpipe
and the inner contact surfaces of the muffler.
1. Remove:
• Seat
Refer to “GENERAL CHASSIS” on page
4-1.
2. Remove:
• Air filter case cover “1”
3-8
Such solvents may cause a fire or an explosion.
TIP
After cleaning, gently squeeze the air filter element to remove the excess solvent.
ECA13430
Do not twist the air filter element when
squeezing it.
3. Remove:
• Wing bolt “1”
• Air filter element “2”
• Air filter element frame “3”
ECA2PA1301
• Never operate the engine without the air
filter element installed.
• Unfiltered air will cause rapid wear of
engine parts and may damage the engine.
• Operating the engine without the air filter
element will leading to poor engine performance and possible overheating.
5. Check:
• Air filter element
Damage → Replace.
6. Apply the recommended oil to the entire
surface of the air filter element and
squeeze out the excess oil. The air filter
element should be wet but not dripping.
Air filter oil grade
Yamaha foam air filter oil or
equivalent oil
7. Install:
• Air filter element frame
8. Apply:
• Lithium-soap-based grease
On the matching surface “a” on air filter
element.
4. Clean:
(with solvent)
EWA13020
WARNING
9. Install:
• Wing bolt
Never use low flash point solvents, such as
gasoline, to clean the air filter element.
3-9
TIP
Make sure its sealing surface matches the
sealing surface of the case so there is no air
leak.
10. Install:
• Air filter case cover
11. Install:
• Seat
4-1.
d. Tighten the locknut.
e. Slide the rubber cover to its original position.
EAS20870
ADJUSTING THE CLUTCH CABLE FREE
PLAY
1. Check:
• Clutch cable free play “a”
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS2PA1312
CHECKING THE BRAKE OPERATION
1. Check:
• Brake operation
Brake not working properly → Check the
brake system.
Refer to “FRONT BRAKE” on page 4-17
and “REAR BRAKE” on page 4-30.
5.0–10.0 mm (0.20–0.39 in)
TIP
Drive on the road, operate the front and rear
brakes separately and check to see if the
brakes are operating properly.
EAS21170
ADJUSTING THE FRONT DISC BRAKE
1. Check:
• Brake lever free play “a”
Out of specification → Bleed the front
brake system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-11.
2. Adjust:
• Clutch cable free play
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Slide back the lever cover “1”.
b. Loosen the locknut “2”.
c. Turn the adjusting bolt “3” in direction “a” or
“b” until the specified clutch cable free play
is obtained.
Brake lever free play
0 mm (0 in)
Direction “a”
Clutch cable free play is increased.
Direction “b”
Clutch cable free play is decreased.
EWA13050
WARNING
A soft or spongy feeling in the brake lever
can indicate the presence of air in the brake
system. Before the vehicle is operated, the
air must be removed by bleeding the brake
system. Air in the brake system will considerably reduce braking performance.
3-10
EAS21350
BLEEDING THE HYDRAULIC BRAKE SYSTEM
EWA13100
WARNING
Bleed the hydraulic brake system whenever:
• The system is disassembled.
• A brake hose is loosened, disconnected
or replaced.
• The brake fluid level is very low.
• Brake operation is faulty.
A. Front
B. Rear
TIP
• 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.
• If bleeding is difficult, it may be necessary to
let the brake fluid settle for a few hours.
Repeat the bleeding procedure when the tiny
bubbles in the hose have disappeared.
d. Place the other end of the hose into a container.
e. Slowly apply the brake lever or brake pedal
several times.
f. Fully pull the brake lever or fully press
down the brake pedal and hold it in position.
g. Loosen the bleed screw.
TIP
Loosening the bleed screw will release the
pressure and cause the brake lever to contact
the grip or the brake pedal to fully extend.
1. Bleed:
• Hydraulic brake system
h. Tighten the bleed screw and then release
the brake lever or brake pedal.
i. Repeat steps (e) to (h) until all of the air
bubbles have disappeared from the brake
fluid in the plastic hose.
j. Tighten the bleed screw to specification.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fill the brake fluid reservoir to the proper
level with the recommended brake fluid.
b. Install the diaphragm (brake master cylinder reservoir or brake fluid reservoir).
c. Connect a clear plastic hose “1” tightly to
the bleed screw “2”.
Bleed screw
6 Nm (0.6 m·kgf, 4.3 ft·lbf)
k. Fill the brake fluid reservoir to the proper
level with the recommended brake fluid.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-12.
3-11
• Refill with the same type of brake fluid
that is already in the system. Mixing brake
fluids may result in a harmful chemical
reaction, leading to poor brake performance.
• When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor
lock.
EWA13110
WARNING
After bleeding the hydraulic brake system,
check the brake operation.
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EAS21240
CHECKING THE BRAKE FLUID LEVEL
1. Place the vehicle on a level surface.
TIP
ECA13540
When checking the brake fluid level, make sure
that the top of the brake master cylinder reservoir or brake fluid reservoir is horizontal.
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
2. Check:
• Brake fluid level
Below the minimum level mark “a” → Add
the recommended brake fluid to the
proper level.
TIP
In order to ensure a correct reading of the
brake fluid level, make sure that the top of the
brake master cylinder reservoir or brake fluid
reservoir is horizontal.
Recommended brake fluid
DOT 4
EAS21250
CHECKING THE FRONT BRAKE PADS
brake pads.
1. Remove:
• Front wheels
Refer to “FRONT WHEEL” on page 4-6.
2. Operate the brake.
3. Check:
• Front brake pad
Wear indicators groove “a” have almost
disappeared → Replace the brake pads
as a set.
Refer to “FRONT BRAKE” on page 4-17.
A. Front brake
B. Rear brake
EWA13090
4. Install:
• Front wheels
WARNING
• Use only the designated brake fluid.
Other brake fluids may cause the rubber
seals to deteriorate, causing leakage and
poor brake performance.
3-12
3. Adjust:
• Rear brake light switch
Refer to “ADJUSTING THE REAR
BRAKE LIGHT SWITCH” on page 3-25.
EAS29190
ADJUSTING THE BRAKE PEDAL
1. Check:
• Brake pedal height “a”
EAS21260
Brake pedal height
6.9 mm (0.27 in)
CHECKING THE REAR BRAKE PADS
brake pads.
1. Operate the brake.
2. Check:
• Rear brake pad
Wear indicators “a” almost touch the
brake disc → Replace the brake pads as
a set.
Refer to “REAR BRAKE” on page 4-30.
TIP
The brake pedal height “a” is measured from
the root of the foot rest “A” to the brake pedal
surface “B”.
2. Adjust:
• Rear brake pedal height
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
b. Turn the adjusting bolt “2” until the brake
pedal height is within the specified limits.
EAS21280
CHECKING THE FRONT BRAKE HOSES
brake hoses, brake pipe and brake hose
clamps.
1. Remove:
• Seat
• Front fender
4-1.
2. Check:
• Brake hose “1”
• Brake pipe “2”
Cracks/damage/wear → Replace.
c. Tighten the locknut.
EWA4D3F003
WARNING
After this adjustment is performed, lift the
rear wheels off the ground by placing a
block under the engine, and spin the rear
wheels to ensure there is no brake drag. If
any brake drag is noticed perform the
above steps again.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3-13
4. Check:
• Brake hose
Brake fluid leakage → Replace the damaged hose.
EAS29210
ADJUSTING THE PARKING BRAKE
1. Check:
• Parking brake cable end length “a”
Parking brake cable end length
64.0–68.0 mm (2.52–2.68 in)
3. Check:
• Brake hose clamp
Loose → Tighten the clamp bolt.
4. Hold the vehicle upright and apply the
brake several times.
5. Check:
• Brake hose
Brake fluid leakage → Replace the damaged hose or pipe.
6. Install:
• Front fender
• Seat
4-1.
2. Adjust:
• Parking brake cable end length
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen the locknut “1” and adjusting bolt
“2”.
b. Slide back the rubber cover “3”.
c. Loosen the locknut “4”.
d. Turn the adjusting nut “5” in direction “a” or
“b” until the specified brake cable end
length is obtained.
e. Tighten the locknut “4”.
f. Slowly turn the adjusting bolt “2” clockwise
until resistance is felt.
g. Turn it 1/8 counterclockwise.
h. Tighten the locknut “1”.
EAS21290
CHECKING THE REAR BRAKE HOSE
1. Check:
Adjusting bolt locknut
16 Nm (1.6 m·kgf, 12 ft·lbf)
i.
2. Check:
• Brake hose clamp
Loose → Repair.
3. Hold the vehicle upright and apply the rear
brake several times.
3-14
Slide the rubber cover to its original position.
EAS29340
CHECKING THE TIRES
EWA14940
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
EWA14950
WARNING
Tire characteristics influence the handling
of vehicles. 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
vehicle’s handling characteristics and are
therefore not recommended.
EWA4D3F003
WARNING
After this adjustment is performed, lift the
rear wheels off the ground by placing a
block under the engine, and spin the rear
wheels to ensure there is no brake drag. If
any brake drag is noticed perform the
above steps again.
Front tire
Size
AT19 × 6-10
Manufacturer/model
MAXXIS/M957Y
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS29351
CHECKING THE WHEELS
wheels.
1. Check:
• Wheel “1”
Damage/bends → Replace.
Rear tire
Size
AT18 × 9-8
Manufacturer/model
MAXXIS/M940
EWA14990
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.
Tire pressure
EWA14960
WARNING
• Tire pressure below the minimum specification could cause the tire to dislodge
from the rim under severe riding conditions. The following are minimums:
• Front
22.0 kPa (0.22 kgf/cm², 3.2 psi)
• Rear
27.0 kPa (0.27 kgf/cm², 4.0 psi)
TIP
Always balance the wheel when a tire or wheel
has been changed or replaced.
3-15
• Use no more than the following pressures
when seating the tire beads.
• Front
250 kPa (2.5 kgf/cm², 36 psi)
• Rear
250 kPa (2.5 kgf/cm², 36 psi)
Higher pressures and fast inflation may
cause a tire to burst. Inflate the tires very
slowly and carefully.
Tire air pressure (measured on
cold tires)
Recommended
Front
25.0 kPa (0.25 kgf/cm², 3.6 psi)
Rear
30.0 kPa (0.30 kgf/cm², 4.4 psi)
Minimum
Front
22.0 kPa (0.22 kgf/cm², 3.2 psi)
Rear
27.0 kPa (0.27 kgf/cm², 4.0 psi)
EWA14970
WARNING
Be extra careful of the vehicle balance and
stability when towing a trailer.
EWA14980
WARNING
Uneven or improper tire pressure may
adversely affect the handling of this vehicle
and may cause loss of control.
• Maintain proper tire pressures.
• Set tire pressures when the tires are cold.
• Tire pressures must be equal in both front
tires and equal in both rear tires.
100.0 kg (220 lb)
* Total weight of the cargo, rider, and
accessories.
1. Measure:
• Tire pressure
2. Check:
• Tire surfaces
Wear/damage → Replace.
TIP
• 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.
Tire wear limit “a”
Front
3.0 mm (0.12 in)
Rear
3.0 mm (0.12 in)
EWA13190
WARNING
It is dangerous to ride with a worn-out tire.
When the tire tread reaches the wear limit,
replace the tire immediately.
3-16
EAS2PA1305
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
CHECKING THE WHEEL HUB BEARINGS
Refer to “CHECKING THE FRONT WHEEL
HUBS” on page 4-7.
TIP
The drive chain slack is adjusted by the rotation of the rear axle hub.
EAS2PA1306
a. Place the vehicle on a level surface.
b. Loosen the rear axle pinch bolts “1”.
c. Insert a rod of a diameter of 8 mm (0.31 in)
and length of 10 cm (4 in) “2” in the hole “3”
of rear axle hub “4”.
d. Shift the transmission into the neutral position.
e. To loosen the drive chain, push the vehicle
forward and to tighten the drive chain, pull
the vehicle backward.
CHECKING AND LUBRICATING THE SWINGARM PIVOTS
Refer to “SWINGARM” on page 4-55.
EAS2PA1307
LUBRICATING THE UPPER AND LOWER
ARM PIVOTS
Refer to “FRONT ARMS AND FRONT SHOCK
ABSORBER ASSEMBLIES” on page 4-50.
EAS21390
ADJUSTING THE DRIVE CHAIN SLACK
ECA13550
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.
TIP
• Measure the drive chain slack halfway
between the drive axle and the rear axle.
• When checking and adjusting the drive chain
slack, there should be no weight on the vehicle and all tires must be touching the ground.
ECA4D3F005
Excessive chain slack will overload the
engine and other vital parts; keep the slack
within the specified limits.
f.
If the chain slack cannot be adjusted,
replace the sprockets and drive chain as a
set.
g. Tighten the rear axle pinch bolts.
1. Check:
• Drive chain slack “a”
21 Nm (2.1 m·kgf, 15 ft·lbf)
TIP
• Tighten the rear axle pinch bolts in the
proper sequence as shown.
• The chain should be cleaned and lubricated
after every use of the vehicle.
Drive chain slack
45.0–55.0 mm (1.77–2.17 in)
2. Adjust:
• Drive chain slack
3-17
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Refer to “CHECKING THE FRONT
SHOCK ABSORBER ASSEMBLIES” on
page 4-51.
3. Check:
• Operation
Pump the front shock absorber assembly
up and down several times.
Unsmooth operation → Replace front
shock absorber assembly.
Refer to “FRONT ARMS AND FRONT
SHOCK ABSORBER ASSEMBLIES” on
page 4-50.
EAS21440
EAS29310
ADJUSTING THE FRONT SHOCK
ABSORBER ASSEMBLIES
LUBRICATING THE DRIVE CHAIN
The drive chain consists of many interacting
parts. If the drive chain is not maintained properly, it will wear out quickly. Therefore, the drive
chain should be serviced, especially when the
vehicle is used in dusty areas.
This vehicle has a drive chain with small rubber O-rings between each side plate. Steam
cleaning, high-pressure washing, certain solvents, and the use of a coarse brush can damage these O-rings. Therefore, use only
kerosene to clean the drive chain. Wipe the
drive chain dry and thoroughly lubricate it with
engine oil or chain lubricant that is suitable for
O-ring chains. Do not use any other lubricants
on the drive chain since they may contain solvents that could damage the O-rings.
EWA14920
WARNING
Always adjust the spring preload for both
front shock absorber assemblies to the
same setting. Uneven adjustment can
cause poor handling and loss of stability.
1. Adjust:
• Spring preload
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjusting ring “1” in direction “a” or
“b” with the ring nut wrench “2”.
Direction “a”
Spring preload is increased (suspension
is harder).
Direction “b”
Spring preload is decreased (suspension
is softer).
Recommended lubricant
Engine oil or chain lubricant
suitable for O-ring chains
Spring preload adjusting positions
Minimum
1
Standard
2
Maximum
5
EAS2PA1308
CHECKING THE DRIVE CHAIN ROLLERS
Refer to “CHECKING THE DRIVE CHAIN” on
page 4-59.
EAS2PA1309
CHECKING THE CHASSIS FASTENERS
Refer to “TIGHTENING TORQUES” on page
2-13.
Ring nut wrench
90890-01268
Spanner wrench
YU-01268
EAS29300
CHECKING THE FRONT SHOCK
ABSORBER ASSEMBLIES
The following procedure applies to both of the
front shock absorber assemblies.
2. Check:
• Front shock absorber assembly
• Front shock absorber rod
• Spring
3-18
Direction “a”
Spring preload is increased (suspension
is harder).
Direction “b”
Spring preload is decreased (suspension
is softer).
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS4D3F006
CHECKING THE REAR SHOCK ABSORBER
ASSEMBLY
2. Check:
• Rear shock absorber rod
• Rear shock absorber
• Spring
Refer to “CHECKING THE REAR
SHOCK ABSORBER ASSEMBLY” on
page 4-54.
3. Check:
• Operation
Pump the rear shock absorber assembly
up and down several times.
Unsmooth operation → Replace rear
Refer to “REAR SHOCK ABSORBER
ASSEMBLY” on page 4-53.
Spring preload adjusting length
“c”
Minimum
234.0 mm (9.21 in)
Standard
230.0 mm (9.06 in)
Maximum
222.0 mm (8.74 in)
EAS29330
ADJUSTING THE REAR SHOCK
ABSORBER ASSEMBLY
1. Adjust:
• Spring preload
ECA2PA1303
TIP
Never attempt to turn the adjusting nut
beyond the maximum or minimum setting.
Be sure to remove all dirt and mud from
around the locknut and adjusting nut before
adjustment.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Elevate the rear wheels by placing a suitable stand under the frame.
c. Turn the adjusting nut “2” in direction “a” or
“b”.
Rear shock absorber locknut
42 Nm (4.2 m·kgf, 30 ft·lbf)
TIP
Always tighten the locknut against the adjusting nut, then torque it to specification.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3-19
5. Check:
• Ball joints and wheel bearings
Move the wheels laterally back and forth.
Excessive free play → Replace the front
arms (upper and lower) and/or wheel
bearings.
EAS2PA1310
LUBRICATING THE STEERING SHAFT
Refer to “STEERING STEM” on page 4-46.
EAS29280
CHECKING THE STEERING SYSTEM
2. Check:
• Steering assembly bushings
Move the handlebar up and down, and
back and forth.
Excessive play → Replace the steering
stem bushings.
EAS29290
ADJUSTING THE TOE-IN
2. Measure:
• Toe-in
3. Check:
• Tie-rod ends “1”
Free play → Replace the tie-rod end.
Toe-in (with tire touching the
ground)
8.0–18.0 mm (0.31–0.71 in)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the handlebar left until it stops.
b. Move the handlebar slightly to the right and
left.
c. Check for play in the tie-rod ends.
d. Turn the handlebar right until it stops.
e. Move the handlebar slightly to the left and
right.
f. Check for play in the tie-rod ends.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
TIP
Before measuring the toe-in, make sure that
the tire pressure is correct.
a.
b.
c.
d.
Mark both front tire tread centers.
Face the handlebar straight ahead.
Measure the width “A” between the marks.
Rotate the front tires 180° until the marks
are exactly opposite one another.
e. Measure the width “B” between the marks.
f. Calculate the toe-in using the formula given
below.
Toe-in = “B” – “A”
g. If the toe-in is incorrect, adjust it.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Raise the front end of the vehicle so that
there is no weight on the front wheels.
3-20
d. Tighten the rod end locknuts of both tierods.
Locknut (tie-rod end)
15 Nm (1.5 m·kgf, 11 ft·lbf)
TIP
Adjust the tie-rod ends so that “A” and “B” are
equal.
C. Forward
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Adjust:
• Toe-in
EWA14910
WARNING
• Be sure that both tie-rods are turned the
same amount. If not, the vehicle will drift
right or left even though the handlebar is
positioned straight. This may lead to mishandling and an accident.
• After setting the toe-in to specification,
run the vehicle slowly for some distance
with both hands lightly holding the handlebar and check that the handlebar
responds correctly. If not, turn either the
right or left tie-rod within the toe-in specification.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS2PA1311
CHECKING THE ENGINE MOUNT
1. Check:
• Engine brackets
• Frame
Refer to “ENGINE REMOVAL” on page 51.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
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.
EAS28921
CHECKING THE ENGINE OIL LEVEL
2. Check the engine oil level on a cold engine.
TIP
If the engine was started before checking the
oil level, be sure to warm up the engine sufficiently, and then wait at least ten minutes until
the oil settles for an accurate reading.
3-21
• Do not allow foreign materials to enter the
crankcase.
3. Check:
• Engine oil level
The engine oil level should be between
the minimum level mark “a” and maximum level mark “b”.
Below the minimum level mark → Add the
recommended engine oil to the proper
level.
4. Check the engine oil level again.
EAS20801
CHANGING THE ENGINE OIL
2. Remove:
• Engine skid plate
3. Start the engine, warm it up for several
minutes, and then turn it off.
4. Place a container under the engine oil drain
bolt.
5. Remove:
• Dipstick “1”
(along with the O-ring)
• Engine oil drain bolt “2”
(along with the gasket)
TIP
Do not screw the dipstick “1” in when checking
the oil level.
Recommended brand
YAMALUBE
Type
SAE 5W-30, 10W-30, 10W-40,
15W-40, 20W-40 or 20W-50
Recommended engine oil grade
API service SG type or higher,
JASO standard MA
6. Drain:
• Engine oil
(completely from the crankcase)
7. Install:
• Engine oil drain bolt
ECA13361
• Engine oil also lubricates the clutch and
the wrong oil types or additives could
cause clutch slippage. Therefore, do not
add any chemical additives or use engine
oils with a grade of “CD” or higher and do
not use oils labeled “ENERGY CONSERVING II”.
(along with the gasket New )
Engine oil drain bolt
20 Nm (2.0 m·kgf, 14 ft·lbf)
8. Fill:
• Crankcase
(with the specified amount of the recommended engine oil)
3-22
Engine oil quantity
Total amount
1.50 L (1.59 US qt, 1.32 Imp.qt)
Periodic oil change
1.25 L (1.32 US qt, 1.10 Imp.qt)
Oil check bolt
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS21690
CHECKING AND LUBRICATING THE
CABLES
inner and outer cables.
9. Install:
• Dipstick
(along with the O-ring New )
10. Start the engine, warm it up for several
minutes, and then turn it off.
11. Check:
• Engine
(for engine oil leaks)
12. Check:
• Engine oil level
Refer to “CHECKING THE ENGINE OIL
LEVEL” on page 3-21.
13. Install:
• Engine skid plate
EWA13270
WARNING
Damaged outer cable may cause the cable
to corrode and interfere with its movement.
Replace damaged outer cable and inner
cables as soon as possible.
1. Check:
• Outer cable
Damage → Replace.
2. Check:
• Cable operation
Rough movement → Lubricate or
replace.
Engine skid plate bolt
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Yamaha chain and cable lube
or engine oil
14. Check:
• Engine oil pressure
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Slightly loosen the oil check bolt “1”.
TIP
Hold the cable end up and apply several drops
of lubricant to the cable.
3. Apply:
• Lithium-soap-based grease
(onto end of the cable)
EAS21700
LUBRICATING THE LEVERS
Lubricate the pivoting point and metal-to-metal
moving parts of the levers.
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 and the oil
pump for damage or leakage. Refer to “OIL
PUMP” on page 5-40.
d. Start the engine after solving the problem(s) and check the engine oil pressure
again.
e. Tighten the oil check bolt to specification.
Brake lever
Silicone grease
Clutch lever
EAS21710
LUBRICATING THE PEDAL
Lubricate the pivoting point and metal-to-metal
moving parts of the pedal.
3-23
EAS20660
TIP
ADJUSTING THE THROTTLE CABLE FREE
PLAY
If the specified throttle cable free play cannot
be obtained on the carburetor side of the
cable, use the adjusting nut on the handlebar
side.
TIP
Prior to adjusting the throttle cable free play,
the engine idling speed should be adjusted.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
1. Check:
• Throttle cable free play “a”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Handlebar side
a. Slide back the rubber cover “1”.
c. Turn the adjusting bolt “3” in direction “a” or
“b” until the specified throttle cable free
play is obtained.
Direction “a”
Throttle cable free play is increased.
Direction “b”
Throttle cable free play is decreased.
2.0–4.0 mm (0.08–0.16 in)
2. Adjust:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Carburetor side
a. Slide back the rubber cover “1”.
c. Turn the adjusting nut “3” in direction “a” or
“b” until the specified throttle cable free
play is obtained.
EWA12930
WARNING
Direction “a”
Throttle cable free play is increased.
Direction “b”
Throttle cable free play is decreased.
After adjusting the throttle cable free play,
start the engine and turn the handlebar to
the right or left to ensure that this does not
cause the engine idling speed to change.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS29170
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.
1. Measure:
• Speed limiter length “a”
3-24
1. Check:
• Rear brake light operation timing
Incorrect → Adjust.
Speed limiter length
Less than 12 mm (0.47 in)
2. Adjust:
• Speed limiter length
Rear brake light operation timing
6–15 mm (0.24–0.59 in)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
b. Turn the adjusting screw “2” in or out until
the specified speed limiter length is
obtained.
Direction “b”
Direction “c”
2. Adjust:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Hold the main body “1” of the rear brake
light switch so that it does not rotate and
turn the adjusting nut “2” in direction “a” or
“b” until the rear brake light comes on at the
proper time.
Speed limiter length is
decreased.
Speed limiter length is
increased.
Direction “a”
Brake light comes on sooner.
Direction “b”
Brake light comes on later.
c. Tighten the locknut.
EWA14880
WARNING
• Particularly for a beginner rider, the speed
limiter should be screwed in completely.
Screw it out little by little as their riding
technique improves. Never remove the
speed limiter for a beginning rider.
• For proper throttle lever operation do not
turn out the adjusting screw more than 12
mm (0.47 in). Also, always adjust the
throttle cable free play to 2.0–4.0 mm
(0.08–0.16 in).
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS21780
REPLACING THE HEADLIGHT BULB
1. Disconnect:
• Headlight lead connectors “1”
2. Remove:
• Headlight bulb holder cover “2”
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS21330
ADJUSTING THE REAR BRAKE LIGHT
SWITCH
TIP
• The rear brake light switch is operated by
movement of the brake pedal.
• The rear brake light switch is stepped on by
6–15 mm (0.24–0.59 in) adjusted when the
brake light comes on.
3. Remove:
• Headlight bulb holder “1”
• Headlight bulb “2”
3-25
TIP
TIP
• Remove them from the right side of the vehicle.
• Push the headlight bulb holder inward, turn it
counterclockwise and remove the defective
bulb.
• Install the headlight bulb holder by pushing it
in and turning it clockwise.
• After installing the headlight bulb holder
cover, make sure that the “TOP” mark “a” is
in the position shown.
6. Connect:
• Headlight lead connectors “2”
EAS21800
ADJUSTING THE HEADLIGHT BEAM
1. Adjust:
• Headlight beam (vertically)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjusting bolt “1” in direction “a” or
“b”.
Direction “a”
Headlight beam is raised.
Direction “b”
Headlight beam is lowered.
EWA13320
WARNING
Since the headlight bulb gets extremely
hot, keep flammable products and your
hands away from the bulb until it has
cooled down.
4. Install:
• Headlight bulb New
Secure the new headlight bulb with the
headlight unit.
ECA13690
Avoid touching the glass part of the headlight bulb to keep it free from oil, otherwise
the transparency of the glass, the life of the
bulb and the luminous flux will be
adversely affected. If the headlight bulb
gets soiled, thoroughly clean it with a cloth
moistened with alcohol or lacquer thinner.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Install:
• Headlight bulb holder
• Headlight bulb holder cover “1”
3-26
3-27
CHASSIS
GENERAL CHASSIS....................................................................................4-1
REMOVING THE FRONT PANEL...........................................................4-5
INSTALLING THE FRONT PANEL .........................................................4-5
FRONT WHEEL ............................................................................................4-6
REMOVING THE FRONT WHEELS.......................................................4-7
CHECKING THE FRONT WHEELS .......................................................4-7
CHECKING THE FRONT WHEEL HUBS...............................................4-7
INSTALLING THE FRONT WHEEL HUB BEARINGS............................4-8
INSTALLING THE FRONT WHEEL HUBS .............................................4-8
INSTALLING THE FRONT WHEELS......................................................4-9
REAR WHEEL ............................................................................................4-10
REMOVING THE REAR WHEELS .......................................................4-11
CHECKING THE REAR WHEELS .......................................................4-11
CHECKING THE REAR WHEEL HUBS ...............................................4-11
INSTALLING THE REAR WHEEL HUBS .............................................4-11
INSTALLING THE REAR WHEELS ......................................................4-11
REAR AXLE AND REAR AXLE HUB ........................................................4-12
REMOVING THE REAR AXLE .............................................................4-14
CHECKING THE REAR AXLE .............................................................4-14
CHECKING THE REAR AXLE HUB .....................................................4-15
CHECKING THE REAR WHEEL SPROCKET .....................................4-15
CHECKING THE SPROCKET BRACKET ............................................4-15
INSTALLING THE REAR WHEEL HUB BEARINGS ............................4-15
INSTALLING THE REAR WHEEL SPROCKET....................................4-15
INSTALLING THE REAR AXLE ............................................................4-15
FRONT BRAKE ..........................................................................................4-17
INTRODUCTION ..................................................................................4-22
CHECKING THE FRONT BRAKE DISCS ............................................4-22
REPLACING THE FRONT BRAKE PADS ............................................4-23
REMOVING THE FRONT BRAKE CALIPERS .....................................4-24
DISASSEMBLING THE FRONT BRAKE CALIPER .............................4-24
CHECKING THE FRONT BRAKE CALIPER........................................4-24
ASSEMBLING THE FRONT BRAKE CALIPER ...................................4-25
INSTALLING THE FRONT BRAKE CALIPER ......................................4-25
REMOVING THE FRONT BRAKE MASTER CYLINDER.....................4-26
CHECKING THE FRONT BRAKE MASTER CYLINDER .....................4-27
ASSEMBLING THE FRONT BRAKE MASTER CYLINDER.................4-27
INSTALLING THE FRONT BRAKE MASTER CYLINDER ...................4-27
4
REAR BRAKE ............................................................................................4-30
INTRODUCTION ..................................................................................4-35
CHECKING THE REAR BRAKE DISC .................................................4-35
REPLACING THE REAR BRAKE PADS ..............................................4-35
REMOVING THE REAR BRAKE CALIPER..........................................4-36
DISASSEMBLING THE REAR BRAKE CALIPER................................4-36
CHECKING THE REAR BRAKE CALIPER ..........................................4-37
ASSEMBLING THE REAR BRAKE CALIPER......................................4-37
INSTALLING THE REAR BRAKE CALIPER.........................................4-38
REMOVING THE REAR BRAKE MASTER CYLINDER .......................4-39
CHECKING THE REAR BRAKE MASTER CYLINDER .......................4-39
ASSEMBLING THE REAR BRAKE MASTER CYLINDER ...................4-40
INSTALLING THE REAR BRAKE MASTER CYLINDER......................4-40
HANDLEBAR..............................................................................................4-42
REMOVING THE HANDLEBAR ...........................................................4-43
CHECKING THE HANDLEBAR............................................................4-43
INSTALLING THE HANDLEBAR ..........................................................4-43
STEERING STEM .......................................................................................4-46
CHECKING THE STEERING STEM ....................................................4-47
INSTALLING THE STEERING STEM...................................................4-47
INSTALLING THE LOCK WASHER......................................................4-47
TIE-RODS AND STEERING KNUCKLES ..................................................4-48
REMOVING THE STEERING KNUCKLES ..........................................4-49
CHECKING THE TIE-RODS.................................................................4-49
CHECKING THE STEERING KNUCKLES ...........................................4-49
INSTALLING THE TIE-RODS ...............................................................4-49
FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES ..........4-50
REMOVING THE FRONT ARMS..........................................................4-51
CHECKING THE FRONT ARMS ..........................................................4-51
REMOVING THE FRONT SHOCK ABSORBER ASSEMBLY ..............4-51
CHECKING THE FRONT SHOCK ABSORBER ASSEMBLIES...........4-51
CHECKING THE FRONT ARM BALL JOINTS.....................................4-52
INSTALLING THE FRONT ARMS AND FRONT SHOCK
ABSORBER ASSEMBLIES ..................................................................4-52
REAR SHOCK ABSORBER ASSEMBLY ..................................................4-53
HANDLING THE REAR SHOCK ABSORBER .....................................4-54
DISPOSING OF A REAR SHOCK ABSORBER...................................4-54
REMOVING THE REAR SHOCK ABSORBER ASSEMBLY.................4-54
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY .................4-54
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY ...............4-54
SWINGARM ................................................................................................4-55
REMOVING THE SWINGARM .............................................................4-56
CHECKING THE SWINGARM .............................................................4-56
INSTALLING THE SWINGARM ............................................................4-57
CHAIN DRIVE .............................................................................................4-58
REMOVING THE DRIVE CHAIN ..........................................................4-59
CHECKING THE DRIVE CHAIN ..........................................................4-59
CHECKING THE DRIVE SPROCKET ..................................................4-60
CHECKING THE REAR WHEEL SPROCKET .....................................4-60
CHECKING THE SPROCKET BRACKET ............................................4-60
INSTALLING THE DRIVE CHAIN .........................................................4-60
GENERAL CHASSIS
EAS21830
GENERAL CHASSIS
Removing the seat, front fender and headlight
Order
Job/Parts to remove
Q’ty
Remarks
Pull back the seat lock lever, than pull up on
the rear of the seat.
TIP
1
Seat
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Front panel
Main switch coupler
Wire harness clamp
Fuel tank cap
Front side reflector
Front side reflector bracket
Front fender
Headlight connector
Headlight
Rectifier/regulator
Headlight relay
Starting circuit cut-off relay
CDI unit
1
1
1
1
2
2
1
3
1
1
1
1
1
Disconnect.
CAN
CAN
Disconnect.
4-1
GENERAL CHASSIS
Removing the foot protectors and engine skid plate
Order
1
2
3
Job/Parts to remove
Left foot protector
Right foot protector
Engine skid plate
Q’ty
1
1
1
Remarks
4-2
GENERAL CHASSIS
Removing the rear fender and air filter case
Order
1
2
3
4
5
6
7
8
9
10
11
12
13
Job/Parts to remove
Seat/Front fender
Rear fender
Battery cover
Negative battery lead
Positive battery lead
Battery
Tail/brake light lead
Crankcase breather hose
Clamp
Air filter case cover
Air filter element
Air filter element frame
Tail/brake light
Washer
Q’ty
1
1
1
1
1
3
1
1
1
1
1
1
2
4-3
Remarks
Refer to “GENERAL CHASSIS” on page 4-1.
Disconnect.
Disconnect.
Loosen.
USA, AUS, NZL
GENERAL CHASSIS
Removing the rear fender and air filter case
Order
14
15
16
17
18
Job/Parts to remove
License bracket
Rear reflector
Air filter case
Left side cover
Rear side reflector
Q’ty
1
1
1
1
2
4-4
Remarks
CAN
CAN
CAN
GENERAL CHASSIS
EAS2PA1401
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
REMOVING THE FRONT PANEL
1. Remove:
• Quick fasteners “1”
a. Place the panel in its original position, and
then install the socket “1” (together with the
bulb) by pushing it in.
ECA2PA1401
When installing the panel, be sure not to
pinch the cables or wires.
2. Remove
• Front panel
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Pull the panel upward as shown, and then
remove the socket “1” (together with the
bulb) by pulling it out.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Install:
• Quick fasteners
b. Pull the panel downward, and then remove
the panel by pulling it as shown.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS2PA1402
INSTALLING THE FRONT PANEL
1. Install:
• Front panel
4-5
FRONT WHEEL
EAS21870
FRONT WHEEL
Removing the front wheel and brake discs
Order
1
2
3
4
5
6
7
8
9
10
11
Job/Parts to remove
Q’ty
Cotter pin
Axle nut
Front wheel
Brake disc guard (outer)
Brake caliper assembly
Wheel hub
Collar
Oil seal
Bearing
Spacer
Brake disc
Remarks
The following procedure applies to both of
the front wheels.
1
1
1
1
1
1
1
2
2
1
1
4-6
FRONT WHEEL
EAS21890
REMOVING THE FRONT WHEELS
front wheels.
EWA13120
WARNING
Securely support the vehicle so that there
is no danger of it falling over.
TIP
Place the vehicle on a suitable stand so that
the front wheel is elevated.
2. Remove:
• Front wheel
EAS29380
CHECKING THE FRONT WHEELS
front wheels.
1. Check:
• Tire
• Wheel
Refer to “CHECKING THE TIRES” on
page 3-15 and “CHECKING THE
WHEELS” on page 3-15.
2. Measure:
• Radial wheel runout “1”
• Lateral wheel runout “2”
Over the specified limit → Replace the
wheel or check the wheel bearing play
“3”.
3. Check:
• Wheel balance
Out of balance → Adjust.
EWA15000
WARNING
After replacing the tire, ride conservatively
to allow the tire to be properly seated in the
rim. Failure to do so may cause an accident
resulting in vehicle damage and possible
injury.
2.0 mm (0.08 in)
2.0 mm (0.08 in)
EAS29390
CHECKING THE FRONT WHEEL HUBS
front wheel hubs.
1. Check:
• Wheel hub “1”
4-7
FRONT WHEEL
EAS29400
INSTALLING THE FRONT WHEEL HUB
BEARINGS
1. Install:
• Bearings “1”
TIP
Face the oil seal side of the bearing inward.
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.
a. Bearing press-in surface
b. 0.5 mm (0.02 in)
EAS29410
EWA2PA1401
INSTALLING THE FRONT WHEEL HUBS
front hubs.
1. Install:
• Front wheel hub
• Washer
• Front axle nut “1”
WARNING
Eye protection is recommended when
using striking tools.
c. To install the wheel bearings, reverse the
above sequence. Use a socket that
matches outside diameter of bearing outer
race to drive in bearing.
Front axle nut
70 Nm (7.0 m·kgf, 51 ft·lbf)
ECA2PA1402
Do not strike the center race or balls of the
bearing. Contact should be made only with
the outer race.
• Cotter pin “2” New
TIP
• 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.
• Bend the longer cotter pin up.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4-8
FRONT WHEEL
EAS29420
INSTALLING THE FRONT WHEELS
front wheels.
1. Install:
• Brake disc guard (outer)
2. Install:
• Front wheel
Front wheel nut
45 Nm (4.5 m·kgf, 33 ft·lbf)
4-9
REAR WHEEL
EAS22020
REAR WHEEL
Removing the rear wheel
Order
1
2
3
4
Job/Parts to remove
Q’ty
2
2
2
2
Rear wheel
Cotter pin
Axle nut
Wheel hub
Remarks
4-10
REAR WHEEL
EAS22040
REMOVING THE REAR WHEELS
EWA13120
WARNING
TIP
the rear wheel is elevated.
2. Remove:
• Rear wheels
EAS29450
INSTALLING THE REAR WHEEL HUBS
rear wheel hubs.
1. Install:
• Rear wheel hub
• Washer
• Rear axle nut
EAS29430
CHECKING THE REAR WHEELS
rear wheels.
1. Check:
• Tire
• Wheel
Refer to “CHECKING THE TIRES” on
page 3-15 and “CHECKING THE
2. Measure:
• Wheel runout
Over the specified limit → Replace.
Rear axle nut
120 Nm (12 m·kgf, 87 ft·lbf)
• Cotter pin New
Refer to “INSTALLING THE FRONT
WHEEL HUBS” on page 4-8.
EAS29460
INSTALLING THE REAR WHEELS
rear wheels.
1. Install:
• Rear wheel
2.0 mm (0.08 in)
2.0 mm (0.08 in)
Rear wheel nut
45 Nm (4.5 m·kgf, 33 ft·lbf)
3. Check:
• Wheel balance
Out of balance → Adjust.
EAS29440
CHECKING THE REAR WHEEL HUBS
rear wheel hubs.
1. Check:
• Wheel hub “1”
• Spline (wheel hub) “2”
4-11
REAR AXLE AND REAR AXLE HUB
EAS29470
Removing the rear axle and rear axle hub
Order
1
2
3
Job/Parts to remove
Rear wheels/Rear wheel hubs
Rear axle ring nut
Conical spring washer
Q’ty
Remarks
Refer to “REAR WHEEL” on page 4-10.
2
1
1
TIP
4
Brake caliper
5
6
7
8
9
10
Brake disc/brake disc bracket
Rear axle
Rear wheel sprocket/sprocket bracket
Circlip
Brake caliper bracket
Collar
1
1/1
1
1/1
1
1
1
4-12
Do not apply the brake pedal and do not use
the parking brake when the brake caliper is
off of the brake disc as the brake pads will be
force shut.
Removing the rear axle and rear axle hub
Order
Job/Parts to remove
11
12
13
14
Rear axle hub
Bearing/oil seal
Spacer
Q’ty
4
Remarks
Loosen.
Refer to “ADJUSTING THE DRIVE CHAIN
SLACK” on page 3-17.
1
2/2
1
4-13
EAS29490
ECA16180
REMOVING THE REAR AXLE
2. Remove:
• Rear axle ring nut set bolts “1”
3. Loosen:
• Rear axle ring nut “2”
• 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 on the axle end
and tap it with a soft hammer, then pull
out the rear axle to the left.
TIP
• Apply the brake pedal so that the rear axle
does not turn when loosening the nut.
• Use the axle nut wrench (46 mm) (rear axle
nut wrench 46 mm) “3”.
90890-01498
YM-37134
2. Suitable socket
EAS29500
CHECKING THE REAR AXLE
1. Check:
• Rear axle runout “a”
Out of specification → Replace.
EWA15020
WARNING
Do not attempt to straighten a bent axle.
4. Elevate the rear wheels by placing a suitable stand under the frame.
5. Remove:
• Rear wheels
• Wheel hubs
• Rear axle ring nut
• Conical spring washer
6. Remove:
• Rear axle “1”
(with rear wheel sprocket)
Rear axle runout limit
1.5 mm (0.06 in)
a
4-14
a
EAS2PA1403
CHECKING THE REAR AXLE HUB
1. Check:
• Rear axle hub
EAS29510
CHECKING THE REAR WHEEL SPROCKET
1. Check:
• Rear wheel sprocket
Refer to “CHECKING THE DRIVE
SPROCKET” on page 4-60.
EAS29530
EAS2PA1404
INSTALLING THE REAR AXLE
1. Install:
• Conical spring washer “1”
• Rear axle ring nut
CHECKING THE SPROCKET BRACKET
1. Check:
• Sprocket bracket
TIP
EAS2PA1407
Install the conical spring washer with the convex side of the washer facing inward as shown.
INSTALLING THE REAR WHEEL HUB
BEARINGS
1. Install:
2. Brake disc bracket
2. Tighten:
• Rear axle ring nut “1”
• Rear axle ring nut set bolts “2”
a. Bearing press-in surface
b. 0.5 mm (0.02 in)
EAS29520
Rear axle ring nut
140 Nm (14 m·kgf, 100 ft·lbf)
LOCTITE®
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
LOCTITE®
INSTALLING THE REAR WHEEL
SPROCKET
1. Install:
• Rear wheel sprocket “1”
TIP
Make sure that the blunt-edged corner “a” of
the rear wheel sprocket is facing outward.
TIP
• Apply the brake pedal so that the rear axle
does not turn when tightening the nut.
• Use the axle nut wrench (46 mm) (rear axle
nut wrench 46 mm) “3”.
90890-01498
YM-37134
4-15
4-16
FRONT BRAKE
EAS22210
FRONT BRAKE
Removing the front brake pads
Order
1
2
3
4
Job/Parts to remove
Q’ty
Front wheel
Brake pad retaining bolt
Brake pad
Brake pad spring
Brake pad shim
Remarks
the front brake calipers.
2
2
1
1
4-17
FRONT BRAKE
Removing the front brake master cylinder
Order
Job/Parts to remove
Q’ty
Brake fluid
1
2
3
4
5
6
7
8
9
10
11
Front brake light switch connector
Brake fluid reservoir cap
Brake fluid reservoir diaphragm plate
Brake fluid reservoir diaphragm
Front brake light switch
Brake lever
Union bolt
Copper washer
Brake hose
Brake master cylinder bracket
Brake master cylinder
2
1
1
1
1
1
1
2
1
1
1
Remarks
Drain.
Disconnect.
Disconnect.
4-18
FRONT BRAKE
Disassembling the front brake master cylinder
Order
1
2
Job/Parts to remove
Brake master cylinder kit
Brake master cylinder body
Q’ty
1
1
Remarks
For assembly, reverse the disassembly procedure.
4-19
FRONT BRAKE
Removing the front brake calipers
Order
Job/Parts to remove
Q’ty
Brake fluid
1
2
3
4
Front wheel
Union bolt
Copper washer
Brake hose
1
2
1
1
Remarks
Drain.
Disconnect.
4-20
FRONT BRAKE
Disassembling the front brake calipers
Order
1
2
3
4
5
6
7
8
9
10
11
12
13
Job/Parts to remove
Q’ty
Brake pad
Brake pad spring
Brake pad shim
Dust plug
Slide pin bolt
Boot
Boot
Brake caliper piston
Brake caliper piston dust seal
Brake caliper piston seal
Bleed screw
Remarks
2
2
1
1
1
1
1
1
1
1
1
1
1
4-21
FRONT BRAKE
EAS22221
INTRODUCTION
EWA14101
WARNING
Disc brake components rarely require disassembly. Therefore, always follow these
preventive measures:
• Never disassemble brake components
unless absolutely necessary.
• If any connection on the hydraulic brake
system is disconnected, the entire brake
system must be disassembled, drained,
cleaned, properly filled, and bled after
reassembly.
• Never use solvents on internal brake
components.
• Use only clean or new brake fluid for
cleaning brake components.
• Brake fluid may damage painted surfaces
• Avoid brake fluid coming into contact
with the eyes as it can cause serious
injury.
FIRST AID FOR BRAKE FLUID ENTERING
THE EYES:
• Flush with water for 15 minutes and get
immediate medical attention.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Measure:
• Brake disc thickness “a”
Measure the brake disc thickness at a
few different locations.
3.0 mm (0.12 in)
5. Adjust:
• Brake disc deflection
EAS22240
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
CHECKING THE FRONT BRAKE DISCS
The following procedure applies to both brake
discs.
1. Remove:
• Front wheel
Refer to “REMOVING THE FRONT
2. Check:
• Brake disc
Damage/galling → Replace.
3. Measure:
Out of specification → Correct the brake
disc deflection or replace the brake disc.
a. Remove the brake disc.
b. Rotate the brake disc by one bolt hole.
c. Install the brake disc.
TIP
• Install the brake disc with its spot-faced side
facing the bolt heads.
• Tighten the brake disc bolts in stages and in
a crisscross pattern.
0.15 mm (0.006 in)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the brake disc with wheel hub.
b. Hold the dial gauge at a right angle against
the brake disc surface.
c. Measure the deflection 2.5 mm (0.10 in)
below the edge of the brake disc.
Brake disc bolt
28 Nm (2.8 m·kgf, 20 ft·lbf)
LOCTITE®
4-22
FRONT BRAKE
d. Measure the brake disc deflection.
e. If out of specification, repeat the adjustment steps until the brake disc deflection is
within specification.
f. If the brake disc deflection cannot be
brought within specification, replace the
brake disc.
2. Install:
• Brake pads
• Brake pad shim (brake caliper piston
side)
(onto the brake pad)
• Brake pad spring
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Always install new brake pads, brake pad shim
and brake pad spring as a set.
TIP
6. Install:
• Front wheel
Refer to “INSTALLING THE FRONT
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect a clear plastic hose “1” tightly to
the bleed screw “2”. Put the other end of
the hose into an open container.
b. Loosen the bleed screw and push the
brake caliper piston into the brake caliper
with your finger.
EAS22251
REPLACING THE FRONT BRAKE PADS
The following procedure applies to both brake
calipers.
TIP
When replacing the brake pads, it is not necessary to disconnect the brake hose or disassemble the brake caliper.
1. Measure:
• Brake pad wear limit “a”
Out of specification → Replace the brake
pads as a set.
Brake pad lining
(inner)
4.5 mm (0.18 in)
Limit
1.0 mm (0.04 in)
Brake pad lining
(outer)
4.5 mm (0.18 in)
Limit
1.0 mm (0.04 in)
thickness
c. Tighten the bleed screw.
Bleed screw
6 Nm (0.6 m·kgf, 4.3 ft·lbf)
thickness
d. Install the brake pads, brake pad shim and
brake pad spring.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Install:
• Brake pad retaining bolts
• Brake caliper
17 Nm (1.7 m·kgf, 12 ft·lbf)
Brake caliper bolt
28 Nm (2.8 m·kgf, 20 ft·lbf)
4. Check:
proper level.
Refer to “CHECKING THE BRAKE
FLUID LEVEL” on page 3-12.
4-23
FRONT BRAKE
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Blow compressed air into the brake hose
joint opening “a” to force out the piston from
the brake caliper.
5. Check:
• Brake lever operation
Soft or spongy feeling → Bleed the brake
system.
EWA13550
WARNING
• Cover the brake caliper piston with a rag.
Be careful not to get injured when the piston is expelled from the brake caliper.
• Never try to pry out the brake caliper piston.
EAS22300
REMOVING THE FRONT BRAKE CALIPERS
brake calipers.
TIP
Before removing the brake caliper, drain the
brake fluid from the entire brake system.
1. Remove:
• Union bolt “1”
• Copper washers “2”
• Brake caliper bolts “4”
b. Remove the brake caliper piston dust seal
and brake caliper piston seal.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS22371
CHECKING THE FRONT BRAKE CALIPER
Recommended brake component replacement schedule
Brake pads
If necessary
Piston seal
Every two years
Piston dust seal
Every two years
Brake hose
Every four years
Every two years and
Brake fluid
whenever the brake is
disassembled
TIP
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
EAS22311
DISASSEMBLING THE FRONT BRAKE
CALIPER
1. Remove:
• Brake caliper piston
• Brake caliper piston dust seal “1”
• Brake caliper piston seal “2”
1. Check:
• Brake caliper piston “1”
Rust/scratches/wear → Replace the
brake caliper piston.
4-24
FRONT BRAKE
• Whenever a brake caliper is disassembled, replace the brake caliper piston dust
seal and brake caliper piston seal.
• Brake caliper cylinder “2”
Scratches/wear → Replace the brake caliper assembly.
• Brake caliper body “3”
Cracks/damage → Replace the brake
caliper assembly.
• Brake fluid delivery passage
(brake caliper body)
Obstruction → Blow out with compressed
air.
Recommended fluid
DOT 4
1. Install:
• Brake caliper piston seal “1” New
• Brake caliper piston dust seal “2” New
2. Install:
EWA13601
WARNING
Whenever a brake caliper is disassembled,
replace the brake caliper piston dust seal
2. Check:
• Brake caliper bracket “1”
caliper assembly.
EAS22420
INSTALLING THE FRONT BRAKE CALIPER
1. Install:
• Brake caliper “1”
(temporarily)
• Copper washers “2” New
EAS22401
ASSEMBLING THE FRONT BRAKE CALIPER
Brake hose union bolt
27 Nm (2.7 m·kgf, 20 ft·lbf)
EWA13621
WARNING
• Before installation, all internal brake components should be cleaned and lubricated
with clean or new brake fluid.
components as they will cause the brake
caliper piston dust seal and brake caliper
piston seal to swell and distort.
EWA13530
WARNING
Proper brake hose routing is essential to
insure safe vehicle operation. Refer to
“CABLE ROUTING” on page 2-27.
4-25
FRONT BRAKE
lock.
ECA14170
When installing the brake hose onto the
brake caliper “1”, make sure the brake pipe
“a” passes notch-shape “b” on the brake
caliper.
ECA13540
5. Bleed:
• Brake system
6. Check:
proper level.
2. Remove:
• Brake caliper
3. Install:
• Brake pads
• Brake pad shim (brake caliper piston
side)
(onto the brake pad)
• Brake pad retaining bolts
• Brake caliper
17 Nm (1.7 m·kgf, 12 ft·lbf)
Brake caliper bolt
28 Nm (2.8 m·kgf, 20 ft·lbf)
Refer to “REPLACING THE FRONT
BRAKE PADS” on page 4-23.
4. Fill:
• Brake master cylinder reservoir
(with the specified amount of the recommended brake fluid)
7. Check:
system.
Recommended fluid
DOT 4
EAS22490
REMOVING THE FRONT BRAKE MASTER
CYLINDER
EWA13090
TIP
WARNING
Before removing the front brake master cylinder, drain the brake fluid from the entire brake
system.
1. Disconnect:
• Brake switch connectors “a”
(from the brake switch)
4-26
FRONT BRAKE
3. Check:
• Brake master cylinder “1”
• Brake master cylinder reservoir diaphragm “2”
Damage/wear → Replace.
2. Remove:
• Union bolt
• Copper washers
• Brake hose
TIP
4. Check:
• Brake hose
To collect any remaining brake fluid, place a
container under the master cylinder and the
end of the brake hose.
EAS22520
ASSEMBLING THE FRONT BRAKE MASTER CYLINDER
EAS22500
CHECKING THE FRONT BRAKE MASTER
CYLINDER
1. Check:
Damage/scratches/wear → Replace.
• Brake fluid delivery passages
(brake master cylinder body)
air.
EWA13520
WARNING
components.
Recommended fluid
DOT 4
EAS22530
INSTALLING THE FRONT BRAKE MASTER
CYLINDER
1. Install:
bolt
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
2. Check:
• Brake master cylinder kit “1”
TIP
• Install the brake master cylinder holder with
the “UP” mark facing up.
• Engage the indentation “a” in the spacer with
the lobe “b” on the brake master cylinder.
• Install the brake lever “2” at 10 degrees angle
as shown.
• Install the brake master cylinder so that the
gaps between the brake master cylinder and
the brake master cylinder bracket are equal.
4-27
FRONT BRAKE
3. Fill:
• Brake master cylinder
Recommended fluid
DOT 4
EWA13540
WARNING
not enter the brake master cylinder reservoir. Water will significantly lower the
boiling point of the brake fluid and could
cause vapor lock.
2. Install:
• Copper washers New
• Brake hose
• Union bolt
ECA13540
27 Nm (2.7 m·kgf, 20 ft·lbf)
EWA13530
WARNING
4. Bleed:
• Brake system
5. Check:
proper level.
TIP
• While holding the brake hose, tighten the
union bolt as shown.
• Turn the handlebar to the left and right to
make sure the brake hose does not touch
other parts (e.g., wire harness, cables,
leads). Correct if necessary.
4-28
FRONT BRAKE
6. Check:
system.
4-29
REAR BRAKE
EAS22550
REAR BRAKE
Removing the rear brake pads
Order
1
2
3
4
Job/Parts to remove
Lock washer
Brake pad
Brake pad spring
Q’ty
2
1
2
1
Remarks
4-30
REAR BRAKE
Removing the rear brake master cylinder
Order
Job/Parts to remove
Right foot protector
Q’ty
Brake fluid
1
2
3
4
5
6
7
8
9
10
11
12
13
Brake fluid reservoir cover
Brake fluid reservoir cap
Brake fluid reservoir diaphragm holder
Brake fluid reservoir diaphragm
Brake fluid reservoir
Brake fluid reservoir hose
Union bolt
Copper washer
Brake hose
Rear brake light switch
Right footrest
Brake pedal/spring
1
1
1
1
1
1
1
2
1
1
1
1
1/1
Remarks
Drain.
Disconnect.
Disconnect.
4-31
REAR BRAKE
Disassembling the rear brake master cylinder
Order
1
2
3
4
Job/Parts to remove
Pin
Joint
Brake master cylinder kit
Q’ty
1
1
1
1
Remarks
4-32
REAR BRAKE
Removing the rear brake caliper
Order
Job/Parts to remove
Q’ty
Brake fluid
1
2
3
4
5
Parking brake cable
Union bolt
Copper washer
Brake hose
1
1
2
1
1
Remarks
Drain.
Disconnect.
Disconnect.
4-33
REAR BRAKE
Disassembling the rear brake caliper
Order
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Job/Parts to remove
Spring
Locknut
Adjusting bolt
Parking brake arm
Lock washer
Brake pad
Brake pad spring
Slide pin bolt
Boot
Boot
Brake caliper piston
Brake caliper piston dust seal
Brake caliper piston seal
Bleed screw
Q’ty
1
1
1
1
2
1
2
1
1
1
2
1
1
1
1
1
Remarks
Loosen.
4-34
REAR BRAKE
EAS22561
INTRODUCTION
3.5 mm (0.14 in)
EWA14101
WARNING
5. Adjust:
BRAKE DISCS” on page 4-22.
Disc brake components rarely require disassembly. Therefore, always follow these
preventive measures:
• Never disassemble brake components
unless absolutely necessary.
• If any connection on the hydraulic brake
system is disconnected, the entire brake
system must be disassembled, drained,
cleaned, properly filled, and bled after
reassembly.
components.
• Use only clean or new brake fluid for
cleaning brake components.
• Brake fluid may damage painted surfaces
• Avoid brake fluid coming into contact
with the eyes as it can cause serious
injury.
FIRST AID FOR BRAKE FLUID ENTERING
THE EYES:
• Flush with water for 15 minutes and get
immediate medical attention.
Brake disc bolt
28 Nm (2.8 m·kgf, 20 ft·lbf)
LOCTITE®
6. Install:
• Rear wheel
EAS22580
REPLACING THE REAR BRAKE PADS
TIP
When replacing the brake pads, it is not necessary to disconnect the brake hose or disassemble the brake caliper.
1. Measure:
• Brake pad wear limit “a”
Out of specification → Replace the brake
pads as a set.
Brake pad lining
(inner)
4.5 mm (0.18 in)
Limit
1.0 mm (0.04 in)
Brake pad lining
(outer)
4.5 mm (0.18 in)
Limit
1.0 mm (0.04 in)
EAS22570
CHECKING THE REAR BRAKE DISC
1. Remove:
• Rear wheel
2. Check:
• Brake disc
Damage/galling → Replace.
3. Measure:
Out of specification → Correct the brake
disc deflection or replace the brake disc.
thickness
thickness
2. Install:
• Brake pads
0.15 mm (0.006 in)
TIP
4. Measure:
• Brake disc thickness
Measure the brake disc thickness at a
few different locations.
Always install new brake pads and brake pad
spring as a set.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect a clear plastic hose “1” tightly to
the bleed screw “2”. Put the other end of
the hose into an open container.
4-35
REAR BRAKE
b. Loosen the bleed screw and push the
brake caliper pistons into the brake caliper
with your finger.
c. Tighten the bleed screw.
7. Check:
• Brake pedal operation
system.
Bleed screw
6 Nm (0.6 m·kgf, 4.3 ft·lbf)
d. Install the brake pads and a brake pad
spring.
EAS22590
REMOVING THE REAR BRAKE CALIPER
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
TIP
3. Install:
Before disassembling the brake caliper, drain
the brake fluid from the entire brake system.
• Lock washer “1” New
• Brake pad retaining bolts “2”
1. Remove:
• Brake caliper bolts “4”
17 Nm (1.7 m·kgf, 12 ft·lbf)
TIP
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
4. Bend the lock washer tabs along a flat side
of the bolts.
5. Install:
• Brake caliper
• Brake caliper bolts
Brake caliper bolt
34 Nm (3.4 m·kgf, 25 ft·lbf)
EAS22601
DISASSEMBLING THE REAR BRAKE CALIPER
1. Remove:
• Brake caliper piston
• Brake caliper piston dust seal “1”
• Brake caliper piston seal “2”
6. Check:
proper level.
4-36
REAR BRAKE
• Brake caliper cylinder “2”
Scratches/wear → Replace the brake caliper assembly.
• Brake caliper body “3”
caliper assembly.
(brake caliper body)
air.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Blow compressed air into the brake hose
joint opening “a” to force out the piston from
the brake caliper.
EWA13550
WARNING
• Cover the brake caliper piston with a rag.
Be careful not to get injured when the piston is expelled from the brake caliper.
• Never try to pry out the brake caliper piston.
EWA13611
WARNING
Whenever a brake caliper is disassembled,
replace the brake caliper piston dust seal
2. Check:
• Brake caliper bracket “1”
caliper assembly.
b. Remove the brake caliper piston dust seal
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS22642
CHECKING THE REAR BRAKE CALIPER
Recommended brake component replacement schedule
Brake pads
If necessary
Piston seals
Every two years
Piston dust seals
Every two years
Brake hoses
Every four years
Every two years and
Brake fluid
whenever the brake is
disassembled
EAS22661
ASSEMBLING THE REAR BRAKE CALIPER
EWA13621
WARNING
components as they will cause the brake
caliper piston dust seal and brake caliper
piston seal to swell and distort.
• Whenever a brake caliper is disassembled, replace the brake caliper piston dust
seal and brake caliper piston seal.
1. Check:
Rust/scratches/wear → Replace the
brake caliper piston.
4-37
REAR BRAKE
EAS22670
INSTALLING THE REAR BRAKE CALIPER
1. Install:
• Brake caliper “1”
(temporarily)
Recommended fluid
DOT 4
1. Install:
• Brake caliper piston seal “1” New
• Copper washers “2” New
• Brake caliper piston dust seal “2” New
31 Nm (3.1 m·kgf, 22 ft·lbf)
EWA13530
WARNING
2. Install:
ECA2PA1404
brake caliper “1”, make sure the brake pipe
touches the projection “a” on the brake caliper.
3. Install:
• Parking brake arm “1”
4. Measure:
• Parking brake arm to parking brake
bracket distance “a”
2. Remove:
• Brake caliper
3. Install:
• Brake pads
Parking brake arm to parking
brake bracket distance
73.3 mm (2.89 in)
•
•
•
•
Lock washer New
Brake pad retaining bolts
Brake caliper
Brake caliper bolts
Refer to “REPLACING THE REAR
BRAKE PADS” on page 4-35.
17 Nm (1.7 m·kgf, 12 ft·lbf)
Brake caliper bolt
34 Nm (3.4 m·kgf, 25 ft·lbf)
4-38
REAR BRAKE
7. Check:
• Brake pedal operation
system.
4. Fill:
• Brake fluid reservoir
Recommended fluid
DOT 4
EAS22700
REMOVING THE REAR BRAKE MASTER
CYLINDER
EWA13090
WARNING
lock.
TIP
Before removing the rear brake master cylinder, drain the brake fluid from the entire brake
system.
1. Remove:
• Rear brake hose union bolt “1”
• Rear brake hose “3”
TIP
To collect any remaining brake fluid, place a
container under the master cylinder and the
end of the brake hose.
ECA13540
5. Bleed:
• Brake system
6. Check:
proper level.
EAS22720
CHECKING THE REAR BRAKE MASTER
CYLINDER
1. Check:
(brake master cylinder body)
air.
4-39
REAR BRAKE
2. Check:
• Brake master cylinder kit “1”
TIP
Turn the adjusting bolt “3” until the clearance
“a” is within the specified limits when install the
joint “2”.
Clearance
2.7 mm (0.11 in)
3. Check:
• Brake fluid reservoir “1”
• Brake fluid reservoir diaphragm “2”
Nut
17 Nm (1.7 m·kgf, 12 ft·lbf)
EAS22740
INSTALLING THE REAR BRAKE MASTER
CYLINDER
1. Install:
• Copper washers New
• Brake hoses “1”
4. Check:
• Brake hose
31 Nm (3.1 m·kgf, 22 ft·lbf)
EAS22730
ASSEMBLING THE REAR BRAKE MASTER
CYLINDER
EWA13530
WARNING
EWA13520
WARNING
components.
ECA14160
brake master cylinder, make sure the brake
pipe “a” touches the projection “b” as
shown.
Recommended fluid
DOT 4
1. Install:
• Brake master cylinder kit
• Nut “1”
• Joint “2”
4-40
REAR BRAKE
ECA13540
4. Bleed:
• Brake system
5. Check:
proper level.
2. Install:
• Brake fluid reservoir hose “1”
TIP
Install the brake fluid reservoir hose with the
white paint mark “a” facing up as shown.
3. Fill:
• Brake fluid reservoir
6. Adjust:
• Brake pedal position
Refer to “ADJUSTING THE BRAKE
PEDAL” on page 3-13.
Recommended fluid
DOT 4
Brake pedal height
6.9 mm (0.27 in)
EWA13090
WARNING
lock.
7. Adjust:
Refer to “ADJUSTING THE REAR
BRAKE LIGHT SWITCH” on page 3-25.
4-41
HANDLEBAR
EAS22840
HANDLEBAR
Removing the handlebar
Order
1
2
3
4
5
6
7
8
9
10
11
12
13
Job/Parts to remove
Handlebar protector
Band
Brake master cylinder/bracket
Throttle lever assembly/bracket
Spacer
Clutch switch
Parking brake lever
Clutch lever/bracket
Handlebar switch
Handlebar grip
Handlebar holder
Handlebar
Q’ty
1
3
1
1/1
1/1
1
1
1
1/1
1
2
2
1
Remarks
4-42
HANDLEBAR
EAS22860
EAS22911
REMOVING THE HANDLEBAR
1. Remove:
• Clutch switch “1”
INSTALLING THE HANDLEBAR
1. Install:
• Handlebar
• Handlebar holders
TIP
Push the fastener when removing the clutch
switch out of the clutch lever holder.
Handlebar holder bolt
20 Nm (2.0 m·kgf, 14 ft·lbf)
TIP
• Install the handlebar horizontally shown in
the illustration.
• The handlebar holder should be installed
with the punched mark “1” forward “2”.
ECA2PA1403
First, tighten the bolts “3” on the front side
of the handlebar holder, and then the bolts
“4” on the rear side.
2. Remove:
• Handlebar grip “1”
TIP
Blow compressed air between the left handlebar and the handlebar grip, and gradually push
the grip off the handlebar.
EAS22880
CHECKING THE HANDLEBAR
1. Check:
• Handlebar “1”
Bends/cracks/damage → Replace.
EWA13690
WARNING
Do not attempt to straighten a bent handlebar as this may dangerously weaken it.
2. Install:
• Handlebar grips “1”
4-43
HANDLEBAR
4. Install:
• Throttle lever assembly
• Spacer
• Brake master cylinder
TIP
• Before applying the adhesive, wipe off
grease or oil on the handlebar surface “a”
with a lacquer thinner.
• Install the handlebar grips so that the “L”
arrow on the left grip and “R” arrow on the
right grip are placed vertically.
bolt
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
TIP
• Engage the indentations “a” in the spacer
with the lobes “b” on the throttle lever assembly and brake master cylinder.
• The “UP” mark on the brake master cylinder
bracket should face up.
• Install the brake lever “1” at 10 degrees angle
as shown.
3. Install:
• Handlebar switch “1”
• Clutch lever
• Clutch lever bracket “2”
Clutch lever bracket bolt
4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
TIP
• Install the clutch lever bracket as shown.
• Install the clutch lever “3” at 10 degrees
angle as shown.
5. Install:
• Clutch switch
• Front brake light switch
6. Adjust:
Refer to “ADJUSTING THE CLUTCH
a. 53–54 mm (2.09–2.13 in)
5.0–10.0 mm (0.20–0.39 in)
7. Adjust:
4-44
HANDLEBAR
2.0–4.0 mm (0.08–0.16 in)
4-45
STEERING STEM
EAS29540
STEERING STEM
Removing the steering stem
Order
1
2
3
4
5
6
7
Job/Parts to remove
Q’ty
Front fender
Lock washer
Bracket
Steering stem bushing
Spacer
Oil seal
Steering stem
Bushing
Remarks
1
1
2
2
2
1
2
4-46
STEERING STEM
EAS29560
EAS29580
CHECKING THE STEERING STEM
1. Check:
• Steering stem “1”
Bends → Replace.
INSTALLING THE LOCK WASHER
1. Install:
• Lock washer “1” New
• Steering stem bushing bolts
EWA15030
WARNING
Steering stem bushing bolt
23 Nm (2.3 m·kgf, 17 ft·lbf)
Do not attempt to straighten a bent stem;
this may dangerously weaken the stem.
2. Bend the lock washer tabs along a flat side
of the bolts.
2. Check:
• Oil seals “1” New
• Steering stem bushings “2”
3. Check:
• O-rings “1” New
• Bushings “2”
EAS2PA1405
INSTALLING THE STEERING STEM
1. Install:
• Steering stem
TIP
Pass the throttle cable through the cable guide.
Refer to “CABLE ROUTING” on page 2-27.
4-47
TIE-RODS AND STEERING KNUCKLES
EAS29660
Removing the tie-rods and steering knuckles
Order
1
2
3
4
Job/Parts to remove
Q’ty
Front wheel
Front brake caliper/Brake disc
Brake disc guard (inner)
Tie-rod
Front bumper
Steering knuckle
Remarks
the tie-rods and steering knuckles.
1
1
1
1
4-48
EAS29670
REMOVING THE STEERING KNUCKLES
steering knuckles.
1. Remove:
• Steering knuckle “1”
TIP
Use a general puller to separate the ball joints
“2” from the steering knuckle “1”.
EAS29700
INSTALLING THE TIE-RODS
tie-rods.
1. Install:
• Tie-rod
Tie-rod nut
25 Nm (2.5 m·kgf, 18 ft·lbf)
TIP
Install the tie-rod so that the groove “1” is on
the wheel side.
EAS29680
CHECKING THE TIE-RODS
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. Adjust:
• Toe-in
Refer to “ADJUSTING THE TOE-IN” on
page 3-20.
2. Check:
• Tie-rod
Bends/damage → Replace.
EAS29690
CHECKING THE STEERING KNUCKLES
steering knuckles.
1. Check:
• Steering knuckle
Damage/pitting → Replace.
4-49
FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES
EAS29710
Removing the front arms and front shock absorber assemblies
Order
Job/Parts to remove
Q’ty
Front wheel
Front brake caliper/Brake disc
Steering knuckle
1
2
3
4
5
6
7
8
Front lower arm
Brake hose holder
Front upper arm
Dust cover
Spacer
Spacer
Bushing
Remarks
the front upper arms, front lower arms, and
Refer to “TIE-RODS AND STEERING
KNUCKLES” on page 4-48.
1
1
1
1
6
1
2
6
4-50
EAS29720
REMOVING THE FRONT ARMS
front upper arms and front lower arms.
1. Check:
• Front arm free play
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Check the front arm side play “A” by moving it from side to side.
If side play is noticeable, check the bushings.
EAS2PA1406
REMOVING THE FRONT SHOCK
ABSORBER ASSEMBLY
EWA2PA1402
WARNING
TIP
the front wheel is elevated.
b. Check the front arm vertical movement “B”
by moving it up and down.
If the vertical movement is tight or rough, or
if there is binding, check the bushings.
2. Remove:
• Front wheel
• Front shock absorber assembly lower bolt
• Front shock absorber assembly upper
bolt
TIP
While removing the front shock absorber
assembly lower bolt, hold the front lower arm
so that it does not drop down.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS29760
2. Remove:
• Front arm
CHECKING THE FRONT SHOCK
ABSORBER ASSEMBLIES
1. Check:
Oil leaks → Replace the front shock
absorber assembly.
• Front shock absorber rod
Bends/damage → Replace the front
• Spring
Move the spring up and down.
Fatigue → Replace the front shock
absorber assembly.
EAS29730
CHECKING THE FRONT ARMS
front upper arms and front lower arms.
1. Check:
• Front upper arm “1”
• Front lower arm “2”
2. Check:
• Bushings “3”
4-51
c. Install the steering knuckle.
Upper steering knuckle nut
25 Nm (2.5 m·kgf, 18 ft·lbf)
Lower steering knuckle nut
25 Nm (2.5 m·kgf, 18 ft·lbf)
d. Install the new cotter pins.
e. Tighten the front upper and lower arm nuts
to specification.
EAS29770
CHECKING THE FRONT ARM BALL JOINTS
The following procedure applies to each of the
front arm ball joints.
1. Check:
• Ball joint
Damage/pitting → Replace the front arm.
Free play → Replace the front arm.
Turns roughly → Replace the front arm.
Front upper arm nut
45 Nm (4.5 m·kgf, 33 ft·lbf)
Front lower arm nut
45 Nm (4.5 m·kgf, 33 ft·lbf)
TIP
Apply lithium-soap-based grease to the grease
nipples “3”.
EAS29790
INSTALLING THE FRONT ARMS AND
FRONT SHOCK ABSORBER ASSEMBLIES
front upper arms, front lower arms, and front
shock absorber assemblies.
1. Install:
• Front upper arm “1”
• Front lower arm “2”
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the front upper arm “1” and front
lower arm “2”.
TIP
• Be sure to position the front upper and lower
arm bolts so that the bolt heads face forward.
• Temporarily tighten the front upper and lower
arm nuts.
b. Install the front shock absorber assembly.
nut
48 Nm (4.8 m·kgf, 35 ft·lbf)
4-52
REAR SHOCK ABSORBER ASSEMBLY
EAS23160
Removing the rear shock absorber assembly
Order
1
Job/Parts to remove
Seat/Rear fender/Air filter case
Q’ty
Remarks
1
4-53
EAS23170
TIP
HANDLING THE REAR SHOCK ABSORBER
EWA13750
WARNING
This rear shock absorber contains highly
compressed nitrogen gas. Before handling
the rear shock absorber, read and make
sure you understand the following information. The manufacturer cannot be held
responsible for property damage or personal injury that may result from improper
handling of the rear shock absorber.
• Do not tamper or attempt to open the rear
shock absorber.
• Do not subject the rear shock absorber to
an open flame or any other source of high
heat. High heat can cause an explosion
due to excessive gas pressure.
• Do not deform or damage the rear shock
absorber in any way. Rear shock absorber
damage will result in poor damping performance.
2. Remove:
• Rear shock absorber assembly lower bolt
• Rear shock absorber assembly upper
bolt
TIP
While removing the rear shock absorber
assembly lower bolt, hold the swingarm so that
it does not drop down.
EAS23250
CHECKING THE REAR SHOCK ABSORBER
ASSEMBLY
1. Check:
• Rear shock absorber rod
Bends/damage → Replace the rear
• Rear shock absorber
Gas leaks/oil leaks → Replace the rear
• Spring
Damage/wear → Replace the rear shock
absorber assembly.
EAS23200
DISPOSING OF A REAR SHOCK
ABSORBER
1. Gas pressure must be released before disposing of a rear shock absorber. To release
the gas pressure, drill a 2–3 mm (0.08–
0.12 in) hole through the rear shock
absorber at a point 15–20 mm (0.59–0.79
in) from its end as shown.
EWA13760
WARNING
Wear eye protection to prevent eye damage
from released gas or metal chips.
EAS23300
INSTALLING THE REAR SHOCK
ABSORBER ASSEMBLY
1. Install:
• Rear shock absorber assembly
TIP
When installing the rear shock absorber
assembly lower bolt, lift up the swingarm.
nut
55 Nm (5.5 m·kgf, 40 ft·lbf)
EAS23210
REMOVING THE REAR SHOCK ABSORBER
ASSEMBLY
EWA13120
WARNING
4-54
SWINGARM
EAS23330
SWINGARM
Removing the swingarm
Order
Job/Parts to remove
Q’ty
Rear axle hub
1
2
3
4
5
6
7
8
9
Plate
Swingarm end cover
Pivot shaft nut/washer
Pivot shaft
Swingarm
Drive chain guide 1
Dust cover/oil seal
Spacer
Bearing
Remarks
Refer to “REAR AXLE AND REAR AXLE
HUB” on page 4-12.
Refer to “REAR SHOCK ABSORBER
ASSEMBLY” on page 4-53.
1
1
1/1
1
1
1
2/2
1
2
4-55
SWINGARM
3. Remove:
• Pivot shaft nut
• Washer
• Pivot shaft
• Swingarm
EAS23340
REMOVING THE SWINGARM
EWA13120
WARNING
EAS23361
CHECKING THE SWINGARM
1. Check:
• Swingarm
TIP
2. Measure:
• Swingarm side play
• Swingarm vertical movement
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure the tightening torque of the swingarm pivot shaft nut.
Pivot shaft nut
100 Nm (10 m·kgf, 72 ft·lbf)
2. Check:
• Pivot shaft
Roll the pivot shaft on a flat surface.
Bends → Replace.
b. Measure the swingarm end free play (axial)
“A” by moving the swingarm from side to
side.
c. If the swingarm side play is out of specification, check the spacers and bearings.
EWA13770
WARNING
Do not attempt to straighten a bent pivot
shaft.
Swingarm end free play limit
(axial)
1.0 mm (0.04 in)
d. Measure the swingarm end free play
(radial) “B” by moving the swingarm up and
down.
e. If swingarm vertical movement is not
smooth or if there is binding, check the
spacers and bearings.
Swingarm end free play limit
(radial)
1.0 mm (0.04 in)
3. Wash:
• Pivot shaft
• Dust covers
• Spacer
• Bearings
Recommended cleaning solvent
Kerosene
4. Check:
• Dust covers
• Spacer
• Bearings
Damage/pitting → Replace.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4-56
SWINGARM
EAS23380
INSTALLING THE SWINGARM
1. Lubricate:
• Bearings
• Spacer
• Oil seals
2. Install:
• Spacer “2”
• Oil seals New
• Dust covers
TIP
Inject the bearing with the character stamp
turned outward.
Installed depth of bearing “a”
1–2 mm (0.04–0.08 in)
3. Install:
• Pivot shaft
Pivot shaft nut
100 Nm (10 m·kgf, 72 ft·lbf)
4. Install:
• Rear shock absorber assembly
• Rear axle hub
• Rear axle
• Rear wheel
Refer to “REAR WHEEL” on page 4-10,
“REAR SHOCK ABSORBER ASSEMBLY” on page 4-53 and “REAR AXLE
AND REAR AXLE HUB” on page 4-12.
5. Adjust:
Refer to “ADJUSTING THE DRIVE
CHAIN SLACK” on page 3-17.
Drive chain slack
45.0–55.0 mm (1.77–2.17 in)
4-57
CHAIN DRIVE
EAS23400
CHAIN DRIVE
Removing the drive chain
Order
1
2
3
4
5
Job/Parts to remove
Swingarm
Drive sprocket cover
Drive chain guide
Drive sprocket lock plate
Drive sprocket
Drive chain
Q’ty
Remarks
1
1
1
1
1
4-58
CHAIN DRIVE
• Perform this procedure 2–3 times, at a different location each time.
EAS23410
REMOVING THE DRIVE CHAIN
EWA13120
WARNING
TIP
2. Remove:
• Swingarm
3. Remove:
• Drive chain
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Clean:
• Drive chain
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
EAS23441
CHECKING THE DRIVE CHAIN
1. Measure:
• 15-link section “a” of the drive chain
Out of specification → Replace the drive
chain.
a. Wipe the drive chain with a clean cloth.
b. Put the drive chain in kerosene and remove
any remaining dirt.
c. Remove the drive chain from the kerosene
and completely dry it.
ECA14290
15-link length limit
191.5 mm (7.54 in)
• This vehicle has a drive chain with small
rubber O-rings “1” between the drive
chain side plates. Never use high-pressure water or air, steam, gasoline, certain
solvents (e.g., benzine), or a coarse brush
to clean the drive chain. High-pressure
methods could force dirt or water into the
drive chain’s internals, and solvents will
deteriorate the O-rings. A coarse brush
can also damage the O-rings. Therefore,
use only kerosene to clean the drive
chain.
• Do not soak the drive chain in kerosene
for more than ten minutes, otherwise the
O-rings can be damaged.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure the length “a” between the inner
sides of the pins and the length “b”
between the outer sides of the pins on a
15-link section of the drive chain as shown
in the illustration.
b. Calculate the length “c” of the 15-link section of the drive chain using the following
formula.
Drive chain 15-link section length “c” =
(length “a” between pin inner sides + length
“b” between pin outer sides)/2
TIP
• When measuring a 15-link section of the
drive chain, make sure that the drive chain is
taut.
4-59
CHAIN DRIVE
b. Correct
1. Drive chain roller
2. Drive chain sprocket
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Check:
• O-rings “1”
Damage → Replace the drive chain.
• Drive chain rollers “2”
Damage/wear → Replace the drive
chain.
• Drive chain side plates “3”
Damage/wear → Replace the drive
chain.
Cracks → Replace the drive chain.
EAS23470
CHECKING THE REAR WHEEL SPROCKET
Refer to “CHECKING THE DRIVE
SPROCKET” on page 4-60.
EAS4D3F030
CHECKING THE SPROCKET BRACKET
Refer to “CHECKING THE SPROCKET
BRACKET” on page 4-15.
EAS23500
INSTALLING THE DRIVE CHAIN
1. Lubricate:
• Drive chain
2. Install:
• Drive chain
• Drive sprocket
• Drive sprocket lock plate
• Drive sprocket bolts
4. Lubricate:
• Drive chain
Drive sprocket bolt
6 Nm (0.6 m·kgf, 4.3 ft·lbf)
TIP
EAS23460
While applying the rear brake, tighten the drive
sprocket bolt.
CHECKING THE DRIVE SPROCKET
1. Check:
• Drive 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.
3. Install:
• Swingarm
4. Adjust:
Refer to “ADJUSTING THE DRIVE
CHAIN SLACK” on page 3-17.
Drive chain slack
45.0–55.0 mm (1.77–2.17 in)
4-60
CHAIN DRIVE
ECA13550
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.
4-61
ENGINE
ENGINE REMOVAL ......................................................................................5-1
INSTALLING THE ENGINE ....................................................................5-4
INSTALLING THE MUFFLER AND EXHAUST PIPE..............................5-4
CYLINDER HEAD.........................................................................................5-6
REMOVING THE CYLINDER HEAD ......................................................5-8
CHECKING THE CYLINDER HEAD ......................................................5-8
CHECKING THE TAPPET COVERS AND CAMSHAFT SPROCKET
COVER ...................................................................................................5-9
CHECKING THE CAMSHAFT SPROCKET ...........................................5-9
CHECKING THE TIMING CHAIN TENSIONER .....................................5-9
INSTALLING THE CYLINDER HEAD ...................................................5-10
CAMSHAFT ................................................................................................5-13
REMOVING THE ROCKER ARMS AND CAMSHAFT .........................5-14
CHECKING THE CAMSHAFT ..............................................................5-14
CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS ......5-15
INSTALLING THE CAMSHAFT AND ROCKER ARMS ........................5-16
VALVES AND VALVE SPRINGS ................................................................5-18
REMOVING THE VALVES ....................................................................5-19
CHECKING THE VALVES AND VALVE GUIDES .................................5-19
CHECKING THE VALVE SEATS ..........................................................5-21
CHECKING THE VALVE SPRINGS......................................................5-23
INSTALLING THE VALVES...................................................................5-24
CYLINDER AND PISTON ...........................................................................5-26
REMOVING THE PISTON ....................................................................5-27
CHECKING THE TIMING CHAIN GUIDE.............................................5-27
CHECKING THE CYLINDER AND PISTON.........................................5-27
CHECKING THE PISTON RINGS ........................................................5-28
CHECKING THE PISTON PIN .............................................................5-29
INSTALLING THE PISTON AND CYLINDER .......................................5-30
CLUTCH......................................................................................................5-31
REMOVING THE CLUTCH...................................................................5-35
CHECKING THE FRICTION PLATES ..................................................5-35
CHECKING THE CLUTCH PLATES.....................................................5-35
CHECKING THE CLUTCH SPRINGS ..................................................5-36
CHECKING THE CLUTCH HOUSING .................................................5-36
CHECKING THE CLUTCH BOSS ........................................................5-36
CHECKING THE PRESSURE PLATE ..................................................5-36
CHECKING THE CLUTCH PUSH LEVER AND CLUTCH PUSH
ROD ......................................................................................................5-37
CHECKING THE PRIMARY DRIVE GEAR AND PRIMARY DRIVEN
GEAR....................................................................................................5-37
INSTALLING THE CLUTCH..................................................................5-37
5
OIL PUMP ...................................................................................................5-40
CHECKING THE OIL PUMP ................................................................5-42
CHECKING THE ROTARY FILTER.......................................................5-42
ASSEMBLING THE OIL PUMP ............................................................5-42
INSTALLING THE OIL PUMP ...............................................................5-43
SHIFT SHAFT .............................................................................................5-45
CHECKING THE SHIFT SHAFT ..........................................................5-46
CHECKING THE STOPPER LEVER ....................................................5-46
CHECKING THE SHIFT DRUM SEGMENT .........................................5-46
INSTALLING THE SHIFT SHAFT .........................................................5-46
GENERATOR AND STARTER CLUTCH....................................................5-48
REMOVING THE GENERATOR ROTOR .............................................5-50
REMOVING THE STARTER CLUTCH .................................................5-50
CHECKING THE STATOR COIL ASSEMBLY .......................................5-51
CHECKING THE STARTER CLUTCH ..................................................5-51
INSTALLING THE STARTER CLUTCH ................................................5-51
INSTALLING THE GENERATOR ROTOR ............................................5-52
ELECTRIC STARTER.................................................................................5-54
CHECKING THE STARTER MOTOR ...................................................5-56
ASSEMBLING THE STARTER MOTOR ...............................................5-57
CRANKCASE .............................................................................................5-58
DISASSEMBLING THE CRANKCASE .................................................5-61
CHECKING THE CRANKCASE ...........................................................5-61
CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDE ..........5-61
CHECKING THE BEARINGS ...............................................................5-61
ASSEMBLING THE CRANKCASE .......................................................5-61
CRANKSHAFT ASSEMBLY.......................................................................5-63
REMOVING THE CRANKSHAFT AND BALANCER ............................5-64
CHECKING THE CRANKSHAFT AND CONNECTING ROD...............5-64
CHECKING THE BALANCER ..............................................................5-65
INSTALLING THE CRANKSHAFT ASSEMBLY ....................................5-65
INSTALLING THE BALANCER.............................................................5-65
TRANSMISSION.........................................................................................5-66
REMOVING THE TRANSMISSION ......................................................5-69
CHECKING THE SHIFT FORKS ..........................................................5-69
CHECKING THE SHIFT DRUM............................................................5-69
CHECKING THE TRANSMISSION ......................................................5-69
CHECKING THE LONG CLUTCH PUSH ROD ....................................5-70
ASSEMBLING THE MAIN AXLE AND DRIVE AXEL ...........................5-70
INSTALLING THE SHIFT FORKS AND SHIFT DRUM.........................5-71
ENGINE REMOVAL
EAS23711
ENGINE REMOVAL
Removing the exhaust pipe and muffler
Order
1
2
3
4
5
6
7
8
Job/Parts to remove
Muffler clamp
Muffler
Muffler gasket
Spark arrester
Gasket
Exhaust pipe
EXhaust pipe protector
Gasket
Q’ty
1
1
1
1
1
1
1
1
Remarks
Loosen.
5-1
ENGINE REMOVAL
Disconnecting the leads and hoses
Order
1
2
3
4
5
6
7
Job/Parts to remove
Q’ty
Carburetor
Drive sprocket
Spark plug cap
Crankcase breather hose
Battery negative lead
Starter motor lead
Starter motor lead guard
Clutch cable
AC magneto coupler
1
1
1
1
1
1
2
* Yamaha bond No.1215 (Three bond No.1215®)
5-2
Remarks
Refer to “CARBURETOR” on page 6-3.
Refer to “CHAIN DRIVE” on page 4-58.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
For assembly, reverse the removal procedure.
ENGINE REMOVAL
Removing the engine
Order
1
2
3
4
5
6
7
Job/Parts to remove
Engine mounting bolt (front)
Engine bracket (left and right)
Engine mounting bolt (upper)
Engine bracket (upper)
Engine mounting bolt (rear upper)
Engine mounting bolt (rear lower)
Engine
Q’ty
1
2
1
1
1
1
1
Remarks
5-3
ENGINE REMOVAL
EAS23720
INSTALLING THE ENGINE
1. Install:
• Engine mounting bolt (rear lower side) “1”
• Engine mounting bolt (rear upper side)
“2”
• Engine bracket bolts (upper side) “3”
• Engine mounting bolt (upper side) “4”
• Engine brackets (front side) “5” “6”
• Engine mounting bolt (front side) “7”
TIP
• The direction of the bolt insertion is made
from the right side of the body.
• Do not fully tighten the bolts.
2. Tighten:
• Engine bracket bolts (upper side) “3”
• Engine mounting nut (rear lower side) “1”
• Engine mounting nut (rear upper side) “2”
• Engine mounting nut (upper side) “4”
• Engine mounting nut (front side) “7”
• Engine bracket bolts (front side)
EAS2PA1001
INSTALLING THE MUFFLER AND EXHAUST
PIPE
1. Install:
• Exhaust pipe protector “1”
• Exhaust pipe protector screws “2”
(to exhaust pipe)
Engine bracket bolt (upper side)
33 Nm (3.3 m·kgf, 24 ft·lbf)
Engine mounting nut (rear
lower side)
44 Nm (4.4 m·kgf, 32 ft·lbf)
Engine mounting nut (rear
upper side)
44 Nm (4.4 m·kgf, 32 ft·lbf)
Engine mounting nut (upper
side)
40 Nm (4.0 m·kgf, 29 ft·lbf)
Engine mounting nut (front
side)
40 Nm (4.0 m·kgf, 29 ft·lbf)
Engine bracket bolt (front side)
33 Nm (3.3 m·kgf, 24 ft·lbf)
Exhaust pipe protector screw
8 Nm (0.8 m·kgf, 5.9 ft·lbf)
LOCTITE®
2. Install:
• Gasket New
• Exhaust pipe “1”
• Exhaust pipe bolts “2”
Exhaust pipe bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
5-4
ENGINE REMOVAL
TIP
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.
3. Install:
• Muffler gasket “1” New
(to muffler)
Installed depth of gasket “a”
3.5 mm (0.14 in)
4. Install:
• Gasket “1” New
• Spark arrester “2”
(to muffler)
Spark arrester bolt
11 Nm (1.1 m·kgf, 8.0 ft·lbf)
5. Install:
• Muffler clamp
Muffler clamp bolt
20 Nm (2.0 m·kgf, 14 ft·lbf)
5-5
CYLINDER HEAD
EAS24100
CYLINDER HEAD
Removing the cylinder head
Order
1
2
3
4
5
6
7
8
9
10
Job/Parts to remove
Spark plug cap
Fuel tank
Carburetor
Engine bracket (upper)
Spark plug
Camshaft sprocket cover
Intake tappet cover
Exhaust tappet cover
Timing chain tensioner assembly
Timing chain tensioner gasket
Camshaft sprocket
Cylinder head
Q’ty
1
1
1
1
1
1
1
1
1
1
5-6
Remarks
Refer to “ENGINE REMOVAL” on page 5-1.
Refer to “FUEL TANK” on page 6-1.
Refer to “CARBURETOR” on page 6-3.
CYLINDER HEAD
Removing the cylinder head
Order
11
12
13
14
Job/Parts to remove
Plate
Gasket
Cylinder head gasket
Dowel pin
Q’ty
1
1
1
2
Remarks
5-7
CYLINDER HEAD
4. Remove:
• Timing chain tensioner
(along with the gasket)
• Camshaft sprocket
• Timing chain
EAS24130
REMOVING THE CYLINDER HEAD
1. Align:
• “I” mark “a” on the generator rotor
(with the stationary pointer “b” on the
generator rotor cover)
TIP
To prevent the timing chain from falling into the
crankcase, fasten it with a wire.
5. Remove:
• Cylinder head
TIP
• Loosen the bolts in the proper sequence as
shown.
• Loosen each nut 1/2 of a turn at a time. After
all of the bolts are fully loosened, remove
them.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
b. When the piston is at TDC on the compression stroke, align the “I” mark “c” on the
camshaft sprocket with the mark “d” on the
cylinder head.
EAS24160
CHECKING THE CYLINDER HEAD
1. Eliminate:
• Combustion chamber carbon deposits
(with a rounded scraper)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
TIP
2. Loosen:
• Camshaft sprocket bolt “1”
Do not use a sharp instrument to avoid damaging or scratching:
• Spark plug bore threads
• Valve seats
TIP
While holding the generator rotor nut with a
wrench, remove the bolt.
2. Check:
• Cylinder head
Damage/scratches → Replace.
3. Loosen:
• Timing chain tensioner cap bolt
5-8
CYLINDER HEAD
3. Measure:
• Cylinder head warpage
Out of specification → Resurface the cylinder head.
Warpage limit
0.03 mm (0.0012 in)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. 1/4 tooth
b. Correct
a. Place a straightedge “1” and a thickness
gauge “2” across the cylinder head.
1. Timing chain
2. Camshaft sprocket
EAS24200
CHECKING THE TIMING CHAIN TENSIONER
1. Check:
Cracks/damage/rough movement →
Replace.
2. Check:
• One-way cam operation
Rough movement → Replace the timing
chain tensioner assembly.
b. Measure the warpage.
c. If the limit is exceeded, resurface the cylinder head as follows.
d. Place a 400–600 grit wet sandpaper on the
surface plate and resurface the cylinder
head using a figure-eight sanding pattern.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Lightly press the timing chain tensioner rod
into the timing chain tensioner housing by
hand.
TIP
TIP
To ensure an even surface, rotate the cylinder
head several times.
While pressing the timing chain tensioner rod,
wind it clockwise with a thin screwdriver “1”
until it stops.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS00212
CHECKING THE TAPPET COVERS AND
CAMSHAFT SPROCKET COVER
tappet covers.
1. Check:
• Tappet covers
• Camshaft sprocket cover
Damage/wear → Replace the defective
part(s).
b. Remove the screwdriver and slowly release
the timing chain tensioner rod.
c. Make sure that the timing chain tensioner
rod comes out of the timing chain tensioner
housing smoothly. If there is rough movement, replace the timing chain tensioner.
EAS24180
CHECKING THE CAMSHAFT SPROCKET
1. Check:
• Camshaft sprocket
More than 1/4 tooth wear “a” → Replace
the camshaft sprocket and the timing
chain as a set.
5-9
CYLINDER HEAD
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Fill:
• Cylinder head
Engine oil (5 ml or more) into the space
“a”.
3. Check:
• Timing chain tensioner cap bolt
• Timing chain tensioner rod
Damage/wear → Replace the timing
chain tensioner assembly.
TIP
Be sure to add engine oil every time the cylinder head is removed.
EAS24230
INSTALLING THE CYLINDER HEAD
1. Install:
• Dowel pins
• Cylinder head gasket New
2. Install:
• Cylinder head
• Washers New
• Cylinder head bolts
TIP
• Apply Yamaha bond No.1215 (Three bond
No.1215®) to the threads of the cylinder
head bolts “5”, “6”.
• Lubricate the contact surfaces of the cylinder
head bolts and on both contact surfaces of
washers with engine oil.
5. Install:
• Camshaft sprocket “1”
• Timing chain “2”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
b. Align the “I” mark “a” on the generator rotor
with the stationary pointer “b” on the generator rotor cover.
3. Tighten:
• Cylinder head bolts
Cylinder head bolt “1”–“4”
22 Nm (2.2 m·kgf, 16 ft·lbf)
Cylinder head bolt “5”, “6”
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
TIP
Tighten the cylinder head bolts in the proper
tightening sequence as shown and torque
them in two stages.
c. Align the “I” mark “c” on the camshaft
sprocket with the stationary pointer “d” on
the cylinder head.
d. Install the timing chain onto the camshaft
sprocket, and then install the camshaft
sprocket onto the camshaft.
5-10
CYLINDER HEAD
ECA13740
Timing chain tensioner bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Do not turn the crankshaft when installing
the camshaft sprocket to avoid damage or
improper valve timing.
TIP
• When installing the camshaft sprocket, be
sure to keep the timing chain as tight as possible on the exhaust side.
• Align the projection “e” on the camshaft
sprocket with the slot in the camshaft.
c. Turn the timing chain tensioner rod counterclockwise with a thin screwdriver “1”,
make sure it releases, and then tighten the
cap bolt to specification.
8 Nm (0.8 m·kgf, 5.8 ft·lbf)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7. Turn:
• Crankshaft
(several turns counterclockwise)
8. Check:
• “I” mark “a”
Align the “I” mark on the generator rotor
with the stationary pointer “b” on the generator rotor cover.
e. While holding the camshaft, temporarily
tighten the camshaft sprocket bolt.
f. Remove the wire from the timing chain.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6. Install:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. While lightly pressing the timing chain tensioner rod by hand, turn the tensioner rod
fully clockwise with a thin screwdriver “1”.
TIP
Make sure that the tensioner rod has been fully
set clockwise.
• “I” mark “c”
Align the “I” mark on the camshaft
sprocket with the stationary pointer “d” on
the cylinder head.
Out of alignment → Correct.
Refer to the installation steps above.
b. Install the gasket and the timing chain tensioner “2” onto the cylinder.
EWA2PA1501
WARNING
Always use a new gasket.
5-11
CYLINDER HEAD
9. Tighten:
• Camshaft sprocket bolts
Camshaft sprocket bolt
26 Nm (2.6 m·kgf, 19 ft·lbf)
ECA13750
Be sure to tighten the camshaft sprocket
bolts to the specified torque to avoid the
possibility of the bolts coming loose and
damaging the engine.
10. Measure:
• Valve clearance
Refer to “ADJUSTING THE VALVE
CLEARANCE” on page 3-4.
11. Install:
• Gasket New
• Plate “1”
Plate bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
TIP
• Make sure the projection “a” of the gasket
face toward the upper side of the vehicle.
• Make sure that the blunt-edged corner “b” of
the plate is facing upward.
5-12
CAMSHAFT
EAS23730
CAMSHAFT
Removing the rocker arms and camshaft
T.
R.
8 Nm (0.8 m kgf, 5.8 ft Ibf)
1
1
6
E
7
E
M
5
LS
2
M
3
E
5
New
4
LT
8
9
E
T.
1
R.
1
2
3
4
5
6
7
8
9
10 Nm (1.0 m kgf, 7.2 ft Ibf)
E
1
T.
Order
R
M
8 Nm (0.8 m kgf, 5.8 ft Ibf)
Job/Parts to remove
Intake tappet cover/exhaust tappet cover
Camshaft sprocket
Locknut/valve clearance adjusting screw
Camshaft retainer
Camshaft
Camshaft bushing
Camshaft bearing
Intake rocker arm shaft
Intake rocker arm
Exhaust rocker arm shaft
Exhaust rocker arm
Q’ty
2/2
1
1
1
2
1
1
1
1
Remarks
Refer to “CYLINDER HEAD” on page 5-6.
Loosen.
5-13
CAMSHAFT
EAS23770
TIP
REMOVING THE ROCKER ARMS AND
CAMSHAFT
1. Loosen:
• Locknuts “1”
• Valve clearance adjusting screws “2”
Remove the rocker arm shafts with the slide
hammer bolt “1” and weight “2”.
Slide hammer bolt
90890-01083
YU-01083-1
Weight
90890-01084
YU-01083-3
2. Remove:
• Camshaft retainer “1”
EAS23840
CHECKING THE CAMSHAFT
1. Check:
• Camshaft bushings
2. Check:
• Camshaft lobes
Blue discoloration/pitting/scratches →
Replace the camshaft.
3. Measure:
• Camshaft lobe dimensions “a” and “b”
Out of specification → Replace the camshaft.
3. Remove:
• Camshaft “1”
TIP
Screw 8 mm (0.31 in) bolt “2” into the threaded
end of the camshaft and then pull out the camshaft.
4. Remove:
• Intake rocker arm shaft
• Intake rocker arm
• Exhaust rocker arm shaft
• Exhaust rocker arm
5-14
CAMSHAFT
Camshaft lobe dimensions
Intake A
25.881–25.981 mm (1.0189–
1.0229 in)
Limit
25.851 mm (1.0178 in)
Intake B
21.194–21.294 mm (0.8344–
0.8383 in)
Limit
21.165 mm (0.8333 in)
Exhaust A
25.841–25.941 mm (1.0174–
1.0213 in)
Limit
25.811 mm (1.0162 in)
Exhaust B
20.997–21.097 mm (0.8267–
0.8306 in)
Limit
20.967 mm (0.8255 in)
EAS23880
CHECKING THE ROCKER ARMS AND
ROCKER ARM SHAFTS
rocker arms and rocker arm shafts.
1. Check:
• Rocker arms
2. Check:
• Rocker arm shafts
Blue discoloration/excessive wear/pitting/
scratches → Replace or check the lubrication system.
3. Check:
• Camshaft lobe
Excessive wear → Replace the camshaft.
4. Measure:
• Rocker arm inside diameter “a”
Rocker arm inside diameter
10.000–10.015 mm (0.3937–
0.3943 in)
Limit
10.030 mm (0.3949 in)
4. Check:
• Camshaft oil passage
air.
5-15
CAMSHAFT
2. Install:
• Exhaust rocker arm “1”
• Exhaust rocker arm shaft “2”
• Intake rocker arm “3”
• Intake rocker arm shaft “4”
5. Measure:
• Rocker arm shaft outside diameter “a”
Rocker arm shaft outside diameter
9.981–9.991
mm
(0.3930–
0.3933 in)
Limit
9.950 mm (0.3917 in)
Slide hammer bolt
90890-01083
YU-01083-1
ECA2PA1502
Install the rocker arm shafts so that the
threaded side faces outward.
TIP
Use a slide hammer bolt “5” to install the
rocker arm shaft.
6. Calculate:
• Rocker-arm-to-rocker-arm-shaft clearance
Out of specification → Replace the defective part(s).
TIP
Calculate the clearance by subtracting the
rocker arm shaft outside diameter from the
rocker arm inside diameter.
Rocker-arm-to-rocker-arm-shaft
clearance
0.009–0.034
mm
(0.0004–
0.0013 in)
Limit
0.08 mm (0.0031 in)
EAS24040
INSTALLING THE CAMSHAFT AND
ROCKER ARMS
1. Lubricate:
• Rocker arm shafts
3. Lubricate:
• Camshaft
• Camshaft bearings
Camshaft
Camshaft bearing
Engine oil
Rocker arm inner surface
Rocker arm shaft outer surface
Engine oil
5-16
CAMSHAFT
4. Install:
• Camshaft “1”
TIP
Screw 8 mm (0.31 in) bolt “2” into the threaded
end of the camshaft and then install the camshaft.
5. Install:
• Camshaft retainer “1”
Camshaft retainer bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
LOCTITE®
5-17
VALVES AND VALVE SPRINGS
EAS24270
Removing the valves and valve springs
Order
1
2
3
4
5
6
7
8
Job/Parts to remove
Cylinder head
Rocker arm/camshaft
Valve cotter
Valve spring retainer
Valve spring
Intake valve
Exhaust valve
Valve stem seal
Valve spring seat
Valve guide
Q’ty
Remarks
Refer to “CAMSHAFT” on page 5-13.
4
2
2
1
1
2
2
2
5-18
EAS24280
REMOVING THE VALVES
valves and related components.
TIP
Before removing the internal parts of the cylinder head (e.g., valves, valve springs, valve
seats), make sure the valves properly seal.
1. Check:
• Valve sealing
Leakage at the valve seat → Check the
valve face, valve seat, and valve seat
width.
Refer to “CHECKING THE VALVE
SEATS” on page 5-21.
3. Remove:
• Valve spring retainer “1”
• Valve spring “2”
• Valve “3”
• Valve stem seal “4”
• Valve spring seat “5”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Pour a clean solvent “a” into the intake and
exhaust ports.
b. Check that the valves properly seal.
TIP
Identify the position of each part very carefully
so that it can be reinstalled in its original place.
TIP
There should be no leakage at the valve seat
“1”.
EAS24290
CHECKING THE VALVES AND VALVE
GUIDES
valves and valve guides.
1. Measure:
• Valve-stem-to-valve-guide clearance
Out of specification → Replace the valve
guide.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Remove:
• Valve cotters “1”
TIP
Remove the valve cotters by compressing the
valve spring with the valve spring compressor
and valve spring compressor attachment “2”.
• Valve-stem-to-valve-guide clearance =
Valve guide inside diameter “a” Valve stem diameter “b”
90890-04019
YM-04019
attachment
90890-04114
adapter 19.5 mm
YM-04114
5-19
Valve-stem-to-valve-guide clearance
Valve-stem-to-valve-guide clearance (intake)
0.010–0.037
mm
(0.0004–
0.0015 in)
Limit
0.080 mm (0.0032 in)
Valve-stem-to-valve-guide clearance (exhaust)
0.025–0.052
mm
(0.0010–
0.0020 in)
Limit
0.100 mm (0.0039 in)
b. Install the new valve guide with the valve
guide installer “2” and valve guide remover
“1”.
c. After installing the valve guide, bore the
valve guide with the valve guide reamer “3”
to obtain the proper valve-stem-to-valveguide clearance.
2. Replace:
• Valve guide
TIP
To ease valve guide removal and installation,
and to maintain the correct fit, heat the cylinder
head to 100 °C (212 °F) in an oven.
TIP
After replacing the valve guide, reface the
valve seat.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the valve guide with the valve
guide remover “1”.
5-20
TIP
Valve guide remover (ø5)
90890-04097
Valve guide remover (5.0 mm)
YM-04097
Valve guide installer (ø5)
90890-04098
Valve guide installer (5.0 mm)
YM-04098
Valve guide reamer (ø5)
90890-04099
Valve guide reamer (5.0 mm)
YM-04099
• When installing a new valve, always replace
the valve guide.
• If the valve is removed or replaced, always
replace the oil seal.
Valve stem runout
Valve stem runout
0.010 mm (0.0004 in)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Eliminate:
• Carbon deposits
(from the valve face and valve seat)
4. Check:
• Valve face
Pitting/wear → Grind the valve face.
• Valve stem end
Mushroom shape or diameter larger than
the body of the valve stem → Replace the
valve.
5. Measure:
• Valve margin thickness “a”
Out of specification → Replace the valve.
EAS24300
CHECKING THE VALVE SEATS
valves and valve seats.
1. Eliminate:
• Carbon deposits
(from the valve face and valve seat)
2. Check:
• Valve seat
Pitting/wear → Replace the cylinder
head.
3. Measure:
• Valve seat width “a”
Out of specification → Replace the cylinder head.
Valve margin thickness
Valve margin thickness (intake)
0.40–0.80 mm (0.0157–0.0315
in)
Valve
margin
thickness
(exhaust)
0.80–1.20 mm (0.0315–0.0472
in)
Valve seat width
Valve seat width (intake)
0.90–1.10 mm (0.0354–0.0433
in)
Valve seat width (exhaust)
0.90–1.10 mm (0.0354–0.0433
in)
6. Measure:
• Valve stem runout
Out of specification → Replace the valve.
5-21
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply Mechanic’s blueing dye (Dykem) “b”
onto the valve face.
b. Apply engine oil onto the valve stem.
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
impression.
d. Measure the valve seat width.
TIP
Where the valve seat and valve face contacted
one another, the blueing will have been
removed.
c. Install the valve into the cylinder head.
d. Turn the valve until the valve face and valve
seat are evenly polished, then clean off all
of the lapping compound.
Valve lapper
90890-04101
Valve lapping tool
YM-A8998
TIP
For the best lapping results, lightly tap the
valve seat while rotating the valve back and
forth between your hands.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Lap:
• Valve face
• Valve seat
TIP
After replacing the cylinder head or replacing
the valve and valve guide, the valve seat and
valve face should be lapped.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply a coarse lapping compound “a” to
the valve face.
ECA13790
e. Apply a fine lapping compound to the valve
face and repeat the above steps.
f. After every lapping procedure, be sure to
clean off all of the lapping compound from
the valve face and valve seat.
g. Apply Mechanic’s blueing dye (Dykem) “b”
onto the valve face.
Do not let the lapping compound enter the
gap between the valve stem and the valve
guide.
5-22
2. Measure:
• Compressed valve spring force “a”
spring.
h. Install the valve into the cylinder head.
i. Press the valve through the valve guide
and onto the valve seat to make a clear
impression.
j. Measure the valve seat width “c” again. If
the valve seat width is out of specification,
reface and lap the valve seat.
Installed compression spring
force (intake)
160.00–184.00 N (16.32–18.76
kgf, 35.97–41.36 lbf)
Installed compression spring
force (exhaust)
160.00–184.00 N (16.32–18.76
kgf, 35.97–41.36 lbf)
Installed length (intake)
25.60 mm (1.01 in)
Installed length (exhaust)
25.60 mm (1.01 in)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS24310
CHECKING THE VALVE SPRINGS
valve springs.
1. Measure:
• Valve spring free length “a”
spring.
b. Install length
Valve spring free length
Free length (intake)
47.06 mm (1.85 in)
Limit
44.71 mm (1.76 in)
Free length (exhaust)
47.06 mm (1.85 in)
Limit
44.71 mm (1.76 in)
3. Measure:
• Valve spring tilt “a”
spring.
Spring tilt limit
Spring tilt (intake)
2.5°/2.1 mm (0.08 in)
Spring tilt (exhaust)
2.5°/2.1 mm (0.08 in)
5-23
TIP
• Install the valve springs with the larger pitch
“a” facing up.
• Install the valve spring with its painted end
facing up.
EAS24340
INSTALLING THE VALVES
valves and related components.
1. Deburr:
• Valve stem end
(with an oil stone)
b. Smaller pitch
2. Lubricate:
• Valve stem “1”
• Valve stem seal “2”
(with the recommended lubricant)
4. Install:
• Valve cotters “1”
TIP
Install the valve cotters by compressing the
valve spring with the valve spring compressor
and the valve spring compressor attachment
“2”.
Engine oil
90890-04019
YM-04019
attachment
90890-04114
adapter 19.5 mm
YM-04114
3. Install:
• Valve stem seat “1”
•
•
•
•
Valve stem seal “2” New
Valve “3”
Valve spring “4”
Valve spring retainer “5”
(into the cylinder head)
5-24
5. To secure the valve cotters onto the valve
stem, lightly tap the valve tip with a softface hammer.
ECA13800
Hitting the valve tip with excessive force
could damage the valve.
5-25
CYLINDER AND PISTON
EAS24350
CYLINDER AND PISTON
Removing the cylinder and piston
Order
1
2
3
4
5
6
7
8
9
10
Job/Parts to remove
Cylinder head
Timing chain guide (exhaust side)
Cylinder
Cylinder gasket
Dowel pin
Piston pin clip
Piston pin
Piston
Top ring
2nd ring
Oil ring
Q’ty
Remarks
1
1
1
2
2
1
1
1
1
1
5-26
CYLINDER AND PISTON
EAS24380
TIP
REMOVING THE PISTON
1. Remove:
• Piston pin clips “1”
• Piston pin “2”
• Piston “3”
When removing a piston ring, open the end
gap with your fingers and lift the other side of
the ring over the piston crown.
ECA13810
Do not use a hammer to drive the piston
pin out.
TIP
• Before removing the piston pin clip, cover the
crankcase opening with a clean rag to prevent the piston pin clip from falling into the
crankcase.
• Before removing 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”.
EAS2PA1503
CHECKING THE TIMING CHAIN GUIDE
1. Check:
• Timing chain guide (exhaust side)
Piston pin puller set
90890-01304
Piston pin puller
YU-01304
EAS24400
CHECKING THE CYLINDER AND PISTON
1. Check:
• Piston wall
• Cylinder wall
Vertical scratches → Rebore or replace
the cylinder, and replace the piston and
piston rings as a set.
2. Measure:
• Piston-to-cylinder clearance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure cylinder bore “C” with the cylinder
bore gauge “1”.
TIP
Measure cylinder bore “C” by taking side-toside and front-to-back measurements of the
cylinder. Then, find the average of the measurements.
Cylinder bore “C”
54.024–54.056 mm (2.1269–
2.1282 in)
Wear limit
54.156 mm (2.1321 in)
“C” = (X+Y)/2
2. Remove:
• Top ring
• 2nd ring
• Oil ring
5-27
CYLINDER AND PISTON
f.
If out of specification, rebore or replace the
cylinder, and replace the piston and piston
rings as a set.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS24430
CHECKING THE PISTON RINGS
1. Measure:
• Piston ring side clearance
Out of specification → Replace the piston
and piston rings as a set.
TIP
a. 40 mm (1.57 in) from the top of the cylinder
Before measuring the piston ring side clearance, eliminate any carbon deposits from the
piston ring grooves and piston rings.
b. If out of specification, rebore or replace the
cylinder, and replace the piston and piston
rings as a set.
c. Measure piston skirt diameter “D” with the
micrometer.
Piston
Diameter D
53.997–54.029
2.1271 in)
mm
Piston ring
Top ring
Ring side clearance
0.035–0.070
mm
(0.0014–
0.0028 in)
Limit
0.120 mm (0.0047 in)
2nd ring
Ring side clearance
0.020–0.060
mm
(0.0008–
0.0024 in)
Limit
0.120 mm (0.0047 in)
(2.1259–
a. 4.5 mm (0.18 in) from the bottom edge of
the piston
d. If out of specification, replace the piston
and piston rings as a set.
e. Calculate the piston-to-cylinder clearance
with the following formula.
2. Install:
• Piston rings
(into the cylinder)
• Piston-to-cylinder clearance =
Cylinder bore “C” - Piston skirt diameter “D”
TIP
Piston-to-cylinder clearance
0.019–0.035
mm
(0.0007–
0.0014 in)
Limit
0.15 mm (0.006 in)
Level the piston ring into the cylinder with the
piston crown.
3. Measure:
• Piston ring end gap
ring.
5-28
CYLINDER AND PISTON
TIP
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
Top ring
End gap (installed)
0.15–0.30 mm (0.006–0.012 in)
Limit
0.40 mm (0.0157 in)
2nd ring
End gap (installed)
0.30–0.45 mm (0.012–0.018 in)
Limit
0.55 mm (0.0217 in)
Oil ring
End gap (installed)
0.20–0.70 mm (0.008–0.028 in)
3. Measure:
• Piston pin bore diameter “b”
Out of specification → Replace the piston.
Piston pin bore inside diameter
15.002–15.013 mm (0.5906–
0.5911 in)
Limit
15.043 mm (0.5922 in)
a. 40 mm (1.57 in)
4. Calculate:
• Piston-pin-to-piston-pin-bore clearance
pin and piston as a set.
EAS24440
CHECKING THE PISTON PIN
1. Check:
• Piston pin
Blue discoloration/grooves → Replace
the piston pin and then check the lubrication system.
2. Measure:
• Piston pin outside diameter “a”
pin.
• Piston-pin-to-piston-pin-bore clearance =
Piston pin bore diameter “b” Piston pin outside diameter “a”
Piston-pin-to-piston-pin-bore
clearance
0.002–0.022
mm
(0.0001–
0.0009 in)
Limit
0.072 mm (0.0028 in)
Piston pin outside diameter
14.991–15.000 mm (0.5902–
0.5906 in)
Limit
14.971 mm (0.5894 in)
5-29
CYLINDER AND PISTON
4. Lubricate:
• Piston
• Piston rings
• Cylinder
EAS24450
INSTALLING THE PISTON AND CYLINDER
1. Install:
• Lower oil ring rail “1”
• Oil ring expander “2”
• Upper oil ring rail “3”
• 2nd ring “4”
• Top ring “5”
Engine oil
TIP
5. Offset:
• Piston ring end gaps
Be sure to install the piston rings so that the
manufacturer’s mark or number face up.
a.
b.
c.
d.
e.
f.
2. Install:
• Piston “1”
• Piston pin “2”
• Piston pin clips “3” New
Top ring
Upper oil ring rail
Oil ring expander
Lower oil ring rail
2nd ring
20 mm (0.79 in)
TIP
A. Exhaust side
• Apply engine oil to the piston pin.
• Make sure the arrow mark “a” on the piston
points towards the exhaust side of the cylinder.
• Before installing the piston pin clip, cover the
crankcase opening with a clean rag to prevent the clip from falling into the crankcase.
6. Install:
• O-ring New
(to the cylinder)
• Cylinder “1”
TIP
• While compressing the piston rings with one
hand, install the cylinder with the other hand.
• Pass the timing chain and timing chain guide
(intake side) through the timing chain cavity.
3. Install:
• O-ring New
• Dowel pins
• Cylinder gasket New
7. Install:
• Timing chain guide (exhaust side)
5-30
CLUTCH
EAS25061
CLUTCH
Removing the clutch cover
Order
Job/Parts to remove
Q’ty
Engine oil
Starter motor
1
2
3
4
Battery negative lead
Clutch cover
Clutch cover gasket
Dowel pin
1
1
1
2
Remarks
Drain.
Refer to “CHANGING THE ENGINE OIL” on
page 3-22.
Refer to “ELECTRIC STARTER” on page 554.
Disconnect.
5-31
CLUTCH
Removing the clutch
Order
1
2
3
4
5
6
7
8
9
10
11
12
13
Job/Parts to remove
Clutch spring
Pressure plate
Locknut/Washer
Clutch push rod holder
Ball
Friction plate
Clutch plate
Washer
Clutch boss nut
Lock washer
Clutch boss
Q’ty
4
1
1/1
1
1
1
4
3
1
1
1
1
1
5-32
Remarks
CLUTCH
Removing the clutch
Order
14
15
16
17
18
Job/Parts to remove
Thrust washer
Clutch housing
Plate washer
Primary drive gear
Straight key
Q’ty
1
1
1
1
1
Remarks
5-33
CLUTCH
Removing the push lever
Order
1
2
3
4
Job/Parts to remove
Clutch cable
Clutch push lever
Clutch push lever spring
Circlip
Oil seal
Q’ty
Remarks
Refer to “CLUTCH” on page 5-31.
1
1
1
1
5-34
CLUTCH
EAS25070
REMOVING THE CLUTCH
1. Remove:
• Clutch cover
TIP
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.
EAS25100
CHECKING THE FRICTION PLATES
friction plates.
1. Check:
• Friction plate
Damage/wear → Replace the friction
plates as a set.
2. Measure:
• Friction plate thickness
Out of specification → Replace the friction plates as a set.
2. Loosen:
• Primary drive gear nut “1”
TIP
Place an aluminum plate “a” between the teeth
of the primary driven gear “2” and primary
drive gear “3”.
TIP
Measure the friction plate at four places.
Friction plate thickness
3.00 mm (0.12 in)
Wear limit
2.80 mm (0.11 in)
3. Straighten the lock washer tab “a”.
4. Loosen:
• Clutch boss nut “1”
TIP
EAS25111
While holding the clutch boss “2” with the universal clutch holder “3”, loosen the clutch boss
nut.
CHECKING THE CLUTCH PLATES
clutch plates.
1. Check:
• Clutch plate
Damage → Replace the clutch plates as
a set.
90890-04086
YM-91042
5-35
CLUTCH
2. Measure:
• Clutch plate warpage
(with a surface plate and thickness gauge
“1”)
Out of specification → Replace the clutch
plates as a set.
EAS25150
CHECKING THE CLUTCH HOUSING
1. Check:
• Clutch housing dogs
Damage/pitting/wear → Deburr the clutch
housing dogs or replace the clutch housing.
Thickness gauge
90890-03180
Feeler gauge set
YU-26900-9
TIP
Pitting on the clutch housing dogs will cause
erratic clutch operation.
Warpage limit
0.05 mm (0.0020 in)
EAS25160
CHECKING THE CLUTCH BOSS
1. Check:
• Clutch boss splines
Damage/pitting/wear → Replace the
clutch boss.
EAS25140
CHECKING THE CLUTCH SPRINGS
clutch springs.
1. Check:
• Clutch spring
Damage → Replace the clutch springs as
a set.
2. Measure:
• Clutch spring free length “a”
Out of specification → Replace the clutch
springs as a set.
TIP
Pitting on the clutch boss splines will cause
erratic clutch operation.
Clutch spring free length
31.7 mm (1.25 in)
Limit
30.1 mm (1.19 in)
EAS25170
CHECKING THE PRESSURE PLATE
1. Check:
• Pressure plate
5-36
CLUTCH
EAS25191
CHECKING THE CLUTCH PUSH LEVER
AND CLUTCH PUSH ROD
1. Check:
• Short clutch push rod “1”
• Ball “2”
• Clutch push lever “3”
Cracks/damage/wear → Replace the
defective part(s).
2. Install:
• Straight key
• Primary drive gear “1”
• Washer
• Primary drive gear nut
(temporarily tighten)
TIP
Install the primary drive gear with its chamfered side facing “a” the rotary filter.
EAS25200
CHECKING THE PRIMARY DRIVE GEAR
AND PRIMARY DRIVEN GEAR
1. Check:
• Primary drive gear “1”
• Primary driven gear “2”
(on the clutch housing)
Damage/wear → Replace the primary
drive and primary driven gears as a set.
Excessive noise during operation →
Replace the primary drive and primary
driven gears as a set.
2. Check:
• Primary-drive-gear-to-primary-drivengear free play
Free play exists → Replace the primary
drive and primary driven gears as a set.
3. Install:
• Clutch boss
• Lock washer New
• Clutch boss nut “1”
TIP
Lubricate the crankshaft end (clutch side) with
engine oil.
4. Tighten:
• Clutch boss nut
Clutch boss nut
60 Nm (6.0 m·kgf, 43 ft·lbf)
EAS25260
TIP
INSTALLING THE CLUTCH
1. Install:
• Clutch push lever spring “1”
• Clutch push lever “2”
While holding the clutch boss “2” with the universal clutch holder “3”, tighten the clutch boss
nut.
TIP
Install the clutch push lever spring as shown.
5-37
CLUTCH
9. Install:
• Pressure plate “1”
• Clutch springs “2”
• Clutch spring bolts “3”
90890-04086
YM-91042
5. Bend the lock washer tab “a” along a flat
side of the nut.
Clutch spring bolt
6 Nm (0.6 m·kgf, 4.3 ft·lbf)
TIP
Tighten the clutch spring bolts in stages and in
a crisscross pattern.
6. Tighten:
• Primary drive gear nut “1”
70 Nm (7.0 m·kgf, 51 ft·lbf)
10. Adjust:
• Clutch mechanism free play
TIP
Place an aluminum plate “a” between the teeth
of the primary drive gear “2” and primary
driven gear “3”.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Check that projection “a” on the clutch push
lever “1” aligns with concave “b” on the
crankcase by pushing the clutch push lever
manually in direction “c” until it stops.
b. If projection “a” is not aligned with concave
“b”, align them as follows:
• Loosen the locknut “2”.
• With the clutch push lever fully pushed in
direction “c”, turn the short clutch push
rod “3” in or out until projection “a” aligns
with concave “b”.
7. Lubricate:
• Friction plates
Engine oil
8. Install:
• Friction plates
• Clutch plates
• Hold the short clutch push rod to prevent
it from moving and then tighten the locknut to specification.
TIP
First, install a friction plate and then alternate
between a clutch plate and a friction plate.
5-38
CLUTCH
Short clutch push rod locknut
8 Nm (0.8 m·kgf, 5.8 ft·lbf)
13. Adjust:
Refer to “ADJUSTING THE CLUTCH
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
11. Install:
• Clutch cover
Clutch cover bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
TIP
Tighten the clutch cover bolts in the proper
tightening sequence as shown.
12. Install:
• Battery negative lead “1”
TIP
• When installing the battery negative lead,
clearance “a” between the top end of the battery negative lead terminal and the contour
of the clutch cover should be 3 mm (0.12 in)
or less.
• The angle of battery negative lead bend “b”
to inside should be 30 degrees angle or less.
The lead should not be bent outward.
5-39
OIL PUMP
EAS24911
OIL PUMP
Removing the oil pump
Order
1
2
3
4
5
Job/Parts to remove
Clutch housing/Primary drive gear
Rotary filter
Oil pump drive gear
Oil pump assembly/oil pump driven gear
Oil pump gasket
Oil strainer
Q’ty
Remarks
1
1
1
1
1
5-40
OIL PUMP
Disassembling the oil pump
Order
1
2
3
4
5
6
7
8
9
10
11
12
13
Job/Parts to remove
Circlip
Washer
Conical spring washer
Oil pump driven gear
Pin
Washer
Oil pump housing cover
Pin
Oil pump shaft
Oil pump inner rotor
Oil pump outer rotor
Oil pump housing
Dowel pin
Q’ty
1
1
1
1
1
1
1
1
1
1
1
1
2
Remarks
* When replacing any of parts, replace the oil pump assembly.
5-41
OIL PUMP
EAS24960
CHECKING THE OIL PUMP
1. Check:
• Oil pump drive gear
• Oil pump driven gear
• Oil pump housing
• Oil pump housing cover
defective part(s).
2. Measure:
• Inner-rotor-to-outer-rotor-tip clearance “a”
• Outer-rotor-to-oil-pump-housing clearance “b”
• Oil-pump-housing-to-inner-rotor-andouter-rotor clearance “c”
Out of specification → Replace the oil
pump.
Inner-rotor-to-outer-rotor-tip
clearance
Less than 0.15 mm (0.0059 in)
Limit
0.23 mm (0.0091 in)
Outer-rotor-to-oil-pump-housing clearance
0.130–0.193
mm
(0.0051–
0.0076 in)
Limit
0.263 mm (0.0104 in)
Oil-pump-housing-to-inner-andouter-rotor clearance
0.060–0.100
mm
(0.0024–
0.0039 in)
Limit
0.15 mm (0.0059 in)
1. Inner rotor
2. Outer rotor
3. Oil pump housing
3. Check:
• Oil pump operation
Rough movement → Repeat steps (1)
and (2) or replace the oil pump assembly.
EAS29010
CHECKING THE ROTARY FILTER
1. Check:
• Rotary filter
Contaminants → Clean with engine oil.
EAS25000
ASSEMBLING THE OIL PUMP
1. Lubricate:
• Oil pump inner rotor
• Oil pump outer rotor
• Oil pump shaft
5-42
OIL PUMP
Engine oil
2. Install:
• Oil pump outer rotor
• Oil pump inner rotor “1”
• Oil pump shaft
• Pin “2”
• Oil pump housing cover
4. Check:
• Oil pump operation
Refer to “CHECKING THE OIL PUMP” on
page 5-42.
Oil pump housing cover screw
5 Nm (0.5 m·kgf, 3.6 ft·lbf)
TIP
When installing the inner rotor, align the pin in
the oil pump shaft with the groove “a” in the
inner rotor.
EAS25030
INSTALLING THE OIL PUMP
1. Install:
• Oil pump gasket “1” New
• Oil pump assembly
Oil pump assembly screw
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
ECA27S1019
After tightening the screws, make sure the
oil pump turns smoothly.
TIP
Install the oil pump gasket as shown in the
illustration.
3. Install:
• Washer
• Pin “1”
• Oil pump driven gear “2”
• Conical spring washer “3”
• Washer
• Circlip New
TIP
• When installing the oil pump driven gear,
align the pin in the oil pump shaft with groove
“a” in the oil pump driven gear.
• Install the spring washer as shown in the
illustration.
2. Install:
• Rotary filter “1”
TIP
Align the projection “a” on the rotary filter with
the oil hole “b” in the crankshaft.
5-43
OIL PUMP
5-44
SHIFT SHAFT
EAS25410
SHIFT SHAFT
Removing the shift shaft and stopper lever
Order
1
2
3
4
5
6
7
8
9
Job/Parts to remove
Q’ty
Right footrest
Clutch assembly
Shift pedal
Shift shaft
Circlip
Shift shaft spring
Shift shaft spring stopper
Stopper lever
Stopper lever spring
Shift drum segment
Dowel pin
Remarks
1
1
1
1
1
1
1
1
2
5-45
SHIFT SHAFT
EAS25420
EAS25451
CHECKING THE SHIFT SHAFT
1. Check:
• Shift shaft “1”
• Shift lever “2”
Bends/damage/wear → Replace.
• Shift lever spring “3”
• Shift shaft spring stopper
INSTALLING THE SHIFT SHAFT
1. Install:
• Stopper lever “1”
• Stopper lever spring “2”
TIP
• Hook the ends of the stopper lever spring
onto the stopper lever and the crankcase
boss “3”.
• Install the stopper lever spring as shown in
the illustration.
• Mesh the stopper lever with the shift drum
segment assembly.
Stopper lever bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
LOCTITE®
EAS25430
CHECKING THE STOPPER LEVER
1. Check:
• Stopper lever “1”
Roller turns roughly → Replace the stopper lever.
• Stopper lever spring
2. Install:
• Shift shaft spring stopper “1”
(to the right crankcase)
Shift shaft spring stopper press
fit height “a”
15.2–15.8 mm (0.60–0.62 in)
EAS2PA1504
CHECKING THE SHIFT DRUM SEGMENT
1. Check:
• Shift drum segment
Damage/wear → Replace the shift drum
segment.
3. Install:
• Shift shaft spring
• Circlip New
• Shift shaft “1”
5-46
SHIFT SHAFT
TIP
Hook the end of the shift shaft spring onto the
shift shaft spring stopper “2”.
4. Install:
• Oil seal New
• Shift pedal “1”
TIP
• Lubricate the oil seal lips with lithium-soapbased grease.
• Install the shift pedal as shown in the illustration.
• For the installation heights of the shift pedal,
height “b” from the center of the shift pedal to
footrest top face “a” should be 20.7 mm (0.81
in).
Shift pedal bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
5-47
GENERATOR AND STARTER CLUTCH
EAS2PA1513
Removing the generator and starter clutch
Order
Job/Parts to remove
Q’ty
Engine oil
1
2
3
4
5
6
7
8
9
10
Left side cover
Drive sprocket cover
AC magneto coupler/pickup coil coupler
Neutral switch lead
Generator rotor cover
Timing mark accessing screw
Crankshaft end accessing screw
Generator rotor cover gasket
Dowel pin
Pickup coil
Stator coil lead holder
Stator coil
1/1
1
1
1
1
1
2
1
1
1
Remarks
Drain.
Refer to “CHANGING THE ENGINE OIL” on
page 3-22.
Refer to “CHAIN DRIVE” on page 4-58.
Disconnect.
Disconnect.
* Yamaha bond No.1215 (Three bond No.1215®) ** When replacing any of parts, replace the
pickup coil/stator coil assembly.
5-48
Removing the generator and starter clutch
Order
11
12
13
14
15
16
17
18
Job/Parts to remove
Generator rotor
Starter clutch assembly
Starter clutch gear
Washer
Woodruff key
Starter clutch idle gear
Starter clutch idle gear shaft
Q’ty
1
1
1
1
1
1
1
1
Remarks
* Yamaha bond No.1215 (Three bond No.1215®) ** When replacing any of parts, replace the
5-49
flywheel puller set’s center bolt and the
crankshaft.
EAS2PA1505
REMOVING THE GENERATOR ROTOR
1. Remove:
• Generator rotor cover
TIP
• Remove the generator rotor using flywheel
puller “2”.
• Make sure the flywheel puller is centered
over the generator rotor.
TIP
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.
Flywheel puller
90890-01362
Heavy duty puller
YU-33270-B
2. Remove:
• Generator rotor nut “1”
• Washer
TIP
• Loosen the generator rotor nut “1” while holding the generator rotor “2” with a sheave
holder “3”.
• Do not allow the sheave holder to touch the
projection on the generator rotor.
4. Remove:
• Starter clutch idle gear holder
• Starter clutch idle gear
• Starter clutch idle gear shaft
EAS2PA1506
REMOVING THE STARTER CLUTCH
1. Remove:
• Starter clutch
Sheave holder
90890-01701
YS-01880-A
TIP
• While holding the generator rotor with the
sheave holder, remove the starter clutch
bolts “1”.
projection on the AC magneto rotor.
Sheave holder
90890-01701
YS-01880-A
3. Remove:
• Generator rotor “1”
• Woodruff key
ECA13880
To protect the end of the crankshaft, place
an appropriate sized socket between the
5-50
starter clutch is faulty and must be
replaced.
c. When turning the starter clutch gear counterclockwise “B”, it should turn freely, otherwise the starter clutch is faulty and must be
replaced.
EAS2PA1507
CHECKING THE STATOR COIL ASSEMBLY
1. Check:
• Stator coil
• Pickup coil
Damage → Replace the stator coil
assembly.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Check:
• Starter clutch idle gear shaft
Damage/fatigue/wear → Replace.
EAS2PA1508
CHECKING THE STARTER CLUTCH
1. Check:
• Starter clutch rollers “1”
• Starter clutch spring caps “2”
• Starter clutch springs “3”
Damage/wear → Replace the starter
clutch assembly.
EAS2PA1509
INSTALLING THE STARTER CLUTCH
1. Install:
• Starter clutch assembly
(to generator rotor)
• Starter clutch bolts “1” New
Starter clutch bolt
30 Nm (3.0 m·kgf, 22 ft·lbf)
TIP
• While holding the generator rotor with the
sheave holder, tighten the starter clutch bolts
“1”.
projection on the generator rotor.
• Stake the end “a” of each starter clutch bolt.
2. Check:
• Starter clutch gear
Burrs/chips/roughness/wear → Replace
the defective part(s).
3. Check:
• Starter clutch gear’s contacting surfaces
Damage/pitting/wear → Replace the
starter clutch gear.
4. Check:
• Starter clutch operation
Sheave holder
90890-01701
YS-01880-A
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the starter clutch gear “1” onto the
starter clutch and hold the generator rotor
“2”.
b. When turning the starter clutch gear clockwise “A”, the starter clutch and the starter
clutch gear should engage, otherwise the
5-51
3. Tighten:
• Generator rotor nut “1”
Generator rotor nut
70 Nm (7.0 m·kgf, 51 ft·lbf)
TIP
• Tighten the generator rotor nut “1” while
holding the generator rotor “2” with sheave
holder “3”.
projection the generator rotor.
EAS2PA1510
INSTALLING THE GENERATOR ROTOR
1. Install:
• Starter clutch idle gear shaft “1”
(to the left crankcase)
• Starter clutch idle gear holder
Sheave holder
90890-01701
YS-01880-A
Starter clutch idle gear shaft
press fit height “a”
14.2–14.5 mm (0.56–0.57 in)
screw
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
4. Apply:
• Sealant
(onto the stator coil lead grommet “1”)
TIP
• Install the grommet within 30 minutes after
application of sealant.
• Wipe off any excess sealant.
2. Left crankcase
Yamaha bond No.1215
90890-85505
2. Install:
• Woodruff key
• Generator rotor
• Washer
• Generator rotor nut
TIP
• Clean the tapered portion of the crankshaft
and the generator rotor hub.
• When installing the generator rotor, make
sure the woodruff key is properly seated in
the key way of the crankshaft.
5-52
5. Install:
• Stator coil
• Stator coil lead holder
• Pickup coil
Stator coil bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
LOCTITE®
Stator coil lead holder screw
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Pickup coil bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
LOCTITE®
6. Install:
• Dowel pin
• Generator rotor cover gasket New
• Generator rotor cover
TIP
Tighten the generator rotor cover bolts in the
proper tightening sequence as shown.
Generator rotor cover bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
7. Install:
• Neutral switch lead “1”
TIP
Route the neutral switch lead as shown in the
illustration, and then apply sealant (Three
bond 7738) to affix the lead to the generator
rotor cover at the locations “a”.
5-53
ELECTRIC STARTER
EAS24780
ELECTRIC STARTER
Removing the starter motor
Order
1
2
Job/Parts to remove
Starter motor lead
Starter motor
Q’ty
1
1
Remarks
Disconnect.
5-54
ELECTRIC STARTER
Disassembling the starter motor
Order
1
2
3
4
5
6
7
8
Job/Parts to remove
Starter motor front cover
Lock washer
Shim
Circlip
Starter motor rear cover
Brush set
Armature assembly
Starter motor yoke
Q’ty
1
1
1
1
1
1
1
1
Remarks
* When replacing any of parts, replace the starter motor assembly.
5-55
ELECTRIC STARTER
EAS24791
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
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.
a. Measure the armature assembly resistances with the digital circuit tester.
Digital circuit tester
90890-03174
Model 88 Multimeter with
tachometer
YU-A1927
Limit
21.0 mm (0.83 in)
Armature coil
Commutator resistance “1”
Continuity (0.0171–0.0209 Ω at
20 °C (68 °F))
Insulation resistance “2”
No continuity (Above 1 MΩ at
20 °C (68 °F))
b. If any resistance is out of specification,
replace the starter motor.
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 (depth)
1.50 mm (0.06 in)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Measure:
• Brush length “a”
brushes as a set.
TIP
The mica of the commutator must be undercut
to ensure proper operation of the commutator.
Limit
3.50 mm (0.14 in)
4. Measure:
• Armature assembly resistances (commutator and insulation)
starter motor.
5-56
ELECTRIC STARTER
6. Measure:
• Brush spring force
Out of specification → Replace the brush
springs as a set.
Brush spring force
5.52–8.28 N (563–844
19.87–29.80 oz)
gf,
7. Check:
• Gear teeth
Damage/wear → Replace the starter
motor.
8. Check:
• Bearing
• Oil seal
Damage/pitting → Replace the starter
motor.
EAS24800
ASSEMBLING THE STARTER MOTOR
1. Install:
• Lock washer “1”
TIP
Align the tabs “a” on the lock washer with the
slots “b” in the starter motor front cover.
2. Install:
• Starter motor yoke “1”
• Starter motor front cover “2”
• Starter motor rear cover “3”
TIP
Align the match marks “a” on the starter motor
yoke with the match marks “b” on the starter
motor front and rear covers.
5-57
CRANKCASE
EAS25540
CRANKCASE
Separating the crankcase
T.
R
Order
Job/Parts to remove
Q’ty
Engine
Cylinder head
Cylinder/Piston
Generator rotor/Starter clutch idle gear
Starter motor
1
2
3
4
Clutch/Primary drive gear
Oil pump
Shift shaft/Shift drum segment
Timing chain guide (intake side)
Timing chain
Neutral switch
Clutch cable holder
1
1
1
1
5-58
10 Nm (1.0 m kgf, 7.2 ft Ibf)
Remarks
Refer to “CYLINDER AND PISTON” on page
5-26.
Refer to “GENERATOR AND STARTER
CLUTCH” on page 5-48.
Refer to “ELECTRIC STARTER” on page 554.
Refer to “OIL PUMP” on page 5-40.
Refer to “SHIFT SHAFT” on page 5-45.
CRANKCASE
T.
R
Order
5
6
7
Job/Parts to remove
Right crankcase
Left crankcase
Dowel pin
Q’ty
1
1
2
10 Nm (1.0 m kgf, 7.2 ft Ibf)
Remarks
5-59
CRANKCASE
Order
Job/Parts to remove
Q’ty
Crankshaft/Balancer shaft
1
2
3
Transmission
Oil seal
Bearing retainer
Bearing
Remarks
Refer to “CRANKSHAFT ASSEMBLY” on
page 5-63.
Refer to “TRANSMISSION” on page 5-66.
1
1
7
5-60
CRANKCASE
2. Check:
• Timing chain guide (intake side)
EAS25570
DISASSEMBLING THE CRANKCASE
1. Remove:
• Crankcase bolts
• Clutch cable holder
EAS2PA1512
CHECKING THE BEARINGS
1. Check:
• Bearings
Clean and lubricate the bearings, then
rotate the inner race with your finger.
Rough movement → Replace.
TIP
• 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.
2. Remove:
• Right crankcase
EAS25690
ASSEMBLING THE CRANKCASE
1. Install:
• Bearing retainer
ECA13900
Tap on one side of the crankcase with a
soft-face hammer. Tap only on reinforced
portions of the crankcase, not on the
crankcase mating surfaces. Work slowly
and carefully and make sure the crankcase
halves separate evenly.
Bearing retainer screw
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
LOCTITE®
TIP
Install the bearing retainer with its rounded
side facing the bearing.
EAS25580
CHECKING THE CRANKCASE
1. Thoroughly wash the crankcase halves in a
mild solvent.
2. Thoroughly clean all the gasket surfaces
and crankcase mating surfaces.
3. Check:
• Crankcase
• Oil delivery passages
air.
2. Install:
• Oil seal “1” New
Oil seal installed depth “a”
1.0–1.5 mm (0.039–0.059 in)
EAS2PA1511
CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDE
1. Check:
• Timing chain
Damage/stiffness → Replace the timing
chain and camshaft sprocket as a set.
3. Thoroughly clean all the gasket mating surfaces and crankcase mating surfaces.
4. Apply:
• Sealant
(onto the crankcase mating surfaces)
Yamaha bond No.1215
90890-85505
TIP
Do not allow any sealant to come into contact
with the oil gallery.
5-61
CRANKCASE
5. Install:
• Clutch cable holder
• Crankcase bolts
TIP
Apply sealant to the threads of the crankcase
bolts.
Yamaha bond No.1215
90890-85505
A. Left crankcase
B. Right crankcase
6. Tighten:
• Crankcase bolts
7. Apply:
• Engine oil
(onto the connecting rod big end bearing
and crankshaft bearings)
8. Check:
• Crankshaft and transmission operation
Rough movement → Repair.
Crankcase bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
TIP
Tighten each bolt 1/4 of a turn at a time, in
stages and in the proper sequence as shown.
• M6 × 45 mm bolts: “1”–“4”, “7”–“9”, “11”–
“13”
• M6 × 30 mm bolts: “5”, “6”
• M6 × 55 mm bolts: “10”
5-62
CRANKSHAFT ASSEMBLY
EAS25970
CRANKSHAFT ASSEMBLY
Removing the crankshaft and balancer
Order
Job/Parts to remove
Q’ty
Crankcase
1
2
Balancer
Crankshaft
Remarks
Separate.
Refer to “CRANKCASE” on page 5-58.
1
1
5-63
CRANKSHAFT ASSEMBLY
EAS2PA1514
TIP
REMOVING THE CRANKSHAFT AND BALANCER
1. Remove:
• Balancer “1”
Turn the crankshaft slowly.
Runout limit C
0.030 mm (0.0012 in)
2. Measure:
• Big end side clearance
Out of specification → Replace the big
end bearing, crankshaft pin, or connecting rod.
Big end side clearance D
0.15–0.45 mm (0.0059–0.0177
in)
Limit
0.50 mm (0.0197 in)
2. Remove:
• Crankshaft “1”
ECA2PA1501
3. Measure:
• Crankshaft width
Out of specification → Replace the crankshaft.
• To protect the end of the crankshaft,
place an appropriate sized socket
between the crankcase separating tool
bolt and the crankshaft.
• Do not tap on the crankshaft.
Width A
46.95–47.00 mm (1.848–1.850
in)
TIP
• Remove the crankshaft with the crankcase
separating tool “2”.
• Make sure the crankcase separating tool is
centered over the crankshaft.
Crankcase separating tool
90890-01135
Crankcase separator
YU-01135-B
4. Check:
• Crankshaft sprocket
Damage/wear → Replace the crankshaft.
• Bearing
crankshaft.
5. Check:
• Crankshaft journal
Scratches/wear → Replace the crankshaft.
• Crankshaft journal oil passage
air.
EAS26060
CHECKING THE CRANKSHAFT AND CONNECTING ROD
1. Measure:
• Crankshaft runout
Out of specification → Replace the crankshaft, bearing or both.
5-64
CRANKSHAFT ASSEMBLY
the oil seal lips with lithium-soap-based
grease and each bearing with engine oil.
EAS26120
CHECKING THE BALANCER
1. Check:
• Balancer gear
Damage/wear → Replace the balancer
gear assembly.
2. Check:
• Balancer shaft
Cracks/damage/wear → Replace the balancer shaft.
Dirt → Clean.
TIP
Hold the connecting rod at top dead center
(TDC) with one hand while turning the nut of
the crankshaft installer bolt with the other. Turn
the crankshaft installer bolt until the crankshaft
assembly bottoms against the bearing.
EAS26220
INSTALLING THE BALANCER
1. Install:
• Balancer “1”
EAS26210
INSTALLING THE CRANKSHAFT ASSEMBLY
1. Install:
• Crankshaft “1”
TIP
Align the punch mark “a” on the balancer
driven gear with the punch mark “b” on the balancer drive gear.
TIP
Install the crankshaft with the crankshaft
installer pot “2”, crankshaft installer bolt “3”,
adapter (M12) “4” and spacer “5”.
Crankshaft installer pot
90890-01274
Installing pot
YU-90058
Crankshaft installer bolt
90890-01275
Bolt
YU-90060
Adapter (M12)
90890-01278
Adapter #3
YU-90063
Spacer (crankshaft installer)
90890-04081
Pot spacer
YM-91044
ECA13970
To avoid scratching the crankshaft and to
ease the installation procedure, lubricate
5-65
TRANSMISSION
EAS26241
TRANSMISSION
Removing the transmission, shift drum assembly, and shift forks
Order
Job/Parts to remove
Q’ty
Crankcase
1
2
3
4
5
6
7
8
9
10
11
Long shift fork guide bar
Short shift fork guide bar
Shift fork-R
Shift fork-L
Shift fork-C
Shift drum
Main axle assembly
Long clutch push rod
Collar
Drive axle assembly
Washer
Remarks
Separate.
Refer to “CRANKCASE” on page 5-58.
1
1
1
1
1
1
1
1
1
1
1
5-66
TRANSMISSION
Disassembling the main axle
Order
1
2
3
4
5
6
7
Job/Parts to remove
5th pinion gear
2nd pinion gear
3rd pinion gear
Circlip
Washer
4th pinion gear
Main axle/1st pinion gear
Q’ty
1
1
1
1
1
1
1
Remarks
5-67
TRANSMISSION
Disassembling the drive axle
Order
1
2
3
4
5
6
7
8
9
10
Job/Parts to remove
5th wheel gear
2nd wheel gear
Circlip
Washer
1st wheel gear
4th wheel gear
Circlip
Washer
3rd wheel gear
Drive axle
Q’ty
1
1
1
1
1
1
1
1
1
1
Remarks
5-68
TRANSMISSION
EAS26250
REMOVING THE TRANSMISSION
1. Remove:
• Long shift fork guide bar “1”
• Short shift fork guide bar “2”
• Shift drum “3”
• Shift fork-R “4”
• Shift fork-L “5”
• Shift fork-C “6”
• Transmission “7”
3. Check:
• Shift fork movement
(along the shift fork guide bar)
Rough movement → Replace the shift
forks and shift fork guide bar as a set.
EAS26260
CHECKING THE SHIFT FORKS
shift forks.
1. Check:
• Shift fork cam follower “1”
• Shift fork pawl “2”
Bends/damage/scoring/wear → Replace
the shift fork.
EAS26270
CHECKING THE SHIFT DRUM
1. Check:
• Shift drum groove
Damage/scratches/wear → Replace the
shift drum assembly.
2. Check:
• Shift fork guide bar
Roll the shift fork guide bar on a flat surface.
Bends → Replace.
EAS26280
CHECKING THE TRANSMISSION
1. Measure:
• Main axle runout
(with a centering device and dial gauge
“1”)
Out of specification → Replace the main
axle.
EWA12840
WARNING
Do not attempt to straighten a bent shift
fork guide bar.
Main axle runout limit
0.03 mm (0.0012 in)
5-69
TRANSMISSION
5. Check:
• Transmission gear movement
Rough movement → Replace the defective part(s).
EAS27S1023
CHECKING THE LONG CLUTCH PUSH ROD
1. Check:
• Long clutch push rod
long clutch push rod.
2. Measure:
• Long clutch push rod bending limit
Out of specification → Replace the long
clutch push rod.
2. Measure:
• Drive axle runout
(with a centering device and dial gauge
“1”)
Out of specification → Replace the drive
axle.
Push rod bending limit
0.5 mm (0.02 in)
Drive axle runout limit
0.03 mm (0.0012 in)
EAS29020
ASSEMBLING THE MAIN AXLE AND DRIVE
AXEL
1. Install:
• Washer “1”
• Circlip “2” New
TIP
• Be sure the circlip sharp-edged corner “a” is
positioned opposite side to the washer and
gear.
• Be sure the circlip ends “b” are positioned at
axle spline groove “c”.
3. Check:
• Transmission gears
Blue discoloration/pitting/wear →
Replace the defective gear(s).
• Transmission gear dogs
Cracks/damage/rounded edges →
Replace the defective gear(s).
2. Install:
• 5th pinion gear “1”
TIP
4. Check:
• Transmission gear engagement
(each pinion gear to its respective wheel
gear)
Incorrect → Reassemble the transmission axle assemblies.
Press the 5th pinion gear into the main axle
“2”, as shown in the illustration.
Main axle assembly width “a”
83.25–83.45 mm (3.278–3.285
in)
5-70
TRANSMISSION
EAS26320
INSTALLING THE SHIFT FORKS AND SHIFT
DRUM
1. Install:
• Transmission “1”
• Shift fork-C “2”
• Shift fork-L “3”
• Shift fork-R “4”
• Shift drum “5”
• Short shift fork guide bar “6”
• Long shift fork guide bar “7”
TIP
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”.
2. Check:
• Transmission
Rough movement → Repair.
TIP
• Apply engine oil to each gear, shaft, and
bearing thoroughly.
• Before assembling the crankcase, make sure
that the transmission is in neutral and that
the gears turn freely.
5-71
FUEL SYSTEM
FUEL TANK ..................................................................................................6-1
REMOVING THE FUEL TANK ................................................................6-2
CHECKING THE FUEL COCK ...............................................................6-2
CARBURETOR .............................................................................................6-3
CHECKING THE CARBURETOR...........................................................6-6
CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD......6-7
ASSEMBLING THE CARBURETOR ......................................................6-8
INSTALLING THE CARBURETOR .........................................................6-9
MEASURING AND ADJUSTING THE FUEL LEVEL..............................6-9
6
FUEL TANK
EAS26620
FUEL TANK
Removing the fuel tank
Order
1
2
3
4
5
Job/Parts to remove
Q’ty
Seat
Front fender
Fuel hose (fuel cock side)
Fuel tank
Fuel cock
Drain hose
Fuel tank shield
1
1
1
1
1
Remarks
Disconnect.
Disconnect.
6-1
FUEL TANK
EAS26630
REMOVING THE FUEL TANK
1. Extract the fuel in the fuel tank through the
fuel tank cap with a pump.
2. Remove:
• Fuel hose (fuel cock side)
ECA14700
Although the fuel has been removed from
the fuel tank be careful when removing the
fuel hoses, since there may be fuel remaining in it.
TIP
Before removing the hoses, place a few rags in
the area under where it will be removed.
3. Remove:
• Fuel tank
EAS26650
CHECKING THE FUEL COCK
1. Check:
• Fuel cock
2. Check:
• Fuel cock strainer “1”
Obstruction → clean.
Blow out the jets with compressed air.
Damage → Replace the fuel cock.
6-2
CARBURETOR
EAS26730
CARBURETOR
Removing the carburetor
Order
1
2
3
4
5
6
7
8
9
Job/Parts to remove
Seat
Front fender
Rear fender
Air filter case
Carburetor warmer coupler
Air vent hose
Fuel hose (carburetor side)
Throttle cable cover
Throttle cable
Clamp
Carburetor
Carburetor joint
Intake manifold
Q’ty
1
1
1
1
1
2
1
1
1
Remarks
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Loosen.
6-3
CARBURETOR
Disassembling the carburetor
Order
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Job/Parts to remove
Q’ty
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Drain hose
Throttle stop screw
Diaphragm cover
Piston valve spring
Piston valve
Ring
Piston valve diaphragm
Jet needle set
Diaphragm cover
Diaphragm spring
Coasting enricher diaphragm
Coasting enricher jet (P. A. J. 2)
Starter plunger set
Carburetor warmer positive lead
Carburetor warmer
Carburetor warmer negative lead
Float chamber
Float pin
Float
Needle valve set
6-4
Remarks
CARBURETOR
Disassembling the carburetor
Order
21
22
23
24
25
Job/Parts to remove
Q’ty
1
1
1
1
1
Main jet
Needle jet holder
Needle jet
Pilot jet
Starter jet
Remarks
AUS, NZL
TIP
26
Pilot screw set
1
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.
6-5
CARBURETOR
EAS26770
CHECKING THE CARBURETOR
1. Check:
• Carburetor body
• Float chamber
2. Check:
• Fuel passages
Obstruction → Clean.
6. Check:
• Piston valve “1”
• Piston valve diaphragm “2”
Cracks/tears → Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Wash the carburetor in a petroleum-based
solvent. Do not use any caustic carburetor
cleaning solution.
b. Blow out all of the passages and jets with
compressed air.
7. Check:
• Diaphragm cover “1”
• Piston valve spring “2”
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Check:
• Float chamber body
Dirt → Clean.
4. Check:
• Float “1”
• Float tang “2”
Damage → Replace.
8. Check:
• Coasting enricher diaphragm “1”
• Diaphragm spring “2”
5. Check:
• Needle valve seat “1”
• Needle valve “2”
Contamination → Clean.
Damage/obstruction/wear → Replace the
needle valve, needle valve seat and Oring as a set.
6-6
CARBURETOR
9. Check:
• Jet needle “1”
Bends/wear/damage → Replace.
• Clip groove
Free play/wear → Replace.
• Clip position (AUS, NZL)
Standard clip position
No. 2 groove (AUS, NZL)
12. Check:
• Starter plunger “1”
• Starter plunger spring “2”
10. Check:
• Main jet “1”
• Pilot jet “2”
• Pilot screw “3” (AUS, NZL)
• Needle jet “4”
• Needle jet holder “5”
• Starter jet “6”
• Coasting enricher jet (P. A. J. 2) “7”
• Bends/damage/wear → Replace.
Blow out the jets with compressed air.
13. Check:
• Air vent hose joint
14. Check:
• Air vent hoses
• Fuel hose
• Drain hose
Blow out the hoses with compressed air.
EAS20990
CHECKING THE CARBURETOR JOINT AND
INTAKE MANIFOLD
1. Check:
• Carburetor joint “1”
• Intake manifold “2”
11. Check:
• Piston valve movement
Insert the piston valve into the carburetor
body and move it up and down.
Tightness → Replace the piston valve.
• Throttle valve movement
Sticks → Replace the carburetor.
6-7
CARBURETOR
EAS26810
TIP
ASSEMBLING THE CARBURETOR
The float arm should be resting on the needle
valve, but not compressing it.
ECA14110
• Before assembling the carburetor, wash
all of the parts in a petroleum-based solvent.
• Always use a new gasket.
c. If the float height is not within the specification, check the valve seat and needle valve.
d. If either is worn, replace the valve seat,
needle valve and O-ring as a set.
e. If both are fine, adjust the float height by
bending the float tang “1” on the float.
1. Install:
• Needle jet
• Needle jet holder “1”
• Main jet “2”
• Pilot jet “3”
• Starter jet “4”
f.
Recheck the float height.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Install:
• Float chamber
• O-ring New
5. Install:
• Pilot screw “1” (AUS, NZL)
2. Install:
• Needle valve seat
• O-ring New
• Needle valve
• Float
• Float pin
3. Measure:
• Float height “a”
2–1/2 (AUS, NZL)
TIP
Before disassembling 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.
Float height
13.0 mm (0.51 in)
6. Install:
• Coasting enricher jet (P.A.J.2)
• Coasting enricher diaphragm
• Diaphragm spring
• Diaphragm cover
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Hold the carburetor in an upside down
position.
b. Measure the distance from the front mating
surface of the float chamber (O-ring
removed) to the top of the float.
6-8
CARBURETOR
7. Install:
• Starter plunger
• O-ring New
8. Install:
• Piston valve (along with the diaphragm)
• Jet needle set
• Piston valve spring
• Diaphragm cover
EAS26890
INSTALLING THE CARBURETOR
1. Install:
• Clamps
4. Install:
• Throttle cable
TIP
• O-ring New
• Throttle cable cover
5. Adjust:
Refer to “ADJUSTING THE ENGINE
IDLING SPEED” on page 3-6.
Align the projection “a” on the carburetor joint
with the slot “b” in the clamp.
Engine idling speed
1550–1650 r/min
6. Adjust:
2. Install:
• Carburetor joint
2.0–4.0 mm (0.08–0.16 in)
TIP
Align the projection “a” on the intake manifold
with the slot “b” in the carburetor joint.
EAS26910
MEASURING AND ADJUSTING THE FUEL
LEVEL
1. Measure:
• Fuel level “a”
Fuel level (above the float
chamber mating surface)
4.0–5.0 mm (0.16–0.20 in)
3. Install:
• Carburetor
TIP
Align the projection “a” on the carburetor with
the slot “b” in the carburetor joint.
6-9
CARBURETOR
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Stand the vehicle on a level surface.
b. Install the fuel level gauge “1” onto the fuel
drain pipe “2”.
Fuel level gauge
90890-01312
YM-01312-A
c. Loosen the fuel drain screw “3”.
d. Hold the fuel level gauge vertically next to
the float chamber “4”.
e. Measure the fuel level “a”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Adjust:
• Fuel level
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the carburetor.
b. Check the needle valve seat and needle
valve.
c. If either is worn, replace the valve seat,
needle valve and O-ring as a set.
d. If both are fine, adjust the float level by
slightly bending the float tang “1”.
e. Install the carburetor.
f. Measure the fuel level again.
g. Repeat steps (a) to (f) until the fuel level is
within specification.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6-10
CARBURETOR
6-11
ELECTRICAL SYSTEM
IGNITION SYSTEM.......................................................................................7-1
CIRCUIT DIAGRAM................................................................................7-1
TROUBLESHOOTING ............................................................................7-3
ELECTRIC STARTING SYSTEM..................................................................7-5
CIRCUIT DIAGRAM................................................................................7-5
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION.........................7-7
TROUBLESHOOTING ............................................................................7-9
CHARGING SYSTEM .................................................................................7-11
CIRCUIT DIAGRAM..............................................................................7-11
TROUBLESHOOTING ..........................................................................7-13
LIGHTING SYSTEM ...................................................................................7-15
CIRCUIT DIAGRAM..............................................................................7-15
SIGNALING SYSTEM.................................................................................7-19
CIRCUIT DIAGRAM..............................................................................7-19
CARBURETOR HEATING SYSTEM ..........................................................7-23
CIRCUIT DIAGRAM..............................................................................7-23
ELECTRICAL COMPONENTS...................................................................7-27
CHECKING THE SWITCHES...............................................................7-29
CHECKING THE BULBS AND BULB SOCKETS.................................7-32
CHECKING THE FUSES......................................................................7-33
CHECKING AND CHARGING THE BATTERY.....................................7-33
CHECKING THE RELAYS....................................................................7-37
CHECKING THE DIODE ......................................................................7-38
CHECKING THE SPARK PLUG CAP...................................................7-38
CHECKING THE IGNITION COIL ........................................................7-38
CHECKING THE PICKUP COIL ...........................................................7-39
CHECKING THE STARTER MOTOR OPERATION..............................7-40
CHECKING THE STATOR COIL...........................................................7-40
CHECKING THE RECTIFIER/REGULATOR ........................................7-40
CHECKING THE THERMO SWITCH ...................................................7-41
CHECKING THE CARBURETOR WARMER .......................................7-41
7
IGNITION SYSTEM
EAS27090
IGNITION SYSTEM
EAS27100
CIRCUIT DIAGRAM
7-1
IGNITION SYSTEM
1. Pickup coil
4. Main switch
5. Battery
8. Fuse
9. CDI unit
10.Ignition coil
11.Spark plug
22.Left handlebar switch
24.Engine stop switch
7-2
IGNITION SYSTEM
EAS27131
TROUBLESHOOTING
The ignition system fails to operate (no spark or intermittent spark).
TIP
• Before troubleshooting, remove the following part(s):
1. Seat
2. Front panel
3. Front fender
4. Rear fender
5. Left side cover
1. Check the fuse.
Refer to “CHECKING THE FUSES”
on page 7-33.
NG→
Replace the fuse.
OK↓
2. Check the battery.
Refer to “CHECKING AND
CHARGING THE BATTERY” on
page 7-33.
NG→
• Clean the battery terminals.
• Recharge or replace the battery.
OK↓
3. Check the spark plug.
Refer to “CHECKING THE SPARK
PLUG” on page 3-4.
NG→
Re-gap or replace the spark plug.
OK↓
4. Check the ignition spark gap.
Refer to “CHECKING THE IGNITION COIL” on page 7-38.
OK→
Ignition system is OK.
NG↓
5. Check the spark plug cap.
Refer to “CHECKING THE SPARK
PLUG CAP” on page 7-38.
NG→
Replace the spark plug cap.
OK↓
6. Check the ignition coil.
Refer to “CHECKING THE IGNITION COIL” on page 7-38.
NG→
Replace the ignition coil.
OK↓
7. Check the pickup coil.
Refer to “CHECKING THE PICKUP
COIL” on page 7-39.
NG→
OK↓
7-3
Replace the pickup coil/stator coil
assembly.
IGNITION SYSTEM
8. Check the main switch.
Refer to “CHECKING THE
SWITCHES” on page 7-29.
NG→
Replace the main switch.
OK↓
9. Check the engine stop switch.
NG→
Replace the left handlebar switch.
OK↓
10.Check the entire ignition system’s
wiring.
Refer to “CIRCUIT DIAGRAM” on
page 7-1.
NG→
Properly connect or repair the ignition
system’s wiring
OK↓
Replace the CDI unit.
7-4
ELECTRIC STARTING SYSTEM
EAS27160
EAS27170
CIRCUIT DIAGRAM
7-5
4. Main switch
5. Battery
6. Starter relay
7. Starter motor
8. Fuse
12.Diode 1
14.Clutch switch
24.Engine stop switch
25.Start switch
28.Neutral switch
7-6
EAS27180
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION
If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed),
the starter motor can only operate if at least one of the following conditions is met:
• The transmission is in neutral (the neutral switch is closed).
• The clutch lever is pulled to the handlebar (the clutch switch is closed).
The starting circuit cut-off relay prevents the starter motor from operating when neither of these conditions has been met. In this instance, the starting circuit cut-off relay is open so current cannot
reach the starter motor. When at least one of the above conditions has been met the starting circuit
cut-off relay is closed and the engine can be started by pressing the starter switch.
7-7
a. WHEN THE TRANSMISSION IS IN NEUTRAL
b. WHEN THE CLUTCH LEVER IS PULLED
TO THE HANDLEBAR
1. Battery
2. Fuse
3. Main switch
4. Engine stop switch
5. Starting circuit cut-off relay
6. Clutch switch
7. Neutral switch
8. Start switch
9. Starter relay
10.Starter motor
7-8
EAS27190
TROUBLESHOOTING
The starter motor fails to turn.
TIP
1. Seat
2. Front panel
3. Front fender
4. Rear fender
5. Left side cover
1. Check the fuse.
on page 7-33.
NG→
Replace the fuse.
OK↓
page 7-33.
NG→
OK↓
3. Check the starter motor operation.
STARTER MOTOR OPERATION”
on page 7-40.
OK→
Starter motor is OK. Perform the electric starting system troubleshooting,
starting with step 5.
NG↓
4. Check the starter motor.
STARTER MOTOR” on page 5-56.
NG→
Repair or replace the starter motor.
OK↓
5. Check the starting circuit cut-off
relay.
RELAYS” on page 7-37.
NG→
Replace the starting circuit cut-off
relay.
OK↓
6. Check the starter relay.
NG→
Replace the starter relay.
OK↓
NG→
OK↓
7-9
8. Check the engine stop switch.
NG→
OK↓
9. Check the diode 1.
Refer to “CHECKING THE DIODE”
on page 7-38.
NG→
Replace the diode 1.
OK↓
10.Check the neutral switch.
NG→
Replace the neutral switch.
OK↓
11.Check the clutch switch.
NG→
Replace the clutch switch.
OK↓
12.Check the start switch.
NG→
OK↓
13.Check the entire starting system’s
wiring.
page 7-5.
NG→
Properly connect or repair the starting
system’s wiring.
OK↓
The starting system circuit is OK.
7-10
CHARGING SYSTEM
EAS27200
CHARGING SYSTEM
EAS27210
CIRCUIT DIAGRAM
7-11
CHARGING SYSTEM
2.
3.
5.
8.
Stator coil
Rectifier/regulator
Battery
Fuse
7-12
CHARGING SYSTEM
EAS27230
TROUBLESHOOTING
The battery is not being charged.
TIP
1. Seat
2. Front panel
3. Front fender
4. Rear fender
5. Left side cover
1. Check the fuse.
on page 7-33.
NG→
Replace the fuse.
OK↓
page 7-33.
NG→
OK↓
3. Check the stator coil.
Refer to “CHECKING THE STATOR
COIL” on page 7-40.
NG→
Replace the pickup coil/stator coil
assembly.
OK↓
4. Check the rectifier/regulator.
Refer to “CHECKING THE RECTIFIER/REGULATOR” on page 7-40.
NG→
Replace the rectifier/regulator.
OK↓
5. Check the entire charging system’s
wiring.
page 7-5.
NG→
Properly connect or repair the charging system’s wiring.
OK↓
The charging system circuit is OK.
7-13
CHARGING SYSTEM
7-14
LIGHTING SYSTEM
EAS27240
LIGHTING SYSTEM
EAS27250
CIRCUIT DIAGRAM
7-15
LIGHTING SYSTEM
4. Main switch
5. Battery
8. Fuse
21.Tail/brake light
23.Dimmer switch
26.Headlight relay
27.Headlight
7-16
LIGHTING SYSTEM
EAS27260
TROUBLESHOOTING
Any of the following fail to light: headlight, taillight.
TIP
1. Seat
2. Front panel
3. Front fender
4. Rear fender
5. Left side cover
1. Check the each bulbs and bulb
sockets condition.
Refer to “CHECKING THE BULBS
AND BULB SOCKETS” on page 732.
NG→
Replace the bulb(s) and bulb
socket(s).
OK↓
2. Check the fuse.
on page 7-33.
NG→
Replace the fuse.
OK↓
page 7-33.
NG→
OK↓
NG→
OK↓
5. Check the dimmer switch.
NG→
The dimmer switch is faulty. Replace
the left handlebar switch.
OK↓
6. Check the headlight relay.
NG→
Replace the headlight relay.
OK↓
7-17
LIGHTING SYSTEM
7. Check the entire lighting system’s
wiring.
page 7-15.
NG→
Properly connect or repair the lighting
system’s wiring.
OK↓
This circuit is OK.
7-18
SIGNALING SYSTEM
EAS27270
SIGNALING SYSTEM
EAS27280
CIRCUIT DIAGRAM
7-19
SIGNALING SYSTEM
4. Main switch
5. Battery
8. Fuse
13.Neutral indicator light
19.Rear brake light switch
20.Front brake light switch
21.Tail/brake light
28.Neutral switch
7-20
SIGNALING SYSTEM
EAS27290
TROUBLESHOOTING
Any of the following fail to light: brake light or an indicator light.
TIP
1. Seat
2. Front panel
3. Front fender
4. Rear fender
5. Left side cover
1. Check the fuse.
on page 7-33.
NG→
Replace the fuse.
OK↓
page 7-33.
NG→
OK↓
NG→
OK↓
4. Check the entire signaling system’s
wiring.
page 7-19.
NG→
Properly connect or repair the signaling system’s wiring.
OK↓
This circuit is OK.
Check the signaling system
The tail/brake light fails to come on.
1. Check the tail/brake light bulb and
socket.
NG→
Replace the tail/brake light bulb,
socket or both.
OK↓
2. Check the brake light switch.
NG→
Replace the brake light switch.
OK↓
7-21
SIGNALING SYSTEM
wiring.
page 7-19.
NG→
OK↓
This circuit is OK.
The neutral indicator light fails to come on.
1. Check the neutral indicator light
bulb and socket.
NG→
Replace the neutral indicator light
bulb, socket or both.
OK↓
2. Check the neutral switch.
NG→
Replace the neutral switch.
OK↓
wiring.
page 7-19.
NG→
OK↓
This circuit is OK.
7-22
CARBURETOR HEATING SYSTEM
EAS27490
EAS27500
CIRCUIT DIAGRAM
7-23
4. Main switch
5. Battery
8. Fuse
17.Thermo switch
18.Carburetor warmer
7-24
EAS27510
TROUBLESHOOTING
The carburetor heating system fails to operate.
TIP
1. Seat
2. Front panel
3. Front fender
4. Rear fender
1. Check the fuse.
on page 7-33.
NG→
Replace the fuse.
OK↓
page 7-33.
NG→
OK↓
NG→
OK↓
4. Check the thermo switch.
THERMO SWITCH” on page 7-41.
NG→
Replace the thermo switch.
OK↓
5. Check the carburetor warmer.
Refer to “CHECKING THE CARBURETOR WARMER” on page 741.
NG→
Replace the carburetor warmer.
OK↓
6. Check the entire carburetor heating
system’s wiring.
page 7-23.
NG→
Properly connect or repair the carburetor heating system’s wiring.
OK↓
This circuit is OK.
7-25
7-26
ELECTRICAL COMPONENTS
EAS27973
7-27
1. Main switch
2. Front brake light switch
3. Clutch switch
4. Left handlebar switch
5. Starter relay
6. Fuse
7. Battery
8. Tail/brake light
9. Thermo switch
10.Carburetor warmer
11.Spark plug
12.Pickup coil/stator assembly
13.Neutral switch
14.Rear brake light switch
15.Starter motor
16.Rectifier/regulator
18.Headlight relay
19.CDI unit
20.Headlight
21.Neutral indicator light
22.Ignition coil
7-28
EAS27981
CHECKING THE SWITCHES
7-29
1.
2.
3.
4.
5.
6.
7.
8.
9.
Light switch
Engine stop switch
Start switch
Main switch
Clutch switch
Fuse
Neutral switch
Rear brake light switch
7-30
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.
Pocket tester
90890-03112
YU-03112-C
TIP
• Before checking for continuity, set the pocket tester to “0” and to the “Ω × 1” range.
• When checking for continuity, switch back and forth between the switch positions a few times.
The switches and their terminal connections are illustrated as in the following example of the main
switch.
The switch positions “a” are shown in the far left column and the switch lead colors “b” are shown in
the top row.
The continuity (i. e., a closed circuit) between switch terminals at a given switch position is indicated
by “
”.
There is continuity between red and brown when the switch is set to “ON”.
7-31
EAS27990
EWA13320
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.
WARNING
Since the headlight bulb gets extremely
hot, keep flammable products and your
hands away from the bulb until it has
cooled down.
ECA14380
• 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.
• Avoid touching the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the
life of the bulb, and the luminous flux will
be adversely affected. If the headlight
bulb gets soiled, thoroughly it with a cloth
moistened with alcohol or lacquer thinner.
Types of bulbs
The bulbs used on this vehicle are shown in
the illustration.
• Bulb “a” is used for the headlight and can be
pulled out by turning counterclockwise while
pushing the bulb holder and removing. After
this, you can remove the bulb.
• Bulb “b” is used for tail/brake lights and can
be removed from the socket by pushing and
turning the bulb counterclockwise.
• Bulb “c” is used for indicator lights and can
be removed from their respective socket by
carefully pulling them out.
2. Check:
• Bulb (for continuity)
No continuity → Replace.
Pocket tester
90890-03112
YU-03112-C
TIP
Before checking for continuity, set the pocket
tester to “0” and to the “Ω × 1” range.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the positive tester probe to terminal “1” and the negative tester probe to terminal “2”, and check the continuity.
b. Connect the positive tester probe to terminal “1” and the negative tester probe to terminal “3”, and check the continuity.
c. If either of the readings indicate no continuity, replace the bulb.
Checking the condition of the bulbs
bulbs.
1. Remove:
• Bulb
Refer to “REPLACING THE HEADLIGHT
BULB” on page 3-25.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7-32
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester to the fuse and
check the continuity.
TIP
Set the pocket tester selector to “Ω × 1”.
Pocket tester
90890-03112
YU-03112-C
Checking the condition of the bulb sockets
bulb sockets.
1. Check:
• Bulb socket (for continuity)
No continuity → Replace.
b. If the pocket tester indicates “∞”, replace
the fuse.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Replace:
• Blown fuse
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Set the main switch to “OFF”.
b. Install a new fuse of the correct amperage
rating.
c. Set on the switches to verify if the electrical
circuit is operational.
d. If the fuse immediately blows again, check
the electrical circuit.
Pocket tester
90890-03112
YU-03112-C
TIP
Check each bulb socket for continuity in the
same manner as described in the bulb section;
however, note the following.
Fuses
Main
Reserve
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install a good bulb into the bulb socket.
b. Connect the pocket tester probes to the
respective leads of the bulb socket.
c. Check the bulb socket for continuity. If any
of the readings indicate no continuity,
replace the bulb socket.
Amperage
rating
15 A
15 A
Q’ty
1
1
EWA13310
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.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28000
CHECKING THE FUSES
fuses.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Install:
• Seat
ECA13680
To avoid a short circuit, always set the main
switch to “OFF” when checking or replacing a fuse.
EAS28031
CHECKING AND CHARGING THE BATTERY
EWA13290
WARNING
1. Remove:
• Seat
2. Check:
• Fuse
Batteries generate explosive hydrogen gas
and contain electrolyte which is made of
poisonous and highly caustic sulfuric acid.
Therefore, always follow these preventive
measures:
7-33
2. Disconnect:
• Battery leads
(from the battery terminals)
• Wear protective eye gear when handling
or working near batteries.
• Charge batteries in a well-ventilated area.
• Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,
lighted cigarettes).
• DO NOT SMOKE when charging or handling batteries.
• KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.
• Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye
injury.
FIRST AID IN CASE OF BODILY CONTACT:
EXTERNAL
• Skin — Wash with water.
• Eyes — Flush with water for 15 minutes
and get immediate medical attention.
INTERNAL
• Drink large quantities of water or milk followed with milk of magnesia, beaten egg
or vegetable oil. Get immediate medical
attention.
ECA13640
First, disconnect the negative battery lead
“1”, and then positive battery lead “2”.
3. Remove:
• Battery
4-1.
4. Check:
• Battery charge
ECA13661
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• This is a VRLA (Valve Regulated Lead
Acid) battery. Never remove the sealing
caps because the balance between cells
will not be maintained and battery performance will deteriorate.
• Charging time, charging amperage and
charging voltage for a VRLA (Valve Regulated Lead Acid) battery are different from
those of conventional batteries. The
VRLA (Valve Regulated Lead Acid) battery should be charged according to the
appropriate charging method. If the battery is overcharged, the electrolyte level
will drop considerably. Therefore, take
special care when charging the battery.
a. Connect a pocket tester to the battery terminals.
• Positive tester probe →
positive battery terminal
• Negative tester probe →
negative battery terminal
TIP
• The charge state of a VRLA (Valve Regulated Lead Acid) battery can be checked by
measuring its open-circuit voltage (i.e., the
voltage when the positive battery terminal is
disconnected).
• No charging is necessary when the open-circuit voltage equals or exceeds 12.8 V.
TIP
b. Check the charge of the battery, as shown
in the charts and the following example.
Since VRLA (Valve Regulated Lead Acid) 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.
Example
Open-circuit voltage = 12.0 V
Charging time = 6.5 hours
Charge of the battery = 20–30%
1. Remove:
• Battery cover
4-1.
7-34
•
•
•
A. Open-circuit voltage (V)
B. Charging time (hours)
C. Relationship between the open-circuit voltage and the charging time at 20 °C (68 °F)
D. These values vary with the temperature,
the condition of the battery plates, and the
electrolyte level.
•
•
on the vehicle, disconnect the negative
battery lead from the battery terminal.)
To reduce the chance of sparks, do not
plug in the battery charger until the battery charger leads are connected to the
battery.
Before removing the battery charger lead
clips from the battery terminals, be sure
to turn off the battery charger.
Make sure the battery charger lead clips
are in full contact with the battery terminal and that they are not shorted. A corroded battery charger lead clip may
generate heat in the contact area and a
weak clip spring may cause sparks.
If the battery becomes hot to the touch at
any time during the charging process,
disconnect the battery charger and let the
battery cool before reconnecting it. Hot
batteries can explode!
As shown in the following illustration, the
open-circuit voltage of a VRLA (Valve
Regulated Lead Acid) battery stabilizes
about 30 minutes after charging has been
completed. Therefore, wait 30 minutes
after charging is completed before measuring the open-circuit voltage.
A. Open-circuit voltage (V)
B. Charging condition of the battery (%)
C. Ambient temperature 20 °C (68 °F)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Charge:
• Battery
(refer to the appropriate charging
method)
EWA13300
WARNING
A.
B.
C.
D.
E.
Do not quick charge a battery.
ECA13671
• Do not use a high-rate battery charger
since it forces a high-amperage current
into the battery quickly and can cause
battery overheating and battery plate
damage.
• If it is impossible to regulate the charging
current on the battery charger, be careful
not to overcharge the battery.
• When charging a battery, be sure to
remove it from the vehicle. (If charging
has to be done with the battery mounted
Open-circuit voltage (V)
Time (minutes)
Charging
Ambient temperature 20 °C (68 °F)
Check the open-circuit voltage.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Charging method using a variable-current
(voltage) charger
a. Measure the open-circuit voltage prior to
charging.
TIP
Voltage should be measured 30 minutes after
the engine is stopped.
7-35
c. Make sure that the current is higher than
the standard charging current written on
the battery.
b. Connect a charger and ammeter to the battery and start charging.
TIP
Set the charging voltage to 16–17 V. If the setting is lower, charging will be insufficient. If too
high, the battery will be over-charged.
TIP
If the current is lower than the standard charging current written on the battery, this type of
battery charger cannot charge the VRLA
(Valve Regulated Lead Acid) battery. A variable voltage charger is recommended.
c. Make sure that the current is higher than
the standard charging current written on
the battery.
d. Charge the battery until the battery’s charging voltage is 15 V.
TIP
If the current is lower than the standard charging current written on the battery, set the
charging voltage adjust dial at 20–24 V and
monitor the amperage for 3–5 minutes to
check the battery.
TIP
Set the charging time at 20 hours (maximum).
e. Measure the battery open-circuit voltage
after leaving the battery unused for more
than 30 minutes.
• Standard charging current is reached
Battery is good.
• Standard charging current is not reached
Replace the battery.
12.8 V or more --- Charging is complete.
12.7 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery.
d. Adjust the voltage so that the current is at
the standard charging level.
e. Set the time according to the charging time
suitable for the open-circuit voltage.
f. If charging requires more than 5 hours, it is
advisable to check the charging current
after a lapse of 5 hours. If there is any
change in the amperage, readjust the voltage to obtain the standard charging current.
g. Measure the battery open-circuit voltage
after leaving the battery unused for more
than 30 minutes.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6. Install:
• Battery
4-1.
7. Connect:
• Battery leads
(to the battery terminals)
ECA13630
First, connect the positive battery lead “1”,
and then the negative battery lead “2”.
12.8 V or more --- Charging is complete.
12.7 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Charging method using a constant voltage
charger
a. Measure the open-circuit voltage prior to
charging.
8. Check:
• Battery terminals
Dirt → Clean with a wire brush.
9. Lubricate:
• Battery terminals
TIP
Voltage should be measured 30 minutes after
the engine is stopped.
b. Connect a charger and ammeter to the battery and start charging.
7-36
Starting circuit cut-off relay
Dielectric grease
10. Install:
• Battery cover
4-1.
EAS28040
CHECKING THE RELAYS
Check each switch for continuity with the
pocket tester. If the continuity reading is incorrect, replace the relay.
1.
2.
3.
4.
Pocket tester
90890-03112
YU-03112-C
Positive battery terminal
Negative battery terminal
Positive tester probe
Negative tester probe
Result
Continuity/No continuity
(between “3” to “4”)
1. Disconnect the relay from the wire harness.
2. Connect the pocket tester (Ω × 1) and battery (12 V) to the relay terminal as shown.
Check the relay operation.
Headlight relay
Starter relay
1.
2.
3.
4.
1.
2.
3.
4.
5.
Result
Continuity
No continuity
Relay operation
Continuity/No continuity
7-37
b. Connect the pocket tester (Ω × 1 k) to the
spark plug cap as shown.
EAS28050
CHECKING THE DIODE
1. Check:
• Diode 1
Pocket tester
90890-03112
YU-03112-C
Pocket tester
90890-03112
YU-03112-C
TIP
The pocket tester or the analog pocket tester
reading are shown in the following table.
No continuity
Positive tester probe → Black/
Yellow “1”
Negative tester probe → Sky
blue “2”
Continuity
Positive tester probe → Sky
blue “2”
Negative tester probe →
Black/Yellow “1”
c. Measure the spark plug cap resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28090
CHECKING THE IGNITION COIL
1. Check:
• Primary coil resistance
Primary coil resistance
0.18–0.28 Ω
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the ignition coil connector from
the ignition coil terminal.
b. Connect the pocket tester (Ω × 1) to the
ignition coil as shown.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the diode from the wire harness.
diode coupler as shown.
c. Check the diode for continuity.
d. Check the diode for no continuity.
Pocket tester
90890-03112
YU-03112-C
• Positive tester probe
Ignition coil terminal “1”
• Negative tester probe
Ignition coil base “2”
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28060
CHECKING THE SPARK PLUG CAP
1. Check:
• Spark plug cap resistance
Resistance
7.5–12.5 kΩ
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the spark plug cap from the spark
plug lead.
7-38
c. Measure the primary coil resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check:
• Secondary coil resistance
Secondary coil resistance
6.32–9.48 kΩ
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the spark plug cap from the
ignition coil.
b. Connect the pocket tester (Ω × 1 k) to the
ignition coil as shown.
2. Spark plug cap
c. Set the main switch to “ON”.
d. Measure the ignition spark gap “a”.
e. Crank the engine by pushing the starter
switch and gradually increase the spark
gap until a misfire occurs.
Pocket tester
90890-03112
YU-03112-C
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Spark plug lead “1”
Ignition coil terminal “2”
EAS28110
CHECKING THE PICKUP COIL
1. Disconnect:
• Pickup coil coupler
(from the wire harness)
2. Check:
• Pickup coil resistance
Pickup coil resistance
248.0–372.0 Ω (R–W)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (Ω × 100) to the
pickup coil terminal as shown.
c. Measure the secondary coil resistance.
Pocket tester
90890-03112
YU-03112-C
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Check:
• Ignition spark gap
Minimum ignition spark gap
6.0 mm (0.24 in)
Red “1”
White “2”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the spark plug cap from the
spark plug.
b. Connect the ignition checker/Opama pet4000 spark checker “1” as shown.
Ignition checker
90890-06754
Opama pet-4000 spark checker
YM-34487
7-39
EAS28150
CHECKING THE STATOR COIL
1. Disconnect:
• Stator coil coupler
2. Check:
• Stator coil resistance
Stator coil resistance
0.64–0.96 Ω (W–W)
b. Measure the pickup coil resistance.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
a. Connect the pocket tester (Ω × 1) to the
stator coil coupler as shown.
EAS28940
CHECKING THE STARTER MOTOR OPERATION
1. Check:
• Starter motor operation
Does not operate → Perform the electric
starting system troubleshooting, starting
with step 4.
Refer to “TROUBLESHOOTING” on page
7-9.
Pocket tester
90890-03112
YU-03112-C
White “1”
White “2”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the positive battery terminal “1”
and starter motor lead “2” with a jumper
lead “3”.
EWA13810
WARNING
• A wire that is used as a jumper lead must
have at least the same capacity of the battery lead, otherwise the jumper lead may
burn.
• This check is likely to produce sparks,
therefore, make sure no flammable gas or
fluid is in the vicinity.
b. Measure the stator coil resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28170
CHECKING THE RECTIFIER/REGULATOR
1. Check:
• Charging voltage
Out of specification → Replace the rectifier/regulator.
Charging voltage
14 V at 5000 r/min
b. Check the starter motor operation.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7-40
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Black “1”
Black “2”
a. Set the digital tachometer to the ignition
coil.
b. Connect the pocket tester (AC 20 V) to the
battery terminal as shown.
Digital tachometer
90890-06760
YU-39951-B
Pocket tester
90890-03112
YU-03112-C
Red “1”
Black “2”
Test step Coolant temperature
Less than 13–19 °C
(55.4–66.2 °F)
More than 13–19 °C
(55.4–66.2 °F)
More than 8–14 °C
(46.4–57.2 °F)
Less than 8–14 °C
(46.4–57.2 °F)
1
2
3
4
Continuity
YES
NO
NO
YES
Step 1 and 2: Heating phase
Step 3 and 4: Cooling phase
c. Start the engine and let it run at approximately 5000 r/min.
d. Measure the charging voltage.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28270
CHECKING THE THERMO SWITCH
1. Remove:
• Thermo switch
EWA13830
WARNING
A. Heating phase
B. Cooling phase
• Handle the thermo switch with special
care.
• Never subject the thermo switch to strong
shocks. If the thermo switch is dropped,
replace it.
3. Install:
• Thermo switch
EAS28310
2. Check:
• Thermo switch continuity
thermo switch.
CHECKING THE CARBURETOR WARMER
1. Check:
• Carburetor warmer resistance
7-41
Carburetor warmer resistance
5.6–8.4 Ω at 25 °C (77 °F)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the carburetor warmer from the
carburetor.
carburetor warmer as shown.
Pocket tester
90890-03112
YU-03112-C
Carburetor warmer terminal “1”
Carburetor warmer body “2”
c. Measure the carburetor warmer resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7-42
7-43
TROUBLESHOOTING
TROUBLESHOOTING ..................................................................................8-1
GENERAL INFORMATION .....................................................................8-1
STARTING FAILURES ............................................................................8-1
INCORRECT ENGINE IDLING SPEED .................................................8-1
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ........................8-2
FAULTY GEAR SHIFTING ......................................................................8-2
SHIFT PEDAL DOES NOT MOVE..........................................................8-2
JUMPS OUT OF GEAR ..........................................................................8-2
FAULTY CLUTCH ...................................................................................8-2
OVERHEATING ......................................................................................8-3
POOR BRAKING PERFORMANCE .......................................................8-3
UNSTABLE HANDLING..........................................................................8-3
FAULTY LIGHTING OR SIGNALING SYSTEM ......................................8-3
8
TROUBLESHOOTING
•
•
•
•
•
•
•
EAS28451
TROUBLESHOOTING
EAS28460
GENERAL INFORMATION
TIP
The following guide for troubleshooting does
not cover all the possible causes of trouble. It
should be helpful, however, as a guide to basic
troubleshooting. Refer to the relative procedure in this manual for checks, adjustments,
and replacement of parts.
Damaged float
Worn needle valve
Improperly installed needle valve seat
Incorrect fuel level
Improperly installed pilot jet
Clogged starter jet
Faulty starter plunger
Electrical system
1. Battery
• Discharged battery
• Faulty battery
2. Fuse
• Blown, damaged or incorrect fuse
• Improperly installed fuse
3. Spark plug
• Incorrect spark plug gap
• Incorrect spark plug heat range
• Fouled spark plug
• Worn or damaged electrode
• Worn or damaged insulator
• Faulty spark plug cap
4. Ignition coil
• Cracked or broken ignition coil body
• Broken or shorted primary or secondary
coils
• Faulty spark plug lead
5. Ignition system
• Faulty CDI unit
• Faulty pickup coil
• Faulty stator coil
• Broken generator rotor woodruff key
6. Switches and wiring
• Faulty main switch
• Faulty engine stop switch
• Broken or shorted wiring
• Faulty neutral switch
• Faulty start switch
• Faulty clutch switch
• Improperly grounded circuit
• Loose connections
7. Starting system
• Faulty starter motor
• Faulty starter relay
• Faulty starting circuit cut-off relay
• Faulty starter clutch
EAS28470
STARTING FAILURES
Engine
1. Cylinder and cylinder head
• Loose spark plug
• Loose cylinder head or cylinder
• Damaged cylinder head gasket
• Damaged cylinder gasket
• Worn or damaged cylinder
• Incorrect valve clearance
• Improperly sealed valve
• Incorrect valve-to-valve-seat contact
• Incorrect valve timing
• Faulty valve spring
• Seized valve
2. Piston and piston ring
• Improperly installed piston ring
• Damaged, worn or fatigued piston ring
• Seized piston ring
• Seized or damaged piston
3. Air filter
• Improperly installed air filter
• Clogged air filter element
4. Crankcase and crankshaft
• Improperly assembled crankcase
• Seized crankshaft
Fuel system
1. Fuel tank
• Empty fuel tank
• Clogged fuel strainer
• Clogged fuel tank breather hose
• Deteriorated or contaminated fuel
2. Fuel cock
• Clogged or damaged fuel hose
3. Carburetor
• Deteriorated or contaminated fuel
• Clogged pilot jet
• Clogged pilot air passage
• Sucked-in air
EAS28490
INCORRECT ENGINE IDLING SPEED
Engine
1. Cylinder and cylinder head
• Incorrect valve clearance
• Damaged valve train components
8-1
TROUBLESHOOTING
2. Air filter
• Loosen air filter joint
EAS28530
FAULTY GEAR SHIFTING
Shifting is difficult
Refer to “Clutch drags”.
Fuel system
1. Carburetor
• Faulty starter plunger
• Loose or clogged pilot jet
• Loose or clogged pilot air jet
• Damaged or loose carburetor joint
• Improperly adjusted engine idling speed
(throttle stop screw)
• Improper throttle lever free play
• Flooded carburetor
EAS28540
SHIFT PEDAL DOES NOT MOVE
Shift shaft
• Improperly adjusted shift rod
• Bent shift shaft
Shift drum and shift forks
• Foreign object in a shift drum groove
• Seized shift fork
• Bent shift fork guide bar
Electrical system
1. Battery
• Discharged battery
• Faulty battery
2. Spark plug
• Fouled spark plug
• Worn or damaged electrode
• Worn or damaged insulator
• Faulty spark plug cap
3. Ignition coil
• Broken or shorted primary or secondary
coils
• Faulty spark plug lead
• Cracked or broken ignition coil
4. Ignition system
• Faulty CDI unit
• Faulty pickup coil
• Broken generator rotor woodruff key
Transmission
• Seized transmission gear
• Foreign object between transmission gears
• Improperly assembled transmission
EAS28550
JUMPS OUT OF GEAR
Shift shaft
• Incorrect shift pedal position
• Improperly returned stopper lever
Shift forks
• Worn shift fork
Shift drum
• Incorrect axial play
• Worn shift drum groove
Transmission
• Worn gear dog
EAS28510
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE
Refer to “STARTING FAILURES” on page 8-1.
EAS28560
FAULTY CLUTCH
Clutch slips
1. Clutch
• Improperly assembled clutch
• Improperly adjusted clutch cable
• Loose or fatigued clutch spring
• Worn friction plate
• Worn clutch plate
2. Engine oil
• Incorrect oil level
• Incorrect oil viscosity (low)
• Deteriorated oil
Engine
1. Air filter
Fuel system
1. Carburetor
• Faulty diaphragm
• Incorrect fuel level
• Loose or clogged main jet
Clutch drags
1. Clutch
• Unevenly tensioned clutch springs
8-2
TROUBLESHOOTING
• Warped pressure plate
• Bent clutch plate
• Swollen friction plate
• Bent clutch push rod
• Broken clutch boss
• Burnt primary driven gear bushing
• Match marks not aligned
2. Engine oil
• Incorrect oil viscosity (high)
• Deteriorated oil
EAS28670
UNSTABLE HANDLING
1. Handlebar
• Bent or improperly installed handlebar
2. Steering components
• Incorrect toe-in
• Improperly installed steering stem
• Bent tie-rods
• Bent steering stem
• Damaged bushing
• Deformed steering knuckles
3. Front shock absorber assembly(-ies)
• Faulty front shock absorber spring
• Leaking oil
4. Swingarm
• Worn bearing or bushing
• Bent or damaged swingarm
5. Rear shock absorber assembly
• Faulty rear shock absorber spring
• Leaking oil or gas
6. Tire(s)
• Uneven tire pressures (front and rear)
• Incorrect tire pressure
• Uneven tire wear
7. Wheel(s)
• Incorrect wheel balance
• Deformed cast wheel
• Damaged wheel bearing
• Bent or loose wheel axle
• Excessive wheel runout
8. Frame
• Bent frame
• Improperly installed bushing
EAS28590
OVERHEATING
Engine
1. Cylinder head and piston
• Heavy carbon buildup
2. Engine oil
• Incorrect oil viscosity
• Inferior oil quality
Fuel system
1. Carburetor
• Incorrect main jet setting
• Incorrect fuel level
• Damaged or loose carburetor joint
2. Air filter
Chassis
1. Brake(s)
• Dragging brake
EAS28710
Electrical system
1. Spark plug
2. Ignition system
• Faulty CDI unit
FAULTY LIGHTING OR SIGNALING SYSTEM
Headlight does not come on
• Wrong headlight bulb
• Too many electrical accessories
• Hard charging
• Incorrect connection
• Poor contacts (main or light switch)
• Burnt-out headlight bulb
EAS28620
POOR BRAKING PERFORMANCE
• Worn brake pad
• Worn brake disc
• Air in hydraulic brake system
• Leaking brake fluid
• Faulty brake caliper kit
• Faulty brake caliper seal
• Loose union bolt
• Damaged brake hose
• Oil or grease on the brake disc
• Oil or grease on the brake pad
• Incorrect brake fluid level
Headlight bulb burnt out
• Wrong headlight bulb
• Faulty battery
• Faulty rectifier/regulator
• Faulty main switch
• Faulty light switch
• Headlight bulb life expired
8-3
TROUBLESHOOTING
Tail/brake light does not come on
• Wrong tail/brake light bulb
• Too many electrical accessories
• Incorrect connection
• Burnt-out tail/brake light bulb
Tail/brake light bulb burnt out
• Wrong tail/brake light bulb
• Faulty battery
• Incorrectly adjusted rear brake light switch
• Tail/brake light bulb life expired
8-4
EAS28740
WIRING DIAGRAM
YFM125RA
1. Pickup coil
2. Stator coil
3. Rectifier/regulator
4. Main switch
5. Battery
6. Starter relay
7. Starter motor
8. Fuse
9. CDI unit
10. Ignition coil
11. Spark plug
12. Diode 1
13. Neutral indicator light
14. Clutch switch
15. Starting circuit cut-off relay
16. Diode 2
17. Thermo switch
18. Carburetor warmer
19. Rear brake light switch
20. Front brake light switch
21. Tail/brake light
22. Left handlebar switch
23. Dimmer switch
24. Engine stop switch
25. Start switch
26. Headlight relay
27. Headlight
28. Neutral switch
EAS28750
COLOR CODE
B
Br
G
L
O
R
Sb
W
Y
B/R
B/Y
L/B
R/B
Y/R
R/W
Black
Brown
Green
Blue
Orange
Red
Sky blue
White
Yellow
Black/Red
Black/Yellow
Blue/Black
Red/Black
Yellow/Red
Red/White
YAMAHA MOTOR CO., LTD.
2500 SHINGAI IWATA SHIZUOKA JAPAN
WIRING DIAGRAM
YFM125RA
WIRING DIAGRAM
YFM125RA

Raptor 125 - Maul Tech ATV

Transcription

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