Yamaha 2009 YFM25RY Service Manual

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2009

SERVICE MANUAL

YFM25RY

YFM25RSEY

YFM25RSE2Y

LIT-11616-22-09

4D3-28197-11

Table of Contents

Chapters

Table of Contents

Troubleshooting

Summary of Contents for Yamaha 2009 YFM25RY

Page 1 2009 SERVICE MANUAL YFM25RY YFM25RSEY YFM25RSE2Y LIT-11616-22-09 4D3-28197-11...
Page 2 EAS20040 YFM25RY/YFM25RSEY/YFM25RSE2Y SERVICE MANUAL ©2008 by Yamaha Motor Corporation, U.S.A. First edition, April 2008 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-11616-22-09...
Page 3 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.
Page 4 EAS20090 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. •...
Page 5 EAS20100 SYMBOLS The following symbols are used in this manual for easier understanding. The following symbols are not relevant to every vehicle. SYMBOL DEFINITION Serviceable with engine mounted Filling fluid Lubricant Special tool Tightening torque Wear limit, clearance Engine speed Electrical data Engine oil...
Page 6 SYMBOL DEFINITION Gear oil Molybdenum-disulfide oil Brake fluid Wheel-bearing grease Lithium-soap-based grease Molybdenum-disulfide grease Silicone grease Apply locking agent (LOCTITE®) Replace the part...
Page 7: Table Of Contents
EAS20110 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING...
Page 9: General Information
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..........1-3 LOCK WASHERS/PLATES AND COTTER PINS ........1-3 BEARINGS AND OIL SEALS ..............1-3 CIRCLIPS ....................1-3 CHECKING THE CONNECTIONS ...............1-4 SPECIAL TOOLS..................1-5...
Page 10: Identification
IDENTIFICATION EAS20130 IDENTIFICATION EAS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the right side of the steering head pipe. EAS20150 MODEL LABEL The model label “1” is affixed to the frame. This information will be needed to order spare parts.
Page 11: Important Information
5. Keep all parts away from any source of fire. EAS20200 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but...
Page 12: Gaskets, Oil Seals And O-Rings
IMPORTANT INFORMATION EAS20210 GASKETS, OIL SEALS AND O-RINGS 1. When overhauling the engine, replace all gaskets, seals and O-rings. All gasket sur- faces, oil seal lips and O-rings must be cleaned. 2. During reassembly, properly oil all mating parts and bearings and lubricate the oil seal lips with grease.
Page 13: Checking The Connections
CHECKING THE CONNECTIONS EAS20250 CHECKING THE CONNECTIONS Pocket tester 90890-03112 Check the leads, couplers, and connectors for Analog pocket tester stains, rust, moisture, etc. YU-03112-C 1. Disconnect: • Lead • Coupler • If there is no continuity, clean the terminals. •...
Page 14: Special Tools
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 inappropri- ate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country.
Page 15 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Crankshaft installer pot 5-60 90890-01274 Installing pot YU-90058 Crankshaft installer bolt 5-60 90890-01275 Bolt YU-90060 Adapter (M10) 5-60 90890-01383 Adapter #2 YU-90062 Spacer 5-60 90890-01288 Piston pin puller set 5-25 90890-01304 Piston pin puller YU-01304...
Page 16 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Tappet adjusting tool 90890-01311 Six piece tappet set YM-A5970 Flywheel puller 5-46 90890-01362 Heavy duty puller YU-33270-B Bolt (M8 × 80 mm) 5-46 90890-01359 Sheave holder 5-46, 5-47 90890-01701 Primary clutch holder YS-01880-A Thickness gauge 3-4, 5-33...
Page 17 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Extension 90890-04082 Pocket tester 1-4, 5-51, 7-31, 90890-03112 7-32, 7-33, 7- Analog pocket tester 37, 7-38, 7-39, YU-03112-C 7-40, 7-41, 7-42 Timing light 90890-03141 Inductive clamp timing light YU-03141 Valve spring compressor 5-17, 5-22 90890-04019 YM-04019...
Page 18 Valve lapping tool YM-A8998 PTT wrench 46 4-13, 4-14 90890-06588 Axle nut wrench (46 mm) YM-37134 Ignition checker 7-39 90890-06754 Opama pet-4000 spark checker YM-34487 Digital tachometer 3-5, 3-8 90890-06760 YU-39951-B Yamaha bond No. 1215 5-55 (Three Bond No.1215®) 90890-85505...
Page 19: Specifications
SPECIFICATIONS GENERAL SPECIFICATIONS ..............2-1 ENGINE SPECIFICATIONS................2-4 CHASSIS SPECIFICATIONS..............2-10 ELECTRICAL SPECIFICATIONS...............2-12 TIGHTENING TORQUES................2-14 GENERAL TIGHTENING TORQUE SPECIFICATIONS.......2-14 ENGINE TIGHTENING TORQUES ............2-15 CHASSIS TIGHTENING TORQUES ............2-17 LUBRICATION POINTS AND LUBRICANT TYPES ........2-19 ENGINE ....................2-19 LUBRICATION SYSTEM CHART AND DIAGRAMS .........2-21 ENGINE OIL LUBRICATION CHART ...........2-21 LUBRICATION DIAGRAMS ..............2-23 CABLE ROUTING ..................2-29...
Page 20: General Specifications
GENERAL SPECIFICATIONS EAS29110 GENERAL SPECIFICATIONS Model Model 4D3D/4D3H/4D3M Dimensions Overall length 1625 mm (64.0 in) Overall width 1070 mm (42.1 in) Overall height 1040 mm (40.9 in) Seat height 730 mm (28.7 in) Wheelbase 1110 mm (43.7 in) Ground clearance 100 mm (3.9 in) Minimum turning radius 2900 mm (114 in)
Page 21 GENERAL SPECIFICATIONS Spark plug (s) Manufacturer/model NGK/DR7EA Spark plug gap 0.6–0.7 mm (0.024–0.028 in) Clutch type Wet, multiple-disc Transmission Primary reduction system Spur gear Primary reduction ratio 76/22 (3.455) Secondary reduction system Chain drive Secondary reduction ratio 38/14 (2.714) Transmission type Constant mesh 5-speed Operation Left foot operation...
Page 22 GENERAL SPECIFICATIONS Rear suspension Type Swingarm Spring/shock absorber type Coil spring/gas-oil damper Wheel travel 200 mm (7.9 in) Electrical system Ignition system DC. CDI Charging system AC magneto Model YTZ7S Voltage, capacity 12 V, 6.0 Ah Headlight Bulb type Krypton bulb Bulb voltage, wattage ×...
Page 23: Engine Specifications
ENGINE SPECIFICATIONS EAS29120 ENGINE SPECIFICATIONS Cylinder head Volume 20.50–21.50 cm (1.25–1.31 cu.in) Warpage limit 0.05 mm (0.0020 in) Cylinder Bore 74.000–74.016 mm (2.9134–2.9140 in) Wear limit 74.100 mm (2.9173 in) Camshaft Drive system Chain drive (right) Camshaft lobe dimensions Intake A 36.890–36.990 mm (1.4524–1.4563 in) Limit 36.790 mm (1.4484 in)
Page 24 ENGINE SPECIFICATIONS Valve, valve seat, valve guide Valve clearance (cold) Intake 0.05–0.10 mm (0.0020–0.0039 in) Exhaust 0.10–0.15 mm (0.0039–0.0059 in) Valve dimensions Valve head diameter A (intake) 33.90–34.10 mm (1.3346–1.3425 in) Valve head diameter A (exhaust) 28.40–28.60 mm (1.1181–1.1260 in) Valve face width B (intake) 2.26 mm (0.0890 in) Valve face width B (exhaust)
Page 25 ENGINE SPECIFICATIONS Valve spring Inner spring Free length (intake) 36.17 mm (1.42 in) Limit 34.36 mm (1.35 in) Free length (exhaust) 36.17 mm (1.42 in) Limit 34.36 mm (1.35 in) Installed length (intake) 30.50 mm (1.20 in) Installed length (exhaust) 30.50 mm (1.20 in) Spring rate K1 (intake) 14.70 N/mm (1.50 kgf/mm, 83.94 lbf/in)
Page 26 ENGINE SPECIFICATIONS Piston Piston-to-cylinder clearance 0.010–0.025 mm (0.0004–0.0010 in) Limit 0.15 mm (0.0059 in) Diameter D 73.983–73.998 mm (2.9127–2.9133 in) Height H 5.0 mm (0.20 in) Offset 0.25 mm (0.0098 in) Offset direction Intake side Piston pin bore inside diameter 17.002–17.013 mm (0.6694–0.6698 in) Limit 17.043 mm (0.6710 in)
Page 27 ENGINE SPECIFICATIONS Crankshaft Width A 69.25–69.30 mm (2.726–2.728 in) Runout limit C 0.03 mm (0.0012 in) Big end side clearance D 0.350–0.650 mm (0.0138–0.0256 in) Limit 0.50 mm (0.0197 in) Big end radial clearance E 0.010–0.025 mm (0.0004–0.0010 in) Balancer Balancer drive method Gear Clutch...
Page 28 ENGINE SPECIFICATIONS Carburetor ID mark 4D31 00 Main jet #133.8 Main air jet #140 Jet needle 5DH66-1 Needle jet P-0M (922) Pilot air jet 1 Pilot air jet 2 #170 Pilot outlet Pilot jet Bypass 1 Bypass 2 Bypass 3 Valve seat size Starter jet 1 Starter jet 2...
Page 29: Chassis Specifications
CHASSIS SPECIFICATIONS EAS29130 CHASSIS SPECIFICATIONS Front suspension Shock absorber travel 90.7 mm (3.57 in) (4D3D) 88.4 mm (3.48 in) (4D3H, 4D3M) Spring free length 248.5 mm (9.78 in) (4D3D) 224.6 mm (8.84 in) (4D3H, 4D3M) Spring rate K1 23.00 N/mm (2.35 kgf/mm, 131.33 lbf/in) Spring stroke K1 0.0–90.7 mm (0.00–3.57 in) (4D3D) 0.0–88.4 mm (0.00–3.48 in) (4D3H, 4D3M)
Page 30 CHASSIS SPECIFICATIONS Front brake Type Dual disc brake Disc outside diameter × thickness 161.0 × 3.5 mm (6.34 × 0.14 in) Brake disc thickness limit 3.0 mm (0.12 in) Brake disc deflection limit 0.15 mm (0.006 in) Brake pad lining thickness (inner) 4.4 mm (0.17 in) Limit 1.5 mm (0.06 in)
Page 31: Electrical Specifications
24.4 °/5000 r/min Advanced timing (B.T.D.C.) Advancer type Digital DC. CDI 248-372 Ω (R–W) Pickup coil resistance CDI unit model/manufacturer 4D3/YAMAHA Ignition coil Model/manufacturer 2JN/YAMAHA Minimum ignition spark gap 6.0 mm (0.24 in) 0.18–0.28 Ω Primary coil resistance Secondary coil resistance 6.32–9.48 kΩ...
Page 32 ELECTRICAL SPECIFICATIONS Headlight relay Model/manufacturer G8HN-1C4T-DJ-Y52/OMRON 94.5–115.5 Ω Coil resistance Circuit breaker Circuit breaker type Fuse Fuse Fuse 15.0 A Reserve 15.0 A 2-13...
Page 33: Tightening Torques
TIGHTENING TORQUES EAS20320 TIGHTENING TORQUES EAS20330 GENERAL TIGHTENING TORQUE SPECIFI- CATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for spe- cial components or assemblies are provided for each chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached.
Page 34: Engine Tightening Torques
TIGHTENING TORQUES EAS20340 ENGINE TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size See TIP Cylinder head bolt (upper) 24 Nm (2.4 m·kg, 18 ft·lb) Cylinder head bolt 20 Nm (2.0 m·kg, 15 ft·lb) Camshaft lock plate bolt 8 Nm (0.8 m·kg, 5.9 ft·lb) Cylinder head side cover bolt (1 and 2) 18 Nm (1.8 m·kg, 13 ft·lb) Cylinder head side cover bolt 3...
Page 35 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Use a lock Primary drive gear nut 80 Nm (8.0 m·kg, 59 ft·lb) washer. Use a lock Clutch boss nut 75 Nm (7.5 m·kg, 55 ft·lb) washer. Clutch spring screw 8 Nm (0.8 m·kg, 5.9 ft·lb) Push lever adjusting screw locknut 8 Nm (0.8 m·kg, 5.9 ft·lb) Push lever shaft bolt...
Page 36: Chassis Tightening Torques
TIGHTENING TORQUES EAS20350 CHASSIS TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Engine upper stay and frame 33 Nm (3.3 m·kg, 24 ft·lb) Engine upper stay and engine 66 Nm (6.6 m·kg, 49 ft·lb) Engine lower stay and frame 33 Nm (3.3 m·kg, 24 ft·lb) Engine lower stay and engine 40 Nm (4.0 m·kg, 30 ft·lb)
Page 37 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Front brake disc and front wheel hub 28 Nm (2.8 m·kg, 21 ft·lb) Rear wheel and rear wheel hub 45 Nm (4.5 m·kg, 33 ft·lb) Rear axle and rear wheel hub 120 Nm (12.0 m·kg, 89 ft·lb) 140 Nm (14.0 m·kg, 103 Rear axle ring nut...
Page 38: Lubrication Points And Lubricant Types
Push rod ball Transmission gears (inside and end) Transmission gears (fork ditch) Shift fork guide bar Shift drum Shift shafts Yamaha bond Crankcase mating surfaces No.1215 (Three bond No.1215®) Yamaha bond AC magneto lead grommet (AC magneto cover) No.1215 (Three bond No.1215®)
Page 39 LUBRICATION POINTS AND LUBRICANT TYPES 2-20...
Page 40: Lubrication System Chart And Diagrams
LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 2-21...
Page 41 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil pan 2. Oil strainer 3. Oil pump 4. Oil cooler 5. Oil filter element 6. Cylinder head 7. Camshaft 8. Pin with hole 9. Crankshaft 10.Drive axle 11.Main axle 2-22...
Page 42: Lubrication Diagrams
LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20410 LUBRICATION DIAGRAMS 2-23...
Page 43 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Camshaft 2. Oil filter element 3. Oil pump 4. Oil strainer 2-24...
Page 44 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-25...
Page 45 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Camshaft 2. Drive axle 3. Main axle 4. Push lever shaft 5. Oil pump assembly 6. Oil strainer 7. Crankshaft assembly 8. Oil filter element 2-26...
Page 46 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-27...
Page 47 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil cooler 2. Oil hose 1 3. Oil hose 2 2-28...
Page 48: Cable Routing
CABLE ROUTING EAS20430 CABLE ROUTING 2-29...
Page 49 CABLE ROUTING 1. Clutch switch lead 2. Clutch cable 3. Front brake hose 1 4. Front brake light switch lead 5. Throttle cable 6. Plastic band 7. Parking brake cable 8. Handlebar switch lead A. Route the clutch cable and parking brake cable through the guide of the handlebar protector.
Page 50 CABLE ROUTING 2-31...
Page 51 CABLE ROUTING O. When installing the brake pipe, place the 1. Indicator light lead marking on top and tighten the above flare 2. Main switch lead nut first. 3. Coupler joint P. Route the rear brake light switch lead 4. Front brake hose 2 under the bracket.
Page 52 CABLE ROUTING 2-33...
Page 53 CABLE ROUTING 1. Rear brake reservoir 2. Rear brake light switch 3. Clip 4. Rear brake reservoir hose 5. Rear brake master cylinder 6. Parking brake cable 7. Rear brake hose 8. Rear brake caliper A. Make sure that the end of the clip is facing downward.
Page 54 CABLE ROUTING 2-35...
Page 55 CABLE ROUTING 4D3D 1. Clutch switch lead 2. Handlebar switch lead 3. Bolt 4. Hexagonal head bolt 5. Main harness 6. Air vent hose 7. Clamp 8. Battery negative lead 9. AC magneto lead 10.Carburetor overflow hose 11.Neutral switch lead 12.Starter motor lead 13.Ignition coil spark plug lead 14.Ignition coil...
Page 56 CABLE ROUTING 2-37...
Page 57 CABLE ROUTING 4D3H/4D3M 1. Clutch switch lead 2. Handlebar switch lead 3. Bolt 4. Hexagonal head bolt 5. Main harness 6. Air vent hose 7. Clamp 8. Battery negative lead 9. AC magneto lead 10.Carburetor overflow hose 11.Neutral switch lead 12.Starter motor lead 13.Ignition coil spark plug lead 14.Ignition coil...
Page 58 CABLE ROUTING 2-39...
Page 59 CABLE ROUTING 1. Indicator light 2. Coupler joint 3. Main switch lead 4. Main switch 5. Front brake light switch lead 6. Throttle cable 7. Air vent hose 8. Clutch switch lead 9. Handlebar switch lead 10.Parking brake cable 11.Clutch cable 12.Flange bolt 13.Headlight lead 14.Indicator light lead...
Page 60 CABLE ROUTING 2-41...
Page 61 CABLE ROUTING 1. Battery 2. CDI unit 3. Band 4. Starter relay lead 5. Starter relay 6. Taillight lead 7. Battery negative lead 8. AC magneto coupler 9. Starter motor lead 10.Headlight relay 11.Neutral relay 12.Damper 13.CDI unit lead 14.Relay lead A.
Page 62 CABLE ROUTING 2-43...
Page 63: Periodic Checks And Adjustments
PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE .................3-1 INTRODUCTION ..................3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM................3-1 GENERAL MAINTENANCE AND LUBRICATION CHART.....3-2 ENGINE......................3-4 ADJUSTING THE VALVE CLEARANCE ..........3-4 ADJUSTING THE ENGINE IDLING SPEED ..........3-5 ADJUSTING THE THROTTLE CABLE FREE PLAY ......3-6 ADJUSTING THE SPEED LIMITER ............3-7 CHECKING THE SPARK PLUG .............3-7 CHECKING THE IGNITION TIMING ............3-8...
Page 64 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY (for 4D3H, 4D3M)..................3-28 CHECKING THE TIRES ...............3-29 CHECKING THE WHEELS ..............3-31 CHECKING AND LUBRICATING THE CABLES ........3-31 LUBRICATING THE LEVERS...............3-31 LUBRICATING THE PEDAL ..............3-31 ELECTRICAL SYSTEM................3-32 CHECKING AND CHARGING THE BATTERY........3-32 CHECKING THE FUSES..............3-32 REPLACING THE HEADLIGHT BULBS..........3-32 ADJUSTING THE HEADLIGHT BEAMS ..........3-32...
Page 66: Periodic Maintenance
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.
Page 67: General Maintenance And Lubrication Chart
PERIODIC MAINTENANCE EAS4D3F012 GENERAL MAINTENANCE AND LUBRICATION CHART INITIAL EVERY Whichever month CHECK OR MAINTENANCE comes first ITEM 1300 2500 2500 5000 (mi) (200) (800) (1600) (1600) (3200) hours Every 20–40 hours (more often in wet or Air filter element •...
Page 68 PERIODIC MAINTENANCE INITIAL EVERY Whichever month CHECK OR MAINTENANCE comes first ITEM 1300 2500 2500 5000 (mi) (200) (800) (1600) (1600) (3200) hours Lights and • Check operation and correct if necessary. √ √ √ √ √ 25 * switches •...
Page 69: Engine
ENGINE EAS20472 ENGINE Valve clearance (cold) Intake valve 0.05–0.10 mm (0.0020–0.0039 EAS20520 ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the Exhaust valve valves. 0.10–0.15 mm (0.0039–0.0059 • Valve clearance adjustment should be made ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ on a cold engine, at room temperature. a.
Page 70: Adjusting The Engine Idling Speed
ENGINE e. If the valve clearance is still out of specifi- cation, repeat all of the valve clearance adjustment steps until the specified clear- ance is obtained. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 6. Install: • All removed parts For installation, reverse the removal proce- dure.
Page 71: Adjusting The Throttle Cable Free Play
ENGINE 5. Detach: • Digital tachometer 6. Adjust: • Throttle cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY” on page 3-6. Throttle cable free play 2.0–4.0 mm (0.08–0.16 in) EAS20660 ADJUSTING THE THROTTLE CABLE FREE PLAY If the specified throttle cable free play cannot be obtained on the carburetor side of the Prior to adjusting the throttle cable free play, cable, use the adjusting nut on the handlebar...
Page 72: Adjusting The Speed Limiter
ENGINE EAS29170 EAS20690 ADJUSTING THE SPEED LIMITER CHECKING THE SPARK PLUG The speed limiter keeps the carburetor throttle 1. Disconnect: from becoming fully-opened even when the • Spark plug cap throttle lever is applied to the maximum posi- 2. Remove: tion.
Page 73: Checking The Ignition Timing
ENGINE 7. Install: • Spark plug c. Check that the stationary pointer “a” is within the firing range “b” on the pickup coil Spark plug rotor. 18 Nm (1.8 m·kg, 13 ft·lb) Incorrect firing range → Check the ignition system. Before installing the spark plug, clean the spark plug and gasket surface.
Page 74: Checking The Engine Oil Level
ENGINE 4. Remove: b. With the throttle wide open, crank the • Spark plug engine until the reading on the compres- ECA13340 sion gauge stabilizes. EWA4D3F002 WARNING Before removing the spark plug, use com- pressed air to blow away any dirt accumu- To prevent sparking, ground spark plug lated in the spark plug wells to prevent it lead before cranking the engine.
Page 75: Changing The Engine Oil
ENGINE • Do not screw the dipstick “1” in when check- ing the oil level. 4. Start the engine, warm it up for several minutes, and then turn it off. 5. Check the engine oil level again. Type Before checking the engine oil level, wait a few YAMALUBE 4 (10W-40) or SAE minutes until the oil has settled.
Page 76 ENGINE 6. Drain: Engine oil quantity • Engine oil Without filter element (completely from the crankcase) replacement 7. If the oil filter element is also to be 1.25 L (1.32 US qt, 1.10 Imp.qt) replaced, perform the following procedure. With oil filter element replace- ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
Page 77: Adjusting The Clutch Cable Free Play
ENGINE EAS20870 EAS20941 ADJUSTING THE CLUTCH CABLE FREE CLEANING THE AIR FILTER ELEMENT PLAY 1. Check: On the bottom of the air filter case is a check • Clutch cable free play “a” hose “1”. If dust or water or both collects in this Out of specification →...
Page 78: Checking The Carburetor Joint And Intake Manifold
ENGINE 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 Foam air filter oil or equivalent 7.
Page 79: Checking The Fuel Line
ENGINE • Air filter case 2. Check: Refer to “GENERAL CHASSIS” on page • Tightening torque 4-1. Exhaust pipe nut • Carburetor 18 Nm (1.8 m·kg, 13 ft·lb) Refer to “CARBURETOR” on page 6-3. Muffler joint bolt 2. Check: 20 Nm (2.0 m·kg, 15 ft·lb) •...
Page 80 ENGINE d. Insert the tailpipe and gasket “3” into the muffler and align the bolt holes. e. Insert the bolts and tighten it. Spark arrester bolt 11 Nm (1.1 m·kg, 8.1 ft·lb) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3-15...
Page 81: Chassis
CHASSIS EAS29360 CHASSIS 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 3-20. ECA13490 Brake lever free play (at the end of the brake lower) After adjusting the brake lever position, 0 mm (0 in)
Page 82: Checking The Brake Fluid Level
CHASSIS EWA14900 WARNING After this adjustment is performed, lift the front and rear wheels off the ground by placing a block under the engine, and spin the rear wheels to ensure there is no brake drag. If any brake drag is noticed perform the above steps again.
Page 83: Checking The Front Brake Pads
CHASSIS EAS21250 CHECKING THE FRONT BRAKE PADS The following procedure applies to all of the brake pads. 1. Remove: • Front wheels Refer to “FRONT WHEEL” on page 4-4. 2. Operate the brake. 3. Check: • Front brake pad Wear indicators groove almost disap- peared “a”...
Page 84: Adjusting The Parking Brake
CHASSIS 3. Hold the vehicle upright and apply the front brake several times. 4. Check: • Brake hose Brake fluid leakage → Replace the dam- aged hose. Refer to “REAR BRAKE” on page 4-27. EAS29210 ADJUSTING THE PARKING BRAKE 1. Check: •...
Page 85: Bleeding The Hydraulic Brake System
CHASSIS c. Connect a clear plastic hose “1” tightly to Direction “a” the bleed screw “2”. Brake light comes on sooner. Direction “b” Brake light comes on later. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS21350 BLEEDING THE HYDRAULIC BRAKE SYS- EWA13100 WARNING Bleed the hydraulic brake system when- ever: •...
Page 86: Adjusting The Shift Pedal
CHASSIS k. Fill the brake fluid reservoir to the proper EAS21390 ADJUSTING THE DRIVE CHAIN SLACK level with the recommended brake fluid. Refer to “CHECKING THE BRAKE FLUID • Measure the drive chain slack halfway LEVEL” on page 3-17. between the drive axle and the rear axle. EWA13110 WARNING •...
Page 87: Lubricating The Drive Chain
CHASSIS age 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 sol- vents that could damage the O-rings.
Page 88: Adjusting The Toe-In
CHASSIS 4. Raise the front end of the vehicle so that there is no weight on the front wheels. 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.
Page 89: Checking The Front Shock Absorber Assemblies
CHASSIS 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 4-47. EAS29310 ADJUSTING THE FRONT SHOCK d.
Page 90: Adjusting The Front Shock Absorber Assemblies (For 4D3H, 4D3M)
CHASSIS ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS4D3F031 ADJUSTING THE FRONT SHOCK ABSORBER ASSEMBLIES (for 4D3H, 4D3M) EWA14920 WARNING Be sure to remove all dirt and mud from Always adjust the spring preload for both around the locknut and adjusting ring before front shock absorber assemblies to the adjustment.
Page 91 CHASSIS Rebound damping adjusting Compression damping (slow positions compression damping) adjusting Minimum positions 20 clicks in direction: “b”* Minimum Standard 20 clicks in direction: “b”* 12 clicks in direction: “b”* Standard Maximum 10 clicks in direction: “b”* 3 clicks in direction: “b”* Maximum 1 clicks in direction: “b”* * With the adjusting screw fully turned-in...
Page 92: Checking The Rear Shock Absorber Assembly
CHASSIS EAS29330 Compression damping (fast com- ADJUSTING THE REAR SHOCK pression damping) adjusting ABSORBER ASSEMBLY (for 4D3D) positions 1. Adjust: Minimum • Spring preload 4 turns in direction: “b”* ECA4D3F006 Standard 2 turns in direction: “b”* Never attempt to turn the adjusting nut Maximum beyond the maximum or minimum setting.
Page 93: Adjusting The Rear Shock Absorber Assembly (For 4D3H, 4D3M)
CHASSIS Spring preload adjusting length Be sure to remove all dirt and mud from “c” around the locknut and adjusting nut before Minimum adjustment. 232.0 mm (9.13 in) Standard d. Tighten the locknut. 228.0 mm (8.98 in) Maximum Rear shock absorber locknut 220.0 mm (8.66 in) 42 Nm (4.2 m·kg, 31 ft·lb) Always tighten the locknut against the adjust-...
Page 94: Checking The Tires
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.
Page 95 CHASSIS • If dust or the like is stuck to this gauge, it will Front tire not provide the correct readings. Therefore, Size take two measurements of the tire’s pressure AT20 × 7-10 and use the second reading. Manufacturer/model DUNLOP/KT201 Rear tire Size AT19 ×...
Page 96: Checking The Wheels
Damage → Replace. 2. Check: • Cable operation Rough movement → Lubricate or replace. Recommended lubricant Yamaha chain and cable lube or engine oil Hold the cable end up and apply several drops EAS29350 of lubricant to the cable. CHECKING THE WHEELS The following procedure applies to all of the 3.
Page 97: Electrical System
ELECTRICAL SYSTEM EAS21750 EWA13320 ELECTRICAL SYSTEM WARNING Since the headlight bulb gets extremely EAS21760 hot, keep flammable products and your CHECKING AND CHARGING THE BATTERY hands away from the bulb until it has Refer to “ELECTRICAL COMPONENTS” on cooled down. page 7-27.
Page 98 ELECTRICAL SYSTEM ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjusting bolt “1” in direction “a” or “b”. Direction “a” Headlight beam is raised. Direction “b” Headlight beam is lowered. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3-33...
Page 99 CHASSIS GENERAL CHASSIS..................4-1 FRONT WHEEL ....................4-4 REMOVING THE FRONT WHEELS............4-5 CHECKING THE FRONT WHEELS ............4-5 CHECKING THE FRONT WHEEL HUBS..........4-5 CHECKING THE FRONT BRAKE DISCS ..........4-6 INSTALLING THE FRONT WHEEL HUB BEARINGS......4-6 INSTALLING THE FRONT BRAKE DISCS..........4-6 INSTALLING THE FRONT WHEEL HUBS ..........4-6 ADJUSTING THE FRONT WHEEL STATIC BALANCE ......4-7 INSTALLING THE FRONT WHEELS............4-8 REAR WHEEL ....................4-9...
Page 100 REPLACING THE REAR BRAKE PADS ..........4-32 REMOVING THE REAR BRAKE CALIPER..........4-33 DISASSEMBLING THE REAR BRAKE CALIPER........4-34 CHECKING THE REAR BRAKE CALIPER ..........4-34 ASSEMBLING THE REAR BRAKE CALIPER........4-34 INSTALLING THE REAR BRAKE CALIPER.........4-35 REMOVING THE REAR BRAKE MASTER CYLINDER .......4-36 CHECKING THE REAR BRAKE MASTER CYLINDER .......4-36 ASSEMBLING THE REAR BRAKE MASTER CYLINDER ....4-37 INSTALLING THE REAR BRAKE MASTER CYLINDER......4-37 HANDLEBAR....................4-39...
Page 101 CHAIN DRIVE .....................4-57 REMOVING THE DRIVE CHAIN ............4-58 CHECKING THE DRIVE CHAIN ............4-58 CHECKING THE DRIVE SPROCKET ..........4-59 CHECKING THE REAR WHEEL SPROCKET ........4-59 CHECKING THE SPROCKET BRACKET ..........4-59 INSTALLING THE DRIVE CHAIN ............4-59...
Page 102 GENERAL CHASSIS EAS21830 GENERAL CHASSIS Removing the seat, front fender and headlights Order Job/Parts to remove Q’ty Remarks Pull back the seat lock lever, than pull up on Seat the rear of the seat. Indicator light coupler Disconnect. Front panel Plate Main switch coupler Disconnect.
Page 103: General Chassis
GENERAL CHASSIS Removing the foot protectors and engine skid plate Order Job/Parts to remove Q’ty Remarks Left foot protector Right foot protector Engine skid plate For installation, reverse the removal proce- dure.
Page 104 GENERAL CHASSIS Removing the rear fender and air filter case Order Job/Parts to remove Q’ty Remarks Seat/Front fender Refer to “GENERAL CHASSIS” on page 4-1. Rear fender Battery cover ECA4D3F001 Battery lead First disconnect the negative lead, then disconnect the positive lead. Battery Relay CDI unit...
Page 105 FRONT WHEEL EAS21870 FRONT WHEEL Removing the front wheels and brake discs Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front wheels. Cotter pin Axle nut Front wheel Brake disc guard (outer) Brake caliper assembly Wheel hub Brake disc For installation, reverse the removal proce-...
Page 106: Front Wheel
FRONT WHEEL EAS21890 REMOVING THE FRONT WHEELS The following procedure applies to both of the front wheels. 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. Place the vehicle on a suitable stand so that the front wheel is elevated.
Page 107: Checking The Front Brake Discs
FRONT WHEEL EAS29400 INSTALLING THE FRONT WHEEL HUB BEARINGS 1. Install: • Bearings “1” 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.
Page 108: Adjusting The Front Wheel Static Balance
FRONT WHEEL f. Repeat steps (d) through (f) several times until all the marks come to rest at the same EAS21970 ADJUSTING THE FRONT WHEEL STATIC spot. BALANCE g. The spot where all the marks come to rest is the front wheel’s heavy spot “X”. After replacing the tire, wheel or both, the front ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
Page 109: Installing The Front Wheels
FRONT WHEEL ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the front wheel and make sure it stays at each position shown. b. If the front wheel does not remain station- ary at all of the positions, rebalance it. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS29420 INSTALLING THE FRONT WHEELS The following procedure applies to both of the front wheels.
Page 110: Rear Wheel
REAR WHEEL EAS22020 REAR WHEEL Removing the rear wheels Order Job/Parts to remove Q’ty Remarks Rear wheel Cotter pin Axle nut Wheel hub For installation, reverse the removal proce- dure.
Page 111: Removing The Rear Wheels
REAR WHEEL EAS22040 REMOVING THE REAR WHEELS 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. Place the vehicle on a suitable stand so that the rear wheel is elevated.
Page 112: Rear Axle And Rear Axle Hub
REAR AXLE AND REAR AXLE HUB EAS29470 REAR AXLE AND REAR AXLE HUB Removing the rear axle and rear axle hub Order Job/Parts to remove Q’ty Remarks Rear wheels/Rear wheel hubs Refer to “REAR WHEEL” on page 4-9. Rear axle ring nut set bolt Rear axle ring nut Conical spring washer Do not apply the brake pedal and do not use...
Page 113 REAR AXLE AND REAR AXLE HUB Removing the rear axle and rear axle hub Order Job/Parts to remove Q’ty Remarks Dust cover For installation, reverse the removal proce- dure. 4-12...
Page 114: Removing The Rear Axle
REAR AXLE AND REAR AXLE HUB EAS29490 • Attach a suitable socket “2” on the axle REMOVING THE REAR AXLE end and tap it with a soft hammer, then 1. Place the vehicle on a level surface. pull out the rear axle to the right. 2.
Page 115: Checking The Rear Wheel Sprocket
REAR AXLE AND REAR AXLE HUB EAS29510 CHECKING THE REAR WHEEL SPROCKET Rear axle ring nut 1. Check: 140 Nm (14.0 m·kg, 103 ft·lbf) • Rear wheel sprocket LOCTITE® Refer to “CHECKING THE DRIVE Rear axle ring nut set bolt SPROCKET”...
Page 116: Front Brake
FRONT BRAKE EAS22210 FRONT BRAKE Removing the front brake pads Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers. Front wheel Refer to “FRONT WHEEL” on page 4-4. Bolt Brake pad retaining bolt Brake pad Brake pad spring For installation, reverse the removal proce-...
Page 117 FRONT BRAKE Removing the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-20. Brake fluid reservoir cap Brake fluid reservoir diaphragm plate Brake fluid reservoir diaphragm Front brake light switch Brake lever Union bolt...
Page 118 FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Brake master cylinder body For assembly, reverse the disassembly pro- cedure. 4-17...
Page 119 FRONT BRAKE Removing the front brake calipers Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers. Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-20. Front wheel Refer to “FRONT WHEEL” on page 4-4. Union bolt Copper washer Brake hose...
Page 120 FRONT BRAKE Disassembling the front brake calipers Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers. Bolt Brake pad retaining bolt Brake pad Brake pad spring Caliper bracket Caliper piston Dust seal Caliper piston seal Bleed screw For assembly, reverse the disassembly pro-...
Page 121: Introduction
FRONT BRAKE EAS22220 INTRODUCTION Brake disc thickness limit EWA14100 3.0 mm (0.12 in) WARNING Disc brake components rarely require dis- assembly. 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...
Page 122: Replacing The Front Brake Pads
FRONT BRAKE EAS22250 b. Loosen the bleed screw and push the REPLACING THE FRONT BRAKE PADS brake caliper pistons into the brake caliper The following procedure applies to both brake with your finger. calipers. c. Tighten the bleed screw. Bleed screw When replacing the brake pads, it is not neces- 5 Nm (0.5 m·kg, 3.7 ft·lb) sary to disconnect the brake hose or disas-...
Page 123: Disassembling The Front Brake Caliper
FRONT BRAKE Before removing the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: • Union bolt “1” • Copper washers “2” • Brake hose “3” • Brake caliper bolts “4” b. Remove the brake caliper piston seal and brake caliper dust seal.
Page 124: Assembling The Front Brake Caliper
FRONT BRAKE EWA4D3F006 WARNING Whenever a brake caliper is disassembled, replace the brake caliper piston seal and brake caliper dust seal. 2. Check: • Brake caliper bracket “1” Cracks/damage → Replace. EAS22420 INSTALLING THE FRONT BRAKE CALIPER 1. Install: • Brake caliper “1” (temporarily) •...
Page 125: Removing The Front Brake Master Cylinder
FRONT BRAKE Brake pad retaining bolt 17 Nm (1.7 m·kg, 13 ft·lb) Brake caliper bolt 28 Nm (2.8 m·kg, 21 ft·lb) Refer to “REPLACING THE FRONT BRAKE PADS” on page 4-21. 4. Fill: • Brake master cylinder reservoir (with the specified amount of the recom- mended brake fluid) 7.
Page 126: Assembling The Front Brake Master Cylinder
FRONT BRAKE EAS22530 INSTALLING THE FRONT BRAKE MASTER CYLINDER 1. Install: • Brake master cylinder “1” Brake master cylinder bracket bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) • Install the brake master cylinder holder with 2. Check: the “UP” mark facing up. •...
Page 127 FRONT BRAKE 3. Fill: 6. Check: • Brake master cylinder reservoir • Brake lever operation (with the specified amount of the recom- Soft or spongy feeling → Bleed the brake mended brake fluid) system. Refer to “BLEEDING THE HYDRAULIC Recommended fluid BRAKE SYSTEM”...
Page 128: Rear Brake
REAR BRAKE EAS22550 REAR BRAKE Removing the rear brake pads Order Job/Parts to remove Q’ty Remarks Brake pad retaining bolt Lock washer Brake pad Brake pad spring For installation, reverse the removal proce- dure. 4-27...
Page 129 REAR BRAKE Removing the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Right foot protector Refer to “GENERAL CHASSIS” on page 4-1. Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-20. Brake fluid reservoir cover Brake fluid reservoir cap Brake fluid reservoir diaphragm holder Brake fluid reservoir diaphragm...
Page 130 REAR BRAKE Disassembling the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Hose joint Brake master cylinder kit Brake master cylinder For assembly, reverse the disassembly pro- cedure. 4-29...
Page 131 REAR BRAKE Removing the rear brake caliper Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-20. Parking brake cable Disconnect. Union bolt Copper washer Brake hose Brake caliper assembly For installation, reverse the removal proce- dure.
Page 132 REAR BRAKE Disassembling the rear brake calipers Order Job/Parts to remove Q’ty Remarks Adjusting bolt Locknut Parking brake arm Brake pad retaining bolt Lock washer Brake pad Brake pad spring Retaining bolt Caliper bracket Brake caliper piston Dust seal Caliper piston seal Bleed screw For assembly, reverse the disassembly pro- cedure.
Page 133: Introduction
REAR BRAKE EAS22560 INTRODUCTION Brake disc thickness limit EWA14100 3.5 mm (0.14 in) WARNING 5. Adjust: Disc brake components rarely require dis- • Brake disc deflection assembly. Therefore, always follow these Refer to “CHECKING THE FRONT preventive measures: BRAKE DISCS” on page 4-20. •...
Page 134: Removing The Rear Brake Caliper
REAR BRAKE 6. Check: • Brake fluid level Below the minimum level mark “a” → Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 3-17. b. Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger.
Page 135: Disassembling The Rear Brake Caliper
REAR BRAKE EAS22600 1. Check: DISASSEMBLING THE REAR BRAKE CALI- • Brake caliper piston “1” Rust/scratches/wear → Replace the 1. Remove: brake caliper piston. • Brake caliper piston • Brake caliper cylinder “2” • Brake caliper dust seal “1” Scratches/wear → Replace the brake cal- •...
Page 136: Installing The Rear Brake Caliper
REAR BRAKE 1. Install: Brake hose union bolt • O-ring “1” 31 Nm (3.1 m·kg, 23 ft·lb) • Caliper piston seal “2” EWA13530 • Caliper dust seal “3” WARNING Proper brake hose routing is essential to insure safe vehicle operation. Refer to “CABLE ROUTING”...
Page 137: Removing The Rear Brake Master Cylinder
REAR BRAKE EWA13090 EAS22700 REMOVING THE REAR BRAKE MASTER WARNING CYLINDER • Use only the designated brake fluid. Other brake fluids may cause the rubber Before removing the rear brake master cylin- seals to deteriorate, causing leakage and der, drain the brake fluid from the entire brake poor brake performance.
Page 138: Assembling The Rear Brake Master Cylinder
REAR BRAKE Clearance 2.2–3.2 mm (0.09–0.13 in) 3. Check: • Brake fluid reservoir “1” Cracks/damage → Replace. • Brake fluid reservoir diaphragm “2” Cracks/damage → Replace. EAS22740 INSTALLING THE REAR BRAKE MASTER CYLINDER 1. Install: • Copper washers • Brake hose “1” •...
Page 139 REAR BRAKE 3. Fill: • Brake fluid reservoir 6. Adjust: (with the specified amount of the recom- • Brake pedal position mended brake fluid) Refer to “ADJUSTING THE BRAKE PEDAL” on page 3-16. Recommended fluid DOT 4 Brake pedal height 40.0 mm (1.57 in) EWA13090 WARNING...
Page 140: Handlebar
HANDLEBAR EAS22840 HANDLEBAR Removing the handlebar Order Job/Parts to remove Q’ty Remarks Handlebar protector Band Front brake light switch Brake master cylinder/bracket Throttle lever assembly/bracket Spacer Clutch switch Parking brake lever Clutch lever/bracket Handlebar switch Handlebar grip Handlebar holder Handlebar For installation, reverse the removal proce- dure.
Page 141: Removing The Handlebars
HANDLEBAR EAS22860 EAS22911 REMOVING THE HANDLEBARS INSTALLING THE HANDLEBAR 1. Remove: 1. Install: • Clutch switch “1” • Handlebar • Upper handlebar holders Push the fastener when removing the clutch Upper handlebar holder bolt switch out of the clutch lever holder. 20 Nm (2.0 m·kg, 15 ft·lb) •...
Page 142 HANDLEBAR 4. Install: • Throttle lever assembly • Before applying the adhesive, wipe off • Spacer grease or oil on the handlebar surface “a” • Brake master cylinder with a lacquer thinner. • Install the handlebar grips so that the “L” Brake master cylinder bracket arrow on the left grip and “R”...
Page 143 HANDLEBAR Throttle cable free play 2.0–4.0 mm (0.08–0.16 in) 4-42...
Page 144: Steering Stem
STEERING STEM EAS29540 STEERING STEM Removing the steering stem Order Job/Parts to remove Q’ty Remarks Front fender Refer to “GENERAL CHASSIS” on page 4-1. Lock washer Bracket Steering stem bushing Spacer Oil seal Steering stem Bushing For installation, reverse the removal proce- dure.
Page 145: Checking The Steering Stem
STEERING STEM EAS29560 EAS29580 CHECKING THE STEERING STEM INSTALLING THE LOCK WASHER 1. Check: 1. Install: • Steering stem “1” • Lock washer “1” Bends → Replace. • Steering stem bushing bolts EWA15030 WARNING Steering stem bushing bolt Do not attempt to straighten a bent stem; 23 Nm (2.3 m·kg, 17 ft·lb) this may dangerously weaken the stem.
Page 146 TIE-RODS AND STEERING KNUCKLES EAS29660 TIE-RODS AND STEERING KNUCKLES Removing the tie-rods and steering knuckles Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the tie-rods and steering knuckles. Front wheel Refer to “FRONT WHEEL” on page 4-4. Front brake caliper/Brake disc Refer to “FRONT BRAKE”...
Page 147: Tie-Rods And Steering Knuckles
TIE-RODS AND STEERING KNUCKLES EAS29670 REMOVING THE STEERING KNUCKLES The following procedure applies to both of the steering knuckles. 1. Remove: • Steering knuckle “1” Use a general puller to separate the ball joints “2” from the steering knuckle “1”. EAS29700 INSTALLING THE TIE-RODS The following procedure applies to both of the...
Page 148: Front Arms And Front Shock Absorber Assemblies
FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES EAS29710 FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES Removing the front arms and front shock absorber assemblies Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front upper arms, front lower arms, and front shock absorber assemblies.
Page 149: Removing The Front Arms
FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES EAS29720 REMOVING THE FRONT ARMS The following procedure applies to both of the front upper arms and front lower arms. 1. Check: • Front arm free play ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Check the front arm side play “A” by mov- ing it from side to side.
Page 150: Checking The Front Shock Absorber Assemblies
FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES 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 →...
Page 151 FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES Apply lithium-soap-based grease to the grease nipples “3”. Front upper arm nut 45 Nm (4.5 m·kg, 33 ft·lb) Front lower arm nut 45 Nm (4.5 m·kg, 33 ft·lb) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4-50...
Page 152: Rear Shock Absorber Assembly
REAR SHOCK ABSORBER ASSEMBLY EAS23160 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly Order Job/Parts to remove Q’ty Remarks Seat/Rear fender/Air filter case Refer to “GENERAL CHASSIS” on page 4-1. Loosen. Clamp For 4D3H, 4D3M Rear shock absorber assembly For installation, reverse the removal proce- dure.
Page 153: Handling The Rear Shock Absorber
REAR SHOCK ABSORBER ASSEMBLY EAS23170 HANDLING THE REAR SHOCK ABSORBER EWA13750 WARNING This rear shock absorber and gas cylinder contains highly compressed nitrogen gas. Before handling the rear shock absorber and gas cylinder, read and make sure you understand the following information. The manufacturer cannot be held responsible for property damage or personal injury that B.
Page 154: Installing The Rear Shock Absorber Assembly
REAR SHOCK ABSORBER ASSEMBLY A. for 4D3D B. for 4D3H, 4D3M EAS23300 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1. Install: • Rear shock absorber assembly When installing the rear shock absorber assembly lower bolt, lift up the swingarm. Rear shock absorber assembly 55 Nm (5.5 m·kg, 41 ft·lb) 4-53...
Page 155: Swingarm
SWINGARM EAS23330 SWINGARM Removing the swingarm Order Job/Parts to remove Q’ty Remarks Refer to “REAR AXLE AND REAR AXLE Rear axle hub HUB” on page 4-11. Refer to “REAR SHOCK ABSORBER Rear shock absorber assembly ASSEMBLY” on page 4-51. Plate Swingarm end cover Pivot shaft nut/washer Pivot shaft...
Page 156: Removing The Swingarm
SWINGARM EAS23340 EAS23360 REMOVING THE SWINGARM CHECKING THE SWINGARM 1. Stand the vehicle on a level surface. 1. Check: EWA13120 • Swingarm Bends/cracks/damage → Replace. WARNING Securely support the vehicle so that there is no danger of it falling over. Place the vehicle on a suitable stand so that the rear wheel is elevated.
Page 157: Installing The Swingarm
SWINGARM EAS23380 INSTALLING THE SWINGARM 1. Lubricate: • Bearings • Spacer • Oil seals Recommended lubricant Lithium-soap-based grease 2. Install: • Bearings “1” • Spacer “2” • Oil seals • Dust covers Inject the bearing with the character stamp turned outward. Installed depth of bearing “a”...
Page 158 CHAIN DRIVE EAS23400 CHAIN DRIVE Removing the drive sprocket and drive chain Order Job/Parts to remove Q’ty Remarks Drive sprocket cover Drive chain guide 2 Drive chain guide 3 Drive sprocket nut Lock washer Drive sprocket Drive chain For installation, reverse the removal proce- dure.
Page 159 CHAIN DRIVE EAS23430 b. Calculate the length “c” of the 15-link sec- REMOVING THE DRIVE CHAIN tion of the drive chain using the following 1. Remove: formula. • Master link clip Drive chain 15-link section length “c” = (with interlocking slip-joint pliers) (length “a”...
Page 160 CHAIN DRIVE EAS23460 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. b. Correct 1.
Page 161 CHAIN DRIVE 6. Adjust: • Drive chain slack Refer to “ADJUSTING THE DRIVE CHAIN SLACK” on page 3-21. Drive chain slack 45–55 mm (1.77–2.17 in) ECA13550 A drive chain that is too tight will overload the engine and other vital parts, and one 3.
Page 162 CHAIN DRIVE 4-61...
Page 163: Engine
ENGINE ENGINE REMOVAL ..................5-1 INSTALLING THE ENGINE ..............5-4 INSTALLING THE MUFFLER AND EXHAUST PIPE......5-4 CAMSHAFT ....................5-6 REMOVING THE ROCKER ARMS AND CAMSHAFT ......5-7 CHECKING THE CAMSHAFT ..............5-7 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS ..5-8 INSTALLING THE CAMSHAFT AND ROCKER ARMS ......5-9 CYLINDER HEAD..................5-10 REMOVING THE CYLINDER HEAD ............5-12 CHECKING THE CYLINDER HEAD ............5-12...
Page 164 ASSENBLING THE BALANCER WEIGHT GEAR........5-41 INSTALLING THE OIL PUMP ...............5-41 INSTALLING THE BALANCER WEIGHT GEAR ........5-41 SHIFT SHAFT .....................5-42 CHECKING THE SHIFT SHAFT ............5-43 CHECKING THE STOPPER LEVER............5-43 INSTALLING THE SHIFT SHAFT ............5-43 PICKUP COIL ROTOR AND STARTER CLUTCH ........5-45 REMOVING THE PICKUPCOIL ROTOR..........5-46 CHECKING THE STARTER CLUTCH..........5-46 INSTALLING THE PICKUP COIL ROTOR..........5-47...
Page 166 ENGINE REMOVAL EAS23711 ENGINE REMOVAL Removing the muffler and exhaust pipe Order Job/Parts to remove Q’ty Remarks Seat/front panel/front fender/rear fender Refer to “GENERAL CHASSIS” on page 4-1. Clamp Loosen. Muffler Gasket Exhaust pipe EXhaust pipe protector Gasket For installation, reverse the removal proce- dure.
Page 167 ENGINE REMOVAL Disconnecting the leads, cables and hoses Order Job/Parts to remove Q’ty Remarks Engine oil Drain. Oil cooler hose 1, 2 Refer to “CLUTCH” on page 5-29. Carburetor Refer to “CARBURETOR” on page 6-3. Drive sprocket/drive chain Refer to “CHAIN DRIVE” on page 4-57. Ignition coil spark plug lead Air filter case breather hose Starter motor lead...
Page 168 ENGINE REMOVAL Removing the engine Order Job/Parts to remove Q’ty Remarks Crankcase bolt 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 assembly For installation, reverse the removal proce- dure.
Page 169: Engine Removal
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” •...
Page 170 ENGINE REMOVAL 4. Install: • Gasket • Exhaust pipe “1” 5. Tighten: • Nuts (exhaust pipe) “2” Exhaust pipe nut 18 Nm (1.8 m·kg, 13 ft·lb) 6. Install: • Clamp Slide the clamp onto the end of the muffler and insert the projection “a”...
Page 171: Camshaft
CAMSHAFT EAS23730 CAMSHAFT Removing the rocker arms and camshaft Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-10. Lock plate Locknut/valve clearance adjusting screw Camshaft Intake rocker arm shaft Intake rocker arm Exhaust rocker arm shaft Exhaust rocker arm For installation, reverse the removal proce- dure.
Page 172: Removing The Rocker Arms And Camshaft
CAMSHAFT EAS23770 REMOVING THE ROCKER ARMS AND CAMSHAFT 1. Loosen: • Locknut “1” • Valve clearance adjusting screw “2” 2. Remove: • Lock plate “3” EAS23840 CHECKING THE CAMSHAFT 1. Check: • Bearing Damage/wear → Replace. 2. Check: • Camshaft lobes Blue discoloration/pitting/scratches →...
Page 173: Checking The Rocker Arms And Rocker Arm Shafts
CAMSHAFT 2. Check: • Rocker arm shaft Blue discoloration/excessive wear/pitting/ scratches → Replace or check the lubri- cation system. 3. Measure: • Rocker arm inside diameter “a” Out of specification → Replace. Rocker arm inside diameter 12.000–12.018 mm (0.4724– 0.4731 in) Limit 12.036 mm (0.4739 in) 4.
Page 174: Installing The Camshaft And Rocker Arms
CAMSHAFT Out of specification → Replace the defec- • Install the intake rocker arm shaft so that tive part(s). groove “a” is horizontal and aligning the notch of the pointed end “b” with the hole in Rocker-arm-to-rocker-arm-shaft the cylinder head. clearance 0.009–0.037 mm (0.0004–...
Page 175: Cylinder Head
CYLINDER HEAD EAS24100 CYLINDER HEAD Removing the cylinder head Order Job/Parts to remove Q’ty Remarks Seat/front panel/front fender Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank/fuel tank shield Refer to “FUEL TANK” on page 6-1. Muffler and exhaust pipe/Ignition coil spark plug Refer to “ENGINE REMOVAL”...
Page 176 CYLINDER HEAD Removing the cylinder head Order Job/Parts to remove Q’ty Remarks For installation, reverse the removal proce- dure. 5-11...
Page 177: Removing The Cylinder Head
CYLINDER HEAD EAS24130 Breather plate 2 REMOVING THE CYLINDER HEAD • Camshaft sprocket 1. Align: • Timing chain • “I” mark “a” on the pickup coil rotor (with the stationary pointer “b” on the To prevent the timing chain from falling into the crankcase cover) crankcase, fasten it with a wire.
Page 178: Checking The Timing Chain Guides
CYLINDER HEAD 2. Check: b. Correct • Cylinder head Damage/scratches → Replace. 1. Timing chain 3. Measure: 2. Camshaft sprocket • Cylinder head warpage 2. Check: Out of specification → Resurface the cyl- • Timing chain guide (exhaust side) inder head. Damage/wear →...
Page 179: Installing The Cylinder Head
CYLINDER HEAD 3. Check: • Cap bolt • Spring • One-way cam • Timing chain tensioner rod Damage/wear → Replace the timing chain tensioner. EAS24230 INSTALLING THE CYLINDER HEAD 1. Install: • Cylinder head gasket c. Remove the wire from the timing chain. •...
Page 180 CYLINDER HEAD b. With the timing chain tensioner rod turned all the way into the timing chain tensioner housing (with the thin screwdriver still installed), install the new gasket and the timing chain tensioner “2” onto the body cylinder. c. Tighten the timing chain tensioner bolts “3” to the specified torque.
Page 181 VALVES AND VALVE SPRINGS EAS24270 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-10. Rocker arm/camshaft Refer to “CAMSHAFT” on page 5-6. Valve cotter Valve spring retainer Outer valve spring Inner valve spring...
Page 182: Valves And Valve Springs
VALVES AND VALVE SPRINGS EAS24280 REMOVING THE VALVES The following procedure applies to all of the valves and related components. Before removing the internal parts of the cylin- der head (e.g., valves, valve springs, valve seats), make sure the valves properly seal. 1.
Page 183 VALVES AND VALVE SPRINGS Valve-stem-to-valve-guide clear- ance Valve-stem-to-valve-guide clear- ance (intake) 0.010–0.037 mm (0.0004– 0.0015 in) Limit 0.080 mm (0.003 in) Valve-stem-to-valve-guide clear- ance (exhaust) b. Install the new valve guide with the valve 0.025–0.052 mm (0.0010– guide installer “2” and valve guide remover 0.0020 in) “1”.
Page 184: Checking The Valve Seats
VALVES AND VALVE SPRINGS Valve guide remover (ø6) • When installing a new valve, always replace 90890-04064 the valve guide. Valve guide remover (6.0 mm) • If the valve is removed or replaced, always YM-04064-A replace the oil seal. Valve guide installer (ø6) 90890-04065 Valve guide installer (6.0 mm) Valve stem runout...
Page 185 VALVES AND VALVE SPRINGS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ ECA13790 a. 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. b. Install the valve into the cylinder head. c.
Page 186: Checking The Valve Springs
VALVES AND VALVE SPRINGS a. Compressed valve spring force ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ b. Installed length EAS24310 CHECKING THE VALVE SPRINGS Inner spring The following procedure applies to all of the Installed compression spring valve springs. force (intake) 1. Measure: 75.00–91.70 N (7.65–9.35 kgf, •...
Page 187: Installing The Valves
VALVES AND VALVE SPRINGS • Outer valve spring “5” Inner spring • Upper spring seat “6” Spring tilt (intake) (into the cylinder head) 2.5 °/1.60 mm (2.5 °/0.063 in) Spring tilt (exhaust) Install the valve springs with the larger pitch “a” 2.5 °/1.60 mm (2.5 °/0.063 in) facing up.
Page 188 VALVES AND VALVE SPRINGS 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft- face hammer. ECA13800 Hitting the valve tip with excessive force could damage the valve. 5-23...
Page 189 CYLINDER AND PISTON EAS24350 CYLINDER AND PISTON Removing the cylinder and piston Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-10. Oil delivery pipe Cylinder Dowel pin Cylinder gasket Piston pin clip Piston pin Piston Piston ring set For installation, reverse the removal proce-...
Page 190: Cylinder And Piston
CYLINDER AND PISTON EAS24380 REMOVING THE PISTON When removing a piston ring, open the end 1. Remove: gap with your fingers and lift the other side of • Piston pin clips “1” the ring over the piston crown. • Piston pin “2” •...
Page 191: Checking The Piston Rings
CYLINDER AND PISTON b. If out of specification, rebore or replace the Piston ring cylinder, and replace the piston and piston Top ring rings as a set. Ring side clearance c. Measure piston skirt diameter D “a” with 0.030–0.065 mm (0.0012– the micrometer.
Page 192: Checking The Piston Pin
CYLINDER AND PISTON Piston ring Top ring End gap (installed) 0.19–0.31 mm (0.007–0.012 in) Limit 0.56 mm (0.022 in) 2nd ring End gap (installed) 0.30–0.45 mm (0.012–0.018 in) Limit 3. Measure: 0.80 mm (0.032 in) • Piston pin bore diameter “b” Oil ring Out of specification →...
Page 193 CYLINDER AND PISTON • Upper oil ring rail “3” 4. Lubricate: • 2nd ring “4” • Piston • Top ring “5” • Piston rings • Cylinder (with the recommended lubricant) Be sure to install the piston rings so that the “T”...
Page 194: Clutch
CLUTCH EAS25061 CLUTCH Removing the clutch cover Order Job/Parts to remove Q’ty Remarks Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-10. Cotter pin/Washer Clevis pin Brake pedal/Footrest Oil delivery pipe Oil cooler hose O-ring Right crankcase cover Dowel pin Crankcase cover gasket For installation, reverse the removal proce-...
Page 195 CLUTCH Removing the clutch Order Job/Parts to remove Q’ty Remarks Clutch spring Pressure plate Primary drive gear nut Friction plate Clutch plate Clutch boss nut Clutch boss Thrust washer Clutch housing Claw washer Primary drive gear Locknut/Washer Push rod 1 Push plate Push rod 2/Ball For installation, reverse the removal proce-...
Page 196 CLUTCH Removing the push lever shaft Order Job/Parts to remove Q’ty Remarks Shift pedal Refer to “SHIFT SHAFT” on page 5-42. Refer to “PICKUP COIL ROTOR AND Left crankcase cover STARTER CLUTCH” on page 5-45. Clutch assembly Clutch cable Bolt Push lever shaft Torsion spring Circlip...
Page 197: Removing The Clutch
CLUTCH EAS25070 REMOVING THE CLUTCH 1. Remove: • Bolt “1” • Clutch spring “2” Loosen the bolts in stages and in a crisscross pattern. 4. Remove: • Clutch boss nut “1” • Lock washer “2” • Clutch boss “3” • Thrust washer “4” •...
Page 198: Checking The Clutch Plates
CLUTCH EAS25140 CHECKING THE CLUTCH SPRINGS Measure the friction plate at four places. The following procedure applies to all of the clutch springs. Friction plate thickness 1. Check: 2.90–3.10 mm (0.114–0.122 in) • Clutch spring Damage → Replace the clutch springs as Wear limit 2.80 mm (0.110 in) a set.
Page 199: Checking The Pressure Plate
CLUTCH EAS25260 INSTALLING THE CLUTCH Pitting on the clutch boss splines will cause 1. Install: erratic clutch operation. • Primary drive gear • Claw washer • Lock washer • Primary drive gear nut 2. Install: • Clutch housing • Thrust washer •...
Page 200 CLUTCH After installing the clutch cable, bend the push lever shaft tab along a flat side of the nut. 8. Install: • Push rod 2 • Ball • Push rod 1 • Push plate • Washer • Locknut • Pressure plate •...
Page 201 CLUTCH 13. Install: • Clamp • Dowel pin • Crankcase cover gasket 11. Adjust: • Push lever position ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Loosen the locknut “1”. b. Turn the adjusting screw “2” in or out until the marks are aligned. c. Hold the adjusting screw to prevent it from moving and then tighten the locknut to specification.
Page 202 CLUTCH 14. Install: • Right crankcase cover 15. Install: • Crankcase cover bolts M6 × 50 mm “1”, “2” • Copper washers to “1”, “2” • Crankcase cover bolts M6 × 40 mm “3”– “6” • Crankcase cover bolts M6 × 25 mm “7”– “13”...
Page 203: Oil Pump
OIL PUMP EAS24911 OIL PUMP Removing the oil pump Order Job/Parts to remove Q’ty Remarks Right crankcase cover /clutch /primary drive Refer to “CLUTCH” on page 5-29. gear Balancer weight gear nut Lock washer Buffer boss Balancer weight gear Absorber plate Compression spring Dowel pin Straight key...
Page 204 OIL PUMP Disassemble the oil pump Order Job/Parts to remove Q’ty Remarks Oil pump housing Dowel pin Outer rotor Inner rotor Dowel pin Shaft Oil pump cover For installation, reverse the removal proce- dure. 5-39...
Page 205: Removing The Oil Pump
OIL PUMP EAS24940 REMOVING THE OIL PUMP Inner-rotor-to-outer-rotor-tip 1. Straighten the lock washer tab. clearance 2. Remove: 0.15 mm (0.0059 in) • Balancer weight gear nut Limit • Lock washer 0.23 mm (0.0091 in) • Balancer weight gear Outer-rotor-to-oil-pump-hous- ing clearance 0.100–0.151 mm (0.0039–...
Page 206: Assenbling The Balancer Weight Gear
OIL PUMP • Compression spring • Dowel pin • Align the punch mark “a” in the balancer Cracks/damage/wear → Replace. drive gear with the punch mark “b” in the bal- ancer weight gear EAS4D3F018 • Place the aluminium plate “c” between bal- ASSENBLING THE BALANCER WEIGHT ancer drive gear “1”...
Page 207 SHIFT SHAFT EAS25410 SHIFT SHAFT Removing the shift shaft and stopper lever Order Job/Parts to remove Q’ty Remarks Right crankcase cover/clutch Refer to “CLUTCH” on page 5-29. Shift pedal Shift shaft assembly Stopper lever Torsion spring For installation, reverse the removal proce- dure.
Page 208: Checking The Shift Shaft
SHIFT SHAFT EAS25420 CHECKING THE SHIFT SHAFT 1. Check: • Shift shaft “1” • Shift lever “2” Bends/damage/wear → Replace. • Shift lever spring Damage/wear → Replace. 2. Tighten: • Stopper lever bolt Stopper lever bolt 10 Nm (1.0 m·kg, 7.4 ft·lb) LOCTITE®...
Page 209 SHIFT SHAFT 6. Tighten: • Shift pedal bolt Shift pedal bolt 10 Nm (1.0 m·kg, 7.4 ft·lb) 7. Adjust: • Shift pedal height Refer to “ADJUSTING THE SHIFT PEDAL” on page 3-21. 5-44...
Page 210 PICKUP COIL ROTOR AND STARTER CLUTCH EAS403F008 PICKUP COIL ROTOR AND STARTER CLUTCH Removing the pickup coil rotor and starter clutch Order Job/Parts to remove Q’ty Remarks Drain. Engine oil Refer to “ENGINE” on page 3-4. Shift pedal Refer to “SHIFT SHAFT” on page 5-42. Drive sprocket cover Refer to “CHAIN DRIVE”...
Page 211: Pickup Coil Rotor And Starter Clutch
PICKUP COIL ROTOR AND STARTER CLUTCH EAS403F009 REMOVING THE PICKUPCOIL ROTOR 1. Remove: • Pickup coil rotor bolt “1” • Washer • Loosen the pickup coil rotor bolt “1” while holding the rotor with a sheave holder “2”. • Do not allow the sheave holder to touch the projection on the rotor “a”.
Page 212: Installing The Pickup Coil Rotor
PICKUP COIL ROTOR AND STARTER CLUTCH 3. Check: • Starter clutch gear’s contacting surfaces 2. Install: Damage/pitting/wear → Replace the • Woodruff key “1” starter clutch gear. • Pickup coil rotor “2” 4. Check: • Washer “3” • Starter clutch operation •...
Page 213 PICKUP COIL ROTOR AND STARTER CLUTCH Crank case cover bolt M6 × 30 mm: “1”–“5” 10 Nm (1.0 m·kg, 7.4 ft·lb) M6 × 45 mm: “6” 10 Nm (1.0 m·kg, 7.4 ft·lb) M6 × 40 mm: “7”–“9” 10 Nm (1.0 m·kg, 7.4 ft·lb) 4.
Page 214: Electric Starter
ELECTRIC STARTER EAS24780 ELECTRIC STARTER Removing the starter motor Order Job/Parts to remove Q’ty Remarks Exhaust pipe Refer to “ENGINE REMOVAL” on page 5-1. Refer to “PICKUP COIL ROTOR AND Starter idle gear cover/Starter idle gear STARTER CLUTCH” on page 5-45. Clutch cable holder Starter motor lead Disconnect.
Page 215 ELECTRIC STARTER Disassembling the starter motor Order Job/Parts to remove Q’ty Remarks Front bracket Tang washer Plate washer Circlip Rear bracket/Brush holder Armature assembly Starter motor yoke Brush/spring For assembly, reverse the disassembly pro- cedure. 5-50...
Page 216: Checking The Starter Motor
ELECTRIC STARTER EAS24790 CHECKING THE STARTER MOTOR Pocket tester 1. Check: 90890-03112 • Commutator Analog pocket tester Dirt → Clean with 600 grit sandpaper. YU-03112-C 2. Measure: • Commutator diameter “a” Armature coil Out of specification → Replace the Commutator resistance “1” starter motor.
Page 217: Assembling The Starter Motor
ELECTRIC STARTER 7. Check: • Gear teeth Damage/wear → Replace the gear. 8. Check: 4. Install: • Bushing • Starter motor yoke “1” • Bearing • Oil seal Damage/wear → Replace the defective Align the match marks “a” on the starter yoke “1”...
Page 218: Crankcase
CRANKCASE EAS25540 CRANKCASE Separating the crankcase Order Job/Parts to remove Q’ty Remarks Engine Refer to “ENGINE REMOVAL” on page 5-1. Cylinder head Refer to “CYLINDER HEAD” on page 5-10. Refer to “CYLINDER AND PISTON” on page Cylinder/piston 5-24. Clutch Refer to “CLUTCH” on page 5-29. Oil pump/balancer weight gear Refer to “OIL PUMP”...
Page 219 CRANKCASE Removing the bearing Order Job/Parts to remove Q’ty Remarks Refer to “CRANKSHAFT ASSEMBLY” on Crankshaft assembly page 5-57. Main axle assembly/drive axle assembly Refer to “TRANSMISSION” on page 5-61. Oil seal Bearing For assembly, reverse the removal proce- dure. 5-54...
Page 220: Disassembling The Crankcase
• Oil delivery passages Obstruction → Blow out with compressed air. EAS25690 ASSEMBLING THE CRANKCASE 1. Apply: • Yamaha bond No.1215 (Three Bond No.1215®) “1” (onto the crankcase mating surfaces) 3. Turn: • Shift drum segment Yamaha bond No.1215 (Three Bond No.1215®) Turn the shift drum segment “1”...
Page 221 CRANKCASE Timing chain guide (intake side) bolt 8 Nm (0.8 m·kg, 5.9 ft·lb) LOCTITE® 3. Install: • Right crankcase (onto the left crankcase) Tap lightly on the right crankcase with a soft- 9. Apply: face hammer. • Engine oil 4. Install: (onto the crankshaft pins bearings and oil •...
Page 222: Crankshaft Assembly
CRANKSHAFT ASSEMBLY EAS25970 CRANKSHAFT ASSEMBLY Removing the crankshaft assembly Order Job/Parts to remove Q’ty Remarks Crankcase Refer to “CRANKCASE” on page 5-53. Balancer weight Crankshaft assembly Dowel pin Plunger seal Bearing For installation, reverse the removal proce- dure. 5-57...
Page 223: Removing The Crankshaft Assembly
CRANKSHAFT ASSEMBLY EAS25990 EAS26060 REMOVING THE CRANKSHAFT ASSEMBLY CHECKING THE CRANKSHAFT AND CON- 1. Remove: NECTING ROD • Balancer weight 1. Measure: • Crankshaft assembly “1” • Crankshaft runout Out of specification → Replace the crank- shaft, bearing or both. •...
Page 224: Checking The Timing Chain
CRANKSHAFT ASSEMBLY 4. Check: • Crankshaft sprocket Damage/wear → Replace the crankshaft. • Bearing Cracks/damage/wear → Replace the crankshaft. 5. Check: • Crankshaft journal Scratches/wear → Replace the crank- a. 1/4 tooth b. Correct shaft. 1. Timing chain roller • Crankshaft journal oil passage Obstruction →...
Page 225 CRANKSHAFT ASSEMBLY Install the crankshaft assembly with the crank- shaft installer pot “2”, crankshaft installer bolt “3”, adapter “4” and spacer “5”. Crankshaft installer pot 90890-01274 Installing pot YU-90058 Crankshaft installer bolt 90890-01275 Bolt YU-90060 Adapter (M10) 90890-01383 Adapter #2 YU-90062 Spacer 90890-01288...
Page 226: Transmission
TRANSMISSION EAS26241 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-53. Shift fork guide bar Shift drum assembly Shift fork-3 (R) Shift fork-2 (C) Shift fork-1 (L) Main axle assembly Drive axle assembly For installation, reverse the removal proce-...
Page 227 TRANSMISSION Disassembling the transmission Order Job/Parts to remove Q’ty Remarks 2nd pinion gear 5th pinion gear 3rd pinion gear Circlip/washer 4th pinion gear Main axle Plain washer 1st wheel gear 4th wheel gear Circlip/washer 3rd wheel gear/collar Claw washer 1 Claw washer 2 5th wheel gear Circlip/washer...
Page 228: Removing The Transmission
TRANSMISSION EAS26250 REMOVING THE TRANSMISSION 1. Remove: • Shift fork guide bar “1” • Shift drum assembly “2” • Shift fork 3 (R) “3” • Shift fork 2 (C) • Shift fork 1 (L) “4” 2. Remove: • Transmission “5” 3.
Page 229: Checking The Transmission
TRANSMISSION EAS26280 CHECKING THE TRANSMISSION 1. Measure: • Main axle runout (with a centering device and dial gauge) Out of specification → Replace the main axle. Main axle runout limit 0.06 mm (0.0024 in) 4. Check: • Transmission gear engagement (each pinion gear to its respective wheel gear) Incorrect →...
Page 230: Installing The Shift Forks And Shift Drum Assembly
TRANSMISSION EAS26320 INSTALLING THE SHIFT FORKS AND SHIFT Check the transmission and shift forks for DRUM ASSEMBLY smooth operation by turning the shift cam with 1. Install: your hand. • Transmission “1” • Shift fork 1 (L) “2” • Shift fork 2 (C) •...
Page 231: Fuel System
FUEL SYSTEM FUEL TANK ....................6-1 REMOVING THE FUEL TANK ..............6-2 CHECKING THE FUEL COCK ...............6-2 CHECKING THE FUEL COCK OPERATION .........6-2 CARBURETOR .....................6-3 CHECKING THE CARBURETOR............6-6 ASSEMBLING THE CARBURETOR ............6-7 INSTALLING THE CARBURETOR ............6-8...
Page 232: Fuel Tank
FUEL TANK EAS26620 FUEL TANK Removing the fuel tank Order Job/Parts to remove Q’ty Remarks Seat/front fender Refer to “GENERAL CHASSIS” on page 4-1. Fuel hose (fuel cock side) Fuel tank Clamp Fuel tank shield For installation, reverse the removal proce- dure.
Page 233: Removing The Fuel Tank
FUEL TANK EAS26630 REMOVING THE FUEL TANK 1. 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. Before removing the hose, turn the fuel cock to “OFF”...
Page 234: Carburetor
CARBURETOR EAS26720 CARBURETOR Removing the carburetor Order Job/Parts to remove Q’ty Remarks Seat/front fender/rear fender/air filter case Refer to “GENERAL CHASSIS” on page 4-1. Carburetor warmer coupler Disconnect. Air vent hose Disconnect. Fuel hose (carburetor side) Disconnect. Throttle cable cover Throttle cable Disconnect.
Page 235 CARBURETOR Disassembling the carburetor Order Job/Parts to remove Q’ty Remarks Drain hose Throttle stop screw Cover Diaphragm spring Piston valve Jet needle Cover Spring Coasting enricher diaphragm Coasting enricher jet (P. A. J. 2) Starter plunger Carburetor warmer positive lead Carburetor warmer Carburetor warmer negative lead Float chamber...
Page 236 CARBURETOR Disassembling the carburetor Order Job/Parts to remove Q’ty Remarks Starter jet For assembly, reverse the disassembly pro- cedure.
Page 237: Checking The Carburetor
CARBURETOR EAS26760 CHECKING THE CARBURETOR 1. Check: • Carburetor body • Float chamber Cracks/damage → Replace. • Float chamber body Contamination → Clean. 2. Check: • Fuel passages Obstruction → Clean. 5. Check: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Piston valve “1” a. Wash the carburetor in a petroleum-based Damage/scratches/wear →...
Page 238: Assembling The Carburetor
CARBURETOR 8. Check: • Jet needle “1” Bends/wear/damage → Replace. • Clip groove Free play/wear → Replace. 12. Check: • Hose joints Cracks/damage → Replace. 13. Check: 9. Check: • Air vent hose • Main jet “1” • Fuel hose •...
Page 239: Installing The Carburetor
CARBURETOR c. If the float height is not within the specifica- 3. Install: tion, check the valve seat and needle valve. • Carburetor d. If either is worn, replace the valve seat, needle valve and O-ring as a set. Align the projection “a” on the carburetor with e.
Page 240 CARBURETOR...
Page 241: Electrical System
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 TROUBLESHOOTING ................7-17 SIGNALING SYSTEM.................7-19 CIRCUIT DIAGRAM................7-19 TROUBLESHOOTING ................7-21 CARBURETOR HEATING SYSTEM ............7-23 CIRCUIT DIAGRAM................7-23 TROUBLESHOOTING ................7-25...
Page 242: Ignition System
IGNITION SYSTEM EAS27090 IGNITION SYSTEM EAS27100 CIRCUIT DIAGRAM...
Page 243 IGNITION SYSTEM 1. Pickup coil 2. Stator coil 4. Main switch 5. Battery positive lead 6. Battery 7. Fuse 10.CDI unit 11.Ignition coil 12.Spark plug 24.Engine stop switch 28.Ground...
Page 244: Troubleshooting
IGNITION SYSTEM EAS27130 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). • Before troubleshooting, remove the following part(s): 1. Seat 2. Front panel 3. Front fender 4. Rear fender 5. Side cover 1. Check the fuse. NG→...
Page 245 IGNITION SYSTEM 8. Check the stator coil. NG→ Refer to “CHECKING THE STATOR Replace the stator assembly. COIL” on page 7-40. OK↓ 9. Check the main switch. NG→ Refer to “CHECKING THE Replace the main switch. SWITCHES” on page 7-29. OK↓...
Page 246: Electric Starting System
ELECTRIC STARTING SYSTEM EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM...
Page 247 ELECTRIC STARTING SYSTEM 4. Main switch 5. Battery positive lead 6. Battery 7. Fuse 8. Starter relay 9. Starter motor 13.Starting circuit cut-off relay 14.Clutch switch 18.Neutral switch 24.Engine stop switch 25.Start switch 28.Ground...
Page 248: Starting Circuit Cut-Off System Operation
ELECTRIC STARTING SYSTEM EAS27180 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: •...
Page 249 ELECTRIC STARTING SYSTEM a. WHEN THE TRANSMISSION IS IN NEU- TRAL 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.
Page 250: Troubleshooting
ELECTRIC STARTING SYSTEM EAS27190 TROUBLESHOOTING The starter motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Seat 2. Front panel 3. Front fender 4. Rear fender 5. Side cover NG→ 1. Check the fuse. Refer to “CHECKING THE FUSES” Replace the fuse.
Page 251 ELECTRIC STARTING SYSTEM 8. Check the main switch. NG→ Refer to “CHECKING THE Replace the main switch. SWITCHES” on page 7-29. OK↓ 9. Check the engine stop switch. NG→ Refer to “CHECKING THE Replace the handlebar switch. SWITCHES” on page 7-29. OK↓...
Page 252: Charging System
CHARGING SYSTEM EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM 7-11...
Page 253 CHARGING SYSTEM 2. Stator coil 3. Rectifier/regulator 5. Battery positive lead 6. Battery 7. Fuse 28.Ground 7-12...
Page 254: Troubleshooting
CHARGING SYSTEM EAS27230 TROUBLESHOOTING The battery is not being charged. • Before troubleshooting, remove the following part(s): 1. Seat 2. Front panel 3. Front fender 4. Rear fender 5. Side cover NG→ 1. Check the fuse. Refer to “CHECKING THE FUSES” Replace the fuse.
Page 255 CHARGING SYSTEM 7-14...
Page 256: Lighting System
LIGHTING SYSTEM EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM 7-15...
Page 257 LIGHTING SYSTEM 2. Stator coil 3. Rectifier/regulator 4. Main switch 5. Battery positive lead 6. Battery 7. Fuse 21.Tail/brake light 23.Light switch 26.Headlight relay 27.Headlight 28.Ground 7-16...
Page 258: Troubleshooting
LIGHTING SYSTEM EAS27260 TROUBLESHOOTING Any of the following fail to light: headlight, tail/brake light. • Before troubleshooting, remove the following part(s): 1. Seat 2. Front panel 3. Front fender 4. Rear fender 5. Side cover NG→ 1. Check the each bulbs and bulb sockets condition.
Page 259 LIGHTING SYSTEM 7. Check the entire lighting system’s NG→ wiring. Properly connect or repair the lighting Refer to “CIRCUIT DIAGRAM” on system’s wiring. page 7-15. OK↓ This circuit is OK. 7-18...
Page 260: Signaling System
SIGNALING SYSTEM EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM 7-19...
Page 261 SIGNALING SYSTEM 4. Main switch 5. Battery positive lead 6. Battery 7. Fuse 17.Neutral indicator light 18.Neutral switch 19.Rear brake light switch 20.Front brake light switch 21.Tail/brake light 28.Ground 7-20...
Page 262: Troubleshooting
SIGNALING SYSTEM EAS27290 TROUBLESHOOTING Any of the following fail to light: brake light or an indicator light. • Before troubleshooting, remove the following part(s): 1. Seat 2. Front fender 1. Check the fuse. NG→ Refer to “CHECKING THE FUSES” Replace the fuse. on page 7-33.
Page 263 SIGNALING SYSTEM 3. Check the entire signaling system’s NG→ wiring. Properly connect or repair the signal- Refer to “CIRCUIT DIAGRAM” on ing system’s wiring. page 7-19. OK↓ This circuit is OK. The neutral indicator light fails to come. NG→ 1. Check the neutral indicator light bulb and socket.
Page 264: Carburetor Heating System
CARBURETOR HEATING SYSTEM EAS27490 CARBURETOR HEATING SYSTEM EAS27500 CIRCUIT DIAGRAM 7-23...
Page 265 CARBURETOR HEATING SYSTEM 4. Main switch 5. Battery positive lead 6. Battery 7. Fuse 15.Thermo switch 16.Carburetor warmer 28.Ground 7-24...
Page 266: Troubleshooting
CARBURETOR HEATING SYSTEM EAS27510 TROUBLESHOOTING The carburetor heating system fails to operate. • Before troubleshooting, remove the following part(s): 1. Seat 2. Front panel 3. Front fender 4. Rear fender 5. Side cover NG→ 1. Check the fuse. Refer to “CHECKING THE FUSES” Replace the fuse.
Page 267 CARBURETOR HEATING SYSTEM 7-26...
Page 268: Electrical Components
ELECTRICAL COMPONENTS EAS27972 ELECTRICAL COMPONENTS 7-27...
Page 269 ELECTRICAL COMPONENTS 1. Main switch 2. Front brake light switch 3. Clutch switch 4. Handlebar switch 5. CDI unit 6. Starter relay 7. Fuse 8. Battery 9. Tail/brake light 10.Headlight relay 11.Starting circuit cut-off relay 12.Thermo switch 13.Carburetor warmer 14.Starter motor 15.Pickup coil/stator assembly 16.Neutral switch 17.Rear brake light switch...
Page 270: Checking The Switches
ELECTRICAL COMPONENTS EAS27980 CHECKING THE SWITCHES 7-29...
Page 271 ELECTRICAL COMPONENTS 1. Light switch 2. Engine stop switch 3. Start switch 4. Main switch 5. Front brake light switch 6. Clutch switch 7. Fuse 8. Neutral switch 9. Rear brake light switch 7-30...
Page 272 ELECTRICAL COMPONENTS Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. ECA14370 Never insert the tester probes into the coupler terminal slots “a”. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.
Page 273: Checking The Bulbs And Bulb Sockets
ELECTRICAL COMPONENTS EAS27990 hands away from the bulb until it has CHECKING THE BULBS AND BULB SOCK- cooled down. ECA14380 Check each bulb and bulb socket for damage or wear, proper connections, and also for conti- • Be sure to hold the socket firmly when nuity between the terminals.
Page 274: Checking The Fuses
ELECTRICAL COMPONENTS Checking the condition of the bulb sockets ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ The following procedure applies to all of the a. Connect the pocket tester to the fuse and bulb sockets. check the continuity. 1. Check: • Bulb socket (for continuity) Set the pocket tester selector to “Ω × 1”. (with the pocket tester) No continuity →...
Page 275 ELECTRICAL COMPONENTS Therefore, always follow these preventive 1. Remove: measures: • Seat • Wear protective eye gear when handling • Battery cover or working near batteries. Refer to “GENERAL CHASSIS” on page • Charge batteries in a well-ventilated area. 4-1. •...
Page 276 ELECTRICAL COMPONENTS • When charging a battery, be sure to remove it from the vehicle. (If charging has to be done with the battery mounted 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 bat- tery charger leads are connected to the battery.
Page 277 ELECTRICAL COMPONENTS Voltage should be measured 30 minutes after Voltage should be measured 30 minutes after the machine is stopped. the machine is stopped. b. Connect a charged and AMP meter to the b. Connect a charger and AMP meter to the battery and start charging.
Page 278: Checking The Relays
ELECTRICAL COMPONENTS 9. Lubricate: Starting circuit cut-off relay • Battery terminals Recommended lubricant Dielectric grease 10. Install: • Battery cover • Seat Refer to “GENERAL CHASSIS” on page 4-1. 1. Positive battery terminal 2. Positive tester probe EAS28040 3. Negative battery terminal CHECKING THE RELAYS 4.
Page 279: Checking The Spark Plug Cap
ELECTRICAL COMPONENTS Continuity Positive tester probe → sky blue “1” Negative tester probe → black/ yellow “2” No continuity Positive tester probe → black/ yellow “2” Negative tester probe → sky c. Measure the spark plug cap resistance. blue “1” ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
Page 280: Checking The Pickup Coil
ELECTRICAL COMPONENTS Secondary coil resistance 6.32–9.48 kΩ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the spark plug cap from the ignition coil. b. Connect the pocket tester (Ω × 1k) to the ignition coil as shown. Pocket tester 90890-03112 2. Spark plug cap Analog pocket tester YU-03112-C c.
Page 281: Checking The Starter Motor Operation
ELECTRICAL COMPONENTS EAS28150 CHECKING THE STATOR COIL 1. Disconnect: • Stator coil coupler (from the wire harness) 2. Check: • Stator coil resistance Out of specification → Replace the stator coil. Stator coil resistance 0.688–1.032 Ω (W–W) b. Measure the pickup coil resistance. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
Page 282: Checking The Rectifier/Regulator
ELECTRICAL COMPONENTS EAS28170 • Positive tester probe CHECKING THE RECTIFIER/REGULATOR Black “1” 1. Check: • Negative tester probe • Rectifier/regulator output voltage Out of specification → Replace the recti- Black “2” fier/regulator. Rectifier/regulator output volt- 14 V at 5000 r/min ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
Page 283: Checking The Carburetor Warmer
ELECTRICAL COMPONENTS EAS28310 CHECKING THE CARBURETOR WARMER 1. Check: • Carburetor warmer resistance Out of specification → Replace. Carburetor warmer resistance 6–12 Ω ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the carburetor warmer from the carburetor. b. Connect the pocket tester (Ω × 1) to the carburetor warmer as shown.
Page 284 ELECTRICAL COMPONENTS 7-43...
Page 285: Troubleshooting
TROUBLESHOOTING TROUBLESHOOTING ..................8-1 GENERAL INFORMATION ..............8-1 STARTING FAILURES ................8-1 INCORRECT ENGINE IDLING SPEED ..........8-2 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...
Page 286: Troubleshooting
TROUBLESHOOTING EAS28451 • Sucked-in air TROUBLESHOOTING • Damaged float • Worn needle valve EAS28460 • Improperly installed needle valve seat GENERAL INFORMATION • Incorrect fuel level • Improperly installed pilot jet The following guide for troubleshooting does • Clogged starter jet not cover all the possible causes of trouble.
Page 287: Incorrect Engine Idling Speed
TROUBLESHOOTING EAS28490 Fuel system INCORRECT ENGINE IDLING SPEED 1. Carburetor • Faulty diaphragm Engine • Incorrect fuel level 1. Cylinder and cylinder head • Loose or clogged main jet • Incorrect valve clearance • Improper jet needle clip position • Damaged valve train components •...
Page 288: Overheating
TROUBLESHOOTING • Incorrect oil level • Faulty brake caliper kit • Incorrect oil viscosity (low) • Faulty brake caliper seal • Deteriorated oil • Loose union bolt • Damaged brake hose Clutch drags • Oil or grease on the brake disc 1.
Page 289 TROUBLESHOOTING • Faulty battery • Faulty rectifier/regulator • Improperly grounded circuit • Faulty main switch • Faulty light switch • Headlight bulb life expired Tail/brake light does not come on • Wrong tail/brake light bulb • Too many electrical accessories •...
Page 290 EAS28740 WIRING DIAGRAM YFM25RY/YFM25RSEY/ YFM25RSE2Y 1. Pickup coil 2. Stator coil 3. Rectifier/regulator 4. Main switch 5. Battery positive lead 6. Battery 7. Fuse 8. Starter relay 9. Starter motor 10. CDI unit 11. Ignition coil 12. Spark plug 13. Starting circuit cut-off relay 14.
Page 292 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN...
Page 293 WIRING DIAGRAM YFM25RY/YFM25RSEY/YFM25RSE2Y...

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2009 yfm25rsey 2009 yfm25rse2y 2009 raptor 250

Yamaha 2009 YFM25RY Service Manual

Table of Contents

Specifications

Periodic Checks and Adjustments

Periodic Maintenance

Engine

Chassis

Electrical System

Chassis

General Chassis

Front Wheel

Rear Wheel

Rear Axle and Rear Axle Hub

Front Brake

Rear Brake

Handlebar

Steering Stem

Tie-Rods and Steering Knuckles

Front Arms and Front Shock Absorber Assemblies

Rear Shock Absorber Assembly

Swingarm

Engine

Engine Removal

Camshaft

Cylinder Head

Valves and Valve Springs

Cylinder and Piston

Clutch

Oil Pump

Pickup Coil Rotor and Starter Clutch

Electric Starter

Crankcase

Crankshaft Assembly

Transmission

Fuel System

Fuel Tank

Carburetor

Electrical System

Ignition System

Electric Starting System

Charging System

Lighting System

Signaling System

Carburetor Heating System

Electrical Components

Troubleshooting

Quick Links

Chapters

Troubleshooting

Related Manuals for Yamaha 2009 YFM25RY

Summary of Contents for Yamaha 2009 YFM25RY