Yamaha YFM70RY Service Manual
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Yamaha YFM70RY Service Manual

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2009
SERVICE MANUAL
YFM70RY
1S3-28197-E2

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Summary of Contents for Yamaha YFM70RY

  • Page 1 2009 SERVICE MANUAL YFM70RY 1S3-28197-E2...
  • Page 2 EAS20040 YFM70RY SERVICE MANUAL ©2008 by Yamaha Motor Co., Ltd. First edition, June 2008 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
  • 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 1. Serviceable with engine mounted SYMBOLS 2. Filling fluid The following symbols are used in this manual 3. Lubricant for easier understanding. 4. Special tool 5. Tightening torque The following symbols are not relevant to every 6. Wear limit, clearance vehicle.

  • Page 7: Table Of Contents

    EAS20110 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING...

  • Page 9: General Information

    GENERAL INFORMATION IDENTIFICATION .................... 1-1 VEHICLE IDENTIFICATION NUMBER ............. 1-1 MODEL LABEL..................1-1 FEATURES...................... 1-2 OUTLINE OF THE FI SYSTEM..............1-2 FI SYSTEM....................1-3 SELF-ADJUSTING PARKING BRAKE MECHANISM....... 1-4 PARKING BRAKE OPERATION ............... 1-5 INSTRUMENT FUNCTIONS ..............1-7 IMPORTANT INFORMATION ................. 1-8 PREPARATION FOR REMOVAL AND DISASSEMBLY......

  • Page 10: Identification

    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.

  • Page 11: Features

    FEATURES EAS20170 FEATURES EAS1S3L001 OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective carburetor.

  • Page 12: Fi System

    FEATURES EAS1S3L002 FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at only 324 kPa (3.24 kg/cm², 46.1 psi). Accordingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the passage remains open.

  • Page 13: Self-Adjusting Parking Brake Mechanism

    FEATURES EAS1S3L003 SELF-ADJUSTING PARKING BRAKE MECHANISM Usually, for vehicles equipped with a parking brake that must be adjusted manually, it is necessary to adjust the adjusting bolt “5” to achieve the proper clearance between the brake caliper piston “7” and the adjusting bolt.

  • Page 14: Parking Brake Operation

    FEATURES EAS1S3L004 PARKING BRAKE OPERATION When the parking brake is operated, the parking brake cable turns the parking brake arm “1”. The ro- tation of the parking brake arm is changed to axial thrust in the parking brake shaft “2” and the adjusting bolt “3”...
  • Page 15 FEATURES When the brake pedal is operated, the brake fluid pressure in the master cylinder increases and the brake caliper piston “1” and the nut “2” are pushed. When there is proper clearance between the brake caliper piston and the brake pad, no other parts move because the movement of the brake caliper piston and the nut is absorbed by the backlash of the threads of the nut and the adjusting bolt “3”.

  • Page 16: Instrument Functions

    FEATURES Clock mode EAS1S3L005 INSTRUMENT FUNCTIONS Pushing the “CLOCK” button for at least three seconds to switch the display between the clock Multi-function display mode “CLOCK” and the hour meter mode “HOUR” in the following order: CLOCK → HOUR → CLOCK To set the clock: 1.

  • Page 17: 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 18: Bearings And Oil Seals

    IMPORTANT INFORMATION EAS20230 BEARINGS AND OIL SEALS Install bearings “1” and oil seals “2” so that the manufacturer marks or numbers are visible. When installing oil seals “2”, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if appropriate.

  • Page 19: 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 20: 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 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.
  • Page 21 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Steering nut wrench 3-29, 3-32 90890-01443 Spanner wrench YU-33975 Ring nut wrench 3-32 90890-01268 Spanner wrench YU-01268 Axle nut wrench (46 mm) 4-14, 4-15 90890-01498 Rear axle nut wrench 46 mm YM-37134 Damper rod holder (30 mm) 4-46 90890-01327...
  • Page 22 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Weight 5-15 90890-01084 YU-01083-3 YU-01083-3 Valve spring compressor 5-20, 5-25 90890-04019 YM-04019 Valve spring compressor attachment 5-20, 5-25 90890-01243 Valve spring compressor adapter (26 mm) YM-01253-1 Valve guide remover (ø6) 5-21 90890-04064 Valve guide remover (6.0 mm) YM-04064-A Valve guide installer (ø6)
  • Page 23 Piston pin puller set 5-27 90890-01304 Piston pin puller YU-01304 YU-01304 Sheave holder 5-33, 5-35 90890-01701 Primary clutch holder YS-01880-A Flywheel puller 5-33 90890-01404 YM-01404 Yamaha bond No. 1215 5-35, 5-60 90890-85505 (Three Bond No.1215®) Universal clutch holder 5-44, 5-48 90890-04086 YM-91042 1-14...
  • Page 24 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Crankcase separating tool 5-63 90890-01135 Crankcase separator YU-01135-B Crankshaft installer pot 5-63 90890-01274 Installing pot YU-90058 YU-90058/YU-90059 Crankshaft installer bolt 5-63 90890-01275 Bolt YU-90060 Adapter (M16) 5-63 90890-04130 Adapter #13 YM-04059 Spacer (crankshaft installer) 5-63 90890-04081 Pot spacer...
  • Page 25 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Spacer 5-63 ø35 90890-01309 Pot spacer YU-90059 Radiator cap tester 90890-01325 Radiator pressure tester YU-24460-01 YU-24460-01 Radiator cap tester adapter 90890-01352 Radiator pressure tester adapter YU-33984 YU-33984 Mechanical seal installer 90890-04132 Water pump seal installer YM-33221-A Middle driven shaft bearing driver 90890-04058...
  • Page 26 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Fuel pressure adapter 90890-03176 YM-03176 Digital circuit tester 90890-03174 Model 88 Multimeter with tachometer YU-A1927 Ignition checker 8-68 90890-06754 Opama pet-4000 spark checker YM-34487 1-17...

  • Page 27: Specifications

    SPECIFICATIONS GENERAL SPECIFICATIONS ................ 2-1 ENGINE SPECIFICATIONS ................2-2 CHASSIS SPECIFICATIONS ................2-9 ELECTRICAL SPECIFICATIONS ..............2-12 TIGHTENING TORQUES ................2-15 GENERAL TIGHTENING TORQUE SPECIFICATIONS......2-15 ENGINE TIGHTENING TORQUES............2-16 CHASSIS TIGHTENING TORQUES............2-19 LUBRICATION POINTS AND LUBRICANT TYPES ........2-22 ENGINE....................

  • Page 28: General Specifications

    GENERAL SPECIFICATIONS EAS29110 GENERAL SPECIFICATIONS Model Model 1S3R, 1S3X (For CDN) 1S3V, 1S3Y (For Europe) 1S3L, 1S3W (For Oceania) Dimensions Overall length 1845 mm (72.6 in) Overall width 1170 mm (46.1 in) Overall height 1130 mm (44.5 in) Seat height 815 mm (32.1 in) Wheelbase 1280 mm (50.4 in)

  • Page 29: Engine Specifications

    ENGINE SPECIFICATIONS EAS29120 ENGINE SPECIFICATIONS Engine Engine type Liquid-cooled 4-stroke, SOHC Displacement 686.0 cm³ Cylinder arrangement Forward-inclined single cylinder Bore × stroke 102.0 × 84.0 mm (4.02 × 3.31 in) Compression ratio 9.20 :1 Standard compression pressure (at sea level) 450 kPa (4.5 kgf/cm², 64.0 psi) Minimum–maximum 390–500 kPa (3.9–5.0 kgf/cm², 55.5–71.1 psi)
  • Page 30 ENGINE SPECIFICATIONS From low to full level 0.15 L (0.16 US qt, 0.13 Imp.qt) Radiator cap opening pressure 93.3–122.7 kPa (0.9–1.2 kgf/cm², 13.3–17.4 psi) Thermostat Model/manufacturer 5VK1/NIPPON THERMOSTAT Valve opening temperature 69–73 °C (156–163 °F) Valve full open temperature 85 °C (185 °F) Valve lift (full open) 8.0 mm (0.31 in) Radiator core...
  • Page 31 ENGINE SPECIFICATIONS Timing chain Model/number of links 98XRH2010/126 Tensioning system Automatic Rocker arm/rocker arm shaft Rocker arm inside diameter 12.000–12.018 mm (0.4724–0.4731 in) Rocker arm shaft outside diameter 11.981–11.991 mm (0.4717–0.4721 in) Rocker-arm-to-rocker-arm-shaft clearance 0.009–0.037 mm (0.0004–0.0015 in) Valve, valve seat, valve guide Valve clearance (cold) Intake 0.09–0.13 mm (0.0035–0.0051 in)
  • Page 32 ENGINE SPECIFICATIONS Valve guide inside diameter (intake) 6.000–6.012 mm (0.2362–0.2367 in) Limit 6.050 mm (0.2382 in) Valve guide inside diameter (exhaust) 6.000–6.012 mm (0.2362–0.2367 in) Limit 6.050 mm (0.2382 in) Valve-stem-to-valve-guide clearance (intake) 0.010–0.037 mm (0.0004–0.0015 in) Limit 0.080 mm (0.0031 in) Valve-stem-to-valve-guide clearance (exhaust) 0.025–0.052 mm (0.0010–0.0020 in) Limit...
  • Page 33 ENGINE SPECIFICATIONS Piston Piston-to-cylinder clearance 0.030–0.055 mm (0.0012–0.0022 in) Limit 0.13 mm (0.0051 in) Diameter D 101.955–101.970 mm (4.0140–4.0146 in) Height H 10.0 mm (0.39 in) Offset 0.50 mm (0.0197 in) Offset direction Intake side Piston pin bore inside diameter 23.004–23.015 mm (0.9057–0.9061 in) Limit 23.045 mm (0.9073 in)
  • Page 34 ENGINE SPECIFICATIONS End gap (installed) 0.20–0.70 mm (0.01–0.03 in) Crankshaft Width A 74.95–75.00 mm (2.951–2.953 in) Runout limit C 0.030 mm (0.0012 in) Big end side clearance D 0.350–0.650 mm (0.0138–0.0256 in) Limit 1.00 mm (0.040 in) Big end radial clearance E 0.010–0.025 mm (0.0004–0.0010 in) Small end free play F 0.16–0.40 mm (0.01–0.02 in)
  • Page 35 ENGINE SPECIFICATIONS 25/22 (1.136) 22/24 (0.917) 24/13 × 29/12 (4.462) Reverse gear Main axle runout limit 0.08 mm (0.0031 in) Drive axle runout limit 0.08 mm (0.0031 in) Shifting mechanism Shift mechanism type Shift drum and guide bar Shift fork thickness 5.76–5.89 mm (0.2268–0.2319 in) Reverse knob free play 0 mm (0 in)

  • Page 36: Chassis Specifications

    CHASSIS SPECIFICATIONS EAS29130 CHASSIS SPECIFICATIONS Chassis Frame type Aluminum die-cast and steel tube frame Caster angle 5.0° Camber angle -1.0° Kingpin angle 14.8° Kingpin offset 2.8 mm (0.11 in) Trail 21.0 mm (0.83 in) Tread rear (STD) 900.0 mm (35.43 in) Tread front (STD) 940.0 mm (37.01 in) Toe-in (with tires touching the ground)
  • Page 37 CHASSIS SPECIFICATIONS Front brake Type Dual disc brake Operation Right hand operation Front 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) 4.3 mm (0.17 in)
  • Page 38 CHASSIS SPECIFICATIONS Compression damping setting (for fast compression damping) Minimum Standard Maximum Compression damping setting (for slow compression damping) Minimum Standard Maximum Rear suspension Type Swingarm (link suspension) Spring/shock absorber type Coil spring/gas-oil damper Rear shock absorber assembly travel 110.0 mm (4.33 in) Spring free length 255.0 mm (10.04 in) Installed length...

  • Page 39: Electrical Specifications

    ELECTRICAL SPECIFICATIONS EAS29140 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system TCI (digital) Advancer type Digital Ignition timing (B.T.D.C.) 9.0°/1600 r/min Engine control unit Model/manufacturer TBDF18/DENSO Fuel injection sensor 192.0–288.0 Ω at 20 °C (68 °F) Crankshaft position sensor resistance Intake air pressure sensor output voltage 3.00–4.00 V 2.21–2.69 Ω...
  • Page 40 ELECTRICAL SPECIFICATIONS Bulb voltage, wattage × quantity 12 V, 30.0/30.0 W × 2 Headlight Tail/brake light Indicator light Neutral indicator light Fuel level warning light Reverse indicator light Coolant temperature warning light Engine trouble warning light Electric starting system System type Constant mesh Starter motor Model/manufacturer...
  • Page 41 ELECTRICAL SPECIFICATIONS Ignition fuse 10.0 A Fuel injection system fuse 10.0 A Spare fuse 20.0 A Spare fuse 15.0 A Spare fuse 10.0 A 2-14...

  • Page 42: Tightening Torques

    TIGHTENING TORQUES EAS20320 TIGHTENING TORQUES EAS20330 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for special com- ponents or assemblies are provided for each chapter of this manual. To avoid warpage, tight- en multi-fastener assemblies in a crisscross pat- tern and progressive stages until the specified tightening torque is reached.

  • Page 43: Engine Tightening Torques

    TIGHTENING TORQUES EAS20340 ENGINE TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Cylinder head stud bolt (exhaust 15 Nm (1.5 m·kg, 11 ft·lb) pipe) Cylinder head bolt 35 Nm (3.5 m·kg, 25 ft·lb) Cylinder head bolt 38 Nm (3.8 m·kg, 27 ft·lb) Cylinder head bolt 10 Nm (1 m·kg, 7.2 ft·lb) Spark plug...
  • Page 44 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Engine oil drain bolt (oil tank) 19 Nm (1.9 m·kg, 13 ft·lb) Oil baffle plate 1 bolt 4 Nm (0.4 m·kg, 2.9 ft·lb) Oil baffle plate 2 bolt 10 Nm (1 m·kg, 7.2 ft·lb) Oil pump bolt 10 Nm (1 m·kg, 7.2 ft·lb) Oil pump housing 2 screw...
  • Page 45 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Clutch spring bolt 8 Nm (0.8 m·kg, 5.8 ft·lb) Clutch boss nut 95 Nm (9.5 m·kg, 68 ft·lb) Stake Clutch cover bolt 10 Nm (1 m·kg, 7.2 ft·lb) Use a Drive sprocket nut 85 Nm (8.5 m·kg, 61 ft·lb) lock washer.

  • Page 46: Chassis Tightening Torques

    TIGHTENING TORQUES EAS20350 CHASSIS TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Engine upper bracket bolt 33 Nm (3.3 m·kg, 24 ft·lb) Engine mounting nut (upper) 40 Nm (4 m·kg, 29 ft·lb) Engine lower bracket bolt 41 Nm (4.1 m·kg, 30 ft·lb) Engine mounting nut (middle) 66 Nm (6.6 m·kg, 48 ft·lb) Engine mounting nut (lower)
  • Page 47 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Pitman arm and tie-rod ball joint 25 Nm (2.5 m·kg, 18 ft·lb) Bearing retainer nut 65 Nm (6.5 m·kg, 47 ft·lb) Fuel pump nut 7 Nm (0.7 m·kg, 5.1 ft·lb) Fuel tank bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) Front wheel hub nut 45 Nm (4.5 m·kg, 32 ft·lb)
  • Page 48 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Rear brake master cylinder union 30 Nm (3 m·kg, 22 ft·lb) bolt Rear brake master cylinder ad- 17 Nm (1.7 m·kg, 12 ft·lb) justing bolt Parking brake adjusting bolt 10 Nm (1 m·kg, 7.2 ft·lb) Rear brake disc mounting bolt 33 Nm (3.3 m·kg, 24 ft·lb) Brake hose holder bolt...

  • Page 49: Lubrication Points And Lubricant Types

    Transmission gears (wheel and pinion) Shift drum Shift forks Shift fork guide bar Shift lever assembly Shift shaft Reverse shift shaft Yamaha bond No. Crankcase mating surface 1215 (Three bond No.1215®) Yamaha bond No. AC magneto lead grommet (AC magneto cover) 1215 (Three bond No.1215®)

  • Page 50: Lubrication System Chart And Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 2-23...
  • Page 51 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil strainer 2. Oil pump 3. Right crankcase 4. Left crankcase 5. AC magneto cover 6. Oil tank inlet hose 7. To oil tank 8. Main axle 9. Drive axle 10. Counter axle 11. From oil tank 12.

  • Page 52: Lubrication Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20410 LUBRICATION DIAGRAMS 2-25...
  • Page 53 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil tank breather hose 2. Oil tank outlet hose 3. Oil tank inlet hose 4. Oil tank 2-26...
  • Page 54 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-27...
  • Page 55 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil delivery pipe 2. Oil filter 3. Oil pump 2-28...
  • Page 56 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-29...
  • Page 57 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil filter 2. Oil pump driven gear 3. Oil pump rotor 1 4. Oil pump rotor 2 5. Oil tank outlet hose joint 6. Main axle 7. Counter axle 2-30...
  • Page 58 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-31...
  • Page 59 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil strainer 2. Oil pump rotor 2 3. Oil pump rotor 1 4. Oil pump driven gear A. To oil tank 2-32...
  • Page 60 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-33...
  • Page 61 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Balancer 1 2. Crankshaft 2-34...

  • Page 62: Cooling System Diagrams

    COOLING SYSTEM DIAGRAMS EAS20420 COOLING SYSTEM DIAGRAMS 2-35...
  • Page 63 COOLING SYSTEM DIAGRAMS 1. Thermostat cover 2. Fast idle plunger outlet hose 3. Radiator inlet hose 4. Radiator 5. Radiator outlet hose 6. Water pump breather hose 7. Water pump A. Install the radiator inlet hose onto the thermostat cover pipe, making sure that it contacts the cover and its yellow paint mark is facing outward.
  • Page 64 COOLING SYSTEM DIAGRAMS 2-37...
  • Page 65 COOLING SYSTEM DIAGRAMS 1. Radiator 2. Radiator fan motor breather hose 3. Fuel tank shield 4. Coolant reservoir breather hose 5. Coolant reservoir 6. Coolant reservoir hose 7. Drain hose A. Pass the radiator fan motor breather hose through the guide. B.
  • Page 66 COOLING SYSTEM DIAGRAMS 2-39...
  • Page 67 COOLING SYSTEM DIAGRAMS 1. Water pump outlet hose 2. Water pump 3. Water pump breather hose 4. Water jacket inlet housing A. From radiator B. Install the water pump outlet hose onto the water jacket inlet housing, making sure to align the yellow paint mark on the hose with the projection on the water jacket inlet housing.

  • Page 68: Cable Routing

    CABLE ROUTING EAS20430 CABLE ROUTING 2-41...
  • Page 69 CABLE ROUTING 1. Handlebar switch lead N. Pass the throttle cable, clutch cable, parking brake cable, front brake light switch lead, main switch 2. Clutch switch lead lead, handlebar switch lead, clutch switch lead, 3. Parking brake cable meter assembly lead, and radiator fan motor 4.
  • Page 70 CABLE ROUTING 2-43...
  • Page 71 CABLE ROUTING 1. Headlight lead (left) M. Route the AC magneto lead, negative battery lead, sub-wire harness, rear brake light switch lead, and 2. Radiator speed sensor lead between the crankcase 3. Coolant reservoir hose breather hose and the starter motor lead, and to 4.
  • Page 72 CABLE ROUTING 2-45...
  • Page 73 CABLE ROUTING 1. Starter relay lead 2. Relay unit 3. Fuse box lead 4. Radiator fan motor relay 5. Headlight relay 6. Tail/brake light 7. Tail/brake light lead 8. Fuse box 9. Relay unit lead 10. ECU (engine control unit) 11.
  • Page 74 CABLE ROUTING 2-47...
  • Page 75 CABLE ROUTING 1. Parking brake cable 2. Radiator fan motor coupler 3. Ignition coil leads 4. Headlight lead (right) 5. Rectifier/regulator lead 6. Reverse control cable 7. Throttle cable 8. Handlebar switch lead 9. Clutch switch lead 10. Main switch lead 11.
  • Page 76 CABLE ROUTING 2-49...
  • Page 77 CABLE ROUTING 1. Radiator fan motor relay 2. Headlight relay 3. Fuse box 4. Relay unit 5. Relay unit lead 6. Starter motor lead 7. Starter relay lead 8. Starter relay 9. Fuse box lead 10. Headlight relay lead 11. Radiator fan motor relay lead 12.
  • Page 78 CABLE ROUTING 2-51...
  • Page 79 CABLE ROUTING 1. Throttle position sensor lead 2. Fast idle plunger outlet hose 3. Fuel injector lead 4. Intake air pressure sensor 5. Coolant temperature sensor lead 6. Spark plug lead 7. Rectifier/regulator 8. Headlight lead (right) 9. Reverse control cable 10.
  • Page 80 CABLE ROUTING 2-53...

  • Page 81: 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 ....... 3-1 ENGINE ......................3-4 ADJUSTING THE VALVE CLEARANCE ..........3-4 ADJUSTING THE ENGINE IDLING SPEED ..........3-6 ADJUSTING THE EXHAUST GAS VOLUME (for Europe and Oceania) .................
  • Page 82 CHASSIS ....................... 3-21 ADJUSTING THE FRONT DISC BRAKE..........3-21 ADJUSTING THE REAR DISC BRAKE ..........3-21 CHECKING THE BRAKE FLUID LEVEL..........3-21 CHECKING THE FRONT BRAKE PADS ..........3-22 CHECKING THE REAR BRAKE PADS ..........3-22 CHECKING THE FRONT BRAKE HOSES ..........3-22 CHECKING THE REAR BRAKE HOSE ..........

  • Page 84: Periodic Maintenance

    However, keep in mind that if the ATV isn’t used for a long period of time, the month mainte- nance 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 85 PERIODIC MAINTENANCE INITIAL EVERY month CHECK OR MAINTENANCE Whichever ITEM 1300 2500 2500 5000 comes first km (mi) (200) (800) (1600) (1600) (3200) hours • Check operation and correct if necessary. √ √ √ √ √ • Check fluid level and ATV for fluid leakage, and cor- Rear brake rect if necessary.
  • Page 86 PERIODIC MAINTENANCE • 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.

  • Page 87: Engine

    ENGINE EAS20472 ENGINE EAS20520 ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. • Valve clearance adjustment should be made on a cold engine, at room temperature. • When the valve clearance is to be measured or 6.
  • Page 88 ENGINE • Hold the adjusting screw to prevent it from moving and tighten the locknut to specifica- tion. Locknut 14 Nm (1.4 m·kg, 10 ft·lb) d. Measure the valve clearance again. e. If the valve clearance is still out of specifica- tion, repeat all of the valve clearance adjust- ment steps until the specified clearance is L LLL...

  • Page 89: Adjusting The Engine Idling Speed

    ENGINE • Front fender EAS20600 ADJUSTING THE EXHAUST GAS VOLUME • Seat (for Europe and Oceania) Refer to “GENERAL CHASSIS” on page 4-1. EAS20620 Be sure to set the CO density level to standard, ADJUSTING THE ENGINE IDLING SPEED and then adjust the exhaust gas volume. 1.

  • Page 90: Adjusting The Throttle Lever Free Play

    ENGINE Throttle lever free play 2.0–4.0 mm (0.08–0.16 in) 2. Adjust: • Throttle lever free play M MMM M MMM M MMM M MMM M MMM Throttle body side a. Slide back the rubber cover “1”. b. Loosen the locknut “2”. 6.

  • Page 91: Adjusting The Speed Limiter

    ENGINE EWA1S3L001 c. Tighten the locknut. WARNING EWA14880 WARNING After adjusting the throttle lever free play, start the engine and turn the handlebar to the • Particularly for a beginner rider, the speed right or left to ensure that this does not limiter should be screwed in completely.

  • Page 92: Checking The Ignition Timing

    ENGINE • Digital tachometer (to spark plug lead) Timing light 90890-03141 Inductive clamp timing light YU-03141 2. Check: • Ignition timing M MMM M MMM M MMM M MMM M MMM 5. Clean: a. Start the engine, warm it up for several min- •...

  • Page 93: Measuring The Compression Pressure

    ENGINE EAS20710 MEASURING THE COMPRESSION Standard compression pressure PRESSURE (at sea level) 450 kPa (4.5 kgf/cm², 64.0 psi) Minimum–maximum Insufficient compression pressure will result in a 390–500 kPa (3.9–5.0 kgf/cm², loss of performance. 55.5–71.1 psi) 1. Measure: M MMM M MMM M MMM M MMM M MMM...

  • Page 94: Checking The Engine Oil Level

    ENGINE EAS20750 CHECKING THE ENGINE OIL LEVEL 1. Place the vehicle on a level surface. 130˚F 2. Start the engine, warm it up until the engine oil has reached a normal temperature of 60 YAMALUBE 4 20W-50 or SAE 20W-50 °C (140 °F), let it continue to idle for ten sec- YAMALUBE 4 10W-40 or SAE 10W-40 onds, and then turn the engine off.

  • Page 95: Changing The Engine Oil

    ENGINE EAS20800 CHANGING THE ENGINE OIL 1. Start the engine, warm it up for several min- utes, and then turn it off. 2. Place a container under the engine oil drain bolt. 3. Remove: • Engine oil filler bolt “1” •...

  • Page 96: Adjusting The Clutch Lever Free Play

    ENGINE c. Check the engine oil passages, the oil filter Oil filter element drain bolt element and the oil pump for damage or leak- 10 Nm (1.0 m·kg, 7.2 ft·lb) age. Refer to “OIL PUMP” on page 5-50. d. Start the engine after solving the problem(s) 11.Fill: and check the engine oil pressure again.

  • Page 97: Cleaning The Air Filter Element

    ENGINE 1. Remove: • Seat Refer to “GENERAL CHASSIS” on page 4-1. 2. Remove: • Air filter case cover “1” If the specified clutch cable free play cannot be obtained on the handlebar side of the cable, use the adjusting nut on the engine side. L LLL L LLL L LLL...

  • Page 98: Checking The Throttle Body Joint

    ENGINE EWA13020 WARNING Never use low flash point solvents, such as gasoline, to clean the air filter element. Such solvents may cause a fire or an explosion. After cleaning, gently squeeze the air filter ele- ment to remove the excess solvent. ECA13430 NOTICE EAS21030...

  • Page 99: Checking The Exhaust System

    ENGINE ECA13450 NOTICE Make sure the crankcase breather hose is routed correctly. EAS21080 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the ex- haust pipes and gaskets. 1. Check: • Exhaust pipe “1” • Muffler “2” EAS28970 •...

  • Page 100: Checking The Coolant Level

    ENGINE d. Insert the tailpipe into the muffler and align ECA13470 NOTICE the bolt holes. • Adding water instead of coolant lowers the e. Insert the bolt and tighten it. antifreeze content of the coolant. If water is Spark arrester bolt used instead of coolant check, and if nec- 8 Nm (0.8 m·kg, 5.8 ft·lb) essary, correct the antifreeze concentra-...

  • Page 101: Changing The Coolant

    ENGINE 3. Drain: • Coolant (from the coolant reservoir) 4. Connect: • Coolant reservoir hose 5. Remove: • Radiator cap “1” EWA13030 WARNING A hot radiator is under pressure. Therefore, do not remove the radiator cap when the en- gine is hot. Scalding hot fluid and steam may 3.
  • Page 102 ENGINE Recommended antifreeze High-quality ethylene glycol anti- freeze containing corrosion in- hibitors for aluminum engines Mixing ratio 1:1 (antifreeze:water) Radiator capacity (including all routes) 1.61 L (1.70 US qt, 1.42 Imp.qt) Coolant reservoir capacity (up to the maximum level mark) 7.
  • Page 103 ENGINE 15.Install: • Coolant reservoir cap 16.Start the engine, warm it up for several min- utes, and then stop it. 17.Check: • Coolant level Refer to “CHECKING THE COOLANT LEV- EL” on page 3-17. Before checking the coolant level, wait a few minutes until the coolant has settled.

  • Page 104: Chassis

    CHASSIS b. Turn the adjusting bolt “2” until the brake ped- EAS29360 CHASSIS al height is within the specified limits. EAS21170 Brake pedal position (from foot- ADJUSTING THE FRONT DISC BRAKE rest) 1. Adjust: 15.3 mm (0.60 in) • Brake lever position “a” M MMM M MMM M MMM...

  • Page 105: Checking The Front Brake Pads

    CHASSIS 1. Remove: • Front wheel Refer to “FRONT WHEELS” on page 4-5. 2. Check: • Front brake pad Wear indicator “1” almost touches the brake disc → Replace the brake pads as a set. Refer to “FRONT BRAKES” on page 4-17. 3.

  • Page 106: Checking The Rear Brake Hose

    CHASSIS EAS29210 ADJUSTING THE PARKING BRAKE 1. Check: • Parking brake cable end length “a” Out of specification → Adjust. Parking brake cable end length 56–58 mm (2.20–2.28 in) 3. Check: • Brake hose clamp Loose → Tighten the clamp bolt. 4.

  • Page 107: Adjusting The Rear Brake Light Switch

    CHASSIS caution could allow air to enter the hydraulic EAS21330 ADJUSTING THE REAR BRAKE LIGHT brake system, considerably lengthening the SWITCH bleeding procedure. • If bleeding is difficult, it may be necessary to let The rear brake light switch is operated by move- the brake fluid settle for a few hours.

  • Page 108: Adjusting The Shift Pedal

    CHASSIS i. Repeat steps (e) to (h) until all of the air bub- Shift pedal bolt bles have disappeared from the brake fluid in 16 Nm (1.6 m·kg, 11 ft·lb) the plastic hose. j. Tighten the bleed screw to specification. L LLL L LLL L LLL...

  • Page 109: Adjusting The Drive Chain Slack

    CHASSIS Loosen the rear axle pinch bolts in the proper se- quence as shown. b. Insert an appropriate shaft “2” in the hole “4” of rear axle hub “3” so that the sprocket bracket “5” does not move. d. Tighten the locknut. e.

  • Page 110: Checking The Steering System

    CHASSIS EAS29280 CHECKING THE STEERING SYSTEM 1. Place the vehicle on a level surface. 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 1.

  • Page 111: Checking The Front Shock Absorber Assemblies

    CHASSIS d. Tighten the rod end locknuts of both tie-rods. Locknut (tie-rod end) 18 Nm (1.8 m·kg, 13 ft·lb) Adjust the tie-rod ends so that “A” and “B” are equal. C. Forward L LLL L LLL L LLL L LLL L LLL 3.

  • Page 112: Adjusting The Front Shock Absorber Assemblies

    CHASSIS Refer to “FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES” on page 4-49. 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”...
  • Page 113 CHASSIS Locknut Make sure that the position indicator marks “c” 42 Nm (4.2 m·kgf, 30 ft·lbf) are aligned when the shock absorber is set to the standard setting. ECA1S3L003 NOTICE Do not force the adjuster past the minimum or maximum extent of adjustment. The ad- juster may be damaged.

  • Page 114: Checking The Rear Shock Absorber Assembly

    CHASSIS ECA1S3L003 EAS29320 CHECKING THE REAR SHOCK ABSORBER NOTICE ASSEMBLY Do not force the adjuster past the minimum 1. Place the vehicle on a level place. or maximum extent of adjustment. The ad- 2. Check: juster may be damaged. • Damper rod Bends/damage →...
  • Page 115 CHASSIS b. Loosen the locknut “2” with the ring nut wrench “1”. • Be sure to remove all dirt and mud from around the locknut and adjusting ring before adjust- Ring nut wrench ment. 90890-01268 • The length of the spring (installed) changes 1.5 Spanner wrench mm (0.06 in) per turn of the adjuster.
  • Page 116 CHASSIS Rebound damping adjusting posi- Compression damping setting (for tions fast compression damping) Minimum Minimum 20 click(s) out* 4 click(s) out* Standard Standard 13 click(s) out* 2 click(s) out* Maximum Maximum 3 click(s) out* 0 click(s) out* * With the adjusting konb fully turned in * With the adjusting screw fully turned in ECA1S3L003 NOTICE...

  • Page 117: Checking The Tires

    Tire characteristics psi) EWA14950 Rear WARNING 24.5 kPa (0.245 kgf/cm², 3.6 Tire characteristics influence the handling of psi) vehicles. The tires listed below have been approved by Yamaha Motor Co., Ltd. for this model. If other tire combinations are used, 3-34...

  • Page 118: Checking The Wheels

    CHASSIS Maximum loading limit Wear limit (front) EWA14970 3 mm (0.12 in) WARNING Wear limit (rear) Be extra careful of the vehicle balance and 3 mm (0.12 in) stability when towing a trailer. EWA1S3L015 Maximum loading limit WARNING 100.0 kg (220 lb) It is dangerous to ride with a worn-out tire.

  • Page 119: Lubricating The Clutch Lever

    CHASSIS EWA13270 WARNING Recommended lubricant Lithium-soap-based grease Damaged outer cable may cause the cable to corrode and interfere with its movement. Re- place damaged outer cable and inner cables as soon as possible. 1. Check: • Outer cable Damage → Replace. 2.

  • Page 120: Electrical System

    ELECTRICAL SYSTEM EAS21750 ECA13690 ELECTRICAL SYSTEM NOTICE Avoid touching the glass part of the head- EAS21760 light bulb to keep it free from oil, otherwise CHECKING AND CHARGING THE BATTERY the transparency of the glass, the life of the Refer to “ELECTRICAL COMPONENTS” on bulb and the luminous flux will be adversely page 8-55.
  • Page 121 ELECTRICAL SYSTEM L LLL L LLL L LLL L LLL L LLL 3-38...
  • Page 122 ELECTRICAL SYSTEM 3-39...
  • Page 123 CHASSIS GENERAL CHASSIS..................4-1 FRONT WHEELS .................... 4-5 REMOVING THE FRONT WHEELS ............4-6 CHECKING THE FRONT WHEELS............4-6 CHECKING THE FRONT WHEEL HUBS ..........4-6 INSTALLING THE FRONT WHEEL HUB BEARINGS ......4-7 INSTALLING THE FRONT BRAKE DISCS..........4-7 INSTALLING THE FRONT WHEEL HUBS ..........
  • Page 124 REAR BRAKE ....................4-28 INTRODUCTION ..................4-34 CHECKING THE REAR BRAKE DISC............ 4-34 REPLACING THE REAR BRAKE PADS..........4-34 REMOVING THE REAR BRAKE CALIPER ..........4-35 DISASSEMBLING THE REAR BRAKE CALIPER ........4-36 CHECKING THE REAR BRAKE CALIPER..........4-36 ASSEMBLING THE REAR BRAKE CALIPER ........4-36 INSTALLING THE REAR BRAKE CALIPER...........
  • Page 125 SWINGARM....................4-59 REMOVING THE SWINGARM..............4-61 CHECKING THE SWINGARM ..............4-61 INSTALLING THE SWINGARM .............. 4-61 CHAIN DRIVE....................4-63 CHECKING THE DRIVE CHAIN ............. 4-64 INSTALLING THE DRIVE CHAIN ............4-65...

  • Page 126: General Chassis

    GENERAL CHASSIS EAS21830 GENERAL CHASSIS Removing the seat, front panel, foot protectors and engine skid plate 4 Nm (0.4 m kg, 2.9 ft • • 16 Nm (1.6 m kg, 11 ft • • 13 Nm (1.3 m kg, 9.4 ft •...
  • Page 127 GENERAL CHASSIS Removing the headlights and front fender 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 128 GENERAL CHASSIS Removing the rear fender 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 9 Nm (0.9 m kg, 6.5 ft • • 4 Nm (0.4 m kg, 2.9 ft •...
  • Page 129 GENERAL CHASSIS Removing the rear fender 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 9 Nm (0.9 m kg, 6.5 ft • • 4 Nm (0.4 m kg, 2.9 ft •...

  • Page 130: Front Wheels

    FRONT WHEELS EAS21870 FRONT WHEELS 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. Place the vehicle on a level surface. Front wheel Brake disc guard (outer) Cotter pin Front wheel axle nut Do not squeeze the brake lever when the...

  • Page 131: Removing The Front Wheels

    FRONT WHEELS EAS21890 REMOVING THE FRONT WHEELS 1. Place the vehicle on a level surface. 2. Elevate: • Front wheels Place the vehicle on a suitable stand so that the front wheels are elevated. 3. Remove: • Front brake calipers Do not apply the brake lever when removing the brake calipers.

  • Page 132: Installing The Front Wheel Hub Bearings

    FRONT WHEELS Face the oil seal side of the bearing inward. 2. Check: • Wheel bearings Wheel hub play/wheel turns roughly → Re- place. EAS1S3L013 INSTALLING THE FRONT BRAKE DISCS M MMM M MMM M MMM M MMM M MMM a.

  • Page 133: Installing The Front Wheels

    FRONT WHEELS Wheel nut 45 Nm (4.5 m·kg, 32 ft·lb) 2. Check: • Brake disc Refer to “CHECKING THE FRONT BRAKE DISCS” on page 4-22. EAS29420 INSTALLING THE FRONT WHEELS The following procedure applies to both of the front wheels. 1.

  • Page 134: Rear Wheels

    REAR WHEELS EAS22020 REAR WHEELS Removing the rear wheels Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the rear wheels. Place the vehicle on a level surface. Rear wheel Cotter pin Rear wheel axle nut Rear wheel hub For installation, reverse the removal proce- dure.

  • Page 135: Removing The Rear Wheels

    REAR WHEELS EAS1S3L014 REMOVING THE REAR WHEELS 1. Place the vehicle on a level surface. 2. Elevate: • Rear wheels Place the vehicle on a suitable stand so that the rear wheels are elevated. EAS29430 CHECKING THE REAR WHEELS EAS29450 The following procedure applies to both of the INSTALLING THE REAR WHEEL HUBS rear wheels.

  • Page 136: Installing The Rear Wheels

    REAR WHEELS EAS29460 INSTALLING THE REAR WHEELS The following procedure applies to both of the rear wheels. 1. Install: • Wheel The arrow mark “1” on the tire must point in the direction of rotation “A” of the wheel. 2. Tighten: •...

  • Page 137: 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 34 Nm (3.4 m kg, 24 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 21 Nm (2.1 m kg, 15 ft •...
  • Page 138 REAR AXLE AND REAR AXLE HUB Removing the rear axle and rear axle hub 34 Nm (3.4 m kg, 24 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 21 Nm (2.1 m kg, 15 ft • •...

  • Page 139: Removing The Rear Axle

    REAR AXLE AND REAR AXLE HUB EAS29490 ECA16180 REMOVING THE REAR AXLE NOTICE 1. Place the vehicle on a level surface. • Never directly tap the axle end with a ham- 2. Remove: mer, since this will result in damage to the •...

  • Page 140: Checking The Rear Wheel Sprocket

    REAR AXLE AND REAR AXLE HUB 2. Install: EAS29510 CHECKING THE REAR WHEEL SPROCKET • Rear wheels 1. Check: Refer to “REAR WHEELS” on page 4-9. • Rear wheel sprocket 3. Tighten: Refer to “CHAIN DRIVE” on page 4-63. • Rear axle ring nut “1” •...
  • Page 141 REAR AXLE AND REAR AXLE HUB 4. Adjust: • Drive chain slack Refer to “ADJUSTING THE DRIVE CHAIN SLACK” on page 3-26. 4-16...

  • Page 142: Front Brakes

    FRONT BRAKES EAS22210 FRONT BRAKES Removing the front brake pads 17 Nm (1.7 m kg, 12 ft • • 28 Nm (2.8 m kg, 20 ft Ib) • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers.
  • Page 143 FRONT BRAKES Removing the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake fluid Drain. Brake fluid reservoir cap Brake fluid reservoir diaphragm Front brake light switch connector Disconnect. Front brake light switch Brake lever Union bolt Copper washer Brake hose Disconnect.
  • Page 144 FRONT BRAKES Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Dust boot Circlip Brake master cylinder kit Brake master cylinder body For assembly, reverse the disassembly pro- cedure. 4-19...
  • Page 145 FRONT BRAKES Removing the front brake calipers 17 Nm (1.7 m kg, 12 ft • • 28 Nm (2.8 m kg, 20 ft • • 27 Nm (2.7 m kg, 19 ft • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers.
  • Page 146 FRONT BRAKES Disassembling the front brake calipers 17 Nm (1.7 m kg, 12 ft • • 6 Nm (0.6 m kg, 4.3 ft • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers. Brake caliper retaining bolt Brake pad/pad shim Brake pad spring...

  • Page 147: Introduction

    FRONT BRAKES EAS22220 INTRODUCTION Brake disc deflection limit EWA14100 0.15 mm (0.006 in) WARNING Disc brake components rarely require disas- M MMM M MMM M MMM M MMM M MMM a. Hold the dial gauge at a right angle against sembly.

  • Page 148: Replacing The Front Brake Pads

    FRONT BRAKES e. If out of specification, repeat the adjustment M MMM M MMM M MMM M MMM M MMM a. Connect a clear plastic hose “1” tightly to the steps until the brake disc deflection is within bleed screw “2”. Put the other end of the hose specification.

  • Page 149: Checking The Front Brake Caliper

    FRONT BRAKES Recommended brake component replace- Before disassembling the brake caliper, drain ment schedule the brake fluid from the entire brake system. Brake hoses Every four years 1. Remove: Every two years and • Brake caliper pistons Brake fluid whenever the brake •...

  • Page 150: Installing The Front Brake Calipers

    FRONT BRAKES EWA13530 WARNING Recommended fluid DOT 4 Proper brake hose routing is essential to in- sure safe vehicle operation. Refer to “CABLE 1. Install: ROUTING” on page 2-41. • Caliper piston seals “1” ECA1S3L011 NOTICE • Dust seals “2” When installing the brake hose onto the brake caliper, make sure the brake pipe “a”...

  • Page 151: Checking The Front Brake Master Cylinder

    FRONT BRAKES 4. Check: • Brake fluid level Below the minimum level mark → Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 3-21. 5. Check: • Brake lever operation Soft or spongy feeling → Bleed the brake sys- tem.
  • Page 152 FRONT BRAKES 2. Install: • When refilling, be careful that water does not enter the brake master cylinder reser- • Copper washers voir. Water will significantly lower the boil- • Brake hose ing point of the brake fluid and could cause •...
  • Page 153 REAR BRAKE EAS22550 REAR BRAKE Removing the rear brake pads 17 Nm (1.7 m kg, 12 ft • • 34 Nm (3.4 m kg, 24 ft • • Order Job/Parts to remove Q’ty Remarks Brake caliper bolt Brake pad retaining bolt Brake pad/insulator/pad shim 2/1/1 Brake pad spring...
  • Page 154 REAR BRAKE Removing the rear brake master cylinder 4 Nm (0.4 m kg, 2.9 ft • • 20 Nm (2.0 m kg, 14 ft • • 30 Nm (3.0 m kg, 22 ft • • 20 Nm (2.0 m kg, 14 ft •...
  • Page 155 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. 4-30...
  • Page 156 REAR BRAKE Removing the rear brake caliper 30 Nm (3.0 m kg, 22 ft • • 34 Nm (3.4 m kg, 24 ft • • Order Job/Parts to remove Q’ty Remarks Brake fluid Drain. Parking brake cable Disconnect. Union bolt Copper washer Brake hose Disconnect.
  • Page 157 REAR BRAKE Disassembling the rear brake caliper Order Job/Parts to remove Q’ty Remarks Adjusting bolt Locknut Parking brake arm Parking brake shaft Rubber boot Parking brake bracket mounting bolt Parking brake case bracket Parking brake case Gasket Brake pad retaining bolt Brake pad/insulator/pad shim 2/1/1 Brake pad spring...
  • Page 158 REAR BRAKE Disassembling the rear brake caliper Order Job/Parts to remove Q’ty Remarks Bleed screw For assembly, reverse the disassembly pro- cedure. 4-33...

  • Page 159: Rear Brake

    REAR BRAKE EAS22560 INTRODUCTION Brake disc thickness limit EWA14100 3.0 mm (0.12 in) WARNING Disc brake components rarely require disas- 5. Adjust: sembly. Therefore, always follow these pre- • Brake disc deflection ventive measures: Refer to “CHECKING THE FRONT BRAKE •...

  • Page 160: Removing The Rear Brake Caliper

    REAR BRAKE • Brake pad spring d. Install new brake pads, a new insulator, a new pad shim, and a new brake pad spring. Always install new brake pads, brake pad shims, and a brake pad spring as a set. Align the projection “c”...

  • Page 161: Disassembling The Rear Brake Caliper

    REAR BRAKE 1. Check: EAS22630 DISASSEMBLING THE REAR BRAKE • Brake caliper piston “1” CALIPER Rust/scratches/wear → Replace the brake caliper piston. Before disassembling the brake caliper, drain • Brake caliper cylinder “2” Scratches/wear → Replace the brake caliper the brake fluid from the entire brake system. assembly.

  • Page 162: Installing The Rear Brake Caliper

    REAR BRAKE When installing the parking brake arm, turn the parking brake shaft clockwise and align the punch mark “a” on the parking brake arm with the punch mark “b” on the parking brake shaft. 2. Install: • Brake caliper piston “1” Turn the brake caliper piston clockwise until section “a”...
  • Page 163 REAR BRAKE 2. Fill: • Brake fluid reservoir (with the specified amount of the recom- mended brake fluid) Recommended fluid DOT 4 EWA13090 WARNING • Use only the designated brake fluid. Other M MMM M MMM M MMM M MMM M MMM brake fluids may cause the rubber seals to a.

  • Page 164: Checking The Rear Brake Master Cylinder

    REAR BRAKE EAS22720 EAS22730 CHECKING THE REAR BRAKE MASTER ASSEMBLING THE REAR BRAKE MASTER CYLINDER CYLINDER 1. Check: EWA1S3L011 WARNING • Brake master cylinder “1” Damage/scratches/wear → Replace. • Before installation, all internal brake com- ponents should be cleaned and lubricated •...
  • Page 165 REAR BRAKE Recommended fluid DOT 4 EWA13090 WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • Refill with the same type of brake fluid that is already in the system.

  • Page 166: Handlebar

    HANDLEBAR EAS22840 HANDLEBAR Removing the handlebar 7 Nm (0.7 m kg, 5.1 ft • • 23 Nm (2.3 m kg, 17 ft • • 4 Nm (0.4 m kg, 2.9 ft • • 4 Nm (0.4 m kg, 2.9 ft •...

  • Page 167: Removing The Clutch Switch

    HANDLEBAR EAS1S3L016 REMOVING THE CLUTCH SWITCH 1. Remove: • Clutch switch “1” EAS22911 INSTALLING THE HANDLEBAR 1. Place the vehicle on a level surface. 2. Install: • Handlebar Push the fastener when removing the clutch • Upper handlebar holders switch out of the clutch lever holder. Upper handlebar holder bolt 23 Nm (2.3 m·kg, 17 ft·lb) EAS22860...
  • Page 168 HANDLEBAR • Clutch lever bracket “2” Install the clutch lever bracket as shown. a. 53–54 mm (2.09–2.13 in) 5. Install: • Brake master cylinder “1” Brake master cylinder bracket bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) 3. Install: • Handlebar grip “1” •...
  • Page 169 HANDLEBAR 7. Install: • Clutch cable 8. Connect: • Clutch switch coupler Lubricate the end of the clutch cable with a thin coat of lithium-soap-based grease. 9. Adjust: • Clutch cable free play Refer to “ADJUSTING THE CLUTCH LEVER FREE PLAY” on page 3-13. Clutch lever free play (lever end) 5.0–10.0 mm (0.20–0.39 in) 10.Adjust:...

  • Page 170: Steering Stem

    STEERING STEM EAS29540 STEERING STEM Removing the steering stem Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Front fender/fuel tank 4-1. Pitman arm Lock washer Steering stem bushing Spacer Oil seal Steering stem Oil seal Oil seal Bearing retainer Bearing For installation, reverse the removal proce-...

  • Page 171: Removing The Bearing Retainer

    STEERING STEM EAS29550 REMOVING THE BEARING RETAINER Damper rod holder (30 mm) 1. Remove: 90890-01327 • Bearing retainer YM-01327 Damper rod holder (30 mm) EAS29580 90890-01327 INSTALLING THE LOCK WASHER YM-01327 1. Install: • Lock washer EAS29560 • Steering stem bushing bolts CHECKING THE STEERING STEM 1.
  • Page 172 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/brake disc Refer to “FRONT WHEELS” on page 4-5. Front brake caliper Refer to “FRONT BRAKES”...

  • Page 173: 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 174 FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES EAS29710 FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES Removing the front arms and front shock absorber assemblies 38 Nm (3.8 m kg, 27 ft 55 Nm (5.5 m kg, 40 ft • • •...

  • Page 175: Front Arms And Front Shock Absorber Assemblies

    FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES Removing the front arms and front shock absorber assemblies 38 Nm (3.8 m kg, 27 ft 55 Nm (5.5 m kg, 40 ft • • • • 48 Nm (4.8 m kg, 35 ft •...

  • Page 176: Handling The Front Shock Absorber Assemblies

    FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES M MMM M MMM M MMM M MMM M MMM EAS1S3L017 HANDLING THE FRONT SHOCK ABSORBER a. Check the front arm side play “A” by moving ASSEMBLIES it from side to side. EWA1S3L012 If side play is noticeable, check the bushings.

  • Page 177: Checking The Front Shock Absorber Assemblies

    FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES EAS29760 CHECKING THE FRONT SHOCK ABSORBER ASSEMBLIES The following procedure applies to both of the front shock absorber assemblies. 1. Check: • Front shock absorber assembly Oil leaks → Replace the front shock absorber assembly.

  • Page 178: Installing The Front Arms And Front Shock Absorber Assemblies

    FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES d. Hold the body “4” in place while turning in the long bolt “5” to remove the ball joint “10” from the front lower arm “11”. g. Remove the ball joint remover/installer. h. Install a new circlip. e.
  • Page 179 FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES Upper steering knuckle nut 25 Nm (2.5 m·kg, 18 ft·lb) Lower steering knuckle nut 25 Nm (2.5 m·kg, 18 ft·lb) d. Install the new cotter pins. e. Tighten the front upper and lower arm nuts to specification.

  • Page 180: Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY EAS1S3L019 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 55 Nm (5.5 m kg, 40 ft • • 43 Nm (4.3 m kg, 31 ft • • 43 Nm (4.3 m kg, 31 ft •...
  • Page 181 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 55 Nm (5.5 m kg, 40 ft • • 43 Nm (4.3 m kg, 31 ft • • 43 Nm (4.3 m kg, 31 ft • • 55 Nm (5.5 m kg, 40 ft •...

  • Page 182: Handling The Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY EAS1S3L045 EAS23230 HANDLING THE REAR SHOCK ABSORBER REMOVING THE REAR SHOCK ABSORBER ASSEMBLY ASSEMBLY 1. Place the vehicle on a level surface. EWA1S3L016 WARNING This rear shock absorber assembly contains Place the vehicle on a suitable stand so that the highly compressed nitrogen gas.

  • Page 183: Installing The Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY • Gas cylinder Damage/gas leaks → Replace the rear shock absorber assembly. 3. Install: • Connecting arm • Relay arm • Rear shock absorber EAS1S3L021 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY When installing the rear shock absorber, lift up 1.

  • Page 184: Swingarm

    SWINGARM EAS23330 SWINGARM Removing the swingarm 100 Nm (10.0 m kg, 72 ft 7 Nm (0.7 m kg, 5.1 ft • • • • 12 9 10 10 (4) 1 7 Nm (0.7 m kg, 5.1 ft • • 55 Nm (5.5 m kg, 40 ft •...
  • Page 185 SWINGARM Removing the swingarm 100 Nm (10.0 m kg, 72 ft 7 Nm (0.7 m kg, 5.1 ft • • • • 12 9 10 10 (4) 1 7 Nm (0.7 m kg, 5.1 ft • • 55 Nm (5.5 m kg, 40 ft •...

  • Page 186: Removing The Swingarm

    SWINGARM 2. Check: EAS23350 REMOVING THE SWINGARM • Pivot shaft 1. Place the vehicle on a level surface. Roll the pivot shaft on a flat surface. 2. Check: Bends → Replace. • Swingarm side play EWA13770 • Swingarm vertical movement WARNING M MMM M MMM...
  • Page 187 SWINGARM 3. Install: • Relay arm • Rear shock absorber assembly Refer to “REAR SHOCK ABSORBER AS- SEMBLY” on page 4-55. 4. Install: • Rear wheels Refer to and “REAR WHEELS” on page 4-9. 5. Adjust: • Drive chain slack Refer to “ADJUSTING THE DRIVE CHAIN SLACK”...

  • Page 188: Chain Drive

    CHAIN DRIVE EAS23400 CHAIN DRIVE Removing the drive chain 10 Nm (1.0 m kg, 7.2 ft • • 85 Nm (8.5 m kg, 61 ft • • 32 Nm (3.2 m kg, 23 ft • • Order Job/Parts to remove Q’ty Remarks Swingarm...

  • Page 189: Checking The Drive Chain

    CHAIN DRIVE c. Remove the drive chain from the kerosene EAS23441 CHECKING THE DRIVE CHAIN and completely dry it. 1. Measure: ECA14290 • 15-link section of the drive chain NOTICE Out of specification → Replace the drive • This motorcycle has a drive chain with chain.

  • Page 190: Installing The Drive Chain

    CHAIN DRIVE While applying the rear brake, tighten the drive sprocket nut. Drive sprocket nut 85 Nm (8.5 m·kg, 61 ft·lb) 4. Lubricate: • Drive chain Recommended lubricant Engine oil or chain lubricant suitable for O-ring chains 5. Check: 3. Bend the lock washer tab along a flat side of •...

  • Page 191: Engine

    ENGINE ENGINE REMOVAL ..................5-1 INSTALLING THE EXHAUST PIPES AND MUFFLER ......5-2 INSTALLING THE ENGINE............... 5-7 CYLINDER HEAD.................... 5-8 REMOVING THE CYLINDER HEAD............5-9 CHECKING THE CYLINDER HEAD ............5-9 CHECKING THE CAMSHAFT SPROCKET..........5-10 CHECKING THE TAPPET COVERS AND CAMSHAFT SPROCKET COVER ............
  • Page 192 CLUTCH ......................5-40 REMOVING THE CLUTCH ..............5-44 REMOVING THE PRIMARY DRIVE GEAR AND BALANCER DRIVEN GEAR ..............5-44 CHECKING THE FRICTION PLATES............. 5-44 CHECKING THE CLUTCH PLATES ............5-45 CHECKING THE CLUTCH SPRINGS............. 5-45 CHECKING THE CLUTCH HOUSING ............ 5-45 CHECKING THE CLUTCH BOSS............

  • Page 194: Engine Removal

    ENGINE REMOVAL EAS23711 ENGINE REMOVAL Removing the muffler and exhaust pipe 38 Nm (3.8 m kg, 27 ft • • 18 Nm (1.8 m kg, 13 ft • • 20 Nm (2.0 m kg, 14 ft • • 8 Nm (0.8 m kg, 5.8 ft •...

  • Page 195: Installing The Exhaust Pipes And Muffler

    ENGINE REMOVAL EAS1S3L022 INSTALLING THE EXHAUST PIPES AND MUFFLER 1. Tighten: • Exhaust pipe nuts “1”, “2”, and “3” Tighten the exhaust pipe nuts in the order “1”, “2”, “3”. 2. Install: • Gasket “1” (to muffler) Install the gasket with the chamfer “a”, located on an inner rim of the gasket, and the chamfer “b”, located on an outer rim of the gasket, as shown.
  • Page 196 ENGINE REMOVAL Removing the oil tank 16 Nm (1.6 m kg, 11 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 197 ENGINE REMOVAL Disconnecting the leads, cables and hoses Order Job/Parts to remove Q’ty Remarks Coolant Drain. Right foot protector/air filter case/battery/fuel Refer to “GENERAL CHASSIS” on page tank 4-1. Rear brake light switch/right footrest Refer to “REAR BRAKE” on page 4-28. Radiator inlet hose Refer to “THERMOSTAT”...
  • Page 198 ENGINE REMOVAL Disconnecting the leads, cables and hoses Order Job/Parts to remove Q’ty Remarks Sub-wire harness Ground lead Clutch cable Parking brake cable Reverse control cable For installation, reverse the removal proce- dure.
  • Page 199 ENGINE REMOVAL Removing the engine 33 Nm (3.3 m kg, 24 ft • • 40 Nm (4.0 m kg, 29 ft • • 100 Nm (10.0 m kg, 72 ft • • 66 Nm (6.6 m kg, 48 ft • •...

  • Page 200: Installing The Engine

    ENGINE REMOVAL EAS23720 INSTALLING THE ENGINE Engine upper bracket bolt “1” ECA1S3L015 33 Nm (3.3 m·kg, 24 ft·lb) NOTICE Engine upper bracket bolt “2” Install all of the bolts/nuts and then tighten 33 Nm (3.3 m·kg, 24 ft·lb) them to full torque specifications. Engine mounting bolt (upper)/nut “3”...

  • Page 201: Cylinder Head

    CYLINDER HEAD EAS24100 CYLINDER HEAD Removing the cylinder head 20 Nm (2.0 m kg, 14 ft • • 33 Nm (3.3 m kg, 24 ft 13 Nm (1.3 m kg, 9.4 ft • • • • 35 Nm (3.5 m kg, 25 ft •...

  • Page 202: Removing The Cylinder Head

    CYLINDER HEAD 4. Remove: EAS24130 REMOVING THE CYLINDER HEAD • Timing chain tensioner 1. Align: (along with the gasket) • “I” mark “a” on the AC magneto rotor • Camshaft sprocket (with the stationary pointer “b” on the AC • Timing chain magneto cover) M MMM M MMM...

  • Page 203: Checking The Camshaft Sprocket

    CYLINDER HEAD 3. Measure: • Cylinder head warpage Out of specification → Resurface the cylinder head. Warpage limit 0.03 mm (0.0012 in) M MMM M MMM M MMM M MMM M MMM a. Place a straightedge “1” and a thickness gauge “2”...

  • Page 204: Installing The Cylinder Head

    CYLINDER HEAD • Timing chain tensioner rod Damage/wear → Replace the defective part(s). 3. Install: • Camshaft sprocket • Timing chain M MMM M MMM M MMM M MMM M MMM EAS24230 a. Turn the crankshaft counterclockwise. INSTALLING THE CYLINDER HEAD b.
  • Page 205 CYLINDER HEAD ECA1S3L016 NOTICE Do not turn the crankshaft when installing the camshaft to avoid damage or improper valve timing. e. While holding the camshaft, temporarily tight- en the camshaft sprocket bolts. f. Remove the wire from the timing chain. L LLL L LLL L LLL...
  • Page 206 CYLINDER HEAD ECA13750 NOTICE 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. 8. Measure: • Valve clearance Out of specification → Adjust. Refer to “ADJUSTING THE VALVE CLEAR- ANCE”...

  • Page 207: Camshaft

    CAMSHAFT EAS23730 CAMSHAFT Removing the rocker arms and camshaft 14 Nm (1.4 m kg, 10 ft • • 14 Nm (1.4 m kg, 10 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Cylinder head...

  • Page 208: Removing The Rocker Arms And Camshaft

    CAMSHAFT 2. Measure: EAS23770 REMOVING THE ROCKER ARMS AND • Camshaft lobe dimensions “a” and “b” CAMSHAFT Out of specification → Replace the camshaft. 1. Loosen: • Locknuts Camshaft lobe dimension limit • Valve clearance adjusting screws Intake A 2. Remove: 43.300–43.400 mm (1.7047–...

  • Page 209: Checking The Decompression System

    CAMSHAFT Rocker arm inside diameter 12.000–12.018 mm (0.4724– 0.4731 in) EAS1S3L025 CHECKING THE DECOMPRESSION SYSTEM 1. Check: • Decompression system M MMM M MMM M MMM M MMM M MMM 4. Measure: a. Check the decompression system with the • Rocker arm shaft outside diameter camshaft sprocket installed on and the de- Out of specification →...
  • Page 210 CAMSHAFT • Apply engine oil to the bearing. Install the camshaft so that the camshaft sprock- • Install the bearing so that the seal “a” is facing et mounting pins “a” can be aligned with the the camshaft. camshaft sprocket cover bolt holes “b”. Installed depth “b”...
  • Page 211 CAMSHAFT Camshaft retainer bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) 5-18...
  • Page 212 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 5-8. Rocker arms/rocker arm shafts/camshaft Refer to “CAMSHAFT” on page 5-14. Valve cotter Valve spring retainer Valve spring...

  • Page 213: 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 cylinder head (e.g., valves, valve springs, valve seats), make sure the valves properly seal. 1.
  • Page 214 VALVES AND VALVE SPRINGS b. Install the new valve guide with the valve Valve-stem-to-valve-guide clear- guide installer “2” and valve guide remover ance (intake) “1”. 0.010–0.037 mm (0.0004–0.0015 Limit 0.080 mm (0.0031 in) Valve-stem-to-valve-guide clear- ance (exhaust) 0.025–0.052 mm (0.0010–0.0020 Limit 0.100 mm (0.0039 in) c.

  • Page 215: Checking The Valve Seats

    VALVES AND VALVE SPRINGS • Valve stem end 2. Check: Mushroom shape or diameter larger than the • Valve seat body of the valve stem → Replace the valve. Pitting/wear → Replace the cylinder head. 5. Measure: 3. Measure: • Valve margin thickness “a” •...

  • Page 216: Checking The Valve Springs

    VALVES AND VALVE SPRINGS e. Apply a fine lapping compound to the valve face and repeat the above steps. After replacing the cylinder head or replacing the f. After every lapping procedure, be sure to valve and valve guide, the valve seat and valve clean off all of the lapping compound from the face should be lapped.

  • Page 217: Installing The Valves

    VALVES AND VALVE SPRINGS 2. Measure: EAS24340 INSTALLING THE VALVES • Compressed valve spring force “a” Out of specification → Replace the valve The following procedure applies to all of the valves and related components. spring. 1. Deburr: • Valve stem end (with an oil stone) b.
  • Page 218 VALVES AND VALVE SPRINGS • Make sure each valve is installed in its original place. • Install the valve springs with the larger pitch “a” facing up. 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft-face hammer.

  • Page 219: Cylinder And Piston

    CYLINDER AND PISTON EAS24350 CYLINDER AND PISTON Removing the cylinder and piston 1st 15Nm (1.5 m kg, 11 ft • • 2nd 50Nm (5.0m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft •...

  • Page 220: Removing The Piston

    CYLINDER AND PISTON EAS24380 REMOVING THE PISTON When removing a piston ring, open the end gap 1. Remove: with your fingers and lift the other side of the ring • Piston pin clips “1” over the piston crown. • Piston pin “2” •...

  • Page 221: Checking The Piston Rings

    CYLINDER AND PISTON EAS24430 CHECKING THE PISTON RINGS Bore 1. Measure: 102.000–102.010 mm (4.0157– • Piston ring side clearance 4.0161 in) Out of specification → Replace the piston Wear limit 102.080 mm (4.0189 in) and piston rings as a set. Taper limit 0.05 mm (0.002) Before measuring the piston ring side clearance,...

  • Page 222: Checking The Piston Pin

    CYLINDER AND PISTON 3. Measure: Piston pin bore inside diameter • Piston ring end gap 23.004–23.015 mm (0.9057– Out of specification → Replace the piston 0.9061 in) ring. Limit 23.045 mm (0.9073 in) The oil ring expander spacer’s end gap cannot be measured.
  • Page 223 CYLINDER AND PISTON 2. Install: 6. Install: • Piston “1” • Cylinder “1” • Piston pin “2” • Timing chain guide (exhaust side) • Piston pin clips “3” • While compressing the piston rings with one hand, install the cylinder with the other hand. •...

  • Page 224: Ac Magneto And Starter Clutch

    AC MAGNETO AND STARTER CLUTCH EAS1S3L026 AC MAGNETO AND STARTER CLUTCH Removing the AC magneto and starter clutch 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • (14) 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 225 AC MAGNETO AND STARTER CLUTCH Removing the AC magneto and starter clutch 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • (14) 7 Nm (0.7 m kg, 5.1 ft • • 30 Nm (3.0 m kg, 22 ft •...

  • Page 226: Removing The Ac Magneto Rotor

    AC MAGNETO AND STARTER CLUTCH EAS24490 ECA13880 REMOVING THE AC MAGNETO ROTOR NOTICE 1. Remove: To protect the end of the crankshaft, place an • AC magneto cover appropriate sized socket between the fly- wheel puller set center bolt and the crank- Loosen each bolt 1/4 of a turn at a time, in stag- shaft.

  • Page 227: Checking The Torque Limiter

    AC MAGNETO AND STARTER CLUTCH c. When turning the starter wheel gear clock- Starter clutch bolt wise “B”, it should turn freely; otherwise, the 30 Nm (3.0 m·kg, 22 ft·lb) starter clutch is faulty and must be replaced. LOCTITE® L LLL L LLL L LLL L LLL...
  • Page 228 90890-01701 Primary clutch holder YS-01880-A 2. Apply: • Sealant “1” (onto the crankshaft position sensor/stator assembly lead grommet) Yamaha bond No. 1215 5. Install: 90890-85505 (Three Bond No.1215®) • Gasket • AC magneto cover • AC magneto cover bolts AC magneto cover bolt 10 Nm (1.0 m·kg, 7.2 ft·lb)

  • Page 229: Electric Starter

    ELECTRIC STARTER EAS24780 ELECTRIC STARTER Removing the starter motor 5 Nm (0.5 m kg, 3.6 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Exhaust pipe Refer to “ENGINE REMOVAL” on page 5-1. Starter motor lead Disconnect.
  • Page 230 ELECTRIC STARTER Disassembling the starter motor Order Job/Parts to remove Q’ty Remarks O-ring Starter motor front cover Square ring Lock washer Shim Armature assembly Starter motor yoke Brush holder assembly Square ring Shim Starter motor rear cover For assembly, reverse the disassembly pro- cedure.

  • Page 231: Checking The Starter Motor

    ELECTRIC STARTER M MMM M MMM M MMM M MMM M MMM EAS24790 CHECKING THE STARTER MOTOR a. Measure the armature assembly resistances 1. Check: with the pocket tester. • Commutator Dirt → Clean with 600 grit sandpaper. Pocket tester 90890-03112 2.

  • Page 232: Assembling The Starter Motor

    ELECTRIC STARTER Brush spring force 7.65–10.01 N (780–1021 gf, 27.54–36.03 oz) 7. Check: • Gear teeth Damage/wear → Replace the gear. 8. Check: • Bushing • Bearing • Oil seal Damage/wear → Replace the defective part(s). EAS24800 ASSEMBLING THE STARTER MOTOR 1.

  • Page 233: Clutch

    CLUTCH EAS25061 CLUTCH Removing the clutch cover 10 Nm (1.0 m kg, 7.2 ft • • 12 Nm (1.2 m kg, 8.7 ft • • 10 Nm (1.0 m kg, 7.2 ft • • (14) 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 234 CLUTCH Removing the pull lever shaft Order Job/Parts to remove Q’ty Remarks Circlip Pull lever Pull lever spring Circlip Pull lever shaft Oil seal Bearing Bearing For installation, reverse the removal proce- dure. 5-41...
  • Page 235 CLUTCH Removing the clutch 8 Nm (0.8 m kg, 5.8 ft • • 60 Nm (6.0 m kg, 43 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 110 Nm (11.0 m kg, 80 ft • • 60 Nm (6.0 m kg, 43 ft 95 Nm (9.5 m...
  • Page 236 CLUTCH Removing the clutch 8 Nm (0.8 m kg, 5.8 ft • • 60 Nm (6.0 m kg, 43 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 110 Nm (11.0 m kg, 80 ft • • 60 Nm (6.0 m kg, 43 ft 95 Nm (9.5 m...

  • Page 237: Removing The Clutch

    CLUTCH EAS25070 REMOVING THE CLUTCH 1. Remove: • Clutch cover Loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them. EAS1S3L030 REMOVING THE PRIMARY DRIVE GEAR AND BALANCER DRIVEN GEAR 1.

  • Page 238: Checking The Clutch Plates

    CLUTCH 1. Check: • Clutch spring Measure the friction plate at four places. Damage → Replace the clutch springs as a set. Friction plate 1 thickness 2. Measure: 2.92–3.08 mm (0.11–0.12 in) • Clutch spring free length “a” Wear limit Out of specification →...

  • Page 239: Checking The Pressure Plate

    CLUTCH • Water pump drive gear “4” Damage/wear → Replace the balancer drive gear and balancer driven gear as a set. Replace the water pump drive gear and water pump driven gear as a set. Excessive noise during operation → Replace the balancer drive gear and balancer driven gear as a set.

  • Page 240: Installing The Clutch

    CLUTCH 3. Bend the lock washer tabs along a flat side of the nut. • Align the punch mark “a” on the balancer drive gear with the punch mark “b” on the balancer EAS25240 driven gear 2. INSTALLING THE CLUTCH •...
  • Page 241 CLUTCH • While holding the clutch boss “1” with the uni- versal clutch holder “4”, tighten the clutch boss nut. • Stake the clutch boss nut “3” at a cutout “b” in the main axle. Universal clutch holder 90890-04086 YM-91042 6.
  • Page 242 CLUTCH 9. Adjust: • Clutch cable length Move the pull lever a notch until the cable length is within specification. 10.Adjust: • Clutch lever free play Refer to “ADJUSTING THE CLUTCH LEVER FREE PLAY” on page 3-13. 5-49...

  • Page 243: Oil Pump

    OIL PUMP EAS24911 OIL PUMP Removing the oil pump Order Job/Parts to remove Q’ty Remarks Clutch housing Refer to “CLUTCH” on page 5-40. Oil baffle plate 1 Circlip Oil pump driven gear Oil baffle plate 2 Oil pump Oil pump gasket O-ring For installation, reverse the removal proce- dure.
  • Page 244 OIL PUMP Disassembling the oil pump Order Job/Parts to remove Q’ty Remarks Oil pump housing 1/oil seal Oil pump outer rotor 1 Dowel pin Oil pump inner rotor 1 Oil pump housing cover/oil seal Dowel pin Oil pump shaft Dowel pin Oil pump inner rotor 2 Oil pump outer rotor 2 Oil pump housing 2...

  • Page 245: Checking The Oil Pump

    OIL PUMP 3. Check: EAS24960 CHECKING THE OIL PUMP • Oil pump operation 1. Check: Rough movement → Repeat steps (1) and • Oil pump driven gear “1” (2) or replace the defective part(s). • Oil pump housing 1 “2” •...

  • Page 246: Shift Shaft

    SHIFT SHAFT EAS25410 SHIFT SHAFT Removing the shift shaft and stopper lever Order Job/Parts to remove Q’ty Remarks Clutch housing Refer to “CLUTCH” on page 5-40. Shift pedal Shift shaft Shift shaft spring Stopper lever/washer Stopper lever spring Roller Shift guide Shift lever assembly Pawl holder Pawl...

  • Page 247: Checking The Shift Shaft

    SHIFT SHAFT EAS25420 CHECKING THE SHIFT SHAFT 1. Check: • Shift shaft “1” Bends/damage/wear → Replace. • Shift lever spring “2” Damage/wear → Replace. EAS1S3L034 CHECKING THE SHIFT DRUM SEGMENT 1. Check: • Shift drum segment Damage/wear → Replace. EAS25430 CHECKING THE STOPPER LEVER 1.

  • Page 248: Installing The Shift Shaft

    SHIFT SHAFT • Shift guide “4” (to the pawl holder) 3. Install: • Shift lever assembly “1” • Shift guide “2” Shift guide bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) LOCTITE® 2. Install: The shift lever assembly is installed at the same •...
  • Page 249 CRANKCASE EAS25540 CRANKCASE Separating the crankcase Order Job/Parts to remove Q’ty Remarks Engine assembly Refer to “ENGINE REMOVAL” on page 5-1. Refer to “CYLINDER AND PISTON” on page Piston 5-26. Refer to “AC MAGNETO AND STARTER AC magneto CLUTCH” on page 5-31. Balancer driven gears Refer to “CLUTCH”...
  • Page 250 CRANKCASE Separating the crankcase Order Job/Parts to remove Q’ty Remarks Circlip Right crankcase Left crankcase Dowel pin Dowel pin/O-ring Oil strainer For installation, reverse the removal proce- dure. 5-57...

  • Page 251: Crankcase

    CRANKCASE Removing the crankcase bearings 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Crankshaft Refer to “CRANKSHAFT” on page 5-62. Transmission Refer to “TRANSMISSION”...

  • Page 252: Separating The Crankcase

    CRANKCASE EAS1S3L036 SEPARATING THE CRANKCASE 1. Remove: • Crankcase bolts Loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Check: •...

  • Page 253: Checking The Crankcase

    • Sealant “1” (onto the crankcase mating surfaces) • Install the bearing by pressing its outer race evenly. Yamaha bond No. 1215 • To prevent the bearing retainer screws “2” from 90890-85505 becoming loose, flatten the edge “a” of each (Three bond No.1215®)
  • Page 254 CRANKCASE 5. Fit the right crankcase onto the left crank- case. Tap lightly on the case with a soft ham- mer. ECA1S3L018 NOTICE Before installing and torquing the crankcase holding bolts, be sure to check whether the transmission is functioning properly by manually rotating the shift drum in both di- rections.

  • Page 255: Crankshaft

    CRANKSHAFT EAS25960 CRANKSHAFT Removing the crankshaft Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-56. Balancer 1 Balancer 2 Crankshaft For installation, reverse the removal proce- dure. 5-62...

  • Page 256: Removing The Crankshaft

    CRANKSHAFT EAS1S3L038 REMOVING THE CRANKSHAFT 1. Remove: • Crankshaft “1” • 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 EAS1S3L040 INSTALLING THE CRANKSHAFT 1.
  • Page 257 CRANKSHAFT ECA1S3L019 NOTICE Apply engine oil to each bearing to protect the crankshaft against scratches and to make installation easier. 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 as- sembly bottoms against the bearing.

  • Page 258: 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 5-56. Spacer Circlip Washer Reverse wheel gear 2 Spacer Counter axle assembly Shift drum Shift fork “R” Shift fork “C”...
  • Page 259 TRANSMISSION Disassembling the main axle Order Job/Parts to remove Q’ty Remarks Circlip 2nd pinion gear Toothed lock washer Toothed washer retainer 4th pinion gear Toothed spacer Toothed washer Circlip 3rd pinion gear 5th pinion gear Main axle/1st pinion gear For installation, reverse the removal proce- dure.
  • Page 260 TRANSMISSION Disassembling the drive axle Order Job/Parts to remove Q’ty Remarks Circlip Washer Reverse wheel gear 2 Spacer Dog clutch Circlip Toothed washer 1st wheel gear Toothed spacer 5th wheel gear Toothed lock washer Toothed washer retainer 3rd wheel gear Toothed spacer Toothed washer Circlip...
  • Page 261 TRANSMISSION Disassembling the drive axle Order Job/Parts to remove Q’ty Remarks Circlip Toothed washer 2nd wheel gear Spacer Drive axle For installation, reverse the removal proce- dure. 5-68...
  • Page 262 TRANSMISSION Disassembling the counter axle Order Job/Parts to remove Q’ty Remarks Circlip Washer Spacer Reverse wheel gear 1 Counter axle For installation, reverse the removal proce- dure. 5-69...

  • Page 263: Checking The Shift Forks

    TRANSMISSION EAS26260 EAS26270 CHECKING THE SHIFT FORKS CHECKING THE SHIFT DRUM ASSEMBLY The following procedure applies to all of the shift 1. Check: forks. • Shift drum grooves Damage/scratches/wear → Replace the shift 1. Check: • Shift fork cam follower “1” drum assembly.

  • Page 264: Assembling The Main Axle And Drive Axle

    TRANSMISSION 3. Check: • Shift fork-L “3” • Transmission gear engagement (to drive axle) (each pinion gear to its respective wheel • Shift fork-C “4” gear) (to main axle) Incorrect → Reassemble the transmission • Shift fork-R “5” axle assemblies. (to drive axle) 4.
  • Page 265 TRANSMISSION 5-72...
  • Page 266 TRANSMISSION 5-73...

  • Page 267: Cooling System

    COOLING SYSTEM RADIATOR ...................... 6-1 CHECKING THE RADIATOR..............6-2 INSTALLING THE RADIATOR..............6-2 THERMOSTAT ....................6-3 CHECKING THE THERMOSTAT.............. 6-4 INSTALLING THE THERMOSTAT............6-4 WATER PUMP....................6-5 DISASSEMBLING THE WATER PUMP............ 6-7 CHECKING THE WATER PUMP .............. 6-7 ASSEMBLING THE WATER PUMP............6-7...
  • Page 268 RADIATOR EAS26380 RADIATOR Removing the radiator 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Front fender 4-1. Coolant Drain.

  • Page 269: Radiator

    RADIATOR EAS26390 CHECKING THE RADIATOR 1. Check: • Radiator fins Obstruction → Clean. Apply compressed air to the rear of the radia- tor. Damage → Repair or replace. Straighten any flattened fins with a thin, flat-head screwdriver. b. Apply the specified pressure for ten seconds and make sure there is no drop in pressure.

  • Page 270: Thermostat

    THERMOSTAT EAS26440 THERMOSTAT Removing the thermostat 18 Nm (1.8 m kg, 13 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Front fender 4-1. Coolant Drain.

  • Page 271: Checking The Thermostat

    THERMOSTAT 2. Check: EAS26450 CHECKING THE THERMOSTAT • Thermostat cover 1. Check: • Thermostat housing (cylinder head) • Thermostat “1” Cracks/damage → Replace. Does not open at 69–73 °C (156.2–163.4 °F) → Replace. EAS1S3L009 INSTALLING THE THERMOSTAT 1. Install: • Thermostat “1” •...

  • Page 272: Water Pump

    WATER PUMP EAS26500 WATER PUMP Removing the water pump 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks It is not necessary to remove the water...
  • Page 273 WATER PUMP Disassembling the water pump 11 Nm (1.1 m kg, 8.0 ft • • Order Job/Parts to remove Q’ty Remarks Water pump housing cover Gasket Circlip Impeller shaft gear Washer Impeller shaft assembly Water pump seal Oil seal Bearing Water pump housing For assembly, reverse the disassembly pro- cedure.

  • Page 274: Disassembling The Water Pump

    WATER PUMP 2. Check: EAS26510 DISASSEMBLING THE WATER PUMP • Bearing 1. Remove: Rough movement → Replace. • Water pump seal “1” • Impeller shaft gear Pitting/wear → Replace. Remove the water pump seal from the inside of EAS26560 the water pump housing “2”. ASSEMBLING THE WATER PUMP 1.
  • Page 275 WATER PUMP 3. Mechanical seal installer 4. Middle driven shaft bearing driver A. Push down 3. Measure: • Impeller shaft tilt Impeller shaft tilt limit 0.15 mm (0.006 in) 1. Straightedge 2. Impeller...
  • Page 276 WATER PUMP...

  • Page 277: Fuel System

    FUEL SYSTEM FUEL TANK..................... 7-1 REMOVING THE FUEL TANK ..............7-2 REMOVING THE FUEL PUMP ..............7-2 CHECKING THE FUEL PUMP BODY............7-2 INSTALLING THE FUEL PUMP..............7-2 INSTALLING THE FUEL HOSE ..............7-3 THROTTLE BODY................... 7-4 CHECKING THE INJECTOR ..............7-7 CHECKING THE THROTTLE BODY ............
  • Page 278 FUEL TANK EAS26620 FUEL TANK Removing the fuel tank 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS”...

  • Page 279: Fuel Tank

    FUEL TANK 3. Remove: EAS26630 REMOVING THE FUEL TANK • Fuel tank 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. Do not set the fuel tank down on the installation 2. Remove: surface of the fuel pump.

  • Page 280: Installing The Fuel Hose

    FUEL TANK EAS1S3L011 INSTALLING THE FUEL HOSE 1. Install: • Fuel hose • Fuel hose holder • Fuel pump coupler ECA1S3L007 NOTICE When installing the fuel hose, make sure that it is securely connected, and that the fuel hose holder is in the correct position, other- wise the fuel hose will not be properly in- stalled.

  • Page 281: Throttle Body

    THROTTLE BODY EAS26970 THROTTLE BODY Removing the throttle body 3 Nm (0.3 m kg, 2.2 ft • • 12 13 4 Nm (0.4 m kg, 2.9 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Fuel tank shield 4-1.
  • Page 282 THROTTLE BODY Removing the throttle body 3 Nm (0.3 m kg, 2.2 ft • • 12 13 4 Nm (0.4 m kg, 2.9 ft • • Order Job/Parts to remove Q’ty Remarks Air filter case joint clamp screw Loosen. Throttle body assembly For installation, reverse the removal proce- dure.
  • Page 283 THROTTLE BODY Disassembling the throttle body Order Job/Parts to remove Q’ty Remarks Throttle position sensor Fuel injection pipe Fuel injector ECA1S3L008 NOTICE Throttle body The throttle body should not be disas- sembled. For assembly, reverse the disassembly pro- cedure.

  • Page 284: Checking The Injector

    THROTTLE BODY d. Connect the pressure gauge “3” and adapter EAS26980 CHECKING THE INJECTOR “4” to the fuel pump and fuel hose. 1. Check: • Injector Pressure gauge Damage → Replace. 90890-03153 YU-03153 EAS26990 Fuel pressure adapter CHECKING THE THROTTLE BODY 90890-03176 1.

  • Page 285: Installing The Throttle Body

    THROTTLE BODY Digital circuit tester 90890-03174 Model 88 Multimeter with ta- chometer YU-A1927 2. Install: • Throttle cable 3. Adjust: • Throttle lever free play Refer to “ADJUSTING THE THROTTLE LE- VER FREE PLAY” on page 3-7. 4. Adjust: c. Measure the throttle position sensor voltage. •...
  • Page 286 THROTTLE BODY...

  • Page 287: Electrical System

    ELECTRICAL SYSTEM IGNITION SYSTEM ..................8-1 CIRCUIT DIAGRAM .................. 8-1 TROUBLESHOOTING ................8-3 ELECTRIC STARTING SYSTEM ..............8-5 CIRCUIT DIAGRAM .................. 8-5 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION ......8-7 TROUBLESHOOTING ................8-9 CHARGING SYSTEM..................8-11 CIRCUIT DIAGRAM ................8-11 TROUBLESHOOTING ................8-13 LIGHTING SYSTEM ..................
  • Page 288 ELECTRICAL COMPONENTS..............8-55 CHECKING THE SWITCHES ..............8-57 CHECKING THE BULBS AND BULB SOCKETS ........8-60 CHECKING THE FUSES ................ 8-61 CHECKING AND CHARGING THE BATTERY........8-62 CHECKING THE RELAYS ..............8-65 CHECKING THE DIODES............... 8-66 CHECKING THE SPARK PLUG CAP ............. 8-66 CHECKING THE IGNITION COIL ............

  • Page 290: Ignition System

    IGNITION SYSTEM EAS27090 IGNITION SYSTEM EAS27100 CIRCUIT DIAGRAM...
  • Page 291 IGNITION SYSTEM 1. Crankshaft position sensor 4. Main switch 6. Battery 7. Main fuse 21.ECU (engine control unit) 22.Ignition coil 23.Spark plug 30.Lean angle sensor 36.Engine stop switch 45.Ignition fuse...

  • Page 292: 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. Fuel tank top panel 3. Fuel tank 4. Front panel 5. Front fender NG → 1.
  • Page 293 IGNITION SYSTEM NG → 8. Check the main switch. Refer to “CHECKING THE Replace the main switch. SWITCHES” on page 8-57. OK ↓ NG → 9. Check the engine stop switch. The engine stop switch is faulty. Replace Refer to “CHECKING THE the left handlebar switch.

  • Page 294: Electric Starting System

    ELECTRIC STARTING SYSTEM EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM...
  • Page 295 ELECTRIC STARTING SYSTEM 4. Main switch 6. Battery 7. Main fuse 8. Starter relay 9. Starter motor 11.Starting circuit cut-off relay 32.Neutral switch 33.Clutch switch 36.Engine stop switch 37.Start switch 45.Ignition fuse...

  • Page 296: 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 297 ELECTRIC STARTING SYSTEM 1. Battery 2. Main 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 11. Ignition fuse...

  • Page 298: Troubleshooting

    ELECTRIC STARTING SYSTEM EAS27190 TROUBLESHOOTING The starter motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Seat 2. Fuel tank top panel 3. Front fender NG → 1. Check the fuses. (Main and ignition) Replace the fuse(s). Refer to “CHECKING THE FUS- ES”...
  • Page 299 ELECTRIC STARTING SYSTEM NG → 9. Check the neutral switch. Refer to “CHECKING THE Replace the neutral switch. SWITCHES” on page 8-57. OK ↓ NG → 10.Check the clutch switch. Refer to “CHECKING THE Replace the clutch switch. SWITCHES” on page 8-57. OK ↓...

  • Page 300: Charging System

    CHARGING SYSTEM EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM (GRAY) L/Y B/L G/W L/Y Br/G L/W Br (BLACK) B R/L Br/L Br/Y B/Y B Br/R Br/L Br/Y Br/Y Br/Y Br/Y Br/R Y Br/Y (BLACK) (BLACK) 8-11...
  • Page 301 CHARGING SYSTEM 2. AC magneto 3. Rectifier/regulator 6. Battery 7. Main fuse 8-12...

  • Page 302: Troubleshooting

    CHARGING SYSTEM EAS27230 TROUBLESHOOTING The battery is not being charged. • Before troubleshooting, remove the following part(s): 1. Seat 2. Fuel tank top panel 3. Front panel 4. Front fender NG → 1. Check the fuse. (Main) Replace the fuse. Refer to “CHECKING THE FUS- ES”...
  • Page 303 CHARGING SYSTEM 8-14...

  • Page 304: Lighting System

    LIGHTING SYSTEM EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM (GRAY) Br/G L/Y B/L G/W L/Y Br/G L/W Br (BLACK) Br/G B R/L Br/L Br/Y B/Y B Br/R Br/L Br/Y Br/Y Br/Y Br/Y Br/R Y Br/Y Br/R (BLACK) (BLACK) B R/B (BLACK) (BLACK) (BLACK) (BLACK)
  • Page 305 LIGHTING SYSTEM 4. Main switch 6. Battery 7. Main fuse 35.Light switch 38.Headlight relay 39.Headlight 40.Tail/brake light 43.Headlight fuse 8-16...

  • Page 306: Troubleshooting

    LIGHTING SYSTEM EAS27260 TROUBLESHOOTING Any of the following fail to light: headlight or taillight. • Before troubleshooting, remove the following part(s): 1. Seat 2. Fuel tank top panel 3. Front panel 4. Front fender NG → 1. Check the condition of each bulb and bulb socket.
  • Page 307 LIGHTING SYSTEM 8-18...

  • Page 308: Signaling System

    SIGNALING SYSTEM EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM 8-19...
  • Page 309 SIGNALING SYSTEM 4. Main switch 6. Battery 7. Main fuse 10.Relay unit 14.Multi-function meter 16.Fuel level warning light 17.Coolant temperature warning light 18.Reverse indicator light 19.Neutral indicator light 20.Reverse switch 21.ECU (engine control unit) 26.Coolant temperature sensor 27.Speed sensor 31.Fuel pump 32.Neutral switch 40.Tail/brake light 41.Rear brake light switch...

  • Page 310: Troubleshooting

    SIGNALING SYSTEM EAS27290 TROUBLESHOOTING • Any of the following fail to light: warning light, brake light or an indicator light. • Before troubleshooting, remove the following part(s): 1. Seat 2. Fuel tank top panel 3. Front panel 4. Front fender NG →...
  • Page 311 SIGNALING SYSTEM NG → 3. Check the entire signaling system wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM” on system wiring. page 8-19. OK ↓ Replace the tail/brake light assembly. The neutral indicator light fails to come on. NG →...
  • Page 312 SIGNALING SYSTEM NG → 2. Check the entire signaling system wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM” on system wiring. page 8-19. OK ↓ Replace the meter assembly or ECU. The fuel level warning light fails to come on. NG →...
  • Page 313 SIGNALING SYSTEM 8-24...

  • Page 314: Cooling System

    COOLING SYSTEM EAS27300 COOLING SYSTEM EAS27310 CIRCUIT DIAGRAM 8-25...
  • Page 315 COOLING SYSTEM 4. Main switch 6. Battery 7. Main fuse 21.ECU (engine control unit) 26.Coolant temperature sensor 45.Ignition fuse 46.Radiator fan motor 47.Radiator fan motor relay 48.Circuit breaker (fan motor) 8-26...

  • Page 316: Troubleshooting

    COOLING SYSTEM EAS27320 TROUBLESHOOTING The radiator fan motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Seat 2. Fuel tank top panel 3. Front panel 4. Front fender NG → 1. Check the fuses. (Main and ignition) Replace the fuse(s).
  • Page 317 COOLING SYSTEM NG → 8. Check the entire cooling system wiring. Properly connect or repair the cooling sys- Refer to “CIRCUIT DIAGRAM” on tem wiring. page 8-25. OK ↓ Replace the ECU. 8-28...

  • Page 318: Fuel Injection System

    FUEL INJECTION SYSTEM EAS27330 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM 8-29...
  • Page 319 FUEL INJECTION SYSTEM 1. Crankshaft position sensor 4. Main switch 5. Fuel injection system fuse 6. Battery 7. Main fuse 12.Fuel pump relay 14.Multi-function meter 15.Engine trouble warning light 19.Neutral indicator light 21.ECU (engine control unit) 22.Ignition coil 23.Spark plug 24.Fuel injector 25.Intake air temperature sensor 26.Coolant temperature sensor...

  • Page 320: Ecu Self-Diagnostic Function

    FUEL INJECTION SYSTEM EAS27350 ECU SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the en- gine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.
  • Page 321 FUEL INJECTION SYSTEM Self-diagnostic function table Able / un- Fault Able / un- Item Symptom able to code No. able to start drive No normal signals are received Crankshaft position from the crankshaft position sen- Unable Unable sensor sor. Intake air pressure Intake air pressure sensor-open or sensor Able...

  • Page 322: Troubleshooting Method

    FUEL INJECTION SYSTEM Communication error with the meter Able / un- Fault Able / un- Item Symptom able to code No. able to start drive ECU internal malfunc- No signals are received from the Er-1 tion Unable Unable ECU. (output signal error) ECU internal malfunc- No signals are received from the Er-2...
  • Page 323 FUEL INJECTION SYSTEM Setting the diagnostic mode 1. Turn the main switch to “OFF” and set the engine stop switch to “OFF”. 2. Disconnect the wire harness coupler from the fuel pump. 3. Simultaneously press and hold the “SELECT” and “RESET” buttons, turn the main switch to “ON”, and continue to press the buttons for 8 seconds or more.
  • Page 324 FUEL INJECTION SYSTEM Diagnostic code table Fault Diagnostic code Symptom Probable cause of malfunction code No. • Open or short circuit in wire harness. • Defective crankshaft position sensor. No normal signals are re- • Malfunction in crankshaft position sensor ceived from the crankshaft —...
  • Page 325 FUEL INJECTION SYSTEM Fault Diagnostic code Symptom Probable cause of malfunction code No. Power supply to the fuel in- • Open or short circuit in wire harness. jector and fuel pump is not • Malfunction in ECU. normal. Error is detected while •...
  • Page 326 FUEL INJECTION SYSTEM Diag- nostic Item Meter display Checking method code Lean angle sensor Remove the lean angle sensor and incline it more • Upright 0.4–1.4 than 65 degrees. • Overturned 3.7–4.4 Fuel system voltage Approximately 12.0 Set the engine stop switch (battery voltage) to “RUN”, and then com- pare with the actually mea-...

  • Page 327: Troubleshooting Details

    FUEL INJECTION SYSTEM Diag- nostic Item Actuation Checking method code Actuates the ignition coil five Check that the ignition coil times in one-second inter- actuates five times by Ignition coil vals. watching for the spark. The engine trouble warning • Connect an ignition light also flashes five times.
  • Page 328 FUEL INJECTION SYSTEM Fault code No. Symptom No normal signals are received from the crankshaft posi- tion sensor. Diagnostic code No. — — Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of crankshaft posi- Check for looseness or pinching. Cranking the tion sensor engine.
  • Page 329 FUEL INJECTION SYSTEM Fault code No. Symptom Intake air pressure sensor: open or short circuit detected. Diagnostic code No. Intake air pressure sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •...
  • Page 330 FUEL INJECTION SYSTEM Fault code No. Symptom Intake air pressure sensor: hose line malfunction (clogged or detached hose). Diagnostic code No. Intake air pressure sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Intake air pressure sensor hose. •...
  • Page 331 FUEL INJECTION SYSTEM Fault code No. Symptom Throttle position sensor: open or short circuit detected. Diagnostic code No. Throttle position sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of throttle position • Check for looseness or pinch- Turning the sensor.
  • Page 332 FUEL INJECTION SYSTEM Fault code No. Symptom Stuck throttle position sensor detected. Diagnostic code No. Throttle position sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of throttle position • Check the installed area for Reinstated by sensor.
  • Page 333 FUEL INJECTION SYSTEM Fault code No. Symptom Intake air temperature sensor: open or short circuit de- tected. Diagnostic code No. Intake air temperature sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of intake air tem- Check for looseness or pinching.
  • Page 334 FUEL INJECTION SYSTEM Fault code No. Symptom Malfunction detected in the primary lead of the ignition coil. Diagnostic code No. Ignition coil Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the connector and cou- Starting the en- •...
  • Page 335 FUEL INJECTION SYSTEM Fault code No. Symptom Lean angle sensor: open or short circuit detected. Diagnostic code No. Lean angle sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •...
  • Page 336 FUEL INJECTION SYSTEM Fault code No. Symptom A. No normal signals are received from the speed sensor. Diagnostic code No. d07 Speed sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Starting the en- •...
  • Page 337 FUEL INJECTION SYSTEM Fault code No. Symptom B. Open circuit is detected in the neutral switch. Diagnostic code No. d21 Neutral switch Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Starting the en- •...
  • Page 338 FUEL INJECTION SYSTEM Fault code No. Symptom Power supply to the fuel injector and fuel pump is not nor- mal. Diagnostic code No. Fuel system voltage Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Starting the en- •...
  • Page 339 FUEL INJECTION SYSTEM Fault code No. Symptom Power supply to the fuel injection system is not normal. Diagnostic code No. — — Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Starting the en- •...

  • Page 340: Fuel Pump System

    FUEL PUMP SYSTEM EAS27550 FUEL PUMP SYSTEM EAS27560 CIRCUIT DIAGRAM 8-51...
  • Page 341 FUEL PUMP SYSTEM 4. Main switch 5. Fuel injection system fuse 6. Battery 7. Main fuse 12.Fuel pump relay 21.ECU (engine control unit) 31.Fuel pump 36.Engine stop switch 45.Ignition fuse 8-52...

  • Page 342: Troubleshooting

    FUEL PUMP SYSTEM EAS27570 TROUBLESHOOTING If the fuel pump fails to operate. • Before troubleshooting, remove the following part(s): 1. Seat 2. Fuel tank top panel NG → 1. Check the fuses. (Main, ignition and fuel injection system) Replace the fuse(s). Refer to “CHECKING THE FUS- ES”...
  • Page 343 FUEL PUMP SYSTEM 8-54...

  • Page 344: Electrical Components

    ELECTRICAL COMPONENTS EAS27972 ELECTRICAL COMPONENTS 8-55...
  • Page 345 ELECTRICAL COMPONENTS 1. Main switch 2. Meter assembly 3. Front brake light switch 4. Clutch switch 5. Handlebar switch 6. Lean angle sensor 7. Battery 8. Starter relay 9. Main fuse 10. Circuit breaker (fan) 11. Fuse box 12. Radiator fan motor relay 13.

  • Page 346: Checking The Switches

    ELECTRICAL COMPONENTS EAS27980 CHECKING THE SWITCHES Br R/B Y/R L Y L/B B R/B B Br L/B R Br 8-57...
  • Page 347 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. Reverse switch 9. Neutral switch 10. Rear brake light switch 8-58...
  • Page 348 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 NOTICE 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 349: Checking The Bulbs And Bulb Sockets

    ELECTRICAL COMPONENTS • Avoid touching the glass part of a headlight EAS27990 CHECKING THE BULBS AND BULB bulb to keep it free from oil, otherwise the SOCKETS transparency of the glass, the life of the bulb, and the luminous flux will be adverse- Do not check any of the lights that use LEDs.

  • Page 350: Checking The Fuses

    ELECTRICAL COMPONENTS Check each bulb socket for continuity in the same manner as described in the bulb section; however, note the following. M MMM M MMM M MMM M MMM M MMM a. Install a good bulb into the bulb socket. b.

  • Page 351: Checking And Charging The Battery

    ELECTRICAL COMPONENTS specific gravity of the electrolyte. Therefore, the EAS28030 CHECKING AND CHARGING THE BATTERY charge of the battery has to be checked by mea- EWA13290 suring the voltage at the battery terminals. WARNING Batteries generate explosive hydrogen gas 1. Remove: and contain electrolyte which is made of poi- •...
  • Page 352 ELECTRICAL COMPONENTS • 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.
  • Page 353 ELECTRICAL COMPONENTS Set the charging voltage at 16–17 V. If the set- If the current is lower than the standard charging ting is lower, charging will be insufficient. If too current written on the battery, this type of battery high, the battery will be over-charged. charger cannot charge the VRLA (Valve Regu- lated Lead Acid) battery.

  • Page 354: Checking The Relays

    ELECTRICAL COMPONENTS EAS28040 CHECKING THE RELAYS Result Check each switch for continuity with the pocket Continuity tester. If the continuity reading is incorrect, re- (between “3” and “4”) place the relay. Relay unit (fuel pump relay) Pocket tester 90890-03112 Analog pocket tester YU-03112-C 1.

  • Page 355: Checking The Diodes

    ELECTRICAL COMPONENTS Second step: The pocket tester or the analog pocket tester readings are shown in the following table. Continuity Positive tester probe → sky blue“1” Negative tester probe → red/black “2” No continuity Positive tester probe → 1. Positive battery terminal red/black “2”...

  • Page 356: Checking The Ignition Coil

    ELECTRICAL COMPONENTS b. Connect the pocket tester (Ω × 1k) to the c. Measure the primary coil resistance. spark plug cap as shown. L LLL L LLL L LLL L LLL L LLL 2. Check: Pocket tester • Secondary coil resistance 90890-03112 Out of specification →...

  • Page 357: Checking The Crankshaft Position Sensor

    ELECTRICAL COMPONENTS M MMM M MMM M MMM M MMM M MMM • Positive tester probe a. Disconnect the spark plug cap from the spark blue/yellow “1” plug. • Negative tester probe b. Connect the ignition checker “1” as shown. green/white “2”...

  • Page 358: Checking The Starter Motor Operation

    ELECTRICAL COMPONENTS c. Set the main switch to “ON”. b. Check the starter motor operation. d. Tilt the lean angle sensor to 65°. L LLL L LLL L LLL L LLL L LLL EAS28150 CHECKING THE STATOR COIL 1. Disconnect: •...

  • Page 359: Checking The Rectifier/Regulator

    ELECTRICAL COMPONENTS EAS28230 CHECKING THE FUEL SENDER 1. Disconnect: • Fuel pump coupler (from the wire harness) 2. Drain • Fuel (from the fuel tank) 3. Remove: • Fuel pump assembly (from the fuel tank) b. Measure the stator coil resistance. 4.

  • Page 360: Checking The Speed Sensor

    ELECTRICAL COMPONENTS DC 5A O/G B/W B b. Set the main switch to “ON”. c. Elevate the rear wheels and slowly rotate them. d. Measure the voltage (DC 20 V) of white and black/blue. With each full rotation of the rear wheel, the voltage reading should cycle from 0.6 V to 4.8 V to 0.6 V to 4.8 V.

  • Page 361: Checking The Coolant Temperature Sensor

    ELECTRICAL COMPONENTS • Never subject the coolant temperature sen- sor to strong shocks. If the coolant temper- The radiator fan motor circuit breaker “1” is at- ature sensor is dropped, replace it. tached to the wire harness with white tape near the headlight relay “2”.

  • Page 362: Checking The Throttle Position Sensor

    ELECTRICAL COMPONENTS e. Measure the coolant temperature sensor re- EAS28410 CHECKING THE INTAKE AIR PRESSURE sistance. SENSOR L LLL L LLL L LLL L LLL L LLL 1. Check: EAS28300 • Intake air pressure sensor output voltage CHECKING THE THROTTLE POSITION Out of specification →...
  • Page 363 ELECTRICAL COMPONENTS Intake air temperature sensor re- sistance 2.21–2.69 Ω at 20 °C (68 °F) M MMM M MMM M MMM M MMM M MMM a. Connect the pocket tester (Ω × 100) to the in- take air temperature sensor terminal as shown.
  • Page 364 ELECTRICAL COMPONENTS 8-75...

  • Page 365: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING..................9-1 GENERAL INFORMATION ............... 9-1 STARTING FAILURES................9-1 INCORRECT ENGINE IDLING SPEED ............ 9-1 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ......9-2 FAULTY GEAR SHIFTING................ 9-2 SHIFT PEDAL DOES NOT MOVE ............9-2 JUMPS OUT OF GEAR................9-2 FAULTY CLUTCH ..................9-2 OVERHEATING ..................

  • Page 366: Troubleshooting

    TROUBLESHOOTING 3. Throttle body EAS28451 TROUBLESHOOTING • Deteriorated or contaminated fuel • Vacuum leak EAS28460 GENERAL INFORMATION Electrical system 1. Battery The following guide for troubleshooting does not • Discharged battery cover all the possible causes of trouble. It should •...

  • Page 367: Poor Medium-And-High-Speed Performance

    TROUBLESHOOTING • Improper throttle cable free play • Foreign object between transmission gears • Flooded throttle body • Improperly assembled transmission EAS28550 Electrical system JUMPS OUT OF GEAR 1. Battery • Discharged battery Shift shaft • Faulty battery • Incorrect shift pedal position 2.

  • Page 368: Overcooling

    TROUBLESHOOTING • Heavy carbon buildup • Leaking brake fluid 2. Engine oil • Faulty brake caliper kit • Incorrect oil level • Faulty brake caliper seal • Incorrect oil viscosity • Loose union bolt • Inferior oil quality • Damaged brake hose •...

  • Page 369: Faulty Lighting Or Signaling System

    TROUBLESHOOTING EAS28710 FAULTY LIGHTING OR SIGNALING SYSTEM Headlight does not come on • Wrong headlight bulb • Too many electrical accessories • Hard charging • Incorrect connection • Improperly grounded circuit • Poor contacts (main or light switch) • Burnt-out headlight bulb Headlight bulb burnt out •...
  • Page 370 EAS28740 EAS28750 WIRING DIAGRAM COLOR CODE Black YFM70RY 2009 Brown 1. Crankshaft position sensor Green 2. AC magneto Blue 3. Rectifier/regulator Light green 4. Main switch Orange 5. Fuel injection system fuse Pink 6. Battery 7. Main fuse Sky blue 8.
  • Page 372 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN...
  • Page 373 YFM70RY 2009 YFM70RY 2009 WIRING DIAGRAM SCHÉMA DE CÂBLAGE G/W B/Y Br/W G/W Sb Y Br/Y Sb G/W Br/Y Y (GRAY) (GRAY) (BLACK) (BLACK) SUB-WIRE FRONT BRAKE LIGHT SWITCH WIRE HARNESS WIRE HARNESS HARNESS SUB-WIRE HARNESS R/L R/B (GRAY) (GRAY)
  • Page 374 YFM70RY 2009 YFM70RY 2009 WIRING DIAGRAM SCHÉMA DE CÂBLAGE (GRAY) (GRAY) (BLACK) (BLACK) SUB-WIRE FRONT BRAKE LIGHT SWITCH WIRE HARNESS WIRE HARNESS HARNESS SUB-WIRE HARNESS (GRAY) (GRAY) (BLACK) (BLACK) (DARK GREEN) (BLACK) (BLACK) (BLACK) (BLACK) (BLACK) (BLACK) (GRAY) (BLACK) (BLACK)

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Raptor 700r 2009

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