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Yamaha YP250R 2005 Service Manual

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2005
YP250R
SERVICE MANUAL
1C0-F8197-E0

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Summary of Contents for Yamaha YP250R 2005

  • Page 1 2005 YP250R SERVICE MANUAL 1C0-F8197-E0...
  • Page 2 EAS00000 YP250R 2005 SERVICE MANUAL ©2007 by Yamaha Motor España, S.A. First edition, February 2007 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor España, S.A. is expressly prohibited.
  • Page 3 EAS00002 NOTICE This manual was produced by the Yamaha Motor España S.A. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.

  • Page 4: Periodic Checks And

    EAS00007 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. 1 The manual is divided into chapters.

  • Page 5: General Information

    EAS00008 SYMBOLS The following symbols are not relevant to SPEC every vehicle. INFO Symbols 1 to 9 indicate the subject of each chapter. 1 General information 2 Specifications CHAS 3 Periodic checks and adjustments 4 Chassis 5 Engine 6 Cooling system 7 Carburetor COOL 8 Electrical system...

  • Page 6: Table Of Contents

    EAS00010 TABLE OF CONTENTS GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC CHECKS AND ADJUSTMENTS CHASSIS CHAS ENGINE COOLING SYSTEM COOL CARBURETOR CARB – ELECTRICAL SYSTEM ELEC TROUBLESHOOTING TRBL SHTG...
  • Page 7 INFO CHAPTER 1 GENERAL INFORMATION IDENTIFICATION .................... 1-1 VEHICLE IDENTIFICATION NUMBER .............1-1 MODEL LABEL..................1-1 MULTI-FUNCTION DISPLAY................1-2 IMPORTANT INFORMATION ................. 1-5 PREPARATION FOR REMOVAL AND DISASSEMBLY......1-5 REPLACEMENT PARTS................1-5 GASKETS, OIL SEALS AND O-RINGS ............ 1-5 LOCK WASHERS/PLATES AND COTTER PINS ........1-6 BEARINGS AND OIL SEALS ..............

  • Page 8: General Information

    IDENTIFICATION INFO EAS00015 GENERAL INFORMATION IDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the frame. EAS00018 MODEL LABEL The model label 1 is affixed underneath the seat. This information will be needed when ordering spare parts. 1 - 1...

  • Page 9: Multi-Function Display

    MULTI-FUNCTION DISPLAY INFO MULTI-FUNCTION DISPLAY The multi-function display is equipped with the following: • an odometer (which shows the total dis- tance traveled) • two tripmeters (which show the distance traveled since they were last set to zero, the time passed since the tripmeters were set to zero, and the average speed traveled during this time) 1 “MODE”...
  • Page 10 MULTI-FUNCTION DISPLAY INFO Pushing the “SET” button when in the tripme- ter mode switches the display between the dif- ferent tripmeter functions in the following order: Distance → Time → Average speed → Dis- tance If the fuel level warning light comes on, the dis- play will automatically change to the fuel reserve tripmeter mode “Trip/fuel”...
  • Page 11 MULTI-FUNCTION DISPLAY INFO Ambient temperature display This display shows the ambient temperature from -30 °C to 50 °C. The frost warning indicator “*” automatically comes on if the temperature is lower than 3 °C. 1 Frost warning indicator 2 Negative symbol 3 Ambient temperature Oil change indicator “OIL”...

  • Page 12: Important Information

    5. Keep all parts away from any source of fire. EAS00021 REPLACEMENT PARTS Use only genuine Yamaha parts for all replacements. Use oil and grease recom- mended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.

  • Page 13: Lock Washers/Plates And Cotter Pins

    IMPORTANT INFORMATION INFO EAS00023 LOCK WASHERS/PLATES AND COTTER PINS After removal, replace all lock washers/plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut. EAS00024 BEARINGS AND OIL SEALS Install bearings and oil seals so that the manu-...

  • Page 14: Checking The Connections

    CHECKING THE CONNECTIONS INFO EAS00026 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: • lead • coupler • connector 2. Check: • lead • coupler • connector Moisture → Dry with an air blower. Rust/stains →...

  • Page 15: Special Tools

    SPECIAL TOOLS INFO EAS00027 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropri- ate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country.
  • Page 16 SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Tappet adjusting tool 90890-01311 This tool is used to adjust valve clear- ance. T-handle 90890-01326 This tool is used to hold the damper rod when removing or installing the damper rod. Clutch spring holder 90890-01337 This tool is used to disassembly and assembly the secondary sheave.
  • Page 17 SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Steering nut wrench 90890-01403 This tool is used to loosen or tighten the steering ring nuts. Clutch spring holder arm 90890-01464 This tool is used to disassembly and assembly the secondary sheave. Adapter (M14) 90890-01478 This tool is used to install the crankshaft.
  • Page 18 SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Valve spring compressor 90890-04019 This tool is used to remove or install the valve assemblies. Middle driven shaft bearing driver 90890-04058 This tool is used to install the water pump seal. Valve guide remover (ø6) 90890-04064 This tool is used to remove or install the valve guides.
  • Page 19 This tool is used to check the air cut-off valve. Fuel sender removal tool 90890-11098 This tool are used to remove the fuel sender. Yamaha bond No. 1215 90890-85505 This bond is used to seal two mating sur- faces (e.g., crankcase mating surfaces). 1 - 12...
  • Page 20 SPEC CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS ................ 2-1 ENGINE SPECIFICATIONS ................2-2 CHASSIS SPECIFICATIONS ................2-11 ELECTRICAL SPECIFICATIONS ..............2-15 CONVERSION TABLE .................. 2-18 GENERAL TIGHTENING TORQUE SPECIFICATIONS.......2-18 TIGHTENING TORQUES ................2-19 ENGINE TIGHTENING TORQUES............2-19 CHASSIS TIGHTENING TORQUES............2-21 LUBRICATION POINTS AND LUBRICANT TYPES ........2-23 ENGINE LUBRICATION POINTS AND LUBRICANT TYPES ....

  • Page 21: Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Model code 1C01 Dimensions Overall length 2,210 mm (87.0 in) Overall width 790 mm (31.1 in) Overall height 1,380 mm (54.3 in) Seat height 775 mm (30.5 in) Wheelbase 1,545 mm (60.8 in) Minimum ground clearance 113 mm (4.45 in) Minimum turning radius...

  • Page 22: Engine

    SPEC ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS Item Standard Limit Engine Engine type Liquid cooled 4-stroke, SOHC ---- Displacement 249.7 cm ---- Cylinder arrangement Forward-inclined single cylinder ---- Bore × stroke 69.0 × 66.8 mm (2.72 × 2.63 in) ---- Compression ratio 10.00 :1 ---- Standard compression pressure (at...

  • Page 23: Cooling System

    SPEC ENGINE SPECIFICATIONS Item Standard Limit Oil pump Oil pump type Trochoid ---- Inner-rotor-to-outer-rotor-tip clear- Less than 0.15 mm (0.0059 in) 0.23 mm ance (0.0091 in) Outer-rotor-to-oil-pump-housing 0.013 ~ 0.036 mm (0.0005 ~ 0.0014 in) 0.106 mm clearance (0.0042 in) Oil-pump-housing-to-inner-and- 0.04 ~ 0.09 mm (0.0016 ~ 0.0035 in) 0.16 mm...
  • Page 24 SPEC ENGINE SPECIFICATIONS Item Standard Limit Camshaft Drive system Chain drive (left) ---- Intake camshaft lobe dimensions Measurement A 37.051 ~ 37.151 mm (1.4587 ~ 1.4626 in) 36.956 mm (1.4550 in) Measurement B 30.074 ~ 30.174 mm (1.1840 ~ 1.1880 in) 29.973 mm (1.1800 in) Exhaust camshaft lobe dimensions Measurement A...
  • Page 25 SPEC ENGINE SPECIFICATIONS Item Standard Limit Valves, valve seats, valve guides Valve clearance (cold) Intake 0.08 ~ 0.12 mm (0.0031 ~ 0.0047 in) ---- Exhaust 0.16 ~ 0.20 mm (0.0063 ~ 0.0079 in) ---- Valve dimensions Head Diameter Face Width Seat Width Margin Thickness Valve head diameter A...
  • Page 26 SPEC ENGINE SPECIFICATIONS Item Standard Limit Valve stem runout ---- 0.010 mm (0.0004 in) Cylinder head valve seat width Intake 0.90 ~ 1.10 mm (0.0354 ~ 0.0433 in) 1.6 mm (0.06 in) Exhaust 0.90 ~ 1.10 mm (0.0354 ~ 0.0433 in) 1.6 mm (0.06 in) Valve springs...
  • Page 27 SPEC ENGINE SPECIFICATIONS Item Standard Limit Winding direction (top view) Intake Counterclockwise ---- Exhaust Counterclockwise ---- Outer spring Free length Intake 36.93 mm (1.45 in) 35.00 mm (1.38 in) Exhaust 36.93 mm (1.45 in) 35.00 mm (1.38 in) Installed length (valve closed) Intake 31.60 mm (1.24 in) ----...
  • Page 28 SPEC ENGINE SPECIFICATIONS Item Standard Limit Piston Piston-to-cylinder clearance 0.020 ~ 0.040 mm (0.0008 ~ 0.0016 in) 0.15 mm (0.0059 in) Diameter D 68.965 ~ 68.980 mm (2.7152 ~ 2.7157 in) ---- Height H 5.0 mm (0.20 in) ---- Piston pin bore (in the piston) Diameter 17.004 ~ 17.015 mm (0.6694 ~ 0.6699 in) 17.045 mm (0.6711 in)
  • Page 29 SPEC ENGINE SPECIFICATIONS Item Standard Limit Oil ring Dimensions (B × T) 1.50 × 2.50 mm (0.06 × 0.10 in) ---- End gap (installed) 0.20 ~ 0.70 mm (0.0079 ~ 0.0276 in) ---- Ring side clearance 0.060 ~ 0.150 mm (0.0024 ~ 0.0059 in) ---- Crankshaft Width A...

  • Page 30: Spec

    SPEC ENGINE SPECIFICATIONS Item Standard Limit Air filter Air filter element Oil-coated paper element ---- Fuel pump Pump type Electrical ---- Model/manufacturer 2GV0/MITSUBISHI ---- Output pressure 12.5 kPa (0.13 kgf/cm , 1.8 psi) ---- Carburetor Type × quantity 1C0 × 1 ---- Manufacturer KEIHIN...

  • Page 31: Chassis Specifications

    SPEC CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS Item Standard Limit Frame Frame type Steel tube underbone ---- Caster angle 28.00° ---- Trail 100.0 mm (3.94 in) ---- Front wheel Wheel type Cast wheel ---- 15 × MT3.50 Size ---- Material Aluminum ---- Wheel travel 94.0 mm (3.70 in) ----...
  • Page 32 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Rear tire Tire type Tubeless ---- Size 140/70-14 M/C 68S or 68P ---- Manufacturer/model MICHELIN/GOLD STANDARD ---- PIRELLI/GTS24 Tire pressure (cold) 0 ~ 90 kg (0 ~ 198 lb) 220 kPa (2.20 kgf/cm , 32 psi) ---- 90 ~ 180 kg (198 ~ 397 lb) 250 kPa (2.50 kgf/cm...
  • Page 33 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Steering Steering bearing type Angular bearing ---- Center to lock angle (left) 62.0° ---- Center to lock angle (right) 62.0° ---- Front suspension Suspension type Telescopic fork ---- Front fork type Coil spring/oil damper ---- Front fork travel 110.0 mm (4.33 in)
  • Page 34 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Rear suspension Suspension type Unit swing ---- Rear shock absorber type Coil spring/oil damper ---- Rear shock absorber assembly travel 95.0 mm (3.74 in) ---- Spring Free length 270.1 mm (10.63 in) 264.7 mm (10.42 in) Installed length 249 mm (9.80 in)

  • Page 35: Electrical Specifications

    SPEC ELECTRICAL SPECIFICATIONS ELECTRICAL SPECIFICATIONS Item Standard Limit System voltage 12 V Ignition system ---- Ignition system type ---- Ignition timing (B.T.D.C.) 10.0° ---- Advancer type Digital ---- 130 ~ 150 Ω Pickup coil resistance ---- CDI unit model/manufacturer 5510-F/MITSUBA ---- Ignition coil Model/manufacturer...
  • Page 36 SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit Indicator light LED × 1 Meter lighting ---- LED × 2 Turn signal indicator light ---- LED × 1 High beam indicator light ---- LED × 1 Fuel level warning light ---- LED × 1 Immobilizer system indicator light ---- Electric starting system...
  • Page 37 SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit Starting circuit cut-off relay Model/manufacturer ACA12115 M02 ---- 72 ~ 88 Ω at 20 °C (68 °F) Coil resistance ---- Headlight relay Model/manufacturer ACM33211 M05 ---- 96 Ω at 20 °C (68 °F) Coil resistance ---- Fuel pump relay Model/manufacturer...

  • Page 38: Conversion Table

    CONVERSION TABLE/ SPEC GENERAL TIGHTENING TORQUE SPECIFICATIONS EAS00028 EAS00029 CONVERSION TABLE GENERAL TIGHTENING TORQUE All specification data in this manual are listed SPECIFICATIONS in SI and METRIC UNITS. This chart specifies tightening torques for stan- Use this table to convert METRIC unit data to dard fasteners with a standard ISO thread IMPERIAL unit data.

  • Page 39: Tightening Torques

    SPEC TIGHTENING TORQUES TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Tightening torque Thread Item Part name Q’ty Remarks size Nm m · kg ft · lb Oil check bolt Bolt Exhaust pipe stud bolt Bolt Air induction system pipe stud bolt Bolt Spark plug —...
  • Page 40 SPEC TIGHTENING TORQUES Tightening torque Thread Item Part name Q’ty Remarks size Nm m · kg ft · lb Timing mark accessing plug — Starter clutch Bolt Secondary sheave Primary sheave cap Screw Primary sheave Clutch carrier Secondary sheave bracket Bolt Stator coil Bolt...

  • Page 41: Chassis Tightening Torques

    SPEC TIGHTENING TORQUES CHASSIS TIGHTENING TORQUES Tightening torque Item Thread size Remarks Nm m · kg ft · lb Frame and engine bracket Frame and engine bracket rod Engine bracket, engine bracket rod and engine Frame and sidestand bolt Frame and sidestand nut Passenger footrest and frame Grab bar and frame Fuel tank and frame...
  • Page 42 SPEC TIGHTENING TORQUES Tightening torque Item Thread size Remarks Nm m · kg ft · lb Rear brake master cylinder and holder Rear brake master cylinder and brake lever Grip end Front cowling inner panel and frame Radiator cover and frame Rear side cover (left and right) and frame Mudguard and frame Footrest board and frame...

  • Page 43: Lubrication Points And Lubricant Types

    O-ring and collar (clutch housing) Primary sheave weights Shell BT grease 3® BEL-RAY assembly Secondary sheave lube® BEL-RAY assembly Oil seal (secondary sliding sheave) lube® BEL-RAY assembly Secondary sheave guide pins lube® Yamaha bond Crankcase mating surfaces No. 1215 2 - 23...

  • Page 44: Chassis Lubrication Points And Lubricant Types

    SPEC LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Yamaha bond Pickup coil/stator assembly lead grommet No. 1215 EAS00032 CHASSIS LUBRICATION POINTS AND LUBRICANT TYPES Lubrication Point Symbol Engine mounting bolt Swingarm oil seal lips Steering bearings (upper and lower)

  • Page 45: Cooling System Diagrams

    SPEC COOLING SYSTEM DIAGRAMS COOLING SYSTEM DIAGRAMS 1 Radiator filler hose 0 Radiator outlet hose 2 Radiator A Radiator cap 3 Coolant reservoir hose B Water pump inlet hose 4 Coolant reservoir È 3 ~ 4 mm (0.12 ~ 0.16 in) 5 Thermostat inlet hose 6 Thermostat outlet hose 7 Water pump...

  • Page 46: Cable Routing

    SPEC CABLE ROUTING EAS00035 CABLE ROUTING 1 Front brake hose 0 Throttle cable (accelerator cable) 2 Rear brake hose È Connect the air temperature sensor coupler, and 3 Rear brake light switch lead 4 Front turn signal light coupler (left) then place the air temperature sensor in the 5 Handlebar upper cover left switches coupler steering head pipe.
  • Page 47 SPEC CABLE ROUTING Ë After connecting the throttle cables, check the operation of the throttle grip and make sure that it returns to its home position easily after being released. È É Ë Ê Ê 2 - 27...
  • Page 48 SPEC CABLE ROUTING 1 Wire harness B Radiator filler hose 2 Rear brake hose C Radiator fan motor coupler 3 Front brake hose D Fuel pump coupler 4 Turn signal relay E Thermo switch (radiator fan motor) 5 Fuse box F Thermo switch (auto choke) 6 Seat lock cable G Coolant reservoir hose...
  • Page 49 SPEC CABLE ROUTING É Be sure to leave a little slack in the speed sensor M Starting circuit cut-off relay N Fuel pump relay lead since the front fork moves 10 mm (0.040 in) O Main switch coupler vertically. Ê Fasten the front brake hose and speed sensor P immobilizer antenna coupler Q Throttle cables lead with a holder, making sure to fasten the...
  • Page 50 SPEC CABLE ROUTING Î Connect each thermo switch connectors (auto Ò Fasten the wire harness and starter motor lead choke) to the switch terminals of the same color. to the frame with a plastic locking tie. Ï Fasten the coolant reservoir hose, fuel pump Ó...
  • Page 51 SPEC CABLE ROUTING Õ Fasten the wire harness, rear brake pipe, starter × Fasten the speed sensor lead with a plastic lock- motor lead and speed sensor lead to the frame ing tie, making sure to install the tie around the with a plastic locking tie, making sure to fasten protective sleeve of the lead, not the lead itself, the wire harness at the tape.
  • Page 52 SPEC CABLE ROUTING È Route the license plate light lead as shown in 1 Tail/brake light assembly coupler (right) 2 License plate light the illustration. É Fasten the wire harness, tail/brake light lead and 3 Wire harness 4 Rear brake hose license plate light lead with a plastic locking tie.
  • Page 53 SPEC CABLE ROUTING Ì Fasten the wire harness, starter motor lead, rear brake pipe, pickup coil/stator assembly lead to the frame with a plastic locking tie. Í Connect each ignition coil connectors to the coil terminals of the same color. Í...
  • Page 54 SPEC CABLE ROUTING 1 Headlight assembly coupler B Fuel hose (fuel pump to carburetor) 2 Seat lock cable C Fuel tank overflow hose 3 Starter motor lead È Pass the battery lead through the opening in the 4 Starter relay 5 Positive battery lead battery box.
  • Page 55 SPEC CABLE ROUTING Ì Fasten the sidestand switch lead to the frame with a plastic locking tie. Í Pass the fuel tank overflow hose through the hole in the under cover. 2 3 4 5 6 È Ë É Ê Í...
  • Page 56 SPEC CABLE ROUTING È Fasten the seat lock cable and throttle cables 1 Fuel hose (fuel pump to carburetor) 2 Throttle cables with a plastic locking tie, making sure to fasten 3 Seat lock cable the throttle cables at the mark É...
  • Page 57 SPEC CABLE ROUTING Ì Fasten the tail/brake light assembly lead (left) to the frame with a plastic locking tie. Í Fasten the anti-theft coupler (OPTION) to the frame with a plastic locking tie. Í Ì Ë É È Ê 2 - 37...
  • Page 58 SPEC CABLE ROUTING 1 Fuse box B Speed sensor coupler 2 Wire harness C Main switch coupler 3 Rear brake hose D Turn signal relay 4 Throttle cables E Seat lock cable 5 Front brake hose È To wire harness 6 CDI unit É...
  • Page 59 SPEC CABLE ROUTING 1 Fuel hose (fuel tank to fuel pump) B Fuel sender lead 2 Fuel hose (fuel pump to carburetor) È Fasten the sidestand switch lead to the frame 3 Sidestand switch coupler 4 Starter motor lead cross member with a plastic locking tie. É...
  • Page 60 SPEC CABLE ROUTING Ë Fasten the starter motor lead and ground lead with the holder, making sure to align the white tape on the starter motor lead with the holder. Ì Pass the auto choke unit lead and air induction system vacuum hose with a plastic locking tie.
  • Page 61 CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION....................3-1 PERIODIC MAINTENANCE AND LUBRICATION CHART ......3-1 COVERS AND PANELS.................. 3-3 SEAT AND SIDE COVERS ............... 3-3 FOOTREST BOARD ................. 3-4 HANDLEBAR COVERS ................3-5 STORAGE COMPARTMENT..............3-6 AIR FILTER CASE ..................3-7 ENGINE ......................3-8 ADJUSTING THE VALVE CLEARANCE ..........
  • Page 62 CHASSIS ....................... 3-34 CHECKING THE BRAKE FLUID LEVEL..........3-34 CHECKING THE FRONT AND REAR BRAKE PADS ......3-35 CHECKING THE FRONT AND REAR BRAKE HOSES......3-35 BLEEDING THE HYDRAULIC BRAKE SYSTEM ........3-36 CHECKING AND ADJUSTING THE STEERING HEAD ......3-37 CHECKING THE FRONT FORK .............

  • Page 63: Periodic Checks And Adjustments

    • From 50000 km, repeat the maintenance intervals starting from 10000 km. • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. ODOMETER READING (× 1000 Km)
  • Page 64 PERIODIC MAINTENANCE AND LUBRICATION CHART ODOMETER READING (× 1000 Km) ANNUAL ITEM CHECK OR MAINTENANCE JOB CHECK √ √ √ √ √ √ 15 * Sidestand switch • Check operation. √ √ √ √ 16 * Front fork • Check operation and for oil leakage. Shock absorber •...

  • Page 65: Covers And Panels

    COVERS AND PANELS EAS00038 COVERS AND PANELS SEAT AND SIDE COVERS 23 Nm (2.3 m kg, 17 ft 7 Nm (0.7 m kg, 5.1 ft 7 Nm (0.7 m kg, 5.1 ft • • • • • • 23 Nm (2.3 m kg, 17 ft •...

  • Page 66: Footrest Board

    COVERS AND PANELS EAS00040 FOOTREST BOARD 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks Removing the footrest board Remove the parts in the order listed. Center panel 1 (left and right) Protector (left and right) Center panel 2 (left and right) Footrest board mat (left and right)

  • Page 67: Handlebar Covers

    COVERS AND PANELS EAS00042 HANDLEBAR COVERS Order Job/Part Q’ty Remarks Removing the handlebar covers Remove the parts in the order listed. Front turn signal light assembly Front turn signal light coupler Disconnect. Windshield Rearview mirror (left and right) Handlebar upper cover right switch Disconnect.

  • Page 68: Storage Compartment

    COVERS AND PANELS EAS00043 STORAGE COMPARTMENT 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks Removing the storage compartment Remove the parts in the order listed. Upper panel Headlight assembly coupler Disconnect. Front cowling Battery cover Storage compartment For installation, reverse the removal pro- cedure.

  • Page 69: Air Filter Case

    AIR FILTER CASE AIR FILTER CASE 9 Nm (0.9 m kg, 6.5 ft • • Order Job/Part Q’ty Remarks Removing the air filter case assem- Remove the parts in the order listed. Storage box Refer to “COVERS AND PANELS”. Cylinder head breather hose Air induction system hose (air filter case to air cut-off valve assembly) Air filter case assembly...

  • Page 70: Engine

    ADJUSTING THE VALVE CLEARANCE EAS00049 ENGINE ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: • Valve clearance adjustment should be made on a cold engine, at room temperature. • When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke.
  • Page 71 ADJUSTING THE VALVE CLEARANCE 5. Measure: • valve clearance Out of specification → Adjust. Valve clearance (cold) Intake valve 0.08 ~ 0.12 mm (0.0031 ~ 0.0047 in) Exhaust valve 0.16 ~ 0.20 mm (0.0063 ~ 0.0079 in) M MMM M MMM M MMM M MMM M MMM...
  • Page 72 ADJUSTING THE VALVE CLEARANCE 6. Adjust: • valve clearance M MMM M MMM M MMM M MMM M MMM a. Loosen the locknut 1. b. Insert a thickness gauge between the end of the adjusting screw and the valve tip. c.

  • Page 73: Adjusting The Engine Idling Speed

    ADJUSTING THE ENGINE IDLING SPEED EAS00054 ADJUSTING THE ENGINE IDLING SPEED NOTE: Prior to adjusting the engine idling speed, the air filter element should be cleaned, and the engine should have adequate compression. 1. Remove: • storage box Refer to “COVERS AND PANELS”. 2.

  • Page 74: Checking The Exhaust Gas At Idle

    ADJUSTING THE ENGINE IDLING SPEED/ CHECKING THE EXHAUST GAS AT IDLE 6. Adjust: • throttle cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY”. Throttle cable free play (at the flange of the throttle grip) 4.0 ~ 6.0 mm (0.16 ~ 0.24 in) CHECKING THE EXHAUST GAS AT IDLE Check the exhaust gas at idle when the air induction system is operating.
  • Page 75 CHECKING THE EXHAUST GAS AT IDLE/CHECKING AND ADJUSTING THE EXHAUST GAS AT IDLE 6. Measure: • engine idling speed Out of specification → Adjust. Refer “ADJUSTING ENGINE IDLING SPEED”. Engine idling speed 1,550 ~ 1,650 r/min 7. Connect: • CO tester 1 (to the exhaust attachment) 8.

  • Page 76: Checking And Adjusting The Exhaust Gas At Idle

    CHECKING AND ADJUSTING THE EXHAUST GAS AT IDLE 4. Connect: • temperature probe tester 1 (to the engine oil drain bolt) • engine tachometer (to the spark plug lead) • exhaust attachment 2 (to the exhaust pipe) Exhaust attachment 90890-03134 5.
  • Page 77 CHECKING AND ADJUSTING THE EXHAUST GAS AT IDLE/ADJUSTING THE THROTTLE CABLE FREE PLAY 9. Measure: • CO density Out of specification → Adjust. Within specification → Checking the air induction system. Refer to “AIR INDUCTION SYSTEM” in chapter 7. CO density (when air induction system is not operating) 6.0% 10.Adjust:...

  • Page 78: Adjusting The Throttle Cable Free Play

    ADJUSTING THE THROTTLE CABLE FREE PLAY/ CHECKING THE SPARK PLUG 2. Remove: • front turn signal light assembly Refer to “COVERS AND PANELS”. M MMM M MMM M MMM M MMM M MMM a. Slide back the rubber cover 1. b.

  • Page 79: Checking The Ignition Timing

    CHECKING THE SPARK PLUG/ CHECKING THE IGNITION TIMING 4. Check: • spark plug type Incorrect → Change. Spark plug type (manufacturer) DR8EA (NGK) 5. Check: • electrode 1 Damage/wear → Replace the spark plug. • insulator 2 Abnormal color → Replace the spark plug. Normal color is medium-to-light tan.
  • Page 80 CHECKING THE IGNITION TIMING 2. Remove: • storage box Refer to “COVERS AND PANELS”. 3. Remove: • timing mark accessing plug 1 4. Connect: • timing light 1 • engine tachometer (to the spark plug lead) Timing light 90890-03141 5. Check: •...

  • Page 81: Measuring The Compression Pressure

    MEASURING THE COMPRESSION PRESSURE EAS00067 MEASURING THE COMPRESSION PRESSURE NOTE: Insufficient compression pressure will result in a loss of performance. 1. Remove: • storage box Refer to “COVERS AND PANELS”. 2. Measure: • valve clearance Out of specification → Adjust. Refer “ADJUSTING VALVE...
  • Page 82 MEASURING THE COMPRESSION PRESSURE 7. Measure: • compression pressure Out of specification → Refer to steps (c) and (d). Compression pressure (at sea level) Minimum 1,120 kPa (11.2 kg/cm , 159.3 psi) Standard 1,400 kPa (14.0 kg/cm , 199.1 psi) Maximum 1,570 kPa (15.7 kg/cm...

  • Page 83: Checking The Engine Oil Level

    MEASURING THE COMPRESSION PRESSURE/ CHECKING THE ENGINE OIL LEVEL 8. Install: • spark plug 18 Nm (1.8 m · kg, 13 ft · lb) 9. Connect: • spark plug cap 10.Install: • storage box Refer to “COVERS AND PANELS”. EAS00070 CHECKING THE ENGINE OIL LEVEL 1.

  • Page 84: Changing The Engine Oil

    CHECKING THE ENGINE OIL LEVEL/ CHANGING THE ENGINE OIL 4. Start the engine, warm it up for several min- utes, and then turn it off. 5. Check the engine oil level again. NOTE: Before checking the engine oil level, wait a few minutes until the oil has settled.
  • Page 85 CHANGING THE ENGINE OIL 8. Install: • engine oil drain bolt (along with the gasket) 20 Nm (2.0 m · kg, 14 ft · lb) 9. Fill: • crankcase (with the specified amount of the recom- mended engine oil) Quantity Total amount 1.40 L (1.23 Imp qt, 1.48 US qt) Periodic oil change...

  • Page 86: Changing The Final Transmission Oil

    CHANGING THE ENGINE OIL/ CHANGING THE FINAL TRANSMISSION OIL 15.Reset: • oil change indicator M MMM M MMM M MMM M MMM M MMM a. Set the main switch to “ON” while holding the “MODE” and “SET” buttons pushed for two to five seconds.

  • Page 87: Replacing The Air Filter Element

    CHANGING THE FINAL TRANSMISSION OIL/ REPLACING THE AIR FILTER ELEMENT 6. Install: • final transmission oil drain bolt 22 Nm (2.2 m · kg, 16 ft · lb) 7. Fill: • transmission case (with the specified amount of the recom- mended transmission oil) Recommended oil SAE 10W30 type SE motor oil...

  • Page 88: Cleaning The V-Belt Case Air Filter Element

    REPLACING THE AIR FILTER ELEMENT/ CLEANING THE V-BELT CASE AIR FILTER ELEMENT 2. Check: • air filter element Damage → Replace. NOTE: • Replace filter element every 20,000 km of operation. • The air filter needs more frequent service if you are riding in unusually wet or dusty areas.

  • Page 89: Checking The Fuel And Vacuum Hoses

    CLEANING THE V-BELT CASE AIR FILTER ELEMENT/ CHECKING THE FUEL AND VACUUM HOSES/ CHECKING THE BREATHER HOSES 4. Check: • V-belt case air filter element Damage → Replace. CAUTION: Since the V-belt case air filter element is a dry type, do not let grease or water contact 5.

  • Page 90: Checking The Breather Hoses

    CHECKING THE BREATHER HOSES/ CHECKING THE EXHAUST SYSTEM 2. Check: • cylinder head breather hose 1 • transmission case breather hose 2 Cracks/damage → Replace. Loose connection → Connect properly. CAUTION: Make sure the cylinder head breather hose and transmission case breather hose are routed correctly.

  • Page 91: Checking The Coolant Level

    CHECKING THE COOLANT LEVEL/ CHECKING THE COOLING SYSTEM EAS00103 CHECKING THE COOLANT LEVEL 1. Stand the vehicle on a level surface. NOTE: • Place the vehicle on a centerstand. • Make sure that the vehicle is upright. 2. Check: • coolant level The coolant level should be between the maximum level mark a and minimum level mark b.

  • Page 92: Changing The Coolant

    CHECKING THE COOLING SYSTEM/ CHANGING THE COOLANT 2. Check: • radiator 1 • radiator outlet hose 2 • radiator inlet hose 3 • radiator inlet/outlet pipe 4 • water pump inlet hose 5 • radiator filler hose 6 • thermostat cover 7 •...
  • Page 93 CHANGING THE COOLANT 5. Remove: • radiator cap 1 WARNING A hot radiator is under pressure. Therefore, do not remove the radiator cap when the engine is hot. Scalding hot fluid and steam may be blown out, which could cause seri- ous injury.
  • Page 94 CHANGING THE COOLANT 10.Fill: • cooling system (with the specified amount of the recom- mended coolant to the specified level) Recommended antifreeze High-quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines Mixing ratio 1:1 (antifreeze:water) Quantity Radiator and engine capacity 0.70 L (0.62 Imp qt, 0.74 US qt) Coolant reservoir capacity...
  • Page 95 CHANGING THE COOLANT CAUTION: • Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant check, and if necessary, correct the antifreeze concentration of the coolant. • Use only distilled water. However, if dis- tilled water is not available, soft water may be used.

  • Page 96: Chassis

    CHECKING THE BRAKE FLUID LEVEL EAS01160 CHASSIS CHECKING THE BRAKE FLUID LEVEL 1. Stand the vehicle on a level surface. NOTE: • Place the vehicle on the centerstand. • Make sure the vehicle is upright. 2. Check: È • brake fluid level Below the minimum level mark a →...

  • Page 97: Checking The Front And Rear Brake Pads

    CHECKING THE FRONT AND REAR BRAKE PADS/ CHECKING THE FRONT AND REAR BRAKE HOSES EAS01220 È CHECKING THE FRONT AND REAR BRAKE PADS The following procedure applies to all of the brake pads. 1. Operate the brake. 2. Check: • front brake pad Wear limit a reached →...

  • Page 98: Bleeding The Hydraulic Brake System

    BLEEDING THE HYDRAULIC BRAKE SYSTEM EAS01350 BLEEDING THE HYDRAULIC BRAKE SYSTEM WARNING Bleed the hydraulic brake system when- ever: • the system is disassembled. • a brake hose is loosened, disconnected or replaced. • the brake fluid level is very low. •...

  • Page 99: Checking And Adjusting The Steering Head

    BLEEDING THE HYDRAULIC BRAKE SYSTEM/ CHECKING AND ADJUSTING THE STEERING HEAD g. Loosen the bleed screw. NOTE: Loosening the bleed screw will release the pressure and cause the brake lever to contact the handlebar. h. Tighten the bleed screw and then release the brake lever.
  • Page 100 CHECKING AND ADJUSTING THE STEERING HEAD 3. Remove: • handlebar lower holder Refer to “STEERING HEAD” in chapter 4. 4. Adjust: • steering head M MMM M MMM M MMM M MMM M MMM a. Remove the upper ring nut 1, lock washer 2, the center ring nut 3 and the rubber washer.

  • Page 101: Checking The Front Fork

    CHECKING AND ADJUSTING THE STEERING HEAD/ CHECKING THE FRONT FORK g. Finger tighten the center ring nut, then align the slots of both ring nuts. If necessary, hold the lower ring nut and tighten the center ring nut until their slots are aligned. NOTE: When aligning the slots, align them by turning the center ring nut in the tightening direction.

  • Page 102: Adjusting The Rear Shock Absorber Assemblies

    ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLIES/CHECKING THE TIRES EAS01600 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLIES The following procedure applies to both of the rear shock absorber assemblies. WARNING • Securely support the vehicle so that there is no danger of it falling over. •...

  • Page 103: Checking The Tires

    CHECKING THE TIRES WARNING • The tire pressure should only be checked and regulated when the tire temperature is at ambient air temperature. • The tire pressure and the suspension must be adjusted according to the total weight (including cargo, rider, passenger and accessories) and the anticipated riding speed.
  • Page 104 The front and rear tires should always be by the same manufacturer and of the same design. No guarantee concerning handling characteristics can be given if a tire combination other than one approved by Yamaha is used on this vehicle. Front tire Manufacturer Model Size...

  • Page 105: Checking The Wheels

    CHECKING THE TIRES/ CHECKING THE WHEELS WARNING New tires have a relatively low grip on the road surface until they have been slightly worn. Therefore, approximately 100 km should be traveled at normal speed before any high-speed riding is done. NOTE: For tires with a rotation direction mark 1: Install the tire with the mark pointing in the...

  • Page 106: Checking And Lubricating The Cables

    CHECKING AND LUBRICATING THE CABLES/ LUBRICATING THE SIDESTAND/ LUBRICATING THE CENTERSTAND EAS01700 CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the inner and outer cables. WARNING Damaged outer cable may cause the cable to corrode and interfere with its movement. Replace damaged outer cable and inner cable as soon as possible.

  • Page 107: Chk Adj

    CHECKING AND CHARGING THE BATTERY EAS01790 ELECTRICAL SYSTEM CHECKING AND CHARGING THE BATTERY WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: • Wear protective eye gear when handling or working near batteries.
  • Page 108 CHECKING AND CHARGING THE BATTERY NOTE: NOTE: Since MF batteries are sealed, it is not possi- ble to check the charge state of the battery by measuring the specific gravity of the electro- lyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals.
  • Page 109 CHECKING AND CHARGING THE BATTERY b. Check the charge of the battery, as shown Relationship between the open-circuit volt- in the charts and the following example. age and the charging time at 20 °C. Example c. Open-circuit voltage = 12.0 V d.
  • Page 110 CHECKING AND CHARGING THE BATTERY • If the battery becomes hot to the touch at any time during the charging process, disconnect the battery charger and let the battery cool before reconnecting it. Hot batteries can explode! • As shown in the following illustration, the open-circuit voltage of an MF battery sta- bilizes about 30 minutes after charging has been completed.
  • Page 111 CHECKING AND CHARGING THE BATTERY Charging method using a variable-current (voltage) charger Charger NOTE: Measure the open-circuit Ammeter Leave the battery unused for more voltage prior to charging. than 30 minutes before measuring its open-circuit voltage. Connect a charger and NOTE: Set the charging voltage to 16 ~ ammeter to the battery and...
  • Page 112 CHECKING AND CHARGING THE BATTERY Charging method using a constant voltage charger Measure the open-circuit NOTE: voltage prior to charging. Leave the battery unused for more than 30 minutes before measuring its open-circuit voltage. Connect a charger and ammeter to the battery and start charging.

  • Page 113: Checking The Fuses

    CHECKING AND CHARGING THE BATTERY/ CHECKING THE FUSES 7. Install: • battery 8. Connect: • battery leads (to the battery terminals) CAUTION: First, connect the positive battery lead 1, and then the negative battery lead 2. 9. Check: • battery terminals Dirt →...
  • Page 114 CHECKING THE FUSES 2. Check: • fuse M MMM M MMM M MMM M MMM M MMM a. Connect the pocket tester to the fuse and check the continuity. NOTE: Set the pocket tester selector to “Ω × 1”. Pocket tester 90890-03112 b.

  • Page 115: Replacing The Headlight Bulbs

    CHECKING THE FUSES/ REPLACING THE HEADLIGHT BULBS WARNING Never use a fuse with an amperage rating other than that specified. Improvising or using a fuse with the wrong amperage rat- ing may cause extensive damage to the electrical system, cause the lighting and ignition systems to malfunction and could possibly cause a fire.

  • Page 116: Adjusting The Headlight Beam

    REPLACING THE HEADLIGHT BULBS/ ADJUSTING THE HEADLIGHT BEAM 6. Install: • headlight bulb Secure the new headlight bulb with the headlight bulb holder. CAUTION: Avoid touching the glass part of the head- light bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb and the luminous flux will be adversely affected.

  • Page 117: Chas

    CHAS CHAPTER 4 CHASSIS FRONT WHEEL AND BRAKE DISC............... 4-1 REMOVING THE FRONT WHEEL............4-3 CHECKING THE FRONT WHEEL ............4-3 CHECKING THE BRAKE DISC..............4-5 ADJUSTING THE FRONT WHEEL STATIC BALANCE ......4-6 INSTALLING THE FRONT WHEEL ............4-8 REAR WHEEL AND BRAKE DISC..............4-9 REMOVING THE REAR WHEEL ............
  • Page 118 CHAS INSTALLING THE HANDLEBAR ............4-61 STEERING HEAD..................4-64 LOWER BRACKET ................. 4-64 REMOVING THE LOWER BRACKET.............4-66 CHECKING THE STEERING HEAD ............4-67 INSTALLING THE STEERING HEAD .............4-68 REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM....4-69 REMOVING THE REAR SHOCK ABSORBER ASSEMBLIES ....4-71 CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES....

  • Page 119: Front Wheel And Brake Disc

    CHAS FRONT WHEEL AND BRAKE DISC EAS05130 CHASSIS FRONT WHEEL AND BRAKE DISC 9 Nm (0.9 m kg, 6.5 ft • • 59 Nm (5.9 m kg, 43 ft • • 12 Nm (1.2 m kg, 8.7 ft • • Order Job/Part Q’ty...
  • Page 120 CHAS FRONT WHEEL AND BRAKE DISC EAS05130 Order Job/Part Q’ty Remarks Disassembling the front wheel Remove the parts in the order listed. Oil seal Bearing Collar For assembly, reverse the disassembly procedure. 4 - 2...

  • Page 121: Removing The Front Wheel

    CHAS FRONT WHEEL AND BRAKE DISC EAS05200 REMOVING THE FRONT WHEEL 1. Stand the vehicle on a level surface. WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Elevate: • front wheel NOTE: Place the vehicle on a suitable stand so that the front wheel is elevated.
  • Page 122 CHAS FRONT WHEEL AND BRAKE DISC 3. Measure: • radial wheel runout 1 • lateral wheel runout 2 Over the specified limits → Replace. Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in) 4.

  • Page 123: Checking The Brake Disc

    CHAS FRONT WHEEL AND BRAKE DISC EAS05280 CHECKING THE BRAKE DISC 1. Check: • brake disc Damage/galling → Replace. 2. Measure: • brake disc deflection Out of specification → Correct the brake disc deflection or replace the brake disc. Brake disc deflection limit (maxi- mum) Front: 0.10 mm (0.0039 in) Rear: 0.15 mm (0.0059 in)

  • Page 124: Adjusting The Front Wheel Static Balance

    CHAS FRONT WHEEL AND BRAKE DISC 4. Adjust: • brake disc deflection M MMM M MMM M MMM M MMM M MMM a. Remove the brake disc. b. Rotate the brake disc by one bolt hole. c. Install the brake disc. NOTE: •...
  • Page 125 CHAS FRONT WHEEL AND BRAKE DISC M MMM M MMM M MMM M MMM M MMM a. Spin the front wheel. b. When the front wheel stops, put an “X ” mark at the bottom of the wheel. c. Turn the front wheel 90° so that the “X ”...

  • Page 126: Installing The Front Wheel

    CHAS FRONT WHEEL AND BRAKE DISC EAS05420 INSTALLING THE FRONT WHEEL 1. Lubricate: • oil seal lips • speed sensor Recommended lubricant Lithium-soap-based grease 2. Install: • spacer • speed sensor • front wheel NOTE: • Make sure that the speed sensor and the wheel hub are installed with the projection a of the wheel hub inserted in a slot b of the speed sensor.

  • Page 127: Rear Wheel And Brake Disc

    CHAS REAR WHEEL AND BRAKE DISC EAS05520 REAR WHEEL AND BRAKE DISC 9 Nm (0.9 m kg, 6.5 ft • • 23 Nm (2.3 m kg, 17 ft • • Order Job/Part Q’ty Remarks Removing the rear wheel and brake Remove the parts in the order listed.
  • Page 128 CHAS REAR WHEEL AND BRAKE DISC 9 Nm (0.9 m kg, 6.5 ft • • 23 Nm (2.3 m kg, 17 ft • • Order Job/Part Q’ty Remarks Washer Rear brake disc For installation, reverse the removal pro- cedure. 4 - 10...

  • Page 129: Removing The Rear Wheel

    CHAS REAR WHEEL AND BRAKE DISC REMOVING THE REAR WHEEL 1. Stand the vehicle on a level surface. WARNING Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a centerstand so that the rear wheel is elevated.

  • Page 130: Adjusting The Rear Wheel Static Balance

    CHAS REAR WHEEL AND BRAKE DISC EAS05750 ADJUSTING THE REAR WHEEL STATIC BALANCE NOTE: • After replacing the tire, wheel or both, the rear wheel static balance should be adjusted. • Adjust the rear wheel static balance with the brake disc installed. 1.

  • Page 131: Front And Rear Brakes

    CHAS FRONT AND REAR BRAKES EAS05770 FRONT AND REAR BRAKES FRONT BRAKE PADS 23 Nm (2.3 m kg, 17 ft • • 6 Nm (0.6 m kg, 4.3 ft • • 12 Nm (1.2 m kg, 8.7 ft • • Order Job/Part Q’ty...

  • Page 132: Rear Brake Pads

    CHAS FRONT AND REAR BRAKES EAS05780 REAR BRAKE PADS 6 Nm (0.6 m kg, 4.3 ft • • 27 Nm (2.7 m kg, 19 ft • • * Apply silicone grease. 40 Nm (4.0 m kg, 29 ft • • Order Job/Part Q’ty...

  • Page 133: Replacing The Front Brake Pads

    CHAS FRONT AND REAR BRAKES EAS00579 CAUTION: Disc brake components rarely require dis- assembly. Therefore, always follow these preventive measures: • Never disassemble brake components unless absolutely necessary. • If any connection on the hydraulic brake system is disconnected, the entire brake system must be disassembled, drained, cleaned, properly filled, and bled after reassembly.
  • Page 134 CHAS FRONT AND REAR BRAKES 2. Measure: • brake pad wear limit a Out of specifications → Replace the brake pads as a set. Brake pad wear limit 0.5 mm (0.02 in) 3. Install: • brake pad support • brake pad spring •...

  • Page 135: Replacing The Rear Brake Pads

    CHAS FRONT AND REAR BRAKES 5. Check: • brake fluid level Below the minimum level mark a → Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” in chapter 3. 6. Check: • brake lever operation Soft or spongy feeling →...
  • Page 136 CHAS FRONT AND REAR BRAKES 3. Install: • brake pad supports • brake pads (along with the brake pad shims) NOTE: Always install new brake pads, brake pad shims, and a brake pad supports as a set. M MMM M MMM M MMM M MMM M MMM...

  • Page 137: Front Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EAS05840 FRONT BRAKE MASTER CYLINDER 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 23 Nm (2.3 m kg, 17 ft • • Order Job/Part Q’ty Remarks Removing the front brake master Remove the parts in the order listed.
  • Page 138 CHAS FRONT AND REAR BRAKES 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 23 Nm (2.3 m kg, 17 ft • • Order Job/Part Q’ty Remarks Brake hose union bolt Refer to “DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER”...
  • Page 139 CHAS FRONT AND REAR BRAKES ** Apply brake fluid Order Job/Part Q’ty Remarks Disassembling the front brake mas- Remove the parts in the order listed. ter cylinder Brake master cylinder kit Refer to “ASSEMBLING AND INSTALL- ING THE FRONT BRAKE MASTER CYL- INDER”.

  • Page 140: Rear Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EAS05860 REAR BRAKE MASTER CYLINDER 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 23 Nm (2.3 m kg, 17 ft • • Order Job/Part Q’ty Remarks Removing the rear brake master cyl- Remove the parts in the order listed.
  • Page 141 CHAS FRONT AND REAR BRAKES 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 23 Nm (2.3 m kg, 17 ft • • Order Job/Part Q’ty Remarks Rear brake light switch connector Disconnect.

  • Page 142: Disassembling The Rear Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EAS05870 ** Apply brake fluid Order Job/Part Q’ty Remarks Disassembling the rear brake mas- Remove the parts in the order listed. ter cylinder Brake master cylinder kit Refer to “ASSEMBLING AND INSTALL- ING THE REAR BRAKE MASTER CYL- INDER”.
  • Page 143 CHAS FRONT AND REAR BRAKES EAS05880 DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER NOTE: Before disassembling the front brake master cylinder, drain the brake fluid from the entire brake system. 1. Remove: • brake hose union bolt 1 • copper washers 2 •...

  • Page 144: Checking The Front And Rear Brake Master Cylinders

    CHAS FRONT AND REAR BRAKES EAS05920 È É CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS The following procedure applies to both of the brake master cylinders. 1. Check: • brake master cylinder 1 Damage/scratches/wear → Replace. • brake fluid delivery passages (brake master cylinder body) Obstruction →...

  • Page 145: Assembling And Installing The Front Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EAS06000 ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER WARNING • Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. • Never use solvents on internal brake components.
  • Page 146 CHAS FRONT AND REAR BRAKES 3. Install: • copper washers 1 • brake hose 2 • brake hose union bolt 3 23 Nm (2.3 m · kg, 17 ft · lb) WARNING Proper brake hose routing is essential to insure safe vehicle operation. Refer to “CABLE ROUTING”...

  • Page 147: Assembling And Installing The Rear Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES CAUTION: Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 5. Bleed: • brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. 6. Check: •...
  • Page 148 CHAS FRONT AND REAR BRAKES 1. Install: • brake master cylinder kit 1 NOTE: Install the spring with its smaller diameter end towards the circlip and dust boot. 2. Install: • brake master cylinder 1 • brake master cylinder holder 7 Nm (0.7 m ·...
  • Page 149 CHAS FRONT AND REAR BRAKES 4. Fill: • brake master cylinder reservoir (with the specified amount of the recom- mended brake fluid) Recommended brake fluid DOT 4 WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.
  • Page 150 CHAS FRONT AND REAR BRAKES 7. Check: • brake lever operation Soft or spongy feeling → Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. 4 - 32...

  • Page 151: Front Brake Caliper

    CHAS FRONT AND REAR BRAKES EAS06120 FRONT BRAKE CALIPER 6 Nm (0.6 m kg, 4.3 ft • • 23 Nm (2.3 m kg, 17 ft • • 23 Nm (2.3 m kg, 17 ft • • Order Job/Part Q’ty Remarks Removing the front brake caliper Remove the parts in the order listed.
  • Page 152 CHAS FRONT AND REAR BRAKES Apply silicone grease ** Apply brake fluid Order Job/Part Q’ty Remarks Disassembling the front brake cali- Remove the parts in the order listed. Brake pad clip Brake pad pin Brake pad Refer to “ASSEMBLING AND INSTALL- Brake pad support ING THE FRONT BRAKE CALIPER”.
  • Page 153 CHAS FRONT AND REAR BRAKES Apply silicone grease ** Apply brake fluid Order Job/Part Q’ty Remarks Bleed screw/cap Brake caliper body For assembly, reverse the disassembly procedure. 4 - 35...

  • Page 154: Rear Brake Caliper

    CHAS FRONT AND REAR BRAKES EAS06160 REAR BRAKE CALIPER 23 Nm (2.3 m kg, 17 ft • • 6 Nm (0.6 m kg, 4.3 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 40 Nm (4.0 m kg, 29 ft •...

  • Page 155: Disassembling The Rear Brake Caliper

    CHAS FRONT AND REAR BRAKES 6 Nm (0.6 m kg, 4.3 ft • • 27 Nm (2.7 m kg, 19 ft • • Apply silicone grease ** Apply brake fluid Order Job/Part Q’ty Remarks Disassembling the rear brake cali- Remove the parts in the order listed. Rear brake caliper retaining bolt Brake caliper bracket Refer to “ASSEMBLING AND INSTALL-...
  • Page 156 CHAS FRONT AND REAR BRAKES EAS06190 DISASSEMBLING THE FRONT BRAKE CALIPER NOTE: Before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: • brake hose union bolt 1 • copper washers 2 • brake hose 3 •...
  • Page 157 CHAS FRONT AND REAR BRAKES EAS00627 DISASSEMBLING THE REAR BRAKE CALIPER NOTE: Before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: • brake hose union bolt 1 • copper washers 2 • brake hose 3 •...

  • Page 158: Checking The Front And Rear Brake Calipers

    CHAS FRONT AND REAR BRAKES EAS06330 CHECKING THE FRONT AND REAR BRAKE CALIPERS Recommended brake component replacement schedule Brake pads If necessary Dust seals, Piston Every two years seals Brake hose Every four years È Every years and whenever the Brake fluid brake is disassem- bled...

  • Page 159: Assembling And Installing The Front Brake Caliper

    CHAS FRONT AND REAR BRAKES EAS06350 ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPER WARNING • Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. • Never use solvents on internal brake components as they will cause the piston seals to swell and distort.
  • Page 160 CHAS FRONT AND REAR BRAKES 4. Remove: • brake caliper 5. Install: • brake pad support • brake pad spring • brake pads Refer “REPLACING FRONT BRAKE PADS”. 6. Install: • brake caliper • brake caliper bolts 23 Nm (2.3 m · kg, 17 ft · lb) 7.

  • Page 161: Assembling And Installing The Rear Brake Caliper

    CHAS FRONT AND REAR BRAKES 9. Check: • brake fluid level Below the minimum level mark a → Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” in chapter 3. 10.Check: • brake lever operation Soft or spongy feeling →...
  • Page 162 CHAS FRONT AND REAR BRAKES 3. Install: • brake caliper 1 (temporarily) • copper washers 2 • brake hose 3 • brake hose union bolt 4 23 Nm (2.3 m · kg, 17 ft · lb) WARNING Proper brake hose routing is essential to insure safe vehicle operation.
  • Page 163 CHAS FRONT AND REAR BRAKES 7. Fill: • brake master cylinder reservoir (with the specified amount of the recom- mended brake fluid) Recommended brake fluid DOT 4 WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.
  • Page 164 CHAS FRONT AND REAR BRAKES 10.Check: • brake lever operation Soft or spongy feeling → Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. 4 - 46...

  • Page 165: Front Fork

    CHAS FRONT FORK EAS06460 FRONT FORK 22 Nm (2.2 m kg, 16 ft • • 23 Nm (2.3 m kg, 17 ft • • Order Job/Part Q’ty Remarks Removing the front fork legs Remove the parts in the order listed. The following procedure applies to both of the front fork legs.
  • Page 166 CHAS FRONT FORK Order Job/Part Q’ty Remarks Disassembling the front fork legs Remove the parts in the order listed. The following procedure applies to both of the front fork legs. Rubber cap Circlip Front fork cap O-ring Fork spring Refer to “DISASSEMBLING THE Dust seal FRONT FORK LEGS”...
  • Page 167 CHAS FRONT FORK Order Job/Part Q’ty Remarks Inner tube Inner tube bushing Oil flow stopper Refer to “DISASSEMBLING THE Oil seal FRONT FORK LEGS” and “ASSEM- BLING THE FRONT FORK LEGS”. Washer Outer tube bushing Outer tube For assembly, reverse the disassembly procedure.

  • Page 168: Removing The Front Fork Legs

    CHAS FRONT FORK EAS06490 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the vehicle on a level surface. WARNING Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the front wheel is elevated.
  • Page 169 CHAS FRONT FORK 2. Drain: • fork oil NOTE: Stroke the inner tube several times while draining the fork oil. 3. Remove: • dust seal 1 • oil seal clip 2 (with a flat-head screwdriver) CAUTION: Do not scratch the inner tube. 4.

  • Page 170: Checking The Front Fork Legs

    CHAS FRONT FORK 5. Remove: • inner tube M MMM M MMM M MMM M MMM M MMM a. Hold the front fork leg horizontally. b. Securely clamp the brake caliper bracket in a vise with soft jaws. c. Separate the inner tube from the outer tube by pulling the inner tube forcefully but care- fully.

  • Page 171: Assembling The Front Fork Legs

    CHAS FRONT FORK 3. Check: • damper rod 1 Damage/wear → Replace. Obstruction → Blow out all of the oil pas- sages with compressed air. • oil flow stopper 2 Damage → Replace. CAUTION: When disassembling and assembling the front fork leg, do not allow any foreign material to enter the front fork.
  • Page 172 CHAS FRONT FORK 1. Install: • damper rod 1 • rebound spring 2 CAUTION: Allow the damper rod to slide slowly down the inner tube 3 until it protrudes from the bottom of the inner tube. Be careful not to damage the inner tube.
  • Page 173 CHAS FRONT FORK 5. Tighten: • damper rod bolt 1 Damper rod bolt 28 Nm (2.8 m · kg, 20 ft · lb) NOTE: Hold the damper rod with the damper rod holder 2 and T-handle 3, then tighten the damper rod bolt.
  • Page 174 CHAS FRONT FORK 7. Install: • oil seal 1 (with the fork seal driver weight 2 and fork seal driver attachment 3) CAUTION: Make sure the numbered side of the oil seal faces up. Fork seal driver weight 90890-01367 Fork seal driver attachment (ø36) 90890-01370 NOTE: •...
  • Page 175 CHAS FRONT FORK 10.Fill: • front fork leg (with the specified amount of the recom- mended fork oil) Quantity (each front fork leg) 195.0 cm (6.86 Imp oz, 6.59 US oz) Recommended oil Fork oil 15 W or equivalent Front fork leg oil level a (from the top of the inner tube, with the inner tube fully compressed and without the fork spring)

  • Page 176: Installing The Front Fork Legs

    CHAS FRONT FORK EAS06630 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Install: • front fork leg 1 • lower bracket pinch bolts 2 22 Nm (2.2 m · kg, 16 ft · lb) NOTE: Pull up the inner tube until it stops, and then tighten the lower bracket pinch bolts.

  • Page 177: Handlebar

    CHAS HANDLEBAR EAS06640 HANDLEBAR 23 Nm (2.3 m kg, 17 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 26 Nm (2.6 m kg, 19 ft • • 26 Nm (2.6 m kg, 19 ft •...
  • Page 178 CHAS HANDLEBAR 23 Nm (2.3 m kg, 17 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 26 Nm (2.6 m kg, 19 ft • • 26 Nm (2.6 m kg, 19 ft •...

  • Page 179: Removing The Handlebar

    CHAS HANDLEBAR EAS06660 REMOVING THE HANDLEBAR 1. Stand the vehicle on a level surface. WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: • throttle cable housings 1 • throttle cables 2 •...
  • Page 180 CHAS HANDLEBAR 2. Install: • handlebar 1 • upper handlebar holders 2 23 Nm (2.3 m · kg, 17 ft · lb) CAUTION: First, tighten the bolt on the front side of the handlebar holders, and then on the rear side.
  • Page 181 CHAS HANDLEBAR 5 Install: • throttle grip 1 • throttle cables 2 • throttle cable housings 3 NOTE: • Lubricate the inside of the throttle grip with a thin coat of lithium-soap-based grease and install it onto the handlebar. • Align the projection a on the throttle cable housing with the hole b in the handlebar.

  • Page 182: Steering Head

    CHAS STEERING HEAD EAS06750 STEERING HEAD LOWER BRACKET 120 Nm (12.0 m kg, 85 ft • • 75 Nm (7.5 m kg, 54 ft • • 38 Nm (3.8 m kg, 27 ft • • 22 Nm (2.2 m kg, 16 ft •...
  • Page 183 CHAS STEERING HEAD 120 Nm (12.0 m kg, 85 ft • • 75 Nm (7.5 m kg, 54 ft • • 38 Nm (3.8 m kg, 27 ft • • 22 Nm (2.2 m kg, 16 ft • • Order Job/Part Q’ty Remarks...

  • Page 184: Removing The Lower Bracket

    CHAS STEERING HEAD EAS06780 REMOVING THE LOWER BRACKET 1. Stand the vehicle on a level surface. WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: • lower handlebar holder 1 • woodruff key 2 3.

  • Page 185: Checking The Steering Head

    CHAS STEERING HEAD EAS06810 CHECKING THE STEERING HEAD 1. Wash: • bearings • bearing races Recommended cleaning solvent Kerosene 2. Check: • bearings • bearing races Damage/pitting → Replace. 3. Replace: • bearings • bearing races M MMM M MMM M MMM M MMM M MMM...

  • Page 186: Installing The Steering Head

    CHAS STEERING HEAD EAS06840 INSTALLING THE STEERING HEAD 1. Lubricate: • upper bearing • lower bearing • bearing races Recommended lubricant Lithium-soap-based grease 2. Install: • upper bearing WARNING When installing the upper bearing, do not mistake the up and down directions for the upper bearing.

  • Page 187: Rear Shock Absorber Assemblies And Swingarm

    REAR SHOCK ABSORBER ASSEMBLIES AND CHAS SWINGARM EAS06850 REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM 59 Nm (5.9 m kg, 43 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 16 Nm (1.6 m kg, 11 ft • •...
  • Page 188 REAR SHOCK ABSORBER ASSEMBLIES AND CHAS SWINGARM 59 Nm (5.9 m kg, 43 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 16 Nm (1.6 m kg, 11 ft • • 18 Nm (1.8 m kg, 13 ft 135 Nm (13.5 m kg, 98 ft •...

  • Page 189: Removing The Rear Shock Absorber Assemblies

    REAR SHOCK ABSORBER ASSEMBLIES AND CHAS SWINGARM EAS06930 REMOVING THE REAR SHOCK ABSORBER ASSEMBLIES 1. Stand the vehicle on a level surface. WARNING Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a centerstand so that the rear wheel is elevated.

  • Page 190: Installing The Rear Shock Absorber Assemblies

    REAR SHOCK ABSORBER ASSEMBLIES AND CHAS SWINGARM EAS06990 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLIES 1. Install: • rear shock absorber upper nuts 1 32 Nm (3.2 m · kg, 23 ft · lb) • rear shock absorber lower bolts 2 18 Nm (1.8 m ·...

  • Page 191: Checking The Swingarm

    REAR SHOCK ABSORBER ASSEMBLIES AND CHAS SWINGARM EAS07070 CHECKING THE SWINGARM 1. Check: • swingarm Bends/cracks/damage → Replace. 2. Check: • spacer 1 • collar 2 • oil seals 3 • bearing 4 Damage/wear → Replace. EAS07120 INSTALLING THE SWINGARM 1.

  • Page 192: Eng

    CHAPTER 5 ENGINE ENGINE REMOVAL ..................5-1 LEADS, HOSES, EXHAUST PIPE AND MUFFLER .........5-1 ENGINE..................... 5-3 INSTALLING THE ENGINE............... 5-4 CYLINDER HEAD.................... 5-5 REMOVING THE CYLINDER HEAD............5-7 CHECKING THE CYLINDER HEAD ............5-8 CHECKING THE CAMSHAFT SPROCKET..........5-9 CHECKING THE TIMING CHAIN TENSIONER........5-9 INSTALLING THE CYLINDER HEAD ............5-9 CAMSHAFT AND ROCKER ARMS ..............5-13 REMOVING THE ROCKER ARMS AND CAMSHAFT......
  • Page 193 BELT DRIVE....................5-36 V-BELT CASE COVER ................5-36 V-BELT, PRIMARY SHEAVE AND SECONDARY SHEAVE ....5-37 SECONDARY SHEAVE ................5-39 REMOVING THE PRIMARY SHEAVE............5-40 REMOVING THE SECONDARY SHEAVE AND V-BELT .......5-40 DISASSEMBLING THE SECONDARY SHEAVE........5-41 CHECKING THE V-BELT................5-42 CHECKING THE PRIMARY SHEAVE WEIGHTS........5-42 CHECKING THE SECONDARY SHEAVE ..........

  • Page 194: Engine

    ENGINE REMOVAL EAS00188 ENGINE ENGINE REMOVAL LEADS, HOSES, EXHAUST PIPE AND MUFFLER 11 10 40 Nm (4.0 m kg, 29 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 65 Nm (6.5 m kg, 47 ft • •...
  • Page 195 ENGINE REMOVAL 11 10 40 Nm (4.0 m kg, 29 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 65 Nm (6.5 m kg, 47 ft • • 20 Nm (2.0 m kg, 14 ft • • 14 Nm (1.4 m kg, 10 ft •...

  • Page 196: Engine

    ENGINE REMOVAL EAS00191 ENGINE 32 Nm (3.2 m kg, 23 ft • • 59 Nm (5.9 m kg, 43 ft • • 18 Nm (1.8 m kg, 13 ft • • 32 Nm (3.2 m kg, 23 ft • • 64 Nm (6.4 m kg, 46 ft 64 Nm (6.4 m...

  • Page 197: Installing The Engine

    ENGINE REMOVAL EAS00192 INSTALLING THE ENGINE 1. Install: • engine bracket 1 • engine bracket rods 2 NOTE: Engine bracket bolts and rod bolts should be temporarily tightened. 2. Install: • engine 3. Tighten: • engine bracket rod bolts 3 64 Nm (6.4 m ·...

  • Page 198: Cylinder Head

    CYLINDER HEAD EAS00221 CYLINDER HEAD 18 Nm (1.8 m kg, 13 ft • • 8 Nm (0.8 m kg, 5.8 ft • • 22 Nm (2.2 m kg, 16 ft • • 10 Nm (1.0 m kg, 7.2 ft • •...
  • Page 199 CYLINDER HEAD 18 Nm (1.8 m kg, 13 ft • • 8 Nm (0.8 m kg, 5.8 ft • • 22 Nm (2.2 m kg, 16 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft •...

  • Page 200: Removing The Cylinder Head

    CYLINDER HEAD EAS00225 REMOVING THE CYLINDER HEAD 1. Remove: • camshaft sprocket cover • V-belt case air filter cover 2. Align: • “I” mark a on the generator rotor (with the stationary pointer b on the gener- ator cover) M MMM M MMM M MMM M MMM...

  • Page 201: Checking The Cylinder Head

    CYLINDER HEAD EAS00229 CHECKING THE CYLINDER HEAD 1. Eliminate: • combustion chamber carbon deposits (with a rounded scraper) NOTE: Do not use a sharp instrument to avoid damag- ing or scratching: • spark plug bore threads • valve seats 2. Check: •...

  • Page 202: Checking The Camshaft Sprocket

    CYLINDER HEAD EAS00207 CHECKING THE CAMSHAFT SPROCKET 1. Check: • camshaft sprocket More than 1/4 tooth wear a → Replace the camshaft sprocket and the timing chain as a set. a 1/4 tooth b Correct 1 Timing chain roller 2 Camshaft sprocket EAS00210 CHECKING THE TIMING CHAIN TENSIONER...
  • Page 203 CYLINDER HEAD 3. Tighten: • cylinder head nuts 1 22 Nm (2.2 m · kg, 16 ft · lb) • cylinder head bolts 2 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: • Apply engine oil to the threads of the cylinder head nuts.
  • Page 204 CYLINDER HEAD 5. Install: • camshaft sprocket plate 1 • washer 2 • camshaft sprocket bolt 3 6. Install: • timing chain tensioner M MMM M MMM M MMM M MMM M MMM a. Remove the cap bolt 1 and spring 2. b.
  • Page 205 CYLINDER HEAD 9. Tighten: • camshaft sprocket bolt 60 Nm (6.0 m · kg, 43 ft · lb) CAUTION: Be sure to tighten the camshaft sprocket bolt to the specified torque to avoid the possibility of the bolt coming loose and damaging the engine.

  • Page 206: Camshaft And Rocker Arms

    CAMSHAFT AND ROCKER ARMS EAS00195 CAMSHAFT AND ROCKER ARMS 14 Nm (1.4 m kg, 10 ft • • 8 Nm (0.8 m kg, 5.8 ft • • 14 Nm (1.4 m kg, 10 ft • • Order Job/Part Q’ty Remarks Removing the camshaft and rocker Remove the parts in the order listed.

  • Page 207: Removing The Rocker Arms And Camshaft

    CAMSHAFT AND ROCKER ARMS EAS00202 REMOVING THE ROCKER ARMS AND CAMSHAFT 1. Straighten the lock plate tabs a. 2. Remove: • lock plate 1 • camshaft retainer 2 3. Remove: • camshaft 1 NOTE: Screw a 10 mm bolt 2 into the threaded end of the camshaft, and then pull the camshaft out.

  • Page 208: Checking The Rocker Arms And Rocker Arm Shafts

    CAMSHAFT AND ROCKER ARMS 2. Measure: • camshaft lobe dimensions a and b Out of specification → Replace the cam- shaft. Camshaft lobe dimensions Intake a 37.051 ~ 37.151 mm (1.4587 ~ 1.4626 in) <Limit>: 36.956 mm (1.4550 in) b 30.074 ~ 30.174 mm (1.1840 ~ 1.1880 in) <Limit>: 29.973 mm (1.1800 in) Exhaust...
  • Page 209 CAMSHAFT AND ROCKER ARMS 3. Measure: • rocker arm inside diameter Out of specification → Replace. Rocker arm inside diameter 12.000 ~ 12.018 mm (0.4724 ~ 0.4731 in) <Limit>: 12.030 mm (0.4736 in) 4. Measure: • rocker arm shaft outside diameter Out of specification →...

  • Page 210: Installing The Camshaft And Rocker Arms

    CAMSHAFT AND ROCKER ARMS EAS00220 INSTALLING THE CAMSHAFT AND ROCKER ARMS 1. Lubricate: • camshaft Recommended lubricant Camshaft Molybdenum disulfide oil Camshaft bearing Engine oil 2. Lubricate: • rocker arms Recommended lubricant Molybdenum disulfide oil 3. Install: • exhaust rocker arm •...
  • Page 211 CAMSHAFT AND ROCKER ARMS 5. Install: • camshaft 1 6. Install: • camshaft retainer 1 • lock plate 2 • camshaft retainer bolts 3 8 Nm (0.8 m · kg, 5.8 ft · lb) NOTE: Bend the lock plate tab along a flat side of the camshaft retainer bolts 3.

  • Page 212: Valves And Valve Springs

    VALVES AND VALVE SPRINGS EAS00236 VALVES AND VALVE SPRINGS Order Job/Part Q’ty Remarks Removing the valves and valve Remove the parts in the order listed. springs Cylinder head Refer to “CYLINDER HEAD”. Rocker arms and camshaft Refer to “CAMSHAFT AND ROCKER ARMS”.

  • Page 213: Removing The Valves

    VALVES AND VALVE SPRINGS EAS00237 REMOVING THE VALVES The following procedure applies to all of the valves and related components. NOTE: Before removing the internal parts of the cylin- der head (e.g., valves, valve springs, valve seats), make sure the valves properly seal. 1.

  • Page 214: Checking The Valves And Valve Guides

    VALVES AND VALVE SPRINGS 3. Remove: • upper spring seat 1 • outer valve spring 2 • inner valve spring 3 • valve 4 • valve stem seal 5 • lower spring seat 6 NOTE: Identify the position of each part very carefully so that they can be reinstalled in their original place.
  • Page 215 VALVES AND VALVE SPRINGS 2. Replace: • valve guide NOTE: To ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100 °C (212 °F) in an oven. M MMM M MMM M MMM M MMM M MMM a.

  • Page 216: Checking The Valve Seats

    VALVES AND VALVE SPRINGS 5. Measure: • valve margin thickness a Out of specification → Replace the valve. Valve margin thickness Intake 0.80 ~ 1.20 mm (0.0315 ~ 0.0472 in) <Limit> 0.5 mm (0.02 in) Exhaust 0.80 ~ 1.20 mm (0.0315 ~ 0.0472 in) <Limit>...
  • Page 217 VALVES AND VALVE SPRINGS 2. Check: • valve seat Pitting/wear → Replace the cylinder head. 3. Measure: • valve seat width a Out of specification → Replace the cylinder head. Valve seat width Intake 0.90 ~ 1.10 mm (0.0354 ~ 0.0433 in) <Limit>: 1.6 mm (0.06 in) Exhaust 0.90 ~ 1.10 mm...

  • Page 218: Checking The Valve Springs

    VALVES AND VALVE SPRINGS b. Apply molybdenum disulfide oil to the valve stem. c. Install the valve into the cylinder head. d. Turn the valve until the valve face and valve seat are evenly polished, and then clean off all of the lapping compound. NOTE: For the best lapping results, lightly tap the valve seat while rotating the valve back and...

  • Page 219: Installing The Valves

    VALVES AND VALVE SPRINGS 2. Measure: • compressed valve spring force a Out of specification → Replace the valve spring. b Installed length Compressed valve spring force (installed) Intake and exhaust inner valve spring 76 ~ 88 N (7.80 ~ 9.00 kg, 17.20 ~ 19.85 lb) at 30.10 mm (1.19 in) Intake and exhaust outer valve spring...
  • Page 220 VALVES AND VALVE SPRINGS 2. Lubricate: • valve stem 1 • valve stem seal 2 (with the recommended lubricant) Recommended lubricant Molybdenum disulfide oil 3. Install: • lower spring seat 1 • valve stem seal 2 • valve 3 • inner valve spring 4 •...
  • Page 221 VALVES AND VALVE SPRINGS 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft face hammer. CAUTION: Hitting the valve tip with excessive force could damage the valve. 5 - 28...

  • Page 222: Cylinder And Piston

    CYLINDER AND PISTON EAS00251 CYLINDER AND PISTON 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks Removing the cylinder and piston Remove the parts in the order listed. Cylinder head Refer to “CYLINDER HEAD”. Water pump outlet pipe Timing chain guide (exhaust side) Cylinder Cylinder gasket...

  • Page 223: Removing The Piston

    CYLINDER AND PISTON EAS00253 REMOVING THE PISTON 1. Remove: • piston pin clips 1 • piston pin 2 • piston 3 CAUTION: Do not use a hammer to drive the piston pin out. NOTE: • Before removing the piston pin clip, cover the crankcase opening with a clean rag to pre- vent the piston pin clip from falling into the crankcase.
  • Page 224 CYLINDER AND PISTON 2. Measure: • piston-to-cylinder clearance M MMM M MMM M MMM M MMM M MMM a. Measure cylinder bore “C” with the cylinder bore gauge. NOTE: Measure cylinder bore “C” by taking side-to- side and front-to-back measurements of the cylinder.

  • Page 225: Checking The Piston Rings

    CYLINDER AND PISTON f. If out of specification, rebore or replace the cylinder, and replace the piston and piston rings as a set. L LLL L LLL L LLL L LLL L LLL EAS00264 CHECKING THE PISTON RINGS 1. Measure: •...

  • Page 226: Checking The Piston Pin

    CYLINDER AND PISTON 3. Measure: • piston ring end gap Out of specification → Replace the piston ring. NOTE: The end gap of the oil ring expander spacer cannot be measured. If the oil ring rail gap is excessive, replace all three piston rings. Piston ring end gap Top ring 0.15 ~ 0.30 mm...

  • Page 227: Installing The Piston And Cylinder

    CYLINDER AND PISTON 3. Measure: • piston pin bore diameter b (in the piston) Out of specification → Replace the piston pin. Piston pin bore diameter 17.004 ~ 17.015 mm (0.6694 ~ 0.6699 in) <Limit>: 17.045 mm (0.6711 in) 4. Calculate: •...
  • Page 228 CYLINDER AND PISTON 2. Install: • piston 1 • piston pin 2 • piston pin clips 3 NOTE: • Apply engine oil to the piston pin. • Make sure the arrow mark a on the piston points towards the exhaust side of the cylin- der.

  • Page 229: Belt Drive

    BELT DRIVE EAS00316 BELT DRIVE V-BELT CASE COVER 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks Removing the V-belt case cover Remove the parts in the order listed.

  • Page 230: V-Belt, Primary Sheave And Secondary Sheave

    BELT DRIVE V-BELT, PRIMARY SHEAVE AND SECONDARY SHEAVE ® Apply Shell BT grease 3 (YAMAHA grease G 90793-40016) 80 Nm (8.0 m kg, 58 ft • • 22 Nm (2.2 m kg, 16 ft • • 3 Nm (0.3 m kg, 2.2 ft...
  • Page 231 BELT DRIVE ® Apply Shell BT grease 3 (YAMAHA grease G 90793-40016) 80 Nm (8.0 m kg, 58 ft • • 22 Nm (2.2 m kg, 16 ft • • 3 Nm (0.3 m kg, 2.2 ft 60 Nm (6.0 m kg, 43 ft •...

  • Page 232: Secondary Sheave

    BELT DRIVE SECONDARY SHEAVE ® Apply BEL-RAY assembly lube 90 Nm (9.0 m kg, 65 ft • • Order Job/Part Q’ty Remarks Disassembling the secondary Remove the parts in the order listed. sheave Clutch carrier nut Clutch carrier Clutch carrier plate Clutch shoe spring Compression spring Spring seat...

  • Page 233: Removing The Primary Sheave

    BELT DRIVE EAS00317 REMOVING THE PRIMARY SHEAVE 1. Remove: • V-belt case air filter cover • V-belt case cover • V-belt case NOTE: Loosen each V-belt case bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them.

  • Page 234: Disassembling The Secondary Sheave

    BELT DRIVE 2. Loosen: • clutch carrier nut 1 CAUTION: Do not remove the clutch carrier nut at this stage. NOTE: While holding the clutch carrier with the sheave holder 2, loosen the clutch carrier nut one full turn with the locknut wrench 3. Sheave holder 90890-01701 Locknut wrench...

  • Page 235: Checking The V-Belt

    BELT DRIVE EAS00320 CHECKING THE V-BELT 1. Check: • V-belt 1 Cracks/damage/wear → Replace. Grease/oil → Clean the primary and sec- ondary sheaves. 2. Measure: • V-belt width 2 Out of specification → Replace. V-belt width 23.0 mm (0.91 in) <Limit>: 21.0 mm (0.83 in) EAS00321 CHECKING THE PRIMARY SHEAVE...

  • Page 236: Checking The Clutch Shoes

    BELT DRIVE 2. Check: • torque cam groove 1 Damage/wear → Replace the secondary fixed and sliding sheaves as a set. 3. Check: • guide pin 2 Damage/wear → Replace the secondary fixed and sliding sheaves as a set. 4. Check: •...

  • Page 237: Assembling The Primary Sheave

    BELT DRIVE EAS00323 ASSEMBLING THE PRIMARY SHEAVE 1. Clean: • primary fixed sheave 1 • primary sliding sheave 2 • spacer 3 • primary sheave weights 4 • primary sliding sheave cam face 5 2. Install: • primary sheave weights 1 •...

  • Page 238: Assembling The Secondary Sheave

    BELT DRIVE EAS00324 ASSEMBLING THE SECONDARY SHEAVE 1. Lubricate: • secondary fixed sheave’s inner surface 1 • secondary sliding sheave’s inner surface 2 • oil seals (with the recommended lubricant) Recommended lubricant ® BEL-RAY assembly lube 2. Install: • oil seals •...

  • Page 239: Installing The Secondary Sheave, V-Belt, And Primary Sheave

    BELT DRIVE 5. Install: • spring seat • compression spring • clutch carrier 1 • clutch carrier nut 2 NOTE: While compressing the compression spring with the clutch spring holder 3 and clutch spring holder arm 4, install the clutch carrier nut.
  • Page 240 BELT DRIVE 2. Install: • clutch carrier nut 1 90 Nm (9.0 m · kg, 65 ft · lb) NOTE: While holding the clutch carrier with the sheave holder 2, tighten the clutch carrier nut with the locknut wrench 3. Sheave holder 90890-01701 Locknut wrench...
  • Page 241 BELT DRIVE 4. Install: • V-belt • primary fixed sheave 1 • washer • primary sheave nut 2 80 Nm (8.0 m · kg, 58 ft · lb) NOTE: • Install the V-belt onto the primary sheave (when the pulley is at its widest position) and onto the secondary sheave (when the pulley is at its narrowest position), and make sure the V-belt is tight.

  • Page 242: Starter Clutch And Generator

    STARTER CLUTCH AND GENERATOR EAS00341 STARTER CLUTCH AND GENERATOR GENERATOR COVER AND STATOR COIL 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • •...
  • Page 243 STARTER CLUTCH AND GENERATOR 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Stator coil For installation, reverse the removal pro- cedure.

  • Page 244: Starter Clutch

    STARTER CLUTCH AND GENERATOR EAS00342 STARTER CLUTCH 80 Nm (8.0 m kg, 58 ft 30 Nm (3.0 m kg, 22 ft • • • • Order Job/Part Q’ty Remarks Removing the starter clutch Remove the parts in the order listed. Generator rotor Refer to “REMOVING THE GENERA- TOR”, “REMOVING THE STARTER...

  • Page 245: Removing The Generator

    STARTER CLUTCH AND GENERATOR EAS00347 REMOVING THE GENERATOR 1. Remove: • generator cover NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them.

  • Page 246: Removing The Starter Clutch

    STARTER CLUTCH AND GENERATOR EAS00344 REMOVING THE STARTER CLUTCH 1. Remove: • starter clutch bolts 1 NOTE: • While holding the generator rotor 2 with the sheave holder 3, remove the starter clutch bolts. • Do not allow the sheave holder to touch the projection on the generator rotor.

  • Page 247: Installing The Starter Clutch

    STARTER CLUTCH AND GENERATOR EAS00355 INSTALLING THE STARTER CLUTCH 1. Install: • starter clutch bolts 1 30 Nm (3.0 m · kg, 22 ft · lb) NOTE: • While holding the generator rotor 2 with the sheave holder 3, tighten the starter clutch bolts.
  • Page 248 STARTER CLUTCH AND GENERATOR 3. Apply: • sealant (onto the pickup coil/stator assembly lead grommet) Yamaha bond No.1215 90890-85505 5 - 55...

  • Page 249: Oil Pump

    OIL PUMP EAS00357 OIL PUMP 7 Nm (0.7 m kg, 5.1 ft • • 12 Nm (1.2 m kg, 8.7 ft • • Order Job/Part Q’ty Remarks Removing the oil pump assembly Remove the parts in the order listed. Starter clutch gear Refer to “STARTER CLUTCH AND GEN- ERATOR”.
  • Page 250 OIL PUMP 7 Nm (0.7 m kg, 5.1 ft • • 12 Nm (1.2 m kg, 8.7 ft • • Order Job/Part Q’ty Remarks Oil pump outer rotor Oil pump housing For installation, reverse the removal pro- cedure. 5 - 57...

  • Page 251: Checking The Oil Pump

    OIL PUMP EAS00364 CHECKING THE OIL PUMP 1. Check: • oil pump drive gear • oil pump driven gear • oil pump housing • oil pump housing cover Cracks/damage/wear → Replace the defec- tive part(s). 2. Measure: • inner-rotor-to-outer-rotor-tip clearance È •...

  • Page 252: Assembling The Oil Pump

    OIL PUMP EAS00375 ASSEMBLING THE OIL PUMP 1. Lubricate: • inner rotor • outer rotor • oil pump shaft (with the recommended lubricant) Recommended lubricant Engine oil 2. Install: • oil pump shaft 1 • pin 2 NOTE: When installing the pin, align the pin with the groove a in the inner rotor.

  • Page 253: Transmission

    TRANSMISSION TRANSMISSION È É 16 Nm (1.6 m kg, 11 ft • • Order Job/Part Q’ty Remarks Removing the transmission Remove the parts in the order listed. Final transmission oil Drain. Refer to “CHANGING THE FINAL TRANSMISSION OIL” in chapter 3. Rear wheel Refer to “REAR WHEEL AND BRAKE DISC”...
  • Page 254 TRANSMISSION È É 16 Nm (1.6 m kg, 11 ft • • Order Job/Part Q’ty Remarks Conical spring washer Drive axle Main axle Conical spring washer Primary driven gear Washer For installation, reverse the removal pro- cedure. 5 - 61...

  • Page 255: Removing The Transmission

    TRANSMISSION REMOVING THE TRANSMISSION 1. Remove: • transmission case cover NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, removed them. EAS00425 CHECKING THE TRANSMISSION 1.

  • Page 256: Crankshaft

    CRANKSHAFT EAS00381 CRANKSHAFT CRANKSHAFT ASSEMBLY 22 Nm (2.2 m kg, 16 ft • • 32 Nm (3.2 m kg, 23 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 20 Nm (2.0 m kg, 14 ft • •...
  • Page 257 CRANKSHAFT 22 Nm (2.2 m kg, 16 ft • • 32 Nm (3.2 m kg, 23 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 20 Nm (2.0 m kg, 14 ft • • 10 Nm (1.0 m kg, 7.2 ft •...

  • Page 258: Disassembling The Crankcase

    CRANKSHAFT EAS00385 DISASSEMBLING THE CRANKCASE 1. Remove: • crankcase bolts 1 NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Remove: •...

  • Page 259: Checking The Timing Chain And Timing Chain Guide

    CRANKSHAFT 2. Remove: • crankshaft assembly 1 NOTE: • Remove the crankshaft assembly with the crankcase separating tool 2. • Make sure that the crankcase separating tool is centered over the crankshaft. CAUTION: Do not tap on the crankshaft. Crankcase separating tool 90890-01135 EAS00207 CHECKING THE TIMING CHAIN AND...

  • Page 260: Checking The Crankshaft And Connecting Rod

    CRANKSHAFT EAS00394 CHECKING THE CRANKSHAFT AND CONNECTING ROD 1. Measure: • crankshaft runout Out of specification → Replace the crank- shaft. NOTE: Turn the crankshaft slowly. Crankshaft runout 0.030 mm (0.0012 in) 2. Measure: • big end side clearance Out of specification → Replace the crank- shaft.

  • Page 261: Checking The Crankcase

    CRANKSHAFT 5. Check: • crankshaft journal oil passage Obstruction → Blow out with compressed air. EAS00399 CHECKING THE CRANKCASE 1. Thoroughly wash the crankcase halves in a mild solvent. 2. Thoroughly clean all the gasket surfaces and crankcase mating surfaces. 3.
  • Page 262 CRANKSHAFT 3. Install: • crankshaft assembly 1 • left crankcase 2 NOTE: • Install the crankshaft assembly with the crankshaft installer crankshaft installer bolt 4, adapter 5, and spacer 6. • After installing the crankcase, make sure that timing chain is securely meshed with the crankshaft sprocket.

  • Page 263: Assembling The Crankcase

    1. Thoroughly clean all the gasket mating sur- faces and crankcase mating surfaces. 2. Apply: • sealant (onto the crankcase mating surfaces) Yamaha bond No. 1215 90890-85505 NOTE: Do not allow any sealant to come into contact with the oil gallery.

  • Page 264: Cool

    COOL CHAPTER 6 COOLING SYSTEM RADIATOR ...................... 6-1 CHECKING THE RADIATOR..............6-3 INSTALLING THE RADIATOR..............6-3 THERMOSTAT ....................6-4 CHECKING THE THERMOSTAT.............. 6-5 INSTALLING THE THERMOSTAT............6-5 WATER PUMP....................6-6 DISASSEMBLING THE WATER PUMP............ 6-8 CHECKING THE WATER PUMP .............. 6-9 ASSEMBLING THE WATER PUMP............6-9 INSTALLING THE WATER PUMP ............

  • Page 265: Cooling System

    COOL RADIATOR EAS00454 COOLING SYSTEM RADIATOR 6 Nm (0.6 m kg, 4.3 ft • • 30 Nm (3.0 m kg, 22 ft • • 30 Nm (3.0 m kg, 22 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 266 COOL RADIATOR 6 Nm (0.6 m kg, 4.3 ft • • 30 Nm (3.0 m kg, 22 ft • • 30 Nm (3.0 m kg, 22 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Thermo switch connector (auto choke)

  • Page 267: Checking The Radiator

    COOL RADIATOR EAS00455 CHECKING THE RADIATOR 1. Check: • radiator fins Obstruction → Clean. Apply compressed air to the rear of the radi- ator. Damage → Repair or replace. NOTE: Straighten any flattened fins with a thin, flat- head screwdriver. 2.

  • Page 268: Thermostat

    COOL THERMOSTAT EAS00460 THERMOSTAT 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Removing the thermostat Remove the parts in the order listed. Rear side cover (left and right) Refer to “COVERS AND PANELS” in chapter 3. Coolant Drain.

  • Page 269: Checking The Thermostat

    COOL THERMOSTAT EAS00462 CHECKING THE THERMOSTAT 1. Check: • thermostat 1 Does not open at 80.5 ~ 83.5 °C (176.9 ~ 182.3 °F) → Replace. M MMM M MMM M MMM M MMM M MMM a. Suspend the thermostat in a container filled with water.

  • Page 270: Water Pump

    COOL WATER PUMP WATER PUMP 12 Nm (1.2 m kg, 8.7 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • •...
  • Page 271 COOL WATER PUMP 12 Nm (1.2 m kg, 8.7 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks...

  • Page 272: Disassembling The Water Pump

    COOL WATER PUMP EAS00471 DISASSEMBLING THE WATER PUMP 1. Remove: • rubber damper holder 1 • rubber damper 2 (from the impeller with a thin, flathead screwdriver) NOTE: Do not scratch the impeller shaft. 2. Remove: • water pump seal 1 NOTE: Remove the water pump seal from the inside of the water pump housing.

  • Page 273: Checking The Water Pump

    COOL WATER PUMP EAS00474 CHECKING THE WATER PUMP 1. Check: • water pump housing cover • water pump housing • impeller shaft Cracks/damage/wear → Replace. 2. Check: • bearing Rough movement → Replace. 3. Check: • impeller shaft gear Pitting/wear → Replace. 4.
  • Page 274 • Install the water pump seal with the mechan- ical seal installer 2 and middle driven shaft bearing driver 3. • Before installing the water pump seal, apply Yamaha bond No.1215 4 to the water pump housing 5. Mechanical seal installer 90890-04132...

  • Page 275: Installing The Water Pump

    COOL WATER PUMP 4. Measure: • impeller shaft tilt Out of specification → Repeat steps (3) and (4). CAUTION: Make sure the rubber damper and rubber damper holder are flush with the impeller. Impeller shaft tilt limit 0.15 mm (0.0059 in) 1 Straightedge 2 Impeller 5.
  • Page 276 COOL WATER PUMP 2. Install: • water pump 10 Nm (1.0 m · kg, 7.2 ft · lb) 3. Fill: • cooling system (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT” in chapter 3. 4.

  • Page 277: Carb

    CARB CHAPTER 7 CARBURETOR CARBURETOR....................7-1 DISASSEMBLING THE CARBURETOR........... 7-5 CHECKING THE CARBURETOR ............. 7-5 ASSEMBLING THE CARBURETOR............7-6 INSTALLING THE CARBURETOR ............7-7 CHECKING THE AUTO CHOKE UNIT .............7-8 AIR INDUCTION SYSTEM ................7-10 CHECKING THE AIR INDUCTION SYSTEM..........7-11 FUEL TANK....................7-12 REMOVING THE FUEL SENDER............

  • Page 278: Carburetor

    CARB CARBURETOR CARBURETOR CARBURETOR 11 Nm (1.1 m kg, 8.0 ft • • 2 Nm (0.2 m kg, 1.4 ft • • 2 Nm (0.2 m kg, 1.4 ft • • Order Job/Part Q’ty Remarks Removing the carburetor Remove the parts in the order listed. Storage box/footrest board Refer to “COVERS AND PANELS”...
  • Page 279 CARB CARBURETOR 11 Nm (1.1 m kg, 8.0 ft • • 2 Nm (0.2 m kg, 1.4 ft • • 2 Nm (0.2 m kg, 1.4 ft • • Order Job/Part Q’ty Remarks Carburetor Refer to “INSTALLING THE CARBURE- TOR” For installation, reverse the removal pro- cedure.
  • Page 280 CARB CARBURETOR EAS00483 Order Job/Part Q’ty Remarks Disassembling the carburetor Remove the parts in the order listed. Coolant hose joint Auto choke unit Pilot screw Vacuum chamber cover Piston valve spring Piston valve Jet needle Coasting enricher assembly Float chamber Float pin Float Needle valve...
  • Page 281 CARB CARBURETOR Order Job/Part Q’ty Remarks Needle jet holder Needle jet Pilot jet Accelerator pump assembly Fuel drain screw For assembly, reverse the disassembly procedure. 7 - 4...

  • Page 282: Disassembling The Carburetor

    CARB CARBURETOR DISASSEMBLING THE CARBURETOR 1. Remove: • float pin 1 • needle valve 2 • float 3 NOTE: Remove the float pin in the direction of the arrow. EAS00485 CHECKING THE CARBURETOR 1. Check: • carburetor body • float chamber •...

  • Page 283: Assembling The Carburetor

    CARB CARBURETOR 8. Check: • jet needle 1 • main jet 2 • needle jet holder 3 • pilot jet 4 • pilot screw 5 • needle jet 6 Bends/damage/wear → Replace. Obstruction → Clean. Blow out the jets with compressed air. 9.

  • Page 284: Installing The Carburetor

    CARB CARBURETOR b. Measure the distance from the front mating surface of the float chamber (gasket removed) to the top of the float. NOTE: The float arm should be resting on the needle valve, but not compressing it. c. If the float height is not within the specifica- tion, check the needle valve.

  • Page 285: Checking The Auto Choke Unit

    CARB CARBURETOR 2. Adjust: • engine idling speed Engine idling speed 1,550 ~ 1,650 r/min Refer “ADJUSTING ENGINE IDLING SPEED” in chapter 3. 3. Adjust: • throttle cable free play Throttle cable free play (at the flange of the throttle grip) 4.0 ~ 6.0 mm (0.16 ~ 0.24 in) Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY”...
  • Page 286 CARB CARBURETOR 3. Check: • auto choke unit (with battery) M MMM M MMM M MMM M MMM M MMM a. Connect the auto choke unit lead to a 12.0 V battery for five minutes. Positive battery lead → yellow 1 Negative battery lead →...

  • Page 287: Air Induction System

    CARB AIR INDUCTION SYSTEM AIR INDUCTION SYSTEM 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 • • Order Job/Part Q’ty Remarks Removing the air cut-off valve Remove the parts in the order listed.

  • Page 288: Checking The Air Induction System

    CARB AIR INDUCTION SYSTEM EAS00510 CHECKING THE AIR INDUCTION SYSTEM 1. Check: • hoses Loose connection → Connect properly. Cracks/damage → Replace. • pipe Cracks/damage → Replace. 2. Check: • air cut-off valve Cracks/damage → Replace. 3. Check: • air cut-off valve operation Does not operate →...

  • Page 289: Fuel Tank

    CARB FUEL TANK FUEL TANK 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks Removing the fuel tank Remove the parts in the order listed. Storage box/under cover Refer to “COVERS AND PANELS”...
  • Page 290 CARB FUEL TANK 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks Fuel sender Refer to “REMOVING THE FUEL SENDER” and “INSTALLING THE FUEL SENDER”. For installation, reverse the removal pro- cedure.

  • Page 291: Removing The Fuel Sender

    CARB FUEL TANK REMOVING THE FUEL SENDER 1. Remove: • fuel sender 1 NOTE: Remove the fuel sender using the fuel sender removal tool 2. Fuel sender removal tool 90890-11098 EAS00504 CHECKING THE FUEL PUMP 1. Check: • fuel pump 1 M MMM M MMM M MMM...

  • Page 292: Installing The Fuel Sender

    CARB FUEL TANK INSTALLING THE FUEL SENDER 1. Install: • fuel sender 1 NOTE: • Install the fuel sender using the fuel sender removal tool. • Lubricate the gasket with lithium-soap-based grease. • Position the fuel sender coupler a as shown in the illustration.

  • Page 293: Elec

    – ELEC CHAPTER 8 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS................ 8-1 CHECKING SWITCH CONTINUITY..............8-2 CHECKING THE SWITCHES................8-3 CHECKING THE BULBS AND BULB SOCKETS .......... 8-4 TYPES OF BULBS ..................8-4 CHECKING THE CONDITION OF THE BULBS ........8-5 CHECKING THE CONDITION OF THE BULB SOCKETS .......8-6 IGNITION SYSTEM ..................
  • Page 294 – ELEC FUEL PUMP SYSTEM...................8-47 CIRCUIT DIAGRAM ................8-47 FUEL PUMP CIRCUIT OPERATION ............8-48 TROUBLESHOOTING ................8-49 AUTO CHOKE SYSTEM ................8-51 CIRCUIT DIAGRAM ................8-51 TROUBLESHOOTING ................8-52 IMMOBILIZER SYSTEM................8-55 SYSTEM DIAGRAM ................8-55 CIRCUIT DIAGRAM ................8-56 GENERAL INFORMATION ..............8-57 KEY CODE REGISTRATION ..............

  • Page 295: Electrical System

    – ELEC ELECTRICAL COMPONENTS EAS07290 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS 1 CDI unit 8 Main fuse E Horn 2 Turn signal relay 9 Coolant temperature sensor F Rectifier/regulator 3 immobilizer antenna 0 Pickup coil/stator assembly G Starting circuit cut-off relay 4 Main switch A Spark plug cap H Fuel pump relay 5 Air temperature sensor...

  • Page 296: Checking Switch Continuity

    – ELEC CHECKING SWITCH CONTINUITY EAS00730 CHECKING SWITCH CONTINUITY Check each switch for continuity with the pocket tester. If the continuity reading is incor- rect, check the wiring connections and if nec- essary, replace the switch. CAUTION: Never insert the tester probes into the cou- pler terminal slots a.

  • Page 297: Checking The Switches

    – ELEC CHECKING THE SWITCHES EAS00731 CHECKING THE SWITCHES Check each switch for damage or wear, proper connections, and also for continuity between the ter- minals. Refer to “CHECKING SWITCH CONTINUITY”. Damage/wear → Repair or replace. Improperly connected → Properly connect. Incorrect continuity reading →...

  • Page 298: Checking The Bulbs And Bulb Sockets

    – ELEC CHECKING THE BULBS AND BULB SOCKETS EAS00733 CHECKING THE BULBS AND BULB SOCKETS NOTE: Do not check any of the lights that use LEDs. Check each bulb and bulb socket for damage or wear, proper connections, and also for con- tinuity between the terminals.

  • Page 299: Checking The Condition Of The Bulbs

    – ELEC CHECKING THE BULBS AND BULB SOCKETS CHECKING THE CONDITION OF THE BULBS The following procedure applies to all of the bulbs. 1. Remove: • bulb WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down.

  • Page 300: Checking The Condition Of The Bulb Sockets

    – ELEC CHECKING THE BULBS AND BULB SOCKETS CHECKING THE CONDITION OF THE BULB SOCKETS The following procedure applies to all of the bulb sockets. 1. Check: • bulb socket (for continuity) (with the pocket tester) No continuity → Replace. Pocket tester 90890-03112 NOTE:...

  • Page 301: Ignition System

    – ELEC IGNITION SYSTEM EAS00734 IGNITION SYSTEM CIRCUIT DIAGRAM 8 - 7...

  • Page 302: Troubleshooting

    – ELEC IGNITION SYSTEM EAS00736 EAS00739 TROUBLESHOOTING 2. Battery The ignition system fails to operate (no • Check the condition of the battery. spark or intermittent spark). Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: 1. main, ignition, and CDI unit fuses Minimum open-circuit voltage 2.
  • Page 303 – ELEC IGNITION SYSTEM EAS00742 EAS00744 4. Ignition spark gap 5. Spark plug cap resistance • Disconnect the spark plug cap from the • Remove the spark plug cap from the spark spark plug. plug lead. • Connect the pocket tester (“Ω × 1k” range) •...
  • Page 304 – ELEC IGNITION SYSTEM EAS00746 EAS00748 6. Ignition coil resistance 7. Pickup coil resistance • Disconnect the ignition coil connectors • Disconnect the pickup coil coupler from from the ignition coil terminals. the wire harness. • Connect the pocket tester (Ω × 1) to the •...
  • Page 305 – ELEC IGNITION SYSTEM EAS00752 9. Sidestand switch • Check the sidestand switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the sidestand switch OK? Replace side- stand switch. EAS00754 10.Wiring • Check the entire ignition system wiring. Refer to “CIRCUIT DIAGRAM”. •...

  • Page 306: Electric Starting System

    – ELEC ELECTRIC STARTING SYSTEM EAS00755 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM 8 - 12...

  • Page 307: Starting Circuit Cut-Off System Operation

    – ELEC ELECTRIC STARTING SYSTEM EAS00756 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the main switch is set to “ON” (switch is closed), the starter motor can only operate if the following conditions are met: • A brake lever is pulled to the handlebar (the brake light switch is closed) and the side- stand is up (the sidestand switch is closed).

  • Page 308: Troubleshooting

    – ELEC ELECTRIC STARTING SYSTEM EAS00757 EAS00739 TROUBLESHOOTING 2. Battery The starter motor fails to turn. • Check the condition of the battery. Refer to “CHECKING AND CHARGING Check: THE BATTERY” in chapter 3. 1. main, ignition, and signaling system fuses 2.
  • Page 309 – ELEC ELECTRIC STARTING SYSTEM EAS00759 EAS00761 4. Starting circuit cut-off relay 5. Starter relay • Remove the starting circuit cut-off relay. • Remove the starter relay. • Connect the pocket tester (Ω × 1) and bat- • Connect the pocket tester (Ω × 1) and bat- tery (12 V) to the starting circuit cut-off tery (12 V) to the starter relay terminal as relay terminals as shown.
  • Page 310 – ELEC ELECTRIC STARTING SYSTEM EAS00751 EAS00766 7. Brake light switch (front and rear) 10.Wiring • Check the brake light switches for continu- • Check the entire starting system wiring. ity. Refer to “CIRCUIT DIAGRAM”. Refer to “CHECKING THE SWITCHES”. •...

  • Page 311: Starter Motor

    – ELEC ELECTRIC STARTING SYSTEM STARTER MOTOR 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 5 Nm (0.5 m kg, 3.6 ft • • Order Job/Part Q’ty Remarks Removing the starter motor Remove the parts in the order listed.
  • Page 312 – ELEC ELECTRIC STARTING SYSTEM 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 5 Nm (0.5 m kg, 3.6 ft • • Order Job/Part Q’ty Remarks Disassembling the starter motor Remove the parts in the order listed.

  • Page 313: Checking The Starter Motor

    – ELEC ELECTRIC STARTING SYSTEM EAS00770 CHECKING THE STARTER MOTOR 1. Check: • commutator Dirt → Clean with 600 grit sandpaper. 2. Measure: • commutator diameter a Out of specification → Replace the starter motor. Commutator wear limit 27 mm (1.06 in) 3.

  • Page 314: Assembling The Starter Motor

    – ELEC ELECTRIC STARTING SYSTEM 5. Measure: • brush length a Out of specification → Replace the brushes as a set. Brush length wear limit 4.0 mm (0.16 in) 6. Measure: • brush spring force Out of specification → Replace the brush springs as a set.

  • Page 315: Charging System

    – ELEC CHARGING SYSTEM EAS00773 CHARGING SYSTEM CIRCUIT DIAGRAM 8 - 21...

  • Page 316: Troubleshooting

    – ELEC CHARGING SYSTEM EAS00774 EAS00739 TROUBLESHOOTING 2. Battery The battery is not being charged. • Check the condition of the battery. Refer to “CHECKING AND CHARGING Check: THE BATTERY” in chapter 3. 1. main fuse 2. battery Minimum open-circuit voltage 3.
  • Page 317 – ELEC CHARGING SYSTEM EAS00775 EAS00776 3. Charging voltage 4. Stator coil resistance • Connect the pocket tester (DC 20 V) to the • Disconnect the stator coil coupler from the battery as shown. wire harness. • Connect the pocket tester (Ω × 1) to the Positive tester probe →...

  • Page 318: Lighting System

    – ELEC LIGHTING SYSTEM EAS00780 LIGHTING SYSTEM CIRCUIT DIAGRAM 8 - 24...

  • Page 319: Troubleshooting

    – ELEC LIGHTING SYSTEM EAS00781 EAS00739 TROUBLESHOOTING 2. Battery Any of the following fail to light: head- • Check the condition of the battery. lights, high beam indicator light, taillight, Refer to “CHECKING AND CHARGING license plate light, auxiliary lights or THE BATTERY”...
  • Page 320 – ELEC LIGHTING SYSTEM EAS00752 EAS00787 5. Sidestand switch 7. Wiring • Check the sidestand switch for continuity. • Check the entire lighting system wiring. Refer to “CHECKING THE SWITCHES”. Refer to “CIRCUIT DIAGRAM”. • Is the sidestand switch OK? •...

  • Page 321: Checking The Lighting System

    – ELEC LIGHTING SYSTEM EAS00788 High beam indicator light CHECKING THE LIGHTING SYSTEM Positive tester probe → yellow 4 1. The headlights and the high beam indicator Negative tester probe → black 5 light fail to come on. Meter assembly coupler 1.
  • Page 322 – ELEC LIGHTING SYSTEM EAS00789 2. Voltage 2. The meter light fails to come on. • Connect the pocket tester (DC 20 V) to the 1. Voltage tail/brake light assembly coupler (wire har- • Connect the pocket tester (DC 20 V) to the ness side) as shown.
  • Page 323 – ELEC LIGHTING SYSTEM EAS00791 EAS00792 4. The auxiliary lights fail to come on. 5. The license plate light fails to come on. 1. Auxiliary light bulb and socket 1. License plate light bulb and socket • Check the auxiliary light bulb and socket •...

  • Page 324: Signaling System

    – ELEC SIGNALING SYSTEM EAS00793 SIGNALING SYSTEM CIRCUIT DIAGRAM 8 - 30...
  • Page 325 – ELEC SIGNALING SYSTEM 5 Backup fuse (meter assembly) 6 Main switch 0 Signaling system fuse A Ground lead B Battery C Main fuse K Fuel sender N Hazard switch Z Rear brake light switch [ Front brake light switch \ Turn signal/hazard relay ] Horn c Horn switch...

  • Page 326: Troubleshooting

    – ELEC SIGNALING SYSTEM EAS00794 EAS00739 TROUBLESHOOTING 2. Battery • Any of the following fail to light: turn • Check the condition of the battery. signal light, brake light or an indicator Refer to “CHECKING AND CHARGING light. THE BATTERY” in chapter 3. •...

  • Page 327: Checking The Signaling System

    – ELEC SIGNALING SYSTEM EAS00796 3. Horn CHECKING THE SIGNALING SYSTEM 1. The horn fails to sound. • Disconnect the pink connector at the horn terminal. 1. Horn switch • Connect a jumper lead 1 to the horn ter- • Check the horn switch for continuity. minal and ground the jumper lead.
  • Page 328 – ELEC SIGNALING SYSTEM EAS00797 3. Voltage 2. The tail/brake light fails to come on. • Connect the pocket tester (DC 20 V) to the 1. Tail/brake light bulbs and sockets tail/brake light assembly coupler (wire har- • Check the tail/brake light bulbs and sock- ness side) as shown.
  • Page 329 – ELEC SIGNALING SYSTEM EAS00799 4. Voltage 3. The turn signal light, turn signal indicator light or both fail to blink. • Connect the pocket tester (DC 20 V) to the turn signal/hazard relay coupler as shown. 1. Turn signal light bulbs and sockets Turn signal function •...
  • Page 330 – ELEC SIGNALING SYSTEM 5. Voltage Hazard function • Set the main switch to “ON”. • Connect the pocket tester (DC 20 V) to the • Set the hazard switch to “ ”. turn signal/hazard relay coupler as shown. • Measure the voltage (DC 12 V) on choco- Turn signal function late 1 at the turn signal/hazard relay cou- Left turn signal light...
  • Page 331 – ELEC SIGNALING SYSTEM 6. Voltage • Set the main switch to “ON”. • Set the turn signal switch to “ ” or “ ”. • Connect the pocket tester (DC 20 V) to the • Measure the voltage (DC 12 V) of the turn signal light assembly coupler or meter chocolate 1 or dark green 2 at the turn assembly coupler as shown.
  • Page 332 – ELEC SIGNALING SYSTEM EAS00806 2. Voltage 4. The speedometer fails to operate. • Connect the pocket tester (DC 20 V) to the 1. Speed sensor meter assembly coupler as shown. • Connect the pocket tester (DC 20 V) to the Positive tester probe →...
  • Page 333 – ELEC SIGNALING SYSTEM EAS00804 2. Voltage 5. The fuel level gauge fails to operate. • Connect the pocket tester (DC 20 V) to the 1. Fuel sender meter assembly coupler as shown. • Remove the fuel sender from the fuel tank. Positive tester probe →...
  • Page 334 – ELEC SIGNALING SYSTEM EAS00804 2. Voltage 6. The ambient temperature display fails to operate. • Connect the pocket tester (DC 20 V) to the meter assembly coupler as shown. 1. Air temperature sensor Positive tester probe → brown 1 •...
  • Page 335 – ELEC SIGNALING SYSTEM 7. Coolant temperature gauge fails to operate. EAS00812 1. Coolant temperature sensor • Remove the coolant temperature sensor from the cylinder head. • Connect the pocket tester (Ω × 10k) to the coolant temperature sensor 1 as shown. •...
  • Page 336 – ELEC SIGNALING SYSTEM 2. Voltage • Connect the pocket tester (DC 20 V) to the meter assembly coupler as shown. Positive tester probe → brown 1 Negative tester probe → black 2 Br/G Br/G Gy/R Gy/B Gy Br • Set the main switch to “ON”. •...

  • Page 337: Cooling System

    – ELEC COOLING SYSTEM EAS00807 COOLING SYSTEM CIRCUIT DIAGRAM 8 - 43...

  • Page 338: Troubleshooting

    – ELEC COOLING SYSTEM EAS00808 EAS00739 TROUBLESHOOTING 2. Battery The radiator fan motor fails to turn. • Check the condition of the battery. Refer to “CHECKING AND CHARGING Check: THE BATTERY” in chapter 3. 1. main, ignition, and radiator fan motor fuses 2.
  • Page 339 – ELEC COOLING SYSTEM EAS00809 5. Radiator fan motor relay 4. Radiator fan motor • Remove the radiator fan motor relay. • Connect the pocket tester (Ω × 1) and bat- • Disconnect the radiator fan motor coupler from the wire harness. tery (12 V) to the radiator fan motor terminal •...
  • Page 340 – ELEC COOLING SYSTEM EAS00811 WARNING 6. Thermo switch (radiator fan motor) • Handle the thermo switch with special • Remove the thermo switch (radiator fan care. motor) from the radiator. • Never subject the thermo switch to • Connect the pocket tester (Ω × 1) to the strong shocks.

  • Page 341: Fuel Pump System

    – ELEC FUEL PUMP SYSTEM EAS00814 FUEL PUMP SYSTEM CIRCUIT DIAGRAM 8 - 47...

  • Page 342: Fuel Pump Circuit Operation

    – ELEC FUEL PUMP SYSTEM EB808010 FUEL PUMP CIRCUIT OPERATION The fuel pump circuit consists of the fuel pump 1 Battery 2 Main fuse relay, fuel pump, and CDI unit. 3 Main switch The CDI unit includes the control unit for the 4 Ignition fuse fuel pump.

  • Page 343: Troubleshooting

    – ELEC FUEL PUMP SYSTEM EAS00816 EAS00739 TROUBLESHOOTING 2. Battery The fuel pump fails to operate. • Check the condition of the battery. Refer to “CHECKING AND CHARGING Check: THE BATTERY” in chapter 3. 1. main, ignition, and CDI unit fuses 2.
  • Page 344 – ELEC FUEL PUMP SYSTEM EAS00759 EAS00817 4. Fuel pump relay 5. Fuel pump operation • Remove the fuel pump relay. • Check the fuel pump operation. • Connect the pocket tester (Ω × 1) and bat- Refer to “CHECKING THE FUEL PUMP” tery (12 V) to the fuel pump relay terminals in chapter 7.

  • Page 345: Auto Choke System

    – ELEC AUTO CHOKE SYSTEM EAS00820 AUTO CHOKE SYSTEM CIRCUIT DIAGRAM 8 - 51...

  • Page 346: Troubleshooting

    – ELEC AUTO CHOKE SYSTEM EAS00821 EAS00739 TROUBLESHOOTING 2. Battery The auto choke system fails to operate. • Check the condition of the battery. Refer to “CHECKING AND CHARGING Check: THE BATTERY” in chapter 3. 1. main and ignition fuses 2.
  • Page 347 – ELEC AUTO CHOKE SYSTEM 4. Thermo switch (auto choke) WARNING • Remove the thermo switch (auto choke) • Handle the thermo switch with special from the radiator. care. • Connect the pocket tester (Ω × 1) to the • Never subject the thermo switch to thermo switch 1 as shown.
  • Page 348 – ELEC AUTO CHOKE SYSTEM EAS00825 5. Auto choke unit • Remove the auto choke unit coupler from the wire harness. • Connect the pocket tester (Ω × 10) to the auto choke unit coupler as shown. Tester positive probe → green/black 1 Tester negative probe →...

  • Page 349: Immobilizer System

    – ELEC IMMOBILIZER SYSTEM IMMOBILIZER SYSTEM SYSTEM DIAGRAM 1 CDI unit 2 Main switch and immobilizer antenna 3 Immobilizer system indicator light Main switch R ..Red Br/L Br/L . . . Brown/Blue CDI unit fuse G/L .

  • Page 350: Circuit Diagram

    – ELEC IMMOBILIZER SYSTEM CIRCUIT DIAGRAM 8 - 56...

  • Page 351: General Information

    – ELEC IMMOBILIZER SYSTEM GENERAL INFORMATION This vehicle is equipped with an immobilizer system to help prevent theft by registering codes in standard keys. This system consists of the following: • a code re-registering key (with a red bow) • two standard keys (with black bows) that can be re-registered with new codes •...

  • Page 352: Key Code Registration

    – ELEC IMMOBILIZER SYSTEM KEY CODE REGISTRATION Code registration of the code re-registering key or standard keys may be required when CDI is replaced or a standard key is lost. NOTE: Each standard key is registered during production, therefore, registering the keys at purchase is not necessary.
  • Page 353 – ELEC IMMOBILIZER SYSTEM 2. Using the code re-registering key, turn the main switch to “ON”, then to “OFF”, and then remove the key within 3 seconds. NOTE: All existing standard key codes will be erased from the memory when the key registration mode is activated.
  • Page 354 – ELEC IMMOBILIZER SYSTEM Voiding a standard key code: If a registered standard key has been lost and you want to disable its use, register a new standard key or re-register the other standard key. For registration of a standard key, refer to “Standard key registration:”.

  • Page 355: Self-Diagnosis Malfunction Codes

    – ELEC IMMOBILIZER SYSTEM SELF-DIAGNOSIS MALFUNCTION CODES When a system malfunction occurs, the malfunction code number is signaled by the immobilizer system indicator light flash patterns. Malfunc- Immobilizer system Malfunctioning Symptom Cause Action tion code condition part Engine cannot start. CDI unit is not recev- Key malfunction Replace the standard...

  • Page 356: Troubleshooting

    – ELEC IMMOBILIZER SYSTEM EAS00794 EAS00739 TROUBLESHOOTING 2. Battery When the main switch is turned “ON”, • Check the condition of the battery. the immobilizer system indicator light Refer to “CHECKING AND CHARGING does not come on or flash. THE BATTERY” in chapter 3. Check: Minimum open-circuit voltage 1.

  • Page 357: Checking The Immobilizer System

    – ELEC IMMOBILIZER SYSTEM EAS00788 CHECKING THE IMMOBILIZER SYSTEM 1. The immobilizer system indicator light does not come on. 1. Voltage • Connect the pocket tester (DC 20 V) to the meter assembly coupler as shown. B Dg Br/G Br/G Gy/R Gy/B Gy Br...
  • Page 358 – ELEC IMMOBILIZER SYSTEM 2. When the main switch is turned to “ON”, the immobilizer system indicator light flashes. • Check if a metal object or other immobilizer system keys are placed near the immobilizer antenna. If so, remove the objects or keys, and then check the condition again. Turn the main switch to “ON”...

  • Page 359: Part Replacement Key Registration Requirements

    – ELEC IMMOBILIZER SYSTEM PART REPLACEMENT KEY REGISTRATION REQUIREMENTS Parts to be replaced Required key Accessory Main Standard registration lock immobilizer switch unit antenna Standard key is lost New standard key All keys have been lost Code re-registering (including code re-reg- key and standard keys istering key) CDI unit is defective...

  • Page 360: Trbl Shtg

    TRBL SHTG CHAPTER 9 TROUBLESHOOTING STARTING FAILURE/HARD STARTING ............9-1 ENGINE..................... 9-1 FUEL SYSTEM..................9-1 ELECTRICAL SYSTEMS ................9-2 INCORRECT ENGINE IDLING SPEED............9-2 ENGINE..................... 9-2 FUEL SYSTEM..................9-2 ELECTRICAL SYSTEMS ................9-2 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE .........9-3 ENGINE..................... 9-3 FUEL SYSTEM..................9-3 FAULTY CLUTCH ................... 9-3 ENGINE OPERATES BUT VEHICLE WILL NOT MOVE ......
  • Page 361 TRBL SHTG FAULTY LIGHTING OR SIGNALING SYSTEM..........9-5 HEADLIGHT DOES NOT COME ON ............9-5 HEADLIGHT BULB BURNT OUT.............. 9-5 TAIL/BRAKE LIGHT DOES NOT COME ON ..........9-5 TAIL/BRAKE LIGHT BULB BURNT OUT..........9-5 TURN SIGNAL DOES NOT COME ON ............ 9-5 TURN SIGNAL FLASHES SLOWLY ............9-5 TURN SIGNAL REMAINS LIT..............9-5 TURN SIGNAL FLASHES QUICKLY ............9-5 HORN DOES NOT SOUND ..............

  • Page 362: Troubleshooting

    TRBL STARTING FAILURE/HARD STARTING SHTG EAS00845 TROUBLESHOOTING NOTE: The following guide for troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this man- ual for checks, adjustments, and replacement of parts.

  • Page 363: Electrical Systems

    STARTING FAILURE/HARD STARTING/ TRBL INCORRECT ENGINE IDLING SPEED SHTG ELECTRICAL SYSTEMS Battery Ignition system • Discharged battery • Faulty CDI unit • Faulty battery • Faulty pickup coil Fuse(s) • Broken generator rotor woodruff key • Blown, damaged or incorrect fuse Switches and wiring •...

  • Page 364: Poor Medium-And-High-Speed Performance

    POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE/ TRBL FAULTY CLUTCH SHTG EAS00849 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE Refer to “STARTING FAILURE/HARD STARTING”. ENGINE FUEL SYSTEM Air filter Carburetor • Clogged air filter element • Faulty diaphragm Air intake system • Incorrect fuel level • Bent, clogged or disconnected carburetor •...

  • Page 365: Overheating

    OVERHEATING/OVERCOOLING/ TRBL POOR BRAKING PERFORMANCE SHTG EAS00855 OVERHEATING ENGINE FUEL SYSTEM Clogged coolant passages Carburetor • Cylinder head and piston • Incorrect main jet setting • Heavy carbon buildup • Incorrect fuel level Engine oil • Damaged or loose carburetor joint •...

  • Page 366: Faulty Front Fork Legs

    FAULTY FRONT FORK LEGS/ TRBL FAULTY LIGHTING OR SIGNALING SYSTEM SHTG EAS00860 FAULTY FRONT FORK LEGS LEAKING OIL MALFUNCTION • Bent, damaged or rusty inner tube • Bent or damaged inner tube • Cracked or damaged outer tube • Bent or damaged outer tube •...
  • Page 367 YP250R 2005 WIRING DIAGRAM 1 AC magneto j Front turn signal light (right) COLOR CODE 2 Pickup coil k Front turn signal light (left) B ....Black 3 Rectifier/regulator l License plate light Br ...Brown 4 CDI unit fuse m Headlight assembly Ch ..Chocolate...
  • Page 368 YAMAHA MOTOR ESPAÑA, S.A.
  • Page 369 YP250R 2005 YP250R 2005 YP250R 2005 YP250R 2005 YP250R 2005 WIRING DIAGRAM SCHALTPLAN DIAGRAMA ELÉCTRICO SCHÉMA DE CÂBLAGE SCHEMA ELETTRICO W/L W/R (BLUE) (GREEN) Ch P/W P/W R/L Dg W W W (BLACK) å (BLACK) Sb O/W G/W G/W (BLACK)
  • Page 370 YP250R 2005 YP250R 2005 YP250R 2005 YP250R 2005 YP250R 2005 WIRING DIAGRAM SCHALTPLAN DIAGRAMA ELÉCTRICO SCHÉMA DE CÂBLAGE SCHEMA ELETTRICO (BLUE) (GREEN) (BLACK) å (BLACK) (BLACK) (BLACK) (BLACK) (BLACK) (WHITE) (BLUE) (BLUE) (GREEN) (WHITE) (GREEN) (RED) (BLACK) v w x...

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