Page 1 2011 SERVICE MANUAL YFM125RA LIT-11616-24-36 2PA-28197-10...
Page 2 EAS20050 YFM125RA SERVICE MANUAL ©2010 by Yamaha Motor Corporation, U.S.A. First edition, May 2010 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. P/N LIT-11616-24-36...
Page 3 If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives.
Page 4 EAS20091 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. •...
Page 5 EAS30370 SYMBOLS The following symbols are used in this manual for easier understanding. The following symbols are not relevant to every vehicle. SYMBOL DEFINITION SYMBOL DEFINITION Serviceable with engine Gear oil mounted Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque...
Page 7: Table Of Contents
EAS20110 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING...
Page 9: General Information
GENERAL INFORMATION IDENTIFICATION ..................1-1 VEHICLE IDENTIFICATION NUMBER...........1-1 MODEL LABEL ..................1-1 IMPORTANT INFORMATION ...............1-2 PREPARATION FOR REMOVAL AND DISASSEMBLY......1-2 REPLACEMENT PARTS.................1-2 GASKETS, OIL SEALS AND O-RINGS..........1-2 LOCK WASHERS/PLATES AND COTTER PINS ........1-2 BEARINGS AND OIL SEALS ..............1-3 CIRCLIPS ....................1-3 BASIC SERVICE INFORMATION..............1-4 QUICK FASTENERS ................1-4 ELECTRICAL SYSTEM ................1-5 SPECIAL TOOLS..................1-9...
Page 10: Identification
IDENTIFICATION EAS20130 IDENTIFICATION EAS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the left side of the frame. EAS20150 MODEL LABEL The model label “1” is affixed to the air filter case cover. This information will be needed to order spare parts.
Page 11: Important Information
5. Keep all parts away from any source of fire. EAS20200 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but...
Page 12: Bearings And Oil Seals
IMPORTANT INFORMATION EAS20231 BEARINGS AND OIL SEALS Install bearings “1” and oil seals “2” so that the manufacturer marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if appropriate.
Page 13: Basic Service Information
BASIC SERVICE INFORMATION EAS30380 BASIC SERVICE INFORMATION EAS30390 QUICK FASTENERS Rivet type 1. Remove: • Quick fastener Screw type To remove the quick fastener, push its pin with 1. Remove: a screwdriver, then pull the fastener out. • Quick fastener To remove the quick fastener, loosen the screw with a screwdriver, then pull the fastener out.
Page 14: Electrical System
BASIC SERVICE INFORMATION EAS30402 ECA16760 ELECTRICAL SYSTEM Be sure to connect the battery leads to the Electrical parts handling correct battery terminals. Reversing the ECA16600 battery lead connections could damage the electrical components. Never disconnect a battery lead while the engine is running;...
Page 15 BASIC SERVICE INFORMATION ECA16620 Checking the electrical system Handle electrical components with special Before checking the electrical system, make care, and do not subject them to strong sure that the battery voltage is at least 12 V. shocks. ECA14371 ECA16630 Never insert the tester probes into the cou- Electrical components are very sensitive to pler terminal slots.
Page 16 BASIC SERVICE INFORMATION Checking the connections Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: • Lead • Coupler • Connector ECA16780 • When disconnecting a coupler, release the coupler lock, hold both sections of 3. Check: the coupler securely, and then disconnect •...
Page 17 BASIC SERVICE INFORMATION 5. Check: • Continuity (with the pocket tester) Pocket tester 90890-03112 Analog pocket tester YU-03112-C • If there is no continuity, clean the terminals. • When checking the wire harness, perform steps (1) to (3). • As a quick remedy, use a contact revitalizer available at most part stores.
Page 18: Special Tools
SPECIAL TOOLS EAS20260 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropri- ate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country.
Page 19 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Crankshaft installer pot 5-65 90890-01274 Installing pot YU-90058 Crankshaft installer bolt 5-65 90890-01275 Bolt YU-90060 Adapter (M12) 5-65 90890-01278 Adapter #3 YU-90063 Spacer (crankshaft installer) 5-65 90890-04081 Pot spacer YM-91044 YM-91044 Piston pin puller set 5-27 90890-01304 Piston pin puller...
Page 20 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Tappet adjusting tool 90890-01311 Six piece tappet set YM-A5970 Flywheel puller 5-50 90890-01362 Heavy duty puller YU-33270-B Sheave holder 5-50, 5-51, 5-52 90890-01701 Primary clutch holder YS-01880-A Thickness gauge 3-5, 5-36 90890-03180 Feeler gauge set YU-26900-9 Digital circuit tester...
Page 21 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Valve spring compressor 5-19, 5-24 90890-04019 YM-04019 Valve spring compressor attachment 5-19, 5-24 90890-04114 Valve spring compressor adapter 19.5 mm YM-04114 Fuel level gauge 6-10 90890-01312 YM-01312-A Universal clutch holder 5-35, 5-38 90890-04086 YM-91042 Valve guide remover (ø5)
Page 22 Axle nut wrench (46 mm) 4-14, 4-15 90890-01498 Rear axle nut wrench 46 mm YM-37134 Ignition checker 7-39 90890-06754 Opama pet-4000 spark checker YM-34487 Digital tachometer 3-6, 7-41 90890-06760 YU-39951-B Yamaha bond No. 1215 5-52, 5-61, 5-62 (Three bond No.1215®) 90890-85505 1-13...
Page 23: Specifications
SPECIFICATIONS GENERAL SPECIFICATIONS ..............2-1 ENGINE SPECIFICATIONS................2-4 CHASSIS SPECIFICATIONS................2-9 ELECTRICAL SPECIFICATIONS...............2-11 TIGHTENING TORQUES................2-13 GENERAL TIGHTENING TORQUE SPECIFICATIONS.......2-13 ENGINE TIGHTENING TORQUES ............2-14 CHASSIS TIGHTENING TORQUES ............2-16 LUBRICATION POINTS AND LUBRICANT TYPES ........2-20 ENGINE ....................2-20 LUBRICATION SYSTEM CHART AND DIAGRAMS .........2-21 ENGINE OIL LUBRICATION CHART ...........2-21 LUBRICATION DIAGRAMS ..............2-23 CABLE ROUTING ..................2-27...
Page 24: General Specifications
Oil filter type Centrifugal Air filter Air filter element Wet element Air filter oil grade Yamaha foam air filter oil or equivalent oil Fuel Recommended fuel Unleaded gasoline only (USA, AUS, NZL) Regular unleaded gasoline only (CAN) Fuel tank capacity 9.0 L (2.38 US gal, 1.98 Imp.gal)
Page 25 GENERAL SPECIFICATIONS Clutch Type Wet, multiple-disc Transmission Primary reduction system Helical gear Primary reduction ratio 68/20 (3.400) Secondary reduction system Chain drive Secondary reduction ratio 48/14 (3.429) Transmission type Constant mesh 5-speed Operation Left foot operation 37/14 (2.643) 32/18 (1.778) 25/19 (1.316) 23/22 (1.045) 21/24 (0.875)
Page 26 GENERAL SPECIFICATIONS Spring/shock absorber type Coil spring/oil damper Wheel travel 190 mm (7.5 in) Rear suspension Type Swingarm Spring/shock absorber type Coil spring/gas-oil damper Wheel travel 200 mm (7.9 in) Electrical system Ignition system Charging system AC magneto Battery Model YTZ7S Voltage, capacity 12 V, 6.0 Ah...
Page 27: Engine Specifications
ENGINE SPECIFICATIONS EAS29120 ENGINE SPECIFICATIONS Cylinder head Volume 15.20–15.60 cm³ (0.93–0.95 cu.in) Warpage limit 0.03 mm (0.0012 in) Cylinder Bore 54.024–54.056 mm (2.1269–2.1282 in) Wear limit 54.156 mm (2.1321 in) Camshaft Drive system Chain drive (left) Camshaft lobe dimensions Intake A 25.881–25.981 mm (1.0189–1.0229 in) Limit 25.851 mm (1.0178 in)
Page 28 ENGINE SPECIFICATIONS Valve, valve seat, valve guide Valve clearance (cold) Intake 0.08–0.12 mm (0.0032–0.0047 in) Exhaust 0.10–0.14 mm (0.0039–0.0055 in) Valve dimensions Valve head diameter A (intake) 25.90–26.10 mm (1.0197–1.0276 in) Valve head diameter A (exhaust) 21.90–22.10 mm (0.8622–0.8701 in) Valve face width B (intake) 1.10–3.00 mm (0.0433–0.1181 in) Valve face width B (exhaust)
Page 29 ENGINE SPECIFICATIONS Free length (exhaust) 47.06 mm (1.85 in) Limit 44.71 mm (1.76 in) Installed length (intake) 25.60 mm (1.01 in) Installed length (exhaust) 25.60 mm (1.01 in) Spring rate K1 (intake) 8.01 N/mm (0.82 kgf/mm, 45.74 lbf/in) Spring rate K2 (intake) 9.33 N/mm (0.95 kgf/mm, 53.27 lbf/in) Spring rate K1 (exhaust) 8.01 N/mm (0.82 kgf/mm, 45.74 lbf/in)
Page 30 ENGINE SPECIFICATIONS 2nd ring Ring type Taper Dimensions (B × T) 1.00 × 2.10 mm (0.04 × 0.08 in) End gap (installed) 0.30–0.45 mm (0.012–0.018 in) Limit 0.55 mm (0.0217 in) Ring side clearance 0.020–0.060 mm (0.0008–0.0024 in) Limit 0.120 mm (0.0047 in) Oil ring Dimensions (B ×...
Page 31 ENGINE SPECIFICATIONS Shifting mechanism Shift mechanism type Shift drum and guide bar Shift fork thickness 4.76–4.89 mm (0.1874–0.1925 in) Carburetor ID mark 2PA1 00 (USA, CAN) 2PA1 10 (AUS, NZL) Main jet #123.8 Main air jet #110 Jet needle 5DH54-1 (USA, CAN) 5DH72-2 (AUS, NZL) Needle jet P-0M (922)
Page 32: Chassis Specifications
CHASSIS SPECIFICATIONS EAS29130 CHASSIS SPECIFICATIONS Front suspension Shock absorber travel 90.7 mm (3.57 in) Spring free length 248.5 mm (9.78 in) Spring rate K1 23.00 N/mm (2.35 kgf/mm, 131.33 lbf/in) Spring stroke K1 0.0–90.7 mm (0.00–3.57 in) Optional spring available Spring preload adjusting positions Minimum Standard...
Page 33 CHASSIS SPECIFICATIONS Brake pad lining thickness (inner) 4.5 mm (0.18 in) Limit 1.0 mm (0.04 in) Brake pad lining thickness (outer) 4.5 mm (0.18 in) Limit 1.0 mm (0.04 in) Master cylinder inside diameter 12.7 mm (0.50 in) Caliper cylinder inside diameter 32.03 mm (1.26 in) Recommended fluid DOT 4...
Page 34: Electrical Specifications
ELECTRICAL SPECIFICATIONS EAS29140 ELECTRICAL SPECIFICATIONS System voltage System voltage 12 V Ignition system Ignition timing (B.T.D.C.) 7.0°/1600 r/min Advanced timing (B.T.D.C.) 32.5°/9400 r/min Advancer type Digital 248.0–372.0 Ω (R–W) Pickup coil resistance CDI unit model/manufacturer 2PA-0/MORIC Ignition coil Minimum ignition spark gap 6.0 mm (0.24 in) 0.18–0.28 Ω...
Page 35 ELECTRICAL SPECIFICATIONS Carburetor warmer 5.6–8.4 Ω at 25 °C (77 °F) Resistance Circuit breaker Circuit breaker type Fuse Fuse Fuse 15.0 A Reserve 15.0 A 2-12...
Page 36: Tightening Torques
TIGHTENING TORQUES EAS20320 TIGHTENING TORQUES EAS20331 GENERAL TIGHTENING TORQUE SPECIFI- CATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for spe- cial components or assemblies are provided for each chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached.
Page 37: Engine Tightening Torques
Item Q’ty Tightening torque Remarks size See TIP Cylinder head bolt 22 Nm (2.2 m·kgf, 16 ft·lbf) See TIP Yamaha bond Cylinder head bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) No.1215 (Three bond No.1215®) Oil check bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Spark plug 13 Nm (1.3 m·kgf, 9.4 ft·lbf)
Page 38 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Cylinder head bolt 1. Apply Yamaha bond No.1215 (Three bond No.1215®) to the threads of the cylinder head bolts “5”, “6”. 2. Lubricate the contact surfaces of the cylinder head bolts and on both contact surfaces of wash- ers with engine oil.
Page 39: Chassis Tightening Torques
TIGHTENING TORQUES EAS20350 CHASSIS TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Engine bracket (upper side) and 33 Nm (3.3 m·kgf, 24 ft·lbf) frame bolt Engine bracket (upper side) and 40 Nm (4.0 m·kgf, 29 ft·lbf) engine nut Engine bracket (front side) and 40 Nm (4.0 m·kgf, 29 ft·lbf) engine nut Engine and frame nut...
Page 40 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Steering knuckle and front brake 28 Nm (2.8 m·kgf, 20 ft·lbf) caliper bracket bolt Front brake disc and front wheel 28 Nm (2.8 m·kgf, 20 ft·lbf) hub bolt Rear axle and rear wheel hub nut 120 Nm (12 m·kgf, 87 ft·lbf) Rear brake caliper and brake cali- 34 Nm (3.4 m·kgf, 25 ft·lbf)
Page 41 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Rear brake fluid reservoir, cover 7 Nm (0.7 m·kgf, 5.1 ft·lbf) and frame bolt Front bumper and frame bolt 31 Nm (3.1 m·kgf, 22 ft·lbf) Front fender stay and frame bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Side cover and frame bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Page 42 TIGHTENING TORQUES 2-19...
Page 43: Lubrication Points And Lubricant Types
Long clutch push rod ends and ball Main axle and pinion gears Drive axle and wheel gears Shift drum Shift forks and shift fork guide bars Yamaha bond Crankcase mating surface No.1215 (Three Bond No.1215®) Yamaha bond Stator coil lead grommet No.1215 (Three Bond...
Page 44: Lubrication System Chart And Diagrams
LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 2-21...
Page 45 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil pan 2. Oil strainer 3. Oil pump 4. Rotary filter 5. Cylinder head 6. Camshaft 7. Crankshaft 8. Drive axle 9. Main axle 2-22...
Page 46: Lubrication Diagrams
LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20410 LUBRICATION DIAGRAMS 2-23...
Page 47 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Camshaft 2. Rotary filter 3. Oil pump 4. Oil strainer 5. Push lever shaft 2-24...
Page 48 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-25...
Page 49 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Camshaft 2. Rotary filter 3. Crankshaft 4. Main axle 5. Drive axle 2-26...
Page 50: Cable Routing
CABLE ROUTING EAS20430 CABLE ROUTING Handlebar (top view) 2-27...
Page 51 CABLE ROUTING 1. Brake hose 2. Throttle cable 3. Plastic band 4. Parking brake cable 5. Clutch cable A. Pass the brake hose and throttle cable through the guide of the handlebar protec- tor. Pass the throttle cable behind the brake hose.
Page 52 CABLE ROUTING Frame (right side view) 2-29...
Page 53 CABLE ROUTING 1. Neutral indicator light lead 2. Front brake light switch lead 3. Main switch lead 4. Headlight lead 5. Brake hose 6. Starter motor lead 7. Battery negative lead 8. Parking brake cable 9. Rear brake light switch lead 10.Carburetor warmer lead 11.Air vent hose 12.Crankcase breather hose...
Page 54 CABLE ROUTING Rear brake (right side view) 2-31...
Page 55 CABLE ROUTING 1. Rear brake reservoir 2. Rear brake light switch 3. Clip 4. Rear brake reservoir hose 5. Rear brake master cylinder 6. Parking brake cable 7. Parking brake cable adjusting nut 8. Brake hose 9. Rear brake caliper 10.Swingarm A.
Page 56 CABLE ROUTING Frame (left side view) 2-33...
Page 57 CABLE ROUTING 1. Spring 2. Adjusting screw 3. Washer 4. Adjusting nut 5. Rectifier/regulator 6. Clutch switch lead 7. Handlebar switch lead 8. Rectifier/regulator lead 9. Wire harness 10.Neutral switch lead 11.Drain hose 12.Clamp 13.Screw 14.Collar 15.Headlight 16.Spring nut 17.Headlight stay 18.Frame 19.Damper plate A.
Page 58 CABLE ROUTING Rear frame (left side view) 2-35...
Page 59 CABLE ROUTING 1. Air vent hose 2. Clamp 3. Starter motor lead 4. AC magneto lead 5. Carburetor overflow hose 6. Frame 7. Seat pad 8. Wire harness 9. Battery negative lead 10.Rear brake light switch lead 11.Carburetor warmer lead 12.Side cover 13.Crankcase breather hose 14.Air filter joint...
Page 60 CABLE ROUTING Front fender (top view) 2-37...
Page 61 CABLE ROUTING 1. Neutral indicator light 2. Main switch lead coupler 3. Main switch lead 4. Headlight lead 5. Main switch 6. Front brake light switch lead 7. Throttle cable 8. Air vent hose 9. Clutch switch lead 10.Handlebar switch lead 11.Parking brake cable 12.Clutch cable 13.Front fender...
Page 62 CABLE ROUTING Frame (top view) 2-39...
Page 63 CABLE ROUTING 1. Main switch lead 2. Headlight lead 3. Neutral indicator light lead 4. Front brake light switch lead 5. Clutch cable 6. Parking brake cable 7. Throttle cable 8. Brake fluid reservoir 9. Rear brake light switch lead 10.Air vent hose 11.Carburetor warmer lead 12.Starter motor lead...
Page 64 CABLE ROUTING Air filter case (top view) 2-41...
Page 65 CABLE ROUTING 1. Tool kit 2. Air filter case 3. Tail/brake light 4. Tail/brake light lead 5. Battery 6. Starter relay lead 7. Starter relay 8. Battery positive lead 9. Battery negative lead 10.AC magneto coupler 11.Starter motor lead A. Clamp the tail/brake light lead. B.
Page 66 CABLE ROUTING 2-43...
Page 67: Periodic Checks And Adjustments
PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE .................3-1 INTRODUCTION ..................3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM................3-1 GENERAL MAINTENANCE AND LUBRICATION CHART .....3-2 CHECKING THE FUEL LINE ..............3-4 CHECKING THE SPARK PLUG .............3-4 ADJUSTING THE VALVE CLEARANCE ..........3-4 CHECKING THE STARTER (CHOKE) OPERATION ......3-6 ADJUSTING THE ENGINE IDLING SPEED ..........3-6 CHECKING THE CRANKCASE BREATHER HOSE ......3-7 CHECKING THE EXHAUST SYSTEM ...........3-7...
Page 68 REPLACING THE HEADLIGHT BULB ..........3-25 ADJUSTING THE HEADLIGHT BEAM ..........3-26...
Page 70: Periodic Maintenance
However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance intervals should be followed. • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
Page 71: General Maintenance And Lubrication Chart
However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance intervals should be followed. • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
Page 72 PERIODIC MAINTENANCE INITIAL EVERY month Whichever CHECK OR MAINTENANCE ITEM 1300 2500 2500 5000 comes first (mi) (200) (800) (1600) (1600) (3200) hours • Check operation and correct if necessary. Throttle lever hous- √ √ √ √ √ • Check throttle cable free play and adjust if necessary. ing and cable •...
Page 73: Checking The Fuel Line
PERIODIC MAINTENANCE EAS21030 CHECKING THE FUEL LINE The following procedure applies to all of the fuel and breather hoses. 1. Check: • Fuel hose “1” • Fuel tank breather hose “2” Cracks/damage → Replace. Loose connection → Connect properly. ECA14940 5.
Page 74 PERIODIC MAINTENANCE • When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke. 1. Remove: • Spark plug cap • Spark plug • Intake tappet cover “1” •...
Page 75: Checking The Starter (Choke) Operation
PERIODIC MAINTENANCE 5. Install: • All removed parts For installation, reverse the removal proce- dure. EAS2PA1304 CHECKING THE STARTER (CHOKE) OPER- ATION 1. Check: • Starter (choke) operation Unsmooth operation/Sticks → Replace. c. Turn the adjusting screw “3” in direction “a” or “b”...
Page 76: Checking The Crankcase Breather Hose
PERIODIC MAINTENANCE 4. Adjust: Throttle cable free play • Engine idling speed 2.0–4.0 mm (0.08–0.16 in) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the pilot screw “1” in until it is lightly EAS2PA1303 seated. (AUS, NZL) CHECKING THE CRANKCASE BREATHER b. Turn the pilot screw out the specified num- HOSE ber of turns.
Page 77: Cleaning The Spark Arrester
PERIODIC MAINTENANCE d. Insert the tailpipe and gasket “3” into the muffler and align the bolt holes. EAS28970 CLEANING THE SPARK ARRESTER 1. Clean: • Spark arrester e. Insert the bolts and tighten it. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ EWA14680 Spark arrester bolt WARNING 11 Nm (1.1 m·kgf, 8.0 ft·lbf) •...
Page 78 The air filter element should be wet but not dripping. Air filter oil grade Yamaha foam air filter oil or equivalent oil 7. Install: • Air filter element frame 8.
Page 79: Adjusting The Clutch Cable Free Play
PERIODIC MAINTENANCE Make sure its sealing surface matches the sealing surface of the case so there is no air leak. 10. Install: • Air filter case cover 11. Install: • Seat Refer to “GENERAL CHASSIS” on page 4-1. d. Tighten the locknut. EAS20870 ADJUSTING THE CLUTCH CABLE FREE e.
Page 80: Bleeding The Hydraulic Brake System
PERIODIC MAINTENANCE EAS21350 BLEEDING THE HYDRAULIC BRAKE SYS- EWA13100 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. • Brake operation is faulty. A.
Page 81: Checking The Brake Fluid Level
PERIODIC MAINTENANCE EWA13110 • Refill with the same type of brake fluid WARNING that is already in the system. Mixing brake fluids may result in a harmful chemical After bleeding the hydraulic brake system, reaction, leading to poor brake perfor- check the brake operation.
Page 82: Adjusting The Brake Pedal
PERIODIC MAINTENANCE EAS29190 3. Adjust: ADJUSTING THE BRAKE PEDAL • Rear brake light switch 1. Check: Refer to “ADJUSTING THE REAR • Brake pedal height “a” BRAKE LIGHT SWITCH” on page 3-25. Out of specification → Adjust. EAS21260 Brake pedal height CHECKING THE REAR BRAKE PADS 6.9 mm (0.27 in) The following procedure applies to all of the...
Page 83: Checking The Rear Brake Hose
PERIODIC MAINTENANCE 4. Check: • Brake hose Brake fluid leakage → Replace the dam- aged hose. Refer to “REAR BRAKE” on page 4-30. EAS29210 ADJUSTING THE PARKING BRAKE 1. Check: • Parking brake cable end length “a” Out of specification → Adjust. Parking brake cable end length 64.0–68.0 mm (2.52–2.68 in) 3.
Page 84: Checking The Wheels
WARNING of vehicles. The tires listed below have After this adjustment is performed, lift the been approved by Yamaha Motor Co., Ltd. rear wheels off the ground by placing a for this model. If other tire combinations block under the engine, and spin the rear are used, they can adversely affect your wheels to ensure there is no brake drag.
Page 85 PERIODIC MAINTENANCE • Use no more than the following pressures Tire air pressure (measured on when seating the tire beads. cold tires) • Front Recommended 250 kPa (2.5 kgf/cm², 36 psi) Front • Rear 25.0 kPa (0.25 kgf/cm², 3.6 psi) 250 kPa (2.5 kgf/cm², 36 psi) Rear Higher pressures and fast inflation may...
Page 86: Checking The Wheel Hub Bearings
PERIODIC MAINTENANCE EAS2PA1305 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ CHECKING THE WHEEL HUB BEARINGS Refer to “CHECKING THE FRONT WHEEL The drive chain slack is adjusted by the rota- HUBS” on page 4-7. tion of the rear axle hub. EAS2PA1306 a. Place the vehicle on a level surface. CHECKING AND LUBRICATING THE SWIN- b.
Page 87: Lubricating The Drive Chain
PERIODIC MAINTENANCE Refer to “CHECKING THE FRONT SHOCK ABSORBER ASSEMBLIES” on page 4-51. 3. Check: • Operation Pump the front shock absorber assembly up and down several times. Unsmooth operation → Replace front shock absorber assembly. Refer to “FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES”...
Page 88: Checking The Rear Shock Absorber Assembly
PERIODIC MAINTENANCE Direction “a” Spring preload is increased (suspension is harder). Direction “b” Spring preload is decreased (suspension is softer). ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS4D3F006 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 1. Place the vehicle on a level surface. 2. Check: • Rear shock absorber rod Spring preload adjusting length •...
Page 89: Lubricating The Steering Shaft
PERIODIC MAINTENANCE EAS2PA1310 5. Check: LUBRICATING THE STEERING SHAFT • Ball joints and wheel bearings Refer to “STEERING STEM” on page 4-46. Move the wheels laterally back and forth. Excessive free play → Replace the front EAS29280 CHECKING THE STEERING SYSTEM arms (upper and lower) and/or wheel 1.
Page 90: Checking The Engine Mount
PERIODIC MAINTENANCE d. Tighten the rod end locknuts of both tie- rods. Locknut (tie-rod end) 15 Nm (1.5 m·kgf, 11 ft·lbf) Adjust the tie-rod ends so that “A” and “B” are equal. C. Forward ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Adjust: • Toe-in EWA14910 WARNING •...
Page 91: Changing The Engine Oil
PERIODIC MAINTENANCE 3. Check: • Do not allow foreign materials to enter the • Engine oil level crankcase. The engine oil level should be between 4. Check the engine oil level again. the minimum level mark “a” and maxi- mum level mark “b”. EAS20801 CHANGING THE ENGINE OIL Below the minimum level mark →...
Page 92: Checking And Lubricating The Cables
Engine skid plate bolt replace. 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Recommended lubricant 14. Check: Yamaha chain and cable lube • Engine oil pressure or engine oil ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Slightly loosen the oil check bolt “1”. Hold the cable end up and apply several drops of lubricant to the cable.
Page 93: Adjusting The Throttle Cable Free Play
PERIODIC MAINTENANCE EAS20660 ADJUSTING THE THROTTLE CABLE FREE If the specified throttle cable free play cannot PLAY be obtained on the carburetor side of the cable, use the adjusting nut on the handlebar Prior to adjusting the throttle cable free play, side.
Page 94: Adjusting The Rear Brake Light Switch
PERIODIC MAINTENANCE 1. Check: Speed limiter length • Rear brake light operation timing Less than 12 mm (0.47 in) Incorrect → Adjust. 2. Adjust: Rear brake light operation tim- • Speed limiter length ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 6–15 mm (0.24–0.59 in) a. Loosen the locknut “1”. 2.
Page 95 PERIODIC MAINTENANCE • Remove them from the right side of the vehi- • Install the headlight bulb holder by pushing it cle. in and turning it clockwise. • Push the headlight bulb holder inward, turn it • After installing the headlight bulb holder counterclockwise and remove the defective cover, make sure that the “TOP”...
Page 96 PERIODIC MAINTENANCE 3-27...
Page 97: Chassis
CHASSIS GENERAL CHASSIS..................4-1 REMOVING THE FRONT PANEL............4-5 INSTALLING THE FRONT PANEL ............4-5 FRONT WHEEL ....................4-6 REMOVING THE FRONT WHEELS............4-7 CHECKING THE FRONT WHEELS ............4-7 CHECKING THE FRONT WHEEL HUBS..........4-7 INSTALLING THE FRONT WHEEL HUB BEARINGS......4-8 INSTALLING THE FRONT WHEEL HUBS ..........4-8 INSTALLING THE FRONT WHEELS............4-9 REAR WHEEL ....................4-10 REMOVING THE REAR WHEELS ............4-11...
Page 98 REAR BRAKE ....................4-30 INTRODUCTION ..................4-35 CHECKING THE REAR BRAKE DISC ..........4-35 REPLACING THE REAR BRAKE PADS ..........4-35 REMOVING THE REAR BRAKE CALIPER..........4-36 DISASSEMBLING THE REAR BRAKE CALIPER........4-36 CHECKING THE REAR BRAKE CALIPER ..........4-37 ASSEMBLING THE REAR BRAKE CALIPER........4-37 INSTALLING THE REAR BRAKE CALIPER.........4-38 REMOVING THE REAR BRAKE MASTER CYLINDER .......4-39 CHECKING THE REAR BRAKE MASTER CYLINDER .......4-39 ASSEMBLING THE REAR BRAKE MASTER CYLINDER ....4-40...
Page 99 CHAIN DRIVE .....................4-58 REMOVING THE DRIVE CHAIN ............4-59 CHECKING THE DRIVE CHAIN ............4-59 CHECKING THE DRIVE SPROCKET ..........4-60 CHECKING THE REAR WHEEL SPROCKET ........4-60 CHECKING THE SPROCKET BRACKET ..........4-60 INSTALLING THE DRIVE CHAIN ............4-60...
Page 100 GENERAL CHASSIS EAS21830 GENERAL CHASSIS Removing the seat, front fender and headlight Order Job/Parts to remove Q’ty Remarks Pull back the seat lock lever, than pull up on Seat the rear of the seat. Front panel Main switch coupler Disconnect. Wire harness clamp Fuel tank cap Front side reflector...
Page 101 GENERAL CHASSIS Removing the foot protectors and engine skid plate Order Job/Parts to remove Q’ty Remarks Left foot protector Right foot protector Engine skid plate For installation, reverse the removal proce- dure.
Page 102 GENERAL CHASSIS Removing the rear fender and air filter case Order Job/Parts to remove Q’ty Remarks Seat/Front fender Refer to “GENERAL CHASSIS” on page 4-1. Rear fender Battery cover Negative battery lead Positive battery lead Battery Tail/brake light lead Disconnect. Crankcase breather hose Disconnect.
Page 103 GENERAL CHASSIS Removing the rear fender and air filter case Order Job/Parts to remove Q’ty Remarks License bracket Rear reflector Air filter case Left side cover Rear side reflector For installation, reverse the removal proce- dure.
Page 104: General Chassis
GENERAL CHASSIS EAS2PA1401 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ REMOVING THE FRONT PANEL a. Place the panel in its original position, and 1. Remove: then install the socket “1” (together with the • Quick fasteners “1” bulb) by pushing it in. ECA2PA1401 When installing the panel, be sure not to pinch the cables or wires.
Page 105: Front Wheel
FRONT WHEEL EAS21870 FRONT WHEEL Removing the front wheel and brake discs Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front wheels. Cotter pin Axle nut Front wheel Brake disc guard (outer) Brake caliper assembly Wheel hub Collar Oil seal...
Page 106: Removing The Front Wheels
FRONT WHEEL EAS21890 REMOVING THE FRONT WHEELS The following procedure applies to both of the front wheels. 1. Place the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. Place the vehicle on a suitable stand so that the front wheel is elevated.
Page 107: Installing The Front Wheel Hub Bearings
FRONT WHEEL EAS29400 INSTALLING THE FRONT WHEEL HUB BEARINGS 1. Install: • Bearings “1” Face the oil seal side of the bearing inward. 2. Check: • Wheel bearings Wheel hub play/wheel turns roughly → Replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Clean wheel hub exterior. b.
Page 108: Installing The Front Wheels
FRONT WHEEL EAS29420 INSTALLING THE FRONT WHEELS The following procedure applies to both of the front wheels. 1. Install: • Brake disc guard (outer) 2. Install: • Front wheel Front wheel nut 45 Nm (4.5 m·kgf, 33 ft·lbf)
Page 109: Rear Wheel
REAR WHEEL EAS22020 REAR WHEEL Removing the rear wheel Order Job/Parts to remove Q’ty Remarks Rear wheel Cotter pin Axle nut Wheel hub For installation, reverse the removal proce- dure. 4-10...
Page 110: Removing The Rear Wheels
REAR WHEEL EAS22040 REMOVING THE REAR WHEELS 1. Place the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. Place the vehicle on a suitable stand so that the rear wheel is elevated.
Page 111: Rear Axle And Rear Axle Hub
REAR AXLE AND REAR AXLE HUB EAS29470 REAR AXLE AND REAR AXLE HUB Removing the rear axle and rear axle hub Order Job/Parts to remove Q’ty Remarks Rear wheels/Rear wheel hubs Refer to “REAR WHEEL” on page 4-10. Rear axle ring nut set bolt Rear axle ring nut Conical spring washer Do not apply the brake pedal and do not use...
Page 112 REAR AXLE AND REAR AXLE HUB Removing the rear axle and rear axle hub Order Job/Parts to remove Q’ty Remarks Loosen. Rear axle pinch bolt Refer to “ADJUSTING THE DRIVE CHAIN SLACK” on page 3-17. Rear axle hub Bearing/oil seal Spacer For installation, reverse the removal proce- dure.
Page 113: Removing The Rear Axle
REAR AXLE AND REAR AXLE HUB EAS29490 ECA16180 REMOVING THE REAR AXLE 1. Place the vehicle on a level surface. • Never directly tap the axle end with a 2. Remove: hammer, since this will result in damage • Rear axle ring nut set bolts “1” to the axle thread and spline.
Page 114: Checking The Rear Axle Hub
REAR AXLE AND REAR AXLE HUB EAS2PA1403 CHECKING THE REAR AXLE HUB 1. Check: • Rear axle hub Cracks/damage → Replace. EAS29510 CHECKING THE REAR WHEEL SPROCKET 1. Check: • Rear wheel sprocket Refer to “CHECKING THE DRIVE SPROCKET” on page 4-60. EAS29530 EAS2PA1404 INSTALLING THE REAR AXLE...
Page 115 REAR AXLE AND REAR AXLE HUB 4-16...
Page 116: Front Brake
FRONT BRAKE EAS22210 FRONT BRAKE Removing the front brake pads Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers. Front wheel Refer to “FRONT WHEEL” on page 4-6. Brake pad retaining bolt Brake pad Brake pad spring Brake pad shim...
Page 117 FRONT BRAKE Removing the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-11. Front brake light switch connector Disconnect. Brake fluid reservoir cap Brake fluid reservoir diaphragm plate Brake fluid reservoir diaphragm Front brake light switch Brake lever...
Page 118 FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Brake master cylinder body For assembly, reverse the disassembly pro- cedure. 4-19...
Page 119 FRONT BRAKE Removing the front brake calipers Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers. Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-11. Front wheel Refer to “FRONT WHEEL” on page 4-6. Union bolt Copper washer Brake hose...
Page 120 FRONT BRAKE Disassembling the front brake calipers Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers. Brake pad retaining bolt Brake pad Brake pad spring Brake pad shim Dust plug Slide pin bolt Boot Brake caliper bracket Boot...
Page 121: Introduction
FRONT BRAKE EAS22221 INTRODUCTION EWA14101 WARNING Disc brake components rarely require dis- assembly. Therefore, always follow these preventive measures: • Never disassemble brake components unless absolutely necessary. • If any connection on the hydraulic brake ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ system is disconnected, the entire brake 4.
Page 122: Replacing The Front Brake Pads
FRONT BRAKE d. Measure the brake disc deflection. 2. Install: e. If out of specification, repeat the adjust- • Brake pads ment steps until the brake disc deflection is • Brake pad shim (brake caliper piston within specification. side) f. If the brake disc deflection cannot be (onto the brake pad) brought within specification, replace the •...
Page 123: Removing The Front Brake Calipers
FRONT BRAKE ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Blow compressed air into the brake hose 5. Check: joint opening “a” to force out the piston from • Brake lever operation Soft or spongy feeling → Bleed the brake the brake caliper. EWA13550 system. WARNING Refer to “BLEEDING THE HYDRAULIC •...
Page 124: Assembling The Front Brake Caliper
FRONT BRAKE • Brake caliper cylinder “2” • Whenever a brake caliper is disassem- Scratches/wear → Replace the brake cal- bled, replace the brake caliper piston dust iper assembly. seal and brake caliper piston seal. • Brake caliper body “3” Cracks/damage →...
Page 125: Removing The Front Brake Master Cylinder
FRONT BRAKE ECA14170 • When refilling, be careful that water does not enter the brake fluid reservoir. Water will significantly lower the boiling point of When installing the brake hose onto the the brake fluid and could cause vapor brake caliper “1”, make sure the brake pipe lock.
Page 126: Checking The Front Brake Master Cylinder
FRONT BRAKE 3. Check: • Brake master cylinder “1” Cracks/damage → Replace. • Brake master cylinder reservoir dia- phragm “2” Damage/wear → Replace. 2. Remove: • Union bolt • Copper washers • Brake hose 4. Check: To collect any remaining brake fluid, place a •...
Page 127 FRONT BRAKE 3. Fill: • Brake master cylinder (with the specified amount of the recom- mended brake fluid) Recommended fluid DOT 4 EWA13540 WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.
Page 128 FRONT BRAKE 6. Check: • Brake lever operation Soft or spongy feeling → Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-11. 4-29...
Page 129 REAR BRAKE EAS22550 REAR BRAKE Removing the rear brake pads Order Job/Parts to remove Q’ty Remarks Brake pad retaining bolt Lock washer Brake pad Brake pad spring For installation, reverse the removal proce- dure. 4-30...
Page 130 REAR BRAKE Removing the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Right foot protector Refer to “GENERAL CHASSIS” on page 4-1. Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-11. Brake fluid reservoir cover Brake fluid reservoir cap Brake fluid reservoir diaphragm holder Brake fluid reservoir diaphragm...
Page 131 REAR BRAKE Disassembling the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Joint Brake master cylinder kit Brake master cylinder For assembly, reverse the disassembly pro- cedure. 4-32...
Page 132 REAR BRAKE Removing the rear brake caliper Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-11. Parking brake cable Disconnect. Union bolt Copper washer Brake hose Disconnect. Brake caliper assembly For installation, reverse the removal proce- dure.
Page 133 REAR BRAKE Disassembling the rear brake caliper Order Job/Parts to remove Q’ty Remarks Spring Locknut Loosen. Adjusting bolt Parking brake arm Brake pad retaining bolt Lock washer Brake pad Brake pad spring Slide pin bolt Brake caliper bracket Boot Boot Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal...
Page 134: Rear Brake
REAR BRAKE EAS22561 INTRODUCTION Brake disc thickness limit EWA14101 3.5 mm (0.14 in) WARNING 5. Adjust: Disc brake components rarely require dis- • Brake disc deflection assembly. Therefore, always follow these Refer to “CHECKING THE FRONT preventive measures: BRAKE DISCS” on page 4-22. •...
Page 135: Removing The Rear Brake Caliper
REAR BRAKE b. Loosen the bleed screw and push the brake caliper pistons into the brake caliper 7. Check: with your finger. • Brake pedal operation Soft or spongy feeling → Bleed the brake c. Tighten the bleed screw. system. Bleed screw Refer to “BLEEDING THE HYDRAULIC 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
Page 136: Checking The Rear Brake Caliper
REAR BRAKE • Brake caliper cylinder “2” Scratches/wear → Replace the brake cal- iper assembly. • Brake caliper body “3” Cracks/damage → Replace the brake caliper assembly. • Brake fluid delivery passages (brake caliper body) Obstruction → Blow out with compressed ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
Page 137: Installing The Rear Brake Caliper
REAR BRAKE EAS22670 INSTALLING THE REAR BRAKE CALIPER Recommended fluid 1. Install: DOT 4 • Brake caliper “1” 1. Install: (temporarily) • Brake caliper piston seal “1” • Copper washers “2” • Brake hose “3” • Brake caliper piston dust seal “2” •...
Page 138: Removing The Rear Brake Master Cylinder
REAR BRAKE 4. Fill: 7. Check: • Brake fluid reservoir • Brake pedal operation Soft or spongy feeling → Bleed the brake (with the specified amount of the recom- mended brake fluid) system. Refer to “BLEEDING THE HYDRAULIC Recommended fluid BRAKE SYSTEM”...
Page 139: Assembling The Rear Brake Master Cylinder
REAR BRAKE 2. Check: • Brake master cylinder kit “1” Turn the adjusting bolt “3” until the clearance Damage/scratches/wear → Replace. “a” is within the specified limits when install the joint “2”. Clearance 2.7 mm (0.11 in) 3. Check: • Brake fluid reservoir “1” Cracks/damage →...
Page 140 REAR BRAKE ECA13540 Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 4. Bleed: • Brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-11. 5. Check: 2. Install: •...
Page 141: Handlebar
HANDLEBAR EAS22840 HANDLEBAR Removing the handlebar Order Job/Parts to remove Q’ty Remarks Handlebar protector Band Front brake light switch Brake master cylinder/bracket Throttle lever assembly/bracket Spacer Clutch switch Parking brake lever Clutch lever/bracket Handlebar switch Handlebar grip Handlebar holder Handlebar For installation, reverse the removal proce- dure.
Page 142: Removing The Handlebar
HANDLEBAR EAS22860 EAS22911 REMOVING THE HANDLEBAR INSTALLING THE HANDLEBAR 1. Remove: 1. Install: • Clutch switch “1” • Handlebar • Handlebar holders Push the fastener when removing the clutch Handlebar holder bolt switch out of the clutch lever holder. 20 Nm (2.0 m·kgf, 14 ft·lbf) •...
Page 143 HANDLEBAR 4. Install: • Throttle lever assembly • Before applying the adhesive, wipe off • Spacer grease or oil on the handlebar surface “a” • Brake master cylinder with a lacquer thinner. • Install the handlebar grips so that the “L” Brake master cylinder bracket arrow on the left grip and “R”...
Page 144 HANDLEBAR Throttle cable free play 2.0–4.0 mm (0.08–0.16 in) 4-45...
Page 145: Steering Stem
STEERING STEM EAS29540 STEERING STEM Removing the steering stem Order Job/Parts to remove Q’ty Remarks Front fender Refer to “GENERAL CHASSIS” on page 4-1. Lock washer Bracket Steering stem bushing Spacer Oil seal Steering stem Bushing For installation, reverse the removal proce- dure.
Page 146: Checking The Steering Stem
STEERING STEM EAS29560 EAS29580 CHECKING THE STEERING STEM INSTALLING THE LOCK WASHER 1. Check: 1. Install: • Steering stem “1” • Lock washer “1” Bends → Replace. • Steering stem bushing bolts EWA15030 WARNING Steering stem bushing bolt Do not attempt to straighten a bent stem; 23 Nm (2.3 m·kgf, 17 ft·lbf) this may dangerously weaken the stem.
Page 147: Tie-Rods And Steering Knuckles
TIE-RODS AND STEERING KNUCKLES EAS29660 TIE-RODS AND STEERING KNUCKLES Removing the tie-rods and steering knuckles Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the tie-rods and steering knuckles. Front wheel Refer to “FRONT WHEEL” on page 4-6. Front brake caliper/Brake disc Refer to “FRONT BRAKE”...
Page 148: Removing The Steering Knuckles
TIE-RODS AND STEERING KNUCKLES EAS29670 REMOVING THE STEERING KNUCKLES The following procedure applies to both of the steering knuckles. 1. Remove: • Steering knuckle “1” Use a general puller to separate the ball joints “2” from the steering knuckle “1”. EAS29700 INSTALLING THE TIE-RODS The following procedure applies to both of the...
Page 149 FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES EAS29710 FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES Removing the front arms and front shock absorber assemblies Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front upper arms, front lower arms, and front shock absorber assemblies.
Page 150: Front Arms And Front Shock Absorber Assemblies
FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES EAS29720 REMOVING THE FRONT ARMS The following procedure applies to both of the front upper arms and front lower arms. 1. Check: • Front arm free play ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Check the front arm side play “A” by mov- ing it from side to side.
Page 151: Checking The Front Arm Ball Joints
FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES c. Install the steering knuckle. Upper steering knuckle nut 25 Nm (2.5 m·kgf, 18 ft·lbf) Lower steering knuckle nut 25 Nm (2.5 m·kgf, 18 ft·lbf) d. Install the new cotter pins. e. Tighten the front upper and lower arm nuts EAS29770 to specification.
Page 152: Rear Shock Absorber Assembly
REAR SHOCK ABSORBER ASSEMBLY EAS23160 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly Order Job/Parts to remove Q’ty Remarks Seat/Rear fender/Air filter case Refer to “GENERAL CHASSIS” on page 4-1. Rear shock absorber assembly For installation, reverse the removal proce- dure.
Page 153: Handling The Rear Shock Absorber
REAR SHOCK ABSORBER ASSEMBLY EAS23170 HANDLING THE REAR SHOCK ABSORBER Place the vehicle on a suitable stand so that EWA13750 the rear wheel is elevated. WARNING This rear shock absorber contains highly 2. Remove: compressed nitrogen gas. Before handling • Rear shock absorber assembly lower bolt the rear shock absorber, read and make •...
Page 154: Swingarm
SWINGARM EAS23330 SWINGARM Removing the swingarm Order Job/Parts to remove Q’ty Remarks Refer to “REAR AXLE AND REAR AXLE Rear axle hub HUB” on page 4-12. Refer to “REAR SHOCK ABSORBER Rear shock absorber assembly ASSEMBLY” on page 4-53. Plate Swingarm end cover Pivot shaft nut/washer Pivot shaft...
Page 155: Removing The Swingarm
SWINGARM EAS23340 3. Remove: REMOVING THE SWINGARM • Pivot shaft nut 1. Place the vehicle on a level surface. • Washer EWA13120 • Pivot shaft WARNING • Swingarm Securely support the vehicle so that there is no danger of it falling over. EAS23361 CHECKING THE SWINGARM 1.
Page 156: Installing The Swingarm
SWINGARM EAS23380 INSTALLING THE SWINGARM 1. Lubricate: • Bearings • Spacer • Oil seals Recommended lubricant Lithium-soap-based grease 2. Install: • Bearings “1” • Spacer “2” • Oil seals • Dust covers Inject the bearing with the character stamp turned outward. Installed depth of bearing “a”...
Page 157 CHAIN DRIVE EAS23400 CHAIN DRIVE Removing the drive chain Order Job/Parts to remove Q’ty Remarks Swingarm Refer to “SWINGARM” on page 4-55. Drive sprocket cover Drive chain guide Drive sprocket lock plate Drive sprocket Drive chain For installation, reverse the removal proce- dure.
Page 158 CHAIN DRIVE EAS23410 • Perform this procedure 2–3 times, at a differ- REMOVING THE DRIVE CHAIN ent location each time. 1. Place the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. Place the vehicle on a suitable stand so that the rear wheel is elevated.
Page 159 CHAIN DRIVE b. Correct 1. Drive chain roller ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Drive chain sprocket 3. Check: • O-rings “1” EAS23470 Damage → Replace the drive chain. CHECKING THE REAR WHEEL SPROCKET Refer to “CHECKING THE DRIVE • Drive chain rollers “2” Damage/wear →...
Page 160 CHAIN DRIVE ECA13550 A drive chain that is too tight will overload the engine and other vital parts, and one that is too loose can skip and damage the swingarm or cause an accident. Therefore, keep the drive chain slack within the speci- fied limits.
Page 161: Engine
ENGINE ENGINE REMOVAL ..................5-1 INSTALLING THE ENGINE ..............5-4 INSTALLING THE MUFFLER AND EXHAUST PIPE......5-4 CYLINDER HEAD..................5-6 REMOVING THE CYLINDER HEAD ............5-8 CHECKING THE CYLINDER HEAD ............5-8 CHECKING THE TAPPET COVERS AND CAMSHAFT SPROCKET COVER ....................5-9 CHECKING THE CAMSHAFT SPROCKET ...........5-9 CHECKING THE TIMING CHAIN TENSIONER ........5-9 INSTALLING THE CYLINDER HEAD ...........5-10 CAMSHAFT ....................5-13...
Page 162 OIL PUMP ....................5-40 CHECKING THE OIL PUMP ..............5-42 CHECKING THE ROTARY FILTER............5-42 ASSEMBLING THE OIL PUMP ............5-42 INSTALLING THE OIL PUMP ...............5-43 SHIFT SHAFT .....................5-45 CHECKING THE SHIFT SHAFT ............5-46 CHECKING THE STOPPER LEVER ............5-46 CHECKING THE SHIFT DRUM SEGMENT .........5-46 INSTALLING THE SHIFT SHAFT ............5-46 GENERATOR AND STARTER CLUTCH............5-48 REMOVING THE GENERATOR ROTOR ..........5-50...
Page 164 ENGINE REMOVAL EAS23711 ENGINE REMOVAL Removing the exhaust pipe and muffler Order Job/Parts to remove Q’ty Remarks Muffler clamp Loosen. Muffler Muffler gasket Spark arrester Gasket Exhaust pipe EXhaust pipe protector Gasket For installation, reverse the removal proce- dure.
Page 165 Spark plug cap Disconnect. Crankcase breather hose Disconnect. Battery negative lead Disconnect. Starter motor lead Disconnect. Starter motor lead guard Clutch cable Disconnect. AC magneto coupler Disconnect. For assembly, reverse the removal proce- dure. * Yamaha bond No.1215 (Three bond No.1215®)
Page 166 ENGINE REMOVAL Removing the engine Order Job/Parts to remove Q’ty Remarks Engine mounting bolt (front) Engine bracket (left and right) Engine mounting bolt (upper) Engine bracket (upper) Engine mounting bolt (rear upper) Engine mounting bolt (rear lower) Engine For installation, reverse the removal proce- dure.
Page 167: Engine Removal
ENGINE REMOVAL EAS23720 INSTALLING THE ENGINE 1. Install: • Engine mounting bolt (rear lower side) “1” • Engine mounting bolt (rear upper side) “2” • Engine bracket bolts (upper side) “3” • Engine mounting bolt (upper side) “4” • Engine brackets (front side) “5” “6” •...
Page 168 ENGINE REMOVAL Slide the clamp onto the end of the muffler and insert the projection “a” of the clamp into a slot “b” in the muffler. Tighten the clamp after installing the muffler. 3. Install: • Muffler gasket “1” (to muffler) Installed depth of gasket “a”...
Page 169: Cylinder Head
Refer to “CARBURETOR” on page 6-3. Engine bracket (upper) Spark plug Camshaft sprocket cover Intake tappet cover Exhaust tappet cover Timing chain tensioner cap bolt Timing chain tensioner assembly Timing chain tensioner gasket Camshaft sprocket Cylinder head * Yamaha bond No.1215 (Three bond No.1215®)
Page 170 CYLINDER HEAD Removing the cylinder head Order Job/Parts to remove Q’ty Remarks Plate Gasket Cylinder head gasket Dowel pin For installation, reverse the removal proce- dure. * Yamaha bond No.1215 (Three bond No.1215®)
Page 171: Removing The Cylinder Head
CYLINDER HEAD EAS24130 4. Remove: REMOVING THE CYLINDER HEAD • Timing chain tensioner 1. Align: (along with the gasket) • “I” mark “a” on the generator rotor • Camshaft sprocket (with the stationary pointer “b” on the • Timing chain generator rotor cover) To prevent the timing chain from falling into the crankcase, fasten it with a wire.
Page 172: Checking The Tappet Covers And Camshaft Sprocket Cover
CYLINDER HEAD 3. Measure: • Cylinder head warpage Out of specification → Resurface the cyl- inder head. Warpage limit 0.03 mm (0.0012 in) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. 1/4 tooth a. Place a straightedge “1” and a thickness b. Correct gauge “2” across the cylinder head. 1.
Page 173: Installing The Cylinder Head
• Cylinder head gasket 2. Install: • Cylinder head • Washers • Cylinder head bolts • Apply Yamaha bond No.1215 (Three bond No.1215®) to the threads of the cylinder 5. Install: head bolts “5”, “6”. • Camshaft sprocket “1” • Lubricate the contact surfaces of the cylinder •...
Page 174 CYLINDER HEAD ECA13740 Timing chain tensioner bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Do not turn the crankshaft when installing the camshaft sprocket to avoid damage or improper valve timing. • When installing the camshaft sprocket, be sure to keep the timing chain as tight as pos- sible on the exhaust side.
Page 175 CYLINDER HEAD 9. Tighten: • Camshaft sprocket bolts Camshaft sprocket bolt 26 Nm (2.6 m·kgf, 19 ft·lbf) ECA13750 Be sure to tighten the camshaft sprocket bolts to the specified torque to avoid the possibility of the bolts coming loose and damaging the engine.
Page 176: Camshaft
CAMSHAFT EAS23730 CAMSHAFT Removing the rocker arms and camshaft 8 Nm (0.8 m kgf, 5.8 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) 8 Nm (0.8 m kgf, 5.8 ft Ibf) Order Job/Parts to remove Q’ty Remarks Intake tappet cover/exhaust tappet cover Refer to “CYLINDER HEAD”...
Page 177: Removing The Rocker Arms And Camshaft
CAMSHAFT EAS23770 REMOVING THE ROCKER ARMS AND Remove the rocker arm shafts with the slide CAMSHAFT hammer bolt “1” and weight “2”. 1. Loosen: • Locknuts “1” Slide hammer bolt • Valve clearance adjusting screws “2” 90890-01083 Slide hammer bolt 6 mm YU-01083-1 Weight 90890-01084...
Page 178: Checking The Rocker Arms And Rocker Arm Shafts
CAMSHAFT Camshaft lobe dimensions Intake A 25.881–25.981 mm (1.0189– 1.0229 in) Limit 25.851 mm (1.0178 in) Intake B 21.194–21.294 mm (0.8344– 0.8383 in) Limit EAS23880 21.165 mm (0.8333 in) CHECKING THE ROCKER ARMS AND Exhaust A ROCKER ARM SHAFTS 25.841–25.941 mm (1.0174– The following procedure applies to all of the 1.0213 in) rocker arms and rocker arm shafts.
Page 179: Installing The Camshaft And Rocker Arms
CAMSHAFT 5. Measure: 2. Install: • Rocker arm shaft outside diameter “a” • Exhaust rocker arm “1” Out of specification → Replace. • Exhaust rocker arm shaft “2” • Intake rocker arm “3” Rocker arm shaft outside diam- • Intake rocker arm shaft “4” eter 9.981–9.991 (0.3930–...
Page 180 CAMSHAFT 4. Install: • Camshaft “1” Screw 8 mm (0.31 in) bolt “2” into the threaded end of the camshaft and then install the cam- shaft. 5. Install: • Camshaft retainer “1” Camshaft retainer bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LOCTITE®...
Page 181 VALVES AND VALVE SPRINGS EAS24270 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-6. Rocker arm/camshaft Refer to “CAMSHAFT” on page 5-13. Valve cotter Valve spring retainer Valve spring Intake valve...
Page 182: Valves And Valve Springs
VALVES AND VALVE SPRINGS EAS24280 REMOVING THE VALVES The following procedure applies to all of the valves and related components. Before removing the internal parts of the cylin- der head (e.g., valves, valve springs, valve seats), make sure the valves properly seal. 1.
Page 183 VALVES AND VALVE SPRINGS Valve-stem-to-valve-guide clear- ance Valve-stem-to-valve-guide clear- ance (intake) 0.010–0.037 (0.0004– 0.0015 in) Limit 0.080 mm (0.0032 in) Valve-stem-to-valve-guide clear- ance (exhaust) 0.025–0.052 (0.0010– b. Install the new valve guide with the valve 0.0020 in) guide installer “2” and valve guide remover Limit “1”.
Page 184: Checking The Valve Seats
VALVES AND VALVE SPRINGS Valve guide remover (ø5) • When installing a new valve, always replace 90890-04097 the valve guide. Valve guide remover (5.0 mm) • If the valve is removed or replaced, always YM-04097 replace the oil seal. Valve guide installer (ø5) 90890-04098 Valve stem runout Valve guide installer (5.0 mm)
Page 185 VALVES AND VALVE SPRINGS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Apply Mechanic’s blueing dye (Dykem) “b” onto the valve face. b. Apply engine oil onto the valve stem. b. Install the valve into the cylinder head. c. Press the valve through the valve guide and onto the valve seat to make a clear impression.
Page 186: Checking The Valve Springs
VALVES AND VALVE SPRINGS 2. Measure: • Compressed valve spring force “a” h. Install the valve into the cylinder head. Out of specification → Replace the valve Press the valve through the valve guide spring. and onto the valve seat to make a clear impression.
Page 187: Installing The Valves
VALVES AND VALVE SPRINGS • Install the valve springs with the larger pitch “a” facing up. • Install the valve spring with its painted end facing up. EAS24340 INSTALLING THE VALVES The following procedure applies to all of the valves and related components. 1.
Page 188 VALVES AND VALVE SPRINGS 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft- face hammer. ECA13800 Hitting the valve tip with excessive force could damage the valve. 5-25...
Page 189 CYLINDER AND PISTON EAS24350 CYLINDER AND PISTON Removing the cylinder and piston Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-6. Timing chain guide (exhaust side) Cylinder Cylinder gasket Dowel pin Piston pin clip Piston pin Piston Top ring...
Page 190: Cylinder And Piston
CYLINDER AND PISTON EAS24380 REMOVING THE PISTON When removing a piston ring, open the end 1. Remove: gap with your fingers and lift the other side of • Piston pin clips “1” the ring over the piston crown. • Piston pin “2” •...
Page 191: Checking The Piston Rings
CYLINDER AND PISTON f. If out of specification, rebore or replace the cylinder, and replace the piston and piston rings as a set. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS24430 CHECKING THE PISTON RINGS 1. Measure: • Piston ring side clearance Out of specification → Replace the piston and piston rings as a set.
Page 192: Checking The Piston Pin
CYLINDER AND PISTON The oil ring expander spacer’s end gap cannot be measured. If the oil ring rail’s gap is exces- sive, replace all three piston rings. Piston ring Top ring End gap (installed) 0.15–0.30 mm (0.006–0.012 in) Limit 0.40 mm (0.0157 in) 3.
Page 193: Installing The Piston And Cylinder
CYLINDER AND PISTON EAS24450 4. Lubricate: INSTALLING THE PISTON AND CYLINDER • Piston 1. Install: • Piston rings • Lower oil ring rail “1” • Cylinder • Oil ring expander “2” (with the recommended lubricant) • Upper oil ring rail “3” •...
Page 194: Clutch
CLUTCH EAS25061 CLUTCH Removing the clutch cover Order Job/Parts to remove Q’ty Remarks Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-22. Refer to “ELECTRIC STARTER” on page 5- Starter motor Battery negative lead Disconnect. Clutch cover Clutch cover gasket Dowel pin For installation, reverse the removal proce-...
Page 195 CLUTCH Removing the clutch Order Job/Parts to remove Q’ty Remarks Clutch spring Pressure plate Locknut/Washer Short clutch push rod Clutch push rod holder Ball Friction plate Clutch plate Primary drive gear nut Washer Clutch boss nut Lock washer Clutch boss 5-32...
Page 196 CLUTCH Removing the clutch Order Job/Parts to remove Q’ty Remarks Thrust washer Clutch housing Plate washer Primary drive gear Straight key For installation, reverse the removal proce- dure. 5-33...
Page 197 CLUTCH Removing the push lever Order Job/Parts to remove Q’ty Remarks Clutch cable Refer to “ENGINE REMOVAL” on page 5-1. Short clutch push rod Refer to “CLUTCH” on page 5-31. Clutch push lever Clutch push lever spring Circlip Oil seal For installation, reverse the removal proce- dure.
Page 198: Removing The Clutch
CLUTCH EAS25070 REMOVING THE CLUTCH 1. Remove: • Clutch cover Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. EAS25100 CHECKING THE FRICTION PLATES The following procedure applies to all of the friction plates.
Page 199: Checking The Clutch Springs
CLUTCH 2. Measure: EAS25150 CHECKING THE CLUTCH HOUSING • Clutch plate warpage 1. Check: (with a surface plate and thickness gauge • Clutch housing dogs “1”) Damage/pitting/wear → Deburr the clutch Out of specification → Replace the clutch housing dogs or replace the clutch hous- plates as a set.
Page 200: Checking The Clutch Push Lever And Clutch Push Rod
CLUTCH EAS25191 CHECKING THE CLUTCH PUSH LEVER AND CLUTCH PUSH ROD 1. Check: • Short clutch push rod “1” • Ball “2” • Clutch push lever “3” Cracks/damage/wear → Replace the defective part(s). 2. Install: • Straight key • Primary drive gear “1” •...
Page 201 CLUTCH 9. Install: Universal clutch holder • Pressure plate “1” 90890-04086 • Clutch springs “2” YM-91042 • Clutch spring bolts “3” 5. Bend the lock washer tab “a” along a flat Clutch spring bolt side of the nut. 6 Nm (0.6 m·kgf, 4.3 ft·lbf) Tighten the clutch spring bolts in stages and in a crisscross pattern.
Page 202 CLUTCH Short clutch push rod locknut 8 Nm (0.8 m·kgf, 5.8 ft·lbf) 13. Adjust: • Clutch cable free play Refer to “ADJUSTING THE CLUTCH CABLE FREE PLAY” on page 3-10. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 11. Install: • Clutch cover Clutch cover bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Tighten the clutch cover bolts in the proper tightening sequence as shown.
Page 203: Oil Pump
OIL PUMP EAS24911 OIL PUMP Removing the oil pump Order Job/Parts to remove Q’ty Remarks Clutch housing/Primary drive gear Refer to “CLUTCH” on page 5-31. Rotary filter Oil pump drive gear Oil pump assembly/oil pump driven gear Oil pump gasket Oil strainer For installation, reverse the removal proce- dure.
Page 204 OIL PUMP Disassembling the oil pump Order Job/Parts to remove Q’ty Remarks Circlip Washer Conical spring washer Oil pump driven gear Washer Oil pump housing cover Oil pump shaft Oil pump inner rotor Oil pump outer rotor Oil pump housing Dowel pin For assembly, reverse the disassembly pro- cedure.
Page 205: Checking The Oil Pump
OIL PUMP EAS24960 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 defective part(s). 2. Measure: • Inner-rotor-to-outer-rotor-tip clearance “a” •...
Page 206: Installing The Oil Pump
OIL PUMP Recommended lubricant Engine oil 2. Install: • Oil pump outer rotor • Oil pump inner rotor “1” • Oil pump shaft • Pin “2” • Oil pump housing cover 4. Check: Oil pump housing cover screw • Oil pump operation 5 Nm (0.5 m·kgf, 3.6 ft·lbf) Refer to “CHECKING THE OIL PUMP”...
Page 207 OIL PUMP 5-44...
Page 208: Shift Shaft
SHIFT SHAFT EAS25410 SHIFT SHAFT Removing the shift shaft and stopper lever Order Job/Parts to remove Q’ty Remarks Right footrest Refer to “REAR BRAKE” on page 4-30. Clutch assembly Refer to “CLUTCH” on page 5-31. Shift pedal Shift shaft Circlip Shift shaft spring Shift shaft spring stopper Stopper lever...
Page 209: Checking The Shift Shaft
SHIFT SHAFT EAS25420 EAS25451 CHECKING THE SHIFT SHAFT INSTALLING THE SHIFT SHAFT 1. Check: 1. Install: • Shift shaft “1” • Stopper lever “1” • Shift lever “2” • Stopper lever spring “2” Bends/damage/wear → Replace. • Shift lever spring “3” •...
Page 210 SHIFT SHAFT Hook the end of the shift shaft spring onto the shift shaft spring stopper “2”. 4. Install: • Oil seal • Shift pedal “1” • Lubricate the oil seal lips with lithium-soap- based grease. • Install the shift pedal as shown in the illustra- tion.
Page 211 Timing mark accessing screw Crankshaft end accessing screw Generator rotor cover gasket Dowel pin Pickup coil Stator coil lead holder Stator coil * Yamaha bond No.1215 (Three bond No.1215®) ** When replacing any of parts, replace the pickup coil/stator coil assembly. 5-48...
Page 212 Starter clutch idle gear holder Starter clutch idle gear Starter clutch idle gear shaft For installation, reverse the removal proce- dure. * Yamaha bond No.1215 (Three bond No.1215®) ** When replacing any of parts, replace the pickup coil/stator coil assembly. 5-49...
Page 213: Generator And Starter Clutch
GENERATOR AND STARTER CLUTCH EAS2PA1505 flywheel puller set’s center bolt and the REMOVING THE GENERATOR ROTOR crankshaft. 1. Remove: • Generator rotor cover • Remove the generator rotor using flywheel puller “2”. Loosen each bolt 1/4 of a turn at a time, in •...
Page 214: Checking The Stator Coil Assembly
GENERATOR AND STARTER CLUTCH starter clutch is faulty and must be replaced. c. When turning the starter clutch gear coun- terclockwise “B”, it should turn freely, other- wise the starter clutch is faulty and must be replaced. EAS2PA1507 CHECKING THE STATOR COIL ASSEMBLY 1.
Page 215: Installing The Generator Rotor
(onto the stator coil lead grommet “1”) • Install the grommet within 30 minutes after application of sealant. • Wipe off any excess sealant. 2. Left crankcase Yamaha bond No.1215 2. Install: (Three bond No.1215®) • Woodruff key 90890-85505 • Generator rotor •...
Page 216 GENERATOR AND STARTER CLUTCH 5. Install: • Stator coil • Stator coil lead holder • Pickup coil Stator coil bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LOCTITE® Stator coil lead holder screw 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Pickup coil bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LOCTITE®...
Page 217: Electric Starter
ELECTRIC STARTER EAS24780 ELECTRIC STARTER Removing the starter motor Order Job/Parts to remove Q’ty Remarks Starter motor lead Disconnect. Starter motor For installation, reverse the removal proce- dure. 5-54...
Page 218 ELECTRIC STARTER Disassembling the starter motor Order Job/Parts to remove Q’ty Remarks Starter motor front cover Lock washer Shim Circlip Starter motor rear cover Brush set Armature assembly Starter motor yoke For assembly, reverse the disassembly pro- cedure. * When replacing any of parts, replace the starter motor assembly. 5-55...
Page 219: Checking The Starter Motor
ELECTRIC STARTER EAS24791 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ CHECKING THE STARTER MOTOR a. Measure the armature assembly resis- 1. Check: tances with the digital circuit tester. • Commutator Dirt → Clean with 600 grit sandpaper. Digital circuit tester 2. Measure: 90890-03174 • Commutator diameter “a” Model 88 Multimeter with Out of specification →...
Page 220: Assembling The Starter Motor
ELECTRIC STARTER 6. Measure: • Brush spring force Out of specification → Replace the brush springs as a set. Brush spring force 5.52–8.28 (563–844 19.87–29.80 oz) 7. Check: • Gear teeth Damage/wear → Replace the starter motor. 8. Check: • Bearing •...
Page 221: Crankcase
Oil pump Refer to “OIL PUMP” on page 5-40. Shift shaft/Shift drum segment Refer to “SHIFT SHAFT” on page 5-45. Timing chain guide (intake side) Timing chain Neutral switch Clutch cable holder * Yamaha bond No.1215 (Three bond No.1215®) 5-58...
Page 222 CRANKCASE Separating the crankcase 10 Nm (1.0 m kgf, 7.2 ft Ibf) Order Job/Parts to remove Q’ty Remarks Right crankcase Left crankcase Dowel pin For installation, reverse the removal proce- dure. * Yamaha bond No.1215 (Three bond No.1215®) 5-59...
Page 223 CRANKCASE Separating the crankcase Order Job/Parts to remove Q’ty Remarks Refer to “CRANKSHAFT ASSEMBLY” on Crankshaft/Balancer shaft page 5-63. Transmission Refer to “TRANSMISSION” on page 5-66. Oil seal Bearing retainer Bearing For installation, reverse the removal proce- dure. 5-60...
Page 224: Disassembling The Crankcase
4. Apply: • Sealant (onto the crankcase mating surfaces) Yamaha bond No.1215 (Three bond No.1215®) 90890-85505 Do not allow any sealant to come into contact with the oil gallery.
Page 225 CRANKCASE 5. Install: • Clutch cable holder • Crankcase bolts Apply sealant to the threads of the crankcase bolts. Yamaha bond No.1215 (Three bond No.1215®) 90890-85505 A. Left crankcase 6. Tighten: B. Right crankcase • Crankcase bolts 7. Apply: Crankcase bolt •...
Page 226: Crankshaft Assembly
CRANKSHAFT ASSEMBLY EAS25970 CRANKSHAFT ASSEMBLY Removing the crankshaft and balancer Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-58. Balancer Crankshaft For installation, reverse the removal proce- dure. 5-63...
Page 227: Removing The Crankshaft And Balancer
CRANKSHAFT ASSEMBLY EAS2PA1514 REMOVING THE CRANKSHAFT AND BAL- Turn the crankshaft slowly. ANCER 1. Remove: • Balancer “1” Runout limit C 0.030 mm (0.0012 in) 2. Measure: • Big end side clearance Out of specification → Replace the big end bearing, crankshaft pin, or connect- ing rod.
Page 228: Checking The Balancer
CRANKSHAFT ASSEMBLY EAS26120 the oil seal lips with lithium-soap-based CHECKING THE BALANCER grease and each bearing with engine oil. 1. Check: • Balancer gear Damage/wear → Replace the balancer Hold the connecting rod at top dead center gear assembly. (TDC) with one hand while turning the nut of 2.
Page 229: Transmission
TRANSMISSION EAS26241 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-58. Long shift fork guide bar Short shift fork guide bar Shift fork-R Shift fork-L Shift fork-C Shift drum Main axle assembly...
Page 230 TRANSMISSION Disassembling the main axle Order Job/Parts to remove Q’ty Remarks 5th pinion gear 2nd pinion gear 3rd pinion gear Circlip Washer 4th pinion gear Main axle/1st pinion gear For assembly, reverse the disassembly pro- cedure. 5-67...
Page 231 TRANSMISSION Disassembling the drive axle Order Job/Parts to remove Q’ty Remarks 5th wheel gear 2nd wheel gear Circlip Washer 1st wheel gear 4th wheel gear Circlip Washer 3rd wheel gear Drive axle For assembly, reverse the disassembly pro- cedure. 5-68...
Page 232: Removing The Transmission
TRANSMISSION EAS26250 REMOVING THE TRANSMISSION 1. Remove: • Long shift fork guide bar “1” • Short shift fork guide bar “2” • Shift drum “3” • Shift fork-R “4” • Shift fork-L “5” • Shift fork-C “6” • Transmission “7” 3.
Page 233: Checking The Long Clutch Push Rod
TRANSMISSION 5. Check: • Transmission gear movement Rough movement → Replace the defec- tive part(s). EAS27S1023 CHECKING THE LONG CLUTCH PUSH ROD 1. Check: • Long clutch push rod Cracks/damage/wear → Replace the long clutch push rod. 2. Measure: 2. Measure: •...
Page 234: Installing The Shift Forks And Shift Drum
TRANSMISSION EAS26320 INSTALLING THE SHIFT FORKS AND SHIFT DRUM 1. Install: • Transmission “1” • Shift fork-C “2” • Shift fork-L “3” • Shift fork-R “4” • Shift drum “5” • Short shift fork guide bar “6” • Long shift fork guide bar “7” The embossed marks on the shift forks should face towards the right side of the engine and be in the following sequence: “R”, “C”, “L”.
Page 235: Fuel System
FUEL SYSTEM FUEL TANK ....................6-1 REMOVING THE FUEL TANK ..............6-2 CHECKING THE FUEL COCK ...............6-2 CARBURETOR .....................6-3 CHECKING THE CARBURETOR............6-6 CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD..6-7 ASSEMBLING THE CARBURETOR ............6-8 INSTALLING THE CARBURETOR ............6-9 MEASURING AND ADJUSTING THE FUEL LEVEL......6-9...
Page 236: Fuel Tank
FUEL TANK EAS26620 FUEL TANK Removing the fuel tank Order Job/Parts to remove Q’ty Remarks Seat Refer to “GENERAL CHASSIS” on page 4-1. Front fender Refer to “GENERAL CHASSIS” on page 4-1. Fuel hose (fuel cock side) Disconnect. Fuel tank Fuel cock Drain hose Disconnect.
Page 237: Removing The Fuel Tank
FUEL TANK EAS26630 REMOVING THE FUEL TANK 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: • Fuel hose (fuel cock side) ECA14700 Although the fuel has been removed from the fuel tank be careful when removing the fuel hoses, since there may be fuel remain- ing in it.
Page 238: Carburetor
CARBURETOR EAS26730 CARBURETOR Removing the carburetor Order Job/Parts to remove Q’ty Remarks Seat Refer to “GENERAL CHASSIS” on page 4-1. Front fender Refer to “GENERAL CHASSIS” on page 4-1. Rear fender Refer to “GENERAL CHASSIS” on page 4-1. Air filter case Refer to “GENERAL CHASSIS”...
Page 239 CARBURETOR Disassembling the carburetor Order Job/Parts to remove Q’ty Remarks Drain hose Throttle stop screw Diaphragm cover Piston valve spring Piston valve Ring Piston valve diaphragm Jet needle set Diaphragm cover Diaphragm spring Coasting enricher diaphragm Coasting enricher jet (P. A. J. 2) Starter plunger set Carburetor warmer positive lead Carburetor warmer...
Page 240 CARBURETOR Disassembling the carburetor Order Job/Parts to remove Q’ty Remarks Main jet Needle jet holder Needle jet Pilot jet Starter jet AUS, NZL Before disassembling the carburetor, make Pilot screw set sure to note the number of times the pilot screw is turned out from the seated position to its set position.
Page 241: Checking The Carburetor
CARBURETOR EAS26770 CHECKING THE CARBURETOR 1. Check: • Carburetor body • Float chamber Cracks/damage → Replace. 2. Check: • Fuel passages 6. Check: Obstruction → Clean. • Piston valve “1” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Damage/scratches/wear → Replace. a. Wash the carburetor in a petroleum-based •...
Page 242: Checking The Carburetor Joint And Intake Manifold
CARBURETOR 9. Check: • Jet needle “1” Bends/wear/damage → Replace. • Clip groove Free play/wear → Replace. • Clip position (AUS, NZL) Standard clip position No. 2 groove (AUS, NZL) 12. Check: • Starter plunger “1” • Starter plunger spring “2” Bends/cracks/damage →...
Page 243: Assembling The Carburetor
CARBURETOR EAS26810 ASSEMBLING THE CARBURETOR The float arm should be resting on the needle ECA14110 valve, but not compressing it. • Before assembling the carburetor, wash c. If the float height is not within the specifica- all of the parts in a petroleum-based sol- tion, check the valve seat and needle valve.
Page 244: Installing The Carburetor
CARBURETOR 7. Install: • Starter plunger • O-ring 8. Install: • Piston valve (along with the diaphragm) • Jet needle set • Piston valve spring • Diaphragm cover EAS26890 INSTALLING THE CARBURETOR 1. Install: 4. Install: • Clamps • Throttle cable •...
Page 245 CARBURETOR ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Stand the vehicle on a level surface. b. Install the fuel level gauge “1” onto the fuel drain pipe “2”. Fuel level gauge 90890-01312 YM-01312-A c. Loosen the fuel drain screw “3”. d. Hold the fuel level gauge vertically next to the float chamber “4”.
Page 246 CARBURETOR 6-11...
Page 247: Electrical System
ELECTRICAL SYSTEM IGNITION SYSTEM..................7-1 CIRCUIT DIAGRAM................7-1 TROUBLESHOOTING ................7-3 ELECTRIC STARTING SYSTEM..............7-5 CIRCUIT DIAGRAM................7-5 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION......7-7 TROUBLESHOOTING ................7-9 CHARGING SYSTEM .................7-11 CIRCUIT DIAGRAM................7-11 TROUBLESHOOTING ................7-13 LIGHTING SYSTEM ...................7-15 CIRCUIT DIAGRAM................7-15 TROUBLESHOOTING ................7-17 SIGNALING SYSTEM.................7-19 CIRCUIT DIAGRAM................7-19 TROUBLESHOOTING ................7-21 CARBURETOR HEATING SYSTEM ............7-23 CIRCUIT DIAGRAM................7-23 TROUBLESHOOTING ................7-25...
Page 248: Ignition System
IGNITION SYSTEM EAS27090 IGNITION SYSTEM EAS27100 CIRCUIT DIAGRAM...
Page 249 IGNITION SYSTEM 1. Pickup coil 4. Main switch 5. Battery 8. Fuse 9. CDI unit 10.Ignition coil 11.Spark plug 22.Left handlebar switch 24.Engine stop switch...
Page 250: Troubleshooting
IGNITION SYSTEM EAS27131 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). • Before troubleshooting, remove the following part(s): 1. Seat 2. Front panel 3. Front fender 4. Rear fender 5. Left side cover 1. Check the fuse. NG→...
Page 251 IGNITION SYSTEM 8. Check the main switch. NG→ Refer to “CHECKING THE Replace the main switch. SWITCHES” on page 7-29. OK↓ 9. Check the engine stop switch. NG→ Refer to “CHECKING THE Replace the left handlebar switch. SWITCHES” on page 7-29. OK↓...
Page 252: Electric Starting System
ELECTRIC STARTING SYSTEM EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM...
Page 253 ELECTRIC STARTING SYSTEM 4. Main switch 5. Battery 6. Starter relay 7. Starter motor 8. Fuse 12.Diode 1 14.Clutch switch 15.Starting circuit cut-off relay 22.Left handlebar switch 24.Engine stop switch 25.Start switch 28.Neutral switch...
Page 254: Starting Circuit Cut-Off System Operation
ELECTRIC STARTING SYSTEM EAS27180 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: •...
Page 255 ELECTRIC STARTING SYSTEM a. WHEN THE TRANSMISSION IS IN NEU- TRAL b. WHEN THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 1. Battery 2. Fuse 3. Main switch 4. Engine stop switch 5. Starting circuit cut-off relay 6. Clutch switch 7.
Page 256: Troubleshooting
ELECTRIC STARTING SYSTEM EAS27190 TROUBLESHOOTING The starter motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Seat 2. Front panel 3. Front fender 4. Rear fender 5. Left side cover 1. Check the fuse. NG→ Refer to “CHECKING THE FUSES” Replace the fuse.
Page 257 ELECTRIC STARTING SYSTEM 8. Check the engine stop switch. NG→ Refer to “CHECKING THE Replace the left handlebar switch. SWITCHES” on page 7-29. OK↓ 9. Check the diode 1. NG→ Refer to “CHECKING THE DIODE” Replace the diode 1. on page 7-38. OK↓...
Page 258: Charging System
CHARGING SYSTEM EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM 7-11...
Page 259 CHARGING SYSTEM 2. Stator coil 3. Rectifier/regulator 5. Battery 8. Fuse 7-12...
Page 260: Troubleshooting
CHARGING SYSTEM EAS27230 TROUBLESHOOTING The battery is not being charged. • Before troubleshooting, remove the following part(s): 1. Seat 2. Front panel 3. Front fender 4. Rear fender 5. Left side cover 1. Check the fuse. NG→ Refer to “CHECKING THE FUSES” Replace the fuse.
Page 261 CHARGING SYSTEM 7-14...
Page 262: Lighting System
LIGHTING SYSTEM EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM 7-15...
Page 263 LIGHTING SYSTEM 4. Main switch 5. Battery 8. Fuse 21.Tail/brake light 22.Left handlebar switch 23.Dimmer switch 26.Headlight relay 27.Headlight 7-16...
Page 264: Troubleshooting
LIGHTING SYSTEM EAS27260 TROUBLESHOOTING Any of the following fail to light: headlight, taillight. • Before troubleshooting, remove the following part(s): 1. Seat 2. Front panel 3. Front fender 4. Rear fender 5. Left side cover 1. Check the each bulbs and bulb NG→...
Page 265 LIGHTING SYSTEM 7. Check the entire lighting system’s NG→ wiring. Properly connect or repair the lighting Refer to “CIRCUIT DIAGRAM” on system’s wiring. page 7-15. OK↓ This circuit is OK. 7-18...
Page 266: Signaling System
SIGNALING SYSTEM EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM 7-19...
Page 267 SIGNALING SYSTEM 4. Main switch 5. Battery 8. Fuse 13.Neutral indicator light 19.Rear brake light switch 20.Front brake light switch 21.Tail/brake light 28.Neutral switch 7-20...
Page 268: Troubleshooting
SIGNALING SYSTEM EAS27290 TROUBLESHOOTING Any of the following fail to light: brake light or an indicator light. • Before troubleshooting, remove the following part(s): 1. Seat 2. Front panel 3. Front fender 4. Rear fender 5. Left side cover 1. Check the fuse. NG→...
Page 269 SIGNALING SYSTEM 3. Check the entire signaling system’s NG→ wiring. Properly connect or repair the signal- Refer to “CIRCUIT DIAGRAM” on ing system’s wiring. page 7-19. OK↓ This circuit is OK. The neutral indicator light fails to come on. NG→ 1.
Page 270: Carburetor Heating System
CARBURETOR HEATING SYSTEM EAS27490 CARBURETOR HEATING SYSTEM EAS27500 CIRCUIT DIAGRAM 7-23...
Page 271 CARBURETOR HEATING SYSTEM 4. Main switch 5. Battery 8. Fuse 17.Thermo switch 18.Carburetor warmer 7-24...
Page 272: Troubleshooting
CARBURETOR HEATING SYSTEM EAS27510 TROUBLESHOOTING The carburetor heating system fails to operate. • Before troubleshooting, remove the following part(s): 1. Seat 2. Front panel 3. Front fender 4. Rear fender 1. Check the fuse. NG→ Refer to “CHECKING THE FUSES” Replace the fuse.
Page 273 CARBURETOR HEATING SYSTEM 7-26...
Page 274: Electrical Components
ELECTRICAL COMPONENTS EAS27973 ELECTRICAL COMPONENTS 7-27...
Page 275 ELECTRICAL COMPONENTS 1. Main switch 2. Front brake light switch 3. Clutch switch 4. Left handlebar switch 5. Starter relay 6. Fuse 7. Battery 8. Tail/brake light 9. Thermo switch 10.Carburetor warmer 11.Spark plug 12.Pickup coil/stator assembly 13.Neutral switch 14.Rear brake light switch 15.Starter motor 16.Rectifier/regulator 17.Starting circuit cut-off relay...
Page 276: Checking The Switches
ELECTRICAL COMPONENTS EAS27981 CHECKING THE SWITCHES 7-29...
Page 277 ELECTRICAL COMPONENTS 1. Light switch 2. Engine stop switch 3. Start switch 4. Front brake light switch 5. Main switch 6. Clutch switch 7. Fuse 8. Neutral switch 9. Rear brake light switch 7-30...
Page 278 ELECTRICAL COMPONENTS Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. Pocket tester 90890-03112 Analog pocket tester YU-03112-C • Before checking for continuity, set the pocket tester to “0” and to the “Ω × 1” range. •...
Page 279: Checking The Bulbs And Bulb Sockets
ELECTRICAL COMPONENTS EAS27990 EWA13320 CHECKING THE BULBS AND BULB SOCK- WARNING Since the headlight bulb gets extremely Check each bulb and bulb socket for damage hot, keep flammable products and your or wear, proper connections, and also for conti- hands away from the bulb until it has nuity between the terminals.
Page 280: Checking The Fuses
ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester to the fuse and check the continuity. Set the pocket tester selector to “Ω × 1”. Pocket tester 90890-03112 Analog pocket tester YU-03112-C Checking the condition of the bulb sockets b. If the pocket tester indicates “∞”, replace The following procedure applies to all of the the fuse.
Page 281 ELECTRICAL COMPONENTS • Wear protective eye gear when handling 2. Disconnect: or working near batteries. • Battery leads • Charge batteries in a well-ventilated area. (from the battery terminals) • Keep batteries away from fire, sparks or ECA13640 open flames (e.g., welding equipment, lighted cigarettes).
Page 282 ELECTRICAL COMPONENTS on the vehicle, disconnect the negative battery lead from the battery terminal.) • To reduce the chance of sparks, do not plug in the battery charger until the bat- tery charger leads are connected to the battery. • Before removing the battery charger lead clips from the battery terminals, be sure to turn off the battery charger.
Page 283 ELECTRICAL COMPONENTS b. Connect a charger and ammeter to the bat- c. Make sure that the current is higher than tery and start charging. the standard charging current written on the battery. Set the charging voltage to 16–17 V. If the set- ting is lower, charging will be insufficient.
Page 284: Checking The Relays
ELECTRICAL COMPONENTS Starting circuit cut-off relay Recommended lubricant Dielectric grease 10. Install: • Battery cover Refer to “GENERAL CHASSIS” on page 4-1. EAS28040 CHECKING THE RELAYS Check each switch for continuity with the pocket tester. If the continuity reading is incor- 1.
Page 285: Checking The Diode
ELECTRICAL COMPONENTS b. Connect the pocket tester (Ω × 1 k) to the EAS28050 CHECKING THE DIODE spark plug cap as shown. 1. Check: • Diode 1 Pocket tester Out of specification → Replace. 90890-03112 Analog pocket tester Pocket tester YU-03112-C 90890-03112 Analog pocket tester...
Page 286: Checking The Pickup Coil
ELECTRICAL COMPONENTS c. Measure the primary coil resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Check: • Secondary coil resistance Out of specification → Replace. Secondary coil resistance 6.32–9.48 kΩ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the spark plug cap from the ignition coil. 2. Spark plug cap b.
Page 287: Checking The Starter Motor Operation
ELECTRICAL COMPONENTS EAS28150 CHECKING THE STATOR COIL 1. Disconnect: • Stator coil coupler (from the wire harness) 2. Check: • Stator coil resistance Out of specification → Replace the pickup coil/stator coil assembly. Stator coil resistance 0.64–0.96 Ω (W–W) b. Measure the pickup coil resistance. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
Page 288: Checking The Thermo Switch
ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Positive tester probe a. Set the digital tachometer to the ignition Black “1” coil. • Negative tester probe b. Connect the pocket tester (AC 20 V) to the Black “2” battery terminal as shown. Digital tachometer 90890-06760 YU-39951-B Pocket tester...
Page 289 ELECTRICAL COMPONENTS Carburetor warmer resistance 5.6–8.4 Ω at 25 °C (77 °F) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the carburetor warmer from the carburetor. b. Connect the pocket tester (Ω × 1) to the carburetor warmer as shown. Pocket tester 90890-03112 Analog pocket tester YU-03112-C •...
Page 290 ELECTRICAL COMPONENTS 7-43...
Page 291: Troubleshooting
TROUBLESHOOTING TROUBLESHOOTING ..................8-1 GENERAL INFORMATION ..............8-1 STARTING FAILURES ................8-1 INCORRECT ENGINE IDLING SPEED ..........8-1 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ......8-2 FAULTY GEAR SHIFTING ..............8-2 SHIFT PEDAL DOES NOT MOVE............8-2 JUMPS OUT OF GEAR ................8-2 FAULTY CLUTCH ...................8-2 OVERHEATING ..................8-3 POOR BRAKING PERFORMANCE ............8-3 UNSTABLE HANDLING................8-3 FAULTY LIGHTING OR SIGNALING SYSTEM ........8-3...
Page 292: Troubleshooting
TROUBLESHOOTING EAS28451 • Damaged float TROUBLESHOOTING • Worn needle valve • Improperly installed needle valve seat EAS28460 • Incorrect fuel level GENERAL INFORMATION • Improperly installed pilot jet • Clogged starter jet The following guide for troubleshooting does • Faulty starter plunger not cover all the possible causes of trouble.
Page 293: Poor Medium-And-High-Speed Performance
TROUBLESHOOTING 2. Air filter EAS28530 FAULTY GEAR SHIFTING • Clogged air filter element • Loosen air filter joint Shifting is difficult Refer to “Clutch drags”. Fuel system 1. Carburetor EAS28540 • Faulty starter plunger SHIFT PEDAL DOES NOT MOVE • Loose or clogged pilot jet Shift shaft •...
Page 294: Overheating
TROUBLESHOOTING • Warped pressure plate EAS28670 UNSTABLE HANDLING • Bent clutch plate 1. Handlebar • Swollen friction plate • Bent or improperly installed handlebar • Bent clutch push rod 2. Steering components • Broken clutch boss • Incorrect toe-in • Burnt primary driven gear bushing •...
Page 295 TROUBLESHOOTING Tail/brake light does not come on • Wrong tail/brake light bulb • Too many electrical accessories • Incorrect connection • Burnt-out tail/brake light bulb Tail/brake light bulb burnt out • Wrong tail/brake light bulb • Faulty battery • Incorrectly adjusted rear brake light switch •...
Page 296 EAS28740 WIRING DIAGRAM YFM125RA 1. Pickup coil 2. Stator coil 3. Rectifier/regulator 4. Main switch 5. Battery 6. Starter relay 7. Starter motor 8. Fuse 9. CDI unit 10. Ignition coil 11. Spark plug 12. Diode 1 13. Neutral indicator light 14.
Page 298 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN...
Page 299 WIRING DIAGRAM YFM125RA...
Page 300 WIRING DIAGRAM YFM125RA...

Yamaha RAPTOR YFM125RA Service Manual

Table of Contents

Specifications

Periodic Checks and Adjustments

Chassis

General Chassis

Front Wheel

Rear Wheel

Rear Axle and Rear Axle Hub

Front Brake

Rear Brake

Handlebar

Steering Stem

Tie-Rods and Steering Knuckles

Front Arms and Front Shock Absorber Assemblies

Rear Shock Absorber Assembly

Swingarm

Engine

Engine Removal

Cylinder Head

Camshaft

Valves and Valve Springs

Cylinder and Piston

Clutch

Oil Pump

Shift Shaft

Generator and Starter Clutch

Electric Starter

Crankcase

Crankshaft Assembly

Transmission

Fuel System

Fuel Tank

Carburetor

Electrical System

Ignition System

Electric Starting System

Charging System

Lighting System

Signaling System

Carburetor Heating System

Electrical Components

Troubleshooting

Quick Links

Chapters

Troubleshooting

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Summary of Contents for Yamaha RAPTOR YFM125RA