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Troubleshooting

   Summary of Contents for Yamaha 2003 YFZ450S

  • Page 3

    YFZ450S SERVICE MANUAL LIT-11616-17-11 5TG-28197-10...

  • Page 4

    EBS00001 YFZ450S SERVICE MANUAL ©2003 by Yamaha Motor Corporation, U.S.A. First Edition, May 2003 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. LIT-11616-17-11...

  • Page 5: Specifications

    EBS00002 NOTICE This manual was produced by the Yamaha Motor Company 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, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha machine has a basic understanding of the mechanical ideas and the procedures of machine repair.

  • Page 6

    EBS00004 HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual consists of chapters for the main categories of subjects. (See “symbols”) 1st title 1: This is the title of the chapter with its symbol in the upper right corner of each page. 2nd title 2: This title indicates the section of the chapter and only appears on the first page of each section.

  • Page 7: Engine

    EBS00006 SYMBOLS The following symbols are not relevant to SPEC every machine. INFO Symbols 1 to 9 indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Cooling system 6 Carburetor 7 Chassis COOL CARB...

  • Page 9: Table Of Contents

    EBS00008 TABLE OF CONTENTS GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC CHECKS AND ADJUSTMENTS ENGINE COOLING SYSTEM COOL CARBURETOR CARB CHASSIS CHAS – ELECTRICAL ELEC TROUBLESHOOTING TRBL SHTG...

  • Page 10: Table Of Contents

    CHAPTER 1 GENERAL INFORMATION MACHINE 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 ........1-3 BEARINGS AND OIL SEALS ..............1-3 CIRCLIPS ....................1-3 CHECKING THE CONNECTIONS............

  • Page 11: Table Of Contents

    CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION....................3-1 PERIODIC MAINTENANCE/LUBRICATION ..........3-1 SEAT, FENDERS AND FUEL TANK .............. 3-3 SEAT, FUEL TANK COVER AND SIDE COVERS ........3-3 FOOT PROTECTORS AND ENGINE SKID PLATE .........3-4 HEADLIGHTS AND FRONT FENDER............3-5 REAR FENDER..................3-6 FUEL TANK....................

  • Page 12: Table Of Contents

    CHECKING THE WHEELS ..............3-55 CHECKING AND LUBRICATING THE CABLES ........3-55 LUBRICATING THE LEVERS AND PEDALS .........3-56 ELECTRICAL SYSTEM................. 3-57 CHECKING AND CHARGING THE BATTERY........3-57 CHECKING THE FUSES ................3-64 ADJUSTING THE HEADLIGHT BEAM ...........3-65 REPLACING A HEADLIGHT BULB ............3-66 CHAPTER 4 ENGINE ENGINE REMOVAL ..................4-1...

  • Page 13: Table Of Contents

    CYLINDER AND PISTON................4-34 REMOVING THE PISTON ..............4-35 CHECKING THE CYLINDER AND PISTON ...........4-35 CHECKING THE PISTON RINGS............4-37 CHECKING THE PISTON PIN ..............4-38 INSTALLING THE PISTON ..............4-40 INSTALLING THE CYLINDER ..............4-41 A.C. MAGNETO..................... 4-42 REMOVING THE A.C. MAGNETO ROTOR..........4-44 CHECKING THE STATOR COIL AND PICKUP COIL ......

  • Page 14: Table Of Contents

    CRANKCASE ....................4-65 OIL SEAL AND BEARING............... 4-67 SEPARATING THE CRANKCASE............4-68 CHECKING THE OIL STRAINER AND OIL DELIVERY PIPE 2 ..... 4-68 CHECKING THE TIMING CHAIN AND GUIDE........4-69 CHECKING THE BEARINGS AND OIL SEALS........4-69 CHECKING THE CRANKCASE ..............4-69 ASSEMBLING THE CRANKCASE............

  • Page 15: Table Of Contents

    CHAPTER 7 CHASSIS FRONT AND REAR WHEELS ................ 7-1 FRONT WHEELS ..................7-1 REAR WHEELS ..................7-3 CHECKING THE WHEELS ............... 7-4 CHECKING THE WHEEL HUBS............... 7-4 CHECKING THE BRAKE DISCS .............. 7-5 INSTALLING THE FRONT WHEEL HUB BEARINGS ......7-6 INSTALLING THE FRONT BRAKE DISCS..........7-6 INSTALLING THE FRONT WHEELS............7-6 INSTALLING THE WHEEL HUBS.............

  • Page 16: Table Of Contents

    INSTALLING THE HANDLEBAR ............7-44 INSTALLING THE HANDLEBAR GRIPS ..........7-44 INSTALLING THE CLUTCH LEVER ............7-45 INSTALLING THE BRAKE MASTER CYLINDER ........7-45 STEERING STEM ...................7-46 REMOVING THE BEARING RETAINER ..........7-48 CHECKING THE STEERING STEM ............7-48 INSTALLING THE BEARING RETAINER ..........7-48 INSTALLING THE STEERING STEM .............7-48 INSTALLING THE LOCK WASHER............

  • Page 17: Table Of Contents

    CHAPTER 8 ELECTRICAL ELECTRICAL COMPONENTS................ 8-1 CHECKING SWITCH CONTINUITY..............8-2 CHECKING THE SWITCHES................8-4 CHECKING THE BULBS AND BULB SOCKETS .......... 8-6 TYPES OF BULBS ..................8-6 CHECKING THE CONDITION OF THE BULBS ........8-6 CHECKING THE CONDITION OF THE BULB SOCKETS .......8-8 IGNITION SYSTEM ..................

  • Page 18: Table Of Contents

    CHAPTER 9 TROUBLESHOOTING STARTING FAILURE/HARD STARTING ............9-1 FUEL SYSTEM..................9-1 ELECTRICAL SYSTEM................9-1 COMPRESSION SYSTEM................ 9-2 POOR IDLE SPEED PERFORMANCE ............9-2 POOR IDLE SPEED PERFORMANCE.............9-2 POOR MEDIUM AND HIGH-SPEED PERFORMANCE........9-2 POOR MEDIUM AND HIGH-SPEED PERFORMANCE ......9-2 FAULTY GEAR SHIFTING................9-3 HARD SHIFTING..................9-3 SHIFT PEDAL DOES NOT MOVE ............

  • Page 19: Machine Identification

    MACHINE IDENTIFICATION INFO EBS00009 GENERAL INFORMATION MACHINE IDENTIFICATION EBS00010 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the left side of the frame. EBS00011 MODEL LABEL The model label 1 is affixed to the air filter case cover. This information will be needed to order spare parts.

  • Page 20: Important Information

    5. Keep all parts away from any source of fire. EBS00014 REPLACEMENT PARTS 1. 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 21: Lock Washers/plates And Cotter Pins

    IMPORTANT INFORMATION INFO EBS00016 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. EBS00017 BEARINGS AND OIL SEALS Install bearings and oil seals so that the manu-...

  • Page 22: Checking The Connections

    IMPORTANT INFORMATION INFO EBS00019 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 23: Special Tools

    SPECIAL TOOLS INFO EBS00021 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools; this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools may differ by shape and part number from country to country.

  • Page 24

    SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Radiator cap tester adapter 90890-01352 YU-33984 This tool is used to check the cooling sys- tem. Damper rod holder (30 mm) 90890-01327 YM-01327 This tool is needed to loosen and tighten the steering stem bearing retainer. Steering nut wrench 90890-01443 YU-33975...

  • Page 25

    SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Valve spring compressor Compressor Valve spring compressor attachment 90890-04019 YM-04019 Attachment 90890-04114 This tool is needed to remove and install YM-04114 the valve assemblies. Universal clutch holder 90890-04086 YM-91042 This tool is needed to hold the clutch car- rier when removing or installing the carrier nut.

  • Page 26

    90890-06754 This instrument is necessary for checking the ignition system components. Dynamic spark tester YM-34487 This instrument is necessary for checking the ignition system components. Yamaha bond No. 1215 ® Sealant (Quick Gasket Bond 90890-85505 Sealant ACC-11001-05-01 This sealant (bond) is used on crankcase mating surfaces, etc.

  • Page 27: General Specifications

    SPEC GENERAL SPECIFICATIONS EBS01001 SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Model code 5TG1 Dimensions Overall length 1,840 mm (72.4 in) Overall width 1,170 mm (46.1 in) Overall height 1,090 mm (42.9 in) Seat height 800 mm (31.5 in) Wheelbase 1,280 mm (50.4 in) Minimum ground clearance 255 mm (10.04 in) Minimum turning radius...

  • Page 28

    SPEC GENERAL SPECIFICATIONS Item Standard Carburetor 5TG1 00 × 1 Type/quantity Manufacturer KEIHIN Spark plug Type/manufacturer CR8E/NGK Spark plug gap 0.7 ~ 0.8 mm (0.028 ~ 0.031 in) Clutch type Wet, multiple disc Transmission Primary reduction system Spur gear Primary reduction ratio 62/22 (2.818) Secondary reduction system Chain drive...

  • Page 29

    SPEC GENERAL SPECIFICATIONS Item Standard Brake Front brake type Dual disc brake operation Right hand operation Rear brake type Single disc brake operation Right foot operation Suspension Front suspension Double wishbone Rear suspension Swingarm (link suspension) Shock absorber Front shock absorber Coil spring/gas-oil damper Rear shock absorber Coil spring/gas-oil damper...

  • Page 30: Engine Specifications

    SPEC ENGINE SPECIFICATIONS EBS01002 ENGINE SPECIFICATIONS Item Standard Limit Cylinder head Warp limit ---- 0.05 mm (0.002 in) Cylinder Bore size 95.00 ~ 95.01 mm (3.7402 ~ 3.7406 in) ---- Camshaft Drive method Chain drive (Left) Camshaft cap inside diameter 22.000 ~ 22.021 mm (0.8661 ~ 0.8670 in) ---- Camshaft journal diameter...

  • Page 31

    SPEC ENGINE SPECIFICATIONS Item Standard Limit Valve, valve seat, valve guide Valve clearance (cold) 0.10 ~ 0.15 mm (0.0039 ~ 0.0059 in) ---- 0.20 ~ 0.25 mm (0.0079 ~ 0.0098 in) ---- Valve dimensions Head Diameter Face Width Seat Width Margin Thickness “A”...

  • Page 32

    SPEC ENGINE SPECIFICATIONS Item Standard Limit Valve spring Free length 37.03 mm (1.46 in) 35.17 mm (1.38 in) 37.68 mm (1.48 in) 35.79 mm (1.41 in) Set length (valve closed) IN 27.87 mm (1.10 in) ---- 27.38 mm (1.08 in) ---- Compressed pressure (installed)

  • Page 33

    SPEC ENGINE SPECIFICATIONS Item Standard Limit Piston rings Top ring Type Barrel ---- Dimensions (B × T) 1.2 × 3.5 mm (0.047 × 0.138 in) ---- End gap (installed) 0.20 ~ 0.30 mm (0.008 ~ 0.012 in) 0.55 mm (0.022 in) Side clearance 0.030 ~ 0.065 mm (0.0012 ~ 0.0026 in) 0.12 mm...

  • Page 34

    SPEC ENGINE SPECIFICATIONS Item Standard Limit Balancer Balancer drive method Gear ---- Clutch Friction plate 1 (inside dia.: 120 mm) Thickness 2.9 ~ 3.1 mm (0.114 ~ 0.122 in) 2.8 mm (0.110 in) Quantity ---- Friction plate 2 (inside dia.: 128 mm) Thickness 2.9 ~ 3.1 mm (0.114 ~ 0.122 in) 2.8 mm...

  • Page 35: Cooling System

    SPEC ENGINE SPECIFICATIONS Item Standard Limit Carburetor I. D. mark 5TG1 00 ---- Main jet (M.J) #158 ---- Main air jet (M.A.J) ø1.0 ---- Jet needle/clip position (J.N) NDSR/4 ---- Cutaway (C.A) ---- Pilot air jet (P.A.J.1) #100 ---- Pilot outlet (P.O) ø0.9 ----...

  • Page 36

    SPEC ENGINE SPECIFICATIONS Lubrication chart Oil tank Pressure feed Splashed scavenge Camshaft Valve lifter Cylinder head Piston Transmission gears Piston pin Main axle Oil filter Crank pin Drive axle Check ball Oil pump rotor 1 Oil pump rotor 2 Oil strainer Oil pan 2 - 10...

  • Page 37

    SPEC ENGINE SPECIFICATIONS Cylinder head tightening sequence 2 - 11...

  • Page 38: Chassis Specifications

    SPEC CHASSIS SPECIFICATIONS EBS01003 CHASSIS SPECIFICATIONS Item Standard Limit Steering system Steering bearing type Ball and race bearing ---- Front suspension Shock absorber travel 110 mm (4.33 in) ---- Fork spring free length 265 mm (10.43 in) ---- Spring fitting length 255 mm (10.04 in) ---- Spring rate (K1)

  • Page 39

    SPEC CHASSIS SPECIFICATIONS Item Standard Limit Front disc brake Type Dual ---- Disc outside diameter × thickness 161.0 × 3.5 mm (6.34 × 0.14 in) ---- Pad thickness inner 4.5 mm (0.18 in) 1.0 mm (0.04 in) Pad thickness outer 4.5 mm (0.18 in) 1.0 mm (0.04 in)

  • Page 40: Electrical Specifications

    SPEC ELECTRICAL SPECIFICATIONS EBS01004 ELECTRICAL SPECIFICATIONS Item Standard Limit Voltage 12 V ---- Ignition system Ignition timing (B.T.D.C.) 7.5°/1,800 r/min ---- Advancer type Digital type ---- C.D.I. C.D.I. unit model/manufacturer 5TG/MORIC ---- 248 ~ 372 Ω at 20 °C (68 °F) red–white Pickup coil resistance/color ---- Ignition coil...

  • Page 41

    SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit Starter relay Model/manufacturer 2768079-A/JIDECO ---- Amperage rating 180 A ---- 4.18 ~ 4.62 Ω Coil winding resistance ---- Thermo switch Thermo switch 1 Model/manufacturer 5GH/NIPPON THERMOSTAT ---- Opening temperature 95 ~ 101 °C (203.0 ~ 213.8 °F) ---- Closing temperature 89 ~ 95 °C (192.2 ~ 203.0 °F)

  • Page 42: Tightening Torques

    SPEC TIGHTENING TORQUES EBS01005 TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Tightening torque Thread Part to be tightened Part name Q’ty Remarks size Nm m · kg ft · lb Spark plug — M10S Cylinder head cover Bolt Camshaft cap Bolt Cylinder head blind plug screw Screw Timing chain tensioner Bolt...

  • Page 43: Carburetor

    SPEC TIGHTENING TORQUES Tightening torque Thread Part to be tightened Part name Q’ty Remarks size Nm m · kg ft · lb Cylinder head water jacket Bolt Water pump housing cover Bolt Coolant reservoir Bolt Clutch cover Bolt Clutch spring Bolt Clutch boss Use a lock...

  • Page 44

    SPEC TIGHTENING TORQUES Tightening torque Thread Part to be tightened Part name Q’ty Remarks size Nm m · kg ft · lb Thermo switch 2 — Starter motor Bolt Starter motor lead Bush holder assembly and rear bracket nut NOTE: *1: Tighten the cylinder head bolts to 30 Nm (3.0 m ·...

  • Page 45: Chassis Tightening Torques

    SPEC TIGHTENING TORQUES EBS01006 CHASSIS TIGHTENING TORQUES Tightening torque Part to be tightened Thread size Remarks Nm m · kg ft · lb Engine stay and frame Engine stay and engine upper bracket Engine upper bracket and engine Engine lower bracket and engine Engine and frame Engine lower bracket and frame Swingarm pivot shaft, engine, and frame...

  • Page 46

    SPEC TIGHTENING TORQUES Tightening torque Part to be tightened Thread size Remarks Nm m · kg ft · lb Front brake master cylinder and brake lever Front brake master cylinder and brake hose Brake hose joint and frame Bleed screw Front brake pad retaining bolt Front brake caliper and brake hose Rear brake caliper retaining bolt...

  • Page 47: How To Use The Conversion Table

    HOW TO USE THE CONVERSION TABLE/ SPEC GENERAL TIGHTENING TORQUE SPECIFICATIONS EBS00022 EBS00023 HOW TO USE THE CONVERSION GENERAL TIGHTENING TORQUE TABLE SPECIFICATIONS All specification data in this manual are listed This chart specifies tightening torques for stan- in SI and METRIC UNITS. dard fasteners with a standard ISO thread Use this table to convert METRIC unit data to pitch.

  • Page 48: Lubrication Points And Lubricant Types

    Transmission gears (wheel and pinion) Shift forks and shift fork guide bars Transmission gears (wheel and pinion) splines Shift drum shaft Shift shaft Shift shaft assembly Sealant ® (Quick Gasket Cylinder head cover mating surface Yamaha bond No.1215 2 - 22...

  • Page 49

    SPEC LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Sealant ® (Quick Gasket Crankcase mating surfaces Yamaha bond No.1215 Sealant ® (Quick Gasket Cylinder head and cylinder head cover mating surfaces Yamaha bond No.1215 Sealant ® (Quick Gasket AC magneto lead grommet (AC magneto cover) Yamaha bond No.1215...

  • Page 50: Coolant Flow Diagrams

    SPEC COOLANT FLOW DIAGRAMS EBS00025 COOLANT FLOW DIAGRAMS 1 Radiator inlet hose 2 Radiator 3 Radiator fan 4 Radiator outlet hose 5 Water pump inlet pipe 6 Water pump 7 Thermo switch 1 8 Thermo switch 2 9 Cylinder head water jacket Ì...

  • Page 51

    SPEC COOLANT FLOW DIAGRAMS È Install the radiator outlet hose with the white paint mark parallel to the ground as shown. É Install the radiator outlet hose completely on the radiator pipe until the hose contacts the flange of the pipe. Ê...

  • Page 52: Oil Flow Diagrams

    SPEC OIL FLOW DIAGRAMS EBS00026 OIL FLOW DIAGRAMS 1 Intake camshaft 0 Oil pump 2 Exhaust camshaft A Oil strainer 3 Oil filter element 4 Oil tank 5 Oil pipe 1 6 Oil pipe 2 7 Main axle 8 Drive axle 9 Oil delivery pipe 1 2 - 26...

  • Page 53

    SPEC OIL FLOW DIAGRAMS 1 Camshaft 2 Oil filter element 3 Crankshaft 4 Main axle 5 Drive axle 6 Oil delivery pipe 2 7 Connecting rod 2 - 27...

  • Page 54: Cable Routing

    SPEC CABLE ROUTING EBS00028 CABLE ROUTING 1 Parking brake cable 2 Clutch cable 3 Clutch switch lead 4 Handlebar switch lead 5 Front brake light switch lead 6 Throttle switch lead 7 Front brake hose 8 Throttle cable É È Ê...

  • Page 55

    SPEC CABLE ROUTING È Fasten the clutch switch lead and handlebar switch lead to the handlebar with the plastic band. É Fasten the front brake light switch lead and throttle switch lead to the handlebar with the plastic band. Ê Less than 10 mm (0.39 in) Ë...

  • Page 56

    SPEC CABLE ROUTING 1 Throttle cable B C.D.I. unit leads 2 Front brake hose C Rectifier/regulator coupler 3 Front brake light switch lead D Brake pipe 4 Throttle switch lead E Rectifier/regulator 5 Clutch cable F C.D.I. unit 6 Parking brake cable G Diode 1 7 Clutch switch lead H Diode 2...

  • Page 57

    SPEC CABLE ROUTING È Pass the throttle cable through the cable guide. Ì Fasten the front brake light switch lead, throttle É Pass the throttle cable, leads (front brake light switch lead, clutch switch lead, and handlebar switch, throttle switch, clutch switch, and handle- switch lead with the plastic band and then place bar switch), parking brake cable, and clutch the end of the band under the fuel tank cover.

  • Page 58

    SPEC CABLE ROUTING Ï Slide the rubber cover over the couplers (front brake light switch, throttle switch, clutch switch, and handlebar switch) and fasten the center of the cover with the plastic band. Ð Pass the clutch cable and parking brake cable through the cable guide in this order.

  • Page 59

    SPEC CABLE ROUTING 1 Indicator coupler B Battery negative lead M Indicator leads 2 Radiator fan motor coupler C Starter motor lead N Cylinder head breather hose 3 Thermo switch 2 D Neutral switch lead 4 Fuel tank breather hose E A.C.

  • Page 60

    SPEC CABLE ROUTING È Route the neutral switch lead, A.C. magneto Í Fasten the wire harness, throttle position sensor lead, and radiator fan motor lead under the lead, and carburetor switch lead with the plastic frame. band. Make sure that there is no slack in the É...

  • Page 61

    SPEC CABLE ROUTING Ñ Fasten the negative battery lead and starter Ô Fasten the neutral switch lead with the lead motor lead with the plastic band and then face holder. Õ Fasten the neutral switch lead with the clamp. the end of the plastic band inward. Ò...

  • Page 62

    SPEC CABLE ROUTING Ù When installing the fuel tank cover, do not pinch the front brake hose, throttle cable, front brake light switch lead, or throttle switch lead. Ú Route the front brake hose in front of the handle- bar cover. Û...

  • Page 63

    SPEC CABLE ROUTING 1 Wire harness B Starter motor lead 2 Air filter case breather hose 3 Cylinder head breather hose È When installing the rear fender, make sure that 4 Coolant reservoir breather hose the rear fender does not overlap or pinch the cyl- 5 Coolant reservoir hose inder head breather hose, coolant reservoir 6 Tail/brake light...

  • Page 64

    SPEC CABLE ROUTING Ë Install the coolant reservoir breather hose with- Ï Pass the carburetor drain hose and carburetor out twisting the hose. air vent hoses through the hose guide on the Ì Fasten the coolant reservoir hose and the cool- engine from the left side of the machine in the ant reservoir breather hose with a clamp.

  • Page 65

    SPEC CABLE ROUTING Ò Route the carburetor drain hose between the frame and connecting arm and let it hang freely under the vehicle. Ñ Ò Ð Ï Ê Ë Ì È É Í Î 2 - 39...

  • Page 66

    SPEC CABLE ROUTING 1 Rear brake light switch lead È Fasten the coolant reservoir hose with a clamp 2 Throttle cable so that it is not pinched. 3 Clutch cable É Route the thermo switch 1 lead under the frame. 4 Coolant reservoir hose Ê...

  • Page 67

    SPEC CABLE ROUTING 1 Rear brake hose È Install the lead protector of the rear brake light 2 Parking brake cable switch lead between the clamps. 3 Rear brake light switch É Face the rear brake light switch lead holder 4 Rear brake light switch lead inward and then fasten the lead with the holder.

  • Page 68

    SPEC CABLE ROUTING 1 Rectifier/regulator B Throttle position sensor lead 2 Headlight lead (right) C Wire harness 3 Main switch lead D Headlight lead (left) 4 Thermo switch 1 lead E C.D.I. unit 5 Coolant reservoir hose 6 Oil tank breather hose È...

  • Page 69

    SPEC CABLE ROUTING Ê Route the main switch lead under the frame and Ð To carburetor Ñ Fasten the wire harness with the holder on the connect. Ë To thermo switch 1 shield under the fuel tank. Ì To main switch Ò...

  • Page 70

    SPEC CABLE ROUTING 1 Starter relay È Pass the coolant reservoir hose through the 2 Battery positive lead hose guide. 3 Tail/brake light lead É Route the earth lead and wire harness under the 4 Starter motor lead battery bracket. 5 Starting circuit cut-off relay Ê...

  • Page 71

    SPEC CABLE ROUTING Ì Fasten the coolant reservoir hose and the cylin- der head breather hose to the frame with the plastic beaded tie at its loosest position so that the hoses are not pinched. È Ì Ë Ê É 2 - 45...

  • Page 72: Introduction

    INTRODUCTION/ PERIODIC MAINTENANCE/LUBRICATION EBS00029 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable machine operation and a longer service life. The need for costly overhaul work will be greatly reduced. This information applies to machines already in service as well as to new machines that are being prepared for sale.

  • Page 73

    • Correct if necessary. Lights and • Check operation. switches* • Adjust headlight beams. Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. EBS00031 NOTE: • Recommended brake fluid: DOT4 • Brake fluid replacement: 1.

  • Page 74: Seat, Fenders And Fuel Tank

    SEAT, FENDERS AND FUEL TANK EBS00033 SEAT, FENDERS AND FUEL TANK SEAT, FUEL TANK COVER AND SIDE COVERS 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft •...

  • Page 75: Foot Protectors And Engine Skid Plate

    SEAT, FENDERS AND FUEL TANK EBS00034 FOOT PROTECTORS AND ENGINE SKID PLATE 16 Nm (1.6 m kg, 11 ft • • 13 Nm (1.3 m kg, 9.4 ft 13 Nm (1.3 m kg, 9.4 ft • • • • 16 Nm (1.6 m kg, 11 ft •...

  • Page 76: Headlights And Front Fender

    SEAT, FENDERS AND FUEL TANK EBS00036 HEADLIGHTS AND FRONT FENDER 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft 7 Nm (0.7 m kg, 5.1 ft...

  • Page 77: Rear Fender

    SEAT, FENDERS AND FUEL TANK EBS00039 REAR FENDER 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft •...

  • Page 78: Fuel Tank

    SEAT, FENDERS AND FUEL TANK EBS00042 FUEL TANK 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. Seat/fuel tank cover/side covers (left Refer to “SEAT, FENDERS AND FUEL and right) TANK”.

  • Page 79

    ADJUSTING THE VALVE CLEARANCE EAS00048 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 the Top Dead Center (TDC) on the compression stroke.

  • Page 80

    ADJUSTING THE VALVE CLEARANCE M MMM M MMM M MMM M MMM M MMM a. Turn the crankshaft counterclockwise. b. When the piston is at the Top Dead Center (TDC) on the compression stroke, align the “I” mark a on the A.C. magneto rotor with the stationary pointer b on the A.C.

  • Page 81

    ADJUSTING THE VALVE CLEARANCE 6. Adjust: • valve clearance M MMM M MMM M MMM M MMM M MMM a. Remove the valve lifter 1 and the valve pad 2 with a valve lapper 3. Valve lapper 90890-04101 NOTE: • Cover the timing chain opening with a rag to prevent the valve pad from falling into the crankcase.

  • Page 82

    ADJUSTING THE VALVE CLEARANCE EXAMPLE: Original valve pad number = 148 {thickness = 1.48 mm (0.058 in)} Rounded value = 150 d. Locate the rounded number of the original valve pad and the measured valve clear- ance in the valve pad selection table. The point where the column and row intersect is the new valve pad number.

  • Page 83

    ADJUSTING THE VALVE CLEARANCE INTAKE MEASURED INSTALLED PAD NUMBER CLEARANCE 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.00 ~ 0.04 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 0.05 ~ 0.09 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 0.10 ~ 0.15...

  • Page 84: Adjusting The Engine Idling Speed

    ADJUSTING THE VALVE CLEARANCE/ ADJUSTING THE ENGINE IDLING SPEED 7. Install: • all removed parts NOTE: For installation, reverse the removal proce- dure. EBS00051 ADJUSTING THE ENGINE IDLING SPEED 1. Start the engine and let it warm up for sev- eral minutes.

  • Page 85: Adjusting The Throttle Lever Free Play

    ADJUSTING THE ENGINE IDLING SPEED/ ADJUSTING THE THROTTLE LEVER FREE PLAY 6. Adjust: • engine idling speed M MMM M MMM M MMM M MMM M MMM a. Turn the throttle stop screw 1 in direction a or b until the specified idling speed is obtained.

  • Page 86

    ADJUSTING THE THROTTLE LEVER FREE PLAY 1. Measure: • throttle lever free play a Out of specification → Adjust. Throttle lever free play 2 ~ 4 mm (0.08 ~ 0.16 in) 2. Adjust: • throttle lever free play M MMM M MMM M MMM M MMM...

  • Page 87: Adjusting The Speed Limiter

    ADJUSTING THE SPEED LIMITER EBS00053 ADJUSTING THE SPEED LIMITER The speed limiter keeps the carburetor throttle from becoming fully-opened even when the throttle lever is applied to the maximum posi- tion. Screwing in the adjusting screw stops the engine speed from increasing. 1.

  • Page 88: Checking The Spark Plug

    CHECKING THE SPARK PLUG EBS00057 CHECKING THE SPARK PLUG 1. Remove: • seat • fuel tank cover • side covers (left and right) • fuel tank NOTE: Slide the fuel tank. 2. Remove: • ignition coil 3. Remove: • spark plug 4.

  • Page 89: Checking The Ignition Timing

    CHECKING THE SPARK PLUG/ CHECKING THE IGNITION TIMING 9. Install: • ignition coil • fuel tank • side covers (left and right) • fuel tank cover • seat Refer to “SEAT, FENDERS AND FUEL TANK”. EBS00058 CHECKING THE IGNITION TIMING NOTE: Engine idling speed and throttle cable free play should be adjusted properly before checking...

  • Page 90: Checking The Engine Oil Level

    CHECKING THE IGNITION TIMING/ CHECKING THE ENGINE OIL LEVEL 4. Check: • ignition timing M MMM M MMM M MMM M MMM M MMM a. Warm up the engine and keep it at the specified speed. Engine speed 1,750 ~ 1,850 r/min b.

  • Page 91

    CHECKING THE ENGINE OIL LEVEL 3. Check: • engine oil level Oil level should be between the minimum level mark a and the maximum level mark Low oil level → Add oil to the proper level. NOTE: • Wait a few minutes until the oil settles before checking the oil level.

  • Page 92: Changing The Engine Oil

    CHANGING THE ENGINE OIL EBS00067 CHANGING THE ENGINE OIL 1. Remove: • engine skid plate Refer to “SEAT, FENDERS AND FUEL TANK”. 2. Start the engine, warm it up for several min- utes, and then turn it off. 3. Place a container under the engine oil drain bolt.

  • Page 93

    CHANGING THE ENGINE OIL 9. If the oil filter element is also to be replaced, perform the following procedure. M MMM M MMM M MMM M MMM M MMM a. Remove the oil filter element cover 1 and oil filter element 2. b.

  • Page 94

    CHANGING THE ENGINE OIL SPCBXFF Overhaul Total amount 1.95 L (1.72 Imp qt, 2.06 US qt) Quantity in oil tank 1.55 L (1.36 Imp qt, 1.64 US qt) Quantity in crankcase 0.40 L (0.35 Imp qt, 0.42 US qt) Periodic oil replacement Total amount 1.75 L (1.54 Imp qt, 1.85 US qt) Quantity in oil tank...

  • Page 95: Adjusting The Clutch Cable

    CHANGING THE ENGINE OIL/ ADJUSTING THE CLUTCH CABLE 17.Check: • engine oil pressure M MMM M MMM M MMM M MMM M MMM a. Slightly loosen the oil gallery bolt 1. b. Start the engine and keep it idling until engine oil starts to seep from the oil gallery bolt.

  • Page 96

    ADJUSTING THE CLUTCH CABLE 2. Adjust: • clutch release lever free play M MMM M MMM M MMM M MMM M MMM Handlebar side a. Turn the adjusting nut 1 in direction a or b until the specified clutch cable free play is obtained.

  • Page 97: Cleaning The Air Filter Element

    CLEANING THE AIR FILTER ELEMENT EBS00073 CLEANING THE AIR FILTER ELEMENT NOTE: There is a check hose 1 at the bottom of the air filter case. If dust and/or water collects in this hose, clean the air filter element and air fil- ter case.

  • Page 98

    CLEANING THE AIR FILTER ELEMENT 5. Clean: • air filter element M MMM M MMM M MMM M MMM M MMM a. Wash the element gently, but thoroughly in solvent. WARNING Use a cleaning solvent which is designed to clean parts only. Never use gasoline or low flash point solvents as they may cause a fire or explosion.

  • Page 99: Checking The Coolant Level

    CHECKING THE COOLANT LEVEL/ CHANGING THE COOLANT EBS00076 CHECKING THE COOLANT LEVEL 1. Place the machine on a level surface. 2. Check: • coolant level The coolant level should be between the minimum level mark a and maximum level mark b. Below the minimum level mark →...

  • Page 100

    CHANGING THE COOLANT 5. Install: • coolant reservoir • coolant reservoir bolts 7 Nm (0.7 m · kg, 5.1 ft · lb) 6. Connect: • coolant reservoir breather hose 7. Remove: • radiator cap 1 WARNING A hot radiator is under pressure. Therefore, do not remove the radiator cap when the engine is hot.

  • Page 101

    CHANGING THE COOLANT 12.Fill: • cooling system (with the specified amount of the recom- mended coolant) Recommended antifreeze High-quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines Mixing ratio 1:1 (antifreeze:water) Quantity Total amount 1.3 L (1.14 Imp qt, 1.37 US qt) Coolant reservoir capacity 0.29 L (0.26 Imp qt, 0.31 US qt) Handling notes for coolant...

  • Page 102

    CHANGING THE COOLANT 14.Fill: • coolant reservoir (with the recommended coolant to the maxi- mum level mark a) 15.Install: • coolant reservoir cap 16.Start the engine, warm it up for several min- utes, and then stop it. 17.Check: • coolant level Refer to “CHECKING THE COOLANT LEVEL”.

  • Page 103: Checking The Coolant Temperature Warning Light

    CHECKING THE COOLANT TEMPERATURE WARNING LIGHT EBS00077 CHECKING THE COOLANT TEMPERATURE WARNING LIGHT 1 Coolant temperature warning light Coolant temperature warning light checking method Turn the main switch “ON” and the engine stop switch to “RUN”. Coolant temperature warning Coolant temperature warning light does not come on.

  • Page 104: Cleaning The Spark Arrester

    CLEANING THE SPARK ARRESTER CLEANING THE SPARK ARRESTER 1. Clean: • Spark arrester M MMM M MMM M MMM M MMM M MMM WARNING • Select a well-ventilated area free of com- bustible materials. • Always let the exhaust system cool before performing this operation.

  • Page 105: Chassis

    ADJUSTING THE FRONT BRAKE/ADJUSTING THE BRAKE LEVER/ADJUSTING THE REAR BRAKE EBS00080 CHASSIS ADJUSTING THE FRONT BRAKE 1. Measure: • brake lever free play a Out of specification → Bleed the front brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM”. Brake lever free play (at the end of the brake lever) 0 mm (0 in)

  • Page 106: Adjusting The Parking Brake

    ADJUSTING THE REAR BRAKE/ ADJUSTING THE PARKING BRAKE 2. Adjust: • rear brake pedal height M MMM M MMM M MMM M MMM M MMM a. Loosen the locknut 1. b. Turn the adjusting bolt 2 until the brake pedal height is within the specified limits. c.

  • Page 107: Checking The Brake Fluid Level

    ADJUSTING THE PARKING BRAKE/ CHECKING THE BRAKE FLUID LEVEL 2. Adjust: • parking brake cable end length M MMM M MMM M MMM M MMM M MMM a. Loosen the locknut 1 and adjusting bolt 2. b. Slide back the rubber cover 3. c.

  • Page 108: Checking The Front Brake Pads

    CHECKING THE BRAKE FLUID LEVEL/ CHECKING THE FRONT BRAKE PADS 2. Check: È • brake fluid level Below the minimum level mark 1 → Add the recommended brake fluid to the proper level. Recommended brake fluid DOT 4 È Front brake É...

  • Page 109: Checking The Rear Brake Pads

    CHECKING THE FRONT BRAKE PADS/ CHECKING THE REAR BRAKE PADS 2. Check: • brake pads Wear indicators 1 almost touch the brake disc → Replace the brake pads as a set. Refer to “FRONT AND REAR BRAKES” in chapter 7. Brake pad wear limit a 1.0 mm (0.04 in) 3.

  • Page 110: Adjusting The Rear Brake Light Switch

    ADJUSTING THE REAR BRAKE LIGHT SWITCH/ CHECKING THE BRAKE HOSES ADJUSTING THE REAR BRAKE LIGHT SWITCH NOTE: • The rear brake light switch is operated by movement of the brake pedal. • The rear brake light switch is properly adjusted when the brake light comes on just before the braking effect starts.

  • Page 111: Bleeding The Hydraulic Brake System

    CHECKING THE BRAKE HOSES/ BLEEDING THE HYDRAULIC BRAKE SYSTEM 2. Check: • front brake hoses 1 • rear brake hose 2 Cracks/wear/damage → Replace. 3. Check: • brake hose clamps Loosen → Tighten. 4. Hold the machine in an upright position and apply the front or rear brake.

  • Page 112

    BLEEDING THE HYDRAULIC BRAKE SYSTEM NOTE: • Be careful not to spill any brake fluid or allow the brake master cylinder reservoir or brake fluid reservoir to overflow. • When bleeding the hydraulic brake system, make sure there is always enough brake fluid before applying the brake.

  • Page 113: Adjusting The Shift Pedal

    BLEEDING THE HYDRAULIC BRAKE SYSTEM/ ADJUSTING THE SHIFT PEDAL i. Repeat steps (e) to (h) until all of the air bubbles have disappeared from the brake fluid in the plastic hose. j. Tighten the bleed screw to specification. Bleed screw 6 Nm (0.6 m ·...

  • Page 114: Adjusting The Drive Chain Slack

    ADJUSTING THE DRIVE CHAIN SLACK ADJUSTING THE DRIVE CHAIN SLACK NOTE: Measure the drive chain slack halfway between the drive axle and the rear axle. CAUTION: 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.

  • Page 115: Checking The Steering System

    ADJUSTING THE DRIVE CHAIN SLACK/ CHECKING THE STEERING SYSTEM CAUTION: Excessive chain slack will overload the engine and other vital parts; keep the slack within the specified limits. d. If the chain slack cannot be adjusted, replace the sprockets and drive chain as a set.

  • Page 116: Adjusting The Toe-in

    ADJUSTING THE TOE-IN EBS00108 ADJUSTING THE TOE-IN 1. Place the machine on a level surface. 2. Measure: • toe-in Out of specification → Adjust. Toe-in 2 ~ 12 mm (0.08 ~ 0.47 in) M MMM M MMM M MMM M MMM M MMM NOTE: Before measuring the toe-in, make sure that...

  • Page 117: Checking The Front And Rear Shock Absorbers

    ADJUSTING THE TOE-IN/CHECKING THE FRONT AND REAR SHOCK ABSORBERS M MMM M MMM M MMM M MMM M MMM a. Mark both tie-rods ends. This reference point will be needed during adjustment. b. Loosen the locknuts (tie-rod end) 1 of both tie-rods.

  • Page 118: Adjusting The Front Shock Absorbers

    ADJUSTING THE FRONT SHOCK ABSORBERS EBS00111 ADJUSTING THE FRONT SHOCK ABSORBERS WARNING Always adjust the spring preload, rebound damping force and compression damping force of both front shock absorbers to the same setting. Uneven adjustment can result in poor handling and loss of stability. 1.

  • Page 119

    ADJUSTING THE FRONT SHOCK ABSORBERS Steering nut wrench P/N. YU-33975, 90890-01443 Locknut 30 Nm (3.0 m · kg, 22 ft · lb) NOTE: Always tighten the locknut against the adjust- ing ring, then torque it to specification. L LLL L LLL L LLL L LLL L LLL...

  • Page 120: Adjusting The Rear Shock Absorber

    ADJUSTING THE FRONT SHOCK ABSORBERS/ ADJUSTING THE REAR SHOCK ABSORBER 3. Adjust: • compression damping force M MMM M MMM M MMM M MMM M MMM a. Turn the adjusting screw 1 in direction a or b. Compression damping Direction a force is increased.

  • Page 121

    ADJUSTING THE REAR SHOCK ABSORBER 3. Disconnect the air filter case breather hose 1, and then remove the air filter case 2 with the air intake duct. 4. Adjust: • spring preload M MMM M MMM M MMM M MMM M MMM a.

  • Page 122

    ADJUSTING THE REAR SHOCK ABSORBER Steering nut wrench P/N. YU-33975, 90890-01443 Locknut 45 Nm (4.5 m · kg, 32 ft · lb) NOTE: Always tighten the locknut against the adjust- ing ring, then torque it to specification. L LLL L LLL L LLL L LLL L LLL...

  • Page 123

    ADJUSTING THE REAR SHOCK ABSORBER 7. Adjust: • compression damping force M MMM M MMM M MMM M MMM M MMM a. Turn the adjusting screw 1 in direction a or b. Compression damping Direction a force is increased. Compression damping Direction b force is decreased.

  • Page 124: Checking The Tires

    • TIRE CHARACTERISTICS 1) Tire characteristics influence the han- dling of ATVs. The tires listed below have been approved by Yamaha Motor Co., Ltd. for this model. If other tire com- binations are used, they can adversely affect your machine’s handling charac- teristics and are therefore not recom- mended.

  • Page 125

    CHECKING THE TIRES 1. Measure: • tire pressure Out of specification → Adjust. NOTE: • The low-pressure tire gauge 1 is included as standard equipment. • If dust or the like is stuck to this gauge, it will not provide the correct readings. Therefore, take two measurements of the tire’s pressure and use the second reading.

  • Page 126: Checking The Wheels

    • cable operation → Unsmooth operation Lubricate replace. Recommended lubricant Yamaha chain and cable lube or engine oil NOTE: Hold the cable end up and apply several drops of lubricant to the cable. 3. Apply: • Lithium-soap-based grease (onto end of the cable)

  • Page 127: Lubricating The Levers And Pedals

    LUBRICATING THE LEVERS AND PEDALS EBS00118 LUBRICATING THE LEVERS AND PEDALS Lubricate the pivoting point and metal-to-metal moving parts of the levers and pedals. Recommended lubricant Lithium-soap-based grease 3 - 56...

  • Page 128: Electrical System

    CHECKING AND CHARGING THE BATTERY EBS00120 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 129

    CHECKING AND CHARGING THE BATTERY 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 130

    CHECKING AND CHARGING THE BATTERY NOTE: • The charge state of an MF battery can be checked by measuring its open-circuit volt- age (i.e., the voltage when the positive termi- nal is disconnected). • No charging is necessary when the open-cir- cuit voltage equals or exceeds 12.8 V.

  • Page 131

    CHECKING AND CHARGING THE BATTERY • Before removing the battery charger lead clips from the battery terminals, be sure to turn off the battery charger. • Make sure the battery charger lead clips are in full contact with the battery termi- nal and that they are not shorted.

  • Page 132

    CHECKING AND CHARGING THE BATTERY Charging method using a variable-current (voltage) charger NOTE: Measure the open-circuit Leave the battery unused for voltage prior to charging. more 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 17 V.

  • Page 133

    CHECKING AND CHARGING THE BATTERY Charging method using a constant voltage charger NOTE: Measure the open-circuit Leave the battery unused for voltage prior to charging. more than 30 minutes before measuring its open-circuit voltage. Connect a charger and ammeter to the battery and start charging.

  • Page 134

    CHECKING AND CHARGING THE BATTERY 7. Install: • battery 8. Install: • battery holding bracket Refer to “SEAT, FENDERS AND FUEL TANK”. 9. Connect: • battery leads (to the battery terminals) CAUTION: First, connect the positive battery lead 1, and then the negative battery lead 2. 10.Check: •...

  • Page 135: Checking The Fuses

    CHECKING THE FUSES EBS00121 CHECKING THE FUSES The following procedure applies to all of the fuses. CAUTION: To avoid a short circuit, always set the main switch to “OFF” when checking or replacing a fuse. 1. Remove: • seat Refer to “SEAT, FENDERS AND FUEL TANK”.

  • Page 136: Adjusting The Headlight Beam

    CHECKING THE FUSES/ ADJUSTING THE HEADLIGHT BEAM Amperage Items Q’ty rating Main 15 A Reserve 15 A 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...

  • Page 137: Replacing A Headlight Bulb

    REPLACING A HEADLIGHT BULB EBS00124 REPLACING A HEADLIGHT BULB 1. Remove: • headlight Refer to “SEAT, FENDERS AND FUEL TANK”. 2. Disconnect: • headlight lead coupler 1 3. Remove: • headlight bulb holder cover 2 4. Remove: • bulb holder 1 •...

  • Page 138

    REPLACING A HEADLIGHT BULB 6. Install: • bulb holder • headlight bulb holder cover 1 NOTE: After installing the bulb holder cover, make sure that the “TOP” mark a is in the position shown. 7. Connect: • headlight lead coupler 2 8.

  • Page 139: Engine Removal

    ENGINE REMOVAL EBS00198 ENGINE ENGINE REMOVAL MUFFLER AND EXHAUST PIPE 34 Nm (3.4 m kg, 24 ft • • 20 Nm (2.0 m kg, 14 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 13 Nm (1.3 m kg, 9.4 ft •...

  • Page 140: Installing The Exhaust Pipe And Muffler

    ENGINE REMOVAL INSTALLING THE EXHAUST PIPE AND MUFFLER 1. Install: • gasket 1 (to muffler) NOTE: Install the gasket with the chamfer a, located on an inner rim of the gasket, and the chamfer b, located on an outer rim of the gasket, as shown.

  • Page 141

    ENGINE REMOVAL 4. Install: • clamp NOTE: 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. 4 - 3...

  • Page 142: Leads, Cables And Hoses

    ENGINE REMOVAL EBS00204 LEADS, CABLES AND HOSES 10 Nm (1.0 m kg, 7.2 ft • • 8 Nm (0.8 m kg, 5.8 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 8 Nm (0.8 m kg, 5.8 ft •...

  • Page 143

    ENGINE REMOVAL 10 Nm (1.0 m kg, 7.2 ft • • 8 Nm (0.8 m kg, 5.8 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 8 Nm (0.8 m kg, 5.8 ft • • Order Job/Part Q’ty Remarks Starter motor lead...

  • Page 144: Engine Mounting Bolts

    ENGINE REMOVAL EBS00205 ENGINE MOUNTING BOLTS 33 Nm (3.3 m kg, 24 ft • • 26 Nm (2.6 m kg, 19 ft • • 100 Nm (10.0 m kg, 72 ft • • 40 Nm (4.0 m kg, 29 ft •...

  • Page 145

    ENGINE REMOVAL 33 Nm (3.3 m kg, 24 ft • • 26 Nm (2.6 m kg, 19 ft • • 100 Nm (10.0 m kg, 72 ft • • 40 Nm (4.0 m kg, 29 ft • • 66 Nm (6.6 m kg, 48 ft •...

  • Page 146: Installing The Engine

    ENGINE REMOVAL EBS00206 INSTALLING THE ENGINE 1. Install: • pivot shaft/nut/washer 1 • engine upper bracket (left) 2 • engine upper bracket (right) • engine mounting bolt (upper) 3 • engine stay 4 • engine stay bolts/washers 5 • engine upper bracket bolts 6 •...

  • Page 147: Camshafts

    CAMSHAFTS EBS00208 CAMSHAFTS CYLINDER HEAD COVER Order Job/Part Q’ty Remarks Removing the cylinder head cover Remove the parts in the order listed. Seat/fuel tank cover/side covers (left Refer to “SEAT, FENDERS AND FUEL and right) TANK” in chapter 3. Spark plug Engine upper bracket (right) Engine upper bracket (left) Engine stay...

  • Page 148

    CAMSHAFTS CAMSHAFTS Order Job/Part Q’ty Remarks Removing the camshafts Remove the parts in the order listed. Tensioner cap bolt Timing chain tensioner Gasket Exhaust camshaft cap Refer “REMOVING CAM- Clip SHAFTS” and “INSTALLING THE CAM- SHAFTS”. Exhaust camshaft Intake camshaft cap Clip Intake camshaft For installation, reverse the removal pro-...

  • Page 149: Removing The Camshafts

    CAMSHAFTS REMOVING THE CAMSHAFTS 1. Remove: • timing mark accessing screw 1 • crankshaft end accessing screw 2 2. Align: • “I” mark on the A.C. magneto rotor (with stationary pointer on the A.C. magneto cover) M MMM M MMM M MMM M MMM M MMM...

  • Page 150: Checking The Camshafts

    CAMSHAFTS 6. Remove: • exhaust camshaft 1 • intake camshaft 2 • clips NOTE: To prevent the timing chain from falling into the crankcase, fasten it with a wire 3. CHECKING THE CAMSHAFTS 1. Check: • camshaft lobes Pitting/scratches/blue discoloration → Replace the camshaft.

  • Page 151

    CAMSHAFTS 4. Measure: • camshaft-journal-to-camshaft-cap clearance Out of specification → Measure the cam- shaft journal diameter. Camshaft-journal-to-camshaft-cap clearance 0.020 ~ 0.054 mm (0.0008 ~ 0.0021 in) <Limit>: 0.080 mm (0.0032 in) M MMM M MMM M MMM M MMM M MMM a.

  • Page 152: Checking The Camshaft Sprockets

    CAMSHAFTS EBS00224 CHECKING THE CAMSHAFT SPROCKETS 1. Check: • camshaft sprockets Wear/damage → Replace the camshaft sprockets and timing chain as a set. a 1/4 of a tooth b Correct 1 Roller 2 Sprocket EBS00225 CHECKING THE DECOMPRESSION SYSTEM 1. Check: •...

  • Page 153: Checking The Timing Chain Tensioner

    CAMSHAFTS EBS00228 CHECKING THE TIMING CHAIN TENSIONER 1. Check: • chain tensioner rod Damage/wear → Replace. 2. Check: • timing chain tensioner play M MMM M MMM M MMM M MMM M MMM a. While pressing the tensioner rod lightly with fingers, use a thin screwdriver 1 and wind the tensioner rod up fully clockwise.

  • Page 154

    CAMSHAFTS 2. Install: • clips • intake camshaft cap 1 • exhaust camshaft cap 2 • camshaft cap bolts 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: Tighten the camshaft cap bolts in stages and in a crisscross pattern, working from the inner caps out.

  • Page 155

    • cylinder head cover 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: ® • Apply Sealant (Quick Gasket ) or Yamaha bond No. 1215 1 onto the mating surfaces of the cylinder head cover and cylinder head cover gasket. ®...

  • Page 156: Cylinder Head

    CYLINDER HEAD CYLINDER HEAD Order Job/Part Q’ty Remarks Removing the cylinder head Remove the parts in the order listed. Seat/fuel tank cover/side covers (left Refer to “SEAT, FENDERS AND FUEL and right)/fuel tank TANK” in chapter 3. Muffler and exhaust pipe Refer to “MUFFLER AND EXHAUST PIPE”.

  • Page 157

    CYLINDER HEAD Order Job/Part Q’ty Remarks Cylinder head Refer to “REMOVING THE CYLINDER HEAD” and “INSTALLING THE CYLIN- DER HEAD”. Cylinder head gasket Dowel pin Timing chain guide (exhaust side) For installation, reverse the removal pro- cedure. NOTE: *1: Tighten the cylinder head bolts to 30 Nm (3.0 m · kg, 22 ft · lb) in the proper tightening sequence, remove and retighten the cylinder head bolts to 20 Nm (2.0 m ·...

  • Page 158: Removing The Cylinder Head

    CYLINDER HEAD REMOVING THE CYLINDER HEAD 1. Remove: • cylinder head NOTE: • Loosen the bolts in the proper sequence. • Follow the numerical order shown in the illus- tration. Loosen each bolt 1/4 of a turn at a time until all of the bolts are loose. EBS00230 CHECKING THE CYLINDER HEAD 1.

  • Page 159: Checking The Oil Delivery Pipe

    CYLINDER HEAD NOTE: To ensure an even surface, rotate the cylinder head several times. L LLL L LLL L LLL L LLL L LLL CHECKING THE OIL DELIVERY PIPE 1. Check: • oil delivery pipe 1 Cracks/damage → Replace. Clogged → Blow out with compressed air. CHECKING THE TIMING CHAIN GUIDE 1.

  • Page 160

    CYLINDER HEAD 3. Install: • washers • bolts 1: = 159 mm (6.26 in) • bolts 2: = 149 mm (5.87 in) M MMM M MMM M MMM M MMM M MMM NOTE: Tighten the bolts to the specified torque in two or three steps in the proper tightening sequence as shown.

  • Page 161

    CYLINDER HEAD h. Put a mark on the corner 1 of the cylinder head bolt and the cylinder head 2 as shown. NOTE: Tighten the bolts 90° in each of the two steps to reach the specified angle of 180° in the proper tightening sequence as shown.

  • Page 162: Valves And Valve Springs

    VALVES AND VALVE SPRINGS EBS00234 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”. Valve lifter Refer to “REMOVING Adjusting pad THE VALVES AND Valve cotter VALVE SPRINGS”...

  • Page 163

    VALVES AND VALVE SPRINGS Order Job/Part Q’ty Remarks Stem seal Refer to “REMOVING Lower valve spring seat THE VALVES AND Exhaust valve VALVE SPRINGS” Intake valve 1 = 76.3 mm and “INSTALLING (3.00 in) THE VALVES AND Intake valve 2 = 77.2 mm VALVE SPRINGS”.

  • Page 164: Removing The Valves And Valve Springs

    VALVES AND VALVE SPRINGS EBS00238 REMOVING THE VALVES AND VALVE SPRINGS 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 165: Checking The Valves And Valve Springs

    VALVES AND VALVE SPRINGS Valve spring compressor P/N. YM-04019, 90890-04019 Valve spring compressor attach- ment P/N. YM-04114, 90890-04114 4. Remove: • upper valve spring seat 1 • valve spring 2 • valve stem seal 3 • lower valve spring seat 4 •...

  • Page 166

    VALVES AND VALVE SPRINGS 2. Replace: • valve guide M MMM M MMM M MMM M MMM M MMM NOTE: To ease guide removal, installation and to maintain correct fit, heat the cylinder head to 100 °C (212 °F) in an oven. a.

  • Page 167

    VALVES AND VALVE SPRINGS 4. Measure: • margin thickness a Out of specification → Replace. Margin thickness Intake 1.0 mm (0.0394 in) <Limit>: 0.85 mm (0.033 in) Exhaust 1.0 mm (0.0394 in) <Limit>: 0.85 mm (0.033 in) 5. Measure: • valve stem runout Out of specification →...

  • Page 168

    VALVES AND VALVE SPRINGS M MMM M MMM M MMM M MMM M MMM a. Apply Mechanic’s blueing dye (Dykem) b to the valve face. 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 pattern.

  • Page 169

    VALVES AND VALVE SPRINGS f. Apply Mechanic’s blueing dye (Dykem) to the valve face. g. Install the valve into the cylinder head. h. Press the valve through the valve guide and onto the valve seat to make a clear pattern. i.

  • Page 170: Checking The Valve Lifters

    VALVES AND VALVE SPRINGS 12.Measure: • valve spring tilt a Out of specification → Replace. Valve spring tilt limit Intake 2.5°/1.61 mm (0.063 in) Exhaust 2.5°/1.65 mm (0.065 in) EAS00242 CHECKING THE VALVE LIFTERS The following procedure applies to all of the valve lifters.

  • Page 171

    VALVES AND VALVE SPRINGS 3. Install: • valve cotters NOTE: Install the valve cotters while compressing the valve spring with the valve spring compressor 1 and attachment 2. Valve spring compressor P/N. YM-04019, 90890-04019 Valve spring compressor attach- ment P/N. YM-04114, 90890-04114 4.

  • Page 172: Cylinder And Piston

    CYLINDER AND PISTON EBS00245 CYLINDER AND PISTON Order Job/Part Q’ty Remarks Removing the cylinder and piston Remove the parts in the order listed. Cylinder head Refer to “CYLINDER HEAD”. Cylinder Refer to “INSTALLING THE CYLINDER”. Cylinder gasket Dowel pin Dowel pin/O-ring Piston pin clip Piston pin Piston...

  • Page 173: Removing The Piston

    CYLINDER AND PISTON EBS00247 REMOVING THE PISTON 1. Remove: • piston pin clips 1 • piston pin 2 • piston 3 NOTE: Before removing each piston pin, deburr the clip groove and pin hole area. If the piston pin groove is deburred and the piston pin is still difficult to remove, use the piston pin puller 4.

  • Page 174

    CYLINDER AND PISTON 2. Measure: • piston-to-cylinder clearance M MMM M MMM M MMM M MMM M MMM a. Measure the cylinder bore “C” with a cylin- der bore gauge. NOTE: Measure the cylinder bore “C” in parallel to and right angles to the crankshaft.

  • Page 175: Checking The Piston Rings

    CYLINDER AND PISTON f. If out of specification, replace the cylinder, and the piston and piston rings as a set. L LLL L LLL L LLL L LLL L LLL EBS00250 CHECKING THE PISTON RINGS 1. Measure: • piston ring side clearance Out of specification →...

  • Page 176: Checking The Piston Pin

    CYLINDER AND PISTON 3. Measure: • piston ring end gap Out of specification → Replace the piston ring. NOTE: 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 end gap Top ring 0.20 ~ 0.30 mm...

  • Page 177

    CYLINDER AND PISTON 2. Measure: • piston pin outside diameter a Out of specification → Replace the piston pin. Piston pin outside diameter 19.991 ~ 20.000 mm (0.7870 ~ 0.7874 in) <Limit>: 19.971 mm (0.786 in) 3. Measure: • piston pin bore inside diameter Out of specification →...

  • Page 178: Installing The Piston

    CYLINDER AND PISTON EBS00252 INSTALLING THE PISTON 1. Install: • piston rings (onto the piston) NOTE: • Be sure to install the piston rings so that the manufacturer’s marks numbers located on the upper side of the rings. • Lubricate the piston and piston rings liberally with engine oil.

  • Page 179: Installing The Cylinder

    CYLINDER AND PISTON 4. Lubricate: • piston • piston rings • cylinder NOTE: Apply a liberal coating of engine oil. EBS00253 INSTALLING THE CYLINDER 1. Install: • cylinder gasket 1 • dowel pins • O-ring • cylinder 2 • bolts 10 Nm (1.0 m ·...

  • Page 180: A.c. Magneto

    A.C. MAGNETO EBS00256 A.C. MAGNETO 16 Nm (1.6 m kg, 11 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 16 14 65 Nm (6.5 m kg, 47 ft • • 10 Nm (1.0 m kg, 7.2 ft •...

  • Page 181

    A.C. MAGNETO 16 Nm (1.6 m kg, 11 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 16 14 65 Nm (6.5 m kg, 47 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft •...

  • Page 182: Removing The A.c. Magneto Rotor

    A.C. MAGNETO EBS00259 REMOVING THE A.C. MAGNETO ROTOR 1. Remove: • A.C. magneto 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. 2.

  • Page 183: Checking The Starter Clutch

    A.C. MAGNETO EBS00263 CHECKING THE STARTER CLUTCH 1. Check: • starter one-way clutch 1 Cracks/damage → Replace. • bolts 2 Loose → Replace with a new one, and clinch the end of the bolt. Starter clutch bolt 16 Nm (1.6 m · kg, 11 ft · lb) ®...

  • Page 184: Checking The Torque Limiter

    Align the projection a on the stator coil with the slot b in the A.C. magneto cover. 2. Apply: ® • sealant (Quick Gasket ) or Yamaha bond No. 1215 1 (into the slit) ® Sealant (Quick Gasket P/N. ACC-11001-05-01 Yamaha bond No.

  • Page 185

    A.C. MAGNETO 4. Tighten: • A.C. magneto rotor nut 1 65 Nm (6.5 m · kg, 47 ft · lb) NOTE: • While holding the A.C. magneto rotor 2 with the sheave holder 3, tighten the A.C. mag- neto rotor nut. •...

  • Page 186: Clutch

    CLUTCH EBS00291 CLUTCH Order Job/Part Q’ty Remarks Removing the clutch Remove the parts in the order listed. Engine oil Drain. Clutch cable Refer “LEADS, CABLES HOSES”. Clutch cover Refer to “REMOVING THE CLUTCH” and “INSTALLING THE CLUTCH”. Gasket Dowel pin Clutch spring Refer to “INSTALLING THE CLUTCH”.

  • Page 187

    CLUTCH Order Job/Part Q’ty Remarks Push rod 2 Friction plate 1 Clutch plate Refer to “INSTALLING THE CLUTCH”. Friction plate 2 Spring washer Seat plate Lock washer Clutch boss Refer to “REMOVING THE CLUTCH” and “INSTALLING THE CLUTCH”. Thrust washer Clutch housing Push lever shaft Refer to “INSTALLING THE CLUTCH”.

  • Page 188: Removing The Clutch

    CLUTCH EBS00297 REMOVING THE CLUTCH 1. Remove: • clutch cover 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. Straighten the lock washer tab. 3.

  • Page 189: Checking The Clutch Plates

    CLUTCH EBS00301 CHECKING THE CLUTCH PLATES The following procedure applies to all of the clutch plates. 1. Check: • clutch plate Damage → Replace the clutch plates as a set. 2. Measure: • clutch plate warpage (with a surface plate and thickness gauge Out of specification →...

  • Page 190: Checking The Clutch Boss

    CLUTCH EBS00304 CHECKING THE CLUTCH BOSS 1. Check: • clutch boss splines Damage/pitting/wear → Replace the clutch boss. NOTE: Pitting on the clutch boss splines will cause erratic clutch operation. EBS00305 CHECKING THE PRESSURE PLATE 1. Check: • pressure plate Cracks/damage →...

  • Page 191: Installing The Clutch

    CLUTCH EBS00311 INSTALLING THE CLUTCH 1. Install: • push lever NOTE: Align the punch mark a on the push lever with the punch mark b on the push lever shaft. 2. Install: • clutch housing NOTE: • Make sure that the primary driven gear teeth and primary drive gear teeth mesh correctly.

  • Page 192

    CLUTCH 6. Install: • clutch cover 1 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: Tighten the bolts in stages, using a crisscross pattern. 7. Install: • clutch cable 1 8. Check: • clutch cable length a Out of specification →...

  • Page 193: Balancer

    BALANCER BALANCER Order Job/Part Q’ty Remarks Removing the balancer Remove the parts in the order listed. Clutch housing Refer to “CLUTCH”. Right crankcase cover Refer to “WATER PUMP” in chapter 5. A.C. magneto rotor Refer to “A.C. MAGNETO”. Primary drive gear nut Refer to “REMOVING THE BALANCER DRIVE GEAR...

  • Page 194: Removing The Balancer Drive Gear And Balancer Driven Gear

    BALANCER REMOVING THE BALANCER DRIVE GEAR AND BALANCER DRIVEN GEAR 1. Straighten the lock washer tab. 2. Loosen: • primary drive gear nut 1 • balancer driven gear nut 2 NOTE: Place an aluminum plate a between the teeth of the balancer drive gear 3 and driven gear 3.

  • Page 195: Installing The Balancer Drive Gear And Balancer Driven Gear

    BALANCER INSTALLING THE BALANCER DRIVE GEAR AND BALANCER DRIVEN GEAR 1. Install: • balancer driven gear 1 NOTE: Install the balancer driven gear onto the bal- ancer while aligning the punch mark a on the balancer driven gear with the shorter spline b on the balancer end.

  • Page 196: Oil Pump

    OIL PUMP EBS00315 OIL PUMP Order Job/Part Q’ty Remarks Removing the oil pump Remove the parts in the order listed. Clutch housing Refer to “CLUTCH”. Right crankcase cover Refer to “WATER PUMP” in chapter 5. Circlip Washer Oil pump drive gear Oil pump assembly Dowel pin Outer rotor 2...

  • Page 197

    OIL PUMP Order Job/Part Q’ty Remarks Oil pump housing cover Outer rotor 1 Inner rotor 1 Washer Oil pump driven gear Oil pump housing For installation, reverse the removal pro- cedure. 4 - 59...

  • Page 198: Checking The Oil Pump

    OIL PUMP EBS00317 CHECKING THE OIL PUMP 1. Check: • oil pump drive gear • oil pump driven gear • oil pump housing • oil pump housing cover Cracks/wear/damage → Replace. 2. Measure: • inner-rotor-to-outer-rotor-tip clearance a • outer-rotor-to-oil-pump-housing clearance Out of specification →...

  • Page 199: Shift Shaft

    SHIFT SHAFT SHIFT SHAFT Order Job/Part Q’ty Remarks Removing the shift shaft Remove the parts in the order listed. Clutch Refer to “CLUTCH”. Oil pump drive gear Refer to “OIL PUMP”. Shift pedal Refer to “INSTALLING THE SHIFT Shift shaft SHAFT”.

  • Page 200

    SHIFT SHAFT Order Job/Part Q’ty Remarks Stopper lever Refer to “INSTALLING THE SHIFT Stopper lever spring LEVER”. Shift drum segment For installation, reverse the removal pro- cedure. 4 - 62...

  • Page 201: Checking The Shift Shaft

    SHIFT SHAFT EBS01018 CHECKING THE SHIFT SHAFT 1. Check: • shift shaft 1 Bends/damage/wear → Replace. • shift shaft spring 2 Damage/wear → Replace. EBS01019 CHECKING THE STOPPER LEVER 1. Check: • stopper lever 1 Bends/damage → Replace. Roller turns roughly → Replace the stopper lever.

  • Page 202: Installing The Shift Shaft

    SHIFT SHAFT 2. Install: • stopper lever spring 1 • stopper lever 2 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: Align the stopper lever roller with a slot on the shift drum segment. 3. Install: • springs 1 •...

  • Page 203: Crankcase

    CRANKCASE EBS00320 CRANKCASE Order Job/Part Q’ty Remarks Separating the crankcase Remove the parts in the order listed. Engine assembly Refer to “ENGINE REMOVAL”. Camshafts Refer to “CAMSHAFTS”. Cylinder head Refer to “CYLINDER HEAD”. A.C. magneto Refer to “A.C. MAGNETO”. Clutch Refer to “CLUTCH”.

  • Page 204

    CRANKCASE Order Job/Part Q’ty Remarks Circlip/spacer Oil delivery pipe 2 Right crankcase Refer to “SEPARATING THE CRANK- CASE”. Left crankcase Dowel pin/O-ring Dowel pin Oil stainer For installation, reverse the removal pro- cedure. 4 - 66...

  • Page 205: Oil Seal And Bearing

    CRANKCASE EBS00321 OIL SEAL AND BEARING Order Job/Part Q’ty Remarks Removing the crankcase bearings Remove the parts in the order listed. Crankshaft Refer to “CRANKSHAFT”. Transmission Refer to “TRANSMISSION”. Oil seal holder Oil seal Bearing retainer Bearing For installation, reverse the removal pro- cedure.

  • Page 206: Separating The Crankcase

    CRANKCASE EBS00332 SEPARATING THE CRANKCASE 1. Separate: • right crankcase • left crankcase M MMM M MMM M MMM M MMM M MMM a. Remove the crankcase bolts. NOTE: • Loosen each bolt 1/4 of a turn at a time and after all the bolts are loosened, remove them.

  • Page 207: Checking The Timing Chain And Guide

    CRANKCASE 2. Check: • oil delivery pipe 2 Cracks/damage → Replace. • oil delivery pipe holes 1 Clogged → Blow out with compressed air. EBS00335 CHECKING THE TIMING CHAIN AND GUIDE 1. Check: • timing chain Cracks/stiffness → Replace the timing chain and camshaft as a set.

  • Page 208: Assembling The Crankcase

    È Right crankcase É Left crankcase 2. Apply: ® • sealant (Quick Gasket ) or Yamaha bond No. 1215 1 (to the mating surfaces of both case halves) ® Sealant (Quick Gasket ACC-11001-05-01 Yamaha bond No. 1215 90890-85505 3.

  • Page 209

    CRANKCASE 4. Fit the right crankcase onto the left crank- case. Tap lightly on the case with a soft hammer. CAUTION: Before installing and torquing the crank- case holding bolts, be sure to check whether the transmission is functioning properly by manually rotating the shift drum in both directions.

  • Page 210: Crankshaft

    CRANKSHAFT CRANKSHAFT Order Job/Part Q’ty Remarks Removing the crankshaft Remove the parts in the order listed. Crankcase Separate. Refer to “CRANKCASE”. Crankshaft Refer to “REMOVING THE CRANK- SHAFT” and “INSTALLING THE CRANK- SHAFT”. For installation, reverse the removal pro- cedure. 4 - 72...

  • Page 211: Removing The Crankshaft

    CRANKSHAFT EBS00337 REMOVING THE CRANKSHAFT 1. Remove: • crankshaft 1 Use a crankcase separating tool 2. Crankcase separating tool P/N. YU-01135-A, 90890-01135 EBS00360 CHECKING THE CRANKSHAFT 1. Measure: • side clearance d Out of specification → Replace the crank- shaft. Big end side clearance 0.15 ~ 0.45 mm (0.0059 ~ 0.0177 in)

  • Page 212: Installing The Crankshaft

    CRANKSHAFT INSTALLING THE CRANKSHAFT 1. Install: • crankshaft 1 Crankshaft installer pot 2 P/N. 90890-01274 Crankshaft installer bolt 3 P/N. 90890-01275 Crankshaft installer set P/N. YU-90050 Adapter 4 P/N. YM-90063, 90890-01278 Spacer (crankshaft installer) 5 P/N. YM-91044, 90890-04081 NOTE: Hold the connecting rod at the Top Dead Cen- ter (TDC) with one hand while turning the nut of the installing tool with the other.

  • Page 213: Transmission

    TRANSMISSION EBS00345 TRANSMISSION Order Job/Part Q’ty Remarks Removing the transmission Remove the parts in the order listed. Crankcase Separate. Refer to “CRANKCASE”. Shift fork “C” Shift fork “R” Refer to “INSTALLING THE TRANSMIS- SION”. Shift fork “L” Shift drum Main axle assembly Spacer Drive axle assembly For installation, reverse the removal pro-...

  • Page 214: Main Axle

    TRANSMISSION EBS00347 MAIN AXLE Order Job/Part Q’ty Remarks Disassembling the main axle Remove the parts in the order listed. 2nd pinion gear Refer to “ASSEMBLING THE MAIN AXLE AND DRIVE AXLE”. 4th pinion gear 3rd pinion gear Circlip Refer to “ASSEMBLING THE MAIN AXLE AND DRIVE AXLE”.

  • Page 215: Drive Axle

    TRANSMISSION EBS00348 DRIVE AXLE Order Job/Part Q’ty Remarks Disassembling the drive axle Remove the parts in the order listed. Crankcase Refer to “CRANKCASE”. 1st wheel gear 5th wheel gear Circlip Refer to “ASSEMBLING THE MAIN AXLE AND DRIVE AXLE”. Toothed washer 3rd wheel gear Toothed spacer Toothed lock washer...

  • Page 216: Checking The Shift Forks

    TRANSMISSION EBS00350 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks. 1. Check: • shift fork cam follower 1 • shift fork pawl 2 Bends/damage/scoring/wear → Replace the shift fork. 2. Check: • shift fork movement Rough movement →...

  • Page 217: Assembling The Main Axle And Drive Axle

    TRANSMISSION 3. Check: • transmission gear engagement (each pinion gear to its respective wheel gear) Incorrect → Reassemble the transmission axle assemblies. 4. Check: • transmission gear movement Rough movement → Replace the defective part(s). 5. Check: • circlips Bends/damage/looseness → Replace. EBS00355 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE...

  • Page 218: Installing The Transmission

    TRANSMISSION EBS00356 INSTALLING THE TRANSMISSION 1. Install: • shift fork “L” 1 (to drive axle) • shift fork “C” 2 (to main axle) • shift fork “R” 3 (to drive axle) • shift drum 4 • transmission assembly NOTE: 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 219: Radiator

    COOL RADIATOR EBS00125 COOLING SYSTEM RADIATOR 9 Nm (0.9 m kg, 6.5 ft • • 7 Nm (0.7 m kg, 5.1 ft 28 Nm (2.8 m kg, 20 ft • • • • 28 Nm (2.8 m kg, 20 ft •...

  • Page 220

    COOL RADIATOR 9 Nm (0.9 m kg, 6.5 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 28 Nm (2.8 m kg, 20 ft • • 28 Nm (2.8 m kg, 20 ft • • 7 Nm (0.7 m kg, 5.1 ft •...

  • Page 221: Checking The Radiator

    COOL RADIATOR EBS00127 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 222: Installing The Radiator

    COOL RADIATOR EBS00128 INSTALLING THE RADIATOR 1. Fill: • cooling system (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT” in chapter 3. 2. Check: • cooling system Leaks → Repair or replace any faulty part. 5 - 4...

  • Page 223: Water Pump

    COOL WATER PUMP EBS00134 WATER PUMP Order Job/Part Q’ty Remarks Removing the water pump Remove the parts in the order listed. Engine oil Drain. Coolant Drain. Exhaust pipe Refer “ENGINE REMOVAL” chapter 4. Rear brake light switch/footrest (right) Refer to “FRONT AND REAR BRAKES” in chapter 7.

  • Page 224

    COOL WATER PUMP Order Job/Part Q’ty Remarks Oil hose 1 Right crankcase cover Gasket Impeller Washer Impeller shaft Oil seal Bearing Oil seal For installation, reverse the removal pro- cedure. 5 - 6...

  • Page 225: Checking The Water Pump

    COOL WATER PUMP EBS00139 CHECKING THE WATER PUMP 1. Check: • water pump housing 1 • impeller 2 • impeller shaft 3 Cracks/damage/wear → Replace. 2. Check: • oil seal • water pump inlet pipe Cracks/damage/wear → Replace. • bearing Rough movement →...

  • Page 226

    CARB CARBURETOR EBS00141 CARBURETOR CARBURETOR 4 Nm (0.4 m kg, 2.9 ft • • 4 Nm (0.4 m kg, 2.9 ft • • 3 Nm (0.3 m kg, 2.2 ft • • 3 Nm (0.3 m kg, 2.2 ft • •...

  • Page 227

    CARB CARBURETOR EBS00144 Order Job/Part Q’ty Remarks Disassembling the carburetor Remove the parts in the order listed. Drain hose Air vent hose Throttle position sensor Cover Carburetor switch/throttle stop screw assembly Starter plunger Carburetor top cover Screw (throttle shaft) Throttle valve Throttle valve plate 6 - 2...

  • Page 228

    CARB CARBURETOR Order Job/Part Q’ty Remarks Needle holder Jet needle Cover/spring Pilot air diaphragm Cover/spring Accelerator pump diaphragm Float chamber Accelerator jet Float pin Float 6 - 3...

  • Page 229

    CARB CARBURETOR Order Job/Part Q’ty Remarks Needle valve Main jet Needle jet Spacer Pilot jet Starter jet Pilot air jet For assembly, reverse the disassembly procedure. 6 - 4...

  • Page 230: Disassembling The Carburetor

    CARB CARBURETOR EBS00146 DISASSEMBLING THE CARBURETOR NOTE: Before disassembling the carburetor, make sure to note the number of times the pilot screw is turned out from the seated position to its set position. EBS00148 CHECKING THE CARBURETOR 1. Check: • carburetor body •...

  • Page 231

    CARB CARBURETOR 4. Check: • throttle valve 1 • throttle valve plate 2 Scratches/wear/damage → Replace. 5. Check: • accelerator pump diaphragm 1 • pilot jet diaphragm 2 • spring 3 6. Check: • jet needle 1 Bends/wear/damage → Replace. •...

  • Page 232: Assembling The Carburetor

    CARB CARBURETOR EBS00150 ASSEMBLING THE CARBURETOR CAUTION: Before reassembling, wash all of the parts in a clean petroleum based solvent. 1. Install: • pilot screw 1 NOTE: Before assembling the carburetor, make sure to turn out the pilot screw the same number of times, as noted before disassembly, from the seated position to the set position.

  • Page 233: Adjusting The Accelerator Pump Timing

    CARB CARBURETOR ADJUSTING THE ACCELERATOR PUMP TIMING 1. Adjust: • accelerator pump timing M MMM M MMM M MMM M MMM M MMM NOTE: Insert a rod 1 with an outer diameter equal to the specified throttle valve height a under the throttle valve plate 2 to achieve the specified value.

  • Page 234: Installing The Carburetor

    CARB CARBURETOR INSTALLING THE CARBURETOR 1. Install: • carburetor NOTE: Align the projection a on the carburetor with the slot b in the carburetor joint, and then align the projection c on the carburetor with the slot d in the air intake duct. 2.

  • Page 235

    CARB CARBURETOR 2. Adjust: • throttle position sensor angle M MMM M MMM M MMM M MMM M MMM a. Loosen the throttle position sensor screw b. Turn the throttle position sensor in direction a or b until the specified throttle position sensor output voltage is indicated on the pocket tester.

  • Page 236: Front And Rear Wheels

    CHAS FRONT AND REAR WHEELS EBS00378 CHASSIS FRONT AND REAR WHEELS FRONT WHEELS Order Job/Part Q’ty Remarks Removing the front wheels Remove the parts in the order listed. The following procedure applies to both of the front wheels. Place the machine on a level surface. WARNING Securely support the machine so there is no danger of it falling over.

  • Page 237

    CHAS FRONT AND REAR WHEELS Order Job/Part Q’ty Remarks Brake caliper assembly NOTE: Do not squeeze the brake lever when the brake caliper is off of the brake discs as the brake pads will be forced shut. Wheel hub Brake disc For installation, reverse the removal pro- cedure.

  • Page 238: Rear Wheels

    CHAS FRONT AND REAR WHEELS REAR WHEELS Order Job/Part Q’ty Remarks Removing the rear wheels Remove the parts in the order listed. Place the machine on a level surface. WARNING Securely support the machine so there is no danger of it falling over. Rear wheel Cotter pin Refer to “INSTALLING THE WHEEL...

  • Page 239

    CHAS FRONT AND REAR WHEELS EBS00383 CHECKING THE WHEELS 1. Check: • wheels 2. Measure: • wheel runout Over the specified limit → Replace the wheel or check the wheel bearing play 1. Wheel runout limit Radial 2: 2.0 mm (0.08 in) Lateral 3: 2.0 mm (0.08 in) 3.

  • Page 240: Checking The Brake Discs

    CHAS FRONT AND REAR WHEELS 2. Check: • wheel bearings Wheel hub play/wheel turns roughly → Replace. M MMM M MMM M MMM M MMM M MMM a. Clean wheel hub exterior. b. Drive bearing out by pushing spacer aside and tapping around perimeter of bearing inner race.

  • Page 241: Installing The Front Wheel Hub Bearings

    CHAS FRONT AND REAR WHEELS INSTALLING THE FRONT WHEEL HUB BEARINGS 1. Install: • bearings 1 NOTE: Face the oil seal side of the bearing inward. INSTALLING THE FRONT BRAKE DISCS 1. Install: • brake discs NOTE: Install the brake disc with its spot-faced side facing the bolt heads.

  • Page 242: Installing The Wheel Hubs

    CHAS FRONT AND REAR WHEELS EBS00390 INSTALLING THE WHEEL HUBS 1. Install: • front axle nuts 1 70 Nm (7.0 m · kg, 50 ft · lb) • rear axle nuts 1 120 Nm (12.0 m · kg, 85 ft · lb) •...

  • Page 243: Rear Axle And Rear Axle Hub

    CHAS REAR AXLE AND REAR AXLE HUB EBS00382 REAR AXLE AND REAR AXLE HUB Order Job/Part Q’ty Remarks Removing the rear axle and rear axle Remove the parts in the order listed. Rear wheels/rear wheel hubs Refer to “FRONT AND REAR WHEELS”. Bolt Refer to “REMOVING THE REAR Conical spring washer...

  • Page 244

    CHAS REAR AXLE AND REAR AXLE HUB Order Job/Part Q’ty Remarks Brake disc/brake disc bracket Refer to “REMOVING THE REAR Rear axle AXLE”. Circlip Driven sprocket/sprocket bracket Refer to “INSTALLING THE DRIVEN SPROCKET”. Brake caliper bracket Rear axle hub Spacer/bearing/oil seal 1/2/2 Refer to “INSTALLING THE FRONT WHEEL HUB BEARINGS”.

  • Page 245: Removing The Rear Axle

    CHAS REAR AXLE AND REAR AXLE HUB EBS00393 REMOVING THE REAR AXLE 1. Place the machine on a level surface. 2. Remove: • bolts 3. Loosen: • nut 1 NOTE: • Apply the brake pedal so that the rear axle does not turn, when loosening the nut.

  • Page 246: Checking The Rear Axle

    CHAS REAR AXLE AND REAR AXLE HUB 8. Remove: • rear axle 1 (with driven sprocket) CAUTION: • Never directly tap the axle end with a hammer, since this will result in damage to the axle thread and spline. • Attach a suitable socket 2 on the axle end and tap it with a soft hammer, then pull out the rear axle to the right.

  • Page 247: Installing The Driven Sprocket

    CHAS REAR AXLE AND REAR AXLE HUB INSTALLING THE DRIVEN SPROCKET 1. Install: • driven sprocket NOTE: Make sure that the blunt-edged corner a of the driven sprocket is facing outward. EBS00397 INSTALLING THE REAR AXLE 1. Install: • conical spring washer 1 NOTE: Install the conical spring washer with the con- vex side of the washer facing outward as...

  • Page 248: Front And Rear Brakes

    CHAS FRONT AND REAR BRAKES EBS00400 FRONT AND REAR BRAKES FRONT BRAKE PADS 18 Nm (1.8 m kg, 13 ft • • 28 Nm (2.8 m kg, 20 ft • • Order Job/Part Q’ty Remarks Removing the front brake pads Remove the parts in the order listed.

  • Page 249: Rear Brake Pads

    CHAS FRONT AND REAR BRAKES EBS00401 REAR BRAKE PADS 18 Nm (1.8 m kg, 13 ft • • 31 Nm (3.1 m kg, 22 ft • • Order Job/Part Q’ty Remarks Removing the rear brake pads Remove the parts in the order listed. Brake caliper mounting bolt Refer “REPLACING THE REAR...

  • Page 250: Replacing The Front Brake Pads

    CHAS FRONT AND REAR BRAKES EBS00402 CAUTION: Disc brake components rarely require dis- assembly. DO NOT: • disassemble components unless abso- lutely necessary; • use solvents on internal brake compo- nents; • use spent brake fluid for cleaning; (use only clean brake fluid) •...

  • Page 251

    CHAS FRONT AND REAR BRAKES 2. Install: • brake pads • brake pad spring NOTE: Always install new brake pads and brake pad spring as a set. M MMM M MMM M MMM M MMM M MMM a. Connect a suitable hose 1 tightly to the brake caliper bleed screw 2.

  • Page 252: Replacing The Rear Brake Pads

    CHAS FRONT AND REAR BRAKES EBS00405 REPLACING THE REAR BRAKE PADS NOTE: It is not necessary to disassemble the brake caliper and brake hose to replace the brake pads. 1. Remove: • brake pads a wear limit NOTE: Replace the brake pads as a set if either is found to be worn to the wear limit.

  • Page 253

    CHAS FRONT AND REAR BRAKES f. Bend the lock washer tabs along a flat side of the bolts. L LLL L LLL L LLL L LLL L LLL 3. Check: • brake fluid level Refer to “CHECKING THE BRAKE FLUID LEVEL”...

  • Page 254: Front Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EBS00407 FRONT BRAKE MASTER CYLINDER Order Job/Part Q’ty Remarks Removing the front brake master Remove the parts in the order listed. cylinder Brake fluid Drain. Brake fluid reservoir cap Brake fluid reservoir diaphragm Front brake light switch Brake lever Union bolt Copper washer...

  • Page 255

    CHAS FRONT AND REAR BRAKES EBS00409 Order Job/Part Q’ty Remarks Disassembling the front brake mas- Remove the parts in the order listed. ter cylinder Dust boot Refer to “ASSEMBLING THE FRONT Circlip BRAKE MASTER CYLINDER”. Brake master cylinder kit For assembly, reverse the disassembly procedure.

  • Page 256: Rear Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EBS00410 REAR BRAKE MASTER CYLINDER Order Job/Part Q’ty Remarks Removing the rear brake master cyl- Remove the parts in the order listed. inder Right foot protector Refer to “SEAT, FENDERS AND FUEL TANK” in chapter 3. Brake fluid Drain.

  • Page 257

    CHAS FRONT AND REAR BRAKES Order Job/Part Q’ty Remarks Union bolt Refer “INSTALLING Copper washer THE REAR BRAKE MAS- Brake hose Disconnect. TER CYLINDER”. Brake master cylinder Rear brake light switch Right footrest Brake pedal/spring For installation, reverse the removal pro- cedure.

  • Page 258

    CHAS FRONT AND REAR BRAKES EBS00411 Order Job/Part Q’ty Remarks Disassembling the rear brake mas- Remove the parts in the order listed. ter cylinder Hose joint Brake master cylinder kit Refer to “ASSEMBLING THE REAR BRAKE MASTER CYLINDER”. Brake master cylinder For assembly, reverse the disassembly procedure.

  • Page 259: Checking The Master Cylinders

    CHAS FRONT AND REAR BRAKES È EBS00413 CHECKING THE MASTER CYLINDERS 1. Check: • brake master cylinder 1 Wear/scratches → Replace the brake mas- ter cylinder assembly. • brake master cylinder body Cracks/damage → Replace. • brake fluid delivery passage (brake master cylinder body) Blockage →...

  • Page 260: Assembling The Front Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EBS00415 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER WARNING • All internal brake components should be cleaned and lubricated with new brake fluid only before installation. Recommended brake fluid DOT 4 • Whenever a master cylinder is disassem- bled, replace the piston seals and dust seals.

  • Page 261: Installing The Front Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EBS00418 INSTALLING THE FRONT BRAKE MASTER CYLINDER 1. Install: • brake master cylinder 1 7 Nm (0.7 m · kg, 5.1 ft · lb) NOTE: • The “UP” mark on the brake master cylinder bracket should face up. •...

  • Page 262: Installing The Rear Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES WARNING • Use only the designated quality brake fluid: other brake fluids may deteriorate the rubber seals, causing leakage and poor brake performance. • Refill with the same type of brake fluid: mixing brake fluids may result in a harm- ful reaction and lead to poor brake perfor- mance.

  • Page 263

    CHAS FRONT AND REAR BRAKES 2. Install: 35˚ • brake fluid reservoir hose 1 NOTE: Install the brake fluid reservoir hose with the white paint mark a facing up as shown. 3. Fill: • brake fluid reservoir Recommended brake fluid DOT 4 CAUTION: Brake fluid may damage painted surfaces...

  • Page 264: Front Brake Calipers

    CHAS FRONT AND REAR BRAKES EBS00421 FRONT BRAKE CALIPERS 18 Nm (1.8 m kg, 13 ft • • 28 Nm (2.8 m kg, 20 ft • • 27 Nm (2.7 m kg, 19 ft • • Order Job/Part Q’ty Remarks Removing the front brake calipers Remove the parts in the order listed.

  • Page 265

    CHAS FRONT AND REAR BRAKES EBS00423 18 Nm (1.8 m kg, 13 ft 6 Nm (0.6 m kg, 4.3 ft • • • • Order Job/Part Q’ty Remarks Disassembling the front brake cali- Remove the parts in the order listed. pers The following procedure applies to both of the front brake calipers.

  • Page 266: Rear Brake Caliper

    CHAS FRONT AND REAR BRAKES EBS00424 REAR BRAKE CALIPER Order Job/Part Q’ty Remarks Removing the rear brake caliper Remove the parts in the order listed. Brake fluid Drain. Parking brake cable Disconnect. Refer to “REMOVING THE PARKING BRAKE CABLE”. Union bolt Copper washer Refer “INSTALLING...

  • Page 267

    CHAS FRONT AND REAR BRAKES EBS00425 Order Job/Part Q’ty Remarks Disassembling the rear brake cali- Remove the parts in the order listed. Adjusting bolt Locknut Parking brake arm Parking brake case mounting bolt Parking brake case bracket Parking brake case Gasket Spring Bearing...

  • Page 268

    CHAS FRONT AND REAR BRAKES Order Job/Part Q’ty Remarks Brake pad holding bolt Lock washer Brake pad/pad shim Brake pad spring Retaining bolt Caliper bracket Brake caliper piston Refer “DISASSEMBLING Dust seal FRONT AND REAR BRAKE CALI- PERS” and “ASSEMBLING THE REAR Caliper piston seal BRAKE CALIPER”.

  • Page 269: Removing The Parking Brake Cable

    CHAS FRONT AND REAR BRAKES REMOVING THE PARKING BRAKE CABLE 1. Loosen: • nut • adjusting bolt 2. Disconnect: • parking brake cable (from parking brake lever) 3. Disconnect: • parking brake cable (from rear brake) È EBS00427 DISASSEMBLING THE FRONT AND REAR BRAKE CALIPERS 1.

  • Page 270: Checking The Front And Rear Brake Calipers

    CHAS FRONT AND REAR BRAKES EBS00429 CHECKING THE FRONT AND REAR BRAKE CALIPERS Recommended brake component replacement schedule Brake pads As required Piston seals, dust Every two years seals Brake hoses Every four years Replace when Brake fluid brakes are disassembled.

  • Page 271: Assembling The Front Brake Calipers

    CHAS FRONT AND REAR BRAKES EBS00431 ASSEMBLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the front brake calipers. WARNING • All internal brake components should be cleaned and lubricated with new brake fluid only before installation. Recommended brake fluid DOT 4 •...

  • Page 272

    CHAS FRONT AND REAR BRAKES 2. Install: • brake caliper piston 1 3. Install: • lock washer 1 • brake pad holding bolts 2 18 Nm (1.8 m · kg, 13 ft · lb) 4. Bend the lock washer tabs along a flat side of the bolts.

  • Page 273: Installing The Front Brake Calipers

    CHAS FRONT AND REAR BRAKES EBS00434 INSTALLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the front brake calipers. 1. Install: • brake caliper assembly • brake caliper mounting bolts 1 28 Nm (2.8 m · kg, 20 ft · lb) •...

  • Page 274: Installing The Rear Brake Caliper

    CHAS FRONT AND REAR BRAKES 3. Air bleed: • brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. 4. Check: • brake fluid level Brake fluid level is below the “LOWER” level line → Add the recommended brake fluid to the proper level.

  • Page 275

    CHAS FRONT AND REAR BRAKES CAUTION: Brake fluid may damage painted surfaces or plastic parts. Always clean up spilled brake fluid immediately. WARNING • Use only the designated quality brake fluid: other brake fluids may deteriorate the rubber seals, causing leakage and poor brake performance.

  • Page 276: Steering System

    CHAS STEERING SYSTEM EBS00444 STEERING SYSTEM HANDLEBAR 7 Nm (0.7 m kg, 5.1 ft • • 23 Nm (2.3 m kg, 17 ft • • 4 Nm (0.4 m kg, 2.9 ft • • 4 Nm (0.4 m kg, 2.9 ft •...

  • Page 277

    CHAS STEERING SYSTEM 7 Nm (0.7 m kg, 5.1 ft • • 23 Nm (2.3 m kg, 17 ft • • 4 Nm (0.4 m kg, 2.9 ft • • 4 Nm (0.4 m kg, 2.9 ft • • 7 Nm (0.7 m kg, 5.1 ft •...

  • Page 278: Removing The Front Brake Light Switch And Clutch Switch

    CHAS STEERING SYSTEM EBS00446 REMOVING THE FRONT BRAKE LIGHT SWITCH AND CLUTCH SWITCH 1. Remove: • front brake light switch 1 • clutch switch NOTE: • Push the fastener when removing the front brake light switch out of the brake master cyl- inder.

  • Page 279: Installing The Handlebar

    CHAS STEERING SYSTEM EBS00449 INSTALLING THE HANDLEBAR 1. Install: • handlebar • handlebar holders 23 Nm (2.3 m · kg, 17 ft · lb) NOTE: • Install the handlebar within 3.3° from the hor- izontal line shown in the illustration. •...

  • Page 280: Installing The Clutch Lever

    CHAS STEERING SYSTEM EBS00452 INSTALLING THE CLUTCH LEVER 1. Install: • handlebar switch 1 • clutch lever • clutch lever bracket 2 NOTE: Install the clutch lever bracket as shown. a 68 ~ 69 mm (2.68 ~ 2.72 in) EBS00453 INSTALLING THE BRAKE MASTER CYLINDER 1.

  • Page 281: Steering Stem

    CHAS STEERING SYSTEM EBS00454 STEERING STEM Order Job/Part Q’ty Remarks Removing the steering stem Remove the parts in the order listed. Fuel tank cover/side covers (left and Refer to “SEAT, FENDERS AND FUEL right)/fuel tank/front fender TANK” in chapter 3. Pitman arm Refer to “INSTALLING THE PITMAN ARM”.

  • Page 282

    CHAS STEERING SYSTEM Order Job/Part Q’ty Remarks Bearing retainer Refer to “REMOVING THE BEARING RETAINER” and “INSTALLING THE BEARING RETAINER”. Bearing For installation, reverse the removal pro- cedure. 7 - 47...

  • Page 283: Removing The Bearing Retainer

    CHAS STEERING SYSTEM EBS00455 REMOVING THE BEARING RETAINER 1. Remove: • bearing retainer Damper rod holder (30 mm) P/N. YM-01327, 90890-01327 EBS00456 CHECKING THE STEERING STEM 1. Check: • steering stem Bends → Replace. WARNING Do not attempt to straighten a bent stem; this may dangerously weaken the stem.

  • Page 284: Installing The Lock Washer

    CHAS STEERING SYSTEM EBS00459 INSTALLING THE LOCK WASHER 1. Install: • lock washer • bolts 23 Nm (2.3 m · kg, 17 ft · lb) 2. Bend the lock washer tab along a flat side of the bolt. INSTALLING THE PITMAN ARM 1.

  • Page 285: Tie-rods And Steering Knuckles

    CHAS STEERING SYSTEM EBS00460 TIE-RODS AND STEERING KNUCKLES Order Job/Part Q’ty Remarks Removing the tie-rods and steering Remove the parts in the order listed. knuckles The following procedure applies to both of the tie-rods and steering knuckles. Front wheel/brake disc Refer to “FRONT AND REAR WHEELS”.

  • Page 286: Removing The Steering Knuckles

    CHAS STEERING SYSTEM EBS00461 REMOVING THE STEERING KNUCKLES 1. Remove: • steering knuckles 1 NOTE: Use a general puller to separate the ball joint 2 and steering knuckle. EBS00462 CHECKING THE TIE-RODS 1. Check: • tie-rod free play and movement Free play →...

  • Page 287: Front Arms And Front Shock Absorber Assemblies

    FRONT ARMS AND FRONT SHOCK ABSORBER CHAS ASSEMBLIES EBS00468 FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES Order Job/Part Q’ty Remarks Removing the front arms and front Remove the parts in the order listed. shock absorber assemblies The following procedure applies to both of the front arms and front shock absorber assemblies.

  • Page 288

    FRONT ARMS AND FRONT SHOCK ABSORBER CHAS ASSEMBLIES Order Job/Part Q’ty Remarks Nut/bolt Refer to “REMOVING THE FRONT Lower front arm ARMS” and “INSTALLING THE FRONT Nut/bolt ARMS”. Upper front arm Nut/bolt Front shock absorber/bushing Steering knuckle Dust cover Spacer Spacer Bushing Circlip...

  • Page 289: Removing The Front Arms

    FRONT ARMS AND FRONT SHOCK ABSORBER CHAS ASSEMBLIES EBS00469 REMOVING THE FRONT ARMS 1. Check: • front arm free play M MMM M MMM M MMM M MMM M MMM a. Check the front arm side play È by moving È...

  • Page 290: Disposing Of A Front Shock Absorber And Gas Cylinder

    FRONT ARMS AND FRONT SHOCK ABSORBER CHAS ASSEMBLIES • Do not deform or damage the front shock absorber or gas cylinder in any way. If the front shock absorber, gas cylinder or both are damaged, damping performance will suffer. EBS00486 DISPOSING OF A FRONT SHOCK ABSORBER AND GAS CYLINDER Gas pressure must be released before dispos-...

  • Page 291: Checking The Ball Joints

    FRONT ARMS AND FRONT SHOCK ABSORBER CHAS ASSEMBLIES EBS00472 CHECKING THE BALL JOINTS The following procedure applies to both of the front arm ball joints. 1. Check: • ball joint (upper front arm) Damage/pitting → Replace the upper front arm. Free play →...

  • Page 292: Installing The Front Arms

    FRONT ARMS AND FRONT SHOCK ABSORBER CHAS ASSEMBLIES f. Attach the assembled ball joint remover/ installer, new ball joint (with rubber boot and retaining ring) B, installer spacer 8 and installer washer 9 to the lower front arm A. NOTE: •...

  • Page 293: Rear Shock Absorber And Relay Arm

    CHAS REAR SHOCK ABSORBER AND RELAY ARM EBS00484 REAR SHOCK ABSORBER AND RELAY ARM 80 Nm (8.0 m kg, 58 ft • • 55 Nm (5.5 m kg, 40 ft • • 55 Nm (5.5 m kg, 40 ft • •...

  • Page 294

    CHAS REAR SHOCK ABSORBER AND RELAY ARM 80 Nm (8.0 m kg, 58 ft • • 55 Nm (5.5 m kg, 40 ft • • 55 Nm (5.5 m kg, 40 ft • • 43 Nm (4.3 m kg, 31 ft •...

  • Page 295: Handling The Rear Shock Absorber And Gas Cylinder

    CHAS REAR SHOCK ABSORBER AND RELAY ARM EBS00485 HANDLING THE REAR SHOCK ABSORBER AND GAS CYLINDER WARNING This rear shock absorber and gas cylinder contain highly compressed nitrogen gas. Before handling the rear shock absorber or gas cylinder, read and make sure you understand the following information.

  • Page 296: Removing The Rear Shock Absorber

    CHAS REAR SHOCK ABSORBER AND RELAY ARM EBS00487 REMOVING THE REAR SHOCK ABSORBER 1. Remove: • relay arm-to-rear shock absorber lower bolt • rear shock absorber upper bolt NOTE: While removing the relay arm-to-rear shock absorber lower bolt, hold the swingarm so that it does not drop down.

  • Page 297: Installing The Rear Shock Absorber

    CHAS REAR SHOCK ABSORBER AND RELAY ARM EBS00490 INSTALLING THE RELAY ARM AND CONNECTING ARM 1. Install: • bearing 1 (to connecting arm) Installed depth of bearing a 4 mm (0.16 in) 2. Install: • bearings 1 to 3 (to relay arm) Installed depth of bearing a 6.5 mm (0.26 in) Installed depth of bearing b...

  • Page 298: Swingarm And Drive Chain

    CHAS SWINGARM AND DRIVE CHAIN EBS00492 SWINGARM AND DRIVE CHAIN Order Job/Part Q’ty Remarks Removing the swingarm and drive Remove the parts in the order listed. chain Rear axle hub Refer to “REAR AXLE AND REAR AXLE HUB”. Rear shock absorber Refer to “REAR SHOCK ABSORBER AND RELAY ARM”.

  • Page 299

    CHAS SWINGARM AND DRIVE CHAIN Order Job/Part Q’ty Remarks Drive chain guide 2 Refer to “INSTALLING THE DRIVE SPROCKET”. Lock washer Drive sprocket Drive chain Dust cover/washer/bearing 2/2/2 Refer to “INSTALLING THE SWING- Spacer ARM”. Oil seal Bushing For installation, reverse the removal pro- cedure.

  • Page 300: Removing The Swingarm

    CHAS SWINGARM AND DRIVE CHAIN EBS00493 NOTE: Before removing the drive chain and the sprockets, measure the drive chain slack and a 15-link section of the drive chain. EBS00494 REMOVING THE SWINGARM 1. Check: • swingarm free play M MMM M MMM M MMM M MMM...

  • Page 301

    CHAS SWINGARM AND DRIVE CHAIN 2. Check: • pivot shaft Roll the axle on a flat surface. Bends → Replace. WARNING Do not attempt to straighten a bent pivot shaft. 3. Clean: • pivot shaft • spacer • bearings • bushings Recommended cleaning solvent Kerosene 4.

  • Page 302: Checking The Drive Chain

    CHAS SWINGARM AND DRIVE CHAIN EBS00496 CHECKING THE DRIVE CHAIN 1. Measure: • 15-link section a of the drive chain Out of specification → Replace the drive chain. 15-link drive chain section limit (maximum) 240.5 mm (9.47 in) NOTE: • While measuring the 15-link section, push down on the drive chain to increase its ten- sion.

  • Page 303: Installing The Swingarm

    CHAS SWINGARM AND DRIVE CHAIN 4. Check: • O-rings 1 Damage → Replace the drive chain. • drive chain rollers 2 Damage/wear → Replace the drive chain. • drive chain side plates 3 Cracks/damage/wear → Replace the drive chain. 5. Lubricate: •...

  • Page 304: Installing The Drive Sprocket

    CHAS SWINGARM AND DRIVE CHAIN EBS00498 INSTALLING THE DRIVE SPROCKET 1. Install: • drive sprocket 1 • lock washer 2 • nut 3 75 Nm (7.5 m · kg, 54 ft · lb) 2. Bend the lock washer tab along a flat side of the nut.

  • Page 305: Electrical Components

    – ELEC ELECTRICAL COMPONENTS EBS00500 ELECTRICAL ELECTRICAL COMPONENTS 1 Main switch 9 Starting circuit cut-off F Thermo switch 2 L Rectifier/regulator 2 Throttle switch G Pickup coil/stator M C.D.I. unit relay 3 Front brake light switch 0 Tail/brake light N Headlight assembly 4 Indicator light A Battery...

  • Page 306: Checking Switch Continuity

    – ELEC CHECKING SWITCH CONTINUITY EBS01028 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 1.

  • Page 307

    – ELEC CHECKING SWITCH CONTINUITY 8 - 3...

  • Page 308: Checking The Switches

    – ELEC CHECKING THE SWITCHES EBS01029 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 309

    – ELEC CHECKING THE SWITCHES 1 Light switch 2 Engine stop switch 3 Start switch 4 Main switch 5 Front brake light switch 6 Throttle switch 7 Clutch switch 8 Carburetor switch 9 Fuse 0 Neutral switch A Rear brake light switch 8 - 5...

  • Page 310: Checking The Bulbs And Bulb Sockets

    – ELEC CHECKING THE BULBS AND BULB SOCKETS EBS01030 CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage or wear, proper connections, and also for con- tinuity between the terminals. Damage/wear → Repair or replace the bulb, bulb socket or both.

  • Page 311

    – ELEC CHECKING THE BULBS AND BULB SOCKETS WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. CAUTION: • Be sure to hold the socket firmly when removing the bulb.

  • Page 312: 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 P/N.

  • Page 313: Ignition System

    – ELEC IGNITION SYSTEM EBS00503 IGNITION SYSTEM CIRCUIT DIAGRAM 1 A.C. magneto 3 Main switch 4 Battery 5 Fuse A C.D.I. unit B Ignition coil C Spark plug E Throttle switch F Carburetor switch Q Engine stop switch 8 - 9...

  • Page 314: Throttle Override System (t.o.r.s.) Operation

    – ELEC IGNITION SYSTEM THROTTLE OVERRIDE SYSTEM (T.O.R.S.) OPERATION This model is equipped with a throttle override system as a safety device that operates according to the positions of the throttle switch and carburetor switch and stops the flow of electricity from the C.D.I.

  • Page 315: Troubleshooting

    – ELEC IGNITION SYSTEM EBS01045 EBS01044 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. fuse Minimum open-circuit voltage 2.

  • Page 316

    – ELEC IGNITION SYSTEM EBS01034 EBS01038 4. Ignition spark gap 5. Ignition coil resistance • Disconnect the ignition coil from the spark • Disconnect the ignition coil coupler from plug. the ignition coil. • Connect the dynamic spark tester 1 as •...

  • Page 317

    – ELEC IGNITION SYSTEM EBS01041 EBS01040 6. Main switch 10.Pickup coil resistance • Check the main switch for continuity. • Disconnect the pickup coil coupler from Refer to “CHECKING THE SWITCHES”. the wire harness. • Connect the pocket tester (Ω × 100) to the •...

  • Page 318: Checking The Throttle Override System

    – ELEC IGNITION SYSTEM CHECKING THE THROTTLE OVERRIDE SYSTEM WARNING • Make sure that the parking brake is applied. • Make sure that the transmission is in neu- tral. NOTE: Make sure that the throttle lever moves smoothly. 1. Remove: •...

  • Page 319

    – ELEC IGNITION SYSTEM 5. Install: • throttle lever cover • carburetor switch/throttle stop screw assembly cover • throttle position sensor Refer to “CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR” in chapter 6. 8 - 15...

  • Page 320: Electric Starting System

    – ELEC ELECTRIC STARTING SYSTEM EBS00506 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM 8 - 16...

  • Page 321: Starting Circuit Cut-off System Operation

    – ELEC ELECTRIC STARTING SYSTEM EBS00508 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION The starting circuit on this model consists of the starter motor, starter relay, clutch switch, and neutral switch. If the main switch is on and the engine stop switch is in the RUN position, the starter motor can be operated only if: •...

  • Page 322

    – ELEC ELECTRIC STARTING SYSTEM EBS01050 EBS01044 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. fuse 2. battery Minimum open-circuit voltage 3.

  • Page 323

    – ELEC ELECTRIC STARTING SYSTEM EBS01052 EBS01053 4. Starting circuit cut-off relay 5. Starting circuit cut-off relay (diode) • Remove the starting circuit cut-off relay • Remove the starting circuit cut-off relay from the wire harness. from the wire harness. •...

  • Page 324

    – ELEC ELECTRIC STARTING SYSTEM EBS01054 EBS01042 6. Starter relay 8. Engine stop switch • Disconnect the starter relay coupler from • Check the engine stop switch for continu- the wire harness. ity. • Connect the pocket tester (Ω × 1) and bat- Refer to “CHECKING THE SWITCHES”.

  • Page 325

    – ELEC ELECTRIC STARTING SYSTEM EBS01059 12.Wiring • Check the entire starting system’s wiring. Refer to “CIRCUIT DIAGRAM”. • Is the starting system’s wiring properly connected and without defects? The starting system Properly connect or circuit is OK. repair starting system’s wiring.

  • Page 326: Starter Motor

    – ELEC STARTER MOTOR EBS01061 STARTER MOTOR 20 Nm (2.0 m kg, 14 ft • • 18 Nm (1.8 m kg, 13 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft •...

  • Page 327

    – ELEC STARTER MOTOR EBS01062 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks Disassembling the starter motor Remove the parts in the order listed. Front bracket O-ring Shim Lock washer Rear bracket Refer to “ASSEMBLING THE STARTER MOTOR”.

  • Page 328: Checking The Starter Motor

    – ELEC STARTER MOTOR EBS01064 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 329: Assembling The Starter Motor

    – ELEC STARTER MOTOR 5. Measure: • brush length a Out of specification → Replace the brushes as a set. Brush length wear limit 3.5 mm (0.14 in) 6. Measure: • brush spring force Out of specification → Replace the brush springs as a set.

  • Page 330: Charging System

    – ELEC CHARGING SYSTEM EBS00516 CHARGING SYSTEM CIRCUIT DIAGRAM ( BLACK ) ( BLACK ) R Y/R ( BLACK ) Br/L Br/L ( GRAY ) ( GRAY ) Br/L ( BLACK ) BrR/B PUSH R/B Br ( BLACK ) ( BLACK ) ( BLACK ) ( BLACK ) ( BLACK )

  • Page 331

    – ELEC CHARGING SYSTEM EBS01065 EBS01044 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. fuse 2. battery Minimum open-circuit voltage 3.

  • Page 332

    – ELEC CHARGING SYSTEM EBS01066 EBS01100 3. Charging voltage 4. Charging coil resistance • Connect the engine tachometer to on to • Disconnect the A.C. magneto coupler from the ignition coil. the wire harness. • Connect the pocket tester (Ω × 1) to the •...

  • Page 333: Lighting System

    – ELEC LIGHTING SYSTEM EBS00518 LIGHTING SYSTEM CIRCUIT DIAGRAM ( BLACK ) ( BLACK ) R Y/R ( BLACK ) Br/L Br/L ( GRAY ) ( GRAY ) Br/L ( BLACK ) BrR/B PUSH R/B Br ( BLACK ) ( BLACK ) ( BLACK ) ( BLACK ) ( BLACK )

  • Page 334

    – ELEC LIGHTING SYSTEM EBS01067 EAS00776 TROUBLESHOOTING 2. Lighting coil resistance Any of the following fail to light: head- • Disconnect the A.C. magneto coupler from light, tail/brake light. the wire harness. • Connect the pocket tester (Ω × 1) to the Check: lighting coil terminals as shown.

  • Page 335: Checking The Lighting System

    – ELEC LIGHTING SYSTEM EBS01069 2. Voltage 3. Wiring • Connect the pocket tester (AC 20 V) to the • Check the entire lighting system’s wiring. headlight couplers as shown. Refer to “CIRCUIT DIAGRAM”. È When the light switch is set to “LO” •...

  • Page 336

    – ELEC LIGHTING SYSTEM 2. The tail/brake light fails to come on. 1. Tail/brake light bulb and socket • Check the tail/brake light bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS”. • Are the tail/brake light bulb and socket Replace tail/ brake...

  • Page 337: Signal System

    – ELEC SIGNAL SYSTEM EBS00521 SIGNAL SYSTEM CIRCUIT DIAGRAM 8 - 33...

  • Page 338

    – ELEC SIGNAL SYSTEM EBS01073 EBS01044 TROUBLESHOOTING 2. Battery Any of the following fail to light: brake • Check the condition of the battery. light or an indicator light. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: 1.

  • Page 339: Checking The Signaling System

    – ELEC SIGNAL SYSTEM EBS01075 3. Voltage CHECKING THE SIGNALING SYSTEM EBS01076 • Connect the pocket tester (DC 20 V) to the 1. The tail/brake light fails to come on. tail/brake light coupler (wire harness side) as shown. 1. Tail/brake light bulb and bulb socket Positive tester probe →...

  • Page 340

    – ELEC SIGNAL SYSTEM EBS01083 2. Neutral switch 3. The coolant temperature warning light does not come on when the start switch is • Check the neutral switch for continuity. pushed on, or if the coolant temperature Refer to “CHECKING THE SWITCHES”. warning light does not come on when the •...

  • Page 341

    – ELEC SIGNAL SYSTEM È The thermo switch circuit is open and the cool- 2. Thermo switch 2 ant temperature warning light is off. • Remove the thermo switch 2 from the radi- É The thermo switch circuit is closed and the ator.

  • Page 342

    – ELEC SIGNAL SYSTEM 3. Voltage • Connect the pocket tester (DC 20 V) to the indicator light connector (wire harness side) as shown. Positive tester probe → red/black 1 Negative tester probe → white/blue 2 NOTE: When you switch the tester’s positive and negative probes, the readings in the above chart will be reversed.

  • Page 343

    – ELEC COOLING SYSTEM EBS00532 COOLING SYSTEM CIRCUIT DIAGRAM ( BLACK ) Y/B B/Y ( BLACK ) Br/L Br/L ( GRAY ) ( GRAY ) Br/L ( BLACK ) Br/L ( GR BrR/B ( GR PUSH W/L Br R/B Br ( BLACK ) ( BLACK ) R/B W/L...

  • Page 344

    – ELEC COOLING SYSTEM EBS01085 EBS01044 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. fuse 2. battery Minimum open-circuit voltage 3.

  • Page 345

    – ELEC COOLING SYSTEM EBS01086 EBS01088 4. Radiator fan motor 6. Thermo switch 1 • Disconnect the radiator fan motor coupler • Remove the thermo switch 1 from the radi- from the wire harness. ator. • Connect the pocket tester (Ω × 1) to the •...

  • Page 346

    – ELEC COOLING SYSTEM WARNING • Handle the thermo switch with special care. • Never subject the thermo switch to strong shocks. If the thermo switch is dropped, replace it. Thermo switch 28 Nm (2.8 m · kg, 20 ft · lb) È...

  • Page 347: Starting Failure/hard Starting

    TRBL STARTING FAILURE/HARD STARTING SHTG EBS00537 TROUBLESHOOTING NOTE: The following troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to troubleshooting. Refer to the relative procedure in this manual for check, adjustment and replacement of parts.

  • Page 348: Compression System

    TRBL STARTING FAILURE/HARD STARTING/POOR IDLE SPEED SHTG PERFORMANCE/POOR MEDIUM AND HIGH-SPEED PERFORMANCE COMPRESSION SYSTEM Cylinder and cylinder head Piston and piston rings • Loose spark plug • Improperly installed piston ring • Loose cylinder head or cylinder • Worn, fatigued or broken piston ring •...

  • Page 349: Faulty Gear Shifting

    FAULTY GEAR SHIFTING/ TRBL CLUTCH SLIPPING/DRAGGING SHTG EBS00541 FAULTY GEAR SHIFTING HARD SHIFTING Refer to “CLUTCH DRAGGING”. SHIFT PEDAL DOES NOT MOVE Shift shaft Transmission • Bent shift shaft • Seized transmission gear Shift drum and shift forks • Jammed impurities •...

  • Page 350: Overheating

    OVERHEATING/FAULTY BRAKE/ TRBL SHOCK ABSORBER MALFUNCTION SHTG EBS00547 OVERHEATING OVERHEATING Ignition system Engine oil • Improper spark plug gap • Improper oil level • Improper spark plug heat range • Improper oil viscosity • Faulty C.D.I. unit • Inferior oil quality Fuel system Brake •...

  • Page 351: Unstable Handling

    UNSTABLE HANDLING/ TRBL LIGHTING SYSTEM SHTG EBS00552 UNSTABLE HANDLING UNSTABLE HANDLING Handlebar Wheels • Improperly installed or bent • Deformed wheel Steering • Loose bearing • Incorrect toe-in • Bent or loose wheel axle • Bent steering stem • Excessive wheel runout •...

  • Page 354

    YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U.S.A.

  • Page 355

    YFZ450S WIRING DIAGRAM 1 A.C. magneto 2 Rectifier/regulator (BLACK) (BLACK) 3 Main switch 4 Battery 5 Fuse 6 Starter relay 7 Starter motor (BLACK) (BLACK) R Y/R 8 Diode 1 (BLACK) 9 Starting circuit cut-off relay 0 Clutch switch A C.D.I. unit B Ignition coil C Spark plug D Throttle position sensor...

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