Yamaha XT250X Service Manual
  1. Manuals
  2. Brands
  3. Yamaha Manuals
  4. Motorcycle
  5. XT250X
  6. Service manual

Yamaha XT250X Service Manual

Hide thumbs Also See for XT250X:
Table of Contents

Advertisement

Quick Links

Download this manual See also: Owner's Manual
2008
SERVICE MANUAL
XT250X
XT250XC
LIT-11616-21-52
3C5-28197-10

Advertisement

Table of Contents
loading

Related Manuals for Yamaha XT250X

Summary of Contents for Yamaha XT250X

  • Page 1 2008 SERVICE MANUAL XT250X XT250XC LIT-11616-21-52 3C5-28197-10...
  • Page 3 EAS20050 XT250X XT250XC SERVICE MANUAL ©2008 by Yamaha Motor Corporation, U.S.A. First edition, August 2007 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. P/N LIT-11616-21-52...
  • Page 4 If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives.

  • Page 5: How To Use This Manual

    EAS20090 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. The manual is divided into chapters and each chapter is divided into sections.

  • Page 6: Symbols

    EAS20100 1. Serviceable with engine mounted SYMBOLS 2. Filling fluid The following symbols are used in this manual 3. Lubricant for easier understanding. 4. Special tool NOTE: 5. Tightening torque The following symbols are not relevant to every 6. Wear limit, clearance vehicle.

  • Page 7: Table Of Contents

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

  • Page 9: General Information

    GENERAL INFORMATION IDENTIFICATION ...................1-1 VEHICLE IDENTIFICATION NUMBER............1-1 MODEL LABEL ..................1-1 IMPORTANT INFORMATION ................1-2 PREPARATION FOR REMOVAL AND DISASSEMBLY ......1-2 REPLACEMENT PARTS .................1-2 GASKETS, OIL SEALS AND O-RINGS ...........1-2 LOCK WASHERS/PLATES AND COTTER PINS........1-2 BEARINGS AND OIL SEALS..............1-2 CIRCLIPS....................1-3 CHECKING THE CONNECTIONS..............1-4 SPECIAL TOOLS...................1-5...

  • Page 10: Identification

    IDENTIFICATION EAS20130 IDENTIFICATION EAS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the right side of the steering head pipe. EAS20150 MODEL LABEL The model label “1” is affixed to the frame. This information will be needed to order spare parts.

  • Page 11: Important Information

    Oil bearings liberally when installing, if appropri- EAS20200 ate. REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but...

  • Page 12: Circlips

    IMPORTANT INFORMATION ECA13300 CAUTION: Do not spin the bearing with compressed air because this will damage the bearing surfac- EAS20240 CIRCLIPS Before reassembly, check all circlips carefully and replace damaged or distorted circlips. Al- ways replace piston pin clips after one use. When installing a circlip “1”, make sure the sharp-edged corner “2”...

  • Page 13: Checking The Connections

    CHECKING THE CONNECTIONS EAS20250 CHECKING THE CONNECTIONS Pocket tester 90890-03132 Check the leads, couplers, and connectors for stains, rust, moisture, etc. NOTE: 1. Disconnect: If there is no continuity, clean the terminals. Lead When checking the wire harness, perform Coupler steps (1) to (3).

  • Page 14: Special Tools

    SPECIAL TOOLS EAS20260 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes.
  • Page 15 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Steering nut wrench 3-23 90890-01403 Spanner wrench YU-33975 Ring nut wrench 3-24, 4-49 90890-01268 Spanner wrench YU-01268 Spoke wrench 3-27 90890-01522 Cylinder cup installer 4-22, 4-33 90890-01996 Damper rod holder 4-42, 4-44 90890-01460 T-handle 4-44...
  • Page 16 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Fork seal driver attachment (ø35) 4-44 90890-01369 Replacement 35 mm YM-A9409-5 Slide hammer bolt 5-14 90890-01083 Slide hammer bolt 6 mm YU-01083-1 Weight 5-14 90890-01084 YU-01083-3 YU-01083-3 Valve spring compressor 5-18, 5-23 90890-04019 YM-04019 Valve guide remover (ø6)
  • Page 17 Universal clutch holder 5-33, 5-35 90890-04086 YM-91042 Sheave holder 5-47, 5-48 90890-01701 Primary clutch holder YS-01880-A Flywheel puller 5-47 90890-01362 Heavy duty puller YU-33270-B Yamaha bond No. 1215 (Three Bond 5-56 No.1215®) 90890-85505 Crankcase separating tool 5-59 90890-01135 Crankcase separator YU-01135-B...
  • Page 18 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Crankshaft installer pot 5-60 90890-01274 Installing pot YU-90058 YU-90058/YU-90059 Crankshaft installer bolt 5-60 90890-01275 Bolt YU-90060 Adapter (M10) 5-60 90890-01383 Adapter #2 YU-90062 Spacer 5-60 90890-01288 Ignition checker 7-43 90890-06754 Opama pet-4000 spark checker YM-34487 Digital circuit tester 7-46...

  • Page 19: Specifications

    SPECIFICATIONS GENERAL SPECIFICATIONS ...............2-1 ENGINE SPECIFICATIONS................2-2 CHASSIS SPECIFICATIONS.................2-9 ELECTRICAL SPECIFICATIONS..............2-11 TIGHTENING TORQUES................2-13 GENERAL TIGHTENING TORQUE SPECIFICATIONS......2-13 ENGINE TIGHTENING TORQUES............2-13 CHASSIS TIGHTENING TORQUES............2-15 LUBRICATION POINTS AND LUBRICANT TYPES ........2-18 ENGINE....................2-18 CHASSIS....................2-19 LUBRICATION SYSTEM CHART AND DIAGRAMS ........2-21 ENGINE OIL LUBRICATION CHART ............2-21 LUBRICATION DIAGRAMS ..............2-23 CABLE ROUTING..................2-25...

  • Page 20: General Specifications

    GENERAL SPECIFICATIONS EAS20280 GENERAL SPECIFICATIONS Model Model 3C58 (U49) 3C59 (CAL) Dimensions Overall length 2150 mm (84.6 in) Overall width 805 mm (31.7 in) Overall height 1160 mm (45.7 in) Seat height 810 mm (31.9 in) Wheelbase 1360 mm (53.5 in) Ground clearance 285 mm (11.22 in) Minimum turning radius...

  • Page 21: Engine Specifications

    ENGINE SPECIFICATIONS EAS20290 ENGINE SPECIFICATIONS Engine Engine type Air cooled 4-stroke, SOHC Displacement 249.0 cm Cylinder arrangement Forward-inclined single cylinder Bore × stroke 74.0 × 58.0 mm (2.91 × 2.28 in) Compression ratio 9.50 :1 Starting system Electric starter Fuel Recommended fuel Unleaded gasoline only Fuel tank capacity...
  • Page 22 ENGINE SPECIFICATIONS Camshaft lobe dimensions Intake A 36.520–36.620 mm (1.4378–1.4417 in) Limit 36.460 mm (1.4354 in) Intake B 30.201–30.301 mm (1.1890–1.1930 in) Limit 30.151 mm (1.1870 in) Exhaust A 36.564–36.664 mm (1.4395–1.4435 in) Limit 36.514 mm (1.4376 in) Exhaust B 30.216–30.316 mm (1.1896–1.1935 in) Limit 30.166 mm (1.1876 in)
  • Page 23 ENGINE SPECIFICATIONS Valve margin thickness D (intake) 0.80–1.20 mm (0.0315–0.0472 in) Valve margin thickness D (exhaust) 0.80–1.20 mm (0.0315–0.0472 in) Valve stem diameter (intake) 5.975–5.990 mm (0.2352–0.2358 in) Limit 5.950 mm (0.2343 in) Valve stem diameter (exhaust) 5.960–5.975 mm (0.2346–0.2352 in) Limit 5.935 mm (0.2337 in) Valve guide inside diameter (intake)
  • Page 24 ENGINE SPECIFICATIONS Winding direction (intake) Counter clockwise Winding direction (exhaust) Counter clockwise Outer spring Free length (intake) 36.63 mm (1.44 in) Limit 34.63 mm (1.36 in) Free length (exhaust) 36.63 mm (1.44 in) Limit 34.63 mm (1.36 in) Installed length (intake) 32.00 mm (1.26 in) Installed length (exhaust) 32.00 mm (1.26 in)
  • Page 25 ENGINE SPECIFICATIONS Offset 0.50 mm (0.0197 in) Offset direction Intake side Piston pin bore inside diameter 16.002–16.013 mm (0.6300–0.6304 in) Limit 16.043 mm (0.6316 in) Piston pin outside diameter 15.991–16.000 mm (0.6296–0.6299 in) Limit 15.971 mm (0.6288 in) Piston-pin-to-piston-pin-bore clearance 0.002–0.022 mm (0.0001–0.0009 in) Piston ring Top ring...
  • Page 26 ENGINE SPECIFICATIONS Crankshaft Width A 69.25–69.30 mm (2.726–2.728 in) Runout limit C 0.030 mm (0.0012 in) Big end side clearance D 0.350–0.850 mm (0.0138–0.0335 in) Balancer Balancer drive method Gear Clutch Clutch type Wet, multiple-disc Clutch release method Inner push, cam push Clutch lever free play 10.0–15.0 mm (0.39–0.59 in) Friction plate thickness...
  • Page 27 ENGINE SPECIFICATIONS Air filter Air filter element Oil-coated paper element Carburetor Type × quantity MV33 x 1 Manufacturer TEIKEI ID mark 3C58 00 (U49) 3C59 00 (CAL) Main jet #135 Main air jet 1.20 Jet needle 5A21-1 Needle jet 2.585 Pilot air jet 1 0.90 Pilot outlet...

  • Page 28: Chassis Specifications

    CHASSIS SPECIFICATIONS EAS20300 CHASSIS SPECIFICATIONS Chassis Frame type Semi double cradle 26.42 ° Caster angle Trail 106.0 mm (4.17 in) Front wheel Wheel type Spoke wheel Rim size 21x1.60 Rim material Aluminum Wheel travel 225.0 mm (8.86 in) Radial wheel runout limit 2.0 mm (0.08 in) Lateral wheel runout limit 2.0 mm (0.08 in)
  • Page 29 472.2 mm (18.59 in) Spring rate K1 3.65 N/mm (20.84 lb/in) (0.37 kgf/mm) Spring stroke K1 0.0–225.0 mm (0.00–8.86 in) Optional spring available Recommended oil Yamaha fork oil 15WT Quantity 385.0 cm (13.02 US oz) (13.58 Imp.oz) Level 125.0 mm (4.92 in) Swingarm Swingarm end free play limit (radial) 1.0 mm (0.04 in)

  • Page 30: Electrical Specifications

    System voltage 12 V Ignition system Ignition system Advancer type Digital 10.0 °/1400 r/min Ignition timing (B.T.D.C.) Magneto model/manufacturer F5XT/YAMAHA 248–372 Ω (Red–white) Pickup coil resistance CDI unit model/manufacturer 3C5/YAMAHA Ignition coil Model/manufacturer 2JN/YAMAHA Minimum ignition spark gap 6.0 mm (0.24 in) 0.18–0.28 Ω...
  • Page 31 ELECTRICAL SPECIFICATIONS Electric starting system System type Constant mesh Starter motor Model/manufacturer 3C5/YAMAHA Power output 0.40 kW 0.0126–0.0154 Ω Armature coil resistance Brush overall length 10.0 mm (0.39 in) Limit 3.50 mm (0.14 in) Brush spring force 5.52–8.28 N (19.87–29.80 oz) (563–844 gf) Commutator diameter 22.0 mm (0.87 in)

  • Page 32: Tightening Torques

    TIGHTENING TORQUES EAS20320 TIGHTENING TORQUES EAS20330 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for special com- ponents or assemblies are provided for each chapter of this manual. To avoid warpage, tight- en multi-fastener assemblies in a crisscross pat- A.
  • Page 33 TIGHTENING TORQUES Threa Item Q’ty Tightening torque Remarks d size Breather plate bolt 10 Nm (1.0 m•kg, 7.2 ft•lb) Spark plug 18 Nm (1.8 m•kg, 13 ft•lb) Exhaust pipe stud bolt 15 Nm (1.5 m•kg, 11 ft•lb) Oil check bolt 7 Nm (0.7 m•kg, 5.1 ft•lb) Generator rotor bolt 60 Nm (6.0 m•kg, 43 ft•lb)

  • Page 34: Chassis Tightening Torques

    TIGHTENING TORQUES Threa Item Q’ty Tightening torque Remarks d size lock Clutch boss nut 75 Nm (7.5 m•kg, 54 ft•lb) washer Clutch spring bolt 8 Nm (0.8 m•kg, 5.8 ft•lb) Lock nut (Push lever adjusting 8 Nm (0.8 m•kg, 5.8 ft•lb) screw) Push lever holding bolt 12 Nm (1.2 m•kg, 8.7 ft•lb)
  • Page 35 TIGHTENING TORQUES Threa Item Q’ty Tightening torque Remarks d size Relay arm nut (frame side) 50 Nm (5.0 m•kg, 36 ft•lb) Steering stem nut 110 Nm (11.0 m•kg, 80 ft•lb) Lower ring nut – NOTE Fuel tank bolt 7 Nm (0.7 m•kg, 5.1 ft•lb) Brake hose union bolt 30 Nm (3.0 m•kg, 22 ft•lb) Brake hose holding bolt...
  • Page 36 TIGHTENING TORQUES Threa Item Q’ty Tightening torque Remarks d size Rear brake disc bolt 28 Nm (2.8 m•kg, 21 ft•lb) Front brake master cylinder 7 Nm (0.7 m•kg, 5.1 ft•lb) holder bolt Front brake lever nut 7 Nm (0.7 m•kg, 5.1 ft•lb) Rear brake hose joint (caliper 26 Nm (2.6 m•kg, 19 ft•lb) side)

  • Page 37: Lubrication Points And Lubricant Types

    LUBRICATION POINTS AND LUBRICANT TYPES EAS20360 LUBRICATION POINTS AND LUBRICANT TYPES EAS20370 ENGINE Lubrication point Lubricant Oil seal lips All O-rings All bearing retainers Seat surface of cylinder head bolt (226 mm) Threaded portion of cylinder head bolt (226 mm) Cylinder inner surface Crankshaft pin surface Thrust end surface of connecting rod big end...

  • Page 38: Chassis

    Main axle assembly Drive axle assembly Shift fork guide bar Shift drum assembly Shift shaft assembly Shift pedal (bolt mount inner surface) Yamaha bond No. Crankcase mating surface 1215 (Three Bond No. 1215®) Yamaha bond No. Threaded portion of starter motor bolt 1215 (Three Bond No.
  • Page 39 LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Clutch lever cable mount Clutch lever bolt shaft Clutch lever moving parts Pivot shaft surface Swing arm bushing, spacer, and oil seal lip Relay arm bushing, spacer, and oil seal lip Relay arm bolt shaft (on the frame and connecting arm) Relay arm bolt shaft Connecting arm bolt shaft Lower bolt shaft of rear shock absorber assembly...

  • Page 40: Lubrication System Chart And Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 2-21...
  • Page 41 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Camshaft 2. Oil filter element 3. Oil level check window 4. Oil pump assembly 5. Oil strainer 6. Drive axle 7. Main axle 8. Plunger pin 9. Crankshaft 10. Cylinder head 11. Oil pan 2-22...

  • Page 42: Lubrication Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20410 LUBRICATION DIAGRAMS 2-23...
  • Page 43 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Crankshaft 2. Oil pump assembly 3. Oil strainer 4. Camshaft 5. Push lever shaft 6. Drive axle 7. Main axle 8. Oil filter element 2-24...

  • Page 44: Cable Routing

    CABLE ROUTING EAS20430 CABLE ROUTING 2-25...
  • Page 45 CABLE ROUTING 1. Headlight relay (lead having gray tape) R. Pass the negative battery lead behind the wire harness. Also, pass the battery lead from the 2. Starting circuit cut-off relay battery/electric parts box through the inside of 3. Carburetor warmer lead the vehicle.
  • Page 46 CABLE ROUTING 2-27...
  • Page 47 CABLE ROUTING 1. Clutch cable O. Secure two carburetor air vent hoses, carbure- tor fuel drain hose, and negative battery lead 2. Starter cable using clamp. Face the clamp holders on the left 3. Air induction system hose (from air filter case to of the vehicle.
  • Page 48 CABLE ROUTING 2-29...
  • Page 49 CABLE ROUTING 1. Clutch cable 2. Front brake hose 3. Front brake light switch lead 4. Right handlebar switch lead 5. Throttle cable (decelerator cable) 6. Throttle cable (accelerator cable) 7. Carburetor warmer lead 8. Starter motor lead 9. Rear brake light switch lead 10.
  • Page 50 CABLE ROUTING 2-31...
  • Page 51 CABLE ROUTING 1. Throttle cable (accelerator cable) 2. Throttle cable (decelerator cable) 3. Meter assembly leads 4. Clutch cable 5. Left front turn signal light lead 6. Main switch lead 7. Right front turn signal light lead 8. Front brake hose A.
  • Page 52 CABLE ROUTING 2-33...
  • Page 53 CABLE ROUTING 1. Fuel tank 2. Roll over valve 3. Canister 4. Canister breather hose A. Face the end of clip toward the vehicle. B. Install the hose to fuel tank by facing the white paint mark left side of the vehicle. C.
  • Page 54 CABLE ROUTING 2-35...

  • Page 55: Periodic Checks And Adjustments

    PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE................3-1 INTRODUCTION..................3-1 Periodic maintenance chart for the emission control system ....3-1 General maintenance and lubrication chart..........3-2 ENGINE ......................3-5 ADJUSTING THE VALVE CLEARANCE ..........3-5 ADJUSTING THE ENGINE IDLING SPEED..........3-6 ADJUSTING THE THROTTLE CABLE FREE PLAY .......3-7 CHECKING THE SPARK PLUG ..............3-8 CHECKING THE IGNITION TIMING............3-8 MEASURING THE COMPRESSION PRESSURE........3-9...

  • Page 56: Periodic Maintenance

    All service technicians should be familiar with this entire chapter. NOTE: If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform it for you. EWA10340...

  • Page 57: General Maintenance And Lubrication Chart

    Air induction sys- √ √ damage. Replace any damaged parts. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. EAS32164 General maintenance and lubrication chart INITIAL ODOMETER READINGS 7000 mi 10000 mi...
  • Page 58 Check operation. Front and rear √ √ √ √ √ √ 24 * brake switches Apply Yamaha chain and √ √ √ √ √ √ 25 * Control cables cable lube or engine oil SAE 10W-30 thoroughly. Check operation and free play.
  • Page 59 Adjust headlight beam. and switches * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. NOTE: From 19000 mi (31000 km) or 36 months, repeat the maintenance intervals starting from 7000 mi (11000 km) or 12 months.

  • Page 60: Engine

    ENGINE EAS20471 ENGINE Valve clearance (cold) Intake EAS20520 0.05–0.10 mm (0.0020–0.0039 in) ADJUSTING THE VALVE CLEARANCE Exhaust The following procedure applies to all of the 0.10–0.15 mm (0.0039–0.0059 in) valves. NOTE: MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM Valve clearance adjustment should be made a. Turn the crankshaft counterclockwise. on a cold engine, at room temperature.

  • Page 61: Adjusting The Engine Idling Speed

    ENGINE 8. Install: Spark plug LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL Spark plug cap 6. Adjust: Spark plug Valve clearance 18 Nm (1.8 m•kg, 13 ft•lb) MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a. Loosen the locknut “1” 9. Install: b. Insert special thickness gauge “2” between O-ring the adjusting screw and the valve stem end. Camshaft sprocket cover c.

  • Page 62: Adjusting The Throttle Cable Free Play

    ENGINE 2. Start the engine and let it warm up until it 5. Adjust: reaches specified oil temperature. Throttle cable play Refer to “ADJUSTING THE THROTTLE CA- Oil temperature BLE FREE PLAY” on page 3-9. 95.0–105.0 °C (203.00–221.00 °F) Throttle cable free play 3.

  • Page 63: Checking The Spark Plug

    ENGINE 4. Check: MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM Electrode “1” Handlebar side Damage/wear → Replace the spark plug. a. Loosen the locknut “1”. Insulator “2” b. Adjust the play of throttle cable by turning the Abnormal color → Replace the spark plug. adjusting nut “2” in direction “a” or “b”. Normal color is medium-to-light tan.

  • Page 64: Measuring The Compression Pressure

    ENGINE 2. Connect: NOTE: Timing light “1” The ignition timing is not adjustable. Digital tachometer Timing light LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 90890-03141 4. Remove: Inductive clamp timing light Digital tachometer YU-03141 Timing light Digital tachometer 90890-06760 5. Install: YU-39951-B Timing mark accessing screw EAS20710 MEASURING THE COMPRESSION PRESSURE...

  • Page 65: Checking The Engine Oil Level

    ENGINE Compression pressure (with oil applied into the Compression gauge cylinder) 90890-03081 Engine compression tester Reading Diagnosis YU-33223 Piston ring(s) wear or Higher than without oil damage → Repair. Piston, valves, cylinder head gasket or pis- Same as without oil ton possibly defec- tive →...

  • Page 66: Changing The Engine Oil

    ENGINE 3. Remove: Type Engine oil filler cap “1” YAMALUBE 4, SAE10W30 or Engine oil drain bolt “2” SAE20W40 (along with the gasket) Recommended engine oil grade Oil filter element drain bolt “3” API service SG type or higher, JASO standard MA ACEA standard G4 or G5 ECA13360...

  • Page 67: Adjusting The Clutch Cable Free Play

    ENGINE LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 6. Check: Engine oil drain bolt gasket Oil filter element drain bolt gasket Damage → Replace. 7. Install: Engine oil drain bolt Oil filter element drain bolt (along with the gasket) b. Start the engine and keep it idling until engine Engine oil drain bolt oil starts to seep from the oil check bolt.

  • Page 68: Replacing The Air Filter Element

    ENGINE NOTE: MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM Check the air filter check hose locating at the Clutch lever side bottom of air filter case. If a foreign material such a. Slide rubber cover “1” from the clutch lever. as dust and water is found, replace the air filter b.

  • Page 69: Checking The Carburetor Joint And Intake Manifold

    ENGINE NOTE: Make sure that the air filter element is installed securely in the air filter case to prevent any air leaks. 6. Install: Seat Refer to “GENERAL CHASSIS” on page 4-1. EAS20990 CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD 3.
  • Page 70 ENGINE Exhaust gas leaks → Replace. 2. Check: Tightening torque Exhaust pipe nut “3” Exhaust pipe joint bolt “4” Muffler bolt “5” Exhaust pipe nut 18 Nm (1.8 m•kg, 13 ft•lb) Exhaust pipe joint bolt 20 Nm (2.0 m•kg, 15 ft•lb) Muffler bolt 42 Nm (4.2 m•kg, 30 ft•lb) 3-15...

  • Page 71: Chassis

    CHASSIS erably reduce braking performance. EAS21140 CHASSIS ECA13490 CAUTION: EAS21170 ADJUSTING THE FRONT DISC BRAKE After adjusting the brake lever position, 1. Check: make sure there is no brake drag. Brake lever free play “a” Out of specification → Adjust. LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL EAS21200 ADJUSTING THE REAR DISC BRAKE...

  • Page 72: Checking The Brake Fluid Level

    CHASSIS c. Tighten the locknut “1” to specification. Locknut 17 Nm (1.7 m•kg, 12.5 ft•lb) EWA5UXB005 WARNING A soft or spongy feeling in the brake pedal can indicate the presence of air in the brake system. Before the vehicle is operated, the air must be removed by bleeding the brake system.

  • Page 73: Checking The Rear Brake Pads

    CHASSIS Loose connection → Tighten the clamp bolt. 2. Check: Front brake pad 3. Hold the vehicle upright and apply the front Wear indicator grooves “a” almost disap- brake several times. peared → Replace the brake pads as a set. 4.

  • Page 74: Bleeding The Hydraulic Brake System

    CHASSIS screw “2”, and place an oil pan under the Direction “a” plastic hose end. Brake light comes on sooner. Direction “b” Brake light comes on later. LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL EAS21350 BLEEDING THE HYDRAULIC BRAKE SYSTEM EWA13100 WARNING A. Front Bleed the hydraulic brake system whenever: B.

  • Page 75: Adjusting The Drive Chain Slack

    CHASSIS check the brake operation. Drive chain slack MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a. Loosen the wheel axle nut “1”. b. Turn the drive chain adjusting plate “2” in di- LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL rection “a” or “b” until the specified drive chain EAS21420 slack is obtained. ADJUSTING THE DRIVE CHAIN SLACK NOTE: Direction “a”...

  • Page 76: Checking And Adjusting The Steering Head

    CHASSIS Recommended lubricant Engine oil or chain lubricant suitable for O-ring chains EAS21510 CHECKING AND ADJUSTING THE STEERING HEAD 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is Steering nut wrench no danger of it falling over.

  • Page 77: Checking The Front Fork

    CHASSIS EAS21590 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. Spring preload ECA13590 CAUTION: Never go beyond the maximum or minimum adjustment positions. 1. Adjust: LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL Spring preload 5.

  • Page 78: Checking The Tires

    CHASSIS speed. Spring length “c” Operation of an overloaded vehicle could Standard cause tire damage, an accident or an injury. 197.0 mm NEVER OVERLOAD THE VEHICLE. Minimum (hard) 187.0 mm Tire air pressure (measured on Maximum (soft) cold tires) 207.0 mm Loading condition 0–90 kg (0–198 lb) Front...

  • Page 79: Checking The Wheels

    WARNING en if a tire combination other than one Never attempt to make any repairs to the approved by Yamaha is used on this vehicle. wheel. NOTE: After a tire or wheel has been changed or re- placed, always balance the wheel.

  • Page 80: Checking And Tightening The Spokes

    CHASSIS EAS21680 EAS21690 CHECKING AND TIGHTENING THE SPOKES CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the The following procedure applies to all of the in- spokes. ner and outer cables. 1. Check: EWA13270 Spoke WARNING Bends/damage →...

  • Page 81: Electrical System

    ELECTRICAL SYSTEM EAS21750 ELECTRICAL SYSTEM EAS21760 CHECKING AND CHARGING THE BATTERY Refer to “ELECTRICAL COMPONENTS” on page 7-29. EAS21770 CHECKING THE FUSES Refer to “ELECTRICAL COMPONENTS” on page 7-29. EWA13320 EAS21780 WARNING REPLACING THE HEADLIGHT BULB Since the headlight bulb gets extremely hot, 1.
  • Page 82 ELECTRICAL SYSTEM LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 3-27...
  • Page 83 CHASSIS GENERAL CHASSIS ..................4-1 FRONT WHEEL .....................4-2 REMOVING THE FRONT WHEEL ............4-4 CHECKING THE FRONT WHEEL ............4-4 DISASSEMBLING THE FRONT WHEEL..........4-4 ASSEMBLING THE FRONT WHEEL............4-5 ADJUSTING THE FRONT WHEEL STATIC BALANCE ......4-5 INSTALLING THE FRONT WHEEL (DISC) ..........4-6 REAR WHEEL....................4-8 REMOVING THE REAR WHEEL (DISC)..........4-10 DISASSEMBLING THE REAR WHEEL ...........4-10 CHECKING THE REAR WHEEL .............4-10...
  • Page 84 CHECKING THE HANDLEBAR ...............4-36 INSTALLING THE HANDLEBAR .............4-36 FRONT FORK ....................4-39 REMOVING THE FRONT FORK LEGS...........4-42 DISASSEMBLING THE FRONT FORK LEGS.........4-42 CHECKING THE FRONT FORK LEGS ...........4-43 ASSEMBLING THE FRONT FORK LEGS..........4-43 INSTALLING THE FRONT FORK LEGS ..........4-46 STEERING HEAD ..................4-47 REMOVING THE LOWER BRACKET .............4-49 CHECKING THE STEERING HEAD............4-49 INSTALLING THE STEERING HEAD............4-49...

  • Page 85: General Chassis

    GENERAL CHASSIS EAS21830 GENERAL CHASSIS Removing the cowling 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 9 Nm (0.9 m kg, 6.5 ft • • 4 Nm (0.4 m kg, 2.9 ft 7 Nm (0.7 m kg, 5.1 ft •...

  • Page 86: Front Wheel

    FRONT WHEEL EAS21870 FRONT WHEEL Removing the front wheel and brake disc 85 Nm (8.5 m kg, 62 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks NOTE: Use a suitable stand to raise the front wheel off the ground.
  • Page 87 FRONT WHEEL Disassembling the front wheel Order Job/Parts to remove Q’ty Remarks Oil seal Wheel bearing Spacer For assembly, reverse the disassembly pro- cedure.

  • Page 88: Removing The Front Wheel

    FRONT WHEEL Over the specified limits → Replace. EAS21890 REMOVING THE FRONT WHEEL 1. Stand the vehicle on a level surface. Radial wheel runout limit 2.0 mm (0.08 in) EWA13120 WARNING Lateral wheel runout limit 2.0 mm (0.08 in) Securely support the vehicle so that there is no danger of it falling over.

  • Page 89: Assembling The Front Wheel

    FRONT WHEEL c. Remove the wheel bearings with a general bearing puller. LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL EAS21970 ADJUSTING THE FRONT WHEEL STATIC BALANCE NOTE: After replacing the tire, wheel or both, the front wheel static balance should be adjusted. Adjust the front wheel static balance with the brake disc installed.

  • Page 90: Installing The Front Wheel (Disc)

    FRONT WHEEL LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 4. Check: Front wheel static balance MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a. Turn the front wheel and make sure it stays at each position shown. f. Repeat steps (d) through (f) several times un- til all the marks come to rest at the same spot. g.
  • Page 91 FRONT WHEEL Front axle nut 85 Nm (8.5 m•kg, 62 ft•lb) EWA13500 WARNING Make sure the brake hose is routed properly. ECA14140 CAUTION: Before tightening the wheel axle nut, push down hard on the handlebar(s) several times and check if the front fork rebounds smooth-...

  • Page 92: Rear Wheel

    REAR WHEEL EAS22020 REAR WHEEL Removing the rear wheel, brake disc and rear wheel sprocket 33 Nm (3.3 m kg, 24 ft • • 28 Nm (2.8 m kg, 21 ft • • 85 Nm (8.5 m kg, 62 ft •...
  • Page 93 REAR WHEEL Disassembling the rear wheel Order Job/Parts to remove Q’ty Remarks Oil seal Wheel bearing Spacer For installation, reverse the removal proce- dure.

  • Page 94: Removing The Rear Wheel (Disc)

    REAR WHEEL Refer to “CHECKING THE TIRES” on page EAS22040 REMOVING THE REAR WHEEL (DISC) 3-23 and “CHECKING THE WHEELS” on 1. Stand the vehicle on a level surface. page 3-24. EWA13120 3. Check: WARNING Spokes Securely support the vehicle so that there is Bends/damage →...

  • Page 95: Assembling The Rear Wheel

    REAR WHEEL Rear wheel sprocket self-locking Recommended lubricant Lithium-soap-based grease 33 Nm (3.3 m•kg, 29 ft•lb) 3. Adjust: Drive chain slack NOTE: Tighten the self-locking nuts in stages and in a Refer to “ADJUSTING THE DRIVE CHAIN crisscross pattern. SLACK” on page 3-20. Drive chain slack 40.0–45.0 mm (1.57–1.77 in) 4.

  • Page 96: Front Brake

    FRONT BRAKE EAS22210 FRONT BRAKE Removing the front brake pads 6 Nm (0.6 m kg, 4.3 ft • • 32 Nm (3.2 m kg, 23 ft • • Order Job/Parts to remove Q’ty Remarks NOTE: Front brake caliper support bolt Remove the lower parts only.
  • Page 97 FRONT BRAKE Removing the front brake master cylinder 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 30 Nm (3.0 m kg, 22 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “BLEEDING THE HYDRAULIC Drain the brake fluid...
  • Page 98 FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Master cylinder kit For assembly, reverse the disassembly pro- cedure. 4-14...
  • Page 99 FRONT BRAKE Removing the front brake calipers 32 Nm (3.2 m kg, 23 ft • • 40 Nm (4.0 m kg, 29 ft • • 30 Nm (3.0 m kg, 22 ft • • 32 Nm (3.2 m kg, 23 ft •...
  • Page 100 FRONT BRAKE Disassembling the front brake calipers 6 Nm (0.6 m kg, 4.3 ft • • Order Job/Parts to remove Q’ty Remarks Brake caliper piston Brake caliper piston seal Brake caliper dust seal Bleed screw For assembly, reverse the disassembly pro- cedure.

  • Page 101: Introduction

    FRONT BRAKE EAS22220 MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM INTRODUCTION a. Place the vehicle on a suitable stand so that EWA14100 the front wheel is elevated. WARNING b. Before measuring the front brake disc deflec- Disc brake components rarely require disas- tion, turn the handlebar to the left or right to sembly.

  • Page 102: Replacing The Front Brake Pads

    FRONT BRAKE 2. Install: Brake disc bolt Brake pad shims 10 Nm (1.0 m•kg, 7.2 ft•lb) (onto the inner brake pads) Apply locking agent (LOC- Front brake pads TITE®) Brake pad spring NOTE: Always install new brake pads, brake pad shims, d.

  • Page 103: Removing The Front Brake Caliper

    FRONT BRAKE EAS22320 Front brake caliper support bolt DISASSEMBLING THE FRONT BRAKE Silicone grease CALIPER 1. Remove: ECA14150 Brake caliper pistons “1” CAUTION: Brake caliper piston seals “2” Brake caliper dust seals “3” Do not allow grease to contact the brake pads.

  • Page 104: Assembling The Front Brake Caliper

    FRONT BRAKE 1. Check: Copper washers Brake caliper pistons “1” Front brake hose Rust/scratches/wear → Replace the brake Union bolt caliper pistons. Front brake caliper bracket bolt Brake caliper cylinders “2” 40 Nm (4.0 m•kg, 29 ft•lb) Scratches/wear → Replace the brake caliper Union bolt assembly.

  • Page 105: Removing The Front Brake Master Cylinder

    FRONT BRAKE brake fluids may cause the rubber seals to (from the brake switch) deteriorate, causing leakage and poor NOTE: brake performance. Remove the master cylinder by pressing the Refill with the same type of brake fluid that projection. is already in the system. Mixing brake flu- ids may result in a harmful chemical reac- tion, leading to poor brake performance.

  • Page 106: Assembling The Front Brake Master Cylinder

    FRONT BRAKE Front brake hose EAS22530 INSTALLING THE FRONT BRAKE MASTER Cracks/damage/wear → Replace. CYLINDER 1. Install: EAS22520 ASSEMBLING THE FRONT BRAKE MASTER Front brake master cylinder “1” CYLINDER Front brake master cylinder hold- EWA13520 WARNING er bolt 7 Nm (0.7 m•kg, 5.1 ft•lb) Before installation, all internal brake com- ponents should be cleaned and lubricated NOTE:...
  • Page 107 FRONT BRAKE 15 25˚ 3. Fill: 6. Check: Brake master cylinder reservoir Brake lever operation Soft or spongy feeling → Bleed the brake (with the specified amount of the recom- mended brake fluid) system. Refer to “BLEEDING THE HYDRAULIC Recommended fluid BRAKE SYSTEM”...

  • Page 108: Rear Brake

    REAR BRAKE EAS22550 REAR BRAKE Removing the rear brake pads 6 Nm (0.6 m kg, 4.3 ft • • 17 Nm (1.7 m kg, 12 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Rear wheel...
  • Page 109 REAR BRAKE Removing the rear brake master cylinder 13 Nm (1.3 m kg, 9.4 ft • • 30 Nm (3.0 m kg, 22 ft • • 13 Nm (1.3 m kg, 9.4 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “BLEEDING THE HYDRAULIC Drain the brake fluid...
  • Page 110 REAR BRAKE Disassembling the rear brake master cylinder 17 Nm (1.7 m kg, 12 ft • • Order Job/Parts to remove Q’ty Remarks Master cylinder kit For assembly, reverse the disassembly pro- cedure. 4-26...
  • Page 111 REAR BRAKE Removing the rear brake calipers 26 Nm (2.6 m kg, 19 ft • • 14 Nm (1.4 m kg, 10 ft • • 17 Nm (1.7 m kg, 12 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 112 REAR BRAKE Disassembling the rear brake calipers 6 Nm (0.6 m kg, 4.3 ft • • Order Job/Parts to remove Q’ty Remarks Brake caliper piston Brake caliper piston seal Brake caliper dust seal Bleed screw For assembly, reverse the disassembly pro- cedure.

  • Page 113: Introduction

    REAR BRAKE EAS22560 INTRODUCTION Brake disc thickness limit 4.0 mm (0.16 in) EWA14100 WARNING 5. Adjust: Disc brake components rarely require disas- sembly. Therefore, always follow these pre- Brake disc deflection Refer to “CHECKING THE FRONT BRAKE ventive measures: DISC” on page 4-17. Never disassemble brake components un- less absolutely necessary.

  • Page 114: Removing The Rear Brake Caliper

    REAR BRAKE 5. Check: Brake pad support bolt Brake fluid level Silicone grease Below minimum level mark “a” → Add the recommended brake fluid to proper level. ECA14150 Refer to “CHECKING THE BRAKE FLUID CAUTION: LEVEL” on page 3-17. Do not allow grease to contact the brake pads.

  • Page 115: Checking The Rear Brake Caliper

    REAR BRAKE MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a. Blow compressed air into the brake hose joint opening “a” to force out the piston from the brake caliper. EWA13560 WARNING Cover the brake caliper pistons with a rag. Be careful not to get injured when the pis- tons are expelled from the brake caliper.

  • Page 116: Removing The Rear Brake Master Cylinder

    REAR BRAKE brake performance. Brake hose joint (caliper side) Refill with the same type of brake fluid that 26 Nm (2.6 m•kg, 19 ft•lb) is already in the system. Mixing brake flu- Brake hose joint (hose side) ids may result in a harmful chemical reac- 14 Nm (1.4 m•kg, 10 ft•lb) tion, leading to poor brake performance.

  • Page 117: Checking The Rear Brake Master Cylinder

    REAR BRAKE container under the master cylinder and the end Cylinder cup installer of the brake hose. 90890-01996 EAS22710 CHECKING THE REAR BRAKE MASTER CYLINDER 1. Check: Rear brake master cylinder “1” Damage/scratches/wear → Replace. Brake fluid delivery passages “2” (brake master cylinder body) Obstruction →...
  • Page 118 REAR BRAKE 2. Add the recommended brake fluid to the 5. Check: proper level. Brake lever operation Soft or spongy feeling → Bleed the brake Brake master cylinder reservoir system. Recommended fluid Refer to “BLEEDING THE HYDRAULIC DOT 4 BRAKE SYSTEM” on page 3-19. EWA13090 WARNING Use only the designated brake fluid.

  • Page 119: Handlebar

    HANDLEBAR EAS22840 HANDLEBAR Removing the handlebar 7 Nm (0.7 m kg, 5.1 ft • • 23 Nm (2.3 m kg, 17 ft • • Order Job/Parts to remove Q’ty Remarks Back view mirror Front brake light switch Front brake master cylinder holder Front brake master cylinder assembly Right handlebar switch Throttle cable housing...

  • Page 120: Removing The Handlebars

    HANDLEBAR EAS22860 EAS22921 REMOVING THE HANDLEBARS INSTALLING THE HANDLEBAR 1. Stand the vehicle on a level surface. 1. Stand the vehicle on a level surface. EWA13120 EWA13120 WARNING WARNING Securely support the vehicle so that there is Securely support the vehicle so that there is no danger of it falling over.
  • Page 121 HANDLEBAR c. Clean the excessive rubber adhesive with a Slightly coat the end of slot cable and inside of clean cloth. rubber adhesive throttle grip with Yamaha Grease B. Then, mount the throttle grip onto the handlebar. EWA13700 WARNING Do not touch the handlebar grip until the rub- ber adhesive has fully dried.
  • Page 122 HANDLEBAR 6. Adjust: Clutch cable free play Refer to “ADJUSTING THE CLUTCH CA- BLE FREE PLAY” on page 3-12. Clutch lever free play 10.0–15.0 mm (0.39–0.59 in) 7. Adjust: Throttle cable free play Refer to “ADJUSTING THE THROTTLE CA- BLE FREE PLAY” on page 3-7 Throttle cable free play 3.0–5.0 mm (0.12–0.2 in) 4-38...

  • Page 123: Front Fork

    FRONT FORK EAS22950 FRONT FORK Removing the front fork legs 23 Nm (2.3 m kg, 17 ft • • 23 Nm (2.3 m kg, 17 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 23 Nm (2.3 m kg, 17 ft •...
  • Page 124 FRONT FORK Disassembling the front fork legs 23 Nm (2.3 m kg, 17 ft • • 18 Nm (1.8 m kg, 13 ft • • Order Job/Parts to remove Q’ty Remarks Front fork cap bolt Cap bolt O-ring Spacer Spring seat Fork spring Dust seal Oil seal clip...
  • Page 125 FRONT FORK Disassembling the front fork legs 23 Nm (2.3 m kg, 17 ft • • 18 Nm (1.8 m kg, 13 ft • • Order Job/Parts to remove Q’ty Remarks For assembly, reverse the disassembly pro- cedure. 4-41...

  • Page 126: Removing The Front Fork Legs

    FRONT FORK EAS22970 EAS22980 REMOVING THE FRONT FORK LEGS DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the The following procedure applies to both of the front fork legs. front fork legs. 1. Stand the vehicle on a level surface. 1.

  • Page 127: Checking The Front Fork Legs

    FRONT FORK EWA13650 WARNING Do not attempt to straighten a bent inner tube as this may dangerously weaken it. 2. Measure: Spring free length “a” Out of specification → Replace. Fork spring free length 482.0 mm (18.98 in) Limit 4. Remove: 472.3 mm (18.59 in) Inner tube MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM...
  • Page 128 Fork seal driver attachment (ø35) 90890-01369 Replacement 35 mm YM-A9409-5 2. Lubricate: Inner tube’s outer surface Recommended oil Yamaha fork oil 15WT 3. Tighten: Damper rod bolt “1” Damper rod bolt 5. Install: 18 Nm (1.8 m•kg, 13 ft•lb) Oil seal “1”...
  • Page 129 Quantity 385.0 cm (13.02 US oz) (13.58 Imp.oz) Recommended oil Yamaha fork oil 15WT Level 125.0 mm (4.92 in) At position “a” from the inner tube top end when the inner tube is fully compressed in the outer tube 6.

  • Page 130: Installing The Front Fork Legs

    FRONT FORK EAS23050 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Install: Dust boot Clamp screw (temporarily) 2. Install: Front fork leg Temporarily tighten the upper and lower bracket pinch bolts. NOTE: The inner tube top face must match the upper bracket top face.

  • Page 131: Steering Head

    STEERING HEAD EAS23090 STEERING HEAD Removing the head light unit, meter assembly and front fender 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 3 Nm (0.3 m kg, 2.2 ft •...
  • Page 132 STEERING HEAD Removing the lower bracket 110 Nm (11 m kg, 80 ft • • 38 Nm (3.8 m kg, 28 ft • • Return fully 4 Nm (0.4 m kg, 2.9 ft • • Order Job/Parts to remove Q’ty Remarks Headlight unit/meter assembly/front fender Refer to “STEERING HEAD”...

  • Page 133: Removing The Lower Bracket

    STEERING HEAD b. Remove the bearing from the lower bracket EAS23110 REMOVING THE LOWER BRACKET with a floor chisel “2” and hammer. 1. Stand the vehicle on a level surface. c. Install new bearing races. EWA13120 ECA14270 WARNING CAUTION: Securely support the vehicle so that there is If the bearing race is not installed properly, no danger of it falling over.
  • Page 134 STEERING HEAD Upper ring nut “3” Lock washer “4” Refer to “CHECKING AND ADJUSTING THE STEERING HEAD” on page 3-21. NOTE: Portion “a” having the large tapered area must face downward when the lower ring nut is mounted. 3. Install: Upper bracket Steering stem nut NOTE:...

  • Page 135: Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY EAS23160 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 50 Nm (5.0 m kg, 36 ft • • 40 Nm (4.0 m kg, 29 ft • • 50 Nm (5.0 m kg, 36 ft •...

  • Page 136: Handling The Rear Shock Absorber

    REAR SHOCK ABSORBER ASSEMBLY EAS23180 NOTE: HANDLING THE REAR SHOCK ABSORBER Place the vehicle on a suitable stand so that the EWA13740 rear wheel is elevated. WARNING This rear shock absorber contains highly EAS23240 compressed nitrogen gas. Before handling CHECKING THE REAR SHOCK ABSORBER the rear shock absorber, read and make sure ASSEMBLY you understand the following information.

  • Page 137: Installing The Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY Installed depth “a” 4.5 mm Installed depth “b” 3 mm Installed depth “c” 4 mm EAS23310 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1. Install: Rear shock absorber assembly NOTE: Install the rear shock absorber by facing its valve backward.

  • Page 138: Swingarm

    SWINGARM EAS23330 SWINGARM Removing the swingarm 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 80 Nm (8.0 m kg, 58 ft • • Order Job/Parts to remove Q’ty Remarks Rear wheel Refer to “REAR WHEEL”...

  • Page 139: Removing The Swingarm

    SWINGARM EAS23350 EAS23360 REMOVING THE SWINGARM CHECKING THE SWINGARM 1. Stand the vehicle on a level surface. 1. Check: Swingarm EWA13120 WARNING Bends/cracks/damage → Replace. Securely support the vehicle so that there is 2. Check: no danger of it falling over. Pivot shaft Roll the pivot shaft on a flat surface.
  • Page 140 SWINGARM Oil seal “2” Spacer “3” (to the swingarm “4”) Installed depth “a” 3 mm 3. Install: Rear shock absorber assembly Rear wheel Refer to “REAR SHOCK ABSORBER AS- SEMBLY” on page 4-51 and “REAR WHEEL” on page 4-8. 4. Adjust: Drive chain slack Refer to “ADJUSTING THE DRIVE CHAIN SLACK”...

  • Page 141: Chain Drive

    CHAIN DRIVE EAS23400 CHAIN DRIVE Removing the drive chain 110 Nm (11 m kg, 80 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Swingarm Refer to “SWINGARM” on page 4-54. Drive sprocket cover Drive sprocket nut Lock washer...

  • Page 142: Removing The Drive Chain

    CHAIN DRIVE EAS23420 REMOVING THE DRIVE CHAIN 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the rear wheel is elevated.

  • Page 143: Checking The Drive Sprocket

    CHAIN DRIVE b. Put the drive chain in kerosene and remove 5. Lubricate: any remaining dirt. Drive chain c. Remove the drive chain from the kerosene Recommended lubricant and completely dry it. Engine oil or chain lubricant EC3C51003 suitable for O-ring chains CAUTION: This vehicle has a drive chain with small rub- EAS23460...
  • Page 144 CHAIN DRIVE NOTE: Tighten the drive sprocket nut by applying the rear drive. Be sure to bend the lock washer tab along to the nut side face. 5. Adjust: Drive chain slack Refer to “ADJUSTING THE DRIVE CHAIN SLACK” on page 3-20 Drive chain slack 40.0–45.0 mm (1.57–1.77 in) ECA13550...

  • Page 145: Engine

    ENGINE ENGINE REMOVAL ..................5-1 INSTALLING THE ENGINE ..............5-4 INSTALLING THE SHIFT PEDAL ............5-4 CYLINDER HEAD ..................5-6 REMOVING THE CYLINDER HEAD ............5-8 CHECKING THE CYLINDER HEAD ............5-9 CHECKING THE TAPPET COVERS AND CAMSHAFT SPROCKET COVER ............5-9 CHECKING THE CAMSHAFT SPROCKET AND TIMING CHAIN GUIDE (EXHAUST SYSTEM SIDE)......5-9 CHECKING THE TIMING CHAIN TENSIONER ........5-10 INSTALLING THE CYLINDER HEAD ............5-10...
  • Page 146 OIL PUMP AND BALANCER GEAR .............5-38 REMOVING THE BALANCER GEAR ............5-40 CHECKING THE OIL PUMP ..............5-40 CHECKING THE OIL STRAINER ............5-40 ASSEMBLING THE OIL PUMP..............5-41 INSTALL THE OIL PUMP AND BALANCER GEAR ........5-41 SHIFT SHAFT ....................5-43 CHECKING THE SHIFT SHAFT ..............5-44 CHECKING THE STOPPER LEVER ............5-44 INSTALLING THE SHIFT SHAFT ............5-44 GENERATOR AND STARTER CLUTCH ............5-45...

  • Page 147: Engine Removal

    ENGINE REMOVAL EAS23710 ENGINE REMOVAL Removing the exhaust pipe 42 Nm (4.2 m kg, 30 ft • • 20 Nm (2.0 m kg, 15 ft • • 42 Nm (4.2 m kg, 30 ft • • 18 Nm (1.8 m kg, 13 ft •...
  • Page 148 ENGINE REMOVAL Removing the shift pedal assembly and leads and hoses 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 149 ENGINE REMOVAL Removing the engine 60 Nm (6.0 m kg, 43 ft • • 44 Nm (4.4 m kg, 32 ft • • 60 Nm (6.0 m kg, 43 ft • • 60 Nm (6.0 m kg, 43 ft • •...

  • Page 150: Installing The Engine

    ENGINE REMOVAL Down tube nut (front) EAS23720 INSTALLING THE ENGINE 1. Install: Down tube nut (front) 60 Nm (6.0 m•kg, 43 ft•lb) Engine assembly “1” Engine mounting bolt (rear upper side)“2” Engine mounting nut (front upper) Engine mounting bolt (rear lower side)“3” Down tube “4”...
  • Page 151 ENGINE REMOVAL in). When this adjustment is complete, tighten the locknut “1”. Locknut 10 Nm (1.0 m•kg, 7.2 ft•lb)

  • Page 152: Cylinder Head

    CYLINDER HEAD EAS24100 CYLINDER HEAD Removing the cylinder head 10 Nm (1.0 m kg, 7.2 ft • • 60 Nm (6.0 m kg, 43 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 153 CYLINDER HEAD Removing the cylinder head 10 Nm (1.0 m kg, 7.2 ft • • 60 Nm (6.0 m kg, 43 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft •...

  • Page 154: Removing The Cylinder Head

    CYLINDER HEAD EAS24130 REMOVING THE CYLINDER HEAD 1. Disconnect: LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL Wire harness 3. Loosen: NOTE: Camshaft sprocket bolt Disconnect the wire harness from the T-stud of NOTE: vehicle frame. Tighten the generator rotor bolts but loosen the camshaft sprocket bolts using a wrench. 2.

  • Page 155: Checking The Cylinder Head

    CYLINDER HEAD head several times. EAS24160 CHECKING THE CYLINDER HEAD e. When the cylinder head warpage is out of 1. Eliminate: specification after resurfacing, replace the Combustion chamber carbon deposits cylinder head. (with a rounded scraper) NOTE: Do not use a sharp instrument to avoid damag- LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL ing or scratching: Spark plug bore threads...

  • Page 156: Checking The Timing Chain Tensioner

    CYLINDER HEAD 2. Check: Tighten the cylinder head bolts in two stages in Timing chain guide (exhaust side) the correct sequence as shown. Crack/wear → Replace. EAS24200 CHECKING THE TIMING CHAIN TENSIONER 1. Check: Timing chain tensioner Cracks/damage/rough movement → Re- place.
  • Page 157 CYLINDER HEAD d. While holding the camshafts, temporarily tighten the camshaft sprocket bolts. LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL e. Remove the wire from the timing chain. 4. Tighten: Camshaft sprocket bolts LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL Camshaft sprocket bolt 3. Install: 60 Nm (6.0 m•kg, 43 ft•lb) Timing chain tensioner MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM ECA13750 a.
  • Page 158 CYLINDER HEAD 7. Measure: Bulb clearance Out of specification → Adjust. Refer to “ADJUSTING THE VALVE CLEAR- ANCE” on page 3-5. 5-12...

  • Page 159: Camshaft

    CAMSHAFT EAS3C51006 CAMSHAFT REMOVING THE ROCKER ARMS AND CAMSHAFT Order Job/Part Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-6. Camshaft retainer Camshaft Intake rocker arm shaft Rocker arm Exhaust rocker arm shaft Locknut Valve clearance adjusting screws For installation, reverse the removal proce- dure.

  • Page 160: Removing The Rocker Arms And Camshaft

    CAMSHAFT EAS23770 REMOVING THE ROCKER ARMS AND CAMSHAFT 1. Loosen: Locknuts “1” Valve clearance adjusting screws “2” 2. Remove: Camshaft retainer “3” EAS23840 CHECKING THE CAMSHAFT 1. Check: Camshaft lobes Blue discoloration/pitting/scratches → Re- place the camshaft. 2. Measure: Camshaft lobe dimensions “a” and “b” 3.

  • Page 161: Checking The Rocker Arms And Rocker Arm Shafts

    CAMSHAFT Rocker arm shaft outside diame- 11.981–11.991 mm (0.4717–0.4721 in) Limit 11.950 mm (0.4705 in) 3. Check: Camshaft oil passage Obstruction → Blow out with compressed air. EAS23880 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS The following procedure applies to all of the 5.
  • Page 162 CAMSHAFT NOTE: Assemble the camshaft by inserting the 10-mm bolt into the camshaft hole and tightening it. 3. Install: Intake rocker arm Intake rocker arm shaft NOTE: Insert cylinder head bolt “1” (226-mm long) into the cylinder head bolt hole. Keep slot “a”...
  • Page 163 VALVES AND VALVE SPRINGS EAS24270 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-6. Rocker arm/Camshaft Refer to “CAMSHAFT” on page 5-13. Valve cotter Valve spring retainer Outer valve spring Inner valve spring...

  • Page 164: Valves And Valve Springs

    VALVES AND VALVE SPRINGS EAS24280 REMOVING THE VALVES The following procedure applies to all of the valves and related components. NOTE: Before removing the internal parts of the cylin- der head (e.g., valves, valve springs, valve seats), make sure the valves properly seal. 1.
  • Page 165 VALVES AND VALVE SPRINGS Valve-stem-to-valve-guide clear- ance Valve-stem-to-valve-guide clear- ance (intake) 0.010–0.037 mm (0.0004–0.0015 Limit 0.080 mm (0.0032 in) Valve-stem-to-valve-guide clear- ance (exhaust) 0.025–0.052 mm (0.0010–0.0020 b. Install the new valve guide with the valve guide installer “2” and valve guide remover Limit “1”.

  • Page 166: Checking The Valve Seats

    VALVES AND VALVE SPRINGS Valve guide remover (ø6) Valve stem runout 90890-04064 Valve stem runout Valve guide remover (6.0 mm) 0.030 mm (0.0012 in) YM-04064-A Valve guide installer (ø6) 90890-04065 Valve guide installer (6.0 mm) YM-04065-A Valve guide reamer (ø6) 90890-04066 Valve guide reamer (6.0 mm) YM-04066...

  • Page 167: Checking The Valve Springs

    VALVES AND VALVE SPRINGS seat are evenly polished, then clean off all of the lapping compound. NOTE: For the best lapping results, lightly tap the valve seat while turning the valve back and forth be- tween your hands. e. Apply a fine lapping compound to the valve face and repeat the above steps.
  • Page 168 VALVES AND VALVE SPRINGS Valve spring free length Inner spring Inner spring Installed compression spring Free length (intake) force (intake) 36.17 mm (1.42 in) 75.00–91.70 N (16.86–20.61 lbf) Free length (exhaust) (7.65–9.35 kgf) 36.17 mm (1.42 in) Installed length (intake) Outer spring 30.50 mm (1.20 in) Free length (intake)

  • Page 169: Installing The Valves

    VALVES AND VALVE SPRINGS EAS24340 INSTALLING THE VALVES The following procedure applies to all of the valves and related components. 1. Deburr: Valve stem end (with an oil stone) 2. Lubricate: Valve stem “1” Valve stem seal “2” (with the recommended lubricant) a.
  • Page 170 VALVES AND VALVE SPRINGS 5-24...

  • Page 171: Cylinder And Piston

    CYLINDER AND PISTON EAS24350 CYLINDER AND PISTON Removing the cylinder and piston 20 Nm (2.0 m kg, 15 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 17 Nm (1.7 m kg, 12 ft • • Order Job/Parts to remove Q’ty Remarks...

  • Page 172: Removing The Piston

    CYLINDER AND PISTON Vertical scratches → Rebore or replace the EAS24380 REMOVING THE PISTON cylinder, and replace the piston and piston 1. Remove: rings as a set. Piston pin clips “1” 2. Measure: Piston pin “2” Piston-to-cylinder clearance Piston “3” MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM ECA13810 a.

  • Page 173: Checking The Piston Rings

    CYLINDER AND PISTON Piston ring side clearance Top ring Ring side clearance 0.030–0.065 mm (0.0012–0.0026 Limit 0.115 mm (0.0045 in) 2nd ring Ring side clearance 0.020–0.055 mm (0.0008–0.0022 a. Piston skirt diameter Limit b. 11 mm (0.43 in) from the bottom edge of the pis- 0.115 mm (0.0045 in) Diameter D 73.983–73.998 mm...

  • Page 174: Checking The Piston Pin

    CYLINDER AND PISTON Piston ring end gap Top ring End gap (installed) 0.19–0.31 mm (0.0075–0.0122 in) Limit 0.60 mm (0.0236 in) 2nd ring End gap (installed) 0.30–0.45 mm (0.0118–0.0177 in) Limit 0.60 mm (0.0236 in) 4. Calculate: Oil ring Piston-pin-to-piston-pin-bore clearance End gap (installed) Out of specification →...
  • Page 175 CYLINDER AND PISTON Make sure the arrow mark “a” on the piston (exhaust side) through the timing chain cavity. points towards the exhaust side of the cylinder. Before installing the piston pin clip, cover the crankcase opening with a clean rag to prevent the clip from falling into the crankcase.

  • Page 176: Clutch

    CLUTCH EAS25061 CLUTCH Removing the clutch cover 20 Nm (2.0 m kg, 15 ft • • 30 Nm (3.0 m kg, 22 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 177 CLUTCH Removing the clutch 8 Nm (0.8 m kg, 5.8 ft • • 75 Nm (7.5 m kg, 54 ft • • 80 Nm (8.0 m kg, 58 ft • • Order Job/Parts to remove Q’ty Remarks Clutch spring Pressure plate Adjusting screw Push plate Friction plate...
  • Page 178 CLUTCH Removing the push lever shaft 7 Nm (0.7 m kg, 5.1 ft • • 12 Nm (1.2 m kg, 8.7 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “AIR INDUCTION SYSTEM” on Air cut-off valve page 6-9. Refer to “GENERATOR AND STARTER Generator rotor cover CLUTCH”...

  • Page 179: Removing The Clutch

    CLUTCH EAS25070 NOTE: REMOVING THE CLUTCH Measure the friction plate at four places. 1. Straighten the lock washer tab. 2. Loosen: Friction plate thickness Primary drive gear nut “1” 2.70–2.90 mm (0.106–0.114 in) NOTE: Wear limit Insert aluminum plate “a” between primary drive 2.60 mm (0.1024 in) gear “2”...

  • Page 180: Checking The Clutch Housing

    CLUTCH Clutch spring free length “a” Out of specification → Replace the clutch springs as a set. Clutch spring free length 40.10 mm (1.58 in) Limit 38.10 mm (1.50 in) EAS25170 CHECKING THE PRESSURE PLATE 1. Check: Pressure plate Cracks/damage → Replace. EAS25190 CHECKING THE CLUTCH PUSH RODS 1.
  • Page 181 CLUTCH Clutch housing “2” Thrust washer Clutch boss “3” Lock washer “4” Claw washer “5” Lock washer “6” NOTE: Assemble the primary drive gear by facing its flat face “a” toward the crankcase. Align lock washer projection “b” with the clutch boss slit during assembling.
  • Page 182 CLUTCH 10.Adjust: Push lever position MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a. Loosen the locknut “1”. b. Turn the adjusting screw “2” in or out until the marks are aligned. c. Hold the adjusting screw to prevent it from moving and then tighten the locknut to speci- fication.
  • Page 183 CLUTCH 12.Adjust: Clutch cable free play Refer to “ADJUSTING THE CLUTCH CA- BLE FREE PLAY” on page 3-12. 5-37...

  • Page 184: Oil Pump And Balancer Gear

    OIL PUMP AND BALANCER GEAR EAS3C51007 OIL PUMP AND BALANCER GEAR Removing oil pump and balancer gear 6 Nm (0.6 m kg, 4.3 ft • • 55 Nm (5.5 m kg, 40 ft • • Order Job/Part Q’ty Remarks Primary drive gear Refer to “CLUTCH”...
  • Page 185 OIL PUMP AND BALANCER GEAR Disassembling the oil pump Order Job/Part Q’ty Remarks Oil pump cover Dowel pin Oil pump shaft Dowel pin Inner rotor Outer rotor Oil pump housing For assembly, reverse the disassembly pro- cedure. 5-39...

  • Page 186: Removing The Balancer Gear

    OIL PUMP AND BALANCER GEAR EAS3C51008 REMOVING THE BALANCER GEAR Inner-rotor-to-outer-rotor-tip clearance 1. Straighten the lock washer tab. 0.150 mm (0.0059 in) 2. Loosen: Limit Balancer driven gear unit “1” 0.200 mm (0.0079 in) NOTE: Outer-rotor-to-oil-pump-housing Insert aluminum plate “a” between balancer clearance drive gear “2”...

  • Page 187: Assembling The Oil Pump

    OIL PUMP AND BALANCER GEAR arrow direction as shown. EAS25000 ASSEMBLING THE OIL PUMP 1. Lubricate: Inner rotor Outer rotor Oil pump shaft (with the recommended lubricant) Recommended lubricant Engine oil 2. Install: Oil pump housing “1” Dowel pin 2. Install: Outer rotor “2”...
  • Page 188 OIL PUMP AND BALANCER GEAR Assemble the dowel pin on the spring as shown. 9. Be sure to bend the lock washer tab along to the nut side face. 6. Install: Balancer driven gear “1” Lock washer Balancer driven gear nut NOTE: Align mark “a”...

  • Page 189: Shift Shaft

    SHIFT SHAFT EAS25410 SHIFT SHAFT Removing the shift shaft and stopper lever 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Shift pedal assembly Refer to “ENGINE REMOVAL” on page 5-1. Clutch housing Refer to “CLUTCH” on page 5-30. Shift shaft assembly Stopper lever Stopper lever spring...

  • Page 190: Checking The Shift Shaft

    SHIFT SHAFT EAS25420 CHECKING THE SHIFT SHAFT 1. Check: Shift shaft Shift lever Bends/damage/wear → Replace. Shift lever spring Damage/wear → Replace. EAS25430 CHECKING THE STOPPER LEVER 1. Check: Stopper lever Bends/damage → Replace. Roller turns roughly → Replace the stopper lever.

  • Page 191: Generator And Starter Clutch

    GENERATOR AND STARTER CLUTCH EAS3C51010 GENERATOR AND STARTER CLUTCH Removing the generator rotor and starter clutch 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 192 GENERATOR AND STARTER CLUTCH Removing the generator rotor and starter clutch 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 30 Nm (3.0 m kg, 22 ft •...

  • Page 193: Removing The Generator

    GENERATOR AND STARTER CLUTCH EAS24490 REMOVING THE GENERATOR 1. Remove: Generator rotor bolt “1” Washer NOTE: While holding the generator rotor “2” with the sheave holder “3”, loosen the generator rotor bolt. Do not allow the sheave holder to touch the projection on the generator rotor.

  • Page 194: Installing The Starter Clutch

    GENERATOR AND STARTER CLUTCH MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a. Install the starter clutch gear “1” onto the starter clutch and hold the starter clutch. b. When turning the starter clutch gear clock- wise “A”, the starter clutch and the starter clutch gear should engage, otherwise the starter clutch is faulty and must be replaced.
  • Page 195 GENERATOR AND STARTER CLUTCH Generator rotor cover bolt 10 Nm (1.0 m•kg, 7.2 ft•lb) NOTE: Tighten the bolts diagonally. M6 × 30 mm bolt “2” M6 × 40 mm bolt “3” M6 × 45 mm bolt “4” 5-49...

  • Page 196: Electric Starter

    ELECTRIC STARTER EAS24780 ELECTRIC STARTER Removing the starter motor 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Carburetor...
  • Page 197 ELECTRIC STARTER Disassembling the starter motor Order Job/Parts to remove Q’ty Remarks Starter motor front cover Lock washer Armature assembly Starter motor yoke Starter motor rear cover Brush Brush spring For assembly, reverse the disassembly pro- cedure. 5-51...

  • Page 198: Checking The Starter Motor

    ELECTRIC STARTER with the pocket tester. EAS24790 CHECKING THE STARTER MOTOR 1. Check: Pocket tester 90890-03132 Commutator Dirt → Clean with 600 grit sandpaper. 2. Measure: Armature coil Commutator diameter “a” Commutator resistance “1” Out of specification → Replace the starter 0.0126–0.0154 Ω...

  • Page 199: Assembling The Starter Motor

    ELECTRIC STARTER Gear teeth Damage/wear → Replace the gear. 8. Check: Bearing Oil seal Damage/wear → Replace the defective part(s). EAS24800 ASSEMBLING THE STARTER MOTOR 1. Install: Lock washer “1” NOTE: Align the tab “a” on the brush seat with the slot “b”...

  • Page 200: Crankcase

    CRANKCASE EAS25540 CRANKCASE Separating the crankcase 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 • • 20 Nm (2.0 m kg, 15 ft •...
  • Page 201 CRANKCASE Removing the Bearing 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “CRANKSHAFT ASSEMBLY” on Crankshaft assembly page 5-58. Main axle assembly/Drive axle assembly Refer to “TRANSMISSION” on page 5-61. Bearing retainer Oil seal Bearing For installation, reverse the removal proce-...

  • Page 202: Disassembling The Crankcase

    1. Thoroughly clean all the gasket mating sur- faces and crankcase mating surfaces. 2. Apply: Sealant (onto the crankcase mating surfaces) 3. Remove: Yamaha bond No. 1215 (Three Right crankcase Bond No.1215®) 90890-85505 EC3C51004 CAUTION: Tap on one side the crankcase with a...
  • Page 203 CRANKCASE crankcase during its assembling. Tighten the bolts diagonally in two (2) stages, with 1/4 turn each. M6 × 70 mm bolt (with gasket)“1” M6 × 60 mm bolt “2” M6 × 55 mm bolt “3” M6 × 45 mm bolt “4” 4.
  • Page 204 CRANKSHAFT ASSEMBLY EAS3C51013 CRANKSHAFT ASSEMBLY Crankshaft assembly and balancer Order Job/Part Q’ty Remarks Separate the crank case. Refer to “CRANKCASE” on page 5-54. Balancer Crankshaft assembly Dowel pin Plunger pin Bearing For installation, reverse the removal proce- dure. 5-58...

  • Page 205: Crankshaft Assembly

    CRANKSHAFT ASSEMBLY EAS26000 REMOVING THE CRANKSHAFT ASSEMBLY Runout limit C 0.030 mm (0.0012 in) 1. Remove: Crankshaft assembly “1” NOTE: Remove the crankshaft assembly using crank- shaft separating tool “2”. Crankcase separating tool 90890-01135 Crankcase separator YU-01135-B 2. Measure: Big end side clearance Out of specification →...
  • Page 206 CRANKSHAFT ASSEMBLY 2. Install: Crankshaft assembly “1” NOTE: Install the crankshaft assembly using spacer “2”, adapter (M10) “3”, crankshaft installer “4”, and crankshaft installer bolt “5”. Crankshaft installer pot 90890-01274 Installing pot YU-90058 Crankshaft installer bolt 90890-01275 Bolt YU-90060 Adapter (M10) 90890-01383 Adapter #2 YU-90062...

  • Page 207: Transmission

    TRANSMISSION EAS26241 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Q’ty Remarks Crankcase separation Refer to “CRANKCASE” on page 5-54. Shift fork guide bar Shift drum assembly Shift fork-R Shift fork-C Shift fork-L Main axle assembly Drive axle assembly For installation, reverse the removal proce- dure.
  • Page 208 TRANSMISSION Disassembling the transmission Order Job/Parts to remove Q’ty Remarks 2nd pinion gear 5th pinion gear 3rd/4th pinion gear Main axle/1st pinion gear Circlip 1st wheel gear Dog clutch Circlip Lock washer 3rd wheel gear 4th wheel gear 5th wheel gear Circlip Lock washer 2nd wheel gear...

  • Page 209: Checking The Shift Forks

    TRANSMISSION EAS26260 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. EAS26290 CHECKING THE TRANSMISSION 1. Measure: Main axle runout (with a centering device and dial gauge “1”) Out of specification →...

  • Page 210: Installing The Shift Forks And Shift Drum Assembly

    TRANSMISSION 3. Check: Transmission gears Blue discoloration/pitting/wear → Replace the defective gear(s). Transmission gear dogs Cracks/damage/wear → Replace the defec- tive gear(s). 4. Check: Transmission gear engagement (each pinion gear to its respective wheel gear) 2. Check: Incorrect → Reassemble the transmission Transmission axle assemblies.

  • Page 211: Fuel System

    FUEL SYSTEM FUEL TANK ....................6-1 CHECKING THE FUEL COCK..............6-2 CARBURETOR ....................6-3 CHECKING THE CARBURETOR ............6-6 ASSEMBLING THE CARBURETOR............6-7 INSTALLING THE CARBURETOR ............6-8 AIR INDUCTION SYSTEM................6-9 CHECKING THE AIR INDUCTION SYSTEM ..........6-12...
  • Page 212 FUEL TANK EAS26620 FUEL TANK Removing the fuel tank 7 Nm (0.7 m kg, 5.1 ft 7 Nm (0.7 m kg, 5.1 ft • • • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Left fuel tank side cover/right fuel tank side...

  • Page 213: Fuel Tank

    FUEL TANK EAS26650 CHECKING THE FUEL COCK 1. Check: Fuel cock Cracks/damage/wear → Replace. 2. Check: Fuel cock strainer “1” Obstruction → clean. Blow out the jets with compressed air. Damage → Replace.

  • Page 214: Carburetor

    CARBURETOR EAS26720 CARBURETOR Removing the carburetor 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Fuel tank Refer to “FUEL TANK” on page 6-1. Refer to “AIR INDUCTION SYSTEM” on Air cut-off valve page 6-9.
  • Page 215 CARBURETOR Disassembling the carburetor Order Job/Parts to remove Q’ty Remarks Throttle stop screw Vacuum chamber cover Piston valve spring Jet needle holder Spring Jet needle kit Piston valve Coasting enricher cover Coasting enricher spring Coasting enricher diaphragm Carburetor warmer lead Carburetor warmer Pilot screw set Float chamber...
  • Page 216 CARBURETOR Disassembling the carburetor Order Job/Parts to remove Q’ty Remarks Main jet holder Needle jet Pilot jet For assembly, reverse the disassembly pro- cedure.

  • Page 217: Checking The Carburetor

    CARBURETOR Cracks/tears → Replace. EAS26760 CHECKING THE CARBURETOR 1. Check: Carburetor body Float chamber Jet housing Cracks/damage → Replace. 2. Check: Fuel passages Obstruction → Clean. MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a. Wash and clean the carburetor with a kero- 7. Check: sene. Never use a poor volatile carburetor Vacuum chamber cover cleaner.

  • Page 218: Assembling The Carburetor

    CARBURETOR Cracks/damage → Replace. ber matching face to the float top face. 13.Check: Float height Carburetor air vent hose 11.9 mm (0.47 in) Carburetor fuel drain hose Fuel hoses Cracks/damage/wear → Replace. Obstruction → Clean. Blow out the hoses with compressed air. EAS26800 ASSEMBLING THE CARBURETOR ECA14110...

  • Page 219: Installing The Carburetor

    CARBURETOR Clip position Standard clip position 3 levels EAS26890 INSTALLING THE CARBURETOR 1. Adjust: Engine idling speed Refer to “ADJUSTING THE ENGINE IDLING SPEED” on page 3-8. Engine idling speed 1300–1500 r/min 2. Adjust: Throttle cable free play Refer to “ADJUSTING THE THROTTLE CA- BLE FREE PLAY”...

  • Page 220: Air Induction System

    AIR INDUCTION SYSTEM EAS27040 AIR INDUCTION SYSTEM...
  • Page 221 AIR INDUCTION SYSTEM 1. Cylinder head 2. Air induction system pipe 3. Air induction system hose (from the air cut-off valve to the cylinder head) 4. Air induction system vacuum hose 5. Air cut-off valve 6. Air induction system hose (from the air filter to the air cut-off valve) 7.
  • Page 222 AIR INDUCTION SYSTEM Removing the air cut-off valve and hose 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks Fuel tank Refer to “FUEL TANK” on page 6-1. Air induction system vacuum hose Air induction system hose (from the air cut-off valve to the cylinder head) Air cut-off valve Air induction system hose (from the air filter to...

  • Page 223: Checking The Air Induction System

    AIR INDUCTION SYSTEM Cracks/damage → Replace the reed valve. EAS27060 CHECKING THE AIR INDUCTION SYSTEM Air induction The air induction system burns unburned ex- haust gases by injecting fresh air (secondary air) into the exhaust port, reducing the emission of carbon monoxide.
  • Page 224 AIR INDUCTION SYSTEM 6-13...

  • Page 225: Electrical System

    ELECTRICAL SYSTEM IGNITION SYSTEM ..................7-1 CIRCUIT DIAGRAM .................7-1 TROUBLESHOOTING ................7-3 ELECTRIC STARTING SYSTEM..............7-5 CIRCUIT DIAGRAM .................7-5 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION......7-7 TROUBLESHOOTING ................7-9 CHARGING SYSTEM ..................7-11 CIRCUIT DIAGRAM .................7-11 TROUBLESHOOTING ................7-13 LIGHTING SYSTEM..................7-15 CIRCUIT DIAGRAM .................7-15 TROUBLESHOOTING ................7-17 SIGNALING SYSTEM ..................7-19 CIRCUIT DIAGRAM .................7-19 TROUBLESHOOTING ................7-21 CARBURETOR HEATING SYSTEM .............7-25...

  • Page 226: Ignition System

    IGNITION SYSTEM EAS27090 IGNITION SYSTEM EAS27100 CIRCUIT DIAGRAM...
  • Page 227 IGNITION SYSTEM 1. Pickup coil 2. A.C. magneto 4. Fuse 6. Battery 9. Main switch 10. Right handlebar switch 11. Engine stop switch 13. Diode 15. Sidestand switch 16. Starting circuit cut-off relay 17. Diode 3 18. Neutral switch 19. C.D.I. unit 20.

  • Page 228: Troubleshooting

    IGNITION SYSTEM EAS27130 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). NOTE: Before troubleshooting, remove the following part(s): 1.Seat 2.Rear side cover 3.Tool box 4.Fuel tank 5.Carburetor assembly 6.Starter (choke) knob Check the fuse. Refer to NG→...
  • Page 229 IGNITION SYSTEM 10.Check the sidestand switch. NG→ Replace the sidestand switch. Refer to “CHECKING THE SWITCHES” on page 7-33 OK↓ 11.Check the clutch switch. NG→ Replace the clutch switch. Refer to “CHECKING THE SWITCHES” on page 7-33 OK↓ 12.Checking the entire ignition sys- tem’s wiring.

  • Page 230: Electric Starting System

    ELECTRIC STARTING SYSTEM EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM...
  • Page 231 ELECTRIC STARTING SYSTEM 4. Fuse 5. Starter relay 6. Battery 7. Starter motor 8. Diode 1 9. Main switch 10. Right handlebar switch 11. Engine stop switch 12. Start switch 13. Diode 2 14. Clutch switch 15. Sidestand switch 16. Starting circuit cut-off relay 17.

  • Page 232: Starting Circuit Cut-Off System Operation

    ELECTRIC STARTING SYSTEM EAS27180 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: The transmission is in neutral (the neutral switch is closed).
  • Page 233 ELECTRIC STARTING SYSTEM a. WHEN THE TRANSMISSION IS IN NEU- TRAL b. WHEN THE SIDESTAND IS UP AND THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 1. Battery 2. Fuse 3. Main switch 4. Diode2 5. Clutch switch 6. Sidestand switch 7.

  • Page 234: Troubleshooting

    ELECTRIC STARTING SYSTEM EAS27190 TROUBLESHOOTING The starter motor fails to turn. NOTE: Before troubleshooting, remove the following part(s): 1.Seat 2.Rear side cover 3.Tool box 4.Fuel tank 5.Carburetor assembly 1. Check the fuse. Refer to NG→ Replace the fuse(s). “CHECKING THE FUSE” on page 7-37 OK↓...
  • Page 235 ELECTRIC STARTING SYSTEM 10.Check the engine stop switch. NG→ Replace the right handlebar switch. Refer to “CHECKING THE SWITCHES” on page 7-33 OK↓ 11.Check the neutral switch. NG→ Replace the neutral switch. Refer to “CHECKING THE SWITCHES” on page 7-33 OK↓...

  • Page 236: Charging System

    CHARGING SYSTEM EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM 7-11...
  • Page 237 CHARGING SYSTEM 2. A.C. magneto 3. Rectifier/regulator 4. Fuse 6. Battery 7-12...

  • Page 238: Troubleshooting

    CHARGING SYSTEM EAS27220 TROUBLESHOOTING The battery is not being charged. NOTE: Before troubleshooting, remove the following part(s): 1.Seat 2.Rear side cover 3.Fuel tank 4.Carburetor assembly 1. Check the fuse. Refer to NG→ Replace the fuse. “CHECKING THE FUSE” on page 7-37 OK↓...
  • Page 239 CHARGING SYSTEM 7-14...

  • Page 240: Lighting System

    LIGHTING SYSTEM EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM 7-15...
  • Page 241 LIGHTING SYSTEM 4. Fuse 6. Battery 9. Main switch 19. C. D. I. unit 22. Meter assembly 26. High beam indicator light 29. Tail/brake light 31. Front turn signal light (right) 32. Front turn signal light (left) 34. Headlight 38. Headlight relay 40.

  • Page 242: Troubleshooting

    LIGHTING SYSTEM EAS27260 TROUBLESHOOTING Any of the following fail to light: headlight, high beam indicator light, taillight, license light or meter light. NOTE: Before troubleshooting, remove the following part(s): 1.Seat 2.Rear side cover 3.Tool box 1. Check the each bulbs and bulb sockets condition.
  • Page 243 LIGHTING SYSTEM 7-18...

  • Page 244: Signaling System

    SIGNALING SYSTEM EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM 7-19...
  • Page 245 SIGNALING SYSTEM 4. Fuse 6. Battery 9. Main switch 18. Neutral switch 19. C. D. I. unit 22. Meter assembly 23. Neutral indicator light 24. Multi-function display 25. Speedometer 27. Turn signal indicator light 28. Speed sensor 29. Tail/brake light 30.

  • Page 246: Troubleshooting

    SIGNALING SYSTEM EAS27290 TROUBLESHOOTING Any of the following fail to light: turn signal light, brake light or an indicator light. The horn fails to sound. The speedometer fails to operate. NOTE: Before troubleshooting, remove the following part(s): 1.Seat 2.Rear side cover 3.Tool box 1.
  • Page 247 SIGNALING SYSTEM The tail/brake light fails to come on. 1. Check the tail/brake light bulb and Replace the tail/brake light bulb, socket or socket. NG→ Refer to “CHECKING THE BULBS both. AND BULB SOCKETS” on page 7-36 OK↓ 2. Check the front brake light switch. Refer to NG→...
  • Page 248 SIGNALING SYSTEM The neutral indicator light fails to come. 1. Check the neutral switch. Refer to NG→ Replace the neutral switch. “CHECKING THE SWITCHES” on page 7-33 OK↓ 2. Check the entire signaling system’s Properly connect or repair the signaling wiring.
  • Page 249 SIGNALING SYSTEM 7-24...

  • Page 250: Carburetor Heating System

    CARBURETOR HEATING SYSTEM EAS27490 CARBURETOR HEATING SYSTEM EAS27500 CIRCUIT DIAGRAM 7-25...
  • Page 251 CARBURETOR HEATING SYSTEM 4. Fuse 6. Battery 9. Main switch 44. Thermo switch 45. Carburetor warmer 7-26...

  • Page 252: Troubleshooting

    CARBURETOR HEATING SYSTEM EAS27510 TROUBLESHOOTING The carburetor warmer system fails to operate. NOTE: Before troubleshooting, remove the following part(s): 1.Seat 2.Rear side cover 3.Tool box 4.Fuel tank 5.Carburetor assembly 6.Rectifier/regulator 1. Check the fuse. Refer to NG→ Replace the fuse(s). “CHECKING THE FUSE”...
  • Page 253 CARBURETOR HEATING SYSTEM 7-28...

  • Page 254: Electrical Components

    ELECTRICAL COMPONENTS EAS27971 ELECTRICAL COMPONENTS EAS3C51017 7-29...
  • Page 255 ELECTRICAL COMPONENTS 1. Main switch 2. Diode1 3. Diode3 4. Diode2 5. Fuse 6. Starter relay 7. Battery 8. Rectifier/regulator 9. Sidestand switch 10. Rear brake light switch 11. Headlight relay 12. Starting circuit cut-off relay 13. Wire harness 7-30...
  • Page 256 ELECTRICAL COMPONENTS 7-31...
  • Page 257 ELECTRICAL COMPONENTS 1. Horn 2. CDI unit 3. Thermo switch 4. Speed sensor 5. Neutral switch 6. Carburetor warmer 7. Carburetor warmer lead 8. Ignition coil 9. Spark plug cap 7-32...

  • Page 258: Checking The Switches

    ELECTRICAL COMPONENTS EAS27980 CHECKING THE SWITCHES 7-33...
  • Page 259 ELECTRICAL COMPONENTS 1. Horn switch 2. Dimmer switch 3. Turn signal switch 4. Clutch switch 5. Sidestand switch 6. Main switch 7. Engine stop switch 8. Start switch 9. Front brake light switch 10. Neutral switch 11. Rear brake light switch 7-34...
  • Page 260 ELECTRICAL COMPONENTS Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. ECA14370 CAUTION: Never insert the tester probes into the coupler terminal slots “a”. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.

  • Page 261: Checking The Bulbs And Bulb Sockets

    ELECTRICAL COMPONENTS Bulb EAS27990 CHECKING THE BULBS AND BULB EWA13320 SOCKETS WARNING Check each bulb and bulb socket for damage or Since the headlight bulb gets extremely hot, wear, proper connections, and also for continu- keep flammable products and your hands ity between the terminals.

  • Page 262: Checking The Fuse

    ELECTRICAL COMPONENTS Checking the condition of the bulb sockets The following procedure applies to all of the bulb LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL sockets. 3. Replace: 1. Check: Blown fuse Bulb socket (for continuity) (with the pocket tester) MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a. Set the main switch to “OFF”. No continuity →...
  • Page 263 ELECTRICAL COMPONENTS OUT OF REACH OF CHILDREN. Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury. FIRST AID IN CASE OF BODILY CONTACT: EXTERNAL Skin — Wash with water. Eyes — Flush with water for 15 minutes and get immediate medical attention.
  • Page 264 ELECTRICAL COMPONENTS the battery quickly and can cause battery voltage adjust dial at 20–24 V and monitor the amperage for 3–5 minutes to check the battery. overheating and battery plate damage. If it is impossible to regulate the charging current on the battery charger, be careful Reach the standard charging current not to overcharge the battery.

  • Page 265: Checking The Relays

    ELECTRICAL COMPONENTS ter leaving the battery unused for more than 1. Disconnect the relay from the wire harness. 2. Connect the pocket tester (Ω × 1) and battery 30 minutes. (12 V) to the relay terminal as shown. 12.8 V or more --- Charging is complete. Check the relay operation.

  • Page 266: Checking The Turn Signal Relay

    ELECTRICAL COMPONENTS Headlight relay b. Turn the main switch “ON”. c. Measure the input voltage of the turn signal 1. Positive battery terminal light and hazard relay. 2. Negative battery terminal 3. Positive tester probe 4. Negative tester probe LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 2.

  • Page 267: Checking The Diode

    ELECTRICAL COMPONENTS LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL EAS28050 CHECKING THE DIODE 1. Check: Diode2 Diode3 Out of specification → Replace. Pocket tester 90890-03132 A. Diode2 B. Diode3 NOTE: MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM The following lists the specifications if you use a. Disconnect the diode from the wire harness. the pocket tester (90890-03132).

  • Page 268: Checking The Ignition Coil

    ELECTRICAL COMPONENTS EAS28090 CHECKING THE IGNITION COIL Positive tester probe 1. Check: High tension code “1” Primary coil resistance Negative tester probe Out of specification → Replace. Orange “2” Primary coil resistance 0.18–0.27 Ω MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a. Disconnect the ignition coil connectors from the wire harness.

  • Page 269: Checking The Pickup Coil

    ELECTRICAL COMPONENTS b. Measure the pickup coil resistance. 2. Spark plug cap c. Turn the main switch “ON” and set the engine stop switch to the “ LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL d. Measure ignition spark gap “a”. EAS28150 e. Press start switch “ ” to crank the engine, CHECKING THE STATOR COIL and gradually increase the spark plug gap 1.

  • Page 270: Checking The Rectifier/Regulator

    ELECTRICAL COMPONENTS LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL EAS28180 CHECKING THE HORN 1. Check: Horn resistance Out of specification → Replace. Horn resistance 1.01–1.11 Ω at 20°C (68°F) b. Measure the stator coil resistance. MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a. Disconnect the horn leads from the horn ter- LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL minals.

  • Page 271: Checking The Speed Sensor

    ELECTRICAL COMPONENTS EAS28270 CHECKING THE THERMO SWITCH 1. Remove: Thermo switch (from the thermostat housing) EWA13830 WARNING Handle the thermo switch with special care. Never subject the thermo switch to strong shocks. If the thermo switch is dropped, re- place it. 2.

  • Page 272: Checking The Carburetor Warmer

    ELECTRICAL COMPONENTS LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL A. When the water temperature increases B. When the water temperature decreases e. Check the thermo switch for continuity. LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL EAS28310 CHECKING THE CARBURETOR WARMER 1. Check: Carburetor warmer element resistance Out of specification → Replace. Carburetor warmer resistance 4.7–9.5 Ω...

  • Page 273: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING ...................8-1 GENERAL INFORMATION ..............8-1 STARTING FAILURES................8-1 INCORRECT ENGINE IDLING SPEED ...........8-1 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE......8-2 FAULTY GEAR SHIFTING...............8-2 SHIFT PEDAL DOES NOT MOVE............8-2 JUMPS OUT OF GEAR ................8-2 FAULTY CLUTCH ..................8-2 OVERHEATING ..................8-3 POOR BRAKING PERFORMANCE............8-3 FAULTY FRONT FORK LEGS..............8-3 UNSTABLE HANDLING................8-3 FAULTY LIGHTING OR SIGNALING SYSTEM........8-3...

  • Page 274: General Information

    TROUBLESHOOTING Deteriorated or contaminated fuel EAS28450 TROUBLESHOOTING Clogged pilot jet Clogged pilot air passage EAS28460 Sucked-in air GENERAL INFORMATION Damaged float NOTE: The following guide for troubleshooting does not Worn needle valve cover all the possible causes of trouble. It should Improperly installed needle valve seat be helpful, however, as a guide to basic trouble- Incorrect fuel level...

  • Page 275: Poor Medium-And-High-Speed Performance

    TROUBLESHOOTING Incorrect valve clearance EAS28530 FAULTY GEAR SHIFTING Damaged valve train components Shifting is difficult 2. Air filter Refer to “Clutch drags”. Clogged air filter element Fuel system EAS28540 SHIFT PEDAL DOES NOT MOVE 1. Carburetor(s) Shift shaft Faulty starter plunger Improperly adjusted shift rod Loose or clogged pilot jet Bent shift shaft...

  • Page 276: Overheating

    TROUBLESHOOTING Incorrect oil level Cracked or damaged cap bolt O-ring Incorrect oil viscosity (high) Malfunction Deteriorated oil Bent or damaged inner tube Bent or damaged outer tube EAS28590 Damaged fork spring OVERHEATING Worn or damaged outer tube bushing Engine Bent or damaged damper rod 1.
  • Page 277 TROUBLESHOOTING Incorrect connection Improperly grounded circuit Poor contacts (main or light switch) Burnt-out headlight bulb Headlight bulb burnt out Wrong headlight bulb Faulty battery Faulty rectifier/regulator Improperly grounded circuit Faulty main switch Faulty light switch Headlight bulb life expired Tail/brake light does not come on Wrong tail/brake light bulb Too many electrical accessories Incorrect connection...
  • Page 278 EAS28740 EAS28750 Red/White WIRING DIAGRAM COLOR CODE Red/Yellow XT250X/XT250XC 2008 Black Sb/W Sky blue/White 1.Pickup coil Brown 2.A.C. magneto White/Black Chocolate 3.Rectifier/regulator White/Red 4.Fuse Dark green 5.Starter relay White/Yellow Green 6.Battery Yellow/Black Gray 7.Starter motor Yellow/Green 8.Diode 1 Blue 9.Main switch...
  • Page 280 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U.S.A...

This manual is also suitable for:

Xt250Xt250xc

Table of Contents