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Yamaha XG250 Service Manual

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XG250
SERVICE MANUAL

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  • Page 1 XG250 SERVICE MANUAL...
  • Page 2 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 3: Table Of Contents

    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 4: Symbols

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

  • Page 6: General Information

    GENERAL INFORMATION IDENTIFICATION ..................1-1 VEHICLE IDENTIFICATION NUMBER...........1-1 MODEL LABEL ..................1-1 ENGINE SERIAL NUMBER ..............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 7: Identification

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

  • Page 8: Important Information

    Oil bearings liberally when installing, if appropri- REPLACEMENT PARTS ate. 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 9: Circlips

    IMPORTANT INFORMATION CAUTION: Do not spin the bearing with compressed air because this will damage the bearing surfac- 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 10: Checking The Connections

    CHECKING THE CONNECTIONS (with the pocket tester) CHECKING THE CONNECTIONS Pocket tester Check the leads, couplers, and connectors for 90890-03112 stains, rust, moisture, etc. Analog pocket tester 1. Disconnect: YU-03112-C Lead ● Coupler NOTE: ● Connector If there is no continuity, clean the terminals. ●...

  • Page 11: Special Tools

    SPECIAL TOOLS 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 12 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Valve spring compressor 5-18, 5-23 90890-04019 YM-04019 Ring nut wrench 4-50 90890-01268 Spanner wrench YU-01268 Crankshaft installer pot 5-61 90890-01274 Installing pot YU-90058 YU-90058/YU-90059 Crankshaft installer bolt 5-61 90890-01275 Bolt YU-90060 Spacer 5-61 90890-01288 Adapter (M10)
  • Page 13 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Damper rod holder 4-43, 4-45 90890-01294 Damping rod holder set YM-01300 YM-01300 T-handle 4-43, 4-45 90890-01326 T-handle 3/8" drive 60 cm long YM-01326 Tappet adjusting tool 90890-01311 Valve adjuster 3 mm & 4 mm YM-08035-A Flywheel puller 5-51...
  • Page 14 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Steering nut wrench 3-20 90890-01403 Spanner wrench YU-33975 Sheave holder 5-51, 5-52 90890-01701 Primary clutch holder YS-01880-A Thickness gauge 90890-03079 Narrow gauge set YM-34483 Compression gauge 90890-03081 Engine compression tester YU-33223 Extension 90890-04082 Pocket tester 1-4, 7-35, 7-36,...
  • Page 15 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Valve guide installer (ø6) 5-20 90890-04065 Valve guide installer (6.0 mm) YM-04065-A Valve guide reamer (ø6) 5-20 90890-04066 Valve guide reamer (6.0 mm) YM-04066 Universal clutch holder 5-33, 5-35 90890-04086 YM-91042 Valve lapper 5-21 90890-04101 Valve lapping tool...

  • Page 16: Specifications

    SPECIFICATIONS GENERAL SPECIFICATIONS ..............2-1 ENGINE SPECIFICATIONS ................2-2 CHASSIS SPECIFICATIONS..............2-9 ELECTRICAL SPECIFICATIONS ...............2-12 TIGHTENING TORQUES ................2-14 GENERAL TIGHTENING TORQUE SPECIFICATIONS......2-14 ENGINE TIGHTENING TORQUES............2-14 CHASSIS TIGHTENING TORQUES............2-16 LUBRICATION POINTS AND LUBRICANT TYPES ........2-19 ENGINE....................2-19 CHASSIS....................2-20 LUBRICATION SYSTEM CHART AND DIAGRAMS .........2-21 ENGINE OIL LUBRICATION CHART .............2-21 LUBRICATION DIAGRAMS ..............2-23 CABLE ROUTING ..................2-25...

  • Page 17: General Specifications

    GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS Model Model 4D61 4D62 Dimensions Overall length 2010 mm (79.1 in) Overall width 800 mm (31.5 in) Overall height 1145 mm (45.1 in) Seat height 790 mm (31.1 in) Wheelbase 1330 mm (52.4 in) Ground clearance 280 mm (11.02 in) Minimum turning radius 1900 mm (74.8 in)

  • Page 18: Engine Specifications

    ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS Engine Engine type Air cooled 4-stroke, SOHC Displacement 249.0 cm (15.19 cu.in) Cylinder arrangement Forward-inclined single cylinder Bore × stroke 74.0 × 58.0 mm (2.91 × 2.28 in) Compression ratio 9.50 :1 Standard compression pressure (at sea level) 1200 kPa/300 r/min (170.7 psi/300 r/min) (12.0 kgf/cm /300 r/min)
  • Page 19 ENGINE SPECIFICATIONS Camshaft Drive system Chain drive (right) Camshaft journal diameter 24.960–24.980 mm (0.9827–0.9835 in) 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...
  • Page 20 ENGINE SPECIFICATIONS Valve seat width C (intake) 0.90–1.10 mm (0.0354–0.0433 in) Valve seat width C (exhaust) 0.90–1.10 mm (0.0354–0.0433 in) 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)
  • Page 21 ENGINE SPECIFICATIONS 2.5 °/1.6 mm Spring tilt (intake) 2.5 °/1.6 mm Spring tilt (exhaust) 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)
  • Page 22 ENGINE SPECIFICATIONS Piston Piston-to-cylinder clearance 0.025–0.050 mm (0.0010–0.0020 in) Limit 0.15 mm (0.0059 in) Diameter D 73.960–73.975 mm (2.9118–2.9124 in) Height H 11.0 mm (0.43 in) 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)

  • Page 23: Clutch Spring

    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 24 ENGINE SPECIFICATIONS Shifting mechanism Shift mechanism type Shift drum and guide bar Shift fork thickness 4.76–4.89 mm (0.1874–0.1925 in) Air filter Air filter element Oil-coated paper element Carburetor Type × quantity MV33 x 1 Manufacturer TEIKEI ID mark 4D61 00 Main jet #135 Main air jet...

  • Page 25: Chassis Specifications

    CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS Chassis Frame type Semi double cradle 25.17 ° Caster angle Trail 92.0 mm (3.62 in) Front wheel Wheel type Spoke wheel Rim size 19x1.85 Rim material Aluminum Wheel travel 180.0 mm (7.09 in) Radial wheel runout limit 2.0 mm (0.08 in) Lateral wheel runout limit 2.0 mm (0.08 in)
  • Page 26 CHASSIS SPECIFICATIONS Master cylinder inside diameter 11.00 mm (0.43 in) Caliper cylinder inside diameter 26.99 mm (1.06 in) Caliper cylinder inside diameter 22.22 mm (0.87 in) Recommended fluid DOT 4 Rear brake Type Single disc brake Operation Right foot operation Brake pedal position 35.0 mm (1.38 in) Rear disc brake...
  • Page 27 CHASSIS SPECIFICATIONS Drive chain Type/manufacturer 428V/DAIDO Link quantity Drive chain slack 40.0–45.0 mm (1.57–1.77 in) 15-link length limit 191.5 mm (7.54 in) 2-11...

  • Page 28: 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 248.0–372.0 Ω Pickup coil resistance CDI unit model/manufacturer 5XT/YAMAHA Ignition coil Model/manufacturer 2JN/YAMAHA Minimum ignition spark gap 6.0 mm (0.24 in) 0.18–0.28 Ω...
  • Page 29 12 V, 1.7 W × 1 High beam indicator light Electric starting system System type Constant mesh Starter motor Model/manufacturer 3C5/YAMAHA Power output 0.40 kW 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)

  • Page 30: Tightening Torques

    TIGHTENING TORQUES TIGHTENING TORQUES 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- A.
  • Page 31 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Timing chain guide (intake side) 8 Nm (0.8 m•kg, 5.8 ft•lb) Oil filter element cover (under) 10 Nm (1.0 m•kg, 7.2 ft•lb) Oil delivery pipe 20 Nm (2.0 m•kg, 14 ft•lb) Oil delivery pipe and cylinder 17 Nm (1.7 m•kg, 12 ft•lb) Oil pump assembly...

  • Page 32: Chassis Tightening Torques

    TIGHTENING TORQUES Cylinder head tightening sequence: CHASSIS TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Engine stay and frame 30 Nm (3.0 m•kg, 22 ft•lb) Engine stay and engine 72 Nm (7.2 m•kg, 52 ft•lb) Engine and frame (rear upper) 72 Nm (7.2 m•kg, 52 ft•lb) Engine and frame (rear under) 72 Nm (7.2 m•kg, 52 ft•lb)
  • Page 33 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Rear shock absorber and relay 40 Nm (4.0 m•kg, 29 ft•lb) Relay arm and frame 50 Nm (5.0 m•kg, 36 ft•lb) Relay arm and connecting rod 59 Nm (5.9 m•kg, 43 ft•lb) Connecting rod and swingarm 59 Nm (5.9 m•kg, 43 ft•lb) Chain case and swingarm...
  • Page 34 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Rear caliper bleed screw 6 Nm (0.6 m•kg, 4.3 ft•lb) Rear caliper and joint 26 Nm (2.6 m•kg, 19 ft•lb) Joint and brake hose 14 Nm (1.4 m•kg, 10 ft•lb) Union bolt 30 Nm (3.0 m•kg, 22 ft•lb) Shift pedal 30 Nm (3.0 m•kg, 22 ft•lb)

  • Page 35: Lubrication Points And Lubricant Types

    Starter idler gears 2 Starter wheel gear Push rods Clutch housing Push lever shaft Push rod ball Drive axle main axle Transmission gear Shift fork guide bar Shift drum Shift shaft Shift shaft pawl Yamaha bond Crankcase matting surface No.1215 2-19...

  • Page 36: Chassis

    LUBRICATION POINTS AND LUBRICANT TYPES CHASSIS Lubrication point Lubricant Head pipe bearing Head pipe steering ring seal lip Front wheel oil seal lip (left and right) Rear wheel oil seal lip (left and right) Brake pedal shaft Shift pedal shaft Frame, sidestand and sidestand collar moving point Guide tube and throttle cable Front brake lever bolt and pivoting point and metal moving point...

  • Page 37: Lubrication System Chart And Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS LUBRICATION SYSTEM CHART AND DIAGRAMS ENGINE OIL LUBRICATION CHART Oil filter Pin, Cylinder with hole head Oil pump Drive axle Main axle Crank Cam shaft shaft Oil strainer Oil pan 2-21...
  • Page 38 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Camshaft 2. Oil filter element 3. Oil check window 4. Oil pump assembly 5. Oil strainer 2-22...

  • Page 39: Lubrication Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS LUBRICATION DIAGRAMS 2-23...
  • Page 40 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Camshaft 2. Drive axle 3. Main axle 4. Push lever shaft 5. Oil pump assembly 6. Oil strainer 7. Crankshaft assembly 8. Oil filter element 2-24...

  • Page 41: Cable Routing

    CABLE ROUTING CABLE ROUTING 2-25...
  • Page 42 CABLE ROUTING H. Fasten the handlebar switch right lead, 1. Rear brake switch leads front brake light switch, front turn signal 2. Throttle pulley light right lead, meter lead and headlight 3. Grommet (tool box cover) relay with a clamp at the place around 4.
  • Page 43 CABLE ROUTING 2-27...
  • Page 44 CABLE ROUTING X. Store the left handlebar switch lead, clutch switch coupler, main switch lead, left turn signal light coupler in cover at front. Y. Install the cover, and position its front/ rear below the bottom of the tool box stay.
  • Page 45 CABLE ROUTING 2-29...
  • Page 46 CABLE ROUTING L. install the connectors and face their 1. Grommet heads inside to the body. 2. Side cover M. Fasten the left handlebar switch lead, 3. Side cover frame stay clutch switch lead, front left turn signal 4. Air induction system hose (air filter—air light lead and main switch lead with a cut-off valve) clamp.
  • Page 47 CABLE ROUTING 2-31...
  • Page 48 CABLE ROUTING N. Turn toward the front of the body. 1. Front brake hose O. Turn to the ground. 2. Right handlebar switch lead P. The upper part of the body. 3. Front brake light switch lead 4. Throttle cable (decelerator) 5.
  • Page 49 CABLE ROUTING 2-33...
  • Page 50 CABLE ROUTING 1. Front brake hose 2. Throttle cable 3. Speedometer cable 4. Clutch cable 5. Headlight lead 6. Meter lead A. Route the front turn signal light left lead behind the speedometer cable and in front of the clutch cable. B.

  • Page 51: Periodic Checks And Adjustments

    PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE ................3-1 INTRODUCTION..................3-1 Periodic maintenance and lubrication chart ..........3-1 ENGINE .......................3-3 ADJUSTING THE VALVE CLEARANCE ..........3-3 CHECKING THE EXHAUST GAS............3-4 CHECKING THE EXHAUST GAS............3-6 ADJUSTING THE ENGINE IDLING SPEED...........3-6 ADJUSTING THE THROTTLE CABLE FREE PLAY ......3-7 CHECKING THE SPARK PLUG .............3-8 MEASURING THE COMPRESSION PRESSURE........3-9 CHECKING THE ENGINE OIL LEVEL ...........3-10...

  • Page 52: Periodic Maintenance

    From 50000 km, repeat the maintenance intervals starting from 10000 km. ● Items marked with an asterisk should be performed by a Yamaha dealer as they require special ● tools, data and technical skills. ODOMETER READING (× 1000 km)
  • Page 53 PERIODIC MAINTENANCE ODOMETER READING (× 1000 km) ANNUAL ITEM CHECK OR MAINTENANCE JOB CHECK √ √ √ √ √ Check bearing play and steering for roughness. ● 14 * Steering bearings Lubricate with lithium-soap-based grease. Every 50000 km ● Make sure that all nuts, bolts and screws are ●...

  • Page 54: Engine

    ENGINE 3. Measure: EAS20470 ENGINE Valve clearance ● Out of specification → Adjust. EAS20520 ADJUSTING THE VALVE CLEARANCE Valve clearance (cold) The following procedure applies to all of the Intake valves. 0.05–0.10 mm (0.0020–0.0039 in) NOTE: Exhaust Valve clearance adjustment should be made ●...

  • Page 55: Checking The Exhaust Gas

    ENGINE Thickness gauge Cylinder head side cover 90890-03079 18 Nm (1.8 m•kg, 13 ft•lb) Narrow gauge set YM-34483 O-rings ● Cylinder head side cover 3 ● Cylinder head side cover bolts ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 10 Nm (1.0 m•kg, 7.2 ft•lb) 4. Adjust: Valve clearance ●...
  • Page 56 ENGINE NOTE: Since it is necessary to insert the sampling ● probe 600 mm into the exhaust pipe, be sure to use a heat-resistant rubber tube as shown in the illustration. Be sure to set the heat-resistant rubber tube ● so that exhaust gas does not leak out.

  • Page 57: Adjusting The Engine Idling Speed

    ENGINE Refer to “REPLACING THE AIR FILTER EL- EMENT” on page 3-12. Carburetor ● Refer to “CARBURETOR” on page 6-3. EAS20590 CHECKING THE EXHAUST GAS (When the air induction system is operating) 1. Stand the vehicle on a level surface. NOTE: Place the vehicle on a suitable stand.

  • Page 58: Adjusting The Throttle Cable Free Play

    ENGINE 1. Install: Pilot screw turns out Temperature probe tester “1” ● 1-1/4 (onto the engine oil drain bolt) Digital tachometer ● c. Turn the throttle stop screw “2” until the spec- (onto the spark plug lead of cylinder #1) ified engine idling speed is obtained.

  • Page 59: Checking The Spark Plug

    ENGINE ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ change. Carburetor side a. Loosen the locknut “1” on the accelerator ca- ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ble. b. Turn the adjusting nut “2” until the length “a” EAS20690 is 5mm (0.197 in). CHECKING THE SPARK PLUG c. Tighten the locknuts “1”. 1.

  • Page 60: Measuring The Compression Pressure

    ENGINE 7. Install: Spark plug ● Spark plug 18 Nm (1.8 m•kg, 13 ft•lb) NOTE: Before installing the spark plug, clean the spark plug and gasket surface. 8. Connect: Spark plug cap ● 6. Measure: Compression pressure ● EAS20710 Out of specification → Refer to steps (c) and MEASURING THE COMPRESSION PRESSURE (d).

  • Page 61: Checking The Engine Oil Level

    ENGINE Compression pressure (with oil applied into the Type cylinder) SAE10W30 SAE10W40 SAE15W40 SAE20W40 Reading Diagnosis SAE20W50 Piston ring(s) wear or Recommended engine oil grade Higher than without oil ● damage → Repair. API service SE, SF, SG type or higher Piston, valves, cylin- der head gasket or...
  • Page 62 ENGINE 3. Remove: Engine oil filler bolt “1” ● ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Engine oil drain bolt “2” ● 7. Install: (along with the gasket) Engine oil drain bolt gasket ● 4. Loosen: Engine oil drain bolt ● Oil filter element drain bolt “3” ●...

  • Page 63: Adjusting The Clutch Cable Free Play

    ENGINE turn the engine off so that it will not seize. c. Check the engine oil passages, the oil filter element and the oil pump for damage or leakage. Refer to “OIL PUMP AND BLANC- ER WEIGHT GEAR” on page 5-38. d.

  • Page 64: Checking The Carburetor Joint And Intake Manifold

    ENGINE EAS20990 CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD 1. Remove: Left side cover ● Right side cover ● Seat ● Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank ● Refer to “FUEL TANK” on page 6-1. 2. Check: 3.

  • Page 65: Checking The Cylinder Head Breather Hose

    ENGINE Exhaust pipe nut “1” 18 Nm (1.8 m•kg, 13 ft•lb) Exhaust pipe and muffler bolt “2” 20 Nm (2.0 m•kg, 14 ft•lb) Muffler and muffler bracket bolt “3” 42 Nm (4.2 m•kg, 30 ft•lb) Muffler and muffler bracket bolt “4”...

  • Page 66: Chassis

    CHASSIS EAS21140 CHASSIS ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS21170 ADJUSTING THE FRONT DISC BRAKE EAS21200 1. Check: ADJUSTING THE REAR DISC BRAKE Brake lever free play “a” 1. Check: ● Out of specification → Adjust. Brake pedal position ● (distance “a” from the top of the rider footrest to the top of the brake pedal) Out of specification →...

  • Page 67: Checking The Brake Fluid Level

    CHASSIS Locknut 18 Nm (1.8 m•kg, 13 ft•lb) EWA13050 WARNING A soft or spongy feeling in the brake lever 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 68: Checking The Rear Brake Pads

    CHASSIS 4. Check: Brake hose ● Brake fluid leakage → Replace the damaged hose. Refer to “FRONT BRAKE” on page 4-13. EAS21290 CHECKING THE REAR BRAKE HOSE 1. Check: Brake hose “1” ● Cracks/damage/wear → Replace. EAS21260 CHECKING THE REAR BRAKE PADS The following procedure applies to all of the brake pads.

  • Page 69: Bleeding The Hydraulic Brake System

    CHASSIS b. Install the diaphragm (brake master cylinder Direction “a” reservoir or brake fluid reservoir). Brake light comes on sooner. c. Connect a clear plastic hose “1” tightly to the Direction “b” bleed screw “2”. Brake light comes on later. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...

  • Page 70: Adjusting The Drive Chain Slack

    CHASSIS LEVEL” on page 3-16. that drive chain touch to the seal guard “2”. EWA13110 WARNING After bleeding the hydraulic brake system, check the brake operation. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS21420 ADJUSTING THE DRIVE CHAIN SLACK NOTE: The drive chain slack must be checked at the A.

  • Page 71: Lubricating The Drive Chain

    CHASSIS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the lock washer “1”, the upper ring ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ nut “2”, and the rubber washer “3”. EAS21440 LUBRICATING THE DRIVE CHAIN The drive chain consists of many interacting parts. If the drive chain is not maintained proper- ly, it will wear out quickly.

  • Page 72: Checking The Front Fork

    CHASSIS binding by turning the front fork all the way in times and check if the front fork rebounds both directions. If any binding is felt, remove smoothly. Rough movement → Repair. the lower bracket and check the upper and lower bearings.
  • Page 73 2. Check: cerning handling characteristics can be giv- Tire surfaces ● en if a tire combination other than one Damage/wear → Replace the tire. approved by Yamaha is used on this vehicle. Front tire Size 80/100-19M/C 49P Manufacturer/model BRIDGESTONE/TW201 Rear tire...

  • Page 74: Checking The Wheels

    CHASSIS Align the mark “2” with the valve installation ● point. NOTE: A tight spoke will emit a clear, ringing tone; a loose spoke will sound flat. 2. Tighten: Spoke ● (with a spoke wrench “1”) EAS21670 CHECKING THE WHEELS The following procedure applies to both of the wheels.

  • Page 75: Lubricating The Levers

    CHASSIS Recommended lubricant Engine oil or a suitable cable lu- bricant NOTE: Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suit- able lubricating device. EAS21700 LUBRICATING THE LEVERS Lubricate the pivoting point and metal-to-metal moving parts of the levers.

  • Page 76: Electrical System

    ELECTRICAL SYSTEM 3. Disconnect: EAS21750 ELECTRICAL SYSTEM Headlight coupler “1” ● 4. Remove: EAS21760 CHECKING AND CHARGING THE BATTERY Headlight bulb holder “2” ● Refer to “ELECTRICAL COMPONENTS” on page 7-29. EAS21770 CHECKING THE FUSES Refer to “ELECTRICAL COMPONENTS” on page 7-29.
  • Page 77 ELECTRICAL SYSTEM Direction “a” Headlight beam is raised. Direction “b” Headlight beam is lowered. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3-26...
  • Page 78 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..........4-5 CHECKING THE SPEEDOMETER GEAR UNIT ........4-5 ASSEMBLING THE FRONT WHEEL............4-5 ADJUSTING THE FRONT WHEEL STATIC BALANCE ......4-6 INSTALLING THE FRONT WHEEL (DISC) ..........4-7 REAR WHEEL.....................4-9 REMOVING THE REAR WHEEL (DISC)..........4-11 CHECKING THE REAR WHEEL ............4-11...
  • Page 79 INSTALLING THE HANDLEBAR ............4-39 FRONT FORK .....................4-41 REMOVING THE FRONT FORK LEGS..........4-43 DISASSEMBLING THE FRONT FORK LEGS........4-43 CHECKING THE FRONT FORK LEGS ..........4-44 ASSEMBLING THE FRONT FORK LEGS..........4-44 INSTALLING THE FRONT FORK LEGS ..........4-47 STEERING HEAD ..................4-48 REMOVING THE LOWER BRACKET ............4-50 CHECKING THE STEERING HEAD............4-50 INSTALLING THE STEERING HEAD.............4-51 REAR SHOCK ABSORBER ASSEMBLY ..........4-52...

  • Page 80: General Chassis

    GENERAL CHASSIS EAS21830 GENERAL CHASSIS Removing the seat, side cover Order Job/Parts to remove Q’ty Remarks Seat Side cover (left/right) Fuel tank side cover (left/right) Tool box cover (left/right) For installation, reverse the removal proce- dure.

  • Page 81: Front Wheel

    FRONT WHEEL EAS21870 FRONT WHEEL Removing the front wheel and brake discs Order Job/Parts to remove Q’ty Remarks Speedometer cable Washer/Front wheel axle nut Front wheel axle Front wheel assembly Speedometer gear unit Collar/Spacer Front brake disc For installation, reverse the removal proce- dure.
  • Page 82 FRONT WHEEL Disassembling the front wheel Order Job/Parts to remove Q’ty Remarks Oil seal Bearing Spacer For assembly, reverse the disassembly pro- cedure.

  • Page 83: Removing The Front Wheel

    FRONT WHEEL EAS21890 page 3-23. REMOVING THE FRONT WHEEL 3. Check: 1. Stand the vehicle on a level surface. Spokes ● EWA13120 Bends/damage → Replace. WARNING Loose → Tighten. Securely support the vehicle so that there is Tap the spokes with a screwdriver. no danger of it falling over.

  • Page 84: Disassembling The Front Wheel

    FRONT WHEEL c. Remove the wheel bearings “3” with a gener- Radial wheel runout limit al bearing pulle “4”. 2.0 mm (0.08 in) Lateral wheel runout limit 2.0 mm (0.08 in) 6. Check: Collar ● Damage/wear → Replace. 7. Check: Wheel bearings ●...

  • Page 85: Adjusting The Front Wheel Static Balance

    FRONT WHEEL the wheel bearing outer race and oil seal. e. When the wheel stops, put an “X ” mark at the bottom of the wheel. b. Check the front brake disc. f. Repeat steps (d) through (f) several times Refer to “CHECKING THE FRONT BRAKE until all the marks come to rest at the same DISC”...

  • Page 86: Installing The Front Wheel (Disc)

    FRONT WHEEL tion, install a heavier weight. d. Repeat steps (b) and (c) until the front wheel is balanced. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Check: Front wheel static balance ● ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the front wheel and make sure it stays at each position shown. 3.
  • Page 87 FRONT WHEEL down hard on the handlebar(s) several times and check if the front fork rebounds smooth-...

  • Page 88: Rear Wheel

    REAR WHEEL EAS22020 REAR WHEEL Removing the rear wheel Order Job/Parts to remove Q’ty Remarks Rear wheel axle nut/Washer Left drive chain puller Rear wheel axle/Washer Right drive chain puller Drive chain Rear wheel assembly Spacer Collar Rear wheel sprocket For installation, reverse the removal proce- dure.
  • Page 89 REAR WHEEL Disassembling the rear wheel Order Job/Parts to remove Q’ty Remarks Brake disc Oil seal Bearing Spacer For assembly, reverse the disassembly pro- cedure. 4-10...

  • Page 90: Removing The Rear Wheel (Disc)

    REAR WHEEL Damage/wear → Replace. EAS22040 REMOVING THE REAR WHEEL (DISC) Refer to “CHECKING THE TIRES” on page 1. Stand the vehicle on a level surface. 3-21 and “CHECKING THE WHEELS” on EWA13120 page 3-23. WARNING 3. Check: Securely support the vehicle so that there is Spokes no danger of it falling over.

  • Page 91: Assembling The Rear Wheel

    REAR WHEEL ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Washer ● a. Remove the self-locking nuts and the rear Right drive chain puller “1” ● wheel sprocket. Wheel axle ● Left drive chain puller b. Clean the rear wheel drive hub with a clean ● Washer cloth, especially the surfaces that contact the ●...

  • Page 92: Front Brake

    FRONT BRAKE EAS22210 FRONT BRAKE Removing the front brake pads Order Job/Parts to remove Q’ty Remarks Front brake caliper bolt Lower side only. Front brake caliper Slide the brake caliper upward. Front brake pad Brake pad shim Brake pad spring For installation, reverse the removal proce- dure.
  • Page 93 FRONT BRAKE Removing the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-18. Right rear view mirror Front brake lever/Compression spring Front brake light switch connector Disconnect.
  • Page 94 FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Master cylinder boot Circlip Master cylinder kit Spring For assembly, reverse the disassembly pro- cedure. 4-15...
  • Page 95 FRONT BRAKE Removing the front brake calipers Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-18. Union bolt Copper washers Front brake hose Brake caliper bolt Front brake caliper assembly Brake caliper bracket For installation, reverse the removal proce- dure.
  • Page 96 FRONT BRAKE Disassembling the front brake calipers Order Job/Parts to remove Q’ty Remarks Brake caliper piston Dust seal Brake caliper piston seal Bleed screw For assembly, reverse the disassembly pro- cedure. 4-17...

  • Page 97: Introduction

    FRONT BRAKE EAS22220 INTRODUCTION EWA14100 WARNING Disc brake components rarely require disas- sembly. Therefore, always follow these pre- ventive measures: Never disassemble brake components un- ● less absolutely necessary. If any connection on the hydraulic brake ● system is disconnected, the entire brake system must be disassembled, drained, cleaned, properly filled, and bled after re- assembly.

  • Page 98: Replacing The Front Brake Pads

    FRONT BRAKE c. Install the brake disc “1”. Brake pad lining thickness (inner) NOTE: 5.3 mm (0.21 in) Tighten the brake disc bolts in stages and in a Limit crisscross pattern. 0.8 mm (0.03 in) Brake pad lining thickness (outer) 5.3 mm (0.21 in) Limit 0.8 mm (0.03 in)

  • Page 99: Removing The Front Brake Caliper

    FRONT BRAKE brake pad. EAS22320 DISASSEMBLING THE FRONT BRAKE e. Install new brake pads and a new brake pad CALIPER spring. 1. Remove: Brake caliper pistons ● ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Dust seals “1” ● Brake caliper piston seals “2” 3. Install: ● Brake caliper bolts ●...

  • Page 100: Assembling The Front Brake Caliper

    FRONT BRAKE Recommended brake component replacement Recommended fluid schedule DOT 4 Every two years and Brake fluid whenever the brake is dis- EAS22420 INSTALLING THE FRONT BRAKE CALIPER assembled 1. Install: 1. Check: Brake caliper piston seals “1” ● Brake caliper cylinders “1” ●...

  • Page 101: Removing The Front Brake Master Cylinder

    FRONT BRAKE brake performance. Brake caliper bracket bolt Refill with the same type of brake fluid that ● 40 Nm (4.0 m•kg, 29 ft•lb) is already in the system. Mixing brake flu- Union bolt ids may result in a harmful chemical reac- 30 Nm (3.0 m•kg, 22 ft•lb) tion, leading to poor brake performance.

  • Page 102: Checking The Front Brake Master Cylinder

    FRONT BRAKE 1. Disconnect: Front brake switch coupler ● (from the brake switch) 2. Remove: Union bolt ● Copper washers ● Front brake hose ● NOTE: To collect any remaining brake fluid, place a container under the master cylinder and the end 2.

  • Page 103: Installing The Front Brake Master Cylinder

    FRONT BRAKE with clean or new brake fluid. Brake hose union bolt Never use solvents on internal brake com- ● 30 Nm (3.0 m•kg, 22 ft•lb) ponents. Recommended fluid DOT 4 EAS22530 INSTALLING THE FRONT BRAKE MASTER CYLINDER 1. Install: Front brake master cylinder “1”...
  • Page 104 FRONT BRAKE cause vapor lock. ECA13540 CAUTION: Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 4. Bleed: Brake system ● Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-18. 5.

  • Page 105: Rear Brake

    REAR BRAKE EAS22550 REAR BRAKE Removing the rear brake pads Order Job/Parts to remove Q’ty Remarks Rear brake caliper cover Brake caliper bolt Rear brake pad Brake pad shim For installation, reverse the removal proce- dure. *Apply silicone grease 4-26...
  • Page 106 REAR BRAKE Removing the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-18. Union bolt Copper washers Rear brake hose Cotter pin Washer Clevis pin Master cylinder cap assembly Rear brake master cylinder For installation, reverse the removal proce- dure.
  • Page 107 REAR BRAKE Disassembling the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Master cylinder boot Circlip Master cylinder kit Spring For assembly, reverse the disassembly pro- cedure. *Apply silicone grease 4-28...
  • Page 108 REAR BRAKE Removing the rear brake calipers Order Job/Parts to remove Q’ty Remarks Rear wheel Refer to “REAR WHEEL” on page 4-9. Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-18. Rear brake caliper cover Rear brake hose assembly/Joint Copper washer Brake caliper bolt Brake pad...
  • Page 109 REAR BRAKE Disassembling the rear brake calipers Order Job/Parts to remove Q’ty Remarks Brake caliper piston Dust seal Brake caliper piston seal Bleed screw For assembly, reverse the disassembly pro- cedure. 4-30...

  • Page 110: Introduction

    REAR BRAKE Refer to “CHECKING THE FRONT BRAKE EAS22560 INTRODUCTION DISC” on page 4-18. EWA14100 WARNING Brake disc thickness limit Disc brake components rarely require disas- 4.0 mm (0.16 in) sembly. Therefore, always follow these pre- ventive measures: 5. Adjust: Never disassemble brake components un- ●...

  • Page 111: Removing The Rear Brake Caliper

    REAR BRAKE recommended brake fluid to the proper level. NOTE: Always install new brake pads, brake pad shims, Refer to “CHECKING THE BRAKE FLUID and a brake pad spring as a set. LEVEL” on page 3-16. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect a clear plastic hose “1” tightly to the bleed screw “2”.

  • Page 112: Checking The Rear Brake Caliper

    REAR BRAKE ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Blow compressed air into the brake hose joint opening “a” to force out the piston from the brake caliper. EWA13550 WARNING Cover the brake caliper piston with a rag. ● Be careful not to get injured when the pis- ton is expelled from the brake caliper.
  • Page 113 REAR BRAKE PADS” on page 4-31. Brake caliper bolt 17 Nm (1.7 m•kg, 12 ft•lb) 2. Install: Copper washers “1” ● Joint “2” ● Rear brake hose “3” ● Tighten the locknut. 4. Fill: Brake fluid reservoir ● (with the specified amount of the recom- mended brake fluid) Recommended fluid DOT 4...

  • Page 114: Removing The Rear Brake Master Cylinder

    REAR BRAKE and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 5. Bleed: Brake system ● Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-18. 6. Check: Brake fluid level ● Below the minimum level mark “a” → Add the recommended brake fluid to the proper level.

  • Page 115: Assembling The Rear Brake Master Cylinder

    REAR BRAKE To the brake master cylinder “5” 3. Check: Brake master cylinder cap 2. Install: ● Brake master cylinder reservoir diaphram Rear brake master cylinder “1” ● ● holder Brake master cylinder bolt “2” ● Brake master cylinder reservoir diaphram “1” ●...
  • Page 116 REAR BRAKE 4. Fill: 7. Check: Brake fluid reservoir Brake lever operation ● ● Soft or spongy feeling → Bleed the brake (to the maximum level mark) system. Recommended fluid Refer to “BLEEDING THE HYDRAULIC DOT 4 BRAKE SYSTEM” on page 3-18. EWA13090 WARNING Use only the designated brake fluid.

  • Page 117: Handlebar

    HANDLEBAR EAS22840 HANDLEBAR Removing the handlebar Order Job/Parts to remove Q’ty Remarks Back view mirror (left/right) Front brake light switch Front brake master cylinder holder Master cylinder assembly Holder Right handlebar switch Throttle cable housing Throttle cable Throttle grip Clutch cable Clutch switch Bracket Clutch lever holder...

  • Page 118: Removing The Handlebar

    HANDLEBAR side. EAS22860 REMOVING THE HANDLEBAR Turn the handlebar all the way to the left ● 1. Stand the vehicle on a level surface. and right. If there is any contact with the EWA13120 fuel tank, adjust the handlebar position. WARNING Securely support the vehicle so that there is NOTE:...
  • Page 119 HANDLEBAR 4. Install: 7. Install: Right handlebar switch Clutch lever holder “1” ● ● Front brake master cylinder Clutch cable ● ● Front brake master cylinder bracket “1” NOTE: ● Align the groove on the clutch lever holder with NOTE: Align the groove on the master cylinder bracket the punch mark “a”...

  • Page 120: Front Fork

    FRONT FORK EAS22950 FRONT FORK Removing the front fork legs Order Job/Parts to remove Q’ty Remarks Front wheel Refer to “FRONT WHEEL” on page 4-2. Brake hose holder Cable holder Front fender Front brake caliper Upper bracket pinch bolt Loosen. Cap bolt Loosen.
  • Page 121 FRONT FORK Disassembling the front fork legs Order Job/Parts to remove Q’ty Remarks Cap bolt O-ring Spacer Fork spring seat Fork spring Dust seal Oil seal clip Damper rod bolt Inner tube Oil lock piece Rebound spring Damper rod Oil seal Outer tube bushing Inner tube bushing Outer tube...

  • Page 122: Removing The Front Fork Legs

    FRONT FORK 2. Drain: EAS22960 REMOVING THE FRONT FORK LEGS Fork oil ● The following procedure applies to both of the 3. Remove: front fork legs. Dust seals ● 1. Stand the vehicle on a level surface. Oil seal clip “1” ●...

  • Page 123: Checking The Front Fork Legs

    FRONT FORK vise with soft jaws. Fork spring free length c. Separate the inner tube from the outer tube 478.0 mm (18.82 in) by pulling the inner tube forcefully but care- Limit fully. 468.4 mm (18.44 in) ECA14190 CAUTION: Excessive force will damage the oil seal ●...
  • Page 124 FRONT FORK legs are equal. damper rod bolt. Uneven oil levels can result in poor han- ● dling and a loss of stability. Damper rod holder 90890-01294 NOTE: Damping rod holder set When assembling the front fork leg, be sure to ●...
  • Page 125 FRONT FORK with fork oil. Before installing the oil seal, cover the top of ● the front fork leg with a plastic bag “2” to pro- tect the oil seal during installation. 7. Fill: Front fork leg ● (with the specified amount of the recom- mended fork oil) 342-034 5.

  • Page 126: Installing The Front Fork Legs

    FRONT FORK Fork spring seat “2” ● Cap bolt Spacer “3” ● 23 Nm (2.3 m•kg, 17 ft•lb) O-ring “4” ● Cap bolt “5” ● Upper bracket pinch bolt “3” ● NOTE: Install the spring with the smaller pitch facing Upper bracket pinch bolt ●...

  • Page 127: Steering Head

    STEERING HEAD EAS23090 STEERING HEAD Removing the headlight and meter Order Job/Parts to remove Q’ty Remarks Fuel tank Refer to “FUEL TANK” on page 6-1. Handlebar Refer to “HANDLEBAR” on page 4-38. Headlight body Headlight coupler Disconnect. Tool box Front turn signal leads Front turn signal light assembly (left/right) Meter lead coupler Speedometer cable...
  • Page 128 STEERING HEAD Removing the lower bracket Order Job/Parts to remove Q’ty Remarks Front fork Refer to “FRONT FORK” on page 4-41. Handlebar Refer to “HANDLEBAR” on page 4-38. Headlight Meter Cable guide Steering stem nut Main switch coupler/Upper bracket Lock washer Upper ring nut Rubber washer Lower ring nut...

  • Page 129: Removing The Lower Bracket

    STEERING HEAD Bearing races “2” EAS23110 ● REMOVING THE LOWER BRACKET Damage/pitting → Replace. 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: Lock washer ●...

  • Page 130: Installing The Steering Head

    STEERING HEAD Lower bracket pinch bolts ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 23 Nm (2.3 m•kg, 17 ft•lb) 4. Check: Refer to “FRONT FORK” on page 4-41. Upper bracket ● Lower bracket ● (along with the steering stem) Bends/cracks/damage → Replace. EAS23140 INSTALLING THE STEERING HEAD 1.

  • Page 131: Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY EAS23160 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Seat 4-1. Refer to “CHECKING AND CHARGING THE Battery BATTERY” on page 7-38. Connecting rod Relay arm Rear shock absorber assembly...

  • Page 132: Handling The Rear Shock Absorber

    REAR SHOCK ABSORBER ASSEMBLY no danger of it falling over. EAS23180 HANDLING THE REAR SHOCK ABSORBER NOTE: EWA13740 WARNING Place the vehicle on a suitable stand so that the This rear shock absorber contains highly rear wheel is elevated. compressed nitrogen gas. Before handling 2.

  • Page 133: Checking The Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY EAS23240 CHECKING THE REAR SHOCK ABSORBER Rear shock absorber assembly ASSEMBLY lower nut 1. Check: 40 Nm (4.0 m•kg, 29 ft•lb) Rear shock absorber rod ● Bends/damage → Replace the rear shock absorber assembly. Rear shock absorber ●...

  • Page 134: Swingarm

    SWINGARM EAS23330 SWINGARM Removing the swingarm Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Seat 4-1. Refer to “CHECKING AND CHARGING THE Battery BATTERY” on page 7-38. Refer to “REAR SHOCK ABSORBER Rear shock absorber assembly ASSEMBLY”...

  • Page 135: Removing The Swingarm

    SWINGARM EAS23350 REMOVING THE SWINGARM 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 136: Installing The Swingarm

    SWINGARM 3. Install: Recommended cleaning solvent Relay arm ● Kerosene Connecting rod (left and right) ● 4. Tighten: 4. Check: Relay-arm-to-frame nut ● Dust covers “1” ● Spacer “2” Relay-arm-to-frame nut ● Washers “3” 50 Nm (5.0 m•kg, 36 ft•lb) ●...

  • Page 137: Chain Drive

    CHAIN DRIVE EAS23400 CHAIN DRIVE Removing the drive chain Order Job/Parts to remove Q’ty Remarks “SWINGARM” on page 4-55 Swingarm Refer to Drive sprocket cover Disconnect. Lock washer Straighten the lock washer tab. Drive sprocket Loosen the rear wheel sprocket nut. Drive chain For installation, reverse the removal proce- dure.

  • Page 138: 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 139: Checking The Drive Sprocket

    CHAIN DRIVE ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Wipe the drive chain with a clean cloth. b. Put the drive chain in kerosene and remove any remaining dirt. c. Remove the drive chain from the kerosene and completely dry it. ECA14290 CAUTION: This motorcycle has a drive chain with ●...
  • Page 140 CHAIN DRIVE 5. Adjust: Recommended lubricant Drive chain slack ● Engine oil or chain lubricant suit- Refer to “ADJUSTING THE DRIVE CHAIN able for O-ring chains SLACK” on page 3-19. 2. Install: Drive chain slack Drive chain 40.0–45.0 mm (1.57–1.77 in) ●...

  • Page 141: Engine

    ENGINE ENGINE REMOVAL ..................5-1 INSTALLING THE ENGINE ..............5-4 CYLINDER HEAD ..................5-5 REMOVING THE CYLINDER HEAD ............5-7 CHECKING THE CYLINDER HEAD ............5-7 CHECKING THE TIMING CHAIN GUIDES..........5-8 CHECKING THE TIMING CHAIN TENSIONERS ........5-8 INSTALLING THE CYLINDER HEAD .............5-9 ROCKER ARM, CAMSHAFT ..............5-12 REMOVING THE ROCKER ARMS AND CAMSHAFT ......5-13 CHECKING THE CAMSHAFT ..............5-13 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS ..5-14...
  • Page 142 CHECKING THE SHIFT SHAFT .............5-44 CHECKING THE STOPPER LEVER ............5-44 INSTALLING THE SHIFT SHAFT ............5-44 ELECTRIC STARTER .................5-45 CHECKING THE STARTER MOTOR .............5-47 ASSEMBLING THE STARTER MOTOR..........5-48 PICKUP COIL ROTOR AND STARTER CLUTCH ........5-49 REMOVING THE PICKUPCOIL ROTOR..........5-51 CHECKING THE STARTER CLUTCH............5-51 INSTALLING THE PICKUP COIL ROTOR ..........5-52 CRANKCASE ....................5-54 DISASSEMBLING THE CRANKCASE ...........5-56...

  • Page 143: Engine Removal

    ENGINE REMOVAL EAS23710 ENGINE REMOVAL Removing the exhaust pipe Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Seat 4-1. Loosen the clamp screw, and then remove Muffler from exhaust pipe. Gasket Exhaust pipe For installation, reverse the removal proce- dure.
  • Page 144 ENGINE REMOVAL Removing the drive sprocket Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Side cover (left/right) 4-1. Fuel tank Refer to “FUEL TANK” on page 6-1. Carburetor Refer to “CARBURETOR” on page 6-3. Breather hose Air induction system hose Disconnect.
  • Page 145 ENGINE REMOVAL Removing the engine Order Job/Parts to remove Q’ty Remarks Place a suitable stand under the frame and engine. Engine bracket (left/right) Engine mounting bolt (rear upper side) Down tube bolts Engine mounting bolt (rear side) Engine mounting bolt (rear lower side) Engine mounting bolts (front upper side) Engine mounting bolt (front lower side) Down tube...

  • Page 146: Installing The Engine

    ENGINE REMOVAL EAS23720 INSTALLING THE ENGINE Engine mounting nuts (front upper 1. Install: side) 72 Nm (7.2 m•kg, 52 ft•lb) Engine mounting bolts (front upper side) “1” ● Engine mounting nut (front lower Engine mounting bolt (front lower side) “2” ●...

  • Page 147: Cylinder Head

    CYLINDER HEAD EAS24100 CYLINDER HEAD Removing the cylinder head Order Job/Parts to remove Q’ty Remarks Fuel tank Refer to “FUEL TANK” on page 6-1. Tool box Refer to “STEERING HEAD” on page 4-48. Carburetor assembly Refer to “CARBURETOR” on page 6-3. Spark plug cap Refer to “ENGINE REMOVAL”...
  • Page 148 CYLINDER HEAD Removing the cylinder head Order Job/Parts to remove Q’ty Remarks Timing chain guide Dowel pin Cylinder head gasket For installation, reverse the removal proce- dure.

  • Page 149: Removing The Cylinder Head

    CYLINDER HEAD Camshaft sprocket bolt EAS24130 ● REMOVING THE CYLINDER HEAD Breather plate 2 ● 1. Align: Camshaft sprocket ● “I” mark “a” on the Pickup coil rotor ● Timing chain ● (with the stationary pointer “b” on the crank- NOTE: case cover) To prevent the timing chain from falling into the...

  • Page 150: Checking The Timing Chain Guides

    CYLINDER HEAD 2. Check: Cylinder head ● Damage/scratches → Replace. 3. Measure: Cylinder head warpage ● Out of specification → Resurface the cylinder head. Warpage limit 0.03 mm (0.0012 in) a. 1/4 tooth ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ b. Correct a. Place a straightedge “1” and a thickness 1.

  • Page 151: Installing The Cylinder Head

    CYLINDER HEAD ment, replace the timing chain tensioner. 4. Install: Camshaft sprocket ● Dowel pin ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ● Timing chain ● 3. Check: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Cap bolt ● a. Turn the Pickup coil rotor counterclockwise. Copper washer ● b. Align the “I” mark “a” on the Pickup coil rotor Spring ●...
  • Page 152 CYLINDER HEAD f. While holding the camshaft, temporarily tighten the camshaft sprocket bolts. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 6. Turn: ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Crankshaft ● 5. Install: (several turns counterclockwise) Timing chain tensioner 7. Check: ● ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ “I” mark “a” ● a. While lightly pressing the timing chain ten- Align the “I”...
  • Page 153 CYLINDER HEAD Camshaft sprocket bolt 60 Nm (6.0 m•kg, 44 ft•lb) ECA13750 CAUTION: Be sure to tighten the camshaft sprocket bolts to the specified torque to avoid the possibility of the bolts coming loose and damaging the engine. 9. Measure: Valve clearance ●...

  • Page 154: Rocker Arm, Camshaft

    ROCKER ARM, CAMSHAFT EAS23730 ROCKER ARM, CAMSHAFT Removing the rocker arms and camshaft Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-5. Stopper plate Locknut/valve clearance adjusting screw Camshaft Intake rocker arm shaft Intake rocker arm Exhaust rocker arm shaft Exhaust rocker arm For installation, reverse the removal proce-...

  • Page 155: Removing The Rocker Arms And Camshaft

    ROCKER ARM, CAMSHAFT EAS23770 REMOVING THE ROCKER ARMS AND CAMSHAFT 1. Loosen: Locknuts “1” ● Valve clearance adjusting screws “2” ● Stopper plate “3” ● EAS23840 CHECKING THE CAMSHAFT 1. Check: Bearing ● Damage/wear → Replace. 2. Check: Camshaft lobes ●...

  • Page 156: Checking The Rocker Arms And Rocker Arm Shafts

    ROCKER ARM, CAMSHAFT 2. Check: Rocker arm shaft ● Blue discoloration/excessive wear/pitting/ scratches → Replace or check the lubrica- tion system. 3. Measure: Rocker arm inside diameter “a” ● Out of specification → Replace. Rocker arm inside diameter 4. Check: 12.000–12.018 mm (0.4724–0.4731 Camshaft oil passage ●...

  • Page 157: Installing The Camshaft And Rocker Arms

    ROCKER ARM, CAMSHAFT 4. Install: 5. Calculate: Intake rocker arm ● Rocker-arm-to-rocker-arm-shaft clearance ● Intake rocker arm shaft ● NOTE: NOTE: Calculate the clearance by subtracting the rock- Insert a cylinder head bolt (226 mm) “1” into ● er arm shaft outside diameter from the rocker the hole in the cylinder head and the intake arm inside diameter.
  • Page 158 ROCKER ARM, CAMSHAFT 6. Install: Lock plate ● Lock plate bolt ● Lock plate bolt 8 Nm (0.8 m•kg, 5.8 ft•lb) 5-16...
  • Page 159 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 5-5. Refer to “ROCKER ARM, CAMSHAFT” on Rocker arm page 5-12. Camshaft Valve cotter Valve spring retainer...

  • Page 160: Valves And Valve Springs

    VALVES AND VALVE SPRINGS EAS24280 REMOVING THE VALVES Valve spring compressor The following procedure applies to all of the 90890-04019 YM-04019 valves and related components. Valve spring compressor attach- NOTE: ment Before removing the internal parts of the cylin- 90890-01243 der head (e.g., valves, valve springs, valve Valve spring compressor adapter seats), make sure the valves properly seal.
  • Page 161 VALVES AND VALVE SPRINGS Valve-stem-to-valve-guide clearance = Valve guide inside diameter “a” - Valve stem diameter “b” Valve-stem-to-valve-guide clear- ance Valve-stem-to-valve-guide clear- ance (intake) 0.010–0.037 mm (0.0004–0.0015 b. Install the new valve guide with the valve Limit guide installer “2” and valve guide remover 0.080 mm (0.0032 in) “1”.

  • Page 162: Checking The Valve Seats

    VALVES AND VALVE SPRINGS If the valve is removed or replaced, always re- ● Valve guide remover (ø6) place the oil seal. 90890-04064 Valve guide remover (6.0 mm) Valve stem runout YM-04064-A Valve stem runout Valve guide installer (ø6) 0.030 mm (0.0012 in) 90890-04065 Valve guide installer (6.0 mm) YM-04065-A...
  • Page 163 VALVES AND VALVE SPRINGS gap between the valve stem and the valve guide. 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 impres- b. Apply molybdenum disulfide oil onto the sion.

  • Page 164: Checking The Valve Springs

    VALVES AND VALVE SPRINGS Out of specification → Replace the valve h. Install the valve into the cylinder head. i. Press the valve through the valve guide and spring. onto the valve seat to make a clear impres- sion. j. Measure the valve seat width “c” again. If the valve seat width is out of specification, reface and lap the valve seat.

  • Page 165: Installing The Valves

    VALVES AND VALVE SPRINGS Outer valve spring “5” ● Inner spring Upper spring seat “6” ● Spring tilt (intake) (into the cylinder head) 2.5 °/1.6 mm NOTE: Spring tilt (exhaust) Install the valve springs with the larger pitch “a” 2.5 °/1.6 mm facing up.
  • Page 166 VALVES AND VALVE SPRINGS 5. To secure the valve cotters “1” onto the valve stem, lightly tap the valve tip with a soft-face hammer. ECA13800 CAUTION: Hitting the valve tip with excessive force could damage the valve. 5-24...

  • Page 167: Cylinder And Piston

    CYLINDER AND PISTON EAS24350 CYLINDER AND PISTON Removing the cylinder and piston Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-5. Oil delivery pipe Cylinder Dowel pin Cylinder gasket Piston pin clip Piston pin Piston Piston ring set For installation, reverse the removal proce-...

  • Page 168: Removing The Piston

    CYLINDER AND PISTON EAS24380 EAS24400 REMOVING THE PISTON CHECKING THE CYLINDER AND PISTON 1. Remove: 1. Check: Piston pin clips “1” Piston wall ● ● Piston pin “2” Cylinder wall ● ● Vertical scratches → Rebore or replace the Piston “3” ●...

  • Page 169: Checking The Piston Rings

    CYLINDER AND PISTON Piston ring Top ring Ring side clearance 0.030–0.065 mm (0.0012–0.0026 Limit 0.100 mm (0.0039 in) 2nd ring Ring side clearance 0.020–0.055 mm (0.0008–0.0022 b. 11 mm (1 in) from the bottom edge of the piston Limit Piston size diameter “D” 0.100 mm (0.0039 in) Standard 73.960–73.975 mm (2.9118–2.9124...

  • Page 170: Checking The Piston Pin

    CYLINDER AND PISTON Piston ring 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 4. Calculate: 0.60 mm (0.0236 in) Oil ring Piston-pin-to-piston-pin-bore clearance ● Out of specification →...
  • Page 171 CYLINDER AND PISTON (with the recommended lubricant) Recommended lubricant Engine oil 5. Offset: Piston ring end gaps ● a. Top ring b. Upper oil ring rail c. Spacer d. Lower oil ring rail 2. Install: e. 2nd ring Piston “1” ●...

  • Page 172: Clutch

    CLUTCH EAS25060 CLUTCH Removing the clutch cover Order Job/Parts to remove Q’ty Remarks Refer to “CHANGING THE ENGINE OIL” on Engine oil page 3-10. Cotter pin/Washer Clevis pin Brake pedal Oil delivery pipe Right crankcase cover Dowel pin Gasket For installation, reverse the removal proce- dure.

  • Page 173: Pressure Plate

    CLUTCH Removing the clutch Order Job/Parts to remove Q’ty Remarks Clutch spring Pressure plate Primary drive gear nut Friction plate Clutch plate Cushion spring Seat plate Clutch boss nut Clutch boss Thrust washer Clutch housing Claw washer Primary driven gear Locknut/Washer Push rod1 Push plate...
  • Page 174 CLUTCH Removing the push lever shaft Order Job/Parts to remove Q’ty Remarks Shift pedal Refer to “ENGINE REMOVAL” on page 5-1. Left crankcase cover Clutch assembly Clutch cable Bolt Push lever shaft Torsion spring Circlip Oil seal Bearing For installation, reverse the removal proce- dure.

  • Page 175: Removing The Clutch

    CLUTCH EAS25070 REMOVING THE CLUTCH 1. Remove: Bolt “1” ● Clutch spring “2” ● NOTE: Loosen the bolts in stages and in a crisscross pattern. 4. Remove: Clutch boss nut “1” ● Lock washer “2” ● Clutch boss “3” ● Thrust washer “4”...

  • Page 176: Checking The Clutch Plates

    CLUTCH Out of specification → Replace the friction 1. Check: plate. Clutch spring ● Damage → Replace the clutch spring. NOTE: Measure the friction plate at four places. 2. Measure: Clutch spring free length “a” ● Out of specification → Replace the clutch Friction plate thickness 2.70–2.90 mm (0.106–0.114 in) spring.

  • Page 177: Checking The Pressure Plate

    CLUTCH EAS25260 INSTALLING THE CLUTCH 1. Install: Primary drive gear ● Claw washer ● Lock washer ● Primary drive gear nut ● 2. Install: Clutch housing ● Thrust washer ● Clutch boss ● EAS25170 CHECKING THE PRESSURE PLATE Lock washer “1” ●...

  • Page 178: Friction Plate

    CLUTCH 7. Install: Bearing ● Oil seal ● Circlip ● Torsion spring ● Push lever shaft ● Bolt ● Clutch cable ● NOTE: After installing the clutch cable, bend the push lever shaft tab along a flat side of the nut. 8.
  • Page 179 CLUTCH 10.Adjust: Push lever position ● ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 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 spec- ification.

  • Page 180: Oil Pump And Blancer Weight Gear

    OIL PUMP AND BLANCER WEIGHT GEAR EAS24910 OIL PUMP AND BLANCER WEIGHT GEAR Removing the oil pump and balancer weight gear Order Job/Parts to remove Q’ty Remarks Right crankcase cover Refer to “CLUTCH” on page 5-30. Clutch Primary drive gear Balancer weight gear nut Lock washer Buffer boss...
  • Page 181 OIL PUMP AND BLANCER WEIGHT GEAR Removing the oil pump and balancer weight gear Order Job/Parts to remove Q’ty Remarks For installation, reverse the removal proce- dure. 5-39...
  • Page 182 OIL PUMP AND BLANCER WEIGHT GEAR Disassembling the oil pump Order Job/Parts to remove Q’ty Remarks Oil pump housing Dowel pin Outer rotor Inner rotor Dowel pin Shaft Oil pump cover For assembly, reverse the disassembly pro- cedure. 5-40...

  • Page 183: Removing The Balancer Weight Gear And Oil Pump

    OIL PUMP AND BLANCER WEIGHT GEAR EAS4D601 REMOVING THE BALANCER WEIGHT GEAR Inner-rotor-to-outer-rotor-tip clear- AND OIL PUMP ance 1. Straighten the lock washer tab. 0.150 mm (0.0059 in) Limit 2. Remove: 0.20 mm (0.0079 in) Balancer weight gear nut ● Outer-rotor-to-oil-pump-housing Lock washer ●...

  • Page 184: Assenbling The Balancer Drive Gear

    OIL PUMP AND BLANCER WEIGHT GEAR gear with the punch mark “b” in the balancer EAS4D603 ASSENBLING THE BALANCER DRIVE weightn gear. GEAR Place the aluminum plate “c” between balanc- ● 1. Assemble: er drive gear “2” and balancer weight gear “3”, Dowel pin “1”...

  • Page 185: Shift Shaft

    SHIFT SHAFT EAS25410 SHIFT SHAFT Removing the shift shaft and stopper lever Order Job/Parts to remove Q’ty Remarks Right crankcase cover Refer to “CLUTCH” on page 5-30. Clutch Shift shaft assembly Stopper lever Torsion spring For installation, reverse the removal proce- dure.

  • Page 186: Checking The Shift Shaft

    SHIFT SHAFT EAS25420 CHECKING THE SHIFT SHAFT 1. Check: Shift shaft “1” ● Shift lever “2” ● Bends/damage/wear → Replace. Shift lever spring ● Damage/wear → Replace. 2. Tighten: Stopper lever bolt ● Stopper lever bolt 10 Nm (1.0 m•kg, 7.2 ft•lb) 3.

  • Page 187: Electric Starter

    ELECTRIC STARTER EAS24780 ELECTRIC STARTER Removing the starter motor Order Job/Parts to remove Q’ty Remarks Fuel tank Refer to “FUEL TANK” on page 6-1. Refer to “CHECKING AND CHARGING THE Battery negative lead BATTERY” on page 7-38. Carburetor Refer to “CARBURETOR” on page 6-3. Starter motor lead Starter motor assembly For installation, reverse the removal proce-...
  • Page 188 ELECTRIC STARTER Disassembling the starter motor Order Job/Parts to remove Q’ty Remarks Front bracket O-ring Tang washer/Plate washer Rear bracket O-ring Armature coil Stator assembly O-ring Brush/brush spring For assembly, reverse the disassembly pro- cedure. 5-46...

  • Page 189: Checking The Starter Motor

    ELECTRIC STARTER ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ EAS24790 CHECKING THE STARTER MOTOR a. Measure the armature assembly resistances 1. Check: with the pocket tester. Commutator ● Dirt → Clean with 600 grit sandpaper. Digital circuit tester 2. Measure: 90890-03174 Model 88 Multimeter with tachome- Commutator diameter “a”...

  • Page 190: Assembling The Starter Motor

    ELECTRIC STARTER springs as a set. Brush spring force 5.52–8.28 (19.87–29.80 (563–844 gf) 4. Install: Stator assembly “1” ● NOTE: Align the match marks “a” on the starter assem- bly with the match marks “b” on the rear bracket. 7. Check: Bearing ●...

  • Page 191: Pickup Coil Rotor And Starter Clutch

    PICKUP COIL ROTOR AND STARTER CLUTCH EAS24550 PICKUP COIL ROTOR AND STARTER CLUTCH Removing the pickup coil rotor and starter clutch Order Job/Parts to remove Q’ty Remarks Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-10. Shift pedal Refer to “ENGINE REMOVAL”...
  • Page 192 PICKUP COIL ROTOR AND STARTER CLUTCH Removing the pickup coil rotor and starter clutch Order Job/Parts to remove Q’ty Remarks For installation, reverse the removal proce- dure. 5-50...

  • Page 193: Removing The Pickupcoil Rotor

    PICKUP COIL ROTOR AND STARTER CLUTCH EAS24530 REMOVING THE PICKUPCOIL ROTOR 1. Remove: Pickup coil rotor bolt “1” ● Washer ● NOTE: Loosen the pickup coil rotor bolt “1” while ● holding the rotor with a sheave holder “2”. Do not allow the sheave holder to touch the ●...

  • Page 194: Installing The Pickup Coil Rotor

    PICKUP COIL ROTOR AND STARTER CLUTCH Starter idle gear 2 “4” ● 3. Check: Starter clutch gear’s contacting surfaces 2. Install: ● Damage/pitting/wear → Replace the starter Woodruff key “1” ● clutch gear. Pickup coil rotor “2” ● 4. Check: Washer “3”...
  • Page 195 PICKUP COIL ROTOR AND STARTER CLUTCH 4. Install: 7. Install: Stater coil “1” Starter idle gear 1 ● ● Pickup coil “2” Shaft ● ● 8. Install: Stater coil bolt O-ring ● 7 Nm (0.7 m•kg, 5.1 ft•lb) Starter idle gear cover ●...

  • Page 196: Crankcase

    CRANKCASE EAS25540 CRANKCASE Separating the crankcase Order Job/Parts to remove Q’ty Remarks Engine Refer to “ENGINE REMOVAL” on page 5-1. Cylinder head Refer to “CYLINDER HEAD” on page 5-5. Refer to “CYLINDER AND PISTON” on Cylinder page 5-25. Clutch Refer to “CLUTCH” on page 5-30. Refer to “OIL PUMP AND BLANCER Oil pump WEIGHT GEAR”...
  • Page 197 CRANKCASE Removing the bearing 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 5-62. Bearing retainer Oil seal Bearing For installation, reverse the removal proce- dure.

  • Page 198: Disassembling The Crankcase

    Obstruction → Blow out with compressed air. EAS25690 ASSEMBLING THE CRANKCASE 1. Apply: Sealant “1” ● (onto the crankcase mating surfaces) Yamaha bond No. 1215 90890-85505 3. Turn: NOTE: Shift drum segment ● Do not allow any sealant to come into contact NOTE: with the oil gallery.
  • Page 199 CRANKCASE 3. Install: 7. Apply: Right crankcase Engine oil ● ● (onto the left crankcase) (onto the crankshaft pins bearings and oil de- livery holes) NOTE: Tap lightly on the right crankcase with a 8. Check: soft-face hammer. Crankshaft and transmission operation ●...
  • Page 200 CRANKSHAFT ASSEMBLY EAS25970 CRANKSHAFT ASSEMBLY Removing the crankshaft assembly Order Job/Parts to remove Q’ty Remarks Crankcase Refer to “CRANKCASE” on page 5-54. Balancer weight Crankshaft assembly Dowel pin Plunger seal Bearing For installation, reverse the removal proce- dure. 5-58...

  • Page 201: Crankshaft Assembly

    CRANKSHAFT ASSEMBLY EAS25990 NOTE: REMOVING THE CRANKSHAFT ASSEMBLY Turn the crankshaft slowly. 1. Remove: Balancer weight ● Runout limit C Crankshaft assembly “1” ● 0.030 mm (0.0012 in) NOTE: Remove the crankshaft assembly with the ● crankcase separating tool “2”. Make sure the crankcase separating tool is ●...

  • Page 202: Checking The Timing Chain, Crankshaft Sprocket And Timing Chain Guide

    CRANKSHAFT ASSEMBLY Obstruction → Blow out with compressed air. EAS4D607 INSTALLING THE PLUNGER SEAL EAS4D606 1. Install: CHECKING THE TIMING CHAIN, CRANKSHAFT SPROCKET AND TIMING Compression spring “1” ● CHAIN GUIDE Plunger seal “2” ● The following procedure applies to all of the Dowel pin “3”...
  • Page 203 CRANKSHAFT ASSEMBLY Crankshaft installer pot 90890-01274 Installing pot YU-90058 Crankshaft installer bolt 90890-01275 Bolt YU-90060 Spacer 90890-01288 Adapter (M10) 90890-01383 Adapter #2 YU-90062 ECA13970 CAUTION: To avoid scratching the crankshaft and to ease the installation procedure, lubricate the oil seal lips with lithium-soap-based grease and each bearing with engine oil.
  • Page 204 TRANSMISSION EAS26240 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKSHAFT ASSEMBLY” on page 5-58. Shift fork guide bar Shift drum assembly Shift fork-3 (R) Shift fork-2 (C) Shift fork-1 (L) Main axle assembly Drive axle assembly...
  • Page 205 TRANSMISSION Disassembling the transmission Order Job/Parts to remove Q’ty Remarks 2nd pinion gear 5th pinion gear 3rd pinion gear Main axle Circlip/washer 1st wheel gear Dog clutch Circlip/washer 3rd wheel gear 4th wheel gear 5th wheel gear Circlip/washer 2nd wheel gear Drive axle For installation, reverse the removal proce- dure.

  • Page 206: Transmission

    TRANSMISSION EAS26250 REMOVING THE TRANSMISSION 1. Remove: Shift fork guide bar “1” ● Shift drum assembly “2” ● Shift fork 3 (R) “3” ● Shift fork 2 (C) ● Shift fork 1 (L) “4” ● 2. Remove: Transmission “5” ● 3.

  • Page 207: Checking The Transmission

    TRANSMISSION EAS26290 CHECKING THE TRANSMISSION 1. Measure: Main axle runout ● (with a centering device and dial gauge) Out of specification → Replace the main ax- Main axle runout limit 0.08 mm (0.0032 in) 4. Check: Transmission gear engagement ● (each pinion gear to its respective wheel gear) Incorrect →...

  • Page 208: Installing The Shift Forks And Shift Drum Assembly

    TRANSMISSION EAS26330 INSTALLING THE SHIFT FORKS AND SHIFT DRUM ASSEMBLY 1. Install: Transmission “1” ● Shift fork 1 (L) “2” ● Shift fork 2 (C) ● Shift fork 3 (R) “3” ● Shift drum assembly “4” ● Shift fork guide bar “5” ●...

  • Page 209: Fuel System

    FUEL SYSTEM FUEL TANK....................6-1 CHECKING THE FUEL COCK..............6-2 CARBURETOR ...................6-3 CHECKING THE CARBURETOR ............6-5 ASSEMBLING THE CARBURETOR............6-6 INSTALLING THE CARBURETOR ............6-7 AIR INDUCTION SYSTEM ................6-9 CHECKING THE AIR INDUCTION SYSTEM .........6-12...

  • Page 210: Fuel Tank

    FUEL TANK EAS26620 FUEL TANK Removing the fuel tank Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Seat 4-1. Fuel tank side cover (left/right) Check that the fuel cock lever is positioned Fuel tank to “OFF”. For installation, reverse the removal proce- dure.

  • Page 211: Checking The Fuel Cock

    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. 3. Check: Fuel cock operation ●...
  • Page 212 CARBURETOR EAS26720 CARBURETOR Removing the carburetor Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Seat 4-1. Side cover (left/right) Fuel tank Refer to “FUEL TANK” on page 6-1. Battery Throttle cable 1/throttle cable 2 Starter plunger Carburetor warmer lead coupler Disconnect.
  • Page 213 CARBURETOR Disassembling the carburetor 16 15 Order Job/Parts to remove Q’ty Remarks Throttle stop screw Cover/Diaphram spring Diaphragm Cover Spring Coasting enricher diaphragm Carburetor warmer positive lead Carburetor warmer Carburetor warmer negative lead Pilot screw set Float chamber/Gasket Float pin Float Needle valve seat set Main jet...

  • Page 214: Carburetor

    CARBURETOR EAS26760 CHECKING THE CARBURETOR 1. Check: Carburetor body ● Float chamber ● Cracks/damage → Replace. 2. Check: Fuel passages ● Obstruction → Clean. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Wash the carburetor in a petroleum-based 7. Check: solvent. Do not use any caustic carburetor Piston valve “1”...

  • Page 215: Assembling The Carburetor

    CARBURETOR 2. Install: 10.Check: Main jet “1” Piston valve movement ● ● Needle valve seat “2” Insert the piston valve into the carburetor ● body and move it up and down. NOTE: Tightness → Replace the piston valve. Install the screw “a” securely. 11.Check: Starter plunger “1”...

  • Page 216: Installing The Carburetor

    CARBURETOR Float height 10.5 mm (0.41 in) 8. Install: Coasting enricher diaphram ● Cover “1” ● Hoser “2” ● 5. Adjust: Stopper “3” ● Float height ● Adjust the float height by bending the float tang “1” on the float. EAS26890 INSTALLING THE CARBURETOR 1.
  • Page 217 CARBURETOR...

  • Page 218: Air Induction System

    AIR INDUCTION SYSTEM EAS27040 AIR INDUCTION SYSTEM...
  • Page 219 AIR INDUCTION SYSTEM 1. Air induction system pipe 2. Air induction system hose (air cut-off valve — cylinder head) 3. Air induction system hose (carburetor joint — air cut-off valve) 4. Air cut-off valve 5. Air cleaner 6-10...
  • Page 220 AIR INDUCTION SYSTEM Removing the air cut-off valve Order Job/Parts to remove Q’ty Remarks Air induction system hose (air cut-off valve — cylinder head) Air induction system hose (carburetor joint — air cut-off valve) Air cut-off valve For installation, reverse the removal proce- dure.

  • Page 221: Checking The Air Induction System

    AIR INDUCTION SYSTEM 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 hydrocarbons. When there is negative pressure at the exhaust port, the reed valve opens, allow- ing secondary air to flow into the exhaust port.
  • Page 222 AIR INDUCTION SYSTEM 6-13...

  • Page 223: 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 224: Ignition System

    IGNITION SYSTEM EAS27090 IGNITION SYSTEM EAS27100 CIRCUIT DIAGRAM...
  • Page 225 IGNITION SYSTEM 1. Main switch 2. Pickup coil rotor 5. Engine stop switch 7. CDI unit 8. Ignition coil 9. Diode 11. Sidestand switch 12. Starting circuit cut-off relay 28. Neutral switch lead 29. Neutral switch 38. Main fuse 39. Battery positive lead 41.

  • Page 226: 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. Side cover (left/right) 3. Fuel tank side cover (left/right) 4. Fuel tank 5. Tool box (left/right) 1.
  • Page 227 IGNITION SYSTEM 10.Check the neutral switch. Refer to “CHECKING THE NG→ Replace the neutral switch. SWITCHES” on page 7-33. OK↓ 11.Check the sidestand switch. Refer to “CHECKING THE NG→ Replace the sidestand switch. SWITCHES” on page 7-33. OK↓ 12.Check the starting circuit cut-off relay. Refer to “CHECKING THE RELAYS”...

  • Page 228: Electric Starting System

    ELECTRIC STARTING SYSTEM EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM...
  • Page 229 ELECTRIC STARTING SYSTEM 1. Main switch 5. Engine stop switch 6. Start switch 7. CDI unit 9. Diode 10. Clutch switch 11. Sidestand switch 12. Starting circuit cut-off relay 28. Neutral switch lead 29. Neutral switch 37. Starter relay 38. Main fuse 39.

  • Page 230: 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 231 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. Main fuse 3. Main switch 4. Engine stop switch 5. Starting circuit cut-off relay 6.

  • Page 232: Troubleshooting

    ELECTRIC STARTING SYSTEM EAS27190 TROUBLESHOOTING The starter motor fails to turn. NOTE: Before troubleshooting, remove the following part(s): 1. Seat 2. Side cover (left/right) 3. Fuel tank side cover (left/right) 4. Fuel tank 5. Tool box (left/right) 1. Check the fuse. Refer to “CHECKING THE FUSE”...
  • Page 233 ELECTRIC STARTING SYSTEM 10.Check the clutch switch. Refer to “CHECKING THE NG→ Replace the clutch switch. SWITCHES” on page 7-33. OK↓ 11.Check the start switch. Refer to “CHECKING THE NG→ Replace the right handlebar switch. SWITCHES” on page 7-33. OK↓ 12.Check the entire starting system’s wiring.

  • Page 234: Charging System

    CHARGING SYSTEM EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM 7-11...
  • Page 235 CHARGING SYSTEM 2. Pickup coil rotor 3. Rectifier/regulator 38. Main fuse 39. Battery positive lead 41. Battery 42. Battery negative lead 7-12...

  • Page 236: Troubleshooting

    CHARGING SYSTEM EAS27220 TROUBLESHOOTING The battery is not being charged. NOTE: Before troubleshooting, remove the following part(s): 1. Seat 2. Side cover (right) 1. Check the fuse. Refer to “CHECKING THE FUSE” on NG→ Replace the fuse. page 7-37. OK↓ 2.
  • Page 237 CHARGING SYSTEM 7-14...

  • Page 238: Lighting System

    LIGHTING SYSTEM EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM 7-15...
  • Page 239 LIGHTING SYSTEM 1. Main switch 2. Pickup coil rotor 7. CDI unit 15. Tail/brake light 17. Headlight relay 21. Dimmer switch 27. Headlight 32. Meter light 35. High beam indicator light 38. Main fuse 39. Battery positive lead 41. Battery 42.

  • Page 240: 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. Side cover (left/right) 3. Fuel tank side cover (left/right) 4.
  • Page 241 LIGHTING SYSTEM 7-18...

  • Page 242: Signaling System

    SIGNALING SYSTEM EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM 7-19...
  • Page 243 SIGNALING SYSTEM 1. Main switch 13. Rear brake light switch 14. Front brake light switch 15. Tail/brake light 16. Turn signal relay 18. Horn 20. Turn switch 22. Horn switch 23. Rear right turn signal light 24. Rear left turn signal light 25.

  • Page 244: 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. ● NOTE: Before troubleshooting, remove the following part(s): 1. Seat 2. Side cover (left/right) 3.
  • Page 245 SIGNALING SYSTEM The tail/brake light fails to come on. 1. Check the tail/brake light bulb and socket. NG→ Refer to “CHECKING THE BULBS Replace the tail/brake light bulb, socket or both. AND BULB SOCKETS” on page 7-36. OK↓ 2. Check the brake light switch. Refer to “CHECKING THE NG→...
  • Page 246 SIGNALING SYSTEM The neutral indicator light fails to come. 1. Check the neutral indicator light bulb and socket. Replace the neutral indicator light bulb, socket Refer to “CHECKING THE BULBS NG→ or both. AND BULB SOCKETS” on page 7-36. OK↓ 2.
  • Page 247 SIGNALING SYSTEM 7-24...

  • Page 248: Carburetor Heating System

    CARBURETOR HEATING SYSTEM EAS27490 CARBURETOR HEATING SYSTEM EAS27500 CIRCUIT DIAGRAM 7-25...
  • Page 249 CARBURETOR HEATING SYSTEM 1. Main switch 38. Main fuse 39. Battery positive lead 41. Battery 42. Battery negative lead 43. Thermo switch 44. Carburetor warmer 7-26...

  • Page 250: Troubleshooting

    CARBURETOR HEATING SYSTEM EAS27510 TROUBLESHOOTING The carburetor heating system fails to operate. NOTE: Before troubleshooting, remove the following part(s): 1. Seat 2. Side cover (left/right) 3. Fuel tank side cover (left/right) 4. Fuel tank 5. Tool box (left/right) 6. Battery 7.
  • Page 251 CARBURETOR HEATING SYSTEM 7-28...

  • Page 252: Electrical Components

    ELECTRICAL COMPONENTS EAS27970 ELECTRICAL COMPONENTS 7-29...
  • Page 253 ELECTRICAL COMPONENTS 1. Main switch 2. Starter relay 3. Battery 4. Rectifier/regurator 5. Sidestand switch 6. Rear brake light switch 7. Starting circuit cut-off relay 8. Headlight relay 9. Wire harness 7-30...
  • Page 254 ELECTRICAL COMPONENTS 7-31...
  • Page 255 ELECTRICAL COMPONENTS 10. Horn 11. CDI unit 12. Thermo switch 13. Neutral switch 14. Ignition coil 7-32...

  • Page 256: Checking The Switches

    ELECTRICAL COMPONENTS EAS27980 CHECKING THE SWITCHES Br/L LOCK L/W L/B G/Y Br PUSH L/W R/W Ch B Br/W Br/W G/W Br G/Y (Br) (Br) 7-33...
  • Page 257 ELECTRICAL COMPONENTS 1. Main switch 5. Engine stop switch 6. Start switch 10. Clutch switch 11. Sidestand switch 13. Rear brake light switch 14. Front brake light switch 20. Turn signal switch 21. Dimmer switch 22. Horn switch 29. Neutral switch 7-34...
  • Page 258 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 259: Checking The Bulbs And Bulb Sockets

    ELECTRICAL COMPONENTS 1. Remove: EAS27990 CHECKING THE BULBS AND BULB Bulb ● SOCKETS EWA13320 Check each bulb and bulb socket for damage or WARNING wear, proper connections, and also for continu- Since the headlight bulb gets extremely hot, ity between the terminals. keep flammable products and your hands Damage/wear →...

  • Page 260: Checking The Fuse

    ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester to the fuse and check the continuity. NOTE: Set the pocket tester selector to “Ω × 1”. Pocket tester 90890-03112 Analog pocket tester YU-03112-C Checking the condition of the bulb sockets The following procedure applies to all of the bulb b.

  • Page 261: Checking And Charging The Battery

    ELECTRICAL COMPONENTS suring the specific gravity of the electrolyte. EAS28030 CHECKING AND CHARGING THE BATTERY Therefore, the charge of the battery has to be EWA13290 checked by measuring the voltage at the battery WARNING terminals. Batteries generate explosive hydrogen gas and contain electrolyte which is made of poi- 1.
  • Page 262 ELECTRICAL COMPONENTS to be done with the battery mounted on the Example vehicle, disconnect the negative battery Open-circuit voltage = 12.0 V lead from the battery terminal.) Charging time = 6.5 hours To reduce the chance of sparks, do not ●...
  • Page 263 ELECTRICAL COMPONENTS the machine is stopped. battery and start charging. c. Make sure that the current is higher than the b. Connect a charged and AMP meter to the standard charging current written on the bat- battery and start charging. tery.

  • Page 264: Checking The Relays

    ELECTRICAL COMPONENTS Starter relay Recommended lubricant Dielectric grease 10.Install: Battery band ● Side cover (right) ● Refer to “GENERAL CHASSIS” on page 4-1. EAS28040 CHECKING THE RELAYS Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, re- 1.

  • Page 265: Checking The Diode

    ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (DC 20 V) to the turn signal relay terminal as shown. Pocket tester Br/W 90890-03112 Analog pocket tester YU-03112-C Positive tester probe ● brown “1” b. Turn the main switch to “ON”. Negative tester probe ●...

  • Page 266: Checking The Spark Plug Cap

    ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ d. Check the diode for no continuity. a. Disconnect the ignition coil connectors from NOTE: When you switch the positive and negative the ignition coil terminals. b. Connect the pocket tester (Ω × 1) to the igni- tester probes, the readings in the above chart will be reversed.

  • Page 267: Checking The Pickup Coil

    ELECTRICAL COMPONENTS ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS28110 CHECKING THE PICKUP COIL 1. Disconnect: Pickup coil coupler ● (from the wire harness) 2. Check: Pickup coil resistance ● Out of specification → Replace. c. Measure the secondary coil resistance. Pickup coil resistance ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 248.0–372.0 Ω 3.

  • Page 268: Checking The Rectifier/Regulator

    ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Stator coil resistance a. Set the engine tachometer to the ignition coil 0.56–0.84 Ω of cylinder #1. b. Connect the pocket tester (AC 20 V) to the ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ rectifier/regulator coupler as shown. a. Connect the pocket tester (Ω × 1) to the sta- tor coil coupler as shown.

  • Page 269: Checking The Thermo Switch

    ELECTRICAL COMPONENTS 2. Check: Positive tester probe ● Thermo switch continuity ● Horn terminal “1” Out of specification → Replace the thermo Negative tester probe ● switch. Horn terminal “2” Continuit Test step Coolant temperature Less than 16±3°C (60.8±5.4°F) More than 16±3°C (60.8±5.4°F) More than 11±3°C (51.8±5.4°F)

  • Page 270: Checking The Carburetor Warmer

    ELECTRICAL COMPONENTS ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Install: Thermo switch ● EAS28310 CHECKING THE CARBURETOR WARMER 1. Check: Carburetor warmer resistance ● Out of specification → Replace. Resistance 4.7–9.5 Ω ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the carburetor warmer leads from the carburetor. b. Connect the pocket tester (Ω × 1) to the car- buretor warmer as shown.

  • Page 271: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING ................8-1 GENERAL INFORMATION ..............8-1 STARTING FAILURES................8-1 INCORRECT ENGINE IDLING SPEED ..........8-2 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........8-4...

  • Page 272: Troubleshooting

    TROUBLESHOOTING 3. Fuel cock EAS28450 TROUBLESHOOTING Clogged or damaged fuel hose ● 4. Carburetor(s) EAS28460 GENERAL INFORMATION Deteriorated or contaminated fuel ● NOTE: Clogged pilot jet ● The following guide for troubleshooting does not Clogged pilot air passage ● cover all the possible causes of trouble. It should Sucked-in air ●...

  • Page 273: Incorrect Engine Idling Speed

    TROUBLESHOOTING Faulty starter relay Fuel system ● 1. Carburetor(s) Faulty starting circuit cut-off relay ● Faulty diaphragm Faulty starter clutch ● ● Incorrect fuel level ● EAS28490 Loose or clogged main jet INCORRECT ENGINE IDLING SPEED ● 2. Fuel pump Engine Faulty fuel pump 1.

  • Page 274: Overheating

    TROUBLESHOOTING Clutch drags Oil or grease on the brake pad ● 1. Clutch Incorrect brake fluid level ● Unevenly tensioned clutch springs ● EAS28660 Warped pressure plate ● FAULTY FRONT FORK LEGS Bent clutch plate Leaking oil ● Swollen friction plate Bent, damaged or rusty inner tube ●...

  • Page 275: Faulty Lighting Or Signaling System

    TROUBLESHOOTING 7. Wheel(s) Faulty turn signal switch ● Incorrect wheel balance Incorrect turn signal bulb ● ● Deformed cast wheel Turn signal remains lit ● Faulty turn signal relay Damaged wheel bearing ● ● Burnt-out turn signal bulb Bent or loose wheel axle ●...
  • Page 276 XG250 2005 WIRING DIAGRAM EAS28740 EAS28750 White/Red WIRING DIAGRAM COLOR CODE White/Yellow XG250 2005 Black Yellow/Black 1. Main switch Brown Yellow/Green 2. Pickup coil rotor Chocolate Yellow/Blue 3. Rectifier/regulator Dark green Yellow/Red 4. Right handlebar switch Green 5. Engine stop switch Gray 6.
  • Page 277 XG250 2005 XG250 2005 XG250 2005 SCHEMA ELETTRICO DIAGRAMA ELÉCTRICO DE LA WIRING DIAGRAM SCHÉMA DE CÂBLAGE SCHALTPLAN XG250 2005 XG250 2005 R/L W/L L/Y W/B W/R O Br/L W/L W/R LOCK L/W L/B Br R/W L/W R/W Br G/Y...
  • Page 278 XG250 2005 XG250 2005 XG250 2005 SCHEMA ELETTRICO DIAGRAMA ELÉCTRICO DE LA WIRING DIAGRAM SCHÉMA DE CÂBLAGE SCHALTPLAN XG250 2005 XG250 2005 LOCK (Br) (Br) PUSH MAIN HARNESS CAB. HEATER...

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