Yamaha YBR250 2007 Service Manual
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Yamaha YBR250 2007 Service Manual

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2007
YBR250
SERVICE MANUAL
5D1-F8197-E0

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Summary of Contents for Yamaha YBR250 2007

  • Page 1 2007 YBR250 SERVICE MANUAL 5D1-F8197-E0...
  • Page 3 YBR250 SERVICE MANUAL ©2007 Yamaha Motor da Amazônia Ltda. First edition, February 2007 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor da Amazônia Ltda is expressly prohibited.
  • Page 4 This manual was produced by the YAMAHA MOTOR DA AMAZÔNIA LTDA., primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
  • Page 5 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. 1 The manual is divided into chapters.

  • Page 6: General Information

    SYMBOLS The following symbols are not common to all vehicles SPEC INFO Symbols indicate the subject of each chapter. General information Specifications CHAS Periodic checks and adjustments Chassis Engine Fuel Injection system Electrical system Troubleshooting TRBL ELEC SHTG Symbols indicate the following: Serviceable with engine mounted Filling fluid Lubricant...

  • Page 7: Table Of Contents

    TABLE OF CONTENTS GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC CHECKS AND ADJUSTMENTS CHASSIS CHAS ENGINE FUEL INJECTION SYSTEM ELECTRICAL SYSTEM ELEC TROUBLESHOOTING TRBL SHTG...
  • Page 8 CHAPTER 1 GENERAL INFORMATION VEHICLE IDENTIFICATION ................. 1-1 VEHICLE IDENTIFICATION NUMBER ........... 1-1 MODEL LABEL ..................1-1 FEATURES ....................1-2 FEATURES ....................1-2 FI SYSTEM ....................1-3 IMPORTANT INFORMATION ............... 1-4 PREPARATION FOR REMOVAL AND DISASSEMBLY ......1-4 REPLACEMENT PARTS ................. 1-4 GASKETS, OIL SEALS AND O-RINGS ..........

  • Page 9: Gen Info

    VEHICLE IDENTIFICATION INFO VEHICLE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER Chassis serial 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.

  • Page 10: Features

    FEATURES INFO FEATURES The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet that is used in the respective chamber.

  • Page 11: Fi System

    FEATURES INFO FI SYSTEM The fuel pump delivers fuel to the injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the injector at 36,3psi (250 kpa). Accordingly, when the energizing signal from the ECU energizes the injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the passage remains open.

  • Page 12: Important Information

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

  • Page 13: Lock Washers, Plates And Cotter Pins

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

  • Page 14: Checking The Connections

    CHECKING THE CONNECTIONS INFO CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: • lead • coupler • connector 2. Check • lead • coupler • connector Moisture Dry with an air blower. -->...
  • Page 15 INFO 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 16: Special Tools

    Use to measure fuel pump pressure. 90890-03174 Pocket tester Use to check electrical system 90890-06754 Spark dynamic tester Use to check the length of spark at the spark plug. 90890-85505 Yamaha Bond # 1215 Use to seal surfaces (e.g.: engine cases).
  • Page 17 INFO SPECIAL TOOLS Tool Nº Tool name / Function Illustration 90890-06760 Inductive tachometer Use to check engine rotation. 90890-04064 Valve guide extractor Use to extract and install valve guides. 90890-04065 Valve guide installer Use to install valve guides. 90890-04066 Valve guide reamer Use to rebore the hole on the new valve guides.
  • Page 18 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS ..............2-1 ENGINE SPECIFICATIONS ................2-2 CHASSIS SPECIFICATIONS ..............2-10 ELECTRICAL SPECIFICATIONS ............... 2-14 CONVERSION TABLE ................2-16 GENERAL TIGHTENING TORQUE SPECIFICATION ....... 2-16 TIGHTENING TORQUES ................2-17 ENGINE TIGHTENING TORQUES ............2-17 CHASSIS TIGHTENING TORQUES ............. 2-19 LUBRICATION POINTS AND LUBRICANT TYPES ........

  • Page 19: Spec

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Limit ---- Model YBR250 Model code 5D11 Dimensions 2,025 mm (79,724 in) ---- Overall length 745 mm (29,33 in) ---- Overall width 1,065 mm (41,93 in) Overall height ---- 805 mm (31,69 in) ---- Seat height 1,360 mm (53,54 in)

  • Page 20: Engine Specifications

    SPEC ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS Item Standard Limit Engine Engine type Air-cooled, 4-strokes, SOHC Cylinder arrangement 249.0 cm³ (15 cu.in) ---- Displacement Forward-inclined 1-cylinder Cylinder - bore x stroke 74.0 x 58.0 mm (2.91 x 2.28 in) ---- Compression ratio 9,8 : 1 ---- Idle speed...
  • Page 21 SPEC ENGINE SPECIFICATIONS Item Standard Limit Cylinder head 20.50~21.50 cm (1.25 ~ 1.31 cu.in) Volume ---- ---- Maximum distortion * 0.03 mm (0.001 in) Camshaft Drive system Chain drive (right) Camshaft dimensions (intake) Measurement A 36.890~36,990 mm (1.452 ~ 1.456 in) Measurement B 30.111~30,211 mm (1.185 ~ 1.189 in)
  • Page 22 SPEC ENGINE SPECIFICATIONS Item Standard Limit Rocker / Rocker shaft Rocker inner diameter 12.000~12.018 mm 12.036mm (0.4724 ~0.4731 in) (0.4739 in) Shaft outer diameter 11.981~11.991 mm 11.955mm (0.4717 ~0.4721 in) (0.4707 in) Gap between rocker and shaft 0.009~0.037 mm (0.0003 ~0.0014 in) ---- Valves, valve seats, valve guides Valve clearance (cold)
  • Page 23 SPEC ENGINE SPECIFICATIONS Item Standard Limit Valve stem clearance 0.080 mm Intake 0.010~0.037 mm (0.0004 ~ 0.0015 in) (0.0032 in) Exhaust 0.100 mm 0.025~0.052 mm (0.0010 ~ 0.0020 in) (0.0040 in) Valve stem limit and runout 0.030 mm ---- (0.0012 in) Valve seat width Intake 1.7 mm...
  • Page 24 SPEC ENGINE SPECIFICATIONS Item Standard Limit Cylinder Cylinder arrangement Forward inclined 1-cylinder Bore 74.000 ~ 74.016 mm (2.913 ~ 2.914 in) 74.10 mm (2.917 in) Taper ---- 0.05 mm (0.002 in) Out of round ---- 0.05 mm (0.002 in) Piston Piston-to-cylinder clearance 0.010~0.025 mm (0.0004 ~ 0.0010 in) 0.15mm...
  • Page 25 SPEC ENGINE SPECIFICATIONS Item Standard Limit 2nd ring Ring type Taper Dimensions (B x T) 0.80 x 2.80 mm (0.0315 x 0.1102 in) ---- End gap (installed) 0.30-0.45 mm (0.0118 ~ 0.0177 in) 0.60mm (0.0236 in) Ring side clearance 0.020-0.055 mm (0.0008 ~ 0.0022 in) 0.10mm (0.004 in) Oil ring...
  • Page 26 SPEC ENGINE SPECIFICATIONS Item Standard Limit Clutch Clutch type Wet, multiple discs Clutch release method Inner push, cam push Clutch cable free play Left hand ---- (at the end of clutch lever) 10.0 ~ 15.0mm (0.4~0.6 in) Friction plate Thickness 2.90 ~ 3.10 mm (0.11 ~0.12 in) 2.80mm (0.11 in)
  • Page 27 SPEC ENGINE SPECIFICATIONS Item Standard Limit Air filter ---- Wet element Air filter element Fuel pump Type of pump Electrical Model / manufacturer 5VK/DENSO Amperage consumption <maximum> 3,5 A ---- Output pressure 250 kPa (1875.2 mmHg, 73.825 inHg) ---- Fuel injector Model / manufacturer 1100-87F70 / AISAN Quantity...
  • Page 28 SPEC CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS Item Standard Limit Frame Steel double cradle Frame type 26.5° ---- Caster angle Trail 104.5 mm (4.1142 in) ---- Front wheel Wheel type Cast wheel ---- Size 17M/C X MT2.15 ---- Material Aluminium Wheel travel 120.0 mm (4.7244 in) ---- Rim runout...

  • Page 29: Chassis Specifications

    SPEC CHASSIS SPECIFICATIONS Item Standard Limit Front tire Tire type Tubeless 100/80-17M/C 52S Size Model / manufacturer SPORT DEMON / PIRELLI Tire pressure (cold) 0 ~ 90kg (0 ~ 198 lb) 225 kPa (2.25 kgf/cm , 33 psi) 90kg - Maximum load* 225 kPa (2.25 kgf/cm , 33 psi) (198lb - Maximum load)
  • Page 30 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Rear brake Brake type Drum brake Operation Right foot Brake pedal position (below the rider 29.0 mm (1.14 in) ---- footrest) Brake pedal free play 15.0 ~ 20.0 mm (0.6 ~ 0.8 in) ---- Rear drum brake Drum brake type Leading trailing...
  • Page 31 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Rear suspension ---- Suspension type Swingarm (link suspension) ---- Rear shock absorber Coil spring / Oil dumper ---- Shock absorber assembly travel 54.0 mm (2.13 in) Spring ---- Free lenght 183.4 mm (7.22 in) ---- Installed lenght 168.4mm (6.63 in)

  • Page 32: Electrical Specifications

    Engine control unit Model / ECU manufacturer AZ112100-6110 / DENSO ---- Ignition coil Model / manufacturer 2JN / YAMAHA Minimum ignition spark gap 6.0mm (0.24 in) ---- 2.16 ~ 2.64 Ω at 20 °C (68 °F) Primary coil resistance ---- Secondary coil resistance 8.64 ~ 12.96 KΩ+-20 % at 20 °C (68 °F)
  • Page 33 SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit Electric starting system System type Constant mesh Starter motor Model / manufacturer SM13/MITSUBA DO BRAZIL LTDA Power output 0.65 kW ---- 0.0012~0.0022 Ω at 20°C (68°F) Armature coil resistance ---- Brushes Overall length 12.5 mm (0.5 in) 4.00mm (0.16 in) Spring force...

  • Page 34: Conversion Table

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

  • Page 35: Tightening Torques

    SPEC TIGHTENING TORQUE TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Tightening torque Part to be tightened Part name Thread Remarks size kgf.m ft.lb Clutch push lever Bolt Gearshift cam selector stopper Bolt Clutch cable holder Bolt Neutral switch Sensor Crankcase oil drain screw Plug Speed sensor Bolt...
  • Page 36 SPEC TIGHTENING TORQUE Tightening torque Part to be mounted Part name Thread Remarks size N.m kgf.m ft.lb Oil filter cap L = 70mm Bolt L = 20mm Bolt Cylinder head (drive side) L = 45mm Bolt L = 117mm Bolt Starting motor Bolt Magneto rotor...
  • Page 37 SPEC TIGHTENING TORQUE CHASSIS TIGHTENING TORQUE Tightening torque Part to be mounted Part name Thread Remarks size N.m kgf.m ft.lb Locknut of transmission chain clearance adjusters 11.8 Rear grab bar Bolt 22.0 Shock absorber and chassis Bolt 42.8 Fuel tank dumper Bolt Sidestand 31.7...
  • Page 38 SPEC TIGHTENING TORQUE Tightening torque Part to be mounted Part name Thread Remarks size N.m kgf.m ft.lb Fork and break calipers Bolt Chassis and oil radiator Bolt Rectifier regulator Bolt Break calipers bleeder Bolt Leaning angle shutoff sensor Bolt Turn signal lamps 0.15 1.1 Brake light bracket Bolt...

  • Page 39: Lubrication Points And Lubricant Types

    Transmission gears (sprocket and pinion) Driving main shaft Gearshift forks Gearshift cam Forks shaft Speed sensor (O-rings) Crankcase mating surface Yamaha Bond N° 1215 Yamaha Bond A.C. magneto wireharness grommer (A.C. magneto cover) N° 1215 Oil timing pipe mounting bolt Yamaha Bond N°...

  • Page 40: Chassis

    LUBRICATION POINTS SPEC AND LUBRICANT TYPES CHASSIS Lubrication Points Symbol Front wheel oil seal lips (left and right) Rear wheel oil seal lips (left and right) Rear wheel drive hub mating surface Pivot shaft of swingarm and oil seals Boot surfaces Damper and rear arm screw Damper and swingarm oil seal lips Relay arm and rear arm screw...

  • Page 41: Oil Cooling System Diagram

    SPEC OIL COOLING SYSTEM DIAGRAM OIL COOLING SYSTEM DIAGRAM 1 Radiator A Hot oil inlet 2 Oil inlet hose 3 Oil outlet hose B Cooled oil outlet 4 Seal rings - “O-rings” 2-23...

  • Page 42: Lubrication Flow

    SPEC LUBRICATION FLOW LUBRICATION FLOW Oil supply with pressure Oil return by gravity and centrifugation Oil filter Oil radiator Check valve Cylinder head Drive axle Main axle Oil pump Crankshaft Drive shaft Metalic filter Crankcase 2-24...

  • Page 43: Lubrication System Diagrams

    SPEC LUBRICATION SYSTEM DIAGRAMS LUBRICATION SYSTEM DIAGRAMS Oil pump Pump driving gear Strainer (oil sub-filter) 4 Oil level gauge 2-25...
  • Page 44 SPEC LUBRICATION SYSTEM DIAGRAMS Oil delivery hose Oil return hose Oil pump Strainer (oil sub-filter) 5 Oil filter 2-26...
  • Page 45 SPEC LUBRICATION SYSTEM DIAGRAMS Guide pins A Arrow indicates direction to the oil radiator Seal rings “O-rings” B Arrow indicates direction from the oil Oil filter radiator Oil pump rotor 1 Oil pump driving gear Oil timing tube Oil filter housing 2-27...
  • Page 46 SPEC LUBRICATION SYSTEM DIAGRAMS Valve driving shaft Oil timing tube Screw - gasket Main axle Drive axle Clutch lever rod 2-28...

  • Page 47: Cable Routing

    SPEC CABLE ROUTING CABLE ROUTING Handlebar switch wire harness (RS) Instruments panel wireharness Clutch switch wire harness Ignition key wireharness Clutch cable Brake hose A Main wire harness Front brake switch wire harness B Front flasher wire harness (RS ) Handlebar switch wire harness (LS) C Front flasher wire harness (LS) Throttle cables...
  • Page 48 SPEC CABLE ROUTING A When fastening the wire harness, of the front break D Put inside the headlight box the wire harnesses of switch let a clearance at the shown area. the instruments panel, ignition key, handlebar B Fasten the brake switch (front) and the handlebar switches (LS and RS) and the front turn indication switch wire harness (RS) with a band.
  • Page 49 SPEC CABLE ROUTING 8 Clutch cable 1 Brake hose 9 Temperature sensor wire harness 2 Throttle cable 0 Starter motor cable 3 Handlebar switch wire harness (RS) A Grounding cable (negative) 4 Main wire harness B Speed sensor wire harness 5 Engine breather hose C Rear brake switch wire harness 6 Air induction valve hose...
  • Page 50 SPEC CABLE ROUTING sensor lead wire shall be through cable bracket A Fasten the wire harness switch to the handlebar with guide. a plastic band. Fix the rear brake switch wire harness and the O B Taking out lead wire shall be in front of the vehicle. sensor wire harness to the chassis with a plastic C Route the two throttle cables through the inside portion band.
  • Page 51 SPEC CABLE ROUTING 1 Left handlebar switch wire harness A Sidestand switch wire harness 2 Clutch switch wire harness B Horn wire harness 3 Clutch cable C Speed sensor wire harness 4 High voltage cable D Air induction hose 5 Throttle cables E Engine breather hose 6 Fuel supply hose F Rear brake switch wire harness...
  • Page 52 SPEC CABLE ROUTING A Pass the clutch cable through the guide. Fix the sidestand switch, neutral switch and stator B Clamp wire harness. wire harness with a plastic band. C Cover side wire harness should not be bent. G Clamp sidestand switch lead wire to pipe. D Wire harness through battery box guide.
  • Page 53 SPEC CABLE ROUTING 1 Throttle cable 8 Fuel pump connector 2 Clutch cable 9 Battery negative cable 3 Horn wire harness 0 ECU cable 4 Main wire harness A Grounding wire harness 5 Engine temperature sensor wire harness B Seat lock cable 6 Starter motor cable C Rear light wire harness 7 Grounding cable (negative)
  • Page 54 SPEC CABLE ROUTING 1 Front brake hose A Fit the brake hose grommet into the holder. 2 Front brake master cylinder B Assemble the brake hose with the metalic terminal 3 Lower bracket contacting the brake calipers stopper. 4 Front brake calipers C The brake hose must not be assembled twisted, 5 Headlight bracket bended or forcibly.
  • Page 55 CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION .................... 3-1 PERIODIC MAINTENANCE AND LUBRICATION TABLE ......3-1 COWLING AND SIDE COVERS ..............3-3 SIDE COVERS ..................3-3 FUEL TANK ....................3-4 REMOVING THE FUEL TANK ............. 3-5 REMOVING THE FUEL PUMP ............3-5 INSTALLING THE FUEL PUMP ............
  • Page 56 ELETRICAL SYSTEM.................. 3-43 CHECKING AND CHARGING THE BATTERY ........3-43 CHECKING THE FUSES ..............3-49 REPLACING THE HEADLIGHT BULB ..........3-50 REPLACING THE HEADLIGHT AUXILIARY BULB ......3-51 ADJUSTING THE HEADLIGHT BEAM ..........3-51 ADJUSTING THE DIGITAL CLOCK ........... 3-51...

  • Page 57: Chk Adj

    From 50.000 km, repeat the maintenance intervals starting from 10.000 km. • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. O D O M E TE R R E A D IN G...
  • Page 58 INTRODUCTION/PERIODIC MAINTENANCE AND LUBRICATION TABLE OD OMETER R EA D IN G A N N U A L ITEM C H EC K OR MA IN TEN A N C E JOB (x 1,000K M) C H EC K • C hec k bearing play and s teering for •...

  • Page 59: Cowling And Side Covers

    COWLING AND SIDE COVERS COWLING AND SIDE COVERS SIDE COVERS 7 N.m (0.7 kgf.m, 5.1 ft.lb) 30 N.m (3.0 kgf.m, 22 ft.lb) 7 N.m (0.7 kgf.m, 5.1 ft.lb) 7 N.m (0.7 kgf.m, 5.1 ft.lb) 7 N.m (0.7 kgf.m, 5.1 ft.lb) 7 N.m (0.7 kgf.m, 5.1 ft.lb) Order Job/Part...

  • Page 60: Fuel Tank

    FUEL TANK FUEL TANK 7 N.m (0.7 kgf.m, 5.1 ft.lb) 10 N.m (1.0 kgf.m, 7.2 ft.lb ) 7 N.m (0.7 kgf.m, 5.1 ft.lb) 7 N.m (0.7 kgf.m, 5.1 ft.lb) Order Job / Part Q’ty Remarks Removing the fuel tank Remove the parts in the order listed. Seat/Side covers (left and right) Fuel tank Drain.

  • Page 61: Removing The Fuel Tank

    FUEL TANK REMOVING THE FUEL TANK 1. Extract the fuel in the fuel tank through the fuel tank filling cap with a pump. 2. Remove: • fuel hose CAUTION: Although the fuel has been removed from the fuel tank be careful when removing the fuel hose, since there may be fuel remaining in it.

  • Page 62: Installing The Fuel Pump

    FUEL TANK INSTALLING THE FUEL PUMP 1. Install: • fuel pump FRONT Fuel pump screw 4 N.m (0.4 kgf.m, 2.9 ft.lb) NOTE: • Do not damage the installation surfaces of the fuel tank when installing the fuel pump. Always use a new fuel pump gasket. •...

  • Page 63: Engine

    ADJUSTING THE VALVE CLEARANCE ENGINE ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: • Valve clearance adjustment should be made on a cold engine, at room temperature. • When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke.
  • Page 64 ADJUSTING THE VALVE CLEARANCE 6. Measure: valve clearance • Out of specification Adjust. --> Valve clearance (cold) Intake valve 0.05 ~ 0.10mm (0.002 ~ 0.004 in) Exhaust valve 0.08 ~ 0.13mm (0.003 ~ 0.005 in) a. Turn the crankshaft counterclockwise. b.
  • Page 65 ADJUSTING THE VALVE CLEARANCE d. Prevent the bolt from moving by holding it and tighten the locknut to the specified torque. Locknut 14 N.m (1.4 kgf.m, 10.3 ft.lb) e. Measure the clearance valve again. f. If the valve clearance is still out of specification, repeat all of the valve clearance adjustment steps until the specified clearance is obtained.

  • Page 66: Adjusting The Exhaust Gas Volume

    ADJUSTING THE EXHAUST GAS VOLUME ADJUSTING THE EXHAUST GAS VOLUME V V V V V WARNING Carry out the adjustments after being sure that the battery is fully charged. To adjust the exhaust gas volume, it is necessary: • Gas analyzer; •...
  • Page 67 ADJUSTING THE EXHAUST GAS VOLUME 8. Change the CO volume adjustment by pressing the “UP” and “DOWN” buttons. NOTE: The CO volume adjusted and the low idle rotation are indicated on the display 1. • To reduce the CO volume adjusted, press “DOWN” •...

  • Page 68: Adjusting The Engine Idling Speed

    ADJUSTING THE ENGINE IDLING SPEED/ ADJUSTING THE THROTTLE CABLE FREE PLAY ADJUSTING THE ENGINE IDLING SPEED NOTE: Before adjusting the engine idling speed, the air filter case should be clean and the engine should have adequate compression. 1. Start the engine and let it warm up for several minutes.
  • Page 69 ADJUSTING THE THROTTLE CABLE FREE PLAY 1. Check: • throttle cable free play a --> Out of specification Adjust. Throttle cable free play (at the flange of the throttle grip) 3,0 ~ 5,0 mm (0.12 ~ 0.20 in) 2. Adjust: •...
  • Page 70 ADJUSTING THE THROTTLE CABLE FREE PLAY/ CHECKING THE SPARK PLUGS c. Tighten the locknut. V V V V V WARNING After adjusting the throttle cable free play, start the engine and turn the handlebar to the right and to the left to ensure that this does not cause the engine idling speed to change.

  • Page 71: Checking The Spark Plug

    CHECKING THE SPARK PLUG/ CHECKING THE IGNITION TIMING 7. Install: • spark plug Spark plug 18 N.m (1.8 kgf.m, 13.3 ft.lb) NOTE: Before installing the spark plug, clean the spark plug and gasket surface. 8. Connect: • spark plug cap CHECKING THE IGNITION TIMING NOTE: Prior to checking the ignition timing, check the wiring...

  • Page 72: Checking The Compression

    CHECKING THE COMPRESSION CHECKING THE COMPRESSION NOTE: Insufficient compression pressure will result in a loss of performance. 1. Measure: • valve clearance Out of specifications Adjust. --> Refer to "ADJUSTING THE VALVE CLEARANCE". 2. Start the engine, warm it up for several minutes,and then turn it off.
  • Page 73 CHECKING THE COMPRESSION 6. Measure: • compression pressure Out of specification Refer to steps (c) and --> (d). Compression (at sea level) Standard 1200Kpa (12kg/cm 170.7 psi) Minimum 1050Kpa (10.5kg/cm , 152.3 psi) Maximum 1300Kpa (13.0kg/cm , 188.5 psi) a. Set the starting switch to "ON" and the “engine stop”...

  • Page 74: Checking The Engine Oil Level

    CHECKING THE COMPRESSION/ CHECKING THE ENGINE OIL LEVEL 7. Install: • spark plug Spark plug 18 N.m (1.8 kgf.m, 13.3 ft.lb) 8. Connect: • spark plug cap CHECKING THE ENGINE OIL LEVEL 1. Stand the vehicle on a level surface. NOTE: •...

  • Page 75: Changing The Engine Oil

    CHECKING THE ENGINE OIL LEVEL/ CHANGING THE ENGINE OIL CAUTION: • Engine oil also lubricates the clutch and the wrong oil types or additives could cause clutch slippage. Therefore, do not add any chemical additives or use engine oils with a grade of CD c c c c c or higher and do not use oils labeled “ENERGY CONSERVING II”...
  • Page 76 CHANGING THE ENGINE OIL 6. Check: • engine oil drain bolt gasket 1 Damage Replace. --> 7. Install: oil drain bolt 2 (crankcase) • (along with the gasket) -2-3-4-5 Oil drain bolt (crankcase) 20 N.m (2.0 kgf.m, 14 ft.lb) 8. Fill: •...
  • Page 77 CHANGING THE ENGINE OIL 9. Install: • dipstick 10. Start the engine, warm it up for several minutes and turn it off. 11. Check: • engine (for engine oil leaks) 12. Check: • engine oil level Refer to "CHECKING THE ENGINE OIL LEVEL"...

  • Page 78: Adjusting The Clutch Cable Free Play

    ADJUSTING THE CLUTCH CABLE FREE PLAY ADJUSTING THE CLUTCH CABLE FREE PLAY 1. Check: • clutch cable free play 3 Out of specification Adjust. --> Clutch cable free play (at the end of the clutch lever) 10 ~ 15 mm (0.4 ~ 0.6 in) 2.

  • Page 79: Checking The Air Filter Element

    CHECKING THE AIR FILTER ELEMENT CHECKING THE AIR FILTER ELEMENT NOTE: There is a checking hose 1 in the bottom of the air filter case. If dust and/or water accumulate into this hose, clean the air filter and the air filter case. 1.

  • Page 80: Checking The Throttle Body Junction

    CHECKING THE AIR FILTER ELEMENT/ CHECKING THE THROTTLE BODY JUNCTION / CHECKING THE FUEL HOSE 6. Install: • right side cover • seat Refer to "COWLING AND SIDE COVERS". CHECKING THE THROTTLE BODY JUNCTION 1. Check: • injection body junction 1 Breakage/damage Replace.

  • Page 81: Checking The Engine Breather Hose

    CHECKING THE ENGINE BREATHER HOSE / CHECKING THE EXHAUST SYSTEM CHECKING THE ENGINE BREATHER HOSE 1. Check: • crankcase breather hose 1 Cracks/damage Replace. --> CAUTION: Make sure the engine breather hose is routed correctly. CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the exhaust pipes, mufflers and gaskets.

  • Page 82: Checking The Oil Radiator

    CHECKING THE OIL RADIATIOR CHECKING THE OIL RADIATOR 1. Remove: • seat • tank side covers Refer to “COWLING AND SIDE COVERS” 2. Check: oil radiator 1 • radiator output hose 2 • radiator input hose 3 • Cracks / damage Replace -->...

  • Page 83: Chassis

    CHASSIS/CHECKING THE BRAKE FLUID LEVEL CHASSIS CHECKING THE BRAKE FLUID LEVEL 1. Stand the vehicle on a level surface. NOTE: • Place the vehicle on a suitable stand. • Make sure the vehicle is upright. 2. Check: • brake fluid level Below the minimum mark level a Add the -->...

  • Page 84: Checking The Front Brake Pads

    CHECKING THE FRONT BRAKE PADS/ BLEEDING THE HYDRAULIC BRAKE SYSTEM CHECKING THE FRONT BRAKE PADS The following procedure applies to all of the brake pads 1. Operate the front brake. 2. Check: • front brake pads Wear indicator groove 1 almost disappeared Replace the brake pad as a set.
  • Page 85 BLEEDING THE HYDRAULIC BRAKE SYSTEM 1. Bleed: • hydraulic brake system. a. Fill the brake fluid reservoir to the proper level with the recommended brake fluid. b. Install the diaphragm (brake master cylinder reservoir or brake fluid reservoir). c. Connect a clear plastic hose 1 tightly to the bleed screw 2.

  • Page 86: Checking The Front Brake Hose

    CHECKING THE FRONT BRAKE HOSE/ ADJUSTING THE REAR BRAKE PEDAL CHECKING THE FRONT BRAKE HOSE The following procedure applies to all of the brake hose clamps. 1. Check: • front brake hose 1 Cracks/damage/wear Replace. --> 2. Check: • brake hose bracket 2 Loosen Screw the clamp bolt.

  • Page 87: Checking The Brake Lining

    ADJUSTING THE REAR BRAKE PEDAL/ CHECKING THE BRAKE LINING/ c. Loosen the locknut Brake pedal locknut 7 N.m (0.7 kgf.m, 5.1 ft.lb) V V V V V WARNING After adjusting the pedal position, adjust the brake pedal free play. 3. Check: •...

  • Page 88: Adjusting The Rear Brake Switch

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

  • Page 89: Adjusting The Drive Chain Slack

    ADJUSTING THE DRIVE CHAIN SLACK ADJUSTING THE DRIVE CHAIN SLACK NOTE: The drive chain slack must be checked at the tightest point on the chain. CAUTION: A drive chain that is too tight will overload the engine and other vital parts, and one that is too loose can skip and damage the swingarm or cause an accident.

  • Page 90: Lubricating The Drive Chain

    ADJUSTING THE DRIVE CHAIN SLACK/ LUBRICATING THE DRIVE CHAIN Direction a a a a a Drive chain is tightened Direction b b b b b Drive chain is loosened NOTE: To maintain the proper wheel alignment, adjust both sides evenly, using the arm grooves 4 as reference.

  • Page 91: Checking And Adjusting The Steering Head

    CHECKING AND ADJUSTING THE STEERING HEAD CHECKING AND ADJUSTING THE STEERING HEAD 1. Stand the vehicle on a level surface. V V V V V WARNING Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the front wheel is elevated.
  • Page 92 CHECKING AND ADJUSTING THE STEERING HEAD 6. Adjust: • Steering head a. Remove the lock-washer 1, the upper ring nut 2 and the rubber washer 3. b. Loosen the lower ring nut 4 and then tighten it to the specified torque with the steering nut wrench 5.
  • Page 93 CHECKING AND ADJUSTING THE STEERING HEAD/ CHECKING THE FRONT FORK 7. Install: • upper bracket • washer • steering stem nut Steering stem nut 110 N.m (11.0 kgf.m, 81.1 ft.lb) 8. Fix: • steering stem side bolts Steering stem side bolt 25 N.m (2.5 kgf.m, 18.4 ft.lb) 9.

  • Page 94: Checking The Front Fork

    CHECKING THE FRONT FORK/ ADJUSTING THE REAR SHOCK ABSORBER 3. Hold the vehicle upright and apply the front brake. 4. Check: • front fork operation Push down hard on the handlebar several times and check if the front fork rebounds smoothly. Rough movement Repair.

  • Page 95: Checking The Tires

    CHECKING THE TIRES CHECKING THE TIRES The following procedure applies to both of the tires. 1. Check: • tire pressure Out of specification Adjust. --> V V V V V WARNING • The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature.
  • Page 96 No guarantee concerning handling characteristics can be given if a tire combination other than one approved by Yamaha is used on this vehicle. 3-40...
  • Page 97 CHECKING THE TIRES Front tire Manufacturer Model Size SPORT 100/80 -17M/ PIRELLI DEMON C 52S Rear tire Manufacturer Model Size SPORT 130/70 -17M/ PIRELLI DEMON C 62S V V V V V WARNING New tires have a relative low adherence until they are slightly wear.

  • Page 98: Checking And Lubricating The Cables

    CHECKING AND LUBRICATING THE CABLES/ LUBRICATING THE BRAKE LEVERS AND PEDALS/ LUBRICATING THE SIDESTAND CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the inner V V V V V WARNING Damaged outer cable may cause the cable to corrode and interfere with its movement.

  • Page 99: Eletrical System

    CHECKING AND CHARGING THE BATTERY ELECTRICAL SYSTEM CHECKING AND CHARGING THE BATTERY V V V V V WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: •...
  • Page 100 CHECKING AND CHARGING THE BATTERY NOTE: Since MF batteries are sealed, it is not possible to check the charge state of the battery by measuring the specific gravity of the electrolyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals.
  • Page 101 CHECKING AND CHARGING THE BATTERY Charging 5. Charge: Ambient temperature 20 °C (68 °F) • battery (refer to the appropriate charging method illustration) V V V V V WARNING Do not quick charge a battery. Time (minutes) Check the open-circuit voltage CAUTION: •...
  • Page 102 CHECKING AND CHARGING THE BATTERY Charging method using a variable-current (voltage) charger Charge NOTE: Ammeter Leave the battery unused for more than 30 minutes Measure the open-circuit before measuring its open- voltage prior to charging. circuit voltage. NOTE: Set the charging voltage to Connect a charger and 16 ~ 17 V.
  • Page 103 CHECKING AND CHARGING THE BATTERY Charging method using a constant voltage charger NOTE: Leave the battery unused for more than 30 minutes Measure the open-circuit before measuring its open- voltage prior to charging. circuit voltage. Connect a charger and ammeter to the battery and start charging.
  • Page 104 CHECKING AND CHARGING THE BATTERY 6. Install: • battery 7. Connect: • battery leads (to the battery terminals) CAUTION: First, connect the positive battery lead 1, and then the negative battery lead 2. 8. Check: • battery terminals Dirt Clean with a wire brush -->...

  • Page 105: Checking The Fuses

    CHECKING THE FUSES CHECKING THE FUSES The following procedure applies to all of the fuses. CAUTION: To avoid a short circuit, always set the main switch to “OFF” when checking or replacing a fuse. 1. Remove: • seat Refer to "COWLING AND SIDE COVERS". 2.

  • Page 106: Replacing The Headlight Bulb

    CHECKING THE FUSES/ REPLACING THE HEADLIGHT BULB 4. Install: • seat Refer to "COWLING AND SIDE COVERS". REPLACING THE HEADLIGHT BULB 1. Remove: • headlight bolts 1 2. Disconnect: • headlight bulb connector 1 3. Remove: • headlight bulb holder cover 2 V V V V V WARNING Since the headlight bulb gets extremely hot, keep...

  • Page 107: Replacing The Headlight Auxiliary Bulb

    ADJUSTING THE HEADLIGHT BEAM/ ADJUSTING THE DIGITAL CLOCK REPLACING THE HEADLIGHT AUXILIARY BULB 1. Remove: • headlight bolts • socket 1 2. Remove: • auxiliary bulb 2 V V V V V WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down.
  • Page 108 CHAPTER 4 CHASSIS FRONT WHEEL AND BRAKE DISC ............4-1 FRONT WHEEL ..................4-2 REMOVING THE FRONT WHEEL ............4-3 CHECKING THE FRONT WHEEL ............4-3 CHECKING THE FRONT BRAKE DISC ..........4-6 INSTALLING THE FRONT WHEEL ............4-7 ADJUSTING THE FRONT WHEEL STATIC BALANCING ....4-8 REAR WHEEL, BRAKE DISC AND REAR WHEEL SPROCKET ...
  • Page 109 STEERING HEAD ..................4-60 REMOVING THE LOWER BRACKET ..........4-62 CHECKING THE STEERING HEAD ............ 4-62 INSTALLING THE STEERING HEAD ........... 4-63 REAR SHOCK ABSORBER ASSEMBLY ..........4-65 HANDLING THE REAR SHOCK ABSORBER ........4-67 DISPOSING A REAR SHOCK ABSORBER ........4-67 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY ....

  • Page 110: Chas

    CHAS FRONT WHEEL AND BRAKE DISC CHASSIS FRONT WHEEL AND BRAKE DISC 54 N.m (5.4 kgf.m, 40 ft.lb) 23 N.m (2.3 kgf.m, 17 ft.lb) 59 N.m (5.9 kgf.m, 43 ft.lb) Job/Part Remarks Qt’y Order Removing the front brake disc and wheel Remove the parts in the order listed NOTE: Place the vehicle on a suitable stand...

  • Page 111: Front Wheel

    CHAS FRONT WHEEL AND BRAKE DISC FRONT WHEEL Order Job/Part Remarks Qt’y Disassembling the front wheel Remove the parts in the order listed Oil seal Bearing Collar For assembly, reverse the disassembly procedure...

  • Page 112: Removing The Front Wheel

    CHAS FRONT WHEEL AND BRAKE DISC REMOVING THE FRONT WHEEL 1. Stand the vehicle on a level surface. V V V V V WARNING Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the front wheel is elevated.
  • Page 113 CHAS FRONT WHEEL AND BRAKE DISC 3. Measure: • radial alignment 1 • lateral alignment 2 Above the specified limits --> Replace. Radial alignment limit 1.0 mm (0.04 in) Lateral alignment limit 0.5 mm (0.02 in) V V V V V WARNING After assembling a new tire, drive carefully during a period for getting used to the new tire...
  • Page 114 CHAS FRONT WHEEL AND BRAKE DISC 6. Replace: • oil seal • wheel bearing a. Clean the outer part of the front wheel hub. b. Remove the oil seals 1 with a flat-head screwdriver. NOTE: To prevent damaging the wheel, place a rag 2 between the screwdriver and the wheel.

  • Page 115: Checking The Front Brake Disc

    CHAS FRONT WHEEL AND BRAKE DISC CHECKING THE FRONT BRAKE DISC 1. Check: • brake disc Damage/friction --> Replace. 2. Measure: • brake disc deflection Out of specification --> correct the brake disc deflection or replace. Deflection limit (maximum) 0.10 mm (0.04 in) a.

  • Page 116: Installing The Front Wheel

    CHAS FRONT WHEEL AND BRAKE DISC 4. Adjust: • brake disc deflection a. Remove the brake disc. b. Offset the brake disc from one screw hole to another. c. Install the brake disc. NOTE: Tighten the brake discs screws in stages and in a crisscross pattern.

  • Page 117: Adjusting The Front Wheel Static Balancing

    CHAS FRONT WHEEL AND BRAKE DISC 2. Install: • wheel axle (from the right side) 1 Wheel axle 59 N.m (5.9 kgf.m, 43 ft.lb) • axle mounting bolt 2 Axle mounting bolt 54 N.m (5.4 kgf.m, 40 ft.lb) V V V V V WARNING Make sure that the brake hose is properly placed.
  • Page 118 CHAS FRONT WHEEL AND BRAKE DISC 2. Find • heavy spot “x” (unbalance) NOTE: Place the front wheel over a suitable stand for balancing. a. Spin the front wheel. b. When the wheel stops, make a “x” mark at its lowest part found.
  • Page 119 REAR WHEEL, BRAKE DISC CHAS AND REAR WHEEL SPROCKET REAR WHEEL, BRAKE DISC AND REAR WHEEL SPROCKET REAR WHEEL 104 N.m (10.4 kgf.m, 76.7 ft.lb) 16 N.m (1.6 kgf.m, 11.8 ft.lb) 49 N.m (4.9 kgf.m, 36 ft.lb) Job/Part Remarks Order Qt’y Removing the rear wheel Remove the parts in the order listed...

  • Page 120: Rear Wheel, Brake Disc And Rear Wheel Sprocket

    REAR WHEEL, BRAKE DISC CHAS AND REAR WHEEL SPROCKET 104 N.m (10.4 kgf.m, 76.7 ft.lb) 16 N.m (1.6 kgf.m, 11.8 ft.lb) 49 N.m (4.9 kgf.m, 36 ft.lb) Order Job/Part Remarks Qt’y Adjusting nut Wheel axle nut Refer to “INSTALLING THE Wheel axle washer REAR WHEEL”...

  • Page 121: Brake Shoe Plate And Rear Wheel Sprocket

    REAR WHEEL, BRAKE DISC CHAS AND REAR WHEEL SPROCKET BRAKE SHOE PLATE AND REAR WHEEL SPROCKET 43 N.m (4.3 kgf.m, 31.7 ft.lb) Order Job/Part Remarks Qt’y Removing the brake shoe plate and sprocket Remove the parts in the order listed Oil seal Sprocket mounting nuts Sprocket...

  • Page 122: Wheel

    REAR WHEEL, BRAKE DISC CHAS AND REAR WHEEL SPROCKET WHEEL Order Job/Part Remarks Qt’y Disassembling the rear wheel Remove the parts in the order listed Bearing Oil seals Collar For assembling, reverse the disassembly procedure 4-13...

  • Page 123: Brake Shoe Plate

    REAR WHEEL, BRAKE DISC CHAS AND REAR WHEEL SPROCKET BRAKE SHOE PLATE Order Job/Part Remarks Qt’y Disassembling the brake lining Remove the parts in the order listed Brake shoe assembly Brake camshaft lever Brake shoe wear indicator Brake camshaft For assembly, reverse the disassembly procedure 4-14...

  • Page 124: Removing The Rear Wheel

    REAR WHEEL, BRAKE DISC CHAS AND REAR WHEEL SPROCKET REMOVING THE REAR WHEEL 1. Stand the vehicle on a level surface. V V V V V 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 125: Checking The Rear Wheel

    REAR WHEEL, BRAKE DISC CHAS AND REAR WHEEL SPROCKET CHECKING THE REAR WHEEL 1. Check: • wheel axle • rear wheel • wheel bearings • oil seals Refer to “CHECKING THE FRONT WHEEL”. 2. Check: • tire • rear wheel Refer to “CHECKING THE TIRES”...

  • Page 126: Checking And Replacing The Sprocket

    REAR WHEEL, BRAKE DISC CHAS AND REAR WHEEL SPROCKET CHECKING AND REPLACING THE SPROCKET 1. Check: • sprocket More than 1/4 tooth a wear --> Replace the rear wheel spur gear. Bent teeth => Replace. b correct 1 drive chain roller 2 sprocket 2.

  • Page 127: Removing The Rear Brake Lining

    REAR WHEEL, BRAKE DISC CHAS AND REAR WHEEL SPROCKET REMOVING THE REAR BRAKE LINING 1. Remove: • brake shoe lining 1 • springs 2 NOTE: Remove the linings pulling them out, with the pivoting pin 3 and the brake camshaft 4 as support points, in the arrow direction.
  • Page 128 REAR WHEEL, BRAKE DISC CHAS AND REAR WHEEL SPROCKET 3. Check: • brake shoe lining surface Glazed areas --> Remove. Use a rough sandpaper. NOTE: After using the sandpaper, clean the remaining particles with a cloth. 4. Measure: • brake shoe lining thickness a Out of specification -->...

  • Page 129: Assembling The Rear Brake

    REAR WHEEL, BRAKE DISC CHAS AND REAR WHEEL SPROCKET 6. Measure: • brake drum inner diameter a Out of specification --> Replace the rear wheel. Brake drum inner diameter: Standard: 130 mm (5.12 in) Limit: 131mm (5.16 in) ASSEMBLING THE REAR BRAKE Reverse the “REMOVING THE BRAKE LININGS”...
  • Page 130 REAR WHEEL, BRAKE DISC CHAS AND REAR WHEEL SPROCKET 3. Install: • brake shoe wear indicator 1 NOTE: When installing the brake shoe wear indicator, place the lobes into the brake camshaft groove and align the pointer with the wear display 2. 4.

  • Page 131: Installing The Rear Wheel

    REAR WHEEL, BRAKE DISC CHAS AND REAR WHEEL SPROCKET INSTALLING THE REAR WHEEL 1. Lubricate: • wheel axle • oil seal lips Recommended lubricant Lithium-based-soap grease 2. Install: • rear wheel • drive chain • washer • rear wheel axle 1 •...

  • Page 132: Rear Wheel Static Balance

    REAR WHEEL, BRAKE DISC CHAS AND REAR WHEEL SPROCKET REAR WHEEL STATIC BALANCE NOTE: • After replacing the tire, wheel or both, the rear wheel static balance must be performed. • Adjust the rear wheel static balance with the sprocket and the hub installed. 1.

  • Page 133: Front Brake

    CHAS FRONT BRAKE FRONT BRAKE FRONT BRAKE PADS 30 N.m (3.0 kgf.m, 22 ft.lb) 4 4 4 4 4 1 1 1 1 1 3 3 3 3 3 2 2 2 2 2 18 N.m (1.8 kgf.m, 13.3 ft.lb) Order Job/Part Remarks...

  • Page 134: Replacing The Front Brake Pads

    CHAS FRONT BRAKE CAUTION: Disc brake components rarely require disassembly. Therefore, always follow these preventive measures: • Never disassemble brake components unless absolutely necessary. • If any connection on the hydraulic brake system is disconnected, the entire brake system must be disassembled, drained, cleaned, properly filled, and bled after reassembly.
  • Page 135 CHAS FRONT BRAKE 3. Remove: • brake pads 4 • brake pads spring 4. Measure: • brake pads wear limit a Out of specification --> Replace the brake pads as a set. Pad wear limit 1.5 mm (0.06 in) 5. Check: •...
  • Page 136 CHAS FRONT BRAKE d. Install the new spring 1. e. Install the brake pads. 7. Install: • brake pad guide pins • brake calipers • calipers screws NOTE: Install the inner pad with the a detail aligned with the calipers b pin. Guide pins 18 N.m (1.8 kgf.m, 13.3 ft.lb) 8.

  • Page 137: Front Brake Master Cylinder

    CHAS FRONT BRAKE FRONT BRAKE MASTER CYLINDER 10 N.m (1.0 kgf.m, 7.2 ft.lb) 10 N.m (1.0 kgf.m, 7.2 ft.lb) 25 N.m (2.5 kgf.m, 18.5 ft.lb) Order Job/Part Remarks Qt’y Removing the front brake master cylinder Remove the parts in the order listed Brake fluid Drain Rearview mirror (right)
  • Page 138 CHAS FRONT BRAKE Order Job/Part Remarks Qt’y Disassembling the brake master cylinder Remove the parts in the order listed Dust boot Circlip Washer Brake master cylinder kit Brake master cylinder For assembly, reverse the disassembly procedure 4-29...

  • Page 139: Disassembling The Front Brake Master Cylinder

    CHAS FRONT BRAKE DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER NOTE: Before disassembling the brake master cylinder, drain the brake system fluid. 1. Disconnect: • brake front switch 1 2. Remove: • union bolt 1 • copper washers 2 • brake hose 3 NOTE: To collect any remaining brake fluid, place a container under the brake master cylinder and the...

  • Page 140: Checking The Brake Master Cylinder

    CHAS FRONT BRAKE CHECKING THE BRAKE MASTER CYLINDER 1. Check: • brake master cylinder 1 Damage/Scratches/Wear --> Replace. • brake fluid routing (master cylinder body). Clog --> Blow out with compressed air 2. Check: • brake master cylinder kit Damage/Scratches/Wear --> Replace as a set.
  • Page 141 CHAS FRONT BRAKE 1. Install: • brake master cylinder 1 • brake master cylinder holder 2 Master cylinder holder bolt 10 N.m (1.0 kgf.m, 7.2 ft.lb) NOTE: • Install the brake master cylinder holder with the “UP” mark a facing up. •...
  • Page 142 CHAS FRONT BRAKE 1. Fill: • Brake master cylinder reservoir (with the specified amount of the recommended brake fluid) Brake fluid recommended DOT4 V V V V V WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.

  • Page 143: Front Brake Calipers

    CHAS FRONT BRAKE FRONT BRAKE CALIPERS 25 N.m (2.5 kgf.m, 18.5 ft.lb) 30 N.m (3.0 kgf.m, 22 ft.lb) Order Job/Part Qt’y Remarks Removing the front brake caliper Remove the parts in the order listed Brake fluid Drain Brake hose bracket Union bolt Copper washer Refer to...
  • Page 144 CHAS FRONT BRAKE 6 N.m (0.6 kgf.m, 4.4 ft.lb) Order Job/Part Remarks Qt’y Disassembling the front brake caliper Remove the parts in the order listed Guide pins Brake pads Refer to “INSTALLING THE Brake pad spring FRONT BRAKE CALIPERS” For assembly, reverse the disassembly procedure 4-35...

  • Page 145: Removing The Front Brake Caliper

    CHAS FRONT BRAKE REMOVING THE FRONT BRAKE CALIPER NOTE: Before removing the brake caliper, drain the brake fluid from the brake systems. 1. Remove: • union bolt 1 • copper washer 2 • brake hose 3 • brake caliper 4 Refer to “REPLACING THE FRONT BRAKE PADS”.
  • Page 146 CHAS FRONT BRAKE 1. Check: • brake caliper pistons 1 Rust/scratches/wear --> Replace the brake caliper. • brake caliper body 2 Cracks/damage --> Replace the brake caliper. • brake calipers Brake fluid leakage --> Replace the brake caliper V V V V V WARNING Replace the piston oil seal whenever the caliper is disassembled.

  • Page 147: Assembling The Brake Caliper

    CHAS FRONT BRAKE ASSEMBLING THE BRAKE CALIPER 1. Install: • oil seals 1 • brake caliper piston 2 2. Install: • brake caliper bracket NOTE: Place tightly the rubber sleeve into the proper groove of the guide pin 1. 3. Install: •...

  • Page 148: Installing The Brake Caliper

    CHAS FRONT BRAKE INSTALLING THE BRAKE CALIPER 1. Install: • brake caliper 1 • brake caliper bolts 2 Brake caliper bolts 30 N.m (3.0 kgf.m, 22 ft.lb) • copper washers • brake hose 3 • union bolt 4 Union bolt 25 N.m (2.5 kgf.m, 18.5 ft.lb) V V V V V WARNING...
  • Page 149 CHAS FRONT BRAKE V V V V V WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • Refill with the same type of brake fluid that is already in the system.

  • Page 150: Front Fork

    CHAS FRONT FORK FRONT FORK 25 N.m (2.5 kgf.m, 18.5 ft.lb) 7 N.m (0.7 kgf.m, 5.1 ft.lb) 30 N.m (3.0 kgf.m, 22 ft.lb) 30 N.m (3.0 kgf.m, 22 ft.lb) 7 N.m (0.7 kgf.m, 5.1 ft.lb) 6 N.m (0.6 kgf.m, 4.4 ft.lb) Order Job/Part Remarks...
  • Page 151 CHAS FRONT FORK 25 N.m (2.5 kgf.m, 18.5 ft.lb) 7 N.m (0.7 kgf.m, 5.1 ft.lb) 30 N.m (3.0 kgf.m, 22 ft.lb) 30 N.m (3.0 kgf.m, 22 ft.lb) 7 N.m (0.7 kgf.m, 5.1 ft.lb) 6 N.m (0.6 kgf.m, 4.4 ft.lb) Order Job/Part Remarks Qt’y...
  • Page 152 CHAS FRONT FORK 23 N.m (2.3 kgf.m, 17 ft.lb) 23 N.m (2.3 kgf.m, 17 ft.lb) Order Job/Part Remarks Qt’y Disassembling the front fork leg Remove the parts in the order listed NOTE: The following procedure applies to both Cap bolt front fork legs.
  • Page 153 CHAS FRONT FORK 23 N.m (2.3 kgf.m, 17 ft.lb) 23 N.m (2.3 kgf.m, 17 ft.lb) Order Job/Part Remarks Qt’y Inner tube Oil seal Washer Refer to “ASSEMBLING THE Outer tube bushing FRONT FORK LEG” Oil flow stopper Inner tube bushing Outer tube For assembly, reverse the disassembly procedure...

  • Page 154: Removing The Front Fork Legs

    CHAS FRONT FORK REMOVING THE FRONT FORK LEGS The following procedure applies to both front fork legs. 1. Stand the vehicle on a level surface. V V V V V WARNING Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the front wheel is elevated.
  • Page 155 CHAS FRONT FORK 2. Drain: • fork oil NOTE: Move the outer tube several times while drain the fork oil. 3. Remove: • boot 1 • oil seal clip 2 (flat head screwdriver) CAUTION: Do not scratch the inner tube. 4.

  • Page 156: Checking The Front Fork Legs

    CHAS FRONT FORK CAUTION: • Excessive force will damage the oil seal and the inner tube bushing. A damaged oil seal or bushing must be replaced. • Avoid standing the inner tube from the outer tube during the above procedure, or this will damage the oil flow tip.

  • Page 157: Assembling The Front Fork Legs

    CHAS FRONT FORK 3. Check: • shock absorber rod 1 Damage/Wear --> Replace. Clogged --> Blow out all of the oil passages with compressed air. • oil flow switch 2 Damage --> Replace. CAUTION: • The front fork leg has a built-in damper adjusting rod and a very sophisticated internal construction, which are particularly sensitive to foreign material.
  • Page 158 CHAS FRONT FORK 2. Lubricate: • inner tube’s outer surface Recommended lubricant fork and shock oil 10 W or equivalent 3. Tighten: • shock absorber rod bolt 1 Shock absorber rod mounting 23 N.m (2.3 kgf.m, 17 ft.lb) LOCTITE NOTE: While holding the damper rod assembly with the shock absorber rod holder 2 and the T-handle 3, tighten the shock absorber rod assembly...
  • Page 159 CHAS FRONT FORK 5. Install: • oil seal (with the sliding installer 1 and the adapter CAUTION: Make sure the numbered side of the oil seal faces up. NOTE: • Before installing the oil seal, lubricate its lips with lithium-soap-based grease. •...
  • Page 160 CHAS FRONT FORK 8. Fill: • front fork leg (with the specified amount of the recommended fork oil) Amount (each leg) 0.319 L (0.07 Imp gal, 0.08 US gal) Recommended oil Fork and shock oil 10W or equivalent 9. Measure: •...

  • Page 161: Installing The Front Fork Legs

    CHAS FRONT FORK INSTALLING THE FRONT FORK LEGS The following procedure applies to both front fork legs. 1. Install: • front fork leg Temporarily tighten the lower bracket mounting bolts. NOTE: When installing the front fork leg, align the inner tube with its upper end exceeding the upper bracket top in 1.0 mm.
  • Page 162 CHAS FRONT FORK 3. Tighten: • brake hose holders 1 Brake hose holders 7 N.m (0.7 kgf.m, 5.1 ft.lb) • front fender V V V V V WARNING Proper brake hose routing is essential to insure safe vehicle operation. Refer to“CABLE ROUTING”...

  • Page 163: Handlebar

    CHAS HANDLEBAR HANDLEBAR 23 N.m (2.3 kgf.m, 17 ft.lb) 4 N.m (0.4 kgf.m, 3.0 ft.lb) 4 N.m (0.4 kgf.m, 3.0 ft.lb) Order Job/Part Remarks Qt’y Removing the handlebar Remove the parts in the order listed Rearview mirror (left and right) Plastic clamp Front brake light switch Disconnect...
  • Page 164 CHAS HANDLEBAR 23 N.m (2.3 kgf.m, 17 ft.lb) 4 N.m (0.4 kgf.m, 3.0 ft.lb) 4 N.m (0.4 kgf.m, 3.0 ft.lb) Order Job/Part Remarks Qt’y Throttle grip Disconnect Refer to “INSTALLING Clutch switch THE HANDLEBAR” Clutch lever holder Clutch lever Left handlebar switch Handlebar grip Refer to “REMOVING THE HANDLEBAR”...

  • Page 165: Removing The Handlebar

    CHAS HANDLEBAR REMOVING THE HANDLEBAR 1. Stand the vehicle on a level surface. V V V V V WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: • front brake light switch •...
  • Page 166 CHAS HANDLEBAR 2. Install: • handlebar 1 • handlebar upper holders 2 Handlebar upper holders 23 N.m (2.3 kgf.m, 17 ft.lb) CAUTION: • First, tighten the bolts on the front side of the handlebar upper holder, and then the rear side bolts. •...
  • Page 167 CHAS HANDLEBAR 4. Install: • left handlebar switch 1 NOTE: Align the projection a on the left handlebar switch with the hole b in the handlebar. 5. Install: • clutch lever • clutch lever holder 1 Lever holder bolt 4 N.m (0.4 kgf.m, 3.0 ft.lb) NOTE: Align the contact surfaces of the clutch lever holder with the punction mark a in the handlebar.
  • Page 168 CHAS HANDLEBAR 8. Install: • brake master cylinder • brake master cylinder holder Refer to “REAR AND FRONT BRAKES”. 9. Adjust: • clutch cable free play Refer to “ADJUSTING THE CLUTCH CABLE FREE PLAY” in chapter 3. Clutch cable free play (on the clutch lever end) 10.0 ~ 15.0 mm (0.4 ~ 0.6 in) 10.

  • Page 169: Steering Head

    CHAS STEERING HEAD STEERING HEAD 110 N.m (11.0 kgf.m, 81 ft.lb) 52 N.m (5.2 kgf.m, 38.4 ft.lb) 18 N.m (1.8 kgf.m, 13.3 ft.lb) Order Job/Part Remarks Qt’y Removing the lower bracket Remove the parts in the order listed Front wheel Refer to “FRONT BRAKE DISC AND WHEEL”...
  • Page 170 CHAS STEERING HEAD 110 N.m (11.0 kgf.m, 81 ft.lb) 52 N.m (5.2 kgf.m, 38.4 ft.lb) 18 N.m (1.8 kgf.m, 13.3 ft.lb) Order Job/Part Remarks Qt’y Lower ring nut Refer to “REMOVING THE Lower bracket LOWER BRACKET” and “INSTALLING THE STEERING Bearing cover HEAD”...

  • Page 171: Removing The Lower Bracket

    CHAS STEERING HEAD REMOVING THE LOWER BRACKET 1. Stand the vehicle on a level surface. V V V V V WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: • upper ring nut 1 •...

  • Page 172: Installing The Steering Head

    CHAS STEERING HEAD 3. Replace: • bearing cover • upper bearing • lower bearing a. With a long rod 1 and a hammer, remove the bearing races from the steering head. b. Remove the lower bracket bearing race with a floor chisel 2 and a hammer.
  • Page 173 CHAS STEERING HEAD 3. Install: • upper bracket • steering head nut NOTE: Temporarily tighten the steering rod nut. 4. Install: • front fork legs Refer to “INSTALLING THE FRONT FORK LEGS”. NOTE: Temporarily tighten the lower bracket. 5. Tighten: •...

  • Page 174: Rear Shock Absorber Assembly

    CHAS REAR SHOCK ABSORBER ASSEMBLY REAR SHOCK ABSORBER ASSEMBLY 58 N.m (5.8 kgf.m, 42.8 ft.lb) 58 N.m (5.8 kgf.m, 42.8 ft.lb) 58 N.m (5.8 kgf.m, 42.8 ft.lb) Order Job/Part Qt’y Remarks Removing the rear shock absorber assembly Remove the parts in the order listed Seat / rear side covers (left and right) / tail Refer to “COWLING AND SIDE Rear fender / air filter case...
  • Page 175 CHAS REAR SHOCK ABSORBER ASSEMBLY 58 N.m (5.8 kgf.m, 42.8 ft.lb) 58 N.m (5.8 kgf.m, 42.8 ft.lb) 58 N.m (5.8 kgf.m, 42.8 ft.lb) Order Job/Part Remarks Qt’y Self-locking nut / washer / bolt 1/1/1 Refer to “REMOVING THE Relay arm REAR SHOCK ABSORBER Self-locking nut / washer / bolt 1/1/1...

  • Page 176: Handling The Rear Shock Absorber

    CHAS REAR SHOCK ABSORBER ASSEMBLY HANDLING THE REAR SHOCK ABSORBER V V V V V WARNING This rear shock absorber contain highly compressed nitrogen gas. Before handling the rear shock absorber, read and make sure you understand the following information. The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling of the rear shock...

  • Page 177: Removing The Rear Shock Absorber Assembly

    CHAS REAR SHOCK ABSORBER ASSEMBLY REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1. Stand the vehicle on a level surface. V V V V V 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 178: Checking The Rear Shock Absorber Assembly

    CHAS REAR SHOCK ABSORBER ASSEMBLY CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 1. Check: • rear shock absorber rod Bends/Damage --> Replace the rear shock absorber assembly. • rear shock assembly Oil leakage --> Replace the rear shock absorber assembly. • spring Damage/Wear -->...

  • Page 179: Installing The Rear Shock Absorber Assembly

    CHAS REAR SHOCK ABSORBER ASSEMBLY INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1. Lubricate: • bushings • bolt Recommended lubricant Lithium-soap-based grease 2. Install: • rear shock absorber assembly NOTE: When installing the rear shock absorber assembly, lower the rear swingarm. 3.

  • Page 180: Swingarm And Drive Chain

    CHAS SWINGARM AND DRIVE CHAIN SWINGARM AND DRIVE CHAIN 58 N.m (5.8 kgf.m, 42.8 ft.lb) 110 N.m (11.0 kgf.m, 81 ft.lb) 58 N.m (5.8 kgf.m, 42.8 ft.lb) Order Job/Part Remarks Qt’y Removing the swingarm and drive chain Remove the parts in the order listed Rear Wheel Refer to “REAR WHEEL, BRAKE Shock absorber...
  • Page 181 CHAS SWINGARM AND DRIVE CHAIN 58 N.m (5.8 kgf.m, 42.8 ft.lb) 110 N.m (11.0 kgf.m, 81 ft.lb) 58 N.m (5.8 kgf.m, 42.8 ft.lb) Order Job/Part Remarks Qt’y Bolt (relay arm - connecting arm) Swingarm shaft Swingarm Cover Washer Refer to “INSTALLING THE Bearing REAR SWINGARM”.

  • Page 182: Removing The Swingarm

    CHAS SWINGARM AND DRIVE CHAIN REMOVING THE SWINGARM 1. Stand the vehicle on a level surface. V V V V V 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 183: Checking The Swingarm

    CHAS SWINGARM AND DRIVE CHAIN CHECKING THE SWINGARM 1. Check: • swingarm Bends/Cracks/Damage --> Replace. 2. Check: • Swingarm shaft Roll the rear swingarm shaft on a level surface. Bends --> Replace. V V V V V WARNING Do not attempt to straighten a bent pivot shaft. 3.

  • Page 184: Removing The Sprocket

    CHAS SWINGARM AND DRIVE CHAIN REMOVING THE SPROCKET NOTE: Loosen the drive sprocket nut before removing the -2-3-4-5 rear wheel. 1. Remove: • bolt 1 • shift pedal pivot 2 2. Remove: • drive sprocket cover 3. Lift the lock washer tab a 4.
  • Page 185 CHAS SWINGARM AND DRIVE CHAIN 15-links segment limit (maximum) 191.5 mm (7.54 in) NOTE: • While measuring the 15-links segment, push down on the drive chain to increase its tension. • Perform this measurement at two or three different places. 2.
  • Page 186 CHAS SWINGARM AND DRIVE CHAIN 4. Check: • O-rings 1 Damage --> Replace the drive chain. • drive chain rollers 2 Damage/Wear --> Replace the drive chain. • drive chain side plates 3 Cracks --> Replace the drive chain and make sure the battery breather hose is properly routed away from the drive chain and below the rear swingarm.

  • Page 187: Installing The Swingarm

    CHAS SWINGARM AND DRIVE CHAIN INSTALLING THE SWINGARM 1. Lubricate: • spacers • dust seals • swingarm shaft Recommended lubricant lithium-soap-based grease 2. Install: • bushing 1 • bearings 2 • washers 3 3. Install: • swingarm • swingarm shaft •...
  • Page 188 CHAS SWINGARM AND DRIVE CHAIN 5. Install: • drive sprocket 1 • lock washer 2 • drive sprocket nut 3 Drive sprocket nut 110 N.m (11.0 kgf.m, 81.0 ft.lb) NOTE: Install the drive sprocket 1 and the nut 3 as •...
  • Page 189 CHAPTER 5 ENGINE REMOVING THE ENGINE ................ 5-1 MUFFLER AND EXHAUST PIPE ............5-1 LEADS, CABLES, HOSES AND IGNITION COIL ......5-2 ENGINE ....................5-4 INSTALLING THE ENGINE ..............5-6 CYLINDER HEAD ..................5-7 REMOVING THE CYLINDER HEAD ..........5-9 CHECKING THE CYLINDER HEAD ..........
  • Page 190 OIL PUMP AND BALANCER GEAR ............. 5-48 OIL PUMP ..................5-50 CHECKING THE OIL PUMP ............5-51 CHECKING THE OIL DELIVERY HOSES AND PIPES ....5-52 ASSEMBLING THE OIL PUMP ............5-52 INSTALLING THE OIL PUMP ............5-53 REMOVING THE BALANCER GEAR ..........5-54 CHECKING THE BALANCER GEAR ..........

  • Page 191: Eng

    REMOVING THE ENGINE ENGINE MUFFLER AND EXHAUST PIPE 40 N.m (4.0 kgf.m, 30ft.lb) 20 N.m (2.0 kgf.m, 15 ft.lb) 17.5 N.m (1.7kgf.m, 12.9 ft.lb) Order Job/Part Remarks Qt’y Removing the muffler and the exhaust pipes Remove the parts in the order listed Muffler Exhaust pipe Gasket...

  • Page 192: Leads, Cables, Hoses And Ignition Coil

    REMOVING THE ENGINE LEADS, CABLES, HOSES AND IGNITION COIL 10 N.m (1.0 kgf.m, 7.2 ft.lb) 110 N.m (11.0 kgf.m, 81 ft.lb) 30 N.m (3.0 kgf.m, 22 ft.lb) 10 N.m (1.0 kgf.m, 7.2 ft.lb) Order Job/Part Remarks Qt’y Removing the leads, cables, hoses Remove the parts in the order listed and ignition coil Radiator / engine oil...
  • Page 193 REMOVING THE ENGINE 10 N.m (1.0 kgf.m, 7.2 ft.lb) 110 N.m (11.0 kgf.m, 81 ft.lb) 30 N.m (3.0 kgf.m, 22 ft.lb) 10 N.m (1.0 kgf.m, 7.2 ft.lb) Order Job/Part Remarks Qt’y Drive chain Engine breather hose Disconnect Starter motor cable Clutch cable lock Clutch cable Main wire harness connectors...

  • Page 194: Engine

    REMOVING THE ENGINE ENGINE 65 N.m (6.5 kgf.m, 48 ft.lb) 65 N.m (6.5 kgf.m, 48 ft.lb) 30 N.m (3.0 kgf.m, 22 ft.lb) 30 N.m (3.0 kgf.m, 22 ft.lb) 65 N.m (6.5 kgf.m, 48 ft.lb) Order Job/Part Remarks Qt’y Removing the engine Remove the parts in the order listed NOTE: Place a suitable stand under the...

  • Page 195: Installing The Engine

    REMOVING THE ENGINE 65 N.m (6.5 kgf.m, 48 ft.lb) 65 N.m (6.5 kgf.m, 48 ft.lb) 30 N.m (3.0 kgf.m, 22 ft.lb) 30 N.m (3.0 kgf.m, 22 ft.lb) 65 N.m (6.5 kgf.m, 48 ft.lb) Order Job/Part Remarks Qt’y Bolt / nut (lower front) NOTE: Bolts (front brackets) Refer to...
  • Page 196 REMOVING THE ENGINE INSTALLING THE ENGINE 1. Install: • front / upper brackets 1 • bolts (front brackets) 2 • bolts / nut (upper bracket) 3 • bolt / nut (upper front) 4 • bolt / nut (lower front) 5 •...

  • Page 197: Cylinder Head

    CYLINDER HEAD CYLINDER HEAD 60 N.m (6.0 kgf.m, 44 ft.lb) 10 N.m (1.0 kgf.m, 7.2 ft.lb) 7,5 N.m (0.75 kgf.m, 5.5 ft.lb) 10 N.m (1.0 kgf.m, 7.2 ft.lb) 18 N.m (1.8 kgf.m, 13 ft.lb) 10 N.m (1.0 kgf.m, 7.2 ft.lb) 22 N.m (2.2 kgf.m, 16 ft.lb)
  • Page 198 CYLINDER HEAD 60 N.m (6.0 kgf.m, 44 ft.lb) 10 N.m (1.0 kgf.m, 7.2 ft.lb) 7,5 N.m (0.75 kgf.m, 5.5 ft.lb) 10 N.m (1.0 kgf.m, 7.2 ft.lb) 18 N.m (1.8 kgf.m, 13 ft.lb) 10 N.m (1.0 kgf.m, 7.2 ft.lb) 22 N.m (2.2 kgf.m, 16 ft.lb) 20 N.m...

  • Page 199: Removing The Cylinder Head

    HEAD CYLINDER REMOVING THE CYLINDER HEAD 1. Align: • “I” mark a on the AC magneto (with the stationary pointer b on the AC magneto cover) a. Turn the crankshaft counterclockwise. b. When piston is at TDC on the compression stroke, align the “I”...

  • Page 200: Checking The Cylinder Head

    CYLINDER HEAD CHECKING THE CYLINDER HEAD 1. Dispose: • combustion chambers carbon deposits (with a round scraper) NOTE: Do not use a sharpen tool, to prevent damage or scratches in: • spark plug threads • valve seats 2. Check: • cylinder head Damage/Scratches -->...

  • Page 201: Checking The Tappet Covers And Camshaft

    CYLINDER HEAD CHECKING THE TAPPET COVERS AND CAMSHAFT SPROCKET COVER 1. Check: • valve covers • timing sprocket cap • O-rings Damage/Wear --> Replace. CHECKING THE TIMING CHAIN TENSIONER 1. Check: • timing chain tensioner Cracks/Damage --> Replace. 2. Check: •...

  • Page 202: Installing The Cylinder Head

    CYLINDER HEAD INSTALLING THE CYLINDER HEAD 1. Install: • dowel pins • cylinder head gasket 2. Install: • cylinder head • washers • cylinder head bolts NOTE: • Lubricate the threads and the mating surface of the cylinder head bolts with engine oil. •...
  • Page 203 CYLINDER HEAD 4. Install: • camshaft sprocket a. Turn the crankshaft counterclockwise. b. Align the “I” mark a on the AC magneto with the stationary pointer b on the AC magneto cover. c. Remove the wire which blocks the cam chain downfall.
  • Page 204 CYLINDER HEAD Bolts (cam chain puller): 10 N.m (1.0 kgf.m, 7.2 ft.lb) Cap bolt (cam chain puller): 7.5 N.m (0.75 kgf.m, 5.5 ft.lb) 6. Turn: • crankshaft (several times counterclockwise) 7. Check: • “I” mark a NOTE: Check if the “I” mark in the AC magneto is aligned with the stationary pointer b on the AC magneto cover.
  • Page 205 CYLINDER HEAD 8. Tighten: • timing sprocket bolt 1 Timing sprocket bolt 60 N.m (6.0 kgf.m, 44 ft.lb) 9. Measure: • valve clearance Out of specification --> Adjust. Refer to “ADJUSTING THE VALVE CLEARANCE” in chapter 3. 5-15...

  • Page 206: Rocker Arms And Camshaft

    ROCKER ARMS AND CAMSHAFT ROCKER ARMS AND CAMSHAFT 14 N.m (1.4 kgf.m, 10.3 ft.lb) 10 N.m (1.0 kgf.m, 7.2 ft.lb) Order Job/Part Qt’y Remarks Removing the rocker arms and camshaft Remove the parts in the order listed Cylinder head Refer to “CYLINDER HEAD” Bearing holder Refer to “REMOVING THE...

  • Page 207: Removing The Rocker Arms And Camshaft

    ROCKER ARMS AND CAMSHAFT REMOVING THE ROCKER ARMS AND CAMSHAFT 1. Loosen: • Locknuts 1 • clearance adjusting bolts 2 2. Remove: • camshaft holder 3 3. Remove: • intake rocker shaft • exhaust rocker shaft • intake rocker arm •...

  • Page 208: Checking The Rocker Arms And Camshafts

    ROCKER ARMS AND CAMSHAFT 2. Measure: • camshaft came dimensions a and b Out of specification --> Replace the camshaft Camshaft came dimensions Intake a a a a a 36.890 ~36.990mm (1.452 ~1.456 in) b b b b b 30.111 ~ 30.211mm (1.185 ~ 1.189 in) Exhaust a a a a a 36.891 ~ 36.991mm...

  • Page 209: Installing The Rocker Arms And Camshafts

    ROCKER ARMS AND CAMSHAFT 3. Measure: • rocker arm inner diameter a Out of specification --> Replace. Rocker arm inner diameter 12.000 ~ 12.018mm (0.4724 ~ 0.4731 in) <limit>: 12.036mm (0.4739 in) 4. Measure: • rocker arm outer diameter a Out of specification -->...
  • Page 210 ROCKER ARMS AND CAMSHAFT 4. Install: • camshaft 1 • bearing 2 NOTE: • Place the guide pin hole upward. • Use a bolt with 10mm thread to install the camshaft. 5. Apply: • molybdenum disulfide oil Recommended lubricant Molybdenum disulfide oil 6.

  • Page 211: Valves And Valve Springs

    VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS Order Job/Part Remarks Qt’y Removing the valves and valve springs Remove the parts in the order listed Cylinder head Refer to “CYLINDER HEAD” Rocker arms / rocker shafts / camshaft Refer to “ROCKER ARMS AND CAMSHAFT”...
  • Page 212 VALVES AND VALVE SPRINGS Order Job/Part Remarks Qt’y Exhaust valve Valve stem seal Refer to“REMOVING THE Valve spring seat VALVES” and “INSTALLING Valve guide THE VALVES” 5-22...

  • Page 213: Removing The Valves

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

  • Page 214: Checking The Valves And Valve Guides

    VALVES AND VALVE SPRINGS 3. Remove: • valve spring retainer 1 • outer valve spring 2 • inner valve spring 3 • valve stem seal 4 • valve spring seat 5 • valve 6 NOTE: Identify the position of each part very carefully so that it can be reinstalled in its original place.
  • Page 215 VALVES AND VALVE SPRINGS 2. Replace: • valve guide NOTE: To ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100 C in an oven. a. Remove the valve guide with the valve guide remover 1.

  • Page 216: Checking The Valve Seat

    VALVES AND VALVE SPRINGS 6. Measure: • stem runout Out of specification --> Replace the valve. NOTE: • When installing a new valve, always replace the valve guide. • If the valve is removed or replaced, replace the valve stem oil seal. Runout limit 0.030 mm (0.0012 in) CHECKING THE VALVE SEAT...
  • Page 217 VALVES AND VALVE SPRINGS 4. Lap: • valve face • valve seat NOTE: After replacing the cylinder head or replacing the valve and valve guide, the valve seat and valve face should be lapped. a. Apply a coarse lapping compound a to the valve face.

  • Page 218: Checking The Valve Springs

    VALVES AND VALVE SPRINGS CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs. 1. Measure: • spring free length a Out of specification --> Replace. Spring free length Intake (inside) 36.17mm (1.424 in) <limit>: 34.47mm (1.357 in) Exhaust (inside) 36.17mm (1.424 in) <limit>: 34.47mm (1.357 in)

  • Page 219: Installing The Valves

    VALVES AND VALVE SPRINGS 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 (with the recommended lubricant) Recomended lubricant Molybdenum disulfide oil 3.
  • Page 220 CYLINDER AND PISTON CYLINDER AND PISTON 10 N.m (1.0 kgf.m, 7.2 ft.lb) 17 N.m (1.7 kgf.m, 12.5 in) Order Job/Part Remarks Qt’y Removing the cylinder and piston Remove the parts in the order listed Oil delivery pipe Refer to “INSTALLING THE Cylinder PISTON AND CYLINDER”...

  • Page 221: Cylinder And Piston

    CYLINDER AND PISTON REMOVING THE CYLINDER AND PISTON 1. Remove: • piston pin circlips 1 • piston pin 2 • piston 3 CAUTION: Do not use a hammer to drive the piston pin out. NOTE: • Before removing the piston pin clip, cover the crankcase opening with a clean rag to prevent the piston pin clip from falling into the crankcase.
  • Page 222 CYLINDER AND PISTON 2. Measure: • piston-to-cylinder clearance a. Measure the cylinder diameter “C” with the cylinder bore gauge. NOTE: Measure cylinder bore “C” by taking side-to-side and front-to-back measurements of the cylinder. Then, find the average of the measurements. 74.000 ~74.016mm Cylinder bore “C”...

  • Page 223: Checking The Piston Rings

    CYLINDER AND PISTON CHECKING THE PISTON RINGS 1. Measure: • piston ring side clearance Out of specification --> Replace the piston and piston rings as a set. NOTE: Before measuring the piston ring side clearance, eliminate any carbon deposits from the piston ring grooves and piston rings.

  • Page 224: Checking The Piston Pin

    CYLINDER AND PISTON CHECKING THE PISTON PIN 1. Check: • piston pin Blue discoloration/grooves --> Replace the pin and check the lubrication system. 2. Measure: • piston pin outside diameter a Out of specification --> Replace. Piston pin outside diameter 16.991 ~ 17.000 mm (0.6689 ~ 0.6692 in) <Limit>: 16.970 mm (0.6681 in)

  • Page 225: Installing The Cylinder And Piston

    CYLINDER AND PISTON INSTALLING THE CYLINDER AND PISTON 1. Install: • top ring 1 • 2nd ring 2 • oil ring expander 3 • lower oil ring rail 4 • upper oil ring rail 5 NOTE: Be sure to install the piston rings so that the manufacturer’s marks or numbers face up.
  • Page 226 CYLINDER AND PISTON • piston ring end gaps a top ring b Oil ring upper trail c Oil ring expander d Oil ring lower rail e 2nd ring f 20mm A Exhaust side 6. Install: • cylinder 1 • timing chain guide (exhaust) NOTE: •...

  • Page 227: Clutch

    CLUTCH CLUTCH CLUTCH COVER 20 N.m (2.0 kgf.m, 14 ft.lb) 10 N.m (1.0 kgf.m, 7.2 ft.lb) 10 N.m (1.0 kgf.m, 7.2 ft.lb) Order Job/Part Remarks Qt’y Removing the clutch Remove the parts in the order listed Engine oil Refer to “CHANGING THE ENGINE OIL”...

  • Page 228: Pull Lever Shaft

    CLUTCH PULL LEVER SHAFT 12 N.m (1.2 kgf.m, 8.85 ft.lb) Order Job/Part Remarks Qt’y Removing the pull lever shaft Remove the parts in the order listed Clutch pedal Refer to “REMOVING THE ENGINE” Starter worm gear Refer to “STARTER MOTOR” Neutral switch wire Engine left cover Clutch cable...
  • Page 229 CLUTCH CLUTCH 75 N.m (7.5 kgf.m, 5.5 ft.lb) 8 N.m (0.8 kgf.m, 5.9 ft.lb) Order Job/Part Remarks Qt’y Removing the clutch Remove the parts in the order listed Clutch spring / bolt Pressure plate Primary gear nut Friction plates Clutch plate Cusion plate Refer to “INSTALLING THE Seat plate...
  • Page 230 CLUTCH 75 N.m (7.5 kgf.m, 5.5 ft.lb) 8 N.m (0.8 kgf.m, 5.9 ft.lb) Order Job/Part Remarks Qt’y Thrust washer Primary drive gear Refer to “REMOVING THE Locknut CLUTCH” and “INSTALLING THE Adjusting bolt CLUTCH” Ball / push rod For installation, reverse the removal procedure 5-40...

  • Page 231: Removing The Clutch

    CLUTCH REMOVING THE CLUTCH 1. Remove: • bolts 1 NOTE: Loosen each bolt of a turn in crisscross pattern. After all the bolts are fully loosen, remove them. 2. Loosen: • primary gear nut 3 NOTE: • Place a kinked aluminum plate a between the primary gear tooth 2 and the clutch housing teeth 1.

  • Page 232: Checking The Primary Drive Gear

    CLUTCH CHECKING THE PRIMARY DRIVE GEAR 1. Check: • primary gear nut 1 • lock washer 2 • washer 3 • primary drive gear 4 Wear/Cracks --> Replace. CHECKING THE FRICTION PLATES The following procedure applies to all of the clutch plates.

  • Page 233: Checking The Clutch Springs

    CLUTCH CHECKING THE CLUTCH SPRINGS The following procedure applies to all of the clutch springs. 1. Check: • clutch spring Damage --> Replace the springs as a set. 2. Measure: • spring free length a Out of specification --> Replace the clutch springs as a set.

  • Page 234: Checking The Pressure Plate

    CLUTCH CHECKING THE PRESSURE PLATE 1. Check: • pressure plate Cracks/Damage --> Replace. CHECKING THE PUSH LEVER SHAFT AND PUSH ROD 1. Check: • pull lever shaft cames 1 Damage/Wear --> Replace. 2. Check: • pull rod 2 • steel ball 3 Damage/Wear -->...
  • Page 235 CLUTCH 2. Tighten: • clutch boss nut 1 NOTE: While holding the clutch boss with the universal clutch holder 2, tighten the clutch boss nut 1. Universal clutch holder 90890-04086 Clutch boss nut 75 N.m (7.5 kgf.m, 5.5 ft.lb) 3. Tighten: •...
  • Page 236 CLUTCH 7. Install: • adjusting bolt nut 1 • pressure plate 2 • adjusting bolt 3 • washer 4 • nut 5 8. Install: • clutch springs 1 bolts 1 • Bolts (clutch spring) 8 N.m (0.8 kgf.m, 5.9 ft.lb) NOTE: Tighten the spring bolts in stages and in a crisscross patern.
  • Page 237 CLUTCH 11. Install: • dowel pins • cover gasket • crankcase cover (RS) Crankcase cover bolts 10 N.m (1.0 kgf.m, 7.2 ft.lb) 5-47...

  • Page 238: Oil Pump And Balancer Gear

    OIL PUMP AND BALANCER GEAR OIL PUMP AND BALANCER GEAR 7 N.m (0.7 kgf.m, 5.1 ft.lb) 55 N.m (5.5 kgf.m, 40.5 ft.lb) Order Job/Part Remarks Qt’y Removing the oil pump and the balancer gear Remove the parts in the order listed Engine oil Drain Clutch cover...
  • Page 239 OIL PUMP AND BALANCER GEAR 7 N.m (0.7 kgf.m, 5.1 ft.lb) 55 N.m (5.5 kgf.m, 40.5 ft.lb) Order Job/Part Remarks Qt’y Circlip Oil pump gear Oil pump Oil pump gasket Refer to “ASSEMBLING THE Woodruff key OIL PUMP” Drive gear Strainer (oil sub-filter) For installation, reverse the removal procedure...

  • Page 240: Oil Pump

    OIL PUMP 7 N.m (0.7 kgf.m, 5.1 ft.lb) Order Job/Part Remarks Qt’y Disassembling the oil pump Remove the parts in the order listed Oil pump cover Dowel pin Outer rotor Inner rotor Lock pin Shaft Oil pump housing For assembly, reverse the removal procedure 5-50...

  • Page 241: Checking The Oil Pump

    OIL PUMP AND BALANCER GEAR CHECKING THE OIL PUMP 1. Check: • oil pump gear Cracks/Damage/Wear --> Replace the damaged part(s). 2. Measure: • clearance a between the outer rotor and the inner rotor • clearance b between the outer rotor and the oil pump crankcase •...

  • Page 242: Checking The Oil Delivery Hoses And Pipes

    OIL PUMP CHECKING THE OIL DELIVERY HOSES AND PIPES The following procedure applies to all of the oil delivery hoses and pipe. 1. Check: • oil delivery pipe • oil delivery hose Damage --> Replace. Clogged --> Wash and blow out with compressed air.

  • Page 243: Installing The Oil Pump

    OIL PUMP INSTALLING THE OIL PUMP 1. Install: • oil pump gasket • oil pump Oil pump crankcase bolt 7 N.m (0.7 kgf.m, 5.1 ft.lb) • oil pump gear • circlip CAUTION: After tighten the bolts, make sure the pump oil turns smoothly.

  • Page 244: Removing The Balancer Gear

    BALANCER GEAR REMOVING THE BALANCER GEAR 1. Straighten the lock washer tab 2. Loosen: • balancer gear nut 3 • balancer gear NOTE: • Place a kinked aluminum plate a between the driven gear teeth 1 and the balancer gear teeth •...

  • Page 245: Assembling The Balancer Gear

    BALANCER GEAR ASSEMBLING THE BALANCER GEAR 1. Install: • spacer 1 • woodruf key 2 • absorber plate 3 • balancer gear 4 (with the timing point facing up) • boss 5 • compression springs and pins 6 NOTE: Be sure to carry out the balancer gear assembly properly.

  • Page 246: Oil Cooler

    OIL COOLER OIL COOLER 10 N.m (1.0 kgf.m, 7.2 ft.lb) 10 N.m (1.0 kgf.m, 7.2 ft.lb) Order Job/Part Qt’y Remarks Removing the oil cooler Remove the parts in the order listed. Seat Refer to “COWLING AND SIDE COVERS” in chapter 3. Fuel tank side covers (left and right)/ Refer to “FUEL TANK”...
  • Page 247 OIL COOLER 10 N.m (1.0 kgf.m, 7.2 ft.lb) 10 N.m (1.0 kgf.m, 7.2 ft.lb) Order Job/Part Qt’y Remarks O-rings Guide pins Radiator Oil hose 1 Oil hose 2 For installation, reverse the removal procedure. 5-57...

  • Page 248: Checking The Oil Cooler

    OIL COOLER CHECKING THE OIL COOLER 1. Remove: • spacers 1 • grommets 2 2. Check: • grommets Damage/Wear --> Replace. 3. Remove: • hose upper bolts 1 • oil hoses 1 2 • oil hoses 2 3 • o-rings 4 4.

  • Page 249: Assembling The Oil Cooler

    OIL COOLER ASSEMBLING THE OIL COOLER 1. Install: • o-rings 1 • oil hose 1 2 • oil hose 2 3 • upper bolts 4 Upper bolts 10 N.m (1.0 kgf.m, 7.2 ft.lb) Recommended lubricant Lithium-soap-based grease NOTE: • Lubricate the O-rings with a thin coat of lithium- soap-based grease.

  • Page 250: Shift Shaft

    SHIFT SHAFT SHIFT SHAFT SHIFT SHAFT AND STOPPER LEVER 10 N.m (1.0 kgf.m, 7.2 ft.lb) Job/Part Remarks Order Qt’y Removing the shift shaft and stopper lever Remove the parts in the order listed Engine oil Drain Clutch cover Refer to “CLUTCH COVER” Clutch pedal pivot Shift shaft Refer to “DISASSEMBLING THE...

  • Page 251: Disassembling The Shift Shaft

    SHIFT SHAFT DISASSEMBLING THE SHIFT SHAFT 1. Remove: • shift shaft bolt 1 • stopper lever 2 • stopper lever spring 3 • CHECKING THE SHIFT SHAFT 1. Remove: • shift shaft 1 • shift shaft pawl 2 Runout/Wear --> Replace. CHECKING THE STOPPER LEVER 1.
  • Page 252 SHIFT SHAFT 2. Check: driven pawl 1 • shift drum segment 2 • Difficult meshing --> Adjust. NOTE: The measurements a and b must be identical. Stopper lever bolt 10 N.m (1.0 kgf.m, 7.2 ft.lb) 3. Install: • clutch pedal pivot Refer to “ADJUSTING THE CLUTCH PEDAL”...

  • Page 253: Starter Clutch And Ac Magneto

    STARTER CLUTCH AND AC MAGNETO STARTER CLUTCH AND AC MAGNETO 10 N.m (1.0 kgf.m, 7.2 ft.lb) 7 N.m (0.7 kgf.m, 5.1 ft.lb) 60 N.m (6.0 kgf.m, 44 ft.lb) 10 N.m (1.0 kgf.m, 7.2 ft.lb) 10 N.m (1.0 kgf.m, 7.2 ft.lb) Order Job/Part Remarks...
  • Page 254 STARTER CLUTCH AND AC MAGNETO 10 N.m (1.0 kgf.m, 7.2 ft.lb) 7 N.m (0.7 kgf.m, 5.1 ft.lb) 60 N.m (6.0 kgf.m, 44 ft.lb) 10 N.m (1.0 kgf.m, 7.2 ft.lb) 10 N.m (1.0 kgf.m, 7.2 ft.lb) Order Job/Part Remarks Qt’y Starter idle gear 2/ shaft AC magneto Woodruff key Starter wheel gear...

  • Page 255: Removing The Ac Magneto

    STARTER CLUTCH AND AC MAGNETO REMOVING THE AC MAGNETO 1. Remove: • AC magneto bolt • washer • AC magneto NOTA: • While holding the AC magneto 1 with the sheave holder 2, loosen the rotor bolt. • Do not allow the sheave holder to touch the projection a on the AC magneto.

  • Page 256: Checking The Starter Clutch (One Way)

    STARTER CLUTCH AND AC MAGNETO CHECKING THE STARTER CLUTCH (ONE WAY) 1. Check: • starter clutch rollers 1 Damage/Wear --> Replace. 2. Check: • starter idle gear 1 1 • starter idle gear 2 2 • starter wheel gear 3 Burrs/Wear -->...
  • Page 257 STARTER CLUTCH AND AC MAGNETO 2. Install: • woodruff key 1 • AC magneto 2 • washer 3 • rotor bolt 4 NOTE: • Clean the crankshaft and AC magneto bevel portion. • When installing the AC magneto, make sure the woodruff key is properly installed at the crankshaft groove.
  • Page 258 STARTER CLUTCH AND AC MAGNETO 5. Install: • gasket • crankcase cover (left) Crankcase cover bolt 10 N.m (1.0 kgf.m, 7.2 ft.lb) NOTE: Tighten the crankcase cover bolts in stages and in a crisscross pattern. 6. Install: • neutral switch wire NOTE: Place the neutral switch terminal so that the wire is fitted, refer to “CABLE ROUTING”...

  • Page 259: Crankshaft And Crankcases

    CRANKSHAFT AND CRANKCASES CRANKSHAFT AND CRANKCASES 10 N.m (1.0 kgf.m, 7.2 ft.lb) 8 N.m (0.8 kgf.m, 5.9 ft.lb) 10 N.m (1.0 kgf.m, 7.2 ft.lb) 10 N.m (1.0 kgf.m, 7.2 ft.lb) Order Job/Part Remarks Qt’y Separating the crankcases and removing the Remove the parts in the order listed crankshaft Engine oil...
  • Page 260 CRANKSHAFT AND CRANKCASES 10 N.m (1.0 kgf.m, 7.2 ft.lb) 8 N.m (0.8 kgf.m, 5.9 ft.lb) 10 N.m (1.0 kgf.m, 7.2 ft.lb) 10 N.m (1.0 kgf.m, 7.2 ft.lb) Order Job/Part Remarks Qt’y Timing chain guide (intake side) Timing chain Crankshaft sprocket Crankcase (right) Dowel pin Balancer...

  • Page 261: Disassembling The Crankcases

    CRANKSHAFT AND CRANKCASES DISASSEMBLING THE CRANKCASES 1. Remove: • timing chain guide 1 • timing chain 2 • crankshaft sprocket 3 2. Remove: • neutral switch wire 1 • bolt with washer 2, 3 and 4 • engine bolts 5 to C NOTE: •...

  • Page 262: Removing The Balancer And Crankshaft Assembly

    CRANKSHAFT AND CRANKCASES REMOVING THE BALANCER AND CRANKSHAFT ASSEMBLY 1. Remove: • balancer • crankshaft assembly 1 NOTE: • Remove the crankshaft along with the crankshaft extractor 2. • Tighten the crankhaft extractor bolts until the end. • Make sure the extractor shaft is aligned with the crankshaft.

  • Page 263: Checking The Crankcases

    CRANKSHAFT AND CRANKCASES 5. Check: • bearing Damage/Excessive noise Replace. --> 6. Check: • crankshaft oil galleries Obstruction --> Blow out with compressed air. CHECKING THE CRANKCASES 1. Check: • crankcase (right) Runout/Cracks --> Replace. • oil routing galleries Obstruction --> Blow out with compressed air. 2.

  • Page 264: Assembling The Crankshaft

    CRANKSHAFT AND CRANKCASES 3. Check: • timing chain guide (intake side) Damage/Wear Replace. --> ASSEMBLING THE CRANKSHAFT 1. Install: • compression spring 1 • plunger seal 2 • lock pin 3 2. Check: • plunger seal operation INSTALLING THE CRANKSHAFT ASSEMBLY 1.
  • Page 265 CRANKSHAFT AND CRANKCASES CRANKCASE (RIGHT SIDE) 1. Apply: • bond 1 (at the crankcase closing surfaces). Bond: Yamaha Bond no. 1215 90890-85505 NOTE: Do not allow the bond to get into contact with the oil galleries. 2. Install: • dowel pines 2 3.
  • Page 266 CRANKSHAFT AND CRANKCASES 6. Apply • engine oil 4T (to the bearings and oil galleries) 7. Check: • transmission and crankshaft operation Defective operation --> Repair. 8. Install: • neutral switch wire 9. Install: • crankshaft sprocket 1 • timing chain guide 2 •...
  • Page 267 TRANSMISSION TRANSMISSION Order Job/Part Remarks Qt’y Removing the transmission, shift drum, shift forks Remove the parts in the order listed Crankcases Separate Refer to “CRANKCASES” Shift fork shaft Shift drum assembly Shift fork 3 (R) Shift fork 2 (C) Shift fork 1 (L) Main axle assembly Drive axle assembly For installation, reverse the...

  • Page 268: Transmission

    TRANSMISSION MAIN AXLE / DRIVE AXLE Order Job/Part Remarks Qt’y Disassembling the main axle assembly and Remove the parts in the order listed the drive axle assembly Main axle and 1 pinion gear pinion gear Washer Circlip pinion gear pinion gear pinion gear Bearing Bearing...
  • Page 269 TRANSMISSION Order Job/Part Remarks Qt’y Washer / circlip wheel gear Spacer wheel gear Washer / circlip wheel gear wheel gear Washer / circlip Bearing Bearing lock For assembly, reverse the disassembly procedure 5-79...

  • Page 270: Removing The Transmission

    TRANSMISSION REMOVING THE TRANSMISSION 1. Remove: • shift fork shaft 1 • shift drum assembly 2 • shift fork 3 (R) 3 • shift fork 2 (C) • shift fork 1 (L) 4 NOTE: Move the gears to ease the forks removal. CHECKING SHIFT DRUM AND SHIFT FORKS 1.

  • Page 271: Checking The Transmission

    TRANSMISSION 4. Check: • shift fork shafts 1 Runout/Wear --> Replace. CAUTION: Do not attempt to align a bent shift fork shaft. CHECKING THE TRANSMISSION 1. Measure: • main axle alignment (use the centering device and a dial gauge 1). Out of specification -->...

  • Page 272: Installing The Transmission

    TRANSMISSION INSTALLING THE TRANSMISSION 1. Install: • 2nd pinion gear 1 NOTE: Press the 2nd pinion gear onto the main axle 2, as shown in the illustration. 2nd pinion press length 102.2 ~102.4 mm (4.02 ~ 4.03 in) 2. Install: •...
  • Page 273 CHAPTER 6 FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM ................6-1 ELECTRICAL CIRCUIT DIAGRAM ............... 6-2 ECU’S SELF-DIAGNOSTIC FUNCTION ............6-3 SELF-DIAGNOSTIC FUNCTION TABLE ............6-5 TROUBLESHOOTING METHOD ..............6-7 DIAGNOSTIC MODE ................6-8 TROUBLESHOOTING DETAILS ..............6-14 THROTTLE BODY ..................6-27 REMOVING THE FUEL HOSE ..............

  • Page 274: Fuel Injection System

    FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM C Engine temperature sensor 1 ECU (engine control unit) FID (fast idle solenoid) D Spark plug 2 Engine trouble warning Throttle body sensor E Fuel tank assembly light 9 Battery F Fuel pump 3 Lean angle sensor G Air induction system 0 Air filter case 4 Fuel delivery hose...

  • Page 275: Electrical Circuit Diagram

    FUEL INJECTION SYSTEM ELECTRICAL CIRCUIT DIAGRAM...

  • Page 276: Ecu's Self-Diagnostic Function

    FUEL INJECTION SYSTEM ECU’S SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the engine control system is operating normally. If this function detects a malfunction in the system, it immediately operates the engine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.
  • Page 277 FUEL INJECTION SYSTEM Engine trouble warning light indication and fuel injection system operation W arning light ECU operation Fuel injection operation Vehicle operation indication W arning provided when unable to Operation stopped Cannot be operated Flashing start engine Operated with substitute characteristics in Can or cannot be Malfunction...

  • Page 278: Self-Diagnostic Function Table

    FUEL INJECTION SYSTEM Checking the engine trouble warning light bulb The engine trouble warning light comes on for 3 seconds after main switch has been turned to “ON”. If the warning light does not come on under these conditions, the warning light bulb may be defective.
  • Page 279 FUEL INJECTION SYSTEM Able / Able / Fault Item Symptom Fail-safe action unable to unable code No. start to drive Intake air Intake air temperature temperature sensor sensor: open or short Able Able (open or short circuit) circuit detected No normal signal is sensor received from the O Able...

  • Page 280: Troubleshooting Method

    FUEL INJECTION SYSTEM TROUBLESHOOTING METHOD The engine operation is not normal but the The engine operation is not normal and the engine trouble warning light does not come engine trouble warning light comes on. 1. Check: 1. Check operation of following sensors and •...

  • Page 281: Diagnostic Mode

    FUEL INJECTION SYSTEM DIAGNOSTIC MODE It is possible to monitor the sensor output data or activate the actuators by connecting the F.I. diagnostic tool on the normal mode or in the diagnostic mode. F.I. diagnostic tool 90890-03182 Setting the normal mode 1.
  • Page 282 FUEL INJECTION SYSTEM Setting the diagnostic mode 1. Set the starter switch to OFF and the stop engine switch to ON. 2. Disconnect the connector of the self-diagnostic 1 and connect the diagnostic tool 2 as shown. V V V V V WARNING Disconnect the fuel pump connector to prevent fuse blowing.
  • Page 283 FUEL INJECTION SYSTEM Diagnostic code table Fault Diagnostic Symptom Probable cause of malfunction code No. code No. No normal signals are Open or short circuit in wiring harness. received from the Defective crankshaft position sensor. crankshaft position Malfunction in ACM rotor. ---- sensor.
  • Page 284 FUEL INJECTION SYSTEM Fault Probable cause of Diagnostic code Symptom malfunction code No. The amount of air-fuel ratio Open or short circuit in wiring feedback compensation is harness. maintained continuously in Fuel pressure too low. the vicinity of the upper Clogged injectors.
  • Page 285 FUEL INJECTION SYSTEM F a u lt D ia g n o s tic S y m p to m P ro b a b le c a u s e o f m a lfu n c tio n c o d e c o d e N o .
  • Page 286 FUEL INJECTION SYSTEM Diagnostic Item FI diagnostic tool display Checking method code No. Vehicle speed 0 ~ 999 Check that the number increases when pulse the front wheel is rotated. The number is cumulative and does not reset each time the wheel is stopped.

  • Page 287: Troubleshooting Details

    FUEL INJECTION SYSTEM Communication error with the FI diagnostic tool LCD Display Symptom Probable cause of malfunction Improper connection in connecting lead. No signals received from the The main switch is OFF position. Waiting for connection... Malfunction in FI diagnostic tool. Malfunction in ECU.
  • Page 288 FUEL INJECTION SYSTEM Fault code No. Symptom Intake air pressure sensor: open or short circuit defected Diagnostic code No. Intake air pressure sensor Reinstatement Order Item/components and probable cause Check or maintenance job method Connections • Check the coupler for any pins that may Turning the main •...
  • Page 289 FUEL INJECTION SYSTEM Intake air pressure sensor hose Symptom Fault code No. (disconnected or clogged) Diagnostic code No. Intake air pressure sensor Item/components and Reinstatement Order Check or maintenance job probable cause method Intake air pressure sensor • Check and repair the connection. Starting the engine malfunction at intermediate and operating it at...
  • Page 290 FUEL INJECTION SYSTEM F a ult co d e N o . S y m p to m T h ro ttle p o s ition s e n so r: o p en o r sh o rt circu it d e fec te d . D ia gn o s tic c o d e N o .
  • Page 291 FUEL INJECTION SYSTEM Fault Intake air tem perature sensor: open or short circuit Sym ptom code no. detected. Diagnostic code No. Intake air tem perature sensor Item / components and Reinstatem ent O rder Check or m aintenance job probable cause m ethod •...
  • Page 292 FUEL INJECTION SYSTEM Fault Symptom No normal signal is received from the O sensor. code no. Diagnostic code No. — — Reinstatement Order Item/components and probable cause Check or maintenance job method Installed state of O sensor. Check for looseness or pinching Reinstated by starting the Connections...
  • Page 293 FUEL INJECTION SYSTEM Fault Symptom Engine temperature sensor: open or short circuit detected. code No. Diagnostic code No. Engine temperature sensor Item / components and Reinstatement Order Check or maintenance job probable cause method • Check the coupler for any pins that may be Turning the main Connections •...
  • Page 294 FUEL INJECTION SYSTEM No normal signal is received from the lean angle Fault code No. Symptom sensor. Diagnostic code No. Lean angle sensor Item / components and Reinstatement Order Check or maintenance job probable cause method The vehicle has Raise the vehicle upright. Turning the overturned.
  • Page 295 FUEL INJECTION SYSTEM The amount of air-fuel ratio feedback compesation is Fault code No. Symptom maintained continously in the vicinity of the upper limit Diagnostic code No. — — Item / components and Reinstatement Order Check or maintenance job probable cause method Installed state of O sensor...
  • Page 296 FUEL INJECTION SYSTEM The amount of air-fuel ratio feedback compensation is Fault code No. Symptom maintained continuously in the vicinity of lower limit (air-fuel ratio is rich). Diagnostic code No. — — Item / components and Reinstatement Order Check or maintenance job probable cause method Installed state of O...
  • Page 297 FUEL INJECTION SYSTEM Fault Symptom Primary lead of the ignition coil: open circuit detected. code No. Diagnostic code No. D30 Ignition coil Item / components and Reinstatement Order Check or maintenance job probable cause method • Connections Check the connector and coupler for any Starting the •...
  • Page 298 FUEL INJECTION SYSTEM Fault Symptom Lean angle sensor: open or short circuit detected. code No. Diagnostic code No. D08 Lean angle sensor Item / components and Reinstatement Order Check or maintenance job probable cause method • Check the coupler for any pins that may Connections Turning the main •...
  • Page 299 FUEL INJECTION SYSTEM Error is detected while reading from writing on EEPROM (CO Fault Symptom adjustment value, code re-registering key code, and throttle valve code No. fully closed notification value). Diagnostic code No. D60 EEPROM fault code display Item / components and Reinstatement Order Check or maintenance job...

  • Page 300: Throttle Body

    THROTLE BODY THROTTLE BODY Qt’y Remarks Order Job/Part Removing the Throttle body Remove the parts in the order listed Seat Refer to “COWLING AND SIDE COVERS” in chapter 3. Fuel tank Refer to “FUEL TANK” in chapter 3. Injector connector Disconnect Throttle body sensor assembly connector Disconnect...
  • Page 301 THROTTLE BODY Order Job/Part Qt’y Remarks Throttle body Disconnect Clamps bolt Refer to “INSTALLING THE THROTTLE BODY”. Clamps For installation reverse the removal procedure 6-28...
  • Page 302 THROTTLE BODY Order Job/Part Qt’y Remarks Disassembling the throttle body assembly Remove the parts in the order listed Throttle body sensor assembly Injector FDI sensor Throttle body CAUTION: Do not disassembly the throttle body. For assembly, reverse the disassembly procedure. 6-29...

  • Page 303: Removing The Fuel Hose

    THROTTLE BODY REMOVING THE FUEL HOSE 1. Drain the fuel tank through the pump. 2. Remove: • hose connector (press and pull down the lock) 3. Disconnect • fuel hose. CAUTION: Even with the fuel being removed from the tank, take care during the removal of the hose because there may be some fuel inside.

  • Page 304: Checking The Fuel Injector

    THROTTLE BODY CHECKING THE FUEL INJECTOR 1. Check: • fuel injector Damage Replace. --> CHECKING THE THROTTLE BODY 1. Check: • Throttle body Cracks/damage Replace the throttle body --> INSTALLING THE THROTTLE BODY 1. Install: • throttle body junction clamps NOTE: Align the union projection a to the groove b in the throttle body clamp.

  • Page 305: Checking The Fuel Pump

    THROTTLE BODY CHECKING THE FUEL PUMP V V V V V WARNING Gasoline is extremely inflammable and under certain conditions can provoke fire or explosion. Be extremely careful and watch over the following: • Stop the engine before refilling. • Do not smoke, and keep yourself away from open flames, sparks, or any other fire source.

  • Page 306: Installing The Fuel Pump

    THROTTLE BODY INSTALLING THE FUEL PUMP 1. Install: FRONT • fuel pump Fuel pump bolt 4 N.m (0.4 kgf.m, 3,0 ft.lb) NOTE: • When installing the fuel pump, take care not to damage the tank pump surface. • Always use a new gasket. Align the fuel tank projection a to the fuel pump •...

  • Page 307: Checking The Fid (Fast Idle Solenoid) System

    THROTTLE BODY CHECKING THE FID (FAST IDLE SOLENOID) SYSTEM 1. Check: • FID (Fast idle solenoid) a. Disconnect the FID system connector from the wiring harness. b. Connect the pocket tester to the FID connector terminals 1. Positive probe --> red/white Negative probe -->...

  • Page 308: Air Induction System

    AIR INDUCTION SYSTEM AIR INDUCTION SYSTEM DIAGRAM 1 Hose 1 (air filter case to the air cut-off valve) 2 Air cut-off valve 3 Hose 2 (air cut-off valve to the exhaust) 6-35...

  • Page 309: Air Injection

    AIR INDUCTION SYSTEM AIR INJECTION The air induction system bums unburned exhaust 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, allowing secondary air to flow into the exhaust port.
  • Page 310 CHAPTER 7 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS ..............7-1 CHECKING SWITCH CONTINUITY .............. 7-3 CHECKING THE SWITCHES ................ 7-4 CHECKING THE BULBS AND BULB SOCKETS ........7-5 TYPES OF BULBS ................... 7-5 CHECKING THE CONDITION OF THE BULBS ........7-6 CHECKING THE CONDITION OF THE BULB SOCKETS ..... 7-7 IGNITION SYSTEM ..................

  • Page 311: Elec

    ELEC ELECTRICAL COMPONENTS ELECTRICAL SYSTEM ELECTRICAL COMPONENTS 1 Spark plug 9 Left handlebar switch 2 Spark plug cap 0 Hybrid sensor: 3 Ignition coil • 4 Brake front switch Air intake temperature • 5 Right handlebar switch Air intake pressure •...
  • Page 312 ELEC ELECTRICAL COMPONENTS D Battery M Stator coil E Fuse case 1 N Rear brake switch F Starter relay O Speed sensor G Main fuse P Starter motor H Rectifier/regulator Q Horn I ECU R Temperature Sensor J Sidestand switch S F.I.D.

  • Page 313: Checking Switch Continuity

    ELEC CHECKING SWITCH CONTINUITY CHECKING SWITCH CONTINUITY 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. CAUTION: Never insert the tester probes into the coupler terminal slots 1 1 1 1 1 .

  • Page 314: Checking The Switches

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

  • Page 315: Checking The Bulbs And Bulb Sockets

    ELEC CHECKING THE BULBS AND BULB SOCKETS CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage or wear, proper connections, and also for continuity between the terminals. Damage/wear Repair or replace the bulb, --> bulb socket or both. Improperly connected Properly connect.

  • Page 316: Checking The Condition Of The Bulbs

    ELEC CHECKING THE BULBS AND BULB SOCKETS CHECKING THE CONDITION OF THE BULBS The following procedure applies to all of the bulbs. 1. Remove: • bulb V V V V V WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down.
  • Page 317 ELEC CHECKING THE CONDITION OF THE SOCKETS CHECKING THE CONDITION OF THE SOCKETS The following procedure applies to all of the bulb sockets. 1. Check: • bulb socket (continuity) (with the pocket tester) No continuity Replace. --> Pocket tester 90890-03174 NOTE: Check each bulb socket for continuity in the same manner as described in the bulb section;...
  • Page 318 ELEC IGNITION SYSTEM IGNITION SYSTEM CIRCUIT DIAGRAM...
  • Page 319 ELEC IGNITION SYSTEM TROUBLESHOOTING The ignition system fails to operate 2. Battery (no spark or intermittent spark). • Check the condition of the battery. Refer to “CHECKING AND CHARGING Check: THE BATTERY” in chapter 3. 1. Main and ignition fuses 2.
  • Page 320 ELEC IGNITION SYSTEM 5. Spark plug cap resistance 4. Ignition spark gap • Disconnect the spark plug cap 1 from the • Remove the spark plug cap from lead. spark plug. • Connect the pocket tester to the spark • Connect the spark dynamic tester 2 as plug cap, as shown.

  • Page 321: Ignition System

    ELEC IGNITION SYSTEM 7. Crankshaft position sensor resistance 6. Ignition coil resistance • Disconnect the crankshaft position sensor • Disconnect the ignition coil leads from the connector from the witing harness. wire harness. • Connect the pocket tester (Ω x 100) to •...
  • Page 322 ELEC IGNITION SYSTEM 9. Engine stop switch 11. Wiring • Check the engine stop switch for continuity. • Check the entire ignition system’s wiring. Refer to “CHECKING THE SWITCHES”. Refer to “CIRCUIT DIAGRAM”. • Is the engine stop switch OK? •...

  • Page 323: Circuit Diagram

    ELEC ELECTRIC STARTING SYSTEM ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM 7-13...
  • Page 324 ELEC ELECTRIC STARTING SYSTEM STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to " " and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: •...

  • Page 325: Troubleshooting

    ELEC ELECTRIC STARTING SYSTEM TROUBLESHOOTING 2. Battery The starter motor fails to turn. • Check the condition of the battery. Check: Refer to “CHECKING AND CHARGING Main and ignition fuses THE BATTERY” in chapter 3. Battery Starter motor Minimum open-circuit voltage Starter relay 12.8 V or more at 20°C (68°F) Main switch...
  • Page 326 ELEC ELECTRIC STARTING SYSTEM 4. Starter relay 6. Engine stop switch • Disconnect the starter relay connector. • Check the engine stop switch for • Connect the Pocket tester (Ω x 1) and the continuity. battery (12V) to the starter relay connector, Refer to “CHECKING THE SWITCHES”.
  • Page 327 ELEC ELECTRIC STARTING SYSTEM 10. Start switch • Check the start switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the start switch OK? Replace the start switch. 11. Wiring • Check the entire starting system’s wiring. Refer to “CIRCUIT DIAGRAM”. •...

  • Page 328: Starter Motor

    ELEC STARTER MOTOR STARTER MOTOR 10 N.m (1,0 kgf.m, 7.2 ft.lb) 10 N.m (1,0 kgf.m, 7.2 ft.lb) Order Job/Part Qt’y Remarks Removing the starter motor Remove the parts in the order listed Battery positive lead Disconnect Bolts Starter motor For installation, reverse the removal procedure 7-18...
  • Page 329 ELEC STARTER MOTOR Order Job/Part Qt’y Remarks Disassembling the starter motor Remove the parts in the order listed Front bracket O-ring Rear bracket Bearing washer Armature assembly Starter motor yoke Brush assembly Starter motor cable For assembly, reverse the disassembly procedure 7-19...

  • Page 330: Checking The Starter Motor

    ELEC STARTER MOTOR CHECKING THE STARTER MOTOR 1. Check: • inducted commutator Dirt Clean with 600 grit sandpaper. --> 2. Measure: • commutator diameter a Out of specification Replace --> Commutator diameter limit 27.0 mm (1.06 in) 3. Measure: • mica undercut a Out of specification Scrape the mica to the -->...
  • Page 331 ELEC STARTER MOTOR a. Measure the resistances with the pocket tester. b. If any resistance is out of specification, replace the starter motor. Pocket tester 90890-03174 Armature coil Commutator resistance 0.0012 ~ 0.0022 Ω Ω Ω Ω Ω at 20 °C (68°C) Insulation resistance above 1MΩ...

  • Page 332: Assembling The Starter Motor

    ELEC STARTER MOTOR ASSEMBLING THE STARTER MOTOR 1. Install: • brush holder 1 • brushes 2 2. Install: • inducted 1 NOTE: • Tighten the rear bracket to ease the operation. • With a screwdriver, block one of the brushes. 3.
  • Page 333 ELEC CHARGING SYSTEM CHARGING SYSTEM CIRCUIT DIAGRAM 7-23...

  • Page 334: Charging System

    ELEC CHARGING SYSTEM TROUBLESHOOTING 1. Main fuse The battery is not being charged. • Check the main fuse for continuity. Refer to “CHECKING THE FUSES” in Check: chapter 3. • Is the main fuse OK? 1. main fuse 2. battery 3.
  • Page 335 ELEC CHARGING SYSTEM 4. Stator coil resistance 3. Charging voltage • Connect the pocket tester (DC 20 V) to the • Disconnect the generator connector from battery, as shown. wiring harness. • Connect the pocket tester (Ω x 1) to the Positive tester probe-->...

  • Page 336: Circuit Diagram

    ELEC LIGHTING SYSTEM LIGHTING SYSTEM CIRCUIT DIAGRAM 7-26...

  • Page 337: Troubleshooting

    ELEC LIGHTING SYSTEM TROUBLESHOOTING Any of the following fail to light: headlight, 1. Headlight and main switch fuses high beam indicator light, taillight, auxiliary • Check the main switch and headlight fuses light or meter light. for continuity. Refer to CHECKING THE FUSES” in Check: chapter 3.
  • Page 338 ELEC LIGHTING SYSTEM 4. Dimmer switch 6. Headlight relay • Check the dimmer switch for continuity. • Disconnect the headlight relay from the wire harness Refer to “CHECKING THE SWITCHES”. • Connect the pocket tester (Ω x 1) (12V) to •...
  • Page 339 ELEC LIGHTING SYSTEM CHECKING THE LIGHTING SYSTEM 1. The headlight and the high beam indicator light fail to come on. Headlight 1. Headlight bulb and socket. Positive tester probe --> yellow 1 1 1 1 1 or green 2 2 2 2 2 •...
  • Page 340 ELEC LIGHTING SYSTEM 3. The auxiliary light fails to come on. 2. The tail/brake light fails to come on. 1. Tail/brake light bulb and socket 1. Auxiliary light bulb and socket. • Check the tail/brake light bulb and socket • Check the auxiliary light bulb and socket for continuity.

  • Page 341: Signaling System

    ELEC SIGNALING SYSTEM SIGNALING SYSTEM CIRCUIT DIAGRAM 7-31...

  • Page 342: Troubleshooting

    ELEC SIGNALING SYSTEM TROUBLESHOOTING • Any of the following fail to light: turn 2. Battery signal light, brake light or an indicator • Check the condition of the battery. light. Refer to"CHECKING AND CHARGING • The horn fails to sound. THE BATTERY", in chapter 3.

  • Page 343: Checking The Signaling System

    ELEC SIGNALING SYSTEM CHECKING THE SIGNALING SYSTEM 1. The horn fails to sound. 1. Horn switch 3. Horn • Disconnect the pink connector at the horn • Check the horn switch for continuity. terminal. Refer to “CHECKING THE SWITCHES”. • Connect a jumper lead 1 to the horn •...
  • Page 344 ELEC SIGNALING SYSTEM 2. The brake light fails to come on. 3. Voltage 1. Brake light bulb and socket. • Connect the pocket tester (DC 20 V) to • Check the brake light bulb and socket for the brake light coupler (wire harness side) continuity.
  • Page 345 ELEC SIGNALING SYSTEM 3. The turn signal light, turn signal indicator light or both fail to blink. 4. Input voltage 1. Turn signal indicator light bulb and socket • Connect the pocket tester (DC 20 V) to the • Check the turn signal light bulb and socket turn signal relay coupler (wire harness), as for continuity.
  • Page 346 ELEC SIGNALING SYSTEM 5. Output voltage • Connect the pocket tester (DC 20 V) to the turn signal relay coupler (wire harness), as shown. B Ch B Dg Positive tester probe --> brown/white 1 Negative tester probe --> ground • Set the main switch to "ON". •...
  • Page 347 ELEC SIGNALING SYSTEM 4. The neutral indicator light fails to come on. 1. Neutral indicator light 3. Voltage • Check the neutral indicator light. • Connect the pocket tester (DC 20 V) to the Refer to "CHECKING THE BULBS AND panel coupler (wire harness), as shown.
  • Page 348 ELEC SIGNALING SYSTEM 5. The fuel level gauge fails to operate. 2. Voltage 1. Fuel gauge • Disconnect the fuel gauge coupler from the • Connect the pocket tester (DC 20 V) to the fuel pump. panel coupler (wire harness), as shown. •...
  • Page 349 ELEC SIGNALING SYSTEM 6. The speedometer fails to operate. 1. Voltage 2. Speed sensor • Connect the pocket tester (DC 20 V) to • Connect the pocket tester (DC 20 V) to the the speed sensor, as shown. panel coupler (wire harness), as shown. Positive tester probe -->...
  • Page 350 ELEC SIGNALING SYSTEM 7. The engine falls to operate and the temperature is high. 1. Temperature sensor • Remove the temperature sensor from the engine. • Connect the pocket tester to the temperature sensor 1, as shown. • Plunge the temperature sensor into a container with engine oil 2.
  • Page 351 CHAPTER 8 TROUBLESHOOTING STARTING FAILURES ................... 8-1 INCORRECT ENGINE IDLING SPEED ............8-2 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ....... 8-3 FAULTY GEAR SHIFTING ................8-3 FAULTY CLUTCH ..................8-3 OVERHEATING ....................8-4 POOR BRAKING PERFORMANCE .............. 8-4 FAULTY FRONT FORK LEGS ..............8-5 UNSTABLE HANDLING ................

  • Page 352: Troubleshooting

    TRBL STARTING FAILURES SHTG TROUBLESHOOTING NOTE: The following guide for troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this manual for checks, adjustments, and replacement of parts. STARTING FAILURES ENGINE FUEL SYSTEM...

  • Page 353: Incorrect Engine Idling Speed

    STARTING FAILURES/ TRBL INCORRECT ENGINE IDLING SPEED SHTG Ignition system ELECTRICAL SYSTEMS • Faulty ECU Battery • Faulty crankshaft position sensor • Discharged battery • Broken generator rotor woodruff key • Faulty battery Switches and wiring Fuse(s) • Faulty ignition •...

  • Page 354: Poor Medium-And-High-Speed Performance

    POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE/FAULTY GEAR SHIFTING TRBL FAULTY CLUTCH SHTG POOR MEDIUM-AND-HIGH- FUEL SYSTEM SPEED PERFORMANCE Fuel pump Refer to “STARTING FAILURES”. • Faulty fuel pump ENGINE Air filter • Clogged air filter element FAULTY GEAR SHIFTING JUMPS OUT OF GEAR SHIFTING IS DIFFICULT Refer to “CLUTH DRAGS”...

  • Page 355: Overheating

    OVERHEATING/ TRBL POOR BRAKING PERFORMANCE SHTG OVERHEATING ENGINE FUEL SYSTEM Engine oil Throttle body • Incorrect oil level • Faulty throttle body • Incorrect oil viscosity • Damaged or loose throttle body joint • Inferior oil quality Air filter COOLING SYSTEM •...

  • Page 356: Faulty Front Fork Legs

    FAULTY FRONT FORK LEGS/ TRBL UNSTABLE HANDLING SHTG FAULTY FRONT FORK LEGS OIL LEAKAGE MALFUNCTION • Bent or damaged inner tube • Bent, damaged or rusty inner tube • Bent or damaged outer tube • Cracked or damaged outer tube •...

  • Page 357: Trbl Shtg

    TRBL FAULTY LIGHTING OR SIGNALING SYSTEM SHTG FAULTY LIGHTING OR SIGNALING SYSTEM HEADLIGHT DOES NOT COME ON TURN SIGNAL DOES NOT COME ON • Wrong headlight bulb • Faulty turn signal switch • Too many electrical accessories • Faulty turn signal relay •...
  • Page 358 YBR250 2007 WIRING DIAGRAM COLOR CODES WIRING DIAGRAM B ....Black YBR250 2007 Br ....Brown 1 Rectifier/ regulator Ch ....Chocolate 2 Generator/Crankshaft position sensor Dg ....Dark green 3 Battery G ....Green 4 Starter motor Gy ....Gray...
  • Page 359 YAMAHA MOTOR DA AMAZÔNIA LTDA.

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