Page 1 2014 Read this manual carefully before operating this vehicle. Il convient de lire attentivement ce manuel avant la première utilisation du véhicule. Bitte lesen Sie diese Bedienungsanleitung sorgfältig durch, bevor Sie das Fahrzeug in Betrieb nehmen. Leggere attentamente questo manuale prima di utilizzare questo veicolo. Lea atentamente este manual antes de utilizar el vehículo.
Page 2 Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold. Il convient de lire attentivement ce manuel avant la première utilisation du véhicule. Le manuel doit étre remis avec le véhicule en cas de vente de ce dernier. Bitte lesen Sie diese Bedienungsanleitung sorgfältig durch, bevor Sie das Fahrzeug in Betrieb nehmen.
Page 3 2014 2014 Read this manual carefully before operating this vehicle. Read this manual carefully before operating this vehicle. OWNER’S SERVICE MANUAL OWNER’S SERVICE MANUAL WR250F(E) WR250F(E) 1HC-28199-53-E0 1HC-28199-53-E0...
Page 5 WR250F (E) OWNER'S SERVICE MANUAL ©2013 by Yamaha Motor Co., Ltd. 1st Edition, June 2013 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan...
Page 6: Important Manual Information
ORDER. Congratulations on your purchase of distinguished in this manual by the For safety and reliability, the ma- a Yamaha WR series. This model is following notations. chine must be properly maintained. the culmination of Yamaha's vast ex- Always perform the pre-operation perience in the production of paceset- checks indicated in this manual.
Page 7: Manual Format
HOW TO USE THIS MANUAL FINDING THE REQUIRED PAGE 1. This manual consists of seven chapters; "General Information", "Specifications", "Regular inspec- tion and adjustments", "Tuning", "Engine", "Chassis" and "Electri- cal". 2. The table of contents is at the be- ginning of the manual. Look over the general layout of the book be- fore finding then required chapter and item.
Page 8 2. Numbers "2" are given in the or- 4. A job instruction chart "4" accom- HOW TO READ DESCRIPTIONS der of the jobs in the exploded di- panies the exploded diagram, To help identify parts and clarify pro- agram. A number that is enclosed providing the order of jobs, names cedure steps, there are exploded dia- by a circle indicates a disassem-...
Page 9: Table Of Contents
TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS REGULAR INSPECTION AND ADJUSTMENTS TUNING ENGINE CHASSIS ELECTRICAL...
Page 10: General Information
CONTENTS CHAPTER 1 CHAPTER 3 ENGINE REMOVAL..5-54 CRANKCASE AND GENERAL INFOR- REGULAR INSPEC- CRANKSHAFT ....5-58 MATION TION AND AD- TRANSMISSION, SHIFT CAM AND JUSTMENTS SHIFT FORK....5-64 LOCATION OF IMPORTANT LABELS ..1-1 MAINTENANCE INTER- CHAPTER 6 DESCRIPTION ....1-4 VALS FOR COMPETITION CONSUMER CHASSIS USE........
Page 11 LOCATION OF IMPORTANT LABELS GENERAL INFORMATION LOCATION OF IMPORTANT LABELS Please read the following important labels carefully before operating this vehicle. EUROPE...
Page 12: Location Of Important Labels
LOCATION OF IMPORTANT LABELS AUS, NZ, ZA...
Page 13 LOCATION OF IMPORTANT LABELS Familiarize yourself with the following pictograms and read the explanatory text. Read Owner's service manual. This unit contains high-pressure nitrogen gas. Mishandling can cause explosion. Do not incinerate, puncture or open. Turn off the main switch after riding to avoid draining the battery. Use unleaded gasoline only.
Page 14 DESCRIPTION DESCRIPTION Clutch lever 14. Headlight Hot starter lever 15. Radiator Engine stop switch 16. Coolant drain bolt Multi-function display 17. Rear brake pedal Main switch 18. Valve joint Start switch 19. Fuel cock Front brake lever 20. Cold starter knob Throttle grip 21.
Page 15: Consumer Information
1. Remove all dirt, mud, dust, and 1. When ordering parts, you can foreign material before removal give the number to your Yamaha and disassembly. dealer for positive identification of • When washing the machine with the model you own.
Page 16: Checking Of Connection
The two connectors "click" together. ALL REPLACEMENT PARTS 7. Check for continuity with a tester. 1. We recommend to use Yamaha genuine parts for all replace- • If there in no continuity, clean the ments. Use oil and/or grease rec- terminals.
Page 17: Special Tools
SPECIAL TOOLS SPECIAL TOOLS The proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques. The shape and part number used for the special tool differ by country, so two types are provided.
Page 18 SPECIAL TOOLS Tool name/Part number How to use Illustration Steering nut wrench This tool is used when tighten the YU-A9472, 90890-01403 steering ring nut to specification. Damper rod holder Use this tool to remove and install YM-01494, 90890-01494 the damper rod. Fork seal driver This tool is used when install the fork YM-A0948, 90890-01502...
Page 19 SPECIAL TOOLS Tool name/Part number How to use Illustration Timing light This tool is necessary for checking YU-03141, 90890-03141 ignition timing. Valve spring compressor This tool is needed to remove and YM-04019, 90890-04019 install the valve assemblies. Clutch holding tool This tool is used to hold the clutch YM-91042, 90890-04086 when removing or installing the...
Page 20 Ignition checker nents. 90890-06754 Vacuum/pressure pump gauge set This tool is used to check the air in- YS-42423, 90890-06756 duction system. Yamaha bond No. 1215 This sealant (Bond) is used for 90890-85505 crankcase mating surface, etc. (Three bond No.1215®) 1-10...
Page 21 SPECIAL TOOLS 1-11...
Page 22: Control Functions
CONTROL FUNCTIONS CONTROL FUNCTIONS CLUTCH LEVER The clutch lever "1" is located on the MAIN SWITCH left handlebar; it disengages or en- Functions of the respective switch po- gages the clutch. Pull the clutch lever sitions are as follows: to the handlebar to disengage the clutch, and release the lever to en- The engine can be started only at this gage the clutch.
Page 23: Multifunction Display
MULTI-FUNCTION DISPLAY MULTI-FUNCTION DISPLAY COLD STARTER KNOB BASIC MODE When cold, the engine requires a Changing speedometer display richer air-fuel mixture for starting. A (for U.K.) Be sure to stop the machine before separate starter circuit, which is con- 1. Push the "SLCT2" button for 2 making any setting changes to the trolled by the cold starter knob "1", seconds or more to change the...
Page 24: Changeover To Basic Mode/ Race Mode
MULTI-FUNCTION DISPLAY Changing odometer and tripmeter Manual start A/B (TRIP A/B) 1. Push the "SLCT2" button to Initial setting at changeover to RACE change the tripmeter display. The MODE will remain for manual start. display will change in the follow- 1.
Page 25 MULTI-FUNCTION DISPLAY Resetting tripmeter A (TRIP A) and timer 3. Run the machine and start timer 1. Check that the timer is not in op- measurement. eration. If the timer is in operation, 4. To stop timer measurement, stop it by pushing the "SLCT1" pushing the "SLCT1"...
Page 26: Function Diagram
MULTI-FUNCTION DISPLAY FUNCTION DIAGRAM A short push on the button changes the operation in the arrowed direction. Meter function A short push on the button changes the operation in both arrowed directions. Function that can be performed whether the time is or is not in operation. A long push on the button changes the operation in the arrowed direction.
Page 27 MULTI-FUNCTION DISPLAY The following diagram illustrates the multi-function display regarding the direction and operation condition in- volved in each of its functions. A short push on the button changes the operation in the ar- rowed direction. A short push on the button changes the operation in both arrowed directions.
Page 28: Starting And Break-In
STARTING AND BREAK-IN AIR FILTER MAINTENANCE 7. Return the cold starter knob to its STARTING AND BREAK-IN According to "CLEANING THE AIR original position and run the en- FUEL FILTER ELEMENT" section in the gine at 3,000–5,000 r/min for 1 or Always use the recommended fuel as CHAPTER 3, apply the foam-air-filter 2 minutes.
Page 29: Break-In Procedures
STARTING AND BREAK-IN BREAK-IN PROCEDURES Thro 1. Before starting the engine, fill the ttle Cold fuel tank with the fuel. grip start- start- 2. Perform the pre-operation checks er le- on the machine. era- knob 3. Start and warm up the engine. tion* Check the idle speed, and check the operation of the controls and...
Page 30: Torque-Check Points
TORQUE-CHECK POINTS TORQUE-CHECK POINTS Frame construction Frame to rear frame Combined seat and fuel tank Fuel tank to frame Exhaust system Silencer to rear frame Engine mounting Frame to engine Engine bracket to engine Engine bracket to frame Steering Steering stem to handlebar Steering stem to frame Steering stem to upper bracket Upper bracket to handlebar...
Page 31: Cleaning And Storage
CLEANING AND STORAGE CLEANING AND STORAGE STORAGE If your machine is to be stored for 60 CLEANING days or more, some preventive mea- Frequent cleaning of your machine sures must be taken to avoid deterio- will enhance its appearance, maintain ration.
Page 32: General Specifications
GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Model name: WR250FE (AUS, NZ) WR250F (EUROPE, ZA) Model code number: 1HCD (EUROPE) 1HCE (AUS, NZ, ZA) Dimensions: AUS, NZ EUROPE Overall length 2,165 mm (85.2 2,175 mm (85.6 2,185 mm (86.0 Overall width 825 mm (32.5 in) ←...
Page 33 GENERAL SPECIFICATIONS Fuel: Type Premium unleaded gasoline only with a research octane number of 95 or higher. Tank capacity 8.0 L (1.76 Imp gal, 2.11 US gal) Reserve 1.1 L (0.24 Imp gal, 0.29 US gal) Carburetor: Type FCR-MX37 Manufacturer KEIHIN Spark plug: Type/manufacturer...
Page 34: Maintenance Specifications
MAINTENANCE SPECIFICATIONS Shock absorber: Front shock absorber Coil spring/oil damper Rear shock absorber Coil spring/gas, oil damper Wheel travel: Front wheel travel 300 mm (11.81 in) Rear wheel travel 310 mm (12.20 in) Electrical: Ignition system Generator system AC magneto Battery type YTZ7S (F) Battery voltage/capacity...
Page 35 MAINTENANCE SPECIFICATIONS Item Standard Limit Intake "A" 29.650–29.750 mm (1.1673–1.1713 in) 29.550 mm (1.1634 in) Intake "B" 22.450–22.550 mm (0.8839–0.8878 in) 22.350 mm (0.8799 in) Exhaust "A" 30.399–30.499 mm (1.1968–1.2007 in) 30.299 mm (1.1929 in) Exhaust "B" 22.450–22.550 mm (0.8839–0.8878 in) 22.350 mm (0.8799 in) Camshaft runout limit...
Page 36 MAINTENANCE SPECIFICATIONS Item Standard Limit "D" margin thickness (IN) 0.8 mm (0.0315 in) ---- "D" margin thickness (EX) 0.7 mm (0.0276 in) ---- Stem outside diameter (IN) 3.975–3.990 mm (0.1565–0.1571 in) 3.945 mm (0.1553 in) Stem outside diameter (EX) 4.460–4.475 mm (0.1756–0.1762 in) 4.430 mm (0.1744 in) Guide inside diameter (IN)
Page 37 MAINTENANCE SPECIFICATIONS Item Standard Limit Tilt limit* (IN) ---- 2.5°/1.6 mm (2.5°/0.06 in) Tilt limit* (EX) ---- 2.5°/1.6 mm (2.5°/0.06 in) Direction of winding (top view) (IN) Clockwise ---- Direction of winding (top view) (EX) Clockwise ---- Piston: Piston to cylinder clearance 0.030–0.055 mm (0.0012–0.0022 in) 0.1 mm (0.004 Piston size "D"...
Page 38 MAINTENANCE SPECIFICATIONS Item Standard Limit Oil ring: Dimensions (B × T) 1.50 × 2.25 mm (0.06 × 0.09 in) ---- End gap (installed) 0.10–0.40 mm (0.0039–0.0157 in) ---- Crankshaft: Crank width "A" 55.95–56.00 mm (2.203–2.205 in) ---- Runout limit "C" 0.030 mm (0.0012 in) 0.050 mm (0.002 in)
Page 39 MAINTENANCE SPECIFICATIONS Item Standard Limit Carburetor: ZA, AUS, NZ EUROPE Type/manufacturer FCR-MX37/KEIHIN ← ---- I. D. mark 5UME E0 5UML L0 ---- Main jet (M.J) #170 #160 ---- Main air jet (M.A.J) #115 ---- ← Jet needle (J.N) NJRU NNGU ---- Cutaway (C.A) ----...
Page 40 MAINTENANCE SPECIFICATIONS Item Standard Limit Front suspension: Front fork travel 300.0 mm (11.81 in) ---- Fork spring free length 460.0 mm (18.11 in) 455.0 mm (17.91 in) Spring rate, STD K = 4.40 N/mm (0.45 kg/mm, 25.12 lb/in) ---- Optional spring/spacer ---- Oil capacity 648.0 cm...
Page 41 4.56–6.84 kΩat 20 °C (68 °F) ---- Charging system: System type AC magneto ---- Model (stator)/manufacturer 5UM 30/YAMAHA ---- Normal output 14.0 V/120 W at 5,000 r/min ---- Charging coil resistance (color) 0.28–0.43 Ω at 20 °C (68 °F) (White–Ground)
Page 42 12.0 A ---- Rectifier capacity (DC) 8.0 A ---- Electric starting system: Type Constant mesh ---- Starter motor: Model/manufacturer 5UM01/YAMAHA ---- Operation voltage 12.0 V ---- Output 0.35 kW ---- Armature coil resistance 0.0189–0.0231 Ω at 20 °C (68 °F) ---- Brush overall length 7.0 mm (0.28 in)
Page 43: Tightening Torques
TIGHTENING TORQUES TIGHTENING TORQUES ENGINE △ - marked portion shall be checked for torque tightening after break-in or before each race. Thread Item Q'ty Tightening torque Remarks size Spark plug M10S 13 Nm (1.3 m•kg, 9.4 ft•lb) Camshaft cap 10 Nm (1.0 m•kg, 7.2 ft•lb) Cylinder head blind plug screw 28 Nm (2.8 m•kg, 20 ft•lb) Cylinder head (stud bolt)
Page 44 TIGHTENING TORQUES Thread Item Q'ty Tightening torque Remarks size Throttle cable adjust bolt and locknut 4 Nm (0.4 m•kg, 2.9 ft•lb) Throttle cable (pull) 4 Nm (0.4 m•kg, 2.9 ft•lb) Throttle cable (return) 11 Nm (1.1 m•kg, 8.0 ft•lb) Throttle cable cover 4 Nm (0.4 m•kg, 2.9 ft•lb) Hot starter plunger 2 Nm (0.2 m•kg, 1.4 ft•lb)
Page 45 TIGHTENING TORQUES CHASSIS △ - marked portion shall be checked for torque tightening after break-in or before each race. Thread Item Q'ty Tightening torque Remarks size Upper bracket and outer tube 21 Nm (2.1 m•kg, 15 ft•lb) △ Lower bracket and outer tube 21 Nm (2.1 m•kg, 15 ft•lb) △...
Page 46 TIGHTENING TORQUES Thread Item Q'ty Tightening torque Remarks size Front brake disc 12 Nm (1.2 m•kg, 8.7 ft•lb) △ Rear brake disc 14 Nm (1.4 m•kg, 10 ft•lb) △ Brake pedal 26 Nm (2.6 m•kg, 19 ft•lb) △ Rear brake master cylinder 10 Nm (1.0 m•kg, 7.2 ft•lb) △...
Page 47 TIGHTENING TORQUES Thread Item Q'ty Tightening torque Remarks size Side cover 7 Nm (0.7 m•kg, 5.1 ft•lb) △ Seat 22 Nm (2.2 m•kg, 16 ft•lb) Multi-function display bracket and upper 7 Nm (0.7 m•kg, 5.1 ft•lb) bracket Multi-function display 4 Nm (0.4 m•kg, 2.9 ft•lb) Plate 1 and front fork protector 4 Nm (0.4 m•kg, 2.9 ft•lb) Plate 2 and front fork protector...
Page 48: General Torque Specifications
TIGHTENING TORQUES GENERAL TORQUE TORQUE SPECIFI- SPECIFICATIONS CATION (Bolt This chart specifies torque for stan- (Nut) dard fasteners with standard I.S.O. m•kg ft•lb pitch threads. Torque specifications 6 mm for special components or assem- blies are included in the applicable sections of this book.
Page 49 TIGHTENING TORQUES 2-18...
Page 50: Lubrication Diagrams
LUBRICATION DIAGRAMS LUBRICATION DIAGRAMS Oil filter element Oil pump Drive axle Main axle Intake camshaft Exhaust camshaft Oil tank Oil delivery pipe To oil tank 2-19...
Page 51 LUBRICATION DIAGRAMS Crankshaft Oil filter element Oil tank Oil hose From oil pump 2-20...
Page 52: Cable Routing Diagram
CABLE ROUTING DIAGRAM CABLE ROUTING DIAGRAM Fuel tank breather hose 10. Oil hose 19. Carburetor overflow hose Clamp 11. Clutch cable 20. Catch tank breather hose Diode 12. Starter motor lead 21. Hot starter cable protector Hot starter cable 13. Cable guide 22.
Page 53 CABLE ROUTING DIAGRAM Insert the end of the fuel tank Pass the clutch cable and wire breather hose into the hole in harness through the cable the steering stem. guide. Fasten the throttle cable, hot Locate the couplers in the frame starter cable and rectifier/regula- recess.
Page 54 CABLE ROUTING DIAGRAM Throttle cable (pull) Cross the pull and push throttle Pass the carburetor breather Throttle cable (return) cables. hose (of the throttle cable cover) Catch tank hose Fasten the catch tank hose and through the hose holder. Ignition coil air induction hose (air cut-off Clamp valve-rear of cylinder head) onto...
Page 55 CABLE ROUTING DIAGRAM Brake master cylinder Install the brake hose so that its Install the brake hose so that its Brake hose holder pipe portion directs as shown pipe portion directs as shown Brake hose and lightly touches the projec- and lightly touches the projec- tion on the brake caliper.
Page 56 CABLE ROUTING DIAGRAM Clamp Positive battery lead Battery Negative battery lead Taillight coupler CDI unit coupler (6-pin) CDI unit coupler (3-pin) CDI unit coupler (6-pin) 2-25...
Page 57 CABLE ROUTING DIAGRAM Fasten the wire harness, nega- Fasten the taillight lead to the tive battery lead and starter mo- rear frame. Locate the clamp tor lead to the upper engine end facing toward the upper side bracket (left side). Locate the of the frame and cut off the tie clamp end facing toward the up- end.
Page 58 CABLE ROUTING DIAGRAM Throttle cable 12. Upper bracket Clamp 13. Clutch switch coupler Brake hose 14. Engine stop switch coupler Clutch cable 15. Multi-function display coupler Hose guide 16. Start switch coupler Main switch coupler 17. Speed sensor coupler Wire harness 18.
Page 59 CABLE ROUTING DIAGRAM Fasten the start switch lead to the handlebar with the plastic bands. Fasten the engine stop switch lead and clutch switch lead to the handlebar with the plastic bands. Pass the brake hose through the hose guides. Secure the coupler by inserting it into the multi-function display bracket.
Page 60: Regular Inspection And Adjustments
If you are a doubt as to what intervals to follow in maintaining and lubricating your machine, consult your Yamaha dealer. • Periodic inspection is essential in making full use of the machine performance. The service life of the parts varies sub- stantially according to the environment in which the machine runs (e.g., rain, dirt, etc.).
Page 61 MAINTENANCE INTERVALS FOR COMPETITION USE Every Every After third fifth (or Every As re- Item break- Remarks race (or 500 1,000 quired CYLINDER Inspect and clean Inspect score marks. ● Replace ● Inspect wear. CLUTCH Inspect and adjust Inspect housing, friction plate, clutch ●...
Page 62 MAINTENANCE INTERVALS FOR COMPETITION USE Every Every After third fifth (or Every As re- Item break- Remarks race (or 500 1,000 quired OIL FILTER Replace ● ● ENGINE GUARD Replace Breakage ● FRAME Clean and inspect ● ● FUEL TANK, COCK Clean and inspect ●...
Page 63 ● Lubricate Lithium base grease ● THROTTLE, CONTROL CABLE Check routing and connection ● ● Lubricate Yamaha cable lube or SAE 10W-40 ● ● motor oil HOT STARTER, CLUTCH LEVER Inspect free play ● BATTERY Check terminal for looseness ●...
Page 64: Pre-Operation Inspection And Maintenance
PRE-OPERATION INSPECTION AND MAINTENANCE PRE-OPERATION INSPECTION AND MAINTENANCE Before riding for break-in operation or practice, make sure the machine is in good operating condition. Before using this machine, check the following points. GENERAL INSPECTION AND MAINTENANCE Item Routine Page Check that coolant is filled up to the radiator cap. Check the cool- Coolant P.3-9 –...
Page 65 ENGINE ENGINE REMOVING THE SEAT, FUEL TANK AND SIDE COVERS Order Part name Q'ty Remarks Turn the fuel cock to "OFF". Disconnect the fuel hose. Seat Air scoop (left and right) Bolt (fuel tank) Fuel tank Left side cover Open the air filter case cover. Right side cover Refer to removal section.
Page 66: Removing The Side Cover
ENGINE REMOVING THE SIDE COVER 1. Remove: • Bolt (side cover) • Right side cover "1" Draw the side cover backward to re- move it because its claw "a" is insert- ed in the air filter case.
Page 67 ENGINE REMOVING THE EXHAUST PIPE AND SILENCER Order Part name Q'ty Remarks Refer to "REMOVING THE SEAT, FUEL Right side cover TANK AND SIDE COVERS" section. Bolt (silencer clamp) Only loosening. Bolt [silencer (front)] Bolt [silencer (rear)] Collar Silencer Silencer clamp Nut (exhaust pipe) Exhaust pipe Gasket...
Page 68: Engine
ENGINE CHECKING THE SILENCER AND CHECKING THE COOLANT LEVEL CHANGING THE COOLANT EXHAUST PIPE 1. Inspect: Do not remove the radiator cap Do not remove the radiator cap • Gasket "1" "1", drain bolt and hoses when the when the engine is hot. Damage →...
Page 69: Checking The Radiator Cap Opening Pressure
ENGINE CHECKING THE RADIATOR CAP OPENING PRESSURE • Do not apply pressure more than • Do not mix more than one type of 1. Attach: specified pressure. ethylene glycol antifreeze con- • Radiator cap tester "1" and adapt- • Radiator should be filled fully. taining corrosion inhibitors for er "2"...
Page 70: Adjusting The Throttle Grip Free Play
ENGINE LUBRICATING THE THROTTLE 1. Remove: • Cover (throttle cable cap) "1" • Cover (grip cap) "2" • Throttle grip cap "3" ADJUSTING THE THROTTLE GRIP FREE PLAY CLEANING THE AIR FILTER 1. Check: ELEMENT • Throttle grip free play "a" Out of specification →...
Page 71: Checking The Engine Oil Level
ENGINE 4. Clean: Recommended brand: • Air filter element YAMALUBE Clean them with solvent. Recommended engine oil type After cleaning, remove the remaining SAE 10W-30, SAE 10W- solvent by squeezing the element. 40, SAE 10W-50, SAE 15W-40, SAE 20W-40 or SAE 20W-50 9.
Page 72: Checking The Oil Pressure
ENGINE • Oil strainer "2" Oil strainer: 9 Nm (0.9 m•kg, 6.5 ft•lb) • Oil hose • Bolt (oil hose) Bolt (oil hose): 11. Check: 8 Nm (0.8 m•kg, 5.8 • Oil leakage ft•lb) 12. Install: • Oil hose clamp •...
Page 73: Adjusting The Pilot Screw
This section is intended for those who 0.17–0.22 mm 2 turns out have basic knowledge and skill con- (0.0067–0.0087 in) cerning the servicing of Yamaha mo- torcycles (e.g., Yamaha dealers, service engineers, etc.) Those who Checking steps: have little knowledge and skill con- a.
Page 74 ENGINE g. Install the camshafts (exhaust and intake). The thickness "a" of each pad is indi- Refer to "CAMSHAFTS" section cated in hundredths of millimeters on in the CHAPTER 5. the pad upper surface. d. Round off the last digit of the in- stalled pad number to the nearest increment.
Page 75 ENGINE INTAKE INSTALLED PAD NUMBER MEASURED CLEARANCE 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.00 - 0.04 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 0.05 - 0.09 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 0.10 - 0.15...
Page 76: Chassis
CHASSIS CHASSIS f. Pull the lever in or push down on 2. Remove: the pedal. Hold the lever or pedal • Brake lever cover BLEEDING THE HYDRAULIC in position. 3. Adjust: BRAKE SYSTEM g. Loosen the bleed screw and allow •...
Page 77 CHASSIS 2. Adjust: 2. Replace: g. Tighten the bleed screw. • Brake pedal height • Brake pad Bleed screw: 6 Nm (0.6 m•kg, 4.3 Pedal height adjustment steps: Brake pad replacement steps: ft•lb) a. Loosen the locknut "1". a. Remove the pad pin plug "1". h.
Page 78: Checking The Rear Brake Pad Insulator
CHASSIS 3. Inspect: d. Remove the pad pin "6" and brake Tighten the pad pin "14". • Brake fluid level pads "7". Pad pin: Refer to "CHECKING THE 18 Nm (1.8 m•kg, 13 BRAKE FLUID LEVEL" section. ft•lb) 4. Check: •...
Page 79: Checking The Brake Fluid Level
CHASSIS CHECKING THE BRAKE FLUID CHECKING THE DRIVE CHAIN 4. Inspect: LEVEL 1. Measure: • O-ring "1" (drive chain) 1. Place the brake master cylinder • Drive chain length (15 links) "a" Damage → Replace the drive so that its top is in a horizontal po- Out of specification →...
Page 80: Cleaning The Front Fork Oil Seal And Dust Seal
CHASSIS b. Adjust the drive chain slack by CLEANING THE FRONT FORK OIL turning the adjusters "3". SEAL AND DUST SEAL 1. Remove: To tighten→Turn the adjuster "3" • Protector counterclockwise. • Dust seal "1" To loosen→Turn the adjuster "3" clockwise and push wheel for- Use a thin screw driver, and be care- ward.
Page 81: Checking The Rear Shock Absorber
CHASSIS ADJUSTING THE FRONT FORK ADJUSTING THE REAR SHOCK Extent of adjustment: REBOUND DAMPING FORCE ABSORBER SPRING PRELOAD 1. Adjust: 1. Elevate the rear wheel by placing Maximum Minimum • Rebound damping force the suitable stand under the en- By turning the adjuster "1". gine.
Page 82 CHASSIS Extent of adjustment: Maximum Minimum 20 clicks out Fully turned in (from maximum position position) • STANDARD POSITION: Extent of adjustment: This is the position which is back by the specific number of clicks Maximum Minimum from the fully turned-in position. (Which align the punch mark "a"...
Page 83: Checking And Tightening The Spokes
CHASSIS CHECKING AND TIGHTENING THE 2. Inspect: SPOKES • Bearing free play The following procedure applies to all Exist play → Replace. of the spokes. 1. Check: • Spokes Bend/damage → Replace. Loose spoke → Retighten. • STANDARD POSITION: Tap the spokes with a screw- This is the position which is back driver.
Page 84 CHASSIS • Install the handlebar so that the pro- jection "c" of the handlebar upper holder is positioned at the mark on the handlebar as shown. • Insert the end of the fuel breather hose "13" into the hole in the steer- ing stem.
Page 85 CHASSIS LUBRICATION To ensure smooth operation of all Use Yamaha cable lube or components, lubricate your machine equivalent on these areas. during setup, after break-in, and after Use SAE 10W-40 motor oil or every ride. suitable chain lubricants. All control cable...
Page 86: Electrical
ELECTRICAL ELECTRICAL CHECKING THE IGNITION TIMING CHECKING AND CHARGING THE 1. Remove: BATTERY CHECKING THE SPARK PLUG • Timing mark accessing screw "1" 1. Remove: • Spark plug Batteries generate explosive hy- 2. Inspect: drogen gas and contain electrolyte • Electrode "1" which is made of poisonous and Wear/damage →...
Page 87 ELECTRICAL 1. Remove: • Seat • Never remove the MF battery 2. Disconnect: sealing caps. • Battery leads • Do not use a high-rate battery (from the battery terminals) charger since it forces a high- amperage current into the bat- First, disconnect the negative bat- tery quickly and can cause bat- tery lead "1", and then the positive...
Page 88 ELECTRICAL Charging method using a variable voltage charger 3-29...
Page 89 ELECTRICAL Charging method using a constant voltage charger 3-30...
Page 90: Replacing The Headlight Bulbs
ELECTRICAL 6. Install: REPLACING THE HEADLIGHT • Battery BULBS • Battery band 1. Remove: 7. Connect: • Headlight • Battery leads Refer to "REMOVING THE SEAT, (to the battery terminals) FUEL TANK AND SIDE COV- ERS" section. 2. Remove: First, connect the positive lead "1", 2.
Page 91: Adjusting The Headlight Beams
ELECTRICAL 6. Install: • Headlight bulb holder 7. Install: • Headlight bulb holder cover 8. Install: • Headlight Headlight: 7 Nm (0.7 m•kg, 5.1 ft•lb) Refer to "REMOVING THE SEAT, FUEL TANK AND SIDE COV- ERS" section. ADJUSTING THE HEADLIGHT BEAMS 1.
Page 92 ENGINE TUNING • After installing the carburetor, CONSTRUCTION OF check that the throttle operates CARBURETOR AND SETTING ENGINE correctly and opens and closes PARTS CARBURETOR SETTING smoothly. The FLATCR carburetor has a prima- • The air/fuel mixture will vary de- ry main jet.
Page 93 ENGINE ADJUSTING THE PILOT JET Effects of changing the jet needle ADJUSTING THE LEAK JET The richness of the air-fuel mixture groove position (reference) (ADJUSTING THE ACCELERATOR with the throttle open 1/4 or less can PUMP) be set by adjusting the pilot jet "1". The leak jet "1"...
Page 94 ENGINE CARBURETOR SETTING PARTS Part Leak jet Size number Part (-1494F-) Main jet Size number Rich 4JT-11 (-14943-) (STD) 4JT-15 Rich #182 4MX-94 4JT-19 #180 4MX-43 4JT-23 #178 4MX-93 #100 4JT-27 #175 4MX-42 #110 4JT-29 #172 4MX-92 Lean #120 4JT-31 * (STD) #170 4MX-41...
Page 95 ENGINE EXAMPLES OF CARBURETOR SETTING DEPENDING ON SYMPTOM Symptom Setting Checking At full throttle Increase main jet calibration no. (Gradual- Discoloration of spark plug → If tan color, it Hard breathing is in good condition. Shearing noise If cannot be corrected: Whitish spark plug Clogged float valve seat Clogged fuel hose...
Page 96 CHASSIS CHASSIS DRIVE AND REAR WHEEL SPROCKETS SETTING PARTS SELECTION OF THE SECONDARY For EUROPE REDUCTION RATIO (SPROCKET) Part Size Part number Secondary reduction ratio = name Number of rear wheel sprocket Drive teeth/Number of drive sprocket sprocket teeth "1" 47/14 9383B-13218 Standard secondary...
Page 97: Adjusting The Spring Preload
CHASSIS CHANGE IN LEVEL AND ADJUSTING THE SPRING CHARACTERISTICS OF FORK OIL PRELOAD Generally a soft spring gives a soft Damping characteristic near the final The spring preload is adjusted by in- riding feeling. Rebound damping stroke can be changed by changing stalling the adjustment washer "1"...
Page 98 CHASSIS 3. Loosen the locknut "1" and make adjustment by turning the spring When using a rear shock absorber adjuster "2" to achieve the stan- other than currently installed, use dard figure from the subtraction of the one whose overall length "a" the length "b"...
Page 99 CHASSIS • Extent of adjustment (spring pre- load) SPRING PART NUM- Maximum Minimum (-22212-) 5UN-00 Position 5UN-10 in which 5UN-20 the spring 5UN-30 is turned in 20 mm Position (0.79 in) in which from its the spring free is turned length.
Page 100: Suspension Setting (Front Fork)
CHASSIS SUSPENSION SETTING (FRONT FORK) • If any of the following symptoms is experienced with the standard position as the base, make resetting by reference to the adjustment procedure given in the same chart. • Before any change, set the rear shock absorber sunken length to the standard figure 90–100 mm (3.5–3.9 in). Section Medi- Symptom...
Page 101: Suspension Setting (Rear Shock Absorber)
CHASSIS SUSPENSION SETTING (REAR SHOCK ABSORBER) • If any of the following symptoms is experienced with the standard position as the base, make resetting by reference to the adjustment procedure given in the same chart. • Adjust the rebound damping in 2-click increments or decrements. •...
Page 102: Removing The Radiator
RADIATOR ENGINE This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.) Those who have little knowledge and skill concerning servicing are request- ed not to undertake inspection, adjustment, disassembly, or reassembly only by reference to this manual. It may lead to servicing trouble and mechanical damage.
Page 103 RADIATOR Order Part name Q'ty Remarks Catch tank hose Right radiator Radiator hose 2 Radiator hose 4 Radiator pipe 1 Catch tank breather hose Catch tank...
Page 104: Handling Note
RADIATOR HANDLING NOTE 2. Install: 5. Tighten: • Catch tank hose "1" • Radiator hose clamp "4" • Radiator hose 2 "2" Radiator hose clamp: Do not remove the radiator cap • Radiator hose 3 "3" 2 Nm (0.2 m•kg, 1.4 when the engine and radiator are •...
Page 105: Removing The Carburetor
CARBURETOR CARBURETOR REMOVING THE CARBURETOR 4 Nm (0.4 m kg, 2.9 ft lb) 2 Nm (0.2 m kg, 1.4 ft lb) 11 Nm (1.1 m kg, 8.0 ft lb) 4 Nm (0.4 m kg, 2.9 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 3 Nm (0.3 m kg, 2.2 ft lb) 3 Nm (0.3 m kg, 2.2 ft lb) Order...
Page 106: Disassembling The Carburetor
CARBURETOR DISASSEMBLING THE CARBURETOR Order Part name Q'ty Remarks Carburetor breather hose Valve lever housing cover Screw (throttle shaft) Throttle valve Needle holder Jet needle Accelerator pump cover Spring Diaphragm (accelerator pump) Air cut valve cover Spring (air cut valve) Diaphragm (air cut valve) Float chamber Leak jet...
Page 107 CARBURETOR Order Part name Q'ty Remarks Main jet Needle jet Spacer Pilot jet Starter jet Push rod Pull the push rod. Throttle shaft assembly Push rod link lever assembly Main air jet Pilot air jet Cold starter plunger...
Page 108 CARBURETOR HANDLING NOTE 2. Inspect: CHECKING THE JET NEEDLE • Main jet "1" 1. Inspect: • Pilot jet "2" • Jet needle "1" Do not loosen the screw (throttle • Needle jet "3" Bends/wear → Replace. position sensor) "1" except when •...
Page 109 CARBURETOR e. If both are fine, adjust the float 2. Inspect: height by bending the float tab "b" • Throttle shaft "1" on the float. • Spring "2" • Lever 1 "3" • Spring 1 "4" • Lever 2 "5" •...
Page 110 CARBURETOR 8. Install: 10. Install: 13. Install: • Throttle shaft assembly "1" • Starter jet "1" • O-ring • Washer (metal) "2" • Pilot jet "2" • Leak jet "1" • Washer (resin) "3" • Spacer "3" • Float chamber "2" •...
Page 111: Installing The Carburetor
CARBURETOR 16. Install: ADJUSTING THE ACCELERATOR • Jet needle "1" PUMP TIMING • Collar "2" • Spring "3" Adjustment steps: • Needle holder "4" • Throttle valve plate "5" In order for the throttle valve height To throttle valve "6". "a"...
Page 112 CARBURETOR 6. Adjust: • Throttle grip free play Refer to "ADJUSTING THE THROTTLE GRIP FREE PLAY" section in the CHAPTER 3. 7. Install: • Throttle cable cover "1" • Bolt (throttle cable cover) "2" Bolt (throttle cable cov- er): 4 Nm (0.4 m•kg, 2.9 ft•lb) 8.
Page 113: Air Indictoin System
AIR INDICTOIN SYSTEM AIR INDICTOIN SYSTEM REMOVING THE AIR INDUCTION SYSTEM 7 Nm (0.7 m kg, 5.1 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 4 Nm (0.4 m kg, 2.9 ft lb) Order Part name Q'ty Remarks Bracket Air cut-off valve assembly Air induction hose (air cut-off valve - front of cyl-...
Page 114: Checking The Air Induction System
AIR INDICTOIN SYSTEM CHECKING THE AIR INDUCTION SYSTEM 1. Inspect: • Air induction hose Crack/damage → Replace. • Air induction pipe Crack/damage → Replace. 2. Check: • Operation of air cut valve a. From air filter Pass air through the pipe and b.
Page 115: Removing The Cylinder Head Cover
CAMSHAFTS CAMSHAFTS REMOVING THE CYLINDER HEAD COVER Order Part name Q'ty Remarks Refer to "REMOVING THE SEAT, FUEL Seat and fuel tank TANK AND SIDE COVERS" section in the CHAPTER 3. Air cut-off valve assembly Refer to "AIR INDUCTION SYSTEM" section. Spark plug Cylinder head breather hose Bolt (cylinder head cover)
Page 116: Removing The Camshafts
CAMSHAFTS REMOVING THE CAMSHAFTS Order Part name Q'ty Remarks Timing mark accessing screw Refer to removal section. Crankshaft end accessing screw Refer to removal section. Timing chain tensioner cap bolt Refer to removal section. Timing chain tensioner Refer to removal section. Camshaft cap Refer to removal section.
Page 117: Removing The Camshaft
CAMSHAFTS REMOVING THE CAMSHAFT 3. Remove: CHECKING THE CAMSHAFT 1. Remove: • Timing chain tensioner cap bolt 1. Inspect: • Timing mark accessing screw "1" "1" • Cam lobe • Crankshaft end accessing screw • Timing chain tensioner "2" Pitting/scratches/blue discolor- "2"...
Page 118: Checking The Camshaft Sprocket
CAMSHAFTS 4. Measure: • Camshaft-to-cap clearance Out of specification → Measure camshaft outside diameter. Camshaft-to-cap clear- ance: 0.028–0.062 mm (0.0011–0.0024 in) CHECKING THE CAMSHAFT <Limit>:0.08 mm (0.003 SPROCKET 1. Inspect: • Camshaft sprocket "1" Wear/damage → Replace the Measurement steps: camshaft assembly and timing a.
Page 119 Apply the sealant on the cylinder d. Install the clips, camshaft caps "4" ft•lb) head cover gasket. and bolts (camshaft cap) "5". Bolt (camshaft cap): Yamaha bond No. 1215: 10 Nm (1.0 m•kg, 7.2 90890-85505 ft•lb) (Three bond No.1215®) c. Release the screwdriver, check the tensioner rod to come out and tighten the gasket "4"...
Page 120: Removing The Cylinder Head
CYLINDER HEAD CYLINDER HEAD REMOVING THE CYLINDER HEAD Order Part name Q'ty Remarks Refer to "REMOVING THE SEAT, FUEL Seat and fuel tank TANK AND SIDE COVERS" section in the CHAPTER 3. Refer to "REMOVING THE EXHAUST PIPE Exhaust pipe and silencer AND SILENCER"...
Page 121: Checking The Cylinder Head
CYLINDER HEAD CHECKING THE CYLINDER HEAD INSTALLING THE CYLINDER 1. Eliminate: HEAD • Carbon deposits (from the com- 1. Install: bustion chambers) • Dowel pin "1" Use a rounded scraper. • Cylinder head gasket "2" • Timing chain guide (exhaust side) "3"...
Page 122: Removing The Valves And Valve Springs
VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS REMOVING THE VALVES AND VALVE SPRINGS Order Part name Q'ty Remarks Cylinder head Refer to "CYLINDER HEAD" section. Valve lifter Refer to removal section. Adjusting pad Refer to removal section. Valve cotter Refer to removal section.
Page 123: Checking The Valve
VALVES AND VALVE SPRINGS REMOVING THE VALVE LIFTER a. Remove the valve guide using a Valve spring compres- valve guide remover "1". AND VALVE COTTER sor: 1. Remove: YM-04019/90890-04019 • Valve lifter "1" Valve spring compressor • Pad "2" adapter 19.5 mm: YM-04114 Valve spring compressor Identify each lifter "1"...
Page 124 VALVES AND VALVE SPRINGS 3. Inspect: • When replacing the valves or valve Valve seat width: • Valve face guides, use new valves to lap the Intake: Pitting/wear → Grind the face. valve seats, and then replace them 0.90–1.10 mm •...
Page 125: Checking The Valve Springs
VALVES AND VALVE SPRINGS h. Press the valve through the valve 3. Install: guide and onto the valve seat to • Valve cotter make a clear pattern. Measure the valve seat width Install the valve cotters by compress- again. If the valve seat width is out ing the valve spring with the valve of specification, reface and relap spring compressor "1"...
Page 126: Removing The Cylinder And Piston
CYLINDER AND PISTON CYLINDER AND PISTON REMOVING THE CYLINDER AND PISTON Order Part name Q'ty Remarks Cylinder head Refer to "CYLINDER HEAD" section. Bolt (cylinder) Cylinder Piston pin clip Refer to removal section. Piston pin Refer to removal section. Piston Refer to removal section.
Page 127: Checking The Cylinder And Piston
CYLINDER AND PISTON REMOVING THE PISTON AND CHECKING THE CYLINDER AND d. If out of specification, replace the PISTON RING PISTON piston and piston rings as a set. 1. Remove: 1. Inspect: e. Calculate the piston-to-cylinder • Piston pin clip "1" •...
Page 128: Checking The Piston Pin
CYLINDER AND PISTON b. Measure the inside diameter (pis- ton) "b". Inside diameter (piston): 16.002–16.013 mm (0.6300–0.6304 in) 10 mm (0.39 in) Top ring end 3. Measure: 2nd ring end • Ring end gap Oil ring end (upper) Out of specification → Replace. Oil ring Oil ring end (lower) 3.
Page 129: Installing The Cylinder
CYLINDER AND PISTON INSTALLING THE CYLINDER 1. Lubricate: • Piston • Piston ring • Cylinder Apply a liberal coating of engine oil. 2. Install: • Dowel pin "1" • O-ring "2" Apply the lithium soap base grease on the O-ring. 3.
Page 130: Removing The Clutch
CLUTCH CLUTCH REMOVING THE CLUTCH Order Part name Q'ty Remarks Refer to "CHANGING THE ENGINE OIL" Drain the engine oil. section in the CHAPTER 3. Brake pedal Refer to "ENGINE REMOVAL" section. Clutch cable Disconnect at engine side. Clutch cover Clutch spring Pressure plate Push rod 1...
Page 131 CLUTCH Order Part name Q'ty Remarks Nut (clutch boss) Refer to removal section. Lock washer Refer to removal section. Clutch boss Refer to removal section. Thrust washer Primary driven gear Push lever shaft 5-30...
Page 132: Checking The Clutch Springs
CLUTCH REMOVING THE CLUTCH BOSS CHECKING THE CLUTCH CHECKING THE PUSH LEVER 1. Remove: SPRINGS SHAFT • Nut "1" 1. Measure: 1. Inspect: • Lock washer "2" • Clutch spring free length "a" • Push lever shaft "1" • Clutch boss "3" Out of specification →...
Page 133: Installing The Clutch
CLUTCH INSTALLING THE CLUTCH 1. Install: • Install the seat plate with its cham- • Primary driven gear "1" fered portion "a" facing the clutch • Thrust washer "2" boss "3". • Clutch boss "3" • Install the seat plate so that it is not caught on the step "b".
Page 134 CLUTCH 10. Install: • Dowel pin "1" • Gasket (clutch cover) "2" 11. Install: • Clutch cover "1" • Bolt (clutch cover) Bolt (clutch cover): 10 Nm (1.0 m•kg, 7.2 ft•lb) Tighten the bolts in stage, using a crisscross pattern. 5-33...
Page 135: Oil Filter Element And Water Pump
OIL FILTER ELEMENT AND WATER PUMP OIL FILTER ELEMENT AND WATER PUMP REMOVING THE OIL FILTER ELEMENT AND WATER PUMP Order Part name Q'ty Remarks Refer to "CHANGING THE ENGINE OIL" Drain the engine oil. section in the CHAPTER 3. Refer to "CHANGING THE COOLANT"...
Page 136 OIL FILTER ELEMENT AND WATER PUMP Order Part name Q'ty Remarks Washer Refer to removal section. Impeller shaft Refer to removal section. Oil seal Refer to removal section. Bearing Refer to removal section. 5-35...
Page 137 OIL FILTER ELEMENT AND WATER PUMP REMOVING THE IMPELLER INSTALLING THE OIL SEAL SHAFT 1. Install: 1. Remove: • Oil seal "1" • Impeller "1" • Washer "2" • Apply the lithium soap base grease • Impeller shaft "3" on the oil seal lip. •...
Page 138: Installing The Right Crankcase Cover
OIL FILTER ELEMENT AND WATER PUMP INSTALLING THE KICKSTARTER LEVER 1. Install: • Kickstarter lever "1" • Washer • Bolt (kickstarter lever) Bolt (kickstarter lever): 33 Nm (3.3 m•kg, 24 INSTALLING THE RIGHT INSTALLING THE WATER PUMP ft•lb) CRANKCASE COVER HOUSING 1.
Page 139 OIL FILTER ELEMENT AND WATER PUMP INSTALLING THE OIL FILTER ELEMENT 1. Install: • Oil filter element "1" • O-ring "2" • Oil filter element cover "3" • Bolt (oil filter element cover) Bolt (oil filter element cover): 10 Nm (1.0 m•kg, 7.2 ft•lb) Apply the lithium soap base grease on the O-ring.
Page 140: Removing The Balancer
BALANCER BALANCER REMOVING THE BALANCER Order Part name Q'ty Remarks Primary driven gear Refer to "CLUTCH" section. Refer to "OIL FILTER ELEMENT AND WA- Right crankcase cover TER PUMP" section. Refer to "AC MAGNETO AND STARTER Stator CLUTCH" section. Nut (primary drive gear) Refer to removal section.
Page 141: Checking The Balancer Shaft
BALANCER REMOVING THE BALANCER CHECKING THE BALANCER 1. Straighten the lock washer tab. SHAFT 2. Loosen: 1. Inspect: • Nut (primary drive gear) "1" • Balancer shaft • Nut (balancer shaft driven gear) Cracks/damage → Replace. "2" Place an aluminum plate "a" between 4.
Page 142: Removing The Oil Pump
OIL PUMP OIL PUMP REMOVING THE OIL PUMP Order Part name Q'ty Remarks Primary driven gear Refer to "CLUTCH" section. Refer to "OIL FILTER ELEMENT AND WA- Right crankcase cover TER PUMP" section. Circlip Washer Oil pump drive gear Oil pump assembly Outer rotor 2 Circlip Inner rotor 2...
Page 143: Removing The Oil Tank
OIL PUMP REMOVING THE OIL TANK Order Part name Q'ty Remarks Refer to "CHANGING THE ENGINE OIL" Drain the engine oil. section in the CHAPTER 3. Oil hose 2 Oil hose 1 Dowel pin Oil tank breather hose Oil tank Oil strainer 5-42...
Page 144: Checking The Oil Pump
OIL PUMP CHECKING THE OIL PUMP 3. Check: 1. Inspect: • Unsmooth→Repeat steps #1 and • Oil pump drive gear "1" #2 or replace the defective parts. • Oil pump drive shaft "2" • Rotor housing "3" • Oil pump cover "4" Cracks/wear/damage →...
Page 145: Kick Shaft And Shift Shaft
KICK SHAFT AND SHIFT SHAFT KICK SHAFT AND SHIFT SHAFT REMOVING THE KICK SHAFT AND SHIFT SHAFT Order Part name Q'ty Remarks Oil pump Refer to "OIL PUMP" section. Kick idle gear Kick shaft assembly Refer to removal section. Spring guide Torsion spring Ratchet wheel Kick gear...
Page 146 KICK SHAFT AND SHIFT SHAFT Order Part name Q'ty Remarks Pawl Pawl pin Spring Bolt (stopper lever) Stopper lever Torsion spring Segment Refer to removal section. 5-45...
Page 147: Removing The Kick Shaft Assembly
KICK SHAFT AND SHIFT SHAFT REMOVING THE KICK SHAFT CHECKING THE KICK SHAFT AND CHECKING THE SHIFT GUIDE AND ASSEMBLY RATCHET WHEEL SHIFT LEVER ASSEMBLY 1. Remove: 1. Check: 1. Inspect: • Kick shaft assembly "1" • Ratchet wheel "1" smooth move- •...
Page 148: Installing The Stopper Lever
KICK SHAFT AND SHIFT SHAFT INSTALLING THE STOPPER 3. Install: INSTALLING THE KICK SHAFT LEVER • Shift lever assembly "1" ASSEMBLY 1. Install: • Shift guide "2" 1. Install: • Torsion spring "1" • Kick gear "1" • Stopper lever "2" •...
Page 149: Installing The Kick Idle Gear
KICK SHAFT AND SHIFT SHAFT 4. Install: • Kick shaft assembly "1" • Washer "2" • Apply the molybdenum disulfide grease on the contacting surfaces of the kick shaft stopper "a" and kick shaft ratchet wheel guide "3". • Apply the engine oil on the kick shaft.
Page 150: Ac Magneto And Starter Clutch
AC MAGNETO AND STARTER CLUTCH AC MAGNETO AND STARTER CLUTCH REMOVING THE AC MAGNETO AND STARTER CLUTCH Order Part name Q'ty Remarks Refer to "CHANGING THE ENGINE OIL" Drain the engine oil. section in the CHAPTER 3. Refer to "REMOVING THE SEAT, FUEL Seat and fuel tank TANK AND SIDE COVERS"...
Page 151 AC MAGNETO AND STARTER CLUTCH Order Part name Q'ty Remarks Starter clutch Refer to removal section. Bearing Washer Idle gear plate Idle gear Holder Pickup coil Stator Tighten the rotor nut to 65 Nm (6.5 m•kg, 47 ft•lb), loosen and retighten the rotor nut to 65 Nm (6.5 m•kg, 47 ft•lb). 5-50...
Page 152: Removing The Starter Clutch
AC MAGNETO AND STARTER CLUTCH REMOVING THE ROTOR 3. Check: 1. Remove: • Starter clutch operation • Nut (rotor) "1" • Washer a. Install the starter clutch drive gear Use the sheave holder "2". "1" onto the starter clutch "2" and hold the starter clutch.
Page 153 • Starter clutch "1" Nut (rotor): the AC magneto lead. To rotor "2". 65 Nm (6.5 m•kg, 47 ft•lb) Yamaha bond No. 1215: • Install the starter clutch with its 90890-85505 Use the sheave holder "2" plate side upward. (Three bond No.1215®) •...
Page 154 AC MAGNETO AND STARTER CLUTCH 10. Install: • Dowel pin • Gasket [crankcase cover (left)] • Crankcase cover (left) "1" • Bolt [crankcase cover (left)] "2" Bolt [crankcase cover (left)]: 13. Connect: 10 Nm (1.0 m•kg, 7.2 • AC magneto lead ft•lb) Refer to "CABLE ROUTING DIA- •...
Page 155: Engine Removal
ENGINE REMOVAL ENGINE REMOVAL REMOVING THE ENGINE Order Part name Q'ty Remarks Hold the machine by placing the suitable stand Refer to "HANDLING NOTE". under the frame. Refer to "CHANGING THE ENGINE OIL" Drain the engine oil. section in the CHAPTER 3. Refer to "REMOVING THE SEAT, FUEL Seat and fuel tank TANK AND SIDE COVERS"...
Page 156 ENGINE REMOVAL Order Part name Q'ty Remarks Disconnect the AC magneto lead. Negative battery lead Disconnect at the engine side. Engine guard Neutral switch Drive chain sprocket cover Nut (drive sprocket) Refer to removal section. Lock washer Refer to removal section. Drive sprocket Refer to removal section.
Page 157: Removing The Drive Sprocket
ENGINE REMOVAL HANDLING NOTE 2. Remove: • Engine "1" • Apply the molybdenum disulfide From right side. grease on the pivot shaft. Support the machine securely so • Install the patch with the claw "a" there is no danger of it falling over. Make sure that the couplers, hoses facing outside the chassis.
Page 158 ENGINE REMOVAL 2. Install: • Lock washer "1" • Nut (drive sprocket) "2" Nut (drive sprocket): 75 Nm (7.5 m•kg, 54 ft•lb) Tighten the nut while applying the rear brake. 3. Bend the lock washer tab to lock the nut. 4.
Page 159: Crankcase And Crankshaft
CRANKCASE AND CRANKSHAFT CRANKCASE AND CRANKSHAFT REMOVING THE CRANKSHAFT Order Part name Q'ty Remarks Engie Refer to "ENGINE REMOVAL" section. Piston Refer to "CYLINDER AND PISTON" section. Refer to "KICK SHAFT AND SHIFT SHAFT" Kick shaft assembly section. Refer to "KICK SHAFT AND SHIFT SHAFT" Segment section.
Page 160 CRANKCASE AND CRANKSHAFT Order Part name Q'ty Remarks Right crankcase Refer to removal section. Left crankcase Refer to removal section. Oil strainer Crankshaft Refer to removal section. 5-59...
Page 161: Removing The Crankcase Bearing
CRANKCASE AND CRANKSHAFT REMOVING THE CRANKCASE BEARING Order Part name Q'ty Remarks Refer to "TRANSMISSION, SHIFT CAM AND Transmission SHIFT FORK" section. Refer to "TRANSMISSION, SHIFT CAM AND Shift cam and shift fork SHIFT FORK" section. Oil seal Bearing Refer to removal section. 5-60...
Page 162: Disassembling The Crankcase
CRANKCASE AND CRANKSHAFT DISASSEMBLING THE c. Remove the dowel pins and O- CHECKING THE CRANKCASE CRANKCASE ring. 1. Inspect: 1. Separate: • Contacting surface "a" • Right crankcase Scratches → Replace. REMOVING THE CRANKSHAFT • Left crankcase • Engine mounting boss "b", crank- 1.
Page 163: Checking The Oil Strainer
On the right crankcase "1". • Bearing other. Operate the installing tool un- • Bearing stopper Yamaha bond No. 1215: til the crankshaft bottoms against • Bolt (bearing stopper) 90890-85505 the bearing.
Page 164 CRANKCASE AND CRANKSHAFT Apply the lithium soap base grease on the Orings. 5. Install: • Dowel pin "1" • O-ring "2" • Right crankcase 8. Install: To left crankcase. • Timing chain "1" • Timing chain guide (intake side) • Apply the lithium soap base grease "2"...
Page 165: Transmission, Shift Cam And Shift Fork
TRANSMISSION, SHIFT CAM AND SHIFT FORK TRANSMISSION, SHIFT CAM AND SHIFT FORK REMOVING THE TRANSMISSION, SHIFT CAM AND SHIFT FORK Order Part name Q'ty Remarks Engine Refer to "ENGINE REMOVAL" section. Refer to "CRANKCASE AND CRANK- Separate the crankcase. SHAFT" section. Main axle Refer to removal section.
Page 166 TRANSMISSION, SHIFT CAM AND SHIFT FORK REMOVING THE TRANSMISSION CHECKING THE BEARING INSTALLING THE TRANSMISSION 1. Remove: 1. Inspect: 1. Install: • Main axle "1" • Bearing "1" • 5th pinion gear (19T) "1" • Drive axle "2" Rotate inner race with a finger. •...
Page 167 TRANSMISSION, SHIFT CAM AND SHIFT FORK 3. Install: • Washer "1" • Circlip "2" • Be sure the circlip sharp-edged cor- ner "a" is positioned opposite side to the washer and gear "b". • Install the circlip with its ends "c" settled evenly on the spline crests.
Page 168: Front Wheel And Rear Wheel
FRONT WHEEL AND REAR WHEEL CHASSIS This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.) Those who have little knowledge and skill concerning servicing are request- ed not to undertake inspection, adjustment, disassembly, or reassembly only by reference to this manual.
Page 169: Removing The Rear Wheel
FRONT WHEEL AND REAR WHEEL REMOVING THE REAR WHEEL 14 Nm (1.4 m kg, 10 ft lb) 125 Nm (12.5 m kg, 90 ft lb) 19 Nm (1.9 m kg, 13 ft lb) 50 Nm (5.0 m kg, 36 ft lb) 19 Nm (1.9 m kg, 13 ft lb) Order Part name...
Page 170 FRONT WHEEL AND REAR WHEEL HANDLING NOTE Support the machine securely so there is no danger of it falling over. REMOVING THE REAR WHEEL 1. Remove: • Wheel "1" CHECKING THE WHEEL AXLE 1. Measure: Push the wheel forward and remove •...
Page 171: Installing The Rear Wheel
FRONT WHEEL AND REAR WHEEL 2. Install: • Brake disc "1" • Bolt (brake disc) "2" Bolt (brake disc): 12 Nm (1.2 m•kg, 8.7 ft•lb) Tighten the bolts in stage, using a crisscross pattern. 6. Install: INSTALLING THE REAR WHEEL •...
Page 172 FRONT WHEEL AND REAR WHEEL 2. Install: 5. Install: 9. Adjust: • Brake disc "1" • Wheel • Drive chain slack "a" • Bolt (brake disc) "2" Drive chain slack: Install the brake disc "1" between the Bolt (brake disc): 48.0–58.0 mm (1.89–...
Page 173: Front Brake And Rear Brake
FRONT BRAKE AND REAR BRAKE FRONT BRAKE AND REAR BRAKE REMOVING THE FRONT BRAKE Order Part name Q'ty Remarks Hold the machine by placing the suitable stand Refer to "HANDLING NOTE". under the engine. Drain the brake fluid. Refer to removal section. Brake hose holder (protector) Brake hose holder (brake caliper) Union bolt...
Page 174 FRONT BRAKE AND REAR BRAKE REMOVING THE REAR BRAKE Order Part name Q'ty Remarks Hold the machine by placing the suitable stand Refer to "HANDLING NOTE". under the engine. Refer to "FRONT WHEEL AND REAR Rear wheel WHEEL" section. Drain the brake fluid. Refer to removal section.
Page 175 FRONT BRAKE AND REAR BRAKE DISASSEMBLING THE BRAKE CALIPER Order Part name Q'ty Remarks Front Rear Pad pin Brake pad Pad support Brake caliper piston Refer to removal section. Brake caliper piston dust seal Refer to removal section. Brake caliper piston seal Refer to removal section.
Page 176 FRONT BRAKE AND REAR BRAKE DISASSEMBLING THE BRAKE MASTER CYLINDER Order Part name Q'ty Remarks Front Rear Brake master cylinder cap Diaphragm Reservoir float Brake master cylinder boot Circlip Use a long nose circlip pliers. Washer Push rod Brake master cylinder kit...
Page 177 FRONT BRAKE AND REAR BRAKE HANDLING NOTE REMOVING THE BRAKE CALIPER PISTON 1. Remove: Support the machine securely so • Brake caliper piston there is no danger of it falling over. Use compressed air and proceed carefully. DRAINING THE BRAKE FLUID 1.
Page 178: Checking The Brake Hose
FRONT BRAKE AND REAR BRAKE 3. Inspect: (front brake only) CHECKING THE BRAKE HOSE • Reservoir float "1" 1. Inspect: Damage → Replace. • Brake hose "1" Crack/damage → Replace. 4. Inspect: • Brake master cylinder piston "1" HANDLING NOTE •...
Page 179: Installing The Front Brake Caliper
FRONT BRAKE AND REAR BRAKE INSTALLING THE FRONT BRAKE CALIPER Apply the brake fluid on the brake 1. Install: master cylinder cup. • Pad support "1" • Brake pad "2" • Pad pin "3" After installing, cylinder cup should be installed as shown di- •...
Page 180: Installing The Front Brake Master Cylinder
FRONT BRAKE AND REAR BRAKE • Nut (brake lever) "3" 2. Install: • Brake master cylinder "1" Nut (brake lever): • Bolt (brake master cylinder) "2" 6 Nm (0.6 m•kg, 4.3 ft•lb) Bolt (brake master cylin- der): 10 Nm (1.0 m•kg, 7.2 Apply the silicone grease on the ft•lb) brake lever sliding surface, bolt and...
Page 181 FRONT BRAKE AND REAR BRAKE INSTALLING THE FRONT BRAKE HOSE Always use new copper washers. 1. Install: • Copper washer "1" • Brake hose "2" • Union bolt "3" Union bolt: 30 Nm (3.0 m•kg, 22 4. Pass the brake hose through the ft•lb) front brake hose guides "1".
Page 182 FRONT BRAKE AND REAR BRAKE FILLING THE BRAKE FLUID 4. Install: 1. Fill: • Reservoir float (front brake) • Brake fluid • Diaphragm Until the fluid level reaches • Brake master cylinder cap "1" "LOWER" level line "a". • Screw (bolt) {brake master cylin- der cap} "2"...
Page 183: Removing The Front Fork
FRONT FORK FRONT FORK REMOVING THE FRONT FORK Order Part name Q'ty Remarks Hold the machine by placing the suitable stand Refer to "HANDLING NOTE". under the engine. Refer to "FRONT WHEEL AND REAR Front wheel WHEEL" section. Refer to "FRONT BRAKE AND REAR Front brake caliper BRAKE"...
Page 184 FRONT FORK DISASSEMBLING THE FRONT FORK Order Part name Q'ty Remarks Front fork cap bolt Refer to removal section. Fork spring Drain the fork oil. Dust seal Refer to removal section. Stopper ring Refer to removal section. Inner tube Refer to removal section. Outer tube Piston metal Slide metal...
Page 185 FRONT FORK HANDLING NOTE REMOVING THE INNER TUBE CHECKING THE DAMPER ROD 1. Remove: 1. Inspect: • Dust seal "1" • Damper rod "1" Support the machine securely so • Stopper ring "2" Bend/damage→Replace damper there is no danger of it falling over. Using slotted-head screwdriver.
Page 186 FRONT FORK CHECKING THE INNER TUBE ASSEMBLING THE FRONT FORK 5. Install: 1. Inspect: 1. Wash the all parts in a clean sol- • Spring guide "1" • Inner tube surface "a" vent. • Locknut "2" Score marks → Repair or replace. 2.
Page 187 FRONT FORK 7. Install: 10. Install: 14. Compress the front fork fully. • Piston metal "1" • Oil seal "1" 15. Fill: • Front fork oil Until outer tube top surface with Install the piston metal onto the slot Press the oil seal into the outer tube recommended fork oil "1".
Page 188 FRONT FORK 19. Wait ten minutes until the air bub- 21. Measure: bles have been removed from the • Distance "a" front fork, and the oil has dis- Out of specification → Turn into pense evenly in system before the locknut. setting recommended oil level.
Page 189: Installing The Front Fork
FRONT FORK INSTALLING THE FRONT FORK 7. Install: 1. Install: • Protector "1" • Front fork "1" • Bolt (protector) "2" Bolt (protector): • Temporarily tighten the pinch bolts 7 Nm (0.7 m•kg, 5.1 (lower bracket). ft•lb) • Do not tighten the pinch bolts (up- per bracket) yet.
Page 190: Removing The Handlebar
HANDLEBAR HANDLEBAR REMOVING THE HANDLEBAR Order Part name Q'ty Remarks Headlight Hot starter cable Disconnect at the lever side. Hot starter lever holder Clutch cable Disconnect at the lever side. Clutch lever holder Disconnect the clutch switch lead. Engine stop switch Disconnect the engine stop switch lead.
Page 191: Removing The Brake Master Cylinder
HANDLEBAR REMOVING THE BRAKE MASTER INSTALLING THE HANDLEBAR CYLINDER 1. Install: 1. Remove: • Handlebar lower holder "1" • Brake master cylinder bracket "1" • Washer "2" • Brake master cylinder "2" • Nut (handlebar lower holder) "3" • Install the handlebar lower holder •...
Page 192 HANDLEBAR 7. Install: 10. Install: • Throttle cables "1" • Start switch "1" To tube guide "2". Start switch: 0.5 Nm (0.05 m•kg, 0.36 Apply the lithium soap base grease ft•lb) on the throttle cable end and tube • Brake master cylinder "2" guide cable winding portion.
Page 193 HANDLEBAR • Hot starter lever holder "4" • Bolt (hot starter lever holder) "5" Bolt (hot starter lever holder): 4 Nm (0.4 m•kg, 2.9 ft•lb) • Clamp "6" • The engine stop switch, clutch lever holder and clamp should be in- stalled according to the dimensions shown.
Page 194 STEERING STEERING REMOVING THE STEERING Order Part name Q'ty Remarks TIGHTENING STEPS: • Tighten ring nut. 38 Nm (3.8 m•kg, 27 ft•lb) • Loosen it one turn. • Retighten it. 7 Nm (0.7 m•kg, 5.1 ft•lb) Hold the machine by placing the suitable stand Refer to "HANDLING NOTE".
Page 195 STEERING Order Part name Q'ty Remarks Bearing race cover Upper bearing Lower bearing Refer to removal section. Bearing race Refer to removal section. 6-28...
Page 196 STEERING HANDLING NOTE CHECKING THE STEERING STEM 1. Inspect: • Steering stem "1" Support the machine securely so Bend/damage → Replace. there is no danger of it falling over. REMOVING THE STEERING RING 1. Remove: 3. Install: • Steering ring nut "1" •...
Page 197 STEERING 10. After tightening the nut, check the steering for smooth movement. If Pass the throttle cables "3", clutch ca- not, adjust the steering by loosen- ble "4" and hot starter cable "5" be- ing the steering ring nut little by lit- tween the multi-function display tle.
Page 198: Removing The Swingarm
SWINGARM SWINGARM REMOVING THE SWINGARM Order Part name Q'ty Remarks Hold the machine by placing the suitable stand Refer to "HANDLING NOTE". under the engine. Refer to "FRONT BRAKE AND REAR Brake hose holder BRAKE" section. Refer to "FRONT BRAKE AND REAR Rear brake caliper BRAKE"...
Page 199: Disassembling The Swingarm
SWINGARM DISASSEMBLING THE SWINGARM Order Part name Q'ty Remarks Refer to removal section. Relay arm Connecting rod Collar Oil seal Thrust bearing Bushing Oil seal Bearing Refer to removal section. 6-32...
Page 200 SWINGARM HANDLING NOTE CHECKING THE RELAY ARM 1. Inspect: • Bearing "1" Support the machine securely so • Collar "2" there is no danger of it falling over. Free play exists/unsmooth revolu- tion/rust → Replace bearing and REMOVING THE CAP collar as a set.
Page 201: Installing The Swingarm
SWINGARM 3. Install: • Collar "1" • Apply the molybdenum disulfide • Apply the molybdenum disulfide To connecting rod "2". grease on the bearing when install- grease on the pivot shaft. ing. • Insert the pivot shaft from right side. •...
Page 202 SWINGARM 10. Tighten: 14. Install: • Nut (connecting rod) "1" • Drive chain support "1" • Drive chain support cover "2" Nut (connecting rod): • Bolt {drive chain support [L = 50 80 Nm (8.0 m•kg, 58 mm (1.97 in)]} "3" ft•lb) •...
Page 203: Removing The Rear Shock Absorber
REAR SHOCK ABSORBER REAR SHOCK ABSORBER REMOVING THE REAR SHOCK ABSORBER Order Part name Q'ty Remarks Hold the machine by placing the suitable stand Refer to "HANDLING NOTE". under the engine. Refer to "REMOVING THE SEAT, FUEL Seat and side cover TANK AND SIDE COVERS"...
Page 204 REAR SHOCK ABSORBER Order Part name Q'ty Remarks Taillight coupler CDI unit coupler Plastic band Clamp (air filter joint) Only loosening. Rear frame Bolt (rear shock absorber-relay arm) Hold the swingarm. Bolt (rear shock absorber-frame) Rear shock absorber Locknut Only loosening. Adjuster Only loosening.
Page 205 To dispose of a damaged or worn- out rear shock absorber, take the unit to your Yamaha dealer for this disposal procedure. 6-38...
Page 206: Installing The Rear Shock Absorber
REAR SHOCK ABSORBER 2. Install: 3. Adjust: • Nut (rear shock absorber-frame) • Stopper ring (upper bearing) "1" • Spring length (installed) "3" Refer to "ADJUSTING THE Nut (rear shock absorb- REAR SHOCK ABSORBER er-frame): SPRING PRELOAD" section in After installing the stopper ring, push 56 Nm (5.6 m•kg, 40 the CHAPTER 3.
Page 207 REAR SHOCK ABSORBER 7. Tighten: • Screw (air filter joint) "1" Screw (air filter joint): 3 Nm (0.3 m•kg, 2.2 ft•lb) 8. Install: • Plastic band • Taillight coupler • Locking tie 6-40...
Page 208 ELECTRICAL COMPONENTS AND WIRING DIAGRAM ELECTRICAL This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.) Those who have little knowledge and skill concerning servicing are request- ed not to undertake inspection, adjustment, disassembly, or reassembly only by reference to this manual.
Page 209: Electrical Components And Wiring Diagram
ELECTRICAL COMPONENTS AND WIRING DIAGRAM WIRING DIAGRAM Headlight COLOR CODE Multi-function display Black Engine stop switch Brown Clutch switch Chocolate Diode Dark green Starter relay diode Green Throttle position sensor Gray Starter relay Blue Fuse Orange 10. Starting circuit cut-off relay 11.
Page 210: Ignition System
IGNITION SYSTEM IGNITION SYSTEM INSPECTION STEPS Use the following steps for checking the possibility of the malfunctioning engine being attributable to ignition system failure and for checking the spark plug which will not spark. *1 Check fuse. No good → Replace fuse and check wire harness.
Page 211 IGNITION SYSTEM SPARK GAP TEST CHECKING THE ENGINE STOP 1. Disconnect the ignition coil from SWITCH spark plug. 1. Inspect: 2. Remove the ignition coil cap. • Engine stop switch conduction 3. Connect the dynamic spark tester Tester (+) lead → Black lead "1" "1"...
Page 212: Electric Starting System
ELECTRIC STARTING SYSTEM 3. Inspect: CHECKING THE NEUTRAL • Secondary coil resistance SWITCH Out of specification → Replace. 1. Inspect: • Neutral switch conduction Tester (+) lead → Orange lead "1" Tester (-) lead → Spark plug termi- Tester (+) lead→Sky blue lead "1" nal "2"...
Page 213 ELECTRIC STARTING SYSTEM INSPECTION STEPS If the starter motor will not operate, use the following inspection steps. *1 Check fuse. No good → Replace fuse and check wire harness. OK ↓ *2 Check battery. No good → Recharge or replace. OK ↓...
Page 214 ELECTRIC STARTING SYSTEM CHECKING THE COUPLERS AND CHECKING THE CLUTCH SWITCH LEADS CONNECTION 1. Inspect: 1. Check: • Clutch switch conduction • Couplers and leads connection Tester (+) lead → Black lead "1" Rust/dust/looseness/short-circuit Tester (-) lead → Black lead "2" →...
Page 215 ELECTRIC STARTING SYSTEM CHECKING THE START SWITCH 1. Inspect: • Start switch conduction Tester (+) lead → Black lead "1" Tester (-) lead → Black lead "2" Result Conductive (while the start switch is pushed) Not conductive while it is pushed → Replace.
Page 216: Removing The Starter Motor
ELECTRIC STARTING SYSTEM REMOVING THE STARTER MOTOR Order Part name Q'ty Remarks Refer to "REMOVING THE EXHAUST PIPE Exhaust pipe AND SILENCER" section in the CHAPTER 3. Starter motor...
Page 217: Disassembling The Starter Motor
ELECTRIC STARTING SYSTEM DISASSEMBLING THE STARTER MOTOR Order Part name Q'ty Remarks Starter motor front cover Washer (starter motor front cover) Gasket Starter motor yoke Armature assembly Starter motor rear cover Brush Brush spring 7-10...
Page 218: Assembling The Starter Motor
ELECTRIC STARTING SYSTEM CHECKING AND REPAIRING THE ASSEMBLING THE STARTER Armature assembly: STARTER MOTOR MOTOR Commutator resis- 1. Check: 1. Install: tance "1": • Commutator • Brush spring "1" 0.0189–0.0231 Ω at 20 Dirt → Clean with 600 grit sandpa- •...
Page 219 ELECTRIC STARTING SYSTEM • For installation, align the projec- tions on the washer with the slots in the front cover. • Align the match mark "a" on the starter motor yoke with the match mark "b" on the starter motor front cover.
Page 220: Charging System
CHARGING SYSTEM CHARGING SYSTEM INSPECTION STEPS If the battery is not charged, use the following inspection steps. *1 Check fuse. No good → Replace fuse and check wire harness. OK ↓ *2 Check battery. No good → Recharge or replace. OK ↓...
Page 221: Checking The Charging Voltage
CHARGING SYSTEM CHECKING THE COUPLERS AND LEADS CONNECTION 1. Check: • Couplers and leads connection Rust/dust/looseness/short-circuit → Repair or replace. CHECKING THE CHARGING VOLTAGE 1. Start the engine. 2. Inspect: • Charging voltage Out of specification → If no failure is found in checking the source coil resistance, replace the rectifi- er/regulator.
Page 222: Throttle Position Sensor System
THROTTLE POSITION SENSOR SYSTEM THROTTLE POSITION SENSOR SYSTEM INSPECTION STEPS If the throttle position sensor will not operate, use the following inspection steps. Check entire ignition system for connection. No good → Repair or replace. OK ↓ Check throttle position sensor.(Throttle position No good →...
Page 223 THROTTLE POSITION SENSOR SYSTEM HANDLING NOTE 3. Inspect: 4. Install: • Throttle position sensor coil vari- • Throttle position sensor "1" able resistance • Screw (throttle position sensor) Do not loosen the screw (throttle Check that the resistance in in- "2"...
Page 224: Checking The Throttle Position Sensor Input Voltage
THROTTLE POSITION SENSOR SYSTEM 9. Adjust: CHECKING THE THROTTLE • Throttle position sensor output POSITION SENSOR INPUT voltage VOLTAGE 1. Disconnect the throttle position sensor coupler. Adjustment steps: 2. Start the engine. a. Adjust the installation angle of the 3. Inspect: throttle position sensor "1"...
Page 225: Lighting System
LIGHTING SYSTEM LIGHTING SYSTEM INSPECTION STEPS Refer to the following flow chart when inspecting the lighting system for possible problems. Check the bulb and bulb socket. No good → Replace the bulb and/or bulb socket. OK ↓ Check the taillight (LEDs). No good →...
Page 226: Checking The Rectifier/ Regulator
LIGHTING SYSTEM CHECKING THE TAILLIGHT CHECKING THE RECTIFIER/ (LEDs) REGULATOR 1. Disconnect the taillight coupler. 1. Connect the battery leads. 2. Connect two jumper leads "1" 2. Start the engine. from the battery terminals to the 3. Turn on the headlight and taillight respective coupler terminal as by turning on the light switch.
Page 227: Signaling System
SIGNALING SYSTEM SIGNALING SYSTEM INSPECTION STEPS If the speedometer will not operate, use the following inspection steps. *1 Check battery. No good → Recharge or replace. OK ↓ Check each coupler and wire connection. No good → Repair or replace. OK ↓...
Page 228 SIGNALING SYSTEM CHECKING THE COUPLERS AND LEADS CONNECTION Make sure that a short-circuit does 1. Check: not develop between the terminals • Couplers and leads connection because it may cause damage to Rust/dust/looseness/short-circuit electrical components. → Repair or replace. CHECKING THE MULTI-FUNCTION DISPLAY INPUT VOLTAGE 1.
Page 230 PRINTED ON RECYCLED PAPER PRINTED IN JAPAN...

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