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Yamaha 2009 YFM25RY, Service Manual

The Yamaha 2009 YFM25RY Service Manual is a comprehensive guide that allows you to maintain, troubleshoot, and repair your ATV with ease. Download this manual for free from 88.208.23.73:8080, and enjoy a hassle-free riding experience with your Yamaha 2009 YFM25RY.

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4

CHASSIS

GENERAL CHASSIS

....................................................................................4-1

FRONT WHEEL

............................................................................................4-4

REMOVING THE FRONT WHEELS.......................................................4-5
CHECKING THE FRONT WHEELS .......................................................4-5
CHECKING THE FRONT WHEEL HUBS...............................................4-5
CHECKING THE FRONT BRAKE DISCS ..............................................4-6
INSTALLING THE FRONT WHEEL HUB BEARINGS............................4-6
INSTALLING THE FRONT BRAKE DISCS.............................................4-6
INSTALLING THE FRONT WHEEL HUBS .............................................4-6
ADJUSTING THE FRONT WHEEL STATIC BALANCE .........................4-7
INSTALLING THE FRONT WHEELS......................................................4-8

REAR WHEEL

..............................................................................................4-9

REMOVING THE REAR WHEELS .......................................................4-10
CHECKING THE REAR WHEELS .......................................................4-10
CHECKING THE REAR WHEEL HUBS ............................................... 4-10
INSTALLING THE REAR WHEEL HUBS ............................................. 4-10
ADJUSTING THE REAR WHEEL STATIC BALANCE.......................... 4-10
INSTALLING THE REAR WHEELS ...................................................... 4-10

REAR AXLE AND REAR AXLE HUB

........................................................ 4-11

REMOVING THE REAR AXLE ............................................................. 4-13
CHECKING THE REAR AXLE ............................................................. 4-13
CHECKING THE REAR AXLE HUB ..................................................... 4-13
CHECKING THE REAR WHEEL SPROCKET ..................................... 4-14
CHECKING THE SPROCKET BRACKET ............................................ 4-14
INSTALLING THE REAR WHEEL SPROCKET.................................... 4-14
INSTALLING THE REAR AXLE ............................................................ 4-14

FRONT BRAKE

.......................................................................................... 4-15

INTRODUCTION .................................................................................. 4-20
CHECKING THE FRONT BRAKE DISCS ............................................ 4-20
REPLACING THE FRONT BRAKE PADS ............................................ 4-21
REMOVING THE FRONT BRAKE CALIPERS ..................................... 4-21
DISASSEMBLING THE FRONT BRAKE CALIPER ............................. 4-22
CHECKING THE FRONT BRAKE CALIPER........................................ 4-22
ASSEMBLING THE FRONT BRAKE CALIPER ................................... 4-23
INSTALLING THE FRONT BRAKE CALIPER ...................................... 4-23
REMOVING THE FRONT BRAKE MASTER CYLINDER..................... 4-24
CHECKING THE FRONT BRAKE MASTER CYLINDER ..................... 4-24
ASSEMBLING THE FRONT BRAKE MASTER CYLINDER................. 4-25
INSTALLING THE FRONT BRAKE MASTER CYLINDER ................... 4-25

REAR BRAKE

............................................................................................ 4-27

INTRODUCTION .................................................................................. 4-32
CHECKING THE REAR BRAKE DISC ................................................. 4-32

Summary of Contents for 2009 YFM25RY

Page 1: ...SERVICE MANUAL YFM25RY YFM25RSEY YFM25RSE2Y 4D3 28197 11 LIT 11616 22 09 2009 ...

Page 2: ...UAL 2008 by Yamaha Motor Corporation U S A First edition April 2008 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in U S A P N LIT 11616 22 09 ...

Page 3: ...er with the most satisfaction from his vehicle and to conform to federal environmental quality objectives Yamaha Motor Company Ltd is continually striving to improve all of its models Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha deal ers and will appear in future editions of this manual where applicable TIP This Service Manual con...

Page 4: ...age 1 Sub section titles appear in smaller print than the section title 2 To help identify parts and clarify procedure steps there are exploded diagrams at the start of each removal and disassembly section 3 Numbers are given in the order of the jobs in the exploded diagram A number indicates a disas sembly step 4 Symbols indicate parts to be lubricated or replaced 5 Refer to SYMBOLS A job instruc...

Page 5: ...sier understanding TIP The following symbols are not relevant to every vehicle No SYMBOL DEFINITION 1 Serviceable with engine mounted 2 Filling fluid 3 Lubricant 4 Special tool 5 Tightening torque 6 Wear limit clearance 7 Engine speed 8 Electrical data 9 Engine oil T R E ...

Page 6: ... disulfide oil 12 Brake fluid 13 Wheel bearing grease 14 Lithium soap based grease 15 Molybdenum disulfide grease 16 Silicone grease 17 Apply locking agent LOCTITE 18 Replace the part No SYMBOL DEFINITION G M BF B LS M S LT New ...

Page 7: ...1 2 3 4 5 6 7 8 EAS20110 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING ...

Page 8: ......

Page 9: ...1 1 MODEL LABEL 1 1 IMPORTANT INFORMATION 1 2 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 2 REPLACEMENT PARTS 1 2 GASKETS OIL SEALS AND O RINGS 1 3 LOCK WASHERS PLATES AND COTTER PINS 1 3 BEARINGS AND OIL SEALS 1 3 CIRCLIPS 1 3 CHECKING THE CONNECTIONS 1 4 SPECIAL TOOLS 1 5 ...

Page 10: ...20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe EAS20150 MODEL LABEL The model label 1 is affixed to the frame This information will be needed to order spare parts 1 1 ...

Page 11: ... and other parts that have been mated through normal wear Mated parts must always be reused or replaced as an assembly 4 During disassembly clean all of the parts and place them in trays in the order of dis assembly This will speed up assembly and allow for the correct installation of all parts 5 Keep all parts away from any source of fire EAS20200 REPLACEMENT PARTS Use only genuine Yamaha parts f...

Page 12: ...of the bolt or nut EAS20230 BEARINGS AND OIL SEALS Install bearings and oil seals so that the manu facturer s marks or numbers are visible When installing oil seals 1 lubricate the oil seal lips with a light coat of lithium soap based grease Oil bearings liberally when installing if appro priate ECA13300 Do not spin the bearing with compressed air because this will damage the bearing surfaces EAS2...

Page 13: ...al times 3 Check All connections Loose connection Connect properly TIP If the pin 1 on the terminal is flattened bend it up 4 Connect Lead Coupler Connector TIP Make sure all connections are tight 5 Check Continuity with the pocket tester TIP If there is no continuity clean the terminals When checking the wire harness perform steps 1 to 3 As a quick remedy use a contact revitalizer available at mo...

Page 14: ...ay differ depending on the country When placing an order refer to the list provided below to avoid any mistakes TIP For U S A and Canada use part number starting with YM YU or ACC For others use part number starting with 90890 Tool name Tool No Illustration Reference pages Slide hammer bolt 90890 01083 Slide hammer bolt 6 mm YU 01083 1 5 7 Weight 90890 01084 YU 01083 3 5 7 Crankcase separating too...

Page 15: ...ing pot YU 90058 5 60 Crankshaft installer bolt 90890 01275 Bolt YU 90060 5 60 Adapter M10 90890 01383 Adapter 2 YU 90062 5 60 Spacer 90890 01288 5 60 Piston pin puller set 90890 01304 Piston pin puller YU 01304 5 25 Tool name Tool No Illustration Reference pages ...

Page 16: ... Heavy duty puller YU 33270 B 5 46 Bolt M8 80 mm 90890 01359 5 46 Sheave holder 90890 01701 Primary clutch holder YS 01880 A 5 46 5 47 Thickness gauge 90890 03180 Feeler gauge set YU 26900 9 3 4 5 33 Compression gauge 90890 03081 Engine compression tester YU 33223 3 9 Tool name Tool No Illustration Reference pages ...

Page 17: ...Inductive clamp timing light YU 03141 3 8 Valve spring compressor 90890 04019 YM 04019 5 17 5 22 Valve spring compressor attachment 90890 01243 Valve spring compressor adapter 26 mm YM 01253 1 5 17 5 22 Universal clutch holder 90890 04086 YM 91042 5 32 5 34 Valve guide remover ø6 90890 04064 Valve guide remover 6 0 mm YM 04064 A 5 19 Tool name Tool No Illustration Reference pages ...

Page 18: ...M 04066 5 19 Valve lapper 90890 04101 Valve lapping tool YM A8998 5 20 PTT wrench 46 90890 06588 Axle nut wrench 46 mm YM 37134 4 13 4 14 Ignition checker 90890 06754 Opama pet 4000 spark checker YM 34487 7 39 Digital tachometer 90890 06760 YU 39951 B 3 5 3 8 Yamaha bond No 1215 Three Bond No 1215 90890 85505 5 55 Tool name Tool No Illustration Reference pages ...

Page 19: ...IONS 2 12 TIGHTENING TORQUES 2 14 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 14 ENGINE TIGHTENING TORQUES 2 15 CHASSIS TIGHTENING TORQUES 2 17 LUBRICATION POINTS AND LUBRICANT TYPES 2 19 ENGINE 2 19 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 21 ENGINE OIL LUBRICATION CHART 2 21 LUBRICATION DIAGRAMS 2 23 CABLE ROUTING 2 29 ...

Page 20: ... min 11 0 kgf cm2 720 r min 156 5 psi 720 r min Starting system Electric starter Lubrication system Wet sump Engine oil Type YAMALUBE 4 10W 40 or SAE 10W 40 YAMALUBE 4 20W 50 or SAE 20W 50 Recommended engine oil grade API service SG type or higher JASO standard MA Engine oil quantity Without oil filter element replacement 1 25 L 1 32 US qt 1 10 Imp qt With oil filter element replacement 1 35 L 1 4...

Page 21: ...il 23 0 mm 0 91 in Tread rear STD 824 0 mm 32 44 in Tread front STD 826 0 mm 32 52 in Toe in with tire touching the ground 9 0 19 0 mm 0 35 0 75 in Front tire Type Tubeless Size AT20 7 10 Manufacturer model DUNLOP KT201 Rear tire Type Tubeless Size AT19 10 9 Manufacturer model DUNLOP KT205A Tire air pressure measured on cold tires Maximum loading limit 100 0 kg 220 lb Off road riding Front 27 5 kP...

Page 22: ...vel 200 mm 7 9 in Electrical system Ignition system DC CDI Charging system AC magneto Model YTZ7S Voltage capacity 12 V 6 0 Ah Headlight Bulb type Krypton bulb Bulb voltage wattage quantity Headlight 12 V 30 0 30 0 W 2 Tail brake light 12 V 5 0 21 0 W 1 4D3D 12 V 0 5 3 9 W 1 4D3H 4D3M Neutral indicator light 12 V 1 7 W 1 ...

Page 23: ...855 1 1894 in Limit 30 011 mm 1 1815 in Exhaust A 36 891 36 991 mm 1 4524 1 4563 in Limit 36 791 mm 1 4485 in Exhaust B 30 092 30 192 mm 1 1847 1 1887 in Limit 29 992 mm 1 1808 in Camshaft runout limit 0 030 mm 0 0012 in Timing chain Model number of links DID SCR 0404 SV 104 Tensioning system Automatic Rocker arm rocker arm shaft Rocker arm inside diameter 12 000 12 018 mm 0 4724 0 4731 in Limit 1...

Page 24: ...kness D exhaust 0 80 1 20 mm 0 0315 0 0472 in Valve stem diameter intake 5 975 5 990 mm 0 2352 0 2358 in Limit 5 945 mm 0 234 in Valve stem diameter exhaust 5 960 5 975 mm 0 2346 0 2352 in Limit 5 930 mm 0 233 in Valve guide inside diameter intake 6 000 6 012 mm 0 2362 0 2367 in Limit 6 050 mm 0 238 in Valve guide inside diameter exhaust 6 000 6 012 mm 0 2362 0 2367 in Limit 6 050 mm 0 238 in Valv...

Page 25: ...tilt exhaust 2 5 1 60 mm 2 5 0 063 in Winding direction intake Counterclockwise Winding direction exhaust Counterclockwise Outer spring Free length intake 36 63 mm 1 44 in Limit 34 80 mm 1 37 in Free length exhaust 36 63 mm 1 44 in Limit 34 80 mm 1 37 in Installed length intake 32 00 mm 1 26 in Installed length exhaust 32 00 mm 1 26 in Spring rate K1 intake 30 90 N mm 3 15 kgf mm 176 44 lbf in Spr...

Page 26: ...ton pin to piston pin bore clearance 0 002 0 022 mm 0 0001 0 0009 in Limit 0 072 mm 0 0028 in Piston ring Top ring Ring type Barrel Dimensions B T 0 90 2 75 mm 0 04 0 11 in End gap installed 0 19 0 31 mm 0 007 0 012 in Limit 0 56 mm 0 022 in Ring side clearance 0 030 0 065 mm 0 0012 0 0026 in Limit 0 115 mm 0 0045 in 2nd ring Ring type Taper Dimensions B T 0 80 2 80 mm 0 03 0 11 in End gap install...

Page 27: ...te quantity 6 pcs Clutch plate thickness 1 50 1 70 mm 0 059 0 067 in Plate quantity 5 pcs Clutch plate warpage limit 0 20 mm 0 0079 in Clutch spring free length 47 80 mm 1 88 in Limit 46 50 mm 1 83 in Spring quantity 5 pcs Clutch release method Inner push cam push Push rod 2 bending limit 0 10 mm 0 004 in Transmission Main axle runout limit 0 06 mm 0 0024 in Drive axle runout limit 0 06 mm 0 0024 ...

Page 28: ...e idling speed 1500 1600 r min CO 4 0 5 0 Intake vacuum 34 0 kPa 255 mmHg 10 0 inHg Oil temperature 55 0 65 0 C 131 0 149 0 F Oil pump Oil pump type Trochoid Inner rotor to outer rotor tip clearance 0 15 mm 0 0059 in Limit 0 23 mm 0 0091 in Outer rotor to oil pump housing clearance 0 100 0 151 mm 0 0039 0 0059 in Limit 0 22 mm 0 0087 in Oil pump housing to inner and outer rotor clearance 0 04 0 09...

Page 29: ...ing stroke K1 0 0 87 0 mm 0 00 3 43 in Optional spring available No Enclosed gas air pressure STD 2500 kPa 25 0 kgf cm2 355 6 psi 4D3D 1150 1250 kPa 11 5 12 5 kgf cm2 166 8 1813 psi 4D3H 4D3M Rear axle Rear axle runout limit 1 5 mm 0 06 in Swingarm Swingarm end free play limit radial 1 0 mm 0 04 in Swingarm end free play limit axial 1 0 mm 0 04 in Front wheel Wheel type Panel wheel Rim size 10 5 5...

Page 30: ...ameter thickness 200 0 4 0 mm 7 87 0 16 in Brake disc thickness limit 3 5 mm 0 14 in Brake disc deflection limit 0 15 mm 0 006 in Brake pad lining thickness inner 4 2 mm 0 17 in Limit 1 0 mm 0 04 in Brake pad lining thickness outer 4 2 mm 0 17 in Limit 1 0 mm 0 04 in Master cylinder inside diameter 12 7 mm 0 50 in Caliper cylinder inside diameter 33 96 mm 1 34 in Recommended fluid DOT 4 Lever and ...

Page 31: ...ard output 14 0 V 190 W 5000 r min Stator coil resistance 0 688 1 032 Ω W W Rectifier regulator Regulator type Semi conductor short circuit Model manufacturer SH640E 11 SHINDENGEN No load regulated voltage 14 1 14 9 V Rectifier capacity 14 0 A Withstand voltage 200 0 V Battery Specific gravity 1 31 Electric starting system System type Constant mesh Starter motor Model manufacturer 4D3 YAMAHA Power...

Page 32: ...ELECTRICAL SPECIFICATIONS 2 13 Headlight relay Model manufacturer G8HN 1C4T DJ Y52 OMRON Coil resistance 94 5 115 5 Ω Circuit breaker Circuit breaker type Fuse Fuse Fuse 15 0 A Reserve 15 0 A ...

Page 33: ...al To avoid warpage tighten multi fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specifications require clean dry threads Com ponents should be at room temperature A Distance between flats B Outside thread diameter A nut B bolt General tightening torques Nm m kg ft lb 10 mm 6 mm 6 0 6 ...

Page 34: ... 4 ft lb Timing chain tensioner cap bolt M6 1 8 Nm 0 8 m kg 5 9 ft lb Timing chain guide bolt intake side M6 2 8 Nm 0 8 m kg 5 9 ft lb Oil filter element cover bolt M6 3 10 Nm 1 0 m kg 7 4 ft lb Oil delivery pipe and right crankcase cover union bolt M10 1 20 Nm 2 0 m kg 15 ft lb Oil delivery pipe and cylinder union bolt M8 1 17 Nm 1 7 m kg 13 ft lb Oil pump assembly screw M6 3 6 Nm 0 6 m kg 4 4 ft...

Page 35: ...rew locknut M6 1 8 Nm 0 8 m kg 5 9 ft lb Push lever shaft bolt M8 1 12 Nm 1 2 m kg 8 9 ft lb Chain case cover bolt M10 2 10 Nm 1 0 m kg 7 4 ft lb Drive sprocket nut M18 1 110 Nm 11 0 m kg 81 ft lb Use a lock washer Stopper lever bolt M6 1 10 Nm 1 0 m kg 7 4 ft lb Shift pedal bolt M6 1 10 Nm 1 0 m kg 7 4 ft lb Neutral switch M10 1 20 Nm 2 0 m kg 15 ft lb Starter motor bolt M6 2 10 Nm 1 0 m kg 7 4 f...

Page 36: ...100 Nm 10 0 m kg 74 ft lb Rear shock absorber and frame M12 1 55 Nm 5 5 m kg 41 ft lb Rear shock absorber and swingarm M12 1 55 Nm 5 5 m kg 41 ft lb Rear axle pinch bolt M8 4 21 Nm 2 1 m kg 15 ft lb Swingarm and swingarm skid plate M6 4 9 Nm 0 9 m kg 6 6 ft lb Swingarm and drive chain guide 1 M6 1 7 Nm 0 7 m kg 5 2 ft lb Upper front arm and frame M10 2 45 Nm 4 5 m kg 33 ft lb Lower front arm and f...

Page 37: ...cylinder and brake lever M6 1 6 Nm 0 6 m kg 4 4 ft lb Clutch lever holder and handlebar M5 2 4 Nm 0 4 m kg 3 0 ft lb Parking brake lever assembly and clutch lever holder M6 2 7 Nm 0 7 m kg 5 2 ft lb Throttle lever assembly and handlebar M5 2 4 Nm 0 4 m kg 3 0 ft lb Footrest and frame M10 4 73 Nm 7 3 m kg 54 ft lb Rear brake master cylinder and frame M8 2 20 Nm 2 0 m kg 15 ft lb Rear brake master c...

Page 38: ...intake and exhaust Rocker arm shafts intake and exhaust Camshaft lobes Rocker arms inner surface Oil pump rotors inner and outer and oil pump housing and shaft Starter idler gear 1 Starter idler gear 2 Starter wheel gear Push rods Clutch housing primary driven gear Push lever shaft Push rod ball Transmission gears inside and end Transmission gears fork ditch Shift fork guide bar Shift drum Shift s...

Page 39: ...LUBRICATION POINTS AND LUBRICANT TYPES 2 20 ...

Page 40: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 21 EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART ...

Page 41: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 22 1 Oil pan 2 Oil strainer 3 Oil pump 4 Oil cooler 5 Oil filter element 6 Cylinder head 7 Camshaft 8 Pin with hole 9 Crankshaft 10 Drive axle 11 Main axle ...

Page 42: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 23 EAS20410 LUBRICATION DIAGRAMS ...

Page 43: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 24 1 Camshaft 2 Oil filter element 3 Oil pump 4 Oil strainer ...

Page 44: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 25 ...

Page 45: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 26 1 Camshaft 2 Drive axle 3 Main axle 4 Push lever shaft 5 Oil pump assembly 6 Oil strainer 7 Crankshaft assembly 8 Oil filter element ...

Page 46: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 27 ...

Page 47: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 28 1 Oil cooler 2 Oil hose 1 3 Oil hose 2 ...

Page 48: ...CABLE ROUTING 2 29 EAS20430 CABLE ROUTING ...

Page 49: ...ing brake cable through the guide of the handlebar protector B Route the clutch cable in front of the park ing brake cable C Route the front brake hose and throttle cable through the guide of the handlebar protector D Clamp the front brake light switch lead at the bends of handlebar E Route the throttle cable under the front brake hose F Clamp the clutch switch lead and handle bar switch lead at t...

Page 50: ...CABLE ROUTING 2 31 ...

Page 51: ...e the air vent hose through the bracket I Route the breather hose under the 3 way connector and outside of the throttle cable cover J Face the white paint mark on the breather hose upward Face the tab of the clip to the left K To the handlebar L Route the throttle cable under the cross pipe and left of the steering column as shown in the illustration M Route the parking brake cable and the clutch ...

Page 52: ...CABLE ROUTING 2 33 ...

Page 53: ...int mark pointing down C Install the rear brake hose in the direction shown in the illustration D Insert the rear brake hose until it contacts the projection E Make sure that the end of the clip is facing outward F Install the rear brake reservoir hose mak ing sure to face the white paint mark out ward G Insert the rear brake reservoir hose until it contacts the projection H When installing the re...

Page 54: ...CABLE ROUTING 2 35 ...

Page 55: ...Air filter joint 24 Air filter case A To the left headlight B To the front fender C Route the wire harness above the guide for the damper plate D Fix point for wire harness E Clamp near the hook of the air filter F Clamp near the edge of the air filter case G Route the drain hose in front of the left oil cooler hose H Clamp on top of the frame bracket I Route the clamp through the damper plate hol...

Page 56: ...CABLE ROUTING 2 37 ...

Page 57: ... absorber sub tank hose A To the left headlight B To the front fender C Route the wire harness above the guide for the damper plate D Fix point for wire harness E Clamp near the hook of the air filter F Clamp near the edge of the air filter case G Route the drain hose in front of the left oil cooler hose H Clamp on top of the frame bracket I Route the clamp through the damper plate hole J Route th...

Page 58: ...CABLE ROUTING 2 39 ...

Page 59: ...r C Connect the main switch lead on top of the front fender Route both leads from the front D Route the front brake light switch lead and throttle cable through the guide E Insert the air vent hose into the front fender F Route the clutch switch lead and handlebar switch lead on the box shaped part G Connect the clutch switch lead and handle bar switch lead on top of the front fender Route the wir...

Page 60: ...CABLE ROUTING 2 41 ...

Page 61: ...cting the battery negative lead push the sag in the box C After connecting the wire harness and each electric part the length between the air filter and AC magneto coupler should be 185 mm 7 28 in on straight line D Clamp the taillight lead E Do not clamp F Set the insulator lock on the wire harness behind the fixed point G Insert the starter relay all the way into the rib on the air filter side H...

Page 62: ...CABLE ROUTING 2 43 ...

Page 63: ...BREATHER HOSE 3 14 CHECKING THE EXHAUST SYSTEM 3 14 CLEANING THE SPARK ARRESTER 3 14 CHASSIS 3 16 ADJUSTING THE FRONT DISC BRAKE 3 16 ADJUSTING THE BRAKE PEDAL 3 16 CHECKING THE BRAKE FLUID LEVEL 3 17 CHECKING THE FRONT BRAKE PADS 3 18 CHECKING THE REAR BRAKE PADS 3 18 CHECKING THE FRONT BRAKE HOSES 3 18 CHECKING THE REAR BRAKE HOSE 3 18 ADJUSTING THE PARKING BRAKE 3 19 ADJUSTING THE REAR BRAKE LI...

Page 64: ... 3 29 CHECKING THE WHEELS 3 31 CHECKING AND LUBRICATING THE CABLES 3 31 LUBRICATING THE LEVERS 3 31 LUBRICATING THE PEDAL 3 31 ELECTRICAL SYSTEM 3 32 CHECKING AND CHARGING THE BATTERY 3 32 CHECKING THE FUSES 3 32 REPLACING THE HEADLIGHT BULBS 3 32 ADJUSTING THE HEADLIGHT BEAMS 3 32 ...

Page 65: ......

Page 66: ...er keep in mind that if the ATV isn t used for a long period of time the month maintenance intervals should be followed Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools data and technical skills NO ITEM CHECK OR MAINTENANCE JOB Whichever comes first INITIAL EVERY month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 ...

Page 67: ...ion and for excessive play and replace bear ings if necessary Lubricate with lithium soap based grease 11 Upper and lower arm pivots Lubricate with lithium soap based grease 12 Drive chain Check chain slack and adjust if necessary Check rear wheel alignment and correct if necessary Clean and lubricate 13 Drive chain rollers Check for wear and replace if necessary 14 Chassis fasteners Make sure tha...

Page 68: ...ke master cylinders and calipers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged WARNING EWA4D3F004 Indicates a potential hazard that could result in serious injury or death 25 Lights and switches Check operation and correct if necessary Adjust headlight beams NO ITEM CHECK OR MAINTENANCE JOB Whichever comes first INITIAL EVERY month 1 3 6 6 12 km mi 3...

Page 69: ...1 Cylinder head side cover 2 2 3 Remove Timing mark accessing screw 1 Crankshaft end accessing screw 2 4 Measure Valve clearance Out of specification Adjust a Turn the crankshaft counterclockwise b When the piston is at TDC on the compres sion stroke align the mark a on the pickup coil rotor with the stationary pointer b on the left crankcase cover c Align the mark c on the camshaft sprocket with ...

Page 70: ... For installation reverse the removal proce dure EAS29150 ADJUSTING THE ENGINE IDLING SPEED 1 Start the engine and let it warm up for sev eral minutes 2 Attach Digital tachometer onto the ignition coil spark plug lead 3 Measure Engine idling speed Out of specification Adjust 4 Adjust Engine idling speed a Turn the throttle stop screw 1 in direction a or b until the specified idling speed is obtain...

Page 71: ...cable free play cannot be obtained on the carburetor side of the cable use the adjusting nut on the handlebar side Handlebar side a Slide back the rubber cover 1 b Loosen the locknut 2 c Turn the adjusting bolt 3 in direction a or b until the specified throttle cable free play is obtained d Tighten the locknut e Slide the rubber cover to its original posi tion WARNING EWA12930 After adjusting the ...

Page 72: ...le lever operation do not turn out the adjusting screw more than 12 mm 0 47 in Also always adjust the throttle cable free play to 2 0 4 0 mm 0 08 0 16 in EAS20690 CHECKING THE SPARK PLUG 1 Disconnect Spark plug cap 2 Remove Spark plug ECA13330 Before removing the spark plug blow away any dirt accumulated in the spark plug well with compressed air to prevent it from fall ing into the cylinder 3 Che...

Page 73: ... the stationary pointer a is within the firing range b on the pickup coil rotor Incorrect firing range Check the ignition system d Install the timing mark accessing screw TIP The ignition timing is not adjustable 3 Detach Timing light Digital tachometer EAS20710 MEASURING THE COMPRESSION PRES SURE The following procedure applies to the cylinder TIP Insufficient compression pressure will result in ...

Page 74: ...nstall Spark plug 8 Connect Spark plug cap EAS28920 CHECKING THE ENGINE OIL LEVEL 1 Place the vehicle on a level surface 2 Start the engine warm it up for several minutes and then turn it off 3 Check Engine oil level The engine oil level should be between the minimum level mark a and maxi mum level mark b Below the minimum level mark Add the recommended engine oil to the proper level TIP Before ch...

Page 75: ...up for several minutes and then turn it off 5 Check the engine oil level again TIP Before checking the engine oil level wait a few minutes until the oil has settled EAS20800 CHANGING THE ENGINE OIL 1 Place the vehicle on a level surface 2 Start the engine warm it up for several minutes and then turn it off 3 Place a container under the engine oil drain bolt 4 Remove Dipstick 1 Oil filter element d...

Page 76: ...ressure a Slightly loosen the oil gallery bolt 1 b Start the engine and keep it idling until engine oil starts to seep from the oil gallery bolt If no engine oil comes out after one minute turn the engine off so that it will not seize c Check the engine oil passages the oil filter element and the oil pump for damage or leakage Refer to OIL PUMP on page 5 38 d Start the engine after solving the pro...

Page 77: ... 1 If dust or water or both collects in this hose clean the air filter element and air filter case 1 Remove Seat Refer to GENERAL CHASSIS on page 4 1 2 Remove Air filter case cover 1 3 Remove Wing bolt 1 Air filter element 2 Air filter element frame 3 ECA4D3F003 Never operate the engine without the air filter element installed Unfiltered air will cause rapid wear of engine parts and may damage the...

Page 78: ...the entire surface of the air filter element and squeeze out the excess oil The air filter element should be wet but not dripping 7 Install Air filter element frame 8 Apply Lithium soap based grease On the matching surface a on air filter element 9 Install Air filter element Wing bolt TIP Make sure its sealing surface matches the sealing surface of the case so there is no air leak 10 Install Air f...

Page 79: ...nnect properly ECA14920 Make sure the cylinder head breather hose is routed correctly EAS21080 CHECKING THE EXHAUST SYSTEM 1 Check Exhaust pipe Muffler Cracks damage Replace Gasket Exhaust gas leaks Replace 2 Check Tightening torque EAS28970 CLEANING THE SPARK ARRESTER 1 Clean Spark arrester WARNING EWA14680 Select a well ventilated area free of com bustible materials Always let the exhaust system...

Page 80: ...ENGINE 3 15 d Insert the tailpipe and gasket 3 into the muffler and align the bolt holes e Insert the bolts and tighten it Spark arrester bolt 11 Nm 1 1 m kg 8 1 ft lb ...

Page 81: ...e brake lever forward turn the adjusting bolt 2 in direction b or c until the specified brake lever free play is obtained c Tighten the locknut ECA13490 After adjusting the brake lever position make sure there is no brake drag EAS29190 ADJUSTING THE BRAKE PEDAL 1 Check Brake pedal height a Out of specification Adjust 2 Adjust Brake pedal height a Loosen the locknut 1 b Turn the adjusting bolt 2 un...

Page 82: ...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 Mixing brake fluids may result in a harmful chemical reaction leading to poor brake perfor mance When refilling be careful that water does not enter the brake fluid reservoir Water will significantl...

Page 83: ... Replace the brake pads as a set Refer to REAR BRAKE on page 4 27 EAS21280 CHECKING THE FRONT BRAKE HOSES The following procedure applies to all of the brake hoses Brake pipe and brake hose clamps 1 Remove Seat Front fender Refer to GENERAL CHASSIS on page 4 1 2 Check Brake hose 1 Brake pipe 2 Cracks damage wear Replace 3 Check Brake hose clamp Loose Tighten the clamp bolt 4 Hold the vehicle uprig...

Page 84: ... to its original posi tion WARNING EWA4D3F003 After this adjustment is performed lift the rear wheels off the ground by placing a block under the engine and spin the rear wheels to ensure there is no brake drag If any brake drag is noticed perform the above steps again EAS21330 ADJUSTING THE REAR BRAKE LIGHT SWITCH TIP The rear brake light switch is operated by movement of the brake pedal The rear...

Page 85: ...peared 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 cylin der reservoir or brake fluid reservoir c Connect a clear plastic hose 1 tightly to the bleed screw 2 d Place the other end of the hose into a con tainer e Slowly apply the brake lever or brake pedal several times f Fully pull the bra...

Page 86: ... drive chain slack there should be no weight on the vehi cle and all tires must be touching the ground ECA13550 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 Therefore keep the drive chain slack within the speci fied limits 1 Check Drive chain slack a Out of specification Adjust 2 Adjus...

Page 87: ...nd the use of a coarse brush can dam age these O rings Therefore use only kerosene to clean the drive chain Wipe the drive chain dry and thoroughly lubricate it with engine oil or chain lubricant that is suitable for O ring chains Do not use any other lubricants on the drive chain since they may contain sol vents that could damage the O rings EAS29280 CHECKING THE STEERING SYSTEM 1 Place the vehic...

Page 88: ...la given below g If the toe in is incorrect adjust it 3 Adjust Toe in WARNING EWA14910 Be sure that both tie rods are turned the same amount If not the vehicle will drift right or left even though the handlebar is positioned straight This may lead to mis handling and an accident After setting the toe in to specification run the vehicle slowly for some distance with both hands lightly holding the h...

Page 89: ...er assembly Refer to FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES on page 4 47 EAS29310 ADJUSTING THE FRONT SHOCK ABSORBER ASSEMBLIES for 4D3D WARNING EWA14920 Always adjust the spring preload for both front shock absorber assemblies to the same setting Uneven adjustment can cause poor handling and loss of stability 1 Adjust Spring preload ECA4D3F010 Never attempt to turn the adjuster beyond the...

Page 90: ...locknut and adjusting ring before adjustment d Tighten the locknut TIP Always tighten the locknut against the adjust ing ring then torque it to specification Rebound damping ECA4D3F008 Do not force the adjuster past the minimum or maximum extent of adjustment The adjuster may be damaged 1 Adjust Rebound damping a Turn the adjusting screw 1 in direction a or b Direction a Spring preload is increase...

Page 91: ...ment The adjuster may be damaged 1 Adjust Compression damping fast compression damping a Turn the adjusting bolt 1 in direction a or b Rebound damping adjusting positions Minimum 20 clicks in direction b Standard 12 clicks in direction b Maximum 3 clicks in direction b With the adjusting screw fully turned in direction a Direction a turn in Compression damping is increased suspension is harder Dir...

Page 92: ...330 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY for 4D3D 1 Adjust Spring preload ECA4D3F006 Never attempt to turn the adjusting nut beyond the maximum or minimum setting a Elevate the rear wheels by placing a suit able stand under the frame b Loosen the locknut 1 c Turn the adjusting nut 2 in direction a or b Compression damping fast com pression damping adjusting positions Minimum 4 turns in direc...

Page 93: ...he locknut and adjusting ring before adjustment d Tighten the locknut TIP Always tighten the locknut against the adjust ing ring then torque it to specification Rebound damping ECA4D3F008 Do not force the adjuster past the minimum or maximum extent of adjustment The adjuster may be damaged 1 Adjust Rebound damping a Turn the adjuster 1 in direction a or b Rear shock absorber locknut 42 Nm 4 2 m kg...

Page 94: ...tics influence the handling of vehicles The tires listed below have been approved by Yamaha Motor Co Ltd for this model If other tire combinations are used they can adversely affect your vehicle s handling characteristics and are therefore not recommended Rebound damping adjusting positions Minimum 20 clicks in direction b Standard 12 clicks in direction b Maximum 3 clicks in direction b With the ...

Page 95: ...t will not provide the correct readings Therefore take two measurements of the tire s pressure and use the second reading WARNING EWA14980 Uneven or improper tire pressure may adversely affect the handling of this vehicle and may cause loss of control Maintain proper tire pressures Set tire pressures when the tires are cold Tire pressures must be equal in both front tires and equal in both rear ti...

Page 96: ...bles WARNING EWA13270 Damaged outer cable may cause the cable to corrode and interfere with its movement Replace damaged outer cable and inner cables as soon as possible 1 Check Outer cable Damage Replace 2 Check Cable operation Rough movement Lubricate or replace TIP Hold the cable end up and apply several drops of lubricant to the cable 3 Apply Lithium soap based grease onto end of the cable EAS...

Page 97: ...ammable products and your hands away from the bulb until it has cooled down 5 Install Headlight bulb Secure the new headlight bulb with the headlight unit ECA13690 Avoid touching the glass part of the head light bulb to keep it free from oil otherwise the transparency of the glass the life of the bulb and the luminous flux will be adversely affected If the headlight bulb gets soiled thoroughly cle...

Page 98: ...ELECTRICAL SYSTEM 3 33 a Turn the adjusting bolt 1 in direction a or b Direction a Headlight beam is raised Direction b Headlight beam is lowered ...

Page 99: ...R AXLE HUB 4 11 REMOVING THE REAR AXLE 4 13 CHECKING THE REAR AXLE 4 13 CHECKING THE REAR AXLE HUB 4 13 CHECKING THE REAR WHEEL SPROCKET 4 14 CHECKING THE SPROCKET BRACKET 4 14 INSTALLING THE REAR WHEEL SPROCKET 4 14 INSTALLING THE REAR AXLE 4 14 FRONT BRAKE 4 15 INTRODUCTION 4 20 CHECKING THE FRONT BRAKE DISCS 4 20 REPLACING THE FRONT BRAKE PADS 4 21 REMOVING THE FRONT BRAKE CALIPERS 4 21 DISASSE...

Page 100: ...4 45 REMOVING THE STEERING KNUCKLES 4 46 CHECKING THE TIE RODS 4 46 CHECKING THE STEERING KNUCKLES 4 46 INSTALLING THE TIE RODS 4 46 FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES 4 47 REMOVING THE FRONT ARMS 4 48 CHECKING THE FRONT ARMS 4 48 HANDLING THE FRONT SHOCK ABSORBER AND GAS CYLINDER 4 48 DISPOSING OF A FRONT SHOCK ABSORBER AND GAS CYLINDER 4 48 CHECKING THE FRONT SHOCK ABSORBER ASSEMBLIE...

Page 101: ...DRIVE 4 57 REMOVING THE DRIVE CHAIN 4 58 CHECKING THE DRIVE CHAIN 4 58 CHECKING THE DRIVE SPROCKET 4 59 CHECKING THE REAR WHEEL SPROCKET 4 59 CHECKING THE SPROCKET BRACKET 4 59 INSTALLING THE DRIVE CHAIN 4 59 ...

Page 102: ...Remarks 1 Seat 1 TIP Pull back the seat lock lever than pull up on the rear of the seat 2 Indicator light coupler 1 Disconnect 3 Front panel 1 4 Plate 1 5 Main switch coupler 1 Disconnect 6 Front fender 1 7 Headlight coupler 2 Disconnect 8 Left headlight 1 9 Right headlight 1 For installation reverse the removal proce dure ...

Page 103: ...IS 4 2 Removing the foot protectors and engine skid plate Order Job Parts to remove Q ty Remarks 1 Left foot protector 1 2 Right foot protector 1 3 Engine skid plate 1 For installation reverse the removal proce dure ...

Page 104: ...S on page 4 1 1 Rear fender 1 2 Battery cover 1 3 Battery lead 2 ECA4D3F001 First disconnect the negative lead then disconnect the positive lead 4 Battery 1 5 Relay 2 6 CDI unit 1 7 Tail brake light lead 1 Disconnect 8 Air filter case breather hose 1 Disconnect 9 Clamp 1 Loosen 10 Air filter case 1 For installation reverse the removal proce dure ...

Page 105: ...scs Order Job Parts to remove Q ty Remarks The following procedure applies to both of the front wheels 1 Cotter pin 1 2 Axle nut 1 3 Front wheel 1 4 Brake disc guard outer 1 5 Brake caliper assembly 1 6 Wheel hub 1 7 Brake disc 1 For installation reverse the removal proce dure ...

Page 106: ...KING THE TIRES on page 3 29 and CHECKING THE WHEELS on page 3 31 2 Measure Radial wheel runout 1 Lateral wheel runout 2 Over the specified limit Replace the wheel or check the wheel bearing play 3 3 Check Wheel balance Out of balance Adjust WARNING EWA15000 After replacing the tire ride conservatively to allow the tire to be properly seated in the rim Failure to do so may cause an accident resulti...

Page 107: ...earing Contact should be made only with the outer race EAS4D3F026 CHECKING THE FRONT BRAKE DISCS Refer to CHECKING THE FRONT BRAKE DISCS on page 4 6 EAS29400 INSTALLING THE FRONT WHEEL HUB BEARINGS 1 Install Bearings 1 TIP Face the oil seal side of the bearing inward EAS4D3F027 INSTALLING THE FRONT BRAKE DISCS 1 Install Brake discs Refer to CHECKING THE FRONT BRAKE DISCS on page 4 6 EAS29410 INSTA...

Page 108: ...ease the front wheel e When the wheel stops put an X2 mark at the bottom of the wheel f Repeat steps d through f several times until all the marks come to rest at the same spot g The spot where all the marks come to rest is the front wheel s heavy spot X 3 Adjust Front wheel static balance a Install a balancing weight 1 onto the rim exactly opposite the heavy spot X TIP Start with the lightest wei...

Page 109: ...nce it EAS29420 INSTALLING THE FRONT WHEELS The following procedure applies to both of the front wheels 1 Install Brake disc guard outer 1 TIP Install the brake disc guard outer with punched burrs 2 on the wheel hub side 2 Install Front wheel TIP The arrow mark 1 on the must point in the direction of rotation A of the wheel Front wheel nut 45 Nm 4 5 m kg 33 ft lb ...

Page 110: ...EAR WHEEL 4 9 EAS22020 REAR WHEEL Removing the rear wheels Order Job Parts to remove Q ty Remarks 1 Rear wheel 2 2 Cotter pin 2 3 Axle nut 2 4 Wheel hub 2 For installation reverse the removal proce dure ...

Page 111: ...following procedure applies to both of the rear wheel hubs 1 Check Wheel hub 1 Cracks damage Replace Splines wheel hub 2 Wear damage Replace EAS29450 INSTALLING THE REAR WHEEL HUBS The following procedure applies to both of the rear wheel hubs 1 Install Rear wheel hub Washer Rear axle nut Cotter pin Refer to INSTALLING THE FRONT WHEEL HUBS on page 4 6 EAS22150 ADJUSTING THE REAR WHEEL STATIC BALAN...

Page 112: ...ut set bolt 2 2 Rear axle ring nut 1 3 Conical spring washer 1 4 Brake caliper 1 TIP Do not apply the brake pedal and do not use the parking brake when the brake caliper is off of the brake disc as the brake pads will be force shut 5 Brake disc brake disc bracket 1 1 6 Rear axle 1 7 Rear wheel sprocket sprocket bracket 1 1 8 Circlip 1 9 Brake caliper bracket 1 10 Collar 1 11 Rear axle hub 1 12 Bea...

Page 113: ...REAR AXLE AND REAR AXLE HUB 4 12 14 Dust cover 2 For installation reverse the removal proce dure Removing the rear axle and rear axle hub Order Job Parts to remove Q ty Remarks ...

Page 114: ...axle ring nut Conical spring washer 6 Remove Rear axle 1 ECA16180 Never directly tap the axle end with a hammer since this will result in damage to the axle thread and spline Attach a suitable socket 2 on the axle end and tap it with a soft hammer then pull out the rear axle to the right EAS29500 CHECKING THE REAR AXLE 1 Check Rear axle runout a Out of specification Replace WARNING EWA15020 Do not...

Page 115: ...procket is facing outward EAS29530 INSTALLING THE REAR AXLE 1 Install Conical spring washer 1 Rear axle ring nut TIP Install the conical spring washer with the con vex side of the washer facing inward as shown 2 Tighten Rear axle ring nut 1 Rear axle ring nut set bolts 3 TIP Apply the brake pedal so that the rear axle does not turn when tightening the nut Use the PTT wrench 46 or axle nut wrench 4...

Page 116: ...rder Job Parts to remove Q ty Remarks The following procedure applies to both of the front brake calipers Front wheel Refer to FRONT WHEEL on page 4 4 1 Bolt 1 2 Brake pad retaining bolt 1 3 Brake pad 2 4 Brake pad spring 1 For installation reverse the removal proce dure ...

Page 117: ... BRAKE SYSTEM on page 3 20 1 Brake fluid reservoir cap 1 2 Brake fluid reservoir diaphragm plate 1 3 Brake fluid reservoir diaphragm 1 4 Front brake light switch 1 5 Brake lever 1 6 Union bolt 1 7 Copper washer 2 8 Brake hose 1 Disconnect 9 Brake master cylinder bracket 1 10 Brake master cylinder 1 For installation reverse the removal proce dure ...

Page 118: ...T BRAKE 4 17 Disassembling the front brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 2 Brake master cylinder body 1 For assembly reverse the disassembly pro cedure ...

Page 119: ...h of the front brake calipers Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 20 Front wheel Refer to FRONT WHEEL on page 4 4 1 Union bolt 1 2 Copper washer 2 3 Brake hose 1 Disconnect 4 Bolt 1 5 Brake pad retaining bolt 1 Loosen 6 Brake caliper assembly 1 For installation reverse the removal proce dure ...

Page 120: ...Remarks The following procedure applies to both of the front brake calipers 1 Bolt 1 2 Brake pad retaining bolt 1 3 Brake pad 2 4 Brake pad spring 1 5 Caliper bracket 1 6 Caliper piston 1 7 Dust seal 1 8 Caliper piston seal 1 9 Bleed screw 1 For assembly reverse the disassembly pro cedure ...

Page 121: ...e applies to both brake discs 1 Remove Front wheel Refer to REMOVING THE FRONT WHEELS on page 4 5 2 Check Brake disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc Brake disc thickness a Measure the brake disc thickness at a few different locations Out of specification Replace 4 Adjust Brake disc deflection a ...

Page 122: ...bricate Brake caliper guide bar ECA14150 Do not allow grease to contact the brake pads Remove any excess grease 4 Install Brake pad retaining bolt Bolt Brake caliper Brake caliper bolts 5 Check Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 17 6 Check Brake lever operation Soft or spongy feeling...

Page 123: ...a rag Be careful not to get injured when the pis ton is expelled from the brake caliper Never try to pry out the brake caliper pis ton b Remove the brake caliper piston seal and brake caliper dust seal EAS22370 CHECKING THE FRONT BRAKE CALIPER 1 Check Brake caliper piston 1 Rust scratches wear Replace the brake caliper piston Brake caliper cylinder 2 Scratches wear Replace the brake cal iper assem...

Page 124: ...caliper piston seal and brake caliper piston dust seal 1 Install Caliper piston seal 1 Caliper dust seal 2 2 Install Brake caliper piston 1 EAS22420 INSTALLING THE FRONT BRAKE CALIPER 1 Install Brake caliper 1 temporarily Copper washers 2 Brake hose 3 Union bolt 4 WARNING EWA13530 Proper brake hose routing is essential to insure safe vehicle operation Refer to CABLE ROUTING on page 2 29 ECA4D3F014...

Page 125: ...THE HYDRAULIC BRAKE SYSTEM on page 3 20 6 Check Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 17 7 Check Brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 20 EAS22490 REMOVING THE FRONT BRAKE MASTER CYLINDER TIP Before rem...

Page 126: ...er 1 TIP Install the brake master cylinder holder with the UP mark facing up Install the brake master cylinder so that the gaps between the brake master cylinder and the brake master cylinder bracket are equal 2 Install Copper washers Brake hose Union bolt WARNING EWA13530 Proper brake hose routing is essential to insure safe vehicle operation Refer to CABLE ROUTING on page 2 29 TIP While holding ...

Page 127: ...er does not enter the brake master cylinder reser voir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 4 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 20 5 Check Brake fluid level Below the minimum ...

Page 128: ... EAS22550 REAR BRAKE Removing the rear brake pads Order Job Parts to remove Q ty Remarks 1 Brake pad retaining bolt 2 2 Lock washer 1 3 Brake pad 2 4 Brake pad spring 1 For installation reverse the removal proce dure ...

Page 129: ...STEM on page 3 20 1 Brake fluid reservoir cover 1 2 Brake fluid reservoir cap 1 3 Brake fluid reservoir diaphragm holder 1 4 Brake fluid reservoir diaphragm 1 5 Brake fluid reservoir 1 6 Brake fluid reservoir hose 1 7 Union bolt 1 8 Copper washer 2 9 Brake hose 1 10 Brake master cylinder 1 11 Rear brake light switch 1 12 Right footrest 1 13 Brake pedal spring 1 1 For installation reverse the remov...

Page 130: ...KE 4 29 Disassembling the rear brake master cylinder Order Job Parts to remove Q ty Remarks 1 Hose joint 1 2 Brake master cylinder kit 1 3 Brake master cylinder 1 For assembly reverse the disassembly pro cedure ...

Page 131: ...arts to remove Q ty Remarks Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 20 1 Parking brake cable 1 Disconnect 2 Union bolt 1 3 Copper washer 2 4 Brake hose 1 5 Brake caliper assembly 1 For installation reverse the removal proce dure ...

Page 132: ...justing bolt 1 2 Locknut 1 3 Parking brake arm 1 4 Brake pad retaining bolt 2 5 Lock washer 1 6 Brake pad 2 7 Brake pad spring 1 8 Retaining bolt 1 9 Caliper bracket 1 10 Brake caliper piston 1 11 Dust seal 1 12 Caliper piston seal 1 13 Bleed screw 1 For assembly reverse the disassembly pro cedure ...

Page 133: ...t of specification Correct the brake disc deflection or replace the brake disc Refer to CHECKING THE FRONT BRAKE DISCS on page 4 20 4 Measure Brake disc thickness Measure the brake disc thickness at a few different locations Out of specification Replace Refer to CHECKING THE FRONT BRAKE DISCS on page 4 20 5 Adjust Brake disc deflection Refer to CHECKING THE FRONT BRAKE DISCS on page 4 20 6 Install...

Page 134: ... to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 17 7 Check Brake pedal operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 20 EAS22590 REMOVING THE REAR BRAKE CALIPER TIP Before disassembling the brake caliper drain the brake fluid from the entire brake system 1 Remove Union bolt 1 Copper washers 2 Brake hose 3 Brake...

Page 135: ...acks damage Replace the brake caliper assembly Brake fluid delivery passages brake caliper body Obstruction Blow out with compressed air WARNING EWA4D3F006 Whenever a brake caliper is disassembled replace the brake caliper piston seal and brake caliper dust seal 2 Check Brake caliper bracket Cracks damage Replace EAS22660 ASSEMBLING THE REAR BRAKE CALIPER WARNING EWA4D3F007 Before installation all...

Page 136: ... on page 2 29 ECA14170 When installing the brake hose onto the brake caliper 1 make sure the brake pipe touches the projection a on the brake cal iper 2 Remove Brake caliper 3 Install Brake pads Brake pad spring Lock washer Brake pad retaining bolts Brake caliper Brake caliper bolts Refer to REPLACING THE REAR BRAKE PADS on page 4 32 4 Fill Brake fluid reservoir with the specified amount of the re...

Page 137: ... 3 20 6 Check Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 17 7 Check Brake pedal operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 20 EAS22700 REMOVING THE REAR BRAKE MASTER CYLINDER TIP Before removing the rear brake master cylin d...

Page 138: ...olt 3 until the clearance a is within the specified limits when install the joint 2 EAS22740 INSTALLING THE REAR BRAKE MASTER CYLINDER 1 Install Copper washers Brake hose 1 Union bolt 2 WARNING EWA13530 Proper brake hose routing is essential to insure safe vehicle operation Refer to CABLE ROUTING on page 2 29 ECA14160 When installing the brake hose onto the brake master cylinder make sure the brak...

Page 139: ...ir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 4 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 20 5 Check Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the ...

Page 140: ...1 2 Band 3 3 Front brake light switch 1 4 Brake master cylinder bracket 1 1 5 Throttle lever assembly bracket 1 1 6 Spacer 1 7 Clutch switch 1 8 Parking brake lever 1 9 Clutch lever bracket 1 1 10 Handlebar switch 1 11 Handlebar grip 2 12 Handlebar holder 2 13 Handlebar 1 For installation reverse the removal proce dure ...

Page 141: ...bar 1 Bends cracks damage Replace WARNING EWA13690 Do not attempt to straighten a bent handle bar as this may dangerously weaken it EAS22911 INSTALLING THE HANDLEBAR 1 Install Handlebar Upper handlebar holders TIP Install the handlebar horizontally shown in the illustration The upper handlebar holder should be installed with the punched mark 1 forward 2 ECA4D3F004 First tighten the bolts 3 on the ...

Page 142: ...der TIP Engage the indentations a in the spacer with the lobes b on the throttle lever assem bly and brake master cylinder The UP mark on the brake master cylinder bracket should face up Install the brake lever 1 at 10 degrees angle as shown 5 Install Clutch switch Front brake light switch 6 Adjust Clutch cable free play Refer to ADJUSTING THE CLUTCH CABLE FREE PLAY on page 3 12 7 Adjust Throttle ...

Page 143: ...HANDLEBAR 4 42 Throttle cable free play 2 0 4 0 mm 0 08 0 16 in ...

Page 144: ...teering stem Order Job Parts to remove Q ty Remarks Front fender Refer to GENERAL CHASSIS on page 4 1 1 Lock washer 1 2 Bracket 1 3 Steering stem bushing 2 4 Spacer 2 5 Oil seal 2 6 Steering stem 1 7 Bushing 2 For installation reverse the removal proce dure ...

Page 145: ...2 Wear damage Replace 3 Check O rings 1 Bushings 2 Wear damage Replace EAS4D3F007 INSTALLING THE STEERING STEM 1 Install Steering stem TIP Pass the throttle cable through the cable guide Refer to CABLE ROUTING on page 2 29 EAS29580 INSTALLING THE LOCK WASHER 1 Install Lock washer 1 Steering stem bushing bolts 2 Bend the lock washer tabs along a flat side of the bolts New New Steering stem bushing ...

Page 146: ...rks The following procedure applies to both of the tie rods and steering knuckles Front wheel Refer to FRONT WHEEL on page 4 4 Front brake caliper Brake disc Refer to FRONT BRAKE on page 4 15 1 Brake disc guard inner 1 2 Tie rod 1 3 Front bumper 1 4 Lower front arm 1 5 Upper front arm 1 6 Steering knuckle 1 For installation reverse the removal proce dure ...

Page 147: ...d free play and movement Free play Replace the tie rod end Turns roughly Replace the tie rod end 2 Check Tie rod Bends damage Replace EAS29690 CHECKING THE STEERING KNUCKLES The following procedure applies to both of the steering knuckles 1 Check Steering knuckle Damage pitting Replace EAS29700 INSTALLING THE TIE RODS The following procedure applies to both of the tie rods 1 Install Tie rod TIP In...

Page 148: ... of the front upper arms front lower arms and front shock absorber assemblies Front wheel Refer to FRONT WHEEL on page 4 4 Front brake caliper Brake disc Refer to FRONT BRAKE on page 4 15 1 Front bumper 1 2 Brake disc guard inner 1 3 Tie rod 1 Disconnect 4 Lower front arm 1 5 Upper front arm 1 6 Front shock absorber assembly 1 7 Steering knuckle 1 8 Dust cover 6 9 Spacer 1 10 Spacer 2 11 Bushing 6...

Page 149: ...rogen gas Before handling the front shock absorber or gas cylinder read and make sure you understand the following informa tion The manufacturer cannot be held responsible for property damage or per sonal injury that may result from improper handling of the front shock absorber and gas cylinder Do not tamper or attempt to open the front shock absorber or gas cylinder Do not subject the front shock...

Page 150: ...rm Free play Replace the front arm Turns roughly Replace the front arm EAS29790 INSTALLING THE FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES The following procedure applies to both of the front upper arms front lower arms and front shock absorber assemblies 1 Install Front upper arm 1 Front lower arm 2 Front shock absorber assembly a Install the front upper arm 1 and front lower arm 2 TIP Be sure...

Page 151: ...FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES 4 50 TIP Apply lithium soap based grease to the grease nipples 3 Front upper arm nut 45 Nm 4 5 m kg 33 ft lb Front lower arm nut 45 Nm 4 5 m kg 33 ft lb ...

Page 152: ...EMBLY Removing the rear shock absorber assembly Order Job Parts to remove Q ty Remarks Seat Rear fender Air filter case Refer to GENERAL CHASSIS on page 4 1 1 Clamp 2 Loosen For 4D3H 4D3M 2 Rear shock absorber assembly 1 For installation reverse the removal proce dure ...

Page 153: ...ing of a rear shock absorber and gas cylinder To release the gas pressure drill a 2 3 mm 0 08 0 12 in hole through the rear shock absorber at a point 15 20 mm 0 59 0 79 in from its end as shown WARNING EWA13760 Wear eye protection to prevent eye damage from released gas or metal chips EAS23210 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1 Stand the vehicle on a level surface WARNING EWA13120 Securel...

Page 154: ...TALLING THE REAR SHOCK ABSORBER ASSEMBLY 1 Install Rear shock absorber assembly TIP When installing the rear shock absorber assembly lower bolt lift up the swingarm A for 4D3D B for 4D3H 4D3M Rear shock absorber assembly nut 55 Nm 5 5 m kg 41 ft lb ...

Page 155: ...LE AND REAR AXLE HUB on page 4 11 Rear shock absorber assembly Refer to REAR SHOCK ABSORBER ASSEMBLY on page 4 51 1 Plate 1 2 Swingarm end cover 1 3 Pivot shaft nut washer 1 1 4 Pivot shaft 1 5 Swingarm 1 6 Drive chain guide 1 1 7 Dust cover oil seal 2 2 8 Spacer 1 9 Bearing 2 For installation reverse the removal proce dure ...

Page 156: ...bearings d Check the swingarm vertical movement B by moving the swingarm up and down If swingarm vertical movement is not smooth or if there is binding check the spacers and bearings 3 Remove Pivot shaft nut Washer Pivot shaft Swingarm EAS23360 CHECKING THE SWINGARM 1 Check Swingarm Bends cracks damage Replace 2 Check Pivot shaft Roll the pivot shaft on a flat surface Bends Replace WARNING EWA1377...

Page 157: ...t 4 Install Rear shock absorber assembly Rear axle hub Rear wheel Refer to REAR SHOCK ABSORBER ASSEMBLY on page 4 51 and REAR AXLE AND REAR AXLE HUB on page 4 11 5 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 21 Recommended lubricant Lithium soap based grease Installed depth of bearing a 1 2 mm 0 04 0 08 in Pivot shaft nut 100 Nm 10 0 m kg 74 ft lb Drive chain slack ...

Page 158: ...sprocket and drive chain Order Job Parts to remove Q ty Remarks 1 Drive sprocket cover 1 2 Drive chain guide 2 1 3 Drive chain guide 3 1 4 Drive sprocket nut 1 5 Lock washer 1 6 Drive sprocket 1 7 Drive chain 1 For installation reverse the removal proce dure ...

Page 159: ... link section of the drive chain make sure that the drive chain is taut Perform this procedure 2 3 times at a differ ent location each time 2 Clean Drive chain a Wipe the drive chain with a clean cloth b Put the drive chain in kerosene and remove any remaining dirt c Remove the drive chain from the kerosene and completely dry it ECA14290 This vehicle has a drive chain with small rubber O rings 1 b...

Page 160: ... THE REAR WHEEL SPROCKET Refer to CHECKING THE DRIVE SPROCKET on page 4 59 EAS4D3F030 CHECKING THE SPROCKET BRACKET Refer to CHECKING THE SPROCKET BRACKET on page 4 14 EAS23500 INSTALLING THE DRIVE CHAIN 1 Lubricate Drive chain Master link 2 Install Drive chain Drive sprocket 1 Lock washer 2 Drive sprocket nut 3 TIP While applying the rear brake tighten the drive sprocket nut Recommended lubricant...

Page 161: ...link clip 1 ECA4D3F007 The closed end of the master link clip mast face in the direction of drive chain rotation 6 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 21 ECA13550 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 Therefore keep the drive chain slack w...

Page 162: ...CHAIN DRIVE 4 61 ...

Page 163: ...LVES AND VALVE GUIDES 5 17 CHECKING THE VALVE SEATS 5 19 CHECKING THE VALVE SPRINGS 5 21 INSTALLING THE VALVES 5 22 CYLINDER AND PISTON 5 24 REMOVING THE PISTON 5 25 CHECKING THE CYLINDER AND PISTON 5 25 CHECKING THE PISTON RINGS 5 26 CHECKING THE PISTON PIN 5 27 INSTALLING THE PISTON AND CYLINDER 5 27 CLUTCH 5 29 REMOVING THE CLUTCH 5 32 CHECKING THE FRICTION PLATES 5 32 CHECKING THE CLUTCH PLATE...

Page 164: ...TER MOTOR 5 52 CRANKCASE 5 53 DISASSEMBLING THE CRANKCASE 5 55 CHECKING THE CRANKCASE 5 55 ASSEMBLING THE CRANKCASE 5 55 CRANKSHAFT ASSEMBLY 5 57 REMOVING THE CRANKSHAFT ASSEMBLY 5 58 REMOVING THE PLUNGER SEAL 5 58 CHECKING THE CRANKSHAFT AND CONNECTING ROD 5 58 CHECKING THE TIMING CHAIN 5 59 CHECKING THE CRANKSHAFT SPROCKET 5 59 CHECKING THE TIMING CHAIN GUIDE 5 59 INSTALLING THE PLUNGER SEAL 5 5...

Page 165: ......

Page 166: ...haust pipe Order Job Parts to remove Q ty Remarks Seat front panel front fender rear fender Refer to GENERAL CHASSIS on page 4 1 1 Clamp 1 Loosen 2 Muffler 1 3 Gasket 1 4 Exhaust pipe 1 5 EXhaust pipe protector 1 6 Gasket 1 For installation reverse the removal proce dure ...

Page 167: ...on page 6 3 Drive sprocket drive chain Refer to CHAIN DRIVE on page 4 57 1 Ignition coil spark plug lead 1 2 Air filter case breather hose 1 3 Starter motor lead 1 Disconnect 4 Battery negative lead 1 Disconnect 5 Clutch cable 1 6 Plastic band 1 Disconnect 7 Parking brake cable 1 8 AC magneto coupler 2 Disconnect 9 Neutral switch connector 1 Disconnect For assembly reverse the removal proce dure ...

Page 168: ...1 Crankcase bolt 1 2 Engine mounting bolt front 1 3 Engine bracket left and right 2 4 Engine mounting bolt upper 1 5 Engine bracket upper 1 6 Engine mounting bolt rear upper 1 7 Engine mounting bolt rear lower 1 8 Engine assembly 1 For installation reverse the removal proce dure ...

Page 169: ... Engine mounting nut upper side 4 Engine mounting nut front side 7 Engine bracket bolts front side Crankcase nut 8 EAS4D3F003 INSTALLING THE MUFFLER AND EXHAUST PIPE 1 Install Gasket 1 to muffler 2 Install Exhaust pipe protector 3 Tighten Exhaust pipe protector screws Engine bracket bolt upper side 33 Nm 3 3 m kg 24 ft lb Engine mounting nut rear lower side 66 Nm 6 6 m kg 49 ft lb Engine mounting ...

Page 170: ... Tighten Nuts exhaust pipe 2 6 Install Clamp TIP Slide the clamp onto the end of the muffler and insert the projection a of the clamp into a slot b in the muffler Tighten the clamp after installing the muffler Exhaust pipe nut 18 Nm 1 8 m kg 13 ft lb New ...

Page 171: ...move Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 5 10 1 Lock plate 1 2 Locknut valve clearance adjusting screw 2 2 3 Camshaft 1 4 Intake rocker arm shaft 1 5 Intake rocker arm 1 6 Exhaust rocker arm shaft 1 7 Exhaust rocker arm 1 For installation reverse the removal proce dure ...

Page 172: ... EAS23840 CHECKING THE CAMSHAFT 1 Check Bearing Damage wear Replace 2 Check Camshaft lobes Blue discoloration pitting scratches Replace the camshaft 3 Measure Camshaft lobe dimensions a and b Out of specification Replace the cam shaft Slide hammer bolt 90890 01083 Slide hammer bolt 6 mm YU 01083 1 Weight 90890 01084 YU 01083 3 Camshaft lobe dimension limit Intake a 36 890 36 990 mm 1 4524 1 4563 i...

Page 173: ... pitting scratches Replace or check the lubri cation system 3 Measure Rocker arm inside diameter a Out of specification Replace 4 Measure Rocker arm shaft outside diameter a Out of specification Replace 5 Calculate Rocker arm to rocker arm shaft clear ance TIP Calculate the clearance by subtracting the rocker arm shaft outside diameter from the rocker arm inside diameter Rocker arm inside diameter...

Page 174: ... head and the intake rocker arm shaft as shown Install the intake rocker arm shaft so that groove a is horizontal and aligning the notch of the pointed end b with the hole in the cylinder head 5 Install Camshaft 1 TIP Screw a 10 mm bolt into the threaded end of the camshaft and then install the camshaft 6 Install Lock plate 7 Tighten Lock plate bolts Rocker arm to rocker arm shaft clearance 0 009 ...

Page 175: ... REMOVAL on page 5 1 Carburetor Refer to CARBURETOR on page 6 3 1 Spark plug 1 2 Cylinder head cover 1 O ring 1 1 3 Cylinder head cover 2 O ring 1 1 4 Cylinder head cover 3 O ring 1 1 5 Breather plate 1 Gasket 1 1 6 Crankshaft end accessing screw O ring 1 1 7 Timing mark accessing screw O ring 1 1 8 Camshaft sprocket bolt 1 Loosen 9 Cap bolt 1 Loosen 10 Timing chain tensioner gasket 1 1 11 Breathe...

Page 176: ...CYLINDER HEAD 5 11 For installation reverse the removal proce dure Removing the cylinder head Order Job Parts to remove Q ty Remarks ...

Page 177: ...ylinder head 2 Loosen Camshaft sprocket bolt 1 3 Remove Timing chain tensioner cap Timing chain tensioner 1 along with the gasket Camshaft sprocket bolt Breather plate 2 Camshaft sprocket Timing chain TIP To prevent the timing chain from falling into the crankcase fasten it with a wire 4 Remove Cylinder head 1 EAS24160 CHECKING THE CYLINDER HEAD 1 Eliminate Combustion chamber carbon deposits with ...

Page 178: ... tooth wear a Replace the camshaft sprockets and the timing chain as a set 2 Check Timing chain guide exhaust side Damage wear Replace the defective part s EAS24200 CHECKING THE TIMING CHAIN TEN SIONER 1 Check Timing chain tensioner Cracks damage Replace 2 Check One way cam operation Rough movement Replace the timing chain tensioner housing a Lightly press the timing chain tensioner rod into the t...

Page 179: ...ve the wire from the timing chain d Install the timing chain onto the camshaft sprocket and then install the camshaft sprocket onto the camshaft TIP When installing the camshaft sprocket be sure to keep the timing chain as tight as pos sible on the exhaust side Align the pin on the camshaft with the slot in the camshaft sprocket ECA13740 Do not turn the crankshaft when installing the camshaft s to...

Page 180: ...unterclockwise 7 Check I mark a Align the I mark on the generator rotor with the stationary pointer b on the crankcase cover I mark c Align the I mark on the camshaft sprocket with the stationary pointer d on the cylinder head Out of alignment Correct Refer to the installation steps above 8 Tighten Camshaft sprocket bolt ECA13750 Be sure to tighten the camshaft sprocket bolts to the specified torq...

Page 181: ...emarks Cylinder head Refer to CYLINDER HEAD on page 5 10 Rocker arm camshaft Refer to CAMSHAFT on page 5 6 1 Valve cotter 4 2 Valve spring retainer 2 3 Outer valve spring 2 4 Inner valve spring 2 5 Intake valve 1 6 Exhaust valve 1 7 Valve stem seal 2 8 Valve spring seat 2 9 Valve guide 2 For installation reverse the removal proce dure ...

Page 182: ... Remove the valve cotters by compressing the valve spring with the valve spring compressor and the valve spring compressor attachment 2 3 Remove Upper spring seat 1 Inner valve spring 2 Outer valve spring 3 Valve 4 Lower spring seat 5 Valve stem seal 6 TIP Identify the position of each part very carefully so that it can be reinstalled in its original place EAS24290 CHECKING THE VALVES AND VALVE GU...

Page 183: ... guide installer 2 and valve guide remover 1 c After installing the valve guide bore the valve guide with the valve guide reamer 3 to obtain the proper valve stem to valve guide clearance TIP After replacing the valve guide reface the valve seat Valve stem to valve guide clear ance Valve stem to valve guide clear ance intake 0 010 0 037 mm 0 0004 0 0015 in Limit 0 080 mm 0 003 in Valve stem to val...

Page 184: ...pplies to all of the valves and valve seats 1 Eliminate Carbon deposits from the valve face and valve seat 2 Check Valve seat Pitting wear Replace the cylinder head 3 Measure Valve seat width C a Out of specification Replace the cylin der head Valve guide remover ø6 90890 04064 Valve guide remover 6 0 mm YM 04064 A Valve guide installer ø6 90890 04065 Valve guide installer 6 0 mm YM 04065 A Valve ...

Page 185: ...num disulfide oil onto the valve stem c Install the valve into the cylinder head d Turn the valve until the valve face and valve seat are evenly polished then clean off all of the lapping compound TIP For the best lapping results lightly tap the valve seat while rotating the valve back and forth between your hands e Apply a fine lapping compound to the valve face and repeat the above steps f After...

Page 186: ...g Free length intake 36 63 mm 1 44 in Free length exhaust 36 63 mm 1 44 in a Compressed valve spring force b Installed length Inner spring Installed compression spring force intake 75 00 91 70 N 7 65 9 35 kgf 16 86 20 61 lbf Installed compression spring force exhaust 75 00 91 70 N 7 65 9 35 kgf 16 86 20 61 lbf Installed length intake 30 50 mm 1 20 in Installed length exhaust 30 50 mm 1 20 in Outer...

Page 187: ...th the larger pitch a facing up 4 Install Valve cotters 1 TIP Install the valve cotters by compressing the valve spring with the valve spring compressor and the valve spring compressor attachment 2 Inner spring Spring tilt intake 2 5 1 60 mm 2 5 0 063 in Spring tilt exhaust 2 5 1 60 mm 2 5 0 063 in Outer spring Spring tilt intake 2 5 1 60 mm 2 5 0 063 in Spring tilt exhaust 2 5 1 60 mm 2 5 0 063 i...

Page 188: ...ALVES AND VALVE SPRINGS 5 23 5 To secure the valve cotters onto the valve stem lightly tap the valve tip with a soft face hammer ECA13800 Hitting the valve tip with excessive force could damage the valve ...

Page 189: ...d piston Order Job Parts to remove Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 5 10 1 Oil delivery pipe 1 2 Cylinder 1 3 Dowel pin 2 4 Cylinder gasket 1 5 Piston pin clip 2 6 Piston pin 1 7 Piston 1 8 Piston ring set 1 For installation reverse the removal proce dure ...

Page 190: ... ring 2nd ring Oil ring TIP When removing a piston ring open the end gap with your fingers and lift the other side of the ring over the piston crown EAS24400 CHECKING THE CYLINDER AND PISTON 1 Check Piston wall Cylinder wall Vertical scratches Rebore or replace the cylinder and replace the piston and piston rings as a set 2 Measure Piston to cylinder clearance a Measure cylinder bore C with the cy...

Page 191: ...te any carbon deposits from the piston ring grooves and piston rings 2 Install Piston ring into the cylinder TIP Level the piston ring into the cylinder with the piston crown 3 Measure Piston ring end gap Out of specification Replace the piston ring TIP The oil ring expander spacer s end gap cannot be measured If the oil ring rail s gap is exces sive replace all three piston rings Piston size diam...

Page 192: ...ND CYLINDER 1 Install Lower oil ring rail 1 Oil ring expander 2 Piston ring Top ring End gap installed 0 19 0 31 mm 0 007 0 012 in Limit 0 56 mm 0 022 in 2nd ring End gap installed 0 30 0 45 mm 0 012 0 018 in Limit 0 80 mm 0 032 in Oil ring End gap installed 0 10 0 35 mm 0 004 0 014 in a 40 mm 1 476 in Piston pin outside diameter 16 991 17 000 mm 0 6689 0 6693 in Limit 16 971 mm 0 6681 in Piston p...

Page 193: ...to pre vent the clip from falling into the crankcase 3 Install O ring Cylinder gasket Dowel pins 4 Lubricate Piston Piston rings Cylinder with the recommended lubricant 5 Offset Piston ring end gaps 6 Install Cylinder TIP While compressing the piston rings with one hand install the cylinder with the other hand Pass the timing chain and timing chain guide intake side through the timing chain cavity...

Page 194: ...ngine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 10 1 Cotter pin Washer 1 1 2 Clevis pin 1 3 Brake pedal Footrest 1 1 4 Oil delivery pipe 1 5 Oil cooler hose 2 6 O ring 2 7 Right crankcase cover 1 8 Dowel pin 2 9 Crankcase cover gasket 1 For installation reverse the removal proce dure ...

Page 195: ...e 1 3 Primary drive gear nut 1 4 Friction plate 6 5 Clutch plate 5 6 Clutch boss nut 1 7 Clutch boss 1 8 Thrust washer 1 9 Clutch housing 1 10 Claw washer 1 11 Primary drive gear 1 12 Locknut Washer 1 1 13 Push rod 1 1 14 Push plate 1 15 Push rod 2 Ball 1 1 For installation reverse the removal proce dure ...

Page 196: ... pedal Refer to SHIFT SHAFT on page 5 42 Left crankcase cover Refer to PICKUP COIL ROTOR AND STARTER CLUTCH on page 5 45 Clutch assembly 1 Clutch cable 1 2 Bolt 1 3 Push lever shaft 1 4 Torsion spring 1 5 Circlip 1 6 Oil seal 1 7 Bearing 1 For installation reverse the removal proce dure ...

Page 197: ...clutch boss with the univer sal clutch holder 4 loosen the clutch boss nut 5 4 Remove Clutch boss nut 1 Lock washer 2 Clutch boss 3 Thrust washer 4 Clutch housing 5 5 Remove Primary drive gear nut 1 Lock washer 2 Claw washer 3 Primary drive gear 4 EAS25100 CHECKING THE FRICTION PLATES The following procedure applies to all of the friction plates 1 Check Friction plate Damage wear Replace the frict...

Page 198: ...lutch springs as a set 2 Measure Clutch spring free length a Out of specification Replace the clutch springs as a set EAS25150 CHECKING THE CLUTCH HOUSING 1 Check Clutch housing dogs Damage pitting wear Deburr the clutch housing dogs or replace the clutch hous ing TIP Pitting on the clutch housing dogs will cause erratic clutch operation EAS25160 CHECKING THE CLUTCH BOSS 1 Check Clutch boss spline...

Page 199: ...r free play Free play exists Replace the primary drive and primary driven gears as a set EAS25260 INSTALLING THE CLUTCH 1 Install Primary drive gear Claw washer Lock washer Primary drive gear nut 2 Install Clutch housing Thrust washer Clutch boss Lock washer 1 Clutch boss nut TIP Make sure the teeth on the lock washer are correctly aligned with the grooves on the clutch boss 3 Tighten Clutch boss ...

Page 200: ... After installing the clutch cable bend the push lever shaft tab along a flat side of the nut 8 Install Push rod 2 Ball Push rod 1 Push plate Washer Locknut Pressure plate Clutch spring 1 Bolt 2 9 Tighten Clutch spring bolt Locknut TIP Tighten the clutch spring bolts in stages and in a crisscross pattern 10 Check Push lever position Push lever mark a and crankcase mark b not aligned Correct TIP Pu...

Page 201: ... moving and then tighten the locknut to specification ECA13820 Do not overtighten the locknut since this will remove the free play between both push rods 12 Check Clutch cable free play Refer to ADJUSTING THE CLUTCH CABLE FREE PLAY on page 3 12 13 Install Clamp Dowel pin Crankcase cover gasket Locknut 8 Nm 0 8 m kg 5 9 ft lb Clutch cable free play 5 0 10 0 mm 0 20 0 39 in New ...

Page 202: ...r bolts M6 40 mm 3 6 Crankcase cover bolts M6 25 mm 7 13 Oil filter element cover bolt M6 70 mm 14 16 Tighten Crankcase cover bolts 1 13 Oil filter element cover bolt 14 TIP Tighten the bolts in stages using a crisscross pattern Crankcase cover bolt 10 Nm 1 0 m kg 7 4 ft lb Oil filter element cover bolt 10 Nm 1 0 m kg 7 4 ft lb ...

Page 203: ...on page 5 29 1 Balancer weight gear nut 1 2 Lock washer 1 3 Buffer boss 1 4 Balancer weight gear 1 5 Absorber plate 1 6 Compression spring 6 7 Dowel pin 3 8 Straight key 1 9 Spacer 1 10 Circlip 1 11 Oil pump driven gear 1 12 Oil pump assembly 1 13 Gasket 1 14 Balancer drive gear 1 15 Oil strainer 1 16 Spacer 1 For installation reverse the removal proce dure ...

Page 204: ...assemble the oil pump Order Job Parts to remove Q ty Remarks 1 Oil pump housing 1 2 Dowel pin 2 3 Outer rotor 1 4 Inner rotor 1 5 Dowel pin 1 6 Shaft 1 7 Oil pump cover 1 For installation reverse the removal proce dure ...

Page 205: ...otor tip clearance a Outer rotor to oil pump housing clear ance b Oil pump housing to inner rotor and outer rotor clearance c Out of specification Replace the oil pump 3 Check Oil pump operation Rough movement Repeat steps 1 and 2 or replace the defective part s EAS4D3F015 CHECKING THE BALANCER WEIGHT GEAR 1 Check Balancer weight gear Buffer boss Inner rotor to outer rotor tip clearance 0 15 mm 0 ...

Page 206: ... bolts make sure the oil pump turns smoothly EAS4D3F020 INSTALLING THE BALANCER WEIGHT GEAR 1 Install Balancer weight gear Lock washer Balancer weight gear nut TIP Align the punch mark a in the balancer drive gear with the punch mark b in the bal ancer weight gear Place the aluminium plate c between bal ancer drive gear 1 and balancer weight gear 2 and then tighten the balancer weight gear nut 3 2...

Page 207: ...shift shaft and stopper lever Order Job Parts to remove Q ty Remarks Right crankcase cover clutch Refer to CLUTCH on page 5 29 1 Shift pedal 1 2 Shift shaft assembly 1 3 Stopper lever 1 4 Torsion spring 1 For installation reverse the removal proce dure ...

Page 208: ... 1 Install Stopper lever 1 TIP Hook the ends of the stopper lever spring onto the stopper lever and the crankcase boss Mesh the stopper lever with the shift drum segment assembly 2 Tighten Stopper lever bolt 3 Install Shift shaft 1 TIP Install the shift shaft 1 by aligning the shift shaft spring 2 with the stopper 3 4 Check When the gear position is in Neutral check the length a b between the tip ...

Page 209: ...SHIFT SHAFT 5 44 6 Tighten Shift pedal bolt 7 Adjust Shift pedal height Refer to ADJUSTING THE SHIFT PEDAL on page 3 21 Shift pedal bolt 10 Nm 1 0 m kg 7 4 ft lb ...

Page 210: ...ive sprocket cover Refer to CHAIN DRIVE on page 4 57 1 Starter idle gear cover O ring 1 1 2 Starter idler gear 1 shaft 1 1 3 Pickup coil rotor lead coupler 2 Disconnect 4 Left crankcase cover 1 5 Dowel pin 2 6 Crank case cover gasket 1 7 Stator coil assembly pickup coil 1 1 8 Starter idler gear 2 shaft 1 1 9 Pickup coil rotor 1 10 Woodruff key 1 11 Starter wheel gear 1 12 Bearing 1 13 Washer 1 14 ...

Page 211: ... Remove the rotor using flywheel puller 2 3 Remove Woodruff key 1 4 Remove Starter idle gear 2 1 Starter wheel gear 2 Bearing 3 Washer 4 EAS403F013 CHECKING THE STARTER CLUTCH 1 Check Starter clutch rollers Damage wear Replace the starter clutch 2 Check Starter idle gear 1 Starter wheel gear 2 Starter clutch gear 3 Burrs chips roughness wear Replace the defective part s Sheave holder 90890 01701 P...

Page 212: ...faulty and must be replaced 5 Check Shaft Damage fatigue wear Replace the defective part s EAS403F014 INSTALLING THE PICKUP COIL ROTOR 1 Install Washer 1 Bearing 2 Starter wheel gear 3 Starter idle gear 2 4 2 Install Woodruff key 1 Pickup coil rotor 2 Washer 3 pickup coil rotor bolt 4 TIP Clean the tapered portion of the crankshaft and the rotor hub When installing the rotor make sure the woo druf...

Page 213: ... in a crisscross pattern as shown 9 Install Starter idle gear 1 Shaft 10 Install O ring Starter idle gear cover 11 Tighten Starter idle gear cover bolt Stator coil bolt 10 Nm 1 0 m kg 7 4 ft lb LOCTITE Pickup coil bolt 10 Nm 1 0 m kg 7 4 ft lb LOCTITE Left crankcase cover bolt 7 Nm 0 7 m kg 5 2 ft lb LOCTITE New Crank case cover bolt M6 30 mm 1 5 10 Nm 1 0 m kg 7 4 ft lb M6 45 mm 6 10 Nm 1 0 m kg ...

Page 214: ... remove Q ty Remarks Exhaust pipe Refer to ENGINE REMOVAL on page 5 1 Starter idle gear cover Starter idle gear Refer to PICKUP COIL ROTOR AND STARTER CLUTCH on page 5 45 1 Clutch cable holder 1 2 Starter motor lead 1 Disconnect 3 Starter motor 1 For installation reverse the removal proce dure ...

Page 215: ...otor Order Job Parts to remove Q ty Remarks 1 Front bracket 1 2 Tang washer 1 3 Plate washer 1 4 Circlip 1 5 Rear bracket Brush holder 1 1 6 Armature assembly 1 7 Starter motor yoke 1 8 Brush spring 2 2 For assembly reverse the disassembly pro cedure ...

Page 216: ...and insulation Out of specification Replace the starter motor a Measure the armature assembly resis tances with the pocket tester b If any resistance is out of specification replace the starter motor 5 Measure Brush length a Out of specification Replace the brushes as a set 6 Measure Brush spring force Out of specification Replace the brush springs as a set Commutator wear limit 21 mm 0 83 in Mica...

Page 217: ... 1 Install Brush spring 1 Brush 2 2 Install Armature coil 1 3 Install O ring 1 To starter motor yoke 2 4 Install Starter motor yoke 1 TIP Align the match marks a on the starter yoke 1 with the match marks b on the rear bracket 5 Install Tang washer 1 Plate washer 2 Front bracket 3 TIP Align the match marks a on the starter motor yoke with the match marks b on the front bracket New ...

Page 218: ...D PISTON on page 5 24 Clutch Refer to CLUTCH on page 5 29 Oil pump balancer weight gear Refer to OIL PUMP on page 5 38 Shift shaft Refer to SHIFT SHAFT on page 5 42 Pickup coil rotor Refer to PICKUP COIL ROTOR AND STARTER CLUTCH on page 5 45 1 Timing chain guide intake side 1 2 Timing chain 1 3 Crankshaft sprocket 1 4 Right crankcase 1 5 Dowel pin 2 6 Left crankcase 1 7 Spacer 1 For installation r...

Page 219: ...er Job Parts to remove Q ty Remarks Crankshaft assembly Refer to CRANKSHAFT ASSEMBLY on page 5 57 Main axle assembly drive axle assembly Refer to TRANSMISSION on page 5 61 1 Oil seal 2 2 Bearing 8 For assembly reverse the removal proce dure ...

Page 220: ...contact the crankcase during crankcase separation 4 Remove Right crankcase ECA13910 First check that the shift drum segment s teeth and the drive axle circlip are prop erly positioned then remove the right crankcase Do not damage the crankcase mating sur faces EAS25580 CHECKING THE CRANKCASE 1 Thoroughly wash the crankcase halves in a mild solvent 2 Thoroughly clean all the gasket surfaces and cra...

Page 221: ...ts 1 12 TIP Tighten each bolt 1 4 of a turn at a time in stages and in a crisscross pattern 6 Install Neutral switch 13 7 Install Crankshaft sprocket 1 Timing chain guide intake side 2 Timing chain 3 8 Tighten Timing chain guide intake side bolt 9 Apply Engine oil onto the crankshaft pins bearings and oil delivery holes 10 Check Crankshaft and transmission operation Rough movement Repair Crankcase...

Page 222: ...BLY Removing the crankshaft assembly Order Job Parts to remove Q ty Remarks Crankcase Refer to CRANKCASE on page 5 53 1 Balancer weight 1 2 Crankshaft assembly 1 3 Dowel pin 1 4 Plunger seal 1 5 Bearing 1 For installation reverse the removal proce dure ...

Page 223: ...ush the plunger seal lightly and remove the dowel pin EAS26060 CHECKING THE CRANKSHAFT AND CON NECTING ROD 1 Measure Crankshaft runout Out of specification Replace the crank shaft bearing or both TIP Turn the crankshaft slowly 2 Measure Big end side clearance Out of specification Replace the big end bearing crankshaft pin or connect ing rod 3 Measure Crankshaft width Out of specification Replace t...

Page 224: ...3 CHECKING THE CRANKSHAFT SPROCKET 1 Check Crankshaft sprocket More than 1 4 tooth wear a Replace the timing chain and camshaft sprocket and crankshaft sprocket as a set EAS4D3F024 CHECKING THE TIMING CHAIN GUIDE 1 Check Timing chain guide intake side Damage wear Replace the timing chain guide intake side EAS4D3F025 INSTALLING THE PLUNGER SEAL 1 Install Compression spring 1 Plunger seal 2 Dowel pi...

Page 225: ...th lithium soap based grease and each bearing with engine oil TIP Hold the connecting rod at top dead center TDC with one hand while turning the nut of the crankshaft installer bolt with the other Turn the crankshaft installer bolt until the crankshaft assembly bottoms against the bearing Crankshaft installer pot 90890 01274 Installing pot YU 90058 Crankshaft installer bolt 90890 01275 Bolt YU 900...

Page 226: ... forks Order Job Parts to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 53 1 Shift fork guide bar 1 2 Shift drum assembly 1 3 Shift fork 3 R 1 4 Shift fork 2 C 1 5 Shift fork 1 L 1 6 Main axle assembly 1 7 Drive axle assembly 1 For installation reverse the removal proce dure ...

Page 227: ...inion gear 1 4 Circlip washer 1 1 5 4th pinion gear 1 6 Main axle 1 7 Plain washer 1 8 1st wheel gear 1 9 4th wheel gear 1 10 Circlip washer 1 1 11 3rd wheel gear collar 1 1 12 Claw washer 1 1 13 Claw washer 2 1 14 5th wheel gear 1 15 Circlip washer 1 1 16 2nd wheel gear 1 17 Drive axle 1 For installation reverse the removal proce dure ...

Page 228: ...cam follower 1 Shift fork pawl 2 Bends damage scoring wear Replace the shift fork 3 Check Shift fork guide bar Roll the shift fork guide bar on a flat sur face Bends Replace WARNING EWA12840 Do not attempt to straighten a bent shift fork guide bar EAS26270 CHECKING THE SHIFT DRUM ASSEMBLY 1 Check Shift drum groove 1 Damage scratches wear Replace the shift drum assembly Shift drum segment 2 Damage ...

Page 229: ...ive gear s Transmission gear dogs Cracks damage rounded edges Replace the defective gear s 4 Check Transmission gear engagement each pinion gear to its respective wheel gear Incorrect Reassemble the transmis sion axle assemblies TIP When reassembling the main axle press the 2nd pinion gear 1 onto it 2 as shown 5 Check Transmission gear movement Rough movement Replace the defec tive part s 6 Check ...

Page 230: ...Shift drum assembly 4 Shift fork guide bar 5 Spacer Right crankcase TIP The embossed marks on the shift forks should face towards the left side of the engine and be in the following sequence L C R 2 Check Shift cam operation Unsmooth operation Repair TIP Check the transmission and shift forks for smooth operation by turning the shift cam with your hand ...

Page 231: ...TEM FUEL TANK 6 1 REMOVING THE FUEL TANK 6 2 CHECKING THE FUEL COCK 6 2 CHECKING THE FUEL COCK OPERATION 6 2 CARBURETOR 6 3 CHECKING THE CARBURETOR 6 6 ASSEMBLING THE CARBURETOR 6 7 INSTALLING THE CARBURETOR 6 8 ...

Page 232: ...moving the fuel tank Order Job Parts to remove Q ty Remarks Seat front fender Refer to GENERAL CHASSIS on page 4 1 1 Fuel hose fuel cock side 1 2 Fuel tank 1 3 Clamp 1 4 Fuel tank shield 1 For installation reverse the removal proce dure ...

Page 233: ... breather hose through the hole in the han dlebar protector EAS26650 CHECKING THE FUEL COCK 1 Check Fuel cock Cracks damage wear Replace 2 Check Fuel cock strainer Obstruction clean Blow out the jets with compressed air Damage Replace EAS26660 CHECKING THE FUEL COCK OPERATION TIP After installing the fuel cock check its opera tion 1 Check Fuel cock operation Out of specification Replace the fuel c...

Page 234: ...Refer to GENERAL CHASSIS on page 4 1 1 Carburetor warmer coupler 1 Disconnect 2 Air vent hose 1 Disconnect 3 Fuel hose carburetor side 1 Disconnect 4 Throttle cable cover 1 5 Throttle cable 1 Disconnect 6 Clamp 1 Loosen 7 Clamp 2 Loosen 8 Carburetor 1 9 Carburetor joint 2 1 10 Carburetor joint 1 1 For installation reverse the removal proce dure ...

Page 235: ...lve 1 6 Jet needle 1 7 Cover 1 8 Spring 1 9 Coasting enricher diaphragm 1 10 Coasting enricher jet P A J 2 1 11 Starter plunger 1 12 Carburetor warmer positive lead 1 13 Carburetor warmer 1 14 Carburetor warmer negative lead 1 15 Float chamber 1 16 Float pin 1 17 Float 1 18 Needle valve seat set 1 19 Main jet 1 20 Needle jet holder 1 21 Needle jet 1 22 Pilot jet 1 ...

Page 236: ...CARBURETOR 6 5 23 Starter jet 1 For assembly reverse the disassembly pro cedure Disassembling the carburetor Order Job Parts to remove Q ty Remarks ...

Page 237: ...ges and jets with compressed air 3 Check Float 1 Float Tang 2 Damage Replace 4 Check Needle valve seat 1 Needle valve 2 Contamination Clean Damage obstruction wear Replace the needle valve needle valve seat and O ring as a set TIP Always replace the valve seat needle valve and O ring as a set 5 Check Piston valve 1 Damage scratches wear Replace Piston valve diaphragm 2 Cracks tears Replace 6 Check...

Page 238: ...arter plunger spring Bends cracks damage Replace 12 Check Hose joints Cracks damage Replace 13 Check Air vent hose Fuel hose Drain hose Cracks damage wear Replace Obstruction Clean Blow out the hoses with compressed air EAS26800 ASSEMBLING THE CARBURETOR ECA14110 Before assembling the carburetor wash all of the parts in a petroleum based sol vent Always use a new gasket 1 Measure Float height a Ou...

Page 239: ...he carburetor joint with the slot b in the clamp 2 Install Carburetor joint TIP Align the projection a on the cylinder head with the slot b in the carburetor joint 3 Install Carburetor TIP Align the projection a on the carburetor with the slot b in the carburetor joint 4 Install Throttle cable Throttle cable cover 5 Adjust Engine idling speed Refer to ADJUSTING THE ENGINE IDLING SPEED on page 3 5 ...

Page 240: ...CARBURETOR 6 9 ...

Page 241: ...BLESHOOTING 7 21 CARBURETOR HEATING SYSTEM 7 23 CIRCUIT DIAGRAM 7 23 TROUBLESHOOTING 7 25 ELECTRICAL COMPONENTS 7 27 CHECKING THE SWITCHES 7 29 CHECKING THE BULBS AND BULB SOCKETS 7 32 CHECKING THE FUSES 7 33 CHECKING AND CHARGING THE BATTERY 7 33 CHECKING THE RELAYS 7 37 CHECKING THE DIODE 7 37 CHECKING THE SPARK PLUG CAP 7 38 CHECKING THE IGNITION COIL 7 38 CHECKING THE PICKUP COIL 7 39 CHECKING...

Page 242: ...IGNITION SYSTEM 7 1 EAS27090 IGNITION SYSTEM EAS27100 CIRCUIT DIAGRAM ...

Page 243: ...IGNITION SYSTEM 7 2 1 Pickup coil 2 Stator coil 4 Main switch 5 Battery positive lead 6 Battery 7 Fuse 10 CDI unit 11 Ignition coil 12 Spark plug 24 Engine stop switch 28 Ground ...

Page 244: ...RGING THE BATTERY on page 7 33 Clean the battery terminals Recharge or replace the battery 3 Check the spark plug Refer to CHECKING THE SPARK PLUG on page 3 7 Re gap or replace the spark plug 4 Check the ignition spark gap Refer to CHECKING THE IGNI TION COIL on page 7 38 Ignition system is OK 5 Check the spark plug cap Refer to CHECKING THE SPARK PLUG CAP on page 7 38 Replace the spark plug cap 6...

Page 245: ...age 7 29 Replace the handlebar switch 11 Check the neutral switch Refer to CHECKING THE SWITCHES on page 7 29 Replace the neutral switch 12 Check the clutch switch Refer to CHECKING THE SWITCHES on page 7 29 Replace the clutch switch 13 Check the starting circuit cut off relay Refer to CHECKING THE RELAYS on page 7 37 Replace the starting circuit cut off relay 14 Check the entire ignition system s...

Page 246: ...ELECTRIC STARTING SYSTEM 7 5 EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM ...

Page 247: ...NG SYSTEM 7 6 4 Main switch 5 Battery positive lead 6 Battery 7 Fuse 8 Starter relay 9 Starter motor 13 Starting circuit cut off relay 14 Clutch switch 18 Neutral switch 24 Engine stop switch 25 Start switch 28 Ground ...

Page 248: ...al the neutral switch is closed The clutch lever is pulled to the handlebar the clutch switch is closed The starting circuit cut off relay prevents the starter motor from operating when neither of these con ditions has been met In this instance the starting circuit cut off relay is open so current cannot reach the starter motor When at least one of the above conditions has been met the starting ci...

Page 249: ...RANSMISSION IS IN NEU TRAL b WHEN THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 1 Battery 2 Fuse 3 Main switch 4 Engine stop switch 5 Starting circuit cut off relay 6 Clutch switch 7 Neutral switch 8 Start switch 9 Starter relay 10 Starter motor ...

Page 250: ...y 3 Check the starter motor operation Refer to CHECKING THE STARTER MOTOR OPERATION on page 7 40 Starter motor is OK Perform the elec tric starting system troubleshooting starting with step 5 4 Check the starter motor Refer to CHECKING THE STARTER MOTOR on page 5 51 Repair or replace the starter motor 5 Check the starting circuit cut off relay Refer to CHECKING THE RELAYS on page 7 37 Replace the ...

Page 251: ...0 Check the neutral switch Refer to CHECKING THE SWITCHES on page 7 29 Replace the neutral switch 11 Check the clutch switch Refer to CHECKING THE SWITCHES on page 7 29 Replace the clutch switch 12 Check the start switch Refer to CHECKING THE SWITCHES on page 7 29 Replace the handlebar switch 13 Check the entire starting system s wiring Refer to CIRCUIT DIAGRAM on page 7 5 Properly connect or repa...

Page 252: ...CHARGING SYSTEM 7 11 EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM ...

Page 253: ...CHARGING SYSTEM 7 12 2 Stator coil 3 Rectifier regulator 5 Battery positive lead 6 Battery 7 Fuse 28 Ground ...

Page 254: ...ck the battery Refer to CHECKING AND CHARGING THE BATTERY on page 7 33 Clean the battery terminals Recharge or replace the battery 3 Check the stator coil Refer to CHECKING THE STATOR COIL on page 7 40 Replace the pickup coil stator coil assembly 4 Check the main switch Refer to CHECKING THE SWITCHES on page 7 29 Replace the main switch 5 Check the entire charging system s wiring Refer to CIRCUIT ...

Page 255: ...CHARGING SYSTEM 7 14 ...

Page 256: ...LIGHTING SYSTEM 7 15 EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM ...

Page 257: ...LIGHTING SYSTEM 7 16 2 Stator coil 3 Rectifier regulator 4 Main switch 5 Battery positive lead 6 Battery 7 Fuse 21 Tail brake light 23 Light switch 26 Headlight relay 27 Headlight 28 Ground ...

Page 258: ...KETS on page 7 32 Replace the bulb s and bulb socket s 2 Check the fuse Refer to CHECKING THE FUSES on page 7 33 Replace the fuse 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 7 33 Clean the battery terminals Recharge or replace the battery 4 Check the main switch Refer to CHECKING THE SWITCHES on page 7 29 Replace the main switch 5 Check the light switch Refer to CHECKING...

Page 259: ...LIGHTING SYSTEM 7 18 NG OK 7 Check the entire lighting system s wiring Refer to CIRCUIT DIAGRAM on page 7 15 Properly connect or repair the lighting system s wiring This circuit is OK ...

Page 260: ...SIGNALING SYSTEM 7 19 EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM ...

Page 261: ...GNALING SYSTEM 7 20 4 Main switch 5 Battery positive lead 6 Battery 7 Fuse 17 Neutral indicator light 18 Neutral switch 19 Rear brake light switch 20 Front brake light switch 21 Tail brake light 28 Ground ...

Page 262: ... AND CHARGING THE BATTERY on page 7 33 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 7 29 Replace the main switch 4 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 7 19 Properly connect or repair the signal ing system s wiring This circuit is OK 1 Check the tail brake light bulb and socket Refe...

Page 263: ...ircuit is OK 1 Check the neutral indicator light bulb and socket Refer to CHECKING THE BULBS AND BULB SOCKETS on page 7 32 Replace the neutral indicator light bulb socket or both 2 Check the neutral switch Refer to CHECKING THE SWITCHES on page 7 29 Replace the neutral switch 3 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 7 19 Properly connect or repair the signal in...

Page 264: ...CARBURETOR HEATING SYSTEM 7 23 EAS27490 CARBURETOR HEATING SYSTEM EAS27500 CIRCUIT DIAGRAM ...

Page 265: ...CARBURETOR HEATING SYSTEM 7 24 4 Main switch 5 Battery positive lead 6 Battery 7 Fuse 15 Thermo switch 16 Carburetor warmer 28 Ground ...

Page 266: ...HARGING THE BATTERY on page 7 33 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 7 29 Replace the main switch 4 Check the thermo switch Refer to CHECKING THE THERMO SWITCH on page 7 41 Replace the thermo switch 5 Check the carburetor warmer Refer to CHECKING THE CAR BURETOR WARMER on page 7 42 Replace the carburetor warmer ...

Page 267: ...CARBURETOR HEATING SYSTEM 7 26 ...

Page 268: ...ELECTRICAL COMPONENTS 7 27 EAS27972 ELECTRICAL COMPONENTS ...

Page 269: ...er relay 7 Fuse 8 Battery 9 Tail brake light 10 Headlight relay 11 Starting circuit cut off relay 12 Thermo switch 13 Carburetor warmer 14 Starter motor 15 Pickup coil stator assembly 16 Neutral switch 17 Rear brake light switch 18 Ignition coil 19 Spark plug 20 Headlight 21 Rectifier regulator 22 Neutral indicator light ...

Page 270: ...ELECTRICAL COMPONENTS 7 29 EAS27980 CHECKING THE SWITCHES ...

Page 271: ...ELECTRICAL COMPONENTS 7 30 1 Light switch 2 Engine stop switch 3 Start switch 4 Main switch 5 Front brake light switch 6 Clutch switch 7 Fuse 8 Neutral switch 9 Rear brake light switch ...

Page 272: ... checking for continuity switch back and forth between the switch positions a few times The terminal connections for switches e g main switch engine stop switch are shown in an illus tration similar to the one on the left The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row in the switch illustration TIP indicates a continuity of electricity...

Page 273: ...THE HEADLIGHT BULBS on page 3 32 WARNING EWA13320 Since the headlight bulb gets extremely hot keep flammable products and your hands away from the bulb until it has cooled down ECA14380 Be sure to hold the socket firmly when removing the bulb Never pull the lead otherwise it may be pulled out of the ter minal in the coupler Avoid touching the glass part of the head light bulb to keep it free from ...

Page 274: ...d check the continuity TIP Set the pocket tester selector to Ω 1 b If the pocket tester indicates replace the fuse 3 Replace Blown fuse a Set the main switch to OFF b Install a new fuse of the correct amperage rating c Set on the switches to verify if the electrical circuit is operational d If the fuse immediately blows again check the electrical circuit WARNING EWA13310 Never use a fuse with an a...

Page 275: ...ry should be charged as explained in the charging method illustrations If the battery is overcharged the electrolyte level will drop considerably Therefore take special care when charging the bat tery TIP Since VRLA Valve Regulated Lead Acid bat teries 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...

Page 276: ...ull contact with the battery termi nal and that they are not shorted A cor roded battery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks If the battery becomes hot to the touch at any time during the charging process disconnect the battery charger and let the battery cool before reconnecting it Hot batteries can explode As shown in the following illu...

Page 277: ...od using a constant voltage charger a Measure the open circuit voltage prior to charging TIP Voltage should be measured 30 minutes after the machine is stopped b Connect a charger and AMP meter to the battery and start charging c Make sure that the current is higher than the standard charging current written on the battery TIP If the current is lower than the standard charg ing current written on ...

Page 278: ...1 CHECKING THE DIODE 1 Check Diode Out of specification Replace Recommended lubricant Dielectric grease Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Relay operation Continuity No continuity between 3 to 4 1 Positive battery terminal 2 Positive tester probe 3 Negative battery termina...

Page 279: ...spark plug cap resistance EAS28090 CHECKING THE IGNITION COIL 1 Check Primary coil resistance Out of specification Replace a Disconnect the ignition coil connectors from the ignition coil terminals b Connect the pocket tester Ω 1 to the ignition coil as shown c Measure the primary coil resistance 2 Check Secondary coil resistance Out of specification Replace Continuity Positive tester probe sky bl...

Page 280: ... spark gap until a misfire occurs EAS28110 CHECKING THE PICKUP COIL 1 Disconnect Pickup coil coupler from the wire harness 2 Check Pickup coil resistance Out of specification Replace a Connect the pocket tester Ω 100 to the pickup coil terminal as shown Secondary coil resistance 6 32 9 48 kΩ Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe High tension code 1 Negativ...

Page 281: ... may burn This check is likely to produce sparks therefore make sure no flammable gas or fluid is in the vicinity b Check the starter motor operation EAS28150 CHECKING THE STATOR COIL 1 Disconnect Stator coil coupler from the wire harness 2 Check Stator coil resistance Out of specification Replace the stator coil a Connect the pocket tester Ω 1 to the stator coil coupler as shown b Measure the sta...

Page 282: ...CH 1 Remove Thermo switch from the wire harness 2 Check Thermo switch continuity Out of specification Replace the thermo switch Step 1 and 2 Heating phase Step 3 and 4 Cooling phase 3 Install Thermo switch Rectifier regulator output volt age 14 V at 5000 r min Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe Red 1 Negative tester probe Black 2 Positive tester probe B...

Page 283: ... the carburetor warmer from the carburetor b Connect the pocket tester Ω 1 to the carburetor warmer as shown c Measure the carburetor warmer resistance Carburetor warmer resistance 6 12 Ω Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe Carburetor warmer terminal 1 Negative tester probe Carburetor warmer body 2 ...

Page 284: ...ELECTRICAL COMPONENTS 7 43 ...

Page 285: ...8 1 INCORRECT ENGINE IDLING SPEED 8 2 POOR MEDIUM AND HIGH SPEED PERFORMANCE 8 2 FAULTY GEAR SHIFTING 8 2 SHIFT PEDAL DOES NOT MOVE 8 2 JUMPS OUT OF GEAR 8 2 FAULTY CLUTCH 8 2 OVERHEATING 8 3 POOR BRAKING PERFORMANCE 8 3 UNSTABLE HANDLING 8 3 FAULTY LIGHTING OR SIGNALING SYSTEM 8 3 ...

Page 286: ... rollover valve Deteriorated or contaminated fuel 2 Fuel cock Clogged or damaged fuel hose 3 Carburetor Deteriorated or contaminated fuel Clogged pilot jet Clogged pilot air passage Sucked in air Damaged float Worn needle valve Improperly installed needle valve seat Incorrect fuel level Improperly installed pilot jet Clogged starter jet Faulty starter plunger Choke valve malfunction Electrical sys...

Page 287: ... EAS28510 POOR MEDIUM AND HIGH SPEED PER FORMANCE Refer to STARTING FAILURES on page 8 1 and INCORRECT ENGINE IDLING SPEED on page 8 2 Engine 1 Air filter Clogged air filter element Fuel system 1 Carburetor Faulty diaphragm Incorrect fuel level Loose or clogged main jet Improper jet needle clip position Deteriorated or contaminated fuel EAS28530 FAULTY GEAR SHIFTING Shifting is difficult Refer to ...

Page 288: ...e fluid Faulty brake caliper kit Faulty brake caliper seal Loose union bolt Damaged brake hose Oil or grease on the brake disc Oil or grease on the brake pad Incorrect brake fluid level EAS28670 UNSTABLE HANDLING 1 Handlebar Bent or improperly installed handlebar 2 Steering Incorrect toe in Improperly installed steering stem Bent tie rods Bent steering stem Damaged ball bearing or bearing race Def...

Page 289: ...e light bulb Too many electrical accessories Hard charging Incorrect connection Improperly grounded circuit Poor contacts main or light switch Burnt out tail brake light bulb Tail brake light bulb burnt out Wrong tail brake light bulb Faulty battery Faulty rectifier regulator Improperly grounded Faulty main and or light switch Incorrectly adjusted rear brake light switch Tail brake light bulb life...

Page 290: ...itch 15 Thermo switch 16 Carburetor warmer 17 Neutral indicator light 18 Neutral switch 19 Rear brake light switch 20 Front brake light switch 21 Tail brake light 22 Handlebar switch 23 Light switch 24 Engine stop switch 25 Start switch 26 Headlight relay 27 Headlight 28 Ground EAS28750 COLOR CODE B Black Br Brown G Green L Blue O Orange R Red Sb Sky blue W White Y Yellow B Y Black Yellow L B Blue...

Page 291: ......

Page 292: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN ...

Page 293: ...WIRING DIAGRAM YFM25RY YFM25RSEY YFM25RSE2Y ...

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