Yamaha YFM700RV 2009 Service Manual Download

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ENG

CYLINDER AND PISTON

2. Install:

• piston

• piston pin

• piston pin clips

NOTE:

• Apply engine oil to the piston pin.
• Make sure the punch mark

on the piston

points towards the exhaust side of the cylin-
der.

• Before installing the piston pin clips, cover

the crankcase opening with a clean rag to
prevent the clips from falling into the crank-
case.

3. Install:

• cylinder gasket
• dowel pins

4. Lubricate:

• piston
• piston rings
• cylinder

(with the recommended lubricant)

Recommended lubricant

Engine oil

New

5. Offset:

• piston ring end gaps

Top ring

Upper oil ring rail

Oil ring expander

Lower oil ring rail

2nd ring

20 mm (0.79 in)

Exhaust side

f f

120˚

6. Install:

• cylinder

• timing chain guide (exhaust)

NOTE:

• While compressing the piston rings with one

hand, install the cylinder with the other hand.

• Pass the timing chain and timing chain guide

(exhaust side) through the timing chain cav-
ity.

Summary of Contents for YFM700RV 2009

Page 1: ...YFM700RV SERVICE MANUAL 1S3 28197 E0 ...

Page 2: ... YFM700RV SERVICE MANUAL 2005 by Yamaha Motor Co Ltd First edition May 2005 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited ...

Page 3: ...tions and sig nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable NOTE _ Designs and specifications are subject to change without notice EBS00003 IMPORTANT INFORMATION Particularly important information is distinguished in this manual by the following notations The Safety Alert Symbol...

Page 4: ...parts and clarify procedure steps there are exploded diagrams at the start of each removal and disassembly section 1 An easy to see exploded diagram 4 is provided for removal and disassembly jobs 2 Numbers 5 are given in the order of the jobs in the exploded diagram A number that is enclosed by a circle indicates a disassembly step 3 An explanation of jobs and notes is presented in an easy to read...

Page 5: ...torque E Wear limit clearance F Engine speed G Electrical data Ω V A Symbols H to M in the exploded diagrams indicate the types of lubricants and lubrication points H Apply engine oil I Apply gear oil J Apply molybdenum disulfide oil K Apply wheel bearing grease L Apply lithium soap based grease M Apply molybdenum disulfide grease Symbols N to O in the exploded diagrams indicate where to apply a l...

Page 6: ...TENTS GENERAL INFORMATION GEN INFO 1 SPECIFICATIONS SPEC 2 PERIODIC CHECKS AND ADJUSTMENTS CHK ADJ 3 ENGINE ENG 4 COOLING SYSTEM COOL 5 FUEL INJECTION SYSTEM FI 6 CHASSIS CHAS 7 ELECTRICAL ELEC 8 TROUBLESHOOTING TRBL SHTG 9 ...

Page 7: ...INE OF THE FI SYSTEM 1 2 FI SYSTEM 1 3 SELF ADJUSTING PARKING BRAKE MECHANISM 1 4 IMPORTANT INFORMATION 1 7 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 7 REPLACEMENT PARTS 1 7 GASKETS OIL SEALS AND O RINGS 1 7 LOCK WASHERS PLATES AND COTTER PINS 1 8 BEARINGS AND OIL SEALS 1 8 CIRCLIPS 1 8 CHECKING THE CONNECTIONS 1 9 SPECIAL TOOLS 1 10 ...

Page 8: ...LE IDENTIFICATION EBS00010 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the left side of the frame 1 EBS00011 MODEL LABEL The model label 1 is affixed to the air filter case cover This information will be needed to order spare parts 1 ...

Page 9: ...uirements for the engine to deliver more performance and cleaner exhaust gases increase it becomes necessary to control the air fuel ratio in a more precise and finely tuned man ner To accommodate this need this model has adopted an electronically controlled fuel injection FI system in place of the conventional carburetor system This system can achieve an optimum air fuel ratio required by the eng...

Page 10: ...he injection duration and the injection timing are controlled by the ECU Signals that are input from the throttle position sensor crankshaft position sensor intake air pressure sensor intake air tem perature sensor coolant temperature sensor and speed sensor enable the ECU to determine the injection duration The injection timing is determined through the signals from the crankshaft posi tion senso...

Page 11: ...en the brake caliper piston 7 and the adjusting bolt 5 This adjustment procedure is unnecessary for vehicles equipped with a self adjusting parking brake mechanism The proper clearance is automatically maintained at all times ensuring stable braking performance when parking the vehicle 1 Parking brake arm 2 Parking brake shaft 3 Adjusting bolt 4 Adjusting bolt sleeve 5 Adjusting bolt 6 Nut 7 Brake...

Page 12: ...ng brake shaft 2 and the adjusting bolt 3 is pushed against the adjusting bolt sleeve 4 When the adjusting bolt sleeve receives the force the dark shaded area in the above illustration is pushed and the brake pad 6 is pushed against the brake disc When the brake pad wears the clearance between the brake caliper piston 5 and the brake pad becomes larger and the force applied to the brake pad become...

Page 13: ...ing brake makes no adjustment The adjustment operation is as follows 1 When the brake pedal is operated the brake fluid pressure increases and the brake caliper pis ton and the nut move 2 When the movement of the brake caliper piston and the nut is greater than the backlash of the threads of the nut and the adjusting bolt the force È will be required to pull the adjusting bolt The force to pull th...

Page 14: ...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 EBS00014 REPLACEMENT PARTS 1 Use only genuine Yamaha parts for all replacements Use oil and grease recom mended by Yamaha for all lubrication jobs Other brands may be similar in function and appearance bu...

Page 15: ...sible When installing oil seals lubricate the oil seal lips with a light coat of lithium soap based grease Oil bearings liberally when installing if appro priate 1 Oil seal CAUTION _ Do not spin the bearing with compressed air because this will damage the bearing surfaces 1 Bearing EBS00018 CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlips Always rep...

Page 16: ...l times 3 Check all connections Loose connection Connect properly NOTE _ If the pin 1 on the terminal is flattened bend it up 4 Connect lead coupler connector NOTE _ Make sure all connections are tight 5 Check continuity with the pocket tester NOTE _ 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 availab...

Page 17: ...S and CDN P N 90890 Tool No Tool name Function Illustration 90890 01083 YU 01083 1 Slide hammer bolt Slide hammer bolt 6 mm This tool is used to remove the rocker arm shaft 90890 01084 YU 01083 3 Weight This tool is used to remove the rocker arm shaft 90890 01135 YU 01135 B Crankcase separating tool Crankcase separator This tool is used to separate the crank case 90890 01268 YU 01268 Ring nut wren...

Page 18: ...ve adjuster 3 mm 4 mm This tool is necessary for adjusting the valve clearance 90890 01325 YU 24460 01 Radiator cap tester Radiator pressure tester This tool is used to check the cooling sys tem 90890 01352 YU 33984 Radiator cap tester adapter Radiator pressure tester adapter This tool is used to check the cooling sys tem 90890 01327 YM 01327 Damper rod holder 30 mm This tool is needed to loosen a...

Page 19: ...s 90890 01498 YM 37134 Rear axle nut wrench 46 mm Axle nut wrench 46 mm This tool is needed to loosen or tighten the rear axle nut 90890 01701 YS 01880 A Sheave holder Primary clutch holder This tool is used to hold the A C magneto rotor when loosen or tighten the A C mag neto rotor nut 90890 03079 YM 34483 Thickness gauge Narrow gauge set This tool is used to measure the valve clearance 90890 030...

Page 20: ...sure adapter This tool is used to measure fuel pressure 90890 03174 YU A1927 Digital circuit tester Model 88 Multimeter with tachometer This tool is used to check the electrical system 90890 03182 YU 03182 FI diagnostic tool This tool is used to check the diagnosis 90890 04019 YM 04019 Valve spring compressor This tool is needed to remove and install the valve assemblies 90890 01243 YM 01253 1 Val...

Page 21: ...lve guide installer ø6 Valve guide installer 6 0 mm This tool is needed to install the valve guides 90890 04066 YM 04066 Valve guide reamer ø6 Valve guide reamer 6 0 mm This tool is needed to rebore the new valve guides 90890 04086 YM 91042 Universal clutch holder This tool is needed to hold the clutch boss when removing or installing the clutch boss nut 90890 06754 YM 34487 Ignition checker Opama...

Page 22: ...1 15 GEN INFO 90890 85505 Yamaha bond No 1215 Three bond No 1215 This bond is used on crankcase mating surfaces etc Tool No Tool name Function Illustration SPECIAL TOOLS ...

Page 23: ...ICAL SPECIFICATIONS 2 14 TIGHTENING TORQUES 2 16 ENGINE TIGHTENING TORQUES 2 16 CHASSIS TIGHTENING TORQUES 2 19 HOW TO USE THE CONVERSION TABLE 2 22 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 22 LUBRICATION POINTS AND LUBRICANT TYPES 2 23 ENGINE 2 23 COOLANT FLOW DIAGRAMS 2 24 OIL FLOW DIAGRAMS 2 28 CABLE ROUTING 2 33 ...

Page 24: ...asic weight With oil and full fuel tank 192 kg 423 lb Engine Engine type Liquid cooled 4 stroke SOHC Cylinder arrangement Forward inclined single cylinder Displacement 686 cm3 41 86 cu in Bore stroke 102 0 84 0 mm 4 02 3 31 in Compression ratio 9 20 1 Standard compression pressure at sea level 450 kPa 4 5 kg cm2 64 0 psi Starting system Electric starter Lubrication system Dry sump Oil type or grad...

Page 25: ...urer CR8E NGK Spark plug gap 0 7 0 8 mm 0 028 0 031 in Clutch type Wet multiple disc Transmission Primary reduction system Spur gear Primary reduction ratio 77 34 2 265 Secondary reduction system Chain drive Secondary reduction ratio 38 14 2 714 Transmission type Constant mesh 5 speed forward 1 speed reverse Operation Left foot operation Gear ratio 1st gear 38 13 2 923 2nd gear 28 14 2 000 3rd gea...

Page 26: ...on Front suspension Double wishbone Rear suspension Swingarm link suspension Shock absorber Front shock absorber Coil spring oil damper Rear shock absorber Coil spring gas oil damper Wheel travel Front wheel travel 230 mm 9 06 in Rear wheel travel 256 mm 10 08 in Electrical system Ignition system Transistorized coil ignition digital Generator system A C magneto Battery type GT9B 4 Battery capacity...

Page 27: ... 002 in Camshaft Drive system Chain drive left Camshaft lobe dimensions Intake measurement A 43 300 43 400 mm 1 7047 1 7087 in 43 200 mm 1 7008 in B 37 026 37 126 mm 1 4577 1 4617 in 36 926 mm 1 4538 in Exhaust measurement A 43 129 43 229 mm 1 6980 1 7019 in 43 029 mm 1 6941 in B 37 057 37 157 mm 1 4589 1 4629 in 36 957 mm 1 4550 in Maximum camshaft runout 0 03 mm 0 0012 in Timing chain Model numb...

Page 28: ...6 mm 0 0890 in Valve seat width C Intake 1 0 1 2 mm 0 0394 0 0472 in 1 6 mm 0 063 in Exhaust 1 0 1 2 mm 0 0394 0 0472 in 1 6 mm 0 063 in Valve margin thickness D Intake 0 8 1 2 mm 0 0315 0 0472 in Exhaust 0 8 1 2 mm 0 0315 0 0472 in Valve stem diameter Intake 5 975 5 990 mm 0 2352 0 2358 in 5 945 mm 0 2341 in Exhaust 5 960 5 975 mm 0 2346 0 2352 in 5 930 mm 0 2335 in Valve guide inside diameter In...

Page 29: ...in 36 85 mm 1 45 in Exhaust 38 79 mm 1 53 in 36 85 mm 1 45 in Installed length valve closed Intake 35 00 mm 1 38 in Exhaust 35 00 mm 1 38 in Compressed spring force installed Intake 169 0 199 0 N 17 23 20 29 kg 37 99 44 73 lb Exhaust 169 0 199 0 N 17 23 20 29 kg 37 99 44 73 lb Spring tilt Intake 2 5 1 70 mm 2 5 0 067 in Exhaust 2 5 1 70 mm 2 5 0 067 in Winding direction top view Intake Clockwise E...

Page 30: ...0 9052 0 9055 in 22 971 mm 0 9044 in Piston pin to piston pin bore clear ance 0 004 0 024 mm 0 0002 0 0009 in 0 074 mm 0 0029 in Piston rings Top ring Ring type Barrel Dimensions B T 1 20 3 80 mm 0 05 0 15 in End gap installed 0 20 0 35 mm 0 008 0 014 in 0 60 mm 0 024 in Ring side clearance 0 030 0 070 mm 0 0012 0 0028 in 0 12 mm 0 0047 in 2nd ring Ring type Taper Dimensions B T 1 20 4 00 mm 0 05 ...

Page 31: ...0 025 mm 0 0004 0 0010 in Small end free play F 0 16 0 40 mm 0 0063 0 0157 in Balancer Balancer drive method Gear Clutch Friction plate 1 inside dia 121 mm Thickness 2 92 3 08 mm 0 115 0 121 in 2 82 mm 0 111 in Quantity 7 Friction plate 2 inside dia 128 mm Thickness 2 90 3 10 mm 0 114 0 122 in 2 80 mm 0 110 in Quantity 1 Clutch plate Thickness 1 50 1 60 mm 0 059 0 063 in Quantity 7 Maximum warpage...

Page 32: ...e Trochoid Inner rotor to outer rotor tip clear ance Less than 0 12 mm 0 0047 in 0 20 mm 0 0079 in Outer rotor to oil pump housing clearance 0 09 0 15 mm 0 0035 0 0059 in 0 22 mm 0 0087 in Bypass valve opening pressure 40 0 80 0 kPa 0 40 0 80 kg cm2 5 70 11 4 psi Oil pressure hot 40 0 kPa at 1 600 r min 0 40 kg cm2 at 1 600 r min 5 70 psi at 1 600 r min Pressure check location Element cover Coolin...

Page 33: ...Camshaft Oil delivery pipe Main axle Drive axle To oil tank Oil tank inlet pipe A C magneto cover Left crankcase Right crankcase Oil strainer From oil tank Right crankcase Clutch cover Crankshaft To clutch cover Oil filter element Drain bolt Oil tank outlet hose joint Oil pump Right crankcase ...

Page 34: ...2 11 SPEC ENGINE SPECIFICATIONS Cylinder head tightening sequence 1 3 2 4 5 7 8 6 ...

Page 35: ...length 255 0 mm 10 04 in Installed length 236 0 mm 9 29 in Spring rate K1 46 00 N mm 4 69 kg mm 262 66 lb in Spring stroke K1 0 110 0 mm 0 4 33 in Optional spring available No Swingarm Free play limit radial 1 0 mm 0 04 in Free play limit axial 1 0 mm 0 04 in Front wheel Type Panel wheel Rim size 10 5 5 AT Rim material Aluminum Maximum radial wheel runout 2 0 mm 0 08 in Maximum lateral wheel runou...

Page 36: ... diameter thickness 200 0 3 6 mm 7 87 0 14 in Pad thickness inner 5 6 mm 0 22 in 1 0 mm 0 04 in Pad thickness outer 5 6 mm 0 22 in 1 0 mm 0 04 in Master cylinder inside diameter 12 70 mm 0 50 in Caliper cylinder inside diameter 32 03 mm 1 26 in Brake fluid type DOT 4 Brake lever and brake pedal Brake pedal position 15 3 mm 0 60 in Parking brake cable end length 58 60 mm 2 28 2 36 in Clutch lever f...

Page 37: ...k plug cap Material Resin Resistance 10 0 kΩ A C magneto Model manufacturer LMX58 DENSO Standard output 14 V 17 2 A at 5 000 r min Stator coil resistance color 0 248 0 372 Ω at 20 C 68 F white white Rectifier regulator Type Semiconductor short circuit type Model manufacturer SH650D 11 SHINDENGEN No load regulated voltage DC 14 1 14 9 V Rectifier capacity 18 0 A Withstand voltage 200 0 V Electric s...

Page 38: ...ECO Amperage rating 180 0 A Coil winding resistance 4 18 4 62 Ω at 20 C 68 F Circuit breaker Circuit breaker type Fuse Fuses Main fuse 20 A Headlight fuse 15 A Signaling system fuse 10 A Ignition fuse 10 A Fuel injection system fuse 10 A Spare fuse 20 A 15 A 10 A Item Standard Limit ...

Page 39: ...6 0 43 E A C magneto cover Bolt M6 14 10 1 0 7 2 Balancer driven gear Nut M16 2 60 6 0 43 Use a lock washer Breather plate Bolt M6 3 10 1 0 7 2 Primary drive gear Nut M20 1 110 11 0 80 Use a lock washer Valve adjusting screw Nut M6 4 14 1 4 10 Camshaft bearing retainer Bolt M6 2 10 1 0 7 2 LT Timing chain guide intake side Bolt M6 2 10 1 0 7 2 Timing chain tensioner cap bolt Bolt M16 1 20 2 0 14 T...

Page 40: ...or Bolt M6 4 8 0 8 5 8 LT Oil seal retainer clutch cover Bolt M6 2 10 1 0 7 2 LT Timing mark accessing screw Screw M14 1 6 0 6 4 3 Crankshaft end accessing screw Screw M36 1 10 1 0 7 2 Crankcase bearing retainer Screw M6 2 10 1 0 7 2 LT Crankcase bearing retainer Bolt M6 2 10 1 0 7 2 LT Crankcase Bolt M6 17 10 1 0 7 2 Engine oil filler bolt Bolt M20 1 12 1 2 8 7 Starter clutch Bolt M8 3 30 3 0 22 ...

Page 41: ...ghten the cylinder bolts to 15 Nm 1 5 m kg 11 ft lb and then tighten them to 50 Nm 5 0 m kg 36 ft lb Reverse switch M10 1 17 1 7 12 Neutral switch M10 1 17 1 7 12 Part to be tightened Part name Thread size Q ty Tightening torque Remarks Nm m kg ft lb ...

Page 42: ...5 1 Drive sprocket cover and engine M6 10 1 0 7 2 Upper front arm and frame M10 38 3 8 27 Lower front arm and frame M10 55 5 5 40 Front shock absorber and frame M10 48 4 8 35 Front shock absorber and lower front arm M10 48 4 8 35 Steering stem pitman arm and frame M14 180 18 0 130 Steering stem bushing and frame M8 23 2 3 17 Use a lock washer Steering stem and handlebar holder M8 23 2 3 17 Tie rod...

Page 43: ...skid plate and frame M6 7 0 7 5 1 LT Rear axle ring nut M36 240 24 0 175 LT Rear axle ring nut set bolt M6 7 0 7 5 1 LT Rear brake pad retaining bolt M10 17 1 7 12 Rear brake caliper and brake hose M10 30 3 0 22 Parking brake case bracket and parking brake case M8 22 2 2 16 LT Rear brake master cylinder and frame M6 20 2 0 14 Rear brake master cylinder and brake hose M10 30 3 0 22 Rear brake maste...

Page 44: ...axle washers 2 Tighten the rear axle nuts 200 Nm 20 0 m kg 145 ft lb 3 Loosen the rear axle nuts completely 4 Retighten the rear axle nuts 200 Nm 20 0 m kg 145 ft lb Do not loosen the axle nuts after tightening them If an axle nut slot is not aligned with the cotter pin hole on either side of the axle further tighten the axle nut until a slot is aligned with the hole ...

Page 45: ...nless otherwise specified tightening torque specifications require clean dry threads Com ponents should be at room temperature A Distance between flats B Outside thread diameter Ex METRIC MULTIPLIER IMPERIAL mm 0 03937 in 2 mm 0 03937 0 08 in METRIC TO IMPERIAL Torque Metric unit Multiplier Imperial unit m kg m kg cm kg cm kg 7 233 86 794 0 0723 0 8679 ft lb in lb ft lb in lb Weight kg g 2 205 0 0...

Page 46: ...t lobes M Decompressor lever pin E Decompressor lever spring E Water pump impeller shaft E Oil pump rotors inner rotor 2 and outer rotor 2 and pump E Oil pump rotors inner rotor 1 and outer rotor 1 and pump LS Torque limiter E Starter idle gear and starter wheel gear inner surface E Primary driven gear E Clutch pull rod LS Transmission gears wheel and pinion M Shift drum E Shift forks E Shift leve...

Page 47: ...ther hose 7 Water pump È Install the radiator inlet hose onto the thermostat cover pipe making sure that it contacts the cover and its yellow paint mark is facing out ward É Fasten the fast idle plunger outlet hose and the radiator inlet hose with the plastic band Ê Install the radiator inlet hose with its white paint mark facing outward B B A A A A B B 2 3 4 5 6 7 1 È É Ê Ë Ì Ë Í Ï Ð Î ...

Page 48: ...d Í Install the radiator outlet hose with its yellow paint mark facing outward Î From fast idle plunger Ï Make sure that the end of the screw clamp does not protrude past the side of the radiator inlet hose Ð Make sure that the end of the screw clamp does not protrude past the side of the radiator outlet hose B B A A A A B B 2 3 4 5 6 7 1 È É Ê Ë Ì Ë Í Ï Ð Î COOLANT FLOW DIAGRAMS ...

Page 49: ...the guide É Install the coolant reservoir hose onto the radia tor pipe making sure that it contacts the radia tor Ê Pass the coolant reservoir hose and radiator fan breather hose through the guide on the fuel tank shield Ë 60 mm 2 36 in Ì Pass the clamp through the hole in the stay on the frame and then fasten the coolant reservoir hose and drain hose with the clamp B A C C D D C C A D D B 6 7 1 2...

Page 50: ...r pump breather hose 4 Water jacket inlet housing È From radiator É Install the water pump outlet hose onto the water jacket inlet housing making sure to align the yel low paint mark on the hose with the projection on the water jacket inlet housing A B B È È 4 1 1 2 2 3 É A B B ...

Page 51: ...2 28 SPEC OIL FLOW DIAGRAMS EBS00026 OIL FLOW DIAGRAMS 1 Oil tank breather hose 2 Oil tank outlet hose 3 Oil tank inlet hose 4 Oil tank 1 4 3 1 2 3 4 ...

Page 52: ...2 29 SPEC OIL FLOW DIAGRAMS 1 Oil delivery pipe 2 Oil filter 3 Oil pump 2 3 A A A A 2 1 ...

Page 53: ...2 30 SPEC OIL FLOW DIAGRAMS 1 Oil filter 2 Oil pump driven gear 3 Oil pump rotor 1 4 Oil pump rotor 2 5 Oil pipe joint 6 Main axle 7 Counter axle 1 2 3 4 5 6 7 ...

Page 54: ...2 31 SPEC OIL FLOW DIAGRAMS 1 Oil strainer 2 Oil pump rotor 2 3 Oil pump rotor 1 4 Oil pump driven gear È To oil tank A A A A 4 1 2 3 1 È ...

Page 55: ...2 32 SPEC OIL FLOW DIAGRAMS 1 Balancer 1 2 Crankshaft 2 1 ...

Page 56: ... cable 5 Front brake hose 6 Front brake light switch lead 7 Throttle cable 8 Indicator light assembly lead 9 Radiator fan breather hose 0 Coolant reservoir breather hose A Coolant reservoir hose B Radiator fan motor lead C Main switch lead 2 1 3 4 7 5 6 7 6 5 4 3 È É È Ë Ì Í Î Ï Ð Ñ Ó Ô Õ Ö Ø Ù Ú Û A A A 0 9 8 1 2 Ê Ò B C ...

Page 57: ... and clutch cable in front of the front brake light switch and main switch lead Ì To radiator Í Route the coolant reservoir breather hose under the wire harness and over the handlebar switch lead clutch switch lead front brake light switch lead main switch lead and indicator light assem bly lead and then fasten the hose with the holder on the fuel tank shield Î To resistor Ï To left headlight 2 1 ...

Page 58: ...ten the wire harness with the band making sure to face the end of the band backward Ò To radiator fan Ó Secure the plastic band by inserting the projection on the band into the hole in the frame and then fasten the wire harness and radiator fan motor lead with the band making sure to face the end of the band backward Ô To rectifier regulator Õ To ignition coil Ö To right headlight Pass the clutch ...

Page 59: ...guide Ù Route the throttle cable in front of the clutch cable and parking brake cable Ú Pass the throttle cable clutch cable parking brake cable front brake light switch lead main switch lead handlebar switch lead clutch switch lead indicator light assembly lead and radiator fan breather hose through the wire guide Û Route the front brake light switch lead behind the front brake hose and throttle ...

Page 60: ...se 0 Coolant reservoir breather hose A Resistor lead B Resistor C Headlight lead D Main switch lead E Handlebar switch lead F Clutch switch lead G Front brake light switch lead H Wire harness I Indicator assembly lead J Fuel tank shield K Fuel tank L Rubber damper B A C C D D F F E E C C D D E E F F A B A B C 9 3 2 1 0 F F 8 7 6 4 5 H H H H 5 J K K L J J 0 0 3 2 1 I E F D 1 9 G Ñ Ò È É Ê Ð Ì Í Î Ï...

Page 61: ...e into the steering stem Ì Route the wire harness to the inside of the frame Í Connect the A C magneto lead wire sub lead rear brake switch lead and speed sensor lead and then fasten the leads with the plastic band Face the end of the plastic band inward Î Fasten the oil tank outlet hose and reverse con trol cable with the clamp making sure that the reverse control cable does not contact the edge ...

Page 62: ...end of the band inward Ñ Route the resistor lead over the frame making sure that its coupler is positioned to the inside of the frame Ò Route the headlight lead over the frame con nect the headlight coupler and then insert the projection on the coupler into the hole in the stay on the front fender bracket B A C C D D F F E E C C D D E E F F A B A B C 9 3 2 1 0 F F 8 7 6 4 5 H H H H 5 J K K L J J 0...

Page 63: ... breather hose or coolant reservoir hose Route the indica tor light assembly lead to the left of the other leads Ô Pass the wire harness through the rubber damper Õ Route the fuel hose to the outside of the wire harness Ö Route the wire harness above the fuel tank shield Pass the clamp through the hole in the stay on the frame and then fasten the coolant reservoir hose and drain hose with the clam...

Page 64: ... 8 Tail brake light 9 Tail brake light lead 0 ECU A ECU lead B Battery box C Starter motor lead D Speed sensor lead E Rear brake light switch lead F Wire sub lead G Reverse switch lead H Neutral switch lead I Speed sensor J Wire harness E E E F F F I D D 1 3 B D B D A A C C E E F F E E C C F F A A C J 8 9 9 8 2 1 H G E F C B D A 0 9 5 4 3 Ú Õ Ö È É Ê Ë Ò Ó Ô ÑÐ Ï Í Î 8 7 6 Ù Ø Ì ...

Page 65: ...ttery lead to the nega tive battery terminal Ë Secure the plastic band by inserting the projec tion on the band into the hole in the frame and then fasten the wire harness at the center of its positioning tape with the band making sure that the end of the band faces rearward and the leads that branch off from the wire harness do not contact the frame Ì Make sure that there is no slack in the wire ...

Page 66: ...he radiator fan motor relay lead and tail brake light lead with the plastic band making sure to face the end of the band downward Fas ten the leads near the tail brake light coupler and after the split in the wire harness making sure to install the plastic band around the protective sleeve of the tail brake light lead not the lead itself E E E F F F I D D 1 3 B D B D A A C C E E F F E E C C F F A ...

Page 67: ...n in the illus tration Õ Route the wire sub lead as shown in the illustra tion The longer lead past the end of the protec tive sleeve is the neutral switch lead and the shorter lead is the reverse switch lead Ö Route the A C magneto lead negative battery lead wire sub lead rear brake light switch lead and speed sensor lead between the crankcase breather hose and the starter motor lead and to the r...

Page 68: ...serting the projec tion on the band into the hole in the frame and then fasten the wire harness and starter motor lead with the band making sure to face the end of the band upward and to fasten the wire har ness between the sections where the starter relay lead and ECU lead branch off from the wire harness Ú Fasten the tail brake light lead with the plastic band E E E F F F I D D 1 3 B D B D A A C...

Page 69: ...e sensor 8 Crankcase breather hose 9 Negative battery lead 0 Lean angle sensor A Fuel injector B Fuel pump C Fuel hose D Fuel pump lead E Front brake light switch lead F Radiator fan breather hose G Indicator light assembly lead H Clutch cable I Parking brake cable J Indicator light assembly K Throttle cable L Handlebar switch lead A A B B 8 8 D C B A 0 9 8 7 6 5 4 3 2 1 A A I H J K L M N E F G B ...

Page 70: ...e lean angle sensor and the wire harness Ì Route the negative battery lead connector as shown Í Connect the A C magneto lead wire sub lead rear brake switch lead and speed sensor lead in front of the lean angle sensor Î Route the fuel pump lead under the fuel hose Ï 10 mm 0 39 in Pass the indicator light assembly lead through the guide on the front fender Ñ Insert the projection on the indicator l...

Page 71: ... through the guide on the radiator cover Ó Fasten the leads with the holder at the section before the intake air temperature sensor lead branches off from the other leads A A B B 8 8 D C B A 0 9 8 7 6 5 4 3 2 1 A A I H J K L M N E F G B B 7 G È Ï É Ê Ë Ì Í Î Ð Ñ Ò Ó ...

Page 72: ...rake light lead È Route the starter motor lead under the starter relay lead É Make sure that the self diagnosis signal coupler is positioned above the relay unit lead fuse box lead headlight relay lead and radiator fan motor relay lead Ê Install the headlight relay then the radiator fan motor relay onto the tab on the rear fender The headlight relay is identified by the presence of white tape wrap...

Page 73: ...rake light switch B Throttle position sensor lead C Coolant temperature sensor D Hose air filter joint to throttle body right side E Coolant temperature sensor lead F Intake air pressure sensor G Fuel injector lead H Intake air pressure sensor lead I Parking brake cable J Clutch cable K Headlight lead L Radiator fan motor lead Ë Ì Í Ï Ð Ñ E F G B C D A A I I A A C E G D F I I K K 4 6 5 3 L N 3 M L...

Page 74: ... light switch lead does not contact the swingarm There should be no slack in the rear brake light switch lead between the holder shown in the illustration and the holder on the left side of the vehicle Ë Route the rear brake light switch lead behind the spring Ì Route the rear brake light switch lead to the right of the rear brake light switch holder Ë Ì Í Ï Ð Ñ E F G B C D A A I I A A C E G D F I...

Page 75: ...r filter joint Ð Route the leads that branch off from the wire harness over the fast idle plunger outlet hose and to the right of the hose air filter joint to right side of throttle body Ñ Route the fuel injector lead over the intake air pressure sensor Ò Route the headlight lead over the frame con nect the headlight coupler and then insert the projection on the coupler into the hole in the stay o...

Page 76: ... making sure that the lead does not contact the cylinder head Õ Route the reverse control cable in front of the wire harness Ö Fasten the reverse control cable to the frame with the plastic band making sure to face the end of the band downward Ë Ì Í Ï Ð Ñ E F G B C D A A I I A A C E G D F I I K K 4 6 5 3 L N 3 M L P H H 7 8 J 2 1 H G F D E C B A 0 I I I I J J J A 0 7 J O 5 6 4 3 Õ Ò Ó Ö È É 3 4 Î ...

Page 77: ...ly 3 16 ADJUSTING THE ENGINE IDLING SPEED 3 17 ADJUSTING THE THROTTLE LEVER FREE PLAY 3 18 ADJUSTING THE SPEED LIMITER 3 19 CHECKING THE SPARK PLUG 3 20 CHECKING THE IGNITION TIMING 3 21 MEASURING THE COMPRESSION PRESSURE 3 22 CHECKING THE ENGINE OIL LEVEL 3 24 CHANGING THE ENGINE OIL 3 26 ADJUSTING THE CLUTCH CABLE 3 29 CLEANING THE AIR FILTER ELEMENT 3 29 CHECKING THE THROTTLE BODY JOINT 3 31 CH...

Page 78: ...DAL 3 47 ADJUSTING THE REVERSE CONTROL CABLE 3 47 ADJUSTING THE DRIVE CHAIN SLACK 3 48 CHECKING THE STEERING SYSTEM 3 50 ADJUSTING THE TOE IN 3 50 CHECKING THE FRONT AND REAR SHOCK ABSORBERS 3 52 ADJUSTING THE FRONT SHOCK ABSORBERS 3 52 ADJUSTING THE REAR SHOCK ABSORBER 3 53 CHECKING THE TIRES 3 56 CHECKING THE WHEELS 3 58 CHECKING AND LUBRICATING THE CABLES 3 58 LUBRICATING THE LEVERS AND PEDALS ...

Page 79: ...maintenance inter vals For ATVs equipped with an odometer or an hour meter follow the km mi or hours maintenance intervals However 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 ITEM ROUTINE Whichever come...

Page 80: ... operation Adjust if necessary Front brake Check free play operation fluid leakage See NOTE Correct if necessary Rear brake Check operation fluid leakage See NOTE Correct if necessary Wheels Check balance damage runout Replace if necessary Wheel bearings Check bearing assemblies for looseness damage Replace if damaged Rear arm pivots Lubricate every 6 months with lithium soap based grease Upper an...

Page 81: ...sary Fuel injection Check and adjust engine idle speed Crankcase breather system Check breather hose for cracks or damage Replace if necessary Exhaust system Check for leakage Tighten if necessary Replace gasket if necessary Air filter element Clean Replace if necessary Every 20 40 hours More often in wet or dusty areas Clutch Check operation Adjust if necessary Front brake Check free play operati...

Page 82: ...d caliper cylinder replace the oil seals every two years Replace the brake hoses every four years or if cracked or damaged Engine oil Replace Warm engine before draining Engine oil filter ele ment Replace Cooling system Check coolant leakage Repair if necessary Replace coolant every 24 months Lights and switches Check operation Adjust headlight beams ITEM ROUTINE Whichever comes first INITIAL EVER...

Page 83: ... 7 Nm 0 7 m kg 5 1 ft Ib LT T R 4 Nm 0 4 m kg 2 9 ft Ib Order Job Part Q ty Remarks Removing the seat front panel foot protectors and engine skid plate Remove the parts in the order listed 1 Seat 1 NOTE _ Pull back the seat lock lever than pull up on the rear of the seat 2 Front panel 1 3 Left foot protector 1 4 Right foot protector 1 5 Engine skid plate 1 For installation reverse the removal pro ...

Page 84: ... 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib Order Job Part Q ty Remarks Removing the headlights and front fender Remove the parts in the order listed Seat front panel Refer to SEAT FENDERS AND FUEL TANK 1 Headlight coupler 2 Disconnect 2 Left headlight 1 3 Right headlight 1 4 Fuel tank top panel 1 5 Indicator light assembly coupler 1 Disconnect 6 Front fender 1 For installation reverse the remo...

Page 85: ...5 6 9 7 10 Order Job Part Q ty Remarks Removing the rear fender Remove the parts in the order listed Seat front panel fuel tank top panel front fender Refer to SEAT FENDERS AND FUEL TANK 1 Air filter case cover 1 2 Battery holding bracket 1 3 Battery lead 2 Disconnect CAUTION _ First disconnect the negative lead then disconnect the positive lead 4 Battery 1 5 ECU 1 6 Intake air temperature sensor ...

Page 86: ... Ib 2 3 4 3 12 8 1 11 5 6 9 7 10 Order Job Part Q ty Remarks 7 Hose throttle body joint to throttle body left side 1 8 Hose throttle body joint to throttle body right side 1 9 Crankcase breather hose 1 10 Clamp throttle body joint 1 Loosen 11 Air filter case 1 12 Rear fender 1 For installation reverse the removal pro cedure SEAT FENDERS AND FUEL TANK ...

Page 87: ...eat front panel fuel tank top panel front fender Refer to SEAT FENDERS AND FUEL TANK 1 Fuel pump coupler 1 Disconnect 2 Fuel hose connector holder 1 Refer to REMOVING THE FUEL TANK and INSTALLING THE FUEL HOSE 3 Fuel hose 1 4 Fuel tank 1 NOTE _ When installing the fuel tank pass the fuel tank breather hose through the hole in the handlebar cover and then insert the end of the hose into the steerin...

Page 88: ... ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib 6 New 5 Order Job Part Q ty Remarks 7 Fuel pump 1 Refer to REMOVING THE FUEL PUMP and INSTALLING THE FUEL PUMP For installation reverse the removal pro cedure SEAT FENDERS AND FUEL TANK ...

Page 89: ...xt insert a slotted head screwdriver etc in the slot part a of the fuel hose connector cover 1 then slide the screwdriver in the direction of the arrow and remove the fuel hose To remove the fuel hose from the throttle body slide the fuel hose connector cover 2 on the end of the hose in direction of the arrow shown press the two buttons 3 on the sides of the connector and then remove the hose Befo...

Page 90: ...ction on the fuel tank Tighten the bolts to the specified torque in the proper tightening sequence as shown Install the fuel pump in the direction shown in the illustration 1 3 5 2 4 6 a a New T R 7 Nm 0 7 m kg 5 1 ft lb INSTALLING THE FUEL HOSE 1 Install fuel hose fuel hose holder fuel pump coupler CAUTION When installing the fuel hose make sure that it is securely connected and that the fuel hos...

Page 91: ...perature When the valve clearance is to be measured or adjusted the piston must be at top dead center TDC on the compression stroke 1 Remove seat front fender fuel tank Refer to SEAT FENDERS AND FUEL TANK 2 Remove intake tappet cover exhaust tappet cover 1 camshaft sprocket cover 2 2 1 3 Disconnect spark plug cap 1 4 Remove spark plug 2 2 1 5 Remove timing mark accessing screw 1 crankshaft end acc...

Page 92: ...tionary pointer d on the cylinder head as shown in the illustration c Measure the valve clearance with a thick ness gauge 1 Out of specification Adjust 7 Adjust valve clearance a Loosen the locknut 1 b Insert a thickness gauge 2 between the end of the adjusting screw and the valve tip c Turn the adjusting screw 3 with the tappet adjusting tool 4 until the specified valve clearance is obtained Valv...

Page 93: ...btained 8 Install timing mark accessing screw crankshaft end accessing screw 9 Install spark plug 10 Connect spark plug cap 11 Install O ring camshaft sprocket cover O ring 1 intake tappet cover O ring exhaust tappet cover 12 Install fuel tank front fender seat Refer to SEAT FENDERS AND FUEL TANK T R Locknut 14 Nm 1 4 m kg 10 ft lb T R 6 Nm 0 6 m kg 4 3 ft lb T R 10 Nm 1 0 m kg 7 2 ft lb T R 13 Nm...

Page 94: ...upler cap and then connect the FI diagnostic tool 1 as shown FI diagnostic tool 90890 03182 YU 03182 1 4 While pressing the MODE button 1 turn the main switch to ON NOTE DIAG appears on the LCD 2 of the FI diag nostic tool POWER LED green 3 comes on 5 Press the UP button to select the CO adjustment mode CO or the diagnostic mode DIAG 6 After selecting CO press the MODE but ton 7 Check that C1 appe...

Page 95: ...1 Turn the main switch to OFF to cancel the mode 12 Disconnect the FI diagnostic tool and con nect the self diagnosis signal coupler cap FI Diagnostic Tool C1 0 1600pm EBS00051 ADJUSTING THE ENGINE IDLING SPEED 1 Start the engine and let it warm up for sev eral minutes 2 Attach tachometer to the spark plug lead 3 Measure idling speed Out of specification Adjust 4 Adjust engine idling speed a Turn ...

Page 96: ...eed should be adjusted prop erly before adjusting the throttle lever free play 1 Measure throttle lever free play a Out of specification Adjust Throttle lever free play 2 4 mm 0 08 0 16 in a 2 Adjust throttle lever free play First step a Slide back the rubber cover 1 b Loosen the locknut 2 on the throttle body side c Turn the adjusting nut 3 in direction a or b until the correct free play is obtai...

Page 97: ...he rubber cover to its original posi tion WARNING _ After adjusting the free play turn the han dlebar to the right and left to make sure that the engine idling speed does not increase Direction c Free play is increased Direction d Free play is decreased 4 6 d c 5 EBS00053 ADJUSTING THE SPEED LIMITER The speed limiter keeps the carburetor throttle from becoming fully opened even when the throttle l...

Page 98: ...ove the speed limiter for a beginning rider For proper throttle lever operation do not turn out the adjusting screw more than 12 mm 0 47 in Also always adjust the throttle lever free play to 2 4 mm 0 08 0 16 in Turning in Speed limiter length is decreased Turning out Speed limiter length is increased EBS00057 CHECKING THE SPARK PLUG 1 Remove spark plug 2 Check spark plug type Incorrect Change 3 Ch...

Page 99: ... 0 8 mm 0 028 0 031 in T R 13 Nm 1 3 m kg 9 4 ft lb EBS00058 CHECKING THE IGNITION TIMING NOTE _ Engine idling speed and throttle cable free play should be adjusted properly before checking the ignition timing 1 Attach tachometer timing light to spark plug lead 2 Check ignition timing a Warm up the engine and keep it at the specified speed Digital tachometer 90890 06760 YU 39951 B Timing light 908...

Page 100: ...h the exhaust muffler d Install the timing mark accessing screw 3 Detach timing light tachometer 1 b a EBS00061 MEASURING THE COMPRESSION PRESSURE NOTE _ Insufficient compression pressure will result in a loss of performance 1 Measure valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEARANCE 2 Start the engine warm it up for several min utes and then turn it off 3 Disconne...

Page 101: ...zes WARNING _ To prevent sparking ground the spark plug lead before cranking the engine c If the compression pressure is above the maximum specification check the cylinder head valve surfaces and piston crown for carbon deposits Carbon deposits Eliminate Compression gauge 90890 03081 Engine compression tester YU 33223 Extension 90890 04082 Compression pressure at sea level Minimum 392 kPa 3 92 kg ...

Page 102: ...r damage Repair Same as without oil Piston rings valves cylinder head gasket or piston possibly defective Repair T R 13 Nm 1 3 m kg 9 4 ft lb EBS01101 CHECKING THE ENGINE OIL LEVEL 1 Place the vehicle on a level surface 2 Start the engine warm it up until the engine oil has reached a normal temperature of 60 C 140 F let it continue to idle for ten seconds and then turn the engine off NOTE _ To ach...

Page 103: ...clutch slippage Therefore do not add any chemical additives or use engine oils with a grade of CD c or higher and do not use oils labeled ENERGY CON SERVING II d or higher Do not add any chemical additives Engine oil also lubricates the clutch and additives could cause clutch slippage Do not allow foreign material to enter the crankcase È For CDN É For Europe Oceania 4 Start the engine warm it up ...

Page 104: ...ine oil drain bolt oil tank 1 along with the washer 1 5 Remove engine oil drain bolt crankcase 1 along with the gasket 1 6 Remove oil filter element drain bolt 1 7 Drain engine oil completely from the oil tank and the crank case 1 8 If the oil filter element is also to be replaced perform the following procedure a Remove the oil filter element cover 1 and oil filter element 2 b Check the O rings 3...

Page 105: ... R Oil filter element cover bolt 10 Nm 1 0 m kg 7 2 ft lb Overhaul Total amount 2 30 L 2 02 Imp qt 2 43 US qt Quantity in oil tank 1 30 L 1 14 Imp qt 1 37 US qt Quantity in crankcase 1 00 L 0 88 Imp qt 1 06 US qt Periodic oil replacement Total amount 1 75 L 1 54 Imp qt 1 85 US qt Quantity in oil tank 1 30 L 1 14 Imp qt 1 37 US qt Quantity in crankcase 0 45 L 0 40 Imp qt 0 48 US qt With oil filter ...

Page 106: ... 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 in chapter 4 d Start the engine after solving the problem s and check t...

Page 107: ... 5 until the clutch lever free play is within the specified limits e Tighten the locknut 4 NOTE If the specified clutch lever free play cannot be obtained on it use the adjusting bolt 3 f Turn the adjusting bolt 3 until the clutch lever free play is within the specified limits g Tighten the locknut 2 h Pull the rubber cover 1 in Clutch lever free play at the clutch lever end 5 10 mm 0 20 0 39 in 2...

Page 108: ... cover 1 1 3 Remove wing bolt 1 air filter element 2 air filter element frame 3 CAUTION _ The engine should never be run without the air filter excessive piston and or cylinder wear may result 4 Check air filter element Damage Replace 1 2 3 2 5 Clean air filter element a Wash the element gently but thoroughly in solvent ...

Page 109: ... material c Apply Yamaha foam air filter oil or other quality foam air filter oil to the element d Squeeze out the excess oil NOTE _ The element should be wet but not dripping 6 Install air filter element frame 7 Install air filter element wing bolt NOTE _ Make sure its sealing surface matches the sealing surface of the case so there is no air leak 8 Install air filter case cover 9 Install seat Re...

Page 110: ...e Loose connection Connect properly 3 Install fuel tank front fender seat Refer to SEAT FENDERS AND FUEL TANK 1 EAS00098 CHECKING THE BREATHER HOSES 1 Check crankcase breather hose 1 hose throttle body joint to throttle body left side 2 hose throttle body joint to throttle body right side 3 Cracks damage Replace Loose connection Connect properly CAUTION Make sure the breather hoses are routed corr...

Page 111: ...ent of the coolant If water is used instead of coolant check and if necessary correct the antifreeze concentration of the coolant Use only distilled water However soft water may be used if distilled water is not available 3 Start the engine warm it up for several min utes and then turn it off 4 Check coolant level NOTE _ Before checking the coolant level wait a few minutes until the coolant has se...

Page 112: ...hick rag or a towel over the radia tor cap and slowly turn the radiator cap counterclockwise toward the detent to allow any residual pressure to escape When the hissing sound has stopped press down on the radiator cap and turn it counterclockwise to remove 1 6 Remove coolant drain bolt 1 along with the copper washer 7 Drain coolant from the engine and radiator 1 8 Check coolant drain bolt 1 Damage...

Page 113: ...lant lowers the antifreeze content of the coolant If water is used instead of coolant check and if necessary correct the antifreeze concentration of the coolant Use only distilled water However if dis tilled water is not available soft water may be used If coolant comes into contact with painted surfaces immediately wash them with water Do not mix different types of antifreeze 12 Install air bleed...

Page 114: ...NG THE COOLANT LEVEL NOTE _ Before checking the coolant level wait a few minutes until the coolant has settled a EAS00104 CHECKING THE COOLING SYSTEM 1 Remove seat front fender Refer to SEAT FENDERS AND FUEL TANK 2 Check radiator 1 radiator outlet hose 2 radiator inlet hose 3 water pump assembly 4 water jacket inlet housing 5 water pump outlet hose 6 Cracks damage Replace Refer to COOLING SYSTEM i...

Page 115: ...h ON and the engine stop switch to RUN Coolant temperature warning light does not come on Coolant temperature warning light comes on Push start switch with transmission in neutral Coolant temperature warning light comes on momentarily Coolant temperature warning light does not come on Check the electrical circuit Refer to SIGNALING SYSTEM in chapter 8 Coolant temperature and electrical circuit are...

Page 116: ...8 Nm 3 8 m kg 27 ft lb Exhaust pipe and muffler bolt 9 18 Nm 1 8 m kg 13 ft lb Muffler protector bolt 0 8 Nm 0 8 m kg 5 8 ft lb Exhaust pipe protector bolt A 8 Nm 0 8 m kg 5 8ft lb LT LT LT LT LT 1 6 1 6 5 5 5 A A 0 2 3 9 4 7 A 8 CLEANING THE SPARK ARRESTER 1 Clean spark arrester WARNING Select a well ventilated area free of com bustible materials Always let the exhaust system cool before performi...

Page 117: ...Insert the tailpipe into the muffler and align the bolt holes e Insert the bolt 1 and tighten it f Remove the purging bolt 3 g Start the engine and rev it up approximately twenty times while momentarily creating exhaust system back pressure by blocking the end of the muffler with a shop towel h Stop the engine and allow the exhaust pipe to cool i Install the purging bolt 3 and tighten it T R Bolt ...

Page 118: ...HYDRAULIC BRAKE SYSTEM Brake lever free play at the end of the brake lever 0 mm 0 in EBS00085 ADJUSTING THE REAR BRAKE 1 Measure brake pedal height a Out of specification Adjust Brake pedal height 15 3 mm 0 60 in a 2 Adjust brake pedal height a Loosen the locknut 1 b Turn the adjusting bolt 2 until the brake pedal height is within the specified limits c Tighten the locknut T R Locknut 17 Nm 1 7 m ...

Page 119: ...pecification Adjust Parking brake cable end length 58 60 mm 2 28 2 36 in a 2 Adjust parking brake cable end length a Slide back the rubber cover 1 b Loosen the locknut 2 c Turn the adjusting nut 3 in direction a or b until the specified brake cable end length is obtained d Tighten the locknut 2 e Slide the rubber cover to its original posi tion WARNING After this adjustment is performed lift the r...

Page 120: ...e 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 performance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock CAUTION _ Brake...

Page 121: ...place the brake pads as a set Refer to FRONT AND REAR BRAKES in chapter 7 3 Operate the brake lever 4 Install front wheels Refer to FRONT AND REAR WHEELS in chapter 7 Brake pad wear limit a 1 0 mm 0 04 in EBS00089 CHECKING THE REAR BRAKE PADS 1 Check brake pads Wear indicator 1 almost touch the brake disc Replace the brake pads as a set Refer to FRONT AND REAR BRAKES in chapter 7 2 Operate the bra...

Page 122: ...tion timing a Hold the main body 1 of the rear brake light switch so that it does not rotate and turn the adjusting nut 2 in direction a or b until the rear brake light comes on at the proper time Direction a Brake light comes on sooner Direction b Brake light comes on later 1 2 a b EBS00092 CHECKING THE BRAKE HOSES 1 Remove seat fuel tank top panel front fender Refer to SEAT FENDERS AND FUEL TANK...

Page 123: ...hose is loosened disconnected or replaced the brake fluid level is very low brake operation is faulty NOTE _ Be careful not to spill any brake fluid or allow the brake master cylinder reservoir or brake fluid reservoir to overflow When bleeding the hydraulic brake system make sure there is always enough brake fluid before applying the brake Ignoring this precaution could allow air to enter the hyd...

Page 124: ... it in posi tion g Loosen the bleed screw NOTE _ Loosening the bleed screw will release the pressure and cause the brake lever to contact the throttle grip or the brake pedal to fully extend h Tighten the bleed screw and then release the brake lever or brake pedal i Repeat steps e to h until all of the air bubbles have disappeared from the brake fluid in the plastic hose j Tighten the bleed screw ...

Page 125: ...pedal height 48 mm 1 89 in a 2 Adjust shift pedal position a Loosen the bolt 1 b Remove the shift pedal 2 c Install the shift pedal at the correct height d Tighten the bolt to specification T R Shift pedal bolt 16 Nm 1 6 m kg 11 ft lb 1 2 EBS00096 ADJUSTING THE REVERSE CONTROL CABLE 1 Check reverse knob free play a Out of specification Adjust Reverse knob free play 0 mm 0 in ...

Page 126: ...ment so that it does not move d Tighten the locknut 3 e Pull the boots 1 and 2 in a 5 6 ADJUSTING THE DRIVE CHAIN SLACK NOTE Measure the drive chain slack halfway between the drive axle and the rear axle CAUTION A drive chain that is too tight will overload the engine and other vital parts and one that is too loose can skip and damage the swingarm or cause an accident Therefore keep the drive chai...

Page 127: ...tral posi tion d To loosen the drive chain push the vehicle forward and to tighten the drive chain pull the vehicle backward CAUTION Excessive chain slack will overload the engine and other vital parts keep the slack within the specified limits e If the chain slack cannot be adjusted replace the sprockets and drive chain as a set f Tighten the rear axle pinch bolts 1 NOTE Tighten the rear axle pin...

Page 128: ...site direction Tie rod end s 1 have vertical play Replace the tie rod end s 1 1 4 Raise the front end of the vehicle so that there is no weight on the front wheels 5 Check ball joints and or wheel bearings Move the wheels laterally back and forth Excessive free play Replace the front arms upper and lower and or wheel bear ings EBS00108 ADJUSTING THE TOE IN 1 Place the vehicle on a level surface 2 ...

Page 129: ...and an accident After setting the toe in to specification run the vehicle slowly for some distance with both hands lightly holding the han dlebar and check that the handlebar responds correctly If not turn either the right or left tie rod within the toe in speci fication a Mark both tie rods ends This reference point will be needed during adjustment b Loosen the locknuts tie rod end 1 of both tie ...

Page 130: ...igue Replace the front rear shock absorber assembly Refer to FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES and REAR SHOCK ABSORBER AND RELAY ARM in chapter 7 3 Check operation Pump the shock absorbers up and down for several times Unsmooth operation Replace the front rear shock absorber assembly Refer to ADJUSTING THE FRONT SHOCK ABSORBERS and ADJUSTING THE REAR SHOCK ABSORBER È Front shock absor...

Page 131: ...locknut 2 with the ring nut wrench 1 c Turn the adjusting ring 3 in direction a or b Direction a Spring preload is increased suspension is harder Direction b Spring preload is decreased suspension is softer Standard position 2 Minimum position 1 Maximum position 5 Ring nut wrench 90890 01268 Spanner wrench YU 01268 Direction a Spring preload is increased suspension is harder Direction b Spring pre...

Page 132: ...ION _ Never attempt to turn the adjusting ring beyond the maximum or minimum setting d Tighten the locknut 2 with a steering nut wrench 4 NOTE Set the torque wrench at a right angle to the steering nut wrench NOTE Always tighten the locknut against the adjust ing ring then torque it to specification 3 Install air filter case with air intake duct Steering nut wrench 90890 01443 Spanner wrench YU 33...

Page 133: ...ster past the minimum or maximum extent of adjustment The adjuster may be damaged 6 Install air filter case seat Refer to SEAT FENDERS AND FUEL TANK Direction a Rebound damping force is increased Direction b Rebound damping force is decreased From the fully turned in position Standard 12 clicks out Minimum 20 clicks out Maximum 3 clicks out Direction a Compression damping force is increased Direct...

Page 134: ...i Rear 27 5 kPa 0 275 kg cm2 4 0 psi 2 Tire pressure below the minimum speci fication could cause the tire to dislodge from the rim under severe riding condi tions The following are minimums Front 24 5 kPa 0 245 kg cm2 3 5 psi Rear 24 5 kPa 0 245 kg cm2 3 5 psi 3 Use no more than Front 250 kPa 2 5 kg cm2 36 psi Rear 250 kPa 2 5 kg cm2 36 psi when seating the tire beads Higher pressures may cause t...

Page 135: ...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 tires 2 Check tire surfaces Wear damage Replace WARNING _ It is dangerous to ride with a worn out tire When tire wear is out of specification replace the tire immediately Cold tire pressure Front Rear Standard 27 5 kPa 0 275kg c...

Page 136: ...NG THE CABLES WARNING _ A damaged cable sheath may cause corro sion and interfere with the cable move ment An unsafe condition may result so replace a damaged cable as soon as possi ble 1 Check cable sheath Damage Replace 2 Check cable operation Unsmooth operation Lubricate or replace NOTE _ Hold the cable end up and apply several drops of lubricant to the cable 3 Apply lithium soap based grease o...

Page 137: ...J LUBRICATING THE LEVERS AND PEDALS EBS00118 LUBRICATING THE LEVERS AND PEDALS Lubricate the pivoting point and metal to metal moving parts of the levers and pedals Recommended lubricant Lithium soap based grease ...

Page 138: ...yte as it can cause severe burns or permanent eye injury FIRST AID IN CASE OF BODILY CONTACT EXTERNAL Skin Wash with water Eyes Flush with water for 15 minutes and get immediate medical attention INTERNAL Drink large quantities of water or milk fol lowed with milk of magnesia beaten egg or vegetable oil Get immediate medical attention CAUTION _ This is a sealed battery Never remove the sealing cap...

Page 139: ...ry lead 1 and then the positive battery lead 2 3 Remove battery 4 Check battery charge a Connect a pocket tester to the battery termi nals NOTE _ The charge state of an MF battery can be checked by measuring its open circuit volt age i e the voltage when the positive termi nal is disconnected No charging is necessary when the open cir cuit voltage equals or exceeds 12 8 V Positive tester probe pos...

Page 140: ...ery When charging a battery be sure to remove it from the vehicle If charging has to be done with the battery mounted on the vehicle disconnect the negative battery lead from the battery terminal To reduce the chance of sparks do not plug in the battery charger until the bat tery charger leads are connected to the battery Before removing the battery charger lead clips from the battery terminals be...

Page 141: ...ct the battery charger and let the battery cool before reconnecting it Hot batteries can explode As shown in the following illustration the open circuit voltage of an MF battery sta bilizes about 30 minutes after charging has been completed Therefore wait 30 minutes after charging is completed before measuring the open circuit volt age ...

Page 142: ...THE BATTERY If the amperage does not exceed the standard charging amperage after 5 minutes replace the battery If the required charging time exceeds 5 hours it is advisable to check the charging amperage after 5 hours If there is any change in the amperage readjust the voltage to obtain the standard charging amperage Leave the battery unused for more than 30 minutes before measuring its open circu...

Page 143: ...rge the battery until the charging voltage reaches 15 V This type of battery charger cannot charge an MF battery A variable volt age charger is recommended Leave the battery unused for more than 30 minutes before measuring its open cir cuit voltage 12 8 V Charging is complete 12 0 12 7 V Recharging is required Under 12 0 V Replace the battery Constant amperage chargers are not suitable for chargin...

Page 144: ...s Dirt Clean with a wire brush Loose connection Connect properly 9 Lubricate battery terminals 10 Install battery holding bracket seat Refer to SEAT FENDERS AND FUEL TANK Recommended lubricant Dielectric grease 2 1 EBS00121 CHECKING THE FUSES The following procedure applies to all of the fuses CAUTION _ To avoid a short circuit always set the main switch to OFF when checking or replacing a fuse 1 ...

Page 145: ...n switch to OFF b Install a new fuse of the correct amperage c Set on the switches to verify if the electrical circuit is operational d If the fuse immediately blows again check the electrical circuit Pocket tester 90890 03112 Analog pocket tester YU 03112 C Items Amperage rating Q ty Main fuse 20 A 1 Headlight fuse 15 A 1 Signaling sys tem fuse 10 A 1 Ignition fuse 10 A 1 Fuel injection system fu...

Page 146: ...trical system cause the lighting and ignition systems to malfunction and could possibly cause a fire 4 Install seat Refer to SEAT FENDERS AND FUEL TANK EBS00122 ADJUSTING THE HEADLIGHT BEAMS 1 Adjust headlight beam vertically a Turn the adjusting bolt 1 in direction a or b Direction a Headlight beam is raised Direction b Headlight beam is lowered 1 a b EBS00124 REPLACING A HEADLIGHT BULB 1 Disconn...

Page 147: ...ith the headlight unit CAUTION _ Avoid touching the glass part of the bulb Keep it free from oil otherwise the trans parency of the glass life of the bulb and luminous flux will be adversely affected If oil gets on the bulb thoroughly clean it with a cloth moistened with alcohol or lac quer thinner 1 New 5 Install bulb holder headlight bulb holder cover 1 NOTE After installing the bulb holder cove...

Page 148: ...19 CHECKING THE CAMSHAFT 4 19 CHECKING THE DECOMPRESSION SYSTEM 4 20 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS 4 21 INSTALLING THE CAMSHAFT AND ROCKER ARMS 4 22 VALVES AND VALVE SPRINGS 4 24 REMOVING THE VALVES AND VALVE SPRINGS 4 25 CHECKING THE VALVES AND VALVE SPRINGS 4 26 INSTALLING THE VALVES AND VALVE SPRINGS 4 31 CYLINDER AND PISTON 4 33 REMOVING THE PISTON 4 34 CHECKING THE CYLINDER A...

Page 149: ...4 55 INSTALLING THE CLUTCH 4 56 OIL PUMP 4 59 CHECKING THE OIL PUMP 4 61 ASSEMBLING THE OIL PUMP 4 62 SHIFT SHAFT 4 63 CHECKING THE SHIFT SHAFT 4 65 CHECKING THE STOPPER LEVER 4 65 CHECKING THE SHIFT GUIDE 4 65 CHECKING THE SHIFT DRUM SEGMENT 4 65 INSTALLING THE SHIFT LEVER 4 65 INSTALLING THE SHIFT SHAFT 4 66 CRANKCASE 4 67 CRANKCASE BEARINGS 4 69 SEPARATING THE CRANKCASE 4 70 CHECKING THE OIL ST...

Page 150: ...AIN AXLE 4 79 DRIVE AXLE 4 80 COUNTER AXLE 4 82 CHECKING THE SHIFT FORKS 4 83 CHECKING THE SHIFT DRUM ASSEMBLY 4 83 CHECKING THE TRANSMISSION 4 83 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 4 84 INSTALLING THE TRANSMISSION 4 85 ...

Page 151: ...Ib New New New LT LT LT 1 2 3 4 6 7 5 8 8 Order Job Part Q ty Remarks Removing the muffler and exhaust pipes Remove the parts in the order listed Seat fuel tank top panel Refer to SEAT FENDERS AND FUEL TANK in chapter 3 1 Muffler 1 Refer to INSTALLING THE EXHAUST PIPES AND MUFFLER 2 Muffler protector 1 3 Gasket 1 4 Exhaust pipe 1 1 5 Gasket 1 6 Exhaust pipe 2 1 7 Exhaust pipe protector 1 8 Gasket ...

Page 152: ...ND MUFFLER 1 Install gasket 1 to muffler NOTE Install the gasket with the chamfer a located on an inner rim of the gasket and the chamfer b located on an outer rim of the gasket as shown Installed depth of gasket c 1 0 1 5 mm 0 04 0 06 in a c 1 b New New ...

Page 153: ...ew New LS LS T R 7 Nm 0 7 m kg 5 1 ft Ib T R 16 Nm 1 6 m kg 11 ft Ib Order Job Part Q ty Remarks Removing the oil tank Remove the parts in the order listed Engine oil Drain Engine skid plate Refer to SEAT FENDERS AND FUEL TANK in chapter 3 1 Shift pedal 1 2 Oil tank inlet hose 1 3 Oil tank outlet hose 1 4 Oil tank breather hose 1 5 Oil tank 1 For installation reverse the removal pro cedure ENGINE ...

Page 154: ...tery fuel tank Refer to SEAT FENDERS AND FUEL TANK in chapter 3 Rear brake light switch right footrest Refer to REAR BRAKE MASTER CYL INDER in chapter 7 Radiator inlet hose Refer to THERMOSTAT in chapter 5 Radiator outlet hose Refer to WATER PUMP in chapter 5 Throttle body Refer to THROTTLE BODY in chapter 6 Drive sprocket Refer to SWINGARM AND DRIVE CHAIN in chapter 7 1 Spark plug cap 1 2 Starter...

Page 155: ...ler 1 6 Speed sensor coupler 1 7 A C magneto coupler 1 Disconnect 8 Crankshaft position sensor coupler 1 Disconnect 9 Rear brake light switch coupler 1 10 Rear brake light switch lead 1 11 Wire sub lead 1 12 Ground lead 1 13 Clutch cable 1 14 Parking brake cable 1 15 Reverse control cable 1 For installation reverse the removal pro cedure ...

Page 156: ...0 0 m kg 72 ft lb Order Job Part Q ty Remarks Removing the engine mounting bolts Remove the parts in the order listed 1 Engine upper bracket bolt 2 CAUTION _ Install all of the bolts nuts and then tighten them to full torque specifica tions 2 Engine mounting bolt upper nut 1 1 3 Engine upper bracket 1 4 Engine lower bracket bolt 4 5 Engine mounting bolt middle nut 1 1 6 Engine lower bracket 2 7 En...

Page 157: ... kg 30 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib 6 5 4 6 4 5 7 8 2 3 1 7 8 9 T R 33 Nm 3 3 m kg 24 ft Ib 2 T R 100 Nm 10 0 m kg 72 ft lb Order Job Part Q ty Remarks 9 Engine assembly 1 NOTE _ Remove the engine assembly from the right side of the vehicle For installation reverse the removal pro cedure ENGINE REMOVAL ...

Page 158: ...ting bolt upper nut NOTE _ Do not fully tighten the bolts and nuts 3 Tighten engine upper bracket bolt 1 engine upper bracket bolt 2 engine mounting bolt upper nut 3 pivot shaft nut 4 engine mounting bolt lower nut 5 engine mounting bolt middle nut 6 engine lower bracket bolts 7 NOTE Tighten the bolts and nuts in the proper tight ening sequence as shown 2 1 3 7 6 5 4 T R 33 Nm 3 3 m kg 24 ft lb T ...

Page 159: ... 9 10 6 7 4 New 2 4 4 4 4 3 T R 40 Nm 4 0 m kg 29 ft Ib T R 33 Nm 3 3 m kg 24 ft Ib 1 Order Job Part Q ty Remarks Removing the cylinder head Remove the parts in the order listed Throttle body Refer to THROTTLE BODY in chapter 6 Thermostat coolant temperature sen sor Refer to THERMOSTAT in chapter 5 1 Engine upper bracket 1 2 Spark plug 1 3 Camshaft sprocket cover O ring 1 1 4 Tappet cover O ring 2...

Page 160: ...m 3 8 m kg 27 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib New New New New New New New 8 11 12 4 5 LS LS E E 9 10 6 7 4 New 2 4 4 4 4 3 T R 40 Nm 4 0 m kg 29 ft Ib T R 33 Nm 3 3 m kg 24 ft Ib 1 Order Job Part Q ty Remarks 9 Decompressor assembly 1 Refer to REMOVING THE CYLINDER HEAD and INSTALLING THE CYLIN DER HEAD 10 Cylinder head 1 11 Cylinder head gasket 1 12 Dowel pin 2 For i...

Page 161: ... the cylinder head a b d c 2 Loosen camshaft sprocket bolts 1 NOTE While holding the A C magneto rotor nut with a wrench loosen the bolt 3 Loosen timing chain tensioner cap bolt 4 Remove timing chain tensioner along with the gasket camshaft sprocket timing chain NOTE _ To prevent the timing chain from falling into the crankcase fasten it with a wire 1 5 Remove cylinder head NOTE _ Loosen the bolts...

Page 162: ... deposits rust Eliminate 3 Measure cylinder head warpage Out of specification Resurface the cylin der head a Place a straightedge 1 and a thickness gauge 2 across the cylinder head b Measure the warpage c If the limit is exceeded resurface the cylin der head as follows d Place 400 600 grit wet sandpaper on the surface plate and resurface the cylinder head using a figure eight sanding pattern NOTE ...

Page 163: ...ne way cam operation Rough movement Replace the timing chain tensioner 3 Check timing chain tensioner cap bolt copper washer spring one way cam gasket timing chain tensioner rod Damage wear Replace the defective part s New New EBS00224 CHECKING THE CAMSHAFT SPROCKET 1 Check camshaft sprocket Wear damage Replace the camshaft sprocket and timing chain as a set a 1 4 of a tooth b Correct 1 Roller 2 S...

Page 164: ...d bolts in the proper tightening sequence as shown and torque them in two stages 3 1 1 4 7 8 5 6 4 4 2 2 3 3 T R 35 Nm 3 5 m kg 25 ft lb T R 35 Nm 3 5 m kg 25 ft lb T R 38 Nm 3 8 m kg 27 ft lb T R 10 Nm 1 0 m kg 7 2 ft lb 4 Install camshaft sprocket onto the camshaft a Turn the primary pulley counterclockwise b Align the I mark a on the A C magneto rotor with the stationary pointer b on the A C ma...

Page 165: ... Remove the timing chain tensioner cap bolt 1 copper washer 2 and spring 3 b Release the timing chain tensioner one way cam 4 and push the timing chain tensioner rod 5 all the way into the timing chain ten sioner housing c Install the timing chain tensioner and gasket 6 onto the cylinder NOTE Install the gasket with its beaded side facing the timing chain tensioner end d Install the spring and tim...

Page 166: ... the stationary pointer d on the cylinder head Out of alignment Correct Repeat steps 4 to 7 if necessary 8 Tighten camshaft sprocket bolts CAUTION _ Be sure to tighten the camshaft sprocket bolts to the specified torque to avoid the possibility of the bolts coming loose and damaging the engine 9 Measure valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEARANCE in chapter 3...

Page 167: ...r Job Part Q ty Remarks Removing the rocker arms and cam shaft Remove the parts in the order listed Cylinder head Refer to CYLINDER HEAD 1 Bearing retainer 1 Refer to REMOV ING THE ROCKER ARMS AND CAM SHAFT and INSTALLING THE CAMSHAFT AND ROCKER ARMS 2 Rocker arm shaft 2 3 Rocker arm 2 4 Locknut valve adjuster 4 4 5 Camshaft 1 CAUTION Do not disas semble the cam shaft assembly 6 Decompressor lever...

Page 168: ...10 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib E E LT 1 5 7 6 2 E 8 3 2 3 4 4 4 4 E M M Order Job Part Q ty Remarks 7 Decompressor lever pin 1 Refer to REMOVING THE ROCKER ARMS AND CAMSHAFT and INSTALLING THE CAMSHAFT AND ROCKER ARMS 8 Bearing 1 For installation reverse the removal pro cedure ...

Page 169: ...ust rocker arm shaft intake rocker arm exhaust rocker arm NOTE _ Remove the rocker arm shafts with the slide hammer bolt 1 and weight 2 4 Remove camshaft Slide hammer bolt 90890 01083 Slide hammer bolt 6 mm YU 01083 1 Weight 90890 01084 YU 01083 3 1 2 EAS00205 CHECKING THE CAMSHAFT 1 Check camshaft lobes Blue discoloration pitting scratches Replace the camshaft and camshaft sprocket ...

Page 170: ...926 mm 1 4538 in Exhaust a 43 129 43 229 mm 1 6980 1 7019 in Limit 43 029 mm 1 6941 in b 37 057 37 157 mm 1 4589 1 4629 in Limit 36 957 mm 1 4550 in Camshaft runout limit 0 030 mm 0 0012 in EBS00225 CHECKING THE DECOMPRESSION SYSTEM 1 Check decompression system a Check the decompression system with the camshaft sprocket installed on and the decompressor lever pin installed in the cam shaft b Check...

Page 171: ...wear Replace 2 Check rocker arm shaft Blue discoloration excessive wear pitting scratches Replace or check the lubrica tion system 3 Measure rocker arm inside diameter Out of specification Replace Rocker arm inside diameter 12 000 12 018 mm 0 4724 0 4731 in 4 Measure rocker arm shaft outside diameter Out of specification Replace Rocker arm shaft outside diame ter 11 981 11 991 mm 0 4717 0 4721 in ...

Page 172: ...ve part s Rocker arm to rocker arm shaft clearance 0 009 0 037 mm 0 0004 0 0015 in EAS00243 INSTALLING THE CAMSHAFT AND ROCKER ARMS 1 Install bearing 1 onto the camshaft NOTE Apply engine oil to the bearing Install the bearing so that the seal is facing a the camshaft 2 Lubricate camshaft decompressor lever pin decompressor lever Installed depth b 0 mm 0 in Recommended lubricant Camshaft Molybdenu...

Page 173: ...horizontal 5 Lubricate rocker arm shafts 6 Install exhaust rocker arm 1 exhaust rocker arm shaft 2 intake rocker arm intake rocker arm shaft NOTE _ Use a slide hammer bolt 3 to install the rocker arm shaft Make sure the rocker arm shafts intake and exhaust are completely pushed into the cyl inder head 7 Install camshaft retainer camshaft retainer bolts Recommended lubricant Engine oil Slide hammer...

Page 174: ...arts in the order listed Cylinder head Refer to CYLINDER HEAD Rocker arms rocker arm shafts cam shaft Refer to ROCKER ARMS AND CAM SHAFT 1 Valve cotter 8 Refer to REMOVING THE VALVES AND VALVE SPRINGS and INSTALL ING THE VALVES AND VALVE SPRINGS 2 Valve spring retainer 4 3 Valve spring 4 4 Exhaust valve 2 5 Intake valve 2 6 Valve stem seal 4 7 Valve spring seat 4 For installation reverse the remov...

Page 175: ...k the valve face valve seat and valve seat width Refer to CHECKING THE VALVES AND VALVE SPRINGS a Pour a clean solvent a into the intake and exhaust ports b Check that the valve seals properly There should be no leakage at the valve seat 1 2 Remove valve cotters NOTE _ Attach a valve spring compressor 1 and attachment 2 between the valve spring retainer and the cylinder head to remove the valve co...

Page 176: ...e EBS00240 CHECKING THE VALVES AND VALVE SPRINGS The following procedure applies to all of the valves and valve guides 1 Measure valve stem to valve guide clearance Out of specification Replace the valve guide Stem to guide clearance Valve guide inside diameter a Valve stem diameter b Stem to guide clearance Intake 0 010 0 037 mm 0 0004 0 0015 in Limit 0 08 mm 0 0031 in Exhaust 0 025 0 052 mm 0 00...

Page 177: ...th the valve guide reamer 3 to obtain the proper stem to guide clear ance NOTE _ After replacing the valve guide reface the valve seat 3 Check valve face Pitting wear Grind the face valve stem end Mushroom shape or diameter larger than the body of the valve stem Replace 4 Measure margin thickness a Out of specification Replace Valve guide remover ø6 90890 04064 Valve guide remover 6 0 mm YM 04064 ...

Page 178: ... seat width a Out of specification Replace the valve seat a Apply Mechanic s blueing dye Dykem b to the valve face b Install the valve into the cylinder head c Press the valve through the valve guide and onto the valve seat to make a clear pattern d Measure the valve seat width Where the valve seat and valve face made contact blueing will have been removed e If the valve seat is too wide too narro...

Page 179: ...seat are evenly polished then clean off all of the compound NOTE _ For 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 NOTE _ After every lapping operation be sure to clean off all of the compound from the valve face and valve seat f Apply Mechanic s blueing dye D...

Page 180: ...re compressed spring force a Out of specification Replace b Installed length Compressed valve spring force installed Intake 169 0 199 0 N at 35 00 mm 17 23 20 29 kg at 35 00 mm 37 99 44 73 lb at 1 38 in Exhaust 169 0 199 0 N at 35 00 mm 17 23 20 29 kg at 35 00 mm 37 99 44 73 lb at 1 38 in 12 Measure valve spring tilt a Out of specification Replace Valve spring tilt limit Intake 2 5 1 70 mm 0 067 i...

Page 181: ...an oil stone 2 Lubricate valve stem 1 valve stem seal 2 with the recommended lubricant Recommended lubricant Molybdenum disulfide oil 3 Install valve 1 valve spring seat 2 valve stem seal 3 valve spring 4 valve spring retainer 5 into the cylinder head NOTE _ Install the valve spring with the larger pitch a facing up Install the valve spring with its painted end facing up b Smaller pitch ...

Page 182: ...ng compressor 1 and attachment 2 5 To secure the valve cotters onto the valve stem lightly tap the valve tip with a piece of wood CAUTION _ Hitting the valve tip with excessive force could damage the valve Valve spring compressor 90890 04019 YM 04019 Valve spring compressor attach ment 90890 01243 Valve spring compressor adapter 26 mm YM 01253 1 ...

Page 183: ... ty Remarks Removing the cylinder and piston Remove the parts in the order listed Cylinder head Refer to CYLINDER HEAD 1 Timing chain guide exhaust 1 2 Water jacket joint 1 3 O ring 1 4 Cylinder 1 Refer to INSTALLING THE PISTON AND CYLINDER 5 Cylinder gasket 1 6 Dowel pin 2 7 Piston pin clip 2 Refer to REMOVING THE PISTON and INSTALLING THE PISTON AND CYLINDER 8 Piston pin 1 9 Piston 1 10 Top ring...

Page 184: ... the piston pin puller 4 CAUTION _ Do not use a hammer to drive the piston pin out 2 Remove piston rings NOTE _ Spread the end gaps apart while at the same time lifting the piston ring over the top of the piston crown as shown in the illustration Piston pin puller set 90890 01304 Piston pin puller YU 01304 1 2 3 EBS00249 CHECKING THE CYLINDER AND PISTON 1 Check piston wall cylinder wall Vertical s...

Page 185: ...mm 0 39 in from the bottom edge of the pis ton d If out of specification replace the piston and piston rings as a set e Calculate the piston to cylinder clearance with the following formula Cylinder bore C 102 000 102 010 mm 4 0157 4 0161 in Taper limit T 0 05 mm 0 002 in Out of round R 0 05 mm 0 002 in C Maximum D T Maximum D1 or D2 Maximum D5 or D6 R Maximum D1 D3 or D5 Minimum D2 D4 or D6 Pisto...

Page 186: ...iston rings as a set NOTE _ Before measuring the piston ring side clear ance eliminate any carbon deposits from the piston ring grooves and piston rings Piston ring side clearance Top ring 0 030 0 070 mm 0 0012 0 0028 in Limit 0 12 mm 0 0047 in 2nd ring 0 030 0 070 mm 0 0012 0 0028 in Limit 0 13 mm 0 0051 in 2 Install piston ring into the cylinder NOTE _ Level the piston ring into the cylinder wit...

Page 187: ... ring 0 20 0 35 mm 0 008 0 014 in Limit 0 60 mm 0 024 in 2nd ring 0 35 0 50 mm 0 014 0 020 in Limit 0 85 mm 0 033 in Oil ring 0 20 0 70 mm 0 008 0 028 in EBS00251 CHECKING THE PISTON PIN 1 Check piston pin Blue discoloration grooves Replace the piston pin and then check the lubrication system 2 Measure piston pin outside diameter a Out of specification Replace the piston pin Piston pin outside dia...

Page 188: ... 0 9057 0 9061 in Limit 23 045 mm 0 9073 in Piston pin to piston pin bore clearance Piston pin bore inside diameter b Piston pin outside diameter a Piston pin to piston pin bore clearance 0 004 0 024 mm 0 0002 0 0009 in Limit 0 074 mm 0 0029 in EBS00252 INSTALLING THE PISTON AND CYLINDER 1 Install top ring 1 2nd ring 2 oil ring expander 3 lower oil ring rail 4 upper oil ring rail 5 NOTE _ Be sure ...

Page 189: ...ylinder gasket dowel pins 4 Lubricate piston piston rings cylinder with the recommended lubricant Recommended lubricant Engine oil 2 3 1 a New New New 5 Offset piston ring end gaps a Top ring b Upper oil ring rail c Oil ring expander d Lower oil ring rail e 2nd ring f 20 mm 0 79 in È Exhaust side e a f f d c b 120 120 120 È 6 Install cylinder 1 timing chain guide exhaust NOTE _ While compressing t...

Page 190: ...E Lubricate the cylinder bolt 1 threads and mat ing surface with engine oil 8 Tighten cylinder bolts 1 1st cylinder bolts 1 2nd cylinder bolts timing chain side 2 1 1 2 2 E E T R 15 Nm 1 5 m kg 11 ft lb T R 50 Nm 5 0 m kg 36 ft lb T R 10 Nm 1 0 m kg 7 2 ft lb ...

Page 191: ...Ib Order Job Part Q ty Remarks Removing the A C magneto Remove the parts in the order listed Engine oil Drain Front fender Refer to SEAT FENDERS AND FUEL TANK in chapter 3 Oil tank inlet hose Refer to OIL TANK Drive sprocket cover Refer to SWINGARM AND DRIVE CHAIN in chapter 7 1 A C magneto coupler 1 Disconnect 2 Crankshaft position sensor coupler 1 Disconnect 3 A C magneto cover 1 4 A C magneto c...

Page 192: ...4 10 13 12 7 6 1 2 T R 60 Nm 6 0 m kg 43 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib Order Job Part Q ty Remarks 9 Torque limiter 1 10 Starter idle gear 1 11 Starter idle gear shaft 1 12 A C magneto rotor 1 Refer to REMOVING THE A C MAG NETO ROTOR and INSTALLING THE A C MAGNETO ROTOR 13 Starter clutch 1 14 Woodruff key 1 15 Starter wheel gear 1 16 Washer 1 For installation reverse the removal pro cedure ...

Page 193: ...nut 1 washer NOTE _ While holding the A C magneto rotor 2 with the sheave holder 3 loosen the A C magneto rotor nut Sheave holder 90890 01701 Primary clutch holder YS 01880 A 3 2 1 3 Remove A C magneto rotor 1 NOTE _ Use the flywheel puller 2 Flywheel puller 90890 01404 YM 01404 2 1 EBS00262 CHECKING THE STATOR COIL AND CRANKSHAFT POSITION SENSOR 1 Check stator coil crankshaft position sensor Dama...

Page 194: ...counter clockwise È the starter clutch and the wheel gear should be engaged If not the starter clutch is faulty Replace it c When turning the starter wheel gear clock wise É the starter wheel gear should turn freely If not the starter clutch is faulty Replace it T R Starter clutch bolt 30 Nm 3 0 m kg 22 ft lb LOCTITE LT 1 2 È É 2 Check starter idle gear teeth 1 starter wheel gear teeth 2 Burrs cli...

Page 195: ...tor coil with the slot b in the A C magneto cover 1 a b T R 7 Nm 0 7 m kg 5 1 ft lb LT 2 Apply Yamaha bond No 1215 Three bond No 1215 1 into the slit Yamaha bond No 1215 Three bond No 1215 90890 85505 1 3 Install woodruff key A C magneto rotor NOTE _ Before installing the rotor clean the outside of the crankshaft and the inside of the rotor After installing the rotor check that the rotor rotates s...

Page 196: ...th the sheave holder 3 tighten the A C mag neto rotor nut Sheave holder 90890 01701 Primary clutch holder YS 01880 A 3 2 1 T R 60 Nm 6 0 m kg 43 ft lb 5 Install gasket A C magneto cover bolts NOTE _ Tighten the A C magneto cover bolts in stages using a crisscross pattern New T R 10 Nm 1 0 m kg 7 2 ft lb ...

Page 197: ... order listed Engine oil Drain Front fender Refer to SEAT FENDERS AND FUEL TANK in chapter 3 Rear brake light switch right foot rest brake pedal spring Refer to FRONT AND REAR BRAKES in chapter 7 Oil delivery pipe Refer to CYLINDER HEAD 1 Oil filter cover O ring 1 1 2 Oil filter 1 3 O ring 1 4 Clutch cover 1 Refer to REMOVING THE CLUTCH and INSTALLING THE CLUTCH 5 Clutch cover gasket 1 6 Dowel pin...

Page 198: ...rder Job Part Q ty Remarks Removing the pull lever shaft Remove the parts in the order listed 1 Circlip 1 2 Pull lever 1 3 Pull lever spring 1 4 Circlip 1 5 Pull lever shaft 1 6 Oil seal 1 7 Bearing 1 8 Bearing 1 For installation reverse the removal pro cedure ...

Page 199: ...er Job Part Q ty Remarks Removing the clutch Remove the parts in the order listed 1 Clutch spring 6 Refer to INSTALLING THE CLUTCH 2 Pressure plate 1 3 Pull rod 1 4 Bearing 1 5 Friction plate 1 7 Refer to INSTALLING THE CLUTCH 6 Clutch plate 7 7 Conical spring washer 1 Refer to REMOVING THE CLUTCH and INSTALLING THE CLUTCH 8 Wire circlip 1 9 Friction plate 2 1 10 Clutch damper spring 1 11 Clutch d...

Page 200: ...12 13 E E E E M Order Job Part Q ty Remarks 15 Breather plate 1 16 Lock washer 1 Refer to REMOVING THE PRIMARY DRIVE GEAR AND BALANCER DRIVEN GEAR and INSTALLING THE PRIMARY DRIVE GEAR AND BAL ANCER DRIVEN GEARS 17 Balancer driven gear 1 1 18 Straight key 1 19 Lock washer 1 20 Water pump drive gear 1 21 Primary drive gear 1 22 Balancer drive gear 1 23 Straight key 1 24 Lock washer 1 25 Balancer dr...

Page 201: ...sen clutch boss nut 1 NOTE _ While holding the clutch boss 2 with the uni versal clutch holder 3 loosen the clutch boss nut Universal clutch holder 90890 04086 YM 91042 2 3 a 1 4 Remove clutch boss nut 1 conical spring washer 2 clutch boss assembly 3 NOTE There is a built in damper between the clutch boss and the clutch plate It is not necessary to remove the wire circlip 4 and disassemble the bui...

Page 202: ...ate 9 between the teeth of the balancer driven gear 2 8 and balancer drive gear 6 then loosen the nut 3 Place an aluminum plate 7 between the teeth of the balancer drive gear 6 and bal ancer driven gear 2 8 then loosen the nut 2 8 4 6 2 5 1 9 3 7 EBS00300 CHECKING THE FRICTION PLATES The following procedure applies to all of the friction plates 1 Check friction plate Damage wear Replace the fricti...

Page 203: ...h plates as a set 2 Measure clutch plate warpage with a surface plate and thickness gauge 1 Out of specification Replace the clutch plates as a set Maximum clutch plate warpage 0 2 mm 0 0079 in EBS00302 CHECKING THE CLUTCH SPRINGS The following procedure applies to all of the clutch springs 1 Check clutch spring Damage Replace the clutch springs as a set 2 Measure clutch spring free length a Out o...

Page 204: ...TCH BOSS 1 Check clutch boss splines Damage pitting wear Replace the clutch boss NOTE _ Pitting on the clutch boss splines will cause erratic clutch operation EBS00305 CHECKING THE PRESSURE PLATE 1 Check pressure plate Cracks damage Replace EBS00306 CHECKING THE PULL LEVER SHAFT AND PULL ROD 1 Check pull lever shaft pinion gear teeth a pull rod teeth b Damage wear Replace the pull lever shaft and ...

Page 205: ...er driven gear as a set Replace the water pump drive gear and water pump driven gear as a set Excessive noise during operation Replace the balancer drive gear and bal ancer driven gear as a set Replace the water pump drive gear and water pump driven gear as a set 4 1 2 3 EBS00310 INSTALLING THE PRIMARY DRIVE GEAR AND BALANCER DRIVEN GEARS 1 Install balancer drive gear primary drive gear water pump...

Page 206: ...e balancer driven gear 2 5 and balancer drive gear 6 then tighten the nut 2 Place an aluminum plate 8 between the teeth of the balancer drive gear 6 and bal ancer driven gear 1 9 then tighten the nut 3 3 Bend the lock washer tabs along a flat side of the nut 5 6 2 9 3 7 8 4 1 T R 60 Nm 6 0 m kg 43 ft lb T R 110 Nm 11 0 m kg 80 ft lb T R 60 Nm 6 0 m kg 43 ft lb EBS00311 INSTALLING THE CLUTCH 1 Inst...

Page 207: ...with the clutch holding tool 4 tighten the clutch boss nut Stake the clutch boss nut 3 at a cutout b in the main axle Universal clutch holder 90890 04086 YM 91042 OUT 3 1 4 b 2 a New T R 95 Nm 9 5 m kg 68 ft lb 4 Install clutch springs NOTE _ Tighten the bolts in stages using a crisscross pattern T R 8 Nm 0 8 m kg 5 8 ft lb 5 Install clutch cover NOTE _ To install the clutch cover position the pul...

Page 208: ... 1 2 New 7 Install clutch cable 1 8 Check clutch cable length a Out of specification Adjust NOTE Push the pull lever in direction b and check the cable length a Bend the tab c on the pull lever to secure the clutch cable 9 Adjust clutch cable length NOTE Move the pull lever a notch until the cable length is within specification 10 Adjust clutch cable free play Refer to ADJUSTING THE CLUTCH CABLE i...

Page 209: ... Removing the oil pump Remove the parts in the order listed Clutch housing Refer to CLUTCH 1 Oil baffle plate 1 1 2 Circlip 1 3 Oil pump driven gear 1 4 Oil baffle plate 2 1 5 Oil pump 1 6 Oil pump gasket 1 7 O ring 2 For installation reverse the removal pro cedure ...

Page 210: ...ng 1 oil seal 1 1 2 Oil pump outer rotor 1 1 3 Dowel pin 1 4 Oil pump inner rotor 1 1 5 Oil pump housing cover oil seal 1 1 6 Dowel pin 2 7 Oil pump shaft 1 8 Dowel pin 1 9 Oil pump inner rotor 2 1 Refer to ASSEMBLING THE OIL PUMP 0 Oil pump outer rotor 2 1 A Oil pump housing 2 1 For assembly reverse the disassembly procedure ...

Page 211: ...ance a outer rotor to oil pump housing clearance b Out of specification Replace the oil pump 1 inner rotor 2 outer rotor 3 oil pump housing Inner rotor to outer rotor tip clearance Less than 0 12 mm 0 0047 in Limit 0 20 mm 0 0079 in Outer rotor to oil pump housing clearance 0 09 0 15 mm 0 0035 0 0059 in Limit 0 22 mm 0 0087 in 3 Check oil pump operation Rough movement Repeat steps 1 and 2 or repla...

Page 212: ...pump outer rotor 2 1 oil pump inner rotor 2 2 to the oil pump housing 2 oil pump housing NOTE Align the match mark a on the inner rotor 2 with the match mark b on the outer rotor 2 2 Check oil pump operation Refer to CHECKING THE OIL PUMP T R 7 Nm 0 7 m kg 5 1 ft lb ...

Page 213: ...isted Clutch housing Refer to CLUTCH 1 Shift pedal 1 Refer to INSTALLING THE SHIFT LEVER 2 Shift shaft 1 3 Shift shaft spring 1 4 Stopper lever washer 1 1 5 Stopper lever spring 1 6 Roller 1 Refer to INSTALLING THE SHIFT LEVER 7 Shift guide 1 8 Shift lever assembly 1 9 Pawl holder 1 10 Pawl 2 11 Pawl pin 2 12 Spring 2 ...

Page 214: ...4 64 ENG SHIFT SHAFT Order Job Part Q ty Remarks 13 Shift drum segment 1 Refer to INSTALLING THE SHIFT LEVER For installation reverse the removal pro cedure ...

Page 215: ...lever stopper lever spring 2 Damage wear Replace 1 2 EBS00359 CHECKING THE SHIFT GUIDE 1 Check shift guide 1 pawl holder 2 pawls 3 pawl pins 4 springs 5 Wear cracks damage Replace 1 2 3 4 5 3 4 5 CHECKING THE SHIFT DRUM SEGMENT 1 Check shift drum segment Damage wear Replace INSTALLING THE SHIFT LEVER 1 Install shift drum segment 1 shift drum segment bolt NOTE Align the notch a on the shift drum se...

Page 216: ...BS00343 INSTALLING THE SHIFT SHAFT 1 Install stopper lever 1 stopper lever spring 2 shift shaft 3 roller 4 shift shaft spring NOTE Hook the ends of the stopper lever spring onto the stopper lever and the crankcase boss 5 Install the end of the shift shaft spring onto the shift shaft spring stopper 6 Install the end of the shift shaft lever onto the roller 4 2 Install shift pedal Refer to ADJUSTING...

Page 217: ... to ENGINE REMOVAL Piston Refer to CYLINDER AND PISTON A C magneto Refer to A C MAGNETO Balancer driven gears Refer to CLUTCH Oil pump Refer to OIL PUMP Shift drum segment Refer to SHIFT SHAFT Starter motor Refer to STARTER MOTOR in chapter 8 1 Timing chain guide intake side 1 2 Timing chain 1 3 Neutral switch 1 4 Reverse switch 1 5 Oil pipe joint 1 ...

Page 218: ... 6 Reverse shift lever 1 7 Reverse shift lever spring 1 8 Circlip 1 9 Right crankcase 1 Refer to SEPARATING THE CRANK CASE 10 Left crankcase 1 11 Dowel pin 2 12 Dowel pin O ring 1 1 13 Oil strainer 1 For installation reverse the removal pro cedure ...

Page 219: ... 5 5 E E E E New New T R 10 Nm 1 0 m kg 7 2 ft Ib Order Job Part Q ty Remarks Removing the crankcase bearings Remove the parts in the order listed Crankshaft Refer to CRANKSHAFT Transmission Refer to TRANSMISSION 1 Oil seal retainer 1 2 Bearing retainer 1 3 Bearing retainer 1 4 Oil seal 4 5 Bearing 10 For installation reverse the removal pro cedure ...

Page 220: ...e NOTE _ Insert a screwdriver or pry bar into the pry points in the crankcase and then carefully pry apart the crankcase halves CAUTION _ Use a soft hammer to tap on one side of the crankcase Tap only on reinforced portions of the crankcase Do not tap on the crank case mating surfaces Work slowly and carefully Make sure that the crankcase halves separate evenly c Remove the dowel pins and O ring 1...

Page 221: ...G THE BEARINGS AND OIL SEALS 1 Check bearings Clean and lubricate then rotate the inner race with a finger Roughness Replace 2 Check oil seals Damage wear Replace EBS00338 CHECKING THE CRANKCASE 1 Thoroughly wash the case halves in a mild solvent 2 Clean all the gasket mating surfaces and crankcase mating surfaces thoroughly 3 Check crankcase Cracks damage Replace oil delivery passages Clogged Blo...

Page 222: ...oose flatten the edge a of each screw into the depression b using a punch etc Be careful not to damage the hole for the screwdriver in the screw heads È Right crankcase É Left crankcase 1 È New T R 10 Nm 1 0 m kg 7 2 ft lb LT T R 10 Nm 1 0 m kg 7 2 ft lb LT a 2 b É 2 Apply Yamaha bond No 1215 Three bond No 1215 1 to the mating surfaces of both case halves 3 Install dowel pins 2 O ring 3 Yamaha bon...

Page 223: ...ng properly by manually rotating the shift drum in both directions 5 Install crankcase bolts È Left crankcase É Right crankcase 6 Tighten crankcase bolts follow the proper tightening sequence NOTE _ Tighten the bolts in stages using a crisscross pattern 7 Apply 4 stroke engine oil to the crankshaft pin bearing and oil deliv ery hole 8 Check crankshaft and transmission operation Unsmooth operation ...

Page 224: ...y Remarks Removing the crankshaft and bal ancer Remove the parts in the order listed Crankcase Separate Refer to CRANKCASE 1 Balancer 1 1 2 Balancer 2 1 3 Crankshaft 1 Refer to REMOVING THE CRANK SHAFT and INSTALLING THE CRANK SHAFT For installation reverse the removal pro cedure ...

Page 225: ...360 CHECKING THE CRANKSHAFT 1 Measure crank width a Out of specification Replace the crank shaft 2 Measure side clearance d Out of specification Replace the crank shaft 3 Measure runout c Out of specification Replace the crank shaft Crank width 74 95 75 00 mm 29 51 29 53 in Big end side clearance 0 35 0 65 mm 0 0138 0 0256 in Limit 1 00 mm 0 040 in Runout limit 0 03 mm 0 0012 in c c a d ...

Page 226: ...e nut of the installing tool with the other Operate the installing tool until the crankshaft bottoms against the bearing CAUTION _ Apply engine oil to each bearing to protect the crankshaft against scratches and to make installation easier Crankshaft installer pot 2 90890 01274 Installer pot YU 90058 Pot installer YU 90059 Crankshaft installer bolt 3 90890 01275 Bolt YU 90060 Adapter M16 4 90890 0...

Page 227: ... New New New 9 7 10 8 2 3 4 5 11 6 1 New LS Order Job Part Q ty Remarks Removing the transmission shift drum and shift forks Remove the parts in the order listed Crankcase Separate Refer to CRANKCASE 1 Spacer 1 2 Circlip 1 3 Washer 1 4 Reverse wheel gear 2 1 5 Spacer 1 ...

Page 228: ...w LS Order Job Part Q ty Remarks 6 Counter axle assembly 1 Refer to INSTALLING THE TRANSMIS SION 7 Shift drum 1 8 Shift fork R 1 9 Shift fork C 1 10 Shift fork L 1 11 Drive axle assembly 1 12 Main axle assembly 1 13 Reverse shift shaft 1 For installation reverse the removal pro cedure ...

Page 229: ...the parts in the order listed 1 Circlip 1 2 2nd pinion gear 1 3 Toothed lock washer 1 4 Toothed washer retainer 1 5 4th pinion gear 1 6 Toothed spacer 1 7 Toothed washer 2 Refer to ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 8 Circlip 2 9 3rd pinion gear 1 0 5th pinion gear 1 A Main axle 1st pinion gear 1 For assembly reverse the disassembly procedure ...

Page 230: ...the parts in the order listed 1 Circlip 1 2 Washer 1 Refer to ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 3 Reverse wheel gear 2 1 4 Spacer 1 5 Dog clutch 1 6 Circlip 3 Refer to ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 7 Toothed washer 3 8 1st wheel gear 1 9 Toothed spacer 1 0 5th wheel gear 1 A Toothed lock washer 1 B Toothed washer retainer 1 C 3rd wheel gear 1 D Toothed spacer 1 ...

Page 231: ...ISSION M M M H G A 2 3 4 5 6 7 8 9 0 1 B C D 7 6 E 7 F 6 New New New New M M M Order Job Part Q ty Remarks E 4th wheel gear 1 F 2nd wheel gear 1 G Spacer 1 H Drive axle 1 For assembly reverse the disassembly procedure ...

Page 232: ... 3 2 1 2 1 New New M Order Job Part Q ty Remarks Disassembling the counter axle Remove the parts in the order listed 1 Circlip 2 2 Washer 2 3 Spacer 1 4 Reverse wheel gear 1 1 5 Counter axle 1 For assembly reverse the disassembly procedure ...

Page 233: ... wear Replace the shift fork 2 Check shift fork movement Rough movement Replace the shift forks 1 2 EBS00351 CHECKING THE SHIFT DRUM ASSEMBLY 1 Check shift drum grooves Scratches wear damage Replace EBS00354 CHECKING THE TRANSMISSION 1 Measure main axle runout with a centering device and dial gauge 1 Out of specification Replace the main axle Main axle runout limit 0 08 mm 0 0031 in 1 ...

Page 234: ...Incorrect Reassemble the transmission axle assemblies 4 Check transmission gear movement Rough movement Replace the defective part s 5 Check circlips Bends damage looseness Replace EBS00355 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 1 Install toothed washer 1 circlip 2 NOTE _ Be sure the circlip shape edged corner a is positioned on the opposite side to the toothed washer and gear Install the circlip...

Page 235: ...e R C L Be sure that the shift fork cam follower is properly seated in the shift drum groove 5 4 3 6 2 1 2 Install counter axle assembly NOTE _ Engage the concave part a of the left crank case and convex part b of the counter axle Align the edge height of reverse wheel gear 1 c and main axle 1st pinion gear d a b c d 3 Check shift operation Unsmooth operation Repair NOTE _ Apply engine oil to each...

Page 236: ...R 5 1 CHECKING THE RADIATOR 5 3 INSTALLING THE RADIATOR 5 4 THERMOSTAT 5 5 CHECKING THE THERMOSTAT 5 6 INSTALLING THE THERMOSTAT 5 6 WATER PUMP 5 7 DISASSEMBLING THE WATER PUMP 5 9 CHECKING THE WATER PUMP 5 9 ASSEMBLING THE WATER PUMP 5 10 ...

Page 237: ... parts in the order listed Front fender Refer to SEAT FENDERS AND FUEL TANK in chapter 3 Coolant Drain 1 Radiator fan motor coupler 1 Disconnect 2 Coolant reservoir hose 1 3 Radiator fan breather hose 1 Disconnect 4 Radiator outlet hose 1 Disconnect 5 Radiator inlet hose 1 Disconnect 6 Fast idle plunger outlet hose 1 Disconnect 7 Radiator 1 8 Radiator fan 1 9 Coolant reservoir breather hose 1 ...

Page 238: ...IATOR 1 4 8 2 2 10 11 9 5 6 3 7 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib Order Job Part Q ty Remarks 10 Coolant reservoir 1 11 Coolant reservoir cap 1 For installation reverse the removal pro cedure ...

Page 239: ...sure Replace the radiator cap a Install the radiator cap tester 1 and radiator cap tester adapter 2 to the radiator cap 3 b Apply the specified pressure for ten sec onds and make sure there is no drop in pressure 4 Check radiator fan Damage Replace Malfunction Check and repair Refer to COOLING SYSTEM in chapter 8 Radiator cap opening pressure 93 3 122 7 kPa 0 933 1 227 kg cm2 13 27 17 45 psi Radia...

Page 240: ...the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT in chapter 3 2 Check cooling system Leaks Repair or replace any faulty part 3 Measure radiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR ...

Page 241: ...er Job Part Q ty Remarks Removing the thermostat Remove the parts in the order listed Front fender Refer to SEAT FENDERS AND FUEL TANK in chapter 3 Coolant Drain 1 Radiator inlet hose 1 2 Thermostat cover 1 3 O ring 1 4 Thermostat 1 5 Coolant temperature sensor 1 6 Copper washer 1 For installation reverse the removal pro cedure ...

Page 242: ...d É Fully open NOTE _ If the accuracy of the thermostat is in doubt replace it A faulty thermostat could cause seri ous overheating or overcooling 2 Check thermostat cover thermostat housing cylinder head Cracks damage Replace Temperature Opening EBS00133 INSTALLING THE THERMOSTAT 1 Install thermostat 1 O ring 2 thermostat cover 3 NOTE Install the thermostat with its breather hole a facing up 2 Fi...

Page 243: ...w 1 2 5 7 6 New 4 3 LS Order Job Part Q ty Remarks Removing the water pump Remove the parts in the order listed Coolant Drain 1 Radiator outlet hose 1 Disconnect 2 Water pump outlet hose 1 3 Water pump 1 4 O ring 1 5 Water pump breather hose 1 6 Water jacket inlet housing 1 7 O ring 1 For installation reverse the removal pro cedure ...

Page 244: ...the parts in the order listed 1 Water pump housing cover 1 2 Gasket 1 3 Circlip 1 Refer to ASSEMBLING THE WATER PUMP 4 Impeller shaft gear 1 5 Pin 1 6 Washer 1 7 Impeller shaft assembly 1 Refer to DISASSEMBLING THE WATER PUMP and ASSEMBLING THE WATER PUMP 8 Water pump seal 1 9 Oil seal 1 0 Bearing 1 A Water pump housing 1 For assembly reverse the disassembly procedure ...

Page 245: ... pump housing 1 2 2 Remove bearing 1 oil seal 2 NOTE _ Tap out the bearing and oil seal from the out side of the water pump housing 3 Water pump housing 1 2 3 EBS00139 CHECKING THE WATER PUMP 1 Check water pump housing 1 impeller 2 water pump housing cover 3 Cracks damage wear Replace 2 Check bearing Rough movement Replace impeller shaft gear Pitting wear Replace 3 1 2 ...

Page 246: ...er lubricate the water pump seal sur face with oil or grease NOTE _ Install the water pump seal with the special tools È Push down 3 Measure impeller shaft tilt CAUTION _ Make sure that the rubber damper and rub ber damper holder are bottom with the impeller 1 Straightedge 2 Impeller Mechanical seal installer 3 90890 04132 Water pump seal installer YM 33221 A Middle driven shaft bearing driver 4 9...

Page 247: ...6 7 TROUBLESHOOTING DETAILS 6 11 CHECKING THE SPEED SENSOR 6 25 CHECKING THE INTAKE AIR PRESSURE SENSOR 6 26 CHECKING THE INTAKE AIR TEMPERATURE SENSOR 6 27 THROTTLE BODY 6 28 CHECKING THE INJECTOR 6 31 CHECKING THE THROTTLE BODY 6 31 INSTALLING THE THROTTLE BODY ASSEMBLY 6 31 CHECKING THE FUEL PUMP AND PRESSURE REGULATOR OPERATION 6 32 CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR 6 33 ...

Page 248: ...tank 4 Fuel hose 5 Fuel pump 6 Intake air pressure sensor 7 Lean angle sensor 8 Battery 9 Intake air temperature sensor 0 ECU A Air filter case B Relay unit fuel pump relay C Speed sensor D Throttle position sensor E Crankshaft position sensor F Fuel injector G Coolant temperature sensor H Spark plug 1 2 3 4 5 6 7 8 9 0 A B C D E F G H ...

Page 249: ...CK GREEN BLACK GLAY L B L Y Lg B Y Sb Br L R L W R L L B R B L W Br G W L Y R L R B R B R L B L Y P L G Pu R G W G L L G Y B W O O B Br L Y W O G Y G Lg Sb L W MAIN HARNESS WIRE SUB LEAD A B L R W R W R L R L B Y Y L B Y B B B B P Y B L B L B L R B L G R B R B W R Pu R L G Pu R W O O L B L W L B L Y L B L Y G P L L B Y Y Y G Y G Y B B B G L L L Y B R R R R R R B B B B B B R R R Br G L W L W Br Br ...

Page 250: ...t H Neutral indicator light J Self diagnosis signal coupler K ECU L Ignition coil M Spark plug N Fuel injector O Intake air temperature sensor P Coolant temperature sensor Q Speed sensor R Throttle position sensor S Intake air pressure sensor T Lean angle sensor U Fuel pump W Neutral switch Engine stop switch f Ignition fuse FUEL INJECTION SYSTEM ...

Page 251: ... diagnostic function this mode pro vides an appropriate substitute characteristic operation and alerts the rider of the detected malfunction by illuminating the engine trou ble warning light After the engine has been stopped the low est fault code number displays on the FI diagnostic tool This fault code remains stored in the memory of the ECU until it is deleted Engine trouble warning light fault...

Page 252: ...circuit detected Able Able 16 Throttle position sensor Stuck throttle position sensor detected Able Able 21 Coolant temperature sensor Coolant temperature sensor open or short circuit detected Able Able 22 Intake air temperature sen sor open or short circuit Intake air temperature sensor open or short circuit detected Able Able 30 Lean angle sensor latch up detected The vehicle has overturned Unab...

Page 253: ...action Refer to Rein statement method in TROUBLESHOOTING DETAILS Turn the main switch to OFF turn the main switch back to ON and then check if the fault code number is still displayed Repairs completed Fault code number not displayed Erasing the malfunction history The malfunction history is stored even if the main switch is turned OFF The malfunction history must be erased in the diagnostic mode ...

Page 254: ...move the self diagnosis signal coupler cap and then connect the FI diagnostic tool 1 as shown 3 Turn the main switch to ON and start the engine NOTE _ Coolant temperature and engine revolution appear on the LCD of the FI diagnostic tool POWER LED Green comes on If a malfunction is detected in the system WARNING LED Orange comes on 4 Stop the engine NOTE _ If a malfunction is detected in the system...

Page 255: ...WN buttons NOTE _ The diagnostic code number appears on the LCD D01 D70 To decrease the selected diagnostic code number press the DOWN button Press the DOWN button for 1 second or longer to automatically decrease the diagnostic code numbers To increase the selected diagnostic code number press the UP button Press the UP button for 1 second or longer to auto matically increase the diagnostic code n...

Page 256: ...perature sensor Malfunction in ECU Improperly installed intake air temperature sensor D05 30 The vehicle has overturned Overturned Malfunction in ECU D08 33 Malfunction detected in the primary lead of the ignition coil Open or short circuit in wire harness Malfunction in ignition coil Malfunction in ECU Malfunction in a component of ignition cut off circuit sys tem D30 D32 41 Lean angle sensor ope...

Page 257: ...mber increases when the rear wheel is rotated The number is cumulative and does not reset each time the wheel is stopped D08 Lean angle sensor Remove the lean angle sensor and incline it more than 65 degrees Upright 0 4 1 4 Overturned 3 7 4 4 D09 Fuel system voltage battery voltage Approximately 12 0 Set the engine stop switch to RUN and then compare with the actually measured battery voltage If t...

Page 258: ...injector for five times every second Illuminates the WARNING on the FI diagnostic tool and engine trouble warning light Check the operating sound of the injector five times D50 Fuel pump relay Actuates the fuel pump relay for five times every second Illuminates the WARNING on the FI diagnostic tool and engine trouble warning light The engine trouble warning light is OFF when the relay is ON and th...

Page 259: ...ion sensor cou pler Main wire harness ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler securely 3 Open or short circuit in wire har ness Repair or replace if there is an open or short circuit Between the crankshaft position sensor coupler and ECU cou pler blue yellow blue yellow ...

Page 260: ...ns that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler securely Turning the main switch to ON 2 Open or short circuit in wire har ness Repair or replace if there is an open or short circuit Between intake air pressure sen sor coupler and ECU coupler black blue black blue pink pink blue blue 3 Defective intake air pressure se...

Page 261: ... operating it at idle 2 Intake air pressure sensor mal function at intermediate electrical potential Check and repair the connec tion Replace it if there is a malfunc tion 3 Connections Intake air pressure sensor cou pler Main wire harness ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the...

Page 262: ...oupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler securely 3 Open or short circuit in wire har ness Repair or replace if there is an open or short circuit Between throttle position sensor coupler and ECU coupler blue blue yellow yellow black blue black blue 4 Throttle position sensor lead wire open circ...

Page 263: ...pen or short circuit detected Diagnostic code No D06 Coolant temperature sensor Order Item components and probable cause Check or maintenance job Reinstatement method 1 Installed condition of coolant tem perature sensor Check the installed area for loose ness or pinching Turning the main switch to ON 2 Connections Coolant temperature sensor cou pler Main wire harness ECU coupler Check the coupler ...

Page 264: ...re sensor coupler Main wire harness ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler securely 3 Open or short circuit in wire har ness Repair or replace if there is an open or short circuit Between air temperature sensor coupler and ECU coupler brown white brown white black white...

Page 265: ...ed unless the main switch is first turned OFF 2 Installed condition of the lean angle sensor Check for looseness or pinching 3 Connections Lean angle sensor coupler Main wire harness ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler securely 4 Defective lean angle sensor Execute t...

Page 266: ...eck the locking condition of the connector and coupler If there is a malfunction repair it and connect the coupler or con nector securely Starting the engine and operating it at idle 2 Open or short circuit in wire har ness Repair or replace if there is an open or short circuit Between ignition coil connector and ECU coupler main wire har ness red black red black orange orange 3 Defective ignition...

Page 267: ...at may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler securely Turning the main switch to ON 2 Open or short circuit in lead wire Repair or replace if there is an open or short circuit Between lean angle sensor cou pler and ECU coupler blue blue yellow green yellow green black blue black blue 3 Defective lean angle switch Execut...

Page 268: ...on of the coupler If there is a malfunction repair it and connect the coupler securely Starting the engine and activating the vehicle speed sensor by oper ating the vehi cle at 20 to 30 km h A 2 Open or short circuit in speed sen sor lead Repair or replace if there is an open or short circuit Between speed sensor coupler and ECU coupler blue blue white white black blue black blue A 3 Gear for dete...

Page 269: ... a malfunction repair it and connect the coupler securely Starting the engine and activating the vehicle speed sensor by oper ating the vehi cle at 20 to 30 km h B 2 Open circuit in neutral switch lead Repair or replace if there is an open circuit Between neutral switch connec tor and relay unit coupler sky blue sky blue Between relay unit coupler and ECU coupler light green brown black yellow sky...

Page 270: ...an open or short circuit Between relay unit coupler and ECU coupler blue red blue red red blue red blue Between relay unit coupler and battery terminal brown green red Between relay unit coupler and handlebar switch coupler red black red black 3 Malfunction or open circuit in fuel pump relay Execute the diagnostic mode Code No D09 Replace if defective If there is no malfunction with the relay unit...

Page 271: ...apter 3 3 Malfunction in rectifier regulator Replace if defective Refer to CHARGING SYSTEM in chapter 8 4 Open or short circuit in wire har ness Repair or replace if there is an open or short circuit Between battery and main switch red red Between main switch and igni tion fuse brown blue brown blue Between ignition fuse and ECU brown brown Fault code No 50 Symptom Faulty ECU memory When this malf...

Page 272: ... rear wheels and slowly rotate them d Measure the voltage of white and black blue With each full rotation of the rear wheels the voltage reading should cycle from 0 6 V to 4 8 V to 0 6 V to 4 8 V Output voltage reading cycle 0 6 V to 4 8 V to 0 6 V to 4 8 V Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe white 1 Negative tester probe black blue 2 L P W O R B W B L 1...

Page 273: ... V to the intake air pressure sensor coupler as shown b Turn the main switch to ON c Measure the intake air pressure sensor out put voltage Intake pressure sensor output voltage 3 00 4 00 V Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe pink blue terminal 1 Negative tester probe black blue terminal 2 L B L P L 1 2 FUEL INJECTION SYSTEM ...

Page 274: ... replace it 2 Check air temperature sensor resistance Out of specification Replace a Connect the pocket tester Ω 100 to the air temperature sensor terminal as shown b Measure the air temperature sensor resis tance Intake air temperature sensor resistance 2 21 2 69 kΩ at 20 C 68 F Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe brown white 1 Negative tester probe bla...

Page 275: ... FENDERS AND FUEL TANK in chapter 3 Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 1 Fuel hose 1 Disconnect 2 Fuel injector coupler 1 Disconnect 3 Intake air pressure sensor coupler 1 Disconnect 4 Throttle position sensor coupler 1 Disconnect 5 Throttle cable housing cover 1 6 Throttle cable 1 7 Hose air filter joint to throttle body left side 1 Disconnect 8 Hose air filter joint to thro...

Page 276: ...ks 9 Fast idle plunger inlet hose 1 10 Fast idle plunger outlet hose 1 Disconnect 11 Intake air pressure sensor hose 1 12 Intake air pressure sensor 1 13 Intake manifold clamp screw 1 Loosen 14 Air filter case joint clamp screw 1 Loosen 15 Throttle body assembly 1 For installation reverse the removal pro cedure THROTTLE BODY ...

Page 277: ...tor Remove the parts in the order listed 1 Throttle position sensor 1 2 Fuel injection pipe 1 3 Fuel injector 1 4 Fast idle plunger unit 1 5 Throttle body 1 CAUTION _ The throttle body should not be disas sembled For installation reverse the removal pro cedure THROTTLE BODY ...

Page 278: ...y caustic carburetor cleaning solution b Blow out all of the passages with com pressed air INSTALLING THE THROTTLE BODY ASSEMBLY 1 Install throttle body assembly NOTE Align the projection a on the throttle body assembly with the slot b throttle body joint 2 Install throttle cable 3 Adjust throttle lever free play Refer to ADJUSTING THE THROTTLE LEVER FREE PLAY in chapter 3 4 Adjust engine idling s...

Page 279: ...m the fuel pump remove the fuel hose connector holder first and next insert a slotted head screw driver etc in the slot part a of the fuel hose connector cover 2 then slide it in the direction of the arrow and remove the fuel hose Before removing the hose place a few rags in the area under where it will be removed d Connect the pressure gauge 3 and adapter 4 to the fuel pump and fuel hose e Start ...

Page 280: ...asure the maximum throttle position sen sor resistance Out of specification Replace the throttle position sensor e Connect the pocket tester Ω 1k to the terminals of the throttle position sensor f While slowly opening the throttle check that the throttle position sensor resistance is within the specified range Resistance does not change or it changes abruptly Replace the throttle position sensor P...

Page 281: ...le position sensor c Measure the throttle position sensor volt age d Adjust the throttle position sensor angle so that the voltage is within the specified range e After adjusting the throttle position sensor angle tighten the throttle position sensor screws 3 Throttle position sensor resis tance 0 5 1 kΩ at 20 C 68 F yellow black blue Positive digital circuit tester probe yellow 1 Negative digital...

Page 282: ... FRONT BRAKE PADS 7 14 REAR BRAKE PADS 7 15 REPLACING THE FRONT BRAKE PADS 7 16 REPLACING THE REAR BRAKE PADS 7 18 FRONT BRAKE MASTER CYLINDER 7 20 REAR BRAKE MASTER CYLINDER 7 22 REMOVING THE FRONT BRAKE LIGHT SWITCH 7 25 CHECKING THE MASTER CYLINDERS 7 25 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER 7 26 ASSEMBLING THE REAR BRAKE MASTER CYLINDER 7 26 INSTALLING THE FRONT BRAKE MASTER CYLINDER 7 27...

Page 283: ...RING KNUCKLES 7 54 INSTALLING THE TIE RODS 7 54 FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES 7 55 REMOVING THE FRONT ARMS 7 57 CHECKING THE FRONT ARMS 7 57 CHECKING THE FRONT SHOCK ABSORBER ASSEMBLIES 7 57 CHECKING THE BALL JOINTS 7 58 INSTALLING THE FRONT ARMS 7 59 REAR SHOCK ABSORBER AND RELAY ARM 7 60 HANDLING THE REAR SHOCK ABSORBER AND GAS CYLINDER 7 62 DISPOSING OF A REAR SHOCK ABSORBER AN...

Page 284: ...arts in the order listed The following procedure applies to both of the front wheels Place the vehicle on a level surface WARNING _ Securely support the vehicle so there is no danger of it falling over 1 Front wheel 1 Refer to INSTALLING THE FRONT WHEELS 2 Brake disc guard outer 1 3 Cotter pin 1 Refer to INSTALLING THE FRONT WHEEL HUBS 4 Axle nut 1 ...

Page 285: ...e caliper assembly 1 NOTE _ Do not squeeze the brake lever when the brake caliper is off of the brake discs as the brake pads will be forced shut 6 Wheel hub 1 7 Brake disc 1 For installation reverse the removal pro cedure FRONT AND REAR WHEELS ...

Page 286: ...e order listed Place the vehicle on a level surface WARNING _ Securely support the vehicle so there is no danger of it falling over 1 Rear wheel 2 2 Cotter pin 2 Refer to INSTALLING THE REAR WHEEL HUBS 3 Axle nut 2 4 Wheel hub 2 For installation reverse the removal pro cedure FRONT AND REAR WHEELS ...

Page 287: ...cing the tire ride conservatively to allow the tire to be properly seated in the rim Failure to do so may cause an accident resulting in vehicle damage and possible operator injury Wheel runout limit Radial 2 2 0 mm 0 08 in Lateral 3 2 0 mm 0 08 in EBS00385 CHECKING THE WHEEL HUBS 1 Check wheel hubs 1 Cracks damage Replace splines wheel hub 2 Wear damage Replace the wheel hub È Front É Rear È É FR...

Page 288: ... the wheel bearings reverse the above sequence Use a socket that matches outside diameter of bearing outer race to drive in bearing CAUTION _ Do not strike the center race or balls of the bearing Contact should be made only with the outer race 1 EBS00389 CHECKING THE BRAKE DISCS 1 Check brake discs Galling damage Replace 2 Measure brake disc deflection Out of specification Check the wheel runout b...

Page 289: ...scs NOTE Install the brake discs with their spot faced side facing the bolt heads EBS00392 INSTALLING THE FRONT WHEELS 1 Install brake disc guards outer 1 NOTE _ Install the brake disc guard outer with the punched burrs 2 on the wheel hub side 2 Install wheels NOTE _ The arrow mark 1 on the tire must point in the direction of rotation È of the wheel FRONT AND REAR WHEELS ...

Page 290: ... pins 3 a Apply a rust preventive lubricant to the threads on both sides of the rear axle and to the wheel hub surfaces that contact the rear axle washers b Tighten the rear axle nuts to specification c Loosen the rear axle nuts completely d Retighten the rear axle nuts to specification NOTE Do not loosen the axle nut after torquing it If an axle nut slot is not aligned with the cotter pin hole on...

Page 291: ...rder listed Rear wheels rear wheel hubs Refer to FRONT AND REAR WHEELS 1 Bolt 2 Refer to REMOVING THE REAR AXLE and INSTALLING THE REAR AXLE 2 Nut 1 3 Conical spring washer 1 4 Rear axle pinch bolt 4 5 Brake caliper 1 NOTE _ 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 pad will be force shut ...

Page 292: ...E 7 Rear axle 1 8 Circlip 1 9 Driven sprocket sprocket bracket 1 1 Refer to INSTALLING THE DRIVEN SPROCKET 10 Circlip 1 11 Brake caliper bracket 1 12 Spacer 1 13 Rear axle hub 1 14 Oil seal 2 15 Bearing 2 16 Bearing 2 17 Spacer 1 For installation reverse the removal pro cedure REAR AXLE AND REAR AXLE HUB ...

Page 293: ...ace 2 Remove bolts 1 3 Loosen nut 2 NOTE _ Apply the brake pedal so that the rear axle does not turn when loosening the nut Use the rear axle nut wrench 46 mm 3 4 Loosen drive chain Refer to ADJUSTING THE DRIVE CHAIN SLACK in chapter 3 5 Elevate the rear wheels by placing the suit able stand under the frame 6 Remove rear wheels wheel hubs nut 2 conical spring washer Rear axle nut wrench 46 mm 9089...

Page 294: ...suitable socket 2 on the axle end and tap it with a soft hammer then pull out the rear axle to the left 8 Remove circlip driven sprocket bracket 1 EBS00395 CHECKING THE REAR AXLE 1 Check rear axle runout a Out of specification Replace WARNING _ Do not attempt to straighten a bent axle Rear axle runout limit 1 5 mm 0 06 in CHECKING THE DRIVEN SPROCKET 1 Check driven sprocket Refer to SWINGARM AND D...

Page 295: ...ET 1 Install driven sprocket NOTE Make sure that the blunt edged corner a of the driven sprocket is facing outward a EBS00397 INSTALLING THE REAR AXLE 1 Install conical spring washer 1 nut NOTE Install the conical spring washer with the con vex side of the washer facing outward as shown 2 Install rear wheels Refer to FRONT AND REAR WHEELS 1 ...

Page 296: ...ng the rear axle b Tighten bolts 3 4 Adjust drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK in chapter 3 Rear axle nut wrench 46 mm 90890 01498 Axle nut wrench 46 mm YM 37134 T R Nut 240 Nm 24 0 m kg 170 ft lb LOCTITE T R Bolt 7 Nm 0 7 m kg 5 1 ft lb LOCTITE 2 1 3 3 1 REAR AXLE AND REAR AXLE HUB ...

Page 297: ...brake pads Remove the parts in the order listed The following procedure applies to both of the front brake calipers Refer to FRONT AND REAR WHEELS Front wheel 1 Brake caliper mounting bolt 2 Refer to REPLACING THE FRONT BRAKE PADS 2 Brake pad retaining bolt 2 3 Brake pad pad shim 2 1 4 Brake pad spring 1 For installation reverse the removal pro cedure FRONT AND REAR BRAKES ...

Page 298: ... Part Q ty Remarks Removing the rear brake pads Remove the parts in the order listed 1 Brake caliper mounting bolt 2 Refer to REPLACING THE REAR BRAKE PADS 2 Brake pad retaining bolt 2 3 Brake pad insulator pad shim 2 1 1 4 Brake pad spring 1 For installation reverse the removal pro cedure FRONT AND REAR BRAKES ...

Page 299: ...aces or plastic parts as this may cause dam age disconnect any hydraulic connection as this would require the entire brake sys tem to be disassembled drained cleaned properly filled and bled after reassembly EBS00404 REPLACING THE FRONT BRAKE PADS The following procedure applies to both of the front brake calipers NOTE _ It is not necessary to disassemble the brake calipers and brake hoses to repl...

Page 300: ...iper c Tighten the brake caliper bleed screw d Install new brake pads and a new brake pad spring e Install the retaining bolts and brake caliper 3 Check brake fluid level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 4 Check brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 T R Brake caliper bleed screw 6 Nm 0 6 m k...

Page 301: ...pad spring as a set a Connect a suitable hose 1 tightly to the brake caliper bleed screw 2 Put the other end of this hose into an open container b Loosen the brake caliper bleed screw and then turn the brake caliper piston 3 clock wise until section a of the brake caliper pis ton is level with the surface of the brake caliper body NOTE Align the recesses b in the brake caliper pis ton with the bra...

Page 302: ...per piston e Install the retaining bolts and brake caliper 3 Check brake fluid level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 4 Check brake lever or brake pedal operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 T R Brake pad retaining bolt 17 Nm 1 7 m kg 12 ft lb Brake caliper mounting bolt 34 Nm 3 4 m kg 24 ft lb c FRONT ...

Page 303: ...luid Drain 1 Brake fluid reservoir cap 1 2 Brake fluid reservoir diaphragm 1 3 Front brake light switch 1 4 Brake lever 1 5 Union bolt 1 Refer to INSTALLING THE FRONT BRAKE MASTER CYLINDER 6 Copper washer 2 7 Brake hose 1 Disconnect 8 Brake master cylinder bracket 1 9 Brake master cylinder 1 For installation reverse the removal pro cedure FRONT AND REAR BRAKES ...

Page 304: ...embling the front brake mas ter cylinder Remove the parts in the order listed 1 Dust boot 1 Refer to ASSEMBLING THE FRONT BRAKE MASTER CYLINDER 2 Circlip 1 3 Brake master cylinder kit 1 For assembly reverse the disassembly procedure FRONT AND REAR BRAKES ...

Page 305: ... ft Ib Order Job Part Q ty Remarks Removing the rear brake master cyl inder Remove the parts in the order listed Right foot protector Refer to SEAT FENDERS AND FUEL TANK in chapter 3 Brake fluid Drain 1 Brake fluid reservoir hose 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 hos...

Page 306: ... m kg 22 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib Order Job Part Q ty Remarks 7 Union bolt 1 Refer to INSTALLING THE REAR BRAKE MAS TER CYLINDER 8 Copper washer 2 9 Brake hose 1 Disconnect 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 removal pro cedure FRONT AND REAR BRAKES ...

Page 307: ...g the rear brake mas ter cylinder Remove the parts in the order listed 1 Hose joint 1 2 Brake master cylinder kit 1 Refer to ASSEMBLING THE REAR BRAKE MASTER CYLINDER 3 Brake master cylinder 1 For assembly reverse the disassembly procedure FRONT AND REAR BRAKES ...

Page 308: ...der 1 Wear scratches Replace the brake mas ter cylinder assembly brake master cylinder body Cracks damage Replace brake fluid delivery passage brake master cylinder body Blockage Blow out with compressed air È Front É Rear È É 2 Check brake master cylinder kit Scratches wear damage Replace as a set È Front É Rear É È 3 Check front brake master cylinder reservoir 1 front brake master cylinder reser...

Page 309: ...fluid only before installation Whenever a master cylinder is disassem bled replace the piston seals and dust seals Recommended brake fluid DOT 4 EBS00416 ASSEMBLING THE REAR BRAKE MASTER CYLINDER WARNING _ All internal brake components should be cleaned and lubricated with new brake fluid only before installation Whenever a master cylinder is disassem bled replace the piston seals and dust seals R...

Page 310: ...t are equal T R 7 Nm 0 7 m kg 5 1 ft lb 2 Install copper washers brake hose union bolt NOTE _ Tighten the union bolt while holding the brake hose as shown Turn the handlebar to the left and to the right to check that the brake hose does not touch other parts throttle cable wire harness leads etc Correct if necessary WARNING _ Proper brake hose routing is essential to insure safe vehicle operation ...

Page 311: ...e fluids may result in a harm ful reaction and lead to poor brake perfor mance Be careful that water does not enter the brake master cylinder when refilling Water will significantly lower the boiling point of the brake fluid and may result in vapor lock 4 Air bleed brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 5 Check brake fluid level Brake fluid level is under the LOWER ...

Page 312: ...uid may damage painted surfaces or plastic parts Always clean up spilled brake fluid immediately WARNING _ Use only the designated quality brake fluid other brake fluids may deteriorate the rubber seals causing leakage and poor brake performance Refill with the same type of brake fluid mixing brake fluids may result in a harm ful chemical reaction and lead to poor brake performance Be careful that...

Page 313: ...id level Brake fluid level is under the LOWER level line Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 brake pedal height Out of specification Adjust Refer to ADJUSTING THE REAR BRAKE in chapter 3 Brake pedal height 15 3 mm 0 60 in FRONT AND REAR BRAKES ...

Page 314: ...ts in the order listed The following procedure applies to both of the front brake calipers Brake fluid Drain Front wheel Refer to FRONT AND REAR WHEELS 1 Union bolt 1 Refer to INSTALLING THE FRONT BRAKE CALIPERS 2 Copper washer 2 3 Brake hose 1 Disconnect 4 Brake pad retaining bolt 2 Loosen 5 Brake caliper mounting bolt 2 6 Brake caliper assembly 1 For installation reverse the removal pro cedure F...

Page 315: ...er listed The following procedure applies to both of the front brake calipers 1 Brake pad retaining bolt 2 2 Brake pad pad shim 2 1 3 Brake pad spring 1 4 Caliper bracket 1 5 Caliper piston 2 Refer to DISASSEMBLING THE FRONT BRAKE CALIPERS and ASSEMBLING THE FRONT BRAKE CALIPERS 6 Dust seal 2 7 Caliper piston seal 2 8 Bleed screw 1 For assembly reverse the disassembly procedure FRONT AND REAR BRAK...

Page 316: ...ng the rear brake caliper Remove the parts in the order listed Brake fluid Drain 1 Parking brake cable 1 Disconnect 2 Union bolt 1 Refer to INSTALLING THE REAR BRAKE CALI PER 3 Copper washer 2 4 Brake hose 1 Disconnect 5 Brake caliper mounting bolt 2 6 Brake caliper assembly 1 For installation reverse the removal pro cedure FRONT AND REAR BRAKES ...

Page 317: ...cknut 1 3 Parking brake arm 1 Refer to ASSEMBLING THE REAR BRAKE CALIPER 4 Parking brake shaft 1 5 Rubber boot 1 6 Parking brake bracket mounting bolt 1 7 Parking brake case bracket 1 8 Parking brake case 1 9 Gasket 1 0 Brake pad retaining bolt 2 A Brake pad insulator pad shim 2 1 1 B Brake pad spring 1 C Caliper bracket 1 FRONT AND REAR BRAKES ...

Page 318: ...rks D Brake caliper piston 1 Refer to DISASSEMBLING THE REAR BRAKE CALIPER and ASSEMBLING THE REAR BRAKE CALIPER E Dust seal 1 F Caliper piston seal 1 G Bleed screw 1 For assembly reverse the disassembly procedure FRONT AND REAR BRAKES ...

Page 319: ... caliper pistons dust seals 1 caliper piston seals 2 a Blow compressed air into the hose joint opening to force out the caliper piston from the brake caliper body WARNING _ Never try to pry out the caliper piston Cover the caliper piston with a rag Be careful not to get injured when the piston is expelled from the caliper cylinder b Remove the dust seals and the caliper pis ton seals 1 2 FRONT AND...

Page 320: ...eal and caliper piston seal 1 2 3 EBS00429 CHECKING THE FRONT AND REAR BRAKE CALIPERS WARNING _ All internal brake components should be cleaned in new brake fluid only Do not use solvents as they will cause seals to swell and distort Recommended brake component replacement schedule Brake pads As required Piston seals dust seals Every two years Brake hoses Every four years Brake fluid Replace when ...

Page 321: ... dust seals whenever the brake caliper is disas sembled È Front É Rear 1 2 3 1 2 È 2 3 1 É EBS00431 ASSEMBLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the front brake calipers WARNING _ All internal brake components should be cleaned and lubricated with new brake fluid only before installation Replace the caliper piston seals when ever a brake caliper is disassembled 1 ...

Page 322: ...on a of the brake caliper piston is level with the surface of the brake caliper body NOTE Align an end b of the groove in the brake cali per piston with the punch mark c on the brake caliper body 3 Install parking brake shaft 1 NOTE When installing the parking brake shaft the punch mark a should be between the marks b with the parking brake shaft fully turned in 1 a b c 1 1 a b 1 4 Install rubber ...

Page 323: ...der reservoir CAUTION _ Brake fluid may damage painted surfaces or plastic parts Always clean up spilled brake fluid immediately WARNING _ Use only the designated quality brake fluid other brake fluids may deteriorate the rubber seals causing leakage and poor brake performance Refill with the same type of brake fluid mixing brake fluids may result in a harm ful chemical reaction and lead to poor b...

Page 324: ...LING THE REAR BRAKE CALIPER 1 Install brake caliper assembly brake caliper mounting bolts 1 brake hose 2 copper washers 3 union bolt 4 CAUTION _ When installing the brake hose on the brake caliper make sure that the brake pipe touches the projection a on the brake caliper WARNING _ Proper brake hose routing is essential to insure safe vehicle operation Refer to CABLE ROUTING in chapter 2 1 2 New 3...

Page 325: ...ds may result in a harm ful chemical reaction and lead to poor brake performance Be careful that water does not enter the master cylinder when refilling Water will significantly lower the boiling point of the brake fluid and may result in vapor lock 3 Air bleed brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 4 Check brake fluid level Brake fluid level is below the LOWER leve...

Page 326: ...t g Tighten the locknut 1 h Set the parking brake lever and wait more than 5 minutes i Release the parking brake lever j Repeat step a to g k Slide the rubber cover to its original posi tion WARNING 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...

Page 327: ...bar Remove the parts in the order listed 1 Handlebar cover 1 2 Plastic band 3 3 Front brake light switch 1 Refer to REMOVING THE FRONT BRAKE LIGHT SWITCH AND CLUTCH SWITCH 4 Brake master cylinder holder 1 1 Refer to INSTALLING THE BRAKE MASTER CYLINDER 5 Throttle lever assembly holder 1 1 6 Spacer 1 7 Clutch switch 1 Refer to REMOVING THE FRONT BRAKE LIGHT SWITCH AND CLUTCH SWITCH 8 Parking brake ...

Page 328: ... T R 23 Nm 2 3 m kg 17 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 4 Nm 0 4 m kg 2 9 ft Ib Order Job Part Q ty Remarks 11 Handlebar grip 2 Refer to REMOVING THE HANDLEBAR GRIPS and INSTALLING THE HAN DLEBAR GRIPS 12 Handlebar holder 2 Refer to INSTALLING THE HANDLE BAR 13 Handlebar 1 For installation reverse the removal pro cedure ...

Page 329: ...r Push the fastener when removing the clutch switch out of the clutch lever holder EBS00447 REMOVING THE HANDLEBAR GRIPS 1 Remove handlebar grips 1 NOTE _ Blow compressed air between the handlebar and handlebar grip and gradually push the grip off the handlebar EBS00448 CHECKING THE HANDLEBAR 1 Check handlebar 1 Bends cracks damage Replace WARNING _ Do not attempt to straighten a bent handle bar a...

Page 330: ...he punched mark 1 forward 2 CAUTION _ First tighten the bolt 3 on the front side of the handlebar holder and then tighten the bolt 4 on the rear side T R 23 Nm 2 3 m kg 17 ft lb EBS00450 INSTALLING THE HANDLEBAR GRIPS 1 Install handlebar grips 1 NOTE _ Before applying the adhesive wipe off grease or oil on the handlebar surface a with a lacquer thinner Install the handlebar grips to the handlebar ...

Page 331: ...3 in a 1 2 EBS00453 INSTALLING THE BRAKE MASTER CYLINDER 1 Install brake master cylinder spacer throttle lever assembly NOTE _ The UP mark on the brake master cylinder bracket should face up Engage the indentations a in the spacer with the lobes b on the throttle lever assem bly and brake master cylinder a b T R 7 Nm 0 7 m kg 5 1 ft lb T R 4 Nm 0 4 m kg 2 9 ft lb STEERING SYSTEM ...

Page 332: ... Remove the parts in the order listed Front fender fuel tank Refer to SEAT FENDERS AND FUEL TANK in chapter 3 1 Pitman arm 1 Refer to INSTALLING THE PITMAN ARM 2 Lock washer 1 Refer to INSTALLING THE LOCK WASHER 3 Steering stem bushing 2 4 Spacer 2 5 Oil seal 2 6 Steering stem 1 7 Oil seal 1 8 Oil seal 1 ...

Page 333: ... CHAS STEERING SYSTEM Order Job Part Q ty Remarks 9 Bearing retainer 1 Refer to REMOVING THE BEARING RETAINER and INSTALLING THE BEARING RETAINER 10 Bearing 1 For installation reverse the removal pro cedure ...

Page 334: ...pt to straighten a bent stem this may dangerously weaken the stem 2 Check oil seals 1 steering stem bushings 2 Wear damage Replace New EBS00457 INSTALLING THE BEARING RETAINER 1 Install bearing retainer Damper rod holder 30 mm 90890 01327 YM 01327 T R 65 Nm 6 5 m kg 47 ft lb EBS00459 INSTALLING THE LOCK WASHER 1 Install lock washer bolts 2 Bend the lock washer tab along a flat side of the bolts Ne...

Page 335: ...LLING THE PITMAN ARM 1 Install pitman arm washer nut clip NOTE _ Make sure that the threads of the steering stem washers nuts and the installation sur faces of the pitman arm are free of grease and oil T R 180 Nm 18 0 m kg 130 ft lb ...

Page 336: ...es to both of the tie rods and steering knuckles Front wheel brake disc Refer to FRONT AND REAR WHEELS Front brake caliper Refer to FRONT AND REAR BRAKES 1 Brake disc guard inner 1 2 Tie rod 2 Refer to INSTALLING THE TIE RODS 3 Pitman arm 1 4 Front guard 1 5 Lower front arm 1 6 Upper front arm 1 7 Steering knuckle 1 Refer to REMOVING THE STEERING KNUCKLES For installation reverse the removal pro c...

Page 337: ...ovement Free play Replace the tie rod end Turns roughly Replace the tie rod end 2 Check tie rods Bends damage Replace EBS00464 CHECKING THE STEERING KNUCKLES 1 Check steering knuckles Damage pitting Replace EBS00465 INSTALLING THE TIE RODS 1 Install tie rods left and right NOTE _ The tie rod side which must be installed on the outside has grooves 1 2 Adjust toe in Refer to ADJUSTING THE TOE IN in ...

Page 338: ...llowing procedure applies to both of the front arms and front shock absorber assemblies Front wheel brake disc Refer to FRONT AND REAR WHEELS Front brake caliper Refer to FRONT AND REAR BRAKES Steering knuckle Refer to STEERING SYSTEM 1 Nut washer bolt 1 1 1 2 Nut bolt 2 2 Refer to REMOVING THE FRONT ARMS and INSTALLING THE FRONT ARMS 3 Lower front arm 1 4 Nut bolt 1 1 5 Upper front arm 1 6 Nut bo...

Page 339: ...RMS AND FRONT SHOCK ABSORBER ASSEMBLIES Order Job Part Q ty Remarks 9 Spacer 1 10 Spacer 2 11 Bushing 6 12 Circlip 1 13 Rubber boot boot retaining ring 1 1 14 Ball joint 1 For installation reverse the removal pro cedure ...

Page 340: ...l movement is tight or rough or if there is binding check the bushings 2 Remove front arm È È É É EBS00470 CHECKING THE FRONT ARMS 1 Check front arms 1 Bends damage Replace 2 Check bushings 2 Wear damage Replace 1 1 2 2 EBS00488 CHECKING THE FRONT SHOCK ABSORBER ASSEMBLIES The following procedure applies to both of the front shock absorber assemblies 1 Check shock absorber Oil leaks Replace the fr...

Page 341: ...e outside of the lower front arm b Remove the circlip 1 boot retaining ring 2 and rubber boot 3 Use the ball joint remover and installer set c Install the body 4 long bolt 5 base 6 and attachment 7 onto ball joint d Hold the body 4 in place while turning in the long bolt 5 to remove the ball joint 0 from the lower front arm A e Remove the ball joint remover Ball joint remover 90890 01474 YM 01474 ...

Page 342: ...ust be aligned with the projection on the head of the ball joint B g Remove the ball joint remover h Install a new circlip NOTE _ Always use a new ball joint set EBS00473 INSTALLING THE FRONT ARMS The following procedure applies to both of the front arms 1 Install upper front arm 1 lower front arm 2 NOTE _ Be sure to position the bolts upper and lower so that the bolt head faces forward Apply lith...

Page 343: ... ft Ib T R 43 Nm 4 3 m kg 31 ft Ib T R 43 Nm 4 3 m kg 31 ft Ib Order Job Part Q ty Remarks Removing the rear shock absorber and relay arm Remove the parts in the order below Rear wheels Refer to REAR WHEELS 1 Self locking nut bolt spacer 1 1 1 Refer to REMOVING THE REAR SHOCK ABSORBER 2 Self locking nut bolt spacer 1 1 1 3 Self locking nut bolt 1 1 4 Self locking nut bolt 1 1 5 Rear shock absorber...

Page 344: ...5 Nm 5 5 m kg 40 ft Ib T R 43 Nm 4 3 m kg 31 ft Ib T R 43 Nm 4 3 m kg 31 ft Ib Order Job Part Q ty Remarks 8 Self locking nut bolt 1 1 9 Relay arm 1 10 Spacer oil seal bushing 1 2 2 Refer to INSTALLING THE RELAY ARM AND CONNECTING ARM 11 Connecting arm 1 12 Dust cover 4 13 Spacer 1 14 Spacer 1 15 Bushing 4 Refer to INSTALLING THE RELAY ARM AND CONNECTING ARM For installation reverse the removal pr...

Page 345: ...r or gas cylinder Do not subject the rear shock absorber or gas cylinder to an open flame or any other source of high heat High heat can cause an explosion due to excessive gas pressure Do not deform or damage the rear shock absorber or gas cylinder in any way If the rear shock absorber gas cylinder or both are damaged damping performance will suffer EBS00486 DISPOSING OF A REAR SHOCK ABSORBER AND...

Page 346: ...ECKING THE REAR SHOCK ABSORBER 1 Check shock absorber Oil leaks Replace the rear shock absorber assembly shock absorber rod Bends damage Replace the rear shock absorber assembly spring Fatigue Replace the rear shock absorber assembly Move the spring up and down gas cylinder Damage gas leaks Replace the rear shock absorber assembly EBS00489 CHECKING THE RELAY ARM AND CONNECTING ARM 1 Check relay ar...

Page 347: ...s when installing Installed depth of bushing a 1 0 mm 0 04 in 2 Install bushings 1 oil seals 2 to relay arm NOTE Apply lithium soap based grease on the bush ings when installing Installed depth of bushing a 6 5 mm 0 26 in New INSTALLING THE REAR SHOCK ABSORBER 1 Install connecting arm relay arm rear shock absorber NOTE When installing the rear shock absorber lift up the swingarm ...

Page 348: ...ts in the order below Rear axle hub Refer to REAR AXLE AND REAR AXLE HUB Rear shock absorber Refer to REAR SHOCK ABSORBER AND RELAY ARM 1 Rear axle pinch bolt 4 2 Dust seal 1 3 Swingarm skid plate 1 4 Drive chain guide 1 1 5 Pivot shaft nut 1 6 Pivot shaft 1 7 Swingarm 1 Refer to REMOVING THE SWINGARM 8 Drive sprocket cover 1 9 Drive chain guide 2 1 ...

Page 349: ...ive sprocket nut 1 Refer to INSTALLING THE DRIVE SPROCKET 11 Lock washer 1 12 Drive sprocket 1 13 Drive chain 1 14 Dust cover washer 2 2 15 Spacer 2 16 Oil seal 2 17 Bushing 2 Refer to INSTALLING THE SWING ARM 18 Bearing 2 For installation reverse the removal pro cedure ...

Page 350: ...the swingarm side play È by moving it from side to side If side play is noticeable check the spacers bearings bushings and frame pivot c Check the swingarm vertical movement É by moving it up and down If vertical movement is tight or rough or if there is binding check the spacers bear ings bushings and frame pivot 2 Remove pivot shaft nut washer pivot shaft swingarm T R Pivot shaft nut 100 Nm 10 0...

Page 351: ... of 15 links on the inner side a and outer side b of the pin and cal culate the length between pin centers Length c between pin centers inner dimension a outer dimension b 2 15 link section c of the drive chain Out of specification Replace the drive chain drive sprocket and rear wheel sprocket as a set NOTE _ While measuring the 15 link section push down on the drive chain to increase its ten sion...

Page 352: ...ts e g benzine or a coarse brush to clean the drive chain High pressure methods could force dirt or water into the drive chain s internal parts and solvents will deteriorate the O rings A coarse brush can also damage the O rings Therefore use only kerosene to clean the drive chain Don t soak the drive chain in kerosene for more than ten minutes Kerosene will dam age the O rings 4 Check O rings 1 D...

Page 353: ... EBS00497 INSTALLING THE SWINGARM 1 Install bearings 1 bushings 2 to swingarm NOTE _ Apply the lithium soap based grease on the bushings when installing Installed depth of bearing a 5 mm 0 20 in Installed depth of bushing b 9 mm 0 35 in 1 2 2 1 b a EBS00498 INSTALLING THE DRIVE SPROCKET 1 Install drive sprocket 1 lock washer 2 drive sprocket nut 3 2 Bend the lock washer tab along a flat side of th...

Page 354: ...CTRIC STARTING SYSTEM 8 14 CIRCUIT DIAGRAM 8 14 STARTING CIRCUIT CUT OFF SYSTEM OPERATION 8 15 TROUBLESHOOTING 8 16 STARTER MOTOR 8 20 CHECKING THE STARTER MOTOR 8 22 ASSEMBLING THE STARTER MOTOR 8 23 CHARGING SYSTEM 8 25 CIRCUIT DIAGRAM 8 25 TROUBLESHOOTING 8 26 LIGHTING SYSTEM 8 28 CIRCUIT DIAGRAM 8 28 TROUBLESHOOTING 8 29 CHECKING THE LIGHTING SYSTEM 8 30 SIGNALING SYSTEM 8 33 CIRCUIT DIAGRAM 8...

Page 355: ...lebar switch 6 Lean angle sensor 7 Battery 8 Starter relay 9 Main fuse 0 Circuit breaker fan A Fuse box B Radiator fan motor relay C Headlight relay D Relay unit E Tail brake light F ECU G Speed sensor H Rear brake light switch I Neutral switch J Reverse switch K Coolant temperature sensor L Ignition coil M Rectifier regulator N Resistor O Radiator fan P Headlight ...

Page 356: ...When 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 illustration 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 NOTE _ indicates a continuity of elect...

Page 357: ...s and also for continuity between the ter minals Refer to CHECKING SWITCH CONTINUITY Damage wear Repair or replace Improperly connected Properly connect Incorrect continuity reading Replace the switch LO OFF Y R L Y HI L Y Y R Br L B R B B PUSH OFF L B B ON OFF Br R B OFF ON R Br R Br B B B B B B 1 2 3 4 5 6 0 7 8 9 ...

Page 358: ...4 ELEC CHECKING THE SWITCHES 1 Light switch 2 Engine stop switch 3 Start switch 4 Main switch 5 Front brake light switch 6 Clutch switch 7 Fuses 8 Reverse switch 9 Neutral switch 0 Rear brake light switch ...

Page 359: ...oth TYPES OF BULBS The bulbs used on this vehicle are shown in the illustration on the left Bulbs a and b are used for the headlights and usually use a bulb holder that must be detached before removing the bulb The majority of these types of bulbs can be removed from their respective socket by turning them counterclockwise CHECKING THE CONDITION OF THE BULBS The following procedure applies to all ...

Page 360: ...s soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 2 Check bulb for continuity with the pocket tester No continuity Replace NOTE _ Before checking for continuity set the pocket tester to 0 and to the Ω 1 range a Connect the positive tester probe to termi nal 1 and the negative tester probe to ter minal 2 and check the continuity b Connect the positive tester probe ...

Page 361: ...et for continuity in the same manner as described in the bulb section however note the following a Install a good bulb into the bulb socket b Connect the pocket tester probes to the respective leads of the bulb socket c Check the bulb socket for continuity If any of the readings indicate no continuity replace the bulb socket Pocket tester 90890 03112 Analog pocket tester YU 03112 C CHECKING THE BU...

Page 362: ... L B L Y P L Br W B Y G W G L L G Y B W O O B Br L Y W O G Y G Lg Sb L W MAIN HARNESS WIRE SUB LEAD A B L R W R W R L R L B Y Y L B Y B B B B P L Y B L B W B L R B Br W R B R B R L B Y Br W W O O L B L W L B L Y L B L Y G P L L L B Y Y Y G Y G Y B B B G L L L Y B R R R R R R B B B B B B R R R Br G L W L W Br Br B Y B Y R L O G O G B W O G O B O B G Y W L G L Y G R L G L W L L R L W Lg Lg Br Lg Br ...

Page 363: ...bleshoot with the following special tool s EBS01043 YES NO EBS01044 YES NO The ignition system fails to operate no spark or intermittent spark Ignition checker 90890 06754 Opama pet 4000 spark checker YM 34487 Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 Main and ignition fuses Check the main and ignition fuses for con tinuity Refer to CHECKING THE FUSES in chapter 3 Are the main an...

Page 364: ...on is it of the correct type and is its gap within spec ification Re gap or replace the spark plug 4 Ignition spark gap Disconnect the ignition coil from the spark plug Connect the ignition checker 1 as shown 2 Ignition coil Set the main switch to ON Measure the ignition spark gap a Crank the engine by pushing the start switch and gradually increase the spark gap until a misfire occurs Minimum ign...

Page 365: ... ignition coil connectors from the ignition coil terminals Connect the pocket tester Ω 1 to the ignition coil as shown Positive tester probe red black lead terminal 1 Negative tester probe orange lead terminal 2 Measure the primary coil resistance Primary coil resistance 3 4 4 6 Ω at 20 C 68 F Connect the pocket tester Ω 1k to the ignition coil as shown Positive tester probe red black lead termina...

Page 366: ...the handle bar switch 9 Crankshaft position sensor resistance Disconnect the crankshaft position sensor coupler from the wire harness Connect the pocket tester Ω 100 to the crankshaft position sensor coupler as shown Positive tester probe blue yellow 1 Negative tester probe green white 2 Measure the crankshaft position sensor resistance Crankshaft position sensor resis tance 192 288 Ω at 20 C 68 F...

Page 367: ...ster probe blue 1 Negative tester probe yellow green 2 Set the main switch to ON Measure the lean angle sensor voltage Lean angle sensor voltage Less than 65 10 a Approximately 1 V More than 65 10 b Approximately 4 V Is the lean angle sensor OK Replace the lean angle sensor 11 Wiring Check the entire ignition system s wiring Refer to CIRCUIT DIAGRAM Is the ignition system s wiring properly connect...

Page 368: ... L R B R B R L B L Y P L Br W B Y G W G L L G Y B W O O B Br L Y W O G Y G Lg Sb L W MAIN HARNESS WIRE SUB LEAD A B L R W R W R L R L B Y Y L B Y B B B B P L Y B L B W B L R B Br W R B R B R L B Y Br W W O O L B L W L B L Y L B L Y G P L L L B Y Y Y G Y G Y B B B G L L L Y B R R R R R R B B B B B B R R R Br G L W L W Br Br B Y B Y R L O G O G B W O G O B O B G Y W L G L Y G R L G L W L L R L W Lg ...

Page 369: ...n and the engine stop switch is in the RUN position the starter motor can be operated only if 1 Battery 2 Main fuse 3 Main switch 4 Engine stop switch 5 Starting circuit cutoff relay 6 Clutch switch 7 Neutral switch 8 Start switch 9 Starter relay 0 Starter motor A Ignition fuse The transmission is in neutral the neutral switch is closed or You pull in the clutch lever the clutch switch is closed 1...

Page 370: ... YU 03112 C 1 Main and ignition fuses Check the main and ignition fuses for con tinuity Refer to CHECKING THE FUSES in chapter 3 Are the main and ignition fuses OK Replace the fuse s 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C 68 F Is the battery OK Clean the battery terminals Recharge or r...

Page 371: ...hite and blue black Replace the relay unit Lg B Y Sb Br L R L W R L L B R B L W Br G 4 1 5 3 2 5 Relay unit diode Remove the relay unit from the wire har ness Connect the pocket tester Ω 1 to the relay unit as shown Measure the relay unit for continuity as fol lows NOTE _ The pocket tester 90890 03112 and the ana log pocket tester YU 03112 C readings are shown in the following table Positive teste...

Page 372: ...in switch for continuity Refer to CHECKING THE SWITCHES Is the main switch OK Replace the main switch R R L W Br R B 1 2 4 3 8 Engine stop switch Check the engine stop switch for continu ity Refer to CHECKING THE SWITCHES Is the engine stop switch OK Replace the handle bar switch 9 Neutral switch Check the neutral switch for continuity Refer to CHECKING THE SWITCHES Is the neutral switch OK Replac...

Page 373: ... YES NO 12 Wiring Check the entire starting system s wiring Refer to CIRCUIT DIAGRAM Is the starting system s wiring properly connected and without defects The starting system circuit is OK Properly connect or repair the starting system s wiring ...

Page 374: ... Nm 1 0 m kg 7 2 ft Ib Order Job Part Q ty Remarks Removing the starter motor Remove the parts in the order listed Exhaust pipe Refer to ENGINE REMOVAL in chapter 4 1 Starter motor lead 1 Disconnect 2 Parking brake cable 1 3 Starter motor 1 For installation reverse the removal pro cedure ...

Page 375: ...e the parts in the order listed 1 O ring 1 2 Front bracket 1 Refer to ASSEMBLING THE STARTER MOTOR 3 Square ring 1 4 Lock washer 1 5 Shim 1 6 Armature assembly 1 7 Starter motor yoke 1 8 Brush holder assembly 1 9 Square ring 1 0 Shim 1 A Rear bracket 1 For assembly reverse the disassembly procedure ...

Page 376: ...it the commutator NOTE _ The mica of the commutator must be undercut to ensure proper operation of the commutator Commutator wear limit 27 mm 1 06 in Mica undercut 0 7 mm 0 03 in a 4 Measure armature assembly resistances commutator and insulation Out of specification Replace the starter motor a Measure the armature assembly resis tances with the pocket tester Pocket tester 90890 03112 Analog pocke...

Page 377: ...Replace the brush springs as a set 7 Check gear teeth Damage wear Replace the gear 8 Check bushing bearing oil seal Damage wear Replace the defective part s Brush length wear limit 5 0 mm 0 20 in Brush spring force 7 65 10 01 N 780 1021 gf 27 54 36 03 oz EBS00515 ASSEMBLING THE STARTER MOTOR 1 Install brush seat 1 NOTE _ Align the projection a on the rear bracket with the slot b in the yoke STARTE...

Page 378: ...8 24 ELEC STARTER MOTOR 2 Install yoke bracket NOTE _ Align the match marks a on the yoke with the match mark b on the front bracket and the rear bracket b b a ...

Page 379: ... G B G Y B BLACK BLACK Y L Br R L Y Y R L B Br B R B Br L B R B B Lg G L W L G Y O B Br R R L W Br W W W B R W W W W W W Sb L W B L R W R W R L R L B Y Y L B Y B B Y Y Y G Y G Y B B B G L L L Y B R R R R R R B B B B B B R R R Br G L W L W Br B B Y B Y R L O B G Br L B L R Sb Sb Sb Sb L W Br G R B Lg Br L Br L Br L Br Y Br L Br Y Br Y Br R Br R B L B Br R Y R Br Br Br R W W W W W W A 2 1 3 6 7 4 i ...

Page 380: ...t with the following special tool s EBS01043 YES NO EBS01044 YES NO The battery is not being charged Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 Main fuse Check the main fuse for continuity Refer to CHECKING THE SWITCHES Is the main fuse OK Replace the main fuse 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit...

Page 381: ...ion The charging circuit is OK 4 Stator coil resistance Disconnect the A C magneto coupler from the wire harness Connect the pocket tester Ω 1 to the stator coils Tester lead White terminal 1 Tester lead White terminal 2 Tester lead White terminal 1 Tester lead White terminal 3 Tester lead White terminal 2 Tester lead White terminal 3 Measure the stator coil resistance Stator coil resistance 0 248...

Page 382: ... Y Y R L B Br B R B Br L B R B B Lg G L W L G Y O B Br R R L W Br W W W B R W W W W W W G W Lg Sb L W B L R W R W R L R L B Y Y L B Y B B Y Y Y G Y G Y B B B G L L L Y B R R R R R R B B B B B B R R R Br G L W L W Br Br B Y B Y R L O B G Y Br L B L R Sb Sb Sb Sb L W Br G R B Lg Br L Br L Br L Br Y Br L Br Y Br Y Br R Br R B L B Br R Y R Br Br Br R W W W W W W A 2 1 3 6 7 4 i h g Z Y X b a c 5 f e d...

Page 383: ...nalog pocket tester YU 03112 C 1 Main and headlight fuses Check the main and headlight fuses for continuity Refer to CHECKING THE FUSES in chapter 3 Are the main and headlight fuses OK Replace the fuse s 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C 68 F Is the battery OK Clean the battery te...

Page 384: ...cket Check the headlight bulb and socket for continuity Refer to CHECKING THE BULBS AND BULB SOCKETS Are the headlight bulb and socket OK Replace the head light bulb socket or both 2 Headlight relay Remove the headlight relay Connect the pocket tester Ω 1 and bat tery 12 V to the headlight relay as shown È high beam É low beam Positive battery terminal yellow 1 Negative battery terminal black 2 Po...

Page 385: ...V of yellow 1 or green 2 on the headlight coupler wire harness side Is the voltage within specification This circuit is OK The wiring circuit from the main switch to the headlight cou pler is faulty and must be repaired G Y B DC20V 1 3 2 È É 1 Tail brake light Disconnect the tail brake light coupler tail brake light assembly side Connect the battery 12 V to the corre sponding coupler terminals as ...

Page 386: ...Positive tester probe blue 1 Negative tester probe black 2 Set the main switch to ON Set the light switch to LO or HI Measure the voltage DC 12 V of blue 1 on the tail brake light coupler wire har ness side Is the voltage within specification This circuit is OK The wiring circuit from the main switch to the tail brake light coupler is faulty and must be repaired Y L B L Y B 1 2 ...

Page 387: ...R W R W R L R L B Y Y L B Y B B B B P L Y B L B W B L R B Br W R B R B R L B Y Br W W O O L B L W L B L Y L B L Y G P L L L B Y Y Y G Y G Y B B B G L L L Y B R R R R R R B B B B B B R R R Br G L W L W Br Br B Y B Y R L O G O G B W O G O B O B G Y W L G L Y G R L G L W L L R L W Lg Lg Br Lg Br B G Y L Y Br G W Sb Y R R L L B L R Sb Sb Sb Sb L W Br G R B Lg Br L Br L Br L Br Y Br L Br Y Br Y Br R Br...

Page 388: ...ing sys tem fuses for continuity Refer to CHECKING THE FUSES in chapter 3 Are the main ignition and signaling sys tem fuses OK Replace the fuse s 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C 68 F Is the battery OK Clean the battery terminals Recharge or replace the battery 3 Main switch Chec...

Page 389: ...e light 2 Brake light switches Check the brake light switches for continu ity Refer to CHECKING THE SWITCHES Is the brake light switch OK Replace the brake light switch L Y B 1 2 3 Voltage Connect the pocket tester DC 20 V to the tail brake light coupler wire harness side as shown Positive tester probe yellow 1 Negative tester probe black 2 Set the main switch to ON Pull in the brake lever or push...

Page 390: ...ly 2 Neutral switch Check the neutral switch for continuity Refer to CHECKING THE SWITCHES Is the neutral switch OK Replace the neutral switch W L G L Sb Br O B G Y 1 2 3 Relay unit diode Remove the relay unit from the wire har ness Connect the pocket tester Ω 1 to the relay unit as shown Measure the relay unit for continuity as fol lows NOTE _ The pocket tester 90890 03112 and the ana log pocket ...

Page 391: ...iring circuit from the main switch to the indicator light assembly coupler is faulty and must be repaired W L G L Sb Br O B G Y Lg G L W L G Y O B Br 1 2 1 Indicator light assembly Disconnect the indicator light assembly coupler from the wire harness Connect the battery 12V to the indicator light assembly coupler as shown When the jumper leads are connected to the terminals the reverse indicator l...

Page 392: ... 12 V of brown 1 and green blue 2 at the indicator light assembly coupler wire harness side Is the voltage within specification The wiring circuit from the main switch to the indicator light assembly coupler is faulty and must be repaired W L G L Sb Br O B G Y Lg G L W L G Y O B Br 1 2 1 Indicator light assembly Disconnect the indicator light assembly coupler from the wire harness Connect the batt...

Page 393: ...and then let it cool to the specified temperature indicated in the table Check the coolant temperature sensor for continuity at the temperatures indicated in the table Test step Coolant temperature Resistance 1 20 C 68 F 2 32 2 59 kΩ 2 80 C 176 F 0 310 0 326 kΩ 3 110 C 230 F 0 140 0 144 kΩ WARNING _ Handle the coolant temperature sensor with special care Never subject the coolant temperature senso...

Page 394: ...mbly after the main switch is set to ON Is the voltage within specification This circuit is OK The wiring circuit from the main switch to the indicator light assembly coupler is faulty and must be repaired W L G L Sb Br O B G Y Lg G L W L G Y O B Br 1 2 1 Indicator light assembly Disconnect the indicator light assembly coupler from the wire harness Connect the battery 12V to the indicator light as...

Page 395: ...09 85 4 32 in mm a Less than 60 mA More than 109 85 4 32 in mm a More than 135 mA Is the fuel sender OK Replace the fuel pump R L O G B B a 1 2 DC 5A 3 Resistor Disconnect the resistor coupler from the wire harness Connect the pocket tester Ω 100 to the resistor terminal as shown Positive tester probe black 1 Negative tester probe black 2 Measure the resistor resistance Resistor resistance 68 Ω at...

Page 396: ...B L Y P L Br W B Y G W G L L G Y B W O O B Br L Y W O G Y G Lg Sb L W MAIN HARNESS WIRE SUB LEAD A B L R W R W R L R L B Y Y L B Y B B B B P L Y B L B W B L R B Br W R B R B R L B Y Br W W O O L B L W L B L Y L B L Y G P L L L B Y Y Y G Y G Y B B B G L L L Y B R R R R R R B B B B B B R R R Br G L W L W Br Br B Y B Y R L O G O G B W O G O B O B G Y W L G L Y G R L G L W L L R L W Lg Lg Br Lg Br B G...

Page 397: ...041 YES NO The radiator fan motor fails to turn Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 Main and ignition fuses Check the main and ignition fuses for con tinuity Refer to CHECKING THE FUSES in chapter 3 Are the main and ignition fuses OK Replace the fuse s 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit v...

Page 398: ...1 and bat tery 12 V to the radiator fan motor relay terminal as shown CAUTION When checking the radiator fan motor relay reversing the polarity connections will damage the relay If a damaged relay is installed and the main switch is turned to ON the ECU will also be damaged Check the radiator fan motor relay of conti nuity Positive battery lead brown 1 Negative battery lead yellow red 2 Positive t...

Page 399: ...e coolant temperature sensor in a container filled with coolant 2 NOTE _ Make sure the coolant temperature sensor terminals do not get wet Place a thermometer 3 in the coolant Slowly heat the coolant and then let it cool to the specified temperature indicated in the table Check the coolant temperature sensor for continuity at the temperatures indicated in the table Test step Coolant temperature Re...

Page 400: ...sensor operate properly Replace the coolant temperature sensor 8 Wiring Check the entire cooling system s wiring Refer to CIRCUIT DIAGRAM Is the cooling system s wiring properly connected and without defects Replace the ECU Properly connect or repair the cooling system s wiring ...

Page 401: ... 2 FAULTY GEAR SHIFTING 9 2 HARD SHIFTING 9 2 SHIFT PEDAL DOES NOT MOVE 9 2 JUMPS OUT GEAR 9 2 CLUTCH SLIPPING DRAGGING 9 3 CLUTCH SLIPPING 9 3 CLUTCH DRAGGING 9 3 OVERHEATING 9 3 OVERHEATING 9 3 OVERCOOLING 9 3 COOLING SYSTEM 9 3 FAULTY BRAKE 9 4 POOR BRAKING EFFECT 9 4 SHOCK ABSORBER MALFUNCTION 9 4 MALFUNCTION 9 4 UNSTABLE HANDLING 9 4 UNSTABLE HANDLING 9 4 LIGHTING SYSTEM 9 5 HEADLIGHT DOES NO...

Page 402: ...y crankshaft position sensor Switches and wiring Faulty main switch Faulty engine stop switch Broken or shorted wiring Faulty neutral switch Faulty start switch Faulty clutch switch Loose connections Starter motor Faulty starter motor Faulty starter relay Faulty relay unit Faulty starter clutch Battery Faulty battery COMPRESSION SYSTEM Cylinder and cylinder head Loose spark plug Loose cylinder hea...

Page 403: ...logged air filter element Air intake system Clogged or leaking air duct FUEL SYSTEM Fuel pump Faulty fuel pump EBS00541 FAULTY GEAR SHIFTING HARD SHIFTING Refer to CLUTCH DRAGGING SHIFT PEDAL DOES NOT MOVE Shift shaft Bent shift shaft Shift cam shift forks Groove jammed with impurities Seized shift fork Bent shift fork guide bar Transmission Seized transmission gear Jammed impurities Incorrectly a...

Page 404: ...ear bushing Bent clutch plate Swollen friction plate Broken clutch boss Engine oil Improper quality high viscosity Deteriorated oil EBS00546 OVERHEATING OVERHEATING Ignition system Improper spark plug gap Improper spark plug heat range Faulty ECU Fuel system Clogged air filter element Compression system Heavy carbon build up Engine oil Improper oil level Improper oil viscosity Inferior oil quality...

Page 405: ...ALFUNCTION Bent or damaged damper rod Damaged oil seal lip Fatigued shock absorber spring Leaking oil or gas EBS00552 UNSTABLE HANDLING UNSTABLE HANDLING Handlebar Improperly installed or bent Steering Incorrect toe in Bent steering stem Improperly installed steering stem Damaged bearing or bearing race Bent tie rods Deformed steering knuckles Tires Uneven tire pressures on both sides Incorrect ti...

Page 406: ...tor Incorrect connection Improperly grounded Poor contacts main or light switch Bulb life expired Faulty headlight relay TAIL BRAKE LIGHT DOES NOT COME ON Too many electrical accessories Incorrect connection Wrong tail brake light LED HEADLIGHT BULB BURNT OUT Improper bulb Faulty battery Faulty rectifier regulator Improperly grounded Faulty main switch Faulty light switch Bulb life expired ...

Page 407: ...n angle sensor U Fuel pump V Resistor W Neutral switch X Clutch switch Y Handlebar switch Z Light switch Engine stop switch Start switch Headlight relay _ Headlight a Tail brake light b Rear brake light switch c Front brake light switch d Headlight fuse e Signaling system fuse f Ignition fuse g Radiator fan motor h Radiator fan motor relay i Circuit breaker fan motor COLOR CODE B Black Br Brown G ...

Page 408: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN ...

Page 409: ...B L W Br G W L Y R L R B R B R L B L Y P L Br W B Y G W G L L G Y B W O O B Br L Y W O G Y G Lg Sb L W MAIN HARNESS WIRE SUB LEAD A B L R W R W R L R L B Y Y L B Y B B B B P L Y B L B W B L R B Br W R B R B R L B Y Br W W O O L B L W L B L Y L B L Y G P L L L B Y Y Y G Y G Y B B B G L L L Y B R R R R R R B B B B B B R R R Br G L W L W Br Br B Y B Y R L O G O G B W O G O B O B G Y W L G L Y G R L G...

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