manualshive.com logo in svg

Yamaha YZ 2016 Series, Owner'S Service Manual


Share
Download
background image

CABLE ROUTING DIAGRAM

2-32

1. Clutch cable

2. Throttle cable (return)

3. Throttle cable (pull)

4. Engine stop switch lead

5. Coupler for connecting optional part

6. Engine stop switch coupler

7. Rectifier/regulator coupler

8. AC magneto lead

9. Starter knob/idle screw

10. Starter motor lead

11. Radiator fan fuse

12. Starting circuit cut-off relay (no identification 

tape)

13. Diode

14. Holder plate

15. Left of the vehicle:radiator fan motor relay (blue 

tape)

Right of the vehicle:main relay (red tape)

16. Neutral switch lead

17. Engine bracket

18. Front engine bracket

19. Plastic locking tie

20. Radiator hose

21. Neutral switch coupler

22. Crankshaft position sensor coupler

23. Tension arm

24. Wire harness

25. Tank rail

26. Rectifier/regulator

27. Rectifier/regulator bracket

28. Rear frame

29. Side cover 5

30. Crankcase cover

31. Crankcase

32. Lead holder

33. Frame

A. Pass the engine stop switch lead between the 

frame and the cable holder.

B. Insert the coupler for connecting optional part into 

the connector, and fix it to the bracket.

C. Insert and fix the engine stop switch coupler to 

the bracket.

D. Insert and fix the rectifier/regulator coupler to the 

bracket.

E. Pass the AC magneto lead to the front of the ve-

hicle beyond the starter knob/idle screw and to 

the rear of the vehicle beyond the radiator. No 

pinch is allowed between the radiator and the 

tension arm.

F. Pass the starter motor lead so that the lead does 

not contact with the end of the bolt.

G. Place the rear grommet of the starter motor lead 

matching the rear end of the side cover 5.

H. Insert the radiator fan motor fuse into the protru-

sion of the holder plate.

I. Place the diode on top of the rear fender on the 

inner side of the rear frame.

J. Bring the neutral switch lead into line with the 

crankcase cover with no sag allowed.

K. Route the AC magneto lead under the starter 

clutch cover.

L. Pass the neutral switch lead to the inside of the 

front engine bracket (the side of the vehicle).

M. Insert the plastic locking tie into the bracket hole 

and clamp the clutch cable. Clamp it so that the 

lock of the plastic locking tie faces downward, 

and then cut off the end of the plastic locking tie.

N. Pass the clutch cable with no downward sag al-

lowed.

O. Place the grommet of the clutch cable so that it 

contacts the radiator hose. Route the clutch cable 

outside the neutral switch lead, AC magneto lead 

and starter motor lead.

P. Route each lead so that the leads are not pinched 

between the radiator hose and the frame.

Q. 40 mm (1.57 in)

R. Clamp the clutch cable, AC magneto lead, neu-

tral switch lead and starter motor lead by the plas-

tic locking tie. Make sure that they are clamped at 

the positioning tapes in the clutch cable and the 

starter motor lead. Make the lock on the plastic 

locking tie face the front of the vehicle, and cut 

the end.

S. Clamp the starter motor lead to the inside of the 

tension arm with a plastic locking tie. Clamp it so 

that the lock of the plastic locking tie faces up-

ward and outward, and do not cut off the end of 

the plastic locking tie. Route the lead so that there 

is no slack at the bottom from the clamp position 

onwards.

T. After connecting the neutral switch coupler, at-

tach the coupler cover.

U. After connecting the crankshaft position sensor 

coupler, attach the coupler cover.

V. Pass the rectifier/regulator lead to the inside of 

the tension arm (the side of the vehicle).

W. Pass the main harness to the front of the radiator 

hose (the front of the vehicle), and to the inside of 

the clutch cable (the side of the vehicle).

X. Pass the engine stop switch lead between the 

coupler for connecting optional part and the tank 

rail, with the lead on the main harness side facing 

the top of the vehicle.

Y. Insert the starter motor lead completely into the 

end of the side cover 5.

Z. Clamp the clutch cable at the front of the lead (the 

front of the vehicle).

AA.Insert the clip of the plastic locking tie into the 

frame. Face the lock of the plastic locking tie for-

ward, and then cut off the end.

Summary of Contents for YZ 2016 Series

Page 1: ...UAL YZ250FXG B29 28199 11 LIT 11626 29 53 YZ250FXG 2016 q Read this manual carefully before operating this vehicle PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2015 07 0 3 1 E B29 28199 11_cover_12mm in...

Page 2: ...e Take care of your Yamaha with legendary Yamalube oils lubricants and care products They re formulated and approved by the toughest judges we know the Yamaha engineering teams that know your Yamaha f...

Page 3: ...2015 by Yamaha Motor Corporation U S A 1st Edition June 2015 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohi...

Page 4: ...ANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MACHINE DO NOT ATTEMPT TO OPERATE THIS MACHINE UNTIL YOU HAVE ATTAINED A SATISFACTORY KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YO...

Page 5: ...HIGHLY FLAMMABLE Always turn off the engine while refueling Take care to not spill any gasoline on the engine or exhaust system Never refuel in the vicinity of an open flame or while smoking GASOLINE...

Page 6: ...EASB296006 YAMAHA MOTOR CORPORATION U S A YZ MOTORCYCLE LIMITED WARRANTY...

Page 7: ...he section title To help identify parts and clarify procedure steps there are exploded diagrams 3 at the start of each removal and disassembly section Numbers 4 are given in the order of the jobs in t...

Page 8: ...FINITION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque Lithium soap based grease Wear limit...

Page 9: ...1 2 3 4 5 6 7 8 9 10 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING TUNING...

Page 10: ......

Page 11: ...ON 1 5 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 5 REPLACEMENT PARTS 1 5 GASKETS OIL SEALS AND O RINGS 1 6 LOCK WASHERS PLATES AND COTTER PINS 1 6 BEARINGS AND OIL SEALS 1 6 CIRCLIPS 1 6 BASIC SERVICE...

Page 12: ...E 1 20 AIR FILTER MAINTENANCE 1 20 STARTING A COLD ENGINE 1 20 STARTING A WARM ENGINE 1 22 BREAK IN PROCEDURES 1 22 MAINTENANCE AFTER BREAK IN 1 23 MAJOR MAINTENANCE 1 23 TORQUE CHECK POINTS 1 24 MOTO...

Page 13: ...asoline only 3FB 2415E 02 4AA 22259 80 WARNING This unit contains high pressure nitrogen gas Mishandling can cause explosion Read owner s manual for instructions Do not incinerate puncture or open 17D...

Page 14: ...those for the vehicle you have pur chased 1 Clutch lever 10 Radiator 2 Front brake lever 11 Coolant drain bolt 3 Throttle grip 12 Rear brake pedal 4 Start switch 13 Air filter 5 Radiator cap 14 Drive...

Page 15: ...ositive iden tification of the model you own 2 If your vehicle is stolen the authorities will need the number to search for and identify your vehicle EASB296012 VEHICLE IDENTIFICATION NUMBER The vehic...

Page 16: ...ed to pre vent mud dust and other foreign materials from entering the inside when the fuel hose is disconnected EASB296019 COUPLER FOR CONNECTING OPTIONAL PART The coupler 1 is used for connecting the...

Page 17: ...ach section 5 Flammable Keep servicing areas away from any source of fire 6 During servicing take special care not to re ceive an injury or a burn on the engine the exhaust pipe the silencer or the li...

Page 18: ...ASB296024 BEARINGS AND OIL SEALS Install bearings 1 and oil seals 2 with their manufacturer s marks or size symbols facing outward During installation of an oil seal make sure that its main lip faces...

Page 19: ...ry lead is difficult to disconnect due to rust on the battery terminal remove the rust us ing hot water ECA NOTICE Be sure to connect the battery leads to the correct battery terminals Reversing the b...

Page 20: ...en push the starter switch Be sure to wait for five seconds or lon ger before pushing the start switch after the en gine is stopped Checking the electrical system TIP Before checking the electrical sy...

Page 21: ...e to check the type of cou pler lock before disconnecting the cou pler ECA NOTICE When disconnecting a connector do not pull the leads Hold both sections of the connector and then disconnect the con n...

Page 22: ...terminals are connected securely Make sure all connections are tight 5 Check No continuity TIP If there is no continuity clean the terminals When checking the wire harness perform steps 1 to 4 As a q...

Page 23: ...se tool number starting with YM YU or ACC For others use tool number starting with 90890 Tool name Part number How to use Illustration Dial gauge stand set 90890 01252 Dial gauge set YU 03097 B This t...

Page 24: ...01403 Exhaust flange nut wrench YU A9472 This tool is used to remove or tighten the steering nut Cap bolt wrench 90890 01500 YM 01500 This tool is used to remove or tighten the base valve Cap bolt rin...

Page 25: ...is used to mount the pressure gauge Test harness S pressure sensor 3P 90890 03207 YU 03207 This tool is used to check the throttle position sensor input voltage Test harness lean angle sen sor 6P 9089...

Page 26: ...is used to hold the clutch when removing or in stalling the clutch boss secur ing nut Valve guide remover 5 90890 04097 Valve guide remover 5 0 mm YM 04097 This tool is used to replace the valve guid...

Page 27: ...Valve guide installer 4 5 90890 04117 Valve guide installer 4 5 mm YM 04117 This tool is used to replace the valve guide Valve guide reamer 4 5 90890 04118 Valve guide reamer 4 5 mm YM 04118 This too...

Page 28: ...ital tachometer 90890 06760 YU 39951 B This tool is used to measure the engine speed Three bond No 1215 90890 85505 This sealant Bond is used for crankcase mating sur face etc Tool name Part number Ho...

Page 29: ...clutch Pull the clutch lever toward the handlebar to disengage the clutch and release the lever to engage the clutch EASB296033 SHIFT PEDAL The shift pedal 1 has adopted a method of 1 down 5 ups pres...

Page 30: ...TING SCREW Starting a cold engine requires a larger amount of intake air which is supplied by the starter knob idle screw 1 Pulling the knob toward a turns ON the start er resulting in a larger amount...

Page 31: ...CONTROL FUNCTIONS 1 19 a 2...

Page 32: ...poisonous they can cause loss of consciousness and death in a very short time Always operate the ma chine in a well ventilated area ECA NOTICE Unlike a two stroke engine this engine cannot be kick sta...

Page 33: ...rter knob idle screw to its original posi tion EWA WARNING Since exhaust gas contains harmful ingre dients do not start or warm it up at an ill ventilated place or a closed narrow place 5 To stop the...

Page 34: ...il leaks or other problems 3 Then drive it for about 40 minutes at a throt tle opening of 3 4 or less 4 Make a pit stop again and thoroughly check mounted areas for looseness oil leaks or other proble...

Page 35: ...is connected Silencer Check the main body and stay for cracks Check for leaks Mounting bolts and nuts Check for looseness in mounted areas of parts as well as engine mounting bolts and engine brackets...

Page 36: ...absorber Link to swingarm Mounting of rear shock absorber Rear shock absorber and frame Mounting of swingarm Tightening of pivot shaft Wheel s Mounting of wheel Front Tightening of wheel axle Tighten...

Page 37: ...2 Plastic cover Tightening of number plate Tightening of front fender Tightening of fork leg protector Tightening of air scoop Left cover to rear frame Tightening of side cover Tightening of rear fend...

Page 38: ...may be used Be sure to rinse off any detergent residue using plenty of water as it is harmful to plastic parts Do not use any harsh chemical products on plastic parts Be sure to avoid using cloths or...

Page 39: ...ill wear away the paint TIP Consult a Yamaha dealer for advice on what products to use EASB296053 STORAGE Short term Always store your motorcycle in a cool dry place and if necessary protect it agains...

Page 40: ...es from becoming degraded in one spot 6 Cover the muffler outlet with a plastic bag to prevent moisture from entering it 7 Remove the battery and fully charge it Store it in a cool dry place and charg...

Page 41: ...FICATIONS 2 10 TIGHTENING TORQUES 2 12 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 12 ENGINE TIGHTENING TORQUES 2 13 CHASSIS TIGHTENING TORQUES 2 16 LUBRICATION POINTS AND LUBRICANT TYPES 2 19 ENGINE 2...

Page 42: ...8 EUR B299 AUS NZL ZAF B29A JPN Dimensions Overall length 2165 mm 85 2 in Overall width 825 mm 32 5 in Overall height 1280 mm 50 4 in Seat height 965 mm 38 0 in Wheelbase 1465 mm 57 7 in Ground cleara...

Page 43: ...L 0 88 US qt 0 73 Imp qt With oil filter removal 0 85 L 0 90 US qt 0 75 Imp qt Oil filter Oil filter type Paper Bypass valve opening pressure 40 0 80 0 kPa 0 40 0 80 kgf cm2 5 8 11 6 psi Oil pump Oil...

Page 44: ...clearance cold Intake 0 12 0 19 mm 0 0047 0 0075 in Exhaust 0 17 0 24 mm 0 0067 0 0094 in Valve dimensions Valve head diameter intake 30 90 31 10 mm 1 2165 1 2244 in Valve head diameter exhaust 24 90...

Page 45: ...ckwise Cylinder Bore 77 000 77 010 mm 3 0315 3 0319 in Taper limit 0 050 mm 0 0020 in Out of round limit 0 050 mm 0 0020 in Piston Piston to cylinder clearance 0 030 0 055 mm 0 0012 0 0022 in Limit 0...

Page 46: ...bending limit 0 10 mm 0 004 in Transmission Transmission type Constant mesh 6 speed Primary reduction system Spur gear Primary reduction ratio 3 353 57 17 Final drive Chain Secondary reduction ratio...

Page 47: ...injection sensor Crankshaft position sensor resistance 228 342 Intake air pressure sensor output voltage 3 61 3 67 V at 101 3 kPa 3 61 3 67 V at 1 01 kgf cm2 3 61 3 67 V at 14 7 psi Intake air tempera...

Page 48: ...ut limit 2 0 mm 0 08 in Wheel axle bending limit 0 50 mm 0 02 in Front tire Type With tube Size 90 90 21 54M Manufacturer model DUNLOP AT81F Rear tire Type With tube Size 110 100 18 64M Manufacturer m...

Page 49: ...type Coil spring Hydraulic damper Front fork travel 310 0 mm 12 20 in Fork spring free length 470 0 mm 18 50 in Limit 465 0 mm 18 31 in Fork spring installed length 470 0 mm 18 50 in Spring rate K1 4...

Page 50: ...0 mm 0 39 in from its free length Maximum Position in which the spring is turned in 18 mm 0 71 in from its free length Rebound damping adjusting positions Minimum 30 clicks out Standard 11 clicks out...

Page 51: ...le 3 6 4 4 V Output voltage over operating angle 0 3 1 4 V AC magneto Standard output 14 0 V 160 W at 5000 r min Stator coil resistance 0 528 0 792 W W Rectifier regulator Regulator type Three phase N...

Page 52: ...AL SPECIFICATIONS 2 11 Starter relay Amperage 180 0 A Coil resistance 4 18 4 62 Starting circuit cut off relay Coil resistance 75 6 92 5 Fuses Main fuse 15 0 A Spare fuse 15 0 A Radiator fan motor fus...

Page 53: ...To avoid warpage tighten multi fastener assemblies in a criss cross pattern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specif...

Page 54: ...Timing chain guide stopper plate exhaust side M6 1 10 Nm 1 0 m kgf 7 2 ft lbf Timing chain tensioner cap bolt M6 1 6 Nm 0 6 m kgf 4 3 ft lbf Timing chain tensioner bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lb...

Page 55: ...M6 12 12 Nm 1 2 m kgf 8 7 ft lbf Clutch cable holder bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Crankshaft end accessing screw M36 1 10 Nm 1 0 m kgf 7 2 ft lbf Timing mark accessing screw M14 1 6 Nm 0 6 m...

Page 56: ...sensor bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Damper assembly cover bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Starter clutch bolt M6 6 16 Nm 1 6 m kgf 12 ft lbf Starter motor bolt M6 1 12 Nm 1 2 m kgf 8 7 ft...

Page 57: ...m kgf 0 94 ft lbf Front fork protector bolt M6 6 5 Nm 0 5 m kgf 3 6 ft lbf Front fork protector and brake hose holder bolt M6 2 9 Nm 0 9 m kgf 6 5 ft lbf Throttle grip cap screw M5 2 3 8 Nm 0 38 m kg...

Page 58: ...lt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Rear brake caliper protector bolt M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Engine mounting bolt upper side M10 2 45 Nm 4 5 m kgf 33 ft lbf Engine mounting bolt front side M10...

Page 59: ...0 40 m kgf 2 9 ft lbf Seat set bracket and fuel tank screw M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Seat bolt M8 2 22 Nm 2 2 m kgf 16 ft lbf Left side cover bolt M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Right side cover...

Page 60: ...stem moving parts Water pump impeller shaft Oil pump rotors inner and outer Oil passage gasket Oil pump shaft Kick gear and ratchet wheel Kick shaft Kick idle gear inner surface Ratchet wheel and ratc...

Page 61: ...seal lip Pivot shaft outer surface Relay arm bearing and oil seal lip Relay arm thrust washer surface both sides Relay arm collar outer surface and bolt outer surface Relay arm bolt threads swingarm s...

Page 62: ...brake caliper piston outer surface Front brake caliper pin bolt and boot Front brake master cylinder push rod end Front brake master cylinder kit Rear brake caliper piston Rear brake caliper piston se...

Page 63: ...LUBRICATION POINTS AND LUBRICANT TYPES 2 22...

Page 64: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 23 EASB296064 LUBRICATION SYSTEM CHART AND DIAGRAMS EASB296065 LUBRICATION DIAGRAMS...

Page 65: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 24 1 Intake camshaft 2 Exhaust camshaft 3 Piston 4 Oil nozzle 5 Oil filter element 6 Oil pump 7 Oil strainer 8 Crankshaft 9 Drive axle 10 Main axle...

Page 66: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 25...

Page 67: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 26 1 Connecting rod 2 Crankshaft 3 Main axle 4 Oil strainer 5 Drive axle...

Page 68: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 27...

Page 69: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 28 1 Exhaust camshaft 2 Intake camshaft 3 Oil filter element 4 Oil pump...

Page 70: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 29...

Page 71: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 30 1 Camshaft 2 Oil pressure check bolt 3 Oil filter element 4 Oil pump...

Page 72: ...CABLE ROUTING DIAGRAM 2 31 EASB296066 CABLE ROUTING DIAGRAM...

Page 73: ...side of the front engine bracket the side of the vehicle M Insert the plastic locking tie into the bracket hole and clamp the clutch cable Clamp it so that the lock of the plastic locking tie faces do...

Page 74: ...CABLE ROUTING DIAGRAM 2 33...

Page 75: ...f the radiator B Route each lead so that the leads are not pinched between the tank rail and air filter joint C Insert the projection of the wire harness into the hole in the frame D Route the cylinde...

Page 76: ...CABLE ROUTING DIAGRAM 2 35...

Page 77: ...throttle position sensor lead to the out side of the tension arm the outside of the vehi cle D After connecting the throttle position sensor cou pler attach the cover E Pass the radiator breather hos...

Page 78: ...CABLE ROUTING DIAGRAM 2 37...

Page 79: ...the wire harness into the battery bracket hole and holder plate hole F After connecting the negative lead coupler place it on the right side of the battery G After installing the plastic cover to the...

Page 80: ...CABLE ROUTING DIAGRAM 2 39...

Page 81: ...ber plate band D Pass the engine stop switch lead between the head pipe and the cable guide E Pass the front brake hose to the front of the num ber plate F Pass the start switch lead and clutch switch...

Page 82: ...CABLE ROUTING DIAGRAM 2 41...

Page 83: ...all the two breather hoses so that the yellow paint mark is pointing forwards C Align the white paint mark to the protruding por tion of the pipe to install breather hose 3 D Protruding portion of the...

Page 84: ...CABLE ROUTING DIAGRAM 2 43...

Page 85: ...s shown and bring it into contact with the projection on the brake caliper B Pass the brake hose into the brake hose holders C If the brake hose interferes with the rear shock absorber correct its twi...

Page 86: ...CABLE ROUTING DIAGRAM 2 45...

Page 87: ...CHECKING THE ENGINE OIL LEVEL 3 14 CHANGING THE ENGINE OIL 3 14 ADJUSTING THE ENGINE IDLING SPEED 3 16 ADJUSTING THE VALVE CLEARANCE 3 17 CHASSIS 3 22 BLEEDING THE BRAKE SYSTEM 3 22 CHECKING THE BRAKE...

Page 88: ...3 35 LUBRICATING THE LEVERS 3 35 LUBRICATING THE PEDAL 3 35 LUBRICATING THE DRIVE CHAIN 3 35 LUBRICATING THE SIDESTAND 3 36 CHECKING THE CHASSIS FASTENERS 3 36 ELECTRICAL SYSTEM 3 37 CHECKING THE SPAR...

Page 89: ...to the list below ITEM After break in Every race about 2 5 hours Every third about 7 5 hours Every fifth about 12 5 hours As re quired Remarks VALVE Check the valve clearances The engine must be cold...

Page 90: ...d eliminate them Inspect and clean Check for warpage and re place the gasket CYLINDER Inspect and clean Inspect score marks Replace Inspect wear ENGINE OIL Inspect Check the engine oil amount Replace...

Page 91: ...air filter oil or equiv alent oil Replace BREATHER SYS TEM Inspect Check ventilation hose for cracks or damage and drain any deposits Replace Every two years SPARK PLUG Inspect and clean Check the el...

Page 92: ...d adjust Replace oil Replace oil seal Clean and grease oil seals and dust seals Lithium soap based grease PROTECTOR GUIDE Replace REAR SHOCK AB SORBER Inspect and adjust Lubricate After rain ride Grea...

Page 93: ...en Molybdenum disulfide grease RELAY ARM CON NECTING ROD Inspect lube and retighten Molybdenum disulfide grease SIDESTAND Lubricate Lithium soap based grease STEERING HEAD Inspect free play and retigh...

Page 94: ...and grease Check and clean throttle cable Check throttle cables on the throttle body for dirt and wear LEVERS Adjust clutch lever free play KICKSTARTER LE VER BRAKE PED AL FOOTREST Lubricate OUTSIDE N...

Page 95: ...Check the play of front brake and effect of front and rear brake 3 22 28 Drive chain Check drive chain slack and alignment Check that the drive chain is lubricated properly 3 28 4 66 67 Wheels Check...

Page 96: ...minutes until the coolant has settled EASB296073 CHECKING THE COOLING SYSTEM 1 Remove Seat Side cover left right Air scoop left right Refer to GENERAL CHASSIS on page 4 1 Air filter case cover Refer t...

Page 97: ...el Refer to CHECKING THE COOLANT LEV EL on page 3 8 EASB296075 CHECKING THE RADIATOR CAP 1 Check Seal radiator cap 1 Valve and valve seat 2 Crack damage Replace Exist fur deposits Clean or replace EAS...

Page 98: ...a cloth beforehand EASB296078 ADJUSTING THE CLUTCH LEVER FREE PLAY 1 Check Clutch lever free play a Out of specification Regulate 2 Adjust Clutch lever free play Handlebar side a Turn the adjuster 1 i...

Page 99: ...ned c Tighten the locknut EWA WARNING After adjusting the throttle grip free play turn the handlebar to the right and to the left to ensure that this does not cause the en gine idling speed to change...

Page 100: ...r filter element 3 Wash Air filter element EWA WARNING Do not use gasoline or organic acid alka line volatile oil for washing TIP After washing the element with air filter cleaner or kerosene squeeze...

Page 101: ...rrectly EASB296084 CHECKING THE EXHAUST SYSTEM 1 Remove Exhaust pipe protector 2 Check Exhaust pipe 1 Exhaust pipe 2 Silencer Crack damage Replace Refer to ENGINE REMOVAL on page 5 1 Exhaust gas Leaks...

Page 102: ...ld be between the minimum level mark a and maximum level mark b Below the minimum level mark Add the recommended engine oil to the proper level ECA NOTICE Since engine oil also lubricates the clutch t...

Page 103: ...sh with kerosene c Replace the O ring 2 d Install the oil strainer 6 Install Gasket Drain bolt 7 Pour the specified amount of engine oil into the oil filler cap hole 8 Install Oil filler cap 9 Check O...

Page 104: ...er at high alti tudes the air fuel mixture will become richer If the idling speed is low turn the starter knob idle screw a few clicks counterclockwise to in crease the speed before the adjustment Bef...

Page 105: ...sure that the piston is positioned in the top dead center TDC 1 Remove Seat Side cover left right Air scoop left right Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 EC...

Page 106: ...chain space to pre vent adjusting pads from falling into the crank case Identity each valve lifter and adjusting pad po sition very carefully so that they can be rein stalled in their original place...

Page 107: ...Do not twist adjusting pads and valve lifters forcibly during installation TIP Apply the engine oil on the valve lifters Apply molybdenum disulfide oil to the valve stem ends Check that the valve lift...

Page 108: ...205 210 215 220 225 230 235 240 0 70 0 74 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0 75 0 79 180 185 190 195 200 205 210 215 220 225 230 235 240 0 80 0 84 185 190 195 200 205 210 215 2...

Page 109: ...15 220 225 230 235 240 0 70 0 74 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0 75 0 79 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0 80 0 84 180 185 190 195 200 205 210 215...

Page 110: ...the plastic hose 1 to the bleed screw 2 securely and place a container under the end of the plastic hose d Slowly apply the brake several times e Fully pull the brake lever or fully press down the br...

Page 111: ...b Turn the adjusting bolt 2 in direction a or b until the specified brake lever position is obtained c Tighten the locknut EWA WARNING A soft or spongy feeling in the brake lever can indicate the pre...

Page 112: ...ir in the brake system will cause braking performance to be reduced ECA NOTICE After adjusting the brake pedal position make sure that there is no brake drag EASB296095 CHECKING THE FRONT BRAKE PADS 1...

Page 113: ...jections a into the brake caliper recesses b Temporarily tighten the pad pin at this point i Install the brake caliper 8 and tighten the pad pin 9 j Install the pad pin plug 10 3 Check Brake fluid lev...

Page 114: ...move the pad pin 6 and the brake pads 7 e Connect the plastic hose 8 to the bleed screw 9 and place a container under the end of the plastic hose f Loosen the bleed screw and push the brake caliper pi...

Page 115: ...BRAKE PAD INSU LATOR 1 Remove Brake pads Refer to REAR BRAKE on page 4 21 2 Check Rear brake pad insulator 1 Damage Replace EASB296098 CHECKING THE BRAKE FLUID LEVEL 1 Stand the vehicle upright on a...

Page 116: ...uitable stand to raise the rear wheel off the ground EWA WARNING Securely support the vehicle so that there is no danger of it falling over 2 Shift the transmission into the neutral posi tion 3 Pull t...

Page 117: ...ification Replace TIP The protector guide reaches the limit of its use when it is worn down to the same height a as of the outer tube circumference EASB296102 CLEANING THE FRONT FORK OIL SEAL AND DUST...

Page 118: ...nd its adjusting range 1 Adjust Compression damping a Turn the adjuster 1 in the direction of a or b to make an adjustment Air bleed screw 1 3 Nm 0 13 m kgf 0 94 ft lbf Direction a Rebound damping is...

Page 119: ...A WARNING Securely support the vehicle so that there is no danger of it falling over Spring preload ECA NOTICE Do not turn the adjuster forcibly beyond its adjusting range 1 Remove Rear frame Refer to...

Page 120: ...the direction of a or b to make an adjustment Locknut 30 Nm 3 0 m kgf 22 ft lbf Direction a Rebound damping is increased sus pension is harder Direction b Rebound damping is decreased sus pension is...

Page 121: ...the tire is considered to be slipping off its position Cor rect the tire position EASB296109 CHECKING AND TIGHTENING THE SPOKES 1 Check Spokes Bend damage Replace Loose Tighten TIP A tight spoke will...

Page 122: ...teering head Grasp the bottom of the front fork legs and gently rock the front fork Blinding looseness Adjust the steering head 3 Remove Handlebar Refer to HANDLEBAR on page 4 31 Upper bracket Refer t...

Page 123: ...points and metal to metal moving parts of the following parts Brake lever Clutch lever EASB296115 LUBRICATING THE PEDAL 1 Lubricate the pivoting point and metal to metal moving parts of the pedal EAS...

Page 124: ...ivoting point and metal to metal moving parts of the sidestand EASB296118 CHECKING THE CHASSIS FASTENERS Make sure that all nuts bolts and screws are properly tightened Refer to CHASSIS TIGHTENING TOR...

Page 125: ...oving the spark plug 3 Check Spark plug type Wrong type Replace 4 Check Electrode Damage wear Replace the spark plug Insulator Abnormal color Replace the spark plug Normal color is medium to light tan...

Page 126: ...nt mark a on the left crankcase cover is within the firing range b on the rotor Incorrect firing range Check rotor and Crankshaft position sensor 5 Install Timing mark accessing screw EASB296122 CHECK...

Page 127: ...PER 4 15 CHECKING THE FRONT BRAKE CALIPER 4 16 ASSEMBLING THE FRONT BRAKE CALIPER 4 16 INSTALLING THE BRAKE CALIPER PISTON 4 16 INSTALLING THE FRONT BRAKE CALIPER 4 17 REMOVING THE FRONT BRAKE MASTER...

Page 128: ...EMBLY 4 55 HANDLING THE REAR SHOCK ABSORBER 4 58 DISPOSING OF A REAR SHOCK ABSORBER 4 58 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4 58 REMOVING THE BEARING 4 58 CHECKING THE REAR SHOCK ABSORBER ASSEM...

Page 129: ...this manual It may lead to servicing trouble and mechanical damage EASB296124 GENERAL CHASSIS Removing the seat and side cover Order Part name Q ty Remarks 1 Seat 1 2 Air scoop left 1 3 Air scoop rig...

Page 130: ...e seat always remove the fuel tank cap cover beforehand 1 Remove Fuel tank cap cover 1 Refer to FUEL TANK CAP on page 1 18 2 Remove Seat 1 EASB296127 REMOVING THE NUMBER PLATE 1 Remove Bolt number pla...

Page 131: ...wheel axle pinch bolt 4 Loosen 2 Front wheel axle nut 1 3 Front wheel axle 1 4 Front wheel 1 5 Collars 2 6 Oil seals 2 7 Bearing 2 8 Brake disc 1 For installation reverse the removal proce dure 12 Nm...

Page 132: ...CHECKING THE WHEELS on page 3 34 3 Check Spokes Bend damage Replace Loose Tighten Tap the spokes with a screwdriver TIP A tight spoke will emit a clear ringing tone a loose spoke will sound flat 4 Ti...

Page 133: ...2 Bearing right side 3 Oil seals 4 TIP Apply the lithium soap based grease to the bearing and the oil seal lip when installing Left side of bearing shall be installed first Install the oil seal with i...

Page 134: ...l Front wheel axle 1 TIP Apply the lithium soap based grease to the front wheel axle 3 Tighten Front wheel axle nut 1 ECA NOTICE Before tightening the front wheel axle nut push down hard on the handle...

Page 135: ...el axle 1 3 Drive chain puller 2 4 Rear wheel 1 5 Collars 2 6 Rear wheel sprocket 1 7 Oil seals 2 8 Circlip 1 9 Bearing 3 10 Brake disc 1 For installation reverse the removal proce dure 6 21 Nm 2 1 m...

Page 136: ...CHECKING THE FRONT WHEEL on page 4 4 4 Measure Radial wheel runout Lateral wheel runout Refer to CHECKING THE FRONT WHEEL on page 4 4 EASB296137 DISASSEMBLING THE REAR WHEEL 1 Remove Oil seals Bearing...

Page 137: ...talled first Install the oil seal with its manufacture s marks or numbers facing outward ECA NOTICE Install the bearing by pressing its outer race parallel TIP Use a socket 1 that matches the diameter...

Page 138: ...eel axle from the left side Apply the lithium soap based grease to the rear wheel axle 4 Install Right drive chain puller 1 Washer 2 Rear wheel axle nut 3 TIP Temporarily tighten the nut rear wheel ax...

Page 139: ...washers 2 3 Front brake hose 1 4 Brake pad pin plug 1 5 Brake pad pin 1 6 Brake pads 2 7 Brake pad spring 1 8 Front brake caliper assembly 1 9 Front brake caliper bracket 1 For installation reverse th...

Page 140: ...ke caliper Order Part name Q ty Remarks 1 Brake caliper piston 2 2 Brake caliper piston dust seal 2 3 Brake caliper piston seal 2 4 Bleed screw 1 For assembly reverse the disassemble pro cedure 1 2 3...

Page 141: ...Front brake hose 1 5 Brake master cylinder reservoir cap 1 6 Brake master cylinder reservoir diaphragm 1 7 Front brake master cylinder float 1 8 Front brake master cylinder holder 1 9 Front brake mas...

Page 142: ...ssembling the front brake master cylinder Order Part name Q ty Remarks 1 Push rod 1 2 Dust boot 1 3 Circlip 1 4 Washer 1 5 Brake master cylinder kit 1 For assembly reverse the disassemble pro cedure B...

Page 143: ...ion EASB296143 CHECKING THE FRONT BRAKE DISC 1 Remove Front wheel Refer to FRONT WHEEL on page 4 3 2 Check Front brake disc Damage galling Replace 3 Measure Brake disc thickness Measure the brake disc...

Page 144: ...clean and lubricate the internal parts Use new brake fluid for cleaning and lubricating Never use solvents on internal brake com ponents as they will cause the piston seals to swell and distort When...

Page 145: ...t the brake hose holder 2 is in stalled with its upper end a aligned with the paint b on the brake hose 4 Pour brake fluid to the brake master cylinder reservoir up to the specified level EWA WARNING...

Page 146: ...cylinder and the end of the brake hose EASB296151 CHECKING THE FRONT BRAKE MASTER CYLINDER 1 Check Brake master cylinder 1 Damage scratches wear Replace Brake fluid delivery passages 2 brake master c...

Page 147: ...296153 INSTALLING THE FRONT BRAKE MASTER CYLINDER 1 Install Brake master cylinder 1 TIP Install the front brake master cylinder holder with the UP mark facing up First tighten the upper bolt then the...

Page 148: ...poor brake performance When refilling be careful that water does not enter the brake master cylinder reser voir Water will significantly lower the boil ing point of the brake fluid and could cause va...

Page 149: ...pad pin plug 1 6 Brake pad pin 1 7 Rear brake pad assembly 2 8 Rear brake caliper bracket 1 9 Brake pad springs 2 10 Rear brake disc cover 1 11 Rear brake caliper assembly 1 For installation reverse...

Page 150: ...brake caliper Order Part name Q ty Remarks 1 Brake caliper piston 1 2 Brake caliper piston dust seal 1 3 Brake caliper piston seal 1 4 Bleed screw 1 For assembly reverse the disassemble pro cedure 1 2...

Page 151: ...age 3 22 1 Union bolt 1 2 Copper washers 2 3 Brake hose 1 4 Split pin 1 5 Washer 1 6 Pin 1 7 Brake master cylinder reservoir cap 1 8 Brake master cylinder reservoir diaphragm plate 1 9 Brake master cy...

Page 152: ...4 Disassembling the rear brake master cylinder Order Part name Q ty Remarks 1 Dust boot 1 2 Circlip 1 3 Push rod 1 4 Brake master cylinder kit 1 For assembly reverse the disassemble pro cedure 4 3 2 1...

Page 153: ...96156 CHECKING THE REAR BRAKE DISC 1 Remove Rear wheel Refer to REAR WHEEL on page 4 7 2 Check Brake disc Damage galling Replace 3 Measure Brake disc thickness Measure the brake disc thickness at a fe...

Page 154: ...159 CHECKING THE REAR BRAKE CALIPER 1 Check Brake caliper piston 1 Rust scratches wear Replace the brake caliper piston Brake caliper cylinder 2 Scratches wear Replace the brake cali per assembly Brak...

Page 155: ...ith its side a facing the brake caliper Never force to insert EASB296162 INSTALLING THE REAR BRAKE CALIPER 1 Install Rear brake caliper Rear brake caliper bracket 2 Install Rear wheel Refer to REAR WH...

Page 156: ...CHECKING THE BRAKE FLUID LEVEL on page 3 27 7 Check Brake pedal operation A softy or spongy feeling Bleed the brake system Refer to BLEEDING THE BRAKE SYS TEM on page 3 22 EASB296163 REMOVING THE REA...

Page 157: ...s shown Wrong orientation in installation causes poor braking perfor mance 3 Install Spring 1 Install to the brake master cylinder piston 2 TIP Install the spring with a smaller inside diameter to the...

Page 158: ...y result in a harmful chemical reac tion leading to poor brake performance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling poin...

Page 159: ...e 1 Disconnect 2 Clutch switch 1 3 Clutch lever holder 1 4 Engine stop switch 1 5 Brake master cylinder 1 6 Throttle cable cap 1 7 Throttle cable pull 1 Disconnect 8 Throttle cable return 1 Disconnect...

Page 160: ...HANDLEBAR 4 32 16 Damper 4 For installation reverse the removal proce dure Removing the handlebar Order Part name Q ty Remarks...

Page 161: ...296170 INSTALLING THE HANDLEBAR 1 Stand the vehicle upright on a level surface EWA WARNING Securely support the vehicle so that there is no danger of it falling over 2 Install Damper 1 Lower handlebar...

Page 162: ...ll Handlebar grip 1 a Slightly coat the handlebar left end with a rubber adhesive b Install the handlebar grip on the handlebar by pressing the grip from the left side c Wipe off any excess adhesive w...

Page 163: ...f grease or oil on the tube guide surface a with a lac quer thinner Install the grip to the tube guide so that the grip match mark b and tube guide slot c form the angle as shown 7 Install Rubber cove...

Page 164: ...assembly 2 Front brake master cylinder holder 3 Bolt brake master cylinder holder 4 Clamp 5 TIP Install the brake master cylinder holder with the UP mark facing up Install in order for the top of the...

Page 165: ...er to ADJUSTING THE CLUTCH LE VER FREE PLAY on page 3 10 14 Adjust Throttle grip free play Refer to ADJUSTING THE THROTTLE GRIP FREE PLAY on page 3 11 Clutch lever free play 7 0 12 0 mm 0 28 0 47 in T...

Page 166: ...rake caliper Refer to FRONT BRAKE on page 4 11 Number plate Refer to GENERAL CHASSIS on page 4 1 1 Protector 1 2 Upper bracket pinch bolts 2 Loosen 3 Damper assembly 1 Loosen 4 Lower bracket pinch bol...

Page 167: ...n metal 1 8 Protector guide 1 9 Slide metal 1 10 Washer 1 11 Oil seals 1 12 Base valve 1 13 Damper assembly 1 For assembly reverse the disassemble pro cedure LS 13 2 6 9 8 10 11 4 3 1 5 7 12 New New N...

Page 168: ...mbly 1 with the cap bolt ring wrench 2 3 Remove Front fork leg s EASB296173 DISASSEMBLING THE FRONT FORK LEGS 1 Drain Fork oil 2 Remove Adjuster 1 from the inner tube TIP While compressing the inner t...

Page 169: ...a bent inner tube as this may dangerously weaken it 2 Check Outer tube Scratches wear damage Replace 3 Measure Fork spring free length a Out of specification Replace 4 Check Damper assembly 1 Bend dam...

Page 170: ...an dling and a loss of stability TIP When assembling the front fork leg be sure to replace the following parts Inner tube bushing Outer tube bushing Oil seals Copper washers Before assembling the fron...

Page 171: ...P Fully finger tighten the locknut onto the damper assembly 6 Loosen Compression damping force adjuster 1 TIP Before loosening the damping force adjuster record the setting position Unless the damping...

Page 172: ...rotecting the damper assembly 1 with a cloth and compressing fully allow ex cessive oil to overflow on the base valve side ECA NOTICE Take care not to damage the damper assem bly 12 Allow the overflow...

Page 173: ...lip Apply the fork oil on the inner tube When installing the oil seal use vinyl seat a with fork oil applied to protect the oil seal lip 15 Install Inner tube bushing 1 TIP Install the inner tube bush...

Page 174: ...e groove in the outer tube 20 Install Dust seal 1 TIP Apply lithium soap based grease on the inner tube 21 Check Inner tube smooth movement Tightness binding rough spots Repeat the steps 14 to 20 22 M...

Page 175: ...g force adjuster is fully loosened correct damping characteristic can not be obtained after installation 26 Install Damper adjusting rod 1 Copper washer 2 Adjuster 3 to the damper assembly 4 TIP While...

Page 176: ...the front fork leg do not allow any foreign ma terial to enter the front fork 31 Install Damper assembly 1 to the outer tube TIP Temporarily tighten the damper assembly Adjuster locknut 29 Nm 2 9 m k...

Page 177: ...he damper assembly 3 Adjust Front fork top end a 4 Tighten Pinch bolt upper bracket 1 Pinch bolt lower bracket 2 EWA WARNING Tighten the lower bracket to specified torque If torqued too much it may ca...

Page 178: ...e TIP Turn in the damping adjuster 1 finger tight and then turn out to the originally set position 7 Adjust Compression damping force TIP Turn in the damping adjuster 1 finger tight and then turn out...

Page 179: ...ront fender 1 2 Steering stem nut 1 3 Front fork leg s 2 Refer to FRONT FORK on page 4 38 4 Upper bracket 1 5 Steering ring nut 1 6 Lower bracket 1 7 Bearing race cover 1 8 Upper bearing 1 9 Bearing l...

Page 180: ...3 Replace Bearing Bearing races a Remove the bearing race from the steering head pipe with a long rod 1 and a hammer b Remove the bearing race from the lower bracket with a chisel 2 and a hammer c In...

Page 181: ...e steering nut with its stepped side a facing downward Tighten the steering ring nut with a steering nut wrench 2 Refer to CHECKING AND ADJUSTING THE STEERING HEAD on page 3 34 5 Check the steering st...

Page 182: ...steering ring nut little by little 10 Adjust Front fork top end a 11 Tighten Pinch bolt upper bracket 1 Pinch bolt lower bracket 2 EWA WARNING Tighten the lower bracket to specified torque If torqued...

Page 183: ...1 Air scoop left right Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 1 Rear shock absorber assembly lower bolt 1 2 Rear shock absorber assembly upper bolt 1 3 Rear sho...

Page 184: ...14 Dust seal 2 15 Stopper ring 1 16 Bearing 1 For installation reverse the removal proce dure Removing the rear shock absorber assembly Order Part name Q ty Remarks 2 12 16 15 14 13 12 14 4 5 7 6 8 3...

Page 185: ...arm Order Part name Q ty Remarks 1 Relay arm 1 2 Connecting arm 1 3 Collars 3 4 Oil seals 6 5 Washers 8 6 Bearing 6 For assembly reverse the disassemble pro cedure 5 3 5 6 1 6 5 4 5 5 4 5 6 6 5 4 3 2...

Page 186: ...km of run ning EASB296183 DISPOSING OF A REAR SHOCK ABSORB ER Before disposing the rear shock absorber be sure to extract the nitrogen gas from valve 1 EWA WARNING Wear protective glasses to prevent...

Page 187: ...ng Damage wear Replace Spring guide Damage wear Replace Bearing Damage wear Replace Bolts Bends damage wear Replace EASB296187 CHECKING THE CONNECTING ARM AND RELAY ARM 1 Check Connecting arm Relay ar...

Page 188: ...ck absorber assembly lower side TIP Install the dust seals with their lips facing in ward 5 Lubricate Connecting arm and frame bolt Relay arm and connecting arm bolt Relay arm and swingarm bolt circum...

Page 189: ...m side Rear shock absorber assembly lower bolt Rear shock absorber assembly upper bolt 56 Nm 5 6 m kgf 41 ft lbf Connecting arm bolt frame side 80 Nm 8 0 m kgf 58 ft lbf Connecting arm bolt relay arm...

Page 190: ...ake hose holder Refer to REAR BRAKE on page 4 21 Rear brake caliper Refer to REAR BRAKE on page 4 21 Bolt brake pedal Drive chain 1 Collars 2 2 Oil seals 2 3 Thrust bearing 2 4 Bushing 2 5 Oil seals 2...

Page 191: ...the swingarm up and down If swingarm vertical movement is not smooth or if there is binding check the spacers the bearings and the collars EASB296192 REMOVING THE BEARING 1 Remove Bearing 1 TIP Remov...

Page 192: ...Install Swingarm TIP Install the pivot shaft from the right 4 Install Rear wheel Refer to REAR WHEEL on page 4 7 5 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 28 Recomm...

Page 193: ...ving the drive chain Job Order Part name Q ty Servicing Information Drive sprocket Refer to ENGINE REMOVAL on page 5 1 1 Drive chain 1 For installation reverse the removal proce dure 1 T R 75 Nm 7 5 m...

Page 194: ...gth b between pin outer sides 2 TIP When measuring a 15 link section of the drive chain make sure that the drive chain is taut Perform this procedure 2 3 times at a differ ent location each time 2 Che...

Page 195: ...eel sprocket as a set EASB296197 CHECKING THE REAR WHEEL SPROCKET Refer to CHECKING AND REPLACING THE REAR WHEEL SPROCKET on page 4 8 EASB296198 INSTALLING THE DRIVE CHAIN 1 Install Drive chain ECA NO...

Page 196: ...CE Never install a new drive chain onto worn drive chain sprockets this will dramatically shorten the drive chain s life 4 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 2...

Page 197: ...NG THE DECOMPRESSION SYSTEM 5 17 INSTALLING THE CAMSHAFTS 5 17 CYLINDER HEAD 5 19 REMOVING THE CYLINDER HEAD 5 21 CHECKING THE TIMING CHAIN GUIDE INTAKE SIDE 5 21 CHECKING THE CYLINDER HEAD 5 21 INSTA...

Page 198: ...51 CHECKING THE KICK GEAR KICK IDLE GEAR AND RATCHET WHEEL 5 51 INSTALLING THE KICK SHAFT ASSEMBLY 5 51 INSTALLING THE KICK IDLE GEAR 5 52 SHIFT SHAFT 5 53 REMOVING THE SHIFT GUIDE AND SHIFT LEVER ASS...

Page 199: ...UIDE OIL STRAINER 5 73 CHECKING THE CRANKCASE 5 73 INSTALLING THE OIL SEAL 5 74 ASSEMBLING THE CRANKCASE 5 74 CRANKSHAFT ASSEMBLY AND BALANCER SHAFT 5 75 REMOVING THE CRANKSHAFT ASSEMBLY 5 76 CHECKING...

Page 200: ...AUST PIPE AND MUFFLER on page 5 10 Side cover right Refer to GENERAL CHASSIS on page 4 1 Rear shock absorber assembly lower bolt Refer to REAR SHOCK ABSORBER AS SEMBLY on page 4 55 Connecting arm bolt...

Page 201: ...pipe Order Part name Q ty Remarks 10 5 9 2 6 1 6 6 3 8 4 7 4 6 30 Nm 3 0 m kgf 22 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R New New 10 Nm 1 0 m kgf 7 2 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 12 Nm...

Page 202: ...S on page 4 1 Air scoop left right Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Air filter case cover 1 Rectifier regulator 1 2 ECU 1 3 Ignition coil 1 4 Neutral switc...

Page 203: ...ge 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Exhaust pipe and silencer Refer to ENGINE REMOVAL on page 5 1 Air filter case Refer to THROTTLE BODY on page 7 5 Throttle body Refer to THROTTLE BODY on...

Page 204: ...r engine bracket 2 9 Washer 1 Thickness 2 3 mm 0 09 in 10 Washer 1 Thickness 1 0 mm 0 04 in 11 Lower engine bracket 2 12 Pivot shaft 1 13 Engine 1 For installation reverse the removal proce dure Remov...

Page 205: ...silencer EASB296202 REMOVING THE EXHAUST PIPE 2 1 Remove Exhaust pipe 2 TIP Put the Exhaust pipe 2 into the state as shown by moving this and then remove it EASB296203 REMOVING THE DRIVE SPROCKET 1 St...

Page 206: ...e TIP Make sure that the couplers the hoses and the cables are disconnected Lift up the engine and remove this from its lower part toward the right of the chassis EASB296205 CHECKING THE SILENCER AND...

Page 207: ...t 2 TIP Apply heat resistant sealant to the areas a shown making sure that there are no gaps in the beads of sealant Take care not to allow the fiber out of place when installing the silencer body 3 E...

Page 208: ...O rings and brake pedal bracket EASB296209 INSTALLING THE DRIVE SPROCKET 1 Install Drive sprocket 1 Drive chain 2 TIP Install the drive sprocket together with the drive chain 2 Install Lock washer 1...

Page 209: ...stall Gasket Exhaust pipe 1 1 Nut exhaust pipe 1 2 TIP First temporarily tighten all nuts to 13 Nm 1 3 m kgf 9 4 ft lbf Then retighten them to 20 Nm 2 0 m kgf 14 ft lbf 2 Install Clamp Exhaust pipe 2...

Page 210: ...t is positioned as shown with respect to the exhaust pipe 2 4 Tighten Bolt exhaust pipe 2 Clamp TIP Tighten while checking that their front and rear joints are inserted in position Bolt exhaust pipe 2...

Page 211: ...left right Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 1 Spark plug 1 2 Cylinder head breather hose 1 3 Bolt cylinder head cover 2 4 Cylinder head cover 1 5 Cylinder...

Page 212: ...Timing chain tensioner 1 5 Camshaft cap 2 6 Clip 2 7 Intake camshaft 1 8 Exhaust camshaft 1 For installation reverse the removal proce dure 6 Nm 0 6 m kgf 4 3 ft Ibf T R 6 Nm 0 6 m kgf 4 3 ft Ibf T R...

Page 213: ...et with the edge of the cylinder head 3 Remove Timing chain tensioner cap bolt 1 Timing chain tensioner 2 Gaskets 4 Remove Bolt camshaft cap 1 Camshaft cap 2 Clip 3 TIP Remove the bolts camshaft cap i...

Page 214: ...the camshaft into the cylinder head b Position a strip of Plastigauge 1 onto the camshaft journal as shown Camshaft lobe dimensions Lobe height Intake 31 730 31 830 mm 1 2492 1 2531 in Limit 31 630 m...

Page 215: ...1 Damage stiffness Replace the timing chain and camshaft as a set 2 Check Camshaft sprocket More than 1 4 tooth wear a Replace the camshaft and the timing chain as a set EASB296215 CHECKING THE TIMING...

Page 216: ...Make sure that the alignment mark c on the exhaust camshaft sprocket and the alignment mark d on the intake camshaft sprocket are aligned with the edge of the cylinder head ECA NOTICE Do not turn the...

Page 217: ...kwise several turns 4 Check Top dead center TDC mark on the rotor Align with the crankcase alignment mark Camshaft match marks Align with the cylinder head surface Out of alignment Adjust 5 Install Ti...

Page 218: ...pipe and silencer Refer to ENGINE REMOVAL on page 5 1 Radiator hose Disconnect Coolant temperature sensor coupler Disconnect Throttle body Refer to THROTTLE BODY on page 7 5 Camshaft Refer to CAMSHAF...

Page 219: ...HEAD 5 20 For installation reverse the removal proce dure Removing the cylinder head Order Part name Q ty Remarks 6 10 Nm 1 0 m kgf 7 2 ft Ibf T R 33 Nm 3 3 m kgf 24 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft...

Page 220: ...trument in order not to damage or scratch the spark plug bore threads 2 Check Cylinder head Damage scratches Replace TIP When replacing the cylinder head replace also the valve Refer to CHECKING THE V...

Page 221: ...he cylin der head 2 Install Washer 1 Cylinder head bolt 2 Cylinder head nut 3 TIP Apply molybdenum disulfide grease to the threads and contact surfaces of the bolts and to both contact surfaces of the...

Page 222: ...gs Order Part name Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 5 19 1 Valve lifter 4 2 Adjusting pad 4 3 Valve cotter 8 4 Valve spring retainer 4 5 Valve spring 4 6 Valve stem seal 4 7 V...

Page 223: ...e seat Check the valve face the valve seat and the valve seat contact width Refer to CHECKING THE VALVE SEATS on page 5 26 a Pour a clean solvent a into the intake and exhaust ports b Check that the v...

Page 224: ...inder head to 100 C 212 F in an oven a Remove the valve guide with the valve guide remover 1 b Install the new valve guide with the valve guide installer 2 and the valve guide re mover 1 Valve stem to...

Page 225: ...alve TIP When installing a new valve always replace the valve guide If the valve is removed or replaced always re place the valve stem seal EASB296226 CHECKING THE VALVE SEATS 1 Eliminate Carbon depos...

Page 226: ...valve guides use new valves to lap the valve seats and then replace them with new valves a Apply a coarse lapping compound a to the valve face ECA NOTICE Do not let the lapping compound enter the gap...

Page 227: ...re Compressed valve spring force a Out of specification Replace the valve spring 3 Measure Valve spring tilt a Out of specification Replace the valve spring Free length intake 36 69 mm 1 44 in Limit 3...

Page 228: ...d in its original place Install the valve springs with the larger pitch a facing up 4 Install Valve cotter 1 TIP Install the valve cotters by compressing the valve spring with the valve spring compres...

Page 229: ...sting pad 1 Valve lifter 2 7 Install Adjusting pad Valve lifter TIP Check that the valve lifter turns smoothly when rotated with your finger Make sure that the valve lifter and the adjust ing pad are...

Page 230: ...marks Cylinder head Refer to CYLINDER HEAD on page 5 19 1 Cylinder body 1 2 Gaskets 1 3 Dowel pin 2 4 Piston pin clip 2 5 Piston pin 1 6 Piston 1 7 Piston ring set 1 For installation reverse the remov...

Page 231: ...piston crown EASB296232 CHECKING THE CYLINDER AND PISTON 1 Check Piston wall Sidewall Cylinder wall Vertical scratches Replace the cylinder and replace the piston and piston rings as a set 2 Measure...

Page 232: ...place the piston and piston rings as a set TIP Before measuring the piston ring side clear ance eliminate any carbon deposits from the piston ring grooves and piston rings 2 Install Piston rings TIP L...

Page 233: ...CYLINDER 1 Install Oil ring expander 1 Lower oil ring rail 2 Upper oil ring rail 3 Top ring 4 TIP Be sure to install the piston ring so that the manufacturer s marks or numbers face up 2 Install Pisto...

Page 234: ...lip ends are 3 mm 0 12 in c or more from the cutout in the piston 3 Lubricate Piston Piston rings Cylinder 4 Offset Piston ring end gap 5 Install Cylinder gasket Dowel pin Cylinder TIP While compressi...

Page 235: ...ELECTRIC STARTER Removing the starter motor Order Job Parts to remove Q ty Remarks Exhaust pipe Refer to ENGINE REMOVAL on page 5 1 1 Starter motor 1 For assembly reverse the disassemble pro cedure 1...

Page 236: ...mbling the starter motor Order Job Parts to remove Q ty Remarks 1 Starter motor front cover 1 2 Starter motor yoke 1 3 Armature assembly 1 4 Starter motor rear cover 1 5 Brush set 2 For assembly rever...

Page 237: ...stances commuta tor and insulation Out of specification Replace the starter motor a Measure the armature assembly resistanc es with the pocket tester b If any resistance is out of specification re pla...

Page 238: ...Starter motor yoke 2 ECA NOTICE Install the part that has a smaller step differ ence a with the magnet of the starter mo tor yoke facing the starter motor front cover TIP Align the match mark a on th...

Page 239: ...ELECTRIC STARTER 5 40 5 Install Bolt 1 O ring 2 TIP Apply the lithium soap based grease on the O ring New...

Page 240: ...dal Refer to ENGINE REMOVAL on page 5 1 1 Clutch cable 1 Disconnect 2 Clutch cover 1 3 Gasket 1 4 Clutch spring 5 5 Pressure plate 1 6 Push rod 1 1 7 Circlip 1 8 Washer 1 9 Bearing 1 10 Ball 1 11 Push...

Page 241: ...7 Thrust washer 1 18 Primary driven gear 1 19 Spacer 1 20 Bearing 1 21 Washer 1 22 Push lever shaft 1 For installation reverse the removal proce dure Removing the clutch Order Part name Q ty Remarks N...

Page 242: ...Refer to CHANGING THE COOLANT on page 3 8 Brake pedal Refer to ENGINE REMOVAL on page 5 1 Clutch cover Refer to CLUTCH on page 5 41 1 Oil filter element cover 1 2 Oil filter element 1 3 Radiator pipe...

Page 243: ...plate EASB296242 CHECKING THE CLUTCH PLATES 1 Check Clutch plate Damage Replace the clutch plates as a set 2 Measure Clutch plate warpage with a surface plate and thickness gauge 1 Out of specificati...

Page 244: ...place EASB296247 CHECKING THE PUSH LEVER SHAFT 1 Check Push lever shaft Wear damage Replace EASB296248 CHECKING THE CLUTCH PUSH RODS 1 Check Push rod 1 1 Bearing 2 Washer 3 Push rod 2 4 Ball 5 Cracks...

Page 245: ...ll the oil seal in parallel with its manufac ture s marks or numbers facing inward EASB296252 INSTALLING THE RIGHT CRANKCASE COVER 1 Install Dowel pin 1 O ring 2 Collar 3 Gasket 4 TIP Apply the lithiu...

Page 246: ...rt that is fastened together TIP Use the clutch holding tool 3 to hold the clutch boss 4 Bend the lock washer 1 tab 5 Install Friction plate 1 1 Clutch plate 2 Cushion spring 3 Friction plate 2 4 TIP...

Page 247: ...oil on the push rod 1 2 and ball 8 Install Pressure plate 1 9 Install Clutch spring Clutch spring bolt TIP Tighten the bolts in stages and in a crisscross pattern 10 Install Gasket 1 11 Install Clutch...

Page 248: ...all Kickstarter lever 1 Washer Bolt kickstarter lever TIP Install so that there is a clearance a of 5 mm 0 2 in or more between the kickstarter lever and the frame and that the kickstarter lever does...

Page 249: ...haft Order Part name Q ty Remarks Primary driven gear Refer to CLUTCH on page 5 41 1 Kick idle gear 1 2 Kick shaft assembly 1 3 Spring guide 1 4 Torsion spring 1 5 Ratchet wheel 1 6 Kick gear 1 7 Kick...

Page 250: ...Kick gear 1 Wear damage Replace the kick shaft as sembly Kick idle gear 2 Ratchet wheel 3 Gear teeth a Ratchet teeth b Wear damage Replace EASB296259 INSTALLING THE KICK SHAFT ASSEMBLY 1 Install Kick...

Page 251: ...kick shaft stopper a Apply the engine oil on the kick shaft Slide the kick shaft assembly into the crank case and make sure the kick shaft stopper a fits into the kick shaft ratchet wheel guide 5 Ins...

Page 252: ...1 3 Oil seal 1 4 Collar 1 5 Shift shaft spring 1 6 Roller 1 7 Shift guide 1 8 Shift lever assembly 1 9 Shift lever 1 10 Pawl 2 11 Pawl pin 2 12 Spring 2 13 Stopper lever 1 14 Stopper lever spring 1 15...

Page 253: ...e dure Removing the shift shaft and stopper lever Order Part name Q ty Remarks LS 1 3 13 15 14 LT 6 10 11 12 11 8 12 10 4 2 5 LT 7 LT E 12 Nm 1 2 m kgf 8 7 ft Ibf T R 30 Nm 3 0 m kgf 22 ft T R 10 Nm 1...

Page 254: ...oosen the bolt ECA NOTICE If the segment gets an impact the stopper lever may be damaged Take care not to give an impact to it when removing the bolt EASB296264 CHECKING THE SHIFT SHAFT 1 Check Shift...

Page 255: ...ged Take care not to give an impact to it when tightening the bolt EASB296269 INSTALLING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY 1 Install Spring 1 Pawl pin 2 Pawl 3 to the shift lever 4 TIP Apply th...

Page 256: ...Apply the engine oil on the roller collar and shift shaft 2 Install Oil seal EASB296271 INSTALLING THE SHIFT PEDAL 1 Install Shift pedal 1 Shift pedal bolt 2 TIP Align the punch mark a on the shift sh...

Page 257: ...Refer to CLUTCH on page 5 41 Right crankcase cover Refer to CLUTCH on page 5 41 1 Oil pump assembly 1 2 Oil pump cover 1 3 Outer rotor 1 4 Dowel pin 1 5 Inner rotor 1 6 Oil pump drive shaft 1 7 Rotor...

Page 258: ...CLUTCH on page 5 64 1 Nut balancer 1 2 Nut primary drive gear 1 3 Nut balancer shaft driven gear 1 4 Conical washer 1 5 Balancer 1 6 Conical washer 1 7 Primary drive gear 1 8 Collar 1 9 Balancer shaft...

Page 259: ...EIGHT GEAR 1 Check Primary drive gear 1 Balancer shaft drive gear 2 Balancer weight gear 3 Wear damage Replace EASB296275 CHECKING THE BALANCER 1 Check Balancer Crack damage Replace EASB296276 CHECKIN...

Page 260: ...e in the inner rotor 2 Install Outer rotor 1 TIP Apply the engine oil on the outer rotor 3 Install Oil pump cover 1 Oil pump cover screw 2 Inner rotor to outer rotor tip clearance 0 000 0 150 mm 0 000...

Page 261: ...ch other 4 Install Conical washer 1 Balancer weight gear nut 2 Primary drive gear 3 Conical washer 4 Primary drive gear nut 5 Balancer 6 Conical washer 7 Balancer nut 8 TIP Apply engine oil to the con...

Page 262: ...OIL PUMP AND BALANCER GEAR 5 63 a 2 10 b 2 9 1 b 5 3 a 4 10 5 9 3 E c d 6 7 8 8 b 6...

Page 263: ...k Refer to GENERAL CHASSIS on page 4 1 and FUEL TANK on page 7 1 Disconnect the AC magneto lead Clutch cable Shift pedal Refer to SHIFT SHAFT on page 5 53 1 Cover Damper assembly 1 2 Damper assembly 1...

Page 264: ...clutch 1 13 Starter clutch drive gear 1 14 Crankshaft position sensor 1 15 Stator 1 For installation reverse the removal proce dure Removing the generator Order Job Parts to remove Q ty Remarks T R T...

Page 265: ...clutch gear 4 Check Damper assembly Damage pitting wear Replace the damp er assembly Check the gear of the starter motor arma ture 5 Check Starter clutch operation a Install the starter clutch drive...

Page 266: ...cumference 3 Install Starter clutch 1 To generator rotor 2 EASB296283 INSTALLING THE GENERATOR 1 Install Woodruff key 1 Generator rotor 2 TIP Clean the contact surfaces of the tapered por tions of the...

Page 267: ...cover gasket Left crankcase cover 1 Lead holder 2 Crankcase cover bolt Neutral switch lead 3 TIP Pass the AC magneto lead 4 under the left crankcase cover a as shown Tighten the bolts in stage using...

Page 268: ...AND STARTER CLUTCH 5 69 6 Install Cover damper assembly 1 Bracket 2 Bolt 3 Breather hose 2 4 TIP Install the cover damper assembly with its mark a facing upward Bolt 10 Nm 1 0 m kgf 7 2 ft lbf T R 1...

Page 269: ...Segment Refer to SHIFT SHAFT on page 5 53 Generator rotor Refer to GENERATOR AND STARTER CLUTCH on page 5 64 1 Timing chain guide exhaust side 1 2 Timing chain guide stopper plate 1 3 Timing chain 1 4...

Page 270: ...assembly reverse the disassemble pro cedure Separating the crankcase Order Part name Q ty Remarks 10 Nm 1 0 m kgf 7 2 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 12 Nm 1...

Page 271: ...Transmission Refer to TRANSMISSION on page 5 78 Shift cam and shift fork Refer to TRANSMISSION on page 5 78 1 Circlip 2 2 Oil seals 3 3 Bearing 11 For installation reverse the removal proce dure LT L...

Page 272: ...lf Tap only on reinforced portions of case Do not tap on gasket mating surface Work slowly and carefully Make sure the case halves separate evenly If the cases do not separate check for a remaining ca...

Page 273: ...se onto the left crankcase Tap lightly on the case with soft hammer When installing the crankcase the connecting rod should be positioned at top dead center TDC Tighten the bolts in a crisscross patte...

Page 274: ...R SHAFT Removing the crankshaft assembly and balancer shaft Order Part name Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 70 Transmission Refer to TRANSMISSION on page 5 78 1 Balancer s...

Page 275: ...rankshaft slowly 2 Measure Big end side clearance a Out of specification Replace the big end bearing crankshaft pin or connecting rod 3 Measure Crank assembly width a Out of specification Replace the...

Page 276: ...the connecting rod at top dead center TDC with one hand while turning the nut of the crankshaft installer bolt with the other Turn the crankshaft installer bolt until the crankshaft as sembly bottoms...

Page 277: ...NE REMOVAL on page 5 1 Crankcase Separate Refer to CRANKCASE on page 5 70 1 Main axle 1 2 Drive axle 1 3 Long shift fork guide bar 1 4 Short shift fork guide bar 1 5 Spring 4 6 Shift cam 1 7 Shift for...

Page 278: ...on of shift forks Remove the main axle and the drive axle all together by tapping the drive axle lightly with a soft hammer EASB296298 CHECKING THE SHIFT FORKS 1 Check Shift fork cam follower 1 Shift...

Page 279: ...heck Transmission gears Blue discoloration pitting wear Replace the defective gear s Transmission gear dogs Cracks damage rounded edges Replace the defective gear s 4 Check Transmission gear movement...

Page 280: ...ease on the O ring 3 Install Washer 1 Circlip 2 TIP Be sure the circlip sharp edged corner a is positioned opposite side to the washer and gear b Install the circlip with its ends c settled even ly on...

Page 281: ...th the 5th wheel gear 5 and 3 R with the 6th wheel gear 7 on the drive axle Mesh the shift fork 2 C with the 3rd 4th pin ion gear 6 on the main axle 7 Install Long shift fork guide bar 1 Short shift f...

Page 282: ...TRANSMISSION 5 83...

Page 283: ...TEM RADIATOR 6 1 HANDLING NOTE 6 3 CHECKING THE RADIATOR 6 3 WATER PUMP 6 4 REMOVING THE OIL SEAL 6 6 CHECKING THE WATER PUMP 6 6 CHECKING THE BEARING 6 6 INSTALLING THE OIL SEAL 6 6 ASSEMBLING THE WA...

Page 284: ...vicing trouble and mechanical damage EASB296303 RADIATOR Removing the radiator Order Part name Q ty Remarks Coolant Drain Refer to CHANGING THE COOLANT on page 3 8 Seat Refer to GENERAL CHASSIS on pag...

Page 285: ...9 Radiator breather hose 1 10 Left radiator 1 11 Radiator hose 1 1 12 Radiator pipe 1 1 13 Coolant temperature sensor 1 For installation reverse the removal proce dure Removing the radiator Order Par...

Page 286: ...ra diator cap EASB296305 CHECKING THE RADIATOR 1 Check Radiator fins 1 Obstructions Clean Apply compressed air to the rear of the radi ator Damage Repair or replace TIP Correct any flattened fins with...

Page 287: ...efer to CHANGING THE ENGINE OIL on page 3 14 Right crankcase cover Refer to CLUTCH on page 5 41 1 Water pump housing 1 2 Dowel pin 2 3 Gasket 1 4 Washer 2 5 Collar 1 6 Gear 1 7 Pin 1 8 Impeller shaft...

Page 288: ...For installation reverse the removal proce dure Removing the water pump Order Part name Q ty Remarks 9 8 2 2 3 1 10 6 7 5 4 4 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R New New New...

Page 289: ...spot seizure Replace EASB296310 INSTALLING THE OIL SEAL 1 Install Oil seals 1 TIP Apply the lithium soap based grease on the oil seal lip Install the oil seal with its manufacture s marks or numbers f...

Page 290: ...1 Gasket 2 3 Install Water pump housing 1 Water pump housing bolt 2 Washer 3 Coolant drain bolt 4 Water pump housing bolt 10 Nm 1 0 m kgf 7 2 ft lbf Coolant drain bolt 10 Nm 1 0 m kgf 7 2 ft lbf New 2...

Page 291: ...2 INSTALLING THE FUEL PUMP 7 2 INSTALLING THE FUEL TANK 7 3 CHECKING THE FUEL PRESSURE 7 3 CHECKING THE DAMPER 7 4 CHECKING AND REPLACING THE PROTECTOR 7 4 THROTTLE BODY 7 5 CHECKING THE INJECTOR 7 8...

Page 292: ...icing trouble and mechanical damage EASB296313 FUEL TANK Removing the fuel tank Order Part name Q ty Remarks Seat Refer to GENERAL CHASSIS on page 4 1 Side cover left right Air scoop left right 1 Fuel...

Page 293: ...ign ma terials from entering the fuel pump install the included fuel hose joint cover 1 3 and the fuel hose joint cover 2 4 onto the disconnect ed fuel hose and the fuel pump 3 Remove Side cover left...

Page 294: ...ght Refer to GENERAL CHASSIS on page 4 1 EASB296319 CHECKING THE FUEL PRESSURE 1 Check Fuel pressure a Remove the side cover left right the seat and the air scoop left right Refer to GENERAL CHASSIS o...

Page 295: ...arrow on each damper pointing outward Affix the damper 2 with its projection a facing the rear of the vehicle EASB296321 CHECKING AND REPLACING THE PRO TECTOR 1 Check Protector 1 Wear damage Replace T...

Page 296: ...AL on page 5 1 Ignition coil Refer to ENGINE REMOVAL on page 5 1 1 Intake air temperature sensor coupler 1 Disconnect 2 Breather hose 3 1 3 Air filter case 1 4 Fuel injector coupler 1 Disconnect 5 Int...

Page 297: ...int 1 For installation reverse the removal proce dure Removing the throttle body Order Part name Q ty Remarks 3 1 2 7 11 12 10 9 4 8 6 5 3 5 Nm 0 35 m kgf 2 5 ft Ibf T R 3 5 Nm 0 35 m kgf 2 5 ft Ibf T...

Page 298: ...ks 1 Fuel inlet pipe 1 2 Injector 1 3 Gaskets 1 4 Throttle position sensor 1 5 Intake air pressure sensor 1 For installation reverse the removal proce dure 1 2 2 2 5 4 3 T R 3 4 Nm 0 34 m lbf kgf 2 5...

Page 299: ...eign material from falling into the engine If the throttle body is subject to strong shocks or dropped during cleaning re place it Do not use any caustic carburetor clean ing solution Do not directly...

Page 300: ...YAMAHA DIAGNOSTIC TOOL on page 8 22 b Temporary tighten the throttle position sen sor c Check that the throttle grip is fully closed d Connect the throttle position sensor to the wire harness e Set th...

Page 301: ...8 ELECTRICAL COMPONENTS 8 50 CHECKING THE SWITCHES 8 54 CHECKING THE FUSES 8 57 CHECKING AND CHARGING THE BATTERY 8 57 CHECKING THE RELAYS 8 60 CHECKING THE DIODE 8 61 CHECKING THE IGNITION SPARK GAP...

Page 302: ...8 CHECKING THE INTAKE AIR TEMPERATURE SENSOR 8 68 CHECKING THE FUEL INJECTOR 8 68...

Page 303: ...servicing of Yamaha motorcycles e g Yamaha dealers service engineers etc Those who have little knowl edge and skill concerning servicing are requested not to undertake inspection adjustment disas semb...

Page 304: ...Br O O O O R R Gy R L L L L B B B B B B B B B B Sb Sb Sb Sb Br Br Lg Lg R L R R R R Gy B B W W W W W W R R B B B B B B B Br Br B B L G B L B B B B R R R R L Br Br Br Br Gy Gy B L Gy W W W B Gy B R W W...

Page 305: ...nt connector 4 AC magneto 8 Battery 9 Frame ground 10 Starter relay 11 Main fuse 16 ECU engine control unit 17 Ignition coil 18 Spark plug 24 Joint connector 29 Lean angle sensor 30 Engine stop switch...

Page 306: ...terminals Recharge or replace the battery OK 3 Check the spark plug Refer to CHECKING THE FUSES on page 8 57 NG Re gap or replace the spark plug OK 4 Check the ignition spark gap Refer to CHECKING TH...

Page 307: ...Refer to CHECKING THE LEAN ANGLE SENSOR on page 8 63 NG Replace the lean angle sensor OK 9 Check the entire ignition system s wiring Refer to CIRCUIT DIAGRAM on page 8 2 NG Properly connect or repair...

Page 308: ...R W R W Br O R Gy L L L L B B B B B B B B B B Sb Sb Sb Sb Br Br Lg Lg R L R R R R Gy B B W W W W W W R R B B B B Br Br B L G B L R L O O O R R B B B B B B R R R R L Br Br Br Br Gy Gy B L Gy W W W B Gy...

Page 309: ...Main relay 8 Battery 9 Frame ground 10 Starter relay 11 Main fuse 12 Starter motor 13 Starter relay diode 16 ECU engine control unit 24 Joint connector 30 Engine stop switch 31 Neutral switch 32 Diod...

Page 310: ...er is pulled to the handlebar the clutch switch is closed The starting circuit cut off relay prevents the starter motor from operating when neither of these con ditions has been met In this instance t...

Page 311: ...E TRANSMISSION IS IN NEU TRAL b WHEN THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 1 Battery 2 Main fuse 3 Main relay 4 Starting circuit cut off relay 5 Start switch 6 Diode 7 Clutch switch 8 Neutral sw...

Page 312: ...battery OK 3 Check the starter motor operation Refer to CHECKING THE START ER MOTOR OPERATION on page 8 64 OK Starter motor is OK Perform the electric starting system troubleshooting starting with st...

Page 313: ...ch Refer to CHECKING THE SWITCHES on page 8 54 NG Replace the clutch switch OK 11 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 8 54 NG Replace the start switch OK 12 Check the s...

Page 314: ...r O R Gy L L L L B B B B B B B B B B Sb Sb Sb Sb Br Br Lg Lg R L R R R R Gy B B W W W W W W R R B B B B Br Br B L G B L R L O O O R R B B B B B B R R R R L Br Br Br Br Gy Gy B L Gy W W W B Gy B R W W...

Page 315: ...CHARGING SYSTEM 8 13 4 AC magneto 5 Rectifier regulator 8 Battery 9 Frame ground 10 Starter relay 11 Main fuse 38 Negative battery lead...

Page 316: ...HARGING THE BATTERY on page 8 57 NG Clean the battery terminals Recharge or replace the battery OK 3 Check the stator coil Refer to CHECKING THE STA TOR COIL on page 8 64 NG Replace the stator assembl...

Page 317: ...CHARGING SYSTEM 8 15...

Page 318: ...W R W R W Br O R Gy L L L L B B B B B B B B B B Sb Sb Sb Sb Br Br Lg Lg R L R R R R Gy B B W W W W W W R R B B B B Br Br B L G B L R L O O O R R B B B B B B R R R R L Br Br Br Br Gy Gy B L Gy W W W B...

Page 319: ...ctor 3 Joint connector 6 Main relay 8 Battery 9 Frame ground 10 Starter relay 11 Main fuse 16 ECU engine control unit 21 Radiator fan motor relay 22 Radiator fan motor fuse 23 Radiator fan motor 24 Jo...

Page 320: ...main relay Refer to CHECKING THE RE LAYS on page 8 60 NG Replace the main relay OK 4 Check the radiator fan motor Refer to CHECKING THE RADIA TOR FAN MOTOR For JPN on page 8 65 NG Replace the radiator...

Page 321: ...COOLING SYSTEM For JPN 8 19...

Page 322: ...W R W R W Br O R Gy L L L L B B B B B B B B B B Sb Sb Sb Sb Br Br Lg Lg R L R R R R Gy B B W W W W W W R R B B B B Br Br B L G B L R L O O O R R B B B B B B R R R R L Br Br Br Br Gy Gy B L Gy W W W B...

Page 323: ...ter relay 11 Main fuse 16 ECU engine control unit 19 Injector 24 Joint connector 25 Intake air temperature sensor 26 Coolant temperature sensor 27 Throttle position sensor 28 Intake air pressure senso...

Page 324: ...e diagnostic tool cannot be used to freely change the basic vehicle functions such as adjusting the ignition timing CONNECTING THE YAMAHA DIAGNOSTIC TOOL 1 Remove the coupler for connecting setting to...

Page 325: ...er to YAMAHA DIGNO STIC TOOL OPERATION MANUAL Operation of the Yamaha diagnostic tool Malfunction mode Malfunction results are displayed in the top part of the window area FI diagnostic tool sub lead...

Page 326: ...ist of the malfunction currently occurred are displayed 3 Code The following icons and the fault code numbers for the detected malfunctions are displayed 4 ECU The types of the control units are displ...

Page 327: ...he items or components that are the probable cause of the malfunction following the or der given After the check and service of the malfunctioning part have been completed reset the diagnostic tool di...

Page 328: ...finished Fault code number is dis played Go to item 4 4 Installed condition of crank shaft position sensor Check for looseness or pinching Check the gap between the crankshaft position sensor and the...

Page 329: ...replace the wire har ness Push the start switch Fault code number is not dis played Service is finished Fault code number is dis played Go to item 2 2 Connection of wire harness ECU coupler Check the...

Page 330: ...ge 8 67 Push the start switch Fault code number is not dis played Service is finished Fault code number is dis played Go to item 6 6 Malfunction in ECU Replace the ECU Fault code No 14 Item Intake air...

Page 331: ...nsor open or short circuit detected Fail safe system Able to start engine Able to drive vehicle Diagnostic code No 01 Diagnostic tool display Throttle position sensor signal 11 14 fully closed positio...

Page 332: ...ION SEN SOR on page 7 9 Push the start switch Fault code number is not dis played Service is finished Fault code number is dis played Go to item 5 5 Applied voltage of throttle po sition sensor lead C...

Page 333: ...sensor Check for looseness or pinching Improperly installed sensor Reinstall or replace the sensor Refer to ADJUSTING THE THROTTLE POSITION SEN SOR on page 7 9 Push the start switch Fault code number...

Page 334: ...e har ness Push the start switch Fault code number is not dis played Service is finished Fault code number is dis played Go to item 2 2 Connection of wire harness ECU coupler Check the locking conditi...

Page 335: ...intake air temperature Procedure Compare the actually measured intake air temperature with the Yamaha diagnostic tool display value Item Probable cause of malfunc tion and check Maintenance job Confi...

Page 336: ...ambient temper ature The displayed temperature is not close to the ambient tem perature Check the intake air temperature sensor Replace if defective Refer to CHECKING THE INTAKE AIR TEMPERA TURE SENS...

Page 337: ...coil is actuated Procedure Check that a spark is generated five times Connect an ignition checker Item Probable cause of malfunc tion and check Maintenance job Confirmation of service completion 1 Co...

Page 338: ...played Service is finished Fault code number is dis played Go to item 5 5 Installed condition of ignition coil Check for looseness or pinching Improperly installed sensor Reinstall or replace the sens...

Page 339: ...No operating sound Go to item 2 Operating sound Go to item 6 2 Defective injector Measure the fuel injector re sistance Replace if out of specifica tion Refer to CHECKING THE FUEL INJECTOR on page 8 6...

Page 340: ...vice is finished Fault code number is dis played Go to item 2 2 Connection of wire harness ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro...

Page 341: ...bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler securely or repair replace the wire har ness Start the engine and let it idle for approximately 5...

Page 342: ...in Diagnostic mode Code No 60 EEP ROM data error for adjust ment of CO concentration Change the CO concentra tion and rewrite in EEPROM After this adjustment push the engine stop switch then push the...

Page 343: ...et it idle for approximately 5 seconds Fault code number is not dis played Service is finished Fault code number is dis played Go to item 2 2 Wire harness continuity Open or short circuit Re place the...

Page 344: ...malfunctioning Diagnostic code No Diagnostic tool display Procedure Item Probable cause of malfunc tion and check Maintenance job Confirmation of service completion 1 Connection of Yamaha diag nostic...

Page 345: ...Yamaha diag nostic tool coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Co...

Page 346: ...e wire har ness Push the start switch Fault code number is not dis played Service is finished Fault code number is dis played Go to item 2 2 Connection of wire harness ECU coupler Check the locking co...

Page 347: ...is not dis played Service is finished Fault code number is dis played Go to item 2 2 Connection of wire harness ECU coupler Check the locking condition of the coupler Disconnect the coupler and check...

Page 348: ...R W Br O R Gy L L L L B B B B B B B B B B Sb Sb Sb Sb Br Br Lg Lg R L R R R R Gy B B W W W W W W R R B B B B Br Br B L G B L R L O O O R R B B B B B B R R R R L Br Br Br Br Gy Gy B L Gy W W W B Gy B...

Page 349: ...PUMP SYSTEM 8 47 1 Joint connector 2 Joint connector 8 Battery 9 Frame ground 10 Starter relay 11 Main fuse 16 ECU engine control unit 20 Fuel pump 24 Joint connector 30 Engine stop switch 36 Frame gr...

Page 350: ...Refer to CHECKING AND CHARGING THE BATTERY on page 8 57 NG Clean the battery terminals Recharge or replace the battery OK 3 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 8 54 NG...

Page 351: ...FUEL PUMP SYSTEM 8 49...

Page 352: ...ELECTRICAL COMPONENTS 8 50 EASB296346 ELECTRICAL COMPONENTS EASB296347 7 8 9 1 3 2 4 5 6...

Page 353: ...ELECTRICAL COMPONENTS 8 51 1 Rectifier regulator 2 Clutch switch 3 Ignition coil 4 ECU engine control unit 5 Fuel pump 6 Battery 7 Neutral switch 8 Radiator fan motor For JPN 9 Injector...

Page 354: ...ELECTRICAL COMPONENTS 8 52 11 10 9 2 3 1 6 7 8 4 5...

Page 355: ...ature sensor 2 Intake air pressure sensor 3 Throttle position sensor 4 Starter relay 5 Main fuse 6 Starting circuit cut off relay 7 Lean angle sensor 8 Radiator fan motor fuse 9 Radiator fan motor rel...

Page 356: ...ELECTRICAL COMPONENTS 8 54 EASB296348 CHECKING THE SWITCHES 4 1 3 2 B B Sb B B B B B B B B...

Page 357: ...ELECTRICAL COMPONENTS 8 55 1 Engine stop switch 2 Neutral switch 3 Clutch switch 4 Start switch...

Page 358: ...et tester range to 1 to make a 0 adjustment When checking for continuity switch back and forth between the switch positions a few times Terminal connections of the switch are shown in the terminal con...

Page 359: ...th the wrong amperage rating may cause extensive damage to the electri cal system cause the lighting and ignition systems to malfunction and could possibly cause a fire 4 Install Seat Side cover left...

Page 360: ...specific gravity of the electrolyte Therefore the charge of the battery has to be checked by measuring the voltage at the battery terminals 1 Remove Side cover left right Seat Refer to GENERAL CHASSI...

Page 361: ...nect 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 a VRLA Valve Reg ulated Lead Acid...

Page 362: ...ger is recommended d Charge the battery until the battery s charg ing voltage is 15 V TIP Set the charging time at 20 hours maximum e Measure the battery open circuit voltage af ter leaving the batter...

Page 363: ...n 3 to 4 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe 2 1 3 4 R W Br W R L G 1 2 3 4 L R Br R R R W 1 2 3 4 G B L B L G L W Result Continuity...

Page 364: ...e ignition spark gap a e Crank the engine by pushing the start switch and gradually increase the spark gap until a misfire occurs EASB296354 CHECKING THE SPARK PLUG CAP 1 Remove Spark plug cap from th...

Page 365: ...r coupler b Measure the crankshaft position sensor re sistance EASB296357 CHECKING THE LEAN ANGLE SENSOR 1 Remove Lean angle sensor from the bracket 2 Check Lean angle sensor output voltage Out of spe...

Page 366: ...e coolant temperature sensor is dropped replace it b Check the starter motor operation EAS28150 CHECKING THE STATOR COIL 1 Disconnect Stator coil coupler from the wire harness 2 Check Stator coil resi...

Page 367: ...or coupler from the wire harness b Connect the battery DC 12 V as shown c Measure the radiator fan motor movement EASB296361 CHECKING THE COOLANT TEMPERATURE SENSOR 1 Remove Coolant temperature sensor...

Page 368: ...the table EASB296362 CHECKING THE THROTTLE POSITION SENSOR 1 Remove Throttle position sensor from the throttle body EWA WARNING Handle the throttle position sensor with special care Never subject the...

Page 369: ...sure the throttle position sensor input voltage EASB296364 CHECKING THE INTAKE AIR PRESSURE SENSOR 1 Check Intake air pressure sensor output voltage Out of specification Replace a Connect the pocket t...

Page 370: ...the intake air temperature sensor terminal EASB296366 CHECKING THE FUEL INJECTOR 1 Remove Fuel injector Refer to THROTTLE BODY on page 7 5 2 Check Fuel injector resistance Out of specification Replace...

Page 371: ...AND HIGH SPEED PERFORMANCE 9 2 SHIFTING IS DIFFICULT 9 2 SHIFT PEDAL DOES NOT MOVE 9 2 JUMPS OUT OF GEAR 9 2 CLUTCH SLIPS 9 2 CLUTCH DRAGS 9 2 OVERHEATING 9 2 OVERCOOLING 9 3 POOR BRAKING PERFORMANCE...

Page 372: ...pump Faulty fuel pump 3 Throttle body Deteriorated or contaminated fuel Sucked in air Electrical system 1 Spark plug Incorrect spark plug gap Incorrect spark plug heat range Fouled spark plug Worn or...

Page 373: ...og EASB296375 CLUTCH SLIPS Engine 1 Clutch Improperly assembled clutch Loose or fatigued clutch spring Worn friction plate Worn clutch plate 2 Engine oil Incorrect oil level Incorrect oil viscosity lo...

Page 374: ...ked or damaged cap bolt O ring EASB296381 FAULTY FRONT FORK LEGS Chassis 1 Front fork Bent or damaged inner tube Bent or damaged outer tube Broken fork spring Bent or damaged damper rod Incorrect oil...

Page 375: ...32 22 Intake air temperature sensor open or short circuit detected 8 33 30 Latch up detected 8 34 33 Ignition coil open or short circuit detected in the primary lead of the ignition coil 8 35 39 Injec...

Page 376: ...en engine is hot Displays current coolant temperature Compare the actually mea sured coolant temperature with the Yamaha diagnostic tool display value 08 Lean angle sensor Upright Overturned Displays...

Page 377: ...o Diag nostic code No Item Actuation Procedure 30 Ignition coil Actuates the ignition coil five times at one second inter vals WARNING on the Yamaha diagnostic tool blinks five times when the ignition...

Page 378: ...LIST OF SELF DIAGNOSTIC AND FAIL SAFE ACTIONS 9 7...

Page 379: ...FORK SETTING 10 2 CHANGE IN AMOUNT AND CHARACTERISTICS OF FORK OIL 10 2 SETTING OF SPRING AFTER REPLACEMENT 10 2 FRONT FORK SETTING PARTS 10 3 REAR SUSPENSION SETTING 10 3 CHOOSING SET LENGTH 10 3 SET...

Page 380: ...eed the ma chine is generally set such that it can develop its maximum revolutions toward the end of the straight line with care taken to avoid the en gine over revving TIP Riding technique varies fro...

Page 381: ...the air spring characteristics to have a tendency to be stiffer with the consequent deteriorated performance and characteris tics Therefore adjust the front fork within the specified range EASB296391...

Page 382: ...of damping force Change the rebound damping force Change the compression damping force EASB296394 CHOOSING SET LENGTH 1 Place a stand or a block under the engine to put the rear wheel above the floor...

Page 383: ...ng load Run with the rebound damping force adjuster one or two clicks turned in and readjust it to suit your preference TIP Adjusting the rebound damping force will be fol lowed more or less by a chan...

Page 384: ...BSORBER ASSEMBLY on page 3 31 Spring preload adjusting positions Minimum Position in which the spring is turned in 1 5 mm 0 06 in from its free length Standard Position in which the spring is turned i...

Page 385: ...ticeable scars etc If any replace affected parts Slide metal Replace with a new one for ex tended use Piston metal Replace with a new one for ex tended use Lower bracket tightening torque Retighten to...

Page 386: ...nt Increase oil amount by about 5 cm3 0 2 US oz 0 2 Imp oz Obtrusive front tending to upper front pos ture Compression damping force Turn adjuster counterclock wise about 2 clicks to de crease damping...

Page 387: ...senger is astride seat Spring Replace with soft spring Bottoming out High compres sion damping Turn adjuster clockwise about 1 6 turn to increase damping Spring set length Set sunken length for 90 100...

Page 388: ...ensor 27 Throttle position sensor 28 Intake air pressure sensor 29 Lean angle sensor 30 Engine stop switch 31 Neutral switch 32 Diode 33 Starting circuit cut off relay 34 Clutch switch 35 Start switch...

Page 389: ...e Take care of your Yamaha with legendary Yamalube oils lubricants and care products They re formulated and approved by the toughest judges we know the Yamaha engineering teams that know your Yamaha f...

Page 390: ...UAL YZ250FXG B29 28199 11 LIT 11626 29 53 YZ250FXG 2016 q Read this manual carefully before operating this vehicle PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2015 07 0 3 1 E B29 28199 11_cover_12mm in...

Page 391: ...L R R R R Gy B B W W W W W W R R B B B B B B B Br Br B B L G B L B B B B R R R R L Br Br Br Br Gy Gy B L Gy W W W B Gy B R W W W B R R R W Br R L R B R R W Br W L G Br W Br L W R R L R Lg W B B B Gy B...

Page 392: ...ON OFF ON OFF Gy Gy B B Gy B B B L L B B B B B YZ250FXG 2016 WIRING DIAGRAM B29 28199 11_W D indd 2 2015 06 15 13 19 32...

Reviews:

No comments

Related manuals for YZ 2016 Series

Rally Pack 04910 Installation Instructions preview
04910
Brand: Rally Pack Pages: 2
Kabuto FR-1 Instruction Manual preview
FR-1
Brand: Kabuto Pages: 12
N-Com SPCOM00000091 Quick Start Manual preview
SPCOM00000091
Brand: N-Com Pages: 6
X-lite X-801 R Safety And Instructions For Use preview
X-801 R
Brand: X-lite Pages: 38
PUIG 0295 Mounting Instructions preview
0295
Brand: PUIG Pages: 2
PerTronix Compu-Fire 55120 32 Installation Instructions preview
Compu-Fire 55120 32
Brand: PerTronix Pages: 3
Shark SHKC7800N User Manual preview
SHKC7800N
Brand: Shark Pages: 16
hepco & becker 503674 00 01 Quick Start Manual preview
503674 00 01
Brand: hepco & becker Pages: 2
Royal Enfield SCRAM 411 2021 Owner'S Manual preview
SCRAM 411 2021
Brand: Royal Enfield Pages: 110
R&G RGH0007BK Fitting Instructions Manual preview
RGH0007BK
Brand: R&G Pages: 6
Wunderlich 8160952 Fitting Instructions preview
8160952
Brand: Wunderlich Pages: 2
Wunderlich 25440 Series Fitting Instructions preview
25440 Series
Brand: Wunderlich Pages: 2
Wunderlich 30940 Fitting Instruction preview
30940
Brand: Wunderlich Pages: 3
Wunderlich 20571 Series Manual preview
20571 Series
Brand: Wunderlich Pages: 3
Wunderkind Custom littleOne BMR18T Installation Manuals And Safety Information preview
littleOne BMR18T
Brand: Wunderkind Custom Pages: 4
Wunderlich F 850 GS Manual preview
F 850 GS
Brand: Wunderlich Pages: 6
BOS Suspension Factory Series Service Manual preview
Factory Series
Brand: BOS Suspension Pages: 32
Yamaha XVS950CU Owner'S Manual preview
XVS950CU
Brand: Yamaha Pages: 86

Brands by name

Popular brands

Load more brands