Yamaha YFM25RY manual

SERVICE MANUAL YFM25RY YFM25RSEY YFM25RSE2Y 4D3-28197-11 LIT-11616-22-09 2009[...]

EAS20040 YFM25R Y/YFM25RSEY/YFM25RSE2Y SER VI CE MANU A L ©2008 b y Y amaha Motor Corporation, U .S.A. First edition, April 2008 All rights reserved. An y reproduction or unauthorized use without the written permission of Y amaha Mo tor Corporation, U .S.A. is expressly pr ohibited. Printed in U .S.A. P/N LIT -11616-22-09[...]

EAS20071 IMPOR T ANT This manual was prod uced b y the Y amaha Motor Company , Ltd. primar ily f or use b y Y amaha deal- ers and their qualified mech anics. It is not possib le to include all the kno wledge of a mechan ic in one manual. Theref ore, an yone who uses this book to perf or m maintenance and repairs o n Y amaha v ehicles should ha v e [...]

EAS20090 HO W T O USE THIS MANU AL This manual is intende d as a handy , easy-to-read ref erence book f or the mechanic. Comprehensiv e e xplanations of all installation, remov al, disasse mb ly , assembly , repair and chec k procedures are laid out with the individual steps in sequential order . • The manual is divided into chapters an d each ch[...]

EAS20100 SYMBOLS The f ollowing symbols are used in this man ual for easier understanding. TIP The f ollowing symbols are not rele vant to e v er y v ehicle . No SYMBOL DEFINITION 1 Ser viceable with e ngine mounted 2 Filling fluid 3 Lubricant 4 Special tool 5 Tightening torque 6 W ear limit, clear ance 7 Engine speed 8 Electrical data 9 Engine oil[...]

10 Gear oil 11 Molybdenum-disulfide oil 12 Brak e fluid 13 Wheel-bearing grease 14 Lithium-soap-based gre ase 15 Molybdenum-disu lfide grease 16 Silicone grease 17 Apply loc king agent (LOCTITE®) 18 Replace the par t No SYMBOL DEFINITION G M BF B LS M S LT New[...]

1 2 3 4 5 6 7 8 EAS20110 T ABLE OF CONTENTS GENERAL INFORMA TION SPECIFICA TIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE FUEL SYSTEM ELECTRICAL SYSTEM TR OUBLESHOO TING[...]

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1 GENERAL INFORMA TION IDENTIFICA TION ................................. ........................................... .............. 1-1 VEHICLE IDENTIFICA TION NUMBER ................................................... 1-1 MODEL LABEL .............................. ......................................................... 1-1 IMPORT ANT INFORMA TIO[...]

IDENTIFICATION 1-1 EAS20130 IDENTIFICA TION EAS20140 VEHICLE IDENTIFICA TION NUMBER The v ehicle identification number “1” is stamped into the right side of the steering head pipe . EAS20150 MODEL LABEL The model label “1” is affix ed to the frame. This inf or mation will be needed to order spare par ts. 1 1[...]

IMPORTANT INFORMATION 1-2 EAS20180 IMPOR T ANT INFORMA TION EAS20190 PREP A RA TION FOR REMO V AL AND DISAS- SEMBL Y 1. Bef ore remov al and disassemb ly , remov e all dir t, mud, dust and f oreign material. 2. Use only the proper tools and cleaning equipment. Ref er to “SPECIAL T OOLS” on page 1-5. 3. When disassemb ling, always k eep mated pa[...]

IMPORTANT INFORMATION 1-3 EAS20210 GASKETS, OIL SEALS AND O-RINGS 1. When ov erhauling the engine, replace all gask ets, seals and O-rings. All gask et sur- f aces, oil seal lips and O-rings must be cleaned. 2. During reassembly , proper ly oil all mating par ts and bearings and lubricate the oil seal lips with grease . EAS20220 LOCK W ASHERS/PLA T[...]

CHECKING THE CONNECTIONS 1-4 EAS20250 CHECKING THE CONNECTIONS Check the leads , couplers, and connectors f or stains, rust, moisture, etc. 1. Disconnect: • Lead • Coupler • Connector 2. Chec k: • Lead • Coupler • Connector Moisture → Dr y with an air b low er . Rust/stains → Connect and disconne ct se ver al time s . 3. Chec k: •[...]

SPECIAL TOOLS 1-5 EAS20260 SPECIAL T OOLS The f ollowing special tools are necessary for comple te and accurate tune-up a nd assemb ly . Use only the appropriate special tools as this will h e lp pre vent damage caused b y the use of inappropri- ate tools or improvised te chniques . Special tools , pa r t numbers or both ma y diff er depending o n [...]

SPECIAL TOOLS 1-6 Crankshaft installer pot 90890-01274 Installing pot YU-90058 5-60 Crankshaft installer bolt 90890-01275 Bolt YU-90060 5-60 Adapter (M10) 90890-01383 Adapter #2 YU-90062 5-60 Spacer 90890-01288 5-60 Piston pin puller set 90890-01304 Piston pin puller YU-01304 5-25 T ool name/T ool No. Illustration Reference pages[...]

SPECIAL TOOLS 1-7 T appet adjusting tool 90890-01311 Six piece tappet set YM-A5970 3-5 Flywheel puller 90890-01362 Heavy duty puller YU-33270-B 5-46 Bolt (M8 × 80 mm) 90890-01359 5-46 Sheav e holder 90890-01701 Primar y clutch holder YS-01880-A 5-46, 5-47 Thickne ss gauge 90890-03180 F eeler gauge set YU-26900-9 3-4, 5-33 Compression gauge 90890-0[...]

SPECIAL TOOLS 1-8 Extension 90890-04082 3-9 P ock et tester 90890-03112 Analog poc ket tester YU-03112-C 1-4, 5-51, 7-31, 7-32, 7-33, 7- 37, 7-38, 7-39, 7-40, 7-41, 7-42 Timing light 90890-03141 Inductiv e clamp timing light YU-03141 3-8 V alv e spring compressor 90890-04019 YM-04019 5-17, 5-22 V alv e spring compressor attachment 90890-01243 V alv[...]

SPECIAL TOOLS 1-9 V alve guide installer (ø6) 90890-04065 V alve guide installer (6.0 mm) YM-04065-A 5-19 V alv e guide reamer (ø6) 90890-04066 V alv e guide reamer (6.0 mm) YM-04066 5-19 V alv e lapper 90890-04101 V alv e lapping tool YM-A8998 5-20 PTT wrench 46 90890-06588 Axle nut wrench (46 mm) YM-37134 4-13, 4-14 Ignition chec ker 90890-0675[...]

2 SPECIFICA TIONS GENERAL SPECIFICA TIONS ........................................................ .............. 2-1 ENGINE SPECIFICA TIONS ............................ .......................................... .... 2-4 CHASSIS SPECIFICA TIONS ...................................................................... 2-10 ELECTRICAL SPECIFICA TIONS .[...]

GENERAL SPECIFICATIONS 2-1 EAS29110 GENERAL SPECIFICA TIONS Model Model 4D3D/4D3H/4D3M Dimensions Ov erall length 1625 mm (64.0 in) Ov erall width 1070 mm (42.1 in) Ov erall height 1040 mm (40.9 in) Seat height 730 mm (28.7 in) Wheelbase 1110 mm (43.7 in) Ground clearance 100 mm (3.9 in) Minimum turning radius 2900 mm (114 in) W eight With oil and [...]

GENERAL SPECIFICATIONS 2-2 Spark plug (s) Manuf acturer/model NGK/DR7EA Spark plug gap 0.6–0.7 mm (0.024–0.0 28 in) Clutch type Wet, m ultiple-disc T ran smission Primar y reduction system Spur gear Primar y reduction ratio 76/22 (3.455) Secondar y reduction system Chain drive Secondar y reduction ratio 38/14 (2.714) T ransmission type Const an[...]

GENERAL SPECIFICATIONS 2-3 Rear suspension T ype Swingarm Spring/shock absorber type Coil spring/gas-oil damper Wheel tra vel 200 mm (7.9 in) Electrical system Ignition system DC . CDI Charging system A C magneto Model YTZ7S V oltage, capacity 12 V , 6.0 Ah Headlight Bulb type Kr ypton bulb Bulb v oltage , wattage × quantity Headlight 12 V , 30.0/[...]

ENGINE SPECIFICATIONS 2-4 EAS29120 ENGINE SPECIFICA TIONS Cylinder head V olume 20.50–21.50 cm 3 (1.25–1. 31 cu.in) W ar page limit 0.05 mm (0.0020 in) Cylinder Bore 74.000–74.016 mm (2. 9134–2.9140 in) W ear limit 74.100 mm (2.9173 in) Camshaft Drive system Chain drive (right) Camshaft lobe dimensions Intak e A 36.890–36.990 mm (1.4524?[...]

ENGINE SPECIFICATIONS 2-5 V alve, v alve seat, valve guide V alv e clearance (cold) Intak e 0.05–0.10 mm (0.0020–0.0039 in) Exhaust 0.10–0.15 mm (0.0039–0.0059 in) V alv e dimensions V alv e head diameter A (intak e) 33.90–34.10 mm (1.3346–1.3425 in) V alv e head diameter A (e xhaust) 28.40–28.60 mm (1.1181–1.1260 in) V alv e f ace [...]

ENGINE SPECIFICATIONS 2-6 V alve spring Inner spring F ree length (intak e) 36.17 mm (1.42 in) Limit 34.36 mm (1.35 in) F ree length (e xhaust) 36.17 mm (1.42 in) Limit 34.36 mm (1.35 in) Installed length (intak e) 30.50 mm (1.20 in) Installed length (e xhaust) 30.50 mm (1.20 in) Spring rate K1 (intak e) 14.70 N/mm (1.50 kgf/mm, 83.94 lbf/in) Sprin[...]

ENGINE SPECIFICATIONS 2-7 Piston Piston-to-cylinder clearance 0.010–0.025 mm (0.0004–0.0010 in) Limit 0.15 mm (0.0059 in) Diameter D 73.983–73.998 mm (2.9127–2.9133 in) Height H 5.0 mm (0.20 in) Offset 0.25 mm (0.0098 in) Offset direction Intak e side Piston pin bore inside diameter 17.002–17.013 mm (0.6694–0.6698 in) Limit 17.043 mm (0[...]

ENGINE SPECIFICATIONS 2-8 Crankshaft Width A 69.25 –69.30 mm (2.726–2.728 in) Runout limit C 0.03 mm (0.0012 in) Big end side clear ance D 0.350–0.650 mm (0.0138–0.0256 in) Limit 0.50 mm (0.0197 in) Big end radial clearance E 0.010–0.025 mm (0.0004–0.0010 in) Balancer Balancer drive method Gear Clutch F riction plate thickness 2.90–3.[...]

ENGINE SPECIFICATIONS 2-9 Carburetor ID mark 4D31 00 Main jet #133 .8 Main air jet #140 Jet needle 5DH66-1 Needle jet P-0M (922) Pilot air jet 1 #85 Pilot air jet 2 #170 Pilot outlet 0.9 Pilot jet #25 Bypass 1 0.8 Bypass 2 0.8 Bypass 3 0.8 V alv e se at size 2 Star ter jet 1 #55 Star ter jet 2 0.5 Throttle v alve size #100 Float height 13.0 mm (0.5[...]

CHASSIS SPECIFICATIONS 2-10 EAS29130 CHASSIS SPECIFICA TIONS Fr ont suspension Shoc k absorber tra vel 90.7 mm (3.57 in) (4D3D) 88.4 mm (3.48 in) (4D3H, 4D3M) Spring free length 248.5 mm (9.78 in) (4D3D) 224.6 mm (8.84 in) (4D3H, 4D3M) Spring rate K1 23.00 N/mm (2.35 kgf/mm, 131.33 lbf/in) Spring stroke K1 0.0–90.7 mm (0.00–3.57 in) (4D3D) 0.0?[...]

CHASSIS SPECIFICATIONS 2-11 Fr ont brake T ype Dual disc brak e Disc outside diameter × thic kness 161.0 × 3.5 mm (6.34 × 0.14 in) Brak e disc thickness limit 3.0 mm (0.12 in) Brak e disc deflection limit 0.15 mm (0.006 in) Brak e pad lining thickness (inner) 4.4 mm (0.17 in) Limit 1.5 mm (0.06 in) Brak e pad lining thickness (outer) 4.4 mm (0.1[...]

ELECTRICAL SPECIFICATIONS 2-12 EAS29140 ELECTRICAL SPECIFICA TIONS System v oltage System v oltage 12 V Ignition system Ignition timing (B.T .D .C .) 10.0 ° /1550 r/min Adv an ced timing (B .T .D .C .) 24.4 ° /5000 r/min Adv ancer type Digital DC. CDI Pic kup coil resistance 248-372 Ω (R–W) CDI unit model/manuf acturer 4D3/Y AMAHA Ignition co[...]

ELECTRICAL SPECIFICATIONS 2-13 Headlight rela y Model/manuf acturer G8HN-1C4T -DJ-Y52/OMRON Coil resistance 94.5–115.5 Ω Circuit breaker Circuit breaker type Fuse Fuse Fuse 15.0 A Reser ve 15.0 A[...]

TIGHTENING TORQUES 2-14 EAS20320 TIGHTENING T ORQ UES EAS20330 GENERAL TIGHTENING T ORQUE SPECIFI- CA TIONS This char t specifies tightening torques f or stan- dard f asteners with a standard ISO thread pitch. Tightening torque specifications f or spe- cial components or assemb lies are provided f or each chapter of this manual. T o av oid warpage,[...]

TIGHTENING TORQUES 2-15 EAS20340 ENGINE TIGHTENING T ORQUES Item Thread size Q’ty Tightening tor que Remarks Cylinder head bolt (upper) M8 4 24 Nm (2.4 m·kg, 18 ft·lb) See TIP Cylinder head bolt M8 2 20 Nm (2.0 m·kg, 15 ft·lb) Camshaft loc k plate bolt M6 2 8 Nm (0.8 m·kg, 5.9 ft·lb) Cylinder head side co v er bolt (1 and 2) M55 2 18 Nm (1.[...]

TIGHTENING TORQUES 2-16 TIP Apply oil to the bearing surf ace of (upper) cyli nder head bolt. Fur ther , apply molybden um disulfide grease to thread p ar t. Primar y dr ive gear n ut M16 1 80 Nm (8.0 m·kg, 59 ft·lb) Use a loc k was h er. Clutch boss nut M16 1 75 Nm (7.5 m·kg, 55 ft·lb) Use a lock was h er. Clutch spring screw M6 5 8 Nm (0.8 m?[...]

TIGHTENING TORQUES 2-17 EAS20350 CHASSIS TIGHTENING T ORQUES Item Thread size Q’ty Tightening tor que Remarks Engine upper sta y and frame M8 2 33 Nm (3.3 m·kg, 24 ft·lb) Engine upper sta y and engine M10 1 66 Nm (6.6 m·kg, 49 ft·lb) Engine low e r stay and frame M8 4 33 Nm (3.3 m·kg, 24 ft·lb) Engine low e r stay and engine M10 1 40 Nm (4.[...]

TIGHTENING TORQUES 2-18 F ront brak e disc and front wheel hub M8 8 28 Nm (2.8 m·kg, 21 ft·lb) Rear wheel and rear wheel hub M10 8 45 Nm (4.5 m·kg, 33 ft·lb) Rear axle and rear wheel h ub M14 2 120 Nm (12.0 m·kg, 89 ft·lb) Rear axle ring nut M33 1 140 Nm (14.0 m·kg, 103 ft·lb) Rear axle ring nut set bolt M6 2 7 Nm (0.7 m·kg, 5.2 ft·lb) Re[...]

LUBRICATION POINTS AND LUBRICANT TYPES 2-19 EAS20360 LUBRICA TION POINTS AND LUBRICANT TYPES EAS20370 ENGINE Lubrication point Lubricant Oil seal lips O-rings Bearings Cylinder head bolts (bearing surf ace of bolts) Cylinder head bolts (thread par t) Cylinder body surf ace Crankshaft journals Connecting rod small end and big e nd Piston pin Piston [...]

LUBRICATION POINTS AND LUBRICANT TYPES 2-20[...]

LUBRICATION SYSTEM CHART AND DIAGRAMS 2-21 EAS20390 LUBRICA TION SYSTEM CHART AND DIA GRAMS EAS20400 ENGINE OIL LUBRICA TION CHART[...]

LUBRICATION SYSTEM CHART AND DIAGRAMS 2-22 1. Oil pan 2. Oil strainer 3. Oil pump 4. Oil cooler 5. Oil filter element 6. Cylinder head 7. Camshaft 8. Pin with hole 9. Crankshaft 10.Dr ive a xle 11.Main axle[...]

LUBRICATION SYSTEM CHART AND DIAGRAMS 2-23 EAS20410 LUBRICA TION DIA GRAMS[...]

LUBRICATION SYSTEM CHART AND DIAGRAMS 2-24 1. Camshaft 2. Oil filter element 3. Oil pump 4. Oil strainer[...]

LUBRICATION SYSTEM CHART AND DIAGRAMS 2-25[...]

LUBRICATION SYSTEM CHART AND DIAGRAMS 2-26 1. Camshaft 2. Dr ive axle 3. Main axle 4. Push le v er shaft 5. Oil pump assemb ly 6. Oil strainer 7. Crankshaft asse mbly 8. Oil filter element[...]

LUBRICATION SYSTEM CHART AND DIAGRAMS 2-27[...]

LUBRICATION SYSTEM CHART AND DIAGRAMS 2-28 1. Oil cooler 2. Oil hose 1 3. Oil hose 2[...]

CABLE ROUTING 2-29 EAS20430 CABLE R OUTING[...]

CABLE ROUTING 2-30 1. Clutch s witch lead 2. Clutch cable 3. F ront brak e hose 1 4. F ront brak e light switch lead 5. Throttle ca b le 6. Plastic band 7. P ar king brak e cable 8. Handlebar s witch lead A. Route the clutch cab le and parking brak e cab le through the guide of the han dlebar protector . B. Route the clutch ca bl e in front of th e[...]

CABLE ROUTING 2-31[...]

CABLE ROUTING 2-32 1. Indicator light lead 2. Main s witc h lead 3. Coupler joint 4. F ront brak e hose 2 5. Oil cooler hose 1, 2 6. Exhaust pipe 7. Engine brac ket 8. P ar king brak e cable 9. Rear br ake light s witch lead 10.Batter y negativ e lead 11.Carburetor w a rmer lead 12.Air vent hose 13.3 way conn ecto r 14.Breather hose 15.Fr on t brak[...]

CABLE ROUTING 2-33[...]

CABLE ROUTING 2-34 1. Rear br ake reservoir 2. Rear br ake light s witch 3. Clip 4. Rear br ake reservoir hose 5. Rear br ake master cylinder 6. P ar king brak e cable 7. Rear br ake hose 8. Rear br ake caliper A. Make sure t ha t the end of the clip is f acing downw ard. B. Set th e rear brake reser voir hose with th e positioning yello w paint ma[...]

CABLE ROUTING 2-35[...]

CABLE ROUTING 2-36 4D3D 1. Clutch s witch lead 2. Handlebar s witch lead 3. Bolt 4. He xagonal head bolt 5. Main harness 6. Air v ent hose 7. Clamp 8. Battery negative lead 9. A C magneto lead 10. Carburetor overflow hose 11.Neutral s witch le ad 12.Star ter motor lead 13. Ignition coil spar k plug lead 14. I gnition coil 15.Drain hose 16.Fr ame co[...]

CABLE ROUTING 2-37[...]

CABLE ROUTING 2-38 4D3H/4D3M 1. Clutch s witch lead 2. Handlebar s witch lead 3. Bolt 4. He xagonal head bolt 5. Main harness 6. Air v ent hose 7. Clamp 8. Battery negative lead 9. A C magneto lead 10. Carburetor overflow hose 11.Neutral s witch le ad 12.Star ter motor lead 13. Ignition coil spar k plug lead 14. I gnition coil 15.Drain hose 16.Fr a[...]

CABLE ROUTING 2-39[...]

CABLE ROUTING 2-40 1. Indicator light 2. Coupler joint 3. Main s witc h lead 4. Main s witc h 5. F ront brak e light switch lead 6. Throttle ca b le 7. Air v ent hose 8. Clutch s witch lead 9. Handlebar s witch lead 10. P arki ng brake cable 11. C lutch cable 12.Flange bolt 13.Headlight lead 14.Indicator light lead 15. Rear brake reser voir 16.Rear[...]

CABLE ROUTING 2-41[...]

CABLE ROUTING 2-42 1. Battery 2. CDI unit 3. Band 4. Star ter rela y lead 5. Star ter rela y 6. T aillight lead 7. Battery negative lead 8. A C magneto coupler 9. Star ter motor lead 10.Headlight relay 11.N eutral rela y 12.Damper 13.CDI unit lead 14.Relay lead A. Route the starter relay lead under the star ter motor le ad. B. After connecting t he[...]

CABLE ROUTING 2-43[...]

3 PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE ................................................ ......................... 3-1 INTR ODUCTION .................................................................................... 3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTR OL SYSTEM......................................................[...]

ADJUSTING THE REAR SHOCK ABSORBER ASSEMBL Y (f or 4D3H, 4D3M) ................................................................................ .. 3-28 CHECKING THE TIRES ..................................................................... .. 3-29 CHECKING THE WHEELS ........................................... ....................... 3-31 CHECKING [...]

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PERIODIC MAINTENANCE 3-1 EAS20450 PERIODIC MAINTENANCE EAS20460 INTRODUCTI ON This chapter includes all inf or mation necessar y to perf or m recommended checks and adjustme nts. If f ollowed, these pre ventiv e maintenance procedures will ensure more reliable v ehicle operation, a longer ser vice lif e and reduce the need f or costly ov erha ul wo[...]

PERIODIC MAINTENANCE 3-2 EAS4D3F012 GENERAL MAINTENANCE AND LUBRICA TION CHART NO . ITEM CHECK OR MAINTENANCE JOB Whiche ver comes first INITIAL EVER Y m o n t h 1366 1 2 km (mi) 320 (200) 1300 (800) 2500 (1600) 2500 (1600) 5000 (3200) hours 20 80 160 160 320 1 Air filter element • Clean and rep lace if necessary . Every 20–40 hours (more often[...]

PERIODIC MAINTENANCE 3-3 TIP • The air filter needs more frequ ent ser vice if yo u are riding in unusually wet or dusty areas. • Hydraulic br ake service • Regularly chec k and, if necessary , correct the brak e fluid le v el. • Ev er y two years replace the inter nal components of the brak e master cylinders and calipers, and change the b[...]

ENGINE 3-4 EAS20472 ENGINE EAS20520 ADJUSTING THE V AL VE CLEARA NCE The f ollowing procedure applies to all of the va lve s. TIP • V alv e clearance adjus tment should be made on a cold engine , at room temperature. • When the v a lv e clearance is to be measured or adjusted, the piston m ust be at top dead center (TDC) on the compression stro[...]

ENGINE 3-5 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Adjust: • V alve clearan ce ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Loosen the loc knut. b . Inser t a thickness gau ge between the e nd of the adjusting scre w and the valv e tip . c. T ur[...]

ENGINE 3-6 5. Detach: • Digital tachometer 6. Adjust: • Throttle cab le free pla y Ref er to “ADJUSTING THE THR O TTLE CABLE FREE PLA Y” on page 3-6. EAS20660 ADJUSTING THE THRO TTLE CABLE FREE PLA Y TIP Prior to adjusting the throttle cab le free play , the engine idling speed sh ould be adjusted. 1. Chec k: • Throttle cab le free pla y [...]

ENGINE 3-7 EAS29170 ADJUSTING THE SPEED LIMITER The speed limiter k eeps the carburetor throttle from becoming fully-opened e ven when the throttle le ver is applied to the maxim um posi- tion. Scre wing in the adju sting scre w stops the engine speed from increasing. 1. Measure: • Speed limiter length “a” Out of specification → Adjust. 2. [...]

ENGINE 3-8 7. Install: • Spark plug TIP Bef ore installing the spark plug, clean the spark plug and gask et surface . 8. Connect: • Spark plug cap EAS20700 CHECKING THE IGNITION TIMING TIP Prior to checking the ignition timing, check the wiring connections of the entire ignition sys- tem. Mak e sure all connections are tight and free of corrosi[...]

ENGINE 3-9 4. Remov e: • Spark plug ECA13340 Bef ore removing th e spark plug, use com- pressed air to blo w away a ny dirt accum u- lated in the spark plug wells to prevent it fro m falling into the cylinder . 5. Install: • Compression gauge “1 ” • Extension “2” 6. Measure: • Compression pressure Out of specification → Ref er to [...]

ENGINE 3-10 • Do not scre w the dipstick “1” in when chec k- ing the oil le v el. ECA13360 • Engine oil also lubricates the c lutch and the wr ong oil types or additives could cause c lutch slippa g e. Therefore, do not add an y c hemical ad ditives or use engine oils with a grade of CD “a” or higher and do not use oils labeled “ENERG[...]

ENGINE 3-11 6. Drain: • Engine oil (completely from the crankcase) 7. If the oil filter element is also t o be replaced, perf or m the f ollowing procedure . ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remov e the oil filter element cov er “1” and oil filter element “2”. b . Install ne w O[...]

ENGINE 3-12 EAS20870 ADJUSTING THE CLUTCH CABLE FREE PLA Y 1. Chec k: • Clutch cab le free play “a ” Out of specification → Adjust. 2. Adjust: • Clutch cab le free play ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Slide bac k the le ver co ver “1”. b . Loosen the loc knut “2”. c. T [...]

ENGINE 3-13 4. Clean: • Air filter element (with solv ent) W ARNING EW A13020 Never use lo w flash point solvents, such as gasoline, to clean the air filter element. Such solvents ma y cause a fire or an e xplo- sion. TIP After cleaning, gently squeez e the air filter ele- ment to remov e th e e xcess solv ent. ECA13430 Do not twist the air filte[...]

ENGINE 3-14 • Air filter case Ref er to “GENERAL CHASSIS” on page 4-1. •C a r b u r e t o r Ref er to “CARBURET OR” on page 6-3. 2. Chec k: • Carb uretor joint • Intak e manifo ld Crac ks/damage → Replace. Ref er to “CARBURET OR” on page 6-3. 3. Install: •C a r b u r e t o r Ref er to “CARBURET OR” on page 6-3. • Air f[...]

ENGINE 3-15 d. Inser t the tailpipe and gask et “3” into the muffler and alig n the bolt holes . e. Inser t the bolts and tighten it. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Spark arrester bolt 11 Nm (1.1 m·kg, 8.1 ft·lb)[...]

CHASSIS 3-16 EAS29360 CHASSIS EAS21170 ADJUSTING THE FRONT DISC BRAKE 1. Chec k: • Brak e lev er free pla y “a” Out of specification → Bleed the f ront brak e system. Ref er to “BLEEDING THE HYDRA ULIC BRAKE SYSTEM” on page 3-20. W ARNING EW A13050 A soft or spong y feeling in the brak e lever can indicate the presence of air in the bra[...]

CHASSIS 3-17 W ARNING EW A14900 After this adjustment is performed, l ift the fro nt and rear wheels off the gr ound by placing a bloc k under the engine, and spin the rear wheels to ensure there is n o brake drag. If an y brake drag is noticed perf orm the abov e steps again. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲[...]

CHASSIS 3-18 EAS21250 CHECKING THE FRONT BRAKE P ADS The f ollowing procedure applies to all of the brak e pads. 1. Remov e: • F ront wheels Ref er to “FR ONT WHEEL ” on page 4-4. 2. Operate the b rak e. 3. Chec k: • F ront brak e pad W ear indicators g roov e almost disap- peared “a” → Replace the br ake pa ds as a set. Ref er to “[...]

CHASSIS 3-19 3. Hold the v ehicle upright and apply the front brak e sev eral times. 4. Chec k: • Brak e hose Brak e fluid leakage → Replace the dam- aged hose. Ref er to “REAR BRAKE” on page 4-27. EAS29210 ADJUSTING THE P ARKING BRA KE 1. Chec k: • P arking brake cab le end length “a” Out of specification → Adjust. 2. Adjust: • P[...]

CHASSIS 3-20 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS21350 BLEEDING THE HYDRA ULIC BRAKE SYS- TEM W ARNING EW A13100 Bleed the h ydraulic brake system when- ever: • the system is disassemb led. • a brake hose is loosened, d isconnected or replaced. • the brake fluid le vel is ver y low . ?[...]

CHASSIS 3-21 k. Fill the brak e fluid reser voir to the pro per le vel with the recommended br ak e fluid. Ref er to “CH ECKING THE BRAKE FLUID LEVEL ” on page 3-17. W ARNING EW A13110 After bleeding the h ydraulic brake system, chec k the brake operation. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲?[...]

CHASSIS 3-22 ECA4D3F005 Excessive chain slac k will ove rload the engine and other vital parts; keep the slac k within the specified limits. e. If the chain slac k cannot be adjusted, replace the sproc kets and driv e chain as a set. f . Tighten the rear axle pinch bolt s. TIP • Tighten the rear axle pinch bolts in the proper sequence as sho w n.[...]

CHASSIS 3-23 4. Raise the front end of the v ehicle so that there is no weight on the fr ont wheels. 5. Chec k: • Ball joints an d wheel bearings Mov e the wheels laterally bac k and forth. Excessiv e free pla y → Replace the front ar ms (upper and lo wer) and/or whee l bearings. EAS29290 ADJUSTING THE T OE-IN 1. Place the v ehicle on a le v el[...]

CHASSIS 3-24 d. Tighten the rod end loc knuts of both tie- rods. TIP Adjust the tie-rod ends so that “A” a nd “B” are equal. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS29300 CHECKING THE FRONT SHOCK ABSORBER ASSEMBLIES The f ollowing procedure applies to both of the front shoc k absorber as[...]

CHASSIS 3-25 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS4D3F031 ADJUSTING THE FRONT SHOCK ABSORBER ASSEMBLIES (for 4D3H, 4D3M) W ARNING EW A14920 Alwa ys adjust the spring preload f or both fro nt shock a bsorber assemblies to the same setting. Une ven adjustment can cause poor handling and loss of[...]

CHASSIS 3-26 TIP Mak e sure that the positio n indicator marks “c” are aligned when the shoc k absorber is set to the standard setting. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Compression damping (slow comp ression damping) ECA4D3F008 Do not for ce the adjuster past the minim um or maximu m ext[...]

CHASSIS 3-27 TIP Mak e sure that the positio n indicator marks “c” are aligned when the shoc k absorber is set to the standard setting. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS4D3F006 CHECKING THE REAR SHOCK ABSORBER ASSEMBL Y 1. Place the v ehicle on a le v el surf ace. 2. Chec k: • Rear [...]

CHASSIS 3-28 TIP Be sure to remov e all dir t and mud from around the loc knut and adjusting nut bef ore adjustment. d. Tighten the loc knut. TIP Alwa ys tighten the lockn ut against the adjust- ing nut, then torq ue it to specification. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS4D3F032 ADJUSTING [...]

CHASSIS 3-29 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Compression damping ECA4D3F008 Do not for ce the adjuster past the minim um or maximu m extent of adjustment. The adjuster ma y be damaged. 1. Adjust: • Compression damping ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼?[...]

CHASSIS 3-30 Tire pressure W ARNING EW A14960 • Tire pressure belo w the minim um specifi- cation could cause the tire to dislodge fr om the rim under se vere riding condi- tions. The f ollowing are minim ums: • Fr ont 24.5 kP a (0.25 kgf/cm 2 , 3.6 psi) • Rear 24.5 kP a (0.25 kgf/cm 2 , 3.6 psi) • Use no more than the fol lowing pressu res[...]

CHASSIS 3-31 W ARNING EW A13190 It is dangerous to ride with a w orn-out tire . When the tire tread reac hes the wear limit, replace the tire immediatel y . EAS29350 CHECKING THE WHEELS The f ollowing procedure applies to all of the wheels. 1. Chec k: • Wheel “1” Damage/bends → Replac e . TIP Alwa ys balance the wheel when a tire or wheel h[...]

ELECTRICAL SYSTEM 3-32 EAS21750 ELECTRICAL SYSTEM EAS21760 CHECKING AND CHARGING THE BA TTER Y Ref er to “ELECTRICAL COMPONENTS ” on page 7-27. EAS21770 CHECKING THE FUSES Ref er to “ELECTRICAL COMPONENTS ” on page 7-27. EAS21790 REPLA CING THE HEADLIGHT BULBS The f ollowing procedure applies to both of the headlight b ulbs. 1. Remov e: •[...]

ELECTRICAL SYSTEM 3-33 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. T ur n the adjusting bolt “1” in direction “a” or “b”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Direction “a” Headlight beam is ra ised. Direction “b” Headlight be[...]

4 CHASSIS GENERAL CHASSIS ........................................................... ......................... 4-1 FR ONT WHEEL ................................... ........................................... .............. 4-4 REMO VING THE FR ONT WHEELS ....................................................... 4-5 CHECKING THE FRONT WHEELS ........[...]

REPLA CING THE REAR BRAKE P ADS ............................................ .. 4-32 REMO VING THE REAR BR AKE CALIPER .......................................... 4-33 DISASSEMBLING THE REAR BRAKE CALIPER ................................ 4-34 CHECKING THE REAR BRAKE CALIPER .......................................... 4-34 ASSEMBLING THE REAR BRAKE CA[...]

CHAIN DRIVE ........................................................... .................................. 4-57 REMO VING THE DRIVE CHAIN .............................................. ............ 4-58 CHECKING THE DRIVE CHAIN .............................................. ............ 4-58 CHECKING THE DRIVE SPROCKET ........................... .[...]

GENERAL CHASSIS 4-1 EAS21830 GENERAL CHASSIS Removing the seat, fr ont fender and headlights Order Job/Parts to remove Q’ty Remarks 1S e a t 1 TIP Pull bac k the seat lock le ver , than pu l l up on the rear of the seat. 2 Indicator light coupler 1 Disconnect. 3 F ront pa nel 1 4P l a t e 1 5 Main sw itch coupler 1 Disco nnect. 6 Front fender 1 7[...]

GENERAL CHASSIS 4-2 Removing the fo ot pr otector s and engine skid plate Order Job/Parts to remove Q’ty Remarks 1 Left foot protector 1 2 Right foot protector 1 3 Engine skid plate 1 For installation, re verse the remov al proce- dure.[...]

GENERAL CHASSIS 4-3 Removi ng the rear f ende r and air filter case Order Job/Parts to remove Q’ty Remarks Seat/F ront fender Ref er to “GENERAL CHASSIS” on page 4-1. 1 Rear fender 1 2B a t t e r y c o v e r 1 3B a t t e r y l e a d 2 ECA4D3F001 First disconnect the negative lead, then disconnect the positive lea d. 4B a t t e r y 1 5R e l a [...]

FRONT WHEEL 4-4 EAS21870 FR ONT WHEEL Removing the fr ont wheels and brake discs Order Job/Parts to remove Q’ty Remarks The follo wing procedure applies to both of the front wheels. 1 Cotter pin 1 2A x l e n u t 1 3 Fro nt wheel 1 4 Brake disc guard (outer) 1 5 Brake caliper assembly 1 6 Wheel hub 1 7 Brake disc 1 For installation, re verse the r[...]

FRONT WHEEL 4-5 EAS21890 REMO VING THE FR ONT WHEELS The f ollowing procedure applies to both of the front wheels . 1. Stand the v ehicle on a lev el surface . W ARNING EW A13120 Securely support the vehic le so that there is no danger of it falling ov er . TIP Place the v ehicle on a suitable stand so that the front wheel is ele vate d. 2. Remov e[...]

FRONT WHEEL 4-6 2. Chec k: • Wheel bearings Wheel hub pla y/wheel tur ns roughly → Replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Clean wheel hub e xter ior . b . Drive bearing out b y pushing spacer aside and tapping around perimeter of bearing inner race . Use soft metal drift punch and [...]

FRONT WHEEL 4-7 EAS21970 ADJUSTING THE FRONT WHEEL ST A TIC B ALANCE TIP After replacing the tire , wheel or both, the front wheel static balance should be adjusted. 1. Remov e: • Balancing w eight(s) 2. Find: • F ront wheel’ s hea vy spot TIP Place the front wheel on a suitab le balancing stand. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼?[...]

FRONT WHEEL 4-8 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. T ur n the front wheel and make sure it sta ys at each position sho wn. b . If the front wheel does not remain station - ar y at all of the positions, rebala nce it. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲?[...]

REAR WHEEL 4-9 EAS22020 REAR WHEEL Removi ng the rear wheels Order Job/Parts to remove Q’ty Remarks 1 Rear wheel 2 2 Cotter pin 2 3A x l e n u t 2 4 Wheel hub 2 F or install ation, re verse the removal proce- dure.[...]

REAR WHEEL 4-10 EAS22040 REMO VING THE REAR WHEELS 1. Stand the v ehicle on a lev el surface . W ARNING EW A13120 Securely support the vehic le so that there is no danger of it falling ov er . TIP Place the v ehicle on a suitable stand so that the rear wheel is ele vated. 2. Remov e: • Rear wheels EAS29430 CHECKING THE REAR WHEELS The f ollowing [...]

REAR AXLE AND REAR AXLE HUB 4-11 EAS29470 REAR AXLE AND REAR AXLE HUB Removi ng the rear axle an d rear axle hub Order Job/Parts to remove Q’ty Remarks Rear wheels/Rear wheel hubs Refer to “REAR WHEEL ” on page 4-9. 1 Rear axle ring nut set bolt 2 2 Rear axle ring nut 1 3 Conical spr ing washer 1 4 Brake caliper 1 TIP Do not apply the brake p[...]

REAR AXLE AND REAR AXLE HUB 4-12 14 Dust cover 2 F or installation, re verse the removal proce- dure. Removi ng the rear axle an d rear axle hub Order Job/Parts to remove Q’ty Remarks[...]

REAR AXLE AND REAR AXLE HUB 4-13 EAS29490 REMO VING THE REAR AXLE 1. Place the v ehicle on a le v el surf ace. 2. Loosen: • Rear axle ring nut set bolts “1” 3. Remov e: • Rear axle ring nut “2” TIP • Apply the brak e pedal so that the rear axle does not turn when loosening the nut. • Use the PTT wrench 46 or axle n ut wrench (46 mm)[...]

REAR AXLE AND REAR AXLE HUB 4-14 EAS29510 CHECKING THE REAR WHEEL SPROCKET 1. Chec k: • Rear wheel sproc ket Ref er to “CHECKING THE DRIVE SPR OCKET” on page 4-59. EAS4D3F029 CHECKING THE SPROCKET BRA CKET 1. Chec k: • Sproc ket brac ket Crac ks/damage → Replace. EAS29520 INST ALLING THE REAR WHEEL SPROCKET 1. Install: • Rear wheel spro[...]

FRONT BRAKE 4-15 EAS22210 FR ONT BRAKE Removing the fr ont brake pads Order Job/Parts to remove Q’ty Remarks The follo wing procedure applies to both of the front brak e calipers. F ront whe el Refer to “FRONT WHEEL ” on page 4-4. 1B o l t 1 2 Brake pad retaining bolt 1 3 Brake pad 2 4 Brake pad spring 1 For installation, re verse the removal[...]

FRONT BRAKE 4-16 Removing the fr ont brake master c ylinder Order Job/Parts to remove Q’ty Remarks Brake fluid Drain. Refer to “BLEEDING THE HYDRA ULIC BRAKE SYSTEM” on page 3-20. 1 Brake fluid reservoir cap 1 2 Brake fluid reser voir diaphragm plate 1 3 Brake fluid reser voir diaphragm 1 4 F ront brake light switch 1 5B r a k e l e v e r 1 6[...]

FRONT BRAKE 4-17 Disassembl ing the fr ont brake master cyli nder Order Job/Parts to remove Q’ty Remarks 1 Brake master cylinder kit 1 2 Brake master cylinder body 1 For assemb ly , rev erse the disassembly pro- cedure.[...]

FRONT BRAKE 4-18 Removi ng the fr ont brake calipers Order Job/Parts to remove Q’ty Remarks The follo wing procedure applies to both of the front brak e calipers. Brake fluid Drain. Refer to “BLEEDING THE HYDRA ULIC BRAKE SYSTEM” on page 3-20. F ront whe el Refer to “FRONT WHEEL ” on page 4-4. 1 Union bolt 1 2 Copper washer 2 3 Brake hose[...]

FRONT BRAKE 4-19 Disassem bling the front b rake cali pers Order Job/Parts to remove Q’ty Remarks The follo wing procedure applies to both of the front brak e calipers. 1B o l t 1 2 Brake pad retaining bolt 1 3 Brake pad 2 4 Brake pad spring 1 5 Caliper brack e t 1 6 Caliper piston 1 7 Dust seal 1 8 Caliper piston seal 1 9 Bleed screw 1 F or asse[...]

FRONT BRAKE 4-20 EAS22220 INTRODUCTI ON W ARNING EW A14100 Disc brake components rarel y require dis- assembl y . Theref ore , alwa ys follo w these preventive meas ures: • Never dis assemble brake components unless absolutel y necessary . • If any connection on the h ydraulic brake system is disconnected, the entire b rake system m ust be disa[...]

FRONT BRAKE 4-21 EAS22250 REPLA CING THE FRONT BRAKE P ADS The f ollowing procedure applies to both brak e calipers . TIP When replacing the brak e pads , it is not neces- sar y to disconnect the bra ke hose or d isas- semb le the brake caliper . 1. Measure: • Brak e pad wear limit “a” Out of specif ication → Rep lace the br a k e pads as a[...]

FRONT BRAKE 4-22 TIP Bef ore removing the brak e caliper , drain the brak e fluid from the entire brak e system. 1. Remov e: • Union bolt “1” • Copper w ashers “2” • Brak e hose “3” • Brak e caliper bolts “4” TIP Put the end of the bra k e hose into a container and pump out the br ak e fluid carefully . EAS22310 DISASSEMBLIN[...]

FRONT BRAKE 4-23 W ARNING EW A4D3F006 Whenever a brake caliper is disassemb led, replace the brake caliper piston se al and brake caliper dust seal. 2. Chec k: • Brak e caliper brac ket “1” Crac ks/damage → Replace. EAS22400 ASSEMBLING THE FRONT BRAKE CALI- PER W ARNING EW A4D3F007 • Bef ore installation, all internal brake com- ponents s[...]

FRONT BRAKE 4-24 Ref er to “RE PLACING THE FR ONT BRAKE P ADS” on page 4-21. 4. Fill: • Brak e master cylinder reservoir (with the specified a mount of the recom- mended brak e fluid) W ARNING EW A13090 • Use onl y the designated brake fluid. Other brake fluids ma y cause the rubber seals to deteriorate, causing leakage and poor brake perf [...]

FRONT BRAKE 4-25 2. Chec k: • Brak e master cylinder kit “1” Damage/scratches/w ear → Replace. 3. Chec k: • Brak e master cylinder reser voir “1” Crac ks/damage → Replace. • Brak e master cylinder reservoir dia - phragm “2” Damage/wear → Replace. EAS22520 ASSEMBLING THE FRONT BRAKE MAS- TER CYLINDER W ARNING EW A13520 • Be[...]

FRONT BRAKE 4-26 3. Fill: • Brak e master cylinder reservoir (with the specified a mount of the recom- mended brak e fluid) W ARNING EW A13540 • Use onl y the designated brake fluid. Other brake fluids ma y cause the rubber seals to deteriorate, causing leakage and poor brake perf ormance . • Refill with the same type o f brake fluid that is [...]

REAR BRAKE 4-27 EAS22550 REAR BRAKE Removi ng the rear brake pads Order Job/Parts to remove Q’ty Remarks 1 Brake pad retaining bolt 2 2 Lock washer 1 3 Brake pad 2 4 Brake pad spring 1 For installation, re verse the removal proce- dure.[...]

REAR BRAKE 4-28 Removi ng the rear brake mast er cyli nder Order Job/Parts to remove Q’ty Remarks Right foot protector Refer to “GENERAL CHASSIS” on page 4-1. Brake fluid Drain. Refer to “BLEEDING THE HYDRA ULIC BRAKE SYSTEM” on page 3-20. 1 Brake fluid reservoir cov e r 1 2 Brake fluid reservoir cap 1 3 Brake fluid reser voir diaphragm h[...]

REAR BRAKE 4-29 Disassembl ing the r ear brake ma ster c ylinder Order Job/Parts to remove Q’ty Remarks 1 Hose joint 1 2 Brake master cylinder kit 1 3 Brake master cylinder 1 For assemb ly , rev erse the disassemb ly pro- cedure.[...]

REAR BRAKE 4-30 Removi ng the rear brake cal iper Order Job/Parts to remove Q’ty Remarks Brake fluid Drain. Refer to “BLEEDING THE HYDRA ULIC BRAKE SYSTEM” on page 3-20. 1 P a rking brake cable 1 Disconnect. 2 Union bolt 1 3 Copper washer 2 4 Brake hose 1 5 Brake caliper assembly 1 For installation, re verse the remov al proce- dure.[...]

REAR BRAKE 4-31 Disassembl ing the r ear brake caliper s Order Job/Parts to remove Q’ty Remarks 1 Adjusting bolt 1 2 Locknut 1 3 P a rking brake ar m 1 4 Brake pad retaining bolt 2 5 Lock washer 1 6 Brake pad 2 7 Brake pad spring 1 8 Retaining bolt 1 9 Caliper brack e t 1 10 Brake caliper piston 1 11 Dust seal 1 12 Calip er piston seal 1 13 Bleed[...]

REAR BRAKE 4-32 EAS22560 INTRODUCTI ON W ARNING EW A14100 Disc brake components rarel y require dis- assembl y . Theref ore , alwa ys follo w these preventive meas ures: • Never dis assemble brake components unless absolutel y necessary . • If any connection on the h ydraulic brake system is disconnected, the entire b rake system m ust be disas[...]

REAR BRAKE 4-33 b . Loosen the b leed screw and push the brak e caliper pistons into the brak e caliper with your finger . c. Tighten the b leed screw . d. Install ne w brake pads and a ne w brak e pad spring. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Install: • Loc k washer “1” • Brak e p[...]

REAR BRAKE 4-34 EAS22600 DISASSEMBLING THE REAR BRAK E CALI- PER 1. Remov e: • Brak e caliper piston • Brak e caliper dust seal “1” • Brak e caliper piston seal “2” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Blow compressed a ir into the br ake ho se joint opening “a” to f orce ou[...]

REAR BRAKE 4-35 1. Install: • O-ring “1” • Caliper piston seal “2” • Caliper dust seal “3” 2. Install: • Brak e caliper piston “1” 3. Install: • P arking brake arm “1” 4. Measure: • P arking brake arm to parking brak e brac ket distance “a” Out of specification → Adjust. EAS22670 INST ALLING THE REAR BRAKE CALI[...]

REAR BRAKE 4-36 W ARNING EW A13090 • Use onl y the designated brake fluid. Other brake fluids ma y cause the rubber seals to deteriorate, causing leakage and poor brake perf ormance . • Refill with the same type o f brake fluid that is already in the system. Mixin g brake fluids ma y result in a harmful chemical reaction, leading to poor bra ke[...]

REAR BRAKE 4-37 3. Chec k: • Brak e fluid reser voir “1” Crac ks/damage → Replace. • Brak e fluid reser voir diaphra gm “2” Crac ks/damage → Replace. 4. Chec k: • Brak e hoses Crac ks/damage/wear → Replace. EAS22730 ASSEMBLING THE REAR BRAKE MASTE R CYLINDER W ARNING EW A13520 • Bef ore installation, all internal brake com- po[...]

REAR BRAKE 4-38 3. Fill: • Brak e fluid reser v oir (with the specified a mount of the recom- mended brak e fluid) W ARNING EW A13090 • Use onl y the designated brake fluid. Other brake fluids ma y cause the rubber seals to deteriorate, causing leakage and poor brake perf ormance . • Refill with the same type o f brake fluid that is already i[...]

HANDLEBAR 4-39 EAS22840 HANDLEB AR Removing the handlebar Order Job/Parts to remove Q’ty Remarks 1 Handlebar pro tector 1 2B a n d 3 3 F ront brake light switch 1 4 Brake master cylinder/brack et 1/1 5 Throttle lev er assembly/brack et 1/1 6S p a c e r 1 7 Clutch switch 1 8 P a rking brake lev er 1 9 Clutch lev er/brack e t 1/1 10 H andlebar swit[...]

HANDLEBAR 4-40 EAS22860 REMO VING THE HANDLEB ARS 1. Remov e: • Clutch s witch “1” TIP Push the f astener when removing the clutch s witch out of the clutch lev er holder . 2. Remov e: • Handlebar grip “1” TIP Blow co mpressed air betw een the left handle- bar and the handlebar grip , and gradually push the grip off the handlebar . EAS2[...]

HANDLEBAR 4-41 TIP • Bef ore applying the adhesiv e, wipe o ff grease or oil on the handlebar surf ace “a” with a lacquer thinner . • Install the handlebar grips so that the “L ” arrow on the left g r ip and “R” arrow on the right grip are placed v er tically . 3. Install: • Handlebar s witch “1” • Clutch le ver • Clutch l[...]

HANDLEBAR 4-42 Thrott le cable fre e play 2.0–4.0 mm (0.08–0.16 in)[...]

STEERING STEM 4-43 EAS29540 STEERING STEM Removing the steering stem Order Job/Parts to remove Q’ty Remarks F ront fender Ref er to “GENERAL CHASSIS” on pag e 4-1. 1 Lock washer 1 2 Br acke t 1 3 Steer ing stem b ushing 2 4S p a c e r 2 5 Oil seal 2 6 Steering stem 1 7 Bushing 2 F or installation, re verse the removal proce- dure.[...]

STEERING STEM 4-44 EAS29560 CHECKING THE STEERING STEM 1. Chec k: • Steering stem “1” Bends → Replace. W ARNING EW A15030 Do not attempt to straighten a bent ste m; this ma y dangerous ly weaken the stem. 2. Chec k: • Oil seals “1” • Steering stem bushin gs “2” W ear/damage → Replace . 3. Chec k: • O-rings “1” • Bushin[...]

TIE-RODS AND STEERING KNUCKLES 4-45 EAS29660 TIE-R O DS AND ST EERING KNUCKLES Removi ng the tie-r ods and steering knuc kles Order Job/Parts to remove Q’ty Remarks The follo wing procedure applies to both of the tie-rods and steering knuckles. F ront whe el Refer to “FRONT WHEEL ” on page 4-4. F ront brake caliper/Brak e disc Ref e r to “F[...]

TIE-RODS AND STEERING KNUCKLES 4-46 EAS29670 REMO VING THE STEERING KNUCKLES The f ollowing procedure applies to both of the steer ing k nuckles. 1. Remov e: • Steering knuckle “1” TIP Use a general puller to separate the ball joints “2” from the steering knuc kle “1”. EAS29680 CHECKING THE TIE- R ODS The f ollowing procedure applies [...]

FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES 4-47 EAS29710 FR ONT ARMS AND FRONT SH OCK ABSORBER ASSEMBLIES Removi ng the fr ont arms and front shoc k absorber assembl ies Order Job/Parts to remove Q’ty Remarks The follo wing procedure applies to both of the front upper ar ms, front lo wer arms, and front shock absorber assemb lies. F ront whe [...]

FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES 4-48 EAS29720 REMO VING THE FR ONT ARMS The f ollowing procedure applies to both of the front upper arms and front lowe r ar ms. 1. Chec k: • F ront ar m free pla y ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Chec k the front arm side play “A” b y[...]

FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES 4-49 EAS29760 CHECKING THE FRONT SHOCK ABSORBER ASSEMBLIES The f ollowing procedure applies to both of the front shoc k absorber assemblies . 1. Chec k: • F ront shoc k absorber assemb ly Oil leaks → Replace the front sho ck absorber assemb ly . • F ront shoc k absorber rod Bends/damage → Repla[...]

FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES 4-50 TIP Apply lithium-soap-based gre ase to the grease nipples “3”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Front upper arm nut 45 Nm (4.5 m·kg, 33 ft·lb) Front lower arm n ut 45 Nm (4.5 m·kg, 33 ft·lb)[...]

REAR SHOCK ABSORBER ASSEMBLY 4-51 EAS23160 REAR SHOCK ABSORBER ASSEMBL Y Removi ng the rear shoc k absorber assembl y Order Job/Parts to remove Q’ty Remarks Seat/Rear fender/Air filter case Refer to “GENERAL CHASSIS” on page 4-1. 1C l a m p 2 Loosen. F or 4D3H, 4D3M 2 Rear shock absorber assembly 1 For installation, re verse the remov al proc[...]

REAR SHOCK ABSORBER ASSEMBLY 4-52 EAS23170 HANDLING THE REAR SHOCK ABSORBER W ARNING EW A13750 This rear shoc k absorber and gas cylinder contains highly compressed nitr og en gas. Before handli ng the rear shock absorber and gas cylinder , read and make sure y ou understand the f ollowing inf ormation. The manufacturer cannot be held responsible f[...]

REAR SHOCK ABSORBER ASSEMBLY 4-53 EAS23300 INST ALLING THE REAR SHOCK ABSORBER ASSEMBL Y 1. Install: • Rear shoc k absorber assembly TIP When installing the rear shoc k absorber assembly lo wer bolt, lift up the s wingar m. A. fo r 4D3D B. f or 4D3H, 4D3M Rear shoc k absorber assemb ly nut 55 Nm (5.5 m·kg, 41 ft·lb)[...]

SWINGARM 4-54 EAS23330 SWINGARM Removing the swingarm Order Job/Parts to remove Q’ty Remarks Rear axle hub Refer to “REAR AXLE AND REAR AXLE HUB” on page 4-11. Rear shock absorber assembly Refer to “REAR SHOCK ABSORBER ASSEMBL Y” on page 4-51. 1P l a t e 1 2 Swingar m end cov er 1 3 Pivot shaft nut/w a sher 1/1 4 Pivot shaft 1 5 Swingar m[...]

SWINGARM 4-55 EAS23340 REMO VING THE SWINGARM 1. Stand the v ehicle on a lev el surface . W ARNING EW A13120 Securely support the vehic le so that there is no danger of it falling ov er . TIP Place the v ehicle on a suitable stand so that the rear wheel is ele vated. 2. Measure: • Swingarm side pla y • Swingarm ver tical mov ement ▼▼▼▼?[...]

SWINGARM 4-56 EAS23380 INST ALLING THE SWINGARM 1. Lubricate: • Bearings • Spacer • Oil seals 2. Install: • Bearings “1” • Spacer “2” • Oil seals •D u s t c o v e r s TIP Inject the bearing with the character stamp turned outward. 3. Install: • Piv ot shaft 4. Install: • Rear shoc k absorber assembly • Rear axle hub • [...]

CHAIN DRIVE 4-57 EAS23400 CHAIN DRIVE Removing the drive spr oc ket and drive cha i n Order Job/Parts to remove Q’ty Remarks 1 Drive sprock et cover 1 2 Drive chain guide 2 1 3 Drive chain guide 3 1 4 D r i ve s pr ocke t nu t 1 5 Lock washer 1 6 D r i ve s pr ocke t 1 7D r i v e c h a i n 1 F or installation, re verse the remo val proce- dure.[...]

CHAIN DRIVE 4-58 EAS23430 REMO VING THE DRIVE CHAIN 1. Remov e: • Master link clip (with interlocking slip-joint pliers) 2. Remov e: • Master link plate “1” • O-ring “2” • Master link “3” 3. Remov e: • Drive chain EAS23441 CHECKING THE DRIVE CHAIN 1. Measure: • 15-link section “a” of the driv e chain Out of specification[...]

CHAIN DRIVE 4-59 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Chec k: • O-rings “1” Damage → Replace the drive chain. • Drive chain rollers “2” Damage/wear → Replace the dr iv e chain. • Drive chain side plates “3” Damage/wear → Replace the dr iv e chain. Cracks → Replace th[...]

CHAIN DRIVE 4-60 3. Bend the loc k washer tab along a flat side of the nut. 4. Install: • Master link “1” • O-ring “2” • Master link plate “3” ECA14300 Never install a ne w drive chain onto w orn drive chain spr ockets; this will dramaticall y shorten the drive chain’ s lif e . 5. Install: • Master link clip “1” ECA4D3F007[...]

CHAIN DRIVE 4-61[...]

5 ENGINE ENGINE REMO V AL .................................................. .................................... 5-1 INST ALLING THE ENGINE ........... ......................................................... 5-4 INST ALLING THE MUFFLER AND EXHA UST PIPE.............................. 5-4 CAMSHAFT ..................................................[...]

ASSENBLING THE BALANCER WEIGHT GEAR ................................ 5-41 INST ALLING THE OIL PUMP ............................. .................................. 5-41 INST ALLING THE BALANCER WEIGHT GEAR .................................. 5-41 SHIFT SHAFT ........................................................... ................................[...]

[...]

ENGINE REMOVAL 5-1 EAS23711 ENGINE REMO V AL Removing the muf fler an d exhau st pipe Order Job/Parts to remove Q’ty Remarks Seat/front panel/front fender/rear f en der Refer to “GENER AL CHASSIS” on page 4-1. 1 Clamp 1 Lo osen. 2M u f f l e r 1 3G a s k e t 1 4 Exhaust pipe 1 5 EXhaust pipe protector 1 6G a s k e t 1 F or installation, re ve[...]

ENGINE REMOVAL 5-2 Disconne cting the leads, ca bles and ho ses Order Job/Parts to remove Q’ty Remarks Engine oil D rain. Oil cooler hose 1, 2 Refer to “CLUTCH” on page 5-29. Carburetor Refer to “CARBURET OR” on page 6-3. Drive sprock et/dr ive chain Refer to “CHAIN DRIVE” on page 4-57. 1 Ignition coil spar k plug lead 1 2 Air filter [...]

ENGINE REMOVAL 5-3 Removing the engine Order Job/Parts to remove Q’ty Remarks 1 C rankcase bolt 1 2 Engine mounting bolt (front) 1 3 Engine brack et (left an d right) 2 4 Engine mounting bolt (u pp e r) 1 5 Engine brac ket (upper) 1 6 Engine mounting bo lt (rear upper) 1 7 Engine mounting bolt (rear lo wer) 1 8 Engine assembly 1 For installation,[...]

ENGINE REMOVAL 5-4 EAS23720 INST ALLING THE ENGINE 1. Install: • Engine mounting bolt (rear lo wer side) “1” • Engine mounting bolt (rear upper side) “2” • Engine br ack et bolts (upper side) “3” • Engine mounting bolt (upper side) “4” • Engine brac kets (front side) “5” “6” • Engine mounting bolt (front side) ?[...]

ENGINE REMOVAL 5-5 4. Install: •G a s k e t • Exhaust pipe “1” 5. Tighten: • Nuts (e xhaust pipe) “2” 6. Install: •C l a m p TIP Slide the clamp onto the end of the muffler and inser t the projection “a” of the clamp into a slot “b” in the muffler . Tighten the clamp after installing the m uffler . Exhaust pipe nut 18 Nm (1.[...]

CAMSHAFT 5-6 EAS23730 CAMSHAFT Removi ng the r ocke r arms and camshaft Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-10. 1 Lock plate 1 2 Locknut/v alve clearance adjusting screw 2/2 3 Camshaft 1 4 Intake roc k er ar m shaft 1 5 Intake roc k er ar m 1 6 Exhaust rock er arm shaft 1 7 Exhaust rock er a[...]

CAMSHAFT 5-7 EAS23770 REMO VING THE ROCKER ARMS AND CAMSHAFT 1. Loosen: • Loc knut “1” • V alv e cle arance adjusting s crew “2” 2. Remov e: • Loc k plate “3” 3. Remov e: • Camshaft “1” • Bearing “2” TIP Screw 10 mm (0.396 in) bolt “3” into the threaded end of the camshaft and then pull out the camshaft. 4. Remov e[...]

CAMSHAFT 5-8 4. Chec k: • Camshaft oil passage Obstr uction → Blow out with compressed air . EAS23880 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS The f ollowing procedure applies to all of the rock er ar ms and rock er ar m shafts. 1. Chec k: • Roc k er arms “1” • V alv e cle arance adjusting screws “2” Damage/wear → Replace. 2[...]

CAMSHAFT 5-9 Out of specification → Replace the def ec- tiv e par t(s). EAS24040 INST ALLING THE CAMSHAFT AND ROCKER ARMS 1. Lubricate: • Camshaft 2. Lubricate: • R o cke r a r m • Roc ker ar m shafts 3. Install: • Exhaust roc ker arm “1” • Exhaust roc ker arm shaft “2” TIP Mak e sure the e xhaust rock er ar m shaft is completel[...]

CYLINDER HEAD 5-10 EAS24100 CYLINDER HEAD Removi ng the cylin der he ad Order Job/Parts to remove Q’ty Remarks Seat/front panel/front fender Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank/fue l ta nk shield Ref er to “FUEL T ANK” on page 6-1. Muffler and exhaust pipe/Ignition coil spark plug lead/Engine bracket (upper side) Refer to ?[...]

CYLINDER HEAD 5-11 F or installation, re verse the remo val proce- dure. Removi ng the cylin der he ad Order Job/Parts to remove Q’ty Remarks[...]

CYLINDER HEAD 5-12 EAS24130 REMO VING THE CYLINDER HEAD 1. Align: • “I” mark “a” on the pic kup coil rotor (with the stationary pointer “b” on the crankcase c ov er) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. T ur n the pickup coil rotor countercloc kwise. b . When the piston is at TD[...]

CYLINDER HEAD 5-13 2. Chec k: • Cylinder head Damage/scratches → Re place. 3. Measure: • Cylinder head w ar page Out of specification → Resurf ace the cyl- inder head. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Place a straightedge “1” a nd a thic kness gauge “2” across the cylinder[...]

CYLINDER HEAD 5-14 3. Chec k: • Cap bolt •S p r i n g •O n e - w a y c a m • Timing chain tensioner rod Damage/wear → Replace the timing chain tensioner . EAS24230 INST ALLING THE CYLINDER HEAD 1. Install: • Cylinder head gask et • Dow el pins 2. Install: • Cylinder head • Copper w ashers • Cylinder head bolts 3. Tighten: • Cy[...]

CYLINDER HEAD 5-15 b . With the timing chain tensioner rod tur ned all the w ay into the timing chain tensioner housing (with the thin scre wdr iv er still installed), install the ne w gask et and the timing chain tensioner “2” onto the bo dy cylinder . c. Tighten the timing chain tensio ner bolts “3” to the specified torque . d. Remov e th[...]

VALVES AND VALVE SPRINGS 5-16 EAS24270 V AL VES AND V AL VE SPRINGS Removi ng the v alves and v alve springs Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-10. Rock er arm/camshaft Refer to “CAMSHAFT” on page 5-6. 1 V alve cotter 4 2 V alve spring retainer 2 3 Outer valv e sp ring 2 4 Inner valv e [...]

VALVES AND VALVE SPRINGS 5-17 EAS24280 REMO VING THE V AL V ES The f ollowing procedure applies to all of the v alv es and related components. TIP Bef ore removing the internal par ts of the cylin- der head (e.g ., v alves , v alve springs, v alve seats), mak e sure the v alves properly seal. 1. Chec k: • V a lv e sealing Leakage at the v alve se[...]

VALVES AND VALVE SPRINGS 5-18 2. Replace: •V a l v e g u i d e TIP T o ease v alve guide remov al and installation, and to maintain the correct fit, heat the cylinder head to 100 ° C (212 ° F) in an o ven. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remov e the valv e guide with the valv e guide[...]

VALVES AND VALVE SPRINGS 5-19 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Eliminate: • Carbon deposits (from the v alv e f ace and valv e seat) 4. Chec k: •V a l v e f a c e Pitting/wear → Grind the v alv e f ace. • V a lv e stem end Mushroom shape or diameter larger tha n the body of the va[...]

VALVES AND VALVE SPRINGS 5-20 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Apply Mechanic’ s b lueing dye (Dyk em) “b” onto the v alv e f ace. b . Install the v alve into the cylinder head. c. Press the v alve through the v alve guide and onto the v alve seat to mak e a clear impression. d. Mea[...]

VALVES AND VALVE SPRINGS 5-21 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS24310 CHECKING THE V AL VE SPRINGS The f ollowing procedure applies to all of the v alv e springs. 1. Measure: • V alve spring free length “a” Out of specification → Replace the v alve spring. 2. Measure: • Compresse[...]

VALVES AND VALVE SPRINGS 5-22 EAS24340 INST ALLING THE V AL VES The f ollowing procedure applies to all of the v alv es and related components. 1. Debu rr : • V a lv e stem end (with an oil stone) 2. Lubricate: •V a l v e s t e m • V alve stem seal (with the recommended lubricant) 3. Install: • V alve spring seat “1” • V a lv e stem s[...]

VALVES AND VALVE SPRINGS 5-23 5. T o secure the valv e cotters onto the v alve stem, lightly tap the v alve tip with a soft- f ace hammer . ECA13800 Hitting the v alve tip with e xcessive f orce could damage the v alve .[...]

CYLINDER AND PISTON 5-24 EAS24350 CYLINDER AND PIST ON Removing the cylinder an d pis ton Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-10. 1 Oil deliver y pipe 1 2 Cylinder 1 3D o w e l p i n 2 4 C ylinder gask et 1 5 Piston pin clip 2 6 Piston pin 1 7P i s t o n 1 8 Piston r ing set 1 For installati[...]

CYLINDER AND PISTON 5-25 EAS24380 REMO VING THE PIST ON 1. Remov e: • Piston pin clips “1” • Piston pin “2” •P i s t o n “ 3 ” ECA13810 Do not use a hammer to drive the piston pin out. TIP • Bef ore removing the piston pin clip , co ver the crankcase opening with a clean rag to pre- v ent the piston pin clip from f alling into t[...]

CYLINDER AND PISTON 5-26 b . If out of specification, rebore or replace the cylinder , and replace the piston a nd piston rings as a set. c. Measure piston skir t diameter D “a” with the micrometer . d. If out of specification, replace the piston and piston rings as a set. e. Calculate the piston-to-cylinder clear ance with the follo wing formu[...]

CYLINDER AND PISTON 5-27 EAS24440 CHECKING THE PIST ON PIN 1. Chec k: • Piston pin Blue discolora tion/groo ves → Replace the piston pin and then chec k the lubrica- tion system. 2. Measure: • Piston pin outside diameter “a” Out of specification → Replace the piston pin. 3. Measure: • Piston pin bore diameter “b” Out of specificat[...]

CYLINDER AND PISTON 5-28 • Upper oil ring rail “3” • 2nd ring “4” • T op r ing “5” TIP Be sure to install the piston rings so that the “T” marks or numbers f ace up . 2. Install: •P i s t o n “ 1 ” • Piston pin “2” • Piston pin clips “3” TIP • Apply engine oil the piston pin. • Mak e sure the dot “a” [...]

CLUTCH 5-29 EAS25061 CLUTCH Removi ng the c l utch co ver Order Job/Parts to remove Q’ty Remarks Engine oil Drain. Refer to “CHANGING THE ENGINE OIL ” on page 3-10. 1 Cotter pin/Washer 1/1 2 C levis pin 1 3 Brake pedal/F oo trest 1/1 4 Oil deliver y pipe 1 5 Oil cooler hose 2 6O - r i n g 2 7 Right crankcase cover 1 8D o w e l p i n 2 9 C ran[...]

CLUTCH 5-30 Removi ng the clutch Ord er Job/P ar ts to remove Q’ty Remarks 1C l u t c h s p r i n g 5 2 Pre ssur e pla te 1 3 Pr i mar y driv e gear n ut 1 4 Frict ion plate 6 5 Clutch plate 5 6 Cl ut ch b oss nu t 1 7C l u t c h b o s s 1 8 Thr ust w asher 1 9 Clutch housi ng 1 10 Cla w washer 1 11 Primary drive g ear 1 12 L ocknut/Washe r 1 /1 [...]

CLUTCH 5-31 Removing the push leve r shaf t Order Job/Parts to remove Q’ty Remarks Shift pedal Refer to “SHIFT SHAFT” on page 5-42. Left crankcase co v er Refer to “PICKUP COIL RO TOR AND ST ARTER CLU T CH” on page 5- 45. Clutch assembly 1C l u t c h c a b l e 1 2B o l t 1 3 Push lev er shaft 1 4 T orsion spr ing 1 5 Circlip 1 6 Oil seal [...]

CLUTCH 5-32 EAS25070 REMO VING THE CLUTCH 1. Remov e: •B o l t “ 1 ” • Clutch spring “2” TIP Loosen the bolts in stages and in a crisscross pattern. 2. Straighten the loc k washer tab . 3. Loosen: • Primar y dr ive gear n ut • Clutch boss nut TIP • Place the aluminum plate “a” be twe en clutch housing “1” and primar y driv[...]

CLUTCH 5-33 TIP Measure the friction plate at f our places . EAS25110 CHECKING THE CLUTCH PLA TES The f ollowing procedure applies to all of the clutch plates . 1. Chec k: • Clutch plate Damage → Replace the clutch plates as a set. 2. Measure: • Clutch plate w ar page (with a surf ace plate and thic kness gauge “1”) Out of specification ?[...]

CLUTCH 5-34 TIP Pitting on the clutch boss splines will cause erratic clutch opera tion. EAS25170 CHECKING THE PRESSURE PLA TE 1. Chec k: • Pressure plate Crac ks/damage → Replace. EAS25190 CHECKING THE CLUTCH PUSH RODS 1. Chec k: • Push le v er shaft “1” • Push rod 2 “2” • Ball “3” Crac ks/damage/wear → Replace the def ecti[...]

CLUTCH 5-35 4. Bend the l ock w asher tab along a flat side of the nut. 5. Lubricate: • F riction plates • Clutch plat es (with the recommended l ubr icant) 6. Instal l: • F riction plates (6 piece) • Clutch plat es (5 piece) TIP First, install a friction pl ate and the n alternate between a clutch plate and a friction plat e. 7. Instal l: [...]

CLUTCH 5-36 11. Adjust: • Push lever positio n ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Loosen the lo c knut “1”. b . T ur n the adjusti ng screw “2” in or out until the marks are aligned. c. Hold the adjust ing scre w to pre vent i t from mo ving and then ti ghten the l ocknu t to spec[...]

CLUTCH 5-37 14. Install: • Right crankcase co ver 15. Install: • Crankc ase co v er bolts M6 × 50 mm “1”, “2” • Copper w ashers to “1”, “2” • Crankc ase co v er bolts M6 × 40 mm “3”– “6” • Crankc ase co v er bolts M6 × 25 mm “7”– “13” • Oil filter element cov er bolt M6 × 70 mm “14” 16. Tighte[...]

OIL PUMP 5-38 EAS24911 OIL PUMP Removing the oil pump Order Job/Parts to remove Q’ty Remarks Right crankcase cover /clutch /primar y dr ive gear Refer to “CLUTCH” on page 5-29. 1 Balancer weight gear nut 1 2 Lock washer 1 3 Buffer boss 1 4 Balancer weight gear 1 5 Absorber plate 1 6 Compression spr ing 6 7D o w e l p i n 3 8S t r a i g h t k [...]

OIL PUMP 5-39 Disassembl e the oil pump Order Job/Parts to remove Q’ty Remarks 1 Oil pump housin g 1 2D o w e l p i n 2 3 O uter rotor 1 4 Inner rotor 1 5D o w e l p i n 1 6S h a f t 1 7O i l p u m p c o v e r 1 F or installation, re verse the remo val proce- dure.[...]

OIL PUMP 5-40 EAS24940 REMO VING THE OIL PUMP 1. Straighten the loc k washer tab . 2. Remov e: • Balancer w eight gear n ut • Loc k washer • Balancer w eight gear TIP Place the aluminium plate “a” betw een bal- ancer drive gear “1” an d balancer weight g ear “2”, and then loosen the balancer w eight gear nut “3”. 3. Remov e: ?[...]

OIL PUMP 5-41 • Compression spring • Dow el pin Crac ks/damage/wear → Replace. EAS4D3F018 ASSENBLING THE B ALANCER WEIGHT GEAR 1. Assemble: • Dow el pin “1” • Compression spring “2” TIP Install the dow el pins and compression spr ings alternately as shown as . 2. Assemble: • Buff er boss EAS25020 INST ALLING THE OIL PUMP 1. Inst[...]

SHIFT SHAFT 5-42 EAS25410 SHIFT SHAFT Removing the shift shaft and stoppe r lever Order Job/Parts to remove Q’ty Remarks Right crankcase cover/clutch Refer to “CLUTCH” on page 5-29. 1 Shift pedal 1 2 Shift shaft assembly 1 3 Stopper lev er 1 4 T orsion spr ing 1 For installation, re verse the remova l proce- dure.[...]

SHIFT SHAFT 5-43 EAS 2542 0 CHECKING THE SHIFT SHAFT 1. Chec k: • Shif t shaf t “1” • Shi ft lev er “2” Bends/d amage/wear → Re pl a ce. • Shi ft lev er spr ing Damage/w ear → Replace . EAS 2543 0 CHECKING THE ST OPPER LEVER 1. Chec k: • Stopper l e ver Bends/damag e → Replace . Roller t u rns roughly → Replace the stop- per[...]

SHIFT SHAFT 5-44 6. Tighten: • Shif t pedal bolt 7. Adjust: • Shift pedal height Ref er to “ADJUSTING THE SHIFT PED AL ” on page 3-21. Shift pedal bolt 10 Nm (1.0 m·kg, 7.4 ft·lb)[...]

PICKUP COIL ROTOR AND STARTER CLUTCH 5-45 EAS403F008 PICKUP COIL R O T OR AND ST ARTER CLUTCH Removing the pic k up coil rot or and starter clutc h Order Job/Parts to remove Q’ty Remarks Engine oil Drain. Refer to “ENGINE” on page 3-4. Shift pedal Refer to “SHIFT SHAFT” on page 5-42. Drive sprock et cover Refer to “CHAIN DRIVE” on pag[...]

PICKUP COIL ROTOR AND STARTER CLUTCH 5-46 EAS403F009 REMO VING THE PICKUPCOIL RO T OR 1. Remov e: • Pic kup coil rot or bolt “1” • W asher TIP • Loosen the pic kup coil rotor bolt “1” while holding the rotor with a sh ea v e holder “2”. • Do not allo w the shea v e holder to touch the projection on the rotor “a”. 2. Remov e:[...]

PICKUP COIL ROTOR AND STARTER CLUTCH 5-47 3. Chec k: • Star ter clutch gear’ s contacting surf aces Damage/pitting/w ear → Replace the star ter clutch gear . 4. Chec k: • Star ter clutch operation ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Install the star ter wheel gear “1” onto th e s[...]

PICKUP COIL ROTOR AND STARTER CLUTCH 5-48 4. Install: • Stator coil “1” •P i c k u p c o i l “ 2 ” 5. Tighten: • Stator coil bolts “3” • Pic kup coil bolts “4” • Left crankcase co ver bolt “5” 6. Install: • Dow el pin • Crankc ase co ver gask et 7. Install: • Left crankcase co ver 8. Tighten: • Crankcase cov er[...]

ELECTRIC STARTER 5-49 EAS24780 ELECTRIC ST ARTER Removing the starter motor Order Job/Parts to remove Q’ty Remarks Exhaust pipe Ref e r to “ENGINE REMO V AL ” o n page 5-1. Star ter idle gear cove r/Star ter idle gear Refer to “PICKUP COIL RO T O R AND ST ARTER CLU T CH” on page 5- 45. 1 Clutch cable holder 1 2 Star ter motor lead 1 Disco[...]

ELECTRIC STARTER 5-50 Disassembling th e st ar te r mo to r Order Job/Parts to remove Q’ty Remarks 1 F ront bracket 1 2 T ang washer 1 3 Plate washer 1 4 Circlip 1 5 Rear brac ket/Brush hol der 1/1 6 Ar m ature assembly 1 7 S t ar t er m ot o r yo ke 1 8B r u s h / s p r i n g 2 / 2 F or assemb ly , re verse the disassembly pro- cedure.[...]

ELECTRIC STARTER 5-51 EAS24790 CHECKING THE ST ARTER MO T OR 1. Chec k: • Commutator Dir t → Clean with 600 grit sandpaper . 2. Measure: • Commutator d iameter “a” Out of specification → Replace t he star ter motor . 3. Measure: • Mica undercut “a” Out of specification → Scr ape the mica to the proper measurement with a hac ksaw[...]

ELECTRIC STARTER 5-52 7. Chec k: • Gear teeth Damage/wear → Replace the gear . 8. Chec k: • Bushing • Bearing • Oil seal Damage/wear → Re place the de fectiv e par t(s). EAS24800 ASSEMBLING THE ST ARTER MO T OR 1. Install: • Brush spring “1” •B r u s h “ 2 ” 2. Install: • Armature coil “1” 3. Install: • O-ring “1?[...]

CRANKCASE 5-53 EAS25540 CRANKCASE Separating the cra nkcase Order Job/Parts to remove Q’ty Remarks Engine Refer to “ENGINE REMO V AL ” on page 5-1. Cylinder head Refer to “CYLINDER HEAD” on page 5-10. Cylinder/pi ston Ref er to “CYLINDER AND PIST ON” on page 5-24. Clutch Refer to “CLUTCH” on page 5-29. Oil pump/balancer weight gea[...]

CRANKCASE 5-54 Removing the bearing Order Job/Parts to remove Q’ty Remarks Cranks haft assemb ly Refer to “CRANKSHAFT ASSEMBL Y” on page 5-57. Main axle assembly/drive axle assemb ly Refer to “TRANSMISSION” on page 5-61. 1 Oil seal 2 2 Bearing 8 F or assembly , re verse the remo val proce- dure.[...]

CRANKCASE 5-55 EAS25570 DISASSEMBLING THE CR ANKCASE 1. Remov e: • Timing chain guide (intak e side) “1” • Timing chain “2” • Crankshaft sproc ket “3” 2. Remov e: • Neutral s witch “1” • Crankcase bolts M6 × 70 mm “2”–“4” • Copper w ashers • Crankcase bolts M6 × 60 mm “5”, “6” • Crankcase bolts M6[...]

CRANKCASE 5-56 3. Install: • Right crankcase (onto the left cr ankcase) TIP T ap lightly on the right crankcase with a soft- fa c e h a m m e r. 4. Install: • Crankcase bolt M6 × 70 mm: “1”–“3” • Copper w ashers T o “1”–“3”. • Crankcase bolt M6 × 60 mm: “4”, “5” • Crankcase bolt M6 × 55 mm: “6”–“8”[...]

CRANKSHAFT ASSEMBLY 5-57 EAS25970 CRANKSHAFT ASSEMBL Y Removi ng the crankshaf t assembl y Order Job/Parts to remove Q’ty Remarks Crankcase Ref er to “CRANKCASE” on page 5-53. 1 Balancer weight 1 2 C rankshaft assemb ly 1 3D o w e l p i n 1 4 Plunger seal 1 5 Bearing 1 F or installation, rev erse the removal proce- dure.[...]

CRANKSHAFT ASSEMBLY 5-58 EAS25990 REMO VING THE CRANKSHAFT ASSEMBL Y 1. Remov e: • Balancer w eight • Crankshaft a ssemb ly “1” TIP • Remov e the crankshaft assemb ly with the crankcase separ ating tool “2”. • Mak e sure the crankcase separ ating tool is centered ov er the crankshaft assemb ly . EAS4D3F021 REMO VING THE PLUNGER SEAL[...]

CRANKSHAFT ASSEMBLY 5-59 4. Chec k: • Crankshaft sproc ket Damage/wear → Replace the crankshaft. • Bearing Crac ks/damage/wear → Replace the crankshaft. 5. Chec k: • Crankshaft journal Scratches/w ear → Replace the cr ank- shaft. • Crankshaft journal oil passage Obstr uction → Blow out with compressed air . EAS4D3F022 CHECKING THE T[...]

CRANKSHAFT ASSEMBLY 5-60 TIP Install the crankshaft assemb ly with the crank- shaft installer pot “2”, cr ankshaft installer bolt “3”, adapter “4” and spacer “5”. ECA13970 T o av oid scratching the crankshaft and to ease the installation pr ocedure, lubricate the oil seal lips with lithium-soap-based grease and each bearing with eng[...]

TRANSMISSION 5-61 EAS26241 TRANSMISSION Removing the transm ission, s hift drum asse mbly , and shift forks Order Job/Parts to remove Q’ty Remarks Crank case Separate . Refer to “CRANKCASE” on page 5-53. 1 Shift fork guide bar 1 2 Shift drum assembly 1 3 Shift fork-3 (R) 1 4 Shift fork-2 (C) 1 5 Shift fork-1 (L) 1 6 Main axle assembly 1 7 D r[...]

TRANSMISSION 5-62 Disassembl ing the transmi ssion Order Job/Parts to remove Q’ty Remarks 1 2nd pinion gear 1 2 5th pinio n gear 1 3 3rd pinion gear 1 4 Circlip/washer 1/1 5 4th pinio n gear 1 6 Main axle 1 7 Plain washer 1 8 1st wheel gear 1 9 4th wheel gear 1 10 Circlip/washer 1/1 11 3 r d whee l gear/collar 1/1 12 Claw washer 1 1 13 Claw washe[...]

TRANSMISSION 5-63 EAS26250 REMO VING THE TRANSMISSION 1. Remov e: • Shift f or k guide bar “1” • Shift drum assembly “2” • Shift f or k 3 (R) “3” • Shift f or k 2 (C) • Shift f or k 1 (L) “4” 2. Remov e: • T ransmission “5” EAS26260 CHECKING THE SHIFT FORKS The f ollowing procedure applies to all of the shift f or ks[...]

TRANSMISSION 5-64 EAS26280 CHECKING THE TRANSMISSION 1. Measure: • Main axle runout (with a centering de vice and dial gauge) Out of specification → Replace t he main axle. 2. Measure: • Drive a xle runout (with a centering de vice and dial gauge) Out of specification → Replace the driv e axle. 3. Chec k: • T ransmission gears Blue discol[...]

TRANSMISSION 5-65 EAS26320 INST ALLING THE SHIFT FORKS AND SHIFT DRUM ASSEMBL Y 1. Install: • T ransmission “1” • Shift f or k 1 (L) “2” • Shift f or k 2 (C) • Shift f or k 3 (R) “3” • Shift drum assembly “4” • Shift f or k guide bar “5” • Spacer • Right crankcase TIP The embossed marks on the shift f orks shou l[...]

6 FUEL SYSTEM FUEL T ANK .......... .......................................... .......................................... .... 6-1 REMO VING THE FUEL T A NK .................. .............................................. 6-2 CHECKING THE FUEL COCK ............................................................... 6-2 CHECKING THE FUEL COCK OPERA TIO[...]

FUEL TANK 6-1 EAS26620 FUEL T ANK Removing the fuel tank Order Job/Parts to remove Q’ty Remarks Seat/front fender Refer to “GENERAL CHASSIS” on page 4-1. 1 Fuel hose (fuel cock side) 1 2F u e l t a n k 1 3C l a m p 1 4 Fuel tank shield 1 For installation, re verse the remov al proce- dure.[...]

FUEL TANK 6-2 EAS26630 REMO VING THE FUEL T ANK 1. Remov e: • Fuel hose (fuel coc k side) ECA14700 Although the fuel has been removed fr om the fuel tank be careful when remo ving the fuel hoses, since there ma y be fuel remaining in it. TIP Bef ore removing the hose , tur n the fuel cock to “OFF” and place a f ew rags in the area under where[...]

CARBURETOR 6-3 EAS26720 CARBURET OR Removi ng the carb uretor Order Job/Parts to remove Q’ty Remarks Seat/front fender/rear f ende r/air filter case Refer to “GENERAL CHASSIS” on page 4-1. 1 Carburetor wa rm er couple r 1 Disco nnect. 2 Air vent hose 1 Disconnect. 3 Fuel hose (carburetor side) 1 Disconnect. 4 Throttle cable cov er 1 5 Throttl[...]

CARBURETOR 6-4 Disassembling t he carburetor Order Job/Parts to remove Q’ty Remarks 1 D rain hose 1 2 Throttle stop screw 1 3C o v e r 1 4 Diaphragm spring 1 5P i s t o n v a l v e 1 6 Jet needle 1 7C o v e r 1 8S p r i n g 1 9 Coasting enr icher diaphragm 1 10 C oasting enriche r jet (P . A. J. 2) 1 11 Star ter plunger 1 12 Carburetor warmer pos[...]

CARBURETOR 6-5 23 Star ter jet 1 For assemb ly , re verse the disassembly pro- cedure. Disassembling t he carburetor Order Job/Parts to remove Q’ty Remarks[...]

CARBURETOR 6-6 EAS26760 CHECKING THE CARBURET OR 1. Chec k: • Carb uretor body • Float cham b er Crac ks/damage → Replace. • Float chamber body Contamination → Clean. 2. Chec k: • Fuel passages Obstr uction → Clean. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. W ash the carburetor in a [...]

CARBURETOR 6-7 8. Chec k: • Jet needle “1” Bends/wear/damage → Replace . • Clip groo ve F ree pla y/wear → Replace. 9. Chec k: • Main jet “1” • Pilot jet “2” • Needle jet “3” • Needle jet holde r “4” • Star ter jet “5” • Coasting enricher jet (P . A. J. 2) “6” Bends/damage/wear → Replace . Obstr uct[...]

CARBURETOR 6-8 c. If the float height is not with in the specifica- tion, chec k the v alv e seat and needle v alv e . d. If either is wo r n, replace the v alve seat, needle v alve and O-ring as a set. e. If both are fine , adjust the float height by bending the float tang “1” on the float. f . Recheck the f loat height. ▲▲▲▲▲▲▲?[...]

CARBURETOR 6-9[...]

7 ELECTRICAL SYSTEM IGNITION SYSTEM ......................................................................... .............. 7-1 CIRCUIT DIA GRAM ............. ................................................................... 7-1 TR OUBLESHOO TING .............................. .......................................... .... 7-3 ELECTRIC ST ARTIN[...]

IGNITION SYSTEM 7-1 EAS27090 IGNITION SYSTEM EAS27100 CIRCUIT DIA GRAM[...]

IGNITION SYSTEM 7-2 1. Pick up coil 2. Stator co il 4. Main s witc h 5. Batter y positiv e lead 6. Battery 7. Fuse 10.CDI unit 11. I gnition coil 12.Spar k plug 24.Engine stop switch 28.Ground[...]

IGNITION SYSTEM 7-3 EAS27130 TR OUBLESHOO TING The ignition system f ails to operate (no spark or intermittent spar k). TIP • Bef ore troubleshooting, remo v e the f ollowing par t(s): 1. Seat 2. F ront panel 3. F ront f ender 4. Rear f ender 5. Side cov er NG → OK ↓ NG → OK ↓ NG → OK ↓ OK → NG ↓ NG → OK ↓ NG → OK ↓ NG →[...]

IGNITION SYSTEM 7-4 NG → OK ↓ NG → OK ↓ NG → OK ↓ NG → OK ↓ NG → OK ↓ NG → OK ↓ NG → OK ↓ 8. Check the stator coil. Ref er to “CHECKING THE ST A T OR COIL ” on page 7-40. Replace the stator assemb ly . 9. Check the main s witch. Ref er to “CHECKING THE SWITCHES” on page 7-29. Replace the main s witch. 10.Chec k t[...]

ELECTRIC STARTING SYSTEM 7-5 EAS27160 ELECTRIC ST ARTI NG SYSTEM EAS27170 CIRCUIT DIA GRAM[...]

ELECTRIC STARTING SYSTEM 7-6 4. Main s witc h 5. Batter y positiv e lead 6. Battery 7. Fuse 8. Star ter rela y 9. Star ter motor 13.Star t ing circuit cut-off rela y 14. C lutch switch 18.N eutral s witch 24.Engine stop switch 25.Star t s witch 28.Ground[...]

ELECTRIC STARTING SYSTEM 7-7 EAS27180 ST ARTING CIRCUIT CUT -OFF SYSTEM OPERA TION If the engine stop s witch is set to “ ” and the main s witch is set to “ON” (both s witches are closed), the star ter motor can only operate if at least one of the f ollowing conditions is met: • The transmission is in neutr al (the neutral s witch is clos[...]

ELECTRIC STARTING SYSTEM 7-8 a. WHEN THE TRANSMISSION IS IN NEU- TRAL b . WHEN THE CLUTCH LEVER IS PULLED T O THE HANDLEBAR 1. Battery 2. Fuse 3. Main s witc h 4. Engine stop s witch 5. Star ting circui t cut -o ff re lay 6. Clutch s witch 7. Neutral s witch 8. Star t s witch 9. Star ter rela y 10. Star ter m otor[...]

ELECTRIC STARTING SYSTEM 7-9 EAS27190 TR OUBLESHOO TING The star ter motor f ails to turn. TIP • Bef ore troubleshooting, remo v e the f ollowing par t(s): 1. Seat 2. F ront panel 3. F ront f ender 4. Rear f ender 5. Side cov er NG → OK ↓ NG → OK ↓ OK → NG ↓ NG → OK ↓ NG → OK ↓ NG → OK ↓ NG → OK ↓ 1. Check the fuse . R[...]

ELECTRIC STARTING SYSTEM 7-10 NG → OK ↓ NG → OK ↓ NG → OK ↓ NG → OK ↓ NG → OK ↓ NG → OK ↓ 8. Check the main s witch. Ref er to “CHECKING THE SWITCHES” on page 7-29. Replace the main s witch. 9. Check the engine stop s witch. Ref er to “CHECKING THE SWITCHES” on page 7-29. Replace the handlebar s witch. 10.Chec k the [...]

CHARGING SYSTEM 7-11 EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIA GRAM[...]

CHARGING SYSTEM 7-12 2. Stator co il 3. Rectifier/regulator 5. Batter y positiv e lead 6. Battery 7. Fuse 28.Ground[...]

CHARGING SYSTEM 7-13 EAS27230 TR OUBLESHOO TING The battery is not being charged. TIP • Bef ore troubleshooting, remo v e the f ollowing par t(s): 1. Seat 2. F ront panel 3. F ront f ender 4. Rear f ender 5. Side cov er NG → OK ↓ NG → OK ↓ NG → OK ↓ NG → OK ↓ NG → OK ↓ 1. Check the fuse . Ref er to “CHECKIN G THE FUSES” on[...]

CHARGING SYSTEM 7-14[...]

LIGHTING SYSTEM 7-15 EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIA GRAM[...]

LIGHTING SYSTEM 7-16 2. Stator co il 3. Rectifier/regulator 4. Main s witc h 5. Batter y positiv e lead 6. Battery 7. Fuse 21.T ail/brak e light 23. L ight switch 26.Headlight relay 27.Headlight 28.Ground[...]

LIGHTING SYSTEM 7-17 EAS27260 TR OUBLESHOO TING Any of the f ollowing f ail to light: headlight, tail/brak e light. TIP • Bef ore troubleshooting, remo v e the f ollowing par t(s): 1. Seat 2. F ront panel 3. F ront f ender 4. Rear f ender 5. Side cov er NG → OK ↓ NG → OK ↓ NG → OK ↓ NG → OK ↓ NG → OK ↓ NG → OK ↓ 1. Check t[...]

LIGHTING SYSTEM 7-18 NG → OK ↓ 7. Check the entire lighting system’ s wiring. Ref er to “CIRCUIT DIA GRAM” on page 7-15. Properly connect or repair the lighting system’ s wir ing. This circuit is OK.[...]

SIGNALING SYSTEM 7-19 EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIA GRAM[...]

SIGNALING SYSTEM 7-20 4. Main s witc h 5. Batter y positiv e lead 6. Battery 7. Fuse 17.N eutral indicator light 18.N eutral s witch 19.Rear brake l ight switch 20.Fr on t brak e light switch 21.T ail/brak e light 28.Ground[...]

SIGNALING SYSTEM 7-21 EAS27290 TR OUBLESHOO TING Any of the f ollowing f ail to light: brak e light or an indicator light. TIP • Bef ore troubleshooting, remo v e the f ollowing par t(s): 1. Seat 2. F ront f ender NG → OK ↓ NG → OK ↓ NG → OK ↓ NG → OK ↓ Check the signaling system The tail/brak e light f ails to come on. NG → OK [...]

SIGNALING SYSTEM 7-22 NG → OK ↓ The neutral indicator light f ails to come. NG → OK ↓ NG → OK ↓ NG → OK ↓ 3. Check the entire signalin g system’ s wiring. Ref er to “CIRCUIT DIA GRAM” on page 7-19. Properly connect or repair the signal- ing system’ s wiring. This circuit is OK. 1. Check the neutral indicator light bulb a nd [...]

CARBURETOR HEATING SYSTEM 7-23 EAS27490 CARBURET OR HEA TING SYSTEM EAS27500 CIRCUIT DIA GRAM[...]

CARBURETOR HEATING SYSTEM 7-24 4. Main s witc h 5. Batter y positiv e lead 6. Battery 7. Fuse 15.Ther mo swit ch 16. Carburetor war me r 28.Ground[...]

CARBURETOR HEATING SYSTEM 7-25 EAS27510 TR OUBLESHOO TING The carburet or heating system f ails to oper ate. TIP • Bef ore troubleshooting, remo v e the f ollowing par t(s): 1. Seat 2. F ront panel 3. F ront f ender 4. Rear f ender 5. Side cov er NG → OK ↓ NG → OK ↓ NG → OK ↓ NG → OK ↓ NG → OK ↓ NG → OK ↓ 1. Check the fuse[...]

CARBURETOR HEATING SYSTEM 7-26[...]

ELECTRICAL COMPONENTS 7-27 EAS27972 ELECTRICAL COMPONENTS[...]

ELECTRICAL COMPONENTS 7-28 1. Main s witc h 2. F ront brak e light switch 3. Clutch s witch 4. Handlebar s witch 5. CDI unit 6. Star ter rela y 7. Fuse 8. Battery 9. T ail/brak e light 10.Headlight relay 11.Star t ing circuit cut-off rela y 12.Ther mo swit ch 13. Carburetor war me r 14. Star ter m otor 15. Pickup coil/stator assembly 16.N eutral s [...]

ELECTRICAL COMPONENTS 7-29 EAS27980 CHECKING THE SWITCHES[...]

ELECTRICAL COMPONENTS 7-30 1. Light s witch 2. Engine stop s witch 3. Star t s witch 4. Main s witc h 5. F ront brak e light switch 6. Clutch s witch 7. Fuse 8. Neutral s witch 9. Rear br ake light s witch[...]

ELECTRICAL COMPONENTS 7-31 Check each s witch f or continuity with the poc ket tester . If the continuity reading is incorre ct, chec k the wiring connections and if necessar y , replace the switch. ECA14370 Never insert the tester pr obes into the coupler terminal sl ots “a”. Al wa ys insert the probes fro m the opposite end of the coupler , t[...]

ELECTRICAL COMPONENTS 7-32 EAS27990 CHECKING THE BULBS AND BULB SOCK- ETS Check each b ulb and bulb soc ket f or damage or wear , proper conne ctions, an d also f or conti- nuity betw een the terminals. Damage/wear → Repair or replace the b ulb , bulb soc ket or both. Improperly connected → Properly connect. No continuity → Repair or replace [...]

ELECTRICAL COMPONENTS 7-33 Checking the condition of the b ulb sockets The f ollowing procedure applies to all of the bul b s o cket s. 1. Chec k: • Bulb soc k et (f or continuity) (with the poc ke t tester) No continuity → Replace . TIP Check each b ulb sock et fo r continuit y in the same manner as described in the b ulb section; how ev er , [...]

ELECTRICAL COMPONENTS 7-34 Therefore, al wa ys f ollow these pre ventive measures: • W ear protective e ye gear when handling or wo rking near batteries. • Charge batteries in a we ll-ventilated area. • Keep ba tteries awa y from fire, sparks or open flames (e.g., welding equipment, lighted cigarettes). • DO NO T SMOKE when char ging or han[...]

ELECTRICAL COMPONENTS 7-35 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Charge: • Batter y (ref er to the appropriate charging method illustration) W ARNING EW A13300 Do not quick char g e a battery . ECA4D3F013 • Never rem o ve the VRLA (V alve Regulated Lead Acid) battery sealing caps. • Do n[...]

ELECTRICAL COMPONENTS 7-36 TIP V oltage should be measured 30 min utes after the machine is stopped. b . Connect a charged and AMP meter t o the battery and star t charging. TIP Set the charging v oltage at 16–17 V .If the set- ting is lo w er , charging will be insuffi cient. If too high, the battery will be ov er-charged. c. Make sure t hat the[...]

ELECTRICAL COMPONENTS 7-37 9. Lubricate: • Batter y ter minals 10. Install: • Batter y cov er • Seat Ref er to “GENERAL CHASSIS” on page 4-1. EAS28040 CHECKING THE RELA YS Check each s witch f or continuity with the pock et tester . If the continuity reading is incor- rect, replace the rela y . 1. Disconnect the rela y from the wire harne[...]

ELECTRICAL COMPONENTS 7-38 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the star ting circuit cut-off relay from the wire harness. b . Connect the poc ket tester ( Ω × 1) to the diode coup ler as shown. c. Check th e diode f or continuity . d. Chec k the diode f or no continuity . TIP W[...]

ELECTRICAL COMPONENTS 7-39 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the spark plug cap from the ignition coil. b . Connect the poc ket tester ( Ω × 1k) to the ignition coil as shown. c. Measure the secondar y coil resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲[...]

ELECTRICAL COMPONENTS 7-40 b . Measure the pic kup coil resistance . ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS28940 CHECKING THE ST ARTER MO T OR OPERA- TION 1. Chec k: • Star ter motor operation Does not operate → P e rf or m the electric star ting system troubleshooting, starting with step [...]

ELECTRICAL COMPONENTS 7-41 EAS28170 CHECKING THE RECTIFIER/REGULA TOR 1. Chec k: • Rectifier/regulator outp ut v oltage Out of specification → Replace t he recti- fier/regulator . ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Set the engine tachomet er to the ignition coil. b . Connect the poc ket[...]

ELECTRICAL COMPONENTS 7-42 EAS28310 CHECKING THE CARBURET OR W ARMER 1. Chec k: • Carb uretor warmer resistance Out of specification → Replace . ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remov e the carburetor w ar mer from the carbureto r . b . Connect the poc ket tester ( Ω × 1) to the ca[...]

ELECTRICAL COMPONENTS 7-43[...]

8 TR OUBLESHOO TING TR OUBLESHOO TING .............................................. .................................... 8-1 GENERAL INFORMA TION ................................. .................................... 8-1 ST AR TING F AILURES .............................................................. .............. 8-1 INCORRECT ENGINE IDLING S[...]

TROUBLESHOOTING 8-1 EAS28451 TR OUBLESHOO TING EAS28460 GENERAL INFORMA TION TIP The f ollowing guide f or trouble shooting does not cov er all the possib le causes of troub le. It should be helpful, ho we v er , as a guide to basic troubleshooting. Ref er to the relativ e proce- dure in this manual f or checks , adjustments, and replacement of par[...]

TROUBLESHOOTING 8-2 EAS28490 INCORRECT ENGINE IDLING SPEED Engine 1. Cylinder and cylinder head • Incorrect v alve cleara nce • Damaged v alve tr ain components 2. Air filter • Clogged air filte r element • Loosen air filter joint Fuel system 1. Carbu retor • F aulty star ter plunger • Loose or clogged pilot jet • Loose or clogged pil[...]

TROUBLESHOOTING 8-3 • Incorrect oil le vel • Incorrect oil viscosity (low ) • Deteriorated oil Clutch drags 1. Clutch • Une venly tensioned clutch springs • W ar ped pressure plate • Bent clutch plate • Swollen friction plate • Bent clutch push rod • Damaged clutch boss • Burnt pr imar y driven gear b ushing • Loose clutch bos[...]

TROUBLESHOOTING 8-4 • F aulty batter y • F aulty rectifier/regulator • Improperly grounded circuit • F aulty main s witch • F aulty light s witch • Headlight b ulb lif e expired T ail/brake light does not come on • Wrong tail/brak e light bulb • T oo many electrical accessor ies • Hard charging • Incorrect connection • Imprope[...]

EAS28740 WIRING DIA GRAM YFM25R Y/YFM25RSEY/ YFM25RSE2Y 1. Pickup coil 2. Stator coil 3. Rectifier/regulator 4. Main switch 5. Batter y positive lead 6. Battery 7. Fuse 8. Star ter rela y 9. Star ter motor 10. CDI unit 11. Ignition coil 12. Spark plug 13. Star ting circuit cut-off relay 14. Clutch switch 15. Ther mo switch 16. Carburetor w ar mer 1[...]

[...]

YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN[...]

WIRING DIAGRAM YFM25RY/YFM25RSEY/YFM25RSE2Y[...]