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Yamaha 2009 Raptor 250 Service Manual - Important Information

Summary of 2009 Raptor 250

  • Page 1

    Service manual yfm25ry yfm25rsey yfm25rse2y 4d3-28197-11 lit-11616-22-09 2009.

  • Page 2

    Eas20040 yfm25ry/yfm25rsey/yfm25rse2y service manual ©2008 by yamaha motor corporation, u.S.A. First edition, april 2008 all rights reserved. Any reproduction or unauthorized use without the written permission of yamaha motor corporation, u.S.A. Is expressly prohibited. Printed in u.S.A. P/n lit-116...

  • Page 3

    Eas20071 important this manual was produced by the yamaha motor company, ltd. Primarily for use by yamaha deal- ers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on y...

  • Page 4

    Eas20090 how to use this manual this manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. • the manual is di...

  • Page 5

    Eas20100 symbols the following symbols are used in this manual for easier understanding. Tip the following symbols are not relevant to every vehicle. No symbol definition 1 serviceable with engine mounted 2 filling fluid 3 lubricant 4 special tool 5 tightening torque 6 wear limit, clearance 7 engine...

  • Page 6

    10 gear oil 11 molybdenum-disulfide oil 12 brake fluid 13 wheel-bearing grease 14 lithium-soap-based grease 15 molybdenum-disulfide grease 16 silicone grease 17 apply locking agent (loctite®) 18 replace the part no symbol definition g m bf b ls m s lt new.

  • Page 7: Table of Contents

    1 2 3 4 5 6 7 8 eas20110 table of contents general information specifications periodic checks and adjustments chassis engine fuel system electrical system troubleshooting.

  • Page 9: General Information

    1 general information identification ..........................................................................................1-1 vehicle identification number...................................................1-1 model label ............................................................................

  • Page 10: Identification

    Identification 1-1 eas20130 identification eas20140 vehicle identification number the vehicle identification number “1” is stamped into the right side of the steering head pipe. Eas20150 model label the model label “1” is affixed to the frame. This information will be needed to order spare parts. 1 ...

  • Page 11: Important Information

    Important information 1-2 eas20180 important information eas20190 preparation for removal and disas- sembly 1. Before removal and disassembly, remove all dirt, mud, dust and foreign material. 2. Use only the proper tools and cleaning equipment. Refer to “special tools” on page 1-5. 3. When disassemb...

  • Page 12: Important Information

    Important information 1-3 eas20210 gaskets, oil seals and o-rings 1. When overhauling the engine, replace all gaskets, seals and o-rings. All gasket sur- faces, oil seal lips and o-rings must be cleaned. 2. During reassembly, properly oil all mating parts and bearings and lubricate the oil seal lips...

  • Page 13: Checking The Connections

    Checking the connections 1-4 eas20250 checking the connections check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: • lead • coupler • connector 2. Check: • lead • coupler • connector moisture → dry with an air blower. Rust/stains → connect and disconnect several...

  • Page 14: Special Tools

    Special tools 1-5 eas20260 special tools the following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropri- ate tools or improvised techniques. Special tools, part numbers ...

  • Page 15: Special Tools

    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 tool name/tool no....

  • Page 16: Special Tools

    Special tools 1-7 tappet 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 sheave holder 90890-01701 primary clutch holder ys-01880-a 5-46, 5-47 thickness gauge 90890-03180 feeler gauge set yu...

  • Page 17: Special Tools

    Special tools 1-8 extension 90890-04082 3-9 pocket tester 90890-03112 analog pocket 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 inductive clamp timing light yu-03141 3-8 valve spring compressor 90890-04019 ym-04019 5-17, 5-22 valve spri...

  • Page 18: Special Tools

    Special tools 1-9 valve guide installer (ø6) 90890-04065 valve guide installer (6.0 mm) ym-04065-a 5-19 valve guide reamer (ø6) 90890-04066 valve guide reamer (6.0 mm) ym-04066 5-19 valve lapper 90890-04101 valve lapping tool ym-a8998 5-20 ptt wrench 46 90890-06588 axle nut wrench (46 mm) ym-37134 4...

  • Page 19: Specifications

    2 specifications general specifications ......................................................................2-1 engine specifications..........................................................................2-4 chassis specifications....................................................................

  • Page 20: General Specifications

    General specifications 2-1 eas29110 general specifications model model 4d3d/4d3h/4d3m dimensions overall length 1625 mm (64.0 in) overall width 1070 mm (42.1 in) overall 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...

  • Page 21: General Specifications

    General specifications 2-2 spark plug (s) manufacturer/model ngk/dr7ea spark plug gap 0.6–0.7 mm (0.024–0.028 in) clutch type wet, multiple-disc transmission primary reduction system spur gear primary reduction ratio 76/22 (3.455) secondary reduction system chain drive secondary reduction ratio 38/1...

  • Page 22: General Specifications

    General specifications 2-3 rear suspension type swingarm spring/shock absorber type coil spring/gas-oil damper wheel travel 200 mm (7.9 in) electrical system ignition system dc. Cdi charging system ac magneto model ytz7s voltage, capacity 12 v, 6.0 ah headlight bulb type krypton bulb bulb voltage, w...

  • Page 23: Engine Specifications

    Engine specifications 2-4 eas29120 engine specifications cylinder head volume 20.50–21.50 cm 3 (1.25–1.31 cu.In) warpage limit 0.05 mm (0.0020 in) cylinder bore 74.000–74.016 mm (2.9134–2.9140 in) wear limit 74.100 mm (2.9173 in) camshaft drive system chain drive (right) camshaft lobe dimensions int...

  • Page 24: Engine Specifications

    Engine specifications 2-5 valve, valve seat, valve guide valve clearance (cold) intake 0.05–0.10 mm (0.0020–0.0039 in) exhaust 0.10–0.15 mm (0.0039–0.0059 in) valve dimensions valve head diameter a (intake) 33.90–34.10 mm (1.3346–1.3425 in) valve head diameter a (exhaust) 28.40–28.60 mm (1.1181–1.12...

  • Page 25: Engine Specifications

    Engine specifications 2-6 valve spring inner spring free length (intake) 36.17 mm (1.42 in) limit 34.36 mm (1.35 in) free length (exhaust) 36.17 mm (1.42 in) limit 34.36 mm (1.35 in) installed length (intake) 30.50 mm (1.20 in) installed length (exhaust) 30.50 mm (1.20 in) spring rate k1 (intake) 14...

  • Page 26: Engine Specifications

    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 intake side piston pin bore inside diameter 17.002–17.013 mm ...

  • Page 27: Engine Specifications

    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 clearance 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...

  • Page 28: Engine Specifications

    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 valve seat size 2 starter jet 1 #55 starter jet 2 0.5 throttl...

  • Page 29: Chassis Specifications

    Chassis specifications 2-10 eas29130 chassis specifications front suspension shock absorber travel 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...

  • Page 30: Chassis Specifications

    Chassis specifications 2-11 front brake type dual disc brake disc outside diameter × thickness 161.0 × 3.5 mm (6.34 × 0.14 in) brake disc thickness limit 3.0 mm (0.12 in) brake disc deflection limit 0.15 mm (0.006 in) brake pad lining thickness (inner) 4.4 mm (0.17 in) limit 1.5 mm (0.06 in) brake p...

  • Page 31: Electrical Specifications

    Electrical specifications 2-12 eas29140 electrical specifications system voltage system voltage 12 v ignition system ignition timing (b.T.D.C.) 10.0 °/1550 r/min advanced timing (b.T.D.C.) 24.4 °/5000 r/min advancer type digital dc. Cdi pickup coil resistance 248-372 Ω (r–w) cdi unit model/manufactu...

  • Page 32: Electrical Specifications

    Electrical specifications 2-13 headlight relay model/manufacturer g8hn-1c4t-dj-y52/omron coil resistance 94.5–115.5 Ω circuit breaker circuit breaker type fuse fuse fuse 15.0 a reserve 15.0 a.

  • Page 33: Tightening Torques

    Tightening torques 2-14 eas20320 tightening torques eas20330 general tightening torque specifi- cations this chart specifies tightening torques for stan- dard fasteners with a standard iso thread pitch. Tightening torque specifications for spe- cial components or assemblies are provided for each cha...

  • Page 34: Tightening Torques

    Tightening torques 2-15 eas20340 engine tightening torques item thread size q’ty tightening torque 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 lock plate bolt m6 2 8 nm (0.8 m·kg, 5.9 ft·lb) cylinder head side...

  • Page 35: Tightening Torques

    Tightening torques 2-16 tip apply oil to the bearing surface of (upper) cylinder head bolt. Further, apply molybdenum disulfide grease to thread part. Primary drive gear nut m16 1 80 nm (8.0 m·kg, 59 ft·lb) use a lock washer. Clutch boss nut m16 1 75 nm (7.5 m·kg, 55 ft·lb) use a lock washer. Clutch...

  • Page 36: Tightening Torques

    Tightening torques 2-17 eas20350 chassis tightening torques item thread size q’ty tightening torque remarks engine upper stay and frame m8 2 33 nm (3.3 m·kg, 24 ft·lb) engine upper stay and engine m10 1 66 nm (6.6 m·kg, 49 ft·lb) engine lower stay and frame m8 4 33 nm (3.3 m·kg, 24 ft·lb) engine low...

  • Page 37: Tightening Torques

    Tightening torques 2-18 front brake 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 hub 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 bo...

  • Page 38

    Lubrication points and lubricant types 2-19 eas20360 lubrication points and lubricant types eas20370 engine lubrication point lubricant oil seal lips o-rings bearings cylinder head bolts (bearing surface of bolts) cylinder head bolts (thread part) cylinder body surface crankshaft journals connecting...

  • Page 39

    Lubrication points and lubricant types 2-20

  • Page 40

    Lubrication system chart and diagrams 2-21 eas20390 lubrication system chart and diagrams eas20400 engine oil lubrication chart.

  • Page 41

    Lubrication system chart and diagrams 2-22 1. Oil pan 2. Oil strainer 3. Oil pump 4. Oil cooler 5. Oil filter element 6. Cylinder head 7. Camshaft 8. Pin with hole 9. Crankshaft 10.Drive axle 11.Main axle.

  • Page 42

    Lubrication system chart and diagrams 2-23 eas20410 lubrication diagrams.

  • Page 43

    Lubrication system chart and diagrams 2-24 1. Camshaft 2. Oil filter element 3. Oil pump 4. Oil strainer.

  • Page 44

    Lubrication system chart and diagrams 2-25.

  • Page 45

    Lubrication system chart and diagrams 2-26 1. Camshaft 2. Drive axle 3. Main axle 4. Push lever shaft 5. Oil pump assembly 6. Oil strainer 7. Crankshaft assembly 8. Oil filter element.

  • Page 46

    Lubrication system chart and diagrams 2-27.

  • Page 47

    Lubrication system chart and diagrams 2-28 1. Oil cooler 2. Oil hose 1 3. Oil hose 2.

  • Page 48: Cable Routing

    Cable routing 2-29 eas20430 cable routing.

  • Page 49: Cable Routing

    Cable routing 2-30 1. Clutch switch lead 2. Clutch cable 3. Front brake hose 1 4. Front brake light switch lead 5. Throttle cable 6. Plastic band 7. Parking brake cable 8. Handlebar switch lead a. Route the clutch cable and parking brake cable through the guide of the handlebar protector. B. Route t...

  • Page 50: Cable Routing

    Cable routing 2-31.

  • Page 51: Cable Routing

    Cable routing 2-32 1. Indicator light lead 2. Main switch lead 3. Coupler joint 4. Front brake hose 2 5. Oil cooler hose 1, 2 6. Exhaust pipe 7. Engine bracket 8. Parking brake cable 9. Rear brake light switch lead 10.Battery negative lead 11.Carburetor warmer lead 12.Air vent hose 13.3 way connecto...

  • Page 52: Cable Routing

    Cable routing 2-33.

  • Page 53: Cable Routing

    Cable routing 2-34 1. Rear brake reservoir 2. Rear brake light switch 3. Clip 4. Rear brake reservoir hose 5. Rear brake master cylinder 6. Parking brake cable 7. Rear brake hose 8. Rear brake caliper a. Make sure that the end of the clip is facing downward. B. Set the rear brake reservoir hose with...

  • Page 54: Cable Routing

    Cable routing 2-35.

  • Page 55: Cable Routing

    Cable routing 2-36 4d3d 1. Clutch switch lead 2. Handlebar switch lead 3. Bolt 4. Hexagonal head bolt 5. Main harness 6. Air vent hose 7. Clamp 8. Battery negative lead 9. Ac magneto lead 10.Carburetor overflow hose 11.Neutral switch lead 12.Starter motor lead 13.Ignition coil spark plug lead 14.Ign...

  • Page 56: Cable Routing

    Cable routing 2-37.

  • Page 57: Cable Routing

    Cable routing 2-38 4d3h/4d3m 1. Clutch switch lead 2. Handlebar switch lead 3. Bolt 4. Hexagonal head bolt 5. Main harness 6. Air vent hose 7. Clamp 8. Battery negative lead 9. Ac magneto lead 10.Carburetor overflow hose 11.Neutral switch lead 12.Starter motor lead 13.Ignition coil spark plug lead 1...

  • Page 58: Cable Routing

    Cable routing 2-39.

  • Page 59: Cable Routing

    Cable routing 2-40 1. Indicator light 2. Coupler joint 3. Main switch lead 4. Main switch 5. Front brake light switch lead 6. Throttle cable 7. Air vent hose 8. Clutch switch lead 9. Handlebar switch lead 10.Parking brake cable 11.Clutch cable 12.Flange bolt 13.Headlight lead 14.Indicator light lead...

  • Page 60: Cable Routing

    Cable routing 2-41.

  • Page 61: Cable Routing

    Cable routing 2-42 1. Battery 2. Cdi unit 3. Band 4. Starter relay lead 5. Starter relay 6. Taillight lead 7. Battery negative lead 8. Ac magneto coupler 9. Starter motor lead 10.Headlight relay 11.Neutral relay 12.Damper 13.Cdi unit lead 14.Relay lead a. Route the starter relay lead under the start...

  • Page 62: Cable Routing

    Cable routing 2-43.

  • Page 63

    3 periodic checks and adjustments periodic maintenance .........................................................................3-1 introduction ....................................................................................3-1 periodic maintenance chart for the emission control system............

  • Page 64

    Adjusting the rear shock absorber assembly (for 4d3h, 4d3m).................................................................................. 3-28 checking the tires ....................................................................... 3-29 checking the wheels ........................................

  • Page 66: Periodic Maintenance

    Periodic maintenance 3-1 eas20450 periodic maintenance eas20460 introduction this chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer service life and redu...

  • Page 67: Periodic Maintenance

    Periodic maintenance 3-2 eas4d3f012 general maintenance and lubrication chart no. Item check or maintenance job whichever comes first initial every month 1 3 6 6 12 km (mi) 320 (200) 1300 (800) 2500 (1600) 2500 (1600) 5000 (3200) hours 20 80 160 160 320 1 air filter element • clean and replace if ne...

  • Page 68: Periodic Maintenance

    Periodic maintenance 3-3 tip • the air filter needs more frequent service if you are riding in unusually wet or dusty areas. • hydraulic brake service • regularly check and, if necessary, correct the brake fluid level. • every two years replace the internal components of the brake master cylinders a...

  • Page 69: Engine

    Engine 3-4 eas20472 engine eas20520 adjusting the valve clearance the following procedure applies to all of the valves. Tip • valve clearance adjustment should be made on a cold engine, at room temperature. • when the valve clearance is to be measured or adjusted, the piston must be at top dead cent...

  • Page 70: Engine

    Engine 3-5 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Adjust: • valve clearance ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Loosen the locknut. B. Insert a thickness gauge between the end of the adjusting screw and the valve tip. C. Turn the adjusting screw “2” in direction “a” or “b” until the specified valve clearan...

  • Page 71: Engine

    Engine 3-6 5. Detach: • digital tachometer 6. Adjust: • throttle cable free play refer to “adjusting the throttle cable free play” on page 3-6. Eas20660 adjusting the throttle cable free play tip prior to adjusting the throttle cable free play, the engine idling speed should be adjusted. 1. Check: •...

  • Page 72: Engine

    Engine 3-7 eas29170 adjusting the speed limiter the speed limiter keeps the carburetor throttle from becoming fully-opened even when the throttle lever is applied to the maximum posi- tion. Screwing in the adjusting screw stops the engine speed from increasing. 1. Measure: • speed limiter length “a”...

  • Page 73: Engine

    Engine 3-8 7. Install: • spark plug tip before installing the spark plug, clean the spark plug and gasket 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. Make sure all...

  • Page 74: Engine

    Engine 3-9 4. Remove: • spark plug eca13340 before removing the spark plug, use com- pressed air to blow away any dirt accumu- lated in the spark plug wells to prevent it from falling into the cylinder. 5. Install: • compression gauge “1” • extension “2” 6. Measure: • compression pressure out of spe...

  • Page 75: Engine

    Engine 3-10 • do not screw the dipstick “1” in when check- ing the oil level. Eca13360 • engine oil also lubricates the clutch and the wrong oil types or additives could cause clutch slippage. Therefore, do not add any chemical additives or use engine oils with a grade of cd “a” or higher and do not...

  • Page 76: Engine

    Engine 3-11 6. Drain: • engine oil (completely from the crankcase) 7. If the oil filter element is also to be replaced, perform the following procedure. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the oil filter element cover “1” and oil filter element “2”. B. Install new o-ring “3”. C. Install the new...

  • Page 77: Engine

    Engine 3-12 eas20870 adjusting the clutch cable free play 1. Check: • clutch cable free play “a” out of specification → adjust. 2. Adjust: • clutch cable free play ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Slide back the lever cover “1”. B. Loosen the locknut “2”. C. Turn the adjusting bolt “3” in direction...

  • Page 78: Engine

    Engine 3-13 4. Clean: • air filter element (with solvent) warning ewa13020 never use low flash point solvents, such as gasoline, to clean the air filter element. Such solvents may cause a fire or an explo- sion. Tip after cleaning, gently squeeze the air filter ele- ment to remove the excess solvent...

  • Page 79: Engine

    Engine 3-14 • air filter case refer to “general chassis” on page 4-1. • carburetor refer to “carburetor” on page 6-3. 2. Check: • carburetor joint • intake manifold cracks/damage → replace. Refer to “carburetor” on page 6-3. 3. Install: • carburetor refer to “carburetor” on page 6-3. • air filter ca...

  • Page 80: Engine

    Engine 3-15 d. Insert the tailpipe and gasket “3” into the muffler and align the bolt holes. E. Insert the bolts and tighten it. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ spark arrester bolt 11 nm (1.1 m·kg, 8.1 ft·lb).

  • Page 81: Chassis

    Chassis 3-16 eas29360 chassis eas21170 adjusting the front disc brake 1. Check: • brake lever free play “a” out of specification → bleed the front brake system. Refer to “bleeding the hydraulic brake system” on page 3-20. Warning ewa13050 a soft or spongy feeling in the brake lever can indicate the ...

  • Page 82: Chassis

    Chassis 3-17 warning ewa14900 after this adjustment is performed, lift the front and rear wheels off the ground by placing a block under the engine, and spin the rear wheels to ensure there is no brake drag. If any brake drag is noticed perform the above steps again. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ e...

  • Page 83: Chassis

    Chassis 3-18 eas21250 checking the front brake pads the following procedure applies to all of the brake pads. 1. Remove: • front wheels refer to “front wheel” on page 4-4. 2. Operate the brake. 3. Check: • front brake pad wear indicators groove almost disap- peared “a” → replace the brake pads as a ...

  • Page 84: Chassis

    Chassis 3-19 3. Hold the vehicle upright and apply the front brake several times. 4. Check: • brake hose brake fluid leakage → replace the dam- aged hose. Refer to “rear brake” on page 4-27. Eas29210 adjusting the parking brake 1. Check: • parking brake cable end length “a” out of specification → ad...

  • Page 85: Chassis

    Chassis 3-20 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas21350 bleeding the hydraulic brake sys- tem warning ewa13100 bleed the hydraulic brake system when- ever: • the system is disassembled. • a brake hose is loosened, disconnected or replaced. • the brake fluid level is very low. • brake operation is fault...

  • Page 86: Chassis

    Chassis 3-21 k. Fill the brake fluid reservoir to the proper level with the recommended brake fluid. Refer to “checking the brake fluid level” on page 3-17. Warning ewa13110 after bleeding the hydraulic brake system, check the brake operation. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas4d3f004 adjusting the ...

  • Page 87: Chassis

    Chassis 3-22 eca4d3f005 excessive chain slack will overload the engine and other vital parts; keep the slack within the specified limits. E. If the chain slack cannot be adjusted, replace the sprockets and drive chain as a set. F. Tighten the rear axle pinch bolts. Tip • tighten the rear axle pinch ...

  • Page 88: Chassis

    Chassis 3-23 4. Raise the front end of the vehicle so that there is no weight on the front wheels. 5. Check: • ball joints and wheel bearings move the wheels laterally back and forth. Excessive free play → replace the front arms (upper and lower) and/or wheel bearings. Eas29290 adjusting the toe-in ...

  • Page 89: Chassis

    Chassis 3-24 d. Tighten the rod end locknuts of both tie- rods. Tip adjust the tie-rod ends so that “a” and “b” are equal. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas29300 checking the front shock absorber assemblies the following procedure applies to both of the front shock absorber assemblies. 1. Place the...

  • Page 90: Chassis

    Chassis 3-25 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas4d3f031 adjusting the front shock absorber assemblies (for 4d3h, 4d3m) warning ewa14920 always adjust the spring preload for both front shock absorber assemblies to the same setting. Uneven adjustment can cause poor handling and loss of stability. Sprin...

  • Page 91: Chassis

    Chassis 3-26 tip make sure that the position indicator marks “c” are aligned when the shock absorber is set to the standard setting. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ compression damping (slow compression damping) eca4d3f008 do not force the adjuster past the minimum or maximum extent of adjustment. Th...

  • Page 92: Chassis

    Chassis 3-27 tip make sure that the position indicator marks “c” are aligned when the shock absorber is set to the standard setting. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas4d3f006 checking the rear shock absorber assembly 1. Place the vehicle on a level surface. 2. Check: • rear shock absorber rod • rear...

  • Page 93: Chassis

    Chassis 3-28 tip be sure to remove all dirt and mud from around the locknut and adjusting nut before adjustment. D. Tighten the locknut. Tip always tighten the locknut against the adjust- ing nut, then torque it to specification. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas4d3f032 adjusting the rear shock abs...

  • Page 94: Chassis

    Chassis 3-29 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ compression damping eca4d3f008 do not force the adjuster past the minimum or maximum extent of adjustment. The adjuster may be damaged. 1. Adjust: • compression damping ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjusting screw “1” in direction “a” or “b”....

  • Page 95: Chassis

    Chassis 3-30 tire pressure warning ewa14960 • tire pressure below the minimum specifi- cation could cause the tire to dislodge from the rim under severe riding condi- tions. The following are minimums: • front 24.5 kpa (0.25 kgf/cm 2 , 3.6 psi) • rear 24.5 kpa (0.25 kgf/cm 2 , 3.6 psi) • use no more...

  • Page 96: Chassis

    Chassis 3-31 warning ewa13190 it is dangerous to ride with a worn-out tire. When the tire tread reaches the wear limit, replace the tire immediately. Eas29350 checking the wheels the following procedure applies to all of the wheels. 1. Check: • wheel “1” damage/bends → replace. Tip always balance th...

  • Page 97: Electrical System

    Electrical system 3-32 eas21750 electrical system eas21760 checking and charging the battery refer to “electrical components” on page 7-27. Eas21770 checking the fuses refer to “electrical components” on page 7-27. Eas21790 replacing the headlight bulbs the following procedure applies to both of the...

  • Page 98: Electrical System

    Electrical system 3-33 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjusting bolt “1” in direction “a” or “b”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ direction “a” headlight beam is raised. Direction “b” headlight beam is lowered..

  • Page 99: Chassis

    4 chassis general chassis....................................................................................4-1 front wheel ............................................................................................4-4 removing the front wheels.........................................................

  • Page 100

    Replacing the rear brake pads .............................................. 4-32 removing the rear brake caliper.......................................... 4-33 disassembling the rear brake caliper................................ 4-34 checking the rear brake caliper ....................................

  • Page 101

    Chain drive ............................................................................................. 4-57 removing the drive chain .......................................................... 4-58 checking the drive chain .......................................................... 4-58 checking th...

  • Page 102: General Chassis

    General chassis 4-1 eas21830 general chassis removing the seat, front fender and headlights order job/parts to remove q’ty remarks 1 seat 1 tip pull back the seat lock lever, than pull up on the rear of the seat. 2 indicator light coupler 1 disconnect. 3 front panel 1 4 plate 1 5 main switch coupler...

  • Page 103: General Chassis

    General chassis 4-2 removing the foot protectors and engine skid plate order job/parts to remove q’ty remarks 1 left foot protector 1 2 right foot protector 1 3 engine skid plate 1 for installation, reverse the removal proce- dure..

  • Page 104: General Chassis

    General chassis 4-3 removing the rear fender and air filter case order job/parts to remove q’ty remarks seat/front fender refer to “general chassis” on page 4-1. 1 rear fender 1 2 battery cover 1 3 battery lead 2 eca4d3f001 first disconnect the negative lead, then disconnect the positive lead. 4 bat...

  • Page 105: Front Wheel

    Front wheel 4-4 eas21870 front wheel removing the front wheels and brake discs order job/parts to remove q’ty remarks the following procedure applies to both of the front wheels. 1 cotter pin 1 2 axle nut 1 3 front wheel 1 4 brake disc guard (outer) 1 5 brake caliper assembly 1 6 wheel hub 1 7 brake...

  • Page 106: Front Wheel

    Front wheel 4-5 eas21890 removing the front wheels the following procedure applies to both of the front wheels. 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. Tip place the vehicle on a suitable stand so that the ...

  • Page 107: Front Wheel

    Front wheel 4-6 2. Check: • wheel bearings wheel hub play/wheel turns roughly → replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Clean wheel hub exterior. B. Drive bearing out by pushing spacer aside and tapping around perimeter of bearing inner race. Use soft metal drift punch and hammer. The spacer “1” ...

  • Page 108: Front Wheel

    Front wheel 4-7 eas21970 adjusting the front wheel static balance tip after replacing the tire, wheel or both, the front wheel static balance should be adjusted. 1. Remove: • balancing weight(s) 2. Find: • front wheel’s heavy spot tip place the front wheel on a suitable balancing stand. ▼▼▼▼▼▼▼▼▼▼▼▼...

  • Page 109: Front Wheel

    Front wheel 4-8 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the front wheel and make sure it stays at each position shown. B. If the front wheel does not remain station- ary at all of the positions, rebalance it. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas29420 installing the front wheels the following procedure ...

  • Page 110: Rear Wheel

    Rear wheel 4-9 eas22020 rear wheel removing the rear wheels order job/parts to remove q’ty remarks 1 rear wheel 2 2 cotter pin 2 3 axle nut 2 4 wheel hub 2 for installation, reverse the removal proce- dure..

  • Page 111: Rear Wheel

    Rear wheel 4-10 eas22040 removing the rear wheels 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. Tip place the vehicle on a suitable stand so that the rear wheel is elevated. 2. Remove: • rear wheels eas29430 chec...

  • Page 112: Rear Axle and Rear Axle Hub

    Rear axle and rear axle hub 4-11 eas29470 rear axle and rear axle hub removing the rear axle and 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 spring washer 1 4 brak...

  • Page 113: Rear Axle and Rear Axle Hub

    Rear axle and rear axle hub 4-12 14 dust cover 2 for installation, reverse the removal proce- dure. Removing the rear axle and rear axle hub order job/parts to remove q’ty remarks.

  • Page 114: Rear Axle and Rear Axle Hub

    Rear axle and rear axle hub 4-13 eas29490 removing the rear axle 1. Place the vehicle on a level surface. 2. Loosen: • rear axle ring nut set bolts “1” 3. Remove: • rear axle ring nut “2” tip • apply the brake pedal so that the rear axle does not turn when loosening the nut. • use the ptt wrench 46 ...

  • Page 115: Rear Axle and Rear Axle Hub

    Rear axle and rear axle hub 4-14 eas29510 checking the rear wheel sprocket 1. Check: • rear wheel sprocket refer to “checking the drive sprocket” on page 4-59. Eas4d3f029 checking the sprocket bracket 1. Check: • sprocket bracket cracks/damage → replace. Eas29520 installing the rear wheel sprocket 1...

  • Page 116: Front Brake

    Front brake 4-15 eas22210 front brake removing the front brake pads order job/parts to remove q’ty remarks the following procedure applies to both of the front brake calipers. Front wheel refer to “front wheel” on page 4-4. 1 bolt 1 2 brake pad retaining bolt 1 3 brake pad 2 4 brake pad spring 1 for...

  • Page 117: Front Brake

    Front brake 4-16 removing the front brake master cylinder order job/parts to remove q’ty remarks brake fluid drain. Refer to “bleeding the hydraulic brake system” on page 3-20. 1 brake fluid reservoir cap 1 2 brake fluid reservoir diaphragm plate 1 3 brake fluid reservoir diaphragm 1 4 front brake l...

  • Page 118: Front Brake

    Front brake 4-17 disassembling the front brake master cylinder order job/parts to remove q’ty remarks 1 brake master cylinder kit 1 2 brake master cylinder body 1 for assembly, reverse the disassembly pro- cedure..

  • Page 119: Front Brake

    Front brake 4-18 removing the front brake calipers order job/parts to remove q’ty remarks the following procedure applies to both of the front brake calipers. Brake fluid drain. Refer to “bleeding the hydraulic brake system” on page 3-20. Front wheel refer to “front wheel” on page 4-4. 1 union bolt ...

  • Page 120: Front Brake

    Front brake 4-19 disassembling the front brake calipers order job/parts to remove q’ty remarks the following procedure applies to both of the front brake calipers. 1 bolt 1 2 brake pad retaining bolt 1 3 brake pad 2 4 brake pad spring 1 5 caliper bracket 1 6 caliper piston 1 7 dust seal 1 8 caliper ...

  • Page 121: Front Brake

    Front brake 4-20 eas22220 introduction warning ewa14100 disc brake components rarely require dis- assembly. Therefore, always follow these preventive measures: • never disassemble brake components unless absolutely necessary. • if any connection on the hydraulic brake system is disconnected, the ent...

  • Page 122: Front Brake

    Front brake 4-21 eas22250 replacing the front brake pads the following procedure applies to both brake calipers. Tip when replacing the brake pads, it is not neces- sary to disconnect the brake hose or disas- semble the brake caliper. 1. Measure: • brake pad wear limit “a” out of specification → rep...

  • Page 123: Front Brake

    Front brake 4-22 tip before removing the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: • union bolt “1” • copper washers “2” • brake hose “3” • brake caliper bolts “4” tip put the end of the brake hose into a container and pump out the brake fluid carefully. Eas22310 ...

  • Page 124: Front Brake

    Front brake 4-23 warning ewa4d3f006 whenever a brake caliper is disassembled, replace the brake caliper piston seal and brake caliper dust seal. 2. Check: • brake caliper bracket “1” cracks/damage → replace. Eas22400 assembling the front brake cali- per warning ewa4d3f007 • before installation, all ...

  • Page 125: Front Brake

    Front brake 4-24 refer to “replacing the front brake pads” on page 4-21. 4. Fill: • brake master cylinder reservoir (with the specified amount of the recom- mended brake fluid) warning ewa13090 • use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causi...

  • Page 126: Front Brake

    Front brake 4-25 2. Check: • brake master cylinder kit “1” damage/scratches/wear → replace. 3. Check: • brake master cylinder reservoir “1” cracks/damage → replace. • brake master cylinder reservoir dia- phragm “2” damage/wear → replace. Eas22520 assembling the front brake mas- ter cylinder warning ...

  • Page 127: Front Brake

    Front brake 4-26 3. Fill: • brake master cylinder reservoir (with the specified amount of the recom- mended brake fluid) warning ewa13540 • use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • refill with the...

  • Page 128: Rear Brake

    Rear brake 4-27 eas22550 rear brake removing the rear brake pads order job/parts to remove q’ty remarks 1 brake pad retaining bolt 2 2 lock washer 1 3 brake pad 2 4 brake pad spring 1 for installation, reverse the removal proce- dure..

  • Page 129: Rear Brake

    Rear brake 4-28 removing the rear brake master cylinder 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 hydraulic brake system” on page 3-20. 1 brake fluid reservoir cover 1 2 brake fluid reservoir cap 1 3 ...

  • Page 130: Rear Brake

    Rear brake 4-29 disassembling the rear brake master cylinder order job/parts to remove q’ty remarks 1 hose joint 1 2 brake master cylinder kit 1 3 brake master cylinder 1 for assembly, reverse the disassembly pro- cedure..

  • Page 131: Rear Brake

    Rear brake 4-30 removing the rear brake caliper order job/parts to remove q’ty remarks brake fluid drain. Refer to “bleeding the hydraulic brake system” on page 3-20. 1 parking brake cable 1 disconnect. 2 union bolt 1 3 copper washer 2 4 brake hose 1 5 brake caliper assembly 1 for installation, reve...

  • Page 132: Rear Brake

    Rear brake 4-31 disassembling the rear brake calipers order job/parts to remove q’ty remarks 1 adjusting bolt 1 2 locknut 1 3 parking brake arm 1 4 brake pad retaining bolt 2 5 lock washer 1 6 brake pad 2 7 brake pad spring 1 8 retaining bolt 1 9 caliper bracket 1 10 brake caliper piston 1 11 dust s...

  • Page 133: Rear Brake

    Rear brake 4-32 eas22560 introduction warning ewa14100 disc brake components rarely require dis- assembly. Therefore, always follow these preventive measures: • never disassemble brake components unless absolutely necessary. • if any connection on the hydraulic brake system is disconnected, the enti...

  • Page 134: Rear Brake

    Rear brake 4-33 b. Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger. C. Tighten the bleed screw. D. Install new brake pads and a new brake pad spring. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Install: • lock washer “1” • brake pad retaining bolts “2” 4. Bend...

  • Page 135: Rear Brake

    Rear brake 4-34 eas22600 disassembling the rear brake cali- per 1. Remove: • brake caliper piston • brake caliper dust seal “1” • brake caliper piston seal “2” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Blow compressed air into the brake hose joint opening “a” to force out the piston from the brake caliper. ...

  • Page 136: Rear Brake

    Rear brake 4-35 1. Install: • o-ring “1” • caliper piston seal “2” • caliper dust seal “3” 2. Install: • brake caliper piston “1” 3. Install: • parking brake arm “1” 4. Measure: • parking brake arm to parking brake bracket distance “a” out of specification → adjust. Eas22670 installing the rear brak...

  • Page 137: Rear Brake

    Rear brake 4-36 warning ewa13090 • use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chem...

  • Page 138: Rear Brake

    Rear brake 4-37 3. Check: • brake fluid reservoir “1” cracks/damage → replace. • brake fluid reservoir diaphragm “2” cracks/damage → replace. 4. Check: • brake hoses cracks/damage/wear → replace. Eas22730 assembling the rear brake master cylinder warning ewa13520 • before installation, all internal ...

  • Page 139: Rear Brake

    Rear brake 4-38 3. Fill: • brake fluid reservoir (with the specified amount of the recom- mended brake fluid) warning ewa13090 • use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • refill with the same type ...

  • Page 140: Handlebar

    Handlebar 4-39 eas22840 handlebar removing the handlebar order job/parts to remove q’ty remarks 1 handlebar protector 1 2 band 3 3 front brake light switch 1 4 brake master cylinder/bracket 1/1 5 throttle lever assembly/bracket 1/1 6 spacer 1 7 clutch switch 1 8 parking brake lever 1 9 clutch lever/...

  • Page 141: Handlebar

    Handlebar 4-40 eas22860 removing the handlebars 1. Remove: • clutch switch “1” tip push the fastener when removing the clutch switch out of the clutch lever holder. 2. Remove: • handlebar grip “1” tip blow compressed air between the left handle- bar and the handlebar grip, and gradually push the gri...

  • Page 142: Handlebar

    Handlebar 4-41 tip • before applying the adhesive, wipe off grease or oil on the handlebar surface “a” with a lacquer thinner. • install the handlebar grips so that the “l” arrow on the left grip and “r” arrow on the right grip are placed vertically. 3. Install: • handlebar switch “1” • clutch lever...

  • Page 143: Handlebar

    Handlebar 4-42 throttle cable free play 2.0–4.0 mm (0.08–0.16 in).

  • Page 144: Steering Stem

    Steering stem 4-43 eas29540 steering stem removing the steering stem order job/parts to remove q’ty remarks front fender refer to “general chassis” on page 4-1. 1 lock washer 1 2 bracket 1 3 steering stem bushing 2 4 spacer 2 5 oil seal 2 6 steering stem 1 7 bushing 2 for installation, reverse the r...

  • Page 145: Steering Stem

    Steering stem 4-44 eas29560 checking the steering stem 1. Check: • steering stem “1” bends → replace. Warning ewa15030 do not attempt to straighten a bent stem; this may dangerously weaken the stem. 2. Check: • oil seals “1” • steering stem bushings “2” wear/damage → replace. 3. Check: • o-rings “1”...

  • Page 146

    Tie-rods and steering knuckles 4-45 eas29660 tie-rods and steering knuckles removing the tie-rods and steering knuckles order job/parts to remove q’ty remarks the following procedure applies to both of the tie-rods and steering knuckles. Front wheel refer to “front wheel” on page 4-4. Front brake ca...

  • Page 147

    Tie-rods and steering knuckles 4-46 eas29670 removing the steering knuckles the following procedure applies to both of the steering knuckles. 1. Remove: • steering knuckle “1” tip use a general puller to separate the ball joints “2” from the steering knuckle “1”. Eas29680 checking the tie-rods the f...

  • Page 148

    Front arms and front shock absorber assemblies 4-47 eas29710 front arms and front shock absorber assemblies removing the front arms and front shock absorber assemblies order job/parts to remove q’ty remarks the following procedure applies to both of the front upper arms, front lower arms, and front ...

  • Page 149

    Front arms and front shock absorber assemblies 4-48 eas29720 removing the front arms the following procedure applies to both of the front upper arms and front lower arms. 1. Check: • front arm free play ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Check the front arm side play “a” by mov- ing it from side to s...

  • Page 150

    Front arms and front shock absorber assemblies 4-49 eas29760 checking the front shock absorber assemblies the following procedure applies to both of the front shock absorber assemblies. 1. Check: • front shock absorber assembly oil leaks → replace the front shock absorber assembly. • front shock abs...

  • Page 151

    Front arms and front shock absorber assemblies 4-50 tip apply lithium-soap-based grease to the grease nipples “3”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ front upper arm nut 45 nm (4.5 m·kg, 33 ft·lb) front lower arm nut 45 nm (4.5 m·kg, 33 ft·lb).

  • Page 152: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-51 eas23160 rear shock absorber assembly removing the rear shock absorber assembly order job/parts to remove q’ty remarks seat/rear fender/air filter case refer to “general chassis” on page 4-1. 1 clamp 2 loosen. For 4d3h, 4d3m 2 rear shock absorber assembly 1 for inst...

  • Page 153: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-52 eas23170 handling the rear shock absorber warning ewa13750 this rear shock absorber and gas cylinder contains highly compressed nitrogen gas. Before handling the rear shock absorber and gas cylinder, read and make sure you understand the following information. The m...

  • Page 154: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-53 eas23300 installing the rear shock absorber assembly 1. Install: • rear shock absorber assembly tip when installing the rear shock absorber assembly lower bolt, lift up the swingarm. A. For 4d3d b. For 4d3h, 4d3m rear shock absorber assembly nut 55 nm (5.5 m·kg, 41 ...

  • Page 155: Swingarm

    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 assembly” on page 4-51. 1 plate 1 2 swingarm end cover 1 3 pivot shaft nut/washer...

  • Page 156: Swingarm

    Swingarm 4-55 eas23340 removing the swingarm 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. Tip place the vehicle on a suitable stand so that the rear wheel is elevated. 2. Measure: • swingarm side play • swingarm...

  • Page 157: Swingarm

    Swingarm 4-56 eas23380 installing the swingarm 1. Lubricate: • bearings • spacer • oil seals 2. Install: • bearings “1” • spacer “2” • oil seals • dust covers tip inject the bearing with the character stamp turned outward. 3. Install: • pivot shaft 4. Install: • rear shock absorber assembly • rear a...

  • Page 158: Chain Drive

    Chain drive 4-57 eas23400 chain drive removing the drive sprocket and drive chain order job/parts to remove q’ty remarks 1 drive sprocket cover 1 2 drive chain guide 2 1 3 drive chain guide 3 1 4 drive sprocket nut 1 5 lock washer 1 6 drive sprocket 1 7 drive chain 1 for installation, reverse the re...

  • Page 159: Chain Drive

    Chain drive 4-58 eas23430 removing the drive chain 1. Remove: • master link clip (with interlocking slip-joint pliers) 2. Remove: • master link plate “1” • o-ring “2” • master link “3” 3. Remove: • drive chain eas23441 checking the drive chain 1. Measure: • 15-link section “a” of the drive chain out...

  • Page 160: Chain Drive

    Chain drive 4-59 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Check: • o-rings “1” damage → replace the drive chain. • drive chain rollers “2” damage/wear → replace the drive chain. • drive chain side plates “3” damage/wear → replace the drive chain. Cracks → replace the drive chain. 4. Lubricate: • drive chai...

  • Page 161: Chain Drive

    Chain drive 4-60 3. Bend the lock 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 new drive chain onto worn drive chain sprockets; this will dramatically shorten the drive chain’s life. 5. Install: • master link cli...

  • Page 162: Chain Drive

    Chain drive 4-61.

  • Page 163: Engine

    5 engine engine removal ......................................................................................5-1 installing the engine ....................................................................5-4 installing the muffler and exhaust pipe..............................5-4 camshaft .............

  • Page 164

    Assenbling the balancer weight gear................................ 5-41 installing the oil pump ............................................................... 5-41 installing the balancer weight gear ..................................5-41 shift shaft ..................................................

  • Page 166: Engine Removal

    Engine removal 5-1 eas23711 engine removal removing the muffler and exhaust pipe order job/parts to remove q’ty remarks seat/front panel/front fender/rear fender refer to “general chassis” on page 4-1. 1 clamp 1 loosen. 2 muffler 1 3 gasket 1 4 exhaust pipe 1 5 exhaust pipe protector 1 6 gasket 1 fo...

  • Page 167: Engine Removal

    Engine removal 5-2 disconnecting the leads, cables and hoses order job/parts to remove q’ty remarks engine oil drain. Oil cooler hose 1, 2 refer to “clutch” on page 5-29. Carburetor refer to “carburetor” on page 6-3. Drive sprocket/drive chain refer to “chain drive” on page 4-57. 1 ignition coil spa...

  • Page 168: Engine Removal

    Engine removal 5-3 removing the engine order job/parts to remove q’ty remarks 1 crankcase bolt 1 2 engine mounting bolt (front) 1 3 engine bracket (left and right) 2 4 engine mounting bolt (upper) 1 5 engine bracket (upper) 1 6 engine mounting bolt (rear upper) 1 7 engine mounting bolt (rear lower) ...

  • Page 169: Engine Removal

    Engine removal 5-4 eas23720 installing the engine 1. Install: • engine mounting bolt (rear lower side) “1” • engine mounting bolt (rear upper side) “2” • engine bracket bolts (upper side) “3” • engine mounting bolt (upper side) “4” • engine brackets (front side) “5” “6” • engine mounting bolt (front...

  • Page 170: Engine Removal

    Engine removal 5-5 4. Install: • gasket • exhaust pipe “1” 5. Tighten: • nuts (exhaust pipe) “2” 6. Install: • clamp tip slide the clamp onto the end of the muffler and insert the projection “a” of the clamp into a slot “b” in the muffler. Tighten the clamp after installing the muffler. Exhaust pipe...

  • Page 171: Camshaft

    Camshaft 5-6 eas23730 camshaft removing the rocker 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/valve clearance adjusting screw 2/2 3 camshaft 1 4 intake rocker arm shaft 1 5 intake rocker arm 1 6 exhaust rocke...

  • Page 172: Camshaft

    Camshaft 5-7 eas23770 removing the rocker arms and camshaft 1. Loosen: • locknut “1” • valve clearance adjusting screw “2” 2. Remove: • lock plate “3” 3. Remove: • 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. ...

  • Page 173: Camshaft

    Camshaft 5-8 4. Check: • camshaft oil passage obstruction → blow out with compressed air. Eas23880 checking the rocker arms and rocker arm shafts the following procedure applies to all of the rocker arms and rocker arm shafts. 1. Check: • rocker arms “1” • valve clearance adjusting screws “2” damage...

  • Page 174: Camshaft

    Camshaft 5-9 out of specification → replace the defec- tive part(s). Eas24040 installing the camshaft and rocker arms 1. Lubricate: • camshaft 2. Lubricate: • rocker arm • rocker arm shafts 3. Install: • exhaust rocker arm “1” • exhaust rocker arm shaft “2” tip make sure the exhaust rocker arm shaft...

  • Page 175: Cylinder Head

    Cylinder head 5-10 eas24100 cylinder head removing the cylinder head order job/parts to remove q’ty remarks seat/front panel/front fender refer to “general chassis” on page 4-1. Fuel tank/fuel tank shield refer to “fuel tank” on page 6-1. Muffler and exhaust pipe/ignition coil spark plug lead/engine...

  • Page 176: Cylinder Head

    Cylinder head 5-11 for installation, reverse the removal proce- dure. Removing the cylinder head order job/parts to remove q’ty remarks.

  • Page 177: Cylinder Head

    Cylinder head 5-12 eas24130 removing the cylinder head 1. Align: • “i” mark “a” on the pickup coil rotor (with the stationary pointer “b” on the crankcase cover) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the pickup coil rotor counterclockwise. B. When the piston is at tdc on the compres- sion stroke, a...

  • Page 178: Cylinder Head

    Cylinder head 5-13 2. Check: • cylinder head damage/scratches → replace. 3. Measure: • cylinder head warpage out of specification → resurface the cyl- inder head. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Place a straightedge “1” and a thickness gauge “2” across the cylinder head. B. Measure the warpage. C....

  • Page 179: Cylinder Head

    Cylinder head 5-14 3. Check: • cap bolt • spring • one-way cam • timing chain tensioner rod damage/wear → replace the timing chain tensioner. Eas24230 installing the cylinder head 1. Install: • cylinder head gasket • dowel pins 2. Install: • cylinder head • copper washers • cylinder head bolts 3. Ti...

  • Page 180: Cylinder Head

    Cylinder head 5-15 b. With the timing chain tensioner rod turned all the way into the timing chain tensioner housing (with the thin screwdriver still installed), install the new gasket and the timing chain tensioner “2” onto the body cylinder. C. Tighten the timing chain tensioner bolts “3” to the s...

  • Page 181: Valves and Valve Springs

    Valves and valve springs 5-16 eas24270 valves and valve springs removing the valves and valve springs order job/parts to remove q’ty remarks cylinder head refer to “cylinder head” on page 5-10. Rocker arm/camshaft refer to “camshaft” on page 5-6. 1 valve cotter 4 2 valve spring retainer 2 3 outer va...

  • Page 182: Valves and Valve Springs

    Valves and valve springs 5-17 eas24280 removing the valves the following procedure applies to all of the valves and related components. Tip before removing the internal parts of the cylin- der head (e.G., valves, valve springs, valve seats), make sure the valves properly seal. 1. Check: • valve seal...

  • Page 183: Valves and Valve Springs

    Valves and valve springs 5-18 2. Replace: • valve guide tip to ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100 °c (212 °f) in an oven. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the valve guide with the valve guide remover “1”. B. Install the n...

  • Page 184: Valves and Valve Springs

    Valves and valve springs 5-19 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Eliminate: • carbon deposits (from the valve face and valve seat) 4. Check: • valve face pitting/wear → grind the valve face. • valve stem end mushroom shape or diameter larger than the body of the valve stem → replace the valve. 5. Mea...

  • Page 185: Valves and Valve Springs

    Valves and valve springs 5-20 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Apply mechanic’s blueing dye (dykem) “b” onto the valve face. B. Install the valve into the cylinder head. C. Press the valve through the valve guide and onto the valve seat to make a clear impression. D. Measure the valve seat width. T...

  • Page 186: Valves and Valve Springs

    Valves and valve springs 5-21 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas24310 checking the valve springs the following procedure applies to all of the valve springs. 1. Measure: • valve spring free length “a” out of specification → replace the valve spring. 2. Measure: • compressed valve spring force “a” ou...

  • Page 187: Valves and Valve Springs

    Valves and valve springs 5-22 eas24340 installing the valves the following procedure applies to all of the valves and related components. 1. Deburr: • valve stem end (with an oil stone) 2. Lubricate: • valve stem • valve stem seal (with the recommended lubricant) 3. Install: • valve spring seat “1” ...

  • Page 188: Valves and Valve Springs

    Valves and valve springs 5-23 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft- face hammer. Eca13800 hitting the valve tip with excessive force could damage the valve..

  • Page 189: Cylinder and Piston

    Cylinder and piston 5-24 eas24350 cylinder and piston removing the cylinder and piston order job/parts to remove q’ty remarks cylinder head refer to “cylinder head” on page 5-10. 1 oil delivery pipe 1 2 cylinder 1 3 dowel pin 2 4 cylinder gasket 1 5 piston pin clip 2 6 piston pin 1 7 piston 1 8 pist...

  • Page 190: Cylinder and Piston

    Cylinder and piston 5-25 eas24380 removing the piston 1. Remove: • piston pin clips “1” • piston pin “2” • piston “3” eca13810 do not use a hammer to drive the piston pin out. Tip • before removing the piston pin clip, cover the crankcase opening with a clean rag to pre- vent the piston pin clip fro...

  • Page 191: Cylinder and Piston

    Cylinder and piston 5-26 b. If out of specification, rebore or replace the cylinder, and replace the piston and piston rings as a set. C. Measure piston skirt 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-cyli...

  • Page 192: Cylinder and Piston

    Cylinder and piston 5-27 eas24440 checking the piston pin 1. Check: • piston pin blue discoloration/grooves → replace the piston pin and then check the lubrica- tion system. 2. Measure: • piston pin outside diameter “a” out of specification → replace the piston pin. 3. Measure: • piston pin bore dia...

  • Page 193: Cylinder and Piston

    Cylinder and piston 5-28 • upper oil ring rail “3” • 2nd ring “4” • top ring “5” tip be sure to install the piston rings so that the “t” marks or numbers face up. 2. Install: • piston “1” • piston pin “2” • piston pin clips “3” tip • apply engine oil the piston pin. • make sure the dot “a” on the pi...

  • Page 194: Clutch

    Clutch 5-29 eas25061 clutch removing the clutch cover 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 clevis pin 1 3 brake pedal/footrest 1/1 4 oil delivery pipe 1 5 oil cooler hose 2 6 o-ring 2 7 right crankcase cov...

  • Page 195: Clutch

    Clutch 5-30 removing the clutch order job/parts to remove q’ty remarks 1 clutch spring 5 2 pressure plate 1 3 primary drive gear nut 1 4 friction plate 6 5 clutch plate 5 6 clutch boss nut 1 7 clutch boss 1 8 thrust washer 1 9 clutch housing 1 10 claw washer 1 11 primary drive gear 1 12 locknut/wash...

  • Page 196: Clutch

    Clutch 5-31 removing the push lever shaft order job/parts to remove q’ty remarks shift pedal refer to “shift shaft” on page 5-42. Left crankcase cover refer to “pickup coil rotor and starter clutch” on page 5-45. Clutch assembly 1 clutch cable 1 2 bolt 1 3 push lever shaft 1 4 torsion spring 1 5 cir...

  • Page 197: Clutch

    Clutch 5-32 eas25070 removing the clutch 1. Remove: • bolt “1” • clutch spring “2” tip loosen the bolts in stages and in a crisscross pattern. 2. Straighten the lock washer tab. 3. Loosen: • primary drive gear nut • clutch boss nut tip • place the aluminum plate “a” between clutch housing “1” and pr...

  • Page 198: Clutch

    Clutch 5-33 tip measure the friction plate at four places. Eas25110 checking the clutch plates the following procedure applies to all of 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 gau...

  • Page 199: Clutch

    Clutch 5-34 tip pitting on the clutch boss splines will cause erratic clutch operation. Eas25170 checking the pressure plate 1. Check: • pressure plate cracks/damage → replace. Eas25190 checking the clutch push rods 1. Check: • push lever shaft “1” • push rod 2 “2” • ball “3” cracks/damage/wear → re...

  • Page 200: Clutch

    Clutch 5-35 4. Bend the lock washer tab along a flat side of the nut. 5. Lubricate: • friction plates • clutch plates (with the recommended lubricant) 6. Install: • friction plates (6 piece) • clutch plates (5 piece) tip first, install a friction plate and then alternate between a clutch plate and a...

  • Page 201: Clutch

    Clutch 5-36 11. Adjust: • push lever position ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Loosen the locknut “1”. B. Turn the adjusting screw “2” in or out until the marks are aligned. C. Hold the adjusting screw to prevent it from moving and then tighten the locknut to specification. Eca13820 do not overtigh...

  • Page 202: Clutch

    Clutch 5-37 14. Install: • right crankcase cover 15. Install: • crankcase cover bolts m6 × 50 mm “1”, “2” • copper washers to “1”, “2” • crankcase cover bolts m6 × 40 mm “3”– “6” • crankcase cover bolts m6 × 25 mm “7”– “13” • oil filter element cover bolt m6 × 70 mm “14” 16. Tighten: • crankcase cov...

  • Page 203: Oil Pump

    Oil pump 5-38 eas24911 oil pump removing the oil pump order job/parts to remove q’ty remarks right crankcase cover /clutch /primary drive 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 spring...

  • Page 204: Oil Pump

    Oil pump 5-39 disassemble the oil pump order job/parts to remove q’ty remarks 1 oil pump housing 1 2 dowel pin 2 3 outer rotor 1 4 inner rotor 1 5 dowel pin 1 6 shaft 1 7 oil pump cover 1 for installation, reverse the removal proce- dure..

  • Page 205: Oil Pump

    Oil pump 5-40 eas24940 removing the oil pump 1. Straighten the lock washer tab. 2. Remove: • balancer weight gear nut • lock washer • balancer weight gear tip place the aluminium plate “a” between bal- ancer drive gear “1” and balancer weight gear “2”, and then loosen the balancer weight gear nut “3...

  • Page 206: Oil Pump

    Oil pump 5-41 • compression spring • dowel pin cracks/damage/wear → replace. Eas4d3f018 assenbling the balancer weight gear 1. Assemble: • dowel pin “1” • compression spring “2” tip install the dowel pins and compression springs alternately as shown as. 2. Assemble: • buffer boss eas25020 installing...

  • Page 207: Shift Shaft

    Shift shaft 5-42 eas25410 shift shaft removing the shift shaft and stopper lever order job/parts to remove q’ty remarks right crankcase cover/clutch refer to “clutch” on page 5-29. 1 shift pedal 1 2 shift shaft assembly 1 3 stopper lever 1 4 torsion spring 1 for installation, reverse the removal pro...

  • Page 208: Shift Shaft

    Shift shaft 5-43 eas25420 checking the shift shaft 1. Check: • shift shaft “1” • shift lever “2” bends/damage/wear → replace. • shift lever spring damage/wear → replace. Eas25430 checking the stopper lever 1. Check: • stopper lever bends/damage → replace. Roller turns roughly → replace the stop- per...

  • Page 209: Shift Shaft

    Shift shaft 5-44 6. Tighten: • shift pedal bolt 7. Adjust: • shift pedal height refer to “adjusting the shift pedal” on page 3-21. Shift pedal bolt 10 nm (1.0 m·kg, 7.4 ft·lb).

  • Page 210

    Pickup coil rotor and starter clutch 5-45 eas403f008 pickup coil rotor and starter clutch removing the pickup coil rotor and starter clutch 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 sprocket cover re...

  • Page 211

    Pickup coil rotor and starter clutch 5-46 eas403f009 removing the pickupcoil rotor 1. Remove: • pickup coil rotor bolt “1” • washer tip • loosen the pickup coil rotor bolt “1” while holding the rotor with a sheave holder “2”. • do not allow the sheave holder to touch the projection on the rotor “a”....

  • Page 212

    Pickup coil rotor and starter clutch 5-47 3. Check: • starter clutch gear’s contacting surfaces damage/pitting/wear → replace the starter clutch gear. 4. Check: • starter clutch operation ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Install the starter wheel gear “1” onto the starter clutch “2” and hold the st...

  • Page 213

    Pickup coil rotor and starter clutch 5-48 4. Install: • stator coil “1” • pickup coil “2” 5. Tighten: • stator coil bolts “3” • pickup coil bolts “4” • left crankcase cover bolt “5” 6. Install: • dowel pin • crankcase cover gasket 7. Install: • left crankcase cover 8. Tighten: • crankcase cover bolt...

  • Page 214: Electric Starter

    Electric starter 5-49 eas24780 electric starter removing the starter motor order job/parts to remove q’ty remarks exhaust pipe refer to “engine removal” on page 5-1. Starter idle gear cover/starter idle gear refer to “pickup coil rotor and starter clutch” on page 5-45. 1 clutch cable holder 1 2 star...

  • Page 215: Electric Starter

    Electric starter 5-50 disassembling the starter motor order job/parts to remove q’ty remarks 1 front bracket 1 2 tang washer 1 3 plate washer 1 4 circlip 1 5 rear bracket/brush holder 1/1 6 armature assembly 1 7 starter motor yoke 1 8 brush/spring 2/2 for assembly, reverse the disassembly pro- cedur...

  • Page 216: Electric Starter

    Electric starter 5-51 eas24790 checking the starter motor 1. Check: • commutator dirt → clean with 600 grit sandpaper. 2. Measure: • commutator diameter “a” out of specification → replace the starter motor. 3. Measure: • mica undercut “a” out of specification → scrape the mica to the proper measurem...

  • Page 217: Electric Starter

    Electric starter 5-52 7. Check: • gear teeth damage/wear → replace the gear. 8. Check: • bushing • bearing • oil seal damage/wear → replace the defective part(s). Eas24800 assembling the starter motor 1. Install: • brush spring “1” • brush “2” 2. Install: • armature coil “1” 3. Install: • o-ring “1”...

  • Page 218: Crankcase

    Crankcase 5-53 eas25540 crankcase separating the crankcase order job/parts to remove q’ty remarks engine refer to “engine removal” on page 5-1. Cylinder head refer to “cylinder head” on page 5-10. Cylinder/piston refer to “cylinder and piston” on page 5-24. Clutch refer to “clutch” on page 5-29. Oil...

  • Page 219: Crankcase

    Crankcase 5-54 removing the bearing order job/parts to remove q’ty remarks crankshaft assembly refer to “crankshaft assembly” on page 5-57. Main axle assembly/drive axle assembly refer to “transmission” on page 5-61. 1 oil seal 2 2 bearing 8 for assembly, reverse the removal proce- dure..

  • Page 220: Crankcase

    Crankcase 5-55 eas25570 disassembling the crankcase 1. Remove: • timing chain guide (intake side) “1” • timing chain “2” • crankshaft sprocket “3” 2. Remove: • neutral switch “1” • crankcase bolts m6 × 70 mm “2”–“4” • copper washers • crankcase bolts m6 × 60 mm “5”, “6” • crankcase bolts m6 × 55 mm ...

  • Page 221: Crankcase

    Crankcase 5-56 3. Install: • right crankcase (onto the left crankcase) tip tap lightly on the right crankcase with a soft- face hammer. 4. Install: • crankcase bolt m6 × 70 mm: “1”–“3” • copper washers to “1”–“3”. • crankcase bolt m6 × 60 mm: “4”, “5” • crankcase bolt m6 × 55 mm: “6”–“8” • crankcase...

  • Page 222: Crankshaft Assembly

    Crankshaft assembly 5-57 eas25970 crankshaft assembly removing the crankshaft assembly order job/parts to remove q’ty remarks crankcase refer to “crankcase” on page 5-53. 1 balancer weight 1 2 crankshaft assembly 1 3 dowel pin 1 4 plunger seal 1 5 bearing 1 for installation, reverse the removal proc...

  • Page 223: Crankshaft Assembly

    Crankshaft assembly 5-58 eas25990 removing the crankshaft assembly 1. Remove: • balancer weight • crankshaft assembly “1” tip • remove the crankshaft assembly with the crankcase separating tool “2”. • make sure the crankcase separating tool is centered over the crankshaft assembly. Eas4d3f021 removi...

  • Page 224: Crankshaft Assembly

    Crankshaft assembly 5-59 4. Check: • crankshaft sprocket damage/wear → replace the crankshaft. • bearing cracks/damage/wear → replace the crankshaft. 5. Check: • crankshaft journal scratches/wear → replace the crank- shaft. • crankshaft journal oil passage obstruction → blow out with compressed air....

  • Page 225: Crankshaft Assembly

    Crankshaft assembly 5-60 tip install the crankshaft assembly with the crank- shaft installer pot “2”, crankshaft installer bolt “3”, adapter “4” and spacer “5”. Eca13970 to avoid scratching the crankshaft and to ease the installation procedure, lubricate the oil seal lips with lithium-soap-based gre...

  • Page 226: Transmission

    Transmission 5-61 eas26241 transmission removing the transmission, shift drum assembly, and shift forks order job/parts to remove q’ty remarks crankcase separate. Refer to “crankcase” on page 5-53. 1 shift fork guide bar 1 2 shift drum assembly 1 3 shift fork-3 (r) 1 4 shift fork-2 (c) 1 5 shift for...

  • Page 227: Transmission

    Transmission 5-62 disassembling the transmission order job/parts to remove q’ty remarks 1 2nd pinion gear 1 2 5th pinion gear 1 3 3rd pinion gear 1 4 circlip/washer 1/1 5 4th pinion gear 1 6 main axle 1 7 plain washer 1 8 1st wheel gear 1 9 4th wheel gear 1 10 circlip/washer 1/1 11 3rd wheel gear/co...

  • Page 228: Transmission

    Transmission 5-63 eas26250 removing the transmission 1. Remove: • shift fork guide bar “1” • shift drum assembly “2” • shift fork 3 (r) “3” • shift fork 2 (c) • shift fork 1 (l) “4” 2. Remove: • transmission “5” eas26260 checking the shift forks the following procedure applies to all of the shift fo...

  • Page 229: Transmission

    Transmission 5-64 eas26280 checking the transmission 1. Measure: • main axle runout (with a centering device and dial gauge) out of specification → replace the main axle. 2. Measure: • drive axle runout (with a centering device and dial gauge) out of specification → replace the drive axle. 3. Check:...

  • Page 230: Transmission

    Transmission 5-65 eas26320 installing the shift forks and shift drum assembly 1. Install: • transmission “1” • shift fork 1 (l) “2” • shift fork 2 (c) • shift fork 3 (r) “3” • shift drum assembly “4” • shift fork guide bar “5” • spacer • right crankcase tip the embossed marks on the shift forks shou...

  • Page 231: Fuel System

    6 fuel system fuel tank ..................................................................................................6-1 removing the fuel tank ................................................................6-2 checking the fuel cock ...............................................................

  • Page 232: Fuel Tank

    Fuel tank 6-1 eas26620 fuel tank 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 2 fuel tank 1 3 clamp 1 4 fuel tank shield 1 for installation, reverse the removal proce- dure..

  • Page 233: Fuel Tank

    Fuel tank 6-2 eas26630 removing the fuel tank 1. Remove: • fuel hose (fuel cock side) eca14700 although the fuel has been removed from the fuel tank be careful when removing the fuel hoses, since there may be fuel remaining in it. Tip before removing the hose, turn the fuel cock to “off” and place a...

  • Page 234: Carburetor

    Carburetor 6-3 eas26720 carburetor removing the carburetor order job/parts to remove q’ty remarks seat/front fender/rear fender/air filter case refer to “general chassis” on page 4-1. 1 carburetor warmer coupler 1 disconnect. 2 air vent hose 1 disconnect. 3 fuel hose (carburetor side) 1 disconnect. ...

  • Page 235: Carburetor

    Carburetor 6-4 disassembling the carburetor order job/parts to remove q’ty remarks 1 drain hose 1 2 throttle stop screw 1 3 cover 1 4 diaphragm spring 1 5 piston valve 1 6 jet needle 1 7 cover 1 8 spring 1 9 coasting enricher diaphragm 1 10 coasting enricher jet (p. A. J. 2) 1 11 starter plunger 1 1...

  • Page 236: Carburetor

    Carburetor 6-5 23 starter jet 1 for assembly, reverse the disassembly pro- cedure. Disassembling the carburetor order job/parts to remove q’ty remarks.

  • Page 237: Carburetor

    Carburetor 6-6 eas26760 checking the carburetor 1. Check: • carburetor body • float chamber cracks/damage → replace. • float chamber body contamination → clean. 2. Check: • fuel passages obstruction → clean. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Wash the carburetor in a petroleum-based solvent. Do not u...

  • Page 238: Carburetor

    Carburetor 6-7 8. Check: • jet needle “1” bends/wear/damage → replace. • clip groove free play/wear → replace. 9. Check: • main jet “1” • pilot jet “2” • needle jet “3” • needle jet holder “4” • starter jet “5” • coasting enricher jet (p. A. J. 2) “6” bends/damage/wear → replace. Obstruction → clean...

  • Page 239: Carburetor

    Carburetor 6-8 c. If the float height is not within the specifica- tion, check the valve seat and needle valve. D. If either is worn, replace the valve seat, needle valve 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 floa...

  • Page 240: Carburetor

    Carburetor 6-9.

  • Page 241: Electrical System

    7 electrical system ignition system.......................................................................................7-1 circuit diagram................................................................................7-1 troubleshooting ..............................................................

  • Page 242: Ignition System

    Ignition system 7-1 eas27090 ignition system eas27100 circuit diagram.

  • Page 243: Ignition System

    Ignition system 7-2 1. Pickup coil 2. Stator coil 4. Main switch 5. Battery positive lead 6. Battery 7. Fuse 10.Cdi unit 11.Ignition coil 12.Spark plug 24.Engine stop switch 28.Ground.

  • Page 244: Ignition System

    Ignition system 7-3 eas27130 troubleshooting the ignition system fails to operate (no spark or intermittent spark). Tip • before troubleshooting, remove the following part(s): 1. Seat 2. Front panel 3. Front fender 4. Rear fender 5. Side cover ng → ok ↓ ng → ok ↓ ng → ok ↓ ok → ng ↓ ng → ok ↓ ng → o...

  • Page 245: Ignition System

    Ignition system 7-4 ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 8. Check the stator coil. Refer to “checking the stator coil” on page 7-40. Replace the stator assembly. 9. Check the main switch. Refer to “checking the switches” on page 7-29. Replace the main switch. 10.Chec...

  • Page 246: Electric Starting System

    Electric starting system 7-5 eas27160 electric starting system eas27170 circuit diagram.

  • Page 247: Electric Starting System

    Electric starting system 7-6 4. Main switch 5. Battery positive lead 6. Battery 7. Fuse 8. Starter relay 9. Starter motor 13.Starting circuit cut-off relay 14.Clutch switch 18.Neutral switch 24.Engine stop switch 25.Start switch 28.Ground.

  • Page 248: Electric Starting System

    Electric starting system 7-7 eas27180 starting circuit cut-off system operation if the engine stop switch is set to “ ” and the main switch is set to “on” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: • the transmission is in neutr...

  • Page 249: Electric Starting System

    Electric starting system 7-8 a. When the transmission is in neu- tral b. When the clutch lever is pulled to the handlebar 1. Battery 2. Fuse 3. Main switch 4. Engine stop switch 5. Starting circuit cut-off relay 6. Clutch switch 7. Neutral switch 8. Start switch 9. Starter relay 10.Starter motor.

  • Page 250: Electric Starting System

    Electric starting system 7-9 eas27190 troubleshooting the starter motor fails to turn. Tip • before troubleshooting, remove the following part(s): 1. Seat 2. Front panel 3. Front fender 4. Rear fender 5. Side cover ng → ok ↓ ng → ok ↓ ok → ng ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fu...

  • Page 251: Electric Starting System

    Electric starting system 7-10 ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 8. Check the main switch. Refer to “checking the switches” on page 7-29. Replace the main switch. 9. Check the engine stop switch. Refer to “checking the switches” on page 7-29. Replace the handlebar switch. 10...

  • Page 252: Charging System

    Charging system 7-11 eas27200 charging system eas27210 circuit diagram.

  • Page 253: Charging System

    Charging system 7-12 2. Stator coil 3. Rectifier/regulator 5. Battery positive lead 6. Battery 7. Fuse 28.Ground.

  • Page 254: Charging System

    Charging system 7-13 eas27230 troubleshooting the battery is not being charged. Tip • before troubleshooting, remove the following part(s): 1. Seat 2. Front panel 3. Front fender 4. Rear fender 5. Side cover ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuse. Refer to “checking the ...

  • Page 255: Charging System

    Charging system 7-14.

  • Page 256: Lighting System

    Lighting system 7-15 eas27240 lighting system eas27250 circuit diagram.

  • Page 257: Lighting System

    Lighting system 7-16 2. Stator coil 3. Rectifier/regulator 4. Main switch 5. Battery positive lead 6. Battery 7. Fuse 21.Tail/brake light 23.Light switch 26.Headlight relay 27.Headlight 28.Ground.

  • Page 258: Lighting System

    Lighting system 7-17 eas27260 troubleshooting any of the following fail to light: headlight, tail/brake light. Tip • before troubleshooting, remove the following part(s): 1. Seat 2. Front panel 3. Front fender 4. Rear fender 5. Side cover ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1...

  • Page 259: Lighting System

    Lighting system 7-18 ng → ok ↓ 7. Check the entire lighting system’s wiring. Refer to “circuit diagram” on page 7-15. Properly connect or repair the lighting system’s wiring. This circuit is ok..

  • Page 260: Signaling System

    Signaling system 7-19 eas27270 signaling system eas27280 circuit diagram.

  • Page 261: Signaling System

    Signaling system 7-20 4. Main switch 5. Battery positive lead 6. Battery 7. Fuse 17.Neutral indicator light 18.Neutral switch 19.Rear brake light switch 20.Front brake light switch 21.Tail/brake light 28.Ground.

  • Page 262: Signaling System

    Signaling system 7-21 eas27290 troubleshooting any of the following fail to light: brake light or an indicator light. Tip • before troubleshooting, remove the following part(s): 1. Seat 2. Front fender ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ check the signaling system the tail/brake light fails to c...

  • Page 263: Signaling System

    Signaling system 7-22 ng → ok ↓ the neutral indicator light fails to come. Ng → ok ↓ ng → ok ↓ ng → ok ↓ 3. Check the entire signaling system’s wiring. Refer to “circuit diagram” on page 7-19. Properly connect or repair the signal- ing system’s wiring. This circuit is ok. 1. Check the neutral indica...

  • Page 264: Carburetor Heating System

    Carburetor heating system 7-23 eas27490 carburetor heating system eas27500 circuit diagram.

  • Page 265: Carburetor Heating System

    Carburetor heating system 7-24 4. Main switch 5. Battery positive lead 6. Battery 7. Fuse 15.Thermo switch 16.Carburetor warmer 28.Ground.

  • Page 266: Carburetor Heating System

    Carburetor heating system 7-25 eas27510 troubleshooting the carburetor heating system fails to operate. Tip • before troubleshooting, remove the following part(s): 1. Seat 2. Front panel 3. Front fender 4. Rear fender 5. Side cover ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check...

  • Page 267: Carburetor Heating System

    Carburetor heating system 7-26.

  • Page 268: Electrical Components

    Electrical components 7-27 eas27972 electrical components.

  • Page 269: Electrical Components

    Electrical components 7-28 1. Main switch 2. Front brake light switch 3. Clutch switch 4. Handlebar switch 5. Cdi unit 6. Starter relay 7. Fuse 8. Battery 9. Tail/brake light 10.Headlight relay 11.Starting circuit cut-off relay 12.Thermo switch 13.Carburetor warmer 14.Starter motor 15.Pickup coil/st...

  • Page 270: Electrical Components

    Electrical components 7-29 eas27980 checking the switches.

  • Page 271: Electrical Components

    Electrical components 7-30 1. Light switch 2. Engine stop switch 3. Start switch 4. Main switch 5. Front brake light switch 6. Clutch switch 7. Fuse 8. Neutral switch 9. Rear brake light switch.

  • Page 272: Electrical Components

    Electrical components 7-31 check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. Eca14370 never insert the tester probes into the coupler terminal slots “a”. Always insert the probes from th...

  • Page 273: Electrical Components

    Electrical components 7-32 eas27990 checking the bulbs and bulb sock- ets check each bulb and bulb socket for damage or wear, proper connections, and also for conti- nuity between the terminals. Damage/wear → repair or replace the bulb, bulb socket or both. Improperly connected → properly connect. N...

  • Page 274: Electrical Components

    Electrical components 7-33 checking the condition of the bulb sockets the following procedure applies to all of the bulb sockets. 1. Check: • bulb socket (for continuity) (with the pocket tester) no continuity → replace. Tip check each bulb socket for continuity in the same manner as described in th...

  • Page 275: Electrical Components

    Electrical components 7-34 therefore, always follow these preventive measures: • wear protective eye gear when handling or working near batteries. • charge batteries in a well-ventilated area. • keep batteries away from fire, sparks or open flames (e.G., welding equipment, lighted cigarettes). • do ...

  • Page 276: Electrical Components

    Electrical components 7-35 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Charge: • battery (refer to the appropriate charging method illustration) warning ewa13300 do not quick charge a battery. Eca4d3f013 • never remove the vrla (valve regulated lead acid) battery sealing caps. • do not use a high-rate battery...

  • Page 277: Electrical Components

    Electrical components 7-36 tip voltage should be measured 30 minutes after the machine is stopped. B. Connect a charged and amp meter to the battery and start charging. Tip set the charging voltage at 16–17 v.If the set- ting is lower, charging will be insufficient. If too high, the battery will be ...

  • Page 278: Electrical Components

    Electrical components 7-37 9. Lubricate: • battery terminals 10. Install: • battery cover • seat refer to “general chassis” on page 4-1. Eas28040 checking the relays check each switch for continuity with the pocket tester. If the continuity reading is incor- rect, replace the relay. 1. Disconnect th...

  • Page 279: Electrical Components

    Electrical components 7-38 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the starting circuit cut-off relay from the wire harness. B. Connect the pocket tester ( Ω × 1) to the diode coupler as shown. C. Check the diode for continuity. D. Check the diode for no continuity. Tip when you switch the posi...

  • Page 280: Electrical Components

    Electrical components 7-39 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the spark plug cap from the ignition coil. B. Connect the pocket tester ( Ω × 1k) to the ignition coil as shown. C. Measure the secondary coil resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Check: • ignition spark gap out of spec...

  • Page 281: Electrical Components

    Electrical components 7-40 b. Measure the pickup coil resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas28940 checking the starter motor opera- tion 1. Check: • starter motor operation does not operate → perform the electric starting system troubleshooting, starting with step 4. Refer to “troubleshootin...

  • Page 282: Electrical Components

    Electrical components 7-41 eas28170 checking the rectifier/regulator 1. Check: • rectifier/regulator output voltage out of specification → replace the recti- fier/regulator. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Set the engine tachometer to the ignition coil. B. Connect the pocket tester (ac 20 v) to th...

  • Page 283: Electrical Components

    Electrical components 7-42 eas28310 checking the carburetor warmer 1. Check: • carburetor warmer resistance out of specification → replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the carburetor warmer from the carburetor. B. Connect the pocket tester ( Ω × 1) to the carburetor warmer as shown. C. ...

  • Page 284: Electrical Components

    Electrical components 7-43.

  • Page 285: Troubleshooting

    8 troubleshooting troubleshooting ..................................................................................8-1 general information .....................................................................8-1 starting failures ........................................................................

  • Page 286: Troubleshooting

    Troubleshooting 8-1 eas28451 troubleshooting eas28460 general information tip the following guide for troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to basic troubleshooting. Refer to the relative proce- dure in this manual for checks, ad...

  • Page 287: Troubleshooting

    Troubleshooting 8-2 eas28490 incorrect engine idling speed engine 1. Cylinder and cylinder head • incorrect valve clearance • damaged valve train components 2. Air filter • clogged air filter element • loosen air filter joint fuel system 1. Carburetor • faulty starter plunger • loose or clogged pilo...

  • Page 288: Troubleshooting

    Troubleshooting 8-3 • incorrect oil level • incorrect oil viscosity (low) • deteriorated oil clutch drags 1. Clutch • unevenly tensioned clutch springs • warped pressure plate • bent clutch plate • swollen friction plate • bent clutch push rod • damaged clutch boss • burnt primary driven gear bushin...

  • Page 289: Troubleshooting

    Troubleshooting 8-4 • faulty battery • faulty rectifier/regulator • improperly grounded circuit • faulty main switch • faulty light switch • headlight bulb life expired tail/brake light does not come on • wrong tail/brake light bulb • too many electrical accessories • hard charging • incorrect conne...

  • Page 290

    Eas28740 wiring diagram yfm25ry/yfm25rsey/ yfm25rse2y 1. Pickup coil 2. Stator coil 3. Rectifier/regulator 4. Main switch 5. Battery positive lead 6. Battery 7. Fuse 8. Starter relay 9. Starter motor 10. Cdi unit 11. Ignition coil 12. Spark plug 13. Starting circuit cut-off relay 14. Clutch switch 1...

  • Page 292

    Yamaha motor co., ltd. 2500 shingai iwata shizuoka japan.

  • Page 293

    Wiring diagram yfm25ry/yfm25rsey/yfm25rse2y.