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Yamaha YFM250RX 2008 Service Manual

Manual is about: Raptor 250

Summary of YFM250RX 2008

  • Page 1

    Service manual yfm250rx 4d3-28197-10 lit-11616-21-22 2008.

  • Page 2

    Yfm250rx service manual © 2007 by yamaha motor corporation, u.S.A. First edition, july 2007 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 lit-11616-21-22 ebs00001.

  • Page 3: Notice

    Ebs00002 notice this manual was produced by the yamaha motor company primarily for use by yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man- ual, so it is assumed that anyone who uses this book to perform maintenance and repairs on...

  • Page 4: How To Use This Manual

    Ebs00004 how to use this manual manual organization this manual consists of chapters for the main categories of subjects. (see “symbols”) 1st title : this is the title of the chapter with its symbol in the upper right corner of each page. 2nd title : this title indicates the section of the chapter a...

  • Page 5: Gen

    Gen info chas ebs00006 symbols the following symbols are not relevant to every machine. Symbols to indicate the subject of each chapter. General information specifications periodic checks and adjustments engine carburetor chassis electrical troubleshooting symbols to indicate the following serviceab...

  • Page 7: Table of Contents

    Ebs00008 table of contents general information gen info 1 specifications spec 2 periodic checks and adjustments chk adj 3 engine eng 4 carburetor carb 5 chassis chas 6 electrical elec 7 troubleshooting trbl shtg 8.

  • Page 8

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

  • Page 9

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

  • Page 10

    Checking and lubricating the cables . . . . . . . . . . . . . . . . 3-43 lubricating the levers and pedals . . . . . . . . . . . . . . . . . . . 3-44 electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45 checking and charging the battery . . . . . . . . ....

  • Page 11

    Checking the clutch plates . . . . . . . . . . . . . . . . . . . . . . . . . 4-44 checking the clutch springs . . . . . . . . . . . . . . . . . . . . . . . . 4-45 checking the clutch housing . . . . . . . . . . . . . . . . . . . . . . . . 4-45 checking the clutch boss . . . . . . . . . . . . . . . ....

  • Page 12

    Chapter 5 carburetor carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 checking the carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 assembling the carburetor . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 installing t...

  • Page 13

    Assembling the rear brake caliper . . . . . . . . . . . . . . . . . . 6-36 installing the front brake calipers . . . . . . . . . . . . . . . . . 6-38 installing the rear brake caliper . . . . . . . . . . . . . . . . . . . 6-40 steering system . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 14

    Checking the bulbs and bulb sockets . . . . . . . . . . . . . . . . . . 7-5 types of bulbs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 checking the condition of the bulbs . . . . . . . . . . . . . . . . . 7-5 checking the condition of the bulb sockets . . . . . ...

  • Page 15

    Clutch slipping/dragging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 clutch slipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 clutch dragging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 overheating . . . . ....

  • Page 16: Gen

    Gen info 1-1 ebs00009 general information machine identification ebs00010 vehicle identification number the vehicle identification number is stamped into the left side of the frame. Ebs00011 model label the model label is affixed to the air filter case cover. This information will be needed to order...

  • Page 17: Gen

    Gen info 1-2 1 2 3 4 5 6 7 8 ebs00013 important information preparation for removal and disassembly 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”. 3. When disassembling always keep mate...

  • Page 18: Gen

    Gen info 1-3 ebs00017 bearings and oil seals install bearings and oil seals so that the manu- facturer’s marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if appro- priate. Oil ...

  • Page 19: Gen

    Gen info 1-4 ebs00019 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 times. 3. Chec...

  • Page 20: Gen

    Gen info 1-5 ebs00021 special tools the following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools; this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools may differ by shape and...

  • Page 21: Gen

    Gen info 1-6 tool no. Tool name/function illustration adapter 90890-01383 yu-90062 adapter (m10) adapter #2 this tool is used to install the crankshaft. 90890-01288 spacer this tool is used to install the crankshaft. 90890-01304 yu-01304 piston pin puller set piston pin puller this tool is used to r...

  • Page 22: Gen

    Gen info 1-7 tool no. Tool name/function illustration 90890-03081 yu-33223 compression gauge engine compression tester this tool is needed to measure the engine compression. 90890-04082 extension this tool is needed to measure engine com- pression. 90890-03112 yu-03112-c pocket tester analog pocket ...

  • Page 23: Gen

    Gen info 1-8 tool no. Tool name/function illustration 90890-04065 ym-04065-a valve guide installer ( φ 6) valve guide installer (6.0 mm) this tool is needed to install the valve guides. 90890-04066 ym-04066 valve guide reamer ( φ 6) valve guide reamer (6.0 mm) this tool is needed to rebore the new v...

  • Page 24: Spec

    Spec 2-1 ebs01001 specifications general specifications item standard model code 4d31 4d35 4d39 dimensions overall length 1,625 mm (64.0 in) overall width 1,070 mm (42.1 in) overall height 1,040 mm (40.9 in) seat height 730 mm (28.7 in) wheelbase 1,110 mm (43.7 in) minimum ground clearance 100 mm (3...

  • Page 25: Spec

    Spec 2-2 1 2 3 4 5 6 7 8 item standard fuel type unleaded gasoline only fuel tank capacity 9.0 l (1.97 imp gal, 2.37 us gal) fuel reserve amount 1.0 l (0.22 imp gal, 0.26 us gal) carburetor type/quantity bsr29 × 1 manufacturer mikuni spark plug type/manufacturer dr7ea/ngk spark plug gap 0.6 ~ 0.7 mm...

  • Page 26: Spec

    Spec 2-3 item standard brake front brake type dual disc brake operation right hand operation rear brake type single disc brake operation right foot operation suspension front suspension double wishbone rear suspension swingarm shock absorber front shock absorber coil spring/oil damper rear shock abs...

  • Page 27: Spec

    Spec 2-4 ebs01002 engine specifications item standard limit cylinder head volume 20.50 ~ 21.50 cm 3 (1.25 ~ 1.31 cu.In) • • • warp limit • • • 0.05 mm (0.0020 in) cylinder bore size 74.000 ~ 74.016 mm (2.9134 ~ 2.9140 in) 74.100 mm (2.9173 in) camshaft drive method chain drive (right) • • • camshaft...

  • Page 28: Spec

    Spec 2-5 item standard limit valve, valve seat, valve guide valve clearance (cold) in 0.05 ~ 0.10 mm (0.0020 ~ 0.0039 in) • • • ex 0.10 ~ 0.15 mm (0.0039 ~ 0.0059 in) • • • valve dimensions “a” head diameter in 33.90 ~ 34.10 mm (1.3346 ~ 1.3425 in) • • • ex 28.40 ~ 28.60 mm (1.1181 ~ 1.1260 in) • • ...

  • Page 29: Spec

    Spec 2-6 item standard limit valve spring inner spring free length in 36.17 mm (1.42 in) 34.36 mm (1.35 in) ex 36.17 mm (1.42 in) 34.36 mm (1.35 in) installed length (valve closed) in 30.50 mm (1.20 in) • • • ex 30.50 mm (1.20 in) • • • spring rate k1 in 14.70 n/mm (1.50 kg/mm, 83.94 lb/in) • • • k2...

  • Page 30: Spec

    Spec 2-7 item standard limit tilt limit in • • • 2.5°/1.60 mm (2.5°/0.063 in) ex • • • 2.5°/1.60 mm (2.5°/0.063 in) direction of winding (top view) in clockwise • • • ex clockwise • • • piston piston to cylinder clearance 0.010 ~ 0.025 mm (0.0004 ~ 0.0010 in) 0.15 mm (0.006 in) piston size “d” 73.98...

  • Page 31: Spec

    Spec 2-8 item standard limit piston rings top ring type barrel • • • dimensions (b × t) 0.90 × 2.75 mm (0.035 × 0.108 in) • • • end gap (installed) 0.19 ~ 0.31 mm (0.007 ~ 0.012 in) 0.56 mm (0.022 in) side clearance 0.030 ~ 0.065 mm (0.0012 ~ 0.0026 in) 0.115 mm (0.0045 in) 2nd ring type taper • • •...

  • Page 32: Spec

    Spec 2-9 item standard limit balancer balancer drive method gear • • • clutch friction plate 1 (inside dia.: 104.5 ~ 105.5 mm) thickness 2.9 ~ 3.1 mm (0.114 ~ 0.122 in) 2.8 mm (0.110 in) quantity 4 • • • friction plate 2 (inside dia.: 104.5 ~ 105.5 mm) thickness 2.9 ~ 3.1 mm (0.114 ~ 0.122 in) 2.8 m...

  • Page 33: Spec

    Spec 2-10 item standard limit carburetor i. D. Mark 4d31 00 • • • main jet (m.J) #133.8 • • • main air jet (m.A.J) #140 • • • jet needle (j.N) 5dh66-1 • • • needle jet (n.J) p-0m • • • pilot air jet 1 (p.A.J.1) #85 • • • pilot air jet 2 (p.A.J.2) #170 • • • pilot outlet (p.O) ø0.9 • • • pilot jet (p...

  • Page 34: Spec

    Spec 2-11 ebs01003 chassis specifications item standard limit front suspension shock absorber travel 90.7 mm (3.57 in) • • • spring free length 248.5 mm (9.78 in) • • • spring rate 23.0 n/mm (2.34 kg/mm, 131.26 lb/in) • • • spring stroke 0.0 ~ 90.7 mm (0.0 ~ 3.57 in) • • • optional spring no • • • r...

  • Page 35: Spec

    Spec 2-12 item standard limit front disc brake type dual • • • disc outside diameter × thickness 161.0 × 3.5 mm (6.34 × 0.14 in) 3.0 mm (0.12 in) brake disk maximum deflection 0.15 mm (0.006 in) pad thickness inner 4.4 mm (0.17 in) 1.5 mm (0.06 in) pad thickness outer 4.5 mm (0.18 in) 1.5 mm (0.06 i...

  • Page 36: Spec

    Spec 2-13 ebs01004 electrical specifications item standard limit voltage 12 v • • • ignition system ignition timing (b.T.D.C.) 10.0°/1,550 r/min • • • advanced timing (b.T.D.C.) 24.4°/5,000 r/min advancer type digital type • • • cdi cdi unit model/manufacturer 4d3/yamaha • • • pickup coil resistance...

  • Page 37: Spec

    Spec 2-14 item standard limit starter relay model/manufacturer a4616-051/jideco • • • amperage rating 180 a • • • coil winding resistance 4.18 ~ 4.62 Ω • • • headlight relay headlight relay model/manufacturer g8hn-1c4t-dj-y52/omron • • • coil resistance 94.5 Ω ~ 115.5 Ω • • • circuit breaker type fu...

  • Page 38: Spec

    Spec 2-15 ebs01005 tightening torques engine tightening torques part to be tightened part name thread size q’ty tightening torque remarks nm m•kg ft•lb cylinder head (upper) bolt m8 4 24 2.4 18 see note *1 cylinder head bolt m8 2 20 2.0 15 camshaft lock plate bolt m6 2 8 0.8 5.9 cylinder head side c...

  • Page 39: Spec

    Spec 2-16 note: *1: apply oil to the bearing surface of (upper) cylinder head bolt. Further, apply molybdenum disulfide grease to thread part. Part to be tightened part name thread size q’ty tightening torque remarks nm m•kg ft•lb clutch boss nut nut m16 1 75 7.5 55 use a lock washer. Clutch spring ...

  • Page 40: Spec

    Spec 2-17 ebs01006 chassis tightening torques part to be tightened thread size tightening torque remarks nm m•kg ft•lb engine upper stay and frame m8 33 3.3 24 engine upper stay and engine m10 66 6.6 49 engine lower stay and engine m10 40 4.0 30 engine and frame m10 66 6.6 49 engine lower stay and f...

  • Page 41: Spec

    Spec 2-18 part to be tightened thread size tightening torque remarks nm m•kg ft•lb front brake master cylinder and brake lever m6 6 0.6 4.4 throttle assembly and handlebar m5 4 0.4 3.0 front brake master cylinder and brake hose m10 27 2.7 20 brake hose joint and frame m6 10 1.0 7.4 bleed screw m8 5 ...

  • Page 42: Spec

    Spec 2-19 ebs00022 how to use the conversion table all specification data in this manual are listed in si and metric units. Use this table to convert metric unit data to imperial unit data. Ex. Conversion table ebs00023 general tightening torque specifications this chart specifies tightening torques...

  • Page 43: Spec

    Spec 2-20 ebs00024 lubrication points and lubricant types 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 rod small end and big end piston pin pisto...

  • Page 44: Spec

    Spec 2-21 lubrication point lubricant crankcase mating surfaces sealant (three bond no.1215 ® ) yamaha bond no.1215 ac magneto lead grommet (ac magneto cover) sealant (three bond no.1215 ® ) yamaha bond no.1215 lubrication points and lubricant types.

  • Page 45: Spec

    Spec 2-22 ebs00026 oil flow diagrams camshaft oil filter element oil pump oil strainer oil cooler drive axle main axle pin, with hole crank shaft oil pump oil strainer cylinder head cam shaft oil pan oil filter oil flow diagrams.

  • Page 46: Spec

    Spec 2-23 camshaft drive axle main axle push lever shaft oil pump assembly oil strainer crankshaft assembly oil filter element oil flow diagrams.

  • Page 47: Spec

    Spec 2-24 oil cooler oil hose 1 oil hose 2 oil flow diagrams.

  • Page 48: Spec

    Spec 2-25 ebs00028 cable routing front brake hose front brake light switch lead throttle cable plastic band clutch cable parking brake cable clutch switch lead handlebar switch lead cable routing.

  • Page 49: Spec

    Spec 2-26 clamp the front brake light switch lead at the bends of handlebar. Route the front brake hose and throttle cable through the guide of the handlebar protector. Route the throttle cable under the front brake hose. Route the clutch cable and parking brake cable through the guide of the handle...

  • Page 50: Spec

    Spec 2-27 indicator light lead main switch lead coupler joint front brake light switch lead front brake hose 2 oil cooler hose 1, 2 exhaust pipe engine bracket rear brake light switch lead parking brake cable battery negative lead carburetor warmer lead air vent hose air filter case breather hose th...

  • Page 51: Spec

    Spec 2-28 to the front panel to the front fender to the handlebar to the right headlight make sure to route the oil cooler hoses 1and 2 through the guide wire. Install the front brake hose 2, making sure to face the white paint mark forward. Route the oil cooler hose 1 and 2 between the exhaust pipe...

  • Page 52: Spec

    Spec 2-29 route the parking brake cable and the clutch cable under the cross pipe and right of the steering col- umn as shown in the illustration. Route the rear brake light switch lead, neutral switch lead, air vent hose, carburetor overflow hose and parking brake cable through the bracket. Route t...

  • Page 53: Spec

    Spec 2-30 rear brake reservoir rear brake light switch clip rear brake reservoir hose rear brake master cylinder parking brake cable rear brake hose rear brake caliper e e d-d c-c d d c c cable routing.

  • Page 54: Spec

    Spec 2-31 make sure that the end of the clip is facing down- ward. Set the rear brake reservoir hose with the position- ing yellow paint mark pointing down. Install the rear brake hose in the direction shown in the illustration. Insert the rear brake hose until it contacts the pro- jection. Make sur...

  • Page 55: Spec

    Spec 2-32 clutch switch lead handlebar switch lead bolt main harness air vent hose clamp battery negative lead ac magneto lead carburetor overflow hose starter motor lead neutral switch lead ignition coil spark plug lead ignition coil drain hose frame complete damper plate seat pad cover rear brake ...

  • Page 56: Spec

    Spec 2-33 to the front fender route the wire harness above the guide for the damper plate. Fix point for wire harness clamp near the hook of the air filter. Clamp near the edge of the air filter case. Route the drain hose in front of the left oil cooler hose. Clamp on top of the frame bracket. To th...

  • Page 57: Spec

    Spec 2-34 indicator light coupler joint main switch lead front brake light switch lead throttle cable regulator flange bolt headlight lead indicator light lead clutch cable parking brake cable rear brake reservoir rear brake light switch lead air vent hose battery negative lead carburetor warmer lea...

  • Page 58: Spec

    Spec 2-35 install the indicator light as shown in the illustra- tion. Place the coupler joint above the front fender. Route the front brake light switch lead and throttle cable through the guide. Connect the main switch lead on top of the front fender. Route both leads from the front. Route the head...

  • Page 59: Spec

    Spec 2-36 route the cables and leads through the guide of the front fender. Route the leads behind the clutch and parking brake cable. Cable routing nn j j k k j-j k-k.

  • Page 60: Spec

    Spec 2-37 cdi unit band battery starter relay lead starter relay taillight lead battery negative lead ac magneto coupler starter motor lead headlight relay neutral relay damper cdi unit lead relay lead cable routing j a a b a-a j b.

  • Page 61: Spec

    Spec 2-38 route the starter relay lead under the starter motor lead. Clamp the taillight lead. Do not clamp. When clamping the wire harness, make sure that the insulator lock is behind the clamp. After connecting the battery negative lead, push the sag in the box. After connecting the taillight lead...

  • Page 62: Chk

    Chk adj 3-1 ebs00029 periodic checks and adjustments introduction this chapter includes all information necessary to perform recommended checks and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable machine operation and a longer service life. The need for c...

  • Page 63: Chk

    Chk adj 3-2 1 2 3 4 5 6 7 8 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 necessary....

  • Page 64: Chk

    Chk adj 3-3 note: • 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 and calipers...

  • Page 65: Chk

    Chk adj 3-4 ebs00033 seat, fenders and fuel tank seat, front fender and headlights order job/part q’ty remarks removing the seat, front fender and headlights remove the parts in the order listed. 1 seat 1 note: note: pull back the seat lock lever, than pull up on the rear of the seat. 2 indicator li...

  • Page 66: Chk

    Chk adj 3-5 ebs00034 foot protectors and engine skid plate order job/part q’ty remarks removing the foot protectors and engine skid plate remove the parts in the order listed. 1 left foot protector 1 2 right foot protector 1 3 engine skid plate 1 for installation, reverse the removal procedure. 2 1 ...

  • Page 67: Chk

    Chk adj 3-6 rear fender and air fillter case order job/part q’ty remarks removing the rear fender and air fillter case remove the parts in the order listed. Seat/front fender refer to “seat, fenders and fuel tank”. 1 rear fender 1 2 battery cover 1 3 battery lead 2 caution: first disconnect the nega...

  • Page 68: Chk

    Chk adj 3-7 order job/part q’ty remarks 10 air filter case 1 for installation, reverse the removal procedure. 7 nm (0.7 m•kg, 5.2 ft•ib) 7 nm (0.7 m•kg, 5.2 ft•ib) 7 nm (0.7 m•kg, 5.2 ft•ib) 7 nm (0.7 m•kg, 5.2 ft•ib) seat, fenders and fuel tank.

  • Page 69: Chk

    Chk adj 3-8 ebs00042 fuel tank order job/part q’ty remarks removing the fuel tank remove the parts in the order listed. Seat/front fender refer to “seat, fenders and fuel tank”. 1 fuel hose (fuel cock side) 1 note: note: before disconnecting the fuel hose, turn the fuel cock to “off”. 2 fuel tank 1 ...

  • Page 70: Chk

    Chk adj 3-9 eas00048 engine adjusting the valve clearance the following procedure applies to all of the valves. Note: note: • 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 the top dead ...

  • Page 71: Chk

    Chk adj 3-10 a. Turn the crankshaft counterclockwise. B. When the piston is at the top dead center (tdc) on the compression stroke, align the “i” mark on the ac magneto rotor with the stationary pointer on the crankcase cover. Note: note: top dead center (tdc) is a point where the mark on the ac mag...

  • Page 72: Chk

    Chk adj 3-11 d. Measure the valve clearance again. E. If the valve clearance is still out of specifica- tion, repeat all of the valve clearance adjustment steps until the specified clear- ance is obtained. 6. Install: • all removed parts note: note: for installation, reverse the removal proce- dure....

  • Page 73: Chk

    Chk adj 3-12 4. Adjust: • engine idling speed a. Turn the throttle stop screw in direction or until the specified idling speed is obtained. 5. Remove: • fuel tank note: note: slide the fuel tank. 6. Detach: • digital tachometer 7. Adjust: • throttle lever free play refer to “adjusting the throttle l...

  • Page 74: Chk

    Chk adj 3-13 2. Adjust: • throttle lever free play first step: a. Slide back the rubber cover . B. Loosen the locknut on the carburetor side. C. Turn the adjusting nut in direction or until the correct free play is obtained. D. Tighten the locknut. E. Slide the rubber cover to its original posi- tio...

  • Page 75: Chk

    Chk adj 3-14 1. Measure: • speed limiter length out of specification → adjust. 2. Adjust: • speed limiter length a. Loosen the locknut . B. Turn the adjusting screw in or out until the specified speed limiter length is obtained. C. Tighten the locknut. Warning • particularly for a beginner rider, th...

  • Page 76: Chk

    Chk adj 3-15 ebs00057 checking the spark plug 1. Disconnect: • spark plug cap 2. Remove: • spark plug 3. Check: • spark plug type incorrect → change. 4. Check: • electrode wear/damage → replace. • insulator abnormal color → replace. Normal color is a medium-to-light tan color. 5. Clean: • spark plug...

  • Page 77: Chk

    Chk adj 3-16 ebs00058 checking the ignition timing note: note: engine idling speed and throttle cable free play should be adjusted properly before checking the ignition timing. 1. Attach: • digital tachometer • timing light (onto the ignition coil spark plug lead) 2. Check: • ignition timing a. Warm...

  • Page 78: Chk

    Chk adj 3-17 measuring the compression pressure the following procedure applies to the cylinder. Note: note: insufficient compression pressure will result in a loss of performance. 1. Measure: • valve clearance out of specification → adjust. Refer to “adjusting the valve clear- ance” 2. Start the en...

  • Page 79: Chk

    Chk adj 3-18 6. Measure: • compression pressure out of specification → refer to steps (c) and (d). A. Set the main switch to “on”. B. With the throttle wide open, crank the engine until the reading on the compres- sion gauge stabilizes. Warning to prevent sparking, ground the spark plug lead before ...

  • Page 80: Chk

    Chk adj 3-19 7. Install: • spark plug 8. Connect: • spark plug cap ebs01101 checking the engine oil level 1. Place the machine on a level surface. 2. Start the engine, warm it up several min- utes, and then turn it off. 3. Check: • engine oil level oil level should be between the minimum level mark ...

  • Page 81: Chk

    Chk adj 3-20 4. Start the engine, warm it up for several min- utes, and then turn it off. 5. Check: • engine oil level note: note: before checking the engine oil level, wait a few minutes until the oil has settled. Ebs00067 changing the engine oil 1. Place the machine on a level surface. 2. Start th...

  • Page 82: Chk

    Chk adj 3-21 8. Install: • engine oil drain bolt gasket • engine oil drain bolt • oil filter element drain bolt 9. Fill: • crankcase (with the specified amount of the recom- mended engine oil) 10.Install: • dipstick 11.Start the engine, warm it up for several min- utes, and then turn it off. 12.Chec...

  • Page 83: Chk

    Chk adj 3-22 14.Check: • engine oil pressure a. Slightly loosen the oil gallery bolt . B. Start the engine and keep it idling until engine oil starts to seep from the oil gallery bolt. If no engine oil comes out after one minute, turn the engine off so that it will not seize. C. Check the engine oil...

  • Page 84: Chk

    Chk adj 3-23 ebs00073 cleaning the air filter element note: note: there is a check hose at the bottom of the air filter case. If dust and/or water collects in this hose, clean the air filter element and air fil- ter case. 1. Remove: • seat refer to “seat, fenders and fuel tank”. 2. Remove: • air fil...

  • Page 85: Chk

    Chk adj 3-24 5. Clean: • air filter element a. Wash the element gently, but thoroughly in solvent. Warning use a cleaning solvent which is designed to clean parts only. Never use gasoline or low flash point solvents as they may cause a fire or explosion. B. Squeeze the excess solvent out of the ele-...

  • Page 86: Chk

    Chk adj 3-25 cleaning the spark arrester 1. Clean: • spark arrester warning • select a well-ventilated area free of com- bustible materials. • always let the exhaust system cool before performing this operation. • do not start the engine when removing the tailpipe from the muffler. A. Remove the bol...

  • Page 87: Chk

    Chk adj 3-26 ebs00080 chassis adjusting the front brake 1. Measure: • brake lever free play out of specification → bleed the front brake system. Refer to “bleeding the hydraulic brake system”. Adjusting the brake lever (for adjustment type model) 1. Adjust: • brake lever position a. While pushing th...

  • Page 88: Chk

    Chk adj 3-27 2. Adjust: • rear brake pedal height a. Loosen the locknut . B. Turn the adjusting bolt until the brake pedal height is within the specified limits. C. Tighten the locknut. Note: note: when adjusting the brake pedal height make sure the locknut-to-adjusting bolt clearance does not excee...

  • Page 89: Chk

    Chk adj 3-28 2. Adjust: • parking brake cable end length a. Loosen the locknut and adjusting bolt . B. Slide back the rubber cover . C. Loosen the locknut . D. Turn the adjusting nut in direction or until the specified brake cable end length is obtained. E. Tighten the locknut. F. Slowly turn the ad...

  • Page 90: Chk

    Chk adj 3-29 2. Check: • brake fluid level below the minimum level mark → add the recommended brake fluid to the proper level. Front brake rear brake warning • use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performanc...

  • Page 91: Chk

    Chk adj 3-30 2. Check: • brake pads wear indicator groove almost disappeared → replace the brake pads as a set. Refer to “front and rear brakes” in chapter 6. 3. Operate the brake lever. 4. Install: • front wheels refer to “front and rear wheels” in chapter 6. Ebs00089 checking the rear brake pads 1...

  • Page 92: Chk

    Chk adj 3-31 adjusting the rear brake light switch note: note: • the rear brake light switch is operated by movement of the brake pedal. • the rear brake light switch is properly adjusted when the brake light comes on just before the braking effect starts. 1. Check: • rear brake light operation timi...

  • Page 93: Chk

    Chk adj 3-32 2. Check: • front brake hoses • front brake pipe • rear brake hose cracks/wear/damage → replace. 3. Check: • brake hose clamps loosen → tighten. 4. Hold the machine in an upright position and apply the front or rear brake. 5. Check: • brake hoses apply the brake lever or brake pedal sev...

  • Page 94: Chk

    Chk adj 3-33 note: note: • be careful not to spill any brake fluid or allow the brake master cylinder reservoir or brake fluid reservoir to overflow. • when bleeding the hydraulic brake system, make sure there is always enough brake fluid before applying the brake. Ignoring this pre- caution could a...

  • Page 95: Chk

    Chk adj 3-34 j. Tighten the bleed screw to specification. K. Fill the brake fluid reservoir to the proper level with the recommended brake fluid. Refer to “checking the brake fluid level”. Warning after bleeding the hydraulic brake system, check the brake operation. Ebs00098 adjusting the shift peda...

  • Page 96: Chk

    Chk adj 3-35 adjusting the drive chain slack note: note: • measure the drive chain slack halfway between the drive axle and the rear axle. • when checking and adjusting the drive chain slack, there should be no weight on the vehi- cle and all tires must be touching the ground. Caution: a drive chain...

  • Page 97: Chk

    Chk adj 3-36 caution: excessive chain slack will overload the engine and other vital parts; keep the slack within the specified limits. E. If the chain slack cannot be adjusted, replace the sprockets and drive chain as a set. F. Tighten the rear axle pinch bolts . Note: note: • tighten the rear axle...

  • Page 98: Chk

    Chk adj 3-37 ebs00108 adjusting the toe-in 1. Place the machine on a level surface. 2. Measure: • toe-in out of specification → adjust. Note: note: before measuring the toe-in, make sure that the tire pressure is correct. A. Mark both front tire tread centers. B. Face the handlebar straight ahead. C...

  • Page 99: Chk

    Chk adj 3-38 a. Mark both tie-rods ends. This reference point will be needed during adjustment. B. Loosen the locknuts (tie-rod end) of both tie-rods. C. The same number of turns should be given to both the right and left tie-rods until the specified toe-in is obtained. This is to keep the length of...

  • Page 100: Chk

    Chk adj 3-39 ebs00111 adjusting the front shock absorbers warning always adjust the spring preload of both front shock absorbers to the same setting. Uneven adjustment can result in poor han- dling and loss of stability. 1. Adjust: • spring preload a. Turn the adjusting ring in direction or with the...

  • Page 101: Chk

    Chk adj 3-40 ebs00111 adjusting the rear shock absorber 1. Adjust: • spring preload a. Elevate the rear wheels by placing a suit- able stand under the frame. B. Loosen the locknut . C. Turn the adjusting nut in direction or . Note: note: • be sure to remove all dirt and mud from around the locknut a...

  • Page 102: Chk

    Chk adj 3-41 ebs00114 checking the tires warning this model is equipped with low pressure tires. It is important that they be inflated correctly and maintained at the proper pressures. • tire characteristics 1) tire characteristics influence the han- dling of atvs. The tires listed below have been a...

  • Page 103: Chk

    Chk adj 3-42 1. Measure: • tire pressure out of specification → adjust. Note: note: • the low-pressure tire gauge is included as standard equipment. • if dust or the like is stuck to this gauge, it will not provide the correct readings. Therefore, take two measurements of the tire’s pressure and use...

  • Page 104: Chk

    Chk adj 3-43 ebs00116 checking the wheels 1. Check: • wheel damage/bends → replace. Note: note: always balance the wheel when a tire or wheel has been changed or replaced. Warning • never attempt even small repairs to the wheel. • ride conservatively after installing a tire to allow it to seat itsel...

  • Page 105: Chk

    Chk adj 3-44 ebs00118 lubricating the levers and pedals lubricate the pivoting point and metal-to-metal moving parts of the levers and pedal. Recommended lubricants brake lever silicone grease clutch lever and brake pedal lithium-soap-based grease lubricating the levers and pedals.

  • Page 106: Chk

    Chk adj 3-45 ebs00120 electrical system checking and charging the battery warning batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: • wear protective eye gear when handlin...

  • Page 107: Chk

    Chk adj 3-46 note: note: since mf batteries are sealed, it is not possi- ble to check the charge state of the battery by measuring the specific gravity of the electro- lyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals. 1. Remove: • seat • ...

  • Page 108: Chk

    Chk adj 3-47 example c. Open-circuit voltage = 12.0 v d. Charging time = 6.5 hours e. Charge of the battery = 20 ~ 30% 5. Charge: • battery (refer to the appropriate charging method illustration) warning do not quick charge a battery. Caution: • never remove the mf battery sealing caps. • do not use...

  • Page 109: Chk

    Chk adj 3-48 • as shown in the following illustration, the open-circuit voltage of an mf battery sta- bilizes about 30 minutes after charging has been completed. Therefore, wait 30 minutes after charging is completed before measuring the open-circuit voltage. Checking and charging the battery.

  • Page 110: Chk

    Chk adj 3-49 charging method using a variable-current (voltage) charger measure the open-circuit voltage prior to charging. Connect a charger and ammeter to the battery and start charging. Is the amperage higher than the standard charg- ing amperage written on the battery? Leave the battery unused f...

  • Page 111: Chk

    Chk adj 3-50 charging method using a constant voltage charger measure the open-circuit voltage prior to charging. Connect a charger and ammeter to the battery and start charging. Charge the battery until the charging voltage reaches 15 v. Leave the battery unused for more than 30 minutes before meas...

  • Page 112: Chk

    Chk adj 3-51 6. Install: • battery 7. Connect: • battery leads (to the battery terminals) caution: first, connect the positive battery lead , and then the negative battery lead . 8. Check: • battery terminals dirt → clean with a wire brush. Loose connection → connect properly. 9. Lubricate: • batter...

  • Page 113: Chk

    Chk adj 3-52 ebs00121 checking the fuses the following procedure applies to all of the fuses. Caution: to avoid a short circuit, always set the main switch to “off” when checking or replac- ing a fuse. 1. Remove: • seat • battery cover refer to “seat, fenders and fuel tank”. 2. Check: • fuse a. Conn...

  • Page 114: Chk

    Chk adj 3-53 warning never use a fuse with an amperage rating other than that specified. Improvising or using a fuse with the wrong amperage rat- ing may cause extensive damage to the electrical system, cause the lighting and ignition systems to malfunction and could possibly cause a fire. 4. Instal...

  • Page 115: Chk

    Chk adj 3-54 ebs00124 replacing a headlight bulb 1. Remove: • headlight refer to “seat, fenders and fuel tank”. 2. Disconnect: • headlight lead coupler 3. Remove: • headlight bulb holder cover 4. Remove: • bulb holder • bulb note: note: push the headlight bulb holder inward, turn it counterclockwise...

  • Page 116: Chk

    Chk adj 3-55 6. Install: • bulb holder • headlight bulb holder cover note: note: after installing the bulb holder cover, make sure that the “top” mark is in the position shown. 7. Connect: • headlight lead coupler 8. Install: • headlight refer to “seat, fenders and fuel tank”. Replacing a headlight ...

  • Page 117: Eng

    Eng 4-1 1 2 3 4 5 6 7 8 engine engine removal muffler and exhaust pipe order job/parts to remove q’ty remarks removing the muffler and exhaust pipe remove the parts in the order listed. Seat/front panel/fender refer to “seat, fenders and fuel tank” in chapter 3. 1 clamp 1 loosen 2 muffler 1 3 gasket...

  • Page 118: Eng

    Eng 4-2 installing the exhaust pipe and muffler 1. Install: • gasket (to muffler) 2. Install: • exhaust pipe protector 3. Tighten: • exhaust pipe protector screws 4. Install: • gasket • exhaust pipe 5. Tighten: • nuts (exhaust pipe) 6. Install: • clamp note: note: slide the clamp onto the end of the...

  • Page 119: Eng

    Eng 4-3 leads, cables and hoses order job/parts to remove q’ty remarks removing the leads, cables and hoses remove the parts in the order listed. Engine oil drain. Oil cooler hose 1, 2 refer to “clutch”. Carburetor refer to “carburetor” in chapter 5. Drive sprocket/drive chain refer to “rear shock a...

  • Page 120: Eng

    Eng 4-4 order job/parts to remove q’ty remarks 9 neutral switch connector 1 disconnect. For installation, reverse the removal procedure. 6 7 3 1 2 9 8 4 5 10 nm (1.0 m•kg, 7.4 ft•lb) engine removal.

  • Page 121: Eng

    Eng 4-5 engine mounting bolts order job/parts to remove q’ty remarks removing the engine mounting bolts remove the parts in the order listed. 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 m...

  • Page 122: Eng

    Eng 4-6 installing the engine 1. Install: • engine mounting bolt (rear lower side) • engine mounting bolt (rear upper side) • engine bracket bolts (upper side) • engine mounting bolt (upper side) • engine brackets (front side) • engine mounting bolt (front side) note: note: • the direction of the bo...

  • Page 123: Eng

    Eng 4-7 cylinder head order job/parts to remove q’ty remarks removing the cylinder head seat/front fender/fuel tank/fuel tank shield refer to “seat, fenders and fuel tank” in chapter 3. Muffler and exhaust pipe refer to “muffler and exhaust pipe”. Carburetor refer to “carburetor” in chapter 5. Ignit...

  • Page 124: Eng

    Eng 4-8 order job/parts to remove q’ty remarks 9 cap bolt 1 loosen. 10 timing chain tensioner/gasket 1/1 11 breather pipe 2 1 12 camshaft sprocket/dowel pin 1/1 13 cylinder head 1 14 timing chain guide 1 15 dowel pin 2 16 cylinder head gasket 1 for installation, reverse the removal procedure. 20 nm ...

  • Page 125: Eng

    Eng 4-9 removing the cylinder head 1. Align: • “i” mark on the pickup coil rotor (with the stationary pointer on the crank- case cover) a. Turn the pickup coil rotor counterclockwise. B. When the piston is at tdc on the compres- sion stroke, align the “i” mark on the camshaft sprocket with the mark ...

  • Page 126: Eng

    Eng 4-10 checking the cylinder head 1. Eliminate: • combustion chamber carbon deposits (with a rounded scraper) note: do not use a sharp instrument to avoid damag- ing or scratching: • spark plug bore threads • valve seats 2. Check: • cylinder head damage/scratches → replace. 3. Measure: • cylinder ...

  • Page 127: Eng

    Eng 4-11 checking the timing chain guides the following procedure applies to the cam- shaft sprockets and timing chain guides. 1. Check: • timing chain damage/stiffness → replace the timing chain and camshaft sprocket and crank- shaft sprocket as a set. 2. Check: • camshaft sprocket more than 1/4 to...

  • Page 128: Eng

    Eng 4-12 b. Remove the screwdriver and slowly release the timing chain tensioner rod. C. Make sure that the timing chain tensioner rod comes out of the timing chain tensioner housing smoothly. If there is rough move- ment, replace the timing chain tensioner. 3. Check: • cap bolt • copper washer • sp...

  • Page 129: Eng

    Eng 4-13 a. Turn the pickup coil rotor counterclockwise. B. Align the “i” mark on the pickup coil rotor with the stationary pointer on the crank- case cover. C. Remove the wire from the timing chain. D. Install the timing chain onto the camshaft sprocket, and then install the camshaft sprocket onto ...

  • Page 130: Eng

    Eng 4-14 6. Turn: • crankshaft (several turns counterclockwise) 7. Check: • “i” mark align the “i” mark on the pickup coil rotor with the stationary pointer on the crank- case cover. • “i” mark align the “i” mark on the camshaft sprocket with the stationary pointer on the cylin- der head. Out of ali...

  • Page 131: Eng

    Eng 4-15 rocker arm, camshaft order job/parts to remove q’ty remarks removing the rocker arms and cam- shaft remove the parts in the order listed. Cylinder head refer to “cylinder head”. 1 lock plate 1 2 locknut/valve clearance adjusting screw 2/2 3 camshaft 1 4 intake rocker arm shaft 1 5 intake ro...

  • Page 132: Eng

    Eng 4-16 removing the rocker arms and camshaft 1. Loosen: • locknut • valve clearance adjusting screw 2. Remove: • stopper plate 3. Remove: • camshaft • bearing note: note: screw 10 mm (0.396 in) bolt into the threaded end of the camshaft and then pull out the camshaft. 4. Remove: • intake rocker ar...

  • Page 133: Eng

    Eng 4-17 checking the camshaft 1. Check: • bearing damage/wear → replace. 2. Check: • camshaft lobes blue discoloration/pitting/scratches → replace the camshaft. 3. Measure: • camshaft lobe dimensions and out of specification → replace the cam- shaft. 4. Check: • camshaft oil passage obstruction → b...

  • Page 134: Eng

    Eng 4-18 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 • valve clearance adjusting screws damage/wear → replace. 2. Check: • rocker arm shaft blue discoloration/excessive wear/pitting/ scratches...

  • Page 135: Eng

    Eng 4-19 installing the camshaft and rocker arms 1. Lubricate: • camshaft 2. Lubricate: • rocker arm • rocker arm shaft 3. Install: • exhaust rocker arm • exhaust rocker arm shaft note: note: make sure the exhaust rocker arm shaft is completely pushed into the cylinder head. 4. Install: • intake roc...

  • Page 136: Eng

    Eng 4-20 5. Install: • camshaft note: note: screw a 10 mm bolt into the threaded end of the camshaft and then install the camshaft. 6. Install: • lock plate 7. Tighten: • lock plate bolts lock plate bolt 8 nm (0.8 m•kg, 5.9 ft•lb) loctite ® rocker arm, camshaft.

  • Page 137: Eng

    Eng 4-21 valves and valve springs order job/parts to remove q’ty remarks removing the valves and valve springs remove the parts in the order listed. Cylinder head refer to “cylinder head”. Rocker arm camshaft 1 valve cotter 4 2 valve spring retainer 2 3 outer valve spring 2 4 inner valve spring 2 5 ...

  • Page 138: Eng

    Eng 4-22 removing the valves the following procedure applies to all of the valves and related components. Note: note: 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 sealing leakage at the val...

  • Page 139: Eng

    Eng 4-23 3. Remove: • upper spring seat • inner valve spring • outer valve spring • valve • lower spring seat • valve stem seal note: note: identify the position of each part very carefully so that it can be reinstalled in its original place. Checking the valves and valve guides the following proced...

  • Page 140: Eng

    Eng 4-24 2. Replace: • valve guide note: note: 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 . B. Install the new valve guide with the valve guide installer and...

  • Page 141: Eng

    Eng 4-25 5. Measure: • valve margin thickness d out of specification → replace the valve. 6. Measure: • valve stem runout out of specification → replace the valve. Note: note: • when installing a new valve, always replace the valve guide. • if the valve is removed or replaced, always replace the oil...

  • Page 142: Eng

    Eng 4-26 3. Measure: • valve seat width out of specification → replace the cylinder head. A. Apply mechanic’s blueing dye (dykem) 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 impres- sion. D. Meas...

  • Page 143: Eng

    Eng 4-27 a. Apply a coarse lapping compound to the valve face. Caution: do not let the lapping compound enter the gap between the valve stem and the valve guide. B. Apply molybdenum disulfide oil onto the valve stem. C. Install the valve into the cylinder head. D. Turn the valve until the valve face...

  • Page 144: Eng

    Eng 4-28 checking the valve springs the following procedure applies to all of the valve springs. 1. Measure: • valve spring free length out of specification → replace the valve spring. 2. Measure: • compressed valve spring force out of specification → replace the valve spring. Compressed valve sprin...

  • Page 145: Eng

    Eng 4-29 3. Measure: • valve spring tilt out of specification → replace the valve spring. 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 recommen...

  • Page 146: Eng

    Eng 4-30 4. Install: • valve cotters note: note: install the valve cotters by compressing the valve spring with the valve spring compressor and the valve spring compressor attachment . 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft- face hammer. Caution: hi...

  • Page 147: Eng

    Eng 4-31 cylinder and piston order job/parts to remove q’ty remarks removing the cylinder and piston remove the parts in the order listed. Cylinder head refer to “cylinder head”. 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 148: Eng

    Eng 4-32 + removing the piston 1. Remove: • piston pin clips • piston pin • piston note: note: • before removing the piston pin clip, cover the crankcase opening with a clean rag to pre- vent the piston pin clip from falling into the crankcase. • before removing each piston pin, deburr the clip groo...

  • Page 149: Eng

    Eng 4-33 a. Measure cylinder bore “c” with the cylinder bore gauge. Note: note: measure cylinder bore “c” by taking side-to- side and front-to-back measurements of the cylinder. Then, find the average of the mea- surements. B. If out of specification, rebore or replace the cylinder, and replace the ...

  • Page 150: Eng

    Eng 4-34 f. If out of specification, rebore or replace the cylinder, and replace the piston and piston rings as a set. Checking the piston rings 1. Measure: • piston ring side clearance out of specification → replace the piston and piston rings as a set. Note: note: before measuring the piston ring ...

  • Page 151: Eng

    Eng 4-35 2. Install: • piston ring (into the cylinder) note: note: level the piston ring into the cylinder with the piston crown. 40 mm (1.476 in) 3. Measure: • piston ring end gap out of specification → replace the piston ring. Note: note: the oil ring expander spacer’s end gap cannot be measured. ...

  • Page 152: Eng

    Eng 4-36 checking the piston pin 1. Check: • piston pin blue discoloration/grooves → replace the piston pin and then check the lubrication system. 2. Measure: • piston pin outside diameter out of specification → replace the piston pin. 3. Measure: • piston pin bore diameter out of specification → re...

  • Page 153: Eng

    Eng 4-37 installing the piston and cylinder 1. Install: • lower oil ring rail • oil ring expander • upper oil ring rail • 2nd ring • top ring note: note: be sure to install the piston rings so that the “t” marks or numbers face up. 2. Install: • piston • piston pin • piston pin clips note: note: • a...

  • Page 154: Eng

    Eng 4-38 5. Offset: • piston ring end gaps top ring upper oil ring rail oil ring expander lower oil ring rail 2nd ring 20 mm 6. Install: • cylinder note: note: • while compressing the piston rings with one hand, install the cylinder with the other hand. • pass the timing chain and timing chain guide...

  • Page 155: Eng

    Eng 4-39 clutch order job/parts to remove q’ty remarks removing the clutch cover remove the parts in the order listed. Engine oil drain. 1 cotter pin/washer 1/1 2 clevis pin 1 3 brake pedal/footrest 1/1 4 oil delivery pipe 1 5 oil cooler hose 2 6 o-ring 2 7 right crankcase cover 1 8 dowel pin 2 9 cr...

  • Page 156: Eng

    Eng 4-40 order job/parts to remove q’ty remarks removing the clutch remove the parts in the order listed. 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 p...

  • Page 157: Eng

    Eng 4-41 order job/parts to remove q’ty remarks 15 push rod 2/ball 1/1 for installation, reverse the removal procedure. 80 nm (8.0 m•kg, 59 ft•lb) 8 nm (0.8 m•kg, 5.9 ft•lb) 75 nm (7.5 m•kg, 55 ft•lb) clutch.

  • Page 158: Eng

    Eng 4-42 order job/parts to remove q’ty remarks removing the push lever shaft remove the parts in the order listed. Shift pedal refer to “shift shaft”. Left crankcase cover refer to “pick up coil rotor and starter clutch”. Clutch assembly 1 clutch cable 1 2 bolt 1 3 push lever shaft 1 4 torsion spri...

  • Page 159: Eng

    Eng 4-43 removing the clutch 1. Remove: • bolt • clutch spring note: note: 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 note: note: • place the aluminum plate between clutch housing and primary drive ...

  • Page 160: Eng

    Eng 4-44 checking the friction plates the following procedure applies to all of the friction plates. 1. Check: • friction plate damage/wear → replace the friction plate. 2. Measure: • friction plate thickness out of specification → replace the friction plate. Note: note: measure the friction plate a...

  • Page 161: Eng

    Eng 4-45 checking the clutch springs the following procedure applies to all of the clutch springs. 1. Check: • clutch spring damage → replace the clutch spring. 2. Measure: • clutch spring free length out of specification → replace the clutch spring. Checking the clutch housing 1. Check: • clutch ho...

  • Page 162: Eng

    Eng 4-46 checking the clutch push rods 1. Check: • push lever shaft • push rod 2 • ball cracks/damage/wear → replace the defective part(s). Checking the primary drive gear 1. Check: • primary drive gear damage/wear → replace the primary drive and primary driven gears as a set. Excessive noise during...

  • Page 163: Eng

    Eng 4-47 3. Tighten: • clutch boss nut • primary drive gear nut note: note: • while holding the clutch boss with the univer- sal clutch holder , tighten the clutch boss nut. • place the aluminum plate between pri- mary drive gear and clutch housing , and then tighten the primary drive gear nut. 4. B...

  • Page 164: Eng

    Eng 4-48 7. Install: • bearing • oil seal • circlip • torsion spring • push lever shaft • bolt • clutch cable note: note: after installing the clutch cable, bend the push lever shaft tab along a flat side of the nut. 8. Install: • push rod 2 • ball • push rod 1 • push plate • washer • locknut • pres...

  • Page 165: Eng

    Eng 4-49 11.Adjust: • push lever position a. Loosen the locknut . B. Turn the adjusting screw 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. Caution: do not overtighten the locknut since this will remove the...

  • Page 166: Eng

    Eng 4-50 oil pump and blancer weight gear order job/parts to remove q’ty remarks removing the oil pump and bal- ancer weight gear remove the parts in the order listed. Right crankcase cover refer to “clutch”. Clutch primary drive gear 1 balancer weight gear nut 1 2 lock washer 1 3 buffer boss 1 4 ba...

  • Page 167: Eng

    Eng 4-51 order job/parts to remove q’ty remarks 14 balancer drive gear 1 15 oil strainer 1 16 spacer 1 for installation, reverse the removal procedure. 6 nm (0.6 m•kg, 4.4 ft•lb) 55 nm (5.5 m•kg, 41 ft•lb) oil pump and blancer weight gear.

  • Page 168: Eng

    Eng 4-52 order job/parts to remove q’ty remarks disassembling the oil pump remove the parts in the order listed. Oil pump housing 1 dowel pin 2 outer rotor 1 inner rotor 1 dowel pin 1 shaft 1 oil pump cover 1 for assembly, reverse the disassembly procedure. 7 nm (0.7 m•kg, 5.0 ft•lb) oil pump and bl...

  • Page 169: Eng

    Eng 4-53 removing the balancer weight gear and oil pump 1. Straighten the lock washer tab. 2. Remove: • balancer weight gear nut • lock washer • balancer weight gear note: note: place the aluminum plate between balancer drive gear and balancer weight gear , and then loosen the balancer weight gear n...

  • Page 170: Eng

    Eng 4-54 3. Check: • oil pump operation rough movement → repeat steps (1) and (2) or replace the defective part(s). Checking the balancer weight gear 1. Check: • balancer weight gear • buffer boss • compression spring • dowel pin • cracks/damage/wear → replace. Inner-rotor-to-outer-rotor-tip clearan...

  • Page 171: Eng

    Eng 4-55 assenbling the balancer drive gear 1. Assemble: • dowel pin • compression spring note: note: install the dowel pins and compression springs alternately as shown as. 2. Assemble: • buffer boss installing the oil pump 1. Install: • gasket • oil pump 2. Tighten: • oil pump bolts caution: after...

  • Page 172: Eng

    Eng 4-56 installing the balancer weight gear 1. Install: • balancer weight gear • lock washer • balancer weight gear nut 2. Tighten: • balancer weight gear nut note: note: • align the punch mark in the balancer drive gear with the punch mark in the balancer weight gear. • place the aluminum plate be...

  • Page 173: Eng

    Eng 4-57 shift shaft order job/parts to remove q’ty remarks removing the shift shaft and stopper lever remove the parts in the order listed. Right crankcase cover refer to “clutch”. Clutch 1 shift pedal 1 2 shift shaft assembly 1 3 stopper lever 1 4 torsion spring 1 for installation, reverse the rem...

  • Page 174: Eng

    Eng 4-58 checking the shift shaft 1. Check: • shift shaft • shift lever bends/damage/wear → replace. • shift lever spring damage/wear → replace. Checking the stopper lever 1. Check: • stopper lever bends/damage → replace. Roller turns roughly → replace the stopper lever. • torsion spring damage/wear...

  • Page 175: Eng

    Eng 4-59 4. Check: • when the gear position is in neutral, check the length ( , ) between the tip of the shift lever and dowel pin are equal. If not → replace the shift shaft. 5. Install: • shift pedal 6. Tighten: • shift pedal bolt 7. Adjust: • shift pedal height refer to “adjusting the shift pedal...

  • Page 176: Eng

    Eng 4-60 pickup coil rotor and starter clutch order job/parts to remove q’ty remarks removing the pickup coil rotor and starter clutch remove the parts in the order listed. Engine oil drain. Shift pedal refer to “shift shaft”. Drive sprocket cover refer to “rear shock absorber, swingarm and drive ch...

  • Page 177: Eng

    Eng 4-61 order job/parts to remove q’ty remarks 12 bearing 1 13 washer 1 14 starter clutch assembly 1 for installation, reverse the removal procedure. 30 nm (3.0 m•kg, 22 ft•lb) 10 nm (1.0 m•kg, 7.4 ft•lb) 10 nm (1.0 m•kg, 7.4 ft•lb) 60 nm (6.0 m•kg, 44 ft•lb) 10 nm (1.0 m•kg, 7.4 ft•lb) 7 nm (0.7 m...

  • Page 178: Eng

    Eng 4-62 removing the pickupcoil rotor 1. Remove: • pickup coil rotor bolt • washer note: note: • loosen the pickup coil rotor bolt while holding the rotor with a sheave holder . • do not allow the sheave holder to touch the projection on the rotor . 2. Remove: • pickup coil rotor note: note: remove...

  • Page 179: Eng

    Eng 4-63 checking the starter clutch 1. Check: • starter clutch rollers damage/wear → replace the starter clutch. 2. Check: • starter idle gear • starter wheel gear • starter clutch gear burrs/chips/roughness/wear → replace the defective part(s). 3. Check: • starter clutch gear’s contacting surfaces...

  • Page 180: Eng

    Eng 4-64 installing the pickup coil rotor 1. Install: • washer • bearing • starter wheel gear • starter idle gear 2 2. Install: • woodruff key • pickup coil rotor • washer • pickup coil rotor bolt note: note: • clean the tapered portion of the crankshaft and the rotor hub. • when installing the roto...

  • Page 181: Eng

    Eng 4-65 4. Install: • stater coil • pickup coil 5. Tighten: • stater coil bolts • pickup coil bolts • left crankcase cover bolt 6. Install: • dowel pin • crankcase cover gasket 7. Install: • left crankcase cover 8. Install: • crankcase cover bolts m6 × 30 mm ~ • crankcase cover bolt m6 × 45 mm • cr...

  • Page 182: Eng

    Eng 4-66 crankcase order job/parts to remove q’ty remarks separating the crankcase remove the parts in the order listed. Engine refer to “engine removal”. Cylinder head refer to “cylinder head”. Cylinder refer to “cylinder and piston”. Clutch refer to “clutch”. Oil pump refer to “oil pump and blance...

  • Page 183: Eng

    Eng 4-67 order job/parts to remove q’ty remarks 7 spacer 1 for installation, reverse the removal procedure. 1 2 3 4 5 5 6 7 8 nm (0.8 m•kg, 5.9 ft•lb) 20 nm (2.0 m•kg, 14.8 ft•lb) 10 nm (1.0 m•kg, 7.4 ft•lb) crankcase.

  • Page 184: Eng

    Eng 4-68 order job/parts to remove q’ty remarks removing the bearing remove the parts in the order listed. Crankshaft assembly refer to “crankshaft assembly”. Main axle assembly/drive axle assem- bly refer to “transmission”. 1 oil seal 2 2 bearing 8 for installation, reverse the removal procedure. 2...

  • Page 185: Eng

    Eng 4-69 disassembling the crankcase 1. Remove: • timing chain guide (intake side) • timing chain • crankshaft sprocket 2. Remove: • neutral switch • crankcase bolts m6 × 70 mm ~ • copper washers • crankcase bolts m6 × 60 mm , • crankcase bolts m6 × 55 mm ~ • crankcase bolts m6 × 45 mm ~ note: note:...

  • Page 186: Eng

    Eng 4-70 checking the crankcase 1. Thoroughly wash the crankcase halves in a mild solvent. 2. Thoroughly clean all the gasket surfaces and crankcase mating surfaces. 3. Check: • crankcase cracks/damage → replace. • oil delivery passages obstruction → blow out with compressed air. Assembling the cran...

  • Page 187: Eng

    Eng 4-71 4. Install: • crankcase bolts m6 × 70 mm ~ • copper washers to ~ . • crankcase bolts m6 × 60 mm , • crankcase bolts m6 × 55 mm ~ • crankcase bolts m6 × 45 mm ~ 5. Tighten: • crankcase bolts ~ note: note: tighten each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. 6. In...

  • Page 188: Eng

    Eng 4-72 crankshaft assembly order job/parts to remove q’ty remarks removing the crankshaft assembly remove the parts in the order listed. Crankcase refer to “crankcase”. 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 189: Eng

    Eng 4-73 removing the crankshaft assembly 1. Remove: • balancer weight • crankshaft assembly note: note: • remove the crankshaft assembly with the crankcase separating tool . • make sure the crankcase separating tool is centered over the crankshaft assembly. Removing the plunger seal 1. Remove: • do...

  • Page 190: Eng

    Eng 4-74 2. Measure: • big end side clearance out of specification → replace the big end bearing, crankshaft pin, or connecting rod. 3. Measure: • crankshaft width out of specification → replace the crank- shaft. 4. Check: • crankshaft sprocket damage/wear → replace the crankshaft. • bearing cracks/...

  • Page 191: Eng

    Eng 4-75 3. Check: • timing chain guide (intake side) damage/wear → replace the timing chain guide (intake side) installing the plunger seal 1. Install: • compression spring • plunger seal • dowel pin check the plunger seal smooth operation pushing the plunger seal by your finger. Installing the cra...

  • Page 192: Eng

    Eng 4-76 caution: to avoid scratching the crankshaft and to ease the installation procedure, lubricate the oil seal lips with lithium-soap-based grease and each bearing with engine oil. Note: note: hold the connecting rod at top dead center (tdc) with one hand while turning the nut of the crankshaft...

  • Page 193: Eng

    Eng 4-77 transmission order job/parts to remove q’ty remarks removing the transmission, shift drum assembly, and shift forks remove the parts in the order listed. Crankcase separate. Refer to “crankcase”. 1 shift fork guide bar 1 2 shift drum assembly 1 3 shift fork-3 (r) 1 4 shift fork-2 (c) 1 5 sh...

  • Page 194: Eng

    Eng 4-78 order job/parts to remove q’ty remarks disassembling the transmission remove the parts in the order listed. 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/wa...

  • Page 195: Eng

    Eng 4-79 order job/parts to remove q’ty remarks 17 drive axle 1 for installation, reverse the removal procedure. 7 8 9 10 11 12 13 14 15 1 2 5 4 3 6 16 transmission.

  • Page 196: Eng

    Eng 4-80 removing the transmission 1. Remove: • shift fork guide bar • shift drum assembly • shift fork 3 (r) • shift fork 2 (c) • shift fork 1 (l) 2. Remove: • transmission checking the shift forks the following procedure applies to all of the shift forks. 1. Check: • shift fork movement (along the...

  • Page 197: Eng

    Eng 4-81 checking the shift drum assembly 1. Check: • shift drum groove damage/scratches/wear → replace the shift drum assembly. • shift drum segment damage/wear → replace the shift drum assembly. • shift drum bearing damage/pitting → replace the shift drum assembly. Checking the transmission 1. Mea...

  • Page 198: Eng

    Eng 4-82 4. Check: • transmission gear engagement (each pinion gear to its respective wheel gear) incorrect → reassemble the transmission axle assemblies. Note: note: when reassembling the main axle, press the 2nd pinion gear onto it as shown. 102.2 ~ 102.4 mm (4.02 ~ 4.03 in) 5. Check: • transmissi...

  • Page 199: Carb

    Carb 5-1 1 2 3 4 5 6 7 8 ebs00141 carburetor carburetor order job/part q’ty remarks removing a carburetor remove the parts in the order listed. Seat/front fender/rear fender/air filter case refer to “seat, fenders and fuel tank” in chapter 3. 1 carburetor warmer coupler 1 disconnect. 2 air vent hose...

  • Page 200: Carb

    Carb 5-2 ebs00144 order job/part q’ty remarks disassembling the carburetor remove the parts in the order listed. Drain hose 1 throttle stop screw 1 cover 1 diaphragm spring 1 piston valve 1 jet needle 1 cover 1 spring 1 coasting enricher diaphragm 1 coasting enricher jet (p. A. J. 2) 1 starter plung...

  • Page 201: Carb

    Carb 5-3 order job/part q’ty remarks float 1 needle valve seat set 1 main jet 1 needle jet holder 1 needle jet 1 pilot jet 1 starter jet 1 for assembly, reverse the disassembly procedure. Carburetor.

  • Page 202: Carb

    Carb 5-4 ebs00148 checking the carburetor 1. Check: • carburetor body • float chamber cracks/damage → replace. • fuel passage contamination → clean as indicated. • fuel chamber body contamination → clean. A. Wash the carburetor in a petroleum based solvent. Do not use any caustic carburetor cleaning...

  • Page 203: Carb

    Carb 5-5 5. Check: • piston valve movement sticks → replace. Insert the piston valve into the carburetor body, and check for free movement. 6. Check: • throttle valve movement sticks → replace. 7. Check: • cover • diaphragm spring cracks/damage → replace. 8. Check: • coasting enricher diaphragm • sp...

  • Page 204: Carb

    Carb 5-6 11.Check: • starter plunger • starter plunger spring bends/cracks/damage → replace. Ebs00150 assembling the carburetor caution: before reassembling, wash all of the parts in a clean petroleum based solvent. 1. Measure: • float height out of specification → adjust. A. Hold the carburetor in ...

  • Page 205: Carb

    Carb 5-7 installing the carburetor joint 1. Install: • clamp note: note: align the projection on the carburetor joint with the slot in the clamp. 2. Install: • carburetor joint note: note: align the projection on the cylinder head with the slot in the carburetor joint. Installing the carburetor 1. I...

  • Page 206: Chas

    Chas 6-1 ebs00378 chassis front and rear wheels front wheels order job/part q’ty remarks removing the front wheels remove the parts in the order listed. The following procedure applies to both of the front wheels. Place the machine on a level surface. Warning securely support the machine so there is...

  • Page 207: Chas

    Chas 6-2 1 2 3 4 5 6 7 8 order job/part q’ty remarks 5 brake caliper assembly 1 note: note: do not squeeze the brake lever when the brake caliper is off of the brake discs as the brake pads will be forced shut. 6 wheel hub 1 refer to “installing the wheel hub bearings”. 7 brake disc 1 rear to “insta...

  • Page 208: Chas

    Chas 6-3 rear wheels order job/part q’ty remarks removing the rear wheels remove the parts in the order listed. Place the machine on a level surface. Warning securely support the machine so there is no danger of it falling over. 1 rear wheel 2 2 cotter pin 2 3 axle nut 2 4 wheel hub 2 for installati...

  • Page 209: Chas

    Chas 6-4 ebs00383 checking the wheels 1. Check: • wheels 2. Measure: • wheel runout over the specified limit → replace the wheel or check the wheel bearing play . 3. Check: • wheel balance out of balance → adjust. Warning after replacing the tire, ride conservatively to allow the tire to be properly...

  • Page 210: Chas

    Chas 6-5 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 “floats” between bearings. Remove both bea...

  • Page 211: Chas

    Chas 6-6 installing the front wheel hub bearings 1. Install: • bearings note: note: face the oil seal side of the bearing inward. Installing the front brake discs 1. Install: • brake discs note: note: install the brake disc with its spot-faced side facing the bolt heads. Ebs00392 installing the fron...

  • Page 212: Chas

    Chas 6-7 ebs00390 installing the wheel hubs 1. Install: • front axle nuts • rear axle nuts • cotter pins note: note: • do not loosen the axle nut after torquing it. If the axle nut groove is not aligned with the cot- ter pin hole, align the groove with the hole by tightening the axle nut. • bend the...

  • Page 213: Chas

    Chas 6-8 ebs00382 rear axle and rear axle hub order job/part q’ty remarks removing the rear axle and rear axle hub remove the parts in the order listed. Rear wheels/rear wheel hubs refer to “front and rear wheels”. 1 bolt 2 2 nut 1 3 conical spring washer 1 4 brake caliper 1 note: note: do not apply...

  • Page 214: Chas

    Chas 6-9 order job/part q’ty remarks 5 brake disc/brake disc bracket 1/1 6 rear axle 1 refer to “removing the rear axle”. 7 driven sprocket/sprocket bracket 1/1 refer to “installing the driven sprocket”. 8 circlip 1 9 brake caliper bracket 1 10 collar 1 11 rear axle hub 1 12 bearing/oil seal 2/2 13 ...

  • Page 215: Chas

    Chas 6-10 ebs00393 removing the rear axle 1. Place the machine on a level surface. 2. Loosen: • bolts 3. Remove: • nut note: note: • apply the brake pedal so that the rear axle does not turn, when loosening the nut. • use the ptt wrench 46 or axle nut wrench (46 mm) . 4. Elevate the rear wheels by p...

  • Page 216: Chas

    Chas 6-11 ebs00395 checking the rear axle 1. Check: • rear axle runout out of specification → replace. Warning do not attempt to straighten a bent axle. Checking the driven sprocket 1. Check: • driven sprocket refer to “rear shock absorber, swingarm and drive chain”. Checking the brake disc 1. Check...

  • Page 217: Chas

    Chas 6-12 2. Tighten: • nut a. Tighten the nut with ptt wrench 46 or rear axle nut wrench to specification while holding the rear axle. B. Tighten bolts . 140 nm (14.0 m•kg, 103 ft•lb) ptt wrench 46 90890-06588 axle nut wrench (46 mm) ym-37134 7 nm (0.7 m•kg, 5.2 ft•lb) rear axle and rear axle hub.

  • Page 218: Chas

    Chas 6-13 ebs00400 front and rear brakes front brake pads order job/part q’ty remarks removing the front brake pads remove the parts in the order listed. The following procedure applies to both of the front brake calipers. Front wheel refer to “front and rear wheels”. 1 bolt 1 2 brake pad retaining ...

  • Page 219: Chas

    Chas 6-14 ebs00401 rear brake pads order job/part q’ty remarks removing the rear brake pads remove the parts in the order listed. 1 brake pad retaining bolt 2 2 lock washer 1 3 brake pad 2 4 brake pad spring 1 for installation, reverse the removal procedure. 34 nm (3.4 m•kg, 25 ft•lb) 17 nm (1.7 m•k...

  • Page 220: Chas

    Chas 6-15 ebs00402 caution: disc brake components rarely require dis- assembly. Do not: • disassemble components unless abso- lutely necessary; • use solvents on internal brake compo- nents; • use spent brake fluid for cleaning; (use only clean brake fluid) • allow brake fluid to come in contact wit...

  • Page 221: Chas

    Chas 6-16 2. Install: • brake pads • brake pad spring note: note: always install new brake pads and brake pad spring as a set. A. Connect a suitable hose tightly to the brake caliper bleed screw . Put the other end of this hose into an open container. B. Loosen the brake caliper bleed screw and, usi...

  • Page 222: Chas

    Chas 6-17 ebs00405 replacing the rear brake pads note: note: it is not necessary to disassemble the brake caliper and brake hose to replace the brake pads. 1. Remove: • brake pads wear limit note: note: replace the brake pads as a set if either is found to be worn to the wear limit. 2. Install: • br...

  • Page 223: Chas

    Chas 6-18 5. Check: • brake lever or brake pedal operation soft or spongy feeling → bleed the brake system. Refer to “bleeding the hydraulic brake system” in chapter 3. Front and rear brakes.

  • Page 224: Chas

    Chas 6-19 ebs00407 front brake master cylinder order job/part q’ty remarks removing the front brake master cylinder remove the parts in the order listed. Brake fluid drain. Refer to “bleeding the hydraulic brake system” in chapter 3. 1 brake fluid reservoir cap 1 2 brake fluid reservoir diaphragm pl...

  • Page 225: Chas

    Chas 6-20 ebs00409 order job/part q’ty remarks disassembling the front brake master cylinder remove the parts in the order listed. Dust boot 1 circlip 1 brake master cylinder kit 1 for assembly, reverse the disassembly procedure. Refer to “assembling the front brake master cylinder”. Front and rear ...

  • Page 226: Chas

    Chas 6-21 ebs00410 rear brake master cylinder order job/part q’ty remarks removing the rear brake master cylinder remove the parts in the order listed. Right foot protector refer to “seat, fenders and fuel tank” in chapter 3. Brake fluid drain. Refer to “bleeding the hydraulic brake system” in chapt...

  • Page 227: Chas

    Chas 6-22 order job/part q’ty remarks 7 union bolt 1 8 copper washer 2 9 brake hose 1 disconnect. 10 brake master cylinder 1 11 rear brake light switch 1 12 right footrest 1 13 brake pedal/spring 1/1 for installation, reverse the removal procedure. 7 nm (0.7 m•kg, 5.2 ft•lb) 31 nm (3.1 m•kg, 23 ft•l...

  • Page 228: Chas

    Chas 6-23 ebs00411 order job/part q’ty remarks disassembling the rear brake master cylinder remove the parts in the order listed. Hose joint 1 brake master cylinder kit 1 brake master cylinder 1 for assembly, reverse the disassembly procedure. 17 nm (1.7 m•kg, 13 ft•lb) refer to “assembling the rear...

  • Page 229: Chas

    Chas 6-24 ebs00413 checking the master cylinders 1. Check: • brake master cylinder wear/scratches → replace the brake mas- ter cylinder assembly. • brake master cylinder body cracks/damage → replace. • brake fluid delivery passage (brake master cylinder body) blockage → blow out with compressed air....

  • Page 230: Chas

    Chas 6-25 ebs00415 assembling the front brake master cylinder warning • all internal brake components should be cleaned and lubricated with new brake fluid only before installation. • whenever a master cylinder is disassem- bled, replace the piston seals and dust seals. Ebs00416 assembling the rear ...

  • Page 231: Chas

    Chas 6-26 2. Tighten: • nut ebs00418 installing the front brake master cylinder 1. Install: • brake master cylinder note: note: • the “up” mark on the brake master cylinder bracket should face up. • install the brake master cylinder so that the gaps between the brake master cylinder and the brake ma...

  • Page 232: Chas

    Chas 6-27 3. Fill: • brake fluid reservoir caution: brake fluid may damage painted surfaces or plastic parts. Always clean up spilled brake fluid immediately. Warning • use only the designated quality brake fluid: other brake fluids may deteriorate the rubber seals, causing leakage and poor brake pe...

  • Page 233: Chas

    Chas 6-28 ebs00419 installing the rear brake master cylinder 1. Install: • copper washers • brake hose • union bolt caution: when installing the brake hose onto the brake master cylinder, make sure the brake pipe touches the projection as shown. Warning proper brake hose routing is essential to insu...

  • Page 234: Chas

    Chas 6-29 warning • use only the designated quality brake fluid: other brake fluids may deteriorate the rubber seals, causing leakage and poor brake performance. • refill with the same type of brake fluid: mixing brake fluids may result in a harm- ful chemical reaction and lead to poor brake perform...

  • Page 235: Chas

    Chas 6-30 ebs00421 front brake calipers order job/part q’ty remarks removing the front brake calipers remove the parts in the order listed. The following procedure applies to both of the front brake calipers. Brake fluid drain. Refer to “bleeding the hydraulic brake system” in chapter 3. Front wheel...

  • Page 236: Chas

    Chas 6-31 ebs00423 order job/part q’ty remarks disassembling the front brake calipers remove the parts in the order listed. The following procedure applies to both of the front brake calipers. Bolt 1 brake pad retaining bolt 1 brake pad 2 brake pad spring 1 caliper bracket 1 caliper piston 1 dust se...

  • Page 237: Chas

    Chas 6-32 ebs00424 rear brake caliper order job/part q’ty remarks removing the rear brake caliper remove the parts in the order listed. Brake fluid drain. Refer to “bleeding the hydraulic brake system” in chapter 3. 1 parking brake cable 1 disconnect. Refer to “removing the parking brake cable”. 2 u...

  • Page 238: Chas

    Chas 6-33 ebs00425 order job/part q’ty remarks disassembling the rear brake caliper remove the parts in the order listed. Adjusting bolt 1 locknut 1 parking brake arm 1 brake pad retain bolt 2 lock washer 1 brake pad 2 brake pad spring 1 retaining bolt 1 caliper bracket 1 brake caliper piston 1 dust...

  • Page 239: Chas

    Chas 6-34 removing the parking brake cable 1. Loosen: • nut • adjusting bolt 2. Disconnect: • parking brake cable (from parking brake lever) 3. Disconnect: • parking brake cable (from rear brake) ebs00427 disassembling the front and rear brake calipers 1. Remove: • brake caliper piston • caliper dus...

  • Page 240: Chas

    Chas 6-35 ebs00429 checking the front and rear brake calipers warning all internal brake components should be cleaned in new brake fluid only. Do not use solvents as they will cause seals to swell and distort. 1. Check: • brake caliper piston scratches/rust/wear → replace the brake caliper assembly....

  • Page 241: Chas

    Chas 6-36 ebs00431 assembling the front brake calipers the following procedure applies to both of the front brake calipers. Warning • all internal brake components should be cleaned and lubricated with new brake fluid only before installation. • replace the caliper piston seal whenever a brake calip...

  • Page 242: Chas

    Chas 6-37 2. Install: • brake caliper piston 3. Install: • lock washer • brake pad retaining bolts 4. Bend the lock washer tabs along a flat side of the bolts. 5. Install: • parking brake arm 6. Measure: • parking brake arm to parking brake bracket distance out of specification → adjust. Brake pad r...

  • Page 243: Chas

    Chas 6-38 ebs00434 installing the front brake calipers the following procedure applies to both of the front brake calipers. 1. Install: • brake caliper assembly • brake caliper mounting bolts • brake hose • copper washers • union bolt caution: when installing the brake hose on the brake caliper, mak...

  • Page 244: Chas

    Chas 6-39 warning • use only the designated quality brake fluid: other brake fluids may deteriorate the rubber seals, causing leakage and poor brake performance. • refill with the same type of brake fluid: mixing brake fluids may result in a harm- ful chemical reaction and lead to poor brake perform...

  • Page 245: Chas

    Chas 6-40 ebs00436 installing the rear brake caliper 1. Install: • brake caliper assembly • brake caliper mounting bolts • brake hose • copper washers • union bolt caution: when installing the brake hose on the brake caliper, make sure that the brake pipe touches the projection on the brake cali- pe...

  • Page 246: Chas

    Chas 6-41 warning • use only the designated quality brake fluid: other brake fluids may deteriorate the rubber seals, causing leakage and poor brake performance. • refill with the same type of brake fluid: mixing brake fluids may result in a harm- ful chemical reaction and lead to poor brake perform...

  • Page 247: Chas

    Chas 6-42 ebs00444 steering system handlebar order job/part q’ty remarks removing the handlebar remove the parts in the order listed. 1 handlebar protecter 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 r...

  • Page 248: Chas

    Chas 6-43 order job/part q’ty remarks 11 handlebar grip 2 refer to “removing the handlebar grips” and “installing the handlebar grips”. 12 handlebar holder 2 13 handlebar 1 for installation, reverse the removal procedure. 4 nm (0.4 m•kg, 3.0 ft•lb) 7 nm (0.7 m•kg, 5.2 ft•lb) 20 nm (2.0 m•kg, 15 ft•l...

  • Page 249: Chas

    Chas 6-44 ebs00446 removing the clutch switch 1. Remove: • clutch switch note: note: push the fastener when removing the clutch switch out of the clutch lever holder. Ebs00447 removing the handlebar grips 1. Remove: • handlebar grips note: note: blow compressed air between the handlebar and handleba...

  • Page 250: Chas

    Chas 6-45 ebs00449 installing the handlebar 1. Install: • handlebar • handlebar holders note: note: • install the handlebar horizontally shown in the illustration. • the upper handlebar holder should be installed with the punched mark forward . Caution: first tighten the bolt on the front side of th...

  • Page 251: Chas

    Chas 6-46 ebs00452 installing the clutch lever 1. Install: • handlebar switch • clutch lever • clutch lever bracket note: note: • install the clutch lever bracket as shown. • install the clutch lever at 10 degrees angle as shown. 53 ~ 54 mm (2.09 ~ 2.13 in) ebs00453 installing the brake master cylin...

  • Page 252: Chas

    Chas 6-47 ebs00454 steering stem order job/part q’ty remarks removing the steering stem remove the parts in the order listed. Front fender refer to “seat, fenders and fuel tank” in chapter 3. 1 lock washer 1 refer to “installing the lock washer”. 2 bracket 1 3 steering stem bushing 2 4 spacer 2 5 oi...

  • Page 253: Chas

    Chas 6-48 ebs00456 checking the steering stem 1. Check: • steering stem bends/damage → replace. Warning do not attempt to straighten a bent stem; this may dangerously weaken the stem. 2. Check: • oil seals • steering stem bushings wear/damage → replace. 3. Check • o-rings • bushings wear/damage → re...

  • Page 254: Chas

    Chas 6-49 ebs00460 tie-rods and steering knuckles order job/part q’ty remarks removing the tie-rods and steering knuckles remove the parts in the order listed. The following procedure applies to both of the tie-rods and steering knuckles. Front wheel/brake disc refer to “front and rear wheels”. Fron...

  • Page 255: Chas

    Chas 6-50 ebs00461 removing the steering knuckles 1. Remove: • steering knuckles note: note: use a general puller to separate the ball joint and steering knuckle. Ebs00462 checking the tie-rods 1. Check: • tie-rod free play and movement free play → replace the tie-rod end. Turns roughly → replace th...

  • Page 256: Chas

    Chas 6-51 ebs00468 front arms and front shock absorber assemblies order job/part q’ty remarks removing the front arms and front shock absorber assemblies remove the parts in the order listed. The following procedure applies to both of the front arms and front shock absorber assemblies. Front wheel/b...

  • Page 257: Chas

    Chas 6-52 order job/part q’ty remarks 8 dust cover 6 9 spacer 1 10 spacer 2 11 bushing 6 for installation, reverse the removal procedure. 31 nm (3.1 m•kg, 23 ft•lb) 45 nm (4.5 m•kg, 33 ft•lb) 45 nm (4.5 m•kg, 33 ft•lb) 25 nm (2.5 m•kg, 18 ft•lb) 25 nm (2.5 m•kg, 18 ft•lb) 48 nm (4.8 m•kg, 35 ft•lb) ...

  • Page 258: Chas

    Chas 6-53 ebs00469 removing the front arms 1. Check: • front arm free play a. Check the front arm side play by moving it from side to side. If side play is noticeable, check the bush- ings. B. Check the front arm vertical movement by moving it up and down. If the vertical movement is tight or rough,...

  • Page 259: Chas

    Chas 6-54 ebs00472 checking the ball joints the following procedure applies to both of the front arm ball joints. 1. Check: • ball joint damage/pitting → replace the front arm. Free play → replace the front arm. Turns roughly → replace the front arm. Ebs00473 installing the front arms the following ...

  • Page 260: Chas

    Chas 6-55 rear shock absorber, swingarm and drive chain order job/part q’ty remarks removing the rear shock absorber, swingarm and drive chain remove the parts in the order listed. Seat/rear fender/air filter case refer to “seat, fenders and fuel tank” in chapter 3. Rear axle hub refer to “rear axle...

  • Page 261: Chas

    Chas 6-56 order job/part q’ty remarks 9 drive chain guide 2 1 10 drive chain guide 3 1 11 nut 1 12 lock washer 1 13 drive sprocket 1 14 drive chain 1 15 dust cover/oil seal 2/2 16 spacer 1 17 bearing 2 for installation, reverse the removal procedure. 23 nm (2.3 m•kg, 17 ft•lb) 55 nm (5.5 m•kg, 41 ft...

  • Page 262: Chas

    Chas 6-57 handling the rear shock absorber warning this rear shock absorber contains highly compressed nitrogen gas. Before handling the rear shock absorber read and make sure you understand the following informa- tion. The manufacturer cannot be held responsible for property damage or per- sonal in...

  • Page 263: Chas

    Chas 6-58 ebs00487 removing the rear shock absorber 1. Remove: • rear shock absorber lower bolt • rear shock absorber upper bolt note: note: while removing the rear shock absorber lower bolt, hold the swingarm so that it does not drop down. Ebs00488 checking the rear shock absorber 1. Check: • shock...

  • Page 264: Chas

    Chas 6-59 b. Check the swingarm side play by mov- ing it from side to side. If side play is noticeable, check the spacer, bearings and frame pivot. C. Check the swingarm vertical movement by moving it up and down. If vertical movement is tight or rough, or if there is binding, check the spacer, bear...

  • Page 265: Chas

    Chas 6-60 4. Check: • oil seals damage/wear → replace. • bearings damage/pitting → replace. Ebs00496 checking the drive chain 1. Measure: • 15-link section of the drive chain out of specification → replace the drive chain. Note: note: • while measuring the 15-link section, push down on the drive cha...

  • Page 266: Chas

    Chas 6-61 3. Clean: • drive chain a. Wipe the drive chain with a clean cloth. B. Put the drive chain in kerosene and remove any remaining dirt. C. Remove the drive chain from the kerosene and completely dry it. Caution: this machine has a drive chain with small rubber o-rings between the drive chain...

  • Page 267: Chas

    Chas 6-62 6. Check: • drive sprocket • driven sprocket more than 1/4 tooth wear → replace the drive chain sprockets as a set. Bent teeth → replace the drive chain sprockets as a set. Correct drive chain roller drive chain sprocket ebs00497 installing the swingarm 1. Install: • bearings • spacer note...

  • Page 268: Elec

    Elec 7-1 ebs00500 electrical electrical components main switch front brake light switch clutch switch handlebar switch cdi unit starter relay fuse battery tail/brake light headlight relay starting circuit cut-off relay thermo switch carburetor warmer starter motor pickup coil/stator assembly neutral...

  • Page 269: Elec

    Elec 7-2 1 2 3 4 5 6 7 8 ebs01028 checking switch continuity check each switch for continuity with the pocket tester. If the continuity reading is incor- rect, check the wiring connections and if nec- essary, replace the switch. Caution: never insert the tester probes into the cou- pler terminal slo...

  • Page 270: Elec

    Elec 7-3 ebs01029 checking the switches check each switch for damage or wear, proper connections, and also for continuity between the ter- minals. Refer to “checking switch continuity”. Damage/wear → repair or replace. Improperly connected → properly connect. Incorrect continuity reading → replace t...

  • Page 271: Elec

    Elec 7-4 light switch engine stop switch start switch main switch front brake light switch clutch switch fuse neutral switch rear brake light switch checking the switches.

  • Page 272: Elec

    Elec 7-5 ebs01030 checking the bulbs and bulb sockets 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. No continuity → repai...

  • Page 273: Elec

    Elec 7-6 warning since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. Caution: • be sure to hold the socket firmly when removing the bulb. Never pull the lead, otherwise it may be pulled out of the ter- minal in the coupler....

  • Page 274: Elec

    Elec 7-7 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 note: note: check each bulb socket for continuity in the same manner as described in the bulb sect...

  • Page 275: Elec

    Elec 7-8 ebs00503 ignition system circuit diagram a a b/y b r br rb r on off off lo hi off on off push r/b l br r/w gy b r/b l br l/b y b r r l/b y/b b/y b b b o o b/y b y/b b/y r/b sb gy b g y b gy b g y b w w w w r w/l w/r w ww l y b g y r/b b w w o w/l w/r w br sb br sb y br y br sub-wire harness...

  • Page 276: Elec

    Elec 7-9 ebs01045 troubleshooting check: 1. Fuse 2. Battery 3. Spark plug 4. Ignition spark gap 5. Ignition coil resistance 6. Main switch 7. Engine stop switch 8. Pickup coil resistance 9. Wiring connections (of the entire ignition system) note: note: • before troubleshooting, remove the following ...

  • Page 277: Elec

    Elec 7-10 ebs01034 eas00745 4. Ignition spark gap the following procedure applies to all of the spark plugs. • disconnect the spark plug cap from the spark plug. • connect the ignition checker and spark plug cap as shown. • set the main switch to “on”. • measure the ignition spark gap . • crank the ...

  • Page 278: Elec

    Elec 7-11 ebs01038 ebs01041 ebs01042 ebs01040 6. Ignition coil resistance • disconnect the ignition coil coupler from the ignition coil. • connect the pocket tester ( Ω × 1) to the ignition coil as shown. Positive tester probe → orange lead terminal negative tester probe → ignition coil base • measu...

  • Page 279: Elec

    Elec 7-12 ebs01047 10. Wiring • check the entire ignition system’s wiring. Refer to “circuit diagram”. • is the ignition system’s wiring properly con- nected and without defects? Yes no replace the cdi unit. Properly connect or repair the ignition system’s wiring. Ignition system.

  • Page 280: Elec

    Elec 7-13 ebs00506 electric starting system circuit diagram a a b/y b r br rb r on off off lo hi off on off push r/b l br r/w gy b r/b l br l/b y b r r l/b y/b b/y b b b b/y b y/b b/y r/b sb gy b g y b gy b g y b w w w w r w/l w/r w ww l y b g y r/b b w w o w/l w/r w br sb br sb y br y br sub-wire h...

  • Page 281: Elec

    Elec 7-14 ebs00508 starting circuit cut-off system operation the starting circuit on this model consists of the starter motor, starter relay, clutch switch, and neutral switch. If the main switch is on and the engine stop switch is in the run position, the starter motor can be operated only if: batt...

  • Page 282: Elec

    Elec 7-15 ebs01050 troubleshooting check: 1. Fuse 2. Battery 3. Starter motor 4. Starting circuit cut-off relay 5. Starting circuit cut-off relay (diode) 6. Starter relay 7. Main switch 8. Engine stop switch 9. Neutral switch 10.Clutch switch 11.Start switch 12.Wiring connections (of the entire star...

  • Page 283: Elec

    Elec 7-16 ebs01052 ebs01053 4. Starting circuit cut-off relay • remove the starting circuit cut-off relay from the wire harness. • connect the pocket tester ( Ω × 1) and bat- tery (12 v) to the starting circuit cut-off relay as shown. Positive battery terminal → red/black negative battery terminal →...

  • Page 284: Elec

    Elec 7-17 ebs01054 ebs01041 ebs01042 ebs01046 ebs01056 ebs01057 6. Starter relay • disconnect the starter relay coupler from the wire harness. • connect the pocket tester ( Ω × 1) and bat- tery (12 v) to the starter relay as shown. Positive battery terminal → blue/black negative battery terminal → y...

  • Page 285: Elec

    Elec 7-18 ebs01059 12. Wiring • check the entire starting system’s wiring. Refer to “circuit diagram”. • is the starting system’s wiring properly con- nected and without defects? Yes no the starting system circuit is ok. Properly connect or repair the starting system’s wiring. Electric starting syst...

  • Page 286: Elec

    Elec 7-19 ebs01061 starter motor order job/part q’ty remarks removing the starter motor remove the parts in the order listed. Exhaust pipe idle gear cover and idle gear refer to “engine removal” in chapter 4. 1 clutch cable holder 1 2 starter motor lead 1 disconnect. 3 starter motor 1 for installati...

  • Page 287: Elec

    Elec 7-20 ebs01062 order job/part q’ty remarks disassembling the starter motor remove the parts in the order listed. Front bracket 1 tang washer 1 plate washer 1 circlip 1 rear bracket/brush 1/1 armature assembly 1 starter motor yoke 1 brush/spring 2/2 for assembly, reverse the disassembly procedure...

  • Page 288: Elec

    Elec 7-21 ebs01064 checking the starter motor 1. Check: • commutator dirt → clean with 600-grit sandpaper. 2. Measure: • commutator diameter out of specification → replace the starter motor. 3. Measure: • mica undercut out of specification → scrape the mica to the proper measurement with a hacksaw b...

  • Page 289: Elec

    Elec 7-22 b. If any resistance is out of specification, replace the starter motor. 5. Measure: • brush length out of specification → replace the brushes as a set. 6. Measure: • brush spring force out of specification → replace the brush springs as a set. 7. Check: • gear teeth damage/wear → replace ...

  • Page 290: Elec

    Elec 7-23 ebs00515 assembling the starter motor 1. Install: • brush spring • brush 2. Install: • armature coil 3. Install • o-rings to starter motor yoke . 4. Install • starter motor yoke note: note: align the match marks on the starter motor york with the match marks on the rear bracket. 5. Install...

  • Page 291: Elec

    Elec 7-24 ebs00516 charging system circuit diagram r br rb r on off r r l/b y/b w w w w r w/l w/r w ww r - b w w w w/r w/l w w w w w w b r r b r r r r r r br y/b l/b b b stator coil rectifier/regulator battery positive lead battery fuse ground charging system.

  • Page 292: Elec

    Elec 7-25 ebs01065 troubleshooting check: 1. Fuse 2. Battery 3. Charging voltage 4. Stator coil resistance 5. Wiring connections (of the entire charging system) note: note: • before troubleshooting, remove the following part(s): 1. Seat 2. Front panel 3. Front fender 4. Rear fender 5. Side cover • t...

  • Page 293: Elec

    Elec 7-26 ebs01066 ebs01100 3. Charging voltage • connect the engine tachometer to on to the ignition coil. • connect the pocket tester (dc 20 v) to the battery as shown. Positive tester probe → positive battery terminal negative tester probe → negative battery terminal • start the engine and let it...

  • Page 294: Elec

    Elec 7-27 ebs00518 lighting system circuit diagram a a b/y b r br rb r on off off lo hi off on off push r/b l br r/w gy b r/b l br l/b y b r r l/b y/b b/y b b b b/y b y/b b/y r/b sb gy b g y b gy b g y b w w w w r w/l w/r w ww l y b g y r/b b w w o w/l w/r w br sb br sb y br y br sub-wire harness a ...

  • Page 295: Elec

    Elec 7-28 ebs01067 troubleshooting check: 1. Light switch 2. Stator coil resistance 3. Wiring connections (of the entire lighting system) note: note: • before troubleshooting, remove the following part(s): 1. Seat 2. Front panel 3. Front fender 4. Rear fender 5. Side cover • troubleshoot with the fo...

  • Page 296: Elec

    Elec 7-29 ebs01069 ebs01070 checking the lighting system 1. The headlights fail to come on. 3. Wiring • check the entire lighting system’s wiring. Refer to “circuit diagram”. • is the lighting system’s wiring properly con- nected and without defects? Yes no check the condition of each of the light- ...

  • Page 297: Elec

    Elec 7-30 2. The tail/brake light fails to come on. 1. Tail/brake light bulb and bulb socket (4d31) • check the tail/brake light bulb and socket for continuity. Refer to “checking the bulbs and bulb sockets”. • are the tail/brake light bulb and socket ok? Yes no replace the tail/brake light bulb, so...

  • Page 298: Elec

    Elec 7-31 ebs00521 signal system circuit diagram a a b/y b r br rb r on off off lo hi off on off push r/b l br r/w gy b r/b l br l/b y b r r l/b y/b b/y b b b b/y b y/b b/y r/b sb gy b g y b gy b g y b w w w w r w/l w/r w ww l y b g y r/b b w w o w/l w/r w br sb br sb y br y br sub-wire harness a wi...

  • Page 299: Elec

    Elec 7-32 ebs01073 troubleshooting check: 1. Fuse 2. Battery 3. Main switch 4. Wiring connections (of the entire signaling system) note: note: • before troubleshooting, remove the following part(s): 1. Seat 2. Front fender • troubleshoot with the following special tool(s). Ebs01043 ebs01044 ebs01041...

  • Page 300: Elec

    Elec 7-33 ebs01075 checking the signaling system ebs01076 1. The tail/brake light fails to come on. 1. Tail/brake light bulb and bulb socket (4d31) • check the tail/brake light bulb and bulb socket for continuity. Refer to “checking the bulbs and bulb sockets”. • are the tail/brake light bulb and bu...

  • Page 301: Elec

    Elec 7-34 ebs01077 2. The neutral indicator light fails to come on. 1. Neutral indicator light bulb and socket • check the neutral indicator light bulb and socket for continuity. Refer to “checking the bulbs and bulb sockets”. • are the neutral indicator light bulb and socket ok? Yes no replace the ...

  • Page 302: Elec

    Elec 7-35 ebs01083 3. The carburetor heater fails to come on. 1. Thermo switch • disconnect the thermo switch from the wire- harness. • connect the pocket tester ( Ω × 1) to the thermo switch lead. Tester positive probe → black tester negative probe → black • check the thermo switch for continuity a...

  • Page 303: Trbl

    Trbl shtg 8-1 1 2 3 4 5 6 7 8 ebs00537 troubleshooting note: the following troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to troubleshooting. Refer to the relative procedure in this manual for check, adjustment and replacement of parts. S...

  • Page 304: Trbl

    Trbl shtg 8-2 compression system cylinder and cylinder head • loose spark plug • loose cylinder head or cylinder • broken cylinder head gasket • broken cylinder gasket • worn, damaged or seized cylinder valve and camshaft • improperly sealed valve • improperly contacted valve and valve seat • improp...

  • Page 305: Trbl

    Trbl shtg 8-3 ebs00541 faulty gear shifting hard shifting refer to “clutch dragging”. Shift pedal does not move shift shaft • bent shift shaft shift drum and shift forks • groove jammed with impurities • seized shift fork • bent shift fork guide bar transmission • seized transmission gear • jammed i...

  • Page 306: Trbl

    Trbl shtg 8-4 ebs00547 overheating overheating ignition system • improper spark plug gap • improper spark plug heat range • faulty cdi unit fuel system • improper carburetor main jet (improper setting) • improper fuel level • clogged air filter element compression system • heavy carbon deposit engin...

  • Page 307: Trbl

    Trbl shtg 8-5 ebs00552 unstable handling unstable handling handlebar • improperly installed or bent steering • incorrect toe-in • bent steering stem • improperly installed steering stem • damaged bearing or bearing race • bent tie-rods • deformed steering knuckles tires • uneven tire pressures on bo...

  • Page 310

    Yamaha motor co., ltd. 2500 shingai iwata shizuoka japan printed in u.S.A..

  • Page 311

    Yfm250rx wiring diagram pickup coil stator coil rectifier/regulator main switch battery positive lead battery fuse starter relay starter motor cdi unit ignition coil spark plug starting circuit cut-off relay clutch switch thermo switch carburetor warmer neutral indicator light neutral switch rear br...