Yamaha X-MAX 250 Service Manual en

YP250R
SERVICE MANUAL
2005
1C0-F8197-E0
EAS00000
YP250R 2005
SERVICE MANUAL
2007 by Yamaha Motor Espaa, S.A.
First edition, February 2007
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Espaa, S.A.
is expressly prohibited.
EAS00002
NOTICE
This manual was produced by the Yamaha Motor Espaa S.A. primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one
manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha
vehicles should have a basic understanding of mechanics and the techniques to repair these types
of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to
render the vehicle unsafe and unfit for use.
Yamaha Motor Espaa S.A. is continually striving to improve all of its models. Modifications and sig-
nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers
and will appear in future editions of this manual where applicable.
NOTE:
_
Designs and specifications are subject to change without notice.
EAS00005
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death to
the vehicle operator, a bystander or a person checking or repairing the vehicle.
A CAUTION indicates special precautions that must be taken to avoid damage
to the vehicle.
A NOTE provides key information to make procedures easier or clearer.
WARNING
CAUTION:
NOTE:
EAS00007
HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are
laid out with the individual steps in sequential order.
1The manual is divided into chapters. An abbreviation and symbol in the upper right corner of
each page indicate the current chapter.
Refer to SYMBOLS.
2Each chapter is divided into sections. The current section title is shown at the top of each page,
except in Chapter 3 (PERIODIC CHECKS AND ADJUSTMENTS), where the sub-section
title(s) appears.
3Sub-section titles appear in smaller print than the section title.
4To help identify parts and clarify procedure steps, there are exploded diagrams at the start of
each removal and disassembly section.
5Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a
disassembly step.
6Symbols indicate parts to be lubricated or replaced.
Refer to SYMBOLS.
7A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.
8Jobs requiring more information (such as special tools and technical data) are described sequen-
tially.
EAS00008
SYMBOLS
The following symbols are not relevant to
every vehicle.
Symbols 1 to 9 indicate the subject of each
chapter.
1General information
2Specifications
3Periodic checks and adjustments
4Chassis
5Engine
6Cooling system
7Carburetor
8Electrical system
9Troubleshooting
Symbols 0 to G indicate the following.
0Serviceable with engine mounted
AFilling fluid
BLubricant
CSpecial tool
DTightening torque
EWear limit, clearance
FEngine speed
GElectrical data
Symbols H to M in the exploded diagrams
indicate the types of lubricants and lubrication
points.
HEngine oil
IGear oil
JMolybdenum-disulfide oil
KWheel-bearing grease
LLithium-soap- based grease
MMolybdenum-disulfide grease
Symbols N to O in the exploded diagrams
indicate the following.
NApply locking agent (LOCTITE
)
OReplace the part
1 2
3 4
5 6
7 8
9 0
A B
C D
E F G
H I J
K L M
N O
GEN
INFO
SPEC
CHK
ADJ
CHAS
ENG COOL
CARB
+
ELEC
TRBL
SHTG
T

R
.
.
E G M
B
LS M
LT
New
EAS00010
TABLE OF CONTENTS
GENERAL INFORMATION
GEN
INFO
1
SPECIFICATIONS
SPEC
2
PERIODIC CHECKS AND
ADJUSTMENTS
CHK
ADJ
3
CHASSIS
CHAS
4
ENGINE
ENG
5
COOLING SYSTEM
COOL
6
CARBURETOR
CARB
7
ELECTRICAL SYSTEM
ELEC
8
TROUBLESHOOTING
TRBL
SHTG
9
+
GEN
INFO
CHAPTER 1
GENERAL INFORMATION
IDENTIFICATION ............................................................................................ 1-1
VEHICLE IDENTIFICATION NUMBER..................................................... 1-1
MODEL LABEL.......................................................................................... 1-1
MULTI-FUNCTION DISPLAY.......................................................................... 1-2
IMPORTANT INFORMATION ......................................................................... 1-5
PREPARATION FOR REMOVAL AND DISASSEMBLY........................... 1-5
REPLACEMENT PARTS........................................................................... 1-5
GASKETS, OIL SEALS AND O-RINGS.................................................... 1-5
LOCK WASHERS/PLATES AND COTTER PINS..................................... 1-6
BEARINGS AND OIL SEALS.................................................................... 1-6
CIRCLIPS.................................................................................................. 1-6
CHECKING THE CONNECTIONS.................................................................. 1-7
SPECIAL TOOLS............................................................................................ 1-8
1 - 1
GEN
INFO
EAS00015
GENERAL INFORMATION
IDENTIFICATION
EAS00017
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number 1 is
stamped into the frame.
1
EAS00018
MODEL LABEL
The model label 1 is affixed underneath the
seat. This information will be needed when
ordering spare parts.
1
IDENTIFICATION
1 - 2
GEN
INFO
MULTI-FUNCTION DISPLAY
The multi-function display is equipped with the
following:
an odometer (which shows the total dis-
tance traveled)
two tripmeters (which show the distance
traveled since they were last set to zero, the
time passed since the tripmeters were set
to zero, and the average speed traveled
during this time)
1MODE button
2Multi-function display
3SET button
a fuel reserve tripmeter (which shows the
distance traveled since the fuel level warn-
ing light came on)
a clock
an ambient temperature display
an oil change indicator (which comes on
when the engine oil should be changed)
NOTE:
For the UK, the distance traveled is dis-
played in miles and the temperature reading
is displayed in F.
For other countries, the distance traveled is
displayed in kilometers and the temperature
reading is displayed in C.
1Total
2Trip 1
3Trip 2
4Trip/Fuel
Odometer and tripmeter modes
Pushing the MODE button switches the dis-
play between the odometer mode Total and
the tripmeter modes Trip in the following
order:
1Distance
2Time
3Average speed
NOTE:
The Trip/fuel odometer is only activated if the
fuel level warning light comes on.
The Trip 2 odometer is automatically reset
after turning the key to OFF and two hours
have passed.
Total Trip 1 Trip 2 Trip/fuel Total
1 - 3
GEN
INFO
Pushing the SET button when in the tripme-
ter mode switches the display between the dif-
ferent tripmeter functions in the following
order:
Distance Time Average speed Dis-
tance
If the fuel level warning light comes on, the dis-
play will automatically change to the fuel
reserve tripmeter mode Trip/fuel and start
counting the distance traveled from that point.
In that case, pushing the MODE button
switches the display between the various trip-
meter and odometer modes in the following
order:
To reset a tripmeter, select it by pushing the
MODE button, and then push the SET but-
ton for at least one second. If you do not reset
the fuel reserve tripmeter manually, it will reset
itself automatically and the display will return
to the prior mode after refueling and traveling 5
km.
Trip/Fuel Trip 1 Trip 2 Total Trip/
fuel
Clock mode
To set the clock:
1. When the display is in the Total mode,
push the SET button for at least two sec-
onds.
2. When the hour digits start flashing, push
the SET button to set the hours.
3. Push the MODE button, and the minute
digits will start flashing.
4. Push the SET button to set the minutes.
5. Push the MODE button and then release it
to start the clock. The display will return to
the Total mode.
1 - 4
GEN
INFO
Ambient temperature display
This display shows the ambient temperature
from -30 C to 50 C.
The frost warning indicator * automatically
comes on if the temperature is lower than 3 C.
1Frost warning indicator
2Negative symbol
3Ambient temperature
Oil change indicator OIL
The engine oil should be changed when this
indicator comes on. The indicator stays on
until it is reset. After changing the engine oil,
reset the indicator as follows.
1Oil change indicator OIL
To reset the oil change indicator:
1. Set the main switch to ON while holding
the MODE and SET buttons pushed for
two to five seconds.
2. Release the buttons, and the oil change
indicator will go off.
NOTE:
The oil change indicator will come on at the
initial 1000 km and every 3000 km thereafter.
If the engine oil is changed before the oil
change indicator comes on, the indicator
must be reset after the oil change for the
next periodic oil change to be indicated at
correct time.
1 - 5
GEN
INFO
IMPORTANT INFORMATION
EAS00020
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 mated
parts together. This includes gears, cylin-
ders, pistons and other parts that have been
mated through normal wear. Mated parts
must always be reused or replaced as an
assembly.
4. During disassembly, clean all of the parts
and place them in trays in the order of dis-
assembly. This will speed up assembly and
allow for the correct installation of all parts.
5. Keep all parts away from any source of fire.
EAS00021
REPLACEMENT PARTS
Use only genuine Yamaha parts for all
replacements. Use oil and grease recom-
mended by Yamaha for all lubrication jobs.
Other brands may be similar in function and
appearance, but inferior in quality.
EAS00022
GASKETS, OIL SEALS AND O-RINGS
1. When overhauling the engine, replace all
gaskets, seals and O-rings. All gasket sur-
faces, oil seal lips and O-rings must be
cleaned.
2. During reassembly, properly oil all mating
parts and bearings and lubricate the oil seal
lips with grease.
1 - 6
GEN
INFO
EAS00023
LOCK WASHERS/PLATES AND COTTER
PINS
After removal, replace all lock washers/plates
1 and cotter pins. After the bolt or nut has
been tightened to specification, bend the lock
tabs along a flat of the bolt or nut.
EAS00024
BEARINGS AND OIL SEALS
Install bearings and oil seals so that the manu-
facturers 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.
1Oil seal
CAUTION:
_
Do not spin the bearing with compressed
air because this will damage the bearing
surfaces.
2Bearing
EAS00025
CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips.
Always replace piston pin clips after one use.
When installing a circlip 1, make sure the
sharp-edged corner 2 is positioned opposite
the thrust 3 that the circlip receives.
4Shaft
1 - 7
GEN
INFO
CHECKING THE CONNECTIONS
EAS00026
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 sev-
eral times.
3. Check:
all connections
Loose connection Connect properly.
NOTE:
_
If the pin 1 on the terminal is flattened, bend it
up.
4. Connect:
lead
coupler
connector
NOTE:
_
Make sure all connections are tight.
5. Check:
continuity
(with the pocket tester)
NOTE:
_
If there is no continuity, clean the terminals.
When checking the wire harness, perform
steps (1) to (3).
As a quick remedy, use a contact revitalizer
available at most part stores.
Pocket tester
90890-03112
1 - 8
GEN
INFO
SPECIAL TOOLS
EAS00027
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use
only the appropriate special tools as this will help prevent damage caused by the use of inappropri-
ate tools or improvised techniques. Special tools, part numbers or both may differ depending on the
country.
When placing an order, refer to the list provided below to avoid any mistakes.
Tool No. Tool name/Function Illustration
90890-01083
90890-01084
Slide hammer bolt
Weight
These tools are used to remove or install
the rocker arm shafts.
90890-01135
Crankshaft separating tool
This tool is used to remove the crank-
shaft.
90890-01235
Rotor holding tool
This tool is used to hold the primary fixed
sheave.
90890-01274
Crankshaft installer pot
This tool is used to install the crankshaft.
90890-01275
Crankshaft installer bolt
90890-01294
Damper rod holder
This tool is used to hold the damper rod
when removing or installing the damper
rod.
90890-01304
Piston pin puller set
This tool is used to remove the piston
pins.
1 - 9
GEN
INFO
SPECIAL TOOLS
90890-01311
Tappet adjusting tool
This tool is used to adjust valve clear-
ance.
90890-01326
T-handle
This tool is used to hold the damper rod
when removing or installing the damper
rod.
90890-01337
Clutch spring holder
This tool is used to disassembly and
assembly the secondary sheave.
90890-01348
Locknut wrench
This tool is used to remove or install the
clutch carrier nut.
90890-01362
Flywheel puller
This tool is used to remove the generator
rotor.
90890-01367
Fork seal driver weight
This tool is used to install the oil seal,
dust seal, and the outer tube bushing of a
front fork leg.
90890-01370
Fork seal driver attachment (36)
This tool is used to install the oil seal and
the outer tube bushing of the front fork
leg.
90890-01396
Oil seal guide (41)
This tool is used for protecting the oil seal
lip when installing the secondary sliding
sheave.
1 - 10
GEN
INFO
SPECIAL TOOLS
90890-01403
Steering nut wrench
This tool is used to loosen or tighten the
steering ring nuts.
90890-01464
Clutch spring holder arm
This tool is used to disassembly and
assembly the secondary sheave.
90890-01478
Adapter (M14)
90890-01701
Sheave holder
This tool is used to hold the generator
rotor, clutch housing, and clutch carrier.
90890-03081
Compression gauge
This tool is used to measure the engine
compression.
90890-03112
Pocket tester
This tool is used to check the electrical
system.
90890-03134
Exhaust attachment
This tool is used to measure the CO den-
sity.
90890-03141
Timing light
This tool is used to check the ignition tim-
ing.
1 - 11
GEN
INFO
SPECIAL TOOLS
90890-04019
Valve spring compressor
valve assemblies.
90890-04058
Middle driven shaft bearing driver
This tool is used to install the water pump
seal.
90890-04064
Valve guide remover (6)
valve guides.
90890-04065
Valve guide installer (6)
This tool is used to install the valve
guides.
90890-04066
Valve guide reamer (6)
This tool is used to rebore the new valve
guides.
90890-04081
Spacer (crankshaft installer)
90890-04108
Valve spring compressor attachment
valve assemblies.
90890-04132
Mechanical seal installer
This tool is used to install the water pump
seal.
1 - 12
GEN
INFO
SPECIAL TOOLS
90890-06754
Ignition checker
This tool is used to check the ignition sys-
tem components.
90890-06756
Vacuum/pressure pump gauge set
This tool is used to check the air cut-off
valve.
90890-11098
Fuel sender removal tool
This tool are used to remove the fuel
sender.
90890-85505
Yamaha bond No. 1215
This bond is used to seal two mating sur-
faces (e.g., crankcase mating surfaces).
SPEC
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS ........................................................................ 2-1
ENGINE SPECIFICATIONS............................................................................ 2-2
CHASSIS SPECIFICATIONS........................................................................ 2-11
ELECTRICAL SPECIFICATIONS................................................................. 2-15
CONVERSION TABLE.................................................................................. 2-18
GENERAL TIGHTENING TORQUE SPECIFICATIONS............................... 2-18
TIGHTENING TORQUES.............................................................................. 2-19
ENGINE TIGHTENING TORQUES......................................................... 2-19
CHASSIS TIGHTENING TORQUES....................................................... 2-21
LUBRICATION POINTS AND LUBRICANT TYPES .................................... 2-23
ENGINE LUBRICATION POINTS AND LUBRICANT TYPES ................ 2-23
CHASSIS LUBRICATION POINTS AND LUBRICANT TYPES .............. 2-24
COOLING SYSTEM DIAGRAMS.................................................................. 2-25
CABLE ROUTING......................................................................................... 2-26
2 - 1
SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item Standard
Model code 1C01
Dimensions
Overall length 2,210 mm (87.0 in)
Overall width 790 mm (31.1 in)
Overall height 1,380 mm (54.3 in)
Seat height 775 mm (30.5 in)
Wheelbase 1,545 mm (60.8 in)
Minimum ground clearance 113 mm (4.45 in)
Minimum turning radius 3,600 mm (143.7 in)
Weight
Wet (with oil and a full fuel tank) 176 kg (388 lb)
Maximum load (total of cargo, rider, passen-
ger, and accessories)
180 kg (397 lb)
GENERAL SPECIFICATIONS
2 - 2
SPEC
ENGINE SPECIFICATIONS
Item Standard Limit
Engine
Engine type Liquid cooled 4-stroke, SOHC ----
Displacement 249.7 cm
3
----
Cylinder arrangement Forward-inclined single cylinder ----
Bore stroke 69.0 66.8 mm (2.72 2.63 in) ----
Compression ratio 10.00 :1 ----
Standard compression pressure (at
sea level)
1,400 kPa (14.0 kgf/cm
2
, 199.1 psi) at
500 r/min
----
Starting system Electric starter ----
Fuel
Recommended fuel Regular unleaded gasoline only ----
Fuel tank capacity
Total (including reserve) 13.0 L (2.86 Imp.gal, 3.43 US gal) ----
Fuel reserve amount 2.0 L (0.44 Imp.gal, 0.53 US gal) ----
Engine oil
Lubrication system Wet sump ----
Recommended oil type SAE10W30, SAE10W40, SAE15W40,
SAE20W40, or SAE20W50
----
Recommended engine oil grade API service SG type or higher, JASO
standard MA
----
Quantity
Total amount 1.40 L (1.23 Imp.qt, 1.48 US qt) ----
Periodic oil change 1.20 L (1.06 Imp.qt, 1.27 US qt) ----
Oil temperature 65 ~ 75 C (149 ~ 167 F) ----
Final transmission oil
Type SAE10W30 type SE motor oil ----
Oil quantity 0.25 L (0.22 Imp.qt, 0.26 US qt) ----
2 - 3
SPEC
Oil pump
Oil pump type Trochoid ----
Inner-rotor-to-outer-rotor-tip clear-
ance
Less than 0.15 mm (0.0059 in) 0.23 mm
(0.0091 in)
Outer-rotor-to-oil-pump-housing
clearance
0.013 ~ 0.036 mm (0.0005 ~ 0.0014 in) 0.106 mm
(0.0042 in)
Oil-pump-housing-to-inner-and-
outer-rotor clearance
0.04 ~ 0.09 mm (0.0016 ~ 0.0035 in) 0.16 mm
(0.0063 in)
Cooling system
Radiator and engine capacity 0.70 L (0.62 Imp.qt, 0.74 US qt) ----
Radiator capacity 0.34 L (0.30 Imp.qt, 0.36 US qt) ----
Radiator core
Width 229.0 mm (9.02 in) ----
Height 111.5 mm (4.39 in) ----
Depth 33.0 mm (1.30 in) ----
Coolant reservoir capacity (up to the
maximum level mark)
0.26 L (0.23 Imp.qt, 0.28 US qt) ----
Water pump
Water pump type Single suction centrifugal pump ----
Reduction ratio 37/22 25/37 (1.136) ----
Impeller shaft tilt limit ---- 0.15 mm
(0.0059 in)
Coolant temperature 80 ~ 90 C (176 ~ 194 F) ----
Spark plug
Manufacturer/model quantity NGK/DR8EA 1 ----
Spark plug gap 0.6 ~ 0.7 mm (0.024 ~ 0.028 in) ----
Cylinder head
Maximum warpage ---- 0.05 mm
(0.0020 in)
Item Standard Limit
2 - 4
SPEC
Camshaft
Drive system Chain drive (left) ----
Intake camshaft lobe dimensions
Measurement A 37.051 ~ 37.151 mm (1.4587 ~ 1.4626 in) 36.956 mm
(1.4550 in)
Measurement B 30.074 ~ 30.174 mm (1.1840 ~ 1.1880 in) 29.973 mm
(1.1800 in)
Exhaust camshaft lobe dimensions
Measurement A 37.053 ~ 37.153 mm (1.4588 ~ 1.4627 in) 36.956 mm
(1.4550 in)
Measurement B 30.091 ~ 30.191 mm (1.1847 ~ 1.1886 in) 29.194 mm
(1.1494 in)
Maximum camshaft runout ---- 0.030 mm
(0.0012 in)
Timing chain
Model/number of links DID SC.A-0404A SV/104 ----
Tensioning system Automatic ----
Rocker arms/rocker arm shafts
Rocker arm inside diameter 12.000 ~ 12.018 mm (0.4724 ~ 0.4731 in) 12.030 mm
(0.4736 in)
Rocker arm shaft outside diameter 11.981 ~ 11.991 mm (0.4717 ~ 0.4721 in) 11.950 mm
(0.4705 in)
Rocker-arm-to-rocker-arm-shaft
clearance
0.009 ~ 0.037 mm (0.0004 ~ 0.0015 in) 0.080 mm
(0.0031 in)
Item Standard Limit
A
B
A
B
2 - 5
SPEC
Valves, valve seats, valve guides
Valve clearance (cold)
Intake 0.08 ~ 0.12 mm (0.0031 ~ 0.0047 in) ----
Exhaust 0.16 ~ 0.20 mm (0.0063 ~ 0.0079 in) ----
Valve dimensions
Valve head diameter A
Intake 33.90 ~ 34.10 mm (1.3346 ~ 1.3425 in) ----
Exhaust 28.40 ~ 28.60 mm (1.1181 ~ 1.1260 in) ----
Valve face width B
Intake 3.394 ~ 3.960 mm (0.1336 ~ 0.1559 in) ----
Exhaust 3.394 ~ 3.960 mm (0.1336 ~ 0.1559 in) ----
Valve seat width C
Intake 0.90 ~ 1.10 mm (0.0354 ~ 0.0433 in) 1.6 mm
(0.06 in)
Exhaust 0.90 ~ 1.10 mm (0.0354 ~ 0.0433 in) 1.6 mm
(0.06 in)
Valve margin thickness D
Intake 0.80 ~ 1.20 mm (0.0315 ~ 0.0472 in) 0.5 mm
(0.02 in)
Exhaust 0.80 ~ 1.20 mm (0.0315 ~ 0.0472 in) 0.5 mm
(0.02 in)
Valve stem diameter
Intake 5.975 ~ 5.990 mm (0.2352 ~ 0.2358 in) 5.940 mm
(0.2339 in)
Exhaust 5.960 ~ 5.975 mm (0.2346 ~ 0.2352 in) 5.920 mm
(0.2331 in)
Valve guide inside diameter
Intake 6.000 ~ 6.012 mm (0.2362 ~ 0.2367 in) 6.050 mm
(0.2382 in)
Exhaust 6.000 ~ 6.012 mm (0.2362 ~ 0.2367 in) 6.050 mm
(0.2382 in)
Valve-stem-to-valve-guide clear-
ance
Intake 0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in) 0.080 mm
(0.0031 in)
Exhaust 0.025 ~ 0.052 mm (0.0010 ~ 0.0020 in) 0.100 mm
(0.0039 in)
Item Standard Limit
B
C
D
A
Head Diameter Face Width Seat Width Margin Thickness
2 - 6
SPEC
Valve stem runout ---- 0.010 mm
(0.0004 in)
Cylinder head valve seat width
Intake 0.90 ~ 1.10 mm (0.0354 ~ 0.0433 in) 1.6 mm
(0.06 in)
Exhaust 0.90 ~ 1.10 mm (0.0354 ~ 0.0433 in) 1.6 mm
(0.06 in)
Valve springs
Inner spring
Free length
Intake 38.10 mm (1.50 in) 36.10 mm
(1.42 in)
Exhaust 38.10 mm (1.50 in) 36.10 mm
(1.42 in)
Installed length (valve closed)
Intake 30.10 mm (1.19 in) ----
Exhaust 30.10 mm (1.19 in) ----
Spring rate - intake (K1) 10.29 N/mm (1.05 kgf/mm, 58.75 lb/in) ----
Spring rate - exhaust (K1) 10.29 N/mm (1.05 kgf/mm, 58.75 lb/in) ----
Compression spring force
(installed)
Intake 76 ~ 88 N
(7.80 ~ 9.00 kgf, 17.20 ~ 19.85 lbf)
----
Exhaust 76 ~ 88 N
(7.80 ~ 9.00 kgf, 17.20 ~ 19.85 lbf)
----
Spring tilt
Intake ---- 2.5/1.7 mm
(2.5/0.067 in)
Exhaust ---- 2.5/1.7 mm
(2.5/0.067 in)
Item Standard Limit
2 - 7
SPEC
Winding direction (top view)
Intake Counterclockwise ----
Exhaust Counterclockwise ----
Outer spring
Free length
Intake 36.93 mm (1.45 in) 35.00 mm
(1.38 in)
Exhaust 36.93 mm (1.45 in) 35.00 mm
(1.38 in)
Installed length (valve closed)
Intake 31.60 mm (1.24 in) ----
Exhaust 31.60 mm (1.24 in) ----
Compression spring force
(installed)
Intake 115 ~ 133 N (11.73 ~ 13.56 kgf,
25.85 ~ 29.90 lbf)
----
Exhaust 115 ~ 133 N (11.73 ~ 13.56 kgf,
25.85 ~ 29.90 lbf)
----
Spring tilt
Intake ---- 2.5/1.6 mm
(2.5/0.063 in)
Exhaust ---- 2.5/1.6 mm
(2.5/0.063 in)
Winding direction
Intake Clockwise ----
Exhaust Clockwise ----
Cylinder
Bore 69.000 ~ 69.005 mm (2.7165 ~ 2.7167 in) 69.100 mm
(2.7205 in)
Maximum taper ---- 0.050 mm
(0.0020 in)
Maximum out of round ---- 0.030 mm
(0.0012 in)
Item Standard Limit
2 - 8
SPEC
Piston
Piston-to-cylinder clearance 0.020 ~ 0.040 mm (0.0008 ~ 0.0016 in) 0.15 mm
(0.0059 in)
Diameter D 68.965 ~ 68.980 mm (2.7152 ~ 2.7157 in) ----
Height H 5.0 mm (0.20 in) ----
Piston pin bore (in the piston)
Diameter 17.004 ~ 17.015 mm (0.6694 ~ 0.6699 in) 17.045 mm
(0.6711 in)
Offset 0.50 mm (0.0197 in) ----
Offset direction Intake side ----
Piston pin
Outside diameter 16.991 ~ 17.000 mm (0.6689 ~ 0.6693 in) 16.971 mm
(0.6681 in)
Piston-pin-to-piston-pin-bore clear-
ance
0.004 ~ 0.024 mm (0.0002 ~ 0.0009 in) 0.074 mm
(0.0029 in)
Piston rings
Top ring
Ring type Barrel ----
Dimensions (B T) 1.00 2.60 mm (0.04 0.10 in) ----
End gap (installed) 0.15 ~ 0.30 mm (0.0059 ~ 0.0118 in) 0.45 mm
(0.0177 in)
Ring side clearance 0.040 ~ 0.080 mm (0.0016 ~ 0.0031 in) 0.120 mm
(0.0047 in)
2nd ring
Ring type Taper ----
End gap (installed) 0.30 ~ 0.45 mm (0.0118 ~ 0.0177 in) 0.70 mm
(0.0276 in)
Ring side clearance 0.030 ~ 0.070 mm (0.0012 ~ 0.0028 in) 0.120 mm
(0.0047 in)
Item Standard Limit
H
D
T
B
B
T
2 - 9
SPEC
Oil ring
End gap (installed) 0.20 ~ 0.70 mm (0.0079 ~ 0.0276 in) ----
Ring side clearance 0.060 ~ 0.150 mm (0.0024 ~ 0.0059 in) ----
Crankshaft
Width A 59.75 ~ 59.80 mm (2.352 ~ 2.354 in) ----
Maximum runout C ---- 0.030 mm
(0.0012 in)
Big end side clearance D 0.350 ~ 0.850 mm (0.0138 ~ 0.0335 in) ----
Big end radial clearance E 0.010 ~ 0.025 mm (0.0004 ~ 0.0010 in) ----
Automatic centrifugal clutch
Clutch type Dry, centrifugal automatic ----
Clutch shoe thickness 3.3 mm (0.13 in) 2.0 mm
(0.08 in)
Clutch shoe spring free length 31.3 mm (1.23 in) ----
Clutch housing inside diameter 145.0 mm (5.71 in) 145.5 mm
(5.73 in)
Compression spring free length 102.4 mm (4.03 in) 90.0 mm
(3.54 in)
Primary sheave weight outside diam-
eter
20.0 mm (0.79 in) 19.5 mm
(0.77 in)
Clutch-in revolution 2,250 ~ 2,850 r/min ----
Clutch-stall revolution 3,700 ~ 4,700 r/min ----
V-belt
V-belt width 23.0 mm (0.91 in) 21.0 mm
(0.83 in)
Transmission
Transmission type V-belt automatic ----
Primary reduction system Helical gear ----
Primary reduction ratio 40/15 (2.666) ----
Secondary reduction system Helical gear ----
Secondary reduction ratio 40/14 (2.857) ----
Operation Centrifugal automatic type ----
Single speed automatic 2.44 ~ 0.83 : 1 ----
Item Standard Limit
B
T
C
C
D
A
E
2 - 10
SPEC
Air filter
Air filter element Oil-coated paper element ----
Fuel pump
Pump type Electrical ----
Model/manufacturer 2GV0/MITSUBISHI ----
Output pressure 12.5 kPa (0.13 kgf/cm
2
, 1.8 psi) ----
Carburetor
Type quantity 1C0 1 ----
Manufacturer KEIHIN ----
ID mark 1C0D ----
Main jet #122 ----
Main air jet #90 ----
Jet needle N425-DVD00 ----
Needle jet 2.6 ----
Pilot air jet 1 #125 ----
Pilot outlet 0.85 ----
Pilot jet #35 ----
Bypass 1 0.7 ----
Bypass 2 0.7 ----
Bypass 3 0.7 ----
Bypass 4 0.7 ----
Pilot screw turns out 2 ----
Valve seat size 1.6 ----
Starter jet 1 #38 ----
Throttle valve size 10 ----
Float height 17.5 mm (0.69 in) ----
Idling condition
Engine idling speed 1,550 ~ 1,650 r/min ----
CO density (when air induction sys-
tem is operating)
4.0% ----
CO density (when air induction sys-
tem is not operating)
6.0% ----
Throttle cable free play 4.0 ~ 6.0 mm (0.16 ~ 0.24 in) ----
Item Standard Limit
2 - 11
SPEC
CHASSIS SPECIFICATIONS
Item Standard Limit
Frame
Frame type Steel tube underbone ----
Caster angle 28.00 ----
Trail 100.0 mm (3.94 in) ----
Front wheel
Wheel type Cast wheel ----
Rim
Size 15 MT3.50 ----
Material Aluminum ----
Wheel travel 94.0 mm (3.70 in) ----
Wheel runout
Maximum radial wheel runout ---- 1.0 mm
(0.04 in)
Maximum lateral wheel runout ---- 0.5 mm
(0.02 in)
Wheel axle bending limit ---- 0.03 mm
(0.0012 in)
Rear wheel
Wheel type Cast wheel ----
Rim
Size 14 MT3.75 ----
Material Aluminum ----
Wheel travel 83.0 mm (3.27 in) ----
Wheel runout
Maximum radial wheel runout ---- 1.0 mm
(0.04 in)
Maximum lateral wheel runout ---- 0.5 mm
(0.02 in)
Front tire
Tire type Tubeless ----
Size 120/70-15 M/C 56S or 56P ----
Manufacturer/model MICHELIN/GOLD STANDARD
PIRELLI/GTS23
----
Tire pressure (cold)
0 ~ 90 kg (0 ~ 198 lb) 190 kPa (1.90 kgf/cm
2
, 28 psi) ----
90 ~ 235 kg (198 ~ 518 lb) 210 kPa (2.10 kgf/cm
2
, 30 psi) ----
Maximum tire tread depth ---- 1.6 mm
(0.06 in)
2 - 12
SPEC
Rear tire
Tire type Tubeless ----
Size 140/70-14 M/C 68S or 68P ----
Manufacturer/model MICHELIN/GOLD STANDARD
PIRELLI/GTS24
----
Tire pressure (cold)
0 ~ 90 kg (0 ~ 198 lb) 220 kPa (2.20 kgf/cm
2
, 32 psi) ----
90 ~ 180 kg (198 ~ 397 lb) 250 kPa (2.50 kgf/cm
2
, 36 psi) ----
Maximum tire tread depth ---- 1.6 mm
(0.06 in)
Front brake
Brake type Single disc brake ----
Operation Right hand operation ----
Recommended fluid DOT 4 ----
Brake disc
Diameter thickness 267.0 5.0 mm (10.51 0.20 in) ----
Minimum thickness ---- 4.5 mm
(0.18 in)
Maximum deflection ---- 0.20 mm
(0.0079 in)
Brake pad lining thickness (inner) 4.5 mm (0.18 in) 0.5 mm
(0.02 in)
Brake pad lining thickness (outer) 4.5 mm (0.18 in) 0.5 mm
(0.02 in)
Master cylinder inside diameter 12.70 mm (0.50 in) ----
Caliper cylinder inside diameter 25.00 mm 1 and 28.00 mm 1 (0.98 in
1 and 1.10 in 1)
----
Rear brake
Brake type Single disc brake ----
Operation Left hand operation ----
Recommended fluid DOT 4 ----
Brake disc
Diameter thickness 240.0 5.0 mm (9.45 0.20 in) ----
Minimum thickness ---- 4.5 mm
(0.18 in)
Maximum deflection ---- 0.20 mm
(0.0079 in)
Brake pad lining thickness (inner) 5.3 mm (0.21 in) 0.8 mm
(0.03 in)
Brake pad lining thickness (outer) 5.3 mm (0.21 in) 0.8 mm
(0.03 in)
Master cylinder inside diameter 11.0 mm (0.43 in) ----
Caliper cylinder inside diameter 22.20 mm 2 (0.87 in 2) ----
Item Standard Limit
2 - 13
SPEC
Steering
Steering bearing type Angular bearing ----
Center to lock angle (left) 62.0 ----
Center to lock angle (right) 62.0 ----
Front suspension
Suspension type Telescopic fork ----
Front fork type Coil spring/oil damper ----
Front fork travel 110.0 mm (4.33 in) ----
Spring
Free length 308.0 mm (12.126 in) 301.87 mm
(11.885 in)
Installed length 277.4 mm (10.921 in) ----
Spring rate (K1) 8.00 N/mm (0.82 kgf/mm, 45.68 lb/in) ----
Spring stroke (K1) 0 ~ 80.0 mm (0 ~ 3.15 in) ----
Spring stroke (K2) 80.0 ~ 110.0 mm (3.15 ~ 4.33 in) ----
Inner tube outer diameter 36.0 mm (1.42 in) ----
Inner tube bending limit ---- 0.2 mm
(0.008 in)
Optional spring available No ----
Fork oil
Recommended oil Fork oil 15W or equivalent ----
Quantity (each front fork leg) 195.0 cm
3
(6.86 Imp.oz, 6.59 US oz) ----
Level (from the top of the inner
tube, with the inner tube fully com-
pressed, and without the fork
spring)
105.0 mm (4.13 in) ----
Item Standard Limit
2 - 14
SPEC
Rear suspension
Suspension type Unit swing ----
Rear shock absorber type Coil spring/oil damper ----
Rear shock absorber assembly travel 95.0 mm (3.74 in) ----
Spring
Free length 270.1 mm (10.63 in) 264.7 mm
(10.42 in)
Installed length 249 mm (9.80 in) ----
Spring stroke (K1) 0 ~ 42.0 mm (0 ~ 1.65 in) ----
Optional spring available No ----
Spring preload adjusting positions
Minimum 1 ----
Standard 1 ----
Maximum 4 ----
Item Standard Limit
2 - 15
SPEC
ELECTRICAL SPECIFICATIONS
Item Standard Limit
System voltage 12 V
Ignition system ----
Ignition system type CDI ----
Ignition timing (B.T.D.C.) 10.0 ----
Advancer type Digital ----
Pickup coil resistance 130 ~ 150 ----
CDI unit model/manufacturer 5510-F/MITSUBA ----
Ignition coil
Model/manufacturer 4719/MITSUBA ----
Minimum ignition spark gap 6 mm (0.24 in) ----
Primary coil resistance 0.225 ~ 0.275 at 25 C (77 F) ----
Secondary coil resistance 1.89 ~ 2.31 k at 25 C (77 F) ----
Spark plug cap
Material Resin ----
Resistance 10.0 k ----
Charging system
System type AC magneto
Model/manufacturer 5425-H/Mitsuba ----
Standard output 14.0 V, 235 W at 5,000 r/min ----
Stator coil resistance 0.385 ~ 0.415 at 20 C (68 F) ----
Rectifier/regulator
Regulator type Semi conductor-short circuit ----
Model/manufacturer SH678-11/SHINDENGEN ----
No-load regulated voltage 14.1 ~ 14.9 V ----
Rectifier capacity 22.0 A ----
Withstand voltage 200.0 V ----
Battery
Model YTX9-BS ----
Voltage, capacity 12 V, 8.0 Ah ----
Manufacturer YUASA ----
Ten hour rate amperage 0.8 A ----
Headlight
Bulb type Halogen bulb ----
Bulb (voltage, wattage quantity)
Headlight 12 V, 35.0 W/35.0 W 2 ----
Auxiliary light 12 V, 5.0 W 2 ----
Tail/brake light 12 V, 5.0 W/21.0 W 2 ----
Front turn signal light 12 V, 10.0 W 2 ----
Rear turn signal light 12 V, 10.0 W 2 ----
License plate light 12 V, 5.0 W 1 ----
2 - 16
SPEC
Indicator light
Meter lighting LED 1 ----
Turn signal indicator light LED 2 ----
High beam indicator light LED 1 ----
Fuel level warning light LED 1 ----
Immobilizer system indicator light LED 1 ----
Electric starting system
System type Constant mesh ----
Starter motor
Model/manufacturer SM-13/MITSUBA ----
Power output 0.65 kW ----
Brush
Overall length 10.0 mm (0.39 in) 4.0 mm
(0.16 in)
Spring force 7.65 ~ 10.01 N
(780 ~ 1,021 gf, 27.5 ~ 36.0 oz)
----
Armature coil resistance 0.0012 ~ 0.0022 at 20 C (68 F) ----
Commutator diameter 28.0 mm (1.10 in) 27.0 mm
(1.06 in)
Mica undercut (depth) 0.7 mm (0.028 in) ----
Starter relay
Model/manufacturer MS5F-631/JIDECO ----
Amperage 180.0 A ----
Coil resistance 4.18 ~ 4.62 at 20 C (68 F) ----
Horn
Horn type Plane ----
Quantity 1 pc ----
Model/manufacturer YF-12/NIKKO ----
Maximum amperage 3.0 A ----
Performance 105 ~ 113 dB/2 m ----
Coil resistance 1.15 ~ 1.25 at 20 C (68 F) ----
Turn signal/hazard relay
Relay type Full transistor ----
Model/manufacturer 01 8610A/GUILERA ----
Built-in, self-canceling device No ----
Turn signal blinking frequency 70.0 ~ 100.0 cycles/min ----
Wattage 10 W 2.0 + 1.2 W ----
Fuel sender
Model/manufacturer 1C0/BITRON ----
Sender unit resistance (full) 0 ~ 7 ----
Sender unit resistance (empty) 90 ~ 103 ----
Item Standard Limit
2 - 17
SPEC
Starting circuit cut-off relay
Model/manufacturer ACA12115 M02 ----
Coil resistance 72 ~ 88 at 20 C (68 F) ----
Headlight relay
Model/manufacturer ACM33211 M05 ----
Coil resistance 96 at 20 C (68 F) ----
Fuel pump relay
Radiator fan motor relay
Coolant temperature sensor
Model/manufacturer C40 1734/PRICOL ----
Resistance at 80 C (176 F) 69.0 ----
Resistance at 100 C (212 F) 37.2 ----
Speed sensor
Output voltage
When sensor is on DC 4.8 V or more ----
When sensor is off DC 0.6 V or less ----
Fuses
Main fuse 30.0 A ----
Headlight fuse 15.0 A ----
Signaling system fuse 15.0 A ----
Ignition fuse 5.0 A ----
Radiator fan motor fuse 10.0 A ----
CDI unit fuse 5.0 A ----
Backup fuse (meter assembly) 5.0 A ----
Reserve fuse 30.0 A ----
Item Standard Limit
2 - 18
SPEC
CONVERSION TABLE/
GENERAL TIGHTENING TORQUE SPECIFICATIONS
EAS00028
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.
CONVERSION TABLE
EAS00029
GENERAL TIGHTENING TORQUE
SPECIFICATIONS
This chart specifies tightening torques for stan-
dard fasteners with a standard ISO thread
pitch. Tightening torque specifications for spe-
cial components or assemblies are provided
for each chapter of this manual. To avoid
warpage, tighten multi-fastener assemblies in
a crisscross pattern and progressive stages
until the specified tightening torque is reached.
Unless otherwise specified, tightening torque
specifications require clean, dry threads. Com-
ponents should be at room temperature.
A: Distance between flats
B: Outside thread diameter
Ex.
METRIC MULTIPLIER IMPERIAL
** mm 0.03937 = ** in
2 mm 0.03937 = 0.08 in
METRIC TO IMPERIAL
Tighten-
ing torque
Metric unit Multiplier Imperial unit
mkg
mkg
cmkg
cmkg
7.233
86.794
0.0723
0.8679
ftlb
inlb
ftlb
inlb
Weight
kg
g
2.205
0.03527
lb
oz
Speed km/hr 0.6214 mph
Distance
km
m
m
cm
mm
0.6214
3.281
1.094
0.3937
0.03937
mi
ft
yd
in
in
Volume/
Capacity
cc (cm
3
)
cc (cm
3
)
lt (liter)
lt (liter)
0.03527
0.06102
0.8799
0.2199
oz (IMP lip.)
cu.in
qt (IMP liq.)
gal (IMP liq.)
Misc.
kg/mm
kg/cm
2
Centigrade
(C)
55.997
14.2234
9/5+32
lb/in
psi (lb/in
2
)
Fahrenheit (F)
A
(nut)
B
(bolt)
General tightening
torques
Nm m kg ft lb
10 mm 6 mm 6 0.6 4.3
12 mm 8 mm 15 1.5 11
14 mm 10 mm 30 3.0 22
17 mm 12 mm 55 5.5 40
19 mm 14 mm 85 8.5 61
22 mm 16 mm 130 13.0 94
2 - 19
SPEC
TIGHTENING TORQUES
TIGHTENING TORQUES
ENGINE TIGHTENING TORQUES
Item Part name
Thread
size
Qty
Tightening torque
Remarks
Nm m kg ft lb
Oil check bolt Bolt M6 1 7 0.7 5.1
Exhaust pipe stud bolt Bolt M8 2 13 1.3 9.4
Air induction system pipe stud bolt Bolt M6 2 10 1.0 7.2
Spark plug M12 1 18 1.8 13
Camshaft sprocket cover Bolt M6 2 10 1.0 7.2
Cylinder head and cylinder Nut M8 4 22 2.2 16 See page
2-20 for
tightening
sequence.
Cylinder head and cylinder Bolt M6 2 10 1.0 7.2
Tappet cover Bolt M6 5 10 1.0 7.2
Generator rotor Nut M16 1 80 8.0 58
Valve clearance adjusting screw lock-
nut
Nut M6 2 14 1.4 10
Camshaft retainer Bolt M6 2 8 0.8 5.8
Camshaft sprocket Bolt M10 1 60 6.0 43
Timing chain tensioner Bolt M6 2 10 1.0 7.2
Timing chain tensioner cap bolt Bolt M8 1 8 0.8 5.8
Timing chain guide (intake side) Bolt M6 1 10 1.0 7.2
Water pump housing cover Bolt M6 2 10 1.0 7.2
Water pump housing Bolt M6 2 10 1.0 7.2
Coolant drain bolt Bolt M6 1 10 1.0 7.2
Water pump outlet pipe Bolt M6 2 7 0.7 5.1
Thermostat cover Bolt M6 2 10 1.0 7.2
Oil pump assembly Bolt M6 2 7 0.7 5.1
Oil strainer cover M35 1 32 3.2 23
Intake manifold Bolt M6 2 10 1.0 7.2
Carburetor clamp screw Screw M6 1 2 0.2 1.4
Throttle cable bracket Bolt M5 2 11 1.1 8.0
Air induction system pipe Nut M6 2 12 1.2 8.7
Air cut-off valve assembly Bolt M6 2 10 1.0 7.2
Air cut-off valve assembly bracket Bolt M6 2 10 1.0 7.2
Crankcase Bolt M6 7 10 1.0 7.2
Cylinder head stud bolt Bolt M8 4 13 1.3 9.4
Engine oil drain bolt Bolt M12 1 20 2.0 14
Final transmission oil drain bolt Bolt M8 1 22 2.2 16
Final transmission oil filler plug M14 1 3 0.3 1.4
Transmission case cover Bolt M8 6 16 1.6 11
V-belt case Bolt M6 11 10 1.0 7.2
V-belt case cover Screw M6 4 7 0.7 5.1
Generator cover Bolt M6 10 10 1.0 7.2
Oil baffle plate Bolt M6 2 12 1.2 8.7
LT
2 - 20
SPEC
TIGHTENING TORQUES
Timing mark accessing plug M16 1 8 0.8 5.8
Starter clutch Bolt M8 3 30 3.0 22
LT
Secondary sheave Nut M14 1 60 6.0 43
Primary sheave cap Screw M4 4 3 0.3 2.2
Primary sheave Nut M14 1 80 8.0 58
Clutch carrier Nut M36 1 90 9.0 65
Secondary sheave bracket Bolt M8 4 22 2.2 16
LT
Stator coil Bolt M6 3 10 1.0 7.2
LT
Pickup coil Bolt M5 2 7 0.7 5.1
LT
Starter motor Bolt M6 2 10 1.0 7.2
Coolant temperature sensor Pt 1/8 1 8 0.8 5.8
LT
Air filter case mounting bolt Bolt M6 2 9 0.9 6.5
Exhaust pipe nut Nut M8 2 20 2.0 14
Muffler mounting bolt Bolt M12 3 65 6.5 47
Muffler joint bolt Bolt M8 1 14 1.4 10
Coolant reservoir Bolt M6 2 7 0.7 5.1
Radiator Bolt M6 2 10 1.0 7.2
Thermo switch (auto choke) M18 1 30 3.0 22
Thermo switch (radiator fan motor) M18 1 30 3.0 22
Cylinder head tightening sequence:
Item Part name
Thread
size
Qty
Tightening torque
Remarks
Nm m kg ft lb
2 - 21
SPEC
TIGHTENING TORQUES
CHASSIS TIGHTENING TORQUES
Item Thread size
Tightening torque
Remarks
Nm m kg ft lb
Frame and engine bracket M12 59 5.9 43
Frame and engine bracket rod M10 64 6.4 46
Engine bracket, engine bracket rod and engine M10 32 3.2 23
Frame and sidestand bolt M10 23 2.3 17
Frame and sidestand nut M10 40 4.0 29
Passenger footrest and frame M8 25 2.5 18
Grab bar and frame M8 23 2.3 17
Fuel tank and frame M6 7 0.7 5.1
Sidestand switch M5 6 0.6 4.3
Battery bracket and frame M8 23 2.3 17
Seat lock cable bracket and frame M6 10 1.0 7.2
Swingarm and engine M10 59 5.9 43
Rear brake hose holder and frame M6 7 0.7 5.1
Rear shock absorber and engine M8 18 1.8 13
Rear shock absorber and swingarm M8 18 1.8 13
Rear shock absorber and frame M10 32 3.2 23
Rear fender bracket and swingarm M8 16 1.6 11
Front wheel axle M14 59 5.9 43
Front wheel axle pinch bolt M6 9 0.9 6.5
Rear wheel axle nut M14 135 13.5 98
Front brake caliper and outer tube M8 23 2.3 17
Brake pad pin M8 12 1.2 8.7
Brake caliper retaining nut M8 22 2.2 16
Brake caliper housing bolt M10 45 4.5 32
Front brake disc and wheel hub M6 12 1.2 8.7
LT
Rear brake disc and wheel hub M8 23 2.3 17
LT
Brake hose union bolt M10 23 2.3 17
Bleed screw (front brake caliper) M7 6 0.6 4.3
Bleed screw (rear brake caliper) M7 6 0.6 4.3
Rear brake hose holder and frame M6 7 0.7 5.1
Rear brake caliper bracket and swingarm M10 40 4.0 29
Rear brake caliper retaining bolt M10 27 2.7 19
Steering stem nut M20 120 12.0 85
Upper handlebar holder and lower handlebar
holder
M8 23 2.3 17
Lower ring nut (initial tightening torque) M25 38 3.8 27 See NOTE.
Lower ring nut (final tightening torque) M25 22 2.2 16 See NOTE.
Upper ring nut M25 75 7.5 54 See NOTE.
Lower bracket pinch bolt M8 22 2.2 16
Damper rod bolt M10 28 2.8 20
Front brake master cylinder and holder M6 7 0.7 5.1
Front brake master cylinder and brake lever M6 10 1.0 7.2
2 - 22
SPEC
TIGHTENING TORQUES
NOTE:
1. Tighten the lower ring nut 38 Nm (3.8 m kg, 27 ft lb) with a torque wrench and the steering nut
wrench, and then loosen the nut 1/4 turn.
2. Tighten the lower ring nut 22 Nm (2.2 m kg, 16 ft lb) with a torque wrench and the steering nut
wrench.
3. Install the rubber washer and the center ring nut.
4. Finger tighten the center ring nut, align the slots of both ring nuts, and then install the lock
washer.
5. Hold the lower and center ring nuts, and then tighten the upper ring nut 75 Nm (7.5 m kg, 54 ft lb)
with a torque wrench and the steering nut wrench.
Rear brake master cylinder and holder M6 7 0.7 5.1
Rear brake master cylinder and brake lever M6 10 1.0 7.2
Grip end M16 26 2.6 19
Front cowling inner panel and frame M6 7 0.7 5.1
Radiator cover and frame M6 7 0.7 5.1
Rear side cover (left and right) and frame M6 7 0.7 5.1
Mudguard and frame M6 7 0.7 5.1
Footrest board and frame M6 7 0.7 5.1
Storage compartment and frame M6 7 0.7 5.1
Item Thread size
Tightening torque
Remarks
Nm m kg ft lb
2 - 23
SPEC
LUBRICATION POINTS AND LUBRICANT TYPES
EAS00031
ENGINE LUBRICATION POINTS AND LUBRICANT TYPES
Lubrication point Lubricant
Oil seal lips
LS
Bearings
E
O-rings
LS
Cylinder head nut mounting surface
E
Crankshaft pin
E
Connecting rod big end thrust surface
E
Rotary filter inner surface
E
Oil pump drive gear inner surface
E
Timing chain sprocket inner surface
E
Piston pin
E
Piston, ring grooves, and piston rings
E
Cylinder inner surface
E
Camshaft lobes M
Valve stems (intake and exhaust) M
Valve stem ends (intake and exhaust) M
Valve stem seals M
Rocker arm shafts
E
Rocker arm inner surface M
Oil pump assembly shaft
E
Oil pump assembly gasket
LS
Oil pump rotors (inner and outer)
E
Starter clutch idle gear thrust surfaces
E
Starter clutch idle gear shaft
E
Starter clutch gear thrust surfaces
E
Starter clutch gear inner surface
E
Main axle thrust surfaces
G
Main and drive axle serration
G
O-ring and collar (clutch housing)
LS
Primary sheave weights Shell BT grease 3
Secondary sheave
BEL-RAY assembly
lube
Oil seal (secondary sliding sheave)
BEL-RAY assembly
lube
Secondary sheave guide pins
BEL-RAY assembly
lube
Crankcase mating surfaces
Yamaha bond
No. 1215
2 - 24
SPEC
EAS00032
CHASSIS LUBRICATION POINTS AND LUBRICANT TYPES
Pickup coil/stator assembly lead grommet
Yamaha bond
No. 1215
Lubrication Point Symbol
Engine mounting bolt
LS
Swingarm oil seal lips
LS
Steering bearings (upper and lower)
LS
Throttle cable end
LS
Handlebar grip inner surface Rubber adhesive
Throttle grip inner surface and throttle cables
LS
Seat hinge pin
LS
Seat damper
LS
Front wheel oil seal lip
LS
Speed sensor oil seal lip
LS
Sidestand pivoting point and metal-to-metal moving parts
LS
Centerstand shaft pivoting point and metal-to-metal moving parts
LS
Centerstand stopper pivoting point
LS
Centerstand and sidestand spring hook metal-to-metal moving parts
LS
Lubrication point Lubricant
2 - 25
SPEC
COOLING SYSTEM DIAGRAMS
COOLING SYSTEM DIAGRAMS
1Radiator filler hose
2Radiator
3Coolant reservoir hose
4Coolant reservoir
5Thermostat inlet hose
6Thermostat outlet hose
7Water pump
8Radiator inlet/outlet pipe
9Radiator inlet hose
0Radiator outlet hose
ARadiator cap
BWater pump inlet hose
3 ~ 4 mm (0.12 ~ 0.16 in)
A B
B
A
1
2
3
4
5
6
7
8
8
9
0
A
B
6
8
8 9
0
1
2
3
A
6
2 - 26
SPEC
CABLE ROUTING
EAS00035
CABLE ROUTING
1Front brake hose
2Rear brake hose
3Rear brake light switch lead
4Front turn signal light coupler (left)
5Handlebar upper cover left switches coupler
6Handlebar upper cover right switches coupler
7Front turn signal light coupler (right)
8Front brake light switch lead
9Throttle cable (decelerator cable)
0Throttle cable (accelerator cable)
Connect the air temperature sensor coupler, and
then place the air temperature sensor in the
steering head pipe.
Connect the meter assembly coupler, and then
install the rubber cover.
Apply grease to the throttle cable ends and rub-
ber covers.
A
C
C
B
C-C
A
B
1
0
2
0
9
0
9
2
0
9
7
6
2
4
5
1
3
1
8
9
8
7
6
5
4
3
2 - 27
SPEC
CABLE ROUTING
After connecting the throttle cables, check the
operation of the throttle grip and make sure that
it returns to its home position easily after being
released.
A
C
C
B
C-C
A
B
1
0
2
0
9
0
9
2
0
9
7
6
2
4
5
1
3
1
8
9
8
7
6
5
4
3
2 - 28
SPEC
CABLE ROUTING
1Wire harness
2Rear brake hose
3Front brake hose
4Turn signal relay
5Fuse box
6Seat lock cable
7Headlight assembly coupler
8Starter motor lead
9Headlight relay
0Radiator fan motor relay
ASpeed sensor lead
BRadiator filler hose
CRadiator fan motor coupler
DFuel pump coupler
EThermo switch (radiator fan motor)
FThermo switch (auto choke)
GCoolant reservoir hose
HFuel pump
IFuel hose (fuel tank to fuel pump)
JFuel hose (fuel pump to carburetor)
KGround lead
LFuel sender lead
K
L
M
N
O
P
1
1
O
P
3
Q
1
2
3
4
5
6
8
9
0
A
C
D
G H I J
7

A
B
A
B
E F
B
2 - 29
SPEC
CABLE ROUTING
MStarting circuit cut-off relay
NFuel pump relay
OMain switch coupler
Pimmobilizer antenna coupler
QThrottle cables
Fasten the wire harness with a plastic locking
tie, making sure to fasten the wire harness at the
tape.
Be sure to leave a little slack in the speed sensor
lead since the front fork moves 10 mm (0.040 in)
vertically.
Fasten the front brake hose and speed sensor
lead with a holder, making sure to fasten the
front brake hose at the white tape.
15 mm (0.60 in)
To horn, and rectifier/regulator
Connect each thermo switch connectors (radia-
tor fan motor) to the switch terminals of the
same color.
K
L
M
N
O
P
1
1
O
P
3
Q
1
2
3
4
5
6
8
9
0
A
C
D
G H I J
7

A
B
A
B
E F
B
2 - 30
SPEC
CABLE ROUTING
Connect each thermo switch connectors (auto
choke) to the switch terminals of the same color.
Fasten the coolant reservoir hose, fuel pump
lead, radiator fan motor lead and thermo switch
leads (radiator fan motor and auto choke unit) to
the frame with a plastic locking tie.
Fasten the coolant reservoir hose to the frame
with a plastic locking tie.
Fasten the wire harness, rear brake pipe, starter
motor lead and sidestand switch lead with a
plastic locking tie.
Fasten the wire harness and starter motor lead
to the frame with a plastic locking tie.
Fasten the rear brake pipe with a plastic locking
tie.
Fasten the wire harness, relay leads (headlight
relay, radiator fan motor relay, fuel pump relay
and starting circuit cut-off relay), starter motor
lead and radiator filler hose with a plastic locking
tie.
K
L
M
N
O
P
1
1
O
P
3
Q
1
2
3
4
5
6
8
9
0
A
C
D
G H I J
7

A
B
A
B
E F
B
2 - 31
SPEC
CABLE ROUTING
Fasten the wire harness, rear brake pipe, starter
motor lead and speed sensor lead to the frame
with a plastic locking tie, making sure to fasten
the wire harness at the tape.
Fasten the main switch lead, immobilizer
antenna lead, speed sensor lead and wire har-
ness to the frame with a plastic locking tie, mak-
ing sure to position the tie between the blue tape
sections of the wire harness and to fasten the tie
around the lead protectors, not the leads them-
selves.
Fasten the speed sensor lead with a plastic lock-
ing tie, making sure to install the tie around the
protective sleeve of the lead, not the lead itself,
and then connect the speed sensor coupler
Cover the anti-theft alarm LED connector
(OPTION) and auxiliary DC jack fuse connector
(OPTION) with the protector.
K
L
M
N
O
P
1
1
O
P
3
Q
1
2
3
4
5
6
8
9
0
A
C
D
G H I J
7

A
B
A
B
E F
B
2 - 32
SPEC
CABLE ROUTING
1Tail/brake light assembly coupler (right)
2License plate light
3Wire harness
4Rear brake hose
5Starter motor lead
6Ignition coil
7Spark plug lead
8Coolant reservoir
9Coolant reservoir hose
Route the license plate light lead as shown in
the illustration.
Fasten the wire harness, tail/brake light lead and
license plate light lead with a plastic locking tie.
Fasten the wire harness with the holder
Fasten the wire harness, starter motor lead,
pickup coil/stator assembly lead with to the
frame with a plastic locking tie.
1
A
2 3 4
6
5 6 7
8 9

A
2 - 33
SPEC
CABLE ROUTING
Fasten the wire harness, starter motor lead, rear
brake pipe, pickup coil/stator assembly lead to
Connect each ignition coil connectors to the coil
terminals of the same color.
1
A
2 3 4
6
5 6 7
8 9

A
2 - 34
SPEC
CABLE ROUTING
2Seat lock cable
3Starter motor lead
4Starter relay
5Positive battery lead
6Front brake hose
7Rear brake hose
8Battery
9Throttle cables
0Horn lead
ASidestand switch lead
BFuel hose (fuel pump to carburetor)
CFuel tank overflow hose
Pass the battery lead through the opening in the
battery box.
Route the horn lead to the rear of the frame.
Fasten the seat lock cable and throttle cables to
Fasten the seat lock cable, throttle cables and
sidestand switch lead to the frame with a plastic
locking tie.
1
2 3 4 5 6 7
8
9
0
C
A B

2 - 35
SPEC
CABLE ROUTING
Fasten the sidestand switch lead to the frame
Pass the fuel tank overflow hose through the
hole in the under cover.
1
2 3 4 5 6 7
8
9
0
C
A B

2 - 36
SPEC
CABLE ROUTING
1Fuel hose (fuel pump to carburetor)
2Throttle cables
3Seat lock cable
4Tail/brake light assembly coupler (left)
5Water pump
6Carburetor overflow hose
7Tail/brake light assembly coupler (right)
8Anti-theft alarm lead (OPTION)
9Anti-theft alarm (OPTION)
Fasten the seat lock cable and throttle cables
with a plastic locking tie, making sure to fasten
the throttle cables at the mark
Pass the seat lock cable through the frame tube.
Route the carburetor overflow hose to the out-
side of the water pump.
Fasten the anti-theft alarm lead (OPTION) and
tail/brake light assembly lead (left) to the frame
1
2
6 5
4
7
8
9

3
3
4
A
A
2 - 37
SPEC
CABLE ROUTING
Fasten the tail/brake light assembly lead (left) to
Fasten the anti-theft coupler (OPTION) to the
frame with a plastic locking tie.
1
2
6 5
4
7
8
9

3
3
4
A
A
2 - 38
SPEC
CABLE ROUTING
1Fuse box
2Wire harness
3Rear brake hose
4Throttle cables
5Front brake hose
6CDI unit
7Starter relay
8Ground coupler
0Rectifier/regulator
AHorn
BSpeed sensor coupler
CMain switch coupler
DTurn signal relay
ESeat lock cable
To wire harness
Pass the speed sensor lead through the hole in
the inner fender.
E
D
C
B
A
9
8
7 6 5 4 3 2 1
0
2 - 39
SPEC
CABLE ROUTING
1Fuel hose (fuel tank to fuel pump)
2Fuel hose (fuel pump to carburetor)
3Sidestand switch coupler
4Starter motor lead
5Starter motor
6Ground lead
7Seat lock cable
8Throttle cables
9Carburetor overflow hose
0Auto choke unit lead
AAir induction system vacuum hose
BFuel sender lead
Fasten the sidestand switch lead to the frame
cross member with a plastic locking tie.
Route the fuel hose (fuel tank to fuel pump) and
fuel hose (fuel pump to carburetor) over the fuel
sender lead.
After connecting the pickup coil/stator assembly
coupler, slide the boot over the couplers as
shown the illustration
A
0
9
8
7
6
5
4
3
2
1
B
2 - 40
SPEC
CABLE ROUTING
Fasten the starter motor lead and ground lead
with the holder, making sure to align the white
tape on the starter motor lead with the holder.
Pass the auto choke unit lead and air induction
system vacuum hose with a plastic locking tie.
Fasten the grommet on the fuel hose (fuel pump
to carburetor) with the holder.
A
0
9
8
7
6
5
4
3
2
1
B
CHK
ADJ
CHAPTER 3
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION.............................................................................................. 3-1
PERIODIC MAINTENANCE AND LUBRICATION CHART............................ 3-1
COVERS AND PANELS.................................................................................. 3-3
SEAT AND SIDE COVERS....................................................................... 3-3
FOOTREST BOARD................................................................................. 3-4
HANDLEBAR COVERS ............................................................................ 3-5
STORAGE COMPARTMENT.................................................................... 3-6
AIR FILTER CASE .......................................................................................... 3-7
ENGINE ........................................................................................................... 3-8
ADJUSTING THE VALVE CLEARANCE .................................................. 3-8
ADJUSTING THE ENGINE IDLING SPEED........................................... 3-11
CHECKING THE EXHAUST GAS AT IDLE ............................................ 3-12
CHECKING AND ADJUSTING THE EXHAUST GAS AT IDLE .............. 3-13
ADJUSTING THE THROTTLE CABLE FREE PLAY .............................. 3-15
CHECKING THE SPARK PLUG ............................................................. 3-16
CHECKING THE IGNITION TIMING....................................................... 3-17
MEASURING THE COMPRESSION PRESSURE.................................. 3-19
CHECKING THE ENGINE OIL LEVEL.................................................... 3-21
CHANGING THE ENGINE OIL ............................................................... 3-22
CHANGING THE FINAL TRANSMISSION OIL....................................... 3-24
REPLACING THE AIR FILTER ELEMENT ............................................. 3-25
CLEANING THE V-BELT CASE AIR FILTER ELEMENT ....................... 3-26
CHECKING THE FUEL AND VACUUM HOSES .................................... 3-27
CHECKING THE BREATHER HOSES ................................................... 3-27
CHECKING THE EXHAUST SYSTEM.................................................... 3-28
CHECKING THE COOLANT LEVEL....................................................... 3-29
CHECKING THE COOLING SYSTEM.................................................... 3-29
CHANGING THE COOLANT................................................................... 3-30
CHK
ADJ
CHASSIS....................................................................................................... 3-34
CHECKING THE BRAKE FLUID LEVEL................................................. 3-34
CHECKING THE FRONT AND REAR BRAKE PADS ............................ 3-35
CHECKING THE FRONT AND REAR BRAKE HOSES.......................... 3-35
BLEEDING THE HYDRAULIC BRAKE SYSTEM ................................... 3-36
CHECKING AND ADJUSTING THE STEERING HEAD......................... 3-37
CHECKING THE FRONT FORK............................................................. 3-39
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLIES .............. 3-40
CHECKING THE TIRES.......................................................................... 3-40
CHECKING THE WHEELS..................................................................... 3-43
CHECKING AND LUBRICATING THE CABLES .................................... 3-44
LUBRICATING THE SIDESTAND........................................................... 3-44
LUBRICATING THE CENTERSTAND.................................................... 3-44
ELECTRICAL SYSTEM................................................................................. 3-45
CHECKING AND CHARGING THE BATTERY....................................... 3-45
CHECKING THE FUSES ........................................................................ 3-51
REPLACING THE HEADLIGHT BULBS................................................. 3-53
ADJUSTING THE HEADLIGHT BEAM................................................... 3-54
3 - 1
CHK
ADJ
EAS00036
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments.
If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a
longer service life and reduce the need for costly overhaul work. This information applies to vehicles
already in service as well as to new vehicles that are being prepared for sale. All service technicians
should be familiar with this entire chapter.
EAU17705
PERIODIC MAINTENANCE AND LUBRICATION CHART
NOTE:
The annual checks must be performed every year, except if a kilometer-based maintenance
is performed instead.
From 50000 km, repeat the maintenance intervals starting from 10000 km.
Items marked with an asterisk should be performed by a Yamaha dealer as they require special
tools, data and technical skills.
No ITEM CHECK OR MAINTENANCE JOB
ODOMETER READING ( 1000 Km)
ANNUAL
CHECK
1 10 20 30 40
1 * Fuel line
Check fuel and vacuum hoses for cracks or dam-
age.

2 Spark plug
Check condition.
Clean and regap.

Replace.
3 * Valves
Check valve clearance.
Adjust.

4 Air filter element Replace.
5 *
V-belt case air fil-
ter elements
Clean.
Replace.
6 * Front brake
Check operation, fluid level and vehicle for fluid
leakage.

Replace brake pads. Whenever worn to the limit
7 * Rear brake
Check operation, fluid level and vehicle for fluid
leakage.

Replace brake pads. Whenever worn to the limit
8 * Brake hose
Check for cracks or damage.
Replace. Every 4 years
9 * Wheels Check runout and for damage.
10 * Tires
Check tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.

11 * Wheel bearings Check bearing for looseness or damage.
12 * Steering bearings
Check bearing play and steering for roughness.
Lubricate with lithium-soap-based grease. Every 20000 km
13 * Chassis fasteners
Make sure that all nuts, bolts and screws are
properly tightened.

14
Sidestand, center-
stand
Check operation.
Lubricate.

INTRODUCTION/
3 - 2
CHK
ADJ
EAU18660
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 cylinder and caliper, and
change the brake fluid.
Replace the brake hoses every four years and if cracked or damaged.
15 * Sidestand switch Check operation.
16 * Front fork Check operation and for oil leakage.
17 *
Shock absorber
assemblies
Check operation and shock absorbers for oil leak-
age.

18 * Carburetor Adjust engine idling speed.
19 Engine oil
Change.
When the oil change
indicator light comes on (every 3000 km)
Check oil level and vehicle for oil leakage. Every 3000 km
20 * Engine oil strainer Clean.
21 * Cooling system
Check coolant level and vehicle for coolant leak-
age.

Change. Every 3 years
22
Final transmission
oil
Check vehicle for oil leakage.
Change.
23 * V-belt Replace. Every 20000 km
24 *
Front and rear
brake switches
Check operation.
25
Moving parts and
cables
Lubricate.
26 *
Throttle grip hous-
ing and cable
Check operation and free play.
Adjust the throttle cable free play if necessary.
Lubricate the throttle grip housing and cable.

27 *
Muffler and
exhaust pipe
Check the screw clamp for looseness.
28 *
Lights, signals and
switches
Check operation.
Adjust headlight beam.

No ITEM CHECK OR MAINTENANCE JOB
ODOMETER READING ( 1000 Km)
ANNUAL
CHECK
1 10 20 30 40
3 - 3
CHK
ADJ
COVERS AND PANELS
EAS00038
COVERS AND PANELS
SEAT AND SIDE COVERS
3
6
7
3
4
9
1
2
7
6
5
5
8
T R .
.
7 Nm (0.7 m kg, 5.1 ft Ib) T R .
.
7 Nm (0.7 m kg, 5.1 ft Ib) T R .
.
23 Nm (2.3 m kg, 17 ft Ib)
T R .
.
7 Nm (0.7 m kg, 5.1 ft Ib)
T R .
.
23 Nm (2.3 m kg, 17 ft Ib)
T R .
.
7 Nm (0.7 m kg, 5.1 ft Ib)
(4)
Order Job/Part Qty Remarks
Removing the seat and side covers Remove the parts in the order listed.
1 Seat 1
2 Storage box 1
3 Grab bar 2
4 Rear cover 1
5 Tail/brake light assembly coupler (left
and right)
2 Disconnect.
6 Rear side cover (left and right) 2
7 Tail/brake light assembly (left and right) 2
8 License plate light coupler 1 Disconnect.
9 Mudguard 1
For installation, reverse the removal pro-
cedure.
3 - 4
CHK
ADJ
COVERS AND PANELS
EAS00040
FOOTREST BOARD
6
8
5
2
3
1
4
8
3
1
4
5
2
9
10
7
T R .
.
7 Nm (0.7 m kg, 5.1 ft Ib)
T R .
.
7 Nm (0.7 m kg, 5.1 ft Ib)
LS
Removing the footrest board Remove the parts in the order listed.
1 Center panel 1 (left and right) 2
2 Protector (left and right) 2
3 Center panel 2 (left and right) 2
4 Footrest board mat (left and right) 2
5 Front panel (left and right) 2
6 Fuel tank cap 1
7 Seat damper 1
8 Footrest board 1
9 Fuel tank overflow hose 1
10 Under cover 1
cedure.
3 - 5
CHK
ADJ
COVERS AND PANELS
EAS00042
HANDLEBAR COVERS
3
1
9
2
2
5
6
8
7
4
4
(4)
(5)
Removing the handlebar covers Remove the parts in the order listed.
1 Front turn signal light assembly 1
2 Front turn signal light coupler 2 Disconnect.
3 Windshield 1
4 Rearview mirror (left and right) 2
5 Handlebar upper cover right switch
coupler
1 Disconnect.
6 Handlebar upper cover left switch cou-
pler
1 Disconnect.
7 Handlebar upper cover (with meter
assembly)
1
8 Meter assembly coupler 1 Disconnect.
9 Handlebar lower cover 1
cedure.
3 - 6
CHK
ADJ
COVERS AND PANELS
EAS00043
STORAGE COMPARTMENT
1
3
5
4
2
T R .
.
7 Nm (0.7 m kg, 5.1 ft Ib)
Removing the storage compartment Remove the parts in the order listed.
1 Upper panel 1
2 Headlight assembly coupler 1 Disconnect.
3 Front cowling 1
4 Battery cover 1
5 Storage compartment 1
cedure.
3 - 7
CHK
ADJ
AIR FILTER CASE
AIR FILTER CASE
1 2
3
(3)
(6)
T R .
.
9 Nm (0.9 m kg, 6.5 ft Ib)
Removing the air filter case assem-
bly
Remove the parts in the order listed.
Storage box Refer to COVERS AND PANELS.
1 Cylinder head breather hose 1
2 Air induction system hose (air filter
case to air cut-off valve assembly)
1
3 Air filter case assembly 1
cedure.
3 - 8
CHK
ADJ
ADJUSTING THE VALVE CLEARANCE
EAS00049
ENGINE
The following procedure applies to all of the
valves.
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 top dead
center (TDC) on the compression stroke.
1. Remove:
storage box
footrest board
Refer to COVERS AND PANELS.
2. Remove:
V-belt case air filter cover 1
3. Remove:
spark plug
tappet covers (intake and exhaust) 1
camshaft sprocket cover 2
1
2
1
4. Remove:
timing mark accessing plug 1
1
3 - 9
CHK
ADJ
5. Measure:
valve clearance
Out of specification Adjust.
MMM M M MMM M M MMM M M MMM M M MMM M M MMM M MMM
a. Turn the primary sheave nut on the left side
of the crankshaft counterclockwise to turn
the crankshaft.
b. When the piston is at TDC on the compres-
sion stroke, align the I mark a on the
camshaft sprocket with the stationary
pointer b on the cylinder head.
c. Align the I mark c on the generator rotor
with the stationary pointer d on the genera-
tor cover.
d. Measure the valve clearance with a thick-
ness gauge 1.
LLL L L LLL L L LLL L L LLL L L LLL L L LLL L LLL
Valve clearance (cold)
Intake valve
0.08 ~ 0.12 mm
(0.0031 ~ 0.0047 in)
Exhaust valve
0.16 ~ 0.20 mm
(0.0063 ~ 0.0079 in)
b
a
3 - 10
CHK
ADJ
6. Adjust:
valve clearance
a. Loosen the locknut 1.
b. Insert a thickness gauge between the end
of the adjusting screw and the valve tip.
c. Turn the adjusting screw 2 in direction a
or b until the specified valve clearance is
obtained.
d. Hold the adjusting screw to prevent it from
moving and tighten the locknut to the speci-
fied torque.
e. Measure the valve clearance again.
f. If the valve clearance is still out of specifica-
tion, repeat all of the valve clearance adjust-
ment steps until the specified clearance is
obtained.
7. Install:
timing mark accessing plug
8. Install:
camshaft sprocket cover
O-rings
tappet covers (intake and exhaust)
spark plug
9. Install:
V-belt case air filter cover
10.Install:
footrest board
storage box
Direction a
Valve clearance is
increased.
Direction b
Valve clearance is
decreased.
Tappet adjusting tool
90890-01311
T

R
.
.
Locknut
14 Nm (1.4 m kg, 1.0 ft lb)
T R .
.
8 Nm (0.8 m kg, 5.8 ft lb)
T R .
.
10 Nm (1.0 m kg, 7.2 ft lb)
New
T R .
.
10 Nm (1.0 m kg, 7.2 ft lb)
T R .
.
18 Nm (1.8 m kg, 13 ft lb)
3 - 11
CHK
ADJ
ADJUSTING THE ENGINE IDLING SPEED
EAS00054
ADJUSTING THE ENGINE IDLING SPEED
NOTE:
Prior to adjusting the engine idling speed, the
air filter element should be cleaned, and the
engine should have adequate compression.
1. Remove:
storage box
2. Start the engine and warm it up for several
minutes.
3. Connect:
engine tachometer
(to the spark plug lead)
4. Check:
engine idling speed
5. Adjust:
engine idling speed
a. Turn the pilot screw 1 in or out until it is
lightly seated.
b. Turn the pilot screw out the specified num-
ber of turns.
c. Turn the throttle stop screw 2 in direction
a or b until the specified engine idling
speed is obtained.
Engine idling speed
1,550 ~ 1,650 r/min
Pilot screw
2 turns out
Direction a
Engine idling speed is
increased.
Direction b
Engine idling speed is
decreased.
2
a
1
b
3 - 12
CHK
ADJ
ADJUSTING THE ENGINE IDLING SPEED/
CHECKING THE EXHAUST GAS AT IDLE
6. Adjust:
throttle cable free play
Refer to ADJUSTING THE THROTTLE
CABLE FREE PLAY.
Throttle cable free play
(at the flange of the throttle grip)
4.0 ~ 6.0 mm (0.16 ~ 0.24 in)
CHECKING THE EXHAUST GAS AT IDLE
Check the exhaust gas at idle when the air
induction system is operating.
1. Stand the vehicle on a level surface.
NOTE:
Place the vehicle on a suitable stand.
Make sure that the vehicle is upright.
2. Remove:
storage box
3. Remove:
exhaust pipe bolt 1
1
4. Connect:
temperature probe tester 1
(to the engine oil drain bolt)
engine tachometer
exhaust attachment 2
(to the exhaust pipe)
5. Start the engine and warm it up until the
specified oil temperature is reached.
Exhaust attachment
90890-03134
Oil temperature
65 ~ 75 C (149 ~ 167 F)
2
3 - 13
CHK
ADJ
CHECKING THE EXHAUST GAS AT IDLE/CHECKING
AND ADJUSTING THE EXHAUST GAS AT IDLE
6. Measure:
engine idling speed
Refer to ADJUSTING THE ENGINE
IDLING SPEED.
Engine idling speed
1,550 ~ 1,650 r/min
7. Connect:
CO tester 1
(to the exhaust attachment)
8. Measure:
CO density
Out of specification Check air induction
system.
Refer to AIR INDUCTION SYSTEM in
chapter 7.
CO density (when air induction
system is operating)
4.0%
(Reference value)
CHECKING AND ADJUSTING THE
EXHAUST GAS AT IDLE
Check the exhaust gas at idle when the air
induction system is not operating.
NOTE:
Place the vehicle on a suitable stand.
The air filter element should be cleaned, and
the engine should have adequate compres-
sion.
2. Remove:
footrest board
3. Remove:
exhaust pipe bolt 1
1
3 - 14
CHK
ADJ
CHECKING AND ADJUSTING THE EXHAUST GAS AT
IDLE
4. Connect:
temperature probe tester 1
(to the engine oil drain bolt)
engine tachometer
exhaust attachment 2
(to the exhaust pipe)
Exhaust attachment
90890-03134
2
5. Stop air induction system operation.
NOTE:
Crimp the hose a running from the lead valve
to the air cut-off valve to prevent the air cut-off
valve from operating.
Be sure not to damage the hose while crimping
it.
6. Start the engine and warm it up until the
specified oil temperature is reached.
7. Measure:
engine idling speed
IDLING SPEED.
8. Connect:
CO tester 1
(to the exhaust attachment)
Oil temperature
65 ~ 75 C (149 ~ 167 F)
Engine idling speed
1,550 ~ 1,650 r/min
a
3 - 15
CHK
ADJ
CHECKING AND ADJUSTING THE EXHAUST GAS AT
IDLE/ADJUSTING THE THROTTLE CABLE FREE PLAY
9. Measure:
CO density
Within specification Checking the air
induction system.
Refer to AIR INDUCTION SYSTEM in
chapter 7.
10.Adjust:
pilot screw 1
If the CO density cannot be adjusted by adjust-
ing the pilot screw, overhaul the carburetor
and check the air filter.
If there are no problems found with the carbu-
retor or air filter, replace the muffler assembly.
11.Install:
footrest board
CO density (when air induction
system is not operating)
6.0%
Pilot screw
2 turns out
1
EAS00058
ADJUSTING THE THROTTLE CABLE FREE
PLAY
1. Check:
throttle cable free play a
4.0 ~ 6.0 mm (0.16 ~ 0.24 in)
a
3 - 16
CHK
ADJ
ADJUSTING THE THROTTLE CABLE FREE PLAY/
CHECKING THE SPARK PLUG
2. Remove:
front turn signal light assembly
a. Slide back the rubber cover 1.
b. Loosen the locknut 2.
c. Turn the adjusting nut 3 in direction a or
b until the specified throttle cable free play
is obtained.
d. Tighten the locknut.
e. Slide the rubber cover to its original posi-
tion.
WARNING
After adjusting the throttle cable free play,
start the engine and turn the handlebar to
the right or left to ensure that this does not
cause the engine idling speed to change.
3. Install:
front turn signal light assembly
Direction a
is increased.
Direction b
is decreased.
2
3
1
a
b
EAS00060
CHECKING THE SPARK PLUG
1. Remove:
storage box
2. Disconnect:
spark plug cap
3. Remove:
spark plug
CAUTION:
Before removing the spark plug, blow away
any dirt accumulated in the spark plug well
with compressed air to prevent it from fall-
ing into the cylinder.
3 - 17
CHK
ADJ
CHECKING THE SPARK PLUG/
CHECKING THE IGNITION TIMING
4. Check:
spark plug type
Incorrect Change.
5. Check:
electrode 1
Damage/wear Replace the spark plug.
insulator 2
Abnormal color Replace the spark plug.
Normal color is medium-to-light tan.
6. Clean:
spark plug
(with a spark plug cleaner or wire brush)
7. Measure:
spark plug gap a
(with a wire thickness gauge)
Out of specification Regap.
8. Install:
spark plug
NOTE:
Before installing the spark plug, clean the
spark plug and gasket surface.
9. Connect:
spark plug cap
10.Install:
storage box
EAS00064
NOTE:
Prior to checking the ignition timing, check the
wiring connections of the entire ignition sys-
tem. Make sure that all connections are tight
and free of corrosion.
NOTE:
Place a vehicle on the centerstand.
Spark plug type (manufacturer)
DR8EA (NGK)
Spark plug gap
0.6 ~ 0.7 mm (0.024 ~ 0.028 in)
T R .
.
18 Nm (1.8 m kg, 13 ft lb)
3 - 18
CHK
ADJ
2. Remove:
storage box
3. Remove:
timing mark accessing plug 1
1
4. Connect:
timing light 1
engine tachometer
Timing light
90890-03141
5. Check:
ignition timing
a. Start the engine, warm it up for several min-
utes, and then let it run at the specified
engine idling speed.
b. Check that the stationary pointer a on the
generator cover is within the firing range b
on the generator rotor.
Incorrect firing range Check the ignition
system.
NOTE:
The ignition timing is not adjustable.
6. Install:
timing mark accessing plug
7. Install:
storage box
Engine idling speed
1,550 ~ 1,650 r/min
T R .
.
8 Nm (0.8 m kg, 5.8 ft lb)
3 - 19
CHK
ADJ
MEASURING THE COMPRESSION PRESSURE
EAS00067
MEASURING THE COMPRESSION
PRESSURE
NOTE:
Insufficient compression pressure will result in
a loss of performance.
1. Remove:
storage box
2. Measure:
valve clearance
Refer to ADJUSTING THE VALVE
CLEARANCE.
3. Start the engine, warm it up for several min-
utes, and then turn it off.
4. Disconnect:
spark plug cap
5. Remove:
spark plug
CAUTION:
Before removing the spark plug, use com-
pressed air to blow away any dirt accumu-
lated in the spark plug well to prevent it
from falling into the cylinder.
6. Install:
compression gauge 1
Compression gauge
90890-03081
1
3 - 20
CHK
ADJ
MEASURING THE COMPRESSION PRESSURE
7. 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 compression
gauge stabilizes.
WARNING
To prevent sparking, ground the spark plug
lead before cranking the engine.
c. If the compression pressure is above the
maximum specification, check the cylinder
head, valve surfaces, and piston crown for
carbon deposits.
Carbon deposits Eliminate.
d. If the compression pressure is below the
minimum specification, pour a teaspoonful
of engine oil into the spark plug bore and
measure again.
Refer to the following table.
Compression pressure
(at sea level)
Minimum
1,120 kPa
(11.2 kg/cm
2
, 159.3 psi)
Standard
1,400 kPa
(14.0 kg/cm
2
, 199.1 psi)
Maximum
1,570 kPa
(15.7 kg/cm
2
, 223.3 psi)
Compression pressure
(with oil applied into the cylinder)
Reading Diagnosis
Higher than with-
out oil
Piston ring(s) wear
or damage
Repair.
Same as without
oil
Piston, valves, cyl-
inder head gasket
or piston ring(s)
possibly defective
Repair.
3 - 21
CHK
ADJ
MEASURING THE COMPRESSION PRESSURE/
CHECKING THE ENGINE OIL LEVEL
8. Install:
spark plug
9. Connect:
spark plug cap
10.Install:
storage box
T R .
.
18 Nm (1.8 m kg, 13 ft lb)
EAS00070
CHECKING THE ENGINE OIL LEVEL
NOTE:
Place the vehicle on a centerstand.
3. Check:
engine oil level
Wipe the dipstick 1 clean, insert it into the
oil filler hole (without screwing it in), and
then remove it to check the oil level.
The engine oil level should be between the
minimum level mark a and maximum level
mark b.
Below the minimum level mark Add the
recommended engine oil to the proper level.
NOTE:
Before checking the engine oil level, wait a
few minutes until the oil has settled.
Do not screw the dipstick in when inspecting
the oil level.
CAUTION:
Do not allow foreign materials to enter the
crankcase.
Recommended engine oil type
SAE10W30, SAE10W40,
SAE15W40, SAE20W40, or
SAE20W50
Recommended engine oil grade
API service SG type or higher,
JASO standard MA
3 - 22
CHK
ADJ
CHECKING THE ENGINE OIL LEVEL/
CHANGING THE ENGINE OIL
5. Check the engine oil level again.
NOTE:
Before checking the engine oil level, wait a few
minutes until the oil has settled.
EAS00076
1. Remove:
storage box
footrest board
3. Place a container under the engine oil drain
bolt.
4. Remove:
engine oil filler cap 1
engine oil drain bolt 2
(along with the gasket)
5. Drain:
engine oil
(completely from the crankcase)
6. If the oil strainer is also to be cleaned, per-
form the following procedure.
a. Remove the oil strainer cover 1 and oil
strainer 2.
b. Install new O-ring 3.
c. Install the oil strainer cover.
7. Check:
engine oil drain bolt gasket
Damage Replace.
T

R
.
.
Oil strainer cover
32 Nm (3.2 m kg, 23 ft lb)
3 - 23
CHK
ADJ
8. Install:
engine oil drain bolt
9. Fill:
crankcase
(with the specified amount of the recom-
mended engine oil)
10.Install:
engine oil filler cap
11.Start the engine, warm it up for several min-
12.Check:
engine
(for engine oil leaks)
13.Check:
engine oil level
Refer to CHECKING THE ENGINE OIL
LEVEL.
14.Check:
engine oil pressure
a. Slightly loosen the oil check bolt 1.
b. Start the engine and keep it idling until
engine oil starts to seep from the oil check
bolt. If no engine oil comes out after one
minute, turn the engine off so that it will not
seize.
c. Check the engine oil passages, the oil filter
element and the oil pump for damage or
leakage. Refer to OIL PUMP in chapter 5.
d. Start the engine after solving the problem(s)
and check the engine oil pressure again.
e. Tighten the oil check bolt to specification.
Quantity
Total amount
1.40 L (1.23 Imp qt, 1.48 US qt)
Periodic oil change
1.20 L (1.06 Imp qt, 1.27 US qt)
T

R
.
.
Oil check bolt
7 Nm (0.7 m kg, 5.1 ft lb)
T R .
.
20 Nm (2.0 m kg, 14 ft lb)
1
3 - 24
CHK
ADJ
CHANGING THE ENGINE OIL/
CHANGING THE FINAL TRANSMISSION OIL
15.Reset:
oil change indicator
a. Set the main switch to ON while holding
the MODE and SET buttons pushed for
two to five seconds.
b. Release the buttons and the oil change indi-
cator will go off.
NOTE:
If the engine oil is changed before the oil
change indicator comes on (i.e., before the
periodic maintenance and lubrication interval
has been reached), the oil change indicator
must be reset as soon as possible so that it
comes on for the next periodic maintenance
and lubrication interval.
16.Install:
footrest board
storage box
CHANGING THE FINAL TRANSMISSION
OIL
NOTE:
3. Place a container under the transmission oil
drain bolt.
4. Remove:
final transmission oil filler cap 1
O-ring 2
transmission oil drain bolt 3
5. Drain:
final transmission oil
(completely from the transmission case)
1 1
2
3 - 25
CHK
ADJ
CHANGING THE FINAL TRANSMISSION OIL/
REPLACING THE AIR FILTER ELEMENT
6. Install:
final transmission oil drain bolt
7. Fill:
transmission case
mended transmission oil)
8. Install:
final transmission oil filler cap
O-ring
10.Check:
transmission case
(for transmission oil leaks)
Recommended oil
SAE 10W30 type SE motor oil
Oil quantity
0.25 L (0.22 Imp qt, 0.26 US qt)
T R .
.
22 Nm (2.2 m kg, 16 ft lb)
EAS00089
REPLACING THE AIR FILTER ELEMENT
NOTE:
On the bottom of the air filter case is a check
hoses. If dust or water or both collects in this
hose, remove the clamp from it, and then
remove the plug to drain the hose and clean
the air filter case.
1. Remove:
air filter case cover 1
air filter element 2
1
2
3 - 26
CHK
ADJ
REPLACING THE AIR FILTER ELEMENT/
CLEANING THE V-BELT CASE AIR FILTER ELEMENT
2. Check:
air filter element
Damage Replace.
NOTE:
Replace the air filter element every
20,000 km of operation.
The air filter needs more frequent service if
you are riding in unusually wet or dusty
areas.
3. Install:
air filter element
air filter case cover
CAUTION:
Never operate the engine without the air fil-
ter element installed. Unfiltered air will
cause rapid wear of engine parts and may
damage the engine. Operating the engine
without the air filter element will also affect
the carburetor tuning, leading to poor
engine performance and possible overheat-
ing.
EAS00091
CLEANING THE V-BELT CASE AIR FILTER
ELEMENT
1. Remove:
center panel 1 (left)
2. Remove:
V-belt case air filter cover 1
3. Clean:
V-belt case air filter element 1
Blow the compressed air to the outer sur-
face of the V-belt case air filter element.
3 - 27
CHK
ADJ
CLEANING THE V-BELT CASE AIR FILTER ELEMENT/
CHECKING THE FUEL AND VACUUM HOSES/
CHECKING THE BREATHER HOSES
4. Check:
V-belt case air filter element
Damage Replace.
CAUTION:
Since the V-belt case air filter element is a
dry type, do not let grease or water contact
it.
5. Install:
6. Install:
center panel 1 (left)
EAS00096
CHECKING THE FUEL AND VACUUM
HOSES
1. Remove:
storage box
2. Check:
fuel hose (fuel tnak to fuel pump) 1
fuel hose (fuel pump to carburetor) 2
air induction system vacuum hose 3
Cracks/damage Replace.
3. Install:
storage box
1
3
2
EAS00098
CHECKING THE BREATHER HOSES
1. Remove:
storage box
3 - 28
CHK
ADJ
CHECKING THE BREATHER HOSES/
CHECKING THE EXHAUST SYSTEM
2. Check:
cylinder head breather hose 1
transmission case breather hose 2
CAUTION:
Make sure the cylinder head breather hose
and transmission case breather hose are
routed correctly.
3. Install:
storage box
1
2
EAS00100
CHECKING THE EXHAUST SYSTEM
1. Remove:
center panel 1 (right)
2. Check:
exhaust pipe 1
muffler 2
gaskets
Exhaust gas leaks Replace.
3. Check:
tightening torque
4. Install:
T

R
.
.
Exhaust pipe nut 3
20 Nm (2.0 m kg, 14 ft lb)
Muffler joint bolt 4
14 Nm (1.4 m kg, 10 ft lb)
Muffler mounting bolt 5
65 Nm (6.5 m kg, 47 ft lb)
2
5
5
4
3 - 29
CHK
ADJ
CHECKING THE COOLANT LEVEL/
CHECKING THE COOLING SYSTEM
EAS00103
CHECKING THE COOLANT LEVEL
NOTE:
2. Check:
coolant level
The coolant level should be between the
maximum level mark a and minimum level
mark b.
Below the minimum level mark Add the
recommended coolant to the proper level.
CAUTION:
Adding water instead of coolant lowers
the antifreeze content of the coolant. If
water is used instead of coolant check
and, if necessary, correct the antifreeze
concentration of the coolant.
Use only distilled water. However, if dis-
tilled water is not available, soft water
may be used.
4. Check:
coolant level
NOTE:
Before checking the coolant level, wait a few
minutes until it settles.
EAS00104
CHECKING THE COOLING SYSTEM
1. Remove:
footrest board
storage box
3 - 30
CHK
ADJ
CHECKING THE COOLING SYSTEM/
CHANGING THE COOLANT
2. Check:
radiator 1
radiator outlet hose 2
radiator inlet hose 3
radiator inlet/outlet pipe 4
water pump inlet hose 5
radiator filler hose 6
thermostat cover 7
thermostat outlet hose 8
thermostat inlet hose 9
3. Install:
storage box
footrest board
4
5
1
3
2
6
7
9
8
EAS00105
1. Remove:
battery cover
footrest board mat (right)
storage box
2. Remove:
coolant reservoir cap 1
3. Disconnect:
coolant reservoir hose 2
4. Drain:
coolant
(completely from the coolant reservoir)
2
1
3 - 31
CHK
ADJ
5. Remove:
radiator cap 1
WARNING
A hot radiator is under pressure. Therefore,
do not remove the radiator cap when the
engine is hot. Scalding hot fluid and steam
may be blown out, which could cause seri-
ous injury. When the engine has cooled,
open the radiator cap as follows:
Place a thick rag or a towel over the radia-
tor cap and slowly turn the radiator cap
counterclockwise to allow any residual
pressure to escape. When the hissing
sound has stopped, remove the cap.
1
6. Remove:
coolant drain bolt 1
(along with the copper washer)
7. Drain:
coolant
(completely from the engine and radiator)
8. Install:
copper washer
coolant drain bolt
9. Connect:
coolant reservoir hose
1
New
T R .
.
10 Nm (1.0 m kg, 7.2 ft lb)
3 - 32
CHK
ADJ
10.Fill:
cooling system
mended coolant to the specified level)
NOTE:
The specified amount of coolant is a standard
amount. Fill the cooling system with coolant
until coolant comes out of the air bleed bolt
hole 1.
Recommended antifreeze
High-quality ethylene glycol
antifreeze containing corrosion
inhibitors for aluminum engines
Mixing ratio
1:1 (antifreeze:water)
Quantity
Radiator and engine capacity
0.70 L
(0.62 Imp qt, 0.74 US qt)
Coolant reservoir capacity
0.26 L
(0.23 Imp qt, 0.28 US qt)
Up to the maximum level mark
1
Handling notes for coolant
Coolant is potentially harmful and should be
handled with special care.
WARNING
If coolant splashes in your eyes, thor-
oughly wash them with water and consult
a doctor.
If coolant splashes on your clothes,
quickly wash it away with water and then
with soap and water.
If coolant is swallowed, induce vomiting
and get immediate medical attention.
3 - 33
CHK
ADJ
CAUTION:
Adding water instead of coolant lowers
the antifreeze content of the coolant. If
water is used instead of coolant check,
and if necessary, correct the antifreeze
concentration of the coolant.
Use only distilled water. However, if dis-
tilled water is not available, soft water
may be used.
If coolant comes into contact with painted
surfaces, immediately wash them with
water.
Do not mix different types of antifreeze.
11.Install:
radiator cap
12.Fill:
coolant reservoir
(with the recommended coolant to the maxi-
mum level mark a)
13.Tighten:
air bleed bolt (coolant)
14.Install:
coolant reservoir cap
15.Start the engine, warm it up for several min-
16.Check:
coolant level
Refer to CHECKING THE COOLANT
LEVEL.
NOTE:
Before checking the coolant level, wait a few
minutes until the coolant has settled.
17.Install:
storage box
footrest board mat (right)
battery cover
a
3 - 34
CHK
ADJ
CHECKING THE BRAKE FLUID LEVEL
EAS01160
CHASSIS
CHECKING THE BRAKE FLUID LEVEL
NOTE:
Place the vehicle on the centerstand.
Make sure the vehicle is upright.
2. Check:
brake fluid level
Below the minimum level mark a 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 performance.
Refill with the same type of brake fluid
that is already in the system. Mixing
brake fluids may result in a harmful
chemical reaction, leading to poor brake
performance.
When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor
lock.
CAUTION:
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
NOTE:
In order to ensure a correct reading of the
brake fluid level, make sure the top of the
brake master cylinder reservoir is horizontal.
Recommended brake fluid
DOT 4
a
3 - 35
CHK
ADJ
CHECKING THE FRONT AND REAR BRAKE PADS/
CHECKING THE FRONT AND REAR BRAKE HOSES
EAS01220
CHECKING THE FRONT AND REAR BRAKE
PADS
brake pads.
1. Operate the brake.
2. Check:
front brake pad
Wear limit a reached Replace the brake
pads as a set.
Refer to REPLACING THE FRONT
BRAKE PADS in chapter 4.
rear brake pad
Wear limit a reached Replace the brake
pads as a set.
Refer to REPLACING THE REAR BRAKE
PADS in chapter 4.
Front brake
Rear brake
EAS01320
HOSES
brake hoses and brake hose clamps.
1. Check:
brake hoses 1
Cracks/damage/wear Replace.
Front brake
Rear brake
2. Check:
brake hose clamps
Loose Tighten the clamp bolt.
3. Hold the vehicle upright and apply the brake
several times.
4. Check:
brake hoses
Brake fluid leakage Replace the dam-
aged hose.
Refer to FRONT AND REAR BRAKES in
chapter 4.
Brake pad lining thickness limit
0.5 mm (0.02 in)
Brake pad lining thickness limit
0.8 mm (0.03 in)
a
3 - 36
CHK
ADJ
BLEEDING THE HYDRAULIC BRAKE SYSTEM
EAS01350
BLEEDING THE HYDRAULIC BRAKE
SYSTEM
WARNING
Bleed the hydraulic brake system when-
ever:
the system is disassembled.
a brake hose is loosened, disconnected
or replaced.
the brake fluid level is very low.
brake operation is faulty.
NOTE:
NOTE:
Be careful not to spill any brake fluid or allow
the brake master cylinder reservoir to over-
flow.
When bleeding the hydraulic brake system,
make sure there is always enough brake
fluid before applying the brake. Ignoring this
precaution could allow air to enter the
hydraulic brake system, considerably length-
ening the bleeding procedure.
If bleeding is difficult, it may be necessary to
let the brake fluid settle for a few hours.
Repeat the bleeding procedure when the tiny
bubbles in the hose have disappeared.
1. Bleed:
hydraulic brake system
a. Fill the brake master cylinder reservoir to
the proper level with the recommended
brake fluid.
b. Install the brake master cylinder reservoir
diaphragm.
c. Connect a clear plastic hose 1 tightly to the
bleed screw 2.
Front brake caliper
Rear brake caliper
d. Place the other end of the hose into a con-
tainer.
e. Slowly apply the brake several times.
f. Fully squeeze the brake lever and hold it in
position.
1
2
3 - 37
CHK
ADJ
BLEEDING THE HYDRAULIC BRAKE SYSTEM/
CHECKING AND ADJUSTING THE STEERING HEAD
g. Loosen the bleed screw.
NOTE:
Loosening the bleed screw will release the
pressure and cause the brake lever to contact
the handlebar.
h. Tighten the bleed screw and then release
the brake lever.
i. Repeat steps (e) to (h) until all of the air
bubbles have disappeared from the brake
fluid in the plastic hose.
j. Tighten the bleed screw to specification.
k. Fill the brake master cylinder 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.
T

R
.
.
Bleed screw (front brake caliper)
6 Nm (0.6 m kg, 4.3 ft lb)
Bleed screw (rear brake caliper)
6 Nm (0.6 m kg, 4.3 ft lb)
EAS01480
CHECKING AND ADJUSTING THE
STEERING HEAD
WARNING
Securely support the vehicle so that there
is no danger of it falling over.
NOTE:
Place the vehicle on a suitable stand so that
the front wheel is elevated.
2. Check:
steering head
Grasp the bottom of the front fork legs and
gently rock the front fork.
Binding/looseness Adjust the steering
head.
3 - 38
CHK
ADJ
CHECKING AND ADJUSTING THE STEERING HEAD
3. Remove:
handlebar lower holder
Refer to STEERING HEAD in chapter 4.
4. Adjust:
steering head
a. Remove the upper ring nut 1, lock washer
2, the center ring nut 3 and the rubber
washer.
b. Loosen the lower ring nut 4 and then
tighten it to specification with the steering
nut wrench 5.
NOTE:
NOTE:
Be sure to install all the ring nuts with the
broad side of the inner tapered section facing
down.
Set the torque wrench at a right angle to the
steering nut wrench.
c. Loosen the lower ring nut 4 1/4 of turn and
then tighten it to specification with a steer-
ing nut wrench.
WARNING
Do not overtighten the lower ring nut.
d. Check the steering head for looseness or
binding by turning the front fork all the way
in both directions. If any binding is felt,
remove the lower bracket and check the
upper and lower bearings.
e. Install the rubber washer.
f. Install the center ring nut.
Steering nut wrench
90890-01403
T

R
.
.
Lower ring nut (initial tightening
torque)
38 Nm (3.8 m kg, 27 ft lb)
T

R
.
.
Lower ring nut (final tightening
torque)
22 Nm (2.2 m kg, 16 ft lb)
3 - 39
CHK
ADJ
CHECKING AND ADJUSTING THE STEERING HEAD/
CHECKING THE FRONT FORK
g. Finger tighten the center ring nut, then align
the slots of both ring nuts. If necessary, hold
the lower ring nut and tighten the center ring
nut until their slots are aligned.
NOTE:
When aligning the slots, align them by turning
the center ring nut in the tightening direction.
h. Install the lock washer 2.
NOTE:
Make sure the lock washer tabs a sit correctly
in the ring nut slots b.
i. Hold the lower and center ring nuts with a
steering nut wrench and tighten the upper
ring nut with a steering nut wrench.
5.Install:
handlebar lower holder
EAS01510
CHECKING THE FRONT FORK
WARNING
2. Check:
inner tube
Damage/scratches Replace.
oil seal
Oil leakage Replace.
3. Hold the vehicle upright and apply the front
brake.
4. Check:
front fork operation
Push down hard on the handlebar several
times and check if the front fork rebounds
smoothly.
Rough movement Repair.
Refer to FRONT FORK in chapter 4.
Steering nut wrench
90890-01403
T

R
.
.
Upper ring nut
75 Nm (7.5 m kg, 54 ft lb)
3 - 40
CHK
ADJ
ADJUSTING THE REAR SHOCK ABSORBER
ASSEMBLIES/CHECKING THE TIRES
EAS01600
ADJUSTING THE REAR SHOCK
ABSORBER ASSEMBLIES
The following procedure applies to both of the
rear shock absorber assemblies.
WARNING
Always adjust both rear shock absorber
assemblies evenly. Uneven adjustment
can result in poor handling and loss of
stability.
Spring preload
CAUTION:
Never go beyond the maximum or mini-
mum adjustment positions.
1. Adjust:
spring preload
a. Turn the adjusting ring 1 in direction a or
b.
Align the desired position on the adjusting
ring with the stopper 2.
Direction a
Spring preload is
increased (suspension
is harder).
Direction b
Spring preload is
decreased (suspension
is softer).
Adjusting positions
Minimum: 1
Standard: 1
Maximum: 4
EAS01630
CHECKING THE TIRES
tires.
1. Check:
tire pressure
Out of specification Regulate.
3 - 41
CHK
ADJ
CHECKING THE TIRES
WARNING
The tire pressure should only be checked
and regulated when the tire temperature
is at ambient air temperature.
The tire pressure and the suspension
must be adjusted according to the total
weight (including cargo, rider, passenger
and accessories) and the anticipated
riding speed.
Operation of an overloaded vehicle could
cause tire damage, an accident or an
injury.
NEVER OVERLOAD THE VEHICLE.
* Total weight of rider, passenger, cargo and
accessories
WARNING
It is dangerous to ride with a worn-out tire.
When the tire tread reaches the wear limit,
replace the tire immediately.
Basic weight
(with oil and
a full fuel
tank)
176 kg (388 lb)
Maximum
load*
180 kg (397 lb)
Cold tire
pressure
Front Rear
Up to 90 kg
(198 lb) load*
190 kPa
(1.90 kgf/cm
2
,
28 psi)
220 kPa
(2.20 kgf/cm
2
,
32 psi)
90 kg (198 lb)
~ maximum
load*
210 kPa
(2.10 kgf/cm
2
,
30 psi)
250 kPa
(2.50 kgf/cm
2
,
36 psi)
2. Check:
tire surfaces
Damage/wear Replace the tire.
1Tire tread depth
2Sidewall
3Wear indicator
Minimum tire tread depth
1.6 mm (0.06 in)
3 - 42
CHK
ADJ
CHECKING THE TIRES
WARNING
Do not use a tubeless tire on a wheel
designed only for tube tires to avoid tire
failure and personal injury from sudden
deflation.
When using tube tires, be sure to install
the correct tube.
Always replace a new tube tire and a new
tube as a set.
To avoid pinching the tube, make sure the
wheel rim band and tube are centered in
the wheel groove.
Patching a punctured tube is not recom-
mended. If it is absolutely necessary to
do so, use great care and replace the tube
as soon as possible with a good quality
replacement.
Tire
Wheel
After extensive tests, the tires listed
below have been approved by Yamaha
Motor Espaa, S.A. Ltd. for this model.
The front and rear tires should always be
by the same manufacturer and of the
same design. No guarantee concerning
handling characteristics can be given if a
tire combination other than one approved
by Yamaha is used on this vehicle.
Front tire
Rear tire
Tube wheel Tube tire only.
Tubeless wheel Tube or tubeless tire.
Manufacturer Model Size
MICHELIN
GOLD
STANDARD
120/70-15
M/C 56S
PIRELLI GTS23
120/70-15
M/C 56P
Manufacturer Model Size
MICHELIN
GOLD
STANDARD
140/70-14
M/C 68S
PIRELLI GTS24
140/70-14
M/C 68P

3 - 43
CHK
ADJ
CHECKING THE TIRES/
CHECKING THE WHEELS
WARNING
New tires have a relatively low grip on the
road surface until they have been slightly
worn. Therefore, approximately 100 km
should be traveled at normal speed before
any high-speed riding is done.
NOTE:
For tires with a rotation direction mark 1:
Install the tire with the mark pointing in the
direction of the wheel rotation.
EAS01680
CHECKING THE WHEELS
wheels.
1. Check:
wheel
Damage/out-of-round Replace.
WARNING
Never attempt to make any repairs to the
wheel.
NOTE:
After a tire or wheel has been changed or
replaced, always balance the wheel.
3 - 44
CHK
ADJ
CHECKING AND LUBRICATING THE CABLES/
LUBRICATING THE SIDESTAND/
LUBRICATING THE CENTERSTAND
EAS01700
CHECKING AND LUBRICATING THE
CABLES
inner and outer cables.
WARNING
Damaged outer cable may cause the cable
to corrode and interfere with its movement.
Replace damaged outer cable and inner
cable as soon as possible.
1. Check:
outer cable
Damage Replace.
2. Check:
cable operation
Rough movement Lubricate.
NOTE:
Hold the cable end upright and pour a few
drops of lubricant into the cable sheath or use
a suitable lubricating device.
Recommended lubricant
Engine oil or a suitable cable
lubricant
EAS01720
LUBRICATING THE SIDESTAND
Lubricate the pivoting point and metal-to-metal
moving parts of the sidestand.
Lithium-soap-based grease
EAS01730
LUBRICATING THE CENTERSTAND
Lubricate the pivoting point and metal-to-metal
moving parts of the centerstand.
3 - 45
CHK
ADJ
CHECKING AND CHARGING THE BATTERY
EAS01790
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 handling
or working near batteries.
Charge batteries in a well-ventilated area.
Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,
lighted cigarettes).
DO NOT SMOKE when charging or han-
dling batteries.
KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.
Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye
injury.
FIRST AID IN CASE OF BODILY CONTACT:
EXTERNAL
Skin Wash with water.
Eyes Flush with water for 15 minutes
and get immediate medical attention.
INTERNAL
Drink large quantities of water or milk fol-
lowed with milk of magnesia, beaten egg
or vegetable oil. Get immediate medical
attention.
CAUTION:
This is a sealed battery. Never remove the
sealing caps because the balance
between cells will not be maintained and
battery performance will deteriorate.
Charging time, charging amperage and
charging voltage for an MF battery are dif-
ferent from those of conventional batter-
ies. The MF battery should be charged as
explained in the charging method illustra-
tions. If the battery is overcharged, the
electrolyte level will drop considerably.
Therefore, take special care when charg-
ing the battery.
3 - 46
CHK
ADJ
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:
battery cover
2. Remove:
battery bracket 1
1
3. Disconnect:
battery leads
(from the battery terminals)
CAUTION:
CAUTION:
First, disconnect the negative battery lead
1, and then the positive battery lead 2.
4. Remove:
battery
5. Check:
battery charge
a. Connect a pocket tester to the battery termi-
nals.
NOTE:
NOTE:
The charge state of an MF battery can be
checked by measuring its open-circuit volt-
age (i.e., the voltage when the positive termi-
nal is disconnected).
No charging is necessary when the open-cir-
cuit voltage equals or exceeds 12.8 V.
Positive tester probe
positive battery terminal
Negative tester probe
negative battery terminal
1
2
3 - 47
CHK
ADJ
b. Check the charge of the battery, as shown
in the charts and the following example.
Example
c. Open-circuit voltage = 12.0 V
d. Charging time = 6.5 hours
e. Charge of the battery = 20 ~ 30%
6. Charge:
battery
(Refer to the appropriate charging method
illustration.)
WARNING
Do not quick charge a battery.
CAUTION:
CAUTION:
Never remove the MF battery sealing
caps.
Do not use a high-rate battery charger
since it forces a high-amperage current
into the battery quickly and can cause
battery overheating and battery plate
damage.
If it is impossible to regulate the charging
current on the battery charger, be careful
not to overcharge the battery.
When charging a battery, be sure to
remove it from the vehicle. (If charging
has to be done with the battery mounted
on the vehicle, disconnect the negative
battery lead from the battery terminal.)
To reduce the chance of sparks, do not
plug in the battery charger until the bat-
tery charger leads are connected to the
battery.
Before removing the battery charger lead
clips from the battery terminals, be sure
to turn off the battery charger.
Make sure the battery charger lead clips
are in full contact with the battery termi-
nal and that they are not shorted. A cor-
roded battery charger lead clip may
generate heat in the contact area and a
weak clip spring may cause sparks.
Relationship between the open-circuit volt-
age and the charging time at 20 C.
These values vary with the temperature, the condi-
tion of the battery plates, and the electrolyte level.
Charging time (hours)
O
p
e
n
-
c
i
r
c
u
i
t

v
o
l
t
a
g
e

(
V
)
Ambient temperature 20 C
Charging
Time (minutes)
Check the open-circuit
voltage.
O
p
e
n
-
c
i
r
c
u
i
t

v
o
l
t
a
g
e

(
V
)
Ambient temperature 20 C
Charging condition of the battery (%)
O
p
e
n
-
c
i
r
c
u
i
t

v
o
l
t
a
g
e

(
V
)
3 - 48
CHK
ADJ
If the battery becomes hot to the touch at
any time during the charging process,
disconnect the battery charger and let the
battery cool before reconnecting it. Hot
batteries can explode!
As shown in the following illustration, the
open-circuit voltage of an MF battery sta-
bilizes about 30 minutes after charging
has been completed. Therefore, wait 30
minutes after charging is completed
before measuring the open-circuit volt-
age.
3 - 49
CHK
ADJ
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 charging
amperage written on the
battery?
Leave the battery unused for more
than 30 minutes before measuring
its open-circuit voltage.
NOTE:
YES
NO
Adjust the voltage to obtain the
standard charging amperage.
Adjust the charging voltage to
20 ~ 25 V.
Leave the battery unused for more than 30 minutes before measuring
12.8 V Charging is complete.
12.0 ~ 12.7 V Recharging is required.
Under 12.0 V Replace the battery.
Charger
Ammeter
Set the charging voltage to 16 ~
17 V. (If the charging voltage is
lower charging will be insufficient,
if it is higher, the battery will be
over-charged.)
NOTE:
Monitor the amperage for 3 ~ 5
minutes. Is the standard charg-
ing amperage exceeded?
YES
Set the timer to the charging
time determined by the open-
circuit voltage.
Refer to CHECKING AND
CHARGING THE BATTERY.
If the amperage does not
exceed the standard charging
amperage after 5 minutes,
replace the battery.
If the required charging time exceeds 5 hours, it is advisable to check
the charging amperage after 5 hours. If there is any charge in the
amperage, readjust the voltage to obtain the standard charging
amperage.
NO
3 - 50
CHK
ADJ
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.
Is the amperage higher
than the standard charging
amperage written on the
battery?
Leave the battery unused for more
than 30 minutes before measuring
NOTE:
YES NO
Charge the battery until the charging
voltage reaches 15 V.
Set the charging time to a maxi-
mum of 20 hours.
NOTE:
This type of battery charger cannot
charge an MF battery. A variable volt-
age charger is recommended.
Constant amperage chargers are not
suitable for charging MF batteries.
CAUTION:
Leave the battery unused for
more than 30 minutes before
measuring its open-circuit volt-
age.
12.8 V Charging is complete.
12.0 ~ 12.7 V Recharging is
required.
Under 12.0 V Replace the
battery.
Charger
Voltmeter
Ammeter
3 - 51
CHK
ADJ
CHECKING AND CHARGING THE BATTERY/
CHECKING THE FUSES
7. Install:
battery
8. Connect:
battery leads
(to the battery terminals)
CAUTION:
First, connect the positive battery lead 1,
and then the negative battery lead 2.
9. Check:
battery terminals
Dirt Clean with a wire brush.
10.Lubricate:
battery terminals
11.Install:
battery bracket
12.Install:
battery cover
Dielectric grease
2
1
T R .
.
23 Nm (2.3 m kg, 17 ft lb)
EAS01810
CHECKING THE FUSES
fuses.
CAUTION:
To avoid a short circuit, always set the
main switch to OFF when checking or
replacing a fuse.
1. Remove:
upper panel
3 - 52
CHK
ADJ
CHECKING THE FUSES
2. Check:
fuse
a. Connect the pocket tester to the fuse and
check the continuity.
NOTE:
Set the pocket tester selector to 1.
b. If the pocket tester indicates , replace
the fuse.
3. Replace:
blown fuse
a. Set the main switch to OFF.
b. Install a new fuse of the correct amperage
rating.
c. Set on the switches to verify if the electrical
circuit is operational.
d. If the fuse immediately blows again, check
the electrical circuit.
Pocket tester
90890-03112
Fuses
Amperage
rating
Qty
Main 30 A 1
Headlight 15 A 1
Signaling system 15 A 1
Radiator fan motor 10 A 1
Ignition 5 A 1
CDI unit 5 A 1
Backup (meter
assembly)
5 A 1
Reserve
30 A
15 A
10 A
5 A
1
1
1
1
3 - 53
CHK
ADJ
CHECKING THE FUSES/
REPLACING THE HEADLIGHT BULBS
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. Install:
upper panel
EAS01830
REPLACING THE HEADLIGHT BULBS
headlight bulbs.
1. Remove:
upper panel
2. Disconnect:
headlight coupler 1
3. Remove:
headlight bulb cover 2
4. Detach:
headlight bulb holder 1
5. Remove:
headlight bulb
WARNING
Since the headlight bulb gets extremely
hot, keep flammable products and your
hands away from the bulb until it has
cooled down.
1
2
1
2
1
3 - 54
CHK
ADJ
REPLACING THE HEADLIGHT BULBS/
ADJUSTING THE HEADLIGHT BEAM
6. Install:
headlight bulb
Secure the new headlight bulb with the
headlight bulb holder.
CAUTION:
Avoid touching the glass part of the head-
light bulb to keep it free from oil, otherwise
the transparency of the glass, the life of the
bulb and the luminous flux will be
adversely affected. If the headlight bulb
gets soiled, thoroughly clean it with a cloth
moistened with alcohol or lacquer thinner.
7. Attach:
headlight bulb holder
8. Install:
headlight bulb cover
9. Connect:
headlight coupler
10.Install:
upper panel
New
EAS01860
ADJUSTING THE HEADLIGHT BEAM
1. Adjust:
headlight beam (vertically)
a. Turn the adjusting screw 1 in direction a
or b.
Direction a
Headlight beam is
raised.
Direction b
Headlight beam is low-
ered.
1
a b
CHAS
CHAPTER 4
CHASSIS
FRONT WHEEL AND BRAKE DISC............................................................... 4-1
REMOVING THE FRONT WHEEL............................................................ 4-3
CHECKING THE FRONT WHEEL ............................................................ 4-3
CHECKING THE BRAKE DISC................................................................. 4-5
ADJUSTING THE FRONT WHEEL STATIC BALANCE ........................... 4-6
INSTALLING THE FRONT WHEEL .......................................................... 4-8
REAR WHEEL AND BRAKE DISC................................................................. 4-9
REMOVING THE REAR WHEEL............................................................ 4-11
CHECKING THE REAR WHEEL............................................................. 4-11
ADJUSTING THE REAR WHEEL STATIC BALANCE............................ 4-12
INSTALLING THE REAR WHEEL........................................................... 4-12
FRONT AND REAR BRAKES....................................................................... 4-13
FRONT BRAKE PADS............................................................................ 4-13
REAR BRAKE PADS............................................................................... 4-14
REPLACING THE FRONT BRAKE PADS .............................................. 4-15
REPLACING THE REAR BRAKE PADS................................................. 4-17
FRONT BRAKE MASTER CYLINDER.................................................... 4-19
REAR BRAKE MASTER CYLINDER...................................................... 4-22
DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER............. 4-25
DISASSEMBLING THE REAR BRAKE MASTER CYLINDER................ 4-25
CHECKING THE FRONT AND REAR BRAKE MASTER
CYLINDERS........................................................................................... 4-26
ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER
CYLINDER ............................................................................................. 4-27
ASSEMBLING AND INSTALLING THE REAR BRAKE MASTER
CYLINDER ............................................................................................. 4-29
FRONT BRAKE CALIPER....................................................................... 4-33
REAR BRAKE CALIPER......................................................................... 4-36
DISASSEMBLING THE FRONT BRAKE CALIPER................................ 4-38
DISASSEMBLING THE REAR BRAKE CALIPER .................................. 4-39
CHECKING THE FRONT AND REAR BRAKE CALIPERS .................... 4-40
ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPER ....... 4-41
ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER.......... 4-43
FRONT FORK................................................................................................ 4-47
REMOVING THE FRONT FORK LEGS.................................................. 4-50
DISASSEMBLING THE FRONT FORK LEGS........................................ 4-50
CHECKING THE FRONT FORK LEGS .................................................. 4-52
ASSEMBLING THE FRONT FORK LEGS.............................................. 4-53
INSTALLING THE FRONT FORK LEGS ................................................ 4-58
HANDLEBAR ................................................................................................ 4-59
REMOVING THE HANDLEBAR.............................................................. 4-61
CHECKING THE HANDLEBAR .............................................................. 4-61
CHAS
INSTALLING THE HANDLEBAR ............................................................ 4-61
STEERING HEAD.......................................................................................... 4-64
LOWER BRACKET ................................................................................. 4-64
REMOVING THE LOWER BRACKET..................................................... 4-66
CHECKING THE STEERING HEAD....................................................... 4-67
INSTALLING THE STEERING HEAD..................................................... 4-68
REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM................... 4-69
REMOVING THE REAR SHOCK ABSORBER ASSEMBLIES ............... 4-71
CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES................ 4-71
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLIES.............. 4-72
REMOVING THE SWINGARM................................................................ 4-72
CHECKING THE SWINGARM................................................................ 4-73
INSTALLING THE SWINGARM.............................................................. 4-73
4 - 1
CHAS
EAS05130
CHASSIS
FRONT WHEEL AND BRAKE DISC
2
5
3
6
(5)
4
1
LT
T R .
.
12 Nm (1.2 m kg, 8.7 ft Ib)
LS
T R .
.
59 Nm (5.9 m kg, 43 ft Ib)
T R .
.
9 Nm (0.9 m kg, 6.5 ft Ib)
Removing the front wheel and brake
disc
1 Front wheel axle pinch bolt 2 Loosen.
Refer to REMOVING THE
FRONT WHEEL and
INSTALLING THE FRONT
WHEEL.
2 Front wheel axle 1
3 Front wheel 1
4 Speed sensor 1
5 Spacer 1
6 Front brake disc 1
cedure.
4 - 2
CHAS
EAS05130
Disassembling the front wheel Remove the parts in the order listed.
1 Oil seal 1
2 Bearing 2
3 Collar 1
For assembly, reverse the disassembly
procedure.
4 - 3
CHAS
EAS05200
REMOVING THE FRONT WHEEL
WARNING
2. Elevate:
front wheel
NOTE:
3. Remove:
front wheel
speed sensor
spacer
NOTE:
NOTE:
Do not squeeze the front brake lever when
removing the front wheel.
EAS05250
CHECKING THE FRONT WHEEL
1. Check:
wheel axle
Roll the wheel axle on a flat surface.
Bends Replace.
WARNING
Do not attempt to straighten a bent wheel
axle.
2. Check:
tire
front wheel
Damage/wear Replace.
Refer to CHECKING THE TIRES and
CHECKING THE WHEELS in chapter 3.
4 - 4
CHAS
3. Measure:
radial wheel runout 1
lateral wheel runout 2
Over the specified limits Replace.
Radial wheel runout limit
1.0 mm (0.04 in)
Lateral wheel runout limit
0.5 mm (0.02 in)
4. Check:
wheel bearings
Front wheel turns roughly or is loose
Replace the wheel bearings.
oil seal
5. Replace:
wheel bearings
oil seal
a. Clean the outside of the front wheel hub.
b. Remove the oil seal 1 with a flat-head
screwdriver.
NOTE:
To prevent damaging the wheel, place a rag 2
between the screwdriver and the wheel sur-
face.
c. Remove the wheel bearings 3 with a gen-
eral bearing puller.
d. Install the new wheel bearings and oil seal
in the reverse order of disassembly.
CAUTION:
Do not contact the wheel bearing inner race
4 or ball 5. Contact should be made only
with the outer race 6.
NOTE:
Use a socket 7 that matches the diameter of
the wheel bearing outer race and oil seal.
New
New
4 - 5
CHAS
EAS05280
CHECKING THE BRAKE DISC
1. Check:
brake disc
Damage/galling Replace.
2. Measure:
brake disc deflection
Out of specification Correct the brake
disc deflection or replace the brake disc.
a. Place the vehicle on a suitable stand so that
b. Before measuring the front brake disc
deflection, turn the handlebar to the left or
right to ensure that the front wheel is sta-
tionary.
c. Remove the brake caliper.
d. Hold the dial gauge at a right angle against
the brake disc surface.
e. Measure the deflection 1.5 mm (0.059 in)
below the edge of the brake disc.
Brake disc deflection limit (maxi-
mum)
Front: 0.10 mm (0.0039 in)
Rear: 0.15 mm (0.0059 in)
3. Measure:
brake disc thickness
Measure the brake disc thickness at a few
different locations.
Out of specification Replace.
Brake disc thickness limit (mini-
mum)
Front: 4.5 mm (0.18 in)
Rear: 4.5 mm (0.18 in)
4 - 6
CHAS
4. Adjust:
brake disc deflection
a. Remove the brake disc.
b. Rotate the brake disc by one bolt hole.
c. Install the brake disc.
NOTE:
Install the brake disc with the recessed bolt
holes facing outward. (For front brake disc)
Tighten the brake disc bolts in stages and in
a crisscross pattern.
d. Measure the brake disc deflection.
e. If out of specification, repeat the adjustment
steps until the brake disc deflection is within
specification.
f. If the brake disc deflection cannot be
brought within specification, replace the
brake disc.
T

R
.
.
Brake disc bolt
12 Nm (1.2 m kg, 8.7 ft lb)
LOCTITE
EAS05480
ADJUSTING THE FRONT WHEEL STATIC
BALANCE
NOTE:
After replacing the tire, wheel or both, the
front wheel static balance should be
adjusted.
Adjust the front wheel static balance with the
brake disc installed.
1. Remove:
balancing weight(s)
2. Find:
front wheels heavy spot
NOTE:
Place the front wheel on a suitable balancing
stand.
4 - 7
CHAS
a. Spin the front wheel.
b. When the front wheel stops, put an X
1
mark at the bottom of the wheel.

c. Turn the front wheel 90 so that the X
1
mark is positioned as shown.

d. Release the front wheel.
e. When the wheel stops, put an X
2
mark at
the bottom of the wheel.
f. Repeat steps (d) through (f) several times
until all the marks come to rest at the same
spot.
g. The spot where all the marks come to rest
is the front wheels heavy spot X.
3. Adjust:
front wheel static balance
a. Install a balancing weight 1 onto the rim
exactly opposite the heavy spot X.
NOTE:
Start with the lightest weight.
b. Turn the front wheel 90 so that the heavy
spot is positioned as shown.
c. If the heavy spot does not stay in that posi-
tion, install a heavier weight.
d. Repeat steps (b) and (c) until the front
wheel is balanced.
4. Check:
front wheel static balance
a. Turn the front wheel and make sure it stays
at each position shown.
b. If the front wheel does not remain stationary
at all of the positions, rebalance it.
4 - 8
CHAS
EAS05420
INSTALLING THE FRONT WHEEL
1. Lubricate:
oil seal lips
speed sensor
2. Install:
spacer
speed sensor
front wheel
NOTE:
Make sure that the speed sensor and the
wheel hub are installed with the projection a
of the wheel hub inserted in a slot b of the
speed sensor.
When installing the speed sensor, make sure
that the projection on the wheel hub does not
damage the lip of the speed sensor oil seal.
Make sure that the slot c in the speed sen-
sor fits over the stopper d on the outer tube.
3. Tighten:
front wheel axle
front wheel axle pinch bolts
WARNING
Make sure the brake hose is routed prop-
erly.
CAUTION:
Before tightening the wheel axle, push
down hard on the handlebar several times
and check if the front fork rebounds
smoothly.
b
a
d
c
T R .
.
59 Nm (5.9 m kg, 43 ft lb)
T R .
.
9 Nm (0.9 m kg, 6.5 ft lb)
4 - 9
CHAS
REAR WHEEL AND BRAKE DISC
EAS05520
1
2
3
6
5
4
LS
LT
(4)
T R .
.
9 Nm (0.9 m kg, 6.5 ft Ib)
T R .
.
23 Nm (2.3 m kg, 17 ft Ib)
Removing the rear wheel and brake
disc
NOTE:
Place the vehicle on a suitable stand so
that the rear wheel is elevated.
Muffler Refer to ENGINE REMOVAL in chapter
5.
Swingarm Refer to REAR SHOCK ABSORBER
ASSEMBLIES AND SWINGARM.
1 Air filter case mounting bolt 2 Refer to INSTALLING THE REAR
WHEEL. 2 Rear fender 1
3 Rear wheel 1 Refer to REMOVING THE REAR
WHEEL.
4 Spacer 1
4 - 10
CHAS
1
2
3
6
5
4
LS
LT
(4)
T R .
.
9 Nm (0.9 m kg, 6.5 ft Ib)
T R .
.
23 Nm (2.3 m kg, 17 ft Ib)
5 Washer 1
6 Rear brake disc 1
cedure.
4 - 11
CHAS
REMOVING THE REAR WHEEL
WARNING
NOTE:
Place the vehicle on a centerstand so that the
rear wheel is elevated.
2. Remove:
brake caliper
rear wheel axle nut
swingarm
Refer to REAR SHOCK ABSORBER
ASSEMBLIES AND SWINGARM.
NOTE:
Do not squeeze the rear brake lever when
removing the rear brake caliper.
3. Remove:
rear wheel
EAS05650
CHECKING THE REAR WHEEL
1. Check:
tire
rear wheel
Refer to CHECKING THE TIRES and
CHECKING THE WHEELS in chapter 3.
2. Measure:
radial wheel runout
lateral wheel runout
Refer to CHECKING THE FRONT
WHEEL.
4 - 12
CHAS
EAS05750
ADJUSTING THE REAR WHEEL STATIC
BALANCE
NOTE:
After replacing the tire, wheel or both, the
rear wheel static balance should be adjusted.
Adjust the rear wheel static balance with the
brake disc installed.
1. Adjust:
rear wheel static balance
Refer to ADJUSTING THE FRONT
WHEEL STATIC BALANCE.
INSTALLING THE REAR WHEEL
1. Install:
rear fender
air filter case mounting bolts
NOTE:
Place the rear fender between the air filter
case and the crankcase, and then install the
air filter case mounting bolts.
T R .
.
9 Nm (0.9 m kg, 6.5 ft lb)
4 - 13
CHAS
FRONT AND REAR BRAKES
EAS05770
FRONT BRAKE PADS
4
1
5
3
6
6
7
8
2
T R .
.
6 Nm (0.6 m kg, 4.3 ft Ib)
T R .
.
23 Nm (2.3 m kg, 17 ft Ib)
T R .
.
12 Nm (1.2 m kg, 8.7 ft Ib)
New
Removing the front brake pads Remove the parts in the order listed.
1 Holder 1
2 Front brake caliper bolt 2
BRAKE PADS.
3 Front brake caliper 1
4 Brake pad clip 1
5 Brake pad pin 1
6 Brake pad 2
7 Brake pad spring 1
8 Brake pad support 1
cedure.
4 - 14
CHAS
EAS05780
REAR BRAKE PADS
4
4
5
6
6
2
1
3
T R .
.
40 Nm (4.0 m kg, 29 ft Ib)
T R .
.
27 Nm (2.7 m kg, 19 ft Ib)
T R .
.
6 Nm (0.6 m kg, 4.3 ft Ib)
* Apply silicone grease.
Removing the rear brake pads Remove the parts in the order listed.
5.
1 Rear brake caliper retaining bolt 2
Refer to REPLACING THE REAR
BRAKE PADS.
2 Rear brake caliper 1
3 Brake pad 2
4 Brake pad shim 4
5 Brake caliper bracket 1
cedure.
4 - 15
CHAS
EAS00579
CAUTION:
_
Disc brake components rarely require dis-
assembly.
Therefore, always follow these preventive
measures:
Never disassemble brake components
unless absolutely necessary.
If any connection on the hydraulic brake
system is disconnected, the entire brake
system must be disassembled, drained,
cleaned, properly filled, and bled after
reassembly.
Never use solvents on internal brake
components.
Use only clean or new brake fluid for
cleaning brake components.
Avoid brake fluid coming into contact
with the eyes as it can cause serious
injury.
FIRST AID FOR BRAKE FLUID ENTERING
THE EYES:
Flush with water for 15 minutes and get
immediate medical attention.
EAS05820
REPLACING THE FRONT BRAKE PADS
NOTE:
When replacing the brake pads, it is not neces-
sary to disconnect the brake hose or disas-
semble the brake caliper.
1. Remove:
brake caliper bolts 1
brake caliper 2
brake pad clip 3
brake pad pin 4
brake pads 5
brake pad spring
brake pad support
5 3
1
4
2
4 - 16
CHAS
2. Measure:
brake pad wear limit a
Out of specifications Replace the brake
pads as a set.
Brake pad wear limit
0.5 mm (0.02 in)
a
3. Install:
brake pad support
brake pad spring
brake pads
NOTE:
Always install new brake pads, brake pad
spring, and brake pad support as a set.
a. Connect a clear plastic hose 1 tightly to the
bleed screw 2. Put the other end of the
hose into an open container.
b. Loosen the bleed screw and push the brake
caliper pistons into the brake caliper with
your finger.
c. Tighten the bleed screw.
d. Install the new brake pads, new brake pad
spring, and new brake pad support.
NOTE:
The arrow mark a on the brake pad spring
must point in the direction of disc rotation.
4. Install:
brake caliper bolts
T

R
.
.
Bleed screw
6 Nm (0.6 m kg, 4.3 ft lb)
1
2
a
T R .
.
23 Nm (2.3 m kg, 17 ft lb)
4 - 17
CHAS
5. Check:
brake fluid level
level.
LEVEL in chapter 3.
6. Check:
brake lever operation
Soft or spongy feeling Bleed the brake
system.
Refer to BLEEDING THE HYDRAULIC
BRAKE SYSTEM in chapter 3.
a
EAS05830
REPLACING THE REAR BRAKE PADS
NOTE:
When replacing the brake pads, it is not neces-
sary to disconnect the brake hose or disas-
semble the brake caliper.
1. Remove:
brake caliper retaining bolts 1
brake caliper 2
brake pads
(along with the brake pad shims)
brake caliper bracket 3
brake pad supports
2. Measure:
brake pad wear limit a
Out of specification Replace the brake
pads as a set.
Brake pad wear limit
0.8 mm (0.03 in)
4 - 18
CHAS
3. Install:
brake pad supports
brake pads
(along with the brake pad shims)
NOTE:
Always install new brake pads, brake pad
shims, and a brake pad supports as a set.
a. Connect a clear plastic hose 1 tightly to the
bleed screw 2. Put the other end of the
hose into an open container.
b. Loosen the bleed screw and push the brake
caliper pistons into the brake caliper with
your finger.
c. Tighten the bleed screw.
d. Install new brake pad shims onto each new
brake pads.
e. Install new brake pad supports and new
brake pads.
4. Install:
brake caliper bolts
brake caliper retaining bolts
5. Check:
brake fluid level
level.
LEVEL in chapter 3.
6. Check:
system.
T

R
.
.
Bleed screw
6 Nm (0.6 m kg, 4.3 ft lb)
2
1
T R .
.
40 Nm (4.0 m kg, 29 ft lb)
T R .
.
27 Nm (2.7 m kg, 19 ft lb)
a
4 - 19
CHAS
EAS05840
FRONT BRAKE MASTER CYLINDER
6
5
7
11
1
2
3
8
9
10
T R .
.
23 Nm (2.3 m kg, 17 ft Ib)
T R .
.
10 Nm (1.0 m kg, 7.2 ft Ib)
T R .
.
7 Nm (0.7 m kg, 5.1 ft Ib)
4
New
Removing the front brake master
cylinder
Handlebar lower cover Refer to COVERS AND PANELS in
chapter 3.
Brake fluid Drain.
1 Brake master cylinder reservoir cap 1
2 Brake master cylinder reservoir dia-
phragm holder
1
phragm
1
4 Front brake light switch connector 2 Disconnect.
4 - 20
CHAS
6
5
7
11
1
2
3
8
9
10
T R .
.
23 Nm (2.3 m kg, 17 ft Ib)
T R .
.
10 Nm (1.0 m kg, 7.2 ft Ib)
T R .
.
7 Nm (0.7 m kg, 5.1 ft Ib)
4
New
5 Brake hose union bolt 1 Refer to DISASSEMBLING THE
and ASSEMBLING AND INSTALLING
THE FRONT BRAKE MASTER CYLIN-
DER.
6 Copper washer 2
7 Front brake hose 1
8 Front brake master cylinder holder 1 Refer to ASSEMBLING AND INSTALL-
ING THE FRONT BRAKE MASTER
CYLINDER.
9 Brake master cylinder assembly 1
10 Front brake lever 1
11 Front brake light switch 1
cedure.
4 - 21
CHAS
1
2
New
** Apply brake fluid
Disassembling the front brake mas-
ter cylinder
1 Brake master cylinder kit 1 Refer to ASSEMBLING AND INSTALL-
ING THE FRONT BRAKE MASTER CYL-
INDER.
2 Brake master cylinder body 1
procedure.
4 - 22
CHAS
EAS05860
REAR BRAKE MASTER CYLINDER
8
5
6
4
11
1
2
3
7
9
10
7
New
New
T R .
.
7 Nm (0.7 m kg, 5.1 ft Ib)
T R .
.
23 Nm (2.3 m kg, 17 ft Ib)
T R .
.
10 Nm (1.0 m kg, 7.2 ft Ib)
Removing the rear brake master cyl-
inder
chapter 3.
Brake fluid Drain.
1 Brake master cylinder reservoir cap 1
phragm holder
1
phragm
1
4 Rear brake lever 1
4 - 23
CHAS
8
5
6
4
11
1
2
3
7
9
10
7
New
New
T R .
.
7 Nm (0.7 m kg, 5.1 ft Ib)
T R .
.
23 Nm (2.3 m kg, 17 ft Ib)
T R .
.
10 Nm (1.0 m kg, 7.2 ft Ib)
5 Rear brake light switch connector 2 Disconnect.
6 Brake hose union bolt 1 Refer to DISASSEMBLING THE REAR
BRAKE MASTER CYLINDER and
ASSEMBLING AND INSTALLING THE
REAR BRAKE MASTER CYLINDER.
7 Copper washer 2
8 Rear brake hose 1
9 Rear brake master cylinder holder 1 Refer to ASSEMBLING AND INSTALL-
ING THE REAR BRAKE MASTER CYL-
INDER.
10 Brake master cylinder assembly 1
11 Rear brake light switch 1
cedure.
4 - 24
CHAS
EAS05870
1
2
New
Disassembling the rear brake mas-
ter cylinder
1 Brake master cylinder kit 1 Refer to ASSEMBLING AND INSTALL-
ING THE REAR BRAKE MASTER CYL-
INDER.
2 Brake master cylinder body 1
procedure.
4 - 25
CHAS
EAS05880
DISASSEMBLING THE FRONT BRAKE
MASTER CYLINDER
NOTE:
Before disassembling the front brake master
cylinder, drain the brake fluid from the entire
brake system.
1. Remove:
brake hose union bolt 1
copper washers 2
brake hose 3
NOTE:
To collect any remaining brake fluid, place a
container under the master cylinder and the
end of the brake hose.
2
1
3
EAS05890
DISASSEMBLING THE REAR BRAKE
MASTER CYLINDER
NOTE:
Before disassembling the rear brake master
cylinder, drain the brake fluid from the entire
brake system.
1. Remove:
copper washers 2
brake hose 3
NOTE:
To collect any remaining brake fluid, place a
container under the master cylinder and the
end of the brake hose.
2
1
3
4 - 26
CHAS
EAS05920
MASTER CYLINDERS
brake master cylinders.
1. Check:
brake master cylinder 1
Damage/scratches/wear Replace.
brake fluid delivery passages
(brake master cylinder body)
Obstruction Blow out with compressed
air.
Front
Rear
1
1

2. Check:
brake master cylinder kit 1
1
3. Check:
brake master cylinder reservoir cap 1
brake master cylinder reservoir diaphragm
holder 2
brake master cylinder diaphragm 3
4. Check:
brake hoses
4 - 27
CHAS
EAS06000
WARNING
Before installation, all internal brake com-
ponents should be cleaned and lubricated
with clean or new brake fluid.
components.
DOT 4
1. Install:
NOTE:
Install the spring with its smaller diameter end
towards the circlip and dust boot.
New
2. Install:
brake master cylinder holder
NOTE:
Align the projection a on the brake master
cylinder with the hole b in the handlebar.
First tighten the front bolt, then the rear bolt.
1
b
a
T R .
.
7 Nm (0.7 m kg, 5.1 ft lb)
4 - 28
CHAS
3. Install:
copper washers 1
brake hose 2
WARNING
Proper brake hose routing is essential to
insure safe vehicle operation. Refer to
CABLE ROUTING in chapter 2.
CAUTION:
When installing the brake hose onto the
brake master cylinder, make sure the brake
pipe touches the projection a on the brake
master cylinder.
NOTE:
Turn the handlebar to the left and right to make
sure the brake hose does not touch other parts
(e.g., wire harness, cables, leads). Correct if
necessary.
4. Fill:
brake master cylinder reservoir
mended brake fluid)
WARNING
performance.
not enter the brake master cylinder reser-
voir. Water will significantly lower the
boiling point of the brake fluid and could
cause vapor lock.
DOT 4
1
3
2
a
New
New
T R .
.
23 Nm (2.3 m kg, 17 ft lb)
4 - 29
CHAS
CAUTION:
5. Bleed:
brake system
6. Check:
brake fluid level
level.
LEVEL in chapter 3.
7. Check:
system.
a
EAS06001
REAR BRAKE MASTER CYLINDER
WARNING
components.
DOT 4
4 - 30
CHAS
1. Install:
NOTE:
Install the spring with its smaller diameter end
towards the circlip and dust boot.
New
2. Install:
brake master cylinder holder
NOTE:
1
a
b
T R .
.
7 Nm (0.7 m kg, 5.1 ft lb)
3. Install:
copper washers 1
brake hose 2
WARNING
CAUTION:
brake master cylinder, make sure the brake
pipe touches the projection a on the brake
master cylinder.
NOTE:
Turn the handlebar to the left and right to make
sure the brake hose does not touch other parts
(e.g., wire harness, cables, leads). Correct if
necessary.
1
3
a
2
New
New
T R .
.
23 Nm (2.3 m kg, 17 ft lb)
4 - 31
CHAS
4. Fill:
mended brake fluid)
WARNING
performance.
cause vapor lock.
CAUTION:
5. Bleed:
brake system
DOT 4
6. Check:
brake fluid level
level.
LEVEL in chapter 3.
a
4 - 32
CHAS
7. Check:
system.
4 - 33
CHAS
EAS06120
FRONT BRAKE CALIPER
6
1
2
5
4
3
T R .
.
6 Nm (0.6 m kg, 4.3 ft Ib)
T R .
.
23 Nm (2.3 m kg, 17 ft Ib)
T R .
.
23 Nm (2.3 m kg, 17 ft Ib)
New
Removing the front brake caliper Remove the parts in the order listed.
Brake fluid Drain.
1 Holder 1
2 Brake hose union bolt 1
Refer to DISASSEMBLING THE
FRONT BRAKE CALIPER and
FRONT BRAKE CALIPER.
3 Copper washer 2
4 Front brake hose 1
5 Front brake caliper bolt 2
6 Front brake caliper 1
cedure.
4 - 34
CHAS
* Apply silicone grease
Disassembling the front brake cali-
per
1 Brake pad clip 1
2 Brake pad pin 1
3 Brake pad 2
Refer to ASSEMBLING AND INSTALL-
ING THE FRONT BRAKE CALIPER.
5 Brake pad spring 1
FRONT BRAKE CALIPER and
FRONT BRAKE CALIPER.
7 Brake caliper housing 1
8 Brake caliper piston 2
9 Brake caliper dust seal 2
0 Brake caliper piston seal 2
4 - 35
CHAS
A Bleed screw/cap 1/1
B Brake caliper body 1
procedure.
4 - 36
CHAS
EAS06160
REAR BRAKE CALIPER
1
6
2
5
4
3 New
T R .
.
7 Nm (0.7 m kg, 5.1 ft Ib)
T R .
.
6 Nm (0.6 m kg, 4.3 ft Ib)
T R .
.
40 Nm (4.0 m kg, 29 ft Ib)
T R .
.
23 Nm (2.3 m kg, 17 ft Ib)
Removing the rear brake caliper Remove the parts in the order listed.
Muffler Refer to ENGINE REMOVAL in
chapter5.
Brake fluid Drain.
1 Brake hose holder 1
Refer to DISASSEMBLING THE REAR
BRAKE CALIPER and ASSEMBLING
AND INSTALLING THE REAR BRAKE
CALIPER.
2 Brake hose union bolt 1
3 Copper washer 2
4 Rear brake hose 1
5 Rear brake caliper bolt 3
cedure.
4 - 37
CHAS
2
0
9
1
1
4
3
4
8
6
7
5
5
New
New
T R .
.
6 Nm (0.6 m kg, 4.3 ft Ib)
T R .
.
27 Nm (2.7 m kg, 19 ft Ib)
Disassembling the rear brake cali-
per
1 Rear brake caliper retaining bolt 2
Refer to ASSEMBLING AND INSTALL-
ING THE REAR BRAKE CALIPER.
3 Brake pad 2
4 Brake pad shim 4
6 Brake caliper piston 2 Refer to DISASSEMBLING THE REAR
BRAKE CALIPER and ASSEMBLING
AND INSTALLING THE REAR BRAKE
CALIPER.
7 Brake caliper dust seal 2
8 Brake caliper piston seal 2
9 Bleed screw/cap 1/1
0 Brake caliper body 1
procedure.
4 - 38
CHAS
EAS06190
DISASSEMBLING THE FRONT BRAKE
CALIPER
NOTE:
Before disassembling the brake caliper, drain
the brake fluid from the entire brake system.
1. Remove:
copper washers 2
brake hose 3
brake caliper bolts 4
brake caliper 5
NOTE:
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
3
1
2
4
5
2. Remove:
brake caliper bracket 1
brake caliper housing 2
2
1
3. Remove:
brake caliper pistons 1
brake caliper dust seals and piston seals 2
a. Blow compressed air into the brake hose
joint opening a to force out the pistons
from the brake caliper.
WARNING
Cover the brake caliper pistons with a
rag. Be careful not to get injured when the
pistons are expelled from the brake cali-
per.
Never try to pry out the brake caliper pis-
tons.
b. Remove the brake caliper dust seals and
piston seals.
1
2
2
a
4 - 39
CHAS
EAS00627
DISASSEMBLING THE REAR BRAKE
CALIPER
NOTE:
Before disassembling the brake caliper, drain
the brake fluid from the entire brake system.
1. Remove:
copper washers 2
brake hose 3
brake caliper
NOTE:
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
2. Remove:
brake caliper dust seals and piston seals 2
a. Blow compressed air into the brake hose
joint opening a to force out the pistons
from the brake caliper.
WARNING
Cover the brake caliper pistons with a
rag. Be careful not to get injured when the
pistons are expelled from the brake cali-
per.
Never try to pry out the brake caliper pis-
tons.
b. Remove the brake caliper dust seals and
piston seals.
a
4 - 40
CHAS
EAS06330
CALIPERS
1. Check:
Rust/scratches/wear Replace the brake
caliper pistons.
brake caliper cylinders 2
Scratches/wear Replace the brake cali-
per assembly.
brake caliper body 3
Cracks/damage Replace the brake cali-
per assembly.
brake fluid delivery passages (brake caliper
body)
air.
WARNING
Whenever a brake caliper is disassembled,
replace the brake caliper piston seals.
Front
Rear
2. Check:
brake caliper bracket
Recommended brake component
replacement schedule
Brake pads If necessary
Dust seals, Piston
seals
Every two years
Brake hose Every four years
Brake fluid
Every two years
and whenever the
brake is disassem-
bled
3
2
1
4 - 41
CHAS
EAS06350
FRONT BRAKE CALIPER
WARNING
components as they will cause the piston
seals to swell and distort.
Whenever a brake caliper is disassem-
bled, replace the brake caliper dust seals
and piston seals.
1. Install:
brake caliper dust seals and piston
seals 1
brake calliper pistons 2
2. Install:
brake caliper housing
DOT 4
2
1
1
New
New
New
T R .
.
45 Nm (4.5 m kg, 32 ft lb)
3. Install:
brake caliper 1
(temporarily)
copper washers 2
brake hose 3
WARNING
CAUTION:
While holding the brake hose, tighten the
union bolt within the range shown in the
illustration.
3
4
2
1
New
45 2
New
T R .
.
23 Nm (2.3 m kg, 17 ft lb)
4 - 42
CHAS
4. Remove:
brake caliper
5. Install:
brake pad support
brake pad spring
brake pads
BRAKE PADS.
6. Install:
brake caliper
brake caliper bolts
7. Fill:
mended brake fluid)
WARNING
performance.
cause vapor lock.
CAUTION:
8. Bleed:
brake system
DOT 4
T R .
.
23 Nm (2.3 m kg, 17 ft lb)
4 - 43
CHAS
9. Check:
brake fluid level
level.
LEVEL in chapter 3.
10.Check:
system.
a
EAS06351
REAR BRAKE CALIPER
WARNING
components.
Whenever a brake caliper is disassem-
bled, replace the brake caliper dust seals
and piston seals.
1. Install:
brake caliper dust seals and piston
seals 1
brake calliper pistons 2
2. Install:
brake pad supports
DOT 4
New
T R .
.
40 Nm (4.0 m kg, 29 ft lb)
4 - 44
CHAS
3. Install:
brake caliper 1
(temporarily)
copper washers 2
brake hose 3
WARNING
CAUTION:
brake caliper, make sure the brake pipe
touches the projection a on the brake cali-
per.
4. Remove:
brake caliper
5. Install:
brake pad shims
brake pads
Refer to REPLACING THE REAR BRAKE
PADS.
6. Install:
brake caliper
New
T R .
.
23 Nm (2.3 m kg, 17 ft lb)
T R .
.
27 Nm (2.7 m kg, 19 ft lb)
4 - 45
CHAS
7. Fill:
mended brake fluid)
WARNING
performance.
cause vapor lock.
CAUTION:
8. Bleed:
brake system
DOT 4
9. Check:
brake fluid level
level.
LEVEL in chapter 3.
a
4 - 46
CHAS
10.Check:
system.
4 - 47
CHAS
FRONT FORK
EAS06460
FRONT FORK
3
4
2
5
1
New
T R .
.
22 Nm (2.2 m kg, 16 ft Ib)
T R .
.
23 Nm (2.3 m kg, 17 ft Ib)
Removing the front fork legs Remove the parts in the order listed.
The following procedure applies to both
of the front fork legs.
Front cowling Refer to COVERS AND PANELS in
chapter 3.
Front wheel Refer to FRONT WHEEL AND BRAKE
DISC.
1 Front brake caliper 1 Refer to REMOVING THE FRONT
FORK LEGS.
2 Front fender 1
3 Clip 1
Refer to REMOVING THE FRONT
FORK LEGS and INSTALLING THE
FRONT FORK LEGS.
4 Lower bracket pinch bolt 2
5 Front fork leg 1
cedure.
4 - 48
CHAS
FRONT FORK
Disassembling the front fork legs Remove the parts in the order listed.
The following procedure applies to both
of the front fork legs.
1 Rubber cap 1
FRONT FORK LEGS and ASSEM-
BLING THE FRONT FORK LEGS.
2 Circlip 1
3 Front fork cap 1
4 O-ring 1
5 Fork spring 1
6 Dust seal 1
7 Oil seal clip 1
8 Damper rod bolt 1
9 Copper washer 1
0 Damper rod 1
A Rebound spring 1
4 - 49
CHAS
FRONT FORK
B Inner tube 1
FRONT FORK LEGS and ASSEM-
BLING THE FRONT FORK LEGS.
C Inner tube bushing 1
D Oil flow stopper 1
E Oil seal 1
F Washer 1
G Outer tube bushing 1
H Outer tube 1
procedure.
4 - 50
CHAS
FRONT FORK
EAS06490
REMOVING THE FRONT FORK LEGS
front fork legs.
WARNING
NOTE:
2. Remove:
clip 1
3. Loosen:
lower bracket pinch bolts 2
WARNING
Support the front fork leg while loosening
the lower bracket pinch bolts.
4. Remove:
front fork leg
1
2
EAS06520
DISASSEMBLING THE FRONT FORK LEGS
front fork legs.
1. Remove:
rubber cap
circlip 1
front fork cap 2
O-ring
fork spring
NOTE:
Push the front fork cap in the direction of the
arrow shown in the illustration to remove the
circlip.
2
1 1
4 - 51
CHAS
FRONT FORK
2. Drain:
fork oil
NOTE:
Stroke the inner tube several times while
draining the fork oil.
3. Remove:
dust seal 1
oil seal clip 2
(with a flat-head screwdriver)
CAUTION:
Do not scratch the inner tube.
1
2
4. Remove:
damper rod bolt 1
damper rod
rebound spring
NOTE:
Hold the damper rod with the damper rod
holder 2 and T-handle 3, then loosen the
damper rod bolt.
Damper rod holder
90890-01294
T-handle
90890-01326
4 - 52
CHAS
FRONT FORK
5. Remove:
inner tube
a. Hold the front fork leg horizontally.
b. Securely clamp the brake caliper bracket in
a vise with soft jaws.
c. Separate the inner tube from the outer tube
by pulling the inner tube forcefully but care-
fully.
CAUTION:
Excessive force will damage the oil seal
and bushing. A damaged oil seal or bush-
ing must be replaced.
Avoid bottoming the inner tube into the
outer tube during the above procedure,
as the oil flow stopper will be damaged.
EAS06560
CHECKING THE FRONT FORK LEGS
front fork legs.
1. Check:
inner tube 1
outer tube 2
Bends/damage/scratches Replace.
WARNING
Do not attempt to straighten a bent inner
tube as this may dangerously weaken it.
2. Measure:
spring free length a
Spring free length
308.0 mm (12.126 in)
Limit
301.87 mm (11.885 in)
4 - 53
CHAS
FRONT FORK
3. Check:
damper rod 1
Obstruction Blow out all of the oil pas-
sages with compressed air.
oil flow stopper 2
Damage Replace.
CAUTION:
When disassembling and assembling the
front fork leg, do not allow any foreign
material to enter the front fork.
1
2
EAS06590
ASSEMBLING THE FRONT FORK LEGS
front fork legs.
WARNING
Make sure the oil levels in both front fork
legs are equal.
Uneven oil levels can result in poor han-
dling and a loss of stability.
NOTE:
When assembling the front fork leg, be sure
to replace the following parts:
- outer tube bushing
- inner tube bushing
- oil seal
- dust seal
- O-ring
- clip
Before assembling the front fork leg, make
sure all of the components are clean.
4 - 54
CHAS
FRONT FORK
1. Install:
damper rod 1
rebound spring 2
CAUTION:
Allow the damper rod to slide slowly down
the inner tube 3 until it protrudes from the
bottom of the inner tube. Be careful not to
damage the inner tube.
2. Lubricate:
inner tubes outer surface
Fork oil 15 W or equivalent
2
1
3
3. Install:
inner tube bushing 1
inner tube 2
(into outer tube 3)
oil flow stopper 4
3
4
2
1 New
New
4. Install:
copper washer 1
damper rod bolt 2
2
1
New
New
4 - 55
CHAS
FRONT FORK
5. Tighten:
damper rod bolt 1
NOTE:
Hold the damper rod with the damper rod
holder 2 and T-handle 3, then tighten the
damper rod bolt.
T

R
.
.
Damper rod bolt
28 Nm (2.8 m kg, 20 ft lb)
Damper rod holder
90890-01294
T-handle
90890-01326
6. Install:
outer tube bushing 1
washer 2
(with the fork seal driver weight 3 and fork
seal driver attachment 4)
90890-01367
90890-01370
New
4 - 56
CHAS
FRONT FORK
7. Install:
oil seal 1
(with the fork seal driver weight 2 and fork
seal driver attachment 3)
CAUTION:
Make sure the numbered side of the oil seal
faces up.
NOTE:
Before installing the oil seal, lubricate its lips
with lithium-soap-based grease.
Lubricate the outer surface of the inner tube
with fork oil.
Before installing the oil seal, cover the top of
the front fork leg with a plastic bag to protect
the oil seal during installation.
90890-01367
90890-01370
New
8. Install:
oil seal clip 1
NOTE:
Adjust the oil seal clip so that it fits into the
outer tubes groove.
9. Install:
dust seal 1
(with the fork seal driver weight 2)
90890-01367
New
4 - 57
CHAS
FRONT FORK
10.Fill:
front fork leg
mended fork oil)
NOTE:
While filling the front fork leg, keep it upright.
After filling, slowly pump the front fork leg up
and down to distribute the fork oil.
Quantity (each front fork leg)
195.0 cm
3

(6.86 Imp oz, 6.59 US oz)
Recommended oil
Fork oil 15 W or equivalent
Front fork leg oil level a (from
the top of the inner tube, with the
inner tube fully compressed and
without the fork spring)
105.0 mm (4.13 in)
11.Install:
fork spring 1
NOTE:
Install the spring with the smaller pitch a fac-
ing up.
12.Install:
O-ring
(to front fork cap)
front fork cap
circlip
NOTE:
Before installing the cap, lubricate its O-ring
with grease.
Insert the front fork cap into the inner tube,
and then install the circlip, making sure that
the cap is securely held in place with the cir-
clip.
a
1
New
New
4 - 58
CHAS
FRONT FORK
EAS06630
INSTALLING THE FRONT FORK LEGS
front fork legs.
1. Install:
front fork leg 1
lower bracket pinch bolts 2
NOTE:
Pull up the inner tube until it stops, and then
tighten the lower bracket pinch bolts.
2. Install:
clip 3
2
3 New
T R .
.
22 Nm (2.2 m kg, 16 ft lb)
New
4 - 59
CHAS
HANDLEBAR
EAS06640
HANDLEBAR
6
1 7
5
5
3
12
13
9
11
1
10
8
4 2
T R .
.
7 Nm (0.7 m kg, 5.1 ft Ib)
T R .
.
26 Nm (2.6 m kg, 19 ft Ib)
T R .
.
23 Nm (2.3 m kg, 17 ft Ib)
T R .
.
7 Nm (0.7 m kg, 5.1 ft Ib)
T R .
.
26 Nm (2.6 m kg, 19 ft Ib)
LS
6
LS
Removing the handlebar Remove the parts in the order listed.
chapter 3.
1 Grip end 2
2 Front brake light switch connector 2 Disconnect.
3 Front brake master cylinder holder 1 Refer to INSTALLING THE HANDLE-
BAR. 4 Front brake master cylinder 1
5 Throttle cable housing 2 Refer to REMOVING
THE HANDLEBAR and
INSTALLING THE HAN-
DLEBAR.
6 Throttle cable 2 Disconnect.
7 Throttle grip 1
8 Rear brake light switch connector 2 Disconnect.
9 Rear brake master cylinder holder 1 Refer to INSTALLING THE HANDLE-
BAR. 10 Rear brake master cylinder 1
4 - 60
CHAS
HANDLEBAR
6
1 7
5
5
3
12
13
9
11
1
10
8
4 2
T R .
.
7 Nm (0.7 m kg, 5.1 ft Ib)
T R .
.
26 Nm (2.6 m kg, 19 ft Ib)
T R .
.
23 Nm (2.3 m kg, 17 ft Ib)
T R .
.
7 Nm (0.7 m kg, 5.1 ft Ib)
T R .
.
26 Nm (2.6 m kg, 19 ft Ib)
LS
6
LS
11 Handlebar grip 1 Refer to REMOVING THE HANDLE-
BAR and INSTALLING THE HANDLE-
BAR.
12 Upper handlebar holder 2 Refer to INSTALLING THE HANDLE-
BAR. 13 Handlebar 1
cedure.
4 - 61
CHAS
HANDLEBAR
EAS06660
REMOVING THE HANDLEBAR
WARNING
2. Remove:
throttle cable housings 1
throttle cables 2
throttle grip 3
NOTE:
While removing the throttle cable housing, pull
back the rubber cover 4.
1
2
3
1
4
3. Remove:
handlebar grip 1
NOTE:
Blow compressed air between the handlebar
and the handlebar grip, and gradually push the
grip off the handlebar.
EAS06680
CHECKING THE HANDLEBAR
1. Check:
handlebar 1
Bends/cracks/damage Replace.
WARNING
Do not attempt to straighten a bent handle-
bar as this may dangerously weaken it.
EAS06700
INSTALLING THE HANDLEBAR
WARNING
4 - 62
CHAS
HANDLEBAR
2. Install:
handlebar 1
upper handlebar holders 2
CAUTION:
First, tighten the bolt on the front side of
the handlebar holders, and then on the rear
side.
NOTE:
The upper handlebar holders should be
installed with the arrow marks a facing for-
ward .
Align the match mark b on the handlebar
with the upper surface of the lower handlebar
holder.
3. Install:
handlebar grip
a. Apply a thin coat of rubber adhesive onto
the left end of the handlebar.
b. Slide the handlebar grip over the left end of
the handlebar.
c. Wipe off any excess rubber adhesive with a
clean rag.
WARNING
Do not touch the handlebar grip until the
rubber adhesive has fully dried.
1
2
b
T R .
.
23 Nm (2.3 m kg, 17 ft lb)
4. Install:
rear brake master cylinder 1
rear brake master cylinder holder
NOTE:
1
a
b
T R .
.
7 Nm (0.7 m kg, 5.1 ft lb)
4 - 63
CHAS
HANDLEBAR
5 Install:
throttle grip 1
throttle cables 2
throttle cable housings 3
NOTE:
Lubricate the inside of the throttle grip with a
thin coat of lithium-soap-based grease and
install it onto the handlebar.
Align the projection a on the throttle cable
housing with the hole b in the handlebar.
Be sure to slide the throttle cable rubber
cover to its original position.
3
1
2
3
a
b
6. Install:
front brake master cylinder 1
front brake master cylinder holder
NOTE:
7. Adjust:
CABLE FREE PLAY in chapter 3.
Throttle cable free play (at the
flange of the throttle grip)
4.0 ~ 6.0 mm (0.16 ~ 0.24 in)
1
a
b
T R .
.
7 Nm (0.7 m kg, 5.1 ft lb)
4 - 64
CHAS
STEERING HEAD
EAS06750
STEERING HEAD
LOWER BRACKET
4
5
6
7
8
9
11
12
13
18
3
2
1
10
15
16
14
17
LS
LS T R .
.
75 Nm (7.5 m kg, 54 ft Ib)
T R .
.
38 Nm (3.8 m kg, 27 ft Ib)
22 Nm (2.2 m kg, 16 ft Ib)
1st
2nd
T R .
.
120 Nm (12.0 m kg, 85 ft Ib)
Removing the lower bracket Remove the parts in the order listed.
chapter 3.
Front fork Refer to FRONT WHEEL AND BRAKE
DISC.
Handlebar Refer to HANDLEBAR.
1 Air temperature sensor 1
2 Steering stem nut 1
3 Lower handlebar holder 1
Refer to REMOVING THE LOWER
BRACKET and INSTALLING THE
STEERING HEAD.
4 Woodruff key 1
5 Upper ring nut 1
6 Lock washer 1
7 Center ring nut 1
8 Rubber washer 1
9 Lower ring nut 1
10 Lower bracket 1
4 - 65
CHAS
STEERING HEAD
4
5
6
7
8
9
11
12
13
18
3
2
1
10
15
16
14
17
LS
LS T R .
.
75 Nm (7.5 m kg, 54 ft Ib)
T R .
.
38 Nm (3.8 m kg, 27 ft Ib)
22 Nm (2.2 m kg, 16 ft Ib)
1st
2nd
T R .
.
120 Nm (12.0 m kg, 85 ft Ib)
11 Upper bearing cover 1
12 Upper bearing inner race 1
Refer to INSTALLING THE STEERING
HEAD.
13 Upper bearing 1
14 Lower bearing 1
15 Lower bearing outer race 1
16 Dust seal 1
17 Lower bearing inner race 1 Refer to INSTALLING THE STEERING
HEAD. 18 Upper bearing outer race 1
cedure.
4 - 66
CHAS
STEERING HEAD
EAS06780
REMOVING THE LOWER BRACKET
WARNING
2. Remove:
lower handlebar holder 1
woodruff key 2
1
2
3. Remove:
upper ring nut 1
(with the steering nut wrench 2)
lock washer
center ring nut
rubber washer
Steering nut wrench
90890-01403
2
1
4. Remove:
lower ring nut 1
(with the steering nut wrench 2)
lower bracket
WARNING
Securely support the lower bracket so that
there is no danger of it falling.
Steering nut wrench
90890-01403
4 - 67
CHAS
STEERING HEAD
EAS06810
CHECKING THE STEERING HEAD
1. Wash:
bearings
bearing races
2. Check:
bearings
bearing races
Damage/pitting Replace.
Recommended cleaning solvent
Kerosene
3. Replace:
bearings
bearing races
a. Remove the bearing races from the steering
head pipe with a long rod 1 and a hammer.
b. Remove the bearing race from the lower
bracket with a floor chisel 2 and a hammer.
c. Install a new rubber seal and new bearing
races.
CAUTION:
If the bearing race is not installed properly,
the steering head pipe could be damaged.
NOTE:
Always replace the bearings and bearing
races as a set.
Whenever the steering head is disassem-
bled, replace the dust seal.
4. Check:
lower handlebar holder
lower bracket
(along with the steering stem)
4 - 68
CHAS
STEERING HEAD
EAS06840
INSTALLING THE STEERING HEAD
1. Lubricate:
upper bearing
lower bearing
bearing races
2. Install:
upper bearing
WARNING
When installing the upper bearing, do not
mistake the up and down directions for the
upper bearing.
3. Install:
lower ring nut 1
rubber washer
center ring nut 2
lock washer 3
upper ring nut 4
Refer to CHECKING AND ADJUSTING
THE STEERING HEAD in chapter 3.
4. Install:
woodruff key 1
lower handlebar holder 2
steering stem nut
NOTE:
Align the woodruff key with the groove a in
the lower handlebar holder.
2
1
a
T R .
.
120 Nm (12.0 m kg, 85 ft lb)
4 - 69
CHAS
REAR SHOCK ABSORBER ASSEMBLIES AND
SWINGARM
EAS06850
REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM
4
4
8
3
2
10
12
5
6
11
9
1
7
New
New
New
LS
LS
LS
T R .
.
32 Nm (3.2 m kg, 23 ft Ib) T R .
.
40 Nm (4.0 m kg, 29 ft Ib)
T R .
.
135 Nm (13.5 m kg, 98 ft lb)
T R .
.
16 Nm (1.6 m kg, 11 ft Ib)
T R .
.
59 Nm (5.9 m kg, 43 ft Ib)
T R .
.
7 Nm (0.7 m kg, 5.1 ft Ib)
T R .
.
18 Nm (1.8 m kg, 13 ft Ib)
Removing the rear shock absorber
assemblies and swingarm
Mudguard assembly Refer to COVERS AND PANELS in
chapter 3.
5.
1 Rear wheel axle nut 1 Refer to REMOVING THE SWING-
ARM and INSTALLING THE SWING-
ARM.
4 Rear shock absorber assembly 2 Refer to REMOVING THE REAR
SHOCK ABSORBER ASSEMBLIES and
INSTALLING THE REAR SHOCK
ABSORBER ASSEMBLIES.
4 - 70
CHAS
SWINGARM
4
4
8
3
2
10
12
5
6
11
9
1
7
New
New
New
LS
LS
LS
T R .
.
32 Nm (3.2 m kg, 23 ft Ib) T R .
.
40 Nm (4.0 m kg, 29 ft Ib)
T R .
.
135 Nm (13.5 m kg, 98 ft lb)
T R .
.
16 Nm (1.6 m kg, 11 ft Ib)
T R .
.
59 Nm (5.9 m kg, 43 ft Ib)
T R .
.
7 Nm (0.7 m kg, 5.1 ft Ib)
T R .
.
18 Nm (1.8 m kg, 13 ft Ib)
5 Rear fender bracket 1 Refer to REMOVING THE SWING-
ARM and INSTALLING THE SWING-
ARM.
6 Swingarm 1
7 Spacer 1
8 Collar 1
9 Oil seal 1
10 Oil seal 1
11 Circlip 1
12 Bearing 1
cedure.
4 - 71
CHAS
SWINGARM
EAS06930
REMOVING THE REAR SHOCK ABSORBER
ASSEMBLIES
WARNING
NOTE:
2. Remove:
rear shock absorber lower bolts 1
rear shock absorber upper bolts 2
1
2 2
1
EAS06960
CHECKING THE REAR SHOCK ABSORBER
ASSEMBLIES
1. Check:
rear shock absorber rod
Bends/damage Replace the rear shock
absorber assembly.
rear shock absorber
Oil leaks Replace the rear shock
absorber assembly.
spring
Damage/wear Replace the rear shock
absorber assembly.
bushings
bolts
Bends/damage/wear Replace.
4 - 72
CHAS
SWINGARM
EAS06990
INSTALLING THE REAR SHOCK
ABSORBER ASSEMBLIES
1. Install:
rear shock absorber upper nuts 1
rear shock absorber lower bolts 2
2
1 1
2
T R .
.
32 Nm (3.2 m kg, 23 ft lb)
T R .
.
18 Nm (1.8 m kg, 13 ft lb)
EAS07030
REMOVING THE SWINGARM
WARNING
NOTE:
2. Remove:
rear wheel axle nut 1
brake hose holder 2
rear brake caliper 3
rear shock absorber lower bolt (right) 4
rear fender bracket 5
NOTE:
Do not squeeze the rear brake lever when
removing the rear brake caliper.
3. Remove:
swingarm
2
3
5
4
1
4 - 73
CHAS
SWINGARM
EAS07070
CHECKING THE SWINGARM
1. Check:
swingarm
2. Check:
spacer 1
collar 2
oil seals 3
bearing 4
2
3
3
1
4
EAS07120
INSTALLING THE SWINGARM
1. Lubricate:
bearings
oil seal lips
drive axle
2. Install:
swingarm 1
rear fender bracket 2
rear fender bracket lower bolt
rear shock absorber lower bolt (right) 3
rear brake caliper 4
brake hose holder 5
rear wheel axle nut 6
T R .
.
59 Nm (5.9 m kg, 43 ft lb)
T R .
.
16 Nm (1.6 m kg, 11 ft lb)
T R .
.
18 Nm (1.8 m kg, 13 ft lb)
T R .
.
40 Nm (4.0 m kg, 29 ft lb)
T R .
.
7 Nm (0.7 m kg, 5.1 ft lb)
5
4
2
3
6
1
T R .
.
135 Nm (13.5 m kg, 98 ft lb)
ENG
CHAPTER 5
ENGINE
ENGINE REMOVAL ........................................................................................ 5-1
LEADS, HOSES, EXHAUST PIPE AND MUFFLER ................................. 5-1
ENGINE..................................................................................................... 5-3
INSTALLING THE ENGINE....................................................................... 5-4
CYLINDER HEAD............................................................................................ 5-5
REMOVING THE CYLINDER HEAD......................................................... 5-7
CHECKING THE CYLINDER HEAD......................................................... 5-8
CHECKING THE CAMSHAFT SPROCKET.............................................. 5-9
CHECKING THE TIMING CHAIN TENSIONER........................................ 5-9
INSTALLING THE CYLINDER HEAD....................................................... 5-9
CAMSHAFT AND ROCKER ARMS.............................................................. 5-13
REMOVING THE ROCKER ARMS AND CAMSHAFT............................ 5-14
CHECKING THE CAMSHAFT................................................................. 5-14
CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS ........ 5-15
INSTALLING THE CAMSHAFT AND ROCKER ARMS .......................... 5-17
VALVES AND VALVE SPRINGS.................................................................. 5-19
REMOVING THE VALVES...................................................................... 5-20
CHECKING THE VALVES AND VALVE GUIDES .................................. 5-21
CHECKING THE VALVE SEATS............................................................ 5-23
CHECKING THE VALVE SPRINGS........................................................ 5-25
INSTALLING THE VALVES .................................................................... 5-26
CYLINDER AND PISTON.............................................................................. 5-29
REMOVING THE PISTON ...................................................................... 5-30
CHECKING THE CYLINDER AND PISTON........................................... 5-30
CHECKING THE PISTON RINGS........................................................... 5-32
CHECKING THE PISTON PIN................................................................ 5-33
INSTALLING THE PISTON AND CYLINDER......................................... 5-34
ENG
BELT DRIVE.................................................................................................. 5-36
V-BELT CASE COVER ........................................................................... 5-36
V-BELT, PRIMARY SHEAVE AND SECONDARY SHEAVE.................. 5-37
SECONDARY SHEAVE.......................................................................... 5-39
REMOVING THE PRIMARY SHEAVE.................................................... 5-40
REMOVING THE SECONDARY SHEAVE AND V-BELT ....................... 5-40
DISASSEMBLING THE SECONDARY SHEAVE.................................... 5-41
CHECKING THE V-BELT........................................................................ 5-42
CHECKING THE PRIMARY SHEAVE WEIGHTS................................... 5-42
CHECKING THE SECONDARY SHEAVE.............................................. 5-42
CHECKING THE CLUTCH SHOES ........................................................ 5-43
ASSEMBLING THE PRIMARY SHEAVE................................................ 5-44
ASSEMBLING THE SECONDARY SHEAVE.......................................... 5-45
INSTALLING THE SECONDARY SHEAVE, V-BELT, AND PRIMARY
SHEAVE................................................................................................. 5-46
STARTER CLUTCH AND GENERATOR...................................................... 5-49
GENERATOR COVER AND STATOR COIL .......................................... 5-49
STARTER CLUTCH................................................................................ 5-51
REMOVING THE GENERATOR............................................................. 5-52
REMOVING THE STARTER CLUTCH ................................................... 5-53
CHECKING THE STARTER CLUTCH.................................................... 5-53
INSTALLING THE STARTER CLUTCH.................................................. 5-54
INSTALLING THE GENERATOR............................................................ 5-54
OIL PUMP...................................................................................................... 5-56
CHECKING THE OIL PUMP................................................................... 5-58
ASSEMBLING THE OIL PUMP............................................................... 5-59
INSTALLING THE OIL PUMP ASSEMBLY............................................. 5-59
TRANSMISSION ........................................................................................... 5-60
REMOVING THE TRANSMISSION ........................................................ 5-62
CHECKING THE TRANSMISSION......................................................... 5-62
CRANKSHAFT.............................................................................................. 5-63
CRANKSHAFT ASSEMBLY.................................................................... 5-63
DISASSEMBLING THE CRANKCASE.................................................... 5-65
REMOVING THE CRANKSHAFT ASSEMBLY....................................... 5-65
CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDE............. 5-66
CHECKING THE CRANKSHAFT AND CONNECTING ROD................. 5-67
CHECKING THE CRANKCASE.............................................................. 5-68
CHECKING THE BEARINGS.................................................................. 5-68
INSTALLING THE CRANKSHAFT.......................................................... 5-68
ASSEMBLING THE CRANKCASE.......................................................... 5-70
5 - 1
ENG
EAS00188
ENGINE
ENGINE REMOVAL
LEADS, HOSES, EXHAUST PIPE AND MUFFLER
2
4
3
5
11 10
10
6
7
1
9
8
New
New
T R .
.
40 Nm (4.0 m kg, 29 ft Ib)
T R .
.
65 Nm (6.5 m kg, 47 ft Ib)
T R .
.
14 Nm (1.4 m kg, 10 ft Ib)
T R .
.
7 Nm (0.7 m kg, 5.1 ft Ib)
T R .
.
20 Nm (2.0 m kg, 14 ft Ib)
Removing the leads, hoses, exhaust
pipe and muffler
Seat/rear side covers/footrest board/air
filter case assembly
Refer to COVERS AND PANELS and
AIR FILTER CASE in chapter 3.
Coolant Drain.
Refer to CHANGING THE COOLANT in
chapter 3.
Air cut-off valve Refer to AIR INDUCTION SYSTEM in
chapter 7.
Carburetor Refer to CARBURETOR in chapter 7.
Starter motor Refer to STARTER MOTOR in chapter
8.
1 Spark plug cap 1
2 Coolant temperature sensor connector 1 Disconnect.
3 Pickup coil/stator assembly coupler 2 Disconnect.
ENGINE REMOVAL
5 - 2
ENG
ENGINE REMOVAL
2
4
3
5
11 10
10
6
7
1
9
8
New
New
T R .
.
40 Nm (4.0 m kg, 29 ft Ib)
T R .
.
65 Nm (6.5 m kg, 47 ft Ib)
T R .
.
14 Nm (1.4 m kg, 10 ft Ib)
T R .
.
7 Nm (0.7 m kg, 5.1 ft Ib)
T R .
.
20 Nm (2.0 m kg, 14 ft Ib)
4 Thermostat outlet hose 1 Disconnect.
5 Water pump inlet hose 1
6 Muffler 1
7 Gasket 1
8 Exhaust pipe 1
9 Gasket 1
cedure.
5 - 3
ENG
ENGINE REMOVAL
EAS00191
ENGINE
6
2
2
1
5
7
3
3
3
8
7
1
7
LS
4
5
T R .
.
32 Nm (3.2 m kg, 23 ft Ib)
T R .
.
18 Nm (1.8 m kg, 13 ft Ib)
T R .
.
32 Nm (3.2 m kg, 23 ft Ib)
T R .
.
64 Nm (6.4 m kg, 46 ft Ib) T R .
.
64 Nm (6.4 m kg, 46 ft Ib)
T R .
.
59 Nm (5.9 m kg, 43 ft Ib)
Removing the engine Remove the parts in the order listed.
NOTE:
Place a suitable stand under the engine.
1 Rear shock absorber 2
Refer to INSTALLING THE ENGINE.
2 Engine mounting nut/washer/bolt 1/2/1
3 Engine bracket rod bolt/washer 2/4
4 Engine bracket rod 2
5 Spacer 1
6 Engine 1
7 Engine bracket nut/bolt 2/2
8 Engine bracket 1
cedure.
5 - 4
ENG
ENGINE REMOVAL
EAS00192
INSTALLING THE ENGINE
1. Install:
engine bracket 1
engine bracket rods 2
NOTE:
Engine bracket bolts and rod bolts should be
temporarily tightened.
2. Install:
engine
3. Tighten:
engine bracket rod bolts 3
engine mounting nut 4
engine bracket nuts 5
5
4
2 2
5
1
3
T R .
.
64 Nm (6.4 m kg, 46 ft lb)
T R .
.
32 Nm (3.2 m kg, 23 ft lb)
T R .
.
59 Nm (5.9 m kg, 43 ft lb)
5 - 5
ENG
CYLINDER HEAD
EAS00221
CYLINDER HEAD
New
New
New
LS
LS
LS
14
13
15
6
8
1
2
5
8
4
10
9
11
12
7
LS
New
New
New
New
New
New
3
LT
E
T R .
.
60 Nm (6.0 m kg, 43 ft Ib)
T R .
.
22 Nm (2.2 m kg, 16 ft Ib)
T R .
.
18 Nm (1.8 m kg, 13 ft Ib)
T R .
.
10 Nm (1.0 m kg, 7.2 ft Ib)
T R .
.
8 Nm (0.8 m kg, 5.8 ft Ib)
T R .
.
8 Nm (0.8 m kg, 5.8 ft Ib)
T R .
.
10 Nm (1.0 m kg, 7.2 ft Ib)
T R .
.
10 Nm (1.0 m kg, 7.2 ft Ib)
T R .
.
10 Nm (1.0 m kg, 7.2 ft Ib)
T R .
.
10 Nm (1.0 m kg, 7.2 ft Ib)
T R .
.
7 Nm (0.7 m kg, 5.1 ft Ib)
T R .
.
8 Nm (0.8 m kg, 5.8 ft Ib)
Removing the cylinder head Remove the parts in the order listed.
Engine Refer to ENGINE REMOVAL.
1 Coolant temperature sensor 1
2 Intake manifold 1
3 V-belt case air filter cover 1
4 Timing mark accessing plug 1
5 Spark plug 1
6 Oil check bolt 1
7 Camshaft sprocket cover 1
8 Tappet cover 2
5 - 6
ENG
CYLINDER HEAD
New
New
New
LS
LS
LS
14
13
15
6
8
1
2
5
8
4
10
9
11
12
7
LS
New
New
New
New
New
New
3
LT
E
T R .
.
60 Nm (6.0 m kg, 43 ft Ib)
T R .
.
22 Nm (2.2 m kg, 16 ft Ib)
T R .
.
18 Nm (1.8 m kg, 13 ft Ib)
T R .
.
10 Nm (1.0 m kg, 7.2 ft Ib)
T R .
.
8 Nm (0.8 m kg, 5.8 ft Ib)
T R .
.
8 Nm (0.8 m kg, 5.8 ft Ib)
T R .
.
10 Nm (1.0 m kg, 7.2 ft Ib)
T R .
.
10 Nm (1.0 m kg, 7.2 ft Ib)
T R .
.
10 Nm (1.0 m kg, 7.2 ft Ib)
T R .
.
10 Nm (1.0 m kg, 7.2 ft Ib)
T R .
.
7 Nm (0.7 m kg, 5.1 ft Ib)
T R .
.
8 Nm (0.8 m kg, 5.8 ft Ib)
9 Timing chain tensioner 1
Refer to REMOVING THE CYLINDER
HEAD and INSTALLING THE CYLIN-
DER HEAD.
10 Timing chain tensioner gasket 1
11 Camshaft sprocket plate 1
12 Camshaft sprocket 1
13 Cylinder head 1
14 Cylinder head gasket 1
15 Dowel pin 2
cedure.
5 - 7
ENG
CYLINDER HEAD
EAS00225
REMOVING THE CYLINDER HEAD
1. Remove:
camshaft sprocket cover
2. Align:
I mark a on the generator rotor
(with the stationary pointer b on the gener-
ator cover)
the crankshaft.
b. When the piston is at TDC on the compres-
sion stroke, align the I mark c on the
camshaft sprocket with the alignment mark
d on the cylinder head.
3. Remove:
camshaft sprocket bolt 1
timing chain tensioner
camshaft sprocket plate 2
camshaft sprocket 3
timing chain 4
NOTE:
To prevent the timing chain from falling into
the crankcase, fasten it with a wire.
While holding the primary sheave nut with a
wrench, remove the camshaft sprocket bolt
1.
4. Remove:
cylinder head
NOTE:
Loosen the cylinder head nuts and bolts in
the proper sequence as shown.
Loosen each cylinder head nut 1/2 of a turn
at a time. After all of the cylinder head nuts
are fully loosened, remove them.
5 - 8
ENG
CYLINDER HEAD
EAS00229
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.
cylinder head water jacket
Mineral deposits/rust Eliminate.
3. Measure:
cylinder head warpage
Out of specification Resurface the cylin-
der head.
a. Place a straightedge and a thickness gauge
across the cylinder head.
b. Measure the warpage.
c. If the limit is exceeded, resurface the cylin-
der head as follows.
d. Place a 400 ~ 600 grit wet sandpaper on
the surface plate and resurface the cylinder
head using a figure-eight sanding pattern.
NOTE:
To ensure an even surface, rotate the cylinder
head several times.
Maximum cylinder head warpage
0.05 mm (0.0020 in)
5 - 9
ENG
CYLINDER HEAD
EAS00207
CHECKING THE CAMSHAFT SPROCKET
1. Check:
camshaft sprocket
More than 1/4 tooth wear a Replace the
camshaft sprocket and the timing chain as a
set.
a1/4 tooth
bCorrect
1Timing chain roller
2Camshaft sprocket
EAS00210
CHECKING THE TIMING CHAIN
TENSIONER
1. Check:
2. Check:
one-way cam operation
Rough movement Replace the timing
chain tensioner housing.
3. Check:
cap bolt
spring
one-way cam
timing chain tensioner rod
Damage/wear Replace the defective
part(s).
INSTALLING THE CYLINDER HEAD
1. Install:
dowel pins
cylinder head gasket
2. Install:
cylinder head
NOTE:
Pass the timing chain through the timing chain
cavity.
New
5 - 10
ENG
CYLINDER HEAD
3. Tighten:
cylinder head nuts 1
cylinder head bolts 2
NOTE:
Apply engine oil to the threads of the cylinder
head nuts.
Tighten the cylinder head nuts and bolts in
the proper tightening sequence as shown
and torque them in two stages.
4. Install:
camshaft sprocket 1
timing chain 2
the crankshaft.
b. Align the I mark a on the generator rotor
with the stationary pointer b on the genera-
tor cover.
c. Align the I mark c on the camshaft
sprocket with the stationary pointer d on
the cylinder head.
d. Place the timing chain onto the camshaft
sprocket, and then install the camshaft
sprocket onto the camshaft.
NOTE:
When installing the camshaft sprocket, be
sure to keep the timing chain as tight as pos-
sible on the exhaust side.
Align the pin e on the camshaft with the slot
in the camshaft sprocket.
CAUTION:
Do not turn the crankshaft when installing
the camshaft to avoid damage or improper
valve timing.
e. While holding the camshaft, temporarily
tighten the camshaft sprocket bolt.
f. Remove the wire from the timing chain.
T R .
.
22 Nm (2.2 m kg, 16 ft lb)
T R .
.
10 Nm (1.0 m kg, 7.2 ft lb)
5 - 11
ENG
CYLINDER HEAD
5. Install:
camshaft sprocket plate 1
washer 2
camshaft sprocket bolt 3
6. Install:
a. Remove the cap bolt 1 and spring 2.
b. Release the timing chain tensioner one-way
cam 3 and push the timing chain tensioner
rod 4 all the way into the timing chain ten-
sioner housing.
c. Install the timing chain tensioner and gasket
5 onto the cylinder.
d. Install the spring 2 and cap bolt 1.
7. Turn:
crankshaft
(turn the primary sheave nut on the left side
of the crankshaft several turns counter-
clockwise several times)
8. Check:
I mark
Align the I mark a on the generator rotor
with the stationary pointer b on the genera-
tor cover.
I mark
Align the I mark c on the camshaft
sprocket with the stationary pointer d on
the cylinder head.
Out of alignment Correct.
Refer to the installation steps above.
T

R
.
.
Timing chain tensioner bolt
10 Nm (1.0 m kg, 7.2 ft lb)
T

R
.
.
Timing chain tensioner cap bolt
8 Nm (0.8 m kg, 5.8 ft lb)
5 - 12
ENG
CYLINDER HEAD
9. Tighten:
camshaft sprocket bolt
CAUTION:
Be sure to tighten the camshaft sprocket
bolt to the specified torque to avoid the
possibility of the bolt coming loose and
damaging the engine.
10.Measure:
valve clearance
Refer to ADJUSTING THE VALVE
CLEARANCE in chapter 3.
T R .
.
60 Nm (6.0 m kg, 43 ft lb)
5 - 13
ENG
CAMSHAFT AND ROCKER ARMS
EAS00195
New
1
2
8
5
8
2
1
6
7
4
3
T R .
.
8 Nm (0.8 m kg, 5.8 ft Ib)
T R .
.
14 Nm (1.4 m kg, 10 ft Ib)
T R .
.
14 Nm (1.4 m kg, 10 ft Ib)
Removing the camshaft and rocker
arms
Cylinder head Refer to CYLINDER HEAD.
1 Locknut 2 Loosen.
Refer to REMOVING THE
ROCKER ARMS AND CAM-
SHAFT and INSTALLING
THE CAMSHAFT AND
ROCKER ARMS.
2 Adjusting screw 2 Loosen.
3 Lock plate 1
4 Camshaft retainer 1
5 Camshaft 1
6 Intake rocker arm shaft 1
7 Exhaust rocker arm shaft 1
8 Rocker arm 2
cedure.
5 - 14
ENG
EAS00202
REMOVING THE ROCKER ARMS AND
CAMSHAFT
1. Straighten the lock plate tabs a.
2. Remove:
lock plate 1
camshaft retainer 2
3. Remove:
camshaft 1
NOTE:
Screw a 10 mm bolt 2 into the threaded end
of the camshaft, and then pull the camshaft
out.
4. Remove:
intake rocker arm shaft
exhaust rocker arm shaft
rocker arms
NOTE:
Remove the rocker arm shafts with the slide
hammer bolt 1 and weight 2.
Slide hammer bolt
90890-01083
Weight
90890-01084
EAS00205
CHECKING THE CAMSHAFT
1. Check:
camshaft lobes
Blue discoloration/pitting/scratches
Replace the camshaft.
5 - 15
ENG
2. Measure:
camshaft lobe dimensions a and b
Out of specification Replace the cam-
shaft.
Camshaft lobe dimensions
Intake
a 37.051 ~ 37.151 mm
(1.4587 ~ 1.4626 in)
<Limit>: 36.956 mm (1.4550 in)
b 30.074 ~ 30.174 mm
(1.1840 ~ 1.1880 in)
<Limit>: 29.973 mm (1.1800 in)
Exhaust
a 37.053 ~ 37.153 mm
(1.4588 ~ 1.4627 in)
<Limit>: 36.956 mm (1.4550 in)
b 30.091 ~ 30.191 mm
(1.1847 ~ 1.1886 in)
<Limit>: 29.194 mm (1.1494 in)
3. Check:
camshaft oil passage
air.
EAS00206
CHECKING THE ROCKER ARMS AND
ROCKER ARM SHAFTS
rocker arms and rocker arm shafts.
1. Check:
rocker arm (camshaft lobe contact surface
1)
adjusting screw surface 2
2. Check:
rocker arm shaft
Blue discoloration/excessive wear/pitting/
scratches Replace or check the lubrica-
tion system.
5 - 16
ENG
3. Measure:
rocker arm inside diameter
Rocker arm inside diameter
12.000 ~ 12.018 mm
(0.4724 ~ 0.4731 in)
<Limit>: 12.030 mm (0.4736 in)
4. Measure:
rocker arm shaft outside diameter
5. Calculate:
rocker-arm-to-rocker-arm-shaft clearance
Above 0.080 mm (0.0031 in) Replace the
defective part(s).
NOTE:
Calculate the clearance by subtracting the
rocker arm shaft outside diameter from the
rocker arm inside diameter.
Rocker arm shaft outside diame-
ter
11.981 ~ 11.991 mm
(0.4717 ~ 0.4721 in)
<Limit>: 11.950 mm (0.4705 in)
Rocker-arm-to-rocker-arm-shaft
clearance
0.009 ~ 0.037 mm
(0.0004 ~ 0.0015 in)
<Limit>: 0.080 mm (0.0031 in)
5 - 17
ENG
EAS00220
INSTALLING THE CAMSHAFT AND
ROCKER ARMS
1. Lubricate:
camshaft
2. Lubricate:
rocker arms
Camshaft
Molybdenum disulfide oil
Camshaft bearing
Engine oil
3. Install:
exhaust rocker arm
exhaust rocker arm shaft 1
NOTE:
Make sure the exhaust rocker arm shaft is
completely pushed into the cylinder head.
4. Install:
intake rocker arm
intake rocker arm shaft 1
NOTE:
Insert a guide shaft (8 mm) 2 into the stud bolt
hole in the cylinder head and install the intake
rocker arm shaft as shown.
CAUTION:
Make sure the threaded part of the rocker
arm shaft faces out.
5 - 18
ENG
5. Install:
camshaft 1
6. Install:
camshaft retainer 1
lock plate 2
camshaft retainer bolts 3
NOTE:
Bend the lock plate tab along a flat side of the
camshaft retainer bolts 3.
New
T R .
.
8 Nm (0.8 m kg, 5.8 ft lb)
5 - 19
ENG
VALVES AND VALVE SPRINGS
EAS00236
New New
New
New
7
1
2
4
3
7 8
3 4 2 1
9
8
9
6
5
M
M
M
Removing the valves and valve
springs
Rocker arms and camshaft Refer to CAMSHAFT AND ROCKER
ARMS.
1 Valve cotter 4
Refer to REMOVING THE VALVES
and INSTALLING THE VALVES.
2 Upper spring seat 2
3 Outer valve spring 2
4 Inner valve spring 2
5 Intake valve 1
6 Exhaust valve 1
7 Valve stem seal 2
8 Lower spring seat 2
9 Valve guide 2
cedure.
5 - 20
ENG
EAS00237
REMOVING THE VALVES
valves and related components.
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 valve seat Check the
valve face, valve seat, and valve seat width.
Refer to CHECKING THE VALVE SEATS.
a. Pour a clean solvent into the intake and
exhaust ports a.
b. Check that the valves properly seal.
NOTE:
There should be no leakage at the valve seat
1.
2. Remove:
valve cotters 1
NOTE:
Remove the valve cotters by compressing the
valve spring with the valve spring compressor
and the valve spring compressor attachment
2.
90890-04019
attachment
90890-04108
5 - 21
ENG
3. Remove:
upper spring seat 1
outer valve spring 2
inner valve spring 3
valve 4
valve stem seal 5
lower spring seat 6
NOTE:
Identify the position of each part very carefully
so that they can be reinstalled in their original
place.
EAS00239
CHECKING THE VALVES AND VALVE
GUIDES
valves and valve guides.
1. Measure:
valve-stem-to-valve-guide clearance
Out of specification Replace the valve
guide.
Valve-stem-to-valve-guide clearance =
Valve guide inside diameter a
Valve stem diameter b
Valve-stem-to-valve-guide clear-
ance
Intake
0.010 ~ 0.037 mm
(0.0004 ~ 0.0015 in)
<Limit>: 0.080 mm (0.0031 in)
Exhaust
0.025 ~ 0.052 mm
(0.0010 ~ 0.0020 in)
<Limit>: 0.100 mm (0.0039 in)
5 - 22
ENG
2. Replace:
valve guide
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 1.
b. Install the new valve guide with the valve
guide installer 2 and valve guide remover
1.
c. After installing the valve guide, bore the
valve guide with the valve guide reamer 3
to obtain the proper valve-stem-to-valve-
guide clearance.
NOTE:
After replacing the valve guide, reface the
valve seat.
3. Eliminate:
carbon deposits
(from the valve face and valve seat)
4. Check:
valve face
Pitting/wear Grind the valve face.
valve stem end
Mushroom shape or diameter larger than
the body of the valve stem Replace the
valve.
Valve guide remover (6)
90890-04064
Valve guide installer (6)
90890-04065
Valve guide reamer (6)
90890-04066
5 - 23
ENG
5. Measure:
valve margin thickness a
Out of specification Replace the valve.
Valve margin thickness
Intake
0.80 ~ 1.20 mm
(0.0315 ~ 0.0472 in)
<Limit> 0.5 mm (0.02 in)
Exhaust
0.80 ~ 1.20 mm
(0.0315 ~ 0.0472 in)
<Limit> 0.5 mm (0.02 in)
6. Measure:
valve stem runout
Out of specification Replace the valve.
NOTE:
When installing a new valve, always replace
the valve guide.
If the valve is removed or replaced, always
replace the oil seal.
Valve stem runout
0.010 mm (0.0004 in)
EAS00240
CHECKING THE VALVE SEATS
valves and valve seats.
1. Eliminate:
carbon deposits
(from the valve face and valve seat)
5 - 24
ENG
2. Check:
valve seat
Pitting/wear Replace the cylinder head.
3. Measure:
valve seat width a
Out of specification Replace the cylinder
head.
a. Apply Mechanics blueing dye (Dykem) b to
the valve face.
b. Install the valve into the cylinder head.
c. Press the valve through the valve guide and
onto the valve seat to make a clear impres-
sion.
d. Measure the valve seat width.
NOTE:
Where the valve seat and valve face contacted
one another, the blueing will have been
removed.
4. Lap:
valve face
valve seat
NOTE:
After replacing the cylinder head or replacing
the valve and valve guide, the valve seat and
valve face should be lapped.
a. Apply a coarse lapping compound a to the
valve face.
CAUTION:
Do not let the lapping compound enter the
gap between the valve stem and the valve
guide.
Valve seat width
Intake
0.90 ~ 1.10 mm
(0.0354 ~ 0.0433 in)
<Limit>: 1.6 mm (0.06 in)
Exhaust
0.90 ~ 1.10 mm
(0.0354 ~ 0.0433 in)
<Limit>: 1.6 mm (0.06 in)
5 - 25
ENG
b. Apply molybdenum disulfide oil to the valve
stem.
c. Install the valve into the cylinder head.
d. Turn the valve until the valve face and valve
seat are evenly polished, and then clean off
all of the lapping compound.
NOTE:
For the best lapping results, lightly tap the
valve seat while rotating the valve back and
forth between your hands.
e. Apply a fine lapping compound to the valve
face and repeat the above steps.
f. After every lapping procedure, be sure to
clean off all of the lapping compound from
the valve face and valve seat.
g. Apply Mechanics blueing dye (Dykem) b to
the valve face.
h. Install the valve into the cylinder head.
i. Press the valve through the valve guide and
onto the valve seat to make a clear impres-
sion.
j. Measure the valve seat width again. If the
valve seat width is out of specification,
reface and lap the valve seat.
EAS00241
CHECKING THE VALVE SPRINGS
valve springs.
1. Measure:
valve spring free length a
spring.
Valve spring free length
Intake and exhaust inner valve
spring
38.10 mm (1.50 in)
<Limit>: 36.10 mm (1.42 in)
Intake and exhaust outer valve
spring
36.93 mm (1.45 in)
<Limit>: 35.00 mm (1.38 in)
5 - 26
ENG
2. Measure:
compressed valve spring force a
spring.
bInstalled length
Compressed valve spring force
(installed)
spring
76 ~ 88 N
(7.80 ~ 9.00 kg, 17.20 ~ 19.85 lb)
at 30.10 mm (1.19 in)
spring
115 ~ 133 N
(11.73 ~ 13.56 kg,
25.85 ~ 29.90 lb) at 31.60 mm
(1.24 in)
3. Measure:
valve spring tilt a
spring.
Valve spring tilt limit
spring
2.5/1.7 mm (0.067 in)
spring
2.5/1.6 mm (0.063 in)
EAS00245
INSTALLING THE VALVES
valves and related components.
1. Deburr:
valve stem end
(with an oil stone)
5 - 27
ENG
2. Lubricate:
valve stem 1
valve stem seal 2
(with the recommended lubricant)
3. Install:
lower spring seat 1
valve stem seal 2
valve 3
inner valve spring 4
outer valve spring 5
upper spring seat 6
NOTE:
Install the valve spring with the larger pitch a
facing up.
bSmaller pitch
New
4. Install:
valve cotters 1
NOTE:
Install the valve cotters by compressing the
valve spring with the valve spring compressor
and the valve spring compressor attachment
2.
90890-04019
attachment
90890-04108
5 - 28
ENG
5. To secure the valve cotters onto the valve
stem, lightly tap the valve tip with a soft face
hammer.
CAUTION:
Hitting the valve tip with excessive force
could damage the valve.
5 - 29
ENG
CYLINDER AND PISTON
EAS00251
CYLINDER AND PISTON
LS
E
E
E
T R .
.
7 Nm (0.7 m kg, 5.1 ft Ib)
3
1
4
6
8
7 6
2
5
New
New
New
New
New
LS
9
10
11
Removing the cylinder and piston Remove the parts in the order listed.
1 Water pump outlet pipe 1
2 Timing chain guide (exhaust side) 1
3 Cylinder 1
4 Cylinder gasket 1 Refer to INSTALLING THE PISTON
AND CYLINDER. 5 Dowel pin 2
6 Piston pin clip 2
Refer to REMOVING THE PISTON
and INSTALLING THE PISTON AND
CYLINDER.
7 Piston pin 1
8 Piston 1
9 Top ring 1
10 2nd ring 1
11 Oil ring 1
cedure.
5 - 30
ENG
CYLINDER AND PISTON
EAS00253
REMOVING THE PISTON
1. Remove:
piston pin clips 1
piston pin 2
piston 3
CAUTION:
Do not use a hammer to drive the piston
pin out.
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 the piston pin, deburr the
piston pin clip groove and the piston pin bore
area. If both areas are deburred and the pis-
ton pin is still difficult to remove, remove it
with the piston pin puller set 4.
Piston pin puller set
90890-01304
2. Remove:
top ring
2nd ring
oil ring
NOTE:
When removing a piston ring, open the end
gap with your fingers and lift the other side of
the ring over the piston crown.
EAS00259
CHECKING THE CYLINDER AND PISTON
1. Check:
piston wall
cylinder wall
Vertical scratches Rebore or replace the
cylinder, and replace the piston and piston
rings as a set.
5 - 31
ENG
CYLINDER AND PISTON
2. Measure:
piston-to-cylinder clearance
a. Measure cylinder bore C with the cylinder
bore gauge.
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
rings as a set.
c. Measure piston skirt diameter P with the
micrometer.
a5 mm (0.20 in) from the bottom edge of the pis-
ton
d. If out of specification, replace the piston and
piston rings as a set.
e. Calculate the piston-to-cylinder clearance
with the following formula.
Cylinder bore C
69.000 ~ 69.005 mm
(2.7165 ~ 2.7167 in)
Taper limit T 0.050 mm (0.0020 in)
Out of round R 0.030 mm (0.0012 in)
C = maximum of D
1
~ D
2
T = maximum of D
1
or D
2
maximum of
D
5
or D
6
R = maximum of D
1
, D
3
or D
5
mini-
mum of D
2
, D
4
or D
6
Piston size P
Standard
68.965 ~ 68.980 mm
(2.7152 ~ 2.7157 in)
Piston-to-cylinder clearance =
Cylinder bore C
Piston skirt diameter P
Piston-to-cylinder clearance
0.020 ~ 0.040 mm
(0.0008 ~ 0.0016 in)
<Limit>: 0.15 mm (0.0059 in)
5 - 32
ENG
CYLINDER AND PISTON
f. If out of specification, rebore or replace the
rings as a set.
EAS00264
CHECKING THE PISTON RINGS
1. Measure:
piston ring side clearance
Out of specification Replace the piston
and piston rings as a set.
NOTE:
Before measuring the piston ring side clear-
ance, eliminate any carbon deposits from the
piston ring grooves and piston rings.
Piston ring side clearance
Top ring
0.040 ~ 0.080 mm
(0.0016 ~ 0.0031 in)
<Limit>: 0.120 mm (0.0047 in)
2nd ring
0.030 ~ 0.070 mm
(0.0012 ~ 0.0028 in)
<Limit>: 0.120 mm (0.0047 in)
2. Install:
piston ring
(into the cylinder)
NOTE:
Level the piston ring into the cylinder with the
piston crown.
a5 mm (0.20 in)
5 - 33
ENG
CYLINDER AND PISTON
3. Measure:
piston ring end gap
ring.
NOTE:
The end gap of the oil ring expander spacer
cannot be measured. If the oil ring rail gap is
excessive, replace all three piston rings.
Piston ring end gap
Top ring
0.15 ~ 0.30 mm
(0.0059 ~ 0.0118 in)
<Limit>: 0.45 mm (0.0177 in)
2nd ring
0.30 ~ 0.45 mm
(0.0118 ~ 0.0177 in)
<Limit>: 0.70 mm (0.0276 in)
Oil ring
0.20 ~ 0.70 mm
(0.0079 ~ 0.0276 in)
EAS00266
CHECKING THE PISTON PIN
1. Check:
piston pin
Blue discoloration/grooves Replace the
piston pin, and then check the lubrication
system.
2. Measure:
piston pin outside diameter a
pin.
Piston pin outside diameter
16.991 ~ 17.000 mm
(0.6689 ~ 0.6693 in)
<Limit>: 16.971 mm (0.6681 in)
5 - 34
ENG
CYLINDER AND PISTON
3. Measure:
piston pin bore diameter b (in the piston)
pin.
4. Calculate:
piston-pin-to-piston-pin-bore clearance
pin.
Piston pin bore diameter
17.004 ~ 17.015 mm
(0.6694 ~ 0.6699 in)
<Limit>: 17.045 mm (0.6711 in)
Piston-pin-to-piston-pin-bore clearance =
Piston pin bore diameter
(in the piston)
Piston pin outside diameter
Piston-pin-to-piston-pin-bore
clearance
0.004 ~ 0.024 mm
(0.0002 ~ 0.0009 in)
<Limit>: 0.074 mm (0.0029 in)
EAS00267
INSTALLING THE PISTON AND CYLINDER
1. Install:
top ring 1
2nd ring 2
upper oil ring rail 3
oil ring expander 4
lower oil ring rail 5
NOTE:
Be sure to install the piston rings so that the
manufacturers marks or numbers a face up.
5 - 35
ENG
CYLINDER AND PISTON
2. Install:
piston 1
piston pin 2
piston pin clips 3
NOTE:
Apply engine oil to the piston pin.
Make sure the arrow mark a on the piston
points towards the exhaust side of the cylin-
der.
Before installing the piston pin clip, cover the
crankcase opening with a clean rag to pre-
vent the clip from falling into the crankcase.
3. Install:
dowel pins
cylinder gasket
4. Lubricate:
piston
piston rings
cylinder
Engine oil
New
New
5. Offset:
piston ring end gaps
aTop ring
bUpper oil ring rail
cOil ring expander
dLower oil ring rail
e2nd ring
f20 mm (0.79 in)
Intake side
120
120 120
e
b
c
d
f f
a
6. Install:
cylinder
NOTE:
While compressing the piston rings with one
hand, install the cylinder with the other hand.
Pass the timing chain and timing chain guide
(intake side) through the timing chain cavity.
5 - 36
ENG
BELT DRIVE
EAS00316
BELT DRIVE
V-BELT CASE COVER
1
3
4
5
6
6
2
New
New
New
T R .
.
7 Nm (0.7 m kg, 5.1 ft Ib)
T R .
.
10 Nm (1.0 m kg, 7.2 ft Ib)
T R .
.
7 Nm (0.7 m kg, 5.1 ft Ib)
Removing the V-belt case cover Remove the parts in the order listed.
Center panel 1 (left)/air filter case
assembly
Refer to COVERS AND PANELS in
chapter 3.
1 V-belt case air filter cover 1
2 V-belt case air filter element 1
3 V-belt case cover 1
4 V-belt case 1
5 V-belt case gasket 1
6 Dowel pin 2
cedure.
5 - 37
ENG
BELT DRIVE
V-BELT, PRIMARY SHEAVE AND SECONDARY SHEAVE
LS
LS
E
9
New
New
New
13
10
7
2
1 3
4
5
8
12
14
15
LS
6
LS
11
R .
.
80 Nm (8.0 m kg, 58 ft Ib) T
T R .
.
60 Nm (6.0 m kg, 43 ft Ib)
T R .
.
3 Nm (0.3 m kg, 2.2 ft Ib)
T R .
.
22 Nm (2.2 m kg, 16 ft Ib)
* Apply Shell BT grease 3
(YAMAHA grease G 90793-40016)

Removing the V-belt, primary
sheave and secondary sheave
1 Primary sheave nut/washer 1/1 Refer to REMOVING THE PRIMARY
SHEAVE and INSTALLING THE SEC-
ONDARY SHEAVE, V-BELT, AND PRI-
MARY SHEAVE.
2 Primary fixed sheave 1
3 Secondary sheave bracket 1
4 Secondary sheave nut 1
Refer to REMOVING THE SECOND-
ARY SHEAVE AND V-BELT and
INSTALLING THE SECONDARY
SHEAVE, V-BELT, AND PRIMARY
SHEAVE.
5 Collar 1/1
6 Clutch housing 1
7 Secondary sheave assembly 1
8 V-belt 1
9 Primary sliding sheave 1
10 Spacer 1
5 - 38
ENG
BELT DRIVE
LS
LS
E
9
New
New
New
13
10
7
2
1 3
4
5
8
12
14
15
LS
6
LS
11
R .
.
80 Nm (8.0 m kg, 58 ft Ib) T
T R .
.
60 Nm (6.0 m kg, 43 ft Ib)
T R .
.
3 Nm (0.3 m kg, 2.2 ft Ib)
T R .
.
22 Nm (2.2 m kg, 16 ft Ib)
* Apply Shell BT grease 3
(YAMAHA grease G 90793-40016)

11 Primary sheave cap 1
12 Cam 1
13 Weight 8
14 Slider 4
15 Spacer 4
cedure.
5 - 39
ENG
BELT DRIVE
SECONDARY SHEAVE
1
4
3
7
7
7
7
5
New
New
A
0
8
9
2
6
0
New
New
New
New
T R .
.
90 Nm (9.0 m kg, 65 ft Ib)
New
4
** Apply BEL-RAY assembly lube

Disassembling the secondary
sheave
1 Clutch carrier nut 1
2 Clutch carrier 1
3 Clutch carrier plate 1
4 Clutch shoe spring 3
5 Compression spring 1
6 Spring seat 1
7 Guide pin 4
8 Secondary sliding sheave 1
9 O-ring 2
0 Oil seal 2
A Secondary fixed sheave 1
procedure.
5 - 40
ENG
BELT DRIVE
EAS00317
REMOVING THE PRIMARY SHEAVE
1. Remove:
V-belt case cover
V-belt case
NOTE:
Loosen each V-belt case bolt 1/4 of a turn at a
time, in stages and in a crisscross pattern.
After all of the bolts are fully loosened, remove
them.
2. Remove:
primary sheave nut 1
washer
primary fixed sheave 2
NOTE:
While holding the primary fixed sheave with
the rotor holding tool 3, loosen the primary
sheave nut.
Rotor holding tool
90890-01235
EAS00318
REMOVING THE SECONDARY SHEAVE
AND V-BELT
1. Remove:
secondary sheave nut 1
collar
clutch housing 2
NOTE:
While holding the clutch housing with the
sheave holder 3, loosen the secondary
sheave nut.
Sheave holder
90890-01701
5 - 41
ENG
BELT DRIVE
2. Loosen:
clutch carrier nut 1
CAUTION:
Do not remove the clutch carrier nut at this
stage.
NOTE:
While holding the clutch carrier with the
sheave holder 2, loosen the clutch carrier nut
one full turn with the locknut wrench 3.
Sheave holder
90890-01701
Locknut wrench
90890-01348
1
3
2
3. Remove:
secondary sheave assembly 1
V-belt 2
NOTE:
Remove the V-belt and secondary sheave
assembly from the primary sheave side.
2
1
EAS00319
DISASSEMBLING THE SECONDARY
SHEAVE
1. Remove:
NOTE:
While compressing the compression spring
with the clutch spring holder 2 and clutch
spring holder arm 3, remove the clutch carrier
nut.
90890-01337
90890-01464
5 - 42
ENG
BELT DRIVE
EAS00320
CHECKING THE V-BELT
1. Check:
V-belt 1
Grease/oil Clean the primary and sec-
ondary sheaves.
2. Measure:
V-belt width 2
V-belt width
23.0 mm (0.91 in)
<Limit>: 21.0 mm (0.83 in)
EAS00321
CHECKING THE PRIMARY SHEAVE
WEIGHTS
primary sheave weights.
1. Check:
primary sheave weight
2. Measure:
primary sheave weight outside diameter
Primary sheave weight outside
diameter
20.0 mm (0.79 in)
<Limit>: 19.5 mm (0.77 in)
EAS00322
CHECKING THE SECONDARY SHEAVE
1. Check:
secondary fixed sheave
secondary sliding sheave
Cracks/damage/wear Replace the sec-
ondary fixed and sliding sheaves as a set.
5 - 43
ENG
BELT DRIVE
2. Check:
torque cam groove 1
Damage/wear Replace the secondary
fixed and sliding sheaves as a set.
3. Check:
guide pin 2
Damage/wear Replace the secondary
fixed and sliding sheaves as a set.
4. Check:
compression spring free length
Out of specification Replace the spring.
Compression spring free length
102.4 mm (4.03 in)
<Limit>: 90.0 mm (3.54 in)
CHECKING THE CLUTCH SHOES
clutch shoes.
1. Check:
clutch shoe
Damage/wear Replace the clutch shoes
and springs as a set.
Glazed areas Sand with coarse sandpa-
per.
NOTE:
After sanding the glazed areas, clean the
clutch with a cloth.
2. Measure:
clutch shoe thickness
Out of specification Replace the clutch
shoes and springs as a set.
Clutch shoe thickness
3.3 mm (0.13 in)
<Limit>: 2.0 mm (0.08 in)
5 - 44
ENG
BELT DRIVE
EAS00323
ASSEMBLING THE PRIMARY SHEAVE
1. Clean:
primary sliding sheave 2
spacer 3
primary sheave weights 4
primary sliding sheave cam face 5
2. Install:
primary sheave weights 1
spacer 2
NOTE:
Before installing the primary sheave weights,
lubricate the inside and outside of each weight
with Shell BT grease 3
.
Shell BT grease 3
3. Install:
spacers 1
sliders 2
cam 3
primary sheave cap
T R .
.
3 Nm (0.3 m kg, 2.2 ft lb)
5 - 45
ENG
BELT DRIVE
EAS00324
ASSEMBLING THE SECONDARY SHEAVE
1. Lubricate:
secondary fixed sheaves inner surface 1
secondary sliding sheaves inner surface 2
oil seals
BEL-RAY assembly lube
New
2. Install:
oil seals
secondary sliding sheave 1
NOTE:
Install the secondary sliding sheave onto the
secondary fixed sheave 2 with the oil seal
guide 3.
Oil seal guide (41)
90890-01396
3
1
2
New
3. Install:
guide pins 1
4. Lubricate:
guide pin grooves 2
O-rings 3
BEL-RAY assembly lube
2
1
New
3
New
5 - 46
ENG
BELT DRIVE
5. Install:
spring seat
compression spring
clutch carrier 1
NOTE:
While compressing the compression spring
with the clutch spring holder 3 and clutch
spring holder arm 4, install the clutch carrier
nut.
90890-01337
90890-01464
EAS00325
INSTALLING THE SECONDARY SHEAVE,
V-BELT, AND PRIMARY SHEAVE
1. Install:
V-belt 1
secondary sheave assembly 2
CAUTION:
Do not allow grease to contact the V-belt or
secondary sheave assembly.
NOTE:
Install the V-belt with the printed arrow mark
on the V-belt facing in the direction shown in
the illustration.
Install the V-belt onto the primary sheave
side.
1
2
5 - 47
ENG
BELT DRIVE
2. Install:
NOTE:
While holding the clutch carrier with the
sheave holder 2, tighten the clutch carrier nut
with the locknut wrench 3.
Sheave holder
90890-01701
Locknut wrench
90890-01348
1
3
2
T R .
.
90 Nm (9.0 m kg, 65 ft lb)
3. Install:
clutch housing 1
collar
secondary sheave nut 2
NOTE:
While holding the clutch housing with the
sheave holder 3, tighten the secondary
sheave nut.
Sheave holder
90890-01701
T R .
.
60 Nm (6.0 m kg, 43 ft lb)
5 - 48
ENG
BELT DRIVE
4. Install:
V-belt
washer
primary sheave nut 2
NOTE:
Install the V-belt onto the primary sheave
(when the pulley is at its widest position) and
onto the secondary sheave (when the pulley
is at its narrowest position), and make sure
the V-belt is tight.
While holding the primary fixed sheave with
the rotor holding tool, tighten the primary
sheave nut.
5. Install:
secondary sheave bracket
6. Install:
dowel pins
V-belt case gasket
V-belt case
NOTE:
Make sure that the V-belt case gasket lip fits
properly around the V-belt case.
Tighten the V-belt case bolts in stages and in
a crisscross pattern.
Rotor holding tool
90890-01235
T R .
.
80 Nm (8.0 m kg, 58 ft lb)
T R .
.
22 Nm (2.2 m kg, 16 ft lb)
LT
New
5 - 49
ENG
STARTER CLUTCH AND GENERATOR
EAS00341
GENERATOR COVER AND STATOR COIL
LT
New
1
5
6
3
4
2
4
New
LT
T R .
.
10 Nm (1.0 m kg, 7.2 ft Ib)
T R .
.
10 Nm (1.0 m kg, 7.2 ft Ib)
T R .
.
7 Nm (0.7 m kg, 5.1 ft Ib)
LS
New
Removing the generator cover and
stator coil
Storage box/center panel 1 Refer to COVERS AND PANELS in
chapter 3.
Engine oil Drain.
Refer to CHANGING THE ENGINE OIL
in chapter 3.
Muffler/exhaust pipe Refer to ENGINE REMOVAL.
Air cut-off valve assembly Refer to AIR INDUCTION SYSTEM in
chapter 7.
1 Pickup coil/stator assembly coupler 1/1 Disconnect.
2 Generator cover 1
3 Generator cover gasket 1
4 Dowel pin 2
5 Pickup coil 1
5 - 50
ENG
LT
New
1
5
6
3
4
2
4
New
LT
T R .
.
10 Nm (1.0 m kg, 7.2 ft Ib)
T R .
.
10 Nm (1.0 m kg, 7.2 ft Ib)
T R .
.
7 Nm (0.7 m kg, 5.1 ft Ib)
LS
New
6 Stator coil 1
cedure.
5 - 51
ENG
EAS00342
STARTER CLUTCH
8
7
4
3
2
1
6
5
T R .
.
30 Nm (3.0 m kg, 22 ft Ib) R .
.
80 Nm (8.0 m kg, 58 ft Ib) T
E
LT
LT
E
New
E
Removing the starter clutch Remove the parts in the order listed.
1 Generator rotor 1 Refer to REMOVING THE GENERA-
TOR, REMOVING THE STARTER
CLUTCH, INSTALLING THE
STARTER CLUTCH and INSTALLING
THE GENERATOR.
2 Starter clutch 1
3 Woodruff key 1
4 Starter clutch gear 1
5 Circlip 1
6 Washer 1
7 Starter clutch idle gear shaft 1
8 Starter clutch idle gear 1
cedure.
5 - 52
ENG
EAS00347
REMOVING THE GENERATOR
1. Remove:
generator cover
NOTE:
Loosen each bolt 1/4 of a turn at a time, in
stages and in a crisscross pattern.
After all of the bolts are fully loosened, remove
them.
2. Remove:
generator rotor nut 1
washer
NOTE:
While holding the generator rotor 2 with the
sheave holder 3, loosen the generator rotor
nut.
Do not allow the sheave holder to touch the
projection on the generator rotor.
Sheave holder
90890-01701
1
2
3
3. Remove:
generator rotor 1
(with the flywheel puller 2)
woodruff key
CAUTION:
To protect the end of the crankshaft, place
an appropriate sized socket between the
flywheel puller sets center bolt and the
crankshaft.
NOTE:
Make sure the flywheel puller is centered over
the generator rotor.
Flywheel puller
90890-01362
5 - 53
ENG
EAS00344
REMOVING THE STARTER CLUTCH
1. Remove:
starter clutch bolts 1
NOTE:
sheave holder 3, remove the starter clutch
bolts.
Sheave holder
90890-01701
EAS00351
CHECKING THE STARTER CLUTCH
1. Check:
starter clutch rollers 1
2. Check:
starter clutch idle gear
starter clutch gear
Burrs/chips/roughness/wear Replace the
defective part(s).
3. Check:
starter clutch gears contacting surfaces
Damage/pitting/wear Replace the starter
clutch gear.
4. Check:
starter clutch operation
a. Install the starter clutch gear 1 onto the
starter clutch 2 and hold the starter clutch.
b. When turning the starter clutch gear clock-
wise , the starter clutch and the starter
clutch gear should engage, otherwise the
starter clutch is faulty and must be
replaced.
c. When turning the starter clutch gear coun-
terclockwise , it should turn freely, other-
wise the starter clutch is faulty and must be
replaced.
1
5 - 54
ENG
EAS00355
INSTALLING THE STARTER CLUTCH
1. Install:
starter clutch bolts 1
NOTE:
sheave holder 3, tighten the starter clutch
bolts.
Sheave holder
90890-01701
LT
T R .
.
30 Nm (3.0 m kg, 22 ft lb)
EAS00354
INSTALLING THE GENERATOR
1. Install:
starter clutch gear
woodruff key
generator rotor
washer
generator rotor nut
NOTE:
Clean the tapered portion of the crankshaft
and the generator rotor hub.
When installing the generator rotor, make
sure the woodruff key is properly seated in
the keyway of the crankshaft.
2. Tighten:
generator rotor nut 1
NOTE:
sheave holder 3, tighten the generator rotor
nut.
Sheave holder
90890-01701
T R .
.
80 Nm (8.0 m kg, 58 ft lb)
1
2
3
5 - 55
ENG
3. Apply:
sealant
(onto the pickup coil/stator assembly lead
grommet)
Yamaha bond No.1215
90890-85505
5 - 56
ENG
OIL PUMP
EAS00357
OIL PUMP
9
8
11
10
13
5
6
1
7
12
New
LT
E
T R .
.
7 Nm (0.7 m kg, 5.1 ft Ib)
T R .
.
12 Nm (1.2 m kg, 8.7 ft Ib)
LS
2
3
4
New
Removing the oil pump assembly Remove the parts in the order listed.
Starter clutch gear Refer to STARTER CLUTCH AND GEN-
ERATOR.
1 Oil baffle plate 1
2 Circlip 1
3 Washer 1
4 Oil pump driven gear 1
5 Pin 1
6 Oil pump assembly 1
7 Oil pump gasket 1
8 Oil pump housing cover 1
9 Pin 1
10 Oil pump shaft 1
11 Oil pump inner rotor 1
5 - 57
ENG
OIL PUMP
9
8
11
10
13
5
6
1
7
12
New
LT
E
T R .
.
7 Nm (0.7 m kg, 5.1 ft Ib)
T R .
.
12 Nm (1.2 m kg, 8.7 ft Ib)
LS
2
3
4
New
12 Oil pump outer rotor 1
13 Oil pump housing 1
cedure.
5 - 58
ENG
OIL PUMP
EAS00364
CHECKING THE OIL PUMP
1. Check:
oil pump drive gear
oil pump driven gear
oil pump housing
oil pump housing cover
Cracks/damage/wear Replace the defec-
tive part(s).
2. Measure:
inner-rotor-to-outer-rotor-tip clearance
outer-rotor-to-oil-pump-housing clearance
oil-pump-housing-to-inner-rotor-and-outer-
rotor clearance
Out of specification Replace the oil pump
assembly.
1Inner rotor
2Outer rotor
3Oil pump housing
Inner-rotor-to-outer-rotor-tip
clearance
Less than 0.15 mm (0.0059 in)
<Limit>: 0.23 mm (0.0091 in)
Outer-rotor-to-oil-pump-housing
clearance
0.013 ~ 0.036 mm
(0.0005 ~ 0.0014 in)
<Limit>: 0.106 mm (0.0042 in)
Oil-pump-housing-to-inner-rotor-
and-outer-rotor clearance
0.04 ~ 0.09 mm
(0.0016 ~ 0.0035 in)
<Limit>: 0.16 mm (0.0063 in)
3. Check:
oil pump operation
Rough movement Repeat steps (1) and
(2) or replace the defective part(s).
5 - 59
ENG
OIL PUMP
EAS00375
ASSEMBLING THE OIL PUMP
1. Lubricate:
inner rotor
outer rotor
oil pump shaft
2. Install:
oil pump shaft 1
pin 2
NOTE:
When installing the pin, align the pin with the
groove a in the inner rotor.
3. Check:
oil pump operation
Refer to CHECKING THE OIL PUMP.
Engine oil
1
2
a
EAS00376
INSTALLING THE OIL PUMP ASSEMBLY
1. Install:
oil pump gasket
oil pump assembly
CAUTION:
After tightening the bolts, make sure the oil
pump turns smoothly.
New
T R .
.
7 Nm (0.7 m kg, 5.1 ft lb)
5 - 60
ENG
TRANSMISSION
TRANSMISSION
3
New
New
T R .
.
16 Nm (1.6 m kg, 11 ft Ib)
LS
LS

Removing the transmission Remove the parts in the order listed.
Final transmission oil Drain.
Refer to CHANGING THE FINAL
TRANSMISSION OIL in chapter 3.
Rear wheel Refer to REAR WHEEL AND BRAKE
DISC in chapter 4.
Secondary sheave assembly Refer to BELT DRIVE.
1 Transmission case cover 1
2 Transmission case cover gasket 1
3 Dowel pin 2
4 Primary drive gear 1
5 Washer 1
6 Washer 1
7 1st wheel gear 1
5 - 61
ENG
TRANSMISSION
3
New
New
T R .
.
16 Nm (1.6 m kg, 11 ft Ib)
LS
LS

8 Conical spring washer 1
9 Drive axle 1
10 Main axle 1
11 Conical spring washer 1
12 Primary driven gear 1
13 Washer 1
cedure.
5 - 62
ENG
REMOVING THE TRANSMISSION
1. Remove:
transmission case cover
NOTE:
stages and in a crisscross pattern. After all of
the bolts are fully loosened, removed them.
EAS00425
CHECKING THE TRANSMISSION
1. Check:
transmission gears
Blue discoloration/pitting/wear Replace
the defective gear(s).
transmission gear dogs
Cracks/damage/rounded edges Replace
the defective gear(s).
2. Check:
transmission gear movement
Rough movement Replace the defective
part(s).
3. Check:
circlips
Bends/damage/looseness Replace.
TRANSMISSION
5 - 63
ENG
CRANKSHAFT
EAS00381
CRANKSHAFT
CRANKSHAFT ASSEMBLY
4
4
5
7
6
8
1
2
3
T R .
.
32 Nm (3.2 m kg, 23 ft Ib)
New
New
E
New
New
LS
E
T R .
.
22 Nm (2.2 m kg, 16 ft Ib)
T R .
.
20 Nm (2.0 m kg, 14 ft Ib)
T R .
.
10 Nm (1.0 m kg, 7.2 ft Ib)
T R .
.
10 Nm (1.0 m kg, 7.2 ft Ib)
Removing the crankshaft Remove the parts in the order listed.
Water pump assembly Refer to WATER PUMP in chapter 6.
Engine Refer to ENGINE.
Piston Refer to CYLINDER AND PISTON.
Secondary sheave assembly Refer to BELT DRIVE.
Starter clutch gear Refer to STARTER CLUTCH AND GEN-
ERATOR.
Oil pump assembly Refer to OIL PUMP.
Transmission Refer to TRANSMISSION.
1 Timing chain guide retaining bolt 1
2 Timing chain guide (intake side) 1
3 Right crankcase 1
4 Dowel pin 2
5 - 64
ENG
CRANKSHAFT
4
4
5
7
6
8
1
2
3
T R .
.
32 Nm (3.2 m kg, 23 ft Ib)
New
New
E
New
New
LS
E
T R .
.
22 Nm (2.2 m kg, 16 ft Ib)
T R .
.
20 Nm (2.0 m kg, 14 ft Ib)
T R .
.
10 Nm (1.0 m kg, 7.2 ft Ib)
T R .
.
10 Nm (1.0 m kg, 7.2 ft Ib)
5 Crankshaft assembly 1
6 Timing chain 1
7 Left crankcase 1
8 Oil seal 1
cedure.
5 - 65
ENG
CRANKSHAFT
EAS00385
DISASSEMBLING THE CRANKCASE
1. Remove:
crankcase bolts 1
NOTE:
stages and in a crisscross pattern. After all of
the bolts are fully loosened, remove them.
1
1
1
1
1
1
1
2. Remove:
right crankcase 1
NOTE:
Remove the right crankcase with the crank-
case separating tool 2.
Make sure that the crankcase separating tool
is centered over the crankshaft assembly.
Crankcase separating tool
90890-01135
EAS00389
REMOVING THE CRANKSHAFT
ASSEMBLY
1. Remove:
timing chain
NOTE:
Before removing the crankshaft, remove the
timing chain from the crankshaft sprocket.
The crankshaft cannot be removed if the tim-
ing chain is attached onto the crankshaft
sprocket.
5 - 66
ENG
CRANKSHAFT
2. Remove:
crankshaft assembly 1
NOTE:
Remove the crankshaft assembly with the
crankcase separating tool 2.
Make sure that the crankcase separating tool
is centered over the crankshaft.
CAUTION:
Do not tap on the crankshaft.
Crankcase separating tool
90890-01135
EAS00207
CHECKING THE TIMING CHAIN AND
TIMING CHAIN GUIDE
1. Check:
timing chain
Damage/stiffness Replace the timing
chain and camshaft sprocket as a set.
2. Check:
timing chain guide (intake side)
part(s).
5 - 67
ENG
CRANKSHAFT
EAS00394
CHECKING THE CRANKSHAFT AND
CONNECTING ROD
1. Measure:
crankshaft runout
Out of specification Replace the crank-
shaft.
NOTE:
Turn the crankshaft slowly.
Crankshaft runout
0.030 mm (0.0012 in)
2. Measure:
big end side clearance
shaft.
Big end side clearance
0.350 ~ 0.850 mm
(0.0138 ~ 0.0335 in)
3. Measure:
crankshaft width
shaft.
Crankshaft width
59.75 ~ 59.80 mm
(2.352 ~ 2.354 in)
4. Check:
crankshaft sprocket 1
Damage/wear Replace the crankshaft.
bearing 2
Cracks/damage/wear Replace the crank-
shaft.
oil pump drive gear 3
Damage/wear Replace the crankshaft.
5 - 68
ENG
CRANKSHAFT
5. Check:
crankshaft journal oil passage
air.
EAS00399
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
oil delivery passages
air.
EAS00401
CHECKING THE BEARINGS
1. Check:
bearings
Clean and lubricate the bearings, and then
rotate the inner race with your finger.
Rough movement Replace.
EAS00408
INSTALLING THE CRANKSHAFT
1. Lubricate:
oil seals
bearings
oil pump drive gear
2. Install:
timing chain 1
NOTE:
Install the timing chain so it is not visible
through the opening a in the left crankcase
2.
Oil seal
Bearing, oil pump drive gear
Engine oil
5 - 69
ENG
CRANKSHAFT
3. Install:
crankshaft assembly 1
left crankcase 2
NOTE:
Install the crankshaft assembly with the
crankshaft installer pot 3, crankshaft
installer bolt 4, adapter 5, and spacer 6.
After installing the crankcase, make sure that
timing chain is securely meshed with the
crankshaft sprocket.
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:
Hold the connecting rod at top dead center
(TDC) with one hand while turning the nut of
the crankshaft installer bolt with the other. Turn
the crankshaft installer bolt until the crankshaft
assembly bottoms against the bearing.
Crankshaft installer pot
90890-01274
Crankshaft installer bolt
90890-01275
Adapter (M14)
90890-01478
Spacer (crankshaft installer)
90890-04081
1
2
5
3
4
6
5 - 70
ENG
CRANKSHAFT
EAS00418
ASSEMBLING THE CRANKCASE
1. Thoroughly clean all the gasket mating sur-
faces and crankcase mating surfaces.
2. Apply:
sealant
(onto the crankcase mating surfaces)
NOTE:
Do not allow any sealant to come into contact
with the oil gallery.
Yamaha bond No. 1215
90890-85505
3. Install:
water pump assembly
crankcase bolts
NOTE:
Tighten the crankcase bolts in stages and in a
crisscross pattern.
M6 100 mm (3.94 in) bolts: 1
M6 70 mm (2.76 in) bolts: 2
1
2
1
1
2
1
2
T R .
.
10 Nm (1.0 m kg, 7.2 ft lb)
COOL
CHAPTER 6
COOLING SYSTEM
RADIATOR...................................................................................................... 6-1
CHECKING THE RADIATOR.................................................................... 6-3
INSTALLING THE RADIATOR.................................................................. 6-3
THERMOSTAT................................................................................................ 6-4
CHECKING THE THERMOSTAT.............................................................. 6-5
INSTALLING THE THERMOSTAT............................................................ 6-5
WATER PUMP................................................................................................. 6-6
DISASSEMBLING THE WATER PUMP.................................................... 6-8
CHECKING THE WATER PUMP.............................................................. 6-9
ASSEMBLING THE WATER PUMP.......................................................... 6-9
INSTALLING THE WATER PUMP.......................................................... 6-11
6 - 1
COOL
EAS00454
COOLING SYSTEM
RADIATOR
1
2
3
4
7
6
5
11
9
13
10
8
12
(3)
(3)
14 New
New
T R .
.
6 Nm (0.6 m kg, 4.3 ft Ib)
T R .
.
10 Nm (1.0 m kg, 7.2 ft Ib)
T R .
.
30 Nm (3.0 m kg, 22 ft Ib)
T R .
.
30 Nm (3.0 m kg, 22 ft Ib)
Removing the radiator Remove the parts in the order listed.
Storage compartment/footrest board/
under cover
Refer to COVERS AND PANELS in
chapter 3.
Coolant Drain.
chapter 3.
1 Radiator cap 1
2 Coolant reservoir hose 1
3 Coolant reservoir 1
4 Radiator filler hose 1
5 Radiator outlet hose 1
6 Radiator inlet hose 1
7 Radiator inlet/outlet pipe 1
8 Radiator fan motor coupler 1 Disconnect.
RADIATOR
6 - 2
COOL
RADIATOR
1
2
3
4
7
6
5
11
9
13
10
8
12
(3)
(3)
14 New
New
T R .
.
6 Nm (0.6 m kg, 4.3 ft Ib)
T R .
.
10 Nm (1.0 m kg, 7.2 ft Ib)
T R .
.
30 Nm (3.0 m kg, 22 ft Ib)
T R .
.
30 Nm (3.0 m kg, 22 ft Ib)
9 Thermo switch connector (auto choke) 2 Disconnect.
White.
10 Thermo switch connector (radiator fan
motor)
2 Disconnect.
Green.
11 Radiator 1
12 Radiator fan motor 1
13 Thermo switch (auto choke) 1 White.
14 Thermo switch (radiator fan motor) 1 Green.
cedure.
6 - 3
COOL
RADIATOR
EAS00455
CHECKING THE RADIATOR
1. Check:
radiator fins
Obstruction Clean.
Apply compressed air to the rear of the radi-
ator.
Damage Repair or replace.
NOTE:
_
Straighten any flattened fins with a thin, flat-
head screwdriver.
2. Check:
radiator inlet hose
radiator outlet hose
radiator filler hose
coolant reservoir hose
radiator inlet/outlet pipe
3. Check:
radiator fan motor
Damage Replace.
Malfunction Check and repair.
Refer to COOLING SYSTEM in chapter 8.
EAS00456
INSTALLING THE RADIATOR
1. Fill:
cooling system
mended coolant)
chapter 3.
2. Check:
cooling system
Leaks Repair or replace any faulty part.
6 - 4
COOL
THERMOSTAT
EAS00460
THERMOSTAT
New
3
1
1
2
T R .
.
10 Nm (1.0 m kg, 7.2 ft Ib)
4
Removing the thermostat Remove the parts in the order listed.
Rear side cover (left and right) Refer to COVERS AND PANELS in
chapter 3.
Coolant Drain.
chapter 3.
1 Thermostat inlet hose 1 Disconnect.
2 Thermostat outlet hose 1
3 Thermostat cover 1
4 Thermostat 1
cedure.
6 - 5
COOL
THERMOSTAT
EAS00462
CHECKING THE THERMOSTAT
1. Check:
thermostat 1
Does not open at 80.5 ~ 83.5 C (176.9 ~
182.3 F) Replace.
a. Suspend the thermostat in a container filled
with water.
b. Slowly heat the water.
c. Place a thermometer in the water.
d. While stirring the water, observe the ther-
mostat and thermometers indicated tem-
perature.
1Thermostat
2Container
3Thermometer
4Water
Fully closed
Fully open
NOTE:
_
If the accuracy of the thermostat is in doubt,
replace it. A faulty thermostat could cause seri-
ous overheating or overcooling.
2. Check:
thermostat cover
3. Check:
thermostat inlet hose
thermostat outlet hose
EAS00467
INSTALLING THE THERMOSTAT
1. Fill:
cooling system
mended coolant)
chapter 3.
2. Check:
cooling system
6 - 6
COOL
WATER PUMP
WATER PUMP
LS
New
New
New
New
New
LT
4
2
5
6
1
3
LS
LS
7
8
10
9
T R .
.
7 Nm (0.7 m kg, 5.1 ft Ib)
T R .
.
10 Nm (1.0 m kg, 7.2 ft Ib)
T R .
.
10 Nm (1.0 m kg, 7.2 ft Ib)
T R .
.
12 Nm (1.2 m kg, 8.7 ft Ib)
Removing the water pump Remove the parts in the order listed.
NOTE:
It is not necessary to remove the water
pump unless the coolant level is
extremely low or the coolant contains
engine oil.
Center panel 2 (left) Refer to COVERS AND PANELS in
chapter 3.
Coolant Drain.
chapter 3.
Generator rotor Refer to STARTER CLUTCH AND GEN-
ERATOR in chapter 5.
6 - 7
COOL
WATER PUMP
LS
New
New
New
New
New
LT
4
2
5
6
1
3
LS
LS
7
8
10
9
T R .
.
7 Nm (0.7 m kg, 5.1 ft Ib)
T R .
.
10 Nm (1.0 m kg, 7.2 ft Ib)
T R .
.
10 Nm (1.0 m kg, 7.2 ft Ib)
T R .
.
12 Nm (1.2 m kg, 8.7 ft Ib)
1 Oil baffle plate 1
2 Impeller shaft gear 1
3 Dowel pin/Washer 1/1
4 Shaft 1
5 Water pump inlet hose 1
6 Water pump outlet pipe 1
7 Water pump housing cover 1
8 Water pump housing gasket 1
9 Water pump housing 1
10 Impeller shaft 1
cedure.
6 - 8
COOL
WATER PUMP
EAS00471
DISASSEMBLING THE WATER PUMP
1. Remove:
rubber damper holder 1
rubber damper 2
(from the impeller with a thin, flathead
screwdriver)
NOTE:
Do not scratch the impeller shaft.
2. Remove:
water pump seal 1
NOTE:
Remove the water pump seal from the inside
of the water pump housing.
1
3. Remove:
oil seal 1
bearing 2
(with a thin, flathead screwdriver)
NOTE:
Remove the oil seal and bearing from the out-
side of the water pump housing.
2
1
6 - 9
COOL
WATER PUMP
EAS00474
CHECKING THE WATER PUMP
1. Check:
water pump housing cover
water pump housing
impeller shaft
2. Check:
bearing
Rough movement Replace.
3. Check:
impeller shaft gear
Pitting/wear Replace.
4. Check:
water pump inlet hose
water pump outlet pipe
EAS00475
ASSEMBLING THE WATER PUMP
1. Install:
oil seal 1
(into the water pump housing)
NOTE:
Before installing the oil seal, apply tap water
or coolant onto its outer surface.
Install the oil seal with a socket that matches
its outside diameter.
Installed depth of oil seal a
8.1 ~ 8.7 mm (0.32 ~ 0.34 in)
1
a
New
New
6 - 10
COOL
WATER PUMP
2. Install:
water pump seal 1
CAUTION:
Never lubricate the water pump seal sur-
face with oil or grease.
NOTE:
Install the water pump seal with the mechan-
ical seal installer 2 and middle driven shaft
bearing driver 3.
Before installing the water pump seal, apply
Yamaha bond No.1215 4 to the water pump
housing 5.
Push down.
Mechanical seal installer
90890-04132
Middle driven shaft bearing driver
90890-04058
Yamaha bond No.1215
90890-85505
New
3. Install:
rubber damper 1
rubber damper holder 2
NOTE:
Before installing the rubber damper, apply tap
water or coolant onto its outer surface.
New
New
6 - 11
COOL
WATER PUMP
4. Measure:
impeller shaft tilt
Out of specification Repeat steps (3) and
(4).
CAUTION:
Make sure the rubber damper and rubber
damper holder are flush with the impeller.
1Straightedge
2Impeller
Impeller shaft tilt limit
0.15 mm (0.0059 in)
5. Install:
impeller shaft 1
circlip 2
NOTE:
After installation, check that the impeller shaft
rotates smoothly.
6. Install:
water pump housing cover
New
T R .
.
10 Nm (1.0 m kg, 7.2 ft lb)
INSTALLING THE WATER PUMP
1. Install:
shaft 1
NOTE:
Align the projection a on the shaft 1 with the
slot b in the impeller shaft.
6 - 12
COOL
WATER PUMP
2. Install:
water pump
3. Fill:
cooling system
mended coolant)
chapter 3.
4. Check:
cooling system
T R .
.
10 Nm (1.0 m kg, 7.2 ft lb)
CARB
CHAPTER 7
CARBURETOR
CARBURETOR................................................................................................ 7-1
DISASSEMBLING THE CARBURETOR................................................... 7-5
CHECKING THE CARBURETOR............................................................. 7-5
ASSEMBLING THE CARBURETOR......................................................... 7-6
INSTALLING THE CARBURETOR........................................................... 7-7
CHECKING THE AUTO CHOKE UNIT ..................................................... 7-8
AIR INDUCTION SYSTEM............................................................................ 7-10
CHECKING THE AIR INDUCTION SYSTEM.......................................... 7-11
FUEL TANK................................................................................................... 7-12
REMOVING THE FUEL SENDER........................................................... 7-14
CHECKING THE FUEL PUMP................................................................ 7-14
INSTALLING THE FUEL SENDER......................................................... 7-15
7 - 1
CARB
CARBURETOR
CARBURETOR
CARBURETOR
1
2
3
4
5
6
8
7
T R .
.
2 Nm (0.2 m kg, 1.4 ft Ib)
T R .
.
2 Nm (0.2 m kg, 1.4 ft Ib)
T R .
.
11 Nm (1.1 m kg, 8.0 ft Ib)
Removing the carburetor Remove the parts in the order listed.
Storage box/footrest board Refer to COVERS AND PANELS in
chapter 3.
Coolant Drain.
chapter 3.
1 Auto choke unit coupler 1 Disconnect.
2 Carburetor inlet hose 1 Disconnect
3 Thermostat inlet hose 1 Disconnect
4 Fuel hose (fuel pump to carburetor) 1 Disconnect
5 Throttle cable 2 Disconnect
6 Air filter case clamp screw 1 Loosen.
7 Carburetor clamp screw 1 Loosen.
7 - 2
CARB
CARBURETOR
1
2
3
4
5
6
8
7
T R .
.
2 Nm (0.2 m kg, 1.4 ft Ib)
T R .
.
2 Nm (0.2 m kg, 1.4 ft Ib)
T R .
.
11 Nm (1.1 m kg, 8.0 ft Ib)
8 Carburetor 1 Refer to INSTALLING THE CARBURE-
TOR
cedure.
7 - 3
CARB
CARBURETOR
EAS00483
New
New
New
New
New
4
6
5
7
E
F
D
C
8
1
A
0 3
B
9
G
2
H
New
(4)
(4)
Disassembling the carburetor Remove the parts in the order listed.
1 Coolant hose joint 1
2 Auto choke unit 1
3 Pilot screw 1
4 Vacuum chamber cover 1
5 Piston valve spring 1
6 Piston valve 1
7 Jet needle 1
8 Coasting enricher assembly 1
9 Float chamber 1
0 Float pin 1
A Float 1
B Needle valve 1
C Main jet 1
7 - 4
CARB
CARBURETOR
New
New
New
New
New
4
6
5
7
E
F
D
C
8
1
A
0 3
B
9
G
2
H
New
(4)
(4)
D Needle jet holder 1
E Needle jet 1
F Pilot jet 1
G Accelerator pump assembly 1
H Fuel drain screw 1
procedure.
7 - 5
CARB
CARBURETOR
DISASSEMBLING THE CARBURETOR
1. Remove:
float pin 1
needle valve 2
float 3
NOTE:
Remove the float pin in the direction of the
arrow.
1
2
3
EAS00485
CHECKING THE CARBURETOR
1. Check:
carburetor body
float chamber
jet housing
2. Check:
fuel passages
Obstruction Clean.
a. Wash the carburetor in a petroleum-based
solvent. Do not use any caustic carburetor
cleaning solution.
b. Blow out all of the passages and jets with
compressed air.
3. Check:
float chamber body
Dirt Clean.
4. Check:
float
Damage Replace.
5. Check:
needle valve
Damage/obstruction/wear Replace.
6. Check:
piston valve
piston valve diaphragm
coasting enricher diaphragm
Cracks/tears Replace.
7. Check:
vacuum chamber cover
piston valve spring
7 - 6
CARB
CARBURETOR
8. Check:
jet needle 1
main jet 2
needle jet holder 3
pilot jet 4
pilot screw 5
needle jet 6
Bends/damage/wear Replace.
Obstruction Clean.
Blow out the jets with compressed air.
9. Check:
piston valve movement
Insert the piston valve into the carburetor
body and move it up and down.
Tightness Replace the piston valve.
10.Check:
fuel hoses
Obstruction Clean.
Blow out the hoses with compressed air.
3 1
4
2
5 6
EAS00487
ASSEMBLING THE CARBURETOR
CAUTION:
Before assembling the carburetor, wash
all of the parts in a petroleum-based sol-
vent.
Always use a new gasket.
1. Measure:
float height a
a. Hold the carburetor in an upside down posi-
tion.
Float height (F.H)
17.5 mm (0.69 in)
a
7 - 7
CARB
CARBURETOR
b. Measure the distance from the front mating
surface of the float chamber (gasket
removed) to the top of the float.
NOTE:
_
The float arm should be resting on the needle
valve, but not compressing it.
c. If the float height is not within the specifica-
tion, check the needle valve.
d. If it is worn, replace it.
e. If it is fine, adjust the float height by bending
the float tang 1 on the float.
f. Recheck the float height.
2. Install:
float 1
needle valve 2
float pin 3
NOTE:
Install the float pin in the direction of the arrow.
3. Install:
float chamber rubber gasket
float chamber
pilot air screw
4. Install:
accelerator pump assembly
5. Install:
coasting enricher assembly
Pilot air screw
2 turns out
3
2
1
New
EAS00492
INSTALLING THE CARBURETOR
1. Install
carburetor
NOTE:
Align the projection a on the carburetor with
the slot b on the intake manifold.
b
a
7 - 8
CARB
CARBURETOR
2. Adjust:
engine idling speed
IDLING SPEED in chapter 3.
3. Adjust:
CABLE FREE PLAY in chapter 3.
Engine idling speed
1,550 ~ 1,650 r/min
4.0 ~ 6.0 mm (0.16 ~ 0.24 in)
EAS00503
CHECKING THE AUTO CHOKE UNIT
NOTE:
When checking the auto choke unit, the ambi-
ent temperature must be lower than 45 C
(113 F).
1. Remove:
carburetor
2. Check:
auto choke unit
a. Connect a 3.3 mm (0.13 in) hose 2 to the
starter air passage 1 and blow into the
hose.
NOTE:
When the starter plunger is open, air should
come out of the other side of the starter air
passage.
Starter plunger opens
Perform step (3).
Starter plunger closes
Replace the auto choke unit.
7 - 9
CARB
CARBURETOR
3. Check:
auto choke unit (with battery)
a. Connect the auto choke unit lead to a
12.0 V battery for five minutes.
b. Connect a 3.3 mm (0.13 in) hose 4 to the
starter air passage 3 and blow into the
hose.
Positive battery lead yellow 1
Negative battery lead green/black 2
Starter plunger opens
Replace the auto choke unit.
Starter plunger closes
Auto choke unit is OK.
7 - 10
CARB
AIR INDUCTION SYSTEM
5
6
4
3
2
1
T R .
.
10 Nm (1.0 m kg, 7.2 ft Ib)
New
T R .
.
12 Nm (1.2 m kg, 8.7 ft Ib)
T R .
.
10 Nm (1.0 m kg, 7.2 ft Ib)
Removing the air cut-off valve Remove the parts in the order listed.
Seat/right center panel 2/under cover Refer to COVERS AND PANELS in
chapter 3.
1 Air induction system vacuum hose 1
2 Air induction system hose (to air cut-off
valve assembly)
1
3 Air induction system hose (air cut-off
valve assembly to cylinder head)
1
4 Air induction system pipe (air cut-off
valve assembly to cylinder head)
1
5 Air cut-off valve bracket 1
6 Air cut-off valve assembly 1
For installation, reverse the removal
procedure.
7 - 11
CARB
EAS00510
CHECKING THE AIR INDUCTION SYSTEM
1. Check:
hoses
pipe
2. Check:
air cut-off valve
3. Check:
air cut-off valve operation
Does not operate Replace.
a. Blow air through the end of the air induction
system hose (to air cut-off valve assembly)
and check that air flows from the pipe (air
cut-off valve assembly to cylinder head).
b. Install a vacuum/pressure pump to the air-
cut off valve 1 and apply negative pressure
to the valve.
c. Blow air through the end of the air induction
system hose (to air cut-off valve assembly)
and check that air does not flow and out
through the pipe (air cut-off valve assembly
to cylinder head).
Air cut-off valve opens
Perform step (b).
Air cut-off valve closes
Replace the air cut-off valve.
Vacuum/pressure pump gauge
set
90890-06756
Air cut-off valve opens
Replace the air cut-off valve.
Air cut-off valve closes
Air cut-off valve is OK.
1
7 - 12
CARB
FUEL TANK
2
New
8
T R .
.
7 Nm (0.7 m kg, 5.1 ft Ib)
T R .
.
7 Nm (0.7 m kg, 5.1 ft Ib)
7
6
9
5
1
4
3
10
LS
Removing the fuel tank Remove the parts in the order listed.
Storage box/under cover Refer to COVERS AND PANELS in
chapter 3.
1 Fuel pump coupler 1 Disconnect.
2 Fuel hose holder 1
3 Fuel hose (fuel tank to fuel pump) 1
4 Fuel hose (fuel pump to carburetor) 1 Disconnect.
5 Fuel pump 1
6 Fuel sender coupler 1 Disconnect.
7 Fuel tank lower cover 1
8 Fuel tank 1
9 Fuel pipe 1
FUEL TANK
7 - 13
CARB
2
New
8
T R .
.
7 Nm (0.7 m kg, 5.1 ft Ib)
T R .
.
7 Nm (0.7 m kg, 5.1 ft Ib)
7
6
9
5
1
4
3
10
LS
10 Fuel sender 1 Refer to REMOVING THE FUEL
SENDER and INSTALLING THE FUEL
SENDER.
cedure.
FUEL TANK
7 - 14
CARB
REMOVING THE FUEL SENDER
1. Remove:
fuel sender 1
NOTE:
Remove the fuel sender using the fuel sender
removal tool 2.
90890-11098
2
1
EAS00504
CHECKING THE FUEL PUMP
1. Check:
fuel pump 1
a. Disconnect the fuel hose (fuel pump to car-
buretor fuel hose) 2 from the carburetor.
b. Place a container under the end of the fuel
hose.
c. Turn the main switch to ON and check if
fuel flows from the fuel hose 2.
d. Turn the main switch to OFF and check if
the fuel stops flowing from the fuel hose 2.
Fuel flows. Fuel pump is OK.
Fuel does not flow.
Replace the fuel
pump.
Fuel stops flowing. Fuel pump is OK.
Fuel flows.
Replace the fuel
pump.
FUEL TANK
7 - 15
CARB
INSTALLING THE FUEL SENDER
1. Install:
fuel sender 1
NOTE:
Install the fuel sender using the fuel sender
removal tool.
Lubricate the gasket with lithium-soap-based
grease.
Position the fuel sender coupler a as shown
in the illustration.
90890-11098
a
1
FUEL TANK
+
ELEC
CHAPTER 8
ELECTRICAL SYSTEM
ELECTRICAL COMPONENTS........................................................................ 8-1
CHECKING SWITCH CONTINUITY................................................................ 8-2
CHECKING THE SWITCHES.......................................................................... 8-3
CHECKING THE BULBS AND BULB SOCKETS.......................................... 8-4
TYPES OF BULBS.................................................................................... 8-4
CHECKING THE CONDITION OF THE BULBS ....................................... 8-5
CHECKING THE CONDITION OF THE BULB SOCKETS ....................... 8-6
IGNITION SYSTEM......................................................................................... 8-7
CIRCUIT DIAGRAM.................................................................................. 8-7
TROUBLESHOOTING .............................................................................. 8-8
ELECTRIC STARTING SYSTEM.................................................................. 8-12
CIRCUIT DIAGRAM................................................................................ 8-12
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION........................ 8-13
TROUBLESHOOTING ............................................................................ 8-14
STARTER MOTOR ................................................................................. 8-17
CHECKING THE STARTER MOTOR..................................................... 8-19
ASSEMBLING THE STARTER MOTOR................................................. 8-20
CHARGING SYSTEM.................................................................................... 8-21
CIRCUIT DIAGRAM................................................................................ 8-21
LIGHTING SYSTEM...................................................................................... 8-24
CIRCUIT DIAGRAM................................................................................ 8-24
CHECKING THE LIGHTING SYSTEM.................................................... 8-27
SIGNALING SYSTEM................................................................................... 8-30
CIRCUIT DIAGRAM................................................................................ 8-30
CHECKING THE SIGNALING SYSTEM................................................. 8-33
COOLING SYSTEM....................................................................................... 8-43
CIRCUIT DIAGRAM................................................................................ 8-43
+
ELEC
FUEL PUMP SYSTEM................................................................................... 8-47
CIRCUIT DIAGRAM................................................................................ 8-47
FUEL PUMP CIRCUIT OPERATION...................................................... 8-48
AUTO CHOKE SYSTEM............................................................................... 8-51
CIRCUIT DIAGRAM................................................................................ 8-51
IMMOBILIZER SYSTEM................................................................................ 8-55
SYSTEM DIAGRAM................................................................................ 8-55
CIRCUIT DIAGRAM................................................................................ 8-56
GENERAL INFORMATION..................................................................... 8-57
KEY CODE REGISTRATION.................................................................. 8-58
SELF-DIAGNOSIS MALFUNCTION CODES.......................................... 8-61
CHECKING THE IMMOBILIZER SYSTEM............................................. 8-63
PART REPLACEMENT KEY REGISTRATION REQUIREMENTS......... 8-65
8 - 1
+
ELEC
EAS07290
ELECTRICAL SYSTEM
ELECTRICAL COMPONENTS
1CDI unit
2Turn signal relay
3immobilizer antenna
4Main switch
5Air temperature sensor
6Battery
7Starter relay
8Main fuse
9Coolant temperature sensor
0Pickup coil/stator assembly
ASpark plug cap
BIgnition coil
CSidestand switch
DRadiator fan motor
EHorn
FRectifier/regulator
GStarting circuit cut-off relay
HFuel pump relay
IRadiator fan motor relay
JHeadlight relay
KWire harness
2
E
G
9
K
F
0
A
B
C
D
7
8
6
3
5
4
1
J
I
H
ELECTRICAL COMPONENTS
8 - 2
+
ELEC
CHECKING SWITCH CONTINUITY
EAS00730
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 slots a. Always insert the
probes from the opposite end of the cou-
pler, taking care not to loosen or damage
the leads.
NOTE:
_
Before checking for continuity, set the pocket
tester to 0 and to the 1 range.
When checking for continuity, switch back
and forth between the switch positions a few
times.
The terminal connections for switches (e.g.,
main switch) are shown in an illustration simi-
lar to the one on the left.
The switch positions a are shown in the far
left column and the switch lead colors b are
shown in the top row in the switch illustration.
NOTE:
_
indicates a continuity of electricity
between switch terminals (i.e., a closed circuit
at the respective switch position).
The example illustration on the left shows
that:
There is continuity between red and brown
when the switch is set to ON.
Pocket tester
90890-03112
OFF
Br R
ON
R
Br
b
a
8 - 3
+
ELEC
CHECKING THE SWITCHES
EAS00731
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 the switch.
OFF
ON
Br R
R
Br
8
B
B
(BLUE)
7
L/W
W/Y
W/Y
L/W
Br/W L/W
W/Y B
B
B
Br/W
Br/W
(BLACK)
5 4
R/Y G L/B Y
Br G/B Br/B
(BLACK)
P B
(RED)
B
G/B Br
R/Y L/B
Br/B
Y
G
P
1
9
2 3
G/Y G/Y
Br Br
6 0
L/B Y G R/Y
P B
Br/B Br G/B
1Dimmer/pass switch
2Horn switch
3Turn signal switch
4Start switch
5Hazard switch
6Front brake light switch
7Sidestand switch
8Main switch
9Fuse
0Rear brake light switch
8 - 4
+
ELEC
CHECKING THE BULBS AND BULB SOCKETS
EAS00733
CHECKING THE BULBS AND
BULB SOCKETS
NOTE:
Do not check any of the lights that use LEDs.
Check each bulb and bulb socket for damage
or wear, proper connections, and also for con-
tinuity between the terminals.
Damage/wear Repair or replace the
bulb, bulb socket or both.
Improperly connected Properly connect.
No continuity Repair or replace the bulb,
bulb socket or both.
TYPES OF BULBS
The bulbs used on this vehicle are shown in
the illustration on the left.
Bulbs a and b are used for the headlights
and usually use a bulb holder that must be
detached before removing the bulb. The
majority of these types of bulbs can be
removed from their respective socket by
turning them counterclockwise.
Bulb c is used for turn signal and tail/brake
lights and can be removed from the socket
by pushing and turning the bulb counter-
clockwise.
Bulbs d and e are used for meter and indi-
cator lights and can be removed from their
respective socket by carefully pulling them
out.
8 - 5
+
ELEC
CHECKING THE CONDITION OF THE
BULBS
bulbs.
1. Remove:
bulb
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.
Avoid touching the glass part of the head-
light bulb to keep it free from oil, other-
wise the transparency of the glass, the
life of the bulb, and the luminous flux will
be adversely affected. If the headlight
bulb gets soiled, thoroughly clean it with
a cloth moistened with alcohol or lacquer
thinner.
2. Check:
bulb (for continuity)
No continuity Replace.
NOTE:
_
Before checking for continuity, set the pocket
tester to 0 and to the 1 range.
a. Connect the positive tester probe to termi-
nal 1 and the negative tester probe to ter-
minal 2, and check the continuity.
b. Connect the positive tester probe to termi-
nal 1 and the negative tester probe to ter-
minal 3, and check the continuity.
c. If either of the readings indicate no continu-
ity, replace the bulb.
Pocket tester
90890-03112
8 - 6
+
ELEC
CHECKING THE CONDITION OF THE BULB
SOCKETS
bulb sockets.
1. Check:
bulb socket (for continuity)
No continuity Replace.
NOTE:
_
Check each bulb socket for continuity in the
same manner as described in the bulb section;
however, note the following.
a. Install a good bulb into the bulb socket.
b. Connect the pocket tester probes to the
respective leads of the bulb socket.
c. Check the bulb socket for continuity. If any
of the readings indicate no continuity,
replace the bulb socket.
Pocket tester
90890-03112
8 - 7
+
ELEC
IGNITION SYSTEM
EAS00734
IGNITION SYSTEM
CIRCUIT DIAGRAM
O
F
F
O
N
G
/Y
G
W
/R
R
R
R
RB
B
W
R
WW
WWW W
/L
B
R
/L
B
R
B
r/L
B
r/L
R
/B
B
r/L
B
r/L
R
B
r
R
/W
R
/Y
B
G
/B
L
/W
G
/B
L
/W
G
/B
R
/B
G
/Y
L
/Y
B L L
S
b
O
/W
L
/G
R
/B
R
/G
L
/Y
R
/B
Y
/R
W
/B
W
/R
W
/L
B
L
/G
G
/W
G
/W
G
/W
G
/W
O
O B
R
/G
LL B
P
/G
R
/B
R
/W
G
/Y
G
/Y
B
r
B
r
G
/Y
G
/Y
G
/Y
G
/Y
B
B B
B
D
g
W
C
h
W
B
r
B
r
B
r
B
r
B
C
h
D
g
B
B
B
D
g
C
h
B
r
B
r
GY
B B
B
B
B
r/W
R
/L
B
r/B
B
r/B
G
/B
G
/B
B
r
B
r/B
B
r
B
r
B
r
PP
B B
G G
Y L
/B
L
/B
L
/Y
R
/Y
W
/B
YC
h
D
g
R
/Y
R
/Y
B
r
S
b
O
/W
B
G
/L
R
/L
B
r/G
B
r/G
G
y
G
y
G
y
/R
G
y
/B
B
L
/Y
L
/W
B B
B
r/W
B
r/W
Y
G
/B
G
/L
P
/G
B
G
y
/R
G
y
/B
B
G
/R
B
B
/Y
B
/Y
R
/L
B
r
C
h
D
g
R
/L
P
/W
P
/W
Y
/R
R
/B
Y
/R
B
L
/W
B
B
W
G
/W
G
/W
R
R
/GR
/L
R
W
/Y
G
L
L
G
Y
Y
B
(G
R
E
E
N
)
(G
R
E
E
N
)
(W
H
IT
E
)
(W
H
IT
E
)
(B
L
A
C
K
)
W
/L
W
/R
B
r
R
R
R
R
W
W
W
B
B
R
/Y
L
/B
W
/B
L
/Y
B
r/G
B
r/G
BB
G
y
G
y/B
G
y/R
R B L
R
/WL
R
/B
P
/G
R
/G
L
R
/B
L
/G
L
/W R
G
/B
(B
L
A
C
K
)
R
/Y
B
R
/Y
B
R
B
r/L
RB
r
B
R
W
W
W
G
/L
Y
B
D
g
S
b
G
/R
G
y
/B
O
/W
B
B
r/G
G
y/R
B
r/G
G
y
B
r
C
h
R
/L
B
r
G
B
Y
L
G
B
Y
L
B
B
B
r
B
r
D
g
G
/Y
B
B
r
C
h
G
/Y
B
R
/Y
G
L
/B
Y
PB
r
G
/B
L
/B
R
/Y
B
r/B
Y G
B
B
r/W
B
B
r
C
h
D
g
B
r/B
G
/B
R
/L
BR
BL
(B
L
A
C
K
)
L
/W
W
/Y
B
r/W
L
/W
W
/Y
B
B
r/W
L
/W
B
B
BB
(B
L
U
E
)
L
/Y
B
(B
L
U
E
)
G
/B
L
/W
S
b
O
/W
B
B
r/W
(B
L
A
C
K
)
C
h
B
(B
L
A
C
K
)
D
g
B
(G
R
E
E
N
)
B
r
G
/B
B
r/B
(B
L
A
C
K
)
P
B
(R
E
D
)
B G
/B
B
r
R
/Y
L
/B
B
r/B
YG
P
R
/B
L
/Y
G
/B
G
/Y
(B
L
U
E
)
Y
/R
R
/B
G
/B
Y
B
/L
B
(B
L
A
C
K
)
LB
(B
L
A
C
K
)
R
/L
D
g
B
r
B
/Y
B
C
h
P
/W
P
/W
G
B
Y
G
B
Y
L
/G
G
/W
G
/W
O
W
/R
Y
/R
B
R
/B
R
/G
G
/L
L
/Y
W
/B
W
/L
(G
R
E
E
N
)
B
r
B
D
g
B
B
r
W
G
/Y
B
B
r
W
G
/Y
B
1 2
3
~
45
6
70 89
q
r
s
t
u
v
w
y
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}
|
m
o
o
n
n
x{
p
e
g
f
h
i
g
j
k
l
Z
[
]
\
_
b
c
d
a
A
B
C
D
E
F
N
G
M
J
H
I
K
Q
R
P
O
S
T
U
W
V
Y
X
L
2
P
i
c
k
u
p

c
o
i
l
4
C
D
I

u
n
i
t

f
u
s
e
6
M
a
i
n

s
w
i
t
c
h
7
I
g
n
i
t
i
o
n

f
u
s
e
A
G
r
o
u
n
d

l
e
a
d
B
B
a
t
t
e
r
y
C
M
a
i
n

f
u
s
e
G
S
i
d
e
s
t
a
n
d

s
w
i
t
c
h
S
C
D
I

u
n
i
t
T
I
g
n
i
t
i
o
n

c
o
i
l
U
S
p
a
r
k

p
l
u
g
8 - 8
+
ELEC
IGNITION SYSTEM
EAS00736
TROUBLESHOOTING
Check:
1. main, ignition, and CDI unit fuses
2. battery
3. spark plug
4. ignition spark gap
5. spark plug cap resistance
6. ignition coil resistance
7. pickup coil resistance
8. main switch
9. sidestand switch
10.wiring connections (of the entire ignition
system)
NOTE:
_
Before troubleshooting, remove the following
part(s):
1. storage box
2. front cowling
3. storage compartment
4. footrest board
Troubleshoot with the following special
tool(s).
EAS00738
YES NO
EAS00739
YES NO
EAS00740
YES NO
The ignition system fails to operate (no
spark or intermittent spark).
Ignition checker
90890-06754
Pocket tester
90890-03112
1. Main, ignition, and CDI unit fuses
Check the main, ignition, and CDI unit
fuses for continuity.
Refer to CHECKING THE FUSES in
chapter 3.
Are the main, ignition, and CDI unit fuses
OK?
Replace the fuse(s).
2. Battery
Check the condition of the battery.
Refer to CHECKING AND CHARGING
THE BATTERY in chapter 3.
Minimum open-circuit voltage
12.8 V or more at 20 C (68 F)
Is the battery OK?
Clean the battery
terminals.
Recharge or
3. Spark plug
Check the condition of the spark plug.
Check the spark plug type.
Measure the spark plug gap.
Refer to CHECKING THE SPARK PLUG
in chapter 3.
Standard spark plug
DR8EA (NGK)
Spark plug gap
0.6 ~ 0.7 mm (0.024 ~ 0.028 in)
Is the spark plug in good condition, is it of
the correct type, and is its gap within spec-
ification?
Regap or replace the
spark plug.
8 - 9
+
ELEC
IGNITION SYSTEM
EAS00742
NO YES
EAS00744
YES NO
4. Ignition spark gap
Disconnect the spark plug cap from the
spark plug.
Connect the ignition checker 1 as shown.
2Spark plug cap
Set the main switch to ON.
Measure the ignition spark gap a.
Crank the engine by pushing the start
switch and gradually increase the spark
gap until a misfire occurs.
Minimum ignition spark gap
6 mm (0.24 in)
Is there a spark and is the spark gap within
specification?
The ignition system
is OK.
5. Spark plug cap resistance
Remove the spark plug cap from the spark
plug lead.
Connect the pocket tester ( 1k range)
to the spark plug cap as shown.
Measure the spark plug cap resistance.
Spark plug cap resistance
10.0 k
Is the spark plug cap OK?
Replace the spark
plug cap.
8 - 10
+
ELEC
IGNITION SYSTEM
EAS00746
YES NO
EAS00748
YES NO
EAS00749
YES NO
6. Ignition coil resistance
Disconnect the ignition coil connectors
from the ignition coil terminals.
Connect the pocket tester ( 1) to the
ignition coil as shown.
Positive tester probe orange
Negative tester probe black
Measure the primary coil resistance.
Primary coil resistance
0.225 ~ 0.275 at 25 C (77 F)
Connect the pocket tester ( 1k) to the
ignition coil as shown.
Positive tester probe orange 1
Negative tester probe spark plug lead 2
Measure the secondary coil resistance.
Secondary coil resistance
1.89 ~ 2.31 k at 25 C (77 F)
Is the ignition coil OK?
Replace the ignition
coil.
1k
1
2
7. Pickup coil resistance
Disconnect the pickup coil coupler from
the wire harness.
pickup coil terminal as shown.
Positive tester probe brown 1
Negative tester probe red 2
Measure the pickup coil resistance.
Pickup coil resistance
130 ~ 150 at 20 C (68 F)
Is the pickup coil OK?
Replace pickup coil/
stator assembly.
8. Main switch
Check the main switch for continuity.
Refer to CHECKING THE SWITCHES.
Is the main switch OK?
Replace the main
switch/immobilizer
antenna.
8 - 11
+
ELEC
IGNITION SYSTEM
EAS00752
YES NO
EAS00754
YES NO
9. Sidestand switch
Check the sidestand switch for continuity.
Is the sidestand switch OK?
Replace the side-
stand switch.
10.Wiring
Check the entire ignition system wiring.
Refer to CIRCUIT DIAGRAM.
Is the ignition system wiring properly con-
nected and without defects?
Replace the CDI unit. Properly connect or
repair the ignition
system wiring.
8 - 12
+
ELEC
ELECTRIC STARTING SYSTEM
EAS00755
CIRCUIT DIAGRAM
O
F
F
O
N
G
/Y
G
W
/R
R
R
R
RB
B
W
R
WW
WWW W
/L
B
R
/L
B
R
B
r/L
B
r/L
R
/B
B
r/L
B
r/L
R
B
r
R
/W
R
/Y
B
G
/B
L
/W
G
/B
L
/W
G
/B
R
/B
G
/Y
L
/Y
B L L
S
b
O
/W
L
/G
R
/B
R
/G
L
/Y
R
/B
Y
/R
W
/B
W
/R
W
/L
B
L
/G
G
/W
G
/W
G
/W
G
/W
O
O B
R
/G
LL B
P
/G
R
/B
R
/W
G
/Y
G
/Y
B
r
B
r
G
/Y
G
/Y
G
/Y
G
/Y
B
B B
B
D
g
W
C
h
W
B
r
B
r
B
r
B
r
B
C
h
D
g
B
B
B
D
g
C
h
B
r
B
r
GY
B B
B
B
B
r/W
R
/L
B
r/B
B
r/B
G
/B
G
/B
B
r
B
r/B
B
r
B
r
B
r
PP
B B
G G
Y L
/B
L
/B
L
/Y
R
/Y
W
/B
YC
h
D
g
R
/Y
R
/Y
B
r
S
b
O
/W
B
G
/L
R
/L
B
r/G
B
r/G
G
y
G
y
G
y
/R
G
y
/B
B
L
/Y
L
/W
B B
B
r/W
B
r/W
Y
G
/B
G
/L
P
/G
B
G
y
/R
G
y
/B
B
G
/R
B
B
/Y
B
/Y
R
/L
B
r
C
h
D
g
R
/L
P
/W
P
/W
Y
/R
R
/B
Y
/R
B
L
/W
B
B
W
G
/W
G
/W
R
R
/GR
/L
R
W
/Y
G
L
L
G
Y
Y
B
(G
R
E
E
N
)
(G
R
E
E
N
)
(W
H
IT
E
)
(W
H
IT
E
)
(B
L
A
C
K
)
W
/L
W
/R
B
r
R
R
R
R
W
W
W
B
B
R
/Y
L
/B
W
/B
L
/Y
B
r/G
B
r/G
BB
G
y
G
y/B
G
y/R
R B L
R
/WL
R
/B
P
/G
R
/G
L
R
/B
L
/G
L
/W R
G
/B
(B
L
A
C
K
)
R
/Y
B
R
/Y
B
R
B
r/L
RB
r
B
R
W
W
W
G
/L
Y
B
D
g
S
b
G
/R
G
y
/B
O
/W
B
B
r/G
G
y/R
B
r/G
G
y
B
r
C
h
R
/L
B
r
G
B
Y
L
G
B
Y
L
B
B
B
r
B
r
D
g
G
/Y
B
B
r
C
h
G
/Y
B
R
/Y
G
L
/B
Y
PB
r
G
/B
L
/B
R
/Y
B
r/B
Y G
B
B
r/W
B
B
r
C
h
D
g
B
r/B
G
/B
R
/L
BR
BL
(B
L
A
C
K
)
L
/W
W
/Y
B
r/W
L
/W
W
/Y
B
B
r/W
L
/W
B
B
BB
(B
L
U
E
)
L
/Y
B
(B
L
U
E
)
G
/B
L
/W
S
b
O
/W
B
B
r/W
(B
L
A
C
K
)
C
h
B
(B
L
A
C
K
)
D
g
B
(G
R
E
E
N
)
B
r
G
/B
B
r/B
(B
L
A
C
K
)
P
B
(R
E
D
)
B G
/B
B
r
R
/Y
L
/B
B
r/B
YG
P
R
/B
L
/Y
G
/B
G
/Y
(B
L
U
E
)
Y
/R
R
/B
G
/B
Y
B
/L
B
(B
L
A
C
K
)
LB
(B
L
A
C
K
)
R
/L
D
g
B
r
B
/Y
B
C
h
P
/W
P
/W
G
B
Y
G
B
Y
L
/G
G
/W
G
/W
O
W
/R
Y
/R
B
R
/B
R
/G
G
/L
L
/Y
W
/B
W
/L
(G
R
E
E
N
)
B
r
B
D
g
B
B
r
W
G
/Y
B
B
r
W
G
/Y
B
1 2
3
~
45
6
70 89
q
r
s
t
u
v
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y
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}
|
m
o
o
n
n
x{
p
e
g
f
h
i
g
j
k
l
Z
[
]
\
_
b
c
d
a
A
B
C
D
E
F
N
G
M
J
H
I
K
Q
R
P
O
S
T
U
W
V
Y
X
L
6
M
a
i
n

s
w
i
t
c
h
7
I
g
n
i
t
i
o
n

f
u
s
e
0
S
i
g
n
a
l
i
n
g

s
y
s
t
e
m

f
u
s
e
A
G
r
o
u
n
d

l
e
a
d
B
B
a
t
t
e
r
y
C
M
a
i
n

f
u
s
e
D
S
t
a
r
t
e
r

r
e
l
a
y
E
S
t
a
r
t
e
r

m
o
t
o
r
F
D
i
o
d
e
G
S
i
d
e
s
t
a
n
d

s
w
i
t
c
h
H
S
t
a
r
t
i
n
g

c
i
r
c
u
i
t

c
u
t
-
o
f
f

r
e
l
a
y
M
S
t
a
r
t

s
w
i
t
c
h
Z
R
e
a
r

b
r
a
k
e

l
i
g
h
t

s
w
i
t
c
h
[
F
r
o
n
t

b
r
a
k
e

l
i
g
h
t

s
w
i
t
c
h
8 - 13
+
ELEC
EAS00756
STARTING CIRCUIT CUT-OFF SYSTEM
OPERATION
If the main switch is set to ON (switch is
closed), the starter motor can only operate if
the following conditions are met:
A brake lever is pulled to the handlebar (the
brake light switch is closed) and the side-
stand is up (the sidestand switch is closed).
1Battery
2Main fuse
3Main switch
4Ignition fuse
5Starting circuit cut-off relay
6Sidestand switch
7Signaling system fuse
8Front brake light switch
9Rear brake light switch
0Start switch
ADiode
BStarter relay
CStarter motor
8 - 14
+
ELEC
EAS00757
TROUBLESHOOTING
Check:
1. main, ignition, and signaling system fuses
2. battery
3. starter motor
4. starting circuit cut-off relay
5. starter relay
6. main switch
7. brake light switch (front and rear)
8. sidestand switch
9. start switch
10.wiring connections
(of the entire starting system)
NOTE:
_
part(s):
1. storage box
2. front cowling
4. handlebar upper cover (with meter assem-
bly)
tool(s).
EAS00738
YES NO
EAS00739
YES NO
EAS00758
YES NO
The starter motor fails to turn.
Pocket tester
90890-03112
1. Main, ignition, and signaling system fuses
Check the main, ignition, and signaling
system fuses for continuity.
chapter 3.
Are the main, ignition, and signaling sys-
tem fuses OK?
2. Battery
12.8 V or more at 20 C (68 F)
Is the battery OK?
Clean the battery
terminals.
Recharge or
3. Starter motor
Connect the positive battery terminal 1
and starter motor lead 2 with a jumper
lead 3.
WARNING
_
A wire that is used as a jumper lead
must have at least the same capacity or
more as that of the battery lead, other-
wise the jumper lead may burn.
This check is likely to produce sparks,
therefore make sure nothing flammable
is in the vicinity.
Does the starter motor turn?
Repair or replace the
starter motor.
8 - 15
+
ELEC
EAS00759
YES NO
EAS00761
YES NO
EAS00749
YES NO
4. Starting circuit cut-off relay
Remove the starting circuit cut-off relay.
Connect the pocket tester ( 1) and bat-
tery (12 V) to the starting circuit cut-off
relay terminals as shown.
Positive battery terminal red/black 1
Negative battery terminal blue/yellow 2
Positive tester probe green/yellow 3
Negative tester probe green/black 4
Does the starting circuit cut-off relay have
continuity between green/yellow and
green/black?
Replace the starting
circuit cut-off relay.
5. Starter relay
Remove the starter relay.
tery (12 V) to the starter relay terminal as
shown.
Positive battery terminal green/black 1
Negative battery terminal blue/white 2
Positive tester probe red 3
Negative tester probe black 4
Does the starter relay have continuity
between red and black?
Replace the starter
relay.
6. Main switch
Replace the main
switch/immobilizer
antenna.
8 - 16
+
ELEC
EAS00751
YES NO
EAS00752
YES NO
EAS00764
YES NO
EAS00766
YES NO
7. Brake light switch (front and rear)
Check the brake light switches for continu-
ity.
Is each brake light switch OK?
Replace the brake
light switch(es).
8. Sidestand switch
Replace the side-
stand switch.
9. Start switch
Check the start switch for continuity.
Is the start switch OK?
Replace the start
switch.
10.Wiring
Check the entire starting system wiring.
Is the starting system wiring properly con-
The starting system
circuit is OK.
Properly connect or
repair the starting
system wiring.
8 - 17
+
ELEC
STARTER MOTOR
1
4
3
8
7
A
9
0
B
2
6
5
C
New
1
3
2
T R .
.
10 Nm (1.0 m kg, 7.2 ft Ib)
New
New
New
New
New
LS
T R .
.
7 Nm (0.7 m kg, 5.1 ft Ib)
T R .
.
5 Nm (0.5 m kg, 3.6 ft Ib)
Removing the starter motor Remove the parts in the order listed.
Air filter case assembly Refer to AIR FILTER CASE in chapter
3.
1 Starter motor lead 1 Disconnect.
2 Ground lead 1 Disconnect.
3 Starter motor 1
cedure.
8 - 18
+
ELEC
1
4
3
8
7
A
9
0
B
2
6
5
C
New
1
3
2
T R .
.
10 Nm (1.0 m kg, 7.2 ft Ib)
New
New
New
New
New
LS
T R .
.
7 Nm (0.7 m kg, 5.1 ft Ib)
T R .
.
5 Nm (0.5 m kg, 3.6 ft Ib)
Disassembling the starter motor Remove the parts in the order listed.
1 Starter motor front cover 1
Refer to ASSEMBLING THE STARTER
MOTOR.
2 O-ring 1
3 Shim *
4 Lock washer 1
5 Oil seal 1
6 Bearing 1
7 Starter motor yoke 1
8 Armature assembly 1
9 O-ring 1
0 Shim *
A Brush holder set 1
B Starter motor rear cover 1
C Bushing 1
procedure.
8 - 19
+
ELEC
EAS00770
CHECKING THE STARTER MOTOR
1. Check:
commutator
Dirt Clean with 600 grit sandpaper.
2. Measure:
commutator diameter a
Out of specification Replace the starter
motor.
3. Measure:
mica undercut a
Out of specification Scrape the mica to
the proper measurement with a hacksaw
blade that has been grounded to fit the
commutator.
NOTE:
The mica of the commutator must be undercut
to ensure proper operation of the commutator.
4. Measure:
armature assembly resistances (commuta-
tor and insulation)
Out of specification Replace the starter
motor.
a. Measure the armature assembly resis-
tances with the pocket tester.
b. If any resistance is out of specification,
replace the starter motor.
Commutator wear limit
27 mm (1.06 in)
Mica undercut
0.7 mm (0.028 in)
Pocket tester
90890-03112
Armature coil
Commutator resistance 1
0.0012 ~ 0.0022 at 20 C
(68 F)
Insulation resistance 2
Above 1 M at 20 C (68 F)
8 - 20
+
ELEC
5. Measure:
brush length a
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 the gear.
Brush length wear limit
4.0 mm (0.16 in)
Brush spring force
7.65 ~ 10.01 N
(780 ~ 1,021 gf, 27.5 ~ 36.0 oz)
8. Check:
bearing 1
oil seal 2
bushing 3
part(s).
EAS00772
ASSEMBLING THE STARTER MOTOR
1. Install:
starter motor rear cover 1
armature assembly
starter motor yoke 2
starter motor front cover 3
NOTE:
To prevent damaging the brushes during
installation, push down on the brush springs.
Align the alignment marks a on the starter
motor yoke with the alignment marks b on
the starter motor front and rear covers.
8 - 21
+
ELEC
CHARGING SYSTEM
EAS00773
CHARGING SYSTEM
CIRCUIT DIAGRAM
O
F
F
O
N
W
/
R
R
R
R
RB
B
W
R
WW
WWW W
/
L
B
R
/
L
B
R
B
r
/
L
B
r
/
L
R
/
B
B
r
/
L
R
R
/
W
R
/
Y
B
G
/
B
L
/
W
G
/
B
L
/
W
G
/
B
R
/
B
G
/
Y
L
/
Y
B
L
/
Y
L
/
W
L
/
W
B
R
R
/
GR
/
L
R
W
/
Y
B
W
/
L
W
/
R
B
r
R
R
R
R
W
W
W
B
B
L
/
W
R
G
/
B
(
B
L
A
C
K
)
R
/
Y
B
R
/
Y
B
R
B
r
/
L
RB
r
B
R
W
W
W
L
/
W
W
/
Y
B
r
/
W
L
/
W
W
/
Y
B
B
r
/
W
L
/
W
B
B
BB
(
B
L
U
E
)
L
/
Y
B
(
B
L
U
E
)
G
/
B
L
/
W
R
/
B
L
/
Y
G
/
B
G
/
Y
(
B
L
U
E
)
B
/
L
B
(
B
L
A
C
K
)
LB
(
B
L
A
C
K
)
1 2
3
~
45
6
789
A
B
C
D
E
F
N
G
M
H
L
1
A
C

m
a
g
n
e
t
o
3
R
e
c
t
i
f
i
e
r
/
r
e
g
u
l
a
t
o
r
A
G
r
o
u
n
d

l
e
a
d
B
B
a
t
t
e
r
y
C
M
a
i
n

f
u
s
e
8 - 22
+
ELEC
CHARGING SYSTEM
EAS00774
TROUBLESHOOTING
Check:
1. main fuse
2. battery
3. charging voltage
4. stator coil resistance
5. wiring connections
(of the entire charging system)
NOTE:
_
part(s):
1. upper panel
2. storage box
3. battery cover
tool(s).
EAS00738
YES NO
EAS00739
YES NO
The battery is not being charged.
Pocket tester
90890-03112
1. Main fuse
Check the main fuse for continuity.
chapter 3.
Is the main fuse OK?
Replace the fuse.
2. Battery
12.8 V or more at 20 C (68 F)
Is the battery OK?
Clean the battery
terminals.
Recharge or
8 - 23
+
ELEC
CHARGING SYSTEM
EAS00775
NO YES
EAS00776
YES NO
EAS00779
YES NO
3. Charging voltage
Connect the pocket tester (DC 20 V) to the
battery as shown.
positive battery terminal
Negative tester probe
negative battery terminal
Start the engine and let it run at approxi-
mately 5,000 r/min.
Measure the charging voltage.
Charging voltage
14 V at 5,000 r/min
NOTE:
_
Make sure the battery is fully charged.
Is the charging voltage within specifica-
tion?
The charging circuit
is OK.
4. Stator coil resistance
Disconnect the stator coil coupler from the
wire harness.
stator coil as shown.
Measure the stator coil resistances.
Stator coil resistance
0.385 ~ 0.415 at 20 C (68 F)
Is the stator coil OK?
Replace the pickup
coil/stator assembly.
5. Wiring
Check the entire charging system wiring.
Is the charging system wiring properly
connected and without defects?
Replace the rectifier/
regulator.
Properly connect or
repair the charging
system wiring.
R R
R
2
1 3
8 - 24
+
ELEC
LIGHTING SYSTEM
EAS00780
LIGHTING SYSTEM
CIRCUIT DIAGRAM
O
F
F
O
N
G
/Y
G
W
/R
R
R
R
RB
B
W
R
WW
WWW W
/L
B
R
/L
B
R
B
r/L
B
r/L
R
/B
B
r/L
B
r/L
R
B
r
R
/W
R
/Y
B
G
/B
L
/W
G
/B
L
/W
G
/B
R
/B
G
/Y
L
/Y
B L L
S
b
O
/W
L
/G
R
/B
R
/G
L
/Y
R
/B
Y
/R
W
/B
W
/R
W
/L
B
L
/G
G
/W
G
/W
G
/W
G
/W
O
O B
R
/G
LL B
P
/G
R
/B
R
/W
G
/Y
G
/Y
B
r
B
r
G
/Y
G
/Y
G
/Y
G
/Y
B
B B
B
D
g
W
C
h
W
B
r
B
r
B
r
B
r
B
C
h
D
g
B
B
B
D
g
C
h
B
r
B
r
GY
B B
B
B
B
r/W
R
/L
B
r/B
B
r/B
G
/B
G
/B
B
r
B
r/B
B
r
B
r
B
r
PP
B B
G G
Y L
/B
L
/B
L
/Y
R
/Y
W
/B
YC
h
D
g
R
/Y
R
/Y
B
r
S
b
O
/W
B
G
/L
R
/L
B
r/G
B
r/G
G
y
G
y
G
y
/R
G
y
/B
B
L
/Y
L
/W
B B
B
r/W
B
r/W
Y
G
/B
G
/L
P
/G
B
G
y
/R
G
y
/B
B
G
/R
B
B
/Y
B
/Y
R
/L
B
r
C
h
D
g
R
/L
P
/W
P
/W
Y
/R
R
/B
Y
/R
B
L
/W
B
B
W
G
/W
G
/W
R
R
/GR
/L
R
W
/Y
G
L
L
G
Y
Y
B
(G
R
E
E
N
)
(G
R
E
E
N
)
(W
H
IT
E
)
(W
H
IT
E
)
(B
L
A
C
K
)
W
/L
W
/R
B
r
R
R
R
R
W
W
W
B
B
R
/Y
L
/B
W
/B
L
/Y
B
r/G
B
r/G
BB
G
y
G
y/B
G
y/R
R B L
R
/WL
R
/B
P
/G
R
/G
L
R
/B
L
/G
L
/W R
G
/B
(B
L
A
C
K
)
R
/Y
B
R
/Y
B
R
B
r/L
RB
r
B
R
W
W
W
G
/L
Y
B
D
g
S
b
G
/R
G
y
/B
O
/W
B
B
r/G
G
y/R
B
r/G
G
y
B
r
C
h
R
/L
B
r
G
B
Y
L
G
B
Y
L
B
B
B
r
B
r
D
g
G
/Y
B
B
r
C
h
G
/Y
B
R
/Y
G
L
/B
Y
PB
r
G
/B
L
/B
R
/Y
B
r/B
Y G
B
B
r/W
B
B
r
C
h
D
g
B
r/B
G
/B
R
/L
BR
BL
(B
L
A
C
K
)
L
/W
W
/Y
B
r/W
L
/W
W
/Y
B
B
r/W
L
/W
B
B
BB
(B
L
U
E
)
L
/Y
B
(B
L
U
E
)
G
/B
L
/W
S
b
O
/W
B
B
r/W
(B
L
A
C
K
)
C
h
B
(B
L
A
C
K
)
D
g
B
(G
R
E
E
N
)
B
r
G
/B
B
r/B
(B
L
A
C
K
)
P
B
(R
E
D
)
B G
/B
B
r
R
/Y
L
/B
B
r/B
YG
P
R
/B
L
/Y
G
/B
G
/Y
(B
L
U
E
)
Y
/R
R
/B
G
/B
Y
B
/L
B
(B
L
A
C
K
)
LB
(B
L
A
C
K
)
R
/L
D
g
B
r
B
/Y
B
C
h
P
/W
P
/W
G
B
Y
G
B
Y
L
/G
G
/W
G
/W
O
W
/R
Y
/R
B
R
/B
R
/G
G
/L
L
/Y
W
/B
W
/L
(G
R
E
E
N
)
B
r
B
D
g
B
B
r
W
G
/Y
B
B
r
W
G
/Y
B
1 2
3
~
45
6
70 89
q
r
s
t
u
v
w
y
z
}
|
m
o
o
n
n
x{
p
e
g
f
h
i
g
j
k
l
Z
[
]
\
_
b
c
d
a
A
B
C
D
E
F
N
G
M
J
H
I
K
Q
R
P
O
S
T
U
W
V
Y
X
L
4
C
D
I

u
n
i
t

f
u
s
e
6
M
a
i
n

s
w
i
t
c
h
9
H
e
a
d
l
i
g
h
t

f
u
s
e
0
S
i
g
n
a
l
i
n
g

s
y
s
t
e
m

f
u
s
e
A
G
r
o
u
n
d

l
e
a
d
B
B
a
t
t
e
r
y
C
M
a
i
n

f
u
s
e
G
S
i
d
e
s
t
a
n
d

s
w
i
t
c
h
S
C
D
I

u
n
i
t
_
H
e
a
d
l
i
g
h
t

r
e
l
a
y
b
D
i
m
m
e
r
/
p
a
s
s

s
w
i
t
c
h
g
T
a
i
l
/
b
r
a
k
e

l
i
g
h
t
l
L
i
c
e
n
s
e

p
l
a
t
e

l
i
g
h
t
n
H
e
a
d
l
i
g
h
t
o
A
u
x
i
l
i
a
r
y

l
i
g
h
t
v
M
e
t
e
r

l
i
g
h
t
x
H
i
g
h

b
e
a
m

i
n
d
i
c
a
t
o
r

l
i
g
h
t
8 - 25
+
ELEC
LIGHTING SYSTEM
EAS00781
TROUBLESHOOTING
Check:
1. main, headlight, signaling system, and CDI
unit fuses
2. battery
3. main switch
4. dimmer/pass switch
5. sidestand switch
6. headlight relay
(of the entire lighting system)
NOTE:
_
part(s):
1. storage box
2. front cowling
bly)
tool(s).
EAS00738
YES NO
EAS00739
YES NO
EAS00749
YES NO
EAS00784
YES NO
Any of the following fail to light: head-
lights, high beam indicator light, taillight,
license plate light, auxiliary lights or
meter light.
Pocket tester
90890-03112
1. Main, headlight, signaling system, and
CDI unit fuses
Check the main, headlight, signal system,
and CDI unit fuses for continuity.
chapter 3.
Are the main, headlight, signal system,
and CDI unit fuses OK?
2. Battery
12.8 V or more at 20 C (68 F)
Is the battery OK?
Clean the battery
terminals.
Recharge or
3. Main switch
Replace the main
switch/immobilizer
antenna.
4. Dimmer/pass switch
Check the dimmer/pass switch for continu-
ity.
Is the dimmer/pass switch OK?
Replace the dimmer/
pass switch.
8 - 26
+
ELEC
LIGHTING SYSTEM
EAS00752
YES NO
YES NO
EAS00787
YES NO
5. Sidestand switch
Replace the side-
stand switch.
6. Headlight relay
Remove the headlight relay.
tery (12 V) to the headlight relay terminals
as shown.
Check the headlight relay for continuity.
Positive battery terminal white/black 1
Negative battery terminal blue/yellow 2
Positive tester probe red/yellow 3
Negative tester probe blue/black 4
Does the headlight relay have continuity
between red/yellow and blue/black?
Replace the head-
light relay.
7. Wiring
Check the entire lighting system wiring.
Is the lighting system wiring properly con-
Check the condition
of each of the lighting
system circuits.
Refer to CHECK-
ING THE LIGHTING
SYSTEM.
Properly connect or
repair the lighting
system wiring.
8 - 27
+
ELEC
LIGHTING SYSTEM
EAS00788
CHECKING THE LIGHTING SYSTEM
1. The headlights and the high beam indicator
light fail to come on.
YES NO
YES NO
1. Headlight bulb and socket
Check the headlight bulb and socket for
continuity.
Refer to CHECKING THE BULBS AND
BULB SOCKETS.
Are the headlight bulb and socket OK?
Replace the head-
light bulb, socket or
both.
2. Voltage
headlight (wire harness side) and meter
assembly couplers as shown.
When the dimmer/pass switch is set to
When the dimmer/pass switch is set to
Headlight
yellow 1 or green 2
Headlight coupler
G L
Y B
Br G
B Y
DC 20V
1 3
2
High beam indicator light
Positive tester probe yellow 4
Meter assembly coupler
Start the engine.
Set the dimmer/pass switch to or
.
Measure the voltage (DC 12 V) of yellow
1 (green 2) on the headlight coupler
(wire harness side) and yellow 4 on the
meter assembly coupler.
Is the voltage within specification?
Replace the CDI unit
or meter assembly.
The wiring circuit
from the main switch
to the headlight cou-
pler or meter assem-
bly coupler is faulty
and must be re-
paired.
5
4
G/L Y B Dg Sb
G/R
O/W
B
Br/G Br/G
Gy Br
Ch
R/L Gy/B
Gy/R
8 - 28
+
ELEC
LIGHTING SYSTEM
EAS00789
2. The meter light fails to come on.
YES NO
EAS00790
3. The tail/brake light fails to come on.
YES NO
YES NO
1. Voltage
meter assembly coupler as shown.
Measure the voltage (DC 12 V) of brown
1 on the meter assembly coupler.
Replace the meter
assembly.
The wiring circuit
to the meter assem-
and must be re-
paired.
1. Tail/brake light bulbs and sockets (right
and left)
Check the tail/brake light bulbs and sock-
ets for continuity.
BULB SOCKETS.
Are the tail/brake light bulbs and sockets
OK?
Replace the tail/
brake light bulb,
socket or both.
1
G/L Y B Dg Sb
G/R
O/W
B
Br/G Br/G
Gy Br
Ch
R/L
2
Gy/R
Gy/B
2. Voltage
tail/brake light assembly coupler (wire har-
ness side) as shown.
Tail/brake light (left)
Tail/brake light (right)
1 on the tail/brake light assembly coupler
(wire harness side).
This circuit is OK. The wiring circuit
to the tail/brake light
assembly coupler is
faulty and must be
repaired.
Br
W
G/Y
B
Br
Ch
G/Y
B
1
2
Br
W
G/Y
B
Br
Dg
G/Y
B
2
1
8 - 29
+
ELEC
LIGHTING SYSTEM
EAS00791
4. The auxiliary lights fail to come on.
YES NO
YES NO
EAS00792
5. The license plate light fails to come on.
YES NO
YES NO
1. Auxiliary light bulb and socket
Check the auxiliary light bulb and socket
for continuity.
BULB SOCKETS.
Are the auxiliary light bulb and socket OK?
Replace the auxiliary
light bulb, socket or
both.
2. Voltage
headlight assembly coupler (wire harness
side) as shown.
1 on the headlight assembly coupler (wire
harness side).
to the headlight
assembly coupler is
faulty and must be
repaired.
Br G
B Y
DC 20V 2
1
G L
Y B
1. License plate light bulb and socket
Check the license plate light bulb and
socket for continuity.
BULB SOCKETS.
Are the license plate light bulb and socket
OK?
Replace the license
plate light bulb,
socket or both.
2. Voltage
license plate coupler (wire harness side)
as shown.
1 on the license plate coupler (wire har-
ness side).
to the license plate
coupler is faulty and
must be repaired.
B
Br L
B
2
1
8 - 30
+
ELEC
SIGNALING SYSTEM
EAS00793
SIGNALING SYSTEM
CIRCUIT DIAGRAM
O
F
F
O
N
G
/Y
G
W
/R
R
R
R
RB
B
W
R
WW
WWW W
/L
B
R
/L
B
R
B
r/L
B
r/L
R
/B
B
r/L
B
r/L
R
B
r
R
/W
R
/Y
B
G
/B
L
/W
G
/B
L
/W
G
/B
R
/B
G
/Y
L
/Y
B L L
S
b
O
/W
L
/G
R
/B
R
/G
L
/Y
R
/B
Y
/R
W
/B
W
/R
W
/L
B
L
/G
G
/W
G
/W
G
/W
G
/W
O
O B
R
/G
LL B
P
/G
R
/B
R
/W
G
/Y
G
/Y
B
r
B
r
G
/Y
G
/Y
G
/Y
B
B B
B
D
g
W
C
h
W
B
r
B
r
B
r
B
r
B
C
h
D
g
B
B
B
D
g
C
h
B
r
B
r
Y
B B
B
B
B
r/W
R
/L
B
r/B
B
r/B
G
/B
G
/B
B
r
B
r/B
B
r
B
r
B
r
PP
B B
G G
Y L
/B
L
/B
L
/Y
R
/Y
W
/B
YC
h
D
g
R
/Y
R
/Y
B
r
S
b
O
/W
B
G
/L
R
/L
B
r/G
B
r/G
G
y
G
y
G
y
/R
G
y
/B
B
L
/Y
L
/W
B B
B
r/W
B
r/W
Y
G
/B
G
/L
P
/G
B
G
y
/R
G
y
/B
B
G
/R
B
B
/Y
B
/Y
R
/L
B
r
C
h
D
g
R
/L
P
/W
P
/W
Y
/R
R
/B
Y
/R
B
L
/W
B
B
W
G
/W
G
/W
R
R
/GR
/L
R
W
/Y
G
L
L
G
Y
Y
B
(G
R
E
E
N
)
(G
R
E
E
N
)
(W
H
IT
E
)
(W
H
IT
E
)
(B
L
A
C
K
)
W
/L
W
/R
B
r
R
R
R
R
W
W
W
B
B
R
/Y
L
/B
W
/B
L
/Y
B
r/G
B
r/G
BB
G
y
G
y/B
G
y/R
R B L
R
/WL
R
/B
P
/G
R
/G
L
R
/B
L
/G
L
/W R
G
/B
(B
L
A
C
K
)
R
/Y
B
R
/Y
B
R
B
r/L
RB
r
B
R
W
W
W
G
/L
Y
B
D
g
S
b
G
/R
G
y
/B
O
/W
B
B
r/G
G
y/R
B
r/G
G
y
B
r
C
h
R
/L
B
r
G
B
Y
L
G
B
Y
L
B
B
B
r
B
r
D
g
G
/Y
B
B
r
C
h
G
/Y
B
R
/Y
G
L
/B
Y
PB
r
G
/B
L
/B
R
/Y
B
r/B
Y G
B
B
r/W
B
B
r
C
h
D
g
B
r/B
G
/B
R
/L
BR
BL
(B
L
A
C
K
)
L
/W
W
/Y
B
r/W
L
/W
W
/Y
B
B
r/W
L
/W
B
B
BB
(B
L
U
E
)
L
/Y
B
(B
L
U
E
)
G
/B
L
/W
S
b
O
/W
B
B
r/W
(B
L
A
C
K
)
C
h
B
(B
L
A
C
K
)
D
g
B
(G
R
E
E
N
)
B
r
G
/B
B
r/B
(B
L
A
C
K
)
P
B
(R
E
D
)
B G
/B
B
r
R
/Y
L
/B
B
r/B
YG
P
R
/B
L
/Y
G
/B
G
/Y
(B
L
U
E
)
Y
/R
R
/B
G
/B
Y
B
/L
B
(B
L
A
C
K
)
LB
(B
L
A
C
K
)
R
/L
D
g
B
r
B
/Y
B
C
h
P
/W
P
/W
G
B
Y
G
B
Y
L
/G
G
/W
G
/W
O
W
/R
Y
/R
B
R
/B
R
/G
G
/L
L
/Y
W
/B
W
/L
(G
R
E
E
N
)
B
r
B
D
g
B
B
r
W
G
/Y
B
B
r
W
G
/Y
B
1 2
3
~
45
6
70 89
q
r
s
t
u
v
w
y
z
}
|
m
o
o
n
n
x{
p
e
g
f
h
i
g
j
k
l
Z
[
]
\
_
b
c
d
a
A
B
C
D
E
F
N
G
M
J
H
I
K
Q
R
P
O
S
T
U
W
V
Y
X
L
8 - 31
+
ELEC
SIGNALING SYSTEM
5Backup fuse (meter assembly)
6Main switch
AGround lead
BBattery
CMain fuse
KFuel sender
NHazard switch
ZRear brake light switch
[Front brake light switch
\Turn signal/hazard relay
]Horn
cHorn switch
dTurn signal switch
fRear turn signal light (right)
gTail/brake light
iRear turn signal light (left)
jFront turn signal light (right)
kFront turn signal light (left)
pCoolant temperature sensor
rCoolant temperature gauge
sFuel level gauge
tSpeedometer
uMultifunction meter
wFuel level warning light
yLeft turn signal indicator light
zRight turn signal indicator light
|Air temperature sensor
}Speed sensor
8 - 32
+
ELEC
SIGNALING SYSTEM
EAS00794
TROUBLESHOOTING
Check:
1. main, signaling system, and backup fuses
2. battery
3. main switch
(of the entire signaling system)
NOTE:
_
part(s):
1. storage box
2. front cowling
bly)
tool(s).
EAS00738
YES NO
EAS00739
YES NO
EAS00749
YES NO
EAS00795
YES NO
Any of the following fail to light: turn
signal light, brake light or an indicator
light.
The horn fails to sound.
The fuel level gauge fails to operate.
The speedometer fails operate.
The ambient temperature display fails
to operate.
The coolant temperature gauge (meter
assembly) fails to indicate.
Pocket tester
90890-03112
1. Main, signaling system, and backup fuses
Check the main, signaling system, and
backup fuses for continuity.
chapter 3.
Are the main, signaling system, and
backup fuses OK?
2. Battery
12.8 V or more at 20 C (68 F)
Is the battery OK?
Clean the battery
terminals.
Recharge or
3. Main switch
Replace the main
switch/immobilizer
antenna.
4. Wiring
Check the entire signaling system wiring.
Is the signaling system wiring properly
Check the condition
of each of the signal-
ing system circuits.
Refer to CHECK-
ING THE SIGNAL-
ING SYSTEM.
Properly connect or
repair the signaling
system wiring.
8 - 33
+
ELEC
SIGNALING SYSTEM
EAS00796
CHECKING THE SIGNALING SYSTEM
1. The horn fails to sound.
YES NO
YES NO
YES NO
1. Horn switch
Check the horn switch for continuity.
Is the horn switch OK?
Replace the horn
switch.
2. Voltage
horn connector at the horn terminal as
shown.
Tester positive probe brown 1
Tester negative probe ground
Measure the voltage (12 V) of brown at the
horn terminal.
The wiring circuit
to the horn connector
is faulty and must be
repaired.
3. Horn
Disconnect the pink connector at the horn
terminal.
Connect a jumper lead 1 to the horn ter-
minal and ground the jumper lead.
Does the horn sound?
Repair or replace the
pink lead or ground
lead.
Replace the horn.
8 - 34
+
ELEC
SIGNALING SYSTEM
EAS00797
2. The tail/brake light fails to come on.
YES NO
YES NO
YES NO
1. Tail/brake light bulbs and sockets
Check the tail/brake light bulbs and sock-
ets for continuity.
Are the tail/brake light bulbs and sockets
OK?
Replace the tail/
brake light bulb,
socket or both.
2. Brake light switches
Check the brake light switches for continu-
ity.
Is the brake light switch OK?
Replace the brake
light switch(es).
3. Voltage
tail/brake light assembly coupler (wire har-
ness side) as shown.
Tail/brake light (left)
Tail/brake light (right)
Positive tester probe green/yellow 1
Pull in the brake levers.
Measure the voltage (DC 12 V) of green/
yellow 1 on the tail/brake light assembly
coupler (wire harness side).
to the tail/brake light
assembly coupler is
faulty and must be
repaired.
1 2
Br W
G/Y B
Br Ch
G/Y B
1 2
Br W
G/Y B
Br Dg
G/Y B

8 - 35
+
ELEC
SIGNALING SYSTEM
EAS00799
3. The turn signal light, turn signal indicator
light or both fail to blink.
YES NO
YES NO
YES NO
YES NO
1. Turn signal light bulbs and sockets
Check the turn signal light bulbs and sock-
ets for continuity.
BULB SOCKETS.
Are the turn signal light bulbs and sockets
OK?
Replace the turn sig-
nal light bulb, socket
or both.
2. Turn signal switch
Check the turn signal switch for continuity.
Is the turn signal switch OK?
Replace the turn sig-
nal switch.
3. Hazard switch
Check the hazard switch for continuity.
Is the hazard switch OK?
Replace the hazard
switch.
4. Voltage
turn signal/hazard relay coupler as shown.
Turn signal function
Negative tester probe ground
Hazard function
Positive tester probe red/blue 2
Measure the voltage (DC 12 V) on brown
1 at the turn signal/hazard relay coupler.
Hazard function
Measure the voltage (DC 12 V) on red/
blue 2 at the turn signal/hazard relay cou-
pler.
The wiring circuit
to the turn signal/
hazard relay coupler
is faulty and must be
repaired for the turn
signal function.
The wiring circuit
from the battery to
the turn signal/haz-
ard relay coupler is
faulty and must be
repaired for the haz-
ard function.
8 - 36
+
ELEC
SIGNALING SYSTEM
YES NO
5. Voltage
turn signal/hazard relay coupler as shown.
Left turn signal light
Positive tester probe chocolate 1
Right turn signal light
Positive tester probe dark green 2
Hazard function
Set the turn signal switch to .
Measure the voltage (DC 12 V) on choco-
late 1 at the turn signal/hazard relay cou-
pler.
Set the turn signal switch to .
Measure the voltage (DC 12 V) on dark
green 2 at the turn signal/hazard relay
coupler.
Hazard function
Set the hazard switch to .
Measure the voltage (DC 12 V) on choco-
late 1 at the turn signal/hazard relay cou-
pler.
Measure the voltage (DC 12 V) on dark
green 2 at the turn signal/hazard relay
coupler.
The turn signal/haz-
ard relay is faulty and
must be replaced.
8 - 37
+
ELEC
SIGNALING SYSTEM
YES NO
6. Voltage
turn signal light assembly coupler or meter
assembly coupler as shown.
Front turn signal light (left and right)
Tail/brake light (left and right)
Meter assembly
Left turn signal light
Right turn signal light
1
2
Br
B
Ch
B
Dg
B
Dg
B
1 2
Br W
G/Y B
Br Ch
G/Y B
Br W
G/Y B
Br Dg
G/Y B
2 1
G/L Y B Dg Sb
G/R
O/W Br/G Br/G
Gy Br
Ch
R/L B Gy/B
Gy/R

Set the turn signal switch to or .
Measure the voltage (DC 12 V) of the
chocolate 1 or dark green 2 at the turn
signal light assembly coupler (wire har-
ness side) or meter assembly coupler.
Replace the meter
assembly.
The wiring circuit
from the turn signal
switch to the turn sig-
nal light coupler or
meter assembly cou-
pler is faulty and
must be repaired.
8 - 38
+
ELEC
SIGNALING SYSTEM
EAS00806
4. The speedometer fails to operate.
YES NO
YES NO
1. Speed sensor
speed sensor coupler (wire harness side)
as shown.
Positive tester probe gray 1
Negative tester probe gray/black 2
Elevate the front wheel and slowly rotate
it.
Measure the voltage (DC 5 V) of gray and
gray/black. With each full rotation of the
front wheel, the voltage reading should
cycle from 0.6 V to 4.8 V to 0.6 V to 4.8 V.
Does the voltage reading cycle correctly?
Replace the speed
sensor.
2
1
Gy
Gy/B
Gy/R R
B
L
2. Voltage
Positive tester probe gray 1
Measure the voltage (DC 5 V) of gray 1
on the meter assembly coupler.
This circuit is OK. Replace the meter
assembly.
1 2
G/L Y B Dg Sb
G/R
O/W
B
Br/G Br/G
Gy Br
Ch
R/L Gy/B
Gy/R
8 - 39
+
ELEC
SIGNALING SYSTEM
EAS00804
5. The fuel level gauge fails to operate.
YES NO
YES NO
1. Fuel sender
Remove the fuel sender from the fuel tank.
Connect the pocket tester to the fuel
sender coupler as shown.
Positive tester probe sky blue 1
Negative tester probe orange/white 2
Measure the fuel sender resistances.
Fuel sender resistance
Full position of the float
( 1)
0 ~ 7
Empty position of the float
( 10)
87 ~ 103
Is the fuel sender OK?
Replace the fuel
sender.
Sb
O/W
2
1
2. Voltage
1 and black 2 at the meter assembly
coupler.
Replace the meter
assembly.
The wiring circuit
to the meter assem-
and must be
repaired.
1
G/L Y B
B
Dg Sb
G/R
O/W Br/G Br/G
Gy Br
Ch
R/L
2
Gy/B
Gy/R
8 - 40
+
ELEC
SIGNALING SYSTEM
EAS00804
6. The ambient temperature display fails
to operate.
YES NO
YES NO
1. Air temperature sensor
air temperature sensor coupler as shown.
Positive tester probe brown/green 1
Negative tester probe brown/green 2
Measure the air temperature sensor resis-
tances.
Air temperature sensor resis-
tance
12.09 k at 20 C (68 F)
8.31 k at 30 C (86 F)
Is the air temperature sensor OK?
Replace the air tem-
perature sensor.
Br/G
Br/G
B
B
1
2
2. Voltage
coupler.
Replace the meter
assembly.
The wiring circuit
to the meter assem-
and must be
repaired.
1
G/L Y B
B
Dg Sb
G/R
O/W Br/G Br/G
Gy Br
Ch
R/L
2
Gy/B
Gy/R
8 - 41
+
ELEC
SIGNALING SYSTEM
7. Coolant temperature gauge fails to operate.
EAS00812
YES NO
1. Coolant temperature sensor
Remove the coolant temperature sensor
from the cylinder head.
coolant temperature sensor 1 as shown.
Immerse the coolant temperature sensor
in a container filled with coolant 2.
NOTE:
_
Make sure the coolant temperature sensor
terminals do not get wet.
Place a thermometer 3 in the coolant.
Slowly heat the coolant, and then let it cool
to the specified temperature indicated in
the table.
Check the coolant temperature sensor for
continuity at the temperatures indicated
below.
resistance
80 C (176 F): 69.0
100 C (212 F): 37.2
WARNING
_
Handle the coolant temperature sensor
with special care.
Never subject the coolant temperature
sensor to strong shocks. If the coolant
temperature sensor is dropped, replace
it.
T

R
.
.
8 Nm (0.8 m kg, 5.8 ft lb)
Does the coolant temperature sensor
operate properly?
Replace the coolant
temperature sensor.
8 - 42
+
ELEC
SIGNALING SYSTEM
YES NO
2. Voltage
coupler.
Replace the meter
assembly.
The wiring circuit
to the meter assem-
and must be
repaired.
1
G/L Y B
B
Dg Sb
G/R
O/W Br/G Br/G
Gy Br
Ch
R/L
2
Gy/B
Gy/R
8 - 43
+
ELEC
COOLING SYSTEM
EAS00807
COOLING SYSTEM
CIRCUIT DIAGRAM
O
F
F
O
N
G
/Y
G
W
/R
R
R
R
RB
B
W
R
WW
WWW W
/L
B
R
/L
B
R
B
r/L
B
r/L
R
/B
B
r/L
B
r/L
R
B
r
R
/W
R
/Y
B
G
/B
L
/W
G
/B
L
/W
G
/B
R
/B
G
/Y
L
/Y
B L L
S
b
O
/W
L
/G
R
/B
R
/G
L
/Y
R
/B
Y
/R
W
/B
W
/R
W
/L
B
L
/G
G
/W
G
/W
G
/W
G
/W
O
O B
R
/G
LL B
P
/G
R
/B
R
/W
G
/Y
G
/Y
B
r
B
r
G
/Y
G
/Y
G
/Y
B
B B
B
D
g
W
C
h
W
B
r
B
r
B
r
B
r
B
C
h
D
g
B
B
B
D
g
C
h
B
r
B
r
Y
B B
B
B
B
r/W
R
/L
B
r/B
B
r/B
G
/B
G
/B
B
r
B
r/B
B
r
B
r
B
r
PP
B B
G G
Y L
/B
L
/B
L
/Y
R
/Y
W
/B
YC
h
D
g
R
/Y
R
/Y
B
r
S
b
O
/W
B
G
/L
R
/L
B
r/G
B
r/G
G
y
G
y
G
y
/R
G
y
/B
B
L
/Y
L
/W
B B
B
r/W
B
r/W
Y
G
/B
G
/L
P
/G
B
G
y
/R
G
y
/B
B
G
/R
B
B
/Y
B
/Y
R
/L
B
r
C
h
D
g
R
/L
P
/W
P
/W
Y
/R
R
/B
Y
/R
B
L
/W
B
B
W
G
/W
G
/W
R
R
/GR
/L
R
W
/Y
G
L
L
G
Y
Y
B
(G
R
E
E
N
)
(G
R
E
E
N
)
(W
H
IT
E
)
(W
H
IT
E
)
(B
L
A
C
K
)
W
/L
W
/R
B
r
R
R
R
R
W
W
W
B
B
R
/Y
L
/B
W
/B
L
/Y
B
r/G
B
r/G
BB
G
y
G
y/B
G
y/R
R B L
R
/WL
R
/B
P
/G
R
/G
L
R
/B
L
/G
L
/W R
G
/B
(B
L
A
C
K
)
R
/Y
B
R
/Y
B
R
B
r/L
RB
r
B
R
W
W
W
G
/L
Y
B
D
g
S
b
G
/R
G
y
/B
O
/W
B
B
r/G
G
y/R
B
r/G
G
y
B
r
C
h
R
/L
B
r
G
B
Y
L
G
B
Y
L
B
B
B
r
B
r
D
g
G
/Y
B
B
r
C
h
G
/Y
B
R
/Y
G
L
/B
Y
PB
r
G
/B
L
/B
R
/Y
B
r/B
Y G
B
B
r/W
B
B
r
C
h
D
g
B
r/B
G
/B
R
/L
BR
BL
(B
L
A
C
K
)
L
/W
W
/Y
B
r/W
L
/W
W
/Y
B
B
r/W
L
/W
B
B
BB
(B
L
U
E
)
L
/Y
B
(B
L
U
E
)
G
/B
L
/W
S
b
O
/W
B
B
r/W
(B
L
A
C
K
)
C
h
B
(B
L
A
C
K
)
D
g
B
(G
R
E
E
N
)
B
r
G
/B
B
r/B
(B
L
A
C
K
)
P
B
(R
E
D
)
B G
/B
B
r
R
/Y
L
/B
B
r/B
YG
P
R
/B
L
/Y
G
/B
G
/Y
(B
L
U
E
)
Y
/R
R
/B
G
/B
Y
B
/L
B
(B
L
A
C
K
)
LB
(B
L
A
C
K
)
R
/L
D
g
B
r
B
/Y
B
C
h
P
/W
P
/W
G
B
Y
G
B
Y
L
/G
G
/W
G
/W
O
W
/R
Y
/R
B
R
/B
R
/G
G
/L
L
/Y
W
/B
W
/L
(G
R
E
E
N
)
B
r
B
D
g
B
B
r
W
G
/Y
B
B
r
W
G
/Y
B
1 2
3
~
45
6
70 89
q
r
s
t
u
v
w
y
z
}
|
m
o
o
n
n
x{
p
e
g
f
h
i
g
j
k
l
Z
[
]
\
_
b
c
d
a
A
B
C
D
E
F
N
G
M
J
H
I
K
Q
R
P
O
S
T
U
W
V
Y
X
L
6
M
a
i
n

s
w
i
t
c
h
7
I
g
n
i
t
i
o
n

f
u
s
e
8
R
a
d
i
a
t
o
r

f
a
n

m
o
t
o
r

f
u
s
e
A
G
r
o
u
n
d

l
e
a
d
B
B
a
t
t
e
r
y
C
M
a
i
n

f
u
s
e
W
R
a
d
i
a
t
o
r

f
a
n

m
o
t
o
r
X
T
h
e
r
m
o

s
w
i
t
c
h

(
r
a
d
i
a
t
o
r

f
a
n

m
o
t
o
r
)
Y
R
a
d
i
a
t
o
r

f
a
n

m
o
t
o
r

r
e
l
a
y
8 - 44
+
ELEC
COOLING SYSTEM
EAS00808
TROUBLESHOOTING
Check:
1. main, ignition, and radiator fan motor fuses
2. battery
3. main switch
4. radiator fan motor
5. radiator fan motor relay
6. thermo switch (radiator fan motor)
(the entire cooling system)
NOTE:
_
Before troubleshooting, remove the follow-
ing part(s):
1. storage box
2. front cowling
4. under cover
tool(s).
EAS00738
YES NO
EAS00739
YES NO
EAS00749
YES NO
The radiator fan motor fails to turn.
Pocket tester
90890-03112
1. Main, ignition, and radiator fan motor fuses
Check the main, ignition, and radiator fan
motor fuses for continuity.
chapter 3.
Are the main, ignition, and radiator fan
motor fuses OK?
2. Battery
12.8 V or more at 20 C (68 F)
Is the battery OK?
Clean the battery
terminals.
Recharge or
3. Main switch
Replace the main
switch/immobilizer
antenna.
8 - 45
+
ELEC
COOLING SYSTEM
EAS00809
YES NO
YES NO
4. Radiator fan motor
Disconnect the radiator fan motor coupler
from the wire harness.
Connect the battery (DC 12 V) as shown.
Positive battery lead red 1
Negative battery lead black 2
Does the radiator fan motor turn?
The radiator fan
motor is faulty and
must be replaced.
5. Radiator fan motor relay
Remove the radiator fan motor relay.
tery (12 V) to the radiator fan motor terminal
as shown.
Check the radiator fan motor relay of conti-
nuity.
Negative battery terminal pink/green 2
Positive tester probe red/white 3
Negative tester probe blue 4
Does the radiator fan motor relay have con-
tinuity between red/white and blue?
Replace the radiator
fan motor relay.
8 - 46
+
ELEC
COOLING SYSTEM
EAS00811
YES NO
EAS00813
YES NO
6. Thermo switch (radiator fan motor)
Remove the thermo switch (radiator fan
motor) from the radiator.
thermo switch 1 as shown.
Immerse the thermo switch in a container
filled with coolant 2.
NOTE:
Make sure that the thermo switch terminals
do not get wet.
Slowly heat the coolant, and then let it cool
down to the specified temperature.
Check the thermo switch for continuity at
the temperatures indicated in the table.
Test
step
Coolant temperature
Continu-
ity
Thermo switch
1
Less than 105 3 C
(221 5.4 F)
NO
2
More than 105 3 C
(221 5.4 F)
YES
3
More than 98 3 C
(208.4 5.4 F)
YES
4
Less than 98 3 C
(208.4 5.4 F)
NO
Steps 1 and 2: Heating phase
Steps 3 and 4: Cooling phase
WARNING
Handle the thermo switch with special
care.
Never subject the thermo switch to
strong shocks. If the thermo switch is
dropped, replace it.
T

R
.
.
thermo switch (radiator fan
motor)
30 Nm (3.0 m kg, 22 ft lb)
The thermo switch circuit is open and the radia-
tor fan is off.
The thermo switch circuit is closed and the
radiator fan is on.
Does the thermo switch operate properly
as described above?
Replace the thermo
switch (radiator fan
motor).
7. Wiring
Check the entire cooling system wiring.
Is the cooling system wiring properly con-
This circuit is OK. Properly connect or
repair the cooling
system wiring.
8 - 47
+
ELEC
FUEL PUMP SYSTEM
EAS00814
FUEL PUMP SYSTEM
CIRCUIT DIAGRAM
O
F
F
O
N
G
/Y
G
W
/R
R
R
R
RB
B
W
R
WW
WWW W
/L
B
R
/L
B
R
B
r/L
B
r/L
R
/B
B
r/L
B
r/L
R
B
r
R
/W
R
/Y
B
G
/B
L
/W
G
/B
L
/W
G
/B
R
/B
G
/Y
L
/Y
B L L
S
b
O
/W
L
/G
R
/B
R
/G
L
/Y
R
/B
Y
/R
W
/B
W
/R
W
/L
B
L
/G
G
/W
G
/W
G
/W
G
/W
O
O B
R
/G
LL B
P
/G
R
/B
R
/W
G
/Y
G
/Y
B
r
B
r
G
/Y
G
/Y
G
/Y
B
B B
B
D
g
W
C
h
W
B
r
B
r
B
r
B
r
B
C
h
D
g
B
B
B
D
g
C
h
B
r
B
r
Y
B B
B
B
B
r/W
R
/L
B
r/B
B
r/B
G
/B
G
/B
B
r
B
r/B
B
r
B
r
B
r
PP
B B
G G
Y L
/B
L
/B
L
/Y
R
/Y
W
/B
YC
h
D
g
R
/Y
R
/Y
B
r
S
b
O
/W
B
G
/L
R
/L
B
r/G
B
r/G
G
y
G
y
G
y
/R
G
y
/B
B
L
/Y
L
/W
B B
B
r/W
B
r/W
Y
G
/B
G
/L
P
/G
B
G
y
/R
G
y
/B
B
G
/R
B
B
/Y
B
/Y
R
/L
B
r
C
h
D
g
R
/L
P
/W
P
/W
Y
/R
R
/B
Y
/R
B
L
/W
B
B
W
G
/W
G
/W
R
R
/GR
/L
R
W
/Y
G
L
L
G
Y
Y
B
(G
R
E
E
N
)
(G
R
E
E
N
)
(W
H
IT
E
)
(W
H
IT
E
)
(B
L
A
C
K
)
W
/L
W
/R
B
r
R
R
R
R
W
W
W
B
B
R
/Y
L
/B
W
/B
L
/Y
B
r/G
B
r/G
BB
G
y
G
y/B
G
y/R
R B L
R
/WL
R
/B
P
/G
R
/G
L
R
/B
L
/G
L
/W R
G
/B
(B
L
A
C
K
)
R
/Y
B
R
/Y
B
R
B
r/L
RB
r
B
R
W
W
W
G
/L
Y
B
D
g
S
b
G
/R
G
y
/B
O
/W
B
B
r/G
G
y/R
B
r/G
G
y
B
r
C
h
R
/L
B
r
G
B
Y
L
G
B
Y
L
B
B
B
r
B
r
D
g
G
/Y
B
B
r
C
h
G
/Y
B
R
/Y
G
L
/B
Y
PB
r
G
/B
L
/B
R
/Y
B
r/B
Y G
B
B
r/W
B
B
r
C
h
D
g
B
r/B
G
/B
R
/L
BR
BL
(B
L
A
C
K
)
L
/W
W
/Y
B
r/W
L
/W
W
/Y
B
B
r/W
L
/W
B
B
BB
(B
L
U
E
)
L
/Y
B
(B
L
U
E
)
G
/B
L
/W
S
b
O
/W
B
B
r/W
(B
L
A
C
K
)
C
h
B
(B
L
A
C
K
)
D
g
B
(G
R
E
E
N
)
B
r
G
/B
B
r/B
(B
L
A
C
K
)
P
B
(R
E
D
)
B G
/B
B
r
R
/Y
L
/B
B
r/B
YG
P
R
/B
L
/Y
G
/B
G
/Y
(B
L
U
E
)
Y
/R
R
/B
G
/B
Y
B
/L
B
(B
L
A
C
K
)
LB
(B
L
A
C
K
)
R
/L
D
g
B
r
B
/Y
B
C
h
P
/W
P
/W
G
B
Y
G
B
Y
L
/G
G
/W
G
/W
O
W
/R
Y
/R
B
R
/B
R
/G
G
/L
L
/Y
W
/B
W
/L
(G
R
E
E
N
)
B
r
B
D
g
B
B
r
W
G
/Y
B
B
r
W
G
/Y
B
1 2
3
~
45
6
70 89
q
r
s
t
u
v
w
y
z
}
|
m
o
o
n
n
x{
p
e
g
f
h
i
g
j
k
l
Z
[
]
\
_
b
c
d
a
A
B
C
D
E
F
N
G
M
J
H
I
K
Q
R
P
O
S
T
U
W
V
Y
X
L
4
C
D
I

u
n
i
t

f
u
s
e
6
M
a
i
n

s
w
i
t
c
h
7
I
g
n
i
t
i
o
n

f
u
s
e
A
G
r
o
u
n
d

l
e
a
d
B
B
a
t
t
e
r
y
C
M
a
i
n

f
u
s
e
I
F
u
e
l

p
u
m
p

r
e
l
a
y
J
F
u
e
l

p
u
m
p
S
C
D
I

u
n
i
t
8 - 48
+
ELEC
FUEL PUMP SYSTEM
EB808010
FUEL PUMP CIRCUIT OPERATION
The fuel pump circuit consists of the fuel pump
relay, fuel pump, and CDI unit.
The CDI unit includes the control unit for the
fuel pump.
1Battery
2Main fuse
3Main switch
4Ignition fuse
5CDI unit
6CDI unit fuse
7Fuel pump relay
8Fuel pump
1
2
3
4
5
6
7
8
8 - 49
+
ELEC
FUEL PUMP SYSTEM
EAS00816
TROUBLESHOOTING
Check:
1. main, ignition, and CDI unit fuses
2. battery
3. main switch
4. fuel pump relay
5. fuel pump operation
(the entire fuel system)
NOTE:
part(s):
1. storage box
2. front cowling
4. footrest board
tool(s).
EAS00738
YES NO
EAS00739
YES NO
EAS00749
YES NO
The fuel pump fails to operate.
Pocket tester
90890-03112
1. Main, ignition, and CDI unit fuses
Check the main, ignition, and CDI unit
fuses for continuity.
chapter 3.
Are the main, ignition, and CDI unit fuses
OK?
2. Battery
12.8 V or more at 20 C (68 F)
Is the battery OK?
Clean the battery
terminals.
Recharge or
3. Main switch
Replace the main
switch/immobilizer
antenna.
8 - 50
+
ELEC
FUEL PUMP SYSTEM
EAS00759
YES NO
EAS00817
YES NO
EAS00818
YES NO
4. Fuel pump relay
Remove the fuel pump relay.
tery (12 V) to the fuel pump relay terminals
as shown.
Check the fuel pump relay for continuity.
Negative battery terminal blue/green 2
Positive tester probe red/green 3
Negative tester probe blue 4
Does the fuel pump relay have continuity
between red/green and blue?
Replace the fuel
pump relay.
5. Fuel pump operation
Check the fuel pump operation.
Refer to CHECKING THE FUEL PUMP
in chapter 7.
Is the fuel pump OK?
Replace the fuel
pump.
6. Wiring
Check the entire fuel pump system wiring.
Is the fuel pump system wiring properly
repair the fuel pump
system wiring.
8 - 51
+
ELEC
AUTO CHOKE SYSTEM
EAS00820
AUTO CHOKE SYSTEM
CIRCUIT DIAGRAM
O
F
F
O
N
G
/Y
G
W
/R
R
R
R
RB
B
W
R
WW
WWW W
/L
B
R
/L
B
R
B
r/L
B
r/L
R
/B
B
r/L
B
r/L
R
B
r
R
/W
R
/Y
B
G
/B
L
/W
G
/B
L
/W
G
/B
R
/B
G
/Y
L
/Y
B L L
S
b
O
/W
L
/G
R
/B
R
/G
L
/Y
R
/B
Y
/R
W
/B
W
/R
W
/L
B
L
/G
G
/W
G
/W
G
/W
G
/W
O
O B
R
/G
LL B
P
/G
R
/B
R
/W
G
/Y
G
/Y
B
r
B
r
G
/Y
G
/Y
G
/Y
B
B B
B
D
g
W
C
h
W
B
r
B
r
B
r
B
r
B
C
h
D
g
B
B
B
D
g
C
h
B
r
B
r
Y
B B
B
B
B
r/W
R
/L
B
r/B
B
r/B
G
/B
G
/B
B
r
B
r/B
B
r
B
r
B
r
PP
B B
G G
Y L
/B
L
/B
L
/Y
R
/Y
W
/B
YC
h
D
g
R
/Y
R
/Y
B
r
S
b
O
/W
B
G
/L
R
/L
B
r/G
B
r/G
G
y
G
y
G
y
/R
G
y
/B
B
L
/Y
L
/W
B B
B
r/W
B
r/W
Y
G
/B
G
/L
P
/G
B
G
y
/R
G
y
/B
B
G
/R
B
B
/Y
B
/Y
R
/L
B
r
C
h
D
g
R
/L
P
/W
P
/W
Y
/R
R
/B
Y
/R
B
L
/W
B
B
W
G
/W
G
/W
R
R
/GR
/L
R
W
/Y
G
L
L
G
Y
Y
B
(G
R
E
E
N
)
(G
R
E
E
N
)
(W
H
IT
E
)
(W
H
IT
E
)
(B
L
A
C
K
)
W
/L
W
/R
B
r
R
R
R
R
W
W
W
B
B
R
/Y
L
/B
W
/B
L
/Y
B
r/G
B
r/G
BB
G
y
G
y/B
G
y/R
R B L
R
/WL
R
/B
P
/G
R
/G
L
R
/B
L
/G
L
/W R
G
/B
(B
L
A
C
K
)
R
/Y
B
R
/Y
B
R
B
r/L
RB
r
B
R
W
W
W
G
/L
Y
B
D
g
S
b
G
/R
G
y
/B
O
/W
B
B
r/G
G
y/R
B
r/G
G
y
B
r
C
h
R
/L
B
r
G
B
Y
L
G
B
Y
L
B
B
B
r
B
r
D
g
G
/Y
B
B
r
C
h
G
/Y
B
R
/Y
G
L
/B
Y
PB
r
G
/B
L
/B
R
/Y
B
r/B
Y G
B
B
r/W
B
B
r
C
h
D
g
B
r/B
G
/B
R
/L
BR
BL
(B
L
A
C
K
)
L
/W
W
/Y
B
r/W
L
/W
W
/Y
B
B
r/W
L
/W
B
B
BB
(B
L
U
E
)
L
/Y
B
(B
L
U
E
)
G
/B
L
/W
S
b
O
/W
B
B
r/W
(B
L
A
C
K
)
C
h
B
(B
L
A
C
K
)
D
g
B
(G
R
E
E
N
)
B
r
G
/B
B
r/B
(B
L
A
C
K
)
P
B
(R
E
D
)
B G
/B
B
r
R
/Y
L
/B
B
r/B
YG
P
R
/B
L
/Y
G
/B
G
/Y
(B
L
U
E
)
Y
/R
R
/B
G
/B
Y
B
/L
B
(B
L
A
C
K
)
LB
(B
L
A
C
K
)
R
/L
D
g
B
r
B
/Y
B
C
h
P
/W
P
/W
G
B
Y
G
B
Y
L
/G
G
/W
G
/W
O
W
/R
Y
/R
B
R
/B
R
/G
G
/L
L
/Y
W
/B
W
/L
(G
R
E
E
N
)
B
r
B
D
g
B
B
r
W
G
/Y
B
B
r
W
G
/Y
B
1 2
3
~
45
6
70 89
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b
c
d
a
A
B
C
D
E
F
N
G
M
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I
K
Q
R
P
O
S
T
U
W
V
Y
X
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B
B
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A
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8 - 52
+
ELEC
AUTO CHOKE SYSTEM
EAS00821
TROUBLESHOOTING
Check:
1. main and ignition fuses
2. battery
3. main switch
4. thermo switch (auto choke)
5. auto choke unit
6. CDI unit
(of the entire carburetor heating system)
NOTE:
part(s):
1. storage box
2. front cowling
4. under cover
tool(s).
EAS00738
YES NO
EAS00739
YES NO
EAS00749
YES NO
The auto choke system fails to operate.
Pocket tester
90890-03112
1. Main and ignition fuses
Check the main and ignition fuses for con-
tinuity.
chapter 3.
Are the main and ignition fuses OK?
2. Battery
12.8 V or more at 20 C (68 F)
Is the battery OK?
Clean the battery
terminals.
Recharge or
3. Main switch
Replace the main
switch/immobilizer
antenna.
8 - 53
+
ELEC
AUTO CHOKE SYSTEM
YES NO
4. Thermo switch (auto choke)
Remove the thermo switch (auto choke)
from the radiator.
thermo switch 1 as shown.
Immerse the thermo switch in a container
filled with coolant 2.
NOTE:
Make sure that the thermo switch terminals
do not get wet.
Slowly heat the coolant, then let it cool
down to the specified temperature.
Check the thermo switch for continuity at
the temperatures indicated in the table.
Test
step
Coolant temperature
Continu-
ity
Thermo switch
1
Less than 47 3 C
(116.6 5.4 F)
NO
2
More than 47 3 C
(116.6 5.4 F)
YES
3
More than 42 3 C
(107.6 5.4 F)
YES
4
Less than 42 3 C
(107.6 5.4 F)
NO
Steps 1 and 2: Heating phase
Steps 3 and 4: Cooling phase
WARNING
Handle the thermo switch with special
care.
Never subject the thermo switch to
strong shocks. If the thermo switch is
dropped, replace it.
T

R
.
.
Thermo switch (auto choke)
30 Nm (3.0 m kg, 22 ft lb)
The thermo switch circuit is open and the auto
choke is off.
The thermo switch circuit is closed and the
auto choke is on.
Does the thermo switch operate properly
as described above?
Replace the thermo
switch (auto choke).
8 - 54
+
ELEC
AUTO CHOKE SYSTEM
EAS00825
YES NO
EAS00826
YES NO
5. Auto choke unit
Remove the auto choke unit coupler from
the wire harness.
auto choke unit coupler as shown.
Tester positive probe green/black 1
Tester negative probe yellow 2
Measure the auto choke unit resistance.
Auto choke resistance
30 at 20 C (68 F)
Is the auto choke OK?
Replace the auto
choke unit.
6. Wiring
Check the entire auto choke system wir-
ing.
Is the auto choke system wiring properly
repair the auto choke
system wiring.
8 - 55
+
ELEC
IMMOBILIZER SYSTEM
IMMOBILIZER SYSTEM
SYSTEM DIAGRAM
3
1
2
1CDI unit
2Main switch and immobilizer antenna
3Immobilizer system indicator light
Br/L
R/G R/L R/B
G/W
G/L
G/W
R
R
R
R
R
Main switch
Ignition fuse
immobilizer antenna
Backup fuse
Meter
assembly
Immobilizer
system indi-
cator light
Main fuse
Battery
R . . . . . Red
Br/L . . . Brown/Blue
G/L . . . Green/Blue
G/W. . . Green/White
R/B . . . Red/Black
R/G . . . Red/Green
R/L. . . . Red/Blue
CDI unit
CDI unit fuse
8 - 56
+
ELEC
IMMOBILIZER SYSTEM
CIRCUIT DIAGRAM
O
F
F
O
N
G
/Y
G
W
/R
R
R
R
RB
B
W
R
WW
WWW W
/L
B
R
/L
B
R
B
r/L
B
r/L
R
/B
B
r/L
B
r/L
R
B
r
R
/W
R
/Y
B
G
/B
L
/W
G
/B
L
/W
G
/B
R
/B
G
/Y
L
/Y
B L L
S
b
O
/W
L
/G
R
/B
R
/G
L
/Y
R
/B
Y
/R
W
/B
W
/R
W
/L
B
L
/G
G
/W
G
/W
G
/W
G
/W
O
O B
R
/G
LL B
P
/G
R
/B
R
/W
G
/Y
G
/Y
B
r
B
r
G
/Y
G
/Y
G
/Y
B
B B
B
D
g
W
C
h
W
B
r
B
r
B
r
B
r
B
C
h
D
g
B
B
B
D
g
C
h
B
r
B
r
Y
B B
B
B
B
r/W
R
/L
B
r/B
B
r/B
G
/B
G
/B
B
r
B
r/B
B
r
B
r
B
r
PP
B B
G G
Y L
/B
L
/B
L
/Y
R
/Y
W
/B
YC
h
D
g
R
/Y
R
/Y
B
r
S
b
O
/W
B
G
/L
R
/L
B
r/G
B
r/G
G
y
G
y
G
y
/R
G
y
/B
B
L
/Y
L
/W
B B
B
r/W
B
r/W
Y
G
/B
G
/L
P
/G
B
G
y
/R
G
y
/B
B
G
/R
B
B
/Y
B
/Y
R
/L
B
r
C
h
D
g
R
/L
P
/W
P
/W
Y
/R
R
/B
Y
/R
B
L
/W
B
B
W
G
/W
G
/W
R
R
/GR
/L
R
W
/Y
G
L
L
G
Y
Y
B
(G
R
E
E
N
)
(G
R
E
E
N
)
(W
H
IT
E
)
(W
H
IT
E
)
(B
L
A
C
K
)
W
/L
W
/R
B
r
R
R
R
R
W
W
W
B
B
R
/Y
L
/B
W
/B
L
/Y
B
r/G
B
r/G
BB
G
y
G
y/B
G
y/R
R B L
R
/WL
R
/B
P
/G
R
/G
L
R
/B
L
/G
L
/W R
G
/B
(B
L
A
C
K
)
R
/Y
B
R
/Y
B
R
B
r/L
RB
r
B
R
W
W
W
G
/L
Y
B
D
g
S
b
G
/R
G
y
/B
O
/W
B
B
r/G
G
y/R
B
r/G
G
y
B
r
C
h
R
/L
B
r
G
B
Y
L
G
B
Y
L
B
B
B
r
B
r
D
g
G
/Y
B
B
r
C
h
G
/Y
B
R
/Y
G
L
/B
Y
PB
r
G
/B
L
/B
R
/Y
B
r/B
Y G
B
B
r/W
B
B
r
C
h
D
g
B
r/B
G
/B
R
/L
BR
BL
(B
L
A
C
K
)
L
/W
W
/Y
B
r/W
L
/W
W
/Y
B
B
r/W
L
/W
B
B
BB
(B
L
U
E
)
L
/Y
B
(B
L
U
E
)
G
/B
L
/W
S
b
O
/W
B
B
r/W
(B
L
A
C
K
)
C
h
B
(B
L
A
C
K
)
D
g
B
(G
R
E
E
N
)
B
r
G
/B
B
r/B
(B
L
A
C
K
)
P
B
(R
E
D
)
B G
/B
B
r
R
/Y
L
/B
B
r/B
YG
P
R
/B
L
/Y
G
/B
G
/Y
(B
L
U
E
)
Y
/R
R
/B
G
/B
Y
B
/L
B
(B
L
A
C
K
)
LB
(B
L
A
C
K
)
R
/L
D
g
B
r
B
/Y
B
C
h
P
/W
P
/W
G
B
Y
G
B
Y
L
/G
G
/W
G
/W
O
W
/R
Y
/R
B
R
/B
R
/G
G
/L
L
/Y
W
/B
W
/L
(G
R
E
E
N
)
B
r
B
D
g
B
B
r
W
G
/Y
B
B
r
W
G
/Y
B
1 2
3
~
45
6
70 89
q
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}
|
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p
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b
c
d
a
A
B
C
D
E
F
N
G
M
J
H
I
K
Q
R
P
O
S
T
U
W
V
Y
X
L
4
C
D
I

u
n
i
t

f
u
s
e
5
B
a
c
k
u
p

f
u
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e

(
m
e
t
e
r

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s
s
e
m
b
l
y
)
6
M
a
i
n

s
w
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h
7
I
g
n
i
t
i
o
n

f
u
s
e
A
G
r
o
u
n
d

l
e
a
d
B
B
a
t
t
e
r
y
C
M
a
i
n

f
u
s
e
S
C
D
I

u
n
i
t
V
i
m
m
o
b
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l
i
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m
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8 - 57
+
ELEC
IMMOBILIZER SYSTEM
GENERAL INFORMATION
This vehicle is equipped with an immobilizer system to help prevent theft by registering codes in
standard keys. This system consists of the following:
a code re-registering key (with a red bow)
two standard keys (with black bows) that can be re-registered with new codes
transponders (one installed in each key bow)
an immobilizer antenna
a CDI unit
an immobilizer system indicator light
The key with the red bow is used to register codes in each standard key. Do not use the key with the
red bow for driving. It should only be used for registering new codes in the standard keys. The
immobilizer system cannot be operated with a new standard key until a code is registered in the
key. If you lose the code re-registering key, the main switch, and CDI unit must be replaced. There-
fore, always use a standard key for driving.
NOTE:
Each standard key is registered during production, therefore, registering the keys at purchase is not
necessary.
1Code re-registering key (red bow)
2Standard keys (black bow)
CAUTION:
DO NOT LOSE THE CODE RE-REGISTERING KEY! If the code re-registering key is lost, reg-
istering new codes in the standard keys is impossible. The standard keys can still be used
to start the vehicle, however, if code re-registering is required (i.e., if a new standard key is
made or all keys are lost) the entire immobilizer system must be replaced. Therefore, it is
highly recommended to use either standard key and keep the code re-registering key in a
safe place.
Do not submerse the keys in water.
Do not expose the keys to excessively high temperatures.
Do not place the keys close to magnets (this includes, but not limited to, products such as
speakers, etc.).
Do not place heavy items on the keys.
Do not grind the keys items or alter their shape.
Do not disassemble the keys bows.
Do not put two keys of any immobilizer system on the same key ring.
Keep the standard keys as well as other immobilizer system keys away from the code re-
registering key.
Keep other immobilizer system keys away from the main switch as they may cause signal
interference.
8 - 58
+
ELEC
IMMOBILIZER SYSTEM
KEY CODE REGISTRATION
Code registration of the code re-registering key or standard keys may be required when CDI is
replaced or a standard key is lost.
NOTE:
Each standard key is registered during production, therefore, registering the keys at purchase is not
necessary.
Code re-registering key registration:
When the CDI unit is replaced, the code re-registering key must be re-registered.
To register a code re-registering key:
1. Turn the main switch to ON with the code re-registering key.
NOTE:
Check that the immobilizer system indicator light comes on for 2 seconds, then goes off. When the
indicator light goes off, the code re-registering key has been registered.
2. Check that the engine can be started, (after 3 seconds from switch to ON).
3. Register the standard keys. Refer to Standard key registration:.
Standard key registration:
A standard key should be registered or the other standard keys should be re-registered when a reg-
istered standard key has been lost. The standard keys must be re-registered when the CDI unit has
been replaced and the code re-registering key has been re-registered.
NOTE:
Do not start the engine with a standard key that has not been registered.
If the main switch is turned to ON with a standard key that has not been registered, the immobilizer
system indicator light flashes to indicate malfunction code 3. (Refer to SELF-DIAGNOSIS MAL-
FUNCTION CODES.)
1. Check that the immobilizer system indicator light flashes to indicate the standby mode. To acti-
vate the standby mode, turn the main switch to OFF. The standby mode will be activated after
2.5 seconds. The indicator light stops flashing after 24 hours and the standby mode is deacti-
vated.
Standby mode
Main
switch
LED
2.5 s 24 h
0.05 s 2.5 s
ON
OFF
On
Off
8 - 59
+
ELEC
IMMOBILIZER SYSTEM
2. Using the code re-registering key, turn the main switch to ON, then to OFF, and then remove
the key within 3 seconds.
NOTE:
All existing standard key codes will be erased from the memory when the key registration mode is
activated. When the key registration mode is activated, the immobilizer system indicator light is ON
for 2 seconds, then will be OFF.
3. Insert the standard key to be registered into the main switch, and then turn the main switch to
ON within 3 seconds.
4. After the above procedure, turn the main switch to OFF, remove the key and then insert the
second standard key and turn the main switch to ON to be registered into the main switch within
10 seconds.
5. Turn the main switch from ON, to OFF, and then remove the key within 3 seconds.
6. Within 5 seconds and using the code re-registering key turn the main switch to ON, to OFF,
and then remove the key within 3 seconds.
NOTE:
When the indicator light goes off, registration is complete.
NOTE:
Dont make this registration procedure by standard key for virgin CDI unit. If main switch is turned
ON with a standard key and CDI unit is virgin, then, for the CDI unit, this standard key will be like
re-registering key.
7. Check that the engine can be started with the two registered standard keys.
Standard key
registration
less than 3.0 s less than 10.0 s less than 3.0 s less than 10.0 s
Registration of the sec-
ond standard key is
complete.
Second standard key Code re-regis-
tering key
First standard
key
Registration mode
Immobilizer system indicator light stops flash-
ing when the registration of the second stan-
dard key is complete.
Main
switch
LED
OFF
ON
On
Off
0.5 s 0.5 s
8 - 60
+
ELEC
IMMOBILIZER SYSTEM
Voiding a standard key code:
If a registered standard key has been lost and you want to disable its use, register a new standard
key or re-register the other standard key. For registration of a standard key, refer to Standard key
registration:.
Standard key registration erases the stored standard key codes from memory, therefore, the lost
standard key is disabled.
Standard key
code voiding
method
If the immobilizer system indicator light
stops flashing 5 seconds after the first
standard key is registered, the second
standard key cannot be registered.
less than 3.0 s less than 10.0 s less than 3.0 s
Code re-regis-
tering key
Remaining
standard key
Registration mode
Main
switch
LED
OFF
ON
On
Off
10.0 s
0.5 s 0.5 s
less than 3.0 s
Code re-regis-
tering key
8 - 61
+
ELEC
IMMOBILIZER SYSTEM
SELF-DIAGNOSIS MALFUNCTION CODES
When a system malfunction occurs, the malfunction code number is signaled by the immobilizer
system indicator light flash patterns.
Malfunc-
tion code
Symptom
Immobilizer system
condition
Malfunctioning
part
Cause Action
2
Engine cannot start. CDI unit is not recev-
ing any valid tran-
sponder code.
Key Key malfunction Replace the standard
key.
CDI unit CDI unit malfunction Replace the CDI unit.
Others Radio wave interference
caused by objects around
the keys and antenna.
Keep magnets, metal
objects, and other immo-
bilizer system keys away
from the keys and
antenna.
Noise interference Check for the possible
cause of the interference.
Main switch and
immobilizer
antenna
Disconnected leads Check the leads.
Flash pattern:
3
Engine cannot start. Codes transmitted
between the key and
CDI unit do not
match.
Others Signal received from
other transponder (failed
to recognize code after
consecutive attempts).
Place other keys at least
50 mm away from the
main switch.
Signal received from
unregistered standard
key.
Place other keys at least
50 mm away from the
main switch.
Flash pattern:
2.0 s
Main
switch
LED
OFF
ON
On
Off
1.0 s
0.5 s 0.5 s
2.0 s
2.0 s
Main
switch
LED
OFF
ON
On
Off
1.0 s
0.5 s 0.5 s
2.0 s
0.5 s
8 - 62
+
ELEC
IMMOBILIZER SYSTEM
EAS00794
TROUBLESHOOTING
Check:
1. main, ignition, CDI unit, and backup fuses
2. battery
3. main switch
(of the entire immobilizer system)
NOTE:
part(s):
1. front cowling
tool(s).
EAS00738
YES NO
EAS00739
YES NO
EAS00749
YES NO
EAS00787
YES NO
When the main switch is turned ON,
the immobilizer system indicator light
does not come on or flash.
Pocket tester
90890-03112
1. Main, ignition, CDI unit, and backup fuses
Check the main, ignition, CDI unit, and
backup fuses for continuity.
chapter 3.
Are the main, ignition, CDI unit, and
backup fuses OK?
2. Battery
12.8 V or more at 20 C (68 F)
Is the battery OK?
Clean the battery
terminals.
Recharge or
3. Main switch
Replace the main
switch/immobilizer
antenna.
4. Wiring
Check the entire immobilizer system wir-
ing.
Is the immobilizer system wiring properly
Check the condition
of each of the immo-
bilizer system cir-
cuits.
Refer to CHECK-
ING THE IMMOBI-
LIZER SYSTEM.
Properly connect or
repair the immobilizer
system wiring.
8 - 63
+
ELEC
IMMOBILIZER SYSTEM
EAS00788
CHECKING THE IMMOBILIZER SYSTEM
1. The immobilizer system indicator light does
not come on.
YES NO
1. Voltage
Positive tester probe red/blue 1
Turn the main switch to ON.
Measure the voltage (DC 12 V) at the
meter assembly coupler (wire harness
side).
Replace the meter
assembly.
The wiring circuit
to the meter assem-
and must be
repaired.
1
G/L Y B Dg Sb
G/R
O/W
B
Br/G Br/G
Gy Br
Ch
R/L
Gy/R
Gy/B
2
8 - 64
+
ELEC
IMMOBILIZER SYSTEM
2. When the main switch is turned to ON, the immobilizer system indicator light flashes.
Check if a metal object or other immobilizer system keys are placed near the immobilizer
antenna. If so, remove the objects or keys, and then check the condition again.
Turn the main switch to ON with
another registered standard key and
check the immobilizer system indicator
light. The indicator light goes on for
about 2 seconds, then goes off.
First standard key (transponder) is
defective.
Correct
Turn the main switch to ON with the
code re-registering key and check the
immobilizer system indicator light.
Malfunction
Second standard
key (transpon-
der) is defective.
Correct
Re-register
the stan-
dard key.
Malfunc-
tion
Replace the
standard
key.
Check the immobilizer system indica-
tor light is flashing.
Flashing
Determine the malfunction code
according to the flash pattern and
check the corresponding part.
Refer to SELF-DIAGNOSIS MAL-
FUNCTION CODES.
Malfunction
Not flashing
immobilizer antenna or CDI unit mal-
function
Replace the CDI unit.
Check the signal leads (green/white)
between the immobilizer antenna and
CDI unit connector.
Malfunction Green/white leads are disconnected or
short-circuited. Repair or replace the
circuit.
Correct
8 - 65
+
ELEC
IMMOBILIZER SYSTEM
PART REPLACEMENT KEY REGISTRATION REQUIREMENTS
*1
Replace as a set with the main switch.
*2
Accessory locks include the fuel tank cap lock and storage compartment lock.
NOTE:
If the CDI unit is replaced, both the code re-registering key and the standard keys need to be regis-
tered with the new unit(s).
Parts to be replaced
Required key
registration
Main
switch
Standard
key
CDI
unit
Accessory
lock
*2
and
key
immobilizer
antenna
Standard key is lost New standard key
All keys have been lost
(including code re-reg-
istering key)
*1
Code re-registering
key and standard keys
CDI unit is defective Code re-registering
immobilizer antenna is
defective
Code re-registering
Main switch is defective
*1
Code re-registering
Accessory lock
*2
is
defective
Not required
TRBL
SHTG
CHAPTER 9
TROUBLESHOOTING
STARTING FAILURE/HARD STARTING ....................................................... 9-1
ENGINE..................................................................................................... 9-1
FUEL SYSTEM.......................................................................................... 9-1
ELECTRICAL SYSTEMS.......................................................................... 9-2
INCORRECT ENGINE IDLING SPEED........................................................... 9-2
ENGINE..................................................................................................... 9-2
FUEL SYSTEM.......................................................................................... 9-2
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE................................. 9-3
ENGINE..................................................................................................... 9-3
FUEL SYSTEM.......................................................................................... 9-3
FAULTY CLUTCH........................................................................................... 9-3
ENGINE OPERATES BUT VEHICLE WILL NOT MOVE.......................... 9-3
CLUTCH SLIPS......................................................................................... 9-3
POOR STARTING PERFORMANCE........................................................ 9-3
POOR SPEED PERFORMANCE.............................................................. 9-3
OVERHEATING............................................................................................... 9-4
ENGINE..................................................................................................... 9-4
COOLING SYSTEM.................................................................................. 9-4
FUEL SYSTEM.......................................................................................... 9-4
CHASSIS................................................................................................... 9-4
OVERCOOLING.............................................................................................. 9-4
COOLING SYSTEM.................................................................................. 9-4
POOR BRAKING PERFORMANCE................................................................ 9-4
FAULTY FRONT FORK LEGS........................................................................ 9-5
LEAKING OIL ............................................................................................ 9-5
MALFUNCTION......................................................................................... 9-5
TRBL
SHTG
FAULTY LIGHTING OR SIGNALING SYSTEM.............................................. 9-5
HEADLIGHT DOES NOT COME ON........................................................ 9-5
HEADLIGHT BULB BURNT OUT.............................................................. 9-5
TAIL/BRAKE LIGHT DOES NOT COME ON............................................ 9-5
TAIL/BRAKE LIGHT BULB BURNT OUT.................................................. 9-5
TURN SIGNAL DOES NOT COME ON .................................................... 9-5
TURN SIGNAL FLASHES SLOWLY......................................................... 9-5
TURN SIGNAL REMAINS LIT................................................................... 9-5
TURN SIGNAL FLASHES QUICKLY ........................................................ 9-5
HORN DOES NOT SOUND...................................................................... 9-5
9 - 1
TRBL
SHTG
EAS00845
TROUBLESHOOTING
NOTE:
The following guide for troubleshooting does not cover all the possible causes of trouble. It should
be helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this man-
ual for checks, adjustments, and replacement of parts.
STARTING FAILURE/HARD STARTING
ENGINE
Cylinder and cylinder head
Loose spark plug
Loose cylinder head or cylinder
Damaged cylinder head gasket
Damaged cylinder gasket
Worn or damaged cylinder
Incorrect valve clearance
Improperly sealed valve
Incorrect valve-to-valve-seat contact
Incorrect valve timing
Faulty valve spring
Seized valve
Piston and piston ring(s)
Improperly installed piston ring
Damaged, worn or fatigued piston ring
Seized piston ring
Seized or damaged piston
Air filter
Improperly installed air filter
Clogged air filter element
Crankcase and crankshaft
Improperly assembled crankcase
Seized crankshaft
FUEL SYSTEM
Fuel tank
Empty fuel tank
Clogged fuel tank cap breather hole
Deteriorated or contaminated fuel
Clogged or damaged fuel hose
Carburetor
Deteriorated or contaminated fuel
Clogged pilot jet
Clogged pilot air passage
Sucked-in air
Damaged float
Worn needle valve
Improperly installed needle valve seat
Incorrect fuel level
Improperly adjusted pilot screw
Improperly installed pilot jet
Clogged starter jet
Clogged emulsion tube
Auto choke unit
Faulty CDI unit
Faulty thermo switch (auto choke)
STARTING FAILURE/HARD STARTING
9 - 2
TRBL
SHTG
STARTING FAILURE/HARD STARTING/
INCORRECT ENGINE IDLING SPEED
ELECTRICAL SYSTEMS
Battery
Discharged battery
Faulty battery
Fuse(s)
Blown, damaged or incorrect fuse
Improperly installed fuse
Spark plug
Incorrect spark plug gap
Incorrect spark plug heat range
Fouled spark plug
Worn or damaged electrode
Worn or damaged insulator
Faulty spark plug cap
Ignition coil
Cracked or broken ignition coil body
Broken or shorted primary or secondary
coils
Faulty spark plug lead
Ignition system
Faulty CDI unit
Faulty pickup coil
Broken generator rotor woodruff key
Switches and wiring
Faulty main switch
Faulty engine stop switch
Broken or shorted wiring
Faulty front, rear or both brake light
switches
Faulty start switch
Faulty sidestand switch
Improperly grounded circuit
Loose connections
Starting system
Faulty starter motor
Faulty starter relay
Faulty starting circuit cut-off relay
Faulty starter clutch
EAS00847
INCORRECT ENGINE IDLING SPEED
ENGINE
Cylinder and cylinder head
Incorrect valve clearance
Damaged valve train components
Air filter
FUEL SYSTEM
Carburetor
Loose or clogged pilot jet
Damaged or loose carburetor joint
Improperly adjusted engine idling speed
(throttle stop screw)
Improper throttle cable free play
Flooded carburetor
Auto choke unit
Faulty CDI unit
ELECTRICAL SYSTEMS
Battery
Discharged battery
Faulty battery
Spark plug
Fouled spark plug
Worn or damaged electrode
Worn or damaged insulator
Faulty spark plug cap
Ignition coil
Faulty spark plug lead
Ignition system
Faulty CDI unit
Faulty pickup coil
9 - 3
TRBL
SHTG
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE/
FAULTY CLUTCH
EAS00849
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE
Refer to STARTING FAILURE/HARD STARTING.
ENGINE
Air filter
Air intake system
Bent, clogged or disconnected carburetor
air vent hose
Clogged or leaking air duct
FUEL SYSTEM
Carburetor
Faulty diaphragm
Loose or clogged main jet
EAS00853
FAULTY CLUTCH
ENGINE OPERATES BUT VEHICLE WILL
NOT MOVE
V-belt
Bent, damaged or worn V-belt
Slipping V-belt
Primary pulley cam and primary pulley
slider
Damaged or worn primary pulley cam
Damaged or worn primary pulley slider
Clutch spring(s)
Damaged clutch spring
Transmission gear(s)
Damaged transmission gear
CLUTCH SLIPS
Clutch shoe spring(s)
Damaged, loose or worn clutch shoe spring
Clutch shoe(s)
Damaged or worn clutch shoe
Primary sliding sheave
Seized primary sliding sheave
POOR STARTING PERFORMANCE
V-belt
V-belt slips
Oil or grease on the V-belt
Faulty operation
Worn pin groove
Worn pin
Clutch shoe(s)
Bent, damaged or worn clutch shoe
POOR SPEED PERFORMANCE
V-belt
Oil or grease on the V-belt
Primary pulley weight(s)
Faulty operation
Worn primary pulley weight
Primary fixed sheave
Worn primary fixed sheave
Worn primary sliding sheave
Secondary fixed sheave
Worn secondary fixed sheave
Secondary sliding sheave
Worn secondary sliding sheave
9 - 4
TRBL
SHTG
OVERHEATING/OVERCOOLING/
POOR BRAKING PERFORMANCE
EAS00855
OVERHEATING
ENGINE
Clogged coolant passages
Cylinder head and piston
Heavy carbon buildup
Engine oil
Incorrect oil level
Incorrect oil viscosity
Inferior oil quality
COOLING SYSTEM
Coolant
Low coolant level
Radiator
Damaged or leaking radiator
Faulty radiator cap
Bent or damaged radiator fin
Water pump
Damaged or faulty water pump
Thermostat
Thermostat stays closed
Hose(s) and pipe(s)
Damaged hose
Improperly connected hose
Damaged pipe
Improperly connected pipe
FUEL SYSTEM
Carburetor
Incorrect main jet setting
Damaged or loose carburetor joint
Air filter
CHASSIS
Brake(s)
Dragging brake
ELECTRICAL SYSTEMS
Spark plug
Ignition system
Faulty CDI unit
EAS00856
OVERCOOLING
COOLING SYSTEM
Thermostat
Thermostat stays open
EAS00857
POOR BRAKING PERFORMANCE
Worn brake pad
Worn brake disc
Air in hydraulic brake system
Leaking brake fluid
Faulty brake caliper kit
Faulty brake caliper seal
Loose union bolt
Damaged brake hose
Oil or grease on the brake disc
Oil or grease on the brake pad
Incorrect brake fluid level
9 - 5
TRBL
SHTG
FAULTY FRONT FORK LEGS/
FAULTY LIGHTING OR SIGNALING SYSTEM
EAS00860
FAULTY FRONT FORK LEGS
LEAKING OIL
Bent, damaged or rusty inner tube
Cracked or damaged outer tube
Improperly installed oil seal
Damaged oil seal lip
Incorrect oil level (high)
Loose damper rod assembly bolt
Damaged damper rod assembly bolt copper
washer
Loose drain bolt
Damaged drain bolt gasket
MALFUNCTION
Bent or damaged inner tube
Bent or damaged outer tube
Damaged fork spring
Worn or damaged outer tube bushing
Bent or damaged damper rod
Incorrect oil viscosity
Incorrect oil level
EAS00866
FAULTY LIGHTING OR SIGNALING SYSTEM
HEADLIGHT DOES NOT COME ON
Wrong headlight bulb
Too many electrical accessories
Hard charging
Incorrect connection
Poor contacts (main or dimmer/pass switch)
Burnt-out headlight bulb
HEADLIGHT BULB BURNT OUT
Wrong headlight bulb
Faulty battery
Faulty rectifier/regulator
Faulty main switch
Faulty dimmer/pass switch
Headlight bulb life expired
TAIL/BRAKE LIGHT DOES NOT COME ON
Wrong tail/brake light bulb
Too many electrical accessories
Burnt-out tail/brake light bulb
TAIL/BRAKE LIGHT BULB BURNT OUT
Wrong tail/brake light bulb
Faulty battery
Incorrectly adjusted front and rear brake
light switch
Tail/brake light bulb life expired
TURN SIGNAL DOES NOT COME ON
Faulty turn signal switch
Faulty turn signal/hazard relay
Burnt-out turn signal bulb
Damaged or faulty wire harness
Faulty battery
TURN SIGNAL FLASHES SLOWLY
Faulty main switch
Faulty turn signal switch
Incorrect turn signal bulb
TURN SIGNAL REMAINS LIT
TURN SIGNAL FLASHES QUICKLY
Incorrect turn signal bulb
HORN DOES NOT SOUND
Improperly adjusted horn
Damaged or faulty horn
Faulty main switch
Faulty horn switch
Faulty battery
Faulty wire harness
YP250R 2005 WIRING DIAGRAM
1AC magneto
2Pickup coil
3Rectifier/regulator
4CDI unit fuse
5Backup fuse (meter assem-
bly)
6Main switch
7Ignition fuse
8Radiator fan motor fuse
9Headlight fuse
AGround lead
BBattery
CMain fuse
DStarter relay
EStarter motor
FDiode
GSidestand switch
HStarting circuit cut-off relay
IFuel pump relay
JFuel pump
KFuel sender
LHandlebar upper cover right
switches
MStart switch
NHazard switch
OAnti-theft alarm (OPTION)
PAnti-theft alarm LED
(OPTION)
QAuto choke unit
RThermo switch (auto choke)
SCDI unit
TIgnition coil
USpark plug
Vimmobilizer antenna
WRadiator fan motor
XThermo switch (radiator fan
motor)
YRadiator fan motor relay
ZRear brake light switch
[Front brake light switch
\Turn signal/hazard relay
]Horn
_Headlight relay
aHandlebar upper cover left
switches
bDimmer/pass switch
cHorn switch
dTurn signal switch
eTail/brake light assembly
(right)
fRear turn signal light (right)
gTail/brake light
hTail/brake light assembly
(left)
iRear turn signal light (left)
jFront turn signal light (right)
kFront turn signal light (left)
lLicense plate light
mHeadlight assembly
nHeadlight
oAuxiliary light
pCoolant temperature sensor
qMeter assembly
rCoolant temperature gauge
sFuel level gauge
tSpeedometer
uMultifunction meter
vMeter light
wFuel level warning light
xHigh beam indicator light
yLeft turn signal indicator light
zRight turn signal indicator
light
{Immobilizer system indicator
light
|Air temperature sensor
}Speed sensor
~Auxiliary DC jack fuse
(OPTION)
Auxiliary DC jack (OPTION)
COLOR CODE
B ............Black
Br ...........Brown
Ch..........Chocolate
Dg..........Dark green
G............Green
Gy ..........Gray
L.............Blue
O............Orange
P ............Pink
R............Red
Sb ..........Sky blue
W...........White
Y ............Yellow
B/L .........Black/Blue
B/Y.........Black/Yellow
Br/B........Brown/Black
Br/G.......Brown/Green
Br/L........Brown/Blue
Br/W.......Brown/White
G/B ........Green/Black
G/L.........Green/Blue
G/R ........Green/Red
G/W.......Green/White
G/Y ........Green/Yellow
Gy/B.......Gray/Black
Gy/R ......Gray/Red
L/B .........Blue/Black
L/G.........Blue/Green
L/W........Blue/White
L/Y .........Blue/Yellow
O/W.......Orange/White
P/G ........Pink/Green
R/B.........Red/Black
R/G........Red/Green
R/L.........Red/Blue
R/W........Red/White
R/Y.........Red/Yellow
W/B........White/Black
W/L ........White/Blue
W/R........White/Red
W/Y........White/Yellow
Y/R.........Yellow/Red
YAMAHA MOTOR ESPAA, S.A.
YP250R 2005
WIRING DIAGRAM
YP250R 2005
SCHMA DE CBLAGE
YP250R 2005
SCHALTPLAN
YP250R 2005
SCHEMA ELETTRICO
YP250R 2005
DIAGRAMA ELCTRICO
OFF
ON
G/Y
G
W/R
R R R
R
B
B
W R
W
W
W
W
W
W/L
B
R/L
B
R
Br/L
Br/L R/B
Br/L
Br/L
R
Br
R/W
R/Y
B
G/B
L/W
G/B
L/W
G/B
R/B
G/Y
L/Y
B
L
L
Sb
O/W
L/G
R/B
R/G
L/Y
R/B
Y/R
W/B
W/R
W/L
B
L/G
G/W
G/W
G/W
G/W
O
O
B
R/G
L
L
B
P/G
R/B
R/W
G/Y
G/Y
Br Br
G/Y
G/Y G/Y G/Y
B B
B B
Dg
W
Ch
W
Br
Br
Br
Br
B Ch Dg
B B B
Dg Ch Br Br GY
B
B B B
Br/W
R/L
Br/B
Br/B
G/B
G/B
Br
Br/B
Br
Br
Br
P
P
B
B
G
G
Y
L/B
L/B
L/Y
R/Y
W/B
Y
Ch
Dg
R/Y
R/Y
Br Sb O/W B G/L R/L
Br/G
Br/G
Gy
Gy
Gy/R
Gy/B
B
L/Y
L/W
B
B
Br/W
Br/W
Y G/B
G/L
P/G
B
Gy/R
Gy/B
B G/R
B B/Y
B/Y
R/L
Br Ch Dg R/L
P/W
P/W
Y/R
R/B
Y/R
B
L/W
B
B W
G/W G/W
R
R/G
R/L R
W/Y
G L L G Y Y
B
(GREEN)
(GREEN)
(WHITE)
(WHITE)
(BLACK)
W/L W/R Br R
R R
R
W W
W
B B
R/Y
L/B
W/B L/Y
Br/G
Br/G
B
B
Gy
Gy/B
Gy/R R
B
L
R/W
L
R/B P/G
R/G
L
R/B L/G
L/W
R
G/B
(BLACK)
R/Y
B
R/Y
B
R
Br/L
R
Br
B R
W W W
G/L Y B Dg Sb
G/R Gy/B
O/W
B
Br/G Gy/R Br/G
Gy Br
Ch
R/L
Br G
B Y
L G
B Y
L B
B Br
Br Dg
G/Y B
Br Ch
G/Y B
R/Y G L/B Y
P
Br G/B
L/B R/Y
Br/B
Y
G
B
Br/W B
Br Ch Dg Br/B G/B
R/L
B
R
B
L
(BLACK)
L/W W/Y
Br/W L/W
W/Y B
Br/W L/W
B B
B
B
(BLUE)
L/Y
B
(BLUE)
G/B
L/W
Sb O/W
B Br/W
(BLACK)
Ch
B
(BLACK)
Dg
B
(GREEN)
Br G/B Br/B
(BLACK)
P B
(RED)
B
G/B Br
R/Y L/B
Br/B
Y
G
P
R/B
L/Y
G/B
G/Y
(BLUE)
Y/R
R/B
G/B
Y
B/L
B
(BLACK)
L
B
(BLACK)
R/L Dg Br B/Y B
Ch P/W P/W
G
B Y
G
B Y
L/G
G/W G/W
O
W/R Y/R
B
R/B R/G G/L
L/Y
W/B
W/L
(GREEN)
Br
B
Dg
B Br W
G/Y B
Br W
G/Y B
1
2
3
6
7
A
B
C
D
E
F
N
G
M
H
I
J K
S
T
U
Y
W
Z [
]
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b c d
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YP250R 2005
WIRING DIAGRAM
YP250R 2005
SCHMA DE CBLAGE
YP250R 2005
SCHALTPLAN
YP250R 2005
SCHEMA ELETTRICO
YP250R 2005
DIAGRAMA ELCTRICO
OFF
ON
(GREEN)
(GREEN)
(WHITE)
(WHITE)
(BLACK)
(BLACK)
(BLACK)
(BLUE) (BLUE)
(BLACK)
(BLACK) (GREEN)
(BLACK) (RED)
(BLUE)
(BLACK) (BLACK)
(GREEN)
1
2
3
6
7
A
B
C
D
E
F
N
G
M
H
I
J K
S
T
U
Y
W
Z [
]
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What information is included in the wiring diagram?

YP250R

mark at the bottom of the wheel.

mark is positioned as shown.

(YAMAHA grease G 90793-40016)

(YAMAHA grease G 90793-40016)

Order Job/Part Qty Remarks

Set the main switch to ON.

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