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SERVICE MANUAL YFM25RY YFM25RSEY YFM25RSE2Y 4D3-28197-11 LIT-11616-22-09 2009.
EAS20040 YFM25R Y/YFM25RSEY/YFM25RSE2Y SER VI CE MANU A L ©2008 b y Y amaha Motor Corporation, U .S.A. First edition, April 2008 All rights reserved. An y reproduction or unauthorized use without the written permission of Y amaha Mo tor Corporation, U .
EAS20071 IMPOR T ANT This manual was prod uced b y the Y amaha Motor Company , Ltd. primar ily f or use b y Y amaha deal- ers and their qualified mech anics.
EAS20090 HO W T O USE THIS MANU AL This manual is intende d as a handy , easy-to-read ref erence book f or the mechanic. Comprehensiv e e xplanations of all installation, remov al, disasse mb ly , assembly , repair and chec k procedures are laid out with the individual steps in sequential order .
EAS20100 SYMBOLS The f ollowing symbols are used in this man ual for easier understanding. TIP The f ollowing symbols are not rele vant to e v er y v ehicle .
10 Gear oil 11 Molybdenum-disulfide oil 12 Brak e fluid 13 Wheel-bearing grease 14 Lithium-soap-based gre ase 15 Molybdenum-disu lfide grease 16 Silicone grease 17 Apply loc king agent (LOCTITE®) 18 .
1 2 3 4 5 6 7 8 EAS20110 T ABLE OF CONTENTS GENERAL INFORMA TION SPECIFICA TIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE FUEL SYSTEM ELECTRICAL SYSTEM TR OUBLESHOO TING.
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1 GENERAL INFORMA TION IDENTIFICA TION ................................. ........................................... .............. 1-1 VEHICLE IDENTIFICA TION NUMBER ................................................... 1-1 MODEL LABEL ................
IDENTIFICATION 1-1 EAS20130 IDENTIFICA TION EAS20140 VEHICLE IDENTIFICA TION NUMBER The v ehicle identification number “1” is stamped into the right side of the steering head pipe . EAS20150 MODEL LABEL The model label “1” is affix ed to the frame.
IMPORTANT INFORMATION 1-2 EAS20180 IMPOR T ANT INFORMA TION EAS20190 PREP A RA TION FOR REMO V AL AND DISAS- SEMBL Y 1. Bef ore remov al and disassemb ly , remov e all dir t, mud, dust and f oreign material. 2. Use only the proper tools and cleaning equipment.
IMPORTANT INFORMATION 1-3 EAS20210 GASKETS, OIL SEALS AND O-RINGS 1. When ov erhauling the engine, replace all gask ets, seals and O-rings. All gask et sur- f aces, oil seal lips and O-rings must be cleaned. 2. During reassembly , proper ly oil all mating par ts and bearings and lubricate the oil seal lips with grease .
CHECKING THE CONNECTIONS 1-4 EAS20250 CHECKING THE CONNECTIONS Check the leads , couplers, and connectors f or stains, rust, moisture, etc. 1. Disconnect: • Lead • Coupler • Connector 2. Chec k: • Lead • Coupler • Connector Moisture → Dr y with an air b low er .
SPECIAL TOOLS 1-5 EAS20260 SPECIAL T OOLS The f ollowing special tools are necessary for comple te and accurate tune-up a nd assemb ly . Use only the appropriate special tools as this will h e lp pre vent damage caused b y the use of inappropri- ate tools or improvised te chniques .
SPECIAL TOOLS 1-6 Crankshaft installer pot 90890-01274 Installing pot YU-90058 5-60 Crankshaft installer bolt 90890-01275 Bolt YU-90060 5-60 Adapter (M10) 90890-01383 Adapter #2 YU-90062 5-60 Spacer 90890-01288 5-60 Piston pin puller set 90890-01304 Piston pin puller YU-01304 5-25 T ool name/T ool No.
SPECIAL TOOLS 1-7 T appet adjusting tool 90890-01311 Six piece tappet set YM-A5970 3-5 Flywheel puller 90890-01362 Heavy duty puller YU-33270-B 5-46 Bolt (M8 × 80 mm) 90890-01359 5-46 Sheav e holder .
SPECIAL TOOLS 1-8 Extension 90890-04082 3-9 P ock et tester 90890-03112 Analog poc ket tester YU-03112-C 1-4, 5-51, 7-31, 7-32, 7-33, 7- 37, 7-38, 7-39, 7-40, 7-41, 7-42 Timing light 90890-03141 Induc.
SPECIAL TOOLS 1-9 V alve guide installer (ø6) 90890-04065 V alve guide installer (6.0 mm) YM-04065-A 5-19 V alv e guide reamer (ø6) 90890-04066 V alv e guide reamer (6.
2 SPECIFICA TIONS GENERAL SPECIFICA TIONS ........................................................ .............. 2-1 ENGINE SPECIFICA TIONS ............................ .......................................... .... 2-4 CHASSIS SPECIFICA TIONS .....
GENERAL SPECIFICATIONS 2-1 EAS29110 GENERAL SPECIFICA TIONS Model Model 4D3D/4D3H/4D3M Dimensions Ov erall length 1625 mm (64.0 in) Ov erall width 1070 mm (42.1 in) Ov erall height 1040 mm (40.9 in) Seat height 730 mm (28.7 in) Wheelbase 1110 mm (43.7 in) Ground clearance 100 mm (3.
GENERAL SPECIFICATIONS 2-2 Spark plug (s) Manuf acturer/model NGK/DR7EA Spark plug gap 0.6–0.7 mm (0.024–0.0 28 in) Clutch type Wet, m ultiple-disc T ran smission Primar y reduction system Spur gear Primar y reduction ratio 76/22 (3.455) Secondar y reduction system Chain drive Secondar y reduction ratio 38/14 (2.
GENERAL SPECIFICATIONS 2-3 Rear suspension T ype Swingarm Spring/shock absorber type Coil spring/gas-oil damper Wheel tra vel 200 mm (7.9 in) Electrical system Ignition system DC . CDI Charging system A C magneto Model YTZ7S V oltage, capacity 12 V , 6.
ENGINE SPECIFICATIONS 2-4 EAS29120 ENGINE SPECIFICA TIONS Cylinder head V olume 20.50–21.50 cm 3 (1.25–1. 31 cu.in) W ar page limit 0.05 mm (0.0020 in) Cylinder Bore 74.000–74.016 mm (2. 9134–2.9140 in) W ear limit 74.100 mm (2.9173 in) Camshaft Drive system Chain drive (right) Camshaft lobe dimensions Intak e A 36.
ENGINE SPECIFICATIONS 2-5 V alve, v alve seat, valve guide V alv e clearance (cold) Intak e 0.05–0.10 mm (0.0020–0.0039 in) Exhaust 0.10–0.15 mm (0.0039–0.0059 in) V alv e dimensions V alv e head diameter A (intak e) 33.90–34.10 mm (1.3346–1.
ENGINE SPECIFICATIONS 2-6 V alve spring Inner spring F ree length (intak e) 36.17 mm (1.42 in) Limit 34.36 mm (1.35 in) F ree length (e xhaust) 36.17 mm (1.42 in) Limit 34.36 mm (1.35 in) Installed length (intak e) 30.50 mm (1.20 in) Installed length (e xhaust) 30.
ENGINE SPECIFICATIONS 2-7 Piston Piston-to-cylinder clearance 0.010–0.025 mm (0.0004–0.0010 in) Limit 0.15 mm (0.0059 in) Diameter D 73.983–73.998 mm (2.9127–2.9133 in) Height H 5.0 mm (0.20 in) Offset 0.25 mm (0.0098 in) Offset direction Intak e side Piston pin bore inside diameter 17.
ENGINE SPECIFICATIONS 2-8 Crankshaft Width A 69.25 –69.30 mm (2.726–2.728 in) Runout limit C 0.03 mm (0.0012 in) Big end side clear ance D 0.350–0.650 mm (0.0138–0.0256 in) Limit 0.50 mm (0.0197 in) Big end radial clearance E 0.010–0.025 mm (0.
ENGINE SPECIFICATIONS 2-9 Carburetor ID mark 4D31 00 Main jet #133 .8 Main air jet #140 Jet needle 5DH66-1 Needle jet P-0M (922) Pilot air jet 1 #85 Pilot air jet 2 #170 Pilot outlet 0.9 Pilot jet #25 Bypass 1 0.8 Bypass 2 0.8 Bypass 3 0.8 V alv e se at size 2 Star ter jet 1 #55 Star ter jet 2 0.
CHASSIS SPECIFICATIONS 2-10 EAS29130 CHASSIS SPECIFICA TIONS Fr ont suspension Shoc k absorber tra vel 90.7 mm (3.57 in) (4D3D) 88.4 mm (3.48 in) (4D3H, 4D3M) Spring free length 248.5 mm (9.78 in) (4D3D) 224.6 mm (8.84 in) (4D3H, 4D3M) Spring rate K1 23.
CHASSIS SPECIFICATIONS 2-11 Fr ont brake T ype Dual disc brak e Disc outside diameter × thic kness 161.0 × 3.5 mm (6.34 × 0.14 in) Brak e disc thickness limit 3.0 mm (0.12 in) Brak e disc deflection limit 0.15 mm (0.006 in) Brak e pad lining thickness (inner) 4.
ELECTRICAL SPECIFICATIONS 2-12 EAS29140 ELECTRICAL SPECIFICA TIONS System v oltage System v oltage 12 V Ignition system Ignition timing (B.T .D .C .) 10.
ELECTRICAL SPECIFICATIONS 2-13 Headlight rela y Model/manuf acturer G8HN-1C4T -DJ-Y52/OMRON Coil resistance 94.5–115.5 Ω Circuit breaker Circuit breaker type Fuse Fuse Fuse 15.
TIGHTENING TORQUES 2-14 EAS20320 TIGHTENING T ORQ UES EAS20330 GENERAL TIGHTENING T ORQUE SPECIFI- CA TIONS This char t specifies tightening torques f or stan- dard f asteners with a standard ISO thread pitch. Tightening torque specifications f or spe- cial components or assemb lies are provided f or each chapter of this manual.
TIGHTENING TORQUES 2-15 EAS20340 ENGINE TIGHTENING T ORQUES Item Thread size Q’ty Tightening tor que Remarks Cylinder head bolt (upper) M8 4 24 Nm (2.4 m·kg, 18 ft·lb) See TIP Cylinder head bolt M8 2 20 Nm (2.0 m·kg, 15 ft·lb) Camshaft loc k plate bolt M6 2 8 Nm (0.
TIGHTENING TORQUES 2-16 TIP Apply oil to the bearing surf ace of (upper) cyli nder head bolt. Fur ther , apply molybden um disulfide grease to thread p ar t. Primar y dr ive gear n ut M16 1 80 Nm (8.0 m·kg, 59 ft·lb) Use a loc k was h er. Clutch boss nut M16 1 75 Nm (7.
TIGHTENING TORQUES 2-17 EAS20350 CHASSIS TIGHTENING T ORQUES Item Thread size Q’ty Tightening tor que Remarks Engine upper sta y and frame M8 2 33 Nm (3.3 m·kg, 24 ft·lb) Engine upper sta y and engine M10 1 66 Nm (6.6 m·kg, 49 ft·lb) Engine low e r stay and frame M8 4 33 Nm (3.
TIGHTENING TORQUES 2-18 F ront brak e disc and front wheel hub M8 8 28 Nm (2.8 m·kg, 21 ft·lb) Rear wheel and rear wheel hub M10 8 45 Nm (4.5 m·kg, 33 ft·lb) Rear axle and rear wheel h ub M14 2 120 Nm (12.0 m·kg, 89 ft·lb) Rear axle ring nut M33 1 140 Nm (14.
LUBRICATION POINTS AND LUBRICANT TYPES 2-19 EAS20360 LUBRICA TION POINTS AND LUBRICANT TYPES EAS20370 ENGINE Lubrication point Lubricant Oil seal lips O-rings Bearings Cylinder head bolts (bearing sur.
LUBRICATION POINTS AND LUBRICANT TYPES 2-20.
LUBRICATION SYSTEM CHART AND DIAGRAMS 2-21 EAS20390 LUBRICA TION SYSTEM CHART AND DIA GRAMS EAS20400 ENGINE OIL LUBRICA TION CHART.
LUBRICATION SYSTEM CHART AND DIAGRAMS 2-22 1. Oil pan 2. Oil strainer 3. Oil pump 4. Oil cooler 5. Oil filter element 6. Cylinder head 7. Camshaft 8. Pin with hole 9.
LUBRICATION SYSTEM CHART AND DIAGRAMS 2-23 EAS20410 LUBRICA TION DIA GRAMS.
LUBRICATION SYSTEM CHART AND DIAGRAMS 2-24 1. Camshaft 2. Oil filter element 3. Oil pump 4. Oil strainer.
LUBRICATION SYSTEM CHART AND DIAGRAMS 2-25.
LUBRICATION SYSTEM CHART AND DIAGRAMS 2-26 1. Camshaft 2. Dr ive axle 3. Main axle 4. Push le v er shaft 5. Oil pump assemb ly 6. Oil strainer 7. Crankshaft asse mbly 8.
LUBRICATION SYSTEM CHART AND DIAGRAMS 2-27.
LUBRICATION SYSTEM CHART AND DIAGRAMS 2-28 1. Oil cooler 2. Oil hose 1 3. Oil hose 2.
CABLE ROUTING 2-29 EAS20430 CABLE R OUTING.
CABLE ROUTING 2-30 1. Clutch s witch lead 2. Clutch cable 3. F ront brak e hose 1 4. F ront brak e light switch lead 5. Throttle ca b le 6. Plastic band 7. P ar king brak e cable 8. Handlebar s witch lead A. Route the clutch cab le and parking brak e cab le through the guide of the han dlebar protector .
CABLE ROUTING 2-31.
CABLE ROUTING 2-32 1. Indicator light lead 2. Main s witc h lead 3. Coupler joint 4. F ront brak e hose 2 5. Oil cooler hose 1, 2 6. Exhaust pipe 7. Engine brac ket 8. P ar king brak e cable 9. Rear br ake light s witch lead 10.Batter y negativ e lead 11.
CABLE ROUTING 2-33.
CABLE ROUTING 2-34 1. Rear br ake reservoir 2. Rear br ake light s witch 3. Clip 4. Rear br ake reservoir hose 5. Rear br ake master cylinder 6. P ar king brak e cable 7. Rear br ake hose 8. Rear br ake caliper A. Make sure t ha t the end of the clip is f acing downw ard.
CABLE ROUTING 2-35.
CABLE ROUTING 2-36 4D3D 1. Clutch s witch lead 2. Handlebar s witch lead 3. Bolt 4. He xagonal head bolt 5. Main harness 6. Air v ent hose 7. Clamp 8. Battery negative lead 9. A C magneto lead 10. Carburetor overflow hose 11.Neutral s witch le ad 12.Star ter motor lead 13.
CABLE ROUTING 2-37.
CABLE ROUTING 2-38 4D3H/4D3M 1. Clutch s witch lead 2. Handlebar s witch lead 3. Bolt 4. He xagonal head bolt 5. Main harness 6. Air v ent hose 7. Clamp 8. Battery negative lead 9. A C magneto lead 10. Carburetor overflow hose 11.Neutral s witch le ad 12.
CABLE ROUTING 2-39.
CABLE ROUTING 2-40 1. Indicator light 2. Coupler joint 3. Main s witc h lead 4. Main s witc h 5. F ront brak e light switch lead 6. Throttle ca b le 7. Air v ent hose 8. Clutch s witch lead 9. Handlebar s witch lead 10. P arki ng brake cable 11. C lutch cable 12.
CABLE ROUTING 2-41.
CABLE ROUTING 2-42 1. Battery 2. CDI unit 3. Band 4. Star ter rela y lead 5. Star ter rela y 6. T aillight lead 7. Battery negative lead 8. A C magneto coupler 9. Star ter motor lead 10.Headlight relay 11.N eutral rela y 12.Damper 13.CDI unit lead 14.
CABLE ROUTING 2-43.
3 PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE ................................................ ......................... 3-1 INTR ODUCTION .................................................................................... 3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTR OL SYSTEM.
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBL Y (f or 4D3H, 4D3M) ................................................................................ .. 3-28 CHECKING THE TIRES ..................................................................... .. 3-29 CHECKING THE WHEELS .
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PERIODIC MAINTENANCE 3-1 EAS20450 PERIODIC MAINTENANCE EAS20460 INTRODUCTI ON This chapter includes all inf or mation necessar y to perf or m recommended checks and adjustme nts.
PERIODIC MAINTENANCE 3-2 EAS4D3F012 GENERAL MAINTENANCE AND LUBRICA TION CHART NO . ITEM CHECK OR MAINTENANCE JOB Whiche ver comes first INITIAL EVER Y m o n t h 1366 1 2 km (mi) 320 (200) 1300 (800) 2500 (1600) 2500 (1600) 5000 (3200) hours 20 80 160 160 320 1 Air filter element • Clean and rep lace if necessary .
PERIODIC MAINTENANCE 3-3 TIP • The air filter needs more frequ ent ser vice if yo u are riding in unusually wet or dusty areas. • Hydraulic br ake service • Regularly chec k and, if necessary , correct the brak e fluid le v el.
ENGINE 3-4 EAS20472 ENGINE EAS20520 ADJUSTING THE V AL VE CLEARA NCE The f ollowing procedure applies to all of the va lve s. TIP • V alv e clearance adjus tment should be made on a cold engine , at room temperature.
ENGINE 3-5 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Adjust: • V alve clearan ce ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Loosen the loc knut. b .
ENGINE 3-6 5. Detach: • Digital tachometer 6. Adjust: • Throttle cab le free pla y Ref er to “ADJUSTING THE THR O TTLE CABLE FREE PLA Y” on page 3-6. EAS20660 ADJUSTING THE THRO TTLE CABLE FREE PLA Y TIP Prior to adjusting the throttle cab le free play , the engine idling speed sh ould be adjusted.
ENGINE 3-7 EAS29170 ADJUSTING THE SPEED LIMITER The speed limiter k eeps the carburetor throttle from becoming fully-opened e ven when the throttle le ver is applied to the maxim um posi- tion. Scre wing in the adju sting scre w stops the engine speed from increasing.
ENGINE 3-8 7. Install: • Spark plug TIP Bef ore installing the spark plug, clean the spark plug and gask et surface . 8. Connect: • Spark plug cap EAS20700 CHECKING THE IGNITION TIMING TIP Prior to checking the ignition timing, check the wiring connections of the entire ignition sys- tem.
ENGINE 3-9 4. Remov e: • Spark plug ECA13340 Bef ore removing th e spark plug, use com- pressed air to blo w away a ny dirt accum u- lated in the spark plug wells to prevent it fro m falling into the cylinder . 5. Install: • Compression gauge “1 ” • Extension “2” 6.
ENGINE 3-10 • Do not scre w the dipstick “1” in when chec k- ing the oil le v el. ECA13360 • Engine oil also lubricates the c lutch and the wr ong oil types or additives could cause c lutch slippa g e.
ENGINE 3-11 6. Drain: • Engine oil (completely from the crankcase) 7. If the oil filter element is also t o be replaced, perf or m the f ollowing procedure . ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a.
ENGINE 3-12 EAS20870 ADJUSTING THE CLUTCH CABLE FREE PLA Y 1. Chec k: • Clutch cab le free play “a ” Out of specification → Adjust. 2. Adjust: • Clutch cab le free play ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a.
ENGINE 3-13 4. Clean: • Air filter element (with solv ent) W ARNING EW A13020 Never use lo w flash point solvents, such as gasoline, to clean the air filter element. Such solvents ma y cause a fire or an e xplo- sion. TIP After cleaning, gently squeez e the air filter ele- ment to remov e th e e xcess solv ent.
ENGINE 3-14 • Air filter case Ref er to “GENERAL CHASSIS” on page 4-1. •C a r b u r e t o r Ref er to “CARBURET OR” on page 6-3. 2. Chec k: • Carb uretor joint • Intak e manifo ld Crac ks/damage → Replace. Ref er to “CARBURET OR” on page 6-3.
ENGINE 3-15 d. Inser t the tailpipe and gask et “3” into the muffler and alig n the bolt holes . e. Inser t the bolts and tighten it. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Spark arrester bolt 11 Nm (1.
CHASSIS 3-16 EAS29360 CHASSIS EAS21170 ADJUSTING THE FRONT DISC BRAKE 1. Chec k: • Brak e lev er free pla y “a” Out of specification → Bleed the f ront brak e system.
CHASSIS 3-17 W ARNING EW A14900 After this adjustment is performed, l ift the fro nt and rear wheels off the gr ound by placing a bloc k under the engine, and spin the rear wheels to ensure there is n o brake drag. If an y brake drag is noticed perf orm the abov e steps again.
CHASSIS 3-18 EAS21250 CHECKING THE FRONT BRAKE P ADS The f ollowing procedure applies to all of the brak e pads. 1. Remov e: • F ront wheels Ref er to “FR ONT WHEEL ” on page 4-4. 2. Operate the b rak e. 3. Chec k: • F ront brak e pad W ear indicators g roov e almost disap- peared “a” → Replace the br ake pa ds as a set.
CHASSIS 3-19 3. Hold the v ehicle upright and apply the front brak e sev eral times. 4. Chec k: • Brak e hose Brak e fluid leakage → Replace the dam- aged hose. Ref er to “REAR BRAKE” on page 4-27. EAS29210 ADJUSTING THE P ARKING BRA KE 1. Chec k: • P arking brake cab le end length “a” Out of specification → Adjust.
CHASSIS 3-20 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS21350 BLEEDING THE HYDRA ULIC BRAKE SYS- TEM W ARNING EW A13100 Bleed the h ydraulic brake system when- ever: • the system is disassemb led. • a brake hose is loosened, d isconnected or replaced.
CHASSIS 3-21 k. Fill the brak e fluid reser voir to the pro per le vel with the recommended br ak e fluid. Ref er to “CH ECKING THE BRAKE FLUID LEVEL ” on page 3-17. W ARNING EW A13110 After bleeding the h ydraulic brake system, chec k the brake operation.
CHASSIS 3-22 ECA4D3F005 Excessive chain slac k will ove rload the engine and other vital parts; keep the slac k within the specified limits. e. If the chain slac k cannot be adjusted, replace the sproc kets and driv e chain as a set. f . Tighten the rear axle pinch bolt s.
CHASSIS 3-23 4. Raise the front end of the v ehicle so that there is no weight on the fr ont wheels. 5. Chec k: • Ball joints an d wheel bearings Mov e the wheels laterally bac k and forth. Excessiv e free pla y → Replace the front ar ms (upper and lo wer) and/or whee l bearings.
CHASSIS 3-24 d. Tighten the rod end loc knuts of both tie- rods. TIP Adjust the tie-rod ends so that “A” a nd “B” are equal. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲�.
CHASSIS 3-25 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS4D3F031 ADJUSTING THE FRONT SHOCK ABSORBER ASSEMBLIES (for 4D3H, 4D3M) W ARNING EW A14920 Alwa ys adjust the spring preload f or both fro nt shock a bsorber assemblies to the same setting.
CHASSIS 3-26 TIP Mak e sure that the positio n indicator marks “c” are aligned when the shoc k absorber is set to the standard setting. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲.
CHASSIS 3-27 TIP Mak e sure that the positio n indicator marks “c” are aligned when the shoc k absorber is set to the standard setting. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS4D3F006 CHECKING THE REAR SHOCK ABSORBER ASSEMBL Y 1.
CHASSIS 3-28 TIP Be sure to remov e all dir t and mud from around the loc knut and adjusting nut bef ore adjustment. d. Tighten the loc knut. TIP Alwa ys tighten the lockn ut against the adjust- ing nut, then torq ue it to specification.
CHASSIS 3-29 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Compression damping ECA4D3F008 Do not for ce the adjuster past the minim um or maximu m extent of adjustment.
CHASSIS 3-30 Tire pressure W ARNING EW A14960 • Tire pressure belo w the minim um specifi- cation could cause the tire to dislodge fr om the rim under se vere riding condi- tions. The f ollowing are minim ums: • Fr ont 24.5 kP a (0.25 kgf/cm 2 , 3.
CHASSIS 3-31 W ARNING EW A13190 It is dangerous to ride with a w orn-out tire . When the tire tread reac hes the wear limit, replace the tire immediatel y . EAS29350 CHECKING THE WHEELS The f ollowing procedure applies to all of the wheels. 1. Chec k: • Wheel “1” Damage/bends → Replac e .
ELECTRICAL SYSTEM 3-32 EAS21750 ELECTRICAL SYSTEM EAS21760 CHECKING AND CHARGING THE BA TTER Y Ref er to “ELECTRICAL COMPONENTS ” on page 7-27. EAS21770 CHECKING THE FUSES Ref er to “ELECTRICAL COMPONENTS ” on page 7-27. EAS21790 REPLA CING THE HEADLIGHT BULBS The f ollowing procedure applies to both of the headlight b ulbs.
ELECTRICAL SYSTEM 3-33 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. T ur n the adjusting bolt “1” in direction “a” or “b”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Direction “a” Headlight beam is ra ised.
4 CHASSIS GENERAL CHASSIS ........................................................... ......................... 4-1 FR ONT WHEEL ................................... ........................................... .............. 4-4 REMO VING THE FR ONT WHEELS .
REPLA CING THE REAR BRAKE P ADS ............................................ .. 4-32 REMO VING THE REAR BR AKE CALIPER .......................................... 4-33 DISASSEMBLING THE REAR BRAKE CALIPER ................................ 4-34 CHECKING THE REAR BRAKE CALIPER .
CHAIN DRIVE ........................................................... .................................. 4-57 REMO VING THE DRIVE CHAIN .............................................. ............ 4-58 CHECKING THE DRIVE CHAIN .......................
GENERAL CHASSIS 4-1 EAS21830 GENERAL CHASSIS Removing the seat, fr ont fender and headlights Order Job/Parts to remove Q’ty Remarks 1S e a t 1 TIP Pull bac k the seat lock le ver , than pu l l up on the rear of the seat. 2 Indicator light coupler 1 Disconnect.
GENERAL CHASSIS 4-2 Removing the fo ot pr otector s and engine skid plate Order Job/Parts to remove Q’ty Remarks 1 Left foot protector 1 2 Right foot protector 1 3 Engine skid plate 1 For installation, re verse the remov al proce- dure.
GENERAL CHASSIS 4-3 Removi ng the rear f ende r and air filter case Order Job/Parts to remove Q’ty Remarks Seat/F ront fender Ref er to “GENERAL CHASSIS” on page 4-1. 1 Rear fender 1 2B a t t e r y c o v e r 1 3B a t t e r y l e a d 2 ECA4D3F001 First disconnect the negative lead, then disconnect the positive lea d.
FRONT WHEEL 4-4 EAS21870 FR ONT WHEEL Removing the fr ont wheels and brake discs Order Job/Parts to remove Q’ty Remarks The follo wing procedure applies to both of the front wheels.
FRONT WHEEL 4-5 EAS21890 REMO VING THE FR ONT WHEELS The f ollowing procedure applies to both of the front wheels . 1. Stand the v ehicle on a lev el surface . W ARNING EW A13120 Securely support the vehic le so that there is no danger of it falling ov er .
FRONT WHEEL 4-6 2. Chec k: • Wheel bearings Wheel hub pla y/wheel tur ns roughly → Replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Clean wheel hub e xter ior . b . Drive bearing out b y pushing spacer aside and tapping around perimeter of bearing inner race .
FRONT WHEEL 4-7 EAS21970 ADJUSTING THE FRONT WHEEL ST A TIC B ALANCE TIP After replacing the tire , wheel or both, the front wheel static balance should be adjusted. 1. Remov e: • Balancing w eight(s) 2. Find: • F ront wheel’ s hea vy spot TIP Place the front wheel on a suitab le balancing stand.
FRONT WHEEL 4-8 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. T ur n the front wheel and make sure it sta ys at each position sho wn. b . If the front wheel does not remain station - ar y at all of the positions, rebala nce it.
REAR WHEEL 4-9 EAS22020 REAR WHEEL Removi ng the rear wheels Order Job/Parts to remove Q’ty Remarks 1 Rear wheel 2 2 Cotter pin 2 3A x l e n u t 2 4 Wheel hub 2 F or install ation, re verse the removal proce- dure.
REAR WHEEL 4-10 EAS22040 REMO VING THE REAR WHEELS 1. Stand the v ehicle on a lev el surface . W ARNING EW A13120 Securely support the vehic le so that there is no danger of it falling ov er . TIP Place the v ehicle on a suitable stand so that the rear wheel is ele vated.
REAR AXLE AND REAR AXLE HUB 4-11 EAS29470 REAR AXLE AND REAR AXLE HUB Removi ng the rear axle an d rear axle hub Order Job/Parts to remove Q’ty Remarks Rear wheels/Rear wheel hubs Refer to “REAR WHEEL ” on page 4-9.
REAR AXLE AND REAR AXLE HUB 4-12 14 Dust cover 2 F or installation, re verse the removal proce- dure. Removi ng the rear axle an d rear axle hub Order Job/Parts to remove Q’ty Remarks.
REAR AXLE AND REAR AXLE HUB 4-13 EAS29490 REMO VING THE REAR AXLE 1. Place the v ehicle on a le v el surf ace. 2. Loosen: • Rear axle ring nut set bolts “1” 3. Remov e: • Rear axle ring nut “2” TIP • Apply the brak e pedal so that the rear axle does not turn when loosening the nut.
REAR AXLE AND REAR AXLE HUB 4-14 EAS29510 CHECKING THE REAR WHEEL SPROCKET 1. Chec k: • Rear wheel sproc ket Ref er to “CHECKING THE DRIVE SPR OCKET” on page 4-59. EAS4D3F029 CHECKING THE SPROCKET BRA CKET 1. Chec k: • Sproc ket brac ket Crac ks/damage → Replace.
FRONT BRAKE 4-15 EAS22210 FR ONT BRAKE Removing the fr ont brake pads Order Job/Parts to remove Q’ty Remarks The follo wing procedure applies to both of the front brak e calipers.
FRONT BRAKE 4-16 Removing the fr ont brake master c ylinder Order Job/Parts to remove Q’ty Remarks Brake fluid Drain. Refer to “BLEEDING THE HYDRA ULIC BRAKE SYSTEM” on page 3-20.
FRONT BRAKE 4-17 Disassembl ing the fr ont brake master cyli nder Order Job/Parts to remove Q’ty Remarks 1 Brake master cylinder kit 1 2 Brake master cylinder body 1 For assemb ly , rev erse the disassembly pro- cedure.
FRONT BRAKE 4-18 Removi ng the fr ont brake calipers Order Job/Parts to remove Q’ty Remarks The follo wing procedure applies to both of the front brak e calipers. Brake fluid Drain. Refer to “BLEEDING THE HYDRA ULIC BRAKE SYSTEM” on page 3-20. F ront whe el Refer to “FRONT WHEEL ” on page 4-4.
FRONT BRAKE 4-19 Disassem bling the front b rake cali pers Order Job/Parts to remove Q’ty Remarks The follo wing procedure applies to both of the front brak e calipers.
FRONT BRAKE 4-20 EAS22220 INTRODUCTI ON W ARNING EW A14100 Disc brake components rarel y require dis- assembl y . Theref ore , alwa ys follo w these preventive meas ures: • Never dis assemble brake components unless absolutel y necessary .
FRONT BRAKE 4-21 EAS22250 REPLA CING THE FRONT BRAKE P ADS The f ollowing procedure applies to both brak e calipers . TIP When replacing the brak e pads , it is not neces- sar y to disconnect the bra ke hose or d isas- semb le the brake caliper .
FRONT BRAKE 4-22 TIP Bef ore removing the brak e caliper , drain the brak e fluid from the entire brak e system. 1. Remov e: • Union bolt “1” • Copper w ashers “2” • Brak e hose “3” • Brak e caliper bolts “4” TIP Put the end of the bra k e hose into a container and pump out the br ak e fluid carefully .
FRONT BRAKE 4-23 W ARNING EW A4D3F006 Whenever a brake caliper is disassemb led, replace the brake caliper piston se al and brake caliper dust seal. 2.
FRONT BRAKE 4-24 Ref er to “RE PLACING THE FR ONT BRAKE P ADS” on page 4-21. 4. Fill: • Brak e master cylinder reservoir (with the specified a mount of the recom- mended brak e fluid) W ARNING EW A13090 • Use onl y the designated brake fluid.
FRONT BRAKE 4-25 2. Chec k: • Brak e master cylinder kit “1” Damage/scratches/w ear → Replace. 3. Chec k: • Brak e master cylinder reser voir “1” Crac ks/damage → Replace. • Brak e master cylinder reservoir dia - phragm “2” Damage/wear → Replace.
FRONT BRAKE 4-26 3. Fill: • Brak e master cylinder reservoir (with the specified a mount of the recom- mended brak e fluid) W ARNING EW A13540 • Use onl y the designated brake fluid. Other brake fluids ma y cause the rubber seals to deteriorate, causing leakage and poor brake perf ormance .
REAR BRAKE 4-27 EAS22550 REAR BRAKE Removi ng the rear brake pads Order Job/Parts to remove Q’ty Remarks 1 Brake pad retaining bolt 2 2 Lock washer 1 3 Brake pad 2 4 Brake pad spring 1 For installation, re verse the removal proce- dure.
REAR BRAKE 4-28 Removi ng the rear brake mast er cyli nder Order Job/Parts to remove Q’ty Remarks Right foot protector Refer to “GENERAL CHASSIS” on page 4-1.
REAR BRAKE 4-29 Disassembl ing the r ear brake ma ster c ylinder Order Job/Parts to remove Q’ty Remarks 1 Hose joint 1 2 Brake master cylinder kit 1 3 Brake master cylinder 1 For assemb ly , rev erse the disassemb ly pro- cedure.
REAR BRAKE 4-30 Removi ng the rear brake cal iper Order Job/Parts to remove Q’ty Remarks Brake fluid Drain. Refer to “BLEEDING THE HYDRA ULIC BRAKE SYSTEM” on page 3-20. 1 P a rking brake cable 1 Disconnect. 2 Union bolt 1 3 Copper washer 2 4 Brake hose 1 5 Brake caliper assembly 1 For installation, re verse the remov al proce- dure.
REAR BRAKE 4-31 Disassembl ing the r ear brake caliper s Order Job/Parts to remove Q’ty Remarks 1 Adjusting bolt 1 2 Locknut 1 3 P a rking brake ar m 1 4 Brake pad retaining bolt 2 5 Lock washer 1 6.
REAR BRAKE 4-32 EAS22560 INTRODUCTI ON W ARNING EW A14100 Disc brake components rarel y require dis- assembl y . Theref ore , alwa ys follo w these preventive meas ures: • Never dis assemble brake components unless absolutel y necessary .
REAR BRAKE 4-33 b . Loosen the b leed screw and push the brak e caliper pistons into the brak e caliper with your finger . c. Tighten the b leed screw . d. Install ne w brake pads and a ne w brak e pad spring. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3.
REAR BRAKE 4-34 EAS22600 DISASSEMBLING THE REAR BRAK E CALI- PER 1. Remov e: • Brak e caliper piston • Brak e caliper dust seal “1” • Brak e caliper piston seal “2” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a.
REAR BRAKE 4-35 1. Install: • O-ring “1” • Caliper piston seal “2” • Caliper dust seal “3” 2. Install: • Brak e caliper piston “1” 3. Install: • P arking brake arm “1” 4. Measure: • P arking brake arm to parking brak e brac ket distance “a” Out of specification → Adjust.
REAR BRAKE 4-36 W ARNING EW A13090 • Use onl y the designated brake fluid. Other brake fluids ma y cause the rubber seals to deteriorate, causing leakage and poor brake perf ormance . • Refill with the same type o f brake fluid that is already in the system.
REAR BRAKE 4-37 3. Chec k: • Brak e fluid reser voir “1” Crac ks/damage → Replace. • Brak e fluid reser voir diaphra gm “2” Crac ks/damage → Replace.
REAR BRAKE 4-38 3. Fill: • Brak e fluid reser v oir (with the specified a mount of the recom- mended brak e fluid) W ARNING EW A13090 • Use onl y the designated brake fluid. Other brake fluids ma y cause the rubber seals to deteriorate, causing leakage and poor brake perf ormance .
HANDLEBAR 4-39 EAS22840 HANDLEB AR Removing the handlebar Order Job/Parts to remove Q’ty Remarks 1 Handlebar pro tector 1 2B a n d 3 3 F ront brake light switch 1 4 Brake master cylinder/brack et 1/.
HANDLEBAR 4-40 EAS22860 REMO VING THE HANDLEB ARS 1. Remov e: • Clutch s witch “1” TIP Push the f astener when removing the clutch s witch out of the clutch lev er holder . 2. Remov e: • Handlebar grip “1” TIP Blow co mpressed air betw een the left handle- bar and the handlebar grip , and gradually push the grip off the handlebar .
HANDLEBAR 4-41 TIP • Bef ore applying the adhesiv e, wipe o ff grease or oil on the handlebar surf ace “a” with a lacquer thinner . • Install the handlebar grips so that the “L ” arrow on the left g r ip and “R” arrow on the right grip are placed v er tically .
HANDLEBAR 4-42 Thrott le cable fre e play 2.0–4.0 mm (0.08–0.16 in).
STEERING STEM 4-43 EAS29540 STEERING STEM Removing the steering stem Order Job/Parts to remove Q’ty Remarks F ront fender Ref er to “GENERAL CHASSIS” on pag e 4-1. 1 Lock washer 1 2 Br acke t 1 3 Steer ing stem b ushing 2 4S p a c e r 2 5 Oil seal 2 6 Steering stem 1 7 Bushing 2 F or installation, re verse the removal proce- dure.
STEERING STEM 4-44 EAS29560 CHECKING THE STEERING STEM 1. Chec k: • Steering stem “1” Bends → Replace. W ARNING EW A15030 Do not attempt to straighten a bent ste m; this ma y dangerous ly weaken the stem. 2. Chec k: • Oil seals “1” • Steering stem bushin gs “2” W ear/damage → Replace .
TIE-RODS AND STEERING KNUCKLES 4-45 EAS29660 TIE-R O DS AND ST EERING KNUCKLES Removi ng the tie-r ods and steering knuc kles Order Job/Parts to remove Q’ty Remarks The follo wing procedure applies to both of the tie-rods and steering knuckles. F ront whe el Refer to “FRONT WHEEL ” on page 4-4.
TIE-RODS AND STEERING KNUCKLES 4-46 EAS29670 REMO VING THE STEERING KNUCKLES The f ollowing procedure applies to both of the steer ing k nuckles. 1. Remov e: • Steering knuckle “1” TIP Use a general puller to separate the ball joints “2” from the steering knuc kle “1”.
FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES 4-47 EAS29710 FR ONT ARMS AND FRONT SH OCK ABSORBER ASSEMBLIES Removi ng the fr ont arms and front shoc k absorber assembl ies Order Job/Parts to remove Q’ty Remarks The follo wing procedure applies to both of the front upper ar ms, front lo wer arms, and front shock absorber assemb lies.
FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES 4-48 EAS29720 REMO VING THE FR ONT ARMS The f ollowing procedure applies to both of the front upper arms and front lowe r ar ms. 1. Chec k: • F ront ar m free pla y ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a.
FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES 4-49 EAS29760 CHECKING THE FRONT SHOCK ABSORBER ASSEMBLIES The f ollowing procedure applies to both of the front shoc k absorber assemblies . 1. Chec k: • F ront shoc k absorber assemb ly Oil leaks → Replace the front sho ck absorber assemb ly .
FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES 4-50 TIP Apply lithium-soap-based gre ase to the grease nipples “3”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Front upper arm nut 45 Nm (4.5 m·kg, 33 ft·lb) Front lower arm n ut 45 Nm (4.
REAR SHOCK ABSORBER ASSEMBLY 4-51 EAS23160 REAR SHOCK ABSORBER ASSEMBL Y Removi ng the rear shoc k absorber assembl y Order Job/Parts to remove Q’ty Remarks Seat/Rear fender/Air filter case Refer to “GENERAL CHASSIS” on page 4-1. 1C l a m p 2 Loosen.
REAR SHOCK ABSORBER ASSEMBLY 4-52 EAS23170 HANDLING THE REAR SHOCK ABSORBER W ARNING EW A13750 This rear shoc k absorber and gas cylinder contains highly compressed nitr og en gas. Before handli ng the rear shock absorber and gas cylinder , read and make sure y ou understand the f ollowing inf ormation.
REAR SHOCK ABSORBER ASSEMBLY 4-53 EAS23300 INST ALLING THE REAR SHOCK ABSORBER ASSEMBL Y 1. Install: • Rear shoc k absorber assembly TIP When installing the rear shoc k absorber assembly lo wer bolt, lift up the s wingar m. A. fo r 4D3D B. f or 4D3H, 4D3M Rear shoc k absorber assemb ly nut 55 Nm (5.
SWINGARM 4-54 EAS23330 SWINGARM Removing the swingarm Order Job/Parts to remove Q’ty Remarks Rear axle hub Refer to “REAR AXLE AND REAR AXLE HUB” on page 4-11. Rear shock absorber assembly Refer to “REAR SHOCK ABSORBER ASSEMBL Y” on page 4-51.
SWINGARM 4-55 EAS23340 REMO VING THE SWINGARM 1. Stand the v ehicle on a lev el surface . W ARNING EW A13120 Securely support the vehic le so that there is no danger of it falling ov er . TIP Place the v ehicle on a suitable stand so that the rear wheel is ele vated.
SWINGARM 4-56 EAS23380 INST ALLING THE SWINGARM 1. Lubricate: • Bearings • Spacer • Oil seals 2. Install: • Bearings “1” • Spacer “2” • Oil seals •D u s t c o v e r s TIP Inject the bearing with the character stamp turned outward.
CHAIN DRIVE 4-57 EAS23400 CHAIN DRIVE Removing the drive spr oc ket and drive cha i n Order Job/Parts to remove Q’ty Remarks 1 Drive sprock et cover 1 2 Drive chain guide 2 1 3 Drive chain guide 3 1 4 D r i ve s pr ocke t nu t 1 5 Lock washer 1 6 D r i ve s pr ocke t 1 7D r i v e c h a i n 1 F or installation, re verse the remo val proce- dure.
CHAIN DRIVE 4-58 EAS23430 REMO VING THE DRIVE CHAIN 1. Remov e: • Master link clip (with interlocking slip-joint pliers) 2. Remov e: • Master link plate “1” • O-ring “2” • Master link “3” 3. Remov e: • Drive chain EAS23441 CHECKING THE DRIVE CHAIN 1.
CHAIN DRIVE 4-59 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Chec k: • O-rings “1” Damage → Replace the drive chain. • Drive chain rollers “2” Damage/wear → Replace the dr iv e chain. • Drive chain side plates “3” Damage/wear → Replace the dr iv e chain.
CHAIN DRIVE 4-60 3. Bend the loc k washer tab along a flat side of the nut. 4. Install: • Master link “1” • O-ring “2” • Master link plate “3” ECA14300 Never install a ne w drive chain onto w orn drive chain spr ockets; this will dramaticall y shorten the drive chain’ s lif e .
CHAIN DRIVE 4-61.
5 ENGINE ENGINE REMO V AL .................................................. .................................... 5-1 INST ALLING THE ENGINE ........... ......................................................... 5-4 INST ALLING THE MUFFLER AND EXHA UST PIPE.
ASSENBLING THE BALANCER WEIGHT GEAR ................................ 5-41 INST ALLING THE OIL PUMP ............................. .................................. 5-41 INST ALLING THE BALANCER WEIGHT GEAR .................................. 5-41 SHIFT SHAFT .
.
ENGINE REMOVAL 5-1 EAS23711 ENGINE REMO V AL Removing the muf fler an d exhau st pipe Order Job/Parts to remove Q’ty Remarks Seat/front panel/front fender/rear f en der Refer to “GENER AL CHASSIS” on page 4-1.
ENGINE REMOVAL 5-2 Disconne cting the leads, ca bles and ho ses Order Job/Parts to remove Q’ty Remarks Engine oil D rain. Oil cooler hose 1, 2 Refer to “CLUTCH” on page 5-29. Carburetor Refer to “CARBURET OR” on page 6-3. Drive sprock et/dr ive chain Refer to “CHAIN DRIVE” on page 4-57.
ENGINE REMOVAL 5-3 Removing the engine Order Job/Parts to remove Q’ty Remarks 1 C rankcase bolt 1 2 Engine mounting bolt (front) 1 3 Engine brack et (left an d right) 2 4 Engine mounting bolt (u pp .
ENGINE REMOVAL 5-4 EAS23720 INST ALLING THE ENGINE 1. Install: • Engine mounting bolt (rear lo wer side) “1” • Engine mounting bolt (rear upper side) “2” • Engine br ack et bolts (upper .
ENGINE REMOVAL 5-5 4. Install: •G a s k e t • Exhaust pipe “1” 5. Tighten: • Nuts (e xhaust pipe) “2” 6. Install: •C l a m p TIP Slide the clamp onto the end of the muffler and inser t the projection “a” of the clamp into a slot “b” in the muffler .
CAMSHAFT 5-6 EAS23730 CAMSHAFT Removi ng the r ocke r arms and camshaft Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-10.
CAMSHAFT 5-7 EAS23770 REMO VING THE ROCKER ARMS AND CAMSHAFT 1. Loosen: • Loc knut “1” • V alv e cle arance adjusting s crew “2” 2. Remov e: • Loc k plate “3” 3. Remov e: • Camshaft “1” • Bearing “2” TIP Screw 10 mm (0.396 in) bolt “3” into the threaded end of the camshaft and then pull out the camshaft.
CAMSHAFT 5-8 4. Chec k: • Camshaft oil passage Obstr uction → Blow out with compressed air . EAS23880 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS The f ollowing procedure applies to all of the rock er ar ms and rock er ar m shafts. 1. Chec k: • Roc k er arms “1” • V alv e cle arance adjusting screws “2” Damage/wear → Replace.
CAMSHAFT 5-9 Out of specification → Replace the def ec- tiv e par t(s). EAS24040 INST ALLING THE CAMSHAFT AND ROCKER ARMS 1. Lubricate: • Camshaft 2.
CYLINDER HEAD 5-10 EAS24100 CYLINDER HEAD Removi ng the cylin der he ad Order Job/Parts to remove Q’ty Remarks Seat/front panel/front fender Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank/fue l ta nk shield Ref er to “FUEL T ANK” on page 6-1.
CYLINDER HEAD 5-11 F or installation, re verse the remo val proce- dure. Removi ng the cylin der he ad Order Job/Parts to remove Q’ty Remarks.
CYLINDER HEAD 5-12 EAS24130 REMO VING THE CYLINDER HEAD 1. Align: • “I” mark “a” on the pic kup coil rotor (with the stationary pointer “b” on the crankcase c ov er) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a.
CYLINDER HEAD 5-13 2. Chec k: • Cylinder head Damage/scratches → Re place. 3. Measure: • Cylinder head w ar page Out of specification → Resurf ace the cyl- inder head. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a.
CYLINDER HEAD 5-14 3. Chec k: • Cap bolt •S p r i n g •O n e - w a y c a m • Timing chain tensioner rod Damage/wear → Replace the timing chain tensioner . EAS24230 INST ALLING THE CYLINDER HEAD 1. Install: • Cylinder head gask et • Dow el pins 2.
CYLINDER HEAD 5-15 b . With the timing chain tensioner rod tur ned all the w ay into the timing chain tensioner housing (with the thin scre wdr iv er still installed), install the ne w gask et and the timing chain tensioner “2” onto the bo dy cylinder .
VALVES AND VALVE SPRINGS 5-16 EAS24270 V AL VES AND V AL VE SPRINGS Removi ng the v alves and v alve springs Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-10. Rock er arm/camshaft Refer to “CAMSHAFT” on page 5-6.
VALVES AND VALVE SPRINGS 5-17 EAS24280 REMO VING THE V AL V ES The f ollowing procedure applies to all of the v alv es and related components. TIP Bef ore removing the internal par ts of the cylin- der head (e.g ., v alves , v alve springs, v alve seats), mak e sure the v alves properly seal.
VALVES AND VALVE SPRINGS 5-18 2. Replace: •V a l v e g u i d e TIP T o ease v alve guide remov al and installation, and to maintain the correct fit, heat the cylinder head to 100 ° C (212 ° F) in an o ven. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a.
VALVES AND VALVE SPRINGS 5-19 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Eliminate: • Carbon deposits (from the v alv e f ace and valv e seat) 4. Chec k: •V a l v e f a c e Pitting/wear → Grind the v alv e f ace.
VALVES AND VALVE SPRINGS 5-20 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Apply Mechanic’ s b lueing dye (Dyk em) “b” onto the v alv e f ace. b . Install the v alve into the cylinder head. c. Press the v alve through the v alve guide and onto the v alve seat to mak e a clear impression.
VALVES AND VALVE SPRINGS 5-21 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS24310 CHECKING THE V AL VE SPRINGS The f ollowing procedure applies to all of the v alv e springs. 1. Measure: • V alve spring free length “a” Out of specification → Replace the v alve spring.
VALVES AND VALVE SPRINGS 5-22 EAS24340 INST ALLING THE V AL VES The f ollowing procedure applies to all of the v alv es and related components. 1. Debu rr : • V a lv e stem end (with an oil stone) 2. Lubricate: •V a l v e s t e m • V alve stem seal (with the recommended lubricant) 3.
VALVES AND VALVE SPRINGS 5-23 5. T o secure the valv e cotters onto the v alve stem, lightly tap the v alve tip with a soft- f ace hammer . ECA13800 Hitting the v alve tip with e xcessive f orce could damage the v alve .
CYLINDER AND PISTON 5-24 EAS24350 CYLINDER AND PIST ON Removing the cylinder an d pis ton Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-10.
CYLINDER AND PISTON 5-25 EAS24380 REMO VING THE PIST ON 1. Remov e: • Piston pin clips “1” • Piston pin “2” •P i s t o n “ 3 ” ECA13810 Do not use a hammer to drive the piston pin out.
CYLINDER AND PISTON 5-26 b . If out of specification, rebore or replace the cylinder , and replace the piston a nd piston rings as a set. c. Measure piston skir t diameter D “a” with the micrometer . d. If out of specification, replace the piston and piston rings as a set.
CYLINDER AND PISTON 5-27 EAS24440 CHECKING THE PIST ON PIN 1. Chec k: • Piston pin Blue discolora tion/groo ves → Replace the piston pin and then chec k the lubrica- tion system. 2. Measure: • Piston pin outside diameter “a” Out of specification → Replace the piston pin.
CYLINDER AND PISTON 5-28 • Upper oil ring rail “3” • 2nd ring “4” • T op r ing “5” TIP Be sure to install the piston rings so that the “T” marks or numbers f ace up . 2. Install: •P i s t o n “ 1 ” • Piston pin “2” • Piston pin clips “3” TIP • Apply engine oil the piston pin.
CLUTCH 5-29 EAS25061 CLUTCH Removi ng the c l utch co ver Order Job/Parts to remove Q’ty Remarks Engine oil Drain. Refer to “CHANGING THE ENGINE OIL ” on page 3-10.
CLUTCH 5-30 Removi ng the clutch Ord er Job/P ar ts to remove Q’ty Remarks 1C l u t c h s p r i n g 5 2 Pre ssur e pla te 1 3 Pr i mar y driv e gear n ut 1 4 Frict ion plate 6 5 Clutch plate 5 6 Cl .
CLUTCH 5-31 Removing the push leve r shaf t Order Job/Parts to remove Q’ty Remarks Shift pedal Refer to “SHIFT SHAFT” on page 5-42. Left crankcase co v er Refer to “PICKUP COIL RO TOR AND ST ARTER CLU T CH” on page 5- 45.
CLUTCH 5-32 EAS25070 REMO VING THE CLUTCH 1. Remov e: •B o l t “ 1 ” • Clutch spring “2” TIP Loosen the bolts in stages and in a crisscross pattern.
CLUTCH 5-33 TIP Measure the friction plate at f our places . EAS25110 CHECKING THE CLUTCH PLA TES The f ollowing procedure applies to all of the clutch plates .
CLUTCH 5-34 TIP Pitting on the clutch boss splines will cause erratic clutch opera tion. EAS25170 CHECKING THE PRESSURE PLA TE 1. Chec k: • Pressure plate Crac ks/damage → Replace.
CLUTCH 5-35 4. Bend the l ock w asher tab along a flat side of the nut. 5. Lubricate: • F riction plates • Clutch plat es (with the recommended l ubr icant) 6. Instal l: • F riction plates (6 piece) • Clutch plat es (5 piece) TIP First, install a friction pl ate and the n alternate between a clutch plate and a friction plat e.
CLUTCH 5-36 11. Adjust: • Push lever positio n ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Loosen the lo c knut “1”. b . T ur n the adjusti ng screw “2” in or out until the marks are aligned.
CLUTCH 5-37 14. Install: • Right crankcase co ver 15. Install: • Crankc ase co v er bolts M6 × 50 mm “1”, “2” • Copper w ashers to “1”, “2” • Crankc ase co v er bolts M6 × 40 mm “3”– “6” • Crankc ase co v er bolts M6 × 25 mm “7”– “13” • Oil filter element cov er bolt M6 × 70 mm “14” 16.
OIL PUMP 5-38 EAS24911 OIL PUMP Removing the oil pump Order Job/Parts to remove Q’ty Remarks Right crankcase cover /clutch /primar y dr ive gear Refer to “CLUTCH” on page 5-29.
OIL PUMP 5-39 Disassembl e the oil pump Order Job/Parts to remove Q’ty Remarks 1 Oil pump housin g 1 2D o w e l p i n 2 3 O uter rotor 1 4 Inner rotor 1 5D o w e l p i n 1 6S h a f t 1 7O i l p u m p c o v e r 1 F or installation, re verse the remo val proce- dure.
OIL PUMP 5-40 EAS24940 REMO VING THE OIL PUMP 1. Straighten the loc k washer tab . 2. Remov e: • Balancer w eight gear n ut • Loc k washer • Balancer w eight gear TIP Place the aluminium plate “a” betw een bal- ancer drive gear “1” an d balancer weight g ear “2”, and then loosen the balancer w eight gear nut “3”.
OIL PUMP 5-41 • Compression spring • Dow el pin Crac ks/damage/wear → Replace. EAS4D3F018 ASSENBLING THE B ALANCER WEIGHT GEAR 1. Assemble: • Dow el pin “1” • Compression spring “2” TIP Install the dow el pins and compression spr ings alternately as shown as .
SHIFT SHAFT 5-42 EAS25410 SHIFT SHAFT Removing the shift shaft and stoppe r lever Order Job/Parts to remove Q’ty Remarks Right crankcase cover/clutch Refer to “CLUTCH” on page 5-29. 1 Shift pedal 1 2 Shift shaft assembly 1 3 Stopper lev er 1 4 T orsion spr ing 1 For installation, re verse the remova l proce- dure.
SHIFT SHAFT 5-43 EAS 2542 0 CHECKING THE SHIFT SHAFT 1. Chec k: • Shif t shaf t “1” • Shi ft lev er “2” Bends/d amage/wear → Re pl a ce. • Shi ft lev er spr ing Damage/w ear → Replace . EAS 2543 0 CHECKING THE ST OPPER LEVER 1. Chec k: • Stopper l e ver Bends/damag e → Replace .
SHIFT SHAFT 5-44 6. Tighten: • Shif t pedal bolt 7. Adjust: • Shift pedal height Ref er to “ADJUSTING THE SHIFT PED AL ” on page 3-21. Shift pedal bolt 10 Nm (1.
PICKUP COIL ROTOR AND STARTER CLUTCH 5-45 EAS403F008 PICKUP COIL R O T OR AND ST ARTER CLUTCH Removing the pic k up coil rot or and starter clutc h Order Job/Parts to remove Q’ty Remarks Engine oil Drain. Refer to “ENGINE” on page 3-4. Shift pedal Refer to “SHIFT SHAFT” on page 5-42.
PICKUP COIL ROTOR AND STARTER CLUTCH 5-46 EAS403F009 REMO VING THE PICKUPCOIL RO T OR 1. Remov e: • Pic kup coil rot or bolt “1” • W asher TIP • Loosen the pic kup coil rotor bolt “1” while holding the rotor with a sh ea v e holder “2”.
PICKUP COIL ROTOR AND STARTER CLUTCH 5-47 3. Chec k: • Star ter clutch gear’ s contacting surf aces Damage/pitting/w ear → Replace the star ter clutch gear . 4. Chec k: • Star ter clutch operation ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a.
PICKUP COIL ROTOR AND STARTER CLUTCH 5-48 4. Install: • Stator coil “1” •P i c k u p c o i l “ 2 ” 5. Tighten: • Stator coil bolts “3” • Pic kup coil bolts “4” • Left crankcase co ver bolt “5” 6. Install: • Dow el pin • Crankc ase co ver gask et 7.
ELECTRIC STARTER 5-49 EAS24780 ELECTRIC ST ARTER Removing the starter motor Order Job/Parts to remove Q’ty Remarks Exhaust pipe Ref e r to “ENGINE REMO V AL ” o n page 5-1. Star ter idle gear cove r/Star ter idle gear Refer to “PICKUP COIL RO T O R AND ST ARTER CLU T CH” on page 5- 45.
ELECTRIC STARTER 5-50 Disassembling th e st ar te r mo to r Order Job/Parts to remove Q’ty Remarks 1 F ront bracket 1 2 T ang washer 1 3 Plate washer 1 4 Circlip 1 5 Rear brac ket/Brush hol der 1/1 6 Ar m ature assembly 1 7 S t ar t er m ot o r yo ke 1 8B r u s h / s p r i n g 2 / 2 F or assemb ly , re verse the disassembly pro- cedure.
ELECTRIC STARTER 5-51 EAS24790 CHECKING THE ST ARTER MO T OR 1. Chec k: • Commutator Dir t → Clean with 600 grit sandpaper . 2. Measure: • Commutator d iameter “a” Out of specification → Replace t he star ter motor .
ELECTRIC STARTER 5-52 7. Chec k: • Gear teeth Damage/wear → Replace the gear . 8. Chec k: • Bushing • Bearing • Oil seal Damage/wear → Re place the de fectiv e par t(s). EAS24800 ASSEMBLING THE ST ARTER MO T OR 1. Install: • Brush spring “1” •B r u s h “ 2 ” 2.
CRANKCASE 5-53 EAS25540 CRANKCASE Separating the cra nkcase Order Job/Parts to remove Q’ty Remarks Engine Refer to “ENGINE REMO V AL ” on page 5-1. Cylinder head Refer to “CYLINDER HEAD” on page 5-10. Cylinder/pi ston Ref er to “CYLINDER AND PIST ON” on page 5-24.
CRANKCASE 5-54 Removing the bearing Order Job/Parts to remove Q’ty Remarks Cranks haft assemb ly Refer to “CRANKSHAFT ASSEMBL Y” on page 5-57. Main axle assembly/drive axle assemb ly Refer to “TRANSMISSION” on page 5-61. 1 Oil seal 2 2 Bearing 8 F or assembly , re verse the remo val proce- dure.
CRANKCASE 5-55 EAS25570 DISASSEMBLING THE CR ANKCASE 1. Remov e: • Timing chain guide (intak e side) “1” • Timing chain “2” • Crankshaft sproc ket “3” 2.
CRANKCASE 5-56 3. Install: • Right crankcase (onto the left cr ankcase) TIP T ap lightly on the right crankcase with a soft- fa c e h a m m e r. 4. Install: • Crankcase bolt M6 × 70 mm: “1”–“3” • Copper w ashers T o “1”–“3”.
CRANKSHAFT ASSEMBLY 5-57 EAS25970 CRANKSHAFT ASSEMBL Y Removi ng the crankshaf t assembl y Order Job/Parts to remove Q’ty Remarks Crankcase Ref er to “CRANKCASE” on page 5-53. 1 Balancer weight 1 2 C rankshaft assemb ly 1 3D o w e l p i n 1 4 Plunger seal 1 5 Bearing 1 F or installation, rev erse the removal proce- dure.
CRANKSHAFT ASSEMBLY 5-58 EAS25990 REMO VING THE CRANKSHAFT ASSEMBL Y 1. Remov e: • Balancer w eight • Crankshaft a ssemb ly “1” TIP • Remov e the crankshaft assemb ly with the crankcase separ ating tool “2”. • Mak e sure the crankcase separ ating tool is centered ov er the crankshaft assemb ly .
CRANKSHAFT ASSEMBLY 5-59 4. Chec k: • Crankshaft sproc ket Damage/wear → Replace the crankshaft. • Bearing Crac ks/damage/wear → Replace the crankshaft. 5. Chec k: • Crankshaft journal Scratches/w ear → Replace the cr ank- shaft. • Crankshaft journal oil passage Obstr uction → Blow out with compressed air .
CRANKSHAFT ASSEMBLY 5-60 TIP Install the crankshaft assemb ly with the crank- shaft installer pot “2”, cr ankshaft installer bolt “3”, adapter “4” and spacer “5”.
TRANSMISSION 5-61 EAS26241 TRANSMISSION Removing the transm ission, s hift drum asse mbly , and shift forks Order Job/Parts to remove Q’ty Remarks Crank case Separate .
TRANSMISSION 5-62 Disassembl ing the transmi ssion Order Job/Parts to remove Q’ty Remarks 1 2nd pinion gear 1 2 5th pinio n gear 1 3 3rd pinion gear 1 4 Circlip/washer 1/1 5 4th pinio n gear 1 6 Mai.
TRANSMISSION 5-63 EAS26250 REMO VING THE TRANSMISSION 1. Remov e: • Shift f or k guide bar “1” • Shift drum assembly “2” • Shift f or k 3 (R) “3” • Shift f or k 2 (C) • Shift f or k 1 (L) “4” 2.
TRANSMISSION 5-64 EAS26280 CHECKING THE TRANSMISSION 1. Measure: • Main axle runout (with a centering de vice and dial gauge) Out of specification → Replace t he main axle. 2. Measure: • Drive a xle runout (with a centering de vice and dial gauge) Out of specification → Replace the driv e axle.
TRANSMISSION 5-65 EAS26320 INST ALLING THE SHIFT FORKS AND SHIFT DRUM ASSEMBL Y 1. Install: • T ransmission “1” • Shift f or k 1 (L) “2” • Shift f or k 2 (C) • Shift f or k 3 (R) “3�.
6 FUEL SYSTEM FUEL T ANK .......... .......................................... .......................................... .... 6-1 REMO VING THE FUEL T A NK .................. .............................................. 6-2 CHECKING THE FUEL COCK .
FUEL TANK 6-1 EAS26620 FUEL T ANK Removing the fuel tank Order Job/Parts to remove Q’ty Remarks Seat/front fender Refer to “GENERAL CHASSIS” on page 4-1. 1 Fuel hose (fuel cock side) 1 2F u e l t a n k 1 3C l a m p 1 4 Fuel tank shield 1 For installation, re verse the remov al proce- dure.
FUEL TANK 6-2 EAS26630 REMO VING THE FUEL T ANK 1. Remov e: • Fuel hose (fuel coc k side) ECA14700 Although the fuel has been removed fr om the fuel tank be careful when remo ving the fuel hoses, since there ma y be fuel remaining in it.
CARBURETOR 6-3 EAS26720 CARBURET OR Removi ng the carb uretor Order Job/Parts to remove Q’ty Remarks Seat/front fender/rear f ende r/air filter case Refer to “GENERAL CHASSIS” on page 4-1. 1 Carburetor wa rm er couple r 1 Disco nnect. 2 Air vent hose 1 Disconnect.
CARBURETOR 6-4 Disassembling t he carburetor Order Job/Parts to remove Q’ty Remarks 1 D rain hose 1 2 Throttle stop screw 1 3C o v e r 1 4 Diaphragm spring 1 5P i s t o n v a l v e 1 6 Jet needle 1 7C o v e r 1 8S p r i n g 1 9 Coasting enr icher diaphragm 1 10 C oasting enriche r jet (P .
CARBURETOR 6-5 23 Star ter jet 1 For assemb ly , re verse the disassembly pro- cedure. Disassembling t he carburetor Order Job/Parts to remove Q’ty Remarks.
CARBURETOR 6-6 EAS26760 CHECKING THE CARBURET OR 1. Chec k: • Carb uretor body • Float cham b er Crac ks/damage → Replace. • Float chamber body Contamination → Clean. 2. Chec k: • Fuel passages Obstr uction → Clean. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a.
CARBURETOR 6-7 8. Chec k: • Jet needle “1” Bends/wear/damage → Replace . • Clip groo ve F ree pla y/wear → Replace. 9. Chec k: • Main jet “1” • Pilot jet “2” • Needle jet “3” • Needle jet holde r “4” • Star ter jet “5” • Coasting enricher jet (P .
CARBURETOR 6-8 c. If the float height is not with in the specifica- tion, chec k the v alv e seat and needle v alv e . d. If either is wo r n, replace the v alve seat, needle v alve and O-ring as a set. e. If both are fine , adjust the float height by bending the float tang “1” on the float.
CARBURETOR 6-9.
7 ELECTRICAL SYSTEM IGNITION SYSTEM ......................................................................... .............. 7-1 CIRCUIT DIA GRAM ............. ................................................................... 7-1 TR OUBLESHOO TING .
IGNITION SYSTEM 7-1 EAS27090 IGNITION SYSTEM EAS27100 CIRCUIT DIA GRAM.
IGNITION SYSTEM 7-2 1. Pick up coil 2. Stator co il 4. Main s witc h 5. Batter y positiv e lead 6. Battery 7. Fuse 10.CDI unit 11. I gnition coil 12.Spar k plug 24.
IGNITION SYSTEM 7-3 EAS27130 TR OUBLESHOO TING The ignition system f ails to operate (no spark or intermittent spar k). TIP • Bef ore troubleshooting, remo v e the f ollowing par t(s): 1.
IGNITION SYSTEM 7-4 NG → OK ↓ NG → OK ↓ NG → OK ↓ NG → OK ↓ NG → OK ↓ NG → OK ↓ NG → OK ↓ 8. Check the stator coil. Ref er to “CHECKING THE ST A T OR COIL ” on page 7-40. Replace the stator assemb ly . 9. Check the main s witch.
ELECTRIC STARTING SYSTEM 7-5 EAS27160 ELECTRIC ST ARTI NG SYSTEM EAS27170 CIRCUIT DIA GRAM.
ELECTRIC STARTING SYSTEM 7-6 4. Main s witc h 5. Batter y positiv e lead 6. Battery 7. Fuse 8. Star ter rela y 9. Star ter motor 13.Star t ing circuit cut-off rela y 14.
ELECTRIC STARTING SYSTEM 7-7 EAS27180 ST ARTING CIRCUIT CUT -OFF SYSTEM OPERA TION If the engine stop s witch is set to “ ” and the main s witch is set to “ON” (both s witches are closed), the.
ELECTRIC STARTING SYSTEM 7-8 a. WHEN THE TRANSMISSION IS IN NEU- TRAL b . WHEN THE CLUTCH LEVER IS PULLED T O THE HANDLEBAR 1. Battery 2. Fuse 3. Main s witc h 4. Engine stop s witch 5. Star ting circui t cut -o ff re lay 6. Clutch s witch 7. Neutral s witch 8.
ELECTRIC STARTING SYSTEM 7-9 EAS27190 TR OUBLESHOO TING The star ter motor f ails to turn. TIP • Bef ore troubleshooting, remo v e the f ollowing par t(s): 1. Seat 2. F ront panel 3. F ront f ender 4. Rear f ender 5. Side cov er NG → OK ↓ NG → OK ↓ OK → NG ↓ NG → OK ↓ NG → OK ↓ NG → OK ↓ NG → OK ↓ 1.
ELECTRIC STARTING SYSTEM 7-10 NG → OK ↓ NG → OK ↓ NG → OK ↓ NG → OK ↓ NG → OK ↓ NG → OK ↓ 8. Check the main s witch. Ref er to “CHECKING THE SWITCHES” on page 7-29. Replace the main s witch. 9. Check the engine stop s witch.
CHARGING SYSTEM 7-11 EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIA GRAM.
CHARGING SYSTEM 7-12 2. Stator co il 3. Rectifier/regulator 5. Batter y positiv e lead 6. Battery 7. Fuse 28.Ground.
CHARGING SYSTEM 7-13 EAS27230 TR OUBLESHOO TING The battery is not being charged. TIP • Bef ore troubleshooting, remo v e the f ollowing par t(s): 1. Seat 2. F ront panel 3. F ront f ender 4. Rear f ender 5. Side cov er NG → OK ↓ NG → OK ↓ NG → OK ↓ NG → OK ↓ NG → OK ↓ 1.
CHARGING SYSTEM 7-14.
LIGHTING SYSTEM 7-15 EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIA GRAM.
LIGHTING SYSTEM 7-16 2. Stator co il 3. Rectifier/regulator 4. Main s witc h 5. Batter y positiv e lead 6. Battery 7. Fuse 21.T ail/brak e light 23. L ight switch 26.
LIGHTING SYSTEM 7-17 EAS27260 TR OUBLESHOO TING Any of the f ollowing f ail to light: headlight, tail/brak e light. TIP • Bef ore troubleshooting, remo v e the f ollowing par t(s): 1. Seat 2. F ront panel 3. F ront f ender 4. Rear f ender 5. Side cov er NG → OK ↓ NG → OK ↓ NG → OK ↓ NG → OK ↓ NG → OK ↓ NG → OK ↓ 1.
LIGHTING SYSTEM 7-18 NG → OK ↓ 7. Check the entire lighting system’ s wiring. Ref er to “CIRCUIT DIA GRAM” on page 7-15. Properly connect or repair the lighting system’ s wir ing.
SIGNALING SYSTEM 7-19 EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIA GRAM.
SIGNALING SYSTEM 7-20 4. Main s witc h 5. Batter y positiv e lead 6. Battery 7. Fuse 17.N eutral indicator light 18.N eutral s witch 19.Rear brake l ight switch 20.
SIGNALING SYSTEM 7-21 EAS27290 TR OUBLESHOO TING Any of the f ollowing f ail to light: brak e light or an indicator light. TIP • Bef ore troubleshooting, remo v e the f ollowing par t(s): 1. Seat 2. F ront f ender NG → OK ↓ NG → OK ↓ NG → OK ↓ NG → OK ↓ Check the signaling system The tail/brak e light f ails to come on.
SIGNALING SYSTEM 7-22 NG → OK ↓ The neutral indicator light f ails to come. NG → OK ↓ NG → OK ↓ NG → OK ↓ 3. Check the entire signalin g system’ s wiring. Ref er to “CIRCUIT DIA GRAM” on page 7-19. Properly connect or repair the signal- ing system’ s wiring.
CARBURETOR HEATING SYSTEM 7-23 EAS27490 CARBURET OR HEA TING SYSTEM EAS27500 CIRCUIT DIA GRAM.
CARBURETOR HEATING SYSTEM 7-24 4. Main s witc h 5. Batter y positiv e lead 6. Battery 7. Fuse 15.Ther mo swit ch 16. Carburetor war me r 28.Ground.
CARBURETOR HEATING SYSTEM 7-25 EAS27510 TR OUBLESHOO TING The carburet or heating system f ails to oper ate. TIP • Bef ore troubleshooting, remo v e the f ollowing par t(s): 1. Seat 2. F ront panel 3. F ront f ender 4. Rear f ender 5. Side cov er NG → OK ↓ NG → OK ↓ NG → OK ↓ NG → OK ↓ NG → OK ↓ NG → OK ↓ 1.
CARBURETOR HEATING SYSTEM 7-26.
ELECTRICAL COMPONENTS 7-27 EAS27972 ELECTRICAL COMPONENTS.
ELECTRICAL COMPONENTS 7-28 1. Main s witc h 2. F ront brak e light switch 3. Clutch s witch 4. Handlebar s witch 5. CDI unit 6. Star ter rela y 7. Fuse 8. Battery 9. T ail/brak e light 10.Headlight relay 11.Star t ing circuit cut-off rela y 12.Ther mo swit ch 13.
ELECTRICAL COMPONENTS 7-29 EAS27980 CHECKING THE SWITCHES.
ELECTRICAL COMPONENTS 7-30 1. Light s witch 2. Engine stop s witch 3. Star t s witch 4. Main s witc h 5. F ront brak e light switch 6. Clutch s witch 7.
ELECTRICAL COMPONENTS 7-31 Check each s witch f or continuity with the poc ket tester . If the continuity reading is incorre ct, chec k the wiring connections and if necessar y , replace the switch. ECA14370 Never insert the tester pr obes into the coupler terminal sl ots “a”.
ELECTRICAL COMPONENTS 7-32 EAS27990 CHECKING THE BULBS AND BULB SOCK- ETS Check each b ulb and bulb soc ket f or damage or wear , proper conne ctions, an d also f or conti- nuity betw een the terminals. Damage/wear → Repair or replace the b ulb , bulb soc ket or both.
ELECTRICAL COMPONENTS 7-33 Checking the condition of the b ulb sockets The f ollowing procedure applies to all of the bul b s o cket s. 1. Chec k: • Bulb soc k et (f or continuity) (with the poc ke t tester) No continuity → Replace .
ELECTRICAL COMPONENTS 7-34 Therefore, al wa ys f ollow these pre ventive measures: • W ear protective e ye gear when handling or wo rking near batteries. • Charge batteries in a we ll-ventilated area. • Keep ba tteries awa y from fire, sparks or open flames (e.
ELECTRICAL COMPONENTS 7-35 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Charge: • Batter y (ref er to the appropriate charging method illustration) W ARNING EW A13300 Do not quick char g e a battery .
ELECTRICAL COMPONENTS 7-36 TIP V oltage should be measured 30 min utes after the machine is stopped. b . Connect a charged and AMP meter t o the battery and star t charging. TIP Set the charging v oltage at 16–17 V .If the set- ting is lo w er , charging will be insuffi cient.
ELECTRICAL COMPONENTS 7-37 9. Lubricate: • Batter y ter minals 10. Install: • Batter y cov er • Seat Ref er to “GENERAL CHASSIS” on page 4-1. EAS28040 CHECKING THE RELA YS Check each s witch f or continuity with the pock et tester . If the continuity reading is incor- rect, replace the rela y .
ELECTRICAL COMPONENTS 7-38 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the star ting circuit cut-off relay from the wire harness. b . Connect the poc ket tester ( Ω × 1) to the diode coup ler as shown.
ELECTRICAL COMPONENTS 7-39 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the spark plug cap from the ignition coil. b . Connect the poc ket tester ( Ω × 1k) to the ignition coil as shown. c.
ELECTRICAL COMPONENTS 7-40 b . Measure the pic kup coil resistance . ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS28940 CHECKING THE ST ARTER MO T OR OPERA- TION 1.
ELECTRICAL COMPONENTS 7-41 EAS28170 CHECKING THE RECTIFIER/REGULA TOR 1. Chec k: • Rectifier/regulator outp ut v oltage Out of specification → Replace t he recti- fier/regulator . ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a.
ELECTRICAL COMPONENTS 7-42 EAS28310 CHECKING THE CARBURET OR W ARMER 1. Chec k: • Carb uretor warmer resistance Out of specification → Replace . ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remov e the carburetor w ar mer from the carbureto r .
ELECTRICAL COMPONENTS 7-43.
8 TR OUBLESHOO TING TR OUBLESHOO TING .............................................. .................................... 8-1 GENERAL INFORMA TION ................................. .................................... 8-1 ST AR TING F AILURES ........
TROUBLESHOOTING 8-1 EAS28451 TR OUBLESHOO TING EAS28460 GENERAL INFORMA TION TIP The f ollowing guide f or trouble shooting does not cov er all the possib le causes of troub le.
TROUBLESHOOTING 8-2 EAS28490 INCORRECT ENGINE IDLING SPEED Engine 1. Cylinder and cylinder head • Incorrect v alve cleara nce • Damaged v alve tr ain components 2. Air filter • Clogged air filte r element • Loosen air filter joint Fuel system 1.
TROUBLESHOOTING 8-3 • Incorrect oil le vel • Incorrect oil viscosity (low ) • Deteriorated oil Clutch drags 1. Clutch • Une venly tensioned clutch springs • W ar ped pressure plate • Bent .
TROUBLESHOOTING 8-4 • F aulty batter y • F aulty rectifier/regulator • Improperly grounded circuit • F aulty main s witch • F aulty light s witch • Headlight b ulb lif e expired T ail/brak.
EAS28740 WIRING DIA GRAM YFM25R Y/YFM25RSEY/ YFM25RSE2Y 1. Pickup coil 2. Stator coil 3. Rectifier/regulator 4. Main switch 5. Batter y positive lead 6. Battery 7. Fuse 8. Star ter rela y 9. Star ter motor 10. CDI unit 11. Ignition coil 12. Spark plug 13.
.
YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN.
WIRING DIAGRAM YFM25RY/YFM25RSEY/YFM25RSE2Y.
Ein wichtiger Punkt beim Kauf des Geräts Yamaha YFM25RSEY (oder sogar vor seinem Kauf) ist das durchlesen seiner Bedienungsanleitung. Dies sollten wir wegen ein paar einfacher Gründe machen:
Wenn Sie Yamaha YFM25RSEY noch nicht gekauft haben, ist jetzt ein guter Moment, um sich mit den grundliegenden Daten des Produkts bekannt zu machen. Schauen Sie zuerst die ersten Seiten der Anleitung durch, die Sie oben finden. Dort finden Sie die wichtigsten technischen Daten für Yamaha YFM25RSEY - auf diese Weise prüfen Sie, ob das Gerät Ihren Wünschen entspricht. Wenn Sie tiefer in die Benutzeranleitung von Yamaha YFM25RSEY reinschauen, lernen Sie alle zugänglichen Produktfunktionen kennen, sowie erhalten Informationen über die Nutzung. Die Informationen, die Sie über Yamaha YFM25RSEY erhalten, werden Ihnen bestimmt bei der Kaufentscheidung helfen.
Wenn Sie aber schon Yamaha YFM25RSEY besitzen, und noch keine Gelegenheit dazu hatten, die Bedienungsanleitung zu lesen, sollten Sie es aufgrund der oben beschriebenen Gründe machen. Sie erfahren dann, ob Sie die zugänglichen Funktionen richtig genutzt haben, aber auch, ob Sie keine Fehler begangen haben, die den Nutzungszeitraum von Yamaha YFM25RSEY verkürzen könnten.
Jedoch ist die eine der wichtigsten Rollen, die eine Bedienungsanleitung für den Nutzer spielt, die Hilfe bei der Lösung von Problemen mit Yamaha YFM25RSEY. Sie finden dort fast immer Troubleshooting, also die am häufigsten auftauchenden Störungen und Mängel bei Yamaha YFM25RSEY gemeinsam mit Hinweisen bezüglich der Arten ihrer Lösung. Sogar wenn es Ihnen nicht gelingen sollte das Problem alleine zu bewältigen, die Anleitung zeigt Ihnen die weitere Vorgehensweise – den Kontakt zur Kundenberatung oder dem naheliegenden Service.
