Yamaha XVS250 2001 Service Manual

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Page 3 EB000000 XVS250 SERVICE MANUAL 2000 by Yamaha Motor Co.,Ltd. First edition, September 2000 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
Page 4 It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha mo- torcycles has a basic understanding of the mechanical ideas and the procedures of motorcycle repair.
Page 5 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. 1 The manual is divided into chapters.
Page 6 EAS00009 SYMBOLS The following symbols are not relevant to every SPEC vehicle. INFO Symbols 1 to 8 indicate the subject of each chapter. 1 General information 2 Specifications CHAS 3 Periodic checks and adjustments 4 Chassis 5 Engine 6 Carburetor(-s) 7 Electrical system CARB 8 Troubleshooting...
Page 7 EAS00011 INDEX GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC CHECKS AND ADJUSTMENTS CHASSIS CHAS ENGINE CARBURETOR CARB ELECTRICAL SYSTEM ELEC TROUBLESHOOTING TRBL SHTG...
Page 10: Table Of Contents
INFO CHAPTER 1. GENERAL INFORMATION MOTORCYCLE IDENTIFICATION ....... VEHICLE IDENTIFICATION NUMBER .
Page 11 INFO...
Page 12: General Information
MOTORCYCLE IDENTIFICATION INFO EB100000 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION EB10010 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head. MODEL CODE The model code label 1 is affixed to the frame. This information will be needed to order spare parts.
Page 13: Important Information
5. Keep all parts away from any source of fire. EB101010 REPLACEMENT PARTS 1. Use only genuine Yamaha parts for all re- placements. 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.
Page 14: Lock Washer/Plate And Cotter Pins
IMPORTANT INFORMATION INFO EB101030 LOCK WASHERS/PLATES AND COTTER PINS 1. Replace all lock washers/plates 1 and cot- ter pins after removal. Bend lock tabs along the bolt or nut flats after the bolt or nut has been tightened to specification. EB101040 BEARINGS AND OIL SEALS 1.
Page 15: Checking The Connections
CHECKING THE CONNECTIONS INFO EB103000 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: D lead D coupler D connector 2. Check: D lead D coupler D connector Moisture Dry with an air blower. Rust/stains Connect and disconnect sev- eral times.
Page 16: Special Tools
SPECIAL TOOLS INFO EB102001 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools; this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools may differ by shape and part number from country to country. In such a case, two types are provided.
Page 17 SPECIAL TOOLS INFO Tool No. Tool name / How to use Illustration Sheave holder 90890-01701 This tool is needed to hold the rotor, when removing or installing the rotor bolt. Clutch holding tool 90890-04086 This tool is heed to hold the clutch when removing or installing the clutch boss nut.
Page 18 Ignition checker 90890-06754 This instrument is necessary for checking the ignition system components. Compression gauge set 90890-03081 These tools are needed to measure engine compression. Yamaha bond No.1215 90890-85505 This sealant (bond) is used for crankcase mat- ing surfaces, etc.
Page 21 SPEC CHAPTER 2. SPECIFICATIONS GENERAL SPECIFICATIONS ........ENGINE SPECIFICATIONS .
Page 22 SPEC...
Page 23: Chapter 2. Specifications
SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Limit Model code 5KR2 Dimensions Overall length 2,320 mm Overall width 910 mm Overall height 1,075 mm Seat height 670 mm Wheelbase 1,530 mm Minimum ground clearance 150 mm Minimum turning radius 2,900 mm Weight Wet (with oil and a full fuel tank)
Page 24: Engine Specifications
SPEC ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS Item Standard Limit Engine Engine type Air-cooled, 4-stroke, SOHC Displacement 249 cm Cylinder arrangement V-2 cylinder Bore stroke 66 mm Compression ratio 10.0 : 1 1,200 X 1,400 r/min Engine idling speed Vacuum pressure at engine idling 48 kPa (0.48 kg/cm speed Standard compression pressure...
Page 25 SPEC ENGINE SPECIFICATIONS Item Standard Limit Starting system type Electric starter Spark plugs Model (manufacturer) quantity CR6HSA (NGK), U20FSR-U (DENSO) 0.6 X 0.7 mm Spark plug gap Cylinder head Max. warpage 0.03 mm Camshafts Drive system Chain drive (left and right) 22.000 X 22.021 mm Camshaft cap inside diameter 21.96 X 21.98 mm...
Page 26 SPEC ENGINE SPECIFICATIONS Item Standard Limit Timing chain Model/number of links SILENT CHAIN/110 Tensioning system Automatic Rocker arm/rocker arm shaft 10.000 X 10.015 mm Bearing inside diameter 10.035 mm 9.981 X 9.991 mm Shaft outside diameter 9.961 mm 0.009 X 0.034 mm Arm-to-shaft clearance 0.08 mm Valves, valve seats, valve guides...
Page 27 SPEC ENGINE SPECIFICATIONS Item Standard Limit Valve springs Free length Intake 29.75 mm 28.75 mm Exhaust 29.75 mm 28.75 mm Installed length (valve closed) Intake 25.7 mm Exhaust 25.7 mm Compressed spring force (installed) 71.7 X 79.3 N (71.7 X 7.93 kg) Intake 71.7 X 79.3 N (71.7 X 79.3 kg) Exhaust...
Page 28 SPEC ENGINE SPECIFICATIONS Item Standard Limit Pistons 0.02 X 0.03 mm Piston-to-cylinder clearance 0.15 mm 48.965 X 49.005 mm Diameter D Height H 6 mm Piston pin bore (in the piston) 13.002 X 13.013 mm Diameter 13.045 mm Offset 0.5 mm Offset direction Intake side Piston pins...
Page 29 SPEC ENGINE SPECIFICATIONS Item Standard Limit Connecting rods 0.020 X 0.048 mm Crankshaft-pin-to-big-end-bearing clearance Crankshaft 67.95 X 68.00 mm Width A Max. runout C 0.03 mm 0.40 X 1.05 mm Big end side clearance D 0.020 X 0.048 mm Crankshaft-journal-to-crankshaft- journal-bearing clearance E Clutch Clutch type...
Page 30 SPEC ENGINE SPECIFICATIONS Item Standard Limit Transmission Transmission type Constant mesh, 5-speed Primary reduction system Spur gear Primary reduction ratio 72/23 (3.130) Secondary reduction system Chain drive Secondary reduction ratio 56/20 (2.800) Operation Left-foot operation Gear ratios 1st gear 37/14 (2.643) 2nd gear 32/19 (1.684) 3rd gear...
Page 31: Chassis Specifications
SPEC CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS Item Standard Limit Frame Frame type Double cradle 35_ 0’ Caster angle Trail 135 mm Front wheel Wheel type Spoke wheel Size 1.60 Material Steel Wheel travel 140 mm Wheel runout Max. radial wheel runout 2.0 mm Max.
Page 32 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Front brakes Brake type Single-disc brake Operation Right-hand operation 5 X 8 mm Brake lever free play (at lever end) Recommended fluid DOT 4 Brake discs Diameter thickness 5 mm Min. thickness 4.5 mm Max.
Page 33 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Swingarm Free play (at the end of the swingarm) Radial 1.0 mm Axial 1.0 mm Drive chain Model (manufacturer) 428 V (DID) Link quantity 30 X 40 mm Drive chain slack Maximum ten-link section 129.5 mm 2-11...
Page 34: Electrical Specificatons
SPEC ELECTRICAL SPECIFICATIONS ELECTRICAL SPECIFICATIONS Item Standard Limit System voltage 12 V Ignition system Ignition system type Ignition timing 8_ BTDC at 1,300 r/min Advancer type Digital 192 X 288 Ω/L/Y – G/W Pickup coil resistance/color Transistorized coil ignition unit model TNDF62 (DENSO) (manufacturer) Ignition coils...
Page 35 SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit Indicator light 12 V 1.7 W Meter light 12 V 1.7 W Electric starting system System type Constant mesh Starter motor Model Power output 0.4 kW Brushes Overall length 10 mm 3.5 mm 5.52 X 8.28 N (563 X 844 gf) Spring force 0.0171 X 0.0209 Ω...
Page 36: General Torque Specifications
GENERAL TORQUE SPECIFICATIONS/ SPEC CONVERSION TABLE EB202001 EAS00028 GENERAL TORQUE CONVERSION TABLE SPECIFICATIONS All specification data in this manual are listed in SI and METRIC UNITS. This chart specifies torque for standard fasten- Use this table to convert METRIC unit data to ers with standard I.S.O.
Page 37 SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Tightening torques Tightening Thread torque Part to be tightened Part name Q’ty Remarks size size mDkg Cylinder head and cylinder Bolt Cylinder head (timing chain side, long) Bolt Cylinder head (timing chain side, short) Bolt Cam sprocket cover (hexagon) Bolt...
Page 38 SPEC MAINTENANCE SPECIFICATIONS Tightening Thread torque Part to be tightened Part name Q’ty Remarks size size mDkg Push lever axle Screw Drive sprocket Shift drum segment Screw 0.38 Shift arm Bolt Shift pedal adjuster 1 of 2 has LH thread Neutral switch Stater coil Screw...
Page 39: Maintenance Specifications
SPEC MAINTENANCE SPECIFICATIONS Cylinder head tightening sequence: Crankcase tightening sequence: 2-17...
Page 40 SPEC MAINTENANCE SPECIFICATIONS CHASSIS Tightening torques Tightening torque Thread Part to be tightened Part to be tightened Remarks Remarks size mDkg Upper bracket and inner tube Upper bracket and steering shaft 11.0 Ring nut (steering shaft) See NOTE Under bracket and inner tube Main switch and frame Front wheel axle shaft pinch bolt Front brake master cylinder and bracket...
Page 41 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Thread Part to be tightened Part to be tightened Remarks Remarks size mDkg Fuel cock and tank Fuel tank bracket and frame Speedometer setting nut Speedometer cable Riders seat Passenger seat Front wheel axle shaft Rear wheel axle shaft and nut 10.4 Front brake caliper and front fork...
Page 42: Engine
Oil pump rotor (inner/outer), housing Starter idle gear Starter idle gear shaft Push rod 1, 2 Transmission gear (wheel/pinion) Shift cam Shift fork/guide bar Shift shaft assembly Push rod ball Push lever assembly Crankcase mating surface Yamaha bond No.1215 2-20...
Page 43: Chassis
SPEC LUBRICATION POINTS AND LUBRICANT TYPES EB203010 CHASSIS Lubrication point Symbol Steering head pipe (upper/lower), bearing Steering head pipe, bearing cover lip Steering head pipe, oil seal lip Front wheel oil seal lip (right/left) Rear wheel oil seal lip Clutch hub fitting area Rear brake pedal shaft Shift pedal shaft Sidestand bolt, sidestand sliding surface...
Page 44: Engine Oil Lubrication Chart Specifications
ENGINE OIL LUBRICATION CHART SPEC SPECIFICATIONS ENGINE OIL LUBRICATION CHART SPECIFICATIONS Item Standard Lubrication chart: Connecting rod big end Pressure feed Splashed Crankshaft #1 Cam shaft #2 Cam shaft Drive axle Main axle Bypass valve Oil filter Relief valve Oil pump Oil pan 2-22...
Page 45: Engine Oil Flow Diagrams
SPEC ENGINE OIL FLOW DIAGRAMS EB205000 ENGINE OIL FLOW DIAGRAMS 2-23...
Page 46 SPEC ENGINE OIL FLOW DIAGRAMS 2-24...
Page 47 SPEC ENGINE OIL FLOW DIAGRAMS 2-25...
Page 48: Cable Routing
SPEC CABLE ROUTING CABLE ROUTING Rectifier/ regulator A Clamp the vacuum hose. Ignition coil #1 Avoid the bold section. Ignition coil lead B To the carburetor joint. Front brake light switch lead C Connect the ignition coil lead. Right handlebar switch lead (orange lead: upper) Brake hose (red lead: lower)
Page 49 SPEC CABLE ROUTING Headlight lead Throttle position sensor lead Throttle cable Clutch switch lead Carburetor heater lead Ground connection lead Left handlebar switch lead Carburetor heater ground lead Battery negative (–) lead Clutch cable Flasher relay Alarm lead Starter cable Headlight relay Starter motor lead Speedometer...
Page 50 SPEC CABLE ROUTING C Face the clip end to inward. I Clamp the wireharness, throttle O Connect the ignition coil leads. D Route the speedometer cable, position sensor lead and carbu- (gray lead: upper) speedometer leads and fuel tank retor heater lead to the frame. (red lead: lower) breather hose through the hole J Put the throttle position sensor...
Page 51 SPEC CABLE ROUTING Throttle cable A Through the speedometer cable G Clamp the rectifier / regulator Brake hose between frame of tank rail and lead and tail / brake light lead. Speedometer cable wireharness. Clamp end faces to bottom. Fuel tank breather hose B To the engine.
Page 52 SPEC CABLE ROUTING L Clamp the wireharness, high P Clamp the wireharness, left tersion code (#2) and throttle handlebar switches lead, clutch position sensor lead. switch lead, right handlebar M To the speedometer. switches lead, front brake switch N Clamp the wireharness, left lead, throttle cable, starter cable handlebar switches lead, clutch and thermo switch lead.
Page 53 SPEC CABLE ROUTING Speedometer lead Carburetor heater lead A Route the front brake switch lead Left handlebar switches lead Throttle position sensor lead through the hole of frame from Right handlebar switches lead Ignition coil (#1) lead inside to outside. Clutch switch lead Horn lead B Clamp the white tape section of...
Page 54 SPEC CABLE ROUTING Throttle cables A Route the clutch cable through Brake hose forward of head pipe and outside Right handlebar switches of throttle cables. Front brake switch lead Clutch switch lead Left handlebar switch lead Starter cable Clutch cable Headlight lead 2-32...
Page 55 SPEC CABLE ROUTING Vacuum hose 2 A White paint mark of hose faces Air cut-off valve to the top. Hose 1 B Aligh the white paint mark of Air cleaner assembly hose and arrow mark of nozzle. Nozzle C Clamp the vacuum hose 2. Vacuum hose 1 Avoid connecting the bold Hose 2...
Page 58 CHAPTER 3. PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION ..........PERIODIC MAINTENANCE/LUBRICATON INTERVALS .
Page 59 LUBRICATING THE LEVERS AND PEDALS ....3-39 LUBRICATING THE SIDESTAND ......3-39 LUBRICATING THE REAR SUSPENSION .
Page 60 D The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead. D From 50,000 km, repeat the maintenance intervals starting from 10,000 km. D Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. EB301000...
Page 61 PERIODIC MAINTENANCE/LUBRICATION INTERVALS ODOMETER READING (x 1,000 km) ANNUAL ITEM ITEM CHECKS OR MAINTENANCE JOB CHECKS OR MAINTENANCE JOB CHECK Engine oil filter D Replace. element Front and rear brake D Check operation. awitches Moving parts and D Lubricate. cables D Check the air cut valve and reed valve for damage.
Page 62: Rider And Passenger Seats
RIDER AND PASSENGER SEATS RIDER AND PASSENGER SEATS 7 Nm (0.7 mSkg, 5.1 ftSlb) 20 Nm (2.0 mSkg, 14 ftSlb) Order Job/Part Q’ty Remarks Removing the rider and passenger Remove the parts in the order listed. seats Passenger seat Seat bracket Rider’s seat For installation reverse the removal procedure.
Page 63: Fuel Tank And Air Filter
FUEL TANK AND AIR FILTER FUEL TANK AND AIR FILTER 7 Nm (0.7 mSkg) 23 Nm (2.3 mSkg) Order Job/Part Q’ty Remarks Removing the fuel tank and air filter Remove the parts in the order listed. Rider and passenger seats Refer to “RIDER AND PASSENGER SEATS”.
Page 64: Removal
FUEL TANK AND AIR FILTER REMOVAL 1. Remove: S Ignitor plate NOTE: To remove the quick fastener, push its center in with a screwdriver, then pull the fastener out. INSTALLATION 1. Install: S Ignitor plate NOTE: To install the quick fastener, push its pin so that it protrudes from the fastener head, then insert the fastener into the cowling and push the pin a in with a screwdriver.
Page 65: Engine
ADJUSTING THE VALVE CLEARANCE EAS00047 ENGINE ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: D Valve clearance adjustment should be made on a cold engine, at room temperature. D When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke.
Page 66 ADJUSTING THE VALVE CLEARANCE 6. Remove: S tappet covers 1 7. Remove: S camshaft sprocket cover (front cylinder) 1 S camshaft sprocket cover (rear cylinder) 8. Remove: S timing plug 1 S straight plug 2 9. Measure: S valve clearance Out of specification Adjust.
Page 67 ADJUSTING THE VALVE CLEARANCE a. Turn the crankshaft counterclockwise. b. When the piston is at TDC on the compres- sion stroke, align either the alignment mark in the camshaft sprocket (front cylinder) a or alignment mark in the camshaft sprocket (rear cylinder) c , dependant on which cylin- der you are checking, with the stationary pointer b on the cylinder head.
Page 68: Adjusting The Engine Idling Speed
ADJUSTING THE VALVE CLEARANCE/ ADJUSTING THE ENGINE IDLING SPEED Locknut: 7 Nm (0.7 mkg) 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.
Page 69 ADJUSTING THE IDLING SPEED a. Turn the pilot screw in or out until it is lightly seated. b. Turn the pilot screw out the specified number of turns. Pilot screw 2 5/8 turns out c. Turn the throttle stop screw 1 in direction a or b until the specified engine idling speed is obtained.
Page 70: Adjusting The Throttle Cable Free Play
ADJUSTING THE THROTTLE CABLE FREE PLAY EAS00058 ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE: Prior to adjusting the throttle cable free play, the engine idling speed should be adjusted. 1. Check: S throttle cable free play a Out of specification Adjust. Throttle cable free play (at the flange of the throttle grip) 3 X 5 mm...
Page 71: Checking The Spark Pugs
ADJUSTING THE THROTTLE CABLE FREE PLAY/ CHECKING THE SPARK PLUGS WARNING After adjusting the throttle cable free play, turn the handlebar to the right and to the left to ensure that this does not cause the en- gine idling speed to change. 4.
Page 72 CHECKING THE SPARK PLUGS 7. Install: S spark plug 13 Nm (1.3 mSkg) NOTE: Before installing the spark plug, clean the spark plug and gasket surface. 8. Connect: S spark plug cap 3-13...
Page 73: Checking The Ignition Timing
CHECKING THE IGNITION TIMING EAS00062 CHECKING THE IGNITION TIMING NOTE: Prior to checking the ignition timing, check the wiring connections of the entire ignition system. Make sure that all connections are tight and free of corrosion. 1. Remove: S timing plug 1 2.
Page 74: Measuring The Compression Pressure
MEASURING THE COMPRESSION PRESSURE EAS00065 MEASURING THE COMPRESSION PRES- SURE The following procedure applies to all of the cyl- inders. NOTE: Insufficient compression pressure will result in a loss of performance. 1. Measure: S valve clearance Out of specification Adjust. Refer to “ADJUSTING THE VALVE CLEAR- ANCE”.
Page 75 MEASURING THE COMPRESSION PRESSURE Refer to the following table. Compression pressure (with oil applied into cylinder) Reading Diagnosis Higher than Piston wear or damage Repair. without oil Piston ring(-s), valves, cylinder head gasket or Same as piston possibly defec- tive Repair.
Page 76: Checking The Engine Oil Level
CHECKING THE ENGINE OIL LEVEL EAS00069 CHECKING THE ENGINE OIL LEVEL 1. Stand the motorcycle on a level surface. NOTE: S Place the motorcycle on a suitable stand. S Make sure that the motorcycle is upright. 2. Let the engine idle for a few minutes. 3.
Page 77: Changing The Engine Oil
CHANGING THE ENGINE OIL EAS00075 CHANGING THE ENGINE OIL 1. Start the engine, warm it up for several min- utes, and then turn it off. 2. Place a container under the engine oil drain bolt. 3. Remove: WARNING Be careful not touch the exhaust pipe when removing or attaching the engine oil filler cap 1 or when adding oil.
Page 78: Adjusting The Clutch Cable Free Play
CHANGING THE ENGINE OIL/ ADJUSTING THE CLUTCH CABLE FREE PLAY Quantity Total amount 1.75 L Without oil filter element replacement 1.4 L With oil filter element replacement 1.6 L 9. Install: S engine oil filler cap 10. Start the engine, warm it up for several min- utes, and then turn it off.
Page 79: Cleaning The Air Filter Element
ADJUSTING THE CLUTCH CABLE FREE PLAY/ CLEANING THE AIR FILTER ELEMENT b. Turn the adjusting bolt 2 in direction a or b until the specified clutch cable free play is ob- tained. Clutch cable free play is Direction increased. Clutch cable free play is Direction decreased c.
Page 80: Checking The Carburetor Joint And Intake Manifold
CLEANING THE AIR FILTER ELEMENT/CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD 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 en- gine performance and possible overheat-...
Page 81: Checking The Fuel Hoses
CHECKING THE FUEL HOSES/ CHECKING THE CRANKCASE BREATHER HOSE EAS00097 CHECKING THE FUEL HOSES The following procedure applies to all of the fuel hoses. 1. Remove: S fuel tank S silencer 2. Check: S vacuum hose 1 S fuel hose 2 Cracks/damage Replace.
Page 82: Checking The Exhaust System
CHECKING THE EXHAUST SYSTEM EAS00100 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the ex- haust pipe, muffler and gaskets. 1. Check: S exhaust pipe 1 S muffler 2 Cracks/damage Replace. S gaskets 3 Exhaust gas leaks Replace. 2.
Page 83: Chassis
ADJUSTING THE FRONT BRAKE/ ADJUSTING THE REAR BRAKE EAS00108 CHASSIS ADJUSTING THE FRONT BRAKE 1. Check: S brake lever free play a Out of specification Adjust. Brake lever free play (at the end of the brake lever) 5 X 8 mm 2.
Page 84 ADJUSTING THE REAR BRAKE 2. Adjust: S brake pedal position a. Loosen the locknut 1 . b. Turn the adjusting bolt 2 in direction a or b until the specified brake pedal position is ob- tained. Direction Brake pedal is raised. Direction Brake pedal is lowered.
Page 85: Checking The Brake Fluid Level
CHECKING THE BRAKE FLUID LEVEL EAS00115 CHECKING THE BRAKE FLUID LEVEL 1. Stand the motorcycle on a level surface. NOTE: S Place the motorcycle on a suitable stand. S Make sure that the motorcycle is upright. 2. Check: S brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level.
Page 86: Checking The Brake Pads
CHECKING THE BRAKE PADS/CHECKING THE BRAKE SHOES/ ADJUSTING THE REAR BRAKE LIGHT SWITCH EAS00117 CHECKING THE BRAKE PADS The following procedure applies to all of the brake pads. 1. Operate the brake. 2. Check: S brake pad Wear indicators 1 almost touch the brake disc ! Replace the brake pads as a set.
Page 87: Checking The Brake Hose
CHECKING THE BRAKE HOSE/ BLEEDING THE HYDRAULIC BRAKE SYSTEM EAS00129 CHECKING THE BRAKE HOSE 1. Check: S brake hose 1 Cracks/damage/wear Replace. 2. Check: S brake hose clamp Loose connection Tighten. 3. Hold the motorcycle upright and apply the front or rear brake.
Page 88 BLEEDING THE HYDRAULIC BRAKE SYSTEM 1. Bleed: S hydraulic brake system a. Add the recommended brake fluid to the proper level. b. Install the brake master cylinder reservoir di- aphragm. c. Connect a clear plastic hose 1 tightly to the bleed screw 2 .
Page 89: Adjusting The Shift Pedal
ADJUSTING THE SHIFT PEDAL/ ADJUSTING THE DRIVE CHAIN SLACK EAS00137 ADJUSTING THE SHIFT PEDAL NOTE: The shift pedal position is determined by the ad- justing bolt length a . 1. Measure: D adjusting the length a Incorrect Adjust. Adjusting bolt length 276.8 mm 2.
Page 90 ADJUSTING THE DRIVE CHAIN SLACK 2. Rotate the rear wheel several times and check the drive chain to locate its tightest point. 3. Check: D drive chain slack a Out of specification Adjust. Drive chain slack 40 mm 4. Adjust: D drive chain slack a.
Page 91: Lubricating The Drive Chain
LUBRICATING THE DRIVE CHAIN/ CHECKING AND ADJUSTING THE STEERING HEAD EAS00142 LUBRICATING THE DRIVE CHAIN The drive chain consists of many interacting parts. If the drive chain is not maintained proper- ly, it will wear out rapidly. Therefore, the drive chain should be serviced, especially when the motorcycle is used in dusty areas.
Page 92 CHECKING AND ADJUSTING THE STEERING HEAD 3. Remove: D handlebar D upper bracket pinch bolt 1 D steering stem nut 2 D upper bracket 3 4. Adjust: D steering head a. Remove the lock washer 1 , the upper ring nut 2 , and the rubber washer 3 .
Page 93: Checking The Front Fork
CHECKING AND ADJUSTING THE STEERING HEAD/ CHECKING THE FRONT FORK e. Install the rubber washer 3 . f. Install the upper ring nut 2 . g. Finger tighten the upper ring nut 2 , then align the slots of both ring nuts. If necessary, hold the lower ring nut and tighten the upper ring nut until their slots are aligned.
Page 94: Adjusting The Rear Shock Absorber Assembly
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY EAS00156 ADJUSTING THE REAR SHOCK ABSORB- ER ASSEMBLY WARNING Securely support the motorcycle so that there is no danger of it falling over. Spring preload CAUTION: Never go beyond the maximum or minimum adjustment positions. 1.
Page 95: Checking The Tires
CHECKING THE TIRES EAS00164 CHECKING THE TIRES The following procedure applies to both of the tires. 1. Measure: D tire pressure Out of specification Regulate. WARNING D The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature.
Page 96 No guarantee concerning handling characteristics can be given if a tire combination other than one approved by Yamaha is used on this motorcycle. Front tire Manufacturer Type...
Page 97: Checking And Tightening The Spokes
CHECKING THE TIRES/ CHECKING AND TIGHTENING THE SPOKES Rear tire Manufacturer Type Size 130 / 90-15 CHENG SHIN C-915 M / C 66P MARBELLA 130 / 90-15 INOUE NR31 M / C 66P WARNING D New tires have a relatively low grip on the road surface until they have been slightly worn.
Page 98: Checking And Lubricating The Cables
CHECKING AND LUBRICATING THE CABLES / LUBRICATING THE LEVERS AND PEDALS / LUBRICATING THE SIDESTAND/ LUBRICATING THE REAR SUSPENSION EAS00170 CHECKING LUBRICATING CABLES The following procedure applies to all of the cable sheaths and cables. WARNING Damaged cable sheaths may causes the cable to corrode and interfere with its move- ment.
Page 99 CHECKING AND CHARGING THE BATTERY EB305020 ELECTRICAL SYSTEM CHECKING AND CHARGING THE BATTERY WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of poi- sonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: D Wear protective eye gear when handling or working near batteries.
Page 100 CHECKING AND CHARGING THE BATTERY NOTE: Since MF batteries are sealed, it is not possible to check the charge state of the battery by mea- suring the specific gravity of the electrolyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals.
Page 101 CHECKING AND CHARGING THE BATTERY WARNING Ambient temperature 20_C Do not quick charge a battery. CAUTION: D Make sure that the battery breather hose and battery vent are free of obstructions. D Never remove the MF battery sealing caps. Condition of charge in battery (%) D Do not use a high-rate battery charger.
Page 102 CHECKING AND CHARGING THE BATTERY Charging method using a variable-current (voltage) type charger Charger Measure the open-circuit NOTE: AMP meter voltage prior to charging. Voltage should be measured 30 min- utes after the machine is stopped. Connect a charger and NOTE: AMP meter to the battery Set the charging voltage at 16...
Page 103 CHECKING AND CHARGING THE BATTERY Charging method using a constant-voltage type charger Measure the open-circuit NOTE: voltage prior to charging. Voltage should be measured 30 min- utes after the machine is stopped. Connect a charger and AMP meter to the battery and start charging.
Page 104 CHECKING AND CHARGING THE BATTERY 6. Check: D battery breather hose and battery vent Obstruction Clean. Damage Replace. 7. Install: D battery CAUTION: D When inspecting the battery, make sure that the battery breather hose is properly attached and routed correctly. If the battery breather hose is positioned so as to allow electrolyte or hydrogen gas from the bat- tery to contact the frame, the motorcycle...
Page 105 CHECKING THE FUSES EAS00181 CHECKING THE FUSES The following procedure applies to all of the fuses. CAUTION: To avoid a short circuit, always turn the main switch to “OFF” when checking or replacing a fuse. 1. Remove: D left side cover 1 2.
Page 106 CHECKING THE FUSES/ REPLACING THE HEADLIGHT BULB WARNING Never use a fuse with an amperage rating other than that specified. Improvising or us- ing a fuse with the wrong amperage rating may cause extensive damage to the electri- cal system, cause the lighting and ignition systems to malfunction and could possibly cause a fire.
Page 107 REPLACING THE HEADLIGHT BULB/ ADJUSTING THE HEADLIGHT BEAM 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.
Page 109 CHAS CHAPTER 4. CHASSIS FRONT WHEEL AND BRAKE DISC ......REMOVING THE FRONT WHEEL .
Page 110 CHAS STEERING HEAD ..........4-52 LOWER BRACKET .
Page 111: Chapter 4. Chassis
CHAS FRONT WHEEL AND BRAKE DISC CHASSIS FRONT WHEEL AND BRAKE DISC 40 Nm (4.0 mDkg) 59 Nm (5.9 mDkg) 20 Nm (2.0 mDkg) 23 Nm (2.3 mDkg) Order Job/Part Q’ty Remarks Removing the front wheel and brake Remove the parts in the order listed. disc NOTE: Place the motorcycle on a suitable stand...
Page 112 CHAS FRONT WHEEL AND BRAKE DISC Order Job/Part Q’ty Remarks Disassembling the front wheel Disassemble the parts in the order listed. Oil seal Speedometer clutch retainer Speedometer clutch Bearing Collar For assembly, reverse the disassembly procedure.
Page 113: Removing The Front Wheel
CHAS FRONT WHEEL AND BRAKE DISC EAS00519 REMOVING THE FRONT WHEEL 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated.
Page 114 CHAS FRONT WHEEL AND BRAKE DISC 3. Check: D spokes Bends/damage Replace. Loose Tighten. Tap the spokes with a screwdriver. NOTE: A tight spoke will emit a clear, ringing tone, a loose spoke will sound flat. 4. Tighten: D spokes 3 Nm (0.3 mDkg) NOTE:...
Page 115: Checking The Brake Disc
CHAS FRONT WHEEL AND BRAKE DISC a. Clean the outside of the front wheel hub. b. Remove the oil seals with a flat-head screw- driver. NOTE: To prevent damaging the wheel, place a rag be- tween the screwdriver and the wheel surface. c.
Page 116 CHAS FRONT WHEEL AND BRAKE DISC c. Remove the brake caliper. d. Hold the dial gauge at a right angle against the brake disc surface. e. Measure the center part of the brake disc that the brake pads touches. 3. Measure: D brake disc thickness 1 Measure the brake disc thickness at a few different locations.
Page 117: Checking The Speedometer Gear Unit
CHAS FRONT WHEEL AND BRAKE DISC CHECKING THE SPEEDOMETER GEAR UNIT 1. Check: D speedometer clutch Bends/damage/wear Replace. 2. Check: D speedometer drive gear 1 D speedometer driven gear 2 Damage/wear Replace. EAS00542 INSTALLING THE FRONT WHEEL 1. Lubricate: D wheel axle D wheel bearings D oil seal lips...
Page 118 CHAS FRONT WHEEL AND BRAKE DISC 4. Tighten: 59 Nm (5.9 mDkg) D wheel axle 1 D wheel axle pinch bolt 2 20 Nm (2.0 mDkg) D brake caliper bolts 3 40 Nm (4.0 mDkg) WARNING Make sure that the brake cable is routed properly.
Page 119: Adjusting The Front Wheel Static Balance
CHAS FRONT WHEEL AND BRAKE DISC EAS00549 ADJUSTING THE FRONT WHEEL STATIC BALANCE NOTE: D After replacing the tire, wheel or both, the front wheel static balance should be adjusted. D Adjust the front wheel static balance with the brake discs installed. 1.
Page 120 CHAS FRONT WHEEL AND BRAKE DISC 4. Check: D front wheel static balance a. Turn the front wheel and make sure that it stays at each position shown. b. If the front wheel does not remain stationary at all of the positions, rebalance it. 4-10...
Page 121: Rear Wheel And Rear Brake
CHAS REAR WHEEL AND REAR BRAKE REAR WHEEL AND REAR BRAKE REAR WHEEL 23 Nm (2.3 mDkg) 104 Nm (10.4 mDkg) 16 Nm (1.6 mDkg) 16 Nm (1.6 mDkg) Order Job/Part Q’ty Remarks Removing the rear wheel Remove the parts in the order listed. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevant.
Page 122: Rear Brake And Rear Wheel Sprocket
CHAS REAR WHEEL AND REAR BRAKE REAR BRAKE AND REAR WHEEL SPROCKET 40 Nm (4.0 mDkg) Order Job/Part Q’ty Remarks Removing the rear brake and rear Remove the parts in the order listed. wheel sprocket Shoe plate Sprocket Collar Oil seal Bearing Rear wheel drive hub Rear wheel drive hub damper...
Page 123 CHAS REAR WHEEL AND REAR BRAKE Order Job/Part Q’ty Remarks Disassembling the rear wheel Disassemble the parts in the order listed. Bearing Spacer For assembly, reverse the disassembly procedure. 4-13...
Page 124 CHAS REAR WHEEL AND REAR BRAKE 9 Nm (0.9 m Order Job/Part Q’ty Remarks Disassembling the brake shoe plate Disassemble the parts in the order listed. Brake shoe Tension spring Refer to “REMOVING THE REAR Camshaft lever WHEEL/ASSEMBLING THE BRAKE Indicator plate SHOE PLATE”.
Page 125: Removing The Rear Wheel
CHAS REAR WHEEL AND REAR BRAKE EAS00563 REMOVING THE REAR WHEEL 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated.
Page 126: Checking The Rear Wheel
CHAS REAR WHEEL AND REAR BRAKE EAS00566 CHECKING THE REAR WHEEL 1. Check: D wheel axle D rear wheel D wheel bearings D oil seals Refer to “FRONT WHEEL”. 2. Check: D tire D rear wheel Damage/wear Replace. Refer to “CHECKING THE TIRES” and “CHECKING THE WHEELS”...
Page 127: Checking The Brake
CHAS REAR WHEEL AND REAR BRAKE Rear wheel sprocket self-locking 40 Nm (4.0 mDkg) NOTE: Tighten the self-locking nuts in stages and in a crisscross pattern. EAS00569 CHECKING THE BRAKE The following procedure applies to all of the brake shoes. 1.
Page 128: Assemblilng The Brake Shoe Plate
CHAS REAR WHEEL AND REAR BRAKE 4. Check: D brake drum inner surface Oil deposits Clean. Remove the oil with a rag soaked in lacquer thinner or solvent. Scratches Repair. Lightly and evenly polish the scratches with an emery cloth. 5.
Page 129: Installing The Rear Wheel
CHAS REAR WHEEL AND REAR BRAKE EAS00571 INSTALLING THE REAR WHEEL 1. Lubricate: D wheel axle D wheel bearings D oil seal lips Recommended lubricant Lithium soap base grease 2. Adjust: D drive chain slack Drive chain slack 40 mm Refer to “ADJUSTING THE DRIVE CHAIN SLACK”...
Page 130: Front And Rear Brakes
CHAS FRONT AND REAR BRAKES FRONT AND REAR BRAKES FRONT BRAKE PADS 40 Nm (4.0 m Order Job/Part Q’ty Remarks Removing front brake pads Remove the parts in the order listed. Retaining bolt Brake caliper Refer to “REPLACING THE FRONT Brake pad BRAKE PADS”.
Page 131 CHAS FRONT AND REAR BRAKES EAS00579 CAUTION: Disc brake components rarely require dis- assembly. Therefore, always follow these preventive measures: D Never disassemble brake components un- less absolutely necessary. D If any connection on the hydraulic brake system is disconnected, the entire brake system must be disassembled, drained, cleaned, properly filled, and bled after reas- sembly.
Page 132: Replacing The Front Brake Pads
CHAS FRONT AND REAR BRAKES EAS00581 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: D retaining bolt 1 2. Remove: D brake caliper 2 3.
Page 133 CHAS FRONT AND REAR BRAKES 6. Lubricate: D retaining bolts 1 Recommended lubricant Lithium soap base grease CAUTION: D Do not allow grease to contact the brake pads. D Remove any excess grease. 7. Install: D brake caliper D retaining bolt 40 Nm (4.0 m 8.
Page 134: Front Brake Master Cylinder
CHAS FRONT AND REAR BRAKES FRONT BRAKE MASTER CYLINDER 7 Nm (0.7 mDkg) 30 Nm (3.0 mDkg) Order Job/Part Q’ty Remarks Removing the front brake master Remove the parts in the order listed. cylinder Brake fluid Drain. Rear view mirror Brake lever/compression spring Front brake switch Union bolt...
Page 135 CHAS FRONT AND REAR BRAKES Order Job/Part Q’ty Remarks Disassembling the front brake Remove the parts in the order listed. master cylinder Dust boot Circlip Master cylinder cup Spring For assembly, reverse the disassembly procedure. 4-25...
Page 136: Removing The Front Brake Master Cylinder
CHAS FRONT AND REAR BRAKES EAS00588 REMOVING THE FRONT BRAKE MASTER CYLINDER NOTE: Before removing the front brake master cylin- der, drain the brake fluid from the entire brake system. 1. Remove: D rear view mirror (right) D brake lever/compression spring D brake switch 1 2.
Page 137: Checking The Front Brake Master Cylinders
CHAS FRONT AND REAR BRAKES EAS00592 CHECKING THE FRONT BRAKE MASTER CYLINDERS The following procedure applies to the both of the brake master cylinders. 1. Check: D brake master cylinder 1 Damage/scratches/wear Replace. D brake fluid delivery passages 2 (brake master cylinder body) Obstruction Blow out with compressed air.
Page 138: Installing The Front Brake Master Cylinder
CHAS FRONT AND REAR BRAKES EAS00598 INSTALLING THE FRONT BRAKE MASTER CYLINDER WARNING D Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. D Never use solvents on internal brake com- ponents.
Page 139 CHAS FRONT AND REAR BRAKES WARNING D Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. D 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 perfor- mance.
Page 140: Front Brake Caliper
CHAS FRONT AND REAR BRAKES EAS00612 FRONT BRAKE CALIPER 30 Nm (3.0 mDkg) 40 Nm (4.0 m Order Job/Part Q’ty Remarks Removing the front brake caliper Remove the parts in the order listed. Brake fluid Drain. Brake hose holder Union bolt Copper washer Refer to “REMOVING/INSTALLING Brake hose...
Page 141 CHAS FRONT AND REAR BRAKES 6 Nm (0.6 mDkg) Order Job name/Part name Q’ty Remarks Disassembling the front brake Remove the parts in the order listed. caliper Pad spring Brake caliper piston Refer to “REMOVING THE FRONT Dust seal BRAKE CALIPERS”. Caliper piston seal Bleed screw For assembly, reverse the disassembly...
Page 142: Disassembling The Front Brake Caliper
CHAS FRONT AND REAR BRAKES EAS00619 DISASSEMBLING THE FRONT BRAKE CAL- IPER NOTE: Before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: D union bolt 1 D copper washers 2 D brake hose NOTE: Put the end of the brake hose into a container and pump out the brake fluid carefully.
Page 143: Checking The Front Brake Calipers
CHAS FRONT AND REAR BRAKES EAS00633 CHECKING THE FRONT BRAKE CALIPERS Recommended brake component replacement schedule: Brake pads If necessary Piston seals Every two years Brake hoses Every two years Every two years and whenever the Brake fluid brake is disas- sembled.
Page 144: Assemblling And Installilng The Front Brake Caliper
CHAS FRONT AND REAR BRAKES ASSEMBLING INSTALLING FRONT BRAKE CALIPER WARNING D Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. D Never use solvents on internal brake com- ponents as they will cause the piston seals to swell and distort.
Page 145 CHAS FRONT AND REAR BRAKES 3. Fill: D brake master cylinder reservoir (with the specified amount of the recom- mended brake fluid) Recommended brake fluid DOT 4 WARNING D Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.
Page 146: Front Fork
CHAS FRONT FORK EAS00646 FRONT FORK 20 Nm (2.0 mDkg) 23 Nm (2.3 mDkg) 7 Nm (0.7 mDkg) 7 Nm (0.7 m 30 Nm (3.0 mDkg) 40 Nm (4.0 mDkg) 7 Nm (0.7 mDkg) Order Job/Part Q’ty Remarks Removing the front fork Remove the parts in the order listed.
Page 147 CHAS FRONT FORK 23 Nm (2.3 mDkg) 30 Nm (3.0 mDkg) Order Job name/Part name Q’ty Remarks Disassembling the front fork Disassemble the parts in the order listed. Cap bolt O-ring Spacer Spring seat Fork spring Refer to “DISASSEMBLING/ASSEM- Dust seal BLING THE FRONT FORK LEGS”.
Page 148 CHAS FRONT FORK 23 Nm (2.3 mDkg) 30 Nm (3.0 mDkg) Order Job name/Part name Q’ty Remarks Seal spacer Outer tube bushing Refer to “DISASSEMBLING/ASSEM- Inner tube/inner tube bushing BLING THE FRONT FORK LEGS”. Oil lock piece Outer tube For assembly, reverse the disassembly procedure.
Page 149: Removing The Front Fork Legs
CHAS FRONT FORK EAS00649 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated.
Page 150 CHAS FRONT FORK CAUTION: Do not scratch the inner tube. 4. Remove: D damper rod bolt D copper washer NOTE: While holding the damper rod with the damper rod holder 1 and T-handle 2 , loosen the damper rod bolt 3 . Damper rod holder 90890-01365 T-Handle...
Page 151: Checking The Front Fork Legs
CHAS FRONT FORK EAS00657 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Check: D inner tube 1 D outer tube 2 Bends/damage/scratches Replace. WARNING Do not attempt to straighten a bent inner tube as this may dangerously weaken it.
Page 152 CHAS FRONT FORK NOTE: D When assembling the front fork leg, be sure to replace the following parts: -inner tube bushing -outer tube bushing -oil seal -dust seal D Before assembling the front fork leg, make sure that all of the components are clean. 1.
Page 153 Fork seal driver weight 90890-01367 Adapter 90890-01369 8. Fill: D front fork leg (with the specified amount of the recom- mended fork oil) Quantity (each front fork leg) 310 cm Yamaha fork and shock oil 10 W or equivalent. 4-43...
Page 154 CHAS FRONT FORK Front fork leg oil level a (from the top of the inner tube, with the inner tube fully compressed and without the fork spring) 112 mm NOTE: D While filling the front fork leg, keep it upright. D After filling, slowly pump the front fork leg up and down to distribute the fork oil.
Page 155: Installing The Front Fork Legs
CHAS FRONT FORK EAS00662 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Install: D front fork leg Temporarily tighten the upper and lower bracket pinch bolts. NOTE: Make sure that the inner fork tube is flush with the top of the handlebar holder.
Page 156: Handlebar
CHAS HANDLEBAR HANDLEBAR 7 Nm (0.7 mDkg) 23 Nm (2.3 mDkg) 32 Nm (3.2 mDkg) Order Job/Part Q’ty Remarks Removing the handlebar Remove the parts in the order listed. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over.
Page 157 CHAS HANDLEBAR 7 Nm (0.7 mDkg) 23 Nm (2.3 mDkg) 32 Nm (3.2 mDkg) Order Job/Part Q’ty Remarks Master cylinder assembly Right handlebar switch Throttle cable Throttle grip assembly Handlebar holder (upper) Handlebar Cable guide Handlebar holder (lower) For installation, reverse the removal procedure.
Page 158: Removing The Handlebar
CHAS HANDLEBAR EAS00666 REMOVING THE HANDLEBAR 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. 2. Remove: D front brake master cylinder assembly 1 D right handlebar switch 2 D throttle grip 3 3.
Page 159: Installing The Handlebar
CHAS HANDLEBAR 3. Install: D handlebar grip a. Apply a light 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.
Page 160 CHAS HANDLEBAR 3. Install: D front brake master cylinder assembly D throttle grip D throttle cable D right handlebar switch 2 NOTE: Install the right handlebar switch alignment sur- face position so that it is perpendicular ( a = 90_) to the master cylinder alignment surface. 4.
Page 161 CHAS HANDLEBAR 9. Adjust: D clutch cable free play Refer to “ADJUSTING THE CLUTCH CABLE FREE PLAY” in chapter 3. Clutch cable free play (at the end of the clutch lever) 10 mm 10. Adjust: D throttle cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY”...
Page 162: Steering Head
CHAS STEERING HEAD STEERING HEAD LOWER BRACKET 110 Nm (11.0 mDkg) 52 Nm (5.2 mDkg) 18 Nm (1.8 mDkg) 8 Nm (0.8 m 7 Nm (0.7 mDkg) Order Job name/Part name Q’ty Remarks Removing the lower bracket Remove the parts in the order listed. Stand the motorcycle on a level surface.
Page 163 CHAS STEERING HEAD 110 Nm (11.0 mDkg) 52 Nm (5.2 mDkg) 18 Nm (1.8 mDkg) 8 Nm (0.8 m 7 Nm (0.7 mDkg) Order Job name/Part name Q’ty Remarks Rubber washer Lower ring nut Refer to “REMOVING THE LOWER Bearing cover BRACKET/INSTALLING THE Lower bracket STEERING HEAD”.
Page 164: Removing The Lower Bracket
CHAS STEERING HEAD EAS00677 REMOVING THE LOWER BRACKET 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. 2. Remove: D upper ring nut 1 D lower ring nut 2 NOTE: Hold the lower ring nut with the exhaust and steering nut wrench, then remove the upper ring...
Page 165: Installing The Steering Head
CHAS STEERING HEAD a. Remove the bearing reces from the steering head pipe with a long rod 1 and hammer. b. Remove the bearing race from the lower bracket with a floor chisel 2 and hammer. c. Install a new rubber seal and new bearing re- ces.
Page 166 CHAS STEERING HEAD NOTE: Temporarily tighten the steering stem nut. 4. Install: D front fork legs Refer to “FRONT FORK” NOTE: Temporarily tighten the upper and lower bracket pinch bolts. 4-56...
Page 167: Rear Shock Absorber And Swingarm
CHAS REAR SHOCK ABSORBER AND SWINGARM EAS00685 REAR SHOCK ABSORBER AND SWINGARM REAR SHOCK ABSORBER ASSEMBLY 23 Nm (2.3 mDkg) 23 Nm (2.3 mDkg) Order Job/Part Q’ty Remarks Removing the rear shock absorber Remove the parts in the order listed. assembly Stand the motorcycle on a level surface.
Page 168: Swingarm
CHAS REAR SHOCK ABSORBER AND SWINGARM SWINGARM 46 Nm (4.6 mDkg) 7 Nm (0.7 mDkg) Order Job/Part Q’ty Remarks Removing the swingarm Remove the parts in order listed. Rear wheel Refer to “REAR WHEEL AND REAR BRAKE”. Rear shock absorber Refer to “REMOVING/INSTALLING THE REAR SHOCK ABSORBER”.
Page 169: Handling The Rear Shock Absorber
CHAS REAR SHOCK ABSORBER AND SWINGARM EAS00687 HANDLING THE REAR SHOCK ABSORBER WARNING This rear shock absorber contain highly compressed nitrogen gas. Before handling the rear shock absorber, read and make sure you understand the following information. The manufacturer cannot be held responsi- ble for property damage or personal injury that may result from improper handling of the rear shock absorber.
Page 170: Removing The Rear Shock Absorber Assemblies
CHAS REAR SHOCK ABSORBER AND SWINGARM EAS00691 REMOVING THE REAR SHOCK ABSORBER ASSEMBLIES 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated.
Page 171: Removing The Swingarm
CHAS REAR SHOCK ABSORBER AND SWINGARM EAS00703 REMOVING THE SWINGARM 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated.
Page 172: Checking The Rear Shock Absorber Assembly
CHAS REAR SHOCK ABSORBER AND SWINGARM EAS00696 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 1. Check: D rear shock absorber rod Bends/damage Replace the rear shock absorber assembly. D rear shock absorber Gas leaks/oil leaks Replace the rear shock absorber assembly. D spring Damage/wear Replace the rear shock ab- sorber assembly.
Page 173 CHAS REAR SHOCK ABSORBER AND SWINGARM 4. Check: D dust covers 1 D spacer 2 D oil seals 3 Damage/wear Replace. D bearings Damage/pitting Replace. 4-63...
Page 174: Checking The Drive Chain
CHAS REAR SHOCK ABSORBER AND SWINGARM EAS00709 CHECKING THE DRIVE CHAIN 1. Measure: D ten-link section a of the drive chain Out of specification Replace the drive chain. Max. ten-link drive chain section 129.5 mm NOTE: D While measuring the ten-link section, push down on the drive chain to increase its tension.
Page 175 CHAS REAR SHOCK ABSORBER AND SWINGARM c. Remove the drive chain from the kerosine and completely dry it. CAUTION: This motorcycle has a drive chain with small rubber O-rings 1 between the drive chain side plates. Never use high-pressure water or air, steam, gasoline, certain solvents (e.g., benzine), or a coarse brush to clean the drive chain.
Page 176: Installing The Swingarm
CHAS REAR SHOCK ABSORBER AND SWINGARM EAS00711 INSTALLING THE SWINGARM 1. Lubricate: D bearings D spacers D dust covers D pivot shaft Recommended lubricant Molybdenum disulfide grease 2. Install: D rear shock absorber assembly D rear wheel Refer to “INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY”...
Page 177: Installing The Drive Chain
CHAS REAR SHOCK ABSORBER AND SWINGARM INSTALLING THE DRIVE CHAIN 1. Lubricate: D drive chain Recommended lubricant Engine oil or chain lubricant suitable for O-ring chains 2. Install: D drive chain D chain case D chain cover CAUTION: Connecting the neutral switch lead, starter motor and A.C.
Page 180 CHAPTER 5. ENGINE ENGINE REMOVAL ..........DRIVE SPROCKET AND EXHAUST PIPES .
Page 181 REMOVING THE CLUTCH ........5-43 REMOVING THE PRIMARY DRIVE GEAR .
Page 182: Chapter 5. Engine
ENGINE REMOVAL ENGINE ENGINE REMOVAL DRIVE SPROCKET AND EXHAUST PIPES 60 Nm (6.0 mDkg) 7 Nm (0.7 mDkg) 7 Nm (0.7 mDkg) 10 Nm (1.0 mDkg) 10 Nm (1.0 mDkg) 12 Nm (1.2 mDkg) 25 Nm (2.5 mDkg) Order Job/Part Q’ty Remarks Removing the drive sprocket and...
Page 183 ENGINE REMOVAL 60 Nm (6.0 mDkg) 7 Nm (0.7 mDkg) 7 Nm (0.7 mDkg) 10 Nm (1.0 mDkg) 10 Nm (1.0 mDkg) 12 Nm (1.2 mDkg) 25 Nm (2.5 mDkg) Order Job/Part Q’ty Remarks Rear brake switch lead Disconnect. Footrest/brake pedal Drive chain case Chain cover Sprocket holder...
Page 184: Leads, Shift Pedal And Clutch Cable
ENGINE REMOVAL LEADS, SHIFT PEDAL AND CLUTCH CABLE Order Job/Part Q’ty Remarks Removing the leads, shift pedal and Remove the parts in the order listed. clutch cable Battery negative lead Pickup coil coupler A.C. magneto coupler Plug code Starter motor lead Clutch cable For installation, reverse the removal procedure.
Page 185: Engine
ENGINE REMOVAL EAS00191 ENGINE 35 Nm (3.5 mDkg) 35 Nm (3.5 mDkg) 35 Nm (3.5 mDkg) 35 Nm (3.5 mDkg) 35 Nm (3.5 mDkg) Order Job/Part Q’ty Remarks Removing the engine Remove the parts in the order listed. Bolt (front upper) NOTE: Bolt (front under) Place a suitable stand under the frame and...
Page 186: Installing The Engine
ENGINE EAS00192 INSTALLING THE ENGINE 1. Install: D bolt (front under) 1 D bolt (rear under) 2 D bolt (rear upper) 3 D bolt (front upper) 4 D engine bracket 5 D engine bracket 6 D engine brackets 7 NOTE: Do not fully tighten the bolts.
Page 187: Cylinder Heads
CYLINDER HEADS CYLINDER HEADS FRONT CYLINDER HEAD 10 Nm (1.0 mDkg) 10 Nm (1.0 mDkg) 22 Nm (2.2 mDkg) 12 Nm (1.2 mDkg) 8 Nm (0.8 mDkg) 12 Nm (1.2 mDkg) 10 Nm (1.0 mDkg) 26 Nm (2.6 mDkg) Order Job/Part Q’ty Remarks...
Page 188: Rear Cylinder Head
CYLINDER HEADS REAR CYLINDER HEAD 22 Nm (2.2 mDkg) 12 Nm (1.2 mDkg) 26 Nm (2.6 mDkg) 10 Nm (1.0 mDkg) 12 Nm (1.2 mDkg) 8 Nm (0.8 mDkg) Order Job/Part Q’ty Remarks Removing the rear cylinder head Remove the parts in the order listed. Camshaft sprocket cover Chain tensioner Camshaft sprocket...
Page 189: Removing The Cylinder Heads
CYLINDER HEADS REMOVING THE CYLINDER HEADS Front cylinder head 1. Remove: D camshaft sprocket cover D tappet cover D timing plug D straight plug 2. Align: D “T” mark a on the generator rotor (with the stationary pointer b on the crank case cov- a.
Page 190 CYLINDER HEADS 4. Remove: D timing chain tensioner 1 D gasket 2 5. Remove: D bolt (camshaft sprocket) 1 D camshaft sprocket 2 NOTE: To prevent the timing chain from falling into the crankcase fasten a wire to it. 6. Remove: D cylinder head NOTE: D Loosen the bolts in the proper sequence.
Page 191: Checking The Cylinder Heads
CYLINDER HEADS EAS00228 CHECKING THE CYLINDER HEADS The following procedure applies to all of the cyl- inder heads. 1. Eliminate: D combustion chamber carbon deposits (with a rounded scraper) NOTE: Do not use a sharp instrument to avoid damag- ing or scratching: D spark plug threads D valve seats 2.
Page 192: Checking The Timing Chain Tensioner
CYLINDER HEADS EB401430 CHECKING THE TIMING CHAIN TENSIONER 1. Check: D timing chain tensioner Cracks/damage/rough movement Re- place. a. Lightly press the timing chain tensioner rod into the timing chain tensioner housing by hand. NOTE: While pressing the timing chain tensioner rod, wind it clockwise with a thin screwdriver 1 until it stops.
Page 193 CYLINDER HEADS 3. Tighten: D bolts (cylinder head) M8 1 22 Nm (2.2 mDkg) M6 2 12 Nm (1.2 mDkg) NOTE: D Lubricate the cylinder head bolts with engine oil. D Tighten the cylinder head bolts in the proper tightening sequence as shown and torque them in two stages.
Page 194 CYLINDER HEADS WARNING Always use a new gasket. Timing chain tensioner bolt 10 Nm (1.0 mDkg) d. Remove the screwdriver, make sure that the timing chain tensioner rod releases, and tighten the cap bolt to the specified torque. Cap bolt 8 Nm (0.8 mDkg) 6.
Page 195 CYLINDER HEADS 1. Install: D camshaft sprocket a. Turn the crankshaft counterclockwise 300 . b. Align the “I” mark a with the stationary point- er b on the generator cover. c. Install the camshaft sprocket with the timing mark c facing out. d.
Page 196: Rocker Arms And Camshaft
ROCKER ARMS AND CAMSHAFT ROCKER ARMS AND CAMSHAFT 7 Nm (0.7 mDkg) 7 Nm (0.7 mDkg) 12 Nm (1.2 mDkg) Order Job/Part Q’ty Remarks Removing the rocker arms and Remove the parts in the order listed. camshaft Cylinder head Refer to “CYLINDER HEAD”. Stopper plate Camshaft bushing Refer to “REMOVING/INSTALLING THE...
Page 197: Removing The Rocker Arms And Camshaft
ROCKER ARMS AND CAMSHAFT REMOVING THE ROCKER ARMS AND CAM- SHAFT 1. Loosen: D lock nuts 1 D adjusting screws 2 2. Remove: D rocker arm shaft D rocker arm 3 NOTE: Remove the rocker arm shafts with the slide hammer bolt 1 and weight 2 .
Page 198: Checking The Rocker Arms And Rocker Arm Shafts
ROCKER ARMS AND CAMSHAFT 4. Check: D camshaft oil passage Obstruction Blow out with compressed air. EAS00206 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS The following procedure applies to all of the rocker arms and rocker arm shafts. 1.
Page 199: Installing The Camshaft And Rocker Arms
ROCKER ARMS AND CAMSHAFT EAS00220 INSTALLING THE CAMSHAFT AND ROCK- ER ARMS 1. Lubricate: D camshaft Recommended lubricant Camshaft/Bushing Molybdenum disulfide oil 2. Install: D camshaft 1 D camshaft bushing 2 NOTE: D Make sure that the No.1 camshaft 3 is installed in the front cylinder head and the No.2 camshaft 4 is installed in the rear cylinder head.
Page 200 ROCKER ARMS AND CAMSHAFT 5. Install: D rocker arms 1 D rocker arm shafts 2 NOTE: Make sure that the rocker arm shafts is com- pletely pushed into the cylinder head. 5-19...
Page 201: Valves And Valve Springs
VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS Order Job/Part Q’ty Remarks Removing the valves and valve Remove the parts in the order listed. springs Cylinder heads Refer to “CYLINDER HEADS”. Rocker arms and camshafts Refer to “ROCKER ARMS AND CAMSHAFTS”.
Page 202: Removing The Valves
VALVES AND VALVE SPRINGS EAS00237 REMOVING THE VALVES The following procedure applies to all of the valves and related components. NOTE: Before removing the internal parts of the cylin- der head (e.g., valves, valve springs, valve seats), make sure that the valves properly seal. 1.
Page 203 VALVES AND VALVE SPRINGS Out of specification Replace the valve guide. Valve-stem-to-valve-guide clearance Intake 0.010 0.037 mm <Limit>: 0.08 mm Exhaust 0.025 0.052 mm <Limit>: 0.1 mm 2. Replace. D 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.
Page 204: Checking The Valve Seats
VALVES AND VALVE SPRINGS 5. Measure: D valve margin thickness a Out of specification Replace the valve. Valve margin thickness Intake 0.4 0.8 mm Exhaust 0.8 1.2 mm 6. Measure: D valve stem runout Out of specification Replace the valve. NOTE: D When installing a new valve, always replace the valve guide.
Page 205 VALVES AND VALVE SPRINGS 4. Lap: D valve face D 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 to the valve face.
Page 206: Checking The Valve Springs
VALVES AND VALVE SPRINGS EAS00241 CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs. 1. Measure: D valve spring free length a Out of specification Replace the valve spring. Valve spring free length (intake and exhaust) 29.75 mm, <Limit>: 28.75 mm...
Page 207 VALVES AND VALVE SPRINGS NOTE: Install the valve spring with the larger pitch a facing up. b Smaller pitch 4. Install: D valve cotters NOTE: Install the valve cotters by compressing the valve spring with the valve spring compressor 1 . Valve spring compressor 90890-04019 5.
Page 208 CYLINDERS AND PISTONS CYLINDERS AND PISTONS Order Job/Part Q’ty Remarks Removing the cylinders and pistons Remove the parts in the order listed. Cylinder heads Refer to “CYLINDER HEADS”. Timing chain guide Cylinder O-ring Refer to “INSTALLING THE PISTONS Dowel pin AND CYLINDERS”.
Page 209: Removing The Pistons
CYLINDERS AND PISTONS EAS00254 REMOVING THE PISTONS The following procedure applies to all of the pis- tons. 1. Remove: D piston pin clip 1 D piston pin 2 D piston 3 CAUTION: Do not use a hammer to drive the piston pin out.
Page 210 CYLINDERS AND PISTONS 2. Measure: D piston-to-cylinder clearance a. Measure cylinder bore “C” with the cylinder bore gauge. a 45 mm from the top of the cylinder NOTE: Measure cylinder bore “C” by taking side-to- side and front-to-back measurements of the cyl- inder.
Page 211: Checking The Piston Rings
CYLINDERS AND PISTONS EB404410 CHECKING THE PISTON RINGS 1. Measure: D 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.
Page 212: Checking The Piston Pins
CYLINDERS AND PISTONS EAS00266 CHECKING THE PISTON PINS The following procedure applies to all of the pis- ton pins. 1. Check: D piston pin Blue discoloration/grooves ! Replace, then inspect the lubrication system. 2. Measure: D piston pin outside diameter a Out of specification ! Replace the piston pin.
Page 213 CYLINDERS AND PISTONS 2. Install: D piston 1 D piston pin 2 D piston pin clip NOTE: D Apply engine oil onto the piston pin. D Make sure that the “ ” mark 4 and “K” mark 5 on the piston faces towards the forward of the engine.
Page 214: Generator And Starter Clutch
GENERATOR AND STARTER CLUTCH GENERATOR AND STARTER CLUTCH STATOR COIL AND PICKUP COIL 5 Nm (0.5 mDkg) 7 Nm (0.7 mDkg) 10 Nm (1.0 mDkg) 10 Nm (1.0 mDkg) 10 Nm (1.0 mDkg) Order Job/Part Q’ty Remarks Removing the stator coil and pickup Remove the parts in the order listed.
Page 215: Generator Rotor And Starter Clutch
GENERATOR AND STARTER CLUTCH GENERATOR ROTOR AND STARTER CLUTCH 80 Nm (8.0 mDkg) Order Job/Part Q’ty Remarks Removing the generator rotor and Remove the parts in the order listed. starter clutch Generator rotor Starter clutch assembly Starter clutch drive gear Idler gear Idler gear shaft For installation, reverse the removal...
Page 216: Removing The Generator
GENERATOR AND STARTER CLUTCH REMOVING THE GENERATOR 1. Remove: D footrest/shift pedal Refer to “ENGINE REMOVAL”. D generator cover 2. Remove: D generator rotor nut 1 D washer NOTE: D While holding the generator rotor 2 with the sheave holder 3 , loosen the generator rotor nut.
Page 217: Checking The Starter Clutch
GENERATOR AND STARTER CLUTCH EAS00351 CHECKING THE STARTER CLUTCH 1. Check: D starter clutch idler gear 1 D starter clutch drive gear 2 Burrs/chips/roughness/wear Replace the defective part(-s). 2. Check: D starter clutch gear’s contacting surfaces a Damage/pitting/wear Replace the starter clutch gear.
Page 218: Installing The Generator
D Do not allow the sheave holder to touch the projection on the generator rotor. Sheave holder 90890-01701 3. Apply: D sealant (onto stater coil assembly lead grommet) Yamaha bond No.1215 90890-85505 4. Install: D stator coil D generator cover NOTE: Tighten the generator cover bolts in stages and in a crisscross pattern.
Page 219: Clutch
CLUTCH CLUTCH CLUTCH COVER 10 Nm (1.0 mDkg) 10 Nm (1.0 mDkg) Order Job/Part Q’ty Remarks Removing the clutch cover Remove the parts in the order listed. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so there is no danger of it falling over.
Page 220 CLUTCH 10 Nm (1.0 mDkg) 10 Nm (1.0 mDkg) Order Job/Part Q’ty Remarks Oil filter Clutch cover Dowel pin Clutch cover gasket For installation, reverse the removal procedure. 5-39...
Page 221 CLUTCH CLUTCH 80 Nm (8.0 mDkg) 8 Nm (0.8 mDkg) 75 Nm (7.5 mDkg) 80 Nm (8.0 mDkg) Order Job/Part Q’ty Remarks Removing the clutch Remove the parts in the order listed. Pressure plate Push plate 1 Friction plate Clutch plate Push rod (short) Ball Push rod (long)
Page 222 CLUTCH 80 Nm (8.0 mDkg) 8 Nm (0.8 mDkg) 75 Nm (7.5 mDkg) 80 Nm (8.0 mDkg) Order Job/Part Q’ty Remarks Washer Primary drive gear Spacer For installation, reverse the removal procedure. 5-41...
Page 223: Push Lever Shaft
CLUTCH PUSH LEVER SHAFT 8 Nm (0.8 mDkg) Order Job/Part Q’ty Remarks Removing the push lever shaft Remove the parts in the order listed. Push lever Spring Circlip Oil seal Bearing For installation, reverse the removal procedure. 5-42...
Page 224: Removing The Clutch
CLUTCH EAS00276 REMOVING THE CLUTCH 1. Straighten the lock washer tab. 2. Loosen: D clutch boss nut 1 NOTE: While holding the clutch boss 2 with the univer- sal clutch holder, loosen the clutch boss nut. Universal clutch holder 90890-04086 3.
Page 225: Checking The Friction Plates
CLUTCH EAS00280 CHECKING THE FRICTION PLATES The following procedure applies to all of the fric- tion plates. 1. Check: D friction plate Damage/wear Replace the friction plates as a set. 2. Measure: D friction plate thickness Out of specification Replace the friction plates as a set.
Page 226: Checking The Clutch Springs
CLUTCH EAS00282 CHECKING THE CLUTCH SPRINGS The following procedure applies to all of the clutch springs. 1. Check: D clutch spring Damage Replace the clutch springs as a set. 2. Measure: D clutch spring free length Out of specification Replace the clutch springs as a set.
Page 227: Checking The Pressure Plate
CLUTCH EAS00286 CHECKING THE PRESSURE PLATE 1. Check: D pressure plate 1 Cracks/damage Replace. EAS00288 CHECKING THE CLUTCH PUSH RODS 1. Check: D O-ring 1 D short clutch push rod 2 D long clutch push rod 3 D ball 4 Cracks/damage/wear Replace the de- fective part(-s).
Page 228: Installing The Primary Drive Gear
CLUTCH INSTALLING THE PRIMARY DRIVE GEAR 1. Install: D straight key D primary drive gear 1 D thrust washer D lock washer 2 D primary drive gear nut 3 80 Nm (8.0 mDkg) NOTE: While holding the generator rotor with the sheave holder, tighten the primary drive gear nut.
Page 229 CLUTCH 5. Install: D friction plates D clutch plates NOTE: D First, install a friction plate and then alternate between a clutch plate and a friction plate. D Align the slot a in the friction plates with the marks b in the clutch housing. 6.
Page 230 CLUTCH 10. Adjust: D push lever position a. Loosen the locknut 1 . b. Turn the adjusting screw 2 in or out until the marks are aligned. c. Hold the adjusting screw to prevent it from moving and then tighten the locknut to speci- fication.
Page 231: Oil Pump
OIL PUMP OIL PUMP 7 Nm (0.7 mDkg) 7 Nm (0.7 mDkg) 7 Nm (0.7 mDkg) Order Job/Part Q’ty Remarks Removing the oil pump Remove the parts in the order listed. Engine oil Drain. Clutch cover Refer to “REMOVING THE CLUTCH COVER”.
Page 232 OIL PUMP 7 Nm (0.7 mDkg) Order Job/Part Q’ty Remarks Disassembling the oil pump Disassemble the parts in the order listed. Oil pump cover Inner rotor Outer rotor Dowel pin Dowel pin Oil pump driven gear Housing For assembly, reverse the disassembly procedure.
Page 233: Checking The Oil Pump
OIL PUMP CHECKING THE OIL PUMP 1. Check: D oil pump drive gear 1 D oil pump driven gear 2 D oil pump housing D oil pump housing cover Cracks/damage/wear Replace the de- fective part(-s). 2. Measure: D inner-rotor-to-outer-rotor-tip clearance a D outer-rotor-to-oil-pump-housing clearance D oil-pump-housing-to-inner-rotor-and-outer-...
Page 234: Installing The Oil Pump
OIL PUMP 2. Install: D oil pump shaft 1 (to the oil pump cover 2 ) D pin 3 D inner rotor 4 D outer rotor 5 D pins 6 D oil pump housing 7 D screw 7 Nm (0.7 mDkg) NOTE: When installing the inner rotor, align the pin 3 in the oil pump shaft with the groove a on the in-...
Page 235: Shift Shaft
SHIFT SHAFT SHIFT SHAFT SHIFT SHAFT AND STOPPER LEVER Order Job/Part Q’ty Remarks Removing the shift shaft and stopper Remove the parts in the order listed. lever Engine oil Drain. Refer to “CHANGING THE ENGINE OIL” in chapter 3. Clutch cover Refer to “CLUTCH”.
Page 236 SHIFT SHAFT Order Job/Part Q’ty Remarks Shift cam stopper lever Collar For installation, reverse the removal procedure. 5-55...
Page 237: Checking The Shift Shaft
SHIFT SHAFT EAS00328 CHECKING THE SHIFT SHAFT 1. Check: D shift shaft 1 D stopper lever 2 Bends/damage/wear Replace D stopper lever spring 3 Roller turns roughly Replace the shift le- ver. EB408410 CHECKING THE SHIFT LEVER 1. Check: D shift lever 1 Bends/damage/wear Replace.
Page 238: Crankshaft And Connecting Rods
CRANKSHAFT AND CONNECTING RODS CRANKSHAFT AND CONNECTING RODS CRANKSHAFT ASSEMBLY 10 Nm (1.0 mDkg) 32 Nm (3.2 mDkg) 10 Nm (1.0 mDkg) Order Job/Part Q’ty Remarks Removing the crankshaft assembly Remove the parts in the order listed. Engine assembly Refer to “ENGINE REMOVAL”. Cylinder head Refer to “CYLINDER HEADS”.
Page 239 CRANKSHAFT AND CONNECTING RODS 10 Nm (1.0 mDkg) 32 Nm (3.2 mDkg) 10 Nm (1.0 mDkg) Order Job/Part Q’ty Remarks Timing chain drive gear Crankcase (right) Dowel pin Crankshaft assembly Plug Oil seal Spring Oil strainer For installation, reverse the removal procedure.
Page 240 CRANKSHAFT AND CONNECTING RODS CRANKSHAFT AND CONNECTING RODS Order Job/Part Q’ty Remarks Removing the crankshaft and Remove the parts in the order listed. connecting rods Timing chain drive gear Bearing Crank Washer Crank pin Connecting rod For installation, reverse the removal procedure.
Page 241: Disassembling The Crankcase
CRANKSHAFT AND CONNECTING RODS EAS00386 DISASSEMBLING THE CRANKCASE 1. Remove: D crankcase screws NOTE: D Loosen each screws 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. D Loosen the screws in decreasing numerical or- der (refer to the numbers in the illustration).
Page 242: Checking The Crankshaft And Connecting Rod
CRANKSHAFT AND CONNECTING RODS EAS00394 CHECKING THE CRANKSHAFT AND CON- NECTING ROD 1. Measure: D crankshaft runout Out of specification Replace the crank- shaft, bearing or both. NOTE: Turn the crankshaft slowly. Crankshaft runout Less than 0.03 mm 2. Measure: D big end side clearance Out of specification Replace the big end bearing, crankshaft pin, or connecting rod.
Page 243: Checking The Bearings And Oil Seals
CRANKSHAFT AND CONNECTING RODS EAS00401 CHECKING THE BEARINGS AND OIL SEALS 1. Check: D bearings Clean and lubricate the bearings, then rotate the inner race with your finger. Rough movement Replace. 2. Check: D oil seals Damage/wear Replace. EAS00207 CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKET AND TIMING CHAIN GUIDES...
Page 244: Installing The Crankshaft
1. Thoroughly clean all the gasket mating sur- faces and crankcase mating surfaces. 2. Apply: D sealant (onto the crankcase mating surfaces) Yamaha bond No. 1215 90890-85505 NOTE: Do not allow any sealant to come into contact with the oil gallery a .
Page 245: Transmission
TRANSMISSION TRANSMISSION TRANSMISSION, SHIFT DRUM ASSEMBLY AND SHIFT FORKS Order Job/Part Q’ty Remarks Removing the transmission, shift Remove the parts in the order listed. drum assembly and shift forks Crankcase separating Refer to “CRANKCASE AND CRANKSHAFT”. Shift fork guide bar 2 (short length) Shift fork guide bar 1 (long length) Refer to “INSTALLING THE Shift drum...
Page 246 TRANSMISSION Order Job/Part Q’ty Remarks Disassembling the drive axle and Disassemble the parts in the order listed. main axle Bearing Circlip Washer First wheel gear Forth wheel gear Third wheel gear Fifth wheel gear Second wheel gear Drive axle Second pinion gear Fifth pinion gear Third pinion gear Forth pinion gear...
Page 247: Removing The Transmission
TRANSMISSION EAS00420 REMOVING THE TRANSMISSION 1. Remove: D drive axle assembly 1 D main axle assembly 2 Remove them at same the time. EAS00421 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks and related components. 1.
Page 248: Checking The Transmission
TRANSMISSION EAS00424 CHECKING THE TRANSMISSION 1. Measure: D main axle runout (with a centering device and dial gauge 1 ) Out of specification Replace the main axle. Main axle runout limit 0.08 mm 2. Measure: D drive axle runout (with a centering device and dial gauge 1 ) Out of specification Replace the drive axle.
Page 249: Installing The Transmission, Shift Forks And Shift Drum Assembly
TRANSMISSION EAS00426 INSTALLING THE TRANSMISSION, SHIFT FORKS AND SHIFT DRUM ASSEMBLY 1. Install: D shift fork 1 “1” (left) 1 (face the “1” side for the clutch side.) D shift fork 2 “2” (right) 2 (face the “2” side for the clutch side.) D shift fork 3 “3”...
Page 251 CARB CHAPTER 6. CARBURETOR CARBURETOR ..........CHECKING THE CARBURETOR .
Page 252 CARB...
Page 253: Chapter 6. Carburetor
CARB CARBURETOR CARBURETOR CARBURETOR 10 Nm (1.0 m Order Job/Part Q’ty Remarks Removing the carburetor Remove the parts in the order listed. Refer to “FUEL TANK AND AIR FILTER” Fuel tank in chapter 3. Air filter case assembly Crankcase breather hose Silencer assembly Loosen.
Page 254 CARB CARBURETOR Order Job/Part Q’ty Remarks Disassembling the carburetor Disassemble the parts in the order listed. Vacuum chamber cover Piston valve spring NOTE: Piston valve Before disassembling the carburetor, Jet needle set make sure to note the number of times the Fuel drain bolt pilot screw is turned out from the seated Float chamber...
Page 255 CARB CARBURETOR Order Job/Part Q’ty Remarks Throttle stop screw Throttle position sensor For assembly, reverse the disassembly procedure.
Page 256: Checking The Carburetor
CARB CARBURETOR EB600031 CHECKING THE CARBURETOR NOTE: Before disassembling the carburetor, make sure to note the number of times the pilot screw is turned out from the seated position to its set position. 1. Check: D carburetor body D float chamber D jet housing Cracks/damage Replace.
Page 257 CARB CARBURETOR 6. Check: D piston valve 1 Damage/scratches/wear Replace. D rubber diaphragm 2 Cracks/tears Replace. 7. Check: D vacuum chamber cover 1 D piston valve spring 2 D jet needle set 3 Cracks/damage Replace. 8. Check: D needle jet 1 D main jet 2 D main jet holder 3...
Page 258: Assembling The Carburetor
CARB CARBURETOR EB600042 ASSEMBLING THE CARBURETOR NOTE: Before disassemblling the carburetor, make sure to note the number of times, the pilot screw is turned out from the seated position to its set position. CAUTION: D Before assembling the carburetors, wash all of the parts in a petroleum-based sol- vent.
Page 259: Installing The Carburetor
CARB CARBURETOR EB600051 INSTALLING THE CARBURETOR 1. Adjust: D engine idling speed Engine idling speed 1,200 1,400 r/min Refer to “ADJUSTING THE ENGINE ID- LLING SPEED” in chapter 3. 2. Adjust: D throttle cable free play Throttle cable free play (at the flange of the throttle grip) 5 mm Refer to “ADJUSTING THE THROTTLE...
Page 260 CARB CARBURETOR 2. Adjust: D fuel level a. Remove the carburetor assembly. b. Check the needle valve seat and needle valve. c. If either is worn, replace them as a set. d. If both are fine, adjust the float level by slight- ly bending the float tang 1 .
Page 261: Checking And Adjusting The Throttle Position Sensor
CARB CARBURETOR EAS00502 CHECKING ADJUSTING THROTTLE POSITION SENSOR NOTE: Before adjusting the throttle position sensor, the engine idling speed should be properly ad- justed. 1. Check: D throttle position sensor (installed on the carburetor) a. Disconnect the throttle position sensor cou- pler from the wire harness.
Page 262 CARB CARBURETOR 2. Check: D throttle position sensor (removed from the carburetor) a. Disconnect the throttle position sensor cou- pler from the wire harness. b. Remove the throttle position sensor from the carburetor. c. Connect the pocket tester (Ω 1k) to the throttle position sensor.
Page 263 CARB CARBURETOR 3. Adjust: D throttle position sensor angle a. Disconnect the throttle position sensor cou- pler from the wire harness. b. Connect the pocket tester (Ω 1k) to the throttle position sensor coupler. Positive tester probe blue terminal 1 Negative tester probe black terminal 2 c.
Page 264: Fuel Pump
CARB FUEL PUMP FUEL PUMP CHECKING THE FUEL PUMP 1. Check: D fuel pump a. Turn the fuel cock “OFF”. b. Disconnect the fuel hose. (fuel pump-carburetor) c. Place a container under the fuel hose end. d. Turn the main switch to “ON”. e.
Page 265: Assembling The Fuel Pump
CARB FUEL PUMP 4. Check: D diaphragms and gaskets Turn/fatigue/cracks Replace fuel pump assembly. 5. Check: D valves 1 Cracks/damage Replace fuel pump as- sembly. ASSEMBLING THE FUEL PUMP Reverse the disassembly procedure. NOTE: Be sure to connect the hoses correctly. 6-13...
Page 266: Air Induction System
CARB AIR INDUCTION SYSTEM EAS00507 AIR INDUCTION SYSTEM 1 Air cutoff valve 2 Reed valve 3 Air cleaner 4 Carburetor joint 5 Vacuum pulse 6 Exhaust port To exhaust port of front cylinder head 6-14...
Page 267 CARB AIR INDUCTION SYSTEM EAS00508 A From air cleaner B To reed valve 6-15...
Page 268: Air Induction System Diagrams
CARB AIR INDUCTION SYSTEM EAS00509 AIR INDUCTION SYSTEM DIAGRAMS 1 Reed valve 2 Air cleaner assembly 3 Air cutoff valve 4 Carbretor joint 5 Exhaust port of front cylinder 6 Exhaust port of rear cylinder A From the front cylinder B From the rear cylinder C To the front exhaust pipe D To the rear exhaust pipe...
Page 269: Air Induction Assembly
CARB AIR INDUCTION SYSTEM AIR INDUCTION ASSEMBLY 5 Nm (0.5 m 5 Nm (0.5 m 5 Nm (0.5 m Order Job/Part Q’ty Remarks Removing the air induction assembly Remove the parts in the order listed. Rear wheel Refer to “Rear wheel” in chapter 4 Vacuum hose Air cutoff valve to front cylinder head hose...
Page 270 CARB AIR INDUCTION SYSTEM 5 Nm (0.5 m 4 Nm (0.4 m 5 Nm (0.5 m Order Job/Part Q’ty Remarks Removing the air cutoff valve and air Remove the parts in the order listed. cleaner assembly Air induction case cover Bracket Vacuum hose Air cutoff valve to front cylinder head...
Page 271: Checking The Air Induction System
CARB AIR INDUCTION SYSTEM CHECKING THE AIR INDUCTION SYSTEM 1. Check: D hoses Loose connection Connect properly. Cracks/damage Replace. D pipes Cracks/damage Replace. 2. Check: D air filter element Damage Replace. 3. Clean: D air filter element Apply compressed air to the inner surface of the air filter element.
Page 272: Installing The Air Induction System
CARB AIR INDUCTION SYSTEM 5. Measure: D fiber reed bending Out of specification Replace the reed valve. Maximum fiber reed bending 0.4 mm (0.016 in) 1 Surface plate 6. Check: D air cutoff valve Cracks/damage Replace. INSTALLING THE AIR INDUCTION SYSTEM 1.
Page 273 CARB AIR INDUCTION SYSTEM 4. Install: D air cleaner assembly 5 Nm (0.5 m 5. Install: D air cut-off valve assembly 4 Nm (0.4 m 6. Install: D vacuum hose D hoses NOTE: Fuse the white paint mark of hoses 2 as shown.
Page 276 ELEC CHAPTER 7. ELECTRICAL ELECTRICAL COMPONENTS ........SWITCHES .
Page 277 ELEC...
Page 278: Chapter 7. Electrical
ELEC ELECTRICAL COMPONENTS EB800000 ELECTRICAL ELECTRICAL COMPONENTS Main switch Fuse Thermo switch Starter relay Ignition coil Side stand switch Front brake light switch Neutral switch Clutch switch Battery Carb heater relay Igniter unit Flasher relay Rear brake light switch Rectifier/ regulator Horn...
Page 279: Switches
ELEC SWITCHES EAS0010 SWITCHES CHECKING SWITCH CONTINUITY Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. CAUTION: Never insert the tester probes into the cou- pler terminal slots 1 .
Page 280: Checking The Switches
ELEC CHECKING THE SWITCHES EAS00731 CHECKING THE SWITCHES Check each switch for damage or wear, proper connections, and also for continuity between the termi- nals. Refer to “CHECKING SWITCH CONTINUITY”. Damage/wear Repair or replace the switch. Improperly connected Properly connect. Incorrect continuity reading Replace the switch.
Page 281 ELEC CHECKING THE SWITCHES Clutch switch Engine stop switch Pass switch Start switch Horn switch Rear brake switch Dimmer switch Neutral switch Turn switch Sidestand switch Front brake switch Fuses Main switch Lights switch...
Page 282: Checking The Bulbs And Sockets
ELEC CHECKING THE BULBS AND BULB SOCKETS EAS00732 CHECKING BULBS BULB SOCKETS Check each bulb and bulb socket for damage or wear, proper connections, and also for continu- ity between the terminals. Damage/wear Repair or replace the bulb, bulb socket or both. Improperly connected Properly connect.
Page 283 ELEC CHECKING THE BULBS AND BULB SOCKETS WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. CAUTION: D Be sure to hold the socket firmly when re- moving the bulb.
Page 284: Checking The Condition Of The Bulb Sockets
ELEC CHECKING THE BULBS AND BULB SOCKETS CHECKING THE CONDITION OF THE BULB SOCKETS The following procedure applies to all of the bulb sockets. 1. Check: D bulb socket (for continuity) (with the pocket tester) No continuity Replace. Pocket tester 90890-03112 NOTE: Check each bulb socket for continuity in the...
Page 285: Ignition System
ELEC IGNITION SYSTEM IGNITION SYSTEM CIRCUIT DIAGRAM Main switch Fuse (main) Battery Fuse (ignition) Relay unit Sidestand switch Ignitor Ignition coil #1 Ignition coil #2 Spark plug Pickup coil Neutral switch Engine stop switch...
Page 286: Troubleshooting
ELEC IGNITION SYSTEM EAS00737 EAS00739 TROUBLESHOOTING 2. Battery D Check the condition of the battery. The ignition system fails to operate (no spark or intermittent spark). Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: Min. open-circuit voltage 1.
Page 287 ELEC IGNITION SYSTEM EAS00743 Spark plug cap resistance 4. Ignition spark gap 10 kΩ at 20_C The following procedure applies to all of the D Is the spark plug cap OK? spark plugs. D Disconnect the spark plug cap from the spark plug.
Page 288 ELEC IGNITION SYSTEM EAS00749 8. Main switch D Check the main switch for continuity. Refer to “CHECKING THE SWITCHES”. D Is the main switch OK? Replace the main switch. Secondary coil resistance 10.4 X 15.6 kΩ 20_C EAS00750 D Is the ignition coil OK? 9.
Page 289 ELEC IGNITION SYSTEM NOTE: When you switch the “–” and “+” leads of the EAS00760 digital pocket tester the readings in the above 12. Relay unit (Diode) chart will be reversed. D Disconnect the relay unit from the coupler. D Connect the pocket tester (Ω D Are the tester readings correct? 1) to the starting circuit cutoff relay terminals as...
Page 290: Electric Starting System
ELEC ELECTRIC STARTING SYSTEM ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM Main switch Fuse (main) Starter relay Battery Starter motor Fuse (ignition) Relay unit Clutch switch Sidestand switch Neutral switch Engine stop switch Start switch 7-13...
Page 291: Starting Circuit Operation
ELEC ELECTRIC STARTING SYSTEM EB803010 STARTING CIRCUIT OPERATION The starting circuit on this model consists of the starter motor, starter relay, and the starting cir- cuit cut-off relay. If the engine stop switch is on “RUN” and the main switch is on “ON” (both switches are closed), the starter motor can op- erate only if: The transmission is in neutral (the neutral...
Page 292: Troubleshooting
ELEC ELECTRIC STARTING SYSTEM EAS00757 EAS00739 TROUBLESHOOTING 2. Battery D Check the condition of the battery. The starter motor fails to turn. Refer to “CHECKING AND CHARGING Check: THE BATTERY” in chapter 3. 1. main and ignition fuses Open-circuit voltage 2.
Page 293 ELEC ELECTRIC STARTING SYSTEM EAS00759 Tester positive probe 4. Relay unit (starting eircuit cutoff relay) light green Continuity Tester negative probe D Disconnect the relay unit (starting circuit cut- blue/yellow off relay) from the coupler. D Connect the pocket tester (Ω 1) and bat- Tester positive probe tery (12 V) to the relay unit terminals as...
Page 294 ELEC ELECTRIC STARTING SYSTEM EAS00761 EAS00750 6. Starter relay 8. Engine stop switch D Check the engine stop switch for continuity. D Disconnect the starter relay from the cou- Refer to “CHECKING THE SWITCHES”. pler. D Is the engine stop switch OK? D Connect the pocket tester (Ω...
Page 295 ELEC ELECTRIC STARTING SYSTEM EAS00764 12. Start switch D Check the start switch for continuity. Refer to “CHECKING THE SWITCHES”. D Is the start switch OK? Replace right handlebar switch. EAS00766 13. Wiring D Check the entire starting system’s wiring. Refer to “CIRCUIT DIAGRAM”.
Page 296: Starter Motor
ELEC ELECTRIC STARTING SYSTEM STARTER MOTOR 5 Nm (0.5 mDkg) Order Job/Part Q’ty Remarks Removing the starter motor Remove the parts in the order listed. Starter motor lead Starter motor assembly For installation, reverse the removal procedure. Disassembling the starter motor Disassembly the parts in the order listed.
Page 297: Checking The Starter Motor
ELEC ELECTRIC STARTING SYSTEM EAS00769 CHECKING THE STARTER MOTOR 1. Check: D commutator Dirt Clean with 600 grit sandpaper. 2. Measure: D commutator diameter a Out of specification Replace the starter motor. Min. commutator diameter 21 mm 3. Measure: D mica undercut a Out of specification Scrape the mica to the proper measurement with a hacksaw blade...
Page 298: Assembling The Starter Motor
ELEC ELECTRIC STARTING SYSTEM 5. Measure: D brush length a Out of specification Replace the brushes as a set. Min. brush length 3.5 mm 6. Measure: D brush spring force free length a Out of specification Replace the brush springs as a set.
Page 299 ELEC ELECTRIC STARTING SYSTEM 3. Install: D Starter motor front cover 1 NOTE: Align the match marks a on the rear cover with the match marks b on the front cover. 7-22...
Page 300: Charging System
ELEC CHARGING SYSTEM CHARGING SYSTEM CIRCUIT DIAGRAM A.C. magneto Rectifier/ regulator Fuse (main) Battery 7-23...
Page 301: Troubleshooting
ELEC CHARGING SYSTEM EAS00774 EAS00739 TROUBLESHOOTING 2. Battery D Check the condition of the battery. The battery is not being charged. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: 1. main fuses Open-circuit voltage 2. battery 12.8 V or more at 20_C 3.
Page 302 ELEC CHARGING SYSTEM EAS00779 5. Wiring NOTE: D Check the wiring connections of the entire Make sure that the battery is fully charged. charging system. D Is the charging voltage within specification? Refer to “CIRCUIT DIAGRAM”. D Is the charging system’s wiring properly con- nected and without defects? The charging circuit is OK.
Page 303: Lighting System
ELEC LIGHTING SYSTEM LIGHTING SYSTEM CIRCUIT DIAGRAM Main switch Pass switch Fuse (main) Dimmer switch Battery Headlight High beam indicator light Auxiliary light Meter light Fuse (headlight) Light switch Tail / brake light 7-26...
Page 304: Troubleshooting
ELEC LIGHTING SYSTEM EAS00781 EAS00739 TROUBLESHOOTING 2. Battery D Check the condition of the battery. Any of the following fail to light: headlight, Refer to “CHECKING AND CHARGING high beam indicator light, taillight, auxilia- THE BATTERY” in chapter 3. ry light or meter light. Open-circuit voltage Check: 12.8 V or more at 20_C...
Page 305: Checking The Lighting System
ELEC LIGHTING SYSTEM EAS00784 EAS00788 CHECKING THE LIGHTING SYSTEM 5. Dimmer switch 1. The headlight and the high beam indicator D Check the dimmer switch for continuity. light fail to came on. Refer to “CHECKING THE SWITCHES”. D Is the dimmer switch OK? 1.
Page 306 ELEC LIGHTING SYSTEM 2. Voltage D Connect the pocket tester (20 V) to the meter assembly coupler (wire harness side) as shown. Tester positive probe blue Tester negative probe black D Set the main switch to “ON”. D Set the light switch to “ ”.
Page 307 ELEC LIGHTING SYSTEM 2. Voltage 2. Voltage D Connect the pocket tester (DC 20 V) to the D Connect the pocket tester (DC 20 V) to the tail/brake light coupler (wire harness side) as auxiliary light couplers (wire harness side) as shown.
Page 308: Signaling System
ELEC SIGNALING SYSTEM SIGNALING SYSTEM CIRCUIT DIAGRAM 7-31...
Page 309 ELEC SIGNALING SYSTEM Main switch Fuse (main) Battery Relay unit (Diode) Neutral switch Neutral indicator light Turn signal indicator light Horn switch Turn signal switch Horn Flasher relay Front turn signal light (left) Front turn signal light (right) Rear turn signal light (left) Rear turn signal light (right) Fuse (signal) Rear stop switch...
Page 310: Troubleshooting
ELEC SIGNALING SYSTEM EB806010 EAS00739 TROUBLESHOOTING 2. Battery D Check the condition of the battery. D Any of the following fail to light: turn sig- Refer to “CHECKING AND CHRGING THE nal light, brake light or an indicator light. D The forn fails to sound. BATTERY”...
Page 311: Checking The Signaling System
ELEC SIGNALING SYSTEM EAS00796 3. Horn CHECKING THE SIGNALING SYSTEM 1. The horn fails to sound. D Disconnect the pink connector at the horn terminal. 1. Horn switch D Connect a jumper lead to the horn terminal D Check the forn switch for continuity. and ground the jumper lead.
Page 312 ELEC SIGNALING SYSTEM EAS00797 D Set the main switch to “ON”. 2. A tail/brake light fails to come on. D Pull in the brake lever or push down on the 1. Tail/brake light bulb and socket brake pedal. D Measure the voltage (12 V) of yellow at the D Check the tail/brake light bulb and socket for tail/brake light coupler (wire harness side).
Page 313 ELEC SIGNALING SYSTEM Tester positive probe brown/white 2. Turn signal switch Tester negative probe ground D Check the turn signal for continuity. Refer to “CHECKING THE SWITCHES”. D Is the turn signal switch OK? Replace the left han- dlebar switch.
Page 314 ELEC SIGNALING SYSTEM D Set the main switch to “ON”. 3. Voltage D Set the turn signal switch to “ ” or “ ”. D Connect the pocket tester (DC 20 V) to the D Measure the voltage (12 V) of chocolate meter assembly coupler (wire harness side) dark green at the turn signal light connec-...
Page 315: Carburetor Heater System
ELEC CARBURETOR HEATER SYSTEM CARBURETOR HEATER SYSTEM CIRCUIT DIAGRAM Main switch Fuse (carburetor heater) Fuse (main) Thermo switch Battery Carburetor heater Fuse (ignition) Carburetor heater ground Ignitor unit Carburetor heater relay 7-38...
Page 316: Troubleshooting
ELEC CARBURETOR HEATER SYSTEM EAS00781 EAS00739 TROUBLESHOOTING 2. Battery D Check the condition of the battery. The carburetor heater fails to operate. Refer to “CHECKING AND CHARGING Check: THE BATTERY” in chapter 3. 1. main, and carburetor heater fuses Open-circuit voltage 2.
Page 317 ELEC CARBURETOR HEATER SYSTEM 5. Carburetor heater D Remove the carburetor heater from the car- buretor body. D Connect the pocket tester to the carburetor heater. Tester (+) lead Heater terminal Tester (–) lead Heater body D Immerse the thermo switch in the water D Check the thermo switch for continuity.
Page 318: Self-Diagnosis
ELEC SELF-DIAGNOSIS SELF-DIAGNOSIS The XVS125 features self-diagnosis. When the main switch is turned to “ON”, the following items are monitored and the condition codes are displayed on the engine indicator light (irrespective of whether the engine is running or not). NOTE: The XVS125 features a self-diagnosing system.
Page 319 ELEC SELF-DIAGNOSIS EAS00835 1. Wire harness TROUBLESHOOTING D Check the wire harness for continuity. The engine warning light starts to display Refer to “CIRCUIT DIAGRAM”. the self-diagnosis sequence. D Is the wire harness OK? Check: 1. throttle position sensor NOTE: Repair or replace the D Before troubleshooting, remove the following wire harness.
Page 320 ELEC SELF-DIAGNOSIS 2. Speed sensor (5JX2) 1. Wire harness CIRCUIT DIAGRAM D Check the wire harness for continuity. NOTE: Refer to “CIRCUIT DIAGRAM”. The speed sensor into the speedometer. D Is the wire harness OK? Replace the speed Repair or replace the meter.
Page 323: Troubleshooting
TRBL SHTG CHAPTER 8. TROUBLESHOOTING STARTING PROBLEMS ........ENGINE .
Page 324 TRBL SHTG...
Page 325: Starting Problems
TRBL STARTING PROBLEMS SHTG EAS00844 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 manual for checks, adjustments, and replacement of parts.
Page 326: Incorrect Engine Idling Speed
INCORRECT ENGINE IDLING SPEED/POOR MEDIUM AND- TRBL HIGH-SPEED PERFORMANCE/FAULTY GEAR SHIFTING SHTG EAS00846 INCORRECT ENGINE IDLING SPEED ENGINE ELECTRICAL SYSTEMS Cylinders and cylinder heads Battery D Incorrect valve clearance D Faulty battery D Damaged valve train components D Discharged battery Air filter Spark plugs D Clogged air filter element...
Page 327: Faulty Clutch
TRBL FAULTY CLUTCH/OVERHEATING SHTG EAS00851 FAULTY CLUTCH CLUTCH SLIPS CLUTCH DRAGS Clutch Clutch D Incorrectly assembled clutch D Unevenly tensioned clutch spring D Incorrectly adjusted clutch cable D Warped pressure plate D Loose or fatigued clutch spring D Bent clutch plate D Worn friction plate D Swollen friction plate D Worn clutch plate...
Page 328: Poor Braking Performance
POOR BRAKING PERFORMANCE/FAULTY FRONT FORK TRBL LEGS/UNSTABLE HANDLING SHTG EAS00859 POOR BRAKING PERFORMANCE Front brake Rear brake D Worn brake pad D Improper brake pedal adjustment D Worn brake disc D Worn brake shoe D Air in hydraulic brake system D Improper brake shoe contact D Leaking brake fluid D Worn camshaft...
Page 329: Headlight Does Not Light
TRBL FAULTY LIGHTING AND SIGNALING SYSTEMS SHTG EAS00866 FAULTY LIGHTING AND SIGNALING SYSTEMS HEADLIGHT DOES NOT LIGHT TURN SIGNAL BLINKS SLOWLY D Wrong headlight bulb D Faulty flasher relay D Too many electrical accessories D Faulty main switch D Hard charging D Faulty turn signal switch D Incorrect connection D Wrong turn signal bulb...
Page 331 XVS250 2001 WIRING DIAGRAM (for EUR) A.C. magneto Rectifier/ regulator Main switch Fuse (main) Starter relay Battery Starter motor Fuse (ignition) Relay unit Clutch switch Sidestand switch Throttle position sensor Ignitor unit Ignition coil #1 Ignition coil #2 Spark plug...
Page 332 XVS250 2001 WIRING DIAGRAM (for OCE) A.C. magneto Rectifier/ regulator Main switch Fuse (main) Starter relay Battery Starter motor Fuse (ignition) Relay unit Clutch switch Sidestand switch Throttle position sensor Ignitor unit Ignition coil #1 Ignition coil #2 Spark plug...

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Xvs250n 2001 5kr2 5kr2-ae1

Yamaha XVS250 2001 Service Manual

Chapter 2. Specifications

Chapter 4. Chassis

Chapter 5. Engine

Chapter 6. Carburetor

Chapter 7. Electrical

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Troubleshooting

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Summary of Contents for Yamaha XVS250 2001